Unitek TVD6.2-RS User Manual
MANUAL
G m b H
Industriestraße 1
D-71397 Leutenbach 3 - Nellmersbach
3-Phase-Transistor-Servo-Drive
for
AC-Synchro-Servomotors
with
Resolver
TVD6.2-RS
Version
0899-1
Transistor-Servo-Drive TVD6.2-RS
Content
1 Basic-Information Seite
Safety Advice 3
General Information 4
Application 5
Characteristics 6
Technical Data 7
2 Mechanical Installation
Dimensions 8, 9
Structure of Device 10
Mounting Advice 11
3 Electrical Installation
Connection Overview 12
Connection Plan 13
Earthing Plan EMC-Advice 14
Mains Connection 15,16
Motor Connection 17
Control Connection 18 to 23
Signals 24, 25
Connector Plan 26, 27, 28
4 Device Overview
Resolver 29
Component Positions 30
Block Diagram 31
Frontpanel 32
Adjustment Functions 33
Signals 34
5 Adjustment
Adjustment Advice 35
Nominal Value 36
Actual Value 37
Current 38
Speed Controller 39 to 41
6 Getting Started
Default Setup 42
Getting Started 43
7 Fault Finding
LED Indications 44
Function Faults 45
Function Diagram 46
Encoder Signals 47
8 Guarantee 48
9 Protocol 49
2
1Basic-Information
Electronic devices always involve the risk of failure.
Caution High Voltage
AC 460V~, DC 750V=
This manual has to be read carefully and must be understood
by experts before installing or starting the device.
If there are any doubts call your trader or the manufacturer.
The TVD6 series is designed to regulate electrical currents;
protection standard IP00.
Instructions and rules:
Safety Advice
the devices and accessory components must be set up and connected ac
cording to the local technical regulations. In Germany they are:
- EU-machine guide lines 89/392/EWG,84/528/EWG,86/663/EWG
- VDE-regulation VDE 100, VDE 110, VDE 160 und VDE 0113
- TÜV-regulations
- Regulations of the professional guild.
The user has to assure that:
after
- a failure of the device
- an incorrect handling
- a failure of the control unit etc.
he drive is brought to a secure operating condition.
Machines and installations are to be provided with supervisory and safety
equipment, that is independent of the device.
Adjustment
-
t
- only by qualified personnel
- adher to safety regulations
Installation work
- only when disconnected from all power lines.
QS
The devices are archived by the manufacturer with serial number and their
test specifications.
CE
The EU-guide line 89/336/EWG with the EMC-Regulations EN50081-2 and
EN50082-2 are observed.
TVD6.2-400-x-RS 3
Transistor-Servo-Drive TVD6.2-RS
General Information
The transistor 3-phase current servo amplifier SERVO-TVD6.2 forms toget
her with the brushless direct current motor (synchro-servo (EC-) motor) a
propulsion unit distinguished by its rear-zero maintenance and by its high
dynamic control range.
The drive displays the wellknown good regulation characteristics of the
direct current drives without the disadvantages of the carbon brush wear
and of the communication limits.
The rotor intertia is notably lower and the power envelope is greater
than with equally constructed DC-motors. The result are up to 5 times
higher acceleration values. As the generated heat in the motor occurs in
the stator, the ec-motors are always designed to the protection standard IP
65.
The brushless direct current motor is electrically a synchro-motor with a
permanent magnet rotor and 3-phase stator.
The physical characteristics correspond to those of the direct current
motors, that is, the current is proportional to the torque and the voltage is
proportional to the speed. As both values can be measured precisely, the
-
servo-control unit can be mounted easily. It is possible to control the speed
from the motor voltage, but in order to achieve exact regulation it is prefe
rable touse atways a tachometer regulation.
The tachometer actual value is generated from the sensor unit (resolver).
In the speed controller (P-I-controller) of the servo-drive is the differenz of
nominal value and actual value amplified. The result is the current nomi
nal value, which is transferred by the resolver signal onto the three phase
current controllers such that the stator magnetic field leads ca. 90° electri
cally the rotor magnetic field.
This field frequency is not a controlled variable, it adjusts istself automati
cally. The motor currents, following the resolver interpretation, form a si
ne-waved rotating field.
As occurs in all DC-, AC or ec-servo-amplifiers which are supplied by the
dc-bus, the feed-back of the energy must be observed when braking in the
dc-bus (especially where stroke or eccentric cycles are concerned). The
bleeder switch is set for a 3 % duty cycle. The ballast-resistors have to be
mounted externally.
-
-
-
-
-
Information:
For lower power >>> UNITEK Serie TVD3.2
100V upto 10/20A
For higher power >>> UNITEK Serie MODULA
400V upto 100/200A
4
1 Basic-Information
Application :
for all kinds of machines up to 8KW drive power especially as 4Q-servodrive in travel axes with
-high dynamic acceleration and deceleration cycles
- great regulation range
- high efficiency
- small motor size
- even and smooth travel
for speed or torque regulation or
combined speed-torque regulation with or without superposed position
controller.
Drives with constand speed as in conveyors, lead screw drives, pumps or
divider units.
Synchro-Servo-drives are smaller than other drives.
For Use in:
componenet insertation machines, metall-sheet working machines
machine tools, plastic working machines, assembly machines,
knitting and sewing machines, textile working machines, grinding
machines,
wood and stone working machines, food processing machines,
robots and manipulators, storage across machines, Extruder, Kalander,
and many other machines and installations
Application
Notice:
In bl-drives which mainly require deceleration
for example:
- winding machines, lifts, great centrifugal masses
the braking energy will be annihilated in the ballast circuit
or re-feded to the mains using an external dc-bus converter.
With multiple-axes an energy compensation is possible.
The motors are
- designed to protection standard IP 65
- compact
- suitable in rough surroundings
- suitable with high dynamic overload
- service-free
TVD6.2-400-x-RS 5
Transistor-Servo-Drive TVD6.2-RS
Characteristic
Construction:
- cubicle-mount or 6HE-plug-in unit according to the
VDE- DIN- and EU- regulations.
- standard analog regulation electronics.
- power electronics for 5A, 10A, 16A and 25A.
- wide-band chopper supply unit for the auxiliary voltages.
- power supply unit on the back circuit board .
Galvanic isolation between
- power section and covering
- power section and regulation electronics
- regulation electronics and contol inputs
The leakage distances are according to the VDE regulations.
There are used:
- fully isolated six-pack IGBT-power semiconductors, generous
dimensioning.
- only industrial standard components are used
- All ICs with external connections are mouted on high-quality sockets
- LED displays
- 16 digit binary switches for PI-setup of the speed regulator
- precision trimers for fine adjustment
- plug-in jumpers for system setup.
Characteristics:
* Direct power supply 400V~
* Electronic starting current limitation
* 2 differential reference inputs
* Accelleration and decelleration ramp with second nominal value
* Speed and torque regulation
* Static and dynamic current limit
* Current nominal value output
* Test connectors for current and speed
* Galvanic isolated logic in- and outputs
* Enable and end-switch logic
* Integral disabling
* Quick stop
* Mains failure braking
* Temperature control for motor and device
* Parameter adjustments without soldering
* 10 pin control plug
* Incremental encoder output
6
1Basic-Information
Power connection:
directly on the mains 1x 400V~
3x 400V~
maximum: 460V~
Option :connection voltage < 300V~ >>> notice the advise
Technical data:
type TVD6.2-400- 5 10 16 25
output voltage max. V~eff. 400 400 400 400
output standstill current
duration A= 5 10 16 25
peak A= 10 20 32 40
electrical power max kW 2 4 6,4 10
rapid fuses
built-in A 20 20 20 20
measurements
plug-in device BxH 16TE 16TE 16TE 24TE 6HE
Technical Data
cooling 60% ED convect convect fan fan
100% ED convect fan fan
fan
switch cabinet mounting BxHxT see illustrations of the dimensions
Common specifications:
protection standard IP 00
device layout VDE 0100 group C
VDE 0160
humidity stress class F according to DIN 40040
operation altitude < 1000m above NN
operation range 0 ... 45°C (with external fan 0 ... 35°C)
expanded operation range up to 60° C red. 2%/ °C
bearing reach -30°C up to + 80°C
speed controller
control precision (excl. tacho error) ± 0,1%
control range > 1: 1000
reference inputs ± 10V=
logic inputs +10 ... +30V=
logic outputs >+14V, 6mA
Caution:
When order please specify:
notice cyclic duration factor >>> external cooling system with 100%
several axes with >=10A
within one rack >>> external cooling system recommended
input voltages <300V~ >>> modify power supply unit
exact torque control >>> current controller with PI-wiring
high centrifugal mass >>> external ballast resistor
TVD6.2-400-x-RS 7
Transistor-Servo-Drive TVD6.2-RS
Dimensions
Device Wanne Wanne or mounting angles
Compact- 10 and 16A 25A
8
2 Mechanical Installation
Multi-axes combinations
Dimensions
Dimensions 6HE [mm]
plug-in units
dimension 1 2 3 4 5
A 1xE+3 2xE+3 3xE+3 4xE+3 5xE+3
B 1xE+40 2xE+40 3xE+40 4xE+40 5xE+40
C 1xE+55 2xE+55 3xE+55 4xE+55 5xE+55
Unit-grid dimension
10 and 16 A Device E= 81,28 mm
25 A Device E= 121,92 mm
Mounting height 255 mm
TVD6.2-400-x-RS 9
Transistor-Servo-Drive TVD6.2-RS
X31
TVD6
F1
2
X11
Entfernen
bei externem
Ballastwiederstand
X8 nur bei
Ausführung
IN, RS
80,0
D9
D15
I1
65
32
X7,X8
X11
X11
X11
X31
X1
X2
X3
X11X11
355,0
2
32
2
1
X8
X7
16
17 32
D1
Structure of Device
Power supply unit back panel with plug-in-device (without rack)
Power supply unit setup
Incremental encoder output X8 Jumper J2 IC I7
external ballast resistor Bridge D open cable 1
10
Rack
Hight unit : 6HE
Wide unit : 10/16A = 16TE, 25A = 24TE
Mixed 6HE, 3HE (TVD3) racks on request
2 Mechanical Installation
mounting height 255mm Compact device 10/16A Compakt device 25A (sw)
Compact device 25A (w) Multi-axes combination
Mounting Advice
Free space to switch-cabinet wall min. 100mm
Fixing dimensions [mm]
compact device
current A B C D E screw
5,10, 16 Wanne 95 335 M4
5-w Wanne 135 335 M4
25 sw mounting angles 180 158
190,555 M5
multi-axes combinations
mounting angles A C D E screw
wall mounting n x E+60 n x E+40 190,5 55 M5
front mounting with19" systems
E at <=16A = 81,28 mm n =number of plug-in units
E at 25A = 121,92 mm
Dissipation power at maximum power
rated dissipation power[W]
current Device supply unit fuse M-choke filter
5A 70 20 xx xx
xx
10A 90 20 xx xx xx
16A 125 30 xx xx xx
25A 180 43 xx xx xx
TVD6.2-400-x-RS 11
Transistor-Servo-Drive TVD6.2-RS
Connection Overview
12
Chokes
device- mains filter motor chokes ferrite core
rated current 1ph 3ph
5A FE1-10 FE3-10 MDD 1,3 a EMI742 70107
10A FE1-16 FE3-16 MDD 1,6 a EMI742 70107
16A FE1-16 FE3-16 MDD 2 b EMI742 70107
25A - FE3-25 MDD 2,5 b EMI742 70107
3 Electrical Installation
Connection Plans
Connection compact device: only left diagram without internal connections
Connection multi-axes combination :
One or more axes with power supply unit, plus one or more axes without own power supply unit
power supply unit- positions free choosable
TVD6.2-400-x-RS 13
Transistor-Servo-Drive TVD6.2-RS
Earthing Plan EMC-Advice
The devices are according to EU-regulation 89/336/EWG, the standards EN 50081-2 and
prEN 50082-2 will be observed under the following conditions.
Device,transformer,motor chokes and mains filter fixed on a 500x500x2 mm mounting
board.
Mounting board and motor frame connected to gnd with a 10mm² wire.
Devices reference X1:13 connected to mounting board with a 2,5mm² wire.
Device-PE-screw connected to mounting board with a 50mm long 4mm² line.
Single-phase power supply:
mains filter Type : up to 16A = FE1-16
linelength device - mains filter <100mm
Three-phase power supply:
mains filter Type : up to 16A = FE3-16
up to 25A = FE3-25
linelength transformer - mains filter <500mm
linelength device - mains filter <100mm
Motor connection:
motor chokes Type : 10A = MDD1,6-10
16A = MDDxx-20
25A = MDDxx-30
motor line 1,5m long, 4core shielded. Shielding on device side fixed to mounting
board and on motor side flächig connected to PE.
14
3 Electrical Installation
Caution:
The connection advice concerning the individual attachments of the con
nections to the plug numbers or terminals are binding.
All further advices to this are not binding.
The input and output lines can be altered or completed in consideration of
the electrical regulations.
Notice:
- connection advice and operation advice
- local technical regulations
- EU-machine regulation 89/392/EWG
-
Input filter:
see CE-advice (page 14)
short line length between input filter and device
or shielded line
Mains Connection
FI-switch
- design to DIN VDE 0664
- tripping current > 200mA
- only combined with other protective measure
Connection to 400 V~ mains
Alternating voltage connection 1x400V~ 50/60Hz
compact device up to 10A.
multi axis combination up to 20A
Three-phase current-connection 3x400V~ 50/60Hz
with >10A (multi axes rack >20A) necessary
dimensioning 5/10A 16A 25A max. 30A
wire cross section mm² 0.75 1.5 2.5 2.5
fusing
blow-out fuse AF 10 16 25 30
automatic circuit
breaker A 10 16 25 25
electronical starting current limitation >>> max. current 7A~
TVD6.2-400-x-RS 15
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