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Operation Manual
Disclaimer
The software described in this manual is sold or licensed as is. Should the program prove defective the user (and not PDL
Electronics Ltd, its distributor or its dealer) assumes the entire cost of all necessary servicing, repair, and any incidental or
consequential damages resulting from any defect in the software. Further, PDL Electronics Ltd reserves the right to revise this
publication and to make changes from time to time in the contents hereof without obligation to notify any person of such
revision or changes
CONTENTS
1 Introduction ....................................................................................................................................4
2 Specifications:................................................................................................................................2
3 Background:...................................................................................................................................2
10 Commissioning Parameter Record Sheets and I/O Assignment for Master Drive ......................22
11 Commissioning Parameter Record Sheets I/O Assignment for Slave Drives .............................24
12 Documentation/Manuals ..............................................................................................................27
13 Glossary.......................................................................................................................................28
14 Index ............................................................................................................................................29
1 Introduction
The objective of the ATV71 Position Synchroniser is to ensure the position of 2 or more
devices such as conveyors are kept in alignment or synchronism.
One device is deemed to be the Master and the remaining devices are deemed to be
Slaves. The Master drive is given the desired speed reference. The basic function of the
Slave drive is to follow the speed of the master, but if a positional error is detected its speed
is automatically increased or decreased to maintain position synchronism.
The Master drive consists of an ATV71 variable speed drive with a Controller Inside card
fitted and the ATV position synchroniser program loaded. The Slave drives are standard
ATV71 variable speed drives with no Controller Inside card fitted.
A sensing device such as a proximity switch is mounted to each device to indicate its
position. The proximity switches are connected to the Logical Inputs (digital inputs) of the
Controller Inside card and provide an index pulse at appropriate positions during the
movement of the device being synchronised. The Synchroniser continuously monitors these
index pulses and determines if there is a positional error between the Master drive and any
of the Slaves. If an error is detected a speed adjustment is made to the Slave drive
concerned so that synchronisation is maintained.
Inter-drive communication including the speed reference, command (start/stop) signals and
drive status is achieved via the ATV71 CANopen bus.
2 Specifications:
This system is designed for slow to medium speed applications such as sheep/beef
processing chains.
A constant revolutions per index ratio is required for each drive. This synchronising program
is not suitable for synchronising applications that have a varying revolutions per index such
as with items unevenly spaced in a conveyor.
3 Background:
Position synchronising must be used wherever the position of the motor output device is
important and no accumulation of error can be accepted. The ATV71 Position Synchroniser
provides full position synchronisation for slow speed to medium applications.
The ATV71 Position Synchroniser is a multidrive configuration based around 1 master drive
and up to 8 slaves. Its basic operation is to keep the position of the slave drive output
device synchronised with the position of the master.
The master drive operates at a required speed depending on the process and the speeds
of the slave drives are increased or reduced to maintain position synchronism. The rate of
correction will depend on the motor accel/decel time, the Correction Speed Offset and the
Gain (See section 5 for a description of these parameters).
The master drive must be an ATV71 with a Controller Inside card fitted and the ATV71
Synchroniser control program loaded. The Slave drives must be ATV71s but they do not
require a Controller Inside card.
4.3 Power Up
After power up or a reset, one index pulse must be received by the Master and Slave drive
before position synchronising is started.
(1) Index Error: The index error is the difference between the actual motor
revolutions between index pulses and expected revolutions entered into
screens O17, O19, O22, O25, O28, O31, O37 and O40. If the index error
exceeds the maximum allowable set in screen O13 an Index Fault will be
generated. An index error is recognized only after the drive has received 3
index pulses after power up or a reset.
(2) Missing Index. An index is assumed to have been missed if an index pulse
has not been received within the expected no of revolutions. The expected
revolutions is equal to the R/I for the drive concerned plus the maximum
allowable Index Error set in screen O13. If the number of consecutive
missed index pulses exceeds the amount set in screen O14 an Index fault
will be generated.
The status message will indicate which drive has the index fault
4.6 Offset
The index pulse of each slave drive does not have to occur at the same time. A positional
offset for each Slave drive relative to the Master can be configured.
5 Synchroniser Screens
5.1 Overview:
Name STATUS
Description Status Display Screen
Code O02
Function Displays the status of the synchroniser including any synchroniser
generated fault that may occur.
This screen will update every time a valid index pulse is received.
This value is then entered into the R/I configuration screens (O17,
O19, O22, O25, O28, O31, O37, O40) during commissioning.
Name CONFIGURE
Code O09
Function This screen only acts as a label to indicate the division between the
monitoring screens and the configuration screens.
Name Mode
Description Mode.
Code O11
Range Setup
Synch
Default SynchSync Position
Function In Setup mode the slave drive will follow the master without any
position correction. The speed the slave drive will travel at is:
Name Sync
Max Position
Correctenables
Spd a more sophisticated algorithm which
Description Maximum Correction Speed.
Code O12
Range 0 to 100
Default 30
Units % of motor rated synchronous speed
Function Configures the maximum speed correction that will be applied to a
slave drive. I.e. if the slave drive would travel at 80% speed with
no speed correction and this screen is set to 10% then the speed
limits which the drive will stay within to keep in synchronism are
70% and 90%. This affects the speed of response to a position
error.
Default 10
Units % of the total revolutions between index pulses.
Name Debounce
Description Index debounce.
Code O16
Range 0 to 60
Default 20
Units % of the total revolutions between index pulses.
Function Configures the index pulse debounce for all drives. Eg if the
debounce is set to 50%, when the drive receives an index pulse it
will not accept another index pulse until it has travelled 50% of the
motor revolutions to the next index pulse.
Setup Run the motor in Setup Mode until at least 2 index pulses have
been received. Then enter the Master drive actual R/I from screen
O08 above into this screen.
Setup Run the motor in Setup Mode until at least 2 index pulses have
been received. Then enter the Slave 1 actual R/I from screen O08
above into this screen.
Name 909480IE02c
Description ATV71 Synchroniser program revision number. Read only.
Code O50
6 Setting Up
The steps for setting up the ATV71 drive as outlined in the ATV71 Simplified Manual should
be completed on each drive in the master/slave network before performing the following
synchronizer setup procedure.
Figure 4 gives the recommended I/O wiring for the Master drive and Table 1 gives the
corresponding parameter configuration.
A1
ATV71
+24V
+10V
COM
COM
PWR
AI1+
AO1
AI1-
AI2
LI1
LI2
LI3
LI4
LI5
LI6
0V
SPEED REFERENCE
(OPTIONAL)
RUN FORWARD
FAULT RESET
RUN REVERSE
FAST STOP
The Controller Inside card Logical Inputs are preconfigured per figure 5. Where a slave
drive is not present the input is left unconnected.
VW3 A3 501
AO52
COM
AO51
AI52
COM
AI51
LO56
LO55
COM
LI51
LI52
LI53
LI54
24VDC +24V
Supply
0V
MASTER INDEX
SLAVE 1 INDEX
SLAVE 2 INDEX
SLAVE 3 INDEX
Figure 6 gives the recommended I/O wiring for the Slave drives and Table 2 gives the
corresponding software configuration. The Profile must be set to Separate and the Slave
drive active reference and command channels must be set to CANopen to allow
synchronising control by the Controller Inside. It is recommended that a Fast Stop be hard
wired to the logical inputs.
A1
ATV71
+24V
+10V
COM
COM
PWR
AI1+
AO1
AI1-
AI2
LI1
LI2
LI3
LI4
LI5
LI6
0V
FAULT RESET
FAST STOP
The maximum speed limits of the drives should be set such that the maximum speed limit
of the slave drives does not prevent them from remaining in synchronism with the Master.
1. Construct a CANopen cable from the parts described in section 7. Refer to the ATV71
CANopen manual for correct cabling procedures.
2. Connect a CANopen cable between the Controller Inside card and the Slave drives. It
is not necessary to connect the Master drive to the network. The Controller Inside card
is the CANopen Master for the Network and the Slave drives are all CANopen slaves.
1.9 Communication CANopen bit rate 125kbps The Controller Inside bit
rate is preconfigured to 125
kbps.
3. Cycle the power to all the drives to initialise the new CANopen parameters. And if
necessary reset any faults.
4. The red LED (1.2) on the Controller Inside card should be off. This indicates there
are no errors on the CANopen network. The status of the CANopen network can
be monitored from Menu 1.2 Monitoring Communications Map CANopen map.
1. Enter the approximate Revolutions/Index for each drive into screens O17, O19, O22,
O25, O28, O31, O34, 37, 40.
3. Give the master drive an appropriate speed reference and a run command. All the slave
drives should also run. While in Set up mode the slave drives will not position
synchronise. They will speed follow according to the RPI ratio ie SpeedSlave = SpeedMaster
x R/ISlave / R/IMaster . Run the drives until at least 2 index proximity inputs are received for
each drive. This will allow the synchroniser to calculate the RPI for each drive.
5. Read the Master drive RPI from the RPI monitoring screen (O08).
6. Enter this value into the Master drive RPI configuration screen. (O17 )
6.7 Miscellaneous:
1. Set the Maximum Position Error and Maximum Correction Speed (screens O11 and
O12) to appropriate values.
2. Once the above steps have been carried out, set the Mode to Synch (screen O13).
Start the Master drive. The position of the slave drives should now synchronise with the
master drive after a short time.
3. Run the synchroniser. Check the Index Error and Position Error screens to ensure the
drives are remaining in synchronism. Also visually check the process to ensure
synchronism is being maintained.
The top line of the ATV 71 display is referred to as the Parameter Bar. This can be
customised to display parameters that are peculiar to the synchroniser. Refer to Menu 6.1
PARAMETER BAR SELECT to select the parameters you wish to display.
Also the Monitoring Display of the ATV 71 display can be customised to display a list of
variables or bargraphs. Refer to Menu 6.2 MONITOR SCREEN TYPE.
If a bargraph is configured the maximum value of the graph will be equal to 120%.
7 Synchroniser Parts
When ordering an ATV71 Position Synchroniser the parts described in Table 4 must be ordered in addition
to the ATV71 drives required.
Schneider Part
Description Quantity Note
Number
1
Ernie part number 154-039 may be used in place of 154-824. This connector is an axial type (ie it is not offset) so it
fits the Controller Inside card better. It is not available from Schneider so it must be purchased directly from Erni.
8 Status Messages
The Synchroniser status can be view in screen O02 of Synchroniser Menu 1.14. Also the
Synchroniser has its own set of fault messages which are displayed in this screen.
Status Codes
Status Display Description
Long Short
Sync Dsbl SyDsd Synchronising disabled. Synchronising is disabled
until the first index pulse after power up, if in setup
mode or if a Stop at Prox has been initiated.
Sync Run SyRun Master drive has received 1 index pulse since power
up. Synchronising is enabled if the slave drive has
also received one index pulse.
SlXMisIdx xMsIdx Slave X drive has missed at least 1 missing index
MasMisidx MMsIdx The Master drive has missed at least 1 index pulse
StpAtProx SpPrx The drives will stop at the next proximity switch.
SlXPosFlt xPsFt A position fault has occurred on Slave X
SlXIdxFlt xIxFt A index fault has occurred on Slave X
MasIdxFlt MIxFt An index fault has occurred on the Master drive.
SlXCANFlt xCnFt A CANopen fault has occurred on Slave X
CAN Flt CnFt A CANopen general fault has occurred.
SlXDrvFlt xDvFt A fault has occurred with Slave X drive.
MasDrvFlt MDvFt A fault has occurred with the Master drive.
If the Controller Inside is configured as the Command an Application Fault will be triggered.
If the Controller Inside is not configured as the Command an External Fault will be
triggered.
9 Synchroniser Faults.
There are 4 types of faults that are generated by the ATV71 Synchroniser. If any of these
faults occur the drive will trip and the fault message SYNCH Flt will be displayed. To
narrow down the cause of the fault see the status message in Menu 1.14.
2. Position Fault. A Position Fault is generated when the difference between the
Master and Slave positions (position error) exceeds the maximum allowable
amount set in screen O13. The status message will indicate which Slave drive has
the fault. Ie the status message Sl6PosFlt indicates a position fault with Slave 6
drive. A Position Fault is recognized only after the Master and Slave drive have
both received 3 index pulses after power up or a reset. The actual position error
can be viewed in screen O05 of the Synchroniser Menu 1.14
(1) Index Error: The index error is the difference between the actual motor
revolutions between index pulses and expected revolutions entered into
screens O17, O19, O22, O25, O28, O31, O37 and O40. If the index error
exceeds the maximum allowable set in screen O13 an Index Fault will be
generated. An index error is recognized only after the drive has received 3
index pulses after power up or a reset. The actual index error can be viewed
in screen O06 of the Synchroniser Menu 1.14.
(2) Missing Index. An index is assumed to have been missed if an index pulse
has not been received within the expected no of revolutions. The expected
revolutions is equal to the R/I for the drive concerned plus the maximum
allowable Index Error set in screen O13 of the Synchroniser Menu 1.14. If the
number of consecutive missed index pulses exceeds the amount set in
screen O14 an Index fault will be generated. The actual number of
consecutive missed index pulses can be viewed in screenO07 of the
Synchroniser Menu 1.14.
The status message will indicate which drive has the fault. Ie the status message
MasIdxFlt indicates an Index fault with the Master drive.
4. CAN Fault. A CANopen fault is generated if a fault is detected with the CANopen
network.
A CANopen fault can also be generated by a Slave drive. In this case the Slave
drive concerned will indicate a CANopen fault and the Master will indicate a Drive
Fault with the corresponding Slave drive.
5. Drive fault. A Drive Fault is generated if a fault in any drive in the network is
detected. To narrow down the cause of the fault see the display in the
corresponding drive.
If 2 faults occur at the same time priority is given to the lower fault in Figure 11.
In the event of a resetable fault on any of the drives it may be reset using the reset input on
the master drive. Sometimes 2 reset inputs my have to be given. One to reset the Slave
and then another to reset the Master. Some faults can only be reset by cycling the power
(refer to the ATV71 Simplified Manual).
10 Commissioning Parameter Record Sheets and I/O Assignment for Master Drive
Location:
Volts: RPM:
Recorded
By: Date:
Drive No:
Location:
Model:
Motor kW:
Amps:
Volts:
RPM:
Recorded
By:
Date:
Drive No:
Location:
Model:
Motor kW:
Amps:
Volts:
RPM:
Recorded
By:
Date:
12 Documentation/Manuals
The main manual required for basic ATV71 installation, programming and fault finding.
The main manual required for installation and wiring of the Controller Inside card.
Contains a list of the ATV71 parameter addresses and describes the various operating modes specific to
serial communications. Not required if the start/stop and reference controls to the Master are achieved via
the standard digital and analogue I/O.
Contains useful information on the connection and diagnostics of the CANopen Network. However all the
information required for setting up the Synchroniser CANopen Network is contained in this Addendum.
Modbus, Ethernet, Profibus, INTERBUS, Uni-Telway, FIPIO, Modbus Plus, & DeviceNet Manuals
These manuals are not required unless the corresponding protocol is required for remote control and
supervision of the Synchroniser. Normally only the Master drive would be controlled.
13 Glossary
ATV. Abbreviation for Aptiva, The name given to the Telemecanique range of variable
speed drives.
ATV58. The generation of Telemecanique variable speed drive which is superseded by the
ATV71.
ATV71. The new generation of PDL and Telemecanique variable speed drive containing
advanced control and communication functions.
Controller Inside. An option card which can be fitted into the ATV71 drive. In the case of the ATV71
Synchroniser it contains synchronising control software and is also the CANopen
master.
Elite Series. The current generation PDL variable speed drives which will eventually be
superseded by the ATV71.
Index. An input to the Controller Inside Card indicating the process position.
Profile. The different input/output configurations supported by the ATV71. The ATV71
Synchroniser uses the Sperate Profile.
Logical Input A digital Input. The ATV71 has 6 Logical Inputs named LI1 to LI6. The Controller
Inside card has 10 Logical Inputs named LI51 to LI60.
Master. The drive that sets the speed of the synchroniser system. The Controller Inside is
fitted into the Master drive.
Slave. The drive that changes speed to match the position of the Master drive. A Slave
drive is also a CANopen slave.
14 Index
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