CS-Lab SimDrive M4-H075K Manuel utilisateur

Applies to hardware version : v1

Applies to firmware version : v2.00

Rev 1.0

INDEX

1. Introduction.......................................................................................................................... 4

1.1 Signs used in this guide............................................................................................................ 4

1.2 Standards compliance.............................................................................................................. 4

1.3 Technical data sheet ................................................................................................................ 5

1.4 Drive and brushless motor running - checklist ........................................................................ 6

2. Block connection scheme ...................................................................................................... 8

2.1 Brushless motors (AC / BLDC) .................................................................................................. 9

2.2 Brushed motors (DC).............................................................................................................. 10

3. PINs description on drive connectors ................................................................................... 11

3.1 Connectors arrangement (M4-…040K model)....................................................................... 11

3.2 Connectors arrangement (M4-…075K model)....................................................................... 11

3.3 CN1 - Signals connector ......................................................................................................... 12

3.4 CN2 - communication connector (model M4-…075K) ........................................................... 13

3.5 CN3 - power output stage connector .................................................................................... 14

3.6 CN4 - CAN connector (model M4-…040K) ............................................................................. 14

3.7 CN5 –CAN and configuration connector (model M4-…040K)................................................ 15

4. I/O circuits internal construction ......................................................................................... 16

4.1.1 Encoder inputs ............................................................................................................. 16

4.1.2 HALL sensors inputs ..................................................................................................... 16

4.1.3 STEP/DIR control signals inputs ................................................................................... 16

4.1.4 Digital inputs IN0 – IN5................................................................................................ 17

4.1.5 Digital outputs OUT0 – OUT2 ...................................................................................... 17

5. Starting and configuration ................................................................................................... 18

5.1 Configuration - diagnostic software utility installation ......................................................... 19

5.1.1 USB-RS232 converter installation ................................................................................ 19

5.1.2 csServoManager utility software installation.............................................................. 20

5.2 csServoManager - general rules and notes............................................................................ 20

5.2.1 Connection with a drive ............................................................................................... 20

5.2.2 CAN bus connection ..................................................................................................... 21

5.2.3 Toolbar......................................................................................................................... 22

5.2.4 State bar ...................................................................................................................... 24

5.2.5 Entering numerical values ........................................................................................... 25

5.2.6 Saving in non-volatile memory .................................................................................... 25

5.3 „Parameters Monitor” window – real-time parameters preview ......................................... 26

2 simDrive™ - AC Servo Drive User Guide

5.4 Motor parameters configuration........................................................................................... 29

5.4.1 Motor type ................................................................................................................... 29

5.4.2 Nominal motor parameters ....................................... Błąd! Nie zdefiniowano zakładki.

5.4.3 Brushless motor parameters (AC/BLDC)...................................................................... 30

5.4.4 Motor constants .......................................................................................................... 31

5.4.5 Coupling (Incremental encoder) .................................................................................. 31

5.4.6 HALL sensors – rotor position coupling........................................................................ 31

5.4.7 Reference signal (STEP/DIR) ........................................................................................ 32

5.4.8 Electronic gear ............................................................................................................. 32

5.5 Digital inputs/outputs configuration ..................................................................................... 33

5.5.1 Digital inputs function ................................................................................................. 34

5.5.2 Default inputs functions assignement ......................................................................... 34

5.5.3 Digital outputs functions ............................................................................................. 34

5.5.4 Default outputs functions assignement....................................................................... 34

5.6 PID regulator tuning............................................................................................................... 35

5.6.1 Initial settings of PID regulator.................................................................................... 35

5.6.2 Manual PID regulator tuning procedure...................................................................... 36

5.6.3 Automatic PID regulator tuning procedure ................................................................. 39

5.7 Torque scan function - csTorqueScan™ ................................................................................. 41

6. Drive alarm flags description ............................................................................................... 43

7. Drive overload characteristic ............................................................................................... 44

8. A addition - Firmware update .............................................................................................. 45

8.1 csServoManager™ utility update ........................................................................................... 45

8.2 simDrive™ firmware update .................................................................................................. 45

9. B addition - What is PID controller (regulator)...................................................................... 46

9.1 What is PID controller............................................................................................................ 46

9.2 PID controller terms (parameters) operation........................................................................ 47

9.2.1 The proportional term – P............................................................................................ 47

9.2.2 The integral term – I .................................................................................................... 47

9.2.3The Derivative term – D ............................................................................................... 48

9.2.4 The „sixth” sense – the mysterious KVFF parameter..................................................... 48

10.C addition – Slave axis ......................................................................................................... 49

11.D addition – Diagnostics via Mach3 software ....................................................................... 50

simDrive™ AC Servo Drive - USER GUIDE 3

1. Introduction

1.1 Signs used in this guide

__________________________________________________________________________________

Potential danger and/or possible injury risk

__________________________________________________________________________________

Useful information, tips

__________________________________________________________________________________

Warning, failure to comply with these warnings may lead to inappropriate functioning or

damage of the device

__________________________________________________________________________________

1.2 Standards compliance

simDrive™ servo drives were designed and made in accordance with the national and international

standards for industrial control systems based on electronic components:

EN 61800-5-1

Adjustable speed electrical power drive systems - Safety

requirements - Electrical, thermal and energy

EN 61800-3

Adjustable speed electrical power drives systems. EMC

requirements and specific test methods

EN 61000-6-2

Electromagnetic compatibility (EMC). Generic standards –

Immunity for industrial environments

EN 61000-6-4

Electromagnetic compatibility (EMC). Generic standards -

Emission standard for industrial environments

EN 61000-3-2

Electromagnetic compatibility (EMC). Limits for harmonic

current emissions

EN 61000-3-3

Electromagnetic compatibility (EMC). Limitation of voltage

changes, voltage fluctuations and flicker in public low-

voltage supply systems,

The product was made in lead-free technology, RoHS compliant.

The simDrive™ servo drive is a high-voltage device that can be hazardous to your health and life

Before you start any installation turn off the power of the device and wait min. 10 minutes – it is

the time needed to discharge a capacitor.

4 simDrive™ - AC Servo Drive User Guide

1.3 Technical data sheet

PARAMETER M4-H075K Model M4-H040K Model M4-L075K Model M4-L040K Model

Power supply voltage of

a power output stage

325 VDC1155 VDC

Maximum output

current

12 A 6 A 20 A 10 A

Maximum output

power

3.0 kW 1.2 kW 2.2 kW 1.2 kW

Recommended motor

powerBłąd! Nie

zdefiniowano

zakładki.

750 kW 400 W 750 W 400 W

Motor types supported3

DC / BLDC / AC- Synchronous (HALL)

Power output stage

protection Short circuit, overload, overvoltage and thermal

Digital inputs number 6

Digital outputs number

Encoder inputs number

Logic supply voltage

24VDC +/-10%

Power consumption

(24V)

Maximal permissible

voltage on I/O lines 30VDC

Maximal load on an

output line

50mA

Signal type of

position/speed defining

(STEP/DIR)

Differential signal

Max. STEP signal

frequency

4 MHz

Max. encoder signal

frequency

8 MHz

Encoder type incremental TTL

Encoder signal type

Differential

PC connection

(configuration)

RS232

Connection with a

motion controller

(diagnostics)

CAN bus

Ambient

temperature range

0oC do +50oC

Relative humidity

10% do 95%

(without condensation)

1Recommended power supplying way is 230V AC power supply by CS-Lab s.c. company.

2The difference between maximal drive power and recommended motor comes from the fact that the drive

should have some power reserves to be able to overload the motor. The second reason is limitation of heat

given off from the drive.

3Brushless motors (BLDC, AC and linear AC) must have digital HALL sensors.

4Recommended resolution: 1000 – 8000 (in fact 4000 – 32000 including all edges)

simDrive™ AC Servo Drive - USER GUIDE 5

1.4 Drive and brushless motor running - checklist

Below you can find a checklist with all the activities and operations needed to start up a new drive.

These operations are listed in the order they should be done. In further chapters you will also find

detailed description of the activities described below

Operation name

Make necessary electrical connections:

•Motor encoder

•Motor Hall sensors

•Phases: U, V, W and motor ground

•I/O signals (Servo on / Reset / Alarm)

•STEP/DIR control signals (STEP/DIR)

•CAN bus

•24V logic power supply (don't turn the power supply on yet!)

•HV power output stage power supply (don't turn the power supply on yet!)

Install the csServoManager™ software and possibly the controller to the USB-RS232

converter (if you connect with the drive through RS232 port).

Turn on the 24V logic power supply, for the time being do not turn on the HV power output

stage power supply yet.

Now we are connecting with the drive. If you connect with the drive via CSMIO/IP controller

and you have more than one drive on the CAN bus then you have to set addresses for the

drives – read chapter 5.2.2 - „Connection through the CAN bus"

If the motor supplier is CS-Lab s.c. company load configuration template for the particular

model (available on www.cs-lab.eu) and save the configuration in non-volatile memory by

pressing icon.

Open parameters monitor window and select "Position (Encoder)" from the list. Turn a

motor shaft left and right. Counter should count alternately up and down, depending on

motor shaft rev direction. If the counter doesn't change the value or it skips only between -1

up to 1 then verify encoder connection.

In the parameters monitor window select "HALL sensors state" from the list. Turn the motor

shaft and watch indications. The sensors state should change in one of the following

sequences – depending on revs direction:

•C__/CB_/_B_/_BA/__A/C_A/C__(etc.)

•C__/C_A/__A/_BA/_B_/CB_/C__ (etc.)

If the sequence is incorrect or the state is „___”

or „ABC” then verify HALL sensors

connection.

Open „JOG I/O control” and verify I/O signals operation (for that you need to set the

necessary signals in CNC software – e.g. Mach3). It is good to test simDrive™ outputs by

setting the output on manual mode and clicking "set/clr" buttons. Change assignment of the

function to I/Os in configuration window if necessary.

6 simDrive™ - AC Servo Drive User Guide

Operation name

Verify motion control STEP/DIR signals operation. For that select from the list in parameters

monitor window - "Reference Position" and make a move in CNC software (

it does not

matter if the motor will not move at the moment as there is no power on a power output

stage). "Reference Position" counter should increase or decrease its value - it depends on

motion direction in CNC software.

If it is a motor bought from CS-Lab s.c. and configuration template had been loaded before -

you can skip this point.

Open motor parameters configuration window and set the parameters:

•Motor type

•Nominal voltage and current values and nominal revs.

•Pole pairs number

•Resistance and inductance of windings. If it is unknown - enter 0.

•Torque and voltage constants (if unknown - enter 0).

•Encoder counting direction and pulses number per encoder rev incl. all edges. it's a

value usually presented by a manufacturer as x4 (e.g. if it stays 2500 on the encoder

for us it mean 10 000)

•Set HALL signals negation if necessary.

Save the configuration in non-volatile memory with button,

close the connection in

csServoManager and switch off the 24V power supply for min. 5s. Next switch it on and

connect with the drive .

Open PID regulators tuning window and ensure that the needed values in there are safe for

the first run (look at chapter 5.6.1 - „Initial settings of PID regulator")

Enable power output stage voltage (HV) and open "JOG I/O control" window. Next click

„Reset”. The drive should change its status into "Ready", next - click - the drive should

change its status into "Running".

Test the motion on low revs (about 50-100 rev/min) – few revs left and right. If a motor

doesn't move or it jerks and/or it reports an error then verify connection and settings again

(especially motor parameters configuration).

If you want to use automatic PID regulators tuning function - skip this point.

In „JOG I/O Control” go to "Motion planner" tab. Set speed to 150RPM, 3000 RPM/s

acceleration and relative motion as pulses number per encoder rev - it's range of 1 motor

rev. Next - start cyclic motion .

Launch automatic PID regulator tuning in "PID regulator tuning" window" on "Automatic

tuning" tab or tune the regulators manually as following:

•current regulator

•speed regulator

•

position regulator

Save the configuration in non-volatile memory and click to disconnect the drive.

Verify if the drive works properly when CNC controller and software control the motion (e.g.

Mach3 and CSMIO/IP). If everything works fine the drive is ready to work.

simDrive™ AC Servo Drive - USER GUIDE 7

2. Block connection scheme

Below you will find connection demonstration scheme of three-phase brushless motor (AC) and

brushed motor (DC). It is easy to notice that both schemes are

almost the same. For DC motor we use only extreme phases

for power supply (U and W) of which we connect DC motor

„+” to U phase and „-„ to W phase. Moreover, in case of DC

motor there is no need to use HALL sensors.

CAN bus connection is optional but recommended if we use

the drive with CSMIO/IP-x controller and Mach3 software.

Thanks to the CAN connection with CSMIO/IP controller we

get additional capability for fast drive diagnostics directly in

Mach3 software. In case of breakdown the drive status will be

saved in a log file.

Drive I/O signals connection with a motion controller is also

optional but we recommend Alarm, Reset, Servo ON and

E-Stop signals connection.

The drive has HOME signal and encoder index synchronization function. It means that you can have

precise homing even if CNC motion controller doesn't have such function. If we want to use it then

we connect the HOME signal to the simDrive™ (to one of digital inputs) and not to CNC controller,

and we connect one of the drive outputs to a CNC controller. We set the drive digital input as

"Home In" and we set the output as "Home Out" as well.

The voltage in the simDrive™ device may be dangerous for your health and life. Before you start any

installation - turn off the device and wait at least 10 minutes – it is the time needed to discharge

capacitors.

Do not disconnect or connect any wires (except diagnostic wire) when the device is working. It may

cause unpredictable motor behavior and in extreme cases it may damage the servo drive.

8 simDrive™ - AC Servo Drive User Guide

2.1 Brushless motors (AC / BLDC)

simDrive™ AC Servo Drive - USER GUIDE 9

2.2 Brushed motors (DC)

10 simDrive™ - AC Servo Drive User Guide

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