Parker Hannifin E-AC Drive 88-020292-01 A User's Manual
Contents
1. 1 68 1 40 g 1122 D 84 3 56 7 28 0 0 10 20 30 40 50 Speed RPS VS23B E AC Drive 2 10 mum T 1 75 3 140 8 Nabe A 2 in LIT 1 05 z 70 7 35 0 0 10 20 30 40 50 Speed RPM EEHEHE EHE Series Parallel Full Step Chapter 2 Installation Motor SPECIFICATIONS OS Motors Parameters Static torque Rotor inertia Drive Current Apk Arms Phase Inductance mH Detent Torque Bearings Information Thrust Load Radial Load End Play Reversing load equal to 1 Ib Radial Play Per 0 5 Ib load Motor Weight Certifications VS Motors Parameters Static torque Rotor inertia Drive Current Apk Arms Phase Inductance mH Detent Torque Bearings Information Thrust Load Radial Load End Play with 2 2 Ibs axial load Radial Play with 1 1 Ib radial load Motor Weight Units oz in Nm oz in kg cm Series Parallel Series Parallel oz in N m lb kg Ib kg in mm in mm lb kg UL recognized CE LVD CE EMC amp LVD Units oz in Nm oz in kg cm Series Parallel Series Parallel oz in N m kg Size 23 Frame OS2HB OS21B 61 35 126 5 0 43 0 84 0 39 0 66 0 07 0 12 1 76 1 24 1 88 1 33 3 25 2 48 3 76 2 66 8 6 12 2 2 3 2 5 4 0 0 02 0 03 18 13 5 9 5 9 20 20 9 1 9 1 0 001 0 001 0 025 0 025 0 0008 0 0008 0 02 0 02 1 1 5 0 5 0 7 Pendin2. Flexible boot may be bent as shown Nominal height 1 0 25 4 2X 2 56 UNC 2B 170 MIN ON A 1 812 B C f 1 0 Las Shaft Dia 25 4 1 06 26 9 gt _ lt A 45 de n 9 ES 2 25 1 86 DE 572 47 2 z mx j Le 0 20 5 08 L 0 02500 ee 2 29 0 81 20 6 lt 0 055 1 40 654 1 496 36 08 A gt gt 75 0 04 i Optional rear shaft Model A B C OS2HA OS2HB 1 60 40 7 2 44 620 For flying leads FLY 13 5 343 min OSZIA OS21B 2 06 524 2 90 73 7 For 10 ft cable L10 120 0 3048 OS22A OS22B 3 10 78 8 3 94 100 1 OS Motors Frame Size 23 Dimensions 12 305 MIN 5944 04 15 1 08 02 2 5 79 02 20 5 oes ora Ooto I 6 19685 0 0005 ly 50J 0 01 MODEL A 03 7 VS12 1 520 38 6 VS13 1 850 47 0 VS Motors Frame Size 17 Dimensions 16 E AC Drive Hardware Installation Guide 177 006 E 4 5 15 FLAT 59 01 15 25 6 866 0 001 22 00 0 033 2X 1 654 42 00 HOT e Deo LS ILLINS Qo Chapter 2 RE RC Encoder optional 4X M3 X 02 5 17 4 3 MIN DEEP waw 2X 1 22 008 31 0 2 2X 610 15 50 Installation 18 457 MIN 2X 1 11 28 2 i I 2X 22 2 56 4
3. a VS Motors Frame Size 23 Dimensions 18 457 MIN 3 38 85 8 03 38 85 8 VS Motors Frame Size 34 Dimensions E AC Drive Hardware Installation Guide 002 0 05 MODEL A 03 7 VS31 2 598 66 0 3 780 96 0 98 01 25 0 0 25 FLAT 973 025 0 025 002 0 05 4X6 197 01 5 25 2X 1 86 4X RO 18 4 6 cet lesi 0 003 075 al 61 5 0014 y 03 008 38 1 025 1 6 2 59 001 02 5 X 45 ATTA 15 25 MM t m EE 9 250 0 0005 IN mi 6 35 0 013 9 25 duel 6 354 0 013 III 02 5 X45 i ae Il AMA O 63 004 79 02 16 1 20 5 28 1 003 075 A 5 8 15 002 0 05 2 165 55 0 VS23 3 051 77 5 A O oo3 075 A 39 10 0 62 875 0 001 4 A L1 46 04 37 1 Chapter 2 Installation mm I L 2X 2 74 69 6 AX 9 26 6 6 THR 1 45 0 006 11 5 0 15 FLATS 2X 2X 1 37 34 8 17 2 CONNECT THE MOTOR TO THE DRIVE WIRING Most Compumotor motor windings phase A and phase B are bifilar windings made from double stranded copper wire Each phase has two half windings which can be wired together in series or pa
4. 1 2 3 4 5 6 7 8 Off circuitBoara Auto Test 61718 lame Current E off off off 0 02 isable off off on 0 13 Enabled on off on off 0 24 1 rps for 2 revs in each off on on 0 35 Series S direction until disab on off off 0 46 Parallel P R lution on off on 0 58 esolutio 213 415 on Fon off 0 69 25 000 off off off off on on on 0 80 50 800 on off off off off off off 0 91 50 000 off on off off off off on 1 03 VS12BS VS13BS 36 000 on on off off off on off 1 14 25 600 off off on off off on on 1 25 25 400 on off on off on off off 1 36 21 600 off on on off on off on 1 48 20 000 on on on off on on off 1 59 18 000 off off off on on on on 1 70 OS2HBS 12 800 on off off on off off off 1 82 OS21BS 10 000 off on off on off off on 1 93 5 000 on on off on of on of 204 VS12BP VSTSBP 2000 ot off on on offon on 215 NVS22BS VS23BS 1 000 on off on on on off off 227 VS21BS 400 off on on on on off on 2 38 0S22BS 200 on on on on on on off 2 49 200 amp 400 not affected b on on on 2 60 w
5. Automation p n 88 020292 01 A E AC Drive Hardware Installation Guide Effective April 9 2002 MPORTANT User Information N WARNING A E Series products are used to control electrical and mechanical components of motion control systems You should test your motion system for safety under all potential conditions Failure to do so can result in damage to equipment and or serious injury to personnel E Series products and the information in this user guide are the proprietary property of Parker Hannifin Corporation or its licensers and may not be copied disclosed or used for any purpose not expressly authorized by the owner thereof Since Parker Hannifin constantly strives to improve all of its products we reserve the right to change this user guide and software and hardware mentioned therein at any time without notice In no event will the provider of the equipment be liable for any incidental consequential or special damages of any kind or nature whatsoever including but not limited to lost profits arising from or in any way connected with the use of the equipment or this user guide 2002 Parker Hannifin Corporation All Rights Reserved Technical Assistance Contact your local automation technology center ATC or distributor or North America and Asia Europe non German speaking Germany Austria Switzerland Compumotor Division of Parker Hannifin Parker Digiplan HAUSER Elektronik GmbH 5500 Bu
6. off on on off 20 000 on on on off 18 000 off off off on 12 800 on off off on 10 000 off on off on 5 000 on on off on 2 000 off off on on 1 000 on off on on 400 off on on on 4 200 on on on on 200 amp 400 not affected byl waveform settings Waveform Pure sine 4 3 harmonic off 6 3 harmonic on 8 3 7 harmonic on Auto Standby zc 50 Current Reduci A Remove power before changing DIP switches A 6 7 8 amps Edge of Circuit Board Current off off off off off 0 02 off off 0 13 off on off 0 24 off off off on on 0 35 Series S Parallel P VS12BS VS13BS OS2HBS OS21BS VS12BP VS13BP VS22BS VS23BS fo o o o o o o o o o o o o VS21BS OS22BS VS31BS on on on off off 3 16 VS32BS on jon on off on 3 28 on on nion 32 mH all VS on off 3 39 OS21BP OS22BP n OS motors 32 64 mH Gain off on gt 64 mH Select a setting based on on On gt 64 mH off Disabled Enabled motor inductance in mH Anti Resonance NOTE This drawing is duplicated in nstall
7. Clamshell Clamp Enclosure Panel 360 Bonding Techniques The following clamps and clamp kits are available from Compumotor Clamp Type Compumotor Part Number R Clamp 58 016050 01 R Clamp Kit 10 per R CLAMP KIT Bulkhead Clamshell Clamp 53 016131 01 Clamshell Clamp Kit 2 per CLAMSHELL KIT 44 E AC Drive Hardware Installation Guide Appendix B Regulatory Compliance UL and CE If you use a screw terminal cable breakout device be sure to properly enclose all exposed conductors to avoid contamination and to reduce the risk of electrostatic discharge I O must utilize high quality shielded cabling 85 braid coverage minimum which must be RF earth bonded as shown above Panel Mounting the E AC Drive The mounting panel must be properly earthed and paint must be removed from drive mounting locations You must fasten the motor shield braid close to the drive s heatsink If you use a screw terminal cable breakout device be sure to properly enclose all exposed conductors to avoid contamination and to reduce the risk of electrostatic discharge I O must utilize high quality shielded cabling 85 braid coverage minimum which must be RF earth bonded as shown above System Installation If you mount the E AC Drive in an enclosure terminate cable braids screens at the entrance of the enclosure However the motor braid must be returned only to a location close to the drive s heatsink The next figure shows a typ
8. VIT Shield Shield is internally connected A to the motor s case Motor Connector Wired for SERIES Motor Current Be sure to insulate the center tap connections these are the wires shown joined together in the drawing above but not connected to the drive The operating temperature of a motor connected in series will be lower than that of a motor connected in parallel Therefore you should operate your motor in series if your application permits Typically series connec tions work well in high torque low speed applications 18 E AC Drive Hardware Installation Guide Chapter 2 Installation CONNECTING THE Motor PARALLEL WIRING For parallel motor current connect a Compumotor motor as shown in the following diagram Compumotor Motor OS Motors VS Motors VS Motors NUI e flying lead with cable L Phase A Windings s Red Red A Yellow White Blue Red White Yellow A Yellow Black Orange White B Black White Brown Orange White Orange B Black Green Shield x Shield is internally connected to the motor s case Motor Connector Wired for PARALLEL Motor Current At higher speeds a motor connected in parallel will produce more torque than the same motor connected in series However the operating tem perature of the motor in parallel will be much higher If you operate your motor in parallel you must measure motor tempera ture under actual operating
9. EMC installation 45 enclosure mounting 44 extending motor cables 27 F fan cooling 25 fault output 24 filters 43 G GRA Goods Returned Authorization number 34 grounding AC power ground 29 motor case 18 H humidity 25 I inductance large signal 21 small signal 21 input direction 23 reset 24 shutdown 23 step 22 installation overview 10 test 30 L large signal inductance 21 LED functions 32 losses power 30 LVD 42 M motor connector 18 19 current selection Compumotor motors 20 non Compumotor motors 39 dimensions 16 extending cables 27 grounding 18 mounting 26 parallel wiring 19 selection 14 series wiring 18 19 specifications 15 speed torque curves 14 Index 47 mounting 45 drive 25 motor 26 N non Compumotor motors 36 O output fault 24 overtemperature 25 32 P panellayout 26 panel mounting 45 parallel motor wiring 19 peak power ratings 30 power connection 29 power ratings 30 precautions 10 product return 34 9 quick test See automatic test R regulatory agencies 42 reset input 24 resolution 21 return procedure 34 RMA 34 s series motor wiring 18 19 ship kit 10 short circuit protection 33 shutdown input 23 small signal inductance 21 specifications motor 15 speed torque curves 14 standby automatic 21 step input 22 step down transformer 29 system test 30 T technical support 33 temperature limits drive 25 motor 19 test autom
10. ExTENDING Motor CABLES If you need to extend Compumotor motor cables beyond the standard 10 feet 3 m consult the table below for recommended wire sizes Cables longer than 50 feet 15 m may degrade system performance Do not extend cables beyond 200 feet 61 m Max Current Less than 100 ft 30 m 100 200 ft 30 60 m Motor Type amps Size AWG mm AWG mm OS2HBS 1 70 22 0 34 20 0 50 OS2HBP 3 39 20 0 50 18 0 75 OS21BS 1 82 22 0 34 20 0 50 OS21BP 3 50 20 0 50 18 0 75 OS22BS 2 38 22 0 34 20 0 50 OS22BP 3 50 20 0 50 18 0 75 VS12BS 1 03 22 0 34 20 0 50 VS12BP 2 04 22 0 34 20 0 50 VS13BS 1 03 22 0 34 20 0 50 VS13BP 2 04 22 0 34 20 0 50 VS21BS 2 27 22 0 34 20 0 50 VS21BP 3 50 20 0 50 18 0 75 VS22BS 2 04 22 0 34 20 0 50 VS22BP 3 50 20 0 50 18 0 75 VS23BS 2 04 22 0 34 20 0 50 VS23BP 3 50 20 0 50 18 0 75 VS31BS 3 05 22 0 34 20 0 50 VS31BP 3 50 20 0 50 18 0 75 VS32BS 3 16 22 0 34 20 0 50 VS32BP 3 50 20 0 50 18 0 75 S Series Configuration P Parallel Configuration Rated current in wire sizes shown may result in a maximum temperature rise of 10 C 18 F above ambient E AC Drive Hardware Installation Guide Chapter 2 Installation 27 7 CONNECT THE MOTOR TO THE LOAD COUPLERS Align the motor shaft and load as accurately as possible In most applica tions some misalignment is unavoidable due to tolerance buildups in components However excessive misalignment may degrade your system s performance The three mis
11. conditions If the motor exceeds its maximum case temperature reduce the duty cycle or use automatic standby to reduce current at rest or use forced air cooling to limit motor heating Compumotor motors have maximum case temperature of 100 C 212 F CAUTION High current in parallel connected motors may cause motor overheating You may need to reduce the duty cycle to 50 to decrease motor temperature or use automatic standby SERIES VERSUS PARALLEL SUMMARY The following list summarizes the points discussed above 1 Examine the speed torque curves for your motor 2 Use series connection if possible The motor will run cooler 3 Use parallel connection if you need more torque than series connection provides Typically at higher speeds 4 Parallel connection will cause the motor to run hotter so measure motor temperature under operating conditions 5 If necessary reduce duty cycle use automatic standby or use forced air cooling to keep motor temperature within acceptable limits E AC Drive Hardware Installation Guide Chapter 2 Installation 19 3 SET DIP SWITCHES Two 8 position DIP switches are located on top of the E AC Drive Config ure these DIP switches for your motor and application The table below summarizes switch settings Default Position Drive ships from factory with all DIP switches in the OFF position SESEGSEE GEESE r Edge of TIER mz z y Edge of NE A 12 3 4 5 6 7 8
12. is functioning normally it does not conduct when any of the following conditions exist e No power is applied to the drive e AC line voltage is too low less than 95VAC e Drive temperature is higher than 55 C 131 F e Drive detects a short circuit in motor or motor cable Fault output specifications are VCE 30VDC VCESAT 1 VDC Collector Current 40 mA minimum Dissipation 40 mW maximum Optically Isolated Yes RESET INPUT The reset input provides a means for you to reset the E AC Drive without actually cycling power To activate the reset input apply a positive voltage to RESET with respect to RESET when the motor is not moving The reset will not be complete until 0 7 seconds after the voltage is removed A reset has the same effect on the drive as cycling power e DIP switch settings are loaded into the drive for configuration e Existing faults are cleared e Current to the motor is turned off while voltage is applied to the reset input e After voltage is removed from the reset input the drive s soft start procedure will ramp current up to the startup state The motor will move to the nearest pole position e After voltage is removed from the reset input there will be a 0 7 second delay before reset is complete and normal operations can continue Reset input specifications are Input Current 2 5 mA minimum 30mA maximum Input Voltage 3 5V minimum min required for on or high signal 13V maximum 5V
13. nnns 28 S8 CONNECTAGC POWER tic beta tiec ruht aet verra dented etas ete i Pear a eretta Ea amik Te fad 29 9 TEST THE INSTALLATION corria 30 Chapter 3 Troubleshooting U U U U uuu uuu uu u uu anna 31 Trou bleshiooting Basl6S ul s Aa a ae then e tdg e ae 32 Diagnostic LEDS is tied ttt oM ADI epa OM ay 32 Protective GIICUILS u u adrian o Pra ea cha rob o aces Pee aot aeta ee d 32 OVERTEMPERATURE PROTECTION nennen n essersi aeree renean dns 32 SHORT CIRCUIT PROTECTION lid aid Fi dba v rea eed ed 33 Automatic Testa itus lla ole c a t Ure Fani Pe deis un AP EE RUNE ART HOUSE QUIE E Lelio 33 Anti Resonance Disable iii aia ete rac cere endete ta tL reo rtr illo 33 Technical SUP PON tradi roda 33 Produet Return Procedure uit herd e E ex abe e EA e e E E VR EE Pu 34 Appendix A Using Non Compumotor Motors uurrrriiiii u u u 35 Appendix B Regulatory Compliance UL and CE U uu uu u u 41 Index 47 E AC Drive Hardware Installation Guide 3 4 E AC Drive Hardware Installation Guide CHAPTER ONE Introduction IN THIS CHAPTER E AC Drive Description Compumotor Products E AC Drive Hardware Installation Guide Chapter 1 Introduction E AC DRIVE DESCRIPTION The E AC Drive is a microstepping dri
14. Power W Rating VA OS2HBS 1 70 22 0 22 39 83 151 OS2HBP 3 39 32 0 76 82 190 314 21B 1 82 24 0 30 65 119 205 OS21BP 3 50 55 0 86 129 270 432 OS22BS 2 38 18 0 41 87 146 247 OS22BP 3 50 29 0 93 161 283 451 VS12BS 1 02 17 0 29 32 78 141 VS12BP 2 04 24 0 87 33 144 266 VS13BS 1 02 18 0 25 38 81 147 VS13BP 2 04 39 0 93 32 164 280 VS21BS 2 27 18 0 60 100 178 300 VS21BP 3 50 37 0 105 137 279 438 VS22BS 2 04 13 0 46 93 152 258 VS22BP 3 50 36 0 95 149 280 452 VS23BS 2 04 14 0 39 113 166 281 VS23BP 3 50 24 0 99 202 325 531 VS31BS 3 05 19 0 45 135 199 339 VS32BS 3 16 22 0 57 121 200 334 S Series Configuration P Parallel Configuration 9 TEST THE INSTALLATION System installation should be complete at this point Perform the test procedure below to verify that your system is functioning properly In the test procedure you will command single revolution moves in the clockwise and counterclockwise direction If your mechanics do not permit such moves choose a move that allows you to easily verify correct system response Test PROCEDURE 1 Apply 120VAC power The green LED labeled PWR should illuminate 2 Command a slow move of one revolution in the clockwise direction Verify that the motor turns as commanded 3 Command a slow move of one revolution in the counterclockwise direction Verify that the motor turns as commanded 4 Test the shutdown input With the motor stopped activate the input The motor will have no torque when
15. alignment conditions which can exist in any combination are illustrated and described below Aligned ETT p e Angular Misalignment peu pee i End Float Parallel Misalignment gt Combined Parallel 8 Angular Misalignment Misalignment Condition e Angular Misalignment The center lines of two shafts intersect at an angle other than zero degrees e Parallel Misalignment The offset of two mating shaft center lines although the center lines remain parallel to each other e End Float A change in the relative distance between the ends of two shafts The type of misalignment in your system will affect your choice of coupler SiNGLE FLEx COUPLING Use a single flex coupling when you have angular misalignment only Because a single flex coupling is like a hinge one and only one of the shafts must be free to move in the radial direction without constraint Do not use a double flex coupling in this situation it will allow too much freedom and the shaft will rotate eccentrically which will cause large vibrations and catastrophic failure Do not use a single flex coupling with a parallel misalignment this will bend the shafts causing exces sive bearing loads and premature failure DouBLE FLEX COUPLING Use a double flex coupling whenever two shafts are joined with parallel misalignment or a combination of angular and parallel misalignment the most common situation Single flex and double flex couplings
16. ase to phase and phase to ground The motor must be designed for use with a bipolar drive no common center tap Motors with riveted rotors or stators are not recommended Motors with solid rotors are not recommended Test all motors carefully Verify that the motor temperature in your applica tion is within the system limitations The motor manufacturer s maximum allowable motor case temperature must not be exceeded You should test the motor over a 2 to 3 hour period Motors tend to have a long thermal time constant but can still overheat which results in motor damage CAUTION Consult your motor vendor to verify that your motor meets the above specifications Consult your Automation Technology Center ATC if you have questions regarding the use of a non Compumotor motor with Compumotor equipment WiRING CONFIGURATIONS Refer to the manufacturer s motor specification document to determine the motor s wiring configuration You can also determine the wiring configuration with an ohmmeter using the procedures below 4 Lead Motor 6 Lead Motor 8 Lead Motor Once you determine the correct motor wiring configuration use the terminal connection diagram shown at the end of this section that applies to your configuration 4 LEAD Motor 1 2 3 4 Label one motor lead A Connect one lead of an ohmmeter to the A lead and touch the other lead of the ohmmeter to the three remaining motor leads until you find th
17. atic test 12 33 installation test 30 toll free number 33 48 E AC Drive Hardware Installation Guide torque speed curves 14 transformer 29 troubleshooting 32 U UL 42 unipolar rating 39 V varistors 43 volt amp rating 30 W wiring series vs parallel 19 wiring precautions 18 Index
18. ation Step 3 DIP Switches later in this chapter POWER The E AC Drive does not have an ON OFF switch When you connect power the automatic test will begin the drive will turn on and the motor will start turning Therefore before you apply power to the E AC Drive Properly secure the motor Do not attach a load to the motor shaft To apply power connect one end of your power cable to the drive s 120V and terminals Connect the other end to a grounded 120VAC power source Further instructions are presented later in this chapter 5 OBSERVE THE AUTOMATIC TEST Your E AC Drive should now be running in the automatic test mode Disconnect power to stop the motor Set DIP SW1 1 to off Return DIP The motor shaft should rotate at approximately one revolution per second 1 rps in an alternating mode until you remove power LED Operation observe the LEDs on the front panel PWR LED power green should illuminate FLT LED fault red should be off 6 STOP THE AUTOMATIC TEST switches of previously configured drives to original settings if desired E AC Drive Hardware Installation Guide Chapter 2 Installation OS2HBP VS2xBP VS3xBP INSTALLATION The procedures in the rest of this chapter will lead you through the steps required to permanently install your E AC Drive and motor 1 SELECT A MOTOR Speed Torque curves specifications and motor dimensions for Compumotor motors are
19. aveform settings 6 off off off 2 72 ff off on 283 Waveform Pure sine off off on 2 94 4 3 harmonic off off on on 3 05 vs31BS 6 3 harmonic on on off off 3 16 VS32BS 8 3 harmonic ON on off on 3 28 on on off 3 39 _OS2HBP VS2xBP VS3xBP Auto Standby Full Current on Lon on on 3 50 OS218P OS22BP 50 Current Reduc lt 32 mH all VS OS motors 32 64 mH Gain gt 64 mH Select a setting based on A Remove power before A motor inductance in mH changing DIP switches i ging Anti Resonance NOTE This drawing is duplicated in Quick Test earlier in this chapter DIP Switch Location and Settings DEFAULT SETTINGS The factory default position is off for all switches For the drive to operate correctly you must set the DIP switches for your application Motor CURRENT Set DIP switches SW2 4 SW2 8 for motor current Verify that your connector wiring series or parallel and motor current rating match the current you set with these five switches 20 E AC Drive Hardware Installation Guide Chapter 2 Installation DRIVE RESOLUTION Set DIP switches SW1 2 SW1 5 for drive resolution There are six teen settings which range from 200 to 50 800 steps per revolution The default setting is 25 000 steps per revolution Be sure to set your controller to the same resolution as your E AC Drive If the controller resolution and drive resolution do not match commanded accelerations and veloc
20. cannot obtain an RMA number from your ATC call Parker Compumotor s Cus tomer Service Department at 800 722 2282 Ship the unit to Parker Hannifin Corporation Compumotor Division 5500 Business Park Drive Suite D Rohnert Park CA 94928 Attn RMA xxxxxxx In the UK call Parker Digiplan for a GRA Goods Returned Authori zation number Returned products cannot be accepted without a GRA number The phone number for Parker Digiplan Repair Depart ment is 0202 690911 The phone number for Parker Digiplan Ser vice Applications Department is 0202 699000 Ship the unit to Parker Digiplan Ltd 21 Balena Close Poole Dorset England BH17 7DX 5 Elsewhere Contact the distributor who supplied the equipment 34 E AC Drive Hardware Installation Guide Chapter 3 Troubleshooting APPENDIX A Using Non Compumotor Motors IN THIS APPENDIX e Wiring Configurations 4 6 and 8 lead motors Terminal Connections 4 6 and 8 lead motors Setting Motor Current Series or Parallel Unipolar or Bipolar E AC Drive Hardware Installation Guide Appendix A Non Compumotor Motors 35 UsiNG NoN COMPUMOTOR MOTORS We recommend that you use Compumotor motors with the E AC Drive If you use a non Compumotor motor it must meet the following require ments A minimum inductance of 2 mH series or parallel is required Compumotor recommends a minimum inductance of 5 mH A minimum of 500VDC high pot insulation rating from ph
21. ch table s current settings directly e Ifyou wire the motor in parallel you must double the manufacturer s rating and then use the DIP switch table s current settings to set the motor cur rent Unipolar Rating If the manufacturer specifies the motor current as a unipolar rating Use the following formula to convert the unipolar current rating to the correct bipolar rating Unipolar Current 0 707 Bipolar Current e If you wire the motor in series use the converted value and the DIP switch table s current settings to set the motor current e Ifyou wire the motor in parallel you must double the converted value and use the DIP switch table s current settings to set the motor current If you have questions about setting motor current call Compumotor s Applications Engineering Department at the number shown inside the front cover E AC Drive Hardware Installation Guide Appendix A Non Compumotor Motors 39 40 E AC Drive Hardware Installation Guide Appendix A Non Compumotor Motors APPENDIX B Regulatory Compliance UL and CE IN THIS CHAPTER Installation Instructions Installation Guidelines System Installation Techniques E AC Drive Hardware Installation Guide Appendix B Regulatory Compliance UL and CE 41 Regulatory Agencies The E AC Drive is designed to meet the requirements of global regulatory agencies The E AC Drive has shown compliance with the regulatory agencies in the following list T
22. commutate the motor to increment rotor position To send a step pulse to the drive apply a positive voltage to STEP with respect to STEP The drive regis ters the pulse on the rising edge 22 E AC Drive Hardware Installation Guide Chapter 2 Installation The input is optically isolated You can drive the input differentially or from a single ended source Step input specifications are Input Current 6 5 mA minimum 15 mA maximum Input Voltage 3 5V minimum min required for on or high signal 5 2V maximum Step Pulse 200 nanosecond minimum pulse width 200 nanosecond minimum off time 2MHz maximum pulse rate Optically Isolated Yes As a custom product Compumotor can modify drive for higher input voltage DIRECTION INPUT While a positive voltage is applied to DIRECTION with respect to DIREC TION the drive will commutate the motor in the clockwise positive direction as it receives step pulses on its step input While zero voltage or a negative voltage is applied to DIRECTION with respect to DIRECTION the drive will commutate the motor in the coun terclockwise negative direction as it receives step pulses The input is optically isolated You can drive the input differentially or from a single ended source Direction input specifications are Input Current 6 5 mA minimum 15 mA maximum Input Voltage 3 5V minimum min required for on or high signal 5 2V maximum Optically Isolated Yes Directi
23. d bonded as specified below EMC ready motor or motor with EMC installation information Additional installation hardware as shown in drawings in this appendix Additional Steps to Ensure Compliance 42 To meet the requirements of regulatory agencies you must follow the installation guidelines presented below EMC Electromagnetic Compatibility Directive 89 336 EEC In order to meet the requirements of the Electromagnetic Compatibility Directive 89 336 EEC the entire system must comply motor drive cabling and peripher als The installation of the product must include the following items E AC Drive Hardware Installation Guide Appendix B Regulatory Compliance UL and CE EMC Cabling For electromagnetic compatibility you must use cables shown to be usable in EMC installations Cables should have a minimum of 85 braid coverage and be 360 bonded at both ends EMC Motor For system CE compliance you must use an EMC ready motor or a motor that has demonstrated acceptable EMC performance NOTE Motors may bear the CE mark This mark indicates the motor meets the requirements of construction and safety not EMC compliance Motors with shielded cabling or pipe thread style cabling options allow the easiest integration into machines required to bear the CE mark for EMC Varistors You must install varistors or other voltage surge limiting devices in order to meet the requirements of EN61000 4 5 Place a Littelf
24. ductance range that corresponds to each of the four settings Small signal inductance is the value read on an ordinary inductance bridge or meter NOTE These two switches should be off for all Compumotor VS and OS motors or for any motor whose inductance is less than 32 mH E AC Drive Hardware Installation Guide Chapter 2 Installation 21 4 CONNECT A CONTROLLER INPUTS OUTPUTS Connect your controller cable to the DRIVE I O connector a 25 pin D connector on the front of the drive The cable that comes with Compu motor controllers is prewired for compatibility with the E AC Drive you can plug the cable directly into the E AC Drive s DRIVE I O connector 3 oo0000000 DRIVE 1 0 0000000 0000000 Controller E AC Drive Connecting a Compumotor Controller If you make your own cable or use a non Compumotor controller con sult the drawing below when you wire your cable and connector i Y AT be AW Step 243Q HCPL2631 ep e Direction Y AAT p Direction AW HCPL2631 Shutdown e 2430 CPL263 Shutdown AGL 6812 LD213 Fault E J WA Fault C TA Reset o Reset ke 6812 LD213 E AC Drive Internal Connections Drive I O Connector Descriptions of each function on the 25 pin D connector follow STEP INPUT For every step pulse it receives on its step input the drive will
25. dware Installation Guide Appendix A Non Compumotor Motors 37 TERMINAL CONNECTIONS After you determine the motor s wiring configuration connect the motor leads to the E AC Drive s MOTOR terminals according to the following figure 4 Lead Motor 6 Lead Motor E AC Drive E AC Drive AY vari A Center m Tap A D A A D A B D B B p B O B Center Tap 8 Lead Motor 8 Lead Motor Series Parallel E AC Drive E AC Drive TTT A Center ZY ad 1 0 A AfD A A D B B D D Non Compumotor Motor Connections WARNING A The E AC Drive has no Center Tap terminals You must insulate and properly secure the ends of the motor s center tap wires DIRECTION OF MOTOR ROTATION The procedures above do not determine the direction of motor shaft rotation To find out which direction the shaft turns you must power up your system and command motion If the shaft turns in the opposite direction than you desire exchange the motor leads connected to A and A to reverse the direction of rotation WARNING Motor shaft rotation may be opposite than you expect Do not connect a load to the shaft until you first determine the direction of shaft rotation 38 E AC Drive Hardware Installation Guide Appendix A Non Compumotor Motors SETTING MOTOR CURRENT NON COMPUMOTOR MOTORS To set motor current for a non Com
26. e Hardware Installation Guide Chapter 3 Troubleshooting SHORT CIRCUIT PROTECTION The E AC Drive has short circuit protection When the drive detects a short circuit in the motor or motor cabling it illuminates the FAULT LED and stops producing motor current This is a latched condition To restart the drive first remove power to the drive fix the short in the motor or cable then reapply power AUTOMATIC TEST Often in diagnosing a problem it is helpful to rule out possible causes If you disconnect the load and controller from the drive four components remain the drive motor motor cable and power cable You can then configure the drive to run the automatic test function See instructions near the beginning of Chapter 2 Installation If the motor turns as expected in an alternating mode then the drive motor and cables are probably not the cause of the problem The cause may lie with the controller software mechanics etc ANTI RESONANCE DISABLE If your mechanical system is highly resonant at precisely the wrong frequency anti resonance might interpret the mechanical vibrations as rotor position error You would notice greater torque ripple increased audible noise and possibly even stalling To solve these problems try disabling anti resonance SW2 1 off and see if the problems improve TECHNICAL SUPPORT If you cannot solve your system problems using this documentation contact your local Automation Tech
27. e lead that creates continuity Label this lead A Label the two remaining leads B and B Verify that there is continuity between the B and B leads Proceed to the Terminal Connections section below 6 LEAD Motor 1 9 gu WN Determine with an ohmmeter which three of the six motor leads are common one phase Label each one of these three motor leads A Using the ohmmeter verify that the remaining three leads are common Label the remaining three leads B Set the ohmmeter range to the 100 ohm scale approximately Connect the ohmmeter s negative lead to one of the motor leads labeled A Alternately measure the resistance to the two remaining motor leads also labeled A The resistance measurements will reflect one of the following two scenarios Scenario 1 The resistance measurements to the two remaining motor leads are virtually identical Label the two remaining motor leads A and A Label the motor lead connected to the negative lead of the ohmmeter A CENTER TAP this is the center tap lead for Phase A of the motor 36 E AC Drive Hardware Installation Guide Appendix A Non Compumotor Motors Scenario 2 The resistance measurement to the second of the three motor leads measures 50 of the resistance measurement to the third of the three motor leads Label the second motor lead A CENTER TAP this is the center tap lead for Phase A of the motor Label the third motor lead A Label the motor lead connected t
28. g Pending Yes Yes No No Size 17 Frame VS12B VS13B 55 27 72 8 0 39 0 51 0 3 0 37 0 054 0 068 1 00 0 71 1 01 0 71 2 00 1 42 2 02 1 43 12 8 11 2 3 2 2 8 2 5 4 0 0 02 0 03 11 0 11 0 5 5 7 7 77 3 5 3 5 0 003 0 003 0 075 0 075 0 001 0 001 0 025 0 025 0 55 0 77 0 25 0 35 E AC Drive Haraware Installation Guide OS22B 238 1 68 1 39 0 25 2 38 1 68 4 76 3 36 16 6 4 2 7 0 0 05 13 5 9 20 9 1 0 001 0 025 0 0008 0 02 2 5 1 1 Pending Yes No Size 23 Frame VS21B VS22B VS23B 115 5 194 5 334 5 0 82 1 37 2 36 0 66 1 64 2 62 0 12 0 3 0 48 2 26 1 6 2 01 1 42 2 01 1 42 4 52 3 2 4 02 2 84 4 02 2 84 5 0 12 0 15 4 1 2 3 0 3 8 7 0 8 8 18 0 0 05 0 06 0 13 17 6 17 6 17 6 8 8 8 15 0 15 0 15 0 6 8 6 8 6 8 0 003 0 003 0 003 0 075 0 075 0 075 0 001 0 001 0 001 0 025 0 025 0 025 1 03 1 54 2 2 0 47 0 7 1 0 Size 34 Frame VS31B VS32B 551 8 1269 67 3 90 8 97 7 65 4 8 1 4 2 7 3 0 2 12 3 13 2 21 6 0 4 24 6 26 4 42 15 8 25 4 0 6 25 27 0 50 0 19 0 35 35 3 35 3 16 16 30 9 30 9 14 14 0 0032 0 0032 0 080 0 080 0 0008 0 0008 0 020 0 020 3 86 6 18 1 75 2 8 Chapter 2 Installation 15 Motor DIMENSIONS Dimensions in inches mm 0 200 5 08 dia 4 on 2 625 66 68 BC C 0 2500 6 350 0 2495 6 337
29. h the E AC Drive s 25 pin D connector Available inputs and outputs are ANTI RESONANCE Step Input Direction Input Shutdown Input Fault Output Reset Input All step motors are subject to resonance and to ringing after quick tran sient moves The E AC Drive has an anti resonance circuit This is a general purpose damping circuit that provides aggressive and effective damping Anti resonance can be disabled with a DIP switch E AC DRIVE COMPATIBLE MOTORS Compumotor offers a wide range of motors that are compatible with the E AC Drive See Chapter 2 Installation for recommended motors COMPUMOTOR FAMILY OF PRODUCTS The E AC Drive is compatible with Compumotor s broad range of microstepper controllers single axis and multi axis and motion control products E AC Drive Hardware Installation Guide Chapter 1 Introduction 8 E AC Drive Hardware Installation Guide Chapter 1 Introduction CHAPTER TWO Installation IN THIS CHAPTER Product Ship Kit Quick Test e Motor Selection and Wiring Drive Configuration DIP Switches and I O Mounting the Drive and Motor Attaching the Load Connecting AC Power e Testing the Installation E AC Drive Hardware Installation Guide Chapter 2 Installation WHAT YOU SHOULD HAVE SHIP KIT PRECAUTIONS Inspect your shipment carefully You should have received one or more of the following Part Part Number E AC Drive E AC E AC Drive Quick Reference Gu
30. he list also shows additional steps users must take to ensure compliance Agency Additional Steps User Must Take UL cUL No additional steps are required The E AC Drive is UL recognized as shipped from the factory CE LVD Earth connection for drive and motor if applicable proper installation CE EMC Varistors mains filter EMC cabling EMC ready motor proper installation Installation Instructions Although the E AC Drive is technically considered a motion control component and is therefore not within the scope of the European Union s CE Conformit Europ enne directives Compumotor has taken the initiative to provide its customers with easy to integrate motion control products that meet global require ments The following constitutes what is typically required to install the E AC Drive into a CE compliant system Additional installation measures may be required at some locations The machine builder has ultimate responsibility for machine compli ance Low Voltage Directive LVD Installation Requirements Drive safety earth conductor Motor safety earth Drive must be installed such that the hazardous live terminals barrier strip are not accessible under normal operation Electromagnetic Compatibility EMC Installation Requirements Product does not need to be placed within an enclosure Mains filter see filter recommendations Transient suppressors mains surge test EMC cabling braided an
31. ical EMC installation E AC Drive Mount to earthed metal Ferrite panel Remove paint be absorber from mounting locations Cm e Z Drive I O Cable L1 NAN VAS Mains N Filter Earth A TY O Varistor TTE 3 places O Motor Cable Motor P clip braid to mounting surface make loop as short as possible Ferrite Pid absorber EMC Installation E AC Drive Hardware Installation Guide Appendix B Regulatory Compliance UL and CE 45 46 E AC Drive Hardware Installation Guide Appendix B Regulatory Compliance UL and CE Index Symbols 360 bonding 44 4 lead motor wiring 36 6 lead motor wiring 36 8 lead motor wiring 37 800 358 9070 Compumotor application support 33 A AC power connection 29 ambient temperature limits 25 anti resonance disable 33 application support 33 automatic standby 21 automatic test 12 33 B bipolar rating 39 bonding 45 C cabinet mounting 43 CE 42 clearance requirements 26 connector AC power 29 motor 18 19 couplers 28 cUL 42 current bipolar rating 39 unipolar rating 39 current motor 20 current selection non Compumotor motors 39 current waveform 21 D D connector 22 diagnostic LEDs 32 dimensions drive 25 motor 16 DIP switch settings 20 non Compumotor motors 39 direction input 23 drive resolution 21 E E AC Drive description 6 dimensions 25 drive only 10 electromagnetic compatibility 42 E AC Drive Haraware Installation Guide EMC 42
32. ide 88 020290 01 You may have ordered a motor from one of the following families of Compumotor motors OS Motors VS Motors To prevent injuries to personnel and damage to equipment observe the following guidelines e Never probe the drive Hazardous voltages are present within the drive Never open the drive Opening the drive will void the warranty Never increase the current setting to a value greater than that specified for the motor you are using Excessive current may cause motor overheating and failure e Always remove AC power before changing or reconfiguring DIP switches INSTALLATION OVERVIEW Topics in this chapter are arranged to lead you through the installation process in a step by step manner Complete each step before proceeding to the next The order of topics in the installation procedure is e Quick Test e Motor selection specifications speed torque curves and dimensions e Motor wiring series vs parallel DIP switch configuration e Controller connections and 25 pin D connector input output schematic e Drive mounting e Motor mounting e Connecting the load Connecting AC power e Testing the installation 10 E AC Drive Hardware Installation Guide Chapter 2 Installation INSTALLATION PROCEDURE In the following installation procedure we assume you are using a Compumotor motor with your E AC Drive If you are using a non Compumotor motor consult Appendix A Using Non Compumotor Mo
33. into contact with the E AC Drive or its cables AIRBORNE CONTAMINANTS Particulate contaminants especially electrically conductive material such E AC Drive Hardware Installation Guide Chapter 2 Installation 25 as metal shavings or grinding dust can damage the E AC Drive and motor Do not allow contaminants to come into contact with the drive or motor PANEL LAYOUT Follow these minimum spacing and clearance requirements when you mount multiple E AC Drives 2 39 BOW Reet me SRS Se s E oem i Minimum 1 00 25 4 Minimum Clearance Jo DRIVE I O SERIES 0000000000000 000000000000 0000000000000 000000000000 0 25 6 4 Minimum Clearance 1 00 25 4 Minimum Clearance Compumotor Compumotor I Dimensions in 0 50 i inches millimeters 12 7 Minimum Clearance ee ee Ee lU alata Panel Layout Dimensions 6 MOUNT THE MoToR Use flange bolts to mount rotary step motors The pilot or centering flange on the motor s front face should fit snugly in the pilot hole Do not use a foot mount or cradle configuration because the motor s torque is not evenly distributed around the motor case When a foot mount is used for example any radial load on the motor shaft is multi plied by a much longer lever arm Step Motors can produce very high torques and accelerations If the mounting is inadequate this combina
34. ities will not be properly scaled WAVEFORM Set SW1 6 and SW1 7 to select a current waveform There are four choices one is a pure sine wave the other three reduce the current waveform s 3rd harmonic by 496 696 or 896 In most applications the default setting both switches off 496 3rd harmonic provides the best performance Automatic TEST DIP switch SW1 1 enables or disables the Automatic Test function For more information see the Automatic Test section earlier in this chapter AUTOMATIC STANDBY SW1 8 should be off if you do not use automatic standby Turn this switch on to use automatic standby The automatic standby function allows the motor to cool when it is not moving Automatic standby reduces motor current by 50 if the drive does not receive a step pulse for one second Full current is restored upon the first step pulse that the drive receives Be aware that reduced current results in reduced holding torque If you use the position maintenance feature of 6K or 6000 Series control lers we recommend that you do not use automatic standby ANTI RESONANCE DISABLE SW1 1 should be on for the anti resonance circuit to be enabled Nor mally you will want anti resonance enabled therefore this switch should be on If you must disable anti resonance turn this switch off CURRENT Loop GAIN Set SW2 2 and SW2 3 according to your motor s small signal induc tance in millihenries The table shows the small signal in
35. maximum reverse voltage Reset Voltage Pulse 250 nanosecond minimum pulse width Active Level While voltage is applied reset occurs When voltage is removed normal operations resume Reset Delay 0 7 second delay until reset is complete after voltage is removed from input Optically Isolated Yes 24 E AC Drive Hardware Installation Guide Chapter 2 Installation 5 MOUNT THE DRIVE Dimensions of the E AC Drive are shown below 4 34 110 1 4 10 3 104 1 9o 2 al ss 5 35 135 9 O J J J im o Dimensions in inches mm 2x clearance for 8 or M4 mounting screws Dimensions E AC Drive ENVIRONMENTAL CONSIDERATIONS TEMPERATURE SPECIFICATIONS Maximum Ambient Temperature 50 C 122 F Minimum Ambient Temperature O C 32 F Overtemperature Shutdown Fault 55 C 131 F The E AC Drive has an internal temperature sensor located near the heatsink If the sensor reaches 55 C 131 F it will trigger an overtem perature fault and the drive will shut down FAN COOLING Operating the E AC Drive in high ambient temperatures may require fan cooling to keep the drive from shutting down due to an overtemperature fault HUMIDITY Keep the relative humidity below 95 non condensing Liquips Do not allow liquids or fluids to come
36. may or may not accept end play depending on their design Ricip COUPLING Rigid couplings are generally not recommended because they cannot compensate for any misalignment They should be used only if the motor or load is on some form of floating mounts that allow for alignment com pensation Rigid couplings can also be used when the load is supported entirely by the motor s bearings A small mirror connected to a motor shaft is an example of such an application CouPLiNG MANUFACTURERS HUCO ROCOM CORP HELI CAL 70 Mitchell Blvd Suite 201 5957 Engineer Drive P O Box1069 San Rafael CA 94903 Huntington Beach CA 92649 Santa Maria CA 93456 415 492 0278 714 891 9922 805 928 3851 28 E AC Drive Hardware Installation Guide Chapter 2 Installation 8 CONNECT AC POWER At this point in your installation procedure you should have mounted your drive and motor coupled the motor to the load and connected the controller and motor cables to the drive The E AC Drive does not have an on off switch When you apply power to the drive the drive will turn on Therefore before you apply power verify the following Motor should be properly secured Motor cable should be connected to drive Drive should be properly mounted Controller cable should be connected to drive Controller cable should not be in close physical proximity to motor cable APPLY Power To apply power connect one end of your power cable to the drive s L1 N a
37. nd terminals 95 132VAC External Fuses 50 60 Hz Are not required for AC mains with Single phase Line and Neutral designations For AC mains without Line and Neutral designations 1 Fuse both sides of the AC mains as shown at right 2 Use 125VAC Time Delay 10 amp type RK5 or better fuses AC Input Connections Connect the other end of your power cable to a grounded 120VAC power source that meets the following specifications Specifications AC Power Input Input Power 120VAC nominal 95VAC minimum 132VAC maximum 50 60 Hz Inrush Current 22 2 amps peak maximum Fuses No user serviceable fuses Grounding You must provide a proper AC power ground Transformer Not required for 120VAC operation to size step down transformer use Volt Amp rating see the following table A WARNING The motor case and drive are grounded through the drive s terminal You must provide a proper AC power ground for safety purposes E AC Drive Hardware Installation Guide Chapter 2 Installation 29 PEAK PoweR RATINGS The amount of power the E AC Drive requires from your AC power source depends upon the motor you use whether you wire the motor in series or parallel and upon your specific application The next table shows peak power requirements Power required for your application may be less Motor Type Current Cabinet Peak Motor Peak Shaft Peak Total Volt Amp Amps Loss W Loss W Power W
38. nology Center ATC or distributor for assistance If you need to talk to our in house application engineers contact Parker Compumotor s Applications Department at 800 358 9070 E AC Drive Hardware Installation Guide Chapter 3 Troubleshooting 33 PRODUCT RETURN PROCEDURE If you must return your E AC Drive for repairs use the following steps 1 Get the serial number and the model number of the defective unit and a purchase order number to cover repair costs in the event the unit is determined to be out of warranty Before you return the unit have someone from your organization with a technical understanding of the E AC Drive and its application include answers to the following questions What is the extent of the failure reason for return How long did the unit operate Did any other items fail at the same time What was happening when the unit failed e g installing the unit cycling power starting other equipment etc How was the unit configured in detail What if any cables were modified and how With what equipment is the unit interfaced What was the application What was the system environment temperature enclosure spac ing unit orientation contaminants etc What upgrades if any are required hardware cables etc In the USA call your Automation Technology Center ATC for a Return Material Authorization RMA number Returned products cannot be accepted without an RMA number If you
39. o the ohmmeter A Repeat the procedure as outlined in step 6 for the three leads labeled B B CENTER TAP is the center tap lead for Phase B of the motor Proceed to the Terminal Connections section below 8 Leab Motor Because of the complexity involved in phasing an 8 lead motor you must refer to the manufacturer s motor specification document Using the manufacturer s specifications label the motor leads as shown in the next drawing Phase A Windings Phase B Windings 8 Lead Motor Labeling the Leads You can configure the 8 lead motor in series or parallel Series Configuration Use the following procedure for series configura tions 1 Mh Or Bs or N Connect A2 amp A3 together and relabel this common point A CENTER TAP Connect B2 amp B3 together and relabel this common point B CENTER TAP Relabel the Al lead A Relabel the A4 lead A Relabel the B1 lead B Relabel the B4 lead B Proceed to the Terminal Connections section below Parallel Configuration Use the following procedure for parallel configu rations 1 2 3 4 5 Connect motor leads A1 amp A3 together and relabel this common point A Connect motor leads A2 amp A4 together and relabel this common point A Connect motor leads B1 amp B3 together and relabel this common point B Connect motor leads B2 amp B4 together and relabel this common point B Proceed to the Terminal Connections section below E AC Drive Har
40. on Change Direction input may change polarity coincident with first step pulse As a custom product Compumotor can modify drive for higher input voltage SHUTDOWN INPUT You can use the shutdown input to shutdown or disable the E AC Drive To activate shutdown apply a positive voltage to SHUTDOWN with respect to SHUTDOWN when the motor is not moving During shutdown the drive turns off current to the motor The current stays off as long as the voltage is maintained on the shutdown input When you remove the voltage on the input shutdown ends The drive restores current to the motor in the same phase relationship that existed before shutdown was invoked The shutdown input may also be differentially driven Specifications are Input Current 2 5 mA minimum 30 mA maximum Input Voltage 3 5V minimum min required for on or high signal 13V maximum 5V maximum reverse voltage Active Level While voltage is applied current to motor is shut down When voltage is removed normal operations resume Time 250 nanosecond minimum width Optically Isolated Yes E AC Drive Hardware Installation Guide Chapter 2 Installation 23 FAULT OUTPUT The E AC Drive can signal through its fault output that it has detected a fault Internally the terminals FAULT C and FAULT E connect to the open collector and open emitter respectively of an optically isolated transistor The transistor acts like a switch it conducts when the drive
41. ou repeat or re create the problem Random events may appear to be related but they are not necessarily contributing factors to your problem You may be experiencing more than one problem You must isolate and solve one problem at a time Log document all testing and problem isolation procedures You may need to review and consult these notes later This will also prevent you from duplicating your testing efforts Once you have isolated a problem take the necessary steps to resolve it Refer to the problem solutions contained in this chapter DiAGNOSTIC LEDS The E AC Drive has two LEDs on its front panel The following summary of LED functions may help you isolate problems LED Name Color Function PWR POWER Green Illuminates when AC power is applied Off if AC power is under voltage lt 95VAC FLT FAULT Red Indicates short circuit in motor or cabling or Drive overtemperature PROTECTIVE CIRCUITS The E AC Drive has several protective circuits some of which can indicate fault conditions by illuminating one of the above LEDs OVERTEMPERATURE PROTECTION To protect against damage from high temperatures the E AC Drive has an internal temperature sensor If the sensor reaches 55 C 131 F it will trigger an overtemperature fault The red FAULT LED will illuminate and the drive will shut down This is a latched fault To restart the drive first allow it to cool then cycle power or toggle the reset input 32 E AC Driv
42. pumotor motor refer to the formulas below that correspond to your motor 4 lead 6 lead 8 lead and use the current settings shown in the DIP switch table in Chapter 2 Installation to set the motor s current WARNING Do not connect or disconnect the motor with the power on Doing so will damage the contacts of the motor connector and may cause personal injury 4 Leap Motors If you use a 4 lead motor the manufacturer s current specification will translate directly to the values shown for current in the DIP switch table 6 LEAp Motors Manufacturers generally use either a bipolar rating or a unipolar rating for motor current in 6 lead motors Bipolar Rating If the manufacturer specifies the motor current as a bipolar rating you can use the DIP switch table s current settings directly to set motor current no conversion is required Unipolar Rating If the manufacturer specifies the motor current as a unipolar rating Use the following formula to convert the unipolar current rating to the correct bipolar rating Unipolar Current 0 707 Bipolar Current e Use the converted value and the DIP switch table s current settings to set the motor current 8 Leap Motors Manufacturers generally use either a bipolar rating or a unipolar rating for motor current in 8 lead motors Bipolar Rating If the manufacturer specifies the motor current as a bipolar series rating e Ifyou wire the motor in series use the DIP swit
43. rallel These two alternatives series and parallel produce different speed torque characteristics affect the motor s current rating and alter the motor s operating temperature They are explained below GROUND THE Motor CASE The motor case must be grounded for safety purposes On pre cabled Compumotor motors one end of the cable shield is permanently wired to the motor case you should connect the other end to _L on the drive s motor connector Inside the drive connects directly to the ground pin on the AC power terminals I PRECAUTIONS Follow these precautions when you wire the motor connector 1 Turnoff power to the drive before connecting or disconnecting the motor leads Verify that no wire whiskers short out motor connections Do not apply power to the drive when the motor is not connected Never connect anything other than the motor to the motor terminals After wiring the motor connector perform the Automatic Test to verify that the connector is wired correctly gU RON CONNECTING THE Motor SERIES WIRING For series motor current connect a Compumotor motor as shown in the following diagram OS Motors VS Motors VS Motors flying lead with cable Compumotor Motor Red White Yellow Yellow White Blue 11 w Phase A D Windings Red Red A D Yellow Black A D Orange White B D Black Green B Orange White Orange Black White Brown
44. shown below SPEED TORQUE CURVES OS2HB E AC Drive Torque oz in WN anbio 20 Speed RPS 30 40 VS12B E AC Drive 60 42 50 35 a 40 28 c z 30 21 5 20 14 10 07 0 Torque oz in 0 10 30 40 20 50 Speed RPM VS21B E AC Drive E g 8 2 2 S Zz 9 3 0 10 20 30 40 50 Speed RPM VS31B E AC Drive 600 4 2 500 3 5 3 S 400 28 8 o D 300 2 1 E 200 14 100 70 0 0 0 10 20 30 40 50 Speed RPM 14 OS21B E AC Drive 120 84 uin 100 ENIMS Jb a 80 56 8 5 2 60 42 3 o 3 40 28 7 20 14 0 0 0 10 20 30 40 50 Speed RPS ti EHEEER nnnm Series Parallel Full Step VS13B E AC Drive 80 56 70 49 60 42 a 3 nain nu 8 9 50 CTT Thy CALLS 359 S 40 e e 28 Z o a he 3 30 o 2 20 CS 14 10 ed 07 0 0 0 10 20 30 40 50 Speed RPM VS22B E AC Drive 200 1 40 150 1 05 amp y 8 100 70 2 S z S 3 50 35 0 0 0 10 20 30 40 50 Speed RPM VS32B E AC Drive 1000 7 01 E 800f 5 60 gi 600 4 20 g m z e 400 de 2 80 3 Reed 200 pee ees ees 1 40 BER 0 0 0 10 20 30 40 50 Speed RPM E AC Drive Haraware Installation Guide 250 N 2200 3 150 O E 100 50 OS22B E AC Drive
45. shutdown is activated You should be able to turn the motor manually if your mechanics permit Successful completion of this procedure will verify that your controller and motor are correctly connected to the E AC Drive and that the drive is functioning properly If the test is unsuccessful proceed to Chapter 3 Troubleshooting for problem identification and solution procedures 30 E AC Drive Hardware Installation Guide Chapter 2 Installation CHAPTER THREE Troubleshooting IN THIS CHAPTER e Troubleshooting Basics Diagnostic LEDs Protective Circuits Automatic Test Anti Resonance Disable Product Return Procedure E AC Drive Hardware Installation Guide Chapter 3 Troubleshooting 31 TROUBLESHOOTING BASICS When your system does not function properly or as you expect it to operate the first thing that you must do is identify and isolate the prob lem When you have accomplished this you can effectively begin to resolve the problem The first step is to isolate each system component and ensure that each component functions properly when it is run independently You may have to dismantle your system and put it back together piece by piece to detect the problem If you have additional units available you may want to exchange them with existing components in your system to help iden tify the source of the problem Determine if the problem is mechanical electrical or software related Can y
46. siness Park Drive 21 Balena Close Postfach 77607 1720 Rohnert Park CA 94928 Poole Dorset Robert Bosch Str 22 Telephone 800 358 9070 or 707 584 7558 England BH17 7DX D 77656 Offenburg Fax 707 584 3793 Telephone 44 0 1202 69 9000 Telephone 49 0 781 509 0 FaxBack 800 936 6939 or 707 586 8586 Fax 444 0 1202 69 5750 Fax 449 0 781 509 176 e mail tech_help cmotor com Internet http www compumotor com Parker Technical Support Email Automation tech_help cmotor com Table of Contents ien riigmEnPnenpim E 5 E AC Drive Descriptions i netter eate e erp tices needed eben b t teet lg 6 E AC Drive Compatible Motors i 7 Chapter 2 NSTallatiOnN id 9 What You Should Have ship kit uu uu uuu hte rtr Rei ec eon oie Lh re Ree eR Roca 10 Precaultlols tia coa 10 Installation QVervieWs ied dad as en laa a iaia 10 AUTOM ACE 12 Installation vta nadar 14 1 SELECTA MOTOR sia ironia cs 14 2 CONNECT THE MOTOR TO THE DRIVE WIRING nan nananans 18 3 SErRDIP SWITCHES a as 20 4 CONNECT A CONTROLLER INPUTS amp OUTPUTS sseseseseseeeececcceceececeeeeeeececucauauaeaeaeaeseeceneeeseeseneeees 22 5 MOUNT THE DRIVE SZ uc An is do 25 O MOUNT THE MOTOR cella dede gue oe anale e e n tn e i ad au 26 7 CONNECT THE MOTOR TO THE LOAD COUPLERS enne nenne nnn nn annie
47. t maintain high integrity 360 degree shielding and be constructed with at least 85 braid coverage When you install inputs and outputs you must observe proper noise immunity standards See the EMC Installation drawing at the end of this appendix Ferrite Absorbers To meet the requirements of the EMC directive you must add clip on ferrite absorbers to all cables Compumotor recommends a ferrite with at least 200 ohm impedance at 100 MHz such as Steward Ferrite part number 28A2024 Fair Rite part number 0443164151 These ferrites are available from Compumotor part number 47 015956 01 Enclosure Mounting the E AC Drive The enclosure must be properly earthed and paint must be removed from drive mounting and RF earth bonding locations Proper shield termination of all cables entering and exiting the enclosure is required The motor shield braid must be fastened close to the drive s heatsink The shield must not make contact with other conductors as this will cause common mode drive generated PWM current to flow where not expected The shields of all other cables that enter or exit the enclosure must be RF bonded to the enclosure entrance point via R Clamp bulkhead clamshell clamp or other 360 bonding technique This ensures that no stray noise will enter or exit the enclosure The next drawing illustrates 360 bonding techniques R Clamp Remove outer jacket only Do not cut braid Bulkheak Clamshell Clamp Bulkheak
48. tion of high torque high accelera tion can shear shafts and mounting hardware Because of shock and vibration that high accelerations can produce you may need heavier hardware than for static loads of the same magnitude Under certain move profiles the motor can produce low frequency vibra 26 E AC Drive Hardware Installation Guide Chapter 2 Installation tions in the mounting structure that can cause fatigue in structural members A mechanical engineer should check the machine design to ensure that the mounting structure is adequate WARNING Improper motor mounting can jeopardize personal safety and compromise system performance For Compumotor motor dimensions see Select a Motor earlier in this chapter Motor TEMPERATURE COOLING The motor s face flange is used not only for mounting it is also a heatsink Mount the face flange to a large thermal mass such as a thick steel or aluminum plate which should be unpainted clean and flat Heat will be conducted from inside the motor through the face flange and dissipated in the thermal mass This is the best way to cool the motor You can also use a fan to blow air across the motor for increased cooling if conduction through the flange does not provide enough cooling Motor MobIFICATIONS Modifying or machining the motor shaft will void the motor warranty Contact a Compumotor Applications Engineer 800 358 9070 about shaft modifications as a custom product
49. tors for information you may need during the following installation steps The next drawing shows locations and names of the various connectors switches and LEDs that you will encounter during the installation proce dure Heatsink DIP Switches SD SS ee lt SS DRIVE I O 1 0 Connections Status LEDs AC Power lt ST Motor Power Compumotor Component Locations E AC Drive Hardware Installation Guide Chapter 2 Installation 11 AUTOMATIC TEST Follow this procedure to have your E AC Drive perform its automatic test function Once you set DIP switches connect the motor and connect AC power the automatic test will begin the motor shaft will turn at one revolution per second in an alternating mode until you remove power This will verify that the drive motor and motor cable work properly as a system DRIVE 1 0 To AC Power Source Alternating Shaft Rotation E AC Drive Motor Automatic Test Setup This is a bench top procedure as the drawing shows you can perform it before you connect a controller mount the drive or mount the motor Full installation instructions follow this Automatic Test section 1 SET DIP SWITCHES FOR Motor Current Two 8 position DIP switches are located on top of the E AC Drive NOTE if you are testing a drive that has already been configured for an application make note of the original DIP s
50. use VI40LA1 or equivalent varistor from line to line and from lines to earth before the mains filter as shown in the EMC Installation drawing later in this appendix Intersil General Electric and Littelfuse manufacture equivalent varistors Mains Filter You must install a mains filter The next table lists recommended filters Continuous Filter Current amps 6EP1 6 10EP1 10 FN2070 10 06 10 Corcom Schaffner 3 Available from Compumotor 10 amp filter part number 47 016140 01 Installation Guidelines The E AC Drive is made available under Restricted Distribution for use in the Second Environment as described in EN 61800 3 1996 page 9 Cabinet Mounting For Electromagnetic Compatibility cabinet mounting is not required However the E AC Drive has high voltage terminals for safety purposes the drive must not be user accessible during normal operation Drive Mounting The E AC Drive is designed to be mounted to an earthed metal panel For EMC performance mount the mains filter to the same panel as close to the drive as possible See the EMC Installation drawing at the end of this appendix Cable Routing Route high power cables motor and mains at right angles to low power cables communications and inputs outputs Never route high and low power cables parallel to each other E AC Drive Hardware Installation Guide Appendix B Regulatory Compliance UL and CE 43 Cable Shielding All cables mus
51. ve that runs two phase step motors It operates directly from 120VAC power no separate DC power supply or transformer is required A typical system is shown below o o o o o o o o o El DRIVE 1 0 0000000 0000000 To AC Power Source Compumotor Controller E AC Drive System Components The controller sends step and direction signals to the drive For each step pulse it receives the drive will commutate the motor to increment rotor position This is shown in the next drawing High Level Commands Step Pulses Currents Controller Programmable Controller Block Diagram of E AC Drive System The host computer or programmable controller may or may not be neces sary depending upon the controller s capabilities The motor can be wired in series or parallel the amount of current the drive sends to the motor is set by DIP switches DIP SWITCHES DIP switches are located on top of the E AC Drive accessible through an opening in the top of the cover During the installation procedure the user sets these DIP switches to configure the drive for motor current resolution waveform and other functions CAUTION Remove power before changing DIP switches 6 E AC Drive Hardware Installation Guide Chapter 1 Introduction INPUTS amp OUTPUTS All communications with the controller take place throug
52. witch settings Set DIP switches SW2 4 SW2 8 for the current for your motor according to the table For non Compumotor motors see Appendix A 2 SET DIP SWITCHES FOR THE Automatic Test Function Set DIP switch SW1 1 to the on position This selects the automatic test function 3 CONNECT THE MOTOR Connect your motor cable to the drive s MOTOR terminals Motor wiring instructions are presented later in this chapter For non Compumotor motors see Appendix A Always observe the following two warnings WARNING POWER MUST BE OFF when you connect or disconnect the motor connector Lethal voltages are present on the screw terminals WARNING You must ground the motor case Large potentials can develop at the motor case that can create a lethal shock hazard if the motor case is not grounded 12 E AC Drive Hardware Installation Guide Chapter 2 Installation 4 CONNECT AC Default Position Drive ships from factory with all DIP switches in the OFF position SW1 SW2 Edge of TIE EEEEEEER I Circuit Bead 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 f off Auto Test Disabled Enabled on 1 rps for 2 revs in each direction until disabled Resolution 213 off o 50 800 on off off 50 000 off on off off 36 000 on on off off 25 600 off off on off 25 400 on off on off 21 600
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