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AMKASYN Inverter modules AW AW 1.3 / 2.6, AW 2.5 / 5, AW 4.5 / 9 device description Stand: 2002/22 Part No.: 25321 Technical changes reserved.
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table of contents
1 SYSTEM OVERVIEW
3
2 SAFETY INSTRUCTIONS
4
3 PERFORMANCE DATA INVERTER MODULES AW
5
4 DIMENSIONS OF INVERTER MODULES AW 1.3/2.6 ,
AW 2.5 / 5,
AW 4.5 / 9
6
5 FRONT VIEW INVERTER MODULES AW
7
6 BASIC CIRCUIT DIAGRAM INVERTER MODULES AW
8
7 CONNECTION DIAGRAM INVERTER MODULE, AW
9
8 WIRING AW - AW
10
9 FUNCTIONAL DESCRIPTION OF INVERTER MODULE AW
11
10 INTERFACES, SIGNAL DESCRIPTION INVERTER MODULE AW
12
10.1 DC link voltage feed (DC BUS X52): 10.2 Motor encoder connection 10.2.1
12
Motor encoder connection X156 10.3 Output stage enable X58 (plug-in terminal block) 10.4 Motor PTC thermistor X54 (plug-in terminal block): 10.5
12
Analog inputs
12 13 14 15
11 REPLACING THE AW MODULE
16
12 ENGINE REPLACEMENT INSTRUCTIONS
18
13 GEBERGRUNDABGLEICH
19
14 IMPRINT
20
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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1 System overview
power bus
AZB
Signalbus THE central module
1234 Option
pulse input RF
3x400V ... 480V
FL NK
AA1 AA2 AA3 AA4 QRF SBT DA1
AW
max. 8 AW-Module
inverter
inverter module
module
RS232/ RS422/ RS485
Square
binary inputs
AW
AZ-R01 / AZ-R02
analog outputs +/-10V
EF
Power
excited
stage release
EF power amplifiers QEF freigabe QES
QES
A1 Analogeing. A2 12 Bit,+/-10V
A1 Analogeing. A2 12 Bit,+/- 10V
binary
Option AW-IWx Impulsweiterleitg.
outputs
Motorgeber
Option AW-IWx Impulsweiterleitg. Motorgeber
UVW PE
AZ-EAx
(AZ-K02)
pulse generator inputs SERCOS Interface
AZ-PSx
programmable control PS
AZ-MCx
CNC Multi Control
AZ-RCx
RISK - Processor
AZ-IGx option cards
RF General controller enable FL Clear error NK Ref. point switch
UVW PE
Binary I/O
PTC
PTC
M 3 AC - Motor DV / DS
QRF acknowledgment controller release SBT collective readiness message
DA1 data output
M 3 AC - Motor DV / DS
EF power stage release QEF EF released QES EF blocked
The AMKASYN device series is a modular drive system for feeding the AMK AC motors. The digitally working inverters regulate the drives in 4-quadrant operation precisely and with high dynamics. The power is fed directly from the 400 V three-phase network. The inverter modules are supplied from a common DC link. State-of-the-art power semiconductors in connection with high integration guarantee high availability.
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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2 safety instructions Please also read and observe the "Safety instructions for AMKASYN digital converters".
Explanation of the symbols used:
In the event of imminent danger! danger
Possible consequences: Death or severe injuries!
In the event of a potentially dangerous situation! Possible consequences: Serious injuries or death! warning
Improper, non-intended use of the drive system can endanger the life and limb of the user! This can also result in damage to the operator's machine/system!
warning
In order to minimize the risk of accidents/damage, installation, commissioning, maintenance and repairs must be carried out with great care by trained, experienced specialists.
System parameters may only be specified or changed by the machine manufacturer! Entering incorrect parameters affects the behavior of the drive system and provokes an increased risk of accidents and damage! Before all work on the AMKASYN drive system: Disconnect the mains feed with the MAIN SWITCH OFF. There is a risk of death when working under voltage! After switching off the mains, the capacitors for the danger
intermediate circuit still contain a charge. A dangerous DC voltage is present at terminals UZP and UZN. Before working on the modules, a discharge time of at least 3 minutes must be allowed for.
Plug-in cards and cable connectors may only be plugged in or pulled out when the devices are voltage-free.
Clamps may only be loosened or tightened in a voltage-free state.
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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3 Performance data of inverter modules AW AW 1.3 / 2.6,
AW 2.5 / 5,
AW 4,5 / 9:
Type
AW 1,3 / 2,6 AW 2,5 / 5 AW 4,5 / 9 DC-BUS: 540V...650V DC
Nominal input voltage range
up to 3 x 350V
output voltage output frequency
for sinusoidal output currents 0Hz to 599Hz
output power rating
1.3 kVA
output peak power
2.6 kVA
2.5 kVA 5 kVA
4.5 kVA 9 kVA
2,15 A 4,3 A / 25 s
4,15 A 8,3 A / 25 s
7,5 A 15 A / 25 s
rated output current peak output current/time
> 0,96
efficiency cooling fan voltage fan performance protective functions tax procedure Switching frequency
ÿ
ÿ
ÿ
forced air cooling 230V 2.5 watts
5 W.
Protection against overcurrent PWM 8 kHz
recommended cable crosssections [mm2 ] : AW motor X51 (shielded cable)
4 x 1,5
AW PTC thermistor X54 (shielded cable) PE connection
2 x 0,5
PDK_025321_AZAW_Hardware_AW1,3_de.doc
10
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AW 2.5 / 5, AW 4.5 / 9
4 Dimensions of inverter modules AW 1.3/2.6,
AND
242 =
=
X
297
55
View Y 15
view X
7
3 x45°
7,5 17,5
10
7
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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5 Front view of inverter modules AW
X159
analog inputs
AWN for option cards
AWAG1 IWx /
X57
BUS cable
X154
RT1
X156
RT2 SSS X158
geber motor
excited
QES WQE EF WEF
AMKASYN AW
FAN/
Fan
X53
X52
FAN
DC-BUS
UZP UZP ALREADY N
DC-BUS
X51
U
ALREADY N
MOTOR
V IN
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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6 Basic circuit diagram of inverter modules AW
X57
X159
5V = power adapter
Signal Bus
X158 EF
Control map AW-VE01
analog inputs
Power
X156
stage release EF
Motorgeber EF-Logic
excited
QES
X154 PTC Motors RT1/RT2
ÿ
temperature capture
TO
Inverter control
capture
X51
current capture U,V,W
ground fault
capture
X52
Motor U, V, W
DC-BUS UZP / UZN Red
UZP UZP
short circuit blue
capture fan power supply
X53 Fan Fan
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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7 Inverter module connection diagram, AW
AW
AWN
X57 AW: X57 AZ: X27
rotary coding switch
AW number
Signalbus
Signalbus analog inputs +/- 10V
CNC 1
2
I-/ (A-) / S/T encoder
X156
X159 4
A1I
3
A1N
2
S/T encoder: -RS485 G01 +RS485 G0N
1
2
GND
G1I
3
1
A2I
G1N
4
9
A2N
G2I
5
8
GND
G2N
6
7
GND
05P
7
6
GND
GND
8
5 + 5V
9
-WITHOUT
10
+WITHOUT
-SOMETHING
11
+ COS
12
-Uref
13
+Uref
14
09P
15
for Sort out
S/T encoder
SPS X158
Acknowledgment output stage: released
Motor
RT1
excited
blocked
QES
RT2
+24V ext.
WQE
SSS
power stage release
PTC thermistor
X154
EF
0V ext.
WEF
X53 AW: X53 AZ: X23
X53
Fan
X52 AW: X52 AZ: X22
UZP
UZP
DC-Bus
DC-Bus ALREADY N
TS
TS
ALREADY N
ÿ
X51 U
U
V
V
IN
IN
M 3
ON
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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8 Wiring AW - AW
Cable strain relief and cable shield connection to PE using cable ties at the notches on the top of the housing! PTC Motor PTC Motor
power amplifiers
Motorgeber
Power stage release
Motorgeber
X159
X159
AWN
AWN
X57
X57
The bus termination board plugged into X27 (AZ) on delivery must be removed during installation and plugged into X57 of the AW module on the extreme right.
bus termination board
Bus cable
Bus cable
X154
X154
RT1
X156
RT2 SSS
RT1
X156
RT2 SSS
X158
X158
excited
excited
QES
QES
WQE
WQE
EF
EF
WEF
WEF
AMKASYN AW
AMKASYN AW
FAN/
FAN/
X53
FAN X53
DC-BUS
X52
X52
FAN
DC-BUS
Red
UZP Red ALREADY N
blue
UZP
UZN blue
X51 X51
U
U
MOTOR
V IN
MOTOR
V IN
PE-Backs
Motor
PDK_025321_AZAW_Hardware_AW1,3_de.doc
Motor
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9 Functional Description Inverter Module AW The inverter module contains the following function groups: • Microcontroller for:
field orientation Motor encoder evaluation and monitoring speed control attitude control Control of the power semiconductors current conduction
monitoring • Inverter equipped with IGBT power semiconductors
The microcomputer cyclically calculates the instantaneous values of the target currents for the phases from the specified target value, the actual values of the phase currents and the rotor position. Synchronized with the 8 kHz basic clock, the power semiconductors (IGBT) are controlled with pulse width modulation so that the motor windings carry sinusoidal currents in a stationary manner. The entire control is digital. Logic and power section are galvanically isolated via optocouplers. The converter currents are monitored I2 t. The inverter output is protected against overcurrent. The speed and position control circuits are implemented via the microcontroller. The system derives the actual values for speed and position from the motor encoder signals. The motor encoder types "I" and "T" can be connected directly. An electronic adapter is required for encoder type "A" (AW-AG1). The encoder signals are monitored during operation. If the encoder fails, the "System ready SBT" message is reset, the clock pulses are blocked and the drive coasts down. 2 analog setpoint inputs ± 10V are integrated in the AW module. The effect of the analogue reference value is defined via parameters: analogue input A1 is used as a reference value input (speed, torque), via A2 it is possible to shift the torque limit by changing the analogue voltage.
Numerical or pulse setpoints must be specified via the AZ module. From there they are forwarded to the individual drives via the internal bus system. Each AW inverter module in an AMKASYN drive system is given its own number. This must be set before commissioning on the "AWN" rotary coding switch using a small screwdriver (AWN 1 ... 8, in a system with 8 drives). Multiple assignment of an AWN number is not permitted.
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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10 interfaces, signal description inverter module AW
10.1 DC link voltage feed (DC BUS X52): The individual wires UZP (red) and UZN (blue) are each connected to the left-aligned module (AZ or AW) at terminals UZP and UZN. The intermediate circuit voltage for the next AW module is provided at terminals UZP and UZN (X52).
10.2 Engine operator connection
10.2.1 Motorgeberanschluss X156 D-SUB, 15-pin, sockets, for I/S/T/A sensors, resolvers pin assignment:
AW
X156 I / A S / T Resolver G0I
-RS485
1
G0N
+RS485
2
G1I
G1I
3
G1N
G1N
4
G2I
G2I
5
G2N
G2N
6
05P
78
GND
-
-
-
-
-
-
-
-
5V : max. 250mA ( I / A ) GND
-
Sort out +WITHOUT
9
-
-
-WITHOUT
10
-
-
+WITHOUT
1VSS ... 1,8V SS
9
+
-WITHOUT
-
10
11
-
-
+ COS
-SOMETHING
1V SS ... 1,8V 12
-
-
11
SS
+ COS
-UREF
-
13
-
14
-
-
15
-
09P
+
-SOMETHING
12
-UREF
+UREF
6VSS +/-8% max.75mA
+UREF
13
14 -
9V : max. 400mA (S- / TGeber) (S / T type encoder)
The maximum input frequency from the motor encoder (I/S/T/A encoder) is 100 kHz. To connect a motor with an A encoder, the AW option card AW-AG1 (A encoder adaptation) or AW-IWA (pulse forwarding with A encoder adaptation) must be inserted in the slot at the top right of the AW module.
The encoder connection must be made with a shielded cable. The cable shield must be earthed on both sides.
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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10.3 Output stage enable X58 (plug-in terminal block) Clamp EF:
Binary input "Output stage enable" Electrically isolated via optocoupler Input voltage rating: +24Vext Input rated current: 8mA In normal operation, input "EF" must be set so that the clock pulses for the power semiconductors are released. Interruption of "EF" when the RF controller enable is switched on leads to a system fault. The drive coasts down.
Terminal WEF: Reference potential 0Vext for the input voltage Terminal QEF: Relay contact output (closer) "Acknowledgment power stage released" (24V=, min. 20 my; max. 200mA) QEF reports that the "output stage enable" is set and the clock pulses for the power transistors are enabled. Terminal QES: Relay contact output (opener) "Acknowledgment output stage disabled" (24V=, min. 20 mA; max. 200 mA) QES reports that the enable relay has dropped out and the clock pulses are blocked. The drive is not powered. Clamp WQE: + 24Vext Insertion of the relay contact (exchanger) QEF / QES. By interrupting the EF input and fail-safe evaluation of the acknowledgment signals QEF and QES in the higher-level controller, the motor control can be switched off safely on the power side. It must be monitored for the logic states shown below:
Logic states for output stage enable EF with acknowledgments QEF/QES Control input EF Output stage enable inactive active
PDK_025321_AZAW_Hardware_AW1,3_de.doc
Acknowledgment output stage
released QEF blocked QES 0
0
1
1
1
0
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Pulse diagram for switching the output stage enable EF:
RFx
QRFx
SBM EFx
Error !
QEFx QESx
"Release Access"
10.4 Motor converter X54 (plug clamp):
Terminals RT1, RT2: Connections for the motor thermistor The resistance of the motor thermistor is approx. 170 ÿ at approx. 20°C. Heat resistance: RPTC 3990 ÿ at 140 ° C + 5 ° K Terminals 12P, 12N: ± 12V for service purposes only Clamp SSS:
Not used
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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10.5 Analog inputs Analog inputs A1, A2, X159 (D-SUB, 9-pin, sockets) Two analog inputs are provided for setpoint/limit value specification via analog voltage ± 10V. They are designed as differential inputs. The resolution is 12 bits for ±10V. The query by the microcomputer is carried out cyclically every 250 µs. Depending on the selected operating mode, a torque or speed setpoint can be specified via analog input A1. The limit torque can be influenced via analog input A2 by varying the analog voltage.
The maximum permissible voltage at A1, A2 is ± 12V!
X159 Pin 4: A1I Pin 3: A1N
Analog input A1 (inverting) Analog input A1 (non-inverting) (Differenzeingang )
Pin 1: A2I
Analog input A2 (inverting) Analog input A2 (non-inverting) (Differenzeingang )
Battery 9: A2N
Pin 2: GND Pin 5: GND Pin 8: GND
Internal reference potential GND
Connection of the analogue voltage via shielded cable (twisted pair). The cable shield must be grounded on the AW side via the metalized D-SUB connector housing (X159).
5k
A1 / A2 0V
A1I
20k
-
20k
+
A2I
+- 10V
A1N A2N
ON GND
PDK_025321_AZAW_Hardware_AW1,3_de.doc
GND
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11 Replacing the AW module
Important instructions: 1. MAIN SWITCH OFF: WAIT FOR DISCHARGE TIME > 3 min! 2. Remove front cover. 3. Note the setting of the rotary coding switch "AWN" (AW number). 4. Loosen the strain relief and shield connection of all connection cables. 5. Pull off the D-Sub connector X156 (and X159 if used) after loosening the retaining screws, unplug the plug-in terminal blocks X54, X58. 6. Ribbon cable connector (bus cable) X27/X57 on the previous module and X57 on the AW module release and pull off by pressing the ejector bracket. 7. If AW-IWx is installed: Loosen the retaining screws on the D-Sub connector X60 and pull out the connector. 8. Nur bei AW 2,5/5 , AW 4,5/9: Unplug fan connector X53 from the subsequent AW module and fan connector X23/X53 from the previous module. To do this, loosen the catch on the narrow side with finger pressure. 9. Disconnect the intermediate circuit voltage connections UZP (red) and UZN (blue) at X52 from subsequent AW module and X22/X52 on the previous module. 10. Disconnect motor connections U, V, W (X51). Pay attention to the clear designation of the connecting wires. 11. Disconnect the PE connections and shield connection of the motor cable on the AW module.
12. Loosen the module fastening screws on the mounting panel. 13. Lift the module slightly and pull it out to the front.
14. Insert a new AW module with the same output, lower and tighten the fastening screws attract. 15. Firmly clamp the PE connections and shield connection of the motor cable to the AW module. 16. Firmly clamp motor connections U, V, W. Be sure to observe the phase sequence. Incorrect phase sequence reverses the direction of motor rotation! The sense of the rule is no longer correct! warning
Switching on with the wrong phase sequence leads to uncontrolled rotation of the motor shaft and thus possible damage to the system.
17. DC link voltage connections UZP (red) and UZN (blue) at X52 and at X22/X52 on firmly clamp the previous module. 18. Plug in fan connector X53 (from the following module) and X23/X53 on the preceding module to for snapping. 19. If AW-IWx is installed: Plug the X60 D-Sub connector into the socket and screw it with the two screws secure against unintentional loosening. 20. Plug the bus cable into the previous module (X27/X57) and into the new AW module (X57). To do this, lift the ejector bracket on the socket slightly and press in the ribbon cable plug without using force until the lock closes 21. Plug the plug-in terminal blocks X54, X58 into the corresponding sockets. Plug in D-SUB connector X156 (and X159 if used) and secure with both screws. 22. Shield connection and strain relief for all cables using cable ties.
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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23. Use a small screwdriver to set the "AWN" rotary coding switch to the value (AW no.) which was selected on the removed module (as noted under item 3). 24. If the AW module on the far right has been replaced, the bus termination board must be inserted in slot X57 (bus). This is taken from the removed module. 25. Hang in the front cover. 26. Switching the system on again. Enable RF.
27. In the case of motors with an A encoder, the basic encoder adjustment must now be re-calibrated via the AZB control pan
carried out (see Chapter 13).
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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12 Instructions for replacing the motor All mechanical work must be carried out in consultation with the machine manufacturer and according to his instructions!
1. MAIN SWITCH OFF, WAIT FOR DISCHARGE TIME > 3 MINUTES! 2. Remove the motor terminal box cover by loosening the 4 screws. 3. Make sure that all connection wires in the terminal box are clearly labeled! Disconnect motor connections U, V, W, PE, cable screen and PTC thermistor connection. If available: release connections for holding brake, motor fan.
4. Loosen cable glands of all cables. All cables with screw connections from the terminal box draw.
5. Loosen the knurled nut on the round connector of the motor encoder, unplug the encoder connector. 6. Remove the motor according to the machine manufacturer's instructions and install a new motor. 7. Insert cable with screw connections into motor terminal box, tighten cable screw connections. 8. All connections including PE and cable shield correctly assigned again. Caution: Wrong phase sequence at U, V, W reverses the direction of motor rotation, the sense of control is incorrect! Switching on with the wrong phase sequence leads to uncontrolled rotation of the motor shaft and warning
thus possible damage to the system.
9. Close the cover of the terminal box tightly again by tightening the 4 screws. 10. Reconnecting the mains. 11. Only for motors with motor encoder type "A" (motor designation DV [DH] -xx-yy-4A ..., Option card AW-AG1 / AW-IWA must be installed in the AW: Before starting the system, the basic encoder calibration must be carried out (see Chapter 13)!
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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13 Gebergrundabgleich (Only for motors with encoder type "A")
Shift
GEBERABGL.
SERVICE
F-DELETE
SYSTEM
Password:
F3 F1
ÿÿÿÿÿÿ
(GEBERABGL.) Enter password ("1 2 3 4 5").
#0
AW no. input
CR
Desired AW no. input. rotate drive CR
MANUALLY
JOG
Enter speed:
F4 F2
Rpm
Enter a low speed, eg "255" [rpm]. CANCELLATION
CR
ROTATE +
ROTATE -
F3
As long as one of the function keys F1 (positive direction of rotation) or (negative direction of rotation) is pressed, the motor rotates in speed control. As far as possible, the motor should rotate freely for safe operation.
CAUTION when operating with a coupled load! The operator must pay attention to the mechanical characteristics of the machine in order to avoid possible collisions. Rotate the motor in alternating directions until the message appears: Encoder data are now written
After the data has been transferred to the EEPROM, the following message is displayed:
encoder adjust successful FURTHER Start of normal operation.
PDK_025321_AZAW_Hardware_AW1,3_de.doc
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14 Imprint
title
Inverter modules AW 1.3/2.6 ,
purpose
Device description of the series AW 1.3/2.6...
part number
25321
History
AW 2.5 / 5, AW 4.5 / 9
issue date 2000/44 2002/22
protection notice
^ AMK GmbH & Co. KG Passing on or duplicating these documents, utilization and disclosure of their content is not permitted unless expressly permitted. Violations oblige to compensation. All rights reserved in the event of a patent being granted or a utility model being registered.
reservation
The content of the documentation and the availability of the products are subject to change.
Service
Tel.-Nr. +49 / (0) 7021 / 5005-191, Fax -193 Response times: Mon-Fri 7.30 a.m. - 4.30 p.m., on weekends and public holidays you will receive the telephone number of the on-call service via the answering machine. You contribute to the quick and reliable elimination of the fault if you use our Service inform about: • the type plate information of the devices • the software version • the device constellation and the application • the type of fault, suspected cause of failure • the diagnostic messages (error numbers)
editor
AMK Arnold Müller drive and control technology GmbH & Co. KG Gaußstraße 37 – 39, 73230 Kirchheim/Teck Phone: 07021/5005-0, Fax: 07021/5005-176 Email: [email protected]
Further information www.amk-antriebe.de
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AMK Arnold Müller GmbH & Co. KG drive and control technology Gaußstrasse 37 – 39 D-73230 Kirchheim/Teck Telephone: +49 (0) 70 21 / 50 05-0 Fax: +49 (0) 70 21 / 50 05-199 [email protected] www.amk-antriebe.de
