Quin Systems Limited Qcontrol 4 Installation Manual

Transcription

1 Quin Systems Limited Qcontrol 4 Installation Manual Issue 4 December 2008 (MAN44)

2 Quin Systems Limited Qcontrol 4 Installation Manual Issue 4 December 2008 (MAN44)

3 Important Notice Quin Systems reserves the right to make changes in the products described in this document in order to improve design or performance and for further product development. Examples given are for illustration only, and no responsibility is assumed for their suitability in particular applications. Reproduction of any part hereof without the prior written consent of Quin Systems is prohibited. Although every attempt has been made to ensure the accuracy of the information in this document, Quin Systems assumes no liability for inadvertent errors. Suggestions for improvements in either the products or the documentation are welcome. Relevant Directives The product is designed to be incorporated into a system for the control of machinery, and needs external equipment to enable it to fulfil this function. It must not be relied upon to provide safety-critical features such as guarding or emergency stop functions. It must not be put into service until the machinery into which it has been incorporated has been declared in conformity with the Machinery Directive 8/32/EEC and/or its relevant amendments. The installation instructions in this manual should be followed in constructing a system which meets requirements. The product has been tested in typical configurations, and meets the EMC Directive 8/336/EEC, when fed from power supplies which meet 8/336/EEC and 2/3/EEC. The product uses only low voltages, and is therefore exempt under 73/23/EEC as amended by 3/68/EEC. The product as normally supplied has low voltages accessible to touch, and must be mounted within a suitable cabinet to meet any required IP rating to BS EN 6052.

4 Issue 4 Qcontrol 4 Installation Manual Copyright Notice Copyright 2004 Quin Systems Limited. All rights reserved. Reproduction of this document, in part or whole, by any means, without the prior written consent of Quin Systems Limited is strictly prohibited. Version History Issue Date Update Reason Oct June 2004 JTAG, Anybus tests 3 Sept 2008 QLC plus minor tidies 4 Dec 2008 Extra interface details Amendment Record Date Issue Amdt. Pages By Reason Copyright 2008 Quin Systems Ltd. Page iv

5 Qcontrol 4 Installation Manual Issue 4 Page v Copyright 2008 Quin Systems Ltd.

6 Issue 4 Qcontrol 4 Installation Manual Contents. Introduction 5 2. Unpacking and Inspection 6 3. System Specifications 7 3. Mechanical Specification Environmental specification Power supply specification Electrical specification Relevant directives 4. Mechanical Installation 0 5. Connections 5. Serial Data Position Feedback Process Logic (main board) Expansion board 7 6. Electrical Installation 6. General 6.2 Mains Power supply Earth connections Connecting the motor to the drive Encoder signals Command signal and drive enable Analogue Input Digital inputs and outputs Safety - Using Guards and Limits 2 8. Encoders What is an encoder? Types of encoders Choosing an encoder Encoder installation 35. Motors 36. Types of motor 36.2 Choosing a motor 38.3 Mounting the motor 40.4 Connecting the motor to the load Setup and Tuning 4 0. General Control algorithm Monitoring the performance A simple tuning procedure 42 Copyright 2008 Quin Systems Ltd. Page

7 Qcontrol 4 Installation Manual Issue 4. Testing the System 46. General 46.2 Serial port 46.3 Encoder 47.4 Motor enable relay 48.5 Command signal 48.6 Digital signals 4.7 Analogue Inputs Electrical Details 5 2. Signal names Encoder input circuits Isolated input and output circuits Board Configurations General Anybus board System Configuration Configuration Commands Ports and Interfaces Encoder Configuration Configuration for CANopen encoder Using the Absolute Encoder for Position Feedback Speed limits with absolute encoders Diagnostics and Tests SRV400 Flashboot Sector BDM port access CPLD Download JTAG PTS Language Diagnostics 72 A. Standard Cable Drawings 75 A. Introduction 75 Page 2 Copyright 2008 Quin Systems Ltd.

8 Issue 4 Qcontrol 4 Installation Manual Figures and Tables Figure. Fixing centres for the Servo Controller. 0 Figure 2. Connector Layout Table. RS232 port A, port B connections 2 Table 2. RS485 port B connections 2 Table 3. CANbus connections 3 Table 4. Encoder connections 4 Table 5. Encoder setup links: J - J4 4 Table 6. Back screw terminal connections 5 Table 7. Bottom screw terminal connections 6 Figure 3. Expansion Board Connectors 7 Table 8. Expansion screw terminal connections 8 Figure 4. General installation arrangement. Figure 5. Mains supply installation. 20 Figure 6. Earth connections. 2 Figure 7. Motor connections. 22 Figure 8. Encoder connection. 23 Figure. Typical encoder connections. 24 Figure 0. Command signal connection. 25 Figure. Typical analogue output connections. 26 Figure 2. Typical analogue input connections. 27 Figure 3. Typical 5 volt analogue connections. 27 Figure 4. Input and output circuits 28 Figure 5. Incremental encoder signals. 3 Figure 6. Torque-speed curve for a d.c. motor. 36 Figure 7. Torque-speed curve for an a.c. motor. 37 Figure 8. Torque-speed curve for a brushless motor. 38 Figure. Motor performance for detuned system. 43 Figure 20. Motor performance for faster moves. 44 Figure 2. Motor performance with oscillation. 44 Figure 22. Testing the analogue outputs. 48 Figure 23. Testing the digital signals. 4 Figure 24. Analogue input circuits. 50 Copyright 2008 Quin Systems Ltd. Page 3

9 Qcontrol 4 Installation Manual Issue 4 Figure 25. Encoder input circuits. 5 Figure 26. Isolated Input and output circuits 52 Figure 27. Qcontrol 4 jumper locations 54 Table. Encoder feedback options 6 Table 0. Encoder connections 62 Table. Encoder setup links: J - J4 63 Figure 28. Encoder power separation. 63 Table 2. CANopen encoder connections 65 Table 3. Speed limits with absolute encoders 66 Page 4 Copyright 2008 Quin Systems Ltd.

10 Issue 4 Qcontrol 4 Installation Manual. Introduction This document is the Installation Manual for the Qcontrol 4, a member of the Quin Systems digital Programmable Transmission System (PTS) range. The systems comprise hardware and software to control up to four servo motors, in conjunction with suitable high power drive systems for the motors. The hardware is highly modular, allowing systems to be easily expanded or upgraded. The PTS software provides full control over all aspects of the system, but has a simple high-level user interface, while the QLC software allows the programmer to use his PLC familiarity for programming. The Qcontrol 4 has a MPC555 processor, with 4 Mbyte or more of flash memory for firmware, and 2 Mbyte ram space available. The flash includes the full servo control system firmware. This provides support for four position servo loops, and a fifth virtual axis for use in master-slave linking. It is programmed via an RS-232 serial port or an infra-red link, and uses 256k of flash memory for configuration, user program and map retention. Mb of RAM has battery hold-up; some of this is used for variables (approximately 0000 variables or array elements). The processor uses a 32-bit bus at 40MHz. The controller is intended for installation in an electrical cabinet, used in close coupling with the drive controls and providing a wide choice of position feedback interfaces and logic controls to give a flexible and expandable system. PLEASE READ THIS MANUAL BEFORE INSTALLATION. It is very important that the guidelines for installation are observed, otherwise damage to the system or to the machine may occur. Quin Systems Limited accept no liability for damage or costs arising from incorrect or inadequate installation of the systems, or from incorrect programming of the system for the required application. Digital control systems are not simple, but can be used successfully to control industrial machinery and provide great improvements in reliability, performance and flexibility. Copyright 2008 Quin Systems Ltd. Page 5

11 Qcontrol 4 Installation Manual Issue 4 2. Unpacking and Inspection Inspect the packaging for external signs of damage, if possible before signing the delivery receipt, as this may indicate that it has been mishandled in transit. When unpacking the system, keep all the packaging materials if possible. If it is necessary to ship the system to another site, or to return it for service, the original packing can be re-used. Inspect the system carefully when it is unpacked. Check for any loose parts, any circuit boards loose in their card guides, cables not connected, or any bending of the case or chassis. If any defect or damage is suspected, do not connect power to the system. Notify the carrier immediately, and contact your sales office or the Quin Systems Service Department: Quin Systems Limited Service Department Oaklands Business Centre Oaklands Park Wokingham Berkshire RG4 2FD England Telephone +44 (0) Fax +44 (0) sales@quin.co.uk support@quin.co.uk Web site Page 6 Copyright 2008 Quin Systems Ltd.

12 Issue 4 Qcontrol 4 Installation Manual 3. System Specifications This section gives the overall specifications of the system, including mechanical details and environmental requirements. 3. Mechanical Specification The dimensions of the Qcontrol 4 are as follows: Height 34 mm Width 66 mm (20 mm including connectors) Depth mm Weight 2 kg Sufficient additional clearance must be left above the encoder connectors and in front of the serial port connectors for plugs and cables, and adjacent to the terminals for cable connection. The system is designed to be mounted in the normal orientation with the circuit board vertical, to allow cooling air circulation by convection. If the unit cannot be mounted with the board vertical, then a fan must be fitted to blow air over the unit. 3.2 Environmental specification Temperature: storage 0 to 70 C operating 0 to 40 C Relative humidity: 20 to 80% non-condensing The system may be operated at higher ambient temperatures, but will require additional cooling such as forced air ventilation in order to do so. 3.3 Power supply specification The power supply requirement for the Qcontrol 4 system is nominally 24V 0.4A d.c. The system accepts a supply voltage in the range 28V d.c. The power supply input is protected against reverse voltage connection. Additional power supplies are required for the shaft encoders and the external digital input and output signals. Incremental shaft encoders and EnDat normally require 5V d.c.; SinCos sensors need V d.c and most other absolute encoders need 2 28V d.c.. The digital inputs and outputs use 24V d.c. for compatibility with PLC systems. The input and output lines are fitted with clamp diodes, and a diode provides some protection against reverse connection of the i/o supply. The SERVOnet needs 2V d.c., and this must never be reverse-connected. The unit includes a battery for storage of process variables and axis position. The retention period without other power is typically several weeks. The battery (NiMH 2.4 volt Varta type 2/5H) should be replaced every 5 years, with a new blob of silicone sealant to ensure retention in the socket: Quin can undertake this task. Copyright 2008 Quin Systems Ltd. Page 7

13 Qcontrol 4 Installation Manual Issue Electrical specification The electrical characteristics of the Qcontrol 4 module are listed here. External power supplies : Encoder supply typically +5V Digital i/o supply +24V Logic supply +24V ( to 28V, 400mA) SERVOnet/CANbus +2 V nominal (7 to 3 V range) Encoder input : Incremental: Frequency MHz maximum (4 0 6 counts per second) Z pulse length 500 ns min. Interface voltage 5V p-p max. (Optional channel 5: frequency 750 khz max.) Track A input leads track B input for positive direction Analogue: level V p-p nominal cycle rate 0 5 sin/cos cycles per second SinCos: speed 6000 R.P.M. Interface Hiperface (600 baud data channel) SSI: clock rate 500 khz (max cable 50 M - ref section 8.2.3) bits 2 to 24 Input impedance 20Ω Analogue input : Input range common-mode range (optional range Resolution Input impedance Analogue output : Output range ±0 volts Resolution 2 bits Output impedance <00Ω Relay contacts : Rated load Switch power maximum Contact resistance Operate/release time Service life Digital inputs : ±0V (differential) ±20 volts ±2.5 volts: common mode ±5 volts) 2 bits 20kΩ 0.5A 60V a.c. peak or d.c. 30W 30VA 50 mω maximum 5 ms maximum 0 7 operations (24V 0.2A d.c. resistive load) Voltage rating +24V nominal Input current typical: 7 0 ma Threshold voltage 0 6V Reverse voltage 24V maximum Isolation voltage 250V a.c. peak or d.c. Digital outputs : Saturation voltage (output on) Load current per signal Load current per group of 8 Isolation voltage.v maximum (at full load current) 500 ma maximum 2 A maximum 250V a.c. peak or d.c. Page 8 Copyright 2008 Quin Systems Ltd.

14 Issue 4 Qcontrol 4 Installation Manual 3.5 Relevant directives The product is designed to be incorporated into a system for the control of machinery, and needs external equipment to enable it to fulfil this function. It must not be relied upon to provide safety-critical features such as guarding or emergency stop functions. It must not be put into service until the machinery into which it has been incorporated has been declared in conformity with the Machinery Directive 8/32/EEC and/or its relevant amendments. The installation instructions in this manual should be followed in constructing a system which meets requirements. The product has been tested in typical configurations and meets the EMC Directive 8/336/EEC, when fed from power supplies which meet 8/336/EEC and 2/3/EEC. The product uses only low voltages, and is therefore exempt under 73/23/EEC as amended by 3/68/EEC. The product as normally supplied has low voltages accessible to touch, and must be mounted within a suitable cabinet to meet any required IP rating to BS EN Copyright 2008 Quin Systems Ltd. Page

15 Qcontrol 4 Installation Manual Issue 4 4. Mechanical Installation The Qcontrol 4 system has mounting holes on the rear metal plate, for fixing to the electrical panel inside a cabinet. The unit is fixed with three M5 bolts through holes at the top and bottom of the unit. The fixing centres for these bolts are shown in the diagram below. Note that the bottom fixing hole is slotted and the top fixing holes are keyhole shaped to allow the unit to be slotted over the heads of suitable mounting bolts. Terminal rail connections this side φ5.2 (M5 clearance) Dimensions in mm Figure. Fixing centres for the Servo Controller. The I/O terminals are in two parts, for ease of wiring, and the removable part includes cable-ties. They protrude about 60 mm, and need adequate space for cable routeing. Similarly the analogue and drive terminals at the bottom, and the -way plugs for the encoders at the top, need space for cables, and there should be 75 mm clear above and below the unit for cooling air. Page 0 Copyright 2008 Quin Systems Ltd.

16 Issue 4 Qcontrol 4 Installation Manual 5. Connections The Qcontrol 4 has several connectors. Top view 4 Comms expansion 3 Encoders 2 S2 S T LED T2 LED8 LED Back View of case IR Front panel Ethernet T3 LED6 LED7 S3 Port A/B LED24 S5 CAN open T4 T0 S4 SERVO net T T8 T7 T6 T5 Figure 2. Connector Layout way double D-type sockets S and S2 for the position feedback encoders. way double D-type socket S3 for the RS-232 programming terminal port A (left), and for the RS-485 data port B (right). way double D-type plug/socket S4 for the SERVOnet high speed network, based on CANbus. way double D-type plug/socket S5 for the CANopen device interface, again on CANbus. 8 way RJ45 socket SK4 for Ethernet 0baseT or 00baseTX. Copyright 2008 Quin Systems Ltd. Page

17 Qcontrol 4 Installation Manual Issue 4 3 off 0 way two-part screw terminal connectors T T2 and T3 for the isolated 24V digital inputs and outputs. 2 way two-part terminal connector T4 for 24 volt I/O supply input. 0 way two-part screw terminal connector T5 for analogue inputs. 4 off 5 way two-part screw terminal connectors T6 T7 T8 and T for the drive enable relays and analogue demands. 6 way two-part screw terminal connector T0 for the input of power for the unit and encoder supply volts. 5. Serial Data The RS-232 serial port A on the controller uses the left half of socket S3. The pin connections to this are shown below. S3 pin no. Signal S3 pin no. Signal 6 2 /TXD 7 RTS 3 /RXD 8 CTS 4 5 GND Table : RS232 port A, port B connections It is important that static charge from portable equipment is not discharged by connection to the serial ports: the electronics may be damaged and machine operation affected. Equipment should be earthed by prior connection of a ground lead, and we recommend use of cable CBA3007 and initial connection of its earth tails to PC chassis and a panel earth terminal. The serial port B for the Operator s Panel or Modbus interface uses the right half of socket S3. The RS232 connections to this are as Table, RS-485 as Table 2 below. S3 pin no. Signal S3 pin no. Signal High termination 6 +Vbias 2 TXD (= TxB) 7 /TXD (TxA) 3 RXD (= RxB) 8 /RXD (RxA) 4 Low termination 5 GND Table 2: RS485 port B connections Quin can supply various interface cables. Page 2 Copyright 2008 Quin Systems Ltd.

18 Issue 4 Qcontrol 4 Installation Manual The Qcontrol 4 has two double way D plugs and sockets for two separate CANbus interfaces. The SERVOnet high speed network ports use D-type plug and sockets S4, parallel-connected; this allows units to be daisy chained together easily with standard cables. The CANopen interface similarly uses parallel-connected plug and socket S5, again allowing unit chain or power feed. The connections for the CANbus interfaces on the front panel way plugs are shown below. The plug and socket are connected pin-to-pin, to allow a simple daisy chain connection. Note that these comply with the CAN in Automation (CiA) draft standard DS02 Version 2.0, CAN Physical Layer for Industrial Applications, but with additional signals used for error detection. Pin no. Signal Pin no. Signal LINK 6 CAN_0V 2 CAN_L 7 CAN_H 3 CAN_GND 8 CAN_ERR 4 LINK4 CAN_V+ (7 3V) 5 CAN_SHLD (screen) Table 3: CANbus connections Note that each CANbus interface requires an external power supply to power the isolated network transceivers, each connected separately via the D type connectors. Recommended cable pairing and linking for termination and break-detection are given in the appendix on drawing QDV , and standard cables are available under stock code CBA For further information refer to the SERVOnet handbook. The Qcontrol 4 also provides an Ethernet interface using a twisted pair (0baseT or 00baseTX) interface. This uses an 8 way RJ-45 socket, with the transmit pair on pins and 2, receive on 3 and 6, as standard. 5.2 Position Feedback The unit accepts several types of position-feedback encoder. The standard incremental quadrature encoder may be used, and can be set by commands to various modes of counting; the main four channels can also use up/down with count/direction interfaces. Sine/cosine encoders may be used in a similar manner, with interpolation between the quadrature points using analogue readings. Absolute encoders may be single- or multiturn, with interfaces using SSI, Hiperface or EnDat; commands again can set interface parameters and links set certain signal allocations. Copyright 2008 Quin Systems Ltd. Page 3

19 Qcontrol 4 Installation Manual Issue 4 The pin connections of the encoder sockets are shown below. Pin no. Incremental Hiperface SSI EnDat A + Cos + supply A 2 B + Sin B 3 Z Data - Data Data 4 +5 volt + volts Clock Clock 5 /Clock /Clock 6 /A Ref Cos /A 7 /B Ref Sin /B 8 /Z Data + /Data /Data 0 volts 0 volts 0 volts 0 volts Table 4: Encoder connections The precise functions depend on the linking set on board jumpers J through J4, shown in the next table. The signal allocation allows the standard pinout for incremental encoders, as for the various MiniPTS units, but note that encoder common is now grounded and not isolated. For EnDat, and for any encoder which requires supply volts different from the set, power must be fed separately and not through the Qcontrol 4. For further detail refer to appendix A drawings and to section 6.5. and 4.3. Jumper links Encoder type -2, 3-4 Incremental, Sine/cosine -2, 3-4 Hiperface 2-3, 4-5 SSI -2, 4-5 EnDat Table 5: Encoder setup links: J - J4 A standalone PTS may use one CANopen absolute encoder as a master encoder, but not for servo-loop feedback: it updates only on a 4mS tick. (In later standalone versions, they will be usable for feedback at.3ms). They are connected on the SERVOnet/SynchroLink bus, and defined by command settings - see and 4.4. Connections to S4 are as per table 3 above, with the encoder connecting to pins 2 3 and 7 as a minimum, at a data rate of 500 khz. Maximum cable run is 00 metres. Encoder node number corresponds to node number CN. See also drawing QDV Process Logic (main board) Terminal blocks T to T4 are used for the digital inputs and outputs, and T0 for power input. T and T2 carry 6 digital inputs: inputs : to :8 can be programmed for a fast response, using referencing or position snapshot functions, or are polled in other modes; the other inputs and those on expansion boards are polled. All the 0 volt i/o (T.0, 2.0, 3.0, and 4.2) and all the 24 volt i/o pins (T., 2., 3. and 4.) are commoned, for ease of sensor wiring. They are optically isolated from other supplies. Page 4 Copyright 2008 Quin Systems Ltd.

20 Issue 4 Qcontrol 4 Installation Manual The next table shows the connections on all the two-part screw terminal blocks at the back of the unit. Back screw terminals Listed from top to bottom Signal. 0V i/o.2 Input :.3 Input :2.4 Input :3.5 Input :4.6 Input :5.7 Input :6.8 Input :7. Input : V i/o 2. 0V i/o 2.2 Input 2: 2.3 Input 2:2 2.4 Input 2:3 2.5 Input 2:4 2.6 Input 2:5 2.7 Input 2:6 2.8 Input 2:7 2. Input 2: V i/o 3. 0V i/o 3.2 Output : 3.3 Output :2 3.4 Output :3 3.5 Output :4 3.6 Output :5 3.7 Output :6 3.8 Output :7 3. Output : V i/o V i/o 4.2 0V i/o 0. +encoder supply (normally +5V) 0.2 0V supply 0.3 Screen/earth termination V unit supply 0.5 0V supply 0.6 Screen/earth termination Table 6: Back screw terminal connections Copyright 2008 Quin Systems Ltd. Page 5

21 Qcontrol 4 Installation Manual Issue 4 Note that the 24V power supply input is not isolated from the internal logic supplies, and the 0V supply connection should be earthed. The 24V i/o supply is not necessary for correct operation of the motor enable relays. The bottom screw terminals provide connections for the analogue inputs and outputs, and the motor enable relays. Bottom screw terminals Listed from back to front Signal. Analogue output 4.2 Analogue output 0V.3 Relay 4 n.o..4 Relay 4 common.5 Relay 4 n.c. 8. Analogue output Analogue output 0V 8.3 Relay 3 n.o. 8.4 Relay 3 common 8.5 Relay 3 n.c. 7. Analogue output Analogue output 0V 7.3 Relay 2 n.o. 7.4 Relay 2 common 7.5 Relay 2 n.c. 6. Analogue output 6.2 Analogue output 0V 6.3 Relay n.o. 6.4 Relay common 6.5 Relay n.c. 5. Screen/earth termination 5.2 Analogue input 5.3 Analogue input Analogue input Analogue input Analogue input Analogue input Analogue input 4 5. Analogue input Analogue 0V Table 7: Bottom screw terminal connections All the screen connections are linked together to allow a single earth connection for all the cable screens. They are not connected to the system internal 0V supply. A clean separate earth connection is normally required to the 0V supply on terminal T0.2, or to one of the analogue 0V points on T5.0, T6.2, T7.2, T8.2 or T.2. Page 6 Copyright 2008 Quin Systems Ltd.

22 Issue 4 Qcontrol 4 Installation Manual 5.4 Expansion board The expansion board plugs on to the main board with its 2-part terminal block accessible at the bottom of the assembly. Two versions of expansion are available, with either 6 extra inputs and 8 outputs, or 8 inputs plus 8 outputs plus channel 5 s encoder input. Layout is as follows: Board with 5th encoder - bottom view Front panel Terminal T Terminal T2 Expansion board S6 Encoder 5 Front panel Board with extra I/O - bottom view Terminal T Terminal T2 Expansion board Terminal T3 Figure 3. Expansion Board Connectors The 5th encoder connections are the same as for the other 4 encoders, as per table 4 above, and jumpers at J on the expansion board (section 3. refers) are set as per table 5. For this version giving 5th encoder, terminals T3 are not fitted and there is no physical input group 4:. Copyright 2008 Quin Systems Ltd. Page 7

23 Qcontrol 4 Installation Manual Issue 4 The terminal block allocations are: Screw terminals Listed from front to back Signal. 0V i/o.2 Output 2:.3 Output 2:2.4 Output 2:3.5 Output 2:4.6 Output 2:5.7 Output 2:6.8 Output 2:7. Output 2: V i/o 2. 0V i/o 2.2 Input 3: 2.3 Input 3:2 2.4 Input 3:3 2.5 Input 3:4 2.6 Input 3:5 2.7 Input 3:6 2.8 Input 3:7 2. Input 3: V i/o 3. 0V i/o 3.2 Input 4: 3.3 Input 4:2 3.4 Input 4:3 3.5 Input 4:4 3.6 Input 4:5 3.7 Input 4:6 3.8 Input 4:7 3. Input 4: V i/o Table 8: Expansion screw terminal connections A separate connection of 24 volts I/O is required, but all of this set of 0 volt i/o (T., T2. and T3.) and all these +24 volt i/o pins (T.0, T2.0 and T3.0) are commoned, for ease of sensor wiring. They are isolated from connectors T to T4, and again they are isolated from other supplies. Page 8 Copyright 2008 Quin Systems Ltd.

24 Issue 4 Qcontrol 4 Installation Manual 6. Electrical Installation 6. General This section gives some guidelines for the electrical installation of the control system. The diagram below shows a typical installation for one axis, and will be used to highlight specific areas of interest in the following sections. Note that this is only a very simplified sketch, not a full installation wiring diagram. Details such as isolators, contactors and other switching arrangements are not shown but in most cases should be used. Please refer to the motor and drive manufacturer s instructions for further details on electrical installation. Equipment cabinet 3 phase supply R S T Noise filter Drive Motor +24V power supply Qcontrol4 Encoder Isolation transformer Earth Figure 4. General installation arrangement. Use separate trunking to keep all low voltage signal cables (encoder, resolver, command signal) away from three-phase, high current, or high voltage wiring. Copyright 2008 Quin Systems Ltd. Page

25 Qcontrol 4 Installation Manual Issue Mains Power supply The Qcontrol 4 requires +24V d.c. provided by an external power supply. The mains input may be taken from the same three phase mains used for the motors and drives, but care must be taken to avoid introducing noise onto the supply to the control system. For best results, follow the recommendations below. Use an isolation transformer and a line filter in the mains supply to the system. In some cases a line conditioner may be required. Equipment cabinet 3 phase supply R S T Noise filter Drive Motor +24V power supply Qcontrol4 Encoder Isolation transformer Earth Figure 5. Mains supply installation. Do not tie the input and output cables from the line conditioner or filter together, or run them close together in a conduit or cable duct. Do not tie the three phase cables or the single phase supply cables together with any low voltage signal cables. Page 20 Copyright 2008 Quin Systems Ltd.

26 Issue 4 Qcontrol 4 Installation Manual 6.3 Earth connections Earthing is very important in any electrical installation. It is an essential safety measure to prevent electric shock in case of any failure of the equipment, and is also used for screening between different units. It provides a ground reference point for all units in the system. Incorrect earth connection can result in erratic operation due to noise or earth loops, or may prevent the system from operating at all. These problems can be avoided by careful arrangement of the earth connections, and by such techniques as isolation. The earth connections from the isolation transformer and the line conditioner should be made in heavy gauge wire. All the earth connections should be connected together at one point, preferably on the electronics cabinet chassis. Equipment cabinet 3 phase supply R S T Noise filter Drive Motor +24V power supply Qcontrol4 Encoder Earth Figure 6. Earth connections. Do not tie the earth wires together with any low voltage signal cables, or run them close together in the same conduit or cable duct. All screened cables should have their screens connected directly to earth, not via the system 0V power supply. This is very important, as otherwise noise and transients picked up in the screen will pass through the system, instead of being dissipated directly to earth. Note that the 24V power supply input is not isolated, and an earth connection should be made at the 0 volts (negative side) of the power supply. This avoids the internal paths of the Qcontrol 4 having to provide the earth connection for the power supplies. Copyright 2008 Quin Systems Ltd. Page 2

27 Qcontrol 4 Installation Manual Issue Connecting the motor to the drive The motor should be connected to the drive according to the recommendations of the motor/drive manufacturer(s). A typical motor requires three phases of drive plus safety earth plus outer screening/armouring. The motor should be connected using cables as specified by the manufacturer. These cables usually have a strict specification with regard to size and length. Equipment cabinet 3 phase supply R S T Noise filter Drive Resolver cable Motor cable Motor +24V power supply Qcontrol4 Encoder Earth Figure 7. Motor connections. Do not tie the motor cable and encoder cable together, or run them together in a conduit or cable duct. The motor cable can carry high currents in normal operation, and the encoder cable carries low voltage signals back to the drive. The correct performance and accuracy of the motor and drive depend on the quality of the encoder signals. Use a screened cable with individually screened twisted pairs for resolver signals from the motor to the drive; also in extreme cases for encoder signals. This prevents crosstalk and noise interfering with the encoder signals, and gives best performance. Page 22 Copyright 2008 Quin Systems Ltd.

28 Issue 4 Qcontrol 4 Installation Manual 6.5 Encoder signals The position control system depends on the signals from the encoder. These signals indicate both the distance travelled by the motor and the direction of travel. This information is used to calculate the required correction signal to send to the motor drive. The cables used for the encoder signals should be high quality screened cables. When using the recommended encoders with complementary line driver outputs, the cable should use individually screened twisted pairs, with an overall cable screen as well. The cable screen should be connected directly to the main earth point, not via the control system 0V supply. Equipment cabinet 3 phase supply R S T Noise filter Drive Motor +24V power supply Qcontrol4 Encoder Encoder cable: individually screened twisted pairs Earth Figure 8. Encoder connection. The encoder manufacturer s recommendations for cable type and maximum cable length must be observed. For the line driver output encoders the typical maximum cable length is about 70 m, but this does vary between different encoder manufacturers. It also depends on the cable type and termination used, and is often limited by the tolerable supply volts drop. If the machine installation requires a cable longer than the manufacturer s recommended maximum length, then it may be necessary to install an additional line driver unit to boost the encoder signals, and provide supply locally. Encoders using EnDat or SSI transmission are limited for cable length by the turnaround time from clock to data, and for this system the limit is 50 metres (but refer to section 8.2.3). Hiperface (SinCos) transmission has no such limitation, and the encoder manufacturer sets a limit of 00 metres for the system: however shorter cables will enable better accuracies to be achieved. Copyright 2008 Quin Systems Ltd. Page 23

29 Qcontrol 4 Installation Manual Issue 4 The Qcontrol 4 provides no isolation of the encoder input signals. This means that encoders are earthed at the controller: note that the cable screens should be taken separately to earth. It does require the use of an external power supply to provide the power for the encoders. The diagram below shows the typical connections for an incremental encoder, showing the pin numbers on the -way D socket and the screw terminal numbers on terminal blocks T0. Qcontrol 4 A 6 /A Further Axes Encoder signals D sockets S, S B /B Z /Z +5V 0V Screened twisted pair cable Encoder 4 Jumper 3 Supply Terminals T0.2 Screen connected directly to earth T0. Separate encoder power supply +5V 0V Figure. Typical encoder connections. Other encoder types need connections as follows - section 4.3 gives details: Analogue sine-cosine encoders need the same connections as the incremental encoder above; normal signal levels are volt peak-to-peak differential. SinCos encoders with Hiperface use A /A B /B DATA- and DATA+, and supplies 7 to 2 V d.c. and the same pins. SSI encoders using RS422 levels need ECLK /ECLK EDATA and /EDATA, socket pins and 8, plus appropriate supplies. Encoders using EnDat interface use A /A B /B ECLK /ECLK EDATA and /EDATA, and supplies 5 V d.c. Terminal T0. may be used for encoder power input where all need the same voltage, except for EnDat where there are insufficient pins. Page 24 Copyright 2008 Quin Systems Ltd.

30 Issue 4 Qcontrol 4 Installation Manual 6.6 Command signal and drive enable The analogue command signal should be connected to the motor drive command input with a high quality screened twisted-pair cable. The command signal output from the control system is connected to the positive input on the drive, and the 0 Vcmd signal is connected to the negative or common input on the drive. The cable screen should be connected directly to the main earth point, not to the control system 0V supply. The motor off relay for each axis should be connected into the motor drive enable input, if available. This allows the controller to shut down the drive immediately when required by the MO motor off command, and on any error condition. The controller simply monitors the motor position when in the motor off state, and does not attempt to control the motor, holding the command signal output at 0V. If the motor off relay is not connected into the drive enable, then the motor and drive remain powered up in the motor off state, and any offset or drift in the drive causes the motor to drift slowly. Equipment cabinet 3 phase supply R S T Noise filter Drive Motor +24V power supply Qcontrol4 Encoder Command signal Screened cable Drive enable from relay Earth Figure 0. Command signal connection. The screened command signal cable should have its screen connected directly to earth, not via the system 0V power supply. This is very important, as otherwise noise and transients picked up in the screen will pass through the system, instead of being dissipated directly to earth. Some drives have been found to generate electrical noise on the command signal, and in these cases a 50nF capacitor from each command signal to its adjacent 0V cmd can give sweeter operation. Copyright 2008 Quin Systems Ltd. Page 25

31 Qcontrol 4 Installation Manual Issue 4 The diagram below shows typical connections for the analogue output signals to the motor drives, showing the screw terminal numbers on terminal block T6 T7 T8 and T. Note that drive interfaces differ, so two different methods of connecting the drive enable signal are shown, with drives and 3 connecting to optocoupled enable inputs and drives 2 and 4 connecting to enable inputs with internal pull-up resistors. Qcontrol 4 Logic supply +24V 0V Drive Relay n.o. Relay common Command signal 0V cmd output T6.3 T6.4 T6. T6.2 Screened twisted-pair cable Screen connected directly to earth +enable enable +input input earth Drive 2 Relay 2 n.o. Relay 2 common Command signal 2 0V cmd output T7.3 T7.4 T7. T7.2 Screen +enable enable +input input earth +24V 0V Drive 3 Relay 3 n.o. Relay 3 common Command signal 3 0V cmd output T8.3 T8.4 T8. T8.2 Screen +enable enable +input input earth Relay 4 n.o. T.3 Relay 4 common T.4 Command signal 4 0V cmd output T. T.2 System 0V T5.0 Screen Drive 4 +enable enable +input input earth Figure. Typical analogue output connections. Drive and feedback polarity is best determined on test - refer to the Qcontrol 4 Starter manual, MAN440, for the methods for both PTS and QLC controllers. Page 26 Copyright 2008 Quin Systems Ltd.

32 Issue 4 Qcontrol 4 Installation Manual 6.7 Analogue Input The diagram below shows typical connections for ±0 volt analogue input signals to the Qcontrol 4, showing the terminal numbers of terminal block T5 in this case for channel s input. Note that method 2 is a useful method of using the full analogue input range for a potentiometer, making use of the common-mode voltage range of the input. Method Qcontrol 4 A in + T5.3 A in - T5.2 Screened cable 0K +0V Tension Arm Potentiometer earth 0 V T5.0 0V -0V Method 2 Qcontrol 4 Logic supply 0V +24V K A in + A in - T5.3 T5.2 Screened twisted-pair cable 4K7 0K 0 V T5.0 earth 4K7 Tension Arm Potentiometer Figure 2. Typical analogue input connections. The diagram below shows connections for ±2.5 volt input, available when appropriate jumper links on J8 are removed. Qcontrol 4 Logic supply 0V +5V A in + A in - T5.3 T5.2 Screened twisted-pair cable 4K7 0K 0 V T5.0 earth 4K7 Tension Arm Potentiometer Figure 3. Typical 5 volt analogue connections. The ±2.5 volt input range is probably of more use with active sensors such as load cells. The + terminal is positive to give positive DA value in all modes. Copyright 2008 Quin Systems Ltd. Page 27

33 Qcontrol 4 Installation Manual Issue Digital inputs and outputs The Qcontrol 4 provides sixteen digital inputs and eight digital outputs, all fully isolated. These may be used for several functions, such as monitoring pushbuttons or guards, controlling external solenoids or relays (subject to the quoted current limits), or signalling to a programmable logic controller. The isolated interface allows +24V logic signals to be used. This diagram shows typical input and output circuits, with any protection components shown as well. +24V PNP sensor Input : 0V 0V I/O Fast Input circuit +24V World.. Qcontrol 4 Input 2: Pushbutton 0V 0V I/O Standard Input circuit Qcontrol 4.. World +24V I/O +24V Output : 0V I/O Load 0V Output circuit Figure 4. Input and output circuits * Note the commutating diode local to the output load. This is important for avoiding interference from inductive loads: do not rely on the small protection diode in the Qcontrol 4. Page 28 Copyright 2008 Quin Systems Ltd.

34 Issue 4 Qcontrol 4 Installation Manual 7. Safety - Using Guards and Limits All machines should include comprehensive safety features. This is essential both for normal safety considerations, and to comply with Health and Safety requirements. It can also prevent any unwanted interference with the machine while it is running. All moving machinery must be guarded so that it cannot be reached by anybody while in motion. The guards should be fitted with guard switches or sensors, connected so as to immediately cut power from the motors when any guard is opened. On some machines, it may be useful to lock the guards closed by means of a solenoid to prevent them from being opened while the machine is running. This allows the machine to detect any attempt to open a guard and shut down the machine cleanly before unlocking the guard and allowing it to open. Motors which have constraints or limits on their range of motion should be fitted with hard wired limit switches. These should cut power from the motors if any motor goes outside its limits of travel. The machine must also have one or more locking emergency stop pushbutton switches, accessible from several positions around the machine. Anyone operating or working on the machine must be able to instantly stop the machine at any time by hitting an emergency stop switch. Guards, emergency stop and limit switches may be connected into the motor control systems, by using the digital input lines. However, the programmable input functions on the unit should only be used in addition to the conventional hard wired guard and limit switches, not to replace them. The digital inputs can be used to trigger a smooth shutdown sequence, or to generate a limit switch error and shut down immediately. The control system can then remove power from the motors and drives if required, under software control, by using a digital output line to switch the motor supply contactors. In all installations the limit switches and guard switches MUST remove all electrical power from the motors and drives within a reasonable time, independently of any action of the control system. If power is removed from the control system, then again all power must be removed from the motors. Note that in most cases, it is not necessary to remove power from the control system, only from all the high power equipment. If power to the control system and encoders can be maintained even when the motors and drives are shut down, then the system does not lose any position information. This can allow the machine to start up again much more quickly than if the control system is powered off as well, since the machine does not need to execute a complete initialization before it can be restarted. For more information on programming the Qcontrol 4 for limit switch inputs and user defined functions, please refer to the descriptions of the DL and DI commands in the Input/Output Configuration section of the Reference Manual. Copyright 2008 Quin Systems Ltd. Page 2

35 Qcontrol 4 Installation Manual Issue 4 8. Encoders 8. What is an encoder? An encoder used in a position or speed control system is simply a device to measure the position of some moving part of the machine. Often it is used to measure the shaft position of a motor, but it may equally well be used to read the position of, for example, a linear slide driven by a leadscrew mechanism. In all cases, the encoder measures position (or speed) and converts it to some electrical signal. In the discussions below, rotary encoders are described, but most of the information applies equally well to linear encoders. 8.2 Types of encoders Encoders come in various types. All of them have the same basic design. They have a device to measure positions or angles, and one or more detectors which give signals when the measuring device is moved. In optical encoders, the measuring device is a glass or plastic disc with a graticule or diffraction grating pattern on it. Filament lamps or light emitting diodes (LEDs) shine light through the disc, passing through the pattern and into light sensitive detectors such as phototransistors. When the disc is moved, the motion of the grating causes the light falling on the photodetectors to vary. Magnetic pick-up systems give similar data, but may be more robust. The resulting electrical signals from the detectors are amplified to produce a usable output signal, either analogue sine/cosine or line driver. Some of the basic encoder types are described below Incremental or quadrature encoders These have two photodetectors, but usually only one track on the encoder disc. The two pulse signals are usually denoted by the names A and B. To use an incremental encoder to measure position, it is simply necessary to count the pulse cycles on the A and B tracks produced when the shaft is moved. By distinguishing the positive and negative directions, and counting either up or down appropriately, the count value represents the signed distance from the starting position to the current position. In order to determine the direction of rotation of the shaft, the two detectors are aligned such that the signals from the one track on the disc appear phase shifted on one detector relative to the other by nominally 0, a quarter of a cycle. When two signals have this 0 phase relationship, they are described as being in quadrature. This phase shift between the two signals allows the direction of motion to be distinguished, as well as the distance travelled. In one direction the track A signal will lead the track B signal, while in the opposite direction they are reversed, and the track B signal will lead the track A signal. This allows incremental encoders to be used for position feedback in servo motor control systems. In addition, it is possible to detect every transition on each signal track, to increase the available resolution of the encoder by a factor of four. Page 30 Copyright 2008 Quin Systems Ltd.

36 Issue 4 Qcontrol 4 Installation Manual The major drawback of incremental encoders is that when a system is first turned on, there is no information about the current motor position. The encoder indicates only how far and in what direction the motor moves from this starting position. To provide a datum point, many incremental encoders have an extra track on their optical disc and a third photodetector. This third track, known as the marker or reference track, gives only one pulse per complete revolution of the encoder shaft. It is used to define an absolute zero position for the shaft, by moving until the marker signal is detected and setting the position counters to zero at that point. The marker signal is typically only one half or one quarter of an encoder cycle, and so provides an accurate datum position. cycle 360 phase A 0 phase shift B /4 cycle marker Z /2 cycle marker Z Figure 5. Incremental encoder signals. Incremental encoders are readily available from 000 to 0000 lines per turn, and hardware detection of the four edges increases this by four times to 40,000 counts per turn. Many servo drives give out a simulation of incremental A and B tracks, derived from some other form of sensing. The Qcontrol 4 expects RS422 differential signals (thus A /A B /B Z /Z wires), within the range of 0 volts to +5 volts Sine/Cosine Sensors Incremental encoders can also be selected to give sine and cosine analogue outputs in place of the A and B track square-waves described above. These signals can be used to give higher precision by reading their analogue values and taking the arc tan of their ratio. A typical unit with 024 signal cycles per turn, measured with 8-bit A to D convertors, gives precision of about in of a turn, and higher resolutions are possible if signal noise can be kept small. The Qcontrol 4 requires volt peak-to-peak differential signals. Copyright 2008 Quin Systems Ltd. Page 3

37 Qcontrol 4 Installation Manual Issue Absolute (SSI) encoders Absolute encoders have several tracks on the optical disc, and several photodetectors. The transitions between dark and light portions of the tracks on the encoder disc are arranged such that the parallel data available from the photodetectors represents the absolute position of the shaft. Absolute encoders are available from 8 bits to 4 bits wide, or even more, and with either binary, BCD or Gray code outputs. Gray code is often used to avoid possible problems when sampling the data while it is changing. With Gray code, only one bit of the data changes at any one encoder line transition, so that even if the data output changes while it is sampled, the error can only be ± bit. Absolute encoders overcome the problem with incremental encoders of finding the zero position when the system is first started, since the absolute position value is always available. However, they are much more expensive than incremental encoders, they have to be physically larger to get the increased number of tracks onto the disc, and they require as many data channels as they have data bits. Some also have the limitation that the position values are defined for only one revolution of the shaft, and then they cycle through the same values again; however others include a mechanical memory of turns and include the value in the code output. In contrast, incremental encoders with their counters may be used over any range of position values, limited only by the size of the counters used. The Qcontrol 4 has provision for position feedback using SSI encoders. These are absolute encoders with a synchronous serial interface. They have typically 2 bits of position data per turn (406 counts), and often have up to 2 bits of turns count data (406 turns) available as well. The data from the encoder is returned in a serial format, bit at a time, when requested by the axis card. This avoids the cabling problems of parallel absolute encoders, while giving absolute position information at all times. The cable length is limited by the need to send out a clock signal and return the data at a high rate and at no more than the speed of light: the 50 metre cable limit assumes a turnaround time in the encoder of no more than 250nS, so certain slower encoders such as CoreTech or SSI Heidenhain units are limited to 40 metres Hybrid encoders Hybrid encoders are a combination of sine/cosine and absolute encoders, in an attempt to work around the drawbacks of the two types. They have both sinusoidal and absolute data signals, but usually only at low to medium resolution. They use a low resolution absolute encoder disc of, say, 0 bits precision, in conjunction with a higher resolution incremental encoder track. This gives absolute position information at limited speed - essentially at start-up, and the incremental tracks allows fine position control at dynamic speeds. Typical interfaces are Hiperface, using an asynchronous protocol for the absolute data, and EnDat, using synchronous data with clock. Typical analogue tracks of 024 cycles per turn allow resolutions of around 0 5 counts per turn. Both these protocols use RS422 for digital communications, and volt peak-to-peak signals for sine, cosine analogues. The EnDat cable length is limited to 50 metres, as for SSI. Page 32 Copyright 2008 Quin Systems Ltd.