Quin Q-drive Installation & User Manual

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Page 1

Quin Systems Limited

Q-drive Servo Amplifier

Installation & Users Manual

Issue 1.5

June 1996

(MAN430)

Page 2

prior written consent of Quin Systems Limited is strictly prohibited.

Software Version

This manual reflects the following software versions.

• QDRIVE.EXE version 2.0 or high er.

Important Notice

Quin Systems reserves the right to make changes without notice in the products described in this document in order to improve design or performance and for further product development. Examples given are for illustration only, and no responsibility is assumed for th eir suitability in particular applications.

Although every attempt has been made to ensure the accuracy of the information in this document, Quin Systems assu mes no liability for inadvertent errors.

Suggestions for improvements in either the products or the documentation are welcome.

Relevant Directives

This product is designed to be incorporated into a system for the control of machinery, and needs external equipment to enable it to fulfil this function. It must not be relied upon to provide safety-critical features such as guarding or emergency-stop functions. It must not be put into service until the machinery into which it is incorporated h as been declare d in conformi ty with the Machi nery Directive 89/392/EEC and/or its relevant amendments.

The installation instructions in this manual should be followed in constructing a system which meets requirements.

The product has been tested in typical configurations, and meets the EMC Directive 89/336/EEC When used with the recommended mains filter.

This product as normally supplied has mains level voltages accessible to touch, and requires t o be mounte d within a su itable cabine t to meet a ny required IP rating to BSEN 60529.

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Issue 1.5 Q-Drive Installation Manual

Table of Contents

List of Figures iii List of Tables iv

1. Introduction 1

1.1 Q-Drive Characteristics 2

1.2 EMC Compliance 3

2. Unpacking and Inspection 5

3. Drive Specifications 7

3.1 Mechanical specification 7

3.2 Environmental specification 7

3.3 Power supply specification 7

3.4 Electrical Specification 8

3.4.1 General data for all types 8

3.4.2 Drive Performance Specification 9

3.4.3 Analogue readings on the motherboard 9

3.5 Mounting Details 10

3.6 Relevant Directives 11

4. Connections 13

4.1 General 13

4.1.1 Wiring and connectors 14

4.1.2 Cable lengths and cross-sections 14

4.2 Low Voltage Connections 15

4.2.1 P2 Upper: R esolver 15

4.2.2 P2 Lower: Encoder 16

4.2.3 P4 RS422 Out / RS232 18

4.2.4 P3 RS422 In 18

4.2.5 P10, P11 & P12 19

4.3 High Voltage Connections 20

4.3.1 P7, Three Phase In 20

4.3.2 P8, Earth Terminals 20

4.3.3 P9, Motor 20

4.3.4 Wago Spring Terminals 21

5. Electrical Installation 23

5.1 General 23

5.2 Mains supply 24

5.3 Auxiliary Supply 25

5.4 Earth connections 26

5.5 Connecting the motor to the drive 27

5.6 Connecting the drive to the controller 28

6. Safety - Using Guards and Limits 29

6.1 Choosing a motor 30

6.2 Mounting the motor 32

6.3 Connecting the motor to the load 32

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Q-Drive Installation Manual Issue 1.5

7. Drive Parameters 33

7.1 Serial Link 33

7.2 Getting Around the Configuration Program 33

7.3 Page 0 Parameters 36

7.4 Page 1 Parameters 37

7.5 Page 2 Parameters 39

7.6 Page 3 parameters 41

7.7 Page 6 parameters 41

7.8 Page 8 parameters 42

7.9 Page 9 parameters 43

7.10 Status & Alarm page 44

8. Switching On 47

8.1 Switching the Servo-Amplifier On Without a Motor 47

8.2 Checking LEDS and 7 segment display 47

8.3 7 segment display on the front panel 48

8.3.1 Checking the electrical rotation sense of the resolver 49

8.4 Determining the motor phases 50

8.5 Switch the Servo Amplifier on with a Motor and Optimization 51

8.5.1 Preparation before switching the mains voltage on 51

8.5.2 Switching the mains voltage on 51

8.6 Compensating the speed controller 52

8.6.1 Offset and speed compensation 52

8.7 Trouble Shooting 54

9. Testing the System 55

9.1 General 55

9.2 Serial port 55

9.3 Resolver Interface 55

9.4 Encoder Simulator 56

10. Configurations 57

10.1 General 57

10.2 Resolver Ratio 57

10.3 Amplifier Configuration 58

10.4 Servo-amplifier fuses 58

10.5 Backplane configuration 60

10.6 Backplane Fuse 62

11. Options List 63

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Issue 1.5 Q-Drive Installation Manual

List of Figures

Figure 1: EMC filtering 3 Figure 2: Fixing centres for the Q-Drive. 10 Figure 3: Connections 13 Figure 4: P2 Upper: resolver connector 16 Figure 5: P2 Lower: encoder connector 17 Figure 6: P10, P11, P12: discrete signals 19 Figure 7: P7, P8, P9: power connectors 20 Figure 8: Wago spring terminals 21 Figure 9: General installation arrangement 23 Figure 10: Auxiliary supply connection 25 Figure 11: System earthing 26 Figure 12: Q-Drive.exe: password entry page 34 Figure 13: Q-Drive.exe: scanning for active drives 35 Figure 14: Q-Drive.exe: page 0 parameters. 36 Figure 15: Q-Drive.exe: page 1 parameters 37 Figure 16: Q-Drive.exe: page 2 parameters 39 Figure 17: Q-Drive.exe: page 3 parameters 41 Figure 18: Q-Drive.exe: page 6 parameters 41 Figure 19: Q-Drive.exe: page 8 parameters 42 Figure 20: Q-Drive.exe: page 9 parameters 43 Figure 21: Q-Drive.exe: status display 44 Figure 22: Seven segment display codes 48 Figure 23: Electrical rotation sense of the resolver 49 Figure 24: Backplane configuration 61 Figure 25: Backplane fuse 62 Figure 26: Drive amplifier jumper & fuse locations 64 Figure 27: Complete wiring plan 65

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Q-Drive Installation Manual Issue 1.5

List of Tables

Table 1: Drive Data 9 Table 2: Test Points 9 Table 3: Cable Sizes 14 Table 4: P2 Upper, Resolver Input Connections 15 Table 5: P2 Lower, Encoder Output Connections 17 Table 6: P4 RS422 Out / RS232 Connections 18 Table 7: P3 to P4 RS422 Daisy Chain Connections 18 Table 8: P10, P11, P12 Connections 19 Table 9: Motor Phase Determination 50 Table 10: Q-Drive Trouble Shooting 54 Table 11: Amplifier Configuration 58 Table 12: Amplifier Fuses 58 Table 13: Backplane configuration Jumpers 60

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Issue 1.5 Q-Drive Installation Manual

1. Introduction

This document is the Installation Manual for the Q-Drive s ervo amplifier, a me mber of the Quin Systems Ltd. digital Programmable Transmission System (PTS) range.

The Q-Drive series of servo-amplifiers are intended to control 3 phase AC servomotors with electronic commutation and resolver feedback, up to a maximum rating of 18 Amps, 6.8kW continuous.

Such servo-motors are generally ca lled AC Brushless, but to avoid any confusion, motors which can be used with the Q-Dri ve series servo-amplifiers should have the following characteristics:

• Rotor constructed with permanent magnets a rranged in 1, 2, 3, 4, 5 or 6 po le pairs, without commutator or slip rings.

• Stator constructed with 3 windings connected in star or delta.

• Electronic commutation is effected by means of a resolver (motors with Hall effect sensors or tachogenerators are not suitable).

Note:

Servo-amplifiers which deliver a 3 phase sinusoidal supply are usually called AC Brushless. The name DC Brushless is reserved for servo-amplifiers whose output supply is trapezoidal.

PLEASE READ THIS MANUAL BEFORE INSTALLATION. It is very important that the guidelines for installation are observed, otherwise damage

to the system or to the machine may occur. Quin Systems Limited accept no liability for damage or costs arising from incorrect or inadequate installation of the systems, or from incorrect programming of the system for the required application. Digital control systems are not simple, but can be used successfully to control industrial machinery and provide great improvements in reliability, performance and flexibility.

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Q-Drive Installation Manual Issue 1.5

1.1 Q-Drive Characteristics

The main characteristics of the Q-Drive servo-amplifiers are as follows:

• Digital servo-amplifier with analogue speed command +/- 10V, for Brushless motor with resolver.

• Utilises a 16 bit DSP (Digital Signal Processor)

• Compact unit for connection to 3 phase power supply with built-in braking module.

• Double Eurocard Format using Surface Mount Technology (SMD).

• Completely programmable by a multi-drop RS422 or direct RS 232 serial link.

• Sinusoidal current output assures smooth torque and optimum performance at low speed.

• Power and command circuits are optically isolated from each other.

• Protections and ruggedness for use in severe conditions.

• Easy to use external connections including two part connectors for resolver input and encoder output.

• Simulated incremental encoder output with adjustable resolution to 1024 ppr and adjustable marker pulse. Differential line driver outputs.

• 7 segment status indicator for diagnostic display.

• Short-circuit protected output stage.

• I2t protection.

• Detection of resolver fault, motor overheating.

• Velocity or current regulation.

• Auxiliary voltages are produced within the drive, no external power supply required.

• Drive can be enabled using an optional opto-coupled input or using a volt free contact.

• Motor connections are constantly monitored.

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Issue 1.5 Q-Drive Installation Manual

1.2 EMC Compliance

The Q-Drive amplifier has been tested to and complies with BSEN 50081-1 and BSEN 50081-2 for radiated emissions. The Q-Drive also complies with mains borne interference tests when used with a suitable three phase filter and when both the Q Drive and the filter are securely mounted and earth bonded to a conductive panel. If the auxiliary supply is used then this too must be filtered. Both filters must provide at least 55dB attenuation at 1MHz. The cable between the filters and the Q-Drive should preferably be screened and be kept as short as possible. Figure 1. below shows a typical arrangement between the filter and Q-Drive,

U V W E E E R S T

Q-Drive

transformer

1 ø isolating

B C

2 ø M

1 ø line

filter

uto3 ø A

transformer

B C

3 ø M

Drive

Contactor

3 ø line

filter

Figure 1. EMC filtering

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Issue 1.5 Q-Drive Installation Manual

2. Unpacking and Inspection

Inspect the packaging for external signs of damage if possible before signing the delivery receipt, as this may indicate that the goods have been mishandled in transit. When unpacking the Q-drive , keep all the packaging materials if possible. If it is necessary to ship th e Q-drive to another site, or to return it for service, the original packing can be reused.

Inspect the Q-drive carefully when it is unpacked. Check for any loose parts, any circuit boards loose in their card guides, cables not connected, or any bending of the case or chassis.

If any defect or damage is suspected, do not connect powe r to the system

the carrier immediately, and contact your sales of fice or the Quin Systems Service Department:

Quin Systems Limited Service Department Oaklands Business Centre Oaklands Park Wokingham Berkshire RG11 2FD England

Telephone Wokingham (01734) 771077 Fax (01734) 776728

. Notify

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Issue 1.5 Q-Drive Installation Manual

3. Drive Specifications

This section gives the overall specifications of the drive, including mechanical details and environmental requirements.

3.1 Mechanical specification

The dimensions of the Q-Drive are as follows:

Height 400 mm Width 115 mm Depth 290mm Weight 4 kg IP Rating IP20

The drive is designed to be mounted wit h the circuit board vertical, to allow cooling air circulation by convection. There should be at least 100mm clearance above and below the unit to allow free air flow. If the unit cannot be mounted with the drive vertical, then a fan must be fitted to blow air through the unit. The 18 amp model has built in fans for forced cooling, the fans are optional on other models.

3.2 Environmental specification

Temperature: operating 0°C to 60°C

full power 0°C to 45°C storage -20°C to 70°C

Relative humidity: 20 to 80% non-condensing

The drive may be operated at higher ambient temperatures, but will require additional cooling such as forced air ventilation in order to do so. The drive is normally supplied in a case or chassis with ventilation holes top and bottom, and therefore is not protected against dust, particle s, or liquids. If necessary, the unit can be supplied in a suitable sealed cabinet. Please contact your sales office or Quin Systems directly for further details.

3.3 Power supply specification

Supply voltage 3 x 220V AC +/- 15% Supply frequency 45 to 65 Hz

An additional single phase 230V AC supply is required to keep the resolver interface powered when the main three phase supply to the drive is interrupted, i.e. during an Estop situation. If this auxiliary supply is fitted it is very impo rtant to ensure that the correct phases are used, this is explained further in section 5.3 on page 25.

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Q-Drive Installation Manual Issue 1.5

3.4 Electrical Specification

3.4.1 General data for all types

Supply voltage 3 x 220V AC +/- 15% Supply frequency 45 to 65 Hz Operating temperature range 0 to 60° C Operating temperature range at full power 0 to 45° C (from 45°C, reduce output current by 2%/°C to 60°C)

Storage temperature range -20 °C to + 70 °C PWM chopper frequency 9.99 kHz Differential input reference +/- 10V Speed control range 1/5000 Bandwidth:

speed loop 300 Hz current loop 2 kHz

Rated power dissipation during braking with standard resistance 125W Max. output to motor 3 x 210 V, 0 to 500 Hz

Incremental encoder: output 5V

“low speed” settings available 128, 256, 512, 1024 ppr “high speed” settings available 128, 256, 512 ppr

Theoretical max. speed for motor with resolver:

“low speed” up to 3500 rpm “high speed” up to 6000 rpm

Switching threshold of brake module 385 V DC Over voltage trip threshold 415 V DC Voltage drop trip threshold 180 V DC

RS 232/RS422 serial link

baud rate Standard: 9600 Bd Configured by solder bridge: 19200 Bd transmission Full duplex format 1 Start bit

8 Data bit no parity 1 Stop bit

RTS/DTR controls RS232 transmission flow

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Issue 1.5 Q-Drive Installation Manual

3.4.2 Drive Performance Specification

Servo-amplifier type

Rated rms current Amps 5,9 10,0 18,7 Rated peak current Amps 8,3 14,2 26,4 Max. rms current Amps 11,8 20,1 37,3 Max. peak current Rated power (kW) 2,1 3,6 6,8 Max. power (kW) 4,3 7,3 13,6

Amps 16,7 28,4 52,8

Table 1: Drive Data

PQD506 PQD510 PQD518

Note:

= I

rms

P =1.73 x I

- in star V

rms phase

- in delta V

peak

rms phase

= I

/ 1.41

x V

rms

= 210V / 1.73

rms

rms phase

or P= 3 x I

rms

= 210V

rms phase

x V

rms phase

Example: Type PQD506 I

max

rated

= I

rms

/ 1.73

rms max

= 11.8 A

= 1.73 x 11.8 x 210 = 4.3 kW

= 1.73 x 5.9 x 210 = 2.1 kW

rms rated

= 5.9 A

3.4.3 Analogue readings on the motherboard

The Q-Dri ve mo therboard contains several meas urement points which permit an analogue reading of the three signals shown in Table 2-

Measurement point

Current Instanta neo us Cur rent 10V corresponds to the ma x. current o f

Command Internal command voltage V Speed Motor speed +/- 10V corresponds to the max. speed

Description Scaling

the unit

command

of 6000 rpm

= V

ext. cmd

Table 2: Test Points

The location of the measurement points is shown in Figure 24. on page 61

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Q-Drive Installation Manual Issue 1.5

3.5 Mounting Details

The Q-Drive has mounting holes on the rear plate for fixing to an electrical panel inside a cabinet. The unit is fixed with four M5 bolts using the fixing centres as shown in Figure 2. below.

115.5m m

95.5m m

Braking Over Current

4 off fixing holes M5 Clearance.

385.0mm400.0m

Figure 2. Fixing centres for the Q-Drive.

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Issue 1.5 Q-Drive Installation Manual

3.6 Relevant Directives

The installation instructions in this manual should be followed in constructing a system which meets requirements.

The product has been tested in typical configurations, and meets the EMC Directive 89/336/EEC when used with the recommended mains filter.

This product as normally supplied has mains level voltages accessible to touch, and requires t o be mounte d within a su itable cabine t to meet a ny required IP rating to BSEN 60529.

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Issue 1.5 Q-Drive Installation Manual

4. Connections

4.1 General

High and low voltage cable connections ha ve been segregated in the Q-drive. The positions of the various connectors are shown in Figure 3.

P11

P12

P10

RESOLVER

P2 Upper

SW1

J4 J3

ENCODER

J1J2

RS422/232

P2 Lower

RS422

Fan

SUPPLY

T S R

Figure 3. Connections

Fan

EARTH

P8 P9

MOTOR

W U V

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Q-Drive Installation Manual Issue 1.5

4.1.1 Wiring and connectors

The wiring of the Q-Drive series of servo-amplifiers must be carried out according to the schematics in these instructions. Local wiring regulations must be observed. Special attention should be paid with respect to wiring rules regarding ground, earth and neutral. The earth wire to the amplifier, motor and housing must be as short as possible and connected to a common earth point. The complete wiring plan is represented in on the next page.

4.1.2 Cable lengths and cross-sections

Quin Systems recommend that the following cable cross-sections are used:

Units PQD506 PQD510 PQD518

Supply voltage Motor Earth Command signals

mm mm mm mm

1.50 2.50 4.00

0.18 0.18 0.18

Table 3: Cable Sizes

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Issue 1.5 Q-Drive Installation Manual

4.2 Low Voltage Connections

Details of the low voltage connections which include the Encoder, Resolver, RS422/ RS232 and discrete signals, are described in the following sections.

4.2.1 P2 Upper: Resolver

The resolver interf ace uses the upper half of c onnector P2 and is wired as sh own in Table 4: and Figure 4. . The external screen should be connected at both ends; motor and amplifier. The overall screen must be connected at the amplifier end, pin 1 should be used, and it should also be connected to the motor earth terminal at the motor end of the cable. It is recommended that the three internal screens should be connected only at the servo-amplifier end of the cable. They should be connected to pin 8 along with the Ref. 2 connection. Pins 2 and 3 of the connector are used for the motor thermal overload which can be either normally open or normally closed, or (if a thermal sensor is used) have the following characteristics:

Contacts Open: >10kΩ Contact closed <1kΩ

P2 Pin Number Function

1ScreenBraid J 2 Thermal Trip 1 White T 3 Thermal Trip 2 Brown S 4 Sin 2 Pink E 5Sin 1GreyC 6 Cos 2 Yellow P 7Cos 1GreenD 8Ref. 2Blue B 9Ref. 1Red A

Table 4: P2 Upper, Resolver Input Connections

Suggested Wire

Colour

SEM Motor

Resolver

connector

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Q-Drive Installation Manual Issue 1.5

Screen

White

Brown

Pink

Grey

Yellow

Green

Blue

Red

Heidenhain cable type 200 775 02

Figure 4. P2 Upper: resolver connector

4.2.2 P2 Lower: Encoder

The Encoder output uses the lower half of connector P2 and is wired as shown in Table 5: and Figure 5. . The Q-Drive servo amplifier simulates an incremental encoder using the positional information obtained from the resolver. The encoder resolution can be as high as 1024 pulses per revolution (PPR) when the drive speed is limited to 3500 RPM. If the drive is required to move the motor at higher speeds then the encoder resolution drops to a maximum of 512 PPR. If the drive is set to 1024 PPR and 6000 RPM then an incorrect encoder pulse train will be produced.

The cables used for the encoder signals should be high quality screened cables, using individually screened twisted pairs, with an overall cable screen as well. The cable screen should be connected directly to the main earth point, not via the control system 0V supply.

It is recommended that the maximum cable length for the enc oder output should not exceed 25m, which should not be a problem as the Q-drive and control system can usually be mounted within the same cabinet. If the machine installation requires a cable longer than 25m, then it may be necessary to install an additional line driver unit to boost the encoder signals.

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Issue 1.5 Q-Drive Installation Manual

Q-Drive Pin

Number.

1. A. 1. Pink.

2. /A. 6. Grey.

3. B. 2. Yellow.

4. /B. 7. Green.

5. Z. 3. Blue.

6. /Z. 8. Red.

7. Not Used. . .

8. 0V. 9. White.

9. Screen. 5. All screens.

Table 5: P2 Lower, Encoder Output Connections

Function.

PTS D-type Pin

no.

Suggested Wire

Colour.

Pink

Grey

Yellow

Green

Blue

Red

Screen

Heidenhain cable type 200 775 02

Figure 5. P2 Lower: encoder connector

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Q-Drive Installation Manual Issue 1.5

4.2.3 P4 RS422 Out / RS232

The socket P4 is used as the daisy chain OUT connector in an RS422 multi-drop drive chain or the RS232 port in a single drive application. The RS232 option can only be used if the drive has been setup for this format by Quin systems. The def ault configuration is for RS422, the connections are shown below.

Pin Number. RS422 Function. RS232 Function.

1. Not Used. Not Used.

2. Tx. Tx.

3. Rx. Rx.

4. Not Used. Not Used.

5. Gnd. Gnd.

6. Not Used. Not Used.

7. /Tx. RTS.

8. /Rx. DTR.

9. Not Used. Not Used.

Table 6: P4 RS422 Out / RS232 Connections

4.2.4 P3 RS422 In

The plug P3 is used as the RS422 daisy chain IN connector in a multi -drop drive chain. If the unit has been configured for RS232 then this connector has no function.As a temporary measure, an RS232 device may connect to an RS422 drive (default linking) with the connections shown.

P4 (OUT

Connector)

Pin Number.

1. Not Used. . 1.

2. Tx. . 2.

3. Rx. Gnd. 3.

RS422

Function.

RS232 (temporary

usage).

P3 (IN connector)

Pin Number.

4. Not Used. . 4.

5. Gnd. Gnd. 5.

6. Not Used. . 6.

7. /Tx. Tx. 7.

8. /Rx. Rx. 8.

9. Not Used. . 9.

Table 7: P3 to P4 RS422 Daisy Chain Connections

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Issue 1.5 Q-Drive Installation Manual

4.2.5 P10, P11 & P12

These connectors are used for interfacing all other low voltage signals to the drive and are detailed below in Table 8: Figure 6. shows the pin 1 & 2 socket of connector P10,

Pin Number. Signal Name. Function.

P10.1. Earth. Command shield connection. P10.2. Gnd. Drive internal Ground (not isolated). P10.3. S+. Command signal +ve. P10.4. S-. Command signal -ve. P11.1. EXTILIM. External current limit,+10V

corresponds to max peak current. P11.2. +12V Bat. External 12V battery +ve. P11.3. RDY2. Volt free drive ready relay contact. P11.4. RDY1. Volt free drive ready relay contact. P12.1. -12V Bat. External 12V battery -ve. P12.2. BGnd. External 12V battery Gnd. P12.3. 024V. 0V for ENABLE signal. P12.4. ENABLE. Drive enable signal from controller.

Table 8: P10, P11, P12 Connections

P11 & P12 already inserted into their respective mating half, whilst the pin 3 & 4 connectors are shown waiting to be inserted.

Figure 6. P10, P11, P12: discrete signals

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Q-Drive Installation Manual Issue 1.5

4.3 High Voltage Connections

4.3.1 P7, Three Phase In

P7 is a block of three high current scr ew terminals used to connec t the three pha se or single phase supply to the Q-Drive. If a single phase supply is used then connections ‘R’ and ‘S’ should be use d. The individual phases ar e identified by markings o n the circuit board just above the terminals.

4.3.2 P8, Earth Terminals

P8 is a block of three terminals, all connected to ground. These terminals should be used to connect the earth wire from the three phase supply or transformer and an earth connection to the motor. One of these terminals can also be used to connect an earth bonding strap to the Q-Drive although there is an M4 stud just below these terminals designed expressly for this purpose. All metal parts of the Q-Drive are bonded to this stud and hence it is imperative that it is connected to ground. The earth terminals are marked as ‘EARTH’ on the circuit board just above the terminals.

4.3.3 P9, Motor

P9 is used to connect the three phase output to the motor. As with P7 and P8 it uses high current screw terminals, The output phases are marked just above the terminals and should be connected to the corresponding phases at the motor.The standard connections to an SEM motor plug are phase U to pin A, phase V to pin B, phase W to pin F, and earth to pin E.

Figure 7. P7, P8, P9: power connectors

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Issue 1.5 Q-Drive Installation Manual

4.3.4 Wago Spring Terminals

A group of six Wago spring terminals are positioned to the left of the screw terminals. These are used to connect the auxiliary supply and an external fan.The terminals marked R‘ and S‘ are used to connect the single phase auxiliary supply to the Q-Drive. This supply is required if the resolver position and encoder output signals are to be maintained when the three phase supply is removed, i.e. during an emergency stop, it does not supply power to the amplifier part of the drive. There are two terminals each for R‘ and S‘. It is vitally important to ensure that the same phase is connected to R and R‘ and similarly that the phase connected to S is the same as that connected to S‘. A typical connection diagram is shown in Figure 10. on page 25 .

There are also a pair of terminals for the connection of an externally mounted fan, if one is used. Fans can be fitted internally and if so then the internal power connector should be used, leaving the external terminals free. .

Figure 8. Wago spring terminals

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Issue 1.5 Q-Drive Installation Manual

5. Electrical Installation

5.1 General

This section gives some guidelines for the electrical installation of the drive amplifier system. The diagram below shows a typical installation, and is used to highlight specific areas described in the following sections. Note that this is only a very simplified sketch, not a full installation wiring diagram. Details such as isolators, contactors and other switching arrangements are not shown but in most cases will be used. Please refer to the motor and control manufacturer’s instructions for further details on electrical installation

Control System

ø1 ø2

ø3

Neutral

Earth

8 8

1 ø

Isolating

Transformer

QUIN

Encoder cable

3 ø

Isolating

Transformer

Resolver cable

Q-Drive

Motor

Figure 9. General installation arrangement

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Q-Drive Installation Manual Issue 1.5

5.2 Mains supply

The Q-Drive can be powered from one of four sources:-

• 220V three phase supply

• Isolating transformer

• Auto-transformer.

• Single phase supply The drives are fitted with surge limiting devices which pre vent the bridge rectifier from

being damaged by high inrush currents. If the drive is to operated directly from a 220V three phase or single phase supply then a 4mH three phase choke should be installed between the supply and the drive. The size of the mains tra nsformer is approximat ely calculated from the incoming power per axis.

Mechanical power:

Motor Torque(Nm) Motor Speed(RPM)×

---------------------------------------------------------------------------------------------------- 9550

Mechanical Power(kW)=

The power of the transformer in kVA should be about equal to the mechanical power if the motor efficiency is ignored.

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Issue 1.5 Q-Drive Installation Manual

5.3 Auxiliary Supply

A group of six Wago spring terminals are positioned to the left of the screw terminals. The first four of these (from the left) are used to connect the auxiliary supply. The terminals marked R‘ and S‘ are used to connect the auxiliary single phase supply to the Q-Drive. This supply is needed if the resolver position and encoder output signals are to be maintained during an emergency stop, i.e. when the three phase supply is removed, it will not supply power to the amplifier p art of the drive. There are two terminals each for R‘ and S‘. It is vitally important to ensure that the same phase is connected to R and R‘ and similarly that the phase connected to S is the same as that connected to S‘. A typical connection diagram is shown in Figure 10. below.

U V W E E E R S T

Q-Drive

transformer

1 ø isolating

B C

2 ø M

1 ø line

filter

uto3 ø A

transformer

B C

3 ø M

Drive

Contactor

3 ø line

filter

Figure 10. Auxiliary supply connection

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Q-Drive Installation Manual Issue 1.5

5.4 Earth connections

Earthing is very important in any electrical installation. It is an essential safety measure to prevent electric shock in case of any failure of the eq uipment, and is also used for screening between different units. It provides a ground refer ence point for all units in the system. Incorrect earth connection can result in erratic operation due to noise or earth loops, or may prevent the system from operating a t all. These problems can be avoided by careful arrangement of the earth connections, and by techniques such as isolation.

Control System

8 888

Encoder cable

QUIN

Resolver cable

Q-Drive

ø1 ø2

ø3

Neutral

Earth

1 ø

Isolating

Transformer

3 ø

Isolating

Transformer

Figure 11. System earthing

Motor

• The earth connections from the isolation transf ormer or whatever source of supply is used shoul d be made using a suitab le gauge of wire. The I EE 16th edition wiring regulations (or appropriate local regulations) should be consulted to determine an appropriate gauge of wire for the earth bonding straps. All the earth connections should be connected together at one point, prefera bly on the electronics cabinet chassis earth connection.

•Do

not

tie the earth wires together with any low voltage signal cables, or run

them close together in the same conduit or cable duct.

• All screened cables should have their screens connected directly to earth, not via the system 0V power supply. This is very important, as otherwise noise and transients picked up in the screen will pass through the system, instead of being dissipated directly to earth

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5.5 Connecting the motor to the drive

A typical brushless A.C. motor is connected with two cables; one carries the power to the motor windings, and the other returns sign als from a position or speed feedback device such as a resolver to the drive for positional speed sensing. The motor should be connected using cables as specified by the manufacturer. These cables usually have a strict specification with regard to size and length of motor connections. In general though...

•Do

not

tie the motor cable and resolver cable together, or run them together in the same conduit or cable duct. The motor cable can carry high currents in normal operation, and the resolver cable carries low voltage signals back to the drive. The correct performance and accuracy of the motor and drive depend on the quality of the resolver signals.

• Do use a screened cable with individually screened twisted pairs for the resolver signals from the motor to the drive. This prevents crosstalk and noise interfering with the resolver signals, and gives the best performance.

• Recommended cable for motor drive power:

RS part number 379-198

Recommended cable for Resolver or Encoder:

Heidenhain cable part number 200-775-02

(Formerly part number 2449-5501)

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Q-Drive Installation Manual Issue 1.5

5.6 Connecting the drive to the controller

The drive is connected to a Quin motion controller using usually two multicore cables and two discrete wire leads: one cable carries the analogue speed demand to the drive, and the other returns the position feedback as processed in the drive. A pair of leads connects the command to enable the drive

The analogue speed command uses a 2-core screened cable. The controller’s command output for the chosen axis is connected to P10.3, with its 0 vol ts return to P 10.4 and the screen of the cable to P10.1 - refer to table 8. A suitable scree ned cable is RS part number 367-325.

The encoder simulation output of the drive is connected to a Quin controller as per table 5 and figure 5, using the appropriate axis socket. The chosen axis parameters are to be set for Quadrature x 4 encoder, which is usually the default setting.

The axis enable relay output (“normally open” and “common” pins) is connected across P12.3 and P12.4, as per table 8: by default, the drive sources the 24 volts which is switched by the relay. If an external 24 volts is to be used (maybe to enable a quicker safety stopping), enable the “valid” opto isolator by removing backplane J2 links 1-2 and 3-4, then wire as per the PTS or TRC Installation Manual “typical example”.

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Issue 1.5 Q-Drive Installation Manual

6. Safety - Using Guards and Limits

All machines should include comprehensive safety features. This is essential both for normal safety considerations, and to comply with H ealth and Safety requirements. It can also prevent any unwanted interference with the machine while it is running.

All moving machinery must be guarded so that it cannot be reached by anybody while in motion. The guards should be fitted with guard switches or sensors, connected so as to immediately cut power from the motors when any gu ard is opened. On some machines, it may be useful to lock the guards closed by means of a solenoid to prevent them from being opened while the machine is running. This allows the machine to detect any attempt to open a guard and shut down the machine cleanly before unlocking the guard and allowing it to open.

Motors which have constraints or limits on their range of motion should be fitted with hard wired limit switches. These should cut power from the motors if any motor goes outside its limits of travel. The machine must also have one or more locking em ergency stop push-button switches, accessible from several positions around the machine. Anyone operating or working on the machine must be able to instantly stop the machine at any time by hitting an emergency stop switch.

There are no limit switches available on the Q-Drive but if the machine require s the use of limit switches then they may be implemented using the digital i/o functio ns available on the control system. If the control system is used to provide a limit switch function then this should be backed up with an mechanical switch which should cut the power to the Q-Drive.

Guards, emergency stop and limit switches may be connected into the control system motor control systems, by using the digital input lines. However, the programmable input functions on the control system should only be used in addition to the conventional hard wired guard and limit switches, not to replace them. The digital inputs can be used to trigger a smooth shutdown sequence, or to generate a limit switch error and shut down immediately. The control system can then remove power from the motors and drives if required, under software control, by using a digital output line to switch the motor supply contactors.

switches MUST remove all electrical power fr om the motors and drives, independently of any action of the control system.

control system, then again all power must be removed from the motors. This is easily done by connecting the on board relay on each axis controller into the drive enable function, or into the control circuit for the motor and drive main contactors.

Note that in most cases, it is not necessary to remove power from the control system, only from all the high power equipment. If power to the control system and encoders can be maintained even when the motors and drives are shut down, then the system does not lose any position information. This can allow the machine to start up again much more quickly than if the control system is powered off as well, since the machine does not need to execute a complete initialisation before it can be restarted.

In all installations the limit switches and guard

If power is removed from the

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6.1 Choosing a motor

The choice of motor for a particular application depends on several fac tors. Some of these are given below.

• Maximum torque required.

• Continuous torque required (r.m.s.).

• Maximum motor shaft speed.

• Maximum acceleration rate. The torque is the turning effort required from the motor in order to accelerate the

mechanical load or system at the desired rate. It is usually measured in Newton metres (Nm), gram centimetres (gcm), pound feet (lb. ft ) or ounce inches (oz. in) . In order to calculate the torque required from the motor, it is necessary to find out the following information about the mechanical system.

• The reflected total inertia of the system or load, at the motor shaft.

• The reflected total friction of the load.

• The internal motor inertia and friction.

• The maximum acceleration rate of the motor.

• Any gear or pulley ratios in the mechanical system. For example, consider a motor driving a load via a belt a nd pulleys. The total torque

required from the motor is given by:



------

ILI

 

dθ

------

+ +=

where T = total motor torque required

D1= diameter of motor pulley D2= diameter of load pulley I

= inertia of load

= inertia of motor

d θ

= acceleration at motor shaft

= friction torque of load

= friction of motor.

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Issue 1.5 Q-Drive Installation Manual

In most cases, the inertia and friction can be assumed constant, unless the system has a changing load. In this case the maximum possible load should be used in the calculations. The required velocity profile of the moto r should be sketched out by plotting motor velocity against time. The slope of this gives the motor acceleration, and thus the maximum required acceleration can be found from the steepest slope on the graph. This acceleration value can then be substituted in the torque equation for a given motor to see if the motor is powerful enough to do the job.

This can be repeated along the velocity-time plot for al l accelerations to give a graph of torque against time. This can be used to find the average or r.m.s. continuous torque required by the system. Servo motors are often specified with both a continuous and a peak torque rating, and they should be chosen such that the torque requirement of the machine is well within the capac ity of the motor. Care must al so be taken to ens ure that the maximum speed of the motor is not exceeded.

Note that if too large a motor is selected, the motor inertia is higher than for a smaller motor. This affects the maximum acceleration that the motor produces. It is not always the largest or most powerful motor that accelerates the load at th e quickest rate . Also note that maximum power transfer from the motor into the load is obtained if the motor inertia and reflected load inertia are similar.

The ideal motor should have as high a torque to inertia ratio as possible. Pancake o r printed armature motors are often used beca use they have low rotor inertias. This is also another advantage of brushless motors, in that they have low rotor inertias because the rotor often does not have any electrical windings but consists simply of a permanent magnet on a shaft. Brushless motors also exh ibit better heat dissipation from their wound stator.

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6.2 Mounting the motor

The motor must be mounted rigidly to the structure of the machine or to a solid floor. If it is not mounted securely, it may vibrate or oscillate when the motor is powered up and the position or velocity control loops closed. The motor exerts as much torque on its mountings as it does on the lo ad. If the mountings are flexible, they ma y form a resonant syst em, with the motor supplyi ng plenty of power to susta in severe oscillations.

6.3 Connecting the motor to the load

The motor shaft must be connected se curely to the load. This may be by means of a drive shaft, a toothed belt and pulleys, or by a gearbox. In all cases the coupling between the motor and the load must be as stiff as possible, and must have minimum backlash. At the same time, care must be taken to avo id adding any unnecessary friction into the system, as this reduces the performance of the servo system.

A common problem when connecting the motor to its load is backlash. This is usually found in gearboxes, where the input gear is allowed to move by a small amount between the teeth of the output gear, while the output gear is stationary. A similar effect is seen if the motor mountings are loose or sloppy, or if the coupling between motor and load is too flexible. The effect of backlash is not just a loss of position accuracy, but may in extreme cases result in a highly unstable system. All possible precautions must be taken to minimise or eliminate backlash in the system.

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Issue 1.5 Q-Drive Installation Manual

7. Drive Parameters

7.1 Serial Link

The serial link is used to set or monitor drive parameters stored in non-volatile memory using the configuration program.

This program allows the user to:

• set all user adjustable parameters

• monitor inputs and fault status

• In a multi drive configuration it is possible to acce ss all drives from a singl e PC without having to transfer the serial cable from one drive to another.

With the serial link connected it is possible to monitor the position of the resolver (0-

1024) within one motor revolution.

Hardware: A personal computer with either an RS422 adapter plus cable or an RS232 serial cable.

The choice depends upon how the drive has been configured.

7.2 Getting Around the Configuration Program

The program QDRIVE.EXE should be installed on an IBM compatible personal computer (PC) and used to set the drive p arameters and monitor the servo-amplifier status.

There are 80 parameters available on the Q-Drive that are divided up as detailed below. On the following pages are descriptions of various parameter and their range of values; parameters not described should not be changed.

0..10: Motor parameters

11..31: Installation parameters

32..43

44..59: Internal parameters (for testing)

60..63: Parameter protection bits

64..79: Status parameters, read only

Certain parameters only become active after they have been saved with the <F2> function key. These are denoted by an <F2> symbol in their title

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Q-Drive Installation Manual Issue 1.5

Run the configuration program by typing;

QDRIVE <Return>

The initial screen, shown below, appears asking for the password motor to be entered. The program will allow changes to be made only if the password is correct, but will st ill run if the password is incorrect to allow parameter monitoring only.

Figure 12. Q-Drive.exe: password entry page

The

QDRIVE.EXE

pr ogram presents the servo parameters using nine pa ges or screens. The first three pages involve the setup of the servo-amplifier and the absolute position of the resolver. The last page is used to monitor the inputs and alarm states. Only the parameters on the first three pages can be modified through the computer program. In order to change the parameters it is necessary to “Connect” to a pa rticular drive. This is achieved in the following way.

1 Press the <F8> function key to put the program “On-Line”, the program will

immediately start trying to communicate with drive 1.

2 If drive 1 is not connected then press function key <F4> to scan fo r active

drives, Figure 13. on page 35 shows the program scanning for drives and finding drive 1. When the active drive has been identified use the procedure in steps 3 to 5 to connect to it.

3 To change to the required drive press and hold down the <Shift> key and

then press a function key from <F1> to <F10>, this will access drives 1 through to 10.

4 To access drives 11 to 15 press and hold down the <Ctrl> key and then

press a function key from <F1> to <F5>

5 When the desired drive has been selected, the message near the top of the

screen will show “ONLINE Connected”

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Issue 1.5 Q-Drive Installation Manual

Figure 13. Q-Drive.exe: scanning for active drives

Once a drive has been connected to it, it is possible to change the various pa rameters available on each page. Moving around and selecting the parameters is done using the following keys:

Change Pages: The page displayed on the computer is changed by pressing the <TAB> key. <Shift><Tab> will move backwards through the pages.

Select Parameters

The up/down arrow keys a re used to select the desired parameter on each page. The selected parameter appears in reverse video, Figure 13. shows Proportional Gain as the selected parameter.

Change Values:

The plus key <+> and the minus key <-> change the value of the selected parameter displayed in reverse video. It is also possible to directly enter a value from the keyboard, simply type in the new value and press the <Return> key.

Save Settings:

The <F2> key saves all settings to non-volatile (EEPROM) memory and in some cases activates the changed value.

Read File:

A file containing preset drive parameters can be downloaded to the drive using the

<F3> key. Pressing this key will present the default drive parameter file name, QDRIVE.CFG, this file name can be erased and replaced with another file name.

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Q-Drive Installation Manual Issue 1.5

Exit Program:

Press <ESC> to exit the program.

New Release:

For more information on new releases please look at the file README.TXT.

7.3 Page 0 Parameters

Figure 14. Q-Drive.exe: page 0 parameters.

0 Proportional Gain: (0..127) 1 Integral Gain: (0..127)

These two parameters determine the proportional and integral gain of the servo velocity control loop. They are programmable from 0 to 127. Higher values represent higher gains. The integral gain is cancelled for a value lower or equal to 3.

2 Speed factor: (-127..+127)

This parameter sets the maximum speed and the direction of rotation of the motor. This parameter is programmable from -127 to 127 corresponding to a speed of -6000 rpm to +6000 rpm +/- 10%.

3 Maximum current: (0..127)

This parameter sets the peak current delivered to the motor. This parameter is programmable from 0 to 127 (127 = maximum peak current of the amplifier shown in Table 1: on page 9.

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Issue 1.5 Q-Drive Installation Manual

4 Nominal current: (10..64) <F2>

This parameter sets the con tinuous current delivered to the motor. This parameter is programmable from 10 to 64

5 Pair of motor poles: (1..6)

This parameter sets the number of motor pole pairs for proper commutation. This parameter is programmable from 1 to 6 (number of motor pole pairs).

6 Phase advance: (0..360)

This parameter is used to optimize the phase advance angle for each type of motor. At max. speed (speed factor parameter = 127), this parameter can vary the phase advance angle from 0 to 360 electrical degrees. This parameter is programmable from 0 to 360° (typical value: 20).

7 Resolver Shift Angle: (-180..+180)

This parameter is used to set the resolver shift angle in software to accommodate any resolver shift angle set by the motor manufacturer. This parameter is programmable from -180 to +180 (electrical degrees).

7.4 Page 1 Parameters

Figure 15. Q-Drive.exe: page 1 parameters

8 Motor thermostat normally, open: (0,1)

The servo-amplifier is set to suit the motor thermal switch type by selecting:

0: for motor thermal switch normally CLOSED (or for PTC) 1: for motor thermal switch normally OPEN (or for NTC)

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Q-Drive Installation Manual Issue 1.5

9 Speed Offset:(-127..+127)

The setting of the servo-amplifier speed offset is done with this parameter. which is adjustable between -127 and +127.

10 Parameter not used 11 Not used on Qdrive

12 Direction Stop: (0..3)

This parameter is used to prevent the motor from turning in a particular direction and is setup as follows.

0: Turns in both +ve and -ve directions 1: Only turns in a +ve direction 2: Only turns in a -ve direction 3: Will not turn in either direction

13 Relay, Alarm or Ready: (0,1)

This parameter is used to define the function of the on-board relay:

0: Relay is on when there are no alarms 1: Relay is on when the drive is enabled

14 Inverted display: (0,1)

The 7 segment display can be inverted if the drive is to be mounted upside down.

1: Normal display 0: Inverted display

15 RS232, RS422 Address: (0..17)

This parameter is used to set the address to which the drive amplifier will respond and whether the drive is using RS232 or RS422 commu nications. For use with an RS422 interface the drive can be set to read the address from the Q-Drive backplane or be set to address 1. For use with an RS232 interface it can be set to read the address from the Q-Drive backplane or set to an address in the range 1 to 15:

0: RS422 Read address from backplane

1..15: RS232 Address 1..15 16: RS232 Read address from backplane 17: RS422 Set to address 1

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Issue 1.5 Q-Drive Installation Manual

7.5 Page 2 Parameters

Figure 16. Q-Drive.exe: page 2 parameters

Speed/Resolution: (1,2)

<F2>

This parameter selects one of two maximum motor speeds in order to enable the servo-amplifier for the appropriate encoder resolution range. The limits are:

1: Max. speed = 3500 rpm Max. resolution = 1024 ppr 2: Max. speed = 6000 rpm Max. resolution = 512 ppr

NOTE.

The encoder simulation will not work if the encoder simulation is set

to 1024ppr and the maximum speed is set 6000rpm

Encoder Resolution: (1..1024)

<F2>

This parameter selects the number of pulses generated by the encoder simulator and can be set anywhere in the range 1 to 1024.

Reference Marker Width: (0..2)

<F2>

This parameter selects the width of the simulated encoder marker pulse (Z pulse) relative to the width of the A channel period. The following values are available: 1/4 , 1/2 and 1 and are set up as follows

0: 1/4 pulse width 1: 1/2 pulse width 2: 1 pulse width

Reference shift: (-512..+512)

<F2>

This parameter is used to shift the simulated encoder reference marker pulse by +/- 180° relative to the null position of the resolver. It is programmable over a range of, 512 (-180°) to +512 (+180°).

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Q-Drive Installation Manual Issue 1.5

20 Enable: Hard, Trig, Soft: (0..2) <F2>

This parameter defines the way in which the amplifier is enabled. The first setting, “Hard”, means that the amplifier can only be enabled using the external contacts availa ble at P12 pins 3and 4. The second setting, “Trig”, means that the amplifier has to be hardware enabled as in setting 1 above and then software enabled using the <F5> key. If at any time the ampl ifier becomes disabled e.g. because of a motor fault then the <F5> key will no longer work until the hardware enable has been reset, i.e. re moved and then replaced. The third setting “Soft”, allows the amplifier to be enabled and disabled using the <F5> key, the hardware enable needs to be set all of the time for this function to work.

0: Hard 1: Trig 2: Soft

21 Software Watchdog: (0..65535)

The value set in the watchdog parameter determines the time in milli seconds which the amplifier will wait after the QDRIVE.EXE goes off-line or is disconnected before reporting error code 9 and disabling the motor. The watchdog is only active when the drive is enabled. Setting this value to 0 will disable the watchdog

22 Alarm Latch 2,7,2&7: (0..3) <F2>

This parameters determines how the amplifier treats the Over current (I2t) and Under voltage alarms, i.e. whether or not they are latched.

0: Neither alarm latched 1: Over current alarm latched 2: Under voltage alarm latched 3: Both alarms latched

23 Optional Speed Module

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Issue 1.5 Q-Drive Installation Manual

7.6 Page 3 parameters

Figure 17. Q-Drive.exe: page 3 parameters

24 to 53: Not used

7.7 Page 6 parameters

Figure 18. Q-Drive.exe: page 6 parameters

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Q-Drive Installation Manual Issue 1.5

The parameters on Page 6 are Read only and as such cannot be changed.

54 Resolver position

The resolver position is a 12 bit value of the current resolver position within one rotation.

55 Revolution counter

The revolution counter is a 24 bit count of complete resolver revolutions. This value can be used with the resolver position to effectively produce an absolute encoder.

7.8 Page 8 parameters

Figure 19. Q-Drive.exe: page 8 parameters

The parameters on Page 8 are Read only and as such cannot be changed.

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Issue 1.5 Q-Drive Installation Manual

7.9 Page 9 parameters

Figure 20. Q-Drive.exe: page 9 parameters

Max Peak Current (0..127):

This parameter defines the maximum peak current that the drive will deliver to the motor

75 Max Nominal Current (0..127):

This parameter defines the maximum nominal current that the amplifier will deliver

76 Manufacturing week:

The week number in which the drive amplifier was manufactured.

77 Manufacturing year:

The year in which the drive amplifier was manufactured.

78 Hardware Version:

The hardware version number or revision number of the drive amplifier.

79 Firmware Version:

The firmware or EPROM revision number.

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Q-Drive Installation Manual Issue 1.5

7.10 Status & Alarm page

Figure 21. Q-Drive.exe: status display

Pressing function key <F7> from any of the nine pages will bring up the status page as shown above. This page gives a continually updated display of all alarms and the current status of the drive and is particularly useful whilst commissioning the drive. Whilst this page is displayed it is possible to change from one drive to another to obtain the new drive’s current status. If a non existent drive is selected, i.e. drive 6 in a 5 drive system then the display will continue to show the previous drive’s val ues except for the top line which will show

“Axe 6 ONLINE no connect”

i Earth Defect:-

If the optional Earth Fault module is fitted and the Q-Drive is supplied from an Auto-transformer then this alarm indicates a problem with the amplifier earthing

ii EEPROM Fault

The amplifier has been unable to read data from the EEPROM non-volatile memory or the data is corrupt

iii Resolver Fault

The resolver or the connections to it are faulty and the system can no longer read the resolver.

iv RDC Fault

The part of the system designed to convert the resolver signals into digital signals is faulty.

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Issue 1.5 Q-Drive Installation Manual

v Battery Under voltage

The backup battery voltage is too low to reliably maintain the system in the event of a power failure.

vi Software Watchdog

Software watchdog has tripped, this usually means that the processor has stopped running or it is stuck in a perpetual loop.

vii End Switch 1

This alarm cannot occur in the Q-Drive as it does not support end switches.

viii Link Motor Fault

Failure in the wiring from the amplifier to the motor.

ix I2t reached

The amplifier has reached it’s power limit, if the control system is trying to push the amplifier harder

x Torque Enable Input

This will show ON when the drive is enabled and OFF when the drive is disabled.

xi Motor Thermostat

The thermostat built into the motor has tripped, the motor should be shut down and allowed to cool.

xii Heatsink Thermostat

The amplifiers built-in heatsink has overheated, the amplifier should be switched off and allowed to cool. The optional fans should be fitted into the Q-Drive enclosure if the fault occurs on a regular basis.

xiii End Switch 2

This alarm can not occur in the Q-Drive as it does not support end switches

xiv Power Fault

The power amp section of the Q-Drive has developed a fault and can no longer reliably drive the motor.

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This Page is intentionally Left Blank

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Issue 1.5 Q-Drive Installation Manual

8. Switching On

Preparation of AC Brushless servo motors and servo-amplifiers requires a little more attention than that of DC servo-drives. We recommend that switching on for the first time is done according to the following instructions.

8.1 Switching the Servo-Amplifier On Without a Motor

The first time the amplifier is switched on the enable contacts (connector P12 pins 3 and

4), should be open circuit. This will disable the power stages of the amplifie r. The resolver should be connected to the servo-amplifier and some method o f reading the encoder output, i.e. a Quin PTS system, should also be connected.

The three-motor phases must not be connected to the servo-amplifier.

8.2 Checking LEDS and 7 segment display

LED

“OVER I”

This LED lights up during a short-circuit between two motor phases or a power stage fault.

The state of the LED and the output stage inhibit are latched. To clear a latched fault it is necessary to cycle the power. If the power is cycled, ensur e that at least 30 se conds is allowed between switching off and switching back on. If this delay is shortened then it is possible that the residual power in the smoothing capacitors will hold up the amplifier control circuits and the alarm latch will not be cleared.

“Braking”

This LED lights up when the braking modul e operates. This is a non latching alarm and it is quite normal to see this LED illuminate particularly under fast braking conditions with a heavy load.

red LED normally off

yellow LED normally off

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8.3 7 segment display on the front panel

This display shows the state of the servo-amplifier and motor. The alarm d has the highest priority (following C, 7, 6, 5 etc.). If some alarms take place simultaneously, only the one with the higher priority will be displayed. A alarm reset is only possible by switching off the servo-amplifier supply.

Servo-amplifier powered on and enable contact closed

Servo-amplifier powered on, enable contact closed and motor at zero position

Servo-amplifier powered on and enable contact open

Servo-amplifier powered on, enable contact open and motor at zero position

Continuous current limit reached

Motor over temperature fault (alarm latched)

Amplifier heatsink over temperature fault. Alarm latched

Resolver digital converter not functioning. Alarm latched

Resolver feedback fault. Alarm latched

Power amplifier section faulty.

Decimal point displayed with any other display to show clockwise motor rotation.

Motor connection failure

Ground fault detected. only if option fitted

Figure 22. Seven segment display codes

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8.3.1 Checking the electrical rotation sense of the resolver

The decimal point of the 7 segment display lights up when the motor shaft is turned clockwise.

Figure 23. Electrical rotation sense of the resolver

If the decimal point lights up during anti-clockwise rotation, connections to the upper half of connector P2 pin 7 (COS1) and pin 6 (COS2) must be reversed.

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8.4 Determining the motor phases

This operation must only be done when the three-phase motor order is unknown (motor prototype or no documentation). It is necessary to have a DC supply of about 3A. and of sufficient voltage to move the motor but not in excess of the motor rated voltage.

The procedure is as follows:

1 Define arbitrarily the Phase U as one of the 3 motor phases. 2 Connect U to

“+”

and a

2nd phase

motor to

“-”

of the DC supply. 3 Switch supply on. The shaft will move to a stable position. 4 Mark the new shaft position with a pencil, at top dead centre. 5 Disconnect the “-” of the supply from the 6 connect the “-” to the

3rd phase

motor. Observe the axis rotation direction.

2nd phase

of the motor and

7 Mark with a pencil the new shaft axis position.

With the help of the table below, determine the 2 unknown motor phases.

sense of axis rotation 2nd phase 3rd phase clockwise anti-clockwise

V W W V

Table 9: Motor Phase Determination

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8.5 Switch the Servo Amplifier on with a Motor and Optimization

8.5.1 Preparation before switching the mains voltage on

a) Disconnect motor from the machine.

The 3 phases motor should be again connected to the servo-amplifier. Check if the axis is stopped and release the motor brake.

b) Check the following connections:

• motor cable to the backplane

• resolver cable is plugged into P2 (Upper)

• control signals connected to P10 pins 3 and 4, +ve to pin 3, 0v to pin 4.

• enable contact connected to P12 pins 3 and 4.

c) Reduce the maximum current setting of the servo-amplifier us ing the Q-

DRIVE software. Save this value using the key

< F2 >

d) Set the proportional and integral gains to 25 and 10 respectively. Also set t he

resolver shift angle to 90 degrees. Save these values using

the < F2 > key

e) Open the enable contact connected on P12 pins 3and 4.

8.5.2 Switching the mains voltage on

a) Switch on the amplifier. b) The 7 segment display should indicate “1”. c) Set a positive speed voltage (about 1 V) to the servo-amplifier and close the

enable contact. The 7 segment display should now show “0”.

d) Increase the

max. current

parameter until the motor starts running. If the motor doesn't turn or turns very slowly, check the sta te of the motor brake if fitted.

e) Reverse the polarity of the speed command and check that the motor turns in

the reverse direction.

f) Set the

Save the

max. current

parameter to the initial state.

using the key <F2>.

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8.6 Compensating the speed controller

Optimizing the performance of the motor over the whole speed range can be achieved by adjusting the drive amplifiers

Proportional Gain

Connect a Personal computer to the amplifier and run the QDRIVE.EXE configuration program:

a) Set the value of both proportional (KP) and integral (KI) gain to a value of

10, this represents a very low gain setting.

b) Connect an oscilloscope between measuring points on J1, pins 9 and 10, pin

9 is signal and pin 10 is ground. c) Switch on the servo-amplifier and close the enable contact. d) Apply a low command speed voltage (<100 m V)

Integral Gain

and

parameters.

e) Increase the valu e of the

Integral Gain

parameter whilst ensuring that the

following factors are maintained:

i good static torque i smooth shaft rotation

f) Apply a step function of 2 v olts to the command input and monitor the

response of the drive using an oscilloscope. One of the three following results

will occur:

i The signal shows several oscillations, this means the system is under

damped, in this case increase the

Proportional Gain

value

ii The motor is noisy, this means that the motor is over damped, in which

case decrease the

Proportional Gain

value

iii The signal shows only one small overshoot, this indicates critical

damping has been achieved and therefore the speed loop overshoot is optimized

g) When the

f iii)

condition is achieved, save the gains obtained with key <F2>.

8.6.1 Offset and speed compensation Offset compensation

The setting of the servo-amplifier speed offset is done with the

offset control

parameter in the QDRIVE.EXE software. The setting of the offset can be done with or without the position controller. If a position controller, such a Quin PTS unit, is used then all of the controller gain parameters must be set to zero. Having set the controller gain parameters to zero enable the controller output and adjust the servo-amplifier offset compensation value until the motor stops moving. There will probably be a range of values where the motor appears to be stationary, find the limits of this range and set the value to the mid point. To set the offset value without a controller attached then short out the command input terminals and adjust the offset value. Again there will probably be a range of values which result in

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Issue 1.5 Q-Drive Installation Manual

the motor remaining stationary, find the limits of the range and set the value to the mid point. Press the < F2 > key to save this value.

b) Speed compensation

The Speed factor parameter allows adjustmen t of the motor speed from 6000 rpm to + 6000 rpm.

Press the <F2> key to save this value.

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8.7 Trouble Shooting

The following table shows the most frequent troubles and their causes.

No Trouble Possible cause

1 LED “OVER I”

switched on

2 Display 2 limit of continuous current reached

3 Display 3 motor overloaded

4 Display 4 servo-amplifier overloaded

5 Display 5 resolver conversion circuit failure

6 Display 6 resolver failure - resolver wiring failure 7 Display 7 appears with OVER I LED

8 Display C motor connection failure 9 Display d detection of a motor ground defect (option) with

10 Motor doesn't turn. Display

shows 0 when speed command is applied

short-circuit between 2 motor terminals

Resolver Shift Angle

- badly wired or loose connection of wires for motor thermal switch

- cooling fan failure

Resolver Shift Angle

- brake fuse failure or missing

- appears in case of over-voltage or supply missing

auto-transformer

- max. current of servo-amplifier limited too low

- motor brake engaged

- speed reference short-circuited by

parameter incorrect

REF

Jumper

11 Motor rotation is not smooth

12 Motor turns in wrong

direction

Table 10: Q-Drive Trouble Shooting

Motor pole pairs

- Motor wiring on terminal U, V, W not in the correct sequence

Command signal is wired incorrectly, Reverse connections to PP10.3 and P10.4 and change the setting of jumper J3.

parameter incorrect

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Issue 1.5 Q-Drive Installation Manual

9. Testing the System

9.1 General

This section describes some si mple test procedures for some parts of the Q-Driv e systems. These do not comprise a full system test, but may be useful to verify the basic operation of the system, the motor and the encoder.

All these tests require the use of a personal computer w ith a serial port, preferably RS422. Most test can be carried out on the PC but additional test equipment may be necessary. The test are given in a logical sequence i.e . it is not possible to check the resolver interface if the Serial communications do not work and the encoder simulator will not generate signals until the resolver interface works.

9.2 Serial port

The serial port only transmits data after it receives a request from the QDRIVE.EXE software, this means that it is necessary to connect a personal computer (PC) and run the QDRIVE.EXE software in order to test the serial port. Ensure that the program is requesting data from the axis number which the drive is set to, i.e. if the drive is set to address 7 then the program should request data from axis 7. If the serial communications are working correctly then the program will display the line:

“Axe 7 ONLINE”

Press the <F2> key this should make the 7 segment display on the front of the drive flash. If there is no response from the drive then check the connections between the PC and the drive. If there is still no response from the drive then check the serial data signals using a data analyser or an oscilloscope, to verify whether the drive is actually responding to the characters being sent to it. The serial data analyser should be set for 9600 Baud, 8 data bits, no parity and 1 stop bit.

9.3 Resolver Interface

Connect a resolver to the drive and monitor the 6 of the produce an updating display every time the resolver shaft is moved then the drive will need to be returned to Quin Systems Ltd. for repair.

QDRIVE.EXE

program whilst turning the shaft of the resolver. If this does not

“Resolver Position”

read out on page

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Q-Drive Installation Manual Issue 1.5

9.4 Encoder Simulator

The operation of the encoder simulator can be checked using a control system such as a Quin Systems PTS unit. Connect the encoder output of the drive to the encoder input on a PTS system and switch on both the drive and PTS system. Using a terminal connected to the PTS type the command “DM” and then turn the shaft of the motor.

Whilst monitoring the second column of data turn the shaft in one direction, this should produce positional data climbing in a positive or negative direction, turning the shaft in the opposite direction should take the data back to zero and then climbing in the opposite direction.

If the encoder position counts up and down by only one count, then one of the two phases of the encoder signals is not being detected. If the encoder position value does not change at all, then either or both phase signals are missing. If the position tends to count either up or down whichever direction the shaft is turned, then the track A and B signals are mixed up with their complementary signals, such that instead of the system receiving two signals in quadrature, it always receives two signals in opposite phase regardless of the shaft direction. These problems can be confirmed by monitoring the encoder signals with an oscilloscope.

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Issue 1.5 Q-Drive Installation Manual

4400 K

10. Configurations

10.1 General

This section gives details of the configuration options on all the drive boards used in the Q-Drive range of servo amplifiers, although the settings are not normally changed. The amplifiers are set up as described below when shipped.

10.2 Resolver Ratio

The ratio and the amplitude to the primary of the resolver are determined by resistors RSIN, RCOS and RREF. Standard fitting: RSIN = RCOS = 0 (bridge) for a resolver ratio of 2:1 RREF = 12 k ohm to obtain 4V

Special cases: Use the following formula: Where: - RREF is expressed in k ohm

to the resolver primary

eff

---------- Vref

10–

Rref

where: -Vref is rms voltage applied to the primary of the resolver. Vref max. = 6 V To calculate the values of Rsin and Rcos use the following formula, where Rcos and Rsin are expressed in k ohm

Rsin Rcos

Kr is the resolver ratio (Resolver ratio 2 : 1 corresponds to Kr = 0,5)

-----------------------10 Vref–

r×

100–==

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Q-Drive Installation Manual Issue 1.5

10.3 Amplifier Configuration

The location of the solder bridges and jumper links used for configuration and the fuse locations is given in Figure 26. on page 64 .

Name Element Function

SAD Solder bridge

VITCRT Solder bridge

BD1 BD2

BD3 BD4 BDOUT

INCABS Solder bridge

Solder bridge RS 232 serial link baud rate:

Solder bridge Synchronous link (option):

Table 11: Amplifier Configuration

1-2

: analogue command voltage (default)

2-3

: numeric command vo lta ge th r ough RS 232 se rial

link or through synchronous link (option)

1-2

: speed regulation (standard)

2-3

: current regulation

only BD2 soldered: 9600 Bd (default) only BD1 soldered: 19200 Bd

only BD3 and BDOUT soldered: internal clock at 38400 Hz only BD4 soldered: external clock

2-3

: encoder simulation available at the encoder

output connector (default)

1-2

: absolute position available th rough the se rial link

(option)

10.4 Servo-amplifier fuses

The following fuses are factory fitted on all Q-Dri ve units, the loca tion of the fuses can be found in Figure 26. on page 64

Servo-amplifier type QDV-1-6 QDV-1-10

DC-BUS 10 AT 15 AT 20 AT Braking module 4 AF 5 AF 8 AF Supply 1 AT 1 AT 1 AT

Table 12: Amplifier Fuses

QDV-1-18

DC-BUS Fuse (F1)

“Littlefuse 326" are used on the DC-BUS. Dimensions: 6,3 x 32 mm.

Braking module fuse (FFR)

For units type QDV-1-6, “Wickmann 19194" type fuses are used. Dimensions: 5 x 20 mm.

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Issue 1.5 Q-Drive Installation Manual

For unit types QDV-1-10 and -18, “Littlefuse 314" type fuses are used. Dimensions: 6,3 x 32 mm.

Supply fuse(FHT)

All QDV-1 drives use a 20mm fuse

Warning:

Blown fuses should only be replaced with the same type and rating fuse and only after the fault has been corrected. This work should be undertaken by qualified personnel.

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Q-Drive Installation Manual Issue 1.5

10.5 Backplane configuration

The various jumpers available on the Q-drive backplane are detailed in Table 13: below. Figure 24. on page 61 shows the jumpers in their default positions

Name Jumper Function

Test points J1

“Valid” bypass & RS422 terminators

Ground reference

Address range

Tx inversion

Rx inversion

: Not used

: ISMO

: COMO

: VEMO

2, 4, 6, 8 & 10 1-2

: By-pass “Valid” opto isolator.(Default)

3-4

: 0V connection when “Valid” is by-passed.(Default)

5-6

: RS422 transmit terminator.(Default)

7-8

: RS422 receive terminator.(Default)

1-2

: “S-” differential input connected to 0V (P10-4)

(Default)

2-3

: “S+” differential input connected to 0V(P10-3)

1-2

: Address range 1 to 15 (Default)

2-3

: Address range 16 to 31

1-3 & 2-4 1-2 & 3-4

Table 13: Backplane configuration Jumpers

: Gnd connection

: Tx and /Tx non-inverted (Default) : Tx & /Tx inverted

: Rx and /Rx non-inverted (Default) : Rx & /Rx inverted

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Issue 1.5 Q-Drive Installation Manual

SW1

P12

J4 J3 J2

P11

P10

RESOLVER

ENCODER

RS422/232

J6 J5

P2 Upper

P2 Lower

RS422

Figure 24. Backplane configuration

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Q-Drive Installation Manual Issue 1.5

10.6 Backplane Fuse

The backplane is fitted with a single fuse rated at 500mA fast blow. This fuse is used to protect the auxiliary supply when this option is fitted. It is accessed by removing the front panel and extracting the drive amplifier card, the fuse can then be seen in the lower left hand corner as shown in Figure 25. below.

IMPORTANT: Ensure that the auxiliary power is removed from the drive before attempting to replace this fuse.

FUSE F1

Connector

for optional

fans

Fan

SUPPLY

T S R

Figure 25. Backplane fuse

EARTH

MOTOR

W V U

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Issue 1.5 Q-Drive Installation Manual

11. Options List

Absolute position

The resolver and associated circuits can be permanently powered by an external +/12V battery supply. This option is wired onto the Q-Drive backplane using connectors P11 and P12

Ground Defect

With this option it is possible to detect a ground defect in the supply but will only work with an auto-transformer

220V Auxiliary Supply

An auxiliary supply can be wired into the drive using the connections marked R’ and S’. This auxiliary supply is used to maintain the power to the low voltage part of the drive so that positional info rmati on will not be lost i n the eve nt that the main c ontactor drops out, it will not supply power to the amplifier part of the drive. It is vitally important that the phase wired to R’ is the same phase that is wired to R and similarly that the phase wired to S’ is the same phase that is wired to S. A typical connection diagram is shown in chapter 3

Multi-Modules

Option 4 RDC modules. Each module define a maximum speed motor for a command of +/- 10V.Ex: 6000 rpm - 3000 rpm - 1500 rpm - 700 rpm

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Q-Drive Installation Manual Issue 1.5

Layout of Drive Amplifier

FFR

BO4

BO3

BO2

BO1

SAD

FHT

TRI

SAD

IMAX

VITCRT

INCABS

MO01

RCOS RSIN RREF

Figure 26. Drive amplifier jumper & fuse locations

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Issue 1.5 Q-Drive Installation Manual

to Connect

Use P3 or P4

to PC COM port

Screened Resolver cable

Screened Motor Cable

RS422

P2 Upper

P2 Lower

ENCODER

RESOLVER

P10 P11 P12

SW1

RS422/232

Screened Encoder cable

Interface

Diagnostic

Connect to PC COM

port or dumb terminal

PTS Control System

transformer

1ø isolating

p m

MCB

2ø 3 A

Filter

1ø 3A

uto3ø A

transformer

p m

MCB

3ø 16 A

ø2

ø1

Filter

3ø 16A

ø3

Figure 27. Complete wiring plan

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This Page is intentionally Left Blank

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Issue 1.5 Q-Drive Installation Manual

Index

acceleration 31 alarm

battery undervoltage 45 earth defect 44 EEPROM fault 44 endswitch 45 heatsink thermostat 45 I2t current limit 45 link motor 45 motor thermostat 45 power fault 45 RDC fault 44 resolver fault 44 software watchdog 45

torque enable 45 alarm latch 40 analogue readings 9 average torque 31

backlash 32 braking 47

cable lengths 14 characteristics 2 choice of motor 30 choosing a motor 30 configuration program 33 connections

earth 26

mains supply 24

motor and drive 27, 28 connectors

aux supply 21

earth 20

encoder 16

motor 20

resolver 15

RS232/RS422 18

signals 19

three phase 20 cooling 7 couplings 32

DC brushless 1 depth 7 direction stop 38 directives 11 display 38 drive connections 27, 28 drive parameters 33 drive performance 9

earth connections 26 electrical installation 23 EMC Directive 11 emergency stop 29 encoder

cables 16 faults 56 testing 56

encoder resolution 39

fixing centres 10 friction 31 function key

F2 33 F4 34 F7 44

guards 29

height 7 humidity 7

inertia 31 installation

earth connections 26

mains supply 24 integral gain (KI) 36 introduction 1

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Q-Drive Installation Manual Issue 1.5

LED’s 47

machine guards 29 Machinery Directive 11 mains supply installation 24 maintaining position information 29 max nominal current 43 max peak current 43 maximum current 36 motor connections 27, 28 motor inertia 31 motor installation 32 motor phases 50 motor selection 30 motor thermostat 37 mounting details 10 mounting the motor 32

nominal current 37

offset compensation 52 over current 47

pair of motor poles 37 parameters

page 0 36 page 1 37 page 2 39 page 3 41 page 6 41 page 8 42 page 9 43

status and alarm page 44 phase advance 37 power down 29 proportional gain (KP) 36

QDRIVE.EXE

online 34

password 34

r.m.s. torque 31 read file 35 reference marker width 39 reference shift 39 relay function 38 resolver

rotational sense 49 resolver position 42 resolver shift angle 37 revolution counter 42 RS422 address 38

safety

guards 29

limit switches 29 save settings 35 serial link 33 seven segment display 48 shutdown 29 software watchdog 40 specification 9

electrical 8

environmental 7

mechanical 7

power supply 7 speed compensation 52 speed factor 36 speed module 40 speed offset 38 speed/resolution 39 system tests 55

temperature range 7 testing

encoder 56

general 55

serial port 55 testing the encoder 56 torque 30 torque calculation 30 trouble shooting 54

velocity profile 31

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Issue 1.5 Q-Drive Installation Manual

weight 7 width 7 wiring faults 56

Quin Q-drive Installation & User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. Introduction

1.1 Q-Drive Characteristics

1.2 EMC Compliance

Figure 1. EMC filtering

2. Unpacking and Inspection

3. Drive Specifications

3.1 Mechanical specification

3.2 Environmental specification

3.3 Power supply specification

3.4 Electrical Specification

3.4.1 General data for all types

3.4.2 Drive Performance Specification

Table 1: Drive Data

3.4.3 Analogue readings on the motherboard

Table 2: Test Points

3.5 Mounting Details

Figure 2. Fixing centres for the Q-Drive.

3.6 Relevant Directives

4. Connections

4.1 General

Figure 3. Connections

4.1.1 Wiring and connectors

4.1.2 Cable lengths and cross-sections

Table 3: Cable Sizes

4.2 Low Voltage Connections

4.2.1 P2 Upper: Resolver

Table 4: P2 Upper, Resolver Input Connections

Figure 4. P2 Upper: resolver connector

4.2.2 P2 Lower: Encoder

Table 5: P2 Lower, Encoder Output Connections

Figure 5. P2 Lower: encoder connector

4.2.3 P4 RS422 Out / RS232

Table 6: P4 RS422 Out / RS232 Connections

4.2.4 P3 RS422 In

Table 7: P3 to P4 RS422 Daisy Chain Connections

4.2.5 P10, P11 & P12

Table 8: P10, P11, P12 Connections

Figure 6. P10, P11, P12: discrete signals

4.3 High Voltage Connections

4.3.1 P7, Three Phase In

4.3.2 P8, Earth Terminals

4.3.3 P9, Motor

Figure 7. P7, P8, P9: power connectors

4.3.4 Wago Spring Terminals

Figure 8. Wago spring terminals

5. Electrical Installation

5.1 General

Figure 9. General installation arrangement

5.2 Mains supply

5.3 Auxiliary Supply

Figure 10. Auxiliary supply connection

5.4 Earth connections

Figure 11. System earthing

5.5 Connecting the motor to the drive

5.6 Connecting the drive to the controller

6. Safety - Using Guards and Limits

6.1 Choosing a motor

6.2 Mounting the motor

6.3 Connecting the motor to the load

7. Drive Parameters

7.1 Serial Link

7.2 Getting Around the Configuration Program

Figure 12. Q-Drive.exe: password entry page

7.3 Page 0 Parameters

Figure 14. Q-Drive.exe: page 0 parameters.

7.4 Page 1 Parameters

Figure 15. Q-Drive.exe: page 1 parameters

7.5 Page 2 Parameters

Figure 16. Q-Drive.exe: page 2 parameters

7.6 Page 3 parameters

Figure 17. Q-Drive.exe: page 3 parameters

7.7 Page 6 parameters

Figure 18. Q-Drive.exe: page 6 parameters

7.8 Page 8 parameters

Figure 19. Q-Drive.exe: page 8 parameters

7.9 Page 9 parameters