optional - Uwe Pophof - Antriebstechnik & Automation
Contents
1. 100 Made in Italy H NO JOINT GONSTRUGTION AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 1 POPHOF Antriebstechnik Tel 07821 983 913 Fax 07821 983 914 Funk 0171 80 38 472 Sch tzenstr 14a D 77933 Lahr Mail info pophof de www pophof de External regen resistance dimensions insertion Min Max bus voltage values insertion ver 1 rev 02 08 Ma bu wee van 9 Regen resistance set point values insertion Corrections All rights reserved Reproduction in whole or in part is prohibited without prior written consent of the copyright owner All specifications are subject to change without prior notification This manual has been carefully checked However Axor does not assume liability for errors or inaccuracies Print in Italy 02 2008 A THIS MANUAL CONTAINS A DESCRIPTION OF MiniMagnum AND A GUIDELINES FOR THE DRIVE S INSTALLATION FOR MORE DETAILS SEE ENCLOSURES ON THE CD PROVIDED WITH THE DRIVE USING THE DRIVE INCORRECTLY CAN INJURE PEOPLE OR MANAGE THINGS FULLY RESPECT THE TECHNICAL DATA AND INDICATIONS ON CONNECTION CONDITIONS Summary 1 Description 1 1 Description 1 2 General vievv MiniMagnum 1 3 Technical Data 1 4 Mechanical Dimension 1 5 Product plate and Ordering Code 2 Installation 2 1 General Advices 2 2 Positioning 2 3 Environmental conditions 4 Cables 5 Connection to ground and earth 6 Note about cable shielding 7 Base installation proc2. 845Vdc max External Protections fuses or similar Power supply F 4A 500V 6A 500V 8A 500V Time Lag Time Lag Time Lag Auxiliary power i 6A Time La ee External braking 10 AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 1 4 Mechanical Dimension Dimension in mm Weight Ka PS AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 11 1 5 Product plate and Ordering Code On the side of each MiniMagnum there is a product plate like the follow AXOR INDUSTRIES Tapi MINI MAGNUM CE AC BRUSHLESS SERVODRIVE Read the manual and follow the wiring and safety instructions before use Nominal and peak output current in Size 1 5 3 3 5 7 5 10 Ampere RMS Power Supply 3PH 3x380Vac 10 480 Vac 10 50 60 Hz grounded systems only Logic Supply 24 Voc 0 15 1 Apc 3 Anc with brake from insulating transformer Environmental A Ambient Temperature Protection CI Protection temperatu re Operating 0 45C at full performance EDTEGHLON GEES range Maximum 55C with derating IP20 rating A ELECTRIC SHOCK HAZARDS Disconnect power supply and wait 5 before working
3. Ref on function is disabled The digital input ENABLE is disa bled while the digital input set with the Ref on function is enabled The digital input ENABLE and the digital input set with the Ref on function are both enabled the mo tor does not move The rotor is turning in a clockwise or counter clockwise direction segment appears rotating in a clockwise or counter clockwise direction This appears when the negative lim it switch NSTOP is interrupted This appears when the positive limit switch PSTOP is interrupted This appears when the converter is correctly powered on the digital input ENABLE is disabled and there are no alarms This appears when there is the 24VDC auxiliary supply but not the main supply Ae 42 AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 3 2 Alarms The table below illustrates all the message errors SOLUTION EEPROM alarm Error while memorising parameter to the drive s EEPROM Overcurrent alarm Short circuit between U V W or towards earth Drive Temperature alarm Heat sink temperature too high gt 75 C Hall alarm This alarm comes on if one or more of the hall cell s wires are disconnected Encoder alarm This alarm comes on if one or more of the encoder channels are interrupted T t Drive alarm The internal It function has reached the maximum permitted The cause could be one of the follovving e the vvorking cycle could be t
4. 500mMA max AXOR Industries Service Manual MiniMagnum M ver 1 rev 02 08 27 28 2 13 Digital inputs connection DIGITAL INPUTS connection ins TM CN M1 MiniMagnum 24VDC refered to I O GND DGT IN2 DGT IN3 DGT IN4 1 O GND DGT IN RTN Note e The enable signal should be 24VDC 7mA PLC compatible The enable range is between 14V Min and 30V Max e The M1 8 terminal DGT IN1 ENABLE is used only as the drive s enable If M1 8 is HIGH 24VDC the drive is enabled without active alarms and if start up sequence illustrated on para graph 2 21 is respected if M1 8 is LOW OV the motor is without torque ATTENTION THE DRIVE S ENABLE DISABLE BY USING THE ENABLE INPUT IS NOT CONSIDERED A SECURITY FUNCTION e The M1 9 M1 10 M1 11 programmable inputs can be used to activate pre programmed functions of the drive for example limit switch electromechanical brake homing and positioning procedures emergency stop etc For a detailed description of the pre programmed functions see enclosure Speeder One Interface Additional Features Manual and Positioner Manual on the CD provided with the drive If there is the M3 connector OPTIONAL it provides five additional digital inputs and one of them is programmable e Connect pin M1 12 DGT IN RTN to the ground bar of the system AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 14 Analog and digital outputs connections
5. Base installation procedure 8 Example of base connection 9 Supply connections 10 Motor power connection 11 Regen resistance connections 12 Rel OK connection 13 Digital inputs connection 14 Analog and digital outputs connections 15 Analog inputs connections 16 Emulated encoder outputs connection 17 Pulse Dir inputs connections 18 Feedback signals connections 19 Multidrop connection 20 Canbus connection 21 MiniMagnum power up 22 Motor Test 2 1 General Advices During the transport of the drive respect the follovving indications e the transport must be made by qualified personnel e avoid shocks e the temperature range must be between 20 C and 55 C e the max humidity must be 95 without condensation e The converters contains elements which are sensitive to electrostatic discharges These elements can be damaged by careless manipulation Discharge static electricity from your body before touching the converter Avoid contact with material that insulates well synthetic fibres films of plastic material and so forth e we suggest to check the motor condition at its arrival to survey eventual damages The unused drives must be storage in an environment having the following characteristics e temperature from 20 C to 55 C e max relative humidity 95 without condensation e max time with the drive powered off without supply connections v drive having a power supply 220VAC gt 1 year v dr
6. DIGITAL OUTPUT Connection example CN O 24VDC refered to I O GND KA Max load for each output IN1 DIGITAL 50 mA Always use a relay with a diode in parallel I O GND 24VDC refered to I O GND O IN1 DIGITAL IN1 DIGITAL This digital output can be used to send messages from the pre programmed function of the drive For a detailed description of the pre programmed functions see enclosure Speeder One Interface on the CD provided with the drive If there is the M3 connector OPTIONAL it provides an additional digital output ANALOG OUTPUTS Connections They permit visualisation by oscillo scope of some of the drive s meas urement values MiniMagnum M1 The two outputs furnish 10Volt as the low scale setting refers to They can be set by the Speeder One interface Note We suggest to connect the shield on both sides drive side follow the indications illustrated on paragraph 2 6 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 29 2 15 Analog inputs connections ANALOG DIFFERENTIAL OR COMMON MODE INPUT Vref and TPRC connection DIFFERENTIAL MODE Vref MiniMagnum The technical characteristics of these inputs are as follows v Voltage 10V Max v Input impedance 40k ohm To change the sense of rotation apply the positive voltage reference to M1 2 or change the Rotary Direction parameter in the Speed window from Positive to Negative Not
7. E 7 ENCODER Drive side PTC INPUT Ji connector Sub D 25 pole rae 9 17 pole connector Sn t Encoder Motor Cable Note The ground connection of the external shield must be made on the zinc coated panel using a u clamp near the drive 20 50cm Motor side the shield is connected to connector s metal ring 20 50cm Max 25m oy TE otor AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 33 2 18 Feedback signals connections RESOLVER FEEDBACK connection OPTIONAL Motor side RESOLVER SIN INPUT COS INPUT Sub D 25 pole 12 pole connector Resolver Motor Cable Note The ground connection of the external shield must be made on the zinc coated panel using a u clamp near the drive 20 50cm Motor side the shield is connected to connector s metal ring 20 50cm Max 25m Drive Sr TR 707 34 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 19 Multidrop connection MULTIDROP connection OPTIONAL MiniMagnum 1 MASTER MODBUS a LI LI LI Ll O PGND J4 2 TXD I Ox DI 5 MiniMagnum 2 dc dc Converter Note e Connect the first MiniMagnum to the Master using the RS232 cable J4 connector connect each additional drive with to the drive preceeding it using the Can Bus cables and the J2 and J3 connec tors connect a RESISTOR 1
8. Indication of the drive s in rush phase or the lack of the main power supply AL2O AL23 Auxiliary Voltage Presence of the main supply L1 L2 L3 but the auxiliary 24Vdc voltage is miss ing Flash Alarm Errors in reading writing parameters on the Flash memory or Flash memory is empty Disable the drive check the Max Position Error parameter check the dynamic gains reset the alarm then enable the drive Disable the drive check the limit limit switches and external connections then enable the drive Power off the drive control the short circuit then power on the drive Disconnect the power e control the external connections e control the current absorption of the motor brake e verify the settings of the Holding Brake pa rameter on the Motor window then power up again Disable the drive connect the Auxiliary Voltage and then re enable Disable the drive save new values then re enable If the problem persists contact Axor AL24 Can Bus Alarm Disable the drive check the cabling and Error during communication on CANBus re enable If the problem persists contact Axor Homing Error Position error too high during the homing procedure The motor stops but it is not disabled AL26 Check the homing setup then reset the alarm using the Start Homing function You can find more information in enclosure Alarm Manual available in the CD provided with the drive AXOR Industrie
9. T Transport 14 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 Conformity European directives and norms The servodrives are components that are intended to be incorporated into electrical plant and machines for industrial use When the servodrive is used into machines or plant the electrical plant machine must respect the following directives EC Machinery Directive 98 37 EC EC Directive on EMC 89 336 EC Low Voltage Directive 2006 95 EEC The machine plant manufacturer must examine whether with its machine plant still further or other standards or EEC guidelines are to be used EC Conformity The EC mark that is applied to the drives references to the Low Voltage Directive 2006 95 EC and EC Directive on EMC 89 336 EC The standard EN 61800 5 1 is applied to ensure conformance with the Low Voltage Directive The standard EN 61800 3 is applied to ensure conformance with the EMC Directive In reference to noise immunity and noise emission the converters fulfil the requirement to the category second environment industrial environment If the installation of the drive is carried out differently than described in this manual the user must carry out new measures to satisfy the requisites of law AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 47 UNI EN ISO 9001 CERTIFIED N 9135 A Since XOR Re Motors SERVO prive AXOR INDUSTRIES viale Stazione 5 36054 Monteb
10. until the motor has cooled off reset the alarm then enable the drive Disable the drive e check the AC power supply input e check that the working cycles are not ex cessive e verify if the motor going at half speed shows the same problem Reset the alarm then enable the drive Disable the drive wait until the DC power supply voltage reaches the correct threshold check the AC power supply input then en able the drive Check the AC power supply input and the working cycles This is a visual alarm it an ticipates the intervention of the Maximum recovery alarm ver 1 rel 02 08 3 2 Alarms Resolver alarm Disable the drive control the resolver s contact AL12 f Missing resolver power supply signal reset the alarm then enable the drive Following Error The error between the position reference and the position feedback exceeds the Max Position Error parameter because the Max Position Error parameter is too small or the dynamic gains of the veloc ity positioning loop are wrong Limit Switch AL14 AL15 The two fixed limit switches have both been disabled or interrupted AL17 AL18 Overcurrent regen resistance circuit Possible short circuit in the regen resist ance circuit This causes the opening of the Rel OK contact and the disabling of the function ing Mechanical Brake Overcurrent at the internal brake com mand or wrong connections In rush Bus This is not an alarm
11. 20 Ohm 1 4W between pins 1 and 2 of the J2 or J3 connector of the first MiniMagnum and another resistor between pins 1 and 2 of the J2 or J3 connector of the last drive e Axor drives use MODBUS communication protocol specified in the Modicon instructions see http www modicon com techpubs For more information see enclosure Modbus Manual and CanOpen Reference Manual on the CD provided with the drive AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 35 2 20 Canbus connection CANBUS connection OPTIONAL MiniMagnum 1 CAN Server dc dc Converter MiniMagnum 2 dc dc Converter Note Connect a RESISTOR 120 Ohm 1 4W between pins 1 and 2 of the J2 or J3 connector of the last MiniMagnum 36 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 21 MiniMagnum power up The power up of the MiniMagnum must be done following this diagram in order to save the drive and the electrical box 1 Power the drive utilising the auxiliary supply 24VDC 2 After 1sec power the main supply 3 the Rele Ok contact closes 4 After 100ms it is possible to enable the drive utilising AUXILIARY SUPPLY MAIN SUPPLY RELE OK 24V DGT IN1 the Enable key or the DGT HARDWARE ENABLE ov IN1 digital input C It is possible to close the contact after auxiliary supply insertion setting the Closed when ready function in the General Settings wi
12. 485 INTERFACE using the RS485 interface AVAILABLE SOON It can be configured and controlled using CanBus It supports the following Can Open protocols btiohal e part of the DS301 V4 02 P e part of the DSP402 V2 0 Notes e The current controller is vectorial with sampling time of 62 5us The velocity and position loop both work with sampling time of 250us e The current commutation is sinusoidal FEEDBACK ENCODER incremental encoder signals plus hall signals RESOLVER AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 1 1 Description DIGITAL INPUTS OUTPUTS They are programmable for the limit switch the holdingj 4 standard brake the homing and positioning procedures the emer gency stop the reset alarm etc 5 optional 1 standard 1 optional There are 6 pins dedicated to emulated encoder with EMULATED ENCODER different programmed ratios 1 2 1 4 1 8 1 16 1 32 standard OUTPUTS 1 64 1 128 between output pulse rev and encoder 9 programmable DIGITAL INPUTS 2 programmable They can be used to send messages from pre programmed DIGITAL OUTPUTS functions of the drive resolver ones ANALOG INPUTS OUTPUTS 1 ANALOG COMMON MODE It is used for controlling the current from the drive standard INPUT TPRC 1 ANALOG DIFFERENTIAL or It is used for piloting the drive with an analogue speed t ndard COMMON MODE reference from an external controller sancar INPUTS Vref They a
13. ATIVE MODES It is speed piloting utilising a digital reference or an SPEED CONTROL analogue reference differential or common mode standard It is torque piloting utilising a digital reference or an TORQUE CONTROL analogue reference This function allows you to control the standard current from the drive The positioner can be managed via hardware by using the digital inputs or via RS232 by using the Axor s Speeder One interface or another ModBus Master It supports 32 programmable position profiles a single task or a sequence POSITION CONTROL of tasks are permitted standard The Homing Procedure is implemented It uses the signal coming from the homing sensor and eventually the zero signal of the encoder It is possible to pilot the drive with the quadrature signals ELECTRICAL AXIS of an emulated encoder from a Master drive or with the anal GEARING quadrature signals of an incremental encoder from a Master p motor Electrical Axis or Gearing It is possible to connect the drive to a stepper motor PULSE DIRECTION controller piloting it with the Pulse and Dir signals optional Pulse Dir Mode It can work in Multidrop where the first drive connected via RS232 to the Master PC is piloted with ModBus gt MULTE ROE RS232 communication while the other drives are piloted with the optional duplication of commands using the CanBus interface It is possible to communicate with two or more drives by optional RS
14. During the storage and the installation respect the followings environmental conditions Condizioni ambientali From 0 C to 45 C no derating Working environmental temperature From 45 C to 55 C the drive must be derated 2 5 C in reference to nominal and peak current Humidity From 10 to 85 Up to 1000m without restriction From 1000 to 2500m of altitude the converter must be derated in the output current of 1 5 every 100m Enclosure protection IP20 LEVEL 2 Norm EN60204 EN50178 The drives are designed to be utilized in an electrical box protected against the infiltration of polluting agents such as water oil conductive dust and others Pollution level Notes e The electrical box must have suitably filtered air vents Leave the necessary space both above and below the converters e Periodically check drive case and fans for excess dust or dirt that could interfere with the correct dissipation of the drive 18 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 4 Cables The following table illustrates the technical characteristics of all cables Cables as norm EN60204 Notes O forthe Always insert a power relay or a thermal a 1 5mm 15AWG magnet on every phase of the products power Main Supply supply for the Auxiliary 1 5mm 15AWG Supply for the E Motor s Brake 0 75mm It must shielded It must be shielded Connect the OV of the auxiliary supply to the ground bar f
15. OR Industries Service Manual MiniMagnum ver 1 rev 02 08 25 2 11 Regen resistance connections REGEN RESISTANCE connection INTERNAL resistance a T MiniMagnum M5 The value of internal resistance is 66 ohm 100W It is not necessary any connection EXTERNAL resistance TM MiniMagnum M5 OPTIONAL It is possible to use one external resistance 66 ohm 500W or two external resistances 33 33 ohm 500W The cable must be as short as possible The resistances must be connected to the zinced pannel utilising two screws If the cable length is greater than 20 30cm it must be twisted and shielded The shield must be connected to ground on both ends utilising u clamps to the zinced panel of the electrical box Notes e The temperature of the zinced panel of the electrical box can be higher than 200 C e Do not mount the resistor on surfaces which can be damaged by heat e If the resistors are mounted externally protect them e Respect the distances and shieldings illustrated in Fig 1 e External regen resistance has dimesions illustrated in Fig 2 260mm A 400mm Fig 2 Fig 1 26 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 12 Rele OK connection RELE OK connection MiniMagnum M1 015 DIN 016 It is normally open when the drive is not supplied it is normally closed when the drive is supplied and it has not active alarms 3OVAcIDC
16. Outputs M1 connector Analog and Digital Inputs Outputs Rel OK 34 connector RS232 comunication M2 connector Emulated encoder outputs 31 connector 32 33 connectors OPTIONAL Feedback motor signals CanBus RS485 encoder resolver comunication M4 connector Auxiliary supply 24Vdc Safety Enable Function AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 9 1 8 Technical Data Nominal Data Nominal Voltage Vac Three phase 3x480Vac 10 max 3x380Vac 10 50 60Hz Single phase permitted for setup only Mix Max bus y 380Vac 480Vac voltage 400Vdc min 800Vdc max 500Vdc min 870Vdc max Auxiliary power supply for back up E 557 10 ams 1s fs OC 5 2 sec frequency Control signals Optoisolated digital inputs 24Vdc 7mA PLC compatible Optoisolated digital outputs 24Vdc 50mA PLC compatible Analog programmable outputs 10V 5 C d d 24Vdc 0 15 1Adc 3Adc with brake Analog common mode input TPRC 10V max 20kOhm input resistance Analog differential or common input Vref 10V max 40kOhm input resistance Pulse Dir digital inputs 5V optoisolated max frequency 250kHz Von 2 5V min I 20mMA Emulated encoder outputs V 0 5V max I 20mA Braking Resistance 100W 66 ohm 500W 66 ohm External Resistance 1000W 33 ohm 33 ohm 500W 380Vac 480Vac Set point values E 7 695Vdc min 735Vdc max 815Vdc min
17. ad to the motor 2 Install Speeder One interface from CD 3 Power up the drive apply the auxiliary supply and then the main supply follow the procedure previously described 4 Open the Speeder One interface clicking on Axormb exe executable file on directory C Pro gramm Axor The main window Axor Servo Drive and the Select Driver windows open simul taneously On the Select Driver window insert the drive s address all drives have 1 set as default value then click OK Axor Servo Drive File Users Settings Drive Tuning About amp cj Ej noi E T Profile Tool g Decibscopej General Set I Hide Status x r Drive Status Motor Speed 00000 RPM OP MODE Main Voltage Motor Position 010 0 deg 1 Digital Speed i ea 230v i Motor Curent 00000 Jo a E Digital 1 0 mm e re Speed Current Analog 1 0 a m Analog Outi ard Select Driver x Speed pm 00000 Encoder Out Insert ID fl p Analog Out2 fig x 00000 Homing Off Line Ok Homing Method Sensor O No Homing x I Zero Encoder I den Acceleration Speed Zero Speed Homing Offset m Pm pulses Alarms X Present Drive SS Enable F1 CTRL F1 User Normal Port Comi IdDevice 001 Status Online Dev File 4 5 If the drive is Not configured it is necessary to open a pre set connfiguration file following this procedure in the main windo
18. e We suggest connecting the shield on both sides drive side follow the indications illustrated on paragraph 2 6 COMMON MODE TPRC CN MiniMagnum TORQUE REFERENCE The technical characteristics of TPRC input are as follows v Voltage 10V Max v Input impedance 20k ohm Note We suggest connecting the shield on both sides drive side follow the indications illustrated on paragraph 2 6 30 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 16 Emulated encoder outputs connection EMULATED ENCODER OUTPUTS connection LINE RECEIVER CN inputs MiniMagnum COMMON MODE CN inputs MiniMagnum Note We suggest connecting the shield on both sides drive side follow the indications illustrated on paragraph 2 6 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 31 2 17 Pulse Dir inputs connections PULSE DIRECTION MODE connection OPTIONAL Logical signal 0 5V MiniMagnum CN PULSE Note We suggest connecting the shield on both sides drive side follow the indications illustrated on paragraph 2 6 ELECTRICAL AXIS GEARING Connection OPTIONAL MiniMagnum MiniMagnum Slave M3 M2 Master Note VVe suggest connecting the shield on both sides drive side follovv the indications illustrated on paragraph 2 6 32 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 18 Feedback signals connections ENCODER FEEDBACK connection Motore side
19. e To reduce the capacitive and inductive coupling these cables must be run keeping a distance of more than 30cm from the power cables 10 cm if they are shielded e If it is absolutely necessary to cross the control cables with the I O s do so at 90 in order to reduce the effect of the magnetic fields Motor cables The shield of the motor cable power and signal cables are connected as follows e drive side 20 50cm gt remove the outside sheath and fix shield to the zinced pannel by using a u clamp B POWER CABLE e motor side gt The shield is internally connected to the metal ring of the motor connector thus to earth through the motor s carcass AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 21 22 2 7 Base installation procedure This procedure must be done only by qualified personel which are familiar with drives If you need more information contact Axor a Power off all the supplies of the electrical box b Verify v the drive motor coupling gt the stall current I of the motor should be equal to or greater than the nominal output current of the drive vy the positioning of the drive into the electrical box v the pollution level and the ventilation v the connection to earth of the electrical box where the drive is installed see 2 5 Connection to ground and earth c Execute the wiring following this order avoiding that wiring s pieces cables wires screws conduc tive object
20. e technical field for the installation and operation of servodrives Using the drive incorrectly can injure people or damage things Fully respect the technical data and indications on connection conditions e As well as the points described in this manual current regulations regarding safety and accident prevention must be followed in order to prevent accidents and residual risks The installer must be familiar with and observe the following norms and directives IEC 364 and CENELEC HD 384 or DIN VDE 0100 IEC Report 664 or DIN VDE 0110 national accident prevention dispositions or BGV A2 e The user must analyse possible machine risks and take the necessary measures to avoid injuries to people and damage to things because of unpredictable movements e The converters contains elements which are sensitive to electrostatic discharges These elements can be damaged by careless manipulation Discharge static electricity from your body before touching the converter Avoid contact with material that insulates well synthetic fibres films of plastic material and so forth e During operation the converter surface can become hot Protect the user from accidental contact and keep the indicated distances from all objects e Never loosen electrical connections while the servoamplifiers are being powered The appropriate terminals of the drive must always be connected to earth as instructed in this manual After having disconnected the conv
21. edure 8 Example of base connection 9 Supply connections 10 Motor power connection 11 Regen resistance connections 12 Rel OK connection 13 Digital inputs connection 14 Analog and digital outputs connections 15 Analog inputs connections 16 Emulated encoder outputs connection 17 Pulse Dir inputs connections 18 Feedback signals connections 19 Multidrop connection 20 Canbus connection 21 MiniMagnum power up 22 Motor Test NNNNNNNNNNNNNNNNNNN 3 Diagnostic 3 1 Display 3 2 Alarms Index Conformity AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 42 43 45 47 3 Enclosures to the manual On the CD provided with the drive there are the following enclosures in pdf e Operative Modes Manual e Additional Features Manual e Speeder One Interface e Positioner Manual e Display and Keypad Manual e Alarms Manual e ModBus Manual e CanOpen Reference Manual e Cable Manual e Oscilloscope Manual e Procedures Manual available only on request 4 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 Chapter 1 Description 1 1 Description 1 2 General vievv MiniMagnum 1 3 Technical Data 1 4 Mechanical Dimension 1 5 Product plate and Ordering Code 10 12 6 1 1 Description The MiniMagnum is a digital drive capable of piloting both rotary AC brushless motors and linear motors up to 7 5Nm It can be supplied by a 3 phase voltage equal to 380 or 480Vac OPER
22. ello Vic Vicenza Italy phone 39 0444 440441 fax 39 0444 440418 info axorindustries com www axorindustries com D lo o ANTRIEBSTECHNIK amp AUTOMATION Postfach 1967 D 77909 LAHR Sch tzenstr 14a D 77933 LAHR Tel 07821 98 39 13 Fax 07821 98 39 14 Funk 0171 80 38 472 Mail info pophof de www pophof de v CERTIACAZIONE DEI SISTEMI DI QUALITA DELLE AZIENDE UNI EN ISO 9001 CERTIFIED
23. erters from the supply current always wait at least 5 minutes before touching the powered components e g contacts or loosening connections e Switch off the converter and wait at least 5 minutes before opening it Remove the fuses or switch off the main switch before removing the drive When opening place the converter on a surface that does not belong to the electrical panel e The residual charges in the capacitors can remain at a dangerous level for up to 5 minutes after dis connection from the mains Measure the voltage at the intermediate circuit AT AT and wait until it is below 15V e The command and power connections can still hold current even when the motor has stopped e The MiniMagnum is equipped with electronic protections that deactivate it in case of irregularities The motor as a result is not controlled and can stop or go into neutral for a time determined by the type of system e During installation avoid letting any residue with metallic components fall inside the drive AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 15 2 1 General Advices e Protect the converter from excessive mechanical vibrations in the electrical box e Check that the main supply and the nominal current are coherent vvith the rating of the drive Be sure that the voltage between the connectors L1 L2 L3 is not greater than 10 of the nominal values An excessively high voltage causes the breakdown of the load circuit
24. hermal magnet on every phase of the products power supply e If a power supply between 380V and 480V is utilized and ground protection is not present or there is an asymmetrical grounding system an isolation transformer is required The nominal power of the transformer is calculated by adding the various wattage of each mo tor Pt Pn Pn Pn Pt nominal power of the transformer VA Pn nominal power of each motor VA which can be calculated in this way Pn n x Cn 9 55 Pn nominal motor power W n motor speed rpm Cn motor nominal torque Nm 24 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 10 Motor povver connection MOTOR POVVER t MOTOR HOLDING BRAKE VVITHOUT brake MiniMagnum M6 see note b M7 0 1 NC O 2 NC 3 NC WITH brake MiniMagnum ug OPTIONAL see note a ye oy E e A u 1 I LI 1 LI 1 i I LA I LA Technical characteristics of brake outputs 8 v Output Voltage 24VDC 0 15 FIT v Maximum available current 3A see note b Note a Use 3x1 2mH 20Arms filter series for connections vvith cables longer than 20725 meters b The earth connection of the power cable s shield must be made on B POWER CABLE the zinc coated panel using a u clamp near the drive 20 50cm Motor side the shield is connected to connector s metal ring so it is connected to ground through motor s carcass AX
25. inside AXOR INDUSTRIES phone 39 0444 440441 www axorindustries com No joint Construction MADE in TALY The Part No gives others descrip tive codes about the drive and the settings To order a digital drive serie MiniMagnum refer to this ordering code MM400 3 5 7 RXX S RO 00000X 0X SXXX Specific number presence opt Drive Model S Xxx T 001 999 specific number Size 1 5 3 3 5 7 5 10 Expansion cards 0X T Not in use Holding Brake Drive iti 1 Present opt Additional features 00000X O Not Present std Protection S Standard L Not in use T Tropicalized Additional Connector M3 1 Present opt Feedback O Not Present std RO Resolver EC Commutation encoder SEF Safety Enable Function ER Commutation encoder or resolver both 1 Present opt 0 Not Present std RXDB Black Out Dynamic Brake CBMD CanBus Multidrop Interface 1 Present opt 1 Present opt 0 Not Present std 0 Not Present std Dumping size RXX Internal standard resistor RO5 500W 662 External resistor opt R10 1000W 330 33Q 500W External resistors opt R485 RS485 Interface 1 Present opt O Not Present std 12 AXOR Industries Service Manual MiniMagnum ver rel 02 08 Chapter 2 Installation 1 General Advices 2 Positioning 3 Environmental conditions 4 Cables 5 Connection to ground and earth 6 Note about cable shielding 7
26. ive having a power supply lt 145VAC 200VDC gt 2 years After this time before enable the drive it is necessary activate the capacitors following this procedure remove all electrical connections then supply the input terminals of the supply with the main voltage three phase or single phase for 30 minutes In details for the drive having a power supply equal to 380VAC power it by using a single phase or three phase supply equal to 220VAC for the drive having a power supply equal to 220VAC power it by using a single phase or three phase supply equal to 110 130VAC In order to avoid this procedure we suggest to power on the drive with its rated voltage for 30 minutes before the max time is reached Maintenance The drives does not need maintenance Otherwise e if the casing is dirty clean it with isopropanol or similar e if the drive is dirty the cleaning is reserved to the producer e if the fans are dirty clean them by using a dry brush The disposal should be carried out by a certified company 14 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 1 General Advices Security standard e This manual is exclusively addressed to technical personnel with the following require ments Technician with knowledge on movimentation of elements sensitive to electrostatic discharges for the transport Technician with appropriate technical training and with vast knowledge on electrotech nics driv
27. l SAFETY The converter is protected from short circuitry the Max Min Voltage the drive Ft the Motor I t etc SAFETY When there is an alarm the Rel OK contact opens and thej standard motor is stopped or a message is visualised on the display without compromising the system s functioning optional AVAILABLE SOON BLACK OUT optional DYNAMIC BRAKE It stops the motor when there is a black out AVAILABLE FUNCTION SOON SAFETY ENABLE It is a safety function which avoids the accidental startup of FUNCTION the motor in the absence of 24Vdc on indicated pin EQUIPMENT a drive serie MiniMagnum terminals M1 M2 M4 M5 M6 Service Manual standard a CD ROM with Speeder One software interface and all enclosures to service manual terminals M3 M7 Motor inductance 3x1 2mH for cables over 20 25 meters in length an external braking resistor 5 2 optional CBLS cable for motor feedback signal encoder resolver meter multiple CBLS power cable for motors series SuperSAX motors series SuperSAX All optional features have to be requested by using the proper ordering code see 1 5 Product plate and Ordering code AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 1 2 General vievv MiniMagnum M5 connector Power supply Regen resistance M6 connector Motor supply M7 connector OPTIONAL Holding brake drive Display and Keypad M3 connector OPTIONAL Analog and Digital Inputs
28. llow you to visualise by the oscilloscope some of the 2 programmable ep i drive s measurement values for example the velocity the standard ANALOG OUTPUTS Iq current etc GENERAL FEATURES Four buttons UP DW MODE SET allow the manual KEYPAD insertion of data without using a PC A display with 3 characters visualises the inserted DISPLAY values the drive s status the alarms The Axor Speeder One interface allows you to set and man age all drive s parameters It uses a PC connected to the drive and the communication SPEEDER ONE between the drive and PC is done by a RS232 cable using SOFTWARE the ModBUS protocol standard INTERFACE E The software works on the following operating systems Windows 98 Windows 2000 Windows XP AXOR Industries Service Manual MiniMagnum ver 1 rel 02 08 7 8 1 1 Description The drive has circuitry that allows the control of the elec tromechanical brake integrated in the motor which can HOLDING BRAKE ee with motor not running for blocking the motor s optional The drive supplies the brake with 24Vdc It can be exter nally managed by the user or automatically by the drive The drive is equipped with an integrated EMI anti distur EMI bance filter at the 3 phase power supply input and with Seanad FILTER another EMI anti disturbance filter at the auxiliary 24V power supply input REGEN Circurv TT standard EXPANSION CARDS me a slot for expansion card to implement additiona
29. meter on the Analog OUT1 menu c Connect the probe of the oscilloscope on pins AN OUT1 speed signal and AGND zero sig nal d enable the drive e Adjust the KP and KI gains in a way that you obtain a stable step response in both directions Increasing KP decreases the system s response time however the system gets closer to becoming unstable therefore during adjustment increase the KP to the oscillation limit and then reduce until secure oscillation stoppage Increasing KI the steady state diminishes however increasing the overshoot therefore after adjust ing KP increase KI keeping the overshoot within authorized limits 410 The figure below illustrates some typical oscilloscope tracks A Proportional and integral gains too low Increase the numerical values of KP and KI B and C Good proportional and integral gains Speed 9 At this point it is possible to set other parameters in reference to the desired operative mode see enclosures Operative Modes Manual Additional Features Manual Speeder One Interface available on the CD provided with the drive AXOR Industries Service Manual MiniMagnum M ver 1 rev 02 08 39 40 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 Chapter 3 Diagnostic 3 1 Display 3 2 Alarms 42 43 3 1 Display A display LED visualises the drive s status the inserted values the alarms The digital input ENABLE is enabled while the digital input set with the
30. ndow of the Speeder One interface Attention If the DGT IN1 ENABLE digital input is enabled by the CN before powering the drive A after powering the drive utilising the auxiliary supply and the main supply it is necessary disable and enable the DGT IN1 input B in order to enable the INTERNAL ENABLE If the DGT IN1 is not disabled then re enabled the INTERNAL ENABLE remains disabled and the user cannot execute any movement Attention If the digital input DGT IN1 ENABLE is enabled by the CN after powering the drive utilising the auxiliary supply but before powering the drive utilising the main supply C it is necessary to disable and then re enable DGT IN1 input D in order to enable the INTERNAL ENABLE also If the DGT INI is not disabled then re enabled the INTERNAL ENABLE remains disabled and the user cannot execute any movement DGT IN1 24V HARDWARE ENABLE ov INTERNAL ENABLE AUXILIARY SUPPLY ON MAIN SUPPLY OFF DGT IN1 24V HARDWARE ENABLE ov INTERNAL ENABLE T 24V AUXILIARY SUPPLY ov T ON MAIN SUPPLY OFF AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 37 2 22 Motor Test This procedure is a guide line for the first povver up of the drive motor system It must only be exe A cuted by technically qualified personnel If you need more information contact Axor 1 Follow the basic procedure previously described ATTENTION do not apply lo
31. oo heavy e a possible mechanical block e motor phase inversion e the electronic brake is not unblocked e the amplifier s dynamic costants KP KI and KD could create useless cur rent oscillation Motor Temperature alarm Heat sink temperature too high This causes the opening of the Ok Rel con tact and the disabling of the functioning Regenerative Resistance alarm The value It energy recovery has reached the maximum allowed Min Max Voltage alarm Minimum or maximum converter voltage Pre Alarm Recovery alarm 80 of the I t energy recovery value has been reached AXOR Industries Service Manual MiniMagnum Disable the drive try to memorise the pa rameter then re enable Disconnect the povver verify the vviring then povver up again Disable the drive verify e the forced ventilation functioning e the ambient temperature vvait until the radiator has cooled off reset the alarm then enable the drive Disable the drive verify the cell s vvire con nection reset the alarm then enable the drive Disable the drive control the connections reset the alarm then enable the drive If the alarm persists contact Axor This does not cause the disabling of the drive s functioning Disable the drive e control the heat sink temperature e decrease the dynamic constant if the motor is vibrating This situation causes current oscillation and consequently the overheating of the motor Wait
32. or the It must have a capacity of lt 150pF m 2 Motor s Power 1 5mm 15AWG In the configuration without filter the cable can reach a maximum length of 20 25m If the length exceeds 20 25m insert an Axor 3x1 2mH filter for the Control signals and 0 5mm 20AWG See 2 6 Note about cable shielding I O signals from PLC CNC for the 0 25 0 35mm Encoder signals 22 24AWG It must be shielded for the 0 25 0 35mm It must have a capacity less than 120pF m Resolver signals 22 24AWG for external 2 The length of the cable must be equal to or less than 2 5m for the RS232 0 22mm 24AWG or communication 0 34mm 22AWG It must be connected when the main supply and the auxiliary supply are both powered off It must have a capacity less than 160pF m Cable capacitance max 60 nF km Impedance characteristics 100 1200 for the Lead resistance loop 159 8 Q km CanBus 0 25mm 0 34mm communication The length depends upon the transmission speed e 1000kbit s gt 20m max e 500kbit s gt 70m max e 250kbit s 115m max Note e Avoid crossing overlapping and twisting cables together If it is absolutely necessary to cross them do so at 90 e On request Axor provides motor signal cables series encoder or resolver for motors series Super SAX AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 19 2 5 Connection to ground and earth Make sure that the servodrive and the motor are connected to earth in acc
33. ordance with the current norms This connection must be done by using a copper bar mounted on insulating supports e a Ground bar PE SONE tonte earth then follovv these indications 1 Connect to the ground bar v the earth power terminal of the drives v the CHASSIS of all drives v the DGT IN RTN pin of the digital inputs for each drive v the OV of the auxiliary supply v the internal zero voltage of the CNC v the earth terminals of the PLC CNC frames 2 Connect the ground bar to the zinced panel of the drive by using a screw then connect that screw to earth 3 Connect earth to the motor s carcass aa It suggests a conductive connection as much as possible to the chassis or the heat sink or the mounting panel of the electrical box It refers to the earth connection It refers to the connection of the shield to the drive s carcass as illustrated on page 21 It refers to the connection of the shield to the connector s metal ring 20 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 6 Note about cable shielding Control signal cables The conductor of the analogic signal must be twisted and shielded and the shield must be connected to ground as illustrated below gt f re SOSSOSSSSSSST POOOQOOPESPOSVES Remove the outside sheath and affix the shield to the dedi cated retainer rings by using plastic clamps POQOS S a MANAHI Note
34. rive and the motor In the following page there is an example of a basic connection AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 8 Example of base connection Example of BASE connection RS232 Sy rn Cap 2 19 and 2 20 5 6 Cap 2 14 7 rh Motor B p P DGT IN1 ENABLE Mi feedback _ LUI DGT IN2 7 E MI Cap 2 18 a Il U DGT IN3 i DGT IN4 n 12 DGT IN RTN 13 DGT OUTI Cap 2 14 DGT OUTI RTN RELE OK RELE OK 4 30Vac Dc 500mA max V Cap 2 12 Holding Brake OPTIONAL M3 PULSE PULSE DIR DIR DGT OUT2 DGT OUT2 RTN DGT IN5 DGT IN6 DGT IN7 DGT IN8 DGT IN9 DGT IN RTN Cap 2 9 L2 UIR 2 7 2 11 ap 7 Safety Enable Function OPTIONAL 4 0 oV 1 Auxiliary oA 2 voltage Cap 2 9 24VDC Cap 2 13 PE MAIN EARTH AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 23 2 9 Supply connections AUXILIARY SUPPLY 24Vdc MiniMagnum M4 ge 3PH 50 60Hz 230 480Vac Note e Accepted voltage 24VDC 0 15 e current required for the external supply 3A motor with brake e current required for the external supply LA motor without brake e we suggest to insert the F 6A T fuse e Remember to connect the OV of the external supply to the ground bar POWER SUPPLY MiniMagnum M5 3 PE 50 60Hz 380 480V Note e Always insert a power relay or a t
35. ry and of the drive e The MiniMagnum is equipped with an integrated EMI anti disturbance filter at the 3 phase power supply input and with another EMI anti disturbance filter at the auxiliary 24V power supply input Being implicit to filter operation the deviation towards earth or mass of the undesired frequencies ensure that these devices can produce leakage currents towards earth which are measurable in mil li mpers Please remember that leakage currents must be considered when settings differential devices in order to avoid useless interventions For safety reasons connect the prepared terminal to earth before powering the drive Incorrect con nections make filter operation unreliable 16 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 2 Positioning The MiniMagnum is made to be fixed vertically to the bottom of the electrical box in order to guarantee reliable cooling respecting the following distances Zinced panel Cable duct 20 Cable duc Dimensions in mm Note Arrange the power components converters main s filters resistors terminals in bins of the electrical panel different from those reserved to the command or control systems PLC PC CNC regulators This improves the level of immunity to interference of the system AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 17 2 3 Environmental conditions
36. s etc do not enter into the drive through its slits 1 First connect earth 2 Connect the cables for the motor s power U V W and the filter 3x1 2mH if the cable length is greater than 20 25m 3 Connect the earth of the motor s power PE and if necessary connect the cables of the electromechanical brake 4 Connect the external shield of the motor s cable it must be shielded utilising a u clamp to the zinced panel of the electrical box see 2 6 Note about cable shielding 5 If an external braking resistor is used connect it between pins R and R by using a cable as short as possible If the cable length is greater than 20 30 cm the cable must be twisted and shielded besides the shield must be connected to ground on both ends utilising u clamps to the zinced panel of the electrical box 6 Connect the motor s feedback cable to the drive s J1 connector 7 Connect the main power supply cable L1 L2 L3 and the earth cable PE Always insert a power relay or a thermal magnet on every phase of the products power supply 8 Connect the auxiliary supply cable 24V Use an external power supply that must be stabilized and galvanically isolated from the main supply 9 Connect the PC to the drive utilising the RS232 cable 10 Supply the drive with the auxiliary supply and then main supply following the procedure illustrated at the end of the chapter 11 Open the Speeder One interface 12 Execute the tests on the d
37. s Service Manual MiniMagnum ver 1 rel 02 08 Index A Alarms 43 analog common mode input TPRC 7 10 30 analog differential or common mode inputs Vref 7 10 30 Analog outputs 7 10 29 Auxiliary supply 24Vdc 24 B Braking Resistance 10 C Cables 19 Canbus connection 36 Conformity 47 Connection to earth 20 Connection to ground 20 D Digital inputs 7 10 28 Digital output 7 10 29 Display 7 42 Disposal 14 E EMI filter 8 emulated encoder outputs 7 31 encoder connection 33 Environmental conditions 18 equipment 8 Example of base connection 23 Expansion cards 8 External Protections 10 G General view 9 H Holding brake 8 I installation procedure 22 K KeyPad 7 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 45 46 Index M Maintenance 14 Mechanical Dimension 11 Mechanical specifications 11 Motor holding brake 25 Motor povver 25 Multidrop connection 35 N Nominal Data 10 O Operative Modes 6 CanBus 6 electrical axis 6 multidrop RS232 6 position control 6 pulse direction mode 6 RS485 interface 6 speed control 6 Torque control 6 Ordering code 12 P Positioning 17 Power supply 24 Product plate 12 Pulse Dir digital inputs 10 32 R Regen resistance 26 Rele OK 27 resolver connection 34 S Safety 8 black out dynamic brake function 8 safety enable function 8 Security standard 14 15 Shielding 21 Speeder One 7 Storage 14
38. w select the File menu and then Open in the directory Axor Data Devices select a file reference to the coupling drive motor then click on Open save load parameters by using Save Data To EEPROM icon If the drive is configured for a specified motor it is sufficient to check these parameters v Main voltage Main Voltage menu in the main window of the interface v Number of motor poles Motor window v Feedback type Motor window v Encoder impulse rev or resolver n of poles Motor window v Irms current Current window v Ipk current Current window v Speed Limit Speed window 38 AXOR Industries Service Manual MiniMagnum ver 1 rev 02 08 2 22 Motor Test 6 If alarms should appear resolve them before going forvvard see chapter 3 7 Set the operative mode 1 Digital Speed set a speed reference equal to 100rpm enable the drive vvith the Enable button If shaft turns correctly at teh set speed without alarms it is possible to connect the load and cable the machine possibile procedere con il collegamento del carico e con il cablaggio della macchina at teh contrary if alarms should be compare or if the behavior should not be as set we suggest to control te connections and the settings eventually contact Axor 8 Connecting the load to the motor it shoul be necessary to connect gains of speed loop following this procedure a set the 10 Square wave operating mode b Set the Speed_RPM para
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