User’s Guide For the MX Brushless Servo Drives Amplifier Models MX-280, MX-440 MX-850, MX-1300, MX-1600 Motor Models BL-316, BL-340 BL-455, BL-490, BL-4120 BL-6120, BL-6200, BL-6300
MX AMPLIFIERS User Manual Includes MX Amplifiers and BL Motor Series Information furnished by Emerson EMC is believed to be accurate and reliable, however, no responsibility is assumed by Emerson EMC for its use. Emerson EMC reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. Emerson EMC also assumes no responsibility for any errors that may appear in this document.
CUSTOMER SERVICES Emerson EMC offers a wide range of services to support our customer’s needs. Listed below are some examples of these services. SERVICE SUPPORT (612) 474-8833 Emerson Electronic Motion Control’s products are backed by a team of professionals who will service your installation wherever it may be. Our Customer Service Center in Minneapolis, Minnesota is ready to help you solve those occasional problems over the telephone.
0 INTRODUCTION AND CONTENTS 1 SPECIFICATIONS - AMPLIFIERS/MOTORS 2INSTALLATION - MECHANICAL 3 INSTALLATION - ELECTRICAL 4 FUNCTIONAL DESCRIPTIONS AND CONFIGURATIONS 5 PROGRAMMING - KEYPAD AND MXP 6 START UP PROCEDURES 7 DIAGNOSTICS 8 PARAMETER DESCRIPTIONS 9 SERIAL COMMUNICATIONS 10APPENDICES 11ADDENDUM 12QUICK START (For those who hate reading manuals)
0 Introduction MX servo-drives are designed to operate in one of three command modes - speed, current, or pulse and direction command. For details on the different operation modes, refer to Chapter 4. In speed control mode, the command may be provided by an external analog source, an internal speed preset (4 provided), or serially. In the current command mode the command can also be either an internal digital command, an external analog command or an external serial command.
Figure O.
• FEATURES OF THE MX SERVO DRIVE MX amplifiers can be connected directly to three phase line power. • Customizing adjustments to control parameters can be performed and stored in the removable displaykeypad, or serially through the full duplex RS485 serial link. • Display-keypad module can be transferred, complete with stored personality data, to another amplifier. • MXP user interactive set up program to speed start up, diagnostics and guarantee correct documentation.
Balanced 3Ø, 3-wire, 50 to 60 Hz Voltage range 380V -10% to 460V +10% Output Voltages Motor DC bus voltage Service voltage (380V to 460V) 3Ø less 10 VAC 740V maximum Input signal levels Voltage Range Impedance Analog Digital +/-10V reference supply Output Signals Analog output Digital outputs ±10VDC 10k (Ω) 0.0V to 3.8V = 0 (low) 15k (Ω) +5.
each additional 100m (328 Ft.). Ventilation / Cooling MX servo amplifiers do not require external fans when mounted vertically as described in the amplifier dimensional drawing. Heat sink fans are already integrated into those amplifier sizes that require them. The amplifiers are intended for mounting in an enclosure with adequate space around the amplifier for free air circulation. They should not be mounted above any other device that produces significant heat.
Soft start Max. inrush = 19.5A Resistor capacity: 33Ω 150 W Bus Control (Shunt) Resistors MX Series Amplifiers MX-280 Resistor size Maximum regenerative power MX-440 MX-850 MX-1300 MX-1600 80 Ω, 120 W 1.2 kW for 10 seconds with a minimum cooling time of 90 seconds. 40Ω, 240 W 2.
Fast transient burst IEC 801 - 4 Level 3 Resolver accuracy (arc min.
Motor Specifications BLM/E-3XXX Torque Speed Curve Figure 1.2 BLM/E-3XX TORQUE SPEED CURVE For mechanical dimensions see Appendix. BLM/E-4XXX Torque Speed Curve Figure 1.3 BLM/E-4XXX TORQUE SPEED CURVE For mechanical dimensions see Appendix. BLM/E-6XXX Torque Speed Curve Figure 1.4 BLM/E-6XXX TORQUE SPEED CURVE For mechanical dimensions see Appendix.
2 Installation — Mechanical 2.1 Location and Mounting IP Rating The drive enclosure conforms to international enclosure specification IP20. This means that it is designed so bare human fingers cannot enter the amplifier housing. It is not designed to operate in areas that expose it to high humidity, dirt or dust, wash down, or hazardous or explosive environmental conditions.
screws are provided, to ensure a good ground connection to the mounting surface which should itself be bonded to ground. Spacing Where two or more drives are to be installed side-by-side there must be a gap of 1/8 inch (3mm) minimum, between adjacent drives to facilitate removal of the front terminal cover. 2.2 Cooling and Ventilation Over-Temperature Sensing MX servo-drives are protected from damage caused by overheating. A thermal sensor is mounted on the heat sink.
2.3 Enclosures If an enclosure is to be used, it is important to take into account the dimensions of the amplifiers to ensure adequate clearance for air circulation and for heat dissipation capacity. Your enclosure dealer can assist you with the heat dissipation calculations.
Figure 2.1 shows the mounting hole patterns and air flow requirements. For detailed dimensions, see Appendix. Figure 2.
3 Installation — Electrical 3.1 General Information Safety The voltages present in the supply cables, the output cables and terminals and in certain internal parts of the drive are capable of causing severe electric shock and may be lethal. »» ELECTRIC SHOCK RISK! «« Whenever the drive has been energized, it must be disconnected before work may continue. A period of two minutes must elapse after isolation to allow the internal capacitors to discharge fully.
Table 3.A — Suggested Ground bus bar dimensions: Length inches (mm) Width inches (mm) <20 (500) .75 (20) 20 - 40 (500 - 1000) 1.5 (40) 40 - 60 (1000 - 1500) 2.0 (50) Thickness inches (mm) .1875 to .2500 (5.0 to 6.0) Control Ground The control system grounds should all be connected to a single grounding point in the enclosure and bonded to the enclosure. The control ground point should be placed a minimum of 12 inches away from the Power System Ground.
Figure 3.
Figure 3.1 shows pictorially how an enclosure should be wired for best grounding effectiveness. Notice that the control ground and the high power ground bus are separated physically in the enclosure and that only the control ground bus is actually bonded to the enclosure.
Figure 3.2 Grounding Schematic AZ16 Figure 3.2 shows schematically how a system ground is wired for best grounding and cable shielding. Notice that the logic common on the MX amplifier is referenced to power ground by a 220 KΩ resistor in parallel with a 1 micro farad capacitor. This allows some floating of the logic ground while retaining a reference to Earth ground.
3.2 EMI Interference 3.2.1 IMMUNITY If the instructions in this manual are observed, MX servo drives exhibit excellent immunity to interference from external sources. In accordance with good installation practices, relays, contactors and switches in power circuits adjacent to the drive should have suppressors installed if they control inductive loads. The following paragraphs will suggest the best suppression techniques.
In the case of DC coils, a diode is installed across the coil in a direction that will cause the voltage transient to be shorted out through the diode. The noise is suppressed because its voltage level is limited to less than one volt. In the case of AC coils a capacitor and resistor are installed across the coil. This suppresses the noise by reducing the peak voltage attained and slowing the rise time or it's ability to change voltage quickly.
EMI0 Figure 3.5 Power Connections In the installations that require EMI emissions to be significantly below the acceptable industrial levels there are methods by which the EMI emissions can be reduced. The choices listed here have proven to work but each installation has different characteristics and so must be individually evaluated by the installer. In most cases this requires trying out the solutions to see which one is most effective for that particular installation.
Figure 3.6 EMI Suppression with Ferrite Rings & Capacitors EMI1 In figure 3.5 note the use of a separate isolated power system ground bus for connecting the motor power wire shield and the amplifier ground terminal. The distance between the ground bus and the amplifier terminal should be kept to a minimum for best operation. Figure 3.5 also shows how the recommended connection of a shielded motor cable which should be a satisfactory choice for EMI emission control in most installations.
Figure 3.6 shows how additional suppression is accomplished by smoothing the PWM high frequency signals on the motor power cables and the incoming power supply wires. This is implemented by installing a Ferrite ring on the output wires and decoupling capacitors on the input power wires. The ring has all three phase wires bundled together and wrapped through the ring 3 times as shown. Use very high temperature wire because the rings get VERY HOT!!! -- over 80°C.
Figure 3.7 EMI Suppression with Ferrite Rings EMI2 Figure 3.7 shows a ferrite ring being used to reduce line disturbances if necessary in the installation. The rings are installed by wrapping the bundle of all three supply wires thorugh the ring 3 times as shown. Use very high temperature wire because the rings get VERY HOT!!! -- over 80°C.
3.3 Power Connections POWER WIRING The power terminals are located on the upper surface of the amplifier. (See Figure O.1.) The MX amplifier design allows the power cabling to be run in from above the module and the control wiring from below, with the advantage that the two are well separated for the avoidance of interference with control signals. When using shielded cable, the best results are obtained if the shielding is grounded at both ends - to the motor frame and to the amplifier ground terminal.
3.3.1 Fusing The drive must be protected on the supply side either by dual element fuses (See the fuse ratings chart below) or by suitably-rated three-phase circuit breakers equipped with thermal and magnetic trip. Table 3.B — Power supply fuses and cabling MX Series Amplifiers Units 1 Recommended fuse ratings 2 Typical motor power and line supply cable size MX-280 MX-440 MX-850 MX-1300 MX-1600 Amps 4.0 6.0 10.0 15.0 20.
3.4 Control Connections 3.4.1 Control signal wiring The terminals for the control circuits are on the front, protected by a removable cover 2 (see Figure O.1). The recommended control wiring size is 24 AWG (.25 mm ) to 18 2 AWG (1.0 mm ). Use of wire smaller will result in unreliable connection and use of wire larger can result in strands of wire shorting to adjacent terminals or fatigued and/or broken connectors. For short runs of less than 3 ft. (1 meter), control wiring may be of the twisted-pair type.
and should not run parallel until they are separated by at least 10 to 12 inches. 3.4.4 Serial link Full duplex RS485 (RS 232 compatible) connection is available through the standard male DB type connector identified as Conn. D. in Figure 3.9. RS485 will deliver much greater noise immunity and longer cable length capability than the RS232. Maximum recommended RS232 cable length is 50 ft., whereas RS485 can operate very well up to cable lengths of 3500ft (1000 meters).
Figure 3.
POWER TERMINALS 3.5.1 Power Terminal Connector A (Models MX-280, MX-440) No Function Type Description A1 A2 A3 Phase A Phase B Phase C A4 Ground A5 A6 A7 LINE 1 LINE 2 LINE 3 out out out 1 >Output to motor To System Ground in in in >Power supply input 380 to 460 VAC +/- 10% 3.5.
3.5.2 Control Terminals "B" Connector No Name & Function Type Description B1 External trip/Limit Aux. Analog Input in Auxiliary analog input usable as an external current limit or as an external trip monitor (ref b56). Example - the input from a motor thermistor. Input switches when signal applied drops below 5 v. B2 Zero volts B3 +24V(100mA) out Power supply to external control circuits Driving capacity 100mA B4 Programmable input Digital select./Limit sw. in 5.2 to 30 vdc = 1 (15 KΩ) 0.
3.5.2 Control Terminals "B" Connector No Name & Function Type B11 Zero volts B12 -10V (10mA) out Voltage reference. Max 10mA. B13 +10V (10mA) out Voltage reference. Max 10mA. B14 Drive enable in Logic input to enable the power stage Drive enabled by +5.2 to 30 Vdc at terminal, and b02=1 B15 Drive OK out Logic output to indicate drive healthy Healthy = +24V sourced. PNP open collector output. Active = +18 to 28 VDC output at 50 ma. max. Inactive = 10 Microamps.
3.5.2 Control Terminals "B" Connector No Name & Function Type Description B23 Sine high in Sine signal from resolver B24 Excitation low out B25 Excitation high out 7.812kHz excitation signal for resolver 3.5.3 Simulated Encoder Terminals C No Function Type Description out Channel A of simulated encoder. RS422 5 volt, Line driver output. 10 ma per channel. Refer to Section 4.7 out Inverted channel A simulated encoder. See channel A for specifications.
3.5.3 Simulated Encoder Terminals C No Function Type [Version 2.31 and earlier models only. Pulse Mode selector.] Description [Version 2.31 and earlier] -- +24V selects Pulse / Direction mode reference at C7 and C8. Disables all other Speed References. 0v selects Analog/Digital Reference mode. See Section 4.3 3.5.
AZ18 Figure 3.10 Power Connections In Figure 3.10 note the use of a separate isolated power system ground bus for connecting the motor power wire shield and the amplifier ground terminal. The distance between the ground bus and the amplifier terminal should be kept to a minimum for best operation.
AZ23 Figure 3.11 External Shunt Connections Figure 3.11 shows the amplifier modification required if an external shunt resistor is used. The external resistor is connected between terminals A9 and A10 ONLY AFTER THE INTERNAL RESISTOR IS DISCONNECTED. Users are recommended to ensure that the following precautions are taken when installing an external resistor. • • WARNING IT IS ABSOLUTELY ESSENTIAL that the INTERNAL RESISTOR is DISCONNECTED to avoid overheating it and damaging the driving circuit.
modification has been made. This removes the risk that a modified drive might later be assumed to be in standard condition especially if it is removed from service and possibly used to replace a standard configuration. External Shunt Resistor On the larger MX drives (MX-850/1300/1600) there is a provision on terminal block A to connect an external resistor for applications in which the size of the standard (internal) resistor is inadequate.
AZ20 Figure 3.12 Control Terminals Schematic Figure 3.12 shows a quick overview of the control terminal connections of the MX amplifier. For details of signal operation see the individual connection diagrams and refer to chapter 4.
Figure 3.13 Resolver Wiring AZ19 Figure 3.13 shows a pictorial connection diagram of the resolver interconnection between the MX amplifier and an Emerson EMC motor.
Figure 3.
Figure 3.15 Motor O.T. Switch Connections AZ30 Figures 3.15, 3.16, and 3.17 show the different ways of connecting to digital analog input on Terminal B1. Terminal B1 has two different functions. It can be used to sense the motor temperature either via a PTC (positive temperature coefficient) sensor or a thermal switch in the motor. Figure 3.15 shows the connection to a standard Emerson EMC motor with a thermal switch.
Figure 3.
Figure 3.
AZ24 Figure 3.18 Digital Outputs Schematic Figure 3.18 shows the digital outputs and how they are internally connected to source a signal when in an active state. Each output can drive up to 50 milliamps individually but the limit on the sum total current of all the outputs is 100 milliamps. The recommended connection is to a solid state relay.
Figure 3.19 Programmable Output Assignments AZ6 The Drive OK output is active when all the logic supplies are at the correct levels and there are no Faults that shut down the amplifier output bridge. The Drive OK output will also deactivate when the main power is disconnected and the amplifier logic is being maintained by the logic back-up supply. See sections 4.7.3 and 7.1.
Figure 3.20 Brake Motor Connections AZ25 Figure 3.20 shows how a motor with a brake should be connected. The system controller will have the ultimate decision on when to activate or deactivate the brake signal. The brake should be activated (power removed from brake coil) whenever the amplifier is disabled such as when the Drive OK signal is deactivated or when the drive enable is deactivated either by the hardware input B14 or by the bit parameter b02.
Encoder simulation Version 2.96 and later have 4 resolution AZ41 Figure 3.22 selections available and the selection is made via Pr68. Version 2.31 and AZ21 earlier have two Figure 3.21 resolutions to choose from and are selected via jumpers as shown in Figure 3.23. (The amplifier version is displayed on the keypad during power up.) The resolution selections are in equivalent encoder lines per revolutions per encoder channel. See Section 4.7 for more information. Figure 3.
Figure 3.24 Pulse-Direction Connection AZ22A Figure 3.24 shows how the Pulse and Direction mode of control is connected. See section 4.3 for details on implementation.
Figure 3.25 Serial Port Connection AZ34 RS-485 and RS-232C Connections RS-485 full duplex differential four-wire connection allows a multi-drop links to a maximum of 32 servo drives. The maximum permissible cable length for each link is 3500 ft.(1000 meters). If it is necessary to use an RS-232C link, it is recommended that the cable be well shielded with braided shield cable and the lengths be kept to a maximum of 50 ft. (15 meters) to minimize the noise susceptibility.
4 Functional Descriptions and Configurations In reading this chapter it will be found helpful to refer to the Block diagrams in the Appendix. This section of the User's Guide explains the function of the control logic by treating the principal stages one by one, beginning with the speed command input. Occasionally there are discussions about characteristic differences between various amplifier versions. The version of the particular amplifier in question is easily determined by watching the keypad display.
2 continuous and Peak Current limit, I t limit. These factors are used to set the amplifier to deliver peak performance with maximum safety. (See USER APPENDIX FIGURE 4.1 Logic Flow Diagram.) 4.1.2 Digital This configuration is very convenient in that up to 4 digitally preset speeds can be stored in the amplifier. The presets can be selected by either a binary input pattern applied to the I/O inputs by serial selection or manually via the keypad.
• The status of the inputs at terminals B4 and B5 is displayed by Pr18. 4.1.3 Acceleration and Deceleration Function To enable, B07=1 To disable, b07=0 The ramp values are programmed by setting a time in milliseconds, which is related to a change in speed of 1000 rpm, thus the setting actually specifies the slope of the ramp. The slopes of each of four ramps can be different. When enabled, these ramps are active in all velocity command modes, including analog command. 4.1.
4.2 STOP FUNCTIONS The Stop Function does two things: It stops the motor rotation with or without decel ramps and, it holds the motor position. This means that the motor will not "creep" and will resist forces to move it from it's stopped position. The command stop function can alternatively be programmed to stop and orient the motor shaft to a position - with deceleration ramps only. The motor will be stopped unless all stop commands are removed.
hard the motor will try to maintain the position. If the motor is forced out of position, it will increase current to the motor and will continue increasing it until it returns to the position or until it reaches Icont. It is different than the Pr14 Integral gain which is active during motor rotation. Revision 2.31 and earlier When the motor is rotating at a speed greater than 200 rpm and a Stop command is activated.
stepper which can only assume that the motor actually moved. In performing the motion, the amplifier will provide all the power available to achieve the commanded position. If the position is still not achieved, the amplifier then sends an alarm signal to the controller to alert it of the situation. This closes the position loop and provides for a much more reliable motion control system. 4.3.1 Pulse - Direction Specifications Some of the specifications are dependent on the firmware revision.
digital. The analog current command mode is useful in applications where a servo-motor is to be operated in a "torque helper" type of master/slave configuration. This mode of operation is also applicable when using a position or speed controller capable of commanding current (torque). This controller must have the necessary velocity loop gains and filters built in because when in current command mode, all the amplifier's gains and filter circuits are bypassed.
4.5 Current (torque) Limit function The power stage of the drive is controlled by the current error signal at the summation point where the current feedback from the motor is subtracted from the current command. The current command is subject to limiting in all command configurations before summation with the feedback. Current command is generated by either • the speed error signal after PID, or... • the external analog current command, or...
4.6 Most-used Configuration Settings Note: The MX amplifier utilizes motor current phase advance above 3000 rpm which enables the motor to easily exceed the speed normally determined by the motor voltage constant (Ke) value. A 3000 rpm motor could exceed 5000 rpm! A maximum speed limit is programmable in Pr58. The drive is disabled and will coast if the motor speed exceeds this programmed value in either current or velocity mode. 4.6.1 Speed Controller With Torque Limitation Table 4.
4.6.3 Accel/Decel Ramping To activate ramp function b07=1 Rotation referenced when viewing the motor face. Table 4.F — Description Parameter Setting Default Units CW acceleration CW deceleration Pr09 Pr11 1-9999 1-9999 200 200 ms/1000 rpm " CCW acceleration CCW deceleration Pr10 Pr12 1-9999 1-9999 200 200 " " 4.7 Simulated Encoder The MX amplifier has and encoder simulation output available for the applications that require encoder feedback for position control.
Version 2.31 and earlier, have two resolution selections available - 1024 lines per revolution (4096 steps per rev). or... 512 lines per revolution (2048 steps per rev). (default) Selection is made by adjusting the position of ALL THREE links located on the main logic board (Fig. 1). All three links must be together in one or the other positions. The locations of the links are shown in Figure 4.2. Figure 4.
4.8 Outputs 4.8.1 Programmable Digital Outputs Selected by Pr30 - output at terminal B7 Selected by Pr31 - output at terminal B8 For both outputs, data is selectable from 2 • b89 I t integrating (alarm) • b91 overtemperature (pre-alarm) • b84 overcurrent (alarm) • b38 direction of motor rotation (used for pulse/direction master/slave) • b41 motor status - running/stopped • b42 at-speed status • b48 speed loop saturation status 4.8.
4.9 Fault and Alarm Handling To the MX amplifier a fault is something that is an un-recoverable situation and in these cases, the amplifier output is disabled and the only way to recover is to shut the amplifier down. In the cases where the amplifier has modified it's operation to prevent a failure it will enlist an alarm to warn of the change in operation or of an impending fault. For a list of the alarms and faults, See Chapter 7 on diagnostics.
dangerous if the operator was investigating the reason for the machine stopping and the machine were to restart on it's own. ATTENTION! 2 The amplifier will automatically recover from an I t current limit and will automatically resume full current operation with no warning or operator intervention once the amplifier calculated current level reaches an acceptable level. It is up to the system designer to interlock the machine for operator safety. 4.
Figure 4.
5 Programming Keypad and MXP 5.1 Keypad & Display The keypad and display panel of MX servo drives is a demountable module which incorporates the programmable non-volatile memory. When removed, the module retains any stored parameter settings. This feature enables the amplifier to be replaced without the necessity for reprogramming, or the programmed keypad to be transferred to another amplifier.
Display A five-panel LED display window responds to the actions of the keys, displaying parameter numbers and values in accordance with a simple protocol. Since both Pr and bit parameters are numbered from 00 to 99, they are distinguished in the display by the letters Pr for Parameters and b for bit numbers. Thus, Pr00 is displayed as Pr00, and b00 as b00. The extreme left panel is dedicated to indication of polarity (+ or -) of values, and to values in excess of 9999, for which a figure 1 illuminates.
Figure 5.
5.2 Manipulation of Parameters For details regarding parameter manipulation through the serial link please refer to Chapter 9 after reading this section. When manipulating parameters at the keypad, if no keystroke is made for a period of 8 seconds the display will revert to showing the speed of the motor. Press MODE to return to the point at which the pause occurred. 5.2.
The settings can be saved from the Working Table to the User Table (EEPROM) by setting b99=1. The contents of the Working Table are lost upon powering-off. Notes: • Setting b01=1 recalls the previous values of ALL parameters which have been changed during the present period of use, not only the previous value of the parameter just changed. • Setting b99=1 saves ALL parameter values currently in the Working Table. These values will be active at the next power-on.
Parameter display time-out If, during parameter setting, no keystroke is made for approximately 8 seconds, the display reverts either to rdY if the drive is disabled, or to the present speed if it is enabled. To prevent this, if it is inconvenient during start up and adjustment, set b50=1. This prevents the return to the base display. After the start-up is complete it is recommended to set b50 to 0 afterwards to re-enable the time-out return. Action Effect Press MODE The mode LED illuminates.
5.3.1 To set a Security Code Action Effect Press MODE The mode LED illuminates. The display shows the number of the last parameter to have been accessed, alternating with its value. Press arrow up or down to look through the menu to b00. The present value, 0, will appear in the display and remain steady (not alternating). Press arrow up to change the value to 1. Press MODE to enter the new value. The mode LED extinguishes. Press MODE The mode LED illuminates.
5.3.2 To change a Parameter Protected by the Security Code Action Effect Press MODE The mode LED illuminates. The display shows the number of the last parameter to have been accessed, alternating with its value. Press arrow up or down to look through the parameters to Pr25. Press MODE The value, 0, will appear in the display and remain steady (not alternating). Press arrow up to change Pr25 to whatever number is the correct security code for the drive. Press MODE to enter the code.
6 Start-up Procedures In reading this chapter it will be found helpful to study and refer to the Logic diagrams of the control system and the Mode Selector diagrams in the Appendix. 6.1 Default Status The as-delivered condition of an MX drive is as follows • Speed command is analog ±10V, at terminals B9 and B10. • Acceleration and deceleration ramps are disabled (b07=0). • To enable the drive, a 24V (positive logic) signal is applied to terminal B14. • Limit switch control function is disabled (b16=0).
Figure 6.31 6.3.1 Maximum Current A drive can deliver any level of current up to the maximum for which it is rated. This maximum is marked on MX nameplates as Imax. This level of current is available for a short period of time approximately 4 seconds. However, provision is made to adjust the peak current to a lower value if some aspect of the servo-system requires it.
Pr42 = Ipk x 100 Imax For example, if Imax is 8.8A and Ipk (the desired maximum current) is 5A, then -The resolution of Pr42 is 1(%), so the value entered would be 57 in this example. 6.3.2 Continuous Current The MX amplifier also has a provision to allow adjustment of the continuous motor current. This is the current at which the motor is able to operate indefinitely without overheating (in the specified ambient conditions).
Table 6.A — Standard system settings chart Current limits MX Drive BL Motor Pr42 Pr45 Pr55 MX-280 316-4 100 28 7 340-4 100 44 7 MX-440 455-4 100 36 8 MX-850 490-4 100 27 9 4120-4 100 40 9 6120-4 100 35 10 MX-1300 6200-4 100 28 10 MX-1600 6300-6 100 30 10 6.3.
Figure 6.32 6.4PID Function The default values in the PID gains will need to be adjusted to the values that best match the motor and the load. The best starting values are listed in the following chart.
Table 6.B — Standard system settings chart Gain settings MX Drive BL Motor Pr13 Pr14 Pr15 MX-280 316-4 11 22 33 340-4 14 25 28 MX-440 455-4 14 30 30 MX-850 490-4 14 30 30 4120-4 19 30 30 6120-4 10 20 30 MX-1300 6200-4 24 28 30 MX-1600 6300-6 23 30 30 6.5Full-Scale Speed Calibration Typically, motion controllers match a speed command signal of 8V to 9V with maximum speed, reserving a margin of 1V to 2V to cover tracking errors.
values will be applied at the next power up. 6.6 Resolver Phasing Emerson motors require a setting of Pr16 = 170. If a complete reset is performed on the MX amplifier, (b05 = 1), the resolver offset must be re-entered into Pr16. Motors supplied by Emerson EMC are pre-aligned and will not require this procedure except for diagnostic purposes. If another brand motor is used on an MX amplifier it may not have its resolver set to the same position as an Emerson motor so an alignment procedure must be performed.
Figure 6.
Figure 6.
After the motion is completed, the display will show the phase difference between the motor and the resolver. Record the value displayed. Select Pr16 and enter a value equal to the sum of its present value and the value recorded at the end of the phase control procedure. The range of Pr16 is 0 to 2047. If the sum is <2047, set the values of the sum; if the sum is >2047, subtract 2047 and set the difference. For example 1 The value recorded at the end of phase sequence is 250.
that b18=0 (default value). 6.7.2Motor Function Tests For the following tests it is recommended that the motor should be mechanically uncoupled, although it is not essential if the load is easy to rotate by hand. 1 Select parameter Pr83. Rotate the motor shaft by hand in a clockwise direction (looking at the shaft end of the motor). Observe that the displayed value of Pr83 increments as the shaft is turned. Reverse the direction of rotation and observe that the value decrements.
6.8.1Zero Speed Calibration (Offset) The applied speed command may sometimes have an offset, causing the motor to turn slowly with a zero command. Input offsets can be compensated with Pr06. The offset value entered is the actual motor speed with a resolution of 0.1 rpm. 6.8.2Dynamic Tuning Final tuning is performed with the motor coupled to its normal load.
1 - Preliminary Settings Set b07=0 b12=1 b18=0 Pr58=maximum speed (=Pr99) Pr99=full-scale speed of the motor 1A - for Digital Command system Parameters Set b17=1 Pr00=Pr58/5 Pr01=Pr58/5 Pr02=Pr58/5 Pr03=Pr58/5 Pr19=2 (=.5Hz) Pr21=1 Terminals Disconnect terminal B6, (Stop-hold). 1B - for Analog Command system Parameters Set b17=0 Terminals Disconnect terminal B6,(Stop-hold). Disconnect terminals B9 and B10 disconnect the command. connect terminals B9 to B11.
Speed may be reduced by decreasing the programmed values of Pr00, Pr01, Pr02, Pr03, or the inversion frequency may be increased by decreasing the value of Pr19. Figure 6.
Figure 6.36 Overshoot Response AZ39 Figure 6.37 Ideal Response AZ39B Figure 6.
6.8.3 - Tuning Procedure Enable the drive by a 24V signal at terminal B14 and by setting b02=1. Wave forms such as those shown in Figure 6.5 show a dynamic gain (proportional effect) that is too low. Increasing the value of Pr13 (proportional gain) will achieve a trace similar to Figure 6.6, which, however, shows poor derivative effect. Increasing the value of Pr14 (derivative gain) will reduce the overshoot and remove the oscillation, to achieve a result similar to Figure 6.7.
7 Diagnostic Procedures All read-only (RO) parameters are software 'test points', enabling the user to monitor all significant functions of the drive for diagnostics purposes. RO parameters are identified in Block Diagrams (Chapter 10) by the diamond box. 7.1 Alarm and Fault Codes The keypad / display will automatically display a fault. The fault indications are also accessible serially by interrogating the bit-flags.
shorts in motor leads, verify correct motor and power connections. Et 10 External trip. b55=1 — Usually motor overtemperature sensor connection. Inhibits amplifier and motor coasts. See Chapter 7. Check for proper utilization of External Trip/external current limit input. dOI ---- Drive Operating Incorrectly. Fault may be cleared by power-off and power-on. If this re-occurs then check the system ground and shield integrity. Refer to Section 3.1, (Grounding) and Section 3.2 (Suppression).
has torque, develops peak current, may vibrate, and 2 enters I t region. especially for swapped motor phases. With drive enabled and a speed command applied, motor has no torque. No motor current. Check that current limit (either analog or digital) ≠ 0. (Refer to b11 or Pr42, Pr43 and Pr45. No Serial Communications possible. Serial comms. set up error. Check baud rates and verify the protocol is correct in Terminal mode. Check polarity of wiring connections.
8 Parameter Descriptions Programmable parameters are used in the MX amplifier to set up for the different modes of operation and to make various system adjustments. There are two groups of parameters. One is a bit parameter and the other is a Numerical parameter. The bit parameters can be described as a switch, they are either on or off. Bit parameters are used to either enable or disable certain functions or features.
8.1 Numerical Parameters - Descriptions Pr00 R/W Digital Speed Preset 0 P Range -3000 to +3000 rpm if 200 ≤ Pr99 ≤ 3000 -6000 to +6000 rpm if 3200 ≤ Pr99 ≤ 6000 Default 0 Resolution 1 rpm Parameters Pr00, Pr01, Pr02, and Pr03 are programmable digital speed commands. Their selection is controlled through Pr17, which receives its coding from the values of Pr18, Pr19, and Pr20, as selected by b16 and Pr21. Refer to Pr17, Pr18, Pr19, Pr20, Pr21 and b16.
Pr09 R/W Acceleration Ramp Forward Range 1 to 3000 ms Resolution 1 ms Default 200 ms This is the slope of the ramp, measured in milliseconds per 1000 rpm. See b07. Pr10 R/W Acceleration Ramp Reverse Range 1 to 3000 ms Resolution 1 ms Default 200 ms This is the slope of the ramp, measured in milliseconds per 1000 rpm. See b07. Pr11 R/W Deceleration Ramp Forward Range 1 to 3000 ms Resolution 1 ms Default 200 ms This is the slope of the ramp, measured in milliseconds per 1000 rpm. See b07.
Pr18 RO I/O Digital Input Status (terminals B4 & B5) Range 0 to 3 Signals at terminals B4 and B5 -< 5V = 0 > 5V = 1 Configuration of Pr18 Terminal B4 B5 Pr18 0 0 0 0 1 1 1 0 2 1 1 3 Pr19 R/W Digital Speed Preset Scan Time Range 0.1 to 6000 sec Resolution 0.1 Default 10 sec Refer to the Section 4.1.2 Pr20 R/W Digital Speed Preset Selector Range 0, 1, 2, or 3 Resolution 1 Default 0 Selects one of the speed presets to be active; Pr00, Pr01, Pr02, or Pr03.
Protects all R/W parameters marked P when Pr25 is set to any integer value >0. They can be read at any time, but cannot be changed unless the security procedure is performed after every power up. After power up the correct security code must be entered to allow changing the protected parameters. This accessible status remains until power down. When the drive is in 'as-delivered' condition, the value is the default value, and all parameters are accessible. Refer to Section 5.3 See also b00.
Refer to Section 6.3 Pr41 RO Current Limit Value Range 0 to +100 Resolution 1 Displays the current limit value corresponding to whichever is the least of2 I t limit Pr43 analog limit Pr39 if b11=1 digital limit Pr42 Reads 0 if drive disabled Expressed as a percentage of the maximum amplifier current rating. 100% = Imax Pr42 R/W Current Limit Peak P Range 0 to 100% Resolution 1 Default 100% Expressed as a percentage of the maximum amplifier current rating.
Pr57 R/W At-Speed Window - upper limit Range +Full Scale Speed (Pr99) Resolution 1 rpm Default 5 rpm Sets the upper limit at which the At-Speed output will activate. Accuracy is 1 RPM. Positive (+) value required when in relative mode. Refer to Pr56, b42 and b96. Pr58 R/W Over Speed Limit P Range 0 to 6500 rpm Default 3200 rpm Resolution 1 Fault limit. Absolute value of motor speed at which the amplifier will shut down and disable the output to the motor.
Default 3000 rpm Sets the full scale value range for analog input and sets speed range for digital commands. +/- 10 volts on analog speed command input corresponds with +/- Pr99 value. Fine adjustment to the analog full scale setting is accomplished by the full scale potentiometer accessible through the front of the amplifier just above Terminal B9. Digital speed ranges: -3000 to +3000 rpm if 200 ≤ Pr99 ≤ 3000 -6000 to +6000 rpm if 3200 ≤ Pr99 ≤ 6000 Refer to Section 6.5 See Pr00 8.
b06 R/W Command Selector - speed/current P Default 0 0 Speed command, either analog or digital. 1 Current command, either analog or digital. Warning: b06 may be changed only when the drive is disabled with b02 and the motor is stopped. See b17, b08 b07 R/W Ramping enable P Default 0 0 disable velocity ramping. 1 enable velocity ramping. When enabled, the ramps affect all velocity command modes including analog input and pulse - direction modes.
b14 R/W Pulse / Direction mode P Default 1 Firmware rev. b14 b17 mode 0 1 X 0 0 1 2.95 + Pulse / Direction mode Analog speed command mode I/O speed preset selection Pulse / Direction Resolution Max. Speed Setting Pr99 Max. Frequency 8192 4096 200 to 3000 rpm 3200 to 6000 rpm 409.6Khz Refer to Section 4.3 See b17 b16 R/W I/O Input Function Selector P Default 0 Selects the function of the I/O inputs at terminals B4 and B5.
0 without ramps 1 with ramps Refer to Section 4.2 b33 RO Alarm Status 0 at least one alarm is active 1 no alarm active See Pr98, b03 b38 RO Direction of Motor Rotation Direction described when viewing motor drive shaft end. 0 reverse = counterclockwise 1 forward = clockwise Approx 150ms update time. This bit is available on the outputs by setting the programmable output selectors Pr30 and Pr31. b41 RO Zero Speed Status 0 motor not at zero speed 1 motor at zero speed Actual activation is at 1 rpm.
1 Terminal mode Refer to Chapter 9. b53 R/W Orient Stop Mode Selector P Default 0 0 stop and hold 1 orient stop and hold See Pr37, 27. b55 RO External Trip Alarm 0 no external trip 1 external trip active b56 R/W External Trip Enable P Default 0 0 trip disabled 1 trip enabled b81 RO Short Circuit 0 circuit normal 1 short circuit present Indicates that the 24 volt I/O supply output current exceeds 200 milliamps. See Chapter 7, SC Fault. b82 RO DC Bus Overvoltage 0 D.C.
Defines the meaning of the signal given by the 'At-Speed' Status bit b42. 1 (relative) The Actual motor speed is compared to the Speed Command input and At-Speed Status is set (b42=1) when the motor speed is within the window determined by: (Command + Pr56) < (Actual motor speed) < (Command + Pr57). 0 (absolute) The Actual motor speed is compared to the absolute values set in Pr56 and Pr57, and the At-Speed Status is set (b42=1) when: (Pr56) < (Actual motor speed) < (Pr57). See Pr56, Pr57 and b42.
Summary of Default Values — Numerical Parameters Parameter Default Units Name P P P P P P P P P P P P P P P P P P P P P P Pr00 Pr01 Pr02 Pr03 Pr06 Pr07 Pr08 Pr09 Pr10 Pr11 Pr12 Pr13 Pr14 Pr15 Pr16 Pr19 Pr20 Pr21 Pr22 Pr23 Pr25 Pr27 Pr30 Pr31 Pr37 Pr42 Pr45 Pr55 Pr56 Pr57 Pr58 Pr68 Pr95 Pr99 0 0 0 0 0 1 0 200 200 200 200 30 30 30 0 10 0 0 1 9600 0 0 0 1 255 100 50 7 5 5 3200 1 6 3000 rpm rpm rpm rpm rpm [table] % ref.
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9 Serial Communications The serial interface allows direct connection between MX servo drives and a remote host computer or programmable logic controller (plc). The host can both monitor and control the servo drive. Two types of communication protocol can be used. The more complex complies with ANSI x3.28-2.5-A4 and, for all normal industrial operations, is recommended for its reliability. The second, known as Terminal Mode, is simpler and may be more convenient to use during a commissioning period.
Figure 9.40 Serial Connections AZ34 Figure 9.2 shows the two serial protocol connections. An RS232 cable for connection to an IBM AT (9 pin) is available from Emerson EMC as Model numbers: MSA-10 (10 ft.) MSA-25 (25 ft.) MSA-50 (50 ft.
Control Characters To conform to the standard structure of a message, the stages of a message are signalled by control characters. Each character has a specific meaning, a standard abbreviation, and is transmitted and received in ASCII code. If a message is initiated from a keyboard, the control characters are keyed by holding the Control key down while making a single-letter keystroke. Of the 32 control characters in the ASCII set, the six in the following table are used in MX serial communications.
INTERROGATE THE DRIVE - 'Request Data' Format The query command consists of a maximum of 9 characters, but may use fewer. The format must be correct for the command to be successful. The format is constructed of a number of characters in a set sequence, thus | EOT | Address | Parameter | ENQ | EOT EOT (04 hex) is an ASCII character employed to initialize the message and to alert the receiver that a message is to follow.
DRIVE REPLY TO INTERROGATION "Send data" The drive will reply with a message in the following format: | STX | Parameter | Data | ETX | CR or BCSopt | STX (02 hex) is an ASCII character used to inform the host that a response message is starting. Parameter For confirmation, the message identifies the parameter to which the data relates. The same three-figure format is used as in the transmission query. Data Six characters are available for the data.
Quick Keystrokes After the serial communication has been established to one axis by the first complete query, some data can be acquired with reduced transmission time by using the following quick keystrokes. The amplifier will respond with a full response string. Repeat last response NAK (15 hex) will cause the drive to repeat the data for the last parameter queried. This is a quick way of observing a changing situation, since the drive is always sending updated information.
INSTRUCT THE DRIVE - 'Write Data' Data written to a drive controls its operation. A plc or a computer can therefore be in complete and constant control of each drive in a chain. Complex sequences can be performed under precise control, and with full access for data acquisition. With the only limitation being the transmission speed. Commands can be sent to the amplifiers either individually or globally, that is all receiving the same command at the same time.
TERMINAL MODE Terminal mode uses a simplified protocol | EOT | Address | CR | For example, for drive whose address is 02, if the axis selection string sent is | EOT | 0022 | CR | the drive will respond with 02> The computer will remain in open communication with this drive until a different axis selection string is sent.
Error Messages Plain language error messages are returned in Terminal Mode as follows SYNTAX ERROR Message string does not comply with format. PARAMETER NOT RECOGNIZED The number in the Address field which does not apply to any parameter. VALUE OUT OF RANGE Value sent is above or below the maximum or minimum values permissible for the parameter addressed. TOO MANY CHARACTERS 20 characters is the maximum permitted in Terminal Mode.
SERIAL COMMUNICATIONS PARAMETERS P = Parameter protected by Security Code Pr22 R/W Serial Address P Range 1 to 32 Resolution 1 Default1 Required for all systems where the Serial Link is to be used to identify each individual drive on the serial line. Note: Each address on a single serial line must be unique. Refer to Chapter 9 Pr23 R/W Serial Baud Rate P Range (see below) Default9600 Available values are 300, 600, 1200, 2400, 4800, 9600, 19200 Set this parameter value to the baud rate of the host computer.
Logic Flow Diagram
12 Quick Start This chapter will show people who are experienced with servo drive systems how to get the system started in a basic analog velocity command mode. Very little detail is covered here but references are made to the appropriate sections of the manual as necessary.
Suggested Ground bus bar dimensions: Length inches (mm) Width inches (mm) <20 (500) .75 (20) 20 - 40 (500 - 1000) 1.5 (40) 40 - 60 (1000 - 1500) 2.0 (50) Thickness inches (mm) .1875 to .2500 (5.0 to 6.0) 12.1.2 Power wiring Chapter 3 covers power wiring recommendations in more detail. Fusing The drive must be protected on the supply side either by dual element fuses (See the fuse ratings chart below) or by suitably rated three-phase circuit breakers equipped with thermal and magnetic trip.
Figure 12.
Figure 12.59 Power Connections AZ18 In Figure 12.2 note the use of a separate isolated power system ground bus for connecting the motor power wire shield and the amplifier ground terminal. The distance between the ground bus and the amplifier terminal should be kept to a minimum for best operation.
Figure 12.60 Resolver Connections AZ19 Figure 12.3 shows the resolver cable interconnection between the MX amplifier and an Emerson EMC motor.
Figure 12.61 Brake Motor Connections AZ25 Figure 12.4 shows how a motor with a brake should be connected. The system controller will have the ultimate decision on when to activate or deactivate the brake signal. The Brake should be activated (power removed from brake coil) whenever the amplifier is disabled such as when the Drive OK signal is deactivated or when the drive enable is deactivated either by the hardware input B14 or by the bit parameter b02.
Figure 12.62 Control Terminal Schematic AZ20A Figure 12.5 shows a quick overview of the control terminal connections of the MX amplifier. For details of their operation refer to Chapters 3 and 4.
Figure 12.
Encoder simulation Version 2.96 and later have 4 resolution selections available and the selection is made via Pr68. (The amplifier version is displayed on the keypad during power up.) The resolution selections are in equivalent encoder lines per revolutions per encoder channel. See Section 4.7.2 for more information.
12.2 Preliminary Settings Power up the system with the amplifier disabled (B14 disconnected) until the following parameters are adjusted. NOTE: Remember to store the parameters by setting b99=1. See Section 5.2.3 for keypad operation details. If you are using the MXP set up program, the parameters referred to in Section 12.2 will be automatically set and the amplifier will be ready to operate after the initial system select screens. 12.2.1 Resolver setting.
Amplifier Current capacity chart Current rating (RMS amps) Amp Model Continuous Maximum MX-280 2.8 5.6 MX-440 4.4 8.8 MX-850 8.5 17.0 MX-1300 13.0 26.0 MX-1600 16.0 32.0 12.2.3 System gain settings The best gain settings to start with when setting up an application for the first time are listed in the standard settings chart. Once the gain settings are set, the only calibrations left are the offset and full scale speed calibration.
