ANCA Motion AMD5x Series User manual

ANCA MOTION D-000129 Rev 05 i
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AMD5x Passive Infeed Unit
and AMD5x Servo Drive -
User Guide

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 05 iii
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
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Software visit Software
Documents Reference: D-000129 Revision: 05
Effective: 9 October 2018
© ANCA Motion Pty. Ltd.

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 05 iv
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 05 v
Contents
1Safety .................................................................................................................................................1
1.1 General Safety..........................................................................................................................1
1.2 Safe Start-Up and Operation....................................................................................................2
2Introduction .......................................................................................................................................3
2.1 What this Chapter Contains......................................................................................................3
2.2 Purpose.....................................................................................................................................3
2.3 About the AMD5x Series Passive Infeed Unit..........................................................................3
2.4 About the AMD5x Series Servo Drives.....................................................................................3
2.5 Drive Model Applicability...........................................................................................................4
2.6 PIU Model Applicability.............................................................................................................4
2.7Capacitor Module Model Applicability.......................................................................................4
2.8 Related Documents..................................................................................................................5
2.9 Trademarks...............................................................................................................................5
2.10 Terms and Abbreviations..........................................................................................................6
3Product Overview .............................................................................................................................7
3.1 What this Chapter Contains......................................................................................................7
3.2 Features....................................................................................................................................7
3.3 AMD5x Variant Identification ....................................................................................................8
3.3.1 AMD5x Passive Infeed Unit Catalogue Number Interpretation....................................9
3.3.2 AMD5x Series Drive Catalogue Number Interpretation.............................................10
3.3.3 AMD5x Capacitor Module Catalogue Number Interpretation ....................................11
3.4 Operating Principle .................................................................................................................12
3.5 System Overview....................................................................................................................12
3.5.1 PIU system.................................................................................................................13
3.5.2 Drive system...............................................................................................................15
3.6 PIU Connector Overview........................................................................................................16
3.6.1 X1 –Regenerative Brake Resistor.............................................................................17
3.6.2 X2 –3 Phase Mains + Earth Supply..........................................................................17
3.6.3 X5 –Regenerative Brake Resistor Over-Temperature Switch ..................................17
3.6.4 X6 –LED supply.........................................................................................................18
3.6.5 X7 –24V DC supply...................................................................................................18
3.6.6X3 & X4 –EtherCAT ports .........................................................................................18
3.7 Drive Connector Overview......................................................................................................19
3.7.1 X10 –24V Brake Connections...................................................................................21
3.7.2 X11 –3 Phase Armature Supply................................................................................21
3.7.3 X12 –Motor Temperature Sensor Input ....................................................................21
3.7.4 X13 –Encoder 1 Input ...............................................................................................22
3.7.5 X14 –Encoder 2 Input ...............................................................................................23

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 05 vi
3.7.6 X15 –Probe 1&2 Input, ProbeX +24V Probe/Proxy Feed.........................................24
3.7.7 X16 –Encoder Monitor Output...................................................................................25
3.7.8 X17 & X18 –EtherCAT®ports ...................................................................................25
3.7.9 X20 –IO Expansion ...................................................................................................26
3.7.10 LED Display and Control Panel - PIU ....................................................................27
3.7.11 LED Display and Control Panel - Drive..................................................................28
4Mechanical Installation...................................................................................................................29
4.1 What this Chapter Contains....................................................................................................29
4.2 Pre installation checks............................................................................................................29
4.3 Requirements .........................................................................................................................29
4.3.1 Installation Site...........................................................................................................29
4.3.2Mounting.....................................................................................................................30
4.3.3 Heatsink Cooling with external cabinet air.................................................................30
4.3.4 Heatsink Cooling with internal cabinet air..................................................................31
4.3.5 Example cooling duct design .....................................................................................32
4.3.6 Cabinet Cooling..........................................................................................................34
4.4 Installation...............................................................................................................................35
4.4.1 Installation Order........................................................................................................35
4.4.2 Mounting a PIU...........................................................................................................36
4.4.3 Un-Mounting a PIU.....................................................................................................37
4.4.4 Mounting a Drive........................................................................................................38
4.4.5 Un-Mounting a Drive ..................................................................................................38
4.4.6 Mounting a Capacitor Module ....................................................................................40
4.4.7 Un-Mounting a Capacitor Module ..............................................................................41
4.5 System installation..................................................................................................................42
5Power Wiring ...................................................................................................................................44
5.1 What this Chapter Contains....................................................................................................44
5.2 Mains Power Supply...............................................................................................................44
5.2.1 AC Voltage Supply.....................................................................................................44
5.2.2Connection of PIU to Grounded Systems (TN or TT) ................................................45
5.2.3 Connection of PIU to non-grounded (IT) or Delta systems.......................................45
5.2.4 Residual current-operated protective (RCD) protection.............................................45
5.3 Power Disconnect and Protection Devices.............................................................................46
5.3.1 Power Isolation...........................................................................................................47
5.3.2 Mains Contactors .......................................................................................................47
5.4 Grounding...............................................................................................................................47
5.5 Installations conforming to the EMC Directive........................................................................48
5.5.1 Harmonics and reactive power compensated supplies..............................................49
5.5.2 3 phase supply system wiring ....................................................................................50

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA Motion D-000129 Rev 05 vii
5.5.3 Installation guidelines of EMC components...............................................................50
5.6 Motor Connections..................................................................................................................51
5.6.1 Motor Circuit Contactors ............................................................................................51
5.6.2 Power Cable Shielding...............................................................................................51
5.6.3 Power Cable Shield Clamping ...................................................................................52
5.6.4 Motor signal cable shielding.......................................................................................53
5.6.5 Earth Bond Strap........................................................................................................53
5.6.6 Cable Routing.............................................................................................................53
5.7 Motor Brake Connection.........................................................................................................54
5.8 Motor Thermal Sensor............................................................................................................55
5.9 Regeneration ..........................................................................................................................55
5.9.1 Regenerative Brake Resistor .....................................................................................55
5.9.2 Capacitor Module.......................................................................................................57
5.9.3 Regenerative Energy Calculations.............................................................................57
5.10 DC Busbar & PE Terminals....................................................................................................58
5.11 Checking the Insulation of the Assembly................................................................................59
5.11.1 Checking the Regenerative Brake Resistor Insulation...........................................59
6Control Wiring .................................................................................................................................60
6.1 What this Chapter Contains....................................................................................................60
6.2 Control Cable Routing ............................................................................................................60
6.3 24V Control Circuit Supply......................................................................................................60
6.4 Ethernet Interface ...................................................................................................................61
6.4.1 EtherCAT®..................................................................................................................61
6.4.2 EtherCAT Topology / Port Assignment......................................................................61
6.5 Motor Encoder Feedback .......................................................................................................63
6.5.1 Analogue Encoder Interface signals ..........................................................................63
6.5.2 Analogue Encoder power supplies.............................................................................63
6.6 Probe Inputs ...........................................................................................................................64
6.6.1 Probe/Proxy Interface and Power Supply..................................................................64
6.7 IO Interface.............................................................................................................................64
6.7.1 External Voltage References .....................................................................................65
6.7.2 Distribution .................................................................................................................65
6.7.3 General Purpose Digital Output .................................................................................65
6.7.4 High Speed Digital Output..........................................................................................65
6.7.5 Digital Input ................................................................................................................66
6.7.6 Analog Input...............................................................................................................67
6.7.7 Analog Output ............................................................................................................67
7EtherCAT®Configuration...............................................................................................................69
7.1 Introduction.............................................................................................................................69

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 05 viii
7.2 EtherCAT LED Status Definitions...........................................................................................69
7.2.1 EtherCAT RUN Indicator............................................................................................69
7.2.2 EtherCAT Error Indicator............................................................................................70
7.2.3 EtherCAT L/A LED Indicators ....................................................................................70
7.2.4 EtherCAT LED Indicator Blink Rates .........................................................................70
7.3 PIU Frame Packet Mapping....................................................................................................71
8Installation Checklist......................................................................................................................74
8.1 What this Chapter Contains....................................................................................................74
8.2 Checklist .................................................................................................................................74
9PIU Operation ..................................................................................................................................76
9.1 What this Chapter Contains....................................................................................................76
9.2 PIU not Enabled......................................................................................................................76
9.3 Enabling the PIU.....................................................................................................................76
9.3.1 Mains check ...............................................................................................................76
9.3.2 Capacitor Charging ....................................................................................................77
9.3.3 Regenerative Brake Resistor Test.............................................................................77
9.3.4 Load applied...............................................................................................................77
9.3.5 Disabling the PIU........................................................................................................77
9.4 Monitoring the PIU..................................................................................................................78
9.4.1 DC bus measurements ..............................................................................................78
9.4.2 Temperature measurements......................................................................................78
9.4.3 Control supply voltage................................................................................................78
9.4.4 Grid frequency............................................................................................................78
9.4.5 Fault detection bits.....................................................................................................79
9.5 LED Supply.............................................................................................................................80
9.5.1 LED Fault Detection...................................................................................................80
10 Technical Data.................................................................................................................................81
10.1 What this Chapter Contains....................................................................................................81
10.2 Control Functions....................................................................................................................81
10.2.1 Control Modes........................................................................................................81
10.2.2 Thermal and over-current protection......................................................................81
10.2.3 Self-Protection features..........................................................................................82
10.2.4 DC bus voltage control...........................................................................................82
10.2.5 Advanced control functions....................................................................................82
10.3 Interface Specifications...........................................................................................................83
10.3.1 Motor Position Feedback .......................................................................................83
10.3.2 Encoder Channel 1.................................................................................................83
10.3.3 Encoder Channel 2.................................................................................................83
10.3.4 Encoder Supplies for Ch1 and Ch2........................................................................83

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA Motion D-000129 Rev 05 ix
10.3.5 Ethernet Interface...................................................................................................84
10.3.6 Drive Display ..........................................................................................................84
10.3.7 IO Expansion..........................................................................................................84
10.4 Electrical Specifications..........................................................................................................87
10.4.1 AMD5x PIU.............................................................................................................87
10.4.2 Drive.......................................................................................................................88
10.4.3 Capacitor Module ...................................................................................................88
10.5 Environmental Specifications .................................................................................................89
10.5.1 Storage...................................................................................................................89
10.5.2 Transport................................................................................................................89
10.5.3 Installation and Operation ......................................................................................89
10.5.4 Cooling ...................................................................................................................90
10.5.5 Physical Characteristics.........................................................................................91
10.5.6 PIU Physical Characteristics..................................................................................91
10.5.7 Drive Physical Characteristics................................................................................91
10.5.8 Capacitor Module Physical Characteristics............................................................91
10.6 Dimension Drawings...............................................................................................................92
10.6.1 15kW PIU physical dimensions..............................................................................92
10.6.2 15kW PIU mounting hole positions and heatsink cut-out specifications................93
10.6.3 35A drive mounting hole positions and physical dimensions.................................94
10.6.4 3A, 6A, 12A & 20A drive mounting hole positions and physical dimensions.........96
10.6.5 35A, 3A, 6A, 12 & 20A drive mounting hole positions and heatsink cut-out
specifications ..........................................................................................................................98
10.6.6 Capacitor Module physical dimensions..................................................................99
10.6.7 Capacitor Module mounting hole positions............................................................99
10.6.8 PIU, 35A drive and 12/20A drive mounting hole positions for array....................100
10.6.9 PIU and 12/20A drive mounting hole positions for array......................................101
10.6.10 PIU, 35A and 12/20A drive heat sink cut-out specifications ................................102
10.7 Materials ...............................................................................................................................103
10.8 Standards Conformity...........................................................................................................104
10.8.1 EtherCAT Conformance Marking.........................................................................105
10.8.2 CE Marking...........................................................................................................105
10.8.3 FCC Marking ........................................................................................................106
11 Accessories...................................................................................................................................107
11.1 What this Chapter Contains..................................................................................................107
11.2 EMI Filter ..............................................................................................................................107
11.3 Line Reactor .........................................................................................................................107
11.4 24V Ribbon Cables...............................................................................................................107
11.5 EtherCAT®Cables...............................................................................................................108
11.6 Cooling Duct Fan Kit.............................................................................................................108

AMD5x Passive Infeed Unit and AMD5x Servo Drive - User Guide
ANCA MOTION D-000129 Rev 05 x
11.7 Regen Resistor.....................................................................................................................109
11.7.1 Regen Resistor.....................................................................................................109
11.7.2 Regen Resistor Over-temperature switch............................................................109
11.7.3 Regen Resistor with enclosure and over-temperature switch ............................109
11.8 Cables...................................................................................................................................110
11.8.1 Shielded Encoder Cables for Beta Motors...........................................................110
11.8.2 Shielded Armature Cables for Beta Motors .........................................................110
11.8.3 Shielded Armature Cables for Beta Motors with Temperature Sensor................110
11.8.4 Shielded Armature Cables for Beta Motors with Brake........................................110
11.8.5 Motor power cable shield clamps.........................................................................111
11.9 PIU and Drive Connectors....................................................................................................112
11.10 PIU with Connector Kit..........................................................................................................112
11.11 Drive with Connector Kit.......................................................................................................112
12 Additional Information..................................................................................................................114
12.1 What this Chapter Contains..................................................................................................114
12.2 Maintenance and Repairs.....................................................................................................114
12.3 Product, Sales and Service Enquiries ..................................................................................115
12.4 Feedback..............................................................................................................................115