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U-DS 006.1 - 045.1

1. Power connections U DS 045 1 is 3 x 230V 480V 50 60Hz PE L2 L3 PE external 4 4 4 brake resistance Mai Wirth ee Mains contactor VL 24V DC 20 24V gt ov e PE 4 Mains chokes 3 3 3A C A U DS 045 1 PE Li SL2 413 B1 B2 x3 GND L ee 29 Mains filter 2 5A i Regulation l po Bt semi controlled thyristor bridge gt gt k 4 O PE Fan D C link capacitors L L o O K KA 4 IGBT Output stage AK braking chopper N th A K I 4 W je O ja U dv lw S PE Ut vi wi ie u PE 3 Three phase a c motor Fig 6 6 B10 014 Power connection and controller voltage supply for U DS 045 1 and U DS 035 1 as option with terminals B1 B2 with externally connected braking resistor Operation manual 6 9 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 3 2 Mains connection Fuse protection of the feeding 6 Electrical connections Mains connection is at terminals L1 L2 L3 Ground screw The Servoconverter DriveStar are supplied with a rotary a c voltage of 3 x 230 V 10 to 480 V 15 50 60 Hz U DS 006 1 to U DS 020 1 U DS 035 1 U DS 045 1 Mains fuses 25A slow 50A slow Table 6 2 Mains protection Mains chokes have to be connected in series to the Servoconverter DriveSt
2. Software switch Operation mode wen i 3 Differential input 1 Attentuation oe Limit switch logic 5 x K sai integrator i n regulator 5 zu 2 10V gt JE dai Differential inputs 7 f Med 3 8 E Output stage for Differential input 2 rT I I max E sg S Analogue mode N min oog S Set 2 2 min ESES v X 21 10V gt 5 3 282 2 t 852 2 D Sez 5 Attentuation pal ee g Control inputs 24V l Port o E x 2 2 ol BAL sS 5 lo t 8 Customer specific technological software T O Port Compensating control X1 Signal outputs 24V amp g Pam lu Winding L X 22 ge 8 Positioning wo el gears serial interface i M X 14 x J Ke g aia O Port Actual value filter X14 KI le xn k Sl 10 BUS interface Status i Resolver option BUSK 9 Fault signal Sensor Incremental encode X15 X 16 o K selection Ki Technology 3 E Output stage Output stage inhibit Interface sl Enable j l d option V R Hardware L ncremental enco ler or Enable A Resolver monitoring a l Port H Computer fault Analog monitor 1 CN Reserve X 2 2 ja gt H 10V No A L Fault supply voltage Motor posistor Analog monitor 2 PR ZK Overvoltage and undervoltage X 2 2 9 Se is g 3 3 Overtemperature output stage 10V J LA Shorts
3. 4 1 Block diagram The following illustration shows the basic design of the Servoconverter as a block diagram Analog setpoints l 5 Monitoring Control inputs S 8 2 N oN Signal outputs Oo E Regulation Monitors N gt 3 Communication Q RS232 BUS Operator terminal g p i oO 2 2 2 Output stage E Encoder 8 imitation lt p Technology zrXxz gt Display D DS 1 Fig 4 1 B12 002 Block diagram Operation manual 4 3 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 4 2 Method of operation 4 Construction of unit and method of operation The Servoconverter DriveStar are fully digitalised They were designed for driving synchronous and asynchronous motors The output currents are sinusoidal and are controlled in pulse width modulation The switching frequency is at 2 14kHz The Servoconverter operates digitally with a regulation processor in a VeCon chip having a cycle time of less than 62 us Communication and operation are controlled through a 16 bit processor which is integrated in the VeCon chip Together the two processors form an ASIC Application Specific Integrated Circuit allowing optimum regulation characteristics highest dynamics and a simple menu guided operation The strict splitting of duties of the micro processors allows the linkage of complex tech
4. lt A lt O gt 3 oiio omme p MI g DriveStar ulv w oo D Fig 2 4 B11 022 U DS 035 1 U DS 045 1 with technology card Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 2 4 Applications and intended use 2 5 Operating conditions 2 Technical data The Servoconverter of series DriveStar are used for low loss continuous speed and torgue regulation DriveStar Servoconverter are intended for the operation of e synchronous motors made by LUST DriveTronics GmbH e asynchronous motors with actual speed by LUST DriveTronics GmbH e asynchronous motors without actual speed by LUST DriveTronics GmbH Other motors must only be used when clearly authorized by LUST DriveTronics GmbH Adhere to the motor service instructions TheServoconverter DriveStar must be used only under the prescribed service conditions see chap 8 Commissioning Operation The specified fitting removal commissioning and maintenance instructions must also be observed Caution Failure to observe such instructions or any usage over and above the specified applications will be deemed to be improper use The manufacturer will not be liable for any damage caused by such actions and the user will bear sole responsibility in such cases In particular this applies to the operation of
5. 9550 R IGBT braking chopper brake resistance Fig 6 22 Braking power calculation AM M dynamic Nm An n dynamic 1 min NMot Efficiency degree of the motor including mechanical equipment Nuy ps Effiency degree of the Servoconverter 2 M xt Mett aa ees ges AM x An P EN X nor X Nu zs KW im xt Nm a vu ges M gxn Pott x NMot X Nu ps kW Operation manual U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS Operation manual 6 34 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 7 Parameter setting 7 1 General scissssccivesiisicscacasschatednuuscavistdbunninbiscusdeibovscisaisedvervdeitaresiiee 2 7 2 Description Of parametersS 2 2 222222222022020220200200n00nnnnnnnnn2nn 2 7 2 1 Unit ParaMeters cccccsceccsscssessseseessesessessssesseesssesseeseessses 3 7 2 2 Motor 0aTAmisasnimn v asd va tamatta a KIMONO KVA nk LANTUN 4 7 2 3 Reference selector 1 and 2 rrrnnrnrrnrenvornvrnvnrernornvrnvervennernn 7 7 2 4 Regulator parameter cccccccscscsssssssesssssssesssssssssssssesersaes 8 7 2 5 Command soroorornonnvonvonnonnrrnvervenvenvesvernnsnvesvenvernnsnvesvennennn 10 7 2 6 Output signal and displays srsronronrrnrrnrnrrnrrnrrvrrvrnrrnrrnrnr 11 7 2 7 Interface RS 232 renrrnrrrnornrrvorvornrrnrenververnrenvevernnsnvervenvennne 12 7 2 8 Other parameters
6. 1 customer 2 Manufacturer of the system 3 Type designation of the unit 4 Order Ref No of the unit 5 Fabrication No of the unit 6 In case of service requirement brief description of the fault 7 If possible parameter set and software version This measure saves unnecessary identification works and further inquiries The address for Service and Replacement Parts Sales is as follows LUST DriveTronics GmbH Hansastra e 120 D 59425 Unna Telephone 49 0 2303 779 0 Telefax 49 0 2303 779 440 Should you require a Service Engineer then please contact our Technical Service Department at the above address Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 1 2 Packing 1 3 Delivery condition 1 4 Sensitivity 1 5 Storage 1 6 Items supplied 1 General The type of packing is dependent on the method of transport and the quantity of items to be supplied The symbols applied to the packing must be observed The Servoconverter is supplied as fully assembled within a housing The unit is tested for electrical function and is preset prior to shipment The settings can be found on the accompanying customer specific list as well as the parameter list As theServoconverter is an electronic assembly special care must be taken in transportation so as to prevent damage through impact or careless loading or unloading Both impacts and any large fluctuations in temperatu
7. temperature 155 C A A B IB one ne OV U Data Data CLK CLK Absolut value encoder EQN 1325 Fig 10 3 B10 018 Connection high resolution encoder Operation manual 10 4 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 10 2 3Rotary pulse generator 10 A Appendix LUST DriveStar converter SUB D 15 poles A A B B 0 10 OV 5V X11 2 Is Ja ls e 7 a lo lo ha las 141 l2 43 NN n n c n c gt u x 9 w Te w x 3 a S S o K S 4x 2x0 14 4x0 5 n c n c gt ja 12 poles T A Circular connector 5 6 8 1 3 4 10 12 j 2 7 11 on AC motor 9 Q oO oO LE C 1 L A A B B 0 10 OV U PTC resistors Rotary pulse generator Logic level TTL RS 422 or thermal contacts Response temperature 155 C Fig 10 4 B10 007 Connection rotary pulse generator Operation manual U DS 006 1 045 1 05 03 2003 10 5 LUST DRIVET RONICS 10 A Appendix 10 3 Dimensions for mounting 10 3 1U DS 006 1 to U DS 020 1 Preserve 100mm room height for cold air without technological card wi
8. Operation manual 9 2 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 9 Fault finding 9 1 Fault signal via LED The LEDs located on the front plate of the servo amplifier signalize in flashing mode any fault within or at the periphery of the unit LUST KI LED display on U DS and A DS devices LED 1 green D LED 2 to 10 yellow N o lt gt 2 Le Fig 9 1 B11 015 status LED s LED Permanent light status Flashing light fault signal 1 Ready signal Acknowledgement with controller enable 2 Output stage enable Overspeed 3 Controller enable free 4 Setpoint integrator enable Computer fault 5 C axis operation Overtemperature motor 6 Short circuit or shorts to earth on output stage I signal or brake resistance 7 Release the brake n gt 0 Encoder fault 8 n gt ni Fault supply voltage 9 Nact Net Overvoltage and undervoltage io ren Overtemperature on output stage or brake resistance Table 9 1 Status LED 5 Operation manual 9 3 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 9 2 Fault finding remedies Possible cause 1 Remedy Possible cause 2 Remedy Possible cause 1 Remedy Possible cause 1 Remedy Possible cause 2 Remedy Possible cause 3 Remedy Possible cause 1 Remedy Possible cause 2 9 Fault finding No ready signal no LED flashes
9. Note Set the delay time between the motor overtemperature message and switching off of standby mode to 0 10s Menu 4245 Caution The time offset between the motor overtemperature message and switching off of standby mode must not be set to too long a duration as otherwise the motor will be damaged H level signalises that the temperature of the brake resistance or the output stage is exceeded Simultaneously the readiness for operation of the Servoconverter is cancelled The readiness for operation can be re provided after sufficient cooling down of the brake resistance resp the output stage The output X2 2 Pin 20 is a reserve output which is used for technological software or a special customer s software Operation manual U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS Analog outputs The Servoconverter offers 2 monitor outputs for the analogue representation Monitors of various system variables The assignment of system variable to monitor output may be freely selected Menu option 3 5 for analogue monitor 1 and menu option 3 6 for analogue monitor 2 System variables reference speed actual speed phase current ir e Active current isq e reactive current isd Rotor position actual speed amount Torque setpoint Pin X22 Function 21 gt Monitor 1 22 gt GND analog 23 gt Monitor 2 Table 6 8 Analog outputs monitors X2 2
10. unensesensennennensnnennennennnnennennennenennennennennnn 12 7 3 Terminal program VecWin 2 2 222222222222220002000n0220n00nnnnnann2n 13 7 3 1 CE 13 7 3 2 Cable connection between PC and servoconverter 13 1 3 3 PC configuration and installation 13 7 3 4 Working with V CWiN c cccccscsssssssessessssssssssssssssseseesers 13 Operation manual 7 1 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 71 General Terminal program VecWin E Control unit D DS_1 E 7 2 Description of parameters Parameter set 1 Parameter set 2 ool Parameter set 3 7 Parameter setting The parameter setting allows a variety of applications for the servoconverter E g by selection of the type of motor synchronous asynchronous e Pre selection of the setpoints of different interfaces Simultaneously the parameter setting is the decesive factor for an optimum regulation behaviour of the drive The parameterisation is made via the PC terminal program VecWin The program functions with a PC AT through the interface RS232 of the servoconverter This manual consists of two sections How to handle the parameterisation via terminal program is explained in the special leaflet LUST DriveTronics GmbH manual No 192 00307 Parta Parameter setting Partb Function of oscillograph Optionally the parameterisation can be made via the operator termin
11. LUST DRIVET RONICS 2 Technical data Type of device U DS 006 1 U DS 012 1 U DS 020 1 U DS 035 1 U DS 045 1 Auxiliary voltages from the 10V 5mA 24V DC 100mA encoder simulation Servoconverter Sens r svetem Resolver optionally ROD 426 incremental encoder y high resolution sensor e g ERN 1387 or absolute value encoder e g EQN 1325 Encoder output Standard 1024 increments other number of increments on request Anbarent power of unitwith 3 9 kVA 7 8 KVA 13 kVA 23 kVA 30 kVA oe AN e 3 x 400V max 15ec 7 5 max 1sec 15 max 1sec 26 max 1sec 39 max 1sec 39 9 kVA kVA kVA kVA kVA Power loss approx 150W approx 250W approx 300W approx 350W approx 350W Motor protection PTC evaluation via encoder plug Pte monitoring Overtemperature protection overvoltage protection overcurrent protection braking Converter protection chopper Short circuit Cable ground short circuit Cable cable Weight 6 5 kg 6 5 kg 6 8 kg 9 1 kg 9 5 kg Dimensions HxWxD 362 x 85 x 258 362 x 155 x 258 Table 2 1 Performance data 2 2 Keytotypes X DS XXX X Y Configuration without abbreviation standard BE connection for external brake resistance T Technology technological L Liquid cooled S sinusodial feeding Unit generation Output stage size nominal current DS DriveSt
12. ccccececcceseeseseeeeeseeseeeeeeeseseeteerees 6 LED 8 flashes Fault of the supply voltage rrvrnrerrnvenrsvrnrsvrnrrr 6 LED 9 flashes Over undervoltage soooosisnn inen 6 LED 10 flashes Overtemperature brake resistance 7 9 3 Fault signal via operator terminalD DS 1 rserrnvrnvrnvsnvsvrnernen 8 Fault memory menu 52 rererrsvrrververvesververvesvesvesvesvesvesvesvesvesvessennenn 8 9 4 Fault diagnosis abriged version independent of the LED fault signals sessesnrnvrnvrnvrnvrnvnvvnernennr 9 Danger f necessary to take the unit out of the housing or the rack e g fuse replacement to eliminate a fault the system must be disconnected from the mains supply and must be protected against unintended re engagement Danger After disconnection for a period of a few minutes the unit contains components subject to hazardous voltage causing the death or strong bodily injuries in case of touching capacitor residual charge Danger Before carrying out any maintenance works it is therefore absolutely necessary to assure and to check that the current supply has been disconnected made safe and that the d c link is discharged Immediately before maintenance work the DC link to terminals L DE and L must always be measured When DC operation 0 1000V Operation manual 9 1 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 9 Fault finding
13. This cancellation causes an immediate disengagement of the regulator and output stage enable The drive runs down in uncontrolled manner Due to the normally very high thermal time constant of the motor it is possible to provide a time delay between the signal motor overtemperature and the cancellation of the readiness for operation During that time the superimposed control has the possibility to run the drive into a safe position The time delay can be adjusted between 0 10 sec Caution Pay attention to the motor data An extremely long delay time can result in a motor damage e g with full utilisation of the dynamics Operation manual U DS 006 1 045 1 05 03 2003 r LUST DRIVET RONICS Delay time holding brake 4 2 4 4 Kind of encoder 4 2 4 2 Encoder adjustment 4 2 2 4 2 Commutation 7 Parameter setting The here adjusted delay time has the function to delay the cancellation of the regulator enable on its way to the input signal at terminal X2 2 Pin 7 is made After cancellation of the regulator enable the drive is braked to speed O along the guick stop ramp see chap 6 19 Setpoint integrator enable Pin 10 LED 4 and see chap 6 18 Controller enable Pin 7 LED 3 From that point the drive places at disposal the holding torgue for the period of the adjusted delay time After expiration of the delay time the regulator enable is cancelled and the drive is without torque see chap 6 23 Relea
14. 1 Fuse failure of the 24V supply gt Check the voltage supply and the fuses gt check the fuses in the conduct 2 Unit type adjusted wrongly gt Check the parameter unit type menu 4 2 1 1 LED 1 flashes ready signal with regualator enable 1 Acknowledgement of fault with engaged regulator enable gt Disengage and re engage regulator enable Additional acknowledgement not necessary LED 2 flashes Overspeed 1 Wrong sensor at the motor wrong number of incr of the sensor gt Check the motor sensor 2 Motor speed is overshooting due to non optimised parameters gt Check the regulator parameters 3 Setpoint integrator t1 or t3 resp programmed to 0 s With a setpoint jump from O to Nmax the speed is overshooting gt Program the time for setpoint integrator ramps LED 3 flashes no function LED 4 flashes a Computer fault b check sum fault The function monitors the processors With fault signal the readiness for operation is interrupted 1 Computer fault Fault of the processor due to an internal defect or strong EMC disturbances gt Disengage regulator enable gt Acknowledgement gt Engage regulator enable gt If computer fault cannot be acknowledged disengage the unit and re engage it after 10 sec gt With repeated fault gt Check the EMC measures gt Ship the unit to the after sales service 2 Check sum fault The sum of the parameter content changed after the last disengagement and re engagement
15. DriveStar U DS 006 1 045 1 Operation manual Servoconverter 6A 45A LUST DRIVET RONICS Address Operation Manual Article Issue Note LUST DriveTronics GmbH Hansastra e 120 D 59425 Unna Telephone 49 0 2303 779 0 Telefax 49 0 2303 779 397 info Lust drivetronics de www Lust drivetronics de No 181 00468 Date 07 2004 Technical data subject to modification without notice Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 1 General 1 1 After sales Service rmresersrsvrsrsvrsvsvsersvsennvavnnvnvsvsennvnvnnvavsnnnvne 1 2 PaCkKilOimuniinnsmasenaaa a avannon va aava muna aaa nan vana aan Nanu a aamuna avaa K N naama 1 3 Delivery condition 2 22 22 22222422202022002n0020n00n00nn2nunnnnnnnnnnnannn 1 4 Ty GE n aaaa Nanan Sa Kan vmmanaN nunna mannna NNN n vamma 1 5 STON AGG is siisteist n paikan andansa saaana tucacstscuiessexacetacacsatsessavactexsavacsscs 1 6 Items supplied 1 7 Maintaining stocks of replacement partS rsrraravrnvrnvrnvnnvnennnn 1 8 Hints for waste management 22 22222222220222n020ann0nnnnannann Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 1 General Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 1 1 After sales service Service adress 1 General Note Before consulting the after sales service please provide the following data
16. Encoder fault Inexpert motor mounting shock load of the shaft Defective encoder Defective encoder cable Earthing screen inexpert transition resistances Wrong encoder type selected It signal Motor demagnetised bearing damage Mechanical tightness Brake not released Ref command of the holding brake insufficient or too high Short circuit shorts to earth Winding short circuit in the motor or motor cable Faulty isolation of the motor cable Ambient conditions with metal dust or graphite dust Defective output stage Water in the motor terminal box or switch cabinet Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 9 Fault finding Conseguence possible cause motor does not rotate or is jerking unguiet running Missing enable signals Missing wrong setpoint preselections Wrong parameterisation of the setpoint selector Wrong number of pole pairs selected Motor phases mixed up Encoder cable of a different motor connected wrong number of incr of the sensor Defective encoder encoder adjustment Screen not fitted Interrupted earthing encoder cable output cable Motor grounded incorrectly Wrong belt tension loose effect of the mechanics Mechanical unbalanced mass Wrong parameterisation speed current regulator Defective motor demagnetisation bearing damage Disturbed EMC surroundings radio p
17. Via connector X14 the Servoconverter can be parameter set LUST DriveTronics GmbH operating terminal D DS_1 Description and programming are given in the leaflet LUST DriveTronics GmbH Control unit D DS 1 Nr 182 02 792 Operation manual U DS 006 1 045 1 05 03 2003 6 29 LUST DRIVET RONICS 6 12 Starting inhibit Output stage inhibit with safety relay 6 Electrical connections Inhibit of the output stage by means of a safety relay This option offers another protection against unintended starting of the drive supplementary to the standard electronic output stage inhibit Caution The starting inhibit is no disengaging device to avoid unintended starting as per EN 60204 1 It is intended to stop drives not involved in service duties or other safety measures With the ref command input X2 2 Pin 8 a safety relay is commanded approved by the TUV besides the electronic output stage inhibit The contacts of the relay switch the driver supply of the output stage directly ON or OFF resp Simultaneously an auxiliary contact with feedback output stage inhibited is available Connection to terminal X2 2 Pin 24 and Pin 25 The contacts of the relay are guided so that the information about the switching stage is sure Caution Fora safe application of the inhibit it is absolutely necessary to link the feedback output stage inhibited into the control electronic Output
18. When using a different software version the fault can be displayed The check sum fault also signalises the computer fault Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Remedy Possible cause 1 Remedy Possible cause 2 Remedy Possible cause 3 Remedy Possible cause 4 Remedy Possible cause 1 Remedy 9 Fault finding gt Disengage regulator enable gt Acknowledgement gt Load set of basic parameters gt Parameter set the unit anew gt Disengage the unit and re engage it after 10 gt Set the unit into operation LED 5 flashes Motor overtemperature The fault signal is released after having exceeded a resistance value of the posistor provided in the motor winding Readiness for operation is interrupted 1 Motor overheated by overload gt Assure motor cooling gt Perhaps weaken the regulation Vp lower Tn higher 2 The sensor cable in which the motor posistor is also guided X11 is not connected gt Check the plug link of the sensor cable gt Check the soldering links in the plug connections 3 Defective posistor or cable wire breakage gt Check the cable resistance between pin 14 and 15 in the sensor plug see chap 6 27 Motor sensor X 11 4 Defective posistor evaluation in the servo regulator gt Check the evalution as follows gt Check whether the speed setpoints are in 0 position gt Bridge pin 14 and pin 15 in the plug unit X11 gt
19. Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 5 4 Cable routing earthing EMC in cabling G g 5 Planning information The units are designed according to the protective aims of the EMC law The manufacturer of the installation is held responsible to assure the CE marking of the entire installation The correct operation of the Servoconverter in relation to the requirements of the law is described in the leaflet LUST DriveTronics GmbH EMV instructions Nr 180 00 000 The most important points are stated below Motor cables and control cables should be laid in separate ducts Setpoint and signal cables should always be laid separately from power and or contactor control cables avoid links Minimum distance gt 20 cm Use screened cables for analog signals setpoints monitors Twist cables for control connections and regulator supply it is better to lay screened cables Use screened cables not only for the signal cables but also for the motor cables Lay the screen on both sides Ground the motor with sufficient cross section Only lay the screens of control cables on one side Signal cables should be led into the electric cabinet from only one level Unnecessary extra lengths of cable should be avoided Connections and earthing of the units must be performed in accordance with local protection and safety regulations Dimension the cross sections as per the local regu
20. The quicker the regulator the more tendency to over shooting The active current setpoint can still be smoothed 4 2 2 7 3 To that effect input a time constant for the low pass filter 0 9 99 ms The speed regulator can be optimised by the parameters vpn 4 2 2 6 1 0 01 1 00 and Tnn 4 2 2 6 2 0 1 50 ms The same instructions as to the current regulator apply parameter Vpi and Thi i e the speed regulator as well is optimised through its jump reaction Provide the monitors with the corresponding speed values gt monitor 1 with speed setpoint 3 5 1 gt monitor 2 with actual speed 3 6 2 The speed regulation often reguires a compromise between the dynamics and the concentricity By means of actual speed smoothing 4 2 2 4 1 another parameter 0 00 9 99 ms is available for this duty With large machines this time constant can be increased without influencing the dynamics whereas simultaneously the concentricity is improved On principle the time constant shall be selected as low as possible The flux regulator can be optimized by the parameters v psi 4 2 2 8 1 0 01 1 00ms and Tn psi 4 2 2 8 2 0 1 500ms The same instructions as to the current regulator apply parameter vp and Thi i e the flux regulator as well is optimised through its jump reaction The state variables of the flux regulator cannot be read out through the standard motor The parameters 4 2 2 8 3 5 are stated on the motor namep
21. 1 045 1 05 03 2003 LUST DRIVET RONICS N act N se Pin 15 LED 9 yellow n gt nl Pin 16 LED 8 yellow 6 Electrical connections Caution The I t reduction only acts as an overload protection for the Servoconverter Complete motor protection is only ensured if PTC thermistors are connected x I nom 18 7 i lt Sr oo e f op ie lt f p a lt a I t characteristic curve Fig 6 14 B12 008 Pt characteristic line H level signalises that the actual speed is equal to the set speed The tolerance band can be programmed in the menu item 42253 hysteresis H level signalises that the actual speed is higher than the reference speed n1 menu point 42251 The tolerance band can be programmed in the menu item 42252 hysteresis Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Release the brake n gt 0 Pin 17 6 Electrical connections The signal can be used to ref command a holding brake H level is connected when controller enable is operated Simultaneously the set speed is switched through During that switching time of the brake t assure that the set speed is 0 to prevent the drive from operating against the brake gt tv gt t see Fig 6 15 page 23 When switching off the controller enable at control input X2 2 Pin 7 the drive brakes down to speed 0 When reaching the speed 0 the output X2 2 Pin 17 is set back For a certain period of t
22. Caution The load current per output is 125 mA max 500 mA The sum current of the 8 outputs must not exceed 1 A Pin X 2 2 Function 13 gt Ready signal 14 2 Limit of the current It 15 gt Nact Nset 16 gt n gt ni 17 D Release the brake n gt 0 18 gt Overtemperature motor 19 gt output stage over temperature 20 gt Reserve Table 6 7 Signal outputs X2 2 H level signalises the Servoconverter is ready for operation In case of an internal fault signal the readiness for operation is cancelled thus resulting in an immediate switching off of the enables for the controller and the output stage Note The drive runs down in uncontrolled manner H level signalises the limitation of the current to the programmed motor nominal current The output stage is designed for the unit nominal current Short dated the output stage can supply the double nominal current 1 5 fold at U DS 045 1 For output stage protection the motor current is integrated to a sguare function above the programmed nominal current If the calculated value exceeds the limit load integral of the output stage the current is limited to the nominal value Note The unit is not disengaged To reset the function a return integration has to be made It begins when falling below the load current 0 9 X Inom The integration times are adjusted in the works they must not be changed Operation manual U DS 006
23. RS232 by PC AT and can be set into service Caution Using the terminal program presupposes that the service manual of the corresponding amplifier module has been read and understood In particular adhere to the safety guidelines Loading or sending of files parameter sets from or to the amplifier must only be made with disengaged regulator enable The connection is described in see chap 6 11 1 RS 232 X 14 A PC AT is necessary which meets the following requirements PC AT 486 or Pentium Windows 95 98 NT ME 2000 XP min 16 MB RAM VGA graphics In the currently usual standard configurations no problems occur Should you experience any problems on installation please consult our after sales service How to handle the parameterisation via terminal program is explained in the special leaflet LUST DriveTronics GmbH manual No 192 00307 Operation manual U DS 006 1 045 1 05 03 2003 7 13 LUST 7 Parameter settin DRIVETRONICS g Operation manual 7 14 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 8 Commissioning Operation 8 1 PROGCQO UNG icaceccciccestisictdsscscadestsscndeuessavdesbcsaedesscesadenscanedssvacsdessvics 3 8 1 1 Checking and switch positions rsrrvrsrrnrrnrrnrrvrnrrnrrnrrnrnnnr 3 8 1 2 Engagement cooooooonnin a a a a n a na aan aeneen 4 8 1 3 Parameter setting uoooononn e a eaa aeneen 4 8 1 4 OpPUMISAUION lt 2 c
24. Setpoint integrator times 4 2 2 3 x Setpoint integrator S curve 4 2 2 3 9 7 2 4 Regulator parameters Current regulator 4 2 2 7 1 2 7 Parameter setting Here it is fixed which speed rating corresponds to 10V at the analog inputs 9000 to 9000min For torque regulation 10V are the equivalent of the maximum device current see chap 2 Technical data The setpoints are filtered through a low pass filter The time constant of the low pass filter can be preselected at that point 5 100 ms For the quick analog input extended low pass constants 0 13 99 99 ms are available Here an offset for the analog inputs can be input 100 to 100 1 The offset alignment has to be made with speed regulation Automatically it is also applicable to the torque regulation If the drive drifts with preselected OV this speed can be read in the terminal program VecWin Inputting the speed with reversed sign will then compensate the existing offset Due to the Bit resolution the input offset can differ slightly from the displayed offset The times for the reference value integrator slopes are set here 0 00 99 99s see Fig 6 12 page 19 The start and end of the reference value slopes may be additionally rounded by setting the S curve in the 0 1s range Due to the cascade structure of the regulation the optimization has to begin with the inner regulation circuits gt Current regulator gt Speed regulator gt Flux
25. U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 10 Encoder output X 13 Plug connections Encoder output signals 6 Electrical connections From the sensor signals of the motor applicable at the input X11 a pulse sensor signal is detected Load of 5V output max 25mA A SUB D 9 poles SO X14 X13 A JA B B 0 0 GND 5V nc Ji bs if F r n r xt 1 2 04 s 7 s Is lg lo 9 D ig EH X 13 e c DriveStar Fig 6 18 B11 016 Plug connections 360x el a J gt 3v jal k 90x el B 3V ipl k 90 l 0 pulses 3V EN Fig 6 19 B12 010 Encoder output signals The signal complies with the form of an incremental encoder The number of increments of the encoder output is adjustable Menu 4243 maximum 8192 pulse Output is via a 3 V push pull signal as standard see Fig 6 19 page 28 As an option these signals can be electrically isolated or output as 24V level with electric isolation Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 6 11 Communication interfaces 6 11 1RS 232 X 14 E Oo 6 Electrical connections Communication interfaces are available at the Sub D plugs X 14 X 15 und X 16 The connections are gt X 14 RS 232 D DS 1 H DS 1 see Fig 6 20 page 29 gt X 16 RS 485 gt X 15 and
26. actual values are adjusted which are indicated in the actual value display 1 and 2 at the PC or operator terminal D DS_1 The following actual values are displayed 3 1 1 Actual speed 3 1 2 Set speed 3 2 1 Active current 3 2 2 Reactiv current 3 2 3 Apparent current 3 3 Rotor position 3 4 1 Temperature in the servo amplifier 3 4 2 Temperature in the motor 3 51 Monitor 1 nset 3 5 2 Monitor 1 3 5 3 Monitor 1 3 5 4 Monitor 1 3 5 5 Monitor 1 3 5 6 Monitor 1 3 5 7 Monitor 1 3 5 8 Monitor 1 torque setpoint 3 6 Monitor 2 see Monitor 1 3 7 hours of operation 3 8 D C link voltage Nact phase current active current reactive current rotor position Nact rating PN Ga git git Operation manual U DS 006 1 045 1 05 03 2003 7 11 LUST DRIVET RONICS 7 2 7 Interface RS 232 Baud rate 7 1 2 Parity 7 1 3 Data bits 7 1 4 Stop bits 7 1 5 Unit address 7 1 6 7 2 8 Other parameters Pt limit values 4 2 3 3 1 2 Code 4 2 6 Language 6 1 x Software version 6 2 Scanning time 6 3 7 Parameter setting Note Modifications of the parameters after disengagement and engagement of the servoconverter only Here the transmission speed between the serial interface and the connected unit PC with terminal program VecWin or SPC can be indicated 600 38400 baud Here the parity is adjusted 0 none 1 0dd 2 even Input of
27. as differential amplifiers The input resistance is 20 k Ohm Input voltage range 10V Operation manual 6 15 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS reference voltage 6 Electrical connections Caution Embed screened setpoint cables only Further setpoint preselections are gt digitally through the operator terminal D DS 1 option gt via PC option gt via field bus systems option gt via RS 2332 The Servoconverter offers the possibility to scan a voltage of 10V for the supply of setpoint potentiometers Terminal X2 1 8 10V Terminal X 2 1 9 10V Caution The voltage outputs can be charged with max 5 mA and are short circuit proof Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 6 control inputs X2 2 Control inputs 6 Electrical connections Servoconverter communication is mainly performed via connector X2 2 The following signals are supplied at this connector N 7 Control inputs control outputs Analog outputs Analog inputs Regulator supply Doon x oo Fig 6 11 B11 017 Control inputs gt Control inputs pin 1 to pin 12 gt Signal outputs pin 13 to pin 20 gt Analog outputs pin 21 to pin 25 All control functions can be triggered via switching contacts e g switches or via direct connection of a voltage e g from
28. correspond to the unit max current e U DS 006 1 0 50 0 6 A with 4 kHz e U DS 012 1 0 50 0 12 A with 4 kHz e U DS 020 1 0 50 0 20 A with 4 kHz e U DS 035 1 0 50 0 35 A with 4 kHz e U DS 045 1 0 65 0 45 A with 4 kHz Caution Pay attention to the motor data The here adjusted nominal current must not exceed the motor nominal current Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Max current 4 2 3 2 3 Max speed 4 2 3 1 2 Delay time motor temperature 4 2 4 5 7 Parameter setting Here the max current in percent is adjusted 0 100 100 correspond to the unit max current e U DS 006 1 100 12 A e U DS 012 1 100 24 A e U DS 020 1 100 40 A e U DS 035 1 100 70 A e U DS 045 1 100 70 A The unit max current is intended for the pulse generator It cannot be made available permanently see chap 2 Technical data and see chap 6 21 Signal outputs X 2 2 Caution With current parameter setting pay attention to the motor data With excessive pulse current Imax a demagnetization of the motor can occur Here the max speed is input 0 9000 min When reaching the adjusted max speed the setpoint and consequently the speed are limited Caution Pay attention to the max speed of the motor When reaching the motor limit temperature the readiness for operation of the servoconverter is cancelled
29. for damage caused by the use of non original replacement parts and accessories Please note that special manufacturing and supply specifications often apply to our own and externally sourced parts and that we will always offer you replacement parts which conform to the latest technical standards and the latest regulations To avoid servicing problems we recommend that you purchase complete replacement subassemblies or have faulty subassemblies tested and repaired by LUST DriveTronics GmbH For a quick handling and settlement of spare parts orders the unit data must be known Particularly refer to variants as per the customer s specification Please attach a copy of the unit accompanying list to your spare part order The following information must be given e Order No e Type e Fabrications No Item number and name of replacement part e Trimming data Unit accompanying list e Quantity ordered LUST DriveTronics GmbH Servoconverter contain electronic components After their utilization they must not be thrown to the normal houshold rubbish but must be put to the electronic scrap For the environmentally friendly waste management please consult the local Environment Authority Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 1 General Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 2 Technical data 2 1 Performance data seravrnvsnvnvvnv
30. regulator only for asynchronous machines gt Positon regulator Option The current regulator can be optimised by the parameters v 4 2 2 7 1 0 01 1 00 and Tni 4 2 2 7 2 0 1 20 ms The best way is to optimise the jump reaction of the current regulator The regulator is well optimised when the actual value adapts as quickly as possible and with rather low over shooting to the setpoint Before optimisation read the instructions as per chap 8 Commissioning Operation and adhere to them Proceed as follows for current control optimisation Set the ramp times t1 t4 4 2 2 3 1 4 to 0 Lay setpoint channel 1 to serial interface 2 1 4 Fix internal setpoint 2 3 to 500min Lay monitor 1 to torque setpoint lsg set 3 5 8 Lay monitor 2 to torque setpoint Isg act 3 6 4 Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Speed regulator 4 2 2 6 1 2 Speed actual value smoothing 4 2 2 4 1 Flux regulator 4 2 2 8 1 8 only with asynchronous machines Nominal magnetizing current 4 2 2 8 3 Nominal speed 4 2 2 8 4 7 Parameter setting By actuation of the setpoint integrator enable the jump is released Current setpoint and actual current shall have the same course Now vary the parameters in such a way that the reguired course is reached approximately Here the thumb rule applies gt Increase of v and reduction of T accelerate the regulator gt
31. signal via operator terminal D DS 1 Types of fault Fault memory 9 Fault finding At the operator terminal D DS 1 actual faults are indicated in clear text in the menu 51 In addition up to 32 fault signals memorized in the seguence of time can be inguired in menu 52 The types of fault are coded as per the following numbers Fault No Cause Overtemperature output stage Over undervoltage D C link Internal supply voltage Sensor fault motor sensor Overcurrent short circuit Overtemperature motor Computer fault free Overspeed O oo O 60 s O N Check sum fault The operator terminal and Vec Win display the fault check sum fault in clear text besides the above mentioned faults Fault memory menu 52 Example for display of a fault Fault No 5 7 00 04 34 5 Current fault No 7 Type of fault 00 04 34 Period of fault The displayed fault is Fault No 5 Type of fault 7 computer fault Period of fault hh mm ss 4 min 34s after the last cancel fault memory menu 522 Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 9 4 Fault diagnosis abriged version independent of the LED fault signals 9 Fault finding Consequence possible cause All LED s dark missing 24 volts supply Internal defect of the mains unit Short circuit to 24 V outputs Check sum fault Parameter set not suitable for the unit version
32. the number of data bits 7 or 8 If 7 data bits are selected the option parity none is not available Input of the number of stop bits 1 or 2 Input of unit address 1 2 5 4 The works set upwards 4 2 3 3 1 and downwards integration time t 4 2 3 3 2 may be read off Here the code can be changed which is scanned with parameter modifications 0 9999 Input of the required language German English French Italian only VecWin Here the version numbers of the drive software and the communication software can be read For D DS 1 menu 6 2 and PC information Behind the letter A the software version number for the regulation is indicated Behind the letter B the software version for the communication interfaces RS232 485 D DS 1 and technology are stated Here it can be read the max cycle times the drive regulation 1st value uses and the setpoints 2nd value us can be scanned The cycle time of the drive regulation is influenced by the selected switching freguency Operation manual U DS 006 1 045 1 05 03 2003 7 12 LUST DRIVETRONICS 7 3 Terminal program VecWin 7 3 1 General 7 3 2 Cable connection between PC and servoconverter 7 3 3 PC configuration and installation 7 3 4 Working with VecWin Go 7 Parameter setting With this terminal program VecWin LUST DriveTronics GmbH servoconverter of series CD_ WD_ UD_ AD_ 3 U DS 1 can be parameter set via the interface
33. to earth Ja Short circuit Output of generator pulses X 13 Fig 10 1 B12 015 Schematic circuit diagram Operation manual U DS 006 1 045 1 05 03 2003 10 2 LUST DRIVET RONICS 10 2 Motor sensor connections 10 2 1Resolver 10 A Appendix X11 Xe LUST DriveStar converter SUB D 15 poles be RA NE 7 ls le la 10 J X lg io 14 15 4 gt x 12 poles Circular connector 3x 2x0 14 2x0 5 on AC motor RD S1 RD WH R1 Resolver 2 poles YE WH R2 or BK WH 11 12 PTC resistors or thermal contacts Response temperature 155 C Fig 10 2 B10 006 Connection resolver Operation manual U DS 006 1 045 1 05 03 2003 10 3 LU st 10 A Appendix DRIVET RONICS 10 2 2High resolution encoder Absolut value encoder LUST DriveStar converter SUB D 15 poles A IA oV 5V Xt i 2 7 e lo ho hi h2 aa ha hs n c lt J a o EI x al a x x o I S S S S x s 17 poles lt Ms Circular connector on AC motor E A A 3 1 2 7 8 9 10 11 12 13 14 15 16 I 47 lt n c F po 0 oO oO Ly A IA B B R R O U C IC D D High resolution encoder ERN 1387 PTC resistors or thermal contacts R di NA Responarg
34. 0 ceeeds twa el ee es 7 8 2 Braking chopper rrsrseravrnvrnvnnvrevnvrnvrnvnnrnevnvsnernvvnvnernesnernnnennernener 7 8 3 OperatiON s ssomamssa avus vana PAARE N ENIEIEERASEEREEREIRFOREEFEEREENERERVEREEOEN 8 8 4 Duty Eg EE 8 Danger Before commissioning the whole chapter must have been read and understood Caution Commissioning may only be performed by qualified personnel with electrical engineering training who are instructed in accident prevention measures Caution In the case of servoconverters U DS 006 1 to U DS 020 1 precharging is performed via a precharging resistor Thereby the engaging current is short dated limited by a resistor To avoid a heating of the resistor a rest time of at least 30 sec has to be kept between two engagements Operation manual 8 1 U DS 006 1 045 1 05 03 2003 LUST Are Taos 8 Commissioning Operation Operation manual 8 2 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 8 1 Procedure 8 1 1 Checking and switch positions 8 Commissioning Operation The commissioning is made in steps gt a Checking and switch positions gt b Engagement gt c Parameter setting gt d Optimisation Caution None of the steps may be skipped Assure that on commissioning of several units the steps a to c for each unit are followed individually The other servoconverter should be disengaged during that time Caution On initial engagement mo
35. 06 1 045 1 05 03 2003 LUST DRIVETRONICS 10 A Appendix 10 1 Schematic circuit diagram of control loop 2 2 22z222222222 2 10 2 Motor sensor connections 2 2 22 22 22 22222222202202n0202nnnnnn00n 3 10 2 1 Resor huss ee erlernen gen wire 3 10 2 2 High resolution encoder absolute value encoder 4 10 2 3 Rotary pulse generator enersesensennennensnnennennennenennnnennennennenenn 5 10 3 Dimensions for MOUNTING 2 2 22 22222222202222n00nun20n00nnannann2 6 10 3 1 U DS 006 1 to U DS 020 1 renrenrernrrnrrnrervornvrnrrvernrrnrerververnen 6 10 3 2 U DS 035 1 and U DS 043 1 eeeneeenenennen 7 10 3 3 Mounting dimensions for D C link connection 8 10 4 CCESSOFIES EE maa NUKUN AT 9 10 4 1 Control cables for X 2 1 anining 9 10 4 2 Control cables for X 2 2 cccccscsccsscssessecsecseeseessecseeeseeeseees 10 10 4 3 One phase link reactor cccsceccesssesessesssssssssssrssesssseseres 11 Operation manual 10 1 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 10 1 Schematic circuit diagram of control loop 10 A Appendix
36. 2 21 X2 22 are active with a H level 10 30V or with a L level see chap 6 17 Control inputs Here the brake operation is engaged and disengaged Brake operation means the engagement and disengagement of the brake quadrants in both directions of rotation Operation manual U DS 006 1 045 1 05 03 2003 7 10 LUST DRIVETRONICS 7 2 6 Output signal and displays Display unit 4 2 2 2 1 Monitors 3 5 6 x Encoder output 4 2 4 3 Speed signals 4 2 2 5 x Actual value display 3 7 Parameter setting Here it can be adjusted whether to display or to input the speed values in Hz or rpm Here it is adjusted which system size is displayed on the monitor 1 or 2 see chap 6 25 Analog outputs Monitors Here it is adjusted the number of increments per revolution to be generated by the encoder output X 13 16 8192 incr rev The signal at the encoder output is directly generated from the encoder signals X 11 corresponds to the direction of rotation of the drive With the incremental encoder the number of increments should not be selected higher than its resolution Here the data for the signal outputs hysteresis low pass filter constant trigger n1 X2 2 Pin 15 LED 9 and X2 2 Pin 16 LED 8 are input n Hysteresis n1 Hysteresis n Setpoint Hysteresis n Actual value ni n t LED 9 LED 8 Fig 7 2 B12 014 Hysteresis with speed triggering Here the
37. 7 UlvIw Ground screw M6 id ala N Motor connection terminals U V W Motor connection terminals U V W Connection terminals B1 B2 for external brake resistance X 22 Sal u Ground screw M6 Saa lt olo X24 X3 TT Mains connection terminals L1 L2 L3 Fig 6 2 B11 021 U DS 035 1 terminals B1 B2 as option U DS 045 1 Operation manual 6 4 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 3 Cable cross section 6 Electrical connections The conductors should be selected for maximum ambient temperatures the max current in the conduct or motor nominal current continuous rating in accordance with the local regulations VDE 0100 VDE 0113 etc Connection U DS006 1 U DS 012 1 U DS 020 1 U DS 035 1 U DS 045 1 flexible 0 2 mm 6 mm 0 5 mm 25 mm AWG 24 10 20 4 Table 6 1 Cable cross section Operation manual 6 5 U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVETRONICS 6 3 1 Power connections Power connections U DS 006 1 bis 020 1 internal brake resistance 3 x 230V 480V 50 60Hz PE L1 L2 L3 PE v v v Mains VAN fuses Mains contactor 24V DC 20 24V e N N ov PE Mains ch
38. 85 80 98 64 64 4 8x9 4mm 062 00199 KD 0 2 0 83mH 35A 3 4 105 95 130 84 73 5 8x11 10mm 062 00200 KD 0 25 0 65mH 45A 4 0 120 95 140 90 74 5 8x11 10mm Table 10 1 One phase link reactar Technical data One phase link reactor VDE 0550 0532 Connection voltage 400 500V 50 60Hz Short circuit voltage 9 2V with 50Hz uk ca 4 of 230V Insulation class E maximum ambient temperature 40 C Protection class IP00 Technical data subject to modification without notice Operation manual U DS 006 1 05 03 2003 045 1 10 11 LUST DRIVET RONICS 10 A Appendix Operation manual 10 12 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS Lust DriveTronics GmbH Hansastra e 120 D 59425 Unna Tel 49 0 2303 779 0 Fax 49 0 2303 779 397 Internet http www lust drivetronics de e Mail info lust drivetronics de Technische nderungen vorbehalten Subject to alteration
39. Acknowledge fault gt gt if fault cannot be acknowledged the evaluation in the regulator is defective LED 6 flashes Short circuit short to ground Overcurrent and overtemperature are monitored with the Ucg voltage on IGBT With fault signal the readiness for operation is interrupted 1 Short circuit or short to ground in the motor in the motor cable in the servoconverter or in the brake resistance gt Disconnect the motor gt measure the motor winding gt Detect the resistance against the motor housing by means of a hand generator or a similar device gt Disconnect the motor cable at the amplifier module gt Engage the servo gt If short circuit short to ground is signalised via LED 6 the servoconverter is defective gt gt Ship the regulator to the LUST DriveTronics GmbH after sales service gt gt check external brake resistance Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS Possible cause 2 Remedy Possible cause 3 Remedy Possible cause 4 Remedy Possible cause 1 Remedy Possible cause 1 Remedy Possible cause 2 Remedy 9 Fault finding 2 Undervoltage on IGBT driver gt Regulator voltage X 3 24 V beyond the tolerance LED 7 flashes Encoder fault 1 Sensor cable not connected to the motor or amplifier X11 gt Check the plug connection 2 Defective sensor cable gt Check for damage cable breakage Remarks The fault detection refe
40. Controller Enable enables the controller and setpoints When enable is switched off the drive brakes to a halt at the set rapid stop ramp t5 see Fig 6 12 page 19 When the drive has stopped the Output Stage Enable is also switched off internally Note The drive has no torque Output Stage Enable enables the electrically power switch to function Power switch enable If the enable is not engaged then the drive receives no current If enable is cancelled during operation the drive runs down in an uncontrolled manner Output Stage Enable should always be running in normal operation It is normally only required when a drive has to be interrupted immediately Note The output module hardware enable must always be switched on via a 24V signal so that the start up relay is triggered and the output module enabled A pulse at the input causes after elimination of the fault the acknowledgement of a fault signal sent by the Servoconverter This acknowledgement of fault also occurs after every engagement of the controller supply 24V Note Acknowledgement is possible only with switched off regulator enable Operation manual U DS 006 1 045 1 05 03 2003 6 18 LUST DRIVETRONICS Setpoint integrator enable Pin 10 LED 4 6 Electrical connections Setpoint integrator Enable enables the ramp generator to function The set setpoints are delayed with the set ramps t1 t5 see Fig 6 12 page 19 When
41. Load capacity of the monitor The monitor outputs at pin 21 and pin 23 may be loaded as follows outputs gt ref command 10 V gt Charge max 1 5 mA 6 8 kOhm gt resolution 5 ms Standardisation of the monitor In relation to the size the output voltage is standardized as follows outputs With system size 10V correspond to e speed n max menu 42312 e current max unit current e rotor position 360 Operation manual 6 25 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 8 Regulator supply X3 6 8 1 Fan supply 6 Electrical connections The Servoconverter is supplied from an external supply voltage From this voltage the voltages reguired for the regulator and the processors are generated N nu Control inputs control outputs de Analog outputs ay HH Xx 2 4 Analog inputs gt G x Q Regulator supply EI Oo O a 0O a 0O Fig 6 16 B11 018 Regulator supply 24V DC standard converter 24V DC 20 1 5A 24V DC OV DC OV DC Table 6 9 Connection regulator supply Note After engagement of the 24 V regulator voltage a short time flowing of starting current of 3 to 4 A is possible Note By the regulator supply no inductive loads e g valves may be fed With extensive installations separate current supplies are recommended to feed the Serv
42. UST DRIVET RONICS 10 4 2Control cables for X 2 2 10 A Appendix Assembled cables SUB D 25 pol plug Pin Signal 1 Output 24V 100mA 2 GND analog 3 GND 24V 4 Input reserve 5 Torgue regulation 6 C axis operation 7 Controller enable 8 Output stage enable 9 Acknowledge fault 10 HLA enable 11 Limit switch 1 for clockwise running 12 Limit switch 2 for anticlockwise running 13 Ready signal 14 14 15 n act n set 16 n gt ni 17 Release the brake n gt 0 18 Overtemperature motor 19 output stage over temperature 20 Output reserve 21 Monitor 1 22 GND analog 23 Monitor 2 24 signal contact 25 Starting inhibit option Housing Screen Table 10 2 Control cables for X 2 2 Caution Not used wire must be isolated Cable length 9m Artikel No 182 01810 Operation manual U DS 006 1 045 1 05 03 2003 10 10 LUST DRIVET RONICS 10 4 30ne phase link reactor 10 A Appendix E g P d e St a b E Fig 10 8 B11 043 One phase link reactor line choke Weight Dimensions max Lust b d Cable ArticleNo oppad a g cross Type Induct current kg mm mm mm mn mm mm section 062 00164 EI 54 8A 2 5mH 8A 0 4 46 45 92 38 35 3 5x7 2 5mm 062 00197 KD 0 05 2 44mH 12A 1 2 78 60 90 56 48 4 8x9 4mm 062 00198 KD 0 1 1 46mH 20A 2 2
43. X 16 Profibus DP or Interbus S or CAN BUS Note As a standard the interface RS232 is provided All other interfaces are available on reguest By means of the interface RS 232 the Servoconverter can be parameter set and controlled via a PC or any other control For this duty the LUST PC terminal program LUST DriveTronics GmbH is required Description and programming are given in the leaflet LUST DriveTronics GmbH Terminal program VecWin Nr 192 00 307 DriveStar converter X14 SUB D 9 poles EN 5V RxD TxD GND RTS CTS Burst N 1 2 3 4 5 6 7 8 9 J SD By X 14 i CIENIE h X 11 D 19 EY x13 Drvestar A Ta A ON 2 3 ja 5 E 7 8 N N RxD TxD GND RTS CTS SUB D 9 poles PC SPS Fig 6 20 B10 017 Connection serial interface RS 232 The PC programming allows a simple menu orientated commissioning and also be used for memorizing and loading of parameter sets for the Servoconverter Through the interface communication is not only possible with VecWin but also with other software logs This has to be agreed with LUST DriveTronics GmbH from case to case For connection a three core or five core screened cable is necessary At both ends a 9 poles SUB D plug plug and bushing must be provided LUST DriveTronics GmbH offer this cable as connection assy
44. a stored program controller Trigger voltages of 10 V to 30 VDC are processed as H signal The inputs are electrically isolated from the control electronics by means of opto coupler Caution Pin1on X2 2 is the 24 V output Pin N Function 24V Output max 100 mA 2 GND analog 3 GND 24V 4 Technology option Torgue regulation C axis operation Controller enable Output stage enable Acknowledge fault 10 Setpoint integrator enable ramp generator 11 Limit switch 1 for clockwise running TTT YT IT I a YT 12 Limit switch 2 for anticlockwise running Table 6 4 Control inputs X2 2 Operation manual U DS 006 1 045 1 05 03 2003 6 17 LUST DRIVET RONICS Torgue regulation Pin 5 C axis operation Pin 6 LED 5 gt Controller enable Pin 7 LED 3 av Controller enable Pin 8 LED 2 am Acknowledge fault Pin 9 6 Electrical connections The controller regulates the drive to the prescribed current setpoint Caution Only operate motors when loaded as otherwise the drive will accelerate to the set maximum speed When C axis operation is switched on the setpoint is reduced by the factor 0 1 Then the max speed reduces by the factor 0 1 too thus increasing the accuracy in the low speed range with position regulation of a continuous path control Caution When activating the input during operation the speed changes discontinuously up to current limit
45. ace of approx 10 mm at the Servoconverter sides for radiation of heat provide minimum free space for the plug type facilities and cabling of the unit front approx 20 mm Provide a conductive not lacguered mounting plate in the switch cabinet If necessary remove the paint in the area of the converter mounting Caution Be particularly careful on mounting Assure that no drilling chips wheel swarf or mounting parts screws nuts fall into the housing For the sensor connection use the control cables of LUST DriveTronics GmbH see chap 10 2 Motor sensor connections Cable length up to 50 m longer cables on request Customer specific regulations must be agreed with LUST DriveTronics GmbH Use screened cables for the motor conduct Cable length up to 50 m longer cables on request Embed the motor conduct separately from the other cables e g control and setpoint cables The units have an integrated posistor evaluation When using LUST DriveTronics GmbH sensor cables the thermal motor protection is assured see chap 10 2 Motor sensor connections The connection of other motors has to be agreed with LUST DriveTronics GmbH A thermal motor overloading causes the disengagement of the readiness for operation Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 5 11 Motor holding brake 5 Planning information For motors with integrated holding brake adhere to the servi
46. ade quickly by loading the parameter set 2 as actual parameter set menu 4 2 5 2 2 Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Input ranges 7 2 1 Unit parameters Unit type 4 2 1 Switching frequency 4 2 1 3 7 Parameter setting When loading the parameter set2 or the basic parameters the actual parameter set is overprinted When memorizing the actual parameter set as parameter set 2 the old parameter set 2 is overprinted Speed inputs can be made and displayed in Hz or rpm The type of input or display can be selected menu 4221 In the following text the speed input ranges are stated in rpm Note Some parameters are transferred only with disengaged regulator enable or after a disengagement and re engagement of the servoconverter Following parameters are transferred after disengagement and engagement of the servoconverter only Clock frequency Number of increments of the incremental encoder Type of device Operation mode Number of pole pairs Kind of sensor The parameters setpoint 1 and setpoint 2 are only transferred with disengaged regulator enable All other parameters are modified during the running operation Note The following numbers refer to those menu points which are selected via the D DS_1 Here the output stage type of the unit is selected The output stage type results from the unit designation Note In t
47. al D DS_1 which is placed onto the front plate of the servoconverter How to handle the parameterisation via control unit is explained in the special leaflet LUST DriveTronics GmbH manual No 182 02 792 Three parameter sets are memorized in the converter The parameter set 1 basic parameter set is deposited in an E PROM and cannot be modified Values for a standard parameter setting default values are adjusted in this set By this parameter set a connected motor can only be moved for rotation in a limited way The basic parameter record is required in order to be able to reset the parameters for the servoconverter following a check sum error see chap 9 Fault finding The parameter set 2 contains the parameter setting made in the works in compliance with the customer s application It allows to move the idle running motor to rotation The adjustments of the parameter set 2 are listed on the accompanying lists which are attached to the servoconverter The parameter set3 is the actual parameter set All changes during parameterisation are saved in it Simultaneously it is that parameter set which is used for the regulation after engagement of the unit The actual parameter set can be memorized as parameter set 2 menu 4 2 5 2 1 It is used to memorize an intermediate stage on parameter setting and to carry out any further modifications Should these modifications not offer any advantage the previous condition can be re m
48. anual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 4 4 Visual signals 4 Construction of unit and method of operation The most important status and fault signals are displayed by LEDs The LEDs have double functions e permanent light status signal e flashing light fault signal Note The co ordination of status and fault signals only applies to the standard software With special softwares provided by the customers or with technological software positioning synchronization etc adhere to the separate service manual t LUST KS D LED display on U DS devices ai LED 1 green ready LED 2 to 10 yellow SOR L R Fig 4 2 B11 015 status LED s LED Permanent light status signal Flashing light fault signal 1 Ready signal Acknowledgement with controller enable 2 Output stage enable Overspeed 3 Controller enable free 4 Setpoint integrator enable Computer fault 5 GC axis operation Overtemperature motor 6 Beg Short circuit or shorts to earth on output stage or brake resistance 7 Release the brake n gt 0 Encoder fault n gt ni Fault supply voltage Nact get Overvoltage and undervoltage 10 frea Overtemperature on output stage or brake resistance Table 4 1 Status LED 5 Operation manual 4 6 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 5 Planning
49. apacitors L L o O 4 KA KA IGBT Output stage 4k braking chopper KAI KA KA N o O a U IV JW oPE Ut 1V1 wi N L N M PE oz Three phase a c motor Fig 6 4 B10 012 Power connection and controller voltage supply for U DS 006 1 to U DS 020 1 with externally connected braking resistor Operation manual 6 7 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 Electrical connections Power connections 3 x 230V 480V 50 60Hz PE L1 L2 L3 PE Mains N fuses Mains contactor N 24V DC 20 24V ov Mains chokes 3 3 ses U DS 035 1 PE LI L2 oL3 X3 GND 2 2 5A Mains filter Regulation semi controlled gt thyristor bridge DF O gt DE Fan internal brake resistance D C link capacitors L L o t O K KA KA IGBT Output stage f K braking chopper KAY KA p o O Te U V W oPE U1 1V1 W1 N M PE 3 vw Three phase a c motor Fig 6 5 B10 013 Power connection and controller voltage supply for U DS 035 1 with externally connected braking resistor Operation manual U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS
50. ar They have to be designed in such a way that with nominal unit current at the chokes an inductive voltage drop of 4 of the connection voltage is generated EN 50 178 The corresponding chokes can be purchased from LUST DriveTronics GmbH see chap 10 4 3 One phase link reactor Caution The simultaneous engagement of the mains voltage and the regulator supply is recommended Operation manual U DS 006 1 045 1 05 03 2003 6 10 LUST 6 Electrical connections DRIVET RONICS 6 3 3 Motor connection U DS 006 1 U DS 020 1 U DS 035 1 U DS 045 1 ot a at 2 If f x is X 11 5 O D x13 E X13 3 NS Motor connection DriveStar rs terminals U V W F wen UIVIW Ground screw M6 d olo N Ground screw M6 J Motor connection terminals U V W Fig 6 7 Motor connection The motor connection is made through the terminals U V W Ground screw On motor connection pay attention to the phase sequence As normally numbered cables are used the following connection presents itself DriveStar UV W Cable No 12 3 Motor terminal U1 V1 Wi To adhere to the generic standard EN 50081 a screened motor cable is required Cable length up to 50 m longer cables on request Lay the screen in wide range on the central screen bar and connect it to the mo
51. ar family Hardware U Drive controller with power pack A Modular design without power pack B Power pack with brake resistance R Power pack with refeeding Operation manual U DS 006 1 045 1 05 03 2003 LUST DriveTRonics 2 Technical data 2 3 Device views 2 3 1 U DS 006 1 U DS 020 1 at LUST 9 D Ey lt O gt EIDE D ZN DriveStar Fig 2 1 B11 001 U DS 006 1 U DS 020 1 2 3 2 U DS 006 1 U DS 020 1 with technological card LUST A AD OJ gt FA DriveStai oo n n Fig 2 2 B11 005 U DS 006 1 U DS 020 1 with technological card Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 2 3 3 U DS 035 1 U DS 045 1 2 3 4 U DS 035 1 U DS 045 1 with technological card 2 Technical data L LUST re Az a emo ee p E DriveStar ulv w oja N Fig 2 3 B11 019 U DS 035 1 U DS 045 1 Lt L2 L3 8182 L LUST A
52. ase 17 6 7 Signal outputs X 2 2 ea 21 6 8 Regulator supply X3 rersvenvnnrnvrnvrnvrnvnnrnnvnvrnvrnvsvrnevnesnesnennrnerner 26 6 8 1 Fan SUPPlyis sosser gstspengetupundpunameumieie 26 6 9 Motor sensor X 11 anernanvrnannvnnnnvnnnnvnnnnvnnnnnnnnnnennnvsnnnennnnennnnvsne 27 6 10 Encoder output X 13 neenernrnvrnvrnvrnvrnvrvrnvrnesnvrvrnevnvnesnesnevnenernenn 28 6 11 Communication interfaces rrunvrannrnnnrnnvennvnnnvennvnnnennnennnennnenner 29 6 11 1 RS 232 X Vie 29 6 12 Starbinginhibit hi desmidvessdeistenideksesanesasedvksasdndsendndekedenadnnnne 30 6 13 Braking Chopper rsrsvravrnvnnvnevnevnvnnvnnvnevnevnennvvavsevnenesnesnnvnnnernenn 31 6 13 1 Braking power calculation oororrrrroronronrrrrrrrsrrsrnrrnrrnenn 33 Operation manual 6 1 U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connection DRIVET RONICS cal connections Operation manual 6 2 U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS 6 1 General overview U DS 006 1 020 1 Shield clamp Mains connection terminals L1 L2 L3 Connection terminals 4 5 6 Ground screw M6 Ground screw M6 for external brake resista
53. be released Caution Assure that the motor is separated from the load and that the drive can be observed from the switching point 10 Switching of output stage enable X2 2 Pin 8 regulator enable X2 2 Pin 7 Setpoint integrator enable only necessary if the setpoint is preselected through the setpoint channel 1 X2 2 Pin 10 Check at that point if the co ordination of the direction of rotation is correct the adaptation on utilization of the analog inputs is correct With satisfactory basic functions of the drive clockwise counter clockwise rotation stage signals of the LEDs signal outputs etc the next step is to optimize the drive Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 8 1 5 Optimisation 8 2 Brakeresistance 8 Commissioning Operation Disengage the servoconverter and connect the motor to the load Change the parameters max speed clockwise max speed counter clockwise and the setpoint adaptation to avoid any damage to the system The behaviour of the regulator can be optimized by means of the parameters in the menu parameters sub menu unit parameters sub menus current regulator speed regulator and flux regulator The flux regulator is adjustable for asynchronous machines only For optimisation of the regulators look at the jump reaction of the regulator This reaction can be observed with the monito
54. ce instructions for the motor and the corresponding brake The holding brake is not a working brake It must only be operated with motor standstill e For voltage supply provide an external d c voltage of 24 V 20 The required intensity of current is stated in the brake data sheet e Brake control see chap 6 22 Release the brake n gt 0 Pin 17 Operation manual U DS 006 1 045 1 05 03 2003 LUST 5 Planning information DRIVETRONICS a S Moan Operation manual 5 8 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 6 Electrical connections 6 1 General overview U DS 006 1 020 1 22uu22uu0nuanuu0nnunnnunnnnnnnnn 3 6 2 General overview U DS 035 1 045 1 iunvnrnvnnnvnnnvnnvnnnvnnnvvnnvennens 4 6 3 Gable cross section ssusssssussnsnnsnnsnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 5 6 3 1 Power connections userrvvernvennvennvennvennvennvennvesvernvensvessvennvens 6 6 3 2 Mains connectionS wseravenrvvnnvensvennvennvensvennvenvensvensvensvennnen 10 6 3 3 Motor connection r sssvvrvnvrnnnvvnnnvvnnsvrnssnvvnenvvnssvvnssvressnvnsnn 11 6 3 4 D C link connection L L eseesrerrrsrernreseesnresressvesseesseerne 12 6 4 Control connections X2 nrannvannnannnnnnnannnannnennnnnnennnennnenneennennnr 14 6 5 Analog inputs X2 1 nesnrevrnvrnvrnvrvrnernvrnvrnvnnrnevnvsnernrnernernernernrnerne 15 6 6 Control inputs X2 2 ins scccecisacsesecstacessassssacsccvessivacvestevecsisterscst
55. consulted the LUST DriveTronics GmbH after sales service Caution The sum of the motor output of the converter to be delivered must not exceed the output of the feeding unit U DS 1 Caution Only one of the possible supply variants may be selected Mains feeding L1 L2 L3 or D C feeding D C link L L Caution With D C feeding it is absolutely necessary to pay attention to the polarity No protection against mispoling With mispoling the output stage is destroyed Caution It must be ensured when establishing the DC link connections and fitting the cover plate that no electrical connection earth fault to the housing exists If necessary air gap and creepage distance cannot be kept according to VDE 0110 the connections are to be isolated additionally Operation manual U DS 006 1 045 1 05 03 2003 6 13 LUST DRIVET RONICS 6 4 Control connections X2 6 Electrical connections The control connections are made to the upper side of the modul via SUB D plugs X 2 1 and X 2 2 Fig 6 9 w 2 Control inputs control outputs Analog outputs EEL X 2 1 Analog inputs moan 1 X 3 Regulator supply i B11 017 Control connections Caution The below description of functions is only applicable to standard units Units with user software positioning synchronisatio
56. ed setpoint integrator time N max max speed programmed menu 42312 n1 run speed 1 n2 run speed 2 tla Acceleration time from n 0 to n1 tib acceleration time from n1 to n2 Table 6 6 Acceleration and braking ramps Note Calculation with time t1 also applies for times t2 t5 Note The setpoint integrator function is only active in the setpoint channel 1 When activating these inputs e g by approaching the limit switches the setpoints for clockwise running limit switch 1 or anticlockwise running limit switch 2 are blocked The limit switch inputs can be actively programmed to normally closed or normally open contact in the menu 125 Note On delivery the inputs are actively programmed to normally open contacts By selection of the setpoints the defined ref speed can be controlled in both directions of rotation through the inputs X 2 2 Pin 11 and x 2 2 Pin 12 X2 2 Pin 11 on clockwise direction X2 2 Pin 12 on anticlockwise direction Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 6 7 Signal outputs X 2 2 Ready signal Pin 13 LED 1 green Limit of the current Pt Pin 14 LED 6 yellow 6 Electrical connections All signal outputs are electrically isolated from the electronic regulation and the power pack by means of opto couplers The outputs are switched through transistors and can be used to be switch SPC inputs or coupling relays
57. ely Switch on the 24V supply and mains supply for the device Caution With motor acceleration disengage the unit immediately Check the connections check in particular whether the output stage enable is disengaged For the parameter setting use the terminal program VecWin the operator terminal D DS 1 or special customers programs The following statements refer to the menu designations used in the terminal program VecWin Caution In the works the servoconverter is parameter pre set with the special data given by the customer See the attached accompanying lists With disengaged regulator enable setpoint integrator enable and output stage enable input the following parameters 1 Input of number of pole pairs of the motor menu 4 2 4 1 type of drive type of motor menu 4 2 4 6 Voltage constant of the motor with synchronous motor only in the menu parameters sub menu motor data After a modification of the parameters number of pole pairs or type of drive disengage the converter and re engage it after some seconds Otherwise the converter does not accept the modifications 2 Input of max speed menu 4 2 3 1 2 In the menu parameters sub menu limit values sub menu speed limit values Caution Adhere to the motor and system data 3 Input of the current limit values for max current menu 4 2 3 2 3 nominal current menu 4 2 3 2 4 In the menu pa
58. enable is switched off the drive brakes to a halt at the set rapid stop ramp t5 The drive stands still with holding torque as long as Controller Enable is switched on reference speed Rapid stop 4 v 100 gt S WA 0 gt t s 100 H gt H gt H gt m i gt t1 t2 t3 t4 t1 t5 Fig 6 12 B12 0006 Acceleration and braking ramps t1 ramp for acceleration clockwise running t2 ramp for deceleration clockwise running t3 ramp for acceleration anticlockwise running t4 ramp for deceleration anticlockwise running Ramp for rapid stop t5 Ramp for deceleration clockwise and anti clockwise with regulator enable off and setpoint integrator enable off Table 6 5 Acceleration and braking ramps The ramp times can be selected from the Commissioning and Parameter menu menu 42231 42235 reference speed 100 au n2 ni 0 gt t s r tia t 1b Fig 6 13 B12 007 ramp times The times t1 t5 refer to the max speed programmed in the menu 42312 With this ramp steepness all set point jumps are delayed Operation manual U DS 006 1 045 1 05 03 2003 6 19 LUST DRIVE TRONICS Acceleration time t 14 Acceleration time t 1 Limit switch 1 Pin 11 Limit switch 2 Pin 12 Selection of rotational direction 6 Electrical connections Acceleration time calculation t Enz 14 xt4 fa 7 n max 19 Z Ny x ty t De 1b n max t1 programm
59. er resistor ballast which is integrated in the Servoconverter see Fig 6 1 page 3 and see Fig 6 2 page 4 Caution The external or internal resistor ballast conducts dangerous D C link voltage which can cause death or heavy injuries when touching Approx 6 minutes after disengagement of the Servoconverter the brake resistance external or internal can still be subject to dangerous D C link voltage Before carrying out any maintenance works assure that the current supply is disengaged locked and that the D C link is discharged check Caution The resistor ballast external or internal can become extremely hot which may cause heavy physical burnings Before carrying out any maintenance works assure that the brake resistance has cooled down Caution The brake resistance can conduct a D C link voltage of max 890V D C Therefore a corresponding protection against accidental touch has to be provided namely against the high D C link voltage and the high temperature With higher brake outputs an external resistor can be connected to the converter as option Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS Minimum resistance braking chopper Connection of external brake resistances 6 Electrical connections After having exceeded a fixed voltage threshold of the D C link a transistor switches the resistor ballast to the D C link The resistor is fed wi
60. g machines EN 50178 Electrical equipment for power systems EN 61800 3 EMC product standard electronic drives with variable speeds It may be necessary to observe other regulations if the equipment is to be used for special applications The local protection measures are to be adhered to The Servoconverter must be connected to the mains in accordance with VDE regulations in such a way that they can be disconnected from the mains supply by means of suitable isolation devices e g main switch circuit breaker Because of operationally caused leakage current the fitting of Fl switches into the mains conduct of the Servoconverter is possible only by using a Fl fault current switch of type B Pay attention to the following measures The fault current of the protective switch is at least 0 3 A The N conductor of the supply mains is grounded PerFI protective switch one converter only Motor cable not exceeding 50 m Gold plated contacts or high contact pressure contacts should be used for control contacts Precautionary interference suppression measures should be taken with switching systems e g contactors and relays with RC elements or diodes Ground negative pole Lengths of cable Screened screen gt 40 cm motor cable Mains Servo amplifier o line choke 4 UK Ground cable gt 10 mm EN 50 178 5 2 11 Fig 5 1 B12 004 Typical application
61. ge also with low braking energy gt Brake resistance or its ref command is defective gt Ship the unit to LUST DriveTronics GmbH after sales service Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Possible cause 3 Remedy Possible cause 4 Remedy Possible cause 1 Remedy Possible cause 2 Remedy Possible cause 3 Remedy 9 Fault finding 3 Undervoltage on acceleration gt Acceleration ramp too steep gt Reduce the acceleration energy by extension of the acceleration ramp time on the setpoint integrator gt Mains conduct too weak check the mains 4 Undervoltage also with less power output as a phase in the conduct is missing gt check the fuses in the conduct gt Check terminal connection LED 10 flashes Overtemperature brake resistance Fault signal with overheating of the brake resistance Readiness for operation is interrupted 1 Excessive brake energy see chap 8 7 Brake resistance gt Check system whether the braking energy is excessive or whether the braking time is too long 2 Excessive voltage in the mains conduct gt Check the mains voltage max mains voltage 400V 10 option 480 V 10 3 Output stage overloaded gt Heat accumulation in the module check aeration gt Excessive ambient temperature gt Excessive clock frequency with nominal current Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 9 3 Fault
62. he works it is already adjusted correctly and must be changed only by the after sales service Here the switching frequency of the output stage is adjusted in steps of 1kHz range 2 14kHz Note Please note that the nominal data can only be reached up to 4kHz In case of higher switching frequencies a load reduction is required Motor with resolver maximum 8 kHz Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 7 2 2 Motor data Number of pole pairs 4 2 4 1 Type of drive 4 2 4 6 Voltage constant 4 2 4 7 Nominal current 4 2 3 2 4 7 Parameter setting Here the number of pole pairs of the motor is adjusted In case of a wrong number of pole pairs the motor does not rotate Note To allow the transfer of a newly input number of pole pairs the servoconverter has to be disengaged and then re engaged Here the motor type is input i e asynchronous synchronous or controlled by U F characteristic Note To allow the acceptance of the drive type change disengage and re engage the servoconverter Here the voltage constant Kv of synchronous machines is input V 1000min 1 The value complies with the effective value of the induced voltage against the star point with a speed of 1000 rpm For LUST DriveTronics GmbH motors the value is indicated on the nameplate Note In case of doubt input value OV Here the nominal current in percent is adjusted 100
63. hich the setpoint channel 1 2 receives its setpoint see chap 6 5 Analog inputs X 2 1 Setpoint 0 Analog input 1 ginp O O Analog input 2 O Setpoint channel 1 Setpoint integrator Control unit O Internal setpoint O Field bus O Technology O Analog input 1 2 O Setpoint channel 2 Selection of direction O guick analog input 1 external current limit 2 Fig 7 1 B12 013 Setpoint channels Both setpoint channels can read simultaneously values from different inputs Note Always the sum from both setpoint channels is taken forming the basis for the regulation Each setpoint channel can be permanently set to the value 0 so that one channel only is active The setpoint channel 1 disposes of the option to select the analog input 1 as guick analog input Thereby its scanning time is reduced from 5 ms to 500 ps It has to be assured however that the setpoint signal is not noisy which would cause an unguiet rotation of the drive The setpoint channel 2 disposes of the option preselection of an external current limit If a setpoint channel is put on the serial interface the setpoint can be preselected via that interface Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS Adaptation smoothing and offset of the analog inputs 1 and 2 4 2 2 2 x Adaptation 4 2 2 2 1 4 2 2 2 2 Smoothing 4 2 2 2 3 4 2 2 2 4 4 2 2 2 5 Offset 4 2 2 2 6 4 2 2 2 7
64. ime tx the regulation still places at disposal the standstill torque disengaging delay During that time the brake must be actuated menu 4244 gt tx gt t Controller enable N Internal Enable reference speed reference speed Release the brake Release the brake Fig 6 15 B12 009 times for holding brake ON OUT gt tv delay time of the setpoint customer gt t mechanical switching delay of the brake gt tx disengaging delay menu 4244 If the delay time tx is set to 0 the function operates like that one of a standstill logic H signal with n 0 and the hysteresis menu 42254 Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Motor overtemperature Pin 18 LED 5 yellow flashes Braking resistor overtemperature or output module overtemperature pin 19 LED 10 flashes yellow Reserve Pin 20 LED 10 yellow 6 Electrical connections H level signalises that the motor limit temperature is exceeded posistor in the motor winding Simultaneously the readiness for operation of the Servoconverter is cancelled When cancelling the readiness for operation the motor is running down in an uncontrolled manner as it is no longer connected to current The readiness for operation is cancelled after a programmable delay time only to allow the system to run controlled in a safety position after having got the signal motor over temperature
65. information 5 1 Electrical installation sesseavsvrnvnenvvnvnvenenvrnvnennnvvnenenserennenenenn 3 5 2 Switching devices rsrrvrnvrnvrnvnvrnvvnvrnvsnvnvrnvrnvsnvsennrsevnesnesnenenner 3 5 3 Typical application rssravenvrnvnvrnvrnvrvrnvsnvrnvnernvrnernvvevnernernnnnrnenne 3 5 4 Cable routing earthing EMC in cabling rseraravrnvrnvrnrrvrnernen 4 5 5 Selection Of unitS s ssrarnvrnrnvnnvnvnvenenvrnvnennenvnnvnvnnnennennnnenenevsene 5 5 6 Power stage clock frequency rsrrsrrvrnvrnvrnvrnnnvnnvnvrnernvrnernrnenner 5 5 7 Mounting nn anna nina dan 6 5 8 Sensor cable nsec siccsseestcensseessvarccessnesasortvseviveenssersevercevsneeiered Hehe 6 5 9 Motor conduCt rsrarsvrnvnennvnvnnvnenennenennennnenensnnennenennnnenensenensenenenn 6 5 10 Motor protection 2 22 22222222422202000000n002un0nn0nnnnnunnnnnnnnnnnannann 6 5 11 Motor holding brake 2 2 2 2 22222222222420002000200n020ann0nnnnnannann 7 Operation manual 5 1 U DS 006 1 045 1 05 03 2003 LUST 5 Planning information DRIVETRONICS a 9 ormana Operation manual 5 2 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 5 1 Electrical installation 6o 5 2 Switching devices 5 3 Typical application 5 Planning information Electrical installation should be performed in accordance with the following general installation regulations EN 60204 1 Regulations governing the electrical equipment of tooling and processin
66. k connection L 161 220 22 7 PE L1 L2 L3 Fan L1 L2 L3 ajoja I r alaa I T IT L O gt o o A N KA 3 2 lt O gt lt O gt D a D a E Ef N N DriveStar DriveStar u UIVIW U V IW oja N ojo N Space 6 E i Fig 10 7 B11 012 Mounting dimensions for D C link connection Operation manual 10 8 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 10 A Appendix 10 4 Accessories 10 4 1Control cables for X 2 1 Assembled cables SUB D 9 pol plug v v Signal Analog input 1 Analog input 1 GND analog Analog input 2 Analog input 2 GND analog GND analog Auxiliary voltages 10V 9 Auxiliary voltages 10V Housing Screen Table 10 1 Control cables for X 2 1 O N OG A ON a Caution Notused wire must be isolated Cable length 9m Artikel No 182 01811 Operation manual 10 9 U DS 006 1 045 1 05 03 2003 L
67. lants welding machines Inexpert earthing screening Defective cable screening Computer fault earthing Engagement disengagement cycle shorter than 3 sec Wrong parameter files Interface EMC surroundings Unit does not respond to commands Faulty interface protocol through RS interface Overtemperature motor Excessive ambient temperature Excessive load cycle mechanical tightness Brake not released Motor demagnetised Heating due to not circular running see motor Operation manual U DS 006 1 045 1 05 03 2003 9 10 LUST DRIVET RONICS 9 Fault finding Conseguence possible cause Defective unit fan Covered unit fan not enough space for the cold air Excessive ambient temperature Filter meshes of the switch cabinet polluted Defective switch cabinet fan or air conditioner Units overloaded Excessive clock frequency of the output stages selected Overtemperature servoamplifier No AC DC output feeding available With AC feeding missing phase Fed AC DC voltage outside the tolerance Mains downfalls dissymmetries Undervoltage overvoltage in the mains Inexpert cabling of the DC Bus EMC With D C link feeding from the main drive defective main drive Operation manual 9 11 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 9 Fault finding Operation manual 9 12 U DS 0
68. late and can be calculated from its data as follows The data is given related to the unit max current 1 Z cos lar In 1 cos The nominal speed is stated on the motor nameplate 0 0 9000 0min in percent see chap 2 Technical data Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Rotor time constant 4 2 2 8 5 Release speed 4 2 2 8 6 release current 4 2 2 8 7 7 2 5 Command Type of regulation 1 2 4 Limit switch 1 2 5 Brake operation 1 2 6 7 Parameter setting 2 2 NE Z T ln Imp with nominal slippage i Imr X Or NNa 2nt x s In Nominal current of the motor In Nominal frequency of the motor Ng synchronous speed Np Nominal speed menu point 4 2 2 8 4 cos Nominal output factor With high frequencies the voltage placed at disposal by the servoconverter is no longer sufficient to connect the leakage inductances to high current l e from a defined speed a current reduction is required This means that a current reduction is required from a certain speed onwards From a defined speed point 4 2 2 8 6 the current setpoint 1q set is linearly reduced to an adjustable min current value I abl 4 2 2 8 7 thus keeping the output voltage of the servoconverter below the max value Here the type of regulation torque or speed regulation is adjusted Here it is adjusted whether the inputs for the limit switches X
69. lations For another interference elimination to EN 50081 50082 corresponding filters can be purchased at the LUST DriveTronics GmbH Practical hints in relation to standards and application are given in the following leaflet LUST DriveTronics GmbH EMV instructions Nr 180 00 000 Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 5 5 Selection of unit 5 6 Power stage clock frequency Output reduction Max unit current 5 Planning information On composition of a complete drive Servoconverter and motor we recommend to proceed as follows 1 Selection of drive type Synchronous Asynchronous Field orientated 2 Detect the max speed of the drive 3 Detect the effective torgue i e effective value of the sum of all loads M xt M xto M xt t ges Mes 4 In relation to the load ratios and the dynamics provide sufficient reserve 10 20 for the motor speed and the load torque Respect the dynamics required by the system to be driven in relation to acceleration output gt max drive output and the braking output gt max pulse output of the braking chopper in theServoconverter On principle the mass moment of inertia of the motor has to be considered too 5 Determine the corresponding motor as per the output or torque speed resp 6 Determine the Servoconverter from the motor parameters nominal current max current or nominal output max o
70. lock freguency of output stage 4 kHz to 14 kHz with current reduction up to 1000m without reduction Operating height from 1000 m per 100 m height 1 output reduction max operation height 4000m EE 0 to 40 C with nominal load p gmp gt 40 C to 55 C with reduced load load reduction 2 C Humidity class G no bedew Storage temperature 25 C to 70 C DC link capacity 705 uF 1500 uF SE WiNA khz 6A eff 12A eff 20A eff 35A eff 45A eff Pulse current 1sec on 5sec pause mitet bytet monitorin 12A eff 24A eff 40A eff 70A eff 70A eff eide va oo to 2 75 kW to 5 5 KW to 11 KW to 18 5 KW to 22 KW Output of braking chopper with p 100 W p 250 W internal resistance P nax for 0 4 sec nom 100 en no internal 10866 pause Pmax 7 KW Pmax 31 kW brake resistance Output of brake chopper with external R 309 eo ist P for 0 4 nd 10 min 7 min a max for 0 4 sec und 10sec Prax 22 KW Prax 37 KW internal mains filter Limit values of EN 61800 3 comply with EN 55011 class B Digital inputs 8 Opto coupling 24V 10V to 30V Digital outputs 8 Opto coupling transistor 24V 125mA max 0 5A sum current max 1A Analog inputs 2 Setpoint inputs differential inputs 10V Analog outputs 2 Monitor outputs 10V 1 5mA Rj gt 6 8kQ output quantity freely programmable Table 2 1 Performance data Operation manual U DS 006 1 045 1 05 03 2003
71. modification is not taken over by the converter 6 input of setpoint adaption menu 4 2 2 2 1 2 In the menu parameters sub menu limit values sub menu speed limit values Only reguired if analog input 1 2 or guick analog input 1 has been selected for one of the two channels see point 5 The input speed value is the scaling value for the max input voltage of 10V 7 Input of the regulator parameters for current regulator menu 4 2 2 7 speed regulator menu 4 2 2 6 flux regulator only with asynchronous machines menu 4 2 2 8 In the menu parameters sub menu unit parameters sub menu current regulator or speed regulator or flux regulator Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 8 1 4 Parameter setting with rotating motor 8 Commissioning Operation 8 Input of the setpoint integrator ramps menu 4 2 2 3 In the menu parameters sub menu limit values sub menu setpoint integrator ramps At this point the setpoint integrator times have to be input when the motor has already been connected to the load and the load must not be accelerated too quickly With motor still in idle run operation this parameter can be adjusted on optimisation The setpoint integrator ramps are only applied to setpoints of the setpoint channel 1 9 Pre select a low setpoint By the next step the ref command of the motor can
72. mplifier module The user must ensure that such regulations are adhered to Caution The air drawn in by utilisation of unit fans must be free from conductive particles such as graphite drilling dust etc Protection class IP20 to DIN 40050 The Servoconverter are designed for 100 duty factor in nominal load operation up to 40 C ambient temperature With 1 C each ambient temperature above 40 C up to 55 C a load reduction of 2 has to be considered If the system operates with load cycles the effective load torque has to be detected see chap 5 5 Selection of unit Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 9 Fault finding 9 1 Fault signal via LED rrnvrnornrrvrrornvrnvrnvrvrnernvrnernvsnvsevnesnesnrvernernener 3 9 2 Fault finding remedies 2 22 22222222222220000000200nu2nunnnnnnnnannann 4 No ready signal no LED flashes cccccssccesessessseesseeeseeeeees 4 LED 1 flashes ready signal with regualator enable 4 LED 2 flashes OVErSPeed c ccccccseessessssessessssesesssssessseesssereaes 4 LED 3 flashes no function oseorerronorrororrrvonrrnrnrrnrrnonrrnasrrnenrrnenrnr 4 LED 4 flashes a Computer fault b check sum fault 4 LED 5 flashes Motor overtemperature cccccesssseesseeeereees 5 LED 6 flashes Short circuit short to ground 5 LED 7 flashes Encoder fault
73. n etc have different functional characteristics at the various inputs and outputs In such cases the additional service instructions Technology must be observed Note For the connection control cables with prepared plugs are available which can be purchased from LUST DriveTronics GmbH for X 2 1 Art No 182 01811 for X 2 2 Art No 182 01810 see chap 10 4 Accessories Operation manual U DS 006 1 045 1 05 03 2003 6 14 LUST 6 Electrical connections DRIVET RONICS 6 5 Analog inputs X 2 1 R X 2 1 L R 1 gt m A L R 23 00 D R 3 4 Analog input 1 R X 2 1 L R 4 gt nv A L R 9 Je D R 6 gt 4 Analog input 2 L 100 pH R 20 kOhm Fig 6 10 B10 015 Analog inputs Pin X 2 1 Function 1 gt Input 1 inverted 2 gt Input 1 not inverted 3 gt Input 1 GND 4 gt Input 2 inverted 5 gt Input 2 not inverted 6 gt Input 2 GND 7 gt n C 8 gt 10V auxiliary voltage 9 gt 10V auxiliary voltage Table 6 3 Connection X2 1 The setpoint can be preselected differently Two analog inputs are available They can be used as follows gt reference speed gt torgue setpoints 0 100 x max gt external current limit 0 100 x max setpoint input 2 only gt quick analog input input 1 only The analog inputs are designed
74. n request Type of regulation Synchronous asynchronous asynchronous field orientated by software 2 freely programmable analog monitors e g speed current angle of rotation Setpoint integrator with 4 separately programmable ramps quick stop ramp 12t current reduction with signal Output signals n gt n1 Nset Nact N gt 0 Display of operational status via LEDs Simple menu guided operation Display of all operational states and faults in plain text Comprehensive communication concept RS 232 as standard RS 485 or BUS systems e g Interbus S Profibus DP CAN BUS as an option Integrated technology regulations optionally e g positioning flying saw synchronization winding Integrated display for diagnosis and parameterisation All inputs and outputs for control purposes are electrically isolated via opto couplers level 10V 30V This allows a simple reprocessing by stored program controllers and CNC control systems The Servoconverter DriveStar possess safety systems for monitoring of Overcurrent short circuits and shorts to earth UCE measuring Overspeed Evaluation of motor PTC thermistor Output stage temperature Overvoltage and undervoltage Supply voltage faults Overtemperature resistance brake resistance Overcurrent and short circuit of the internal and external brake resistance In the event of a malfunction the controller is inhibited and standby mode switched off Operation m
75. nce eee nn a 71 Ty Connection terminals L L Oo r ret 5 ge for the D C link I o LED 1 to 10 M d a ME X 14 g g o M 1 1 63 JEP X11 g i g o e L X13 sa Be en terminals JE ul Ground screw M6 Ground screw M6 X 2 2 Shield clamp X 2 1 In x 3 Ground screw M6 S A O 0 0 0 0 0 Fig 6 1 B11 007 U DS 006 1 020 1 Operation manual 6 3 U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS 6 2 General overview U DS 035 1 045 1 Mains connection terminals L1 L2 L3 Connection terminals B1 B2 Mains connection terminals L1 L2 L3 for external brake resistance N S Connection terminals B1 B2 Ground screw M6 ojojo 2 2 ter external brake resistance i aN Li L2 L3 etjpa L f pei an L aja B Connection L L for l for the D C link L f L Screws M6 N er LL o LED 1 to 10 pa O A O gt X 14 H zn f X14 q o Q E X13 q 6 N l DriveStan 22
76. nological regulations and customers specific software l e same hardware with different regulation and technology duties DriveStar units are suitable for Regulation for synchronous drives Regulation for asynchronous motors with detection of current vectors by a calculated flux field orientated regulation for asynchronous motors In both cases the high regulation expenditure results in threephase drives requiring less maintenance having the behaviour of d c drives e Regulation for standard asynchronous motors as frequency converters and speed converters The Servoconverter DriveStar U DS 006 1 045 1 disposes of an integrated mains module In relation to the type of regulation synchronous asynchronous the motor sensor can be a resolver an incremental encoder a high resolution encoder or an absolute value encoder Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 4 3 Important characteristics Safety systems 4 Gonstruction of unit and method of operation Overview of the main features of the DriveStar devices Compact construction Integrated power supply with braking chopper Low loss IGBT output stage 2 KHZ 14kHz with current reduction from 4kHz Sinusoidal output currents through vector modulation Excellent evaluation of resolver or incremental encoder signals Evaluation of high resolution sensors sine cosine tracks Encoder imitation 1024 pulses rev other resolution o
77. oconverter The supply cable for regulator supply has to be screened Under the described conditions the input has a burst factor of gt 2kV For reasons of operational safety this supply cable has to be embedded separately from the power cables The Servoconverter contain fans which dissipate the thermal loss generated in the electronic components to the surroundings The fans are internally connected to the 24 V regulator supply The fans operate with connection of the regulator supply Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 9 Motor sensor X 11 6 Electrical connections The motor sensor connection is made through Sub D plug X 11 Fn RIS A O gt X14 RS 232 ID X 11 feedback D X 13 Encoder N DriveStar LLU Fig 6 17 B11 016 Motor sensor For sensor connection use LUST DriveTronics GmbH control cables with already connected plug type facilities Solutions meeting customer s special requirements need to be agreed with LUST DriveTronics GmbH as otherwise the warranty will no longer apply The following generator types may be connected to the Servoconverter gt resolver gt High resolution encoder absolute value encoder gt Pulse generator Note The plug connections depend on the sensor type see chap 10 2 Motor sensor connections Operation manual
78. okes 3 3 3 3A C U DS006 1 external E U DS 012 1 Wire bridge U DS 020 1 PE L1 L2 oL3 04 5 6 X3 GND 9 9 S 25A Mains filter i Regulation Rectifier s pep St gt Fan Pre charging SED ME internal brake resistance D C link capacitors L L o K K K IGBT Output stage IK braking chopper KA K 2 o o E U Vv W ja Ui lvi w M M PE 3 nu Three phase a c motor Fig 6 3 B10 011 Powerconnection and controller voltage supply for U DS 006 1 bis U DS 020 1 Operation manual 6 6 U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS Power connections U DS 006 1 to 020 1 external brake resistance 3 x 230V 480V 50 60Hz PE L1 L2 L3 PE external 4 4 brake resistance Mai VAN rai Mains contactor VUON 24V DC 20 24V ov PE Mains chokes U DS006 1 ake A U DS 012 1 U DS 020 1 PE L1 L2 oL3 4 05 6 X3 GND e Tv S Mains filter 2 5A Regulation Rectifier A bridge gt CO Fi Pre charging gt gt 2 i I ine D C link c
79. ot accept liability for damage or malfunctioning resulting from non adherence to this manual No operational practice should be used which could adversely affect the safety of the Servoconverter The user must notify the supplier immediately of any changes which occur to the Servoconverter which would adversely affect safety see chap 1 1 After sales service The Servoconverter is designed exclusively for its intended usage We reserve the right to implement technical changes necessary to improve the Servoconverter relative to the information provided in these operating instructions We recommend that these instructions be included as an integral part of the user s operating instructions Caution Be particularly careful on mounting Assure that no drilling chips metal dust or mounting particles screws nuts cable sections are falling into the unit The safety systems used must be tested after any electrical fitting operations or electrical maintenance operations e g earthing resistance In all cases the applicable VDE requirements and all regional and local safety and accident prevention regulations will apply to use of this unit The user must ensure that such regulations are adhered to The DC link voltage level must be taken into account during installation especially in connection with insulation and safety measures Care must be taken to ensure proper earthing conductor dimensions and protection against shor
80. other electric units than described above Limited availability to EN 61800 3 The sale of this Servoconverter is restricted to dealers customers or users who individually or jointly possess technical EMC know how regarding the implementation of electrical drives If the unit is to be used for purposes other than this agreed area of application then the customer should seek the advice of LUST DriveTronics GmbH Service as otherwise the warranty will be invalid for address see chap 1 1 After sales service The guidelines given in VDE 0160 and IEC 68 apply to the operating conditions which must be maintained for the proper operation of the amplifier module The most important specifications are The most important specifications are e protection class IP 00 e humidity class G e vibration test VDE 0160 PKT 7 2 2 e storage temperature 30 C 70 C e Temperature range 0 40 C with nominal load gt 40 C 55 C load reduction 2 pro C Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 2 6 Conformity Standards O 2 Technical data The Servoconverter are designed in accordance with the guidelines contained in e EN 50178 VDE0160 e EN 60204 1 VDE 0113 e EMV product standard EN 61800 3 In this respect the following printed matter should be additionally observed LUST DriveTronics GmbH EMV instructions Nr 180 00 000 the operating manuals of the moto
81. r manufacturers This document only describes the standard version of the Servoconverter U DS 006 1 045 1 with standard software The separate operating manuals should be observed in the case of customised software or when implementing additional communication or technology cards Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 3 Safety information 3 1 3 2 3 3 3 4 Safety instructions for working 2 22 22222222222220220200000nn2nn2n Operation and maintenance 2 22 22 22222222202202n02020nnnnnn0n Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 3 Safety information Operation manual 3 2 U DS 006 1 045 1 05 03 2003 LUST 3 Safety information DRIVETRONICS ty 3 1 Symbols These symbols denote the safety instructions in this manual which deal with danger to life and limb of personnel These instructions must be adhered to and particular caution exercised in these cases All users must be familiarised with the safety instructions Caution Narning of general dangers Incorrect operation may lead to damage or malfunction Danger Danger electric current Incorrect conduct may endanger human life Danger Danger moving parts Drive may start to run automatically Note Useful hint or reference to another text section in this document Note Reference to another document with important hint
82. rameters sub menu limit values sub menu current limit values 100 correspond to the unit max current Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 8 Commissioning Operation The maximum device current cannot be provided permanently if it is greater than the set nominal current see chap 6 21 Limit of the current Pt Pin 14 LED 6 yellow Caution Adhere to the motor data in particular to the motor nominal current see chap 7 4 Motor data 4 Input of the sensor type fitted into the motor menu 4 2 4 2 In the menu parameters sub menu kind of sensor Disengage the converter after a modification of the parameter sensor type and re engage it after some seconds Otherwise the modification is not taken over by the converter Note Hardware modifications in the converter are necessary for the connection of an absolute value generator 5 Input of the setpoint source for setpoint channel 1 menu 2 1 setpoint channel 2 menu 2 2 In the menu setpoints submenu setpoint 1 2 The setpoint channels 1 and 2 must not be connected identically The only exception is point O Only reference values supplied to reference value channel 1 pass through the reference value integrator see chap 7 8 Setpoint integrator S curve 4 2 2 3 9 Modifications in this menu point are accepted with disengaged regulator enable only Otherwise the
83. re carrying out any maintenance works it is therefore absolutely necessary to assure and to check that the current supply has been disconnected made safe and that the D C link is discharged Also assure that the external voltage supply of the regulator 24V is disconnected Only perform work in the vicinity of the machine if the AC supply resp DC supply is disconnected and made safe Circuitry safety devices or disconnection of the enable function are no suitable inhibits and may lead to unintended movements of the drive if a fault occurs Perform commissioning operations with unloaded motors so as to avoid any mechanical damage e g through incorrect direction of rotation Electronic equipment is not inherently fail safe The user must ensure that should the Servoconverter fail his system will be switched to a safe condition Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 3 Safety information Operation manual 3 6 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 4 Construction of unit and method of 4 1 4 2 4 3 4 4 operation Block diagram Method of operation Important characteristics Visual signals Operation manual U DS 006 1 045 1 05 03 2003 LUST Ove Taos 4 Gonstruction of unit and method of operation Operation manual 4 2 U DS 006 1 045 1 05 03 2003 LUST 4 Construction of unit and method of operation DRIVETRONICS
84. re which could lead to the generation of condensation water should be avoided The Servoconverter should only be stored in a dry room in which no condensation water can generate within the Servoconverter When not operating the converters for a longer period of time the D C link capacitors have to be formated With a storage time of one year no measures have to be taken After that time a formatting time of one hour per storage year has to be added during which the connected controllable mains voltage rises in 4 steps over 30 minutes each up to the nominal value The delivery should be checked on receipt to ensure that nothing is missing Compare the content with the pertinent packing list Any transportation damage and or missing parts should be reported immediately in writing Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 1 7 Maintaining stocks of replacement parts 1 8 Hints for waste management 1 General A stock of the most important replacement and wearing parts is crucial for the continuous operation and availability of the unit We can only guarantee original replacement parts supplied by ourselves We would expressly point out that the fitting and or use of original replacement parts not supplied by us may have an adverse effect on the design characteristics of the unit and may therefore reduce active and or passive safety LUST DriveTronics GmbH cannot provide any guarantee whatsoever
85. rnvrnvsnvnvrnevnvsnernvsvvnernesnesnvvernernener 3 2 2 Key to ty POS ansiccisesiscvcsesuscssassesseviessrssctrsnesesuaseevsrnavacstensvsersesadsecs 4 2 3 Device VIEWS nn anna anne 5 2 3 1 U DS 006 1 U DS 020 1 urcusnnennenennnennennennnnennennennenennen 5 2 3 2 U DS 006 1 U DS 020 1 with technological card 5 2 3 3 U DS 035 1 U DS 045 1 ueenesensennennensnnennennenennenennennennennnnn 6 2 3 4 U DS 035 1 U DS 045 1 with technological card 6 2 4 Applications and intended use 2 2s222222222020n02nun20nnannnnn2n 7 2 5 Operating conditions 2 22 2 222222222202202000a000000nunnnnnnnnnnnannann 7 2 6 Conformity Standards 2 222222222220220220000000n02nnnnnnnnnnnnnnnnnna 8 Operation manual 2 1 U DS 006 1 045 1 05 03 2003 LUST DriveTRonics 2 Technical data Operation manual 2 2 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 2 1 Performance data 2 Technical data Type of device U DS 006 1 U DS 012 1 U DS 020 1 U DS 035 1 U DS 045 1 Input mains side Mains voltage 3 x 230V 10 bis 3 x 480V 15 Mains freguency 50 60 Hz 24V DC 20 1 5A to 2 5A depending on the load of the digital outputs Regulator supply Starting current 3A 4 A for 1 5 sec DC link voltage 325V to 680V DC 15 Peak voltage with brake operation up to 890V Output voltage motor side 3 x OV to mains voltage AC C
86. rs see chap 6 25 Analog outputs Monitors Generally the following applies Increase of vp and reduction of T accelerate the regulator The quicker the regulator the more tendency to over shooting For the adjustment of further options number of increments encoder output sensitiveness of the speed signal limit switch logic etc see chap 7 2 Description of parameters The commissioning is finished Caution f the motor runs in braking mode for an extended period so that the braking resistance must be reduced the resistor heats up until module error message is issued LED 10 flashes After switching back of the temperature switch and enable of the servoconverter the brake resistance does not cool down completely If then high brake outputs are still dissipated through the brake resistance the resistor may overheat due to the thermal time constant and in extreme situations it can be destroyed by burning out Result After switching back of the temperature switch it is therefore absolutely necessary to let the resistor cool down completely Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 8 3 Operating the unit 8 4 Duty factor 8 Commissioning Operation Caution Regardless of the following instructions the legally applicable safety and accident prevention regulations in force at the place of use e g VDE must always be applied when operating the a
87. rs to incremental and high resolution encoders only LED 8 flashes Fault of the supply voltage The supply voltage is the voltage supplying the regulator It is connected to the terminals X3 and X3 see chap 6 26 Regulator supply X3 Readiness for operation is interrupted 1 Excessive load or short circuit in the peripheral units which are connected via the plugs X11 X16 SUB D gt Disengage the amplifier module gt Disengage the regulator and output stage enable gt Remove the plugs X11 X16 gt Engage the amplifier module connect 24V X3 and X3 supply gt gt flashes LED 8 fault in the module ship the unit to LUST DriveTronics GmbH atter sales service gt If no fault is signalised fit the SUB D plugs one after the other until the fault occurs gt Check the faulty cable or unit for cable short circuit gt The supply voltage could also be influenced by excessive mains load or other consumers LED 9 flashes Over undervoltage Voltage in the D C link is monitored When exceeding the top and bottom voltage values the readiness for operation is interrupted Trigger threshold U DS 006 1 045 1 Undervoltage 240V DC Overvoltage 890V DC Checking of the D C link voltage at the terminals L and L 1 Overvoltage with braking only gt Excessive braking energy for brake resistance gt Reduce the braking power by increasing the braking slope time on the reference value integrator 2 Overvolta
88. s on this subject 32 BS p 3 2 Instructions caution The term instruction caution denotes those sections in this manual which reguire particular attention so as to ensure that the guidelines reguirements information and proper seguence of operations are adhered to and that any damage to the Servoconverter is prevented Operation manual 3 3 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 3 3 Safety instructions for working Mounting and electric connection VDE reguirements 3 Safety information The herein described units carry electric voltage and control rotating mechanical parts The instructions of this service manual have to be adhered to non adherence can lead to death strong bodily injury or considerable damage to property Caution Electrical units contain the source of danger This unit may present certain dangers if for example it is used improperly by untrained personnel or for other than the intended purpose All persons in the user s company who are involved in the fitting removal and refitting commissioning operation and maintenance inspection servicing repairs of the Servoconverter must be properly authorised trained and gualified electricians within the meaning of VDE 0105 They must have read and understood this manual in full paying special attention to the safety instructions The leaflet LUST DriveTronics GmbH EMV instructions No 180 00 000 We do n
89. se the brake n gt 0 Pin 17 When the delay time is set to 0 sec the function becomes a standstill logic H signal with n O Caution Pay attention to the switching times of the holding brake Here it is adjusted which encoder is fitted into the motor gt Resolver gt Incremental encoder gt High resolution encoder absolute value encoder Hardware modifications in the converter are necessary for the connection of an absolute value generator In case of an incremental encoder its resolution 260 9000 incr rev has to be input menu point 42422 Note To allow the acceptance of a change of the kind of encoder disengage and re engage the servoconverter Here the electric 0 position of the encoder can be adapted to the mechanical 0 position of the rotor commutation As far as possible this parameter should be in 0 position and the encoder adjustment should be made mechanically With LUST DriveTronics GmbH motors the encoder is already adjusted with the rotor position of the motor With 2 poles synchronous motors e g FLP 10 40 an offset of 180 has to be adjusted This value must be set to 0 as standard Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS 7 2 3 Reference selector 1 and 2 Setpoint channels Quick analog input 1 2 1 9 Preselection of an external current limit 2 2 9 7 Parameter setting Here the analog input is adjusted from w
90. stage enable Output stage Driver control 24V nam ek X 2 2 8 K A O Logik Output stage enable JUL 2 HH Safety relay Ls ii Relay off saf N elay off safety Fe GND 24V Relay on Enable Signal X 2 2 25 O 8v Fig 6 21 B12 011 Output stage inhibit Operation manual 6 30 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS Service hints 6 13 braking chopper 6 Electrical connections e Disengagement of the output stage enable causes an inhibit of the output stage The drive becomes currentless When switching the inhibit during operation the drive runs down uncontrolled e In case of emergency stop the output stage enable must be disengaged only provided that at first the drive has been stopped as quickest as possible e g by disengagement of the regulator enable e By ref command of the setpoints setpoint integrator enable or regulator enable it has to be assured that no unintended starting happens due to faulty switching stages contact load capacity of the outputs X2 2 Pin 24 and Pin 25 Imax 3A Umax 30 V DC AC Minmum power 50 mA 12V DC AC The braking chopper converts the brake energy generated in the drive into heat This is particularly necessary with quick braking processes with high masse moments of inertia An output resistor serves as convert
91. t circuits Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS EMV Go 3 4 Operation and maintenance 3 Safety information Servoconverter contain electrostatic hazardous components To avoid damage assure that the own body is electrically discharged before and during any works at the Servoconverter It is recommended to wear protective shoes or wrist bands Discharging of the own body by touching conductive earthed units only offers a short time protection against electrostatic breakdowns and destructions Servoconverter are components The manufacturer of the system or machine has to adhere to the EMC regulations Hints for EMC suitable installation lubrication cable conduct filter are given in the leaflet LUST DriveTronics GmbH EMV instructions No 180 00 000 The user must declare that he will only operate the Servoconverter in a proper condition at all times No independent conversions or changes such as would affect safety are permissible nor is the use of non original accessories components The DC link of the Servoconverter charges up to maximum 890 V in relation to the connected mains voltage This voltage is present at the output terminals L and L Servoconverter must be operated in closed condition only Operation without housing is forbidden Servoconverter may still have dangerous voltages for up to 6 minutes after disconnection residual capacitor charge Befo
92. th current and transfers the output into heat When falling below the threshold with a hysteresis the transistor interrupts the current supply to the resistor Note The voltage threshold is fixed to 820V The internal brake resistance is thermally monitored by a thermal switch After having exceeded a temperature of 80 C a fault is signalized The readiness for operation is disengaged and the LED 10 lightens see chap 9 7 LED 10 flashes Overtemperature brake resistance The loading of the internal or external resistor ballast is stated in the technical data see chap 2 1 Performance data The external resistor must not fall below a defined resistance value which is U DS 006 1 to U DS 020 1 U DS 035 1 U DS 045 1 Minimum resistance 30 Ohm 18 Ohm Table 6 10 Minimum resistance braking chopper _U DS 006 1 to U DS 020 1 U DS035 1 U DS 045 1 Connection of Terminal 4 and 6 Terminal B1 and B2 external brake remove link 5 6 resistances see Fig 6 1 page 3 see Fig 6 2 page 4 Table 6 11 Connection of external brake resistances Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 6 13 1Braking power calculation Effective braking torgue Brake output Average speed Effective brake output 6 Electrical connections Power loss 250 350W P elektr P mech x act Mot Rectifier FT Inverter A HH R P_mech MXN kw
93. th technological card 71 P Thread M8 tt ott Lust LUST D D e N D a N N 11066 i RE KA Zz GI DS Ji I D 2 D S i ZTN ZN DriveStar DriveStar I 0 ii J Ass 15 54 5 85 105 Preserve 100mm room height for cold air Fig 10 5 B11 006 Dimensions U DS 006 1 to U DS 020 1 Operation manual 10 6 U DS 006 1 045 1 05 03 2003 LUST 10 A Appendix DRIVETRONICS PP 10 3 2U DS 035 1 and U DS 045 1 Preserve 100mm room height for cold air x without technological card with technological card 141 olele 65 alee jeje I le Lust L LUST D D o o ED lt A LE 8 SAI oO A A d A JA Jen D S D u Drives Drives LT riveotar riveotar ulv I u v w alalo 6 5 alolo N 51 5 88 IT Q _ 258 _ E 155 len 175 _ Preserve 100mm room height for cold air Fig 10 6 B11 023 Dimensions U DS 035 1 and U DS 045 1 Operation manual 10 7 U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 10 A Appendix 10 3 3Mounting dimensions U DS 035 1 and U DS 045 1 for D C lin
94. tor EMC cable glands are recommended for the motor Operation manual 6 11 U DS 006 1 045 1 05 03 2003 LUST 6 Electrical connections DRIVET RONICS 6 3 4 D C link connection L L U DS 006 1 U DS 020 1 U DS 035 1 U DS 045 1 DI DID 2 L1 L2 L3 L1 L2 L3 0000 IG s i a Connection terminals I EI L R si L L for the T j L D C link 3 o l LED 1 to 10 i Fig 6 8 B11 012 D C link connection With mains feeding of 480 Volts a D C voltage of approx 680 volts 15 is connected to the terminals L L Danger In braking mode voltage peaks up to 890 V may occur The Servoconverter can also be supplied with a D C voltage of 325 volts 10 minimum up to 565 volts 10 maximum connected to the terminals L and L Operation manual 6 12 U DS 006 1 045 1 05 03 2003 LUST DRIVETRONICS D C linkage gt gt Pb 6 Electrical connections It is possible to connect converters of the DriveStar series not containing a mains unit such as e g A DS 1 to the D C link of the Servoconverter A DS 1 Note The connection of other unit types or makes is allowed only after having
95. tor and load should still be separated Caution Fix the motor to prevent it from making any uncontrolled and hazardous motion in case of a speed jump To that effect select the type of operation speed regulation in the menu parameters sub menu selection of type of operation Check the mechanical assembly of the servoconverter and the electrical connections In particular check whether the phase sequence of the motor connection has been adhered to the amplifier module has been connected safely to the blank mounting plate of the switch cabinet e the motor and data cable screens have been layed separately on the two screen terminals e all wire connections and connected sub D plugs are firm e the sensor cable has been connected correctly e the 24V supply has been connected correctly Caution Assure that the output stage enable is switched off Furthermore disengage the regulator and setpoint integrator enable Then the output stage enable can be made at terminal X2 2 Pin 8 The controller and reference integrator enables may be switched via terminal X2 2 Pin 7 and X2 2 Pin 10 and RS 232 e g via terminal program VecWin D DS_1 or a bus system Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 8 1 2 Engagement 8 1 3 Parameter setting with motor standstill 8 Commissioning Operation Note Assure that motions of the drive can be detected immediat
96. utput resp Here as well provide sufficient reserve in relation to the drive ratios at the machine In some special application cases e g theatre technics the switching noise of the servomotors is disturbing A considerable reduction of the switching noise is achieved by an increase of the switching frequency of the output stage Furthermore this measure improves the concentric run of the servomotor Frequency adjusted in the works 4 kHz Frequency adjusted in the works 14 kHz Adjustment via menu point 4 2 1 3 The increase of the switching frequency causes an output reduction of the Servoconverter Factors of the output reduction 4kHz 1 0 8kHz 0 8 10kHz 0 7 12kHz 0 6 14kHz 0 5 Max unit current to4kHz 2 0 X lhom for 1 0 sec to12kHz 1 8 X Inom for 0 5 sec Motor with resolver maximum 8 kHz Operation manual U DS 006 1 045 1 05 03 2003 LUST DRIVET RONICS 5 7 Mounting 5 8 Sensorcable 5 9 Motor conduct 5 10 Motor protection 5 Planning information The Servoconverter are designed for assembly into switch cabinets up to 300 mm The bore dimensions are stated in fig see chap 10 3 Dimensions for mounting On unit arrangement adhere to the following Assure free cooling air inlet outlet Provide minimum free spaces for air circulation of approx 100 mm above and under the Servoconverter do not cover the fan if mounted Provide minimum free sp

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