Service Schulung 16.08.

2000

Sine drive at HEIDELBERG

Advance information on the sine synchronous
main drive (MSK3)
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

Dr. Martin Riese, SFA-33; Joachim Glos, CSO-E

 Service training 16.08.2000

Sine drive at HEIDELBERG

1 Basic information on HEIDELBERG drives
2 Advantages of field-oriented control
3 Motor control board 3 (MSK3)
4 New sine/cosine encoder
5 EMC measures
6 Motor data handling (encoder - MSK3)
7 Troubleshooting
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

8 SP number and software

9 Summary
 Basic information on HEIDELBERG drives 1.1

Variable-speed motors

Variable-speed motors

D.C. drive Brushless d.c. drive A.C. drive (sine drive)

(block commutated drive, BL)

Synchronous drive Asynchronous drive

SM/CD 74 currently not used
SM/CD 102
> 22/37/55/75 kW possibly in future
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

Chronology of development
 Basic information on HEIDELBERG drives 1.2

A comparison of Heidelberg's drives:

D.C. Brushless Sinus

drive d.c. drive a.c. drive
(block commutated)

+ even torque curve + more favourably + more favourably priced motor

+ medium control dynamics priced motor + maintenance-free
- high motor costs + maintenance-free + even torque curve
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

- regular maintenance + simple control + very high dynamics

(wear and tear of brushes) - harmonic torque (good control properties)
- more complex control
 Advantages of the field-oriented control 2.1

Field-oriented control allows for a highly dynamic

embossing of any torque.

• slight harmonic waves in the motor torque

• no excitation of vibrations in the press
• more accurate positioning possible
• practical: external behaviour similar to a d.c. machine
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)
 Motor control board 3 (MSK3) 3.1

X4 (REK1)

X1 (BLT) PowerCon

H1
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

H2
Status LEDs X5 (sensor)
 Motor control board 3 (MSK3) 3.2

Voltage supply

The MSK3 needs three different supply voltages.

+/- 15 Volts
+ 8 Volts
+ 5 Volts

The +/-15 volts and the +8 volts are supplied by the converter and
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

distributor module via the X1 interface to the brushless power part.

The +5 volts come from the RER computer backplane.

All voltages required, including the internal ones, are monitored

and displayed on the MSK3!
 New Sine-Cosine encoder 4.1

Motor encoder: SinCos SRS 50 C3

Prov. fastening

Interface
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)
 New sine-cosine encoder 4.2

Characteristics

• 1024 increments (sine/cosine signal)

• Analog evaluation of sine/cosine tracks and interpolation between
the increments
• Absolute position in high resolution via serial interface
• Contains 4kBit EEPROM which is accessed via a serial interface
• Single-screened, special cable to the MSK3, connected on both
ends (interface X5 on the MSK3)
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

• Method of attachment to the motor not yet finally decided

• Encoder and brake can be replaced separately as a spare part
• Very sensitive to vibrations
 EMC measures 5.1

Precautions

• Single-screened special cable between MSK3 (X5) and encoder,

connected on both ends
• The screen runs on the PE potential
• MSK3 must be connected to PE via a HF ribbon cable (power-con
connection as with RGP5)
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)
 Motor data handling (Geber-MSK3) 6.1

Basic information

• For the first time, individual data per motor is available (e.g.:
inductance, output, field offset angle)
• The data is saved redundantly on an EEPROM in the encoder and
on the MSK3
• The motor is supplied with an encoder that contains the original data
of the motor manufacturer
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

Important: Never change the MSK3 and encoder at the same time!!!
 Motor data handling (encoder - MSK3) 6.2

Initializing

Process flow Read data from encoder

EEPROM
Read data from MSK3 EEPROM
Check validity
and compare

ONLY 1 data record OK

Data records OK Neither data record OK
OR different motor numbers
AND OR
Request motor numbers
same motor number writing on EEPROM not OK
= inconsistent main drive data.
Enter Motor number.

Motor number does not Motor number does not

correspond to encoder data. correspond to MSK3 data.

MSK3 data is overwritten. Encoder data is

overwritten.
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

Awaiting restart: Fatal error:

Go into operation: LED green 2 flashes rapidly LED green 2 flashes rapidly
LED green 2 flashes slowly = EEPROM data main drive LED red 2 flashes rapidly
overwritten. Reboot. = INIT error MSK3.
 Troubleshooting 7.1

Error messages on CPTronic

• Previous INIT and DYN errors continue to be indicated

• In addition, some new DYN error messages (and CP2000
messages) are issued, e.g:
- Error in the encoder EEPROM
- Error in the MSK3 EEPROM
- Software error
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

- Inconsistent main drive data. Enter motor number.

- ...
When changing the MSK3 or the encoder you must reboot the
machine and pay attention to the error message in CP2000!!!
 Troubleshooting 7.2

Indication of HW errors by two LED signal lamps

gr ge rt

H2

H1
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

MSK3
 Troubleshooting 7.3

Meaning of the LEDs

on Initialization on Watchdog timeout

*off no fault *off Watchdog O.K.
flashing error

H2 LED yellow H1 LED yellow

on Initialization on BLT active
off Signal processor not running off BLT not active
*flashing Signal processor is running

H2 LED green H1 LED grün

on Error *on Electronic voltages O.K.
off Initialization off Electronic voltage error
*flashing Main program is running
flickers wait for reboot
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

* = “normal status”
 SP number and Software 8.1

Spare part number and software compatibility

• As of around Nov 2000, the MSK3 can be ordered under the number
00.785.0334/04
• Brakes are available in three different versions SB100/75Nm
C2.101.3023, SB200/160Nm C4.101.3023 and SB320/250Nm
C6.101.3023
• The encoder: Sincos SRS50 C5 has the number C2.101.3013
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

• For an MSK3 with the index 04, the REK1 software version
00.785.0557/01 (corresponds to version 024.03) is required
 Summary 9.1

Summary

• Introduction in motors >22/37/55/75kW, depending on series

• Voltage supply from two sources (BLT and RER)
• New Sin-Cos encoder with serial interface and integrated EEPROM
• Redundant motor data management in the encoder and on the
MSK3
• The encoder line is single-screened and connected at both ends
• The MSK3 must be connected to the PE
Präsentationstitel, 12.11.99, Abteilungskürzel (6 pt, Arial)

• Special MSK3-motor-encoder exchange procedure

• Fault diagnosis via CPTronic and LED signal lamps