Copley Controls Xenus XSL-230-36 - 4: Troubleshooting Manual Phase with Halls and Encoder; 5: Verify Motor Pole Count

Using CME 2 Xenus XSL User Guide
148 Copley Controls Corp.
6.8.4: Troubleshooting Manual Phase With Halls and Encoder
To perform trapezoidal commutation after power-up or reset, the amplifier must receive good Hall
signals. After the first Hall transition is detected, then sinusoidal commutation can be performed.
In sinusoidal commutation, the amplifier uses the encoder for commutation while monitoring the
Halls to verify proper phase. If the error between the encoder count and Hall transition is too large,
then the Hall phase correction will not be performed and a phase fault will be triggered
Here are the most common causes of phase fault problems. Test for them in the order presented.
6.8.4.1 Problem: Wrong data.
1 Verify a rotary motor's pole count. See Verify Motor Pole Count (p. 148)
2 Verify the encoder line count OR a linear motor's magnetic pair length and the
encoder resolution.
6.8.4.2 Problem: Bad wiring of encoders.
If the Halls produce good trapezoidal commutation but a phase fault is persistent in
sinusoidal commutation mode, the encoder is highly suspect.
1 Verify the differential encoder signals.
2 Verify proper twisted shielded cable with good grounding.
3 Disable the amplifier and move the motor manually to test for phase fault.
4 If phase fault only occurs under command of current, make sure the motor power
cable is not bundled with the encoder cable.
6.8.4.3 Problem: Hall signals bad.
1 Make sure Halls change states as the motor moves through one electrical cycle.
2 Some Hall signals are noisy and require filtering. Check with motor manufacturer.
3 Some Halls are not properly calibrated to the motor manufacturer’s specification.
6.8.4.4 Problem: Hall transition wrong. The location of the Hall transition is not within +/-30
degrees.
1 Adjust Hall offset in smaller increments.
2 Verify Hall alignment.
3 Make sure motion is smooth.
6.8.5: Verify Motor Pole Count
Use this procedure if needed to troubleshoot wrong data.
6.8.5.1 Apply a current vector at zero Increment Rate to lock motor in position.
6.8.5.2 Turn the motor shaft and count the number of distinct locking positions.
6.8.5.3 Calculate the number of poles:
Poles = Number of Positions * 2
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