PPB PWM Power Block Installation Manual

Transcription

PPB
PWM Power Block Installation Manual
Edition: V10
Keep all manuals as a product component during the life span of the product.
Pass all manuals to future users / owners of the product.
SERVOTRONIX
always in motionTM
Record of Document Revisions
Revision
Date
Remarks
5
March, 2005
Update error table, remove 8F option
6
February 2010
Brand changed to Servotronix
7
March 2010
Update by DVG, remove F8, add 20 and 35 Amp, update customer support, add
system layouts, setting Foldback and others
8
May 2010
Update Safety information
9
July 2010
Reformat and edit document
Update document to reflect the new product name, PWM Power Block (PPB)
10
July 2010
First Release adding tables re order Servotronix format (DVG)
IMPORTANT NOTICE
Copyright© Servotronix Motion Control Ltd. 2006-2010. All rights reserved. Servotronix Motion Control Ltd. holds the
copyright to this manual. All rights are reserved and no part of this publication may be reproduced or transmitted in any
form or by any means without prior written consent from Servotronix Motion Control Ltd.
Disclaimer
The information in this manual was accurate and reliable at the time of its release. However, Servotronix Motion Control
Ltd. reserves the right to change the specifications of the product described in this manual without notice at any time. This
document contains proprietary and confidential information of Servotronix Motion Control Ltd. The contents of the
document may not be disclosed to third parties, translated, copied or duplicated in any form, in whole or in part, without the
express written permission of Servotronix Motion Control Ltd.
Registered Trademarks
Servotronix always in motion™ is a trade mark of Servotronix Motion System
PMAC® and Accessory 24-X®, 8F® are registered trademarks of Delta Tau Data Systems, Inc.
Technical changes which improve the performance of the device may be made without prior notice! All rights reserved. No
part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method) or stored,
processed, copied or distributed by electronic means without the written permission of Servotronix Motion Control Ltd. All
other proprietary names mentioned in this manual are the trademarks of their respective owners.
2
Servotronix | July 10
PMW Power Block Installation Manual
Table of Contents
1 INTRODUCTION...................................................................................................................................... 5
1.1 SAFETY INSTRUCTIONS ....................................................................................................................... 5
1.2 DIRECTIVES AND STANDARDS ............................................................................................................. 6
1.2.1 CE Mark Conformance........................................................................................................... 6
1.3 READ BEFORE INSTALLING .................................................................................................................. 7
1.4 UNPACKING AND INSPECTING .............................................................................................................. 8
1.5 USE AS DIRECTED .............................................................................................................................. 8
1.6 POWER SUPPLY FOR PPB .................................................................................................................. 9
1.7 LEAKAGE CURRENT ............................................................................................................................ 9
1.8 RESIDUAL CURRENT PROTECTIVE DEVICE (RCD) .............................................................................. 10
1.9 RATED RESIDUAL CURRENTS IN THE RDC......................................................................................... 10
1.10 ISOLATING TRANSFORMERS .............................................................................................................. 10
1.11 FUSING FOR CP335: ........................................................................................................................ 10
1.12 PACKAGING ...................................................................................................................................... 11
1.13 STORAGE ......................................................................................................................................... 11
1.14 MAINTENANCE AND CLEANING ........................................................................................................... 11
1.15 WARRANTY INFORMATION ................................................................................................................. 11
1.16 REPAIR ............................................................................................................................................ 11
2 PPB SPECIFICATION ........................................................................................................................... 12
2.1 OPERATIONAL CONDITIONS ............................................................................................................... 12
2.2 ELECTRICAL AND ENVIRONMENTAL SPECIFICATIONS........................................................................... 12
2.3 HARDWARE SPECIFICATIONS............................................................................................................. 14
2.4 REGEN SPECIFICATION ..................................................................................................................... 15
2.5 OUTLINE DIMENSIONS ....................................................................................................................... 15
3 INSTALLATION ..................................................................................................................................... 17
3.1 MOUNTING PRACTICES ..................................................................................................................... 17
3.2 GUIDE TO MECHANICAL INSTALLATION ............................................................................................... 17
3.3 CE FILTERING TECHNIQUES .............................................................................................................. 18
3.3.1 Input Power Filtering ............................................................................................................ 18
3
3.3.2 Motor Line Filtering............................................................................................................... 19
3.4 GROUNDING ..................................................................................................................................... 20
3.5 BONDING ......................................................................................................................................... 20
3.5.1 Non-Insulated Cable Clamp ................................................................................................. 20
3.5.2 Alternative Bonding Methods ............................................................................................... 21
4 WIRING .................................................................................................................................................. 23
4.1 MAIN POWER CONNECTOR ............................................................................................................... 23
4.2 24V LOGIC POWER CONNECTOR (OPTIONAL) .................................................................................... 23
4.3 PWM CABLE .................................................................................................................................... 24
4.3.1 PWM Pinout ......................................................................................................................... 24
4.3.2 PWM Cable Part Numbers................................................................................................... 25
4.4 SYSTEM WIRING................................................................................................................................ 27
4.5 SYSTEM INTERCONNECT ................................................................................................................... 28
5 PPB INTERFACE .................................................................................................................................. 29
5.1 7-SEGMENT DISPLAY AND FAULT DESCRIPTION ................................................................................. 29
5.2 WATCHDOG...................................................................................................................................... 30
5.3 FREQUENCY FAULT (MAXIMUM PWM FREQUENCY) ............................................................................ 30
5.4 FAULT CODE TRANSMISSION ............................................................................................................. 30
5.5 PPB FOLDBACK DIP SWITCH SETTING .............................................................................................. 30
5.6 CURRENT SCALING ........................................................................................................................... 31
6 TROUBLESHOOTING........................................................................................................................... 33
6.1 TROUBLESHOOTING .......................................................................................................................... 33
6.1.1 Verify Proper Motor Operation ............................................................................................. 33
6.1.2 Verify Proper PPB Drive Operation...................................................................................... 33
6.1.3 Verify Proper PMAC Operation ............................................................................................ 33
6.2 PPB DRIVE TROUBLESHOOTING ........................................................................................................ 34
7 PART NUMBER..................................................................................................................................... 35
8 CUSTOMER SERVICE.......................................................................................................................... 36
4
PMW Power Block Installation Manual | Introduction
1
Introduction
1.1
Safety Instructions
Only qualified personnel are permitted to transport, assemble, commission, and
maintain this equipment. Properly qualified personnel are persons who are familiar
with the transport, assembly, installation, commissioning and operation of motors,
and who have the appropriate qualifications for their jobs. For safety, perform all of
the following:
Read all available documentation before assembling and commissioning.
Incorrect handling of products in this manual can result in injury and damage to
persons and machinery. Strictly adhere to the technical information regarding
installation requirements.
It is vital to ensure that all system components are connected to earth ground.
Electrical safety is provided through a low-resistance earth ground connection.
The PPB product contains static sensitive components that can be damaged by
incorrect handling. Avoid contact with high insulating materials (artificial fabrics,
plastic film, etc.). Place the product on a conductive surface. Ground yourself
(discharge any possible static electricity build-up) by touching an unpainted,
metal, grounded surface.
Keep all covers and cabinet doors shut during operation. Otherwise, potential
hazards could cause severe personal injury or damage to the product.
Be aware that during operation, the product has electrically charged components
and hot surfaces. The heat sink can reach temperatures of 90 °C, Control and
power cables can carry a high voltage, even when the motor is not rotating.
To avoid electric arcing and hazards to personnel and electric contacts, never
disconnect or connect the product while the power source is energized.
After removing the power source from the equipment, wait at least 5 minutes
before touching or disconnecting sections of the equipment that normally carry
electrical charges (e.g., capacitors, contacts, screwed connections). To be safe,
measure the electrical contact points with a meter before touching the equipment.
Wait until the voltage drops below 30 VAC before handling components.
Safety symbols indicate a potential for personal injury or equipment damage, if the
recommended precautions and safe operating practices are not followed. Read and
be familiar with the safety notices in this manual before attempting installation,
operation, or maintenance to avoid serious bodily injury, damage to the equipment, or
operational difficulty. The safety-alert symbols for Drive marking and in this manual
are:
"Note" identifies information required for your
understanding or use of the equipment.
ISO 7000-0434 (2004-01)
Caution
IEC 60417–5019 (2006-08)
Protective earth; protective ground
5
1.2
IEC 60417-5041 (2000-10)
Caution, hot surface
IEC 60417-5036 (2002-10)
Dangerous voltage
Directives and Standards
The PPB has been successfully tested and evaluated according to standards EN
50178 and IEC 61800-5-1, and has been verified according to UL508C. This testing
outlines the minimum requirements for electrically operated power conversion
equipment (frequency converters and servo amplifiers), which are intended to
eliminate the risk of fire, electric shock, or injury to persons.
UL508C refers to UL 840. UL 840 describes the fulfillment by design of air and
insulation creepage spacings for electrical equipment and printed circuit boards.
These drives are open type adjustable frequency motor drives that provide variable
speed control to motors and provide overload protection and current limit control.
For pollution level see specification.
Identification of the terminals on the controller are coded so they can easily be
identified in the instructions. The instructions identify the connections for the
power supply, load, control, and ground.
Integral solid state short circuit protection does not provide branch circuit
protection. Branch circuit protection must be provided in accordance with the
National Electrical Code and any additional local codes, or the equivalent.
1.2.1
CE Mark Conformance
PPB is built in Conformance with the EC EMC Directive 2004/108/EC and the EC
Low Voltage Directive 2006/95/EC. Conformance with the EC EMC Directive
2004/108/EC and the Low Voltage Directive 2006/95/EC is mandatory for all servo
drives provided to the European Community.
PPB drives have been successfully tested and evaluated to the limits and
requirements of the EC EMC Directive 2004/108/EC and the EC Low Voltage
Directive 2006/95/EC.
EC Low Voltage Directive 2006/95/EC complies with standard IEC 61800-5-1.
In connection with the EC EMC Directive (2004/108/EC) the following standards are
used:
IEC 61000-6-1/2 (Interference Immunity in Residential & Industrial Areas)
IEC 61000-6-3/4 (Interference Generation in Residential & Industrial Areas)
Drives are components that are intended to be incorporated into a machine, for
industrial use. Before a drive is in installed, verify that the associated equipment
complies with the following standards:
EC Machinery Directive (2006/42/EC)
EC EMC Directive (2004/108/EC)
EC Low Voltage Directive (2006/95/EC)
6
The standards EN/IEC 60204-1 (Safety and Electrical Equipment in Machines), ISO
12100 (Safety of Machines) and EN 292 must be observed in association with
machinery directive (2006/42/EC).
The standard IEC 60439-1 (Low-voltage switchgear and control gear assemblies)
must be observed for conformance with the EC Low Voltage Directive
(2006/95/EC).
The machine manufacturer must generate a hazard analysis for the machine, and
must implement appropriate measures to ensure that unforeseen movements cannot
cause injury or damage to any person or property.
The machine manufacturer is responsible for ensuring that the machine meets the
requirement specified by the EMC regulations. Advice on the correct installation for
EMC (such as shielding, grounding, treatment of connectors and cable layout) is
shown in this manual.
The machine manufacturer must check whether other standards or EC Directives
must be applied to the machine.
Servotronix only guarantees the conformance of the servo system with the standards
cited in this chapter.
Installation of the equipment is critical in designing system and machine
electromagnetic compatibility (EMC). The user must apply the installation
recommendations in this manual (see Section Error! Reference source not found.,
Error! Reference source not found. and Section 3.3, CE Filtering Techniques when
mounting and installing the drive system for CE conformance).
1.3
Read Before Installing
This manual is provided with your product to assist you in getting your PPB installed
and operational.
High voltage can be hazardous to personnel and equipment. Be sure a qualified
electrician works on this equipment. To ensure your safety, follow all national and
local codes during installation, as well as the safety precautions outlined in the front
of this documentation.
1. Open the box(es) and remove all the contents. Verify that there is no visible
damage to any of the equipment.
2. Mount the PPB to the back panel. for additional details. Metal-to-metal contact
is important for electrical noise control!
3. Wire the PPB according to the System Wiring Diagram. Pay particular attention to
the pinout connector details.
4. Connect a solid earth ground to frames of all components.
5. If your PPB has 24VDC external logic power option, wire the 24VDC power.
6. Wire the motor and feedback. Refer to the Feedback Wiring Diagram for
additional information.
7. Wire the Regen Resistor kit, if applicable.
8. Verify that all wiring is correct.
9. Verify that earth grounds are connected.
10. Verify all electrical and safety codes are met.
7
11. Connect the cable C2
12. Using PEWin32 configured your system for your particular motor.
13. Using PEWin32 Tune the UMAC and PPB for the load and desired performance.
14. Make sure no one is with in motor envelop, than Enable the system.
1.4
Unpacking and Inspecting
Open the box and remove all the contents. Check to ensure there is no visible
damage to any of the equipment.
Electronic components in this amplifier are design-hardened to reduce static
sensitivity. However, proper procedures should be used when handling to avoid
damage to equipment.
Remove all packing material and equipment from the shipping container. Be aware
that some connector kits and other equipment pieces may be quite small and can be
accidentally discarded, if care is not observed when unpacking the equipment. Do not
dispose of shipping materials until the packing list has been checked.
Upon receipt of the equipment, inspect components to ensure that no damage has
occurred in shipment. If damage is detected, notify the carrier immediately. Check all
shipping material for connector kits, documentation, diskettes, CD-ROM, or other
small pieces of equipment.
1.5
Use as Directed
The following guidelines describe the restrictions for proper use of the PPB:
1. The PPB amplifiers are components built into electrical equipment or machines
and can only be used as integral components of such equipment.
2. The PPB amplifiers are to be used only one or three-phase industrial mains
supply networks with earth ground (TN-system, TT-system with earth neutral
point).
3. The PPB amplifiers must not be operated on power supply networks without an
earth ground or with an asymmetrical earth ground.
4. If the servo amplifiers are used in residential areas, or in business or commercial
premises, you must implement additional filter measures.
5. The PPB amplifiers are only intended to drive brushless synchronous
servomotors (Setting of closed-loop control of torque, speed, position. and rated
voltage are define in the UMAC using PEWin32).
6. The PPB amplifiers may only be operated in a closed switch gear cabinet, and
must be within the ambient conditions defined in the environmental specifications.
7. Before you operate your PPB, verify that the PPB is fastened.
8. Verify that you properly wire all cables according to the wiring information to
avoid a dangerous situation.
9. Verify that your motor selection is suitable to the PPB performance (continuous
current, peak current and bus voltage) requirements.
10. The manufacturer of the machine used with a PPB must generate a hazard
analysis for the machine. They must take appropriate measures to ensure that
unforeseen movements cannot cause any personnel injury or property damage.
8
11. PPB must only be operated in a closed control cabinet suitable for the ambient
conditions. End user must select the enclosure ensuring a safe operation of the
PPB.
The enclosure must meet or exceed IP3X protection requirements.
12. Ventilation or cooling may be necessary to maintain the temperature in the
cabinet below 45 °C.
1.6
Power Supply for PPB
The power supply for the drives must comply, as follows:
For 1 or 3 phase PPB, industrial power supply networks, allows not more than 42
kA symmetrical short circuits current at 240 VAC.
Connection to other voltage types of power supply networks is possible when
using an additional isolating transformer.
End user should provide a Mains disconnecting device in accordance with the
local Electrical Code.
Periodic over voltages between phases (L1, L2, L3) and the housing of the drive
must not exceed 1000 volts peak.
In accordance with IEC 61800, voltage spikes (< 50 μs) between phases must
not exceed 1000 V. Voltage spikes (< 50 μs) between a phase and the housing
must not exceed 2000 V.
EMC filter measures must be implemented by the user.
The drive provides solid state motor over current protection at 150A.
AC connection, Motor cables: 600 V,80°C should be connected to L1,L2,L3.
Ma,Mb,Mc,B+,C terminals rated 50A,600V.
Note: For AWG see Hardware specification table 2.3
1.7
Leakage Current
The following assumptions are made to determine the leakage current on our lowcapacity cables with a mains voltage of 400 V, which is dependent on the clock
frequency of the output stage:
Ileak = n x 20 mA + L x 1 mA/m at 8 kHz clock frequency at the output stage
Ileak = n x 20 mA + L x 2 mA/m at a 16 kHz clock frequency at the output stage
(where Ileak=leakage current, n=number of drives, L=length of motor cable)
At other mains voltage ratings, the leakage current varies in proportion to the
voltage.
Example:
In an application where:
Number of drives = 2
Length of motor cable = 25 meters
Clock frequency = 8 kHz:
Then the leakage current is as follows:
Ileak = 2 x 20 mA + 25 m x 1 mA/m = 65 mA leakage current.
9
Since the leakage current to PE is more than 3.5 mA, in compliance with IEC618005-1, the PE connection must either be doubled or a connecting cable with a crosssection >10 mm² must be used. Use the PE terminal and the PE connection screws
to fulfill this requirement.
The following measures can be used to minimize leakage currents:
Reduce the length of the engine cable
Use low-capacity cables
1.8
Residual Current Protective Device (RCD)
Residual current protective devices (RCD) can be used when the RCD complies with
the following regulations:
IEC 60364-4-41 – Regulations for Installation
IEC 60204 – Electrical Equipment of Machinery
The PPB is a 1 or 3-phase system with a B4 or B6 bridges. Therefore, RCDs, which
are sensitive to all current, must be used in order to detect any DC fault current.
1.9
Rated Residual Currents in the RDC
10 -30 mA protection against "indirect contact" (personal fire protection) for
stationary and mobile equipment, as well as for "direct contact".
50 -300 mA protection against "indirect contact" (personal fire protection) for
stationary equipment
Recommendation: To protect against direct contact (with motor cables shorter than
5 meters) we recommend that each drive be protected individually using a 30mA
RCD, which is sensitive to all currents.
When you use a selective RCD, the more intelligent evaluation process will prevent
spurious tripping of the RCD.
1.10
Isolating Transformers
When protection against indirect contact is absolutely essential, despite a higher
leakage current, or when an alternative form of shock-hazard protection is sought,
the PPB can also be operated via an isolating transformer.
A ground-leakage monitor can be used to detect short circuits.
It is recommended that you keep the length of wiring between the transformer and
the drive as short as possible.
1.11
Fusing for CP335:
US fuses: Class J, 600 VAC 200 kA, time-delay. The fuse must be UL and CSA
listed, UR recognized is not sufficient.
EU fuses: Types gRL or gL, 400 V/500 V, time-delay
Fuse holders Combined with the standard fuse blocks, finger safe fuse holders must
be used according to IEC 60529.
Examples:
Bussmann: CH Series Modular Fuse Holders, fuse size 45A class J, 3 poles: CH30J3
Ferraz: Ultrasafe Fuse holders, fuse size 15A class J, 3 poles: US3J3I
10
1.12
Packaging
The PPB packaging consists of a label on the outside of the box.
CP303 and CP306, CP310: Carton box: 340x215x70 mm
CP320 Carton box: 330x285x200 mm
CP335 Carton box: 330x285x200 mm
1.13
Storage
Store the PPB in accordance with IEC 61800-2 as follows:
Store only in the manufacturer’s original packaging.
1.14
Maintenance and Cleaning
The drive does not require any maintenance. Opening the drive voids the
warranty.
The inside of the unit can only be cleaned by the manufacturer.
You should only clean the drive exterior, as follows:
Casing: Clean with isopropanol or similar cleaning solution.
Protective grill on fan: Clean with a dry brush.
Do not immerse or spray the drive.
1.15
Warranty Information
All products are subjected to Servotronix STANDARD TERMS AND CONDITIONS
OF SALE, as general practice, PPB covered in this manual are warranted to be free
of defects in material and workmanship and to conform to the specifications stated
either in this document or product catalog description. PPB warranty for a period of
12 months from the time of shipment, unless determined otherwise in STANDARD
TERMS AND CONDITIONS. There are no other warranties, expressed or implied
(including the warranty of merchantability and fitness for a particular purpose, which
extends beyond this warranty. Servotronix warrants that the products covered in the
manual are free from patent infringement when used for normal purposes.
1.16
Repair
Only the manufacturer can repair the drive. Opening the device voids the warranty.
All products are subjected to Servotronix STANDARD TERMS AND CONDITIONS
OF SALE, As General practice following roles apply for repair PPB’s:
Customer send following information to manufacture contact
PPB serial number
Failure description
PPB warranty YES/NO
Manufacture Send RMA number and commercial information to the customer.
Servotronix will not accept any units for repair with out RMA number.
11
PMW Power Block Installation Manual | PPB Specification
2
PPB Specification
The PPB system must be operated and stored under the environmental conditions
stated in the electrical specification tables. The system may be operated in higher
temperature ambient conditions with a derating applied. Check with the factory for
derating information.
Attention to proper installation and field wiring are of prime importance to ensure
long-term and trouble-free operation. Follow the installation and wiring instructions in
this document and incorporate all applicable electrical and safety codes, laws, and
standards.
2.1
Operational Conditions
Pollution level Pollution level 2, as per IEC 60664-1
Vibrations Class 3M1 according to IEC 60721-3-3
Enclosure protection IP 20
Mounting position: Book mounted Vertical
Ventilation: Built-in fan on all models
The PPB may not be used with a machine that does not comply with appropriate
national directives or standards. The use of the PPB in the following environments is
prohibited:
2.2

Potentially explosive areas

Environment with corrosive and/or electrically conductive acids, alkaline
solutions, oils, vapors, dust, ships or offshore applications
Electrical and Environmental Specifications
Product Model
Voltage (VACL-L) Nominal ±10%
CP303
CP306
110-230
115VAC 1φ / 3φ
1/3
230VAC 1φ / 3φ
1/3
Power
12
CP335
230
47-63
KVA at 115 (1φ)
0.44
0.89
Continuous Current (amps) at 115VAC
3.9
7.7
Peak Current (amps) for 500 mSec
115VAC
11.7
23.1
Peak Current (amps) for 2 Sec 115VAC
7.8
15.4
Inrush current
240A
max
240A
max
KVA at 230 (1φ)
0.89
1.8
Continuous Current (amps) at 230 (1φ)
3.9
7.7
Peak Current (amps) for 500mSec at 230
(1φ)
11.7
23.1
CP320
3φ only
Line Frequency
Main Input
CP310
240A
max
340A
max
340A max
Product Model
Logic Input
Power
SoftStart
CP303
CP306
CP310
CP320
CP335
Peak Current (amps) for 2Sec at 230 (1φ)
7.8
15.4
Line Fuses (FRN-R, LPN, or equivalent)
10
20
KVA at 230 (3φ)
1.4
2.8
4.6
9.2
16.1
Continuous Current (amps) at 230 (3φ)
3.5
7
12
24
42
Peak Current (amps) for 500mSec at 230
(3φ)
10.5
21
36
72
126
Peak Current (amps) for 2Sec at 230 (3φ)
7
14
24
48
84
Line Fuses (FRN-R, LPN, or equivalent)
10
20
25
50
87.5
TBD
TBD
+24VDC Ext. Logic Voltage (volts)
22 - 27
+24VDC Ext. Logic Current (amps sink)
0.5
Max. Surge Current (amps)
30
Max. Charge Time (sec)
0.25
OverTemperature trip (°C)
80°C
Protection
UnderVoltage Trip (nominal)
90 VDC
Functions
OverVoltage Trip
430 VDC
OverTemperature Trip
Internal heat dissipation (watts)
Main Output
60
80
Continuous Power (KVA) at 115VAC 1φ
Line Input (45° Ambient)
0.35
0.7
Line Input (45°C Ambient)
0.7
1.4
Line Input(45° Ambient)
1.1
2.2
3.5
3
6
10
20
35
9
18
20
40
70
6
12
20
40
70
15.5
8
8
8
8
31
16
16
16
16
Continuous Current (Arms)
(Ma, Mb, Mc) Peak Current (Arms) for 500 mSec
Peak Current (Arms) for 2 Sec
Maximum allowed PWM Frequency (kHz)
PWM Motor Current Ripple (kHz)
Operation temperature
132
0°C to 45°C
Storage temperature
-25°C to 55°C
Transport temperature
-25°C to 70°C
Operation relative humidity
Environment
80°C
5% to 85%, no condensation class 3K3
Storage humidity
5% to 95%, no condensation
Transport humidity
up to 95%, no condensation
Atmosphere
with no corrosive gasses or dust
13
Product Model
CP303
Altitude
CP306
CP310
CP335
Site altitude Up to 1000 meters AMSL without
restriction, 1,000 to 2,500 meters AMSL with power
derating of 1.5%/100 m
Vibration
2.3
CP320
0.5 g
Hardware Specifications
Amplifier Model
Unit Weight
lbs / Kgs
CP303
CP306
CP310
CP320
CP335
3.56 / 1.61
4.9 / 2.22
5.94 / 2.69
8.8/4
14.5/6.6
Mounting
English (Metric)
10-32 (M4)
Hardware
Applied Torque
20lb-in (2.26Nm)
Line Screw Size/Torque
M3.5 / 12lb-in (1.35Nm)
MiniFit
M5/TBD
Connection
BUS Screw Size/Torque
M3.5 / 12lb-in (1.35Nm)
MiniFit
M5/TBD
Hardware
Motor Screw Size/Torque
M3.5 / 12lb-in (1.35Nm)
MiniFit
M5/TBD
Ground Screw Size/Torque
M3.5 / 12lb-in (1.35Nm)
M4/TBD
M5/TBD
14
NA
8
NA
8
Motor Line (AWG)
Main Input (AWG)
Wire Size
(AWG#)
Spade Terminals
14
12
10
16/14 AWG: Hollingsworth XSS0954S or
SS20947SF or equivalent
12/10 AWG: Hollingsworth XSS20836 or
SS20832F or equivalent
8 AWG TBD
Ring Terminals
8 AWG (10mm2): Hollingsworth R3027BF or equivalent
2 AWG (35mm2): Hollingsworth R7998BFN or equivalent
Clearance
Side-to-Side
Distance
Top/Bottom
Mating
C2 Cable
Connector
C2 Connector
Hardware
Connector Screw Torque
24V Logic (optional)
14
2.5in (63.5mm)
See Section 4.3.2, PWM Cable Part Numbers
Mini DIN 36
2.25 lb-in (0.25m)
PCD ELFP02210 or equivalent
2.4
Regen Specification
Product Model
External Shunt
Regulator
CP303
CP310
CP320
CP335
Peak current (amps)
20
45
56
Minimum resistance (Ω)
20
6
7
Watts
200
1000
3000
TBD
TBD
Capacitance (Farads)
2.5
CP306
0.00082
0.00164
Application
BUS Voltage (nominal) (VDC)
325
Information
VHYS (Regen circuit turn-off) (VDC)
370
VMAX (Regen circuit turn-on) (VDC)
390
Outline Dimensions
CP310
99.0 [3.90]
CP3 06
88.4 [3.48]
CP3 03
67.4 [2.65]
36.5
[1.44]
15.5
[.61]
163.0
[6.42]
3 x 5.5
[.22]
2.0
[.08]
6.7
[.61]
2x ∅ 10.0
[.39]
HEAT SINK
244.0
[9.61]
256.0
[10.08]
216.0
[8.50]
33.7
[1.33]
Figure 2-1: CP3 03/06/10
15
Figure 2-2: CP320260
Figure 2-3: CP335260
16
PMW Power Block Installation Manual | Installation
3
Installation
3.1
Mounting Practices
The PPB series of electronic system components are designed for panel assembly.
This panel assembly needs to be mounted in a metallic enclosure. Enclosures are
supplied by the manufacturers of the final product and must meet the environmental
IP rating of the end product. To ensure proper grounding (and to optimize EMC), the
enclosure must have continuous ground continuity maintained between all metal
panels. This ground continuity is intended to be both a safety ground and a high
frequency ground. The units should be mounted on a back plane installed into the
enclosure. Ideally, the back plane should be an unpainted metallic surface to optimize
electrical bonding of the frame and provide the lowest possible impedance path to
earth ground. These enclosures also provide added safety.
The PPB units should be mounted vertically for proper ventilation. These products
are designed for mounting in an electrical enclosure to protect them from physical
and environmental damage. When designing the enclosure, particular care should be
made concerning the layout inside the enclosure. Separate power wires from the
small signal wires. The following guidelines highlight important wiring practices to
implement:
Control and signal cables must be separated from power and motor cables.
Distance of 20cm (8 in.) is sufficient in most cases.
Control and signal cables must be shielded to reduce the effects of radiated
interference.
When control cables must cross power or motor cables, they should cross at an
angle of 90 degrees, if possible. This reduces the field coupling effect.
Use only copper conductors for wiring. The conductor cross-sections can be
derived from standard IEC60204 (alternatively for AWG cross-sections: NEC
Table 310-16, 75 °C column).
Color green with or without yellow stripes should only be used for protective
bonding.
Cross-sectional area of protective earth ground conductor, which does not form
part of the supply cable, should be a minimum of 4 mm².
The ground symbol, which you will find in all the wiring diagrams, indicates that
you must provide an electrically conductive connection with the largest feasible
surface area between the unit indicated and the mounting plate in the control
cabinet. This connection is used for the effective grounding of HF interference,
and must not be confused with the PE-symbol (PE = protective earth, safety
measure as per IEC 60204).
3.2
Guide to Mechanical Installation
The following notes should be observed when performing the mechanical installation.
Site installation should be in a closed control cabinet.
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet:
17
Ventilation – Check that the ventilation of the drive is unimpeded, and the
ambient temperature is maintained within the permitted temperatures. Keep
the required space clear above and below the drive.
Cooling System – When cooling systems are used for the control cabinet,
position the cooling system so that the condensation water cannot drip onto
the drive or peripheral devices.
Assembly – Assemble the drive and power supply close together, on the
conductive, earth grounded mounting plate in the cabinet.
Grounding and Shielding – For EMC-compliant shielding and grounding.
Earth ground the mounting plate, motor housing and CNC-GND of the control
system.
3.3
CE Filtering Techniques
The PPB system (power block, drive, motor) meets the CE Mark standards, as stated
in Section 1.2.1. Apply proper bonding and grounding techniques, described in this
section, when incorporating EMC noise filtering components to meet this standard.
Noise currents often occur in two types. The first is conducted emissions passed
through ground loops. The quality of the system-grounding scheme inversely
determines the noise amplitudes in the lines. These conducted emissions are of a
common-mode nature from line-to-neutral (ground). The second is radiated highfrequency emissions that are usually capacitively coupled from line-to-line and are
differential in nature.
To properly mount the filters, the enclosure should have an unpainted metallic
surface. This allows for more surface area to be in contact with the filter housing and
provide a lower impedance path between the housing and the back plane. The back
panel should have a high frequency ground strap connection to the enclosure frame
and earth ground.
3.3.1
Input Power Filtering
The Servotronix PPB electronic system components require EMI filtering in the input
power leads to meet the conducted emission requirements for the industrial
environment. This filtering blocks conducted-type emissions from exiting onto the
power lines and provides a barrier for power line EMI.
Adequately size the system. The type of filter must be based on the voltage and
current rating of the system and whether the incoming line is single- or three-phase.
The implementation of the EMI filter should be done in accordance with the following
guidelines:
Mount the filter on the same panel as the drive.
Mount the filter as close as possible to incoming cabinet power.
When mounting the filter to the panel, remove any paint or material covering. Use
an unpainted metallic back panel, if possible. Filters are provided with an earth
ground connection. All ground connections should be tied to ground.
Filters can produce high leakage currents. Filters must be earth ground before
connecting the supply!
Do not touch filters for a period of 10 seconds after removing the power supply.
18
3.3.2
Motor Line Filtering
Motor filtering may not be necessary for CE compliance of PPB systems. However,
this additional filtering increases the reliability of the system. Poor non-metallic
enclosure surfaces and lengthy, unbonded (or unshielded) motor cables that couple
noise line-to-line (differential) are some of the factors that may lead to the necessity
of motor lead filtering.
Motor lead noise is either common-mode or differential. The common-mode
conducted currents occur between each motor lead and ground (line-to-neutral).
Differential radiated currents exist from one motor lead to another (line-to-line). The
filtering of the lines feeding the motor provides additional attenuation of noise
currents that may enter surrounding cables and equipment I/O ports in close
proximity.
Differential mode currents commonly occur with lengthy motor cables. As the cable
length increases, so does its capacitance and ability to couple noise from line-to-line.
While every final system is different and every application of the product causes a
slightly different emission profile, it may become necessary to use differential mode
chokes to provide additional noise attenuation to minimize the radiated emissions.
The use of a ferrite core placed at the drive end on each motor lead (shown in the
Figure 3-1), attenuates differential mode noise and lowers frequency (30 to 60 MHz)
broadband emissions to within specifications. Servotronix recommends a Fair-Rite
P/N 263665702 (or equivalent) ferrite core. Wrap each motor lead through the core
several times as shown in Figure 3-1:
Warning: Never wrap a ground lead through a core.
Differential Mode Filtering
Common Mode
Filtering
To motor
To Motor
From Drive
V
From Drive Output
Figure 3-1: Motor Line Filtering
Common mode currents occur from noise spikes created by the PWM switching
frequency of the drive. The use of a ferrite or iron-powder core toroid, as shown in the
figure above, places common mode impedance in the line between the motor and the
drive. The use of a common mode choke on the motor leads can increase signal
integrity of encoder outputs and associated I/O signals. Table 3-1 and Table 3-2 list
the toroidal and ferrite cores that can be used to make common mode chokes.
19
Table 3-1: Toroidal Core Recommendations
Manufacturer
Mfg. Part #
Size
Micrometals
T400-26D
OD 4in (102mm) ID 2.25in (57.2mm) HT 1.3in (33mm)
Micrometals
ST102-267
OD 1.025 in (26mm) ID 0.6 in (15.2mm) HT 0.475 in (12.1mm)
Micrometals
ST150-275B
OD 1.52 in (38.6mm) ID 0.835 in (21.2mm) HT 0.825 in (21mm)
Micrometals
ST200-275B
OD 2.01 in (51.1mm) ID 1.24 in (31.5mm) HT 1.025 in (26mm)
Magnetics
77930-A7
OD 1.09 in (27.7mm) ID 0.555in (14.1mm) HT 0.472in (11.99mm)
Fair-Rite
2643803802
OD 2.4in (61mm) ID 1.4in (35.55mm) HT 0.5in (12.7mm)
Table 3-2: Pre-wound Common-Mode Chokes
Manufacturer
Mfg. Part #
Part #
Description
Schaffner
RD7137-36-0m5
A-96843-005
500μH 3 phase common mode choke.
36 amps continuous.
Schaffner
RD8137-64-0m5
A-96843-010
500μH 3 phase common mode choke.
64 amps continuous.
3.4
Grounding
System grounding is essential for proper performance of the drive system. A ground
bus bar is used as a single point ground for the system. Safety grounding is provided
to all pieces of the system from a “star point”. A high frequency ground must also be
provided. It should connect to the back panel to the enclosure, and ultimately to earth
ground. This high frequency ground is made with the use of a flat braid or copper bus
bar. Do not use a standard wire for the high frequency ground. When connecting high
frequency grounds, use the shortest braid possible.
3.5
Bonding
The proper bonding of shielded cables is imperative for minimizing noise emissions
and increasing immunity levels of the drive system. Its effect is to reduce the
impedance between the cable shield and the back panel. Servotronix recommends
that all shielded cables be bonded to the back panel.
Power input wiring does not require shielding (screening), when the power is fed to
the cabinet (enclosure) via metallized conduit. If metallized conduit is not
implemented into the system, shielded cable is required on the power input wires and
proper bonding technologies should be implemented.
The motor and feedback cables should have the shield exposed as close to the drive
as possible. This exposed shield is bonded to the back panel using one of following
suggested methods:
Non-Insulated Cable Clamp
Alternative Bonding Methods
3.5.1
Non-Insulated Cable Clamp
The following figure shows how cable bonding is implemented using non-insulated
metallic cable clamps. The picture on the left demonstrates clamping to the back
panel in the vicinity of the drive. The picture on the right shows a technique for
20
bonding a terminal strip (for best results, it is recommended not to break the shielding
of the cable).
CP3
From the drive
Terminal Strip
Bonded to Back
Plane
To Motor
Figure 3-2: Power Block Clamp and Terminal Clamp
3.5.2
Alternative Bonding Methods
Another option is to use cable bonding clamps (offered by Phoenix Contact and
others). When using the Phoenix Contact parts, make sure that a low impedance
(high frequency) ground is connected from the ground bus bar to the back panel,
using a flat braid or a copper bus bar. The SK parts from Phoenix (SK8, SK14, &
SK20) slide onto the bus bar. The cable (with exposed shield) is inserted through the
SK piece and the thumbscrew on top of the SK piece is used to tighten the
connection between the cable shield and the bus bar.
Table 3-3: Phoenix Part Descriptions
Phoenix Contact Part
Description
Cable Diameter Range
3025163 (Type SK8)
Shielded terminal block - for placing the
shield on bus bars.
SK8
(up to 8mm or 0.315 in)
3025176 (TypeSK14)
shield on bus bars.
SK14
(8mm to 14mm or 0.551 in)
3025189 (Type SK20)
shield on bus bars.
SK20
(14mm to 20mm or 0.787 in)
0404428 (Type AB)
Support for bus bar. 2 needed to mount
ground bus.
N/A
0402174 (Type NLS-CU 3/10)
Bus bar material - 10mm x 3mm copper at
varying lengths.
N/A
The next two figures represent a side and top view of the SK device that clamps
down on the cable shield. The use of the Phoenix SK device is an excellent method
for providing a low impedance path between the cable shield and the back panel.
21
Thumb screw to tighten down
shield to bus bar
cable shield compressed on copper bus bar
SK(8,14,20) - Shielded
terminal block
copper bus bar
Figure 3-3: Phoenix Contact - Side View
Figure 3-4: Phoenix Contact -Top View
22
PMW Power Block Installation Manual | WIRING
4
WIRING
The PPB is a PWM amplifier designed to drive a servo motor by using a PWM input
from an external controller, Delta Tau Data Systems, Inc. PMAC®2 multi-axis
controller. The PPB consists of a smart power stage and an intelligent interface card
for the switching power amplifier. The product allows for dynamic system
performance and excellent control capabilities. Extensive protection features include
encoder loss detection, peak over-current protection, I2t protection, PPB overtemperature protection, and over- and under-voltage protection. All faults are
displayed on a 7-segment display.
Note: The Integrated +8F Option is no longer supported.
4.1
Main Power Connector
The main power terminal block is on the front of the unit, and is protected by a plastic
cover, which snaps closed.
Table 4-1: Power Connector
Label
B+
C
Description
300VDC Bus for External Regeneration Resistor
Common Bus for External Regeneration Resistor
Models
Model
03 06 10 35 Amp
20 Amp
Spade Terminal
Spade Terminal
Connector:2 x PIN Molex MiniFit
STX PN: CON-00000002-44
Molex PN: 42816-0212
Terminal: Molex Terminal (pins)
STX P/N CON-00000002-44 Molex P/N
42815-0031
Connector: 6 x PIN Molex MiniFit STX
Ma
Output to Motor Phase A
Spade Terminal
Mb
Output to Motor Phase B
Spade Terminal
Mc
Output to Motor Phase C
Spade Terminal
Terminal: Molex Terminal (pins)
STX PN: PIN-00042815-00
Molex PN: 42815-0031 L1
Line Input Phase 1
Spade Terminal
L2
Line Input Phase 2
Spade Terminal
L3
Line Input Phase 3
Spade Terminal
PE
Power Earth
Ring Terminals
4.2
STX PN: CON-00000006-38
Molex PN: 42816-0612
Ring Terminals
24V Logic Power Connector (Optional)
For the PPB model 03 06 10 Amp the logic power for the unit is generated internally,
but there is an option available that allows for connection to an external 24 VDC logic
power supply.
For PPB 20 and 35 Amp you must supply 24VDC for the logic power
Matting connector Servotronix PN CON-00000002-05 (PCD ELFP02210)
23
4.3
PWM Cable
4.3.1
PWM Pinout
Table 4-2: Pinout Description
ACC-24
Symbol
Function
Description
Mini-D-36
24
1
FC0
Feedback
Fault code bit
1
2
FC2
Feedback
Fault code bit
2
3
ADC_CLK+
Command
A/D converter clock
3
4
ADC_STB+
Command
A/D converter strobe
4
5
CURRENTA+
Feedback
Phase A actual current data
5
6
CURRENTB+
Feedback
Phase C actual current data
6
7
AENA+
Command
Amplifier enable
7
8
FAULT+
Feedback
Amplifier fault
8
9
PWMATOP+
Command
Phase A top command
9
10
PWMABOT+
Command
Phase A bottom command
10
11
PWMBTOP+
Command
Phase B top command
11
12
PWMBBOT+
Command
Phase B bottom command
12
13
PWMCTOP+
Command
Phase C top command
13
14
PWMCBOT+
Command
Phase C bottom command
14
15
PMAC_GND
Common
Reference voltage
15
16
PMAC_+5V
Power
+5V power from controller
16
17
NC
17
18
NC
18
19
FC1
Feedback
Fault code bit
19
20
FC3
Feedback
Fault code bit
20
21
ADC_CLK-
Command
A/D converter clock, return
21
22
ADC_STB-
Command
A/D converter strobe, return
22
23
CURRENTA-
Feedback
Phase A current data, reference
23
PPB C2
Mini-D-36
ACC-24
Symbol
Function
Description
PPB C2
Mini-D-36
Mini-D-36
24
CURRENTB-
Feedback
Phase C current data, reference
24
25
AENA-
Command
Amplifier enable, return
25
26
FAULT-
Feedback
Amplifier fault, reference
26
27
PWMATOP-
Command
Phase A top command, return
27
28
PWMABOT-
Command
Phase A bottom command, return
28
29
PWMBTOP-
Command
Phase B top command, return
29
30
PWMBBOT-
Command
Phase B bottom command, return
30
31
PWMCTOP-
Command
Phase C top command, return
31
32
PWMCBOT-
Command
Phase C bottom command, return
32
33
PMAC_GND
Common
Reference voltage
33
34
PMAC_+5V
Power
+5V power from controller
34
35
NC
35
36
NC
36
4.3.2
PWM Cable Part Numbers
Cabling can be made by the customer or purchased from Delta Tau directly.
Table 4-3: PWM Cable Delta Tau Part Numbers
Option
Description
Part Number
CABPWM-1
Amplifier PWM Cable, 600 mm (24) inches long, mini-D,
36 conductor, 1 axis
200-602739-024x
CABPWM-2
Amplifier PWM Cable, 900 mm (36 inches long), mini-D,
200-602739-036x
CABPWM-3
Amplifier PWM Cable, 1.5 m (60 inches long), mini-D, 36
conductor, 1 axis
200-602739-060x
CABPWM-4
conductor, 1 axis
200-602739-072x
CABPWM-5
conductor, 1 axis
200-602739-084x
CABPWM-6
Amplifier PWM Cable, 3.6 m (144 inches long), mini-D,
200-602739-144x
25
Figure 4-1: Wiring Diagram for CP303 CP306 and CP310 models
24 VDC
Logic Input
E-STOP
EXTERNAL RESISTIVE
REGEN UNIT
Regen
Resistor
THERMOSTAT
NORMALLY OPEN AUXILLARY
PWM Cable (CABPWM-n)
POWER CONTACTOR FROM
MAIN POWER CONTACTOR
MOMENTARY
PUSHBUTTON
TO ENERGIZE
.POWER MAIN
C2
POWER MAIN
CONTACTOR
VDC 385 ON Regen
VDC 375 OFF Regen
C
B+
Ma
Mb
Mc
MAIN INPUT
Line to Line VAC 230 to 190 POWER
L1
0
11
L2
190
SHIELD
L1
TO
STAR POINT
L2
FUSE1
L3
FUSE2
FUSE3
STAR
POINT
L3
MOTOR
POWER
CUSTOMER SUPPLIED
Figure 4-2: Wiring Diagram for CP320
Note: CP335 is similar to CP303 CP306 and CP310 models
26
TO UMAC
L − L = 3 × Phase[VAC ]
VBUS = 2 × L − L = 2 × 3 × Phase[VAC ]
VBUS :
160 = 2 × 115
290 = 2 × 208
325 = 2 × 230
Figure 4-3: VBUS calculation
4.4
System wiring
HEAT SINK
Ethernet
PPB Connector C2 interfaces between the PPB and an external Delta Tau (or
compatible) digital interface board, such as the Accessory ACC24-E. Connector C2 is
a standard mini-D-36 connector.
ACC24-X 2 – 2Axis
Digital Direct PWM Axis
Interface Board
Turbo UMAC CPU Board Turbo UMAC CPU with onboard USB/2Ethernet
Communications
Figure 4-4: System wiring
27
4.5
System Interconnect
The following diagram illustrates the principle connectivity of a typical PPB system
working with UMAC:
Ιa
Ι b = − ( Ιa + Ιc )
Ιc
Figure 4-5: Typical PPB System
28
PMW Power Block Installation Manual | PPB Interface
5
PPB Interface
5.1
7-Segment Display and Fault Description
The 7-segment display on the front of the drive indicates the status of the drive.
When the drive is disabled and there are no faults, the display is blank. When the
drive is enabled, the decimal point is lit.
When a fault condition occurs, the drive is disabled. The LED displays the cause of
the fault so you can readily determine the source of the problem. Faults are cleared
by removing the cause of the fault, and then toggling the drive enable signal. The
drive over-current fault (P1) can only be cleared by cycling the drive power. The
following table shows the display fault codes and fault description. The PMAC code is
discussed in the next section.
Table 5-1: Fault Codes and Description
Display
Fault Code
(FCA-FCB-FCC-FCD)
Fault Description
t1
1011
Foldback
t3
1011
Power amplifier over-temperature
o
1101
Power amplifier over-voltage
u
1110
Power amplifier under-voltage
≡
Comment
Watch dog
P1
1001
Drive controller over-current
PPB controller calculate the ABS
Ia+Ib+Ic
P
1001
Power stage amplifier over-current
Signal from power module device
F
1100
PWM fault frequency
A1
1010
+12V under-voltage
A2
1010
-12V under-voltage
A3
1010
+5V under-voltage
A4
1010
Reference under-voltage
The following provides a description of some of the more important faults that may be
detected by the PPB:
Drive Over-temperature: The internal heat sink temperature is monitored for unsafe
conditions. This fault occurs when the temperature exceeds the maximum safe
temperature. The fault automatically reset after the drive cools down to a proper
operational temperature.
Bus Over-voltage: This fault may occur during a regen operation, where the BUS
voltage is raised to higher values than what is produced by the power supply.
Bus Under-voltage: This fault may occur if the incoming line voltage drops or if a
problem occurs in the power supply.
Power Stage Fault (Over-current): Hardware circuitry monitors load short-circuit,
transistor failure, and instantaneous over-current. A power stage fault cannot be reset
by toggling the enable line, but only by cycling the power.
29
Power Supply Under-voltage: Hardware monitors the analog ± 12 VDC supply for
out of tolerance voltages. If you receive this fault contact the manufacturer for
assistance.
5.2
Watchdog
To prevent the Watchdog fault from being triggered, the following power up sequence
must be implemented:
1. Power up the PMAC2 controller.
2. Connect the PPB to the PMAC2 controller.
3. Turn the 24 VDC power on (for units that are supplied with separate 24V logic
power).
4. Turn the AC power on.
5.3
Frequency Fault (Maximum PWM frequency)
To prevent the Frequency Fault, the PMAC2 I900 parameter should be set as follows:
Set PWM frequency so that it does not exceed 15.5kHz, for CP303 CP306
Set PWM frequency so that it does not exceed 7.9kHz, for CP310 CP320 CP335
5.4
Fault Code Transmission
The PPB transmits FC_A, FC_B, FC_C and FC_D fault code bits to the PMAC2
controller via lines CHU+, CHV+, CHW+ and CHT+ on connector C2.
(see Section 5.1 for fault codes and fault descriptions)
The following refers to the Motor connected as Axis 1:
Those FC (Fault Code) signal shared internally with Hall input signal --- when the
amplifier fault signal is activated, M124~M127 have the meaning of FC, not hall
inputs.
UMAC Jumper Setting:
For PPB series, to use this, Jumper E10 (CH#1) and E11 (CH#2) located pin no 1
and 2 (1—2).
The following is based on the schematics and manuals from Delta Tau:
M123->X:$078200,15 ; FAULT1 flag input status
(Amp fault Input)
M124->X:$078200,20 ; Channel 1 W flag input status (FC#1)
M125->X:$078200,21 ; Channel 1 V flag input status (FC#2)
M126->X:$078200,22 ; Channel 1 U flag input status (FC#3)
M127->X:$078200,23 ; Channel 1 T flag input status (FC#4)
M128->X:$078200,20,4 ; Channel 1 TUVW inputs as 4-bit value
5.5
PPB Foldback DIP Switch Setting
The PPB Foldback shutdown is controlled by two of the ten DIP switches, which are
located on the top of the PPB. DIP switches 1 and 4 enable or disable the Foldback
shut-down (fault display “t1”). If any switch is in an open position the Foldback is
inactive. The settings are shown in Table 5-2.
30
Table 5-2: PPB Foldback DIP Switch Setting
Feature
S401: Switch 1
S401:Switch 4
PPB Foldback is active
Down (Close)
Down (Close)
PPB Foldback is inactive
Up (Open)
Down (Close)
Down (Close)
Up (Open)
Up (Open)
Up (Open)
When the PPB Foldback feature is active, the drive stops operations as a function of
the current and time. The table below is an example of the Foldback current to time
relationship for the CP335260.
Example Foldback time for CP335260
PWM Current% of 98A peak
50%
60%
70%
80%
90%
100%
Time CP335260 (seconds)
continuous
6
3.1
2.2
1.8
1.6
The PPB does not generate the current command, so the PPB has no way of limiting
the current, besides a full shut-down. A Foldback fault is generated if the peak current
is drawn for 1 second, or if 2/3 peak current is drawn for 2 seconds, the PPB
controller assumes that the ratio of cont/peak is 1/3.
For PMAC2 direct PWM commutation, it is very important to set the I2T protection for
the amplifier/motor system. Normally, an amplifier has internal I2T protection
because it is closing the current loop. However, when PMAC2 is closing the
current loop, then the amplifier cannot protect itself or the motor from a
possible over heating condition. Because the PMAC2 is closing the current loop, it
is crucial to set up I2T protection properly. It can be set up using one of the Setup
Programs or manually set the Ixx69, Ixx57 and Ixx58. For more information, refer to
the Delta Tau manuals.
5.6
Current Scaling
The PPB measures the current of the drive and provides the value to the user via a
±10-volt signal. The currents measured from the power board of the drive are IAA
and ICC, but those signals are not available to the user. The voltage is scaled such
that 10 Volts is equivalent to 125% of the peak current. The peak current value is
based on the PPB model, and the voltage is scaled accordingly, as shown in
Table 5-3.
31
Table 5-3: Current Scaling
SP Model
Continuous Current
Peak Current
Value at 10V
(Amps RMS)
(Amps RMS)
(Amps RMS)
CP3032x0
3
9
11.25
CP3062x0
6
18
22.5
CP3102x0
10
20
25.0
CP320260
20
40
50
CP320260
35
70
87.5
UMAC
32,767
ixx69
ixx57
Peak current limit
Output command limit
CP3
Controller
PWM 0-100%
Continuous current limit
±10V
±10V
Value at 10V is equivalent to 125% of
amplifier PEAK current in Amp RMS
CP3
Power stage
PWM_Bh
PWM_Ch
Dead time IC
Dead time IC
PWM_Bl
PWM_Cl
Ιa
Ι b = − ( Ιa + Ι c )
Ma
Mb
VBUS] DC[
8/16KHz
t] sec[
I] Arms[
Ιc
t] sec[
Mc
Feedback
Figure 5-1: Example of CP3032x0
32
PMW Power Block Installation Manual | Troubleshooting
6
Troubleshooting
6.1
Troubleshooting
This section assumes that the user already has a working knowledge of how to
operate the hardware and software elements of the system. Some general
troubleshooting procedures include:
Verify Proper Motor Operation
Verify Proper PPB Drive Operation
Verify Proper PMAC Operation
6.1.1
Verify Proper Motor Operation
The following troubleshooting procedure offers a simple way to check that the motor
is operating properly.
1. Check the Motor resistance from Phase A to B, from A to C, and from B to C. All
of these tests should return similar values.
2. Check Motor induction from Phase A to B, from A to C, and from B to C. All of
these tests should return similar values.
3. Verify that all motor components are properly aligned and tightened. For
example, check that the motor feedback is properly tightented to the motor.
4. Verify that the Motor PE is connected to the PPB Drive PE
5. Check the motor phase and feedback cable.
6. Switch the suspected motor with a working motor in the system.
6.1.2
Verify Proper PPB Drive Operation
1. Verify that all cables are properly screwed in and tightened to the PPB Drive.
2. Verify that you have attached a proper power supply to the PPB Drive. If your
PPB Drive requires 24VDC, verify that you are using a 24 VDC power supply.
3. Switch the suspected PPB Drive with a working PPB Drive into your system.
6.1.3
Verify Proper PMAC Operation
1. Verify that you are referring to the right PPB Drive channel.
2. Rotate the shaft one revolution and make sure you read the position feedback
from the PEwin32 software.
3. After phasing the motor, make sure the phasing was successful.
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PMW Power Block Installation Manual | Troubleshooting
6.2
PPB Drive Troubleshooting
Table 6-1: Troubleshooting
Display
Fault Code
(FCA-FCB-FCC-FCD)
Fault Description
Suggested Troubleshooting
t1
1011
Foldback
The PPB shot down the drive for Foldback (I2T)
protection. Make sure your Ixx69 Ixx57 and Ixx58 are
correct.
t3
1011
Power amplifier
over-temperature
The power stage reached very high temperatures.
Make sure the PPB is in an environment with a
maximum temperature of 45°C.
o
1101
Power amplifier
over-voltage
An over-voltage condition shut down the PPB and
displays a lower -case “o” in the status display. This
fault will occur mostly during regen operation where
the BUS voltage is raised to higher values than what is
produced by the power supply. Regen occurs during
deceleration of the motor, you need to add a regen
resistor unit to the system.
u
1110
Power amplifier
under-voltage
An under-voltage condition shuts down the PPB and
displays a “u” in the status display.This fault normally
occurs when the incoming line voltage drops out or a
fault occurs in the power supply. Verify that you apply
1P or 3P AC to the PPB.
≡
Watch dog
P1
1001
Drive controller
over-current
PPB controller calculate the Absolute current of
Ia+Ib+Ic
P
1001
Power stage
amplifier overcurrent
Over-current signal from power module device. Verify
that you are not stalled and you are not applying PWM
above the allowed condition.
F
1100
PWM fault
frequency
Your PWM frequency setting in the PEwin32 is above
the allow PWM of the PPB.
Verify that PMAC PE is connected to the PPB PE.
34
A1
1010
+12V under-voltage
Return the PPB to the vendor.
A2
1010
-12V under-voltage
A3
1010
+5V under-voltage
A4
1010
Reference
under-voltage
PMW Power Block Installation Manual | Part Number
7
Part Number
PPB Model Number for 03 06 and 10 Amp RMS CP3 XX 2X 0
Product Designator Current Rating 03: 3 Amp. rms continuous; 9 Amp. rms peak
06: 6 Amp. rms continuous; 18 Amp. rms peak
10: 10 Amp. rms continuous; 20 Amp. rms peak
25: logic power generated internally 26: 24V external logic power
PPB Model Number for 20 and 35 Amp RMS
CP3 XX 26 0
Product Designator Current Rating 20: 20 Amp. RMS continuous; 40 Amp. RMS peak
35: 35 Amp. RMS continuous; 70 Amp. RMS peak
26: 24V external logic power
35
PMW Power Block Installation Manual | Customer Service
8
Customer Service
Servotronix is committed to delivering quality customer service and support for all our
products. Our goal is to provide our customers with the information and resources so
that they are available, without delay, if and when they are needed. In order to serve
in the most effective way, we recommend that you contact your local sales
representative for order status and delivery information, product information and
literature, and application and field technical assistance. If you are unable to contact
your local sales representative for any reason, please use the most relevant of the
contact details below:
For Technical Support, please contact:
[email protected]
To order products, please send orders to:
[email protected]
For all other inquiries on the PPB drives or other Servotronix products, please contact
our Customer Service at:
[email protected]
Servotronix Motion Control Ltd.
21C Yagia Kapayim Street
Petach Tikva 49130
Israel
Tel: +972 (3) 927 3800
Fax: +972 (3) 922 8075
Web site: www.servotronix.com
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