Tolomatic Axidyne AXIOM PLUS PV Series User manual

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3600-4628_05

AXIOM® PLUS PV Series

Brushless Servo Controller/Drive

User Manual

TOL-O-MATIC, INC

Excellence in Motion®

ELECTRIC LINEAR MOTION PRODUCTS

NOW WITH

ANALOG

INPUT

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Product and Safety Notice

Use of Axiom Servo Drives

Axiom Plus systems are intended to be part of a controlled system or to operate in a stand-alone

conﬁguration. Installation and operating instructions for all system components must be observed.

Unless otherwise speciﬁed, Axiom Plus systems are intended for use in a normal industrial environment.

Installation is to be in a suitable electrical cabinet capable of protecting the unit from exposure to excessive

moisture, corrosive agents or excessive ambient temperatures. Installation of the hardware must only be

attempted by skilled personnel and with adherence to the installation instructions in this manual. This unit

does not contain any user serviceable components. Should repair or replacement of a unit become

necessary, please contact the place of purchase for instructions.

Safety Notes

As with any electrical equipment, there are some possible hazards associated with the installation and use of

this hardware. Please observe the following precautions. Further speciﬁc Warnings and Cautions are listed

throughout this manual.

Installation and Maintenance: All installation and maintenance must be carried out by qualiﬁed personnel.

Generation: A mechanically driven motor will act as a generator. Because dangerous voltage levels may be

generated, motor to drive connections must be suitably guarded to protect against electrical shock hazards.

Cables: Use only Tol-O-Matic supplied cables, or cables deemed suitable for use by a competent person

familiar with the electrical and mechanical requirements of a given application.

Supply: Axiom Plus units must be connected to a permanent power source and fused according to the

instructions in this manual, in accordance with all local and national electrical codes.

Safety Requirements: The safe and proper installation and operation of this unit into a machine system is

the responsibility of the machine designer and should comply with all applicable local and national safety

requirements. In Europe, this is likely to include the Machinery Directive, the ElectroMagnetic Compatibility

Directive and the Low Voltage Directive. In the United States this will likely include the National Electrical

Code.

Mechanical Installation: Units must be installed inside an appropriate electrical cabinet providing

environmental controls and protection. The minimum requirements are outlined in this manual.

TOL-O-MATIC, INC.

3800 County Road 116, Hamel, MN 55340

http://www.Tolomatic.com • Email: [email protected]

Phone: (763) 478-8000 • Fax: (763) 478-8080 • Toll Free: 1-800-328-2174

Information furnished is believed to

be accurate and reliable. However,

Tol-O-Matic assumes no respons-

ibility for its use or for any errors

that may appear in this document.

Tol-O-Matic reserves the right to

change the design or operation of the

equipment described herein and any

associated motion products without

notice. Information in this document

is subject to change without notice.

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Contents....................................................................................................................i

List of Figures..........................................................................................................v

Introduction ............................................................................................................ix

Graphic Symbols andWarning Classiﬁcations ....................................................ix

Notices................................................................................................................x

Axiom Plus System Overview ..............................................................................xiii

Power Ratings ................................................................................................xiii

Interface Cables..............................................................................................xiv

Axiom Plus Features.............................................................................................xiv

Motor/Encoder Input.......................................................................................xv

Encoder Follower Input...................................................................................xv

Encoder Output...............................................................................................xv

Digital I/O.......................................................................................................xvi

Ac Input Power ...............................................................................................xvi

Drive and Motor Protection Circuitry...........................................................xvi

Agency Approvals ...........................................................................................xvi

Tol-O-Motion Axiom Plus Software...................................................................xvii

Chapter 1: Safety

Potential Hazards...............................................................................................1-1

Your Responsibilities..........................................................................................1-2

Safety Guidelines................................................................................................1-2

Chapter 2: Theory of Operation

Discussion of DriveTechnologies.....................................................................2-1

Three-Phase Brushless Motors .........................................................................2-1

Commutation.....................................................................................................2-2

Brushless Servo Drives .................................................................................2-3

Hall Commutated Drives...........................................................................2-3

Sine Commutated Drives..........................................................................2-4

Vector Drives............................................................................................2-5

Chapter 3: Unpacking, Inspection and Storage

Unpacking the Drive..........................................................................................3-1

Inspection Procedure.........................................................................................3-1

Storage ................................................................................................................3-1

Chapter 4: Physical Mounting of Drive

Physical Mounting of Drive...............................................................................4-2

Chapter 5: Power Connections and Fusing

GeneralWiring Guidelines ................................................................................5-1

Axiom Plus PV10, PV20, PV30............................................................................5-2

Chapter 6: Motor Encoder and Power Connections

GeneralWiring Guidelines ................................................................................6-1

Axiom Plus Systems ...........................................................................................6-2

Emergency Stop Connection.............................................................................6-3

Contents

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Chapter 7: Software Installation

Hardware and Software Requirements.............................................................7-1

Installation..........................................................................................................7-1

Chapter 8: Initial Check Out

Setup/Conﬁguration Screen .............................................................................8-1

Commands,Setup and Conﬁguration Mode..............................................8-3

Indexer Model Selection/Setup....................................................................8-3

Motor Model Selection/Setup.......................................................................8-4

Phasing Conﬁguration.................................................................................8-4

Gains and Limits..........................................................................................8-5

ModBus Conﬁguration ................................................................................8-6

Check Out Procedure ........................................................................................8-7

Chapter 9: I/O Connections

Inputs ................................................................................................................9-1

Analog Inputs .....................................................................................................9-6

Outputs...............................................................................................................9-9

Chapter 10: Regeneration Resistor Use and Sizing

Regeneration Resistor Use and Sizing............................................................10-1

Chapter 11: Final Checkout and Tuning

OnlineTuning and Diagnosis..........................................................................11-1

Command Menu,Online Tuning/Diagnosis Mode..................................11-1

Indexer Status,Fault,I/O ...........................................................................11-2

Oscilloscope................................................................................................11-3

Encoder Feedback Section .........................................................................11-4

Drive Diagnosis Screen .............................................................................11-4

DriveTuning Screen..................................................................................11-5

DriveTuning ....................................................................................................11-7

Auto Tuning ...............................................................................................11-7

Manual Tuning .........................................................................................11-8

Analog Input Gain and Offset .........................................................................11-8

Adjustments and Diagnostics .........................................................................11-8

Chapter 12: Programming

Programming Environment............................................................................12-2

Sequential Program Editor..............................................................................12-2

PRG Menu...................................................................................................12-3

Sequential Program Debugger..................................................................12-5

User Units...................................................................................................12-7

Sequential Program Listing.......................................................................12-8

Creating a Sequential Motion Program Instruction ................................12-9

Instruction Command Set.........................................................................12-10

Analog Input Position Mode .....................................................................12-12

Analog InputVelocity Mode.......................................................................12-13

Analog Position Conversion Factor...........................................................12-22

PLC Program Editor .........................................................................................12-28

PLC Menu ...................................................................................................12-28

CONTENTS

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Creating / Editing a PLC Rung ..................................................................12-30

Operation Details Screen...........................................................................12-31

Default PLC Program.................................................................................12-44

Chapter 13: Communication/Protocol

ASCII Command ..............................................................................................13-1

RS232 Serial Communications Character Framing Settings...................13-1

Read /Write RegisterValue Using ASCII Commands Over RS232

Serial Port...................................................................................................13-1

Reading Indexer Internal Fault and Status Identiﬁcation FlagWords ...13-5

Reading ProcessVariable/Diagnostic Registers.........................................13-6

Manipulation of PLC Flags Using ASCII Serial Port Commands............13-7

Scaling and Interpretation ofValues Stored in Axiom Plus Registers......13-9

General Analog Input Functionality Analog Register ..............................13-11

ModBus Communication Setting...................................................................13-12

Addressing of Slave Axiom Plus Devices ...................................................13-13

Mapping............................................................................................................13-14

Axiom Plus Registers into Modbus Registers.............................................13-14

Axiom Plus Discrete I/O and Flags into

ModBus 0X and 1X Memory Space............................................................13-20

Command stream Handling,Time-Separation of Commands,Etc........13-23

ModBus Commands Supported by Axiom Plus........................................13-24

Registers......................................................................................................13-29

Chapter 14: Examples

IndexerType Control of the Axiom Plus.........................................................14-1

PLC Program Listing .................................................................................14-1

Sequential Program Listing.......................................................................14-4

Chapter 15: Status and Fault Display

Normal Operation ...........................................................................................15-1

Status Codes .....................................................................................................15-1

Faults ................................................................................................................15-1

Fault and Status Codes .............................................................................15-2

Chapter 16: Maintenance & Troubleshooting

Maintenance ....................................................................................................16-1

Periodic Maintenance................................................................................16-1

Troubleshooting Guide....................................................................................16-2

Appendix A: Options and Accessories

Cables ...............................................................................................................A-1

Communications Cables.............................................................................A-1

Buffered Encoder Output / Auxiliary Encoder Cable .......................................A-1

Motor Cables................................................................................................A-2

iii

CONTENTS

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Appendix B: Speciﬁcations

Agency Approvals...............................................................................................B-1

Power ...............................................................................................................B-1

Command Sources ............................................................................................B-2

Serial Communication Port........................................................................B-2

Control Loops...............................................................................................B-2

Inputs and Outputs.....................................................................................B-2

Connectors ...................................................................................................B-2

Environmental.............................................................................................B-3

Motor Protection................................................................................................B-3

Regeneration Ratings ........................................................................................B-3

Power Dissipation..............................................................................................B-4

Appendix C: Motor Performance Data

Motor Drive Performance Curves for MRV Series Motor Drives...................C-1

Appendix D: Motor Dimension Drawings

Motor Dimension Drawings.............................................................................D-1

Appendix E: Warranty Information

Defective Equipment.........................................................................................E-1

Return Procedure...............................................................................................E-1

Product Support.................................................................................................E-2

Distributor & Representative Network.............................................................E-2

Application Engineers & Field Service .............................................................E-2

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Figure Description Page

4.1 Axiom PV10 Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Axiom PV20 and Axiom PV30 Mounting Dimensions. . . . . . . . . . . . . . . . . . . . 4-3

5.1 Axiom PV10/20/30 Single-Phase Drive Power Connections. . . . . . . . . . . . . . . 5-2

5.2 208/230 Vac Three-Phase; Axiom PV10/20/30

Three-Phase Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6.1 PV10/20/30 Motor Power Cable Connections for MRV 2X, 3X, 5X. . . . . . . . . . 6-2

6.2 PV10/20/30 Motor Encoder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 Emergency Stop Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Drive Remains Powered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

8.1 Tol-O-Motion Axiom Plus Setup Software Opening Screen. . . . . . . . . . . . . . . . 8-1

8.2 Setup and Conﬁguration Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.3 Register Precision Conﬁguration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.4 ModBus Conﬁguration Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

9.1 Axiom Plus Input Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 Axiom Plus Sinking Input Connected to Sourcing Switches

Using Internal Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.3 Axiom Plus Sinking Input Connected to Sourcing Switches

Using External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.4 Axiom Plus Sinking Input Connected to Sourcing Output

Using Internal Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.5 Axiom Plus Sinking Input Connected to Sourcing Output

Using External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.6 Axiom Plus Sourcing Input Connected to Sinking Switches

Using Internal Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.7 Axiom Plus Sourcing Input Connected to Sinking Switches

Using External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.8 Axiom Plus Sourcing Input Connected to Sinking Outputs

Using Internal Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.9 Axiom Plus Sourcing Input Connected to Sinking Outputs

Using External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.10 Front Panel Overlay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9.11 Single Ended and Differential Analog Input Connections . . . . . . . . . . . . . . . . . 9-6

9.12 Pullup/Pulldown Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.13 Axiom Plus Output Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.14 Axiom Plus Sourcing Output Connected to Sinking Input

Using Internal Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.15 Axiom Plus Sourcing Output Connected to Sinking Input

Using External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.16 Axiom Plus Sinking Output Connected to Sourcing Input

Using Internal Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

9.17 Axiom Plus Sinking Output Connected to Sourcing Input

Using External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

List of Figures

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Figure Description Page

9.18

Axiom Plus Sinking Output Connected to Sourcing Opto22 Solid State Relays

. . 9-12

9.19 Axiom Plus Power Off Holding Brake Connection . . . . . . . . . . . . . . . . . . . . . . 9-12

10.1 Brake Connection & Regeneration Resistor Connections . . . . . . . . . . . . . . . 10-2

11.1 Tuning and Diagnosis Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11.2 Drive-Stage Diagnosis Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.3 Drive-Stage Tuning Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

11.4 Tuning and Diagnostic Screen with Analog Input Calibration Function Active. 11-9

12.1 Sequential Program Display / Edit Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12.2 Register Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12.3 I/O Flag Table Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12.4 Sequential Program Debugger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

12.5 Watched Registers & Flags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12.6 View / Edit Default Parameters Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

12.7 Sequential Program Listing Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12.8 Icon Menu Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12-9 Axis Motion Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12-10 Absolute Position Move Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11

12.11 Sequential Instruction Form for Programming of Analog Absolute

Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

12.12 Sequential Instruction Form for Programming of Analog Absolute

Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

12.13 Set/Clear Multiple Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

12.14 Program Control Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

12.15 Branch on Analog Input Compare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

12.16 Branch on Register Compare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

12.17 Parameter Value Change Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

12.18 Axis Homing Routines Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21

12.19 Absolute Position Feedback Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

12.20 Register Manipulation Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

12.21 Increment/Decrement Count Register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27

12.22 PLC Menu and Programming Form Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

12.23 PLC Programming Form Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30

12.24 Operation Details Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31

12.25 Operation Selection Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32

12.26 One Shot Deﬁnition Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33

12.27 Register Comparison Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

12.28 Timer Deﬁnition Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35

12.29 Counter Deﬁnition Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36

12.30 Operand Display / Selection / Comment Screen . . . . . . . . . . . . . . . . . . . . . . . 12-37

12.31 Indexer Control Flags Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-41

12.32 Default PLC Program Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44

13.1 ModBus Conﬁguration and Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12

LIST OF FIGURES

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Figure Description Page

14.1 PLC Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

14.2 PLC Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

14.3 PLC Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4

14.4 Sequential Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5

14.5 Sequential Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6

14.6 Sequential Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7

14.7 Sequential Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8

A.1 RS-232 Communications Cable (P/N 3600-1172).............................................A-1

A.2 Encoder Output Cable (P/N 3604-1213)............................................................A-2

A.3 Tol-O-Matic MRV Motor Connector Pinouts......................................................A-4

C.1 MRV 11Y PV10 Single-Phase, Three-Phase Drive Performance Curves............C-1

C.2 MRV 21Y PV10 Single-Phase, Three-Phase Drive Performance Curves............C-2

C.3 MRV 22Y PV10 Single-Phase, Three-Phase Drive Performance Curves............C-2

C.4 MRV 23Y PV10 Single-Phase, Three-Phase Drive Performance Curves............C-3

C.5 MRV 24Y PV10 Single-Phase, Three-Phase Drive Performance Curves............C-3

C.6 MRV 31Y PV10 Single-Phase, Three-Phase Drive Performance Curves............C-4

C.7 MRV 31Z PV20 Single-Phase, Three-Phase Drive Performance Curves............C-4

C.8 MRV 32Y, PV20 Single-Phase, Three-Phase Drive Performance Curves...........C-5

C.9 MRV 32Z PV30 Single-Phase, Three-Phase Drive Performance Curves............C-5

C.10 MRV 33Y PV30 Single-Phase, Three-Phase Drive Performance Curves............C-6

C.11 MRV 33Z PV30 Single-Phase, Three-Phase Drive Performance Curves............C-6

C.12 MRV 51Z PV30 Single-Phase, Three-Phase Drive Performance Curves............C-7

D.1 MRV 11 Motor ..................................................................................................D-1

D.2 MRV 21/22/23/24 Motors..................................................................................D-1

D.3 MRV 31/32/33 Motors.......................................................................................D-2

D.4 MRV 51 Motor...................................................................................................D-2

vii

LIST OF FIGURES

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viii

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