SMT-BD1/t

SMT-BD1/t
gb

UNWINDER/REWINDER
SERVO DRIVE WITH
PROFIBUS DP
INTERFACE

INFRANOR®

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 SMT-BD1/t

WARNING

!
This is a general manual describing a series of servo amplifiers having output capability suitable for driving AC
brushless sinusoidal servo motors.

Instructions for storage, use after storage, commissioning as well as all technical details require the
MANDATORY reading of the manual before getting the amplifiers operational.

Maintenance procedures should be attempted only by highly skilled technicians having good knowledge
of electronics and servo systems with variable speed (EN 60204-1 standard) and using proper test
equipment.

The conformity with the standards and the "CE" approval is only valid if the items are installed according to the
recommendations of the amplifier manuals. Connections are the user's responsibility if recommendations and
drawings requirements are not met.

Any contact with electrical parts, even after power down, may involve physical damage.
Wait for at least 5 minutes after power down before handling the amplifiers (a residual voltage of several
hundreds of volts may remain during a few minutes).

ESD INFORMATION (ElectroStatic Discharge)

INFRANOR amplifiers are conceived to be best protected against electrostatic discharges. However,
some components are particularly sensitive and may be damaged if the amplifiers are not properly
stored and handled.
STORAGE
- The amplifiers must be stored in their original package.
- When taken out of their package, they must be stored positioned on one of their flat metal
surfaces and on a dissipating or electrostatically neutral support.
- Avoid any contact between the amplifier connectors and material with electrostatic potential
(plastic film, polyester, carpet…).
HANDLING
- If no protection equipment is available (dissipating shoes or bracelets), the amplifiers must
be handled via their metal housing.
- Never get in contact with the connectors.
ELIMINATION
In order to comply with the 2002/96/EC directive of the European Parliament and of the Council of
27 January 2003 on waste electrical and electronic equipment (WEEE), all INFRANOR devices
have got a sticker symbolizing a crossed-out wheel dustbin as shown in Appendix IV of the
2002/96/EC Directive.
This symbol indicates that INFRANOR devices must be eliminated by selective disposal and not
with standard waste.

INFRANOR does not assume any responsibility for any physical or material damage due to improper handling or
wrong descriptions of the ordered items.
Any intervention on the items, which is not specified in the manual, will immediately cancel the warranty.

Infranor reserves the right to change any information contained in this manual without notice.

© INFRANOR, June 2006. All rights reserved.

Issue: 3.1

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Contents
CONTENTS............................................................................................................................................. 3
CHAPTER 1 - GENERAL DESCRIPTION ............................................................................................. 6
1 - INTRODUCTION............................................................................................................................ 6
2 - GENERAL DESCRIPTION............................................................................................................. 6
3 - REFERENCE TO THE STANDARDS ............................................................................................ 7
4 - REFERENCE TO OTHER DOCUMENTS...................................................................................... 7
CHAPTER 2 - SPECIFICATIONS........................................................................................................... 8
1 - TECHNICAL SPECIFICATIONS .................................................................................................... 8
1.1 - Current ratings for the 220 VAC amplifier version.................................................................. 8
1.2 - Current ratings for the 400 VAC amplifier version.................................................................. 9
1.3 - Other specifications .............................................................................................................. 10
2 - FUSE PROTECTION ................................................................................................................... 11
2.1 - Fuse protection for the 220 VAC amplifier version............................................................... 11
2.2 - Fuse protection for the 400 VAC amplifier version............................................................... 11
CHAPTER 3 - INPUTS / OUTPUTS ..................................................................................................... 12
1 - CONNECTORS LOCATION ........................................................................................................ 12
1.1 - RACK connectors ................................................................................................................. 12
1.2 - Amplifier connectors ............................................................................................................. 12
2 - LEDS............................................................................................................................................. 12
2.1 - Amplifier fault LEDs .............................................................................................................. 12
2.2 - Profibus communication LEDs ............................................................................................. 12
3 - X1: RESOLVER CONNECTOR ................................................................................................... 13
4 - X2: ENCODER CONNECTOR ..................................................................................................... 13
5 - X4: CONTROL CONNECTOR ..................................................................................................... 14
6 - X6: PROFIBUS............................................................................................................................. 14
7 - X5: RS-232 CONNECTOR........................................................................................................... 14
8 - X3: TEST CONNECTOR ............................................................................................................. 15
9 - LOGIC INPUTS-OUTPUTS SPECIFICATIONS........................................................................... 15
9.1 - Logic inputs: ENABLE, SEL1, SEL2, START, STOP........................................................... 15
9.2 - Logic inputs: TDI, Lin1.......................................................................................................... 15
9.3 - Logic outputs: TER, Lout1.................................................................................................... 16
CHAPTER 4 - CONNECTIONS ............................................................................................................ 17
1 - CONNECTION DIAGRAMS ......................................................................................................... 17
1.1 - Power supply and motor connections .................................................................................. 17
1.2 - Amplifier I/O connections ..................................................................................................... 17
2 - RS-232 SERIAL LINK CONNECTION.......................................................................................... 18
3 - WIRING RECOMMENDATIONS.................................................................................................. 18
3.1 - GND wiring and ground connections.................................................................................... 18
3.2 - CONNECTORS SHIELD CONNECTION ............................................................................ 19
3.3 - MOTOR AND RESOLVER CABLES.................................................................................... 20
3.4 - SERIAL LINK CABLES ........................................................................................................ 20
CHAPTER 5 - ADJUSTABLE FUNCTIONS ........................................................................................ 21
1 - HARDWARE ADJUSTMENTS..................................................................................................... 21
2 - ADJUSTABLE PARAMETERS .................................................................................................... 23
CHAPTER 6 - COMMISSIONING......................................................................................................... 24
1 - AMPLIFIER HARDWARE CONFIGURATION ............................................................................. 25
1.1 - Standard configuration ......................................................................................................... 25
1.2 - Motor thermal sensor configuration...................................................................................... 25
1.3 - Current loops adjustments ................................................................................................... 26
2 - PUTTING INTO OPERATION ...................................................................................................... 27
3 - MOTOR ADJUSTMENT............................................................................................................... 28

Contents 3
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3.1 - Motor parameter setting........................................................................................................ 28

3.2 - Adjustment to a new motor ................................................................................................... 28
4 - SPEED CONTROL LOOP ADJUSTMENT ................................................................................... 29
4.1 - Regulator parameters adjustment ........................................................................................ 29
4.2 - Enabling ................................................................................................................................ 29
4.3 - Brake control......................................................................................................................... 29
4.4 - Jog control ............................................................................................................................ 29
5 - UNWINDER/REWINDER CONFIGURATION .............................................................................. 30
5.1 - Rotation direction.................................................................................................................. 30
5.2 - Gearing ratio adjustment ...................................................................................................... 30
5.3 - Diameter sensor calibration .................................................................................................. 30
5.4 - Encoder ratio calibration ....................................................................................................... 31
5.5 - Tension measurement calibration ........................................................................................ 31
5.6 - PID loop adjustment for tension control................................................................................ 32
5.7 - Parameters setting for tension control.................................................................................. 33
6 - PROFIBUS ADDRESS ................................................................................................................. 33
7 - PARAMETERS SAVING .............................................................................................................. 33
8 - PROFIBUS OR STAND ALONE MODE SELECTION.................................................................. 33
CHAPTER 7 - PROGRAMMING........................................................................................................... 34
1 - GENERAL DESCRIPTION ........................................................................................................... 34
2 - CONTROL SEQUENCE PARAMETERS ..................................................................................... 34
3 - SEQUENCE SET POINT SELECTION ........................................................................................ 35
4 - VARIABLE DIAMETER OPERATION .......................................................................................... 35
4.1 - Speed gearing ratio adaptation ............................................................................................ 35
4.2 - Torque set point ratio adaptation.......................................................................................... 36
4.3 - Servo loop gains adaptation ................................................................................................. 36
5 - EDITION OF A CONTROL SEQUENCE ...................................................................................... 37
5.1 - Tension control sequence..................................................................................................... 37
5.2 - Gearing ratio initialization sequence..................................................................................... 39
5.3 - Speed 1 control sequence .................................................................................................... 40
5.4 - Speed 2 control sequence .................................................................................................... 41
5.5 - Torque control sequence ...................................................................................................... 42
6 - SEQUENCES CHAINING............................................................................................................. 44
6.1 - Sequence control.................................................................................................................. 44
6.2 - Logic inputs........................................................................................................................... 45
6.3 - Logic outputs ........................................................................................................................ 46
CHAPTER 8 - OPERATION WITH PROFIBUS.................................................................................... 47
1 - PROFIBUS COMMUNICATION ................................................................................................... 47
1.1 - PPO message....................................................................................................................... 47
1.2 - Configuration ........................................................................................................................ 49
1.3 - Parameter setting (PKW)...................................................................................................... 49
1.4 - Global control........................................................................................................................ 50
2 - CONTROL VIA PROFIBUS .......................................................................................................... 51
2.1 - Control word ......................................................................................................................... 51
2.2 - Input command ..................................................................................................................... 51
2.3 - Status.................................................................................................................................... 52
2.4 - Feedback .............................................................................................................................. 52
3 - OPERATION DIAGRAM............................................................................................................... 53
3.1 - Amplifier control process ...................................................................................................... 53
3.2 - Unwind/rewind mode ............................................................................................................ 54
4 - DRIVING OF THE UNWINDER/REWINDER ............................................................................... 55
4.1 - Enabling/disabling................................................................................................................. 55
4.2 - Starting a sequence.............................................................................................................. 55
4.3 - Other movements ................................................................................................................. 55
4.4 - All-speed control ................................................................................................................... 55
CHAPTER 9 - PARAMETER SETTING BY PROFIBUS...................................................................... 56
1 - PARAMETER LIST....................................................................................................................... 56

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2 - PARAMETERS DESCRIPTION ................................................................................................... 57

2.1 - Motor parameters ................................................................................................................. 57
2.2 - Current parameters .............................................................................................................. 58
2.3 - Speed regulator parameters................................................................................................. 59
2.4 - Application parameters......................................................................................................... 60
2.5 - Unwinder/rewinder parameters ............................................................................................ 62
2.6 - Encoder output ..................................................................................................................... 63
2.7 - Manual jog parameters......................................................................................................... 64
2.8 - PID loop parameters............................................................................................................. 64
2.9 - Gearing ratio calibration parameters .................................................................................... 65
2.10 - Tension control parameters................................................................................................ 66
2.11 - Torque control parameters ................................................................................................. 67
2.12 - Sequence Reading/Writing................................................................................................. 68
CHAPTER 10 - TROUBLESHOOTING ................................................................................................ 72
1 - DIAGNOSTICS............................................................................................................................. 72
1.1 - SMT-BD1/t fault display........................................................................................................ 72
1.2 - Fault reset............................................................................................................................. 72
2 - FAULT FINDING .......................................................................................................................... 73
2.1 - System fault.......................................................................................................................... 73
2.2 - Non stored faults .................................................................................................................. 73
2.3 - Stored faults ......................................................................................................................... 73
3 - OPERATING PROBLEMS ........................................................................................................... 75
3.1 - Motor does not move............................................................................................................ 75
3.2 - Motor supplied but no torque................................................................................................ 75
3.3 - Shaft locked, eratic oscillations or rotation at maximum speed ........................................... 75
3.4 - Discontinuous motor rotation with zero torque positions...................................................... 75
3.5 - Loud crackling noise in the motor at standstill ..................................................................... 75
3.6 - Loud noise in the motor at standstill and when running ....................................................... 75
3.7 - Sequence not executed........................................................................................................ 75
4 - SERVICE AND MAINTENANCE .................................................................................................. 75
CHAPTER 11 - APPENDIX .................................................................................................................. 76
1 - USE OF THE POSITIVE & NEGATIVE LOGIC INPUTS .............................................................. 76
2 - USE OF THE "AMP. READY" & "POWER READY" OUTPUTS ................................................... 76
3 - SPEED FOLLOWING ERROR PROTECTION ............................................................................ 77
4 - I2T PROTECTION......................................................................................................................... 77
4.1 - Current limitation in Fusing mode......................................................................................... 77
4.2 - Current limitation in Limiting mode ....................................................................................... 78
5 - MASTER/SLAVE CONFIGURATION........................................................................................... 79
5.1 - Reversible master/slave gearing operation with two SMT-BD1/t amplifiers ........................ 79
5.2 - Configurable master/slave gearing operation with more than two SMT-BD1/t amplifiers.... 80
6 - COGGING TORQUE COMPENSATION ..................................................................................... 81
7 - AMPLIFIER TYPES...................................................................................................................... 81

Contents 5
 SMT-BD1/t

Chapter 1 - General description

1 - INTRODUCTION

Series SMT-BD1/t servo modules are PWM servo amplifiers that provide current and speed control for AC
sinusoidal motors (brushless) with transmitter resolver.

The SMT-BD1/t servo drive is 220 VAC or 400 VAC mains operated. The SMT-BD1 plug-in system with 220 VAC
power supply is available as a single-axis block version or as a multiaxis version that can receive up to six axes in
a standard 19" rack including the power supply. The SMT-BD1/t plug-in system with 400 VAC power supply is
available as a multiaxis version that can receive up to three axes in a standard 19" rack including the power
supply.

2 - GENERAL DESCRIPTION

Series SMT-BD1 amplifiers have their own DC/DC converter to provide the appropriate supply voltage (+5 V,
+/-15V). The source supply voltage for the control board is the auxiliary 310 VDC supply voltage. The auxiliary
supply voltage allows to have the amplifier control board still active when the power supply voltage is turned off.

Each module is packaged as a 6 U "double Eurocard":

- one power board with IGBT transistors
- one control board with DSP (Digital Signal Processing).

The SMT-BD1/t servo amplifiers are suited for unwind/rewind and tension control applications. Up to 64 control
sequences including tension control, speed control and torque control can be programmed and combined in order
to solve various unwind/rewind and tension control applications. The sequence chaining capability allows to
define macro-sequences for complex applications: several control sequences can be linked together in order to
be automatically executed one after the other. The control sequences are pre-programmed. So, the application
programming simply consists in initializing the sequences parameters with the desired values.

The SMT-BD1/t servo amplifier most typical unwind/rewind and tension control applications are listed below :
• Material unwind/rewind force control based on diameter sensor feedback
• Material unwind/rewind line speed control based on diameter sensor feedback
• Material unwind/rewind force control based on line encoder feedback
• Material unwind/rewind line speed control based on line encoder feedback
• Accumulator control for material unwinder based on diameter and accumulator sensors feedback
• Material unwind/rewind tension control based on line encoder and dancer feedback
• Material unwind/rewind tension control based on diameter sensor and dancer feedback

The SMT-BD1/t servo amplifier operates with a PROFIBUS DP interface. The servo amplifier control and the
parameter setting can both be made via the PROFIBUS DP connection. The servo amplifier control via
PROFIBUS DP connection simply consists in selecting one of the amplifier pre-programmed control sequences
and start its execution.

The SMT-BD1/t servo amplifier can also operate with the RS-232 serial link for the parameters setting and the
sequences programming. The INFRANOR BPCW parameter setting software which is IBM-PC compatible makes
the amplifier commissioning and the application programming easier.

The SMT-BD1/t servo amplifier can also run in stand-alone mode without the PROFIBUS DP connection. In this
configuration, a pre-programmed control sequence is selected via the SEL1 and SEL2 logic inputs and its
execution is started by using the START logic input. However, in this case only the sequence numbers 0 to 3 can
be selected by the SEL1 and SEL2 logic inputs activation.

6 CHAPTER 1 – General description

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3 - REFERENCE TO THE STANDARDS

The 220 VAC version of the SMT-BD1/t amplifiers operating in the BF rack, which is equipped with the mains
filter BF-35 or 70, has been approved for its compliance with the Electromagnetic Compatibility standards:
• EN 55011, Group 1, Class A regarding conducted and radiated radioelectric disturbances,
• CEI 801 - 2 - 3 - 4 regarding immunity.

The 220 VAC version of the SMT-BD1/t amplifiers operating in the single-axis racks BM 20 A – BMM 05F – BMM
05A, which are equipped with the appropriate mains filter (FN 612-20/06 or FN 356-16/06 or BF-35), has been
approved for its compliance with the Electromagnetic Compatibility standards:
• EN 55011, Group 1, Class A regarding conducted and radiated radioelectric disturbances,
• CEI 801 - 2 - 3 - 4 regarding immunity.

The 400 VAC version of the SMT-BD1/t amplifiers operating in the BF-400 rack, which is equipped with the mains
filter BF400-35 or 70, has been approved for its compliance with the Electromagnetic Compatibility standards:
• EN 55011, Group 1, Class A regarding conducted and radiated radioelectric disturbances,
• CEI 801 - 2 - 3 - 4 regarding immunity.

Standard to be applied to the electrical equipments of industrial machines: EN 60204.1.

The SMT-BD1 amplifiers have been "CE" marked since year 1995.

4 - REFERENCE TO OTHER DOCUMENTS

♦ BF-400 rack – for the use of the 400 VAC amplifier version in a multiaxis rack.
♦ BF rack – for the use of the 220VAC amplifier version in a multiaxis rack.
♦ BM20A/BMM05F/05AF single-axis rack – for the use of the 220 VAC amplifier version in a single-axis rack.

CHAPTER 1 – General description

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Chapter 2 - Specifications

1 - TECHNICAL SPECIFICATIONS

1.1 - Current ratings for the 220 VAC amplifier version

Operating voltage DC bus 310 VDC (270 VDC < DC bus < 340 VDC max.)
Auxiliary supply voltage 310 VDC ( 200 VDC < Uaux < 340 VDC max.)
Motor terminal to terminal output voltage 200 Vrms for 310 VDC bus
2
Authorized output currents for current pulse mode operation (I t protection in fusing mode)

Max. authorized rated current (Arms)

AMPLIFIER U rated Imax (A rms) of the amplifier
(Vrms) 1s WITHOUT FAN TYPE FAN TYPE
FAN* 1* 2*
SMT-BD1/t - 220/04 240 4,4 2
SMT-BD1/t - 220/08 240 8,8 4
SMT-BD1/t - 220/12 240 13,8 6
SMT-BD1/t - 220/17 240 17,7 8,5
SMT-BD1/t - 220/30 240 30,8 10 12 15
SMT-BD1/t - 220/30r 240 30,8 10 15
SMT-BD1/t - 220/45 240 48,6 10 15 20
SMT-BD1/t - 220/45r 240 48,6 10 20 23
SMT-BD1/t - 220/60 240 61 10 19 25
SMT-BD1/t - 220/60r 240 61 12 26 30
SMT-BD1/t - 220/70 240 70 25 30 35
SMT-BD1/t - 220/100 240 100 25 30 35

Authorized output currents for continuous current mode operation (I2t protection in limiting mode)

Max. authorized continuous current (Arms) of

AMPLIFIER TYPE U rated Imax (A rms) the amplifier
(Vrms) 1s WITHOUT FAN TYPE FAN TYPE
FAN* 1* 2*
SMT-BD1/t - 220/04 240 4,4 2
SMT-BD1/t - 220/08 240 8,8 4
SMT-BD1/t - 220/12 240 13,8 6
SMT-BD1/t - 220/17 240 17,7 8,5 8,5
SMT-BD1/t - 220/30 240 30,8 8,5 12 15
SMT-BD1/t - 220/30r 240 30,8 10 15
SMT-BD1/t - 220/45 240 48,6 8,5 15 18
SMT-BD1/t - 220/45r 240 48,6 10 20 23
SMT-BD1/t - 220/60 240 61 8,5 17 20
SMT-BD1/t - 220/60r 240 61 12 26 30
SMT-BD1/t - 220/70 240 70 17 30 35
SMT-BD1/t - 220/100 240 100 25 30 35

* Maximum ambient temperature = + 40° C, fan 1 = 56 l/s, fan 2 = 90 l/s.

Note: The SMT-BD1/t-X/Xr amplifier types are equipped with an additional heatsink in order to improve the heat
dissipation and increase their rated current. The width of these amplifier types is then 18 TE instead of 12 TE.

8 CHAPTER 2 – Specifications
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Minimum inductance between phases 1 mH

Conformity with the standards: CE approval - EMC standards

with multiaxis power supply configuration Immunity: CEI standards 801- 2 - 3 - 4
BF rack with mains filter BF-35 or 70, Conducted and radiated disturbances: EN 55011,
or SMTB.M 20 A / BMM05F/AF single-axis rack Group 1, class A
with filters FN 612-20/06 or FN 356-16/06 or BF-35. - Electrical standards for industrial machines:
360° shields; equipotentiality according to the wiring rules. EN 60204.1: - Insulator: 1500 VAC/1 min.
- Leakage current > 3 mA
(EMI filters)

Temperature range * storage - 20°C to + 70°C

* operation 5°C to +40°C
From 40°C on, the rated currents
must be reduced of 3 %/°C.
Max. temperature: 50°C

1.2 - Current ratings for the 400 VAC amplifier version

Operating voltage DC bus 565 VDC (480 VDC < DC bus < 685 VDC
max.)
Auxiliary supply voltage 310 VDC ( 200 VDC < Uaux < 340 VDC max.)
Motor terminal to terminal output voltage 380Vrms for 565 VDC bus
2
Authorized output currents for current pulse mode operation (I t protection in fusing mode)

Max. authorized rated current

AMPLIFIER U rated Imax (A rms) (Arms) of the amplifier
(Vrms) 1s WITHOUT FAN TYPE
FAN* 2*
SMT-BD1/t - 400/15 400 15.5 5 7.5
SMT-BD1/t - 400/30 400 30 8 15
SMT-BD1/t - 400/45 400 48 10 19
SMT-BD1/t - 400/60 400 60 not used 28
SMT-BD1/t - 400/100 400 100 not used 35
2
Authorized output currents for continuous current mode operation (I t protection in limiting mode)

Max. authorized continuous

AMPLIFIER TYPE U rated Imax (A rms) current (Arms) of the amplifier
(Vrms) 1s WITHOUT FAN TYPE
FAN* 2*
SMT-BD1/t - 400/15 400 15.5 not used 5
SMT-BD1/t - 400/30 400 30 not used 10
SMT-BD1/t - 400/45 400 48 not used 15
SMT-BD1/t - 400/60 400 60 not used 23
SMT-BD1/t - 400/100 400 100 not used 28

* Maximum ambient temperature = + 40° C, fan 2 = 90 l/s.

Minimum inductance between phases 2 mH

Conformity with the standards: CE approval - EMC standards

with multiaxis power supply configuration Immunity: CEI standards 801- 2 - 3 - 4
BF-400 rack and mains filter F400-35 or 70. Conducted and radiated disturbances: EN 55011,
360° shields; equipotentiality according to the Group 1, class A
wiring rules. - Electrical standards for industrial machines:
EN 60204.1: - Insulator: 2500 VAC/1 min.
- Leakage current > 3 mA
(EMI filters without condensators)

Temperature range * storage - 20°C to + 70°C

* operation 5°C to +40°C
From 40°C on, the rated currents
must be reduced of 3 %/°C.
Max. temperature: 50°C

CHAPTER 2 – Specifications 9
 SMT-BD1/t

1.3 - Other specifications

PWM switching frequency 8 kHz

Current regulator (PI) Adjusted to the motor

Current loop bandwidth Cut-off frequency for 45° phase shift > 1 kHz

Internal current limitation Imax: 20 % to 100 % and Irated: 20 % to 50 %

Imax duration = 1 second

Speed regulator (PI) Sampling period = 0,5 ms

Adjustable digital gains

Tension regulator (PID) Sampling period = 1 ms

Adjustable digital gains

Speed loop bandwidth Selectable cut-off frequency for 45° phase shift: 50 Hz,
75 Hz or 100 Hz

Max. motor speed Adjustable from 100 rpm to 14 000 rpm

Encoder position output Two channels A and B in quadrature + n marker pulses per
revolution.
RS 422 line driver
Programmable resolution:
max. 8 192 ppr up to 900 rpm
max. 4 096 ppr up to 3 600 rpm
max. 1 024 ppr up to 14 000 rpm
Accuracy: 8 arc minutes + ¼ point
(optional: 2 arc minutes + ¼ point)
Note: The total position accuracy must take into account the
accuracy of the motor resolver

Master encoder input Two channels A and B in quadrature + Z marker pulse

RS 422 line receiver.
Maximum pulses frequency: 250 kHz

Analog outputs (monitor) Speed input command (CV): ±10 V for ± max speed
Speed monitor (GT): ±8 V for ±14 000 rpm, linearity: 10%
Current input command (IDC): ±10 V for ± current rating,
DACout1 resolution = 8 bits
Current monitor (Imes): ±10 V for ± current rating,
DACout2 resolution = 8 bits

Analog inputs (control) ANin1 +/- 10V resolution = 12 bit standard (16 bit optional)
Torque or Speed reference
Dancer or Load cell tension measurement
ANin2 0V to 10V resolution = 12 bit standard (16 bit optional)
Diameter sensor measurement

Dedicated logic inputs Positive logic or negative logic:

- Amplifier enabling: ENABLE
- Sequence selection: SEL1, SEL2 (stand alone operation)
- Sequence start : START (stand alone operation)
- Motor stop: STOP
- Fault reset: RAZ
Optocoupled:
- Tension control disable: TDI

Dedicated logic outputs Open collector: Umax = 24V

Imax = 5 mA
« Tension error »: active if tension OK, inactive if tension
error

10 CHAPTER 2 – Specifications
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Relay outputs Relay contact: Umax = 60 V

Imax = 200 mA, Pmax = 10 W
« Amp ready »: closed if amplifier OK, open if fault
« Power ready »: closed if power OK, open if fault
« Brake control » : closed for disabling the motor brake

General purpose I/Os Programmable input: Lin1 (Optocoupled)

Programmable output: Lout1 (Open collector)

PROFIBUS link PPO-1 or PPO-2 or PPO-3 or PPO-4.

Fault display LEDs on front panel and diagnostic by serial link RS232 +
diagnostic by PROFIBUS.

Motor and application parameter setting Serial link RS232 or Profibus DP link

Automatic functions Amplifier adjustment to the motor (AUTO-PHASING)

Automatic regulator tuning (AUTO-TUNING)

Altitude 1000 m

Moisture < 50% to 40° C and < 90% to 20° C: EN 60204-1 standard

Cooling Natural convection or forced air according to the rated

current

2 - FUSE PROTECTION

2.1 - Fuse protection for the 220 VAC amplifier version

F1 : Control of the average DC current of the power board supply (see Hardware adjustments in chapter 5).
F2 : Control of the average DC current of the logic board supply (see Hardware adjustments in chapter 5).

AMPLIFIER TYPE F1 F2
Power Logic
SMT-BD1/t -220/04 to 12 10 AT 1A
SMT-BD1/t -220/17 and 30 15 AT 1A
SMT-BD1/t -220/45 20 AT 1A
SMT-BD1/t -220/60 20 AT 1A
SMT-BD1/t -220/70 - 1A
SMT-BD1/t -220/100 - 1A

2.2 - Fuse protection for the 400 VAC amplifier version

F2 : Control of the average DC current of the logic board supply (see Hardware adjustments in chapter 5).

AMPLIFIER TYPE F2
Logic
SMT-BD1/t - 400/15 1A
SMT-BD1/t - 400/30 1A
SMT-BD1/t - 400/45 1A
SMT-BD1/t - 400/60 1A
SMT-BD1/t - 400/100 1A

CHAPTER 2 – Specifications 11
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Chapter 3 - Inputs / Outputs

1 - CONNECTORS LOCATION

1.1 - RACK connectors

For the 400 VAC amplifier version, see BF-400 RACK manual.
For the 220 VAC amplifier version, see SMTB.M 20 A SINGLE-AXIS RACK manual or BF RACK manual.

1.2 - Amplifier connectors

on/sys LEDs
error display LEDs
X1 X1 Resolver

X5 X5 Serial link

Diag LED X2 Encoder input / output

X2
Run LED

X6 Profibus X6

X4 X4 Command

X3 Test
Offset push button
2 - LEDs

2.1 - Amplifier fault LEDs

Location: above the resolver connector X1

ON SYS

Amplifier faults (red)

ON (green) : power supply

SYS (red) : system fault

2.2 - Profibus communication LEDs

Location: above the Profibus connector X6

DIAG Diagnostic of the PROFIBUS interface (green)

RUN Communication OK (green)

12 CHAPTER 3 – Inputs/Outputs
 SMT-BD1/t

3 - X1: RESOLVER CONNECTOR

Sub D 9 pins female.

PIN FUNCTION NOTE

1 TC (motor thermal sensor) pin H sensor connector for MAVILOR motor
6 Shield connection If no « 360° » connection on the connector
2 TC (motor thermal sensor) pin I sensor connector for MAVILOR motor
7 S1 (+sin resolver) pin C sensor connector for MAVILOR motor
3 S3 (-sin resolver) pin D sensor connector for MAVILOR motor
8 S4 (+cos resolver) pin B sensor connector for MAVILOR motor
4 S2 (-cos resolver) pin A sensor connector for MAVILOR motor
9 R2 (+ref resolver) pin F sensor connector for MAVILOR motor
5 R1 (-ref resolver) pin E sensor connector for MAVILOR motor

4 - X2: ENCODER CONNECTOR

Sub D 25 pins female.

PIN SIGNAL I/O DESCRIPTION

1 /CZ O Differential output of the encoder marker pulse /Z (5 V, 20 mA max.)
Recommended line receiver: 26LS32
2 CZ O Differential output of the encoder marker pulse Z (5 V, 20 mA max.)
Recommended line receiver: 26LS32
3 /CA O Differential output of the encoder channel /A (5 V, 20 mA max.)
Recommended line receiver: 26LS32
4 CA O Differential output of the encoder channel A (5 V, 20 mA max.)
Recommended line receiver: 26LS32
5 /CB O Differential output of the encoder channel /B (5 V, 20 mA max.)
Recommended line receiver: 26LS32
6 CB O Differential output of the encoder channel B (5 V, 20 mA max.)
Recommended line receiver: 26LS32
7, 10, 11 0V
12 /IA I Input of the master encoder channel /A (5 V, 2 mA)
Recommended line driver: 26LS31
13 IA I Input of the master encoder channel A (5 V, 2 mA)
Recommended line driver: 26LS31
14 /IB I Input of the master encoder channel /B (5 V, 2 mA)
Recommended line driver: 26LS31
15 IB I Input of the master encoder channel B (5 V, 2 mA)
Recommended line driver: 26LS31
21 Lin1 I Programmable input (Optocoupled, 5 V to 24 V)
22 TDI I Tension disabled (Optocoupled, 5 V to 24 V)
8 Lout1 O Programmable output (open collector: 24 V max, 5 mA max)
18 TER O Tension error (open collector: 24 V max, 5 mA max)
23 0V logic I/Os O
24 +5V O Master encoder supply: 5 V +/-5 %, 300 mA, with 5 V jumper closed
25 GND
other pins reserved

CHAPTER 3 – Inputs/Outputs 13
 SMT-BD1/t

5 - X4: CONTROL CONNECTOR

Sub D 25 pins male.

PIN SIGNAL I/O REMARK

1 SEL1 I Positive logic or negative logic (stand alone operation only)
14 SEL2 I Positive logic or negative logic (stand alone operation only)
4 START I Positive logic or negative logic (stand alone operation only)
7 STOP I Positive logic or negative logic
23,24,25 0 V logic input
20 ENABLE I Positive logic or negative logic
23 0 V ENABLE I
13 RAZ I Fault reset via 0 Volt (contact between pins 13 and 12)
12 0 V RAZ I
3 ANin2 I 0 V to 10 V resolution = 12 bits, Diameter sensor measurement
17 ANin1 + I +/- 10V resolution = 12 bits, Torque or Speed reference,
16 ANin1 - I Dancer or Load cell tension measurement
15 0 Volt analog inputs I
10 Speed monitor output O GT: ±8 V for ±14 000 rpm, linearity: 10%
2 Current monitor output O DACout2: ±10 V for ± current rating, resolution = 8 bits
11 0 Volt analog output O
18,19 Amp ready O Relay contact: closed when amplifier OK
Pmax = 10 W with Umax = 60 V or Imax = 200 mA
8, 9 Brake control output O Relay contact
Pmax = 10 W with Umax = 60 V or Imax = 200 mA
21 +15 Volts O Max. 50 mA
22 -15 Volts O Max. 50 mA
5, 6 non connected

6 - X6: PROFIBUS

Sub D 9 pins female.

PIN SIGNAL DESCRIPTION

1 Shield Shield
2
3 RxD/TxD-P Data reception/transmission (Plus)
4 CNTR-P Control signal
5 DGND 0V
6 VP Supply for termination resistor
7
8 RxD/TxD-N Data reception/transmission (Minus)
9

7 - X5: RS-232 CONNECTOR

Sub D 9 pins male.

PIN FUNCTION NOTE

5 0 Volt GND (shield connection if no « 360° » connection on the connector)
3 TXD Transmit data RS-232
2 RXD Receive data RS-232
6 TXH Transmit data RS-422
7 TXL Transmit data RS-422
8 RXL Receive data RS-422
9 RXH Receive data RS-422

14 CHAPTER 3 – Inputs/Outputs
 SMT-BD1/t

8 - X3: TEST CONNECTOR

PIN FUNCTION NOTE

1-6 0 Volt
2 Current input command IDC ± 10 V; resolution: 8 bits, linearity: 10 % (DACout1)*
4 Speed monitor GT ± 8 V for ± 14000 rpm
5 Current monitor Imes ± 10 V; resolution: 8 bits, linearity: 10 % (DACout2)*
3 Reserved

* : 10 V for amplifier current rating.

9 - LOGIC INPUTS-OUTPUTS SPECIFICATIONS

9.1 - Logic inputs: ENABLE, SEL1, SEL2, START, STOP

SMT-BD1/t
Log+ Log-
+5V

47 Kohm

ENABLE 4,7 Kohm

SEL1, SEL2,
START, STOP
4,7 V 47 nF

0V

These inputs can be configurated in positive or negative logic by means of jumpers.

9.2 - Logic inputs: TDI, Lin1

SMT-BD1/t
4,1 Kohm
TDI1 Lin1

TLP281

0 V I/Os
100 Kohm 100 nF

These inputs are opto-isolated from the amplifier 0V reference.

CHAPTER 3 – Inputs/Outputs 15
 SMT-BD1/t

9.3 - Logic outputs: TER, Lout1

SMT-BD1/t

TER, Lout1

TLP281
max. voltage = 24 V
max. current = 5 mA

0 V I/Os

These outputs are opto-isolated from the amplifier 0V reference.

16 CHAPTER 3 – Inputs/Outputs
 SMT-BD1/t

Chapter 4 - Connections

1 - CONNECTION DIAGRAMS

1.1 - Power supply and motor connections

For the 400 VAC amplifier version, see BF-400 RACK manual.
For the 220 VAC amplifier version, see SMTB.M 20 A SINGLE-AXIS RACK manual or BF RACK manual.

1.2 - Amplifier I/O connections

1.2.1 - AMPLIFIER CONNECTION WITH MASTER ENCODER

MASTER ENCODER

SMT-BD1/t

X2 X1 RESOLVER
A 13 1 T° motor

A/ 12 2 T° motor

B 15 7 S1

B/ 14 3 S3

+5 V 24 4 S2

GND 25 8 S4

5 R1

9 R2
24 V
TER 18

23
RACK MOTOR
0V
DANCER / LOAD CELL
U U
X4
V+ 17 V V

GND 16 W W
15
GND GND
DIAMETER SENSOR

V+ 3

GND 15

L1

L2 POWER
+24 V (positive logic) ENABLE 20 SUPPLY
or STOP L3
7
0 V (negative logic) START 4 GND
25
0V
+24 V
8
18
Brake
9
AOK
19

13
Reset 12

0V

CHAPTER 4 – Connections 17
 SMT-BD1/t

1.2.2 - MASTER / SLAVE AMPLIFIER CONNECTION

SMT-BD1/t MASTER SMT-BD1/t SLAVE

X2 X2

CA 4 13 IA

/CA 3 12 /IA

CB 6 15 IB

/CB 5 14 /IB

GND 7 7 GND

An SMT-BD1/t master amplifier can supply up to 10 SMT-BD1/t slave amplifiers.

2 - RS-232 SERIAL LINK CONNECTION

360° shield connection

RxD 2 3 TxD
PC SMT-BD1/t
SERIAL PORT TxD 3 2 RxD
X5
GND 5 5 GND

Sub D 9 pts female Sub D 9 pts female

3 - WIRING RECOMMENDATIONS

3.1 - GND wiring and ground connections

CAUTION
Each potential conducting element must be shielded. Several potential conductors in the same sleeve must
be twisted and shielded.

A shield has no effect if it is not connected:

- to a reference potential,
- by a connection as short as possible (a few centimeters; 10 centimeters is prohibited),
- by a "360°" shield connection. This means that the whole circumference of the shield sleeve must be
connected to the reference conductor via a metal collar.

The connectors used for the compliance with the CEI 801 standard must be metal or metallized connectors and
must allow the 360° shield connections.

Reference potential connections (especially with the ground) are recommended only if these connections have a
very low impedance (< 0,1 Ω). Any shield that is used as a conductor can be connected at both ends with the
condition to be connected over 360° at both ends by means of metal links in order to ensure the shield continuity.

The preferred reference potiential is the ground.

Cables with low potential should never run in the proximity of power lines.

18 CHAPTER 4 – Connections
 SMT-BD1/t

If there is a potential reference, i.e. a main chassis or cabinet with a low impedance between its various elements,
it should be used to connect ALL reference to it and also being grounded itself.

3.2 - CONNECTORS SHIELD CONNECTION

RULE
The shield should never be interrupted or corrupted over the whole cable length.

Self-sticking copper ribbon if necessary,

for increasing the shield diameter in order
to get it correctly tightened
under the clamp

W
V
U

Ground

Motor connector for BF RACK

resolver and motor
N

The cable can be soldered on the shield

L2 U V W

because the connector box is metallic.

This solution does not exactly meet
the EMC requirements but
it is acceptable.
L1

Motor connector box

Metallic or metal plated plastic

SUB-D pin package As short as possible

Ground
U
V
360° shield ensured by W
the tightening clamp
X
SMT.AS / M.AS

UV W

The fastening screws must GND

be tightened in order to ensure
SMT-BM 20 A
the shield continuity on the
INFRANOR amplifier housing
amplifier

SUB-D connectors

NOTE
When the 360° shield connection is made by means of a collar, it is not necessary to connect a cable on the
appropriate pin of the SUB-D connector.

CHAPTER 4 – Connections 19
 SMT-BD1/t

3.3 - MOTOR AND RESOLVER CABLES

Motors and resolvers are grounded via their housing.

Cable inputs should be made by means of metal connectors with collars allowing the 360° shield connection.

The resolver cable must be pair twisted and shielded (sin, cos, ref.). Motor cables MUST also be shielded.

3.4 - SERIAL LINK CABLES

The serial link cable must also be shielded according to the above mentioned shield connection
recommendations.

CAUTION
Command cables (resolver, serial link, Profibus) as well as the power lines must be connected and
disconnected with amplifier OFF.

20 CHAPTER 4 – Connections
 SMT-BD1/t

Chapter 5 - Adjustable functions

1 - HARDWARE ADJUSTMENTS

All hardware adjustments of the SMT-BD1/t amplifier module are presented on the following diagrams.

Current loops
(power board) X3 X4 X2 X5 X1

SW2 B
U59
ON C P-RES
1234 Serial link RS422
B3 B2 B1

Amplifier operating mode (SW2-4) Resolver transformation ratio

Enable encoder output (SW2-3)

Firmware memory

U2

Parameters & program Drive address selection

memory (serial link)
SW ON
U18 Power fuse
01640 logic board (power board)
1234

Motor CTN Logic +

Motor thermal Logic - F1
sensor adjustment Motor CTP
M L F
N K
PSTH O J G
P E

ABCD "Undervolt." fault

inhibition

Logic fuse F2
(power board)

NOTE: PSTH = Threshold adjustment for thermal probe on logic board 01640 only

FOR AMPLIFIER RATINGS 4 A TO 100 A

For amplifier versions with 70 A and 100 A current ratings in 220 V and serial numbers
! lower than 260600, please contact INFRANOR.

When using resolvers with other transformation ratios than 0,5, the Cos and Sin signal amplitude must be
adjusted by means of the "P-RES" components according to the table below:

Resolver transformation ratio adjustment P-RES

Transformation ratio value 0,3 0,45 0,5 1
A - B - C - D tolerance < 1 % 21 K 14,3 K 12,7 K 6,34 K

In standard, the serial link is the RS-232 link, with jumper B closed. In option, the amplifier can be delivered with
an RS-422 serial link, with jumper C closed.

CHAPTER 5 – Adjustable functions 21

 SMT-BD1/t

Braking resistor

Braking resistor jumper

for 220/04w to 220/17w

Selection jumper
for 220/30w to 220/60w

BRAKING SYSTEM SELECTION FOR SMT-BD1/t-220/04w to 220/60w

SMT-BM20 A / BMM05F/05AF single-axis racks: Braking resistor jumper closed.

BF rack: Braking resistor jumper open.

NOTE
The braking resistor selection is only available on "w" referenced amplifiers

22 CHAPTER 5 – Adjustable functions

 SMT-BD1/t

2 - ADJUSTABLE PARAMETERS

The SMT-BD1/t parameters can be modified either via the Profibus link or via the serial link and the BPCW
software. The serial link connector (X5) must be connected to the serial interface of a PC for the parameter
setting operation. The BPCW software, which is IBM-PC compatible with the WINDOWS® operating system,
allows the clear display and easy modification of all amplifier parameters. The SMT-BD1/t parameters setting
requires the BPCW software version 2.7 or higher.

CHAPTER 5 – Adjustable functions 23

 SMT-BD1/t

Chapter 6 - Commissioning
The successive steps of the first amplifier commissioning are described below:

- Current regulator adjustment.

2
Motor adjustment - Current limitations and I t protection adjustment.
sections 1, 2 and 3 of this chapter - Motor parameters adjustment.
- Speed limitation adjustment.

- Adjustment of the speed regulator gains.

Speed control loop adjustment - Brake control.
section 4 of this chapter - Jog control.

- Rotation direction & encoder output.

Amplifier configuration - Diameter sensor & dancer or load cell.
sections 5, 6 and 7 of this chapter - Profibus address.

Profibus communication - Start communication between PLC and amplifier.

section 8 of this chapter

Amplifier programming - Sequences programming.

Chapter 7

Amplifier operation - Sequences execution via Profibus or in standalone.

Chapter 8

The amplifier parameters are accessible via:

- the serial link and the BPCW software,

- or by the PKW of the PROFIBUS DP.

CAUTION

Do not make the drive parameter setting by means of both BPCW software and Profibus at the same time.

24 CHAPTER 6 – Commissioning
 SMT-BD1/t

INSTALLATION OF THE PC SOFTWARE

At first, connect the serial RS232 link between PC and amplifier.

The BPCW software is operating with Windows® 3.11/95/98/2000.
The SMT-BD1/t parameters setting requires the BPCW software version 2.7 or higher.
To install the software, insert the disk in driver A and start the installation programme by entering A:INSTALL
Enter the communication port (COM1 or COM2), select the language and start the installation.

1 - AMPLIFIER HARDWARE CONFIGURATION

1.1 - Standard configuration

The amplifier standard configuration is the following:

SMT-BD1/t unwinder/rewinder:
• Resolver adjustment card P RES: 4 x 12,7 KΩ 1%.
• Motor thermal probe PTC: Jumper MN.
• Current loops adjustment: medium gains in position B2.
• Positive control logic: Jumpers E. F. G closed.
• No auxiliary supply: Jumper JK closed and jumper KL open.
• SW "OFF" on all switches: selection of the address 0 for the serial link.
• SW2 "OFF" on all switches: Profibus operating mode and encoder output disabled.

1.2 - Motor thermal sensor configuration

Select the right MN or OP jumper setting according to the motor thermal sensor type (PTC or NTC).

1.2.1 - PTC THERMAL SENSOR

On motors equipped with a PTC thermal sensor (triggering on high impedance), the amplifier configuration is the
following: MN jumper closed and OP jumper open. The triggering threshold adjustment for the PTC thermal
sensor is made by means of the PSTH components, as described below : PSTH-D = 14,3 kΩ; PSTH-B = 28 kΩ;
PSTH-A = 3 x RPTC (120°C) in kΩ. RPTC (120°C) = ohmic value of the PTC thermal sensor resistor at 120°C;
the default adjustment is RPTC (120°C) # 3 kΩ with PSTH-A = 10 kΩ.

1.2.2 - NTC THERMAL SENSOR

On motors equipped with a NTC thermal sensor (triggering on low impedance), the amplifier configuration is the
following: OP jumper closed and MN jumper open. The triggering threshold adjustment for the NTC thermal
sensor is made by means of the PSTH components, as described below: PSTH-D = 14,3 kΩ; PSTH-B = 28 kΩ;
PSTH-A = 3 x RNTC (120°C) in kΩ. RNTC (120°C) = ohmic value of the NTC thermal sensor resistor at 120°C;
the default adjustment is RNTC (120°C) # 3 kΩ with PSTH-A = 10 kΩ.

CHAPTER 6 – Commissioning 25
 SMT-BD1/t

1.3 - Current loops adjustments

1.3.1 - CURRENT LOOPS ADJUSTMENTS FOR THE 400 VAC AMPLIFIER VERSION

Select the right current loops jumpers setting (B1, B2 or B3 position) according to motor and amplifier
specifications.

For the 400 VAC version of the BL MAVILOR motor series, the current loops adjustments are made according to
following selection table.

AMPLIFIER 15 A 30 A 45 A 60 A 100 A
MOTOR
BL 113 B2
BL 114 B2
BL 115 B2 B1
BL 141 B1 B1
BL 142 B2 B1
BL 143 B1 B1 B1
BL 144 B1 B1 B1
BL 191 B3 B3 B2
BL 192 B3 B3 B2

For other motors, the adjustment of the current loops according to the amplifier current rating and to the
inductance between the motor terminals is made as follows:

15 A and 30 A amplifier current ratings

Calculation of G = 0.8 x Amplifier current rating (A) x Inductance between phases (mH),
If G < 60, current loop jumpers (x3) on B3 position,
If 60 < G < 100, current loop jumpers (x3) on B2 position,
If G > 100, current loop jumpers (x3) on B1 position.

45 A, 60 A and 100 A amplifier current ratings

Calculation of G = 0.8 x Amplifier current rating (A) x Inductance between phases (mH),
If G < 100, current loop jumpers (x3) on B3 position,
If 100 < G < 250, current loop jumpers (x3) on B2 position,
If G > 250, current loop jumpers (x3) on B1 position.

26 CHAPTER 6 – Commissioning
 SMT-BD1/t

1.3.2 - CURRENT LOOPS ADJUSTMENTS FOR THE 220 VAC AMPLIFIER VERSION

Select the right current loops jumpers setting (B1, B2 or B3 position) according to motor and amplifier
specifications.

For the BL and MA MAVILOR motor series, the current loops adjustments are made according to following
selection table.

AMPLIFIER 4A 8A 12 A 17 A 30 A 45 A 60 A 70 A 100 A
MOTOR
MA 3 B1
MA 6 B1 B1
MA 10 B2 B1 B1 B1
MA 20 B2 B1 B1 B1 B1 B1
MA 30 B2 B2 B2 B1 B1
MA 45 B2 B2 B1 B1 B1
MA 55 B2 B2 B2 B1
BL 55-3 B1
BL 55-5 B1
BL 71 B2
BL 72 B2 B1 B1
BL 73 B2 B1 B1
BL 74 B2 B1 B1
BL 111 B1 B1
BL 112 B2 B2 B1 B2
BL 113 B3 B3 B2 B2 B2
BL 114 B3 B3 B2 B2
BL 115 B3 B3 B2 B2 B2
BL 141 B2 B2 B2 B1 B1
BL 142 B3 B3 B2 B2 B1
BL 143 B3 B2 B2 B1 B1 B1
BL 144 B2 B2 B2 B1 B1 B1

For other motors, the adjustment of the current loops according to the amplifier current rating and to the
inductance between the motor terminals is made as follows:

4 A, 8 A, 12 A and 17 A amplifier current ratings

Calculation of G = 1,4 x Amplifier current rating (A) x Inductance between phases (mH),
If G < 60, current loop jumpers (x3) on B3 position,
If 60 < G < 100, current loop jumpers (x3) on B2 position,
If G > 100, current loop jumpers (x3) on B1 position.

30 A, 45 A, 60 A, 70 A and 100 A amplifier current ratings

Calculation of G = 1,4 x Amplifier current rating (A) x Inductance between phases (mH),
If G < 100, current loop jumpers (x3) on B3 position,
If 100 < G < 250, current loop jumpers (x3) on B2 position,
If G > 250, current loop jumpers (x3) on B1 position.

2 - PUTTING INTO OPERATION

The auxiliary supply voltage must be applied to the amplifier before the power supply voltage.

Test the auxiliary supply voltage :

Rated value = 230 Vrms single-phase.
Maximum value (must never be exceeded) = 260 Vrms, all mains variation tolerances included.

Switch on the auxillary supply. The green ON Led must be lit and the UNDERVOLT error must be displayed.

Test the power supply voltage :

- For the 220 VAC amplifier version: Rated value = 230 Vrms between phases.
Maximum value (must never be exceeded) = 260 Vrms, all mains variation tolerances included.
- For the 400 VAC amplifier version: Rated value = 400 Vrms between phases.
Maximum value (must never be exceeded) = 480 Vrms, all mains variation tolerances included.

CHAPTER 6 – Commissioning 27
 SMT-BD1/t

Switch on the power supply. The UNDERVOLT error Leds must be unlit. The braking resistor must remain cool.

CAUTION

The braking resistor is under high voltage.

When turning off the amplifier, wait for at least 5 seconds before turning power on again.

Check that the amplifiers front panel screws are correctly fastened on the rack.

If the parameter setting operation is made by the BPCW software, please select the Software control mode in
order to enable and disable the amplifier by the software commands Stop and Manual during the commissioning
operations.

3 - MOTOR ADJUSTMENT

3.1 - Motor parameter setting

Select the motor used in the motor list of the BPCW software or send the motor parameter values via Profibus.

Select the amplifier current limitation in Fusing mode for the commissioning phases. In Fusing mode, the
amplifier is disabled when the current limitation threshold is reached. In Limiting mode, the current is only limited
at the value defined by the Rated current parameter when the limitation threshold is reached.

The parameter Max. current defines the maximum current value supplied by the amplifier. It can vary between
20% and 100% of the amplifier current rating. This parameter is defined according to the amplifier and motor
specifications.
2
The Rated current parameter defines the limitation threshold of the RMS current (I t) supplied by the amplifier. It
can vary between 20 % and 50 % of the amplifier current rating. This threshold is set according to the amplifier
and motor specifications.

Check that the values of the Maximum current and Rated current parameters are complying with motor and
amplifier. Otherwise, modify them according to the appropriate motor and amplifier specifications.

The Max. speed parameter defines the maximum motor rotation speed. The speed range is between 100 and
14000 rpm and the resolution is 5 rpm. Check that its value is complying with motor and application. Otherwise,
modify it according to the motor and application specifications.

3.2 - Adjustment to a new motor

When the motor used cannot be selected in the motor list or if the motor parameter values are unknown, proceed
as follows:

Uncouple the motor from the mechanical load and check that the motor shaft is free and that its free rotation
over 1 revolution is not dangerous for the operator. Execute the auto-phasing procedure (the amplifier must be
disabled and the ENABLE signal must be activated) in order to define the parameters Number of pole pairs,
Motor phase and Resolver adjustment. Please note that during the auto-phasing procedure the motor is
automatically enabled and then disabled when the procedure is over.

The auto-phasing procedure calculates the following parameters:

-The parameter Number of pole pairs defines the number of motor pole pairs.
-The parameter Phases order defines the motor phases order.
-The parameter Resolver offset defines the mechanical shift between both motor and resolver references.

Calculate the parameter Phase lead from the specific motor parameters (the effects of this parameter are
particularly useful on low inductance motors running at high speeds).

28 CHAPTER 6 – Commissioning
 SMT-BD1/t

4 - SPEED CONTROL LOOP ADJUSTMENT

4.1 - Regulator parameters adjustment

Check at first that the Speed regulator gain ratio parameter value is set at 1 (servo loop gains adaptation
mechanism disabled).

The Auto-tuning procedure identifies the motor and load specifications and calculates the regulator gain
parameters. During the procedure, the operator can select a bandwidth (Low = 50 Hz, Medium = 75 Hz and High
= 100 Hz). The auto-tuning can be executed with disabled or enabled motor, but the ENABLE signal must always
be activated. The auto-tuning must be executed with the motor shaft coupled to the mechanical load: the
unwind/rewind spindle and an empty spool corresponding to the minimum diameter value.

Check for free motor shaft rotation over one revolution that is not dangerous for operator and machine before
starting the Auto-tuning with the Standard filter.

After the auto-tuning procedure, check that the motor correctly runs in both directions in speed mode with a digital
set point or in jog mode. Check the response for a small speed reference without IDC saturation.

In case of loud noise in the motor at standstill and when running, check the rigidity of the transmission between
motor and load (backlashes and elasticities in gears and couplings). If necessary, renew the auto-tuning
procedure by selecting a lower bandwidth. If the problem remains, renew the auto-tuning procedure with the
Antiresonance filter selection.

If the motor instability is due to the coupling backlashes between the motor and the load, activate the Reduced
stiffness at standstill command and test its effect when the motor is at standstill and then when the motor is
running at a constant speed higher than 100 rpm.

4.2 - Enabling

The enabling can be made:

- by Profibus (see operation diagram for the enabling procedure) or
- by the BPCW software, in Software control mode.

4.3 - Brake control

The SMT-BD1/t amplifier is equipped with a brake control signal. This brake control signal is low powered and
cannot directly control the brake. The BMM 05 AF single-axis rack is therefore equipped with a power relay that
allows the brake control but the other racks are not equipped with this relay.

The brake control is activated (relay open) or disabled (relay closed) according to the amplifier status (disabled or
enabled). The following parameters allow to adjust the brake control operation:

Brake delay active: defines the time between the brake enabling and the amplifier disabling.
- brake activation (relay open),
- delay time (= 0 in standalone mode),
- amplifier disabling.

Brake delay inactive: defines the time between the amplifier enabling and the brake disabling:
- amplifier enabling,
- delay time (= 0 in standalone mode),
- brake disabling (relay closed).
4.4 - Jog control

The motor is continuously running while the jog input is activated (Jog+ for a movement in the positive direction
and Jog- for a movement in the negative direction). The jog inputs can only be activated with the Profibus control
word. The following parameters allow to adjust the jog control operation:

Jog speed: defines the motor speed set point value in jog mode.
Jog accel time: defines the ramping time value for the motor acceleration from 0 to the maximum speed.
Jog decel time: defines the ramping time value for the motor deceleration from the maximum speed value to 0.

For the amplifier commissioning by means of the BPCW software, jog control can be provided in the control panel
by setting the digital speed reference value.

CHAPTER 6 – Commissioning 29
 SMT-BD1/t

5 - UNWINDER/REWINDER CONFIGURATION

5.1 - Rotation direction

The Reverse movement parameter allows to modify the motor rotation direction with regard to the speed
reference polarity. For the encoder position output, the counting direction remains unchanged with regard to the
motor rotation direction.

5.2 - Gearing ratio adjustment

The parameter Encoder resolution defines the encoder resolution on channels A and B (X2 connector) of the
encoder position output for one motor shaft revolution. Binary and decimal values are both accepted. The
maximum encoder resolution per revolution is limited by the motor rotation speed as shown in the table below.

Max. possible speed (rpm) 900 3600 14000

Max. encoder resolution 8192 4096 1024

The Encoder resolution parameter value also defines the master/slave gearing ratio value corresponding to the
empty spool (minimum diameter and maximum line speed) according to the following formula:
Encoder resolution (ppr) / Master encoder resolution (ppr) = Master encoder speed (rpm) / Motor speed (rpm)

Enter the parameter Maximum speed according to the following formula:

Maximum speed (rpm) = 1.2 x Motor speed (rpm) at the maximum line speed value and the minimum diameter

Enter then the parameter Encoder resolution according to the following formula:
Encoder resolution (ppr) = Master encoder resolution (ppr) x Master encoder speed (rpm) at the maximum line
speed value / Motor speed (rpm) at the maximum line speed value and the minimum diameter.

5.3 - Diameter sensor calibration

If the Gearing ratio adaptation by diameter sensor or Set point ratio modulation by diameter sensor
operation are required, proceed as follows for the diameter sensor calibration :

Put an empty spool corresponding to the minimum diameter value on the unwind/rewind spindle and read the
voltage value given by the diameter sensor by using the command Diameter sensor value. This value is then
entered in the parameter Diameter sensor value for min. diameter.

Put a full spool corresponding to the maximum diameter value on the unwind/rewind spindle and read the voltage
value given by the diameter sensor by using the command Diameter sensor value. This value is then entered in
the parameter Diameter sensor value for max. diameter.

Enter the ratio value between the minimum spool diameter and the maximum spool diameter in the parameter
Spool diameter ratio (Min/Max).
Enable the motor and check its stability with full spool. In case of loud noises in the motor, remove the full spool
and re-engage the empty one. Then, renew the auto-tuning procedure with the empty spool by selecting a lower
bandwidth. If the problem remains, renew the auto-tuning procedure with the empty spool by activating the
antiresonance filter. The audible noise in the motor must be cancelled under both empty spool and full spool
conditions.

If a better servo loop stiffness is required under full spool condition, proceed as follows for the calibration of the
gain / diameter adaptation :

Enter the value of the parameter Diameter sensor value for max. diameter in the parameter Diameter sensor
value for max. gain.

Increase progressively the parameter Speed regulator gain ratio (Max/Min) up to the maximum possible value
without noises in the motor. Do not exceed the limit value calculated by the ratio between both full and empty
spool inertia reflected on the motor shaft (Jmax motor / Jmin motor).

Adjust the value of the parameter Diamenter sensor value for max. gain in order to accurately define the gain
adjustment range according to the spool diameter. This parameter must be reduced when the value of the
parameter Speed regulator gain ratio adjusted before remains quite below the ratio between both full and empty
spool inertia reflected on the motor shaft (Jmax motor / Jmin motor). This parameter can be calculated as follows:
Diameter sensor value for max. gain = Diameter sensor value for min. diameter + ( Diameter sensor
value for max. diameter - Diameter sensor value for min. diameter) x [(Speed regulator gain ratio - 1) x
0,25
(Jmin motor / Jmax motor)]

30 CHAPTER 6 – Commissioning
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5.4 - Encoder ratio calibration

If Gearing ratio adaptation by line encoder or Set point ratio modulation by line encoder operation is
required, enter the ratio value between both minimum and maximum spool diameters in the parameter Spool
diameter ratio (Min/Max).

5.5 - Tension measurement calibration

If a tension control sequence type must be executed, proceed as follows for the tension measurement sensor
(dancer or load cell) calibration :

Set the analog input 1 (ANin1) on the X4 connector at 0 volt and execute the offset compensation procedure with
the amplifier disabled.

Put the dancer or the load cell in the « low » position corresponding to the minimum material tension value. Read
the voltage value given by the dancer or the load cell by using the Tension measurement value command. This
value can be entered in the parameter Undertension limit.

Put the dancer or the load cell in the « high » position corresponding to the rated material tension value. Read the
voltage value given by the dancer or the load cell by using the Tension measurement value command. This
value can be entered in the Tension set point parameter value for the tension sequence programming.

If a ratio init sequence must be executed (unwind/rewind operation without diameter sensor), proceed as follows
for the ratio init procedure calibration :

Engage the material in the unwinder/rewinder via the master encoder roller, up to the traction system.

Stretch the material up to the « low » position of the dancer corresponding to the minimum material tension value.

Reset the master encoder position value.

Stretch the material up to the « high » position of the dancer corresponding to the rated material tension value.

Read the master encoder position value. This value can then be entered in the master encoder reference
displacement parameter value for the ratio init sequence programming. Read the corresponding voltage value
given by the dancer by using the Tension measurement value command. This value can be entered in the
Tension set point parameter value for the ratio init sequence programming.

CHAPTER 6 – Commissioning 31
 SMT-BD1/t

5.6 - PID loop adjustment for tension control

CAUTION

It is advisable to limit the motor torque by limiting the amplifier Max. current and Rated current during the
PID adjustment phase in order to avoid a material braking if the tension loop becomes instable.

The PID loop parameters are at first initialised according to the following values :

Error scaling gain is set at 10 %.

Proportional gain is set at 1.

Integral gain and Derivative gain are both set at 0.

Speed variation limit parameter is set at a low value (100 rpm).

The tension control parameters are at first initialised according to the following values :

Tension error tolerance is set at 10 %.

Overspeed limit is set at the Maximum motor speed value.

Tension sequence error link is not defined in order to get the motor stopped in case of tension sequence error.

If possible, the Undertension limit parameter value is set out off the voltage range given by the dancer or the
load cell (according to the previous tension measurement sensor calibration). This avoids the tension sequence
error to be released during the PID adjustment.

A tension control sequence is programmed according to following conditions:

Tension set point is set according to the previous tension measurement sensor calibration.

Holding time parameter value is set at more than 16000 ms in order to have the sequence active until the STOP
input activation.

Engage the material in the unwinder/rewinder and lock it by means of the downstream traction system.

The TDI input must be disabled in order to enable the PID loop for the tension regulation.

Start the tension control sequence execution.

If the tension loop is instable (continuous material unwinding or saturated motor torque), reverse the sign of the
error scaling gain parameter.

If the tension loop is oscillating, reduce the value of the Proportional gain until the loop remains stable. When
the system is stable, increase the Proportional gain parameter up to the value where it starts oscillating; then
reduce the parameter Proportional gain in order to ensure the tension stability.

Increase progressively the parameters Derivative gain and Integral gain in order to optimise the tension loop
response in case of a disturbance by manual jerking of the spool or of the material.

In case of loud noise in the motor due to the tension measurement signal, reduce the Tension input filter cut-off
frequency value.

Adjust the parameter Speed variation limit according to the speed offset command value that is necessary for
regulating the material tension over the whole speed range (generally 5 to 10 % of the maximum motor speed
value).

32 CHAPTER 6 – Commissioning
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5.7 - Parameters setting for tension control

Enter the value of the parameter Overspeed limit according to following calculation:
Overspeed limit (rpm) = Speed variation limit (rpm) + Motor speed (rpm) at rated line speed value and
minimum diameter.
In this case, when the material is running at rated line speed, a tension sequence error will be generated if the
material tension error becomes too high (dancer or load cell fault), bringing the PID loop to saturation.

The Undertension limit parameter value is set according to the previous tension measurement sensor calibration
in order to have a tension sequence error in case of material braking :
Undertension limit ≥ to the dancer or the load cell voltage value in « low » position
Undertension limit < to the dancer or the load cell voltage value corresponding to the tension set point

The Tension error tolerance must be set at the appropriate level regarding the tension measurement variation
when the material is running at the maximum line speed value. In this case, when the tension error value exceeds
the tolerance level, the TER output desactivation allows to detect any unwinder/rewinder problem.
This parameter value must be carefully adjusted when the Gearing ratio adaptation by line encoder operation
is selected. In this case, when the tension error value exceeds the tolerance level, the gearing ratio gain
adaptation is stopped in order to avoid any wrong gearing ratio value calculation. So, if the tolerance level is too
low, the gearing ratio adaptation cannot be performed anymore and can cause the unwinder/rewinder material
braking.

The Tension sequence error link parameter can define the number of the sequence to be executed when a
tension sequence error is generated. This allows to program the unwinder/rewinder behaviour in case of material
braking according to the application. If the Tension sequence error link parameter is not defined, when a
tension sequence error is generated, the motor is braking according to the STOP deceleration ramp.

6 - PROFIBUS ADDRESS

Each amplifier of the network is identified by one single address (1 to 125). The SMT-BD1/t unwinder/rewinder
amplifier is delivered with the default address 126 which is not an operational address. This address must be
modified before putting the bus into operation.

The SMT-BD1/t address can be modified:

- by the serial RS-232 link (BPCW software). The new address must be saved in the EEPROM and the
amplifier must be switched on in order to get the new address operational;

- or by a Profibus class 2 master device. The address modification is only possible when the bus is not
running. In this case, the address will be automatically saved in the amplifier EEPROM and will be
operational at the bus start.

The identity number of the SMT-BD1/t unwinder/rewinder under Profibus is 0x05B3.

7 - PARAMETERS SAVING

When all adjustments are made, the parameters must be saved in the EEPROM ( with disabled amplifier).

8 - PROFIBUS OR STAND ALONE MODE SELECTION

Switch off the amplifier after the parameters saving and select the desired operation mode (Profibus control or
stand alone operation) by using the SW2-4 configuration switch:

SW2-4 = ON for selecting the stand alone operation mode

SW2-4 = OFF for selecting the Profibus operation mode

In the Profibus operation mode, servo amplifier control and parameter setting can both be made via the
PROFIBUS DP connection. The servo amplifier control via PROFIBUS DP connection simply consists in
selecting one of the amplifier pre-programmed control sequences and start its execution.

In the stand alone operating mode, a pre-programmed control sequence is selected via the SEL1 and SEL2 logic
inputs and its execution is started by using the START logic input. However, in this case only the sequences
numbered 0 to 3 can be selected by the SEL1 and SEL2 logic inputs activation.

CHAPTER 6 – Commissioning 33
 SMT-BD1/t

Chapter 7 - Programming

1 - GENERAL DESCRIPTION

The SMT-BD1/t amplifiers can have up to 64 pre-programmed sequences. Each sequence can be either :
• a gearing ratio initialisation sequence or
• a tension control sequence or
• a speed control sequence or
• a torque control sequence.

The control sequences can be automatically linked up: as soon as a sequence is over, another one can be
executed. This allows to easily solve complex unwind/rewind and tension control applications by chaining several
basic control sequences.
The SMT-BD1/t amplifiers have got 8 programmable logic outputs (triggering at the sequences execution) and 8
programmable logic inputs allowing to control a sequence start or stopping. The logic input 1 is entering the X2
connector on pin 21 (Lin1) while the logic inputs 2 to 8 are virtual. The virtual logic inputs can only be activated or
desactivated on the serial bus interface for the sequence control and have no physical existence. Logic output 1 is
located on the X2 connector on pin 8 (Lout1) while the logic outputs 2 to 8 are virtual. The virtual logic outputs are
only visible on the serial bus interface for the sequence control and has no physical existence.
The programming consists in initializing the sequence parameters with the desired values.

2 - CONTROL SEQUENCE PARAMETERS

Type Defines the control sequence type.

RATIO INIT : gearing ratio initialisation.
TENSION : tension control.
SPEED 1 : single loop speed control.
SPEED 2 : dual loop speed control.
TORQUE : torque control.

Tension Defines the dancer or load cell tension measurement value in Volt (range: -10 V to +10
V) corresponding to the material tension set point value. If the sequence type is a
gearing ratio initialisation, Tension then indicates the dancer position to be reached
during the spool rewind movement for the gearing ratio estimation procedure.

Stretching Defines the material stretching ramp in ms when the tension set point is changing (range
0 to 16000).

Holding Defines the time duration in ms for the material to be maintained at the tension set point
(range 0 to 16000). If this parameter value exceeds 16000, the material is maintained at
the tension set point until the sequence stop condition.

Speed Defines the motor speed in rpm.

Acceleration Defines the motor acceleration time from 0 to the motor max. speed in ms (range 0 to
16000).

Running Defines the motor running time in ms (range 0 to 16000). If this parameter value exceeds
16000, the motor is continuously running until the sequence stop condition.

Deceleration Defines the motor deceleration time from the motor max. speed to 0 in ms (range 0 to
16000). This parameter can be equal to 0 if a sequences linkage can be made without
stopping the motor.

Gearing ratio The master/slave gearing ratio value is calculated according to the master encoder
resolution and the motor encoder resolution as described below :
Motor speed (rpm) / Master encoder speed (rpm) = (Gearing ratio gain(%) / 100) x
Master encoder resolution (ppr) / Motor encoder resolution (ppr)

Torque Defines the motor current set point value in % of the amplifier maximum current.
The corresponding motor torque value is calculated according to the motor
torque/current ratio value.

34 CHAPTER 7 – Programming
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Time Out Defines the time in seconds after which the amplifier releases a procedure error if it
cannot correctly estimate the gearing ratio value during the gearing ratio initialisation
sequence.

Next sequence Defines the sequence to be executed after the current one.

Counter Defines how many times the sequence must be executed. This counter is decremented
each time a sequence is over.

Jump Defines the number of the sequence to be executed while the counter is not at 0.

Logic outputs Defines the possible effect on the outputs.

Triggering Defines the outputs triggering moment.

3 - SEQUENCE SET POINT SELECTION

For each type of control sequence (Tension, Speed 1, Speed 2, Torque), various set point sources can be
selected according to the final application.

The sequence Internal set point is stored into the program memory and remains constant during the complete
sequence execution.

When Analog set point is selected in the sequence, the set point value can be continuously modified during the
sequence execution. In this case, the set point source can be either the amplifier analog input 1 (ANin 1) voltage
value or the PROFIBUS process data words according to the Amplifier configuration parameter.

When Master encoder gearing is selected for a tension control or speed 1 sequence type, the sequence speed
set point value is given by the frequency of the amplifier encoder input pulses.

4 - VARIABLE DIAMETER OPERATION

4.1 - Speed gearing ratio adaptation

The amplifier gearing ratio gain is valid during the Tension, Speed 1 and Torque sequences execution and also in
"Jog" mode. The Speed 2 control sequence is the only sequence which is not concerned by the amplifier gearing
ratio. At the amplifier power up, the gearing ratio gain value is set at 1. The gearing ratio gain value is neither
modified during a Speed 2 control sequence execution nor in Jog mode. During a Tension, Speed 1, Torque or
Ratio init sequence execution, the gearing ratio gain value can be calculated by different ways according to the
unwind/rewind application. The sequence parameter setting allows to select the most appropriate calculation
method as described below :

When Constant gearing ratio gain or Constant set point ratio is selected , the sequence Gearing
ratio gain or Torque set point ratio parameter value is giving the amplifier gearing ratio gain value to
be applied during the complete sequence execution. If the sequence Gearing ratio gain or Torque set
point ratio parameter value is set at 0, the sequence is started with the current amplifier gearing ratio
gain value (final value of the former sequence) and this value is maintained during the complete
sequence execution.

When Gearing ratio adaptation by diameter sensor or Set point ratio modulation by diameter
sensor is selected , the amplifier gearing ratio gain value is continuously calculated according to the
spool diameter value during the sequence execution. In this case, the effective diameter value source
can be either the current analog input 2 (ANin 2) voltage value or the current diameter value received via
the PROFIBUS process data words depending on the Amplifier configuration parameter.

When Gearing ratio adaptation by line encoder or Set point ratio modulation by line encoder is
selected , the amplifier gearing ratio gain value is calculated according to the encoder/motor speed ratio
during the sequence execution. In this case, the sequence Gearing ratio gain or Torque set point
ratio parameter value is giving the amplifier gearing ratio gain to be applied at the sequence start. If the
sequence Gearing ratio gain or Torque set point ratio parameter value is set at 0, the sequence is
started with the current amplifier gearing ratio gain value (final value of the former sequence). The
amplifier gearing ratio gain calculation by the encoder/motor speed ratio is only valid when the material is
stretched and the tension set point is stable.

CHAPTER 7 – Programming 35
 SMT-BD1/t

During a tension control sequence execution, the gearing ratio gain calculation is only performed when
the tension set point error is lower than the tension error tolerance parameter value (TER output
activated). During a torque control sequence execution, the gearing ratio gain calculation is only
performed when the torque set point value is reached (TER output also activated).

The ratio init sequence allows to calculate the gearing ratio gain value for a tension control application based on a
dancer feedback. This sequence must be executed before entering a variable diameter tension control sequence
when Gearing ratio adaptation by line encoder operation is selected, in order to correctly initialise the gearing
ratio gain calculation procedure before starting the material running.

4.2 - Torque set point ratio adaptation

The amplifier torque set point ratio is only valid during the Torque sequence execution. The other control
sequences and the "Jog" mode are not concerned by the torque set point ratio value. At the amplifier power up,
the torque set point ratio value is set at 1. During a Tension, Speed 1 or Ratio init sequence execution, the torque
set point ratio value is continuously updated according to the speed gearing ratio gain value on the following way :
Torque set point ratio = Spool diameter ratio / Speed gearing ratio gain. During a Torque sequence execution, the
torque set point ratio value can be calculated on various ways according to the unwind/rewind application. The
Torque sequence parameter setting allows to select the most appropriate calculation method as described below :

When Constant set point ratio is selected , the sequence Torque set point ratio parameter value is
giving the amplifier torque set point ratio value to be applied during the complete sequence execution. If
the sequence Torque set point ratio parameter value is set at 0, the sequence is started with the
current amplifier torque set point ratio value (final value of the former sequence) and this value is
maintained during the complete sequence execution.

When Set point ratio modulation by diameter sensor is selected , the amplifier torque set point ratio
value is continuously calculated according to the spool diameter value during the sequence execution. In
this case, the effective diameter value source can be either the current analog input 2 (ANin 2) voltage
value or the current diameter value received via the PROFIBUS process data words depending on the
Amplifier configuration parameter.

When Set point ratio modulation by line encoder is selected , the amplifier torque set point ratio value
is calculated according to the encoder/motor speed ratio during the sequence execution. In this case, the
sequence Torque set point ratio parameter value is giving the amplifier torque set point ratio value to
be applied at the sequence start. If the sequence Torque set point ratio parameter value is set at 0, the
sequence is started with the current amplifier torque set point ratio value (final value of the former
sequence). The amplifier torque set point ratio calculation by the encoder/motor speed ratio is only valid
when the material is stretched. During the torque control sequence execution, the torque set point ratio
calculation is only performed when the torque set point value is reached (TER output activated).

During the Torque sequence execution, the speed gearing ratio gain value is continuously updated according to
the torque set point ratio value in the following way :

Speed gearing ratio gain = Spool diameter ratio / Torque set point ratio.

4.3 - Servo loop gains adaptation

The speed servo loop gains adaptation mechanism is always active when the amplifier is enabled. The
proportional and integral speed regulator gains are both continuously multiplied by the gain ratio value. The gain
ratio value is calculated according to the diameter sensor measurement value in order to adapt the speed servo
loop gain values with regard to the spool inertia value. This allows to maintain the best speed servo loop stability
when the spool diameter is changing. The Diameter sensor calibration menu allows to adjust the gains
adaptation parameters according to the spool characteristics. When the Speed regulator gain ratio parameter
is set at 1, the servo loop gains adaptation mechanism is disabled. In this case, the speed regulator gains are
maintained at their rated value regardless of the diameter sensor measurement value.

36 CHAPTER 7 – Programming
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5 - EDITION OF A CONTROL SEQUENCE

5.1 - Tension control sequence

Tension control sequence parameters :

Sequence type = TENSION

Tension set point (V) = 2.5

Stretching time (ms) = 300
Holding time (ms) = 5000

Internal speed set point

Speed set point value (rpm) = 200
Accel/decel time (ms) = 500

Master encoder gearing

Gearing ratio gain (%) = 70

Constant gearing ratio gain

Gearing ratio adaptation by diameter sensor

Gearing ratio adaptation by line encoder

Next sequence =5
Counter =
Jump =
Output (87654321) = ........
Output trigger = End

Start condition (87654321) = .......[] Stop

The tension control structure associated to this sequence is presented below :

ANin2
Diameter
diameter
adaptation Constant
measurement
ratio
IA, IB Encoder
Master encoder adaptation
channels

Speed Accel/decel
set point ramp
Speed ref
+
Tension Stretching + PID + + PI
Gearing motor Motor
set point ramp tension
controller ratio speed
- -
Input
filter Speed
ANin1
tension
measurement

When the TDI input (X2 connector pin 22) is activated, the PID tension controller output is set at 0.

When the tension set point value is reached, if the tension controller error is lower than the Tension error
tolerance parameter value, the TER logic output is activated.

CHAPTER 7 – Programming 37
 SMT-BD1/t

When the motor speed reference value exceeds the Overspeed limit parameter value because of a dancer fault
(blocking or failure), a tension sequence error is generated. When the dancer or the load cell tension
measurement value drops below the Undertension limit parameter value because of a material braking, a
tension sequence error is also generated. When a tension sequence error is generated, the TER logic output is
desactivated and the tension control sequence is immediately stopped and the sequence which number is given
by the Sequence error link parameter value is then automatically executed.

When the Gearing ratio adaptation by diameter sensor operation is selected, the Gearing ratio gain
parameter value is no more valid because the gearing ratio is directly calculated from the spool diameter
measurement value.
The Gearing ratio adaptation by line encoder operation is only valid when the master encoder is connected. In
this case the gearing ratio adaptation procedure is initialised by the Gearing ratio gain parameter value. If the
Gearing ratio gain parameter value is set at 0, the gearing ratio adaptation procedure is initialised according to
the gearing ratio value estimated during a former ratio init sequence.

- A material tension control application with a constant gearing ratio is presented on the following diagram :

Dancer Running material

Motor Roller 1 Master encoder Roller 2

SMT-BD1/t Tension measurement

amplifier

The SMT-BD1/t amplifier is driving the roller 1 motor and provides the running material tension control according
to the tension measurement signal coming from the dancer and the master encoder pulses. In this case, the
Constant gearing ratio gain operation is selected and the corresponding gearing ratio value is adjusted by the
Gearing ratio gain parameter.

- An unwind/rewind tension control application with a variable gearing ratio is presented on the following diagram :

Material
spool Dancer Running material
Diameter
Master encoder Roller
measurement
Motor
Tension measurement

SMT-BD1/t
amplifier

The SMT-BD1/t amplifier is driving the spool motor and provides the running material tension control according to
the tension measurement signal coming from the dancer and the master encoder pulses. When the spool
diameter is changing, the new value of the gearing ratio gain is calculated according to the diameter
measurement value (Gearing ratio adaptation by diameter sensor selected).
If the diameter measurement sensor is not available for a given process, when the spool diameter is changing,
the new value of the gearing ratio gain is calculated during the material running according to the current
encoder/motor speed ratio when the dancer position is stable (Gearing ratio adaptation by line encoder
selected). In this case, the Gearing ratio gain parameter value is used for the gearing ratio initialisation when
starting the tension control sequence, in order to be able to run the motor and stretch the material before starting
the encoder/motor gearing ratio gain calculation. If the Gearing ratio gain parameter is set at 0, the gearing ratio
is initialised according to the gearing ratio gain value estimated during a former ratio init sequence.

38 CHAPTER 7 – Programming
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5.2 - Gearing ratio initialization sequence

Gearing ratio initialization sequence parameters :

Sequence type = RATIO INIT

Tension set point (V) = 2.5

Master encoder reference displacement (pulses) = 3500

Rewind motor speed (rpm) = -20

Accel./Decel. time (ms) = 500

Time out (s) =4

Next sequence =5
Output (87654321) = ........

Start condition (87654321) = ........

This sequence must be executed before starting a variable diameter tension control sequence when Gearing
ratio adaptation by line encoder operation is selected in order to initialise correctly the gearing ratio gain
adaptation procedure before starting the material running. The gearing ratio gain estimation procedure is
described below :

Dancer

Roller
Tension set point
Master encoder
Motor

Material Undertension limit

spool

• The material must be stopped and locked at the roller level in order to be stretched by the spool driving
motor.
• The spool driving motor is running at the constant rewind speed in order to stretch the material
• The motor displacement is measured from the “Undertension limit” dancer position up to the “Tension set
point” dancer position and the gearing ratio gain is then calculated in the following manner :
Gearing ratio gain = Measured motor displacement / Master encoder reference displacement

If the master encoder displacement during the ratio init procedure execution is exceeding 10 % of the Master
encoder reference displacement parameter value (when the material is not correctly locked at the master roller
level), a ratio init sequence error is generated. When the Time out value is over before the end of the ratio init
procedure execution , a ratio init sequence error is also generated. When a ratio init sequence error is generated,
the ratio init sequence is immediately stopped and the sequence which number is given by the Sequence error
link parameter value is then automatically executed.

The Master encoder reference displacement parameter is measured when the material spool driving motor is
locked and the material is stretched at the roller level in order to move the dancer from the Undertension limit
position up to the Tension set point position. The Undertension limit parameter value is entered in the Tension
control parameters menu.

CHAPTER 7 – Programming 39
 SMT-BD1/t

5.3 - Speed 1 control sequence

Speed 1 control sequence parameters :

Sequence type = SPEED 1

Acceleration time (ms) = 500

Running time (ms) = 500
Deceleration time (ms) = 500

Internal speed set point

Speed set point value (rpm) = 200

Analog speed reference

Analog input offset (V) =2

Master encoder gearing

Gearing ratio gain (%) = 70

Constant gearing ratio gain

Gearing ratio modulation by diameter sensor

Next sequence =5
Counter =
Jump =
Output (87654321) = ........
Output trigger = End

Start condition (87654321) = .......[] Stop

The speed control structure associated to this sequence is presented below :

ANin2
diameter Diameter Constant
measurement modulation gain

IA, IB
Master encoder
Speed ref
channels
ANin1 + PI
Accel/decel Gearing Motor
speed motor speed
ramp ratio
reference controller
Speed
-
Speed set
point profile Speed

When the Internal speed set point is selected, the sequences linkage allows to create any desired speed profile
as described below. If the Running time parameter value exceeds 16000 ms, the motor is continuously running
until the sequence stop condition.

sequence 1 sequence 3
Speed = 1500 sequence 2 Speed = 2000
Tacc = 2000 Speed = 3000 Tacc = 3000
Trun = 0 Tacc = 3000 Trun = 0
Tdec = 0 Trun = 0 Tdec = 1500
Next = 2 Tdec = 0 Next = -1
Next = 3

Note: Next = -1 corresponds to an empty field in the PC.

40 CHAPTER 7 – Programming
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The selection of both Analog speed reference and Gearing ratio modulation by diameter sensor allows a
typical unwinder accumulator control application, as shown on the following diagram:

Accumulator height
Material measurement
spool Running material
Diameter
Roller
measurement
Motor
Accumulator

SMT-BD1/t
amplifier

The SMT-BD1/t amplifier is driving the spool motor according to the accumulator height measurement signal and
the diameter measurement signal. When the acumulator material is taken by the roller, the accumulator is going
up and the spool must start running in order to supply new material to the accumulator. So the accumulator height
must be controlled in order to have a linear height variation with regard to the material line speed. Furthermore,
when the spool diameter is decreasing, the motor speed value must be increased according to the diameter
measurement value in order to maintain the right accumulator height with regard to the material line speed. The
accumulator position at standstill (material line speed =0) can be easily adjusted by using the Analog input
offset parameter. This parameter adjustment allows to get an automatic material spool rewind up to the
accumulator standstill position at the sequence start.

5.4 - Speed 2 control sequence

Speed 2 control sequence parameters :

Sequence type = SPEED 2

Acceleration time (ms) = 500

Running time (ms) = 500
Deceleration time (ms) = 500

Internal speed set point

Speed set point value (rpm) = 200

Analog speed reference

Speed ratio gain (%) = 50

Next sequence =5
Counter =
Jump =
Output (87654321) = ........
Output trigger = End

Start condition (87654321) = .......[] Stop

CHAPTER 7 – Programming 41
 SMT-BD1/t

The speed control structure associated to this sequence is presented below :

Speed
ratio gain
ANin1
Accel/decel
speed
ramp
reference + PID + PI
line speed motor speed Motor
Speed set Speed controller
controller -
point profile -
IA, IB
Master encoder Speed
channels

The selection of the Analog speed reference operation allows a typical unwinder/rewinder speed control
application as shown on the following diagram:

Material
spool Running material

Line encoder Roller

Motor

SMT-BD1/t Line speed

amplifier set point

The SMT-BD1/t amplifier is driving the spool motor and provides a constant material line speed control according
to the analog line speed set point value. When the spool diameter is changing, the motor speed value is updated
by the PID line speed controller in order to cancel the line speed error (line speed error = line speed set point -
line speed measurement given by the line encoder). This dual speed loop control structure can ensure very
accurate line speed regulation according to the spool diameter variation without any diameter sensor.

5.5 - Torque control sequence

Torque control sequence parameters:

Sequence type = TORQUE

Speed set point value (rpm) = -100

Acceleration time (ms) = 500
Torque holding time (ms) = 8000

Internal torque set point

Torque set point value (%) = 40

Analog torque set point

Torque set point ratio (%) = 50

Constant set point ratio

Set point ratio modulation by diameter sensor

Set point ratio modulation by line encoder

Next sequence =5
Counter =
Jump =
Output (87654321) = ........
Output trigger = End

Start condition (87654321) = .......[] Stop

42 CHAPTER 7 – Programming
 SMT-BD1/t

The torque control structure associated to this sequence is presented below :

IA, IB
Encoder
Master encoder
modulation
channels
ANin2
Diameter Constant
diameter
modulation ratio
measurement

ANin1
torque set point Torque
ratio
Torque
set point
Speed ref
+ PI
Speed Accel/decel Speed Current Motor
motor speed
set point ramp ratio limit
controller
-
Speed

At the start of a torque control sequence, the motor is accelerating and then running at the Speed set point
parameter value until the shaft is locked. The motor running direction depends on the sign of the Speed set point
parameter. When the motor shaft displacement has been stopped in the running direction, the current is raising
up to the limit value defined by the Internal torque set point parameter or the value given by the ANin1 analog
input voltage if Analog torque set point is selected. When the current limit value has been reached, the TER
logic output is activated and the amplifier is holding the torque set point during the time value defined by the
parameter Torque holding time. The torque control sequence is then automatically over after the holding time
value. If the Torque holding time parameter value exceeds 16000 ms, then the torque holding time is infinite and
the sequence stop condition can be used to leave the torque control sequence.

During the torque holding time, if the motor speed value is exceeding the Overspeed limit parameter value
because of a material braking, a torque sequence error is generated. When a torque sequence error is generated,
the TER logic output is desactivated and the torque control sequence is immediately stopped. The sequence
which number is given by the Sequence error link parameter value is then automatically executed. This security
is useful for a winding application where it is necessary to set the Speed set point parameter value higher than
the line speed value in order to reach the current limitation during the winding operation.

The selection of both Analog torque set point and Set point modulation by diameter sensor allows a typical
winder or unwinder tension control application, as shown on the following diagram:

Material
spool Running material
Diameter
Roller
measurement
Motor

SMT-BD1/t Tension
amplifier set point

The SMT-BD1/t amplifier is driving the spool motor and provides a constant material tension control according to
the analog set point (Analog torque set point selected) and the diameter measurement signal (Set point ratio
modulation by diameter sensor selected). When the spool diameter is changing, the motor torque value is
modified according to the diameter measurement value in order to maintain the right material force with regard to
the tension set point. In an unwinding application, the Speed set point parameter is set at a low value in order to
have the material automatically rewound and progressively stretched up to the tension set point at the sequence
start. In a winding application, the Speed set point parameter must be set at a higher value than the maximum
value of the line speed during the winding operation in order to reach the current limitation.

CHAPTER 7 – Programming 43
 SMT-BD1/t

The selection of both Analog torque set point and Set point ratio modulation by line encoder allows a
second winder or unwinder tension control application, as shown on the following diagram:

Material
spool Running material

Line encoder Roller

Motor

SMT-BD1/t Tension
amplifier set point

The SMT-BD1/t amplifier is driving the spool motor and provides a constant material tension control according to
the analog set point and the encoder/motor gearing ratio. When the spool diameter is changing, the motor torque
value is modified according to the encoder/motor gearing ratio value in order to maintain the right material force
with regard to the tension set point. In this case, the Torque set point ratio parameter value is used for the
torque set point initialisation when starting the torque control sequence, in order to be able to run the motor and
stretch the material at the correct tension value before starting the gearing ratio gain calculation. In an unwinding
application the Speed set point parameter is set at a low value in order to have the material automatically
rewound and progressively stretched up to the tension set point at the sequence start. In a winding application,
the Speed set point parameter must be set at a higher value than the maximum value of the line speed during
the winding operation in order to reach the current limitation.

6 - SEQUENCES CHAINING

6.1 - Sequence control

6.1.1 COUNTER LOOP

The sequences linkage is controlled by the parameters “Next sequence”, “Counter” and “Jump”.

Application example:

Sequence 1: Next sequence = 2

Counter = 0
Jump = -1
Sequence 2: Next sequence = 3
Counter = 2
Jump = 1
Sequence 3: Next sequence = -1
Counter = 0
Jump = -1

Note: Next = - 1 or Jump = - 1 correspond to the empty field in the PC software.

If the execution starts at sequence 1, the programme will be the following:

Sequence 1 Start of sequence 1, then connection to sequence 2

(parameter « Next sequence »)

Sequence 2 First execution of sequence 2, then connection to sequence 1

(parameter « Jump »)

Sequence 1 Execution of sequence 1, then connection to sequence 2

(parameter « Next sequence »)

Sequence 2 Second execution of sequence 2, then connection to sequence 3

(parameter « Next sequence »)

Sequence 3 Execution of sequence 3, then end of the programme

44 CHAPTER 7 – Programming
 SMT-BD1/t

6.1.2 - CONDITIONAL JUMP

The conditional jump is controlled by using the “Start condition” and the parameters “Next sequence”, “Counter”
and “Jump”.

Application example:

Sequence 1: Next sequence = 2

Counter = 0
Jump = -1
Sequence 2: Next sequence = 3
Counter = 0
Jump = 4
Start condition = 0x0100 (Logic input 1 activated )
Sequence 3: Next sequence = -1
Counter = 0
Jump = -1
Sequence 4: Next sequence = -1
Counter = 0
Jump = -1

Note: Next = - 1 or Jump = - 1 correspond to the empty field in the PC software.

If the execution is starting at sequence 1 and logic input 1 is activated, the programme will be the following:

Sequence 1 Start of sequence 1, then connection to sequence 2

(parameter « Next sequence »)

Sequence 2 Execution of sequence 2, then connection to sequence 3

(start condition valid and parameter « Next sequence »)

Sequence 3 Execution of sequence 3, then end of the programme

If the execution is starting at sequence 1 and logic input 1 is desactivated, the programme will be the following:

Sequence 1 Start of sequence 1, then connection to sequence 2

(parameter « Next sequence »)

No execution of sequence 2, connection to sequence 4

(start condition not valid and parameter « Jump »)

Sequence 4 Execution of sequence 4, then end of the programme

6.2 - Logic inputs

Logic input 1 is entering the X2 connector on pin 21 (Lin1) while logic inputs 2 to 8 can only be activated or
desactivated on the serial bus interface (PROFIBUS DP) for the sequence control and have no physical
existence.

The inputs can be used either as a sequence start condition or as a sequence stop condition. A sequence stop
condition is only valid when the running time or the holding time value is higher than 16000 ms.

The 8 logic inputs can be selected as follows:

• ignore the input status,
• trigger on positive level (input activated),
• trigger on negative level (input desactivated).

CHAPTER 7 – Programming 45
 SMT-BD1/t

6.3 - Logic outputs

Logic output 1 is located on pin 8 (Lout1) of the X2 connector while logic outputs 2 to 8 are only visible on the
serial bus interface (PROFIBUS DP) for the sequence control and have no physical existence.

Outputs The action on the 8 logic outputs can be defined as follows:

• do not modify the output status,
• set the output at 1,
• set the output at 0,
• reverse the output status (toggle).

Triggering The outputs triggering moment can be defined during a control sequence according to the
different ways described below.

Speed 1 or speed 2 sequence outputs:

BEGIN: logic SPEED: logic END: logic

output at the output when the output at the
sequence speed reference sequence end
beginning is reached

Speed

Acceleration Running Deceleration

Torque sequence outputs:

BEGIN: logic SPEED: logic TORQUE: logic END: logic

output at the output when the output when the output at the
sequence speed reference torque reference is sequence end
beginning is reached reached
(torque sequence)

Speed

Acceleration
Current

Holding
Tension sequence outputs:

BEGIN: logic SPEED: logic TENS: logic output END: logic

output at the output when the when the tension output at the
sequence speed reference reference is reached sequence end
beginning is reached (tension sequence)

Speed

Acceleration
Tension

Holding
Stretching

In a ratio init sequence, the outputs trigger only at the end of the sequence.

46 CHAPTER 7 – Programming
 SMT-BD1/t

Chapter 8 - Operation with Profibus

1 - PROFIBUS COMMUNICATION
®
The Profibus communication is a master-slave communication. The INFRANOR amplifier is a slave device and
the only important parameter to be defined for the communication is the amplifier address on the bus.

All other parameters (communication speed, configuration, parameters) are defined in the PLC (master) and will
be automatically sent to the amplifier:

- the available communication speeds are: 9,6 KB, 19,2 KB, 93,72 KB, 187,5 KB, 500 KB, 1,5 MB, 3 MB,
6 MB, 12 MB and will be automatically detected by the amplifier.
- the configuration used will be sent to the slave at the bus start. The available configurations are PPO1,
PPO2, PPO3 or PPO4,
- default parameter setting: not used by the amplifier.

These various possibilities are pre-defined in a GSD file proper to each product range running with Profibus. The
®
GSD file for the INFRANOR unwinder/rewinder is INFR05B3.GSD and is provided by the BPCW software disk
(version 2.7 or higher).

When defining the network on the master, please:

- import the slave GSD file if this has not yet been done,
- create a network with the master,
- connect a slave on the network with the same address as defined in the slave.

Note: When the communication is established, the green "RUN" LED lights up.

1.1 - PPO message

In the PROFIBUS-DP communication model, a slave module consists of a certain number of inputs-outputs or
inputs-outputs modules. Each module is defined by an identifier. This identifier contains information on the
module direction (input, output or input-output), on the number of bytes or words and on the module consistancy.
The configuration is defined in the DP master and is sent to the slave by means of the Chk_Cfg functions at the
bus start. The slave checks if this configuration is compatible and configures itself before switching to data
exchange mode (Data_Exchange).

There is also a communication mechanism more complicated than a basic inputs/outputs identifier: the PPO
messages. These messages are often used in the "device profiles".

There are 5 PPO types defined for the various device profiles under Profibus:

PKW PZD

PKE IND PWE PZD1 PZD2 PZD PZD PZD PZD PZD PZD PZD PZD
STW HSW 3 4 5 6 7 8 9 10
ZSW HIW

1st 2nd 3rd 4th 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Word Word Word Word Word Word Word Word Word Word Word Word Word Word

PPO1

PPO2

PPO3

PPO4

PPO5 PKW PZD

CHAPTER 8 – Operation with Profibus 47

 SMT-BD1/t

PKW Parameter setting data.

PKE Parameter code (bytes 1 to 2).
IND Index (byte 3).
PWE Parameter value (bytes 5 to 8).

PZD Process data (cyclically transferred).

STW Control.
ZSW Status.
HSW Input command.
HIW Information feedback.

A PPO message can contain 1 or 2 modules called PKW and PZD.

Each module (PKW or PZD) is defined as input-output and is consistant over the whole module length.
The communication is made by the reading or writing of PPO messages (the PKW and PZD modules are input
and output at the same time). The master sends a message by a PPO-write and receives a message by PPO-
read. The PPO-write and PPO-read messages are cyclically transferred by the PROFIBUS DP Data_Exchange
function.

The modules are consistant. This means that the different words of a same message must be transmitted or
received in one single transfer. So, it is not possible to directly read or write in the PLC inputs/outputs area;
special functions must be used for the data reading or writing.
®
Example: In the STEP7 software, the SFC14 and SFC15 functions are used for the reading and writing of the
consistant modules.

EN SFC14 ENO

W#16#108 LADDR RET_VAL MW100

RECORD P#M 40.0 BYTE 12

EN SFC15 ENO

W#16#108 LADDR RET_VAL MW101

P#M 20.0 BYTE 12 RECORD

In the above example, the SFC14 and SFC15 functions are used for reading or writing the PZD module (PPO2
case). The W#16#108 address is the physical module address on the network that is obtained when connecting
the slave to the network. This address is the same for the reading (SFC14) and writing (SFC15) because the
module is an input-output module. The result of the reading will be transferred in the memory area at the address
40 by SFC14 (12 bytes). The SFC15 function will transfer the data at the address 20 (12 bytes) on the bus.

The PKW will require a SFC14 (reading) and a SFC15 (writing) and the PZD will require a SFC14 and a SFC15.

PKW is by definition used for the amplifier parameter setting and PZD is used for its operational control.
®
The INFRANOR amplifier uses the PPO messages mechanism for communicating by Profibus-DP.

The SMT-BD1/t amplifier accepts the PPO1, PPO2, PPO3 or PPO4 types.

48 CHAPTER 8 – Operation with Profibus

 SMT-BD1/t

1.2 - Configuration

Normally, the identifiers of the various PPO types are automatically provided by the GSD file. Otherwise, they can
be manually defined with values indicated in the table below:

PPO type PKW PZD

Type 1 PKW (4 words) PZD
ReadPPO1, WritePPO1 Inputs/outputs module Inputs/outputs module
4 words 2 words
Consistency Consistency
Configuration 0xF3 0xF1
Type 2 PKW (4 words) PZD
ReadPPO2, WritePPO2 Inputs/outputs module Inputs/outputs module
4 words 6 words
Consistency Consistency
Configuration 0xF3 0xF5
Type 3 PZD
ReadPPO3, WritePPO3 Inputs/outputs module
2 words
Consistency
Configuration 0xF1
Type 4 PZD
ReadPPO4, Write PPO4 Inputs/outputs module
6 words
Consistency
Configuration 0xF5

Example

When PPO2 is used, the identifiers are 0xF3 and 0xF5 (4 words for PKW and 6 words for PZD).

1.3 - Parameter setting (PKW)

The parameter area (PKW) allows to read or modify a parameter.

Parameter identifier (PKE)

Bit : 15 12 11 10 0
AK SPM PNU

AK: Instruction or reply code (0-15)

SPM: Toggle bit for parameter data signal processing.
PNU: Parameter number (1..1999)

1.3.1 - INSTRUCTION/REPLY (PKW)

Instructions code (master -> slave):

Instruction Function Positive Negative

Code reply code reply code
0 No instruction 0
1 Read a parameter 1 7/8
2 Modify a parameter (word) 1 7/8
3 Modify a parameter (double word) 2 7/8

The reply code mentioned in the above table includes the normal replies associated with the instructions.
The parameter code (PKE) is always of 16 bits.

CHAPTER 8 – Operation with Profibus 49

 SMT-BD1/t

Bits 0 to 10 include the parameter number (PNU).

Bit 11 indicates an event message: the parameter is both modified and sent by the amplifier.

Bits 12 to 15 include the instruction or reply code.

Reply codes (slave -> master):

Reply code Function

0 No function.
1 Value of the transferred parameter (word).
2 Value of the transferred parameter (double word).
7 Instruction cannot be executed (see error code).
8 PKW interface inhibited.
th
For instructions that cannot be executed, the slave answers with an error number in the 4 word of the PKW (bits
7 and 8).

Error number Description

0 PNU unlegal.
1 Parameter cannot be changed.
2 Exceeding of lower or upper limit.
3 Index error (2nd word of PKW)
5 Incorrect data type
17 Instruction cannot be executed during operation.
18 Other error

1.3.2 - PARAMETER VALUE (PWE)

PWE includes the data for the parameter to be transferred:

- word: bytes 7 (MSB) and 8 (LSB).

- double word: bytes 5 (MSB) to 8 (LSB).

1.3.3 - RULE OF THE INSTRUCTION/REPLY COMMUNICATION

- The master sends an instruction to the slave with the message "PPO write". It repeats this instruction until it
gets a reply from the slave by "PPO read". This procedure guarantees the instruction/reply communication by
the operator.

- Just one single instruction can be executed at once.

- A slave provides the reply until the master sends a new instruction.

- An instruction (8 bytes) must be completely transferred in a message, and a reply as well.

- If no parameter setting information is required, the master must send 0 in AK (no instruction).

1.4 - Global control

The PROFIBUS DP global control mechanism can be used for synchronizing the outputs and inputs of several
modules and several slaves. There are 4 global controls: SYNC, UNSYNC, FREEZE and UNFREEZE.
When the master sends a global SYNC control, the outputs of the addressed slave are frozen at their current
values. When the master sends the next data, those are stored in the slave and the outputs status remains
unchanged. When the next SYNC control is sent, the stored outputs values are switched through to the outputs.
An UNSYNC control can be used for ending the synchronous mode.
The FREEZE control also allows the slave to freeze the inputs at their current values and to send them with the
next data transfers. The inputs are not updated until the next FREEZE control. The FREEZE mode can be left by
means of an UNFREEZE control.
The SMT-BD1/t amplifier accepts the global controls SYNC, UNSYNC, FREEZE and UNFREEZE.

50 CHAPTER 8 – Operation with Profibus

 SMT-BD1/t

2 - CONTROL VIA PROFIBUS

The unwinder/rewinder is driven by Profibus with the PZD data area.

Master -> slave (PLC -> unwinder/rewinder):

- Control word (STW)
- Input command (HSW)

Slave -> master (unwinder/rewinder -> PLC):

- Status (ZSW)
- Feedback (HIW)

2.1 - Control word

Bit Value Meaning Notes

0 1 ON Enabling.
0 OFF1 Stop, braking and disabling.
1 1 Operational condition Amplifier ready.
0 OFF2
2 1 Operational condition Emergency stop: maximum deceleration.
0 OFF3
3 1 Operation enabled
4 1 Operational condition for the A sequence can be executed on a 6 bit edge.
unwinder/rewinder
0 Stop Maximum braking.
5 1 Operational condition for the Must be set at 1 for a sequence execution.
unwinder/rewinder
0 Intermediate stop Braking with programmed deceleration.
6 ↓↑ Execute unwinder/rewinder Each edge on this bit releases the execution of the selected
function sequence.
7 ↑ Fault acknowledgment Amplifier fault reset.
8 1 Jog + Continuous motor movement in the positive direction.
0
9 1 Jog - Continuous motor movement in the negative direction.
0
10 1 Command Control by Profibus
0 Local Local mode control by RS-232
11
12
13
14
15

2.2 - Input command

The input command is contained in the PZD part of the PPO (2nd word of PZD to 6th word of PZD).
It has got different meanings according to the unwind/rewind or speed control mode.

In unwind/rewind mode:

PZD2 contains the sequence control input (bits 0 to 7: number of the sequence to be executed ; bits 8 to 15: logic
inputs (1 to 8) used for the sequence start or stop conditions).

If PPO2 or PPO4 is used:

PZD3 contains the tension sequence set point (0x7FFF corresponds to 10 V).
PZD4 contains the speed sequence set point (0x7FFF corresponds to the maximum motor speed).
PZD5 contains the torque sequence set point (0x7FFF corresponds to the maximum current).
PZD6 contains the diameter value (0x7FFF corresponds to 10 V).

Remark: PZD3 to PZD6 are only valid when Analog set point is selected in the sequence and PROFIBUS is
selected as the set point source in the Amplifier configuration parameter (PNU742).

CHAPTER 8 – Operation with Profibus 51

 SMT-BD1/t

In speed mode (as from firmware EPROM version 506.64):

PPO2 or PPO4 must be used:

PZD2 contains the speed input command (0x7FFF corresponds to the maximum motor speed).
PZD5 contains the current limitation (0x7FFF corresponds to the maximum current).

2.3 - Status

Bit Value Meaning Notes

0 1 Ready for enabling Ready for enabling (ENABLE).
0 Not ready
1 1 Ready for operation
0
2 1 Operation enabled
0
3 1 Error Amplifier fault after error reset; is in "disabled" status.
0
4 1 No OFF2
0 OFF2 Instruction "OFF2" available
5 1 No OFF3
0 OFF3 Instruction "OFF3" available
6 1 Enabling inhibited
0 Enabling
7 1 Warning Warning signal; the amplifier goes on operating.
0
8 1 No following error
0 Following error
9 1 Operation via Profibus
0 Operation in local mode
10 1
0
11 0 Ratio init already achieved
1
12 ↓↑ Input command Acknowledgment of a sequence triggering
acknowledgment
13 1 Motor stopped
0
14 1 Sequence running
0
15 1 Speed is reached
0

Note

When switching from the "Profibus" mode to local mode or vice versa, the amplifier is disabled.

2.4 - Feedback
nd th
The feedback is included in the PZD part of the PPO (2 word of PZD to 6 word of PZD).
It has got different meanings according to the unwind/rewind or speed control mode.

In unwind/rewind mode:

PZD2 contains the sequence control feedback (bits 0 to 7 of the HIW: number of the running sequence (otherwise
0xFF) ; bits 8 to 15 of the HIW: programmable logic outputs (1 to 8) of the amplifier).

If PPO2 or PPO4 is used:

PZD3 contains the tension monitor (0x7FFF corresponds to 10 V).
PZD4 contains the speed monitor (0x7FFF corresponds to the maximum motor speed).
PZD5 contains the torque monitor (0x7FFF corresponds to the maximum current).
PZD6 contains the diameter monitor (0x7FFF corresponds to 10 V).

52 CHAPTER 8 – Operation with Profibus

 SMT-BD1/t

In speed mode (as from firmware EPROM version 506.64):

PPO2 or PPO4 must be used:

PZD2 contains the motor speed value (0x7FFF corresponds to the maximum motor speed).
PZD5 contains the current monitor (0x7FFF corresponds to the maximum current).

3 - OPERATION DIAGRAM

3.1 - Amplifier control process

Power ENABLE S.6 = 1

ON inhibited

OFF1
control = xxxx x1xx xxxx xxx0

ENABLE S.6 = 1
not ready S.9 = 1

C.3 = 0 control Error

xxxx x1xx xxxx x110

S.2 = 0 Operation Ready for S.0 = 1 S.3 = 1 Error

inhibition ENABLE

Operation inhibited ON Error reset

C.0 = 1 C.7 = 1

Ready S.1 = 1

Enabling
C.3 = 1
OFF1 OFF3 OFF2
C.0 = 0 C.2 = 0 C.1 = 0

Deceleration OFF1 active Fast brake OFF3 Active OFF2 active S.4 = 0
phase 1 S.5 = 0 phase 1

Motor Motor
stop stop

S.1 = 0 OFF1 active OFF3 active

phase 2 phase 2

Disabled disabled disabled

Operation S.2 = 1
enabled

Notes:
ENABLE Enabling.
C.n Indicates bit n of the control word (see section 2.2).
S.n Indicates bit n of the status word (see section 2.2).

This diagram describes the amplifier behaviour.

The enabling process includes 5 stages: "ENABLE inhibited", "ENABLE not ready", "Ready for ENABLE",
"Ready" and "Operation enabled".

CHAPTER 8 – Operation with Profibus 53

 SMT-BD1/t

The 3 OFF1, OFF2 and OFF3 functions allow various ways to disable the motor.

The functions "Error" and "OFF" are effective at each level of the diagram. "OFF3" is a stop with maximum
deceleration. "OFF2" has a priority over "OFF1" which has a priority over "OFF3".

Contrarily to the parameter setting, there is no direct acknowledgement for each control word bit.
The unwinder/rewinder status must be checked in order to make sure that the command could be executed.

3.2 - Unwind/rewind mode

JOG end
C.8 = C.9 = 0

Operation JOG
enabled

JOG
Drive task C.8 = 1 or
over C.9 = 1

Unwinder/rewinder
activation C.4 = 1
edge on C.6

Brake with
max Execution of unwind/rewind Execution of a sequence
deceleration a new function Acknowledgment of the command with edge on
sequence S.12

Stop
C.4 = 0

Intermediate stop C.5 = 1

C.5 = 0

Brake with
ramp

Motor stopped

Intermediate S13=1
stop

When the unwinder/rewinder is in "Operation enabled" status, the following is possible:

- starting a sequence execution (bit 6),
- jog+ or jog- (bit 8 or 9),
- stopping the motor with a programmed deceleration - the one defined by JOG (bit 5) -,
- stopping the motor with maximum deceleration (bit 4).

54 CHAPTER 8 – Operation with Profibus

 SMT-BD1/t

4 - DRIVING OF THE UNWINDER/REWINDER

4.1 - Enabling/disabling

The enabling procedure is defined in the diagram of section 3.1

Example of a simplified enabling:

Stages Communication Value

1 PLC -> Unwinder/rewinder Send control word = 0400h
2 PLC -> Unwinder/rewinder Send control word = 0406h
3 PLC -> Unwinder/rewinder Send control word = 0407h
4 PLC -> Unwinder/rewinder Send control word = 043Fh
5 Unwinder/rewinder -> PLC Check status word = xxxx xx11 xx11 0111b

Notes

- The unwinder/rewinder bus cycle time is 1 ms; check for at least 1 ms between 2 commands.

- In the above procedure, the unwinder/rewinder status is not checked at each stage but only at the end.

The disabling can be simply made by disabling one of the OFF1 or OFF2 or OFF3 bits.

4.2 - Starting a sequence

When the unwinder/rewinder is in "Operation enabled" status, a sequence is started by:

- entering the sequence number in PZD 2,

- reversing bit 6 of the control word.

If a new sequence is started whereas the unwinder/rewinder is executing a sequence, the unwinder/rewinder
immediately executes the new sequence without stopping the motor.

4.3 - Other movements

The other possible non programmed movements are executed by the jog inputs : jog+ or Jog- (bit 8 or 9),

4.4 - All-speed control

As from firmware EPROM version 506.64, it is also possible to control the amplifier in all-speed mode (P, PI or
PI2) :

- switch to speed mode by means of parameter PNU 720, with disabled amplifier.

- the PLC must send the speed command in PZD2 (16 bits full scale) and the current limit command in PZD5
(16 bits full scale) of the PPO-write.

- the PLC can read the motor speed monitor in PZD2 (16 bits full scale) and the current monitor in PZD5 (16
bits full scale) of the PPO-read.

CHAPTER 8 – Operation with Profibus 55

 SMT-BD1/t

Chapter 9 - Parameter setting by Profibus

1 - PARAMETER LIST

PNU Parameter Unit Min. Max. Size R/W Savin Default

g value
700 Number of motor pole pairs 1 12 word R/W E 4
701 Motor phases order word R/W E 0xAAAA
702 Resolver shift 0 65535 word R/W E 0
703 Phase lead word R/W E 0
704 Auto-phasing procedure - W

710 Max. current %/327 6553 32767 word R/W E 0x7FFF

711 Rated current %/327 6553 16384 word R/W E 0x4000
712 I2t protection mode Boolean R/W E 1

720 Amplifier mode word R/W

721 Max. motor speed rpm 100 14000 word R/W E 3000
722 Motor rotation direction Boolean R/W E 0
723 Acceleration ramp ms 0 16000 word R/W E 1
724 Speed following error rpm 1 14000 word R/W E 14000

726 Brake control active delay ms 0 16000 word R/W E 0

727 Brake control inactive delay ms 0 16000 word R/W E 0
728 Manual brake control Boolean W
729 Saving in an EEPROM - W
880 Offset compensation - W

730 Proportional speed loop gain 0 65535 word R/W E 0x64

731 Integral speed loop gain 0 65535 word R/W E 0
732 Integral 2 speed loop gain 0 65535 word R/W E 0
734 Current control filter 2832 61545 word R/W E 0x3000
735 Anti-resonance filter 0 1 Boolean R/W E 0
736 Auto-tuning procedure 0 5 word W
749 Reduced stiffness at standstill 0 1 Boolean R/W E 0
875 Cogging acquisition procedure - W
876 Cogging torque compensation 0 1 Boolean R/W E 0

742 Amplifier configuration word R/W E 0

750 Encoder output resolution 16 8192 word R/W E 0x400

751 Number of marker pulses 1 16 word R/W E 1
752 Marker pulse shift 0 32767 word R/W E 0
753 Marker pulse width 0 32767 word R/W E 0x10
754 Encoder output programming - W
755 Encoder output enabling 0 1 Boolean R/W 0

763 Speed in jog %/327 -32767 32767 word R/W E 0x1F4

764 Acceleration in jog ms 1 16000 word R/W E 0x320
765 Deceleration in jog ms 1 16000 word R/W E 0x320

770 Amplifier software version - double R

771 Profibus software version - word R
773 Amplifier error - double R
774 Motor position pulse double R
775 Resolver value pulse 0 65535 word R
768 Master encoder position pulse double R/W

56 CHAPTER 9 – Parameter setting by Profibus

 SMT-BD1/t

780 Sequence reading word W

781 Sequence writing word W
782 Sequence control 16 bits R/W S
783 Ref. displacement for ratio init pulse -2 31 +2 31 double R/W S
785 Acceleration ms 1 16000 word R/W S
786 Deceleration/Stretching ms 0 16000 word R/W S
787 Running/Holding/Time out ms 0 16767 word R/W S
788 Next sequence -1 63 word R/W S
789 Counter 0 32767 word R/W S
790 Jump -1 63 word R/W S
791 Condition inputs 16 bits R/W S
792 Programmable logic outputs 16 bits R/W S
794 Tension set point/Torque set point V/3276 -32767 32767 word R/W S
810 Speed set point %/327 -32767 32767 word R/W S
811 Gearing ratio gain %/327 0 32767 word R/W S

830 PID loop scaling gain %/327 -32767 32767 word R/W E 32767
831 Proportional PID loop gain 0 65535 word R/W E 1
832 Integral PID loop gain 0 65535 word R/W E 0
833 Derivative PID loop gain 0 65535 word R/W E 0
834 Speed variation limit rpm 0 14000 word R/W E 0
840 Diameter filter ms 1 10000 word R/W E 128
841 Min. diameter V/3276 0 32767 word R/W E 0
842 Max. diameter V/3276 0 32767 word R/W E 32767
843 Diameter value V/3276 0 32767 word R
844 Diameter ratio 1/32767 328 32767 word R/W E 32767
845 Gearing ratio 1/32767 328 32767 word R/W
846 Max gain diameter V/3276 0 32767 word R/W E 32767
847 Regulator gain ratio 1/16 16 16000 word R/W E 16
860 Tension filter 2832 61545 word R/W E 2832
861 Tension value V/3276 -32767 32767 word R
862 Tension tolerance %/327 0 32767 word R/W E 32767
863 Overspeed limit rpm 0 14000 word R/W E 14000
864 Undertension limit V/3276 -32767 32767 word R/W E 0
865 Sequence error link -1 63 word R/W E 63
870 Overtorque factor %/163 0 16383 word R/W E 0
871 Diameter ratio for overtorque 1/32767 328 32767 word R/W E 32767

Note:

R/W Reading/Writing
R Reading only
W Writing only

E These parameters are saved in the EEPROM by instruction 729.

S These parameters are saved in the EEPROM by the instruction “Sequence writing” 781.

2 - PARAMETERS DESCRIPTION

2.1 - Motor parameters

Synchronous motor parameters PNU : 700, 701, 702

Defines the parameters required for driving synchronous motors. These parameters can be calculated by the
auto-phasing procedure.
Parameter Number of motor pole pairs (1 to 12).
Motor phase order: corresponds to the phase order (U, V, W) of the motor connection.
Sensor adjustment: phase shift between resolver and motor rotor.
Conversion Motor phase 2 possible values (0x5555 or 0xAAAA).
Sensor adjustment 5.4931640625e-3*(number of pole pairs). The value obtained is the shift
electrical degrees.
Execution With disabled amplifier.

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Auto-phasing PNU : 704

Parameter None.
Limitation Writing only.
Note This procedure allows the automatic calculation of the motor parameters:
- number of motor pole pairs,
- motor phase order,
- resolver offset.
The motor must first be disabled and uncoupled from the mechanical load. The ENABLE
signal (X4 connector) must also be active. Before executing the procedure, check for free motor
shaft rotation over one revolution, that is not dangerous for the operator.
When the motor parameters are known, it is not necessary to execute the auto-phasing.

Phase lead coefficient PNU : 703

Parameter 16 bits. (55-7446)
Conversion 4.57771654e-5 (electrical degree/1000 rpm)

Phase shift:
0,6.10 −7 .Kt.Np.(Max.MotorSpeed)2
tanϕ =
L.Irated

Kt: motor torque constant (Nm/Arms)

Np: number of motor pole pairs
Max.MotorSpeed: maximum motor speed (rpm)
Irated: motor current (Arms)

with: 0 ≤ ϕ ≤ 45°

Phase lead coefficient (electrical degree/1000 rpm):

1000
Coef = ϕ
Max. MotorSpeed

2.2 - Current parameters

Maximum current PNU : 710

Defines the max. current limitation in the motor.
Parameter 1 word.
Conversion in percentage of the amplifier current rating: x 3.051850948e-3.
Limitation 6554 (20%) to 32767 (100%)
Execution
Note This parameter is defined according to the amplifier and motor specifications.

Rated current PNU : 711

Defines the rated current limitation in the motor.
Parameter 1 word.
Conversion in percentage of the amplifier current rating: x 3.051850948e-3.
Limitation 6554 (20 %) to 16384 (50%)
Execution
Note This parameter is defined according to the amplifier and motor specifications.

I2t mode PNU : 712

Parameter 1 word.
0 limiting mode.
1 fusing mode.
Note See chapter 11 (Appendix) for the I2t protection mode description.

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2.3 - Speed regulator parameters

The structure of the speed regulator is shown below:

KP
Speed reference Idc
KI1+KP.KI2 2.π.Fev
s s + 2.π.Fev

KI1.KI2
s2
Motor speed

All gain parameters (KP, KI1, KI2 and Fev) are automatically calculated during the auto-tuning procedure.

Proportional speed loop gain PNU : 730

Defines the proportional regulator gain (KP) that acts upon the speed error.
Parameter 1 word.
Conversion 1/16
Limitation 0 to 65535

Integral speed loop gain PNU : 731

Defines the integral regulator gain (KI1) that acts upon the speed error.
Parameter 1 word.
Conversion 1/256
Limitation 0 to 65535

Integral 2 speed loop gain PNU : 732

Defines the integral 2 regulator gain (KI2) that acts upon the speed error.
Parameter 1 word.
Conversion 1/65536
Limitation 0 to 65535
Note This parameter can only be used in speed mode.

Current control low-pass filter PNU : 734

Defines the cut-off frequency at -3 dB (Fev) of the first order filter that acts upon the current control. The value of
this parameter is depending on the selected bandwidth.
Parameter 1 word.
Conversion Frequence (Hz) = 1000/pi*Ln(65536/parameter)
Limitation This parameter can take a value between 2832 (1000 Hz) and 61545 (20 Hz).

Antiresonance filter PNU : 735

Releases or inhibits the antiresonance filter.
Parameter 1 word.
= 0: inhibits the filter,
= 1: releases the filter.

Auto-tuning PNU : 736

This procedure identifies the specific motor and load parameters and calculates the regulator gain parameters.
Parameter 1 word.
0 low bandwidth.
1 medium bandwidth.
2 high bandwidth.
3 low bandwidth with antiresonance filter.
4 medium bandwidth with antiresonance filter.
5 high bandwidth with antiresonance filter.
Limitation Writing only.
Execution With disabled amplifier and ENABLE signal activated,
or enabled amplifier and motor at standstill (zero speed).
Note When executing this procedure, the speed loop bandwidth can be selected (low, medium or
high). These values correspond to the cut-off frequency for a 45° speed loop phase shift.
The reading indicates the previously selected bandwidth (0, 1, 2, 3, 4 or 5).
Before executing this instruction, check for free motor shaft rotation over one revolution, that is
not dangerous for the operator.
The auto-tuning procedure is not required when the regulator parameters are known.

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Reduced stiffness at standstill PNU : 749

Reduce the speed regulator gain values at low speeds (below 100 rpm) when activated.
This parameter allows to reduce the motor vibrations in case of motor-load coupling backlashes.
Parameter 1 word.
= 0: disable the gains reduction,
= 1: enable the gains reduction.

Cogging acquisition procedure PNU : 875

Parameter None.
Limitation Writing only.
Note This procedure allows the automatic acquisition of the motor cogging torque value in order to
provide the motor cogging torque compensation.
The motor cogging torque compensation is only necessary for specific applications where
torque accuracy better than 1 % is required. When changing either the motor, the amplifier or
the EEPROM, the cogging torque acquisition procedure must be renewed.
The motor must first be disabled and uncoupled from the mechanical load. The ENABLE
signal (X4 connector) must also be active. Before executing the procedure, check for free motor
shaft rotation over one revolution, that is not dangerous for the operator. Disable the Reduced
stiffness at standstill command if selected, then execute an Auto-tuning procedure with the
High bandwidth and the Standard filter selection before starting the cogging torque acquisition
procedure. The motor shaft must not be disturbed during the cogging torque acquisition
procedure. The procedure is taking a few minutes because the motor is moving at low speed
over 1 or 2 revolutions in both directions. The acquired cogging torque value is automatically
stored in the amplifier memory during the procedure execution.

Cogging torque compensation PNU : 876

Enable the cogging torque compensation when activated.
Parameter 1 word.
= 0: disables the cogging torque compensation,
= 1: enables the cogging torque compensation.
Note The motor cogging torque compensation is only necessary for specific applications where
torque accuracy better than 1 % is required. When changing either the motor, the amplifier or
the EEPROM, the cogging torque acquisition procedure must be renewed. The cogging
acquisition procedure must first be executed before enabling the cogging torque compensation.

2.4 - Application parameters

Amplifier mode PNU : 720

Defines the amplifier operation mode (unwind/rewind, speed or torque).
Parameter 1 word
1 torque mode
2 speed mode with PI regulator
4 unwind/rewind mode
8 speed mode with P regulator
2
16 speed mode with PI regulator
Execution This instruction must be executed with disabled amplifier.
The amplifier is always configurated by default in unwind/rewind mode at power on.
Note As from firmware EPROM version 506.64, the amplifier operating mode is saved in the
parameter EEPROM.

Maximum motor speed PNU : 721

Defines the maximum motor speed value (and the speed scale as well) according to the application.
Parameter 1 word.
Limitation This parameter varies between 100 rpm and 14000 rpm.
Execution With disabled amplifier.

Motor rotation direction PNU : 722

This instruction allows to reverse the motor rotation direction with regard to the input command. It also reverses
the position feedback.
Parameter 1 word :
= 0: normal.
= 1: reversed.
Execution With disabled amplifier.

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Acceleration ramp PNU : 723

Defines the motor acceleration or deceleration time that corresponds to the maximum speed.
Parameter 1 word.
Unit ms
Limitation 1-16000
Note This parameter can only be used in speed mode.

Speed following error PNU : 724

Defines the limit value for the regulator speed error before the following error to be released.
Parameter 1 word.
Limitation This parameter varies between 0 rpm and 14000 rpm.
Execution With disabled amplifier.

Brake delay active PNU : 726

Defines the time between the brake release and the amplifier disabling.
Parameter 1 word
Unit ms
Limitation 0-16000
Note This parameter is not active when the amplifier is configurated in standalone mode. In
standalone mode the brake release and the amplifier disabling are simultaneous.

Brake delay inactive PNU : 727

Defines the time between the amplifier enabling and the brake inhibition.
Parameter 1 word
Unit ms
Limitation 0-16000
Note This parameter is not active when the amplifier is configurated in standalone mode. In
standalone mode, the amplifier enabling and the brake inhibition are simultaneous.

Manual brake control PNU : 728

This instruction enables or inhibits the brake.
Parameter 1 word.
0 disables the motor brake (relay closed).
1 activates the motor brake (relay open).
Limitation Writing only.

Saving in the EEPROM PNU : 729

Saves all amplifier parameters in the EEPROM.
Parameter none.
Limitation Writing only.
Execution With amplifier disabled.
Note All parameters modified by the other instructions (except for the sequence parameters) are not
saved. This instruction must be used to store them definitively in the amplifier.

Offset compensation PNU : 880

Execute the offset compensation procedure for the analog input 1 (ANin1).
Parameter none.
Limitation Writing only.
Execution With amplifier disabled.
Note The ANin1 input on the X4 connector must first be set at 0 volt before executing the offset
compensation procedure. If the analog input voltage value is higher than 0.5 volts, a procedure
error is generated. The offset value is automatically stored in the amplifier EEPROM at the end
of the procedure.
Remark The offset compensation procedure can also be executed by activating the Offset push button
on the amplifier front panel.

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2.5 - Unwinder/rewinder parameters

Amplifier configuration PNU : 742

Defines the amplifier input signals selection (tension set point, speed set point, torque set point, diameter value).
Parameter 1 word
bit description
0 Tension set point source
0 internal
1 Profibus (PZD3)

1 Speed set point source

0 Analog input Ain1
1 Profibus (PZD4)

2 Torque set point source

0 Analog input Ain1
1 Profibus (PZD5)

3 Diameter value source

0 Analog input Ain2
1 Profibus (PZD6)

The Tension set point selection allows to select the tension set point source when a tension control sequence is
executed. The effective tension set point can be either the tension set point value stored in the sequence
parameter or the current tension set point value received via the PROFIBUS process data words (PZD3).

The Speed set point selection allows to select the speed set point source when a Speed 1 or Speed 2 control
sequence type is executed. This choice is only valid when Analog speed reference has been selected during the
sequence programming. In this case, the effective speed set point can be either the current analog input 1 (ANin
1) voltage value or the current speed set point value received via the PROFIBUS process data words (PZD4).

The Torque set point selection allows to select the torque set point source when a torque control sequence is
executed. This choice is only valid when Analog torque set point has been selected at the sequence
programming. In this case, the effective torque set point can be either the current analog input 1 (ANin 1) voltage
value or the current torque set point value received via the PROFIBUS process data words (PZD5).

The Diameter value selection allows to select the diameter input source when Modulation by diameter sensor
or Ratio adaptation by diameter sensor have been selected in the control sequence. In this case, the effective
diameter value can be either the current analog input 2 (ANin 2) voltage value or the current diameter value
received via the PROFIBUS process data words (PZD6).

Execution This instruction must be executed with disabled amplifier.

Unwinder/rewinder software version PNU : 770

Reading of the unwinder/rewinder software version.
Parameter 32 bits in hexadecimal.
Example Version 506.14 is coded as 0x00050614

Profibus software version PNU : 771

Software version reading of the amplifier Profibus interface.
Parameter 16 bits in hexadecimal.
Example Version 4.21 is coded as 0x0421

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Amplifier error code PNU : 773

Reading of the amplifier error code.
Parameter 3 bytes

Byte 1 (low weight):

Bits Meaning Descriptions
0
1 I2 t I2 t
2 RDC Resolver converter error
3 POS Speed following error
4 MEM Memory error
5 BUS Profibus DP mode error
6
7 BUSY Procedure error
Byte 2:
Bits Meaning Descriptions
0
1 POWER Power stage error
2 RES Resolver cable interruption error
3 AP Power undervoltage error
4 ST Amplifier temperature error
5 TMOT Motor temperature error
6 CDG Watchdog error
7

Byte 3 (high weight):

Bits Meaning Descriptions
0
1 E2PPAR Parameters EEPROM checksum error
2 E2PSEQ Sequences EEPROM checksum error
3
4 SEQWR Sequence writing error
5
6
7

Motor position PNU : 774

Reading of the motor position.
Parameter 32 bits

Resolver value PNU : 775

Reading of the value provided by the resolver. This value is an absolute position over one revolution.
Parameter 16 bits

Master encoder position PNU : 768

Reading of the master encoder position.
Parameter 32 bits
Note The master encoder position can be reset by sending the value 0.

2.6 - Encoder output

Encoder output resolution PNU : 750

Defines the encoder output resolution.
Parameter 1 word: encoder resolution
Limitation The encoder resolution is limited by the maximum application speed.

Max. speed Max. encoder resolution

100-900 8192
900-3600 4096
3600-14000 1024

Execution With disabled amplifier.

Note The encoder output is only effective after the end of the encoder output programming
procedure.

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Encoder output marker pulse PNU : 751, 752, 753

Parameter Number of encoder pulses (1 - 16).
Phase shift with regard to the resolver marker pulse (0 - 65535).
Marker pulse width (16 - 32767).
Conversion Marker pulse phase shift: 65536 is equivalent to 360°.
Marker pulse width: 65536 is equivalent to 360°.
Limitation Number of encoder pulses: 1 - 16.
Phase shift with regard to the resolver marker pulse: 0 - 65535.
Marker pulse width: 16 - 32767.
Note The encoder output only takes into account these values after the end of the encoder output
programming procedure.

Encoder output programming PNU : 754

This procedure programs the encoder output with the parameters defined above.
Limitation Writing only.
Execution With disabled amplifier.
Note The execution of this procedure takes approximately 5 s.

Enable encoder output PNU : 755

This command allows to enable or disable the amplifier encoder output lines.
Parameter 1 word.
= 0: encoder output disabled (output lines at high impedance),
= 1: encoder output enabled (CA, /CA, CB,/CB signals active).
Note This parameter is not saved in the EEPROM. At the amplifier power up, the encoder output lines
status (enabled/disabled) depends on the SW2-3 switch position.

2.7 - Manual jog parameters

Speed in jog PNU : 763

Defines the internal speed set point value for the jog mode.
Parameter word
Unit % of the motor maximum speed value
Variation signed value -32767 to +32767
Conversion 1/327.67

Note This parameter is saved in % of the maximum motor speed value in rpm. If the maximum motor
speed value is modified, the jog speed value in rpm is modified accordingly.

Acceleration ramp in jog PNU : 764

Parameter This parameter, defined in ms, corresponds to the acceleration time from standstill up to max.
speed.
Limitation 1 - 16000
Note The minimum value depends on the motor and on the system inertia.

Deceleration ramp in jog PNU : 765

Parameter This parameter, defined in ms, corresponds to the deceleration time from max. speed down to
standstill.
Limitation 1 - 16000
Note This parameter value is also used for the motor STOP operation (braking with ramp).

2.8 - PID loop parameters

Scaling gain of the PID loop PNU : 830

Defines the signed scaling gain of the PID loop for a tension or speed 2 control sequence. The sign of this gain is
chosen in order to get a stable servo loop according to the feedback signal polarity. The absolute value of this
gain is chosen in order to get a stable servo loop according to the open loop gain value of the process.
Parameter 1 word.
Unit %
Conversion 1/327,67
Variation 327 to 32767 for the absolute value

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Proportional gain of the PID loop PNU : 831

Defines the proportional gain of the PID loop for a tension or speed 2 control sequence.
Parameter 1 word.
Conversion 1/512
Limitation 0 to 65535

Integral gain of the PID loop PNU : 832

Defines the integral gain of the PID loop for a tension or speed 2 control sequence.
Parameter 1 word.
Conversion 1/65535
Limitation 0 to 65535

Derivative gain of the PID loop PNU : 833

Defines the derivative gain of the PID loop for a tension or speed 2 control sequence.
Parameter 1 word.
Conversion 1/32
Limitation 0 to 65535

Speed variation limit PNU : 834

Defines the maximum value of the motor speed reference given by the PID regulator.
Parameter 1 word.
Limitation This parameter varies between 0 rpm and the maximum motor speed value in rpm.
Note This parameter refers to the motor speed value at the minimum diameter. The actual speed
variation limit on the motor is obtained by multiplying this value by the current gearing ratio gain.
Remark When the TDI input (X2 connector pin 22) is activated during a tension control sequence, the
PID regulator output is set at 0.

2.9 - Gearing ratio calibration parameters

Diameter low-pass filter PNU : 840

Defines the time constant of the first order filter that acts upon the diameter measurement signal or the encoder
ratio measurement signal.
Parameter 1 word.
Unit ms
Variation 1 to 10000

Diameter sensor value for min. diameter PNU : 841

Defines the voltage value provided by the diameter sensor when the spool is empty (minimum diameter).
Parameter 1 word.
Unit Volts
Conversion 1/3276,7
Variation 0 to 32767

Diameter sensor value for max. diameter PNU : 842

Defines the voltage value provided by the diameter sensor when the spool is full (maximum diameter).
Parameter 1 word.
Unit Volts
Conversion 1/3276,7
Variation 0 to 32767

Diameter sensor value PNU : 843

Reads the voltage value provided by the diameter sensor. The former parameters can be easily initialised
according to the following method:
In a first time, an empty spool corresponding to the minimum diameter is put on the machine and the voltage
value read is entered in the Diameter sensor value for min diameter parameter.
Then, the same operation is executed with a full spool in order to initialise the Diameter sensor value for max
diameter parameter.
Parameter 1 word.
Unit Volts
Conversion 1/3276,7
Variation 0 to 32767

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Spool diameter ratio PNU : 844

Defines the ratio between the minimum and maximum diameter values of the spool to be unwound or rewound.
Parameter 1 word.
Unit min/max ratio (≤ 1)
Variation 328 to 32767
Conversion 1/32767

Gearing ratio PNU : 845

Reads the current gearing ratio value.
Parameter 1 word.
Variation Spool diameter ratio value to 32767
Conversion 1/32767

Diameter sensor value for max. gains PNU : 846

Defines the voltage value provided by the diameter sensor which gives the maximum value for the speed
regulator gains according to the Speed regulator gain ratio parameter.
Parameter 1 word.
Unit Volts
Conversion 1/3276,7
Variation 0 to 32767

Speed regulator gain ratio PNU : 847

Defines the ratio between the maximum gain value of the speed regulator for the full spool and the rated gain
value of the speed regulator for the empty spool. The speed regulator gains are automatically adapted according
to this ratio when the spool diameter sensor value is varying between the Diameter sensor value for min.
diameter and the Diameter sensor value for max. gains.
Parameter 1 word.
Unit max/min ratio (≥ 1)
Conversion 1/16
Variation 16 to 16000

2.10 - Tension control parameters

These parameters are only active for a tension control sequence. The tension controller structure used in this
case is presented below :
Internal speed set point
or
Master encoder gearing
Tension error + TER output Proportional
tolerance control gain
- + Speed ref
+
Tension Stretching + Reversed Error Integral + Speed + Gearing
set point ramp error sign scaling gain gain variation
limit ratio
+1 or -1 0.01 to 1
-
Derivative
+
gain
Input Undertension Overspeed
filter limit
+ + limit
Tension
ANin1 - sequence -
tension error
measurement

Tension measurement low-pass filter PNU : 860

Defines the cut-off frequency at -3 dB of the first order low-pass filter that acts upon the tension measurement.
Parameter 1 word.
Conversion Frequence (Hz) = 1000/pi*Ln(65536/parameter)
Limitation This parameter can take a value between 2832 (1000 Hz) and 61545 (20 Hz).

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Tension measurement value PNU : 861

Reads the voltage value provided by the tension sensor (dancer or load cell).
Parameter 1 word.
Unit Volts
Conversion 1/3276,7
Variation -32767 to +32767

Tension error tolerance PNU : 862

Defines the limit value of the regulator tension error for the TER logic output to be activated when the tension set
point is reached in the tension control sequence.
Parameter 1 word.
Unit %
Conversion 1/327,67
Variation 0 to 32767
Note 100 % correspond to 10 Volts in the tension measurement scale

Overspeed limit PNU : 863

This parameter allows to detect a dancer fault (blocking or failure) when the motor speed reference value is
exceeding this parameter value. In this case, a tension sequence error is generated.
Parameter 1 word.
Limitation This parameter varies between 0 rpm and the maximum motor speed value in rpm.
Note This parameter refers to the motor speed value at the minimum diameter. The actual overspeed
limit on the motor is obtained by multiplying this value by the current gearing ratio gain.

Undertension limit PNU : 864

This parameter allows to detect the material braking when the dancer or the load cell tension measurement value
drops below this parameter value. In this case, a tension sequence error is generated.
This parameter is also used into the ratio init sequence as the start point for the dancer displacement.
Parameter 1 word.
Unit Volts
Conversion 1/3276,7
Variation -32767 to +32767
Note When the dancer or the load cell tension measurement value at the start of the tension
sequence is below the Undertension limit parameter value, the material braking detection is
disabled during the material stretching time and activated only when the tension set point is
reached.

Sequence error link PNU : 865

This parameter defines the sequence number to be executed when a tension sequence error is generated. When
a tension sequence error is generated, the tension control sequence is immediately stopped. Then the sequence
number indicated by the Sequence error link parameter is automatically executed.
Parameter 1 word.
Variation 0 to 63 number of the sequence
-1 no link
Note If the number of the sequence is not defined (-1 value), in case of a tension sequence error, the
motor will stop with the deceleration ramp.

2.11 - Torque control parameters

The material force value variation versus the spool diameter ratio is shown on the following diagramme:

Torque
Diameter

Torque set point

Max. diameter x [1+(Overtorque factor (%)/100)]

Torque set point

Max diameter

Diameter
Max. diameter

Min. Diameter Diameter ratio 1

Max. Diameter for overtorque

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Overtorque factor for minimum diameter PNU : 870

This parameter allows to increase the material force value for the minimum spool diameter when starting a spool
rewind. The actual torque set point value for the minimum diameter is calculated as follow : actual torque set point
= Torque set point x Spool diameter / Max diameter x [1+(Overtorque factor (%)/100)].
Parameter 1 word.
Unit %
Variation 0 to 16383
Conversion 1/163,83

Diameter ratio range for overtorque PNU : 871

This parameter defines the spool diameter range for increasing the torque set point. When the diameter ratio
exceeds this value, the actual torque set point is continuously decreased down to the torque set point value
corresponding to the max. diameter.
Parameter 1 word.
Unit min/max ratio (less or equal to 1)
Variation from Spool diameter ratio parameter value to 32767
Conversion 1/32767

Overspeed limit PNU : 863

This parameter allows to detect a material braking in a winding application with a torque control sequence where
it is necessary to set the Speed set point parameter value higher than the line speed value in order to reach the
current limitation during the winding operation. When the motor speed value is exceeding this parameter value
during the torque holding time, because of a material braking, a torque sequence error is generated.
Parameter 1 word.
Limitation This parameter varies between 0 rpm and the maximum motor speed value in rpm.
Note This parameter refers to the motor speed value at the minimum diameter. The actual overspeed
limit on the motor is obtained by multiplying this value by the current gearing ratio gain.

Sequence error link PNU : 865

This parameter defines the number of the sequence to be executed when a torque sequence error is generated.
When a torque sequence error is generated, the torque control sequence is immediately stopped. Then the
sequence number indicated by the Sequence error link parameter is automatically executed.
Parameter 1 word.
Variation 0 to 63 number of the sequence
-1 no link
Note If the number of the sequence is not defined (-1 value), in case of a tension sequence error, the
motor will stop with the deceleration ramp.

2.12 - Sequence Reading/Writing

A sequence is defined by a list of parameters (PNU 782 to PNU 811):

- Sequence control
- Tension/Torque
- Speed
- Acceleration
- Deceleration/Stretching
- Running/Holding/Time out
- Ratio
- Next sequence
- Counter
- Jump
- Condition
- Logic outputs

All sequences are saved in the EEPROM. The direct access to a sequence is not possible. The transfer requires
a buffer: command PNU 780 allows to transfer the EEPROM parameters to the buffer and command PNU 781
allows to transfer the buffer parameters to the EEPROM. The writing or reading of the buffer parameters are
made by commands PNU 782 to PNU 811.

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Reading of a sequence PNU : 780

Parameter 0-63 sequence number
Limitation Writing only.
Note This instruction transfers the sequence parameters from the EEPROM to the buffer. This allows
the parameter values to be read in the buffer (see below).

Writing of a sequence PNU : 781

Parameter 0-63 sequence number
128 checksum
Limitation Writing only.
Note This instruction transfers the sequence parameters from the buffer to the EEPROM. The
sequence parameters must of course be previously written in the buffer (see below).
When all sequences are written, a sequence must be written with a value of 128; this allows to
update the checksum in the EEPROM (otherwise, the amplifier will indicate an EEPROM fault at
its next powering). The writing in the EEPROM is not instantaneous; wait at first for the amplifier
reply before writing other parameters.

All instructions below allow the access to the parameters of the sequence contained in the buffer.

Sequence control PNU : 782

Parameter bit description
0-3 define the sequence type
0 non valid sequence
1 ratio init sequence
2 tension sequence
3 speed 1 sequence
4 speed 2 sequence
5 torque sequence.
4-7 reserved.
8 -10 define the triggering for the logic inputs:
0 End
1 Begin
2 Tension
3 Speed
4 Torque
11-12 define the sequence set point selection:
0 internal set point
1 set point via analog input or Probibus input
2 set point via master encoder input
13-14 define the sequence gearing ratio adaptation mode:
0 constant ratio value
1 adaptation by the diameter sensor
2 adaptation by the master encoder / motor speed ratio
15 = 0 conditional start
= 1 conditional stop

Note To invalidate a sequence, just send this instruction with value 0; the other parameters will be
ignored.

Reference displacement for ratio init PNU : 783

This parameter defines the master encoder reference displacement value used for the ratio init sequence.
Parameter double word
Unit encoder edges
31 31
Variation -2 to +2

Speed set point PNU : 810

Defines the internal speed set point value for the sequence.
Parameter word
Unit % of the motor maximum speed value
Variation signed value -32767 to +32767
Conversion 1/327.67
Note This parameter is saved in % with regard to the maximum motor speed value in rpm. If the
maximum motor speed value is modified, all the sequence speed set point values in rpm are
modified accordingly.

CHAPTER 9 – Parameter setting by Profibus 69

 SMT-BD1/t

Tension set point/Torque set point/Speed set point offset PNU : 794
This parameter defines either:
- the material tension set point value for a tension control or ratio init sequence or,
- the motor torque set point value for a torque control sequence or,
- the offset value of the analog speed set point for a speed 1 control sequence.
Parameter word
Conversion 1/3276,7 for getting the tension set point value in V
1/327.67 for getting the motor torque set point value in % of the motor maximum current value
1/3276,7 for getting the offset value of the analog speed set point in V

Gearing ratio gain/Speed ratio gain/Torque set point ratio PNU : 811
This parameter defines either:
- the master/slave gearing ratio gain for a tension or speed1 control sequence or,
- the speed ratio gain for a speed 2 control sequence or,
- the torque set point ratio for a torque control sequence.
Parameter word
Conversion 1/327,67 for getting the value in %
Unit % of the encoder gearing ratio for a tension or speed 1 control sequence
% of the speed set point value for a speed 2 control sequence
% of the torque set point value for a torque control sequence

Acceleration PNU : 785

This parameter defines the motor acceleration time for the sequence.
Parameter word
Unit ms
Variation 1 to 16000
Note The real minimum value depends on the motor and the inertia.

Deceleration/Stretching PNU : 786

This parameter defines either:
- the motor deceleration time for a speed control sequence or,
- the material stretching time for a tension control sequence.
Parameter word
Unit ms
Variation 0 to 16000
Note The value 0 allows to link up to another speed control sequence (parameter Next sequence)
without stopping the motor.

Running/Holding/Time out PNU : 787

This parameter defines either:
- the motor running time at constant speed for a speed control sequence or,
- the time for the material tension holding for a tension control sequence or,
- the time for the torque to be maintained for a torque control sequence or,
- the time out for a ratio init sequence.
Parameter word
Unit ms for the tension, torque and speed sequences
seconds for the ratio init sequence
Variation 0 to 16000

Next sequence PNU : 788

Parameter 0-63 number of the next sequence to be executed
-1 no link

Counter PNU : 789

Parameter word
Variation 1 - 32767
0 no counter
-1 conditional jump

Jump PNU : 790

Parameter 0-63 number of the link sequence for the counter loop or the conditional jump
-1 no link
Note For a conditional jump, the counter value must be -1

70 CHAPTER 9 – Parameter setting by Profibus

 SMT-BD1/t

Start conditions PNU : 791

This parameter defines the condition inputs for the start or the end of this sequence.
Parameter word
bit description
1-7 The inputs 2 to 8 must be set at 0.
9-15 The inputs 2 to 8 must be set at 1
Example Conditions: inputs 2 and 4 = 1, input 7 = 0
the value will be 0x0A40
Remark Input 1 is entering the X2 connector on pin 21 (Lin1) and cannot be activated by the serial bus
interface (PROFIBUS DP). Inputs 2 to 8 have no physical existence and can only be
activated or desactivated on the serial bus interface.
The inputs can be used either as a sequence start condition or as a sequence stop condition
(this is defined by bit 15 of PNU 782). A sequence stop condition is only valid when the
running time or the holding time value is higher than 16000 ms. The sequence stop condition is
only tested when the sequence set point value has been reached (at the end of the acceleration
time or the stretching time).

Logic outputs PNU : 792

This parameter defines the effect on the logic outputs in this sequence.
Parameter word
bit description
0-7 mask s for outputs 1 to 8.
8-15 mask r for outputs 1 to 8.
The combination of the s and r masks gives:
rs
01 -> sets at 1 the corresponding output.
00 -> sets at 0 the corresponding output.
10 -> keeps the output unchanged.
11 -> reverses the output.
Example If no output is modified, the value is 0xFF00
Remark Output 1 is located on the X2 connector, pin 8 (Lout1), while outputs 2 to 8 have no physical
existence; they are only visible on the serial bus interface (PROFIBUS DP).

CHAPTER 9 – Parameter setting by Profibus 71

 SMT-BD1/t

Chapter 10 - Troubleshooting

1 - DIAGNOSTICS

A fault diagnostic can be made:

- by display: front panel LED display.
- by serial link: clear fault display in the BPCW software.
- by Profibus link: reading of the error code.

At an error triggering, the amplifier is disabled.

1.1 - SMT-BD1/t fault display

The 5 red LEDs available on the SMT-BD1/t front panel are indicating the fault type:
ON SYS

coded faults

PROTECTION DISPLAY CODE LED

Amplifier rated current overload: z 
2 2
- blinking display = Idyn signal (I t threshold is reached) It  
- continuous display = amplifier disabled (I2t fault)
PROFIBUS fault (DP mode) Profibus z {
{ z
Speed following error Position { {
{ z
Resolver cable interruption Resolver  z

Power stage failure:
- power supply overvoltage Power stage z z
- internal switch protection 
- short circuit between phases
Resolver converter failure R.D.C 
z 
Amplifier overtemperature °C Amp. z 
z 
Power supply undervoltage Undervolt.  z
z 
Motor overtemperature °C Motor z z
z 
Fault of the amplifier parameter memory EEPROM z 
z z
Amplifier automatic procedure: Busy z z
- blinking display = procedure running z z
- continuous display = operating error

: Led is unlit z : Led is lit

All these faults are stored in the amplifier, except for the "Undervolt." and "Profibus" faults.

1.2 - Fault reset

The reset of a stored fault can be made:

- via the fault RESET input of X4, pin 13,
- via the serial link,
- by the control issued from Profibus,
- by switching off the amplifier auxillary supply.

72 CHAPTER 10 – Troubleshooting
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2 - FAULT FINDING

2.1 - System fault

If the red "SYS" LED is lit at power on, the logic board is defective.
* Check that the EPROM (firmware memory) is correctly plugged on the amplifier.
* Check that the EPROM firmware version is correct.
* Check for no conducting dust that may involve short-circuits on the amplifier logic board.

2.2 - Non stored faults

2.2.1 - BUS FAULT (PROFIBUS)

This fault is only displayed when the Profibus communication is interrupted.

The fault is cancelled as soon as the communication is restored.

2.2.2 - "UNDERVOLT." FAULT

If the fault occurs when starting the amplifier:

* Check that the power supply is on.

If the fault occurs during the operation:

* Check that the power supply connections are correct
* Check that the power supply voltage value is correct

2.3 - Stored faults

If a fault occurs on the amplifier, it can generate the detection of several other faults which are only a
consequence of the initial one. In order to make diagnostic and maintenance easier, the faults are displayed and
processed with the priority described below. For safety reasons, the power must be turned off for the cancelling of
some faults that requires the handling of the amplifier; in this case, the RESET is automatic when power is turned
on again. If power is not turned off, do not forget to make a RESET immediately after the fault is cancelled.

2.3.1 - "BUSY" FAULT

- If the BUSY fault is continuously displayed after applying power to the amplifier, the AUTOTEST procedure
has failed and the amplifier is not ready for operation.

- If the BUSY fault is continuously displayed after the execution of the AUTOPHASING function, the procedure
has failed because of an external cause and the calculated parameters are wrong. Check that the ENABLE
input is actually activated. Then check that the motor is unloaded and the shaft movement is free during the
procedure.

- If the BUSY fault is continuously displayed after the execution of the AUTOTUNING function, the procedure
has failed because of an external cause and the calculated parameters are wrong. Check that the ENABLE
input is actually activated. Then check that the motor shaft movement is free during the procedure.

- If the BUSY fault is continuously displayed after the execution of the OFFSET function, the procedure has
failed because of an external cause and the calculated offset is wrong. Check that the ENABLE input is
actually desactivated. Then check that the input voltage value on the analog input 1 is less than 0.5 Volts.

2.3.2 - "EEPROM" FAULT

- Check for the presence of the EEPROM and check its correct orientation.

- If the fault remains, the EEPROM is not correctly initialised (wrong checksum value) or is not compatible with
the amplifier software.

- This fault may occur if the motor is enabled during a parameter saving or during a sequences transfer
between the PC and the amplifier.

- This fault may also occur if the cogging torque compensation has been enabled and the parameters saved in
the EEPROM without doing the cogging acquisition procedure.

CHAPTER 10 – Troubleshooting 73
 SMT-BD1/t

- To cancel this fault, if it is:

* due to the parameters, renew the amplifier parameter setting and the parameter saving,
* due to the sequences, send the sequences file to the amplifier again.
* due to the cogging, disable the cogging torque compensation and save parameters to EEPROM or renew
the cogging acquisition procedure.

2.3.3 - "°C MOTOR" FAULT

- If the fault occurs when commissioning the amplifier:

* Check the configuration of the MN and OP jumpers with regard to the type of thermal switch used in the
motor.
* Check the connection between the thermal switch and the amplifier on the X1 front panel connector or the
X6 rear connector of the rack.

- If the fault occurs during the operation:

* Check the motor temperature and look for the reason of this overheating (mechanical shaft overload, duty
cycle too high, ...).

2.3.4 - "°C AMP." FAULT

- Check for the correct fan type with regard to the rated current required.

Remark: This fault is only valid on amplifiers with current ratings 220/70 and 220/100.

2.3.5 - "POWER STAGE" FAULT

- If the fault occurs when starting the amplifier:

* Check the DC bus voltage and the terminal voltage of the power transformer secondary :
For the 220 VAC version of the amplifier DC bus < 370 VDC and V secondary < 260 VAC
For the 400 VAC version of the amplifier DC bus < 800 VDC and V secondary < 480 VAC

- If the fault occurs during the operation:

* Check the correct braking system operation during the deceleration phases,
* Check the sizing of the braking resistor with regard to the deceleration phases.
* Check for no short-circuit in the motor wiring and at the motor terminals.
* For amplifiers with 220/04 to 220/60 current ratings and 400 VAC range, check that the fan and the heatsink
configurations are correct with regard to the required rated current.

2.3.6 - "RESOLVER" FAULT

- Check the resolver connection on the amplifier connector X1.

- Check for the value of the P-RES components with regard to the resolver type.
- Check the connections between the resolver and the amplifier and at the resolver terminals.

2.3.7 - "R.D.C." FAULT

- If the fault occurs at the amplifier commissioning:

* Check that the values of the P-RES components with regard to the resolver transformation ratio are correct.

- If the fault occurs during the operation:

* Check that the motor speed does not exceed the speed limit defined below.
If Maximum speed < 900 rpm, then the speed limit = 900 rpm.
If 900 rpm < Maximum speed < 3600 rpm, then the speed limit = 3600 rpm.
If 3600 rpm < Maximum speed < 14000 rpm, then the speed limit = 14000 rpm.
Be careful about the torque mode operation where the motor speed is determined by the load.

2.3.8 - "I2T" FAULT

- Check the rated current value required with regard to the table of currents authorized in pulse mode cycle.

- Check the rated current of the amplifier defined in the Rated current parameter with regard to the current
required or the operation cycle.

74 CHAPTER 10 – Troubleshooting
 SMT-BD1/t

2.3.9 - "POSITION" (FOLLOWING ERROR) fault

Check that the Speed following error parameter value is compatible with the required amplifier operating cycle.
If necessary, increase the Speed following error parameter value.

3 - OPERATING PROBLEMS

3.1 - Motor does not move

- Check that the amplifier is on.

- Check that the power supply is on.

- Check the amplifier fuses (F1 and F2) and the motor connection.

- Check the wiring of the ENABLE logic input.

- Check that the amplifier is enabled.

3.2 - Motor supplied but no torque

- Check that the Maximum current and Rated current parameters have no zero value.

3.3 - Shaft locked, eratic oscillations or rotation at maximum speed

- Check the resolver wiring on the X1 connector and the mechanical mounting of the resolver on the motor.

- Check the value of the motor parameters (number of pole pairs, resolver wiring, motor phase).

3.4 - Discontinuous motor rotation with zero torque positions

- Check the connection of all three phase cables between motor and amplifier.

3.5 - Loud crackling noise in the motor at standstill

- Check that the Motor-Amplifier-Controller ground connections comply with the recommendations

3.6 - Loud noise in the motor at standstill and when running

- Check the rigidity of the mechanical transmission chain between motor and load (backlash and elasticity in
the gearboxes and couplings).

- Execute the AUTOTUNING command again by choosing a lower bandwidth (Medium or Low).

3.7 - Sequence not executed

If in "operation enabled" status, the motor does not move at a sequence start:
* Check if a start condition has been defined for this sequence and not been fulfilled.

4 - SERVICE AND MAINTENANCE

When exchanging an amplifier on a machine, proceed as follows:

- Check that the new amplifier has the same hardware configuration as the old one (including its address),
- Plug the parameter EEPROM of the old amplifier on the new one.

The new amplifier is configurated like the old one.

CHAPTER 10 – Troubleshooting 75
 SMT-BD1/t

Chapter 11 - Appendix

1 - USE OF THE POSITIVE & NEGATIVE LOGIC INPUTS

The logic inputs SEL1, SEL2, ENABLE, START, STOP of the logic X4 connector can be configurated in positive
logic (control by +24 V) or in negative logic (control by 0 V) as described below:

SEL 1

SEL 2

ENABLE

START

STOP

+24 V GND

POSITIVE LOGIC: E-F-G jumpers closed. Range: active at level: 5 < V < 30 V
Input impedance: 4,7 KΩ
Response time: 500 µs

NEGATIVE LOGIC: E-F-G jumpers open Range: inactive or open at level 5 < V < 30 V
Input impedance: 4,7 kΩ
Response time: 500 µs

NOTE
The inputs SEL1, SEL2, ENABLE, START,STOP must all be in positive logic or all in negative logic.

2 - USE OF THE "AMP. READY" & "POWER READY" OUTPUTS

When an amplifier fault is released, the AMP. READY output is immediately disabled (contact is open). After
elimination of the error source, the amplifier can be reset via pins 12 and 13 of the X4 connector.

If the amplifier control board must be kept active when a stored fault is released on the amplifier and the power
supply turned off, it is necessary to have an auxiliary supply for the logic board which is independent from the
power supply. In this case, the JK and KL jumpers of the logic board allow to inhibit or to release the "Undervolt."
fault when the amplifier is turned on.

JK jumper closed and KL jumper open configuration :

If the auxiliary supply is turned on before the main power supply, the "Undervolt." fault is displayed and can hide
a fault of lower priority. The AMP READY and POWER READY outputs are both inactive (contact is open) until
the power supply in on.

JK jumper open and KL jumper closed configuration :

The "Undervolt." fault is inhibited when turning on the auxiliary supply before switching on the main power supply.
The AMP READY output is then active and POWER READY remains inactive (contact open) until the main power
supply is on.

NOTE
The POWER READY output is only available on the BF rack housing (see BF RACK or BF-400 RACK manuals).
If the POWER READY signal is not used, make the JK jumper on the amplifier in order to have the AMP. READY
signal taking into account the power statement.

76 CHAPTER 11 – Appendix
 SMT-BD1/t

3 - SPEED FOLLOWING ERROR PROTECTION

During the amplifier operation, when the speed controller error reaches the Following error threshold value, the
Following error fault is released and the amplifier is disabled. The Speed following error threshold parameter
value must be adjusted at its minimum value according to the operation cycle in order to detect any uncontrolled
motor movements that may be dangerous for operator and machine.

CAUTION

Speed following error protection is inactive during the Auto-phasing and the Auto-tuning procedures. When the
amplifier is operating in torque mode (Torque control sequence), the speed following error protection is also
inactive.

4 - I2t PROTECTION

4.1 - Current limitation in Fusing mode

2
When the amplifier RMS current (I t) reaches 85 % of the Rated current, the Idyn signal output is activated and
the I t error display is blinking on the amplifier front panel. If the RMS current (I2t) has not dropped below 85 % of
2
2
the Rated current within 1 second, the I t fault is released and the amplifier is disabled (otherwise, the Idyn signal
2
and the blinking I t error display are both cancelled).
2 2
When the amplifier RMS current (I t) reaches the Rated current value, the I t protection limits the amplifier
current at this value.

The amplifier current limitation diagram in an extreme case (motor overload or locked shaft) is shown below.

Amplifier current

Maximum current
t1 = Idyn signal activation
t2 = current limitation
t3 = I2t fault

Rated current

1 second

Time

t0 t1 t2 t3

The maximum current duration before the release of the Idyn signal depends on the value of the Rated current
and Maximum current parameters. This value is calculated as follows:
2
T dyn (second) = t1 - t0 = 3.3 x [ Rated current (%) / Maximum current (%) ]

The maximum current duration before the limitation at the rated current also depends on the value of the Rated
current and Maximum current parameters. This value is calculated as follows:

T max (second) = t2 - t0 = 4 x [ Rated current (%) / Maximum current (%) ] 2

NOTE 1
The above formulas are valid as long as the Maximum current / Rated current ratio is higher than 3/2. When
the Maximum current / Rated current ratio is close to 1, the calculated values of Tdyn and Tmax are quite
below the real values. For example when Maximum current / Rated current = 1.2, the measured Tdyn = 3.4
seconds and the measured Tmax = 4.4 seconds. When the Maximum current / Rated current ratio is equal to
1, the I2t protection is no more disabling the amplifier but the current is limited at the Rated current value.

CHAPTER 11 – Appendix 77
 SMT-BD1/t

NOTE 2
The amplifier I2t signal can be displayed on the digitizing oscilloscope by selecting the "I2t" signal in the
“ Channel ” menu. The I2t signal threshold values according to the I2t protection mode described above are
calculated in the following manner :

Idyn signal activation threshold (%) = [Rated current (%)] 2 / 70

Current limitation threshold (%) = [Rated current (%)] 2 / 50

The corresponding amplifier RMS current value can be calculated according to following formula :
2 1/2
Amplifier RMS current (%) = [I t signal value (%) x 50]

CAUTION

In Fusing mode, the amplifier Rated current value must be adjusted in order to be lower or equal to the
Maximum authorized rated current of the amplifier.

4.2 - Current limitation in Limiting mode

2
When the amplifier RMS current (I t) reaches 85 % of the Rated current, the Idyn signal output is activated and
the I t error display is blinking on the amplifier front panel. When the RMS current (I2t) drops below 85 % of the
2
2
Rated current, the Idyn signal and the blinking I t error display are both cancelled.

When the amplifier RMS current (I2t) reaches the Rated current value, the I2t protection limits the amplifier
current at this value.

The amplifier current limitation diagram in an extreme case (motor overload or locked shaft) is shown below.

Amplifier current

Maximum current
t1 = Idyn signal
t2 = current limitation

Rated current

Time

t0 t1 t2

The maximum current duration before the release of the Idyn signal output (t1 - t0) and before limitation at the
rated current (t2 - t0) is calculated the same way as for the Fusing mode.
2
The I t signal threshold values and the amplifier RMS current value on the digitizing oscilloscope, are also
calculated the same way as for the Fusing mode.

CAUTION

In Limiting mode, the amplifier Rated current value must be adjusted in order to be lower or equal to the
Maximum authorized continuous current of the amplifier.

78 CHAPTER 11 – Appendix
 SMT-BD1/t

5 - MASTER/SLAVE CONFIGURATION

The following master/slave amplifiers connection schemes allow to easily modify the master and slaves
configuration of the machine according to the unwind/rewind process via the Profibus link.

5.1 - Reversible master/slave gearing operation with two SMT-BD1/t amplifiers

SMT-BD1/t # 1 SMT-BD1/t # 2
X2 connector wiring for X2 connector wiring for
Master/Slave configuration Master/Slave configuration

X2 X2

CA 4 13 IA

/CA 3 12 /IA

CB 6 15 IB

/CB 5 14 /IB

GND 7 7 GND

IA 13 4 CA

/IA 12 3 /CA
IB 15 6 CB
/IB 14 5 /CB

When amplifier #2 is executing a control sequence with the « Master encoder gearing » set point selection,
amplifier #1 is operating as the master and amplifier #2 is operating as the slave.
When amplifier #1 is executing a control sequence with the « Master encoder gearing » set point selection,
amplifier #2 is operating as the master and amplifier #1 is operating as the slave.

CAUTION

If both amplifiers are executing a sequence with the « Master encoder gearing » set point selection, the
master/slave configuration is basically instable and both motors can run up to their maximum speed.

NOTE:
In this wiring configuration the encoder output lines can be enabled on both amplifiers at the same time without
any problem.

CHAPTER 11 – Appendix 79
 SMT-BD1/t

5.2 - Configurable master/slave gearing operation with more than two SMT-BD1/t amplifiers

SMT-BD1/t # 1 SMT-BD1/t # 2 SMT-BD1/t # 3

X2 connector wiring for X2 connector wiring for X2 connector wiring for
Master/Slave configuration Master/Slave configuration Master/Slave configuration

X2 X2 X2

4 13 4

3 12 3

6 15 6

5 14 5

7 7 7

13 4 13

12 3 12
15 6 15

14 5 14

When the encoder output lines are enabled on one amplifier, it is operating as the master and the other amplifiers
are operating as slaves. The slave amplifiers encoder output lines must be disabled. A wrong configuration of the
amplifiers encoder output can damage the amplifier electronic if the encoder output lines are enabled in many
amplifiers at the same time.

Operation in Profibus control mode:

ƒ Put the SW2-3 switch in OFF position on all the amplifiers in order to have all the encoder output lines
disabled at power up.

ƒ After the amplifiers power up, the master amplifier is adressed via Profibus and its encoder output lines are
enabled by means of the Enable encoder output command.

Operation in stand alone mode:

ƒ Put the SW2-3 switch in ON position on the master amplifier and in OFF position on all the slave amplifiers at
power off.

ƒ After the amplifiers power up, the master/slave configuration is immediately valid.

CAUTION

Please check carefully the position of the SW2-3 switches before the first amplifier power up with the
master/slave cable connected to the X2 connector. The amplifiers electronic components can be damaged if
several switches are in ON position.

Please be also very careful when modifying the amplifiers master/slave configuration via the Profibus link:
encoder output lines must first be disabled on all amplifiers before enabling the master amplifier encoder output
lines.

80 CHAPTER 11 – Appendix
 SMT-BD1/t

6 - COGGING TORQUE COMPENSATION

The cogging torque in brushless permanent magnet rotating motors results from the interaction between the rotor
magnets and the stator slots. This disturbance is due to the difference of reluctance between the copper of the
windings and the iron of the stator teeth. For a given motor, the cogging torque can be easily evaluated by simply
moving the motor manually when the amplifier is disabled. The Cogging torque compensation available in the
SMT-BD1/t amplifier allows to cancel the motor cogging effects for specific applications where torque accuracy
higher than 1 % is required.

Proceed as follows for the cogging torque compensation setup :

Start the amplifier commissioning and adjustment as described in chapter 6.

Uncouple the motor from the load in order to avoid any external disturbance on the shaft during the cogging
torque acquisition procedure.

Disable the Reduced stiffness at standstill command if selected, then execute an Auto-tuning procedure with
the High bandwidth and the Standard filter selection.

Execute the Cogging torque acquisition procedure. This procedure is taking a few minutes because the motor
is moving at low speed over 1 or 2 revolutions in both directions. The acquired cogging torque value is
automatically stored in the amplifier EEPROM at the end of the procedure execution.

CAUTION

The motor shaft must not be disturbed during the cogging torque acquisition procedure.

Switch off the amplifier and couple the motor to the load.

Switch on the amplifier again, enable the Cogging compensation command and execute the Save parameters
to EEPROM procedure.

CAUTION

When changing either the motor, the resolver, the amplifier or the EEPROM memory, the cogging torque
acquisition procedure must be renewed.

7 - AMPLIFIER TYPES

SMT-BD1 / _ t - _ / _ _ / _ - T - BS
Serial link :
1 = RS 232 / 2 = RS 422

Amplifier voltage ratings: 220 VAC or 400 VAC

Amplifier current ratings:

4 A to 100 A (220 VAC) or 15 A to 100 A (400 VAC)

r = Additional heatsink for 220 VAC amplifiers

(total width = 18 TE)

w = Braking system for 220 VAC amplifiers (single-axis rack)

CHAPTER 11 – Appendix 81