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Brake control

4.2 Brake control

WARNING

Customer evaluation of the brake control!

The brake control is influenced by other functions (e.g. position con-

trol) depending on the process.

➢ Always evaluate brake control in the customer application.

➢ List and test possible braking scenarios.

➢ Check scenarios again if changes are made in the application.

Specification brake control F6-A / S6-A or F6-P S6-P

For more information, please refer to the instruction manual of the safety module

and the installation instructions of the control board.

Specification brake control F6-K / S6-K

The max. permissible current for the brake is 2A.

If a fault current is exceeded, error 68 "ERROR" overcurrent brake is triggered. The

response threshold of the error is between 2.5A and 4A.

Thus the brake control is short-circuit protected.

Preface3
Signal Words and Symbols3
More Symbols3
Laws and Guidelines4
Warranty4
Support4
Copyright4
Table of Contents5
Basic Safety Instructions14
Target Group14
Validity of this Manual15
Electrical Connection16
Start-Up and Operation16
Product Description17
Product Features17
Functional Overview17
Used Terms and Abbreviations18
Table 3-1: Used Terms and Abbreviations19
Motion Control20
State Machine20
Figure 1: State Machine20
Changes of the State Machine23
Control Word24
Statusword26
Display of the Actual State27
Affect the Behaviour of the State Machine28
Brake Control30
Specification Brake Control F6-A / S6-A or F6-P S6-P30
Specification Brake Control F6-K / S6-K30
Functionality31
Figure 2: Function Brake Control31
Characteristics of the Brake Control32
Influence of the Brake Control on the State Machine35
Times of the Brake Control35
Status of the Brake Control35
Errors and Warnings37
Errors37
Figure 3: Process of a Fault Reaction46
Figure 4: Example Co6349
Automatic Reset of Errors50
Warnings51
Protection Functions54
Overload (OL)54
Figure 5: OL-Counter54
Figure 6: Overload Characteristic55
Overload Power Components (OL2)56
Figure 7: Overload (OL2) Limiting Characteristic57
Figure 8: Increase OL2 for 60A Rated Current and 40°C59
Figure 9: Characteristic of the Current Limit in Relation to the Time61
Overtemperature Heatsink (OH)62
Figure 10: Overtemperature Heatsink (OH)63
Overtemperature Unit (OHI)64
Overtemperature Motor (Doh)65
Figure 11: Sensor Calculation by Excel67
Motor Protection Switch OH268
Figure 12: Tripping Motor Protection Switch69
Figure 13: Dependence of the Motor Protection Function70
Figure 14: Dependence of the Tripping Time70
Figure 15: Determination of the Motor Protection Function Data from the Characteristics of the71
Fieldbus Watchdog72
Maximum Current73
Effective Motor Load74
Figure 16: Effective Motor Load74
Maximum Acceleration or Deceleration75
Monitor the Speed Difference75
External Error / Warning Triggering77
Safety Stop from Safety Module77
Error Underpotential (up / Puready)78
Overvoltage82
Table 4-1: Overvoltage Level82
Table 4-2: Permanent Damage Due to Overvoltage82
Overspeed (ERROR Overspeed / ERROR Overspeed (EMF))83
Encoder Monitoring84
Limit Switch85
Input Phases Failure Detection88
Figure 17: Limit Switch88
Motor Phase Failure Detection89
UPS Mode (Not Available for Compact Cards)92
Power off Function92
Figure 18: Motor Operation93
Figure 19: Regenerative Operation94
Figure 20: Motor Operation Without Power-Off Function94
Figure 21: Regenerative Operation in Case of Mains Power Failure95
Figure 22: Control to Constant DC Link Voltage95
Figure 23: Circuit Diagram of the DC Control (Ppz=Number of Pole Pairs)100
Minimum Switch-Off Times101
Blockade Handling103
Monitoring of the Load108
Quickstop113
Minimum Current Monitoring in the Safety Module113
Figure 24: Minimum Current Course115
Braking Transistor116
Braking Transistor Handling116
Table 4-3: Switching Threshold for Braking Transistor117
Braking Transistor Protective Functions119
Power and Temperature Calculation at the Braking Resistor120
Sub-Mounted Braking Resistor Protection121
Fan Control123
Fan Control F6123
Fan Control S6-A / S6-K124
Terminals Short Circuit Protection124
Control Type K124
Control Type a124
Control Type P125
Operating Modes126
Operating Mode 1: Profile Position Mode127
Figure 25: Profile Positioning Mode (1)128
Figure 26: Profile Positioning Mode (2)129
Figure 27: Single Positioning129
Figure 28: Multi Positioning130
Figure 29: Restart of a Positioning130
Figure 30: Ramps in Profile Position Mode136
Figure 31: Motor Encoder with Initiator at Rotary Table140
Figure 32: Motor Encoder with Encoder and Initiator at Rotary Table141
Figure 33: Operation with Motor Model and Encoder with Initiator at Rotary Table141
Operating Mode 2: Velocity Mode142
Figure 34: Velocity Mode - Overview142
Figure 36: Target Speed Limitation143
Figure 37: Ramp Generator144
Figure 38: S-Curve Type = 0: Continuous S-Curve148
Figure 39: S-Curve Type = 4: Abort in S-Curve148
Figure 40: Pass Zero Type = 0: Not Zero149
Figure 41: Pass Zero Type = 8: Zero149
Figure 42: Calculation Example150
Operating Mode 6: Homing Mode151
Figure 43: Homing - Method 1154
Figure 44: Homing - Method 2155
Figure 45: Homing - Method 3 and 4155
Figure 46: Homing - Method 5 and 6156
Figure 47: Homing - Method 7 to 14 (23 to 26)157
Figure 48: Homing - Method 33 and 34158
Cyclic Referencing161
Operating Mode 8: Cyclic Synchronous Position Mode163
Figure 49: Cyclic Synchronous Position Mode - Overview163
Figure 50: Cyclic Synchronous Position Mode164
Figure 51: Example Interpolation165
Figure 52: Position Precontrol167
Operating Mode 9: Cyclic Synchronous Velocity Mode168
Figure 53: Cyclic Synchronous Velocity Mode - Principle168
Figure 54: Cyclic Synchronous Velocity Mode169
Operating Mode 10: Cyclic Synchronous Torque Mode172
Figure 55: Cyclic Synchronous Torque Mode - Overview172
Figure 56: Transfer Torque Setpoint Telegram -> Current Controller176
Figure 57: Torque Control and Overspeed Interception177
Operating Mode -2: Jog Mode in the CM Customer Modes Group178
Figure 58: Operating Mode Jog Mode178
Figure 59: Drive Profiles in Jog Mode182
Operating Mode-Independent Functions184
Figure 60: Torque Limit in All Quadrants185
Synchronisation187
Synchronous Time187
Optimizing the PLL188
Display Parameters189
Overview of the Ru Parameters189
Speed Displays193
Figure 61: Auxiliary Representation for the Calculation of Ru83[]194
Position Displays195
DC Link Displays196
Current Displays196
Torque Displays196
Power/Energy Displays197
Status Displays198
Ru75 Global Drive State198
Ru76 Drive State202
De115 Global Drive State Mask205
Figure 35: Velocity Mode205
Ru30 SACB Comm State206
Operating Hours Counter208
Real Time Clock208
System Counter208
5.10 Error Displays and Counter209
Error / Warning Displays209
Error Counter209
Error Memory210
5.11 Inverter Data211
Product Code212
Device Type, Software Version and Date213
Power Unit Identification215
Serial Numbers216
Motor Control217
Interface to the Encoder217
Terms and Definitions Used here217
Encoder Types218
Figure 62: Order Designation220
Figure 63: Structure Data Word Biss222
Table 6-1: Selection of Tested Encoders224
Position Resolution of Different Encoder Types228
Scan Time Snd Speed Fluctuations230
Status Parameters of the Encoder Interface and Encoder232
Parameters for the Encoder Adjustment233
Figure 64: Distance-Coded Reference Marks at Heidenhain240
Figure 65: Distance-Coded Reference Marks241
Operation of Absolute Linear Encoders251
Operation of Non-Absolute Linear Encoders (with and Without Reference Marks))254
Operation of Endat Multiturn Encoders with Battery Buffering255
Error and Warning Messages256
Store Data in the Encoder264
Encoder Serial Number266
Assignment of the Encoder Channels267
Motor Parameterization268
General268
Asynchronous Motor270
Figure 66: Equivalent Circuit Diagram Motor271
Synchronous Motor278
Figure 67: Equivalent Circuit Diagram Synchronous Motor279
Structure Overview295
Figure 68: Structure Overview Motor Model295
Magnetizing Current299
Figure 69: Generation of the Magnetizing Current300
Figure 70: Generation of the D-Component301
Current Control304
Measurement / Model Currents307
Currentlimitations309
Torque Adjustment310
Figure 71: Procedure of the Offset Measurement313
Figure 72: Simplified Representation of the Torque Offset Compensation317
Field Weakening318
Figure 73: Field Weakening Range Asynchronous Motor319
Figure 74: Maximum Voltage Controller321
Figure 75: Limit Value at Synchronous Motors322
Figure 76: Maximum Torque Depending on the DC Link Voltage for the Synchronous Motor324
Figure 77: Adjustment of the Torque Limiting Characteristic325
Figure 78: Limit Characteristic Curve327
Figure 79: Safety Distance to the Limit Characteristic328
Flux Controller (ASM)329
Figure 80: Flux Controller (ASM)329
Adaption330
Saturation Characteristic (SM)331
Figure 81: Torque Constant Depending on the Active Current332
Cogging Torque Compensation (SM)334
Control Mode (with Encoder / Encoderless)335
Figure 82: Cogging Torque Compensation335
Figure 83: V/F - Influence of the Additional Setpoint341
Figure 84: V/F - Influence of the DC Link Voltage Compensation342
Figure 85: V/F - Influence of the Maximum Degree of Modulation342
Figure 86: V/F - Influence of Dr48 V/F Characteristic Mode343
Model Control (ASM and SM)345
Figure 87: Model Deactivation Depending on the Motor Type348
Figure 88: Model Deactivation Depending on the Motor Type349
Figure 89: Model Deactivation Depending on the Motor Type350
Figure 90: Torque Limit Depending on the Setpoint Value353
Figure 91: Stabilisation Current Depending on Speed354
Figure 92: Model Stabilisation Term Depending on Motor Speed355
DC Link Voltage Compensation357
Identification358
Deadtime Compensation367
Switching Frequency Adjustment and Derating372
Interrupt Structure of the Software374
Figure 93: Time Allocation374
Hardware/Software Current Control380
Sinus Filter380
Figure 94: Connection Example Sinus Filter381
Speed Search386
Protection Functions (Ramp Stop, Current Limitation in Open-Loop (V/F) Operation)386
DC Braking389
Figure 95: Motor De-Excitation Time ASCL393
Speed Controller395
Overview395
Figure 96: Speed Controller Overview395
PI-Speed Controller396
Figure 97: Pi-Speed Controller396
Variable Proportional Factor ((System Deviation)398
Figure 98: Variable Proportional Factor398
Variable Proportional/Integral Factor (Speed)399
Figure 99: Variable Proportional Factor (Kp) / Integral Factor (Ki) with Cs08=10%, Cs09=20399
Speed Controller Adjustment Via Process Data400
Determination of the Mass Moment of Inertia401
Figure 100: High-Run Test with COMBIVIS401
Speed Controller PT1 Output Filter402
Figure 101: PT1 Output Filter402
Torque Precontrol403
Figure 102: Torque Precontrol Mode 1403
Figure 103: Torque Precontrol Mode 2404
Figure 104: Torque Precontrol Smoothing405
Figure 105: Not Linear Torque Precontrol407
Speed Setpoint Deceleration410
Figure 106: Overshoots in the Speed Setpoint410
Figure 107: Speed Setpoint Deceleration410
Figure 108: Optimal Precontrol Behaviour411
Torque Limits412
Physical Torque Limits412
Figure 109: Torque Limit in the Lower Speed Range412
Application-Dependent Torque Limits413
Position Control415
Position Values415
Figure 110: Position Control Overview416
Position Control Mode418
Position Controller418
Figure 111: KP Reduction in the Position Controller420
Following Error421
Structure Position / Speed Control422
Figure 112: Structure Position / Speed Control422
7 I/O Functions423
Digital Inputs423
Overview423
Figure 113: Digital Inputs Block Diagram423
Terminal State424
Selection of the Input Source425
External Setting of the Input State426
Inversion of the Digital Input State426
Filter for the Digital Inputs427
Controlword Inputs CW 1 / CW 2427
Figure 114: Filter of the Digital Inputs427
Figure 115: Filter of the Digital Inputs 2427
Figure 116: Di28 Cw Input 1429
Figure 117: Ds61: Cw Input 1429
Overview of the Evaluation of Digital Inputs431
Figure 118: Structure: Evaltuation of the Digital Input Status431
Functions of the Digital Inputs432
Figure 119: Digital Input Controlword434
Figure 120: Digital Input Controlword437
Figure 121: Example for the Index Filter443
Figure 122: Example Index Generation with Edge-Active Strobe444
Figure 123: Overview Index Generation with Filters and Strobe445
Overview of the Input Functions446
Digital Outputs448
Control Type K (COMPACT)448
Control Type a (APPLICATION)448
Control Type P (Pro)448
Functional Overview449
Display Internal Digital Outputs449
Figure 124: Digital Outputs Block Diagram449
Source Selection for the Digital Outputs450
External Setting of the Output State452
Output Signal Generation452
Figure 125: Comparator Level453
Function Blocks454
Figure 126: Filter for the Comparison Operation460
Variable Operands (Not Available for Compact Cards)461
Generation of the Linked Function Blocks462
Generation of the Internal Outputs463
Inversion of the Digital Output State465
Overcurrent of the Digital Outputs465
Analog Inputs466
Overview of the Analog Inputs466
Interface Configuration466
Figure 127: Analog Inputs Block Diagram466
Input Level of the Analog Inputs467
Calculation of REF and aux468
Mapping of REF and aux469
PID Process Controller470
Figure 128: PID Controller471
Analog Output477
Hardware Analog Output477
Virtual Analog Outputs477
Status LED478
Function of the Status Leds When Switching on479
Fieldbus State (NET ST)480
Drive Controller State (DEV ST)480
FS Status (Control Type a and P)480
Timer481
Function of Timer / Counter Blocks481
Number of Timers481
Parameter482
Overview482
Configuration of the Counting Unit483
Selection of the Start Bit483
Selection of the Reset Bit484
Selection of the Count Event484
Selection of the Bit for Reversing the Direction of Rotation485
Evaluation of the Counter485
Overview of the Counter Structure486
Figure 129: Timer / Counter Structure486
Object Directory487
Glossary487
Display of Parameters in COMBIVIS 6488
For Information on How to Connect to the Different Object Dictionaries on a KEB Device, See Chapter 9.5488
Communication in this Manual489
KEB Specific Parameters and Standard - Conform Parameters489
Figure 130: Display Object Data in COMBIVIS489
Ethercat Conform Parameters490
Canopen Conform Parameters490
Figure 131: Interpolation492
Parameter Conform to Other Fieldbus System Standards493
Volatile and Non-Volatile Parameters in the Object Dictionary494
Save Mode and Status of the Non-Volatile Memory495
Resetting of the Non-Volatile Parameters496
Figure 132: Loading of Default Values in Download Lists496
Checksum497
User Parameters497
Return Codes at Parameter Accesses498
10 Communication500
Communication Interfaces500
10.2 Diagnostic Interface501
Configuration of the Diagnostic Interface on the Devices of Control Type P501
Configuration of the Diagnostic Interface on the Devices of Control Type a and K506
Communication Modes508
10.3 Fieldbus Interface509
General Information about the Fieldbus Interface509
Use of KEB Diagnostic Tools Via the Fieldbus Interface509
10.4 COMBIVIS 6 Process Data Assistant510
Process Data Assistant for VARAN510
Figure 133: Process Data Assistant for VARAN510
Process Data Assistant for Ethercat511
Process Data Assistant for CAN511
Figure 134: Process Data Assistant for Ethercat511
Figure 135: Process Data Assistant for CAN511
10.5 Connection to the File System512
FTP Connection Set-Up512
Figure 136: Set the Baud Rate512
Figure 137: Disconnect the Connection to the Inverter513
Figure 138: Connect Drive Controller513
Figure 139: Copy Recipe513
11 Special Functions514
Compatibility Objects514
Power Limitation515
Liquid Cooling Management516
PI Controller516
Figure 140: Overview Controller516
Figure 141: Overview Controller Motor Cooling517
Manual Setting518
Pwm518
Figure 142: Structure PWM for Cooling Control518
Signal Output520
12 Safety Modules521
Fsoe Watchdog Time Type 3 (Only F6-A / S6-A)521
Fsoe Watchdog Time Type 5 (Only F6-P / S6-P)521
12.3 Safety Module Objects521
12.4 Safety Module Diagnostic Objects527
12.5 Safety Module Statusword531
Recipe Management (Storage of Parameter Files in the Drive Controller)532
Definition of Terms532
13.2 Basic Function532
Contents of the Configuration Lists532
Storage / Identification of the Recipes532
Limitations533
13.3 Parameter Structure534
Parameter "Recipe Options534
Input-Coded Recipe Selection534
Binary Coded Recipe Selection535
Parameter "Start Recipe536
Parameter "Recipe Status536
13.4 Operating Conditions538
14 Annex539
Inverter Parameters (Address / Resolution /Type)539
14.2 History of Changes540

Brand	KEB
Model	COMBIVERT F6
Category	Controller
Language	English

KEB COMBIVERT F6 Programming Manual

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