Kollmorgen SERVOSTAR-CD servo drive hardware installation and system configuration

Initialization: Depending on the encoder type (MENCTYPE 0-6), it may be necessary to perform a "wake-up swing" initialization process or use Hall signals to obtain rough positions during startup, and finally accurately locate through Index pulses (MENCOFF parameter).

6.3 Sine Encoder

Advantages: Output analog differential sine signals, and the driver can perform x256 interpolation internally, thereby obtaining extremely high resolution (line resolution x 256 x 4) at lower signal frequencies.

Type: Supports interfaces with Index, Hall, C/D signal (single speed rotary type), or Endat absolute type.

Calibration: After the first use or replacement of the motor/driver, it is necessary to run the Sine Zeroing (SINInitiat) process to compensate for the gain and offset of the sine/cosine signal and improve accuracy.

6.4 Encoder Equivalent Output (EEO)

The driver can provide orthogonal encoder signals corresponding to the motor position through the C4 connector, without the need for additional position sensors.

Rotary conversion system: generated by R/D circuit, with configurable resolution (ENCOUT), up to 16384 lines/rev (65536 quadruplex counting).

Encoder system: Directly outputs the actual encoder signal, which can be divided by multiples of 2 (ENCOUTO).

Sine encoder system: It is generated by dividing the interpolated signal by frequency (SININTOUT) and then encoding it.

Phase relationship: The rotation system is A leading B in a clockwise direction; The encoder/sine encoder system corresponds to the clockwise direction of A before B-ultrasound.

7. System communication and configuration software

7.1 Communication Method

Serial communication (C1): Supports RS-232 (point-to-point or multi-point daisy chain connected through C7) and RS-485 (only through C1 daisy chain). The baud rate is set through DIP switch 6 (9600/19200). Set the driver address (0-31) through DIP switches 1-5.

SERCOS interface (C4, dedicated model): high-speed digital communication through fiber optic ring network, supporting up to 31 axes. The address and non-zero power level need to be set through DIP switches.

7.2 MOTIONLINK Configuration Software

This is the main user configuration, debugging, and monitoring tool that runs on Windows systems.

Startup Wizard: Gradually guide the user to set the driver bus voltage, select/define the motor from the database, select the operating mode (OPMODE), and perform loop debugging.

Main interface: Provides comprehensive monitoring, variable editing, I/O configuration, tuning, data recording, and fault status viewing functions.

Terminal mode: allows experienced users to directly input variables and commands for configuration.

Parameter saving: Configuration parameters can be saved to the drive EEPROM or exported as SSV files are used for backing up or cloning to other drives.

7.3 System enablement and status display

The status display on the front panel of the drive indicates the system status:

Number: Display the current operating mode (OPMODE).

The decimal point is constantly on: the driver is enabled and the motor is powered on.

Flashing: may indicate position retention activation, malfunction (displaying fault codes), or encoder initialization in progress.

Active is the result of the combined action of software enable (SWEN), fault free (DRIVE OK), hardware remote enable (REMOTE), and DIP enable switch (DIPEN).

8. Control loop and operating mode

SERVOSTAR adopts fully digital control, with a core of 40MHz embedded controller and DSP.

8.1 Control Loop

Current loop (torque loop): update rate of 16 kHz (62.5 μ s), bandwidth<2400 Hz, using pole placement digital algorithm.

Reversing loop: update rate of 16 kHz, converts single-phase current commands into three-phase sine waves, and optimizes motor performance using torque angle lead technology.

Speed loop: update rate of 4 kHz (250 μ s), bandwidth<400 Hz. Provides various compensators (COMPMODE) such as PI, PDFF, standard pole configuration, etc.

Position loop: update rate of 2 kHz (500 μ s). Supports multiple modes such as electronic gear (OPMODE 4) and positioning control (OPMODE 8).

8.2 Main Operating Mode (OPMODE)

0- Serial speed control

1- Simulated speed control (± 10V)

2- Serial torque control

3- Simulated torque control (± 10V)

4- Electronic gear position control (pulse following)

5- SERCOS interface control

8- Position control (supports serial/analog commands)

9. Protection function and troubleshooting

9.1 Protection Function

Turnback protection:

Driver turn back: protects the electronic components of the driver and prevents continuous overcurrent.

Motor turn back: protects the motor from continuous overcurrent causing overheating. Users can fully configure it.

Hardware limit: Implemented through configurable inputs (IN1-IN3), it prohibits movement in the corresponding direction when triggered.

Software limit: Set the position soft limit through variables.

Thermal protection: Monitor the temperature of the motor thermistor and driver heat sink.

Fault relay: can be configured to indicate "driver ready" or "driver running".

9.2 Troubleshooting Tools

Status display: indicates faults through flashing codes (such as "P" for power level faults and "o" for overvoltage).