ANCA Motion AMD2000 Series User manual

AMD2000 Series - Servo Drive
User Manual
DS619-0-00-0019 –Rev 0

AMD2000 Series - Servo Drive - User Manual
2 DS619-0-00-0019 - Rev 0 ANCA Motion
AMD2000 Series - Servo Drive
User Manual
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Sales and Support Contact Information Product, Sales and Service Enquiries
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Documents reference: DS619-0-00-0019 - Rev 0
Effective: 8-04-2013
© ANCA Motion Pty. Ltd.

AMD2000 Series - Servo Drive - User Manual
ANCA Motion DS619-0-00-0019 - Rev 0 3
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
Planning the Electrical Installation Motor and drive compatibility, electrical isolation,
protection, cable selection and routing
6
Power Wiring Insulation, earthing, power conditioning, brake connection
and regenerative brake
7
Control Wiring Electrical Interfacing with the I/O connectors, EtherCAT and
motor feedback
8
Installation Checklist Pre-power-up checks
9
Start-up Installing and using ANCA Motion Bench to configure and
enable the drive
10
Feature Configuration Feature description and configuration information
13
Accessories Selection of accessories including motors, cables, I/O
interface modules, filters, reactors, chokes magnetic cores
11
Fault Tracing Indicators, drive states and diagnostics
12
Technical Data Functions, specifications, dimensions, de-rating, brake
resistor calculation, standards compliance
13
Accessories
Whatthis Chapter Contains
This chapter contains summarized information on accessories options available for this drive
- Ordering Information / Catalogue Number Interpretation
- Details of Accessories
For additional details, please refer to full catalogue and information available via 14.3 Product,
Sales and Service Enquiries
1.1 Motors

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Contents
1. Safety...............................................................................................................................................................10
1.1 General Safety.......................................................................................................................................10
1.2 Safe Start-Up and Operation.................................................................................................................11
2. Introduction.....................................................................................................................................................12
2.1.11 What this Chapter Contains.................................................................................................12
2.1.12 Purpose...............................................................................................................................12
2.1.13 About the AMD2000 drive....................................................................................................12
2.1.14 Drive Model Applicability......................................................................................................12
2.1.15 Related Documents.............................................................................................................13
2.1.16 Terms and Abbreviations.....................................................................................................13
2.1.17 Trademarks .........................................................................................................................13
3. Product Overview ...........................................................................................................................................14
3.1 What this Chapter Contains...................................................................................................................14
3.2 Features ................................................................................................................................................14
3.3 Operating Principle................................................................................................................................15
3.4 AMD2000 Variant Identification.............................................................................................................15
AMD2000 3A.........................................................................................................................................15
AMD2000 9A.........................................................................................................................................15
3.4.11 AMD2000 Series Drive Catalogue Number Interpretation...................................................16
3.5 System Overview...................................................................................................................................17
3.6 Connector Overview..............................................................................................................................20
3.6.11 AMD2000 3A .......................................................................................................................20
3.6.12 AMD2000 9A .......................................................................................................................21
4. Mechanical Installation...................................................................................................................................25
4.1 What this Chapter Contains...................................................................................................................25
4.2 Pre installation checks...........................................................................................................................25
4.3 Requirements........................................................................................................................................25
4.3.11 Installation Site....................................................................................................................25
4.3.12 Tools Required ....................................................................................................................26
4.3.13 Mounting and Cooling..........................................................................................................26
4.4 Installation .............................................................................................................................................28
4.4.11 Power Isolation....................................................................................................................28
4.4.12 Mounting a Drive .................................................................................................................29
4.4.13 Un-Mounting a Drive............................................................................................................30
5. Planning the Electrical Installation................................................................................................................31
5.1 What this Chapter Contains...................................................................................................................31
5.2 Motor and Drive Compatibility................................................................................................................31
5.3 Power Supply Disconnecting Device.....................................................................................................31

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5.4 Emergency Stop Devices ......................................................................................................................31
5.5 Thermal Overload and Protection..........................................................................................................31
5.6 Power Cable Selection ..........................................................................................................................32
5.7 Control Cable Selection.........................................................................................................................33
5.7.11 EtherCAT Wiring Details......................................................................................................33
5.8 Cable Routing........................................................................................................................................33
6. Power Wiring...................................................................................................................................................35
6.1 What this Chapter Contains...................................................................................................................35
6.2 Checking the Insulation of the Assembly...............................................................................................35
6.3 Mains Power Supply..............................................................................................................................35
6.3.11 Supply Voltage Ranges.......................................................................................................37
6.3.12 Connection of drives to grounded systems (TN or TT)........................................................37
6.3.13 Connection of drives to non-grounded systems (IT)............................................................37
6.3.14 Harmonics and reactive power compensated supplies........................................................37
6.3.15 Residual current-operated protective (RCD) protection.......................................................38
6.4 Grounding..............................................................................................................................................38
6.5 Input EMC (Electromagnetic Compatibility)...........................................................................................38
6.5.11 EMC Filter Specifications.....................................................................................................39
6.5.12 Installation guidelines of EMC filter......................................................................................40
6.6 Power Supply Filters..............................................................................................................................41
6.6.11 Harmonic Suppression ........................................................................................................41
6.7 Power Disconnect and Protection Devices............................................................................................43
6.8 Motor Connections ................................................................................................................................44
6.8.11 Motor Circuit Contactors......................................................................................................45
6.8.12 Motor Power Cable Installation............................................................................................45
6.9 Drive Output Filters................................................................................................................................50
6.9.11 Sinusoidal Filter...................................................................................................................50
6.9.12 du/dt Filter............................................................................................................................52
6.10 Motor Brake Connection........................................................................................................................52
6.11 Motor Thermal Switch............................................................................................................................52
6.12 Motor Thermal Sensor...........................................................................................................................53
6.13 Brake/Regeneration Resistor.................................................................................................................54
7. Control Wiring.................................................................................................................................................55
7.1 What this Chapter Contains...................................................................................................................55
7.2 Analog I/O..............................................................................................................................................55
7.2.11 Analogue Inputs...................................................................................................................55
7.2.12 Analogue Outputs................................................................................................................57
7.3 Digital I/O...............................................................................................................................................58
7.3.11 24V Control Circuit Supply...................................................................................................59
7.3.12 Digital Inputs........................................................................................................................59
7.4 Motor Brake Control...............................................................................................................................62
7.5 Serial Communication Port....................................................................................................................62

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7.6 Ethernet Interface..................................................................................................................................62
7.6.11 EtherCAT®..........................................................................................................................62
7.6.12 EtherCAT topology / Port assignment..................................................................................63
7.7 DIP Buttons ...........................................................................................................................................65
7.8 Motor Feedback.....................................................................................................................................65
7.8.11 Analog Encoder Interface....................................................................................................66
7.8.12 Analog Encoder Cable.........................................................................................................66
7.8.13 Digital Encoder Interface .....................................................................................................67
7.8.14 Digital Encoder Cable..........................................................................................................67
8. Installation Checklist......................................................................................................................................68
8.1 What this Chapter Contains...................................................................................................................68
8.2 Checklist................................................................................................................................................68
9. Start-up............................................................................................................................................................70
9.1 What this Chapter Contains...................................................................................................................70
9.2 Introduction............................................................................................................................................70
9.3 PC minimum specifications....................................................................................................................70
9.4 Configuring the Network Adapter...........................................................................................................71
9.5 Connecting the AMD2000 to a PC.........................................................................................................71
9.6 Starting the AMD2000 ...........................................................................................................................71
9.6.11 Preliminary Checks..............................................................................................................71
9.6.12 Power-On Checks ...............................................................................................................72
9.7 Installing the ANCA MotionBench..........................................................................................................72
9.8 Configuring the AMD2000 Series Servo Drive.......................................................................................77
9.8.11 ANCA MotionBench.............................................................................................................77
10.Feature Configuration ....................................................................................................................................87
10.1 What this Chapter Contains...................................................................................................................87
10.1.11 Analogue Encoder Compensation.......................................................................................87
10.1.12 Backlash Compensation......................................................................................................90
10.1.13 Configuring Wire-Saving UVW Motors.................................................................................92
10.1.14 Digital Output.......................................................................................................................92
10.1.15 Drive Bypass Mode..............................................................................................................97
10.1.16 Drive Data Logger ...............................................................................................................98
10.1.17 Encoders ...........................................................................................................................103
10.1.18 Field Orientation Initialisation.............................................................................................105
10.1.19 Higher Level Functions......................................................................................................113
10.1.20 Modulo Operation..............................................................................................................121
10.1.21 Motion Constraints and Limits ...........................................................................................121
10.1.22 Motor Control.....................................................................................................................129
10.1.23 Operating Modes...............................................................................................................139
10.1.24 Temperature Monitoring ....................................................................................................141
10.1.25 Torque Command Filters...................................................................................................143
11.Fault Tracing .................................................................................................................................................144

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11.1 What this Chapter Contains.................................................................................................................144
11.2 Problem Diagnosis...............................................................................................................................144
11.2.11 AMD2000 Indicators..........................................................................................................144
11.3 Supported Error Codes........................................................................................................................145
11.3.11 Error Code Prefixes...........................................................................................................145
11.3.12 Error / Warning Codes Detailed Descriptions....................................................................148
11.3.13 Firmware Upgrade Errors..................................................................................................156
12.Technical Data...............................................................................................................................................158
12.1 What this Chapter Contains.................................................................................................................158
12.2 Control Functions ................................................................................................................................158
12.2.11 Control Modes...................................................................................................................158
12.2.12 Thermal and over-current protection..................................................................................158
12.2.13 Self-Protection features.....................................................................................................158
12.2.14 DC bus voltage control ......................................................................................................158
12.2.15 Advanced control functions................................................................................................159
12.3 Interface Specifications........................................................................................................................160
12.3.11 Digital I/O Supply...............................................................................................................160
12.3.12 24V Digital Inputs ..............................................................................................................160
12.3.13 24V Digital Outputs............................................................................................................160
12.3.14 5V RS422 Differential Digital Inputs...................................................................................160
12.3.15 Differential Digital Outputs.................................................................................................160
12.3.16 Analogue Inputs.................................................................................................................161
12.3.17 Analogue Outputs..............................................................................................................161
12.3.18 Motor Position Feedback...................................................................................................161
12.3.19 Encoder Channel 1............................................................................................................161
12.3.20 Encoder Channel 2............................................................................................................162
12.3.21 Encoder Supply .................................................................................................................162
12.3.22 Ethernet Interface..............................................................................................................162
12.3.23 Modbus Interface...............................................................................................................162
12.3.24 Drive Display .....................................................................................................................162
12.3.25 Digital I/O Supply...............................................................................................................162
12.4 Electrical Specifications.......................................................................................................................163
12.4.11 Power supply section.........................................................................................................163
12.4.12 Digital servo drive..............................................................................................................163
12.5 Performance Specifications.................................................................................................................164
12.5.11 Resolution..........................................................................................................................164
12.5.12 Steady State Performance.................................................................................................164
12.5.13 Dynamic Performance.......................................................................................................164
12.5.14 Regenerative Braking........................................................................................................164
12.6 Environmental Specifications...............................................................................................................165
12.6.11 Storage..............................................................................................................................165
12.6.12 Transport...........................................................................................................................165
12.6.13 Installation and Operation..................................................................................................165

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12.6.14 Physical Characteristics.....................................................................................................165
12.6.15 Cooling ..............................................................................................................................165
12.7 Dimension Drawings............................................................................................................................166
12.7.11 AMD2000 3A drive mounting hole positions and physical dimensions..............................166
12.7.12 AMD2000 9A drive mounting hole positions and physical dimensions..............................167
12.8 24V Control Circuit Supply...................................................................................................................167
12.9 Effect of AC Input Voltage on DC Bus Ripple......................................................................................167
12.9.11 Effect of AC Input Voltage on DC Bus Voltage..................................................................169
12.9.12 Effect of Bus Capacitance on DC Bus Ripple....................................................................169
12.9.13 Effect of Output Current on DC Bus Ripple Voltage ..........................................................169
12.10 Temperature De-rating ........................................................................................................................169
12.10.11 De-rating Characteristics...................................................................................................170
12.11 Input Power-cycling and Inrush ...........................................................................................................170
12.12 Discharge Period.................................................................................................................................171
12.13 Motor Output Power.............................................................................................................................171
12.14 Brake/Regeneration Resistor...............................................................................................................172
12.14.11 Brake Resistor Selection, Braking Energy and Power.......................................................172
12.15 Materials..............................................................................................................................................174
12.16 Standards Conformity..........................................................................................................................175
Marking & Applicable Regulations ..................................................................................................................175
Standard.........................................................................................................................................................175
Certification Organisation................................................................................................................................175
12.17 EtherCAT® Conformance Marking......................................................................................................176
12.18 CE Marking..........................................................................................................................................176
12.18.11 Compliance with the European EMC Directive is achieved via EN 61800-3 .....................176
12.18.12 Compliance with the European Low Voltage Directive is achieved via EN 61800-5-1 ......176
12.18.13 CE Declaration of Conformity............................................................................................178
13.Accessories...................................................................................................................................................180
13.1 What this Chapter Contains.................................................................................................................180
13.2 Motors..................................................................................................................................................180
13.2.11 Motor Catalogue Number Interpretation ............................................................................180
13.2.12 Motor Electrical Information Summary...............................................................................181
13.2.13 Brake Motor Specific Information.......................................................................................181
13.2.14 Motor Mechanical Information Summary ...........................................................................182
13.3 Cables .................................................................................................................................................183
13.3.11 Cable Catalogue Number Interpretation............................................................................183
13.3.12 Encoder Cables.................................................................................................................183
13.3.13 Armature Cables................................................................................................................184
13.4 Other Accessories ...............................................................................................................................184
13.4.11 I/O Interface Accessories...................................................................................................184
13.4.12 EtherCAT Cables...............................................................................................................185
13.4.13 Armature Shield Clamping Brackets..................................................................................185
13.4.14 AMD2000 3A EMC Kit.......................................................................................................185

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13.4.15 AMD2000 9A EMC Kit.......................................................................................................185
13.4.16 EMI Filters .........................................................................................................................186
13.4.17 Line Reactors ....................................................................................................................186
13.4.18 DC Chokes........................................................................................................................186
13.4.19 Magnetic Cores .................................................................................................................186
13.5 Starter Kits...........................................................................................................................................186
13.5.11 AMD2000 3A Starter Kit ....................................................................................................186
13.5.12 AMD2000 9A Starter Kit ....................................................................................................187
14.Additional Information..................................................................................................................................188
14.1 What this Chapter Contains.................................................................................................................188
14.2 Maintenance and Repairs....................................................................................................................188
14.3 Product, Sales and Service Enquiries..................................................................................................188
14.4 Feedback.............................................................................................................................................189

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1. Safety
Warning: To prevent possible accidents or injury, ensure you read and understand this manual before
commencing installation or service work on the AMD2000 drives.
DANGER HIGH VOLTAGE - The working DC bus is live at all times when power is on. The Main Isolator feeding
the drive must be switched to the Off position at least 15 minutes before any work is commenced on the unit. The
operator must check the bus voltage with a tested working voltage measuring instrument prior to disconnecting
any connectors or opening the DC Bus terminal cover. The red LED indicator on the front of the drive which
indicates that there is charge remaining in the drive is only to be used as an aid to visual troubleshooting. It shall
not be relied on as a means of safety.
This manual and the warnings attached to the AMD2000 only highlight hazards that can be predicted by ANCA
Motion. Be aware they do not cover all possible hazards.
ANCA Motion shall not be responsible for any accidents caused by the misuse or abuse of the device by the
operator.
Safe operation of these devices is your own responsibility. By taking note of the safety precautions, tips and
warnings in this manual you can help to ensure your own safety and the safety of those around you.
The AMD2000 is equipped with safety features to protect the operator and equipment. Never operate the
equipment if you are in doubt about how these safety features work.
1.1 General Safety
The following points must be understood and adhered to at all times:
Equipment operators must read the user manual carefully and make sure of the correct
procedure before operating the AMD2000.
Memorize the locations of the power and drive isolator switches so that you can activate them
immediately at any time if required.
If two or more persons are working together, establish signals so that they can communicate to
confirm safety before proceeding to another step.
Always make sure there are no obstacles or people near the devices during installation and or
operation. Be aware of your environment and what is around you.
Take precautions to ensure that your clothing, hair or personal effects (such as jewelry) cannot
become entangled in the equipment.
Do not remove the covers to access the inside of the AMD2000 unless authorized
Do not turn on any of the equipment without all safety features in place and known to be
functioning correctly. Never remove any covers or guards unless instructed by the procedures
described in this manual.
Never touch any exposed wiring, connections or fittings while the equipment is in operation.
Visually check all switches on the operator panel before operating them.
Do not apply any mechanical force to the AMD2000, which may cause malfunction or failure.
Before removing equipment covers, be sure to turn OFF the power supply at the isolator. (Refer
to 4.4.11 Power Isolation. ) Never remove the equipment covers during operation.
Keep the vicinity of the AMD2000 clean and tidy.