ABB 8 Series, Use And Installation Manual

Page 1: ...s servomotors SERIES 8 and digital convertors BHL D In conformity with EEC Directives and mark Use and installation manual Ref MAN1U04 9607 GB Updating 02 Edition March 1997 ABB Servomotors S r l ABB ABB Servomotors S r l ...

Page 2: ... Servomotors S r l Asti Printed in Italy This document contains confidential information belonging to ABB Servomotors S r l When accepting this document the receiver commits himself not to reproduce copy with any system transmit to third parties the document itself and the information therein contained as a whole or partially and not to allow anyone else for no reason to proceed as described above...

Page 3: ...ves and matching servomotor convertor CHAPTER 3 INSTALLATION OF THE DRIVE 3 1 Installation of convertors BHL D 3 2 Installation of servomotors SERIES 8 3 3 Guidelines on the application of electromagnetic compatibility 3 4 References to safety regulations CHAPTER 4 START UP AND ADJUSTMENT OF THE DRIVE 4 1 Introduction 4 2 How to use the keyboard 4 3 External connections 4 4 Indications for connect...

Page 4: ...uments cited in paragraph 1 3 1 2 1 EMC Electro Magnetic Compatibility the capability of a device an apparatus or of a system to function in its electromagnetic environment satisfactorily without introducing electromagnetic disturbances not acceptable for what is placed in that environment in practice this expression includes all requirements both of emission disturbances provoked by the apparatus...

Page 5: ...CHAPTER 1 INTRODUCTION MANIU04 9607 GB 03 97 Page 1 2 Fig 1 1 ...

Page 6: ...s a single commercial unit 1 2 8 INSTALLATION union made up of several apparatus and or systems combined together so as to obtain a specific aim but not destined to be put on the market as a single commercial unit 1 2 9 COMPONENT element used for the realization of an apparatus but that cannot be regarded as an apparatus itself since it has no intrinsic function for the end user Simple components ...

Page 7: ...ences in the text are in square brackets 1 3 1 Electro Magnetic Compatibility Directive 1 Community Directive 89 336 EEC dtd 3 May 1989 related to Electro Magnetic Compatibility and following modifications 92 31 EEC and 93 68 EEC 2 Italian Decree Law 4 December 1992 n 476 Actuation of the directive 89 336 EEC of the Council on 3 May 1989 on the approximation of the laws of the member states relati...

Page 8: ...tion 1 general directives 1 4 Compliance with the EMC Directives and mark 1 4 1 Conditions for the compliance with the EMC directives of the drives made up of servomotors SERIES 8 and convertors SERIES BHL D The compliance of the drives defined in the title of this paragraphwith directives 1 2 3 on Electro Magnetic Compatibility is valid only under the conditions listed below 1 4 1 1 Drives define...

Page 9: ...e the manufacturer s declaration also known as Declaration of Incorporation Manufacturer s Declaration In order to comply with the Machine Directive MD 89 392 EEC and further amendments ABB Servomotors declares that drives made up of servomotors SERIES 8 and convertors series BHL D must be installed according to its instructions and must not be started up until the machinery into which they are to...

Page 10: ...o our Customer Service in order to make as quick as possible the diagnostics of the fault and its elimination Therefore except for some special cases the repairs foresees the intervention of specialized personnel 1 6 2 Servomotor plate 1 6 3 Convertor plate ABB Servomotors S r l MADE IN ITALY TYPE _________________________________________ S N _____________ PART NUMBER _____________________________...

Page 11: ..._____ FACT HW LEV ____________ D S LAST HW HW HW HW HW D D D 0 INSTAL S s s Is FACT SW LEV ____________ D S LAST SW SW SW SW SW D D D D INSTAL S S S S 1 6 4 Customer Service Address your requests for details service or spare parts to ABB Servomotors S r l Customer Service Frazione Stazione Portaconiaro 97 C I 14100 ASTI ITALY Telephone 39 141 476 456 Telefax 39 141 296 455 ...

Page 12: ...d 6000 RPM Table 2 1 contains some data concerning servomotors of this series complete data regarding dimensions mechanical and electrical characteristics and performances of these servomotors can be found in the catalogue 3AT K 93056 R004 ED 2 96 that can be supplied on request in the following pages of this manual we will refer to this publication as the Catalogue Table 2 1 Servomotor Type SERIE...

Page 13: ...3 6204 2ZR C3 950 750 575 475 20 865 1500 3000 6207 2ZR C3 6205 2ZR C3 1750 1400 1000 850 2715 Notes 1 Values for simultaneous axial and radial stresses are available on request 2 Values for versions with integrated brake special versions are available on request 3 Values for admissible axial loads are valid for force direction FA towards the motor for the opposite direction a reduction is necessa...

Page 14: ...0 optional RBextra W Switching frequency kHz 5 5 5 5 10 10 10 Speed range 0 6000 RPM fmax 300Hz Position transducer 2 pole resolver Resolver motor phase adjustment Automatic procedure Speed reference input 10V input impedance 200kΩ differential Current reference input 10V input impedance 24 kΩ Torque analog limit circuit input 0 10V input impedance 24 kΩ Input for enabling commands Galvanically in...

Page 15: ... 27 7 28 865 2 15 14 28 21 0 48 2 48 2 28 865 230 18 36 19 4 38 9 38 9 36 865 2 30 25 50 21 0 54 40 2 50 865 3 15 14 28 27 1 54 54 28 865 3 30 35 70 29 0 67 9 67 9 70 865 4 15 18 36 36 0 72 72 36 865 4 15 25 50 37 0 100 100 50 865 4 30 35 70 37 0 77 7 77 7 70 Legend T0 Continuous stall torque Tmax Peak stall torque TNmax Peak torque at nominal speed Imax Motor current at Tmax The maximum current o...

Page 16: ...d in a vertical position The distance equal to 150 mm indicated above and below in Fig 3 1 is the room that must be left free for air flow this is valid both for size 223 and for size 224 Do not stop the flow of cooling air with external bodies placed too close to the convertor see minimum distances described in the figure Do not place the drive near heat sources Fig 3 1 ...

Page 17: ...CHAPTER 3 Installation of the drive MANIU04 9607 GB 03 97 Page 3 2 3 1 2 Dimensions SIZE 223 Models from 5 10 to 18 36 Fig 3 2 ...

Page 18: ...CHAPTER 3 Installation of the drive MANIU04 9607 GB 03 97 Page 3 3 SIZE 224 Models 25 50 Fig 3 3 ...

Page 19: ... 3 Installation of the drive MANIU04 9607 GB 03 97 Page 3 4 SIZE 224 Models 35 70 and 50 100 Fig 3 4 3 1 3 Electrical installation As regards power and signal connections please refer to paragraphs 4 3 and 4 4 ...

Page 20: ...nge mounted with passing holes on the flange vertical shaft down IMV3 flange mounted with passing holes on the flange vertical shaft up lMB14 flange mounted with blind tapped holes on the flange horizontal lMV18 flange mounted with blind tapped holes on the flange vertical shaft down lMV19 flange mounted with blind tapped holes on the flange vertical shaft up 3 2 1 3 Pulleys and couplings Coupling...

Page 21: ...ed with A Fig 3 6 must not be connected CAUTION It is necessary to respect the correspondence of the connections between motor and convertor without fail A mistake in phase connection will not make drive operation possible The yellow green connection cable between the ground of the motor and the ground of the convertor must be connected to the terminal marked with the symbol For these connections ...

Page 22: ...CHAPTER 3 Installation of the drive MANIU04 9607 GB 03 97 Page 3 7 Extra M5 hole available outside the connection box Fig 3 5 ...

Page 23: ...CHAPTER 3 Installation of the drive MANIU04 9607 GB 03 97 Page 3 8 Extra M5 hole available outside the connection box Fig 3 6 ...

Page 24: ...mally used in connection with the convertor see paragraph 4 3 5 It can be used for example in special cases as signaling in possible circuits of plant supervision connected to a system PLC The contact can work at 220 Vac with a current up to 5 A 3 2 2 4 Brake connections only if this option exists When the brake option is present connections must be made according to the following instructions WAR...

Page 25: ...nces irradiated disturbances 30 MHz 1000 MHz 3 3 5 Industrial experience has demonstrated that the main causes of lack of compatibility are due to condueted disturbances 3 3 6 The installation of the drive must be executed scrupulously following the instructions contained in the paragraphs 3 1 and 3 2 of this chapter 3 3 7 In view of electromagnetic compatibility the installation must be carried o...

Page 26: ...on the line input of some convertors 3 3 8 4 Cable shieldings must stop as nearer as possible the terminal board if the connection of the shield to a mass or in some cases to ground is prescribed it must be carried out with the shortest possible connections and with conductors with an adequate section 3 3 8 5 lt is important that all panels within the electric board are connected with mechanical c...

Page 27: ...both cabin side and motor side ground connoctions must be of adequate section and very short This is an EMC specific requirement which can apparently in contrast with what often prescribed i e the opportunity to connect shields to ground on one side only this prescription requires very efficient grounds 3 4 External ballast resistors When the ballast resistor is external this must be assembled in ...

Page 28: ...on the dc intermediate circuit and on the associated circuits A proper warning placed visibly must be present on the BHL D convertor to warn about this danger according to what established in EN 60204 1 6 2 3 3 5 3 Supply sectioning device WARNING Since the BHL D convertor is prepared to be put in an electric cabin possibly also containing other apparatus the supply sectioning device manually cont...

Page 29: ...Servomotors series 8 have IP 55 protection degree BHL D convertors have IP20 protection degree to fulfill what prescribed in 4 4 5 Contaminating elements of the standard EN 60204 1 they must care of the manufacturer of the machine be put into an adequate case electric cabin according to the required protection degree ...

Page 30: ...ted with a flat cable in the appropriate connector The keyboard management is arranged in three visualizstion windows each one with a different function the first window the window of References is shown when the unit is switched on The second window shown is for Parameters and the third one contains Flags To move from one window to another use MODE key The first window shows all references of spe...

Page 31: ...TC or NTC are visualized whether it is set or not Flags can be grouped in two different types procedure flags and configuration flags The former are used to generate a particular sequence of actions that will then bring the drive back to start condition usually these are autoadjusting or autotuning procedures In general they are CLEAR type flags lf first ENTER the cursor appears and then the arrow...

Page 32: ...t when the motor is controlled in torque mode The settable value changes from 200 0 In to 200 0 In in relation to the rated current of the drive the value that can be set is limited by parameter P5 I_MAX that represents the maximum absolute value of current always referred to the rated current On the contrary if instead of considering this parameter as current limit analog current limit is used th...

Page 33: ...h the analog output DAC2 to return within the allowed limits or to increase the resolution within a given range In other words it is the scaling factor between the numerical value and the analog value of the internal variable to be visualized On defauft configuration OUT1_A 4 actual speed monitor and OUT2_A 5 torque signal monitor are set already normalized according to the maximum values set with...

Page 34: ...der pulse width at 256 pulse per revolution value equal to 9 lf for the external control it is enough to detect a rising or falling wave front it is not necessary to specify it P38 SER_ID Internal parameter not to be modified except if serial communication is used 4 2 3 Description of flags window This window shows all the flags that it is possible to set either configuration flags or procedure fl...

Page 35: ...se the current analog reference as torque limit to use it it is necessary to set parameter P5 I_MAX to its maximum vaiue 200 0 ln 4 3 External connections BHL D has some signal terminal boards J1 J2 and a power terminal board N1 The latter exists in two versions indicated hereafter as N1A size 223 Fig 4 2 and N1B size 224 Fig 4 3 Besides terminal boards there are two 9 pin sub D connectors J3 and ...

Page 36: ...le output 0V 15V for size 224 0V 24V the configuration can be selected on the keyboard with parameter P17 DIG_O2 see paragraph 4 2 J1 12 ØD Zero reference of the board used also as 0V for the auxiliary supply 15V J1 1 and for speed differential input and current analog input J1 13 10V Stabilized supply 10V available externally with maximum load 10mA J1 14 10V Stabilized supply 10V available extern...

Page 37: ...3 Channel B unipolar output J2 5 Channel TOPØ unipolar output The three unipolar outputs are referred to ØD J2 6 Technical characteristics of the outputs Number of pulses rev programmable resolutions through parameter P36 EN_RES 128 256 512 and 1024 pulses rev Zero notch one pulse rev of width programmable through parameter P37 TOPØ_W Output voltages differential Vout 4V typical Vout 2 5V min Iout...

Page 38: ...ity see paragraph 3 3 a 6 wire cable twisted and shielded two by two 3x 2x0 25 shielded must be used for connection 4 3 3 Power terminal NI Terminal for size 223 N1A CAUTION lt is important to respect phase sequence for connection to the motor if phases are exchanged the drive may not function Fig 4 2 Terminal for size 224 N1B Fig 4 3 ...

Page 39: ...cable shield The resolver cable must be of the type approved of by ABB code 16080125 Connections to the plug must comply with drawing DMGCAV067 available on request As regards the connection of the motor thermal probe the standard configuration foresees the short circuit between terminal J4 7 and J4 8 since flag F9 Thermal Probe is set as PTC The motor thermal protection is carried out through I 2...

Page 40: ...ANIU04 9607 GB 03 97 Page 4 11 4 4 Indications for connections to terminal boards Hereafter you will find some examples of how the convertor should be connected for the start up 4 4 1 Power connection Soft start Power conncetion for SIZE 223 Fig 4 4 ...

Page 41: ...models 5 10 10 20 14 28 18 36 and compulsory for models 25 50 35 70 50 100 In general the limit circuit must be inserted in all cases where the autotransformer T1 has a nominal power higher than 8kVA this rule is also true in case a single autotransformer supplies more than one convertor The soft start resistors must be short circuited after 150 200 ms from start up they must have a value in the r...

Page 42: ...A 1 8 3 6 5 0 6 5 9 12 7 18 2 T1 kVA 1 9 3 8 5 3 7 0 9 6 13 3 19 Q1 Q2 16A 16A 16A 25A 25A 40A 63A F1 AM 10A 16A 25A 25A 32A 50A 63A Power cable section 3 T mm 2 1 5 2 5 4 4 6 10 16 4 4 2 Connection for regulation with potentiometer The diagram below exploits the 15V supply available on terminal for enabling and the 10V supply for speed reference using the speed reference input in a non differenti...

Page 43: ...d regulation The input reference is differential 4 4 4 Connection for torque mode The picture below illustrates a simple application for using the convertor in torque mode To use torque mode see paragraph 4 5 4 The value of the applied signal determines the rms value of the phase current of the motor with a maximum equal to the peak current of the drive The sign indicates the rotation sense of the...

Page 44: ...inal RE J1 3 and speed reference input on terminal SE J1 4 with this procedure the 7 segment display stands still no more blinking and visualizes 0 At this moment set F1 Auto phasing SET with the keyboard At the end of autophasing the keyboard in correspondence of F1 will display the word DONE for a few seconds and will then go back to CLEAR The resolver phase is automatically memorized in paramet...

Page 45: ... torque is increased However it is necessary to adjust the dynamic characteristics of the system convertor motor to the mechanical system in which it is used Therefore we advise to adopt such values for KP and KI as to guarantee a good compromise between dynamic performances and noise sensitivity As well as with analog reference the speed command can be set directly with the keyboard At start up t...

Page 46: ...16 Analog current limit too 4 6 Rules for start up At the moment of installation and start up of the drive You will have to observe the following rules in this order a Make sure that all connections have been carried out according to what prescribed check that all the terminals are tightened in particular the power connections Check that the resolver cable is connected to connector J4 and to the m...

Page 47: ...the speed digital reference read on the alphanumerical display is zero or it turns slowly if the speed analog reference is enabled and there is an offset in both cases you must supply a positive reference and check that the motor turns counterclockwise To correct the offset of speed analog reference if present there is an automatic procedure see paragraph 4 5 3 2 In these conditions the drive is r...

Page 48: ...emaining configurations are sensitive to the level The HW limit switch inputs are used to generate an alarm that can be reset only when the limit switch signal becomes H again There are many different possibilities for the management of such an alarm contact Customer Service in case of need For diagnostics two digital configurable outputs and two analog configurable outputs are available on the te...

Page 49: ...e resolution of the representation with parameters P13 DA1SHF and P15 DA2SHF that determine the number of shifts and therefore the number of divisions by 2 of the numerical value before representing it in an analog way In this way the user can set the use of these signals arbitrarily Since in the majority of cases the most significant numerical values are motor rotation speed and delivered torque ...

Page 50: ...isplay Moreover you can see the various messages that appear cyclically when one or more alarms are memorized the first line of the alphanumerical display blinks lf various alarms are memorized the message which appears is referred to the alarm with highest priority it increases with the increasing of the number except for I2 t and limit switch alarms Description Codifying Visualization Display 00...

Page 51: ...ervoltage on the 5 Overvoltage DC BUS Drive disabled Braking Brake module fault 6 circuit fault Drive disabled Fault on the IPM Fault 7 inverter bridge Drive disabled Undervoltage on the 8 Undervoltage DC BUS Drive disabled I2 t motor or Overtemperature protection 9 convertor Drive enabled NOTE All a m alarms are visualized on the alphanumeric keyboard through parameter P28 ALARM After suspension ...

Page 52: ...de of the cable is specified according to the length the possibility to keep pseudoencoder alive in case of lack of supply by using a separate signal supply The kit related to this function is made up of a personalization inside the convertor and of an external transformer that goes with the convertor This configuration is available please require the suitable code when ordering the convertor Exte...

Page 53: ...Verkauf Service ABB Automation GmbH Edisonstr 15 D 68623 Lampertheim ABB Telefon Telefax 49 0 6206 503 553 49 0 6206 503 269 ...