MicroDS The motion solution INSTALLATION and USER S GUIDE Revision B June 12

Transcription

1 MicroDS The motion soution INSTALLATION and USER S GUIDE Revision B June 12

2 CONTENTS & INTRODUCTION MicroDS User's Manua Revision Date Description Updated Pages A June 2003 C B June 2012 MicroDS Instaation and User s Guide C Revision B, June 2012 Suggestions, corrections and comments shoud be sent to: Moog Itaiana S.r.. Moog Inc., Moog GmbH, Eectric Division East Aurora, Hans Kemm Strae Via Avosso 94 New York 14052, D Bobingen, Casea (Genova) USA. Germany. Itay PAGE I-1

3 MicroDS User s Manua CONTENTS & INTRODUCTION I1 TABLE OF CONTENTS and INTRODUCTION I1 TABLE OF CONTENTS and INTRODUCTION 2 I2 INTRODUCTION 5 I2.1 USING THE MANUAL 6 I2.2 Safety 8 I2.3 Decaration of Conformity (EC) 10 I2.4 CE Requirements 11 I2.5 LEGAL ASPECTS 12 SECTION 1 DESCRIPTION INTRODUCTION PRODUCT RANGE GENERAL FEATURES TECHNICAL DATA Genera features Interfaces Recovery Circuit CODES OPTIONS DIMENSIONS AND DRILLING JIG CONNECTION CABLES EXTERNAL FUSES POWER DISSIPATION SOFT START FANS RESET BUTTON POWER LINKS AND CONNECTORS Power input votage connectors V Auxiiary votage Motor power connector Mains Votage Suppy SINGLE PHASE OPERATION PARALLEL DC BUS OPERATION Recovery circuit CONTROL CARD LINKS AND CONNECTORS Encoder input connector Resover input connector G400 and G330 motors resover wiring Input References Connector Drive enabe connector Encoder Connector (output) RS485 Seria ink Drive Starting Sequence Dynamic Braking MECHANICAL BRAKING 43 PAGE I-2

4 CONTENTS & INTRODUCTION MicroDS User's Manua SECTION 2 INSTALLATION INTRODUCTION INSTALLATION REQUIREMENTS ELECTROMAGNETIC COMPATIBILITY EUROPEAN DIRECTIVE EMC (89/336/EEC) FILTERING Fiter types FILTERS MECHANICAL DIMENSIONS Fiter instaation Wiring and shieding Recovery resistor Shieding Safety Aspects Summary of Connection Instructions Feedback connection (encoder or resover) Temporary / test power wiring Summary of power wiring 14 SECTION 3 STARTUP INTRODUCTION DRIVE SETTING UP INFORMATION First start-up (on test bench, for testing purposes) Configuration for instaation in the eectrica cabinet. 3 SECTION 4 OPERATION INTRODUCTION GENERAL PRINCIPLES Input eectric power conversion Output eectric power conversion Contro section High Speed operation CONTROL LOOPS OPTIMIZATION Current oop optimization Speed oop optimization 5 SECTION 5 COMMANDS DESCRIPTION MOTOR PARAMETERS MENU DESCRIPTION OF MOTOR PARAMETERS Description of Resover parameters Description of Encoder Parameter DRIVE PARAMETERS MENU DESCRIPTION OF DRIVE PARAMETERS CONTROL LOOPS PARAMETERS MENU DESCRIPTION OF CONTROL LOOPS PARAMETERS SPEED LOOP PARAMETERS 17 PAGE I-3

5 MicroDS User s Manua CONTENTS & INTRODUCTION CURRENT LOOP PARAMETERS Enabe menu Description of Enabe Menu DISPLAY VARIABLES MENU Description of Dispay Variabes menu UTILITY MENU Description of Utiity, Configuration Anaog Out Sub Menu Description of Utiity, Parameter Sub menus Description of UTILITY, Phasing & Save Program Sub Menu Description of UTILITY, OFFSET sub MENU Keyboard Lock Menu Description of Keyboard Lock/Unock Menu FAULT MENU Description of Faut Menu 31 SECTION 6 CONTROL LOOPS INTRODUCTION CURRENT LOOP SPEED LOOP ADDITIONAL CONTROL STRUCTURES Soft-start Contro Recovery resistor contro circuit Additiona Drive Data Output current from the DC Bus connection Max Recovery Current on MicroDS Drives 3 SECTION 7 TROUBLESHOOTING INTRODUCTION Fauts on drive power suppy circuit Fauts on output section Fauts on feedback section Contro oops troube 5 Appendix A : Warranty 1 Appendix B : Motors technica data 2 Appendix C : Specia Motors 4 PAGE I-4

6 CONTENTS & INTRODUCTION MicroDS User's Manua I2 INTRODUCTION Introductory note: This manua detais the MicroDS. This drive is a product ine extension of the present DS2000 The Motion Soution drive range. Thus, functionay, these drives are amost identica. Some differences exist in the dynamic braking/recovery resistor functionaity and various other functions which are detaied in the foowing chapters. CAUTION: Repairs or modifications to the product by anyone other than a Moog authorized repair faciity may create unsafe operating conditions and wi invaidate the product warranty. PAGE I-5

7 MicroDS User s Manua CONTENTS & INTRODUCTION I2.1 USING THE MANUAL This user s manua is intended to provide sufficient information on how to insta, wire and tune a Moog brushess eectric motor system. This user s guide must be read and understood before appying power and operating the equipment described. This equipment must be instaed and serviced ony by duy quaified service personne. A information in this manua is directed towards such persons ony. Individuas responsibe for the instaation of the equipment described in this user s guide must ensure; 1) ony technicay quaified individuas are empoyed to work on the instaation, 2) these quaified individuas must have the accompanying documentation avaiabe at a times when working on the instaation and are obiged to use this documentation in a consistent manner, and 3) work on, or cose to, the instaation is prohibited for non-technicay quaified individuas After instaation and before starting up the motor it is aso recommended to check a system parameters to ensure correct system configuration. Particuar attention must be paid to a safety instructions. PAGE I-6

8 CONTENTS & INTRODUCTION MicroDS User's Manua NOTES: Moog assumes no responsibiities for errors or omissions due to the information in this manua. This manua is subject to changes at any time and Moog is not obiged to inform users of manua updates The information in this manua is subject to revision due to product modifications and/or improvements. The manua can differ from previous manua versions. PAGE I-7

9 MicroDS User s Manua CONTENTS & INTRODUCTION I2.2 Safety The safety instructions provided in this Manua are incuded to prevent injury to personne (WARNINGS) or damage to equipment (CAUTIONS). WARNINGS serve to make personne aware of potentiay hazardous actions that may resut in persona injury or death. CAUTIONS are to aert personne to actions that coud cause equipment damage, resuting in the equipment becoming unsafe. Required for CE-Compiance CE-Compiance indicates where a particuar appication-reated safety or EMC requirement is driven by the need for CE-Compiance of the MicroDS when instaed in the system. Customers who do not need CE-Compiance on their machinery may choose not to impement these features. WARNING: DO NOT remove or repace any assembies, subassembies or components with primary power present. WARNING: Letha votages ( 790V dc ) remain present within this equipment when the mains power is removed. It is recommended to refrain from commencing any servicing, maintenance, repair or upgrading of this equipment unti at east five minutes after power shutdown. It is further recommended to measure the votage eve at a high votage terminas before commencing any such activities, to ensure that no etha votages are present. WARNING: The removabe pug-in connectors of the MicroDS Drives are for ease of wiring instaation. These removabe pug-in connectors are not suitabe for connection or disconnection under power. A connections must be made with power removed. WARNING: Repair or interna adjustments to the MicroDS Series Controers must not be attempted. A fauty items must be returned to Moog Service Centres for maintenance and repair. WARNING: High Votage. The recovery resistor is connected to the Drive DC Bus and can have votage 790Vdc. PAGE I-8

10 CONTENTS & INTRODUCTION MicroDS User's Manua WARNING: Do not touch recovery resistor during operation to avoid burns. CAUTION: Ensure that the correct input votage, 230V or 400V, has been set. CAUTION: If an emergency stop is required, opening U-V-W pins and cosing motor phases to resistors, must be preceded by disabing the axis. The deay time must be at east 30 ms. CAUTION: In case of repeated on/off switching, wait 1 minute between power remova and subsequent reappication. CAUTION: Cooing air to the MicroDS must be kept cean. The air suppy must not contain partices that may deposit causing obstruction to airfow. It is recommend to periodicay check the airfow. CAUTION: Do not exceed the tightening torque vaues given in the foowing tabe. See Section 2 of this Manua for the recommended tightening torque of the termina bocks Screw Tightening torque Thread [Nm] [b in] M M M M M PAGE I-9

11 MicroDS User s Manua CONTENTS & INTRODUCTION I2.3 Decaration of Conformity (EC) PAGE I-10

12 CONTENTS & INTRODUCTION MicroDS User's Manua I2.4 CE Requirements Required for CE-Compiance Protection against eectric shock. Eectronic Equipment intended for instaation in cosed eectrica operating areas shoud be kept ocked. Authorized person sha ony open the ock and access shoud ony aowed to skied persons whie the drive is energized. Where the equipment requires manua intervention, of HD S2 sha be consuted. Fixed connection for protection. The equipment may have a continuous eakage current of more than A.C. 3.5 ma or D.C. 10 ma in norma use. The MicroDS must be permanenty and reiaby connected to Earth and a conductive parts in the IP54 rated encosure or cabinet must be permanenty connected to Earth. The impedance between the earth termina and any accessibe part of the encosure or cabinet shoud be ess than or equa to 0.1. Externa DC Suppy Votage Sources. A externa d.c. suppy votages used with the T200 Series Controers must be derived from a Safety Extra Low Votage (SELV) suppy as defined by standard EN Such SELV votages do not exceed a vaue of 60 Vd.c. or 42.4 Va.c. peak under norma conditions and are suppied by circuits which are separated from a hazardous votage conductors by permitted safety methods such as reinforced insuation. RCD. A D.C component can occur in the faut current in the event of a faut connection to earth. Ony a residua-current-operated protective device (RCD) of Type B is aowed. When the protection in instaations with regard to indirect contact is achieved by means of an RCD, their appropriate function/combination sha be verified. Cimatic Conditions. Equipment intended to operate within its performance specification over the range of Cass 3K3, as defined in tabe 1 of EN , EN , EN , EN , party modified. Instaation - The MicroDS must be mounted in a vertica orientation. The MicroDS must be pane mounted within an encosure or cabinet which provides a degree of ingress protection against iquids and objects of at east IP54. Such encosures or cabinets must be accessibe to technicay quaified service or maintenance persons ony. EMC Requirements. The instaer of the equipment is responsibe for ensuring compiance with the EMC standards that appy where the equipment is to be used. Product conformity is subjected to fiters instaation and to recommend procedures, detaied in this Manua. Second Environment (EMC).This equipment intended to be connected to an industria ow-votage power suppy network, or pubic network, which does not suppy buidings used for domestic purposes (second environment, according to EMC PAGE I-11

13 MicroDS User s Manua CONTENTS & INTRODUCTION Standards). If connected to a ow-votage pubic network that suppies domestic premises (first environment), this product may cause radio interference in which case suppementary measures may be required. Cabe Shieding. Shieding of some externa cabes is necessary to ensure compiance with EMC requirements. Detais of these requirements are given in Section 1 and Section 2. The Integra Motor Therma Protection signa sha be connected on the equipment, on T360 connectors J4/J5 (PIN 2-15/6-8), which accepts signas maximum 5.5 Vdc ±10%, 400 µa. The utimate resut of this signa is to "Switch- OFF" the output of the Soid State Motor Controer and thereby "No-Power" is transmitted to the Motor connected to the Motor-Drive. I2.5 LEGAL ASPECTS This manua can ony be used by fina Customers/Users of the Moog product it describes. This manua cannot be reproduced in whoe or in part without prior written consent from Moog. No distribution of this manua by eectronic, mechanica, or printed means is aowed. This manua has been issued with the intention of providing a information necessary to perform a compete instaation of the MicroDS. Moog assumes no responsibiity for errors or omissions contained herein and for incidenta or consequentia damages due to the above mentioned errors and omissions. Moog reserves the right to change and update this manua without notice. This manua is for information purposes ony. Moog assumes no responsibiity with regard to the correspondence of the product features described in the manua and the features on the actua product purchased by the fina Customer/User. No statement or sentence contained in this manua impies further ega obigations, different from those contained in each sae or suppy contract regarding Moog products. PAGE I-12

14 SECTION 1 : DESCRIPTION MicroDS User's Manua SECTION 1 DESCRIPTION 1.1 INTRODUCTION This manua describes the MicroDS drive series and provides information about the instaation and the functiona characteristics of the product. This section describes MicroDS drive features and aso refers to the ordering system. 1.2 PRODUCT RANGE MicroDS is a digita drive for permanent magnet synchronous servomotors (hereafter: brushess). Vector contro of asynchronous servomotors (hereinafter: asynchronous) is aso possibe. The range is made up of 2 modes, corresponding to 3 A rms and 6 A rms nomina currents. The transducers avaiabe with the motor are either an incrementa encoder or a resover. An interna recovery resistor is provided in the drive. An optiona second externa recovery resistor is aso avaiabe. The Moog GUI software pack is avaiabe to manage, by means of a PC, both the drive configuration and the dispay of a interna vaues. The manua together with the notes in the Appendices provides a compete description of the drive. PAGE 1-1

15 MicroDS User s Manua SECTION 1: DESCRIPTION 1.3 GENERAL FEATURES The MicroDS features provide the automation industry with the best response to the most difficut requirements of motion contro. FULL DIGITAL: - Speed and current contro oops and many other functions such as the DC BUS status monitoring, soft-start and recovery circuit management and protection are impemented digitay to ensure reiabe and fexibe operation. - The digita operation ensures maximum system stabiity and reiabiity over time, temperature and varying appication conditions. - Settings are carried out through vaues cacuated in anaytic modes and do not depend upon potentiometric caibrations. FLEXIBLE: - Any brushess motor can be controed by entering a maximum of 8 parameters which adjust the current oop and identify the motor eectromechanica characteristics (peak current, Back EMF, inductance, resistance, number of poes, votage rating, speed, feedback encoder puses characteristics, resover poes). - The drive can contro asynchronous motors by means of vector contro. By entering the additiona parameters, magnetization current (ID) and the sip gain (frequency), it is possibe to use asynchronous motors. The remaining parameters reated to the hardware features remain active. - The motor position transducer can be either a resover (with 2 to 24 poes) or an incrementa encoder (from 1024 to 8192 puses). For the resover, interna hardware gain adjustment aows maximum resoution be achieved depending on the transform ratio of the resover. The required gain setting shoud be specified (for FAS or Goba motor) in the drive order code. - It is possibe to program the device in 2 different anguages: Itaian and Engish; the required anguage shoud be specified in the order code. At any time, using the GUI, it is possibe to oad a different anguage. Ony one anguage can be active in the drive. PAGE 1-2

16 SECTION 1 : DESCRIPTION MicroDS User's Manua - The input suppy votage can range from 65 VAC to 510 VAC three-phase. Operation with a singe-phase power suppy is aso possibe with appropriate de-rating. a times. - Unike the DS2000 modes, it is necessary to suppy 24V backup power at ADVANCED PERFORMANCE: The current oop, based on a traditiona PI structure, is provided with automatic compensation agorithms for the Back EMF and of the KP/KI ratio, as a function of the motor characteristics. Hardware caibration is not necessary for the current oop. Current oop update rate: 10kHz. Speed Loop Update rate: 5kHz. PAGE 1-3

17 MicroDS User s Manua SECTION 1: DESCRIPTION 1.4 TECHNICAL DATA Genera features Three-phase input votage rating: Singe-phase Input votage rating: from 230V ac to 460V ac ±10%, 50/60 Hz 230Vac (Input Power imited to 1.1kW) Min/max Three-phase input votage: 65 / 510 V ac (DC-Bus: 80 / 720 V dc ) Auxiiary votage (required): 24 V dc ±10%, 1A (SELV) Configurabe anaog references: Recovery Resistor: Max dynamic with encoder Switching frequency: Speed adjustment: Anti-resonance ow-pass fiter: Fiter on reference: Notch fiter (programmabe): from 3.2 to 10 V dc 120, 100W (6 Arms Drive) 120, 50W (3 Arms Drive) 200 Hz 10 khz rpm Hz Hz Hz Ambient temperature: C (exceeding Cass 3K3) Storage temperature: C (Cass 1K4) Transport temperature: C (Cass 2K3) Reative humidity: Environment: Derating for atitude >1000 m: Air Pressure 5% to 85% (with no condensation and no formation of ice) For use in a poution degree 2 environment. 1% every 100 m 86 kpa to 106 kpa PAGE 1-4

18 SECTION 1 : DESCRIPTION MicroDS User's Manua Interfaces - Anaog - Speed (or current) reference differentia input: 0 +/- 10V (adjustabe scae) - Auxiiary input votage: 24V dc ±10%, 1A - Output Votage: 15±10% V dc, 100mA - Anaog output (configurabe) - Tachometric signa (adjustabe scae) - Peak current imit (via anaog signa) - Motor temperature (through PTC or NTC) - Resover interface - Digita - RS485 fu-dupex seria ink - encoder input (incrementa) - encoder output (incrementa) - reset - drive OK output - drive enabe input - reference enabe input PAGE 1-5

19 MicroDS User s Manua SECTION 1: DESCRIPTION Drive front contro pane Fig 1.1 MicroDS Front Pane PAGE 1-6

20 SECTION 1 : DESCRIPTION MicroDS User's Manua Protection - motor overtemperature - drive overtemperature - IGBT modue current fodback - input votage out of toerance - bus overvotage - interna recovery resistor power imiting - encoder or resover signa missing - encoder or resover fauty connections - axis short circuit (motor and recovery resistance output) - Overspeed in torque mode contro (if speed is 12% above max set vaue) Recovery Circuit Dynamic braking unit MicroDS Standard recovery resistance (Interna) Mode code Currents (rms/pk) Resistance and power Max Current Max Duty Cyce 1 T360xx03x-xxx xxx 3/11 120Ω/50W (int.) % T360xx06x-xxx xxx 6/22 120Ω/100W (int.) % Tab 1.1 Recovery resistance data 1 Operating with 600V DC Bus. 2 An equivaent resistor of equa resistance and power rating (Order code: C ) can be attached externay to the drive if required. For operation at 230V, a ower vaue resistance can be connected externay. Consut Moog saes office for futher detais. PAGE 1-7

21 MicroDS User s Manua SECTION 1: DESCRIPTION 1.5 CODES The MicroDS can be ordered using the boxcar shown in Fig 1.2. PAGE 1-8

22 SECTION 1 : DESCRIPTION MicroDS User's Manua Numeric Numeric/Apha Apha Numeric Numeric Apha Apha/Numeric Mode Series Designator Current Mode Design Status Resover Gain Option Base Mode Size Letter E (E mode) No. Drive Size 03 3/ /22 T360 X X XX X - XXX XXX No. 0 1 Option Description Resover Transform Ratio = 0.25 (FAS Motors) Resover Transform Ratio = 0.5 (Goba/FASG Motors) Current Hardware Revision A Software Revision Rev. 31E 31I Description MicroDS NTC/PTC & IT Limiting, Engish Menus MicroDS NTC/PTC & IT Limiting, Itaian Menus Reserved Number 000 Description Defaut drive settings Accessories: Graphica User Interface (GUI) part number is CZ5300 RS232/422/485 Converter part number is CZ5200 Users manua is Note: 1) Users must be experienced/quaified in the use of this product range before buiding products from this drawing. 2) A drive options are provided with a 120Ohm Interna Regen Resistor 3) Externa regen resistors are to be ordered and suppied seperatey. Fig 1.2 MicroDS Drive BoxCar PAGE 1-9

23 MicroDS User s Manua SECTION 1: DESCRIPTION 1.6 OPTIONS Optiona devices separatey suppied are - RS232/422/485 Converter (Moog code CZ5200) - Moog GUI communication program (Moog code CZ5300) PAGE 1-10

24 SECTION 1 : DESCRIPTION MicroDS User's Manua 1.7 DIMENSIONS AND DRILLING JIG The foowing figures show the drives dimensions and detais and driing information for mounting the drive. Fig 1.3 A Size drive dimensions and driing jig (in mm.) PAGE 1-11

25 MicroDS User s Manua SECTION 1: DESCRIPTION 1.8 CONNECTION CABLES The foowing tabe shows the cabes specification for each part of the drive. Use Cass 1 wire ony It is recommended to use copper (Cu) cabes, 60/75 C, UL certified, with the cross sections indicated in the tabe. Line power cabe (no. of conductors x AWG) Protective bonding cabe (no. of conductors x. AWG) Motor power cabe (no. of conductors x. AWG) Recovery resistor cabe (no. of conductors x. AWG) 24V power cabe (no. of conductors x AWG) Motor encoder cabe (no. of conductors x. AWG) Motor resover cabe (no. of conductors x AWG) MicroDS Mode A Size Notes 3/11 6/22 3 x 14 AWG 3 x 14 AWG EMC Fiter required. See Section 2 for detais. 1 x 6 AWG 1 x 6 AWG 4 x 14 AWG 4 x 14 AWG shieded 2 x 14 AWG 2 x 14 AWG shieded 2 x 14 AWG 4 Turns on Fairrite core. Schaffner p/n # x 22/20 AWG shieded shieded 8 x 22/20 AWG Tab 1.2 Dimensions of connection cabes Note: The DC Bus connection between drives has the same wire size as the Recovery resistor. It must aso be shieded. AWG mm Tab 1.3 Conversion from AWG to mm 2 PAGE 1-12

26 SECTION 1 : DESCRIPTION MicroDS User's Manua 1.9 EXTERNAL FUSES CAUTION : Equipment suitabe for use on a suppy capabe of deivering not more than 5000RMS Symmetrica Amperes,460V +10% maximum. No fuses are provided inside the drive. It is recommended to use UL certified fuses and fuse bocks as manufactured by BUSSMAN Div. Cooper LTD (UK). Short Circuit Rating Power ine fuse MicroDS Mode A size 3/11 6/ rms Amps 32A, 550 Vot, Type HRC Notes Recovery Resistor 1000V DC, 3A Semiconductor fuse 3 Ferraz Shawmut, A120X range. 24 Vdc auxiiary power suppy fuse 1.10 POWER DISSIPATION 3A 250V Tab 1.4 Recommended fuses Deayed To determine the therma requirements of the cabinet, in which the drive is to be instaed, it is necessary to refer to Tab 1.5. The power dissipation referred to in the tabe assumes the drive is operating at continuous rated current. If the appication empoys continuous braking, it is necessary to add the recovery resistor power dissipation (use the nomina recovery power if that required by the appication is unknown). MicroDS Mode 3/11 6/22 Power 53W 98.8W Tab 1.5 Power dissipation 3 The fuse specified is for operation with a nomina DC bus of 600V. For operation at ower DC bus votages (300V), a ower votage and current fuse can be specified. PAGE 1-13

27 MicroDS User s Manua SECTION 1: DESCRIPTION 1.11 SOFT START The soft start circuit (current imit at start-up) is incuded in the drive-input stage FANS The MicroDS ventiation is provided by one fan mounted over the drive. Fan power is generated internay. CAUTION: Free air circuation must be ensured for correct fan operation RESET BUTTON A reset button is avaiabe on the drive front pane. It aows the digita contro card to be reset. It can aso be used during start-up to access the downoad data mode. PAGE 1-14

28 SECTION 1 : DESCRIPTION MicroDS User's Manua 1.14 POWER LINKS AND CONNECTORS Remark: Moog MicroDS drives incude a necessary connectors for correct operation. A the drives are equipped with pug-in connectors to ensure quick and easy connection of the drive in the contro cabinet. These connectors aso faciitate service and repair activities. The MicroDS connectors aow for easy mounting of the drive inside the contro cabinet, providing the customers with the option of separating the cabinet assemby from system competion with servo-systems. The foowing sections detai the connectors and their specifications for each function of the drive and their associated accessories. PAGE 1-15

29 MicroDS User s Manua SECTION 1: DESCRIPTION Power input votage connectors A SIZE: Power suppy, recovery resistance, motor output connections and 24V suppy are grouped together on connector J6, on the drive s ower side. The conductors are fastened by means of screw terminas. - Fixed connector: 12 pins, mae connector - Mating connector, 12 pins, femae, suppied with the drive - A size wiring: cabe 14AWG (2.1 mm 2 ). Wire stripping: 7 mm. - Tightening torque: 0.5Nm. Pos. Name Function 1 DC- DC Bus Votage minus connection 2 DC+ Externa recovery resistance and DC Pus of DC Bus pus connection 3 RR Externa recovery resistance 4 L1 Phase "L1", three-phase votage input 230/460Vac ±10% 5 L2 Phase "L2", ", three-phase votage input 230/460Vac ±10% 6 L3 Phase "L3", ", three-phase votage input 230/460Vac ±10% 7 PE Protective Earth 8 W Phase "W", motor three-phase output 9 V Phase "V", motor three-phase output 10 U Phase "U", motor three-phase output V Auxiiary votage inputs 24 Vdc ±10%, 1A 12 GND (24V) Auxiiary votage inputs return Tab 1.6 J6 Power connector, A Size Remark: Pins 11 and 12 are the 24-Vot auxiiary votage inputs. Pin 12 is connected to drive ogic 0 and PE. PAGE 1-16

30 SECTION 1 : DESCRIPTION MicroDS User's Manua - Use a 6 AWG or 10 mm 2 cabe and ug for M5 PE stud. Pos. Name Function PE PE Equipotentia protection circuit. Tab 1.7 PE Screw, A Remark: In eectricay noisy environments, it can be usefu to connect the motor ground to the PE stud and pin 7 of J6 connector to PE V Auxiiary votage 24V Auxiiary Suppy +24V GND (24V) Fairrite Camp Core p/n # (4-Turns of Suppy cabe) To further µds Units (Max. 4) Connector J6 µds Connector J6 µds Fig V Auxiiary Suppy Connection to MicroDS The Auxiiary suppy for the MicroDS is connected to pins 11 and 12 of J6. Required for CE-Compiance NOTE: To compy with the EMC Directive an externa fiter (Schaffner Fairrite ferrite camp, p/n # ) is required. Four turns of the 24V suppy cabe are required to pass through the camp for compiance. Upto four MicroDS units can be connected to one fiter. PAGE 1-17

31 MicroDS User s Manua SECTION 1: DESCRIPTION Motor power connector The motor phase connections are made on J6 as detaied in Tab 1.6. The motor phase cabe must be shieded to compy with the EMC Directive. The connections are shown in Fig 1.5. See aso Section 2 Instaation. Motor µds µ DS U V U (10) V (9) W PE W (8) PE J6 J9/J10/J11 grounding of shied via connector camp (or RF connection to ground screw in case of termina board) grounding of shied via connector camp Fig 1.5 Motor phases wiring CAUTION: U-V-W sequence at the drive side must match the corresponding U-V-W sequence at the motor side. Required for CE-Compiance NOTE: To compy with the EMC Directive the motor cabe must be shieded and the shied must be connected to the housing with a 360 connection at both ends. PAGE 1-18

32 SECTION 1 : DESCRIPTION MicroDS User's Manua Mains Votage Suppy The mains suppy votage is connected to pins 4, 5 and 6 of J6. These ines do not require shieding. For EMC compiance, they must be connected to the input EMC fiter. The input PE connection shoud be tied to the PE stud detaied in Tab 1.7. Required for CE-Compiance NOTE: To compy with the EMC Directive, an input EMC fiter is aways required. Detais of the recommended fiters are given in Section 2, Instaation. a.c. Mains L1 L2 L3 Protective Earth EMC Fiter, Fuses etc. See Section 2 Instaation To further µds. (Max. 4) L1 L2 L3 PE Stud L1 L2 L3 PE Stud Connector J6 Connector J6 µds µds Fig 1.6 AC Mains Wiring SINGLE PHASE OPERATION The MicroDS can operate from a singe phase 230V suppy. This wi resut in a DC bus of 320V. However, it is necessary to power imit the appication to an input power of 1.1kW. Increasing the power beyond this point wi resut in the drive reporting an undervotage due to excessive votage rippe on the DC bus. To avoid this, the MicroDS shoud, where possibe, aways be connected to a three phase suppy. If the MicroDS is connected to a singe phase suppy, an EMC fiter must be instaed. This is detaied in Section 2. PAGE 1-19

33 MicroDS User s Manua SECTION 1: DESCRIPTION PARALLEL DC BUS OPERATION The DC bus is avaiabe on pins 1 and 2 of J6. Up to four MicroDS units can operate with their DC bus connections shared. This feature aows the MicroDS units to share recovered motor power. It aso increases the effective recovery energy that the drives can dissipate, as a recovery resistors wi operate in parae. Care shoud be taken when paraeing the MicroDS units to ensure that the DC bus cabes are kept as short as possibe. See Section 2, Instaation. The ratings of the DC ink current is detaied in Section 6. Required for CE-Compiance NOTE: To compy with the EMC Directive the DC Bus cabe must be shieded and the shied must be connected to the housing with a 360 connection at both ends. To further paraeed µds. Max DC- DC+ Tie Screen to chassis via EMC bracket. See Section 2 Instaation 1 2 DC- DC+ Connector J6 µds Connector J6 µds Fig 1.7 DC Bus sharing Wiring 1.15 Recovery circuit Under braking conditions, the motor wi return energy that cannot be sent to the ine, as the rectifier circuit, formed by a diode bridge, is unidirectiona. The regenerated energy wi increase the DC-BUS votage. When DC bus votage reaches the intervention threshod, the digita contro turns on the recovery power switch, thus connecting the recovery resistance across the DC bus and dissipating the motor braking energy as heat. PAGE 1-20

34 SECTION 1 : DESCRIPTION MicroDS User's Manua The correct sizing of the recovery resistance aows motor deceeration within the required times and protects the eectroytic capacitors and drive from overvotage. The MicroDS is equipped with an interna recovery resistor. This resistor is protected in software to prevent the power dissipated exceeding the device ratings (Size:3 50W, 6.25A, Size 6 100W, 6.25A). The regeneration terminas are aso avaiabe on J6, pins 2 and 3. An equivaent resistor can be connected externay to doube the recovery power handing capabiity of the unit. The software mode controing the recovery resistor operation aows increased dynamic braking capabiity at the start of a dynamic braking cyce. This is achieved by modeing the therma response of the recovery resistor. This aows the recovery circuit to turn on initiay for a onger period of time thereby increasing the time for which peak power can be dissipated. The software imits the overa power dissipated to the ratings of the resistor. Recovery Resistor 2 3 DC+ RR Tie Screen to chassis via EMC bracket. See Section 2 Instaation Tie screen to pane on which resistor is mounted. Connector J6 µds Fig 1.8 Recovery Resistor Wiring If the recommended Moog externa recovery resistor is used (C ), it must be provided with suitabe heatsinking. To achieve the rated power of the resistor, a heatsink of 400m x 400mm x 3mm is required. WARNING: High Votage. The recovery resistance is connected to the DC-BUS which can reach a votage of 790V. PAGE 1-21

35 MicroDS User s Manua SECTION 1: DESCRIPTION WARNING: Do not touch recovery resistors during operation to avoid burns due to the heat it dissipates. CAUTION: In appications where the working cyce invoves deceerations with high inertia oads, from high veocity in very short deceeration time, it is necessary to propery size the recovery resistance. In these cases, pease contact Moog Service Centers. Required for CE-Compiance NOTE: To compy with the EMC Directive the recovery resistance cabe must be shieded and the shied must be connected to the housing with a 360 connection at both ends. PAGE 1-22

36 SECTION 1 : DESCRIPTION MicroDS User's Manua 1.16 CONTROL CARD LINKS AND CONNECTORS The foowing connectors are common to a drives sizes and are a ocated on the drive front contro card: Encoder Input Connector, Resover Connector, Reference Connector, Drive Enabe Connector, Encoder Output Connector RS485 Connector. These are detaied in the foowing sections. Sufficient depth must be aowed in the cabinet for the resover and RS485 connectors and their associated cabe bend radii. The recommended depth for these is shown in Fig 1.9. Fig 1.9 Resover \ RS485 Bend Radius Requirements PAGE 1-23

37 MicroDS User s Manua SECTION 1: DESCRIPTION Encoder input connector Remark: Two sections form the motor contro encoder. - The first, (UVW signas), generates signas used by the drive to power the motor phases. The number of motor poes defines this section. - The second, (ABC signas), generates reference signas, which are aso avaiabe for motion contro to an externa CNC. The number of puses in this section is defined according to the customer needs as we as the appication requirements. - The connector for these signas is on the contro card bottom side. - The foating encoder connector at the drive side is a Sub-D 15 pos. and is provided with the drive (Sub-D 15 pos. Code AK5221, conductive she, Code AK4218). - A the motor encoder channes and the PTC/NTC for the motor temperature contro must be connected to J4 connector ocated on the bottom side of the drive. - Incrementa encoder signas are avaiabe as outputs on J2C connector. - For the encoder signas, It is recommended to use a ow capacitance, shieded (with 85% min. coverage), mutipoar cabe with 22 AWG (0,30 mm2 ) or 20 AWG (0,50 mm2 ) conductors. - Cabe ength shoud not exceed 40 m. - It is recommended that the encoder and the motor power cabe be separated, through the use of independent duct, by a distance of 30 cm (1 ). - It is not recommended to make intermediate connections on the encoder cabe. - Motor Encoder port for the Motor Encoder Channes and for the Motor Integra NTC/PTC Temperature Contro (PIN 8-15). This Auxiiary-connector is referred to Limited Votage / Current circuits (rated max 5.5 Vdc ±10%, 400 µa). PAGE 1-24

38 SECTION 1 : DESCRIPTION MicroDS User's Manua Fixed connector (Motor Side): femae, Code AK4220 Pos. name 1 +5V +5 Vdc (max 100 ma) output 2 GND (PTC) Encoder ground and motor PTC/NTC ground 3 W Switching signa: W phase (compiment) 4 W Switching signa: W phase 5 V Switching signa: V phase 6 V Switching signa: V phase (compiment) 7 A A Channe 8 A A Channe (compiment) 9 C Marker 10 C Marker (compiment) 11 U Switching signa: U phase 12 U Switching signa: U phase (compiment) 13 B B Channe (compiment) 14 B B Channe 15 PTC Motor PTC/NTC Note: Signas A,B and C are avaiabe on the connector J2C (Encoder Output) after a buffer circuit which is provided to protect encoder devices from incorrect wiring. Tab 1.8 J4 Connector Sub-D 15 pos. Encoder inputs PAGE 1-25

39 MicroDS User s Manua SECTION 1: DESCRIPTION Motor µ DS A B V R G H P N J K L M E F D C Shied connected to the housing by connector camp Shied connected to the housing by connector she V GND(PTC/NTC) PTC GND(PTC) PTC A Channe A Canae Channe A (compiment) negato CanaLe B B Channe Canae B negato B Channe (compiment) Marker Marker Marker Marker (compiment) negato Fase U U Phase Fase U negata U Phase (compiment) Fase V V Phase V Phase Fase V (compiment) negata Fase W W Fase Phase W negata W Phase (compiment) J4 Fig 1.10 ENCODER CONNECTIONS PAGE 1-26

40 SECTION 1 : DESCRIPTION MicroDS User's Manua (FAE) Fig 1.11 Encoder connection at motor side for FAEN PAGE 1-27

41 MicroDS User s Manua SECTION 1: DESCRIPTION Resover input connector The connector for these signas is J5. J5 is a femae Sub-D 9 pos. and is ocated on the contro card. - The resover foating connector is a mae Sub-D 9 pos. and is provided with the drive. - Depending on the resover transform ratio, (0.5 for Goba/FASG motors, 0.25 for FAS motors), a gain setting for the resover circuit must be set internay during manufacture. The ordering information for this is incuded in the BoxCar. - The resover signas shoud be connected to J5 connector. Fig 1.12 shows the resover wiring ay-out with differentia inputs. - It is recommended to use ow capacitance, mutipoar shieded cabe (85% min. coverage) with 22 AWG (0,30 mm2 ) or 20 AWG (0,50 mm2 ) conductors (Order code: Bare cabe B ). - Cabe ength shoud not exceed 30 m. It is recommended that the resover cabe and the motor power cabe be separated through the use of independent ducts and by a distance of 30 cm (1 ). It is not recommended to make intermediate connections on the resover cabe. - With the resover interface it is possibe to provide simuated encoder outputs on J2C. The maximum number of puses per mechanica revoution of the simuated encoder is 1024 resover poes /2 (i.e.: for a 6 poe resover, the number of puses/revs is 3072) and the standard width of the marker is 90 (width of 180 or 360 is programmabe via keypad). A ower number of puses per revoution is programmabe via keypad or through the Moog GUI. - Ready made cabes for FAS and G400/G330 motors are avaiabe on request. Contact Moog saes for further information. - Motor Resover port for the Motor Resover Signas and for the Motor Integra NTC/PTC Temperature Contro (PIN 6-8). This Auxiiary-connector is referred to Limited Votage / Current circuits (rated max 5.5 Vdc ±10%, 400 µa). PAGE 1-28

42 SECTION 1 : DESCRIPTION MicroDS User's Manua Motor Connector J5 Connector (9-Way Sub D) cos ϕ cos ϕ sin ϕ sin ϕ C E G H Interna Shieds (if Avaiabe) cos ϕ cos ϕ 0V sin ϕ sin ϕ PTC PTC N A 6 8 PTC PTC -Vref (0V) +Vref B D 7 9 -Vref +Vref S Interna Shieds (if Avaiabe) Shied connected to housing through connector camp Shied connected to housing through connector she Fig RESOLVER CONNECTIONS (FAST/FASK motors) Fixed connector: 9 pin, femae, code AK4220 Foating connector: mae, Sub-D 9 pos., code AK5220, provided with the drive. Pos. Name 1 Cos Differentia cos signa non-inverted input ampifier from resover windings. 2 Cos Differentia cos signa inverted input ampifier from resover windings. 3 Shied Shied (internay connected to 0V) 4 Sin Differentia sin signa non-inverted input ampifier from resover windings. 5 Sin Differentia sin signa inverted input ampifier from resover windings. 6 PTC Motor PTC/NTC input 7 V ref 10 khz, 20V pk-pk sinusoida negative output signa to primary resover winding. 8 PTC Motor PTC/NTC input 9 V ref 10 khz, 20V pk-pk sinusoida output signa to primary resover winding (carrier). Tab J5 Connector- Sub-D 9 pos.- FAST/FASK Resover PAGE 1-29

43 MicroDS User s Manua SECTION 1: DESCRIPTION MOTOR RESOLVER CONNECTOR (FAST and FASK) Signa type FAS T/ FAS K FAS N/ FAEN Pos. Pos. Cosϕ C 1 Cos ϕ E 2 V-Ref D 10 0V B 7 PTC N 8 PTC A 9 Sinϕ G 11 Sin ϕ H 12 shied S 3 Tab 1.10 Resover connections to motor Fig 1.13 Resover connection at motor side for FAST and FASK READY MADE MOTOR RESOLVER CABLES (FAST and FASK) Cabe Part No: Length (m) L A001 3 L A002 5 L A L A L A Tab 1.11 Ready Made Resover Cabes (FAST & FASK) PAGE 1-30

44 SECTION 1 : DESCRIPTION MicroDS User's Manua Fig 1.14 Resover connection at motor side for FASN and FASY PAGE 1-31

45 MicroDS User s Manua SECTION 1: DESCRIPTION G400 and G330 motors resover wiring Goba Motor Connector J5 Connector (9-Way Sub D) Interna Shieds (if Avaiabe) V Shied connected to housing through connector camp Shied connected to housing through connector she Fig RESOLVER CONNECTIONS (G400\G330 motors) Termina N Termina Motor side Drive Tab 1.12 Cross references between coor and cabes for G400/G330 - Terminas are identified on the motor side. - As G400 and G330 have an NTC for therma feedback, it is necessary to set this in the motor menu of the MicroDS setup. - If the drive is to be used with a goba motor, the order code must be specified for a resover transform ratio of 0.5. PAGE 1-32

46 SECTION 1 : DESCRIPTION MicroDS User's Manua Note: As the resover is ocked mechanicay in the motor, the customer must perform a PHASING using the drive utiities. READY MADE MOTOR RESOLVER CABLES (G400\G330 Motors) Cabe Part No: Length (m) L A002 5 L A L A L A Tab 1.13 Ready Made Resover Cabes (G400\G330 Motors) PAGE 1-33

47 MicroDS User s Manua SECTION 1: DESCRIPTION Input References Connector The anaog references (speed and current imit references) are avaiabe on J2A mae connector, and accessibe through a foating 4 pin femae connector. The conductors are fastened using spring cips within the connector. These cips are reeased by depressing the tab with a screwdriver. - Fixed connector:- 4 pins mae, MicroCombicon. - Foating connector:-insertion type, 4 pin, code AK4714 (provided with drive). Pos. Name Description 1 V Ref Differentia, non-inverted input of speed or torque reference signa (0 - ±10V, corresponding to 0 -± Max input reference). The scae is adjustabe via software from ± 3.2 to ± 10V in steps of 0.1 V. Input impedance is 10k. Differentia, inverted input of speed or torque reference signa 2 V Ref 3 I imit Differentia, non-inverted input of anaog current imit (0 - ± 10V, corresponding to 0-100% max set current). The scae is adjustabe via software from ± 3.2 to ± 10V in steps of 0.1 V. Input impedance is 10k. 4 I imit Differentia, inverted input of anaog current imit Tab 1.14 Speed and Torque References connection PAGE 1-34

48 SECTION 1 : DESCRIPTION MicroDS User's Manua Exampe for speed and torque reference wiring C N C µ DS 1 2 R E F R E F J 2 A 0 V 2 0 V J 2 B Shied s c h e rmmust o c obe e grf a to a te a io connected c o n c o n n eto s sthe io n ehousing a Grounding of shied via hose camp J 2 IN G RDIFFERENTIAL E S S O D F E INPUT R E N Z IA L E C N C µ D S 0 V 1 2 R E F R E F J 2 A 2 0 V J 2 B sshied c h e rmmust o c o e be grf a to a te a io cconnected o n c o n n eto s s io the n ehousing a s c h e r m o c o e g a to a Grounding of shied te a io tra m ite fa s c e tta via hose camp J 2 IN GUNIPOLAR R E S S O U NINPUT IP O L A R E Note: J2A and J2B with differentia and unipoar connection options. Fig 1.16 Exampe for speed and torque reference wiring PAGE 1-35

49 MicroDS User s Manua SECTION 1: DESCRIPTION Drive enabe connector Drive enabe, Drive OK, Tacho out, Anaog out, and Reference enabe are avaiabe on the mae J2B connector and are accessibe through a foating 12 pin connector. The conductors are fastened using spring cips within the connector. These cips are reeased by depressing the tab with a screwdriver. - Fixed connector: 12 pin, mae, MicroCombicon. - Foating connector: insertion type, 12 pin, code AK4722 Pos. Name Description out +15 V dc output, max 100 ma 2 0V Logic Zero. 3 Anaog out Configurabe output (see Anaog out configuration) Output impedance =100 4 Tacho Out Speed signa output (0 - ± 10V, corresponding to 0 - ± Max speed rpm). The scae is adjustabe via software from ±5 to ±10 V in steps of 0.1 V. Output impedance =100 5 Reset + Opto-isoated Reset inputs (15 V dc / 12 ma). 6 Reset - Reset inputs return. The MicroDS can be reset if a puse > 20ms is appied to the reset inputs. 7 Drive Enabe + Opto-isoated Drive Enabe inputs (15 V dc / 12 ma). 8 Drive Enabe - Drive enabe return. Power cannot be suppied to the motor without this enabe signa. 9 Ref. Enabe + Opto-isoated Ref. Enabe inputs (15 V dc / 12 ma). 10 Ref. Enabe - Ref. Enabe return. When this signa is not appied, the command to the motor is zero. If in speed mode, the speed command is zero. If in torque mode, zero torque is commanded. This input can be used for emergency braking. 11 Drive OK + Drive OK output. Contact coses if no fauts are detected. (24V reays, max 100 ma) 12 Drive OK - Drive OK return. It is recommended to ogicay connect the DRIVE OK isoated output to the power contactor. This ensures that the power suppy is disabed in case of a faut. Tab 1.15 Drive enabe connection PAGE 1-36

50 SECTION 1 : DESCRIPTION MicroDS User's Manua CNC +24V 0V +24V Power Suppy DS2000 MicroDS +24V Reset Drive Enabe 0V Reset+ Reset- Drive Enabe+ Drive Enabe- Ref. Enabe Reference Enabe+ Reference Enabe- Drive OK Drive OK+ Drive OK- J2 J2B Shied must be RF connected to the housing ALIMENTAZIONEESTERNA+24V POWER SUPPLY Grounding of shied via hose camp MicroDS DS V 0V Reset+ Reset- Drive Enabe+ Drive Enabe- Reference Enabe+ Reference Enabe- J2 J2B + ALIMENTAZIONEINTERNA+15V V INTERNAL SUPPLY (TESTDELL'AZIONAMENTO) (for drive test) Fig 1.17 INPUT/OUTPUT WIRING PAGE 1-37

51 MicroDS User s Manua SECTION 1: DESCRIPTION Encoder Connector (output) The drive encoder signas are avaiabe on the 6 pin J2C connector and are accessibe through a 6 pin foating connector (code Moog AK4716). The conductors are fastened using spring cips within the connector. These cips are reeased by depressing the tab with a screwdriver. - Fixed connector: 6 pin, mae, MicroCombicon. - Foating connector: 6 pin, code AK4716 Pos. Name Description 1 A Encoder output: A channe 2 _ A Encoder output: A channe negative 3 B Encoder output: B channe 4 _ B Encoder output: B channe negative 5 C Encoder output: marker 6 _ C Encoder output: marker negative Tab 1.16 Encoder output connections PAGE 1-38

52 SECTION 1 : DESCRIPTION MicroDS User's Manua RS485 Seria ink RS485 seria interface signas are avaiabe on the Sub-D 9 pos., J1 connector. The corresponding foating connector is a femae 9 pin connector (code Moog AK5220). Up to 62 drives can be connected through the RS 485 seria ink. Fixed connector: mae 9 pin, Sub-D Foating connector: femae, Sub-D 9 pos., code AK5220 Pos. Name 1 +RX + Rx (RS485) 2 N.C. (Not Connected) 3 +TX + Tx (RS485) 4 N.C. 5 N.C. 6 -RX - Rx (RS485) 7 0V Digita 0V 8 -TX - Tx (RS485) 9 N.C. Tab 1.17 J1 connector Sub-D 9 pos. RS485 seria ink PAGE 1-39

53 MicroDS User s Manua SECTION 1: DESCRIPTION 1.17 Drive Starting Sequence. In order to correcty power and enabe the MicroDS, it is necessary to foow a start-up sequence. The minimum deay times in order to aow the interna circuits to reach the operating votage eves and to make the interna devices ready for enabing are indicated. The chart beow summarizes the start-up sequence and detais the sources of the deays. t1: Time deay required for the foowing operations: - Switching on of the 24V power suppier and input votages stabiization - Program oading and ogic circuits initiaization - Interna protections check carried out by the interna microprocessor t2: Reset puse to aow the reading of reference votages, as we as the interna offsets initiaization. t3 Time needed by the drive to boot up after the reset. t4 Charge time of Bus capacitors determined by the soft-start circuit and Bus votage stabiization. t5 Time for DRIVE OK acquisition by the contro t6 Time to aow the Drive to reach the torque and to check the proper operation of power stages. The times indicated in the foowing tabe are necessary to avoid FAULT occurring on startup. PAGE 1-40

54 SECTION 1 : DESCRIPTION MicroDS User's Manua t 1 t 2 t 3 t 4 t 5 t 6 24 VDC RESET puse (>100ms) 230/460 Vac Three-phase Drive OK Drive Enabe Ref. Enabe t 1 3 s, t ms., t 3 1 s, t 4 = 3 s, t ms., t ms. Fig 1.18 STARTING SEQUENCE TIMES Remarks: - The reset puse re-initiaizes the card with a interna votages stabiized. This aows a more accurate determination of votages for compensation of interna offsets. - The RESET is necessary ony on the first drive start-up or, in the case of a FAULT, to reset the drive. - The DRIVE OK signa requires the ine votage be appied before becoming active. Once DRIVE OK is active, the drive can be enabed immediatey. PAGE 1-41

55 MicroDS User s Manua SECTION 1: DESCRIPTION 1.18 Dynamic Braking It is possibe to perform dynamic braking of a oad using the motor torque, in an emergency condition, provided that the drive or motor is not in a FAULT condition. To achieve this, the drive command sequence detaied beow shoud be foowed. When dynamic braking of the motor is required, the REFERENCE ENABLE is removed and the motor wi brake with the avaiabe torque. t1: after 100ms (this time can be increased in cases where oad inertia is much arger than motor inertia) the DRIVE ENABLE can be removed. t2: The three-phase input votage remova is deayed with respect to DRIVE ENABLE in order to avoid drive FAULTS due to an undervotage condition being detected. t3: DC BUS discharge time t 1 t 2 t 3 Reference Enabe Drive Enabe 230/460 Vac Three-phase t 1 = 100m s, t 2 = 15 ms, t 3 = 6 min. (before accessing the drive). Fig 1.19 SWITCH-OFF SEQUENCE TIMES PAGE 1-42

56 SECTION 1 : DESCRIPTION MicroDS User's Manua 1.19 MECHANICAL BRAKING The FAST ACT series motors have an optiona eectromagnetic brake. This brake requires an externa suppy of 24V. This brake can be used to hod the motor CAUTION: The brake must be used ony when the motor has come to a standsti. The use of this brake for dynamic braking wi seriousy damage the brake and reduce the braking torque. Note: T1 300 ms, T2 = appication depending, T3 = 100 ms, T4 200 ms T1 T2 T3 T4 OFF ON DRIVE ENABLE OFF ON ALIME NTAZIONE 24 V BRAKE FRENO 24v POWER SUPPLY CLAMP C RELEASE FRENO BRAKE 0V REFERENCE E NAB LE 0 rpm VEMOTOR LOCITA ' MSPEED OTORE Fig 1.20 MECHANICAL BRAKING SEQUENCE Note: 1) The time for brake ON and OFF is different for different brakes modes. Pease refer to the motor cataogue for updated data. 2) Brake votage shoud be 24 vot (-0%, +10%), measured at the motor. PAGE 1-43

57 SECTION 2 : INSTALLATION MicroDS User's Manua SECTION 2 INSTALLATION 2.1 INTRODUCTION This section provides the necessary information for drive instaation. Dimensions and the required connections are aso detaied. 2.2 INSTALLATION REQUIREMENTS For correct instaation it is necessary to: Prepare a meta support on which to mount the drive. Leave at east 20mm (0.8 ) of space around the drive. Provide adequate ventiation to dissipate the heat produced by the drive and the recovery resistance if the drive is instaed in a cabinet. Provide shieded power connection cabes having an appropriate cross section for the motor. Provide a cabe run for the resover or encoder cabes, which is separated from the power cabes by at east 30cm (1 ) is a separate cabe duct. Provide grounding to PE using short cabes having an appropriate cross section to increase immunity from radio disturbance. Insta recommended EMC components for eectromagnetic compatibiity. Detaied information is avaiabe in the foowing paragraphs. PAGE 2-1

58 MicroDS User s Manua SECTION 2: INSTALLATION Fig 2.1 Typica Drive Instaation PAGE 2-2

59 SECTION 2 : INSTALLATION MicroDS User's Manua 2.3 ELECTROMAGNETIC COMPATIBILITY EUROPEAN DIRECTIVE EMC (89/336/EEC) Compiance with the European Directive 89/336/EEC is required for a eectric and eectronic products brought onto the European market after December 31 st, MicroDS drives with FASTACT and Goba motors meet the foowing EMC product standard reated to the Directive: EN (1996) and EN /A11 (2000): Adjustabe speed eectrica power drive systems. Part 3: EMC product standard incuding specific test methods. Second environment (industria) compatibiity eves. Required for CE-Compiance NOTE: To compy with the EMC Directive, the drive must be instaed with the appropriate EMC fiters. The instaation must adhere to the recommendation given in the foowing sections. Required for CE-Compiance NOTE: This equipment is not intended to be used on a ow-votage pubic network, which suppy domestic premises. If connected to such a suppy, this product may cause radio interference in which case suppementary mitigation measures may be required. Testing has been carried out at an independent test house to the above directive. The drive instaer is responsibe for ensuring compiance with the EMC reguations that appy where the drive is to be instaed. Recommended fitering, wiring, grounding and screening is detaied in this section. PAGE 2-3

60 MicroDS User s Manua SECTION 2: INSTALLATION FILTERING Fiter types The foowing fiters are recommended for EMC Compiance. Code Trade-mark Rated current [A] A 50 C (40 C) - Schaffner Fairite Camp Part # AT Schaffner FN 258-7/07 Max Votage [Vac] A 50 C Drive type / input V dc input 7 (8.4) 3x480 MicroDS 3/11 MicroDS 6/22 - Schaffner FN / (12) 1x250 MicroDS 3/11 (Singe Phase Operation ony) Tab 2.1 Recommended fiter types The Fairite camp shoud be paced on the 24V input ines with 4 turns wrapped in a common mode fashion (both ines wrapped in fiter in same direction). The FN258-7/07 can be used with up to four MicroDS drives. Care is necessary to ensure the power requirements of the appication do not exceed the fiter ratings Fiter Sizing In standard appications the fiter can be chosen from Tab 2.1. The fiters can be sized more accuratey if the effective current (rms) the drive absorbed in the appication is known. If this information is not avaiabe, the fiter can be sized according to the motor nomina current. PAGE 2-4

61 SECTION 2 : INSTALLATION MicroDS User's Manua FILTERS MECHANICAL DIMENSIONS The foowing tabe detais the mechanica dimensions of the suggested fiters. Code Trade-mark AT6009 Schaffner FN 258-7/07 - Schaffner FN350-12/29 TOP VIEW Dimensions [mm] Weig ht L1 L2 L3 L4 L5 L6 L7 [kg] ±0.8 ± Termina bocks ony 0.9 SIDE VIEW L1 L2 L5 L7 L6 L3 L4 Tab 2.2 Fiters mechanica dimensions PAGE 2-5

62 MicroDS User s Manua SECTION 2: INSTALLATION Fiter instaation The fiter must be mounted on the same pane as the drive. CAUTION: A space of at east 60mm (2.4 ) must be eft around the fiter for air circuation when the cabinet does not have forced ventiation. The fiter must be ocated as cose as possibe to the drive input. If the separation between fiter and drive exceeds 30 cm (1 ), then a fat cabe (muti-thread copper fat cabe) shoud be used for the RF connection between fiter and drive. Required for CE-Compiance NOTE: Before mounting the drive and the fiter to the cabinet, check that the pane surface is conductive. If not, remove any paint and/or other insuating materia before mounting the drive and fiter. The max tightening torque of mounting screws are as foows: FILTER MAX TORQUE FN 258-7/ Nm FN350 12/29 0.5Nm Tab 2.3 Mounting screws torque tabe PAGE 2-6

63 SECTION 2 : INSTALLATION MicroDS User's Manua EMC fiter can produce high eakage currents to ground (Protective Earth). The current eves associated with individua fiters are detaied in the associated fiter datasheet. Note1: if two phases are interrupted, eakage current can reach six times the defaut eve. Note2: The capacitors within the fiters have discharge resistors. CAUTION: The fiter must be connected to earth before connecting the suppy WARNING: High votage Interna fiter capacitors discharge time: approx. 10 seconds. PAGE 2-7

64 MicroDS User s Manua SECTION 2: INSTALLATION Wiring and shieding Required for CE-Compiance - Motor power cabe (see Fig 2.2 & Fig 2.3) The foowing cabes must be shieded, with 85% minimum shieding coverage: NOTE: if a power termina board is used at motor side, the shied must be RF connected to the ground screw by a meta cip - Externa recovery resistor cabe - DC Bus Cabe The shied of the cabes must be connected at both ends with a connection to a meta connector or with meta hose camps. For Sub-D connectors, the cabe shied must be connected to the meta case of the connector. When there is no connector at the drive, an EMC connector kit is provided. The insuation on the shied of the cabe must be stripped back and the shied RF connected to the stand-off through the hose camp, as in Fig 2.3. Fig 2.2 Grounding of shied To connectors at motor side - Encoder cabe (see Fig 2.2) Fig 2.3 Grounding of shied to housing - Anaog/Digita I/O cabe - RS485 cabe - Resover cabe (see Fig 2.2) PAGE 2-8

65 SECTION 2 : INSTALLATION MicroDS User's Manua Fig 2.4 Connection at Drive Side µa Size Note: Unshieded (three-phase power suppy) and Sub-D cabes are not shown in Fig 2.4 PAGE 2-9

66 MicroDS User s Manua SECTION 2: INSTALLATION Required for CE-Compiance NOTE: - The shieds of cabes inside the cabinet must be 360 camped to the cabinet wa (see Fig 2.5). - noisy cabes must be kept away from sensitive cabes by at east 30 cm (1 ). Noisy cabes incude input power wires, motor power and brake wiring. Sensitive cabes incude anaog or digita signa cabes; encoder cabe; Anaog/Digita I/O cabe; RS485 seria ink. - where noisy cabes must cross sensitive cabes the cabes shoud cross at right anges. The 24V Backup suppy cabe shoud be routed as far from the motor power cabes as possibe to ensure EMC compiance. Backpane (earth) Screen is effectivey earthed 360 of its radius Fig 2.5 Backpane connection PAGE 2-10

67 SECTION 2 : INSTALLATION MicroDS User's Manua Required for CE-Compiance Fig 2.6 Partition penetration Penetrating cabinet partitions shoud be accompished with a RF connection from the cabe shied to the encosure. If a connector is not used, the connecting copper strap shoud be kept as short as possibe (see Fig 2.6) Recovery resistor To meet the EMC Directive the encosures housing the recovery Required for CE-Compiance resistors must be conductive. The recovery resistor cabe must be shieded and the shied must be 360 camped at both sides. CAUTION: Before mounting the recovery resistor encosure to the pane ensure that any paint or other insuating materia is removed Shieding To effectivey shied the system, a the singe shieds (CNC, cabinet, machine, motor housing, cabes) shoud be connected together to form one fu shied. PAGE 2-11

68 MicroDS User s Manua SECTION 2: INSTALLATION Safety Aspects Noise suppression of motor drive systems requires consideration of the earthing system and its effectiveness at high frequencies. Safety aspects must aso be considered and must, where appropriate, take priority over EMC requirements. To reduce the radiated emissions, the use of capacitance to earth is very effective. These capacitors conduct current from phase to earth. Depending on the fiter design, this current can be in the order of hundreds of mii-amps. WARNING: Appropriate safety measures shoud be taken to ensure that this potentiay dangerous current fows to earth by a ow impedance connection. These fiters shoud be connected to Earth before being energized. CAUTION: It is recommended to disconnect the drive and the EMC fiters before carrying out the 50Hz AC votage test of CEI EN (Par.20.4), according to the Machinery Directive (89/392/EEC) and to the Low Votage Directive (73/23/EEC). PAGE 2-12

69 SECTION 2 : INSTALLATION MicroDS User's Manua 2.4 Summary of Connection Instructions Power connections can be divided into: a) Temporary connections. These are made to aow parameter setup with auxiiary power input ony and/or for testing purposes. b) Permanent connections. These shoud be made according to guideines outined above. Signa and motor feedback (resover or encoder) connections shoud aways be made according to the guideines given in this manua, to prevent noise affecting drive operation Feedback connection (encoder or resover) Feedback connection must aways be made according to the specification in of Section 1 regardess of whether the drive is being set up with Temporary or Permanent suppies. Inadequate shieding can cause feedback errors and may affect motor operation Temporary / test power wiring Unike the DS2000, the MicroDS must be suppied 24V backup power before the drive wi operate and any testing can be carried out. Remark: it is not possibe to enabe the output stages when the DC BUS is not powered. A DC BUS UNDERVOLTAGE FAULT wi be reported. If the drive is connected for test purposes ony, an unshieded motor power cabe can be used. The cross section of the cabe connecting the drive to the AC ine suppy and to the motor can be ower than that recommended for the drive size if drive peak current wi not be suppied and the connection is made for test purposes ony. The motor shoud aso be used at ow speed and reduced torque. A soft-start circuit is aways present and active on each drive. The ine current drawn by the drive during soft-start is imited by an interna 120Ω resistor. However, it is recommended to protect the power-input ine with fuses or a circuit beaker. PAGE 2-13

70 MicroDS User s Manua SECTION 2: INSTALLATION Summary of power wiring To correcty wire and insta the drive it is necessary to imit eectromagnetic disturbances between the servosystem and other eectronic devices. The measures needed to ensure this are summarized in the foowing points. a) Insta the EMC fiter on the input ine to reduce the conducted emissions on the AC mains suppy. b) Provide connections between the fiter and drive using minimum cabe engths. c) Use a shieded cabe motor power cabe. d) Use shieded cabe for the feedback signa connection between motor and drive. e) Pace motor power and feedback cabes in separate ducts or separated by at east 30 cm (1 ). f) Use shieded cabes for the anaog reference cabes and digita I/O cabes. Separate them from the motor power cabes. g) Use twisted pair shieded cabe for the encoder connections between the drive and the controer. If termination is not provided, terminate the cabe at the contro side using a 220Ω resistor. PAGE 2-14

71 SECTION 3: STARTUP MicroDS User's Manua SECTION 3 STARTUP 3.1 INTRODUCTION The section outines a series of simpe steps, which wi aow a user to quicky and easiy setup a MicroDS drive for the first time. The information is provided in a manner that is simpe and descriptive to aow it to be understood by those not famiiar with servo-drive operation. Refer to the previous sections for more detaied information on cabe connections. Refer to Section 5 for a detaied description of motor and drive parameters. 3.2 DRIVE SETTING UP INFORMATION To set up the servo-drive and motor, the drive must be configured with the correct motor and drive parameters (uness configured by Moog at the customer s request). The necessary parameters are detaied beow: Motor settings 1) Number of motor poes 2) Motor max current 3) Motor votage rating 4) Motor nomina speed 5) Motor BEFM (at 1000 rpm) 6) Motor resistance 7) Motor inductance 8) ID magnetization current (for asynchronous motors ony) 9) SG sip (for asynchronous motors ony) 10) Resover or Encoder feedback. 11) Resover/Encoder phase. Can be determined using the Phasing function. 12) Number of encoder puses / number of resover poes 13) Number of puses per eectrica revoution needed by the CNC (resover interface ony) 14) Zero marker width (resover interface ony) PAGE 3-1

72 MicroDS User s Manua SECTION 3: STARTUP Remark: It is not possibe to modify the number of output puses and the zero marker width when operating with encoder feedback. This function is avaiabe ony with resover feedback. Drive settings 15) Remote \ Loca drive enabe 16) Max. motor speed command 17) Max. drive current 18) Speed or torque contro. Set to speed contro when drive is used for testing. 19) ACC/DEC vaue (ony in speed contro mode. Function is disabed when set to 0) 20) Anaogue \ Digita reference contro 21) Digita (set by drive) or anaog (set by contro) current (torque) imit 22) Speed oop VKI and VKP (speed integra and speed proportiona gain). Set by motor oading. 23) LPF fiter setting on error and reference. Notch fiter setting Some of the information may be missing during instaation. However, the instaation can be carried out, as it is possibe to enter the data subsequenty using the buit-in keypad or the MOOG GUI Remark: The dispay indicates drive & motor status by the switching on or off the dispay backight. The backight is it if no FAULTS are detected (refer to Section 5). The dispay is not it if no FAULTS are detected (refer to Section 5). PAGE 3-2

73 SECTION 3: STARTUP MicroDS User's Manua 3.3 First start-up (on test bench, for testing purposes) Connect the power suppies (24V backup and AC Mains). Connect the motor feedback (resover or encoder) and motor power cabe. Connect an anaog reference to V ref and enabe signas (signa not active) to DRIVE ENABLE and REFERENCE ENABLE. Power the drive (24V backup & AC Mains) without appying DRIVE ENABLE or REFERENCE ENABLE. The dispay backight shoud ight if no fauts are detected. If a faut is detected, check fauts in the appropriate menu (See Section 5). Hand-rotate the motor shaft. Check the speed reading dispayed in the Dispay Variabes menu (See Section 5). To power the motor, appy DRIVE ENABLE and the REFERENCE ENABLE. The motor shoud rotate correcty if a connections and settings are correct. If the motor does not rotate correcty, refer to Section 8 (Troubeshooting). 3.4 Configuration for instaation in the eectrica cabinet. Additiona setting for instaation, Drive remote enabe. In order for the CNC to contro drive enabe, the Drive enabe setting shoud be set to remote. A test settings used on the test bench which imit performances shoud be removed. PAGE 3-3

74 SECTION 4: OPERATION MicroDS User's Manua SECTION 4 OPERATION 4.1 INTRODUCTION This section detais the operation of the MicroDS. 4.2 GENERAL PRINCIPLES The drive and motor operate as an eectro-mechanica converter transforming eectrica energy, drawn from the power ine, into mechanica energy Input eectric power conversion The three-phase suppy votage is converted to DC using a diode rectifier and smoothed by means of capacitors. The capacitors charge current is imited using a soft start resistor. The operation of the softstart is controed by software. This agorithm used is sef-adapting to different suppy votages. Softstart Circuit DC+ L1 L2 L3 DC- Fig 4.1 Input Rectifier & Softstart PAGE 4-1

75 MicroDS User s Manua SECTION 4: OPERATION Output eectric power conversion The DC bus is connected to a three-phase bridge comprised of six IGBTs and six diodes. The IGBTs are controed using a PWM (Puse Width Moduation) waveform. This appies a pused votage to the motor. The widths of the votage puses are controed to generate a sinusoida current in the motor thereby generating a smooth torque. As the IGBTs aways operate in a saturated mode, the osses in the ampifier are kept to a minimum. The IGBTs are switched with a 10kHz switching frequency. This imits the osses in the motor that resuts from excessive high frequency current rippe in the windings. DC+ U V W DC- Fig 4.2 Output section diagram Each IGBT is protected from short circuit and overoad. The protection is managed directy by the contro card Contro section The drive measures the current anguar position and maintains an ange of 90 between the magnetic fied generated by currents and the fied generated by the magnets on the rotor. The motor position is determined by the feedback signas derived from the encoder or from the resover through advance signa processing on the contro card. PAGE 4-2

76 SECTION 4: OPERATION MicroDS User's Manua From the data provided in the drive and motor parameters and the feedback from the motor, the drive adjusts the commands to the IGBT appropriatey to suppy the currents. The current feedback is obtained by means of HALL sensors paced on motor phases U and V. The position feedback is derived either from a resover or an encoder. Low Pass Fiters (LPF) fiters on the reference and on the speed error aow the servo-system (drive + motor) response be adapted to the appication characteristics. The Notch fiter aows the affects of resonances in the mechanica system to be reduced or eiminated. Resonances can occur due to the imited rigidity of the motor transmission (mechanica transmissions, bets, etc.), particuary in presence of high inertia ratios between motor and oad (mismatched oad condition). Speed Feedback Position feedback (APHAPOS) Speed Loop (VKP.VKT) (Max speed) (ACC.DEC) Reference (Ref. Scae) LPF Fiter (Frequency) LPF Fiter (Frequency) Notch Fiter (Frequency, Band, Gain) Current feedback Current Loop (Rw, LW, E1000, ID, SG) (Max Current) PWM Ampifier (imit) feedback Motor (size, votage, rpm) (encoder) (Poes, puses zero) Fig 4.3 Servo-system bock diagram PAGE 4-3