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User Manual for VACON models including: BC361182932762en-000301, NX OPTBC Resolver Board, NX OPTBC, Resolver Board, Board
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DocumentDocumentvacon® nx ac drives optbc resolver option board user manual Ta b l e o f c o n t en t s Document code: DPD01362C Date: 20.02.2018 1. Resol ver option boar d OPT- BC........................................................................................... 4 1.1 Note about absolute angle and differ ent HW and SW ver sions ............................................... 4 1.2 Resolver basics ........................................................................................................................ 4 1.3 Resolver to digital conversion basics....................................................................................... 5 1.4 Compatible resolver types........................................................................................................ 6 1.5 Resolver board features........................................................................................................... 6 2. Configur ation ..................................................................................................................... 7 2.1 Board parameters and monitoring values ............................................................................... 7 2.2 Connectors and jumpers .......................................................................................................... 8 3. Instal l ation ....................................................................................................................... 14 3.1 Installing the option board ..................................................................................................... 14 3.2 Installing the resolver ............................................................................................................ 16 3.3 Additional cabling instructions............................................................................................... 16 4. Diagnostics and tr oubl eshooting...................................................................................... 17 4.1 Fault handling......................................................................................................................... 17 4.2 LED indicator s ........................................................................................................................ 18 4.3 OPTBC Resolver er r or r egister bits ....................................................................................... 18 NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from http://drives.danfoss.com/knowledge-center/technicaldocum ent at ion/ . REMARQUE Vous pouvez télécharger les versions anglaise et fr ançaise des manuels produit sur le site http://drives.danfoss.com/knowledge-center/technical-documentation/. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 4 I nst al l at i on 1. RESOLVER OPTION BOARD OPT- BC This manual is valid for board versions VB00339i or later. The Resolver option board OPT-BC provides the user with an interface to use resolvers as feedback device to VACON® NXP Drive. The inter face pr ovides speed and position data. The OPT- BC includes also encoder simulation output (HTL level) and secondary encoder input (HTL-level). 1.1 Note about absol ute angl e and differ ent HW and SW ver sions Due to differences in hardware and software, the angle given by OPTBC resolver board to application can differ by 180 degrees in the same system. When replacing OPTBC resolver option board in existing installations, care must be taken that angle value does not change accidentally. To prevent this, it is r ecommended that encoder ID run is always executed when r eplacing OPTBC resolver option boards in existing installations. This will automatically correct the possible 180 degrees difference that might be induced when replacing OPTBC option boar d. Following table shows which OPTBC resolver hardwar e and software combinations are compatible. For example, if you replace OPTBC with HW version G and software version V005 with OPTBC with hardware version K and software version V013 the angle does not change by 180 degrees. In this case, encoder ID run is not needed but still recommended. HW & SW ver sion HW: G or prior, SW: V005 or prior HW: H or later, SW: V010, V011, V012 HW: H or later, SW: V013 = Angles differ by 180 degrees = Angles are the same HW: G or prior, SW V005 or prior HW: H or later, SW: V010, V011, V012 HW: H or later, SW: V013 ! WARNING Not per for ming encoder ID run after replacing OPTBC r esolver option boar d pr ior to any other use of the AC dr ive may result in severe harm or injury to equipment and/or persons. 1.2 Resol ver basics A resolver is a rotary transfor mer where the magnitude of the ener gy through the resol ver windings varies sinusoidal as the shaft rotates. A resolver contains one primary winding and two secondary windings, the SIN and COS windings. Primary winding is in the rotor of the resolver and secondary windings are in the stator. Secondary windings are mechanically displaced 90 degrees from each other. The pr imar y winding is excited by an AC voltage called the r eference voltage (Vr ). The induced voltages in the SIN and COS Windings are equal to the value of the Reference Voltage multiplied by the SIN or COS of the angle of the input shaft from a fixed zero point. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 1 I nst al l at i on vac on 5 Why r esol ver s? Resolver signals When a Motion control application exists in a hot, humid, dusty, oily, or mechanically demanding environment, a resolver-based system is the preferred choice. 1.3 Resol ver to digital conver sion basics The OPT- BC boar d sends the Excitation signal to the resolver , and resolver sends sin and cos signals back to the boar d. In the OPT- BC boar d, sin and cos signals ar e converted to incremental encoder pulses by the ASIC cir cuitr y (see picture 1). The incremental pulses are used for calculating rotation speed in the VACON® NXP control card. The conversion from resolver sin/cos signals to digital pulses is called RTD (Resolver To Digital conver sion). Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 1 6 I nst al l at i on Picture 1 Simulated encoder signals from RTD ASIC 1.4 Compatibl e r esolver types Resolver Output voltage: Resolver Input voltage: Number of poles: 1.8Vrms 4.0Vrms 1.3Vrms 7.5Vrms Not e If the number of poles of the resolver is not 2, then the r esolver can only wor k with a motor that has the same number of poles (e.g. a 6 pole resolver with a 6 pole motor). Maximum tracking rates assume that resolver has 2 poles. NOTE 1.5 Resol ver boar d featur es 14bit 14bit 14bit 16bit Encoder Simulation Output Resolution 10bit 12bit 14bit 14bit Encoder Simulation Pulses / rev 256 1024 4096 4096 osition accuracy* +/- 4 LSB +/- 4 LSB +/- 4 LSB +/- 16 LSB elocity accuracy* +/- 4 LSB +/- 4 LSB +/- 4 LSB +/- 4 LSB Excitation frequency 1-20kHz (adjustable with 1kHz steps) Transformation Ratio Sl ot s The output voltage of the resolver has to be between 1.8Vrms and 4Vrms. Input voltage can be adjusted between 1.3Vrms and 7.5Vrms. C Encoder Simulation Output A,B, Z (max. pulse frequency 150kHz) *tested in zero acceleration Note: by selecting 16bit mode, you can improve only position accur acy. Velocity accuracy remains the same (14bit). Encoder Simulation Pulses per Revolution and Maximum tracking rate depend on the number of resolver poles. Simulated Pulses / rev = 2R Resolver _Poles / 8 R = Encoder simulation output resolution Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 1 I nst al l at i on vac on 7 2. CONFIGURATION 2.1 Boar d par ameter s and monitor ing val ues Monitor Menu Number 7.3.2.1 7.3.2.2 7.3.2.3 7.3.2.4 7.3.2.5 7.3.2.6 Monitor Resolver Freq Resol ver Speed Sim. Pul ses/ r ev Encoder 2 Fr eq Encoder 2 Speed AnIN:C.5 7.3.2.7 AnIN:C.6 Unit Hz RPM - Hz RPM Descr ipt ion Resolver Frequency Resolver Speed Simulated pulsed / r evol ut ion Encoder Frequency from secondary encoder Encoder Speed from secondary encoder Error register bits. Please see chapter 4.3 OPTBC Resolver error register bits Cumulative error register bits. Please see chapter 4.3 OPTBC Resolver er ror register bits Parameters menu Number Par am et er Min 7.3.1.1 Invert Direction 0 Max Defaul t 1 0 7.3.1.2 Reading Rate 0 4 1 7.3.1.3 Exciting freq 0 19 0 7.3.1.4 Resol ut ion 0 3 1 7.3.1.5 Resolver poles 0 9 0 Descr ipt ion 0 = No 1 =Yes 0 = No 1 = 1 ms 2 = 5 ms 3 = 10 ms 4 = 50 ms 0 = 10 kHz 1 = 20 kHz 2 = 1 kHz 3 = 2 kHz 4 = 3 kHz 5 = 4 kHz 6 = 5 kHz 7 = 6 kHz 8 = 7 kHz 9 = 8 kHz 10 = 9 kHz 11 = 11 kHz 12 = 12 kHz 13 = 13 kHz 14 = 14 kHz 15 = 15 kHz 16 = 16 kHz 17 = 17 kHz 18 = 18 kHz 19 = 19 kHz 0 = 10 bit 1 = 12 bit 2 = 14 bit 3 = 16 bit 0 = 2 pole 1 = 4 pole 2 = 6 pole 3 = 8 pole 4 = 10 pole Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 2 8 I nst al l at i on 7.3.1.6 Enc 2 Pulse/Rev 0 7.3.1.7 Encoder 2 Type 1 65535 3 1024 1 5 = 12 pole 6 = 14 pole 7 = 16 pole 8 = 18 pole 9 = 20 pole 1 = A,B=Speed 2 = A=Ref,B=Dir 3 = A=Forw,B=Rev 7.3.2.3 Simulated pulses / r ev is calculated on the basis of resolution bits(R) and r esolver poles. The formula used is: Simulated Pulses/r ev = 2^R * Resolver poles / 8 . Exam pl e: Resolution bits = 12 Resolver poles = 2 Simulated Pulses/rev=2^12 * 2 / 8 Simulated Pulses/r ev = 2^12 * 2 / 8 = 1024 The absolute position value is from 0 to 4095 (2^12=4096). 2.2 Connector s and jumper s X21 X10 X13 X1 X3 X4 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 Picture 2 Connector and pin header placement in OPT Board. Pin number 1 is marked with a small square on the X3, X4, X10, X13 and X21. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 2 I nst al l at i on vac on 9 2.2.1 Ter minal data for X1 and X2 connector s PIN N am e Descr iption 1 S4 SIN 2 S2 SIN\ 3 S1 COS 4 S3 COS\ 5 R1 Excitation HI 6 R2 Excitation LO 7 Fr z+ Freeze signal HTL+ 8 Fr z- Freeze signal HTL- 9 ENC2_C+ Encoder input channel C 10 ENC2_C- Encoder input channel C\ 11 A Encoder Simulation Output A 12 A\ Encoder Simulation Output A\ 13 B Encoder Simulation Output B 14 B\ Encoder Simulation Output B\ 15 C Encoder Simulation Output C 16 C\ Encoder Simulation Output C\ 17 ENC2_A+ Encoder input channel A 18 ENC2_A- Encoder input channel A\ 19 ENC2_B+ Encoder input channel B 20 ENC2_B- Encoder input channel B\ 2.2.2 X21 (C- Pulse sour ce selection) Incremental C-pulse (Zero pulse) to control board is read from the resolver attached to the option board (Default). C-pulse is External. Read from FRZ input. This feature can be used with special applications for marking position data. Not supported in Standard VACON® NXP applications. 2.2.3 X10 and X13 (Gain selection) SIN and COS feedback signals fr om the r esolver should be in the r ange of 1.8 4Vrms (between SINHI - SINLO and COSHI - COSLO). To scale the input signals to an acceptable level we can select 1/3, or 1/4 attenuation for the input lines. Following equation can be used to calculate output signal level. Transformation for the corresponding resolver is told in resolver datasheets. EXC_OUT = excitation output voltage SIN Feedback voltage = EXC_OUT * Transformation ratio 1/4 gain for SIN / COS feedback signals from 3.25 Vrms to 4Vrms Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 2 10 I nst al l at i on 1/3 gain for SIN / COS feedback signals from 2.4 Vrms to 3.24Vrms 1/2 gain for SIN / COS feedback signals from 1.8 Vrms to 2.39Vrms X13 sets SIN attenuation and X10 sets COS attenuation. SIN and COS input pair s should all have the same attenuation to keep signals symmetrical. For example, a resolver that is rated for 5.6Vrms excitation and has a transformation ratio of 0.485 gives output voltage of 2.72Vrms. Excitation voltage and corresponding settings are selected from the table 1 in chapter 2.2.4. In this case exact match is found. Resolver output voltage of 2.72V Vrms fits to the signal range of 1/3 attenuation. 2.2.4 X3 and X4 Excitation Voltage Contr ol Resolver option board has an amplifier for adjusting excitation voltage. Jumpers X3-1-4 and X4-1-3 set the amplifier gain and consequently the excitation voltage. Excitation voltage can be set in the range of 1.3Vrms to 7.5Vrms. To get the best possible accuracy, excitation voltage should be selected to be as high as the used resolver allows AND so that the output voltage fits to the given range. Excitation frequency is set from the control panel and it should be set prior to connecting the resolver to the option board. To set the excitation voltage accurately, measure the excitation voltage when resolver is connected. Notice that measurement device must be capable of measuring high frequency RMS voltage. Typical excitation voltage for each jumper setting can be checked from the table, usable values are highl ight ed. EXC_OUT = target excitation output voltage. This is specified in resolver datasheets (Excitation Vol t age) Now, set the calculated gain with X3 and X4 jumpers. Jumper settings for the desired gain can be found from table. All jumpers attached gives minimum gain and all jumpers open gives maximum gain. Maximum output voltage is limited to the boards internal voltages and is approximately 7.5Vrms. Recommended voltage range is highlighted with blue. X = Jumper installed X3-1 X3-2 X3-3 X3-4 X4-1 X4-2 X4-3 X X X X X X X X X X X X X EXC_OUT [Vr m s] Typical 1.27 1.34 Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 2 I nst al l at i on X X X X X X 1.43 X X X X X 1.50 X X X X X X 1.55 X X X X X 1.62 X X X X X 1.71 X X X X 1.78 X X X X X X 1.87 X X X X X 1.94 X X X X X 2.02 X X X X 2.10 X X X X X 2.15 X X X X 2.22 X X X X 2.30 X X X 2.38 X X X X X X 2.43 X X X x X 2.50 X X X X X 2.58 X X X X 2.66 X X X x X 2.71 X X X X 2.78 X X X X 2.86 X X X 2.94 X X X X X 3.03 X X X X 3.10 X X X X 3.18 X X X 3.25 X X X X 3.31 X X X 3.38 X X X 3.46 X X 3.53 X X X X X X 3.56 X X X X X 3.64 X X X X X 3.72 X X X X 3.79 X X X X X 3.84 X X X X 3.92 X X X X 4.00 X X X 4.07 X X X X X 4.16 X X X X 4.23 X X X X 4.31 X X X 4.39 X X X X 4.44 X X X 4.51 X X X 4.59 X X 4.67 X X X X X 4.72 X X X X 4.79 X X X X 4.87 X X X 4.95 X X X X 5.00 X X X 5.07 X X X 5.15 X X 5.23 X X X X 5.32 X X X 5.39 X X X 5.47 X X 5.54 Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ vac on 11 2 12 I nst al l at i on X X X 5.60 X X 5.67 X X 5.75 X 5.82 X X X X X X 5.85 X X X X X 5.93 X X X X X 6.01 X X X X 6.08 X X X X X 6.13 X X X X 6.21 X X X X 6.29 X X X 6.36 X X X X X 6.45 X X X X 6.52 X X X X 6.61 X X X 6.68 X X X X 6.73 X X X 6.80 X X X 6.89 X X 6.96 X X X X X 7.01 X X X X 7.08 X X X X 7.17 X X X 7.24 X X X X 7.29 X X X 7.36 X X X 7.45 X X 7.52 Table 1 Excitation voltage selection 2.2.5 Configur ation example Example Resolver Datasheet Input Voltage (rms) 6.1 V @10 kHz Tr ansfor m at ion Ratio (+- 5%) 0.485 Output Voltage 2.96V Step 1: Check resolvers input voltage and select corresponding configuration for jumpers X3 and X4 from the table1. ->6.1 V (Use smaller Voltage from the table if exact match is not found = 6.08V) X3-1 X3-2 X3-3 X3-4 X4-1 X4-2 X4-3 X X X X X X X X X EXC_OUT [Vr m s] Typical 6.08 6,.3 Set jumpers to X3- 3, X3-4, X4-1 and X4-2: Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 2 I nst al l at i on vac on 13 Step 2: Find resolver output voltage from the datasheet or calculate it. Output voltage = input voltage transformation ratio. Output Voltage = 6.08 0.485 Output Voltage = 2.95 Vrms 1/4 gain for SIN / COS feedback signals from 3.25 Vrms to 4Vrms 1/3 gain for SIN / COS feedback signals from 2.4 Vrms to 3.24Vrms 1/2 gain for SIN / COS feedback signals from 1.8 Vrms to 2.39Vrms If Output voltage is higher than 4Vrms -> Lower the excitation voltage. ->Use 1/3 gain Step 3: Configure board using the control panel. (Software configuration) 7.3.1.1 Invert Direction ->This parameter can be used for inverting rotation direction 7.3.1.2 Reading Rate -> Default 1ms. In noisy environments this parameter can be used to filter disturbances. Set first to 5ms if the shaft is not running smoothly. 7.3.1.3 Exciting freq -> Select the Exciting frequency as told in specification ->In this example 10kHz 7.3.1.4 Resolution ->Default 12bit - >In slow Speed applications high Resolution can be used. Planned Max Speed in Example is 1500rpm Select highest possible accuracy ->16 bit (16bit) = 7500rpm 2 / Resolver_Poles 7.3.1.5 Resolver poles = 2 poles Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 2 14 I nst al l at i on 3. INSTALLATION Internal components and circuit boards are at high potential when the AC drive is connected to the power source. This voltage is extremely dangerous and may cause death or severe injury if you come into contact with it. WARNING! 3.1 Instal l ing the option boar d Following installation guidelines should be followed carefully to get the best performance of the system. Improper installation of the system might cause to disturbances which may in RTD conversion generate extra encoder pulses or jitter to the pulse lengths. Since the board supports large variation of resolvers, the used resolver should always be verified before installation. The option boar d OPT- BC can only be used with VACON® NXP dr ives. The option boar d OPT- BC can be connected to sl ot C. Disconnect the drive from the mains before starting the installation. A VACON® NXP AC dr ive B Remove the cable cover. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 3 I nst al l at i on C Open the cover of the control unit. vac on 15 D Install the option board in slot C on the control board of the AC drive. Make sure that the grounding plate fits tightly in the clamp. Strip the cable at such distance from the terminal that you can fix it to the enclosure with the grounding clamp. Note! We recommend to use always shielded twisted pair cables with resolvers. Use cables that are recommended for encoder and resolver feedback. Do not mix signals in twisted pairs. Always make grounding contact throughout the full circumference of the cable (360° ) r equir ed. The cable is weakened where the shield is removed E Make a sufficiently wide opening for your cable by cutting the grid as wide as necessary. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 3 16 F Close the cover of the control unit and the cable cover. I nst al l at i on 3.2 Instal l ing the r esol ver Connect the resolver after setting the jumpers. Use cable clamp in the lower part of the VACON® NXP drive to connect cable shield. Strip the cable so that the shield is exposed only from the part that is fitted to the clamp. 3.3 Additional cabling instr uctions The resolver and other control cables should not be in parallel with power cables (supply and motor cabl e). The feedback signals might also suffer from the noise coming fr om motor and supply cables. Use shielded symmetrical motor cables. It is recommended to connect the motor cable shield with 360° emc bushing. The motor and supply cables should not be in parallel with resolver signal cable. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 3 Di a g n o st i c s vac on 17 4. DIAGNOSTICS AND TROUBLESHOOTING The panel shows in the G7.3 that board is OPT-BC. Monitor values from 7.3.2 shows: 7.3.2.1 7.3.2.2 7.3.2.3 7.3.2.4 7.3.2.5 7.3.2.6 7.3.2.7 Resolver Freq (Hz) Resolver Speed (Rpm) Sim. Pulses/rev Encoder 2 Freq Encoder 2 Speed AnIN:C.5* AnIN:C.6* * Er ror r egister bits. Please see chapter 4.3 OPTBC Resolver er r or register bits Parameter values from panel index 7.3.1 7.3.1.1 7.3.1.2 7.3.1.3 7.3.1.4 7.3.1.5 7.3.1.6 7.3.1.7 Invert direction Reading rate Exciting freq (10 / 20 kHz) Resolution bits(10 / 12 bits) Resolver Poles Enc 2 Pulse / Rev Encoder 2 type 7.3.2.3 Simulated pulses / rev is calculated on the basis of resolution bits(R) and resolver poles. The formula used is Simulated Pulses/rev = 2R * Resolver poles / 8. Exam pl e: Resolution bits = 12 Resolver poles = 2 Simulated Pulses/rev=212 * 2 / 8 Simulated Pulses/rev = 2^12 * 2 / 8 = 1024 Lower resolution is used in high speed applications. In 10bit mode the resolver sends 256 pulses / revolution and in 12 bit mode 1024 pulses / revolution = 2 . The absolute position value is from 0 to 4095 (2^12=4096). 4.1 Faul t handl ing OPTBC Resolver option boar d reports fault to the application in case where LOS (loss of signal) or LOT (loss of traction) situation is detected. Actions after the fault depends from the application configur at ion. The option board informs the application when the situation comes back to normal. Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 4 18 Di a g n o st i c s 4.2 LED indicator s There are two LED indicators in the option board: Yellow Board status LED LED is: OFF Fast Blinking Slow Blinking Meaning: Option board not activated Normal operation (cycle 1s) Fault state (cycle 2s) Red Error LED (Loss of traction) LED is: OFF ON Meaning: OK Loss of traction. Error LED is set to OFF when the problem disappear s Fault conditions: - Incorrect settings for resolver - Resolver failure - Cabling failure In case of fail ur e, check the jumper settings, cabl ing and r esol ver assembl ing. 4.3 OPTBC Resol ver er r or r egister bits Analog input variables ANIN5 and ANIN6 shows error registers of OPTBC Resolver option board. These variables can be seen as 7.3.2.6 AnIN:C.5 and 7.3.2.7 AnIN:C.6 monitor values. Application developers can also use this information in application if needed. ANIN5 shows currently active error register bits. ANIN6 shows cumulative er r or r egister bits after AC dr ive boot. Bit Description D7 Sine/cosine inputs clipped D6 Sine/ cosine inputs below LOS thr eshold D5 Sine/ cosine inputs exceed DOS overr ange threshold D4 Sine/ cosine inputs exceed DOS mismatch thr eshold D3 Tr acking err or exceeds LOS threshold D2 Velocity exceeds maximum tracking rate D1 Phase error exceeds phase lock range D0 Configuration parity error Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/ 4 www.danfoss.com Vacon Ltd Member of the Danfoss Group Runsorintie 7 65380 Vaasa Finland Document ID: DPD01362C Rev. C Sales code: DOC-OPTBC+DLUK