Operating Manual BY340 / BY641 High performance low cost synchronous controllers for one slave axis Product Features: Precision angular synchronization and speed ratio control High accuracy due to high feedback frequency range (300 kHz with TTL encoders and 200 kHz with HTL encoders) Full remote phase control by Index pulse operation, Trim functions etc.
Version: BY34002a/April 07/mb/hk BY34002b/July 07/mb/hk BY34002c/Nov 11/sm BY34002d/Feb 12/pp BY34003a / Jun 12 / TJ BY34004a / March 15 / TJ By340_04b_oi/Dez-15/ag Description: First edition Small corrections and supplements Changing relay output BY641 Small corrections and supplements New parameter F08.071; new actual display value Index Correction New parameter F03.
Table of Contents 1. Safety Instructions and Responsibility ............................................................................................ 4 1.1 1.2 1.3 1.4 2. 3. 4. Available Models ........................................................................................................................... 6 Introduction .................................................................................................................................... 7 Electrical Connections ...............
1. Safety Instructions and Responsibility 1.1 General Safety Instructions This operation manual is a significant component of the unit and includes important rules and hints about the installation, function and usage.
1.3 Installation The device is only allowed to be installed and operated within the permissible temperature range. Please ensure an adequate ventilation and avoid all direct contact between the device and hot or aggressive gases and liquids. Before installation or maintenance, the unit must be disconnected from all voltage-sources. Further it must be ensured that no danger can arise by touching the disconnected voltagesources.
2. Available Models The two models as shown below are available. Both models are fully similar in terms of function and performance; however there is some difference with the size, the alert outputs and the speed ratio setting. BY340: Front size 96 x 48 mm (3.780’’ x 1.890’’) Speed ratio setting by keypad Analog output 14 bits 4 power transistor outputs (alert) BY641: Front size 96 x 96 mm (3.780’’ x 3.
3. Introduction The BY340 / BY641 units are suitable to operate as electronic synchronous controllers with speed-variable drives of any kind and any size, provided they dispose of an analog input to set the speed. The operation is based on a Master / Slave principle. The Master could basically be any moving part of a machine, provided there is a quadrature incremental encoder signal available from the Master motion.
Example shows wiring for encoders with 5 volts power supply and RS422 line driver output Master +24 +5 A /A B /B - Slave Slave motor Reset, Trim, Index etc. RS232 Drive Slave speed signal By340_04b_oi_e.doc / Dez-15 +24 +5 A /A B /B Ana.out 20 mA Ana.out +/-10V GND GND Slave, B Slave, A 23 24 25 26 27 28 29 30 31 32 +24V aux.out 17 18 19 20 21 Master, B Master, A K2 out K1 out Cont. 2 Cont. 1 Com+ (K1-K4) TxD (RS232) GND 8 9 10 11 12 13 14 15 16 +Vin +5,2V aux.
Terminal 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Name GND +5,2V out +24V out GND Slave, /B Slave, /A Master, /B Master, /A K4 out K3 out Cont.4 Cont.3 (PROG) RxD Ana.out 20 mA Ana.out +/-10V +Vin +5,2V out +24V out GND Slave, B Slave, A Master, B Master, A K2 out K1 out Cont.2 Cont.1 Com+ (K1-K4) TxD GND GND Function Common Ground Potential (0 V) Aux. output 5.2 V/150 mA* for encoder supply Aux.
4.1. Power Supply The BY340 synchronizer accepts both, a 17 … 40 VDC power or a 24 VAC power for supply via terminals 17 and 1. The current consumption depends on the level of the input voltage and some internal conditions; therefore it can vary in a range from 100 … 200 mA (auxiliary currents taken from the unit for encoder supply not included). 4.2. Auxiliary Outputs for Encoder Supply Terminals 2 and 18 provide an auxiliary output with approx. +5.2 VDC (300 mA totally).
4.4. Control Inputs Cont.1 – Cont.4 These inputs can be configured for remote functions like Reset, Phase trimming, Index evaluation or display selection purpose. All control inputs require HTL level. They can be individually set to either NPN (switch to -) or PNP (switch to +) characteristics. For applications where edge-triggered action is needed, the menu allows to set the active edge (rising or falling). The Control inputs will also accept signals with Namur (2-wire) standard.
5. Principle of Operation 5.1. Synchronization The Synchro controller receives full positional information about the master axis by means of the Master encoder. This incremental information can be scaled by means of the Master Scaling Factor (subsequently named Factor1). From this information the unit can calculate an analog speed output signal which is necessary to make the Slave axis exactly follow to the Master. The feedback of the actual position of the Slave axis is given by the Slave encoder.
5.2. Mechanical Phase and Position Considerations Normally the synchronizer would always keep the angular phase or relative position between Master and Slave, which has existed while the unit has been powered up, or which has been defined manually while the unit was kept in the Reset state. However it may be desirable to adjust the relative position in standstill or on the fly, by means of manual or remote commands, or even to set a certain position automatically, triggered by external events.
Please observe the minimum duration of 50 µs. for index pulses Every index pulse must clearly mark one explicit and repeatable event within one machine cycle 6. Operating Modes The operating mode (parameter F02.004) sets the functions of Trim and Index inputs, provided that these functions have been assigned to some Control Inputs or front keys. Mode Trim Input Function F02.004 +/- Phase trim by internal 1 2 timer. Temporary change of Slave speed while one of the Trim commands is on.
7. Keypad Operation An overview of all parameters and explanations can be found under section 8. The menu of the unit uses four keys, hereinafter named as follows: PROG UP DOWN ENTER Key functions depend on the actual operating state of the unit. Essentially we have to describe three basic states: Normal operation General setup procedure Direct fast access to scaling factors 7.1.
The adjoining sequence of key operations explains how to change Parameter number 052 of group F06 from the original value of 0 to a new value of 8: Step 00 State Key action Normal operation Level: Parameter group 04 Level: Parameter numbers 05 06 > 2 sec. F01 Display of the Parameter group 5x F02 … F06 Select group # F06 F06.050 Confirmation of F06. The first parameter of this group is F06.050 F06.051… F06.052 Select parameter 052 03 Level: Parameter values 2x 09 10 1 ….
7.4. Change of Parameter Values on the Numeric Level The numeric range of the parameters is up to 6 digits. Some of the parameters may also include a sign. For fast and easy setting or these values the menu uses an algorithm as shown subsequently.
7.5. Code Protection against Unauthorized Keypad Access Parameter group F09 allows to define an own locking code for each of the parameter menus. This permits to limit access to certain parameter groups to specific persons only. When accessing a protected parameter group, the display will first show “CODE” and wait for your entry. To continue keypad operations you must now enter the code which you have stored before, otherwise the unit will return to normal operation again.
8. Menu Structure and Description of Parameters All parameters are arranged in a reasonable order of functional groups (F01 to F09) You must only set those parameters which are really relevant for your specific application. Unused parameters can remain as they actually are. 8.1. Summary of the Menu This section shows a summary of the parameter groups, with an assignment to the functional parts of the unit.
F06 Command Assignment F09 Keypad Protection Codes 046 047 048 049 050 051 052 053 054 055 056 057 Key Up Function Key Down Function Key Enter Function Input 1 Configuration Input 1 Function Input 2 Configuration Input 2 Function Input 3 Configuration Input 3 Function Input 4 Configuration Input 4 Function Reserve F07 Serial Communication 058 059 060 061 062 063 Unit Number Serial Baud Rate Serial Format Reserve Reserve Reserve 072 073 074 075 076 077 078 079 080 081 082 083 084 085 086 087 Prote
The following schematics shows how in principle the parameter blocks are assigned to the various elements and functions of the controller. Master Slave Digital Control Inputs Cont1 Cont2 Cont3 Cont4 RS232 F03 F01 F04 F01 F06 F08 F10 up P dn K1 out K2 out K3 out K4 out Alert Outputs ENT F06 F09 F06 +/-10V Analogue F05 20 mA Outputs F07 8.2. Description of the Parameters 8.2.1. Impulse Scaling F01 F01.000 Factor 1: Impulse scaling factor for Master encoder. F01.
F02 F02.007 F02.008 Correction Divider: Function to provide a digital attenuation of the phase correction signal that is produced, when the drive on mechanical grounds (dead band or backlash) cannot respond. In such a case, it is not desirable to make corrections immediately. The "Correction Divider" provides a window for the drive "backlash", within which the controller produces no correction and a division of the differential error count.
F02 F02.011 Sampling Time: Sets the internal digital feed forward control with respect to dynamics and resolution. Lower set values result in faster response, but less accuracy of the feed forward signal. Higher set values result in better accuracy, but slower response with sudden speed changes. Range 0.001 … 9.980 (seconds) Default 0.001 0.01…9.99 9.99 0.1 …300000.0 (Hz) 30000.0 0 … 999 (sec.) 0 0 … 999 (sec.
F02 F02.018 Range -199999 - 199999 Phase Offset * Allows setting a position offset between the Master index and the Slave Index. When set to zero, the controller will align the active edges of both index signals. Setting is in Slave encoder increments. Default 0 Index Master Adjustable Phase Offset Index Slave Slave Pulses Index F02.019 F02.
F02 F02.022 F02.023 Index Window * Sets a window (encoder increments) where the slave index pulse should be within with regard to the actual master index position. The output is ON when the Slave index is inside the tolerance window Max. Index Correction * The response to registered marker pulse errors is limited to the value set here (encoder increments). Works similar to parameter “Phase Adjust” but allows absolute limitation of the amount of index correction to a level that can be handled by the drive.
8.2.3. Definitions for the Master Encoder F03 F03.026 Encoder properties 0= Differential Impulses A, /A, B, /B (2 x 90°) incl. inv. 1= Single-ended Impulses A, B (2 x 90°) without inv. F03.027 Edge counting 0= Simple edge evaluation (x1) 1= Double edge evaluation (x2) 2= Full quadrature edge evaluation (x4) F03.028 Counting direction 0= Up when A leads B 1= Down when A leads B F03.029 Speed Display Factor Multiplication factor to calculate the speed display value from the master frequency (see chapter 9.
8.2.5. Analog output definitions F05 F05.038 Control characteristics and analog format 0= The slave speed changes proportionally to the Factor 1 setting, i.e. doubles motor speed when changing Factor 1 from 1.00000 to 2.00000. (suitable for most of all applications) Output scaled for a -10 volts … +10 volts signal 1= The slave speed is reciprocal to the Factor 1 setting, i.e. halves the motor speed when changing Factor 1 from 1.00000 to 2.00000.
8.2.6. Key command assignments F06 F06.046 Function assignment to key „UP“ 0= No function 1= Reset 2= Trim 3= Trim + 4= n. a. 5= n. a. 6= Integrator off 7= Store EEProm 8= Scroll Display 9= n. a. 10= Clear Min. & Max. 11= n. a. 12= n. a. 13= n. a. 14= Read front thumbwheels (model BY641 only) 15= Stop Slave 16= n. a. F06.047 Function assignment to key „DOWN“ See key „UP“ F06.048 Function assignment to key „ENTER“ See key „UP“ n. a. = not applicable By340_04b_oi_e.
8.2.7. Characteristics and functions of the Control Inputs F06 F06.049 Switching characteristics of input „Cont.1“ 0= NPN (switch to -), function active LOW 1= NPN (switch to -), function active HIGH 2= NPN (switch to -), rising edge 3= NPN (switch to -), falling edge 4= PNP (switch to +), function active LOW 5= PNP (switch to +), function active HIGH 6= PNP (switch to +), rising edge 7= PNP (switch to +), falling edge F06.050 Function assignment to input „Cont.
Unconnected NPN inputs are always HIGH (internal pull-up resistor) Unconnected PNP inputs are always LOW (internal pull-down resistor) When you use Index operation, it is mandatory to use Control Input 1 as Master Index (F06.050 = 12) and Control Input 2 as Slave Index (F06.052 = 11). These two inputs are no more available for other purpose. Index inputs must always be edge-triggered, i.e. parameters F06.049 and F06.051 must be either 2 or 3 or 6 or 7 when you use index operation.
8.2.9. Special functions F08 F08.064 Digital input filter: must be set to “0”. F08.065 Trigger threshold for encoder1 inputs *) F08.066 Trigger threshold for encoder2 inputs *) F08.067 Brightness of the 7-segment LED display 0= 100% of maximum brightness 1= 80% of maximum brightness 2= 60% of maximum brightness 3= 40% of maximum brightness 4= 20% of maximum brightness F08.068 Frequency Control: must be set to “0” F08.
9. Description of Commands and Outputs 9.1. Commands No. Command Description 1 Reset 2 Trim- 3 Trim+ 4 5 6 n. a. n. a. Integrator off 7 Store EEProm 8 Scroll Display 9 Parameter Disable Clear Min. & Max Index Slave Index Master n. a. Read Reads and activates the Factor 1 setting from the front Thumbwheels thumbwheel switches (model BY641 only) Stop Slave Ramps the Slave drive down to standstill using the “Stop Ramp”. When released, the Slave ramps up again and locks into synchronization n. a.
9.2. Outputs No. K1 K2 K3 K4 Output Alert 1 This output indicates that the position error has exceeded the preset tolerance band as specified by parameter F02.16 “Alert 1” Alert 2 / Index ok When operating without index pulses, this output also works as alert signal. It then indicates that the position error has exceeded the preset tolerance band as specified by parameter F02.17 “Alert 2”. With index operation (Parameter F02.004 „Operation Mode“ = 2, 6 or 8), K2 works as “Index ok” output.
9.3. Display of Actual Values During normal operation it is possible to display an actual value. Two LEDs at the front panel indicate the actual value displayed. You can scroll the actual value on the display by Scroll Display command, which can be assigned either to a key or to an input. Parameter F08.071 “Default Display” selects the actual value to be displayed after power up of the unit. No.
10. Steps for Commissioning For easy and uncomplicated commissioning of the BY340 / 641 controllers you need a PC with the actual operator software OS3.x. You can download this software and full instructions, free of charge, from our homepage www.motrona.com. Connect your PC to the synchronizer as shown in section 3.6 and start the OS3.x software.
Set all parameters in the Edit filed according to your needs, following the hints given in this manual. The following parameters should initially be set to the values as shown: Number F02.004 F02.006 F02.007 F05.040 F05.041 Register Operation mode Integration Time Correction Divider Correction Gain Max. Correction Initial Setting 1 0000 0 1.000 10.000 After entry of all parameters click to “Transmit All” followed by “Store EEProm” to store all parameters to the BY340 or BY641 controller.
10.2. Set Directions of Rotation The direction of rotation must be defined for both, master and slave encoder. Make sure the Reset is switched on when you do this (the softkey must show “Reset is ON”) Move the Master encoder into forward direction (manually or by means of a remote speed signal to the Master drive). Observe the “Counter Master” value shown in the monitor window on the right. It must count up to positive values.
10.4. Setting of the Proportional Gain The register “Gain Correction” determines how strong the controller responds to position and speed errors of the drive. In principle, this setting therefore should be as high as possible. However, depending on dynamics and inertia of the whole system, too high gain values will produce stability problems. Please try to increase the setting of Correction Gain from 0.500 to 1.000, 1500, 2.000, 2.500, 3.000 etc.
11. Appendix for model BY 641 11.1. Relay Outputs While model BY340 provides high-speed transistor outputs only, model BY641 provides four additional relay outputs, operating in parallel to the high-speed transistor outputs K1 – K4. C = NO = NC = REL.3 REL.2 REL. 1 Common contact Normally open Normally closed Relay connector with units after Jan, 2009 1 2 3 X6 X5 1 2 3 1 2 3 K1-C K1-NO K1-NC K1-NO K1-NC K1-C K2-NC K2-C K2-NO K3-NC K3-NO K3-C K4-NC K4-NO K4-C REL.
12. Technical Specifications & Dimensions Power supply: Encoder supply: Incremental input: Input voltage (AC): Input voltage (DC): Protection circuit:: Consumption: Connections: Number of aux.
Continuation „Technical Specifications“ Housing: Type / Material: Mounting: Dimensions BY340: Dimensions BY641: Protection class BY340: Protection class BY641: Accessories: Weight: Ambient temperature: Operation: Storage: Conformity & standards: EMC 2004/108/EC: LV 2006/95/EC: Guideline 2011/65/EU: Norly UL94-V-0 / plastic panel cut out (w x h): 91 x 44 mm / 3.59 x 1.73 inch outer dimensions (w x h x d): 110 x 48 x 141 mm / 4.33 x 1.89 x 5.55 inch cut out (w x h): 89 x 91 mm / 3.50 x 3.
12.2. Dimensions of model BY641: 110,0 (4.331’’) 88,5 (3.484) 8,0 (.315) 10,0 (.394) 90,5 (3.563) 96,0 (3.780’’) 12,0 (.472) 111,5 (4.39) 96,0 ( 3.78 ) With optional plexi glass cover for protection class IP65 (motrona part # 64026) 9,0 (.345) 129,0 (5.079) 140,5 (5.531) 18,5 (.728) Panel cut out: w x h = 3.504 x 3.583’’ (89 x 91 mm) By340_04b_oi_e.
