NORD BU0510 User Manual

BU 0510

Positioning control POSICON

for NORD frequency inverters, SK 530E and above

POSICON position control for NORD frequency inverters, SK 530E and above Safety information

N O R D Frequency inverters

Safety and operating instructions for drive power converters

(as per: Low Voltage Directive 2006/95/EEC )

1. General During operation, drive power converters may, depending on their

protection class, have live, bare, moving or rotating parts or hot surfaces.

Unauthorised removal of covers, improper use, incorrect installation or operation causes a risk of serious personal injury or material damage.

Further information can be found in this documentation. All transportation, installation, initialisation and maintenance work

must be carried out by qualified personnel (compliant with IEC 364, CENELEC HD 384, DIN VDE 0100, IEC 664 or DIN VDE 0110, and national accident prevention regulations).

For the purposes of these basic safety instructions, qualified personnel are persons who are familiar with the assembly, installation, commissioning and operation of this product and who have the relevant qualifications for their work.

2. Proper use in Europe

Drive power converters are components intended for installation in electrical systems or machines.

When installed in machines, the drive power converter cannot be commissioned (i.e. commencement of the proper use) until it has been ensured that the machine meets the provisions of the EC Directive 2006/42/EEC (machine directive); EN 60204 must also be complied with.

Commissioning (i.e. implementation of the proper use) is only permitted when the EMC directive (2004/108/EEC) is complied with.

CE-labelled drive power converters meet the requirements of the Low Voltage Directive 2006/95/EEC. The harmonised standards for drive power converters listed in the declaration of conformity are used.

Technical data and information for connection conditions can be found on the rating plate and in the documentation, and must be complied with.

The drive power converters may only be used for safety functions which are described and explicitly approved.

3. Transport, storage

Information regarding transport, storage and correct handling must be complied with.

4. Installation

The installation and cooling of the equipment must be implemented according to the regulations in the corresponding documentation.

The drive power converter must be protected against impermissible loads. Especially during transport and handling, components must not be deformed and/or insulation distances must not be changed. Touching of electronic components and contacts must be avoided.

Drive power converters have electrostatically sensitive components, which can be easily damaged by incorrect handling. Electrical components must not be mechanically damaged or destroyed (this may cause a health hazard!).

5. Electrical connection

When working on live drive power converters, the applicable national accident prevention regulations must be complied with (e.g. VBG A3, formerly VBG 4).

The electrical installation must be implemented according to the applicable regulations (e.g. cable cross-section, fuses, ground lead connections). Further instructions can be found in the documentation.

Information about EMC-compliant installation – such as shielding, earthing, location of filters and installation of cables can be found in the drive power converter documentation. These instructions must be complied with even with CE marked drive power converters. Compliance with the limiting values specified in the EMC regulations is the responsibility of the manufacturer of the system or machine.

6. operation

Where necessary, systems where drive power converters are installed must be equipped with additional monitoring and protective equipment according to the applicable safety requirements, e.g. legislation concerning technical equipment, accident prevention regulations, etc.

The parameterisation and configuration of the drive power converter must be selected so that no hazards can occur.

All covers must be kept closed during operation.

7. Maintenance and repairs

After the drive power converter is disconnected from the power supply, live equipment components and power connections should not be touched immediately, because of possible charged capacitors. Observe the applicable information signs located on the drive power converter.

Further information can be found in this documentation.

These safety instructions must be kept in a safe place!

2 Subject to technical alterations BU 0510 GB-3911

POSICON position control for NORD frequency inverters, SK 530E and above About this document

Designation of previous versions

Software Version

Comments

BU 0510 DE, June 2007 Part No. 607 5101 / 2307

V 1.6 R0

First issue

BU 0510 DE, September 2011 Part No. 607 5101 / 3911

V 2.0 R0

 Implementation of the SK 54xE series with universal

encoder interface for SIN/COS, Hiperface, Endat 2.1, SSI and BISS encoders,

 "Flying Saw" technology function,  extension of static positions from 15 to 63 (for SK 54xE

→4x63 positions, depending on parameter set)

 various corrections

NOTE

This supplementary operating manual is only valid in conjunction with the operating manual supplied for the respective frequency inverter (Manual BU0500).

Documentation

Designation: BU 0510 GB Part No.: 607 51 01 Device series: SK 53xE, SK 54xE

Version list

Publisher

Getriebebau NORD GmbH & Co. KG

Rudolf- Diesel- Str. 1  D-22941 Bargteheide  Germany  http://www.nord.com/ Tel.: +49 (0) 45 32 / 401-0  Fax +49 (0) 45 32 / 401-555

BU 0510 GB-3911 Subject to technical alterations 3

POSICON position control for NORD frequency inverters, SK 530E and above About this document

Intended use of the frequency inverter

The compliance with the operating instructions is necessary for fault-free operation and the acceptance of possible warranty claims. These operating instructions must be read before working with the device!

These operating instructions contain important information about servicing. They must therefore be kept close to the device.

SK 500E series frequency inverters are devices for industrial and commercial systems used for the operation of three-phase asynchronous motors with squirrel-cage rotors and Permanent Magnet Synchronous Motors - PMSM (SK 54xE and above). These motors must be suitable for operation with frequency inverters. Other loads must not be connected to the devices.

Series SK 500E frequency inverters are devices for stationary installation in control cabinets. All details regarding technical data and permissible conditions at the installation site must be complied with.

Commissioning (implementation of the intended use) is not permitted until it has been ensured that the machine complies with the EMC directive 204/108/EEC and that the conformity of the end product meets the machine directive 2006/42/EEC (note EN 60204).

 Getriebebau NORD GmbH & Co. KG, 2011

4 Subject to technical alterations BU 0510 GB-3911

Contents

1 GENERAL INFORMATION ...................................................................................................... 7

2 ENCODER CONNECTIONS ..................................................................................................... 8

2.1 Terminal blocks .................................................................................................... 8

2.1.1 Terminal blocks SK 53xE Size 1 – 4 ......................................................................... 8

2.1.2 Terminal blocks SK 54xE Size 1 – 4 ......................................................................... 9

2.1.3 Terminal blocks, SK 535E Size 5 and above .......................................................... 10

2.2 Colour and contact assignments for encoders ................................................... 11

2.2.1 Incremental encoders.............................................................................................. 12

2.2.2 Sine encoders (SIN/COS encoders) ....................................................................... 13

2.2.3 Hiperface encoders ................................ ................................................................ . 14

2.2.4 Endat encoders ....................................................................................................... 15

2.2.5 SSI encoders .......................................................................................................... 16

2.2.6 BISS encoders ........................................................................................................ 17

2.3 CANopen absolute encoders ............................................................................. 17

2.3.1 Approved CANopen absolute encoders .................................................................. 18

2.3.2 RJ45 WAGO adapter module ................................................................................. 18

2.3.3 Assignment of the CAN interface on the frequency inverter.................................... 19

3 FUNCTION DESCRIPTION .................................................................................................... 20

3.1 Introduction ......................................................................................................... 20

3.2 Position detection ............................................................................................... 20

3.2.1 Position detection with incremental encoders ......................................................... 20

3.2.2 Position detection with absolute encoders .............................................................. 22

3.2.3 Encoder monitoring ................................ ................................................................ . 26

3.2.4 Positioning with absolute / incremental encoders in absolute mode ....................... 27

3.3 Specifying the setpoint ....................................................................................... 30

3.3.1 Position array – absolute setpoint position via digital inputs or BUS I/O In Bits ...... 30

3.3.2 Position increment array– relative setpoint position via digital inputs or

BUS I/O In Bits ........................................................................................................ 31

3.3.3 Bus setpoints .......................................................................................................... 31

3.4 Teach-In function via digital inputs or Bus I/O In Bits......................................... 32

3.5 Conversion ratio of the setpoint and actual values (P607 and P608) ................ 32

3.6 Position control functions (P600) ........................................................................ 33

3.7 Position control ................................................................................................... 34

3.8 Output messages ............................................................................................... 35

3.8.1 Relays (P434, 441) and digital outputs (P450, P455) ............................................. 35

3.8.2 Output messages via BUS I/O Out Bits (P481) ....................................................... 35

4 PARAMETER SETTINGS ....................................................................................................... 36

4.1 Operating display................................................................................................ 36

4.2 Speed control ..................................................................................................... 37

4.3 Control clamps .................................................................................................... 38

4.4 Extra functions .................................................................................................... 47

4.5 Positioning .......................................................................................................... 50

4.6 Information .......................................................................................................... 58

5 COMMISSIONING................................................................................................................... 60

BU 0510 GB-3911 Subject to technical alterations 5

POSICON position control for NORD frequency inverters, SK 530E and above

6 SYNCHRONOUS CONTROL ................................................................................................ 62

6.1 General information ........................................................................................... 62

6.2 Communication settings .................................................................................... 62

6.3 Settings for slave ramp time and maximum frequency ..................................... 63

6.4 Setting the speed and position controls ............................................................ 64

6.5 Taking a speed ratio between master and slave into account .......................... 64

6.6 Monitoring functions .......................................................................................... 64

6.6.1 Achievable precision / Position monitoring ............................................................. 64

6.6.2 Master switch-off on slave error or position slip error ............................................. 65

6.6.3 Slip error monitoring on the slave ........................................................................... 66

6.7 Notes on reference point runs with synchronous operation .............................. 66

6.8 Offset switching in synchronous operation ........................................................ 66

6.9 Flying Saw (extended synchronous operation function) ................................... 67

6.9.1 Determination of acceleration path and initiator position ........................................ 68

6.9.2 Diagonal saw .......................................................................................................... 69

6.9.3 Offset switching in synchronous operation ............................................................. 69

7 TROUBLESHOOTING ........................................................................................................... 70

7.1 Error messages ................................................................................................. 70

7.2 Troubleshooting table ........................................................................................ 72

7.2.1 Sources of faults in servo mode operation (without position control) ...................... 72

7.2.2 General sources of error with positioning control enabled ...................................... 72

7.2.3 Sources of error with incremental position detection (without absolute encoders).. 73

7.2.4 Sources of faults for position detection with absolute encoders.............................. 73

7.2.5 Miscellaneous encoder faults (universal encoder interface) ................................... 74

8 SERVICE INFORMATION / REPAIRS .................................................................................. 75

9 LISTS / INDEX ....................................................................................................................... 76

9.1 Keyword Index ................................................................................................... 76

9.2 Abbreviations: .................................................................................................... 77

9.3 Figures ............................................................................................................... 78

9.4 Tables ................................................................................................................ 78

9.5 Key words .......................................................................................................... 79

6 Subject to technical alterations BU 0510 GB-3911

1 General information

NOTE

This description (BU 0510) only contains a selection of the functions and parameters which are specific and relevant for the positioning function. All standard functions and parameters can be found in the manual (BU 0500).

Due to software updates the parameters described here may differ from those of your device. Therefore care should be taken that both the current NORD CON version and the version of your ParameterBox have the latest software version. In case of doubt, please contact your local NORD agency.

The latest version of all descriptions can be found on the Getriebebau NORD GmbH & Co. KG Internet page (www.nord.com).

SK 53xE and SK 54xE frequency inverters are intermediate voltage circuit converters with fully digital microprocessor technology for controlling the speed of 3-phase motors.

In combination with an incremental encoder or an absolute encoder the standard components form a highprecision positioning drive:

 The SK53xE provides 63 programmable absolute positions.  The SK54xE provides 252 programmable absolute positions.  By means of the position control, the position is maintained even with large load fluctuations.  Time-optimised and safe travel up to the target position by means of path calculation.  In addition to travelling to absolute positions, up to 4 step lengths (so-called position

increments) can be stored in the frequency inverter.

 Required positions can also be transferred via a field bus interface.  The positioning function is available as a function extension for the SK 530E and above.

The parameters (P6xx) required for positioning are inserted into the existing inverter menu structure as an additional menu group (Positioning).

The specified setpoint position can be input via the existing digital inputs, the Bus IO In Bits, or via the USS protocol or other field bus system.

1 General

A switchover from speed control to position control (Positioning) can be achieved by switching over the parameters.

Synchronous operation functionality between a master and one or more slave drives is possible via the integrated CAN bus or RS485 interface. In addition, as an extension to the synchronous operation functionality, the "Flying Saw" enables the slave to be deliberately and independently synchronised to or uncoupled from the master.

A round axis function (Modulo axes) is also available for rotating platforms and similar applications. This controls an endless axis with optimisation of travel. According to the required position, the drive rotates clockwise or anticlockwise.

BU 0510 GB-3911 Subject to technical alterations 7

POSICON position control for NORD frequency inverters, SK 530E and above

X6:

Incremental encoder input Encoder, e.g.: TTL, 10-30V, RS422, 2048 impulses/rotation

Note:

5V encoders should not be used.

X7:

additional digital inputs and outputs

DIP switch:

Switching from analog inputs AIN2/AIN1 current/voltage setpoint

I = current 0/4...20mA V = voltage 0...10V

NOTE:

AIN2 – upper DIP Switch AIN1 – lower DIP Switch

X8:

VI_S 24V, pulse block input

VO_S 15/24V, output for commissioning without safety switching device

only for SK 53xE

and not with 115VAC

devices

further details in

handbook BU 0530

X4:

analog inputs and outputs

+10V max. 5mA

0...10V or

0/4...20mA

Analog output: 0 …

10V

X5: digital inputs and

voltage supply

i DIN

approx. 4.5k

with SK 530E

Terminal 42internal

+15V max. 150mA

+5V max. 250mA

with SK 535E

Terminal 44external

+18-30V min. 800mA

X11:

1x RJ12 socket to connect the RS232 or RS485 interface

X9/X10:

2x RJ45 socket to connect the CAN/CANopen interface

X9 X10 X11

2 Encoder connections

The internal zero point of the inverter can be adjusted by specifying an offset value. A possible reduction ratio between the position measurement system (encoder) and the motor can be taken

into account by the use of transformation and reduction ratios. The motor and the position measurement system (encoder) do not need to have the same direction of rotation. A negative ratio must be set if the direction of rotation is different.

2.1 Terminal blocks

The terminal blocks for the control connections and for the encoder differ between the versions and sizes of the frequency inverter.

2.1.1 Terminal blocks SK 53xE Size 1 – 4

8 Subject to technical alterations BU 0510 GB-3911

Fig. 1: Terminal blocks, SK 53xE Size 1 - 4

2.1.2 Terminal blocks SK 54xE Size 1 – 4

X5: digital inputs and

voltage supply

i DIN

approx. 4.5k

with SK 540ETerminal 42

internal

+15V max. 150mA

+5V max. 250mA

with SK 545ETerminal 44

external

+18-30V min. 800mA

X6: Incremental encoder

input

Incremental encoder,

e.g.:

10-30V, TTL, RS422

2048 Imp./Rpm.

Note: 5V encoders should

not be used.

X7: additional digital inputs

and outputs

DIP switch:

Switching from analog

inputs AIN2/AIN1

current/voltage setpoint

I = current 0/4...20mA

V = voltage 0...10V

NOTE:

AIN2 – upper DIP Switch

AIN1 – lower DIP Switch

X8: VI_S 24V, input of the

pulse lock

VO_S 15/24V, output for

starting up without safety switching unit

not with 115VAC devices

further details in

handbook BU 0530

X4: analog inputs and

outputs

+10V max. 5mA

0...10V or 0/4...20mA

Analog output: 0 … 10V

X11:1x RJ12 socket to

connect the RS232 or RS485 interface

X9/X10: 2x RJ45 socket to

connect the CAN/CANopen interface

X14: Universal encoder

interface

2 Encoder connection

BU 0510 GB-3911 Subject to technical alterations 9

Fig. 2: Terminal blocks, SK 54xE Size 1 - 4

POSICON position control for NORD frequency inverters, SK 530E and above

X5: digital inputs and

voltage supply*

i DIN

approx. 4.5k

Terminal 44internal

+24V max. 200mA

*no supply!

X6: Incremental encoder

input

Incremental encoder,

e.g.:

10-30V, TTL, RS422

2048 Imp./Rpm.

Note: 5V encoders should

not be used.

X7: additional digital inputs

and outputs

DIP switch: left = ON / right = OFF

S4: AIN2: ON =  10 Volt

OFF = 0 … 10 Volt S3: AIN1: ON =  10 Volt OFF = 0 … 10 Volt S2: AIN2: I = ON = current 0/4...20mA V = OFF = voltage S1: AIN1: I = ON = current 0/4...20mA V = OFF = voltage

Note: If S2 is set to ON (AIN2 = Current input), S4 must be set to OFF.

If S1 is set to ON (AIN1 = Current input), S3 must be set to OFF.

X4: analog inputs and

outputs

±10V max. 5mA

-10V … +10V or

0...10V or 0/4...20mA

Analog output: 0 … 10V

X11:1x RJ12 socket to

connect the RS232 or RS485 interface

X9/X10: 2x RJ45 socket to

connect the CAN/CANopen interface

2.1.3 Terminal blocks, SK 535E Size 5 and above

Fig. 3: Terminal blocks, SK 535E Size 5 and above

10 Subject to technical alterations BU 0510 GB-3911

2 Encoder connection

ATTENTION

The rotation of the incremental encoder must correspond to that of the motor. Therefore, depending on the rotation direction of the encoder to the motor (possibly reversed), a negative number must be set in parameter P301.

NOTE

The voltage difference between tracks A and B can be measured with the aid of parameter P709 [-09] and [-10]. If the incremental encoder is rotated, the value of both tracks must jump between -0.8V and 0.8V. If the voltage only jumps between 0 and 0.8V the relevant rack is faulty. The position can no longer be determined via the incremental encoder. We recommend to replace the encoder!

2.2 Colour and contact assignments for encoders

The incremental encoder connection is an input for a type with two tracks and TTL-compatible signals for EIA RS 422-compliant drivers. The maximum current consumption of incremental encoders must not exceed 150 mA. The supply voltage for the rotary encoder is 10-30V.

The pulse number per rotation can be between 500 and 8192 increments. This is set with the normal scaling via parameter P301 "Incremental encoder pulse number" in the menu group "Control parameters". For cable lengths > 20 m and motor speeds above 1500 min-1 the encoder should not have more than 2048 pulses/rotation.

For longer cable lengths the cable cross-section must be selected large enough so that the voltage drop in the cable is not too great. This particularly affects the supply cable, in which the cross-section can be increased by connecting several conductors in parallel.

Unlike incremental encoders, for sine encoders or SIN/COS encoders the signals are not in the form of pulses, but rather in the form of sine signals (shifted by 90°).

BU 0510 GB-3911 Subject to technical alterations 11

POSICON position control for NORD frequency inverters, SK 530E and above

Function

Cable colours,

for incremental

encoder

Assignment for SK 53xE

Assignment for SK 54xE*

10-30V supply

brown / green

X5:42(/44) 15V (/24V)

X5:42( /X5:44 /X6:49)

15V ( /24V /12V)

0V supply

white / green

X6:40 GND/0V

X5:40 GND/0V

Track A

brown

X6:51 ENC A+

Track A inverse

green

X6:52 ENC A-

Track B

grey

X6:53 ENC B+

Track B inverse

pink

X6:54 ENC B+

Track 0

red

X14:63 CLK +

Track 0 inverse

black

X14:64 CLK-

+ 5V Sense

blue

X14:65 DAT +

0V Sense

white

X14:66 DAT -

Cable shield

connected to a large area of the frequency inverter housing or shielding angle

*Zero track not necessary for speed feedback or operation of asynchronous machines.

NOTE

If there are deviations from the standard equipment (Type 5820.0H40, 10-30V encoder, TTL/RS422) for the motors, please note the accompanying data sheet or consult your supplier.

2.2.1 Incremental encoders

According to the resolution (pulse number), incremental encoders generate a defined number of pulses for each rotation of the encoder shaft (Track A / Track A inverse) With this, the precise speed of the encoder or motor can be measured by the frequency inverter. By the use of a second track (B / B inverse) shifted by 90° (¼ period), the direction of rotation can also be determined. In turn, the "zero track" (0 / 0 inverse) provides exactly one pulse per rotation and can therefore be used as a referencing signal for positioning systems.

The voltage source can be an external source or the internal voltage (according to the frequency inverter version: 12V /15V /24V).

Table 1: Connection assignments for incremental encoders

Evaluation of the zero track and the Sense signal is necessary for the operation of PMSM (Permanent Magnet Synchronous Motors). The zero impulse is then used for synchronisation of the rotor position. The offset between the zero pulse and the actual "zero" rotor position is set in parameter P334 "Encoder offset". If the Sense cable (+5V Sense and 0V Sense) is not connected, there is no synchronisation to the zero pulse. The zero track is not required for asynchronous machines. Alternative to the commutation of the position, Hiperface, BISS, Endat or SSI encoders with additional Sin/Cos or incremental tracks may be used.

12 Subject to technical alterations BU 0510 GB-3911

2 Encoder connection

Function

Cable colours for Sin/Cos encoders*

Assignment for SK 54xE

10-30V supply

brown

X5:42( /X5:44 /X6:49)

15V ( /24V /12V)

0V supply

white

X5:40 GND/0V

Track A

green

X6:51 ENC A+

Track A inverse

yellow

X6:52 ENC A-

Track B

grey

X6:53 ENC B+

Track B inverse

pink

X6:54 ENC B+

Track 0

blue

X14:63 CLK +

Track 0 inverse

red

X14:64 CLK-

+ V Sense**

brown

X14:65 DAT +

0V Sense**

white

X14:66 DAT -

Cable shield

connected to a large area of the frequency inverter housing or shielding angle

* E.g. Kübler 5824 ** The Sense cables are internally bridged to the voltage supply of the encoder.

Function

Signal designation

Signal voltage

Sine signal

Sin

max. 5V Uss

Cosine signal

Cos

max. 5V Uss

2.2.2 Sine encoders (SIN/COS encoders)

(SK 540E and above)

The use or function of sine encoders is comparable with that for incremental encoders. However, the encoder provides sine wave signals instead of digital pulses.

The voltage source can be an external source or the internal voltage (according to the frequency inverter version: 12V /15V /24V).

Table 2: Connection assignment for SIN/COS encoders

Table 3: Signal details for SIN/COS encoders

BU 0510 GB-3911 Subject to technical alterations 13

POSICON position control for NORD frequency inverters, SK 530E and above

Function

Signal designation

Signal voltage

Sine reference voltage

Sin Ref

2,5V Um

Cosine reference voltage

Cos Ref

2,5V Um

Sine signal

Sin

1V Uss

Cosine signal

Cos

1V Uss

NOTE

The voltage difference between the SIN and COS tracks can be measured with the aid of parameter P709 [-09] and [-10]. If the Hiperface encoder is rotated, the voltage difference should range between approx. -0.5V and 0.5V.

U U

2.2.3 Hiperface encoders

(SK 540E and above)

Hiperface is a mixture of incremental encoder and absolute encoder and combines the advantages of both encoder types. The absolute value is initially only formed when the device is switched on and is communicated by the RS485 specification bus parameter interface to the external counter in the controller, which then continues counting incrementally from this absolute value using the analog sine/cosine signal. During operation the counted position is continuously compared with the measured absolute position of the encoder.

Hiperface encoders are suitable for positioning in combination with servo mode. The requirements for the analog signal are shown in the following table. It must be noted that the tolerances

in the voltages affect the precision of the determined position. The supply voltage for the encoder is 7-12V. An external source or the internal 12V voltage can be used as

the voltage supply.

Table 4: Signal details for Hiperface encoders

Fig. 4: Signals for Hiperface encoders

14 Subject to technical alterations BU 0510 GB-3911

2 Encoder connection

Function

Cable colours, for Hiperface encoders

Assignment for SK 540E

7-12V supply

red

X6:49 VO 12V

0V supply

blue

X5:40 GND/0V

+ SIN

white

X6:51 ENC A+

REFSIN

brown

X6:52 ENC A-

+COS

pink

X6:53 ENC B+

REFCOS

black

X6:54 ENC B+

Data + (RS485)

grey or yellow

X14:65 DAT +

Data - (RS485)

green or violet

X14:66 DAT-

Cable shield

connected to a large area of the frequency inverter housing or shielding angle

Function

Cable colours for Endat encoders

Assignment for SK 54xE

3.6-14V supply

brown / green

X6:49 VO 12V

Sensor UB

blue

X6:49 VO 12V

0V supply

white / green

X5:40 GND/0V

Sensor 0V

white

X5:40 GND/0V

Track A

green/black

X6:51 ENC A+

Track A inverse

yellow/black

X6:52 ENC A-

Track B

blue/black

X6:53 ENC B+

Track B inverse

red/black

X6:54 ENC B+

Clock +

violet

X14:63 CLK +

Clock -

yellow

X14:64 CLK-

Data + (RS485)

grey

X14:65 DAT +

Data - (RS485)

pink

X14:66 DAT -

Cable shield

connected to a large area of the frequency inverter housing or shielding angle

Table 5: Connection assignment for Hiperface encoders

2.2.4 Endat encoders

(SK 540E and above)

Endat encoders function in a similar manner to SSI encoders with 2 RS485 channels, whereby the data channel is bi-directional. The communication frequency of the inverter is 200kHz.

Endat encoders are also available with an integrated incremental track. The settings for the incremental track correspond to those of a conventional incremental encoder.

The supply voltage for the encoder is 3.6-14V. An external source (recommended: >5V) or the internal 12V can be used as the voltage supply.

Table 6: Connection assignment for Endat encoders

BU 0510 GB-3911 Subject to technical alterations 15

POSICON position control for NORD frequency inverters, SK 530E and above

Function

Cable colours for SSI encoders*

Assignment for SK 54xE

10-30V supply

brown

X5:42( /X5:44 /X6:49)

15V ( /24V /12V)

Sensor UB

red

X5:42( /X5:44 /X6:49)

15V ( /24V /12V)

0V supply

white

X5:40 GND/0V

Sensor 0V

blue

X5:40 GND/0V

Clock +

green

X14:63 CLK +

Clock -

yellow

X14:64 CLK-

Data + (RS485)

grey

X14:65 DAT +

Data - (RS485)

pink

X14:66 DAT -

Cable shield

connected to a large area of the frequency inverter housing or shielding angle

* E.g. Kübler 3670

2.2.5 SSI encoders

(SK 540E and above)

SSI encoders whose signals are TTL-compatible according to EIA RS 422 can be used. The zero point of the absolute encoder is determined by the position of the absolute encoder and should

therefore be adjusted by installation. The clock frequency is 200kHz. With this clock frequency, cable lengths of up to 80m are possible. The

cables should be twisted in pairs and screened. The supply voltage for the encoder is 10-30V. The voltage source can be an external source or the internal

voltage (according to the frequency inverter version: 12V /15V /24V).

Table 7: Connection assignment for SSI encoders

16 Subject to technical alterations BU 0510 GB-3911

2 Encoder connection

Function

Cable colours for BISS encoders*

Assignment for SK 54xE

10-30V supply

brown

X5:42( /X5:44 /X6:49)

15V ( /24V /12V)

0V supply

white

X5:40 GND/0V

Track A

black

X6:51 ENC A+

Track A inverse

violet

X6:52 ENC A-

Track B

grey/pink

X6:53 ENC B+

Track B inverse

red/blue

X6:54 ENC B+

Clock +

green

X14:63 CLK +

Clock -

yellow

X14:64 CLK-

Data + (RS485)

grey

X14:65 DAT +

Data - (RS485)

pink

X14:66 DAT -

Cable shield

connected to a large area of the frequency inverter housing or shielding angle

* E.g. Kübler 5883

2.2.6 BISS encoders

(SK 540E and above)

BISS is a further development of the SSI interface, which also operates with 2 RS485 channels. With BISS encoders, the position is communicated together with a checksum. This provides more reliable communication than SSI.

The encoders are also available with an integrated incremental track. The supply voltage for the encoder is 10-30V. The voltage source can be an external source or the internal

voltage (according to the frequency inverter version: 12V /15V /24V).

Table 8: Connection assignment for BISS encoders

2.3 CANopen absolute encoders

The connection of an absolute encoder to the SK 53xE / SK 54xE is carried out via the internal CANopen interface. As a minimum requirement, the absolute encoder to be connected must have a CAN Bus interface with CANopen protocol. The internal CAN Bus with CANopen protocol can be used for simultaneous control and parameterisation as well as the readout of the absolute encoder position.

The SK 53xE / SK 54xE supports CANopen absolute encoders with the communication profile DS 406. If an absolute encoder supplied by Getriebebau Nord GmbH & Co. KG is used, automatic parameterisation of the absolute encoder via the frequency inverter is possible. Only the CAN address and the baud rate of the encoder still need to be set with the rotary or dip switches on the encoder. All other necessary parameters are set by the frequency inverter via the CAN Bus in the encoder.

BU 0510 GB-3911 Subject to technical alterations 17

POSICON position control for NORD frequency inverters, SK 530E and above

Manufacturer

Single-turn encoder

Multiple-turn encoder

Fritz Kübler

www.kuebler.com

Opto-mechanical encoders Type: Sendix 8.5878.XX2X.XXXX.XXXXX

Opto-mechanical encoders Type: Sendix 8.5888.XX2X.XXXX.XXXXX 10-30V DC

FRABA Posital

www.posital.de

No approval at present.

Please request if required

Opto-mechanical encoders Type: OCD-C2X1B-XXXX-XXXX-0CC 10-30V DC, 25Bit 8192 Inc/rev, 4096 rev

Baumer IVO

www.baumer.com

No approval at present.

Please request if required

Magnetic encoders Type: Multivo GOMMH.X205P32 10-30V DC, 29Bit Default setting: Node ID 1, 50KBd Can be parameterised

Supplier

Name

Part no.

WAGO Kontakttechnik GmbH

Ethernet connection module with CAGE CLAMP connection RJ45 transfer module

289-175

WAGO Kontakttechnik GmbH

Accessories: WAGO shield clamp

790-108

Alternative, complete connection module and shield clamp

Part No.

Getriebebau NORD GmbH & Co.KG

Adapter module RJ45/terminal

278910300

2.3.1 Approved CANopen absolute encoders

The following CANopen encoders (with bus cover) are approved:

Table 9: CANopen encoders approved by NORD

2.3.2 RJ45 WAGO adapter module

This adapter module can be used for the simple wiring of functions of the RJ45 connection (24V supply voltage, CANopen absolute encoder, CANbus) with normal cables.

Pre-assembled RJ45 patch cables are connected to the spring-loaded terminals (1-8 + S) with this adapter (for terminal assignments see the following section).

The shield clamp should be used in order to ensure the correct connection and relief of tension on the shield.

Fig. 5: RJ45 WAGO connection module

Table 10: Overview of RJ45 WAGO connection module

18 Subject to technical alterations BU 0510 GB-3911

2 Encoder connection

NOTE

Recommendation: To provide strain relief, the CAN cable can be connected to the screening angle of the EMC Kit (option). Details of the EMC Kit can be found in the BU0500 manual.

DIP switch and 2xRJ45 terminal block, CAN Bus (SK 520E/530E only)

1 CAN_H

CAN Bus signal

max. baud rate

...500kBaud

1 2

DIP switch 2 for CAN Bus

termination resistor

R=120

CAN _H

CAN _L

CAN _GN D

CAN _SHLD

CAN _GN DncCAN _24V

CAN _H

CAN _L

CAN _GN D

CAN _SHLD

CAN _GN DncCAN _24V

RS48 5 _A

RS48 5 _B

GN D

TXD

RXD

+ 5V

RJ45: Pin No. 1 … 8

2 CAN_L

3 CAN_GND

CAN-Bus GND

4 nc

No function 5 nc

6 CAN_SHD

Cable shield

7 CAN_GND

GND / 0V

8 CAN_24V

External 24VDC +/- 25% voltage supply

(Load capacity at least 30mA)

SK 520E or higher: CAN interface, two RJ45

sockets, the bus termination resistor can be switched in.

2.3.3 Assignment of the CAN interface on the frequency inverter

The 24V supply for the absolute encoder and the CAN Bus/CANopen interface must be provided via an external supply. For the assignment of the terminals, please refer to the encoder manufacturer´s operating instructions.

Table 11: Contact assignment for the RJ45 interface

BU 0510 GB-3911 Subject to technical alterations 19

POSICON position control for NORD frequency inverters, SK 530E and above

NOTE

With SK 5x5E devices the frequency inverter control unit must be supplied with power for a further 5 minutes after the last position change in order to permanently save the data.

3 Function description

3.1 Introduction

A wide range of positioning and position control tasks can be performed with the positioning function. In order to facilitate the decision as to which configuration provides the optimum solution for the task, the various processes for the setting of setpoints and recording of the actual values are described in the following sections.

The setpoint can be specified as either an absolute or a relative position. An absolute position is recommended for applications with fixed positions, for example with travelling trolleys, lifts, shelf access devices etc. A relative position is advisable primarily for all axes which operate in steps, especially for endless axes such as rotating platforms and pulsed compartmentalised conveyor belts.Specification of setpoints is also possible via the bus (e.g. Profibus, CAN-Bus, …). Here the position can be specified as a value or combination of bits as a position number or increment.

If switching between positioning and speed specifications is required, this can be realised by switching between parameter sets. A position regulation in parameter P600 "Positioning" is parameterised to "ON" in one parameter set and to "OFF" in another parameter set. Switching between the parameter sets can take place at any time, i.e. even during operation.

3.2 Position detection

3.2.1 Position detection with incremental encoders

For an absolute actual position, a reference point is needed, with the aid of which the zero position of the axis is determined. The position detection operates as long as the frequency inverter is supplied with power. The pulses of the incremental encoder are counted in the inverter and added to the actual position. The resolution or pulse number of the incremental encoder is set in parameter P301 "Incremental Encoder Pulse Number". By setting negative pulse numbers, the direction of rotation can be adapted to the installation orientation of the rotary encoder. After switching on the inverter supply voltage, the actual position = 0 (P604"Encoder Type" without the option "Save Position") or it is at the value which was present on shut-down (P604 "Encoder Type" with the option "Save Position").

The recording of the position functions independently of the enabling signal of the inverter and parameter P600 "Positioning". The inverter determines the actual position for as long as it is supplied with power. Changes in position which are carried out with the inverter switched off do not cause a change in the actual position. Therefore a reference point run is therefore normally necessary after each "Mains switch-on" of the frequency inverter.

If the inverter is not operated in Servo- Mode P300 "Servo Mode" the incremental encoder can also be mounted at another position than on the motor shaft. In this case, the speed ratio of the motor to the incremental encoder must be parameterised. Rotations of the incremental encoder are converted to motor revolutions by the inverter with the aid of parameter P607 "Speed Ratio" and P608 "Reduction Ratio".

nM: Motor rotations

nM = nG * Üb / Un nG:: Incremental encoder rotations

Üb: Speed Ratio (P607[-01])

Un: Reduction Ratio (P608[-01])

Example: The incremental encoder is installed on the output side of the gear unit. The gear unit has a ratio of i = 26.3. The

20 Subject to technical alterations BU 0510 GB-3911

following values are parameterised.

P607 Speed ratio: 263; P608 Reduction ratio: 10

NOTE

The direction of rotation of the incremental encoder must comply with the direction of rotation of the motor. With a positive output frequency (clockwise rotation) the actual position value must increase. If the direction of rotation is not correct, this can be adjusted with a negative value in P607 "Speed Ratio".

With the aid of a value which can be parameterised in parameter P609 [-01] "Offset Position" the zero point can be set to a different position to that which is determined by the reference point. The offset is applied after conversion of the encoder rotations to motor rotations. After changes to the speed ratio/reduction ratio P607 [-01] and P608 [-01] the offset position value must be entered again.

3.2.1.1 Reference point run via digital inputs or BUS I/O In bits

The Reference point run is started via one of the digital inputs or one of the Bus IO In bits. For this a digital input must be programmed for the appropriate function (P420-P425 or P470 "Function Digital Input", setting

22). For the Bus IO In Bits the corresponding Bit / Array (P480 "Bus IO In Bits", setting 22) must be parameterised. The direction of the reference point search is specified via the signals "Enable Left/Right". The current setpoint frequency determines the speed of the reference point run. Via one of the digital inputs the reference point is also read in. For this a digital input must be programmed for the appropriate function (P420-P425 or P470 "Function Digital Input", setting 23). For the Bus IO In Bits the corresponding Bit / Array (P480 "Bus IO In Bits", setting 23) must be parameterised.

In order to also realise the function "Reference Point Run" via a serial interface or via the Bus IO In bits, one of the "Bus Setpoint Values" (P546, P547 and P548) must be set to the setting "Bus IO In Bits 0...7" and under P480 "Function Bus I/O IN Bits" the function setting 22 must be assigned to the corresponding bit.

Sequence of the reference point run: With the reference point run enabled, the drive unit moves in the direction of its setpoint value (Enable Right/Left, +/- Setpoint). On reaching the reference point switch, the signal at the digital input or Bus IO In Bit "Reference Point" reverses the direction of travel. Therefore the drive unit moves away from the reference switch again.

If the drive unit is already at the switch at the start of the reference point run, the reference point run is immediately started with the inverse direction of rotation.

After leaving the switch, the actual position is set to the value which is set in parameter P609 "Offset Position". If the value in parameter P609 "Offset Position" is not "0" then the drive immediately moves to its new zero position and remains at this position until the "Reference Point Run" signal is removed.

In the setpoint mode P610 "Position Increment Array" = 1 (relative positioning) the setpoint position is simultaneously set to 0. With appropriate parameterisation of one of the parameters "Digital Output Function" (P434, P441, P450, P455, setting 20 - reference point), the frequency inverter reports the end of the reference point run with corresponding adoption of the reference point. The feedback for the end of the reference point run can also be reported via the Bus IO OUT bits (P481, "Bus IO Out Bits", setting 20).

If an incremental encoder without the function "Save Position" is used (See P604 "Encoder Type") the actual position in parameter P601 "Current Position" is set to "0" when the frequency inverter is switched on. For parameterisation with the function "Save Position" the last saved value is taken as the actual position.

The relay or output message "Reference Point" shows that a valid reference point is available. The relay or outputs are switched off when a reference point run is started and are switched on again after completion of the reference point run.

If the option "Save Position" (P604 "Encoder Type") is not selected (factory setting) the relay or the output are switched off when the inverter is switched on.

If the option "Save Position" is selected the relay or the output are switched on immediately after the inverter is switched on. Control via one of the Bus IO Bits is correspondingly identical.

BU 0510 GB-3911 Subject to technical alterations 21

3 Description of function

POSICON position control for NORD frequency inverters, SK 530E and above

NOTE

In this case the frequency inverter does not generate an error message.

Parameter

Meaning

P605[-01] Multi-turn

Number of bits of rotations

P605[-02] Single-turn

Number of bits per one revolution

P605[-03] Sin/Cos periods, Hiperface

Number of bits for Sin/Cos periods per rotation

The reference point run can be cancelled by removing the "Enable" signal or by "Emergency Stop" or "Block Voltage".

For further details of the possible functionality settings, please refer to the relevant parameter description in Section 4 Parameter settings.

3.2.1.2 Reset position via digital inputs or BUS I/O In Bits

tAs an alternative to a reference point run, one of the digital inputs can be programmed to the setting "Reset Position" (P420-P425 or P470, setting 61). Control via one of the Bus IO Bits is correspondingly identical. In

contrast to the reference point function, the input or the Bus IO Bit is always effective and when the signal changes immediately sets the actual position from 0 → 1 to 0. If an offset has been parameterised in parameter P609 "Offset Position", the axis will be displaced by this value. Resetting of the position is carried out independently from the setting of the "Positioning" in parameter P600. In "Position Setpoint Mode" the setpoint position (in parameter P610, 1 = Position increment array) is set to 0.

The precision of reproducibility of the referencing via Reset Position is not as good as with the reference point run - as it depends on the tolerance of the reference point switch and the speed with which the switch is approached. However, the precision achieved is sufficient for many applications. In addition, referencing can be performed without interrupting the positioning.

The function "Reset Position" can also be realised via a serial interface or the Bus IO In Bits. For this, one of the bus setpoint values (P546, P547 and P548) must be set to 17 "Bus IO In bits 0...7" and under P480 "Function Bus I/O In Bits" the function setting 61 must be assigned to the corresponding bit.

For further details of the possible functionality settings, please refer to the relevant parameter description in Section 4.

3.2.2 Position detection with absolute encoders

The absolute encoder transfers the actual position value to the frequency inverter in digital form. The position is always completely available in the absolute encoder and is also correct after displacement of the axis when the inverter is switched off. A reference point run is therefore not necessary.

If an absolute encoder is connected, the parameter P604 "Encoder Type" must be parameterised to one of the absolute functions (Setting 1 or 5-15) of the relevant absolute encoder.

The resolution of the encoder is set in parameter P605.

Table 12: Parameter P605 - Selection of encoder resolution for absolute encoders

22 Subject to technical alterations BU 0510 GB-3911

3 Description of function

NOTE

The maximum possible position in parameter P615 "Maximum Position" results from the resolution of the encoder and the Speed Ratio/Reduction Ratio (P607 and P608). Under no circumstances can the maximum value exceed +/- 65535 (16Bit) rotations. Circulation is not permissible. Endless items, which mainly run in a single direction must be realised with an incremental encoder (See Section 3.2.1). Position setpoints should be internally limited to the maximum possible value range.

If the absolute encoder is not mounted on the motor shaft the gear ratio between the motor and the absolute encoder must be parameterised. Rotations of the absolute encoder are converted to motor revolutions by the inverter with the aid of parameter P607 "Speed Ratio" and P608 "Reduction Ratio".

nM: Motor rotations

nM = nG * Üb / Un nG:: Absolute encoder rotations

Üb: Speed Ratio (P607[-02])

Un: Reduction Ratio (P608[-02])

Example: The absolute encoder is installed on the output side of the gear unit. The gear unit has a ratio of i = 26.3. The

following values are parameterised.

Speed ratio: 263; Reduction ratio: 10

The direction of rotation of the absolute encoder must comply with the direction of rotation of the motor. With a positive output frequency (clockwise rotation) the actual position value must increase. If the direction of rotation is not correct, this can be adjusted with a negative value in P607 "Speed Ratio".

The zero point of the axis can be adjusted with the aid of value which can be parameterised in parameter P609 [-02] "Offset Position". The offset is applied after the calculation. After changes to the Speed Ratio/Reduction Ratio P607 [-02] and P608 [-02] the value in parameter P609 "Offset Position" must be entered again.

nM: Motor rotations

nM = nG * Üb / Un nG:: Absolute encoder rotations

Üb: Speed Ratio (P607[-02])

Un: Reduction Ratio (P608[-02])

Example: The absolute encoder is installed on the output side of the gear unit. The gear unit has a ratio of i = 26.3.

The following values are parameterised.

Speed ratio: 263; Reduction ratio: 10

BU 0510 GB-3911 Subject to technical alterations 23

POSICON position control for NORD frequency inverters, SK 530E and above

P514

Baud rate

[kBaud]

P552 [-01]

Default CAN

Master

[ms]

P552 [-02]

Default CANopen Absolute encoder

[ms]

P552 [-02]

Minimum value for

actual cycle time

[ms]

Bus load caused by

an encoder

[%]

42.5

21.2

10 5 17.0

100 5 5 2 17.0

125 5 5 2 13.6

250 5 2 1 17.0

500 5 2 1 8.5

10001 5 2 1 4.25

3.2.2.1 Supplementary settings - SSI absolute encoders

Protocol settings for SSI encoders are made in parameter P617. In detail, this defines:

 the format in which the positions are transferred (binary / Gray code),  whether a loss of voltage to the encoder is communicated to the FI ("Power Fail Bit") and  whether the encoder supports the communication version "Multiply Transmit" for which the position is

communicated a second time in a mirrored form in order to improve the reliability of the transfer.

3.2.2.2 Supplementary settings - CANopen absolute encoders

The baud rate and the CAN address must be set on the encoder. For the assignment of the switches on the encoder, please refer to the manufacturer´s operating instructions.

The CAN address for the absolute encoder should be set in parameter P515 "CAN Address" according to the following formula:

Encoder CAN address = Inverter CAN address (P515[-01] ) + 1

The CAN baud rate set in the encoder must be identical to the parameter P514 "CAN Baud Rate" and all other participants in the bus system.

If parameterisation of the encoder is carried out via the frequency inverter, the transmission cycle for the absolute encoder position is simultaneously set via the baud rate.

For the operation of several CANopen absolute encoders on a bus system, e.g. for synchronous operation, different transmission cycle times can be set for the CAN master and the CANopen absolute encoders.

With the parameter P552 "CAN Cycle Time" the cycle time for the system bus master mode can be parameterised in Array [-01 and for the CANopen absolute encoder in Array [-02]. Care must be taken that the parameterised values are not lower than the values in the column for the minimum values of the actual cycle time. This value depends on the baud rate set in parameter P514 "CAN Baud Rate".

Table 13: Encoder cycle time dependent on the baud rate

The possible bus load in the system always depends on the real-time specific to the system. Very good results are achieved with a bus load less than 40%. Under no circumstances should a bus load greater than 80% be selected. For the estimation of the bus load, the other possible bus traffic (setpoint and actual values for the FIs and other bus participants) should also be taken into account.

Additional explanations about the CAN interface can be obtained from Manual BU 0060.

Only for testing purposes. Reliable operation is not guaranteed.

24 Subject to technical alterations BU 0510 GB-3911

3 Description of function

NOTE

If an IO extension (e.g. SK TU4-IOE) is also used, it must be noted that the addresses 10 … 13 and 20 … 23 are reserved for this module (For details see Manual BU0200).

Parameter

Meaning

Availability

Setting example

P605 [-01]

Multi-turn resolution in bits

SK 530E and

above

 4096 Encoder rotations

25Bit

encoder

P605 [-02]

Single-turn resolution in bits

SK 530E and

above

 8192 Steps per rotation

P605 [-03]

Sin/Cos periods per rotation (Hiperface)

SK 540E and

above

3.2.2.3 Resetting absolute encoders

With the exception of SSI encoders, absolute encoders can be set to the value "0" or to the value set in P609 [02] "Offset Position" via the functions "Reference Point Run"(see 3.2.1.1).

However, the precision of resetting the encoder position greatly depends on the actual speed of movement, the bus load, the baud rate (CANopen encoders) and the type of encoder. Therefore it is urgently recommended that absolute encoders are only reset when they are at a standstill.

With an SSI encoder the position can only be changed via a position offset P609 [-03]. Resetting ("Reset position" / "Reference Point Run") is not possible.

If both an incremental encoder and an absolute encoder are connected to the frequency inverter, both encoders are reset by performing the functions "Reference Point Run" or "Reset Position".

3.2.2.4 Parameterisation on the frequency inverter

Communication settings If a CANopen absolute encoder is used for position detection, the CAN baud rate (P514) and the CAN

address (P515) must be parameterised on both the encoder and the frequency inverter.

After this, the CAN Bus must be supplied with 24V in order to activate communication between all the connected participants.

For all other absolute encoders such as Endat, SSI, … (SK 540E and above), no communication settings are required between the frequency inverter and the associated encoder.

Encoder data settings The resolution of the absolute encoder is set via the parameter P605 "Absolute Encoder":

Table 14: Parameter P605 - Setting of encoder resolution for absolute encoders The relevant settings should be obtained from the data sheet for the absolute encoder.

The absolute encoder is activated via parameter P604 "Encoder Type". Here, a differentiation is made between normal measurement (for "linear" systems) and "path optimised" measurement (for circulating systems) (see Section 3.2.4).

BU 0510 GB-3911 Subject to technical alterations 25

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