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PAM & SAM System User's Manual

1. 11 PAM ACCOSSOTIGS a cte Do I terea n utes 12 EasyB s Gonnectlons 2 cute RU aa aan 12 AC Supply and Aga aran pa RA nda a daa aana 16 About International AC Supply Voltage Standards 16 Selecting SAM Units that fit to AC Supply 16 Accommodating Multiple AC Supply 17 Earthing 10 21 0 18 rela EE 19 Motor Technology eene 19 MotorSelectlonzz o MM 19 Special Purpose Motors 20 Position Feedback 22 Position Feedback Device Types and Characteristics 2 22 Using a 27 Position Feedback Device ener tenent canes 28 Selecting Compatible Feedback 28 SAM Drive S leit n 30 30 Determining Axis Current 32 Position Feedback 34 Brake Control 34 Userl O Options ta ele ee ae Ep EQ 35 Mating Cables and Plugs for
2. 35 Current carrying capacity for various conductor cross sections at 40 oC Lgs ge devez AA Na Ede ag e dU eed d Pea en utc 38 Correction factor as a function of ambient temperature 38 8 conductor Motor Windings Cable Selection and Ordering information 39 4 Motor Windings Cable Selection Ordering information Gaga a hy Tg a A 39 Feedback Cable Selection and Ordering information 5 meter 40 SAM Drive Mating plug selection and ordering information 41 SAM Supply selection and ordering 43 SAM Supply Model Selection 47 External DB Resistance Selection and Ordering part numbers 48 DC bus Dar data eren icto Mee E 51 Basic Feeding Section Component 55 SAM 24 VDC current requirements 58 PAM Mating Plugs srasah ep ara b Aa NA A BEG re RE 61 SAM Supply Mating 61 Cabling Accessories 62 SAM Drive Mating nean eme 62 and SAM System recommended 65 Page 6 PAM with SAM System Users Han
3. N electrical periods Figure 9 Incremental Sine Cosine Encoder Output The 1 Vpp signal quality is somewhat variable between encoder ruler models and is frequently the limiting factor for servo stiffness For bearingless models the 1 Vpp signal quality is also sensitive to mechanical misalignment Encoder ruler manufacturers seldom specify signal quality Incremental sine cosine encoders and rulers being simple incremental devices do not inherently provide sufficient information for a SAM Drive to determine the magnetic angle of synchronous motors AC servomotors at startup To establish the motor s magnetic angle the SAM Drive must create current vectors of small amplitude at different angles while observing behavior of the rotor until the Page 24 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES magnetic angle is determined There are two ways of determining this magnetic angle at machine start up If the application tolerate a series of small motor movements during initialization then no additional hardware is required as SAM drives provide for a magnetic angle learning function Such small movements usually reach a few sine periods but may reach exceptionally up to half a pole angle distance i e 60 degrees for a 6 pole motor In the other case or if the motor is hold by a brake when the drive is not active then a more
4. 19 Reading Motors Characteristic Curves 20 Resolver Output amplitude as a function of angle 22 Incremental Digital Encoder Output 24 Incremental Sine Cosine Encoder 24 Incremental Sine Cosine Encoder with Commutation Track 26 General Procedure for Selecting a SAM Drive 30 SAM Drive Model Numbering 31 Continuous and Peak Current Requirements for Example 33 SAM Drive Cable Assemblies and Mating 37 General Procedure for Selecting a SAM 42 SAM Supply Model Numbering 43 SAM Supply Mating Connector Configuration 49 DC bus bar wiring diagram 50 DC bus bar outliries tena ie in aon iu 50 Contact principle isinisi erected ore od tuat uan de Ya ead cd 51 Basic Feeding Section 54 Power mating plug drawings for marking specification 63 Signal mating plug drawings for marking specification 64 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2
5. I ok m ole a PSU1 004 tif Figure 19 DC bus bar outlines PAM with SAM System Users Handbook Page 50 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES PSU1_003 tif Figure 20 Contact principle Nb of poles 3 poles DC bus DC bus Max current at any outlet 30 Arms with 4 mm wire and plug 40 Aims with 6 wire and plug Max internal current 250 Arms Short circuit withstanding 61 kA peak 29 6 kA for 90 ms 10 kAms for 1s Insulation 660 VAC Protection degree IP20 Number of contacts 12 contacts for DC bus 12 contacts for DC bus 24 contacts for PE Outlines Length 422 Widih 40 mm Height 35 mm without plugs Weight 0 9 kg Table 23 DC bus bar data DC bus bar and Cables available Ordering part numbers DC bus bar The DC bus bar itself can be ordered as p n 9032 011 935 SAM Supply to DC bus bar cable assemblies If SAM PA 30 is used use following ready made SAM Supply to the DC bus bar cable P n 9032 011 940 DC bus bar to SAM PA 30 cable 2 x 4 mm 400 mm If SAM PA 80 E is used use following cable s Pin 9032 011 939 DC bus bar to SAM DA 28 50 cable x 6 mm 400 mm PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 51 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES Use
6. SELECTING SYSTEM COMPONENTS AND ITS ACCESSORIES Package Configuration or Host System PAM Type Ordering p n Upward Fieldbus CAN CAL PAM F17 Full System 9032 011 773 Table 1 PAM Configurations and Intended Applications PAM Accessories PAM Supply The PAM Full Systems are housed in a panel mountable chassis which requires a single 24 VDC power source which may be the same as for the SAM units refer to 24 VDC Supply and Interlocks page 9 This supply shall satisfy the same requirements as for a PLC according to IEC EN 61131 2 international standard The PAM ISA board and PAM P modules are housed in an industrial PC respectively in a Simatic 55 PLC They do not need any specific supply PAM Connectors and Cables Fatal Error mating plug The PAM ISA board and PAM F51 Full System with Profibus are fitted with a Fatal Error output which requires one mating plug X8 This plug is shipped together with the PAM unit It is also described in Appendix A Communication related cables and plugs Depending upon their communication configuration PAM Full Systems require communication cables in addition i e according to Profibus DP standard We recommend using the same cable mating plug supplier as for the other peripherals that are connected to this fieldbus Please contact an ACC Motion Applications Center for any assistance if required EasyBus Connections General The EasyBus is
7. Z1 EMC line filter suppresses transmission of electrical noise generated within power drive system into AC Supply See below Table 24 Basic Feeding Section Component list For additional information on selecting Feeding Section components refer to the topics listed in Figure 21 EMC Filter The EMC Filters listed in below provide state of the art filtering for PAM amp SAM Systems These filters meet the latest EMC standards UL 1283 and EN 133200 and are rated for use at AC Supply voltages up to 480 VAC at 50 C and at frequencies from DC to 60 Hz Select an EMC filter model depending upon the SAM Supply type used If SAM PA 30 is used use following EMC filter Pin 9032011 149 EMC Filter type FN258 30 07 If SAM PA 80 E is used use following cable 2 pieces in parallel Pin 9032 011 150 EMC Filter type FN258 75 34 When more than 8 SAM Drives are connected to one SAM Supply and when motor cables are over 5 meter each These filters may be insufficient for filtering the earth current that is induced into the motor cables Ask your SAM System supplier for assistance Inrush Current Limiting Components General Information When a SAM System is powered on the DC bus capacitors within all units have to be loaded At the first instant they represent a short circuit behind the SAM Supply rectifier As only the AC Supply impedance then limits the peak current it generally P
8. yes Select other motor optional features brake feedback sensor etc Figure 5 Motor Selection Procedure PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 19 PART 1 SELECTING SYSTEM COMPONENTS MOTORS Figure 6 shows an example of characteristic curves for a motor Four torque speed curves with different style dashed and solid lines also labeled 480V 400V 240V and 208V in the figure define the torque verses speed operating limits of a given motor in a SAM system for each of these four AC Supply voltages Note that these curves include compensation for AC Supply voltage at its low tolerance limit nominal 10 and for SAM System internal voltage drops The dashed curve labeled Current indicates the current verses torque characteristic of the motor Current must always be read from the current scale right hand vertical scale in the figure The axis load continuous operation point must lie within the Continuous operation area In a similar way peak load operation points must lie within the Peak operation area As an example both areas are shown in Figure 6 considering a 400 VAC supply voltage n rpm 6000 M ov sot 5000 o 25 Speed 4000 SS ist 20 3000 NG ter o 15 2 400 y 4 0 10 2000 AN SM 10 1000 5 Current 0 0 0 5 10 15 20 25 Torque T Nm PSU1 001 dsf Figure 6 Rea
9. 1 5 mm 9032011034 LIDALCO 418415205 EUROFLEX CY 4x1 5 2x 2x0 5 2 5 mm 9032011035 LIDALCO 418425275 EUROFLEX COMBI CY 4x2 5 2x 2x0 75 4mm 9032011036 LIDALCO 418442127 EUROFLEX COMBI CY 4x4 2x1 0 2x0 75 6 mm 9032011037 LIDALCO 418460210 EUROFLEX COMBI CY 4 6 2 2 1 0 10 mm 9032011038 LIDALCO 418461210 EUROFLEX COMBI CY 4x10 2x 2x1 0 Table 30 and SAM System recommended Cables PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 65 PART 1 SELECTING SYSTEM COMPONENTS APPENDIK DC BUS ALTERNATIVES Appendix DC bus alternatives For small systems i e a PA 30 and 1 to 3 SAM Drives DC Bus power can be distributed using daisy chained wiring from the SAM Supply to SAM Drives in combination with a simple earth ground rail As an alternative to the SAM System DC bus bar manufacturers including Phoenix Weidm ller offer power distribution components suitable for distributing DC Bus power in a PAM with SAM system Page 66 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000
10. 2 such cables as required for accommodating currents up to 80 A One cable only is acceptable only if the AC supply overload protection is adjusted at 32 Ams reducing thus the SAM Supply output current to 40 Age Cable Assemblies for cascading several DC bus Bars Ready made cable connections for cascading several DC bus bars Pin 9032 011941 DC bus bar to DC bus bar cable 3 x 6 mm 150 mm Pin 9032011942 bar to DC bus bar cable 3 x 6 800 mm SAM Drive to DC bus Bar Cable Assemblies Refer to the DC bus bar Cables available and Ordering part numbers section on page 41 Additional DC bus Capacitors Additional DC Bus capacitance may be used as energy back up which make a controlled machine stop possible also when the main AC supply drops Ask your SAM System supplier for assistance Quick DC bus Discharge The SAM System built in discharge circuitry guarantees that no dangerous voltage remains after a maximum discharge time of 60 seconds Should a quicker discharge time be required or are Additional DC bus Capacitors used then a Quick DC bus Discharge system is required It requires a relay anda power resistor as shown in Part 3 Safety and Protective Functions Page 52 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS FEEDING SECTION Feeding Section General Feeding Section Definition This section discusses sizin
11. 47 Select DB resistor Selecting an External DB if required Resistor page 48 Figure 15 General Procedure for Selecting a SAM Supply Supply Selection Strategy This procedure results in selection of the lowest cost SAM Supply which will the job In some circumstances when one considers the cost of carrying a spares inventory which includes several models of SAM units used in different machine types the lowest total cost solution may be to select for all axes the lowest cost SAM Supply which satisfies the requirements for all machine types A 480 VAC rated SAM Supply can also be used at 400 VAC supply provided that its drive power PprvE nus is derated to the value shown for the equivalent 400 VAC rated SAM Supply On the other side the braking power does not have to be derated Ordering Information SAM Supplies including options and accessories are determined by part number or by model number Figure 16 illustrates the construction of a SAM Supply model Page 42 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES number based on the AC Supply voltage its current rating and included options The SAM Supply options described in this section are not field installable They must be installed at the factory Once the model number is determined locate the part number for se
12. Absolute position Yes over 4096 turns Typical use AC servomotors option Direct drive motors option Linear motors no Relative cost moderate Robustness very good no glass disk Typical applications Any servo applications requiring high dynamic accuracy and direct readout of axis absolute position at startup Pick and place Profiled motions Packaging and handling Start up No motor movement the motor magnetic angle is given together with the multiturn information Table 8 Multiturn Resolver Characteristics Summary Using 274 Position Feedback Device Axes Requiring Two Feedback Devices Two feedback devices are required for applications such direct product position tracking A SAM Drive can support two feedback devices however there are some restrictions on feedback devices combinations When designing such applications refer to Table 12 which lists all possible feedback device combinations supported by the SAM Drive Master Slave Applications The resolver encoder connected to the remote apparatus in master slave tracking applications can be interfaced to the second position feedback port of a SAM Drive Any type of supported feedback device may be used for remote master tracking however there are some restrictions on combinations of feedback devices that can be interfaced to a SAM Drive When designing such applications refer to Table 12 which lists all possible feedback device combin
13. DA 400 07x 9032 011 120 9032 011 121 9032 011 122 SEM AHD142 SAM DA 400 14x SEM AHD190 SAM DA 400 28x 9032 011 125 9032 011 126 9032 011 127 SAM DA 400 50x Table 16 8 Motor Windings Cable Selection and Ordering information l Cross section 4 motor range 4 4 SAM drive J 1mm 1 5 mm 2 5 mm 4mm 6 mm 10 mm Bautz plugs SAM DA 400 07x 9032 011 943 SEM AHD55 SAM DA 400 14x SEM AHD70 SAM DA 400 07x 9032 011 188 9032 011 189 SEM AHD92 SAM DA 400 14x SEM AHD115 SAM DA 400 28x 9032 011 195 SAM DA 400 50x SAM DA 400 07x 9032 011 192 9032 011 193 SEM 142 SAM DA 400 14x SEM AHD190 400 28 9032 011 197 9032 011 198 400 50 Table 17 4 Motor Windings Cable Selection and Ordering information PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 39 PART 1 SELECTING SYSTEM COMPONENTS MATING CABLES AND PLUGS FOR SAM DRIVES Feedback Cable Assemblies General Information Feedback Cable assemblies are terminated on the motor end with the correct mating connector strain relief for the designated motor The other end is terminated with the correct mating connectors for SAM Drives Any length is available up to 100 meter These cable assemblies are tested and approved for use in stationary applications where the cable is not subject to repeated o
14. P5N Encoder EnDAT DB 25P K87 K91 input Metalized housing HADIMEC 1725 OM 38T 001 X24 SAM DA P4N Resolver input 9032010699 Connector ITT Cannon SAM DA P5N Resolver input DE 9P K87 K91 Analog input Metalized housing HADIMEC 1709 OM 38T 001 X31 SAM DA E 2 IN3 inputs 9032011072 Weidmiller OUT1 ouput BL 3 5 1 P3 5 5P option 160667 markings to drwg 080 4152 X32 SAM DA E IN1 Fast input 9032010700 Connector ITT Cannon Alternative DE 9S A197 K91 SIRE for Metalized housing HADIMEC OUT1 1709 OM 38T 001 SAM DA F All user inputs 9032010793 Weidm ller and outputs BL 3 5 1 P3 5 16P option 160678 markings to drwg 080 4128 Table 22 SAM Drive Mating Plugs Page 62 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS APPENDIX A MATING PLUGS SPECIFICATIONS Drawing 080 4119 080 4119 Drawing 080 4120 i p ogo S u G B LAN 0 Sw E 080 4120 tif Zl Drawing 080 4121 ek 2 080 4121 tif Drawing 080 4122 080 4122 tif Drawing 080 4123 5 080 4123 tif Figure 22 Power matin
15. SAM Drives 37 General Information eessssssssssssesseeeeenene nennen rennen 37 Motor Windings Cable 38 Feedback Cable 0244 0060 enne tnnt nnne 40 DC bus Cable Assemblies NEK ae AREN AKAN AKE NAH tenete nente nsn 40 Selecting Mating Plugs ANG AA tnter 41 SAM Supply and its 42 Arodu CIO aaah cies DU tete 42 Estimating Bus Power Requirement 43 SAM Supply Selection Based on Power 46 Selecting an External DB 47 with SAM System Users 9031 011 981 September 13 2000 Page 3 PART 1 SELECTING SYSTEM COMPONENTS TABLE OF CONTENTS SAM Supply Unit 2 0 10 nnns 48 Additional DC bus Capacitors 0 10 52 Quick DC bus Discharge 1 NARA A nnn 52 Feeding SEGUON auct e et eoa ee Ge et eb c PE 53 General ae eee a aa ae ap a ag a aa a 53 Basic Feeding Section Configuration 5
16. Section components such as wire terminals and EMC filters select devices with current ratings greater than max PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 57 PART 1 SELECTING SYSTEM COMPONENTS FEEDING SECTION 24 VDC Supply General Information The 24 VDC supply provides a low voltage power source which each SAM Drive SAM Supply and PAM rack mounted models only utilizes to develop their internal supply voltages On units equipped with cooling fans the fans are powered by 24 VDC The 24 VDC supply may also be utilized as a power source for Operating electro mechanical brakes Devices controlled by the User I O Other system or machine functions Requirements As a general statement the 24 VDC power supply should comply with IEC EN 61131 2 Standard Programmable Controllers It means that the voltage must be between 19 2 and 30 0 V including all AC components An existing unregulated system machine supply may be utilized as long as the requirements are satisfied The 24 VDC supply must have its negative pole solidly earthed either at its terminals or close to the SAM Drives Estimating SAM System Current Requirement on 24 VDC Supply Table 25 should be used to estimate the 24 VDC current requirements of a PAM and SAM system The current values listed do not include the current consumed by the user s I O devices electromechanical brakes and alike The peak values l
17. Table 3 is not exceeded Table 2 shows the properties and selection criteria for all fiber optic cables available Required Standard duty Kevlar reinforced Long distance fiber length plastic fiber cables plastic fiber cables cables 0 3 m 9032 010 776 0 5 m 9032 011 091 1 0 m 9032 011 086 2 0 m 9032 011 087 9032 011 092 3 0 m 9032 011 056 9032 011 093 5 0 m 9032 011 088 9032 011 094 10 9032 010 774 9032 011 095 15 m 9032 011 096 20 m 9032 010 775 9032 010 777 25 m 9032 010 778 50 m 9032 010 779 100 m 9032 011 100 Table 2 EasyBus Cable Ordering part numbers PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 13 PART 1 SELECTING SYSTEM COMPONENTS PAM AND ITS ACCESSORIES Under no circumstance should a fiber optic cable be bent below its minimum bending radius be it temporarily during assembly or definitively as its light transmission capability would be severely decreased Fiber optic cable may get accidentally bent while pulling out electric cables if they are routed together within the same cable channels The PAM and SAM System provides for a fiber optic cable test routine which helps detecting damaged sections and connectors This routine can be initiated i e during machine maintenance The light emission power of all units shall then be reduced to 80 Any transmission capability reduction due to i e damaged cable will then
18. They must be installed at the factory Once the model number is determined locate the part number for selected SAM Drive model in Table 11 Brake Control No Brake Control N Position Feedback Option P4N 1 Resolver input P5N 1 Resolver input amp 1 high resolution sine cosine encoder interface P1N discontinued use PAN Optional E Standard User I O configuration 2 inputs 1 high speed input 1 output 1 analog input 07 F Optional User I O configuration 6 10 inputs Current Rating 4 8 outputs 1 analog input 50 SAM DA 400 A discontinued use E D discontinued use F Figure 12 SAM Drive Model Numbering Key Voltage Switching Output current rating supply used frequency 8 kHz gt Icont Arms 8 15 28 58 400 VAC gt standard Arms 13 34 49 84 4 kHz gt Icont Arms 6 5 15 20 34 optional Arms 10 28 38 62 8 kHz gt Icont Arms 7 15 24 56 480 VAC standard Ipeak Arms 12 33 46 5 79 4 kHz gt Icont Arms 6 15 16 5 30 optional Arms 8 26 34 8 56 SAM DA 400 SAM DA 400 SAM DA 400 SAM DA 400 07 14 28 50 feedback I Os brake output inputs 1 fast yes gt B P4N E 9032 010 552 9032 010 553 9032 010 554 9032 010 555 resolver gt 1 output no N P4N E 9032 010 5
19. an enclosure with the appropriate level of sealing and air filtering for the environment where the enclosure is located An enclosure with the proper access control measures and safety interlocks can provide security for the equipment In some locations safety interlocks are required by law EMI RFI Considerations As the SAM units have been tested on EMC Electromagnetic Compatibility the Emitted Radiation test has been performed and standard requirements met with open cabinet doors Nevertheless we recommend following considerations below Power Drive Systems have the potential to generate high levels electromagnetic emissions A properly designed and installed cabinet is very effective in reducing radiation and in satisfying EMC regulations In order to effectively limit EMI RMI emissions the cabinet construction must satisfy the following criteria The enclosure must be made of metal There must be a nearly continuous uninterrupted metallic bond along the juncture of all planes that form the exterior surface of the cabinet Cabinets assembled with continuous welds are ideal For cabinets assembled by other means i e spot welds screws etc no gap of more than 5 cm in length is allowed along the line of intersection of the planes This means for example that a cabinet assembled with Screws must have a screw every 5 cm joining the sides top and bottom surfaces Access doors must be equipped with EMI RFI gaskets The backpanel eq
20. be detected and signalized so that the cable section can be replaced This feature is especially helpful in case of spurious communication break down Upon test completion the light emission power is brought back to 100 EasyBus Cable Technical Data Standard duty plastic fiber cables Kevlar reinforced plastic fiber cables Long distance fiber cables Intended applications Interconnecting PAM amp SAM Drives within an enclosure Use when cables are run in cable trays or conduits along with other cables Low loss cable for systems where the PAM amp SAM Drives are widely spaced This cable is not reinforced and must be protected from abuse Cable Temperature 20 to 80 C 5 to 70 C 20 to 80 C range Minimum bending 50 mm 50 mm 50 mm radius Cable diameter 2 2mm 5 0 mm 5 0 mm Tensile strength 10N 150 N 150 N 50 N at plug level 50 N at plug level Lengths of standard 0 3 to 20 m 2 0 to 20m 25 to 100 m cable assemblies Table 3 EasyBus Cable Properties and Selection criteria Fiber to Fiber Optical Coupler If required any fiber optic cable segment can be split in 2 parts which are connected together using a Fiber to Fiber Optical Coupler This may be useful if the various PAM and SAM units are housed in different cabinets which must be disconnected i e for shipment This Fiber to Fiber Optical Coupler can be ordered as part number 9032 011 148 Inserting one
21. configurations are possible depending on the specific requirements of an application Most machine control systems include a PC PLC and an operator control station MMI for overall machine control The following paragraphs provide brief descriptions of the principal functions of each PAM with SAM system component Fieldbus EM 4 WA E E s Bee 2 12 Oct MM 522 T o 5 Bus Fiber Optic Ring anther SAM Drives 24V DC lt 2 lt 5 fone User User l L A VO 2 2 11 4 i DB Resistor DC Bus iter Motor Feedback filter Motoi fed ES E D 9 Gp AC Servo Motors Induction Motors Linear amp Special Purpose Motors Psg016 a cdr AC Supply Figure 2 PAM with SAM System Components PAM The PAM Programmable Axis Manager is the system s control and motion coordination center PAM controls motion and program flow as dictated by the application program under execution PAM may be linked to a host PC PLC or factory automation system for hierarchical control and reporting using one of a number of industry standard communications network interfaces PAM is supplied in three packaging configurations mounted in a rack as module for insertion into a S
22. constructed of fiber optic cables that link a PAM and all SAM Drives in a closed ring see Figure 4 Three types of EasyBus cable assemblies are available including Standard duty plastic fiber cables Kevlar reinforced plastic fiber cables Long distance fiber cables The order in which each SAM Drive is placed within the EasyBus ring has no influence as far as functionality is concerned For this reason it may be defined in a way that the total ring length is at the shortest as it will reduce the overall fiber optic cable cost Exception As the SAM Drives that are placed immediately downstream of PAM get thus a higher priority for transmitting events This may have some importance in time critical event handling when the number of axes is larger than 6 Page 12 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS X33 EE X35 Figure 4 Selecting and Ordering EasyBus Cables PAM AND ITS ACCESSORIES SAH049 A CDR EasyBus Cables Link a PAM and SAM Drives in a Closed Ring The total number of EasyBus cables required for a PAM with SAM system equals the number of SAM Drives in the system 1 When estimating the length of EasyBus cable segments allow sufficient length for cable bends so the minimum bend radius specified in
23. direct drive motors For assistance in using induction linear and direct drive motors please contact an ACC Motion Applications Center and discuss your requirements with a motion specialist Motor Selection We provide standard permanent magnet synchronous motors that have been designed and are specified for operation together with SAM drives Selection Procedure Motor selection is often an iterative process which begins with selection of a motor that satisfies the machine load requirements followed by recalculation of the load with the motor s inertial contribution to the axis load considered The procedure illustrated in Figure 5 is optimized for selection of a motor which meets the axis load requirements at the lowest axis cost If there are other constraints such as motor physical size motor type standardization etc these additional constraints must be taking into account during the motor selection process Determine axis load Find the cheapest motor whose stall torque is 20 or greater than the axis load continuous torque Within selected motor size select the winding constant Kr which results in the lowest rated current and yet fulfills max speed requirements when used with selected AC voltage Recalculate axis continuous and peak torque loads with the chosen motor inertia Check if axis continuous and peak operation points torque amp speed no diagram are still within selected motor operating areas
24. inherently absolute position devices over one rotation Electrical period Sine Cosine 1 turn Msc005_a CDR Figure 7 Resolver Output amplitude as a function of angle Resolvers are widely used for position measurement in motion control systems They offer the benefits of low cost sturdiness high reliability wide dynamic range good electrical noise immunity and absolute position readout over one revolution They are passive devices that is no active electronic components reside within the resolver Table 5 summarizes the important characteristics of a typical resolver when used with a SAM Drive PAM with SAM System Users Handbook Page 22 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Accuracy 6 arc min limited by the resolver used Resolution 7 arc sec 200 000 counts turn limited by SAM Drive conversion process Max Speed 8 000 RPM Absolute position Absolute over 1 turn Typical use AC servomotors yes Direct drive motors no Linear motors no Relative cost low Robustness very high no silicon no glass Typical applications Any servo applications requiring high dynamic accuracy pick and place profiled motions Packaging Handling Start up No motor movement the motor magnetic angle is given by the resolver information Table 5 Resolver Characteristics Summary Most servomotor
25. power requirements nus as follows Pacc nus WI 0 41 X Pacc eeu WI Determine for each motor the negative average power requirement Prec avelW as follows Poec _avelW 0 29 x Poec_peax W Don t be surprised if these power values are smaller than the motor rated power as it is a typical phenomena for this type of applications 5 Sum up the RMS power supplied to all SAM Drives Porive_ nus as follows Parive rms total Pace rst Pace rms2 Record computed value of Paiye rms total for subsequent use in Supply Unit selection Sum up the peak and average braking powers as follows peak total _ 1 _ 2 ave total x Paec avet Paec ave2 Paec aves 6 Record computed values of _ total for use in SAM Supply and DB Resistor selection SAM Supply Selection Based on Power Requirements Perform the following steps to select the appropriate SAM Supply unit based on DC Bus Power and Dynamic Braking power required 1 Select the applicable segment of Table 17for the AC Supply voltage i e 400 VAC to be applied to the SAM Supply Within the selected AC Supply Voltage segment select the appropriate subcolumn i e 13 kW of column Porive rus based on the previously computed and recorded RMS power Poaye Su
26. same conduit maximum ambient temperature if not 40 C Table 14 and Table 15 reproduce IEC 60204 1 standard figures and must be used for selecting the minimum cross section required Selecting a larger cross section is allowed and may help reducing the number of different cable types in some cases Cross section 1 1 5 mm 2 5 mm 4 mm 6 mm 10 mm 1 9 6 Ams 12 2 Ams 16 5 Ams 23 0 Aims 29 0 Ams 40 0 Arms Nb of 2 7 7 Ams 9 8 Ams 13 2 Ams 184 Ams 23 2 Aims 32 0 Anns rur ese ADAT Are 10 0 Ang 26 0 Avis conduit 6 5 5Ams 7 0 Ams 9 4 Ams 13 1 Ams 16 5 Ams 22 8 Ams 3 9 48 Ams 6 1 Ams 8 3 Ams 11 5 Ams 14 5 Ams 20 0 Ams Table 14 Current carrying capacity for various conductor cross sections at 40 C ambient air multiply Table 14 temperature current by 30 C 1 15 35 C 1 08 40 C 1 00 45 C 0 91 50 C 0 82 55 C 0 71 Table 15 Correction factor as a function of ambient temperature For applications not covered in this section refer to IEC EN 60204 1 standard Page 38 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS MATING CABLES AND PLUGS FOR SAM DRIVES 274 Selection Criteria 8 or 4 Conductors Two cable configurations are available including 4 conductor cable 4 heavy
27. speed and position The feedback device is usually integrated into the motor A number of feedback devices including resolvers and incremental sine cosine encoders or rulers are supported Motor and Feedback Cables The motor cable transmits the SAM Drive s three phase power output to the motor windings The feedback cable carries power and data for the feedback device AC Supply The AC Supply provides the power that following conversion is applied to the axis motors by the SAM Drives DC Bus The DC Bus distributes a SAM Supply s high DC current high voltage output to SAM Drives A compact DC bus bar system is available DB Resistor The DB Dynamic Braking Resistor dissipates excess energy returned to the DC Bus In some configurations the DB Resistor is located internal to the SAM Supply 24 VDC Supply and Interlocks This 24 VDC power source supplies logic power to the PAM SAM Drives and SAM Supply The same supply often powers other machine functions PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 9 PART 1 SELECTING SYSTEM COMPONENTS INTRODUCTION Feeding Section necessary main power switching protection and safety components represented as a single block called the Feeding Section PAM with SAM System Users Handbook Page 10 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS PAM AND ITS ACCESSORIES PAM and its Accessories Se
28. standard main frequencies Three Phase AC Geographical Remarks Supply Area Nominal Range VAC VAC 208 187 229 North America Use a step up transformer or reduce maximum motor speed 240 216 264 North America Use a step up transformer or reduce maximum motor speed 380 342 418 Europe Slight reduction in maximum motor phased out speed 400 360 440 Europe 415 373 440 UK phased out 460 437 529 North America Automatic 10 current derating 480 432 528 North America Automatic 10 current derating Table 4 Standard AC Supply Voltages that are compatible with SAM Selecting SAM Units that fit to AC Supply SAM Drive Units A single family of SAM Drives is compatible with operation from with any standard voltage listed in Table 4 including 480 VAC The 400 that appears in their ordering key i e SAM DA 400 07N PAN E has actually no meaning SAM Supply Units Two families of SAM Units are available SAM PA 400 These units fit to all standard voltages listed in Table 4 up to and including 415 VAC They may operate up to 447 VAC peak voltage Page 16 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS AC SUPPLY AND EARTHING Above this supply voltage the DB Resistor gets continuously activated which in turn activates the units Fatal Error output for disconnecting the power
29. supply Higher voltages may damage the equipment SAM PA 480 These units fit to the 460 and 480 VAC standard voltages They may operate up to 530 VAC peak voltage Above this supply voltage the DB Resistor gets continuously activated which in turn activates the units Fatal Error output for disconnecting the power supply Higher voltages may damage the equipment Using SAM at higher voltages If the AC Supply voltage exceeds the maximum value listed in Table 4 a transformer must be used to reduce the voltage applied to the SAM Supply to within allowable limits see Optional Transformer on page57 Using SAM at lower voltages A SAM System can be operated at low AC Supply voltages theoretically down to zero volts Machine designers must be aware that while braking the voltage applied to the motor increases slightly over SAM Supply Unit rated voltage All motors used with PAM and SAM System must have all isolations designed for the 400 VAC when SAM PA 400 is used 480 VAC when SAM PA 480 is used Motors that are designed for 240 VAC supplies should never be used Otherwise isolation faults may occur while braking and machine CE compliance cannot be achieved Using a step down transformer does not bring any improvement e rated voltage of the SAM Supply unit that is chosen Single Phase and DC Supplies Using a single phase or DC supply is possible but is beyond this document s Scope For assistance
30. 000 Page 5 PART 1 SELECTING SYSTEM COMPONENTS LIST OF TABLES List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 PAM Configurations and Intended Applications 12 EasyBus Cable Ordering part 13 EasyBus Cable Properties and Selection criteria 14 Standard AC Supply Voltages that are compatible with SAM 16 Resolver Characteristics Summary esse 23 Incremental Sine Cosine Encoder Characteristics Summary 25 Mutli turn Absolute Sine Cosine Encoder Characteristics Summary 27 Multiturn Resolver Characteristics 28 SAM Compatible Rotary Feedback Devices 29 SAM Compatible Linear Feedback 29 SAM Drive selection and ordering information large drives are available only with brake output 31 Feedback Devices and Combinations for Option P5N 34 Standard and Expanded User I O
31. 032 011 104 Only if analog input is used X24 Resolver Optional SAM DA P4N 9032 010 699 Feedback Only if additional resolver is used User analog input Optional SAM DA P4N 9032 010 699 Only if analog input is used X31 Optional SAM DA E I Os 9032 011 072 User I O Only if user s I O are used Optional SAM DA F 14 1 05 9032 010 793 X32 User I O Only if user s I O are used Optional SAM DA E I Os 9032 010 700 Only if fast user s I O are used Table 19 SAM Drive Mating plug selection and ordering information PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 41 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES SAM Supply and its Accessories Introduction Procedure for selecting SAM Supply Figure 15 shows the steps in selecting a SAM Supply including a DB Dynamic Braking resistor and accessories Proceed sequentially through the tasks listed in Figure 15 branching where indicated to the referenced pages that contain the details TASK REFERENCE Determine power Select Power Consumption calculation method Calculation Method p 44 Calculating DC Bus Power for Constant Power Applications page 45 Calculate DC bus power required Calculating DC Bus Power for Dynamic Power Applications page 46 SAM Supply Selection Based on Power Select appropriate SAM Sou Requirements page
32. 12 9032 010 515 6 inputs 4 outputs yes gt B P4N F 9032 010 562 9032010563 9032 010 564 9032 010 565 4 bi directional I Os 9032 010 522 resolver 3 inputs 1 fast yes B P5N E 9032 010 557 9032 010 558 9032 010 559 9032 010 560 encoder 1 output no N P5N E 9032 010 517 6 inputs 4 outputs yes gt B P5N F 9032 010 567 9032010568 9032010569 9032 010 570 resolver 4 bi directional I Os no N P5N F 9032 010 527 Table 11 SAM Drive selection and ordering information large drives are available only with brake output option Example SAM DA 400 07N P5N E with part number 9032 010 517 is a SAM Drive Unit with the following characteristics and options 6 5 Ams continuous current and 10 Ams peak current rating at 400 VAC and 8 kHz switching frequency interface for one resolver and sine cosine encoder feedback with ENDAT PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 31 PART 1 SELECTING SYSTEM COMPONENTS SAM Drives standard User I O configuration 2 inputs 1 fast input 1 output brake control option Determining Axis Current Requirement General Information The SAM Drive current requirement is calculated based on the axis motor plus load continuous and peak torque requirements determined during motor selection These same torque values Tpeax should be used for calculating the SAM Drive cu
33. 4 iiit ite 55 Inrush Current Limiting 55 Optional Transformer sse 57 Circuit Breaker Fuses Relays and 57 24 VDC OUpplyi nana Laa bad aga 58 SYVStOM ENCIOSUIC io hoc e uc 59 Cabinet Selection an a 59 on itr tot eer 60 Appendix Mating Plugs Specifications 61 Appendix B Cables team d etu uo PEN deg 65 Appendix C DC bus alternatives ssssssssseseseeee eene 66 Page 4 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS LIST OF FIGURES List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 PAM with SAM System Component Selection Process 7 PAM with SAM System 8 PAM with SAM System Components 11 EasyBus Cables Link a PAM and SAM Drives a Closed Ring 13 Motor Selection
34. 91 2 markings to drwg 080 4127 Table 27 SAM Supply Mating Plugs PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 61 PART 1 SELECTING SYSTEM COMPONENTS APPENDIX A MATING PLUGS SPECIFICATIONS Unit Function p n Supplier reference EasyBus Fiber to Fiber 9032011148 HUBER amp SUHNER Optical Coupler FSMA FSMA C001 650884 22 DC bus bar Bus bar 9032011935 Auxel 96011X 1 2 5 mm plug 9032011936 Auxel 96530 4 6 mm plug 9032011937 Auxel 96529 Table 28 Cabling Accessories Plugs Conn Unit Function p n Supplier reference code X11 SAM DA 07 DC bus supply 9032011014 Weidm ller SAM DA 14 input STV S 3 S B option 161199 drwg 080 4121 X12 SAM DA 07 Motor output 9032011013 Weidm ller SAM DA 14 STV S 3 S S option 161198 markings to drwg 080 4120 X13 SAM DA all Motor thermal 9032011008 Phoenix Contact protection input MSTB 2 5 3 STF 17 86 84 4 markings to drwg 080 4124 X14 SAM DA B Brake output 9032010791 Phoenix Contact MSTB 2 5 5 STF 17 86 86 0 markings to drwg 080 4125 17 SAM DA all 24 VDC supply 9032011010 Phoenix Contact and MSTB 2 5 6 STF 17 86 87 3 hea markings to drwg 080 4126 X23 SAM DA P4N Analog input 9032011104 Connector ITT Cannon SAM DA
35. AM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 55 PART 1 SELECTING SYSTEM COMPONENTS FEEDING SECTION reaches values that are unacceptable for the rectifier Such high peak currents are generally not acceptable either for the AC supply protective devices For this reason a 2 step switch on system must be used as shown in Figure 21 This requires Inrush Current Limiting Resistors to be inserted into the AC supply These resistors are used only during the DC bus voltage rise Inrush Current Limiting Resistors Selection The Inrush Current Limiting Resistor unit p n 9032 010 785 is currently specified for use with all SAM Supply models It contents three 50 Q 50 W resistors within one housing Inrush current limiting resistors are sized based upon the following restrictions concerning their use in the application Time between two 2 successive power on operations is never less than ten 10 seconds The short circuit sustaining time never exceeds 0 3 seconds Ask your PAM and SAM System supplier should any of these criteria not be fulfilled We recommend utilizing the host PC PLC or some I Os of the PAM amp SAM System to assure compliance with the power on cycle repetition time and short circuit sustaining time requirements Refer to Part 3 Safety and Protective Functions for details on how these protective functions may be implemented Low Cost Inrush Current Limitation Using NTC Resist
36. Selection and Ordering information 5 meter DC bus Cable Assemblies General Information The DC Bus distributes DC Power at high voltage and current levels from a SAM Supply to SAM Drives in a PAM with SAM system Refer to DC bus Bar page 49 Page 40 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS MATING CABLES AND PLUGS FOR SAM DRIVES for further explanations This section relates only to selecting the appropriate cable assemblies for connecting each SAM Drive to the DC bus Bar DC bus bar Cables available and Ordering part numbers Ready made cable connections for each SAM Drive are following Pin 9032 011 938 DC bus bar to SAM DA 07 14 cable x 4 mm 400 mm Pin 9032 011 939 DC bus bar to SAM DA 28 50 cable 3 x 6 mm 400 mm Note load 4kHz Selecting Mating Plugs When SAM System Ready made cables are used only a few mating plugs must be ordered in addition most of them depending upon SAM optional features SAM DA 50 requires 2 cables in parallel when working with continuous full Connector Functions Comments Ordering p n X17 24 VDC supply amp Compulsory 9032 010 696 safety interlocks One piece for every SAM Drive X23 Encoder Feedback Optional SAM DA P5N 9032 011 104 Only if additional encoder ruler interface is used User analog input Optional SAM DA P5N 9
37. This version all previous versions of this document It also replaces the SAM System Designer s Guide 1995 1996 Inmotion Technologies and ACC Motion have made every effort to insure this document is complete and accurate at the time of printing In accordance with our policy of continuing product improvement all data in this document is subject to change or correction without prior notice ACC Motion SA Zone industrielle La Rippe CH 1303 Penthaz Switzerland PAM amp SAM System User s anual Part 1 Selecting System Components Ordering Number 9032 011 981 Issue September 13 2000 P n 9032 011 981 Issue September 13 2000 1995 2000 by ACC Motion SA All rights reserved PART 1 SELECTING SYSTEM COMPONENTS TABLE OF CONTENTS PAM with SAM System Users Page 2 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS TABLE OF CONTENTS Table of Contents Table of Contents eters aera 3 Listot aa eni toe oet ees 5 List Of Tables mamme aenea 5 eL NA A BA 7 Component Selection Procedure sse 7 Overview of System Components eene 8 PAM and its aaa Ba aab aga 11 Selecting the PAM
38. alues where motor torque is used mainly for accelerating and decelerating loads rather than for compensating friction effects Typical dynamic power applications include handling and packaging machines with pick and place cut to length and electronic cam functions Based on these definitions select one of the following DC Bus power consumption calculation methods that best represents the intended application Calculating DC Bus Power for Constant Power Applications The procedure for calculating DC Bus power required in constant power applications is as follows 1 For each axis calculate the continuous DC Bus power Pbre supplied to the SAM Drive as follows PorivelW RPM T s Nm x 0 105 1 where iS the motor average speed RPM T suc IS the axis continuous torque motor load in Newton meters For a winding axis driven by an induction motor use either the spool empty max speed low torque or full max torque low speed condition whichever is larger Do not multiply max speed by max torque Naxis IS motor and drive efficiency naxs 0 85 if the motor is of synchronous AC servomotor type or 0 75 if it is an asynchronous induction motor Multiply this value by the gear efficiency if relevant 2 For each axis determine the rotational kinetic energy as follows Ex x Ngawe RPM x 0 0055 where Jrora IS the axis inertia motor load in kil
39. ations supported by the SAM Drive Selecting Compatible Feedback Devices When selecting feedback devices refer to Table 9 and Table 10 which list compatible feedback devices for the SAM Drive which have been assessed for use and in many cases tested with the SAM Drive PAM with SAM System Users Handbook Page 28 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Rotary Device type tested Manufacturer amp type Resolvers open YES LTN 21 1 04 frame YES LTN RE 15 1 A14 YES SAGEM 21RX 39 02 11 YES SAGEM 15RX 39 01 30 YES HAROWE 21BRCX 607 HG72A Resolvers housed YES LTN R58WVRE151A14 031 07CX Incremental sine YES Heidenhain ROD486 2048 cosine encoders YES Heidenhain ERN 480 2048 YES Heidenhain ERM 180 2048 magnetic hollow YES shaft YES Heidenhain ERN 180 5000 Heidenhain RON287 18000 2 5 accuracy Incremental sine YES Heidenhain ERN1387 2048 cosine encoders YES Hubner HOGS60 DN 1024 with add sine cosine Hengstler S21 commutation track NO Tamagawa OIH35 Multiturn absolute YES Heidenhain EQN1325 4096 turns EnDat sine cosine encoders NO H bner AMG10E512R Single turn absolute NO Heidenhain ECN 1313 1 turn EnDat sine cosine encoders Multiturn resolvers YES LTN MT 21 1 A05 4096 turns EnDat Table 9 SAM Compatible Rotary Feedback Devices Linear Device type tested Manufact
40. ble 29 summarize the functions of all PAM and SAM System plugs and provides supplier references This information is shown for users whose strategy is purchase cables and plugs directly or via third parties Figure 22 and Figure 23 show drawings that specify how mating plugs must be marked Conn Unit Function p n Supplier reference code X1 PAM RS232 Port to 505 3032 Connector ITT Cannon all except PAM ISA Servicing PC DA 15P K87 K91 505 3042 Metalized housing HADIMEC 1715 OM 38 001 PAM ISA RS232 Port to Connector Deltron Servicing PC HD 15 PZ 9032011005 Metalized housing HADIMEC 1709 OM 38T 001 X2 PAM F26 Full System RS 422 port 9032010699 Connector ITT Cannon with RS422 port DE 9P K87 K91 Metalized housing HADIMEC 1709 OM 38T 001 X8 PAM all Fatal Error 505 5402 Weidm ller output BL 3 5 2F SN OR option 160664 markings to drwg 080 4151 Table 26 Plugs Conn Unit Function p n Supplier reference code X1 SAM PA 30 DC bus output 9032011012 Weidm ller STV S 2 S S option 161195 drwg 080 4119 X2 SAM PA E DB resistor 9032011015 Weidm ller output STV S 4 S s option 161201 drwg 080 4122 X5 SAM PA 30 AC supply input 9032011016 Weidm ller STV S 4 S B option 161202 drwg 080 4123 XT SAM PA all 24 VDC supply 9032010792 Phoenix Contact and MSTB 2 5 10 STF option 17 86
41. current Impeax recorded in Step 2 does not exceed leg for the selected SAM Drive If the peak motor current requirement is greater that Isra a SAM Drive with higher current rating must be selected 5 SAM Drive can supply its peak rated current 1 for at least two seconds before tripping due to thermal overload A SAM Drive can supply lesser magnitude currents in excess of Iconr for longer intervals in an lt relationship approximately Proceed as follows to verify the SAM Drive s capability to supply the axis peak current demand 6 Compute lt for the SAM Drive selected in Step 2 above as follows Compute loea 2 where lpeak is the peak rated current of the selected SAM Drive Compute iG where is the peak motor current computed in step 3 teak is the duration in seconds of Page 32 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM Drives Verify that I toave gt I tuoror if not a SAM Drive with larger current rating must be selected Drive Selection Example Consider the following situation AHR115 C6 64 motor has been selected Axis continuous torque is 3 5 Nm and max required speed is 4500 RPM Axis peak torque requirement is 10 7 Nm for 2 1 seconds and occurs once every 30 seconds Supply voltage is 400 VAC Selected drive to be operated at 8 kHz switching fr
42. d the star point must be solidly grounded with a short thick connection to protective earth ground 4 Correct secondary voltage The transformer secondary voltage must be specified at no load condition This is to avoid overvoltage at the SAM Supply unit input when the AC Supply voltage reaches its 10 tolerance point and the transformer is not loaded We recommend specifying also a voltage drop of 2 to 4 at nominal load Be aware These requirements are not usual in transformer business and must be clearly specified 5 Correct power rating Make sure the transformer power rating is correct for the load not higher not lower Power rating should be determined by the power actually consumed by the Power Drive System Porive_ nus tora rather than by the SAM Supply unit size see Estimating DC Bus Power Requirement page 43 Circuit Breaker Fuses Relays and Wiring Choose these components as as well as other machine parts according to international standards and local regulations Chose their current rating based on See Estimating DC Bus Power Requirement page 43 When selecting fuses circuit breakers and other overload protection devices choose a rating slightly higher than Choose a rather slow reacting protection device whose reaction time fits the machine cycle time Select circuit breakers with a short circuit threshold as high as possible i e 8 times lip When selecting other Feeding
43. dbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS INTRODUCTION Introduction Component Selection Procedure Figure 1 presents a logical sequence of steps for selecting PAM with SAM system components and accessories It is based on the fact that certain system components must be selected before others Proceed sequentially through the tasks in Figure 1 branching when necessary to the referenced topics that contain the details TASK REFERENCE Select PAM module Selecting the PAM Model page 11 Select EasyBus fiber Selecting and Ordering optic cables EasyBus Cables page 13 Select AC power supply AC Supply and Earthing voltage page 16 Select motors Motors page 19 Select feedback sensors Position Feedback Devices page 21 Select SAM drive units Procedure for selecting SAM Drives page 29 Select SAM drive cables Mating Cables and Plugs and accessories for SAM Drives page 36 Select SAM supply unit Procedure for selecting SAM Supply page 42 Select SAM supply SAM Supply Unit cables and accessories Accessories page 48 Select Feeding section Feeding Section components page 53 Figure 1 PAM with SAM System Component Selection Process PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 7 PART 1 SELECTING SYSTEM COMPONENTS INTRODUCTION Overview of System Components PAM with SAM System Configuration Figure 2 illustrates a three axis PAM with SAM system Many other
44. der or absolute ruler with ENDAT 4 Resolver Incremental sine cosine encoder or ruler with without commutation track 5 Resolver Single or multi turn absolute sine cosine encoder or absolute ruler with ENDAT 6 Multi turn resolver requires both ports Table 12 Feedback Devices and Combinations for Option P5N Brake Control Option The Brake output is used for controlling a 24 VDC electromechanical motor brake on motors so equipped An external 24 VDC power source must be provided for powering the brake The Brake output is compatible with most holding brakes available on motors Page 34 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM Drives The Brake ouput may also be used to operate a relay based dynamic braking circuit for the axis motor Applications for the Brake Control output are described in Part 3 Safety and Protective Functions Selecting the Brake Control Option If SAM Drive current rating is the lowest one SAM DA 400 07 and if no brake control is required than select No Brake Control In all other cases select With Brake Control it is a standard feature for all SAM Drives with larger current rating User I O Options Selecting the User I O Configuration A SAM Drive may be ordered with either a standard or expanded User I O configuration for controlling machine functions All Users are electrically isolated w
45. ding Motors Characteristic Curves Special Purpose Motors Induction Motors In some applications an induction asynchronous motor is required as for winding unwinding applications Its major benefit is its constant power characteristics Example A motor must be able to deliver 12 Nm at 1500 rpm bobbin is full as well as at 3 Nm at 6000 rpm bobbin is empty that means at 1 9 kW shaft power A permanent magnet servomotor should be selected for achieving 12 Nm and 6000 rpm simultaneously that means 7 6 kW shaft power An induction motor instead can be selected exactly for this 1 9 kW shaft power Using field weakening technique it will be able to provide both high torque at low speed and low torque at high speed The major saving is at the Drive level as a much smaller one can be selected Page 20 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS MOTORS Linear Motors Traditional linear motion solutions such as belt or rack and pinion increasingly fail to satisfy the highest accuracy stiffness and bandwidth requirements The linear motor is a direct drive solution that is readily interfaced to a PAM with SAM system and operated very much like a standard AC Servomotor Linear motor SAM Drive combinations along with an appropriate linear feedback device achieve up to 10 000 N force 20 m s velocity 300 m s 30 g acceleration together with sub micron accurac
46. edback port for interfacing a single resolver to the SAM Drive Normally the resolver providing feedback from the axis motor is connected to this port If the SAM Drive is not controlling a motor this port may be used to interface a remote master resolver to the system Resolver plus Encoder Option P5N Option P5N provides two feedback ports for interfacing one or two feedback devices One port is a standard resolver port The second port is an encoder port with necessary hardware for interfacing the following feedback device types Incremental sine cosine encoder ruler with or without commutation track single turn or multiturn absolute sine cosine encoder or sine cosine ruler with ENDAT serial interface multiturn resolver with ENDAT serial interface requires both ports The encoder ruler port hardware includes a controlled 5 VDC supply with current and voltage sense lines This feature enables encoders to be operated with cable lengths up to 100 meters Table 12 lists the devices and device combinations supported In cases where two feedback devices are connected there is no restriction concerning which port is connected to the feedback device on the axis motor this assignment is made in software Config Resolver port X24 Encoder port X23 1 Resolver 2 Incremental sine cosine encoder or ruler with without commutation track 3 Single or multi turn absolute sine cosine enco
47. equency Using the above procedure and characteristic curves for the 115 6 64 motor the SAM Drive continuous and peak current requirements after compensation for motor torque constant tolerance are see Figure 13 5 1 1 5 5 Ams 15 1 1 16 5 Ams Based on the continuous current requirement a SAM DA 400 07 is a good fit however it cannot supply the peak current required The SAM DA 400 14 can supply both the continuous and peak current required n rpm I A 6000 Continuous Operation Peak 5000 Point one oint 4000 r 3000 2000 pss 1000 3 5 10 7 T Nm T T cont peak 002 a dsf 1 10 96 Figure 13 Continuous and Peak Current Requirements for Example Evaluating the peak current duration requirement f a 5 28B 2 1568 A s 16 52 2 1 572 A s The selected SAM Drive can supply the peak current during the required time Therefore the SAM D 400 14 satisfies the requirement totally and would be a correct choice PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 33 PART 1 SELECTING SYSTEM COMPONENTS SAM Drives Position Feedback Options Selecting the Feedback Option Select feedback option P4N or P5N based on the feedback device type s to be interfaced to the SAM Drive Resolver Input Option PAN This option PAN provides a single fe
48. es the basic Feeding Section circuit fora PAM with SAM System gt gt gt 91 a T1 Optional D C B us SAGO007 D CDR PE Figure 21 Basic Feeding Section Components PAM with SAM System Users Handbook Page 54 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS FEEDING SECTION The functions performed by the components are as follows symbol description 11 12 13 AC Supply PE Protective Earth ground Q1 Circuit breaker provides overload and short circuit protection Fuses may also be used for this function K1 AC starting relay switches AC Supply power to the entire Power Drive system during startup K1 is de energized once the DC Bus capacitance has charged K2 Bypass relay K2 is energized once the DC Bus capacitance has charged before K1 is de energized Rirl Inrush current limiting resistors used at AC Supply switch on to limit input current peaks during initial charging of the DC Bus capacitors When AC power is first applied the starting relay K1 feeds the SAM Supply unit through in rush current limiting resistors Rirl See Inrush Current Limiting Components page55 T1 optional Transformer converts non standard AC supply voltages to voltage level required by SAM Supply T1 is an optional component which is not used in every application See AC Supply and Earthing page 16
49. former is used and only in that case increase wax by 4 to accommodate transformer losses Page 56 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS FEEDING SECTION 4 Record wax Arus for use in component sizing calculations Optional Transformer Requirements A transformer is required under any of the following circumstances AC Supply voltage exceeds the maximum rated voltage that may be applied to a PAM with SAM system see Using SAM at higher voltages on page 17 AC Supply is not a three phase four wire system with solidly earthed neutral see Earthing Requirements in 18 A transformer powering one or more SAM Supply units must meet the following requirements 1 Isolation transformers and non isolation transformers autotransformers are allowed However if the AC Supply is not a three phase four wire system with solidly earthed neutral an isolation transformer must be used 2 For isolation transformers only see Interfacing an Isolation Transformer the transformer secondary must be wired in a Wye configuration and the star point which is the secondary s neutral must be solidly earthed with a short thick connection to protective earth The primary may be either Delta or Wye connected 3 For auto transformers only see Interfacing auto transformers the transformer must be Wye connected an
50. g and selection of components within the Feeding Section which were not addressed in the previous section SAM Supply and Accessories Components that belong to the Feeding Section are defined in IEC EN 61800 2 Semiconductor Power Converters for Adjustable Speed Electric Drive Systems The Feeding Section of a PAM with SAM Power Drive system includes all components of the AC Supply circuit between the AC Supply mains and the SAM Supply unit including filter inrush current limiting components transformer optional AC main contactor short circuit overload and other protection devices circuit breaker or fuses In addition the PAM and SAM System requires a 24 VDC supply Local national or factory regulations may require inclusion of additional protective components beyond those covered in this chapter The system designer must be cognizant of and comply with applicable regulations and standards Special Applications Contact an ACC Motion Applications Center for technical assistance if your application requires special configurations that are beyond the scope of this manual Such as Battery or uninterruptable DC power supply operation Single phase AC Supply for lower cost low power applications PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 53 1 SELECTING SYSTEM 5 FEEDING SECTION Basic Feeding Section Configuration Figure 21 illustrat
51. g plug drawings for marking specification PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 63 PART 1 SELECTING SYSTEM COMPONENTS APPENDIK MATING PLUGS SPECIFICATIONS Drawing 080 4124 080 4124 tif 12 3 SEES Drawing 080 4125 080 4125 tif 12345 Drawing 080 4126 080 4126 tif Drawing 080 4127 080 4127 tif 234567 8 9410 cH SEBHBHHBBBH Drawing 080 4128 1234567 8941011213141516 080 4128 tif Drawing 080 4151 gag 080 4151 tif Drawing 080 4152 0804182 tif Figure 23 Signal mating plug drawings for marking specification PAM with SAM System Users Handbook Page 64 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS APPENDIX CABLES Appendix B Cables Table 30 shows all cables that are used with PAM amp SAM System Cable Type P n Supplier references 8 conductor motor cable 1mm 9032011033 LIDALCO 418410205 EUROFLEX CY 4x1 0 2x 2x0 5
52. he DC Bus just for supplying the motor drive and wiring losses An another characteristic of most multiaxis systems is that thanks to the common DC bus the mechanical energy can be transferred from an axis that is decelerating to other axes that are accelerating This saves tremendous energy consumption from the main supply and reduces also heat production while braking Select Power Consumption Calculation Method Depending on the application DC Bus power drawn by each SAM Drive may be nearly constant or fluctuate between positive and negative peak values The first step is therefore to determine whether the application fits into the constant power or dynamic power category PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 43 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES Constant Power Category Criteria In constant power applications motors run at relatively constant speed and torque requiring continuously nearly the same amount of power During machine starts and stops all motor speeds change at nearly constant acceleration within the same time span Typical constant power applications include printing winding unwinding extrusion and lamination processes with electronic gearing functions Dynamic Power Category Criteria In dynamic power applications the machine performs a repetitive cycle during which motor speed and torque fluctuates between positive and negative peak v
53. imatic PLC and as an ISA board for direct installation in a PC EasyBus This is a high speed fiber optic bus that links PAM and all SAM Drives in a closed ring configuration for exchange of program status and motion information Page 8 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS INTRODUCTION SAM Drive The SAM Drive is a modern high performance digital motion controller with an integral power stage SAM Drives execute motion I O and program tasks in response to data and commands from PAM providing enhanced system performance through distribution and sharing of system functions SAM Drives are available with continuous power output ratings of 1 5 up to 30 kVA for controlling AC servomotors and other special purpose motors Any SAM Drive may be operated at 400 or 480 VAC SAM Supply The SAM Supply provides rectified DC power to each SAM Drive at a voltage proportional to the AC supply voltage The SAM Supplies are available in two versions for operation at 400 and 480 VAC respectively Motors Motors convert electrical power from a SAM Drive to mechanical power AC servo motors and other motor types including linear and direct drive motors are readily interfaced with SAM Drives Feedback Devices A feedback device coupled to each motor provides the SAM Drive an indication of the motor s shaft angle for use in commutating the motor and controlling its
54. in using PAM and SAM products in these circumstances please contact an ACC Motion Applications Center and discuss your requirements with a motion specialist Accommodating Multiple AC Supply Voltages A system machine builder designing systems for international use must decide how to accommodate different AC supply voltage standards for the whole machine as well as for the power drive system This decision normally considers the logistics cost for supporting a separate equipment configuration for each AC supply voltage verses the cost of adding a transformer to standardize the supply voltage internally A trade off study evaluating utilization of a transformer for AC Supply Voltage standardization should not neglect the following facts In favor of using a transformer SAM Power Drive systems do not require isolation from the AC Supply therefore a lower cost auto transformer may be used PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 17 PART 1 SELECTING SYSTEM COMPONENTS AC SUPPLY AND EARTHING Transformers are highly reliable and virtually maintenance free Against the use of a transformer The electrical efficiency of three phase auto transformers is typically 98 It means that 296 of its rated power shall be transformed into heat within the cabinet even when not actually loaded Atransformer increases the voltage fluctuations at the drive system input This may force using motor
55. is generally warranted during comprehensive machine prototype testing 1 Determine the worst case cycle Generally power requirements are most severe at the highest production rate If there is any doubt about this or if the machine can be adjusted for different production rates this procedure should be repeated as many times as necessary in order to determine the worst case machine cycle 2 Determine for each motor the peak positive and the peak negative shaft instantaneous power and Pec as follows PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 45 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES Pacc ee W 0 105 x Nya RPM x T mad NMJ 1 Maxis and Poec_Peak W 0 105 x Nya RPM x T pec Nm where Nmax is the maximum speed in RPM during acceleration deceleration Naxis IS motor and drive efficiency naxs 0 85 if the motor is of synchronous AC servomotor type or 0 75 if itis an asynchronous induction motor Multiply this value by the gear efficiency if relevant T acc is the component of axis peak torque required to accelerate the motor load inertia T pec is the component of axis peak torque required to decelerate the motor load inertia T IS the component of axis peak torque required to overcome motor load friction Determine for each motor the positive root mean square
56. isted occur momentarily upon switch on of 24 VDC power Nominal Peak current Comment current need Adc Adc SAM Drive any size 1 0 2 5 any model SAM drive with or without options SAM Supply any size 1 0 2 5 any model SAM Supply PAM F51 Full System 0 8 1 3 PAM Full System 1 2 22 worst case with Profibus DP interface slightly less with other interface options Table 25 SAM 24 VDC current requirements PAM with SAM System Users Handbook Page 58 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SYSTEM ENCLOSURE System Enclosure Cabinet Selection General The enclosure housing a PAM with SAM system serves several purposes including Environmental protection and security for the equipment Suppression of EMI RFI emissions This section presents some basic guidelines and items for consideration when selecting a system enclosure Environmental Protection and Security Considerations PAM with SAM system components are rugged industrial devices however their environmental ratings and limits must be respected to insure long term reliable operation The accumulation of dust and other deposits can hamper transfer of heat from the equipment resulting in higher internal operating temperature and decreased output capacity Electrically conductive deposits in the presence of moderately high voltages up to 780 volts present in the equipment can cause faults and failures in the system Select
57. ith shared power and common connections Refer to Part 2 System Design and Integration for a functional description and to Part 5 Drive Technical Information for specifications Select either the standard or expanded User I O configuration See Table 13 depending on the types and quantity of User I O needed Standard Expanded I O Configuration Configuration SAM DA E SAM DA F high speed digital 1 0 input digital input 2 6 digital output 1 4 bi directional 0 0 4 analog input 1 1 Table 13 Standard and Expanded User I O configuration High Speed Digital Input The High Speed Digital Input is intended for use with high speed adaptive control functions i e registration mark sensing in an automatic registration function where minimum propagation delay and repeatability are required The High Speed Digital Input is available only with the standard User I O option Bi directional l Os With the expanded configuration 4 bi directional ports user programmable as either digital inputs or digital outputs When configured as an output it can also be read as input It is thus possible to connect several ouputs of several SAM drives together and to use them as a wired OR combination This can be usefull when programming safety function PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 35 PART 1 SELECTING SYSTEM COMPONENTS SAM Dri
58. lected SAM Supply model in Table 20 DC Bus Current 400 AC Supply Voltage 480 Internal Dynamic Braking Resistor E External Dynamic Braking Resistor SAM PA Figure 16 SAM Supply Model Numbering Key SAM_SUPPLY_KEY CDR J Voltage rating l optional features 4 SAM PA 400 SAM PA 480 Current rating DB Resistor 30 ADC internal 30 1 9032 010 441 9032 010 444 30 E 9032 010 442 9032 010 445 80 ADC external 80 9032 010 443 9032 010 446 Table 20 SAM Supply selection and ordering information Example SAM PA 400 80 E with part number 9032 010 443 is a SAM Supply Unit with the following characteristics and options 480 VAC Supply Voltage rating 80 continuous current rating Provisions for an External Dynamic Braking Resistor Estimating DC Bus Power Requirement General Information Proceeding according to the SAM System component selection procedure see Figure 1 load conditions for each motor in terms of velocity and torque have been defined The power drawn by each SAM Drive from the DC Bus equals the power supplied to the load i e the product of motor shaft torque and speed plus electrical and mechanical losses in the motor SAM Drive and wiring For example a motor supplying its rated torque at stall zero speed produces no mechanical power therefore the SAM Drive draws a small amount of power from t
59. lecting the PAM Model General Procedure PAM is available in a number of packaging configurations and with a number of popular network interfaces The type of host controller and network interface required primarily determines the appropriate model PAM for an application Table 1 summarizes the applications for each configuration f e E gt 4 4 T y for PAM ISA for PAM Full System SIMATIC 55 industrial PC stand alone PSU1_007 cdr Figure 3 PAM with SAM System Components Selecting and Ordering a PAM System All PAM versions provide the same core functionality and an identical EasyBus interface Package Host System PAM Type Ordering p n Configuration or Upward Fieldbus ISA bus slot of an industrial PC board 9032 011 899 PC plug in For a Simatic 55 115 system PAM S1N H8F AP P 9032 011 154 Simatic 5 plug in For a Simatic 55 135 system PAM S3N H8F AP P 9032 011 155 For a Simatic 55 155 system PAM S5N H8F AP P 9032 011 156 no interface PAM F25 Full System 9032 011 774 PAM F05 Full System 9032 011 776 Profibus DP PAM F51 Full System _ new type available1Q 01 RAK PAM F26 Full System 9032 011 775 PAM with SAM System Users Handbook P n 9081 011 981 September 13 2000 Page 11 PART 1
60. manufacturers offer an integral resolver as a standard motor option Although most resolvers operate on the same physical principles and show similar electrical characteristics i e impedance transformation ratio and excitation requirements their real accuracy vary widely from model to model Critical effects are Speed accuracy Even if the angle error lies within specification i e 6 arc min its derivative is sometimes to high due to notch effects This reduces tremendously the possible control gain that can be achieved and thus the axis accuracy J Mounting error effects The resolver rotor position toward its stator relies only on the motor flange and bearing accuracy It may slightly change radially and axially by a few tenth of a millimeter depending upon load temperature and aging Only few resolver manufactures are able to keep the resolver s position and speed accuracy within specifications in such conditions We have carefully assessed resolvers used within motor ranges so that best positioning accuracy can be achieved Refer to Table 9 Incremental Digital Encoders and Rulers Incremental digital encoders and rulers are simple optical encoders that typically produce 1 2 or 4 pulses per electrical period as illustrated in Figure 8 Most incremental encoders also provide a once rev reference pulse Although they can be interfaced to SAM Drives incremental digital encoders and rulers are not recommended for a high
61. motor current conductors with shield 8 conductor cable 4 heavy motor current conductors with shield plus two shielded pair of signal conductors for motor thermal protector and optional brake control If the axis uses either a Brake Control Option or motor mounted thermal protector or both the 8 conductor cable should be used In Table 16 locate the article part number for cable needed depending upon cross section motor and SAM drive types For axes not using the Brake Control Option nor motor mounted thermal protector the lower cost 4 conductor motor windings cables listed in Table 17 may be used Winding Cables available and Ordering part numbers Motor Cables available and Ordering part numbers Motor Windings cable assemblies are ordered by part number based on number of conductors select Table 16 or Table 17 cross section select the appropriate column motor and SAM drive combination select the appropriate line Be aware that these part numbers are defined for 5 meter long cables For other lengths ask your SAM System supplier for the corresponding part number l Cross section 4 motor range 4 SAM drive 1mm Bautz plugs SAM DA 400 07x 9032011 114 9032 011 115 SEM AHD55 SAM DA 400 14x SEM AHD70 SAM DA 400 07x 9032 011 116 9032 011 117 9032 011 118 9032 011 119 SEM AHD92 SAM DA 400 14x SEM AHD115 SAM DA 400 28x 9032 011 123 SAM DA 400 50x SAM
62. nd Ordering part numbers PAM and SAM System cables and mating connectors are not systematically shipped with each SAM Drive and must be ordered separately As for SAM Drives the information below assumes that all ready made cables and accessories are used Users who decide purchasing cables connectors and wiring accessories from a third party will find detailed connector information in Appendix A Mating Plugs Specifications and cable information in Appendix B Cable Page 48 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES Safety 24VDC Circuit Supply 1 XT memes SAM Supply X1 amp X5 replaced by an integral i terminal block on PA 80 models S XT x2 pell E EN Cable and Mating i cesat NKS 1 SAM Drive Drive SAH005a CDR 1 1 Tariman aa ah Figure 17 SAM Supply Mating Connector Configuration Selecting Mating Plugs When SAM System Ready made cables and DC bus Bars are used only the plugs below must be ordered in addition depending upon SAM Supply type If SAM PA 30 is used order plug X5 p n 9032 011 016 AC supply plug XT p n 9032 010 792 24 VDC supply amp safety interlocks If SAM PA 80 is used order plug XT p n 9032 010 792 24 VDC supply amp safe
63. nd wiring accessories from a third i Specifications and Appendix B Cables 24 VDC Supply Safety ban Interlocks 35 33 SAM bie e n i Sine cosine SAM Drive a 1 Pa 1 1 7 L4 EN 2 s F is oe 1 1 Ss 1 1 DC Bus Bar d SAHO06 b CDR Tools x11 X12 X13 X14 assembly Figure 14 SAM Drive Cable Assemblies and Mating Connectors PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 37 PART 1 SELECTING SYSTEM COMPONENTS MATING CABLES AND PLUGS FOR SAM DRIVES Motor Windings Cable Assemblies General Information Motor Windings Cable assemblies are terminated on the motor end with the correct mating connector strain relief for the designated motor The other end is terminated in the correct mating connectors for the designated SAM Drive Any length is available up to 100 meter These cable assemblies are tested and approved for use in stationary applications where the cable is not subject to repeated or continuous flexing They are rated for use in systems operated at AC Supply voltages up to 480 VAC 15 Selection Criteria Windings Conductor Cross section According to IEC 60204 1 standard the current carrying capacity for standard PVC cable depends upon following criteria conductor cross section number of cables that are routed within the
64. ogram meters as seen at the motor shaft IS the motor average speed RPM 3 Sum up the power supplied to all SAM Drives Pprve nus or aS follows rms total WV Parivet Parive2 Parivea Parivea with SAM System Users Page 44 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES In some applications winding unwinding for example one motor may be operating with positive power consuming power while another is operating with negative power generating power In such situations only the power losses positive power must be considered when designing the Feeding Section 4 Record computed value of Pprve rus for subsequent use in Supply Unit selection 5 Sum up the kinetic energy Exin all axes as follows 1 Ejang 6 Compute peak braking power Pea aS follows ParaKe_PEAK TOTAL 0 5 K teror where tstop is the braking deceleration process duration in seconds 7 Considering the braking process duration and interval between braking processes cycie determine the average braking power Pase ave Torat requirement as follows Penake TOTAL Ekw In most constant power applications c may reach several minutes or even hours When
65. or two Fiber to Fiber Optical Coupler into an EasyBus segment that is between 2 units restrict the cable length as follow f 1 Fiber to Fiber Optical Coupler is used The Total length is limited to 16 meters Example 15 meter 1 coupler 1 meter segment Page 14 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS PAM AND ITS ACCESSORIES If 2 Fiber to Fiber Optical Couplers are used The Total length is limited to 12 meters Example 1 meter 1 coupler 10 meter 1 coupler 1 meter segment It is not allowed to couple long distance cable with standard nor with Kevlar reinforced types PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 15 PART 1 SELECTING SYSTEM COMPONENTS SUPPLY AND EARTHING AC Supply and Earthing About International AC Supply Voltage Standards The IEC 60038 standard specifies three phase AC supply voltages around the world At this time in Europe as well as many other countries the nominal three phase low voltage AC supply voltage is 400 VAC the older 380 and 415 VAC mains have been phased out In North America four standard three phase AC supply voltages 208 240 460 and 480 VAC are in common use A few other AC supply voltages are used in other countries SAM is compatible with most standard AC Supply voltages as listed in Table 4 SAM is also compatible with both 50 Hz and 60 Hz
66. ors In some applications where yax is less than 10 Aims the inrush current limiting resistors and starting relay K1 can be replaced by NTC Negative Temperature Coefficient resistors placed in series with relay K2 See Figure 21 Using NTC Resistors is simpler and less expensive than the resistors and starting relay solution This approach is not recommended for highly dynamic applications where they may never reach their working temperature thereby preventing motors from reaching their peak velocity Contact your SAM System supplier for additional information or assistance in the application of NTC resistors for inrush current limiting Input Current Computation All Feeding Section components are sized based the RMS power nus actually consumed by the Power Drive System rather than SAM Supply unit or transformer current ratings which may be considerably higher This approach provides better overload protection and frequently some cost savings Proceed as follows 1 Determine the lowest available AC Supply voltage y Generally decreasing the rated AC Supply voltage by 1096 provides a good result 2 Using the RMS power supplied to all SAM drives computed during Supply Unit selection see Estimating DC Bus Power Requirement on page 43 compute the maximum RMS primary current required as follow ma Arms 0 57 e Parive rms total WI Uy 3 Ifa trans
67. otor movements All other characteristics are the same as for the incremental sine cosine encoder see Table 6 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 25 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Electrical period Sine Cosine Coarse Sine Coarse Cosine 1 turn Msc008_a CDR N electrical periods Figure 10 Incremental Sine Cosine Encoder with Commutation Track Multiturn Absolute Sine Cosine Encoders and Absolute Sine Cosine Rulers The multiturn absolute sine cosine encoder combines the characteristics of a standard sine cosine encoder with the capability for absolute position readout over 4096 turns These devices are typically used in applications where the orientation of an axis load not coupled 1 1 to the axis motor must be directly measurable on demand The multiturn absolute sine cosine encoder provides standard sine cosine encoder outputs for motor commutation and servo loop closure On demand typically at startup the multiturn encoder sends data words containing the motor s offset number of turns from a pre defined home reference position and angle the angular position within a turn generally with accuracy better than gt an electrical period This information permits the SAM Drive to establish the axis absolute position and motor s magnetic angle The offset and angle data are transmitted over a separate serial communication
68. performance drive system Servo loop stiffness is largely dependent on the resolution of the speed feedback signal and this is difficult to extract at very low speed from a few pulses and within a reasonable sampling interval PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 23 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Electrical period 4 gt B c Counts Msc007 a CDR 1 turn n electrical periods Figure 8 Incremental Digital Encoder Output Incremental Sine Cosine Encoders and Rulers Incremental sine cosine encoders and rulers are a recent development in the evolution of incremental optical encoders Most versions produces two 90 degree shifted differential 1V peak to peak signals called the sine and cosine outputs because of their quasi sinusoidal relationship to angle plus a once rev reference pulse see Figure 9 These encoders and rulers have a bandwidth of 150 to 300 kHz Incremental sine cosine rulers are the only choice for linear motor applications Table 6 summarizes typical performance characteristics for these encoders when used with SAM Drives Performances for rulers can be estimated by converting angles into sine periods and then into millimeters or microns Electrical period Sine Cosine d 1 turn gt Msc006_a CDR
69. power or not the previously computed average braking power Pasa tora IS greater than 70 W select 30 E for external Dynamic Braking Resistor If Pase ave tora IS less than or equal to 70 W select 30 I for internal Dynamic Braking Resistor unless cooling capacity within the enclosure cannot accommodate 70 Watts from an internal DB resistor 6 Record the complete SAM Supply model number selected from Table 21 i e SAM PA 480 E Selecting an External DB Resistor When an External DB Resistor is Required When a SAM Supply without a built in DB resistor designated by E in the model number has been selected the user must provide an external DB Resistor from among those available from ACC About SAM System DB Resistors These DB resistors incorporate an ID resistor which informs the SAM Supply of the unit s power rating The SAM Supply requires this ID resistor for power dissipation monitoring and DB resistor overload protection Thanks to this feature no manual adjustment is required for adjusting the selected DB resistor power DB Resistors are supplied with a 3 meter length of shielded cable attached to the DB Resistor and a connector kit for attaching to the SAM Supply end One end of the cable is left unterminated to facilitate routing the cable and to permit trimming to required length before installing the supply end connector Refer to for dimensions of DB Resistors PAM with SAM Sy
70. pplied to all SAM Drives Page 46 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES 3 Within the selected AC Supply segment select the appropriate row i e 26 kW of column Page peak tora based on the previously computed and recorded peak braking power peak tora Produced by all SAM Drives 4 The contents of the cell at the intersection of the row selected in step 3 and column selected in step 2 i e 30 E designates the SAM Supply Unit current rating required for the application If the contents of the selected cell is 30 a further evaluation must be made proceed to step 5 otherwise record the current rating and DB Resistor components of the Supply Unit model number Supply Voltage J 400 VAC 480 VAC SAM PA 400 SAM PA 480 TOTAL 4 Porive rms torau V Parake rorAL Porive rms TOTAL lt 13 kW lt 35 kW lt 16 KW lt 42 KW lt 8 5 kW 30 80 lt 6 KW 30 80 E lt 25 kW 30 80 lt 26 KW 30 80 E lt 62 kW 80 80 lt 74 KW 80 E 80 E Table 21 SAM Supply Model Selection Chart 5 If the model number component selected step 4 was 30 2 it is necessary to define if the built in resistor can handle the avarage braking
71. r continuous flexing Feedback cable assemblies are available for all compatible types of position feedback devices including Resolvers integral to AC servomotors Sine cosine encoders integral to AC servomotors with or without ENDAT link Multiturn resolvers integral to servomotors For cables to remote position feedback devices i e a ruler or an encoder that monitors a master axis ask your SAM System supplier 1 Selection Criteria Feedback Type Three feedback cable configurations are available including feedback cable for standard resolver integral to servomotor feedback cable for optional encoder integral to servomotor with ENDAT link feedback cable for optional multiturn resolver integral to servomotor Feedback Cables available and Ordering part numbers Feedback cable assemblies are ordered by part number based on feedback type select the appropriate column motor type select the appropriate line Be aware that these part numbers are defined for 5 meter long cables For other lengths ask your SAM System supplier for the corresponding part number J Feedback type J J motor range 4 Standard Resolver Optional Encoder Optional Multiturn with ENDAT link Resolver Bautz plugs 9032 010 742 ask supplier ask supplier SEM AHD55 SEM AHD70 SEM AHD92 9032 010 745 ask supplier ask supplier SEM AHD115 SEM AHD142 SEM AHD190 Table 18 Feedback Cable
72. rrent requirements The procedure follows SAM Drives have different output current ratings depending on PWM switching frequency selected The nominal 8 kHz switching frequency provides a higher pass band and lower acoustic noise A 4 kHz switching frequency with higher output current but slightly lower pass band and higher acoustic noise may be selected Continuous and Peak Current Calculation 1 Using the performance curves for the selected motor locate the axis continuous torque value on the horizontal axis Draw a vertical line to the CURRENT curve then read continuous motor current required from the right hand vertical axis see Figure 6 Multiply continuous motor current by 1 1 and record the value as lycoy The continuous motor current must be multiplied by 1 1 to accommodate a 1096 tolerance in the motor torque constant 2 Error Reference source not found locate the SAM Drive model whose continuous current rating Iconr at the selected AC Supply Voltage i e 480 or 400 VAC is greater than the continuous motor current recorded in Step 1 Peak Current Duration Calculation 3 Locate the axis peak torque value the horizontal axis Draw a vertical line to the CURRENT curve then read peak motor current prak required from the right hand vertical axis see Figure 6 Multiply peak motor current by 1 1 and record the value as leak 4 Verify that the peak motor
73. s line using a communications protocol such as ENDAT Multiturn absolute sine cosine encoders are available for rotary applications Absolute sine cosine rulers for linear applications with similar functionality are also available and use the same protocol Table 7 summarizes the typical performance characteristics for a multiturn encoder when used with a SAM Drive Performances for rulers can be estimated by converting angles into sine periods and then into millimeters or microns PAM with SAM System Users Handbook Page 26 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Accuracy 32 arc sec for a typical 2048 period encoder Resolution 0 43 arc sec 3 000 000 counts turn resolution of SAM Drive conversion process is 1 4900 of an electrical period Max Speed 4400 RPM 2048 period encoder with 150 kHz bandwidth SAM Drive bandwidth is 450 kHz Absolute position Yes typically over 4096 turns Typical use AC servomotors option Direct drive motors option Linear motors yes Relative cost Robustness Typical applications very high good limited by glass disk and silicon Axes requiring high servo stiffness or high accuracy at constant speed and direct readout of axis absolute position at startup Printing applications Start up No motor movement the motor magnetic angle is given together with the multit
74. s with lower K factor for reaching the speed goals As a consequence higher motor current shall be needed which may required a more powerful and thus more expansive drive Earthing Requirements Four Wire System with Solidly Earthed Neutral The AC Supply must have a solidly earthed neutral as all SAM units have been designed for overvoltage category EN50178 If a three phaseAC Supply with solidly earthed neutral is not available an isolation transformer with W ye connected secondary solidly connected to earth must be used see Optional Transformer on 57 Operating a PAM with SAM system is prohibited with following earthing methods isolated or floating supply resistance earthed neutral solidly earthed line B2 column Three phase four wire systems with earthed neutral line 300 VAC line For additional information on AC Supply earthing refer to IEC 664 1 1992 10 Table to neutral PAM with SAM System Users Handbook Page 18 P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS MOTORS Motors Motor Technology Choices As a universal Drive System PAM with SAM supports both AC servomotors also called permanent magnet synchronous motors or DC brushless servomotors and induction motors also called asynchronous motors In both cases motors should be equipped with a position feedback device for closed loop positioning operation SAM supports also linear and
75. sophisticated encoder is required which provides for single turn absolute value in addition Refer to the sections Incremental Sine Cosine Encoder with Commutation Track and Multiturn Absolute Sine Cosine Encoder below Accuracy 32 arc sec for a typical 2048 period encoder Resolution 0 43 arc sec 3 000 000 counts turn resolution of SAM Drive conversion process is 1 4900 of an electrical period Max Speed 4400 RPM 2048 period encoder with 150 kHz bandwidth SAM Drive bandwidth is 450 kHz Absolute position no Typical use AC servomotors option Direct drive motors option Linear motors yes Relative cost high Robustness good limited by glass disk and silicon Typical applications Axes requiring high servo stiffness or high accuracy at constant speed Printing applications Start up Some fractional turn motor shaft movement is required at startup to determine the motor s magnetic angle Table 6 Incremental Sine Cosine Encoder Characteristics Summary Incremental Sine Cosine Encoders and Rulers with Commutation Track This is a special version of the incremental sine cosine encoder that provides standard sine cosine encoder outputs along with a second low resolution one period turn sine cosine output see Figure 10 The SAM Drive utilizes this coarse sine cosine output to establish the motor s magnetic angle at startup thereby eliminating the necessity for a series of m
76. stem Users Handbook P n 9031 011 981 September 13 2000 Page 47 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES Selection and Ordering Procedures DB Resistor must accommodate the average braking power Pase Torat which determines the resistor power rating and the peak braking power Pea tora Which determines the resistor s ohmic value Referring to Table 22 perform the following steps to select an appropriate DB Resistor 1 Inthe column labeled Pag ave tora Select the lowest wattage rating which is greater than the previously computed average braking power Pese ave If Pene ave ror for the application exceeds the largest rated DB Resistor power rating listed contact an ACC Motion Applications Center for assistance 2 Select the line depending upon SAM Supply used Record the corresponding part number and ohm value for the DB resistor selected TOTAL J SAM Supply used J 0 to 400 0 800W 0 1600 W SAM PA 400 30 E 9032 010 704 9032 010 704 16 8 16 8 400 80 9032010704 9032010 704 16 8 16 8 480 30 9032 010704 9032 010 704 16 8 16 8 SAM PA 480 80 E 9032 010 704 9032 010 704 16 8 16 8 Table 22 SAM Supply Unit Accessories General Information External DB Resistance Selection a
77. ted to the referenced pages for the details TASK REFERENCE Determine necessary Determining Axis Current current rating Requirement page 32 Select User I O Selecting the User confiquration Configuration page 35 Select position feedback Selecting the Feedback interface option Option page 33 Select brake no brake Selecting the Brake Control option Option page 35 Define SAM Drive type Table 11 page 31 Figure 11 General Procedure for Selecting a SAM Drive Drive Selection Strategy This procedure results in selection for each axis of the lowest cost SAM Drive which will do the job In some circumstances when one considers the cost of carrying a spares inventory which includes several models of SAM Drives the lowest total cost solution may be to select for all axes the lowest cost SAM Drive which satisfies the requirements for all axis This is a perfectly acceptable strategy since the user may constrain each SAM Drive to operate within the operating limits of the motor Ordering Information SAM Drives including options and accessories are determined by part number or by model number Figure 12 illustrates the construction of a SAM Drive s model number based on its current rating and included options The SAM Drive options Page 30 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS SAM Drives described in this section are not field installable
78. the braking process duration tsrop is short a much smaller tstop_cycie Value must be used when selecting the Dynamic Braking Resistor Use the following guidelines for selecting When is less than 10 seconds select 10 seconds When tao is greater than 10 seconds select tsrop tstop 8 Record computed values of Page peak ANd Peace ave for use in SAM Supply and DB Resistor selection Calculating DC Bus Power for Dynamic Power Applications This procedure for calculating DC Bus power required in dynamic power applications is based on some rules of thumb which have proven to be convenient for most applications It provides some safety margin as it is very common that while motors decelerate their returned energy is immediately reused for accelerating other motors reducing both the AC Supply furnished energy and dissipated energy Simultaneous deceleration of all motors occurs only infrequently in an emergency stop condition Using more exact analytical methods to detail all energy flow could possibly lead to lower power values and cost savings however experience indicates there are many mechanical values not accurately known at machine design time which influence power needs more dramatically than regenerated energy available for reuse For this reason this rather conservative rule of thumb method is recommended A results based power supply re evaluation
79. ty interlocks DC bus Bar General Information The DC Bus distributes DC Power at high voltage and current levels from a SAM Supply to SAM Drives in a PAM with SAM system The PAM amp SAM System offer a new innovative DC bus Bar Benefits for users are Compact It requires only 40 mm of mounting panel height Safe ltis inherently IP20 protected no cover to put and remove Easy to use Lock on connectors screw driver required only for disconnecting bus bar accommodates up to 12 SAM units DC DC PE Provides for 12 additional PE connections to be used for motor PE connection Possibility to cascade several bus bars PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 49 PART 1 SELECTING SYSTEM COMPONENTS SAM SUPPLY AND ITS ACCESSORIES In addition to the bus bar itself a range of preconfectionned cables are available that fit to all SAM units DC bus bar description 11 2 3 SAM PA Supply Filter DC bus Beppe bar PE Ere A PSU1_005 doc D B Resistor Motor Figure 18 DC bus bar wiring diagram 1 qu IE 8 F 115 3 BABE BABE ie 3 conductors ZU iiu
80. uipment mounting panel must be bare unpainted the areas beneath where the PAM SAM Drives SAM Supplies and EMI filters are mounted providing intimate metallic contact between the units and backpanel PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 59 PART 1 SELECTING SYSTEM COMPONENTS SYSTEM ENCLOSURE Cooling Equipment General The failure to provide adequate cooling for a power drive system is one of the leading causes of unsatisfactory performance and one of the most difficult deficiencies to correct after a system has been installed A detailed presentation on thermal load calculation and cooling equipment sizing is beyond the scope of this manual however please consider the following points when sizing cooling equipment for the system Use the highest expected ambient temperature at the location where the system will be installed for calculating cooling required Do not neglect the contribution of transformers Although their efficiency is very high they transfer a large amount of power and the heat they create can be considerable Extra cooling capacity is relatively inexpensive to purchase but costly to add after the system has been completed Page 60 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS APPENDIX A MATING PLUGS SPECIFICATIONS Appendix A Mating Plugs Specifications Table 26 Table 27 Table 28 and Ta
81. urer amp type Sine cosine ruler YES AMO PMK 01 V coarse magnetic 1mm p riod YES Zeiss LIE 5 1P COFA YES Heidenhain LIDA 187 LIDA 181 Absolute sine cosine NO Heidenhain LC181 EnDat rulers Table 10 SAM Compatible Linear Feedback Devices Incremental encoders and rulers are manufactured with very different characteristics such as measurement principle optical magnetic accuracy 1 arc min to 1 arc sec mechanical mounting etc All incremental encoders and rulers meeting both of the m following conditions can be used with the SAM Drive 1Vpp sine cosine voltage outputs X Less than 250 mA consumption from the 5VDC supply PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 29 PART 1 SELECTING SYSTEM COMPONENTS SAM Drives SAM Drives Introduction Procedure for selecting SAM Drives Since a Power Drive system usually includes multiple axes the system designer must select the appropriate model SAM Drive for each axis considering the motor load torque and options required on an axis by axis basis Proceeding according to the system component selection procedure see Figure 1 load conditions for each axis in terms of velocity and torque have been defined Motors and feedback devices have been selected Figure 11 illustrates the steps in selecting a SAM Drive and accessories Proceed sequentially through the tasks listed in Figure 11 branching where indica
82. urn information Table 7 Mutli turn Absolute Sine Cosine Encoder Characteristics Summary Single Turn Absolute Sine Cosine Encoders This is a less expensive version of the multiturn absolute sine cosine encoder that provides standard sine cosine encoder outputs along with angle readout over an ENDAT serial communications channel for establishing the motor s magnetic angle and absolute position over one turn All other characteristics are the same as listed in Table 7 Multiturn Resolvers The multiturn resolver is functionally similar to the multiturn absolute sine cosine encoder with the exception that it provides standard resolver outputs for motor commutation and servo loop closure along with absolute position readout over 4096 turns This is the most appropriate multiturn absolute sensor for packaging and handling applications thanks to its lowest price and its very high robustness gt 50 000 hours of operation at 125 C Multiturn resolvers are available for rotary applications only Table 8 summarizes the performance characteristics for a multiturn resolver in combination with a SAM Drive PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 27 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Accuracy 6 arc min limited by the resolver used Resolution 7 arc sec 200 000 counts turn limited by SAM Drive conversion process Max Speed 8000 RPM
83. ves within the SAM drives which should be active when the communication with PAM and the rest of the machine fail Analog Input The analog Input is logically a part of the User I O however physically its hardware components are located within the Position Feedback Interface It is a 10 V PLC CNC type differential analog input with 12 bit resolution It is available for general use as a User input Refer to Part 2 System Design and Integration for a functional description and to Part 5 SAM Drive Technical Information for specifications Page 36 PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 PART 1 SELECTING SYSTEM COMPONENTS MATING CABLES AND PLUGS FOR SAM DRIVES Mating Cables and Plugs for SAM Drives General Information PAM and SAM System cables and mating connectors are not systematically shipped with each SAM Drive and must be ordered separately depending upon the user s cable supply strategy which can be either of followings Using SAM System ready made cables DC bus bar and connector kits Using only SAM System connector kits Acquiring all cables and connectors from a third party In that case we recommends using the specified connector suppliers This section describes only the product selections for the first supply strategy party will find detailed cable and connector information in Appendix A Mating Plugs Users who decide purchasing cables connectors a
84. y Direct Drive Motors Direct drive motors provide high torque with high stiffness for critical applications where the standard motor reducer combination is insufficient When combined with a high resolution feedback device such as a sine cosine encoder the direct drive motor can satisfy the most demanding applications requiring high torque with high accuracy Applications Assistance ACC Motion has assisted machine manufacturers in a variety of linear and direct drive projects Our mechatronic experts can provide assistance in selecting the appropriate technology and in choosing the appropriate motor feedback for the application PAM with SAM System Users Handbook P n 9031 011 981 September 13 2000 Page 21 PART 1 SELECTING SYSTEM COMPONENTS POSITION FEEDBACK DEVICES Position Feedback Devices Position Feedback Device Types and Characteristics Resolvers Using a simple analogy a resolver is nothing more than a transformer with a rotating primary and two stationary secondary windings separated radially by 90 degrees The primary winding excited with a low power signal of several kilohertz induces a voltages into each secondary winding The signal amplitude in the secondary windings is a function of their angular relationship to the primary Conversion hardware software in the SAM Drive determines the resolver s angular position from the ratio of signal amplitudes on the secondary windings see Figure 7 Resolvers are

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PAM & SAM System User's Manual