Superior Electric SLO-SYN TD Series User manual

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PRICE:$12.50
INSTRUCTIONS
FOR
SUPERIOR SLO-SYN
TD SERIES
BRUSHLESS SERVO
DRIVES
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Dangerous voltages, currents, temperatures, and energy levels exist within this
unit, on certain accessible terminals, and in the servo motor(s) and motor
wiring. Caution should be exercised when installing and applying this product.
Only qualified personnel should attempt to utilize, install or operate this
product. It is essential that proper electrical practices, applicable electrical
codes, and the contents of this manual be followed.
Servo motors develop high torque and speed. Precautionary measures should
be used prior to performing any mechanical work or applying power to the
unit. Proper preparations should be made ie. installation of limit switches, use
of Following Error (in the Servo controller), power removal guards, etc. to
avoid injury due to motor run away, motor oscillations, improper servo loop
gains, etc..
Servo motors can have temperatures of up to or exceeding 100°
°°
°C. Use caution
when handling the motors. Where appropriate, guards should be used to
prevent inadvertent contact with the motors.
ENGINEERING CHANGES
Superior Electric reserves the right to make engineering refinements on all its products. Such refinements may affect
information given in instructions, Therefore, USE ONLY THE INSTRUCTIONS THAT ARE PACKED WITH THE
PRODUCT.
©Superior Electric 1997
Warning
!
Caution
!
Caution
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i
Table Of Contents
SECTIONS & TITLE PAGE
Things to Know Before Using This Equipment ii
1.0 - Introduction 1
1.1 - Using This Manual 1
1.2 - Product Features
2.0 - Specifications 2
2.1 - Mechanical and Environmental Specifications 2
2.2 - Electrical Specifications 2
2.3 - Signal Specifications 3
2.4 - LED Specifications 4
2.5 - Current Specifications 5
2.6 - Motor Specifications 5
3.0 - Installation 6
3.1 - Mounting 6
3.2 - General Wiring Guidelines 7
3.3 - AC Power Wiring 9
3.4 - Motor Wiring 10
3.5 - Regenerative Resistor Connections 11
3.6 - Control Wiring 12
4.0 - Operation 13
4.1 - Introduction 13
4.2 - Initial Start-Up 13
4.3 - Sequence of Operation 13
4.4 - Protective Features 14
5.0 - Troubleshooting Guide 15
Appendix A - CE Compliance Installation Requirements and Information 17
Warranty Information 19
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ii
THINGS TO KNOW BEFORE GETTING STARTED
•Only qualified personnel should install or perform service on this equipment. Do not operate the unit
without the enclosure as voltage present in this unit can cause serious or fatal injuries.
•Before performing any work on this unit or the wiring, allow at least 5 minutes for the capacitors to fully
discharge, to prevent electrical shock hazards.
•Motors powered by this unit develop high torque. Be sure to disconnect AC power before doing any
mechanical work.
•When energizing the system, be aware that mechanical motion may occur. Be prepared to take the
appropriate action to protect personnel and equipment.
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Introduction 1
1.0 INTRODUCTION
1.1 Using This Manual
It is important that you understand how TD330 units operate before installing and using these products. We
strongly recommend that you read this manual completely before proceeding with the installation.
This manual is an installation and operating guide for the TD330/04 and the TD330/08 Torque Mode
Amplifiers (Drives). Section 1 gives you an overview of the product functions and features. Section 2 gives
detailed information on the specifications for the product and pertinent system requirements. Section 3
provides the recommended installation guidelines. Section 4 contains the recommended operating
instructions for the system.
Other information included is a troubleshooting guide in Section 5, and warranty information.
1.2 Product Features
The TD330 drives are designed to operate hall commutation DC brushless motors. Alternatively, motors
with encoders having the appropriate commutation signals may be used. The amplifier operates in the torque
mode which can be connected to a positioning system such as the Superior SLO-SYN MX2000 control. A
version with a built-in single-axis controller is also available as the TDC330/04 and the TDC 330/08.
* Line operated 115/230 Vac input
* Switch selectable current scaling for easy installation (no potentiometers to adjust)
* Latched short circuit protection (phase to phase and phase to ground)
* Latched over temperature protection
* Latched DC bus over voltage protection
* Optically isolated inputs
* 50 ohm 50 watt regenerative energy circuit included
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2Specifications
2.0 SPECIFICATIONS
2.1 Mechanical and Environmental Specifications
Size: 2.88W x 10.63H x 8.07D (See Figure 3.1)
Weight: TD330/04: 6.75 lbs.
TD330/08: 7.25 lbs.
Temperature: 0°C to 50°C (32°F to 122°F) operating
-40°C to 75°C (-40°F to 167°F) storage
Max. Heatsink Temp: 70°C (158°F); forced air cooling may be necessary
Humidity: 95% maximum, non-condensing
Altitude: 10,000 feet max.
2.2 Electrical Specifications
Input Voltage: Single Phase 95 to 264 Vac, 50/60 Hz
Input Current: TD330/04, 7 amps, fuse rating: 8 amp 3AB Fast Acting
TD330/08, 14 amps, fuse rating 15 amp 3AB Fast Acting
Internal Bus Voltage: 130 to 375 Vdc depending on AC Input Voltage
Motor Current: TD330/04, 4 amps continuous, 8 amps peak
TD330/08, 8 amps continuous, 16 amps peak
(maximum value of a 6-step waveform)
Regenerative Energy Circuit: Internal: 50 ohm, 50 watt resistor
External: Connections available
See example for size selection in Section 3.5 or consult factory
Regenerative Energy Circuit Fusing: 1 amp 3AG Slo-Blo
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Specifications 3
2
4
5
6
2.3 Signal Specifications
Figure 2.1
I/O Signals
+5V and +5V COM: 5Vdc, 0.3 amps
power supply to be used for hall and/or
encoder devices.
HALL 1, 2, 3: Optically isolated inputs
for the commutation devices. The inputs
are pulled up to a +5 V supply through a
1000 ohm resistor. Low level current is
less than 4 milliamperes. See figure 2.1
for details.
SHIELD: Connection to unit ground for
cable shields.
CMD+, CMD-: The analog interface to an
external controller. A voltage from +10 to
-10 Volts between these two inputs
commands the drive to deliver from +2X
full current selected to -2X full current
selected to the motor. See figure 2.1 for
details.
ENABLE: Optically isolated input which
when pulled low activates the drive. The
input is pulled up to the +15 V supply
through a 2200 ohm resistor. The low
level current is < 7 milliamps. See figure
2.1 for details.
READY: A relay output with NO and NC
contacts. The relay activates when the
drive is ready. The contact current rating
is 0.5 amps at 24Vdc resistive load. See
figure 2.1 for details.
+24V & 24V COM: Isolated DC supply
for customer use rated 24 Vdc +/- 10% and
0.5 amps. See figure 2.1 for details.
1
2
3
4
5
6
7
1
3
7
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4Specifications
2.4 LED Specifications
Figure 2.2
LED’s
Power LED: The power LED indicates that there is AC power applied to the drive
and that the logic supply is active.
Over Current LED: The over current LED, when active, indicates the possibility of a short
circuit from phase to ground or phase to phase. It may also be caused
by a non-compatible motor being used.
Over temperature LED: This LED shows that the unit has shut down due to an over
temperature situation, which could be caused by the temperature of
the heat sink being in excess of 70 °C (158°F) or the ambient
temperature is greater than 50 °C (122°F).
Regen on LED: When this LED is on the regenerative circuitry is active. It does not
indicate a fault.
Over Current LED If the over current and the over temperature LED’s are active
& this indicates that an over voltage condition has occurred, bus
Over temperature LED: voltage > 410VDC.
OVER
CURRENT
OVER
TEMPERATURE
REGEN ON
POWER
8
9
10 11
12
8
9
10
11
12
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Specifications 5
2.5 Current Settings:
The current settings of the drive reflect the continuous current capability of the motor. Peak current is twice
the continuous current setting. The TD-04 has a maximum continuous current of 4 amps and a peak current
of 8 amps. The TD-08 has a maximum continuous current of 8 amps with 16 amps peak current. The
highest DIP switch setting in the on position will be the max. continuous current supplied by the drive. See
figure 2.3.
Figure 2.3
Current Settings
2.6 Motor Specifications
Type: 3 Phase Brushless motor with Hall commutation or encoder with commutaion tracks
Voltage: Capable of withstanding bus voltages of 350 Volts.
Current: TD330/04 1 to 4 Amp continuous, 2 to 8 amp peak
TD330/08 2 to 8 Amp continuous, 4 to 16 amp peak
Recommended
Inductance: 4 mH minimum
NOTE: DUTY CYCLE LIMITING WILL BE REQUIRED TO KEEP THE SHELL
TEMPERATURE BELOW ITS RATING.
Current
Settings
8.0
7.0
6.0
5.0
4.0
3.0
OFFON
2.0 - ALL OFF
CURRENT
TD-04
TD-08
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6Installation
3.0 INSTALLATION
3.1 Mounting
The servo drive is intended to be mounted with the brackets supplied with the unit. When selecting a
mounting location, it is important to leave at least 2 inches unrestricted space around the top, bottom, and
sides of the unit to allow for proper airflow for cooling. Keep the unit away from potential noise sources
or sensitive electronic equipment.
NOTE: The unit should be mounted upright with the cooling fins vertical. The case temperature should not
exceed 70 °C (158 °F). Forced air cooling may be required to keep the temperature within the stated limits.
Figure 3.1
Outline Dimensions
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Installation 7
3.2 General Wiring Guidelines
Dangerous voltages, currents, temperatures, and energy levels exist within this
unit, on certain accessible terminals, and at the servo motor. NEVER operate
the unit with its protective cover removed! Caution should be exercised when
installing and applying this product. Only qualified personnel should attempt
to install and/or operate this product. It is essential that proper electrical
practices, applicable electrical codes and the contents of this manual be followed
strictly.
Superior SLO-SYN controls and drives use modern solid-state digital electronics to provide the features
needed for advanced motion control applications. Although care has been taken to ensure proper operation
under a wide range of conditions, some user equipment may produce considerable electromagnetic
interference (EMI) which can cause inappropriate operation of the digital logic used in the control, drive,
or other computer-type equipment in the user’s system.
In general, any equipment that causes arcs or sparks or that switches voltage or current at high frequencies
can cause interference. In addition, ac utility lines are often “polluted” with electrical noise from sources
outside a user’s control (such as equipment in the factory next door). Some of the more common causes of
electrical interference are:
•power from the utility ac line
•relays, contactors, and solenoids
•light dimmers
•arc welders
•motors and motor starters
•induction heaters
•radio controls or transmitters
•switch-mode power supplies
•computer-based equipment
•high frequency lighting equipment
•dc servo and stepper motors and drives
The following wiring practices should be used to reduce noise interference.
Solid grounding of the system is essential. Be sure that there is a solid connection to the ac system
protective earth ground (PE). Insure that there is a good electrical connection through the drive case to the
control system enclosure . A separate grounding strap may be required to properly ground the unit to the
control system enclosure. This strap should ideally be constructed using copper braid at least 0.5" in width.
Use a single-point grounding system for all related components of the system (a “hub and spokes” arrange-
ment). Keep the ground connection short and direct. Grounding through both a mechanical connection to
the control enclosure and through a grounding strap is optimal.
Warning
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8Installation
Keep power and signal wiring separated. Power wiring includes ac wiring, motor wires, etc. Signal
wiring is inputs and outputs (I/O), encoder wiring, serial communications (RS232 lines), etc. If possible,
use separate conduit or ducts for each. If the wires must cross, they should do so at right angles to minimize
coupling.
Use separately bundled shielded cables for the drive to motor, encoder, serial communications, analog
input, and digital I/O wiring. For motor connections, BE SURE TO GROUND THE SHIELD AT THE
SLO-SYN DRIVE END. For other connections it is recommended that the shields be terminated at the Slo-
Syn unit as well. Shield connections are provided on the unit terminal connectors for this purpose. All
cable shielding should be terminated at ONE END ONLY. Grounding the serial communications
connections at the opposite end of the controller may be necessary in some systems. If the cable shield must
be connected at the opposite end from the Slo-Syn unit, the shield should NOT also be connected at the unit
as this may cause a “ground loop” and introduce electrical noise problems.
Suppress all relays as close to the coil as possible to prevent noise generation. Typical suppressors are
diodes, capacitors or MOV’s. (See manufacturer's literature for complete information). Whenever possible,
use solid-state relays instead of mechanical contact types to minimize noise generation.
In some extreme cases of interference, it may be necessary to add external filtering to the ac line(s) feeding
the affected equipment, or to use isolation transformers to supply their ac power.
NOTE: Superior Electric makes a wide range of ac power line conditioners that can help solve electrical
interference problems. Contact 1-800-SUP-ELEC (1-800-787-3532) for further assistance.
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Installation 9
13
3.3 AC Power Wiring
The ac input power, , is connected to the 7 position terminal strip at the connection points marked
AC IN and the chassis ground. The terminals are labeled as follows:
Neutral Line to Line
Connected Connected
Terminal System System
AC IN Line Line 1
AC IN Neutral Line 2
Chassis Ground Ground Ground
Note: Two chassis ground studs are provided (located near each end of the motor/AC terminal strip).
The voltage from “line” to ground in the neutral connected system, or “Line 1” and “Line 2” to ground in
the line to line connected system must not exceed 264 volts ac. Refer to figure 3.2.
14
13
15
EXTERNAL REGEN
EXTERNAL REGEN
Ma
Mb
Mc
AC IN
AC IN
115-
230
VAC
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10 Installation
14
3.4 Motor Wiring
The motor wiring is connected to the 7 position terminal strip at the connection points marked Ma, Mb, and
Mc, . Refer to figure 3.2. The motor ground is connected to the Chassis Ground provided. The
terminals are marked as follows:
Terminal Connection
Ma Motor Phase A
Mb Motor Phase B
Mc Motor Phase C
Chassis Ground Motor Ground
Note: Two chassis ground studs are provided (located near each end of the motor/AC terminal strip).
Motor & Hall Sensor Commutation Table
HALL 1 HALL 2 HALL 3 MOTOR
VOLTAGE
+5 VDC 0V 0V Ma to Mb
0V +5VDC 0V Mb to Mc
0V 0V +5VDC Mc to Ma
The above table must be used to properly “phase” your motor’s windings to the three hall effect sensors or
encoder commutation tracks.
Note: A pull-up resistor of 1Kohm to +5VDC is provided on the three HALL inputs internal to the drive
unit. If an open-collector hall sensor is used, the device must be off to yield a +5VDC signal at the drive
HALL terminal.
Reference figure 3.3 for additional information.
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Installation 11
15
3.5 Regenerative Resistor Connections
An external regenerative resistor can be connected to the 7 position terminal strip connection points marked
external regen, . Refer to Figure 3.2. See the following example to determine if an external regenerative
resistor is required.
For determining if the internal regenerative resistor is sufficient use the following formula:
Jrotor = Inertia of the rotor in lb-in-sec2
Jload = Inertia of the load in lb-in-sec2
P= Power of regen resistor in watts
N= Speed of the motor in RPM
Tfrict = Frictional torque in lb-in
tdecel = Deceleration time
tcyc = Cycle time
E = energy in motor in joules
where: P= Power of the internal resistor = 50 W
The internal resistor is sufficient if the calculated energy is ≤200 Joules and the cycle time is greater than
the calculated cycle time.
Example: Jrotor =.0026 lb in sec2
Jload = 0.130 lb in sec2
P= 50 W
N= 4000
Tfrict = 5 lb. in.
tdecel = .25 sec
Since the energy is less than 200 joules and if the cycle time is greater than 1.9 seconds no external regen
is required. If the energy is greater than 200 joules or the cycle time is less than the calculated cycle time
consult the factory for the proper external regen resistor.
E= * (J
rotor
+J
load
) * N
2
- * T
frict
* N * t
decel
t
cyc
=
1
1616 1
85
E
P
E= * (.0026+.0130) * (4000)
2
- * 5 * 4000 * .25 = 95.63
t
cyc
> > 1.9
1
1616 1
85
95.63
50
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12 Installation
3.6 Control Wiring
The control wiring is grouped together on the terminal strip based on their origin. The hall sensor power and
signals get connected to the motor. The command signals, the enable, and the ready signal typically connect
to the controller. (see Figure 2.1). The 24 volt supply is for customer use and is not ground referenced. The
use of shielded cable is recommended. Refer to figure 3.3 for a typical installation utilizing a MX2000
controller.
Figure 3.3
Typical Control Wiring
+5V
5V COM
HALL 1
HALL 2
HALL 3
SHIELD
CMD +
CMD -
ENABLE
READY
READY
READY
+24V
24V COM
MX Analog
Drive I/O
Out
AGND
EN+
EN-
RDY+
RDY-
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Operation 13
4.0 OPERATION
4.1 Introduction
The TD330 series operates as a torque mode amplifier. When the drive is enabled and there are no internal
shutdowns, a voltage present between the CMD inputs gets translated into motor current. This current
creates torque in the motor which yields a rotational force. When connected to a motion controller such as
the MX2000, the commanded voltage is issued from the MX2000. The drive’s output current is scaled
based on the selected dip switch setting (see Figure 2.3). The setting should be matched to the motor’s
specifications. Always refer to the controller manual to set up your motion control system.
4.2 Initial Start-Up
At this point your system should be wired including all safety devices and limit switches. The functionality
of these devices MUST be verified before proceeding with the drive activation. Be prepared to shutdown
the system in the event of servo loop problems that can include run away situations and motor oscillations.
4.3 Sequence of Operations
This section contains basic information for the start up of a drive and control system. Always refer to the
controller manual for it’s operational characteristics.
1) Power up the controller that is connected to the TD330 drive.
ENSURE THAT THE FOLLOWING ERROR IS ENABLED TO PREVENT MOTOR
RUN AWAY CONDITIONS, SYSTEM DAMAGE, OR INJURY.
2) Verify the CMD signal to the drive is 0 volts and the enable signal is HIGH.
3) Power up the drive and verify the power LED is on. (There should be no motion at this time.)
4) Verify that there are no other drive LED’s on.
5) Have the controller enable the drive. BE PREPARED TO SHUTDOWN THE SYSTEM.
6) If operational problems occur, refer to the troubleshooting guide contained in this manual or in the
controller manual.
!
Caution
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14 Operation
4.4 Protective Features
4.4.1 AC Line Fusing
The AC line is protected by fuses located inside the unit on the circuit card near the input terminals. Since
access to the fuses requires disassembly of the unit and an open fuse would normally indicate a drive
malfunction, such as a blown output IGBT, it is recommended that the unit be returned to the factory for
repair.
4.4.2 Regen Resistor Fusing
The regen resistor is protected by a fuse located inside the unit on the heat sink. An open fuse normally
indicates a drive malfunction, such as a bad regen resistor or a failed driver transistor. Because of this fact
and since access to the fuse requires disassembly of the unit, if the fuse blows, return the unit to the factory
for repair.
4.4.3 Over Current
The over current feature protects the unit from short circuits between the motor output terminals and
between the motor output terminals and the terminals to ground. The LED will activate if either of these
conditions occur. AC power must be turned off and back on to reset the drive. Ensure the LED is off and
the source of the short circuit is corrected before reenergizing the drive.
4.4.4 Over Temperature
The drive is protected from over temperature by utilizing a thermal switch mounted on the inside of the heat
sink. When the switch temperature exceeds 70 °C (158 °F), the over temperature LED will activate. AC
power must be turned off and back on to reset the drive. Fan cooling may be required to keep the drive
within the temperature specifications listed in Section 2.1.
4.4.5 Over Voltage
The drive has over voltage protection which will activate both LED’s when the DC bus voltage exceeds 410
volts. The most likely causes for this condition are too high of a regeneration energy from the servo system
or an open regen fuse. AC power must be turned off and back on to reset the drive. If the load regeneration
is too high, an external regeneration resistor is required. See Section 3.5 for application details.
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Troubleshooting Guide 15
5.0 Troubleshooting Guide
Dangerous high voltages exist in the TD330 drive products. Be certain the power has been
removed for 5 minutes before any service work is performed.
Symptom: Power LED does not come on
1. Verify that the AC power to the unit is between 95 and 264 Vac.
2. Ensure there are no short circuits or heavy electrical loads on the +5 Vdc or +24 Vdc supplies.
3. Check for blown input fuses. Replace with same value and type listed.
In order to provide the correct levels of protection in the unit, replacement fuses must be
the same exact style and ratings as the originals in the unit. If a fuse has been blown,
return the unit to the Factory for repair.
Symptom: Over current LED on
1. Power down the unit until the power and over current LED’s go out. Power the unit back up and see
if fault goes away.
2. Check the motor wiring for short circuits to ground or phase to phase.
3. Verify the motor selected is one that is compatible with the drive.
4. Verify the current setting on the drive matches that of the motor’s specification.
Symptom: Over temperature LED on
1. Power down the unit until the power and over temperature LED’s go out. Power the unit back up and
see if the fault goes away;
2. Check the ambient temperature to be sure it is less than 50 °C (122 °F). If the ambient temperature
is greater;
3. Check heat sink temperature to be sure it is less than 70 °C (158 °F).
Temperature of the heatsink or the unit could be hot to the touch. Caution should be used
when determining the temperature.
Symptom: Both the Over current and Over temperature LED’s are on
1. Power down the unit until the power and over temperature LED’s go out. Power the unit back up and
see if fault goes away.
2. If there is an external regenerative resistor:
a. Insure that it is connected and connected properly.
b. That the values for the wattage and the resistance are correct for the unit.
3. If there is no external regenerative resistor, one may be necessary.
4. Verify that the input voltage is between 95 and 264 VAC.
!
Caution
!
Caution
Warning
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