Unitek TVD6.2-RS User manual

MANUAL
3-Phase-Transistor-Servo-Drive
for
AC-Synchro-Servomotors
with
Resolver
TVD6.2-RS
Version
0899-1
G m b H
Industriestraße 1
D-71397 Leutenbach 3 - Nellmersbach

Transistor-Servo-Drive TVD6.2-RS
2
1 Basic-Information Seite
Safety Advice 3
General Information 4
Application 5
Characteristics 6
Technical Data 7
2 Mechanical Installation
Dimensions 8, 9
Structure of Device 10
Mounting Advice 11
3 Electrical Installation
Connection Overview 12
Connection Plan 13
Earthing Plan EMC-Advice 14
Mains Connection 15,16
Motor Connection 17
Control Connection 18 to 23
Signals 24, 25
Connector Plan 26, 27, 28
4 Device Overview
Resolver 29
Component Positions 30
Block Diagram 31
Frontpanel 32
Adjustment Functions 33
Signals 34
5 Adjustment
Adjustment Advice 35
Nominal Value 36
Actual Value 37
Current 38
Speed Controller 39 to 41
6 Getting Started
Default Setup 42
Getting Started 43
7 Fault Finding
LED Indications 44
Function Faults 45
Function Diagram 46
Encoder Signals 47
8 Guarantee 48
9 Protocol 49
Content

TVD6.2-400-x-RS 3
Electronic devices always involve the risk of failure.
This manual has to be read carefully and must be understood
by experts before installing or starting the device.
If there are any doubts call your trader or the manufacturer.
The TVD6 series is designed to regulate electrical currents;
protection standard IP00.
Instructions and rules:
the devices and accessory components must be set up and connected ac-
cording to the local technical regulations. In Germany they are:
- EU-machine guide lines 89/392/EWG,84/528/EWG,86/663/EWG
- VDE-regulation VDE 100, VDE 110, VDE 160 und VDE 0113
- TÜV-regulations
- Regulations of the professional guild.
The user has to assure that:
after
- a failure of the device
- an incorrect handling
- a failure of the control unit etc.
t
he drive is brought to a secure operating condition.
Machines and installations are to be provided with supervisory and safety
equipment, that is independent of the device.
Adjustment
-only by qualified personnel
- adher to safety regulations
Installation work
-only when disconnected from all power lines.
QS
The devices are archived by the manufacturer with serial number and their
test specifications.
CE
The EU-guide line 89/336/EWG with the EMC-Regulations EN50081-2 and
EN50082-2 are observed.
Caution High Voltage
AC 460V~, DC 750V=
1Basic-Information
Safety Advice

Transistor-Servo-Drive TVD6.2-RS
4
The transistor 3-phase current servo amplifier SERVO-TVD6.2forms toget-
her with the brushless direct current motor (synchro-servo (EC-) motor) a
propulsion unit distinguished by its rear-zero maintenance and by its high
dynamic control range.
The drive displays the wellknown good regulation characteristics of the
direct current drives without the disadvantages of the carbon brush wear
and of the communication limits.
The rotor intertia is notably lower and the power envelope is greater
than with equally constructed DC-motors. The result are up to 5 times
higher acceleration values. As the generated heat in the motor occurs in
the stator, the ec-motors are always designed to the protection standard IP
65.
The brushless direct current motor is electrically a synchro-motor with a
permanent magnet rotor and 3-phase stator.
The physical characteristics correspond to those of the direct current
motors, that is, the current is proportional to the torque and the voltage is
proportional to the speed. As both values can be measured precisely, the
servo-control unit can be mounted easily. It is possible to control the speed
from the motor voltage, but in order to achieve exact regulation it is prefe-
rable touse atways a tachometer regulation.
The tachometer actual value is generated from the sensor unit (resolver).
In the speed controller (P-I-controller) of the servo-drive is the differenz of
nominal value and actual value amplified. The result is the current nomi-
nal value, which is transferred by the resolver signal onto the three phase
current controllers such that the stator magnetic field leads ca. 90° electri-
cally the rotor magnetic field.
This field frequency is not a controlled variable, it adjusts istself automati-
cally. The motor currents, following the resolver interpretation, form a si-
ne-waved rotating field.
As occurs in all DC-, AC or ec-servo-amplifiers which are supplied by the
dc-bus, the feed-back of the energy must be observed when braking in the
dc-bus (especially where stroke or eccentric cycles are concerned). The
bleeder switch is set for a 3 % duty cycle. The ballast-resistors have to be
mounted externally.
Information:
For lower power >>> UNITEK Serie TVD3.2
100V upto 10/20A
For higher power >>> UNITEK Serie MODULA
400V upto 100/200A
General Information

TVD6.2-400-x-RS 5
Application :
for all kinds of machines up to 8KW drive power especially as 4Q-servo-
drive in travel axes with
-high dynamic acceleration and deceleration cycles
- great regulation range
- high efficiency
- small motor size
- even and smooth travel
for speed or torque regulation or
combined speed-torque regulation with or without superposed position
controller.
Drives with constand speed as in conveyors, lead screw drives, pumps or
divider units.
Synchro-Servo-drives are smaller than other drives.
For Use in:
componenet insertation machines, metall-sheet working machines
machine tools, plastic working machines, assembly machines,
knitting and sewing machines, textile working machines, grinding
machines,
wood and stone working machines, food processing machines,
robots and manipulators, storage across machines, Extruder, Kalander,
and many other machines and installations
Notice:
In bl-drives which mainly require deceleration
for example:
- winding machines, lifts, great centrifugal masses
the braking energy will be annihilated in the ballast circuit
or re-feded to the mains using an external dc-bus converter.
With multiple-axes an energy compensation is possible.
The motors are
- designed to protection standard IP 65
- compact
- suitable in rough surroundings
- suitable with high dynamic overload
- service-free
1 Basic-Information
Application

Transistor-Servo-Drive TVD6.2-RS
6
Construction:
- cubicle-mount or 6HE-plug-in unit according to the
VDE- DIN- and EU- regulations.
- standard analog regulation electronics.
- power electronics for 5A, 10A, 16A and 25A.
- wide-band chopper supply unit for the auxiliary voltages.
- power supply unit on the back circuit board .
Galvanic isolation between
- power section and covering
- power section and regulation electronics
- regulation electronics and contol inputs
The leakage distances are according to the VDE regulations.
There are used:
- fully isolated six-pack IGBT-power semiconductors, generous
dimensioning.
- only industrial standard components are used
- All ICs with external connections are mouted on high-quality sockets
- LED displays
- 16 digit binary switches for PI-setup of the speed regulator
- precision trimers for fine adjustment
- plug-in jumpers for system setup.
Characteristics:
* Direct power supply 400V~
* Electronic starting current limitation
* 2 differential reference inputs
* Accelleration and decelleration ramp with second nominal value
* Speed and torque regulation
* Static and dynamic current limit
* Current nominal value output
* Test connectors for current and speed
* Galvanic isolated logic in- and outputs
* Enable and end-switch logic
* Integral disabling
* Quick stop
* Mains failure braking
* Temperature control for motor and device
* Parameter adjustments without soldering
* 10 pin control plug
* Incremental encoder output
Characteristic

TVD6.2-400-x-RS 7
Power connection:
directly on the mains 1x 400V~
3x 400V~
maximum: 460V~
Option :connection voltage < 300V~ >>> notice the advise
Technical data:
type TVD6.2-400- 5 10 16 25
output voltage max. V~eff. 400 400 400 400
output standstill current
duration A= 5 10 16 25
peak A= 10 20 32 40
electrical power max kW 2 4 6,4 10
rapid fuses
built-in A 20 20 20 20
measurements
plug-in device BxH 16TE 16TE 16TE 24TE 6HE
cooling 60% ED convect convect fan fan
100% ED convect fan fan
fan
switch cabinet mounting BxHxT see illustrations of the dimensions
Common specifications:
protection standard IP 00
device layout VDE 0100 group C
VDE 0160
humidity stress class F according to DIN 40040
operation altitude < 1000m above NN
operation range 0 ... 45°C (with external fan 0 ... 35°C)
expanded operation range up to 60° C red. 2%/ °C
bearing reach -30°C up to + 80°C
speed controller
control precision (excl. tacho error) ± 0,1%
control range > 1: 1000
reference inputs ± 10V=
logic inputs +10 ... +30V=
logic outputs >+14V, 6mA
Caution:
When order please specify:
notice cyclic duration factor >>> external cooling system with 100%
several axes with >=10A
within one rack >>> external cooling system recommended
input voltages <300V~ >>> modify power supply unit
exact torque control >>> current controller with PI-wiring
high centrifugal mass >>> external ballast resistor
1Basic-Information
Technical Data

Transistor-Servo-Drive TVD6.2-RS
8
Compact- 10 and 16A 25A Device Wanne Wanne or mounting angles
Dimensions

TVD6.2-400-x-RS 9
Dimensions 6HE [mm]
plug-in units
dimension 1 2 3 4 5
A 1xE+3 2xE+3 3xE+3 4xE+3 5xE+3
B 1xE+40 2xE+40 3xE+40 4xE+40 5xE+40
C 1xE+55 2xE+55 3xE+55 4xE+55 5xE+55
Unit-grid dimension
10 and 16 A Device E= 81,28 mm
25 A Device E= 121,92 mm
Mounting height 255 mm
2 Mechanical Installation
Multi-axes combinations
Dimensions

Transistor-Servo-Drive TVD6.2-RS
10
Power supply unit back panel with plug-in-device (without rack)
Power supply unit setup
Incremental encoder output X8 Jumper J2 IC I7
external ballast resistor Bridge D open cable 1
Rack
Hight unit : 6HE
Wide unit : 10/16A = 16TE, 25A = 24TE
Mixed 6HE, 3HE (TVD3) racks on request
X31
TVD6
F1
2
X11
Entfernen
bei externem
Ballastwiederstand
X8 nur bei
Ausführung
IN, RS
80,0
D9 D15
I1
65
32
X7,X8
X11 X11 X11
X31
X1
X2
X3
X11X11
355,0
2
32
2
1
X8 X7
16
17 32
D1
Structure of Device

TVD6.2-400-x-RS 11
mounting height 255mm Compact device 10/16A Compakt device 25A (sw)
Compact device 25A (w) Multi-axes combination
Dissipation power at maximum power
rated dissipation power[W]
current Device supply unit fuse M-choke filter
5A 70 20 xx xx
xx
10A 90 20 xx xx xx
16A 125 30 xx xx xx
25A 180 43 xx xx xx
Fixing dimensions [mm]
compact device
current A B C D E screw
5,10, 16 Wanne 95 335 M4
5-w Wanne 135 335 M4
25 sw mounting angles 180 158
190,555 M5
multi-axes combinations
mounting angles A C D E screw
wall mounting n x E+60 n x E+40 190,5 55 M5
front mounting with19" systems
E at <=16A = 81,28 mm n =number of plug-in units
E at 25A = 121,92 mm
2 Mechanical Installation
Mounting Advice
Free space to switch-cabinet wall min. 100mm

Transistor-Servo-Drive TVD6.2-RS
12
Chokes
device- mains filter motor chokes ferrite core
rated current 1ph 3ph
5A FE1-10 FE3-10 MDD 1,3 a EMI742 70107
10A FE1-16 FE3-16 MDD 1,6 a EMI742 70107
16A FE1-16 FE3-16 MDD 2 b EMI742 70107
25A - FE3-25 MDD 2,5 b EMI742 70107
Connection Overview

TVD6.2-400-x-RS 13
Connection compact device: only left diagram without internal connections Connection multi-axes combination : One or more axes with power supply unit, plus one or more axes without own power supply unit power supply unit- positions free choosable
3 Electrical Installation
Connection Plans

Transistor-Servo-Drive TVD6.2-RS
14
The devices are according to EU-regulation 89/336/EWG, the standards EN 50081-2 and
prEN 50082-2 will be observed under the following conditions.
Device,transformer,motor chokes and mains filter fixed on a 500 x 500 x 2 mm mounting
board.
Mounting board and motor frame connected to gnd with a 10mm² wire.
Devices reference X1:13 connected to mounting board with a 2,5mm² wire.
Device-PE-screw connected to mounting board with a 50mm long 4mm² line.
Single-phase power supply:
mains filter Type : up to 16A = FE1-16
linelength device - mains filter <100mm
Three-phase power supply:
mains filter Type : up to 16A = FE3-16
up to 25A = FE3-25
linelength transformer - mains filter <500mm
linelength device - mains filter <100mm
Motor connection:
motor chokes Type : 10A = MDD1,6-10
16A = MDDxx-20
25A = MDDxx-30
motor line 1,5m long, 4core shielded. Shielding on device side fixed to mounting
board and on motor side flächig connected to PE.
Earthing Plan EMC-Advice

TVD6.2-400-x-RS 15
Caution:
The connection advice concerning the individual attachments of the con-
nections to the plug numbers or terminals are binding.
All further advices to this are not binding.
The input and output lines can be altered or completed in consideration of
the electrical regulations.
Notice:
- connection advice and operation advice
-local technical regulations
- EU-machine regulation 89/392/EWG
Input filter:
see CE-advice (page 14)
short line length between input filter and device
or shielded line
FI-switch
- design to DIN VDE 0664
- tripping current > 200mA
- only combined with other protective measure
Connection to 400 V~ mains
Alternating voltage connection 1x400V~ 50/60Hz
compact device up to 10A.
multi axis combination up to 20A
Three-phase current-connection 3x400V~ 50/60Hz
with >10A (multi axes rack >20A) necessary
dimensioning 5/10A 16A 25A max. 30A
wire cross section mm² 0.75 1.5 2.5 2.5
fusing
blow-out fuse AF 10 16 25 30
automatic circuit
breaker A 10 16 25 25
electronical starting current limitation >>> max. current 7A~
3 Electrical Installation
Mains Connection

Transistor-Servo-Drive TVD6.2-RS
16
Connection at 400 V mains
AC or three-phase voltage supply
autotransformer or isolation transformer
one transformer for several devices
Notice:
-set safety contacts on transformer inrush current.
-slow fuses in front of the transformer
-fuse value corresponding to the transformer rated current
-quick fuses after the transformer
-fuse value for each power supply unit max. 30AF
Transformer capacity:
primary voltage 500V~
secondary voltage 400V~
Autotransformer
transformer rated power [VA]= 0,2 x400 xIM xGLF xnF
Isolation transformer
transformer rated power [VA]= 1,25 x430 xIM xGLF xnF
IM = total power of the motors
GLF = coincidence factor
nF = speed ratio factor
GLF = nF =
1 with one motor effective speed
0,5 ... 0,7 with 2 motors maximum speed
0,4 ... 0,6 with >2 motors
AC three phase current
Mains Connection

TVD6.2-400-x-RS 17
Motor connections
wire number PE M1 M2 M3
connection X3:6 X3:7 X3:8 X3:9
X3:6 is internally connected with the devices PE-bolt.
motor line at 5A 10A 16A 25A thermo brake
cross section 0,75 1,5 1,5 2,5 0,75 0,75
kind of cable 3x motor line shielded + PE
+ (if required: 2x thermo + 2x brake)
Shielding with earth clamp
connected directly with the entry
of the switch cabinet and the
motor earth manifold if there
are long lines .
Ferrit core
- against HF-failure
Motor chokes
- against HF-failure
- against high discharge current
- for high efficiency of the motor
- for the duration of the motors life
External ballast resistor
dimensioning :
average of the brake power per axis
1xJg xn² Jg² xaxn
P ballast [W] =xf
2 M
M
Jg = motor- and effective load torque [kgm²]
n max = maximum speed [s ¹]
M M = maximum motor torque [Nm]
a = deceleration [s ²]
f = repeating frequency of the braking[s ¹]
To change on back panel power supply unit:
- remove jump wire connection D
- mount cable 1(external ballast resistor)
external ballast resistor >>> smallest resistance value 40W
internal ballast resistor 42W/ 50W, at 3%ED = 1,5 kW
3 Electrical Installation
Motor Connection

Transistor-Servo-Drive TVD6.2-RS
18
The connecting advices are for general information and
without obligation.
Notice:
- Connecting- and operating instructions
- Local regulations
- EU-machine regulation 89/392/EWG
Clamp terminal pin numbers
X1: 1 to X1:16 and X2 : 17 to X2 : 32
Signal lines
shielded and seperated from power lines
nominal value lines paired twisted and shielded
Logical connections
Relay with golden pins or reed relay. Maximum currency on contact 6mA.
Internal logical voltage15V=
- Potential connection
- With relay control
- Jumper J1 and J3 plugged
External logical voltage
- Galvanic isolation
- With SPS or CNC
- UEXT +15 up to 30V= on clamp X2:27
- GNDE on clamp X1:11
-jumper J1 and J3 unplugged
- residual ripple of the logical voltage <20%
Default setup: jumper J1 and J3 plugged.
Inputs and outputs with optocoupler.
Control Connections
Input Output
Output

TVD6.2-400-x-RS 19
Enable >>>active with forward voltage
jumper SW1 position 2-3 (default setup)
enable -internal logical voltage
- internal logical voltage X1:1 +15V/10mA
- chain of contacts between X1:1 and X1:2
Enable -external logical voltage
- enable voltage +10 ... +30V X1:2
Enable >>> active at zero point
Jumper position 1-2 (US-version)
Enable -internal logical voltage
- logical zero point X1:11
- chain of contacts between X1:2 and
X1:11
Enable -external logical voltage
- enable voltage 0V X1:2
Enable switching on
- nominal value and torque control are cleared immediately
- LED D1B bright
Enable switching off
jumper J2 plugged (quick stop) (default setup)
- nominal value immediately set to zero internally (deceleration)
- LED D1B dark.
- after five seconds >>> speed controller locked
jumper J2 unplugged (no braking)
- speed controller immediately locked.
- LED D1B dark
Notice:
Jumper SW1 Pos: 2-3 >> enable active with > +10V (default setup)
Pos: 1-2 >> enable active at zero point
Jumper J2 plugged >> quick stop (default setup)
unplugged >> free run out
Control Connections
enable
3 Electrical Installation

Transistor-Servo-Drive TVD6.2-RS
20
Limit switch
Limit switch inputs
enable for
- positive nominal value LED 1D >>>contact between X2:27 and
X1:16
- negative nominal value LED 1H >>>con-
tact between X2:27 and X2:32
Limit switch direction
contact function
locked enable>LED bright
open
direction lock
> limit switch is occupied >>> contact open
- drive decelerates
> change of the nominal value
- drive moves from limit switch
- limit switch cleared >>> contact closed
Caution:
Without limit switch >>> connection between X2:27, X2:32 and X1:16
Integral switching off
Function - relay contact
contact speed controller
open P-I regulation
locked P- regulation
Function - external logical voltage
voltage X2:31 speed controller
< 2V P-I regulation
> 10V P- regulation
Caution:
Notice optimization advices.
Mains failure-braking
braking function
- nominal value is set immediately to zero
Generatoric rear feed into the intermediate circuit.
endswitch+
Control Connections
endswitch-