Position Synchonizer

1
Altivar 71 Position Synchroniser
Operation Manual
Spinning Control PDL Part No. 90344-010 Rev A

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Disclaimer
The software described in this manual is sold or licensed as is. Should the program prove defective the user (and not PDL
Electronics Ltd, its distributor or its dealer) assumes the entire cost of all necessary servicing, repair, and any incidental or
consequential damages resulting from any defect in the software. Further, PDL Electronics Ltd reserves the right to revise this
publication and to make changes from time to time in the contents hereof without obligation to notify any person of such
revision or changes
Revision History Table

Date Revision Revision Comments
15-07-05 90948011a Initial release of ATV71 Synchroniser.
15-09-05 90948011b Enabled Heartbeat. Added Debounce. Removed Sync prox mode. Improved synchronising.
4-10-05 90948011c Disabled faults in Setup mode. Added Heartbeat On/Off screen. Improved missing index fault
ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

ATV71 POSITION SYNCHRONISER
ATV71 Programming Manual Addendum 90948011c
CONTENTS
1 Introduction ....................................................................................................................................4
2 Specifications:................................................................................................................................2
3 Background:...................................................................................................................................2
4 Synchroniser Program Overview: ..................................................................................................3
4.1 Index Pulse ...........................................................................................................................3

4.2 Revolutions per Index (R/I) ...................................................................................................3
4.3 Power Up...............................................................................................................................3
4.4 Index Monitoring....................................................................................................................3
4.5 Position Monitoring................................................................................................................4
4.6 Offset.....................................................................................................................................4
4.7 CANopen Network ................................................................................................................4
4.8 Control Type..........................................................................................................................4
5 Synchroniser Screens....................................................................................................................5
5.1 Overview: ..............................................................................................................................5

5.2 New Screens .........................................................................................................................6
6 Setting Up ....................................................................................................................................15
6.1 Master Drive Input/Outputs: ................................................................................................15

6.2 Controller Inside Input/Outputs: ..........................................................................................16
6.3 Slave Drive Input/Outputs: ..................................................................................................16
6.4 Maximum Speed Limit: .......................................................................................................17
6.5 CANopen Network: .............................................................................................................17
6.6 RPI setup: ...........................................................................................................................18
6.7 Miscellaneous: ....................................................................................................................18
6.8 Customisation of the Monitoring Display:............................................................................18
7 Synchroniser Parts.......................................................................................................................19
8 Status Messages .........................................................................................................................20
9 Synchroniser Faults. ....................................................................................................................20
10 Commissioning Parameter Record Sheets and I/O Assignment for Master Drive ......................22
11 Commissioning Parameter Record Sheets I/O Assignment for Slave Drives .............................24
12 Documentation/Manuals ..............................................................................................................27
13 Glossary.......................................................................................................................................28
14 Index ............................................................................................................................................29

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1 Introduction
The objective of the ATV71 Position Synchroniser is to ensure the position of 2 or more
devices such as conveyors are kept in alignment or synchronism.
One device is deemed to be the Master and the remaining devices are deemed to be
Slaves. The Master drive is given the desired speed reference. The basic function of the
Slave drive is to follow the speed of the master, but if a positional error is detected its speed
is automatically increased or decreased to maintain position synchronism.
The Master drive consists of an ATV71 variable speed drive with a Controller Inside card
fitted and the ATV position synchroniser program loaded. The Slave drives are standard
ATV71 variable speed drives with no Controller Inside card fitted.
A sensing device such as a proximity switch is mounted to each device to indicate its
position. The proximity switches are connected to the Logical Inputs (digital inputs) of the
Controller Inside card and provide an index pulse at appropriate positions during the
movement of the device being synchronised. The Synchroniser continuously monitors these
index pulses and determines if there is a positional error between the Master drive and any
of the Slaves. If an error is detected a speed adjustment is made to the Slave drive
concerned so that synchronisation is maintained.
Inter-drive communication including the speed reference, command (start/stop) signals and
drive status is achieved via the ATV71 CANopen bus.
Figure 1. Typical Synchroniser Layout

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This addendum applies specifically to synchronising control program number 90948-0-

V11IEO2-c which is designed to replace the PDL Elite Series synchronising Vysta program
number 9974039c
This addendum specifically describes the firmware changes to the ATV71 drive with this
program loaded and operating. The Synchroniser monitoring and configuration screens will
be displayed in Menu 1.14. The individual screens under this menu are described in section
5 of this document. If these screens are not displayed then either the Controller Inside card
is not fitted or alternatively this synchroniser program is not loaded into the card.
RDY Term +0.00Hz 0A

1. DRIVE MENU
1.10 DIAGNOSTICS
1.11 IDENTIFICATION
1.12 FACTORY SETTINGS
1.13 USER MENU
1.14 SYNCHRONISER
Code << >> Quick
Figure 2. Synchroniser Menu
2 Specifications:
Maximum number of Slave drives 8
Minimum time between Index pulses 2 sec
Motor revolutions per index pulse: 10 to 64000
Max length of CANopen bus 500m
This system is designed for slow to medium speed applications such as sheep/beef
processing chains.
A constant revolutions per index ratio is required for each drive. This synchronising program
is not suitable for synchronising applications that have a varying revolutions per index such
as with items unevenly spaced in a conveyor.
Synchronising only operates in the forward direction.
3 Background:
The position synchroniser is typically used in manufacturing industries to synchronise the

position of 2 or more devices such as belt conveyors or muti-chain conveyors as used in
the meat processing industry.
Simple speed synchronising can be achieved utilizing a standard ATV71 without a

Controller Inside. However due to small speed errors an accumulation of slowly increasing
positional error between the motor shafts will not be compensated for. For this reason
speed synchronisation is suited only to systems where no positional conditions are required.
Position synchronising must be used wherever the position of the motor output device is
important and no accumulation of error can be accepted. The ATV71 Position Synchroniser
provides full position synchronisation for slow speed to medium applications.

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4 Synchroniser Program Overview:
The ATV71 Position Synchroniser is a multidrive configuration based around 1 master drive
and up to 8 slaves. Its basic operation is to keep the position of the slave drive output
device synchronised with the position of the master.
The master drive operates at a required speed depending on the process and the speeds
of the slave drives are increased or reduced to maintain position synchronism. The rate of
correction will depend on the motor accel/decel time, the Correction Speed Offset and the
Gain (See section 5 for a description of these parameters).
The master drive must be an ATV71 with a Controller Inside card fitted and the ATV71
Synchroniser control program loaded. The Slave drives must be ATV71s but they do not
require a Controller Inside card.
4.1 Index Pulse

A proximity switch for each drive is employed to indicate the process position. The
Synchroniser continuously monitors these index pulses and when a positional error occurs
the synchroniser responds by a speed correction so that synchronisation is maintained. All
the index proximity switches are connected to the Logical Inputs of the controller inside.
Each index pulse must have a minimum duration of 6 ms.
4.2 Revolutions per Index (R/I)

The R/I is the number of motor revolutions performed between each index. Each drives can
have a different number of Revolutions Per Index which is entered into the ATV71 display.
This is a critical parameter which must be accurately configured for each drive including the
Master.
4.3 Power Up
After power up or a reset, one index pulse must be received by the Master and Slave drive
before position synchronising is started.
4.4 Index Monitoring

There are 2 types of index faults which are monitored:
(1) Index Error: The index error is the difference between the actual motor
revolutions between index pulses and expected revolutions entered into
screens O17, O19, O22, O25, O28, O31, O37 and O40. If the index error
exceeds the maximum allowable set in screen O13 an Index Fault will be
generated. An index error is recognized only after the drive has received 3
index pulses after power up or a reset.
(2) Missing Index. An index is assumed to have been missed if an index pulse
has not been received within the expected no of revolutions. The expected
revolutions is equal to the R/I for the drive concerned plus the maximum
allowable Index Error set in screen O13. If the number of consecutive
missed index pulses exceeds the amount set in screen O14 an Index fault
will be generated.
The status message will indicate which drive has the index fault

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4.5 Position Monitoring

The ATV71 Position Synchroniser continuously monitors the number of revolutions
(position) of each drive. If the difference between the Master drive position and a Slave
drive position exceeds the maximum allowable position error set in screen O13 then a
Position Fault will occur. A Position Fault is only recognized after the Master and Slave
drive have both received 3 index pulses after power up or a reset. The status message will
indicate which Slave drive has the position fault.
4.6 Offset
The index pulse of each slave drive does not have to occur at the same time. A positional
offset for each Slave drive relative to the Master can be configured.
4.7 CANopen Network

The Controller Inside card is the CANopen master for the Network. The Slave drives are all
CANopen slaves. The Master drive is not part of the CANopen Network. The Controller
Inside communicates directly to the master drive over the back plane. From a CANopen
view point the Controller Inside card is separate to the Master drive that is mounted into.
The Controller Inside CANopen address is fixed to Node 1 and the bit rate to 125Mbps.
Therefore the Slave addresses must not be set to Node 1 and the Slave bit rate must be
set to 125Mbps.
4.8 Control Type

The ATV71 synchroniser would normally be operated in sensorless vector mode but it will
still function with reduced accuracy in V/Hz mode. Use of an encoder in closed loop vector
mode will improve the accuracy of the synchroniser. Sometimes closed loop mode is
required to provide a sensitive torque limit in place of an over tension sensor on
mechanisms with a large gearbox reduction.

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5 Synchroniser Screens
5.1 Overview:
To configure the additional synchroniser functions provided by the ATV71 Position

Synchroniser there is a new sub menu 1.14 to monitor and adjust parameters peculiar to
this synchronising control program.
Figure 3. Synchroniser Menu Access

Refer to the Graphic Display Terminal section of the ATV 71 programming Manual for
instructions on how to navigate the display and for information on any standard ATV71
screen which will not be described in this addendum.
Summary of Synchroniser Screens:
Screen Name Description Code Page

MONITOR.. Monitor slave number? O01 6
Status Synchroniser status display O02 6
Mast Postion Master position O03 6
Slv 1 Postion* Slave 1 position O04 6 Monitoring
Slv 1 Pos Er* Slave 1 position error O05 7 Screens
Slv 1 Idx Er* Slave 1 index error O06 7
Slv 1 Mis Idx* Slave 1 missing index count O07 7
Slv 1 R/Idx* Slave 1 revolutions/Index O08 7
CONFIGURE O09 7
No. Of Slaves Select no of slaves O10 8
Mode Select setup or synchronising mode O11 8
Max Corct Spd Max speed correction O12 8
Max Pos Err Max position or index error O13 8
Max Misng Idx Max missing index pulses allowable O14 9
Gain Gain O15 9
Debounce Proximity switch debounce O16 9
Master R/I Master Rev/Index O17 9
Slv 1 R/I Slave 1 Rev/Index O19 10 Configuration
Slv 1 OfSt Slave 1 OffSet O20 10 Screens
Slv 2 R/I Slave 2 Rev/Index O22 10
Slv 2 OfSt Slave 2 OffSet O23 10

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Slv 7 ofSt Slave 7 OffSet O38 13
CAN Heartbeat CANopen heartbeat on/off O48 14
*The text in these screens is dependent on which drive is selected in screen O01
5.2 New Screens
Synchroniser Menu Screens (monitoring screens)

Name MONITOR
Description Monitor Drive
Code O01
Range Master
Slave 1
:
:
Slave 8
Default Slave 1
Function This selects which drive will be monitored in screens O04 to O08
below
Name STATUS
Description Status Display Screen
Code O02
Function Displays the status of the synchroniser including any synchroniser
generated fault that may occur.
A list of all possible synchroniser status messages are given in

section 8 of this manual.
Name Mast Pos

Description Master Drive Position.
Code O03
Range 0 to 120%
Units % of the Master drive Revolutions Per Index
Function Displays the revolutions the Master drive has travelled since its
last index.
Name Slv 1 Pos

Description Slave 1 Position.
Code O04
Range 0 to 120%
Units % of the Revolutions Per Index
Function Displays the revolutions the drive selected in screen O01 (above)
has travelled since its last index. I.e. if screen O01 is set to Slave
6 then this screen will display the revolutions Slave 6 drive has
travelled since its last index.

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Synchroniser Menu Screens (monitoring screens) - Continued

Name Slv 1 Pos Er
Description Slave 1 Position Error.
Code O05
Range 0 to 100
Units % of Revolutions Per Index
Function Displays the positional error between Master drive and the Slave
drive selected in screen O01 (above) If this screen exceeds the
maximum allowable position error set in screen O13 (below) then a
Position Fault will occur.
Name Slv 1 Idx Er

Description Slave 1 Index Error.
Code O06
Range 0 to 100
Units % of Revolutions Per Index
Function Displays the Index Error of the drive selected in screen O01
(above). The Index Error is the difference between the actual
number of motor revolutions between index pulses and the
expected number of revolutions (entered into screens O16 to O40
below). If this screen exceeds the maximum allowable error set in
screen O13 below then an Index Fault will occur.
This screen will update every time a valid index pulse is received.
Name Slv 1 Mis Idx

Description Slv 1 Missing Index Counter.
Code O07
Range 0 to 10
Function Displays the number of consecutive missing index pulses the drive
selected in screen O01 has had. An index is assumed to have been
missed if an index pulse has not been received within the expected
no of revolutions. The expected revolutions is equal to the R/I for
the drive concerned plus the maximum allowable Index Error set in
screen O13. If the number of consecutive missed index pulses
exceeds the amount set in screen O14 an Index fault will be
generated.
Name Slv 1 R/Idx

Description Slave 1 Actual Revolutions per Index.
Code O08
Range 5 to 65000
Units Motor Revolutions
Function Displays the actual number of revolutions per index of the drive
selected in screen O01 (above). This is updated every time an index
pulse is received.
This value is then entered into the R/I configuration screens (O17,
O19, O22, O25, O28, O31, O37, O40) during commissioning.
Name CONFIGURE
Code O09
Function This screen only acts as a label to indicate the division between the
monitoring screens and the configuration screens.

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Synchroniser Menu Screens (configuration screens)

Name No. of Slaves
Description Number of Slave Drives
Code O10
Range 1 to 8
Default 1
Function Configures the number of Slave drives in the system. Whenever
this is altered the drive power must be cycled to reinitialise the
CANopen network.
Name Mode
Description Mode.
Code O11
Range Setup
Synch
Default SynchSync Position
Function In Setup mode the slave drive will follow the master without any
position correction. The speed the slave drive will travel at is:
%SpeedSlave = %SpeedMaster x R/ISlave / R/IMaster
Also when in setup mode any synchroniser faults are disabled.

This includes any position fault, index faults and some CAN faults.
Name Sync
Max Position
Correctenables
Spd a more sophisticated algorithm which
Description Maximum Correction Speed.
Code O12
Range 0 to 100
Default 30
Units % of motor rated synchronous speed
Function Configures the maximum speed correction that will be applied to a
slave drive. I.e. if the slave drive would travel at 80% speed with
no speed correction and this screen is set to 10% then the speed
limits which the drive will stay within to keep in synchronism are
70% and 90%. This affects the speed of response to a position
error.
Name Max Pos Err

Description Maximum Position/Index Error.
Code O13
Range 0 to 100
Default 10
Units % of the total revolutions between index pulses.
Function Configures the maximum allowable position error before a Position

fault is initiated.
Also configures the maximum Index Error before an Index Fault is

initiated.

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Synchroniser Menu Screens (configuration screens) continued

Name Max Misng Idx
Description Maximum Missing Index.
Code O14
Range 0 to 10
Default 1
Function Configures the maximum number of consecutive missing index
pulses before an Index Fault is initiated. The actual number of
consecutive missed index pulses can be viewed in screenO07.
Name Gain
Description Proportional Gain
Code O15
Range 0.1 to 2.0
Default 1
Function Configures the proportional gain of the synchroniser position loop.
Setup Normally this screen can be left at its default value. Reduce this
parameter if the slave motor speed oscillates excessively.
Increase this parameter if the slave drive takes too long get into
synchronism.
Name Debounce
Description Index debounce.
Code O16
Range 0 to 60
Default 20
Units % of the total revolutions between index pulses.
Function Configures the index pulse debounce for all drives. Eg if the
debounce is set to 50%, when the drive receives an index pulse it
will not accept another index pulse until it has travelled 50% of the
motor revolutions to the next index pulse.
Setup Set to an appropriate value if there is a possibility that multiple

index pulses could be received.
Name Master R/I

Description Master Drive Revolutions Per Index.
Code O17
Range 5 to 65535
Default 100
Units Rev/Index
Function Configures the Revolutions Per Index of the Master drive. The
synchroniser program uses this value to calculate the base speed
of the slave drives and to detect missing or out of range index
pulses.
Setup Run the motor in Setup Mode until at least 2 index pulses have
been received. Then enter the Master drive actual R/I from screen
O08 above into this screen.

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Name Slv 1 R/I
Description Slave 1 Drive Revolutions Per Index.
Code O19
Range 5 to 65535
Default 100
Units Motor revolutions / Index pulse (R/I)
Function Configures the Revolutions Per Index of the Slave drive. The
synchroniser program uses this value to calculate the base speed
of the slave drive and to detect missing or out of range index
pulses.
Base SpeedSlave = SpeedMaster x R/ISlave / R/IMaster
Setup Run the motor in Setup Mode until at least 2 index pulses have
been received. Then enter the Slave 1 actual R/I from screen O08
above into this screen.
Name Slv 1 OfSt

Description Slave 1 OffSet
Code O20
Range -50.0 to +50.0
Default 0
Units % of the total revolutions between Slave 1 index pulses (R/I).
Function Configures a position offset of Slave 1 drive relative to the Master.
Setup Set to the required offset.
Name Slv 2 R/I

Code O22
Range 5 to 65535
Default 100
Function Same as for Slv 1 R/I
Setup Same as for Slv 1 except use the Slave 2 actual R/I from screen
O08.
Note This screen is visible when Slave 2 is selected in No. of Slaves

screen above.
Name Slv 2 OfSt

Description Slave 2 OffSet
Code O23
Range -50.0 to +50.0
Default 0
Setup Same as for Slv 1 Offset.
Note This screen is visible when Slave 2 is selected in No. of Slaves
screen above.

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Name Slv 3 R/I
Code O25
Range 5 to 65535
Default 100
O08.
Note This screen is visible if Slave 3 is selected in No. of Slaves
screen above.
Name Slv 3 OfSt

Description Slave 3 position offset
Code O26
Range -50.0 to +50.0
Default 0
Setup Same as for Slv 1 offset.

screen above.
Name Slv 4 R/I

Code O28
Range 5 to 65535
Default 100
O08.

screen above.
Name Slv 4 OfSt

Description Slave 4 position off set
Code O29
Range -50.0 to +50.0
Default 0
Function Configures the position offset of Slave 4 relative to the Master.
Setup Same as for Slv 1 offset.

screen above.

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Name Slv 5 R/I
Code O31
Range 5 to 65535
Default 100
O08.
Note This screen is hidden if Slave 5 is not selected in No. of Slaves

screen above.
Name Slv 5 OfSt

Description Slave 5 position offset.
Code O32
Range -50.0 to +50.0
Default 0
Function Configures the position offset of Slave 5 relative to the Master.
Setup Same as for Slv 1 Offset.
screen above.
Name Slv 6 R/I

Code O34
Range 5 to 65535
Default 100
O08.

screen above.
Name Slv 6 OfSt

Code O35
Range -50.0 to +50.0
Default 0
Function Configures a position offset of Slave 6 relative to the Master.

screen above.

13

Name Slv 7 R/I
Code O37
Range 5 to 65535
Default 100
O08.

screen above.
Name Slv 7 OfSt

Code O38
Range -50.0 to +50.0
Default 0
screen above.
Name Slv 8 R/I

Code O40
Range 5 to 65535
Default 100
O08.

screen above.
Name Slv 8 OfSt

Description Slave 8 position offset
Code O41
Range -50.0 to +50.0
Default 0

screen above.

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Name CAN Flts
Description CANopen Faults.
Code O48
Range On/Off
Default On
Function Disables the Synchroniser initiated CANopen faults. This may
allow the Synchroniser to continue to operate with a slower
response if there are intermittent CANopen errors.
Warning Errors in the CANopen network may not be detected if this
parameter is Off. This may result in loss of control of the slave
drives.
Name 909480IE02c
Description ATV71 Synchroniser program revision number. Read only.
Code O50

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6 Setting Up
The steps for setting up the ATV71 drive as outlined in the ATV71 Simplified Manual should
be completed on each drive in the master/slave network before performing the following
synchronizer setup procedure.
6.1 Master Drive Input/Outputs:
Figure 4 gives the recommended I/O wiring for the Master drive and Table 1 gives the
corresponding parameter configuration.
A1
ATV71
+24V
+10V
COM
COM
PWR
AI1+
AO1
AI1-
AI2
LI1
LI2
LI3
LI4
LI5
LI6
0V
SPEED REFERENCE
(OPTIONAL)
RUN FORWARD
FAULT RESET
RUN REVERSE
FAST STOP
Figure 4. Recommended Master Drive I/O Wiring
Menu Parameter Value Comment
1.3 Settings High Speed As appropriate see section 6.4

1.6 Command Ref.1 chan AI1 Optional
1.6 Command Stop Key priority Yes Optional
1.6 Command Profile Separate Mandatory
1.6 Command Cmd channel 1 Prog. card Recommended
1.6 Command Ref 2 switching C411 Mandatory if using Stop At Prox feature
1.7 Application Funct Fast stop assign LI3 Recommended
1.8 Fault Management Fault Reset LI4 Recommended
Table 1. Master Drive I/O Software Configuration.

Note: LI4 is preconfigured by the synchroniser program to reset a Synchroniser Fault. To
allow this input to also be used to reset a drive fault configure LI4 as in Table 1.

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6.2 Controller Inside Input/Outputs:
The Controller Inside card Logical Inputs are preconfigured per figure 5. Where a slave
drive is not present the input is left unconnected.
VW3 A3 501
AO52
COM
AO51
AI52
COM
AI51
LO56
LO55
LO54 SYNCHRONISER RUN

Controller Inside
LO53 MASTER INDEX OUTPUT
LO52 SYNCHRONISER FAULT
LO51 MISSING INDEX WARNING
LI60 STOP AT PROX

LI59 SLAVE 8 INDEX
LI58 SLAVE 7 INDEX
LI57 SLAVE 6 INDEX
LI56 SLAVE 5 INDEX
LI55 SLAVE 4 INDEX

+24V
COM
LI51
LI52
LI53
LI54
24VDC +24V
Supply
0V
MASTER INDEX
SLAVE 1 INDEX
SLAVE 2 INDEX
SLAVE 3 INDEX
Where a Slave drive is not

present leave the input
unconnected
Figure 5. Controller Inside I/O
6.3 Slave Drive Input/Outputs:
Figure 6 gives the recommended I/O wiring for the Slave drives and Table 2 gives the
corresponding software configuration. The Profile must be set to Separate and the Slave
drive active reference and command channels must be set to CANopen to allow
synchronising control by the Controller Inside. It is recommended that a Fast Stop be hard
wired to the logical inputs.
A1
ATV71
+24V
+10V
COM
COM
PWR
AI1+
AO1
AI1-
AI2
LI1
LI2
LI3
LI4
LI5
LI6
0V
FAULT RESET
FAST STOP
Figure 6. Recommended Slave Drive I/O Wiring

17
1.6 Command Ref.1 chan CAN Mandatory

1.6 Command Stop Key priority Yes Optional
1.6 Command Profile Separate Mandatory
1.6 Command Cmd channel 1 CAN Mandatory
1.7 Application Funct Fast stop assign LI3
1.8 Fault Management Fault Reset LI4
Table 2. Slave Drive I/O Software Configuration
6.4 Maximum Speed Limit:
The maximum speed limits of the drives should be set such that the maximum speed limit
of the slave drives does not prevent them from remaining in synchronism with the Master.
6.5 CANopen Network:
1. Construct a CANopen cable from the parts described in section 7. Refer to the ATV71
CANopen manual for correct cabling procedures.
2. Connect a CANopen cable between the Controller Inside card and the Slave drives. It
is not necessary to connect the Master drive to the network. The Controller Inside card
is the CANopen Master for the Network and the Slave drives are all CANopen slaves.
3. Set the CANopen address in the slave drives according to Table 3.
1.9 Communication CANopen address 2 (Slave 1)

3 (Slave 2)
4 (Slave 3)
The Controller Inside card
5 (Slave 4)
is preconfigured as
6 (Slave 5)
CANopen address 1.
7 (Slave 6)
8 (Slave 7)
9 (Slave 8)
1.9 Communication CANopen bit rate 125kbps The Controller Inside bit
rate is preconfigured to 125
kbps.
Table 3. Slave Drive CANopen address Configuration.
3. Cycle the power to all the drives to initialise the new CANopen parameters. And if
necessary reset any faults.
4. The red LED (1.2) on the Controller Inside card should be off. This indicates there
are no errors on the CANopen network. The status of the CANopen network can
be monitored from Menu 1.2 Monitoring Communications Map CANopen map.

18
6.6 RPI setup:
1. Enter the approximate Revolutions/Index for each drive into screens O17, O19, O22,
O25, O28, O31, O34, 37, 40.
2. Set the Mode to Set up (screen O13).
3. Give the master drive an appropriate speed reference and a run command. All the slave
drives should also run. While in Set up mode the slave drives will not position
synchronise. They will speed follow according to the RPI ratio ie SpeedSlave = SpeedMaster
x R/ISlave / R/IMaster . Run the drives until at least 2 index proximity inputs are received for
each drive. This will allow the synchroniser to calculate the RPI for each drive.
4. Select the Master drive in the Monitor.. screen (screen O01)
5. Read the Master drive RPI from the RPI monitoring screen (O08).
6. Enter this value into the Master drive RPI configuration screen. (O17 )
7. Do steps 4 to 6 for the remaining drives.
6.7 Miscellaneous:
1. Set the Maximum Position Error and Maximum Correction Speed (screens O11 and
O12) to appropriate values.
2. Once the above steps have been carried out, set the Mode to Synch (screen O13).
Start the Master drive. The position of the slave drives should now synchronise with the
master drive after a short time.
3. Run the synchroniser. Check the Index Error and Position Error screens to ensure the
drives are remaining in synchronism. Also visually check the process to ensure
synchronism is being maintained.
6.8 Customisation of the Monitoring Display:
The top line of the ATV 71 display is referred to as the Parameter Bar. This can be
customised to display parameters that are peculiar to the synchroniser. Refer to Menu 6.1
PARAMETER BAR SELECT to select the parameters you wish to display.
Figure 7. Customised Monitoring Display
Also the Monitoring Display of the ATV 71 display can be customised to display a list of
variables or bargraphs. Refer to Menu 6.2 MONITOR SCREEN TYPE.
If a bargraph is configured the maximum value of the graph will be equal to 120%.

19
7 Synchroniser Parts
When ordering an ATV71 Position Synchroniser the parts described in Table 4 must be ordered in addition
to the ATV71 drives required.
Schneider Part
Description Quantity Note
Number
With ATV71 Position

Controller Inside card VW3 A3 501 One
Synchroniser S/W loaded.
CANopen adapter VW3 CAN A71 One per slave drive
One per slave drive

1 VW3 CAN KCDF
CANopen connector and one for the CI Erni part number 154824
180T
card
Refer to the ATV71 Various lengths and types are

CANopen cable
Catalogue available
Table 4 - Synchroniser parts
Figure 9. CANopen Adapter VW3CANA71
Figure 8 CANopen Connector VW3 CANKCDF180T
(Erni part no 154.824)
Figure 10. CANopen Connector
(Erni part no 154.039)
1
Ernie part number 154-039 may be used in place of 154-824. This connector is an axial type (ie it is not offset) so it
fits the Controller Inside card better. It is not available from Schneider so it must be purchased directly from Erni.

20
8 Status Messages
The Synchroniser status can be view in screen O02 of Synchroniser Menu 1.14. Also the
Synchroniser has its own set of fault messages which are displayed in this screen.
Status Codes
Status Display Description
Long Short
Sync Dsbl SyDsd Synchronising disabled. Synchronising is disabled
until the first index pulse after power up, if in setup
mode or if a Stop at Prox has been initiated.
Sync Run SyRun Master drive has received 1 index pulse since power
up. Synchronising is enabled if the slave drive has
also received one index pulse.
SlXMisIdx xMsIdx Slave X drive has missed at least 1 missing index
MasMisidx MMsIdx The Master drive has missed at least 1 index pulse
StpAtProx SpPrx The drives will stop at the next proximity switch.
SlXPosFlt xPsFt A position fault has occurred on Slave X
SlXIdxFlt xIxFt A index fault has occurred on Slave X
MasIdxFlt MIxFt An index fault has occurred on the Master drive.
SlXCANFlt xCnFt A CANopen fault has occurred on Slave X
CAN Flt CnFt A CANopen general fault has occurred.
SlXDrvFlt xDvFt A fault has occurred with Slave X drive.
MasDrvFlt MDvFt A fault has occurred with the Master drive.
Figure 11. Status Messages

Note: X = Any of Slave 1 to 8.
If the Controller Inside is configured as the Command an Application Fault will be triggered.
If the Controller Inside is not configured as the Command an External Fault will be
triggered.
9 Synchroniser Faults.
There are 4 types of faults that are generated by the ATV71 Synchroniser. If any of these
faults occur the drive will trip and the fault message SYNCH Flt will be displayed. To
narrow down the cause of the fault see the status message in Menu 1.14.
2. Position Fault. A Position Fault is generated when the difference between the
Master and Slave positions (position error) exceeds the maximum allowable
amount set in screen O13. The status message will indicate which Slave drive has
the fault. Ie the status message Sl6PosFlt indicates a position fault with Slave 6
drive. A Position Fault is recognized only after the Master and Slave drive have
both received 3 index pulses after power up or a reset. The actual position error
can be viewed in screen O05 of the Synchroniser Menu 1.14
3. Index Fault. There are 2 types of index faults:
(1) Index Error: The index error is the difference between the actual motor
revolutions between index pulses and expected revolutions entered into
screens O17, O19, O22, O25, O28, O31, O37 and O40. If the index error
exceeds the maximum allowable set in screen O13 an Index Fault will be
generated. An index error is recognized only after the drive has received 3
index pulses after power up or a reset. The actual index error can be viewed
in screen O06 of the Synchroniser Menu 1.14.

21
(2) Missing Index. An index is assumed to have been missed if an index pulse
has not been received within the expected no of revolutions. The expected
revolutions is equal to the R/I for the drive concerned plus the maximum
allowable Index Error set in screen O13 of the Synchroniser Menu 1.14. If the
number of consecutive missed index pulses exceeds the amount set in
screen O14 an Index fault will be generated. The actual number of
consecutive missed index pulses can be viewed in screenO07 of the
Synchroniser Menu 1.14.
The status message will indicate which drive has the fault. Ie the status message
MasIdxFlt indicates an Index fault with the Master drive.
4. CAN Fault. A CANopen fault is generated if a fault is detected with the CANopen
network.
A CANopen fault can also be generated by a Slave drive. In this case the Slave
drive concerned will indicate a CANopen fault and the Master will indicate a Drive
Fault with the corresponding Slave drive.
5. Drive fault. A Drive Fault is generated if a fault in any drive in the network is
detected. To narrow down the cause of the fault see the display in the
corresponding drive.
If 2 faults occur at the same time priority is given to the lower fault in Figure 11.
In the event of a resetable fault on any of the drives it may be reset using the reset input on
the master drive. Sometimes 2 reset inputs my have to be given. One to reset the Slave
and then another to reset the Master. Some faults can only be reset by cycling the power
(refer to the ATV71 Simplified Manual).

22
10 Commissioning Parameter Record Sheets and I/O Assignment for Master Drive
10.1 Drive and Motor details.
Drive No: Model:
Location:
Motor kW: Amps:
Volts: RPM:
Recorded
By: Date:
10.2 Functions Assigned to I/O Master & Controller Inside
Master I/O Functions Assigned CI I/O Functions Assigned

LI1 LI51
LI2 LI52
LI3 LI53
LI4 LI54
LI5 LI55
LI6 LI56
R1 LI57
R2 LI58
AI1 LI59
AI2 LI60
AO1 LO51
Encoder LO52
Logic Input Sw LO53
LI6 Input Sw LO54
LO56
AI51
AI52
AO51
AO52
10.3 Menu 1.1 Simply Start Parameters - Master Drive

(no setting entered means the default setting is used)
Code Name Customer Setting Code Name Customer Setting

tCC 2/3 wire control nSP Rated mot speed
CFG Macro Config tFr Max frequency
bFr Stan Mot freq tUn Auto-tuning
IPL Input phase loss PHr Output Ph rotate
nPr Rated mot power
Uns Rated mot volt
nCr Rated mot Current
Frs Rated mot Freq

23
10.4 Menu 1.14 Synchroniser Parameters Master Drive


O10 No. Of Slaves O28 Slv 4 R/I
O11 Mode O29 Slv 4 OffSet
O12 Max corct Spd O31 Slv 5 R/I
O13 Max Pos Err O32 Slv 5 OffSet
O14 Max Missing Idx O34 Slv 6 R/I
O15 Gain O35 Slv 6 OffSet
O16 Debounce O37 Slv 7 R/I
O17 Master R/I O38 Slv 7 OffSet
O19 Slv 1 R/I O40 Slv 8 R/I
O20 Slv 1 OffSet O41 Slv 8 OffSet
O22 Slv 2 R/I O48 CAN Flts
O23 Slv 2 OffSet O50 909480IE02c (program version, read only)
O25 Slv 3 R/I
O26 Slv 3 OffSet
10.5 Other Parameters Master Drive

(table to be created by the user)

24
11 Commissioning Parameter Record Sheets I/O Assignment for Slave Drives
11.1 Drive and Motor details.
Slv1 Slv2 Slv3 Slv4
Drive No:
Location:
Model:
Motor kW:
Amps:
Volts:
RPM:
Recorded
By:
Date:
Slv5 Slv6 Slv7 Slv8
Drive No:
Location:
Model:
Motor kW:
Amps:
Volts:
RPM:
Recorded
By:
Date:

25
11.2 Functions Assigned to I/O Slave Drives

I/O Slv1 Slv2 Slv3 Slv4

LI1
LI2
LI3
LI4
LI5
LI6
R1
R2
AI1
AI2
AO1
Encoder
Logic Input Sw
I/O Slv5 Slv6 Slv7 Slv8

LI1
LI2
LI3
LI4
LI5
LI6
R1
R2
AI1
AI2
AO1
Encoder
Logic Input Sw
11.3 Menu 1.1 Simply Start Parameters Slave Drives

Code Name Slv1 Slv2 Slv3 Slv4

tCC 2/3 wire control
CFG Macro Config
bFr Stan Mot freq
IPL Input phase loss
nPr Rated mot power
Uns Rated mot volt
Frs Rated mot Freq
nSP Rated mot speed
tFr Max frequency
tUn Auto-tuning
PHr Output Ph rotate
ItH Mot therm current
ACC Acceleration
dEC Deceleration
LSP Low speed
HSP High Speed

26

tCC 2/3 wire control
CFG Macro Config
bFr Stan Mot freq
IPL Input phase loss
nPr Rated mot power
Uns Rated mot volt
Frs Rated mot Freq
nSP Rated mot speed
tFr Max frequency
tUn Auto-tuning
PHr Output Ph rotate
ItH Mot therm current
ACC Acceleration
dEC Deceleration
LSP Low speed
HSP High Speed
11.4 Other Parameters Slave Drives

(table to be created by the user)

27
12 Documentation/Manuals
ATV71 Simplified Manual
The main manual required for basic ATV71 installation, programming and fault finding.
Controller Inside Manual
The main manual required for installation and wiring of the Controller Inside card.
ATV71 Installation Manual
A comprehensive description of the installation and wiring of the ATV71
ATV71 Programming Manual
A comprehensive description of all the ATV71 functions and parameters.
ATV71 Communication Parameters
Contains a list of the ATV71 parameter addresses and describes the various operating modes specific to
serial communications. Not required if the start/stop and reference controls to the Master are achieved via
the standard digital and analogue I/O.
ATV71 CANopen Manual
Contains useful information on the connection and diagnostics of the CANopen Network. However all the
information required for setting up the Synchroniser CANopen Network is contained in this Addendum.
Modbus, Ethernet, Profibus, INTERBUS, Uni-Telway, FIPIO, Modbus Plus, & DeviceNet Manuals
These manuals are not required unless the corresponding protocol is required for remote control and
supervision of the Synchroniser. Normally only the Master drive would be controlled.

28
13 Glossary
ATV. Abbreviation for Aptiva, The name given to the Telemecanique range of variable
speed drives.
ATV58. The generation of Telemecanique variable speed drive which is superseded by the
ATV71.
ATV71. The new generation of PDL and Telemecanique variable speed drive containing
advanced control and communication functions.
CANopen. An industrial serial communications protocol adopted by PDL and Telemecanique

for use with the ATV71 variable speed drives. The ATV71 Synchroniser CANopen
network consists of a CANopen Master and up to 8 Slaves. CANopen employs
special connectors and twisted pair cable.
Command. The ATV71 start and stop commands.
Controller Inside. An option card which can be fitted into the ATV71 drive. In the case of the ATV71
Synchroniser it contains synchronising control software and is also the CANopen
master.
Elite Series. The current generation PDL variable speed drives which will eventually be
superseded by the ATV71.
Index. An input to the Controller Inside Card indicating the process position.
Offset. Position offset means a continuous out of synchronism by a set amount.
Profile. The different input/output configurations supported by the ATV71. The ATV71
Synchroniser uses the Sperate Profile.
LI. See Logical Input
Logical Input A digital Input. The ATV71 has 6 Logical Inputs named LI1 to LI6. The Controller
Inside card has 10 Logical Inputs named LI51 to LI60.
Master. The drive that sets the speed of the synchroniser system. The Controller Inside is
fitted into the Master drive.
Revolutions Per Index. Motor revolutions per index pulse
R/I. See Revolutions Per Index.
Slave. The drive that changes speed to match the position of the Master drive. A Slave
drive is also a CANopen slave.

29
14 Index
Bargraph, 18 Parameter Bar, 18
CANopen, 3, 17 Position Monitoring, 3
Fault message, 20 Power Up, 3
I/O R/I. See Revolutions per index
Controller Inside Card, 16 Revolutions per Index, 3, 7
Master Drive, 15 Specifications, 2
Slave Drive, 16 Status Codes, 20

Index Monitoring, 3 Synchroniser Faults, 20
Index Pulse, 3 Synchroniser Screens, 5
Offset, 3

2
PDL Electronics Ltd is an international leader in AC motor drive development offering a

range of advanced motor drives to handle every industrial application. Our customer support
program and Quality Assurance system makes the PDL product, regardless of price, less
expensive than other controllers, in the long term. Offices and distributors worldwide provide
continuous technical support that guarantees quality service and expert advice form delivery
to operation of your installation.
As a member of the Schneider Electric group, PDL Electronicss product range and
renowned effectiveness in high power drive applications, consolidates Schneider Electrics
position as the global leader in industrial motor control.
HEAD OFFICE
81 Austin Street, Napier, New Zealand
Phone +64-6-843 5855 Fax +64-6-843 5185
Internet www.pdlelectronics.com
Email emarketing@pdlelectronics.com
Distributors in countries worldwide.
Distributed by
ATV71 Synchroniser Manual Addendum PDL Part

PDL Number 90344-0-11 Rev B
Part No. 90948001c

Position Synchonizer

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1

Altivar 71 Position Synchroniser

Spinning Control PDL Part No. 90344-010 Rev A

Revision History Table

ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

4 Synchroniser Program Overview: ..................................................................................................3

4.1 Index Pulse ...........................................................................................................................3

5.1 Overview: ..............................................................................................................................5

6.1 Master Drive Input/Outputs: ................................................................................................15

8 Status Messages .........................................................................................................................20

9 Synchroniser Faults. ....................................................................................................................20

ATV71 Synchroniser Manual Addendum PDL Part No. 90948011c

Figure 1. Typical Synchroniser Layout

ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

This addendum applies specifically to synchronising control program number 90948-0-

RDY Term +0.00Hz 0A

Figure 2. Synchroniser Menu

Maximum number of Slave drives 8

Minimum time between Index pulses 2 sec

Motor revolutions per index pulse: 10 to 64000

Max length of CANopen bus 500m

Synchronising only operates in the forward direction.

The position synchroniser is typically used in manufacturing industries to synchronise the

Simple speed synchronising can be achieved utilizing a standard ATV71 without a

ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

4 Synchroniser Program Overview:

4.1 Index Pulse

Each index pulse must have a minimum duration of 6 ms.

4.2 Revolutions per Index (R/I)

4.4 Index Monitoring

ATV71 Synchroniser Manual Addendum PDL Part No. 90948011c

4.5 Position Monitoring

4.7 CANopen Network

4.8 Control Type

ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

To configure the additional synchroniser functions provided by the ATV71 Position

Figure 3. Synchroniser Menu Access

Summary of Synchroniser Screens:

Screen Name Description Code Page

ATV71 Synchroniser Manual Addendum PDL Part No. 90948011c

Slv 6 R/I Slave 6 Rev/Index O34 12

5.2 New Screens

Synchroniser Menu Screens (monitoring screens)

A list of all possible synchroniser status messages are given in

Name Mast Pos

Name Slv 1 Pos

ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

Synchroniser Menu Screens (monitoring screens) - Continued

Name Slv 1 Idx Er

Name Slv 1 Mis Idx

Name Slv 1 R/Idx

ATV71 Synchroniser Manual Addendum PDL Part No. 90948011c

Synchroniser Menu Screens (configuration screens)

%SpeedSlave = %SpeedMaster x R/ISlave / R/IMaster

Also when in setup mode any synchroniser faults are disabled.

Name Max Pos Err

Function Configures the maximum allowable position error before a Position

Also configures the maximum Index Error before an Index Fault is

ATV71 Synchroniser Manual Addendum PDL Part No. 90948001c

Synchroniser Menu Screens (configuration screens) continued

Setup Set to an appropriate value if there is a possibility that multiple

Name Master R/I

ATV71 Synchroniser Manual Addendum PDL Part No. 90948011c

Synchroniser Menu Screens (configuration screens) continued