ANCA Motion AMD5x Series User manual

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09 i
AMD5x Passive Infeed Unit and
AMD5x Servo Drive - User
Guide
D-000129 Rev 09

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09
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AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09
AMD5x Passive Infeed Unit and
AMD5x Servo Drive - User Guide
Some Important Links
Related Manuals and Brochures Related Documentation
Sales and Support Contact Information Product, Sales and Service Enquiries
User manual Manuals
MotionBench Software
Documents Reference: D-000129 Revision: 09
Effective: 12 January 2022
© ANCA Motion Pty. Ltd.

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09
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AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09 i
Chapter Summaries
1
Safety General Product safety information
Introduction Target Audience, model applicability, help in
reading the manual and related
manuals/brochures
2
3
4
Product Overview Features, operating principles, labels,
connector overview
Mechanical Installation Requirements for site, tools, mounting, and
cooling
5
Power Wiring Insulation, earthing, power conditioning,
brake connection and regenerative brake
8
Installation Checklist Pre-power-up checks
12
Additional Information How to contact ANCA Motion with your
enquiries
7
EtherCAT®Configuration EtherCAT Frame Packet Mapping,
EtherCAT LED status
6
Control Wiring Electrical Interfacing with the I/O
connectors, EtherCAT and motor feedback
9
PIU Operation Enabling the PIU, analogue and digital
status information
11
Accessories Selection of accessories including filters,
reactors, ribbon cables
10
Technical Data List of Specifications

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09 ii
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AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09 iii
Contents
1Safety.................................................................................................................................................................1
1.1 General Safety........................................................................................................................................1
2Introduction.......................................................................................................................................................3
2.1 What This Chapter Contains...................................................................................................................3
2.2 Purpose...................................................................................................................................................3
2.3 About The AMD5x Series Passive Infeed Units ......................................................................................3
2.4 About The AMD5x Series Servo Drives ..................................................................................................3
2.5 About The AMD5x Capacitor Module......................................................................................................3
2.6 PIU Model Applicability............................................................................................................................4
2.7 Drive Model Applicability.........................................................................................................................5
2.8 Capacitor Module Model Applicability .....................................................................................................6
2.9 Related Documents.................................................................................................................................7
2.10 Trademarks.............................................................................................................................................7
2.11 Terms and Abbreviations ........................................................................................................................8
3Product Overview.............................................................................................................................................9
3.1 What This Chapter Contains...................................................................................................................9
3.2 Features..................................................................................................................................................9
3.3 AMD5x Variant Identification.................................................................................................................10
3.4 Operating Principle................................................................................................................................11
3.5 System Overview..................................................................................................................................11
3.5.1 PIU ..........................................................................................................................................12
3.6 PIU Connector Overview.......................................................................................................................13
3.6.1 X1 –Regenerative Brake Resistor ..........................................................................................14
3.6.2 X2 –3 Phase Mains + Earth Supply........................................................................................15
3.6.3 X5 –Regenerative Brake Resistor Over-Temperature Switch ................................................15
3.6.4 X6 –LED Supply.....................................................................................................................16
3.6.5 X7 –24 Vdc Supply.................................................................................................................16
3.6.6 X3 & X4 –EtherCAT Ports ......................................................................................................16
3.7 Drive Connector Overview ....................................................................................................................17
3.7.1 X10 –24 Vdc Brake Connections............................................................................................19
3.7.2 X11 –3 Phase Armature Supply .............................................................................................19
3.7.3 X12 –Motor Temperature Sensor Input..................................................................................19
3.7.4 X13 –Encoder 1 Input.............................................................................................................20
3.7.5 X14 –Encoder 2 Input.............................................................................................................22
3.7.6 X15 –Probe 1&2 Input, ProbeX +24 Vdc Probe/Proxy Feed ..................................................24
3.7.7 X16 –Encoder Monitor Output................................................................................................25
3.7.8 X17 & X18 –EtherCAT®Ports.................................................................................................25
3.7.9 X30 –Hiperface DSL Encoder Interface..................................................................................26
3.7.10 X32 BiSS/ABZ Encoder Input..............................................................................................28
3.7.11 X31 BiSS Encoder Functional Safety Output......................................................................30
3.7.12 X20 –IO Interface...............................................................................................................31
3.7.13 LED Display and Control Panel - PIU..................................................................................33
3.7.14 LED Display and Control Panel - Drive ...............................................................................34

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 09 iv
4Mechanical Installation ..................................................................................................................................35
4.1 What This Chapter Contains.................................................................................................................35
4.2 Pre Installation Checks..........................................................................................................................35
4.3 Requirements........................................................................................................................................35
4.3.1 Installation Site........................................................................................................................35
4.3.2 Mounting..................................................................................................................................36
4.3.3 Drive Array Mounting Options and Benefits.............................................................................37
4.3.4 Heatsink Cooling with External Cabinet Air Using Duct Mount Fitment...................................38
4.3.5 Heatsink Cooling with Internal Cabinet Air Using Duct Mount Fitment ....................................38
4.3.6 Example Cooling Duct Design.................................................................................................40
4.3.7 Heatsink Cooling - Wall Mount Fitment ...................................................................................42
4.3.8 Heatsink Cooling - Recessed Mount Fitment...........................................................................42
4.3.9 Cabinet Cooling.......................................................................................................................43
4.4 Installation.............................................................................................................................................44
4.4.1 Installation Order.....................................................................................................................44
4.4.2 Mounting a PIU........................................................................................................................44
4.4.3 Mounting a Drive .....................................................................................................................46
4.4.4 Mounting a Capacitor Module..................................................................................................48
4.4.5 System Installation ..................................................................................................................50
4.4.6 Uninstalling the PIU and Drive System....................................................................................54
4.4.7 Uninstalling the PIU or one Drive from the Array.....................................................................54
4.5 Fan Housing Assembly Replacement ...................................................................................................55
4.5.1 Removing the Faulty Fan Housing Assembly..........................................................................55
4.5.2 Installing the New Fan Housing Assembly ..............................................................................57
4.5.3 Fan Harness Routing and Connection.....................................................................................58
5Power Wiring...................................................................................................................................................59
5.1 What This Chapter Contains.................................................................................................................59
5.2 Mains Power Supply .............................................................................................................................59
5.2.1 3 Phase AC Voltage Supply ....................................................................................................59
5.2.2 Connection of PIU to Grounded Systems (TN or TT)..............................................................60
5.2.3 Connection of PIU to non-grounded (IT) or Delta systems.....................................................60
5.2.4 Residual Current Detection (RCD) protection..........................................................................61
5.3 Power Disconnect and Protection Devices............................................................................................62
5.3.1 Power Isolation........................................................................................................................63
5.3.2 Mains Contactors.....................................................................................................................63
5.4 Grounding .............................................................................................................................................63
5.5 Installations Conforming to the EMC Directive......................................................................................65
5.5.1 Harmonics and Reactive Power Compensated Supplies ........................................................66
5.5.2 3 Phase Supply System Wiring ...............................................................................................66
5.5.3 Installation Guidelines of EMC Components ...........................................................................67
5.6 Motor Connections................................................................................................................................67
5.6.1 Motor Circuit Contactors..........................................................................................................68
5.6.2 Shielded Armature Cable Schematic.......................................................................................68
5.6.3 Shielded Armature Cable with Thermal Sensor for LinX Motor Schematic..............................68
5.6.4 Motor Power Cable Shielding..................................................................................................69
5.6.5 Power Cable Shield Clamping.................................................................................................69
5.6.6 Motor Signal Cable Shielding ..................................................................................................70
5.6.7 Earth Bond Strap.....................................................................................................................70
5.6.8 Cable Routing..........................................................................................................................70
5.6.9 Hiperface DSL Segment Shield Clamping...............................................................................70
5.6.10 Shielded Hiperface DSL Armature Cable............................................................................72
5.6.11 Shielded Hiperface DSL Armature Cable with Brake..........................................................72

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA Motion D-000129 Rev 09 v
5.7 Motor Brake Connection........................................................................................................................73
5.7.1 Shielded Armature Cable with Brake.......................................................................................74
5.8 Motor Thermal Sensor...........................................................................................................................74
5.8.1 Shielded Armature Cable with Thermal Sensor Schematic.....................................................75
5.8.2 Shielded Armature Cable with Brake and Thermal Sensor .....................................................76
5.9 Regeneration.........................................................................................................................................77
5.9.1 Regenerative Brake Resistor...................................................................................................77
5.9.2 Capacitor Module ....................................................................................................................78
5.9.3 Regenerative Energy Calculations ..........................................................................................79
5.10 DC Busbar and PE Terminals...............................................................................................................80
5.11 Checking the Insulation of the Assembly...............................................................................................80
5.11.1 Checking the Regenerative Brake Resistor Insulation ........................................................80
6Control Wiring.................................................................................................................................................81
6.1 What This Chapter Contains.................................................................................................................81
6.2 Control Cable Routing...........................................................................................................................81
6.3 24 Vdc Control Circuit Supply ...............................................................................................................81
6.3.1 Fan Operation on Wall and Recessed Mount Drives...............................................................82
6.4 Ethernet Interface..................................................................................................................................83
6.4.1 EtherCAT®...............................................................................................................................83
6.4.2 EtherCAT Topology / Port Assignment....................................................................................83
6.5 Motor Encoder Feedback......................................................................................................................85
6.5.1 Analogue Encoder Interface signals........................................................................................85
6.5.2 Analogue Encoder Power Supplies.........................................................................................85
6.5.3 Hiperface DSL Encoder...........................................................................................................86
6.5.4 BiSS/ABZ Encoder..................................................................................................................86
6.5.5 BiSS Functional Safety System..............................................................................................86
6.5.6 BiSS RS-422 Physical Interface.............................................................................................87
6.6 Probe Inputs..........................................................................................................................................88
6.6.1 Probe/Proxy Interface and Power Supply................................................................................88
6.7 IO Interface ...........................................................................................................................................89
6.7.1 X20 –IO Interface for the Associated Pin Assignment............................................................90
6.7.2 External Voltage References...................................................................................................90
6.7.3 Distribution...............................................................................................................................90
6.7.4 General Purpose Digital Output...............................................................................................91
6.7.5 High Speed Digital Output.......................................................................................................91
6.7.6 Digital Input..............................................................................................................................92
6.7.7 Analog Input ............................................................................................................................93
6.7.8 Analog Output..........................................................................................................................94
7EtherCAT®Configuration............................................................................................................................... 95
7.1 Introduction ...........................................................................................................................................95
7.2 EtherCAT LED Status Definitions..........................................................................................................95
7.2.1 EtherCAT RUN Indicator .........................................................................................................95
7.2.2 EtherCAT Error Indicator.........................................................................................................96
7.2.3 EtherCAT L/A LED Indicators..................................................................................................96
7.2.4 EtherCAT LED Indicator Blink Rates.......................................................................................96
7.3 PIU Frame Packet Mapping..................................................................................................................97
7.3.1 Inputs –Status, Error and Warning .........................................................................................97
7.3.2 Inputs –Analogue Variables....................................................................................................98
7.3.3 Outputs....................................................................................................................................98

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
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8Installation Checklist......................................................................................................................................99
8.1 What this Chapter Contains ..................................................................................................................99
8.2 Checklist................................................................................................................................................99
9PIU Operation................................................................................................................................................101
9.1 What this Chapter Contains ................................................................................................................101
9.2 PIU Introduction ..................................................................................................................................101
9.3 PIU not Enabled..................................................................................................................................102
9.4 Enabling the PIU.................................................................................................................................102
9.4.1 Mains Check..........................................................................................................................102
9.4.2 Capacitor Charging................................................................................................................103
9.4.3 Regenerative Brake Resistor Test.........................................................................................103
9.4.4 Load Applied..........................................................................................................................103
9.4.5 Disabling the PIU...................................................................................................................104
9.5 Monitoring the PIU ..............................................................................................................................104
9.5.1 DC Bus Measurements .........................................................................................................104
9.5.2 Temperature Measurements .................................................................................................104
9.5.3 Control Supply Voltage..........................................................................................................104
9.5.4 Grid Frequency......................................................................................................................104
9.5.5 Fault Detection Bits ...............................................................................................................105
9.6 LED Supply.........................................................................................................................................106
9.6.1 LED Fault Detection ..............................................................................................................106
10 Technical Data..............................................................................................................................................107
10.1 What this Chapter Contains ................................................................................................................107
10.2 Control Functions................................................................................................................................107
10.2.1 Control Modes...................................................................................................................107
10.2.2 Thermal and Over-Current Protection...............................................................................107
10.2.3 Self-Protection Features....................................................................................................108
10.2.4 DC Bus Voltage Control....................................................................................................108
10.2.5 Advanced Control Functions.............................................................................................108
10.3 Interface Specifications.......................................................................................................................109
10.3.1 Motor Position Feedback...................................................................................................109
10.3.2 Encoder Channel 1 ...........................................................................................................109
10.3.3 Encoder Channel 2 ...........................................................................................................109
10.3.4 Encoder Supplies for Ch1 and Ch2 and BiSS/ABZ...........................................................109
10.3.6 BiSS/ABZ Encoder............................................................................................................110
10.3.7 Ethernet Interface..............................................................................................................110
10.3.8 Drive Display.....................................................................................................................110
10.3.9 IO Interface .......................................................................................................................111
10.4 Electrical Specifications.......................................................................................................................113
10.4.1 AMD5x PIUs......................................................................................................................113
10.4.2 Drives................................................................................................................................114
10.4.3 Capacitor Module..............................................................................................................114
10.4.4 Temperature Derating.......................................................................................................115
10.5 Environmental Specifications..............................................................................................................116
10.5.1 Storage..............................................................................................................................116
10.5.2 Transport...........................................................................................................................116
10.5.3 Installation and Operation .................................................................................................116
10.5.4 Duct Mount Cooling...........................................................................................................117
10.5.5 Wall and Recessed Cooling..............................................................................................117
10.5.6 Physical Characteristics....................................................................................................118
10.5.7 15kW and 24kW PIU Physical Characteristics..................................................................118