OPERATING MANUAL SERIES R B F 400 VAC BRUSHLESS RACK SYSTEM

Transcription

1 OPERATING MANUAL SERIES R B F 400 VAC BRUSHLESS RACK SYSTEM Version 1.0 (European 1.0) This is a general manual describing a series of racks receiving Servo Amplifiers having output capability suitable for driving Brushless Servo Motors. This manual may be used in conjunction with appropriate and referenced drawings pertaining to the various specific models. Maintenance procedures should be attempted only by highly skilled technicians using proper test equipment. Read your warranty provision carefully before attempting to adjust or service the unit.

2 RECEIVING AND HANDLING Upon delivery of the equipment, inspect the shipping containers and contents for indications of damages incurred in transit. If any of the items specified in the bill of lading are damaged, or the quantity is incorrect, do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt. Claims for loss or damage in shipment must not be deducted from your invoice, nor should payment be withheld pending adjustment of any such claims. Store the equipment in a clean, dry area. It is advisable to leave the equipment in its shipping container until ready for use. Each amplifier is checked carefully before shipment. However, upon receipt, the user should make sure that the amplifier received corresponds to or is properly rated in terms of rated voltage and current for the type of motor which is to be driven. The descriptive label affixed to the amplifier specifies electrical ratings. Infranor Inc. reserves the right to change any information contained in this manual without notice. Infranor Inc. does not assume any responsibilities for any errors that may appear INFRANOR INC. 2

3 OPERATING MANUAL INFRANOR SERIES RBF BRUSHLESS RACK SYSTEM (March 1998) GENERAL INTRODUCTION SPECIAL FEATURES SPECIFICATIONS TECHNICAL SPECIFICATIONS FOR RBF-400 RACK SERIES TECHNICAL SPECIFICATIONS FOR SHUNT REGULATOR AMPLIFIER CURRENT TABLE FOR CONTINUOUS CYCLE CONNECTIONS GENERAL CONNECTIONS DIAGRAM RBF-400 BACK PANEL CONNECTIONS POWER CONNECTIONS DIMENSIONS AMPLIFIER DIMENSIONS RBF-400 RACK DIMENSIONS EXTERNAL RESISTOR DIMENSIONS LINE FILTER DIMENSIONS BF-400/45- BF-400/ THREE PHASE LINE REACTANCE DIMENSIONS AUTOTRANSFORMER DIMENSIONS SHIELDING RECOMMENDATIONS

4 1.0.0 GENERAL Introduction The RBF-400 rack system is designed for the Infranor brushless amplifier and SMTBD Series independently of the different amplifier current rating. The power bus voltage is floating and is not connected to the chassis, therefore allowing a transformerless operation. The power supply is integrated into the rack on the left side flange which act as an heat sink. Motor and power supply connections are in the rear of the rack for better noise immunity. A shunt regulator system is also part of the power supply. Three different power dissipations are available, depending upon the energy regenerated by the system Special features 3 axis in a standard 19" rack, height = 355mm, depth = 285mm. 45ADC or 90ADC DC bus power supply available Transformerless operation Fan cooling for optimum heat dissipation (mounted on top) Optional shunt regulator modules available. Rear rack mounting. Easy amplifier plug-in connections. Terminal strip connector over the rack. Standard auxiliary input voltage for logic supply SPECIFICATIONS Technical specifications for RBF-400 Rack Series The RBF-400 rack Series can accept up to 3 axis including one DC bus power supply. Main Power Supply The main DC power supply has a rating of 45 ADC or 90 ADC. It will be necessary to calculate the continuous rms current of the overall system in order to properly size the current rating. The use of an isolation transformer is not necessary, however, an autotransformer can be used to step up/down the voltage. The rack incorporate an in-rush limitting device allowing to use the system without any type of transformer, however a line inductor is recommended but not mandatory to reduce harmonics. Rated input voltage 3Ø 440VAC 50/60 Hz Maximum input voltage 480 VAC (including all variations) Minimum input voltage 340 VAC Maximum wire gauge 6 AWG 4

5 Auxiliary Supply When position interface is used, the position information can be lost if power failure occurs. By applying a separate logic voltage (220VAC single phase), it will retain position information even if main power supply fails. The auxiliary supply input is also used when fan(s) are mounted on the rack chassis Rated input voltage 1Ø 220VAC + 10% 50/60 Hz Maximum input voltage 260 VAC (including all variations) Minimum input voltage 180 VAC Rated output current 1A Logic Signals Some logic signals are available on the rear of the rack by the mean of an eight pin connector. They can be used for common logic signals to all amplifiers as follows: "Inhibit" common to all axis "Power ready and D/R Resistor OK" common to all axis "Amp ready" common to all axis "Idyn" common to all axis In standard all axis signals are in series, but can be set independently from each other by means of jumpers (See chapter 3.2.0). 5

6 Designation of RBF Rack Series BF V F-400 Axis 1 Axis 2 Axis 3 FILTER SIZING 70 according to the power supply NUMBER OF FANS Big fan (90 l/s) - Ex.: 1 big fan = V01 BRAKING RESISTOR D2 22 Ohm / 280 W, mounted on the rack flange Dp 22 Ohm / 280 W, external E 11 Ohm / 560 W, external AXES POSITION 2: axis of 2 spacings (24 TE) Note: decreasing current sizing from left to right The power supply requires 1 spacing (12 TE) Power supply Axis 1 Axis 2 Axis 3 3 axes of 24 TE each A A B 6 84 TE 462,80 481, TE 340,88 359, TE 218,96 237,96 30 B A continous power supply on DC bus A continous power supply on DC bus Dimension of the D2 resistor Dimensions are in mm Note: A fan is required depending upon the amplifier RMS current rating. They are mounted on top of the rack. The input voltage is applied to the auxiliary supply input (XA2). 6

7 2.2.0 Technical specifications for shunt regulator Several shunt regulator circuits are available, depending on the energy regenerated by the system. We do recommend to consult Infranor for proper sizing of this device. Three shunt regulators can be integrated with the RBF-400 rack series as follows: Type Continuous Power Peak Power Shunt Resistors D side flange Dp external resistors E external resistors Type D2: A resistor of 22Ω / 280W is mounted on the outer left side flange of the rack with a finger guard cover. The overall width of the RBF-400 rack will increase by about 30mm (1.2in). This version is standard if not specify otherwise. Type Dp: One resistor of 22Ω / 280W are mounted by the customer via two connectors placed on the rear of the rack. An IGBT transistor is used allowing higher dissipated power. This option is used in case the additional 30mm (1.2 ) of the D2 option are too wide for the rack mounting. Type E: Two resistors of 22Ω / 280W are mounted by the customer via two connectors placed on the rear of the rack. An IGBT transistor is used allowing higher dissipated power. These resistors have to be wired in parallel to allow a dissipation of 560W continuous Amplifier current table for continuous cycle Amplifier U rated Vrms Imax Arms 1s Continuous current Arms Fan type 2 Dimensions SMTBD1-400/ TE SMTBD1-400/ TE SMTBD1-400/ TE SMTBD1-400/ TE Fan type 2 = 220CFM Current rating are for limiting mode. See amplifier operating manual for fusing current rating 7

8 3.0.0 CONNECTIONS General connections diagram K K.1 L1 L2 L3 GND N 400 VAC T/X c P 12/24 X OF T P N (³) Power relay SD N 1 (#) N 2 Aux. ON Aux. OFF Amp. ready *Power ready 24 V Power ON Power OFF Aux. relay ENABLE Disable K1 Power ON Amp. ready Inductanc el400/25/35 80 Aux. relay Power relay Power relay *Power ready 0 V K.1 ENABLE relay Aux. relay Power OFF +24 V XA1 Filter F400-35/70 L1 L2 L XA2 1 Aux 2 Aux. relay Br aki ng res ist or 3 4! * Power ready: only available on X5 of the rack backplane. If not using the Power Ready signal, make JK jumper on the amplifier in order to have Amp. Ready taking into account the power statement; but, in this case, there is no control of the braking system transistor. In order to take into account the short-circuit protection of the braking system transistor, Power Ready must be used and the KL jumper must be made on the amplifiers. BF 400 RACK X X ENABLE GND Amp. ready AMPLIFIER Power ready GND U V W! Rack chassis grounding 4 cables + shield MOTOR X1 RES 6 pair shielded cables (+ thermal probe) (#) : 3 A phase and neutral circuit breaker, curve C. (³) : Differential circuit breaker mandatorily remote controlled by security voltage 12/24 V or 48 V ca and cc 8

9 3.1.1 Principles It is very important to follow some precautions to avoid ground loops around the zero volt logic supply or noise disturbances in order to obtain good results. Here are a few points to pay special attention: Every conductor cable (carrying a potential) MUST be shielded. Two or more wires in the same sleeve MUST be twisted pair and shielded. A shield not carrying a potential can be connected at both ends with a 360º clamp connection (shield to be connected over the whole circumference of the cable by a clamp). The reference of potential IS connected to earth ground. Cable with low potential should NEVER run in the proximity of power lines. Long reference potential leads is suitable ONLY if these loops have a very low impedance (<0.1 ohm). A shielded cable has NO effect if it is not connected: 1. to a reference potential 2. by a short length to a reference potential (few inches) 3. by a 360º shielded connection. If a reference of potential is existing like a main chassis or a cabinet with a low impedance between the different elements of its volume, it should be used to connect all reference to it and also connect this reference to the earth ground. 9

10 3.1.2 Three phase connection without autotransformer In order to improve the current harmonics of a directly fed 400 VAC three phase connection, an inductance sized to match the rack or amplifier current rating is recommended. This inductor is connected in series with the rack input. This inductor is not mandatory for the operation of the system. The reference number for the inductor is: I or I depending on the current rating. If connection is made directly to the 400 VAC without the inductor, then the current rating of the cable must be at least 1.5 times the current rating of the rack. All three phases must ALWAYS be connected to the power supply via a three-phase differential circuit breaker. Example: Type Réfex XC40 + Vigi 300 ma unit, ref 'Merlin Gérin) + Voltage adjustment module MDU, ref (Merlin Gérin). Circuit-breaker sized according to the application or to the amplifier rating: 10 A, ref ; 15 A, ref ; 20 A, ref ; 25 A, ref ; 32 A, ref ; 38 A, ref (Merlin Gérin). Note: Fuses cannot be used immediatly before the power input, because if one of the fuses fails, the life of the system will be shortened when only working with two phases. The magnetothermal circuit-breaker should be used in place of fuses if the recommended differential circuit-breaker is not available. The auxiliary supply must ALWAYS be connected to the 220 VAC single-phase mains. The connection to the auxiliary supply must be made via a phase/neutral circuit breaker. Example: Type DPN, curve C, ref? or DPN N, curve D, ref by Merlin Gérin. Notes: The connections to the main three-phase supply and the single phase auxiliary supply must ABSOLUTELY cut off ALL POLES. Direct connection to the main line is the most economical method, but it it is possible to connect the supplies via a transformer with grounded screen where local supplies dictate. ELECTROMAGNETIC COMPATIBILITY The motor output is equipped with a common mode inductor and the auxiliary supply is also equipped with a line filter. In order to conform with the CE specifications EN standard, group 1, class A, a main line filter for the power is required and must be mounted before the 400 VAC three-phase rack input and as close as possible to the rack in order to ensure equipotentiality. The RBF-400 rack chassis MUST be connected to earth ground in order to ensure the user's protection in case of an isolation failure. INFRANOR will withdraw its warranty on any material that does not meet these requirements. 10

11 3.2.0 RBF-400 back panel connections JUMPER INHIBIT AMP. READY "A" closed on last axis Serial Switches G and H ON "A" closed on each axis Independent Switches G and H OFF "B" closed on last axis Switches E and F ON "B" closed on each axis Switches E and F OFF "N" closed on last axis Switches O and P ON "N" closed on each axis Switches O and P OFF Switch D ON Serial IDYN Serial Independent POWER OK D/R OK Serial Independent only available on connector X5 Switch D OFF Independent In standard, all these signals are wired in series. Consequently, the jumpers A. N, B are closed on the last axis. Jumpers D/R OK are closed on all axis except for the first one X5 - Common signals connector (8 points orange) Pin Function Remarks 1 Common Inhibit Enable to 0 Volt, disable if open 2 0 Volt Inhibit 3 Power ready + D/R OK All relay contacts of each axis in series 4 Power ready + D/R OK if one fails, relay opens. 5 Amplifier ready All relay contacts of each axis in series 6 Amplifier ready if one fails, relay opens. 7 Idyn limitation All relay contacts of each axis in series 8 Idyn limitation if Idyn limitation occurs, contact relay opens. See amplifier operating manuals for more details on the function of these signals. Relay output specifications is rated at 50V, 100mA 11

12 3.2.2 RBF-400 back panel diagram FRONT VIEW OF THE RACK D O P E F G H X5 + + B A N BACK PANEL 24TE 12

13 3.3.0 Power connections XA1 X MOT X MOT XA2 X5 POWER SUPPLY AXIS 1 AXIS 2 AXIS n Power supply connector XA1 - XA2 The power supply connector includes the main line input XA1, the auxiliary and/or fan(s) input XA2 and the connections for the braking resistor(s) according to the option (Dp or E option). 3 phase 400 VAC XA1 Maximum section: 16 mm2 (AWG 6) Maximum continuous current: 82 A L1 L2 L3 Earth/Ground: Screw 5 mm XA Resistor option E 220 VAC Auxiliary supply Fan(s) supply Resistor option E and Dp 13

14 3.3.2 Motor connection EACH MOTOR HOUSING MUST BE CONNECTED TO EARTH GROUND (resistance <0.1 ohms). These connections must be independent of the main power supply voltage. Motor cables must be shielded to avoid the effects of common mode. The recommended cable is a four wires shielded (Mavilor p/n , , Belden p/n 9367). Each motor shield must have a "360 " connection on the motor connector side AND on the clamp provided in the Infranor rack chassis. This will be in accordance with the electromagnetic requirement of IEC 801. The motor cable cannot run in the proximity of the resolver or command cables. The motor cable gauge must be adapted to the rating of the amplifier continuous current. Motor cable Motor cable shield Shield clamping collar over 360 degrees or cable tie Ground screw 4mm Motor connector U V W Maximum section: 6 mm² (AWG 10) Maximum continuous current: 44 Arms 14

15 3.4.1 Main line three phase filter In order to comply with the CE approval and the electromagnetic standard EN group 1 class A, it is necessary to add a three phase line filter as shown in diagram chapter The line filter must be connected as close as possible to the RBF-400 rack (max. 30cm). A metal braid must connect the filter ground terminal to a fastening screw of the RBF-400 rack to maintain equipotentiality. Two current rating line filter are available, that is the BF-400/45 for the RBF-400/45 and the BF-400/90 for the RBF-400/90. The curves below shows the frequency response: Rejection on the main line (curve 8 and 9) Radiated electromagnetic field (curve 10) Curve no.8 15

16 Curve no. 9 Curve no.10 16

17 4.0.0 DIMENSIONS Amplifier dimensions 233,4 mm 24 TE 220 mm Dimensions are in mm RBF-400 rack dimensions 513 mm (option D2) 483 mm 462,8 mm D2 190,5 mm 36,7 mm 355 mm 90 mm 80 mm 266 mm 286 mm 7 x 12 Dimensions are in mm 17

18 External resistor dimensions Braling resistor Power A B C Dp 280W E 560W Dimensions are in mm Line filter dimensions BF-400/45- BF-400/ ,5 MAINS L1 L2 L = = 5 L1 L2 L3 218 LOAD Dimesions are in mm 18

19 4.5.0 Three phase line reactance dimensions W H D CONNECTORS MD MW MODEL RACK CURRENT H W D MW DW LBS. I RBF-45 45A I RBF-90 90A Dimensions are in inches Autotransformer dimensions W H D CONNECTORS MD MW Three phase autotransformer 60Hz Temperature Class H, 155 Degree C Insulation Class N, 200 Degree C Open frame MODEL PRIMARY VOLTAGE SECONDARY VOLTAGE KVA H W D MW DW ATR / ATR / ATR / ATR / ATR / Dimensions are in inches 19

20 4.7.0 Shielding recommendations There must never be a shield interruption on the whole cable length. Self-sticking copper ribbon if necessary for increasing the shield diameter to get properly tightened under the clamp Connector on MAVILOR motor for resolver and motor RBF RACK The cable can be soldered on the shield because the connector box is metalic This solution does not correspond exactly to the IEC requirements, but it is acceptable Connector box on the MAVILOR motor Metallic or metal plated plastic Sub-D pin package 360 degrees shield ensured by the tightening clamp Sub-D connector The fastening screw must be tightened in order to ensure the shield continuity on the amplifier housing Note: When the 360 degrees shield is made by means of a clamp, it is not necessary to connect a wire to the appropriate pin on the Sub-D connector 20