IndexBlok®

Owners Manual

©MTS Systems Corporation 2001 2121 Bridge St, New Ulm, MN 56073

Version 1.0 Phone: 507-354-1616

Fax: 507-354-1611

www.mtsautomation.com

Safety Overview

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Before designing a system or machine that will contain an IndexBlok module or before installing and operating anIndexBlok module, it is extremely important that you read this section very thoroughly and carefully. The IndexBlokmodule will deliver years of reliable, trouble-free, and safe operation if the cautions and warnings outlined in thissection are heeded and the subsequent instructions in the remainder of this manual are followed.

Throughout this manual three unique symbols will be used to identity hazardous andpotentially dangerous situations. The symbols are described here:

THE ELECTRICAL SHOCK SYMBOL SHOWN TO THE LEFT ISUSED TO INDICATE SITUATIONS WHERE ELECTRICAL SHOCKHAZARDS MAY EXIST. Follow these warnings to avoid electrocution of the useror other serious potential issues that could result in serious injury or death.

DANGER THE DANGER SYMBOL SHOWN TO THE LEFT IS USED TOINDICATE SITUATIONS (OTHER THAN ELECTRICAL HAZARDS),WHICH ARE CLEARLY DANGEROUS TO EITHER YOU OR TO THEPRODUCT. Follow these warnings to avoid serious injury to you and damage tothe product.

CAUTION THE CAUTION SYMBOL SHOWN TO THE LEFT IS USED TOINDICATE SITUATIONS WHERE THE CHANCE OF MINOR ORMODERATE INJURY TO YOURSELF OR THE PRODUCT EXISTS. Followthese warnings to avoid injury to you and damage to the product.

General Safety Precautions

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The following indicates a partial list of warnings, precautions, and points of concernthat must be addressed to ensure safe operation of the IndexBlok module and themachine it is installed in. Other more specific precautions are indicated in theappropriate sections of this manual. As you read through the manual, payparticularly close attention to these cautions and warnings as they could save the lifeof the user!

Dangerous voltages, currents, temperatures, and energy levels existwithin this unit, on certain accessible terminals, and at the motor. NEVERoperate the unit with its protective cover removed! Exercise caution when installingand applying this product. Only qualified personnel should attempt to install and/oroperate this produt. It is essential that proper electrical practices, applicableelectrical codes, common sense and suggestions in this manual be strictly adhere.

DANGER Motors can develop high torque and speed. Use extreme cautionduring development of applications and integration into the system. Suddenmotor motion may occur during execution of software programs. All softwareshould be verified for proper operation before integration into your system. Themotor may continue to rotate upon removal of power to the unit. It is yourresponsibility to ensure that no dangerous motion occurs due to gravity loading orfree-running motors upon unit shutdown. Fail-safe brakes may be interfaced to theunit to prevent such dangerous conditions.

DANGER Rotating machinery can cause serious injury or death. Use extremecaution when near any rotating machine. Never wear loose clothing (e.g., neckties) nor allow hands and feet anywhere near a rotating shaft. Always wear safetyglasses when you operate rotating equipment. Refer to OSHA rules and regulations,

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as well as the CE Machinery (IEC 204-1), when designing a mechanical system thatincludes a motor and drive to ensure that the user is protected.

DANGER Motors can have surface temperatures of up to or exceeding 130°°C,and can store heat for some time. Use caution when handling the motor oranything mounted directly to the motor or its shaft, as they can be hot enough tocause potentially serious injury even after the unit has been de-energized for sometime.

Dangerous high voltages exist in this product. Be certain the power hasbeen removed for at least 5 minutes before any service work or circuit boardconfiguration changes are performed.

DANGER IndexBlok products are not suitable for use in explosiveatmosphere, or in a “Hazardous (Classified) Location”. See Article 500 of theNational Electric Code.

Temperature of the heatsink can exceed 60°C, which could cause discomfort orinjury to an operator. The end user should be protected from casual contact withIndexBlok heat exchangers. During diagnostic testing and machine development,exercise caution when determining the temperature or when touching the heatexchanger hardware.

Secure mounting and proper grounding of both the IndexBlok and the BLDC motoris essential for proper operation of the system. Pay particular attention to thesuggested wiring diagrams, as noise currents injected into the motor frame must be

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returned to the drive chassis, and the loop area must be minimized to meetapplicable EMC standards.

It is your responsibility to follow the appropriate federal, state, and local electricaland occupational safety codes in the application of this product.

NEVER wire the unit with the power on! Serious injury as well as damage to the unit may result.

NONE of the inputs to the unit are to be used as EMERGENCY STOP in any application. These inputs go to amicroprocessor-input port, where software determines the proper action - activation of these inputs will discontinuemotion or disable motor current. However, these inputs are NOT designed as fail-safe E-STOP inputs. Relyingexclusively on inputs of the unit to cease motion, which could cause dangerous conditions, is a violation of MachineSafety Codes (ref. IEC 204-1). Other measures such as mechanical stops and fail-safe brakes must be used in thesesituations.

All electronic equipment is susceptible to damage from static discharge. Static control precautions are requiredwhen crating and uncrating, storing (in inventory at your factory), moving to the factory floor, installing, testing andservicing the IndexBlok product. Component damage may result if good static control procedures are ignored. Wheninstalling the module, connect the ground wire as soon as possible. Keep hands and tools away from the electroniccircuits as much as possible. Non-conductive materials (paper, plastic, Styrofoam, tape, etc.) should not be used on oraround the module as they can generate a high static charge.

Printed circuit boards are not field repairable. Attempting to modify or repair these components will invalidate thewarranty and could negate the solid state protection features designed and tested into the IndexBlok family ofproducts, which could cause serious collateral damage if an impaired system is powered up.

Table of Contents

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Safety Overview 2

General Safety Precautions 3

Table of Contents 5

Introduction 11

What is Semipower’s IndexBlok SensorlesServo Drive?................................................................................................... 12Servo Performance ........................................................................................................................................................................ 12Small Flexible Form Factor......................................................................................................................................................... 12Extended Operating Range .......................................................................................................................................................... 12Drive in a Power Module Design ............................................................................................................................................... 12Digital Inputs ................................................................................................................................................................................. 13Digital Outputs .............................................................................................................................................................................. 13Relay Outputs ................................................................................................................................................................................ 13Analog Outputs .............................................................................................................................................................................. 135VDC Auxiliary Power Supply................................................................................................................................................... 1312VDC Power for External Fan.................................................................................................................................................. 13RS485 Serial Communications................................................................................................................................................... 13Serial Cable..................................................................................................................................................................................... 14RJ-12 Connector Description ...................................................................................................................................................... 14IndexBlok Configuration Tool.................................................................................................................................................... 14Multiple Protection Circuit .......................................................................................................................................................... 14AC Input Power.............................................................................................................................................................................. 14EEPROM......................................................................................................................................................................................... 15Manual............................................................................................................................................................................................. 15

Quick Start 15

Shipping Content........................................................................................................................................................................... 15Installing the IndexBlok............................................................................................................................................................... 16Configuring the IndexBlok........................................................................................................................................................... 18

Installation 19

A. Pre-Installation...................................................................................................................................................................... 201. Handling of drive assembly or drive module after delivery...................................................................................202. Where to locate the drive module in the machine....................................................................................................213. Application Considerations.........................................................................................................................................22

a. Motor Selection .............................................................................................................................................................. 22Choosing a Motor 22Preferred Motor Specifications 22

b. Heatsinking and Thermal Design - Cooling the IndexBlok Module .............................................................................. 244. Input Line Considerations............................................................................................................................................24

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a. Input Line Conductor and Circuit Overload Protection Selection ................................................................................. 25b. Grounding Connections.................................................................................................................................................. 27c. Input Line Impedance..................................................................................................................................................... 27d. Harmonic Distortion....................................................................................................................................................... 29e. Input Line Routing ......................................................................................................................................................... 29f. Isolation Transformers ................................................................................................................................................... 29g. Power Factor Correction ................................................................................................................................................ 29h. Standby Power Generation ............................................................................................................................................. 30

5. Output Wiring Considerations....................................................................................................................................30a. Output Power Conductor and Ground Conductor Sizing............................................................................................... 30b. Output Power Conductor Routing .................................................................................................................................. 30c. Overcurrent Protection ................................................................................................................................................... 31d. Power Factor Correction ................................................................................................................................................ 31

6. Analog and Digital I/O Signal Considerations........................................................................................................31a. Analog and Digital Signal Wiring.................................................................................................................................. 31b. Analog and Digital Conductor Routing.......................................................................................................................... 31c. Analog Output Connections ........................................................................................................................................... 32d. Digital Input Connections .............................................................................................................................................. 33f. Digital Output Connections............................................................................................................................................ 35

7. Braking Resistor ............................................................................................................................................................37a. Resistor Value ................................................................................................................................................................ 37b. Average Power Rating.................................................................................................................................................... 38c. Special Consideration - Resistor Construction and Energy Ratings .............................................................................. 39d. Working Voltage............................................................................................................................................................ 40e. Using IB Config to protect the braking resistor ............................................................................................................. 41

8. Fan ...................................................................................................................................................................................419. Capacitor Assembly.......................................................................................................................................................42

Ratings 43

A. Series 1000 Ratings.............................................................................................................................................................. 44B. Series 2000 Ratings.............................................................................................................................................................. 44

Motor Selection - Preferred Motor Specs 44

Choosing A Motor......................................................................................................................................................................... 44Preferred Motor Specifications................................................................................................................................................... 44

Performance 46

Common Specifications 48

A. Environmental....................................................................................................................................................................... 49B. Electrical................................................................................................................................................................................. 49

Product Dimensions 49

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A. SERIES 1000 DIMENSIONS ............................................................................................................................................ 50B. SERIES 2000 DIMENSIONS ............................................................................................................................................ 52

CE Installations 53

Instructions for Compliance with the European Standards.................................................................................................... 54EMC Directive...........................................................................................................................................................................54

A. Outline of Installation Requirements ............................................................................................................................. 54Low Voltage Directive.............................................................................................................................................................55

IndexBlok Configuration Tool – Installation & Configuration 56

Installing IB Config Software ..................................................................................................................................................... 56Configuring IndexBlok with IB Config Software ................................................................................................................... 56

Communication Setup ..............................................................................................................................................................58Communication Timeout Setting ............................................................................................................................................ 58

Motor Setup with IB Config 60

Motor Setup.................................................................................................................................................................................... 60

Tuning with IB Config 62

System Tuning –Using “Calc Gains and Position Assistant.xls” excel file ........................................................................ 62

Application Setup with IB Config 66

Setting up the Application............................................................................................................................................................ 66Serial Jog ...................................................................................................................................................................................69Serial Start (Start Absolute and Start Relative) ..................................................................................................................70Serial Start Preset Function ...................................................................................................................................................72Saving Configuration ...............................................................................................................................................................74

Duplicating Drive with IB Config 74

Duplicating Drives ........................................................................................................................................................................ 74

IndexBlok Configuration Tool - Operation 76

OPERATING IB Config Software ............................................................................................................................................. 77

Serial Parameters and Setup 78

Serial Parameters ........................................................................................................................................................................... 79To Initiate a Serial Jog.................................................................................................................................................................. 80To Serial Stop Motion .................................................................................................................................................................. 80To Serially Start an Absolute Move........................................................................................................................................... 80To Serially Start a Relative Move .............................................................................................................................................. 80

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To Serially Start a Preset Function............................................................................................................................................. 80

Digital Input Settings 81

I/O SETUP Worksheet – Default Settings................................................................................................................................ 82I/O SETUP Worksheet – Hardware............................................................................................................................................ 83

Table 2.0: Input Settings And Associated Parameters.....................................................................................................84Table 2.1: Preset Bit Function Settings And Associated Parameters ...........................................................................84Table 2.2: Move Profile Settings and Associated Parameters .......................................................................................85

Digital Input Functions ................................................................................................................................................................ 87Table 3.0: Digital Inputs Parameters .................................................................................................................................87Table 3.1: Input Function Values for Digital Input Parameters [M00 – M07] ..........................................................89

Digital Input Connections............................................................................................................................................................ 90Preset Bit Function Inputs ........................................................................................................................................................... 92

Table 4.0: Preset Bit Function Parameters [M2A – M39] .............................................................................................93Table 4.1: Preset Bit Functions & Function Values ........................................................................................................93

Preset Position Parameters and Setup 95

Preset Position Setup .................................................................................................................................................................... 95Table 5.0: Calculating Preset Position Parameters.........................................................................................................96Table 5.1: Preset Position Parameters...............................................................................................................................97

Serial Speed & Global Accel/Decel Parameters and Setup 98

Preset Speed ................................................................................................................................................................................... 98Table 6.0: Preset Speed Parameters ...................................................................................................................................99

Global Accel/Decel Parameters ................................................................................................................................................100Table 6.1 Acceleration/Deceleration Rate Parameter.................................................................................................. 100

Digital Output Setup 100

Digital Outputs Functions..........................................................................................................................................................101Table 7.0: Digital Output Parameters............................................................................................................................. 101Table 7.1: Relay Output Parameters................................................................................................................................ 101Table 7.2: FBK LED State Function Parameters.......................................................................................................... 102Table 7.3: Output Functions Values for Digital Outputs 1-2 Parameters [M09 - M0C and M21 - M22].......... 102Table 7.4 At Speed, Overload and Overtemp Alert Customized Activation Level Parameters ............................. 103

Digital Output Connections .......................................................................................................................................................103

Analog Output Setup 104

Analog Output .............................................................................................................................................................................105Analog Output Fucntions..................................................................................................................................................... 105Analog Output Scaling Parameters (M27-M29) .............................................................................................................. 105

Analog Output Connections......................................................................................................................................................107

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Appendix A: Home Routing Examples 107

Appendix B: Calculating Position Values 108

Example 1: Negative Position of –12345 degrees......................................................................................................... 110Example 2: Negative Position of 12345 degrees ........................................................................................................... 111Example 3: Negative Position of 360 degrees................................................................................................................ 112Example 4: Negative Position of 100 degrees................................................................................................................ 112Example 5: 4 Inches Move................................................................................................................................................. 113

Appendix C: Serial Communication Protocol 112

A. Hardware Protocol..............................................................................................................................................................1141. RS-485 Serial Port Specifications............................................................................................................................ 114

a. Overview ...................................................................................................................................................................... 114b. RS-485 Connections..................................................................................................................................................... 114

B. Communication Protocol...................................................................................................................................................1151. Issuing a Read Command.......................................................................................................................................... 1152. Issuing a Write Command......................................................................................................................................... 1163. Drive Transmitted Serial Errors .............................................................................................................................. 1164. Communication Error Detection ............................................................................................................................. 1175. Checksum Calculation............................................................................................................................................... 117

Appendix D: Troubleshooting 117

Troubleshooting – General.........................................................................................................................................................119Troubleshooting – Fault Codes .................................................................................................................................................122A. Sat faults...............................................................................................................................................................................122B. Phase Overcurrent ..............................................................................................................................................................122C. DC Link Undervoltage ......................................................................................................................................................122D. DC Link Overvoltage.........................................................................................................................................................122E. A/D Offset Fault .................................................................................................................................................................123F. Motor Fault ..........................................................................................................................................................................123G. Heat Sink Overtemp ...........................................................................................................................................................124H. Motor Thermal Overload ..................................................................................................................................................124I. Communication Loss.........................................................................................................................................................125J. External Fault ......................................................................................................................................................................125K. EEPROM Fault ...................................................................................................................................................................125L. Motor Parameter Fault .......................................................................................................................................................126

Appendix E: Internal Drive Parameters 125

Group A: Drive Identification...............................................................................................................................................125Group B: Serial Communications........................................................................................................................................128

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Group C: Drive Command ....................................................................................................................................................128Group D: Drive Feedback......................................................................................................................................................129Group E: Fault Queue ............................................................................................................................................................132Group F: Drive Parameters ...................................................................................................................................................135Group G: Motor Parameters ..................................................................................................................................................135Group H: Holding Current Parameters ................................................................................................................................137Group I: Current and Voltage Feedback Parameters – Reserved..................................................................................137Group J: Protection Parameters ...........................................................................................................................................137Group K: Regulator Gains.....................................................................................................................................................138Group L: Internal Parameters ...............................................................................................................................................139Group M: I/O Setup.................................................................................................................................................................139

Terms and Conditions 142

Warranty and RMA Policy 143

A. Warranty Repair..................................................................................................................................................................143B. Return Procedure ................................................................................................................................................................143C. RMA Processing.................................................................................................................................................................145

Warranty Limitation and Liability 144

Introduction

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What is Semipower’s IndexBlok SensorlesServo Drive?Semipower’s new IndexBlok can position any three-phase rotary or linear brushless permanent magnet, 0.8-21.5 kWmotor without a sensor. Semipower’s leading edge SensorlesServo technology replaces the physical sensor (i.e.encoder, resolver, hall device, etc.) with a software algorithm. The algorithm calculates rotor position information fromcurrent and voltage measurements. The rotor position is fed to the PID servo system within the drive. The result is athree phase sinusoidal drive without the need for a physical sensor on the motor.

The IndexBlok allows users to program and select 16 different absolute or relative moves including homing andregistration. Under RS485 control the number of moves are unlimited. It comes with an easy to use software packagefor setting up inputs, outputs and motion parameters like distance, velocity, acceleration and deceleration.

The IndexBlok is available in sizes from 1.7 Arms to 28 Arms continuous current and input voltages from 110VAC–480VAC.

SensorlesServo control provides a cost-effective alternative to stepper motor systems, linear motor and servo motordrive systems.

Servo PerformanceThe IndexBlok has the performance of a Brushless Servo System (high torque, wide speed range and smoothness)and positions with full holding torque while stopping. The torque vs speed performance is equivalent to a traditionalservo system with similar motor and encoder or resolver, within the specified 30:1 speed range. It has a commandedresolution of 16 bits per electrical cycle of the motor to provide greater than 65536 counts per revolution for rotarymotors.

Small Flexible Form FactorThe IndexBlok drive modules are ideal for OEMs and system integrators requiring the flexibility to independentlyoptimize the thermal (heatsink), enclosure and mounting configuration of their motion control system. Its smallmodular footprint enables it to be mounted to all types of heatsinks, cabinets, and NEMA rated enclosures. LikeSemipower’s other Building Blok Solutions for Motion Control, it provides Machine Builders with a complete line ofcomponent based or fully package drives leading to a lower total system cost through small flexible form factors and awide range of application control options.

Extended Operating RangeThe IndexBlok’s enclosed power hybrid construction enables it to be used in a broad range of industrial, commercial,aerospace and high reliability environments. With the addition of Semipower's CapBlok high reliability electrolyticfilter capacitor module, the IndexBlok can be used at elevated temperatures and in other demanding environments up to70°C without compromising reliability.

Drive in a Power Module DesignLike all Semipower Integrated Drive Module (IDM) products, the IndexBlok is a complete motor drive in a hybridpower module. This module includes all power circuitry, protection, isolation and the microcontroller required to runthree phase motors.

Introduction

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Digital InputsDigital Inputs allow the user to program the drive’s inputs for the specific function to fit the application.• 8 digital inputs: intended for dry contact closure and open collector use. These inputs can be configured as

sourcing, sinking or passive closure and are programmable from a list of 19 functions. Logic threshold is 2.5V.Protected from continuous overload of up to +25/-5V DC (dual function I/O pins 15 and 16 require a minimumexternal impedance of 750 Ω). No isolation from internal logic supply is provided.

• The 6 digital input only terminals may be programmed to be all pulled up or all pulled down. The 2 digitalinput/digital output terminals are pulled up only. The logic polarity of all of the inputs may be individuallyprogrammed. Two of the digital inputs (DIN1, DIN2) are high-speed inputs and can be used for home orregistration inputs.

• Not optically isolated

Digital OutputsDigital outputs allow the user to program the drive’s outputs for the specific function to fit the application.• 2 open-collector outputs: can be externally pulled up to 5-24 VDC and are rated at 50mA. They are internally

pulled up to +5V through 4.7 kΩ . The response time is 2 msec and they are programmable from a list of 12functions.

Relay OutputsDigital outputs allow the user to program the drive’s outputs for the specific function to fit the application.• 2 isolated relay outputs: rated at 0.5 A at 125VAC and 1 A at 24VDC. Programmable from a list of 12 functions.

Analog OutputsAnalog Outputs allow the user to customize the analog outputs to fit the application.• 3 analog outputs: 8-bit resolution, programmable from a list of 5 functions. The output voltage is a 0-10 volts.

Protected from continuous overload of up to +25/-5V DC. No isolation from internal logic supply is provided.

5VDC Auxiliary Power SupplyA regulated +5V DC, 80mA isolated power supply is available on PIN 7 to provide power to User Accessories.

12VDC Power for External FanProvision is made to power external 12V DC fan(s) to provide forced air cooling of the heat sink the IndexBlok ismounted on. The maximum allowable current is as follows:

Fan is controlled by continuously monitoring substrate temperature.

RS485 Serial CommunicationsAll parameters, control functions and feedback data are available through the Serial Interface. The baud rate may be setto 300, 600, 1200, 2400, 4800, 9600 or 19,200 baud. The protocol is no parity, 8 data bits, and 1 stop bit. The

Introduction

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IndexBlok may be set up to have 1 of 31 shouldn’t this be 35? addresses, so that multiple IndexBloks may be addressedfrom the same serial bus. For more information on the serial communications protocol, please refer to the IndexBlokOwner’s Manual.

Serial CableA standard RJ-11 6-Pin cable is used to provide RS485 communications between the IndexBlok, host control device ora remote keypad. Included in this serial cable is a 12 VDC power source.

RJ-12 Connector Description

IndexBlok Configuration ToolA Windows based software tool allows the user to set up all the motor parameters, tune, configure I/O, setup moves andget diagnostic information.• Setup is simplified by a series of setup screens• Files can be stored for duplication of drives, application setup, motor setup and tuning and for on-site and off-site

back-up• Files can be printed for on-site and off-site backup• Feedback and Fault Que screens for diagnostics and setup

Multiple Protection CircuitThe following faults are automatically detected by the IndexBlok control software, and the drive is shut down to protectitself or the load.• Ground Faults• Short Circuit• Over-current• Bus Overvoltage• Bus Undervoltage• Motor faults – motor overspeed, end-of-travel, start with drive disable, home with no defined home, reg move with

no defined reg move• Heatsink Over-temperature• Motor thermal Overload (I2T protection)• Communication loss• External Fault

AC Input PowerThe IndexBlok Series is available to be powered directly from 120VAC, 240VAC or 460VAC.

Introduction

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• XDM1001CCH, XDM1002CCH and XDM1003CCH require 120VAC single-phase input power.• XDM1002DCH, XDM1002CCH require 120VAC, 240VAC single phase or 240 VAC three phase input power for

up to 2kW shaft power• XDM1001DCS, XDM1002DCS, XDM1003DCS, XDM1005DCS, XDM2007DCS AND XDM2010DCS require

240VAC three phase input power.• XDM1001ECS, XDM1002ECS, XDM1003ECS, XDM1005ECS, XDM2007ECS AND XDM2010ECS require

460VAC three phase input power.

EEPROMThe EEPROM (Electrically Erasable Programmable Read Only Memory) stores all the drive parameter settingsincluding the application and motor setup.

ManualThis manual provides a checklist, drawings, specifications and pre-installation information to help select the rightequipment, design the machine that will house the unit, and properly install the IndexBlok Module.

To ensure success, thoroughly read and understand the material presented in each section before you attempt tointegrate an IndexBlok into your equipment. If this is your first design or installation, read each section in the sequencepresented since it is assumed that you know the material presented previously. Once experience with the IndexBlokfamily has been gained, use the manual as a reference source to look up the information needed.

IndexBloks are designed to provide position control of rotary and linear brushless, three phase motors. Themicroprocessor based pulse width modulated (PWM) modules have a very general-purpose I/O and functional featureset, which can be programmed to tailor the unit’s performance and behavior. The manual describes how to go aboutthis customization of hardware and software. These sections are important to read and understand before this task isstarted.

If there are any questions or comments, please contact Semipower through any of the following method.

Tel: 408.273.4230Fax: 408.273.1510Email: info@semipower.com

General Informationsales@semipower.comSales Supportapplications@semipower.comTechnical Support

Web: http://www.semipower.com

Quick Start

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The “Quick Start” is written for a user who is familiar with installing, configuring, and operating motion controlproducts. The following directions assume that the user is familiar with motors, motor drives, any related electricalconnections, and use of Windows95, Windows98 or WindowsNT based software.

SHIPPING CONTENT

Verify that you have the following items:

[Required]v IndexBlok

XDM- 10 05 E- CS- XXXXX| | | | | || | | | | Assembled Drive Configurations| | | | | (with Heatsink and Filter Capacitors)| | | | || | | | Optional CapBlok™| | | | • CS – Standard Capacitance| | | | • CH – High Capacitance| | | | • 00 – No capacitor assembly| | | || | | AC Line Voltage Drive Module Only| | | • C – 120 V The first 8 digits of the ordering part numbers identify| | | • D – 200/240 V the basic drive module| | | • E – 380/460 V| | || | Power Rating Drive Module with CapBlok DC Bus Filter Capacitor| | • 01 ~ 1 kW By including the additional capacitor assembly part| | • 02 ~ 2 kW number to the drive module ordering number, the| | … drive module would be supplied with the appropriately| | • 20 ~ 21.5 kW rated electrolytic filter CapBlok capacitor assembly.| | Each capacitor assembly has its own specifications.| Module Type & Footprint The capacitor assembly and drive module are shipped| • 10 – 0.8 – 6.0 kW together in the same box; however, final assembly is| • 20 – 8.7 – 21.5 kW required.|Control Type Assembled Drive Configurations • XDM – SensorlesServo Indexing Drive Semipower offers standard assembled drive Module configurations that include the CapBlok, heatsink,

fan, and other options. Refer to the IndexBlok Owner’sManual specifying a guide for sizes and options.

v Capacitor Assembly (Semipower offers the CapBlok)v Heatsink (Semipower offers a heatsink)

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v Computer with Windows95, Windows98 or WindowsNT operating systemv RJ-12 6-P Cable (for RS-485 serial communication between the drive and the computer)v RS-232/RS-485 converter (Semipower offers this item under the B&B Electronics part number 485SD9TB). See

Figure 1.

RS-485 RS-232

Figure 1

v RS-232 serial communication cablev Motor (Brushless DC) and its appropriate cablesv Power Cables

[Optional]v Dynamic Brake Resistor Bank (Consult factory for resistor values based upon application)

INSTALLING the IndexBlok

1. Mount the drive module to the HEATSINK if not already mounted.2. Mount the CAPACITOR ASSEMBLY if not already mounted.3. Connect the Dynamic Brake Resistor Bank if appropriate.4. Connect the COMPUTER.

Dynamic Brake

Resistor BankPower Motor

Pin Function1 NA2 AGND3 NA4 AOUT15 AOUT26 AOUT37 +5V8 DIGCOM9 DIN110 DIN211 DIN312 DIN413 DIN514 DIN615 DIN716 DIN817 FANRTN18 +12V19 TERM1

20 TERM2

Computer

Capacitor Assembly

Pin Function21 RLY1 NO22 RLY1 COM23 RLY2 NC24 RLY2 COM25 RLY2 NO

[Note: All digital I/O andanalog outputs areconfigurable.]

Figure 2

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5. Connect the MOTOR.6. Connect the POWER CABLES.

I like this symbol but it isn’t used consistently through the document. Consider using the yellow triangle ! instead.

Without a proper cooling system (e.g., heatsink, fan), the drive module will not operate reliably. Visit thefollowing website address, http://www.semipower.com, for information and tools to design an appropriate coolingsystem.

Without a proper capacitor assembly, the drive module will not operate reliably. Please visit the following websiteaddress, http://www.semipower.com, for information and tools to design a proper capacitor assembly.

Output Current, Wire Size, Circuit Breaker, Fuse Information Table

Module 1001C 1002C 1003C105-132 V, 1-φφ• KW 0.8 1.4 2.0• Drive FLA 4 7.2 10.4• Min Wire Size1 (AWG) 14 14 14• Circuit Breaker Rating, A 15 15 20• Fuse Rating2, A 20 20 25• Fuse Class KTK KTK KTK220V – 240V, 3-φφ 1001D 1002D 1003D 1005D 2007D 2010D• KW 1.4 2.7 3.8 6.0 8.8 11.2• Drive FLA 3.4 6.8 9.6 15.2 22 28• Min Wire Size1 (AWG) 14 14 12 8 8 6• Circuit Breaker Rating, A 20 20 25 40 50 60• Fuse Rating2, A 20 20 25 40 50 60• Fuse Class KTK KTK KTK T T T440v-480vV, 3-φφ 1001E 1002E 1003E 1005E 2007E 2010E 2015E 2020E• KW 1.4 2.7 3.8 6.0 8.8 11.2 16.7 21.5• Drive FLA 1.8 3.4 4.8 7.6 11 14 21 27• Min Wire Size1 (AWG) 14 14 14 14 12 10 8 6• Circuit Breaker Rating, A 15 15 15 20 25 35 40 60• Fuse Rating2, A 15 15 15 20 25 35 40 60• Fuse Class KTK KTK KTK KTK T T T T

1. Based on 90°C rated copper wire in a 30°C ambient. Adjust per NEC or applicable code or different conditions.2. Fuses must be current limiting type, Gould Shawmut ATM, A3T, or A6T or equivalent.

DO NOT APPLY POWER UNTIL ALL ELECTRICAL CONNECTIONS ARE COMPLETED!.

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CapBlok terminal connections are –B, +B, IR [IDM1000]CapBlok terminal connections are IR, +B, -B [IDM2000]

Figure 3

After all the mounts and connections have been completed, the drive module is ready to be powered up and configured.

CONFIGURING the IndexBlok

See IndexBlok Configuration Tool section for drive configuration.

Installation

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Document # 0A-0036-01A, June 2, 1999

This section of the IndexBlok Owner’s Manual provides pre-installation information, an installation checklist,drawings, and specifications to help select the right equipment and properly install the IndexBlok module.

To ensure successful installation, thoroughly read and understand the material presented in this section beforeattempting to design the module into the equipment. If this is the first opportunity to use the IndexBlok, read thissection in the sequence it is presented. Once experience with designing the IndexBlok into machines has been gained,use this section as a reference source.

A. Pre-Installation

This part of the Installation section provides guidelines to consider before designing in or installing the drive module:

• Handling of drive assembly or drive module after delivery• Where to locate the drive module in the machine• Application Considerations• Input Line Considerations• Output Wiring Considerations• Analog and Digital I/O Signal Considerations

1. Handling of drive assembly or drive module after delivery

Although every precaution is taken to ensure that every unit shipped will be in good condition, inspect thedrive after delivery.

If a complete open-frame drive assembly (i.e., IndexBlok and CapBlok on a heatsink) was received:

• Inspect the shipping container for evidence of rough handling immediately after the unit arrives. Reportall damage to the freight carrier and Semipower or your Semipower sales representative.

• Carefully unpack the drive, taking care to save the shipping container and any packing material shouldyou need to return the unit at a later date. Verify that the items on the packing list agree with your order.

• If you are not installing the drive right away, store the drive in a clean, dry area where the ambienttemperature is between 0 to 160°F (-20° to 70°C) and less than or equal to 95% humidity (non-condensing). Ensure that the drive is not subject to corrosive atmosphere (such as H2S).

If a drive module (and associated CapBlok Capacitor Assembly) were received:

• Inspect the shipping container for evidence of rough handling immediately after the unit arrives. Reportall damage to the freight carrier and Semipower or your Semipower sales representative.

• Carefully open the shipping container and remove the packing list (i.e., 1-page summary of content form).Inspect these documents to ensure that you have received exactly what you ordered - paying specialattention to any special product configuration (the last 3 digits of the model number).

• Carefully preserve the shipping container, antistatic bags, etc. Do not destroy or misplace these materialsas they may be needed if a drive is to be returned to the factory.

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• If you are planning to inventory these assemblies, it is strongly recommended that you do so in theoriginal shipping containers in which you received them from Semipower. These boxes not only hold allassociated materials (screws, covers, mating connectors, etc.), but they are clearly labeled and providesignificant mechanical and antistatic protection for your IndexBlok modules.

• An IndexBlok module should be uncrated and removed from its protective antistatic bag only immediatelyprior to assembly into your equipment.

Large drive assemblies or multi-axis assemblies, once mounted to their heat exchanger system, may requiremore than one person to move from one location to another. Observe proper lifting techniques to avoid injurywhen handling heavy electrical equipment.

2. Where to locate the drive module in the machine

Consider the following:

• Since the drive module is IP-20 (0.8 – 21.5 kW)) enclosure, the unit is not suitable for standaloneoperation. It is intended to be mounted in a panel, which provides the primary safety enclosure to protectthe operator of the machine from the hazards of electrical shock that these drives would otherwise exposethe user to.

I suggest deleting this paragraph. The user should design according to a standard like UL508A or NFPA 79.

• IndexBlok-Assembled Drive Configurations are rated for an application at a maximum ambienttemperature of 122°F (50°C) for 0.8 - 6kW (IDM1000) ratings, and 108°F (40°C) for 8.7 – 21.5 kWratings, up to 3,300 feet (1000 meters) above sea level. If the drive is installed in a larger enclosure, themaximum ambient temperature must not be exceeded.

If you need to operate at temperatures exceeding these values, you must de-rate the unit as follows:

v For every 9°F (5°C) over the rated temperature you must de-rate the IndexBlok current ratings by10%. However, do not exceed a maximum temperature of 149°F (65°C) for 1 – 5kW units or 131°F(55°C) for 7.5 - 20Hp units under any circumstances.

In addition, for every 1000 feet (300 meters) above the rated altitude, the IndexBlok current ratings must bede-rated by 2%.

• Drive modules are rated based on a baseplate temperature not to exceed 90°C under worst case operatingconditions. The UL Recognition is only valid if you keep the substrate temperature less than 90°C.

Note: The IndexBlok will trip off due to over temperature at 92±2°C.

CAUTION

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This temperature can be maintained in any number of ways:

v At a reasonable ambient temperature (30° - 60°C), an extruded or bonded fin heatsink and suitableBrushless DC fans are sufficient.

v At a higher ambient temperature (50° - 70°C), an exotic bonded fin design or water-cooled heatexchanger is probably required.

Please refer to our Application Notes and Heatsink Design Tools that are available on our web site or fromyour Semipower sales representative for more details.

• Refer to the drawings in Product Dimensions section for the mounting dimensions of each IndexBlokconfiguration.

• If air will be used to cool the IndexBlok, ensure that there is plenty of ventilating space surrounding thedrive, so that its fan has an unobstructed area to draw from. Refer to the drawings in Product Dimensionsfor ventilation clearances.

3. Application Considerations

When designing into a machine, consider how the drive will be used and what you will expect from it.Different applications, such as industrial process control and HVAC system control, require different driveoptions, different motors or motor types, and special software configuration. Plan how the IndexBlok will beused in order to satisfy the end results.

• An input line impedance of at least 1% and not over 5% is required for proper drive operation. Calculatethe input line impedance to determine whether an input reactor is required. Refer to the discussion onInput Line Considerations later in this section for more details on determining line impedance.

• Order a 3% or 5% input line reactor to improve input line harmonic distortion as required. Refer to thediscussion on Input Line Characteristics later in this section for more details on harmonic distortions.

• A circuit breaker is usually required for disconnecting the motor from the power source.• An input line fuse is ALWAYS required to limit the current available to a failed semiconductor device.

The fuse limits or eliminates the collateral damage that can occur when a drive fails catastrophically, andthe possibility of fire that could occur. While this is a remote circumstance, it is important that allreasonable precaution should be taken to avoid the chance of consequential damages. Refer to thediscussion on Input Line Considerations later in this section for more details on determining the correctfuse type and rating for your application.

a. Motor Selection

Careful consideration of the proper motor is essential to obtain optimum performance from theIndexBlok. Contact your Semipower sales representative or distributor for additional assistanceand/or literature regarding motor Selection and other aspects of drive applications.

• It is designed to be connected directly to a single, three phase Permanent Magnet Brushlessmotor. The motor must be selected and applied so that the average operating motor current and

CAUTION

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kW do not exceed the continuous current and kW ratings of the drive. The intermittent operatingcurrent must not exceed the intermittent current rating of the drive.

• Choosing A MotorToday, most brushless servo motors and drives are oversized with significant amount ofheadroom. Our goal is for you to choose the smallest motor and drive system to meet yourapplication requirements. Choose a motor with the highest BEMF constant by calculating thelargest BEMF constant based on the maximum speed, maximum current and bus voltage (e.g.Max speed = 2000 rpm, Input Voltage = 230VAC, find largest BEMF = 230V rms/2 krpm = 115Vrms = 162 V pk). Where is ‘maximum current’ used in the example? For more information,contact our Application Engineering Department and request our Sizing and Selection Tool.

• Preferred Motor SpecificationsSemipower recommends the following motor specification to provide the best motor-driveperformance. Motors near the minimum BEMF constant and maximum resistance will yield poorperformance (min. speed, etc). Selecting a motor which fits in the Optimum (Opt) valuesprovides the BEST performance. I reformatted the tables below for readability.

Preferred BEMF (Kv, Vpk, L-L/Krpm) Parameter for Rotary MotorsRotary Motor For 115VAC and 230VAC Operation For 480VAC Operation

Minimum Optimum Minimum Optimum2 Pole Motor 15 Vpk/krpm 45 - 85 Vpk/krpm 30 Vpk/krpm 90 - 170 Vpk/krpm4 Pole Motor 30 Vpk/krpm 90 - 170 Vpk/krpm 60 Vpk/krpm 180 - 340 Vpk/krpm6 Pole Motor 45 Vpk/krpm 135 - 255 Vpk/krpm 90 Vpk/krpm 270 - 510 Vpk/krpm8 Pole Motor 60 Vpk/krpm 180 - 340 Vpk/krpm 120 Vpk/krpm 360 - 680 Vpk/krpm

Preferred BEMF (Kv, Vpk, L-L/Hz) Parameter for Linear Motors for IndexBlok OnlyLinear Motors For 115VAC and 230VAC Operation For 480VAC Operation

Minimum Optimum Minimum OptimumLinear Motors 0.8 Vpk/Hz 2.4 - 4.5 Vpk/Hz 1.6 Vpk/Hz 4.8 – 9.0 Vpk/Hz

Model Type Drive’sI.rated, cont.(Arms)

MinimumMotor’s

Irated

(Arms)

R_min(l-l ohms)

R_opt(l-l ohms)

R_max(l-l ohms)

L_min(l-l mH)

L_max(l-l mH)

120VACXDM1001C 4.0 1.0 1.2 4.4 18 6.5 69.9XDM1002C 7.2 1.8 0.6 2.3 9.1 3.2 35.0XDM1003C 10.4 2.6 0.4 1.5 6.1 2.3 23.3240VACXDM1001D 3.4 0.85 1.2 4.4 18 6.5 69.9XDM1002D 6.8 1.7 0.6 2.3 9.1 3.2 35.0XDM1003D 9.6 2.4 0.4 1.5 6.1 2.3 23.3

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XDM1005D 15.2 3.8 0.2 0.75 3.0 1.4 11.7XDM2007D 22 5.5 0.15 0.56 2.3 1 8.7XDM2010D 28 7 0.1 0.375 1.5 0.78 5.8480VACXDM1001E 1.7 0.43 4.8 18 72 25 275.4XDM1002E 3.4 0.85 2.4 9 36 13 137.6XDM1003E 4.8 2.4 1.6 6 24 9 91.8XDM1005E 7.6 1.9 0.8 3 12 5.8 45.9XDM2007E 11 2.75 0.6 2.25 9.0 4 34.4XDM2010E 14 3.5 0.4 1.5 6.0 3.1 23.0XDM2015E 21 5.25 0.2 0.75 3 2.1 17.2XDM2020E 27 6.75 0.1 0.4 1.5 1.6 11.5

Personal injury or equipment damage may occur when you operate a motor and drivenmachines above their ratings. Make certain that you do not exceed the rated maximum operationof any component in your motion system. Refer to the motor manufacturer’s datasheet to verifysafe motor speed.

ALWAYS use mechanical guards and shields to protect the user before operating at any speed.

b. Heatsinking and Thermal Design - Cooling the IndexBlok Module

The total energy delivered from the motor shaft has to flow through the drive module - and the morerugged the application is the more heat the IndexBlok will generate. Keep the IndexBlok mountingsurface below 90ºC under absolute worst case conditions. Internal device temperatures areguaranteed to be at safe levels if you do not exceed maximum rated RMS output current and maintainthe baseplate at or below 90ºC. Failure to follow this guideline will cause nuisance overtemperature trip and may degrade the life of the IndexBlok module.

There is a more information on Semipower’s web site concerning this critical issue. Find andevaluate the Application Notes and software tools provided to calculate the required deviceheatsinking and airflow to maintain a reliable design margin.

4. Input Line Considerations

All wiring must comply with the requirements of the National Electrical Code (NEC) and/or other codes asrequired by the authority having jurisdiction over the installation or machine in which the drive module isinstalled. The installer or system integrator must ensure that the electrical connections at the site conform tothe connection diagrams provided in this manual.

I suggest deleting this note. Not all AHJ’s immediately adopt the most recent version of the Code. Oregon, for example, won’t formallyadopt the 1999 NEC until next year.

DANGER

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Table 2 should use consistent units. Wire size is in AWG not mm, so lengths should be in feet not meters. The three wire size columnsare confusing. 100m or less, OK. 500m? What does this mean? 100 to 500m? Over 500m? 100 to 1000m? The voltage drop seemspretty high. My cheap cardboard voltage drop slide rule from Southwire tells me that a 14AWG, copper wire will drop 15V at 325ft at 8amps. This is 18%. 3-5% maximum would be a better design target. I didn’t check the other sizes. Generally, the maximum circuitprotection on a 14AWG wire is limited by Code to 15A. A 14AWG wire would be too small for a 2.1kW drive.

Table 2: Input Line ConsiderationsModuleType

DrivePowerrated,

Input Output Wire Size (AWG)

kW Voltage 1-φ,VAC

Freq,Hz

IRMS, amps Voltage3- φ,VAC

Freq,Hz

IRMS,amps

<100m(325 ft)

500m? 1000mor more

XDM1001C 0.8 120 50/60 7.6 0-120 0-400 4.0 14 10 8

XDM1002C 1.4 120 50/60 13.7 0-120 0-400 7.2 14 8 6

XDM1003C 2.1 120 50/60 19.8 0-120 0-400 10.4 12 6 4

Voltage 3-φ,VAC

Freq,Hz

IRMS, amps Voltage3- φ,VAC

Freq,Hz

IRMS,amps

100mor less

500m 1000mor more

XDM1001D 1.4 200-240 50/60 4.0 0-240 0-400 3.6 14 10 8

XDM1002D 2.7 200-240 50/60 7.5 0-240 0-400 6.8 14 8 6

XDM1003D 3.8 200-240 50/60 10.6 0-240 0-400 9.6 14 6 4

XDM1005D 6.0 200-240 50/60 16.7 0-240 0-400 15.2 12 6 4

XDM2007D 8.7 200-240 50/60 24 0-240 0-400 22 10 4 2

XDM2010D 11.2 200-240 50/60 31 0-240 0-400 28 8 2 1

XDM1001E 1.4 380/480 50/60 2.5 (for 380 VAC)

2.0 (for 460 VAC)

0-480 0-400 1.8 14 14 12

XDM1002E 2.7 380/480 50/60 4.7 (for 380 VAC)

3.7 (for 460 VAC)

0-480 0-400 3.4 14 12 10

XDM1003E 3.8 380/480 50/60 6.7 (for 380 VAC)

5.3 (for 460 VAC)

0-480 0-400 4.8 14 10 8

XDM1005E 6.0 380/480 50/60 10.7 (for 380 VAC)

8.4 (for 460 VAC)

0-480 0-400 7.6 14 8 6

XDM2007E 8.7 380/480 50/60 15.0 (for 380 VAC)

12.1 (for 460 VAC)

0-480 0-400 11 14 6 4

XDM2010E 11.2 380/480 50/60 20.0 (for 380 VAC)

15.0 (for 460 VAC)

0-480 0-400 14 12 6 4

XDM2015E 16.7 380/480 50/60 30.0 (for 380 VAC)

23.0 (for 460 VAC)

0-480 0-400 21 10 4 2

XDM2020E 21.5 380-480 50/60 37.0 (for 380 VAC)

30.0 (for 460 VAC)

0-480 0-400 27 8 2 1

a. Input Line Conductor and Circuit Overload Protection Selection

• The input line conductors must be made of copper with a temperature rating of at least 167º F(75º C). Use a conductor of at least the size specified in Table above.

• Note: Verify that the input line conductor size and branch circuit overload protection are inaccordance with applicable local code requirements.

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• The input line and branch circuit overload protection must be rated for the input voltage andcurrent stated on the nameplate of the drive, and repeated here in Table.

• In addition, consider the wire size capacity of the integral module input line terminals:

v For IDM1000 type modules maximum wire size is #8 AWGv For IDM2000 type modules maximum wire size is #4 AWG

I wouldn’t recommend this. Nearly every electrical inspector will reject the installation.Best design practice would be to always place the drive as close as possible to the motor anduse the appropriate wire. The power terminal tightening torque range is 16-18 in. lbs. onthese power terminals (including L1, L2, L3, T1, T2, T3, and the ground lugs).

• Input Line Fuses are required for safe application of the drive module or open-frame drive.These fast acting fuses are designed to limit the let-through current by disconnecting the drivefrom the power line in the event of a catastrophic failure of the power semiconductors in thedrive; and to reduce or eliminate the chance of consequential damage to the drive and anyassociated equipment in the machine. What about current limiting CBs? Fuse recommendationsare listed in Table 3 .

Table 3: Input Line Conductor and Circuit Overload Protection SelectionModule Type Drive Powerrated,

kWVoltage 1-φφ or

3-φφ , VACIinput , A 3-φφ Line Fuse

(Bussman typesshown)

Fuse Class BranchCircuit

Breaker

XDM1001C 0.8 120 14.4 KTK-20 KTK 15XDM1002C 1.4 120 26.0 KTK-20 KTK 15XDM1003C 2.1 120 37.6 KTK-25 KTK 20XDM1001D 1.4 200-240 4.4 (3- φ)

7.6 (1-φ)KTK-20 KTK 15

XDM1002D 2.7 200-240 8.2 (3- φ)14.2 (1-φ)

KTK-20 KTK 15

XDM1003D 3.8 200-240 20.1 (3- φ)11.7 (1-φ)

KTK-25 KTK 20

XDM1005D 6.0 200-240 31.7 (3- φ)18.4 (1-φ)

JJN-40 300V T 30

XDM2007D 8.7 200-240 45.6 (3- φ)26.4 (1-φ)

JJN-50 300V T 40

XDM2010D 11.2 200-240 58.9 (3- φ)34.1 (1-φ)

JJN-60 300V T 60

XDM1001E 1.4 380480

2.82.2

KTK-10 KTK 15

XDM1002E 2.7 380480

5.24.1

KTK-10 KTK 15

XDM1003E 3.8 380480

7.45.8

KTK-15 KTK 15

XDM1005E 6.0 380 11.8 KTK-20 KTK 15

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480 9.2XDM2007E 8.7 380

48016.513.3

JJS-25 600V T 20

XDM2010E 11.2 380480

22.016.5

JJS-35 600V T 30

XDM2015E 16.7 380480

33.025.3

JJS-50 600V T 40

XDM2020E 21.5 380480

40.733.0

JJS-60 600V T 60

Input Branch Protection - a circuit breaker or equivalent - may be required for your application. Inaddition, some suitable means of safety power disconnect is almost certainly required so that theIndexBlok and the machine may be safely serviced. NEC 430-102(a), 1999: An individualdisconnecting means shall be provided for each controller and shall disconnect the controller. Ensurethat the correct methods applied are in conformance to any and all machinery directives and theNational Electrical Code or your local electrical codes.

b. Grounding Connections

For personal safety and reliable equipment operation, firmly connect each chassis to earth ground asshown in the connection diagrams in the Drawings section of this manual.

The IndexBlok chassis ground conductor should be the same size as the input line conductors or sizedaccording to electrical code requirements. Use a copper or aluminum conductor. Connection to agrounded conduit does not provide an adequate equipment ground. Ensure that all operators’control stations and motor frames are adequately grounded.

c. Input Line Impedance

Ensure that the input line power has an impedance of at least 1% and less than or equal to 5% relativeto the IndexBlok nominal rating for proper operation. Damage to the drive may occur if the sourceimpedance is less than 1%. If the source impedance is more than 5%, the drive may not provide ratedoutput voltage.

Actual input current varies considerably in response to the load on the motor connected to theIndexBlok and the impedance of the power source. Since power source impedance has an effect onthe harmonic content of the input current, the amount of impedance affects the value of the input linecurrent and the input current harmonic distortion.

The value of source impedance is expressed as a percent of the effective impedance of the drive. Todetermine the source impedance of a drive, you must know:

• The short circuit capacity of the power source at the drive’s input power terminals.• The full load (output) current rating of the drive (found on the nameplate).

DANGER

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The following calculation provides the source impedance as a percent of the effective impedance ofthe drive:

Full Load Current * 100 = Source Impedance * Short Circuit Capacity

The short circuit capacity must be at least 20 times the full load current rating (5% input impedance)and no more than 100 times the full load current rating (1% input impedance).

For example, if the full load (output) current of your IndexBlok drive is 22 amps and the short circuitcurrent capacity of the power source is 2200 amps, the source impedance is:

(22 * 100) / 2200 = 1%

Since the design of a power distribution system often includes a short circuit capacity study, powerdistribution system drawings or other distribution system documentation may show the short circuitcapacity at various points. In Table 4, the proper line reactance (i.e. inductor value) at varyingimpedance levels for all drive models is shown.

Table 4: Input Line Impedance [Line reactors are not needed for single phase voltage input.]Module Type Voltagerated,

VACCurrentrated, A 1%

Inductance, mH3%Inductance, mH

5%Inductance, mH

XDM1001C 120, 1-φ 7.6 NA NA NAXDM1002C 120, 1-φ 13.7 NA NA NAXDM1003C 120, 1-φ 19.8 NA NA NAXDM1001D 230, 1-φ 3.6 NA NA NAXDM1002D 230, 1-φ 6.8 NA NA NAXDM1003D 230, 1-φ 9.6 NA NA NAXDM1001D 230, 3-φ 3.6 0.978 2.940 4.890XDM1002D 230, 3-φ 6.8 0.518 1.550 2.590XDM1003D 230, 3-φ 9.6 0.367 1.100 1.830XDM1005D 230, 3-φ 15.2 0.232 0.700 1.160XDM2007D 230, 3-φ 22 0.160 0.480 0.800XDM2010D 230, 3-φ 28 0.126 0.380 0.630XDM1001E 460, 3-φ 1.8 3.914 11.740 19.570XDM1002E 460, 3-φ 3.4 2.072 6.220 10.360XDM1003E 460, 3-φ 4.8 1.468 4.400 7.340XDM1005E 460, 3-φ 7.6 0.927 2.780 4.630XDM2007E 460, 3-φ 11 0.640 1.920 3.200XDM2010E 460, 3-φ 14 0.503 1.510 2.520XDM2015E 460, 3-φ 21 0.335 1.010 1.680XDM2020E 460, 3-φ 27 0.261 0.780 1.300

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d. Harmonic Distortion

As previously stated, Input Line source impedance can affect the harmonic content of the input linecurrent. As source impedance increases, line current harmonic content decreases.

The relationship between Input Line impedance and harmonic voltage distortion is just the opposite:as source impedance increases, so does harmonic voltage distortion.

For example, if the source impedance is 1%, you will cause less than 5% harmonic voltage distortionwhen you connect a single IndexBlok to an undistorted power source. If the source impedanceincreases to 5%, the resulting harmonic voltage distortion is less than 10%.

Contact your Semipower sales representative or distributor for assistance in estimating harmonicdistortion in multiple drive installations. We can also provide assistance in selecting a means ofharmonic reduction such as line reactors.

e. Input Line Routing

• If conduit is used, use a separate conduit for input line conductors and output power conductors.NEVER route analog and digital wiring from any equipment in the same conduit as input oroutput power wiring.

• If cable trays are used, use a separate cable tray for input line conductors and output lineconductors. NEVER route analog and digital wiring from any equipment in the same cable trayas input or output power wiring.

• ALWAYS route the Input and Output Grounding conductors in the same conduit or cable tray asthe respective Input or Output power leads. Preferably, these conductors should be bundled.

• If multi-conductor wiring is used, a separate multi conductor cable must be used for the input linewiring for each drive.

f. Isolation Transformers

Isolation transformers can be used with drive modules. Remember that the input line impedance mustbe at least 1% and not over 5% with the drive running. See the previous discussion on Input LineImpedance.

g. Power Factor Correction

The displacement power factor at the input terminals of the drive is approximately 0.95 at alloperating speeds and loads. Power factor correction capacitors are not required. Furthermore, theycannot alone improve Power Factor and should not be installed. If capacitors for correcting the power

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factor of other equipment are installed too close to the drive, nuisance tripping of the drive may beexperienced.

h. Standby Power Generation

Three phase standby power generators can be used with drive modules as long as the input lineimpedance is within the 1% to 5% range.

5. Output Wiring Considerations

To comply with local and nationally recognized codes, such as the NEC, consider proper output power wiresizing and layout when planning the machine design and IndexBlok installation.

Note: Use the most currently approved version of all applicable codes when installing the IndexBlok.

a. Output Power Conductor and Ground Conductor Sizing

These conductor-sizing issues were discussed in the previous section and Table 3. Refer to thatsection for details.

b. Output Power Conductor Routing

Long output cable runs from multiple drives in the same raceway present a unique safety concern.Since the output leads are electrically coupled when they share the same raceway , the PWM action ofthe inverter power stage in one unit can couple sufficient energy into the DC link of anotherunpowered drive to present an electrical shock hazard.

NEVER work on a drive when other drives are energized in the system.

Although the input power has been opened, NEVER assume the drive is intrinsically safe.

Verify that the DC link is below 30 VDC with a voltmeter before commencing service.

• If conduit is used, use a separate conduit for input line conductors and output power conductors.NEVER route analog and digital wiring from any equipment in the same conduit as input oroutput power wiring.

• If cable trays are used, use a separate cable tray for input line conductors and output lineconductors. NEVER route analog and digital wiring from any equipment in the same cable trayas input or output power wiring.

• ALWAYS route the Input and Output Grounding conductors in the same conduit or cable tray asthe respective Input or Output power leads. Preferably, these conductors should be bundled.

• If multi-conductor wiring is used, a separate multi conductor cable must be used for the input linewiring for each drive.

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c. Overcurrent Protection

Drive modules are designed to automatically provide overcurrent protection for the output powercircuit if only one motor is connected to the drive and sized to match the drive.

If more than one motor is connected to the drive, each motor must have its own overcurrentprotection. In addition, the combined current rating on the nameplate of each motor must not exceedthe output current rating of the drive.

d. Power Factor Correction

Power factor correction capacitors must NEVER be connected to the output of the drive. They willcause severe damage to the drive and would not serve any useful purpose.

6. Analog and Digital I/O Signal Considerations

Comply with local and nationally recognized codes when designing and installing the IndexBlok in theequipment. Consider proper analog and digital signal wiring practices carefully when you planning theapplication.

a. Analog and Digital Signal Wiring

• 18 AWG wire size is recommended. Minimum wire size is 20 AWG; maximum is 14 AWG.• One conductor per terminal for 14 AWG conductors. Two conductors per terminal at 18 AWG.

Three conductors per terminal at 20 AWG.• Maximum length is 500 feet.• Use shielded cable for the analog signal conductors where indicated on the terminal block

connection diagram. Typically, shielding is required for all analog input and output runs.• All digital signal runs should be shielded.• Ground the shield conductor of shielded cable at both ends of the terminal block of the drive for

input signals only. Why doesn’t this create a ground loop? I’ve always grounded only one endof a shielded cable no matter what the signal. Output signals should not be grounded at the driveend of the cable but should be grounded at the device. Shields should be grounded wherever thebest ground can be found. All grounds being equal, the shield should be grounded at the signalsource, which for an output, would be at the drive.

• The analog and digital signal conductors must be made of copper with an insulation temperaturerating of at least 167°F (75°C).

b. Analog and Digital Conductor Routing

If conduit is used, use separate conduit for input and output power and IndexBlok control wiring, upto the drive. If cable trays are used, NEVER route analog and digital wiring from any equipment inthe same cable tray as input or output power wiring.

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Separate analog and digital wiring for the IndexBlok from other control equipment wiring by using ametal tray divider or by bundling to keep the conductors at least 2 inches apart.

Trays containing analog and digital wiring should be separated fromtrays containing AC powerwiring.

Too many different standards differ on the terms “low”, “medium” and “high” voltage. Dependingon the standard, low voltage can be less than 1000VAC (NFPA 70B) or as little as 100VA (limit forOregon limited energy electricians). Generally, always keep signal cables separate from AC powercables regardless of the voltage.

c. Analog Output Connections

There are thee analog outputs. The outputs have 8-bit resolution and produce an output voltage of 0 –10 volts. The outputs are protected from continuous overload of up to +25/-5 VDC. There is noisolation from internal logic supply.

The outputs are configurable from a list of functions. [See Analog Output Section.]

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Analog Output Connection & Schematic

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d. Digital Input Connections

There are eight digital inputs. The inputs are intended for dry contact closure and open collector use.These inputs can be configured as sourcing, sinking or passive closure and are programmable from alist of 19 functions. The logic threshold is 2.5 V. The inputs are protected from continuous overloadof up to +25/-5 VDC (where shared I/O PIN 15 and 16 require a minimum external impedance of750Ω due to their dual functions). There is no isolation from internal logic supply.

The six digital input pins (i.e., PIN 9 through 14) may be configured to be all PULLED UP orPULLED DOWN.

The two digital input/output pins (i.e., PIN 15 and 16) are PULLED UP only.

Two of the digital inputs (i.e., DIN1 and DIN2) are high-speed inputs for a home or registration input.

The inputs are configurable from a list of functions. [See Digital Input Section .]

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Digital Input Connections & Schematicsf. Digital Output Connections

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There are two open-collector outputs. The outputs can be externally pulled up to +5VDC, +12 VDC,or +24 VDC and are rated at 50 mA. The outputs are internally pulled up to +5V through 4.7kΩ . Theresponse time is 2 msec.

The outputs are configurable from a list of functions. [See Digital Output Section.]

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7. Braking Resistor

Provisions are made for the connection of an external braking resistor when braking is required. There is noprovision for an internal braking resistor. The braking transistor is protected from ground fault and shortcircuit via internal circuits. When no braking resistor is provided, braking torque is limited to the powerconsumed by the internal and external losses. Braking transistor duty cycle and frequency vary depending onthe required braking torque, the total bus capacitance, the line voltage, and the brake circuit inductance. Thebraking circuit activates at a DC bus voltage of 410 VDC for 200/240 VAC drives and 820 VDC for 380/480VAC drives. The braking resistor value can be no lower than the minimum specified value. The inductance ofthe braking resistor (and associated wiring) can be no larger than the maximum value specified.

Table 5: Braking ResistorModule Type Voltage Class, VAC Braking

Resistanceminimum , ΩΩInductancemaximum ofBraking Resistor, mH(including wiring)

XDM1001C 120 25 4.6XDM1002C 120 25 4.6XDM1003C 120 18 3.0XDM1001D 200-240 50 2.3XDM1002D 200-240 50 2.4XDM1003D 200-240 35 1.5XDM1005D 200-240 20 0.9XDM2007D 200-240 15 0.6XDM2010D 200-240 10 0.5XDM1001E 380-480 200 9.0XDM1002E 380-480 200 9.0XDM1003E 380-480 140 6.0XDM1005E 380-480 80 3.6XDM2007E 380-480 60 2.4XDM2010E 380-480 40 1.8XDM2015E 380-480 30 1.2XDM2020E 380-480 20 0.9

Power resistors are specified by four characteristic ratings: Resistance, Power (average power rating in Watts),Peak Power or Energy (maximum short duration power handling in Joules), and Rated Working Voltage (ratedoperating terminal voltage in Volts). In addition, the thermal time constant of the resistor must be known toproperly evaluate its suitability as a braking resistor and to protect it in the application.

a. Resistor Value

First, in selecting the correct braking resistor, the required resistance value must be solved. Therequired resistance value is relatively easy to solve based upon basic motor, drive, and application

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setup information. The motor torque rating (given by current and BEMF for a BLDC motor), brakingload limit (the percentage value set in IB Config), and the maximum speed in this application must beknown. Motor torque rating and braking load limit will provide the maximum braking torque.Maximum braking torque times maximum speed will provide the peak braking power. The maximumresistance value that we can use is:

Resistancemaximum = Voltagebraking2/Powermaximum braking, where

Powermaximum braking = Torquerated motor * (Load Limitbraking/100) * Speedmaximum

[Note: For Voltagebraking, use 375 VDC for a 230 VAC drive and 750 VDC for a 480 VAC drive.]

Remember that this value is a maximum resistance when hot. Therefore, select a convenient valueless than this calculated, but not less than about half this value. Also, in order to protect the drive,never select a resistor value smaller than the minimum braking resistor value from the Table 5.

If you think that a smaller value resistor is necessary for a particular drive module type, then the nextlarger drive module for this application is recommended.

b. Average Power Rating

Next, braking resistor’s power rating must be determined. The power rating of the resistor can onlybe calculated if the frequency of how often the drive brakes and the time duration of how long thebraking should be is known. The average power during braking the load from maximum speed tozero speed is equal to half the peak power that you calculated above for linear or S-curve ramps. Ifthe application brakes in Time stop seconds and does this every Time repeat seconds then, the duty cycleis:

Duty Cycle = Timestop/Timerepeat

Powerminimum rating = Duty Cycle * (Powermaximum braking/2)

Example 1:

A drive configured for 200% Load Limitbraking is running a BLDC motor rated at a Ke of 80Volts/kRPM (line-to-linepeak), Speedrated motor of 4000 RPM and a Currentrated motor (0-to-peak) of 5Amps. The drive runs from 4000 RPM to -4000 RPM and back to 4000 RPM continuously as oftenas possible. What is the required resistance and power rating of the braking resistor for thisapplication?

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Torquemotor rating = (0.00827) * Ke * Currentrated motor

= (0.00827) * (80 Volts/kRPM)) * (5 Amps)= 3.308 N-m

Powermaximum braking = Torquerated motor * (Load Limitbraking/100) * Speedmaximum

= 2.208 N-m * (200/100) * (4000 RPM* 2π rad/rev * (1 min/60 sec))= 2771 Watts

Resistancemaximum = Voltagebraking2/Powermaximum braking

= (375 VDC)2/2771 Watts= 50.7 Ω . Select a 40 Ω resistor, which is the next smaller standard resistance rating.

In order to understand how hot the resistor will get, Poweraverage resistor must be determined.

Duty Cycle = Timestop/Timerepeat

= 0.50 since the motor is accelerating one half of the time and decelerating on the other half of thetime.

Powerminimum rated = Duty Cycle * (Powermaximum braking/2)= 0.50 * (277 Watts/2)= 693 Watts. Select a 1000-Watt resistor, which is the next larger standard power rating.

For most applications, sizing can stop right here – there is enough information to order a brakingresistor. However, there are several additional things to be aware of.

c. Special Consideration - Resistor Construction and Energy Ratings

First, the Peak Power or Energy ratings of a resistor depend on its internal construction. A typicalpower wire-wound resistor consists of a resistance wire wound on a hollow ceramic core and weldedto the electrical terminations (e.g., wiring lugs or leads) at each end. If this type of resistor is hit witha large pulse of power, despite a short duration, mechanical stresses at these terminations will beproduced that will cause the resistor to fail prematurely in your machine. Typically, a wire-woundresistor can tolerate 3:1 to 5:1 peak to average power for very short power pulses.

In Example 1, a wire-wound resistor would be a poor choice. Peak to average power is 5595/250 =22.4:1. In example 2, a wire-wound is a good candidate because peak to average power is 2771/1000= 2.77:1. If the wire-wound resistor can be used, buy it. It is usually less expensive and more readilyavailable.

So what do you do when a higher ratio of peak to average power is needed? First, speak with thewire-wound resistor vendor. Several vendors make specially constructed wire-wound resistors thathave a higher Peak Power rating, but it is unlikely that these resistors will be found in the catalog.Contact technical support of the resistor manufacturer.

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The other alternative is to choose a resistor constructed to handle high Peak Power. Several vendorsspecialize in resistors constructed specifically for pulse power applications. Carborundum and HVRAdvanced Power Components are two of the best vendors. Each vendor manufactures a line of solidceramic resistance elements that heat uniformly during the power pulse, thus eliminating thetermination problem inherent in wire-wound resistor construction. These resistors can handlebasically ANY peak power, as long as it does not overheat the entire resistive element; and, therefore,typically rate themselves in Joules (i.e., the number of Watt-seconds that can be delivered withoutraising the temperature too high in a single pulse).

The energy rating required of our application, assuming Time stop is short with respect to the thermaltime constant of the resistor, is:

Energyminimum rated = Timestop * (Powermaximum braking/2)

In example 1, a ceramic resistor capable of at least 1 sec * 5595/2 = 2800 J in addition to the 250 Waverage power rating would be needed. This is a hefty resistor. [Note: Remember that 1 J of energy raises1gm of water 1° C. Therefore, this resistor if it had the same density as water and was 2.5 x 12.5 cm (1in dia x 5in long) wouldheat up to 89.6° C every time you stopped the motor - WOW!]

d. Working Voltage

Normally, the working voltage is not a problem. By the time, a resistor is large enough to handle thepower of a large motor is obtained, it can easily support the voltages applied. However, for smallerdrives this may not be the case. It is recommended that a resistor be rated as follows:

DriveVoltagerated, VAC

Voltageapplied(typical),

VDC

WorkingVoltageminimum

rated(recommended),

VDC240 375 500380/480 750 1000

Table 6

Failure to do so could conceivably lead to insulation failure or could be a fire hazard. BECAREFUL!

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e. Using IB Config to protect the braking resistor

IB Config has a dialog box in which the following brake settings (i.e., Load Limit, Power, and TimeConstant) are entered. With an accurate thermal model, the IndexBlok can keep track of how muchenergy has been dissipated in the braking resistor and estimate its operating temperature in real time,protecting itself from an overload that would damage it.

By default, IB Config assumes that the braking resistor has a load limit of 150%, power rated at zeroWatts (i.e., there is no braking resistor; and, no attempt to perform braking will take place) and athermal time constant of 60 sec.

The power (i.e., average power rating) of the braking resistor must be entered. Any non-zero valueenables the dynamic braking function.

If the thermal time constant data from the resistor manufacturer is known, enter it. Unfortunately, thisdata is generally not available; therefore, the time constant must be estimated, either analytically orempirically, or measured directly. Measuring or analytically determining the correct value isrelatively difficult and beyond the scope of this owner’s manual; however, the time constant can beestimated within the ballpark by looking at the construction of the resistor:

• If a wire-wound resistor that is designed to be bolted to a heatsink and cooled by conduction is used,then the thermal time constant is usually very short - in the 5 - 10 second range.

• If the more common wire-wound resistor style (i.e., constructed by winding the resistance elementabout a hollow ceramic core and finishing with a vitreous enamel or epoxy dip) is used, then thethermal time constant is relatively long - in the 60 - 180 second range. In general, keeping the defaultsetting is the most conservative approach.

• If a solid ceramic resistor like the ones described previously by HVR or Carborundum is used, thenthe thermal time constant is typically in the middle - in the 30 - 60 second range.

• In the absence of any more concrete data from the manufacturer, use the default setting.

Once brake settings have been entered, the IndexBlok will ensure that it will not damage the brakingresistor, even if it has been undersized for the application.

8. Fan

Provision is made to power external 12 VDC fan(s) to provide forced air cooling of the heat sink theIndexBlok is mounted on. See Table 7 for the maximum allowable current. See Figure 8 for the wiringdiagram of the fan(s) the drive.

Module Type Allowable Fan StartCurrent, A

Allowable Fan RunCurrent, A

Voltage, VDC

XDM1001D 0.6 0.3 12.6XDM1002D 0.6 0.3 12.6XDM1003D 0.6 0.3 12.6

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XDM1005D 0.6 0.3 12.6XDM2007D 1.2 0.6 12.6XDM2010D 1.2 0.6 12.6XDM1001E 0.6 0.3 12.6XDM1002E 0.6 0.3 12.6XDM1003E 0.6 0.3 12.6XDM1005E 0.6 0.3 12.6XDM2007E 1.2 0.6 12.6XDM2010E 1.2 0.6 12.6XDM2015E 1.2 0.6 12.6XDM2020E 1.2 0.6 12.6

Table 7

9. Capacitor Assembly

Semipower offers an electrolytic filter capacitor coupled with the appropriate module type or as a separate itemaltogether. In Table 8, the capacitance is given for the standard CapBlok for the respective module type.

In the event that more capacitance is desired for a given drive module, a higher capacitance CapBlok can beused. However, there are few restrictions:

• The higher capacitance CapBlok must have the same voltage rating as the CapBlok it is replacing.• A CapBlok used on a XDM100xx module type can only be used on another XDM100xx module type. For

example, a CapBlok used on an XDM1005D module type can be used on an XDM1001D module type.• A CapBlok used on a XDM2010x module type can only be used on the XDM2010x and XDM2007x

module types.• A CapBlok used on an XDM2020E module type can only be used on the XDM2020E and XDM2015E

module types.

Module Type Capacitance ofCapBlok, µµ F

XDM1001C-CH 2800XDM1002C-CH 4200XDM1003C-CH 4200XDM1001D-CS 540XDM1001D-CH 1080XDM1002D-CS 1080XDM1002D-CH 1620XDM1003D-CS 1080XDM1003D-CH 1620XDM1005D-CS 1620XDM2007D-CS 3000XDM2010D-CS 3000XDM1001E-CS 135

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XDM1002E-CS 270XDM1003E-CS 270XDM1005E-CS 405XDM2007E-CS 750XDM2010E-CS 750XDM2015E-CS 1350XDM2020E-CS 1350

Table 8

Ratings

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A. Series 1000 Ratings

IndexBlok Module Number 1001C

1002C

1003C

1001D

1002D

1003D

1005D

1001E

1002E

1003E

1005E

AC Line Input Voltage VAC 120V ± 10% 200/240V ± 10% 380/480V ± 10%Continuous OutputCurrent (RMS)

Arms 4.0 7.2 10.4 3.4 6.8 9.6 15.2 1.7 3.4 4.8 7.6

Peak OutputCurrent (RMS)

Arms 8.0 14.4 20.8 6.8 13.6 19.2 30.4 3.4 6.8 9.6 13.2

Drive Power 1 kW .8 1.4 2.1 1.4 2.7 3.8 6.0 1.4 2.7 3.8 6.0

NominalOutputPowerRatings

Current Overload % 150% for 1 min., 200% for 3 sec.Power Dissipation(typ)

W 32 57 76 35 64 94 137 49 77 101 140

Thermal Impedance °C/W 0.04 °C / W

ModuleThermalRatings

Base Plate Temp(max)

°C 90°CModule Dimensions In/

mm3.0 x 4.5 x 1.7 in. / 100 x 122 x 43.6 mm

1 Drive Power (kW) = (Input Voltage rms) * (Cont Current rms) * SQRT(3)

B. Series 2000 Ratings

IndexBlok Module Number 2007D 2010D 2007E 2010E 2015E 2020EAC Line Input Voltage VAC 200/240V ± 10% 380/480V ± 10%

Continuous OutputCurrent (RMS)

Arms 22 28 11 14 21 27

Peak Output Current(RMS)

Arms 44 56 22 28 42 54

Drive Power 1 kW 8.7 11.2 8.7 11.2 16.7 21.5

NominalOutputPowerRatings

Current Overload % 150% for 1 min., 200% for 3 sec.Power Dissipation(typ)

W 215 276 192 240 346 436

Thermal Impedance °C/W 0.03 °C / W

ModuleThermalRatings

Base Plate Temp °C 90°CModule Dimensions In/ mm 4.57 x 5.59 x 1.7 in. / 116 x 142 x 43.6 mm

1 Drive Power (kW) = (Input Voltage rms) * (Cont Current rms) * SQRT(3)

Motor Selection – Preferred Motor Specifications

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A lot of this section is repeated from an earlier section. I suggest deleting one or the other…Choosing A MotorToday, most brushless servo motors and drives are oversized with significant amount of headroom. You should choosethe smallest motor and drive system to meet your application requirements. Choose a motor with the highest BEMFconstant by calculating the largest BEMF constant based on the maximum speed, maximum current and bus voltage(e.g. Max speed = 2000 rpm, Input Voltage = 230VAC, find largest BEMF = 230V rms/2 krpm = 115 Vrms = 162 Vpk). For more information, contact our Application Engineering Department and request our Sizing and Selection Tool.

Preferred Motor SpecificationsSemipower recommends the following motor specification to provide the best motor-drive performance. Motors nearthe minimum BEMF constant and maximum resistance will yield poor performance (min. speed, etc). Selecting amotor which fits in the Optimum (Opt) values provides the BEST performance.

Preferred BEMF (Kv, Vpk, L-L/Krpm) Parameter for Rotary MotorsRotary Motor For 115VAC and 230VAC Operation For 480VAC Operation

Minimum Optimum Minimum Optimum2 Pole Motor 15 Vpk/krpm 45 - 85 Vpk/krpm 30 Vpk/krpm 90 - 170 Vpk/krpm4 Pole Motor 30 Vpk/krpm 90 - 170 Vpk/krpm 60 Vpk/krpm 180 - 340 Vpk/krpm6 Pole Motor 45 Vpk/krpm 135 - 255 Vpk/krpm 90 Vpk/krpm 270 - 510 Vpk/krpm8 Pole Motor 60 Vpk/krpm 180 - 340 Vpk/krpm 120 Vpk/krpm 360 - 680 Vpk/krpm

Preferred BEMF (Kv, Vpk, L-L/Hz) Parameter for Linear Motors for IndexBlok OnlyLinear Motors For 115VAC and 230VAC Operation For 480VAC Operation

Minimum Optimum Minimum OptimumLinear Motors 0.8 Vpk/Hz 2.4 - 4.5 Vpk/Hz 1.6 Vpk/Hz 4.8 – 9.0 Vpk/Hz

Model Type Drive’sI.rated, cont.

(Arms)

MinimumMotor’s Irated

(Arms)

R_min(l-l ohms)

R_opt(l-l ohms)

R_max(l-l ohms)

L_min(l-l mH)

L_max(l-l mH)

120VACXDM1001C 4.0 1.0 1.2 4.4 18 6.5 69.9XDM1002C 7.2 1.8 0.6 2.3 9.1 3.2 35.0XDM1003C 10.4 2.6 0.4 1.5 6.1 2.3 23.3240VACXDM1001D 3.4 0.85 1.2 4.4 18 6.5 69.9XDM1002D 6.8 1.7 0.6 2.3 9.1 3.2 35.0XDM1003D 9.6 2.4 0.4 1.5 6.1 2.3 23.3XDM1005D 15.2 3.8 0.2 0.75 3.0 1.4 11.7XDM2007D 22 5.5 0.15 0.56 2.3 1 8.7XDM2010D 28 7 0.1 0.375 1.5 0.78 5.8480VACXDM1001E 1.7 0.43 4.8 18 72 25 275.4XDM1002E 3.4 0.85 2.4 9 36 13 137.6

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XDM1003E 4.8 2.4 1.6 6 24 9 91.8XDM1005E 7.6 1.9 0.8 3 12 5.8 45.9XDM2007E 11 2.75 0.6 2.25 9.0 4 34.4XDM2010E 14 3.5 0.4 1.5 6.0 3.1 23.0XDM2015E 21 5.25 0.2 0.75 3 2.1 17.2XDM2020E 27 6.75 0.1 0.4 1.5 1.6 11.5

Performance Specification

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Parameter Rating ConditionResolution

216 or 65536 per motor electrical cycleRotary Motors2 pole motor: 65,536 counts per mechanical revolution4 pole motor: 131,072 counts per mechanical revolution6 pole motor: 196,608 counts per mechanical revolution8 pole motor: 262,144 counts per mechanical revolutionLinear Motors65536 per motor electrical cycle

Repeatability Typically 1 count per 8000 or 2.7 arc-min(unloaded)

Actual results based on motor type and construction

Absolute Accuracy Typically ± 1 degree unloaded Actual results based on motor type and constructionAbsolute PositioningRange

Rotary Motors0 to (65,536 *2/(# poles)) rev

Linear Motors65536 Electrical Cycles

Rotary Motors2 pole motor: 0 to 65536 revs4 pole motor: 0 to 32768 revs6 pole motor: 0 to 21845 revs8 pole motor: 0 to 16384 revs

Relative PositioningRange

0 degrees to infinite

Maximum singlemove positioncommand

Rotary Motors = 32768 * 2 / (# poles) rev

Linear Motors = 32768 Electrical Cycles

Rotary Motors2 pole motor: ±32768 revs4 pole motor: ±16384 revs6 pole motor: ±10923 revs8 pole motor: ±8192 revs

Velocity Range 3-5% of no load speed* to 400 Hz

Minimum Speed based on 3%-5% x No LoadSpeed*

Rotary MotorsMaximum Speed: Is limited by 400 Hz or lineinput voltage2 pole motor: up to 24,000 rpm max speed4 pole motor: up to 12,000 rpm max speed6 pole motor: up to 8000 rpm max speed8 pole motor: up to 6000 rpm max speed

Linear Motors400 Hz (Electrical Cycles per sec)[Ex. LM with 1.8 in/E.C gives a maximum speed of720 in/s if enough voltage headroom]

Actual results based on motor type and construction (BEMFconstant).

Minimum speed based on 3 – 5% x No Load Speed (NLS)*.

* No Load Speed (NLS): NLS = AC VAC Input / BEMF-Vrms/Krpm OR NLS = (AC VAC * SQRT(2))/(BEMF-Vpk/Krpm)

Example: 230VAC input, BEMF = 60Vrms/Krpm, to give• Min. Move Speed (3%) = (230/60)*1000 * 3% = 115

rpm• Min. Move Speed (5%) = (230/60)*1000 * 5% = 192

rpm

Maximum speed based on line input voltage.

Acceleration Range Rotary Motors: Up to 100,000 rpm/sLinear Motors: Up to 100,000 ElectricalCycles/min/sec

Actual results based on motor type, construction, BEMFconstant and inertia.

Velocity regulation Rotary Motors: ± 2 rpmLinear Motors: ± 2 E.C./min

Maximum change in actual motor speed with change insteady-state load as a % of motor rated speed. Motor no loadto motor rated torque above MINIMUM speed.

Velocity accuracy ± 0.1 % Actual motor speed vs. Commanded speed as a % of motorrated speed. Motor no load to motor rated torque aboveMINIMUM speed.

Holding Torque Selectable up to motor’s rated continuouscurrent

Performance Specification

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Servo Update rate 400 µsPositioningBandwidth

Selectable. Typically 20 Hz with 3 inchdiameter motor.

Based on total inertial.

Common Specifications

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A. Environmental

Parameter Rating ConditionsEnclosure • IDM1000

IDM2000 specs?IP-20 Module CapBlok, Assembled Drive

ConfigurationsMax OperatingAmbientTemperature

-10 to +70°C Module with Sufficient Heat SinkingIDM1000

-10 to +50°C Assembled Drive Configurations IDM1000-10 to +40°C Assembled Drive Configurations IDM2000

Max SubstrateTemp

-20 to +90°C All

StorageTemperature

-20 to +100°C All

Humidity 10 to 95% Non-CondensingAltitude 1000m (3300 ft.) Maximum for Full RatingAltitude Derating 2% for every 330m (1000 ft.) Not Rated for Use Above 4000m (13200 ft.)Vibration IEC68-2 IEC68-2

B. Electrical

Parameter Rating ConditionsAC Line Input Freq 47 to 66HzEfficiency 97% 5-20kW Ratings

95% 1-3kWRatingsLine Drop-Out Ride-Through Time

2 (Sec)1 Short Term Power Interruption withUnloaded Motor Running at RatedSpeed

PWM Frequency 5 kHzProtection Functions Instantaneous Overcurrent, Ground Fault, Short

Circuit, Over Voltage, Under Voltage, SubstrateOver Temp, Motor I2T, AC Input Phase Loss, MotorFault, Brake Overload

Product Dimensions

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A. SERIES 1000 DIMENSIONS

1. IndexBlok Module 2. IndexBlok Module with CapBlok

Product Dimensions

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3. XDM100X-xx-WC00S (IndexBlokmodule with CapBlok and WCHeatsink)

4. XDM100X-xx-BB00S (IndexBlokmodule with CapBlok and BBHeatsink)

Product Dimensions

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B. SERIES 2000 DIMENSIONS

1. IndexBlok Module 2. IndexBlok Module with CapBlok

Dim. in. mm

A 8.92 226.5

B 1.72 43.6 C 3.04 77.2

D 5.60 142.3 K 5.12 130.0

L 5.06 128.5

M 4.04 102.5 N 8.39 213.2

U .209 5.3 V .209 5.3

in. mm

10.40 264.2

1.72 43.6 3.04 77.2

5.60 142.3 5.12 130.0

5.06 128.5

4.04 102.5 9.88 250.5

.209 5.3 .209 5.3

15-20 HP7.5-10 HP

Product Dimensions

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3. XDM200X-xx-WE00S (8.7 – 11.2 kW)

Dim. IN. MM

A 9.15 232.4

B 4.53 115.1

C 5.85 148.6

D 6.50 165.0

K 6.02 153.0

L 8.29 210.5

U .276 7.0

4. XDM200X-xx-WG (8.7 – 21.5kW)

Dim. in. mm

A 14.61 371.0

B 4.90 124.4

C 6.78 172.3

D 8.11 205.9

E 6.08 154.4

K 4.25 108.0

L 13.87 352.4

U .276 7.0

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Instructions for Compliance with the European Standards

EMC Directive

An Integrated Drive Module does not generally function independently. It is a component designed to be integratedinto a machine control system, and is generally intended to be installed within another enclosure with other controlequipment and devices. It is therefore assumed that the IndexBlok is installed in such a manner, and to assurecompliance with the EMC Directive the unit is tested in this configuration.

Suggested Installation for EMC Directive Compliance

A. Outline of Installation Requirements

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1. Install the IndexBlok and EMC components within a totally enclosed seamless steel enclosure. Astandard NEMA or IEC enclosure is adequate for this purpose.

2. Run AC Line Input wiring through a rigid or flexible metal-jacketed conduit, as required byapplicable Electrical Code. Rigidly couple the conduit to the enclosure with a low impedanceelectrical connection (removing paint from the steel enclosure surface as required).

3. Run a separate Ground conductor with the 2- or 3-wire AC Line input wires inside the conduit, andbond this separate conductor directly to a Ground Bonding stud on the enclosure surface.

4. Install a 1-ph or 3-ph 1% (minimum) line reactor, as required, in series with the incoming AC Line.5. Install an appropriately rated 1-ph or 3-ph European Standard-compliant noise filter between the line

reactor and the input terminals of the drive. See the table in the Operator’s Manual for recommendedrepresentative noise filters.

6. Run a separate Ground conductor from the provided Open-Frame Drive Ground bonding screw (or inthe case of an IDM module installation from immediately adjacent to the mounted IndexBlok module)to the enclosure Ground-bonding stud.

7. If required, install a 3-ph 1% (minimum) line reactor in series with the outgoing Motor Cable. This isnormally only required for motor cables over 10m (100ft) in length, but should be tested in yourapplication.

8. Use a shielded cable for wiring between the drive and motor (Motor Cable). Run a separate Groundconductor in the Motor Cable, connected directly to the IndexBlok heatsink Ground-bonding screwon one end, and the motor Ground bonding screw in the motor junction box at the motor end. Thiscable may be run in a rigid conduit, but better EMC suppression is provided by a shielded cable witha braided shield.

9. Clamp a ferrite bead around all analog and digital control I/O and / or serial I/O cables as they exit theenclosure.

It is useful to note that the IndexBlok has passed all EMC emissions and susceptibility tests outside the enclosuredescribed here, with the sole exception of the ESD directive. If the IndexBlok is protected from casual contact andtherefore ESD susceptibility testing is not required, it should be possible with shielded cables to pass all other EMCDirectives outside a sealed secondary enclosure.

Low Voltage Directive

A power electronic system is quite unique in its safety concerns and the methods used to ensure the safety of people,animals, plant and equipment. The applicable Standard for this product family is prEN50178-1995: ElectronicEquipment for use in Power Installations. This Standard details the design requirements and verification testingrequired for power electronic systems, including motor drive products, and we have self-certified compliance to theLow Voltage Directive according to this Standard.

To ensure that your installation is safe, we recommend that the IndexBlok be installed in the following manner:

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• The IndexBlok and CapBlok come in two voltage classes. The 230V class units achieve full rating at 230VAC+10% 3-phase 50/60Hz. Operation at 200V must be derated – the drive current rating cannot be increased at 200Vand so can deliver less total output power under this condition. The 400V class units carry a dual rating – they arerated to deliver full power at 400VAC +10% 3-phase 50/60Hz and 480VAC +10% 3-phase 50/60Hz. This meansthat you can deliver higher output current at 380 / 400V operation to deliver the same shaft power from anappropriately rated motor. The CE Mark applies to all 230V class applications, but for the 400V class onlyapplications at 380 / 400VAC.

• On an Open-Frame Drive model, connect the heatsink Ground-bonding terminals to Earth as shown in the wiringdiagram above. Module customers must bond the Earthing conductor as close to the mounted module as possibleso as to provide a return path for currents injected into the IDM module baseplate. Even if EMC compliance is notrequired, the drive must be bonded to Ground with a suitable conductor rated for continuous current of at least theinput current rating of the drive itself. Wire these connections separately – do not daisy chain Ground connections.

• Do not use an Earth leakage circuit breaker as an electric shock protector.• Install current-limiting fuses on the incoming AC Line power leads to prevent damage to equipment and people in

the event of a catastrophic failure of the power electronic circuits.• While not normally required, it is generally good practice to install a surge suppressor assembly at the input

terminals of the drive. These assemblies are available from many sources – recommended assemblies are listed inthe Operator’s Manual.

The operating rating of the Relay Outputs provided for control I/O is 30V 0.5A for the purpose of a CE compliantinstallation. UL considers them acceptable for 120VAC 1A, but they are not rated at that voltage according toEN50178.

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Seems like this section needs some expansion. It assumes the user is familiar with Windows and knows how to insertthe disk in drive A, double click on My computer, double click on A, and then double click on IB Config.exe It alsoassumes that the customer knows to plug a computer into the RS-485 port, etc. Further, it assumes the user has and isfamiliar with using Microsoft Excel.

The INDEXBLOK CONFIGURATION TOOL program is a preliminary software tool to allow the user to configurethe IndexBlok from Semipower Systems, Inc. The following is a series of instructions on getting started using theIndexBlok Configuration Tool (IB Config) program with the drive from Semipower Systems, Inc.

I. Installing IB Config Software

1. Double click IB Config.exe, and select a directory to store all the files in.

A number of files are bundled with IB Config software including Calc Gains and Position Assistant.xls. Calc Gainsand Position Assistant.xls is an Excel file to help you calculate the tuning gains for your applications as well as theposition in electrical cycles. All position parameters are in electrical cycle units. The Calc Position worksheet convertsvalues from degrees, revolutions, and inches into electrical cycles.

II. Configuring IndexBlok with IB Config Software

The configuration of the IndexBlok will be done via the software program, IndexBlok Configuration Tool , using theMotor Setup, Drive Mode, and Application Setup.

1. Apply appropriate power to the drive module. The green PWR LED on the drive module will turn on andremain on.

2. Open the file, IB Config.exe . The following dialog box should appear,

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3. Click the OK button. The following dialog box should appear,

To verify that communication between the drive module and the computer is set up properly, check Drive Status, for thewords Drive On-Line .

SET BUTTON –Press to accept/set andstore the highlightedvalue.

GET BUTTON –Press to retrieve/get thehighlighted stored value.

JOG FWD BUTTON –Press to run in the fwddir at Serial Jog speed.

JOG REV BUTTON –Press to run in the rev.dir. at Serial Jog speed.

SETALL BUTTON –Press to accept/set andstore all value.

GETALL BUTTON –Press to retrieve/get allstored value.

START ABS BUTTON –Press to start anabsolute serial move.

STOP BUTTON –Press to stop the drive.

START REL BUTTON –Press to start an Relativeserial move.

DISABLE BUTTON –Press to disable thedrive.

DO PRESET BUTTON –Press to start presetfunction.

IO INIT BUTTON –Press to initiate M Seriesparameters. Drive mustbe disabled to IO Init.

DISPLAY –Showsv Last Messagev Drive Statusv Last Faultv Last Error

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Communication Setup If communication between the drive module and the computer is not online, then click on the Communications sub-menu under Utilities menu from the original window. The following dialog box will appear

1. Configure the Communications Setup to the proper Baud Rate, Port Selection, and IDM address untilcommunication between the drive module and the computer is online. An IndexBlok will come from thefactory configured for 9600 baud, with an IDM Address of 1.

2. Click the OK button.

If communication between the drive module and the computer is STILL not online, check the physical connectionbetween the two items until communication between the drive module and the computer is online.

Communication Timeout SettingThe drive has a Communication Timeout Setting, which is calculated from J04 parameter. Parameter J04 is theComm_timer_max. The scaling of J04 is Time(sec) = Comm_timer_max * 0.052 sec. The default setting of J04 is 96,which equates to 5 seconds (e.g. Time (sec) = 96 * 0.052 = 5 sec).

We recommend that you save the default configuration prior to adjusting any parameters,

• Click on the File menu.

• Select Default User List.

• Click on the GET ALL button to get all the default parameters.

• Click on the File menu.

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• Select Save User List As. The following dialog box should appear,

• Enter a filename.

• Click on the SAVE button.

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Motor Setup

1. To set up the motor, click on the Motor Setup sub-menu under Utilities menu from the original window. Thefollowing dialog box will appear. It is very important to enter in correct values since the SensorlesServoalgorithm uses this information. [NOTE: Motor manufacturers rate Ke in Vpk/krpm or Vrms/krpm.Vpk/krpm = Vrms/krpm * √2. Please enter Ke in Vpk/krpm otherwise the value is off by 141 %. For LinearMotors use Vpk/kHz instead of Vpk/krpm]

All the values entered for these motor parameters must be based upon measured or calculated phase-to-phase(i.e., line-to-line) values for optimum performance. Also, the back EMF constant, Ke, and the Rated Currentmust be based upon peak sine values. Consult factory for further technical support.

2. Enter values for each Motor Parameter.

Recommended values for the Starting Current and Starting Delay:

For lightly loaded motors, use 25% of Rated Current.For highly loaded motors, use 50% or more of Rated Current.

For low inertia loads, use 0.25 s for Starting Delay.For high inertia loads, use 1.00 s for Starting Delay.

3. Enter values for the Starting Current and Starting Delay.

4 Click OK

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2. [5.]To Commission the motor, click on the Commission sub-menu under Utilities menu from theoriginal window. The following dialog box will appear. When the dialog box disappears, theIndexBlok is now configured for the motor.

[Note: Prior to commissioning the drive module, ensure that a jumper is connected from digital input 8 (i.e., DIGCOM) to (a) programmableRun-Enable input, (b) programmable Run Fwd Enable (EOT) input, and (c) programmable Run Rev Enable (EOT) input on the I/Oterminal connector.]

Commissioning is a process in which the drive module sends current to the motor to measure themotor’s resistance. The motor will not turn and can remain coupled to its driven load during thisprocess.

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System Tuning –Using “Calc Gains and Position Assistant.xls” excel file bundled with IB Config software

• Launch Calc Gains & Position Assistant.xls and select Calc Rotary Motor Gain Assistant or Linear Motor GainAssistant worksheet. You should see the following screen for Rotary motors. Is this the wrong graphic? It hasnothing consistent with the text which follows it and the graphic is repeated as the next screen shot. This graphicshould show rows 1-47 (If that is where steps 1-6 are shown).

1. Enter the Drive Parameter Ki_imag (A09) value

Product Ki_Imag[A09]

Product Ki_Imag[A09]

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115 & 230VAC 460VAC1D 1870 1E 37422D 936 2E 18703D 624 3E 12485D 312 5E 6247D 234 7E 46810D 156 10E 312

15E 23420E 156

2. Enter Motor’s Rotor Inertia (Jmotor) in kg-m2 for rotary motors(Mass in Kg for Linear motors)

3. Enter the Load-to-Motor Inertia Ratio (Jload/Jmtr)(Linear Mts: Mload/Mmtr)

4. Enter Ke (BEMF Constant) in Vpk,L-L/Krpm(Vpk/KHz for linear motors)

[Note: Vpk = Vrms * SQRT(2); VL-L = VL-N * SQRT(3) This is too hard to read, how ‘bout:2×= VrmsVpk and 3×−=− nVllVl

therefore Vpk, L-L = Vrms * SQRT(2) * VL-N * SQRT(3)] And how ‘bout:32 ×−××= nVlVrmsVpk

Adding MathType to Word makes entering equations very easy to do. “Computer” equations are too hard toread.5. Enter Half Poles ( = Number of motor poles/2; Linear motors use 1)

6. Enter Pole_zero_ratio. Use 8.

[Note: If application has a lot of natural damping use 0. Linear motors typically have low natural damping,use 20. For most rotary motors/applications 8 works well.]

7. Choose the bandwidth frequency (ωω ) to close the loop at. (Freq in Hz.)

• For unloaded motors, try to select bandwidth frequency (ω) such that K00 ~ 20,000 and K02 - 0.

• For loaded motors, try to select bandwidth frequency (ω) such that K00 ~ 20,000 and K02 = 1.

• If ωω is too (same mistake in spreadsheet) high, the parameter(s) will Limit at 32767 andproduct a WARNING! Reduce w(Hz). THIS IS Unstable, need to lower ωω .

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8. These are the values to enter into IB Config - Tuning Parameters K00, K01, K02, K03, and K0E.

9. Return to IndexBlok Configuration Tool software (IB Config). Click on the File menu at the top ofthe window.

10. Select Tuning Parameters. The following dialog box should appear,

11. Enter each value calculated in Calc Rotary Motor Gain Assistant above and SET or SETALL.

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Why can’t the tuning calculator be added to the IB Config software? We’re assuming the customer has Excel and iscomfortable in using it .

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Setting up the ApplicationThe IndexBlok’s I/O and move parameters are not configured. After the motor has been setup and tuned, you will needto configure the drive (set distance, and speed) to get motion. To change the configuration, see the sections afterDefault Settings. Complete the I/O Setup Worksheet – Hardware & Software sections located in Digital Input Section

1. Click on the File menu at the top of the window.

2. Select Application Setup Parameters. The following dialog box should appear,

3. Click on the GET ALL button

4. Setting the Start and Stop Source – Serial or Local (digital)

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To change the Start/Stop method (i.e., serially controlled Start/Stop or locally controlled Start/Stop), or Digital InputPull Up/Down method

• Click on the DriveModes menu. The following dialog box should appear,

• Select the type of Start/Stop Source, Serial or Local.

• Select the type of Digital Pull Up/Down, Pulled Up or Pulled Down.

• Click the OK button.

5. Setting Parameters

To set a parameter (e.g., F08 Global Accel/Decel Parameter),

• Select the parameter you want to set

• Delete the current value.

• Enter the new value

• Click on the SET button.

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• Click on the GET Button to confirm value.

• If the parameter you edit starts with the letter “M” (e.g., M02) click on the IO Init button in addition to theabove instructions or recycle power to the drive to initiate the M series parameters. The drive must be disabled(de-energized) to initiate IO Init the M parameters.

Serial JogSerial Jog buttons uses the F08-Accel/Decel rate and C03-Serial Jog Speed.

• To initiate Jog in the Forward direction, click on the Jog Fwd button.

• To initiate Jog in the Reverse direction, click on the Jog Rev button.

• To stop the Jog, click on the STOP button. The stop uses the F08 value to decelerate.

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Serial Start (Start Absolute and Start Relative)If you want to start an absolute move, click on the Start Abs button. If you want to start an relative/incremental move,click on the Start Rel button. The START buttons utilizes the F08 Accel/Decel rate, C02 Serial Speed, and C08 &C09 for position. See Serial Parameters & Setup section for more information.

Serial Start Absolute Example:Make a 10 revolution absolute move, with a speed of 1500 rpm and an acceleration/deceleration of 5,000 rpm/s on a 4pole motor.

• Set Serial Speed to 1500 rpm by entering 1500 into C02 and click on SET .• Set Global Accel/decel to 5000 rpm/s by entering 500 into F08 and click on SET.

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• Set the position to 10 revolutions by entering 0 in C08 (Serial_Pos_Lo) and click on SET and 20 into C09(Serial_Pos_Hi) click on SET . The position parameters are a 32-bit position in electrical cycles. (See PresetPosition Setup Section in the IndexBlok Owner’s Manual and “Calc Gain and Position.xls” bundled with theIB Config software.

• Click on Start Abs to start the serial absolute move.

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Serial Start Preset Function• If you want to start a preset index move, click on the Do Preset button. The Do Preset button runs the Serial

Preset Index function in C0A. It uses the Preset Function values specified in Preset Position Parameters[M3A-M59], Preset Speed Parameters [M5A-M69], Accel/Decel rate [F08]. To initiate the “M” Seriesparameter values, click on IO INIT button or recycle power to the drive. The drive must be disabled (de-energized) to initiate IO Init the M parameters.

(See Preset Position Setup and Preset Speed and Accel/Decel Setup sections for more information.)

Serial Run Preset Function Example: Run Preset function 1, which is setup for a 1 revolution incremental move with apreset speed of 1000 rpm and a global accel/decel rate of 10,000 rpm/s based o a 4-pole motor:

• Set Preset Function 1 for a Relative Move by setting M2B-Preset Fcn 1 to 7 (Relative Move) and click theSET button.

• Set Preset Position 1 to 1 revolution based on a 4-pole motor, by setting

• M3C Preset_Pos_1_Lo to 0 and click the SET button and

• M3DPreset_Pos_1_Hi to 2 and click the SET button

• Set Preset Speed 1 to 1000 rpm by setting M5B Preset Speed 1 to 1000 and click the SET button

• Set Global Accel/Decel rate to 10,000 rpm/s by setting F08 to 1000 and click the SET button

• Make sure the drive is disabled (de-energized) and click the IO Init button to initiate the “M” seriesparameters

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Saving ConfigurationIf you want to save the current configuration,• Click on the File menu.

• Select Save User List As. The following dialog box should appear,

• Enter a filename.• Click on the SAVE button.

(Note: Save User List, ONLY saves the parameters that are listed. …• To save Motor Setup, Select File Open User List, Select Motor Setup Parameters and do a GET ALL. Then File-

Save User List as …• To save all necessary parameters to duplicate another drive for the same motor/drive/application configurations,

Select File Open User List, Select Duplicate Parameters and do a GET ALL. Then File-Save User List as …• To save entire setting for specific drive (s/n), Select File Default User List and do a GET ALL. Then File – Save

User List As…XDM1001DCSWC00S_SN90123011.def)

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Duplicating Drives1. Connect and Power drive and motor to duplicate.

2. Open IB Config software.

3. File Open Duplicate Drive Parameters. The following screen should appear.

4. Click on the GET ALL button.

5. Save file with user define file name (e.g. Axis1_Dup.def)

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6. Disconnect current drive and motor. Connect drive and motor to be duplicated. (Note: The drive and motorto be duplicated must be of the same models.)

7. With IB Config and Axis1_Dup.def open,(a) Set the password by pressing Ctrl-p(b) Click on the SET ALL button

8. Recycle power to drive. Drive is now duplicated.

9. Due to motor differences, we recommend to commission the drive to the motor being used to provide optimumperformance. Click on Motor Setup sub-menu under Utilities menu. Click on Commission button tocommission this motor to the drive.

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OPERATING the IB Config Software

The operation of the drive module, which includes controlling and monitoring, can be done via the software program,IB Config.

The user can Start moves, monitor feedback, and faults by clicking on the Feedback menu, and Utils Menu-FaultQue, respectively.

Example 1:

1. Select the desired Preset Index Function # by• Entering the value for preset function and clicking the SET button.

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2. Click the Run Preset Fcn Button.

The motor will rotate to the desired Preset Index Function Position if the function was set up for a Move Relative, MoveAbsolute, Home Fwd, Home Rev, Reg Fwd, Reg Rev, Jog Fwd and Jog Relative. If the Preset Index Function was setup for Reset Faults, it would reset faults. You can monitor the position, speed, current and torque through theFeedback menu.

Example 2:

1. Select the desired Preset Index Function # 1 by2. Entering the value 1, for preset function 1 and clicking on the SET button.

3. Click the Run Preset Fcn Button.

The motor will rotate to the desired Preset Index Function. You can monitor the position, speed, current and torque ora number of other parameters through the Feedback menu.

All trademarks, registered trademarks, and logos are of their respective holders.

Windows95 and WindowsNT are registered trademarks of Microsoft Corporation.

IndexBlok™, CapBlok™, and wInControl™ are trademarks of Semipower Systems, Inc.

The information in this Owner’s Manual is provided by Semipower in good faith and to the best of our knowledge is accurate. Semipower does not accept any liability for any loss or damage of anykind suffered as a result of any inaccuracy in any of the information contained in this document.

© Semipower Systems, Inc. 1998. All rights reserved.

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Serial ParametersThe IndexBlok can be run serially through the following Serial Parameters. The most common parameters used forserial control are the motion parameters: start, stop, velocity, position, and global accel/decel or serial_preset_indexfunction. For Serial Communication Protocol, see Appendix C: Serial Communication Protocol.

Serial CommandsC00 DRIVE_COMMAND

Bit 0 → Disable driveBit 1 → Stop requestBit 2 → DC Hold

Bit 3 → Serial Start Abs – Start a Serial Absolute Move to position defined in C08Serial_Pos_Cmd_Lo and C09 Serial_Pos_Cmd_Hi at speed defined in C02Serial_Omega_Cmd and Accel/Decel rate defined in F08 Accel/Decel Rate

Bit 4 → Serial Start Rel – Start a Serial Relative/Incremental Move to position defined inC08 Serial_Pos_Cmd_Lo and C09 Serial_Pos_Cmd_Hi at speed defined in C02Serial_Omega_Cmd and Accel/Decel rate defined in F08 Accel/Decel Rate

Bit 5 → Serial Jog Forward – Start a Serial Jog in the Forward direction with a speeddefined in C03 Serial_Jog_Speed

Bit 6 → Serial Jog Reverse – Start a Serial Jog in the Reverse direction with a speeddefined in C03 Serial_Jog_Speed

Bit 7 → Serial Start Preset Function – Start the Preset function defined in C0ASerial_Preset_Fcn_#

Bit 8 → AlignBit 9 → CommissionBit 10 → External Fault ClearBit 11 → External Fault SetBit 12 → Clear FaultsBit 13 → Reset CommunicationBit 14 → I/O Reset (IO Init)Bit 15 → Processor Reset

Sending a command to the drive is accomplished by setting this parameter with the appropriate bit cleared.The command is acknowledged when the corresponding bit is set.

C02 OMEGA_CMD_SAVE Serial Speed Command, RAM onlyRotary Motors – rpmLinear Motors – Electrical Cycles/min

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C03 SERIAL JOG SPEED Serial jog SpeedRotary Motors – rpmLinear Motors – Electrical Cycles/min

C08 SERIAL_POS_CMD_LO A 32 bit number where the upper 16 Bits are counts of electrical cycles. (SeeAppendix B: Calculating Position Values Examples and “Calc Gain andPosition.xls” bundled with IB Config software)

Lo word of Serial_Pos_Cmd = (move_elec - Pos_cmd_hi)*2^16C09 SERIAL_POS_CMD_HI Hi word of Serial_Pos_Cmd = =INT(move_elc)C0A SERIAL_PRESET_FCN # Set Serial_Preset_Function #.

This allows the user to Homing, jogging or preset moves and functionsserially.

0-15 refers to the preset function #, programmed in parameters Preset_Fnc_0through Preset_Fnc_15 (M2A – M39), which the user wants to Serial Start..

Drive Command (C00) is used to start a preset function serially by clearingBit 7 (Serial Start Preset Function).

F08 Accel/Decel_Rate Rotary Motors = RPM/s ÷ 1000Linear Motors = Electrical Cycles per min per sec ÷ 1000(F08 = Global Accel/Decel Rate for all motion)

To Initiate a Serial Jog• To initiate Jog in the Forward direction, set the C03-Serial Jog speed parameter, F08-Accel/Decel rate

parameter and clear bit 5 (serial jog forward) of C00 parameter.

• To initiate Jog in the Reverse direction, Clear bit 6 (serial jog reverse) of C00 parameter.

To Serial Stop Motion• To stop motion, clear bit 1 of C00 parameter. The stop uses the F08 value to decelerate.

To Serially Start an Absolute MoveMove to the absolute position of 10-revolution position, with a speed of 1500 rpm and an acceleration/deceleration of5,000 rpm/s on a 4-pole motor.• Set Serial Speed parameter C02 to 1500 rpm• Set Global Accel/decel to 5000 rpm/s• Set the position to 10 revolutions by setting 0 in C08 (Serial_Pos_Lo) and 20 into C09 (Serial_Pos_Hi). The

position parameter is a 32-bit position in electrical cycles. (See Appendix B: Calculating Position Values inthe IndexBlok Owner’s Manual and “Calc Gain and Position.xls” bundled with the IB Config software.

• Clear bit 3 (Serial Start Absolute) of C00 parameter to start the serial absolute move. The motor will movesuch that the position counter equals the absolute position value (e.g. D22 Pos Counter Low = 0 and D23 PosCounter Hi = 20).

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To Serially Start a Relative MoveMake a 10 revolution incremental move, with a speed of 1500 rpm and an acceleration/deceleration of 5,000 rpm/s on a4 pole motor.• Set Serial Speed parameter C02 to 1500 rpm• Set Global Accel/decel to 5000 rpm/s• Set the position to 10 revolutions by setting 0 in C08 (Serial_Pos_Lo) and 20 into C09 (Serial_Pos_Hi). The

position parameter is a 32-bit position in electrical cycles. (See Appendix B: Calculating Position Values inthe IndexBlok Owner’s Manual and “Calc Gain and Position.xls” bundled with the IB Config software.

• Clear bit 4 (Serial Start Relative) of C00 parameter to start the serial relative move. The motor will move 10revolutions.

To Initiate a Serial Start Preset FunctionThe Bit 7 of C00 parameter runs the Serial Preset Index function # in C0A. It uses the Preset Function values specifiedin Preset Position Parameters [M3A-M59], Preset Speed Parameters [M5A-M69], Accel/Decel rate [F08]. NOTE:These “M” Series parameter are run lock parameters and thus must be set and initiated with the drive disabled. (SeePreset Position Setup and Preset Speed and Accel/Decel Setup sections for more information.)

Run Preset function 1, which is set up for a 1 revolution incremental move with a preset speed of 1000 rpm and a globalaccel/decel rate of 10,000 rpm/s based o a 4-pole motor:

1. Setting up Preset Function 1 Serially• Disable drive by clearing bit 0 of C00 parameter• Set Preset Function 1 for a Relative Move by setting M2B-Preset Fcn 1 to 7 (Relative Move)• Set Preset Position 1 to 1 revolution based on a 4-pole motor, by setting

• M3C Preset_Pos_1_Lo to 0• M3DPreset_Pos_1_Hi to 2

• Set Preset Speed 1 to 1000 rpm by setting M5B Preset Speed 1 to 1000• Set Global Accel/Decel rate to 10,000 rpm/s by setting F08 to 1000• To initiate the M Series parameters, clear bit 14 of C00 parameter.Note: Typically Preset functions are set up either already set up or they are downloaded from the machine controllerduring initialization.

2. Initiating Preset Function 1 Serially

• Set C0A Serial Preset Function # to 1• Clear bit 7 of C00 parameter to start the Serial Preset Function.

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The IndexBlok’s I/O and move parameters are not configured. You will need to configure the drive (motor setup, tune,and application setup) to get motion. To change the configuration, see the sections after Default Settings. For motor setup and tuning see the Software Introduction, Installation & Instructions Section.

I/O SETUP Worksheet – Default Settings

Pin # Name Description Input/ Output Function Active State (Highor Low polarity)

7 +5V NA NA8 DIGCOM NA NA9 DIN1 Input #1 Null Low10 DIN2 Input #2 Null Low11 DIN3 Input #3 Null Low12 DIN4 Input #4 Null Low13 DIN5 Input #5 Null Low14 DIN6 Input #6 Null Low15 DIN7, DO1 Input #7 Null Low16 DIN8, DO2 Input # 8 Null Low17 FANRTN Switched return for 12VDC

cooling fanNA NA

18 +12v Power for 12VDC coolingfan

NA NA

21 RLY1NO Form A Relay Output #1,Normally Open

Null LOW

22 RLY1COM Form A Relay Output #1,Common

NA NA

23 RLY2NC Form C Relay Output #2,Normally Closed contact

Null HIGH

24 RLY2COM Form C Relay Output #2,Common

NA NA

25 RLY2NO Form C Relay Output #2,Normally Open contact

NA LOW

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I/O SETUP Worksheet – Hardware

Pin # Name Description Input/ Output Function Active State (Highor Low polarity)

7 +5V8 DIGCOM9 DIN1 Input #110 DIN2 Input #211 DIN3 Input #312 DIN4 Input #413 DIN5 Input #514 DIN6 Input #615 DIN7, DO1 Input #7 or Output # 116 DIN8, DO2 Input # 8 or Output #217 FANRTN Switched return for 12VDC

cooling fan18 +12v Power for 12VDC cooling

fan21 RLY1NO Form A Relay Output #1,

Normally OpenLow

22 RLY1COM Form A Relay Output #1,Common

23 RLY2NC Form C Relay Output #2,Normally Closed contact

High

24 RLY2COM Form C Relay Output #2,Common

25 RLY2NO Form C Relay Output #2,Normally Open contact

Low

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I/O Setup Worksheet – Software

Table 2.0: Input Settings And Associated ParametersPin#

Name Description InputParameter

IO Function Setting(Default)

IO FunctionValue (Setting)

Active State (Lowor High Polarity

9 DIN1 Input #1 M0010 DIN2 Input #2 M0111 DIN3 Input #3 M0212 DIN4 Input #4 M0313 DIN5 Input #5 M0414 DIN6 Input #6 M0515 DIN7/

DO1Input #7 orOutput #1

M06 or M09

16 DIN8/DO2

Input #8 orOutput # 2

M07 orM0AM08 Digital Input Function

(0, all low)21 RLY1

NORelay 1 - NO M0B LOW

23 RLY2NC

Relay 2 - NC M0C HIGH

25 RLY2NO

Relay 2 -NO M0C LOW

FBKLED

State 1(Red)

State 1Function

M21

FBKLED

State 2(Org)

State 2Function

M22

Table 2.1: Preset Bit Function Settings And Associated ParametersPresetFunction #

Preset BitFunctionParameter

Bit 0(Input#__)Setting

Bit 1(Input#__)Setting

Bit 2(Input#__)Setting

Bit 3(Input #__ )Setting

Preset Function(reset faults, jogfwd, home fwd,move abs, etc)

PresetFunctionValue (0-7)

0 M2A 0 0 0 01 M2B 1 0 0 02 M2C 0 1 0 03 M2D 1 1 0 04 M2E 0 0 1 05 M2F 1 0 1 06 M30 0 1 1 07 M31 1 1 1 0

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8 M32 0 0 0 19 M33 1 0 0 110 M34 0 1 0 111 M35 1 1 0 112 M36 0 0 1 113 M37 1 0 1 114 M38 0 1 1 115 M39 1 1 1 1

Table 2.2: Move Profile Settings and Associated ParametersPresetFunction#

PresetFunction(from above)

Distance 1

(Rev)[ Electrical Cycles Lo & Hi]

Velocity(rpm)

Accel 2

(rpm/s)[rpm/s ÷÷ 10]

Decel2

(rpm/s)[rpm/s ÷÷ 10]

0[M3A Preset_pos_0_Lo = _______][M3B Preset_pos_0_Hi = _______]

M5A = [F08 = _______] [F09 = _______]

1[M3C Preset_pos_0_Lo = _______][M3D Preset_pos_0_Hi = _______]

M5B =

2[M3E Preset_pos_0_Lo = _______][M3F Preset_pos_0_Hi = _______]

M5C =

3[M40 Preset_pos_0_Lo = _______][M41 Preset_pos_0_Hi = _______]

M5D =

4[M42 Preset_pos_0_Lo = _______][M43 Preset_pos_0_Hi = _______]

M5E =

5[M44 Preset_pos_0_Lo = _______][M45 Preset_pos_0_Hi = _______]

M5F =

6[M46 Preset_pos_0_Lo = _______][M47 Preset_pos_0_Hi = _______]

M60 =

7[M48 Preset_pos_0_Lo = _______][M49 Preset_pos_0_Hi = _______]

M61 =

8[M4A Preset_pos_0_Lo = _______][M4B Preset_pos_0_Hi = _______]

M62 =

9[M4C Preset_pos_0_Lo = _______][M4D Preset_pos_0_Hi = _______]

M63 =

10[M4E Preset_pos_0_Lo = _______][M4F Preset_pos_0_Hi = _______]

M64 =

11[M50 Preset_pos_0_Lo = _______][M51 Preset_pos_0_Hi = _______]

M65 =

12

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[M52 Preset_pos_0_Lo = _______][M53 Preset_pos_0_Hi = _______]

M66 =

13[M54 Preset_pos_0_Lo = _______][M55 Preset_pos_0_Hi = _______]

M67 =

14[M56 Preset_pos_0_Lo = _______][M57 Preset_pos_0_Hi = _______]

M68 =

15[M58 Preset_pos_0_Lo = _______][M59 Preset_pos_0_Hi = _______]

M69 =

1 All distances need to be in electrical cycles. Use excel spreadsheet, Move_Elect_Hi & Lo.xls to convert degrees,revolutions, inch units into electrical cycles for parameters [C08-C09 and M3A – M59]

2 All preset moves (including jog, home and serial position commands) use a global acceleration rate [F08] and globaldeceleration rate [F09]. For serial moves, accel/decel values can be loaded and executed on the fly via serialcommands. Accel and decel rate values are in RPM/s ÷ 10.

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Digital Input Functions I would move this section ahead of page 81

The drive may have up to 8 digital inputs. Their functions are by configuring the value of the internal drive parametersDIGITAL INPUT 1 FCN (M00) through DIGITAL INPUT 8 FCN (M07) via IndexBlok Configuration Tool or theSerial Communication Protocol.

• All the digital inputs may be configured with any of the functions (except Home and Registration which is onlyavailable on Inputs 1 and 2), up to the number of pins available.

• The digital input pins 9 – 14 may be pulled up or down, depending on the configuration of the Pull-Up/Pull-Downmode (Default = Pulled up). This mode can be modified through the Extended Modes menu in IndexBlokConfiguration Tool o r by configuring the value of the internal drive parameter EXTENDED DRIVE MODE(C06 Bit 10) via the Serial Communication Protocol. Changes to this mode will not take affect until the nextpower cycle.

• The polarity of digital inputs 1-6 may be configured to asserted low or asserted high. The polarity can be modifiedin IndexBlok Configuration Tool or via the Serial Communication Protocol by configuring the value of theinternal drive parameter DIGITAL INPUT POLARITY (M08). Each of the first 8 low-order bits corresponds toa digital input (e.g., Bit0 = DIN1, Bit1 = DIN2, etc.). The bit set corresponds to positive acting polarity; the inputis asserted when the input is high (Active Low = 0, Active High = 1). Changing of the polarity of inputs will notresult in transitions that are acted on by the control.[Default value = 0 decimal, 0 Hex (00000000 Bin); Decimal range = 0-255; Hex Range = 0 - FF]

• Digital pins 15 and 16 are programmable as inputs or outputs. These pins can be configured as digital inputs ordigital outputs through IndexBlok Configuration Tool or via the Serial Communication Protocol by configuringthe value of the internal drive parameters DIGITAL INPUT 7 FCN (M06) and/or DIGITAL INPUT 8 FCN(M07) as Null function and DIGITAL OUTPUT 1 FCN (M09) and/or DIGITAL OUTPUT 2 FCN (M0A) as adesired digital output function via the Serial Communication Protocol. These pins are always Pulled-Up.

• Only digital pins 1 and 2 may be configured as high-speed Home input.

To define or change the Digital Input setting, enter the Input Function Value (TABLE 2.1) into the Input Parameter[M00-M07] and SET. Note to initiate the M Series parameters values, one must perform an IO INIT or reset power tothe drive.

Example - Set Input 2 as a Run Enable Input. -> Enter the value 1 into parameter M01 and SET. To initialize, performan IO INIT or reset power to the drive.

Table 3.0: Digital Inputs ParametersInput Parameter Parameter Name Parameter DescriptionM00 Digital Input 1 Function Allows the user to program the function of the input for the specific

application.[e.g. Program input 1 by entering the Input Function Value (below)in the Input Parameter.Example: Set input 1 as a HOME input: Enter101(Home InputFunction Value) into parameter M00 ]

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M01 Digital Input 2 Function “ ”M02 Digital Input 3 Function “ ”M03 Digital Input 4 Function “ ”M04 Digital Input 5 Function “ ”M05 Digital Input 6 Function “ ”M06 1 Digital Input 7 Function “ ”M07 1 Digital Input 8 Function “ ”M08 Digital Input Polarity Each of the first 8 low-order bits corresponds to a digital input (e.g.,

Bit0 = DIN1, Bit1 = DIN2, etc.). The bit set corresponds topositive acting polarity; the input is asserted when the input is high(Active Low = 0, Active High = 1). Changing of the polarity ofinputs will not result in transitions that are acted on by the control.[Default value = 0 decimal, 0 Hex; Decimal range = 0-128; HexRange = 0 - 80]

1 To configure pins 15 & 16 to be outputs functions, need to configure M06 & M0A to Null (0)

Force page break here to prevent leaving the first parameter value as an orphan.

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Table 3.1: Input Function Values for Digital Input Parameters [M00 – M07]Input Function Input

FunctionValue

Description Edge orLevelSensitive

Unused/Null 0 No function N/ARun Enable 1 Enables and Disables the drive. This input function behaves

differently depending on the Local Start/Serial Start flag.

Local start: While all Run Forward Enable and Run ReverseEnable inputs are active and there is not a fault condition, on therising edge of an Enable input the drive will energize the motor.When any Enable input is not active the drive is de-energized, butdeactivating the input does not cause a fault. Faults are cleared onthe falling edge of an enable input.

Serial Start: Faults are cleared on the falling edge of an enableinput. When any Enable input is inactive, the drive is de-energized, but deactivating the input does not cause a fault.

If no input is defined with this function, it is assumed to beactivated.

Note: Activating input, energizes motor to lock position which isreflected by position feedback, thus rotor motion could occur ifrotor is not aligned with our field. (If rotor is 180 degrees from ourfield, motor will have no torque.)

Edge/Levelsensitive

Run Fwd Enable(End Of Travel –Fwd)

2 When the input is active, motion is allowed in the forwarddirection. If the drive is in forward motion and the input is de-activated, the drive will immediately bring the motor to a stop, andcause a fault. Operates in both serial and local start/stop modes.If no input is defined with this function, it is assumed to beactivated.

Levelsensitive

Run Rev Enable(End Of Travel –Rev)

3 When the input is active, motion is allowed in the reversedirection. If the drive is in reverse motion and the input is de-activated, the drive will immediately bring the motor to a stop, andcause a fault. Operates in both serial and local start/stop modes.If no input is defined with this function, it is assumed to beactivated.

Levelsensitive

Start/Go 4 Start input initiates the preset function indicated by the preset bitinputs. Operates only in local start/stop modes.If no input is defined with this function, it is assumed to be de-activated.

Edgesensitive

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Stop 5 Positive-going stop input causes a controlled stop using the decelrate but does not de-energize the motor. Operates in both serialand local start/stop modes. Has no effect on Align or Commissionfunctions.If no input is defined with this function, it is assumed to be de-activated.

Edgesensitive

External fault 6 When asserted, an external fault condition exists.If no input is defined with this function, it is assumed to be de-activated.

Levelsensitive

Preset Bit 0 7 Preset Bit 0Level of preset bits 0-3 designate in binary coding which presetfunction (0-16) will be executed on a start signal. Logical 1 whenasserted, logical 0 when de-asserted. Operates only in localstart/stop modes.If no input is defined with this function, it is assumed to be de-activated.

Levelsensitive

Preset Bit 1 8 Preset Bit 1If no input is defined with this function, it is assumed to be de-activated.

Levelsensitive

Preset Bit 2 9 Preset Bit 2If no input is defined with this function, it is assumed to be de-activated.

Levelsensitive

Preset Bit 3 10 Preset Bit 3If no input is defined with this function, it is assumed to be de-activated.

Levelsensitive

Home 101 Input for Home switch (High speed input function only, inputs 1& 2). Used with Home Forward and Home Reverse functions.(See Find Home Fwd & Find Home Rev descriptions in Preset BitFunctions section)If no input is defined with this function and the Home Forward orHome Reverse functions are started, the drive will fault.

Edgesensitive

Registration Input 102 Input for Registration switch (high speed input function only,inputs 1 & 2). Used with Registration Move Forward andRegistration Move Reverse functions.If no input is defined with this function and the Register Forwardor Register Reverse functions are started, the drive will fault.(See Find Reg Fwd & Find Home Rev descriptions in Preset BitFunctions section)

Edgesensitive

Digital Input Connections

There are eight digital inputs. The inputs are intended for dry contact closure application. The contact closure activatesconfigured inputs. The logic threshold is 2.5 V. The inputs are protected from continuous overload of up to +25/-5

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VDC (where shared I/O PIN 15 and 16 require a minimum external impedance of 750Ω due to their dual functions).There is no isolation from internal logic supply.

The six digital input pins (i.e., PIN 9 through 14) may be configured to be all PULLED UP or PULLED DOWN.

The two digital input/output pins (i.e., PIN 15 and 16) are PULLED UP only.

Two of the digital inputs (i.e., DIN1 and DIN2) are high-speed. The high-speed functions are reserved for a Home orRegistration Inputs. If these inputs (DIN1 and DIN2) are used for functions other than the high-speed functions, theywe behave like the standard inputs.

The inputs are configurable from a list of functions. [See Table 2.1 .]

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This graphic shows ILOOP and VIN which are not available.Figure what?

Preset Bit Function Inputs

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This provides the user to have a greater number of input functions than the number of inputs used. This is provided viaPreset Function Bits 0, 1, 2, 3 which make up a binary number used to select a Preset Function. If 4 inputs are set upfor Preset Function Bits 0, 1, 2, and 3, this allows the user to have a total of 16 preset functions.

To define or change the Preset Bit Function setting, enter the Preset Bit Function Value (TABLE 4.1) into the Preset BitFunction Parameter [M00-M07] and SET.

Note:1 Input(s) must be configured as Preset Bit(s)2 To initiate the M Series parameters values, one must perform an IO INIT or reset power to the drive.

Example - Set Preset Function 0 as a Move Relative Function. -> Enter the value 7 into parameter M2A and SET. Toinitialize, click the IO Init button or reset power to the drive. The drive must be disabled (de-energized) to initiate IOInit the M parameters.

Table 4.0: Preset Bit Function Parameters [M2A – M39]Preset BitFunctionParameter

Parameter Name Parameter Description

M2A Preset_fcn_0 Allows the user to define each Preset Function #.[E.g. Define Preset Function 0 by entering the Preset FunctionValue (below). For example, by setting Preset_fcn_0 = 0, thebinary value 0 on the Preset Bit Inputs would be the fault input]

M2B Preset_fcn_1 “ “M2C Preset_fcn_2 “ “M2D Preset_fcn_3 “ “M2E Preset_fcn_4 “ “M2F Preset_fcn_5 “ “M30 Preset_fcn_6 “ “M31 Preset_fcn_7 “ “M32 Preset_fcn_8 “ “M33 Preset_fcn_9 “ “M34 Preset_fcn_10 “ “M35 Preset_fcn_11 “ “M36 Preset_fcn_12 “ “M37 Preset_fcn_13 “ “M38 Preset_fcn_14 “ “M39 Preset_fcn_15 “ “

Table 4.1: Preset Bit Functions & Function ValuesPreset BitFunction

Preset BitFunction Value

Description

Reset Fault 0 Resets all faults. If Enable input is high and the faults are reset, the motor

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will not re-energize until a rising edge Enable is detected (in local commandmode) or a motion command is detected.

Commission 1 Initiates a standard commissioning sequence.Jog Forward 2 Jog forward at the preset speed defined in corresponding Preset Speed #

parameter [MA5-M69].Jog Reverse 3 Jog reverse at the preset speed defined in corresponding Preset Speed #

parameter [MA5-M69]Find HomeForward

4 Jog forward at the speed defined in corresponding preset_speed_X parameter(M5A-M69). When the rising edge of a home signal is detected, the positionof the signal is marked, and a stop is performed at the current accel/decelrate. The home position (the 0 position) is saved as the position of the homesignal plus the offset in preset_pos_X_hi and preset_pos_X_lo. Note thatthe ending position of the move is NOT the home position.Note 1: If Offset = 0, then leading edge is New 0 position.Note 2: To move to home position, execute a preset absolute move to zero.

Find HomeReverse

5 Jog reverse at the speed defined in corresponding preset_speed_X parameter(M5A-M69). When the falling edge of a home signal is detected, theposition of the signal is marked, and a stop is performed at the currentaccel/decel rate. The home position (the 0 position) is saved as the positionof the home signal plus the offset in preset_pos_X_hi and preset_pos_X_lo.Note that the ending position of the move is NOT the home position.Note 1: If Offset = 0, then leading edge is New 0 position.Note 2: To move to home position, execute a preset absolute move to zero.

Move Absolute 6 Move to the absolute position defined in the preset_pos_X_hi andpreset_pos_X_lo parameters (M3A-M59) at speed defined inpreset_speed_X (M5A-M59).

Move Relative 7 Move to the relative (or incremental) position defined in thepreset_pos_X_hi and preset_pos_X_lo parameters (M3A-M59) at speeddefined in preset_speed_X (M5A-M59).

Find Reg Forward 8 Jog forward at the speed defined in preset_speed_X (M5A-M59) until a

RevOffset

New 0

FwdOffset

New 0

Reg Input

Offset

Fwd

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positive transition is detected on high speed input. The move ends at theregistration position plus the offset in preset_pos_X_hi and preset_pos_X_lo.The offset should provide enough length for the position controller todecelerate to a stop. If the offset is shorter than the deceleration distance,the position controller will exceed the accel/decel rate to attempt to end themove at the correct location. To achieve a proper deceleration segment, theregistration should not come during the acceleration segment.

Find Reg Reverse 9 Jog reverse at the speed defined in preset_speed_X (M5A-M59) until apositive transition is detected on high speed input (register input detected).The move ends at the registration position minus the offset inpreset_pos_X_hi and preset_pos_X_lo. The offset should provide enoughlength for the position controller to decelerate to a stop. If the offset isshorter than the deceleration distance, the position controller will exceed theaccel/decel rate to attempt to end the move at the correct location. Toachieve a proper deceleration segment, the registration should not comeduring the acceleration segment.

Preset PositionCounter

10 Sets the rotor position counter to the value specified in preset_pos_X_hi andpreset_pos_X_lo.

Align 11 Aligns the rotor to the current position command. Unused/Null 255 No function

Note: All moves (moves, jog, home and registration) use a Global Acceleration/Deceleration Parameter [F08]

Reg Input

OffsetRev

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Preset Position Setup

Preset Position Values for Home Offset, Move Relative, Move Absolute, and Registration Parameters[M3A – M59]

The position parameter is 32-bit signed parameter described in 2 words. The Preset Position parameters values(Preset_pos_#_Hi and Preset_pos_#_lo) in TABLE 4.1 are in electrical cycles. See TABLE 5.0, “Calculating PresetPosition parameters, (Preset_pos_#_Hi and Preset_pos_#_lo) in Electrical Cycles” below. To help calculate theposition in electrical cycles, See Appendix B and use “Calc Gains & Position Assistant.xls ” excel file provided withIBConfig software.

To define or change the Preset Position setting, enter the position in electrical cycles into the Preset Position Parameter[M00-M07] and SET.

Note:Preset Bit Functions must be configured as Home Offset, Home Relative or Home Absolute.

To initiate the M Series parameter values, one must perform an IO INIT or reset power to the drive. The drive must bedisabled (de-energized) to initiate IO Init the M parameters.

The maximum value to be entered in each word is ±32768. This translates into a Maximum single move positioncommand forRotary Motors = [32768 * 2 ÷ --(# poles)] revolutions2 pole mtr: ±32768 revolutions4 pole mtr: ±16384 revolutions6 pole mtr: ±10923 revolutions8 pole mtr: ±8192 revolutionsLinear Motors = ±32768 Electrical Cycles (which is well beyond the length of Linear motors)

Example – Set Preset Position 0 as a Move Relative Position of 945 degrees (2.625 revolution):For a 4-pole motor, 945 degrees equates to 5.25 electrical cycles. The 32-bit electrical cycle equivalent is equal to344064. Enter the value 5 into parameter M3B (Preset_pos_0_Hi) and SET. To initialize, perform an IO INIT or resetpower to the drive.

Table 5.0: Calculating Preset Position Parameters, (Preset_pos_#_Hi and Preset_pos_#_lo In ElectricalCycles

To Convert degrees to electrical cycles:Move_deg = 945; Poles = 4move_elec = (move_deg/360) * (poles/2) move_elec = 5.25The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = 344064The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = 5

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The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 16384

To Convert Revolutions to electrical cycles:Move_elec = (move_deg) * (poles/2)Follow the above steps (2) through (5)

Note: See “Calc Gain & Position.xls” which is bundled with IB Config software provided

To Convert Inches to electrical cycles:Move_Inch = 4;Poles = 2 (For Linear Motors use 2 poles)Pitch (Inch/Electrical Cycle) = 2.4 inch/ECmove_elec = (move_inch/Pitch) * (poles/2) move_elec = 1.666667The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = 109226.7The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = 1The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 43691

Note: See “Calc Gain & Position Assistant.xls” which bundled with IB Config software provided.

Table 5.1: Preset Position ParametersPreset PositionParameter #

Parameter Name Parameter Description

M3A Preset_pos_0_Lo Low word of Preset Position 0M3B Preset_pos_0_Hi High word of Preset Position 0M3C Preset_pos_1_Lo Low word of Preset Position 1M3D Preset_pos_1_Hi High word of Preset Position 1M3E Preset_pos_2_Lo Low word of Preset Position 2M3F Preset_pos_2_Hi High word of Preset Position 2M40 Preset_pos_3_Lo Low word of Preset Position 3M41 Preset_pos_3_Hi High word of Preset Position 3M42 Preset_pos_4_Lo Low word of Preset Position 4M43 Preset_pos_4_Hi High word of Preset Position 4M44 Preset_pos_5_Lo Low word of Preset Position 5M45 Preset_pos_5_Hi High word of Preset Position 5M46 Preset_pos_6_Lo Low word of Preset Position 6M47 Preset_pos_6_Hi High word of Preset Position 6

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M48 Preset_pos_7_Lo Low word of Preset Position 7M49 Preset_pos_7_Hi High word of Preset Position 7M4A Preset_pos_8_Lo Low word of Preset Position 8M4B Preset_pos_8_Hi High word of Preset Position 8M4C Preset_pos_9_Lo Low word of Preset Position 9M4D Preset_pos_9_Hi High word of Preset Position 9M4E Preset_pos_10_Lo Low word of Preset Position 10M4F Preset_pos_10_Hi High word of Preset Position 10M50 Preset_pos_11_Lo Low word of Preset Position 11M51 Preset_pos_11_Hi High word of Preset Position 11M52 Preset_pos_12_Lo Low word of Preset Position 12M53 Preset_pos_12_Hi High word of Preset Position 12M54 Preset_pos_13_Lo Low word of Preset Position 13M55 Preset_pos_13_Hi High word of Preset Position 13M56 Preset_pos_14_Lo Low word of Preset Position 14M57 Preset_pos_14_Hi High word of Preset Position 14M58 Preset_pos_15_Lo Low word of Preset Position 15M59 Preset_pos_15_Hi High word of Preset Position 15

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Preset Speed

Preset Speeds Parameters [M5A-M69]The speed values are in RPM for Rotary Motors and Electrical Cycles/Min for Linear Motors.

To define or change the Preset Speed setting, enter the speed value (RPM) into the Preset Speed Parameter [M00-M07] and SET.

Note:Preset Bit Functions must be configured as Home Offset, Home Relative or Home Absolute.

To initiate the M Series parameter values, click the IO Init button or reset power to the drive. The drive must bedisabled (de-energized) to initiate IO Init the M parameters.

Example 1– Set Preset Speed 0 for Move Relative Function 0 to 1000 rpm. -> Enter the value 1000 into parameterM5A and SET. To initialize, perform an IO INIT or reset power to the drive.

Example 2– Set Preset Speed 0 for Move Relative Function 0 to 30 ips for a Linear Motor with a pitch of 2.4 inch/EC.-> Enter the value 750 (=30 in/sec ÷ 2.4 EC/in * 60 sec/min = 750 EC/min) into parameter M5A and SET. Toinitialize, perform an IO INIT or reset power to the drive.

Table 6.0: Preset Speed ParametersPreset SpeedParameter #

Parameter Name Parameter Description

M5A Preset_Spd_0 Allows the user to define each Preset Speed #, which correspondsto the appropriate move, jog or home Preset_fcn_#.

M5B Preset_Spd_1 “ ‘M5C Preset_Spd_2 “ ‘M5D Preset_Spd_3 “ ‘M5E Preset_Spd_4 “ ‘M5F Preset_Spd_5 “ ‘M60 Preset_Spd_6 “ ‘M61 Preset_Spd_7 “ ‘M62 Preset_Spd_8 “ ‘M63 Preset_Spd_9 “ ‘M64 Preset_Spd_10 “ ‘M65 Preset_Spd_11 “ ‘M66 Preset_Spd_12 “ ‘M67 Preset_Spd_13 “ ‘M68 Preset_Spd_14 “ ‘M69 Preset_Spd_15 “ ‘

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Global Accel/Decel ParametersGlobal Acceleration/Deceleration Rate Parameter for all Moves [F08 – F09]Acceleration and deceleration rates values areRotary Motors = RPM/s ÷ 10Linear Motors = Electrical Cycles/min/sec ÷ 10. There is only one acceleration/deceleration parameter for all motion(Jog, Move Relative, Move Absolute, Home and Registration).

To define or change the Preset Acceleration/Deceleration setting, enter the acceleration and deceleration values into theAcceleration and Deceleration Parameters [F08] and SET.

Example 1– Set Acceleration/Deceleration for all motion to 200 rps2. -> Enter the value 1200 (= 200 rps2 * 60 sec/min÷ 10) into parameter F08 and SET.

Example 2– Set Acceleration/Deceleration for all motion to 100 ips2 where the pitch is 2.4 in/EC. -> Enter the value250 (= 100 ips2 ÷ 2.4 in/EC * 60 sec/min ÷ 10) into parameter F08 and SET.

Table 6.1: Acceleration/Deceleration Rate ParameterAccel/DecelParameter #

Parameter Name Parameter Description

F08 Accel/Decel_rate Global Acceleration/Deceleration rate for all motion (moves, jogs,home, and registration.Rotary Motors = RPM/s ÷ 10Linear Motors = Electrical Cycles per min/sec ÷ 10

For example, setting F08 = 1000 provides an acceleration anddeceleration rate of 10,000 RPM/s.

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Digital Outputs Functions

The drive has 2 digital outputs, 2 relay outputs, and a tri-state FBK LED. Their functions are modified through IndexBlokConfiguration Tool or via the Serial Communication Protocol by configuring the value of the internal drive parameters M09through M0CThe tri-state FBK LED has two configurable states via parameters M21 and M22. Third state’s configuration is based upon theconfiguration of the other two states. In other words, the third state is active when the other two states are both active. Thecolor scheme of each of the FBK LED states is as follows:

FBK LEDState

Color

1 Red when state 1 function has been satisfied.2 Orange when state 1 function has been satisfied.3 Yellow when both state 1 & 2 functions has been satisfied.

To define or change the Digital Output setting, enter the Output Function Value (TABLE 7.1) into the Output Parameter [M09-M0A]. Note to initiate the M Series parameters values, one must perform an IO INIT when the drive is disabled or reset powerto the drive.

Example – Set Output 2 as a Fault Output. -> Enter the value 4 into parameter M09 and SET. To initialize the M SeriesParameters, perform an IO INIT when the drive is disabled or reset power to the drive.

Table 7.0: Digital Output ParametersDigital OutputParameter #

Parameter Name Parameter Description

M09 1 Digital Output 1 Function Allows the user to program each output’s function.[e.g. Program output 1 by entering the Output Function Value(below) in the Programmable Output Function]

M0A 1 Digital Output 2 Function “ ”

1 To configure pins 15 & 16 to be outputs functions, need to configure M06 & M0A to Null (0)

Table 7.1: Relay Output ParametersDigital OutputParameter #

Parameter Name Parameter Description

M0B Relay Output 1 Function(RLY1 – Pin 21 is NO)

Allows the user to program each output’s function.[e.g. Program output 1 by entering the Output Function Value(below) in the Programmable Output Function]

M0C Relay Output 2 Function(RLY2 – Pin 23 is NC;RLY2 – Pin 25 is NO)

“ ”

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Table 7.2: FBK LED State Function ParametersDigital OutputParameter #

Parameter Name Parameter Description

M21 FBK LED State 1 Function Allows the user to program the function of FBK LED state. TheFBK LED state 1 will turn red when the condition is satisfied.

[e.g. Program FBK LED State 1 by entering the Output FunctionValue (below) in the Programmable Output Function]

M22 FBK LED State 2 Function Allows the user to program the function of FBK LED state. TheFBK LED state 2 will turn orange when the condition is satisfied.

Table 7.3: Output Functions Values for Digital Outputs 1-2 Parameters [M09 - M0C and M21 - M22]ProgrammableOutput Function

FunctionValue

Description States

Set Output High 0 Sets output to High Sets output state to HighSet Output Lo 1 Sets output to Low Sets output state to LoAt Speed 2 Asserts output when velocity is within

±at_speed_range (M1E) RPMof the commanded velocity.

Linear Motors in Electrical Cycles per min.

Active = motor speed error is lessthan or equal to at_speed_range.Not Active = motor speed error isgreater than at_speed_range.

Drive Enabled 3 Asserted when drive is energized. Active = Drive energizeInactive = Drive de-energized

Fault 4 Asserts output when in fault mode and de-asserts when not in fault mode.

Active = Fault modeNot Active = Not in Fault mode

Reverse 5 Asserts output when in moving inreverse/negative direction.De-asserts output when in moving inforward/positive direction.When drive is stopped, output remains inmost recent moving state.

Active = Reverse/Negative directionNot Active = Forward/Positivedirection

Overload Alert 6 Asserts output when I2T (i_sqr_t, D0E)

exceeds Overload Alert Value (M1A).

Active = Greater than OverloadvalueNot Active = Below Overload value

Overtemp Alert 7 Asserts output when drive temperatureexceeds Overtemp Alert Value (M1B).

Active = OvertempNot Active = Not overtemp

Commissioning 8 Activates output when drive isCommissioning

Active = CommissioningNot Active = Not Commissioning

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In Position/MoveComplete

9 An active output indicates when the drivetransitions from servo mode to DC holdmode. An inactive output indicated thedrive is disabled or is moving.

Active = after transition to DC HoldNot Active = Moving or disabled

Moving/NotMoving

10 An active output indicates that the drive isservoing or moving (jogging, indexing,homing, registration, in motion) and setsoutput to inactive when move is complete.

Active = Moving (Servoing)Not Active = Not Moving (in holdmode or disabled)

Users can customized when the At Speed, Overload Alert and Overtemp Alert outputs activates. To customize these output, theuser needs to specify the level or range in the appropriate parameter below.

Example – Set Output 2 as a At Speed Output. -> Enter the value 2 into parameter M09 and SET. To specify the±at_speed_range , enter the ± rpm value into M1E. To initialize the M Series Parameters, perform an IO INIT when the drive isdisabled or reset power to the drive.

Table 7.4 At Speed, Overload and Overtemp Alert Customized Activation Level ParametersOverload AlertLevel

M1A Scaling: 100*(Ialert/Irated)2 When i_sqr_t reaches this value,the OVERLOAD ALERT digitaloutput will be set, if any outputsare defined to have this function.

Overtemp Alert M1B 0.1 degrees C When heat_sink_temp reachesheat_sink_hot minus this value,the OVERLOAD ALERT digitaloutput will be set, if any outputsare defined to have this function.

At Speed Range M1E Rotary Motors in RPMLinear Motors in Electrical Cycles per min

Any digital output set to functionAt Speed is asserted when drive isrunning and motor speed is withinAT_SPEED_RANGE of speed set-point.

Digital Output Connections

There are two open-collctor outputs. The outputs can be externally pulled up to +5VDC, +12 VDC, or +24 VDC and are ratedat 50 mA. The outputs are internally pulled up to +5V through 4.7kΩ . The response time is 2 msec.

The outputs are configurable from a list of functions. [See Table 7.3 .]

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Digital & Relay Output Connections & SchematicILOOP and VIN appear in this schematic

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Analog Output

The drive has 3 analog outputs. Their functions are modified through IndexBlok Configuration Tool or via the SerialCommunication Protocol by configuring the value of the internal drive parameters ANALOG OUTPUT 1 FCN (M0D),ANALOG OUTPUT 2 FCN (M0E), and ANALOG OUTPUT 3 FCN (M0F). These outputs are individually scaled(M27-M29) and range from 0 to 10 V output.

Analog Output FucntionsFunction M0D – M0F

Internal DriveParameter Value

Function Description

Null Function 0 Ignore 0 – 10 V outputCurrent 1 Current (0 - peak) scaled to AO_X_SCALE.Torque 2 Torque scaled to AO_X_SCALE.Speed 3 Speed scaled to AO_X_SCALE.Vout 4 Output voltage scaled to AO_X_SCALE.DC Link Voltage 5 DC Link voltage scaled to AO_X_SCALE.Hi ResolutionPosition

6 0-1 Electrical Cycle scaled to AO_X_SCALE.

Lo ResolutionPosition

7 0-65,536 Electrical Cycle scaled to AO_X_SCALE.

Null Function > 10 Ignore 0 – 10V outputTable 6.2

[Note: User must define the scale of analog outputs. The scaling of analog outputs is defined by parameters ANALOG OUT 1 SCALE (M27), ANALOG OUT 2 SCALE (M28) and ANALOG OUT3 SCALE (M29). The value of the AO_X_SCALE parameters defines the 10 V output value of the analog output. The scaling of the internal parameters is defined in Appendix E.]

Analog Output Scaling Parameters (M27-M29)Analog OutputFunction to Scale

Units Scaling Description

Current = Current, pk *ki_imag

Set the Current Scale Factor such that 10 V equals the maximum current.The Current AO scale factor must be in the same units as D03 = Current,pk * ki_imag.

Torque = N-m * 100 Set the Torque Scale Factor such that 10 V equals the maximum torque.The Torque AO scale factor must be in the same units as D0B = N-m *100.

Speed Rotary Motors =rpm

Linear Motors =EC/min

Set the Speed Scale Factor such that 10 V equals the maximum speed.The Speed AO scale factor must be in the same units as D09 = rpm forRotary motors and Electrical Cycles/min for Linear motors.

Vout = Motor Volts,pk* drive_kv

Set the Output Voltage Scale Factor such that 10 V equals the maximumOutput Voltage. The Output Voltage AO scale factor must be in the

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same units as D06 = Motor Volts,pk * drive_kv.

DC Link Voltage = VDC *drive_kv.

Set the DC Link Voltage Scale Factor such that 10 V equals themaximum DC Link Voltage. The DC Link Voltage AO scale factormust be in the same units as D07 = VDC * drive_kv.

High ResolutionPosition

= Low word of

216

360 * Position

(degrees)

Set the High Resolution Position Scale Factor such that 10 V equals themaximum High Resolution Position. The High Resolution Position AOscale factor must be in the same units as D20 = Lo word of

216

360 * Position (degrees)

Low ResolutionPosition

= High word of

216

360 * Position

(degrees)

Set the Low Resolution Position Scale Factor such that 10 V equals themaximum Low Resolution Position. The Low Resolution Position AOscale factor must be in the same units as D21 = High word of

216

360 * Position (degrees)

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Analog Output Connections

There are thee analog outputs. The outputs have 8-bit resolution and produce an output voltage of 0 – 10 volts. Theoutputs are protected from continuous overload of up to +25/-5 VDC. There is no isolation from internal logic supply.Why wouldn’t this information appear in the first part of this section? (Including the line below…)

The outputs are configurable from a list of functions. [See Table 6.2 .]

[See Figure 3.]

Figure 3

Appendix A: Home Routine Examples

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All absolute moves are referenced from a ‘zero’ position. Absolute moves consist of a specific number of positive ornegative rotor revolutions and fractions of a revolution from this point. When the IndexBlok is powered up, it assumesthe current rotor position is ‘zero’. For a few applications, this may be perfectly acceptable. However, for mostapplications, it is necessary to establish the ‘zero’ or home position from which all absolute moves are referenced. Todo this, a home signal is required, connected to digital input 1 or 2, that will transition at the exact point of ‘zero’.Typically, this signal will be generated by a switch triggered by movement of the load driven by the motor. The FindHome routines described below are examples of how to command the rotor to find this switch transition.

The home position can be almost anywhere the application can support. However, the home switch should always beapproached from the same direction, if possible. A home switch located in the center of the range of travel means theapplication controller will have to somehow determine which side of the switch the actuator is on to determine whichFind Home routine to use. If the Home switch is at one end of travel, the application could reasonably assume that onlyone of the Find Home routines needs to be used for referencing.

For example: If an IndexBlok is controlling a lead screw and nut assembly, on power up it will assume that the currentposition of the nut is ‘zero’. This probably will not be acceptable because all absolute moves will be referenced fromthis random position. The IndexBlok needs to find the true ‘zero’ position so all absolute moves can be made from thatpoint. After power up, the application controller should command the IndexBlok to perform a Find Home routine.There are two Find Home routines: Find Home Forward and Find Home Reverse.

Find Home Forward jogs forward until the rising edge of a home signal is detected. This position is marked in thedrive and the rotor is ramped to a stop. The ‘zero’ position is the position at which the home signal is received PLUSan offset position. Note that the ending position of this move is NOT the home position. If the offset parameters areequal to zero, then the position at which the home signal is received is ‘zero’. If, after ramping to a stop, the rotor needsto move to 0, then an absolute move to 0 should be executed.

Find Home Reverse jogs backward until the falling edge of a home signal is detected. This is to ensure that Find HomeForward and Find Home Reverse detect the home switch transition at as close to the same point as possible. Note thatusing certain types of switches may result in inadvertent inaccuracies if an application uses both Find Home routines.A magnetic proximity switch may, for example, make and break at different points. When the falling edge is detected,the point is marked in the drive and the motor is ramped to a stop. The ‘zero’ position is the point at which the fallingedge was detected PLUS the offset position.

In the lead screw example, if the home position signal is generated by a switch set somewhere in the middle of travel, itwill be necessary to know which side of the switch the nut is on after a power failure . The application controller isresponsible for knowing which one of the two Find Home moves to perform. If, however, the home signal is generatednear the end of the screw it may be possible to use only one of the Find Home commands. Especially if the nut onlytravels to the home position during referencing.

1) Example of the following Home Routines:a) Search for home on Leading edge, stop & creep back to 1st edge

i) How to program:(1) Set M00 = 101 (set Digital Input 1 = Home Input)(2) Set M01 = 4 (set Digital Input 2 = Preset Bit 0)(3) Set M02 = 5 (set Digital Input 3 = Preset Bit 1)

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(4) Set M03 = 2 (set Digital Input 4 = START)(5) M2B = 4 (set Preset_fnc_1 to Home Fwd)(6) M2C = 6 (set Preset_fnc_2 to Move Absolute)(7) Set M3C = 0 & M3D = 0 (When Homing, make Zero position to Leading edge by setting the offset

distance to 0 by setting Preset_pos_1_lo to 0 and Preset_pos_1_hi to 0)(8) Set M3E = 0 & M3F = 0 (Set Absolute position to Zero for Preset_fnc_2 by setting Preset_pos_2_lo

to 0 and Preset_pos_2_hi to 0)(9) Need to also set the speeds in M5B (HOME-preset_sp_1) & M5C (BACK-UP-preset_sp_2)

ii) How to active this home routine:(1) Active Input 2 (with Input 3 inactive) & Input 4 to start home(2) After home, Active Input 3 (with Input 2 inactive) & Input 4 to move back to Leading Edge (Zero

Position)b) Search for, find Leading edge & offset to some specified distance from the edge to a stop.

i) How to program:(1) Set M00 = 101 (set Digital Input 1 = Home Input)(2) Set M01 = 4 (set Digital Input 2 = Preset Bit 0)(3) Set M02 = 2 (set Digital Input 3 = START)(4) M2B = 4 (set Preset_fnc_1 to Home Fwd)(5) Set M3C = 0 & M3D = 12 (When Homing, make Zero position to 6 Revolutions past the Leading

edge by setting the offset distance to 12 revs by setting Preset_pos_1_lo= 0 andPreset_pos_1_hi =12)

(6) Need to also set the speeds in M5B (HOME-preset_sp_1)ii) How to active this home routine:

(1) Active Input 2 & Input 3 to start home. When it sees the leading edge it will move 6 revolutions, stopand set position to Zero.

Appendix B: Calculating Position Values

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To calculate position values in Electrical Cycles for position parameters, Serial_Pos_ Lo and Hi [C08 and C09] andPreset_Pos # Lo and Hi [M3A-M59], use “Calc Gain & Position Assistant.xls” which is bundled with IB Configsoftware provided.

Open Calc Gain & Position Assistant.xls with Microsoft Excel, and click on Calc Position worksheet. You shouldsee the following screen.

Enter the move distance (in Move_Degrees, Move_Revolutions or Move_Inches).• Enter the number of motor poles. (if using linear distance will need to enter the Pitch in Inches/rev)• Enter the Move_Elec_Hi value calculated in the Pos_Hi parameter and Move_Elec_Lo value calculated in the

Pos_Lo parameter. (e.g. for Move_deg = 12, Set Serial Pos Hi [C09] = 0 and Serial Pos Lo [C08] =4369)• Note: The reference frame of the position will be dependent on the

• Serial start selection (Relative/Incremental or Absolute Serial Start) for serial moves• Preset function selection (Move Absolute or Move Relative)

Example 1: Negative Position of –12345 degrees

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Calculating Preset Position Values In Electrical Cycles for Parameters, (Preset_pos_#_Hi andPreset_pos_#_lo)To Convert degrees to electrical cycles:Move_deg = -12345; Poles = 4move_elec = (move_deg/360) * (poles/2) move_elec = -68.583The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = -4494677The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = -69The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 27307

To Convert Revolutions to electrical cycles:Move_elec = (move_deg) * (poles/2)Follow the above steps (2) through (5)

Note: See “Calc Gain & Position Assistant.xls” which is bundled with IB Config software provided.

Example 2: Negative Position of 12345 degreesCalculating Preset Position Values In Electrical Cycles for Parameters, (Preset_pos_#_Hi andPreset_pos_#_lo)To Convert degrees to electrical cycles:Move_deg = 12345; Poles = 4move_elec = (move_deg/360) * (poles/2) move_elec = 68.583The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = 4494677The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = 68The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 38229

To Convert Revolutions to electrical cycles:Move_elec = (move_deg) * (poles/2)Follow the above steps (2) through (5)Note: See “Calc Gain & Position Assistant.xls” which bundled with IB Config software provided.

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Example 3: Negative Position of 360 degreesCalculating Preset Position Values In Electrical Cycles for Parameters, (Preset_pos_#_Hi andPreset_pos_#_lo)To Convert degrees to electrical cycles:Move_deg = 360; Poles = 4move_elec = (move_deg/360) * (poles/2) move_elec = 2The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = 131072The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = 2The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 0

To Convert Revolutions to electrical cycles:Move_elec = (move_deg) * (poles/2)Follow the above steps (2) through (5)

Note: See “Calc Gain & Position Assistant.xls” which bundled with IB Config software provided.

Example 4: Negative Position of 100 degreesCalculating Preset Position Values In Electrical Cycles for Parameters, (Preset_pos_#_Hi andPreset_pos_#_lo)To Convert degrees to electrical cycles:Move_deg = 100; Poles = 4move_elec = (move_deg/360) * (poles/2) move_elec = 0.556The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = 36409The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = 0The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 36409

To Convert Revolutions to electrical cycles:Move_elec = (move_deg) * (poles/2)Follow the above steps (2) through (5)

Note: See “Calc Gain & Position Assistant.xls” which bundled with IB Config software provided.

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Example 5: 4 Inches MoveCalculating Preset Position Values In Electrical Cycles for Parameters, (Preset_pos_#_Hi andPreset_pos_#_lo)To Convert Inches to electrical cycles:Move_Inch = 4;Poles = 2 (For Linear Motors use 2 poles)Pitch (Inch/Electrical Cycle) = 2.4 inch/ECmove_elec = (move_inch/Pitch) * (poles/2) move_elec = 1.666667The 32 bit move is given by:move_elec_32 = move_elec * 2^16 move_elec_32 = 109226.7The High Word of the move is the integer part of the move, that is the greater integer less than the move:Preset_pos_#_Hi = INT(move_elec) Preset_pos_#_Hi = 1The Low Word of the move is the fraction part time 2^16:Preset_pos_#_Lo = (move_elec - Preset_pos_#_Hi) * 2^16 Preset_pos_#_Lo = 43691

Note: See “Calc Gain & Position Assistant.xls” which bundled with IB Config software provided.

Appendix C: Serial Communication Protocol

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This section describes the serial communication capabilities of the IndexBlok including the following:

• Connection of an external computer to monitor and control the IndexBlok.• Description of how to establish a network of IndexBloks.• How to communicate with the IndexBlok using the serial communication protocol.

A. Hardware Protocol

1. RS-485 Serial Port Specifications

a. Overview

An external computer can be used to remotely setup, monitor, and control the operation of theIndexBlok module by connecting them over the included serial link. As many as 30 drives can belinked together in a network, allowing coordination of integrated systems by a host computer.Standard EIA RS-485 serial connection (up to 30 drives) allows reliable communication overrelatively long distances. This standard has been retired by ANSI. The committee which maintainedthis standard disbanded a few years ago and ANSI was unable to find another group willing to take iton.

b. RS-485 Connections

The IndexBlok has one RS-485 serial connection that utilizes a standard 6-pin RJ-11 phoneconnector. The RS485 differential connections provide greater noise immunity than single-ended RS-232 or RS-422 connections. You can connect an RS-232 device using an RS-485 to RS-232converter/adapter. Consult the factory for more information on this orderable option.

RS-485 SpecificationsBaud Rate 1200 - 19200Data Length 8 bitsStop Bits 1 bitParity none

Serial ConnectionsPin Name Description1 +12V +12V Auxiliary Power2 COM Power Common3 A RS485 Signal4 B RS-485 Signal5 SCOM Signal Common6 NC No Connection

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When daisy chaining drives only pins 2, 3 and 4 should be used. A standard RJ-11 tee can be used for daisy chainingdrivesand can be plugged directly into the IndexBlok. If it is necessary to install the tee in another location, any cablelength between the tee and the drive should be minimized. Up to 300m of twisted pair cable can be used to connectdrives. The power ground/return connection should not be made via the RJ-11 connector; a separate return cable isrequired.

B. Communication Protocol

The host acts as the master and initiates the transmissions. The protocol has two basic commands, read or write. Theread command allows the host to read the value of any parameter. The write command allows the host to write to aparameter that is write accessible.

The typical transmission sequence to the drive is as follows:

• The host transmits a command to the drive, which includes the drive addressing.• The host should receive a response within 400 msec. If it does not receive a response the host should resend the

command. If this is tried for ten (10) times and no response is received, the host should indicate a transmissionerror.

• The drive that is addressed in the command sends a response to the host.• After a proper reply was received, the host should wait approximately 1 msec before sending another message.

1. Issuing a Read Command

The read command consists of 6 characters in the following order: a dollar sign (the read command character);a one-character address; a three-character parameter number, in hex; and a checksum character. The addresscan be 1-9, A-Z. The list of available parameters, and their hex addresses, are provided in Appendix E:Internal Drive Parameters. The checksum is a calculated value and will be discussed later. The format of thetransmission is: $WXXXC<CR>

Read Command Address Param Char1 Param Char2 Param Char3 Checksum Carriage Return$ W X1 X2 X3 C <CR>

Note that the IndexBlok uses a half-duplex serial communications protocol. This means that one twistedpair of wires is used for transmit and receive. A host (computer, PLC, etc.) is required to originate allcommunications. When a drive detects a communication which includes its assigned address the driveresponds with an acknowledgement that the message was received and the instructions carried out, orwith an error message to indicate the message was not received correctly. If the host needs to monitorsome drive data the host must poll the drive asking for the data. The drive will send the informationevery time it is requested, but only when it is specifically requested.

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After a Read Request the IndexBlok responds with the requested message. The message is preceded with the% character, denoting this as a response to a query, followed by W the address of the IndexBlok, XXX theparameter in hex, YYYY the data stored in that parameter in hex, and C the checksum:%WXXXYYYYC<CR>

ReadCommand

Address ParamChar1

ParamChar2

ParamChar3

DataChar1

DataChar2

DataChar3

DataChar4

Check-sum

CarriageReturn

% W X1 X2 X3 Y1 Y2 Y3 Y4 C <CR>

2. Issuing a Write Command

The write command is used to send setup or command and control data to the drive. The host can only senddata to a parameter that is write accessible. If the para meter is not write accessible, the drive will respond withan error. The write command has the same format as that of the response from a read command, but ispreceded by the & write command character. The format for the data string is: &WXXXYYYYC<CR>

WriteCommand

Address ParamChar1

ParamChar2

ParamChar3

DataChar1

DataChar2

DataChar3

DataChar4

Check -sum

CarriageReturn

& W X1 X2 X3 Y1 Y2 Y3 Y4 C <CR>

If the checksum and the command are valid, the drive will write the data to the Parameter indicated and thenrespond back to the host that it has completed the command. The response that is sent is prefaced with the #acknowledgement character (ACK), followed by the address of the responding IndexBlok and the messagechecksum: #XC<CR>.

ACK character Address Checksum Carriage Return# X C <CR>

3. Drive Transmitted Serial Errors

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If the IndexBlok receives a command that is addressed to it but that it does not understand (an invalidcommand) or for which the checksum is incorrect, the module will respond with an error message. Themessage is preceded with the ? error character, the drive address, and the checksum: ?XYC<CR>

Error character Address Error Code Checksum Carriage Return? X Y C <CR>

The error codes are:

Error Code Description1 Bad Checksum2 Bad Hex Character

For example, if a checksum is calculated incorrectly by the host and addressed for drive 1, the drive willrespond with: ?11A<CR>

4. Communication Error Detection

The communication protocol includes a method of detecting errors in the transmission of information. Theseerrors may be caused by electrical interference corrupting the data, by intermittent electrical contact, or by twoor more IndexBloks responding to the same message. The first line of defense for detecting these errors isusing a message checksum. A checksum of all the information to be transmitted is calculated by the host andadded to the message as the last character sent before the end of transmission (carriage Return character). Themodule receives the transmitted information and calculates a checksum on the message it captured, thencompares it to the checksum it received from the host. If the two agree the data is accepted as good. If theyare not the same the drive transmits an error message which should cause the host to retransmit the data.

5. Checksum Calculation

The checksum is calculated as follows:

• Perform an 8-bit ADD of the hex values of each of the ASCII characters that are to be sent. Do notinclude the checksum byte or the carriage return character.

• Take the sum and AND it with 7Fh. This will limit the calculated number to the first 128 ASCIIcharacters.

• Now take the above result and OR it with 40h. This will shift the characters by 40 hex characters,effectively shifting the result to one of the printable characters.

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• Now look up the 8-bit Hex value in a standard ASCII table to determine the character that is to be used asthe checksum.

.

This is a bad example since this is an invalid message! Try this one instead:

Let’s assume that you want to Write the value 0A34h to parameter A21 of drive 1.This results in the command string: ‘&1A210A34’. The ASCII code hex string equivalent is263141323130413334h.

1. Logical 8-bit (Modulus) ADD of each character = D3h.2. Logical AND of D3h with 7Fh = 53h (equivalent to setting bit seven to 0)3. Logical OR of 53h with 40h = 53h (equivalent to setting bit six to 1)4. Look up 53h in an ASCII table = ‘S’ (upper case)

After the host appends the carriage return character, the message ‘&1A211A34S<CR>’ is then transmitted tothe drive. Note that this is the ASCII string representation of this message. The actual hex values transmittedto the drive are: 263141323130413334530Dh.

If the command and the checksum are valid, the drive will respond with the appropriate response, as describedpreviously.If the checksum or the command is not valid, the drive will respond with an error message.

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Troubleshooting – General

Description SolutionNothing happens when I press start 1. Check Run Enable Input

2. Check End of Travel (Run Fwd/Rev Enable) Inputs3. Check Start/Stop Source under Drive Mode in IB

Config or parameter C01

No Motion

No Motion to Serial Move

No Motion to Serial Preset Move

No Motion to Digital Input Preset Moves

4. Check Run Enable Input5. Check End of Travel (Run Fwd/Rev Enable) Inputs6. Check Start/Stop Source under Drive Mode in IB

Config or parameter C01

Same as above and7. Check Serial Move Parameters8. Serial Speed Command (C02)9. Serial Position Command (C08 and C09)10. Global Accel/Decel Command (F08)11. Check Serial Start Mode – Start Absolute or Start

Relative (C00)

Same as above and12. Check Serial Preset Index Parameter (C0A)13. Did you perform an IO Init (C00 bit 14) or press the

IO Init button while the drive was disabled afterchanging any M series parameters. Drive must bedisabled to initiate M parameters – performing an IOInit

14. Check Preset Function parameter (M2B-M39). JogFwd is 2, Jog Rev is 3, Find home Fwd is 4, FindHome Rev is 5, Move absolute is function 6, moverelative is function 7, Reg move Fwd is 8, and Regmove Rev is 9.

15. Check Preset Position Commands (M3A-M59). NotePreset_Cmd_Lo is the low word and Preset_Cmd_Hiis the high word.

16. Check Preset Speed Commands (M5A-M69)

Same as above and17. Check Input connections including digital ground18. Check input active level/Polarity (M08)19. Check Input functions (M00-M07). Note: Home and

Registration inputs are only available on Inputs 1(M00) and Input 2 (M01)

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Does not Commission (Do not hear current going tomotor)

1. Check Run Enable Input2. Check End of Travel (Run Fwd/Rev Enable) Inputs3. Check Omega Base (L1A). Did you recycle power

after changing Omega Base? Did do re-enterparameters after changing Omega base and recyclingpower?

Motor does not run smooth 1. Check Inertia settings – Actual inertia might besmaller than setting in Calc Gains and PositionAssistant.xls to calculate gains, causing gains to betoo low– increase inertia or set inertia values to actualmotor and load settings (Steps 2 & 3) and SET thenew gain values.

2. Check Gain Setting – gains might be too low foractual inertia – Increase bandwidth frequency (Step 7)setting using Use Calc Gains and PositionAssistant.xls and enter new gain values.

Speed overshoots when I accelerate 1. Check Inertia settings – actual inertia might to behigher than setting in Calc Gains and PositionAssistant.xls to calculate gains causing gains to be toohigh– decrease inertia or set inertia values to actualmotor and load settings (Steps 2 & 3) and SET in newgain values.

2. Check Gain Settings – gains might be high for actualinertia – decrease bandwidth frequency (Step 7)setting using Use Calc Gains and PositionAssistant.xls and SET new gain values.

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Motor does not maintain speed 1. Check Inertia settings – Actual inertia might to besmaller than setting in Calc Gains and PositionAssistant.xls to calculate gains. Use Calc Gains andPosition Assistant.xls to calculate gains – set inertiavalues to actual motor and load settings (Steps 2 & 3)

2. Check Gain Setting – gains might be too low foractual inertia – Increase bandwidth frequency (Step 7)setting using Use Calc Gains and PositionAssistant.xls and SET new gain values.

Motor gets too hot 1. Check programmable holding current when at rest,parameter H01.

2. Check current setting in Motor setup.

Motor does not follow accel or decel ramp 1. Check F08 – Global Acceleration/Deceleration rateparameter.

2. Check Load Limit (~ Torque Limit) parameter G123. Check Inertia settings – actual inertia might to be

lower than setting in Calc Gains and PositionAssistant.xls to calculate gains causing gains to be toolow – increase inertia or set inertia values to actualmotor and load settings (Steps 2 & 3) and SET in newgain values.

4. Check Gain Setting – gains might be too low foractual inertia – Increase bandwidth frequency (Step 7)setting using Use Calc Gains and PositionAssistant.xls and SET new gain values.

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Troubleshooting – Fault Codes

The following tables will assist the user to isolate, understand, and solve a problem with the drive based upon the faultnumber generated. The generated fault number can be found under the Fault Que, in the Utility Menu or byrequesting the internal drive parameters E0B, E14, E1D, or E26 via the Serial Communication Protocol.

A. Sat faults

Fault Number(hex)

Description Explanation Solution

1000h Sat fault Sat Fault Contact the Applications Department

B. Phase Overcurrent

Fault Number(hex)

Description Explanation Solution

3000h PhaseOvercurrent

1. Excessive starting torque or high peaktorque transients.

Check the Motor Load Limit. Decrease value.

2. Rapid large increases in load (impact) Check the Rotor Inertia and Load Inertia.Increase the value of K00 (KP_TRQ) and K01(KI_TRQ) proportionally.

3. Rapid accel and/or decel4. Omega_base (L1A) set too high

Increase acceleration and/or deceleration values.Reduce Omega Base to the nearest value of 377,754, and 1131.

C. DC Link Undervoltage

Fault Number(hex)

Description Explanation Solution

5000h DC linkundervoltage

1. The bus voltage is below the specifiedundervoltage trip point.

Undervoltage trip point is 140 VDC for120VAC and 120/240VAC rated modules,200VDC for 230 VAC rated modules and400 VDC for 460 VAC rated modules

An undervoltage condition will not harm thedrive.

Increase the bus voltage above the undervoltagetrip point.

D. DC Link Overvoltage

Fault Number(hex)

Description Explanation Solution

6000h DC link 1. The bus voltage is above the specified Decrease the bus voltage below the overvoltage

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overvoltage overvoltage trip point.

Overvoltage trip point is 220 VDC for120VAC rated modules, 420 VDC for 230VAC rated modules and 820 VDC for 460VAC rated modules.

trip point.

E. A/D Offset Fault

Fault Number(hex)

Description Explanation Solution

8000h A/D offset outof range

Drives current offset measurement issignificantly of from calibrated value.

If persists, contact the Applications department.

F. Motor Fault

Fault Number(hex)

Description Explanation Solution

9001h Motor overspeed Motor is commanded over Maximum speed(F07)

1. Check and/or change commanded motorspeed (Serial Speed Cmd-C02, Serial JogSpeed-C03, Preset speed-M5A-M69)

2. Check and/or change Maximum speed(F07)

9003h Motor pull outfault

Our SensorlesServo tracking algorithm lostalignment with the rotor.1. Dynamic transient (e.g. Instantaneous

Jam) was to fast for use to follow2. BEMF value entered in motor setup is far

off from the motor’s true BEMF value3. Low BEMF motors and Omega Base

parameter (L1E) is set incorrectly (too lowor too high.)

1. Check for Jams or dynamic transients.2. Check Gain settings– Use Calc Gains and

Position Assistant.xls to calculate gains.3. Check BEMF value entered in Motor

setup with actual motor BEMF spec.Check tom make sure value entered is inVpk/krms. A number of motormanufacturers rate BEMF in Vrms/krpm.Vpk = Vrms * SQRT(2).

4. Check Omega Base (L1E) setting to makesure it is set correctly for motor’s BEMF.See Motor Setup – Omega Base SettingSection in Appendix.

9006h Profile remainedon porch toolong

Software profiler ramps down to soon. If persists, contact the Applications Department.

9007h Servo did notlock on positioncommand

Our SensorlesServo algorithm could not findfinal position fast enough.1. Tuning gains are set too low such that we

are too sluggish to find final position.2. Tuning gains are too high for inertia so

that we are ringing and can’t settle.

1. Check Gain settings – Use Calc Gains andPosition Assistant.xls to calculate gains -Tune gains with higher bandwidthfrequency (Step 7) setting.

2. Check Inertia settings – Use Calc Gainsand Position Assistant.xls to calculategains – set inertia values to actual motorand load settings (Steps 2 & 3) and lowerbandwidth frequency (Step 7) setting.

3. Can verify if motor is ringing by setting ananalog output as a Hi Res Position and

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looking at analog output on oscilloscope.

9008h End of travellimit hit

End of travel (Run Fwd/Rev Enable) limit inputis hit or disabled

1. Check End of travel (Run Fwd/RevEnable) inputs. Move load off limits oractivate limit and command motion in theopposite direction.

9009h Start with drivedisabled

Drive is not enabled 1. Check Run Enable input. (note if an inputis not defined as a Run Enable, it isassumed to be activated.

900Ah Home with nodefined homeinput

Drive was commanded to start slewing and lookfor home input but there is no Home Inputdefined.

1. Check Digital Input [M00-M07] setting2. Check Preset Bit Function [M2A-M39]

Settings.3. Home Input can only be configured on

Inputs 1 or 2 [M00 and M01 respectively.

900Bh Reg move withno defined reginput

Drive was commanded to start slewing and lookfor a registration input but there is noRegistration Input defined.

1. Check Digital Input [M00-M07] setting2. Check Preset Bit Function [M2A-M39]

Settings.3. Reg Input can only be configured on

Inputs 1 or 2 [M00 and M01 respectively.

G. Heat Sink Overtemp

Fault Number(hex)

Description Explanation Solution

A000h Heatsinkovertemp

1. Fan malfunction. 1. Verify that the airflow is not blocked.

2. Verify that the fan is wired properly.

3. Verify that the fan operates properly.

2. Excessive ambient temperature. 1. Verify that the ambient temperature is notexceeding the maximum ambienttemperature for a given horsepower anddrive assembly. [See Appendix B.]

H. Motor Thermal Overload

Fault Number(hex)

Description Explanation Solution

B000h Motor thermaloverload

I2T protection with trip point based on J02parameter and time constant based on J01.

1. Check rated motor current setting enteredin Motor Setup

2. Check duty

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3. Check for stead-state load

I. Communication Loss

Fault Number(hex)

Description Explanation Solution

C000h Communicationsloss

1. Serial communication between drive andcomputer is lost.

1. Verify that the physical connectionsbetween the drive and the computer issound.

2. Verify that the serial communication cableand components are sound.

3. Disable the Enable CommunicationsTimeout Fault feature in the I/O Wizard ofwInControl. Where did wInControl comefrom? Doesn ’t this product use only IBConfig?

J. External Fault

Fault Number(hex)

Description Explanation Solution

D000h External fault 1. A digital input configured as an ExternalFault has been activated.

1. De-activate the digital input configured asan External Fault.

K. EEPROM Fault

Fault Number(hex)

Description Explanation Solution

E000h EEPROM readerror

Contact factory-Applications Department for aRMA.

E001h EEPROM writeerror

E002h init parms fault(!EEPROM_valid, code_version!= EEPROM_version)

E003h Wrong FPGAversion.

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L. Motor Parameter Fault

Fault Number(hex)

Description Explanation Solution

F009h Rs out of rangewhilecommissioning

Stator resistance measured duringcommissioning exceeds the Max Resistance.Drive will not be able to commission.

1. Check resistance setting in motor setup.2. Check to make sure motor fits within

drive’s specifications. See MotorSelection section.

F00Ah Switching timemeasured is outof range whilecommissioning

Switching time measured during commissioningis out of range.

1. Check motor connection – are all phasesconnected and making contact.

2. Make sure motor is still whencommissioning (not moving)

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The Internal Drive Parameters are parameters that characterize the drive with respect to configuration, operation, andmonitoring. These parameters are only accessible via the serial communication protocol. [See Appendix C .] Theparameters are divided into 18 different categories. Some of the parameters have reserved access (i.e., these parametersshould not be modified without consulting the factory).

Group A: Drive IdentificationThe Drive Identification parameters are internal drive parameters which are specific to each drive. These parametersSHOULD NOT be changed.

Parm # Name Scaling Access DescriptionA00 eeprom_valid Valid code = A5A5h Read Only Indicates that the EEPROM was initialized

with data, and passed verification.A01 ee_version TBRR

T = 0 (Release)T = 1 (Beta)

B = 2 (IndexBlok)

RR = Release number in hex.

Read Only EEPROM Version

A02 ee_revision 0 – ffffh Read Only TBAA03 code_version TBRR

T = 0 (Release)T = 1 (Beta)

B = 2 (IndexBlok)

RR = Release number in hex.

Read Only Code Version

A04 drive_sn_lo Read Only Drive serial number lowA05 drive_sn_mid Read Only Drive serial number midA06 drive_sn_hi Read Only Drive serial number highA07 drive_volts Volts Read Only Drive voltage ratingA08 drive_hp 10 * HP Read Only Drive horsepower ratingA09 ki_imag I (amps) = i_mag/drive_ki Read Only KI_imag is a internal Drive nominal current

scaling factor with values set to:PRODUCT Ki_Imag [A09]115 & 230VAC1C & 1D 18702C & 2D 9363C & 3D 6245D 3127D 23410D 156460VAC1E 37422E 18703E 12485E 6247E 46810E 31215E 23420E 156

A0A drive_kv Output Voltage (volts) = vout/drive_kv Read Only Drive_kv is an internal Drive volts scale

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factor with values set to:PRODUCT Kv [A0A]115 & 230VAC 65

460VAC 33

A0B drive_kw ω(radians/sec) = ω * drive_kw Read Only Drive_kw is an internal Drive frequencyscale factor with values set to:

A0C product_id Read Only Product IDA0D compatability index Compatibility index Read Only Not used

Group B: Serial CommunicationsThe serial communication parameters allow the user to set up the IndexBlok’s drive address and baud rate.

Parm # Name Scaling Access DescriptionB00 drive_address 1 - 9, A – Z Read/Write The address of this drive. There are 35

possible values.

B01 baud_rate 300, 600, 1200, 2400, 4800, 9600, 19200 Read/Write Default setting = 9600

Group C: Drive CommandThe Drive Commands parameters allows the user to control the drive Serially instead of digitally. The DriveCommands are used for Serial Control of start, stop, position, velocity, and etc. Serial control users will need to usethese parameters as well as F08 Accel/Decel rate parameter.

Parm # Name Scaling Access DescriptionC00 drive_command Bit 0 → Disable drive

Bit 1 → Stop requestBit 2 → DC HoldBit 3 → Serial Start AbsBit 4 → Serial Start RelBit 5 → Serial Jog ForwardBit 6 → Serial Jog ReverseBit 7 → Serial Run Preset FunctionBit 8 → AlignBit 9 → CommissionBit 10 → External Fault ClearBit 11 → External Fault SetBit 12 → Clear FaultsBit 13 → Reset CommunicationBit 14 → I/O Reset (IO Init)Bit 15 → Processor Reset

Read/Write This parameter is bit defined.

Sending a command to the drive isaccomplished by setting this parameter withthe appropriate bit cleared.

The command is acknowledged when thecorresponding bit is set.

C01 drive_mode Bit 0-2 Reserved, write as 1

Bit 3 set Serial Start/Stop

Read/Write This parameter is bit defined.

Set and Clear the appropriate bits to set the

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Bit 3 clr Local Start/Stop

Bit 4-6 Reserved, write as 1

Bit 7 set Normal communication modeBit 7 clr Communication ignore

check-sum

Bit 8-9 Reserved, write as 1

Bit 10 set Digital Inputs Pulled UpBit 10 clr Digital Inputs Pulled Down

Bit 11-15 Reserved, write as 1

drive in the desired mode.

This parameter should be read to determinewhich bits are currently set.

The current value should be modified bysetting or clearing the desired bits, then thenew value written to the drive.

C02 omega_cmd_save (ramonly)

Rotary Motors –RPMLinear Motors – Electrical Cycles/min

Read/Write Serial Position Commanded speed.

C03 serial jog speed Rotary Motors –RPMLinear Motors – Electrical Cycles/min

Serial Jog Speed

C08 serial_pos_cmd_lo(serial positioncommand, low word)

Low word of216 /360 * Position (degrees) or216 Electrical Cycles

Read/Write Serial Position Command - Electrical CycleLo word of Pos CmdThe position parameter values are a 32-bitsigned position in electrical cycles describedin 2 words.

(See Appendix B: Calculating PositionValues Examples and Calc Gains &Position Assistant.xls file provide with IBConfig software.)

C09 serial_pos_cmd_hi(serial positioncommand, low word)

High word of216 /360 * Position (degrees) or216 Electrical Cycles

Read/Write Serial Position Command - Electrical CycleHi word of Pos Cmd

C0A serial_preset_ index 0-15 Read/Write Set Serial_Preset_Index Function #0-15 refers to the preset function #,programmed in parameters Preset_Fnc_0through Preset_Fnc_15 (M2A – M39),which the user wants to Serial Start.

Drive Command (C00) is used to start apreset function serially by clearing Bit 3(Serial Preset_Index Function Request).

Group D: Drive FeedbackThe Drive Feedback parameters allow the user to read feedback information from the drive. The serial feedbackinformation is the same type of information which is available from IB Config software.

Parm # Name Scaling Access DescriptionD00 drive_state Byte 0 State machine location (0-ffh)

Byte 1 Feedback bit indicatingstatus.

Bit 0 set Reverse direction

Read Only This parameter consists of 2 bytes. The lowbyte is the drive control state.

The second byte is used to provide feedbackto the user as to the mode that the drive isin.

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Bit 1 set Moving

Bit 2 set Running

Bit 3 set Reserved

Bit 4 set Commissioning

Bit 5 set Closed Loop

Bit 6 set Jogging

Bit 7 set ReservedD01 drive_status_save Bit 0 clr System faulted. Always clear

when any other bit is clear.

Bit 1 clr Inverter interrupt sat fault.

Bit 2 clr Reserved

Bit 3 clr Phase over current.

Bit 4 clr Reserved.

Bit 5 clr DC Link under voltage.

Bit 6 clr DC Link over voltage.

Bit 7 clr Reserved

Bit 8 clr A/D offsets out of tolerance.

Bit 9 clr Motor fault.

Bit 10 clr Heat sink overtemp.

Bit 11 clr Motor thermal overload.

Bit 12 clr Communications Fault.

Bit 13 clr External Fault

Bit 14 clr EEPROM faultBit 15 clr Motor Parameter Fault

Read Only When the system is not faulted, thisparameter will be read as 0ffffh.

D02 limit_flag Bit 0 set Flux D est. on high limit

Bit 1 set Flux D est. on low limit

Bit 2 set Flux Q est. on high limit

Bit 3 set Flux Q est. on low limit

Bit 4 set Unused

Bit 5 set Unused

Read/Write Bits set in this parameter indicate that thecorresponding limit was hit.

All bits are latched and may be cleared bythe user.

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Bit 6 set Speed reg. on limit .

Bit 7 set Unused

Bit 8 set Unused

Bit 9 set Unused

Bit 10 set vq_cmd on limit

Bit 11 set vmag_cmd on limit

Bit 12 set Unused

Bit 13 set Unused

Bit 14 set Unused

Bit 15 set Unused

D03 i_mag I (amps 0 – peak) * drive_ki Read Only Output current magnitude.D04 id Id (amps 0 – peak) * drive_ki/2 Read Only d-axis current magnitude.D05 iq Iq (amps 0 – peak) * drive_ki/2 Read Only q-axis current magnitude.D06 vout Motor Volts (volts 0 - peak) * drive_kv Read Only Output voltageD07 vdc VDC (volts) * drive_kv Read Only DC link voltageD08 omega_dsp 10 * Hz Read Only Electrical frequency.D09 omega_m_dsp RPM or

Electrical Cycles/min when motor halfpoles set to 1 (motor poles =2)

Read Only Mechanical speed.

D0A heatsink temp 0.1 °C Read Only Heat sink temperatureD0B torque N-m * 100 Read Only Torque calculationD0C elapsed_lo 0.01 hours Read/Write Incremented every 1/100 hour when the

drive is running.D0D elapsed_hrs Hours Read/Write Incremented each time ELAPSED_LO

reaches 100.D0E i_sqr_t TBA Read Only TBAD0F feedback_ptr TBA Read/Write A pointer to the memory location. The

value in the memory location can be read infeedback_value (D17)

D10 feedback_value TBA Read Only The value in the memory location pointedby feedback_ptr (D16)

D11 fluxr_ff TBA Read Only Commanded rotor fluxD12 extended fault code TBA Read Only TBAD13 speed set-point RPM Read Only The current internal speed set-pointD15 digital outputs Current Digital Output State

Each of the first 2 low-order bitscorresponds to a digital outputBit0 = DOUT1,Bit1 = DOUT2, …

Read Only The current value in the digital outputregister. (0 = Low, 1 = High)

D16 digital inputs Current Digital Input StateEach of the first 8 low-order bitscorresponds to a digital inputBit0 = DIN1,Bit1 = DIN2, …

Read Only The current value in the digital inputregister. (0 = Low, 1 = High)

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Bit 7 = DIN8).

D17 digital input assertion Active State Setting

Each of the first 8 low-order bitscorresponds to a digital inputBit0 = DIN1,Bit1 = DIN2, …Bit 7 = DIN8).

Read Only The current active state setting of the digitalinputs. (0 = Active Low; 1 = Active High)

[Default value = 0 decimal, 00 Hex(00000000 BIN); Decimal range = 0-255;Hex Range = 0 - FF]

(See M08 Digital Input Polarity forchanging the active state.)

D1C state flags Bit 0 set → Run Forward DisabledBit 1 set → Run Reverse DisabledBit 6 set → External Fault AssertedBit 15 set → I/O Initialized

Read Only TBA

D20 pos_rtr_lo Low word of

216

360 * Position (degrees)

Read Only Rotor Position feedback values.A 32 bit number where the upper 16 Bits arecounts of electrical cycles.

See Appendix B: Calculating PositionValue and Calc Gain and PositionAssistant.xls excel file.

D21 pos_rtr_hi High word of

216

360 * Position (degrees)

Group E: Fault QueueThe Fault Queue parameters allow the user to read the same information which is provided in the IB Config – FaultQue.

Parm # Name Scaling Access DescriptionE00 fault_cue_full 0 – 1

0 indicates cue not full1 indicates cue full

Read Only Zero when no faults have been recordedsince the queue was last reset, or the faultcue has not rolled over. Indicates that thereare 4 or fewer faults in the cue.

When the fault cue rolls over (from 4 backto 1), this index is set to 1. This indicatesthat the cue is full.

The last fault recorded will beLAST_FAULT_INDEX.

E01 last_fault_index 0 - 4

0 indicates no faults.1 indicates fault 1.2 indicates fault 2.

Read Only Zero when no faults have been recordedsince the queue was last reset.

If FAULT_CUE_FULL is 0, there are 4 orfewer faults in the cue.

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3 indicates fault 3.4 indicates fault 4. If FAULT_CUE_FULL is 1, there are 4

faults in the cue.

The most recent fault isLAST_FAULT_INDEX.

The previous fault isLAST_FAULT_INDEX -1, etc.

The fault cue is circular; therefore, the cuerolls from 1 back to 4, when reading the cue.

E02 first_fault_status drive_status_save at fault Read Only The drive’s drive_status_save (D01) valueat the time of the fault.

E03 first_fault_time_lo elapsed_time_lo at fault0.01 hours

Read Only The drive’s time (D0C and D0D) value atthe time of the fault.

E04 first_fault_time_hi elapsed_time_hi at faulthours

Read Only

E05 first_fault_drive_state drive_state at faultByte 0 State machine location (0-ffh)

Byte 1 Feedback bit indicatingstatus.

Bit 0 set Reverse direction

Bit 1 set Moving

Bit 2 set Running

Bit 3 set Reserved

Bit 4 set Commissioning

Bit 5 set Closed Loop

Bit 6 set Jogging

Bit 7 set Reserved

Read Only The drive’s drive_state (D00) value at thetime of the fault.

This parameter consists of 2 bytes. The lowbyte is the drive control state.

The second byte is used to provide feedbackto the user as to the mode that the drive isin.

E06 first_fault_i i_mag at faultBit 0 clr System faulted. Always clear

when any other bit is clear.

Bit 1 clr Inverter interrupt sat fault.

Bit 2 clr Reserved

Bit 3 clr Phase over current.

Bit 4 clr Reserved.

Bit 5 clr DC Link under voltage.

Bit 6 clr DC Link over voltage.

Read Only The drive’s I_mag (D03) value at the timeof the fault.

When the system is not faulted, thisparameter will be read as 0ffffh.

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Bit 7 clr Reserved

Bit 8 clr A/D offsets out of tolerance.

Bit 9 clr Motor fault.

Bit 10 clr Heat sink overtemp.

Bit 11 clr Motor thermal overload.

Bit 12 clr Communications Fault.

Bit 13 clr External Fault

Bit 14 clr EEPROM faultBit 15 clr Motor Parameter FaultCurrent in Apk * ki_imag

E07 first_fault_vdc Vdc at faultVDC (volts) * drive_kv

Read Only The drive’s DC link voltage (D07) value atthe time of the fault.

E08 first_fault_speed ωm, at fault

Rotary Motors: RPMLinear Motors: Electrical Cycles/min

Read Only The drive’s Mechanical speed (D09) valueat the time of the fault.

E09 first_fault_ext_error first_fault_ext_error at fault Read Only The drive’s Fault Code value at the time ofthe fault. See Troubleshooting – Fault CodeSection.

E0B fault_1_status drive_status_save Read Only Fault Information from the 1st Fault QueueE0C fault_1_time_lo elapsed_time_ Read Only (Same info as above)E0D fault_1_time_hi elapsed_time_hi Read OnlyE0E fault_1_drive_state drive_state Read OnlyE0F fault_1_i i_mag Read OnlyE10 fault_1_vdc vdc Read OnlyE11 fault_1_speed ωm Read OnlyE12 fault_1_ext_error fault_1_ext_error Read OnlyE14 fault_2_status drive_status_save Read Only Fault Information from the 2nd Fault QueueE15 fault_2_time_lo elapsed_time_lo Read Only (Same info as above)E16 fault_2_time_hi elapsed_time_hi Read OnlyE17 fault_2_drive_state drive_state Read OnlyE18 fault_2_i i_mag Read OnlyE19 fault_2_vdc vdc Read OnlyE1A fault_2_speed ωm Read OnlyE1B fault_2_ext_error fault_2_ext_error Read OnlyE1D fault_3_status Drive_status_save Read Only Fault Information from the 3rd Fault QueueE1E fault_3_time_lo Elapsed_time_lo Read Only (Same info as above)E1F fault_3_time_hi Elapsed_time_hi Read OnlyE20 fault_3_drive_state Drive_state Read OnlyE21 fault_3_i i_mag Read OnlyE22 fault_3_vdc vdc Read OnlyE23 fault_3_speed ωm Read OnlyE24 fault_3_ext_error fault_3_ext_error Read OnlyE26 fault_4_status Drive_status_save Read Only Fault Information from the 4th Fault QueueE27 fault_4_time_lo Elapsed_time_lo Read Only (Same info as above)E28 fault_4_time_hi Elapsed_time_hi Read OnlyE29 fault_4_drive_state Drive_state Read OnlyE2A fault_4_i i_mag Read Only

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E2B fault_4_vdc vdc Read OnlyE2C fault_4_speed ωm Read OnlyE2D fault_4_ext_error fault_4_ext_error Read Only

Group F: Drive ParametersThe Drive Parameters allows the user to configure the minimum and maximum speed boundary for the application andset the global accel/decel rate. The minimum and maximum speed is run locked thus the parameters can only bechanged when the drive is disabled. The min and max speed parameters are usually set up for the application and thennever changed.

Parm # Name Scaling Access DescriptionF00 min speed Rotary Motors: RPM

Linear Motors: Electrical Cycles/minRead/WriteRun locked

Minimum allowed commanded speed.

Commanded speeds will be limited to thisminimum value.

To disable jump speeds, set them to MAXSPEED.

F07 max speed Rotary Motors: RPMLinear Motors: Electrical Cycles/min

Read/WriteRun locked

Maximum allowed commanded speed.

F08 accel_rate Rotary Motors: RPM/secLinear Motors: Electical Cycles/min/sec

Read/Write Global accel/decel rate.

Group G: Motor ParametersThe motor parameters are the parameters used by IB Config – Motor Setup to auto setup the Sensorless Motor Model inthe controller. To have an accurate Sensorless Motor Model, it is important to have accurate motor information. Notethat motor manufactures motor specs can be in RMS or Pk. The conversion is Pk = √2 × RMS. Please make sure youenter the requested units in the IB Config Setup, otherwise you could be 1.41 times off.

Parm # Name Scaling Access DescriptionG03 motor rated amps 10 * A-RMS Read/Write Required for all motors. Calculated in Motor

Setup.G09 flux command Flux * Kv*Omega_Base Read/Write This parameter is the initial magnet flux

estimate. It is can be tuned by a manualenhanced commission. An initial estimateshould be provided. Calculated from MotorSetup.

G0A rated iq Rated Amps (pk) * ki_imag/2.0 Read/Write Rated torque producing current. Calculatedin Motor Setup.

This parameter should be the same as ratedcurrent although it is used for load limitcalculations while rated current is used onlyfor overload protection calculations.

G0C stator resistance Rs * 2 * Omega Base* (drive_kw/1000) Read/Write Stator Resistance. Required Parameter.

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* (drive_kv/ki_imag )

Rs is line to neutral stator resistance inohms.

Calculated from Motor Setup.

G0F inductance BLDC Inductance = 16.384 * Lline-line/2 *Kv * Omega_base / Ki_imag

Read/Write Stator leakage inductance. RequiredParameters. Calculated from Motor Setup.

G10 half_poles (Number of Poles)/2 Read/Write Number of BLDC motor’s half polesG12 load_lim_motor % of rated torque (0 – 200) Read/Write Torque limit during motoring as a percent of

rated torque.

G13 load_lim_brake 0 - 200 Read/Write Torque limit during braking as a percent ofrated torque.

G1A rs_max Same scaling as Stator Resistance Read/Write Maximum allowable stator resistanceG1B rs_gain rs = rs_estimated *

rs_gain100

Reserved Gain on commissioned value of rs. This canbe used to make sure rs is never over-estimated. To use exact commissionedvalue of rs, rs_gain = 100.

G22 i_bldc_start Amps (pk)G22 = Start Current in Apk * ki_imag

[A09] /2.0For 2 Apk start current, you should enterinto parameter G22= 2 * Ki_imag / 2.

Read/Write BLDC start current.For lightly loaded motors, use 25% of RatedCurrent.For highly loaded motors, use 50% of RatedCurrent

PRODUCT Ki_Imag [A09]115 & 230VAC1C & 1D 18702C & 2D 9363C & 3D 6245D 3127D 23410D 156460VAC1E 37422E 18703E 12485E 6247E 46810E 31215E 23420E 156

G23 bldc_lock_rtr_wait in units of N(sec) /52 ms, where N =Lengh of time in seconds.For 1 second delay, G23=1 sec / 0.052sec = 19.For 0.25 seconds, G23=0.25 / 0.052 = 5.

Read/Write Starting delay - length of time that the drivewill lock the BLDC rotor.

G24 bldc_start_omega

Calculated in start_calcs=Drive_kw * frequency(rad/s)

Read/Write Operating frequency at which loops areclosed.

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Group H: Holding Current ParametersThe DC_Injection_Nom parameter allows the user to select the proper holding current at the end of the move for theapplication. The Holding Current directly affects how much Holding Torque one has at the end of the move. (Torque =Kt * Current. Remember to enter the appropriate current specified since motor manufactures can rate things in Apk orArms. Apk = SQRT(2) * Arms.

Parm # Name Scaling Access DescriptionH01 dc_injection_ nom = DC injection current (Apk) *

ki_imag/2Read/Write DC injection current is the level of current

the user wants for Holding Current (Apk)which translates into Holding Torque whenat rest or in position (enabled).

PRODUCT Ki_Imag [A09]115 & 230VAC1C & 1D 18702C & 2D 9363C & 3D 6245D 3127D 23410D 156460VAC1E 37422E 18703E 12485E 6247E 46810E 31215E 23420E 156

Group I: Current and Voltage Feedback Parameters – ReservedThe Current and Voltage Feedback parameters are reserved parameters and should never be changed. They are writeand password protected. These parameters are internal parameters specific to the drive.

Group J: Protection ParametersThe protection parameters are set up to provide protection to the drive.

Parm # Name Scaling Access DescriptionJ01 i_sqr_t_wdt Tc/T, T = sampling time(52.429 ms)

J01 default = 4768Read/Write I2T time constant for thermal protection,

where Tc = Motor’s Thermal Constant.Default Tc = 250 sec, which is based onNEMA thermal, protect time constant.

J02 i_sqr_t_lim 100*(I trip/Irated)2

J02 default = 132

Read/Write I2T trip point for thermal protection.With default value of 132, the drive will tripat 115% of rated current value used inMotor setup.

The thermal protection is an exponentialfunction (a low pass filter), see i_sqr_t(D0E).

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The thermal protection will trip if the driveruns at i_sqr_t_lim percent of rated currentfor Tc time (Tc is set in i_sqr_t_wdt).

J04 comm_timer_max 0-65535Time (sec) = comm_timer_max * 0.052sec

J04 default = 96 (5 sec)

Read/Write Communications timeout setting.

0 disables time-out checking.

J06 password 0 - 65535 Read/Write Allows writes to read-only locations whenset.

This value set by the factory.J08 temp_hys 0.1 °C Read/Write Hysteresis used in fan controlJ09 fan_on_temp 0.1 °C Read/Write Fan on tempJ0C vdc_min volts Read/Write Minimum DC bus voltage. VDC less than

this causes a DC Link Undervoltage Fault.

J0D vdc_max volts Read/Write Maximum DC bus voltage. VDC more thanthis causes a DC Link Overvoltage Fault.

J0E vdc_braking volts Read/Write Value at which the DC bus is regulatedduring braking.

Group K: Regulator GainsThe Regulator Gains are the tuning gains for the Inertia/motor/drive system. The inertia or mass affects the PID loopand thus the effectiveness of these gains. Use “Calc Gain and Position Assistant.xls” provided with IB Configsoftware to calculate the gains.

Parm # Name Scaling Access DescriptionK00 kp_trq Use “Calc Gain and Position

Assistant.xls” provided with IB ConfigRead/Write Speed controller proportional gain

K01 ki_trq Use “Calc Gain and PositionAssistant.xls” provided with IB Config

Read/Write Speed controller integral gain

K02 kp_flx|speed reg gn Use “Calc Gain and PositionAssistant.xls” provided with IB Config

Read/Write Gain on speed controller

K03 iq_wdt_speed Use “Calc Gain and PositionAssistant.xls” provided with IB Config

Read/Write The break frequency of the lowpass filter onthe speed regulator

K05 ki_fluxr Read/Write Flux controller integral gainK08 kp_brake 0 ≤ Brake PWM ≤ max_braking

Brake PWM = 1

216

* Kv*volt_gain

vdc_gain *

(vdc_braking – vdc) *

kp + 1

1 - z-1

ki

Read/Write Braking controller proportional gain

K09 ki_brake Read/Write Braking controller integral gainK0A max_braking 0-255 Read/Write Sets the maximum brake PWM duty cycleK0B kp_i_nom Read/Write Current regulator proportional gainK0C ki_omega Read/Write Speed error PLL Integral gain

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K0D pll_dt_w Nominal values:kp_flux = 1-3; pll_dt_w = 0-2

Read/Write Low byte = Break frequency of speed errorPLLHigh byte = Flux estimator stabilizing gain

K0E inv_kp_pos Use “Calc Gain and PositionAssistant.xls” provided with IB Config

Read/Write Inverse proportional position gain

Table 38

Group L: Internal ParametersThe Internal Parameters are internal scale parameters and should not be changed EXCEPT L1A Omega_baseparameter. The L1A Omega_base parameter is a scale factor used in the motor parameter section. One might need tochange this parameter if the motor’s BEMF value is close to the minimum value or significantly higher than theoptimum value (see Changing Omega_Base procedures)

Parm # Name Scaling Access DescriptionL06 dsp_wdt τ ≈ 0.002/-ln(1-wdt/2^16)

(Loop executes appr. Every 2 m-s.)Read/Write Display filter time-constant.

L08 check_time 0.052 second Reserved Delay time used in measuring resistanceduring commissioning.

L0B commission_starts 0 - ffffh Read/Write Commission StartL0C commission_angle 6 Ranges:

0 ≤ angle < 60; d-axis = 0 60 ≤ angle < 120 d-axis = 60120 ≤ angle < 180 d-axis = 120180 ≤ angle < 240 d-axis = 180240 ≤ angle < 300 d-axis = 240300 ≤ angle < 360 d-axis = 300

Read/Write Angle at which skew test is done

L1A omega_base Frequency Scale factor in Radians/sec Read/Write Frequency scaling factor—default is 377rad/sec. Also scales the PLL proportionalgain.

Group M: I/O SetupThe I/O Setup parameters allows the user to configure the Inputs, Outputs, and Preset Functions for the application.The M Series parameters need to be initialized by either serially clearing bite 14 of C00 parameter or by clicking onIO INIT button with the IB Config software. To perform an Initialization, the drive must be disabled.

Parm # Name Scaling Access DescriptionM00 digital input 1 fcn Digital Input Functions

0 = Unused/Null1 = Run Enable2 = Run Fwd Enable (EOT-Fwd)3 = Run Rev Enable (EOT-Rev)4 = Start Preset5 = Stop6 = External Fault7 = Preset Bit 08 = Preset Bit 19 = Preset Bit 210 = Preset Bit 3101 = Home Input

Read/Write Defines the function of Digital Input 1

(For Input Function Descriptions see DigitalInput Setup – Input Function Values)

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102 = Registration InputM01 digital input 2 fcn Read/Write Defines the function of Digital Input 2

(Same as above)M02 digital input 3 fcn Read/Write Defines the function of Digital Input 3

(Same as above)M03 digital input 4 fcn Read/Write Defines the function of Digital Input 4

(Same as above)M04 digital input 5 fcn Read/Write Defines the function of Digital Input 5

(Same as above)M05 digital input 6 fcn Read/Write Defines the function of Digital Input 6

(Same as above)M06 digital input 7 fcn Read/Write Defines the function of Digital Input 7

(Same as above)M07 digital input 8 fcn Read/Write Defines the function of Digital Input 8

(Same as above)

M08 digital input polarity Each of the first 8 low-order bitscorresponds to a digital inputBit0 = DIN1,Bit1 = DIN2, …Bit 7 = DIN8).

Read/Write The bit set corresponds to active state ofeach input (Active Low = 0, Active High =1). Changing of the polarity of inputs willnot result in transitions that are acted on bythe control.[Default value = 0 decimal, 00 Hex(00000000 BIN); Decimal range = 0-255;Hex Range = 0 - FF]

M09 digital output 1 fcn Digital Output Function0 = Set Output High1 = Set Output Low2 = At Speed3 = Drive Enabled4 = Fault5 = Reverse6 = Overload Alert7 = Overtemp Alert8 = Commissioning9 = In Position/Move Complete10 = Moving/Not Moving11-12 = Reserved

Read/Write Defines the function of Digital Input 1

(For Output Function Descriptions seeOutput Setup – Output Function Values)

M0A digital output 2 fcn Read/Write Defines the function of Digital Output 2(Same as above)

M0B relay 1 fcn Relay Out FunctionsSame as Digital Outputs

Read/Write Defines the function of Relay Output 1 (SeeOutput Section)

M0C relay 2 fcn Read/Write Defines the function of Relay output 2

M0D analog output 1 fcn Analog Output Functions0 = Null1 = Current2 = Torque3 = Speed4 = Vout5 = DC Link Voltage6 = Hi Resolution Position7 = Lo Resolution Position8 = Reserved>8 = Null

Read/Write Defines the function of Analog Output 1(See Analog Output Sections)

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M0E analog output 2 fcn Read/Write Defines the function of Analog Output 2M0F analog output 3 fcn Read/Write Defines the function of Analog Output 3M1A overload alert level Scaling: 100*(Ialert/Irated)2 Read/Write When i_sqr_t reaches this value, the

OVERLOAD ALERT digital output will beset, if any outputs are defined to have thisfunction.

M1B overtemp alert 0.1 degrees C Read/Write When heat_sink_temp reachesheat_sink_hot minus this value, theOVERLOAD ALERT digital output will beset, if any outputs are defined to have thisfunction.

M1E at speed range RPM Read/Write Any digital output set to function At Speedis asserted when drive is running and motorspeed is within AT_SPEED_RANGE ofspeed set-point.

M21 led 1 fcn Same Functions as Digital Outputs Read/Write Defines the function of LED1See Output Setup

M22 led 2 fcn Read/Write Defines the function of LED2

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M2A preset_fcn_0 0 – Clear faults1 – Auto tune2 – Jog forward3 – Jog reverse4 – Find home forward5 – Find home reverse6 – Move absolute7 – Move relative8 – Registration Forward9 – Registration Reverse10 – Preset Position Counter11 – Align

Read/Write M2A-M39 “preset_fcn_n”defines functionwhich will be executed when preset function“n” is selected.

M2B preset_fcn_1 Same as preset_fcn_0 Read/Write Same as preset_fcn_0M2C preset_fcn_2 “ Read/Write “M2D preset_fcn_3 Read/WriteM2E preset_fcn_4 Read/WriteM2F preset_fcn_5 Read/WriteM30 preset_fcn_6 Read/WriteM31 preset_fcn_7 Read/WriteM32 preset_fcn_8 Read/WriteM33 preset_fcn_9 Read/WriteM34 preset_fcn_10 Read/WriteM35 preset_fcn_11 Read/WriteM36 preset_fcn_12 Read/WriteM37 preset_fcn_13 Read/WriteM38 preset_fcn_14 Read/WriteM39 preset_fcn_15 Read/WriteM3A preset_pos_0_lo The position parameter are two

words of a 32-bit signed parameter.Read/Write Preset Position Command for Function # -

M3C through M58 are the positioncommands for Preset_Function_n (n = 0-15) requires position information (e.g.Preset functions set up for moves,registration, home.

Electrical Cycle Lo word of Pos CmdThe position parameter values are a 32-bitsigned position in electrical cyclesdescribed in 2 words.

(See Appendix B: Calculating PositionValues Examples and Calc Gains &Position Assistant.xls file provide with IBConfig software.)

M3B preset_pos_0_hi Read/Write Preset Position Command for Function # -Electrical Cycle Hi word of Pos Cmd

M3C preset_pos_1_lo Read/WriteM3D preset_pos_1_hi Read/WriteM3E preset_pos_2_lo Read/WriteM3F preset_pos_2_hi Read/WriteM40 preset_pos_3_lo Read/WriteM41 preset_pos_3_hi Read/WriteM42 preset_pos_4_lo Read/WriteM43 preset_pos_4_hi Read/WriteM44 preset_pos_5_lo Read/Write

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M45 preset_pos_5_hi Read/WriteM46 preset_pos_6_lo Read/WriteM47 preset_pos_6_hi Read/WriteM48 preset_pos_7_lo Read/WriteM49 preset_pos_7_hi Read/WriteM4A preset_pos_8_lo Read/WriteM4B preset_pos_8_hi Read/WriteM4C preset_pos_9_lo Read/WriteM4D preset_pos_9_hi Read/WriteM4E preset_pos_10_lo Read/WriteM4F preset_pos_10_hi Read/WriteM50 preset_pos_11_lo Read/WriteM51 preset_pos_11_hi Read/WriteM52 preset_pos_12_lo Read/WriteM53 preset_pos_12_hi Read/WriteM54 preset_pos_13_lo Read/WriteM55 preset_pos_13_hi Read/WriteM56 preset_pos_14_lo Read/WriteM57 preset_pos_14_hi Read/WriteM58 preset_pos_15_lo Read/WriteM59 preset_pos_15_hi Read/WriteM5A preset_spd_0 Rotary Motors – RPM

Linear Motors – Electrical Cycles/minwith Motor Poles = 2 (Motor Half Poles=1)

Read/Write Used if preset_fcn_0 requires velocityinformation.

M5B preset_spd_1 Read/Write Used if preset_fcn_1 requires velocityinformation.

M5C preset_spd_2 Read/Write Used if preset_fcn_2 requires velocityinformation.

M5D preset_spd_3 Read/Write Used if preset_fcn_3 requires velocityinformation.

M5E preset_spd_4 Read/Write Used if preset_fcn_4 requires velocityinformation.

M5F preset_spd_5 Read/Write Used if preset_fcn_5 requires velocityinformation.

M60 preset_spd_6 Read/Write Used if preset_fcn_6 requires velocityinformation.

M61 preset_spd_7 Read/Write Used if preset_fcn_7 requires velocityinformation.

M62 preset_spd_8 Read/Write Used if preset_fcn_8 requires velocityinformation.

M63 preset_spd_9 Read/Write Used if preset_fcn_9 requires velocityinformation.

M64 preset_spd_10 Read/Write Used if preset_fcn_10 requires velocityinformation.

M65 preset_spd_11 Read/Write Used if preset_fcn_11 requires velocityinformation.

M66 preset_spd_12 Read/Write Used if preset_fcn_12 requires velocityinformation.

M67 preset_spd_13 Read/Write Used if preset_fcn_13 requires velocityinformation.

M68 preset_spd_14 Read/Write Used if preset_fcn_14 requires velocityinformation.

M69 preset_spd_15 Read/Write Used if preset_fcn_15 requires velocityinformation.

Terms and Conditions

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A. Offer and Acceptance: These terms and conditions constitute Seller’s offer to Buyer and acceptance by Buyer and any resulting sale isexpressly limited to and conditioned upon Seller’s terms and conditions as set forth below. If Buyer objects to any of Seller’s terms andconditions, such objections must be expressly stated and brought to the attention of Seller in a written document which is separate fromany purchase order or other printed form of Buyer. Such objections, or the incorporation of any additional or different terms or conditionsby Buyer into a resulting order shall constitute non-acceptance of these terms and conditions, releasing Seller from any obligation orliability hereunder and a proposal for different terms and conditions which shall be termed objected to by Seller unless expressly acceptedin writing by an authorized representative of Seller. Acknowledgements of the receipt of any purchase order, including signing andreturning to Buyer his acknowledgment copy, if any, shall not constitute the acceptance by Seller of any additional or different terms orconditions, nor shall Seller’s commencement of effort, in itself, be construed as acceptance of an order containing additional or differentterms and conditions.

B. Payments Terms: Subject to approval of Buyer’s credit, the full net amount of each invoice is due and payable in cash within thirty (30)days of shipment. No payment discounts are offered, and minor inadvertent administrative errors contained in an invoice are subject tocorrection and shall not constitute reason for untimely payment.

If, in the judgement of the Seller, the financial credit of Buyer at any time does not justify continuance of production or shipment of anyproduct(s) on the payment terms herein specified, Seller may require full or partial payment prior to completion of production or shipment,or may terminate any order, or any part thereof, then outstanding.

C. Transportation: Shipments are F.O.B. shipping point. The Buyer must claim any transportation damaged and the Buyer must submit aclaim to the carrier.

D. Prices: Published prices and discounts schedules are subject to change without notice. They are prepared for the purpose of furnishinggeneral information and are not quotations or offers to sell on the part of the company.

E. Minimum Billing: Minimum billing will be $250.00.

F. Order Scheduled: For all standard products, shipping schedules for the next 30-day period are firm and cannot be rescheduled.Scheduled beyond 30 days may be rescheduled without penalty.

G. Delays: Semipower Systems shall not be liable for any defaults, damaged, or delays in fulfilling any order caused by conditions beyondSemipower's control, including, but not limited to, acts of God, strike, lockout, boycott, or other labor troubles, war, riot, flood,governments regulations, or delays of Semipower's subcontractors or suppliers on furnishing materials or supplies due to one or more ofthe foregoing clauses.

H. Cancellations: By written notice given at any time prior to delivery, Buyer may terminate, for his convenience, any or all of the order.Buyer will be liable for all costs incurred by Seller in performance of the order that is canceled on the actual date of receipt of the writtennotice of termination. Termination charges may be up to and including 100% of the price of the products.

I. Product Warranty: All products are warranted for two years from date of manufacture as determined by the date code on the productlabel. The date code consists of four digits; the first two are the year and the second two are the week.

J. Taxes: Unless otherwise indicated on the face hereof, all prices and charges are exclusive of excise, sales, use, property, occupational, orlike taxes which may be imposed by any taxing authority upon the manufacture, sales or delivery of the items sold hereunder. If the Sellermust pay any such taxes or if Seller is liable for the collection of such tax, the amount thereof shall be in addition to the amounts for theitems sold. Buyer agrees to pay all such taxes or to reimburse Seller therefore upon receipt of its invoice. If Buyer claims exemption fromany sales, use or other tax imposed by any taxing authority, Buyer shall save Seller harmless from and against any such tax, together withany interest or penalties thereon which may assessed if the items are held to be taxable.

Warranty and RMA Policy

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The warranty and limitation of liability statement apply to all goodssold and appear on all Semipower “acknowledgement and orderstatus” reports.

A. Warranty Repair

1. Prior to returning any products for repair,authorization must first be received fromcustomer service.

2. Products that have been modified or damagedby the customer are excluded from thiswarranty repair policy. Examples are damagefrom miswiring and improper settings oncontrols.

3. If a product is returned for warranty repair andis found to contain out-of-warranty damage,Semipower will:

• Within thirty (30) days, notify thecustomer via fax or phone classificationchange and associated non-warrantyconditions and repair charges.

• If the customer does not respond within5 working days, Semipower will returnthe Drive(s) unrepaired.

4. Warranty repairs made during the first year ofwarranty are warranted to the end of theoriginal two-year warranty. Warranty repairsmade during the second year of warranty arewarranted for one year after the repair andtherefore extend beyond the original two-yearwarranty. In the latter case, only those partsthat are replaced or repaired are warranted.

5. A repair label is fixed to repaired products andshows the repair date expressed in four digits(year-week) and the Return MaterialAuthorization number (RMA).

6. A repair report is furnished to the customercontact established under the return procedure.

B. Return Procedure

1. All returns must be authorized by the customerservice department. Efficient and timelyhandling requires that the customer providethe following (when available) during thecustomer service phone call:

• Model type, serial number and date code of theproduct(s) to be returned.

• Reason for return including conditions/symptoms ofproduct failure.

• The person to be contacted for questions and theirphone number.

• The address to send invoices.• The address to send the repaired product(s) and the

preferred carrier.

2. After receiving the above information,customer service will issue a Return MaterialAuthorization number (RMA) which must beincluded on the packing slip and on the outsideof the shipping container of the returnedproducts. Returns without a valid RMA willnot be accepted.

RETURN TO:

Attn: Customer ServiceRMA# Semipower2307 Bering DriveSan Jose, California, 95131

3. All products to be repaired must be returnedfreight prepaid. All returns are onconsignment. They remain the customer’sproperty with no debit to Semipower.Semipower returns to the customer as follows:

• Warranty repairs are returned freightprepaid, surface. Shipping methodsother than surface are at the customer’sexpense.

C. RMA Processing

1. All standard control warranty returns will beprocessed through the factory in 30 workingdays from the date of receipt.

Warranty Limitation and Liability

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Semipower warrants its drive (“Product(s)”) to the original purchaser (the “Customer”), and in case of original equipment manufacturers ordistributors, to their original consumer (the “Customer”) to be free from defects in material and workmanship and to be made in accordance withCustomer’s specifications which have been accepted in writing by Semipower. In no event, however, shall Semipower be liable or have anyresponsibility under such warranty if the Products have been improperly stored, installed, used or maintained, or if customer has permitted anyunauthorized modifications, adjustments and/or repairs to such Products. Semipower's obligation hereunder is limited solely to repairing replacing (atits option), at its factory any Products, or parts thereof, which prove to Semipower's satisfaction to be defective as a result of defective materials orworkmanship, in accordance with Semipower stated warranty, provided, however, that written notice of claimed defects shall have been given toSemipower within two (2) years after the date of the product date code that is affixed to the Product, and within thirty (30) days from the date anysuch defect is first discovered. The products or parts claimed to be defective must be returned to Semipower, transportation prepaid by Customer,with written specifications of the claimed defect. Evidence acceptable to Semipower must be furnished that the claimed defects were not caused bymisuse, abuse, or neglect by anyone other than Semipower.

Semipower also warrants that each of the Semipower Motion Control Software Programs (“Program(s)”) will, when delivered, conform to thespecifications therefore set forth in Semipower's specifications manual. Customer, however, acknowledges that these Programs are of suchcomplexity and that the Programs are used in such diverse equipment and operating environments that defects unknown to Semipower may bediscovered only after the Programs have been used by Customer. Customer agrees that as Semipower's sole liability, and as Customer’s sole remedy,correct documented failures of the Programs to conform to Semipower's specifications manual. SEMIPOWER DOES NOT SEPERATELYWARRANT THE RESULTS OF ANY SUCH CORRECTION OR WARRANT THAT ANY OR ALL FAILURES OR ERRORS WILL BECORRECTED OR WARRANT THAT THE FUNCTIONS CONTAINED IN SEMIPOWER’S PROGRAMS WILL MEET CUSTOMER’SREQUIREMENTS OR WILL OPERATE IN THE COMBINATIONS SELECTED BY CUSTOMER. This warranty for Programs iscontingent upon proper use of the Programs and shall not apply to defects or failure due to: (i) accident, neglect or misuse; (ii) failure of Customer’sequipment; (iii) the use of software or hardware not provided by Semipower; (iv) unusual stress caused by Customer’s equipment; or (v) any partyother than Semipower who modifies, adjusts, repairs, adds to, deleted from or services the Programs. This warranty for Programs is valid for a periodof ninety (90) days from the date Semipower first delivers the Program to Customer.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES (EXCEPT AS TO TITLE), WHETHEREXPRESSED OR IMPLIED. INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR OF FITNESSFOR ANY PARTICULAR PURPOSE, AND ARE IN LIEU OF ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OFSEMIPOWER. SEMIPOWER MAXIMUM LIABILITY WITH RESPECT TO THESE WARRANTIES, ARISING FROM ANY CAUSEWHATSOEVER, INCLUDING WITHOUT LIMITATION, BREACH OF CONTRACT, NEGLIGENCE, STRICT LIABILITY, TORTWARRANTY, PATENT OR COPYRIGHT INFRINGEMENT, SHALL NOT EXCEED THE PRICE SPECIFIED OF THE PRODUCTSOR PROGRAMS GIVING RISE TO THE CLAIM, AND IN NO EVENT SHALL SEMIPOWER BE LIABLE UNDER THESEWARRANTIES OR OTHERWISE, EVEN IF SEMIPOWER HAS BEEN ADVISED OF THE POSSIBILITY IF SUCH DAMAGES, FORSPECIAL, INCEDENTAL OR CONSQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION, DAMAGE OR LOSSRESULTING FROM INABILITY TO USE THE PRODUCTS OR PROGRAMS, INCREASED OPERATING COSTS RESULTINGFROM A LOSS OF THE PRODUCTS OR PROGRAMS, LOSS OF ANTICIPATED PROFITS, OR OTHER SPECIAL INCIDENTAL, ORCONSEQUENTIAL DAMAGES, WHETHER SIMILAR OR DISSIMILAR, OF ANY NATURE ARISING OR RESULTING FROM THEPURCHASE, INSTALLATION, REMOVAL, REPAIR, OPERATION, USE OR BREAKDOWN OF THE PRODUCTS OR PROGRAMS,OR ANY PTHER CAUSE WHATSOEVER, INCLUDING NEGLIGENCE.

The foregoing shall also apply to Products, Programs, or parts for the same which have been repaired or replaced pursuant to such warranty, andwithin the period of time, in accordance with Semipower's date of warranty.

No person, including any agent, distributor, or representative of Semipower, is authorized to make any representation or warranty on behalf ofSemipower concerning any Products or Programs manufactured by Semipower, except to refer purchasers to this warranty.

The Company reserves the right t to make engineering refinements on all products, without notice. Dimensions, software functionality, and other details are subject to change.

All trademarks, registered trademarks, and logos are of their respective holders.

Windows95 and WindowsNT are registered trademarks o Microsoft Corporation.

IndexBlok™, IndexBlok™, CapBlok™, and wInControl™ are trademarks of Semipower Systems, Inc.

The information in this Owner’s Manual is provided by Semipower in good faith and to the best of our knowledge is accurate. Semipower does not accept any liability for any loss or damage of anykind suffered as a result of any inaccuracy in any of the information contained in this document.

© Semipower Systems, Inc. 1998. Al rights reserved.

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