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Setup of Unknown Motors

Valid for S300, S700 (S400 & S600 minimal changes in display)

Requirements:

  • The motor is load-free
  • You can see the output shaft
  • Any brake that is present is open
  • The axis can be turned by hand.

To check that the motor cables are in the right phase position, open a terminal program of your choice and create a connection via the RS232 interface with the controller.
Don't used the DRIVEGUI or DRIVE.EXE! 

Terminal parameters: 
Baud rate at S400/S600=9600 bit/s, at S300/S700=38400 bit/s 
8 data bits 
no parity 
1 stop bit 
no flow control.

As an example, a 16-pole motor is used (MPOLES 16), the resolution is set to 8 pole-pairs * 360°  10 = 28800 counts (PGEARI). A motor pole-pair is thus presented in 1/10°. For a linear motor (MPOLES 2), you can set the resolution to 3600 count accordingly. The procedure is the same.

Procedure: Determine/check the direction of rotation for the feedback system.

Enter the following in the terminal window:

TABLE 1: Commands direction of rotation feedback system

-->K 
-->DIR 
yy 
-->DIR 21 (1) 
--> SAVE 
--> COLDSTART 
-->K 
-->PROMPT 2 
-->PRD 
yyyyy 
--> 
yyyyy 
--> 
yyyyy 
--> 
yyyyy 
--> 

; software disable for the output stage 
; retrieve data about direction of rotation 
; old value for data about direction of rotation. please note! 
; DIR at S600/400 = 1; S300/S700 = 21
 = set default value. 
; DIR must be secured and a restart of the controller 
; is necessary. 
; software disable for the output stage 
; extended input mode in the terminal 
; show position of feedback; 20-bit display 
; current position of feedback 0 - 1048576 
; now turn the motor shaft to the right (positive direction) 
; and hold down the ENTER key. 
; The last command entered will be repeated for as long as 
; the ENTER key is activated or until a new command 
; is entered and sent. 
; The display values will become more positive as the motor shaft 
; is turned towards the right. 

If the values displayed have become more negative, the feedback connection is not right. Swap the analog signals until the values are consistent with the above process. Only then will you be able to continue with the next step.

Procedure: Determine/check the direction of rotation for the motor phase

Requirement:

  • At DIR = 21(1) and with the motor axis turning towards the right, or with a linear motor moving in a positive direction, the feedback display will also become more positive!

ATTENTION! The motor may perform an uncontrolled movement. For your safety, an EMERGENCY STOP switch must always be within reach.

Enter the following ASCII commands in your terminal program:

TABLE 2: Commands motor phase direction of rotation

-->K 
-->OPMODE 2 
-->SAVE 
-->MPOLES 
yy 

 -->MPOLES 0 
-->MPHASE 0  
-->EN 
-->T 0.5

; software disable for the output stage 
; switch to Opmode 2, digital. Current controller 
; and save 
; retrieve and note number of motor pole-pairs entered 

; set Mpoles to 0 
; set elect. phase angle to 0 
; approve output stage. (Motor should not have any torque) 
; current specification in A (30% * MIcont, e.g. 0.5 A) Attention: motor may move!!

Procedure: Determine/check number of motor pole-pairs

Now turn the motor axis through 360° and count the notches. You may need to use the ASCII command: T x.x to adjust the motor current accordingly so that rotation is possible. 
The number of latching torques on one rotation of the axis corresponds to the number of motor pole-pairs. Twice this value must be equal to the ASCII parameter: MPOLES. see above

Procedure: Determine/check the direction of rotation of the motor cables

TABLE 3: Commands direction of rotation of motor cable

..... 
--> T0.5 
-->SETREF 
-->PFB 

-->MPHASE 30 
-->PFB 
-300 

 -->MPHASE 60 
-->PFB 
-600 

 -->MPHASE 90 
-->PFB 
-900 
-->MPHASE 120 
-->PFB 
-1200 
::: 
::: 
-->MPHASE 330 
-->PFB 
-3300 
-->MPHASE 359 
-->PFB 
-3590 

-->K 
-->MPHASE 0 

-->SAVE 
-->COLDSTART

; see Table 2 
; current specification in A (30% * MIcont, e.g. 0.5 A) Attention: motor may move!! 
; set position to 0, (caution with absolute encoder
; retrieve actual position, which should be 0 here. ( depending on ROFFS 

; the phase angle (MPHASE) is now increased at 30° intervals, whereby the motor axis 
; must move each time by approximately 3.75° mech. to the left (negative). 
; PFB shows the current position in 1/10 electr. degrees. (288000 / 8 / 12=300) 
; The value needs to become more negative. 
; If it does not become negative, or if the motor does not move to the left (negative) 
; there is a faulty connection! In this case, switch off the controller and 
; swap 2 motor connections, e.g. U and V. After the restart, begin again at Table 2. 
; Possible combinations are: 

Actual motor phase swap Target motor phases
U V W U <-> V V U W
V U W V <-> W W U V
W U V W <-> U U W V 
U W V U <-> V V W U
V W U V <-> W W V U




; If the test has been performed successfully, disable the output stage, set MPHASE to 0 
; and save the last parameter status. 
; Restart the controller.

Procedure: Calculate the phase angle (MPHASE)

Manual calculation

TABLE 4: Commands manual calculation phase angle

..... 
--> T0.5 
-->MPHASE 90 
-->MSG 2 
-->PFB 
165.449 
194596 
--> MPHASE 244 
--> SAVE 
-->K 
-->COLDSTART

; see Table 2 
; current specification in A (30% * MIcont, e.g. 0.5 A) 
; set phase angle to 90°. Attention: motor may move!! 
; provide extended messages 
; position of motor axis is displayed, the 1st value states the angle of rotation in °. 
; Multiply this angle by the number of pole-pairs, e.g. 165.5 * 8 = 1324. From 
; this result, deduct 360 until a value between 0 and 359 remains. 
; The rounded value is the value for MPHASE: 1324-360-360-360=244. 
: Save value and restart controller. 

; you may need to set the operating mode.

You should possibly repeat this process 2-3 times, ideally obtaining the same value each time.

Automatic calculation

Motor parameters are entered in the controller and saved. The motor current used is REFIP2.

TABLE 5: Commands automatic calculation phase angle

-->K 
-->OPMODE 2 
-->MSG 2 
-->EN 
-->ZERO 5000
mphase = 244 
165.449 
-->ZERO 5000
mphase = 244 
210.449 
--> SAVE 
-->K 
-->COLDSTART 
-->OPMODE x

; Block controller approval 
; switch to current controller operating mode 
; approve extended messages. 
; Set controller approval 
; enter ASCII command ZERO 5000. Attention: motor may move!! 
; Controller performs its function and calculates the MPHASE 
; turn the motor axis approximately 45° and enter the command again. 
; The same MPHASE value should be calculated. 


; Save data and 
; restart controller 
; you may need to set the operating mode.

Important:

If you use the function "Calculate Offset" with an unknown motor with a resolver, which is not adjusted to MPHASE = 0 degrees, an angle (MPHASE) is determined. This angle is valid for the positive counting direction (DIR = 21) only.

In the case of a negative counting direction (DIR = 20), the angle must be calculated manually according to the following formula: MPHASE (negative direction) = 360 - determined (MPHASE)

It does not matter, whether MPHASE has been determined with DIR = 21 (positive direction) or DIR = 20 (negative direction).