Cosmos 2000 - Manual (103-EN)

(COntrol ServoMOtor System)
A driver for brushless motors

Cosmos 2000 - Manual [103-EN].doc
CONTENTS
1 INTRODUCTION..............................................................................................................................................................4
1.1 Purposes of this manual___________________________________________________________________4
2 DECLARATION OF COMPLIANCE.............................................................................................................................5
2.1 WITH CE RULES________________________________________________________________________5
3 SAFETY INSTRUCTIONS..............................................................................................................................................6
4 PRODUCT DESCRIPTION............................................................................................................................................7
4.1 Ratings____________________________________________________________________________________8
4.2 Description_________________________________________________________________________________8
4.3 Expansion slots______________________________________________________________________________9
4.4 Operating modes____________________________________________________________________________9
4.4.1 Speed check by means of an analog controller__________________________________________________9
4.4.2 Speed check by means of VISIO______________________________________________________________9
4.4.3 Position or speed check by means of a field BUS_______________________________________________10
5 START-UP......................................................................................................................................................................11
5.1 Mechanical installation______________________________________________________________________11
5.2 Electrical installation_______________________________________________________________________12
5.2.1 Power section___________________________________________________________________________13
5.2.2 Signal section___________________________________________________________________________19
5.2.3 Expansion slots__________________________________________________________________________24
6 THE VISIO.....................................................................................................................................................................26
6.1 The VISIO________________________________________________________________________________26
6.2 Structure of the menu_______________________________________________________________________27
7 CONFIGURATION........................................................................................................................................................35
7.1 Reset procedure____________________________________________________________________________35
7.2 Driver state and conditions of error___________________________________________________________35
7.3 Measure of the size units_____________________________________________________________________40
7.4 Controller configuration_____________________________________________________________________43
7.5 Motor configuration________________________________________________________________________43
7.6 Control system parameters___________________________________________________________________44
7.7 Parameters for the external resistance_________________________________________________________48
7.8 Analog output configuration_________________________________________________________________49
8 OPERATING MODE.....................................................................................................................................................53
8.1 SERCOS Controller________________________________________________________________________53
8.1.1 General information about standard SERCOS™ (CEI IEC 1491)__________________________________53
8.1.2 SERCOS Interface configuration____________________________________________________________54
8.1.3 SERCOS interface state___________________________________________________________________54
8.1.4 Solution of the communication problems______________________________________________________55
8.1.5 IDN List_______________________________________________________________________________58
2
8.2 Analog controller___________________________________________________________________________62

8.2.1 ANALOG controller configuration___________________________________________________________63
8.2.2 ANALOG controller state__________________________________________________________________64
8.3 Analog controller in electric axis mode (KZ100071 only)__________________________________________65
8.3.1 Description of electric axis functioning_______________________________________________________65
8.3.2 ANALOG controller configuration in electric axis mode_________________________________________69
8.3.3 ANALOG controller status in electric axis mode________________________________________________72
8.4 VISIO controller___________________________________________________________________________73
9 MOTOR ENABLING.....................................................................................................................................................75
9.1 Electrical wiring___________________________________________________________________________75
9.2 Mode setting_______________________________________________________________________________75
9.3 Motor enabling____________________________________________________________________________76
9.4 Performance optimization___________________________________________________________________76
10 TECHNICAL DETAILS..............................................................................................................................................78
10.1 Ratings__________________________________________________________________________________78
10.2 DeRating_________________________________________________________________________________79
11 CERTIFICATION........................................................................................................................................................80
11.1 Directives________________________________________________________________________________80
11.3 Motor protection__________________________________________________________________________80
APPENDIX........................................................................................................................................................................81
A.1 Reference papers___________________________________________________________________________81
A.2 Abbreviations_____________________________________________________________________________81
A.3 Units of measure___________________________________________________________________________83
A.4 Compatible motors__________________________________________________________________________84
LIST OF THE PICTURES
Picture 5.1.1 Mechanical dimensions______________________________________________________________11

Picture 5.2.1 Connectors position_________________________________________________________________12
Picture 5.2.2 ENCODER IN wiring_______________________________________________________________20
Picture 5.2.3 Serial cable for VISIO remote connection_______________________________________________21
Picture 5.2.4 Serial cable for the connection of VISIO emulation computer________________________________21
Picture 6.1.1 VISIO____________________________________________________________________________26
Picture 7.2.1 Driver plate: LEDs_________________________________________________________________36
Picture 8.1.1 SERCOS rings topology_____________________________________________________________53
Picture 8.1.2 Example of SERCOS ring____________________________________________________________57
Picture 8.2.1 Card interface “CDP-AXIS”__________________________________________________________62
3
1 INTRODUCTION
1.1 Purposes of this manual

This manual contains all necessary information for a correct installation and setting of the
driver. All information is in logical order, thus helping the user to optimize the driver
performances.
The below table indicates the sections to make reference to, according to your purposes.
Quick start System project Setting Problems
solution
3 Safety instructions
4 Information
5 Start-up
6 Operator interface
7 Setting
8 Operating mode
9 Motor start-up
10 Technical data
11 Certification
12 Appendix
Symbols used in this manual
Danger: high voltage
General warning
4
3 SAFETY INSTRUCTIONS
The high voltage of some connections or components in the driver might cause
electrocution, if the user came into contact with them. The connectors with a dangerous
voltage are: MOTOR, BRAKE, VDC BUS, 3PH LINE.
There are some condensers inside the driver which maintain a dangerous voltage
for at least 10 minutes after switching them off. Before starting any operation, make sure
that the driver has been switched off at least 10 minutes earlier and that the motor is still.
Never use the driver if the container is not fully assembled.
Avoid any metal components (screws, electrical cables, ...) fall into the driver
during the installation, because they might cause short-circuits.
The brushless motor is an electric generator. The running speed becomes electric
potential. High voltage is already generated at 300 rpm.
The improper use of the motors and/or the wrong assembly of the mechanical
components may seriously injure the user.
Make sure that the personnel is competent and has been instructed about the risks
he may run and about how to avoid them.
5
4 PRODUCT DESCRIPTION
The COSMOS-2000 is a state-of-the-art driver for brushless motors with sinusoidal
electromotive force.
The power section is controlled by an intelligent module with the protections necessary to
guarantee an extreme reliability and efficiency, besides reducing the external logic.
The system core is a 16-bit processor, equipped with a set of instructions optimized for
speed and specialized in controlling precision motors.
Thanks to its design features, the driver can be considered as of digital type, because it is
completely controlled by the processor. As a consequence, the COSMOS-2000 is a very
flexible appliance, which can be reset through a software and is open to all improvements
offered by the new technologies in the future.
Particular care was devoted to the user interface. The parameters setting is very quick and
easy and does not require the help of any external units, thanks to the special removable
keyboard, called VISIO, or to the emulation software "VISIO sw". Moreover, a series of
LEDs shows all essential information about the system state.
The COSMOS-2000 can control up to two removable modules: one for the motor FeedBack
and one for the Field Bus. In this way, it is possible to control all types of motor feedback
and field bus.
Thanks to the digital and analog Inputs/Outputs, it is possible to control the driver by means
of external axis cards, which check the position and provide a speed reference +/-10V.
Last, but not least, the mechanical compactness makes of the COSMOS-2000 a strong
appliance, which can be easily integrated with the fixing systems of the machine electrical
cabinets.
6
4.1 Ratings
Mains voltage 3-phase: 230÷460V ± 10% - 480V ± 5%

Ausiliary: 24V ± 10%
Rated output current 21Arms 8KHz 45°C
Maximum output current 30Arms per 15sec
Digital Inputs/Outputs from 8 to 24Vdc

Rated current for each digital I/O 0,7A
Maximum absorbed current by all digital I/O 4A
Degree of protection IP20

Ambient temperature 0 ÷ 50 °C
The current rated value is valid at 45°C, 1000m altitude and PWM at 8KHz. For higher temperature,
altitude and PWM frequencies it is necessary to apply a de-rating. For further information, please refer to
paragraph 10.2.
4.2 Description
7
4.3 Expansion slots

The following expansion slots are available for COSMOS-2000:
Type Name Description
FeedBack FM - Resolver Motor feed-back by means of a resolver
FM - SinCos Motor feed-back by means of encoder SinCos
FM - HiperFace Motor feed-back by means of encoder HiperFace
FM - Endat Motor feed-back by means of encoder Endat
Field Bus FBM - SERCOS Expansion slot for SERCOS™ (CEI IEC 1491)
FBM - CAN Expansion slot for CANOpen DS402
KeyPad VISIO Removable keyboard LCD 16x2 + 5 keys
VISIO sw Emulation Software VISIO
The modules in grey are planned to be available.
4.4 Operating modes

The COSMOS-2000 can function in the following modes:
- Speed check by means of an analog controller
- Speed check by means of VISIO
- Position or speed check by means of a field BUS
All control modes are to be considered in a close ring, because the motor feedback is
absolutely necessary.
4.4.1 Speed check by means of an analog controller

In this mode, a part of the signals on the I/O connectors are reserved for the driver enabling,
resetting and state functions. Moreover, the analog input In2 becomes the reference signal
for the speed. This modality is available in the driver basic version and is ideal for the
applications in which the motor must be checked while it is running or where the control
card is external. For the latter case, the output for the signals repetition is very useful, in
order to transfer the information from the encoder to the control card, thus permitting to
control the motor in position. Anyway, all parameters can be set by means of VISIO
4.4.2 Speed check by means of VISIO

In this mode, it is possible to check the motor by means of simple commands by VISIO. The
check is made while the motor is running and it is possible to send the required acceleration
and deceleration ramps. Anyway, all setting parameters can be set by means of the VISIO.
This modality is ideal especially for diagnosis purposes. In fact, the motor and its load can
be checked, independently of the other components.
8
4.4.3 Position or speed check by means of a field BUS

In this mode, by means of the expansion module, the check is transferred to the field BUS
master, with the possibilities deriving from its standard. The driver can check the motor
while it is running or while it is in position. All setting parameters can be set by the master,
but some of them can be set by means of VISIO.
9
5 START-UP
5.1 Mechanical installation
The drivers COSMOS-2000 can be installed close to an iron wall connected to earth. It is
recommended to install the driver in vertical position, with the fan side turned downwards,
so that it can be cooled by natural convection. A space of about 15cm must be left above the
driver.
The degree of protection certified for this driver is protection class IP20. Particular attention
is to be paid to the ambient conditions, which might damage the driver.
In order to install the driver inside the electrical panel, make the holes according to the
dimensions in the below picture and fix the driver to the wall by tightening the 3 screws.
Install the blocking plate of the main infeed cable and of the motor cable de-coupling,
according to the modalities described in the next paragraph.
Picture 5.1.1 Mechanical dimensions
5.2 Electrical installation

All driver connectors are situated on the container plate, on the below side.
10
If we take into consideration their position, it is possible to identify the 3 following sections:
1. Power:
It consists of 5 connectors for the connection of the motor power supply, of the brake
resistance, of the VDC bus and of the mains 3-phase voltage; one additional connector is
for the auxiliary power supply (24V). These connectors are situated on the driver below
side.
2. Signal:
It consists of 3 connectors on the driver plate controlling the ENCODER and the digital-
analog I/O.
3. Expansion slots:
The connectors in this section, situated on the below side of the driver, depend on the
type of expansion slots installed.
For the module of motor feedback there is only one connector type, while the connectors
for the field bus depend on the standard in use, from the common D-Sub 9 Pin connector
to the SERCOS optical transmitters and receivers.
Please find a detailed description of the use modalities and of the connectors electrical
features in the next paragraphs. The following picture shows the position of the connectors
on the driver.
Picture 5.2.1 Connectors position
5.2.1 Power section
11
5.2.1.1 Wiring diagram

This picture shows the driver wiring diagram.
Before making the connections, make sure

that the safety conditions described in chapter 3 are
verified.
The following paragraphs will analyse each section

in details, starting from some information about the
connectors up to the choice of the cables section and
of the fuses.
5.2.1.2 “24 VDC” connector

The power section contains a 3-pole green connector, which is considerably different from
the other ones: this is the connector for auxiliary power supply of the driver and for the
output section of the digital I/O. The serigraphy on the driver bottom panel indicates the
univocal polarity of the input voltage. If the connection were reversed, the inside protection
would prevent the power supply from functioning. The absorbed power for the auxiliary
power supply is inferior to 12W. By contrast, the I/O might require up to 0.7A for each
output, up to a maximum rate of 4A; beyond this value, the protection fuse will intervene.
24 VDC Connector
Label Signal
I/O + 24V for the digital I/O
MAIN + 24V for the auxiliary power
supply
MAIN - GND
5.2.1.3 Connector “3PH LINE”

It provides the driver with the 3-phase voltage; the phases order is indicated in the below
serigraphy. Moreover, it is necessary to connect this connector with earth.
12
Connector 3PH LINE

Label Signal
R Line R
S Line S
T Line T
Earth
5.2.1.4 Connector “MOTOR”

It is the connector for the motor connection. A shielded cable is necessary for this wiring, in
order to avoid electro-magnetic interferences.
The shield must be fixed to the special cable-pass that is applied to the mechanics part
perpendicular the the drive's bottom panel.
While preparing the cables B and C, it is therefore necessary to shorten the protecting rubber
and the shield A, so that it can be fastened to the cable-pass. The shield must not be
connected to the motor at all, because it would generate earth loops.
MOTOR Connector
Label
Signal
W Motor W Phase
V Motor V Phase
U Motor U Phase
Earth
The sequence of the motor phases

must be absolutely followed;
otherwise, the driver is not able to
control the motor properly and the
motor might remain still or might
run too quickly, thus overheating the
windings.
5.2.1.5 “BRAKE” Connector

This connector is used for the connection of an external brake resistance. In normal
conditions, the driver internal resistance is enough and can be used by means of a connector
supplied with the driver and a pre-wired jumper between the two contacts “IN”. The internal
resistance can dissipate up to 3000W voltage, with an average value of 950W. Any way, the
13
internal control system will keep the resistance temperature under control and will stop the
driver, if the temperature exceeds the limits.
If an external resistance, with its own electrical features, is necessary, the jumper between
the contacts “IN” shall be eliminated, in order to connect the terminals between the contacts
“OUT”, as indicated in the following pictures:
BRAKE Connector
Label Signal
E External Resistance
C Common Resistance
I Internal Resistance
5.2.1.6 Connector “VDC BUS”

This connector includes the VDC bus, obtained by rectifying and philtering the input three-
phase voltage. Its danger degree is similar to that of the mains voltage, with which it is
directly coupled. Thanks to this connector, it is possible to put into contact the VDC bus of
several drivers. Please do not forget that the drivers with the VDC bus in common must
have the same rated voltage. Moreover, it is obbligatory to make a connection only and
exclusively with the drivers which were disconnected from power supply at least 10
minutes earlier
VDC BUS Connector

Label Signal
+ VDC BUS+
- GND VDC BUS
5.2.1.7 Wiring and electrical features

The connectors used in power section belong to “Mini-Fit, Sr™” series by MOLEX. Thanks
to their electrical features, they can tolerate the high current required by the driver, by
maintaining an adequate insulation among the contacts, as indicated in the following list,
directly taken from MOLEX datasheet:
 Insulation voltage: 2200 VAC

 Maximum current : 49 A
14
 Maximum contact resistance: 1 m

 Minimum insulation resistance: 1000 M
This picture shows the plug connector on the driver bottom

panel. From a mechanical point of view, the polarizations
of the plastic part including the contact prevent wrong and
very dangerous connections.
The interface with these connectors is made through the
corresponding female container (type 42816) belonging to
the same above mentioned series, equipped with the male
contacts to be crimped (type 42817, SMI code KF030032),
which match with the maximum section cables (8 AWG).
In order to crimp a contact, please use MOLEX pliers, code 63811-1600 (SMI TM010291).
Please find the list of the connectors codes in the below table. If you do not need to connect
the external brake resistance, use the pre-crimped connector supplied with the driver.
Table of connectors codes

SMI code Supplier code Serigraphy Number of poles
KF100001 Phoenix MSTB 24 VDC 3
KF030035 Molex 42816-0312 BRAKE 3
KF030035 Molex 42816-0312 VDC BUS 3
KF030028 Molex 42816-0412 3PH LINE 4
KF030036 Molex 42816-0512 MOTOR 5
5.2.1.8 Earth wiring

The earth wiring can be made by means of connector "3PH LINE". The earth of this
connector is conveyed to the driver and to the motor by means of "MOTOR" connector.
For more safety, it is possible to convey the earth directly to the driver by means of a screw
that you can find on the bottom panel, with its special symbol.
5.2.1.9 Requirements of the main power supply:

The main supply must meet the following requirements:
15
 Voltage: three-phase: 230÷460V ± 10% - 480V ± 5%

 Frequency: 48÷62Hz
 Short-circuit current: 5KA
5.2.1.10 Ratings
Voltage Output Input typical Fuse Dimensions of cable
Current current EN 60204
V A A Out mm2 In mm2
230 5 8.03 10 1.0 1.5
230 8 11.39 16 1.5 1.5
230 10 13.42 16 1.5 2.5
230 15 18.15 20 2.5 4.0
230 21 23.24 25 4.0 4.0
400 5 9.22 12 1.0 1.5
400 8 13.18 16 1.5 1.5
400 10 15.54 20 2.5 2.5
400 15 20.98 25 4.0 4.0
400 21 26.88 32 4.0 6.0
480 5 9.67 12 1.0 1.5
480 8 13.80 16 1.5 2.5
480 10 16.32 20 2.5 4.0
480 15 22.08 25 4.0 4.0
480 21 28.19 32 4.0 6.0
The above table shows the minimum values in order to meet the requirements of the
standards. It is possible to use higher values, except for the limits of the power connectors.
The fuses must be ultrarapid, with semi-conductor, in order to protect the

electronical components.
5.2.1.11 Output circuit and motor protection

The output section consists of an electronical power system which integrates the short-
circuit protection. The maximum output current can not exceed 100A. No further protections
are required downstream the driver.
The protection against the motor over-loading is guaranteed by the torque/time control
which disables the driver when it remains within a certain torque limit for a pre-fixed time.
These parameters are both settable.
5.2.1.12 Electro-magnetic compatibility (EMC)
16
The COSMOS-2000 includes a EMI philter on the main power supply, which considerably
eliminates the interferences. However, due to the reduced dimensions of the COSMOS, it is
not possible to create a sophisticated philter; therefore, if you install a battery with 3 or more
COSMOS, it will be necessary to use an adequate filter. The choice of this philter
depends on the requirements of the rules concerning the application where the drivers are
installed.
The internal philter has no influence on the emissions of the output section. Therefore, the
length of the motor cable becomes a crucial factor. If the other devices included in the
application should not tolerate the emissions, it would be possible to insert a common toroid
or a filter on the motor cable, according to the intensity of the interference to be eliminated.
Of course, the use of such philters implies that the electrical installation complies with the
application rules, in order to reduce the interferences. This means making the adequate earth
wiring, keeping an adequate distance between one cable and another, using shielded cables
and so on.
5.2.1.13 Stray currents

The integration of the net philter generates considerable stray currents to earth. In fact the
driver must mandatorily be connected to earth and the interferences are practically
discharged onto it.
According to the recorder data, the stray current is < 12mA at 400V and 50Hz.
Anyway, the device includes some components for the elimination of transient voltage
discharging to earth. In normal conditions the losses are irrelevant.
17
5.2.2 Signal section
The inputs and outputs of the signal connectors are sensitive to electrostatic
charges and/or to the potential difference of more than 30V. It is important to
check that the earth wiring was properly made before the connection.
5.2.2.1 “ENCODER IN” connector

It is a female D-Sub 15 Pin connector, for the interface of the control signals coming from
the motor: encoder signals, NTC and HALL sensors.
These connections must be accurately made, in order to avoid bad functioning, the causes of
which might not be easily understood during the application commissioning.
You must use a shielded multi–poles cable, with twisted torques. The symbol in
the picture shows the torque of twisted cables. The shield must be connected
both on the driver side and on the motor side, so as to extend the shielding to
the cable inside the motor, too.
ENCODER IN Connector
n° Name Signal
1 Shield Terminal for the cable shield
2 Phase A+ Encoder positive phase A
3 Phase B+ Encoder positive phase B
4 Z+ Encoder positive zero index
5 Ntc 1 NTC terminal
6 Hall U Position U sensor
7 Hall V Position V sensor
8 +5 Encoder 5V power supply
9 GND Mass of the power supply and of the signals
10 Phase A- Encoder negative phase A
11 Phase B- Encoder negative phase B
12 Z- Encoder negative zero index
13 Ntc 2 NTC terminal
14 Hall W Position W sensor
15 GND Second mass
(Mod.: MANUTENT.DOC) 18
The position signals coming from the HALL sensors have got an open collector: the pull-up
resistance against the 5V is equal to 10K.
Picture 5.2.2 ENCODER IN wiring
5.2.2.2 “ENCODER OUT” connector

The encoder signals are repeated in balanced modality on the male D-Sub 15 Pin connector,
situated on the right of the “ENCODER IN” connector.
ENCODER OUT connector

n° Name Signal
1 Shield Terminal for the cable shield
2 Phase A+ Encoder positive phase A
3 Phase B+ Encoder positive phase B
4 Z+ Encoder positive zero index
5 - Not connected
6 - Not connected
7 - Not connected
8 +5 5V power supply
9 GND Mass of the power supply and of the
signals
10 Phase A- Encoder negative phase A
11 Phase B- Encoder negative phase B
12 Z- Encoder negative zero index
13 - Not connected
14 - Not connected
15 GND Second mass
5.2.2.3 “RS-232/PROG” Connector
On the label upper side, a female D-Sub 9 Pin connector is assembled, for the connection of:
 the VISIO
 a computer in emulation VISIO
 the device for the setting of the flash inside the micro-controller
The driver includes a user interface programme for a clear display of the system state and an
easy setting of all configuration parameters, for a proper functioning by means of VISIO or
of the emulation software. The communication is possible through the standard interface
RS232. The communication speed is equal to 38400 bit/s without parity with 1 bit stop. No
signal of communication start/end is provided for.
The VISIO has no problem with direct communication, because the mechanism was
designed to this purpose. The electrical wiring is simply made by means of the connector on
the COSMOS and on the VISIO.
However, the VISIO can also be remoted by the following cable:
Picture 5.2.3 Serial cable for VISIO remote connection
The connection to the VISIO emulation computer can be made by means of the following
cable:
Picture 5.2.4 Serial cable for the connection of VISIO emulation computer
Attention !!!
Never use the cable for VISIO remote connection in order to make the
connection to the computer. In fact the pin 4 is under 5V voltage, which might
be in contrast with the computer port.
The same connector is used for the setting of the flash inside the micro-controller, so as to
update the driver firmware.
Attention! This procedure must be undergone by competent people, because a

mistake in one of the setting phases implies the elimination and/or the damage of
the firmware; as a consequence the driver could not be used any longer.
RS-232/PROG connector
n° Name Signal
1 GND Mass for programming
2 TX SERIALE Serial communication transmission
3 RX SERIALE Serial communication reception
4 VCC +5V for programmer and VISIO
5 GND Serial communication mass
6 RESET Programme reset
7 TX PRG Programme transmission
8 RX PRG Programme reception
9 VPP +12V for programming
5.2.2.4 “INPUT/OUTPUT” connector
Thanks to this connector, it is possible to interface the driver with external devices, by
exchanging analog and digital signals:
n° Name Signal n° Name Signal

1 IN1 V- Input of negative differential 1 9 I/O 08 digital I/O of power n° 8
2 IN1 V+ Input of positive differential 1 10 I/O 07 digital I/O of power n° 7
3 AN GND Analog earth 11 I/O 06 digital I/O of power n° 6
4 OUT C+ Output in current 12 I/O 05 digital I/O of power n° 5
5 OUT V+ Output in voltage 13 I/O 04 digital I/O of power n° 4
6 IN2 V- Input of negative differential 2 14 I/O 03 digital I/O of power n° 3
7 IN2 V+ Input of positive differential 2 15 I/O 02 digital I/O of power n° 2
8 AN GND Analog earth 16 I/O 01 digital I/O of power n° 1
17 I/O GND 24V signals earth 18 I/O 24V 24V power supply
Analog signals
Analog input 1 Analog input 2
PIN 1,2 6,7
Function General analog input Speed reference
General analog input
Input type Differential Differential
Range ±10V ±1% ±10V ±1%
RIn 10KΩ 10KΩ
Ts 500μs 500μs
Analog output in voltage Analog output in current

PIN 5 4
Function Programmable analog output Programmable analog output
VOut 0-10V ±1% 12V max
IOut 10mA max 4-20mA ±1%
ROut 1KΩ min 500Ω max
Ts 1ms 1ms
Digital signals
Digital outputs 1-8 Digital inputs 1-8
PIN 9-16 9-16
Function Programmable digital output Programmable digital input
VMax - 30V
Vin Thresholds - 0-12V → 0
12-16V → Indeterminate
16-24V → 1
VOut 24V -
IOut 0.7A rated -
2.5A peak
Ts 1ms 1ms
Power supply
I/O GND I/O 24V
PIN 17 18
Function Reference Power supply terminal
Imax - 250mA
5.2.3 Expansion slots

Thanks to the expansion slots, the driver can match several motor feedback systems and
several field BUSes. The expansion slots are installed on the bottom side of COSMOS-
2000, in a simple modality, though requiring a bit of attention.
The expansion slots are electronical modules without a container; therefore, their
electronical components are unsheltered. They must be handled according to the
provisions against the electro-statical damages (ESD). This implies to be
connected to earth, before handling this device.
The allocation on the right is reserved for the expansion slots for the field
BUSes, whereas the left one is for the expansion slots for the motor feedback.
(Mod.: MANUTENT.DOC)
23
After all above mentioned precautions, it is quite easy to install the expansion slots. First of
all, remove the protection panel by unscrewing the screws. Then install the expansion slot,
by keeping the electronical components downwards and by entering the guide properly.
During the final phase, press the expansion slot strongly, in order to install it correctly into
the connector. Finally, the slot must be perfectly in line with the driver bottom side.
Otherwise, it means that it was installed with the electronical components upwards and
the connectors can not match with it. The below picture should help you better understand
this procedure.
5.2.3.1 FBM - SERCOS

The FBM-SERCOS is the expansion slot for the communication with the SERCOS field
Bus. It must mandatorily be installed in the allocation on the right, otherwise it will not
start.
The connections merely consist of an optical receiver (RX) and an optical transmitter (TX)
to which the optical fibers of the field BUS must be connected. For the optical fibers
specifications, please refer to the standard SERCOS.
The connection must comply with the signal input and output. For instance, if you consider
the ring structure, it is necessary to connect the fiber coming from the TX of the device
preceeding the RX and so on. The ring nut must be fixed manually, without using pliers or
any similar tools.
24
6 THE VISIO
6.1 The VISIO
Picture 6.1.1 VISIO
The VISIO is a keyboard which can be interfaced to any kind of device, through serial
communication. It consists of an alphanumeric display, with 2 rows of 16 characters each,
and 5 membrane keys. On the bottom side, you can find the serial connector to be used for
the connection.
Push-buttons Description
ARROW KEYS. By means of these keys, you can navigate in the menus.
Moreover, they are used during the phase of data modification, in order
to digit the parameter value. The modification of the data is enabled after
pressing “ENTER”.
LEFT ARROW Navigation: by pressing the left arrow, you go back to the upper level
menu. If you are in the main menu, the welcome message will be
displayed.
Data modification: it shifts the tab on the figure on the left side of the
displayed figure. If the tab is already on the figure on the extreme left, no
shift occurs. It is possible to eliminate a modification while it has not
been confirmed yet, by pressing this key for one second.
RIGHT ARROW Navigation: by pressing the right arrow, you go to the lower level menu.
The items accepting a lower value, that is to say a sub-menu, are
indicated by “>“. The active entry is situated on the first row of the LCD.
Data modification: it shifts the tab on the figure on the right side of the
displayed figure. If the tab is already on the figure on the extreme right,
no shift occurs.
ARROW UPWARDS Navigation: by pressing this arrow, you go back to the previous entry of
25
the current menu. If you are at the first entry of the main menu, you will
go back to the welcome message.
Data modification: it increases the figure on which the tab is positioned.
If the figure reaches the maximum value, the LCD will try to increase the
figure on the left, if it is not already at its maximum value.
ARROW Navigation: by pressing this arrow, you go to the next entry of the current
DOWNWARDS menu. The end of the list of the entries in the menu is displayed by a
series of hyphens “----------------”.
Data modification: it decreases the figure on which the tab is positioned.
If the figure reaches the minimum value, the LCD will try to decrease the
figure on the right, if it is not already at its minimum value.
ENTER. This key is used in order to start modifying the data and to
confirm the new values.
ENTER Data modification: if you press “Enter”, it means that you want to modify
the entry you have selected. If the LCD displays only one parameter on
the two rows, the key “enter” modifies the field value immediately.
By contrast, if the LCD displays two parameters, the parameter on the
first row will be flashing, on pressing “enter”. In order to select the data
to be modified, use the arrows and . If you press “Enter” once again, it
will enable the data entering modality, indicated by the tab on the
selected field. In order to confirm the new data, press “Enter” for 1
second.
6.2 Structure of the menu

As soon as you supply auxiliary power, the LCD will display the welcome message, if the
driver is not in error; the message shows the software version:
COSMOS DRIVE
VERS: X.XX
Any error state is displayed on the LCD by a message with the error code:
ERROR: [11]
Press Any Key
By pressing any key, you go back to the menu entry you had previously selected.
The LCD also includes a time function which automatically returns to the starting display, if
no key is pressed for more than 5 minutes. ( RESET-DISPLAY ).
26
Even in this case, as in the connection through terminals, there is an access level
classification; as a consequence, each datum can be matched with a protection level. In order
to shift to the next level, you must enter a password (see “Passwords” table), by using the
special function described here below. If the user does not press any key for 5 minutes, the
system returns to level 1 and it will not be possible to modify the data any longer, unless you
enter the password of the next level.
The menus displayed by the LCD are organized in a hierarchic way: from the welcome
message, it is possible to enter the main menu, by pressing or 
.
The main menu consists of two entries, as follows:
>VISUAL DATA
MODIFY-LEVEL
If you press  , you enter the function MODIFY-LEVEL, which gives you the possibility to
modify the level to enter the parameters:
ACT-LEVEL---[1]
PASSWORD XXXXX
By means of the arrows, it is possible to enter the password and to confirm it with  .
If the password is correct, the LCD will display a message of successful result and a new
access level:
ACT-LEVEL---[2]
PASSWORD VALID
If you press the key  once again, the LCD will return to the main menu.
If you press , you enter the sub-menu associated to the entry VISUAL-DATA, where all
entries for the driver parameters setting are listed, as well as the size units.
List of the entries “VISUALIZZA-DATI”

Entry Description
27
>MEASURES This section displays all the size units measured by the driver.
>STATUS-ERROR Moreover, it stores the maximum or minimum values measured for
some size units.
VEFF-PR[V] 0 -/- Effective value of the main voltage.
VDC [V] 0 -/- Voltage of the main power supply.
VDC-MIN[V] 0 -/- Minimum value measured by the VDC bus.

VDC-MAX[V] 0 -/- Maximum value measured by the VDC bus.
Direct current (active element of the current vector).

IQ-EFF[A] 0.00 -/-
MAX [A] 0.00 -/- Maximum direct current detected.
Reverse current (reactive element of the current vector).

ID-EFF[A] 0.00 -/-
MAX [A] 0.00 -/- Maximum reactive current detected.
VEL [rpm] 0 -/- Motor speed

VEL-R[rpm] 0 -/- Speed set by the active controller.
TORQUE[Nm] 0.0 -/- Torque generated by the motor.

MAX [Nm] 0.0 -/- Maximum torque detected.
T-DRIVE[ºC] 30 -/- Temperature inside the driver

MAX [ºC] 35 -/- Maximum temperature detected.
T-MOTOR[ºC] 28 -/- Temperature inside the motor

T-RES [ºC] 30 -/- Expected temperature of the internal brake resistance.

INP-DIG 00000000 -/- State of the digital inputs.

OUT-DIG 00000000 -/- State of the digital outputs.
INP-A1[V] 0.00 -/- Reading of the analog input 1

INP-A2[V] 0.00 -/- Reading of the analog input 2
OUT-A [V] 0.00 -/- Value of the analog output 0/10V

MAX [V] 0.00 -/- Maximum value reached by the analog output.
MEASURE RESET 1/SI This function enables you to cancel the minimum and
28
NO maximum values of the detected measures.
----------------
>STATUS-ERROR It contains the list of the last 5 errors of the driver and of the SERCOS
>SET-DRIVE controller. Moreover, it indicates the state of the system hardware.
DRIVE-STATE [00] -/- It shows the present state of the driver.
P 00-00-00-00-00 -/- It is the list of the last 5 errors of the driver.
SERCOS-STATE -/- It shows the present state of the SERCOS interface.

[00]
P 00-00-00-00-00 -/- It is the list of the last 5 errors of the SERCOS.
HARDWARE-STATE It indicates the driver hardware state, after the

00000000 -/- irretrievable error 8. If the driver is not in error, the
display shows the state of the previous error 8.
ERROR-RESET NO 1/SI It enables you to cancel the list of the last 5 errors.
----------------
> SET-DRIVE It contains the setting of the controller and of the parameters
>ACTUAL-MOTOR corresponding to the driver control system.
ACT-CONTROLLER It determines the driver control mode.
SERCOS 3/SI
VEL-LIM[rpm]3000 3/SI Vlim

CP-LIM[Nm] 10.00 2/SI Clim
T-PERMAN-CP-LIM TClim
[sec] 2.0 2/SI -
KPV[A/rpm] 0.050 2/SI Kpvel

KIV[A/G] 0.0 2/SI Kpivel
KPP[rpm/G] 0.0 2/SI Kppos

KDP[] 0 2/SI Kdpos
VEFF-NOM[V] 400 3/SI VnomDrv

EXTERNAL-RES NO 3/SI It indicates what resistance is used: the internal one or
the external one.
>ACTIVE-MOTOR It enables you to modify the active motor and the parameters setting.
>SET-SERCOS
29
ACTIVE-MOTOR It selects the motor connected to the driver.
RCVUL714 Vn332 3/SI
VEFF-NOM[V] 400 3/SI VnomRMS

VP-MAX [V] 800 -/NO Not resettable parameter.
IEFF-NOM[A] 7.35 -/NO Not resettable parameter.

MAX [A] 45.00 -/NO Not resettable parameter.
CP-NOM[Nm] 14 -/NO Not resettable parameter.

MAX [Nm] 58 -/NO Not resettable parameter.
VEL-NOM[rpm]3000 3/SI VelmotNOM

MAX [rpm]3500 3/SI VelmotMAX
T-MAX[ºC] 105 3/SI TempMotMAX

N-POLI 4 -/NO Not resettable parameter.
ENCODER 8192 -/NO Not resettable parameter.

NTC 0 -/NO Not resettable parameter.
KP[V/A] 8.24 -/NO Not resettable parameter.

KPI[] 0.62 -/NO Not resettable parameter.
FCEM[V/rpm] 322 -/NO Not resettable parameter.

KT [Nm/A] 1.77 -/NO Not resettable parameter.
OF-[G] 0.00 -/NO Not resettable parameter.

K-/I[G/A] 0.80 -/NO Not resettable parameter.
K-/VEL [3000] -
[G/rpm] 59.27 -/NO Not resettable parameter.
>SET-SERCOS It contains the settings of SERCOS controller.

>SET-ANALOG
ADDRESS 1 3/SI It sets the address of the device.
MBAUD 4 -/NO Not resettable parameter.
>SET-ANALOG It contains the settings of the Analog controller.
>SET-RS-232
DRIVE-STATE [00] -/- It displays the state of the analog controller
RESET-ERROR NO 1/SI It enables you to cancel the state of error
30
RESET-LEVEL L 3/SI It sets the active level of the reset signal
LEVEL-ENABL L 3/SI It sets the active level of the “enable” signal
K-VIN/VEL Kv
[V/rpm] 300 2/SI -
OFFSET[V] 0.000 2/SI VOff

---------------- -
>SET-RS-232 It contains the settings of the driver serial port.

>SET-DIAGNOSTIC
BAUDRATE 38400 -/NO It indicates the connection speed of the driver serial
---------------- port.
> SET-DIAGNOSTIC It enables you to control the driver directly from the LCD.
> SET-EXTERN-RES
MOD-DIAG VEL 3/SI It sets the type of control: torque, speed or position.
STATE DISABL -/- It signals the enable/disable condition.
ABILIT-VEL NO 3/SI It activates the speed ramp.

ACC[rpm/s] 0 3/SI It sets the speed ramp.
VEL-R[rpm] 0 3/SI It sets the speed rate that the motor will try to reach
VEL [rpm] 0 3/SI Present speed rate.
DRIVE-STATE -/- It indicates the driver state

[00]
RESET-ERROR NO 3/SI It cancels the state of error.
> SET-EXTERN-RES It displays the entries concerning the setting of the external brake
>SET-I/O resistance.
RES[Ω] 50 3/SI REst
K-TEMP[°C/W] 0.5 3/SI KdREst
T-AMB[ºC] 25 3/SI TambREst

POT-RES[W] 4000 3/SI PREst
T-RES-MAX[ºC]150 3/SI TmaxREst

---------------- -
>SET-I/O It contains the setting and state of the digital I/O and of the analog
> SET-DRIVE-DATA output.
OUT 87654321 It indicates the reaction of the power digital outputs
2/SI when the main power supply is absent.
31
BACKUP 00000000
TIPO-OUT 0-10V 2/SI It selects the type of analog output: 0-10V or 4/20 mA.
SET-OUT ABS-SPE 2/SI It sets the size unit to be transferred to the analog
output.
OFFSET[V] 0.00 2/SI Offset value of the output in voltage.

OFFSET[mA] 0.00 2/SI Offset value of the output in current.
K-VOUT/IQ KVoutIq
[A/V] 1.0 2/SI -
K-VOUT/VEL KVoutVel
[rpm/V] 300 2/SI -
K-VOUT/ERR-VEL KVoutErrVel
[rpm/V] 300 2/SI -
K-VOUT/ERR-POS KVoutErrPos
[GR/V] 36.0 2/SI -
K-IOUT/IQ KIoutIq
[A/mA] 0.6 2/SI -
K-IOUT/VEL KIoutVel
[rpm/mA] 188 2/SI -
K-IOUT/ERR-VEL KIoutErrVel
[rpm/mA] 188 2/SI -
K-IOUT/ERR-POS KIoutErrPos
[GR/mA] 22.5 2/SI -
> SET-DRIVE-DATA It enables you to set and display the driver parameters.
>SET-LCD
MODEL
0101031000000000 -/NO Not resettable parameter
VEFF-NOM [V] 400 3/SI VnomDrv

MAX-Vdc [V] 850 -/NO Not resettable parameter
MIN-Vdc [V] 400 -/NO Not resettable parameter

VDC-INT [V] 750 -/NO Not resettable parameter
32
IEFF-NOM[A]15.00 3/SI IdrvNom
IEFF-MAX[A]45.00 -/NO Not resettable parameter
VEL-MAX[rpm]3500 -/NO Not resettable parameter

T-MAX[ºC] 70 -/NO Not resettable parameter
ATT-RES[V] 468 -/NO Not resettable parameter

DIS-RES[V] 400 -/NO Not resettable parameter
RES-INT[Ω] 50 -/NO Not resettable parameter

POT-RES[W] 4000 -/NO Not resettable parameter
K-TEMP[°C/W] 1.5 -/NO Not resettable parameter

T-RES-MAX[ºC]150 -/NO Not resettable parameter
EXTERNAL-RES NO 3/SI It indicates what resistance is used: the internal one or

---------------- the external one.
-
>SET-LCD It contains the LCD setting, including the message language and the
> CHANGE-PASSWORD back-lighting control.
ALWAYS-LIGHT NO 1/SI It sets the back-lighting always on.
RESET-DISPLAY NO 1/SI It defines the reaction of the LCD in the event of the
user’s inactivity:
YES -> after 5 minutes of inactivity, the LCD displays
the welcome message;
NO -> the last window selected by the user is displayed.
LANGUAGE-ENGLISH 1/SI It enables you to select the language of the messages

---------------- displayed by the LCD.
>CHANGE-PASSWORD In this section it is possible to modify the passwords of the data

---------------- protection levels from 1 to 3.
LIVELLO [1] The function can be used only by the driver
PASSWORD XXXXX -/NO manufacturer.
-/- = No parameter; -/NO = Not resettable data; n/SI = Resettable data at level “n”.
33
7 CONFIGURATION
The configuration of the driver consists in installing all parameters and main settings for a
proper functioning. In order to make the configuration, the driver must be supplied with the
24V auxiliary voltage; no further connection is needed.
The displayed parameters can not be all modified by the user. Some of them,
strictly linked to the features of the driver and of the motor, are directly set by
the supplier.
7.1 Reset procedure

When you start the driver, the control logic will begin the hardware and software
initializations, by making the diagnosis tests on the system reliability.
During this phase, the integrity of the ROM and RAM memory is checked. If the test is
unsuccessful, the warning LED “HW FAULT” will switch on and the LED called “ERROR
PRESENCE” on the plate will be flashing:
ERROR CODES OF THE LED “ERROR PRESENCE”

N° of flashings Description
2 Error found during the test on the ROM
3 Error found during the test on the RAM
ATTENTION! IF ONE OF THE A.M. ERRORS OCCURS, THE

DRIVER CAN NOT BE USED. IT IS NECESSARY TO REPLACE IT.
If the a.m. tests are successful, it will be possible to proceed with the parameters
configuration.
7.2 Driver state and conditions of error

The driver plate includes eight warning LEDs, informing the user about the operating state
and the configuration of the driver:
34
Picture 7.2.1 Driver plate: LEDs
LEDs
Serigraphy Description
CPU READY Green. It indicates that the microcontroller is keeping the device
under control.
FAULT Red. It indicates the presence of a serious hardware error .
MAIN POWER Yellow. It indicates that the main power supply is on.
DRIVE ENABLED Yellow. It indicates that the driver is enabled.
I/O ENABLED Yellow. It indicates that the digital I/O section is enabled.
S1/ERROR Red. It is the first state led.
It signals the presence of an error.
If the LED is flashing, please refer to paragraph “Reset

procedure” and “SERCOS interface state” for further information.
S2 Yellow. It is the second state led.
The number of its flashings indicates the number of tens in the error
code.
S3 Green. It is the third state led.
The number of its flashings indicates the number of units in the
error code.
As soon as an error occurs, the LED “S1/ERROR” immediately switches on and the VISIO
displays a message with the code error, like the following one:
35
ERROR: [15]
Press Any Key
Moreover, the leds S2 and S3 are flashing, indicating the tens and the units of the error code.
These leds are extremely important, if the VISIO is not at your disposal.
However it is possible to check the driver state at any time, by entering the LCD section,
situated in VISUAL-DATASTATUS-ERROR, also including the list of the last 8 errors
occurred.
The following table lists the error codes of the driver and describes the possible causes.
DRIVER ERRORS
Code Message Description
1 VRef beyond limits Irretrievable. The detected value of the reference voltage
is beyond the tolerance limits permitted.
2 The currents are not Irretrievable. The sum of the three phase currents of the
balanced motor are not balanced. The current may be wasted down
to earth on the motor side and/or a current sensor module
may be damaged.
4 NTC drive interrupted The temperature sensor of the driver is interrupted.
5 NTC motor interrupted The temperature sensor of the motor is interrupted. Make
sure that the cable “ENCODER IN” is connected
properly.
6 Motor temperature too The motor temperature exceeds the limit set in
high TempMotMAX. Make sure that the load applied to the
motor is correct (no obstructions, nor frictions). If
everything is ok or if you are testing the motor and it has
not reached the operating temperature yet, it is
recommended to increase the limit or to cool the motor. If
these hypotheses are all to be discarded, it is
recommended to replace the motor with one of a larger
size.
7 Driver temperature too The temperature inside the driver is too high. It is
high recommended to increase the ventilation.
8 Intervention of the Irretrievable. This error signals the intervention of the
protection hardware protection inside the power card. Here are the
main causes:
a) over-current in the output phases,
b) simultaneous conduction of IGBT,
c) power supply default on the IGBT Gates,
d) disturb current impulse
There are several causes for these defaults, both inside
and outside the driver: motor cable, motor turning-up,
wrong connection of the earth lines. If the error persists, it
will be necessary to replace the driver.
9 Converter I out of limits This error indicates that the data applied to the motor
must be better calibrated, or that the application requires
36
too quick current increases which can not be controlled by
the driver. While waiting for a more precise calibration of
the parameters, please reduce the maximum speed rates
and the speed increase fronts.
Moreover, make sure that the pre-selected motor is the
one actually in use.
10 VDC bus exceeding the This error occurs if the brake resistor can not absorbe all
max. limit power generated by the motor or if it is interrupted. It can
also indicate that the mains voltage is higher than the
limits permitted or is considerably fluctuating.
If you are not using an external brake resistance, make
sure that the jumper for the internal resistance is present.
11 Hall sensor code not This error occurs if the motor encoder cable is not
correct connected or if the wiring is not correct. It can also occur
if the motor encoder or the hardware inside the driver
break down.
13 Brake resistance The brake resistance temperature exceeds the pre-set
temperature too high limits. The cause might be a too high voltage or an
eccessive mass applied to the motor shaft.
14 VDC bus too low The mains voltage is not enough. It is recommended to
check the power supply line and the VnomDrv.
15 Corrupted data in Irretrievable. This error occurs due to the EEPROM
EEPROM memory damaged.
16 Too high speed This error occurs when the VelmotMAX parameter is not
properly installed or when a too high integrative gain
implies an eccessive adjustment, which leads the motor
out of the limits permitted.
17 SW no longer under Irretrievable. The microprocessor does not execute the
control main programme.
18 Torque time limit This error occurs when the Tclim time is inferior to the
time when the motor torque overtakes the pre-set
maximum torque value.
When the torque level exceeds the maximum pre-set value

(*), the timer increases. When the torque returns below
the maximum level, the timer decreases. If the timer
exceeds the pre-set value (**), the error signal is enabled.
This is a safety function that the user has got at his
disposal in order to protect the application.
21 Motor voltage different The rated voltage set for the drive is different from the
37
from drive voltage motor voltage. This causes an excessive power supply to
the motor windings.
22 Excessive current for a Irretrievable. While the driver was disabled, the sensors
disabled drive detected too high current. This problem is due to the
hardware misfunctioning.
23 Hardware chip SERCON Irretrievable. During the HW test on the SERCON chip,
Error some errors occurred. The specifical error code is
indicated in the list of SERCOS errors. Make sure that
the SERCOS module was properly installed.
24 Eccessive deviation of the This error occurs when the position control is active and
position the driver can not position the motor in the required
position. This error could be due to an excessive load
which can not be controlled or to a position too distant
from the present one.
The error is not memorized in EEPROM in order to
avoid saturing the available positions, which might
cause frequent errors.
25 I/O disabled This error occurs when the digital I/O are used, because
an excessive current quantity with one or more outputs is
required. It is recommended to check the absorption of the
loads applied at the outputs and or check if there are any
short-circuits at the positive or negative pole of the power
supply.
If the operating conditions comply with the I/O
specifications, but the error persists, it will be necessary
to replace the driver.
The driver can not be disabled until it is in error. It is necessary to make a precise procedure
in order to cancel the state of error; this procedure is different, according to the selected
controller type.
An irretrievable error indicated by the LED “HW FAULT” can not be cancelled by
software procedures. Try to disconnect the power supply from the driver logic and then
connect it again. If the error persists, proceed with the replacement.
7.3 Measure of the size units

The driver displays the main size units which determine the usage conditions. For some of
them, the maximum and minimum values are stored, so as to help the user better calibrate
the driver parameters and identify the usage critical situations. This possibility offered by
the driver is very useful, if you consider that the measures refer to instantaneous values,
which can vary too quickly to be displayed.
In order to enter the list of the available measures, it is enough to enter the LCD menu
VISUAL-DATA MEASURES.
All tables hereafter contain a list of parameters to be configurated, including the
38
the messages displayed on the LCD, corresponding to the described data.
MEASURED SIZE UNITS

Parameter name Level Unit Description
VEFF-PR[V] 0 - Vrm Calculation of the 3-phase voltage value at the driver
VDC [V] 0 s input. This value is determined according to the voltage of
NO IDN the main philter condensers. As a consequence, any
VeffPR changes of the VDC bus also influence this value.
VEFF-PR[V] 0 - V Calculation of the 3-phase voltage value at the driver

VDC [V] 0 input. This value is determined according to the voltage of
IDN00380 the main philter condensers. As a consequence, any
VDCBus changes of the VDC bus also influence this value.
VDC-MIN [V] 0 - V Minimum value of the VDC bus. Thanks to this value, it
VDC-MAX [V] 0 is possible to monitorize the load peaks applied to the
IDN32784 motor, due to acceleration, increase of the inertial mass or
VDCBusMin fluctuations of the supply voltage. If the value gets lower
than the safety limit, the driver will display error 14.
VDC-MIN [V] 0 - V Minimum value of the VDC bus. After the analysis of this
VDC-MAX [V] 0 value, it will be possible to know the limit reached by the
IDN32800 VDC bus after a deceleration of the motor, a decrease of
VDCBusMax the inertial mass or fluctuations of the supply voltage. If
the value exceeds the safety limit, the driver will display
error 10.
IQ-EFF[A] 0.00 - Arm Calculation of the direct effective current, resulting from
MAX [A] 0.00 s the calculation of the motor phase currents. It indicates the
NO IDN absorption required by the motor.
IQEff
IQ-EFF[A] 0.00 - A Maximum value of the direct current.
MAX [A] 0.00
NO IDN
IQPeakMax
ID-EFF[A] 0.00 - Arm Calculation of the effective reverse current, resulting from
MAX [A] 0.00 s the calculation of the motor phase currents.
NO IDN
IDEff
ID-EFF[A] 0.00 - A Maximum value of the reverse current.
MAX [A] 0.00
NO IDN
IDPeakMax
VEL [rpm] 0 - rpm Measure of the motor rotation speed.
VEL-R[rpm] 0
IDN00040
VelMotMeas
VEL [rpm] 0 - rpm Speed set by the active controller; the motor will try to
VEL-R[rpm] 0 reach this value. If the value exceeds the limit pre-set by
NO IDN the driver supplier, the error 16 will be displayed.
39
VelMotSet
TORQUE [Nm] 0.0 - Nm Value of the torque generated by the motor.
MAX [A] 0.0
IDN00084
CMeas
TORQUE [Nm] 0.0 - Nm Maximum value of the torque generated by the motor.
MAX [A] 0.0
IDN32783
CMeasMax
T-DRIVE[°C] 30 - °C Driver internal temperature.
MAX [°C] 35
IDN00384
TDriveMeas
T-DRIVE[°C] 30 - °C Maximum value of the temperature measured inside the
MAX [°C] 35 driver. If the value exceeds the limit pre-set by the
NO IDN supplier, the error 7 will be displayed.
TDriveMeasMax
T-MOTOR [°C] 28 - °C Motor temperature.
MAX [°C] 30
IDN00383
TMotMeas
T-MOTOR [°C] 28 - °C Maximum value of the temperature measured inside the
MAX [°C] 30 motor. If the value exceeds the limit set by the supplier in
NO IDN the parameter TempMotMAX, it will cause error 6.
TMotMeasMax
T-RES [°C] 30 - °C Value of the present temperature of the internal brake
MAX [°C] 35 resistance.
NO IDN
TResIntMeas
T-RES [°C] 30 - °C Maximum value of the temperature of the internal brake
MAX [°C] 35 resistance. If this value exceeds the temperature limit, the
NO IDN error 13 will be displayed.
TresIntMeasMax
INP-DIG 00000000 - - Digital I/O state.
OUT-DIG 00000000
NO IDN
-
INP-A1[V] 0.00 - V Detection of the analog voltage 0-10V applied to the
INP-A2[V] 0.00 inputs.
IDN32788-89
-
OUT-A[V] 0.00 - V Present and maximum value of the analog voltage 0-10V.
MAX [V] 0.00
IDN32783
-
40
7.4 Controller configuration
The controller indicates the mode in which the motor receives the commands, that is to say
the control unit providing the torque references, the speed references and/or the current
references. The COSMOS-2000 is designed for 3 different operating modes:
CONTROLLERS
Tipo Description
SERCOS This is the default controller set during the production phase. It connects the
driver to the control unit, according to the standard SERCOS specifications.
ANALOGICO The motor is checked by means of an analog signal ±10V and by means of
some digital signals. Moreover, it is possible to set the logic activity level of
the signals “ENABLE IN” and “RESET IN”.
VISIO The motor is checked by means of the VISIO, which is typically used for the
diagnostic tests on the driver.
The procedure for the configuration of the controller type is made by means of the following
parameter in the LCD:
VISUAL-DATASET-DRIVE ACT-CONTROLLER
SERCOS
7.5 Motor configuration

Before using the driver, it is necessary to configurate the motor. Please select the proper
motor from the list of the available ones and calibrate the following parameters.
This procedure can be made from the menu:
VISUAL-DATASET-DRIVE ACTIVE-MOTOR
RCVUL714 Vn314
where you can also find the motor parameters.
The below table contains a list of the parameters which can be configurated directly by the
user, according to the specifical application.
MOTOR PARAMETERS
41
Parameter name Level. Unit Description
VEFF-NOM[V] 400 3 Vrm Effective rated voltage set by the supplier of the motor.
VP-MAX [V] 800 s
NO IDN
VnomRMS
Min = 0
Max = +1000
VEL-NOM[rpm]3000 3 Rpm Rated voltage set by the supplier of the motor.
MAX [rpm]3500
NO IDN
VelmotNOM
Min = 0
Max = +7000
VEL-NOM[rpm]3000 3 rpm Motor maximum speed in rpm; beyond this value, the
MAX [rpm]3500 error “too high speed” is immediately displayed.
IDN00113 It is recommended to set this value at about 100-200 rpm
VelmotMAX more, as compared to the maximum speed required by the
application.
Min = 0 This parameter is a protection for the mechanical
Max = +7000 components and for the motor, in the event that the setting
is damaged or not correct.
T-MAX[°C] 105 3 °C Motor maximum temperature; beyond this value, the error
N-POLI 4 “Motor temperature: too high” is displayed.
IDN00204 This parameter is important for the protection of the
TempMotMAX motor; this value must be set by the supplier.
The supplier’s setting is 105°C, but the motor class
Min = 0 generally allows you to reach up to 120°C. It is
Max = +155 recommended to reach this limit only in the applications
which require the maximum power of the motor and
anyway after discussing the matter with the supplier.
7.6 Control system parameters

A correct configuration of the control system also needs the setting of some parameters
which are available in the menu SET-DRIVE and SET-DATA-DRIVE.
If you are using the SERCOS controller, the setting of the following parameters should not
be necessary, because this operation is directly made by the control unit, by sending
adequate messages. The SERCOS related data, modified by the user, will be overwritten..
1
CONTROL SYSTEM PARAMETERS
42
Parameter name Level Unit Description
VEL-LIM[rpm]3000 3 rpm Motor maximum speed. This parameter indicates the
CP-LIM[Nm] 10.00 maximum motor speed within the application.
IDN00091
Vlim
Min = 0
Max = +7000
VEL-LIM[rpm]3000 2 Nm This is the limit of the torque that the motor can generate
CP-LIM[Nm] 10.00 in this application. This value must be absolutely inferior
IDN00092 to the maximum torque set by the motor supplier in the
Clim parameter Coppia massima. Please also refer to the
parameter Kt, in order to determine the maximum current
Min = 0.00 required by the motor.
Max = +58.00
T-PERMAN-CP-LIM 2 sec If the motor torque exceeds the limit value set in the
[sec] 2.0 parameter Limite Coppia, a timer is increased. As
IDN32771 soon as the torque returns below the limit, the timer is
Tclim decreased. If the total amount of time (expressed in
seconds) marked by this timer exceeds the Tclim value,
Min = 0.0 the error “Superato tempo limite coppia” is displayed.
Max = +32.0 Broadly speaking, a heavy load for a longer time than the
limit value will disable the motor and generate an error.
Thanks to this parameter, it is possible to find out any
jams and/or collisions of the mechanical components.
KPV[A/rpm] 0.050 2 A/ Speed proportional gain, expressed in Ampere per rpm.

KIV[A/G] 0.0 rpm The driver continually detects the rotor speed and
IDN00100 compares it to the reference speed rate. The difference is
Kpvel multiplied by the proportional gain in order to determine
the proportional current.
Min = 0.000 This value of the current is summed up with the current
Max = +3.430 due to the integrative gain. These two values determine
the motor current.
The higher the difference of speed is, the more the current
in the motor is. Through this process, if it is continuous,
the motor tends to assume the reference speed, even when
the load conditions applied to the motor change.
The proportional gain must be usually determined for
each specific case, according to the motor application.
This value is strongly influenced by the inertial mass
applied to the motor shaft. The more the mass is, the
lower the gain will be.
In the practical tests, it is necessary to find out the gain
empirically, by progressively increasing the value, until
the motor begins to be unsteady, depending on the motor
1
43
noise and vibrations. Once you reached the limit, decrease
the gain by 10–20%, as a safety margin.
Larger size motors usually show higher values then
smaller size motors.
KPV[A/rpm] 0.050 2 A/GR Integrative gain, expressed in Ampere per revolution
KIV[A/G] 0.0 degree.
IDN00101 The angular difference between the reference and the rotor
Kpivel is integrated and multiplied by this factor, in order to
determine the integrative current. This current value is
Min = 0.0 summed up to the current due to the proportional gain.
Max = +540.4 They altogether determine the motor current.
If you integrate the angular speed within the time, you
will obtain an angle; as a consequence, it is possible to
express this factor in Ampere per degree; in fact, if you
set a speed rate of 1000 rpm and you set this value at 1,
the current in the motor will increase by 1 ampere when
the rotor slows down and loses 1 degree.
Thanks to this datum, it is possible to adjust the rotor
speed in a very precise way, with consequent great
advantages, especially for the applications requiring high
stability while running.
Please consider that this value is directly proportional to
the proportional gain; therefore it is not possible to set an
integrative gain without a proportional gain.
This parameter has one negative effect on the motion,
especially at low speed rates: hunting. It is necessary to
find the correct value of integrative gain, after
determining the proportional gain, by progressively
increasing it until the hunting begins. Once you reached
the limit, decrease the gain value by 10–20%, as a safety
margin (as you did for the proportional gain).
KPP[rpm/G] 0.0 2 - Position derivative Gain.
KDP[] 0 This value enables you to deduct the speed set-point from
IDN32769 the difference between the two consecutive positions to be
Kdpos reached. Il derivative term considerably improves the
performances of the control in position.
Min = 0 At present, the gain is set at 1. Even if it were
Max = +10 modified, the control would not change.
KPP[rpm/G] 0.0 2 rpm/ Position proportional gain, expressed in rpm per degree.
KDP[] 0 GR The driver continually detects the rotor position and
IDN00104 compares it to the reference position. The difference
Kppos between the two values is multiplied by the proportional
gain, in order to determine the proportional speed.
Min = 0.0 The higher the position difference is, the higher the speed
Max = +2500.0 rate applied to the motor will be. Through this process, if
it is continuous, the motor tends to assume the reference
position, even when the load conditions applied to the
motor change.
The proportional gain must be usually determined for
each specific case, according to the motor application.
44
This value is strongly influenced by the inertial mass
applied to the motor shaft.
In the practical tests, it is necessary to find out the gain
empirically, by progressively increasing the value, until
the motor begins to be unsteady, depending on the motor
noise and vibrations. Once you reached the limit, decrease
the gain by 10–20%, as a safety margin.
VEFF-NOM[V] 400 3 V Driver rated voltage, also called mains voltage. This value
RES-ESTERNA NO indicates the driver power supply.
NO IDN If the rated voltage of the selected motor is not included in
VnomDrv the value interval set for the driver, the error “Motor
voltage different from driver voltage” will be displayed.
Min = 0
Max = +1000
VEFF-NOM[V] 400 3 - This value enables you to decide whether to use the
RES-ESTERNA NO internal resistance or the external one. In order to
NO IDN commute the resistance, please modify this field, by
- setting 0 (NO) for the internal resistance and 1 (YES) for
the external resistance.
IEFF-NOM[A]15.00 3 V Driver efficient rated voltage. This parameter indicates the
IEFF-MAX[A]45.00 current that the driver can supply to the motor.
IDN00112
IdrvNom
Min = 0.00
Max = +45.00
7.7 Parameters for the external resistance

If you want to use the external brake resistance, it is necessary to set the data. To this
purpose, please enter the menu VISUAL DATASET-EXTERN-RES..
BRAKE RESISTANCE PARAMETERS

Parameter name Level Unità Description
RES[Ω] 50 3  This is the ohmic value of the external resistance. This
K-TEMP[°C/W] 0.5 value is set by the supplier.
NO IDN
Rest
Min = +30
45
Max = +500
RES[Ω] 50 3 °C/W Temperature coefficient of the external resistance. It
K-TEMP[°C/W] 0.5 represents the temperature increase, expressed in °C,
NO IDN according to the power function that the resistance must
KdREst dissipate, expressed in W. The best conditions for
dissipation are the low values. The datum is set by the
Min = +01.0 supplier of the resistance.
Max = +10.0
T-AMB[°C] 25 3 W This is the power which can be dissipated by the
POT-RES[W] 4000 external resistance. This value is set by the supplier of
NO IDN the resistance.
PREst
Min = 0
Max = +20000
T-AMB[°C] 25 3 °C Ambient temperature of the external resistance.
POT-RES[W] 4000
NO IDN
TambREst
Min = 0
Max = +150
T-RES-MAX[°C]150 3 °C Maximum temperature value; beyond this value, the
---------------- external resistance is destroyed and the error “Excessive
NO IDN temperature of the brake resistance” is displayed. This
TmaxREst value is set by the supplier of the resistance.
Min = 0
Max = +350
7.8 Analog output configuration

The driver is equipped with an analog output which takes the value of a size unit, by setting
the LCD. The value of this output can be always set independently of the selected controller.
In order to properly define its gain and offset features, it is necessary to install adequate
parameters in the LCD.
Please consider that this setting can be made only through LCD; if you are using a SERCOS
controller, the setting can be made only after exchanging specifical messages and procedure
commands with the control unit.
46
Please refer to the IDN table in the section “IDN List ”
In order to make the settings, select VISUAL DATA from the menu, by pressing the arrow
, go through the entries listed in VISUAL DATA and press the arrow again when you
read SET-I/O.
I/O SECTION CONFIGURATION

Entry Description
OUT 87654321 0 = If the main power supply is lacking, the output state is anyway set to
BACKUP 00000000 0 (output OFF)
IDN32792 1 = If the main power supply is lacking, the output state is maintained.
- Thanks to this function, it is possible to keep the power digital outputs
under power saving conditions, which is very important for backup
batteries.
TIPO-OUT 4-20mA It sets the size unit to be transferred to the analog output:
SET-OUT SERCOS SERCOS: The output value is sent to the SERCOS interface control unit
IDN32794 in a cyclic way. For this setting, the active controller must be
- “SERCOS”.
IQ: Reference of the direct current (active component of the current
vector).
VEL: Reference of the present motor speed.
ABS-VEL: Reference of the absolute value of the present motor speed.
ERR-VEL: Speed error, that is to say the difference between the actual
motor speed and the pre-set speed.
ERR-POS: Position error, that is to say the difference between the actual
motor position and the pre-set position.
TIPO-OUT 4-20mA This datum allows you to select the type of analog output. In fact the
SET-OUT SERCOS connector has got only one output: the setting of this parameter will
IDN32793 indicate whether the user is going to use the output in current (4-20mA)
- or in voltage (0-10V). If the user sets the output in current, the value in
voltage will suffer a calibration error. On the contrary, if the user sets the
output in voltage, the output in current will suffer a calibration error
OFFSET[V] 0.00 These parameters set the offset value which will be summed up to the
OFFSET[mA] 0.00 analog output. Since the output is only one, the two parameters depend
NO IDN on each other; the modification of one parameter will imply the
- modification of the other one, too. If the user selected the output in
current, modify OFFSET[mA]; by contrast, if the user selected the output
in voltage, modify OFFSET[V].
It is very useful to set an offset value different from zero, if the selected
size unit can take negative values (IQ, VEL, ERR-VEL, ERR-POS).
Since the dynamic of the output signal is strictly positive (4÷20 mA or
0÷10 V), the negative part of the size unit would result into a void
output.
47
The following parameters are the proportional constants between the analog output voltage and the
selected reference size unit, according to the following formula:
where,
Vout = analog output voltage;
GRif = reference size unit (IQ, VEL and ABS-VEL, ERR-VEL, ERR-POS);
[K-VOUT/GRif)] = proportional constant;
[OFFSET[V]] = offset value summed up to the analog output.
The setting of these constants and the offset allows you to determine the dynamic of the analog
output and consequently the full-scale value:
K-VOUT/IQ Proportional constant of the IQ current, expressed in A per V. This value

[A/V] 1.0 determines how many A of IQ current correspond to 1 volt of output
NO IDN voltage, to be summed up to an offset value, if any. The parameter is
KVoutIq used when the analog output is set in order to provide the reference value
of the IQ current.
K-VOUT/VEL Proportional constant of the motor speed, expressed in rpm per Volt.
[rpm/V] 300 This value determines how many rpm of the motor correspond to 1 volt
IDN32795 of outpput voltage, to be summed up to an offset value, if any. The
KVoutVel parameter is used when the analog output is set in order to provide the
reference value of the motor present speed (VEL and ABS-VEL).
K-VOUT/ERR-VEL Proportional constant of the motor speed error, expressed in rpm per V.
[rpm/V] 300 This value determines how many rpm of the speed error correspond to 1
NO IDN volt of the output voltage, to be summed up to an offset value, if any.
KVoutErrVel The parameter is used when the analog output is set in order to provide
the reference value of the speed error (ERR-VEL).
K-VOUT/ERR-POS Proportional constant of the motor position error, expressed in Degrees
48
[GR/V] 36.0 per V. This value determines how many Degrees of position error
NO IDN correspond to 1 volt of the output voltage, to be summed up to an offset
KVoutErrPos value, if any. The parameter is used when the analog output is set in
order to provide the reference value of the position error ERR-POS.
The following parameters are the proportional constants between the analog output current and the
selected reference size unit, according to the following formula:
where,
Iout = analog output current;
GRif = reference size unit (IQ, VEL and ABS-VEL, ERR-VEL, ERR-POS);
[K-IOUT/GRif)] = proportional constant;
[OFFSET[mA]] = offset value summed up to the analog output.
The setting of these constants and the offset allows you to determine the dynamic of the analog
output and consequently the full-scale value:
K-IOUT/IQ Proportional constant of IQ current, expressed in A per mA. This value

[A/mA] 0.6 determines how many A of IQ current correspond to 5 mA of the output
NO IDN current to be summed up to an offset value, if any. The parameter is used
KIoutIq when the analog output is set in order to provide the reference value of
the IQ current.
K-IOUT/VEL Proportional constant of the motor speed, expressed in rpm per mA. This
[rpm/mA] 188 value determines how many rpm of the motor correspond to 5 mA of the
IDN32796 output current to be summed up to an offset value, if any. The parameter
KIoutVel is used when the analog output is set in order to provide the reference
value of the motor present speed (VEL and ABS-VEL).
K-IOUT/ERR-VEL Proportional constant of the motor speed error, expressed in rpm per mA.
[rpm/mA] 188 This value determines how many rpm of the motor correspond to 5 mA
NO IDN of the output current to be summed up to an offset value, if any. The
KIoutErrVel parameter is used when the analog output is set in order to provide the
reference value of the motor speed error (ERR-VEL).
K-IOUT/ERR-POS Proportional constant of the motor position error, expressed in Degrees
[GR/mA] 22.5 per mA. This value determines how many Degrees of position error
NO IDN correspond to 5 mA of the output current summed up up to an offset
KIoutErrPos value, if any. The parameter is used when the analog output is set in
order to provide the reference value of the motor position error (ERR-
49
POS).
50
8 OPERATING MODE
8.1 SERCOS Controller
8.1.1 General information about standard SERCOS™ (CEI IEC 1491)

The SERCOS™ is an international standard consisting of an optical serial real-time
interface between the control unit (master) and the devices connected to it (slave or drive).
This interface was created for industrial machines with multiple drives; the use of the optical
fiber is very important, in order to avoid electro-magnetical interferences.
The control unit is connected to the drives according to a ring topology, as follows:
Control Unit
Picture 8.1.1 SERCOS rings topology
The number of devices which can be controlled by a ring depends on the communication
stroke cycle, on the quantity of data to be transferred and on the transfer frequency. Under
normal operating conditions, with a communication stroke cycle of 1 ms and a transfer
frequency of 4 Mbit/s, it is possible to control up to 8 drives per ring. In the standard model
the stroke cycle can be selected among 0.062 ms, 0.125 ms, or whole multiples of 0.25 ms:
our application is set at 1 ms.
However, one control unit can control several ring structures by means of a master for each
ring. The master synchronizes and controls all communication activities of the devices
situated in its ring. Direct data exchanges among the drives are not permitted.
51
8.1.2 SERCOS Interface configuration
In order for the SERCOS control unit to be connected to the driver, it is necessary to set the
communication parameters.
SERCOS INTERFACE CONFIGURATION PARAMETERS

Parameter Description
ADDRESS This is the driver address. It must be the same for each device in the
MBAUD SERCOS ring. The valid values are included within the range of 1÷254.
If an address not requested by the control unit is set, the communication
error SERCOS 21 will occur.
ADDRESS Setting of the communication speed. For this parameter, the standard
MBAUD SERCOS includes the values 2 MBit/s, 4 MBit/s and 16 MBit/s.
TX-POWER Setting of the optical transmitter power. This parameter is created for a
future calibration of the communication system according to the optical
fiber length and according to the attenuation levels. At present this
parameter is set at 6.
The configuration is made by entering the specifical headings of the LCD in VISUAL
DATASET-SERCOS and by using the data installation mode previously described.
8.1.3 SERCOS interface state

At any time it is possible to know the SERCOS interface state, by going through the LCD
headings in VISUAL DATA STATUS-ERROR  SERCOS-STATE.
SERCOS-STATE [00]
P 00-00-00-00-00
The below table lists the SERCOS error codes:

STATO SERCOS
52
State Description
00 / OK No error
21 Communication error while transferring from phase 0 to phase 1. It can be verified
when the device is not addressed.
22 Communication error while transferring from phase 1 to phase 2.
23 e 24 Communication error while transferring from phase 2 to phase 3.
25 Communication error while transferring from phase 3 to phase 4.
28 Transfer to a different phase: forbidden
29 Loss of 2 consecutive MST.
30 Loss of 2 consecutive MDT.
32 Loss of communication (optical signal interrupted)
40 Chip SERCON not found.
41 Chip SERCON version not correct.
42 Error in the reset software of the chip SERCON.
43 Error in the DPRAM reading/writing of the chip SERCON.
The codes equal to or superior to 40 refer to hardware problems in the control logic of the
SERCOS protocol. Due to these errors, the LED “HW FAULT” switches on and the driver
displays the irretrievable error 23.
The other codes refer to errors occurred during the SERCOS communication. Normally
they do not indicate hardware problems, but a wrong data exchange with the master, an
eccessive attenuation of the optical signal or simply a wrong setting of the communication
parameters (address, speed, optical power, operating mode…).
The errors generated by the SERCOS interface are displayed by the LED “S1/ERROR”
flashing (the LED “HW FAULT” is off) and the LCD displays a message with the error
code:
SERCOS-ERR: [32]
Press Any Key
Please notice that these errors have a lower priority than the “driver errors”. As a
consequence, if a SERCOS error and a driver error occur simultaneously, the displayed error
will be the driver error.
8.1.4 Solution of the communication problems

Here are some of the main causes which might create problems during SERCOS
communication, as well as a the way to find the errors and solve them.
The errors listed in the previous paragraph (21÷32) can be divided as follows:
1. ERRORS FROM 21 TO 25
They occur during the phase ramp of the SERCOS communication. In fact, before the
system is operative, it must undergo a process of synchronization with the control unit;
this process consists of 4 standard phases, according to the interface specifications.
53
Error 21: The device was not addressed by the control unit. This is not necessarily a
problem: if you are not going to enable the axis controlled by the driver, you can avoid
considering this error. The SERCOS ring will continue functioning anyway.
Otherwise, check the setting of the address and of the active controller, as indicated in
paragraph “SERCOS interface configuration ”.
Error 22: The device was properly addressed, but it can not make the phase change.
The error is probably due to the fact that the address of another device of the ring is
missing and the control unit has consequently interrupted the communication.
Error 23: It can occur at the beginning of phase 2. The system has not initialized the
non-cyclic communication (see standard SERCOS). This error is a symptom of a bad
functioning of the control device and/or unit.
Error 24 and 25 : The transfer from phase 2 to phase 3 (error 24) or from phase 3 to
phase 4 (error 25) was not possible. These errors are due to a wrong exchange of the
configuration parameters (time, structure of the cyclic message, procedure commands
with negative result). Check the programme of the control unit.
2. ERRORS FROM 28 TO 30
They are strictly linked to phase 4, during which the communication is synchronized
with the control unit and is fully operative.
Error 28: this is due to the attempt of the control unit to make a forbidden change of
communication phase. In fact, the interface specification indicates the passage to phase
0, as the only one permitted.
Error 29 and 30: they signal the loss of a part of the SERCOS message structure for
two consecutive times. Together with error 32, they enable you to find out where the
problem occurred within the ring.
3. ERROR 32
It can occur at any time during the communication. It indicates an interruption of the
lighting signal sent by the optical fiber, due to an excessive attenuation or a total
absence of the signal. Here are the possible causes:
1. There are one or more zones in the optical fiber that follow a path with a too
narrow bending radius;
2. The connection is made by means of fix or mobile joints, causing high losses of
signal;
3. The previous device within the ring is not functioning.
In order to better explain the previous errors, please find here below some examples. We
will take into consideration a SERCOS ring with 4 devices:
54
Picture 8.1.2 Example of SERCOS ring
EXAMPLE 1:
COSMOS 1 COSMOS 2 COSMOS 3 COSMOS 4
ERROR 29 or 30 ERROR 29 or 30 ERROR 32 ERROR 32

The error occurred between COSMOS 2 and COSMOS 3. The control unit is functioning
properly. We recommend you to proceed as follows:
1. Check the section of the optical fiber between the TX of COSMOS 2 and the RX
COSMOS 3: check the attenuation, reduce the too narrow bending radiuses or replace
the optical fiber, if it is damaged.
2. Remove the fiber from the TX of COSMOS 2 and make sure that the transmitter is
on: otherwise the driver must be damaged and it will be necessary to replace it.
3. If the previous problems persist, please replace the driver COSMOS 3.
This example is valid for a lot of devices and for any section of the optical fiber.
55
EXAMPLE 2:
ERROR 32 ERROR 32 ERROR 32 ERROR 32

The error occurred between the control unit and the first device in the ring. Please proceed
in the same way as indicated in the previous example
EXAMPLE 3:
ERROR 29 or 30 ERROR 29 or 30 ERROR 29 or 30 ERROR 29 or 30

The error occurred between the last device in the ring and the control unit. Please refer to
example 1 in order to find out the problem.
ESEMPIO 4:
ERROR 22 ERROR 21 ERROR 22 ERROR 22

The address or the setting of the active controller in COSMOS 2 is not correct. Please
proceed as described in paragraph “SERCOS interface configuration”.
The above instructions are not an infallible guide. The error codes and the
problems causing these errors depend on several conditions, inherent to a
complex communication system such as the SERCOS protocol.
8.1.5 IDN List

The messages transferred through the communication channel consist of a data block of the
SERCOS interface, made of 7 elements, 3 of which must be mandatorily defined:
DATA BLOCK OF THE SERCOS™ INTERFACE

N° element Obbligatory Description
1 SI IDN (Identification number of the message)
2 NO NAME (Name of the message)
3 SI ATTRIBUTE (Attribute of the message)
4 NO UNIT (Measure unit of the datum contained in the message)
5 NO MINIMUM INPUT VALUE (Minimum value valid for the datum)
6 NO MAXIMUM INPUT VALUE (Maximum value valid for the datum)
7 SI OPERATION DATA (Actual datum of the message)
The IDN univocally determines the message to be transferred. The SERCOS protocol fixes
a maximum of 65536 IDN: the interval 0÷32767 is for standard messages, whereas the other
IDN can be used by the manufacturer of the device in order to exchange owner information.
56
The attribute attaches a meaning to the datum to be transferred: type (whole, binary,
hexadecimal,…), length (expressed in number of bytes) and writing protection.
There are particular messages, called “procedure commands”, which are not used for data
transfer, but are used by the control unit in order to have the driver execute the internal
operations.
The below table shows the identification number of the message, the name defined by the
standard or by the manufacturer (for proprietary IDN), the measure unit, the validity limits
and the attribute in explicit format, with the data protection according to the communication
phase. Moreover, the below table provides a short description of proprietary messages.
Further detailed information and the procedures for using proprietary

messages are available in the “Programme Manual”. For standard messages,
please refer to official papers CEI IEC 1491.
STANDARD MESSAGES (DATA)

IDN Name Unit format Length Protected Validity
-byte- data
2–3–4
00001 Tncyc - control unit cycle time µs Int 2 NO-YES-YES 1000
00002 Tscyc - sercos cycle time µs Int 2 NO-YES-YES 1000
00003 T1min - minimum AT transmit starting time µs Int 2 YES-YES-YES -
00004 Tatmt - transmit/receive transition time µs Int 2 YES-YES-YES -
00005 T4min - minimum feedback acquisition time µs Int 2 YES-YES-YES -
00006 T1 - AT transmission starting time µs Int 2 NO-YES-YES 12 ÷ 65535
00007 T4 - feedback acquisition capture point µs Int 2 NO-YES-YES 0 ÷ 65535
00008 T3 - command value valid time µs Int 2 NO-YES-YES 0 ÷ 65535
00009 Position of data record in MDT - Int 2 NO-YES-YES 1 ÷ 65531
00010 Lenght of MDT - Int 2 NO-YES-YES 4 ÷ 65534
00011 Class 1 diagnostic - Bin 2 YES-YES-YES -
00013 Class 3 diagnostic - Bin 2 YES-YES-YES -
00015 Telegram type parameter - Bin 2 0x0004,
NO-YES-YES
0x0007
00016 Configuration list of AT - Int (IDN) Var - 2 NO-YES-YES -
00017 IDN List of all operation data - Int (IDN) Var - 2 YES-YES-YES -
00021 IDN List of invalid operation data for CP2 - Int (IDN) Var - 2 YES-YES-YES -
00022 IDN List of invalid operation data for CP3 - Int (IDN) Var - 2 YES-YES-YES -
00024 Configuration list of MDT - Int (IDN) Var - 2 NO-YES-YES -
00025 IDN List of all procedure command - Int (IDN) Var - 2 YES-YES-YES -
00030 Manufacturer version - Char Var - 1 YES-YES-YES -
00032 Primary operation mode - Bin 2 YES-NO-YES 0x0003
00040 Velocity feedback value - Int 4 YES-YES-YES -
00041 Homing velocity - Int 4 NO-NO-NO 300
00044 Velocity data scaling type - Bin 2 NO-NO-YES 0x000A
00045 Velocity data scaling factor - Int 2 NO-NO-YES 0x0001
00046 Velocity data scaling exponent - Int 2 NO-NO-YES 0x0000
00047 Position command value - Int 4 -2E31 ÷
NO-NO-NO
2E31-1
00051 Position feedback value 1 - Int 4 YES-YES-YES
-2E31 ÷
2E31-1
00052 Reference distance 1 - Int 4 NO-NO-NO -2E31 ÷
57
2E31-1
00055 Position polarity parameter - Bin 2 0x0000,
NO-NO-NO
0x0001
00057 Position window - Bin 4 NO-NO-NO -
00076 Position data scaling type - Bin 2 NO-NO-YES 0x008A
00079 Rotational position resolution - Int 4 NO-NO-NO 65536
00084 Torque feedback value - Int 2 YES-YES-YES -
00086 Torque/force data scaling type - Bin 2 NO-NO-YES -
00088 Tmtsy - receive to receive recovery time µs Int 2 YES-YES-YES -
00089 T2 - MDT transmission starting time µs Int 2 NO-YES-YES 0 ÷ 65535
00090 Tmtsg - command value proceeding time µs Int 2 YES-YES-YES -
00091 Bipolar velocity limit value - Int 4 NO-NO-NO 0 ÷ 7000
00092 Bipolar torque limit value - Int 2 NO-NO-NO 0 ÷ 1000
00095 Diagnostic message - Char Var - 1 YES-YES-YES -
00096 SLKN - slave arrangement - Hex 2 YES-YES-YES -
00098 Class 3 diagnostic mask - Bin 2 NO-NO-NO -
00100 Velocity loop proportional gain - Int 2 NO-NO-NO 0 ÷ 6091
00101 Velocity loop integral action time - Int 2 NO-NO-NO 0 ÷ 5405
00103 Modulo value - Int 4 NO-NO-YES 16777216
00104 Position loop Kv-Factor - Int 2 NO-NO-NO 0 ÷ 9450
00106 Current loop proportional gain 1 - Int 2 NO-NO-NO 0 ÷ 65535
00107 Current loop integral action time 1 - Int 2 NO-NO-NO 0 ÷ 65535
00109 Motor peak current - Int 4 NO-NO-NO 0 ÷ 50000
00110 Amplifier peak current - Int 4 NO-NO-NO 0 ÷ 50000
00111 Motor rated current - Int 4 NO-NO-NO 0 ÷ 35000
00112 Amplifier rated current - Int 4 NO-NO-NO 0 ÷ 35000
00113 Max Motor Speed - Int 4 NO-NO-NO 0 ÷ 7000
00124 Zero velocity window - Int 4 NO-NO-NO 10
00129 Manufacturer class 1 diagnostic - Bin 2 YES-YES-YES -
00159 Monitoring window - Int 4 NO-NO-NO 0 ÷ 16777216
00203 Amplifier shut-down temperature - Int 2 NO-NO-NO 0 ÷ 125
00204 Motor shut-down temperature - Int 2 NO-NO-NO 0 ÷ 155
00208 Temperature data scaling factor - Bin 2 YES-YES-YES -
00259 Positioning velocity - Int 4 -2E31 ÷
NO-NO-NO
2E31-1
00380 DC bus voltage V Int 2 YES-YES-YES -
00383 Motor temperature - Int 2 YES-YES-YES -
00384 Amplifier temperature - Int 2 YES-YES-YES -
00393 Command direction mode for modulo format - Int 2 NO-NO-NO 0÷2
PROPRIETARY MESSAGES (DATA)
32769 Position loop differential time (WKdpos) - Int 2 NO-NO-NO 0 ÷ 10
32771 Current limit maximun time - Int 2 NO-NO-NO 0 ÷ 65535
32773 RESERVED (Don’t use) - - - - -
32778 Position loop crossing point (LSB = 1/1000 rad) - Int 2 NO-NO-NO -
32783 Torque max feedback value - Int 2 YES-YES-YES -
32784 DC bus voltage min V Int 2 YES-YES-YES -
32788 Analog input1 value - Int 2 YES-YES-YES -
32789 Analog input2 value - Int 2 YES-YES-YES -
32792 No main power output state - Bin 2 NO-NO-NO -
32793 Vout type setting - Bin 2 NO-NO-NO -
32794 Vout measure setting - Bin 2 NO-NO-NO -
32795 Vel to Vout conversion factor - Int 2 NO-NO-NO 1 ÷ 1000
58
32796 Vel to Iout conversion factor - Int 2 NO-NO-NO 1 ÷ 1000
32800 DC bus voltage max V Int 2 YES-YES-YES -
32801 Motor Kt - Int 2 YES-YES-YES -
32802 Analog output offset - Int 2 YES-YES-YES -
32803 Analog output value - Int 2 YES-YES-YES -
32804 Distorsion numbers - Int 2 YES-YES-YES -
32805 Distorsion frequency - Int 2 YES-YES-YES -
32806 Maximun communication rate - Int 2 YES-YES-YES -
32807 List of last SERCOS errors - Char Var - 1 YES-YES-YES -
STANDARD MESSAGES (PROCEDURE COMMANDS)

N° Description Execution phase
IDN
00099 Reset class 1 diagnostic (C1D) 2–3–4
00127 Communication phase 3 transition check 2
00128 Communication phase 4 transition check 3
00262 Command load default 2–3–4
PROPRIETARY MESSAGES (PROCEDURE COMMANDS)
N° Description Execution phase
IDN
32780 Setting absolute position command 4
32782 RESERVED (Don’t use) -
32785 Reset minimun and maximun values 2–3–4
32791 RESERVED (Don’t use) 2–3–4
32797 Digital output enable 2–3–4
32798 Digital output disable 2–3–4
32799 Reset I/O class 2 diagnostic (C2D) 2–3–4
32808 Reset distorsion statistics 2–3–4
59
8.2 Analog controller
In this configuration, the driver receives a speed reference value ±10V from an external
device controlling the axes. The software controller will adjust the speed and the torque,
whereas the position check is made by the axis card.
Here is an example of connection with the system “CDP-AXIS”:
Picture 8.2.1 Card interface “CDP-AXIS”
In order for the signals interface to be correct, it is necessary to install 2 resistances 10 K?

1/4W (SMI KD030025) between the terminal I/O 24V and the input signals RESET IN and
ENABLE IN, as indicated in the electrical diagram. It is recommended to insulate the
resistance terminal by using the special sheating SMI EK050044.
The below table lists the I/O used by the analog controller:
60
Digital signals
N° I/O Signal name Description
01 ENABLE IN Enable signal sent to the driver by the axis card.

02 RESET IN Reset signal sent by the driver by an external system (for
example by a push-button). It is used in order to cancel any
errors in the driver.
03 ENABLE OUT Active output signal: high. It indicates the state of the driver
enabling (it can be connected to a LED).
04 ERROR OUT Active output signal: high. It indicates the presence of an
error in the driver.
05 READY Active output signal: high. The signal becomes active after a
time interval set by the LCD, starting from when the driver
can be enabled. This signal can replace the ERROR OUT in
the event that the enabling request is made immediately after
the ERROR OUT disabling.
06 NOT USED -
07 NOT USED -
08 NOT USED -
8.2.1 ANALOG controller configuration

The configuration consists in setting the parameters of the analog input voltage IN-2, so as
to properly understand the speed reference supplied by the external axis card to the driver.
Moreover, it is possible to configurate the active logical level of the two input signals
ENABLE IN and RESET IN.
To this purpose, it is possible to use the LCD menu VISUAL DATASET-ANALOG.
61
ANALOG CONTROLLER PARAMETERS
K-VIN/VEL Speed constant of the analog input expressed in rpm per Volt in
[V/rpm] 300 input.
Kv Thanks to this value, it is possible to modify the necessary gain to
turn the speed analog reference value into rpm, according to the
Min = 0 following formula:
Max= +350
where,
Vel = speed in rpm required from the motor;
Kv = speed constant;
Vin = voltage analog reference (from -10V to +10V);
Voff = analog input offset (from -5V to +5V).
It is recommended to use the whole dynamic of the input, so as to

increase the signal/noise ratio.
OFFSET[V] 0.000 Offset voltage of the analog input expressed in Volt.
This voltage is to be algebrically summed up to the voltage of the
Voff speed analog reference supplied by the driver. Anyway, this sum
can not exceed the analog input limits (± 10V). For further
Min = -5.000 information, please refer to Kv value.
Max = +5.000
LIVELLO-RESET L L = The reset signal is active and low.
LIVELLO-ENABL L H = The reset signal is active and high.
LIVELLO-RESET L L = The enable signal is active and low.

LIVELLO-ENABL L H = The enable signal is active and high.
TEMPO-READY[s] 3 Delay time for the activation of signal READY-OUT; after that,
---------------- the driver is ready to be enabled.
Min = 0 It delays the enabling request, starting from the moment when the
Max = +20 driver is no longer in error state.
8.2.2 ANALOG controller state

The VISIO displays the “Messages” about the analog interface state. The presence of a
message is also signalled by the LED “S1/ERROR”.
WARNING: [50]
Press Any Key
62
Please notice that the priority of the analog interface messages is lower than that of the
“driver errors”. As a consequence, if the analog interface message and the driver error are
simultaneous, the first displayed message will be the driver error.
An analog interface message does not necessarily imply the procedure to reset it, but it will
be automatically cancelled, if the required conditions are complied with. By contrast, a
driver error must be cancelled through the option ERROR-RESETof the LCD. If the error
persists, the procedure will not be successful.
WARNING Codes
Warning message Explanation
Attendo alimentazione principale At the power up, if the auxiliary voltage is

WARNING: [50] present, wait the minimum main power supply
before proceeding.
Attendo spegnimento segnale di At the power up the signal of driver reset must
reset not be active.
WARNING: [51]
Attendo spegnimento segnale di At the power up the signal of motor enabling

abilitazione must not be active.
WARNING: [52]
Attention: a warning and/or an error will not allow you to enable the driver.
8.3 Analog controller in electric axis mode (KZ100071 only)
8.3.1 Description of electric axis functioning

On some models there is the necessity to connect two sections of machine electronically
rather than mechanically, in a way to make the most of the usual flexibility offered by the
electronics. This substantially means that there is one master and one slave that follows it in
a perfectly synchronous mode. The attainment of this functionality passes through a RS-485
communication. Below the architecture and functioning mode are given approximately.
63
Below is a status diagram to describe functioning.
Status Description
Start-up Initial Status. Can be reached after cosmos
switch-on or error reset. Used to request re-
phasing of the cosmos.
Error Error status.
Re-phasing Re-phasing in progress.
Stop Axis re-phased and ready to produce.
Production Driver in movement with master/slave data
exchange.
64
Commissioning
RE-PHASING request RE-PHASING

START-UP
RE-PHAS. OK
RIF. NO OK
Reset Enable IN
STOP
Error
Enable IN
DO NOT Enable
ERROR Error
PRODUCTIO
N
ENABLE IN RESET IN READY PHASE SIGNAL SIGNAL

REQUEST RESET PHASE
REQUEST REQUEST
(master only) (master only)
START-UP ERROR START-UP ON RE-PHASING ON OFF
RE-PHASING NOP START-UP OFF NOP OFF OFF
STOP PRODUCTION START-UP ON NOP OFF OFF
ERROR NOP START-UP OFF NOP OFF ON
PRODUCTION NOP START-UP ON NOP OFF OFF
NOP : No operation and/or status transition
65
MASTER Digital Signals
N° I/O Signal Name Description
01 ENABLE IN Enabling signal supplied to the driver by the axis card.

02 RESET IN Reset signal supplied to the driver by an external system (e.g.
a button). It is used to delete any error present in the driver.
03 SIGNAL RESET Active output signal: high. Indicates that a reset is necessary.
REQUEST
04 SIGNAL PHASE Active output signal: high. Indicates the necessity to re-phase
REQUEST the axis.
05 READY Active output signal: high. It becomes active after a time set
from the LCD from when the driver can be activated.
06 POWER IN Signal in input connected to the emergency.
07 PHASE REQUEST Axis re-phasing request.
COMMAND
08 PHASE SENSOR Input for phase sensor acquirement
SLAVE Digital Signals

N° I/O Signal Name Description
01 ENABLE IN Enabling signal supplied to the driver by the axis card.

02 RESET IN Reset signal supplied to the driver by an external system (e.g.
a button). It is used to delete any error present in the driver.
03 SIGNAL RESET Active output signal: high. Indicates that a reset is necessary.
REQUEST
04 SWITCH Input that allows to select the transmission ration between
Master and Slave.
ON: use Ratio = SLAVE-NUM1/ SLAVE-DEN1 (*)
OFF: use Ratio = SLAVE-NUM2/ SLAVE-DEN2 (*)
(*) refer to the parameters table given below.
05 READY Active output signal: high. It becomes active after a time set
from the LCD from when the driver can be activated.
06 POWER IN Signal in input connected to the emergency.

07 PHASE REQUEST Axis re-phasing request.
COMMAND
08 PHASE SENSOR Input for phase sensor acquirement
8.3.2 ANALOG controller configuration in electric axis mode
The configuration consists in setting parameters relative to the IN-2 analog input voltage, in
a way to correctly interpret the speed reference supplied to the driver from the external axis
management card. It is also possible to configure the active logic level of the two input
signals ENABLE IN and RESET IN.
For the slave it is important to set a Kp value for the position control. This is found in
VISUAL DATA SET-DRIVE.
KPP[rpm/G] 0.0 2 rpm/ Position proportional gain, expressed in rpm per degree.
KDP[] 0 GR The driver continuously detects the position of the rotor
IDN00104 and compares it with that of the position reference
Kppos supplied. The difference between these two values is
multiplied by the proportional gain to determine the
Minimum = 0.0 proportional speed.
Maximum = +2500.0 The greater the difference of position, the faster the speed
set at the motor. This process, which is performed
continuously, tends to make the motor reach the reference
position, also on variation of the load conditions applied
to the motor.
Generally the proportional gain must be searched for case
by case according to the application of the motor. The
value is strongly conditioned by the mass of inertia
applied to the axis motor.
In the practical tests the gain must be searched for
empirically, raising the value progressively, until
instability appears. This can be easily detected by
listening to the noise of the motor and checking vibration.
On reaching the limit, lower the gain by 10-20% as a
safety margin.
To do this it is possible to use the relevant LCD menu VISUAL DATA SET-ANALOG.
67
ANALOG CONTROLLER PARAMETERS
K-VIN/VEL Parameter valid only for the MASTER.
[V/rpm] 300 Analog input speed constant expressed in rpm per input Volt.
Kv Allows to change the gain that is used to transform the analog
speed reference into rpm, according to the following relation:
Minimum = 0
Maximum = +350
where,
Vel = speed in rpm requested by the motor;
Kv = speed constant;
Vin = live analog reference (from -10V to +10V);
Voff = Analog input Offset (from -5V to +5V).
It is recommended to use all input dynamics, so as to increase the

signal/noise relationship.
OFFSET[V] 0.000 Parameter valid only for the MASTER.
Analog input offset voltage expressed in Volts.
Voff This voltage is added in an algebraic mode to the voltage that
represents the analog speed reference supplied to the driver. In all
Minimum = -5.000 cases this sum cannot exceed the analog input limits (± 10V). For
Maximum = +5.000 further information refer to the Kvdata.
RESET-LEVEL L L = The reset signal is active, low.
LEVEL-ENABLE L H = The reset signal is active, high.
RESET-LEVEL L L = The enabling signal is active, low.

LEVEL-ENABLE L H = The enabling signal is active, high.
READY-TIME [s] 3 Delay time for the activation of the READY-OUT signal after the
---------------- driver is ready to be enabled.
Minimum = 0 Allows to delay the enabling request from when the driver is no
Maximum = +20 longer in an error state.
TYPE Allows to select the work mode:
MASTER or SLAVE.
Master /Slave
Parameter valid only for the MASTER.
FM-G[N] At the end of re-phasing the axis stops with a certain unphasing
Minimum = 0 defined by a number of revs.+fraction of rev. The parameter
Maximum = +255 specifies the number of motor revs.
FM-I[N] Parameter valid only for the MASTER.
At the end of re-phasing the axis stops with a certain unphasing
Maximum = +65535 specifies the number of impulses of the fraction of rev. (1
rev=65536 imp).
SENSOR Specifies if re-phasing takes place by means of sensor or not.
Yes / No
68
SLAVE-NUM1[N] Parameter valid only for the SLAVE.
Specify the numerator of the transmission ratio with respect to the
Minimum = 0 master with SWITCH ON input.
Maximum = +65535
SLAVE-DEN1[N] Parameter valid only for the SLAVE.
Specify the denominator of the transmission ratio with respect to
Minimum = 0 the master with SWITCH ON input.
Maximum = +65535
Parameter valid only for the SLAVE.
FS1-G[N] At the end of re-phasing the axis stops with a certain unphasing
Maximum = +255 specifies the number of motor revs. The parameter is used with
SWITCH ON.
FS1-I[N] Parameter valid only for the SLAVE.
rev=65536 imp). The parameter is used with SWITCH ON.
SLAVE-NUM2[N] Parameter valid only for the SLAVE.
Specify the numerator of the transmission ratio with respect to the
Minimum = 0 master with SWITCH OFF input.
Maximum = +65535
SLAVE-DEN2[N] Parameter valid only for the SLAVE.
Specify the denominator of the transmission ratio with respect to
Minimum = 0 the master with SWITCH OFF input.
Maximum = +65535
Parameter valid only for the SLAVE.
FS2-G[N] At the end of re-phasing the axis stops with a certain unphasing
Maximum = +255 specifies the number of motor revs. The parameter is used with
SWITCH ON.
FS2-I[N] Parameter valid only for the SLAVE.
rev=65536 imp). The parameter is used with SWITCH ON.
E-POS[Imp] Parameter valid only for the SLAVE.
Specifies the maximum tolerated position error. The value is
Minimum = 1 expressed in degrees on the motor rev. (360). A value equal to
Maximum = +36000 3600 indicates an error of 10 motor revs.
T-BRAKE[s] Driver enabling signal permanence time during emergency. This
signal allows the slave to maintain the phase during master
Minimum = 0 stopping (which moves due to inertia).
Maximum = +10
TIMEOUT-RIF[s] Defines the maximum time for phase sensor search.
Minimum = 1
Maximum = +30
VEL-RIF[rpm] Specifies the axis re-phasing speed.
69
Minimum = 1
Maximum = +3000
ACC[rpm/s] Specifies acceleration during re-phasing.
Minimum = 1
Maximum = +100
DIRECTION Specifies the direction of motor rotation.
0/1
RAMP[rpm/s] The values included between 100 and 2000 indicate the use of a
ramp on variation of the reference.
Minimum = +100 The value 2001 has a different meaning, it indicates not to use
Maximum = +2001 ramps.
RAMP-E[type] It specifies the ramp to use when the enable signal is missing. To
know the real value of the ramp applied the value must be
Minimum = +3 multiplied by 1000. E.g.: 3 indicates a ramp of 3000 rpm/s.
Maximum = +20
8.3.3 ANALOG controller status in electric axis mode

The VISIO shows the “Warnings” regarding the status of the analog interface. The presence
of a warning is also signalled by the flashing “S1/ERROR” LED.
WARNING: [50]
Press Any Key
I must be remembered that the priority of the analog interface warnings is however lower
with respect to those of the "driver errors". This means that if there is an analog interface
warning and a driver warning at the same time, the driver warning will be signalled.
The presence of an analog interface warning does not imply the necessity to actuate a
deletion procedure, but it will be automatically deleted when the requested conditions are
satisfied. If this is not the case, any error condition in which the driver is found must be
deleted using the RESET-ERROR LCD option. If the error persists the operation will have
no effect.
70
WARNING code
Warning text Explanation
Wait for main power supply On switch-on, the auxiliary voltage is present,
wait for the main minimum power supply
voltage before proceeding.
WARNING: [50]
Wait for reset signal to switch On switch-on the driver reset signal must not be
off activated.
WARNING: [51]
Wait for enabling signal to switch On switch-on the motor enabling signal must
off not be activated.
WARNING: [52]
Start request with axis not re- The axis start has been requested without having
phased rephased it. Press the reset signal and then carry
WARNING: [60] out the re-phasing procedure.
Phase sensor not found No sensor has been found during the re-phasing
WARNING: [61] procedure.
CRC error in the communication A CRC error has been detected in the serial
WARNING: [62] transmission.
Serial error The serial communication has been interrupted.

WARNING: [63]
Error in the flow of the data Signals a discontinuity of the data exchanged on
transmitted the serial.
WARNING: [64]
Attention: the presence of a warning and/or an error does not allow the driver to
be enabled.
71
8.4 VISIO controller
The motor commands are sent to the driver directly by the VISIO. In order to reach the
controller section, go through the following path, starting from the main menu of the LCD:
VISUAL DATASET-DIAGNOSTIC .
Make sure that the active controller is “Diagnostic” and is at access level 3.
Otherwise, il will not be possible to make the following operations.
“DIAGNOSTIC-SET” MENU
Code Description
MOD-DIAG VEL This code indicates the system control mode set on Speed, not
resettable.
STATE DISABIL It indicates the present driver state, enabled or disabled.
ABILIT-VEL NO If the driver is not in error state, the setting of this code enables the
driver.
ACC[rpm/s] 0 This parameter sets the speed ramp incline, expressed in
rpm/500µs. It indicates the speed increase/decrease every 500µs;
the driver will try following this speed rate.
The parameter is always positive: this is the control system which
determines whether the driver accelerates or decelerates.
VEL-R[rpm] 0 It sets the speed in rpm, which the motor has to follow (Max limit
VelmotMAX).
VEL [rpm] 0 Present speed of the motor
72
DRIVE-STATE [00] It indicates the present state of the driver. If it is in error, it will not
be possible to enable the driver.
RESET-ERROR NO It cancels the error. If the error persists, the operation will not reset
anything.
ATTENTION: if the parameters “VEL-R” and “ACC[rpm/s]” are set while the
driver is disabled, no ramp will be executed, but the system will try reaching the
final speed rate as soon as it is enabled.
9 MOTOR ENABLING
This chapter is a guide for inexperienced users of the COSMOS-2000, up to the motor
enabling by means of VISIO control mode.
Follow all safety instructions in chapter 3.

Make sure that the motor mechanical mouvement is not dangerous.
9.1 Electrical wiring

1. The VISIO is expected to be properly installed in its own housing.
2. Take into consideration one of the motors controlled by the driver, for example the
RCV UL503 Vn327
3. Connect the three-phase power supply to the connector 3PH LINE, according to the
mode described in paragraph 5.2.1.2.
4. Connect the motor cable to the connector MOTOR according to the mode described
in paragraph 5.2.1.3.
5. Connect the encoder cable to connector ENCODER-IN according to the mode
described in paragraph 5.2.2.1
6. Connect the 24V power supply to the connector 24 Vdc according to the mode
described in paragraph 5.2.1.1
7. Start the 24V power supplier and make sure that the COSMOS-2000 starts and that
the microcontroller is controlling it (Led CPU READY on)
8. Install the three-phase power supply and make sure that the led MAIN POWER
switches on and the cooling fan starts running.
9.2 Mode setting

It is very likely that the driver is not set on the required mode. It is necessary to set it in such
a way as to enable the VISIO to control the driver.
In order to set the mode, please proceed as follows:
1. Insert the password TARAT, as described in paragraph 6.2
73
2. Enter inside the menu VISUAL DATAACTIVE-MOTOR and set the RCV
UL503Vn327 motor, as described in paragraph 7.5
3. Enter inside the menu VISUAL DATA SET-DRIVE and set the controller on VISIO,
as described in paragraph 7.4
9.3 Motor enabling

1 . G o t o VISUAL DATA S E T - D R I V E a n d s e t t h e C P - L I M [ N m ]
10 on 5. As a consequence, the torque generated by the motor is
limited at 5Nm.
 Go to VISUAL DATA SET-DIAGNOSTIC go to ABILIT-VEL NO and press
 . The code “NO” will start flashing. Press  again and then press the upwards
arrow. When “YES” is displayed, press  for 1 second. When the driver is enabled,
you will hear the click of the internal relay and the led DRIVE ENABLED will switch
on.
2. Now the driver is enabled and the motor is under voltage; it is necessary to set the speed
ramp in order to accelerate the motor. To this purpose, go ACC[rpm/s] 0 and
set it on 10. Higher values correspond to higher acceleration.
3. Go to VEL-R[rpm] 0 and set the speed rate you want the motor to reach. First
set value 1000. If there are no problems, the motor will start the acceleration ramp as
soon as the value is set and it will reach 1000rpm. In order to verify the result, you can
either check the motor or read the value at VEL[rpm].
9.4 Performance optimization

Now that the user has got some practice with the COSMOS, let’s see how it is possible to
optimize the motor performances. Please follow the below procedure:
1. Accelerate the motor up to 2500rpm by setting VEL-R[rpm] 2500
2. Decelerate the motor up to -2500rpm, by simply modifying the sign of the value
VEL-R[rpm] -2500
3. The motor will reverse the rotation direction and it will take some time to shift from
one speed rate to another. However, a brushless motor can certainly grant better
performances.
4. Try accelerating the motor up to 1000rpm/s and repeat the speed reversal several
times. You will probably notice an improvement, but the motor can perform even better.
In fact the driver can limit the current required by the motor. Let’s try increasing this
limit and see what happens.
5. Enter inside the menu VISUAL DATA SET-DRIVE and set the CP-
LIM[Nm] 10 10 on 10. Now the motor can generate up to 10Nm, as
compared to the previous 5Nm.
74
6. Repeat the speed reversal several times. Now the reversal will be almost
instantaneous (it takes about 20ms).
75
10 TECHNICAL DETAILS
10.1 Ratings
Mains voltage Three-phase: 230÷460V ± 10% - 480V ± 5%

Auxiliary: 24V ± 10%, protection against over-current and over-
voltage
Power absorbed by the Less than 15W
running logic
Rated output current 21Arms at 480Vrms, 8KHz and 45°C
Maximum output current 30Arms per 15sec
Number of power supplies Maximum 20 per hour, at equal distances
Start time 4s
Protection functions Short-circuit, over-current, motor and driver over-temperature,
under-voltage, over-voltage, brake resistance over-load, motor over-
speed, torque/time check
Internal brake resistance 50

Voltage of the internal brake 4000W
resistance
Max. temperature of the 150 °C
internal resistance
External brake resistance 30÷500
Voltage of the external brake 0÷20000W
resistance
Temperature range of the 0÷350 °C
external resistance
Motor FeedBack Integrated

Incremental, up to 16384 pulses, with HALL sensors reading
By means of an external removable module
Resolver - SinCos - Endat - HyperFace
Measures of temperature NTC motor, NTC driver
Control system PWM 8-16KHz sinusoidal, with a fully predictive digital loop, with
torque, speed and position adjustment
Operating mode Integrated
Analog ±10V - VISIO
By means of an external removable module
SERCOS - CAN
Parameters control By means of the removable keyboard VISIO or emulation software
Operating state VISIO and LED: problems HW, regular functioning, presence of
error
Event memory EEPROM saving the lists of the last errors, driver parameters and
motor parameters.
Digital I/O from 8 to 24Vdc

76
Rated current for each digital 0,7A
I/O
Peak current for each digital 2A
I/O
Max. current absorbed by the 4A
digital I/O
Analog inputs 2 (±10V)

Analog inputs impedance 10 K
Analog outputs 1 in voltage 0-10 V
1 in current 4-20mA
Connections Voltage: three-phase power supply, three-phase motor output,

external brake resistance, auxiliary power supply, VDC bus
recovery. Signal: motor encoder, encoder signals repeated, RS232,
analog interface, digital I/O
Degree of protection IP20

Ambient conditions Pollution Degree 2
No dust, no corrosive/inflammable gases, no oil
Ambient temperature 0 ÷ 50 °C
(Surrounding air)
Humidity 95% not condensing
Storage temperature -10 ÷ 60 °C
Dimensions: Length x Height 115x296x242 mm
x Width
Weight 6,9 Kg
10.2 DeRating
Rated Current
8KHz 12KHz 16KHz
Altitude < 1000m
21A 16A 12A
Ambient temperature < 45°C
Ambient temperature > 45°C -6% ogni °C
Altitude > 1000m -1% ogni 100m
77
11 CERTIFICATION
11.1 Directives
 The driver is an "Open Type" device and must be installed in an environment with
Pollution Degree 2;
 The max. output current must be 21A at 45°C (Surrounding Air) with a 6% derating
for each °C up to max. 50°C;
 It is necessary to use copper conductors between 8 and 14 AWG according to the
ratings and they must be adequately crimped by means of MOLEX 63811-1600
pliers.
 The protection fuses must be ultrarapid:
o CCN JFHR2
o Voltage >= 480V
o Current <= 40 A
o I2t <= 1050 A2s
 The driver must be installed within a system with short-circuit current not exceeding
5KA (symmetrical), at 480Vac.
 All signals in low voltage, (except the auxiliary power supplies) must be Low
Voltage Limited Current.
11.3 Motor protection

The driver is not equipped with a protection system against the motor over-load.
However, it is equipped with a mechanism controlling the current, with the possibility to fix
a maximum limit and the time of intervention. The driver can also control the motors
integrating the temperature sensor. Therefore, it is possible to protect the motor according to
the detected temperature.
For this section, please refer to paragraph 7.6.
78
APPENDIX
A.1 Reference papers
The following directives are referenced in the manual. Their content is subject to revision.
CEI/IEC 1491: 1995, Electrical equipment of industrial machines – Serial data link for real-
time communication between controls and drives.
CEI/IEC 61491: 1998, Update CEI/IEC 1491.
SMITEC: 2002, Manual for MATROK setting.
SMITEC: Instructions concerning AXIS2000/3000 card.
MOLEX 42815/42816/42817/42818: 1998, 10.00mm (.393”) Pitch Mini-Fit, Sr. ™.
A.2 Abbreviations
Here are the abbreviations used in this manual.
Clim: Motor torque limit
CMeas: Measure of the torque generated by the motor.
CMeasMax: Measure of the max. torque generated by the motor.
IDEff: Effective reverse current measured.
IDPeakMax: Maximum peak reverse current measured.
IdrvNom: Effective rated current of the driver.
IQEff: Effective direct current measured.
IQPeakMax: Max. direct peak current measured.
Kdpos: Position derivative Gain
KdRest: Temperature coefficient of the external brake resistance.
KIoutErrPos: Constant of position error of the analog output in current.
KIoutErrVel: Constant of speed error of the analog output in current.
KIoutIq: Constant of Iq current of the analog output in current.
KIoutVel: Constant of Iq speed of the analog output in current.
Kpivel: Speed integrative gain.
Kppos: Position proportional gain.
Kpvel: Speed proportional gain.
Kv: Speed constant of the analog input.
KVoutErrPos: Constant of the position error of the analog output in voltage.
KVoutErrVel: Constant of the speed error of the analog output in voltage.
79
KVoutIq: Constant of Iq current of the analog output in voltage.
KVoutVel: Constant of the motor speed of the analog output in voltage.
PREst: External resistance power.
REst: Ohmic value of the external resistance.
TambREst: Ambient temperature of the external resistance.
TCLim: Limit couple stay time.
TDriveMeas: Measure of the driver internal temperature.
TDriveMeasMax: Measure of the maximum temperature reached by the driver.
TempMotMax: Max. temperature reached by the motor.
TmaxREst: Max. temperature reached by the external resistance.
TMotMeas: Measure of the motor temperature.
TMotMeasMax: Measure of the motor maximum temperature.
TResIntMeas: Measure of the present temperature of the internal brake resistance.
VDCBus: Measured value of the driver main voltage.
VDCMax: Max. measured value of the driver main voltage.
VDCBusMin: Minimum measured value of the driver main voltage.
VeffPR: Effective voltage of the three-phase input power supply.
VelMotMax: Max. motor speed.
VelMotMeas: Measure of the motor present speed.
VelMotNom: Motor rated speed.
Vlim: Limit speed set for the application.
VNomDrv: Driver rated voltage.
VNomRMS: Effective rated voltage of the motor.
Voff: Offset voltage of the analog input.
80
A.3 Units of measure
The below table lists the units of measure used in this manual
UNITS OF MEASURE
SYMBOL SIZE UNIT NAME S.I. UNITS
[sec] Time Second =
[m] Length Meter =
[Kg] Mass Kilogramme =
[rad] Angle Radian =
[V] Electric voltage Volt =
[A] Electric current Ampere =
[°K] Temperature Degree Kelvin =
[°C] Temperature Centigrade degree [°K] = [°C] + 273
[G] [GR] Angle Degree [rad] = [G] • (2/ 360)
[giro] Angle Turn 1 [giro] = 360 [G]
DERIVED UNITS
SYMBOL SIZE UNIT NAME S.I. UNITS
[N] Power Newton [N] = [Kg] • ( [m] / [s] ²)
[Nm] Work/Energy NewtonMetro Joule [J] = [N] • [m]
[W] Voltage Watt [W] = [J] / [s]
[ohm] [] Electrical resistanceOhm [ohm] = [V] / [A]
[H] Inductance Henry [H] = [J] / [A] ²
[rpm] Rotation Revolutions Per [rpm] = [360G] / [60s] =
Minute [6G] / [s]
[V/rpm] Counter- Volt per revolution [V/rpm] = [V] • [s] / [6G]
electromotive force per minute
[Nm/A] Torque constant Joule per ampere =
[G/A] - Degrees per ampere =
[G/rpm] - Degrees per [G/rpm] = [G] • [s] / [6G] =
revolution per [s] / 6
minute
[A/V] Voltage gain Ampere per volt =
[rpm/V] Voltage gain Revolutions per [rpm/V] = [6G] / ( [s] • [V] )
minute per volt
[GR/V] Voltage gain Degrees per volt =
[A/mA] Current gain Ampere per 1000
milliampere
[rpm/mA] Current gain Revolutions per [rpm/mA] = [6G] / ([s] • [A] •
minute per 10 –3 )
milliampere
[GR/mA] Current gain Degree per [GR/mA] = [GR] / ([A]•10 –3 )
milliampere
[°C/W] Temperature constant Centigrades per watt [°C/W] = ([°K] – 273) / [W]
81
A.4 Compatible motors
Here is a list of the motors which can be connected to the driver at present:
LIST OF THE MOTORS
N° CODE SUPPLIER VN RATED RATED
[Vrms] TORQUE SPEED
[Nm] [rpm]
01 UL714 R.C.V. 314 14.00 3000
02 UL714 R.C.V. 332 14.00 3000
07 UL714 R.C.V. 184 14.00 3000
03 UL708 R.C.V. 331 08.00 3000
08 UL708 R.C.V. 189 08.00 3000
04 UL508 R.C.V. 338 08.00 3000
09 UL508 R.C.V. 177 08.00 3000
05 UL505 R.C.V. 337 05.00 3000
10 UL505 R.C.V. 185 05.00 3000
06 UL503 R.C.V. 327 03.00 3000
11 UL503 R.C.V. 175 03.00 3000
19 B6304 LAF 296 04.00 3000
25 B6304 LAF 170 03.00 3000
24 B6305 LAF 171 03.00 3000
18 B6306 LAF 296 06.00 3000
23 B6306 LAF 171 03.00 3000
17 B6308 LAF 296 08.00 3000
22 B6308 LAF 170 03.00 3000
16 B7108 LAF 296 08.00 3000
21 B7108 LAF 171 03.00 3000
15 B7112 LAF 296 12.00 3000
14 B7114 LAF 296 14.00 3000
13 B7116 LAF 296 16.00 3000
20 B7116 LAF 171 03.00 3000
12 B7128 LAF 296 28.00 3000
At present, we are using R.C.V. and LAF motors, with a nominal torque between 3 Nm and
28 Nm, integrating a NTC temperature sensor instead of the PTC temperature breaker.
Thanks to this sensor, it is possible to monitorize the motor temperature, thus increasing the
system level of reliability and the application flexibility; as a consequence, the user can set
the protection limit for “too high temperature”.
The driver can be connected to other motor models, provided the user checks a motor
sample and modifies the control programme. Both operations must be made in our
laboratories.
The motor can have any number of poles, a rated voltage from 170V to 380V and with
sinusoidal electromotive force. The HALL sensors can be outside the encoder, with an open-
collector or totem-pole output. However, the driver can control the motor up to a maximum
speed rate of 3000 rpm.
82

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(COntrol ServoMOtor System)

A driver for brushless motors

8.2 Analog controller___________________________________________________________________________62

LIST OF THE PICTURES

Picture 5.1.1 Mechanical dimensions______________________________________________________________11

1.1 Purposes of this manual

Symbols used in this manual

Danger: high voltage

Never use the driver if the container is not fully assembled.

Mains voltage 3-phase: 230÷460V ± 10% - 480V ± 5%

Digital Inputs/Outputs from 8 to 24Vdc

Degree of protection IP20

4.3 Expansion slots

4.4 Operating modes

4.4.1 Speed check by means of an analog controller

4.4.2 Speed check by means of VISIO

4.4.3 Position or speed check by means of a field BUS

Picture 5.1.1 Mechanical dimensions

5.2 Electrical installation

Picture 5.2.1 Connectors position

5.2.1 Power section

5.2.1.1 Wiring diagram

Before making the connections, make sure

The following paragraphs will analyse each section

5.2.1.2 “24 VDC” connector

5.2.1.3 Connector “3PH LINE”

Connector 3PH LINE

5.2.1.4 Connector “MOTOR”

The sequence of the motor phases

5.2.1.5 “BRAKE” Connector

5.2.1.6 Connector “VDC BUS”

VDC BUS Connector

5.2.1.7 Wiring and electrical features

 Insulation voltage: 2200 VAC

 Maximum contact resistance: 1 m

This picture shows the plug connector on the driver bottom

Table of connectors codes

5.2.1.8 Earth wiring

5.2.1.9 Requirements of the main power supply:

 Voltage: three-phase: 230÷460V ± 10% - 480V ± 5%

The fuses must be ultrarapid, with semi-conductor, in order to protect the

5.2.1.11 Output circuit and motor protection

5.2.1.12 Electro-magnetic compatibility (EMC)

5.2.1.13 Stray currents

5.2.2.1 “ENCODER IN” connector

Picture 5.2.2 ENCODER IN wiring

5.2.2.2 “ENCODER OUT” connector

ENCODER OUT connector

Picture 5.2.3 Serial cable for VISIO remote connection

Attention! This procedure must be undergone by competent people, because a

n° Name Signal n° Name Signal

Analog output in voltage Analog output in current

5.2.3 Expansion slots

5.2.3.1 FBM - SERCOS

Picture 6.1.1 VISIO

6.2 Structure of the menu

List of the entries “VISUALIZZA-DATI”

VDC-MIN[V] 0 -/- Minimum value measured by the VDC bus.

Direct current (active element of the current vector).