Delta Electronics ASDA-A Series User manual

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Revision April 2009 i
Preface
Thank you very much for purchasing DELTA’s AC servo products.
This manual will be helpful in the installation, wiring, inspection, and operation of Delta AC servo drive and
motor. Before using the product, please read this user manual to ensure correct use.
You should thoroughly understand all safety precautions (DANGERS, WARNINGS and STOPS) before
proceeding with the installation, wiring and operation. If you do not understand please contact your local
Delta sales representative. Place this user manual in a safe location for future reference.
Using This Manual
Contents of this manual
This manual is a user guide that provides the information on how to install, operate and maintain
ASDA-A and ASDA-A+ series AC servo drives, and ASMT and ECMA series AC servo motors. The
contents of this manual are including the following topics:
zInstallation of AC servo drives and motors
zConfiguration and wiring
zTrial run steps
zControl functions and adjusting methods of AC servo drives
zParameter settings
zCommunication protocol
zInspection and maintenance
zTroubleshooting
zApplication examples
Who should use this manual
This user manual is intended for the following users:
zThose who are responsible for designing.
zThose who are responsible for installing or wiring.
zThose who are responsible for operating or programming.
zThose who are responsible for maintaining or troubleshooting.
Important precautions
Before using the product, please read this user manual thoroughly to ensure correct use and store
this manual in a safe and handy place for quick reference whenever necessary. Besides, please
observe the following precautions:
zDo not use the product in a potentially explosive environment.
zInstall the product in a clean and dry location free from corrosive and inflammable gases
or liquids.
zDo not connect a commercial power supply to the U, V, W terminals of motor. Failure to
observe this precaution will damage either the Servo motor or drive.
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Preface|ASDA-A&A+ Series
ii Revision April 2009
zEnsure that the motor and drive are correctly connected to a ground. The grounding
method must comply with the electrical standard of the country (Please refer to NFPA 70:
National Electrical Code, 2005 Ed.).
zDo not disconnect the AC servo drive and motor while the power is ON.
zDo not attach, modify and remove wiring when power is applied to the AC servo drive and
motor.
zBefore starting the operation with a mechanical system connected, make sure the
emergency stop equipment can be energized and work at any time.
zDo not touch the drive heat sink or the servo motor during operation. Otherwise, it may
result in serious personnel injury.
PLEASE READ PRIOR TO INSTALLATION FOR SAFETY.
Carefully note and observe the following safety precautions when receiving, inspecting, installing, operating,
maintaining and troubleshooting. The following words, DANGER, WARNING and STOP are used to mark
safety precautions when using the Delta’s servo product. Failure to observe these precautions may void
the warranty!
ASDA-A and ASDA-A+ series drives are open type servo drives and must be installed in an NEMA enclosure
such as a protection control panel during operation to comply with the requirements of the international
safety standards. They are provided with precise feedback control and high-speed calculation function
incorporating DSP (Digital Signal Processor) technology, and intended to drive three-phase permanent
magnet synchronous motors (PMSM) to achieve precise positioning by means of accurate current output
generated by IGBT (Insulated Gate Bipolar Transistor).
ASDA-A and ASDA-A+ series drives can be used in industrial applications and for installation in an end-use
enclosure that do not exceed the specifications defined in the ASDA-A and ASDA-A+ series user manual
(Drives, cables and motors are for use in a suitable enclosure with a minimum of a UL50 type 1 or NEMA
250 Type 1 rating).
The words, DANGER, WARNING and STOP, have the following meaning:
Indicates a potentially hazardous situation and if not avoided, may result in serious injury
or death.
Indicates a potentially hazardous situation and if not avoided, may result in minor to
moderate injury or serious damage to the product.
Indicates an improper action that it is not recommended to do and if doing it may cause
damage, malfunction and inability.
Unpacking Check
¾Please ensure that both the servo drive and motor are correctly matched for size (power rating). Failure to observe this
precaution may cause fire, seriously damage the drive / motor or cause personal injury.
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Preface|ASDA-A&A+ Series
Revision April 2009 iii
Installation
¾Do not install the product in a location that is outside the stated specification for the drive and motor. Failure to observe this
caution may result in electric shock, fire, or personal injury.
Wiring
¾Connect the ground terminals to a class-3 ground (Ground resistance should not exceed 100 Ω). Improper grounding may result
in electric shock or fire.
¾Do not connect any power supplies to the U, V, W terminals. Failure to observe this precaution may result in serious injury,
damage to the drive or fire.
¾Ensure that all screws, connectors and wire terminations are secure on the power supply, servo drive and motor. Failure to
observe this caution may result in damage, fire or personal injury.
¾In order to prevent fire hazard and accidents, please form the wiring by the cable specifications outlined in this user manual.
Operation
¾Before starting the operation with a mechanical system connected, change the drive parameters to match the user-defined
parameters of the mechanical system. Starting the operation without matching the correct parameters may result in servo drive
or motor damage, or damage to the mechanical system.
¾Ensure that the emergency stop equipment or device is connected and working correctly before operating the motor that is
connected to a mechanical system.
¾Do not approach or touch any rotating parts (e.g. shaft) while the motor is running. Failure to observe this precaution may
cause serious personal injury.
¾In order to prevent accidents, the initial trial run for servo motor should be conducted under no load conditions (separate the
motor from its couplings and belts).
¾For the initial trial run, do not operate the servo motor while it is connected to its mechanical system. Connecting the motor to
its mechanical system may cause damage or result in personal injury during the trail run. Connect the servo motor once it has
successfully completed a trail run.
¾Caution: Please perform trial run without load first and then perform trial run with load connected. After the servo motor is
running normally and regularly without load, then run servo motor with load connected. Ensure to perform trial run in this order
to prevent unnecessary danger.
¾Do not touch either the drive heat sink or the motor during operation as they may become hot and personal injury may result.
Maintenance and Inspection
¾Do not touch any internal or exposed parts of servo drive and servo motor as electrical shock may result.
¾Do not remove the operation panel while the drive is connected to an electrical power source otherwise electrical shock may
result.
¾Wait at least 10 minutes after power has been removed before touching any drive or motor terminals or performing any wiring
and/or inspection as an electrical charge may still remain in the servo drive and servo motor with hazardous voltages even after
power has been removed.
¾Do not disassemble the servo drive or motor as electric shock may result.
¾Do not connect or disconnect wires or connectors while power is applied to the drive and motor.
¾Only qualified personnel who have electrical knowledge should conduct maintenance and inspection.
Main Circuit Wiring
¾Install the encoder cables in a separate conduit from the motor power cables to avoid signal noise. Separate the conduits by
30cm (11.8inches) above.
¾Use multi-stranded twisted-pair wires or multi-core shielded-pair wires for signal, encoder (PG) feedback cables. The maximum
length of command input cable is 3m (9.84ft.) and the maximum length of encoder (PG) feedback cables is 20m (65.62ft.).
¾As a charge may still remain in the drive with hazardous voltages even after power has been removed, be sure to wait at least 10
minutes after power has been removed before performing any wiring and/or inspection.
¾It is not recommended to frequently power the drive on and off. Do not turn the drive off and on more than once per minute as
high charging currents within the internal capacitors may cause damage.
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Preface|ASDA-A&A+ Series
iv Revision April 2009
Main Circuit Terminal Wiring
¾Please perform the wiring after the terminal blocks are all removed from the drive.
¾Insert only one wire into one terminal on the terminal block.
¾When inserting wires, please ensure that the conductors are not shorted to adjacent terminals or wires.
¾Ensure to double check the wiring before applying power to the drive.
¾If the wiring is in error, perform the wiring again with proper tools. Never use force to remove the terminals or wires. Otherwise,
it may result in malfunction or damage.
NOTE
1) In this manual, actual measured values are in metric units. Dimensions in (imperial
units) are for reference only. Please use metric for precise measurements.
2) The content of this manual may be revised without prior notice. Please consult our
distributors or download the most updated version at
http://www.delta.com.tw/industrialautomation.
.
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Revision April 2009
Table of Contents
Chapter 1 Unpacking Check and Model Explanation............................................................. 1-1
1.1 Unpacking Check .................................................................................................................... 1-1
1.2 Model Explanation................................................................................................................... 1-2
1.2.1 Nameplate Information .....................................................................................................1-2
1.2.2 Model Name Explanation ................................................................................................. 1-4
1.3 Servo Drive and Servo Motor Combinations........................................................................... 1-7
1.4 Servo Drive Features .............................................................................................................. 1-9
1.5 Control Modes of Servo Drive ................................................................................................. 1-13
Chapter 2 Installation and Storage......................................................................................... 2-1
2.1 Installation Notes..................................................................................................................... 2-1
2.2 Storage Conditions.................................................................................................................. 2-1
2.3 Installation Conditions ............................................................................................................. 2-2
2.4 Installation Procedure and Minimum Clearances ................................................................... 2-3
Chapter 3 Connections and Wiring ........................................................................................ 3-1
3.1 Connections ............................................................................................................................ 3-1
3.1.1 Connecting to Peripheral Devices .................................................................................... 3-1
3.1.2 Servo Drive Connectors and Terminals ........................................................................... 3-4
3.1.3 Wiring Methods................................................................................................................. 3-6
3.1.4 Motor Power Cable Connector Specifications.................................................................. 3-8
3.1.5 Encoder Connector Specifications ................................................................................... 3-10
3.1.6 Cable Specifications for Servo Drive................................................................................ 3-11
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Table of Contents|ASDA-A&A+ Series
Revision April 2009
3.2 Basic Wiring ............................................................................................................................ 3-13
3.3 Input / Output Interface Connector -CN1 ................................................................................ 3-17
3.3.1 CN1 Terminal Identification .............................................................................................. 3-17
3.3.2 Signals Explanation of Connector CN1 ............................................................................ 3-19
3.3.3 User-defined DI and DO signals....................................................................................... 3-29
3.3.4 Wiring Diagrams of I/O Signals (CN1).............................................................................. 3-30
3.4 Encoder Connector CN2......................................................................................................... 3-35
3.5 Serial Communication Connector CN3 ................................................................................... 3-37
3.5.1 CN3 Terminal Layout and Identification ........................................................................... 3-37
3.5.2 Connection between PC/Keypad and Connector CN3 .................................................... 3-38
3.6 Standard Connection Example ............................................................................................... 3-39
3.6.1 Position (Pt) Control Mode ............................................................................................... 3-39
3.6.2 Position (Pr) Control Mode ............................................................................................... 3-40
3.6.3 Speed Control Mode......................................................................................................... 3-41
3.6.4 Torque Control Mode........................................................................................................ 3-42
Chapter 4 Display and Operation........................................................................................... 4-1
4.1 Description of the Digital Keypad............................................................................................ 4-1
4.2 Display Flowchart.................................................................................................................... 4-3
4.3 Status Display ......................................................................................................................... 4-4
4.3.1 Save Setting Display ........................................................................................................ 4-4
4.3.2 Abort Setting Display ........................................................................................................ 4-4
4.3.3 Fault Message Display .....................................................................................................4-4
4.3.4 Polarity Setting Display..................................................................................................... 4-4
4.3.5 Monitor Setting Display..................................................................................................... 4-5
4.4 General Function Operation.................................................................................................... 4-7
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Table of Contents|ASDA-A&A+ Series
Revision April 2009
4.4.1 Fault Code Display Operation .......................................................................................... 4-7
4.4.2 JOG Operation.................................................................................................................. 4-7
4.4.3 Position Learning Operation ............................................................................................. 4-8
4.4.4 DO Force Output Diagnosis Operation ............................................................................ 4-10
4.4.5 DI Diagnosis Operation .................................................................................................... 4-11
4.4.6 DO Diagnosis Operation................................................................................................... 4-11
Chapter 5 Trial Run and Tuning Procedure ........................................................................... 5-1
5.1 Inspection without Load .......................................................................................................... 5-1
5.2 Applying Power to the Drive.................................................................................................... 5-3
5.3 JOG Trial Run without Load.................................................................................................... 5-7
5.4 Speed Trial Run without Load................................................................................................. 5-9
5.5 Position Trial Run without Load .............................................................................................. 5-11
5.6 Tuning Procedure.................................................................................................................... 5-14
5.6.1 Tuning Flowchart .............................................................................................................. 5-15
5.6.2 Load Inertia Estimation Flowchart .................................................................................... 5-16
5.6.3 Easy Mode Tuning Flowchart ........................................................................................... 5-17
5.6.4 AutoMode (PI) Tuning Flowchart...................................................................................... 5-20
5.6.5 AutoMode (PDFF) Tuning Flowchart................................................................................ 5-22
5.6.6 Limit of Load Inertia Estimation ........................................................................................ 5-24
5.6.7 Relationship between Tuning Modes and Parameters .................................................... 5-24
5.6.8 Gain Adjustment in Manual Mode .................................................................................... 5-25
Chapter 6 Control Modes of Operation .................................................................................. 6-1
6.1 Control Modes of Operation .................................................................................................... 6-1
6.2 Position Control Mode............................................................................................................. 6-2
6.2.1 Command Source of Position (Pt) Control Mode ............................................................. 6-2
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Table of Contents|ASDA-A&A+ Series
Revision April 2009
6.2.2 Command Source of Position (Pr) Control Mode ............................................................. 6-4
6.2.3 Structure of Position Control Mode .................................................................................. 6-5
6.2.4 P-curve Filter for Position Control..................................................................................... 6-6
6.2.5 Electronic Gear Ratio ....................................................................................................... 6-9
6.2.6 Low-pass Filter ................................................................................................................. 6-10
6.2.7 Timing Chart of Position (Pr) Control Mode ..................................................................... 6-11
6.2.8 Position Loop Gain Adjustment ........................................................................................ 6-11
6.3 Speed Control Mode ............................................................................................................... 6-14
6.3.1 Command Source of Speed Control Mode ...................................................................... 6-14
6.3.2 Structure of Speed Control Mode..................................................................................... 6-15
6.3.3 Smoothing Strategy of Speed Control Mode.................................................................... 6-16
6.3.4 Analog Speed Input Scaling ............................................................................................. 6-19
6.3.5 Timing Chart of Speed Control Mode............................................................................... 6-20
6.3.6 Speed Loop Gain Adjustment........................................................................................... 6-20
6.3.7 Resonance Suppression .................................................................................................. 6-28
6.4 Torque Control Mode .............................................................................................................. 6-31
6.4.1 Command Source of Torque Control Mode ..................................................................... 6-31
6.4.2 Structure of Torque Control Mode.................................................................................... 6-32
6.4.3 Smoothing Strategy of Torque Control Mode................................................................... 6-32
6.4.4 Analog Torque Input Scaling ............................................................................................ 6-33
6.4.5 Timing Chart of Speed Control Mode............................................................................... 6-34
6.5 Control Modes Selection ......................................................................................................... 6-35
6.5.1 Speed / Position Control Mode Selection......................................................................... 6-35
6.5.2 Speed / Torque Control Mode Selection .......................................................................... 6-36
6.5.3 Torque / Position Control Mode Selection........................................................................ 6-36
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Table of Contents|ASDA-A&A+ Series
Revision April 2009
6.6 Others...................................................................................................................................... 6-38
6.6.1 Speed Limit....................................................................................................................... 6-38
6.6.2 Torque Limit...................................................................................................................... 6-38
6.6.3 Regenerative Resistor ...................................................................................................... 6-39
6.6.4 Analog Monitor.................................................................................................................. 6-44
6.6.5 Electromagnetic Brake ..................................................................................................... 6-47
Chapter 7 Parameters............................................................................................................7-1
7.1 Definition ................................................................................................................................. 7-1
7.2 Parameter Summary ............................................................................................................... 7-2
7.2.1 Parameters List by Group................................................................................................. 7-2
7.2.2 Parameters List by Function............................................................................................. 7-9
7.3 Detailed Parameter Listings.................................................................................................... 7-20
Chapter 8 MODBUS Communications................................................................................... 8-1
8.1 Communication Hardware Interface ....................................................................................... 8-1
8.2 Communication Parameter Settings ....................................................................................... 8-5
8.3 MODBUS Communication Protocol ........................................................................................ 8-9
8.4 Communication Parameter Write-in and Read-out................................................................. 8-17
Chapter 9 Maintenance and Inspection ................................................................................. 9-1
9.1 Basic Inspection ...................................................................................................................... 9-1
9.2 Maintenance............................................................................................................................ 9-2
9.3 Life of Replacement Components........................................................................................... 9-2
Chapter 10 Troubleshooting..................................................................................................... 10-1
10.1 Fault Messages Table............................................................................................................. 10-1
10.2 Potential Cause and Corrective Actions ................................................................................. 10-3
10.3 Clearing Faults ........................................................................................................................ 10-9
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Table of Contents|ASDA-A&A+ Series
Revision April 2009
Chapter 11 Specifications ........................................................................................................ 11-1
11.1 Specifications of Servo Drive (ASDA-A Series) ...................................................................... 11-1
11.2 Specifications of Servo Drive (ASDA-A+ Series).................................................................... 11-4
11.3 Low Inertia Servo Motor Specifications (ASMTL Series) ................................................. 11-6
11.4 Medium Inertia Servo Motor Specifications (ASMTM Series) .......................................... 11-8
11.5 Medium and Medium / High Inertia Servo Motor Specifications (ECMA Series).................... 11-10
11.6 Servo Motor Speed-Torque Curves (T-N Curves) .................................................................. 11-11
11.7 Overload Characteristics......................................................................................................... 11-13
11.8 Dimensions of Servo Drive...................................................................................................... 11-15
11.9 Dimensions of Low Inertia Servo Motor (ASMTL Series)................................................. 11-21
11.10 Dimensions of Medium Inertia Servo Motor (ASMTM Series) ......................................... 11-23
11.11 Dimensions of Medium / High Inertia Servo Motor (ECMA Series) ........................................ 11-24
Chapter 12 Application Examples ............................................................................................ 12-1
12.1 Position Control (including homing function)........................................................................... 12-1
12.2 Roller Feeding......................................................................................................................... 12-3
12.3 Connecting to Delta DVP-EH Series PLC............................................................................... 12-4
12.4 Connecting to Delta TP04 Series............................................................................................ 12-9
12.5 Position Control Mode (Pr Mode)............................................................................................ 12-11
12.6 Feed Step Control ................................................................................................................... 12-14
12.7 Internal Auto Running Mode ................................................................................................... 12-25
12.8 Homing Function ..................................................................................................................... 12-30
12.9 External Controller Connection Examples .............................................................................. 12-37
Appendix A Accessories ........................................................................................................... A-1
Appendix B Molded-case Circuit Breaker, Fuse Current and EMI Filters ......................................... B-1
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Table of Contents|ASDA-A&A+ Series
Revision April 2009
About this Manual…
User Information
Be sure to store this manual in a safe place.
Due to constantly growing product range, technical improvement and alteration or changed texts, figures and
diagrams, we reserve the right of this manual contained information change without prior notice.
Coping or reproducing any part of this manual, without written consent of Delta Electronics Inc. is prohibited.
Technical Support and Service
Welcome to contact us or visit our web site (http://www.delta.com.tw/industrialautomation/) if you need any
technical support, service and information, or, if you have any question in using the product. We are looking
forward to serve you needs and willing to offer our best support and service to you. Reach us by the
following ways.
ASIA
DELTA ELECTRONICS, INC.
Taoyuan Plant 1
31-1, XINGBANG ROAD,
GUISHAN INDUSTRIAL ZONE,
TAOYUAN COUNTY 33370, TAIWAN, R.O.C.
TEL: [phone]
FAX: [phone]
NORTH/SOUTH AMERICA
DELTA PRODUCTS CORPORATION (USA)
Raleigh Office
P.O. BOX 12173
5101 DAVIS DRIVE,
RESEARCH TRIANGLE PARK, NC 27709, U.S.A.
TEL: [phone]
FAX: [phone]
JAPAN
DELTA ELECTRONICS (JAPAN), INC.
Tokyo Office
DELTA SHIBADAIMON BUILDING
2-1-14 SHIBADAIMON, MINATO-KU,
TOKYO, 105-0012, JAPAN
TEL: [phone]
FAX: [phone]
EUROPE
DELTRONICS (THE NETHERLANDS) B.V.
Eindhoven Office
DE WITBOGT 15, 5652 AG EINDHOVEN,
THE NETHERLANDS
TEL: [phone]
FAX: [phone]
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Revision April 2009
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Revision April 2009 1-1
Chapter 1 Unpacking Check and Model Explanation
1.1 Unpacking Check
After receiving the AC servo drive, please check for the following:
Ensure that the product is what you have ordered.
Verify the part number indicated on the nameplate corresponds with the part number of your order
(Please refer to Section 1.2 for details about the model explanation).
Ensure that the servo motor shaft rotates freely.
Rotate the motor shaft by hand; a smooth rotation will indicate a good motor. However, a servo motor
with an electromagnetic brake can not be rotated manually.
Check for damage.
Inspect the unit to insure it was not damaged during shipment.
Check for loose screws.
Ensure that all necessary screws are tight and secure.
If any items are damaged or incorrect, please inform the distributor whom you purchased the product from or
your local Delta sales representative.
A complete and workable AC servo system should be including the following parts:
Part I : Delta standard supplied parts
(1) Servo drive
(2) Servo motor
(3) 5 PIN Terminal Block (for L1, L2, R, S, T) (available for 100W ~ 1.5kW models)
(4) 3 PIN Terminal Block (for U, V, W) (available for 100W ~ 1.5kW models)
(5) 3 PIN Terminal Block (for P, D, C) (available for 100W ~ 1.5kW models)
(6) One operating lever (for wire to terminal block insertion; available for 100W ~ 1.5kW models)
(7) One jumper bar (for short the circuit of the terminal pins; available for 2kW ~ 4.5kW models)
(8) Quick Start
Part II : Optional parts, not Delta standard supplied part (Refer to Appendix A)
(1) One power cable, which is used to connect servo motor and U, V, W terminals of servo drive. This
power cable is with one green grounding cable. Please connect the green grounding cable to the
ground terminal of the servo drive.
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Chapter 1 Unpacking Check and Model Explanation|ASDA-A&A+ Series
1-2 Revision April 2009
(2) One encoder cable, which is used to connect the encoder of servo motor and CN2 terminal of servo
drive.
(3) CN1 Connector: 50 PIN Connector (3M type analog product)
(4) CN2 Connector: 20 PIN Connector (3M type analog product)
(5) CN3 Connector: 6 PIN Connector (IEEE1394 analog product)
1.2 Model Explanation
1.2.1 Nameplate Information
ASDA-A Series Servo Drive
Nameplate Explanation
Serial Number Explanation
ASMT Series Servo Motor
Nameplate Explanation
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Chapter 1 Unpacking Check and Model Explanation|ASDA-A&A+ Series
Revision April 2009 1-3
Serial Number Explanation
ASDA-A+ Series Servo Drive
Nameplate Explanation
Serial Number Explanation
ECMA Series Servo Motor
Nameplate Explanation
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Chapter 1 Unpacking Check and Model Explanation|ASDA-A&A+ Series
1-4 Revision April 2009
Serial Number Explanation
1.2.2 Model Name Explanation
ASDA-A Series Servo Drive
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Chapter 1 Unpacking Check and Model Explanation|ASDA-A&A+ Series
Revision April 2009 1-5
ASMT Series Servo Motor
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Chapter 1 Unpacking Check and Model Explanation|ASDA-A&A+ Series
1-6 Revision April 2009
ASDA-A+ Series Servo Drive
ECMA Series Servo Motor
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Chapter 1 Unpacking Check and Model Explanation|ASDA-A&A+ Series
Revision April 2009 1-7
1.3 Servo Drive and Servo Motor Combinations
The table below shows the possible combination of Delta ASDA-A and ASDA-A+ series servo drives and
ASMT and ECMA series servo motors. The boxes () in the model names are for optional configurations.
(Please refer to Section 1.2 for model explanation)
ASDA-A Series Servo Drive
Servo drive Servo motor
100W ASD-A0121LASMT01L250
200W ASD-A0221LASMT02L250
400W ASD-A0421LASMT04L250
750W ASD-A0721LASMT07L250
1000W ASD-A1021L
ASMT10L250
2000W ASD-A2023LASMT20L250
Low
inertia
3000W ASD-A3023L
ASMT30L250
1000W ASD-A1021MASMT10M250
1500W ASD-A1521M
ASMT15M250
2000W ASD-A2023MASMT20M250
Medium
inertia
3000W ASD-A3023M
ASMT30M250
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deltaacdrives.com
[email protected]
Call 1(800)985-6929 for Sales
deltaacdrives.com
[email protected]