^1 INSTALLATION MANUAL GEO DIRECT PWM AMPLIFIERS PRELIMINARY DOCUMENTATION ^2 ^3 Direct PWM ^4 500-603700-xIxx ^5 July 29, 2003 Single Source Machine Control Power // Flexibility // Ease of Use 21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.
Copyright Information Original printing 2003. Copyright Delta Tau Data Systems, Inc. - All rights reserved. Printed in the United States of America. Notice: Not for use or disclosure outside of Delta Tau Data Systems, Inc. except under written agreement. All rights reserved. No part of this book shall be reproduced, stored in retrieval form, or transmitted by any means, electronic, mechanical, photocopy, recording, or otherwise without the written permission from the publisher.
Safety Instructions Qualified personnel must transport, assemble, install, and maintain this equipment. Properly qualified personnel are persons who are familiar with the transport, assembly, installation, and operation of equipment. The qualified personnel must know and observe the following standards and regulations: IEC 364 resp.
GEO Direct PWM Amplifiers – Preliminary Documentation Table of Contents Copyright Information................................................................................................................................................i Customer Support.......................................................................................................................................................i Safety Instructions....................................................................................
GEO Direct PWM Amplifiers – Preliminary Documentation Minimum Resistance Value.................................................................................................................................23 Maximum Resistance Value ................................................................................................................................23 Energy Transfer Equations........................................................................................................................
GEO Direct PWM Amplifiers – Preliminary Documentation OVERVIEW Delta Tau Data Systems’ new family of servo amplifiers GEO Drives provide exciting new capabilities. This family of one axis and two axes 3-phase amplifiers can support a wide variety of motor types, power ranges, and interfaces. They will operate directly off the power mains (115- 480 VAC) for motor power and an external power supply of +24 volts DC for logic power.
GEO Direct PWM Amplifiers – Preliminary Documentation • • PMAC Drives — The GEO Drive becomes a standalone-capable controller/drive with storedprogram capability. It contains a “Micro PMAC” controller that provides a subset of PMAC capabilities with full positioning and trajectory capabilities, with synchronization to other drives and/or external encoders.
GEO Direct PWM Amplifiers – Preliminary Documentation Some basic equations can help guide an applications engineer to mate a proper drive with a motor. A typical application accelerates a load to a speed, running the speed for a while and then decelerating the load back into position. Feedback Devices Many motors incorporate a position feedback device. Devices are incremental encoders, resolvers, and sine encoder systems.
GEO Direct PWM Amplifiers – Preliminary Documentation Motor Poles Usually, the number of poles in the motor is not a concern to the actual application. However, it should be noted that each pole-pair of the motor requires an electrical cycle. High-speed motors with high motor pole counts can require high fundamental drive frequencies that a drive amplifier may or may not be able to output.
GEO Direct PWM Amplifiers – Preliminary Documentation Motor Cabling Motor cables are an integral part of a motor drive system. Several factors should be considered when selecting motor cables. First, the PWM frequency of the drive emits electrical noise. Motor cables must have a good-quality shield around them. The motor frame must also have a separate conductor to bring back to the drive amplifier to help quench current flows from the motor due to the PWM switching noise.
GEO Direct PWM Amplifiers – Preliminary Documentation 6 Overview
GEO Direct PWM Amplifiers – Preliminary Documentation UNPACKING Open the box and remove all the contents. Remove all packing material and equipment from the shipping container. Be aware that some connector kits and other equipment pieces may be quite small and can be accidentally discarded if care is not observed when unpacking the equipment. Do not dispose of shipping materials until the packing list has been checked.
GEO Direct PWM Amplifiers – Preliminary Documentation Part Number 8 Unpacking
GEO Direct PWM Amplifiers – Preliminary Documentation Hardware Specifications Controller Model Unit Weight lbs / Kgs English Mounting (Metric) Hardware Applied Torque Line Screw Connection Size/Torque Hardware Motor Screw Size/Torque Ground Screw Size/Torque Control Logic (AWG/ mm2) Motor Line (AWG/ mm2) Main Input (AWG/ mm2) Configurable Wire Size I/O wire (AWG#) gauge Spade Terminals Ring Terminals Clearance Side-to-Side Distance Top/Bottom Unpacking GEO PWM 5.75 lbs. M (rack mount) GEO 3U PWM 3.
GEO Direct PWM Amplifiers – Preliminary Documentation Electrical Specifications (GxL012, GxL032, GxL052, GxL101, GxL151) Product Model Nominal Input Voltage (VAC) Rated Input Voltage (VAC) Rated Continuous Input Current (A ACRMS) Rated Input Power (KVA) Frequency (Hz) Phase Requirements Charge Peak Inrush Current (A) Main Input Peak Line Current (A) for 2 Sec Power Main Bus Capacitance (µf) Mains Wire Gauge (AWG) Output Circuits (axis) Rated Output Voltage (V) Rated Cont.
GEO Direct PWM Amplifiers – Preliminary Documentation (GxH012, GxH032, GxH052, GxH101, GxH151) Product Model Nominal Input Voltage (VAC) Rated Input Voltage (VAC) Rated Continuous Input Current (A ACRMS) Rated Input Power (KVA) Frequency (Hz) Phase Requirements Charge Peak Inrush Current (A) Main Input Peak Line Current (A) for 2 Sec Power Main Bus Capacitance (µf) Mains Wire Gauge (AWG) Output Circuits (axis) Rated Output Voltage (V) Rated Cont.
GEO Direct PWM Amplifiers – Preliminary Documentation Recommended Fusing Model Recommended Fuse (FRN/LPN) GxL012x 20 GxL032x 25 GxL052x 20 GxL101x 20 GxL151x 25 GxH012x 10 GxH032x 15 GxH052x 20 GxH101x 20 GxH151x 25 * See local and national code requirements Recommended Wire Gauge* 12 AWG 10 AWG 12 AWG 12 AWG 10 AWG 14 AWG 12 AWG 12 AWG 12 AWG 10 AWG Mating Connector Kits Connector Kit Description CONKIT1A Mating Connector Kit for drives up to 5 amp continuous rating (Gxx012, Gxx032, Gxx052): Includ
GEO Direct PWM Amplifiers – Preliminary Documentation MOUNTING The GEO drive is installed in an enclosure whose ambient temperature does exceed 45 °C. It must not be exposed to conductive dust or humidity in excess of 90%. Corrosive gasses, corrosive dust, and other contaminants must be kept out of the drive enclosure. The figure below shows the mounting dimensions of the drive.
GEO Direct PWM Amplifiers – Preliminary Documentation The drive is mounted to a back panel. The back panel should be unpainted and electrically conductive to allow for reduced electrical noise interference. The back panel is machined to accept the mounting bolt pattern of the drive, make sure that all metal chips are cleaned up before the drive is mounted so there is no risk of getting metal chips inside the drive. The drive is mounted to the back panel with four M4 screws and internal-tooth lock washers.
GEO Direct PWM Amplifiers – Preliminary Documentation Bonding The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels. The bonding effect is to reduce the impedance between the cable shield and the back panel. Power input wiring does not require shielding (screening) if the power is fed to the cabinet (enclosure) via metallized conduit.
GEO Direct PWM Amplifiers – Preliminary Documentation Motor Line Filtering Motor filtering may not be necessary for CE compliance of GEO Drives. However, this additional filtering increases the reliability of the system. Poor non-metallic enclosure surfaces and lengthy, unbonded (or unshielded) motor cables that couple noise line-to-line (differential) are some of the factors that may lead to the necessity of motor lead filtering. Motor lead noise is either common-mode or differential.
GEO Direct PWM Amplifiers – Preliminary Documentation SYSTEM WIRING Caution Units must be installed in an enclosure that meets the environmental IP rating of the end product (ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 113° F [45° C]).
GEO Direct PWM Amplifiers – Preliminary Documentation WARNING Installation of electrical control equipment is subject to many regulations including national, state, local, and industry guidelines and rules. General recommendations can be stated but it is important that the installation be carried out in accordance with all regulations pertaining to the installation. Wire Sizes Drive electronics create a DC bus by rectifying the incoming AC electricity.
GEO Direct PWM Amplifiers – Preliminary Documentation Noise Problems When problems do occur often it points to electrical noise as the source of the problem. When this occurs, turn to controlling high-frequency current paths. If following the grounding instructions does not work, insert chokes in the motor phases. These chokes can be as simple as several wraps of the individual motor leads through a ferrite ring core (such as Micrometals T400-26D).
GEO Direct PWM Amplifiers – Preliminary Documentation The AC connections from the fuse block to the GEO drive are made via a cable that is either purchased as an option from Delta Tau (CONKIT1 or CONKIT1A) or the terminations to the connector may be made as shown in Appendix A.
GEO Direct PWM Amplifiers – Preliminary Documentation 24V Logic Supply Connector Pin Out Pin # Symbol Function Description Notes 1 2 24V RTN 24V Common Input Control power return Control power input 24V+/-10% 3 Amp Wiring the Motors The cable wiring must be shielded and have a separate conductor connecting the motor frame back to the drive amplifier. The cables are available in connector kits (CONKIT1 or CONKIT1A) from Delta Tau or the terminations can be made as described in Appendix A.
GEO Direct PWM Amplifiers – Preliminary Documentation Regen (Shunt) Resistor Wiring The Geo Drive family offers compatible regen resistors as optional equipment. The regen resistor is used as a shunt regulator to dump excess power during demanding deceleration profiles. The GAR48 and GAR78 resistors are designed to dump the excess bus energy very quickly. The regen circuit is also known as a shunt regulator. Its purpose is to dump power fed back into the drive from a motor acting as a generator.
GEO Direct PWM Amplifiers – Preliminary Documentation Ext. Shunt Connector Pin Out Pin # Symbol Function 1 2 Ext regen+ Ext regen- Output Output Shunt Regulation When the motor is used to slow the moving load, this is called regenerative deceleration. Under this operation, the motor is acting as a generator consuming energy from the load while passing the energy into the DC Bus storage capacitors. Left unchecked, the DC Bus voltage can raise high enough to damage the drive.
GEO Direct PWM Amplifiers – Preliminary Documentation Where: J is the total system inertia (including motor) in lbftsec2 ω is the velocity of the motor in Radians per Second eL is the stored energy, in Joules (watt-seconds), of the load Energy Loss in Transmission The energy loss in the transmission of the energy occurs in two distinctive areas. First, the motor’s resistance burns energy in simple watts. Second the mechanical gearing, bearings, and linkages present a frictional loss.
GEO Direct PWM Amplifiers – Preliminary Documentation Regen Resistor Wattage Converting this energy into wattage can allow the rating of the regen resistor to be analyzed. The unit of Joule is converted to wattage by dividing by the duty cycle of the overall motion profile. Watts rms = eexcess td Where: Td is the motion profile duty cycle, in seconds.
GEO Direct PWM Amplifiers – Preliminary Documentation 26 System Wiring
GEO Direct PWM Amplifiers – Preliminary Documentation DIRECT PWM COMMUTATION CONTROLLER SETUP The 3U amplifier must have the proper controller setup to command the amplifier/motor system. This section summarizes the key variables of both Turbo and Non Turbo PMAC2 controllers that would have to be modified for use with the amplifier. The Delta Tau setup software such as Turbo Setup will help set these parameters for the system automatically.
GEO Direct PWM Amplifiers – Preliminary Documentation Key Motor Variables CAUTION The ADC Strobe Word, I7m06, must be set to $3FFFFF for proper operation. Failure to set I7m06 equal to $3FFFFF could result in damage to the amplifier.
GEO Direct PWM Amplifiers – Preliminary Documentation DIRECT PWM INTERFACE WIRING PWM Cables UMAC Accessory Cables ACC-24E UMAC RACK OPT-5A PWM Cable, 600 mm (24) inches long 200-602739-024x OPT-5B PWM Cable, 900 mm (36 inches long) 200-602739-036x OPT-5C PWM Cable, 1.5 m (60 inches) long 200-602739-060x OPT-5D PWM Cable, 1.8 m (72 inches) long 200-602739-072x OPT-5E PWM Cable, 2.1 m (84 inches) long 200-602739-084x OPT-5F PWM Cable, 3.
GEO Direct PWM Amplifiers – Preliminary Documentation PWM Input 1 PWM 1 (36-Pin Mini-D Connector) ___________________________ 36-Pin Mini-D Connector Controller/Drive Connectors 18 \ • • • • • • • • • • • • • • • • • • / 1 36-pin Mini-D Receptacle 36 \ • • • • • • • • • • • • • • • • • • / 19 Pin# Symbol 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Reserved Reserved ADC_CLK1+ ADC_STB1+ CURRENTA+ CURRENTB+ AENA1+ FAULT1+ PWMATOP1+ PWMABOT1+ PWMBTO
GEO Direct PWM Amplifiers – Preliminary Documentation SETTING I2T PROTECTION It is very important to set the I2T protection for the amplifier/motor system for PMAC2 direct PWM commutation. Normally, an amplifier has internal I2T protection because it is closing the current loop. When PMAC2 is closing the current loop, the amplifier cannot protect itself or the motor from over heating.
GEO Direct PWM Amplifiers – Preliminary Documentation 32 Troubleshooting
GEO Direct PWM Amplifiers – Preliminary Documentation CALCULATING MINIMUM PWM FREQUENCY The minimum PWM frequency requirement for a system is based on the time constant of the motor. Calculate the minimum PWM frequency to determine if the amplifier will properly close the current loop. Systems with very low time constants need the addition of chokes or in-line inductive loads to allow the PMAC to properly close the current loop of the system.
GEO Direct PWM Amplifiers – Preliminary Documentation 34 Troubleshooting
GEO Direct PWM Amplifiers – Preliminary Documentation TROUBLESHOOTING Error Codes In most cases, the GEO Drive communicates error codes with a text message via the serial port to the host. Some error codes are also transmitted to the Status Display. The same message is saved in the EEPROM under an error history log (FLTHIST, ERR) so nothing is lost when power is removed. Not all errors reflect a message back to the host. In these cases, the no-message errors communicate only to the Status Display.
GEO Direct PWM Amplifiers – Preliminary Documentation A Motor Over Temp Axis 2 B Over Voltage. C Under Voltage D Shunt Regulator Fault E Ground Fault F Gate Drive Power Fault Normally-closed input on the front of the GEO drive amplifier connector X3 is detected in open circuit between pins 3 and 4. The bus voltage has exceeded a factor pre-set threshold of 820V for 480V drives or 420V for 230V drives. Lack of ability to dump the regenerated energy from the motor.
GEO Direct PWM Amplifiers – Preliminary Documentation APPENDIX A Motor Cable Information Cable sets (motor and feedback) can be purchased directly from Delta Tau Data Systems, Inc., to provide a complete plug-n-play system. Available cables are listed below.
GEO Direct PWM Amplifiers – Preliminary Documentation 38 AppendixA
GEO Direct PWM Amplifiers – Preliminary Documentation Appendix A 39
GEO Direct PWM Amplifiers – Preliminary Documentation 40 AppendixA
GEO Direct PWM Amplifiers – Preliminary Documentation Appendix A 41
