AFD User`s Manual
Contents
1. CASE GRD P3 1 MOTOR A J3 A J5 A P3 2 MOTOR B J3 B J5 B P3 3 MOTOR C J3 C J5 C Mc RED AC PE J3 D J5 D ERN GRN AC J3 E W a P2 13 5V OUT 11 13 J2 A J6 A MOTOR WHT BLU P2 12 GND 1 1 42 R 15 8 BRN GRN P2 1 HALLA 22 6 26 GRN YEL P2 2 HALL2 1 2 2 26 0 YEL ORG P2 3 HALL3 1 3 22 26 1 GRY BRN 22 10 CTRL SIG 31 10 J2 F J amp F PNK Vio 2 15 CTRL PWR 01 15 J2 T J T BLU VIO J2 U a RED E J2 V GRN GRN gt S V 1 lt P15 REF IN 14 5 WHT BLU Pi amp REF IN dcl WHT RED 2 P4 1 10V QUT 25 1 1 COMMAND SPEED RED 10V OUT 1 3 BLU 21 2 SIG GND 14 2 BLK P1 11 INH EN 1 1 GRN ENABLE P1 9 CURR REF 18 9 WHT BRN CAN P1 8 CURR MON 14 8 BRN CA P1 7 VEL MON 14 7 GRY C P1 14 FAULT 14 18 ORG 5 P1 15 5 OUT 14 5 Vid CR P1 17 CTLR JA 17 A WHT YEL P1 18 CTLR SIGNA J4 18 N YEL 4 5 i NA 24VDC Figure 2 System Wiring Diagram Notes 1 N C1 Supply voltage must be 210 270VAC 3 Phase and 50 60 Hz Power requirement is 4 5 KVA The amplifier contains a 15A slow blow fuse on each AC line input 20 000 Ohm to 50 000 Ohm Potentiometer Crouzet P N 84130104 5VDC Input 24VDC Output Solid State Relay or equivalent 2700 Ohm Watt Resistor 3900 Ohm 1 Watt Resistor PUSHCORP INC AMC2. 2 4 4 4 0 TECHNICAL 8 2 24 1 11111 nnn nnn nnn PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note 1 0 LIMITED WARRANTY Duration One year from date of delivery to the original purchaser Who gives this warranty warrantor PushCorp Inc Telephone 972 840 0208 Corporate Address P O Box 181915 Dallas Texas 75218 Shipping Address 2345 Merrit Drive Garland Texas 75041 Who receives this warranty purchaser The original purchaser other than for purposes of resale of the PushCorp Inc product What products are covered by this warranty Any PushCorp Inc industrial equipment or accessory supplied or manufactured by the Warrantor What is covered under this warranty Defects in material and or workmanship which occur within the duration of the warranty period What is NOT covered in this warranty A IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you B ANY INCIDENTAL INDIRECT OR CONSEQUENTIAL LOSS DAMAGE or EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE MALFUNCTION OF THE PUSHCORP INC PRODUCT Some states do not allow the exclusion or limitati
3. time allowed to reach the desired speed or stop will directly effect the life of the motor PushCorp recommends a smooth linear velocity ramp with a minimum period of one second be used to accelerate to full speed or to decelerate to zero speed The minimum one second acceleration period must be increased if larger higher inertia tools are used to prevent servo amplifier faults and avoid long term damage PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note 4 0 Technical Specifications AMPLIFIER SPECIFICATIONS Input Power 220 270VAC 3 phase 50 60Hz Weight 4 78 Ib 2 16 kg Operating Temperature 13 to 149 F 25 to 65 Thermal Cutoff 149 65 For specific dimensions see www pushcorp com for detail drawings Specifications subject to change without notice Fastener Tightening Torque Specs wm we s vs
4. 0 General Overview The PushCorp Inc B40A40AC is an analog input DC brushless servo amplifier manufactured by Advanced Motion Controls AMC It has been tuned by PushCorp to match the performance characteristics of the 5 0605 SM0605 servo motors This amplifier along with a servo motor feedback cable power cable amplifier input output cable and user supplied abrasive media form a complete system for material removal or cutting applications CAUTION The amplifier is pre configured at PushCorp for a specific motor There is no reason to adjust any of the potentiometers or DIP switch settings Tampering with these components without the approval of PushCorp can cause poor system performance and damage to the amplifier or motor The B40A40AC is capable of producing 20 amps continuous current with 40 amp peak on a 300VDC motor power bus The trapezoidal commutation provided by this amplifier is designed to operate with the hall effect velocity feedback of the STC SM0605 servo motors It is fully protected against over voltage under voltage over current over heating and short circuits With the amplifier I O cable 5 00885 a simple connection to a cell controller PLC robot controller or discreet control devices can be accomplished One red green LED is visible on the front panel to display the operational status 3 0 Installation 3 1 Safety Instructions In order to provide a safe and efficient configuration for an B4OA40AC
5. AMC B40A40AC a COP GAIN VANCED MOTION CONTROLS Jom WWW a m c com E VEDO BER MADE IN U S A meet eram 1 MERO END 1 2 OFF sov ama our FAULT our SIGNAL GNO 7 E 5V 250 mA OUT Aou SIGNAL GND P1 CTUR PUA VEL MONTOR out ENC CH A CURA MONITOR OUT 4 CURR REF OUT ENC CH Be RESERVED 2274 ENC CHE RESERVED rae RESERVED tr V HALL 30 ma our 19250 ma our TACH CTA POWER GREEN RED FAULT MOTORA 4 P3 worons 2 MOTORC Installation Tech Note Dallas Texas CAUTION Do NOT apply air pressure to release the collet while the servo motor is rotating The servo motor spindle must be FULLY STOPPED before actuating the Collet Do NOT overheat the servo motor Supply the motor cooling water or compressed air to maintain a temperature below 176 F 80 C Do NOT start or stop the servo motor instantaneously Doing so will damage the motor and power amplifier PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note Table of Contents 1 0 LIMITED WARRANT Y occsecsccnsicessscuasetaderencetudeatesdcecnicaancuateispoutic 2 0 GENERAL OVERVIEW 22055 rd ka Sa Y ya ran RE 3 0 INSTALLA TION eue Safety Instr ctlOHs c ii ccna eden tenendi eoe c Pet Lm Brut d do 3 4 MOTOR
6. Amplifier the following instructions and warnings must be followed WARNING All system components must be connected to a reliable low resistance earth ground It is impossible to have a safe installation without proper grounding WARNING All covers must be installed and all enclosure doors shut and locked before power is supplied to the amplifier High voltages are present on the amplifier during operation WARNING Do NOT disconnect any cables or wires from the amplifier or the motor while power is supplied to the amplifier Electrical arcing can occur which will damage the terminals or contacts PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note WARNING Do NOT contact the amplifier for a minimum of 10 minutes after power is removed Capacitors inside the amplifier can store high voltages for a period of time after power is disconnected Always check the terminals of the amplifier with a voltmeter before disconnection any cables or wires CAUTION Do NOT spin the motor shaft without power supplied to the amplifier The motor acts as a generator and will charge up the power supply capacitors through the amplifier Excessive speeds may cause over voltage breakdown in the output power devices 3 2 System Wiring PushCorp can provide an optional ASM00885 amplifier I O cable that connects to the P1 user I O connector This cable provides all of the required control and feedback connections for a typical installation The
7. B40A40AC Amplifier Installation Tech Note 3 3 Motor Temperature Feedback The 5 5 0605 is designed to operate below a temperature of 176 F 80 C and within an optimal range of 122 140 F 50 60 C In many situations it is desirable to monitor the internal motor temperature to ensure that the maximum temperature rating is not exceeded and that the optimal temperature range is maintained To facilitate this the STC SMO605 has a thermistor that is embedded in the motor windings The thermistor connection is provided on the yellow and white yellow wires of the ASMOO0885 amplifier cable thermistor temperature signal is a logarithmic function of the output resistance The graph shown in Figure 3 illustrates the internal motor temperature verses the thermistor output resistance In the graph a temperature of 176 80 corresponds to a resistance of 2000 ohms CAUTION f the thermistor indicates a resistance of less than 2000 ohms then the motor should be immediately shut down before thermal damage occurs STC1503 Thermistor Temp vs Resistance Characteristics 160 140 120 DN 100 Degrees C 60 40 20 0 0 1 1 10 100 Resistance KOhms Semitec Type 203GT Thermistor Figure 3 Thermistor Chart The following equation can be used to calculate the motor temperature ba
8. list of connections and a description are shown below in figure 1 A typical system installation with discrete control components is described in figure 2 Name Description Notes 0 10VDC 3 mA For customer use OUTPUT SIGNAL GND Reference Ground SGND Differential 10VDC Command Input 40K Input Resistance 10VDC Max RPM Clockwise INPUT White Blue OVDC 0 RPM 10VDC Max RPM Counterclockwise Actual motor current Brown SW1 3 ON 5 5 Amps Volt OUTPUT SW1 3 OFF 2 75 Amps Volt Command signal to current loop White Brown SW1 3 ON 7 25 Volts 40 Amps OUTPUT SW1 3 OFF 7 25 Volts 20 Amps Fault Inhibit Enable Green pan pulled low enables INPUT Inhibit cause Red Fault LED to light Fault LED On Output activated on fault OUTPUT Temperature thermistor output Resistance is inversely proportional to internal motor temperature If resistance goes below 700 OUTPUT Ohms Indicates 120 C then motor should be immediately shut off Figure 1 ASM00885 I O Cable Pin Out PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note oN
9. on of incidental or consequential damages so the above limitation or exclusion may not apply to you C Any failure that results from an accident purchaser s abuse neglect unauthorized repair or failure to operate the products in accordance with the instructions provided in the owner s manual s supplied with the product Responsibilities of the Warrantor under this warranty Repair or replace at Warrantor s option products or components which have failed within the duration of the warranty period PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note Responsibilities of the purchaser under this warranty A Deliver or ship the PushCorp Inc product or component to PushCorp Inc Service Center Garland TX USA Freight and insurance costs if any must be borne by the purchaser B Use reasonable care in the operation and maintenance of the product as described in the owner s manual s When warrantor will perform repair or replacement under this warranty Repair or replacement will be scheduled and serviced according to the normal work flow at the service center and depending on the availability of replacement parts Purchasers requiring quicker repair may receive such with payment of a PushCorp Inc predetermined expediting fee This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note 2
10. sed on the measured thermistor resistance 1 273 15 2 656 107 2 317X10 In R 1 752107 In R R is resistance in Kohms In is the natural logarithm function Base T is temperature in C PUSHCORP INC AMC B40A40AC Amplifier Installation Tech Note The following circuit shown in figure 4 may be used to provide an approximately linear voltage input to an A D card to indicate the Internal Motor Termperature Thermistor to voltage input circuit USER DEVICE 24 VDC 0 10VDC 3 9 Kohm 2 1 Analog Input Vin v Watt j Yellow 1 lt gt lt 2 7 5 Motor Thermistor inimum gt Watt 7 Ba Input TEM S COM Yellow White 24 VDC Common Figure 4 Thermistor Circuit The voltage input can be converted to approximate internal motor temperature Deg C according to the following equation T 168 41 Vin x 16 02 T is internal motor temperature in C Vin is input voltage in Volts 3 4 Motor Acceleration Deceleration Servo Motors have the ability to start and stop very quickly As long as the motor does not overheat or the amplifier exceed the allowable current input the motor will continue to operate The problem is that the motor and amplifier can experience excessive current spikes with rapid acceleration and declaration Media or tooling with a large mass or large diameter i e high moment of inertia only increases the current surge The amount of
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