Unitek TVD6-200bl User manual

MANUAL
3-phase Transistor Servo-Drive
TVD6-200bl, TVD6.2-400-bl
for brushless DC Motors
with Rotor Position Encoder
TVD6-bl, TVD6.2bl
Version
0108-1

2
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Contents Page
1. Basic Information
Safety advice 3
Standards and guidelines 3
General information 4
Applications 5
Features 6
Technical data 7,8
2. Mechanical installation
Dimensions 9,10
Build 11
Mounting advice 12
3. Electrical installation
Connections 13,14
Earthing diagram 15
EMC advice 15
Power connections 16,17
Connection to the TT and IT mains 18
Motor power connections 19
Control connections 20-25
Signal outputs 26, 27
Terminal connections and connectors 28, 29
4. Device overview
Components 30
Circuit diagram 31
Front panel 32
Adjustments 33
LED signals 34
5. Adjustments
Adjustment advice 35
Command value 36
Speed actual value 37
Current limiting 38
Speed control loop circuit 39-41
6. Commissioning
Basic set-up 42
Commissioning 43
7. Faults
LED displays - faults 44
Fault diagnosis 45
Pulse signals - test point connector X4 46
Encoder signals 47
9. Protocol 49, 50
10. Drawings 51, 52
Contens

TVD6-200bl, TVD6.2-400bl 3
1 Basic Information
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.
TVD6 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 in-
dependent 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
Assembly
- 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.
Atention High voltage
TVD6bl AC 250V~, DC 420V=
TVD6.2bl AC 400V~, DC 800V=
Safety advice

4
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
General Information
The transistor 3-phase current servo amplifier SERVO-TVD6 and TVD6.2 in combination
with the brushless dc motor (synchro servo motor, CE 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 nota-
bly 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, therefore, the bl-motors always have the protection rating IP
65.
From the electrical view, the brushless dc 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, i.e., the current is propor-
tional to the torque and the voltage is proportional to the speed. Current and voltage
are precisely measured, thus the analog circuits are simply constructed.
It is possible to control the speed via the motor voltage, however, in order to achieve
the best control precision, a tacho control is always used. The speed actual value is ge-
nerated in the encoder unit (rotor position encoder plus brushless 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 com-
mand 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 mag-
netic field by 90° electrically.
This field frequency is not controllable, it is automatically adjusted.
The motor currents are trapezoidal.
For dc, ac, or bl-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.
Information:
For motors with incremental encoder UNITEK TVD3-2-xx-IN
with resolver UNITEK TVD3-2-xx-RS
with bl-tacho UNITEK TVD3-2-xx-bl
For low-voltage applications UNITEK TVD3-230-xx-bl
UNITEK TVD3-230-xx-IN
UNITEK TVD3-230-xx-RS
For high power UNITEK TVD6-2 -bl,IN,RS
200V/400V up to 25/40A
For digital servo controllers UNITEK DS400
200V/400V up to 50/100A
General Information

TVD6-200bl, TVD6.2-400bl 5
1 Basic Information
Applications
Machines and installations for all types with a drive power of
4 kW using TVD6-200bl
8 kW using TVD6.2-400bl,
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
For speed or torque control or combined speed/torque control incorporated wit-
hin or independent of position control loops.
Drives with constant speed as in conveyors, spindle drives, pumps, transversal or
longitudinal pitch drives.
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:
Bl-drives where braking operations are predominant, e.g. when dece-
leration 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

6
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Build
- switch cabinet mounting or 6HE plug-in device
according to the VDE, DIN and EU regulations
- standard analog control electronics
- power electronics for 10A, 16A, and 25A
- wide-band chopper power supply unit for the auxiliary voltages
- power section on the rear panel
Galvanic isolation between
- the power section and the housing
- the power section and the control electronics
- the control electronics and the logic inputs
The distance of air gaps and leakage paths adhere to the VDE standards.
Components
- fully insulated six-pack IGBT power semiconductors, comfortably over-dimensioned
- only components customary in trade and industrially standardised are used
- high-quality bases for the IC with external connections
- LED displays
- 16-position binary switches for the P-I adjustment of the speed controller
- precision potentiometers for fine adjustments
- plug-in jumpers for the system set-up
Characteristics
* TVD6-200bl: connection directly to the mains 230V~
* TVD6.2-400bl: connection directly to the mains 400V~
* electronic limitation of the switch-on current
* 2 differential command value inputs
* start-up and braking ramp for the 2
nd
command value
* speed and torque control
* static and dynamic current limiting
* current command value output
* measurement points for current and speed
* optically de-coupled logic inputs and outputs
* logic for enable and the output stage switch
* switch-off of the integral function
* emergency stop
* braking in case of a mains failure
* temperature watchdog for the motor and the device
* solderless parameter adjustment
* 10-pin test point connector
Features

TVD6-200bl, TVD6.2-400bl 7
1 Basic Information
Technical Data
Technical Data
Power connection TVD6-200bl:
directly to the mains 1 x 230V~ +
10% using an auto-transformer 3 x 230V~
+ 10%
Specification
Servo amplifier TVD6-200 10 16 25
Output voltage V~eff. 200 200 200
Stationary current output - continuous
- peak
A= 10 16 25
A= 20 32 40
Max. el. power kW 2 3.2 5
Integrated quick ZW fuses A 20 20 20
Dimensions: - compact device w x h x d see dimension sheet
- plug-in unit w x h 16TE/6HE 16TE/6HE 24TE/6HE
Cooling at 60% duty cycle self self external
at 100% duty cycle external external external
Power connection TVD6.2-400bl:
directly to the mains 1 x 400V~
3 x 400V~
max. 460V~
Option: for voltages < 300V~ >> please inquire
Specification:
Servo amplifier TVD6.2-400- 5 10 16 25
Output voltage V~eff. 400 400 400 400
Stationary current output
- continuous
- peak
A=
A=
5
10
10
20
16
32
25
40
Max. el. power kW 2 4 6,4 10
Integrated quick ZW fuses A 20 20 20 20
Dimensions - plug-in unit w x h 6HE 16TE 16TE 16TE 24TE
Cooling at 60% duty cycle
at 100% duty cycle
external
external
external
external
external
external
external
external
Switch cabinet plug-in module w x h x t see dimension sheets

8
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Technical Data
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 to 45°C (0 to 35°C when
using external fans)
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 act.value error ± 0.1%
control range >1: 1000
Command value inputs ± 10V=
Logic inputs +10 to +30V=
Logic inputs >+14V, 6mA
Note:
Necessary information to be indicated when ordering TVD6-200bl:
Check the switch-on time >>> external fan for 100% duty cycle
Multiple 16A axes on one rack >>> use an external fan
Precise torque control >>> current controller as P-I loop
circuit
Large centrifugal mass >>> external ballast resistance>27W
Necessary information to be indicated when ordering TVD6-400bl:
Check the switch-on time >>> external fan for 100% duty cycle
Multiple axes with >=10A on one rack >>> use an external fan
Precise torque control >>> current controller as P-I loop
circuit
Large centrifugal mass >>> external ballast resistance
Input voltages
Technical Data

TVD6-200bl, TVD6.2-400bl 9
2 Mechanical Installation
Dimensions
Compact- 10 and 16A 25A device case case or lateral angle bracket

10
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Dimensions
Multiple - axes combination
Dimensions 6HE [mm]
Dimensions of the modules 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
Device frame
E for <= 16 A >>> 81.28 mm
E for 25A >>> 121.92 mm
Mounting depth 255 mm
For front mounting the lateral angle bracket is to be fixed on the front side, for
wall mounting it is to be fixed on the rear side.

TVD6-200bl, TVD6.2-400bl 11
2 Mechanical Installation
Rear panel of the mains module
with the module insertion (without supporting frame)
Mains module adjustments
external ballast resistance bridge D1 open
Supporting frame
Height units: 6HE
Splitting units: 10/16A = 16TE, 25A = 24TE
Mixed 6HE, 3HE (TVD3.2): supporting frame on request
Build

12
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Mounting depth 255mm Compact device 10/16A Compact device 25A (sw)
Compact device 25A (w) Multiplex axes combination
Mounting advice
Bore hole dimensions of the compact devices [mm]
Current A B C D E Screw
10, 16 case 95 335 M4
25-w case 135 335 M4
25-sw lat.angle bracket 180 158 190.5 55 M5
Bore hole dimensions of the multiple axes combinations [mm]
Lateral angle bracket A C D E Screw
Wall mouting n x E+60 n x E+40 190,5 55 M5
Front mounting bei 19" systemen
E for <=16A = 81.28 mm
E for 25A = 121.92 mm
n = No. of axis modules
Power loss at max. power
Device
current
Power loss [W]
Amplifier Mains module 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
Free space to the switch cabinet wall at least 100mm.

TVD6-200bl, TVD6.2-400bl
13
3 Electrical Installation
Choke
Device current Power line filter
1ph 3ph
Motor choke
TVD6-200
Motorchoke
TVD6.2-400 Magnetic core
5A FE1-10 FE3-10 - MDD 1,3a EMI742 70107
10A FE1-16 FE3-16 MD78-10 MDD 1,6a EMI742 70107
16A FE1-16 FE3-16 MD84-20 MDD 2 b EMI742 70107
25A —- FE3-25 MD84-30 MDD 2,5b EMI742 70107
Connections

14
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Connections
Compact device connection: only left figure without internal connections Multiple-axis combination: one or multiple axis with a mains module plus one or multiple axis without any mains module; optional position of the mains module

TVD6-200bl, TVD6.2-400bl
15
3 Electrical Installation
CE Advice Earting diagram
The devices adhere to the EU guidelines 89/336/EWG and the technical standards EN 610001-2
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 X1:13 must be connected to the mounting plate using a 2.5mm² wire.
- Device PE screw must be connected to the mounting plate using a 4mm² wire, l =50mm.
Single-phase connection:
Power line filter type : up to 16A = FE1-16
Conductor length between the device and the power line filter <100mm
Three-phase connection:
Power line filter type : up to 16A = FE3-16
up to 25A = FE3-25
Conductor between the transformer and the power line filter <500mm.
Conductor between the device and the power line filter <100mm.
Motor connection:
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:
control conductors must be shielded, 1.5m. Shield must be connected to the ground.
Types of motor lines chokes
TVD6-200bl TVD6.2-400bl
5A - MDD 1.6b-10
10A MD78-10 MDD 1.6b-10
16A MD84-20 MDD 2 b-20
25A MD84-30 MDD 2.5b-30

16
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Attention:
The order of the connections to the connector numbers or screw terminals is ob-
ligatory. 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
Input filter:
rf. to the CE advice, page 16
Short conductor length to be used between the input filter and the device or
a shielded conductor to be used.
FI switch:
- layout acc. to the DIN standard VDE 0664
- release current >200mA
- only in combination with further protection measures
TVD-200bl Connection to the 230V~ mains
AC voltage connection 1 x 230V~, 50/60Hz
Compact device up to 10A
Multiple axes combination up to 20A
Three-phase voltage connection 3 x 230V~, 50/60Hz
for >10A the multiple axes rack 20A is required
TVD.2-400bl Connection to the 400V~ mains (T-NC mains power supply system)
for asymmetrical or unearthed power supply systems the connection
must only be effected via an isolating transformer
AC voltage connection 1 x 400V~, 50/60Hz
Compact device up to 10A
Multiple axes combination up to 20A
Three-phase voltage connection 3 x 400V~, 50/60Hz
for >10A the multiple axes rack 20A is required
Dimensioning 10A 16A 25A max. 30A
Conductor cross-section mm² 0.75 1.5 2.5 2.5
Fuses - safety fuse Aff
- automatic cut-out
(release feature A, acc. to EN60898)
10
10
16
16
25
25
30
25
Input fuses >>> semi-conductor fuses or semi-conductor automatic cut-outs
Power connections

TVD6-200bl, TVD6.2-400bl
17
3 Electrical Installation
Connection with a transformer
- AC or three-phase voltage connection
- Auto-transformer or isolating transformer
(additional over-voltage protection provided)
- One transformer for multiple devices
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
Transformer power: examples
TVD6-200bl TVD6.2-400bl
Autotransformer
Transformer rated power [VA]=
0.6 x 230 x IM x GLF x nF
Isolating transformer
Transformer rated power [VA]=
1.42 x 230 x IM x GLF x nF
Autotransformer
Transformer rated power [VA]=
0.2 x 400 x IM x GLF x nF
Isolating transformer
Transformer rated power [VA]=
1.25 x 400 x IM x GLF x nF
IM = Sum of the motor currents (effective)
GLF = simultaenity factor
nF = speed ratio factor
GLF = nF =
1 with 1 motor effective speed
0.5 ... 0.7with 2 motors maximum speed
0.4 ... 0.6with > 2 motors
ac voltage three-phase voltage
Power connections

18
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
Isolating
transformer
Mains filter
Isolating
transformer
Mains filter
Power connections
Note:
For power supply systems without protective conductors the connection must only
be effected via an isolating transformer!!!
Connection to the TT mains
TT mains:
Symmetrical three or four con-
ductor three-phase mains with
direct earthing.
Device PE via the earthing con-
nection.
Connection to the IT mains
IT mains:
Symmetrical three or four con-
ductor three-phase mains wit-
hout direct earthing.
Device PE via the earthing con-
nection.
Attention:
If the TVD6-Servo is directly
connected and the transformer
primarily switched, it is neces-
sary to connect an additional
over-voltage protection device
(e.g. TRABTECH).

3 Electrical Installation
TVD6-200bl, TVD6.2-400bl
19
Motor connections
Motor power connection
Cable no. PE M1 M2 M3
Connection X3 X3:6 X3:7 X3:8 X3:9
Terminal X3:6 is internally connected to the PE connection bolt of the device
Motor cable for 5A 10A 16A 25A Thermo Brake
Cross-section 0.75 1.5 1.5 2.5 0.75 0.75
Cable type 3 x shielded motor conductor + PE
(+ if required: 2 x thermo + 2 x 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
External ballast resistance
Dimensioning:
Mean value of the braking power per axis
1 x Jg x n² Jg² x a x n
P
Ballast
[W] = ————————— - ————————— x f
2 M
M
Jg = reduced motor and load moment [kgm²]
n = max. speed [s
-1
]
M
M
= max. motor torque [Nm]
a = delay time [s
-2
]
f = repetition frequency of the braking [s
-1
]
Modify on the rear panel of the mains module:
Remove soldered bridge D
TVD6-200bl TVD6.2-400bl
External ballast resistor smallest resistance value 22Wsmallest resistance value 40W
Installed ballast resistor 20W/ 50W, for 3%d.cyc. = 1.5
kW
42W/ 50W, for 3%d.cyc. = 1.5
kW

20
Transistor Servo-Drive TVD6-200bl, TVD6.2-400bl
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. of the terminal connectors
X1:1 to X1:16 and X2:17 to X2:32
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.
Internal logic voltage 15V=
- Potential connection
- for relay control
- Jumpers J1 and J3 plugged-in
External logic voltage
- Potential isolation
- for PLC or CNC
- UEXT +15V to 30V= across terminal X2:27
- GNDE across terminal X1:11
- Jumpers J1 and J3 not plugged-in
- residual ripple of the logic voltage <20%
Basic set-up: Jumpers J1 and J3 are plugged-in.
Inputs and outputs via an optocoupler.
Control connections