BGE 9010 engl - Главная страница | Микропривод Servo Drive BGE9010 Alcatel SEL AG Tel.07703/930-0 Dunkermotorenwerk Allmendstraße 11 Page 2/51 D-79848 Bonndorf/Schwarzwald

Digital Servo Drive BGE9010

Alcatel SEL AG Tel.07703/930-0 www.dunkermotoren.comDunkermotorenwerkAllmendstraße 11 Page 0/51D-79848 Bonndorf/Schwarzwald

OPERATING INSTRUCTIONS

Date : Nov.01 1999



Table of Contents:

1. Overall Description p. 3...61.1 BGE9010's Features p. 41.2 Technical data p. 6

2. How to use this operating instruction p. 7…82.1 Different needs - Different Solutions p. 8

3. Get connected - common part p. 9...183.1 "ENCODER" 8 Pins connector p. 9...103.2 "POWER" 4 Pins connector p. 113.3 "MOTOR" 8 Pins connector p. 12…133.4 "POWER OUT" 8 Pins connector p. 143.5 "INTERFACE" 4 Pins connector p. 153.6 "INPUT1", "INPUT2", "OUTPUT" connectors p. 16…173.7 Summary p. 18

4. Get started: Four quadrants mode or Velocity mode p. 19...224.1 Inputs / Outputs p. 19…214.2 Starting conditions p. 22

5. Get started: Current mode (Torque control) p. 23

6. Get started: On-line positioning mode p. 24…256.1 Inputs / Outputs p. 246.2 Starting conditions p. 25

7. Get started: Programmed mode p. 26

8. Initial operations p. 27…28

9. PC Configuration for Programming p. 29...309.1 Connection of Serial Interface p. 299.2 Configuration with Windows 3.x p. 299.3 Configuration with Windows 95/98 p. 30



10. BGE9010’s commands and system variables p. 31...3910.1 Commands p. 31…3410.2 Reading of System variables p. 3510.3 Modification of the system variables p. 3510.4 Read only system variables p. 3610.5 Read/Write system variables p. 37...39

11. Additional commands and system variables set p. 40…4111.1 Command set p. 4011.2 Parameter set p. 41

Annex A : Quick reference – Setting parameters p. 42Annex B : Quick reference – Connections p. 43Annec C : Formulas p. 44



1. Overall description:

The digital servo controller BGE9010 is designed to operate Dunker's brushless servo motorsseries BG43, BG63, BG63S, BG83 and BG83S. The BGE9010 can be used in variousapplications where simplicity, accuracy and flexibility are key factors.• Simplicity : Plug & Play 4 quadrants mode with holding position (zero-speed) feature.• Accuracy : the BGE9010 is a fully digital controller.• Flexibility : with its basic-like language programmability.

The BGE9010 has been designed for industrial environment and easy-to-setup connection: Theelectronics is enclosed in a metal frame for wall mounting – better protection against mechanicaldamage and reliable electromagnetic shielding; all terminals are easily accessible from the frontpanel.

A RS232 serial port makes the BGE9010 universal and suitable to various systems controlled by aPC or a PLC. Therefore, operating parameters like PID factors, motor speed value, acceleration,deceleration time, target position, etc… can be easily entered as digital values. Eight (8) opto-isolated inputs, eight (8) opto-isolated outputs and two (2) analog inputs are available to trigger thecontroller.

Exact positioning and speed control are ensured by an optical encoder -- type RE30-3-512+TI --directly mounted on the motor rear shaft. Its high resolution - 512 increments per rev., 2 channels inquadrature + index channel - allows the BGE9010 to reach 2048 positions per motor revolution.This corresponds to a positioning accuracy of 10 angular minutes (= 0.18 degree).Plus, the encoder's line driver provide a signal with a high interference immunity, up to 15m (50 ft.)encoder cable length.

The power stage is rated for a continous electric power of 1kVA, and a peak electric power of2,5kVA. The operating voltage range is 24 VDC...100 VDC.

The controller's dimensions -- 6.7" (7.9") x 2.6" x 4.1" (H x W x D) -- demonstrates the compactnessof the design. Please refer to Illustration 1.1. for details.



1.1 BGE9010's features :

• 4-quadrant mode, also nammed Velocity mode, - (default setting): speed control andaccurate zero-speed feature.

• Online positioning mode via RS232 interface for maximum flexibility.

• Current regulator mode: Torque control.

• Programmed mode: To use as alone machine control system.

• Speed to be set either as a digital value or as an analog voltage (+/-10 V), at choice.

• Digitally monitored motor position (actual position) and various controller's parameters.

• 8 digital inputs and 8 digital outputs - opto-isolated, 2 analog inputs.

• Very low torque ripple due to EMF-evaluated current commutation: near sinusoidalcommutation.

• Pulseless and smooth torque curve, even at low speed.

• Precise zero-speed control with holding torque.

• Connection for external ballast resistor.

• +24V, +10V, -10V available to supply potentiometers and opto-isolated I/Os.

• Overall protection features: overload, over-temperature, over-current, over-voltage, short-circuit, reversed polarity

• Visual indication by 2 programmable LEDs : status or failure

• Easy initial operation using factory preset parameters



Illustration 1.1: Servo controller BGE9010 front view and rear view.

170mm

INPU

T 1 Ph.D

MO

TOR

A+10V

P24V

A-10V

X24V

P+15V

OU

TPU

T

O4

INTE

RFA

CE

O7

O8

O5

O6

34

BGE9010

O2

O3

+A2

O1

I5

I6

I7

I8

I1

I2

I3

I4

INPU

T 2

LED

POW

ER-O

UT

21

A0V

A0V

P0V

H2

H1

P0V

X0V

SHLD

24..100V

104mm

+A1

-A2

E0V

E5V

A

A/

-A1

B/

B

ENC

OD

ER

I/

I

Ph.B

Ph.C

Ph.A

R

0V

x

POW

ER

+V

10A

Fuse

66mm

55mm

15mm

18mm

6mm

5mm

6mm

15mm 7,5mm

5mm

18mm

11mm

10mm

5mm

8mm

55mm

15mm

11mm



1.2 Technical Data:

Power supply

Operating voltage 24 V...100 VDC(doesn't have to be regulated)Residual voltage ripple < = 5 %Minimum admissible voltage 24 VDCMaximum admissible voltage 100 VDCUndervoltage tripping 20 VDCOvervoltage tripping 120 VDC

Current

Rated continuous current 10 A rmsPeak current for max.1 s 25 AOvercurrent limit 25 A

PWM frequency 15.625 kHz

Size, form Fully enclosed in a metal box withmounting bracket.170 (200) x 66 x 104 (H x W x D) mm6.7" (7.9") x 2.6" x 4.1" (H x W x D) inch

Operating conditions Ambient temp. - 20…to + 40 oC-4 F…to + 104 F

Free air circulationVertical mounting (cooling finsin upright vertical position)

Fuse: 10 AF (Slow blow)

Subject to modification.



2. How to use this operating instruction

Depending on the application and its needs, the first step is to select the mode the BGE9010will be used on. The next page gives some highlights of each mode. If you need additionalinformation to select the right operating mode, please review your application with our salesengineers.

In any case, we recommend to read all the sections related to the chosen operating mode.

4 Quadrants mode: Read Section 3 : Get connected - Common partSection 4 : Get started: 4 quadrant modeSection 8 : Initial operationsSection 9 : PC Config. with Hyper TerminalSection 10: Commands and System Variables

Current mode: Read Section 3 : Get connected - Common partSection 5 : Get started: Current modeSection 8 : Initial operationsSection 9 : PC Config. with Hyper TerminalSection 10: Commands and System Variables

On-line positioning mode: Read Section 3 : Get connected - Common partSection 6 : Get started: On-line positioning mode

Section 8 : Initial operationsSection 9 : PC Config. with Hyper TerminalSection 10: Commands and System VariablesSection 11: Additional comd. and parameter set

Programmed mode: Read Section 3 : Get connected - Common partSection 7 : Get started: Programmed modeSection 8 : Initial operationsSection 9 : PC Config. with Hyper TerminalSection 10: Commands and System VariablesSection 11: Additional comd. and parameter set

All modes Read also Annex A : Quick reference – Setting parametersAnnex B : Quick reference - ConnectionsAnnec C : Formulas



2.1. Different needs – Different solutions:

The BGE9010 is flexible enough to address various kind of applications. To do so, select themost suitable operating mode depending on your needs:

4 Quadrants mode orvelocity mode (#4)

(default setting)

Ideal mode for accuratespeed control. The pre-programmed inputs/outputs make theBGE9010 easy to set up.The position controlledzero-speed (stop)eliminates possibility ofdrift.

Current amplifier mode(#68)

Ideal when the motortorque has to beaccurately controlled. Atypical application for thatmode is screwdriving.

Online positioningmode (#0)

Ideal when the positioningcan’t be realized with aprogrammed sequence. APLC or a PC can sendcommands "On-line" tothe BGE9010 from itsRS232 port.

Programmed mode (#8)

Use 100% of theBGE9010’s capabilities.Inputs / outputs can beprogrammed to run sub-routines and sequences.Applications are infinite,and the friendly basic-likelanguage makes themeasy to solve.



3. GET CONNECTED - COMMON PART

3.1. "ENCODER" - 8 terminals connector:

If the encoder is not covered by an IP54 cover, then a standard 50cm (1.64 ft.) cable isavailable, to be completed by a separate 8 terminals connector for the BGE9010. Due to itslow degree of protection - IP20 -, this solution is not recommended for industrial application.

+5V Encoder power supply

Channel B

Channel B inverted

Index channel

Index channel inverted

Channel A

Channel A inverted

0V Ground

Encoder input conn.(BGE9010)

Pin Color Function1 Black 0V2 Grey A/3 Yellow A4 Pink I/5 Brown I6 White B/7 Green B8 Red +5V

Encoder conn.Pin Color Function1 n.c.2 Red +5V3 Black 0V4 n.c.5 Grey A/6 Yellow A7 White B/8 Green B9 Pink I/10 Brown I

Part numbers to order (2 separate, 1 of each):

50cm cable + 10 pins conn.SNR: 27573 37059MSTB 2.5/8-ST 8 poles conn. SNR: 24305 57030

n.c.: not connected



For safer and quicker installation, we recommend to use our specifically designed cablesfor encoders delivered with IP54 cover (with a 8 pin round conn.). They are availabe indifferent standard lengths for the motor types BG63/63S and BG83/83S equiped withincremental encoder RE30-3-512+TI+IP54 cover (/w 8 pins round connector):

Part number to order: 2.5m (8.2 ft.) long SNR: 27573 35710(complete cable) 5.0m (16.4 ft.) long SNR: 27573 35711

10.0m (32.8 ft.) long SNR: 27573 35712

Encoder input conn. (BGE9010)Pin Color Function1 Blue OV2 Grey A/3 Yellow A4 Pink I/5 Brown I6 White B/7 Green B8 Red +5V

Cable shield(Black)

Right angle encoderconnector

Encoder round connectorPin Color Function1 Yellow A2 Green B3 Red +5V4 Blue 0V5 Brown I6 Grey A/7 White B/8 Pink I/



3.2. "POWER" - 4 terminals connector:

+V + (plus) DC-supply voltage 24 V...100 V+24..100 V Doesn't have to be regulated.

0V - (minus) DC-supply voltage 0 V

SHLD Connect motor and encoder cable shields with cabinet ground here.

Rx External ballast resistance connection (between +V and Rx):10 Ohm at 90 VDC6,8 Ohm at 60 VDC4,7 Ohm at 40 VDC2,2 Ohm at 24 VDC

The ballast power may vary depending on the application. Ask us for moredetails.

+ Power supply voltage, +24V …+100V DC

- Power supply voltage, 0V

Shield / Ground connection

External ballast resistance connection.

10A / 250V Fast-Acting fuse, 1 1/4 x 1/4 "



3.3. "MOTOR" - 8 terminals connector:

Illustration 3.6.1 : "Motor" - 8 terminals connector.

For safer and quicker installation, we recommend to use our specifically designed cables.They are availabe in different standard lengths for the motor types BG83/83S. See next pagefor BG63/63S cables.

Pin Funct. Color1 Ph. A White2 Ph. B Brown3 Ph. C Green4 Ph. D Yellow5 H1 Grey6 +15V Red7 0V Black8 H2 Pink

Funct. Color PinPh. A White 8Ph. B Brown 7Ph. C Green 6Ph. D Yellow 5H1 Grey 4+15V Red 30V Black 2H2 Pink 1

Part numbers to order:2.5m (8.2 ft.) complete cable SNR: 27573 357055.0m (8.2 ft.) complete cable SNR: 27573 3570610.0m (8.2 ft.) complete cable SNR: 27573 35707

Motor phase A, White

Motor phase B, Brown

Motor phase C, Green

Motor phase D, Yellow

Hall sensor 1, Grey

Hall sensors power supply +15V, Red

Hall sensors power supply 0V, Black

Hall sensor 2, Pink



WARNING : Make sure to insert the right connector in the BGE9010 and theBG83/83S plugs. This cable has labels on each connector to guide the operator. Ifthe cable is connected the other way, the motor hall sensors will be damaged.

When using a BG63 or BG63S motor, we recommend to use our specifically designedcables. They are availabe in different standard lengths. The separate 8 terminals connector(for the BGE9010) has to be ordered also. For a safer and quicker installation, pleaseorder the following part numbers:

1.0 m (3.3 ft.) SNR: 27573 35758 (qty: 1)+ SNR: 24305 57030 (qty: 1)2.5 m (8.2 ft.) SNR: 27573 35759 (qty: 1)+ SNR: 24305 57030 (qty: 1)5 m (16.4 ft.) SNR: 27573 35735 (qty: 1)+ SNR: 24305 57030 (qty: 1)10.0 m (32.8 ft.) SNR: 27573 35736 (qty: 1)+ SNR: 24305 57030 (qty: 1)12.0 m (39.4 ft.) SNR: 27573 35737 (qty: 1)+ SNR: 24305 57030 (qty: 1)15.0 m (49.2 ft.) SNR: 27573 35738 (qty: 1)+ SNR: 24305 57030 (qty: 1)

Please, refer to illustration 3.6.1 to connect the cable with the spare connector.

If you have ordered a terminal box to protect the motor connector, then first pass the cablethrough it, and attach the spare connector.



3.4. "POWER OUT" - 8 terminals connector:

Additional notes:

X0V Isolated connection for external 0V reference to use with opto-isolated I/O.Then, a PC or a PLC can be safely connected to the BGE9010. If thecontroller is operated alone, then X0V and P0V can be connected to use theI/O.

X24 V Isolated connection for external +24V reference to use with opto-isolated I/O.Then, a PC or a PLC can be safely connected to the BGE9010. If thecontroller is operated alone, then X24V and P24V can be connected to usethe I/O.

A-10V -10 V output for external potentiometer, e.g. for speed setting on the analoginputs -A1 / +A1 and -A2 / +A2

A+10V +10 V output for external potentiometer

Note: The pot's resistance value to be connected between A-10 V and A+10 V must beapprox.. 4.7 kOhm.

eXternal 0V (input) for opto-isolated I/O

eXternal +24VDC (input) for opto-isolated I/O

0V (output), same as 0V power supply

+24VDC (output), 200mA max.

-10VDC (output).

0V (output) for A-10V and A+10V

0V (output) for A-10V and A+10V

+10VDC (output).



3.5. "INTERFACE" - 4 terminals connector:

Note: The terminals 2, 3 and 4 must be connected to a PC or a PLC serial interface RS232(SubD 9 pin conn.) as follows:

Pin1 pin4+pin6 Pin6 pin1+pin4Pin2 Tx (term.2) Pin7 n.c.Pin3 Rx (term.4) Pin8 n.c.Pin4 pin1+pin6 Pin9 n.c.Pin5 0 V (term.3)

For safer and quicker installation, we recommend to use our specifically designedinterface cable.

Illustration 3.8.1: Complete Interface cable, 2.5m (8.2 ft.) long, SNR: 27573 35715

n.c.

Tx : transmit data, output

0V floating

Rx : receive data, input



3.6. “INPUTS / OUTPUTS”:

For specific details about pre-programmed functions, please refer to sections 4.1 to4.4.

Differential input A1 (+/-10V)




Opto-isolated Input 1








Opto-isolated Output 1










The analog input circuit is shown bellow for information.

The opto-isolated input and output circuits are shown bellow for information. The referencepotentials are X0V and X24V on the "Power out" connector.

X0V

I1...I82,2k

O1...O8

X0V

X24V

Z 33V

Z 2,7

4,7k



3.7. Summary

Please, review with our sales engineers the necessary components.The BGE9010 (SNR: 49797 57902) is not delivered with mating connectors. Depending onthe number of I/O used you can order from us the necessary terminal blocks. There are 2 kindof connectors: with 4 or 8 positions:

For the "MOTOR", "POWER OUT", "ENCODER", "INPUT1" and "OUTPUT" connectors:From Dunkermotoren: SNR: 24305 57030From Phoenix Contact co.: ref: MSTB 2,5/8-ST-BD:1-8 order #:1765315

For the "INPUT2", "POWER" and "INTERFACE" connectors:From Dunkermotoren: SNR: 24305 57032From Phoenix Contact co.: ref: MSTB 2,5/4-ST-BD:1-4 order #:1751086

Note: For quicker and error-free connection we recommend to use our specific cables forthe MOTOR, ENCODER, and INTERFACE connections. See sections 3.1 to 3.5 for details. Ifso, as the cables are complete, the separate terminal blocks don't have to be ordered forthese functions.

Follow the next steps as described p.7



4. GET STARTED: Four quadrants (velocity) mode

4.1 Inputs / Outputs

In this mode Inputs and Outputs are dedicated to functions for an easy Plug and Playinstallation.

-A1 / +A1 The motor speed is proportional to that analog input if input I6 is high.See also details on VA1OFF and NMUL parameters.

-A2 / +A2 These analog inputs are not active with the default settings. To activate themas an external peak current limit, you need to set the parameter iext to 1. Seealso VA2OFF parameter.

I1 I1=+24 V: Controller EnableI1=0V: Controller Disable - The motor power stage is disabled.

I2 I2=+24 V: Motor start - The motor accelerate to the rated speed accordingto tr parameter.I2=0V: Motor stop - Depends on the input I7 status. If I7 is low, the motor willdecelerate according to tf parameter and hold to position. If I7 is high, brake

Differential Speed input (+/-10V)

Differential Speed input (+/-10V)

Differential peak Current input (+/-10V)

Differential peak Current input (+/-10V)

Power stage Enable (high) / Disable (low)

Motor Start (high) / Stop (low)

Motor direction CCW (high) / CW (low)

CCW direction Enable (high) / Disable (low)



is done by short circuiting the windings, thus, brake time and stop positionare not under program control.

I3 I3=+24 V: CCW directionI3=0V: CW directionThe controller responds to tf and tr parameters to reverse motor direction.

I4 I4=+24 V: CCW direction Enable - Limit switch not reached.I4=0V: CCW direction Disable - Limit switch reached. The motor breaks asfast as possible and holds the position. Doesn't use the tf parameter.

I5 I5=+24 V: CW direction Enable - Limit switch not reached.I5=0V: CW direction Disable - Limit switch reached. The motor breaks asfast as possible and hold the position. Does not respond to tf parameter.

I6 I6=+24 V: Analog input A1 is used to set the rated speedSee also details on VA1OFF and NMUL parameters.I6=0V: Digital speeds spd1 or spd2 are used to set rated speedSee input I8 for details.

I7 I7=+24 V: Select a short-circuit brake for input I2 - See I2 for details.I7=0V: Select a brake with ramp for input I2 - See I2 for details.

I8 I8=+24 VDC: Internal digital speed spd2 active (with I6=0V)I8=0V: Internal digital speed spd1 active (with I6=0V)** In mode 8 or 9 - programmed modes - if input I8=0 and auto=1 thenthe BGE9010 automaticaly launches the program.

CW direction Enable (high) / Disable (low)

Speed select : A1 analog input (high) / digital value (low)

Dynamic brake (high) / Ramp-stop with tf (low)

Digital speed spd2 (high) / spd1 (low) - **autostart (low) in mode 8 or 9



Digital outputs are opto-isolated, thus:• "low"= X0V applied on "Power out" connector.• "high"= X24V applied on "Power out" connector.

Warning: If the voltage reference outputs P0V/P24V are used to supply X0V and X24Vthen the outputs O1..O8 are no longer opto-isolated from the main powersupply.

Additional notes : (only if necessary)

O3 O3=high: Motor is rotating, i.e. n > 50 rpmO3=low: Motor stopped or speed n < 50 rpmThe accuracy of this speed indication is approx.+/-3 rpm

O4 O4=high: DisturbanceO4=low: No disturbanceIn case of electric disturbance - generally due to short time low voltage - theonly way to reset the controller is to power it off. Then, power it on. Typically,this trouble occurs when the power supply is to weak during fast motor ramp-up. Connecting an additional capacitor may help.

Input voltage OK, Ue>22V, true=ON

Overload (over-current or over-temperature), true=ON

Motor speed >50 rpm, true=ON

Electric disturbance / low voltage, true=ON - (BGE must be restarted)

BGE9010 disabled, true=ON (when I1=0)

Command Stop active ( when I2=0), true=ON

Limit switch CCW reached (when I4=0), true=ON

Limit switch CW reached (when I5=0), true=ON



Both LEDs, between "Input1" and "Input2" conn., are internally wired to the O1 and O4outputs:LED1 green lights up as soon as input voltage rates Ue > 22 V.LED2 red lights up as soon as a disturbance occurs (please refer to O4 notes).



4.2 Starting conditions

Due to the pre-programmed functions, the BGE9010 need to "see" some minimum conditionsto operate the motor. This can be done by making the following connections:

For further details about inputs, please refer to sections 4.1.

Internal speeds spd1 and spd2 have default setting values equal to 100 (100rpm) and 1000(1000rpm). There are two possibilities to select other speed values: either by changing thedigital values of spd1 and spd2 (then the serial link needs to be set up as explained in section3.5 & 9), or by connecting a potentiometer - as shown in section 3.4 - and by selectingexternal speed with S6 (I6=1) (can be done without RS232 connection).

It takes approximately 15 minutes to get the system connected and to get the first motorrotations, with the proposed precut cables.



5. GET STARTED: Current mode (Torque control)

This mode is not yet available.



6. GET STARTED: On-line positioning mode


Inputs / Outputs are pre-programmed as follows:

Input voltage OK, Ue>22V, true=ON

Overload (over-current or over-temperature), true=ON

Not active

Electric disturbance, true=ON - (BGE must be powered off to reset)

BGE9010 disabled, true=ON (due to I1=0)

Command Stop active (I2=0), true=ON

Limit switch CCW reached (I4=0), true=ON

Limit switch CW reached (I5=0), true=ON

CW direction Enable (high) / Disable (low)

Not active

Not active

Not active, but if auto=1, autostart is launched when I8 is low.

Differential input A1(+/-10V)




Power stage Enable (high) / Disable (low)

Motor Start (high) / Stop (low)

Not active

CCW direction Enable (high) / Disable (low)



When starting, it is recommended to set I1=0 ; I2=0 ; I4=1 ; I5 = 1 to prevent anyunexpected movement.



6.2 Starting conditions

First of all the BGE9010 must be set in the Mode 0:• Disable the current in the motor with Input1=0 in order to prevent any unexpected

movement.• Type : let mode 0• Type any other command or/and parameter settings to complete your settings:

e.g.: init 3 to recall default settings for BG83Slet tr 30 to change rise time to 30ms per 1000rpmlet ski 1000 to increase speed control loop

• Type : wini to save modifications in Eeprom.



7. GET STARTED: Programmed mode


In this mode, Inputs / Outputs are totally free to be programmed for customized applications.Refer to section 3.6 for details about I/O internal circuits.

The voltage outputs P24V and P0V can be connected to X24V and X0V., then, microswitchescan be used to set inputs high or low. Nonetheless, commutations coming from microswitchesare not "clean" and may cause some unexpected program behavior. It is recommended thento debounce the switches by software.



8. Initial operations:

Using the optional precut cables, its default settings and the I/O's preset functions, theBGE9010 is "Plug and Play". Basically, the BGE9010 can quickly be run in the 4 quadrantsmode without any RS232 connection. Thus, engineers can quickly focus on their application,and not on the connections.

Please, thoroughly follow steps 1 to 4:

1 - Connect the motor cable - see section 3.3 - to the motor and the BGE9010.

Warning: Observe correct polarity, even with precut cables. If missconnected,the motor and the controller can be damaged.

2 - Connect the incremental encoder cable - see section 3.1 - to the BGE9010.

3 - Connect the I/Os. If run in the 4 quadrants mode, please refer to section 4.2 for startingconditions.

4 - Connect the DC supply voltage (+24 V...100 VDC) according to section 3.2 details.Switch the power supply on. Then, the green LED must light up if the supply voltage iscorrect. Verify that the BGE9010's current consumption is approx. 340 mA @ 24 VDC.Then, switch it off.

Warning: If the current draw is significantly higher, there must be a wrongconnection. Immediately disconnect the power supply, and check connections!



Important note:

The BGE9010 is delivered with default settings, thus the user can easily and quickly get thefirst trouble-free motor movements. Nonetheless, depending on the motor used and therequirements, settings have to be modified in order to reach expected performances and tohave safe operations.

To optimize the BGE9010's parameters first of all the serial interface must be set up:

1. Please, refer to section 3.5 to get the BGE9010 connected to a serial port.2. Refer to section 9 to install the Hyper Terminal software and set up the first

communication.3. Refer to section 10 for communication / commands / settings.

We recommend to carefully read notes about the following commands andparameters :• init• init k• tr, tf• spd1, spd2• wini• info k

4. Refer to section 11 for additional command and parameter set when using the BGE9010 inOn-line positioning mode or Programmed mode.



9. PC Configurations with Hyper Terminal

9.1. Connection of the serial interface:

To have a full access to the BGE9010's parameters a PC equiped with a RS232 port can beused. The only necessary software is Hyper Terminal which is delivered with Windows. If thissoftware needs to be installed, it is downloadable on Hilgraeve's web site:www.hilgraeve.com. We recommend to use a version 4.0 or 5.0 with Windows 95, 98 and NT.Plug the INTERFACE cable - see section 3.8 for details - on COM1 or COM2, and go tosection 9.2 or 9.3 depending on your operating system.

9.2. Configuration with Windows 3.x:

a) Double-click on program "Terminal" available in the group named "Accessories". Thenopen "adjustments" and click on "Data Transmission". Go to "Connection" andselect the chosen port COM1 or COM2. Then enter the following Interface Parameters:

Bits per second 9600Data bits 7Parity evenStop bits 1Flow control none

b) Click on "Terminal-Emulation..." in the menu "Adjustments", and select "DEC VT-100(ANSI)" and "Local Echo".



9.3. Configuration with Windows 95 or 98:

We recommend to use Hyper Terminal version 4.0 or 5.0 with Windows 95, 98 and NT.The former versions are reputed not compatible with Windows. If you need to download a newversion of Hyper Terminal, please visit Hilgraeve's web site: www.hilgraeve.com

a) Click on START, PROGRAMS, ACCESSORIES, COMMUNICATIONS then selectHYPER TERMINAL.The parameters for a new connection have to be entered. First of all, give a name (e.g.BGE9010) and choose a symbol. OK. Then, click on "Connect using.." and select"Direct to COM1" or "Direct to COM2" depending on the chosen port. OK.Then enter the following Interface Parameters:

Bits per second 9600Data bits 7Parity evenStop bits 1Flow control none

OK

b) Go to FILE, PROPERTIES, SETTINGS , select VT100 in field EMULATION. Click onASCII-Setup and check Echo typed characters locally. OK. OK.

c) Save the session.



10. BGE9010's Commands and System Variables:

Make sure the INTERFACE cable is connected to the BGE9010 and the PC.Run the pre-configured BGE9010's session of HyperTerminal.Switch the BGE9010 power supply on.If the RS232 interface is connected and configured correctly, then in the Hyper Terminalcommunication window should appear the following message just after switching the powersupply on :

BGE9010 Vers: <firmware_date>

Write this <firmware_date> down in your operating instruction for reference.

Note: If this message does not appear on the screen, there might be a wrong connection, ora wrong configuration in Hyper Terminal. In this case, please proceed as follows:

• Switch the supply voltage off, wait till the LEDs are switched off, and apply the powersupply again. Check the Hyper Terminal window again.

• Check the RS232 connection : plug, port.• Check the terminal program configurations.

The cursor appears on the next line. The BGE9010 controller is ready to be programmed.

Warning: If the parameter auto has been previously set to 1, then the input I8 must be highwhen the BGE9010 is restarted. Otherwise, the BGE9010 restarts in the AutoStart mode andno communication can be done.

10.1. Commands:

Direct commands are described in this section. The commands may either be entered inlower-case or upper-case. Instructions are excecuted after the return key <enter> is pressed.

Command_name or parameter Read only or R/W Where_applicable

Explainations.

Where_applicable legend:Comm.: Only in communication mode with Hyper Terminal or DTERM / Comm.All Modes: Applicable in 4 Quadrant mode, On line, Current, and programmed modes.



info k Comm.

This command returns different groups of information depending on the variable k:

info 1: Returns the current loop parameters (id, ip, iki, ikp), the speed regulatorparameters (ski, skp, tr, tf, spd1, spd2, spdmin, spdmax), and the analog inputsparameters (va1off, va2off, nmul).

info 2: Returns the positioning mode settings (not relevant for the 4Q mode).

info 3: Returns system status like :digital inputs (in1...in8), outputs (out1...out8), thesupply voltage (vs) and the controller temperature (tmp).

info 4: Returns the mode used (mode), the ballast circuit parameters (brv and brt) andthe Hall sensors status (h1 and h2).

init Comm.

Recall the default settings stored in ROM. This command can be used to recover thefactory settings. However, if you decide to keep them after the BGE9010 is shut down youhave to save them in the EEPROM with the wini command (please refer to that commandfor details).Here are the settings applied with the init command :

brt=100 brv=120 id=10000 iext=0iki=128 ikp=400 ip=10000 mode=4nmul=187 pkp=50 ski=100 skp=40spd1=100 spd2=1000 spdmax=10000 spdmin=0tf=200 tr=200 tfs=20 va1off=0va2off=0 pvmax=4000 aposw=0 tposw=0



init k Comm.

Sets appropriate controller amplification values ski and skp for the following drives:

init 1: for BG43 :ski=100 skp=20 tf=50 tr=50 pkp=300 id=3000 ip=9000

init 2: for BG63S:ski=500 skp=200 tf=100 tr=100 pkp=200 id=6500 ip=18000

init 3: for BG83S:ski=200 skp=300 tf=200 tr=200 pkp=100 id=10000 ip=25000

For permanent storage, you must enter the wini command. See details next page.

Note: The nature of the load (inertia, friction, delay) significantly affects thedynamic behavior of the system. To optimize the speed and positioning controlthe parameters ski and skp can be modified. The factory settings are conservativein order to guarantee a stable behavior. Nonetheless, the following settings canbe entered for faster reactions.

For BG63S ski=1000 skp=200 For BG83Sski=4000 skp=300

let Comm.

Please refer to section 10.2

print Comm.

Please refer to section 10.1



wini Comm.

Stores the system variables into an Eeprom. If this command is not entered after anyparameter modification, then the previous settings will be recalled from the Eeprom duringthe next power on.

Attention: Prior to entering the command wini, be sure to disable the controller bythe mean of input I1 (I1=0).

Once the wini command is entered, a check sum is then calculated. If there is no error, thefollowing message will be displayed:

eeprom-chksum: xxxxx

where xxxxx is a 5-digit check sum. The value is not significant to the user.

In case of error - e.g.: if the command wini was entered while the motor was running - thefollowing error message might appear:

EEPROM - DATA NOT CORRECTcopy original parameter to backup please reset to test

In this case, the error can be deleted by switching off, then on the controller.

If the following message appears :fatal error - not able to repair - please make a new initialization..- init with factorydefault parameters.

First, the BGE9010 must be initialized, then enter the init command to recall the defaultsettings, enter any new parameters, then finally make sure the controller is disabled (I1=0)and use the wini command to save the settings into the Eeprom.



10.2 Reading of system variables:

Displaying the system variables is very easy. The syntax is the following:

Print<space>system_variable<enter>

The user can either use print or pr to request a reading. <space> and <enter> mean the keysSPACE and ENTER.

Examples: Type : print aspd <enter> or pr aspd <enter>BGE9010 replies: aspd=1000

The system_variable parameter in that example is aspd , meaning actual speed.

10.3 Modification of the system variables:

The command "let" is used to modify the system variables (when they are Read/Writevariables). The syntax is the following:

let<space>system_variable<space>value<enter>

<space> and <enter> mean the keys SPACE and ENTER.

Example: let tr 500 <enter>tr=500

The system_variable parameter in that example is tr , meaning time rise, or accelerationtime to reach 1000rpm from 0. This parameter has been changed to 500ms, and thecontroller aknowledged it.



10.4 Read only System variables:

The following system variables can be read with the command "print", yet they cannot bemodified:

aspd Read Only All Modes

Current motor speed (actual speed) in rpm. The value displayed corresponds to theaverage over 256 ms, with an accuracy of +/- 1 rpm. A minus sign indicates a CCWrotation when looking at the motor shaft from the front.

h1 , h2 Read Only All Modes

Status of motor Hall sensor H1 or H2. The returned value is either "0" or "1" ,corresponding to "low" or "high".

ia Read Only All Modes

Actual motor current in mA. The value displayed is an average measure over 256ms, withan accuracy of +/- 200 mA.

in1, in2, in3, in4, in5, in6, in7, in8 Read Only All Modes

Digital inputs status. Returned value: "1" or "0", corresponding to "high" or "low".Note: Typing info 3 reads all digital inputs at once.

led1 Read Only All Modes

Green LED status. Returned value: "1" or "0", corresponding to "ON" or "OFF".

out1 , out2, …. out8 Read Only 4Q, On-line

Digital outputs status. Returned value: "1" or "0", corresponding to "high" or "low".Note: Typing info 3 reads all digital outputs at once.

tmp Read Only All Modes

Temperature at the hottest point of the controller (in oCelsius).

vs Read Only All Modes



Input voltage at +VDC/0V in volt, with an accuracy of +/- 1 V.



10.5 Read/Write System variables:

The following system variables can be read with the "print" command, and modified with the"let" command:

auto R/W All Modes

If set and if input I8=0, the BGE9010 starts in AutoStart mode when powered on. Must beused only in Programmed modes (mode=8 or mode=9). Default setting is auto=0.

brt R/W All Modes

Ballast circuit maximum load time - unit is 5ms. e.g. let brt 50 means 50x5ms.

brv R/W All Modes

Ballast circuit threshold voltage in volt.

ip R/W All Modes

Peak current limit in mA. Value range of ip is 1000 to 25000. The motor current is limitedto this maximum value any time.

id R/W All Modes

Continuous current limit in mA. Value range is 1000 to 10000. The motor current can behigher than id for a short time, but never higher than ip. The current is limited to the idvalue by means of a time factor.

iext R/W All Modes

Motor current limitation is set externally (iext=1) by analog input -A2/+A2, or internally(iext=0) by system variable id . Default setting is 0.

Iki , ikp R/W All Modes

Secondary current controller amplification factors, with PI behavior.The factory presettings should not be modified.

inhibit R/W All Modes



If inhibit=1 the output stage is disabled, even if in1=1. Factory presetting is 0. Outputstage disabled means no current, no holding torque at the motor.

mode R/W All Modes

This variable defines the controller operating mode:mode=4: 4-quadrants mode with Sinusoidal commutation (factory presetting). Thisoperating mode has a very smooth-running (pulseless) characteristic,mode=5: like mode=4, but with block commutation. This operating mode is most suitablefor high rpm applications.mode=0: Online positioning mode.mode=68: Operation as current controller only.mode=8: Programmed mode, I/O can be programmed to execute sequences.mode=9: like mode=8, but with block commutation.

Warning: We recommend to disable the output stage ( I1=0 ) before changing theoperating mode. This prevents unexpected movement while the controller ischanging its mode. The command inhibit=1 can be used as well.

nmul R/W All Modes

Scaling factor for external analog speed input (-A1/+A1). The following formula applies:

nmul187300-solln = ( )**va1+ va1off

256

nsoll is the motor speed given when the voltage va1 is applied on –A1/+A1 input. Itdepends also on an offset value, va1off, and the factor nmul . Factory presettings areva1off=0 and nmul=187. This results in a speed of 3000 rpm when va1=10 V.

out1 , out2, …. out8 R/W Programmed

When read: returns value: "1" or "0", corresponding to "high" or "low". ORWhen write: Set or reset outputs x.

pkp R/W All Modes

Positioning controller Proportional amplification: Active when target speed = 0 (e.g. at"Stop"). Factory presetting is pkp=200. This parameter may be increased foroptimization, however, an excessive value may cause the controller to oscillate.



ski , skp R/W All Modes

Speed controller amplification factors with PI behavior. Factory presettings are ski=100and skp=40. These presettings are purposely low in order to get stable conditions. Thus,to improve the motor dynamic behavior it is recommended to optimize them. The init 1,init 2 and init 3 commands allow you to use preset parameters foe aid in start-up ofBG43, BG63S and BG83S motors (please refer to section 10.1).

spd1 R/W All Modes

Internal digital speed 1; factory presetting is 100 rpm.

spd2 R/W All Modes

Internal digital speed 2; factory presetting is 1000 rpm.

spdmax R/W All Modes

Maximum speed in rpm allowed in the 4Q-mode. Only positive integers may be preset.spdmax may be used for limiting speed. The factory presetting is spdmax=10000.

spdmin R/W All Modes

Sets a minimum speed limit in rpm. If the target speed - set by spd1, spd2 or the analoginput - is lower than spdmin then the speed is automatically set to 0. If the target speed ishigher, but lower or equal to spdmax, then the speed is not modified. Factory presettingis spdmin=0.

tf , tr R/W All Modes

Deceleration time (fall time) and acceleration time (rise time) in ms per 1000 rpm.

va1off R/W All Modes



Speed offset factor when speed is preset with the analog input -A1/+A1. The followingformula applies:

va1off=410*Uoffset,

where Uoffset is the offset voltage in volts at the analog input.



11. Additional command and system variables set

This additional set is applicable for the On-line positioning and Programmed modes only. Itcomes in addition to the command and parameter sets introduced in section 10.

11.1 Command set

estop command On-line / Programmed

Emergency stop: Stop immediately the motor movement according to tfs parameter.

mov k command On-line / Programmed

Absolute positioning command. The parameter k is the position to reach in number ofincrements (2048 increments per motor revolution). The position counter is 32 bits wide, i.e.:-231 to +231, with 231=2,147,483,648. Only integer values within that range are accepted.When the BGE9010 is reset by soft or by power supply, the actual position is 0.

movr k command On-line / Programmed

Relative positioning command. The parameter k is the number of increments (+/-) to beadded or subtracted from the actual position.

rpo command On-line / Programmed

Reset position: Set the actual position as absolute position 0. If the motor is running at thetime the command is sent then the motor is stopped according to tf parameter first.Excecution time is 10ms.

<strg><0> command On-line / Programmed

Does a software reset.



11.2 Parameter set

Apos Read only On-line / Programmed

Actual position: give the actual absolute position.

Aposw Read only On-line / Programmed

Actual position window (to be described).

Intpos Read only On-line / Programmed

In target position: If the motor has reached the targeted position and the actual position iswithin the window defined by tposw, then this parameter equals 1, otherwise 0.

Mvend Read only On-line / Programmed

Movement ended: Gives the status of the motion processor. If the movement profile iscompleted then mvend=1, otherwise 0. If mvend=1 it doesn’t necessarily mean that the motorhas reached the target position, only intpos does.

p(I) Read / Write On-line

Position array: 64 positions can be predefined in this array and then used directely in movand movr commands. The variable “i” must be within the range 0 to 63.Example: let p(1)=2048 : save 2048 in p(1)

Mov p(1) : absolute movement to position 2048.Movr p(1) : target position is actual position +2048

tpos Read / Write On-line / Programmed

When read it gives the target position. When written it replaces the mov command.

tposw Read / Write On-line / Programmed

Target position window: Defines in increments a window for the intpos parameter. If apos iswithin the range tpos +/- tposw then intpos=1.

Other commands and parameters previously described should be considered as well:

§ tr, tf, tfs, spd1, pkp, ski, skp, pvmax, pvmin, id, ip,…. See section 10 for details.



Note: In the On-line positioning and Programmed mode, the used speed is spd1.Nonetheless, the shorter parameter spd can be used instead of.



Annex A:Quick reference - Setting parameters procedure

Once the connection is established between a PC (OS: Windows 95/98/NT and HyperTerminal 4.0 or more) and the BGE9010, the previously described parameters can be modify.The procedure is the following:

1. The BGE9010 must be restarted in the Setting mode (I8=+24V if auto=1): Turn theBGE9010 off, switch I8 to +24V, turn the BGE9010 on. An acknowledge message mustappear in the Hyper Terminal window (Autostart must not appear).

2. Parameters can now be changed with the let command:For example, type:let spd1 480<enter> (spaces must be present)The BGE must acknowledge with: spd1 = 480

3. Once the last parameter has been modified, the modifications have to be stored in theEEPROM by: wini<enter>The BGE must acknowledge with: eeprom-chksum: xxxxx

4. The BGE9010 can return to the programmed mode with autostart: Turn the BGE off,switch I8 to 0V (if you had to get I8 tied up), turn the BGE on.



Annex B:Quick reference for connection:

Connect the Encoder cable:

1. Plug the round conn. in

the encoder conn.

2. Plug the Phoenix

conn./BGEConnect the Motor cable:

1. Plug the Phoenix conn.

with its terminal box in

the motor.

2. Plug the Phoenix

conn./BGEConnect inputs / outputs:

1. Use 4 and 8 terminal

Phoenix conn.

2. Connect inputs

according to starting

conditions

3. Connect outputs.

Connect the inputs:

1. Use a 8 terminal Phoenix

conn.

2. Follow instr. section 3.

Connect the interface cable:

1. Use the precut proposed

cable.

2. Connect to RS232 port.

Connect the Power supply:

24…100VDC / 5% max



Annex C:Formulas

As acceleration and deceleration are linears, we can use simple formulas.

Acceleration - deceleration : tr vs angular acceleration:First of all, we need to express the parameters tr (then, tf and tfs as well), not as a time but asan angular acceleration in rad/s2:

tr is the time, in ms, to accelerate from 0 to 1000rpm, therefore the angular acceleration isgiven by :

Accang = (1,000,000*PI)/(30*tr)Where: Accang is the angular acceleration in rad/s2.

Therefore, tf and tfs give the deceleration times by the same formula. (a minus sign shouldapply).

To calculate the parameter tr from an angular acceleration in rad/s2 then apply:

tr= (1,000,000*PI)/(30* Accang)Where: Accang is the angular acceleration in rad/s2. tr is the acceleration time from 0 to 1000rpm in ms.

Position reached after an acceleration:The angular position is given by the following formula:

POSang = 0.5* Accang*t2

Where: Accang is the angular acceleration in rad/s2.t is the acceleration duration in s.POSang is the angular position in rad.

The position in increments is given by:

POSinc = POSang * 2048 / (2*PI)



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