SP SERIES INSTALLATION AND SETUP MANUAL. Old Number M ISSUE 1. New Number MSP000H

Transcription

1 SP SERIES INSTALLATION AND SETUP MANUAL Old Number M ISSUE New Number MSP000H

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3 RECORD OF REVISIONS RECORD OF REVISIONS ( INSTALLATION AND SETUP MANUAL M9700 ) ISSUE NO. (Revision) DATE CHANGED PAGES/BRIEF DESCRIPTION OF CHANGE CHANGE NO. 0 6//97 Original Release Issue /6/98 Incorporate Update Review Comments A

4 RECORD OF REVISIONS SERVOSTAR SP SERIES : B

5 TABLE OF CONTENTS TABLE OF CONTENTS RECORD OF REVISIONS... A TABLE OF CONTENTS Contents... i - iii List of Figures... iv List of Tables... v List of Drawings... vi INTRODUCTION How To Use This Manual... i- Installation and Start-up Guidelines... i- Customer Response... i- Copyright Information... i-4 European Community (EC) Declaration of Conformity... i-5 Abbreviations... i-6 SECTION SYSTEM DESCRIPTION. Introduction Features Theory of Operation Power Supply Module SERVOSTAR SP Drive Module Brushless DC Motor Power Up/Down Sequencing Typical System Diagram Signal Information Current Feedback Signals PWM Input Command Signals Analog Input Signals Six-step Commutation Current Ratings and Duty Cycles SECTION INSTALLATION. Introduction Safety Information Conventions Model Numbering Scheme Abbreviations Unpacking and Inspection Installation Requirements Environmental Requirements Enclosures Assembly Mounting Mounting the External Regeneration Resistor(s) SECTION INSTALLATION (CONTINUED) i

6 TABLE OF CONTENTS SERVOSTAR SP SERIES.7 Electrical Connections Recommended Torque for Electrical Connections Grounding Scheme Connecting the AC Input Voltage Connecting the Main DC Bus Voltage Connecting the External Regeneration Resistor(s) Connecting the Unregulated DC Voltage to the SERVOSTAR SP Series Drive (Connector C5) Connecting the SERVOSTAR SP Series Drive Analog Input / Output (Connector C) Connecting the SERVOSTAR SP Series Drive Digital Input / Output (Connector C) Connecting the SERVOSTAR SP Series Drive Digital Input / Output (Connector C) Connecting the Motor Installation Checklist Checking the Motor Wiring Checking the AC Line Voltages Checking the DC Bus Voltages...- SECTION OPERATION. Introduction...-. Initial Start-up...-. Sequence of Operations...- SECTION 4 MAINTENANCE 4. Introduction Preventative Maintenance Transient Voltages Surge Current Electrical Noise Radio Frequency Energy` Periodic Maintenance Ventilation Grounding Integrity...4- SECTION 5 TROUBLESHOOTING 5. Introduction Field Serviceability Symptoms and Corrections The Motor Exhibits Very Low Torque or is Totally Inoperative The Motor is Erratic or Exhibits an Improper Mode of Operation SERVOSTAR SP Series Drive Status LED's Power Supply Amp Status LED's SERVOSTAR SP Series Drive or Power Supply Reset Procedures...5- APPENDIX A. WARRANTY INFORMATION ii

7 TABLE OF CONTENTS APPENDIX B. REGIONAL SALES OFFICES APPENDIX C. MODEL NUMBERS APPENDIX D. CONNECTOR KITS & TOOLS APPENDIX E. SPECIFICATIONS APPENDIX F. OPTIONS APPENDIX G. CURRENT LOOP COMPENSATION APPENDIX H. DRAWINGS GLOSSARY INDEX iii

8 TABLE OF CONTENTS SERVOSTAR SP SERIES LIST OF FIGURES Figure - - Title Page. - - Typical System Diagram Connector, SERVOSTAR SP Series Drive (C5) & Power Supply SERVOSTAR SP Series Drive Connector (C) SERVOSTAR SP Series Drive Connector (C) Enable and Reset Motor Connections...- iv

9 TABLE OF CONTENTS LIST OF TABLES Table - - Title Page SERVOSTAR SP Series Drive Status LED Indicator Troubleshooting Power Supply Status LED Indicator Troubleshooting v

10 TABLE OF CONTENTS SERVOSTAR SP SERIES LIST OF DRAWINGS Drawing Page SERVOSTAR SP Series & 6 Amp Drive Outline and Dimension Drawing...H- SERVOSTAR SP Series 0 Amp Drive Outline and Dimension Drawing...H-4 SERVOSTAR SP Series 0 Amp Drive Outline and Dimension Drawing...H-5 SERVOSTAR SP Series 0 Amp Drive Outline and Dimension Drawing...H-6 SERVOSTAR SP Series 55 Amp Drive Outline and Dimension Drawing...H-7 Power Supply PA08xx Outline and Dimension Drawing...H-8 Power Supply PA4xx and PA8xx Outline and Dimension Drawing...H-9 Power Supplies PA50xx, PA75xx, and PA85xx Outline and Dimension Drawing...H-0 Power Supply PA08xx Simplified Schematic Diagram...H- Power Supplies PA4xx and PA8xx Simplified Schematic Diagram...H- Power Supplies PA50xx, PA75xx, and PA85xx Simplified Schematic Diagram...H- SPXXXX Simplified Schematic Diagram...H-4 SERVOSTAR SP Series System Wiring - - (Dwg. No. C Sheets)...H-5 vi

11 INTRODUCTION INTRODUCTION HOW TO USE THIS MANUAL This Installation and Setup Manual is designed to help you properly install a SERVOSTAR SP Series Drive System. You do not have to be an expert in motion control to operate the system, however, this manual does assume you have a fundamental understanding of basic electronics and motion control concepts and safety. An understanding of computer operation techniques will be beneficial to most users, however, this product is designed to be used without prior computer knowledge. It is recommended that you read this ENTIRE manual before you attempt to install the SERVOSTAR SP Series Drive. This will familiarize you with the system components and their relationship to one another. After installation check all system parameters to insure you have configured your SERVOSTAR SP system properly. Be sure to follow all instructions carefully and pay special attention to safety. i-

12 INTRODUCTION SERVOSTAR SP SERIES INSTALLATION AND START-UP GUIDELINES In order to ensure proper operation of the SERVOSTAR SP system, it is recommended that the installation and setup information in this manual be read and followed while mounting and wiring the unit. Failure to follow warnings, cautions, notes, and recommendations may affect system performance, safety, and may void the product warranty. REFER TO THE FOLLOWING SECTIONS TO ENSURE PROPER INSTALLATION OF THE SERVOSTAR SP SERIES DRIVE: Section. System Description Section. Installation Appendix E Specifications Appendix H Drawings i-

13 INTRODUCTION THANK YOU! Thank you and congratulations for choosing Industrial Drives' servo products for your motion control requirements. We seek to provide our customers with quality products, excellent support and outstanding value. In an effort to provide you with dependable and useful documentation, we offer you an opportunity to critique this manual with your comments and suggestions. Your feedback on this reader comments form is very important to us. Please answer the questions below and return the form to: INDUSTRIAL DRIVES - Technical Manual Department 0 Rock Road Radford, VA 44 U.S.A. FAX: 540/7/0847 Name: Company: Street Address: Title: City: State: Zip: Telephone: Product: Manual Part Number: Fax: Please check the rating that best represents your opinion on each topic. Excellent Good Fair Poor. Overall clarity and readability.!!!!. Organization of the manual.!!!!. Information completeness.!!!! 4. Information accuracy.!!!! 5. Installation procedures.!!!! 6. Ability to quickly find information you need.!!!! 7. Graphics.!!!! 8. Figures (usefulness).!!!! 9. Tables (usefulness).!!!! 0. Overall rating of this manual.!!!! Please list any errors. What did you like least about this manual? What did you like most about this manual? How would you improve this manual? Signature: Date: i-

14 INTRODUCTION SERVOSTAR SP SERIES COPYRIGHT INFORMATION Copyright 997, Industrial Drives, A Kollmorgen Division. All rights reserved. Printed in the United States of America. NOTICE: Not for use or disclosure outside of Industrial Drives except under written agreement. All rights reserved. No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise without the written permission from the publisher. While every precaution has been taken in the preparation of the book, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. This document is proprietary information of Industrial Drives, A Kollmorgen Division, furnished for customer use ONLY. No other uses are authorized without written permission of Industrial Drives. Information in this document is subject to change without notice and does not represent a commitment on the part of Industrial Drives or the Kollmorgen Corporation. Therefore, information contained in this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every respect to former issues. IBM-PC is a trademark of International Business Machines Corporation. U.L. is a trademark of Underwriters Laboratories. N.E.C. is a trademark of the National Electric Code. GOLDLINE, BDS4, BDS5, PSR4/5, Motion Link, PC-Scope, and Macro Moves are trademarks of the Kollmorgen Corporation. WARNING Dangerous voltages, currents, temperatures, and energy levels exist in this product and in the associated servo motor(s). Extreme caution should be exercised in the application of this equipment. Only qualified individuals should attempt to install, set-up, and operate this equipment. Ensure that the motor, drive, and the end-user assembly are all properly grounded per NEC requirements. INDUSTRIAL DRIVES 0 Rock Road Radford, VA 44 Phone: 540/69/495 Fax: 540/7/0847 i-4

15 INTRODUCTION EUROPEAN COMMUNITY (EC) DECLARATION OF CONFORMITY We, Kollmorgen Corporation Industrial Drives Division, 0 Rock Rd, Radford, VA, USA, declare: under sole responsibility, this equipment is exclusively designed for incorporation in another machine. The operation of this equipment is submitted to the conformity of the machine in which it is incorporated, following the provisions of the EC Electro-Magnetic Compatibility (EMC) directive 89/9/EEC. i-5

16 INTRODUCTION SERVOSTAR SP SERIES ABBREVIATIONS A/D CCW CMR CNC Cont. CW CR-LF D/A D/L EMF EMI ESD GC GCS Hz I I/O khz KMTG KW LED NEC PC P/N PK PLC PWM R/D Regen RMS Tach TL UL Analog-to-Digital Converter Counter Clockwise* Common Mode Rejection Computer Numerical Control Continued Clockwise* ASCII Carriage Return, Line Feed Digital-to-Analog Converter Direction Limit Electro-Motive Force Electro-Magnetic Interference Electrostatic Discharge Goldline Cable Goldline Cable Set Hertz Current Input / Output KiloHertz Kollmorgen Motion Technologies Group KiloWatts Light Emitting Diode National Electrical Code Personal Computer Part Number Peak Programmable Logic Control Pulse Width Modulation Resolver-to-Digital Regeneration Root Mean Square Tachometer Test Limits Underwriters Laboratories * Clockwise and counterclockwise reference as viewing the motor output shaft. i-6

17 SECTION - SYSTEM DESCRIPTION SECTION SYSTEM DESCRIPTION. INTRODUCTION Kollmorgen Motion Technology Group s (KMTG) SERVOSTAR SP Series product line consists of a series of smart power stages and power supplies. They are fully regenerative four-quadrant, bi-directional PWM amplifiers designed to be used with KMTG's high performance permanent magnet brushless motors or other three phase motors or loads. The product is an intelligent switching power amplifier used in high-power servo systems. The SP Series of SERVOSTAR SP Series Drives has three different modes of operation:. Direct Transistor Control.. Two Phase Analog Current Command Input. Current Command Input - Six Step Motor Excitation The SERVOSTAR SP Series Drive modules are available in ratings of, 6, 0, 0, 0, and 55 amps RMS/phase continuous output power. The modular design provides the flexibility for multiple axis to share a common power supply. The power supplies require no input isolation transformer. The SERVOSTAR Power Supply modules are available in sizes of Logic-only, 8, 4, 8, 50, 75,and 85 amps RMS/phase continuous (AC input line ratings). The SERVOSTAR SP Series product line rates all currents as RMS values for sine wave control.. FEATURES Highlighted design features include: Modular construction maximizing serviceability and economy. Two piece plug connectors interfacing. High frequency (up to khz) motor current ripple for quality servo performance, higher efficiency, and less audible noise. Differential analog inputs (Modes & ). Extensive protection features including: Main power bus over-volts shutdown, main power bus under-volts lockout, peak over-current shut-down, short circuit and over-temp shutdown, logic bus under-volts shut-down, and PWM frequency limiting circuitry. Status Indicator: Solid State Relay turns on indicating the amplifier is ready for input command signal; opens on fault conditions. Power Supply units contain a Soft Start function for direct line connection. The 4 and 8 amp Power Supply unit includes 40 watts of internal shunt regulation. The 8, 50, 75 and 85 Amp Power Supplies have external shunt regulator resistor options. Diagnostic LED indicators located on the front panel on both the SERVOSTAR SP Series Drives and the Power Supply modules. -

18 SECTION - SYSTEM DESCRIPTION SERVOSTAR SP SERIES. THEORY OF OPERATION The SERVOSTAR SP Series system consists of five main components:. Power Supply Module. SERVOSTAR SP Series Drive Module. Brushless Motor 4. User Control System 5. Interconnecting Cables.. Power Supply Module The Power Supply Module is divided into four (4) main sections:. The Unregulated Logic Bus, derived from the Control AC line input voltage, is described in Section 4... The 5/60 Volt Main DC Bus (nominal) is supplied by the main AC line input voltage (normally threephase 0 VAC or single-phase 5 VAC).. The Soft-Start Feature circuitry limits the in-rush current (to charge the Main Bus Capacitors) to a specific amount as listed in Appendix E. 4. The Shunt Regulator (regeneration) section includes circuitry which monitors the main bus. During deceleration profiles, the motor operates as a DC generator and pumps energy back into the main bus causing the bus voltage to rise. This action is referred to as regeneration (regen). The Shunt Regulator limits the voltage rise during the deceleration periods by dumping excess energy into the shut resistor... SERVOSTAR SP Drive Module The SERVOSTAR SP Drive Module is divided into four (4) main sections:. Fault Diagnostics circuitry which monitors various signals. When a fault condition occurs the fault circuit will become latched, the SP will become internally inhibited, the appropriate red LED will become illuminated, and the fault output will open indicating that the SERVOSTAR SP Series Drive is in its Inhibit mode. A toggle on the reset input will attempt to reset the latch.. The Input / Output interface circuitry is divided into two functions: (A) Signals between the load and the SERVOSTAR SP Series Drive. (B) Signals between the signal source (PLC, CNC, etc.) and SERVOSTAR SP Series Drive. There are numerous signals that may be used to interface between the signal source (PLC, CNC, etc.) and the SERVOSTAR SP Series Drive. These inputs and modes of operation differ with each application.. When the external current loop mode is selected (Mode ), the command signals are via the three sets of differential inputs. Current feedback outputs for "A" phase and "C" phase leads are supplied for externally closing the current loops. When the current loops are external to the unit there is no control on the PWM frequency and as a result, no control of switching losses. To use the unit in the external current loop mode, DO NOT install the header at location COMP. 4. When the internal current loop mode is selected (Mode ), the command signals are input via the two differential analog inputs (for two out of the three phase current command). Internal circuitry processes these signals to generate current in a load using internal analog proportional plus integral current loops with 0 khz PWM. To use the unit in the internal current loop mode, the header with the current loop compensation components must be installed on the unit (at location COMP ) because the jumper between Pins and 6 sets the unit for this mode of operation. -

19 SECTION - SYSTEM DESCRIPTION 5. When the six-step mode is selected (Mode ), one of the differential analog inputs is used as a current command input and the PWM inputs of Mode are used as the commutation (Hall sensor) inputs. Internal circuitry processes these signals to generate motor current using internal analog proportional plus integral current loop with 0 khz PWM and does the commutation sequencing. To use the unit in the six-step mode, the header with the current loop compensation components must be installed on the unit (at location COMP ). A jumpers between Pins and 6 and the jumper between Pins and 5 set the unit for this mode of operation.. Brushless DC Motor The KMTG GoldLine B and M Series and SilverLine Series brushless motors feature the latest in permanent magnet technology, utilizing high energy Neodymium-Iron-Boron alloys. These brushless motors consist of permanent magnet rotors and three-phase Y-stator windings. This places the heat producing member on the outside where it can best dissipate heat. These motors (depending on size) are either four- or six-pole motors. Since they are brushless motors, there are no commutators or associated brushes. The motors run as synchronous motors, meaning the rotor speed is the same as the speed (frequency) of the stator's rotating magnetic field. The feedback device is typically a brushless resolver, mounted internally as part of the overall motor construction. Other available options include integral brush tachometers and encoders. For more information, refer to the Installation and Service Manual, B Series Brushless Motors M Power Up/Down Sequencing It is recommended that the control voltage be applied first and then apply the main AC voltage. Next, check for faults and then enable the SERVOSTAR SP Series Drive. Typical Power up sequence:. Only the Control AC line input voltage is applied. a. The logic bus comes up. b. A power-up reset pulse is generated in the SERVOSTAR SP Series Drive. c. If no faults (other than main bus under-volts) are present after the power-up reset pulse is generated (a delay of 0.6 seconds) then the drive is ready to be enabled. However, there can be no load activation until the main AC line input voltage is applied.. The Main AC line input voltage is applied. a. The soft-start circuit charges the Main DC bus capacitors in the Power Supply through a current limiting resistor and then this resistor is bypassed. b. The under-voltage fault in the SERVOSTAR SP Series Drive is now cleared (after approximately 0.5 sec delay), and the fault output in the SERVOSTAR SP Series Drive will close. The drive is ready to be enabled and will enable once the enable input is activated.. Only the Main AC line input voltage is removed. a. The main DC Bus will slowly discharge (less than min. to below 50 VDC). b. The fault contact within the SERVOSTAR SP Series Drive will open due to Bus under-volts when the bus drops to below about 0 VDC. 4. Only the Control AC line input voltage is removed. a. The fault output contact in the SERVOSTAR SP Series Drive will open. The drive is immediately disabled. b. The Power Supply fault contact will open. 5. It is recommended that the input commands be held at zero upon applying power. Power up delay is approximately second. The AC line input voltages may be removed in any sequence. -

20 SECTION - SYSTEM DESCRIPTION SERVOSTAR SP SERIES.4 TYPICAL SYSTEM DIAGRAM Figure. illustrates a typical system with all of the major components. SP Unit PA Power Supply (Not available on all models of Power Supplies) Control Power Phase Indicators Logic Supply Analog Input/Output Main Power Phase or Phase Depending on Model Number Digital Input/Output DC Bus AC Input Power (0 VAC Typical) To Earth Ground Transformer (May be Optional) Phase Motor Power Servomotor with Feedback Feedback to user supplied controller Figure.. Typical System Diagram.5 SIGNAL INFORMATION.5. Current Feedback Signals Polarity: positive voltage: current into drive, out of load Magnitude (Maximum): Sinewave commutation: ( ) x (unit s max. RMS rating) = 8 volts (peak of sinewave) Six-step commutation: (unit s max. RMS rating) x ( [/]) = 7.9 volts (peak of six-step wave).5.. PWM Input Command Signals Used in Mode operation. High side positive with respect to low side: results in current out of unit into load (turns phase s top transistor on and bottom transistor off) -4

21 SECTION - SYSTEM DESCRIPTION Low side positive with respect to high side: results in current out of load into unit (turns phase s top transistor off and bottom transistor on High side = low side: turn s phase s top and bottom transistors off.5. Analog Input Signals Polarity: positive voltage: results in current into unit out of load Magnitude (Maximum): Mode operation (sinewave commutation): ( ) x (unit s max. RMS rating) = 0 volts (peak of sinewave) Mode operation (six-step commutation): (unit s max. RMS rating) x ( [/]) = 8.66 volts (DC level) Phasing (Mode operation only): AC_HI:AC_LO leading CC_HI:CC_LO by 0 electrical results in clock-wise rotation (viewing motor s shaft end) for motors with ACB phasing (such as Kollmorgen s GoldLine motors)..5.4 Six-step Commutation Commutation Signals Phasing Requirement: H leads H by 0 elect. which leads H by 0 elect with motor clock-wise rotation (viewing motor s shaft end). Commutation Signals Alignment Requirement: H in phase with: motor s A phase with respect to B phase BEMF(with motor clock-wise rotation; viewing motor s shaft end). Motor s phasing to be ABC sequence (with motor clock-wise rotation; viewing motor s shaft end)..6 CURRENT RATINGS AND DUTY CYCLES The continuous current rating of the SERVOSTAR SP Series Drive units is dependent on how hot the heatsink becomes. This can be a function of duty cycle and switching frequency. The unit is rated for operation in a 45 degree Celsius environment and 6 khz switching for the, 6, and 0 Amp units and 8 khz for the 0, 0, and 55 amp units. The peak current rating of the SERVOSTAR SP Series Drive is twice its continuous rated current. This amount of time the peak current is allowed out of the SERVOSTAR SP Series Drive must be controlled to keep the power devices from overheating. The peak current should not be allowed for more than 6 seconds in a 0 second period. The RMS output current must not exceed the rated current of the SERVOSTAR SP Series Drive. -5

22 SECTION - SYSTEM DESCRIPTION SERVOSTAR SP SERIES -6

23 SECTION - INSTALLATION SECTION INSTALLATION. INTRODUCTION The information in this Section will familiarize you with the safety information, unpacking and inspection, installation requirements, assembly procedures and electrical connections for installing the SERVOSTAR SP Series Drive. A checklist is provided at the end of this Section to insure proper installation.. SAFETY INFORMATION The safety-alert symbols are illustrated as follows: Safety-Alert Symbols When you see these symbols in this manual, be alert to the potential for personal injury. Follow the recommended precautions and safe operating practices included with the alert symbols. Safety notices in this manual provide important information. Read and be familiar with these instructions before attempting installation, operation, or maintenance. The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, or operational difficulty. "Warning" alerts users to potential danger or harm. Failure to follow warning notices could result in personal injury or death. "Caution" directs attention to general precautions, which if not followed, could result in personal injury and/or equipment damage. "Note" highlights information critical to your understanding or use of these products. -

24 SECTION - INSTALLATION SERVOSTAR SP SERIES. CONVENTIONS To assist you in understanding the material in this manual, conventions have been established to enhance reader comprehension. Explanations of these conventions are as follows: Safety warnings, cautions, and notes present material that is important to user safety. Be sure to read any safety notices you see as they could prevent equipment damage, personal injury, or even death to you or a co-worker. Bold text highlights other important information that is critical to system operations. CAPITALIZED text stresses attention to the details of the procedure. Underlined text emphasizes crucial words in sentences that could be misunderstood if the word is not recognized... Model Numbering Scheme All SERVOSTAR components contain a model and serial number printed on a tag on the side panel. The model number identifies how the equipment is configured. Refer to Appendix C for the model number scheme tables. These tables explain what the model configurations are. You should verify that the model numbers represent the equipment desired for your application. Also verify the compatibility between components of the servo system... Abbreviations CCW CW DIFF CMD D/L GC GCS KMTG LED NEC P/N R/D Regen TL UL Counter Clockwise Clockwise Differential Command Direction Limit GoldLine Cable GoldLine Cable Set Kollmorgen Motion Technologies Group Light Emitting Diode National Electrical Code Part Number Resolver-to-Digital Regeneration Test Limits Underwriters Laboratories.4 UNPACKING AND INSPECTION Electronic components in this amplifier are static sensitive. Use proper procedures when handling component boards. Upon receipt of the equipment, closely inspect components to ensure that no damage has occurred in shipment. If damage is detected, notify the carrier immediately. Carefully remove packing material and remove the equipment from the shipping container. Do not dispose of shipping materials until the packing list has been checked. Parts that are contained within the shipment, but not -

25 SECTION - INSTALLATION physically attached to the equipment, should be verified against the packing list. If any parts are missing, notify Industrial Drives at once..5 INSTALLATION REQUIREMENTS Proper installation and field wiring are of prime importance when considering the application of servo amplifiers. Many problems may be avoided if installation of the equipment is done properly. Users should familiarize themselves with and follow installation and wiring instruction in addition to all applicable codes, laws and standards. Pay special attention to the following topics when installing Industrial Drives' equipment..5. Environmental Considerations The environment that this equipment is placed in can have dramatic effects on its operation. Industrial Drives recommends that the SERVOSTAR SP Series Drive and Power Supply be operated and stored under the following conditions: Operating Temperature: 0 C to 45 C Storage Temperature: -0 C to 70 C Humidity: 0% to 90% (Non Condensing).5. Enclosures It is suggested that the SERVOSTAR SP Series Drive and Power Supply be mounted in a cabinet or other suitable enclosure to protect them from physical and environmental damage. Refer to Appendix E for complete system dimensions. Allow sufficient clearance for the large "regenerative" heat producing resistor(s) mounted at the upper edge of the Power Supply unit and the externally mounted regen (shunt regulator) power resistor(s)..6 ASSEMBLY The SERVOSTAR SP Series Drive and Power Supply are both constructed prior to shipping from the factory. The only assembly required is the mounting of the devices. Operation in Modes or may require addition of the COMP header..6. Mounting Refer to the drawing of your model system in Appendix H for outline and dimensions. Be sure to look at the proper drawing for mounting measurements. The Power Supply and SERVOSTAR SP Series Drive modules should be mounted in the vertical position. Depending on the continuous current ratings of the SERVOSTAR SP Series Drive and Power Supply modules, up to four units may be mounted with a single power supply. -

26 SECTION - INSTALLATION SERVOSTAR SP SERIES Refer to the drawing of your model system in Appendix H for the Mounting Hole Pattern information. Allow sufficient clearance for the large "regenerative" heat producing resistor(s). The internal resistors are mounted at the upper edge of the Power Supply unit. The externally mounted regen (shunt regulator) power resistor(s) are mounted above the Power Supply unit..6. Mounting the External Regeneration Resistor(s) External regenerative resistors are a shock hazard! Mount these resistors properly! Enclose these resistors to protect personnel and equipment! External regeneration resistors can become extremely hot! Allow safe clearance around the resistor(s) enclosures. Proper ventilation must be provided. If the application requires greater than 40 watts of regen (shunt regulation) on the PA8, or any regen on the PA50 and 75 then an externally mounted regen resistor is required. The resistor kit includes the resistor(s) and mounting hardware. A suitable enclosed location needs to be set aside for mounting these components while observing the heat and shock requirements of these resistors. The external regen resistor kit includes a thermal overload protection device that must be wired in series with the resistor. The contacts of the overload should be wired to drop power if they open..7 ELECTRICAL CONNECTIONS Dangerous voltages, currents, temperatures, and energy levels exist in this product and in the associated servo motor(s). Extreme caution should be exercised in the application of this equipment. Only qualified individuals should attempt to install, set-up, and operate this equipment. Ensure that he motor, drive, and the end-user assembly are properly grounded per NEC requirements. To facilitate wiring, the SERVOSTAR SP Series Drive units must be mounted next to the PA power supply module in descending order according to their continuous current ratings. Follow these precautions:. Observe all notes on the wiring diagram. -4

27 SECTION - INSTALLATION. All motor stator leads, signal input leads, resolver leads and encoder leads must be shielded.. Twist all AC leads to minimize electromagnetic emissions (noise). 4. Avoid running signal leads (must be shielded) in close proximity to power leads, motor stator leads, or other sources of electromagnetic noise. 5. Minimize lead lengths as much as possible. 6. Connect the SERVOSTAR SP system according to the System Wiring Diagram; pay close attention to the grounding scheme. 7. Provide adequate stress relief for cables. Thermal overload protection for the motor is not provided within the SERVOSTAR SP Series Drive and must be provided externally. Refer to the National Electrical Code for proper sizing of overload protection. Motor thermostat is often sufficient. With the exception of the hook-up of the motor, the main input voltage, and the main Bus+ and Bus- DC voltage, all interface wiring between the SERVOSTAR SP Series Drive, Power Supply, and other equipment is accomplished by connectors supplied with the SERVOSTAR SP Series Drive and Power Supply units. The input/output connections are grouped by connector or terminal block. They are input/output, motor, AC main power and control voltages, main DC bus, and unregulated DC voltages. Captive screws are used in the power terminals of the PA08 module, PA8 module, and the amp through the 0 amp SERVOSTAR SP Series Drive amplifiers. Do not attempt to remove these screws to use ring terminals. Use locking spring terminals similar to Hollingsworth #XSS0945S or #SS0947SF for 6 and 4 AWG wire and #XSS086 or #SS08F for and 0 AWG wire..7. Recommended Torque for Electrical Connections Table. displays the recommended torque values for terminal block and grounding connecting points. All torques are measured with the wire or terminal lug underneath the screw head. Table.. Torque Values Connecting Points SPx0, 06, 0, 0 Amp Units PA08, 8 Amp Units AC Input Screws in. lb. DC Bus Screws in. lb. in. lb. Motor Connecting Screws in. lb. External Regen Screws in. lb. Ground Screws in. lb. in. lb. -5

28 SECTION - INSTALLATION SERVOSTAR SP SERIES.7. Grounding Scheme To prevent shock hazard to personnel and to ensure proper operation of the SERVOSTAR SP Series Drive system, the SERVOSTAR SP Series Drive, Power Supply, and the servo motor must be grounded properly. Each SERVOSTAR SP Series Drive and Power Supply have at least two grounding screws on the front of the chassis. Provisions of the National Electrical Code with respect to grounding should be followed. These precautions generally deal with the ground loop currents arising from multiple ground paths. Only one ground path should be used. One of the screws on the chassis of the Power Supply should go to earth (machine) ground. The other(s) should be connected to the SERVOSTAR SP Series Drive(s) ground screw. The ground wire from the motor and its cable shield should be connected to one of the ground screws for the associated SERVOSTAR SP Series Drive. The other ground screw on the SERVOSTAR SP Series Drive should be connected to a ground screw on the Power Supply unit. For grounding to machine or earth ground, a screw lug should be attached to the ground screw on the Power Supply or SERVOSTAR SP Series Drive. A torque of in.lb. for ground screws is recommended. Also refer to the National Electrical Code (NEC) or UL standard 486B for recommended torque's..7. Connecting the AC Input Voltages The three-phase main AC Input Voltage three-phase, should be connected at L a, L b, and L c on the power terminal block located on the front of the Power Supply unit. The PA08 gets its logic input from L a, and L b,, so when using single phase power, the main AC input voltage should be connected at L a, and L b,. The logic input is universal and needs no settings for operation at 5 V or 0 V. The PA8, 50, and 75 have separate control AC input voltage connections on Connector C - Pins and 6. and must be 0Vac. They are not designed for 5Vac logic supply operation..7.4 Connecting the Main DC Bus Voltage Refer to notes on the SERVOSTAR SP Series Drive Wiring Diagram for details concerning the hook-up of the Bus + and Bus - circuits between the Power Supply and the SERVOSTAR SP Series Drive units. Failure to observe correct polarity will result in damage to the Power Supply and SERVOSTAR SP Series Drive..7.5 Connecting the External Regeneration Resistor(s) If an external regeneration resistor is required, connecting points are provided on the PA Power Supply Unit. Be certain that the overload relay is wired in series with the resistor and that the safety contacts are wired to prevent further operation should they open. -6

29 SECTION - INSTALLATION.7.6 Connecting the Unregulated DC Voltage to the SERVOSTAR SP Series Drive (Connector C5) The wiring between the SERVOSTAR SP Series Drive Connector C5 and the Power Supply Connector (unregulated voltage) is as follows: +5 VDC -5 VDC COMMON +8 VDC Figure.. Connector, SERVOSTAR SP Series Drive (C5) & Power Supply -7

30 SECTION - INSTALLATION SERVOSTAR SP SERIES.7.8 Connecting the SERVOSTAR SP Series Drive Analog Input / Output (Connector C) The pinouts are shown in Figure.. Ic 6 IC RTN Ia 5 IA RTN Shield 4 0 NC Shield 9 Common CC_HI 8 CC_LO AC_HI 7 AC_LO Figure.. SERVOSTAR SP Series Drive Connector (C) Pin "AC_HI" Opmode:, Differential high input command, "AC_HI"; Mode operation - not used; Mode operation - "A phase" channel; Mode operation - "command high input" Pin 7 "AC_LO" Opmode:, Differential low input command, "AC_LO"; Mode operation - not used; Mode operation - "/A phase" channel; Mode operation- "command low input" Pin Shield Opmode:, "A phase" input cable shield connection Pin "CC_HI" Opmode: Differential high input command, "CC_HI"; Mode operation - not used; Mode operation - "C phase" channel; Mode operation - not used Pin 8 "CC_LO" Opmode: Differential low input command, "CC_LO"; Mode operation - not used; Mode operation - "/C phase" channel; Mode operation-not used Pin 4 Shield Opmode: "C phase" input cable shield connection Pin 5 I A Opmode: "A phase" current feedback signal; used with Mode operation; available in other modes -8

31 SECTION - INSTALLATION Pin I A RTN Opmode: "A phase" current feedback signal return; used with Mode operation; available in other modes Pin 6 I C Opmode: "C phase" current feedback signal; used with Mode operation; available in other modes Pin I C RTN Opmode: "C phase" current feedback signal return; used with Mode operation. Pin 9 Common Opmode: All Circuit common Pin 0 Not Used No connection; not used.7.9 Connecting the SERVOSTAR SP Series Drive Digital Input / Output (Connector C) The following descriptions tell the user which inputs and modes of operation are available, enable the user to identify the appropriate connecting points on Connector C, and help the user decide which inputs and modes of operation to use. The pinouts are shown in Figure.. FAULT LO 8 6 FAULT HI ENABLE 7 5 RESET 4 V V C 5 SHIELD 4 SHIELD B B SHIELD 0 SHIELD A 9 A Figure.. SERVOSTAR SP Series Drive Connector (C) Pin A Opmode:, Positive input of differential optically isolated input for A phase (motor) High. -9

32 SECTION - INSTALLATION SERVOSTAR SP SERIES Pin 9 A Opmode:, Negative input of differential optically isolated input for A phase load (motor) Low. Pin Shield Opmode:, "A" Phase input cable shield connection. The shield pins provide termination points for cable shields. To insure there are no ground loops in the shield common, connect only one end, butt and insulate the other end. Pin B Opmode:, Positive input of differential optically isolated for B phase load (motor) High. Pin B Opmode:, Negative input of differential optically isolated for B phase load (motor) Low. Pin 0 Shield Opmode:, "B" Phase input cable shield connection Pin 5 C Opmode:, Positive input of differential optically isolated for C phase load (motor) High. Pin C Opmode:, Negative input of differential optically isolated for C phase load (motor) Low. Pin 4 Shield Opmode:, "C" Phase input cable shield connection Pin 6 4 V (Plus or Minus) Opmode: All Provides optocoupler signal common rail to 4 volts for systems choosing 4 V operation for the enable and reset inputs. This common rail can be connected to positive voltage (user sinks current) or to minus voltages (user sources current). When this input is used, Pin 4 must not be used. Pin 4 5 V (Plus or Minus) Opmode: All Provides optocoupler signal common rail to 5 volts for systems choosing 5 V operation for the enable and reset inputs. This common rail can be connected to positive voltage (user sinks current) or to minus voltages (user sources current). When this input is connected, Pin 6 must not be used. Pin 7 Enable Opmode: All Allows the SERVOSTAR SP Series Drive to be enabled or disabled without removing the main power. When a circuit is closed between Pin 7 and common (assuming Pin 6 is connected to +4 VDC or Pin 4 is connected to +5 VDC, see Figure.5), the SERVOSTAR SP Series Drive will be put into the Drive-Up mode. Opening the circuit puts the SERVOSTAR SP Series Drive into the Inhibit mode (Green LED indicated). Pin 5 Reset Opmode: All Allows any latched fault circuit except OVER-VOLTS or OVER-CORRECT faults to be reset by toggling Pin 5 to common (Assuming Pin 6 is connected to +4 VDC or Pin 4 is connected to +5 VDC). See Figure.4. -0

33 SECTION - INSTALLATION +/- 4V (PIN 6) +/- 5V (PIN 4) ENABLE (PIN 7) RESET (PIN 5) Figure.4 Enable and Reset Pin 8 Fault Output Low Side Opmode: All Optically isolated fault output transistor s source. The transistor is normally on, indicating that no fault conditions exist. Pin 6 Fault Output High Side Opmode: All Optically isolated fault output transistor s drain The transistor is normally on, indicating that no fault conditions exist. Pin Shield Opmode:, Provided for connection of cable shields if necessary. Best shielding may result by connection at the other (source) end..7.0 Connecting the Servostar SP Series Drive Digital Input/Output ( Connector C) See System Wiring Diagram C-9754 sheet 4 of in Appendix H Drawings. -

34 SECTION - INSTALLATION SERVOSTAR SP SERIES.7. Connecting the Motor B SERIES MOTORS have a thermostat switch wired to the resolver connector at the motor. BR SERIES MOTORS have a thermostat switch wired to the stator connector at the motor. The motor thermostat switch is an automatic resetting device and should be connected directly into a latched (locked out) power down type circuit. Incorrect motor resolver or encoder phasing can cause erratic operation, runaway, or damage to the system. The leads of the three-phase synchronous motor are brought out to Pins A, B, and C of the motor connector. Pin D is ground for the motor. Refer to Figure.5 for pin connections. A TOP B TOP C TOP A B C A BOTTOM B BOTTOM C BOTTOM Figure.5. Motor Connections -

35 SECTION - INSTALLATION Terminate Pins A, B, and C of the motor connector to Ma, Mb, and Mc, respectively, on the power terminal block located on the front of the SERVOSTAR SP Series Drive amplifier. Terminate Pin D at the SERVOSTAR SP Series Drive chassis ground screw. Refer to System Wiring Diagram C-9754 in Appendix H Drawings, and the appropriate motor HD (hook-up) drawing..8 INSTALLATION CHECKLIST Refer to SERVOSTAR SP Series Drive Wiring Diagram. See Appendix H. Before applying power to the Power Supply and SERVOSTAR SP Series Drive, check the following items to ensure proper operation: To prevent damage to the equipment, the motor and resolver, the AC line voltage, and the DC bus voltages must be connected as indicated by SERVOSTAR SP Series Drive Wiring Diagram..8. Checking the Motor Wiring Disconnect both the motor stator connector from the motor. Using an ohmmeter, check the continuity of each motor stator lead between the motor stator connector pin and the SERVOSTAR SP Series Drive. The motor stator should be connected according to SERVOSTAR SP Series Drive Wiring Diagram..8. Checking the AC Line Voltages Open the circuit breaker or remove the fuses in the Main AC lines that are connected to the Power Supply at L a, L b, and L c. Remove Connector C7 from the Power Supply. Apply only the AC main power. Use an AC voltmeter to check and record the - or -phase line-to-line voltage at the circuit breaker or fuse holders. Remove power. Note the model number of the Power Supply and refer to Appendix C to confirm the correct Main AC voltage level. Apply only the AC control power. Use an AC voltmeter to check and record the single-phase voltage at Connector C7 of the Power Supply. Remove power. Note the model number of the Power Supply and refer to Appendix E to confirm correct Control AC voltage level. If the voltage levels are within the specifications listed in Appendix E, proceed with the Check-Out procedure. Close the circuit breaker or re-install the fuses for the Main AC input power. Re-install all connectors..8. Checking the DC Bus Voltages Allow sufficient time (after removing power from the system) for the voltage to bleed down before connecting or disconnecting wires at the bus. Remove power. -

36 SECTION - INSTALLATION SERVOSTAR SP SERIES Remove the Bus+ and Bus- leads from the Power Supply power terminal block. Remove mating Connector C from the Power Supply. Apply power. Check and record the Main DC Bus Voltage output at (+) with respect to (-) on the Power Supply terminal block. Check and record the unregulated DC voltage levels at Connector C of the Power Supply. They should be ± 5 to 6 (pin to pin ) and to 8.5 (pin 4 to pin ) VDC. Remove power. Note the model number of the Power Supply and confirm DC voltage levels. If the voltage levels are within the specifications listed in Appendix E, proceed. WAIT FOR THE BUS TO BLEED DOWN and reconnect the B(+) and B(-) leads to the power terminal block of the Power Supply. Be careful to reconnect the leads with the proper polarity. Re-install Connector C on the Power Supply. It may take up to minutes for the Bus to discharge to below 50V. Failure to observe correct polarity will result in damage to the SERVOSTAR SP Series Drive. -4

37 SECTION - OPERATION SECTION OPERATION. INTRODUCTION The information in this Section will enable you to become familiar with system components and their dependence upon one another. Also, it will help you ensure each component is configured and functions properly. At this point, all safety stops and other precautions should be in place and working properly. Be prepared to stop the machine if necessary.. INITIAL START-UP You should now be ready to supply power to test the servo systems functions and features. Work with only one axis section at a time. Confirm all other SERVOSTAR SP Series Drive amplifiers are inhibited, meaning the enable circuits are open. CAUTION Incorrect servo-to-position loop phasing can cause excursion oscillations, or runaways. Appropriate precautions should be taken to stop the machine if necessary. Limit switches and safety devices should be in place.. SEQUENCE OF OPERATIONS This section contains a basic start-up sequence that should be followed the first time the servo system is initialized. READ THIS ENTIRE SECTION BEFORE PERFORMING ANY OF THESE PROCEDURES. When you apply power to the system, pay special attention to the LEDs on the SERVOSTAR SP Series Drive front panel. The CONTROL VOLTS (green) LED should be illuminated. This indicates that the system is functioning properly. Should a FAULT (red) LED remain on for more than a instant, immediately disconnect power and consult Section 5 - Troubleshooting. Apply power. Enable only one SERVOSTAR SP Series Drive. The Green Enabled LED should illuminate. Observe the action of the machine. If the direction of the motor shaft rotation is reversed (motor shaft turns in the wrong direction), remove power. If the servo system performed properly, then read Section 4 - Maintenance for adjustments and other information that may be helpful in adapting your system to your own applications. -

38 SECTION - OPERATION SERVOSTAR SP SERIES -

39 SECTION 4 - MAINTENANCE SECTION 4 MAINTENANCE 4. INTRODUCTION The information in this Section will enable you to maintain the systems components ensuring smooth, efficient operation of the motor. 4. PREVENTATIVE MAINTENANCE CAUTION Preventative maintenance to this equipment must be performed by qualified personnel familiar with the construction, operation, and hazards involved with the application. CAUTION Electronic components in this amplifier are static sensitive. Use proper procedures when handling component boards. Preventative maintenance should be performed with the SERVOSTAR SP Series Drive system out of operation and disconnected from all sources of power. 4.. Transient Voltages NOTE All transient-producing devices must be properly suppressed. Solid state controls of the SERVOSTAR SP Series Drive may be affected by transient voltages. These voltages are in excess of the specified voltage for any given circuit. When these peak voltages occur, even for less than a second, permanent damage to the SERVOSTAR SP Series Drive can occur. In order to help avoid transient voltages that may interfere with electronic circuit functions within the Power Supply and SERVOSTAR SP Series Drive, all switched inductive devices or their wiring (solenoids, relay coils, starter coils, etc.) must be suppressed. A 0 ohm, / watt resistor in series with a 0.5 micro farad, 600 volt capacitor or equivalent is suggested. 4-

40 SECTION 4 - MAINTENANCE SERVOSTAR SP SERIES 4.. Surge Current Excessive current greater than that of the specified limits of the Power Supply and SERVOSTAR SP Series Drive can cause permanent damage to the system. Current limiting means are recommended to protect from these currents. CAUTION If the short circuit inrush current generated by the power source is in excess of 5000 amps RMS symmetrical current, an isolation transformer or line inductor must be utilized in the incoming power circuit. Failure to observe this precaution could result in damage to, or destruction of the Power Supply and SERVOSTAR SP Series Drive. Input transformers step up or step down input voltage and can be either autotransformers or isolation transformers. Isolation transformers help eliminate the following: Damaging AC line voltage transients reaching the Power Supply and SERVOSTAR SP Series Drive. Damaging currents which may develop if a point inside the Power Supply or SERVOSTAR SP Series Drive becomes grounded. 4.. Electrical Noise The low levels of energy in the SERVOSTAR SP Series Drive control circuits may cause them to be vulnerable to electrical noise. Sources of electrical noise are those pieces of equipment that have large, fast changing voltages and currents when they switch on and off. These devices have the capability of inducing critical current and voltage transients on their respective power lines. These transients must be accommodated for with noise immunity provisions. Electrical noise is prevented with the same methods as Surge Current and Transient Voltages. However, there are other methods of preventing electrical noise. Such as: Maintain physical separation between electrical noise sources and the SERVOSTAR SP Series Drive amplifier. Maintain physical separation between electrical noise sources and the SERVOSTAR SP Series Drive control wiring. This can be accomplished by using separate conduits or wiring trays for control wiring and power wiring. Use twisted-pair wiring for control circuits of the SERVOSTAR SP Series Drive. Follow good grounding practices when wiring the Power Supply and SERVOSTAR SP Series Drive. Be careful not to create a grounding loop with multiple ground paths. Follow the NEC's provisions on grounding Radio Frequency Energy NOTE This equipment generates radio frequency energy. This equipment can radiate radio frequency energy and must be installed and used in accordance with this installation and service manual in order to prevent possible interference with radio communications or other electronic equipment. 4. PERIODIC MAINTENANCE 4-