Sanyo denki Pe series User manual

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Sanyo Denki

PE Servo System

Installation and Operation Manual

Sales & Technical Support

8:30 a.m. to 5:30 p.m. EST

Toll Free: 1.888.531.8213

Atlanta Area: 770.497.8086

Fax: 770.497.8666

Support@MotionOnline.com

Automation Intelligence

Motion Products

™

System Integratio

2855 Premiere Parkway, Suite A

Duluth, Georgia 30097-4902

Issued: 27-Apr-00

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Table of Contents

INTRODUCTION.............................................................................................................5

About this Guide....................................................................................................................................................... 5

Safety ........................................................................................................................................................................ 7

Technical Support..................................................................................................................................................... 9

Product Family Overview ....................................................................................................................................... 10

INSTALLATION ............................................................................................................12

Chapter Overview ................................................................................................................................................... 12

Unpacking and Inspection Procedure...................................................................................................................... 13

Inspection Test........................................................................................................................................................ 14

Amplifier Installation.............................................................................................................................................. 17

Motor Installation....................................................................................................................................................22

Installation Check List ............................................................................................................................................30

WIRING.........................................................................................................................31

Chapter Overview ................................................................................................................................................... 31

Wiring Precautions.................................................................................................................................................. 33

Applicable Wire Sizes.............................................................................................................................................34

Input Power.............................................................................................................................................................35

Leakage Current...................................................................................................................................................... 35

Connection Diagram with P2 Motor .......................................................................................................................36

Connection Diagram with P3 Motor .......................................................................................................................37

TB Connector..........................................................................................................................................................38

Input/Output Internal Circuits.................................................................................................................................39

CN1 Control Connector .......................................................................................................................................... 41

CN2 Motor Encoder Connector .............................................................................................................................. 45

Operator Terminal................................................................................................................................................... 46

External Regeneration Resistors ............................................................................................................................. 47

Wiring Check List................................................................................................................................................... 53

SYSTEM CONFIGURATION.........................................................................................54

Chapter Overview ................................................................................................................................................... 54

Using the Remote Operator.....................................................................................................................................55

Quick Setup............................................................................................................................................................. 57

Amplifier Parameters .............................................................................................................................................. 59

Amplifier Tuning.....................................................................................................................................................83

Jogging.................................................................................................................................................................... 86

Monitor Screen........................................................................................................................................................88

Alarm Trace Screen.................................................................................................................................................89

OPERATION .................................................................................................................91

Chapter Overview ................................................................................................................................................... 91

Pre-Operation..........................................................................................................................................................92

Power On Sequence ................................................................................................................................................93

Stop Sequences .......................................................................................................................................................94

Servo OFF Sequence...............................................................................................................................................96

Alarm Reset Sequence ............................................................................................................................................98

Overtravel Sequence ............................................................................................................................................... 99

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MAINTENANCE AND TROUBLESHOOTING ............................................................100

Chapter Overview .................................................................................................................................................100

Maintenance.......................................................................................................................................................... 101

Troubleshooting.................................................................................................................................................... 101

SPECIFICATIONS ......................................................................................................111

Chapter Overview .................................................................................................................................................111

Acceleration and Deceleration Time.....................................................................................................................112

Dynamic Brake...................................................................................................................................................... 113

Miscellaneous Servo Motor Specifications...........................................................................................................114

INDEX .........................................................................................................................115

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List of Tables

Table 1: Manual Syntax................................................................................................................................................6

Table 2: Valid Drive Systems.....................................................................................................................................11

Table 3: Amplifier Environmental Requirements .......................................................................................................20

Table 4: Power Dissipation.........................................................................................................................................20

Table 5: Motor Environmental Requirements............................................................................................................. 22

Table 6: Motor IP Rating............................................................................................................................................ 25

Table 7: Allowable Radial and Thrust Loads.............................................................................................................. 29

Table 8: Applicable Wire Sizes .................................................................................................................................. 34

Table 9: Power Supply Capacity Requirement............................................................................................................35

Table 10: System Leakage Current .............................................................................................................................35

Table 11: TB Connector Pin Assignments.................................................................................................................. 38

Table 12: CN1 Internal Circuits..................................................................................................................................39

Table 13: CN1 Pin Assignments.................................................................................................................................41

Table 14: CN2 Pin Assignments.................................................................................................................................45

Table 15: Amplifier Regeneration Power.................................................................................................................... 47

Table 16: Regeneration Resistor Selection .................................................................................................................50

Table 17: Quick Setup Steps....................................................................................................................................... 58

Table 18: Monitor Mode Page Descriptions...............................................................................................................88

Table 19: Alarm Mode Page Descriptions..................................................................................................................89

Table 20: Amplifier Alarm Codes...............................................................................................................................90

Table 21: Amplifier Status Display............................................................................................................................. 92

Table 22: Holding Brake Specifications ................................................................................................................... 114

••‘’••‘’

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Introduction

About this Guide

This chapter covers the following topics:

About this Guide ............................................................................................................5

In this Chapter 5

Introduction 5

Manual Organization 5

Syntax Information 6

Safety.............................................................................................................................. 7

Technical Support ..........................................................................................................9

Online Support 9

E-Mail Support 9

Telephone Support 9

Field Service 9

Product Family Overview.............................................................................................10

Amplifiers 10

Motors 10

Systems 11

Remote Operator 11

Cables 11

External Regen Resistors 11

This guide provides you with information needed to install, operate, and maintain PE

model servo amplifiers and matching motors.

This guide consists of the following chapters:

Chapter 1. Introduction provides an overview of the Safety issues associated with the

application of servo motors and amplifiers, informs you about all your

product support options, and finally provides an overview of the PE family

of amplifiers, the P2 and P3 family of motors, and system options and

accessories.

Chapter 2. Installation provides detailed directions that take you step by step from

unpacking your system, through installing the motor and installing the

amplifier, and concludes with an installation check list.

Chapter 3. Wiring describes how to wire a system. Starting first with a summary table

indicating recommended wire sizes, followed by connection diagrams, and

concluding with details for connecting external regeneration resistors and

the remote operator. Detailed connector pin assignments are provided as

well as a partial schematic for input and output signals.

In this Chapter

Introduction

Manual

Organization

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Chapter 4. System Configuration describes how to use the remote operator and then

walks you through the configuring and tuning of your system. This chapter

concludes with a detailed description of each amplifier parameter.

Chapter 5. Operation chapter provides a detailed description of the sequence and

timing of operation within the amplifier.

Chapter 6. Maintenance and Troubleshooting provides you with a recommended

maintenance program designed to keep your system in top operating

condition. Should you experience any difficulty with your system, a

detailed troubleshooting guide is provided to help you restore normal

operation quickly.

Chapter 7. Specification section includes detailed specifications for PE drive systems.

This includes a detailed reference for all the amplifier parameters.

To help you locate and interpret information easily, this guide uses consistent visual cues

and text formats. The different symbols and typefaces displayed in this guide are used for

the following purposes:

Table 1: Manual Syntax

‘This symbol is used to identify important information of which you should

take note.

üü DANGER, WARNING or CAUTION require accompanying information

notices to prevent potential personal injury and equipment damage.

DANGER: Indicates an imminently hazardous situation which, if not

avoided, will result in serious injury or death. This signal word is limited

to the most extreme situations.

WARNING: Indicates a potentially hazardous situation which, if not

avoided, could result in serious injury or death.

CAUTION: Indicates a potentially hazardous situation which, if not

avoided, may result in equipment damage or minor or moderate injury.

Earth Gnd Protective conductor terminal, Earth Ground.

Chassis Gnd Chassis terminal, Not a protective ground.

Syntax

Information

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Safety

DANGER

üü Only qualified personnel familiar with the construction and operation of this

equipment and the hazards involved should install, adjust, operate, or service

this equipment. Read and understand this manual and other applicable manuals

in their entirety before proceeding. Failure to observe this could result in severe

injury or loss of life.

DANGER

üü The user is responsible for conforming with all applicable local, national, and

international codes. The wiring examples in this manual are intended only as a

guide. Wiring practices, grounding and disconnects, and over-current protection

are of particular importance. Failure to observe this could result in severe injury

or loss of life.

DANGER

üü Do not operate the system in an explosive atmosphere. Failure to observe this

could result in severe injury or loss of life and equipment damage.

WARNING

üü Perform the initial power-up with the motor shaft disconnected from the load and

the shaft key removed. Improper wiring or undiscovered shipping damage could

result in undesired motion. Be prepared to remove power if excessive motion

occurs. Failure to observe this precaution could result in bodily injury.

WARNING

üü Large leakage currents exist in AC line filters. They must be grounded properly

before applying power. Filter capacitors retain high voltages after power is

removed. Before handling the equipment, voltage should be measured to

determine safe levels. Failure to observe this precaution could result in severe

bodily injury.

WARNING

üü Avoid damaged cables. Cables may be damaged by applying excessive stress,

placing a heavy object on them, or cutting them. Damaged cables may result in

electrical shock which can cause severe bodily injury and damage equipment.

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CAUTION

üü Observe all installation directions. Failure to do so may result in injury, damage

to equipment, or poor performance.

1. Make sure nothing obstructs or impedes ventilation around the amplifier.

2. Observe all mounting clearance distances around the unit.

3. Never install the system in a location where water, or other fluids, may be

splashed, or in a flammable gas atmosphere.

4. Never place objects on this equipment. Doing so may result in damage,

burns or fire.

5. Avoid strong shocks to equipment. This may result in injury or damage to

equipment.

WARNING

üü During normal operation, the amplifier, motor and peripheral equipment could

become hot enough to cause a burn.

Technical Support

The most convenient and effective method for support is online at our web site

www.MotionOnline.com

In addition to this manual, you may download our Handbook of AC Servo Systems,

application notes and answers to frequently asked questions from this site.

Questions can be submitted via e-mail and in most cases our Technical Support staff will

reply the same day, but in all cases you will receive a reply before the end of the next

working day. Send your email questions to:

support@MotionOnline.com

Automation Intelligence maintains a Technical Support center that is staffed weekdays

(except holidays) between 8:30 AM and 5:30 PM Eastern Standard Time.

xTelephone: 770-497-8086

xFacsimile: 770-497-8666

Field service is not included in the product warrantee in order to keep our product cost

low, but it is a service that Automation Intelligence provides. Request for field service

may be made to the Technical Support staff (see above). Automation Intelligence must

receive a Purchase Order before the Technical Support engineer departs.

Online Support

E-Mail Support

Telephone

Support

Field Service

Product Family Overview

Sanyo Denki designs and manufactures a wide range of servo and stepper drives. Seven

models from the PE and PV families are available to you from Automation Intelligence

via MotionOnline.com (this manual covers the PE family of drives).

xPE2A015 15A

xPE2A030 30A

xPE2A050 50A

xPE0A100 100A

xPE0A150 150A

xPV1A015 15A

xPV1A030 30A

Sanyo Denki designs and manufactures a wide range of servo and stepper motors.

Fourteen (7 without brakes and 7 with brakes) models from the P2 and P3 families are

available to you from Automation Intelligence via MotionOnline.com.

xP20B10150D 1.5kW 4.9Nm

xP20B10250D 2.5kW 8.8Nm

xP20B13300D 3.0kW 10.8Nm

xP20B13500D 5.0kW 18.1Nm

xP30B04010D 100W 0.35Nm

xP30B06040D 400W 1.37Nm

xP30B08075D 750W 2.55Nm

Amplifiers

Motors

From these motors and amplifiers, the following 10 systems can be assembled. All the

systems can operate up to 4,500 RPM, the power listed is continuous at 3,000 RPM, and

the torque listed is continuous at 0 RPM.

Table 2: Valid Drive Systems

PV Amplifiers PE AmplifiersMotor Model WNm

15A 30A 15A 30A 50A 100A 150A

P30B04010D 100 0.35 ~~

P30B06040D 400 1.37 ~~

P30B08075D 750 2.55 ~~

P20B10150D 1500 4.9 ~

P20B10250D 2500 8.8 ~

P20B13300D 3000 10.8 ~

P20B13500D 5000 18.1 ~

The remote operator is required to set/change all the parameters in the PE and PV

amplifiers. The remote operator is not required for operation and may therefore be shared

between all the drives in a system. The same remote operator is used for the PE and PV

amplifiers.

To lower life-cycle cost and improve reliability, Automation Intelligence requires

customers to use Sanyo Denki motor power and feedback cables. These cables may be

ordered in standard or custom lengths. Standard cables are usually available directly from

stock.

Optional external regeneration resistors are available to extend the continuous

regeneration power of the amplifier.

Systems

Remote Operator

Cables

External Regen

Resistors

Installation

Chapter Overview

This chapter contains a guide for the installation of the amplifier and matching motor,

from unpacking the equipment, performing an initial test, to mounting it in panels.

Chapter Overview.........................................................................................................12

Unpacking and Inspection Procedure...........................................................................13

Unpack the Amplifier 13

Inspection 13

Inspection Test.............................................................................................................14

Minimum Wiring 14

Set Key Parameters 15

Jog Operation 15

Amplifier Installation ................................................................................................... 17

General Requirement 17

Mounting and Clearance Requirements 18

Amplifier Environmental Requirements 20

Power Dissipation 20

Enclosure Size 21

Motor Installation......................................................................................................... 22

Environmental Requirements 22

Motor Mounting 23

Motor Orientation and Cable Routing 25

Connecting the Load to the Motor 26

Bearing Load Specifications 29

Installation Check List.................................................................................................. 30

Unpacking and Inspection Procedure

ƒBefore opening packages, verify that the model numbers of the box match your order.

If they do not, please contact Automation Intelligence, see page 9 Technical Support.

ƒAfter opening, verify that the model numbers on the product match the box. If they

do not, please contact Automation Intelligence, see page 9 Technical Support.

ƒAfter unpacking, verify that the servo amplifier and motor are free from any physical

damage that may have occurred during shipment. If you find damage, contact your

Buyer to make a claim with the shipper.

ƒPerform the Inspection Test to verify functionality of the system.

Unpack the

Amplifier

Inspection

Inspection Test

WARNING

üThe parameter settings at the start of this inspection test are assumed to be

factory default settings. If this is not the case, the inspection test may not be

successful even though there is nothing wrong with the servo amplifier or motor.

Also, at the conclusion of the test, some amplifier parameters may not be

returned to the initial state.

WARNING

üDamage during shipment could cause erratic motion or a run-away condition.

Therefore the motor should be securely held down during this test and no load

should be attached to the shaft.

During this Inspection Test you will use the Remote Operator to change parameters and

jog the motor. If you have any trouble, refer to the Maintenance and Troubleshooting

chapter on page 100. If you still have difficulty, refer to page 9 for details on the various

methods for contacting the Technical Support team.

1. Wire 230Vac to the rand tterminals of the servo amplifier terminal block.

2. Wire 230Vac to the R, S, and Tterminals of the servo amplifier terminal block and

earth ground to á

3. Connect the motor power cable to the U, V, Wand áterminals of the servo amplifier

using the supplied cable.

4. Connect the encoder to the servo amplifier CN2 connector using the supplied cable.

5. Connect the Remote Operator to the OP connector on the servo amplifier.

6. If the motor has a brake, apply the specified 24Vdc to release the brake.

Minimum Wiring

CN2

230 VAC

230 VAC r

Remote

Operator

Feedback

Cable

Holding Brake

Power Supply

Power

Cable

Servo Motor

Servo Amplifier

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Motor Type

1. Turn ON the control power, the 230Vac attached to the rand tterminals. The

power LED should turn ON and a dash should appear in the middle of the 7-segment

display.

xThe remote Operator Screen should display the [Push Mode Key] screen

and a beep should sound.

2. Enable System Parameter changes using the Remote Operator.

xPress [ON / Mode]and íto enter the parameter set mode.

xPress the \key until you have switched to page 13 where you can set the

Func3 parameters.

xPress the ìkey to change bit 7to a 1.

xPress the [WR] key to save the change.

3. Set the motor type.

xPress [ON / Mode] and ìto enter the parameter select mode.

xPress the \key until you have switched to page 9where you can set the

motor type parameters.

xPress the [and ]keys to change to the proper type.

xPress the [WR] key to save the change.

xCycle the control power supply OFF and back ON.

1. To simplify wiring for this Inspection Test, the overtravel limits will be set for

normally open limit switches.

xPress [ON / Mode] and íto enter the parameter set mode.

xPress the Zand \keys to switch to page 10 where you can set the user

interface functions.

xPress the [key twice and the ìkey once to change bit 5to a 1.

xPress the [WR] key.

2. Enable Test mode operation using the Remote Operator. Jogging and Auto-tuning

are in the test mode.

Set Key

Parameters

Jog Operation

xPress the \key three times to switch to page 13 where you can set the

Func3 parameters.

xPress the [key and the ìkey to change bit 6to a 1.

xPress the [WR] key. Bit 6will return to 0when the control power is turned

OFF.

3. Turn ON the bus power (R, S, and T), the 230Vac attached to the R, S, and T

terminals. The three horizontal bars in the 7-segment display should be ON.

4. Jog the motor.

xPress the [ON / MODE] key and the é.

xPress the ]then the ìkey and the [WR] key. This will set the jog speed

to 10 RPM.

xA rotating figure ;will appear on the 7-segment display.

xContinue pushing the [key. The remote operator will continuously beep

and the motor will rotate counterclockwise (CCW) at 10RPM when viewed

looking at the motor shaft.

xRelease the [key, and press the ]key. Again the remote operator will

continuously beep and the motor will rotate clockwise (CW) at 10RPM.

5. Exit Jogging.

xPush the 0key and then the [ON/Mode] key to exit the test mode.

xA “d” will flash in the 7-segment display.

6. Re-enable the overtravel limits.

xPress [ON / Mode] and íto enter the parameter set mode.

xPress the Zand \keys to switch to page 10 where you can set the user

interface functions.

xPress the [key twice and the íkey once to change bit 5to a 0.

xPress the [WR] key.

7. Turn OFF the 230Vac bus power (R, S, and, T)

8. Turn OFF the 230Vac control power (r, t)

9. If the motor has a brake, turn OFF the brake power, activating the brake.

This completes the Inspection Test. If you have any trouble please call Technical

Support, see page 9.

Amplifier Installation

Condition Recommended Precautions

Amplifier In An

Enclosure The temperature inside an enclosure may be higher than the

outside temperature, depending on the power loss of internal

equipment and the dimensions of the box.

Be sure to determine the dimensions of the box, cooling method,

and panel layout so that the temperature around the amplifier will

be kept lower than 55C.

Amplifier Near A

Vibrating Source Install the amplifier with a shock absorber to dampen the vibration

that is transmitted directly to amplifier.

Amplifier Near A

Heat Source Shield the amplifier so that convection or radiation does not raise

the temperature near the amplifier above 55C.

Corrosive Gas

Environment If the amplifier is operated for a long time in a corrosive

environment then contact failure will occur at contact points (e.g.,

connectors). Therefore, never install the amplifier in a corrosive

gas environment.

Explosive Or

Combustible Gas

Environment

Never install the amplifier in an explosive gas or combustible gas

environment. Relays and contactors, which generate arcs (sparks)

inside boxes and hot parts such as regeneration brake resistor may

become ignition sources, causing a fire or explosion.

Dust And Oil

Environments Never install the amplifier in an environment containing dust or oil

mist. Dust and oil mist which adheres to or accumulates on the

amplifier will result in damage to the amplifier from lower

insulation resistance or leakage currents between conductors or

components.

Electrical Noise

Environments Induction noise will enter input signals and the power supply

circuit, causing the amplifier to malfunction. When installing the

amplifier in an electrically noisy environment, take proper

measures such as inserting a noise filter, shielding, or suppressing

the noise source.

General

Requirement

Install the amplifier vertically as shown in the figure below, with the indicated clearances.

Because the amplifier uses convection cooling it may not be mounted horizontally.

Provide the indicated space above, below and to the side of the amplifier for air flow. If

this space cannot be provided, install a fan to increase air flow around the amplifier.

Mounting and

Clearance

Requirements

50 mm or more

Back Surface

Mounting

4-M5

A B C D

PE2A015 225mm NA 25mm NA

PE2A030 225mm NA 25mm NA

PE2A050 225mm NA 75mm NA

50 mm or more

Back Surface

Mounting

4-M5

Cut-out

for

Cooling

Fins

Cooling

Air Flow

90 mm

or more

A B C D

PE0A100 225mm t197mm 75mm t117mm

PE0A150 225mm t197mm 75mm t142mm

Fins

50 mm or more

Front Surface

Mounting

4-M5

5 mm or more Front

Surface

Cut-out

A B C D

PE2A015 225mm t212mm 25mm t62mm

PE2A030 225mm t212mm 25mm t62mm

PE2A050 225mm t212mm 75mm t127mm

50 mm or more

Front Surface

Mounting

4-M5

A B C D

PE0A100 225mm t212mm 75mm t127mm

PE0A150 225mm t212mm 75mm t152mm

Front

Surface

Cut-out

Cooling

Air Flow

90 mm

or more

Fins

The amplifier should be installed in an environment that meets these requirements.

Table 3: Amplifier Environmental Requirements

Item Specification

Ambient Temperature

Operating

Non-operating

0 to 55C

32° to 131°F

-20 to 65C

-4° to 149°F

Humidity Maximum 90% Non-condensing

Vibration Maximum 0.5G 10 to 55Hz

Shock Maximum 2G

Air Quality Dust-free

Oil-free

Non-corrosive

Non-combustible

Non-explosive

During operation, the amplifier dissipates power that results in cabinet heating. The

following table lists power dissipation values for valid system configurations. These

values assume continuous rated load operation. Calculate the cabinet cooling

requirements using the power dissipation information and the formulas below. For

PE0A100 and PE0A150 amplifiers, details are provided for the power dissipated in the

heatsink.

Table 4: Power Dissipation

Power Dissipation [W]Drive Model Motor Model

Total PCB Heatsink

PE2A015 P30B04010D 19 - -

PE2A030 P30B06040D 31 - -

PE2A030 P30B08075D 46 - -

PE2A050 P20B10150D 100 - -

PE0A100 P20B10250D 170 98 72

PE0A100 P20B13300D 175 103 72

PE0A150 P20B13500D 260 150 110

Power dissipation values shown in the table do not include values for the internal

regeneration resistor.

When using an external regeneration resistor, the internal resistor is disconnected.

Amplifier

Environmental

Requirements

Power Dissipation

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