64
INSTALLATION MANUAL PULSE-WIDTH MODULATED 4-QUADRANT SERVO CONTROLLER TBF-I For electronic commutated servo motors Custom Servo Motors, Antriebstechnik GmbH & Co. KG 1999 Custom Servo Motors Antriebstechnik GmbH & Co. KG Leinenweberstr. 14 Industriegebiet Hochdorf D - 79108 Freiburg Phone 0761-13091-0 Fax 0761-13442 e-mail: [email protected]

Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

  • Upload
    others

  • View
    3

  • Download
    0

Embed Size (px)

Citation preview

Page 1: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

INSTALLATION MANUAL

PULSE-WIDTH MODULATED4-QUADRANT SERVO CONTROLLER

TBF-I

For electronic commutated servo motors

Custom Servo Motors, Antriebstechnik GmbH & Co. KG 1999

Custom Servo MotorsAntriebstechnik GmbH & Co. KG

Leinenweberstr. 14Industriegebiet HochdorfD - 79108 FreiburgPhone 0761-13091-0Fax 0761-13442e-mail: [email protected]

Page 2: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal
Page 3: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

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 manufactures a product which constitutes a risk for life and limb 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:

Protect the amplifier from aggressive and electrically conductive media. These may lead to a malfunction or to the 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, as well as operation of the amplifier in a manner other than its intended use, will void any warranty or liability.

Our "Terms and Conditions" are the basis for all legal transactions.

Page 4: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal
Page 5: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

Table of Contents1 Safety Instructions..........................................................................................................11.1 General notes....................................................................................................................11.2 Qualified personnel...........................................................................................................11.3 Designated use.................................................................................................................11.4 Description of symbols and signal words..........................................................................21.5 Safety notes......................................................................................................................21.6 Set-up................................................................................................................................31.7 Maintenance / Service.......................................................................................................32 Technical Description.....................................................................................................42.1 General Information..........................................................................................................42.2 Technical Data..................................................................................................................52.3 Control Principle................................................................................................................62.4 Block Diagram...................................................................................................................72.5 Function description..........................................................................................................82.6 Function as Current controller.........................................................................................102.7 List of possible adjustments and indicators.....................................................................112.8 Front View.......................................................................................................................133 Connection of the Device.............................................................................................143.1 Pin assignment................................................................................................................143.2 Explanation of Connection..............................................................................................153.3 Wiring..............................................................................................................................193.4 Proper Polarity of Motor and Rotor Position Emitter.......................................................213.5 Connection Diagram.......................................................................................................234 Set-up.............................................................................................................................254.1 Connection......................................................................................................................254.2 Presetting........................................................................................................................254.3 Switching on and configuration.......................................................................................265 Optimizing the Control Behaviour...............................................................................295.1 Amplification of Alternating Current of Current Controllers.............................................295.2 Amplification of Alternating Voltage of the Speed Controller..........................................295.3 Tachometer filtering........................................................................................................295.4 Integral Part of the Speed Controller..............................................................................295.5 Direct voltage amplification of the speed controller........................................................295.6 Differential Part in Tachometer Feedback......................................................................306 Troubleshooting............................................................................................................317 Options.......................................................................................................................... 337.1 Speed Control with 1. three-phase tachometer (DST) 2. incremental emitter (IGT/K). 337.2 Front Plate.......................................................................................................................337.3 Bus Board....................................................................................................................... 34

iii

Page 6: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

8 APPENDIX......................................................................................................................368.1 Dimensional Drawings TBF.............................................................................................368.2 Insertion Plan TBF (Top Side)........................................................................................378.3 Insertion Plan (Bottom Side)...........................................................................................388.4 Classification of Motor Signals........................................................................................39

iv

Page 7: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

1 Safety Instructions

1.1 General notesThis start-up manual describes functions and gives all necessary information for the designated use of the subassemblies produced by MTS Automation. 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 analysis is also the manufacturer's duty.Observance and realization 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 personnelMust 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 damage to the machine or other material property.

1.3 Designated useis 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.

the machine/plant is used only when in a safe and reliable state.

the machine is used in accordance with instructions set out in the operating manual.

1

Page 8: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

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!This symbol refers to any information, important with regard to the use of the machine. Non-observance may lead to problems in operation.

1.5 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.Any work on these subassemblies must be conducted by qualified personnel, who are familiar with these start-up instructions.The instructions included in this manual must be strictly observed in order to reduce any safety 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 safe operation of these products .

2

Page 9: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

1.6 Set-upThe relevant safety and accident prevention regulations for each individual case must be taken into consideration.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 power supplies with 24V, ensure that the low voltage is mechanically separated from the main.Deviations in the line voltage, exceeding the tolerances stated in the technical data for these devices, are not allowed, as this could lead to dangerous operating conditions.Voltage dip or voltage failure requires precautions for restoring an interrupted program. The risk 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 / ServiceFor any measuring or test work on the 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 MTS Automation staff. Incorrect repairs done by unqualified persons may lead to damage of material property and injuries. Open the main switches or unplug the main plug before opening the 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 voids the product warranty and may cause unpredictable risks.

3

Page 10: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2 Technical Description

2.1 General InformationServo controllers of the TBF series concern themselves with the amplifiers for driving D.C. brushless motors. Using a rotor position emitter as the feedback device and a three-phase tachometer or incremental emitter for speed control feedback, these are specially designed for such operation. In small and medium power ranges, these offer the best price-power relationships for drives, via the rotor position emitter controlled block flow. Favorable solutions are achieved, especially for applications which require an incremental emitter anyway for a higher level positioning control.The amplifiers work with a pulse width modulated output in the MOSFET technique. The mounting form is 3 HE (Euroformat) for 19" slide-in casing frames. The power supply device is built in for this equipment. The electronic supply is provided internally from the intermediate voltage, whereby battery operation is also made possible.The main characteristics are: Trapezoidal commutation using Hall sensors Hybrid technique / SMD Technique 19 inch/3HE slide-in mounting Internal power supply High dynamics High efficiency Almost no clock noise by mains frequency doubling Short-circuit proof and ground contact proof Protective circuit for undervoltage, overvoltage, overcurrent, overheating I2t-current limiting External current limiting Differential amplifier-input Enable input Positive and negative Stop PLC compatible inputs Three-phase tachometer or Tachometer emulation from incremental emitter signalsType code:

TBF 60 / 5 I

Series Nominal voltage Nominal current Feedback with: I = Incremental encoder Optional T = Tachometer generator and R = Resolver is defined in a separate manual.

4

Page 11: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.2 Technical DataModel Series TBF 60/5 TBF 60/10 TBF 120/7Nominal voltage 60V 60V 120VNominal current (Irms) 5A 10V 7A *Pulse power current 15A 25V 18A *DC Bux voltage max. 85VDC 85VDC 170VDC min. 25VDC 25VDC 70VDCRecommended transformer voltage 54VAC 54VAC 95VDCElectronic supply internalEfficiency 93%Residual voltage drop in final stage (at Irms)

1.5V

Clock frequency 9.5kHzFrequency of current ripples 19kHzCurrent regulator bandwidth 1kHzMinimum load inductivity (at Irms) 1.2 mH 0.8 mH 1.6mHAuxiliary voltage for external circuits ± 15V/20mA

+ 5V/150mASet point input ± 10VInner resistance of set point input 20kOhmVoltage range of tachometer input 4.5 - 45V(at Uref=±10V and nominal rotation speed)Inner resistance of tachometer input 100kOhmControl inputs Enable, Pos.-Neg.-Stop, Integral-off

"Out" <4V" In" 30V< >12V

Inner resistance of control inputs 3.9kOhmInput external current limiter 0...15A 0...25A 0...18AInner resistance external current limiter 20kOhmIncremental emitter outputs A+,A-;B,B- (0,/0 looped through)

RS422

Inner resistance incremental emitter in 1kOhmElectronic commutation Rotor position emitterInner resistance elect.comm. (pull up) 4.7kOhmOutput processed tachometer voltage Operational amplifier output

External load >10KOhm!Only short shielded wire!

I2t Signal output 12V at 20mAOperational readiness output Potential-free relay contact

max. 10W at 100V, 100mASpeed feedback Three-phase tachometer or incremental emitterConnections 1 plug connector according to DIN 41612-F48Dimensions 160x100x37mm 16x100x55.5 mm 160x100x75mmWeight 0.4kkg 0.8kg 1.0kg*= outside ventilation with Irms; additional screening at Irms> 4A or Iimp > 12A Irms= 4A and Iimp= 12A are factory adjusted settings

5

Page 12: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.3 Control PrincipleThe three-phase servo controller of the TBF-series operates under the principle of speed control with a subordinated current control circuit. Additionally the flow logic controls the commutation of the brushless D.C. motor. The signal flowchart of the control principal is illustrated as follows:

The speed control circuit consists of a speed controller, current circuit, motor, and a speed counter holder. The nominal value of the speed is preset externally with a potentiometer or NC-control for example. The actual speed value is determined directly on the motor shaft from the suitable equipment (three-phase tachometer, incremental emitter). At the summation point the difference between the reference and the actual values is established and sent to the speed controller. This determines the required nominal current value.

The current control circuit consists of the current controller, the amplifier final output stage, current reading, and the motor windings. At the output of the current controller there is available the nominal current value, which via a pulse width modulator controls the six power switches of the inverter. At a PWM frequency of about 9.5 kHz, obtained through a special trigger, this gives a ripple current of 19 kHz and a barely audible clock noise.

This subordinated current control circuit under a speed control circuit guarantees a stable control with good dynamics and a high stiffness to the drive.

The advantage of this control principle is that current limitations which are required for the protection of motor and amplifier can be realized in a simple way, that means only by limiting the output voltage of the speed controller (nominal current value).

6

Page 13: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.4 Block DiagramE

xces

s vo

ltage

Exc

ess

curr

ent

Und

er v

olta

geM

AC

Inco

min

gpo

wer

Pow

er s

uppl

yel

ectr.

vol

t.E

nd s

tage

Div

er s

tage

Failu

re a

ndsu

perv

isio

nci

rcui

t

PW

M

Dea

dTi

me

curr

ent m

easu

ring

poin

t

I²t curr

ent l

imite

rP5

(Irm

s) I-Im

p.

P2Fl

ow c

ontro

ller

RLG I/T

Tach

o pr

oces

s.3-

phas

e or

Incr

em.E

mitt

ler

P4

Offs

et

P3 (

Gai

n)

Spe

ed c

ontro

ller

Impu

t di

ffere

ntia

lam

lifie

rP1

Ena

ble

Iext

.

Pos

.Sto

p

Neg

.Sto

p

E+

E-

End

sta

gelo

gic

-

+

-

+-

-

+

-

+

+

Incr

emen

tal E

mitt

ler

or brus

hles

s ta

cho

Figure 1: Block-diagram

7

Page 14: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.5 Function description The function of the amplifier is described by means of the block diagram shown in 2.4.

2.5.1 Power supply

Power amplifier:Rectification and filtering form the Bus Voltage (UB), necessary to operate the power amplifier from the AC power supply. This DC Bus voltage can also be fed directly as dc voltage.

Electronic supplyThe electronic supply takes place internally through a switch-mode power supply from the DC Bus voltage.

2.5.2 Control system

Speed controller and current limitingThe nominal speed value is conducted to the differential amplifier input. In the post-switched stage, the positive and negative setpoint values are separately suppressed (terminal stage logic). The nominal speed value together with the tachometer voltage is switched up to the speed controller. In this device, via a suitable procedure, the tachometer voltage will be obtained either from the three-phase tachometer (module DST) or from the incremental emitter signal (module IGT/K).

There are different possibilities to limit the nominal current:

The I²t 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 Iext.

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.

8

Page 15: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

Current-mode control and current controllerAs shown in the block diagram, for the generation of the actual nominal current values for the current controller of the U-circuit and the V-circuit current, these must first be fed to the flow controller. In there the nominal current of the speed controller output (current conductor), depending upon the signal of the rotor position emitter, is converted into two 120° shifted nominal current values and fed to the current controller for phases U and V. In the output of the current controller, through substraction there is simulated the nominal current of the third phase W. Thereby it is guaranteed that the sum of the currents is always zero.The pulse width modulator generates out of the three D.C. signals six PWM signals for the current carriers, which after the dead time generation serves to activate the driver stage.

2.5.3 Driver Stage and End StageThe 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, EnableThe 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 temperature 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.

For safety reasons enable is possible only when the device is ready for operation! This ensures, 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.

9

Page 16: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.6 Function as Current controllerIn the event the device was not ordered as a current controller, the standard set-up from the factory is for "speed control".In some applications, it can be useful to operate the TBF device as a pure current controller because an instantaneous controller will be desired or the speed regulator has already been converted into a higher level controller.For setting up the amplifier for current control or for speed control there are three solder jumpers, JP9, JP10, and JP11 (see figure) as follows. The jumpers should be set as follows:

JP9.1 to JP9.2 JP10.1 to JP10.2 JP11.1 to JP11.2Speed control closed closed openCurrent regulator open open closed

Numbering of the solder jumpers is as follows: i.e. JP 9: JP9.1 = right side of the solder jumper, JP 9.2 = left side of the solder jumper.

10

Page 17: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.7 List of possible adjustments and indicators

2.7.1 The LEDs

LED 1 (green) : Indicates operating condition of device. LED1 is also lit when the amplifier is switched to "Disable".

LED 2 (yellow) : I²t - current limiting is in action.

LED 3 (red) : Indicates a fault (overvoltage, overcurrent, overheating).

LED 4 (yellow): Ballast circuit in action (only by 120V amplifier).

2.7.2 The potentiometers

Potentiometer 1 : Setpoint adjustment; P1 matches the typical device setpoint norm to the normalization of the setpoint emitter and serves as an adjustment for maximum motor speed (0...100%).

Potentiometer 2 : Impuls current limiting; setting range 10%...100% of the device´s typical value.

Potentiometer 3 : Adjustment of speed controller´s amplification.

Potentiometer 4 : Offset balance of speed controller.

Potentiometer 5 : Constant current limit value; setting range 0...100% of the device´s specific limit value.

2.7.3 Test Points

MP0 : Reference ground 0 volts

MP1 : Nominal voltage

MP2 : Nominal current

MP3 : Tachometer voltage

MP4 : Error diagnostics: 9V ± 0.4V => excess current

8V ± 0.4V => overvoltage

7V ± 0.4V => over temperature

MP5 : Current monitor Phase V 10V

MP6 : Current monitor Phase U 10V

2.7.4 Soldering Jumpers

JP1: For factory internal adjustment only

JP2: For factory internal adjustment only.

11

Page 18: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

JP3: Selection for speed feedback (three-phase tachometer or incremental emitter); see also 4.3.4. Value for incremental emitter feedback is 80 kHz.

JP4 As with JP3, however with a value of 40kHz.

JP5 As with JP3, however with a value of 20kHz.

JP6 As with JP3, however with a value of 10kHz.

JP7 Voltage range of rotor position emitter inputs (only for emitters having active outputs, in contrast to the usual Open Collector outputs). JP7.2 to JP7.3 closed for 15 volt output level and JP7.2 to JP7.1 for 5 volt output level.

JP8 For factory internal adjustment only

JP9 Closed for operation of the device as a speed controller, open for current controller.

JP10 As with JP9

JP11 Open for operation of the device as speed controller, closed for current controller

JP12 For factory internal adjustment only

JP13 For factory internal adjustment only

2.7.5 Internal Potentiometers

P6 For factory internal adjustment only

P7 For factory internal adjustment only

P8 A potentiometer can be installed here for special requirements to the clock frequency of the output stage (not inserted for standard devices).

12

Page 19: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

2.8 Front View

TBF

POW

ERCU

R FA

ULT

SIGN

ALCU

R RE

SPBA

LANC

ECU

R GN

DVE

L CM

DCU

R CM

DVE

LOCI

TYFL

T DI

AGCU

R V

CUR

U

LMT

PEAK

CONT

TBF

POW

ERCU

R FA

ULT

SIGN

ALCU

R RE

SPBA

LANC

ECU

R GN

DVE

L CM

DCU

R CM

DVE

LOCI

TYFL

T DI

AGCU

R V

CUR

U

LMT

PEAK

CONT

TBF

POW

ERCU

R FA

ULT

SIGN

ALCU

R RE

SPBA

LANC

ECU

R GN

DVE

L CM

DCU

R CM

DVE

LOCI

TYFL

T DI

AGCU

R V

CUR

U

LMT

PEAK

CONT

SHUN

T LO

AD

128.50

40.30

128.50

55.40

128.50

80.80

Figure 2: Front Views

13

Page 20: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

3 Connection of the Device

3.1 Pin assignment (Din F48 connector)2z Integral shut off 18z Ground2b Negative Stop 18b – 15 volts2d Positive Stop 18d + 15 volts

4z Tachometer MP / Ground reference 20z + VBus4b Rotation speed set point input (+) 20b + VBus4d Rotation speed set point input (–) 20d + VBus

6z + 5 volts 22z AC 26b Operational readiness 13 22b AC 26d Operational readiness 14 22d AC 2

8z + 15 volts 24z AC 18b Enable input 24b AC 18d Tachometer output 24d AC 1

10z Hall W 26z Power ground10b Tachometer V; Track I+ 26b Power ground10d Track I- 26d Power ground

12z Hall U 28z Motor T12b Tachometer W; Track A+ 28b Motor T12d Track A- 28d Motor T

14z Hall V 30z Motor R14b Tachometer U; Track B+ 30b Motor R14d Track B- 30d Motor R

16z Ground 32z Motor S16b I2t signal 32b Motor S16d Iext. 32d Motor S

14

Page 21: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

3.2 Explanation of Connection2z Integral Shut Off At this input, via cut in of a high signal (15-30 volts),

the integral part of the speed controller can be shut off. This can be useful for example for positioning operations. With open or at ground level input the integral portion is active.

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.

2b, 2d Negative Stop, Positive Stop

For running the motor in a positive direction, the input Positive Stop must have a +15 to +30 volt connection. By the opening of this connection, for example through a limit switch (open) the positive nominal value will be suppressed and so the motor will be braked with the maximum adjusted impulse current. Negative speed is still possible. At the same time, with an activated stop-function the integral part is shut off. In a similar manner, the Negative Stop input applies for a negative rotation.

When these inputs are not used, they have to be connected to +15V.

4z Three-Phase Tachometer MP/GND Reference

Reference ground for applying the mid-point lead of a three-phase tachometer.

4b,4d

Command+;Command -

Inputs from a differential amplifier for pre-setting the speed setpoints. Terminal 4b works positively as opposed to 4d. The maximum difference voltage may not exceed ±10 volts. Both inputs must always be switched to attached circuits, for example Command+ to the output of a D/A converter and Command- to an analog ground of an NC control.

6z +5V Output of a +5 volt supply, for example for the supply of an incremental emitter or a rotor position emitter. Power rating 100mA.

6b,6d

Ready message Potentialfree reed relay contact to signal the read message of the device. The contact is closed with an operationally ready device.

8z +15V Output of the +15 volt electronic voltage, for example for the supply of a rotor position emitter or the limit switch inputs Positive Stop, Negative Stop.

8b Enable input This connection is to bring a voltage of between +15 volts to +30 volts for operational use, with an open input the motor is without current.

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

15

Page 22: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

motor from running in an uncontrolled manner when the operating voltage is applied to the amplifier while the enable signal is active

8d Output Tachometer Output of the processed tachometer signals. With a power rating of 1 mA, there is a signal available which is equivalent to a D.C. tachometer. The lead-in wire must be a shielded cable and as short as possible. The reference point is 4z (GND ref).

10z12z,14z

Hall W,Hall U, Hall V

Inputs for the rotor position emitter signals. For motors use the following: Lead W to terminal 10z, Lead U to terminal 12z, and Lead V to terminal 14z .

Look about the right connection

10b,12b,14b

Tacho V, Track I+,Tacho W, Track A+Tacho U, Track B+,

Inputs for a three-phase tachometer or an incremental emitter.For our motor, the following applies: For a three-phase tachometer connect Lead W to 12b, Lead U to 14b, and Lead V to 10b. For maximum speed, with 10 volt set-point, voltages from 4.5 volts to 45 volts can be treated. It should be noted that a correct tachometer signal can only be produced with correct synchronization of the rotor position emitter (see also 2.4 and 3.3).With connection of an incremental emitter one should distinguish whether the encoder has a 5 volt TTL output or an RS 422 line driver.If an incremental emitter is used without a line driver, IC 6 must be removed and solder jumper JP1.2 connected to JP1.1 and JP1.3, and as well JP2.2 connected to JP2.1 and JP2.3, and additionally JP8.1 connected to JP8.2. The device is then prepared for utilization of signals with a TTL level. Track A and Track B signals are now drawn over a 2.2kOhm pull-up resistor to 5 volts. Track I+ goes to terminal 10b, Track A+ to terminal 12b and Track B to terminal 14b. Track I+ is not utilized in the device and is only looped through.For an incremental emitter with a line driver, the not inverted signals are placed as described above. The jumpers nevertheless are open and IC 6 is in place (standard).

16

Page 23: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

10d,12d,14d

Track /I,Track A-,Track B-

Incremental emitter inputs with use of line drivers. Track /I is connected to terminal 10d, Track A- to terminal 12d, and Track B- to terminal 14d. Solder jumpers JP1, JP2, and JP8 must be open, IC 6 must be in place (standard).For incremental emitter with TTL output there are available at these terminals the looped through signals Track I, Track A+, and Track B

Look about the right connection.

16z GND 0 volt reference point for inputs and signal outputs.16b I2t Signal If the I2t current limiter is active, then the output is low

impedance tied with +15 volts, otherwise it is high impedance.

16d I external Using an external voltage from 0 to 10 volts, the impulse current at the current limiter input can be limited from 0 to 100%, adjusted by P2. A voltage of 0 volts corresponds to about 0 amps and a voltage of 10 volts to the P2 adjusted impulse current..

If no current limiting is desired, the input must be switched to +15 volts

18z GND 0 volts reference potential for +5 volts, +15 volts, and -15 volts

18b -15V -15 volt supply for external use. Power rating –10mA.18d +15V +15 volt supply for external use. Power rating

together with 8z 10mA.20z,b,d +UB Plus of the D.C. Bus. Here the plus pole can be fed by

a possible available external D.C. voltage, from by-passing the internal rectifier

These three contacts have be switched parallel ! One single contact is ready for constant current of 5A and 45°C.

22z,b,d24z,b,d

AC1AC2

Supply inputs of the device. Here the secondary terminals of the transformer are connected. For safety purposes a fuse must be built into the lead-in wire.

NOTICE! The transformer voltage may not, in any operating condition, exceed 60 volts AC, for a 60 volt device, considering all winding tolerances and mains fluctuations. (120 volts AC for 120 volt device).

These three contacts 22z,22b,22d have be switched parallel!These three contacts 24z,24b,24d have be switched parallel!One single contact is ready for constant current of 5A and 45°C.

17

Page 24: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

26z,b,d Power GND Ground of the D.C. current intermediate circuit. Here the plus pole can be fed by a possible available external D.C. voltage, from by-passing the internal rectifier.

These three contacts have be switched parallel! One single contact is ready for constant current of 5A and 45°C.

28z,b,d30z,b,d32z,b,d

Motor T, Motor R, Motor S

Output terminals of the final stage, to which the motor is connected. 32z,b,d to wiring S, 30z,b,d to wiring R, and 28z,b,d to wiring T.

These three contacts have to be switched parallel! One single contact is ready for constant current of 5A and 45°C.

18

Page 25: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

3.3 Wiring A careful wiring is absolutely necessary to guarantee a troublefree operation of the servo amplifier!The control line for the servo amplifier, the signal lines of the motor, and the motor lines are to be wired separately.See also “Measures for an installation in conformity to the EMC directive“.

3.3.1 Protective earth terminalPower GND (ST1 26z,b,d) must be connected with the protective earth terminal. The 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 1.5mm². As in the amplifier Power GND (ST1 26z,b,d), GND (ST1 18z and ST1 16z) and GND-REF (ST1 4z) are connected, no further terminal must be connected with control GND, to avoid ground loops.

3.3.2 Resolver cableThe resolver cable must be shielded. The pairs S1/S3, 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).

3.3.3 The line cable of the motorThe power supply of the motor, that means the actual motor cable, has to consist of four stranded cores (R¹,S¹,T¹,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).

19

Page 26: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

3.3.4 Control lines and signal lines between master control unit and amplifierFor 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 Iext., Int.off, Ready 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 3.3.1. between TBF and master control unit is sufficient.

3.3.5 The simulated incremental encoder signalsThe connection cable for the incremental encoder signals has to be shielded. The pairs track A+/track A-, track B+/track B- and track I+/track I- have to be twisted, the shorter the twist the better the interference immunity. Each pair is shielded separately within the total shield. The shield has to be connected on amplifier side and control unit side.

20

Page 27: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

3.4 Proper Polarity of Motor and Rotor Position EmitterConnectionThe motor is connected to the amplifier using the power contacts U,V,W, as shown in the terminal board connection diagram in 3.5. Also the signal wiring of the rotor position emitter and the three phase tachometer, or incremental emitter, will be connected as described in 3.5Since the labeling of the rotor position emitter and the three-phase tachometer may vary from one manufacturer to another, the equivalents are:

RLG-U = Hall1 = RLG-KRLG-V = Hall2 = RLG-L ...and so onRLG-W = Hall3 = RLG-M

Tacho-U = U1 = T0ATacho-V = U2 = T0B ...and so onTacho-W = U3 = T0C

If the motor is to be connected where the labeling is unknown or a normally arranged wiring is not successful because the definition of the terminals varies from the basic normally connected system, one can accomplish this in two ways:

1) If one rotates the motor externally and measures the signals on the motor contacts, then the signals must be locked with the phase position to the amplifier, as described in the appendix. Thereby with the rotation of the motor the motor wires should not be clamped to the amplifier, the rotor position emitter wires must first of all be clamped somewhere, since otherwise no signal can be measured.

2) First all the rotor position emitter wires must in some sequence be wired up between the motor and the amplifier. Also, as a first step, the tachometer wiring must be clamped somewhere. At MP3 (Nactual) the voltage must be measurable with an oscilloscope, which with external rotation of the motor follows this rotation and is continuous and smooth, without breaks. If this is not the case, the tachometer leads must be switched around, using the following table:

Equipment Input Tacho U Tacho V Tacho WX Y Z

Motor Y X ZY Z XZ Y XZ X YX Z Y

21

Page 28: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

One sees, that hereby at one time the right leads are switched around and one time the left leads are switched around. After each switching around, one checks whether the processed tachometer voltage at MP3 is correct. If this is so, the correct placement is found.One proceeds in the same way for the motor leads. At first the motor is connected in some fashion, and with a small reference presetting and reduced impulse current (30%) the amplifier is release switched on. The motor must run smoothly and follow the setpoint in both directions. If this is not the case, one should proceed as with the tachometer. When switching the motor leads, the amplifier should be disabled.For use with an incremental emitterIf an incremental emitter is used for speed feedback, the set-up for a tachometer is disregarded. With the determination of the correct motor-amplifier wiring, the incremental emitter must already be linked with the amplifier. It can happen that a connection combination will be found, in which the motor runs to the speed limit, but it is possible to change rotation direction through a change in setpoint polarity. With this combination, Track A+ and B (A- and B-) should be switched around in order to obtain a stable regulation circuit.Adjustment of rotor position emitter / three-phase tachometerThe rotor position emitter and the three-phase tachometer are usually factory adjusted. If it becomes necessary to replace the rotor position emitter or should a new motor/emitter combination be put together, one should proceed in the following manner:One rotates the motor externally and with an oscilloscope measures the tachometer voltage between tachometer U and tachometer MP (the motor, therefore should not be linked with the amplifier). One then connects the rotor position emitter (RLG) with the amplifier and with the second channel of the oscilloscope one measures Track U of the rotor position emitter (RLG). By twisting the rotor position emitter against the tachometer, one brings the phase shift to 0 (mostly the rotor position emitter (RLG) and the tachometer are an already assembled device).Next, with the second channel of the oscilloscope, the EMF between motor phases U and V are measured (GND terminal to V, test point to U). By twisting the complete tachometer/rotor position emitter combination the phase shift will be brought to 0°. Thereafter the motor and the amplifier can be linked together, as indicated on the terminal, that is:

Motor U to 32z,b,d Motor V to 30z,b,d Motor W to 28z,b,dTacho U to 14b Tacho V to 10b Tacho W to 12bRLG U to 12z RLG V to 14z RLG W to 10zTacho MP to 4z

If this does not bring good motor rotation, one should proceed as above described under "Connection".

22

Page 29: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

3.5 Connection Diagram a) With Tachometer

4B 4D

24Z,

B,D

22Z,

B,D

26Z,

B,D

32Z,

B,D

30Z,

B,D

28Z,

B,D

20Z,

B,D

12Z

14Z

10Z 6Z 16Z

18Z

10B

14B

12B 4Z

8Z2D2B8B6D6B2Z16D

+UB

U V W

RLG

UR

LGV

RLG

W+5

VG

ND

Tach

o V

Tach

o U

Tach

o W

Tach

o M

P

4 12 11 8 5 9 1 2 3 10 6 7

Tach

o

RLGM

Pow

er G

ND

(95V

AC

)

52VA

C

10AM

T

230V

AC

depe

ndin

g on

trans

form

erro

tatio

n sp

eed

refe

renc

e va

lue

E+ E-

Iext

.

Int.

Ab

oper

atio

nal

read

ines

sou

tput

Enab

le

Pos.

Sto

p

Neg

. Sto

p

+15V

roto

r pos

ition

emitt

er a

ndta

chom

eter

com

bina

tion

NC

-C

ontro

l

AD-C

onve

rter

AGN

D

GN

D- C

ontro

l

AD- C

onve

rter

2 1 4 3

TBF

Figure 3

23

Page 30: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

b) With Incremental Emitter

4B 4D

24Z,

B,D

22Z,

B,D

26Z,

B,D

32Z,

B,D

30Z,

B,D

28Z,

B,D

20Z,

B,D

12Z

14Z

10Z 6Z 16Z

18Z

10B

14B

14D

10D

8Z2D2B8B6D6B2Z16D

+UB

U V W

RLG

UR

LGV

RLG

W+5

VG

ND

10 11 128 1 42 536 7

INK.

RLGM23

0VAC

E+ E-

Enab

le

Pos.

Sto

p

Neg

. Sto

p

+15V

AGN

D

GN

D- C

ontro

l

2 1 4 3

TBF

...I

Anschlußbeispiel

D0083C

.dsf

13.03.97U

.V.

1 1

NL1PE

TBF (Inkrementalgeber)

ab Motor Seriennr. ...507

12B

12D

track

A+

track

I+

track

B+

track

A-

track

B-

track

I-

18z

gr/y

el

AD- c

onve

rter

CO

NTR

OL

UN

IT

inpu

ts fo

rin

crem

enta

l en

code

r (if

nec

essa

ry)

I EX

T.

Int.o

ff

read

you

tput

appl

ies

for m

otor

ser

ies

"S" w

ith s

eria

l no.

...5

07 a

nd h

ighe

r

norm

inal

spe

ed v

alue

+

nom

inal

spe

ed v

alue

-

AD- c

onve

rter

Figure 4

24

Page 31: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

4 Set-up

4.1 ConnectionWhen the servo amplifier is used together with one of our motors, the connection does not cause any problems. In 3.5 you will find the connection diagrams. Connect the motor power contacts R, S, T, earth and shield as described there. The correct connection sequence of rotor position emitter, tachometer/incremental emitter are also connected as described in 3.5.

When using an auxiliary drive together with the servo amplifier TBF, we offer to work out the correct connection diagram for you.

In end of documentation you will find the connection for other motors.

4.2 PresettingPrior 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 3.5 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 capability of auxiliary drives in-house.

Connect the power amplifier to the motor (see 3.5) Connect the sensors of the motor (resolver) to the servo amplifier (see 3.5) Connect the amplifier with the power supply (see 3.5) The servo amplifier is configured by the factory so our motors will reach 3000 rpm with 10V

setpoint default. 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 stopPulse current potentiometer P2 five turns from left stop

Amplification P3 Shipped adjustment by two turnsto the left

25

Page 32: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

4.3 Switching on and configuration

4.3.1 Procedure until amplifier is enabledSet enable input to logical 0!Give a speed reference of 0V!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 amplificationFor 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 currentFor 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 IAB 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, wait for a recovery time of 10 to 20sec. and carry out the configuration once again; optimum values are often achieved after several repeated adjustments.

26

Page 33: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

4.3.3.2 Continuous current

Leave P2 in the position determined as described above, adjust P5 with five turns from left stop.Here too, 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 IAB must be active.After expire of the pulse current phase, the current is automatically reduced to the continuos 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 speedThe amplifier is set ex factory to a motor speed of max. = 3000RPM 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. When increasing the motor speed, depending upon the speed emitter (tachometer or incremental emitter) one must distinguish:a) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45

volts, for maximum speed and a 10 volt nominal value for use of a motor containing a tachometer with 4 volts per 1000RPM, the maximum nominal speed of the motor can be adjusted by turning to the right the input potentiometer P1. The solder jumpers JP 6.2, JP 5.2, Jp 4.2 and JP 3.2 in each case should be soldered to "3".The connection to "1" must be open.

b) For use with an incremental emitter, a higher rotation speed can be obtained by unsoldering the corresponding solder lugs. In addition the highest possible emitter frequency can be found. That is:

Since the input frequencies of from 10kHz to 150kHz are adjustable only in 10kHz steps, the next higher frequency must always be chosen. The ratings of the solder jumpers are as follows:

JP6.2 to JP6.1 closed 10kHzJP5.2 to JP5.1 closed 20kHzJP4.2 to JP4.1 closed 40kHzJP3.2 to JP3.1 closed 80kHz

If more than one jumper is closed, use the summation of the frequencies; e.g. JP 6.2 to JP 6.1 and JP 5.2 to JP 5.1 gives: 10kHz + 20kHz = 30kHzThe calculated frequency leads to the desired speed via the formula, if the nominal speed value as a 10 volt signal lays at the nominal value input. With lesser reference values for maximum speed, the factor 10 volt/nominal value must be multiplied by Nmax .

27

Page 34: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

4.3.5 Offset adjustment of the speed regulatorThe 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.The amplifier is factory adjusted for a motor for a speed of nmax = 3000 with an input voltage of 10 volts. In order to reduce the maximum speed the input potentiometer should be turned to the left.

28

Page 35: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

5 Optimizing the Control Behaviour

5.1 Amplification of Alternating Current of Current ControllersThe adjustment of the A.C. current amplification of the current controller is obtained with resistors R25 (standard 4.7kOhm) and R26 (standard 4.7kOhm) (see appendix), whereby each resistor is a part of a voltage divider. In the testing phase one can substitute the fixed resistors with potentiometers (25Ohm), and then in production the optimal discovered values can be achieved with fixed resistors.For set up, with a low RPM, one increases the current amplification until vibration starts. The amplification is then immediately reduced until the vibration stops and then a little bit less. Since an excessive current amplification under some circumstances can impose a negative effect on the commutation characteristics, one should also have consideration for this fixation.

5.2 Amplification of Alternating Voltage of the Speed ControllerFor set up the amplifier, couple a load to the motor and preset the nominal value to 0volts. Turn potentiometer P3 to the right until vibration starts, immediately take back the amplification until the oscillation stops and then a little bit less.The amplifier set up using an incremental emitter is less critical the higher the bar numbers of the emitter.

5.3 Tachometer filteringCondensor C21 (see appendix) is responsible for the tachometer filtering. For operation of the drive with a three-phase tachometer the standard value of 22nF is sufficient, which allows for a very good dynamic controller characteristic. If an incremental emitter is used, values of from 22 nF - 220nF are necessary, depending upon the bar numbers of the encoder and dimensioning of the integral portion of the speed controller.With a relatively large value of the tachometer filter, the maximum possible amplification - and consequently the dynamics as well - is reduced. If the influence of the incremental emitter edge is tolerable or should the dynamics of a smaller motor be utilized, then the condensor may be completely removed.

5.4 Integral Part of the Speed ControllerCondensor C27 is responsible for the integral part of the speed controller (see appendix).Several factors have an influence on the choice of C27. A three-phase tachometer as speed feedback allows for a small value, which results in a high dynamic stiffness. An incremental emitter with its larger tachometer filter requires also a somewhat larger condensor. In addition, a possibly available higher order position regulator often makes a reduction of stiffness (larger C27) necessary. The standard value of C27 is 330 nF.

5.5 Direct voltage amplification of the speed controllerFor alteration of the static stiffness, resistor R71 is provided (see appendix). With ever larger resistance values, the stiffness is lessened. The standard value is 330Ohm.

29

Page 36: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

5.6 Differential Part in Tachometer FeedbackFor special applications to the controller, through adaptation of a standard but not inserted resistor (R80) and a condensor (C25), the tachometer feedback can be given a differential characteristic.

30

Page 37: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

6 TroubleshootingGreen light emitting diode (LED 1) does not light up, shaft doesn´t move, no holding torque: Fuse S1 is faulty

External fuse to power portion is faultyGreen light emitting diode (LED 1) lights up, shaft doesn´t move, no holding torque: Open condition of motor lead wiring

Output stage release (Enable) is missing

Output stage release has not taken place even with operationally ready deviceShaft doesn´t move, motor has an advantageous position, which with manual displacement of the motor starts vibrating: Motor wrongly polarized

Motor wiring interrupted

Rotor position emitter improperly connected or misalignedShaft moves, holding torque only weakly formed: Impulse current potentiometer is at far right position (P2)Shaft doesn´t move, motor has holding torque: No nominal speed value available

Motor shaft is blockedI²t Signal LED 2 (yellow) lights up: Potentiometer P5 (Irms) is improperly adjusted

Mechanical friction is too great

Oscillation from improper amplifier adjustment (P3)

Hum on the input wiringOutput stage interference LED 3 (red) lights up: operational voltage too high (8 volts at MP4)

brake energy too high (8 volts at MP4)

thermal switch activated, since the heat sink temperature > 80° (7volts at MP4)

short circuit in motor or ground circuit of a motor wire (9 volts at MP4)

current amplification too lowMotor rotates uncontrollable high: three-phase tachometer or incremental emitter wrongly polarized

rotor position emitter wrongly polarized or incorrectly adjusted

motor wrongly polarizedSpeed is too low:

31

Page 38: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

speed set point is weakened too much

operational voltage is too low

load to be driven is too great, or the current limiter has been set too low

tachometer generator has too high a voltage (>45 volts at Nmax)

incremental emitter adaptation at JP3, JP4, JP5, and JP6 has been improperlyselected

Motor has a rough running: alternating voltage amplification is too big

tachometer wiring, or also the encoder wiring is not properly shielded

pickups due to wrong input wiring

tachometer MP is missing or is not connected as single wire to 4z

32

Page 39: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

7 Options

7.1 Speed Control with 1. three-phase tachometer (DST)2. incremental emitter (IGT/K)

As already described in chapter 3.3, servo regulator TBF offers the possibility to generate the actual speed value either from a three-phase tachometer or from incremental emitter signals. Please note the model code when ordering.

7.2 Front PlateFor this device there is available in the German language a printed front plate for 19 inch cabinet mounting with corresponding holes for all indicators and operator controls.

7.2.1 Ballast SwitchingA ballast switching is necessary then if the regenerated energy from the motor and the load is greater than the energy which can be stored in the ELKO filter. This is the case if the momentum energy in the load during a braking operation must be taken up in the amplifier.The TBF 60/5R comes in most cases without ballast switching, on the basis of the relatively large condensor in the power supply.Since with the TPF 120/7R the filter condensor is only half as large and as well the voltage and also the current are larger, this device is provided on a standard basis with a ballast switch for 35 watts.If by braking the LED 3 lights up and 8 volts are measured at MP4, an additional ballast switch (at least one anyway) must be used.The following ballast switches are available:

for 60 volt devices: BS2/60 with 35 wattsfor 120 volt devices: BS2/120 with 80 watts and BS120/V with 125 watts

If the TBF 120/7R is to be used for more than three axis, it could be more advantageous to employ a large common ballast switch. The internal ballast switches with this option are not used. One connects the intermediate circuits (St1 20z,b,d, +Ub and St1 26z,b,d, Power GND) each with one another and the D.C. voltage is fed from a three-phase rectifier.The ballast threshold is 87 volts for the 60 volt devices and 172 volts for 120 volt devices.To ascertain the braking power, a rough approximation can be found using the following formula:

P = 0.0055 * J * n2/T

P = power in wattsJ = mass moment of inertia in [kgm2]n = speed in RPMT = time length in seconds (time from the start of braking operation until the start of the next braking operation)

33

Page 40: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

7.3 Bus Board

7.3.1 For 19" Rack Mounting (Ordering symbol TBF/BUS):Connector plug layout for screw terminals:1 integral off 22 tachometer MP/GND reference2 Neg.Stop 23 +Command3 Pos. Stop 24 –Command4 + 5 volts 25 + 15 volts5 Ready contact 13 26 Enable6 Ready contact 14 27 output tachometer7 track /0 28 tachometer V; track 08 track A- 29 tachometer W; track A+9 track B- 30 tachometer U; track B10 Hall W 31 I2t signal11 Hall U 32 + 15 volts12 Hall V 33 + 15 volts13 Iext. 34 – 15 volts14 GND 35 GND15 AC2 36 AC216 AC1 37 AC117 Power GND 38 Power GND18 Motor T 39 Power GND19 Motor R 40 Power GND20 Motor S 41 Power GND21 + UB 42 + UB

34

Page 41: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

7.3.2 For Wall Mounting (ordering symbol: TBF/BUS-W)

Connector plug layout for screw terminals:1 +Command 22 Motor S2 Enable 23 Motor R3 Iext 24 Motor T

4 + 15 volts 25 AC15 integral off 26 AC26 tachometer W; track A+ 27 + UB7 track A- 28 Power GND8 –Command 29 track /09 Ready Contact 14 30 track B-10 positive stop 31 track A-11 GND 32 power GND (motor ground)12 GND 33 + 5 volts13 tachometer U; track B 34 power GND14 track B- 35 GND (electronic ground)15 output tachometer 36 tachometer V; track 016 operational readiness 13 37 tachometer U; track B17 negative stop 38 tachometer W; track A+18 – 15 volts 39 tachometer MP; GND reference19 I2t signal 40 Hall W20 tachometer V; track 0 41 Hall U21 track /0 42 Hall V

35

Page 42: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

8 APPENDIX8.1 Dimensional Drawings TBF

36

Page 43: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

8.2 Insertion Plan TBF (Top Side)

37

Page 44: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

8.3 Insertion Plan (Bottom Side)

38

Page 45: Manual - Compumotor Manual.doc · Web viewa) For use with a three-phase tachometer, the tachometer voltage can be from 4.5 volts to 45 volts, for maximum speed and a 10 volt nominal

8.4 Classification of Motor SignalsPhase position of signals with correct connection:

RLG U (12z)

RLG V (14z)

RLG W (10z)

Tacho against MP(4z)Tacho U (14b)

Tacho V (10b)

Tacho W (12b)

V to U (30 nach 32)

(Ground to V Testpoint to U)

W to V (28 to 30)

U to W (32 to 28)

track A (12b)

track /A (12d)

track B (14b)

track /B (14d)

*****end of dokumentation*****

39