Jenaer Antriebstechnik ECOVARIO Servo Troubleshooting Guide

Regenerative braking energy and X4 interface troubleshooting (D11 overvoltage)

When the motor decelerates or the load is suspended by gravity, the motor becomes a generator and feeds back energy to the DC bus, causing the bus voltage to rise. If the energy cannot be consumed in a timely manner, it will trigger D11 (overvoltage in the supply cables) or cause hardware damage.

1. Selection logic of Ballet Resistors

ECOVARIO 214/414 does not have an internal braking resistor and must be externally connected. ECOVARIO 114 integrates a small power resistor of 0.01kW internally. If the braking energy is high, it also needs to be externally connected.

Calculation formula: Braking energy

EBR=one two J(ω one two−ω two two)

E BR= two one J(ω one two−ω two two）The energy that can be absorbed by the busbar

EN−P=onetwo C L(UBUSP two−UBUSN two)

E N−P= two one C L(U BUSP two−U BUSN two）If EBR>EN−PE BR>E N−P

External braking resistors must be used.

Resistance and power: ECOVARIO 114/214 requires selecting a 10 Ω resistor (DPR10-100 or DPR10-200); ECOVARIO 414 requires the selection of a 22 Ω or 24 Ω resistor. When selecting the continuous power of a resistor, the average power needs to be calculated

Pavg=Ppeak×Duty Cycle

P avg=P peak

The duty cycle. Note that JAT's original DPR series resistors are inherently safe and do not require additional fuses for wiring; If non original resistors are used, fast melting fuses (10A fast) must be connected in series between the positive and negative terminals.

2. Adjustment of braking threshold parameters

If there are frequent overvoltage alarms on site, the switch threshold of the braking resistor can be adjusted through ECO Studio software or Object Dictionary (Object 0x2701). For example, the default turn-on threshold of ECOVARIO 414 is 195V and the turn off threshold is 185V. Lowering the threshold appropriately can allow the braking resistor to intervene earlier, but too low will affect system efficiency.

Installation and Fault Diagnosis of Encoder Interface (X11/X12)

ECOVARIO provides two encoder interfaces, X11 for 9-pin Sub-D (encoder A) and X12 for 15 pin high-density Sub-D (encoder B).

1. Adaptive power supply voltage for encoder B

The X12 interface supports standard incremental, SINCOS, and absolute value encoders (Hiperface, BiSS). For BiSS encoder, the supply voltage of X12

UpU p Determined by the external resistors R1 and R2 between terminals 12 (S+) and 6 (DGND):

Up=five V×((Rone/Rtwo)+one)

U p=5V x ((R1/R2)+1). If different types of BiSS encoders are replaced on site, the resistance configuration inside the cable must be rechecked, otherwise it may cause the encoder to malfunction or be damaged.

Fault code D05/D06: Reports "encoder temperature sensor error" or "encoder hardware error". Key points of investigation: Check whether the encoder cable is plugged in and out while it is live (it is strictly prohibited to plug in and out the encoder while it is live, otherwise it is easy to puncture the internal chip); Check if the shielding layer is well grounded; Measure whether the 5V power supply is normal.

2. Communication error E23/E24 (SINCOS orthogonal error)

When using a 1vss sine encoder, if E23/E24 occurs, an oscilloscope should be used to check whether the differential signal amplitude of channels A and B is between 0.8V-1.2V. If the amplitude attenuation is severe, it indicates that the cable is too long (over 50m) or the shielding layer is damaged, causing interference.

Thermal management and hardware maintenance

The casing of ECOVARIO itself serves as a heat sink, with a maximum allowable working environment temperature of 40 ° C (full load).

D02/D03 overheating alarm: If it reports "radiator temperature>85 ° C" or "equipment temperature>60 ° C", first check if the cabinet fan has stopped running. Secondly, check if the servo amplifier is installed vertically as required (X5 motor interface facing downwards), and at least 3mm gap should be left between adjacent devices. There should be no wire slots or components that obstruct air convection above and below. If operating at high temperatures for a long time, it is necessary to install an original radiator (DPX10).

Surface burn risk: During equipment operation or when power is just turned off, the surface temperature of the casing may exceed 70 ° C. Maintenance personnel must wait for it to cool down to below 40 ° C before coming into contact.

Troubleshooting of fieldbus interface faults

ECOVARIO offers a wide range of communication options (CAN, EtherCAT, PROFIBUS, Ethernet).

CAN interface (X21): If communication is not possible, first check if the baud rate settings (1000k, 500k, 250k, etc.) are consistent with the main station. Secondly, check if the X21 terminal 9 (CAN_V+) provides an external power supply of 8-18V (older versions of hardware require external power supply). In terms of terminal resistance, a 120 Ω resistor must be connected to each end of the CAN bus, otherwise signal reflection will cause communication packet loss.