Danaher Motion SuperDrive ACS24 Series User manual

A
C SuperDrive
The AC motor controlle
r
Generation 5
User's Guide 1.0
Item No. 89Y05120A
26.04.2005
Solution b
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Introduction 26.04.2005
Version History
Revision Edition date Reason for revision
Trademark information here
Product was developed under one or more US patents
Printed in Sweden. All rights reserved.
Danaher Motion is a registered trademark of Danaher Corporation. Danaher Motion makes every attempt to
ensure accuracy and ratability of the specification in this publication. Specifications are subject to change
without notice. Danaher motion provides this information “AS IS” and declines all warranties, express or
implied, including, but not limited to, implied warranties of mechanic ability and fitness for a particular purpose.
It is the responsibility of the product user to determine the suitability of this product for a specific application.
©2005 Danaher Motion
Item No. 89Y05120A User's Guide 1.0
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Tables of contents
1Introduction ..................................................................................................................... 7
1.1 About AC SuperDrive documentation ..................................................................7
1.1.1 This version ....................................................................................................................................7
1.1.2 Copyright ........................................................................................................................................7
1.1.3 Scope .............................................................................................................................................7
1.1.4 Warning, caution and information notices ......................................................................................7
1.1.4.1 Product range.............................................................................................................................8
1.1.5 Related documents.........................................................................................................................8
1.2 About the AC SuperDrive.....................................................................................8
1.2.1 Personal safety...............................................................................................................................8
1.2.2 OEM's responsibility .......................................................................................................................8
1.2.3 Technical support ...........................................................................................................................8
1.2.4 Repair .............................................................................................................................................9
1.2.5 Product warranty ............................................................................................................................9
1.3 Product identification............................................................................................9
1.3.1 Configurations ................................................................................................................................9
1.3.2 AC SuperDrive identification label..................................................................................................9
1.4 Standard features and capabilities .....................................................................10
1.5 Available options ................................................................................................11
2Overview ....................................................................................................................... 13
2.1 Principles of operation........................................................................................14
2.1.1 Block diagram...............................................................................................................................14
2.1.2 CAN interface ...............................................................................................................................14
2.1.3 Speed control ...............................................................................................................................14
2.1.4 Flux control ...................................................................................................................................15
2.1.5 Slip and stator frequency estimation ............................................................................................15
2.1.6 Current control and SPWM-sym...................................................................................................15
2.1.7 Power conversion section ............................................................................................................15
2.1.8 Speed sensor interface ................................................................................................................17
2.1.9 Logic power ..................................................................................................................................17
2.2 Safety and protective functions ..........................................................................17
2.2.1 General.........................................................................................................................................17
2.2.2 Errors............................................................................................................................................17
2.2.3 Warnings ......................................................................................................................................18
2.3 Truck controller - AC SuperDrive communications.............................................18
2.3.1 General.........................................................................................................................................18
2.3.2 Node identification........................................................................................................................18
3Installation..................................................................................................................... 19
3.1 Introduction ........................................................................................................19
3.2 Cooling requirements .........................................................................................20
3.2.1 AC SuperDrive with finned heatsink.............................................................................................20
3.2.2 AC SuperDrive with flat heatsink..................................................................................................20
3.3 Clearances for access and air circulation...........................................................20
3.3.1 AC SuperDrive with finned heatsink.............................................................................................20
3.3.2 AC SuperDrive with flat heatsink..................................................................................................20
3.4 Orientation .........................................................................................................20
3.5 Mounting AC SuperDrive with fins heatsink .......................................................21
3.5.1 Dimensions and clearances .........................................................................................................21
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3.5.2 Tools and equipment required...................................................................................................... 21
3.5.3 Procedure ..................................................................................................................................... 21
3.6 Mounting AC SuperDrive with flat heatsink ........................................................22
3.6.1 Dimensions and clearances ......................................................................................................... 22
3.6.2 Tools and equipment required...................................................................................................... 22
3.6.3 Procedure ..................................................................................................................................... 22
3.7 Wiring .................................................................................................................23
3.7.1 Motor and battery connections ..................................................................................................... 23
3.7.2 Making connections to terminal posts .......................................................................................... 24
3.7.3 Equipment required ...................................................................................................................... 25
3.8 On-board fuse sizing and selection ....................................................................25
3.8.1 Key start fuse F2 .......................................................................................................................... 26
3.8.2 Installation of on-board fuses ....................................................................................................... 26
3.9 Inrush current limiting resistance........................................................................27
3.10 Main contactor....................................................................................................27
3.11 Emergency stop switch.......................................................................................28
3.12 Key start input ....................................................................................................28
3.13 Control and I/O connections ...............................................................................28
3.13.1 General......................................................................................................................................... 28
3.13.2 120 ohm termination..................................................................................................................... 29
3.13.3 Speed encoder signals................................................................................................................. 29
3.13.4 ACS ID1 and ID2 inputs ............................................................................................................... 30
3.13.5 Temperature sensor ..................................................................................................................... 31
3.14 Can bus communications ...................................................................................32
4Start up & commissioning.............................................................................................. 35
4.1 General...............................................................................................................35
4.2 Checks prior to initial power up ..........................................................................35
4.3 Verifying AC SuperDrive readiness for operation ...............................................36
4.4 Configuring the AC SuperDrive for the application .............................................36
4.5 Operational checks in vehicle.............................................................................37
5Maintenance..................................................................................................................39
5.1 Periodic preventive maintenance .......................................................................39
5.1.1 AC SuperDrive with finned heatsink.............................................................................................39
5.1.2 AC SuperDrive flat heatsink ......................................................................................................... 40
5.2 Replacement of AC SuperDrive .........................................................................40
5.2.1 Drive removal ............................................................................................................................... 40
5.2.2 Drive Installation........................................................................................................................... 40
6Configuration & control of the AC SuperDrive ...............................................................41
6.1 Introduction.........................................................................................................41
6.2 CANopen and application control .......................................................................42
6.3 Speed measurement ..........................................................................................45
6.3.1 Tuning of speed measurement.....................................................................................................45
6.4 Speed control .....................................................................................................46
6.4.1 Speed ramp .................................................................................................................................. 47
6.4.1.1 General .................................................................................................................................... 47
6.4.1.2 Basics....................................................................................................................................... 48
6.4.1.3 Slopes ...................................................................................................................................... 49
6.4.1.4 Rollback ................................................................................................................................... 50
6.4.1.5 No ramp ................................................................................................................................... 50
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6.4.1.6 PDO controlled ramp................................................................................................................50
6.4.1.7 Parameter controlled ramp ......................................................................................................51
6.5 Best performance curve Option .............................................................................53
6.5.1.1 General ....................................................................................................................................53
6.5.2 Speed PI controller.......................................................................................................................53
6.6 Torque current limitation ....................................................................................53
6.6.1 Tuning of speed control................................................................................................................54
6.6.1.1 Tuning in parameter or PDO controlled ramp mode................................................................ 54
6.6.1.2 Tuning in no ramp mode ..........................................................................................................55
6.7 Flux control ........................................................................................................56
6.7.1 Basics ...........................................................................................................................................56
6.8 Parameters ........................................................................................................57
6.8.1 Tuning Of flux control ...................................................................................................................58
6.9 Slip and stator frequency estimation ..................................................................58
6.9.1 Parameters and variables ............................................................................................................58
6.9.2 Tuning of the slip and stator frequency estimation....................................................................... 59
6.10 Current control ...................................................................................................59
6.10.1 Basics ...........................................................................................................................................59
6.10.2 Parameters and variables ............................................................................................................60
6.11 Tuning of current control ....................................................................................61
6.12 SPWM-sym ........................................................................................................62
6.12.1 Basics ...........................................................................................................................................62
6.13 Open drain output control...................................................................................64
6.13.1 Parameters ...................................................................................................................................65
6.14 How the AC SuperDrive handles parameters ....................................................66
6.14.1 General.........................................................................................................................................66
6.14.2 Parameter verification at startup ..................................................................................................66
6.14.3 Saving parameters .......................................................................................................................67
6.14.4 Duplicating a configuration ...........................................................................................................67
6.14.5 Reverting to default parameters ................................................................................................... 68
7Troubleshooting guide................................................................................................... 69
7.1 General ..............................................................................................................69
7.2 Documentation for OEMs...................................................................................69
7.3 Errors .................................................................................................................69
7.4 Warnings............................................................................................................69
7.5 Status indicator ..................................................................................................70
7.6 Using the troubleshooting guide.........................................................................70
7.7 Troubleshooting chart ........................................................................................72
7.7.1 Main contactor doesn’t close........................................................................................................73
7.7.2 Fuse to power stage is blown.......................................................................................................74
7.7.3 AC SuperDrive status indicator is flashing or off.......................................................................... 75
7.7.4 Motor runs only at low speed .......................................................................................................76
7.7.5 Speed feedback sensor not connected........................................................................................77
7.7.6 Motor temperature error ...............................................................................................................78
7.7.7 Heatsink over temperature error ..................................................................................................80
7.7.8 AC current over current ................................................................................................................83
7.7.9 DC Bus high - hardware detected ................................................................................................84
7.7.10 DC Bus Low..................................................................................................................................85
7.7.11 CAN –time out ..............................................................................................................................86
7.7.12 Heatsink temperature sensor 1,2 – open circuit/short circuit ....................................................... 87
7.7.13 Motor - temp < -50 °C...................................................................................................................88
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7.7.14 Motor temperature sensor open circuit/short circuit ..................................................................... 89
7.7.15 15 V supply low voltage................................................................................................................ 90
7.7.16 Reverted to default parameters.................................................................................................... 91
8AC SuperDrive specifications ........................................................................................ 93
8.1 General...............................................................................................................93
8.2 Current and power output ratings .......................................................................93
8.3 DC supply voltage requirement ..........................................................................94
8.4 Isolation ..............................................................................................................94
8.5 CAN communications interface ..........................................................................94
8.6 Safety system.....................................................................................................94
8.7 Operating environment.......................................................................................94
8.8 EMC ...................................................................................................................95
8.9 Safety and testing standards compliance...........................................................95
8.10 Mechanical tests.................................................................................................95
8.11 Physical characteristics ......................................................................................95
8.11.1 Weight .......................................................................................................................................... 95
8.11.2 Dimensions................................................................................................................................... 96
8.11.3 Surface requirements ................................................................................................................... 96
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1 INTRODUCTION
1.1 ABOUT AC SUPERDRIVE DOCUMENTATION
1.1.1 THIS VERSION
This version replaces all previous versions of this document. Danaher Motion Stockholm AB has
made every effort to insure this document is complete and accurate at the time of printing. In
accordance with our policy of continuing product improvement, all data in this document is
subject to change or correction without prior notice.
1.1.2 COPYRIGHT
This manual is copyrighted 2005 by Danaher Motion Stockholm AB. All rights reserved. This
manual may not be copied in whole or in part, nor transferred to any other media or language,
without the express written permission of Danaher Motion Stockholm AB.
1.1.3 SCOPE
This manual presents instructions, guidelines, diagram and other information relevant for
installation and maintaining the AC SuperDrive in an electrically powered vehicle utilizing the
CAN Bus and CANopen protocol for communications and control.
1.1.4 WARNING, CAUTION AND INFORMATION NOTICES
Special attention must be paid to the information presented in warning, caution and information
notices when they appear in this manual. Examples of caution, warning and information notices
along with an explanation of their purposes follow.
WARNING
♦ A Warning informs the user of a hazard or potential hazard that could
result in serious of fatal injury if the precautions or instructions given in
the warning notice are not observed.
CAUTION
♦ A Caution informs the user of a hazard or potential hazard that could
result in injury or damage to the equipment if the precautions or
instructions given in the caution notice are not observed.
i An Information Box contains supplemental information or references to
supplemental information on a topic.
Stop Box highlights important conceptual or procedural details that
must be understood and applied in order to successfully use the
product.
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1.1.4.1PRODUCT RANGE
This manual presents important information about the AC SuperDrive Product Generation (5)
five.
1.1.5 RELATED DOCUMENTS
Object Dictionary (document number 89Y05110A). The Object Dictionary provides important
information about CANopen communication with the AC SuperDrive.
1.2 ABOUT THE AC SUPERDRIVE
1.2.1 PERSONAL SAFETY
Danaher Motion Stockholm AB provides this and other manuals to assist manufacturers in using
the AC SuperDrive in a correct, efficient and safe manner. Manufacturers must insure that all
persons responsible for the design and use of equipment employing the AC SuperDrive have the
proper professional skill and apparatus knowledge.
WARNING
♦ The high power levels and high torque available from a motor,
AC SuperDrive combination can cause severe or fatal injury.
CAUTION
♦ The AC SuperDrive is intended for connection only to DC battery
power sources and for use with low voltage asynchronous motors.
♦ Always verify before installation that the AC SuperDrive model is
correct for the vehicle’s battery supply voltage. The DC Supply
nominal voltage is stated on a label on the cover of each AC
SuperDrive.
1.2.2 OEM'S RESPONSIBILITY
The Danaher Motion AC SuperDrive products are intended for controlling motors in battery
powered electric vehicles. These drives are supplied to original equipment manufacturers
(OEMs) for incorporation into their vehicles and vehicle control systems.
OEM's are responsible for ensuring that AC SuperDrives are used for their intended purpose
only, safe function of the system and for compliance with all applicable regulations.
Responsibility for the safe functioning of the system reverts to the owner or user in all cases in
which a non-professional has done installation, service or repair and when the system is used for
other than its intended purpose.
1.2.3 TECHNICAL SUPPORT
For additional information on any topic covered in this document, or for additional information or
application assistance on any Danaher Motion Stockholm AB product, contact a Danaher Motion
Stockholm AB Application Center listed in the front of this manual.
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1.2.4 REPAIR
Repair and testing of the APS is available at Danaher Motion Stockholm AB.
The address is listed on page 99.
When returning defective unit in North America, contact Danaher Motion Stockholm AB in
Sewickley and obtain a RMA (Returned Materials Authorization) number prior to returning the
defective unit. Indicate the RMA number on the shipping container and paper work that
accompanies the returned unit.
1.2.5 PRODUCT WARRANTY
Refer to the sales agreement or contract under which the AC SuperDrive was purchased for a
complete statement of the product warranty.
1.3 PRODUCT IDENTIFICATION
1.3.1 CONFIGURATIONS
The AC SuperDrive is manufactured in the following two configurations:
• Convection cooled models (see Figure 1) employing a heat sink with cooling fins that transfer
heat to the surrounding air by convection.
• Conduction cooled models (see Figure 1) with a flat heat sink and mounting surface that
transfers heat into the surrounding vehicle structure by conduction.
1.3.2 AC SUPERDRIVE IDENTIFICATION LABEL
A label containing pertinent product identification information is affixed to the AC SuperDrive
cover next to the B+ terminal post. The product label fields relevant to product identification are
described below. For AC SuperDrive expressions, see Table 1. See Figure 1 for placement and
Figure 2 for a label appearance.
Figure 1. AC Superdrive with fins and flat Mounting Surface.
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Introduction 26.04.2005
Figure 2. AC SuperDrive Product Identification Label.
Field Description
Danaher Motion Unique part number assigned to AC SuperDrives with a specific
hardware and software configuration. AC SuperDrives with the same
part number and revision are identical.
Rev. Indicates the revision level of the item.
Type
* Contact Danaher Motion Stockholm AB for further information.
Serie No. Production lot number (assigned by the factory). The production lot
number together with the sequence number yield a unique serial
number for each AC SuperDrive.
Serie No. Serial number within a production lot.
Manufacture date Year, month and day of manufacture.
Table 1. AC SuperDrive Product expressions.
1.4 STANDARD FEATURES AND CAPABILITIES
The AC SuperDrive incorporates a number of features and capabilities important to the electric
vehicle designer including:
• Modern AC flux-vector control techniques for improved performance and operating efficiency.
• A family of drives covering a wide range of power outputs and battery voltages.
• Programmable to match the characteristics of compatible induction motors.
• Designed for the environment of the electrically powered vehicle.
• Closed loop speed regulator provides unequalled vehicle speed control when moving and
neutral braking for maintaining position when stopped.
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