power automation PA 9000 User manual

PA 9000
ETC Drives Midi / Maxi
Installaon instrucons

Version: PRO
Original installation instructions
© 2017 Power Automation GmbH
Power Automation GmbH
CNC-Automatisierungstechnik
Gottlieb-Daimler-Str. 17/2
74385 Pleidelsheim
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.powerautomation.com
Version 3.0
2 21.02.2017

Table of contents
1 General information................................................................... 9
1.1 Information on this manual................................................ 9
1.2 Explanation of symbols...................................................... 9
1.3 Limitation of liability.......................................................... 10
1.4 Copyright......................................................................... 10
1.5 Warranty terms................................................................. 11
1.6 Customer service............................................................. 11
1.7 Glossary........................................................................... 12
2 Safety........................................................................................ 15
2.1 Customer's responsibility................................................. 15
2.2 Personnel requirements................................................... 16
2.2.1 Qualifications................................................................. 16
2.2.2 Unauthorized persons................................................... 16
2.3 Intended use.................................................................... 17
2.4 Unintended use................................................................ 18
2.5 Safety instructions........................................................... 18
2.6 Personal protective gear.................................................. 21
2.7 Conduct in a dangerous situation and in case of acci-
dents................................................................................ 21
2.8 Environmental protection................................................. 22
2.9 Labels.............................................................................. 22
3 PA ETC-Drives MI / MA Overview........................................... 25
4 Technical Data.......................................................................... 31
4.1 General Specifcation....................................................... 31
4.1.1 PA ETC-Drive MI1015 / MI103...................................... 31
4.1.2 PA ETC-Drive MI1045 / MI106...................................... 35
4.1.3 PA ETC-Drive MI108 / MI110 / MI113........................... 39
4.1.4 PA ETC-Drive MI120 / MI124........................................ 43
4.1.5 PA ETC-Drive MA103 / MA106 / MA112....................... 47
4.1.6 PA ETC-Drive MA124 / MA130..................................... 52
4.2 Control Specifications...................................................... 56
4.3 Protective Functions and Environmental Specifications.. 58
4.4 Communication Specifications......................................... 59
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4.5 I/O Specifications............................................................. 60
4.6 Motor Feedback Specifications........................................ 62
4.7 Conformance with European directives and UL-stand-
ards.................................................................................. 62
4.8 Installation guidelines...................................................... 65
5 Installation................................................................................ 67
5.1 PA ETC-Drive MI 1015 / MI 103...................................... 67
5.2 PA ETC-Drive MI 1045 / MI 106...................................... 69
5.3 PA ETC-Drive MI 108 / MI 110 / MI 113........................... 71
5.4 PA ETC-Drive MI 120 / MI 124........................................ 73
5.5 PA ETC-Drive MA 103 / MA 106...................................... 75
5.6 PA ETC-Drive MA 112..................................................... 77
5.7 PA ETC-Drive MA 124 / MA 130...................................... 79
5.8 Controller Interface Wiring............................................... 81
5.9 Interface........................................................................... 82
5.9.1 Control board connections............................................ 82
5.9.2 Power Board Connections - 120/240 V AC................. 104
5.9.3 Power Board Connections - 400/480 V AC................. 116
5.9.4 Regeneration............................................................... 126
5.9.4.1 Regenerative Energy Overview................................ 126
5.9.4.2 Regeneration Resistence Calculations..................... 126
5.9.4.3 Regeneration Resistor Protection............................. 136
6 Drive Setup............................................................................. 141
6.1 Overview........................................................................ 141
6.2 Preparation.................................................................... 142
6.3 EMI Suppression........................................................... 144
6.4 Electrical System Considerations.................................. 150
6.5 Mechanical Installation.................................................. 151
6.6 Firmware Upgrade......................................................... 152
6.7 Power Up....................................................................... 155
7 Application Setup.................................................................. 157
7.1 Parameters.................................................................... 157
7.2 Configuration Sequence................................................ 159
7.3 Communication.............................................................. 161
7.4 Power Rating................................................................. 164
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7.5 Feedback....................................................................... 165
7.6 Sine Encoder Calibration............................................... 170
7.7 Motion Units................................................................... 175
7.8 Current Foldback........................................................... 176
7.9 Digital Inputs.................................................................. 177
7.10 Digital Outputs............................................................... 177
7.11 Analog Inputs................................................................. 178
7.12 Homing.......................................................................... 183
7.13 Disable Mode................................................................. 185
7.14 Motor Brake Control via Relay....................................... 192
7.15 Motor Temperature Sensor............................................ 194
8 Motor Setup............................................................................ 195
8.1 Motor Setup Wizard....................................................... 195
8.2 Drive Identification......................................................... 201
8.3 Motor Identification........................................................ 201
8.4 Motor Initialization.......................................................... 202
8.5 Current Limits................................................................ 203
8.6 Velocity Limits................................................................ 204
8.7 Position Limits................................................................ 205
8.8 Motor Direction.............................................................. 206
8.9 New Motor Wizard......................................................... 207
9 Operation................................................................................ 213
9.1 Drive Enable.................................................................. 213
9.2 Operation Modes........................................................... 214
9.3 Current Operation.......................................................... 215
9.4 Velocity Operation.......................................................... 216
9.5 Position Operation......................................................... 222
10 Tuning..................................................................................... 227
10.1 MI/MA HD Controller...................................................... 227
10.2 MI/MA HD Controller Autotuning................................... 228
10.3 PC-Based Autotuning.................................................... 229
10.4 Drive-Based Autotuning................................................. 233
10.4.1 Drive-Based Autotuning - Overview............................ 234
10.4.2 Drive-Based Autotuning - Express.............................. 235
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10.4.3 Drive-Based Autotuning - Advanced........................... 236
10.5 Autotuning Parameters Summary.................................. 243
10.6 Recording and Evaluating Performance........................ 245
10.6.1 Diagnostics.................................................................. 245
10.6.2 Recording Data in PA ETC Drive Studio..................... 247
10.6.3 Recording Data in Terminal......................................... 249
10.6.4 Evaluating PTPVCMD................................................. 251
10.6.5 Evaluating ICMD and/or PE Oscillations..................... 252
10.7 Low Pass Filter on Current Command........................... 253
10.8 Gearing Filters............................................................... 255
10.9 Move Smoothing Filter................................................... 257
10.1
0
Notch Filters................................................................... 258
10.1
1
Anti-Vibration Filters...................................................... 259
10.1
2
Gains - Manual Tuning.................................................. 266
10.1
3
Flexibility Compensation Tuning.................................... 271
10.1
4
Tuning Issues - Q&A...................................................... 272
11 Transport, packaging, storage and disposal....................... 273
11.1 Transport....................................................................... 273
11.2 Packaging...................................................................... 274
11.3 Storage.......................................................................... 274
11.4 Disposal......................................................................... 275
12 Maintenance........................................................................... 277
12.1 Safety notes................................................................... 277
12.2 Maintenance schedule................................................... 277
12.3 Measures after maintenance......................................... 279
13 Dismounting and decommissioning.................................... 281
14 Service and return process................................................... 283
14.1 Service........................................................................... 283
14.1.1 Service addresses....................................................... 284
14.2 Spare parts.................................................................... 285
14.3 Return policy and procedure.......................................... 286
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14.4 Training.......................................................................... 288
15 Declaration of Conformity..................................................... 289
16 Proof of change...................................................................... 291
17 Index........................................................................................ 293
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1 General information
1.1 Information on this manual
The manual describes the EtherCATâ drives of the PA ETC-Drive
Midi / Maxi (MI/MA) series.
1.2 Explanation of symbols
Warnings are identified by pictures. These warnings are introduced by
signal words, which express the severity of a danger.
Pay attention to these warnings and act cautiously in order to avoid
accidents, personal injuries and damage to property.
… indicates an imminently hazardous situation which, if unavoid-
able, will result in death or serious injury.
… indicates a potentially hazardous situation which, if unavoid-
able, could result in death or serious injury.
… indicates a potentially hazardous situation which, if unavoid-
able, may result in minor or moderate injury.
… indicates a potentially hazardous situation which, if unavoid-
able, may result in property damage.
… emphasizes useful hints and recommendations as well as informa-
tion for efficient and trouble-free operation.
The following symbols are used in connection with the safety notes to
highlight particular dangers:
… highlights hazards caused by electric current. There is a
danger of serious injury or death if the safety notes are not com-
plied with.
The following symbols and highlights are used to distinguish
instructions, descriptions of results, cross-references and other ele-
ments inside this manual.
.. Highlights a step as part of a procedure of instructions.
ð.. Highlights a state or an automatic process as a result of an
instruction.
n.. Highlights single or unordered instructions and lists.
Ä “Additional symbols and highlighting” on page 9.. Highlights cross-
references to chapters or sections of this manual.
Content
Warnings
L DANGER
L WARNING
L CAUTION
NOTICE
Special Safety Notes
L DANGER
Additional symbols and high-
lighting
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[Key].. Highlights captions of buttons, fields and other elements of the
software's graphical user interface.
“Menu è Submenu è ”.. Highlights a path to access a menu or sub-
menu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts from
configuration files.
1.3 Limitation of liability
All information and notes in this installation manual were compiled
under due consideration of valid standards and regulations, the
present status of technology and our years of knowledge and experi-
ence.
Power Automation can not be held liable for damage resulting from:
ndisregarding this installation manual
nunintended use
nemployment of untrained personnel
nunauthorized conversions
nunauthorized modifications to the software
ntechnical modifications
nuse of unapproved spare parts
nuse in conjunction with machines not deemed compatible by
Power Automation
In case of customized versions the actual scope of delivery can vary
from the explanations and representations in this installation manual,
because of the utilization of additional options or due to the latest tech-
nical changes.
Apart from this, the obligations agreed upon in the delivery contract,
the general terms and conditions, and the delivery conditions of Power
Automation and the legal regulations valid at the time of contract apply.
We reserve the right to make technical modifications in order to
improve usability.
1.4 Copyright
This installation manual is protected by copyright law.
Passing this installation manual on to third parties, duplication of any
kind – even in form of excerpts – as well as the use and/or disclosure
of the contents without the written consent of Power Automation is not
permitted.
Violations oblige to compensation. The right for further claims remains
reserved.
Liability
Copyright
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1.5 Warranty terms
The material warranty terms are provided in Power Automation's terms
and conditions as well as inside the sales documents.
1.6 Customer service
Our Customer Service is always available for technical information.
For information on whom to contact by phone, fax, e-mail or via the
internet, see Power Automation's address on page 2.
Additionally, Power Automation staff is always interested in receiving
new information and experiences resulting from the use of our prod-
ucts, which could be of great value for future improvements.
Material Warranty
Service
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1.7 Glossary
AWG - American wire gauge
BGND - Ground of 24V-supply and holding brake supply voltage
CDM - Complete Drive Module
CE - Communité Europeenne
CLOCK - Clock signal
CMOS - Complementary metal-oxide-semiconductor
CNC - Computerized Numerical Control
CSA - Canadian Standards Association
DDU - Delivered Duty Unpaid
DIN - DIN standard
EEC - European Economic Community
EMC - Electromagnetic compatibility
EMI - EMI-Filter, (electromagnetic interference)
EN - European standard (Euro Norm)
EU - European Parliament and Council of the European Union
HMI - Human Machine Interface
The graphical user interface provided by the PA software.
IEC - International Electrotechnical Commission
IGBT - Insulated Gate Bipolar Transistor
IPC - Insulating Piercing Connector
LED - Light-emitting diode
MDI - Manual Data Input
MTBP - Machine Tool Builder's Panel
Panel including the basic requirements for a machine tool
operator: emergency stop push button, cycle start and stop
push buttons, jog plus and minus push buttons, feed rate
and spindle speed override pots and a number of auxiliary
push buttons.
MTC - Motor thermal contact
NC-Start - Numerical Control Start Button
NC-Stop - Numerical Control Stop Button
PA - Power Automation
PAMIO - Power Automation Modular Input Output
Extendable Superbus based interface allowing connection
of additional I/O modules.
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PC - Personal Computer
PCI - Peripheral Component Interconnect
Personal computer extension for periphery devices con-
nected to the motherboard.
PELV - Protected extra low voltage
PLC - Programmable Logic Controller
POU - Program Organization Unit. PLC functions, function blocks
and programs are POUs
RCD - Residual-current-operated protective device
RMS - Rotating Measuring Systems (Encoder)
RES - Resolver
RMS - Root mean square
Rint. - Connection internal regen resistor
Rtr - Connection regen chopper
SELV - Safety extra low voltage
SVM - Space vector modulation
UL - Underwriters Laboratory
VAC - AC voltage
VDC - DC voltage
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2 Safety
2.1 Customer's responsibility
The control unit is used for commercial purposes. The operating com-
pany is thus subject to the legal obligations concerning industrial
safety.
The safety, accident prevention and environmental protection regula-
tions applicable for the area of application of the machine must be
complied with, along with the safety notes specified in this installation
manual. The following applies in particular:
nThe customer must become familiar with the industrial safety regu-
lations and identify additional dangers which may arise due to the
specific working conditions at the place of use of the control unit,
by means of a risk analysis. These must be converted into oper-
ating instructions for operation of the control unit.
nThroughout the time of use of the control unit the customer must
check whether the operating instructions created by him corre-
spond to the current status of regulations and standards. When-
ever changes in regulations and standards occur, instructions must
be adapted accordingly.
nThe customer must clearly specify the responsibilities for
installation, operation, maintenance, and cleaning.
nThe customer must make sure that all employees who have to
work with the control unit have read and understood these oper-
ating instructions.
In addition, the customer must train and inform his personnel about
potential dangers at regular intervals.
Moreover, the customer is also responsible for keeping the control unit
in technically good condition, and therefore the following applies:
nThe customer must make sure that the maintenance intervals
specified in these operating instructions are complied with.
nThe customer must regularly check all safety features for function
and completeness.
nThe customer must supply his personnel with the necessary pro-
tective equipment.
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2.2 Personnel requirements
2.2.1 Qualifications
Danger of injury in case of insufficient qualification!
– Only those persons who have been specified in the corre-
sponding chapters of this installation manual should be
entrusted with the listed types of work.
– Employ certified experts, if in doubt.
Improper operation can lead to severe personal injuries and/or
material damage.
The following qualifications are specified for different areas of activity
listed in the installation manual.
Instructed person
was instructed by the operating company about the duties assigned to
her/him and the possible dangers that may arise from inappropriate
conduct.
Qualified personnel
are able to carry out assigned work and to recognize possible dangers
due to professional training, knowledge, and experience as well as
profound knowledge of applicable regulations.
2.2.2 Unauthorized persons
Danger for unauthorized persons!
– Keep unauthorized persons away from the working area.
– If in doubt, address such persons and ask them to leave the
working area.
– Interrupt your work as long as unauthorized persons are in
the working area.
Unauthorized persons, who do not meet the requirements
described in this installation manual, are not aware of the dan-
gers in the working area.
Only persons who are expected to perform their tasks reliably are per-
mitted as personnel. Persons whose reaction capability is impaired,
e.g. through drugs, alcohol or medication are not permitted.
nWhen selecting personnel, ensure that the personnel can work
with the control unit in terms of technical and content aspects.
L WARNING
L WARNING
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2.3 Intended use
The ETC drives are exclusively intended and built for the use
described in this installation manual.
The ETC drives of Power Automation are developed and produced
according to the current state of the technology.
They are components which are built in into electrical equipment and
can only be used as integrated component of such equipment.
Before the products are installed, the following requirements have to
be fulfilled to meet the intended use.
nEveryone who is working in any way with the products, has to read
and understand the safety instructions, the intended use and the
unintended use.
nThe ETC drive has to run under the mounting and installation con-
ditions, described in this installation manual. Especially the envi-
ronmental conditions (temperature, protection class, humidity,
mains input, EMC and the mounting position) have to be consid-
ered.
nThe ETC drive has to be assembled in a closed switchgear cab-
inet.
nThe ETC drive has to be used in original delivery condition (without
any mechanical or electrical modification).
nDo not mount or use mechanical or electrical damaged or faulty
servo drives.
nThe ETC drive is intended to control synchronous servo motors, in
closed loop control of torque, speed or position.
nThe ETC drive is developed for usage in industrial environment. If
it is used in residential areas, an additional filter must be installed
in the mains input line.
Beware of unintended use!
– Operate the ETC drive as intended only.
– Observe all instructions in this installation manual.
– Observe the permissible ambient conditions and electromag-
netic compatibility mentioned in the technical data.
Any use exceeding the scope of intended use and/or different
application of the ETC drives can result in hazardous situations.
Claims of any kind for damage resulting from unintended use are void.
The operator is solely responsible for all damage resulting from
unintended use.
Intended Use
Dangers
L WARNING
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2.4 Unintended use
Beware of unintended use!
– In particular, avoid using the ETC drive for the following pur-
poses as these are regarded as not intended:
– Operation by not instructed personnel
– It is not allowed to be used in electrical equipment on
ships (service afloat) or in offshore applications because
of the conductive pollution.
– It must be used in environmental conditions according to
the conditions described in this installation manual (not
too hot, with closed switchgear cabinet, correct mounting
position, etc.).
Be very carefully in plants, were conductive material (carbon fiber,
graphite with machining of graphite cast iron or similar) is easy purge
able on the factory floor.
In this case, the switchgear cabinet has to be sealed very carefully (no
forced ventilation with blower filter) or has to be placed outside the fac-
tory floor.
Especially at setup of the machine, the risk is high because of open
switchgear cabinet doors. ETC drives, which are contaminated in that
way, must not be used anymore.
2.5 Safety instructions
– After removing the power source from the equipment, wait at
least 5 minutes before touching or disconnecting sections of
the equipment that normally carry electrical charges (e.g.
capacitors, contacts, screwed connections). For safety,
measure the electrical contact points with a meter before
touching the equipment. Wait until the voltage drops below 30
V AC before handling components.
– Never remove the electrical connections to the EtherCATâ
amplifier while it is enabled. There is a danger of electric
arcing with damage to contacts and danger to persons.
– If a leakage current sensor is used in the mains supply of the
ETC drive, a leakage current sensor RCD type B has to be
used in any case. If a RCD type A or AC is used, there is a
risk, that the DC ground current of the ETC drive inhibits the
leakage current sensor.
– Failure to observe one of these instructions will lead to death,
serious injury or equipment damage.
Unintended use
L WARNING
Shock Current
L DANGER
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Hot Surface
– During operation, the product has electrically charged compo-
nents and hot surfaces. The heat sink can reach temperatures
of 90°C. Control and power cables can carry a high voltage,
even when the motor is not rotating.
– Failure to observe this precaution can result in severe injury.
L DANGER
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General
– Read all available product documentation before assembling
and commissioning. Incorrect handling of this product may
cause personal injury and/or damage to equipment. Adhere
strictly to the installation instructions and requirements.
– All system components must be connected to ground. Elec-
trical safety is provided through a low-resistance earth ground
connection (Protective Class 1 according standard EN/IEC
618005-1).
Motor should be connected to protective earth by independent
earthing conductor rated not less than the motor phase wire.
This product contains static sensitive components that can be
damaged by incorrect handling. Avoid contact with high insu-
lating materials (artificial fabrics, plastic film, etc.). Place the
product on a conductive surface. Ground yourself (discharge
any possible static electricity build-up) by touching an
unpainted, metal, grounded surface.
– Keep all covers and cabinet doors shut during operation. Oth-
erwise, potential hazards may cause personal injury and/or
damage to equipment.
– To avoid electric arcing and hazards to personnel and electric
contacts, never disconnect or connect the product while the
power source is energized.
– Provide a power mains disconnect device in according with
local regulations.
– Before testing and setting up, the manufacturer of the
machine must generate a hazard analysis for the machine,
and take appropriate measures to ensure that unforeseen
movements cannot cause injury or damage to any person or
property.
– Since the drive meets IP20 according to IEC 60529, and type 1
according to UL 50, the end user must select an enclosure
that permits safe operation of the drive. The enclosure must
meet at least IP54 according to IEC 60529, and at least type 2
according to UL 50, and be made of metal or material with
rating flammability of 5 VA, and not have any openings in the
bottom.
– Since the leakage current to PE is greater than 3.5 mA, com-
pliance with IEC61800-5-1 and UL 508C requires either dou-
bling of the PE connection (by one grounding connection
through the mains power cable earthing wire, and another
connection through the heat sink connection to the grounded
machine base), or the use of a copper connecting cable with a
cross-section greater than 10 mm2. Use the drive mount
screws and the PE connection screws to meet this require-
ment.
– Wiring of green color with or without one or more yellow
stripes must not be used except for protective bonding.
– Power cables should be rated at least 600 V, 75°C.
– The STO input is functional in all PA ETC-Drive MI/MA models
but not yet independently certified in certain models.
L CAUTION
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