MTS Systems Series TBF-R User's Manual
Contents
1. JA A Pen ki Aps ASI D pau dou U ID BL Oy 9 9 Bu BLI valt Labs E ull uluk 4 Buporfu fp cauto prar Wii immu ST 1212 siu ky uty juisi uo dp na iyd neu Ja ttl c Ap sux op cjuo MIL bee JE Sue L Su in wu IS Euh anda D Figure 7 Installation in Compliance with the EMC Directives 26 4 Set up 4 1 Connection When the servo amplifier is used together with one of our motors the connection does not cause any problems In 3 4 you will find the connection diagrams Connect the motor power contacts U V W earth and shield as described there The resolvers are also connected as described in 3 4 Ker When using an auxiliary drive together with the servo amplifier TBF we offer to work out the correct connection diagram for you 4 2 Presetting is Prior to set up please read the chapters 1 2 and 3 For connecting the power amplifier and the motor sensors the specifications given in the connection diagrams 3 40 have to be strictly observed Connecting the motor in any way and to exchange two phase in case of wrong directional run is not useful We therefore offer to first check the ca2. 3 3 3 The Line Cable of the Motor The power supply of the motor that means the actual motor cable has to consist of four stranded cores U V W PE The shorter the twist the better it is In order to minimize interference emission you have to use a shielded cable The shield must be connected with a low inductance to POWER GND 26z b d On the motor side the shield has to be connected to the motor housing via the metallic connector housing To guarantee a reliable functioning of the protective function ground contact resistance safety against contact of the winding with the housing the motor housing has to be connected with POWER GND 26z b d 21 3 3 4 Control Lines And Signal Lines Between Master Control Unit And Amplifier For the definition of the speed reference the master control unit normally provides an output of a digital analogue converter This output signal normally is measured against ground or against reference voltage The input at the amplifier is a differential input with set value at 4d and set value at 4b The lines at these inputs have to be run to the control unit in the same cable This cable has to be shielded with connection of the shield to the servo amplifier and the control unit Input of the TBF R is connected to the set value output of the master control unit Input of the TBF R is connected to the reference point for the set value output at the master control unit The lines lext Int off Read
3. 5 guum ING Figure 6 Connection Diagram TBF R 24 3 5 Measures for an Installation Compliance with the Directives Because of the compact design of servo amplifiers no complete noise suppression measures are possible without modifying the design Therefore the proposed measures shall help to keep the EMC directive for the total system These measures are necessary only for the used inputs and outputs In addition to that a single total interference suppression of the mains lead of all electronic subassemblies installed in the system is possible This would lead to a cost reduction compared to single interference suppression In order to simplify the installation work we offer a number of backplanes with integrated interference suppression elements and connection boards for ring toridal core transformers with interference suppression elements too e Motor lines and control lines have to be wired as shielded lines in principle Avoid interferences and loops All lines shall run in one direction only that means no connection from the servo amplifier via the mounting plate of the switch cabinet The clearance between motor line mains lead and control lines should be at least 20mm Otherwise there is the risk of interference coupling e The shield of each cable has to be connected close by the servo amplifier with a fastening clamp to the mounting plate of the switch cabinet Please ensure a large blank met
4. DODDODOO 00000000 ae Dex v Figure 17 Components Inserted lower side 46 at O O O O O O O O O O O PC TBF RES3 5 BEBBBB_ mn REIR Z Beige t 388 Component mounting diagram sub board PC TBF RES3 o El ea 080 Esa 819 Rig 815 p BEE 8 1 3 47 Figure 19 Components on upper side Figure 18 Components on lower side
5. 10V Always both inputs have to be wired e g set value at the output of the D A converter and set value at the output of the analogue GND of the D A converter Output of a 5V power supply carrying capacity 10mA Potential free Reed contact to indicate the ready for operation status of the device The contact is closed when the device is ready for operation Maximum voltage 100V for 100mA 82 8b A 8d 102 122 142 10b 12b 14b 10 12 14 162 16b 16d 15V Output of the 15V electronic voltage for supply of the limit switch inputs Pos Stop Neg Stop Carrying capacity together with 18d 10mA Enable input This connection is to be applied for enable input to a voltage of 15V to 30V after the ready contact is closed The motor is disabled with the input open As in chapter 2 5 the following applies Enable of the motor is possible only when the device is ready for operation green LED lights This prevents the motor from running in an uncontrolled manner when the operating voltage is applied to the amplifier while the enable signal is active Output Tachometer Output of the conditioned tachometer signal A signal with a carrying capacity of 1mA is available which corresponds to a DC tachometer Use a short shielded cable for the wiring The reference point is 4z GND REF Scaling is 10V 6000 rpm NC These connections are not used not connected but NC they must not be applied wit
6. F48 1x D SUB 9 pole socket Dimensions 160x100x40 3 160x100x55 5mm 160 100 80 8 mm mm mm Weight 0 5kg 0 8kg 1 0kg external ventilation with leff gt 4A additional filtering with leff gt 4A or IIMP gt 12A leff 4A and IIMP 12A is adjustment ex factory 2 3 Principle of the Amplifier The three phase servo amplifiers of Series TBF are based on the principle of the speed control with secondary current control loop In addition to that the current mode logic controls the commutation of the electronically commutated servo amplifier brushless The signal flow of this functional group is shown in the following figure Current Controller Speed Controller nnom O a Resolver Condiitoning Figure 1 Principle of the Amplifier The speed control loop consists of speed controller circuit motor and speed measurement The nominal speed value is externally given e g through potentiometer NC control or something similar The actual speed value is determined at the motor shaft by a resolver The difference between nominal value and actual value is formed at the summing point and transmitted to the speed controller The speed controller then defines the required current set value The current control loop consists of the current controllers the amplifier stage the current measurement and the motor windings The current set values available at the output of the current controller control the six power s
7. GND 15 AC2 36 AC2 16 AC1 37 AC1 17 Power GND 38 Power GND 18 Motor W 39 Power GND 19 Motor V 40 Power GND 20 Motor U 41 Power GND 21 UB 42 UB 35 Figure 8 Pin Assignmeni 19 sub rack 36 Connection diagram TBF R BUS S 7 2 2 140 at f Bu p s 660 18 seyans jun 4 N NNN ANN 550 YAN MOA LL t S snta 4d Aussi jp tara 19 sy dui Hun 19099 IUBET ee Xl 1 ANDY HALE Figure 9 Connection Diagram TBF R BUS S 37 Connection diagram TBF R BUS W 7 2 3 140 948 S YSJMS WIT 206 Gu eps 1600 18 saddi N NN LL N NNN NN uj 500202 MA tn M SnB 38 L Aiast jp IU 19 sy dui Hun 19099 JJ SALIO 3 JNO JABA LUSI 3 ANG Figure 10 Connection Diagram TBF R BUS W 38 7 2 4 Pin assignment for wall mounting article no TBF BUS W Pin assignment of the screw type terminals 1 Set value 8 Set value 15 Tachometer output 2 Enable 9 Ready 14 16 Ready 13 3 lagt 10 Pos Stop 17 Neg Stop 4 415V 11 GND 18 15V 5 Int off 12 GND 19 Pt message 6 Track A 13 Track B4 20 Track I 7 Track 14 Track B 21 Track l e in LL m Figure 11 Assignment wall mounting 22 Motor U 29 Track l 36 Track 1 23 Motor V 30 Track B 37 Track B 24 Motor W 31 Track
8. e Our Terms and Conditions are the basis for all legal transactions Table of Contents Page 1 Safety INStrUCTIONS unnnennnnevnnnennnnnnnvnnnnnenne nates asas asma sana kaa 1 TA GENeraknoles ER 1 1 2 Qualified personnel maate ri e ee at EU PUER 1 123 Designated Use nri cn inci catre iret i re aaa aaa datet 1 1 4 Description of symbols and signal words sse enne 1 1o Safety Notes tU 2 1 6 SOL Up me dead axi a uu T 2 1 72 Maintenance Service 2 aie ted SNS 3 2 Technical descriptiOn ussrnvennnnnnennnvnnvnnonnnennnvnnnennnnnnennnnnnnnennnnvnnnnnnnnnnnennennnennnnnnnennn nunnnnennnennene 4 2 1 General InfOrmMalionis uuu Na dine nee AE Uva ati aab Co ied nan ga 4 2 2 Technical data eret ak apa RH E re atipa a E a ageage si 5 2 3 Principle otthe ambplifiGE ioc ete rtr etr et 6 PAR miO RO Ee Ke a NEPE E reke 7 2 O FUNCHOMAESCAPION aru e s u saus err ore e 8 2 6 Function As c rrent Controler uu osos oae tetto it aeea eene a de bea dg 11 2 7 List of possible adjustments and indicators a 12 2 8 Front VIOW ocaeca debeat re oaa 14 3 Connection of the device s U Uu aana dag avnnnnnnnnnnennnennnnnnnennnnnne 15 3 1 PINGASSIGNMeni eC vires devia 15 3 2 Explanation of the pin assignme
9. safe operation of these products Set up The relevant safety and accident prevention regulations for the individual case are to be considered Devices intended for installation in cabinets and housings must be operated only in built in state Prior to setting up the devices which are operated with line voltage please check that the adjusted nominal voltage range is identical to the local line voltage For supply with 24V ensure that the low voltage is mechanically separated from the mains Deviations in the line voltage exceeding the tolerances stated in the technical data for these devices are not allowed as this may lead to dangerous conditions Voltage dip or voltage failure requires precautions for restoring an interrupted program Arising of dangerous operational states must be avoided EMERGENCY STOP equipment must not effect an uncontrolled or undefined restart after unlocking They must remain effective in all modes of operation 1 7 Maintenance Service For measuring or test work on any live device please observe the relevant accident prevention regulations The work must be done only with suitable measuring instruments and tools Service work on subassemblies is done exclusively by Custom Servo Motors staff Incorrect repair work by unqualified persons may lead to damage to material property and bears a risk of injuries or mortal injuries Open the main switches or unplug the main plug before opening th
10. A 38 Track A 25 AC1 32 Power GND 39 GND REF 26 AC2 33 5 Volt 40 NC 27 UB 34 PE 41 NC 39 28 40 Power GND 35 GND 42 7 2 5 For Wall Mounting with Higher Demands to Article TBF BUS WE Pin assignment of the screw type terminals The bus board TBF BUS WE has the same pin assignment for the screw type terminals as the bus board TBF BUS W see Figure 11 Figure 12 Bus Board TBF BUS WE 41 8 APPENDIK 8 1 Dimensional drawing TBF60 5R 6 30 In TBF 2 TOT EEE lt 75 5 05 in gt Figure 13 Dimensional Drawing TBF60 5 42 TBF 60 10R ul de g m m o a 11829 I Figure 14 Dimensional Drawing TBF60 10 43 120 7R f 75 e A lt 3 18 Figure 15 Dimensional Drawing 120 7 44 Component mounting diagram TBF R upper side 8 1 1 ST1 00000000 Figure 16 Components Inserted upper side 45 Component mounting diagram lower side 8 1 2 000000 000000 21481 24 0000600020 000000 000005 LL U 0 000 0 U 0 0000000 000 0000 0000000 000000 W nog 0200 n 00000009 n 00000000 n sg m mm 02000 00 am 1199 po Hes 00000 qum A poeter 52 Ww mm 00000000 H H 000 00000 D L PARRA
11. Pulse Width Modulated 4 Quadrant Servo Controller Series TBF R Installation Manual For electronic commutated servo motors MTS MTS Systems Corporation mamam Automation Division 2101 North Broadway New Ulm MN 56073 0199 Telephone 507 354 1616 MTS Automation 1999 Fax 507 354 1611 Important Reading these instructions prior to start up is absolutely necessary Dear customer The following items and the Safety Instructions are for your benefit and are designed to protect the amplifier from damage caused by incorrect use According to the product liability law everyone who puts a product which constitutes a risk for life and limb into circulation is obligated to provide safety instructions These instructions should be clearly defined and should have an informative nature To assist you during installation consider the following points e Protect the amplifier from aggressive and electrically conductive media These may lead to a malfunction or destruction of the amplifier Do not touch live parts There is a risk of fatal injury Trained personnel who are knowledgeable of the safety instructions must carry out installation connection and set up Performance and capabilities of the drive can only be guaranteed under proper use Modifications which are not authorized by MTS Automation Custom Servo Motors as well as operation of the amplifier in a manner other than its intended use will void any warranty or liability
12. acts have to be connected parallel Motor W Output terminals of the power amplifier to which the Motor V motor will be connected 32z b d to line U 30z b d to Motor U line V and 28z b d to line W Please consider that when connecting the motor lines all three contacts each have to be connected parallel 19 3 2 2 Connector 2 D SUB 9 pins socket Connector 2 is intended for connecting resolver two pole transmitter with transformation ratio of 0 5 is required as resolver The input voltage of the rotor should be suitable for 7Vms with 10kHz 1 S4 Resolver Input for the stator signal S4 of a two pole resolver 2 S2 Resolver Input for the stator signal S2 of a two pole resolver 3 S3 Resolver Input for the stator signal S3 of a two pole resolver 4 S1 Resolver Input for the stator signal S1 of a two pole resolver 5 R1 Resolver Output of the 7Vms 10kHz reference signal for the rotor connection R1 of the resolver 6 Shield Contact to connect the shielding of the resolver line e g common shield 54 52 and common shield 51 53 7 Shield Contact to connect the shielding of the resolver line e g common shield R1 R2 8 Shield Contact to connect the shielding of the resolver line e g total shielding 9 R2 Resolver Connection for the resolver R2 This connection is internally connected to GND 20 3 3 Wiring A careful wiring is absolutely necessary to guarantee a troublefree operation of the servo amplifier The c
13. allic contact surface The shield of the motor line has to be connected on both sides the resolver line or the tachometer line only at one side to the servo amplifier e The mains transformer has to be installed close by the servo amplifier The secondary line length of the transformer has to be as short as possible Run the primary line of the transformer twisted with a clearance of at least 50mm to all other lines e slide in rack of the servo amplifier has to show a good HF contact to the mounting plate of the switch cabinet provide for sufficient earthing of the switch cabinet e To earth the shieldings the metallic armored screw joints have to be used Run them through the switch cabinet wall with a good metallic contact to the wall For reasons the shields of one connection line must always have contact on both sides Low frequency circulating currents however may occur These so called hum pick ups are for example created by earthing on both sides and can be eliminated by a capacitiv coupling of the shield which consequently allows high frequency efficiency It is useful to carry out an EMC examination for the complete system consisting of many single components such as motor servo amplifier set value resolver EMC filter to guarantee a troublefree operation in compliance with the CE directive 25 anis 18006 BL I nil rss Wuruk du p 45 iuo idu 68
14. ange from 0 to 100 of rated peak current 2 7 3 The Test Points MPO Ground reference OV MP1 Nominal voltage Voltage at the differential nominal speed input referred to ground MP2 Output of the speed controller set value 10V 15A TBF60 5R 25A TBF60 10R 18A TBF120 7R MP3 Tachometer voltage 10V 6000 rpm MP4 Fault diagnosis 9V 0 4V Overcurrent 8V 0 4 Overvoltage 7V 0 4V Overtemperature MP5 Current monitor Phase V 10V 15A TBF60 5R 25A TBF60 10R 18A TBF120 7R 25A TBF60 10R MP6 Current monitor Phase U 10V 15A TBF60 5R 18A TBF120 7R 2 7 4 Soldering Jumpers JP1 to JP8 Adjustment only for devices without resolver JP9 Closed when operating the device as speed controller open for current control JP10 As JP9 JP11 Open when operating the device as speed controller closed for current control JP12 Only for adjustment by factory JP13 Only for adjustment by factory 2 7 5 The Internal Potentiometers P6 Only for adjustment by factory 7 Only for adjustment by factory P8 For special requirements to clock frequency of the power amplifier a potentiometer can be used here normally no components inserted P9 Only for adjustment by factory P10 Only for adjustment by factory 2 7 6 The DIP switches 51 Adjustment to pole number of the motor Comment 8 6 Delivery condition S2 Adjustment of the number of pulses per rotation from incre
15. d controller and current limiting The nominal speed value can be fed through the input differential amplifier In the stage connected on load side the positive and negative set values are suppressed separately limit switch logic The speed set value conditioned by this way is then injected to the speed controller The inverted tachometer voltage injected to the speed controller in this device is gained from the resolver signals by means of a corresponding procedure The current set value is then available at the output of the speed controller There are different possibilities to limit the nominal current The Pt current limiting reduces the current set value using the following procedure The actual current values are rectified quadrated and run to a low pass The circuit limits the current to the continuous current value which corresponds to the position of the potentiometer P5 when the output voltage of the low pass reaches the voltage adjusted at this potentiometer Furthermore the maximum possible nominal current can be adjusted to 0 15A 0 25A or 0 18A with an externally fed voltage of 0 10V at the input lext The maximum pulse current deliverable by the device can be adjusted with the potentiometer P2 of the internal current limiting This current limiting is connected on load side of the previously mentioned current limitations this guarantees that the current adjusted here can never by exceeded e Current mode c
16. e Speed Controller The resistor R71 is intended for modifying the static rigidity see Figure 17 The rigidity decreases with increasing resistor value The standard value is 3300hm 5 6 Derivative Action Component in the Tachometer Feedback By inserting a resistor R80 normally not provided with components and a capacitor C25 a differential action can be given for special requests to the control of the tachometer feedback 31 6 Troubleshooting Green LED POWER does not light axis does not move no holding torque e 15V or 15V or 5V overloaded by external consumers or short circuited e Fuse S1 is defective e External fuse to the power amplifier is defective Green LED POWER lights axis does not move no holding torque e Interruption of the motor lines e Power amplifier enable is missing e Power amplifier enable took place but the device was not ready Input lextern is not wired e Input Pos Stop and Neg Stop are not wired Axis does not move motor has several positions with holding torque during one turn with oscillating engagement when the motor is manually displaced e Wrong polarity of the motor e Wrong setting for number of motor poles e Motor line interrupted e Wrong resolver connection or wrong adjustment of the resolver Axis traveling weakly pronounced holding torque e Pulse current potentiometer in limp left stop position No axis traveling motor has no holding torque e No speed ref
17. e device or pulling it out of the sub rack When replacing defective fuses please observe the stated electrical values Incorrect modifications and work on the subassemblies lead to a loss of warranty claims and involves unpredictable risks 2 Technical description 2 1 General Information The series R amplifiers resolver are servo amplifiers for speed control of brushless servo motors They extract the information for the sine commutation of the motor and for the speed feedback from the signals of the resolver attached to the motor In addition to that incremental encoder signals are simulated by these signals This allows the realization of favorable solutions for a large range of applications with low and medium power levels The amplifiers work with a pulse width modulated power amplifier in MOSFET technique The design is a 3 HE Euroformat for 19 slide in racks These devices have an integrated power supply unit The electronics is supplied internally from the intermediate circuit voltage which also allows a battery powered operation The main characteristics are Sine commutation Hybrid technique SMD technology 19 inch 3HE slide in technique Internal power supply unit High dynamics High efficiency Almost no clock noise by doubling of the current frequency Short circuit proof and ground contact proof Protective circuit Undervoltage overvoltage overcurrent overheating Pt current limiting Differential ampli
18. emperature exceeds the allowed values because of insufficient air circulation or a too high ambient temperature Restart is possible only after switch off and switch on of the supply voltage Now the power amplifier can be enabled at the enable input with an external voltage the motor turns 10 For safety reasons enable is possible only when the device is ready for operation This avoids that the motor starts running in an uncontrolled manner when applying the operating voltage while the enable signal is already applied That means a permanent wired connection of e g 24V after the enable input ensures that the motor will not start running when switching on the operating voltage The logic also switches off in case of undervoltage in the intermediate circuit and undervoltage of the electronic voltages The device changes to readiness only when the minimum voltages necessary for a safe operation are available The motor slows down and enable is disabled if an undervoltage of the electronic supply occurs during the operation If there is an undervoltage in the intermediate circuit the motor slows down and starts running when the minimum voltage is exceeded 2 6 Function as Current Controller In the case the device was not ordered as current controller the adjustment ex factory is Speed control In some applications it may be useful to operate the TBF amplifier as a pure current controller because a torque control is desired o
19. ents inserted upper side TBF BCR2 dra sss 45 Figure 17 Components inserted lower side TBF BSR2 dra 46 Figure 18 Components on lower side 1 47 Figure 19 Components on upper side 1 47 1 Safety Instructions 1 1 General Notes This start up manual describes functions and gives all necessary information for the designated use of the subassemblies produced by Custom Servo Motors The manufacturer is responsible for the preparation of an instruction manual in the national language of the end user The preparation of machine specific risk analyses is also the manufacturer s duty Observance and understanding of the safety instructions and warnings stated in this document is the condition for the riskless transport installation and set up of the components by qualified personnel 1 2 Qualified Personnel Must be able to correctly interpret and realize the safety instructions and warnings Furthermore the personnel entrusted must be familiar with the safety concepts of the automatization technique and must be trained accordingly Unqualified actions at the subassemblies or the non observance of the warnings stated in this document or attached to the subassemblies constitute a risk to life and limb of the user or cause dama
20. erence available e Motor shaft blocked Yellow LED 1 lights e Wrong adjustment of the potentiometer lett e Mechanical friction too large Oscillations approx 200Hz because of wrong adjustment of the potentiometer ampl e Ahumon the input line 32 Red LED FAULT lights e Operational voltage too high 8V 0 4 at MP4 e Braking energy too high 8V 0 4 at MP4 e The thermal switch reacted as the heat sink temperature is gt 80 7V 0 4 at MP4 e Short ircuit in the motor or ground contact of a motor line 9V 0 4 at MP4 Uncontrolled high motor speed e Wrong polarity of the resolver or wrongly adjusted e Wrong polarity of the motor Motor does not reach the desired speed Speed reference values attenuated too strong by P1 e Operational voltage too low Driven load set too high or current limiting set too low No smooth running of the motor e Alternating current amplification too high e Insufficient resolver line shielding or shield connected wrongly e Interference by wrong input wiring Yellow LED BALLAST permanently lights e Power supply too high Motor heats up strongly in idle operation e Amotor with a high internal resistance is used see 5 1 33 7 Options 7 1 Ballast circuit A ballast circuit is necessary when the regenerative energy from motor and load is larger than the energy which can be taken up by the filter electrolytic capacitors until the maximum volta
21. fier input Enable input External current limiting Limit switch inputs PLC compatible inputs Incremental encoder simulation Series Nominal voltage Nominal current Feedback with R Resolver Optional T Tachometer generator and Incremental encoder is separated define 2 2 Technical Data TBF60 5R TBF60 10R TBF120 7R Nominal voltage 60V 60V 120V Nominal current peak value Pulse current peak value Intermediate circuit voltage max 85VDC 85VDC 170VDC min 25VDC 25VDC 70VDC Recommended transformer voltage 54 AC 54VAC 95VAC Ballast circuit Electronic suppl Efficienc Residual voltage drop nominal current Clock frequenc Frequency of the current ripple Current regulator bandwidth Minimum load inductance nominal current Auxiliary voltage for external consumers 15V 10mA 5V 10mA Set value input differential amplifier 10V Internal resistance 20kOhm Control inputs Enable Pos Neg Off lt 4V Stop Integral off On 30V lt gt 12V Internal resistance Input Ext Current limit 0 10V for Internal resistance Incremental encoder outputs A A B B RS422 l I Electronic commutation Resolver 2 Pole Primary Rotor transformation Ratio 0 5 input voltage 7V rms 10 2 Output conditioned tachometer voltage operation amplifier output external load 10kOhm Only short shielded lines Scaling 10V 6000 rpm Pt message output max 10W for 100V 100mA Connections 1x plug type connector DIN 41612
22. g capacity together with 8z 10mA UB Plus pole of the d c intermediate circuit Here the plus pole of a probably existing external d c voltage can be supplied by circumventing the internal rectifier If an additional filtering of the intermediate circuit voltage is necessary the plus pole of the external electrolyte capacitor is connected here An external ballast circuit can be connected here with the plus pole These three contacts have to be connected parallel as the carrying capacity of one contact should not exceed 5A for 45 C AC2 Supply inputs of the device Here all secondary AC1 connections of a transformer are connected For protection a fuse has to be built in the supply line In no mode of operation and under consideration of all winding tolerances and line voltage variations the transformer voltage must never exceed 60VAC for 60 devices and 120VAC for 120V devices These three contacts have to be connected parallel Power GND GND of the d c intermediate voltage circuit GND connection of a probably existing external direct voltage The minus pole of the external electrolyte capacitors has to be connected to 26z b d when an additional filtering of the intermediate circuit voltage is necessary An external ballast circuit can be connected here with your minus pole The housing of the motor is to be connected here too Power GND is the point the protective earth terminal has to be connected to These three cont
23. ge is reached Because of the relatively large capacitor in the power supply unit the TBF60 5R normally can do without a ballast circuit As for the TBF120 7R the filter capacitor is only half as large and the voltage as well as the current is higher this device is normally provided with a ballast circuit of 35W continuous power Should a braking causes the yellow LED BALLAST to light up and 8V can be measured at MP4 an additional ballast circuit or a ballast circuit at all has to be used The following ballast circuits are available e The BS2 60 with 35W for the 60V device e The BS2 120 with 80W and BS120 V with 125W for the 120V device e The ballast threshold is 87V for the 60V device and 172V for 120V devices e For the determination of the braking power the following formula can be used 0 0055 x J x n p T P Power in W J Mass moment of inertia kgm n Speed in rpm T Period duration in s time from the begin of a braking procedure until the begin of the next braking procedure 34 7 2 Bus boards 7 2 1 For 19 sub racks article no TBF BUS S Pin assignment of the screw type terminals 1 Int Off 22 GND REF 2 Neg Stop 23 Set value 3 Pos Stop 24 Set value 4 5V 25 15V 5 Ready 13 26 Enable 6 Ready 14 27 Tachometer output 7 Track l 28 Track 8 Track A 29 Track A 9 Track B 30 Track B 10 NC 31 21 11 NC 32 15V 12 NC 33 15V 13 lext 34 15V 14 GND 35
24. ge to the machine or other material property 1 3 Designated Use is given when any work on equipment of the machine plant is carried out by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician e the machine plant is used only when in a safe and reliable state e the machine is used in accordance with instructions set out in the operating manual 1 4 Description of symbols and signal words DANGER Warning against risk of serious injuries Observance is absolutely necessary ATTENTION Information the non observance of which may lead to substantial damage to material property Observance of these safety instructions is absolutely necessary IMPORTANT LE This symbol refers to an information important with regard to the use of the machine Non observance may lead to troubles Safety Notes As the subassemblies are intended for installation in machines freely accessible parts may carry dangerous voltage The manufacturer must ensure adequate protection against contact Only qualified personnel who knows the contents of these start up instructions must execute any work on these subassemblies The instructions contained in this manual have to be observed strictly as a wrong handling causes additional risks A correct transport storage set up and assembly of the machine as well as careful operation and maintenance is an important condition for the correct and
25. h a voltage NC Track I Together with 10d 12d 14d track track A track B Track A these contacts form the outputs of the simulated Track B incremental encoder signals These outputs are designed as differential output drivers for each track The output levels are gt 2 5V for high and 0 5V for low according to RS422 with a maximum carrying capacity of 20mA per channel By this the TTL specification gt 2 4V for high and 0 8V for low is fulfilled Track I Together with 10b 12b 14b track I track A track Track A B these contacts form the outputs of the simulated Track B incremental encoder signals see above GND OV reference potential for 5V 15V and 15V t message This output has low impedance connection to 15V when the Ft current limiting is active otherwise it has high impedance external Current limiting input at which the pulse current set at P2 can be limited from 0 100 by an external voltage from 0 10V About correspond to a voltage of OV and the pulse current set at P2 corresponds to a voltage of 10V 17 Ss 182 18b 18d 202 b d EF 22z b d 24z b d A 26z b d LES 282 b d 302 b d 32z b d 18 Normally no external current limiting is used In this case the input can be switched to 15V GND OV reference potential for 5V 15V and 15V 15V 15V supply for external use Carrying capacity 10mA 15 V 15V supply for external use Carryin
26. he continuous current adjustable at P5 For adjusting P5 always turn slowly After a short time the new continuos current flows Adjustment becomes essentially easier when instead of the motor three wye connected reactors are connected to the motor connections The reactors should have a minimum load inductance and a saturation current that exceeds the maximum current of the amplifier 4 3 4 Setting the Maximum Motor Speed The amplifier is set ex factory to a motor speed of max 3000 with 10V input voltage for our motors In order to reduce the maximum motor speed turn the input potentiometer to the left to increase the motor speed turn it to the right 4 3 5 Offset Adjustment of the Speed Regulator The offset adjustment has to be carried out in a warm operating status of the device Define the set value zero short circuit the input Adjust motor drift by setting P4 to zero 29 5 Optimizing the Controller Response 5 1 Amplification setting of the current regulators The adjustment a c amplification of the current regulators is done with the resistors R25 standard 4 7kOhm and R26 standard 4 7kOhm see Figure 16 where each resistor is part of a voltage divider Smaller resistor values increase the amplification A response is seldom necessary here Should however motors with higher winding resistors are used the motor heats up already in idle operation as the resistor of the winding together with the inductance of
27. mental encoder simulation 13 Front view 2 8 135440 LSM3A LfidNI Ji 440 O LETE CET dal 01 09591 339 138440 J AIO O 9 45 0931 443 O 195410 swt 171940 Lite NI Figure 4 Front Views 14 3 3 1 Connection of the device Pin Assignment Conn 1 F48 22 2b 2d 4z 4b 4d 62 6b 6d 18d 20z 20b 20d 227 22b 22d 247 24b 24d Integral off Pos Stop Neg Stop GND Ref Nominal speed input Nominal speed input 5V Ready Ready 15V Enable input Tachometer output N C Track I Track I N C Track A Track A N C Track B Track B GND Pt message lext GND 15V 4 15V 4 UB 4 UB UB 2 2 2 AC 1 AC 1 AC 1 262 26 26 282 28 28 302 30b 30d 322 32b 32d Connector 2 D SUB 9 pole socket OND URO N gt Power GND Power GND Power GND Motor W Motor W Motor W Motor V Motor V Motor V Motor U Motor U Motor U S4 Resolver S2 Resolver S3 Resolver S1 Resolver R1 Resolver Shield Shield Shield R2 Resolver 15 3 2 3 2 1 22 2 2d 4b 4d 6z 6b 6d Explanation of the pin assignment Connector 1 F48 Integral switch off The integral action compo
28. nent of the speed controller can be switched off at this input by injecting a high signal 15 to 30V This may be useful e g for positioning tasks The motor does not drift slowly but has a lower holding moment During the normal operation this input is inactive The input is not to be wired for this case or is to be connected to ground Positive Stop Negative Stop A limit switch logic can be realized with these inputs For a running of the motor in positive direction the input Pos Stop is to be connected to 15V 30V When the connection is interrupted e g by a limit switch normally closed contact the positive set values will be suppressed and the motor is therefore braked with the maximum adjusted pulse current Negative speeds are still possible Simultaneously with the active stop function the integral action component is being switched off The same applies for the Neg Stop input but for the negative rotational direction When these inputs are not used they have to be connected to 15V GND REF Set value Set value 5V Ready for operation Ready for operation Reference ground for measuring the conditioned tachometer voltage Avoid external connection with GND or Power GND of the device not via protective earth terminal either ground loops Inputs of a differential amplifier to define the speed set value Terminal 4d has a positive effect against 4b The maximum differential voltage must not exceed
29. nt I nennen enne 16 3 3 WINING 21 3 4 agn edes tetris ag ad 23 3 5 Measures for an installation in compliance with the EMC directives 25 4 EP A 27 4 1 Connection a ER eon aii a hafun diet edges 27 i xe Lite etu Ie dn eR be RR 27 4 3 Switching on and configuration seen nne 28 5 Optimizing the controller response eese nennnennnnnnnennnnnnennnennennnn uuu u 30 5 1 Amplification setting of the current regulators eene 30 5 2 Alternating current amplification of the speed 30 5 3 Tachometer fter th HERR enga 30 5 4 Integrakaction component of the speed controller eee 31 5 5 Direct voltage amplification of the speed controller see 31 5 6 Derivative action component the tachometer 31 6 Troubleshooti g L 32 pr met 34 ZY SEU 34 7 2 BUS OAS on Lae dba iach ean ee ean e aes 35 8 APPENDIX C E n 42 8 1 Dimen
30. ontrol and current controller As shown in the block diagram the current mode control must be passed through first to form the actual current set value for the current controller of the U conductor current and of the V conductor current The nominal current of the speed controller output conductor current is converted depending on signals of the resolver in two current set values with an offset of 120 and fed to the current controllers for the phases U and V The nominal current of the third phase W is imitated by subtraction at the outputs of the current controller This guarantees that the sum of the currents is always zero The pulse width modulator generates from the three d c voltage signals for the conductor currents six PWM signals which serve for activating the driver stage after the creation of the lag time 2 5 3 Driver stage and power amplifier The driver stage amplifies the signals coming from the pulse width modulator and by this activates the power transistors MOSFET transistors are used in the power amplifier which allows short switching intervals and low residual voltage drop and ensures a good efficiency 2 5 4 Monitoring and Fault Logic Enable The intermediate circuit voltage and the current in the intermediate circuit are permanently monitored by the error detection The device switches off the motor through the error logic when these values exceed certain quantities The error logic also reacts when the device t
31. ontrol line for the servo amplifier the signal lines of the motor and the motor lines are to be wired separately See also NMeasures for an installation in conformity to the EMC directive 3 3 1 Protective Earth Terminal Power GND ST1 26z b d must be connected with the protective earth terminal Control unit and amplifier must have an equal potential The equalized potential must be realized by a single connection between control unit and amplifier ST1 26z b d This connection should be a sufficiently strong line The conductor cross section should at least correspond to that of the motor line however should not be smaller than 1 5mm As in the amplifier Power GND ST1 26z b d GND ST1 182 and ST1 162 and GND REF ST1 42 are connected no further terminal must be connected with control GND to avoid ground loops 3 3 2 Resolver Cable The resolver cable must be shielded The pairs S1 53 S2 S4 and R1 R2 must be twisted The shorter the twist the better it is Each pair has to be shielded separately within the total shield see 3 5 The internal shields are to be connected to connector ST2 with ST2 6 ST2 7 ST2 8 the external shield is to be connected to the connector housing Connection of the shields on the side of the motor is not allowed and not to the connector housing either as otherwise interference currents of the motor winding may be discharged through this shield which would partly wreck the shielding effect ground loops
32. pability of auxiliary drives in house e Connect the power amplifier to the motor see 3 4 Figure 5 Figure 6 e Connect the sensors of the motor resolver to the servo amplifier see 3 4 Figure 5 Figure 6 e Connect the amplifier with the power supply see 3 4 Figure 5 Figure 6 e factory configures the servo amplifier so our motors will reach 3000 rpm with 10V setpoint default LE If you need other speed values or if this motor amplifier combination is set up for the first time please proceed as follows Input potentiometer P1 five turns from left stop Pulse current potentiometer P2 turns from left stop Amplification Shipped adjustment by two turns to the left 27 4 3 Switching and Configuration 4 3 1 Procedure Until Amplifier is Enabled Set enable input to logical 0 Give a speed reference of OV Switch on control unit and amplifier supply Release the brake of the motor if available Set enable input to logical 1 Turn P3 to the left if the motor vibrates until the vibration stops 4 3 2 Configuration of the Speed Controller Amplification For the configuration of the amplification the motor has to be coupled to load Turn the potentiometer P3 to the right until vibrations are noticeable reduce the amplification immediately by turning the potentiometer to the left until the oscillation stops and then turn it tick more to the left 4 3 3 Configuration of Pulse Current and Continuous Cu
33. r the speed controller in the master control is already realized To set the amplifier to current control or speed control set the three soldering jumpers JP9 JP10 and JP11 see figure as follows JP11 1 to JP11 2 JP9 1 to JP9 2 JP10 1 to JP10 2 closed closed open open Speed control Current control Numbering of the soldering jumpers is as follows e g for JP9 JP9 1 right field of the soldering jumper JP9 2 left field of the soldering jumper Speed control Current control T SN J000 CODI cs 068 802298 p 00 STR DRZ PC TBF 2 Figure 3 Jumper Settings 11 2 7 List of Possible Adjustments and Indicators 2 7 1 The LEDs LED1 green LED2 yellow LEDS red LED4 yellow Indicates readiness of the device lights also when the amplifier is not enabled Pt current limiting is active Fault overcurrent overvoltage overtemperature Ballast circuit operates only for 120V devices 2 7 2 The Potentiometers Potentiometer 1 Potentiometer 2 Potentiometer 3 Potentiometer 4 Potentiometer 5 Signal Potentiometer scales the nominal speed input to match the maximum velocity feedback used for adjusting the maximum motor speed 10 to 100 Pulse current limiting range from 10 to 100 of the rated peak current Adjustment of the amplification of the speed controller Offset adjustment of the speed controller Continuous current limit r
34. rrent For a first set up where the currents have been reduced as described under 4 1 or when a pulse current or continuous current other than the preset values is required see 2 2 the configuration can be done as follows Measure the current at MP2 The scaling is to be found under 2 7 3 Proceed as follows to load the motor in a way that it is operated to the pulse current and continuous current limits 4 3 3 1 Pulse current Move the motor with minimum speed to a mechanical stop and leave the set value at the amplifier so that the motor still tries to move towards the stop Neither limit switch nor lag must be active Turn P5 to the right stop and P2 to the left stop Use the potentiometer P2 to increase the pulse current to the desired value Should the device reduce the continuous current before the adjustment is completed disable the amplifier and wait for a recovery time of 10 to 20 seconds then carry out the configuration once again Optimum values are often achieved after several repeated adjustments 28 4 3 3 2 Continuous Current Leave P2 in the position determined as described above adjust P5 with five turns from left stop Once again move the motor with minimum speed to a mechanical stop and leave the set value at the amplifier so that the motor still tries to move towards the stop Neither limit switch nor lag must be active After expire of the pulse current phase the current is automatically reduced to t
35. sional drawing eiecti E lean a RED ER deras sed 42 List of Figures Figure 1 Principle of the amplifier DO1404A dsf esses 6 Figure 2 Block diagram D01584A dsf eene 7 Figure 3 Jumper setting PO TBF 2 plt i tte p rte te 11 Figure 4 Front views FRONTS 6 22 14 Figure 5 Connection diagram minimum connection D0159B dsf 23 Figure 6 Connection diagram TBF R 01600 24 Figure 7 Installation in compliance with EMC directives D0026B dsf 26 Figure 8 Pin assignment 191 subrack TBF MZOra sess 36 Figure 9 Connection diagram TBF R BUS S ED0161C dsf 37 Figure 10 Connection diagram TBF R BUS W ED0087D dsf 38 Figure 11 Pin assignment wall mounting TBFWB 39 Figure 12 Bus board TBF BUS WE BUSWE MZ dra 41 Figure 13 Dimensional drawing TBF60 5 23 42 Figure 14 Dimensional drawing TBF60 10 22 43 Figure 15 Dimensional drawing TBF120 7 2 1 44 Figure 16 Compon
36. the winding leads to high reactive current Remedy is possible by increasing the amplification During the test stage the fixed resistors can be replaced by potentiometers 25kOhm and in series production the values determined can be realized by fixed resistors Both resistors must have the same size The accuracy must be 1 or higher For adjustment increase the current amplification with low speed until an oscillation becomes noticeable a stronger motor noise starts with approx 1kHz Immediately reset the amplification until the oscillation stops and a tick more 5 2 Alternating Current Amplification of the Speed Controller To adjust the amplification couple the motor to load and define a set value of OV Turn the potentiometer P3 to the right until the oscillation starts immediately reset the amplification until the oscillation amplified motor noise because of rotary oscillation of the motor shaft with approx 200Hz stops and a tick more 5 3 Tachometer Filtering The capacitor C21 is responsible for the tachometer filtering see Figure 16 When operating the drive with a three phase tachometers a standard value of 22nF is enough It allows a very good dynamic controller response 30 5 4 Integral Action Component of the Speed Controller The capacitor C27 is responsible for the integral action component of the speed controller see Figure 17 The standard value of C27 is 220nF 5 5 Direct Voltage Amplification of th
37. witches of the inverter through a pulse width modulator With a PWM frequency of 9 5kHz this leads due to the special activation to a current ripple of 19kHz and consequently to a merely audible clock noise This secondary control loop current under another one speed guarantees a stable control with good dynamics and high rigidity of the drive This even allows the easy realization of current limitations necessary to protect the motor and the amplifier just by limiting the output voltage of the speed controller current set value Block diagram 2 4 US anus gt JENS Big Walo acidi o 214 pug AI t TE oF ane jis das Ban ding sh To yun Ajddns per per oed 210242211 n M L 1 mtu oF C Bo A ng Figure 2 Block Diagram 2 5 Function Description The function of the amplifier is described by means of the block diagram shown in Figure 2 2 5 1 Power Supply Power amplifier Rectification and filtering form the direct voltage intermediate circuit voltage UB necessary to operate the power amplifier from the AC power supply This intermediate circuit voltage can also be fed directly as d c voltage Electronic supply The electronic supply takes place internally through a switched mode power supply from the intermediate circuit voltage 2 5 2 Control System Spee
38. y output Enable and Pos Stop Neg Stop if used have to be wired in a shielded cable as well These lines are measured against ground that means the connection requested in 0 between TBF and master control unit is sufficient 3 9 5 The Simulated Incremental Encoder Signals The connection cable for the incremental encoder signals has to be shielded The pairs track A track A track B track B and track l track l have to be twisted the shorter the twist the better the interference immunity Each pair is shielded separately within the total shield see O The shield has to be connected on amplifier side and control unit side 22 Connection Diagrams 3 4 Minimum connection 3 4 1 a Bul 206 du LMS sieur Ja si dada a Foy zo TANG n DAN QAN YNN DUX 050500 00 _ S L Qq azee MOKIL sjndhn 9921 hugu ou F ONS 1X4 nehna Figure 5 Connection Diagram minimum connection 23 Connection diagram 3 4 2 pus 206 du ws up S de S YINYMS I WIT IN DE NNQ NNN NOE GOOG D NE 88 LIS TS H LIS hs 22 OWL M J8L og DH 772 vs ar 712 1s LIS 72811 MS 7 8 OWL W xod L asso ibu J bau J8 s du Jun Iut GALEN 0y ANDY
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