IC800SSD Hardware Manual Pub 348R5. for models. A publication of

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1 IC800SSD Hardware Manual Pub 348R5 for models IC800SSD104S1A IC800SSD104RS1A IC800SSD107S1A IC800SSD107RS1A IC800SSD407RS1A IC800SSD216S1A IC800SSD216RS1A IC800SSD420RS1A IC800SSD228S1A IC800SSD228RS1A A publication of 1050 Highland Drive Ann Arbor, Michigan Phone: (734) Fax: (734) Whedco Incorporated, a Subsidiary of GE Fanuc. All rights reserved. Because GE Fanuc equipment may be applied in many diverse situations and in conjunction with products from other vendors, the user and those responsible for specifying this equipment must determine for themselves its suitability for the use intended. In no event shall Whedco Incorporated or GE Fanuc be liable for loss of use, profit, or consequential damages or damage to other equipment resulting from the use of any Whedco or GE Fanuc product. The figures and examples in this manual are designed to demonstrate general concepts for installing and communicating with GE Fanuc. The users should always verify interconnection requirements to and from other equipment and confirm installation and maintenance requirements for their specific application. In no case shall Whedco Incorporated or GE Fanuc be liable for actual use based on the guidelines mentioned herein. GE FANUC Parts

2 Contents Chapter 1 Drive Specifications...3 Input Power...3 Output Power...4 Environmental...4 RS-232 Communication...4 Digital Inputs and Outputs...5 Analog Inputs and Outputs...5 Differential Inputs and Outputs...6 Position Feedback...6 DC Power Supplies...7 Chapter 2 Installation...9 Physical Installation...9 Wiring...10 Motors...16 Chapter 3 Serial Communication Port...17 Chapter 4 Mechanical Drawings...19 Chapter 5 User Connections...21

3 CHAPTER 1 Drive Specifications Input Power IC800SSD Series The IC800SSD is suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes when protected by RK5 fuses listed in table 1.1b. See tables 1.1a and 1.1b for the maximum continuous input power requirements of each model. The actual input power and current is a function of the motor's operating point and the duty cycle. Table 1.1a Maximum Continuous Input Current and KVA for IC800SSD Voltage range IC800SSD104 and IC800SSD107: VAC, 1 or 3 phase IC800SSD407 and IC800SSD420: VAC, 3 phase IC800SSD216 and IC800SSD228: VAC, 3 phase Frequency range Hz Current, max. continuous See table 1.1b Power, max. continuous See table 1.1b Fuses See table 1.1b for recommended branch circuit fuse current ratings. IC800SSD104: No internal fuses. IC800SSD107, IC800SSD216, and IC800SSD228: No internal fuses in motor power section. Logic power supply fused internally with 2A, 250 volt fuse on 2L1 input only. The 2L2 input is not fused. IC800SSD407 and IC800SSD420: No internal fuses in motor power section. Logic power supply fused internally with 5A, 125 volt fuse on +24V input only. The COM input is not fused. Isolation transformer None required. For the SSD104, 107, 216, and 228, if the supply voltage is above 250 VAC, the voltage must be dropped to 230 VAC. For the SSD407 and 420, if the supply voltage is above 528 VAC, the voltage must be dropped to 460 VAC. The transformer should be sized to provide adequate power under all operating conditions. For single-phase operation, choose a transformer rated for a minimum of 125% of the drive maximum continuous input KVA. For three-phase operation, choose a transformer rated for a minimum of 100% of the drive maximum continuous input KVA. Table 1.1b Maximum Continuous Input Current and KVA for IC800SSD Model 1 phase or 3 phase Maximum Continuous Input Maximum Continuous Input KVA Recommended Branch Circuit Fuse Current Ratings RK5 Class Fuses Current IC800SSD Arms Vac 10A time delay IC800SSD Arms Vac 7.5A time delay IC800SSD Arms Vac 15A time delay IC800SSD Arms Vac 15A time delay IC800SSD Arms Vac 20A time delay IC800SSD Arms Vac 30A time delay IC800SSD Arms Vac 10A time delay IC800SSD Arms Vac 25A time delay GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Drive Specifications - Page 3

4 Output Power Table 1.2: Output Power for the IC800SSD104 and IC800SSD107 Voltage range V rms 3 phase Frequency 0 1,000 Hz fundamental (16.4 KHz PWM) Current (a) IC800SSD104: 4.3 Arms continuous per phase, 8.6 Arms peak IC800SSD107: 7.2 Arms continuous per phase, 14.4 Arms peak Table 1.3: Output Power for the IC800SSD216 and IC800SSD228 Voltage range V rms 3 phase Frequency 0 1,000 Hz fundamental (16.4 KHz PWM) Current (a) IC800SSD216: 16 Arms continuous per phase, 32 Arms peak IC800SSD228: 28 Arms continuous per phase, 56 Arms peak Table 1.4: Output Power for the IC800SSD407 and IC800SSD420 Voltage range V rms 3 phase Frequency 0 1,000 Hz fundamental (8.2 KHz PWM) Current (a) Note for tables 1.2 through 1.4: (a) The outputs are provided with internal overload protection. IC800SSD407: 7.2 Arms continuous per phase, 14.4 Arms peak IC800SSD420: 20 Arms continuous per phase, 30 Arms peak Environmental Table 1.5: Environmental Specifications Operating temperature (a) 32 to 122 degrees F (0 to 50 degrees C) Storage and shipping temperature -40 to 176 degrees F (-40 to 80 degrees C) Altitude (b) 1,000 m. (a) assumes heatsink orientation is vertical (b) consult factory for maximum continuous output derating for altitudes greater than 1,000 m. RS-232 Communication Table 1.6: RS-232 Communication Specifications Maximum Addressable Units 1 Maximum Length of Serial Data Link 50 feet Baud Rate 9,600 IC800SSD Hardware Manual, Pub 348R5 Drive Specifications - Page 4

5 Digital Inputs and Outputs Table 1.7: Digital Inputs Operating Range Maximum Off Input Voltage Minimum On input Voltage Load Interface Format VDC, 30 VDC maximum 4 VDC 10 VDC 2K Ohms Optically isolated, source/sink user configurable Table 1.8: Digital Outputs Operating Range Maximum On Resistance Maximum Load Current Maximum Off Leakage Current Interface Format VDC, 30 VDC maximum 35 Ohms 100 ma 200 na Optically isolated, source/sink user configurable Analog Inputs and Outputs Table 1.9: Analog Inputs Number 2 Operating Range +/- 10 VDC Resolution 12 bits Input Impedance 50K Ohms Table 1.10: Analog Outputs Number 1 Parameter user programmable; or velocity, current, or following error Operating Range +/- 10 VDC Resolution 8 bits Current 5 ma GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Drive Specifications - Page 5

6 Differential Inputs and Outputs Table 1.11: Differential Encoder Inputs Number 1 Input Voltage 5, 12, or 15 VDC Input Format Single-ended or differential; quadrature or pulse/direction or CW/CCW; Square or sine wave Maximum Line Count Frequency 3 MHz Table 1.12: Differential Encoder Outputs Number 1 Output Voltage 5 VDC Output Format Differential; quadrature or pulse/direction or CW/CCW; square wave Maximum Line Count Frequency 250 KHz Position Feedback Table 1.13: Encoder Models SSD104S1A SSD107S1A SSD216S1A SSD228S1A Number 1 Resolution 2,500 lines per revolution Maximum Line Count Frequency 3 MHz Input Format Differential; quadrature or pulse/direction or CW/CCW; square wave Table 1.14: Resolver Models SSD104RS1A SSD107RS1A SSD216RS1A SSD228RS1A SSD407RS1A SSD420RS1A Number 1 Resolution 4,096 pulses per revolution Maximum Speed 15,000 rpm Type control transmitter Phase Shift +/ khz Null Voltage < 20 5 khz Transformation Ratio 0.5 IC800SSD Hardware Manual, Pub 348R5 Drive Specifications - Page 6

7 DC Power Supplies Table 1.15: DC Power Supplies +5 volts 0.5 Amps +12 volts 0.5 Amps GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Drive Specifications - Page 7

8 This Page Left Blank Intentionally IC800SSD Hardware Manual, Pub 348R5 Drive Specifications - Page 8

9 CHAPTER 2 Installation Physical Installation Location Location of the IC800SSD is important to achieve proper performance and operating life. The unit is designed with "open" construction. The unit must be installed in an enclosure that protects personnel from contact with wiring terminals and provides a pollution degree 2 environment (per IEC 664-1) that protects the unit from: = = = = = Corrosive gases or liquids Vibration Conductive pollution including extreme or condensing humidity and airborne metallic particles Accidental contact by persons using the equipment Temperature extremes beyond the equipment ratings. It is possible to reduce condensation and high humidity by providing ventilation or by applying continuous heat through the use of heaters or continuous energizing of the equipment when it is in use. Continuous energizing is considered to exist when the equipment is operated with interruptions of a duration that do not permit cooling to the point of condensation to occur. Panel Layout The mounting dimensions appear in Chapter 4. Choose a location in the equipment panel to meet panel electrical safety, electrical signal integrity, and temperature specifications. Heat Load and Cooling Table 2.1: Heat Load and Cooling Model Heat Load (Approximation) Maximum IC800SSD watts + (35 * duty_cycle) watts 60 watts maximum IC800SSD watts + (65 * duty_cycle) watts 100 watts maximum IC800SSD407 IC800SSD watts + (150 * duty_cycle) watts 200 watts maximum IC800SSD watts + (250 * duty_cycle) watts 310 watts maximum IC800SSD watts + (280 * duty_cycle) watts 340 watts maximum IC800SSD104, IC800SSD107, and IC800SSD407 are designed to operate at full rated current with only natural convection cooling at ambient temperatures up to 50 degrees C. IC800SSD407, IC800SSD216, IC800SSD420, and IC800SSD228 models have built-in fan cooling. The IC800SSD must be installed vertically for effective cooling. Allow a minimum clearance of 3 inches above and below the unit. A minimum of 2 to 3 inches clearance is also recommended on the right and left sides of the unit. GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Installation - Page 9

10 Wiring Wiring diagrams for the IC800SSD are provided in Chapter 5, User Connections. See page 3, Input Power, for branch circuit power requirements and fuse and isolation transformer ratings. General Wiring Considerations All power, input, and output (I/O) must be in accordance with Class I, Division 2 wiring methods as defined in Article 501-4(b) of the National Electrical Code, NFPA 70 for installations within the United States, or as specified in Section of the Canadian Electrical Code for installation within Canada. European installations must comply with the EU Low Voltage Directive. Attach wiring connections for the main circuit according to Tables 2.2 through 2.6 while observing the following cautions:! Use vinyl-sheathed or equivalent wire rated for the drive mains voltage or greater. Wire size should be determined considering ampacity and codes.! Never connect AC main power to output terminals.! Never allow wire leads to contact the enclosure.! Never operate the IC800SSD without an earth ground.! WARNING--When using this equipment in a Hazardous (classified) location: A. WARNING--Explosion hazard--substitution of components may impair suitability for Class I, Division 2; B. WARNING--Explosion hazard--when in hazardous locations, turn off power before replacing or wiring modules; C. WARNING--Explosion hazard--do not disconnect equipment unless power has been switched off or the area is known to be nonhazardous. Table 2.2: IC800SSD104S1A Power Terminal Connections and Wire Sizing Terminal Description Connect to Wire Size Notes Symbol AWG Ground Motor ground terminal ,2 T Output phase T Motor phase T ,2 S Output phase S Motor phase S ,2 R Output phase R Motor phase R ,2 Ground Power system ground L3 Drive input power - do not VAC connect for 1 phase input L2 Drive input power VAC L1 Drive input power VAC Notes for table 2.2: 1 - AWG size for stranded copper wire. Minimum wire size required will depend on motor and load. Consult National Electrical Code Handbook ampacities tables for proper wire size. 2 - Cable available from GE Fanuc as part number IC800SKC xxx, where xxx is the cable length in meters. IC800SSD Hardware Manual, Pub 348R5 Installation - Page 10

11 Table 2.3: IC800SSD107 Power Terminal Connections and Wire Sizing Terminal Description Connect to Wire Size Notes Symbol AWG Ground Motor ground terminal ,2 T Output phase T Motor phase T ,2 S Output phase S Motor phase S ,2 R Output phase R Motor phase R ,2 Ground Power system ground L2 2L1 Logic input power VAC L3 Drive input power - do not connect for 1 phase input VAC L2 Drive input power VAC L1 Drive input power VAC EXT External clamp resistor INT INT Internal clamp resistor EXT DC+ High voltage motor power bus positive External clamp resistor Table 2.4: IC800SSD216 and IC800SSD228 Power Terminal Connections and Wire Sizing Terminal Description Connect to Wire Size Notes Symbol AWG R Output phase R Motor phase R ,2 S Output phase S Motor phase S ,2 T Output phase T Motor phase T ,2 Ground Motor ground terminal ,2 DC+ High Voltage motor power bus External clamp resistor positive INT Internal Clamp Resistor EXT EXT External Clamp Resistor INT DC- High Voltage motor power bus negative No connection 1L1 1L2 1L3 Drive input power VAC Ground Power system ground L2 Logic input power VAC L1 Notes for tables 2.3 and 2.4: 1 - AWG size for stranded copper wire. Minimum wire size required will depend on motor and load. Consult National Electrical Code Handbook ampacities tables for proper wire size. 2 - Cable available from GE Fanuc as part number IC800SKC xxx, where xxx is the cable length in meters. 3 - The IC800SSDs dissipate regenerated energy in an internal clamp resistor. If the application produces more regenerated power than the rating of the internal clamp resistor, the IC800SSD will report EC (excessive clamp dissipation). Contact GE Fanuc to determine if an external clamp resistor is required and to receive the procedure for connecting an external clamp resistor. 4 See User Connections, chapter 5, when connecting an external clamp resistor. GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Installation - Page 11

12 Table 2.5 IC800SSD407 Power Terminal Connections and Wire Sizing Terminal Description Connect to Wire Size Notes Symbol AWG Ground Motor ground terminal ,2 T Output phase T Motor phase T ,2 S Output phase S Motor phase S ,2 R Output phase R Motor phase R ,2 DC+ High voltage motor power bus positive External clamp resistor INT Internal clamp resistor EXT EXT External clamp resistor INT L1 1L2 1L3 COM +24V Drive input power VAC Ground Power system ground Logic input power VDC Table 2.6 IC800SSD420 Power Terminal Connections and Wire Sizing Terminal Description Connect to Wire Size Notes Symbol AWG R Output phase R Motor phase R ,2 S Output phase S Motor phase S ,2 T Output phase T Motor phase T ,2 Ground Motor ground terminal ,2 DC+ High voltage motor power bus positive External clamp resistor INT Internal clamp resistor EXT EXT External clamp resistor INT DC- High voltage motor power bus negative No connection 1L1 1L2 1L3 Drive input power VAC Ground Power system ground COM Logic input power VDC V Notes for tables 2.5 and 2.6: 1 - AWG size for stranded copper wire. Minimum wire size required will depend on motor and load. Consult National Electrical Code Handbook ampacities tables for proper wire size. 2 - Cable available from GE Fanuc as part number IC800SKC xxx, where xxx is the cable length in meters. 3 - The IC800SSDs dissipate regenerated energy in an internal clamp resistor. If the application produces more regenerated power than the rating of the internal clamp resistor, the IC800SSD will report EC (excessive clamp dissipation). Contact GE Fanuc to determine if an external clamp resistor is required and to receive the procedure for connecting an external clamp resistor. 4 See User Connections, chapter 5, when connecting an external clamp resistor. IC800SSD Hardware Manual, Pub 348R5 Installation - Page 12

13 Input Mains Wiring and Grounding The IC800 drives are to be permanently connected. The mains input and motor output connections are made to the connector located on the bottom of the IC800SSD. The IC800SSDs are designed to operate with the input voltages provided in table 2.7. Table 2.7 Input Voltage Operating Ranges Model Input Voltage IC800SSD104, 90 to 250 VAC IC800SSD107 IC800SSD216, 180 to 250 VAC IC800SSD228 IC800SSD407, 324 to 528 VAC IC800SSD420 Most applications do not require an isolation transformer. If the supply voltage is above the maximum rated value, the voltage must be dropped to a value in the operating range. See page 3, Input Power, for the required transformer rating if a transformer is necessary. Design Notice. Where residual-current-operated protective device (RCD) is used for protection in case of direct or indirect contact, only RCD of Type B is allowed on the supply side of this Electronic Equipment (EE). Otherwise another protective measure shall be applied such as separation of the EE from the environment by double or reinforced insulation or isolation of EE and supply system by a transformer. The maximum achievable motor speed is directly related to the input voltage. See table 2.8 for best performance recommendations. Table 2.8 Best Performance Recommendations Model Terminal connections Connect to IC800SSD104 L1, L2, and L3 Three-phase 230 VAC IC800SSD107, 1L1, 1L2, and 1L3 Three-phase 230 VAC IC800SSD216, IC800SSD228 IC800SSD407, IC800SSD420 1L1, 1L2, and 1L3 Three-phase 460 VAC All of the terminals marked with the symbol are connected to the chassis ground. Connect the terminal at the mains input end of the connector to the panel earth ground. Connect the terminal near the motor output terminals to the motor frame ground wire in the motor power cable. DO NOT OPERATE THE IC800SSD WITHOUT AN EARTH GROUND. GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Installation - Page 13

14 Motor Power Wiring and Grounding Motor power cables are available from GE Fanuc for the IC800SSD as part number IC800SKC xxx, where xxx is the cable length in meters. Maximum cable length is 50 meters. The motor cable must include a motor ground wire. The motor ground wire must connect a frame ground terminal on the IC800SSD to the frame ground pin on the motor connector. Position Feedback Wiring Position feedback cables are available from GE Fanuc for the IC800SSD as part number IC800SKCE_xxx, where xxx is the cable length in meters. Plug the motor end of the feedback cable into the connector on the motor and the DBtype end of the cable into the DB-15 socket on the front of the drive. The best system reliability is achieved when the feedback cable is returned in a separate conduit from that housing the motor power cable. The feedback cable must be shielded. The shields must be terminated to the isolated ground pins on the DB-15 connector. Maximum encoder cable length is 15 meters using factory-supplied cables. Maximum resolver cable length is 50 meters using factory-supplied cables. Position feedback cables exceeding 30 meters in length must be enclosed in grounded metal conduit. I/O Connector Wiring The discrete inputs and outputs may be wired for either sinking or sourcing operation. The operational voltage range is 12 to 24 volts DC. The output can sink or source 100 ma maximum. The wiring to this connector should be of appropriate size and insulation quality for the application. For wiring diagrams, see Chapter 5, User Connections. I/O cables exceeding 30 meters in length must be enclosed in grounded metal conduit. IC800SSD Hardware Manual, Pub 348R5 Installation - Page 14

15 Diagnostics The front-panel LED on IC800 drives reports real-time diagnostic information as shown in table 2.9. Table 2.9: Diagnostic LEDs Mnemonic Controller Description Status OK okay drive enabled CPUs and operating system functional CC faulted motor power clamp over current DT faulted drive over temperature EC faulted motor power clamp excessive duty cycle EI faulted excessive command increment FE faulted excess following error FL faulted feedback lost LE faulted lost enable MT faulted motor over temperature OC faulted motor over current OV faulted motor power over voltage PF faulted power failure UV faulted motor power under voltage. ok/faulted flashing decimal indicates serial communication is occurring Fault and status registers are also available to report faults for the system and axis status. Those register messages, their causes, and their possible solutions are documented in section 6.2 of the S2K Series Brushless Servo Amplifier Users Manual, publication number GFK Maintenance and Repair The IC800 drives contain no parts that require periodic replacement or adjustment. If service is required contact Whedco or your local distributor for a Return Merchandise Authorization (RMA) number and return procedures: Whedco Incorporated 1050 Highland Drive Ann Arbor, Michigan, U.S.A. (734) phone (734) fax Do not return product to the factory without an RMA number. GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Installation - Page 15

16 Motors The IC800SSD1 and IC800SSD2 are designed for use with AC brushless servo motors rated for 0.75 to 28 amperes per phase with 1 mh line-to-line minimum inductance. The IC800SSD4 is designed for use with AC brushless servo motors rated for 1.5 to 20 amperes per phase with 2 mh line-to-line minimum inductance. In general, the best system performance is achieved by choosing a motor with a continuous current rating approximately equal to or less than the continuous current rating of the IC800SSD. IC800SSD Hardware Manual, Pub 348R5 Installation - Page 16

17 CHAPTER 3 Serial Communication Port RS-232 Serial Communication The IC800SSD is compatible with RS-232 serial communication standards. To wire the connectors properly, refer to the diagram entitled "Serial Port" in Chapter 5, User Connections, for your IC800SSD. RS-232 serial communication cable IC800SKCSxxx is available from GE Fanuc. The cable end labeled "IMC or OIP" connects to the serial port on the front of the unit. The end labeled "RS232 Port" connects to the RS-232 serial communication port on your computer. Tighten screws to fasten the connectors. Cable Length Maximum Communication cables exceeding 30 meters in length must be enclosed in grounded metal conduit. GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Serial Communication Port - Page 17

18 This Page Left Blank Intentionally IC800SSD Hardware Manual, Pub 348R5 Serial Communication Port - Page 18

19 CHAPTER 4 Mechanical Drawing Mechanical Specifications Servo motor drives from 4.3 amps to 7.2 amps Mechanical Dimensions Servo Motor Drive Models Code in Diagram Feature IC800SSD104 IC800SSD107 IC800SSD407 n/a Weight 3.6 lbs 5.5 lbs. A Depth 6.05" 8.15" B Total width 3.20" 3.45" GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 Mechanical - Page 19

20 Mechanical Specifications Servo motor drives from 16 amps to 28 amps Servo Motor Drive Models IC800SSD216 IC800SSD420 IC800SSD228 Weight 15 lbs IC800SSD Hardware Manual, Pub 348R5 Mechanical - Page 20

21 CHAPTER 5 User Connections IC800SSD104S1A Servo Motor Drive with Encoder Feedback 4.3 Arms continuous per phase, Vac GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 21

22 IC800SSD104RS1A Servo Motor Drive with Resolver Feedback 4.3 Arms continuous per phase, Vac IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 22

23 IC800SSD107S1A Servo Motor Drive with Encoder Feedback 7.2 Arms continuous per phase, Vac GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 23

24 IC800SSD107RS1A Servo Motor Drive with Resolver Feedback 7.2 Arms continuous per phase, Vac IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 24

25 IC800SSD216S1A and IC800SSD228S1A Servo Motor Drive with Encoder Feedback IC800SSD216: 16 Arms continuous per phase; IC800SSD228: 28 Arms continuous per phase; Vac GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 25

26 IC800SSD216RS1A and IC800SSD228RS1A Servo Motor Drive with Resolver Feedback IC800SSD216RS1A: 16 Arms continuous per phase; IC800SSD228RS1A: 28 Arms continuous per phase; Vac IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 26

27 IC800SSD407RS1A Servo Motor Drive with Resolver Feedback 7.2 Arms continuous per phase, Vac GE FANUC Parts IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 27

28 IC800SSD420RS1A Servo Motor Drive with Resolver Feedback 20 Arms continuous per phase, Vac IC800SSD Hardware Manual, Pub 348R5 User Connections - Page 28

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