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1. Fig 3 2 The interior wiring block diagram of DAP01 drive unit 14 3 phase 380V 12 ITI ches th 50 60Hz ja Interference filter PE o 117 T Brake 5 Rectifying P feedback Reversing module module G O y lt E 8 i R U 3 KM1 R IU r e oN o R e Lo OUT R SC o y S eel T a o PEL D ka A PE 380V SS Oe TEE p A z Spindl a 21V 220V Bus voltage sampling pindle servo grounding canas motor Relay b drive PWM drive e oT oH R Relay Overvoltage Pumping voltage Braking IPM Current lt drive detection detection triggering alarm detection y Interface circuit of power board ak Radiation i 2 fan ZS GI Motor KE ffer CN2 By Interface circuit of control board PWM buffe 8 encoder WwW g Current detection 5 5 e 7 Sr E S Q A D E o o zo O Gries convertion 288 Se 5 A SP A 568 CN3 pe o O O DSP chip a 3 s O 5 OOO Speed operatorn CPLD logic chip D d Pos AC BE Monitor panel EE REG Encoder feedback output PWM pulse control Encoder feedback signal p and other controls processing Storage Alarm signal processing CNI Input or output points unit AID convertion Analog filtering and amplified Analog command input circuit EMC 3 IPM control power circuit DC DC convertion 5V of GND switch gt 15V power on m 15V Power off 7 Power on REN KM1 KM1 Surge inhibitor CH
2. 347 330 312 lt OO gt Weg t DOR JAD 8 gt GSK CNC EQUIPMENT CO LTD ZE 4 7 160 26 e NY sika _ Air inlet Air outlet 8 3 Yj Y i ASSENS Up gt 100mm Down N Fixing clearance for single drive unit 6 CHAPTER 2 INSTALLATION AND SPECIFICATION gt 150mm Fixing clearance for multiple drive units Multiple units should only be fixed side by side for a better heat dissipation Keep the drilling swarf wire ends etc out of the drive unit during the cabinet installation Keep the oil water metal material etc in the cabinet from entering the drive unit during its using In the place that harmful gas and dust exit do ventilate the cabinet by clean air to prevent them from entering the cabinet Brake resistances can only be installed beside the drive unit and they are not allowed to be installed up and down GSK CNC EQUIPMENT CO LTD 2 3 Dimensions and Installation of Brake Resistance Dimensions of brake resistance Output Brake capacity of resistance Brake s Installation dimensions mm drive unit resistance g l oe O TT ER 356 300 95
3. gt For stable motor running characteristic by improving the power factor o A Used to switch on off spindle servo unit power please install surge inhibitor in using s Don t touch the brake resistance for its high R I a Energy consumption temperature by discharging x brake resistance J GSK CNC EQUIPMENT CO LTD 3 2 The Interior Wiring Block Diagram of DAPO01 Drive Unit External brake resistance
4. Posttioning 4L L L Positioning encoder pulses 4L Positioning encoder pulses by 4 frequency There isa angular error for spindle positioning center in actual positioning so the minimum positioning precision of this DAPO1 drive unit can reach 2 9 The positioning precision can also be expressed by the minimum arc of the positioning circle connected with the spindle or the chord of the minimum arc in practice e g positioning drill on the outer circle of the round part in a lathe the tool setting of machine center and spindle in a milling machine So the positioning precision is related not only with the motor spindle encoder pulses but also with the positioning circle diameter as is shown in following equation d D os 90 Formula 2 O eg ER D Positioning center D positioning circle diameter 01 spindle positioning precision by the chord in positioning circle 48 CHAPTER 7 PROTECTION FUNCTIONS It also can be calculated by following expression 0 D hH Positioning center Formula 3 O gt AD AL Ap spindle positioning precision by the arc in positioning circle As known from the above two expressions the minimum positioning precision for this DAPOI drive unit can reach 26 or 26 gt For example to drill at a fixed position on the outer circle of the round part with a diameter 200mm in the right figure the requirement gt Sk e E of d
5. T 8 Note Curve A means that if the running speed is larger than the positioning speed motor decreases to positioning speed after the positioning position is found the motor decelerates till the positioning is completed So curve B means that the running speed is less than the positioning speed the motor accelerates to the positioning speed and then complete the positioning 2 Set for 1 for negative positioning i e regardless the motor running direction the motor locates by the negative positioning speed The figure is shown as following N r mir Nermin A Runnin speed Positioning speed Set for 2 for positive positioning i e regardless the motor running direction the motor locates by the positive positioning speed The figure is shown as following N r min N rimiy Runnin Positioning speed speed 4 Positioning Y speed Running spee TS 68 gt T S SE Positioning oi Positioning__ 7 speed speed Running speed gt T cgppeed Positioning o Speed Runnin R 10 300 CHAPTER 7 PROTECTION FUNCTIONS There are 3 input interfaces which provide 8 combinations to support 8 point positioning and the positioning locations are defined by PA58 PAGS It is shown as following SP2 SPO Positioning location SP1 Positioning l OFF OFF Positioning location 1 0 30000 location 1 Positioning PAS OFF ON Positioning locat
6. ssssuoooooooooooaoooooooocacooooococe 8 2 4 Servo Drive Unit SPSCIIG Al OM gege O ee 9 CHAPTER3 SYSTEM CONFIGURATION AND WIRING ccccssccccccsscrcccsssscccsssssecceees Il 3 1 Pernpheralis ConnEcElo uzda ee eege 11 3 2 The Interior Wiring Block Diagram of DAPO01 Drive Unit ss oooooooooooooooooooca 14 33 Wiring OF the Main el EE 15 3 3 1 Standard wiring instance of the main circuit 15 3 3 2 Terminal functions of the MAIN circuit 15 3 3 3 Cable diameters and connection terminals ee eseeeaa aaa aaa aaa aa aaa aaa aaa zaawan 17 34 VO Slanals and CONMECU OM EE 17 2 4 1 Wiring for feedback SIGN EE 17 GEET TOF CONTOS JN al eaen E w iR OC 21 3 4 3 Connection principle of input and output points eee aiiiiacea 25 3 5 Standard Wiring RR Vu E ner 28 3 5 1 Standard wiring of trial speed run Gr imode aaa aaa aaa aaa aaa aaa aaa anawa aaaaazaaaciannina 28 3 5 2 Standard wiring of speed JOG mode aaa aaa aaa aaa aaa aaa aaa aaa awa aaa aaaaaaaazaaawiannina 29 3 5 3 Standard wiring of internal speed control mode aaa aaa aaa aaa aa aaa aaa wawa aaaeinnnin 30 3 5 4 Standard wiring of external speed control mode aaa aaa aaa aaa aaa aaa aaa a eaannia 32 XI GSK CNC EQUIPMENT CO LTD CHAPTERS JISPLAY AND OPERA NON seine Wadi dw ee 34 4AT Operator il ONE 34 42 Parametet GEELEN 34 AS MONNOFMOdO ee Ee dA OC WGA 35 44 Parameter Setting awake wania ada 36 4 5 ParameterManacementk ac ia cda Ca ENEE dE
7. Suited brake resistance 1 User manual for DAP01 drive unit 1 i A Quality certificate 1 gt The drive unit damaged or lacking of components can t be used Note Drive unit must be mated to the spindle motor with the suited performance Nameplate pattern AC Spindle Servo Unit Model DAP01 037 Software version V2 23 Motor suited ZJY132 3 7 Power input 3 380V 20 10 50 60Hz No 0701001 Date 2007 01 GSK CNC EQUIPMENT CO LTD e Tel 86 20 81986247 Fax 86 20 81993683 CHAPTER 1 OVERVIEW Model significance DAPO 1 037 ZJY 132 3 7 BS 1 3 Product Outline Form type B5 flange no bottom foot Rated power Unit kW Basement No Spindle servo motor code Spindle servo unit capacity Unit 0 1kW AC asynchronous spindle servo drive unit code Spindle servo drive unit outline Analog signal output terminal CN3 Encoder feedback terminal CN2 Control signal terminal CN Driver panel gt 6 bit LED indicator a 5 operation buttons Wiring terminal block for the main circuit GSK CNC EQUIPMENT CO LTD Servo motor outline _ _ d Motor lead in terminals SRA Connection terminals of encoder SS Encoder inside Mounting surface N CHAPTER 2 INSTALLATION AND SPECIFICATION CHAPTER2 INSTALLATION
8. 24VDC COM 39 Drive enable O o am 2 SFR 4 SRY 25 Positioning start zl smol u Orientation selection el sigla Speed selection 0 ol sb 10 See details in Table 5 2 l Speed selection 1 il spr 10 Speed selection 2 000 srz 26 0 speed clamping DO zs 27 Alarm reset 00 anst 8 CNI Ready _ abv 2 Fb speed output lt ________ asp 20 ag Speed arrivaleg el sw iesse Positioning completion 4 on es Alarm output uw EE DC15V 24V grounding lt om 35 COM 36 Z phase feedback output of encoder Analog command range 0 10V or 10V 10V fels EAB Zu COM PCAt bt PCZ a CNI VCD YCMD 1 OVA 29 OVA l3 3 15 OVA eS T9CNV ke o st a _ deng T E G o a gt A D E o d Ss Si b anl O 0 ge Q Si OI AA CN2 PEO de please exchange any smi two phases l SS Z gt R Spindle encoder E E EE E Nm sn db e em zm ml e em em zl e zm zm vk e zm zl em zm mb e e br e e zm em Je ef bw Motor encoder or spindle encoder output by CNI 16 DAOU PAQ I7 Bn 2 RO 18 YA 3 YAR parameter PA 69 Bee e EE A phase pulse feedback output of j motor encoder spindle
9. 45 16 50 6 2 Note The brake unit begins making brake as the DAP01 drive unit bus voltage reaches 680V If user chooses the brake resistance it should meet the equation H lt 25A in which R is brake resistance value Installation of the brake resistance CHAPTER 2 INSTALLATION AND SPECIFICATION gt l50mm e e DAPO1 gt 140mm gt 150mm Full Digital AC Asynchronous Spindle Servo Drive Unit hI U1 OQwwwxw 2 4 Servo Drive Unit Specification Drive unit model DAP01 037 DAP01 055 DAP01 075 DAP01 110 Continuous output 3 7kW D DKW 7 5kW 11kW power S1 30min output 5 5kW 7 5kW 11kW 15kW power S3 Input power 3 phase AC380V 15 10 50 60Hz Working mode Internal speed run external speed run Jog run trial run Constant torque o 1000 1 speed range of suited motor 1 5 r min 1500 r min timing ratio Constant power 0 4 1 speed range of suited motor 1500 r min 6000r min timing ratio Speed stability s Bottom speed rated speed x0 1 precision Speed control mode Speed closed loop control with speed feedback External speed 10V 10V or 0 V 10V command input Speed feedback 1024p r Incremental rotary encoder A B Z differential signal input For 8 positioning points setting of
10. Now it has developed into a large high tech enterprise integrated with technology education industry and trade by enhancing the popularization and trade of CNC machine tools There are more than 1400 staffs in this company that involves 4 doctors more than 50 graduate students and 500 engineers more than 50 among these staffs are qualified with senior engineer post titles The high performance cost ratio products of GSK are popularized in China and Southeast Asia And the market occupation the turnout and sale of GSK s product rank the top for successive 7 years among the same products in domestic market from the year 2000 to 2006 which makes GSK the largest CNC manufacture base throughout China The main products of GSK includes the CNC systems and devices of GSK series turning machine milling machine machining center DA98 DA98A DA98B DA98D series full digital AC servo drive unit DY3 series compound stepper motor drive device DF3 series responsive stepper motor drive device GSK SJT series AC servo motors CT L CNC slider and so on The current national standard and international standard industry standard as well as the enterprise standard or enterprise internal standard as a supplementary are completely implemented in the production process The capability of abundant technology development and complete production and quality system qualified by GSK will undoubtedly ensure the reliable products to serve our customers 24 48 hours
11. PA 34 PA 39 PA31 Arrival speed Zero speed output threshold value Internal forcefully enable Overload folds Acceleration time constant CHAPTER 7 PROTECTION FUNCTIONS Arrival speed set 2 In speed mode when the actual speed of the spindle motor gets the setting range of the command speed speed arrival signal is output The setting is adjustable in the 0 100 range of the command speed e g if it is set for 10 then the setting value is 10 When the speed command is 1000r min the speed arrival SAR signal is output for the actual speed 900r min 1100r min It is irrelevant with the spindle motor rotation direction If the actual speed is less than or equal to zero speed output threshold value zero speed output ZSP signal is valid If it is set for O the internal enable is invalid If it is set for 1 the signal is forcefully enabled the motor is excited if PA4 2 or 3 SFR OR SRV signal is needed to be added for excitation with no need of external enable signal input if PA4 1 For the motor overload coefficient setting The setting value is the percentage of the rated current E g If it is set for the double rated current the value is 200 Unit 2 This parameter value determines the maximum torque output by the motor For linear acceleration time setting in Speed control mode ilts value is equal to the time the motor accelerates from O to the rated speed 63
12. entered the motor starts to run SRV or SFR signal is needed for motor excitation when the via a serial 4 1kO resistance for an drive unit is running at the external speed control interior photoelectric coupling K pole side When the input terminal is at high level the motor EES AP is in free state that the running is disabled EMKA Ka j photoelectric SFR stop signal Err 7 alarm is issued if SFR and SRV signals are PODL effective at the same time SRV stop signal Err 7 alarm is issued if SFR and SRV signals are effective at the same time Positioning start signal As this input terminal is at low level the servo unit executes positioning function if it finds the BEE point the control will be clamped at this As the double terminals for internal speed positioning selection SPO SP1 SP2 are only regarded as the combination terminals for internal speed see details in parameter PA22 See parameter PA58 PA65 for the 8 point positioning combination terminals for external speed Zero speed clamping signal As this point is at low level the motor is clamped at the zero speed and excited and the speed command is ineffective 22 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING Alarm reset signal When an alarm is issued by drive unit the alarm signal will be cleared by entering this signal after ARST the fault is eliminated Note Only No 1 No 9 alarm can be reset by this signal Those alarms over N
13. s 26 A 11 a 41 m 27 12 O 42 c LJ s 13 m 4 S 29 14 44 S 30 i DB44 PAO 15V VCMD 15V VCMD 21 A phase pulse feedback output of motor encoder spindle encoder Digital grounding B phase pulse feedback output of motor encoder spindle encoder Digital grounding Z phase pulse feedback output of motor encoder spindle encoder Z phase pulse feedback output of motor encoder Zero speed output Speed arrival Ref grounding of exterior input 15 24VDC Positioning completion Motor active Ref grounding of exterior input 15 24 VDC Ready Alarm Power input of control signal 15 24 VDC Ref grounding of exterior input 15 24 VDC Alarm reset Power input of control signal 15 24 VDC Servo enable Forward Stop command Power input of control signal 15 24 VDC Reverse stop command Speed positioning selection O Speed positioning selection 1 Speed positioning selection 2 Positioning start signal Positioning direction selection Zero speed clamping General input 15 V analog voltage output available Analog grounding Analog speed command 15V analog voltage output available Analog grounding Analog speed grounding GSK CNC EQUIPMENT CO LTD Description of input signal functions Interior circuit principle Servo enable signal A id When the input terminal is at low level the motor is PoS a 28 M excited for ready state once a command is EE ES
14. 216 216 D 218 E 60 60 mo mo mo no F G H 15 45 15 15 Outline 28 32 38 48 dimensions 220 290 290 290 GSK CNC EQUIPMENT CO LTD Flange basement installation pattern B35 An example ZJY132 7 5B5 Installation formation type Rated power unit kW Foundation No B5 or B35 Spindle servo motor spindle AC asynchronous servo motor flange installation no foundation flange foundation type B5 B35 The motor 3 phase U V W windings and the shell grounded are led out by the cable fixation ends and their locations in the connection box are shown in the following figure In the figure the 3 82 CHAPTER 8 SUITED SPINDLE SERVO MOTOR phase U V W windings and the shell grounded are connected to the U V W PE terminals of the unit main circuit correspondingly The wind from the air conditioner is blown from the shaft to the other end Air conditioner Motor connection connection block block Grounding screw Encoder lt o ket Cable fixer Socket No No Plug schematic diagram welding side 8 2 GOLDEN AGE Spindle Motor Rated Rated Rated Rated Maximum Rotation power Ke SE Speed Speed inertia A r min r min kgm GM7101 4SB61 6000 9000 Motor technical data GM7103 4SB61 1500 6000 9000 GM7105 4SB61 1500 6000 8000 0 032 GM7131 4SB61 1500__ 6000 8000 83 GSK CNC EQUIPMENT CO LTD Motor installation outline and dimensions
15. CHAPTER 4 DISPLAY AND OPERATION Secondary Bottom Maln menu menu data Monitor SCAR gt a e gt r10000 ES ES gt P45806 Carra P gt z gt C 45810 ae e v 4 aal v 4 PA 2 223 A Pa 3 gt d lt Parameter es E A sar FiniSH management a _ gt StArt gt FiniSH FiniSH l i Trial speed run Sr Sr rEd r 0 0 JOG run Jr rEd gt 1 00 WIE Reserved gt Reserved zm gt Reserved Fig 4 1 Parameter structure diagram 4 3 Monitor Mode There are 25 monitor modes in this drive unit in which the current position type di PoS position command type JHEP ht position error type dP EPo position command pulse frequency type dt are used for advanced development of this spindle servo drive unit that can t be monitored by user 35 GSK CNC EQUIPMENT CO LTD VA Motor speed r min Low 5 bit of current position pulse High 5 bit of current position x 100000 pulse Low 5 bit of position command pulse High 5 bit of position command x 100
16. EEN 39 O AFTER S EE 41 5 1 Check Before RUNNING cassssscisveseccesicsescesscselecsasiestasvesaceesictercusncealenaiciestusteveveusictascuaveeetecsisiaseers 41 5 2 TralRun Dy Eechen 42 5 2 1 Power on time sequence of servount eee aaa aaa aaa aaa aaa aznaiiiiiweca 42 IAA AOG TONINO ee 44 D E RRE UR EE 45 9 2 4 External speed EENEG EE Ee 46 e E WEE un EE tee ei rei Kr ln SE 47 5 2 POSIIONINA FUNCUON WEE 48 5 4 Debugging and Parameter Adjustment sssssssssssssccssssssccsscsssssssssssssssssscccccscessceeees 52 CHAPTER G PARAME ERO 54 6 1 Parameter EISE eege 54 6 2 Parameter Function Description 20000000000000000000000000000000000000000000000000000000000000000000000000 57 6 3 Motor Model Code Parameter Correspondence Table ccssssssssssssssscsccscsseseeees 70 GHAPTER 7 PROTECTION FUNCTIONS wawa wiewia wino 71 nA Alarm ENS Cis ea Ee 71 7 2 Alarm LFOUDICSTIOOUINGS eege 72 7 3 Maintenance and Reparation 222220000000000000000000000000000000000000000000000000000000000000000000000000000 79 CHAPTER8 SUITED SPINDLE SERVO MOTOR eserssserercisesoscessserescessroossrssesescssesoesersss 80 8 1 GSK Spindle Servo lernen 80 8 2 GOLDEN AGE Spindle MOtOr sseoosseeeeeeseseessssooooocoecceeeessseeessosoooooceceeeeeseeseesssososooeeeeeeesesee 83 8 3 CEMA Spindle Servo Motor ssssssseeccceecesssssssosssoscccccoceecesssssssosssssocscccceeccsssssssssssssccccseseees 86 XII CHAPTER 1
17. OVERVIEW CHAPTER 1 OVERVIEW 1 1 Product Brief DAPO1 AC spindle servo drive unit is a fully digital AC servo drive unit with large power high reliability and high quality which is exclusively developed by GSK based on China medium CNC machine tools development requirement It is also called DAPO1 drive unit or drive unit for short This drive unit is applied with the special digital signal processing module DSP massive programmable logic matrix CPLD and intelligent power module IPM Based on the advanced asynchronous motor vector control theory this drive unit designed is qualified with the features such as small volume simple and flexible control function full state display wide timing ratio and high reliability It is suitable for the high speed and stable spindle servo control required by the turning machines milling machines machine centers and so on In addition such functions as internal speed control external speed control JOG running Sr trial run spindle orientation are available by this drive unit Different applications can be met by the proper setting of the drive unit working mode running characteristics And the simple operation abundant I O interfaces and multi level protections provide a full guarantee for using JOG run A fixed speed is preset by the user to the parameter By the operator panel keys A w it runs forward or reversely by the preset speed with no need for I O signal control from CN1 inter
18. Unit mm The pin out of the photoelectric encoder is led out by a 15 core connector whose correspondence is shown as following table The pin out should be connected to the plug of the servo unit feedback signal CN2 Encoder connection table Socket No 13 mar lono pin out Socket No Plug schematic diagram welding side 84 CHAPTER 8 SUITED SPINDLE SERVO MOTOR No 14 15 pins are the output terminals of the motor internal thermal protection switch While there is no such switch inside the motor No 5 overheating alarm occurs after power on Please set parameter PA73 for 1 to shield the alarm then save the setting and re power the unit 6 25 ict a L less than 20m Fig 8 1 Encoder signal cable dimension Unit mm Model significance of GOLDEN AGE GM7 series frequency conversion spindle motor GM7 10 S B 6 1 O Y 1 4 Motor poles 4 means 4 poles GM7 series AC Code Shaft extension None standard Installation type IM BS IM B3 el mes servo frequency Motor conversion specificatio spindle motor wcode Central height integer part of the height divided by10 3 phase AC380V power Feedback component 1024p r square wave Rated speed Forced cooling e EES Code Cooling type encoder 85 GSK CNC EQUIPMENT CO LT
19. differential signal input terminal of motor encoder B B differential signal input terminal of motor B B encoder Z Z differential signal input terminal of motor encoder Input terminals of overheat protector for OH1 OH2 Spindle servo motor and OH2 connecting inside 5V grounding SV OV DC 5V power for motor encoder Gg FG Grounding of signal cable shielding e re fo differential signal input terminal spindle encoder B B differential signal input terminal spindle encoder Z Z differential signal input terminal spindle encoder eeng PC 5V power ior spindle encoder Encoder Drive unit output O S 1 ES XX X O 1209 AM26LS32 X A B Z SCA SCB SCZ Fig 3 4 Wiring principle of encoder feedback signal cables N ote The cable length between the drive unit and spindle motor should be within 20 meters The distance between feedback cables of encoder and main circuit cables should be over 30cm their cables should not go through the same tunnel or be tied up together Twisted shield cable with the sectional sizes 0 15mm 0 20mm should be employed for feedback signal cable and the shielding tier should be connected with FG terminal The main circuit cables and wires should be well fixed as well as not to be adjacent to controller radiator or motor for their insulation protection against heating If thermal resistance or other thermal protection switch
20. feedback to our headquarter by our local outlets III GSK CNC EQUIPMENT CO LTD in order to fully enable this AC spindle servo drive unit and ensure your safety please read this manual carefully before using this product You should operate this drive unit strictly by the precautions and operation procedures described in the manual IV CONTENT WARNINGS In order to avoid physical hurts to the operator or other personnels pay attention to the following warning marks when reading this manual The following warnings with varying degrees of severity appear in the User Manual which is relative to the explanation of the operation safety marks The explanation is very important for the compliance in the operation A Danger It indicates that severe injury or death may be caused if false operation is performed Caution A Caution It indicates that accidents occur if false operation is performed which may cause medium degree injury slight hurt or material loss It indicates that undesirable result or situation may occur if the note is neglected gt It indicates the key requirement or instructions of operation The following symbols indicate some operations that must not or must be performed O It indicates prohibition absolutely not do Q It indicates compulsion must do In addition even items stated in the Note mark may result in serious result GSK CNC EQUIPMENT CO LTD Please sec
21. motor spindle encoder motor Positioning function spindle positioning is started with positioning points chosen by external trigger signal positioning angle errors180 encoder pulses GSK CNC EQUIPMENT CO LTD Spindle position Incremental rotary encoder 128 8000p r pulses setting A B Z feedback input differential signal Position feedback Motor or spindle encoder signal 1 1 output A B Z differential signal output 11 points input such as servo enable zero speed clamping SFR SRV Control input signal aay bas speed positioning point selection positioning start Control output 6 points output such as alarm ready speed in position position signal completion zero speed output motor Z pulse zero Protections such as overvoltage undervoltage overspeed overcurrent Protection overload overheating encoder abnormity 6 bits LED software and hardware version working mode current Display speed speed command encoder position status current torque I O mode bus voltage alarm codes parameters etc can be displayed 5 keys available for operations of working mode content display Operation parameter modification and management etc External energy comsumption brake 330 500W 270 1500W resistance Working temperature and 10C 55C no frosting 90 RH below no condensation humidity lt 0 66 5 9m s Protection degree IP20 10 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING CHAPTER 3 SYSTE
22. suited motor with CN1 not connected LL Set parameter PA4 2 for Trial run mode Set parameter PA33 1 for internal enabling Switch to Sr menu press al key twice it displays with the unit r min Press the A key the motor begins to accelerate release the key the motor remains at a fixed speed press the lt 4 key the motor begins to decelerate so in this mode the i A s 4 keys are used for motor acceleration and deceleration 45 GSK CNC EQUIPMENT CO LTD 5 2 4 External speed control run Connect CNI by the right figure power on and call out the default parameters for the suited motor Servo unit side 37 Set parameter A4 1 for Speed control mode eh 38 COM ncis 24y AT Il A Set parameter PA22 1 for external analog command input 33 COME op SON SFR oO i SFR SRY oA ORY If analog command is 0 10V If analog command is 10V DC WUER Ke set PA46 1 PA45 1 10V set PA46 0 0 10 I VOD Servo unit side Make analog command for OV Make analog command for 0V A S gei Mt SON SFR or SRV for ON SON SFR for ON adjust the a jA E adjust the value of PA44 to value of PA44 to make the 0 SON Servo enabl ome i make the motor for zero speed if motor for zero speed if it runs at SE KEE it runs at a low speed a low speed l4 t ry UD Ai VOD Change the ana
23. technological support and service can be easily and promptly provided by GSK s complete service mechanism and tens of service offices distributed in China and abroad The pursuit of excellent product and superexcellent service has made GSK what it is now and GSK will spare no efforts to continue to consummate this South China CNC industry base and enhance Chinese national CNC industry by GSK s management concept of century enterprise golden brand II PREFACE PREFACE The installation wiring running debugging maintenance for this DAPO1 Full Digital AC Spindle Servo Drive Unit are fully introduced in this manual It will give you a complete knowledge for using this drive unit effectively And this manual also provides some necessary knowledge and notes for using this drive unit You must have a comprehensive understanding on the notes about this drive unit before using it All specifications and designs are subject to change without notice We do not assume any responsibilities for the change of the product by user therefore the warranty sheet will be void for this change e Chinese version of all technical documents in Chinese and English languages is regarded as final This manual is reserved by final user Sincere thanks for your supporting of GSK s products Welcome you to give your suggestions about our product and User Manual by a telephone fax or Email addressed on the back cover of this manual or send a
24. 0 100 0 100 r min 10 300 0 10000 GSK CNC EQUIPMENT CO LTD Deceleration time constant Motor max PA23 speed of maximum analog 10V speed limit Analog command filter coefficient Analog command zero drift compensation For linear deceleration time setting in Speed control mode lts value is equal to the time the motor decelerates from O to the rated speed It is used to set the maximum speed under a 10V analog voltage and it is irrelevant to the rotation direction if the speed command exceeds the maximum speed the actual speed is the maximum speed For command received GH the value is smoothly filtering the speed reduced the analog command filtering will be increased the lower the cut off frequency is the higher the filtering effect is and the speed command response becomes slower GI the value is too large the disturbance and speed fluctuation increase and it will cause motor shaking For user command analog error compensation 64 O 10000 O 20000 r min 3000 3000 PA 45 PA 46 Reversing analog command Analog input mode selection PA4 control mode selection PA22 internal and external speed selection PA46 analog input mode selection PA47 reversing SFR and SRV signal PA4 control mode selection PA22 internal and external speed selection PA45 reversing analog command PA47 reversing SFR an
25. 000 pulse Low 5 it of position error pulse High5 bit of position error x 100000 pulse Motor torque Motor current A Linear speed m min Current control mode Pulse frequency of position command KHz Speed command r min Torque command Absolute position of motor encoder pulse Input terminal state Output terminal state Encoder feedback signal Running state Alarm code DC bus voltage Software version Hardware version Spindle encoder absolute position Reserved r 1000 0 P 45806 P 12 C 45810 c 12 E 213 E 0 t 70 I 23 L 5000 Cnt 0 F 124 210 t 20 3256 Fig 4 2 Monitor modes block diagram 4 4 Parameter Setting Motor speed 1000 r min Current position is 1245806 pulses Position command is 1245810 pulses Position error is 213 pulses Motor torque 70 Motor current 2 3 A Linear speed 5000m min Current mode is 0 Position command pulse frequency is 124 KHz Speed command is 210 r min Torque command 20 Motor encoder absolute position is 3256 Input terminal state Output terminal state Encoder feedback signal In running No 9 alarm DC bus voltage is 567 Software version 2 23 Hardware version 2 00 Spindle encoder absolute position is 2577 Reserved Prior to parameter setting modify the user password paramet
26. 2 Exchange any two Er 2 connection on control Phase sequence not correct phases error power 8 3 Refer to the wiring supply i table in section 3 3 2 78 Positioning location can t signal or cables be found EE n eck the 2 Parameter setting not positioning Na consistency of correct as positioning by feedback encoder and spindle encoder Na positioning encoder selected by parameter CHAPTER 7 PROTECTION FUNCTIONS Occurring in Software SE switching Parameter not adjusted and upgrade Readjust and save Er 28 on control saved after software parameter parameters power upgrade suppl Occurring in error Power switching Parameter value detected Check the parameter Er 29 parameter on control aS power is supplied not range detection error power within the setting range S supply 7 3 Maintenance and Reparation The spindle servo drive unit is mainly comprised by semiconductor components Their performance varies with the ambient temperature humidity dust dirt and shake therefore proper daily maintenance and reparation are necessarily needed Make check as following 1 Check abnormal shaking noise and smell of the running motor Check the running abnormal shaking noise or the parts fastness of the cooling fan 3 Check the surrounding environment change especially whether the vent hole is blocked by dirt Check the screws and bolts fastness and the term
27. A55 Positioning speed 11000 PA56 Position window in locating O 100 PA57 Positioning direction selection 02 0 PA58 Positioning location 1 0 30000 0 pulse 55 PA59 PA60 PA61 PA62 PA63 PA64 PA65 PA66 PA67 PA68 PA69 PA70 PA71 PA72 PA74 PA75 PA76 PA77 PA78 PA79 PA80 GSK CNC EQUIPMENT CO LTD Positioning location2 0 80000 o Positioning location3 0 80000 o Positioning location4 0 80000 o Positioning locations 0 300 0 Positioning locatione 0 80000 o Positioning location 0 80000 o Positioning locations 0 80000 o Positioning encoder selection 03 0 Reversing spindle encoder signal 4 RE input direction Encoder output selection 4 0 o Reversing encoder output o1 o 4 frequency selection of encoder output Shielding of motor overheat alarm Window of zero speed analog command Reserved Reserved Reserved Reserved Reserved S 56 pulse pulse pulse pulse pulse pulse pulse CHAPTER 7 PROTECTION FUNCTIONS 6 2 Parameter Function Description PA 0 PA 1 Password Software version read only Function and meaning Set this parameter for user password 315 when a parameter is to be modified 2 For modification of motor model the motor model parameter can only be modified after this parameter PAO is set for model password 385 8 The password restores to 315 if the unit is repowed after powe
28. AND SPECIFICATION For the direct influence to the functions and life of this DAPO1 spindle servo drive unit by the environment where it locates do install it as the items stated below M Be careful for the protection against rain and straight sunlight a The servo unit must be fixed in an electrical cabinet to prevent dust corrosive gas liquid conductors and inflammable substances from entering it The place where the servo unit is fixed should be ventilative dampproof and dustproof Don t fix the servo unit on or near the inflammable object Please run the servo unit in a temperature below 55 C to ensure a reliable long term use 2 1 Fixing Environment tem Yo SETY Running temperature 10 C S5 C no frosting S i lt 90 RH no condensation Storage delivery temperature and 40C 80C humidity lt 90 RH no condensation i There should be no corrosive gas flammable gas oil fog Atmospheric environment or dust etc in the cabinet GSK CNC EQUIPMENT CO LTD 2 2 Installation Dimension and Space The unit is employed with bottom board installation pattern and its fixing direction is upright to the fixation plane Face the front of the unit forward and bottom upward for heat dissipation The fixation dimensions are shown as the right figure Unit mm 8 od 2 R3 ei EE Z KR Cc Full Digital AC Asynchronous SSS Spindle Servo Drive Unit GC
29. APTER 3 SYSTEM CONFIGURATION AND WIRING 3 3 Wiring of the Main Circuit 3 3 1 Standard wiring instance of the main circuit 3 phase AC380V E 50 60Hz p MCCB External brake resistance AC reactor Spindle servo motor encoder Encoder edback signal The drive unit positioning signal can be obtained from motor encoder by setting parameter PAG6 for 1 SSS See Se er ee ed Upper machine command system 75 CN3 Spindle encoder The drive unit positioning Power off EE 7 Power on o KM1 DAP01 AC spindle servo drive unit e signal can be obtained from spindle encoder by setting parameter PA66 for 0 Fig 3 3 Standard wiring block diagram of the main circuit 3 3 2 Terminal functions of the main circuit The wiring of the main circuit terminals is shown in figure above and their functions are as following table 15 GSK CNC EQUIPMENT CO LTD Terminal Terminal name AC power input terminal Motor connection terminal Brake resistance terminal Grounding terminal Table 3 1 3 phase AC380V 15 10 This DAPO1 drive unit output phase sequence may differ with the phase sequence of the motor which can t be connected to U V W terminals of motor at will by user s
30. C 1 GE any P Asynchronous Spindle p p Servo Drive Unit sy CNI COW 37H External power E 15 24VDC MER ik COM 39 fof a Drive enable Ga 20 24 SIR 9 CR 12 pu 25 e e Positioning start 4_Oo stan Fay i g m Orientation selection G o sro a LF m Speed selection O 00 sm DESEN engt See details in Table 5 1 4 Speed selection 1 Mo 81 46 ear zi E Speed selection 24 Cos o toi S 0 speed clamping o et o 15 Alarm reset o war s LEI S i CN ONS a mm 22 5 lt gt Oj A3 Ready lt RZi 2 5 M m i s 0 speed output sp JEZ lt 1 o Speed arrival lt SAR 5 BOES u scar 4 hi m B 8 Positioning completion ggg Pir rig e sce lt e B Alarm output wu leese El 7 sc lt Ji R DC15V 24V grounding con 35 3 sce r z COM l ee a COM ei on Lem Z pca 19 GND Z ieee Seana PB Last Ele d ol Motor encoder or output or encoder i Ei AA SS spindle encoder output CN EG by parameter PA GO YCMD V VOMD 15 l CNI Ip PA R EB SAM A phase pulse feedback output of I PAO 1 motor encoder spindle encoder Ge ebe 17 PBO l B phase pulse feedback output of 2 PBO OX y motor encoder spindle encoder ebe 18 Pi MY E Z phase pulse feedback output of 3 KAB OWA A i IESTOCA W gt motor encoder spindle encoder Fig 3 9 Standard wiring diagr
31. Cable diameter dimensions Power Terminal suited Earthing cable diameter M5 MS 3 5 5 3 4 I O Signals and Connection 3 4 1 Wiring for feedback signal There are 2 feedback signal interfaces in DAPO1 spindle servo drive unit CN2 DB25 female socket and CN3 DB9 female socket i e for motor encoder feedback signal spindle encoder feedback signal encoder directly connected to the machine spindle as shown in Fig 3 1 User can choose motor encoder feedback signal or spindle encoder feedback signal as positioning encoder 17 GSK CNC EQUIPMENT CO LTD signal by setting parameter PA66 for 1 or O correspondingly If positioning is not needed motor encoder will do If the automatic tool change for precision positioning is needed the motor and spindle transmission ratio 1 1 should be ensured when there is no encoder fixed on spindle Or the spindle encoder must be fixed as a positioning encoder Feedback signal interface CN2 of motor encoder Feedback signal interface CN3 of spindle encoder LU LU The interfaces of CN2 and CN3 should be connected to signal output terminals of the incremental encoder having 1024 2500 5000 pulses just set the parameter PA67 for the corresponding pulse value for using 18 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING Table 3 3 Terminal Interior circuit Interface Terminal meaning NE name principle A A
32. D 8 3 CEMA Spindle Servo Motor Motor technical data Motor output Maximum Rated Current at 380V Motor A power speed torque A specification 100 150 r min N m 100 150 240 80 125 YPNC 50 7 5 B 1 9 Motor installation dimensions Motor installation outline unit mm 86 CHAPTER 8 SUITED SPINDLE SERVO MOTOR Motor installation dimensions form yPNC 50 3 7 B YPNC 50 5 5 B YPNC 50 7 5 B YPNC 50 11 B Vertical dimensions B5 Horizontal dimensions B3 Outline 330 dimensions AD 190 210 210 265 no more than EM mol or we pe extension dimensions Plug schematic map welding side 87 GSK CNC EQUIPMENT CO LTD Model significance of Shanghai CEMA YPNC series motor YPNC 50 55 B E E with encoder B strong overload series Rated output power unit kW Basic frequency unit Hz Special frequency conversion motor for spindle Connections of several model motor encoders are listed above more are unlisted If user want to use other model spindle motor pay attention to the connections of power jack and encoder socket as well as the motor use criterion and requirement 88
33. EQUIPMENT CO LTD Parameter writing Parameter reading Parameter backup A gt Backup restoration Default restoration Fig 4 5 Power on EE OEE If the parameter writing is not executed the parameter modified will not be saved after EE gt rd EE bA Parameter backup EE rS EE dEF Pressing and holding for 38 Cu Operation lll success Operation fail Parameter writing memory memory EEPROM parameter area Backup restoration EEPROM backup area Default value restoration default value Parameter reading EEPROM parameter area Parameter management block diagram memory EEPROM parameter area memory EEPROM backup area memory memory EEPROM parameter area power is down and the modification of this parameter is invalid 40 CHAPTER 7 PROTECTION FUNCTIONS CHAPTERS RUNNING The R S T inlets of power must not be connected with the U V W output Caution terminals of the servo unit otherwise the servo unit will be damaged Note If the drive unit is used for the first time please call out the motor current monitor mode after the initial power on and use this mode to monitor the motor current in real time as the motor enable signal is given If the motor current is too large it means the motor connection is wrong or the spindle servo para
34. M CONFIGURATION AND WIRING A Caution IR Wiring should be done by the qualified technicians according to the user manual The wiring or overhauling should be done in 10 minutes after the drive unit is cut off on the condition that the safe voltage has been confirmed by multimeter or electric shock may occur Ensure the drive unit and the spindle servo motor grounding to be right Don t hurt or drag the cables during wiring or electric shock may occur Don t make the main circuit and signal cables to go through the same channel or tied them up together The main circuit and signal cables should be assigned separately or intersectionally with an interval of over 30 cm between them or the drive unit may work abnormally by strong interference due to coupling generated Don t switch ON or OFF power frequently due to the high charge current generated by the large capacitances inside the servo unit and if ON OFF power frequently the main circuit elements performance in the drive unit will be decreased Don t add device such as power capacitance surge absorber and radio noise filter between the drive unit output terminal and the spindle servo motor 3 1 Peripherals Connection Some peripherals are necessary for spindle servo unit By choosing correct peripherals and connection by Fig 3 1 the spindle servo drive unit stable running can be ensured for a long term Otherwise it will shorten the life of this drive unit eve
35. PREFACE FE This user manual describes all proceedings concerning the operations of the drive unit in detail as much as possible However it is impractical to give particular descriptions for all unnecessary or unallowable system operations due to the manual text limit product specific applications and other causes Therefore the proceedings not indicated herein should be considered impractical or unallowable E this user manual is the property of GSK CNC Equipment Co Ltd All rights are reserved It is against the law for any organization or individual to publish or reprint this manual without the express written permission of GSK and the latter reserves the right to ascertain their legal liability GSK CNC EQUIPMENT CO LTD Dear user It s our great pleasure for your patronage and purchase of this DAP01 AC Spindle Servo Drive Unit made by GSK CNC Equipment Co Ltd GSK PROFILE GSK GSK CNC Equipment Co Ltd is the largest CNC system production and marketing enterprise in China at present It is the Numerical Control industrial base of South China and the undertaking enterprise of the national 863 main project Industrialization Support Technology for Medium Numerical Control System It is also one of the 20 key equipment manufacture enterprises in Guangdong province It has been taking up the research and development design and the manufacture of machine CNC system CNC device drive unit and servo motor in recent 10 years
36. am of internal speed control mode 30 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING When the parameter PA4 is set for 1 and PA22 for 0 the drive unit is in internal speed mode and the motor commands in this mode are got by the combination of SP0 SP1 SP2 input points select the setting values of parameter PA24 PA30 See details for it in Section 5 2 5 Spindle encoder is recommended for accurate position On the condition that the transmission ratio of the motor and the spindle is 1 1 the positioning is allowed to be performed only by motor encoder If the spindle transmission clearance is large it is recommended that the synchronous belt transmission be applied to avoid the spindle inaccurate positioning by this large clearance 31 GSK CNC EQUIPMENT CO LTD 3 5 4 Standard wiring of external speed control mode 3phase 10 AC380V 15 50 60H2 M d Power off ra WA MCCB T Power on PE 1 bn FIL o KM1 go Note The U V W phases of All motors are not AC reactor connected correspondingly KMI OR O o gt d 1 UG If Err27 alarm occurs Power O PE VG in the 15 running External brake resistance grounding EA DAP 01 Full Digital AC P Asynchronous Spindle Servo Drive Unit B CNI External power SIARA COM JB 15
37. d SRV signal CHAPTER 7 PROTECTION FUNCTIONS If set for 1 for PA46 1 when PA47 0 the motor runs forward for the SFR signal reversely for SRV signal when PA47 1 the motor runs reversely for the SFR signal forward for SRV signal GI set for 1 when PA46 0 the motor runs forward for the positive analog command and reversely for the negative GH set for 0 when PA46 1 the motor doesn t run whether for forward signal or reverse signal LUH set for 0 when PA46 0 the motor runs reversely for the positive analog command and forward for the negative OI set for 1 the external analog input voltage is O 10VDC bai GI set for 0 the external analog input command voltage is 10VDC 10VDC 65 GSK CNC EQUIPMENT CO LTD PA4 control mode selection PA22 internal and external PA 47 Reversing speed SFR or SRV selection signal PA45 PA48 Motor type PA49 encoder Motor pole PA50 reversing analog command PA46 analog input mode selection Valid when PA46 1 for SFR and SRV signal exchange When PA47 0 motor forward for enabling SFR signal reversely for enabling SRV signal 9 When PA47 1 motor reversely for enabling SFR signal forward for enabling SRV signal If set for 0 the control object is synchronous motor 0 setting is unallowable If set for 1 the control object is spindle motor its a default setting This parameter must be set corr
38. d be paid that t2 and t3 are different because t2 is for motor braking halt while the motor is excited and it is in free state after it stops and t3 is for free halt while the motor is at free if enable signal is off which is as parameter PA74 0 while PA74 1 the servo enable is off the motor brakes to stop and stays at free In this situation the significances of t3 and t2 are identical 6 Time sequence of spindle alarm and reset Power on Spindle alarm output ALM Ready RDY Alarm reset gt 50ms 9 2 2 JOG running Do switch off load prior to JOG running If the JOG running is well done it means that the connection between the spindle motor and the servo drive unit is correct Steps First call out the default parameters for the suited motor with CN1 not connected Set parameter PA4 3 for JOG mode Set parameter PA21 500 for a 500 r min JOG speed Set parameter PA33 1 for internal enabling 44 CHAPTER 7 PROTECTION FUNCTIONS LL l Switch to Jr menu press s key twice it displays l Hold the A key the motor begins to run at a speed of 500 r min set by parameter PA21 C Hold the A key the motor runs at a speed set by parameter PA21 hold the Vv key for running reversely release the key the motor stops and stays at zero speed 5 2 3 Sr Trial run Similar to JOG run the Trial run steps are as follows First call out the default parameters for the
39. d command is from external analog input If it is set for 1 the speed command is from internal speed PAA There are 8 combinations for the SPO SP1 SP2 inputs If all the inputs are off the control mode motor is in zero excitation And the other 7 internal speeds can be set by parameters which is shown in PA24 PA30 external the Geen Speed parameter SPO Internal speed E selection should be set for 1 n this status OFF ON ON Internal speed 3 Internal and selection Internal speed 6 61 GSK CNC EQUIPMENT CO LTD For max speed set of spindle motor PA42 Max a 2 It is irrelevant to rotation direction motor speed and applicable to both internal and Max speed corresponding 0 20000 PA23 external speed limit to analog 10V r min If PA422PA23 the motor max generally speed is PA23 PA42 lt PA23 4 If PA42 lt PA23 the motor max speed is PA42 Internal Internal speed 1 set PA 24 speed 1 2 See PA22 for details Internal Internal speed 2 set PA 25 speed 2 2 See PA22 for details Internal Internal speed 3 set PA 26 speed 3 2 See PA22 for details Internal Internal speed 4 set PA 27 speed 4 2 See PA22 for details Internal Internal speed 5 set PA 28 speed 5 2 See PA22 for details Internal Internal speed 6 set PA 29 speed 6 See PA22 for details Internal Internal speed 7 set PA 30 speed 7 2 See PA22 for details 62 PA 32 PA 33
40. decimal point of digit 2 flickers while that of digit 5 doesn t Press A key twice it turns to 45 press A key again i e 45 1000 955 it displays 955 Then modify the number for 2045 bit by bit so the modification can be finished by this method ez The decimal point can only move on the right 2 LED nixie tubes while modifying parameter No this is because that the parameter to be modified only contains 2 digits less than 100 As for modifying the parameter values the decimal point may be moved on the right 4 LED nixie tubes 38 CHAPTER A DISPLAY AND OPERATION 4 5 Parameter Management The parameter management is mainly used for memory and EEPROM operation Select EE in the first level and press lt I key to enter parameter management mode 5 operation modes can be selected by A or w key e g for parameter writing select EE Set then press ool and hold it on for over 3 second the monitor displays JEREE p that means the parameter is being written into EEPROM After 1 2 seconds the monitor displays JEI nt SH if the writing is successful otherwise Piece P js displayed Press lt key to back to operation selection mode EE SEt Parameter writing It means to write the parameters in the memory into EEPROM parameter area The parameters modified by user only change the parameter values in the memory that they will restore to their original values after power is on again If the para
41. e or zero speed Servo enable SON Positioning start signal STAO Positioning speed Speed n ospea fo Positioning completion COIN t 20 5s K y 5 4 Debugging and Parameter Adjustment The relevant parameters adjustment is as following figure Modification is unallowed for PA81 AAA PARA PAS PA82 factory setting 10V 10V OP command PA6 PAT filtering Integral time Integral time constant of 9 KC Kl constant of speed Low pass filter of current Ser e 65 proportional gain current command proportional gain PA24 PA30 Speed detection PA8 filter 4 frequency PG 32 CHAPTER 7 PROTECTION FUNCTIONS Relevant parameters adjustment PAS PAG PA7 PAS PA43 Proportional gain of speed loop Steady range 150 900 It is used to set the proportional gain of speed loop adjustor 2 The bigger the setting value is and the higher the gain is the larger the rigidity is The value is determined by the specific servo unit model and the loading Generally the bigger the load inertia is the smaller the setting value is On the condition that no oscillation occurs in the system set a larger value Speed loop integral gain Steady range 1 30 It is used to set the integral gain of speed loop adjustor 2 The bigger the setting value is and the faster the integration is the larger the rigidity is The value is determined by the spec
42. ectly Motor pole pair 1 pole pair 2 poles pole number 2xpole pairs the unit is pole pair Note the conversion for the pole number marked on motor nameplate 66 CHAPTER 7 PROTECTION FUNCTIONS It is from motor nameplate 1 6000 Asynchronous motor time constant 1 1000 Asynchronous motor excitation current 1 300 Excitation current at 1 5 fold rated speed 1 300 Motor rated PA 51 speed Asynchronous PA 52 motor time constant Asynchronous PA 53 motor exciting current Exciting current PA 54 at 1 5 fold rated speed Positioning PA 56 window in positioning a For searching fixed position parameter Positioning a a PA 55 r settable by positioning speed in positioning 1 1000 spee Refer to parameter PA57 In positioning the spindle searches Z pulse by positioning speed then searches the position to be located positioning completion COIN signal is given while the error of the position to be searched is within 0 100 the positioning window 2 The bigger the setting value is the larger the error is the smaller the setting value is the more unsteady the positioning completion COIN signal is 67 GSK CNC EQUIPMENT CO LTD PA 57 Positioning direction selection Set for 0 for random positioning i e positive positioning speed is used for motor forward negative for reverse The figure is shown as following N r min N r min A A Running
43. ee the following warning for operation They are used for energy consumption brake It is connected to the grounding terminals of power and motor for grounding Due to the different manufacture standards of the spindle motors by various manufacturers the U V W output terminal phase sequence of this DAPOI drive unit does not naturally correspond with the U V W phase sequence of the spindle servo motor one by one as for the motor connection Generally when the motor is enabled if the motor shakes or the motor rotates by a constant speed without being controlled till the Err 27 alarm is issued it means the motor phase sequence is wrong Please exchange the two phases of them for use after the power is cut off for 10 minutes As regard to Version 2 x the corresponding connections for several spindle servo motors and DAPO1 drive units are shown in the following table 16 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING Motor terminals of DAPO1 drive unit U V W PE LX ZAN Es YPNC series Shanghai CEMA W V U PE spindle servo motor GM7 series Wuhan Golden V U W PE Age spindle servo motor 3 3 3 Cable diameters and connection terminals The cable and connection terminal specifications for the servo unit input terminals R S T and output terminals U V W are shown in following table Table 3 2 Connection terminal
44. encoder B phase pulse feedback output of motor encoder spindle encoder Se Z phase pulse feedback output of t motor encoder spindle encoder Q Fig 3 10 Standard wiring diagram of external speed control mode 32 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING When the parameter PA4 is set for 1 and PA22 for 1 the drive unit is in external speed mode if the command 10V 10V is entered and the servo enable SON is ON i e low level is effective the motor is not excited only SFR signal is ON is the motor excited Once the analog command is entered the motor runs immediately See Section 5 2 4 Spindle encoder is recommended for accurate position On the condition that the transmission ratio of the motor and the spindle is 1 1 the positioning is allowed to be performed only by motor encoder If the spindle transmission clearance is large it is recommended that the synchronous belt transmission be applied to avoid the spindle inaccurate positioning by this large clearance 33 GSK CNC EQUIPMENT CO LTD CHAPTER4 DISPLAY AND OPERATION 4 1 Operator Panel The operation of DAPO1 servo unit is very easy that the functions required can be set by only 5 keys The outline of its panel is as following a A IL LS I d d d 6 digit LED display For increasing of sequence number value O e N v2 1 For circular moving of digit to be modified For backing t
45. er PA O for 315 according to the parameter table in Section 6 2 Then press all key to confirm the setting The instance for 36 CHAPTER 4 DISPLAY AND OPERATION parameter setting is as following A level Power on backward lt A level A level ben 3 backward lt A A level backward Menu A selection Parameter selection Menu A A level selection forward L A level Default r adjustment M sj a A value man for 3s AE Fig 4 3 Adjustment steps for motor default parameters The shift function by CC key in parameter setting provides an easy way for parameter setting e g for the current parameter PA 7 there are two ways to modify it A Directly press A key to find PA 37 B If the current parameter is i press Q key for once the decimal point shifts one DD _ I I digit left and it changes for then press A key for 3 times the parameter changes for bee SE press ch key and the parameter PA 37 will be found immediately Still an example to change the value 2045 of PA24 for 2045 the steps are as follows 37 GSK CNC EQUIPMENT CO LTD d Press e times Press 2 times A Press once gt lt 4 Press once Ze Press times D Press once dr Pres once L I GO 4 Press once e Fig 4 4 Shift key operation instance Press key continuously for 3 times the LED
46. face Sr trial run Similar to JOG run the manual continuous acceleration deceleration control can be obtained by the operator panel keys of A Ww with no need for I O signal control from CN1 interface internal speed control By the 7 span speeds preset written to the parameters by user the spindle servo motor can run at 7 different speed spans by controlling the input combination of SPO SP1 SP2 input points and it needs no external commands External speed control It is also called analog instruction control mode The precise spindle servo motor speed can be stably and smoothly adjusted by the analog voltage instructions given by upper machine or user independently GSK CNC EQUIPMENT CO LTD Positioning function This drive unit can be rapidly and precisely positioned to a preliminary position by the feedback pulses from the spindle servo motor encoder or the encoder connected to the spindle in order to change or measure the tools This function also includes the single point positioning continuous multi point positioning 1 2 Reception Check 1 Whether the packing is good and goods is damaged 2 Whether the spindle servo drive unit spindle motor are the ordered ones by checking the nameplates of the goods 3 Whether the accessories are complete by checking the packing list 4 Please contact us or our suppliers if you have any questions after receiving your goods ordered Packing list DAPO1 drive unit 1 E
47. for this DAPO1 AC spindle servo drive unit While alarming occurs the motor stops In the meantime alarm code is being displayed on the LED display panel Only the fault is exterminated by operator according to the alarm code displayed can the device be put into use It is at least 10 minutes for the servo drive unit and spindle motor to be touched after they are powered off to prevent from electric shock and burning 7 1 Alarm List Normal The spindle motor speed exceeding its setting Motor overspeed value Main circuit over voltage Main power voltage too high Main circuit under voltage Main power voltage too low Motor overheated Motor temperature too high Abnormity of SFR and SRV SFR and SRV signal ON simultaneously signal I O Motor encoder fault Motor encoder signal error IPM module fault IPM intelligent module fault Over loading Motor overloaded Brake fault Brake circuit fault Spindle servo drive unit and motor overloaded Motor overheating instant overheating Braking time too long It occurring if discharge time too long There is raking signal but no braking feedback Braking circuit fault 1 There is no braking signal but braking Braking circuit fault 2 feedback 71 GSK CNC EQUIPMENT CO LTD Radiator overheating Radiator fan temperature too high U V W connection error U V W phase sequence incorrect Software upgrade parameter Parameters not adjusted and saved a
48. fter error software upgrade Power on parameter Parameter detected as power is supplied but detection error not within setting range 7 2 Alarm Troubleshootings Alarm Running Alarm name code state Occurring in Change servo drive switchin 9 Q Control circuit board fault unit on control 2 Encoder fault 2 Change spindle motor Motor overload Decrease load Q Acceleration deceleration Increase time constant is too small Motor acceleration which will cause too large overspeed deceleration time speed overshooting constant Occurring in The gain adjustment QReadjust the gain for motor parameter E not l l l the overshooting running appropriate Encoder fault Change the encoder Change the encoder Encoder cable is inferior or cable or connect connection is wrong correctly by the wiring diagram 72 Er 2 Er 3 Main circuit over voltage Main circuit under voltage Occurring in switching on power supply Occurring in motor running Occurring in switching on main power supply Occurring in motor running CHAPTER 7 PROTECTION FUNCTIONS Power supply voltage is too high Power supply voltage wave is abnormal The brake resistance is not connected that cause the pumping voltage too high Brake components are damaged Brake resistance is damaged The brake resistance value is not suitable Power supply voltage is
49. he spindle servo motor is run by enable signal SON given by CN1 interface 2 To set parameter PA33 for 1 without connecting CN1 to force the internal enable for spindle motor running See details in 5 2 3 for its operation Refer to Section 5 2 3 for its operations 3 5 2 Standard wiring of speed JOG mode When the parameter PA4 is set for 3 i e in speed JOG run mode its wiring is identical with that of speed trial mode in Fig 3 1X 1 The spindle servo motor is run by enable signal SON given by CNI interface 2 To set parameter PA33 for 1 without connecting CN1 to force the internal enable for spindle servo motor running See details in 5 2 2 for its operation Refer to Section 5 2 3 for its operations 29 GSK CNC EQUIPMENT CO LTD 3 5 3 Standard wiring of internal speed control mode 3phase AC380V i5 50 60Hz Power off mm oa WCCB Power on PE P s KMO PIL lt ae KM S Note The U V W E phases of All motors are not AC reactor connected correspondingly KMI O R LO Os d UG If Err27 alarm occurs Power O PE vO in the 1 running g tO External brake resistance grounding DAP 01 Full Digital A
50. ific servo unit model and the loading Generally the bigger the load inertia is the smaller the setting value is 8 Set a larger value on the condition that there is no oscillation in the system Low pass filtering coefficient of current command reserved Low pass filtering coefficient of soeed detection Steady range 40 1000 The smaller the setting is and the lower the cutoff frequency is the better the filtering effect is and the lower the noise by motor is If the setting is too small the lower response and larger speed fluctuation may result in oscillation and severe motor shaking 2 The bigger the setting is and the higher the cutoff frequency is the faster the speed feedback response is Properly increase the setting value if a higher speed response is required 8 Properly decrease the setting value if the loading inertia is too big External analog command filtering coefficient Steady range 20 4096 1 It is used to smoothly filter the soeed command received 2 If this value is decreased the filtering to the analog command will be increased The lower the cut off frequency is the better the filtering effect is and the lower the speed command response is If this value is too large the command disturbance and speed fluctuation rise and the motor shake occurs GSK CNC EQUIPMENT CO LTD CHAPTER6 PARAMETERS This servo drive unit has various parameters that can be adjusted and set to meet the differen
51. inal blocks due to the temperature variation and the shake 5 Check the insulation resistances between the terminals or the terminal to earth according to a relevant standard 79 GSK CNC EQUIPMENT CO LTD CHAPTER8 SUITED SPINDLE SERVO MOTOR 8 1 GSK Spindle Servo Motor The main technical parameters and outline dimensions of the motors are shown in the following table Bag ZJY132 2 2 ZJY132 3 7 ZJY132 5 5 ZJY132 7 5 ZJY160 7 5 ZJY160 11 ZJY160 15 Rated power 2 2 3 7 9 9 1 5 1 5 11 15 KW Rated a 3 phase AC 340 3 phase AC 330 Rated 50 50 50 50 50 50 50 frequency Hz Rated torque 14 24 35 48 49 72 CN m 30 min power 3 7 5 5 7 5 11 11 15 18 5 KW 30 min current A 9 4 13 17 1 25 26 34 42 30 min torque N m Rated speed 1500 1500 1500 1500 1500 1500 1500 r min Constant power range 1500 8000 1500 6000 r min Maximum l 10000 10000 10000 8000 7000 7000 7000 speed r min Rotation inertia kg m2 0 0103 0 0168 0 0238 0 0309 0 0413 0 0744 0 0826 80 CHAPTER 8 SUITED SPINDLE SERVO MOTOR OS enee une zwi avsars avons zoos 2018 Weight 49 51 77 107 2 125 kg Installation IM B5 or IM B5 or B35 GB T IM B5 type B35 997 2003 Protection IP54 GB T 4942 1 2001 degree Insulation F GB 1094 3 2003 degree Vibration degree Internal Incremental 1024 5000 p r encoder Air conditioner 3 phase AC 380 power V A B C 188 188 188 188 216
52. ion 2 0 30000 location 2 Positioning PA 6 ON OFF Positioning location 3 0 30000 location 3 Positioning PA 61 ON ON Positioning location 4 0 30000 location 4 Eege A A OFF j ore ore Ier Positionin PA 62 ON OFF OFF Positioning location 5 0 30000 location 5 Positioning PA 63 ON OFF ON Positioning location 6 0 30000 location 6 Positioning PA 64 ON ON OFF Positioning location 7 O 30000 location 7 Positioning PA 65 ON ON ON Positioning location 8 0 30000 location 8 69 GSK CNC EQUIPMENT CO LTD 6 3 Motor Model Code Parameter Correspondence Table PA1 parameter correspondence table for spindle motors PA1 Spindle motor model and technical parameters Remarks parameter GM7101 4SB6L 3 7KW 6000r min 0 02kg m 0 GM7103 4SB6L 5 5KW 6000r min 0 02kg m Pm GM7105 4SB6L 7 5KW 6000r min 0 032kg m Ka GM7131 4SB6L 11KW 6000r min 0 076kg m NN 2000r min NECZM EEN SOA 6 YPNC 50 11 B 11kw 380V 6000r min 21 3A 72 0N m HNS O N IN NE WE 20 NE WE N N O stands for motor installation type which may be 1 3 6 See section 8 1 2 The motor models are not fully listed in above table see special explanations for other motor models suited 70 CHAPTER 7 PROTECTION FUNCTIONS CHAPTER 7 PROTECTION FUNCTIONS There are many protection functions such as overheat protection overcurrent protection over voltage protection
53. ire may occur if not observed Don t touch the wiring terminals of the drive unit main circuit Electric shock may occur if not observed Don t stick hands into the servo unit Electric shock may occur if not observed Don t prevent heat dissipation or place objects inside the radiating fan or the radiator Fire or damage may occur if not observed GSK CNC EQUIPMENT CO LTD Don t operate the spindle driver at power on while the terminal block s cover is dismantled Electric shock fault or damage may occur if not Electric shock may occur observed if not observed Don t place the cable by the sharp edge for loading and hauling VIII CONTENT Caution Please do wiring between drive unit and motor strictly by the wiring diagram Equipment damage may occur If not observed Run with load after motor no load trial run Success Equipment damage may occur If not observed Please connect brake resistance by wiring diagram Equipment damage may occur If not observed Please don tredo dismantle or repair the drive unit in private Equipment damage may occur If not observed IX Use the voltage levels by the manual for the terminals Equipment damage may occur If not observed Please eliminate alarm prior to running after alarm occurring Equipment damage may occur If not observed Motor should be suited with proper servo unit Equipment damage may occur If
54. is not fixed inside the motor there will be an Er 5 alarm and parameter PA73 is needed to be modified to shield the overheating alarm of the motor 19 GSK CNC EQUIPMENT CO LTD The following wiring for GOLDEN AGE spindle servo motor encoder in Fig 3 5 is an example of motor encoder wiring If other motor or self made feedback signal cable is used refer to this for encoder wiring U S O Dee O C d O O O Cc d C O O To spindle servo drive unit CN2 Spindle motoi Intermedium Drive unit terminal cable pie terminal Fig 3 5 Standard wiring for motor feedback signal cables A standard wiring instance for spindle encoder by Japan Tamagawa 1S5308N512 encoder ae ware TA M 5 GD RE 2 a 8 ee re sce 7 o g all 3 SE 2 5 L I S wa test tt aw gt 8 S GND A o SE T eet U 5 i O E NE O Spindle encoder terminal Intermediate cable Drive unit terminal Fig 3 6 Standard wiring diagram for spindle encoder feedback signal cables 20 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING 3 4 2 Wiring for control signal The control circuit interface is CN1 DB44 male socket the shielded or twisted pair cable should be employed for the connection 16 OO 17 2 32 s 18 O O i 5 z 34 20 ma 5 O m 21 O s 36 22 m 7 S 7 O 23 O LI 38 e 24 9 O 25 10 m 40
55. it power the motor is not active and the system is in a free state If servo enable signal is cut off or alarming occurs the motor is in a free stat 3 If servo enable SON is on together with SFR SRV signal the motor is excited in about 100 ms Note Frequent switching on or off the power may damage the soft start circuit and energy consumption brake circuit The frequency limit for switching on or off should be limited for once per 10 minutes If the servo unit or motor is overheated only by 30 minutes cooling after the fault is exterminated can the power be switched on again 4 Time sequence diagram for power on 42 CHAPTER 7 PROTECTION FUNCTIONS Power on lt 0 5s no alarm Alarm output ALM Servo enable SON JI LI SFR SRV command w NR FOO Ready RDY t can either be more or less than 0 namely it has the same effect if the servo enable SON signal is commanded before SFR SRV signal or SFR SRV signal before servo enable SON signal Power on lt 0 5s no alarm Alarm output ALM SFR SRV command 2 Servo enable SON A Ready RDY J 2ms 4ms 5 Servo enable and speed time sequence Power on Servo enable signal lem O EE SFR SRV signal Speed n 43 GSK CNC EQUIPMENT CO LTD tl t2 are the acceleration and deceleration time which can be modified by parameter PA39 PA40 t3 is the motor free halt time after Enable is off Attention shoul
56. l damaged as power is error drive unit 2 After reparation the drive unit model must be re specified by power supplied supply parameter PA 1 then restore the default parameters Chip or circuit board is Change the servo drive damaged unit Change the current Current sensor is damaged sensor Q Current feedback drift is GOMake zero too large adjustment Current error too large 2 The voltage of the control Adjust parameters power for detecting chips Check the control not within a valid range power voltage T11 GSK CNC EQUIPMENT CO LTD Spindle encoder connection Check connection is wrong Spindle encoder is Change the spindle damaged encoder PA66 1 without SE Spindle Parameter setting is wrong spindle encoder encoder fault positioning 1 Shorten the cables Spindle encoder cables are Employ with too long that cause the multi core parallel encoder supply voltage low cables for power supply Check Z pulse of the encoder feedback Er 25 Positioning fail GQ The temperature of radiator fins exceeding the WReduce the load or setting value which causes cut off the power to the thermal switch broken cool the module Er 26 ARE off 2 Change the thermal overheating 2 Temperature switch switch damaged 3 Be far away from It is interfered with interference source Connect them Occurring in e correctly U V W switching
57. l COIN 6 The upper machine executes the tool setting after it receives the COIN signal and the positioning start signal STAO is effective during tool changing After the operation the positioning start signal must be cancelled for other operations The operation procedures by taking spindle encoder as positioning encoder is similar to the operations above except the first 3 steps the rest steps are the same The first 3 steps are as follows 1 Invoke the menu DP SPO press gel key it displays 22x the sign E indicates that the spindle is in a false positioning location whose value can t be taken as a reference 2 Make the spindle to run at least a rotation DAPO1 drive unit will automatically search the correct location of the spindle encoder When this location is found DP APO turns _ into k vol it means the current correct encoder position is xxxx 3 Slowly adjust the spindle to the positioning point then note its DP SPO location and write it into parameter PA58 and save then this parameter value will be the positioning location 1 E Spindle positioning time sequence A motor in running 51 GSK CNC EQUIPMENT CO LTD Servo enable SON OOM Command signal sFrisvR fo Positioning start signal STAO Positioning Running speed Speed n Ospeed Positioning completion COIN t 20 5s V s Bi Spindle positioning time sequence B motor at fre
58. le encoder see PA69 PA71 17 PBO Z phase differential output of motor encoder spindle encoder see PA69 PA71 Other signals Interior circuit principle 15V voltage output with maximum output current 43 15V 30mA 15V voltage output with maximum output current 44 15V 30mA OVA Interior analog grounding The 15 24V external DC power with the input COM current over 100mA is used for driving the photoelectric coupler of the input terminal COM 15V 24V external power grounding 23 24 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING 3 4 3 Connection principle of input and output points Instances of input terminals wiring 1 External switching volume instance Drive unit 41K SW o 2 External CNC photoelectric coupler instance CNC Drive unit system COM 24V Grounding Note Drive unit doesn t work if the power poles are reversely connected Instances of output terminal connection 1 Instance of output terminal to relay Drive unit Reverse polarity connection is unallowed 25 GSK CNC EQUIPMENT CO LTD 2 Instance of output terminal to 980TD turning machine Drive unit Drive unit 21M system DC5V 24V 26 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING M Interface output type is collector open circuit with the max current 100mA and the max external DC power voltage is 25V If the load exceeds them or output is connected di
59. log command voltage to make the speed to vary proportionally with this voltage The corresponding maximum speed can be obtained by modifying PA42 as the command voltage is 10V It should be noted that the motor maximum speed is restrained by PA23 In this manual the input point ON indicates the external switch is closed or low level signal is input Actually the internal photoelectric coupler of this input point is on In this mode the motor is not excited by a SON signal if 0 10V command PA46 1 is selected the motor can be excited by another SFR or SRV signal And the motor runs if PA45 is set for 1 not if set for 0 When 10V 10V command PA46 0 is selected another SFR signal should be given for motor excitation where SFR acts as servo enable signal the current motor running direction can be altered by setting parameter PA45 for 0 or 1 46 CHAPTER 7 PROTECTION FUNCTIONS 5 2 5 Internal speed control run Connect CNI by the right figure power on and call out the default parameters for the suited motor Servo unit side 37 External COME power 38 Set parameter A4 1 for Speed control mode DC15 24V COM inl CO I SON Set parameter PA22 0 for internal speed command input 10 a oc ou oo ll SPI Set appropriate value for parameter PA24 PA30 as required 4 26 SP2 LL Set SON for ON the motor is excited for zero speed different motor speed values can be obtai
60. low 2 Instantaneous power off occurs The input power voltage fluctuation is too large Q Power capacity is not enough Instantaneous power down 3 The input power terminals are loosen or input power lacks phases 73 Check power supply Connect it again Change the components damaged 2 Change the brake resistance WReduce the on off frequency 2 Increase deceleration time constant Reduce torque limit 4 Reduce load inertia Change for the Soft start circuit fault Change the servo drive 2 Rectifier is damaged unit Check power supply Check power supply GSK CNC EQUIPMENT CO LTD There s no thermal Occurring in Set PA73 for 1 to GE protection switch inside the switching shield the alarm motor body 1 Cable is broken off 1 Check the cables 2 Internal thermal switch of Check the spindle motor is damaged motor WReduce the load 2 Reduce the on off Motor frequency on control power supply Er 5 overheated Increase the i acceleration decelerati Occurring in Motor is overloaded on time motor Increase the drive running unit and motor capacity Reduce the ambient temperature Change the spindle Motor interior is at fault motor SFR and SRV signal Abnormity of Er 7 SFR and SRV signal I O SFR and SRV signal are cant be input both ON simultaneously Motor encoder connecti
61. meter values are changed permanently parameter writing should be executed to write the parameters in the memory into the EEPROM parameter area so the modified parameter values will be valid after power is on again EE rd Parameter reading It means to read the data in EEPROM parameter area into the memory The process will be executed automatically when power is on At the beginning the parameters in the memory are the same as that of EEPROM parameter area If the parameters are modified by user the parameter values in the memory will be changed If the user is not satisfied with the modified parameter values or the parameters are disordered the parameter reading can be executed to read the data in EEPROM parameter area into the memory to recover the original parameters as power is supplied EE bA Parameter backup reserved EE rS Backup restoration reserved EE dEF Default Restoration It means all default values factory setting of parameters are read into the memory and be written into EEPROM parameter area that they will be used when power is on again Perform the operations above to restore all parameters to their factory settings if the parameters are disordered by user that cause the system to run abnormally Because different servo motor corresponds to different parameter default value of the servo unit the model code of the servo motor must be ensured parameter PAO1 when restoring default parameters 39 GSK CNC
62. meters are not properly set Please cut off the enable if this happens or else the motor may be damaged 5 1 Check Before Running Please make the following check before initial power on by referring to Section 3 3 1 M Check the power supply input terminals R S T PE connection and the fastness of the terminal screws M Check the connection of the output terminals U V W for spindle servo unit with the spindle motor power input terminals U V W M Check whether the correct external brake resistance is connected M Check whether the feedback signal cables of the motor encoder feedback signal cables of the spindle encoder and the control signal cables are securely connected M Make sure the spindle motor shaft has been completely detached from the loading prior to running M Switch on 380V AC power 41 GSK CNC EQUIPMENT CO LTD 5 2 Trial Run by Power On 5 2 1 Power on time sequence of servo unit The wiring of power is shown as Fig 5 1 switch on the power by following steps 1 Connect the power supply with the power input terminals of main circuit R S T by AC contactor KM 1 3 phase AC380 V O O O ae A Lo deen i gt C z PEQ MCC Spindle servo drive unit q E O BR Brake resistance Motor encoder feedback Fig 5 1 Power wiring block diagram 2 If servo enable SON is ON after the connection of the control power with the main circu
63. motor rotor to run at least for a rotation DAPO1 drive unit will automatically search the correct position of the motor encoder When this position is found DP APO l D Se A AAA H H H mgs D turns into IL ml it indicates the current correct encoder position is xxxx There are 2 ways to make the motor to run for a revolution A Power the drive unit without giving enable signal to make the motor to stay in a free state manually rotate the motor rotor or spindle connected to the motor rotor for at least a revolution B Run the motor for at least a revolution in JOG mode see Section 5 2 2 for JOG run 3 Slowly adjust the motor rotor or spindle connected to the positioning point then note its DP APO position and write it into parameter PA58 and save then this parameter value is the positioning location 1 4 User can continuously adjust 8 positioning point and note their locations and write them to PA58 PA65 sequently as Table 5 2 so multiple point positioning can be performed in external speed control mode 50 CHAPTER 7 PROTECTION FUNCTIONS 5 Enable drive unit input SON signal and SFR signal together in external speed control mode whether or not servo motor is running input positioning start signal STAO and keep low level effective servo motor begins to run at a speed set by parameter PA55 after it finds the position point it remains at this point and output the positioning completion signa
64. n damage it 11 GSK CNC EQUIPMENT CO LTD Power 3 phase e C ac3soy RIST E Tt dn Spindle encoder TZS E connector BAJ LEE Incremental encoder SE L T2 p i ji R F A fixed on the machine x f spindle IT Di f k i S h D CN1 Connecting to CNC Interference filter er earthing Magnetic contactor Energy consumption brake resistance Fig 3 1 Peripherals connection system and upper machine Motor encoder connector CHAPTER 3 SYSTEM CONFIGURATION AND WIRING cut off circuit as overcurrent occurs For power wires protection used to U HM EU Breaker MCCB ie D For protection against external interference from power wires
65. ned by inputting the speed selection command according to the combinations of SP0 SP1 SP2 in Table 5 1 In internal speed modes SPO SP1 SP2 are defined as input point combinations for multiple level speeds selection speed selection 0 SPO speed selection 1 SP1 speed selection 2 SP2 As following table shows these three terminals is combined for 8 level speeds that are set in parameters PA24 PA30 respectively Table 5 1 Speed corresponding m oP SPI SPO Ewan oe Parameters for speeds Internal speed 3 Internal spee ON Internal speed 6 ON Internal speed 7 The positioning function is also available in internal speed mode Though the input point combinations above are defined for speed selection the positioning can only be done by a position set by parameter PAS58 47 GSK CNC EQUIPMENT CO LTD 5 3 Positioning Function Spindle positioning As for tool change or measurement requirement the rapid and accurate positioning which is done by the feedback pulses from the spindle servo motor encoder or the encoder directly connected with the spindle and spindle preliminary dwell position i e position of servo motor holding function is called spindle positioning It also involves single point positioning and multiple point continuous positioning Spindle positioning precision It is expressed by a minimum angle 9 of spindle accurate positioning as following equation Formula 1 360 _ 90
66. not observed Don t grip motor cables and shaft during transportation Equipment damage may occur If not observed GSK CNC EQUIPMENT CO LTD Don t touch motor brake resistance or servo unit radiator during running for the high temperature generated Scalding may occur if not observed Don t connect the power R S T leading in wires to the motor U V W leading out terminals Equipment damage may occur if not observed The internal electronic components of a rejected drive unit can only be tackled as industrial waste and can t be repeatedly used Accident may occur if not observed Don t adjust and modify the parameters in an extreme way Equipment damage may occur if not observed Don t run the drive unit if its components are lacked or damaged and contact the dealer immediately Equipment damage may occur if not observed Don t frequently switch on off the leading in power Equipment damage may occur if not observed CONTENT CONTENT PRERACE E Ill WARNINGS EE V CHAFIERT EE 1 bh Product TEE 1 2 Reception CHECK c i AAA R edd 2 u ProdUCEOUUNME Gawin z R ba BG R ai Wh 3 CHAPTER2 INSTALLATION AND SPECIFICATION scccccsssssccsssssccccssssceccsssssccceessees 5 2 Jeune EIERE Dee 5 2 2 Installation Dimension and Space ssssesooo ooo ooo zeza aaaaoo ooo ooo ooo ooo ooo ooo ooo o 00000000000000000000000 6 2 3 Dimensions and Installation of Brake Resistance
67. o 9 can only be reset by repowering Analog speed command input terminal The command voltage OV 10VDC or 10V 10VDC can be set by parameter PA46 Description of output signal functions Interior circuit principle Speed arrival signal If the actual speed reaches the range of the speed specified low level signal is output without the CCW and CW rotation direction See parameter PA31 Reserved Alarm output signal E pole side is When the alarm is issued by drive unit the output connected to COM level is reversed The output level can be set by for two interior parameter PA72 photoelectric Zero speed output signal couplings pole C is When actual speed lt zero speed output threshold output terminal its value set by parameter PA32 the low level maximum load signal is output current lt 100mA Positioning completion signal When positioning error is within the positioning window area the low level signal is output The com completion range is set by parameter PAS6 Ready signal When the servo is enabled and motor is excited low level signal is output 23 GSK CNC EQUIPMENT CO LTD Maximum load current lt 100mA 19 PCZ Z phase pulse feedback output of motor SES 4 PCZ encoder s 16 PAO A phase differential output of motor encoder The interior is the output of 1 PAO spindle encoder see PA69 PA 1 differential chip 26LS31 B phase differential output of motor encoder spind
68. o upper level menu or canceling operation For entering the lower level of menu or confirming input For decreasing of sequence number value While the data is being displayed by the LED nixie tube the decimal point of the digit to be modified flickers and the decimal point in the ultra right nixie tube lights up after the data modification by pressing mall key for the confirmation for the modification this decimal point restores to flickering If alarm occurs the alarm code will be displayed by LED The fault can be resolved by user according to the alarm code 4 2 Parameter Structure The operation of DAPO1 is performed by 3 level menus the first level is the main menu which involves 8 modes the second level is function menu under the modes the 3 level is data level As is shown in Fig 4 1 after the power on initialization in drive unit press lt key to enter the first level main menu the press A o V key to select a mode in 8 modes Only 5 modes are effective in this version i e Monitor mode dP Parameter setting PA Parameter management EE Speed trial run Sr JOG run Jr And the other 3 modes are reserved for further development that is unallowed for operation After a mode is selected press lt q key to enter the lower menu of this mode press key to return to the upper menu if you want to return If the lt l key is repressed the control enters the bottom data level of the 3 level 34
69. on Check the is broke off connection Change the motor Motor encoder is damaged encoder Motor encoder cable is Er 9 Motor encoder Change the cable f inferior fault Q Shorten the cables Motor encoder cables are l 2 Employ with so long that the encoder multi core parallel voltage is too low power supply 74 CHAPTER 7 PROTECTION FUNCTIONS Occurring in switching on control IPM module fault Occurring in motor running Occurring in Er 13 Overloading motor running EN Change the servo drive Circuit board is at fault A unit Control power voltage is Q Check the servo low drive unit 2 IPM module is 2 Check whether the overheated cooling fan is at IPM module is normal overcurrent 3 Correct the loading Drive unit U V WJ Check the terminals are short circuit connection Earthing is not well done Be grounded correctly Motor insulation i Change the spindle damaged motor GAdd the circuit filter 2 Be far away from It is interfered with the interference SOUTCE Drive unit U V W Check the connection terminals are short circuit Earthing is not well done Be grounded correctly Loading is increased Reduce the loading abruptly Motor oscillation or abnormal noise occurs due Readjust gain to improper gain setting 43 GSK CNC EQUIPMENT CO LTD The main power voltage is Check the main power too high Brake
70. ot connected S externally set parameter PA33 SPO 10 ki ki for 1 for internal forcible enabling AM26L532 receiver AM26LS32 receiver P Asynchronous Spindle Servo Drive Unit Standard wiring of trial speed run Sr mode Note The U V W phases of All motors are not connected correspondingly If Err 27 alarm occurs in the initial running please exchange any two phases Spindle servo motor Encoder See encoder wiring table 2 26 S 27 ARST 8 jra CNI Ready RDY 22 0 speed output lt IER Speed artival e sw Positioning completion 4 COIN Alarm output lt MW 7H DC15V 24V groundingeqg sl EP COM 36 COM Z phase PO 41 PCZ output ofencoder P VCMD VCMD OVA gt WA 29 z OVA 30 R 15 AA S 15 43 e M e i i ANE Q 10 A GC CN3 GO PER O 0 A 5 ar o m 9 ao O NERWY 2 o EM SCR ZS SCR a6 i EM SCZ 8 P13 scz za Zo i Ke l Vee 6 p l gt O W GND 2 DG C GND G O Se a AZ lt n E E FG O OH CNI gt PAQ 6 PAO Bs 17 PBO gt PRO Fig 3 7 Standard wiring diagram of trial speed run mode 28 CHAPTER 3 SYSTEM CONFIGURATION AND WIRING When the parameter PA4 is set for 2 i e in speed trial run mode 1 T
71. r down It corresponds to the different power drive unit and motor of the same series 2 Because different motor model code corresponds to different parameter default value the correctness of this parameter must be ensured while using default parameter recovering function Gi When EEPROM alarm 20 occurs this parameter must be set again and recovering its default value or else the drive unit may run abnormally or be damaged Software version can be looked up but can not be modified 57 Parameter setting range 0 9999 223 GSK CNC EQUIPMENT CO LTD Motor speed display Motor torque display Motor current display Control mode display Speed command display Torque command display Input terminal state display Output terminal state display Encoder input signal display Running state display Alarm code display DC bus voltage display Software version display Hardware version display 5 Reserved SP2 SP1 SRV SFR ARST SON SECT ZSP SAR COIN RDY A gt BIE saa eto Co O00 DIG3 DIG2 DIGI display CYO Y O O when the INI ZSLSELO STAO DIG3 DIG2 DIGI servo unit l Annotation e SON servo enable ARST alarm reset signal SFR SFR stop signal SRV SRV stop signal SPO SP1 SP2 internal speed positioning selection duplex signal STAO positioning start signal SELO positioning direction selection ZSL 0 speed clamping
72. rectly with power supply the servo unit may be damaged M If the load is an inductive one the both terminals of load must be reversely connected with parallel freewheeling diodes If freewheeling diode is connected reversely the servo unit will be damaged Connection instance of encoder output Drive unit To connect AM26LS32 or output A Xt other same product AM26LS3 l GND X PAO PBO PZO RZ Dive To connect high speed photoelectric coupler High speed output L X _ 1002 photoelectric coupler ed Ox A A C w ZA AM26LS3 1 There should be an interval of over 30cm between the control signal cables and the main circuit cables and they are not allowed to go through the same tunnel or tied up together to protect against interference The length of control signal cable should be within 3m 21 GSK CNC EQUIPMENT CO LTD 3 5 Standard Wiring Instances 3 9 1 3phase 10 AC380V 45 50 60Hz WA MCCB co i Power on PE p gt KM1 FIL O TT KM 1 RE a D AC reactor KMI Q R 1 O OSs d bY ey Power m9 PE ge External brake resistance grounding DAP 01 Full Digital AC bee WEEE B CNI COM 37 External power OM 38 15 24VDC COM 39 Drive enabl yO sox 24 ke If this signal is n
73. resistance ae Connect it again connection is broken off Brake transistor is damaged Change the servo drive 0 Internal brake resistance unit is damaged Occurring in GReduce the on off Er 14 Brake fault motor fina frequency 2 Increase the deceleration time Brake loop capacity is not constant enough Reduce the load inertia 4 Replace the drive unit and motor with larger power ones Reduce the load 2 Reduce the on off Running exceeding rated frequency torque 3 Increase the Long time motor overheating time overloading 4 Replace the driver Occurring in Motor and motor with the Er 16 motor overheating larger power ones Adjust gain Increase running acceleration Motor oscillates unsteadily Ke deceleration time constant 8 Reduce load inertia 76 CHAPTER 7 PROTECTION FUNCTIONS Brake resistance is not connected DC bus voltage exceeding Increase brake Pumping time In braking too long pumping voltage too long resistance capacity 3 External input voltage is too high Braking circuit There being brake signal Er 18 Refer to Er 14 fault 1 but no brake feedback There being brake feedback but no brake Refer to Er 14 signal 1 Change the servo Braking circuit fault 2 Chip or circuit board fault Occurring in Not initialized switching EEPROM reading data EEPROM Er 20 on contro
74. rilling position error is not more than 50um how many pulses for the encoder should be chosen to meet the requirement For the arc length to meet the requirement not more than 50um A lt 25um should be ensured by this DAPO1 drive unit By formula 3 D AS gt P ee e 4L AAO then L 6280 To ensure the drilling position error not more than 50um the pulses of the encoder selected should be equal to or more than 6280 A single point positioning for DAPO1 drive unit can be achieved by position values setting of parameter PA58 in internal speed control mode In external speed control mode the 3 SPO SP1 SP2 input points are defined for combination input terminals of multiple point positioning selection positioning selection 0 SPO positioning selection 1 SP1 positioning selection 2 SP2 Ae 49 GSK CNC EQUIPMENT CO LTD following table shows 8 positioning angles can be obtained by the combinations of these 3 terminals Table 5 2 Positioning locations Parameters for SP1 SPO positioning locations OFF OFF OFF OFF Either internal speed or external speed control mode the positioning operations are identical and the operating procedures by taking motor encoder as positioning encoder are as following 1 Invoke the menu DP APO press lt key to display E vc the sign E indicates that the motor rotor is in a false position whose value cant be taken as a reference 2 Make the
75. s determined by specific servo unit model and load Generally the bigger the load inertia the smaller the setting value is 3 Set the bigger value if there is no oscillation in the system The smaller the setting value is and the lower the cut off frequency is the more effective the filtering is the lower the motor noise is If the value is too small oscillation may be caused by increased speed fluctuation and slow response and motor shakes acutely 2 The bigger the setting value is and the higher the cut off frequency is the quicker the speed feedback response If higher speed response is needed the setting value may be increased appropriately Properly reduce the setting value if load inertia is too large 60 0 3000 20 1000 CHAPTER 7 PROTECTION FUNCTIONS Proportional gain set of position loop adjustor 2 The bigger the setting value is the higher the gain is and the bigger the rigidity is the smaller the position lag is But if the value is Position too big the oscillation or overshooting may PA 9 proportional occur 1 1000 1 s gain 3 Under the same condition the larger the setting value is the faster the positioning is but motor shake or positioning failure may occur in positioning if the value is too large The value is defined by special servo unit model and loading JOG PA 21 running Running speed set in JOG mode 6000 6000 r min speed If it is set for 1 the spee
76. signal GIN universal input signal RDY ready signal COIN positioning completion signal SAR speed arrival signal ZSP 0 speed output signal SECT motor excitation used ALM driver alarm signal 58 PA 4 PAS Control mode selection Speed proportion al gain CHAPTER 7 PROTECTION FUNCTIONS PA22 Set the servo unit control mode by this internal parameter and 1 Speed control mode speed command 1 3 external input by VCMD VCMD analog volume speed input terminals selection PA45 analog command reversing PA46 Analog input mode selection PA47 SFR and SRV signal reversing Na 2 JOG mode trial speed run PA21 JOG run 3 JOG mode JOG run speed GProportional gain set of speed loop adjustor 2 The bigger the setting value is the PA6 spee higher the gain is and the bigger the rigidity d integral is Parameter value is determined by 10 3000Hz time constant specific servo unit model and load Generally the bigger the load inertia the smaller the setting value is 3 Set a bigger value if there is no oscillation in the system 59 GSK CNC EQUIPMENT CO LTD PA 6 PA 8 Speed integral time constant Speed detection low pass filter PAD speed proportional gain 1 Integral gain set of speed loop adjustor The bigger the setting value is the higher the integral speed is and the bigger the rigidity is 2 Parameter value i
77. t function requirement for performance characteristics and so on by user The user should make a complete study of the parameters before searching setting and adjusting them by the operator panel 6 1 Parameter List Factory e range B PAO 0 0900 Gre PA2 Software version read only 223 PA8 initialdisplay 1 oma o PA4 Control mode selection 13 1 PAG Speed integral time constant _ o 1000 10 Reseved ooo PA7 Reserved E eee ee 100 PA9 Position proportional gain 1 1000 1 s dl PA20 Internal and external speed PA22 O 1 selection 54 CHAPTER 7 PROTECTION FUNCTIONS PA29 Internal speed 6 6000 6000 3000 r min fea nr 9 Deeg MOW PROJ Zero speed output threshold PA32 0 100 r min value PA33 Internal forcefully enable PA34 Overload folds of motor current 10300 SEN Reserved pa Reseved PA48_ Analog command filter coefficient 1 600 100 Analog command zero drift PA44 3000 3000 compensation PA45 Analog command reversing _ 04 o PA46 Analog input mode selection o1 0 PA47 SFRorSRV signal reversing 04 0 Pass Motorype 0a a PA49 Motor encoder pulses 128 8000 1024 Motor pole pairs Pole PA50 1 8 2 pair PA51 Motor rated speed 16000 1500 Asynchronous motor time PASZ 1 1000 constant Asynchronous motor exciting PA53 0 300 current Exciting current at 1 5 fold rated PA54 0 300 25 0 1A speed P
78. ure the wiring terminals by proper force Fire may occur for wiring loosing spark if not observed Ensure the input power disconnection before wiring Electric shock may occur if not observed Please do wiring or checkout by special electrical technicians Electric shock or fire may occur if not observed PE terminal of servo unit should be grounded Electric shock may occur if not observed VI Please fix the drive unit brake resistances on the inflammable objects and far from flammable materials Fire may occur If not observed Please fix breaker interference filter and AC reactor Lightning strike fault or damage may occur if not observed Move wiring checkout or maintenance should be done In 10 minutes after power cut off Electric shock may occur if not observed Please fix emergency stop switch Injury fault or mechanical damage may occur if not observed CONTENT Danger Ensure wiring correctness Equipment damage and D electric shock may occur if not observed Don topen the terminal block scover during power on or running Electric shock may occur if not observed Don t operate the switch by wet hand Electric shock may occur if not observed Abrupt start may occur if power is restored so don t operate the spindle motor coupling immediately Injuries may occur if not observed Secure power terminals and motor leading out terminals F

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