XTL XSJ Xenus User Guide Manual
XTL XSJ Xenus User Guide Manual
XTL XSJ Xenus User Guide Manual
P/N 95-00875-000
Revision 3
June 2008
Xenus XTL User Guide
Product Warnings
Observe all relevant state, regional, and local safety regulations when installing and using this
product. For safety and to assure compliance with documented system data, only Copley Controls
Corporation should perform repairs to amplifiers.
DANGER
DANGER
! After the cause of a non-latched fault is corrected, the amplifier re-enables the PWM
output stage without operator intervention. In this case, motion may re-start
unexpectedly. Configure faults as latched unless a specific situation calls for non-
latched behavior. When using non-latched faults, be sure to safeguard against
DANGER unexpected motion.
Failure to heed this warning can cause equipment damage, injury, or death.
! When operating the amplifier as a CAN node, the use of CME 2 or ASCII serial
commands may affect CAN operations in progress. Using such commands to initiate
motion may cause CAN operations to suspend.
CAN operations may restart unexpectedly when the commanded motion is stopped.
DANGER
Failure to heed this warning can cause equipment damage, injury, or death.
Latching an output does not eliminate the risk of unexpected motion with non-
latched faults.
! Associating a fault with a latched, custom-configured output does not latch the fault
itself. After the cause of a non-latched fault is corrected, the amplifier re-enables
without operator intervention. In this case, motion may re-start unexpectedly.
DANGER For more information, see Clearing Non-Latched Faults (p. 34).
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
Revision History
1.1: Amplifier
Xenus provides 100% digital control of brushless or brush motors in an off-line powered package.
It can also control a Copley Controls ServoTube motor. Xenus can operate from single or three-
phase mains with a continuous power output of up to 4 kW.
Xenus is offered in three versions to support three types of feedback devices. The standard
version supports digital quadrature encoders. The –S version supports analog sin/cos encoders.
The -R version supports brushless resolvers. The –S and -R versions can emulate a digital
quadrature encoder output from the analog encoder or resolver respectively.
Xenus can operate in several basic ways:
• As a traditional motor amplifier accepting current, velocity or position commands from an
external controller. In current and velocity modes it can accept ±10 Vdc analog, digital 50%
PWM or PWM/polarity inputs. In position mode, inputs can be incremental position commands
from step-motor controllers in Pulse and Direction or Count Up/Count Down format, as well as
A/B quadrature commands from a master-encoder. Pulse-to-position ratio is programmable for
electronic gearing.
• As a node on a CANopen network. CANopen compliance allows the amplifier to take
instruction from a master application over a CAN network to perform torque, velocity, and
position profiling, interpolated motion, and homing operations. Multiple drives can be tightly
synchronized for high performance coordinated motion.
• As a node on a DeviceNet network. Xenus can be operated over a DeviceNet network by
PLCs and other controllers.
• As a stand-alone controller running Copley Virtual Machine (CVM) control programs such as
the Indexer 2 Program. It can also be controlled directly over an RS232 serial link with simple
ASCII format commands.
Mains input voltage to the amplifier can range from 100 to 240 Vac, single or three-phase, and 47
to 63 Hz. This allows Xenus the ability to work in the widest possible range of industrial settings.
Several models are available, with peak current ratings of 18 to 40 amps:
Model
Quad A/B Resolver Sin/Cos Encoder Continuous Peak Current Vac
Encoder Current
XTL-230-18 XTL-230-18-R XTL-230-18-S 6A 18 A
100 to
XTL-230-36 XTL-230-36-R XTL-230-36-S 12 A 36 A
240
XTL-230-40 XTL-230-40-R XTL-230-40-S 20 A 40 A
A separate +24 Vdc logic supply powers the internal logic and control circuits. These are isolated
from the high-voltage power supply and inverter stage that connect to the mains. This simplifies
system design by allowing the mains to be completely disconnected from the amplifier for safety
reasons while allowing the logic side of the amplifier to stay powered. This allows the amplifier to
retain position information and maintain communication through the digital I/O or over the serial or
CAN ports when disconnected from the mains.
The Xenus XTL is RoHS compliant.
1.2: CME 2
Amplifier commissioning is fast and simple using Copley Controls CME 2 software. CME 2
communicates with Xenus via an RS-232 link, and all of the operations needed to configure the
amplifier are accessible through CME 2.
The multi-drop feature allows CME 2 to use a single RS-232 serial connection to one amplifier as
a gateway to other amplifiers linked together by CAN bus connections.
Auto phasing of brushless motor Hall sensors and phase wires eliminates “wire and try.”
Connections are made once and CME 2 does the rest. Encoder or resolver wire swapping to
establish the direction of positive motion is also eliminated.
Motor data can be saved as .ccm files. Amplifier data is saved as .ccx files that contain all
amplifier settings plus motor data. This makes it possible to quickly set up amplifiers by copying
configurations from one amplifier to another.
1.3: CMO/CML
Copley Motion Libraries (CML) and Copley Motion Objects (CMO) make CANopen system
commissioning fast and simple. All network housekeeping is taken care of automatically by a few
simple commands linked into your application program. CML provides a suite of C++ libraries,
allowing a C++ application program to communicate with and control an amplifier over the
CANopen network. CMO provides a similar suite of COM objects that can be used by Visual
Basic, .NET, LabVIEW, or any other program supporting the Microsoft COM object interface.
J3 J2
U
L1 1760 PF
~ +
DC BUSS(+)
J1 L2 + PWM V
~ MOTOR
MAINS INVERTER
L3 DC BUSS(-)
~ - W
FRAME CASE
(SAFETY)
GROUND PWM
STAGE
J4 +24 Vdc CONTROL
POWER
ISOLATION BARRIER
+24 BRAKE SHIELD
BRAKE
VDC +5 Vdc @
DC/DC LOGIC
Cntrl & 400mA
RTN SIGNAL +5 Vdc
DC/DC
POWER
HALLS
+24 Vdc Converter SIGNAL GND
GROUND J6
CAN CAN
Bus J8
Network
Ckt
+5 Vdc
CONTROL
SYSTEM +5 Vdc ENCODER
J7
ENABLE [IN1] CONTROL
LOGIC
SIGNAL GND
SIGNAL GND
CONTROL
SIGNAL
GROUND
2.4: Feedback
2.4.1: Encoder and Resolver Support
The Xenus amplifier is offered in three versions to support encoder or resolver feedback. The
standard version supports digital quadrature encoders. The -S version supports analog sin/cos
encoders. These versions normally require the use of Hall switches for the commutation of
brushless motors. The resolver version supports standard, single speed, transmit-type resolvers.
2.4.2: Multi-Mode Port
All versions support a multi-mode port. This interface can be configured to:
• Provide a buffered digital encoder output based on the digital encoder input.
• Provide an emulated digital encoder output based on the analog encoder or resolver input.
• Provide a second digital encoder input to be used in the dual encoder position mode. In this
mode, an encoder attached to the load provides position loop feedback, and the motor
encoder or resolver provides velocity loop feedback.
FILTER
FILTER
Trajectory Position Velocity Velocity Current Current Motor/
Generator Loop Limiter Loop Limiter Loop Sensors
In velocity mode, the velocity loop drives the current loop. In current mode, the current loop is
driven directly by external or internal current commands.
Basic Attributes of All Control Loops
These loops (and servo control loops in general) share several common attributes:
Loop Attribute Description
Command input Every loop is given a value to which it will attempt to control. For example, the velocity loop
receives a velocity command that is the desired motor speed.
Limits Limits are set on each loop to protect the motor and/or mechanical system.
Feedback The nature of servo control loops is that they receive feedback from the device they are
controlling. For example, the position loop uses the actual motor position as feedback.
Gains These are constant values that are used in the mathematical equation of the servo loop. The
values of these gains can be adjusted during amplifier setup to improve the loop
performance. Adjusting these values is often referred to as tuning the loop.
Output The loop generates a control signal. This signal can be used as the command signal to another
control loop or the input to a power amplifier.
Current Loop
PWM
Current Integral Gain (Ci) Command
+
Current Command Limited Current +
Current Limiter Current Proportional Gain (Cp) Motor
+
Current Offset
-
Velocity Loop
Velocity Integral Gain (Vi)
Limited +
Velocity +
Velocity Lim iter Filter Velocity Filter Current
Command Velocity Proportional Gain (Vp)
+ Command
-
Limits:
Velocity
Acceleration* Feedback (Derived Velocity)
Deceleration*
Emergency Stop Deceleration*
*Not used w hen velocity loop is controlled by position loop. See "Velocity Loop Limits" for details.
Inputs
In velocity mode, the velocity command comes from one of the following:
• The amplifier’s analog or PWM inputs.
• A network command, CANopen, DeviceNet, or RS-232 Serial.
• A Copley Virtual Motion (CVM) control program.
• The amplifier’s internal function generator.
In position mode, the velocity command is generated by the position loop.
Velocity Loop Limits
The velocity command is limited based on the following set of parameters designed to protect the
motor and/or the mechanical system.
Limiter Description
Velocity Limit Sets the maximum velocity command input to the velocity loop.
Acceleration Limit Limits the maximum acceleration rate of the commanded velocity input to the velocity loop.
This limit is used in velocity mode only.
Deceleration Limit Limits the maximum deceleration rate of the commanded velocity input to the velocity loop.
This limit is used in velocity mode only.
Fast Stop Ramp Specifies the deceleration rate used by the velocity loop when the amplifier is hardware
disabled. (Fast stop ramp is not used when amplifier is software disabled.) If the brake
delay option is programmed, the fast stop ramp is used to decelerate the motor before
applying the brake.
Note that Fast Stop Ramp is used only in velocity mode. In position mode, the trajectory
generator handles controlled stopping of the motor. There is one exception: if a non-latched
following error occurs in position mode, then the amplifier drops into velocity mode and the
Fast Stop Ramp is used.
For more information, see Following Error Fault Details (p. 37).
Commanded Velocity
Vel Limit
Position Loop
Profile Velocity
Velocity Feed Forw ard (Vff)
+
Target Trajectory Profile Acceleration + Gain Velocity
Position Ge ne rator Acceleration Feed Forw ard (Aff)
Multiplier Command
Limited Position + +
Position Proportional Gain (Pp)
-
Limits:
Max velocity
Feedback from motor encoder or resolver
Max accel
Max decel
from optional position encoder (on load)
Abort decel
Trajectory Limits
In position mode, the trajectory generator applies the following user-set limits to generate the
motion profile.
Limiter Description
Maximum Velocity Limits the maximum speed of the profile.
Maximum Acceleration Limits the maximum acceleration rate of the profile.
Maximum Deceleration Limits the maximum deceleration rate of the profile.
Abort Deceleration Specifies the deceleration rate used by the trajectory generator when motion is aborted.
amplifier treats anything within the dead band ranges as zero, and subtracts the dead band value
from all other values. For instance, with a dead band of 100 mV, the amplifier ignores signals
between –100 mV and +100 mV, and treats 101 mV as 1 mV, 200 mV as 100 mV, and so on.
200
100
Dead Band
Output
-100
-200
-200 -100 0 100 200
Input
Offset
To remove the effects of voltage offsets between the controller and the amplifier in open loop
systems, CME 2 provides an Offset parameter and a Measure function. The Measure function
takes 10 readings of the analog input voltage over a period of approximately 200 ms, averages
the readings, and then displays the results. The Offset parameter allows the user to enter a
corrective offset to be applied to the input voltage.
The offset can also set up the amplifier for bi-directional operation from a uni-polar input voltage.
An example of this would be a 0 to +10 Vdc velocity command that had to control 1000 rpm CCW
to 1000 rpm CW. Scale would be set to 2000 rpm for a +10 Vdc input and Offset set to -5V. After
this, a 0 Vdc input command would be interpreted as -5 Vdc, which would produce 1000 rpm CCW
rotation. A +10 Vdc command would be interpreted as +5 Vdc and produce 1000 rpm CW rotation.
Monitoring the Analog Command Voltage
The analog input voltage can be monitored in the CME 2 control panel and oscilloscope. The
voltage displayed in both cases is after both offset and deadband have been applied.
Analog Command in Position Mode
The Xenus Analog Position command operates as a relative motion command. When the amplifier
is enabled the voltage on the analog input is read. Then any change in the command voltage will
move the axis a relative distance, equal to the change in voltage, from its position when enabled.
To use the analog position command as an absolute position command, the amplifier should be
homed every time it is enabled. The Homing sequence may be initiated by CAN, ASCII serial, or
CVM Indexer program commands.
PWM Input
50 % Duty Cycle
Max +
Amplifie r Output 0
Max -
The command can be inverted so that increased duty cycle commands negative output and vice
versa.
100% Duty Cycle Format (Two-Wire)
One input takes a PWM waveform of fixed frequency and variable duty cycle, and the other input
takes a DC level that controls the polarity of the output. A 0% duty cycle creates a zero command,
and a 100% duty cycle creates a maximum command level. The command can be inverted so that
increasing the duty cycle decreases the output and vice versa.
100% 100%
Duty Cycle Duty Cycle
PWM Input
Direction Input
Max +
Amplifier Output 0
Min -
Pulse Input
Direction Input
Velocity
Command
The amplifier can be set to increment position on the rising or falling edge of the signal. Stepping
resolution can be programmed for electronic gearing.
Up Input
Down Input
Velocity
Command
The amplifier can be set to increment position on the rising or falling edge of the signal. Stepping
resolution can be programmed for electronic gearing.
Quadrature Format
In quadrature format, A/B quadrature commands from a master encoder (via two inputs) provide
velocity and direction commands, as shown below.
A Input
B Input
Velocity
Command
2.6.3: Architecture
As shown below, in a CANopen motion control system, control loops are closed on the individual
amplifiers, not across the network. A master application coordinates multiple devices, using the
network to transmit commands and receive status information. Each device can transmit to the
master or any other device on the network. CANopen provides the protocol for mapping device
and master internal commands to messages that can be shared across the network.
Feedback
Xenus
CANopen
Local Control
CAN port
Motor
Softw are Application Amplifier
Master Controller
Status
Feedback
Xenus
CANopen
Local Control
CAN port Amplifier
Motor
I/O
CAN Network
Sensor
CANopen
Other
CAN port
CANopen
Device
For more information on CAN addressing, see CAN Interface (p. 109).
For more information on CANopen operations, see the following Copley Controls documents:
• CANopen Programmer’s Manual
• CML Reference Manual
• Copley Motion Objects Programmer’s Guide
This sequence is not available in the current mode of operation. Instead, in current mode, the
amplifier output turns off and the brake output activates immediately when the disable command is
received.
200
ms
green
off
200
ms
red
off
200 200
ms ms
red
off
In addition, the CAN status indicator is turned off when the CAN node ID selector (CAN ADDR) is
set to 0. A setting of 0, which is invalid, shuts down most operations on the CAN interface, and the
light is shut off to indicate this status.
2.10: Protection
2.10.1: Faults
Overview
Xenus detects and responds to a set of conditions regarded as faults, such as amplifier over
temperature and excessive following error. When any fault occurs, with the exception of a
following error, the amplifier’s PWM output stage is disabled, the fault type is recorded in the
amplifier’s internal error log (which can be viewed with CME 2), and the status LED changes to
indicate a fault condition exists. A digital output can also be programmed to activate on a fault
condition. The following error fault behaves with slight differences, as described in
Following Error Fault Details (p. 37).
The amplifier’s PWM output stage can be re-enabled after the fault condition is corrected and the
amplifier faults are cleared. The process for clearing faults varies depending on whether the fault
is configured as non-latched or latched.
The fault-clearing descriptions below apply to all faults except for the following error fault, which is
described in Following Error Fault Details (p. 37).
Clearing Non-Latched Faults
The amplifier clears a non-latched fault, without operator intervention, as soon as the fault
condition is corrected.
! After the cause of a non-latched fault is corrected, the amplifier re-enables the PWM
output stage without operator intervention. In this case, motion may re-start
unexpectedly. Configure faults as latched unless a specific situation calls for non-
latched behavior. When using non-latched faults, be sure to safeguard against
DANGER unexpected motion.
Failure to heed this warning can cause equipment damage, injury, or death.
Fault Descriptions
The set of possible faults is described below. For details on limits and ranges, see
Fault Levels (p. 49).
Fault Description Fault Occurs When… Fault is Corrected When…
*Amplifier Over Amplifier's internal temperature exceeds Power module temperature falls below
Temperature specified temperature. specified temperature.
Motor Phasing Error Encoder-based phase angle does not Encoder-based phase angle agrees
agree with Hall switch states. This fault can with Hall switch states.
occur only with brushless motors set up
using sinusoidal commutation. It does not
occur with resolver feedback or with Halls
correction turned off.
*Feedback error Over current condition detected on the Encoder power returns to specified
output of the internal +5 Vdc supply used voltage range.
to power the feedback. Resolver or analog Feedback signals stay within specified
encoder not connected or levels out of levels.
tolerance.
*Motor Over Temperature Motor over-temperature switch changes Temperature switch changes back to
state to indicate an over-temperature normal operating state.
condition.
Under Voltage Bus voltage falls below specified voltage + DC bus voltage returns to specified
limit. voltage range.
Over Voltage Bus voltage exceeds specified voltage + DC bus voltage returns to specified
limit. voltage range.
*Following Error User set following error threshold See
exceeded. Position and Velocity Errors (p. 36).
*Short Circuit Detected Output to output, output to ground, internal Short circuit has been removed.
PWM bridge fault.
2
Over Current (Latched) Output current I T limit has been Amplifier is reset and re-enabled.
exceeded.
*Latched by default.
Limited Velocity
± Tracking Window
Tracking
Time
Tracking Window
Output
2.12: Communication
2.12.1: Communication Interfaces
As described below, the amplifier features two communication interfaces, each used for different
purposes.
Interface Description
RS-232 port The amplifier features a three-wire RS-232 port. CME 2 software communicates with the
amplifier using a binary protocol over this link for commissioning, adjustments, and
diagnostics. In addition, ASCII commands can be issued over the serial port. For RS-232
port specifications, see Serial Interface (p. 49). For RS-232 port wiring instructions, see
RS-232 Serial Communications (J5) (p. 61).
In an RS-232 multi-drop configuration, a single amplifier with a serial connection to a
controller can act as a gateway. Through the gateway amplifier, the controller can use the
serial connection to access other amplifiers on the CAN bus.
CME 2 can be used over a direct RS-232 connection to make adjustments and monitor
operations even when the amplifier is being controlled over the CAN interface or by the
digital inputs.
CAN interface When operating as a CANopen or DeviceNet node, the amplifier takes input commands
over a CAN bus. CAN communications are described in CME 2 and CAN Operation (p.
39). DeviceNet is described in the Copley DeviceNet Programmer’s Guide.
2.13: Inputs
2.13.1: Digital Inputs
The amplifier has twelve digital inputs (IN1-IN12). Eleven of them appear on the control connector.
IN5 appears on the feedback connector, and is intended for the motor over temperature switch
(although it can be programmed for any function). For a list of input functions, see Digital Input
Functions (p. 94 ).
2.13.2: Input Filters
Two types of input RC filters are used: GP (general-purpose) and HS (high-speed). Input
reference functions such as Pulse and Direction, Pulse Up/Pulse Down, and Quadrature A/B are
wired to inputs that have the HS filters, and inputs with the GP filters are used for general-purpose
logic functions, limit switches, and the motor temperature sensor.
2.13.3: Debounce Time
To prevent undesired multiple triggering caused by switch bounce upon switch closures, each
input can be programmed with a debounce time. The programmed time specifies how long an
input must remain stable at a new state before the amplifier recognizes the state. The debounce
time is ignored if the input is used as a digital command input.
2.13.4: Configure for Pull Up/Pull Down Resistors by Groups
Pre-defined groups of inputs can be programmed to have either an internal pull up or pull down
resistor. See J7 Pin Description (p. 64) for groupings.
2.14: Outputs
2.14.1: Digital Outputs
The amplifier has four programmable digital outputs. Three of the outputs (OUT1 - 3) are general-
purpose outputs. The fourth (OUT4) is specifically designed as a brake output but can be
programmed to perform any of the functions. For a list of digital output functions, see Standard
Digital Outputs (p. 95).
The general-purpose outputs are open-drain MOSFETs, each with a pull-up resistor, in series with
a diode, connected to the amplifier’s internal +5 Vdc supply. This design allows the outputs to be
directly connected to optically isolated PLC inputs that reference a voltage higher than
+5 Vdc, typically +24 Vdc. The diode prevents current flow between the +24 Vdc supply and the
internal +5 Vdc supply though the pull-up resistor. This current, if allowed to flow, could turn on the
PLC input, giving a false indication of the amplifier’s true output state.
The general-purpose outputs require an external fly-back diode to be installed across any
inductive loads, such as relays, that are connected to them.
The brake output (OUT4) is described in Brake Operation (p. 31).
Bus Voltage Compensation Changes in bus or mains voltage do not affect tuning.
Input Mode
PWM Input 100Khz
Digital Command 5 MHz (50% Duty Cycle)
Secondary Encoder 5 MHz Line (20 Mcount/sec)
Power Dissipation
120
100
Power Dissipation (W)
80
230 VAC
60
120 VAC
40
20
0
0 5 10 15 20
3.24: Dimensions
DANGER
DANGER
! With the exception of the ground pins on J1, J2, and J3, all of the other circuits on
these connectors are mains-connected and must never be grounded.
Failure to heed this warning can cause equipment damage.
WARNING
! The connecting or disconnecting of cables while the amplifier has 24Vdc and/or
mains power applied is not recommended.
Failure to heed this warning may cause equipment damage.
WARNING
4.1.2: Grounding Considerations
Primary Grounding Functions
A grounding system has three primary functions: safety, voltage-reference, and shielding.
J1-3 Primary Ground
The primary ground at J1-3 is the safety ground and is intended to carry the fault currents from the
mains in the case of an internal failure or short-circuit of electronic components. This ground is
connected to the amplifier chassis. Wiring to this ground should be done using the same gauge
wire as that used for the mains. This wire is a “bonding”’ conductor that should be connected to an
earthed ground point and must not pass through any circuit interrupting devices.
The pin on the amplifier at J1-3 is longer than the other pins on J1, giving it a first-make, last-
break action so that the amplifier chassis is never ungrounded when the mains power is
connected.
J2 and J3 Grounds
The ground terminals at J2-1 and J3-5 also connect to the amplifier chassis.
Motor cases can be safety-grounded in one or optionally both of these ways:
• Direct grounding of the motor frame (assuming the frame of the machine is grounded). Attach
the metal motor case to the metal machine frame or connect the ground wire of the motor to
the metal frame of the machine.
• Grounding of the motor frame through the motor power cable to amplifier J2-1. The ground
wire should be of the same gauge as the power wires.
Likewise, the case of the regen resistor can also be safety-grounded by direct grounding of the
case or by a grounding wire connected to amplifier J3-5. Again, this wire should be of the same
gauge as the other regen resistor conductors.
Cable shields, because of their smaller wire size, must not be used as part of a safety-ground
system.
Signal Grounding
The amplifier signal ground must be connected to the control system signal ground. The amplifier
signal ground is not connected to earth ground internal to the amplifier. Therefore, the control
system signal ground can be connected to earth ground without introducing a ground loop.
Shielding
Shields on cables reduce emissions from the amplifier and help protect internal circuits from
interference due to external sources of electrical noise. The shields shown in the wiring diagrams
are also required for CE compliance. Cable shields should be tied at both ends to earth or chassis
ground. The housing and pin 1 of both J7 and J8 are connected to the amplifier’s chassis.
4.1.3: Connector Locations
Connector locations (J1-J8) are shown below.
3Ø
L2 47-63 Hz
J1-2 B B L2
100-240 VAC
L1
J1-1 A A L1
Earth
Gnd
Ground
Keep wire length
as short as * Filter Concepts 3F15
possible. Not to (or equivalent)
exceed 1 Meter. used for CE compliance
J2-1 Case
Ground
J2-3
V -
J2-2
Case
J2-1 Ground
Pin Description
Pin Signal Function
1 Regen + + DC Bus to one side of regen resistor
2 N/C No connection
3 Regen - Collector of regen transistor to one side of regen resistor
4 N/C No connection
5 Ground Enclosure ground and cable shield
J3-4
J3-5
- DC Bus
Pin Description
Pin Signal Function
1 RTN +24 Vdc return
2 Brake Return or low side of motor brake
3 +24 Vdc +24 Vdc Logic power supply
+24 V
J4-3 +24 Vdc
Brake Power
J4-2
Supply
RTN
J4-1 (Required)
1 2 3 4 5 6
Pin Description
Pin Signal Function
1 N/C No connection
2 RxD Receive data input from computer
3 Signal ground Power supply ground
4 Signal ground Power supply ground
5 TxD Transmit data output to computer
6 N/C No connection
J5-6
Tx D
J5-5
ground To PC
J5-4
RS-232
ground
J5-3 Port
Rx D
J5-2
J5-1
1 2 3 4 5 6 7 8
Pin Description*
Pin Signal Function
1 CAN_H CAN_H bus line (dominant high)
2 CAN _L CAN_L bus line (dominant low)
3 CAN_Gnd Ground / 0 V / V-
4 -- No connection
5 -- Pass though to second connector, no internal connection
6 CAN_SHLD Pass though to second connector, no internal connection
7 CAN_Gnd Ground / 0 V / V-
8 CAN V+ Pass through to second connector, no internal connection
CAN +
J6-1
CAN -
J6-2 CAN Network
CAN Gnd
J6-3
J6-4
J6-5
J6-6 Note 1: If this is the last amplifier on the network,
J6-7 use Copley Terminator Plug PN STP-NT
J6-8
to terminate the bus.
J7 pin connections
9 18 26
J7 Pin Description
Pin Signal Function
1 Frame Ground Cable shield connection
2 Ref - Input Analog command negative input
3 Ref + Input Analog command positive input
Speed Pull-Up/Pull-
Down
4 IN1 Enable Standard Group 1
5 IN2 Standard Group 1
6 IN3 Standard Group 1
7 IN4 Standard Group 2
Programmable inputs
8 IN11 Standard Group 4
9 IN12 Standard Group 4
10 IN6 HS Group 3
11 IN7 HS Group 3
12 IN8 Mode-dependent. See Mode-Dependant HS Group 3
13 IN9 Dedicated Inputs (p. 65) HS Group 4
14 IN10 HS Group 4
15 Signal Ground Signal ground reference for inputs and outputs
16 OUT1
17 OUT2 Programmable outputs
18 OUT3
19 Signal Ground Signal ground for +5Vdc, inputs and outputs
20 +5 Vdc +5 Vdc output.
Total load current on J7-20, J8-2, and J8-4 not to exceed 400 mA.
21 Multi-Mode Port /X
22 Multi-Mode Port X
23 Multi-Mode Port /B Programmable differential input/output port.
24 Multi-Mode Port B See Mode-Dependant Dedicated Inputs (p. 65)
25 Multi-Mode Port /A
26 Multi-Mode Port A
J8 pin connections
5 10 15
2.2 K
A A
J8-14 Incremental
1K A A
J8-13 Encoder
22 pƒ B B
+ J8-12
121 B B
- J8-11
1K X Index
To J8-8
Encoder X Index
22 pƒ J8-7
Output
5V + 5 VDC
J8-4 Encoder
@ 400 mA Gnd Power
J8-2
J8-1 Frame Gnd Case
Ground
Amplifier J8
10 K
U Hall Halls
J8-3
10 K
V Hall
J8-6
3.3 ƒ W Hall
J8-9
5V 5 Vdc Halls
J8-4
@ 400 mA Gnd Power
J8-2
Frame Gnd
J8-1
Case
Ground
Case
Frame Gnd Ground
J8-1
Amplifier J8
REF R1
J8-3
REF R2
J8-2
Resolver
SIN (+) S3
J8-8
SIN (-) S1
J8-7
COS (+) S2
J8-13
COS (-) S4
J8-12
Frame Gnd
J8-1 Case Ground
5.1: Warnings
DANGER: Hazardous voltages.
DANGER
DANGER
! Do not spin motors with power off. Voltages generated by a motor can damage an
amplifier.
Failure to heed this warning can cause equipment damage.
WARNING
5.2.5.1 Start CME 2 by double-clicking the CME 2 shortcut icon on the Windows desktop:
If a serial or CAN port has not been selected, the Communications Wizard Select device
screen appears.
5.2.5.4 From the Available Ports list on the Select Ports screen, choose the serial ports that will be
used to connect to amplifiers.
1 To allow connection of an amplifier through a port, highlight the port name and click
Add (or click Add All to enable all available ports).
2 To remove a port from the Selected Ports list, highlight the port name and click
Remove.
5.2.5.5 Click Next to save the choices and open the Communications Wizard Configure Serial
Ports screen.
5.3: Prerequisites
5.3.1: Hardware and Equipment
5.3.1.1 Verify that +24 Vdc power is OFF and AC power is OFF.
5.3.1.2 Verify wiring and connections.
Ensure the following connections are wired according to the guidelines in
Wiring (p. 53).
1 J8 "FDBCK" motor signals
2 J2 "U V W Earth" motor power
3 J7 "CNTRL" control signals
4 J4 "+24 Vdc, BRAKE" required +24 Vdc (power OFF)
5 J5 "RS-232" PC serial link
6 J1 "L1 L2 L3 Earth" line power (power OFF)
5.3.1.3 Secure the motor:
1 Make sure motor is securely fastened.
2 Make sure that no load is connected to the motor.
5.3.1.4 Apply +24 Vdc to the amplifier’s J4 connection.
(Do NOT apply AC voltage to the amplifier at this point.)
!
mode.
CME 2 can be used while the amplifier is under CAN or DeviceNet control. However,
some extreme changes made with CME 2 could cause unexpected or uncontrolled
motion.
DANGER
Failure to heed this warning can cause equipment damage, injury, or death.
5.3.2.2 Start CME 2 by double-clicking the CME 2 shortcut icon on the Windows desktop:
If there are multiple ports, the Copley Neighborhood root will be selected:
After an amplifier has been selected, the CME 2 Main Screen looks similar to this:
If the Basic Setup options have not been chosen, the Basic Setup screen opens.
5.4.1.3 Click the Basic Setup button ( ) to display the Basic Setup screen.
5.4.1.4 Click Change Settings to start the Basic Setup wizard. Use the Back and Next buttons to
navigate screens. Screen details vary depending on amplifier model and mode selection.
5.4.1.5 View or change the Motor settings described below. Options vary with amplifier model.
Setting Description
Motor Family Select motor family: Brushless or Brush.
Motor Type Select motor type: Rotary or Linear.
5.4.1.6 View or change the Feedback settings described below. Options vary with amplifier model.
Setting Description
Hall Type Select Hall type: None, Digital, or Analog (Analog is used with Copley
Controls ServoTube motors).
Hall Phase If selected, will enable error checking between Hall switches and encoder
Correction based phase angle.
Motor Encoder Select type and source of motor feedback.
• None: No motor encoder.
• Primary Incremental: Incremental encoder on primary feedback connector.
• Secondary Incremental: Incremental encoder on multi-mode port.
• Analog: Analog encoder on primary feedback connector.
• Low Frequency Analog: Copley ServoTube motor on primary feedback
connector.
• Resolver (Resolver version only): Resolver on primary feedback connector.
Position Select type and source of Position (load) feedback.
Encoder
• None: No position encoder.
• Primary Incremental: Incremental encoder on primary feedback connector.
• Secondary Incremental: Incremental encoder on multi-mode port.
• Analog: Analog encoder on primary feedback connector.
Position Select the type of Position (load) encoder:
Encoder Type
• Rotary.
• Linear.
Use Position When this is checked, the position of the position encoder will be reported by
Encoder in the passive load position variable but it will not be used to control the position
Passive of the axis.
(Monitor) Mode
5.4.1.7 View or change the Operating Mode settings described below. Options vary with amplifier
model.
Setting Description
Operating Choose the mode of operation: Current, Velocity, or Position.
Mode
Command Choose the command input source:
Source • Analog Command: Analog voltage provides command input.
See Analog Input (p. 104).
• PWM command (current and velocity mode only): Digital pulse-width
modulated signal provides command input. See PWM Input (p. 106).
• Function Generator: Internal function generator provides command input.
• Software Programmed: The amplifier is controlled by software commands
from either the Copley Virtual Machine (CVM) or an external source. See
Copley Indexer Program User’s Guide or the Copley ASCII Interface
Programmer’s Guide.
• Camming: Amplifier runs in Camming Mode. See Copley Camming User
Guide.
• Digital Input: Command input is provided via the Input Source selected from
the choices described below. See Digital Position Input (p. 107).
• CAN: Command input is provided over the CANopen network. See the
CANopen Programmer’s Guide.
Input Source Choose the input source for PWM or Digital input commands:
• Single-ended Inputs: Command input is provided via two of the amplifier’s
programmable digital inputs.
• Multi-mode Port: Command input is provided via differential inputs on the
amplifier’s multi-mode port.
• Differential Inputs: Command is provided via the amplifier’s differential
inputs.
82 Copley Controls Corp.
Xenus XTL User Guide Quick Setup with CME 2
5.4.1.8 View or change the Miscellaneous settings described below. Options vary with amplifier
model.
Setting Description
Commutation Select commutation method: Sinusoidal or Trapezoidal.
Use back EMF If selected, will use the motor’s measured back EMF to determine
for Velocity motor velocity. Recommended only for medium- to high-speed.
Accuracy depends on the accuracy of the programmed Back EMF
value, and may be affected by factors such as cable resistance.
Use Halls for If selected, will use transitions of the Hall switches to determine
Velocity and motor velocity and position. Recommended only for medium- to
Position high-speed applications (may run roughly at low speeds).
Multi-mode Selects the mode for the amplifier’s multi-mode port:
Port • Buffered Motor Encoder. The multi-mode port functions as a buffered
digital encoder output based on the digital encoder input.
• Emulated Motor Encoder. The multi-mode port functions as an emulated
digital encoder output based on the motor analog encoder or motor
resolver.
• Emulated Position Encoder. The multi-mode port functions as an
emulated digital encoder output based on the position analog encoder.
• Differential Input. The multi-mode port functions as a differential
command input.
5.5.2.2 Click the Motor tab to view or change Rotary Motor Setup Parameters (p. 86)
or Linear Motor Setup Parameters (p. 87).
5.5.2.3
Click the Feedback tab to view or change Feedback Parameters, Rotary (p. 88) or
Feedback Parameters, Linear (p. 89). Read the Feedback Notes (p. 90) for important
related information.
5.5.2.4
Click the Brake/Stop tab to view or change Brake/Stop Parameters (p. 91). Read the
Brake/Stop Notes (p. 91) for important related information.
5.5.2.5
Use The Calculate Function (p. 92) to calculate initial gains and limits.
5.5.2.6 On the Main screen, click Save to Flash to avoid losing the changes.
5.5.2.7 View or change the settings described below. Options vary with amplifier model. Metric
units are shown here.
Analog In Fundamental Lines, enter the number of fundamental encoder lines (see encoder or motor
data sheet). As indicated by the Fundamental Counts field, the number of fundamental encoder
counts per revolution is equal to 4 x the number of Fundamental Lines.
Optionally modify the encoder resolution by changing the Interpolation value. The interpolated
resolution (Interpolated Counts Per Rev) is the product of Fundamental Counts value and the
Interpolation value.
Resolver Optionally modify the feedback resolution by changing the value in Counts Per Rev. Default:
16384.
Halls With amplifier set to Use Halls for Velocity/Position, optionally increase the counts per rev ratio
by incrementing the Halls Count Multiplier.
If two feedback devices are installed, verify that the values of Motor Turns to Position Turns correctly
represent the ratio of motor encoder turns to position encoder turns.
Analog Enter the Fundamental Pitch (distance between encoder lines; see encoder or motor data sheet).
As indicated by the Fundamental Resolution field, Fundamental Pitch divided by four gives
Fundamental Resolution. The interpolated resolution is the dividend of Fundamental Resolution
value/Interpolation value. Optionally modify the Interpolated Resolution by changing the
Interpolation value.
Low Frequency (Normally used with ServoTube) Pole Pitch is the distance between poles in a poll pair, as
Analog entered in the Magnetic Pole Pair Length field on the Motor tab. The interpolated resolution is the
dividend of Pole Pitch/Counts per pole value, expressed in micrometers. Optionally modify the
resolution by changing the Counts/Pole value. Click Restore Default to restore default
Counts/Pole.
Brake/Stop Notes
Many control systems employ a brake to hold the axis when the amplifier is disabled. On brake-
equipped systems, disabling the amplifier by a hardware or software command starts the following
sequence of events.
• The motor begins to decelerate (at Abort Deceleration rate in position mode or Fast Stop Ramp
rate in velocity mode). At the same time, the Brake/Stop Delay Time count begins. This allows the
amplifier to slow the motor before applying the brake.
• When the motor slows to Brake/Stop Activation Velocity OR the Brake/Stop Delay Time expires,
the brake output activates and PWM Delay Brake/Stop Response Time count begins.
• When response time has passed, the amplifier’s output stages are disabled. This delay ensures
the brake has time to lock in before disabling the power section.
This sequence is not available in the current mode of operation. Instead, in current mode, the
amplifier output turns off and the brake output activates immediately when the disable command is
received.
Verify the peak current limit, continuous current limit, and velocity loop velocity limit.
If one or more of these values seems inappropriate, click Cancel and check: Peak Torque
(or Force), Continuous Torque (or Force), Velocity Limit, and Torque (or Force) Constant.
Correct them if needed. See Rotary Motor Setup Parameters (p. 86)
or Linear Motor Setup Parameters (p. 87).
If the Motor/Feedback values were correct but the peak current limit, continuous current
limit, or velocity loop velocity limit values are not optimal for the application, change these
limits during the tuning process.
5.5.9.2 Load the values into volatile memory by clicking OK.
NOTE: If the motor wiring configuration in the motor file does not match the configuration
currently stored in the amplifier, CME prompts for verification on which configuration to use.
Select the file configuration by clicking Yes. The configuration will be tested later, in Auto
Phase (p. 110).
5.5.9.3 On the Main screen, click Save to Flash to avoid losing the changes.
The Restore Defaults button restores all inputs and outputs to factory defaults. The Close button
closes the screen.
Grey light:
Output is not active
Red light:
Output is active
5.6.4.2 Choose any of the following functions for any output. OUT4 is recommended for brake
function.
Output Function Description For More Information
Not Configured No function assigned. Output remains high.
Fault Active High Output goes high when at least one fault is Faults (p. 34).
detected.
Fault-Active Low Output goes low when at least one fault is
detected.
Brake-Active High Output goes high to activate the brake. Brake Operation (p. 31).
Brake-Active Low Output goes low to activate the brake.
PWM Sync Output The PWM synchronization output. Synchronizing PWM Switching
(OUT1 only) Frequency (p. 16) and Digital
Input Functions (p. 94).
Custom Event See Custom Digital Output Settings: Custom Event (p. 96).
Custom Trajectory See Custom Digital Output Settings: Custom Trajectory Status (p. 98).
Status
Custom Position See Custom Digital Output Settings: Position Triggered Output (p. 99).
Triggered Output
Program Control Output state controlled by CVM or external program.
Active High
Program Control Output state controlled by CVM or external program
Active Low
5.6.5.1
Choose Custom Event for an output and then click Configure Custom to open the
Event Configuration screen.
5.6.5.2 Select one or more of the faults described in Fault Descriptions (p. 35) or any of the
following warnings or status conditions described below. Note that multiple functions are
OR’ed together, so any event activates the output.
Custom Events: Warnings
Warning Description
2
Current Limited The current output is being limited by the I T algorithm or a latched current fault
2
has occurred. See I T Time Limit Algorithm (p. 153).
Voltage Limited The current loop is commanding the full bus voltage in an attempt to control
current. Commonly occurs when the motor is running as fast as the available bus
voltage will allow.
Positive Limit Switch Axis has contacted positive limit switch.
Negative Limit Axis has contacted negative limit switch.
Switch
Positive Software Actual position has exceeded the positive software limit setting.
Limit See Home Function (p. 144.
Negative Software Actual position has exceeded the negative software limit setting.
Limit See Home Function (p. 144)
Following Warning Following error has reached programmed warning limit.
See Following Error Fault Details (p. 37).
Velocity Limit Velocity command (from analog input, PWM input, or position loop) has exceeded
Reached the velocity limit that was set as described in Velocity Loop Limits (p. 20).
Acceleration Limit In velocity mode, motor has reached an acceleration or deceleration limit that was
reached set as described in Velocity Loop Limits (p. 20).
Velocity Outside of Difference between target and actual velocity has exceeded the window.
Tracking Window See Tracking Window Details (p. 38).
Position Outside of The following error has exceeded the programmed value.
Tracking Window See Tracking Window Details (p. 38).
Continued…
…Continued:
Custom Events: Status
Status Description
Amplifier Disabled by Amplifier enable input(s) is not active.
Hardware
Amplifier Disabled by Amplifier is disabled by a software command.
Software
Attempting to Stop The amplifier, while in velocity or position mode, has been disabled.
Motor In velocity mode, amplifier is using the Fast Stop Ramp described in
Velocity Loop Limits (p. 20).
In position mode, the amplifier is using the Abort Deceleration rate described in
Trajectory Limits (p. 22).
The output remains active until the amplifier is re-enabled.
Motor Brake Motor brake activated. See Brake Operation (p. 31) for more information.
Activated
PWM Outputs The amplifier’s PWM outputs are disabled.
Disabled
Home Switch is Axis has contacted the home limit switch.
Active
Not Settled The motor is moving, or it has not yet settled after a move. The amplifier is settled
when it comes within the position tracking window and stays there for the tracking
time at the end of a move. Once settled, it remains settled until a new move is
started.
5.6.5.3 Choose Output Active High to have the output go high when active or Output Active Low to
have the output go low when active.
5.6.5.4 To optionally latch the selected events, set Latch Output. For more
information on latching, see Non-Latched and Latched Custom Outputs (p. 100).
Latching an output does not eliminate the risk of unexpected motion with
non-latched faults.
! Associating a fault with a latched, custom-configured output does not latch the
fault itself. After the cause of a non-latched fault is corrected, the amplifier re-
enables without operator intervention. In this case, motion may re-start
DANGER unexpectedly.
Failure to heed this warning can cause equipment damage, injury, or death.
5.6.6.1
Choose Custom Trajectory Status for an output and then click Configure Custom to
open the Trajectory Status Configuration screen.
5.6.6.2 Select one or more trajectory status conditions described below. Multiple functions are
OR’ed together, so any status match activates the output.
Trajectory Status Functions
Status Description
Homing Error Activate output if an error occurred in the last homing attempt.
Referenced (Homed) Activate output if the most recent homing attempt was successful.
Homing in Progress Activate output when a homing move is in progress.
Move Aborted Activate output if move is aborted.
Trajectory Generator Running Activate output while trajectory generator is generating a move.
Camming Buffer Error A camming buffer error has occurred.
5.6.6.3 Choose Output Active High to have the output go high when active or Output Active Low to
have the output go low when active.
5.6.6.4 Click OK to save changes to volatile memory and close the screen.
5.6.7.1
5.6.7.2 Choose Custom Position Triggered Output for an output and then click Configure
Custom to open the In Position Configuration screen.
5.6.7.3 Select one of the configurations described below and enter appropriate values for the
parameters.
Configuration Description and Parameters
In Position Activates the output while the axis is in the window between the programmed Upper and
Window Lower positions.
Trigger at Activates the output for the programmed Time when the axis travels through the
Position programmed Position.
Trigger Positive Activates the output for the programmed Time when the axis travels in the positive direction
Motion through the programmed Position.
Trigger Activates the output for the programmed Time when the axis travels in the negative
Negative Motion direction through the programmed Position.
5.6.7.4 Choose Output Active High to have the output go high when active or Output Active Low to
have the output go low when active.
5.6.7.5 Choose Use Actual Position (the Limited Position choice is for stepper amplifiers only).
5.6.7.6 Click OK to save changes to volatile memory and close the
Custom Output Configuration screen.
5.6.8: Save Input/Output Changes
5.6.8.1 On the Input/Output screen, click Close.
Latching an output does not eliminate the risk of unexpected motion with non-
latched faults.
! Associating a fault with a latched, custom-configured output does not latch the fault
itself. After the cause of a non-latched fault is corrected, the amplifier re-enables
without operator intervention. In this case, motion may re-start unexpectedly.
DANGER For more information, see Clearing Non-Latched Faults (p. 34).
Failure to heed this warning can cause equipment damage, injury, or death.
5.6.10.2 To make a fault condition latching, click to put a check mark next to the fault description.
! After the cause of a non-latched fault is corrected, the amplifier re-enables the PWM
output stage without operator intervention. In this case, motion may re-start
unexpectedly. Configure faults as latched unless a specific situation calls for non-
latched behavior. When using non-latched faults, be sure to safeguard against
DANGER unexpected motion.
Failure to heed this warning can cause equipment damage, injury, or death.
For more information, see Faults (p. 34).
5.6.10.3 To restore factory defaults if needed, click Restore Defaults.
5.6.10.4 Click OK to save fault configuration settings to volatile memory and close the
Fault Configuration screen.
5.6.11.3 Click OK to save regen settings to flash memory and close the Regen Resistor screen.
5.7.1.1 Click Analog Command to open the mode-specific Analog Command screen.
Current mode: Velocity mode: Position mode:
5.7.3.1 Click Digital Position Inputs to open the Digital Position Input screen,
Configuration tab.
5.7.4.2 Click CAN Configuration to open the CAN Configuration screen. (If CAN
is not the Position Loop Input, choose Amplifier CAN Configuration instead.)
Here is a typical CAN Configuration screen. (Features may vary based on amplifier model
and configuration.)
Motor Motion
! Applying AC power to the amplifier may result in motor motion. Be sure that motor
motion will not cause injury.
Failure to heed this warning can result in equipment damage, injury, or death.
Danger
High Voltage
Notes
• Do not connect a load to the motor before performing Auto Phase procedure.
• Always connect the motor using the same configuration.
• Wire properly and consistently.
• Connections are actually changed within the DSP, not at the motor terminals, and the results are
saved to flash memory. The actual wire configuration should NEVER change.
• Brushless motors require two electrical cycles for auto phasing.
Phasing accomplishes several objectives:
• Checks the encoder or resolver and establishes proper commutation.
• Checks the motor power wires for proper connection and establishes proper phasing.
• Checks the Hall switches and establishes proper commutation.
Click Auto Phase to open the Auto Phase Motor Direction Setup screen.
5.8.2.8 Click Start to begin the Phase Count Test. Observe status messages. See the prompt:
5.8.2.9 When you are ready to observe motion, click OK. See the prompt:
5.8.2.10 If motor did not turn 1 full turn, click No and verify that in the Motor/Feedback screen the
following parameters have been set correctly:
Number of Poles for rotary motors.
Magnetic Pole Pair Length for linear motors
Encoder Lines or Fundamental Lines for rotary encoders.
5.8.2.18 Click Finish to close the screen and save values to flash memory
OR
to close the screen without saving changes, click Cancel.
5.8.2.19 If the Auto Phase algorithm does not produce desired results, try adjusting the Auto Phase
Current and Increment Rate values, using the guidelines in
Guidelines for Choosing Auto Phase Current and Increment Rate Values (p. 115).
5.8.2.20 If desired results are not obtained, see “Manual Phasing” in the CME 2 User Guide.
5.8.3: Guidelines for Choosing Auto Phase Current and Increment Rate Values
Here are some considerations in choosing Auto Phase Current and Increment Rate values:
• If friction is high, then more current may be required to move the load.
• High static friction may require more current to overcome stiction.
• Transition from static friction to dynamic friction, and back, may produce jerky motion.
• A faster rate will operate in the dynamic friction range.
• A slower rate will operate in the static friction range.
• If the friction is low, as in the case of air bearings, low frequency oscillations may occur; thus, less
current and slower rates may be required. If oscillations persist, then friction may need to be
temporarily added.
5.8.4: Trouble Shoot Motor Direction Setup
If motor direction setup step failed:
5.8.4.1 Check Encoder or resolver power and signals.
5.8.4.2 Verify that the encoder is differential. (Contact factory if encoder is single-ended.)
5.8.4.3 Check shielding for proper grounding.
5.8.5: Trouble Shoot Motor Wiring Setup
If motor wiring setup step failed:
5.8.5.1 Verify that amplifier is disabled.
5.8.5.2 Check for mechanical jamming.
5.8.5.3 Check for smooth motion with no mechanical jerking.
5.8.5.4 Check for good connections to the motor power wires.
5.8.5.5 Disconnect motor power wires.
5.8.5.6 Measure for proper motor resistance.
5.8.6: Trouble Shoot Halls Wiring Setup
If Halls wiring setup step failed:
5.8.6.1 Check Halls power and signals.
5.8.6.2 Check for smooth motion with no mechanical jerking.
5.8.6.3 Check shielding for proper grounding.
5.8.7: Trouble Shoot Other Problems
If the auto phase procedure fails despite these corrective measures, see
“Manual Phasing” in the CME 2 User Guide.
5.9.2.4 Click Auto Tune to open screen and start the Current Loop Auto Tune.
5.9.2.5 To Change the Auto Tune Current, Press Stop, enter the new current in the Auto Tune
Current field, and then press Start.
Copley Controls Corp. 117
Quick Setup with CME 2 Xenus XTL User Guide
2 Uses a frequency sweep to determine the small signal, current loop bandwidth.
3 Displays the results: a set of Cp, Ci, and bandwidth value alternatives.
NOTE: During tuning, observe any warnings that appear to the left of the trace.
5.10.2.2 Choose Velocity from the Function Generator Apply To: list.
On the Settings tab, make sure Auto Setup is selected.
Auto Setup automatically sets the following parameters:
Function Generator Tab
Parameter Description
Excitation Square Wave
Amplitude 10% of maximum velocity value.
Frequency 5 Hz
Settings Tab
Channel 1 Limited velocity (green)
Channel 2 Actual velocity (white)
5.10.2.3 Verify that Amplitude value is not excessive for the motor.
5.10.2.8 On the Main screen, click Save to Flash to avoid losing the changes.
5.10.2.9 If the amplifier is to be operated in velocity mode, skip the position loop setup procedures
and go to Completion Steps (p. 126).
NOTE: During position loop tuning, observe any warnings that appear to the left of the trace.
5.11.2.1 Perform an auto setup test:
3 On the Settings tab, make sure that Auto Setup is checked. Auto Setup
automatically sets the following options:
Profile Tab
Parameter Description
Move Relative
Type Trap
Distance 2000 counts
Reverse and repeat Not selected
Settings Tab
Channel 1 Profile velocity (green)
Channel 2 Following error (white)
5 Click Start.
The Profile Generator executes a short move.
NOTES:
1 The profile may not reach constant velocity during a short move.
2 If a following error occurs, open the CME 2 Control Panel ( ) and click Clear Faults.
5.11.2.2 Set up a trapezoidal profile by setting the trajectory limits and distance. See table:
5.11.2.3 Adjust position proportional gain (Pp) to minimize following error. Note that too much
position loop proportional gain (Pp) might cause oscillation.
1 On the Gains tab, set velocity feed forward (Vff) and acceleration feed forward (Aff) to
zero.
2 On the Profile tab, click Start. On the Gains tab, adjust position loop proportional gain
(Pp) until best result is obtained.
3 Click Start after each adjustment to test the new value on a new profile move.
NOTE: If a following error occurs, open the CME 2 Control Panel ( ) and click Clear
Faults.
5.11.2.4 Adjust velocity feed forward (Vff):
Velocity feed forward (Vff) reduces following error in the constant velocity portion of the
profile. Often, a velocity feed forward (Vff) value of 16384 (100%) provides best results.
1 Click in the Vff field and adjust the value.
2 Click Start after each adjustment to test the new value on a new profile move.
5.11.2.5 Adjust acceleration feed forward (Aff):
Acceleration feed forward (Aff) reduces following error during profile acceleration and
deceleration.
1 Click in the Aff field and adjust the value.
2 Click Start after each adjustment to test the new value on a new profile move.
NOTES:
1 If, after tuning the position loop, the motor makes a low frequency audible noise while
enabled but not moving, the velocity loop gains (Vp and Vi) may be lowered to reduce
the noise. If the gain values are set too low, the response to instantaneous rates of
change might be reduced (i.e., slow correction to disturbances or transients).
2 If the amplifier is set up to run in position mode under analog input command, and the
analog command signal produces too much noise at the motor after tuning, the
Velocity Loop Command Filter may be used to reduce the noise further. See the CME
2 User Guide for more information about the velocity loop filters.
5.11.2.6 Tune to multiple sets of profiles representing typical moves that might be executed in the
application. Starting with Set up a trapezoidal profile, repeat the process as needed.
5.12.2.7 On the Main screen, click Save to Disk (for backup or duplication).
Main Menu
Tool Bar
Functional
Diagram
Status
Bar
Auto Phase Opens Auto Phase tool. Auto Phase (p. 110).
Auto Tune Opens Auto Tune for Linear CME 2 User Guide.
Servo Motors.
Scope Opens Scope. CME 2 User Guide.
…continued:
Menu Selection Description
Help CME 2 User Guide Opens the CME 2 User Guide.
All Documents Opens the Doc folder in the CME 2 installation folder
(typically c://Program Files/Copley Motion/CME 2/Doc).
This folder contains all of the related documents that were installed with CME 2.
Downloads Web Opens default web browser with relevant pages from Copley Controls’ website.
Page
Software Web Page
View Release Notes Opens latest CME 2 release notes in a text viewer.
About Displays CME 2 version information.
Input Command
The Address field shows the amplifier’s present CAN or DeviceNet address. This value is updated
on +24 Vdc power-up or reset only (for more information, see CAN Addressing [p.29]) or the
Copley DeviceNet Programmer’s Guide. When the Position Loop Input is set to CAN, the State
field shows the state of the amplifier’s CANopen state machine (for more information, see Copley
Control’s CANopen Programmer’s Manual).
The status bar describes the present commutation mode, motor type, and amplifier control status
as shown below. It also includes a reminder that pressing the F12 function key while CME 2 is
running disables the amplifier.
To use a data management tool, click the icon and respond to prompts.
Motor Data Management Tools
Operations performed using the data management tools at the bottom of the Motor/Feedback
screen (shown below) affect only user-entered data that is represented on the Motor/Feedback
screen.
Motor/Feedback
Data Management Tools
To use a data management tool, click the icon and respond to prompts.
6.2.4.3 On the Main screen, click Restore amplifier data from disk.
6.2.4.4 When prompted, navigate to the folder containing the appropriate .ccx file.
Highlight the file name and then click Open to load the file data into volatile memory.
6.2.4.5 On the Main screen, click Save to Flash to save the new settings to flash
memory.
6.2.4.6 If you do not need to load a CVM Control Program, skip to Step 6.2.4.7.
To load a CVM Control Program, choose File Restore CVM Control Program.
When prompted, navigate to the folder containing the appropriate .ccp file.
Highlight the file name and then click Open to load the file data into flash memory.
This procedure also results in the setting of the Indexer 2 Program option Enable
Control Program on Startup. This configures the program to auto start when the
amplifier is powered up or reset.
6.2.4.7 If you do not need to load a set of Cam Tables, the process is complete.
To load a set of Cam Tables, choose File Restore Cam Tables.
When prompted, navigate to the folder containing the appropriate .cct file.
Highlight the file name and then click Open to load the file data into flash memory.
TIP: When copying amplifier data to multiple amplifiers in a production environment, consider
locking CME 2 to prevent accidental changes to settings. For more information on
locking/unlocking CME 2, see the CME 2 User’s Guide.
6.3.2.2 To download new firmware without saving amplifier and motor data, click No
and then proceed to Step 6.3.2.4.
6.3.2.3 To save amplifier and motor data for backup purposes before downloading firmware,
click Yes.
1 Use check marks to select whether to save to disk, flash, both, or neither.
2 Click OK to save data and continue to select a firmware image,
or click Cancel to continue without saving data.
3 If Save Data to Disk was checked, use the Save Amplifier Data to Disk screen to
browse to the folder where you want to save the .ccx file. Then enter a name in the
Name field. Then click Save.
When the Firmware Images window appears, proceed to Step 6.3.2.4.
6.3.2.4 Use the Firmware Images window to locate and select a firmware image file.
Red if fault
is active
Yellow if warning
is active
Message box
Control functions
…continued:
Indicator States/Description
The fault indicator goes red when a fault is active. Check the status message box for a description
of the most recent fault: .
Check the Error Log for a full history of faults and warnings.
The warning indicator goes yellow when a warning is active. Check the status message box for a
description of the most recent: .
Check the Error Log for a full history of faults and warnings.
Message Box Displays status descriptions.
The message box below the indicators displays the most recent active fault or warning message.
To set up a monitor display box, click in the list box and select a variable from the list.
Disabled disables the display. Other options represent the following amplifier values:
• Actual Current • Following Error • Passive Load Position
• Actual Motor Velocity • Commanded Current • Limited Position
• Actual Motor Position • Commanded Velocity • Analog Command
• Actual Load Velocity • Commanded Position • Bus Voltage
• Actual Load Position • Profile Velocity • Amplifier Temperature
• Velocity Error • Profile Acceleration • Motor Phase Angle
Mode: Displays the amplifier’s present operating mode. In camming it also displays the active cam
table number.
Control the operational state of the amplifier using the buttons described below.
Control Description
Enable Click to software enable the amplifier.
Disable Click to software disable the amplifier.
Set Zero Position Click to set the amplifier’s actual position counter to zero.
Clear Faults Click to clear all amplifier faults.
Reset Click to reset the amplifier.
! Using the CME 2 Set Zero Position function while the amplifier is operating under
CANopen control could cause unexpected or uncontrolled motion.
Failure to heed this warning can cause equipment damage.
WARNING
6.4.5: Jog Mode
Jog mode provides a simple way to generate forward or reverse commands as described here:
6.4.5.1 To put the amplifier in jog mode, set the Enable Jog option.
6.4.5.2 Set up a jog move by setting the following mode-specific parameters:
Mode Parameter Description
Current Current Current applied to the motor. Limited by current loop Continuous Current.
Warning: Unloaded motors may, depending on torque setting, ramp up in
speed very quickly.
Current Ramp The rate at which the current will increase and decrease.
Velocity Jog Speed Velocity of the jog move. Limited by velocity loop Vel. Limit.
Position Velocity Velocity of the jog move. Limited by velocity loop Vel. Limit.
Acceleration Acceleration limit of the jog move.
Deceleration Deceleration limit of the jog move.
6.5.2.3
Verify the Current setting and then enable the amp by selecting Enable in the Control
area of the Manual Phase window.
To control the current vector rotation, command the motor forward or reverse.
NOTE: Some motors have bearings stiction, so helping the motor with mechanical
force is acceptable. Motors with no friction may need friction added to steady motion.
6.5.2.4 If the motor cannot keep up with the rate of vector rotation, then reduce the Increment
Rate or increase the Current.
6.5.2.5 Verify that pressing forward button moves motor forward. If it does not, toggle the
Motor Invert Output box setting.
6.5.2.6 Verify actual position count agrees with direction of rotation: increasing counts in
forward direction and decreasing counts in reverse direction. If it does not, toggle the
Encoder Invert Input box setting.
6.5.2.7 Monitor the vector rotation through one electrical cycle for proper Hall transitions.
1 Verify that the red indicator rotates in the same direction as the motor phase angle,
and that the transition occurs when the needle is between indicators (±30 degrees,
as shown below).
2 If the needle and Hall states do not track properly, use the Hall Wiring list box
(shown below) to swap the amplifier’s Hall wire configuration.
3 If the red indicator transition leads or lags behind the centered needle by more than
30 degrees, then try adjusting the Hall Offset in +/- 30 degree increments:
6.5.2.8 Phasing of a motor with encoder and Halls is complete. Click OK.
Actual Current Shows actual current being applied to windings during homing.
! 2
For the regen I T algorithms to work correctly, the values entered in the following
steps must be correct. Damage to the external regen resistor may result from
incorrect values entered. Damage to the amplifier may result if an incorrect
resistance value is entered.
WARNING
Failure to heed this warning can cause equipment damage.
A.2.2.2 If configuring a standard Copley Controls regen resistor, select the model number and
click Finish to save the configuration and close the screen.
Otherwise, continue Select Custom Resistor and then click Configure to open the
Custom Regen Configuration screen.
A.2.2.3 Enter a Resistance within the range described on the screen. Click Next for Step 2.
A.2.2.4 Enter a Continuous Power within the range described. Click Next for Step 3.
A.2.2.5 Enter a Peak Power within the range described. Click Next for Step 4.
16
14 I_commanded
12 I_actual
Current (A)
10
8
6
4
2
0
0 1 2 3 4 5 6 7
Tim e (S)
A)
I2T Accumulator
120
I2T energy (A 2-S)
100
80
I^2T Setpoint
I2T Setpoint
60 2
II^2T
T Accumulator
Accumulator
40
20
0
0 1 2 3 4 5 6 7
Tim e (S)
B)
At time 0, plot diagram A shows that the actual output current follows the commanded current.
Note that the current is higher than the continuous current limit setting of 6 A. Under this condition,
the I2T Accumulator Variable begins increasing from its initial value of zero. Initially, the output
current linearly increases from 6 A up to 12 A over the course of 1.2 seconds. During this same
period, the I2T Accumulator Variable increases in a non-linear fashion because of its dependence
on the square of the current.
2 2
At about 1.6 seconds, the I T Accumulator Variable reaches a values equal to the I T setpoint. At
this time, the amplifier limits the output current to the continuous current limit even though the
2
commanded current remains at 12 A. The I T Accumulator Variable value remains constant during
156 Copley Controls Corp.
Xenus XTL User Guide Regen Resistor Sizing and Configuration
the next 2 seconds since the difference between the actual output current and the continuous
current limit is zero.
At approximately 3.5 seconds, the commanded current falls below the continuous current limit and
once again the output current follows the commanded current. Because the actual current is less
2
than the continuous current, the I T Accumulator Variable value begins to fall incrementally.
2
The I T Accumulator Variable value continues to fall until at approximately 5.0 seconds when the
commanded current goes above the continuous current limit again. The actual output current
follows the current command until the I2T Accumulator Variable value reaches the I2T setpoint and
current limiting is invoked.
Heatsink w/fan 5
4 5 Heatsink w/fan
50 Low Profile 50
3 Low Profile
4
Heatsink w/fan
4 4
Heatsink w/fan
2 Low Profile Heatsink Low Profile Heatsink
40 3 or no Heatsink w/fan 40 3 or no Heatsink w/fan
3
1 Standard Standard
2 2 2
Heatsink 30 Heatsink
30 1
1 No Heatsink 1 No Heatsink
20 20
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Continuous Output Current (Adc) Continuous Output Current (Adc)
20 20
2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20
Continuous Output Current (Adc) Continuous Output Current (Adc)
The various cooling configurations are shown on the following page.
4.25 in
Fan
Low-Profile Heatsink
No Fan With Fan*
4.25 in
Fan
Standard Heatsink
No Fan With Fan*
4.25 in
Fan
* Select a 4.25-inch square fan that supplies forced air at a minimum rate of 300 linear feet per
minute
Dry Film
Interface Pad
C.2.2 Place the interface pad on the amplifier, taking care to center the pad holes over the
heatsink mounting holes.
C.2.3 Remove the clear protective sheet from the pad.
C.2.4 Mount the heatsink onto the amplifier taking care to see that the holes in the heatsink,
interface pad, and amplifier all line up.
C.2.4 Torque the #6-32 mounting screws to 8~10 lb-in (0.9~1.13 Nm).
#6-32 Mounting Screws
Transparent Carrier
(Discard)
Xenus Amplifier
NOTE: The drawing shows the standard heatsink kit (XTL-HS), but the mounting
instructions given are valid for the low profile heatsink kit (XTL-HL) as well.
D.1: Overview
The XTL-FA-01 edge filter can be used to minimize noise on the output of any Xenus amplifier.
D.1.1: Differential and Common Mode Filtering
Most noise is capacitively coupled from the motor power cable to neighboring cables. To minimize
this noise, the XTL-FA-01 edge filter uses both differential edge filtering and common mode
filtering. Differential edge filtering reduces the high frequency component of the PWM signal, thus
producing a signal with less energy that can be coupled during transmission. Common mode
filtering reduces the unnecessary common mode noise generated by PWM signals.
D.1.2: Description and Functional Diagram
The differential filter increases the rise time by at least a factor of 3, substantially reducing noise in
the system. Copley Controls amplifiers typically have a 150 ns-rise time (high frequency
component in the MHz range). Thus, the edge filter can increase rise time to 500 ns, reducing the
high frequency noise emissions by the square law. The differential filter is designed with 82 PH
inductors and a proprietary passive circuit. The inductance will provide a total of 164PH in series
with the load, helping to reduce ripple current. This brings low inductance motors into the required
range.
The common mode filter is designed with a 220 PH common mode toroid that works with the cable
capacitance to earth ground to remove common mode switching noise.
Amp Filter Motor
J1 J2
U U
J1-4 J2-4
82uH
V V
J1-3 J2-3
82uH
W 82uH W
J1-2 J2-2
Common Differential Case GND
J1-1 Mode Mode J2-1
+HV
90%
10%
Raw PWM
500ns
Filtered
150ns
DANGER
! High-voltage circuits on Xenus J1, J2, and J3 and on Filter J1 and J2 are connected
to mains power.
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
! With the exception of the ground pins on Xenus J1, J2, and J3 and on Filter J1 and
J2, all of the other circuits on these connectors are mains-connected and must never
be grounded.
Pin Description
Pin Signal Function
1 Ground Chassis ground and cable shield
2 Phase W Phase W input from amplifier
3 Phase V Phase V input from amplifier (use for DC motor connection)
4 Phase U Phase U input from amplifier (use for DC motor connection)
5 --- No connection
Pin Description
Pin Signal Function
1 Ground Chassis ground and cable shield
2 Phase W Phase W output to motor
3 Phase V Phase V output to motor (use for DC motor connection)
4 Phase U Phase U output to motor (use for DC motor connection)
Amplifier Filter
Brushless
J1-5 Motor
U A
J2-4 J1-4 J2-4
V B
J2-3 J1-3 J2-3
J2-2 W J2-2 C
J1-2
Amplifier Filter
Brush
J1-5 Motor
J2-4
U +
J1-4 J2-4
J2-3
V
J1-3 J2-3 -
J2-2 J1-2 J2-2
Case
J2-1 J1-1 J2-1
Ground
Connector Kit
Model Qty Ref Description Mfr. Model No.
1 J1 Plug, 5 position, 5.0 mm, female Wago 51118042 or
721-105/026-047/RN01-0000
XTL-FK
1 J2 Plug, 4 position, 5.0 mm, female Wago 51118008 or 721-104/026-047/RN01-0000
2 -- Insertion / Extraction Tool Wago 231-131
Serial
Copley Amplifier
PC, PLC, or HMI COM port SER-CK "Serial Cable Kit" CAN
9pin D-sub RJ11 w ith ASCII
for ASCII Control for ADDR
RS-232
RS-232 0
Serial
PC, PLC, or HMI SER-CK "Serial Cable Kit" Copley Amplifier CAN
COM port 9pin D-sub RJ11 CAN Port
for ASCII Control with ASCII RS-232 ADDR
for RS-232
0
RJ45 RJ45
ADDRESSES MUST BE 120 Ohm
SET BEFORE POWER-UP Terminator
OR RESET.
Edge Filter
Model Description
XTL-FA-01 Xenus Edge Filter
! Setting Default Continuous Power for a standard Copley regen resistor to a value greater
than the default of 65 W may cause the resistor casing to heat to temperatures that could
cause injury. If higher settings are required, contact Copley Controls customer support.
WARNING Failure to heed this warning can cause equipment damage or injury.
F.5.2: Dimensions
The diagram below shows XTL-RA-03 and XTL-RA-04 mounting dimensions (in mm).
2007, 2008
Copley Controls Corporation
20 Dan Road
Canton, MA 02021 USA
All rights reserved
Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.
Alternative Proxies: