Danfoss OPTBC VACON NXP Air Cooled User Manual

Danfoss OPTBC VACON NXP Air Cooled

Product Information

• Specifications
  • Resolver Output voltage: 1.8Vrms – 4.0Vrms
  • Resolver Input voltage: 1.3Vrms – 7.5Vrms
  • Number of poles: 2 (for maximum tracking rates)
  • Encoder Simulation Output Resolution: 10bit, 12bit, 14bit, 14bit
  • Encoder Simulation Pulses/rev: 256, 1024, 4096, 4096
  • *Position accuracy:** +/- 4 LSB
  • *Velocity accuracy:** +/- 4 LSB
  • Excitation frequency: 1-20kHz (adjustable with 1kHz steps)
  • Transformation Ratio Slots: A, B, Z (max. pulse frequency 150kHz)

Product Instruction

• Installation
• RESOLVER OPTION BOARD OPT-BC
  • Note about absolute angle and different HW and SW versions
  • The OPTBC resolver hardware and software combinations that are compatible:

WARNING: Not performing the encoder ID run after replacing the OPTBC resolver option board before any other use of the AC drive may result in severe harm or injury to equipment and/or persons.

• Resolver basics
  • Resolver-based systems are preferred in motion control applications that exist in hot, humid, dusty, oily, or mechanically demanding environments.
• Resolver to digital conversion basics
  • Picture 1 shows simulated encoder signals from RTD ASIC.
• Compatible resolver types
  • Resolver Output voltage: 1.8Vrms, 4.0Vrms, 1.3Vrms, 7.5Vrms
  • Number of poles: The resolver must have the same number of poles as the motor it works with (e.g., a 6-pole resolver with a 6-pole motor).
• Resolver board features
  • Encoder Simulation Output Resolution: 14bit, 14bit, 14bit, 16bit
  • Encoder Simulation Pulses/rev: 256, 1024, 4096, 4096
  • Position accuracy*: +/- 4 LSB
  • Velocity accuracy*: +/- 4 LSB
  • Excitation frequency: 1-20kHz (adjustable with 1kHz steps)
  • Transformation Ratio Slots: A, B, Z (max. pulse frequency 150kHz)
• Configuration
  • Board parameters and monitoring values
  • Refer to the user manual for detailed information on board parameters and monitoring values.
  • Connectors and jumpers
  • Refer to the user manual for detailed information on connectors and jumpers.
• FAQ
  • Q: Why are resolvers preferred in certain environments?
  • A: Resolver-based systems are preferred in motion control applications that exist in hot, humid, dusty, oily, or mechanically demanding environments due to their robustness.
  • Q: What is the purpose of resolver to digital conversion?
  • A: Resolver to digital conversion allows the resolver signals to be converted into digital signals that can be processed by the AC drive.
  • Q: What are the compatible resolver types?
  • A: The resolver must have an output voltage between 1.8Vrms and 4Vrms and an input voltage between 1.3Vrms and 7.5Vrms. Additionally, the resolver must have the same number of poles as the motor it works with.
  • Q: What is the position accuracy and velocity accuracy of the resolver board?
  • A: The position accuracy is +/- 4 LSB (Least Significant Bit) and the velocity accuracy is also +/- 4 LSB.

RESOLVER OPTION BOARD OPT-BC

• This manual is valid for board versions VB00339i or later.
• The Resolver option board OPT-BC provides the user with an interface to use resolver as a feedback device to VACON® NXP Dr ive.
• The interface provides speed and position data.
• The OPT-BC includes also encoder simulation output (HTL level ) and secondary encoder input (HTL- level ).

Note about absolute angle and different HW and SW versions

• Due to differences in hardware and software, the angle given by the OPTBC resolver board to the application can differ by 180 degrees in the same system.
• When replacing the OPTBC resolver option board in existing installations, care must be taken that the angle value does not change accidentally.
• To prevent this, it is recommended that the encoder ID run is always executed when replacing OPTBC resolver option boards in existing installations.
• This will automatically correct the possible 180-degree difference that might be induced when replacing the OPTBC option board.
• The following table shows which OPTBC resolver hardware and software combinations are compatible.
• For example, if you replace OPTBC with HW version G and software version V005 with OPTBC with hardware version K and software version V013 the angle does not change by 180 degrees.
• In this case, encoder ID run is not needed but is still recommended.

HW & SW version| HW: G or prior, SW V005 or prior| HW: H or later, SW: V010, V011, V012| HW: H or later, SW: V013
---|---|---|---
HW: G or prior, SW: V005 or prior| | û| ü
HW: H or later, SW: V010, V011, V012| û| | û
HW: H or later, SW: V013| ü| û|

WARNING

• Not performing the encoder ID run after replacing the OPTBC resolver option board before any other use of the AC drive may result in severe harm or injury to equipment and/or persons.

Resolver basics

• A resolver is a rotary transformer where the magnitude of the energy through the resolver windings varies sinusoidal as the shaft rotates.
• A resolver contains one primary winding and two secondary windings, the SIN and COS windings.
• Primary winding is in the rotor of the resolver and secondary windings are in the stator.
• Secondary windings are mechanically displaced 90 degrees from each other.
• The primary winding is excited by an AC voltage called the reference voltage (Vr ).
• The induced voltages in the SIN and COS Windings are equal to the value of the Reference Vol tage mul multiplied by the SIN or COS of the angle of the input shaft from a fixed zero point.

Why resolvers?

• When a Motion control application exists in a hot, humid, dusty, oily, or mechanically demanding environment, a resolver-based system is the preferred red choice.

Resolver to digital conversion basics

• The OPT-BC board sends the Excitation signal to the resolver, and the resolver sends sin and cos signals back to the board.
• In the OPT-BC board, sin and cos signals are converted to incremental encoder pulses by the ASIC circuitry (see picture 1).
• The incremental pulses are used for calculating rotation speed in the VACON® NXP control card.
• The conversion from resolver sin/cos signals to digital pulses is called RTD (Resolver To Digital conversion).

Compatible resolver types

• Resolver Output voltage: 1.8Vrms 4.0Vrms
• Resolver Input voltage: 1.3Vrms 7.5Vrms
• Number of poles: 2, 4, 6 … 20 (System software version V182 or later)

Note
If the number of poles of the resolver is not 2, then the resolver can only work with a motor that has the same number of poles (e.g. a 6-pole resolver with a 6-pole motor ). Maximum tracking rates assume that the resolver has 2 poles.

Resolver board features

| 14bit| 14bit| 14bit| 16bit
---|---|---|---|---
Encoder Simulation Output Resolution| 10bit| 12bit| 14bit| 14bit
Encoder Simulation Pulses/rev| 256| 1024| 4096| 4096
position accuracy| +/- 4 LSB| +/- 4 LSB| +/- 4 LSB| +/- 16 LSB
velocity accuracy| +/- 4 LSB| +/- 4 LSB| +/- 4 LSB| +/- 4 LSB
Excitation frequency| 1- 20kHz (adjustable with 1kHz steps)
Transformation Ratio| The output voltage of the resolver has to be between 1.8Vrms and 4Vrms. Input voltage can be adjusted between 1.3Vrms and 7.5Vrms.
Slots| C
Encoder Simulation Output| A,B, Z (max. pulse frequency 150kHz)

tested in zero acceleration
Note: by selecting 16bit mode, you can improve only position accuracy. Velocity accuracy remains the same (14bit).

• Encoder Simulation Pulses per Revolution and Maximum tracking rate depend on the number of resolver poles.
• Simulated Pulses / rev = 2R ∙ Resolver_Poles / 8
• R = Encoder simulation output resolution

CONFIGURATION

Board parameters and monitoring values
Monitor Menu

Resolver error register bits

7.3.2.7| AnIN: C.6| | Cumulative error register bits. Please see chapter 4.3 OPTBC Resolver errorregister bits

Parameters menu

1 =Yes

7.3.1.2| Reading Rate| 0| 4| 1| 0 = No

1 = 1 ms

2 = 5 ms

3 = 10 ms

4 = 50 ms

7.3.1.3| Exciting freq| 0| 19| 0| 0 = 10 kHz

1 = 20 kHz

2 = 1 kHz

3 = 2 kHz

4 = 3 kHz

5 = 4 kHz

6 = 5 kHz

7 = 6 kHz

8 = 7 kHz

9 = 8 kHz

10 = 9 kHz

11 = 11 kHz

12 = 12 kHz

13 = 13 kHz

14 = 14 kHz

15 = 15 kHz

16 = 16 kHz

17 = 17 kHz

18 = 18 kHz

19 = 19 kHz

7.3.1.4| Resolution| 0| 3| 1| 0 = 10 bit

1 = 12 bit

2 = 14 bit

3 = 16 bit

7.3.1.5| Resolver poles| 0| 9| 0| 0 = 2 pole

1 = 4 pole

2 = 6 pole

3 = 8 pole

4 = 10 pole

| | | | | 5 = 12 pole

6 = 14 pole

7 = 16 pole

8 = 18 pole

9 = 20 pole

---|---|---|---|---|---
7.3.1.6| Enc 2 Pulse/ Rev| 0| 65535| 1024|

7.3.1.7

|

Encoder 2 Type

|

1

|

3

|

1

| 1 = A,B=Speed

2 = A=Ref,B=Dir 3 = A=Forw,B=Rev

Simulated pulses/rev is calculated based on resolution bits(R) and resolver poles. The formula used is:

• Simulated Pulses/ rev = 2^R * Resolver poles / 8

Example:

• Resolution bits = 12
• Resolver poles = 2
• Simulated Pulses/ rev= 2^12 * 2 / 8
• Simulated Pulses/ rev = 2^12 * 2 / 8 = 1024

The absolute position value is from 0 to 4095 (2^12=4096).

Connectors and jumpers

Picture 2 Connector and pin header placement in OPT Board. PIN 1 is marked with a small square on the X3, X4, X10, X13 and X21.

Terminal data for X1 and X2 connectors

X21 (C-Pulse source selection)

• Incremental C-pulse (Zero pulses) to the control board is read from the resolver attached to the option board (Default).
• C-pulse is External. Read from FRZ input. This feature can be used with special applications for marking position data. Not supported in Standard VACON® NXP applications.

X10 and X13 (Gain selection)

SIN and COS feedback signals from the resolver should be in the range of 1.8 4Vrms (between SINHI – SINLO and COSHI – COSLO). To scale the input signals to an acceptable level we can select 1/3, ⅓ or 1/4 attenuation for the input lines. The following equation can be used to calculate the output signal level. Transformation for the corresponding resolver is told in resolver datasheets.

• EXC_OUT= excitation output voltage
• SIN Feedback voltage = EXC_OUT * Transformation ratio
  • 1/4 gain for SIN / COS feedback signals from 3.25 Vrms to 4Vrms
  • 1/3 gain for SIN / COS feedback signals from 2.4 Vrms to 3.24Vrms
  • 1/2 gain for SIN / COS feedback signals from 1.8 Vrms to 2.39Vrms
  • X13 sets SIN attenuation and X10 sets COS attenuation. SIN and COS input pairs should all have the same attenuation to keep signals symmetrical.
  • For example, a resolver that is rated for 5.6Vrms excitation and has a transformation ratio of 0.485 gives an output voltage of 2.72Vrms.
  • Excitation voltage and corresponding settings are selected from Table 1 in Chapter 2.2.4.
  • In this case exact match is found. Resolver output voltage of 2.72V Vrms fits the signal range of 1/3 attenuation.

X3 and X4 Excitat ion Vol tage Cont rol

• The resolver option board has an amplifier for adjusting the excitation voltage. Jumpers X3-1-4 and X4-1-3 set the amplifier gain and consequently the excitation voltage.
• Excitation voltage can be set in the range of 1.3Vrms to 7.5Vrms. To get the best possible accuracy, excitation voltage should be selected to be as high as the used resolver allows AND so that the output voltage fits to the given range.
• The excitation frequency is set from the control panel and it should be set before connecting the resolver to the option board.
• To set the excitation voltage accurately, measure the excitation voltage when the resolver is connected.
• Notice that the measurement device must be capable of measuring high-frequency RMS voltage.
• Typical excitation voltage for each jumper setting can be checked from the table, usable values are highlighted.
• EXC_OUT = target excitation output voltage. This is specified in resolver datasheets (Excitation Voltage)
• Now, set the calculated gain with X3 and X4 jumpers. Jumper settings for the desired gain can be found in the table.
• Al l jumpers attached give minimum gain and al l jumpers open give maximum gain.
• Maximum output voltage is limited to the board’s internal voltages and is approximately 7.5Vrms.
• The recommended voltage range is highlighted in blue.
• X = Jumper instal led

Table 1 Excitation voltage selection

Configurat ion example

Example Resolver Datasheet

Step 1:

• Check the resolver input voltage and select the corresponding configuration for jumpers X3 and X4 from the table1.
• ->6.1 V (Use smaller Vol tage from the table if an exact match is not found = 6.08V)

Set jumpers to X3-3, X3-4, X4-1 and X4-2:

Step 2: Find the resolver output voltage from the datasheet or calculate it.

• Output voltage = input voltage .transformation ratio.
• Output Voltage = 6.08 .0.485
• Output Voltage = 2.95 Vrms
  • 1/4 gain for SIN / COS feedback signals from 3.25 Vrms to 4Vrms
  • 1/3 gain for SIN / COS feedback signals from 2.4 Vrms to 3.24Vrms
  • 1/2 gain for SIN / COS feedback signals from 1.8 Vrms to 2.39Vrms

If the Output voltage is higher than 4Vrms -> Lower the excitation voltage. ->Use 1/3 gain

Step 3: Configure the board using the control panel. (Software configuration)

• Inver t Direction - >This parameter can be used for inverting rotation direction
• Reading Rate - > Defaul t 1ms. In noisy environments, this parameter can be used to filter disturbances. Set first to 5ms if the shaft is not running smoothly.
• Exciting freq - > Select the Exciting frequency as told in specification ->In this example 10kHz
• Resolution - > Defaul t 12bit ->In slow-speed applications high Resolution can be used. Planned Max Speed in Example is 1500rpm Select highest possible accuracy ->16 bit (16bit) = 7500rpm ∙ 2 / Resolver_Poles
• Resolver poles = 2 poles

INSTALLATION

WARNING! Internal components and circuit boards are at high potential when the AC drive is connected to the power source. This voltage is extremely dangerous and may cause death or severe injury if you come into contact with it.

Installing the option board

• Installation guidelines should be followed carefully to get the best performance of the system.
• Improper installation of the system might cause disturbances which may in RTD conversion generate extra encoder pulses or jitter to the pulse lengths.
• Since the board supports ts large variation of resolvers, the used resolver should always be verified before installation.
• The option board OPT-BC can only be used with VACON® NXP drives.
• The option board OPT-BC can be connected to slot C.
• Disconnect the drive from the mains before starting the installation.

Installing the resolver

• Connect the resolver after setting the jumpers. Use cable clamp in the lower part of the VACON®
• NXP drive to connect cable shield. Strip the cable so that the shield is exposed only from the part that is fitted to the clamp.

Additional cable ing instructions

• The resolver and other control cables should not be in parallel with power cables (supply and motor cable).
• The feedback signals might also suffer from the noise coming from the motor and supply cables.
• Use shielded symmetrical motor cables.
• It is recommended to connect the motor cable shield with 360° EMC bushing.
• The motor and supply cables should not be in parallel with the resolver signal cable.

DIAGNOSTICS AND TROUBLESHOOTING

The panel shows in the G7.3 that the board is OPT-BC. Monitor values from 7.3.2 shows:

• Resolver Freq (Hz)
• Resolver Speed (Rpm)
• Sim. Pulses/ rev
• Encoder 2 Freq
• Encoder 2 Speed
• AnIN: C.5*
• AnIN: C.6*

Error register bits. Please see Chapter 4.3 OPTBC Resolver er or register bits

Parameter values from panel index 7.3.1

• Inver t direction
• Reading rate
• Exciting freq (10 / 20 kHz)
• Resolution bits(10 / 12 bits)
• Resolver Poles
• Enc 2 Pulse / Rev
• Encoder 2 type
• Simulated pulses/rev is calculated based on resolution bits(R) and resolver poles.
• The formula used is Simulated Pulses/ rev = 2R * Resolver poles / 8.

Example:

• Resolution bits = 12
• Resolver poles = 2
• Simulated Pulses/ rev= 212 * 2 / 8
• Simulated Pulses/ rev = 2^12 * 2 / 8 = 1024

Lower resolution is used in high-speed applications. In 10-bit mode the resolver sends 256 pulses/revolution and in 12-bit mode 1024 pulses/revolution if the resolver’s poles = 2. The absolute position value is from 0 to 4095 (2^12=4096).

Fault handling

• OPTBC Resolver option board reports ts fault to the application in case where LOS (loss of signal ) or LOT (loss of traction) situation is detected.
• Actions after the fault depend on the application configuration.
• The option board informs the application when the situation comes back to normal.

LED indicators

There are two LED indicators in the option board:

• Yellow Board status LED

Red-Error LED (Loss of traction)

Faul t conditions:

• Incor rect settings for resolver
• Resolver failure
• Calling failure

In case of failure, check the jumper settings, cabling and resolver assembling.
OPTBC Resolver er ror register bits

• Analog input variables ANIN5 and ANIN6 show error registers of the OPTBC Resolver option board.
• These variables can be seen as 7.3.2.6 AnIN: C.5 and 7.3.2.7 AnIN: C.6 monitor values. Application developers can also use this information in applications if needed.
• ANIN5 shows currently active error register bits.
• ANIN6 shows cumulative error register bits after the AC drive boot.

CONTACT

• Vacon Ltd
• Member of the Danfoss Group
• Runsorintie 7
• 65380 Vaasa
• Finland
• Sales code: DOC-OPTBC+DLUK
• Document ID:
• www.danfoss.com.
• Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/.

NOTE! You can download the English and French product manuals with applicable safety, warning and caution information from http://drives.danfoss.com/knowledge-center/technical-documentation/.

• Document code: DPD01362C
• Date: 20.02.2018

References

• Search | Danfoss
• Engineering Tomorrow | Danfoss

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