Emerson LX Series, LX-700, LX-400, DX-316, DX-340 User Manual
...
RGB ELEKTRONIKA AGACIAK CIACIEK
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OTHER SYMBOLS:
LX-400
LX400, LX 400, LX-400
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User’s Guide
for the
LX
Brushless Servo Drives
Amplifier Models
LX-400, LX-700, LX-1100
Motor Models
DX-208, DX-316, DX-340
DX-455, DX-490, DX-4120
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User’s Guide
for the
LX Series
Brushless Analog Servo Drives
LX400, LX-700, LX-1100
Information furnished by EMERSON EMC is believed to be
accurate and reliable. However, no responsibility is assumed by
EMERSON EMC for its use. EMERSON EMC reserves the right
to change the design or operation of the equipment described
herein and any associated motion products without notice.
EMERSON EMC also assumes no responsibility for any errors
that may appear in this document. Information in document is
subject to change without notice.
Part Number 400272-00 Rev: A.2
Date: 01/13/95j
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Section 1 – Page 1
1 INTRODUCTION 1
2 INSTALLATION - MECHANICAL 2
3 INSTALLATION – ELECTRICAL 3
4 CONFIGURATION 4
5 START UP / CALIBRATIONS 5
6 SPECIAL APPLICATIONS 6
7 DIAGNOSTICS 7
8 APPENDICES 8
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Section 1 – Page 2
1.1 Features of the LX Drives
1
Introduction
Ø Uses 96-264 VAC 50/60 Hz, single or
Ø Velocity or torque mode of control
3Ø, direct on-line power source
Ø 1 KW to 3 KW output power range Ø Limit switch inputs
Ø 10 lb.-in. to 100 lb.-in. (1.13 NM to 11.3
Ø Diagnostic LEDs
NM) matching motor series
Ø Resolver feedback tolerates shock and
high temperature
Ø Encoder simulation output for external
Ø Integral power supply minimizes
external wiring
Ø Backup logic supply input
position controller interface
Ø Personality module to maintain axis
Ø Integral brake available on motors
adjustments
Ø Sinusoidal commutation for smooth
motion
Ø Waterproof and connectorized
motors available
Ø Bus power sharing capability
Description
The LX Series of brushless servo drives is the latest in analog amplifier design from
Emerson EMC. The wide input voltage range and compact dimensions make it one of
the most versatile amplifiers available.
There are three amplifiers in the LX Series; the LX-400 (4.0 amps of continuous output
current), the LX-700 (7.0 amps of continuous output current) and the LX-1100 (10.9
amps of continuous output current). All three amplifiers have the same physical
dimensions.
Each LX Amplifier is matched with the proven reliable DX Brushless Servo motors.
When correctly matched, the LX Amplifier and DX Motor combinations offer continuous
torque output ratings of from 10 to 100 lb.-in.
The amplifiers incorporate pulse width modulated (PWM) design to provide efficient
power conversion. Sine wave commutation of the motor results in smooth rotation
across the full range of speed.
All LX Amplifiers are designed with their own power supply, heat sink, shunt resistor and
fan (when needed). This allows for simple installation and expansion.
Section 1 – Page 3
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LX Amplifiers can be easily adjusted to operate with a variety of motors and controllers.
A personality module attached to the amplifier retains all adjustments. If an amplifier
needs to be replaced, the personality module can be removed and attached to a new
amplifier, thus alleviating the re-adjustment process.
Troubleshooting is aided through the use of status LEDs located on the front panel of
the amplifiers. The LEDs continually keep the operator informed of the status of the
amplifier at all times. In addition to the LED indications, fault conditions such as resolver
fault and motor over temperature are announced as a contact signal output which can
be monitored by a host controller.
Input power voltage can range from 96 to 264 VAC 50/60 Hz without jumper or switch
selection. A 230 VAC 50/60 Hz, 3Ø supply will deliver the maximum output power.
Optimum performance from a servo system is accomplished by carefully matching the
motor and amplifier. Emerson EMC’s DX Series of servo motors has been engineered
to compliment the LX servo amplifier, providing unparalleled reliability and performance.
The DX Motors are available in a number of configurations including connectorized or
waterproof (IP65) versions. Most motors are also available with a mechanical holding
brake.
NEMA motor face dimensions are available in addition to the metric dimensions on four
motor models to greatly simplify mounting to many standard reducers.
DXE-208 NEMA 23 compatible
DXE-316 NEMA 34 compatible
DXE-455 NEMA 56C
DXE-490 NEMA 143TC
DXE-4120 NEMA 143TC
The signal and power connections are conveniently located on the drive front panel to
simplify wiring in multi-axis applications.
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Section 1 – Page 4
Figure 1.1 LX Drive, overall layout
Section 1 – Page 5
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1.2 System Components
A complete LX package is made up of an LX amplifier, a DX motor and the appropriate
motor and resolver cables connected as shown in Figure 1.2. Cables are available from
Emerson for both the connectorized and non-connectorized motors. EMC designed
cables are recommended because they have been specially designed for the LX
amplifiers and will minimize installation problems. Table 1-A shows the available cables
and their application. For more information see Chapter 2.
Table 1-A – Motor Cabling
Motor Type Motor Model Motor Cable Resolver Cable
Waterproof Motors DXM/E-3xxW, 4xxW HPS-XXX (shielded)
250224-09
250036-00(non-
shielded)
Connectorized
DXM/E-3xxC, -455C ECM-XXX LCF-XXX
Motors
DXM/E-490C, -4120 ECL-XXX LCF-XXX
DXM/E-208 LCS-XXX
All cabling is PVC, rated for 105° C.
(XXX) is length in feet, consult an Emerson EMC application engineer for cabling
requirements over 100 ft.
Figure 1.2 Typical LX component configuration
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Section 1 – Page 6
1.2.1 User Adjustments and Options
The amplifiers each have a personality module that is used to set up the drive for the
application as required. The drive features which are customized by the user on the
personality board include:
Continuous Current limit value
Maximum Speed Range (3000 / 6000 rpm)
Motor pole selection
Calibration adjustments
Limit Switch enable and polarity
Encoder output resolution
The Limit switch inputs and Emulates encoder outputs are standard on the LX, however
these features can be deleted when purchasing quantities of drives to further reduce
costs. See your Emerson Sales Representative for further details.
1.3 Basic Function and Operation
The amplifier is designed to operate in either a velocity command or current (torque)
mode with an analog ±10 volt command. The velocity command input is a true
differential input while the current command input is a single ended input that doubles
as the current demand output. This signal can be used as a master output in torque
helper applications as well as a test point for detecting the actual motor current required
in an application. For details about the current command mode see the “Special
Applications” section 6.
1.3.1 Feedback Signals
Speed and position feedback signals are accurately derived from the position
information coming from the resolver mounted on the motor shaft.
The derived tachometer signal is used by the amplifiers speed control circuitry and is
available as an analog signal output on the connection strip. This tachometer output
provides analog voltage proportional to the shaft speed with a range of ± 10V equal to ±
3000 / 6000 rpm.
Emulated encoder outputs with zero markers are provided on the standard LX amplifier
for use with position controllers.
1.3.2 Control Loops
The LX drive uses two high performance control loops (current and velocity) to control
the speed and torque of the motor. The “current loop” controls the current flowing into
the motor by comparing the current flowing in the motor to the current command from
the reference signal and correcting it to maintain the commanded current. The current
command can come from either an external controller or directly from the LX amplifiers
speed loop. The velocity loop controls the motor velocity by comparing the actual
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Section 1 – Page 7
velocity of the motor to the velocity commanded by the drive and adjusting the current
command as needed to maintain the commanded velocity.
Velocity Loop
In the velocity loop circuit the error signal is processed by a P.I.D. (Proportional, Integral
and Derivative). The output of the P.I.D. filter is the current reference signal also
available for test on terminal 2 of the front connector. The voltage on this point is ± 10
VDC. At ± 10V the drive generates the maximum current in the designated direction.
All the adjustments shown on the block diagram in Figure 1-3. Zero offset, proportional
gain, response, accel/decel ramp gradient and full scale speed are located on the
personality board and the potentiometers are accessible from the front panel.
Current Loop and Limiting
The current error signal is generated comparing the output of the current limiting stage
with the actual current in the motor. The current error signal is computed to generate
the PWM signals driving the IGBT final stage. In the block diagram in Figure 1-3, the
IGBT devices are shown as switches.
Current Limiting
In the current loop circuit there is a current limiting circuit referred to as Ixt, which
continuously monitors the current commanded and delivered into the motor.
The Ixt limiting circuit is not operational in the current command
mode. See Chapter 6 for details on implementing current command
mode.
This limiting circuit estimates the heating of the motor by continuously monitoring the
amount of current in the motor and the length of time this current has been flowing. The
limiting value is determined by the setting of dip switches on the personality board. If the
current requested exceeds the value set by the dip switches, the Ixt control circuit will
determine how long the commanded peak current will be allowed before limiting the
delivered current to the dip switch value. This current limiting is not a fault condition but
rather an Ixt current fold back limiting and is so indicated by the High Irms LED and
High Irms output. When the drive is in the Ixt limit status, the RED led (HIGH Irms) lights
and terminal 12 becomes open circuit. Once current fold back is engaged the drive will
continue in the limited current condition until the current commanded is reduced below
the dip switch level for length of time sufficient to reset the Ixt limiting circuitry. The
amount of time allowed above the continuous level before Ixt limiting varies is
dependent on the percent of RMS current the drive has been running. Peak current
availability is also dependent on the level of current demand below and the amount of
time below the dip switch level. In addition to the current foldback limiting, the LX
amplifiers also have short circuit protection. This prevents destruction of the amplifiers
due to short circuits either from a short that is applied while in operation or from a short
circuit in effect at power ON.
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Section 1 – Page 8
1.4 Diagnostics and Fault Handling
A number of diagnostic and fault detection circuits are incorporated in the LX amplifier
to protect the drive. Some faults like over voltage, under voltage and amplifier or motor
over temperature reset when the fault is cleared. Other faults such as short- circuit at
the motor output terminals and/or resolver fault need to be reset by cycling power. Ixt
trip is not a fault condition, it simply folds back the current command to the DIP switch
setting until the demand is reduced.
The Ixt trip is not operational in the current command mode. See Section 6
(Special Applications) for details.
Table 1-B
Condition Display Drive OK
Motor over
temperature
Amp overtemp >95°
C
LED on
LED on
Drive OK - contact
Over voltage
Drive OK - LED off
Under voltage
open
Reset Action
Required
Auto reset on temp
drop
Auto reset on temp
drop
Auto reset on return
to normal voltage
Auto reset on return
to normal voltage
Output short ckt Cycle power
Resolver fault LED on
High Irms LED on
Drive OK - on
contact closed
Cycle power
Not a fault.
Indicates current
limiting action.
Drive OK – contact
Backup Logic
Supply
active mode
opens for about 2
seconds then
closes. LED follows
Re-application of
AC Line power
contact action.
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Section 1 – Page 9
1.5 Power Section
On the main board, the high current and the signal sections are optically isolated.
Looking at the block diagram (Figure 1-3) the main functions of the drive can be
identified. The power stage DC bus is supplied by the AC line input to the drive and the
internal diode bridge rectifier followed by a set of filtering capacitors. The internal SMPS
(Switching Mode Power Supply) operates off the power DC bus to generate all the
voltages necessary to supply the low power and control electronics.
To dissipate the energy generated by the motor during high gradient deceleration rates
and continuous regeneration against a load, the braking circuit shunts the excess
current generated by the motor through the internal shunt (braking) resistor. The yellow
LED lights when the shunt circuit is active. If the power capacity of the internal braking
resistor is insufficient for heavy cycles, an external braking resistor with greater power
should be added and the internal resistor disconnected. See the “Special Applications”
in Chapter 6 for more information.
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Section 1 – Page 10
Figure 1-3 Block Diagram
Section 1 – Page 11
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2
INSTALLATION -- MECHANICAL
2.1 Installation
The following installation requirements, methods and procedures are provided to assure
reliable and trouble free installation of your Emerson MC LX Drive.
The methods and procedures are outlined on the following pages and include site
requirements, safety considerations, power and fusing requirements, wire and
transformer sizing, noise suppression, and I/O wiring.
2.2 Safety Considerations
The installer/user is responsible for incorporating appropriate safety features into the
equipment to prevent injury to personnel or damage to equipment.
The installer/user has the responsibility to comply with the safety requirements of the
system. This includes installing the system with an appropriate master interlock switch
for emergency shut down and using the proper wire and transformer sizes (if necessary)
to fit the system. This section will provide you with the information to complete a trouble
free installation.
WARNING!
The user is responsible for providing emergency interlock switches that will
remove AC power from the system any time the equipment is not running, or
when the emergency stop is activated. This is to eliminate the possibility of
electrocution or unwanted movement of the motor. The safety ground
connections should only be disconnected for servicing and only after all AC
power has been removed.
2.3 Selecting an Enclosure
The LX drive is designed for the industrial environment. However, no sophisticated
electronic system can tolerate certain atmospheric contaminants such as moisture, oils,
conductive dust, chemical contaminates and metallic particles. Therefore, if the drive is
going to be subjected to this type of environment it must be mounted vertically in a
NEMA type 12 enclosure.
Proper ventilation and filtering must also be provided. If the equipment environment is
above 50° C, cooling is mandatory. The amount of cooling depends on the size of the
enclosure, the thermal transfer of the enclosure to the ambient air and the amount of
power being dissipated inside the enclosure. Your enclosure supplier can assist you in
properly selecting an enclosure for your application.
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Section 2 – Page 1
2.4 Amplifier Mounting
The LX drives must be mounted in a vertical orientation to insure the best air flow
between the cooling fins of the heatsink. Mounting above other drives or any heat
producing equipment may result in overheating.
The mounting brackets are attached to the LX drive heatsink by self tapping screws and
thus are well grounded to the amplifier chassis. There are two ways to mount the drive
depending on the placement of the mounting brackets. The physical dimensions of all
the LX amplifiers are identical. See Figure 2-1 for mounting information.
Figure 2.1 Amplifier Mounting Information
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Section 2 – Page 2
2.5 Motor Installation
2.5.1 Motor Mounting
To provide good mechanical alignment, the mounting surface of the motor face plate is
held perpendicular to the motor shaft to within 0.005 inches. Projecting above the plane
of the mounting surface is a close tolerance circular pilot boss. Matching the pilot boss
with a pilot hole in the mounting structure facilitates interchanging the motor and
minimizes the need for mechanical adjustments. The mounting surface is fitted with
four holes equally spaced on a bolt circle pattern.
The mounting panel must be stiff enough so it does not deflect significantly when radial
loads are applied to the motor shaft. The mounting panel should also have good
thermal conductivity especially if peak performance is demanded of the motor.
WARNING!
Mechanical shock to the motor case or shaft (e.g., from striking or dropping)
must be avoided to prevent damage to the motor. Possible results from
striking or dropping include: Misalignment of the resolver; damage to
armature bearings; cracking of the motor case; unbonding or demagnetization
of the permanent magnets. Any of these would render the motor
unserviceable.
2.5.2 Conduit Installation
The following procedure must be followed to assure a waterproof motor installation will
be water-tight.
Ø Remove the rear cover from the motor and install the supplied “O” ring into the
groove of the cover.
Ø Wrap the threads of the NPT conduit fitting with at least 2 layers of Teflon
Ø Install the fitting into the motor threads and tighten at least 1 turn after hand
1
tape.
tightening. Do not over torque.
Ø Make the motor wire connections as necessary. DO NOT TIN THE WIRES. Tinning
will compromise the long term integrity of the connection.
Ø Apply a high temperature (100° C.; 212° F.) rated grease (Lubriko ACZ or
equivalent) to the “O” ring.
Ø Install the rear motor cover by tapping it into place taking care not to damage the “O”
ring.
Ø Secure the cover with the four screws provided.
2.5.3 Load Coupling
A flexible coupling MUST be used between the motor shaft and the load to minimize
mechanical stress due to radial loads, axial loads and/or misalignment. Radial and axial
loading cannot exceed specified values. See Table 2-1.
1
Teflon is a registered trademark of the Dupont Corporation.
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Section 2 – Page 3
Table 2-1 – Load Coupling
Motor Maximum Radial
Load (lbf) **
Maximum Axial
Load (lbf)
DXM/E-208 * 20 15
DXM/E-3XX 20 15
DXM/E-4XXX 100 50
* M-(XXX) = Metric E-(XXX) = English
** Maximum Radial Load is rated at 1 inch from the motor face
2.5.4 Gear Reducer Oil
It is strongly suggested that a synthetic oil is used in the gear reducer or rotary tables.
This will reduce the amount of friction in the mechanism and, in turn, reduce the amount
of current it takes to drive the motor.
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Section 2 – Page 4
3
INSTALLATION -- ELECTRICAL
3.1 Wiring
Wiring of any industrial equipment should be done with some consideration for future
troubleshooting and repair. It is a good idea that wiring be either color coded and/or
tagged with industrial wire tabs.
3.1.1 Interlocking
The user is responsible for emergency interlock switches. Any master interlock should
be wired to shut down AC power to all parts of the system. Your system should be
designed such that power is disconnected from the output loads any time the equipment
is not running or when the emergency stop is activated.
3.1.2 EMI/RFI Interference
If there is sensitive electronic equipment (digital computer, test equipment, etc.)
operating on the same AC power line as the Drive, additional EMI/RFI filtering may be
required to reduce the effects of conducted AC line noise.
3.1.3 Shielding Suggestions
Effects of electrical noise on the electronic equipment are greatly reduced when the
techniques outlined below are closely followed.
Ø Do not run low power control signals and high power wiring in the same raceway.
Ø If mixing wires cannot be avoided, then the low voltage control input and output
wiring must be shielded. The shield for these wires should be connected to ground
only at the source end of the signals.
Ø Do not connect both ends of a shielded cable to ground unless specified by the
manufacturer to do so. This may cause a ground loop condition which could cause
erratic equipment behavior and may be very difficult to locate.
Ø All the wires in the system must be kept as short as possible.
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Section 3– Page 1
3.2 Magnetic Coil Noise
In the case of DC coils, a diode is installed across the coil in a direction that will cause
the voltage transient to be dissipated through the diode.
Figure 3.1 DC Coil Suppression
In the case of AC coils, a capacitor and resistor are installed across the coil to suppress
the unwanted transients.
Figure 3.2 AC Coil Suppression
3.3 Grounding
The GND terminal of the drive is bonded to the frame and the mounting tabs. There are
two acceptable methods for connecting the grounds of the enclosure and other
electrical equipment to the Earth ground. Figure 3.3 shows the ideal grounding method
providing a grounding point isolated from the enclosure and ground all the electrical
equipment to this one point. From there, a grounding wire with good conductivity will be
run to the enclosure cabinet ground point. The machine ground wire and earth ground
supply wire are connected to this enclosure ground point. This method provides
maximum isolation of the control and servo grounds from the machine and other
sources of ground imbalances and noise. In most cases however, a single point
enclosure ground can be used as shown in Figure 3.5.
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Section 3– Page 2
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