Unitek TVD3.2 bl Series User manual

MANUAL
3-phase Servo-Drive
TVD3.2-xx-bl
for ac synchro servo motors
with
a rotor position encoder
TVD3.2-bl
Version
0207-1
Industrieelektronik
GmbH
Industriestraße 1
D-71397 Leutenbach 3 - Nellmersbach
Tel. [phone]
Fax [phone]
email [e-mail]
Htt
p
// www.unitek-online.de

Servo - Drive TVD3.2 -xx- bl
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CONTENTS
Page
Safety advice, standards and guidelines 3
General Information 4
Applications 5
Build 6
Characteristics 6
Technical data 7
Dimensions compact device 8
Dimensions transformers and chokes 8
Dimensions multiple-axes combination 9
Connections 11
Connection diagram 12
EMC - advice 13
Connections - isolating transformer, compact device X3 14
Connections - mains module X10, motor power 15
Connection advice 16
Command value 17
Current limiting 18
Actual value connections 19
Signals - drive ready BTB, analog parameter measurement 20
Terminal connections 21
Components 22
Circuit diagram 23
Adjustments 25
Adjustment advice 26
Command value integrator 27
Speed actual value 29
Current limiting 30
Speed control loop circuit 31
Adjustment without measurement equipment 31
Standard set-up 32
Commissioning 33
Faults 34-35
Signals 36
Protocol 37
Guarantee 38
Encoder connections 39
Contents

1 Basic - Information
TVD3.2bl 3
Electronic equipment is not fault proof. This fact should be borne in mind for all possible
operating conditions.
Before installation or commissioning begins, this manual must be thoroughly read and
understood by the technical staff involved.
If any uncertainty arises, the manufacturer or dealer should be contacted.
TVD3.2 devices are power electric parts used for regulating energy flow for power plants.
Protection rating IP00.
Standards and Guidelines
The device and its associated components can only be installed and switched on where
the local regulations and technical standards have been strictly adhered to:
EU Guidelines 89/392/EWG, 84/528/EWG, 86/663/EWG, 72/23/EWG
EN60204, EN50178, EN60439-1, EN60146, EN61800-3
IEC/UL IEC364, IEC 664, UL508C, UL840
VDE Regulations VDE100, VDE110, VDE160
TÜV Regulations
Trade body guidelines VGB4
The user must ensure that in the event of :
- device failure
- incorrect operation
- loss of regulation or control
the axis will be safely de-activated.
It must also be ensured that the machine or equipment are fitted with device independent
monitoring and safety features.
Setting Adjustments
- should only be carried out by suitably trained personnel
- should only be carried out in accordance with health and safety guidelines
Installation
- should only be carried out when all voltages have been removed.
QS
Test results are archived with the device serial number by the manufacturer.
CE
The device adheres to the following: Guideline EU 89/336/EWG. EMV standards
EN61000-2 and EN61000-4.
ATTENTION - High voltage
AC 140V~, DC 220V=
Safety advice

Servo - Drive TVD3.2 -xx- bl
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General Information
The transistor 3-phase current servo amplifier SERVO-TVD3.2 in combination with the
brushless dc motor (ac synchro servo motor, EC motor provide a drive solution free of
maintenance and with a wide dynamic control range.
The drive displays the well-known good control characteristics of dc drives without the
disadvantages of the carbon brushes’ wear and the commutation limits.
The rotor moment of inertia is notably lower and the limit power is greater than with
equally constructed dc motors. This results in up to 5 times higher acceleration values.
The generated heat in the motor only occurs in the stator (cold shaft).
The motors always have the protection rating IP 65.
From the electrical view, the ac synchro motor is a synchro motor with a permanent
magnet rotor and a three-phase current stator.
The physical characteristics correspond to those of dc motors, that is, the current is
proportional to the torque and the voltage is proportional to the speed.
Current and voltage are precisely measured. The analogue circuits are simply
constructed.
It is possible to control the speed via the motor voltage, however, in order to achieve the
best control precision, always the tacho control is used.
The speed actual value is generated in the rotor position encoder plus bl-tacho.
The difference of the command value and the actual value is amplified in the speed
control loop circuit (P-I-controller) of the servo drive. This results in the current command
value, which is transferred to the three phase current controllers by means of the rotor
position signal. In the course of this the stator magnetic field leads the rotor magnetic
field by 90° electrically.
This field frequency is not controllable, it is automatically adjusted.
The motor currents are trapezoidal.
For dc and ac synchro servo amplifiers which are supplied by a dc bus, it must be
checked that the energy is fed back into the bus during brake operation (winding
machines, lifts, great centrifugal masses).
The ballast circuitry is rated for 3% duty cycle. An extended operating time can be
achieved by additional external resistors. (Option)
Information:
For motors
with incremental encoder UNITEK TVD3-2-xx-IN
with resolver UNITEK TVD3-2-xx-RS
with rotor position encoder UNITEK TVD3-2-xx-bl
For low-voltage applications UNITEK TVD3-230-xx-bl,IN,RS
For high power UNITEK TVD6-2 -bl,IN,RS
200V/400V up to 25/40A
For digital servo controllers UNITEK DS 400
200V/400V up to 50/100A
General Information

1 Basic - Information
TVD3.2bl 5
Applications
Machines and installations for all types with a drive power of up to 0.8kW.
Especially as 4Q-servo-drive for feed axes where the following is required:
- high dynamic acceleration and braking cycles
- a wide control range
- high efficiency
- small motor dimensions
- highly repeatable, accurate and quiet moves
- ‘cold shaft’
For speed or torque control or combined speed/torque control incorporated within or
independent of position control loops.
Drives with constant speed as in conveyors, spindle drives, pumps, transversal or
longitudinal pitch drives.
AC synchro-servo-drives are more compact than other electric drives.
Particularly suitable for:
component equipment inserting machines, sheet-metal working machines,
machine tools, plastic working machines, assembly machines,
knitting and sewing machines, textile working machines, grinding machines,
wood and stone working machines, metal working machines, food processing machines,
robots and handling systems, conveyors, extruders, calenders, and
many other machines and installations.
Note
Use bl-drives where braking operations are predominant, e.g. when
deceleration is mainly required:
- winding machines, lifts, great centrifugal masses
The braking energy is annihilated in the ballast circuitry or fed into the
mains through the use of an external dc bus converter.
Energy compensation is possible for drives with several axes.
Motor features
- protection rating IP 65
- compact
- suitable for rough surroundings
- suitable for high dynamic overload
- free of maintenance
Applications

Servo - Drive TVD3.2 -xx- bl
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Build
- Switch cabinet mounting or 3HE plug-in device
according to the VDE, DIN and EU regulations
- Standard analog control electronics
- Power electronics for 5A and 10A
- No galvanic isolation between the power connection and device
ground (GND)
GND = -UB = PE - housing
Components
- IGBT power semiconductors, comfortably over-dimensioned
- Only components customary in trade and industrially standardised are used
- SMD basic equipment
- LED displays
- 4 position binary switches for system set-up
- Precision potentiometers for fine adjustment
Characteristics
* Connection using an isolating transformer nom. 115V~ (max. 140V~)
* Differential command value input
* Speed and torque control
* Static and dynamic current limiting
* Current command value output
* Measurement points for current and speed
* Enable logic
* Emergency stop
* Braking in case of a mains failure
* Temperature watchdog for the motor and the device
Build

1 Basic - Information
TVD3.2bl 7
Technical Data
Power connection
- Compact device
with transformer nominal 115V~ (max. 140V~),20V~/24V=
with transformer + rectifier nominal 180V= (max. 200V=),20V~/24V=
- For a multiple axes mounting with mains module
transformer 1x or 3x 115V~ (max.140V~) plus
1 x 20V~/24V=
- Output voltage max. 3x110~
Spezification
Device TVD3.2-115 5 10
Stationary current output - continuous A= 5 10
- peak A= 10 20
Max. el. power W 450 900
Integrated quick ZW fuses AF AF 12.5 - 16 16
Dimensions compact device wxhxd see "Dimensions"
plug-in device wxh 12TE/3HE 12TE/3HE
Cooling at 60% d.cyc self self
100% d.cyc. self fan
Mains module TVD3-N 100-30
Power supply V~ 1x or 3x 115V~ plus 1x 20V~/24V=
Output voltage V= max. 200
Output current A= max. 30
Regen circuit with V= 220
Ballast power W 100% 50
WS 6000
Common specification
Protection rating IP 00
Format VDE 0100 group C, VDE 0160
Humidity rating class F acc. to DIN 40040
Site of installation < 1000m above sea level
Operating temperature range 0 ... 45°C
Extended operating temp. range up to 60°C reduced by 2%/°C
Storage temperature range -30°C to + 80°C
Speed control loop circuit
- control precision without actual value error ± 0.5%
- control range 1: 1000
Caution: The maximum connection voltages 140V~, 200V=
must not be exceeded even for short times.
The regen circuit may be destroyed.
Technical Data

Servo - Drive TVD3.2 -xx- bl
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Compact device dimensions
Compact device
Transformer dimensions
Transf.
type
Transformer
power VA
Dimensions
a/b/c mm
Weight
kg
TE 8/2 100 85x 89x 82 2.0
TE 12/1 250 120x101x115 4.3
TE 12/3 400 120x133x115 6.8
TE 15/1 500 108x132x122 8.2
TE 15/3 800 150x150x132 13.5
TE 74/2 1300 175x140x160 15.4
TE 74/3 1600 175x150x160 18.5
Choke dimensions
TypeCurr.
A
Inductance Dimensions
mH a/b/c mm
Weight
kg
MDD 1.3a -2.5 3.5 80x 48x 90 1.1
MDD 1.6a -5 1.9 95x 54x108 1.3
MDD 1.6b -10 1.0 95x 58x108 1.4

2 Mechanical Installation
TVD3.2bl 9
Dimensions of a multiple axes combination
Multiple axes combination

Servo - Drive TVD3.2 -xx- bl
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Free

3 Electrical Installation
TVD3.2bl 11
Connections overview

Servo - Drive TVD3.2 -xx- bl
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Compact device
Connections diagram
Multiple axes combination

3 Electrical Installation
TVD3.2bl 13
EMC Advice
The devices adhere to the EU guidelines 89/336/EWG and the technical standards
EN 61000-2 and 61000-4 provided that the following conditions are observed:
- The device, the transformer, motor chokes and power line filter are conductively
mounted on a 500x500x2 mm mounting plate.
- The mounting plate must be connected to ground using a 10mm² wire.
- The motor housing must be connected to ground using a 10mm² wire.
- The device ground X1:7 must be connected to the mounting plate using a 2.5mm² wire.
- X10:1(-U) must be connected to the mounting plate using a 4mm² wire, l = 50mm.
- The rack ground screw must be connected to the mounting plate using a 4mm² wire,
l = 50mm.
Single-phase connection:
Transformer with filter type : TE8/2 F to TE17/3 F
Conductor length between the device and the power line filter <100mm
Three-phase connection:
Transformer with filter type : DT3/50 F to DT4/75 F
Motor connection:
Motor conductor choke type: 5A= MD66-5 10A= MD78-10
Motor conductor l = 1.5m, 4-core, shielded.
Shield must be connected to the mounting plate on the device side as well as to the
ground on the motor side.
Connection of the control conductors:
All control conductors must be shielded, 1.5m. Shield must be connected to the ground.
EMC Advice

Servo - Drive TVD3.2 -xx- bl
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Attention:
The order of the connections to the connector numbers or screw terminals is obligatory.
All further advice is non-obligatory.
The input and output conductors may be altered or supplemented in accordance with the
electrical standards.
Note:
- connection and operating instructions
- local regulations
- EU guideline 89/392/EWG
- VDE and TÜV regulations and Trade body guidelines
- CE and EMC advice
Connection with an isolating transformer
Note:
- The relay contacts must be rated according to the transformer switch-on current.
- Slow fuses must be installed at the input of the transformer
- The fuses must be rated according to the transformer current
- Quick fuses must be used at the output of the transformer
- The fuse value for each mains module is max. 30AF
Isolating transformer
Rated transformer power [VA]= 1.42 x 115 x IM x GLF x nF
IM = Sum of the motor currents (effective)
GLF = simultaneity factor
nF = speed ratio factor
GLF = nF =
1 with 1 motor effective speed
0.5 - 0.7 with 2 motors maximum speed
0.4 - 0.6 with > 2 motors
Connection compact device X3
Auxiliary voltage connection
terminal X3:6, X3:7
- from an external 24V
source
- from an isolating
transformer
Attention: The maximum voltage 140V~ must not be exceeded!
Isolating transformer
Mains connection
Attention:
Do not earth 24V~
Short-circuit to -UB
Connections

3 Electrical Installation
TVD3.2bl 15
Connection to the mains module X10
Alternating voltage Three-phase voltage
1x 115V + 24V 3x115V +24V
Connecting cable
Dimensioning 5A 10A Mains module max. 30A
Conductor cross-section mm² 0,5 0,75 2,5
Fuses
- safety fuse AF
- automatic cut-out A
10
10
16
16
30
30
Motor power connection
Cable no. PE M1 M2 M3
Connection PE bolt X3:1 X3:2 X3:3
Motor cable for 5A 10A thermal brake
Cross-section 0.75 1.5 0.5 0.5
Cable type 3x motor conductor + PE shielded
+ (if required: 2x thermo+2x brake)
Shielding
- with earth clamp
- directly to be connected to the switch cabinet input and to the motor
- multiple earthing in case of long conductor cables
Magnetic cores
- against HF failures
Motor chokes
- against LF failures
- against high leakage currents
- for motor efficiency
- for motor life
Auxiliary voltage connection
terminal X3:6, X3:7
- from the isolating transformer
- from an external 24V source
Attention:
Do not earth 24V~
Isolating transformer
Mains connection
Isolating-
transformer
Mains connection
Connections

Servo - Drive TVD3.2 -xx- bl
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The connection advice is a general information and it is non-obligatory.
Adhere to:
- connection and operating instructions
- local regulations
- EU guideline 89/392/EWG
- VDE and TÜV regulations and Trade body guidelines
Connection no. terminal connector
X1:1 to X1:7 and X2:8 to X2:14
Signal conductors
Shielded and separated from power conductors,
command value pairs twisted and shielded.
Logic connections
Relays with gold contacts or reed relays. Contact current 6mA
Drive enable - internal logic voltage
- internal logic voltage X1:1 +15V/10mA
- contact circuit between X1:1 and X1:2
Drive enable - external logic voltage
- drive enable voltage +10 to +30V X1:2
- GND X1:7
Drive enabled
- command value and speed control loop circuit are immediately active
Drive disabled
- emergency stop
- command value >>> switched internally immediately to 0
- after 2 seconds >>> speed control loop circuit is de-activated
Braking in case of a mains failure
Braking function
- command value switched to 0V in case of a mains failure
- max. braking time 150ms
Feed-back to the bus circuit
Connection advice

3 Electrical Installation
TVD3.2bl 17
Speed command value
Voltage source for command values ±10V, 10mA
+10V X1:3
-10V X1:5
GND X1:7
Command value inputs
- command value voltage max. ±10V=
- differential input
- input resistance 50 kW
- relay contacts: use gold or reed contacts
Attention:
Command value pairs should be twisted and shielded.
The shield should be connected on one side only.
Connections
Command value with an internal voltage source
Command value X1:4 (signal)
X1:7 (GND)
Bridge X1:6 — X1:7
Command value from an external PLC/CNC voltage
Command value X1:4 (signal)
X1:6 (GND)
Command value current from an external PLC/CNC
Resistor for a current command value of 0 to ±20mA Rcom. = 500W
Current command value X1:4 (signal)
X1:6 (GND)
Internal supply CNC/PLC Current command value
Attention: Do not use a command value current of 4 to 20mA !
Command Value

Servo - Drive TVD3.2 -xx- bl
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External current limiting
Voltage source for an external current limit
+10V/10mA X1:13
GND X1:7
Range
0 ... + 5V >> 0 to 100% rated device current
0 ... +10V >> 0 to 200% rated device current
internal over-current watchdog >> max. 5sec.
Current limit input
Max. input voltage +10V
Input resistance 10 kW
Internal attenuation with potentiometer Imax1
Relay contacts: use gold or reed contacts
Switch S1, contact 2 = OFF
Connections
Current limit X2:13 (signal)
X1:7 (GND)
Internal source CNC/PLC Current command value
Attention:
When internally adjusting the current limit
Switch S1 >> contact 2 = ON
Current Limiting

3 Electrical Installation
TVD3.2bl 19
Actual value connection
Connector X7
- 15-pin D-connector
- metallized plastic housing
- shield connected to the housing
Cable: up to 10m 12 x 0.14 shielded
> 10m 12 x 0.25 shielded
Connections
Function Colour (recommended) Pin no.
Bl-tacho mp grey 1
Bl-tacho phase 1 yellow 2
Bl-tacho phase 2 black 3
Bl-tacho phase 3 white 4
+15V violet 10
GND blue 6
Thermal sensor pink 6
Thermal sensor orange 12
Rotor position 1 brown 13
Rotor position 2 green 14
Rotor position 3 red 15
Additional connection when using a dc tacho:
-15V grey 7
dc tacho signal yellow 9
dc tacho GND black 8
(The BL-tacho connections at pin no. 1 and 4 are removed)
Pin no. 6 is double-coated.
For motors without thermal sensor >>> bridge between pin no. 6 and 12
Attention:
It is absolutely necessary to observe the motor-specific connection
data sheets. (Appendix A)
Encoder connection - bl

Servo - Drive TVD3.2 -xx- bl
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Drive ready - BTB signal
Relay RL1
Signal contact X2:11 - X2:12
Switch rating max. 48V, 0.5A
The BTB contact signals to the PLC/CNC that the drive is functional.
The BTB signals of several axes can be connected in series.
Delay time after switching on the power supply >> max. 1sec.
Display
Drive ready LED bright green contact closed
Drive not ready LED dim green contact open
Fault LED bright red contact open
BTB contact drops in case of
over-temperature controller, motor not saved
over-voltage saved
short-circuit, short-circuit to earth saved
voltage error not saved
bus circuit error not saved
To clear the error re-enable the drive (switch off/on)
Attention:
In any case the BTB contact (drive ready) must always be used with the CNC/PLC or
wired into the emergency stop circuit.
It is possible that the drive initiates motion without being instructed to do so.
Fault memory
Fault saving is not effective for all errors!
Signal blocked
Current demand Normal overload
Output X2:14 >+10V <+2V
Analog parameter measurement outputs
Function Motor current Speed
Connector X2:9 - X1:7 X2:8 - X1:7
Measured value Type current
peak current
2.5V
5.0V
unipolar positive
tacho voltage at the input
of the divider
bipolar
Output resistance 1kW4.7 kW
Signals