DeltaMax Series [IB-19B003] by IEB Media

IB‐19B003 DELTA SERIES

JUNE 2003

INSTRUCTION BOOK INDUSTRIAL INDEXING SYSTEMS, Inc. Revision - D Approved By:

Proprietary information of Industrial Indexing Systems, Inc. furnished for customer use only. No other uses are authorized without the prior written permission of Industrial Indexing Systems, Inc.

ER-6028 ERRATA SHEET, IB-19B003 REV. D

JUNE 2008

Date

Rev.

ECN No.

CHK

9/3/03

ECN-03-392 (See Note 1)

10/28/03

ECN-03-446 (See Note 2)

03/25/04

ECN-04-033 (See Note 3)

06/04/04

ECN-04-216 (See Note 4)

ELS/MH

11/24/04

ECN-03-267, 03-358, 03-462 ECN-04-137, 04-198, 04-220, 04-290, 04-404 (See Note 5)

9/23/05

ECN-05-260 (See Note 6)

3/9/06

ECN-06-007 (See Note 7)

8/9/06

ECN-06-181 (See Note 8)

6/6/08

ECN-08-133 (See Note 9)

Notes: 1)

Appendix A, page A-4, dated September 2003, supersedes Appendix A, page A-4, dated June 2003.

2) Appendix B, page B-2, dated October 2003, supersedes Appendix B, page B-2, dated June 2003. 3) Section 7, page 7-7, dated March 2004, supersedes Section 7, page 7-7, dated June 2003. Section 10, page 10-3, dated March 2004, supersedes Section 10, page 10-3, dated June 2003. 4) Section 7, page 7-7, dated June 2004, supersedes Section 7, page 7-7, dated March 2004. Appendix B, pages B-4 and B-5, dated June 2004, supersedes Appendix B, pages B-4 and B-5, dated June 2003. C-329YYY supersedes C-320YYY. DINT-350 revision N supersedes DINT-350 revision K. 5) Appendix B, dated November 2004, supersedes Appendix B, dated June 2003. 6) Table of Contents, page v, dated August 2005, supersedes Table of Contents, page v, dated June 2003, Section 7, page 7-7 dated August 2005, supersedes Section 7, page 7-7, dated June 2004. Appendix A, added DBM120 series motors. Appendix B, added cables for the DBM120 series motors. 7) Section 7, page 7-7, dated March 2006, supersedes Section 7, page 7-7, dated August 2005. 8) Appendix B, DINT-300 drawing, Revision M, supersedes Appendix B, DINT-300, Revision L. 9) Section 10, page 10-2, dated June 2008, supersedes Section 10, page 10-2, dated June 2003. Section 11, page 11-2 dated June 2008, supersedes Section 11, page 11-2, dated June 2003.

INDUSTRIAL INDEXING SYSTEMS, Inc. Tel: (585) 924-9181

626 Fishers Run Victor, New York 14564

Fax: (585) 924-2169

Proprietary information of Industrial Indexing Systems, Inc. furnished for customer use only. No other uses are authorized without the prior written permission of Industrial Indexing Systems, Inc.

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

TABLE OF CONTENTS List of Illustration..................................................................................................................................................vii Introduction .......................................................................................................................................................... ix

SECTION 1 - OVERVIEW 1.1

Identifying DeltaMax Packages ...........................................................................................1 - 1

1.2

Identifying DeltaMax Drives .................................................................................................1 - 2

1.3

Identifying DeltaMax Motors ................................................................................................1 - 3

SECTION 2 - DESCRIPTION 2.1

Components.........................................................................................................................2 - 2 2.1.1 Status Indicators.....................................................................................................2 - 2 2.1.2 Connectors .............................................................................................................2 - 2

SECTION 3 - DELTAMAX SPECIFICATIONS 3.1

Motor Output ........................................................................................................................3 - 1

3.2

Power Supply .......................................................................................................................3 - 2

3.3

Control Performance............................................................................................................3 - 3

3.4

Environment .........................................................................................................................3 - 3

3.5

Digital I/O Signals.................................................................................................................3 - 4

3.6

Analog I/O Signals ...............................................................................................................3 - 5

3.7

Communication Ports...........................................................................................................3 - 5

3.8

Protection .............................................................................................................................3 - 5

3.9

Motor Specifications.............................................................................................................3 - 6 3.9.1 General ...................................................................................................................3 - 6 3.9.2 Feedback Device....................................................................................................3 - 6 3.9.3 Other .......................................................................................................................3 - 6

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

SECTION 4 - THE DELTA DRIVE MENU 4.1

Navigating the Driver’s Menu...............................................................................................4 - 2 4.1.1 Status Display Menu Loop .....................................................................................4 - 4 4.1.2 Diagnostic Display Menu Loop ..............................................................................4 - 6 4.1.3 Adjustment Parameter Menu Loop........................................................................4 - 8 4.1.4 User Parameter Menu Loop...................................................................................4 - 8

SECTION 5 - DELTAMAX WIRING 5.1

Digital I/O..............................................................................................................................5 - 1

5.2

Analog I/O.............................................................................................................................5 - 2

5.3

Port 1 & Port 2......................................................................................................................5 - 2

5.4

DeviceNet/CAN Bus (optional) ............................................................................................5 - 3

5.5

Monitor Output......................................................................................................................5 - 3

5.6

Feedback Interface ..............................................................................................................5 - 4

5.7

Absolute Resolver/Encoder Interface..................................................................................5 - 5

5.8

Absolute Encoder Interface .................................................................................................5 - 6

SECTION 6 - OPERATION 6.1

Firmware Downloading ........................................................................................................6 - 1

6.2

Control Program...................................................................................................................6 - 1

6.3

Drive Parameters .................................................................................................................6 - 2

SECTION 7 - POWER WIRING 7.1

Circuit Breaker......................................................................................................................7 - 1

7.2

Contactor..............................................................................................................................7 - 1

7.3

Wire Sizes ............................................................................................................................7 - 1

7.4

Transformers........................................................................................................................7 - 2

7.5

Branch Circuit Protection for Control Voltage R0, S0 .........................................................7 - 3

7.6

Wiring Practices and Grounding..........................................................................................7 - 4

7.7

Power Sequencing...............................................................................................................7 - 5

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IB-19B003 USER’S GUIDE

SECTION 8 - DRIVE TUNING 8.1

Tuning Procedure ................................................................................................................8 - 2

8.2

Notch Filter Adjustment........................................................................................................8 - 2

SECTION 9 - REGEN RESISTOR SELECTION 9.1

DeltaMax Driver Regeneration Capacities..........................................................................9 - 1

9.2

Selection of Regeneration Resistor.....................................................................................9 - 2

9.3

Standard Regeneration Resistor Packages........................................................................9 - 6

SECTION 10 - DYNAMIC BRAKES SECTION 11 - MECHANICAL BRAKES 11.1

No Mechanical Braking......................................................................................................11 - 1

11.2

Mechanical Braking With Soft Deceleration......................................................................11 - 1

11.3

Mechanical Brake Power Supply.......................................................................................11 - 6

SECTION 12 - ALARM & STATUS CODES 12.1

Alarm Codes.......................................................................................................................12 - 1

12.2

Controller Status ................................................................................................................12 - 4

APPENDIX A - MOTOR/DRIVER SPECIFICATIONS A.1

Motors with Resolvers......................................................................................................... A - 1

A.2

Motors with Mechanical Brakes.......................................................................................... A - 3

A.3

Motors with Encoders ......................................................................................................... A - 4

A.4

Motor/Driver Speed Torque Curves ................................................................................... A - 5

A.5

Driver Mounting and Dimensions ..................................................................................... A - 98

A.6

Resolver Motor Dimensions ........................................................................................... A - 123

A.7

Brake Motor Dimensions ................................................................................................ A - 174

A.8

Encoder Motor Dimensions ............................................................................................ A - 199

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IB-19B003 USER’S GUIDE

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

APPENDIX B - CABLES AND ACCESSORIES B.1

Cable Part Numbers For Motors with Resolvers ............................................................... B - 1

B.2

Cable Part Numbers For Motors with Mechanical Brakes................................................. B - 3

B.3

Cable Part Numbers For Motors with Encoders ................................................................ B - 4

B.4

Accessories ......................................................................................................................... B - 5

APPENDIX C - ABSOLUTE DELTAMAX MOTOR AND DRIVE APPLICATION NOTE

TABLE OF CONTENTS vi

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

LIST OF ILLUSTRATIONS SECTION 1 - OVERVIEW SECTION 2 - DESCRIPTION Figure 2.1

DeltaMax Layout.....................................................................................................2 - 1

SECTION 3 - DRIVER SPECIFICATIONS Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 3.8

Standard .................................................................................................................3 - 4 Optional...................................................................................................................3 - 4 DeltaMax Overload Protection Characteristic .......................................................3 - 7 Standard Resolver Wiring Connections for DBM-XXX/15R, DBM-500/30R and Larger ..............................................................................................................3 - 8 Alternate Resolver Wiring Connections for DBM-XXX/15R, DBM-500/30R and Larger ..............................................................................................................3 - 8 Standard Resolver Wiring Connections for DBM-120/30R, DBM-200/30R, DBM-400/30R, DBM-BXXX/30R, DBM-D30/30R and DBM-D50/30R.................3 - 9 Alternate Resolver Wiring Connections for DBM-120/30R, DBM-200/30R and DBM-400/30R..................................................................................................3 - 9 Standard Resolver Wiring Connections for DBM-D100/30R Through DBM-D800/30R ....................................................................................................3 - 10

SECTION 4 - THE DELTA DRIVE MENU Figure 4.1 Figure 4.2

DeltaMax Keypad and Display...............................................................................4 - 1 Main Menu Loop and Minor Loops ........................................................................4 - 3

SECTION 5 - DELTAMAX WIRING Figure 5.1 Figure 5.2 Figure 5.3 Figure 5.4 Figure 5.5 Figure 5.6 Figure 5.7 Figure 5.8 Figure 5.9

Digital I/O ................................................................................................................5 - 1 Input & Output Configurations................................................................................5 - 1 Analog I/O...............................................................................................................5 - 2 Port 1 & Port 2 ........................................................................................................5 - 2 DeviceNet/CAN Bus...............................................................................................5 - 3 Monitor Output........................................................................................................5 - 3 Feedback Interface.................................................................................................5 - 4 Battery Pack and Resolver/Encoder Wiring ..........................................................5 - 5 Battery Pack and Encoder Wiring..........................................................................5 - 6

SECTION 6 - OPERATION

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LIST OF ILLUSTRATIONS vii

IB-19B003 USER’S GUIDE

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

SECTION 7 - POWER WIRING Figure 7.1 Figure 7.2 Figure 7.3 Figure 7.4

Grounding Technique.............................................................................................7 - 4 DMAX-1.5/RB Through DMAX-8.5/RB Power Wiring...........................................7 - 5 DMAX-1.5/RA Through DMAX-17.5/RA Power Wiring.........................................7 - 6 DMAX-35/RA Through DMAX-115/RA Power Wiring...........................................7 - 7

SECTION 8 - DRIVE TUNING Table 8.1

Adjustment Parameters..........................................................................................8 - 1

SECTION 9 - REGEN RESISTOR SELECTION Figure 9.1 Figure 9.2 Figure 9.3

Table 9.1 Table 9.2

Time ........................................................................................................................9 - 2 Connection of an External Regen Resistor for DeltaMax Driver Sizes DMAX-1.5 Through DMAX-17.5 ............................................................................9 - 3 Connection of an External Regen Resistor for DeltaMax Driver Sizes DMAX-35 and Larger .............................................................................................9 - 4 Energy Absorption Capabilities..............................................................................9 - 1 External Resistor Specifications ............................................................................9 - 3

SECTION 10 - DYNAMIC BRAKES Figure 10.1 Figure 10.2 Figure 10.3

Dynamic Brake Connection for the DMAX-1.5 Through DMAX-17.5 Drivers With a Sourcing I/O Board ...................................................................................10 - 1 Dynamic Brake Connection for the DMAX-35 Through DMAX-115 Drivers ......10 - 2 Dynamic Braking Control Signals ........................................................................10 - 3

SECTION 11 - MECHANICAL BRAKES Figure 11.1 Figure 11.2 Figure 11.3

Mechanical Brake Connection for the DMAX-1.5 Through DMAX-17.5 Drivers with a Sourcing I/O Board........................................................................11 - 2 Mechanical Brake Connection for the DMAX-35 Through DMAX-115 Drivers..11 - 3 Mechanical Brake Sequencing for Soft Decel.....................................................11 - 4

SECTION 12 - ALARM & STATUS CODES Figure 12.1

Controller Status...................................................................................................12 - 4

APPENDIX A - MOTOR/DRIVER SPECIFICATIONS APPENDIX B - CABLES AND ACCESSORIES APPENDIX C - ABSOLUTE DELTAMAX MOTOR AND DRIVE APPLICATION NOTE

LIST OF ILLUSTRATIONS viii

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

INTRODUCTION Thank you for selecting Industrial Indexing Systems’ DeltaMax Series products. You join many other companies around the world in your choice of these powerful, flexible motion control products. The small, lightweight DeltaMax system combines the controller, driver and motor into a single unit. This integrated package delivers the latest in all-digital electronic design, SMT circuit board construction and clever engineering to deliver high performance, advanced features and reasonable cost. Compact, high power density motors provide low rotor inertia, making them the logical choice for all applications including positioning, indexing, master-slave, complex profile shapes, electronic ratios and cams, and many others. The DeltaMax has a wide array of features, including one active servo axis with one-half axis follower fiber optic input, two powerful embedded high speed 32-bit RISC processors, flash ROM and NOVRAM memory, high visibility 5-digit drive status display, 1-digit controller status display, two RS-232 ports, 16 optically isolated inputs, 8 optically isolated outputs, 8 programmable limit switches, analog inputs and output, optional DeviceNet connection and more. The controller is programmed using our friendly MacroProgramming language and powerful new MacroPro II software tools for the PC.

JUNE 2003

INTRODUCTION ix

IB-19B003 USER’S GUIDE

INTRODUCTION x

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 1 - OVERVIEW This manual is organized so that information is easy to find and easy to use. It begins by detailing how to identify the DeltaMax package, Delta drives, and Delta motors. Followed by a general description of the product and its components. The basic electrical characteristics of the DeltaMax package including the Delta Motors are described, and comprehensive product specifications are provided. The operation of the product is then described, complete with signal wiring and parameter set up. Sections on Power and Driver Wiring, Regen Resistor selection and Dynamic and Mechanical Braking follow. A section describing alarms and status can aid you in the unlikely event that anything goes wrong. Motor and Driver Speed/Torque Curves follow this information, allowing you to match Drivers and Motors to your specific applications. A final section which contains cables and various Mechanical Drawings round out this manual.

1.1

IDENTIFYING DELTAMAX PACKAGES

DeltaMax packages can be identified as follows. Your DeltaMax package model number uses this designation: DELTAMAX-XYYYYABCDEFG, WHERE: X

= motor series Blank = standard A = A series B = B series C = Custom D = D series E = E series YYYY = is the rated mechanical output wattage of the package A = H = 3000 rpm rated motor M = 2000 rpm rated motor L = 1500 rpm rated motor C = custom motor B = R = resolver based system RA = absolute resolver sensor based system E = encoder based system EA = absolute encoder sensor based system C = A = 220 VAC system, single or three phase B = 120 VAC system, single phase (only for smallest drive and only up to 200 watts) D = motor and driver options B = integral brake option I = 14 bit analog input T = for windings with “Tropical” fungus protection 1X = 1 cycle resolver others as defined in future EFG = possible various options C = CAN Bus option D = DeviceNet option H = Proprietary S = Sourcing Inputs and Outputs

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IB-19B003 USER’S GUIDE

1.1

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IDENTIFYING DELTAMAX PACKAGES (cont’d)

Example: A DeltaMax package designated DELTAMAX-120HRB is a 120-watt motor, with a 3000 rpm rated motor, a resolver based system, 120 VAC system. If this same package was equipped with DeviceNet and sourcing I/O, it would be designated DELTAMAX-120HRBDS.

1.2

IDENTIFYING DELTAMAX DRIVES

DeltaMax Drivers can be identified as follows. This information is on the Driver label: Your DeltaMax Driver model number uses this designation: DMAX-CURRENT/ZYEFG, WHERE: CURRENT = Peak Driver Current in amps (rms) Z = feedback method: R = resolver feedback E = encoder feedback RA = absolute resolver feedback EA = absolute encoder feedback Y = input voltage: A = 220 VAC input (single or three phase) B = 115 VAC input (single phase) - only available up to 200 watts EFG = possible various options C = CAN Bus option D = DeviceNet option H = Proprietary I = 14 bit analog input A & D converter S = Sourcing Inputs and Outputs Example: A DeltaMax Driver designated DMAX-8.5/RB has a peak current rating of 8.5 A rms, resolver feedback, and 115 VAC 1 input voltage.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

1.3

IB-19B003 USER’S GUIDE

IDENTIFYING DELTA MOTORS

Delta Motors can be identified as follows. This information is on the Motor label: Your Delta Motor model number uses this designation: DBM-SERIES WATTAGE/SPEED YZ, WHERE: SERIES

= Motor series Blank = standard A = A series B = B series C = Custom D = D series E = E series WATTAGE = Rated Motor Power in watts SPEED = Rated Motor Speed in hundreds of RPMs Y = feedback method: R = resolver feedback E = encoder feedback RA = absolute resolver feedback EA = absolute encoder feedback Z = B for a motor with an integral brake T for windings with “Tropical” fungus protection W for washdown sealing 1X = 1 cycle resolver

Example: A Delta Motor designated DBM-120/30R is a 120-watt motor with a 3000 rpm rated speed and resolver feedback. If the same motor was equipped with an integral brake, it would be designated DBM120/30RB. If the same motor was equipped with “Tropical” fungus protection, it would be designated DBM120/30RT and with a brake, it would be designated DBM-120/30RBT.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 2 - DESCRIPTION The DeltaMax product consists of a servo motion controller, containing one active axis and one-half axis fiber optic servo follower and a Delta series drive integrated into one package. The application program that operates the controller is created on a PC using the MacroPro II software tools and sent serially to the controller via an RS-232 link.

NOTE All commands used by the DeltaMax are part of the IIS Macroprogram language. Refer to the separate MacroPro II manual (IB-11B022) for detailed information on the commands and their proper usage. The external connections that exist on the DeltaMax are shown in Figure 2.1, and consist of 2 RS-232 ports, 16 digital inputs and 8 digital outputs, 2 analog inputs, 1 analog output and a reference, a fiber optic input, and an optional DeviceNet port, as well as motor, resolver, and power connections. The Delta drive also has an analog monitor output, which is capable of representing either speed or torque as a function of voltage relative to +/- 3 vdc.

Figure 2.1 - DeltaMax Layout

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IB-19B003 USER’S GUIDE

2.1

COMPONENTS

2.1.1

STATUS INDICATORS

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Drive Status Display - This is a 5-digit seven segment display which indicates the current status of the Delta driver. A fault on the drive would be represented by AL - ## which indicates an alarm with an associated two digit number. These alarm codes and their descriptions can be found in Section 12 - Alarm & Status Codes.

Controller Status Display - This single seven segment LED with decimal point provides status information of various operating conditions. For further information on this display, see Section 12 - Alarm & Status Codes in this manual.

2.1.2

CONNECTORS

NOTE For proper pinouts for each connector refer to Section 5 DeltaMax Wiring. 1.

Port 1 - This 6-pin RJ-11 connector is an RS-232 serial communication port. It uses a custom protocol to communicate with the MacroPro II software tools on a PC. This port also facilitates firmware download.

Port 2 - This 6-pin RJ-11 connector is an RS-232 serial communication port. It can be used to communicate with the IIS OPI-50 or similar RS-232 type device. The protocol is selectable through the Macroprogramming language. This port does default to the custom protocol for communicating with the MacroPro II software tools on a PC.

Digital I/O - This connector provides access to the onboard I/O. IIS offers two options to this connector; there is the C-719YYY cable with ferreled ends or the C-716006 cable, which terminates at the DINT-300, which provides terminal blocks for I/O wiring.

DeviceNet/CAN Bus (optional) - This connector provides DeviceNet or CAN Bus access to controller flags and memory.

Analog Input/Output - This connector provides contacts for two analog inputs, one analog output, and a reference voltage. The Macroprogram controls use of these inputs and output channel.

Fiber Optic Receiver - This connector is used to receive the positional data from the IIS EFC-XXX encoder to fiber optics converter or the RFC-XXX resolver to fiber optics converter. The data being received is in the form for master angle passing.

Resolver Cable Connector - This is a 20-pin mini D connector used for resolver feedback from the motor to the drive.

Motor/Power wiring terminals - These are terminal blocks used to wire the incoming AC line voltage as well as the motor cable.

Monitor Output - This is a connector, which provides access to an analog output signal. The signal is either defined as a conversion of torque or speed and is selectable through the MacroPro II software tools.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 3 - DELTAMAX SPECIFICATIONS DeltaMax Driver Weight

DeltaMax Driver Weight

3.1

DMAX-1.5/RB 3.3 lb 1.5 kg DMAX8.5/RB 3.3 lb 1.5 kg

DMAX8.5/RA 3.3 lb 1.5 kg

DMAX-1.5/RA 3.3 lb 1.5 kg DMAX17.5/RA 5.5 lb 2.5 kg

DMAX-4.25/RB 3.3 lb 1.5 kg

DMAX35/RA 10 lb 4.5 kg

DMAX50/RA 10 lb 4.5 kg

DMAX-4.25/RA 3.3 lb 1.5 kg DMAX70/RA 24 lb 11 kg

DMAX115/RA 35 lb 16 kg

MOTOR OUTPUT

DeltaMax Driver Motor Output Continuous Output Current Max. Output Current See Figure 3.1 Motor Ripple Frequency DeltaMax Driver Motor Output Continuous Output Current Max. Output Current 3 seconds See Figure 3.3 Motor Ripple Frequency

JUNE 2003

DMAX-1.5/RB DMAX-1.5/RA PWM, 3 Phase, sine wave 1.0 1.0 A rms A rms 1.5 1.5 A rms A rms

2.8 A rms 4.25 A rms

20 kHz

DMAX-4.25/RB

DMAXDMAXDMAX8.5/RB 8.5/RA 17.5/RA PWM, 3 Phase, sine wave 2.1 3.4 5.7 A rms A rms A rms 8.5 8.5 17.5 A rms A rms A rms

14.1 A rms 35.0 A rms

18.4 A rms 50.0 A rms

28.3 A rms 70.0 A rms

56.6 A rms 115.0 A rms

20 kHz

10 kHz

20 kHz

DMAX35/RA

DMAX50/RA

DMAX-4.25/RA

DMAX70/RA

DMAX115/RA

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IB-19B003 USER’S GUIDE

3.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

POWER SUPPLY

DeltaMax Driver Main Bus Power Supply Voltage

DMAX-1.5/RB 1 Phase, Nominal: 110 VAC, Max Range: 85-126 VAC, 50/60 Hz

Main Supply Capacity Control Voltage Control Capacity Main Circuit Heat Loss Control Circuit Heat Loss Regeneration Absorption Capacity

350 VA

DeltaMax Driver Main Bus Power Supply Voltage

Main Supply Capacity Control Voltage Control Capacity Main Circuit Heat Loss Control Circuit Heat Loss Regeneration Absorption Capacity

PAGE 3 - 2

350 VA

DMAX-4.25/RA 1 Phase, Nominal: 220 VAC, Max Range: 170-264 VAC, 50/60 Hz 350 VA

17 W

23 W

13 W + 17 J

DMAX8.5/RB 1 Phase, Nominal: 110 VAC, Max Range: 85-126 50/60 Hz 570 VA

DMAX-1.5/RA 1 Phase, Nominal: 220 VAC, Max Range: 170-264 VAC, 50/60 Hz 350 VA

DMAX-4.25/RB 1 Phase, Nominal: 110 VAC, Max Range: 85-126 VAC, 50/60 Hz

DMAXDMAX8.5/RA 17.5/RA 1 Phase, Nominal: 220 VAC, Max Range: 170264 VAC, 50/60 Hz

DMAXDMAXDMAX35/RA 50/RA 70/RA 3 Phase, Nominal: 220 VAC, Max Range: 170-264 VAC, 50/60 Hz

1.2 KVA

5.3 KVA

2.5 KVA

6.7 KVA

13 KVA

DMAX115/RA

25 KVA

Single phase, 170-264 VAC, 50/60 Hz 70 VA 80 VA 110 VA

20 W

27 W

47 W

110 W

130 W

250 W

400 W

23 W

26 W

30 W

60 W

17 W + 17 J

24 W + 17 J

37 W + 22 J

160 W + 54 J

180 W + 54 J

300 W + 94 J

480 W + 188 J

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

3.3

CONTROL PERFORMANCE

Feedback Feedback Resolution Feedback Accuracy Current Loop Update Rate Velocity Loop Update Rate Position Loop Update Rate Speed Regulation Torque Regulation Feedback Feedback Resolution Feedback Accuracy Current Loop Update Rate Velocity Loop Update Rate Position Loop Update Rate Speed Regulation Torque Regulation

3.4

IB-19B003 USER’S GUIDE

Resolver 4096 bits/rev 18 arc minutes spread for motor with 95 mm mounting face or smaller ±20 arc minutes for B series motors 8 arc minute spread for all other motors 100 sec 400 sec 800 sec Load (0%-100%): 0.02% Power (85-126 VAC or 170-264 VAC): 0.02% Temperature (0-55C/32-131F): 0.2% Power (85-126 VAC or 170-264 VAC): 2% Temperature (0-55C/32-131F): 2% Encoder 4096 bits/rev Less than 2 arc minutes 100 sec 400 sec 800 sec Load (0%-100%): 0.02% Power (85-126 VAC or 170-264 VAC): 0.02% Temperature (0-55C/32-131F): 0.2% Power (85-126 VAC or 170-264 VAC): 2% Temperature (0-55C/32-131F): 2%

ENVIRONMENT

Storage Temperature Operating Temperature Humidity Shock and Vibration Operating Conditions Drive Enclosure

JUNE 2003

-10 to 70C/14-158F 0 to 55C/32-131F 35 to 90% Relative Humidity, non-condensing 1 G or less Free of dust, liquids, metallic particles and corrosive gases. Use in a pollution degree 2 environment. The drive is rated as “open type equipment” by Underwriters Laboratories, Inc.

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IB-19B003 USER’S GUIDE

3.5

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

DIGITAL I/O SIGNALS

Control Input Control Output External Power Supply

24 VDC 5 mA, optically isolated 24 VDC 500 mA, optically isolated (See Figures 3.1 and 3.2) 24 VDC  15%

STANDARD Sinking Sinking

OPTIONAL Sourcing Sourcing

Figure 3.1 - Standard

Figure 3.2 - Optional

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

3.6

ANALOG I/O SIGNALS

Analog Inputs

Analog Output

Analog Reference Monitor Output

3.7

Maximum Input Voltage: 0-5 VDC A/D Resolution: 1/1024 10 bit Input Impedance: 20k Ohm Single Ended Scaleable slew rate with Macroprogramming Maximum Output Voltage: 0-5 VDC D/A Resolution: 1/1024 10 bit Output Current: 5mA Scaleable slew rate with Macroprogramming Reference Voltage: 5 VDC / 5 ma Maximum Voltage Swing:  3 VDC at 1 mA Output Impedance: 330  Accuracy: 8% Monitor Scaling Speed: 3V equals motor rated speed Torque: 3V equals motor peak torque

COMMUNICATION PORTS

Port 1

Port 2

DeviceNet / CAN Bus

Fiber Optic Receiver

3.8

IB-19B003 USER’S GUIDE

Classification: RS-232 Data Transfer: Packet protocol Protocol: 19200 baud, 1 stop bit, 8 data bits, No parity Classification: RS-232 Data Transfer: Packet protocol (default), ASCII Programmable Protocol: 19200 baud, 1 stop bit, 8 data bits, No parity (default) This port can be redefined with Macroprogramming. Classification: CAN bus DeviceNet: Data Transfer and Protocol are defined by the DeviceNet specifications. OR CAN Bus: IIS unique software protocol for easy to use DeltaMax multidrop control. Reference IB-11B023. Classification: Fiber Optics Data Transfer: Master Angle (positional information) Protocol: Proprietary

PROTECTION

Fault Checks

Output Short Circuit Protection

JUNE 2003

Under Voltage, Over Voltage, Motor Short, Output Short, Feedback Loss, Regeneration Resistor Over Temperature and Malfunction, Driver Over Temperature, Motor rms Torque (motor overheat) Driver Rated Current, Over Speed, Motor Stall, Dynamic or Mechanical Brake Failure, Following Error, Internal Watchdog Timer, Processor Diagnostics The drives are suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, 240 volts maximum when protected by a circuit breaker having an interrupting rating not less than 5000 rms symmetrical amperes, 240 volts maximum.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

3.9

MOTOR SPECIFICATIONS

3.9.1

GENERAL

Duty Type Insulation Sealing Storage Temperature Ambient Operating Temperature Shock and Vibration Mounting

3.9.2

FEEDBACK DEVICE

Type: Resolver Type Encoder

3.9.3

Continuous at rated speed and rated torque Permanent magnet synchronous Class F See motor drawings in Appendix A.6, A.7 & A.8 -10 to +70ºC/14 to 158ºF -10 to +40ºC/14 to 104ºF 2 G’s Motor can be mounted in any position

Resolver control transformer See motor drawings in Appendix A.6, A.7 & A.8 ABZ plus UVW 5V line driver

OTHER

Weight Shaft Loading Brake Specifications Dimensions Torque Ratings Speed Torque Curves

PAGE 3 - 6

See motor drawings in Appendix A.6, A.7 & A.8

See specifications in Appendix A.4

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IB-19B003 USER’S GUIDE

Figure 3.3 - DeltaMax Overload Protection Characteristic

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Figure 3.4 - Standard Resolver Wiring Connections for DBM-XXX/15R, DBM-500/30R and Larger

Figure 3.5 - Alternate Resolver Wiring Connections for DBM-XXX/15R, DBM-500/30R and Larger

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IB-19B003 USER’S GUIDE

Figure 3.6 - Standard Resolver Wiring Connections for DBM-120/30R, DBM-200/30R, DBM-400/30R, DBM-BXXX/30R, DBM-D30/30R and DBM-D50/30R

Figure 3.7 - Alternate Resolver Wiring Connections for DBM-120/30R, DBM-200/30R and DBM-400/30R

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Figure 3.8 - Standard Resolver Wiring Connections for DBM-D100/30R Through DBM-D800/30R

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IB-19B003 USER’S GUIDE

SECTION 4 - THE DELTA DRIVE MENU The Delta Driver is an integral component of the DeltaMax. In this configuration the built in keypad and display of the Delta Drive can be used to monitor and display various drive settings and parameters. The easy to use menu scheme allows the user to:  

Review drive settings Monitor key parameters

The driver’s keypad and display are shown in Figure 4.1. The functions are as follows: 

LED DISPLAY is a 5-digit unit that displays coded messages, alarms and parameter values. Messages are displayed in coded bit patterns, hexadecimal, decimal and coded letters.



UP-ARROW is used to navigate around the minor menu loops, to increase the value of a parameter and in combination with other keys for special functions.



DOWN-ARROW is used to navigate around the minor menu loops, to decrease the value of a parameter and in combination with other keys for special functions.



is used to navigate the main menu loop and to return to the main menu loop from the MODE minor loops. FLASHING DECIMAL POINT indicates that an alarm is active.



INDUSTRIAL INDEXING SYSTEMS

Monitor

Figure 4.1 - DeltaMax Keypad and Display

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IB-19B003 USER’S GUIDE

4.1

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

NAVIGATING THE DRIVER’S MENU

The menu structure for the driver consists of a main menu loop with several minor menu loops. The main menu loop and partial sections of the minor loops are shown in Figure 4.2. The major loop is shown vertically on the left side of the diagram. There are four major items on the main menu loop. Each of these items are the starting point for minor menu loops.    

The

STATUS DISPLAY minor menu loop contains drive and motor status displays such as motor speed, motor position, following error, etc. DIAGNOSTIC DISPLAY minor menu loop provides diagnostic information such as I/O status, alarms and alarm history. ADJUST PARAMETER minor menu loop contains parameters that are typically adjusted by the user. Parameters include speed scaling, servo tuning values and load inertia setting. USER PARAMETER minor menu loop contains basic configuration parameters that are usually set once per application such as control mode, motor type, electronic gear ratio and analog polarity. key is used to move around the main menu loop. Once the main menu is positioned on the first

parameter of a minor loop the and keys are used to move around the minor menu loop. The mode key can be used to move from anywhere in the minor menu back to the main menu loop.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

4.1

IB-19B003 USER’S GUIDE

NAVIGATING THE DRIVER’S MENU (cont’d)

r ----

A’----

STATUS DISPLAY LOOP

c.in --c ----

A ----

c.ou ---

DIAGNOSTIC DISPLAY LOOP

AJ1 VALUE

AJ0

AJ2

ADJUST PARAMETER LOOP

UP-01 VALUE

UP-01

UP-02 USER PARAMETER LOOP

Figure 4.2 - Main Menu Loop and Minor Loops

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IB-19B003 USER’S GUIDE

4.1.1

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

STATUS DISPLAY MENU LOOP

The Status Display Menu Loop provides a real time display of motor and driver status. The display format uses the left most digits for a coded message of the item to be displayed and the right most digits are the value. The coded item on the left will flash indicating negative (-) value. The sign convention is (+) is CCW and (-) is CW. Some of the display values, such as A’ & A, are too large for a single display so they are broken into two sections and are displayed on two successive menu displays. The prime (‘) symbol indicates the upper four (4) digits or most significant section and the non-prime symbol indicates lower four (4) digits. For example, if successive displays reads [A’ 1466] and [A 6789], the ACTUAL POSITION is 14666789. The driver is set to the (r) Motor Speed at power application. Any alarm will overwrite the display. The Status Display Menu is organized as follows:

r MOTOR SPEED

A’& A

C’ & C

E’ & E

ACTUAL POSITION

COMMAND POSITION

FOLLOWING ERROR

P’ & P

F’ & F

PULSE COMMAND

SCALED MOTOR SPEED

REF1 VOLTAGE

REF2 VOLTAGE

MOTOR PEAK CURRENT

% MOTOR TORQUE

% MOTOR TEMPERATURE

MARKER POSITION

rL % RATED ABSORPTION

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

4.1.1

IB-19B003 USER’S GUIDE

STATUS DISPLAY MENU LOOP (cont’d)

Status Display Descriptions: DISPLAY ITEM

SYMBOL

Motor rpm Actual Position

r A’ A

Command Position

C’ C

9999999 Bits

Following Error

E’ E

9999999 Bits

Pulse Command

P’ P

+32767 32768 Pulses

Scaled Motor Speed

F’ F

9999999 RPM

REF1 Voltage

10.0 V

REF2 Voltage

10.0 V

Motor Peak Current % Motor Torque

L bL

160.0 A (peak) 0255%

% Motor Temperature

0110%

JUNE 2003

RANGE & UNITS 4000 RPM 9999999 Bits

CONTENTS Displays the speed of motor. Displays the actual position of the motor scaled by UP-05/UP-04 * 24000 bits/rev (driver is always 24000 bits/rev internally). With resolver feedback, the 0.0 positions at power up are referenced to the nearest resolver 0.0. The Delta motors have a 2X resolver, and have two 0.0 points or markers per motor shaft rotation. When the count exceeds display range, 9999999 appear. Displays the command position of the driver (scaled by UP-05/UP-04 similar to A’ A above). When the count exceeds display range, 9999999 appear. Displays the difference between command position and actual position (scaled by UP-05/UP-04 similar to A’ A above). Used in position control modes only. Displays the pulse command input register in position control mode. This counter is a signed 16-bit counter with a range of +32767 to -32768. Counter rolls over when it reaches the maximum count (ring counter). Displays the speed of the motor scaled by HP-41/HP-42. This used typically used to display “machine speed” if the speed exceeds display range, 9999999 appears. Displays the input voltage REF1 (speed command or speed limit depending on mode of operation). Displays the input voltage REF2 (torque command, torque limit or speed command depending on mode of operation). Displays the output current to motor. “A (peak)” shows the peak value of AC current. Displays the load ratio (output torque/rated torque) * 100%. The time constant for calculating this ratio is set by HP-33. Displays calculated motor temperature as a % of the maximum rating. The electronic motor thermal limit alarm activates at 110% (AL-17). oL initializes to 90% at power on.

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IB-19B003 USER’S GUIDE

4.1.1

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

STATUS DISPLAY MENU LOOP (cont’d)

Status Display Descriptions (cont’d): DISPLAY ITEM

SYMBOL

Marker Position

RANGE & UNITS 0359.9 deg

% Rated Absorption

0100%

4.1.2

CONTENTS Displays the motor shaft angle from the motor marker ZPD position. The driver has N marker ZPD positions depending on the resolver/encoder installed in the motor. (i.e. a motor with a 2X resolver has 2 ZPD positions per motor revolution, see motor drawings in Appendix A.6, A.7 & A.8). If the motor has 3X resolver and 3 ZPD positions, this display will go from 0.0 to 359.9 degrees 3 times per motor rotation. For DMAX-1.5, DMAX-4.25, DMAX-8.5 and DMAX17.5 the display is (motor absorption torque/motor rated torque) * 100%. For DMAX-35 and up the display is % rating of the regeneration resistor capacity (UL-31).

DIAGNOSTIC DISPLAY MENU LOOP

The Diagnostic Display Menu Loop provides a real time display of I/O points, alarms, and alarm history and driver configurations. The display format uses the left most digits for a coded message of the item to be displayed and the right most digits are the value. The Diagnostic Display Menu Loop is organized as follows:

PAGE 4 - 6

c.in

c.ou

A.L

GENERAL PURPOSE I/O

EXPANDED INPUTS

EXPANDED OUTPUTS

PRESENT ALARM

A.L-H

o.b

H.P-L

ALARM HISTORY

SOFTWARE VERSION

OPTION STATUS

PARAMETER LIST

S.P-L

A.n

PARAMETER LIST

LINK AXIS ADDRESS

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

4.1.2

IB-19B003 USER’S GUIDE

DIAGNOSTIC DISPLAY MENU LOOP (cont’d)

Diagnostic Display Descriptions: DISPLAY ITEM General purpose I/O

SYMBOL CONTENTS Displays the current I/O status using the vertical segment bars in the c. display. The top half of the segment bar are inputs and the bottom half are outputs. The right most vertical bar is IN0 (top half) and OUT0 (bottom half). The vertical bar just to the right of the c. is IN7 (top half) and OUT7 (bottom half). When the bar is illuminated the I/O point is ON. The I/O point can be inverted using HP-44 & HP-45. IN7 OUT7

IN0 OUT0

General Purpose Input General Purpose Output Alarm

c.in

Not used for the modes described in the manual.

c.out

Not used for the modes described in the manual.

A.L

Alarm History

A.L-H

Displays the current alarm if present. A.L with no numbers indicates that there is no current alarm. A.L # indicates a current alarm code #. See Section 12 for alarm code descriptions and reset method. N/A in this configuration.

Software Version Option Status

0-E u. o.b

Displays the revision of the operating system software. Displays the status of any option modules installed.

H.P-L

00: No options 02: 14 bit A/D converter N/A in this configuration.

S.P-L

Displays a history of the SP that has been changed. When

HP Parameter Change History SP Parameter Change List

Link Axis No.

JUNE 2003

key and

key are concurrently pressed the display changes to a list of SP-# parameters that have been changed. The history log is 65 deep. The

A.n

history log can be scrolled forward and backward using the keys. N/A to the Delta driver without option module.

and

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IB-19B003 USER’S GUIDE

4.1.3

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

ADJUSTMENT PARAMETER MENU LOOP

The Adjustment Parameter Menu Loop provides access to setup and tuning parameters that are commonly used. Each parameter is displayed in two successive displays. The coded parameter name appears on the first display and the parameter value appears on the second display. The

key will

always move from the parameter-coded name to the parameter value. The key will always move from the parameter value to the coded parameter name. If the parameter value is negative, a (-) sign appears in the left most digit of the display.

AJ0

- 0.3

The Adjustment Parameter Menu Loop is organized as follows:

AJ0 REF1 VOLTAGE ZERO

AJ1 REF1 VOLTAGE SCALE

AJ2 LOAD INERTIA RATIO

AJ3 HIGH FREQ. RESPONSE

AJ4 POSITION LOOP GAIN

AJ5 REF2 VOLTAGE ZERO

AJ6 REF2 VOLTAGE SCALE

AJ7 “0” SPEED GAIN REDUCTION

AJ8 FEED FORWARD GAIN

AJ9 NOTCH FILTER FREQ.

The Adjustment Parameters have different meaning and content depending on the mode of operation of the driver.

4.1.4

USER PARAMETER MENU LOOP

The User Parameter Menu Loop provides access to basic setup parameters that are commonly used. Each parameter is displayed in two successive displays. The coded parameter name appears on the first display and the parameter value appears on the second display. The parameter-coded name to the parameter value. The to the coded parameter name.

UP-01 PAGE 4 - 8

key will always move from the

key will always move from the parameter value

3 JUNE 2003

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

4.1.4

IB-19B003 USER’S GUIDE

USER PARAMETER MENU LOOP (cont’d)

The User Parameter Menu Loop is organized as follows: UP-01 CONTROL MODE

UP-02 MOTOR CODE

UP-03 RESOLVER CABLE LENGTH

UP-04/UP-05 ELECTRONIC GEAR RATIO

UP-06 MARKER OFFSET

UP-07 POSITION COIN. WIDTH

UP-08 MOTOR STOPPED THRESHOLD

UP-11 TORQUE LIMIT

UP-15 ABSOLUTE CLEAR MODE

UP-16 BRAKE MODE

UP-17 REF1 and REF2 POLARITY

UP-18 COMMAND PULSE TYPE

UP-19 OUTPUT PULSE TYPE

UP-20 OUTPUT PULSE CODING

UP-25 (MON) OUTPUT FUNCTION

UP-26 COMMAND PULSE POLARITY

UP-29 MOTOR TEST SPEED

UP-30 EXT. REGEN. RESISTOR 

UP-31 EXT. REGEN. RESISTOR kW

UP-28 HOLDING BRAKE THRESHOLD

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IB-19B003 USER’S GUIDE

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

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IB-19B003 USER’S GUIDE

SECTION 5 - DELTAMAX WIRING 5.1

DIGITAL I/O

The system requirements will determine the definition of the 16 digital inputs and 8 digital outputs. There are two options for the physical wiring of the I/O circuitry. A discrete cable with flying leads labeled (C719YYY) may be used or a cable (C-716006) which connects to a DINT-300 interface module. The DINT-300 provides terminal blocks for each I/O and for the 24vdc I/O power supply, the configuration of the terminals is shown in Figure 5.1.

Figure 5.1 - Digital I/O The I/O has two available configurations. The standard configuration has sinking outputs and inputs and the optional configuration has sourcing outputs and inputs. All are shown in Figure 5.2.

Figure 5.2 - Input & Output Configurations

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IB-19B003 USER’S GUIDE

5.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

ANALOG I/O

There are two single-ended analog inputs and one analog output. All of which have an operating range of 0 - 5 vdc. A reference voltage of 5vdc has also been provided. The analog I/O pinouts are shown in Figure 5.3.

WARNING Double check all wiring connections. Make sure all are proper and secure. Improper connections may result in system malfunctions.

Figure 5.3 - Analog I/O

5.3

PORT 1 & PORT 2

The ports are used for communication and use RJ-11 connectors to interface to respective devices. The port 1 & port 2 pinouts are shown in Figure 5.4.

Figure 5.4 - Port 1 & Port 2

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

5.4

IB-19B003 USER’S GUIDE

DEVICENET/CAN BUS (optional)

The Devicenet/Can Bus pinouts are shown in Figure 5.5.

Figure 5.5 - DeviceNet/CAN Bus

5.5

MONITOR OUTPUT

This two-pin connector provides a 3 vdc output for monitoring torque or speed. The monitor output pinouts are shown in Figure 5.6.

Figure 5.6 - Monitor Output

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IB-19B003 USER’S GUIDE

5.6

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

FEEDBACK INTERFACE

For usage of cables refer to Appendix B - CABLES AND ACCESSORIES.

Figure 5.7 - Feedback Interface

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

5.7

IB-19B003 USER’S GUIDE

ABSOLUTE RESOLVER/ENCODER INTERFACE

The resolver/encoder cable connects the resolver and micro power encoder in the motor to the DeltaMax controller. The resolver provides the absolute position with the main power applied and the micro power encoder tracks the position of the motor shaft with the main power off. The battery pack supplies 3.6 V to the micro power encoder when the main power is off. The battery life is 5 years. If the battery is replaced with power on the absolute position will be maintained. If the battery is disconnected with power off the absolute position will be lost and an AL-36 will occur. The battery pack and resolver/encoder wiring are shown in Figure 5.8.

Figure 5.8 - Battery Pack and Resolver/Encoder Wiring

JUNE 2003

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IB-19B003 USER’S GUIDE

5.8

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

ABSOLUTE ENCODER INTERFACE

The micro power encoder tracks the position of the motor shaft with the main power off or on the battery pack supplies 3.6 V to the micro power encoder when the main power is off. The battery life is 5 years. If the battery is replaced with power on the absolute position will be maintained. If the battery is disconnected with power off the absolute position will be lost and an AL-36 will occur. The battery pack and encoder wiring are shown in Figure 5.9.

Figure 5.9 - Battery Pack and Encoder Wiring

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IB-19B003 USER’S GUIDE

SECTION 6 - OPERATION The DeltaMax servo controller has an embedded operating system, which operates out of Flash Memory. The application program written in Macroprogramming will control the specific functionality of the DeltaMax. This application program resides in the controller memory as follows: 64000 bytes for Program storage in Flash Memory 16000 bytes of Constant storage in Flash Memory 16000 bytes of Nonvolatile Data (variable) storage in NOVRAM 57344 bytes of Volatile Data storage in Static RAM

6.1

FIRMWARE DOWNLOADING

The DeltaMax operating system has the capability of being updated in the field. To accomplish this requires a computer, special factory available software and a communication cable. The software will run in Windows 3.1, Windows 95, Windows 98, Windows NT, Windows ME, and Windows XP and is available on request. The communication cable is identical to the cable used for loading the Macroprogram.

NOTE Cable connection must be made to Port 1 of the DeltaMax for downloading. After installing the software on a computer, the process may be started by double clicking on the Firmware Downloader icon. The operator will then need to select the file to download and the COM port to use for the operation before selecting the ‘Download’ button to initiate the process. The remainder of the procedure is explained using message boxes and during download the status is updated with a completion bar on the computer. During the Download procedure, the seven-segment controller display will indicate several different statuses. The first being a ‘c’ for chip erase in process, after which, the file transfer begins which is indicated by a clockwise rotating illuminated segment. When the transfer is complete the new firmware number will be displayed one digit at a time (ex. 3902r01). Ultimately the status will display either an ‘A’ indicating program running or a ‘C’ indicating system reset. Downloading new firmware will not erase the Macroprogram currently stored in memory.

6.2

CONTROL PROGRAM

The control program consists of Macroprogram commands arranged using the MacroPro II software tools; refer to IB-11B022 for details on creating Macroprograms. The Macroprogram establishes the motion sequences for the real axis designated Axis 1, the Pseudo axis and Programmable Limit Switch functions are designated as Axis 2 and the analog I/O functions have been designated as Axis 3. The Macroprogram can also be configured to receive positional information from a master encoder or resolver through the fiber optic port. This information can then be placed on an internal Master Angle Bus to create a master-slave relationship. The I/O is designated as 16 inputs and 8 outputs. In addition, the 8 outputs may be used as programmable limit switches.

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IB-19B003 USER’S GUIDE

6.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

CONTROL PROGRAM (cont’d)

The communication ports, Port 1 and Port 2, are defaulted to packet protocol for use with the MacroPro II software tools. Port 2, however, is under software control in the Macroprogram and can be reconfigured for communication with other devices during operation.

NOTE For additional information on creating the system control Macroprogram, refer to the MacroPro II manual (IB-11B022).

6.3

DRIVE PARAMETERS

There are two methods by which an operator can modify several key drive parameters. One method can be accomplished using a Macroprogram instruction ‘delta_comp’ to modify some tuning parameters. A full description of the command as well as its benefits can be found in Section 8 - Drive Tuning. The other method is through a parameter file. The parameter file has an extension of *.par and each Macroprogram has a parameter file associated with it. The file can be modified through the MacroPro II software tool referred to as the ‘Analyzer’. Every time the operator enters the Analyzer, the parameter file of the chosen program is compared to the current parameters in the DeltaMax. If there is a difference, the operator is given the option to either overwrite the drive parameters or keep the current drive parameters. There is an option in the Analyzer, which will allow the operator to open a window in order to edit the drive parameters. The parameter to be edited consists of the drive package, monitor output; resolver cable length, brake mode, home position shift and several torque limiting functions. Drive parameters may only be changed when the system is in its RESET condition visibly indicated on the controller status display with a “C”. It is necessary when changing certain parameters to cycle the power to the DeltaMax controller. This is visibly indicated with a flashing “P” on the controller status display.

NOTE For more information regarding the Analyzer and the parameter menu, refer to the MacroPro II manual (IB-11B022).

PAGE 6 - 2

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 7 - POWER WIRING The DeltaMax driver and motors have three basic power wiring configurations. Each of the configurations is shown in the following power wiring diagrams (Figures 7.2 through 7.4). Each of the diagrams shows recommended circuit breaker, contactor and wire gauge.

7.1

CIRCUIT BREAKER

It is recommended that each driver be provided with a circuit breaker for protection of the driver and motor. All of the drives are suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, 240 vac maximum when protected by a circuit breaker having an interrupting rating not less than 5000 rms symmetrical amperes, 240 volts maximum. Each of the driver wiring diagrams contains a chart of the recommended circuit breaker for each driver size. The breaker is sized for the worst-case maximum power draw of the driver at the worst-case low line voltage. The charts contain specific vendor and size recommendations. Other types of circuit breakers or fuses may be used provided the continuous ratings are equivalent, the instantaneous rating is 10 to 15 times continuous and can support 3 times continuous for at least 3 seconds. Lower rating protection devices may be used that is sized for the motor power rating. Contact the IIS factory for specific recommendations.

7.2

CONTACTOR

The DMAX-1.5 through DMAX-17.5 driver sizes has an internal power bus contactor. The DMAX-35 through DMAX-115 sizes requires an external power bus contactor. The driver-wiring diagram for the larger size drivers contains a chart of the recommended contactor for each driver size. The contactor is sized for the worst-case maximum power draw of the driver at the worst-case low line voltage. The charts contain specific vendor and size recommendations. Other types of contactors may be used provided the continuous ratings are equivalent and the maximum instantaneous rating is 10 to 15 times continuous. The driver is equipped with a soft start circuit to limit the contactor inrush current. The coil voltage should be the same rating as the incoming line. The maximum current draw for the coil cannot exceed 0.25 amps. The contactor coil must be fitted with a transient voltage protection device. An RC type suppression device is preferred.

7.3

WIRE SIZES

It is required that each driver be installed with the appropriate size wire for proper operation. Each of the driver wiring diagrams contains a chart of the recommended wire gauges and terminal connection tightening torques for each driver size. The wire is sized for the worst-case maximum power draw of the driver at the worst-case low line voltage. The charts contain specific METRIC and AWG size recommendations for stranded wire. Use only copper wire rated for 60/75 degree C or greater. The driver terminals are specifically designed to handle the recommended wire gauge with lug or ferrule terminations. See wiring diagrams for more details.

MARCH 2006

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IB-19B003 USER’S GUIDE

7.4

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

TRANSFORMERS

Isolating the driver from the facility power line with a transformer is recommended but not required. A transformer may be required to step down or step up the facility power line to meet the driver voltage specifications in Section 3. If a transformer is used, select a transformer with the following characteristics:     

Isolation type. Load regulation less than 10%. Ability to provide 3 times rated current for 3 to 5 seconds without saturation. Ability to drive load with a power factor of 0.85. Primary or secondary taps to provide -10%; nominal; +10%; supply voltage.

To achieve maximum performance from the driver, the power input to the driver should be as close to nominal driver input voltage rating as possible. The facility line voltage varies through wide ranges in many parts of the world and it is recommended to match the nominal facility voltage to the nominal input voltage rating of the driver with a transformer. This gives the system the maximum operating range with facility line voltage fluctuations. If the line voltage is too low, intermittent under voltage alarms may occur. A high line voltage will result in excessive regeneration dumping or intermittent over voltage alarms. Buck boost transformers may be used to optimally match the facility line voltage to the driver line voltage rating. Buck boost transformers can be used with or without an isolation transformer. If buck boost transformers are used in conjunction with an isolation transformer, it is best to put the buck boost transformers on the primary side of the isolation transformer. As a general rule the transformer rating can be calculated using the following formulas: For single phase transformer: Rated Mechanical Output (Watts) Transformer Capacity (VA) = -----------------------------------------------0.7 Where: Rated Mechanical Output is from DeltaMax Package rating. 0.7 = motor/drive efficiency and single phase full wave rectifier factor Example: Select transformer for a DeltaMax-200HRA motor/drive package 200 Transformer Capacity (VA) = ------------- = .285 VA 0.7 For three phase transformer: Rated Mechanical Output (Watts) Transformer Capacity (Watts) = -------------------------------------------------0.85 Where: Rated Mechanical Output is from DeltaMax Package rating. 0.85 is motor/drive efficiency and three phase rectifier factor Example: Select transformer for a DeltaMax-6500HRA motor/drive package 6500 Transformer Capacity (VA) = ---------------- = 7647 Watts 0.85 PAGE 7 - 2

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

7.4

IB-19B003 USER’S GUIDE

TRANSFORMERS (cont’d)

One transformer can supply multiple motor/driver packages. Simply add the rated mechanical output of the motor/driver packages together and use the above formulas. If one transformer is used to supply multiple drivers, be sure to protect each driver with the appropriate circuit breaker or fuse. IIS offers a full line of transformers for various line voltage and frequencies, enclosed and open frame types. Contact IIS Application Engineering Department for full details.

7.5

BRANCH CIRCUIT PROTECTION FOR CONTROL VOLTAGE R0,S0

The DMAX-35 through DMAX-115 requires a separate control voltage supply (R0 S0) for proper operation. The R0 S0 circuit is fused internal to the driver and need not be externally fused except to protect the control voltage wiring external to the driver using branch circuit protection guidelines. The control voltage circuit of multiple drivers can be fed from a single branch circuit.

MARCH 2006

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IB-19B003 USER’S GUIDE

7.6

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

WIRING PRACTICES AND GROUNDING

All wiring must conform to accept standards such as NEMA and NEC codes. Signal and low voltage I/O wires must be physical separated from high voltage wires by at least 12 inches or separated by a suitable barrier such as steel conduit or wiring trough separator. The driver must be adequately grounded for proper operation and to provide personnel safety. The proper grounding technique is shown in Figure 7.1 below.

Figure 7.1 - Grounding Technique

NOTE Multiple drivers can share a local ground stud if it is located within 12” of each driver’s E terminal. The ground symbol on each drive indicates that a connection must be made between the E terminal of the drive and earth ground.

PAGE 7 - 4

JUNE 2003

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

7.7

IB-19B003 USER’S GUIDE

POWER SEQUENCING

Field wiring connection shall be made by a UL LISTED and CSA Certified closed -loop terminal connector sized for the wire gauge involved. Connector must be fixed using the crimp tool specified by the connector manufacturer.

Figure 7.2 - DMAX-1.5/RB Through DMAX-8.5/RB Power Wiring

MARCH 2006

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IB-19B003 USER’S GUIDE

7.7

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

POWER SEQUENCING (cont’d)

Figure 7.3 - DMAX-1.5/RA Through DMAX-17.5/RA Power Wiring

PAGE 7 - 6

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

7.7

IB-19B003 USER’S GUIDE

POWER SEQUENCING (cont’d)

Field wiring connection shall be made by a UL LISTED and CSA Certified closed loop terminal connector sized for the wire gauge involved. Connector must be fixed using the crimp tool specified by the connector manufacturer.

Figure 7.4 - DMAX-35/RA Through DMAX-115/RA Power Wiring

MARCH 2006

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IB-19B003 USER’S GUIDE

PAGE 7 - 8

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

JUNE 2003

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 8 - DRIVE TUNING The DeltaMax has the ability to optimize the system drive response through the use of software. The macroprogramming instruction ‘delta_comp’ is used to transmit adjustment parameters to the Delta drive. The syntax for this instruction is: label

delta_comp

controller#, AJ2, AJ3, AJ4, AJ7, AJ8, AJ9

The parameters and their default values are defined in Table 8.1. ADJUSTMENT PARAMETER LOAD INERTIA RATIO

SYMBOL AJ2

DRIVE RANGE 0100.0 TIMES

DELTAMAX DEFAULT 1.0 TIMES

HIGH FREQUENCY RESPONSE

AJ3

0.120.0

1.0

POSITION LOOP DC GAIN

AJ4

1200 RAD/SE C

30 RAD/SEC

ZERO SPEED GAIN REDUCTION FEED FORWARD GAIN

AJ7

010000

AJ8

02.0 Times

1.0

NOTCH FILTER FREQUENCY

AJ9

100200 00 rad/s

6000 RAD/SEC

DESCRIPTION Sets the baseline frequency response of the driver using the ratio of the load inertia/motor inertia for a rigidly coupled load. If the load is not rigidly coupled, the value entered may vary from the calculated value. If the value is set too high, the motor and driver may become unstable and oscillate. Sets the high frequency response of the driver. The higher the number the more responsive. If the value is set too high, the motor and driver may become unstable and oscillate. The value in AJ3 is unit less and works in concert with AJ2. Sets the DC gain of the position control loop. A higher value in AJ4 results in stiffer, faster response. If the value is set too high, the motor and driver may become unstable & oscillate. Sets the amount of gain reduction at zero speed. Sets the feed forward gain in the position loop. A value of 50% results in 0.0 following error. Less than 50% will produce a lag between the actual motor position and the commanded position and greater than 50% produces a lead. The lead or lag will be proportional to speed at non 50% settings. Sets the notch frequency of a velocity loop anti-resonance filter. This filter can be used to cancel machine or servo resonance. Power must be turned OFF then ON for this parameter to take effect.

Table 8.1

NOTE Any time a ‘Reset’ is issued from the MacroPro II Analyzer, the parameters will be set to their default values.

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IB-19B003 USER’S GUIDE

8.1

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

TUNING PROCEDURE

AJ2 Load inertia ratio, AJ3 High frequency response and AJ4 Position loop DC gains are the parameters that adjust the response of the driver. A qualified technician using a chart recorder or oscilloscope to view the performance of the system should do adjustment of these parameters. 1. Start the manual adjustment by setting AJ2 to the ratio of the load inertia to the motor rotor inertia. Set AJ3 and AJ4 to the default settings. 2. Connect an oscilloscope or chart recorder to the MON output on the driver front panel. Set monitor output in Analyzer Parameter window for speed.

CAUTION Make sure when executing motion that all personnel are clear of moving parts and that the mechanical systems will permit the full range of motion. 3. Cause the system to move through the most aggressive (highest speed and highest acceleration) motion encountered in normal operation. The stimulus for this motion depends on the system configuration. 4.

Adjust AJ2, AJ3 and AJ4 for the desired response using the Adjustment Parameter Loop.

Parameter AJ2 primarily provides the damping function in the system response. The larger the system inertia the larger the value of AJ2 required. If the load inertia is not rigidly attached to the motor shaft, the value of AJ2 may be smaller than the calculated value. Parameter AJ3 sets the frequency of any small oscillations and overshoots that may be present. Too high a value can result in high frequency oscillations. AJ3 also sets the system frequency response to external stimulus. Parameter AJ4 sets the basic gain of the control loop and should be set as high as practical without causing oscillations. This parameter primarily affects the stiffness of the system response or the conformance of the motor motion to the commanded motion.

8.2

NOTCH FILTER ADJUSTMENT

The DeltaMax drive contains a Notch Filter, adjusted by parameter AJ9 that can be used to eliminate system natural resonance frequency oscillations. Natural frequency resonance oscillations can occur with a belt drive, a flexible coupling or any mechanical component that causes flexing or compliance in the motor drive train. In general, the normal tuning of the driver will not eliminate the natural resonance without lowering the system response to an unacceptable level. If the natural frequency of the system can be determined, the Notch Filter, AJ9, can be set to that frequency to notch out that particular frequency thereby allowing higher gain settings and better response. Once a program has set AJ9 via a delta_comp instruction, the operator must then cycle power to the controller for it to take effect.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 9 - REGEN RESISTOR SELECTION 9.1

DELTAMAX DRIVER REGENERATION CAPACITIES

The DeltaMax motor and driver have the ability to act as a brake for a rotating load. This condition typically occurs during the deceleration of the load or when the system is stopping a vertical load such as an elevator or lift. In both cases, the driver may have to absorb the mechanical and potential energy in the system. The driver must absorb the energy if the energy in the load exceeds to mechanical losses in the system. The driver has 3 ways to absorb the energy from the load.   

Store the energy by charging the internal main DC bus capacitors (EC) Use the energy internally to power the driver control circuitry (PD) Dissipate the energy using a regeneration resistor (PR)

The Delta driver energy absorption capacities are as shown in Table 9.1. DRIVER SIZE DMAX-1.5/RB DMAX-1.5/RA DMAX-4.25/RB DMAX-4.25/RA DMAX-8.5/RA DMAX-8.5/RB DMAX-17.5/RA DMAX-35/RA DMAX-50/RA DMAX-70/RA DMAX-115/RA

INTERNAL POWER INTERNAL REGEN CONSUMPTION (PD) CAPACITY (PR) 0W 13 0W 13 0W 13 0W 13 0W 24 0W 17 0W 37 80 W 80 80 W 100 100 W 200 180 W 300 Table 9.1 - Energy Absorption Capabilities

CHARGING CAPACITY (EC) 17 17 17 17 17 17 22 38 54 94 188

The DeltaMax drivers are equipped with internal circuitry to detect a rise in the main DC power bus indicating energy absorption. If the DC power bus reaches approximately 400 VDC, the regeneration circuit is turned on to prevent the main DC power bus from rising to 420 VDC which will result in an over voltage alarm AL-02.

JUNE 2003

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IB-19B003 USER’S GUIDE

9.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

SELECTION OF REGENERATION RESISTOR

The amount of energy stored in the moving components of the system must be calculated and compared to the energy absorption capacity of the driver to determine if an external regeneration resistor is required. The stored energy is of two basic types, kinetic energy in the form of a moving mass and potential energy of a mass being held against gravity. Ek = 0.5 * (JM + JL) * (2 *  * N / 60) 2 EP = (2 *  * N * Tg * tb / 60) Calculate the system losses in the motor, driver and friction. EL = (PM + PD + ( * N * Tf / 60)) * ta Calculate the regeneration power. PR = (Ek + EP - EL - EC) / tc If regeneration power PR is greater than 0.0, a regeneration resistor will be needed to prevent the main DC power bus from generating an over voltage alarm AL-02. Where: Ek EP EL EC JM JL N PM PD Tf Tg PR ta tb tc

= = = = = = = = = = = = = = =

Net kinetic energy Joules Net Potential energy Joules Energy loss due to friction Joules Driver charging capacity Joules (See Table 9.1) Motor rotor inertia kg-m2 Load inertia kg-m2 Motor speed in RPM Motor loss watts (10% of motor rating) Driver internal power consumption watts (See Table 9.1) System friction torque N-m Net torque to hold up load against gravity N-m Regen power watts (See Table 9.1) Deceleration time Move time See Figure 9.1 Cycle time

* The above equations are reasonable approximations.

Figure 9.1 PAGE 9 - 2

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

JUNE 2003

IB-19B003 USER’S GUIDE

PAGE 9 - 3

IB-19B003 USER’S GUIDE

9.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

SELECTION OF REGENERATION RESISTOR (cont’d)

DeltaMax Drivers DMAX-1.5 through DMAX-17.5 does not contain an internal regeneration resistor. If a regeneration resistor is required, an external resistor with a power rating of at least PR watts must be connected. DeltaMax Drivers DMAX-35 through DMAX-115 contains internal regeneration resistors. If the internal regeneration resistor capacity is greater than PR watts, no external resistor is needed. If the internal resistor is not large enough, an external resistor with a power rating of at least PR watts must be connected. If an external regeneration resistor is needed, parameters UP-30 and UP-31 must be set to the values of the external resistor. The external resistor specifications are shown in Table 9.2. DRIVER SIZE DMAX-1.5/RA DMAX-1.5/RB DMAX-4.25/RA DMAX-4.25/RB DMAX-8.5/RA DMAX-8.5/RB DMAX-17.5/RA DMAX-35/RA DMAX-50/RA DMAX-70/RA DMAX-115/RA

RESISTANCE MAX WATTAGE WIRE GAUGE 30~100 Ohms 300 W 14 AWG 1.25 mm² 30~100 Ohms 300 W 14 AWG 1.25 mm² 30~100 Ohms 300 W 14 AWG 1.25 mm² 30~100 Ohms 300 W 14 AWG 1.25 mm² 30~100 Ohms 300 W 14 AWG 1.25 mm² 30~100 Ohms 300 W 14 AWG 1.25 mm² 30~70 Ohms 400 W 14 AWG 1.25 mm² 12.5~25 Ohms 2.4 KW 12 AWG 3.5 mm² 12.5~25 Ohms 3 KW 12 AWG 3.5 mm² 10~15 Ohms 5.5 KW 10 AWG 5.5 mm² 6~15 Ohms 11 KW 8 AWG 16 mm² Table 9.2 - External Resistor Specifications

Figures 9.2 and 9.3 shows how to connect an external regeneration resistor to the DeltaMax drivers.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

9.2

IB-19B003 USER’S GUIDE

SELECTION OF REGENERATION RESISTOR (cont’d)

Figure 9.2 - Connection of an External Regen Resistor for DeltaMax Driver Sizes DMAX-1.5 Through DMAX-17.5

JUNE 2003

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IB-19B003 USER’S GUIDE

9.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

SELECTION OF REGENERATION RESISTOR (cont’d)

Figure 9.3 - Connection of an External Regen Resistor for DeltaMax Driver Sizes DMAX-35 and Larger The regeneration resistor is subjected to severe peak power loads during regeneration. The driver switches the regeneration resistor across the DC power bus using PWM techniques to regulate the DC power bus voltage during regeneration dumping. When the driver’s switch is on the regeneration resistor is subjected to the following peak power: PEAK POWER = (400 VDC) 2 / RESISTOR VALUE in ohms Be sure to select a regeneration resistor that can sustain the required peak power and continuous power ratings.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

9.3

IB-19B003 USER’S GUIDE

STANDARD REGENERATION RESISTOR PACKAGES

In general, wound metal ribbon resistors are recommended for this type of application. IIS offers a complete line of enclosed panel mounted regen resistor units to complement the DeltaMax driver. Various combinations of series and parallel connections are allowed to provide adequate regen resistor capacity. IIS P/N MFS30A300J* RGH200-30* DRGN-20/400* DRGN-45/420 DRGN-22.5/655 DRGN-15/880 DRGN-11.25/1120

Description 30 Ohm 30 Watts 30 Ohm 200 Watts 20 Ohm 400 Watts 45 Ohm 420 Watts 22.5 Ohm 655 Watts 15 Ohm 880 Watts 11.25 Ohm 1120 Watts

*Not UL/CE approved

EXAMPLE CALCULATION: If 4 KW of regen were needed on a DMAX-115 driver, four (4) DRGN-11.25/1120 units could be connected as follows to yield 11.25 Ohms at 4480 Watts.

DRGN-11.25/1120

DRAWING NUMBER

DESCRIPTION

MFS30A300J RGH200-30 DRGN-20/400 DRGN-45/420 DRGN-45/420-2 DRGN-22.5/655 DRGN-15/880 DRGN-11.25/1120

Resistor Regen Resistor Regen Resistor Regen Resistor Regen Resistor Regen Resistor Regen Resistor Regen Resistor

JUNE 2003

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CAUTION HOT SURFACE

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 10 - DYNAMIC BRAKES The DeltaMax driver is equipped with special circuitry and software to sequence a dynamic braking relay connected across the motor windings. It is very important for proper operation that the dynamic breaking relay contacts are open before the driver circuitry is turned on and that the driver is off before the dynamic braking relay contacts close. The driver in conjunction with external braking relays provide the proper sequencing to prevent driver damage. If dynamic braking is not used, tie the BRAKE CONFIRM input ON for the DMAX-1.5 through DMAX-17.5 driver sizes. For DMAX-35 and larger drivers, a jumper must be provided between B11 and B12. A B11 to B12 jumper is installed by the factory and must be removed if dynamic braking is to be used. The brake mode may be selected through the MacroPro II analyzer, parameters, current drive parameters menu item. Be sure to select a dynamic braking resistor with a sufficient peak power rating. 150 * V2 Resistor Peak Power = --------------R Where V = maximum motor voltage when dynamic braking is applied. General rule: V = 300 * (motor speed @ braking) / (motor maximum speed rating) Figures 10.1 and 10.2 show the connections for dynamic braking.

MARCH 2004

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IB-19B003 USER’S GUIDE

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Figure 10.1 - Dynamic Brake Connection for the DMAX-1.5 Through DMAX-17.5 Drivers with a Sourcing I/O Board

PAGE 10 - 2

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

Figure 10.2 - Dynamic Brake Connection for the DMAX-35 Through DMAX-115 Drivers

MARCH 2004

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Figure 10.3 - Dynamic Braking Control Signals

1. 2. 3. 4. 5. 6. 7.

8. 9.

DRIVE ENABLE may be turned ON within 0.6 seconds of SERVO NORMAL. BRAKE turns on within 800usec. of DRIVE ENABLE. BRAKE CONFIRM must be returned within 100ms. or AL-14 will be generated. The servo will become active within 800usec of sensing BRAKE CONFIRM. When an alarm is sensed, the SERVO NORMAL and BRAKE outputs are turned OFF. The DRIVE ENABLE must be turned OFF before alarm clearing can be accomplished. The BRAKE CONFIRM turns OFF indicating the braking relay has toggled and dynamic braking is engaged. ALARM RESET causes driver to check for clearing of the alarm condition and if all alarm states are clear the SERVO NORMAL will turn ON within 30 ms. ALARM RESET should be turned OFF before DRIVE ENABLE is turned ON. The servo becomes inactive and the BRAKE output turns OFF within 800usec of DRIVE ENABLE being turned OFF. The BRAKE CONFIRM turns OFF indicating the braking relay has toggled and dynamic braking is engaged.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 11 - MECHANICAL BRAKES The DeltaMax driver is equipped with special circuitry and software to sequence an electrically released mechanical brake. The full line of Delta motors are available with mechanical brakes to provide mechanical fail safe braking in the case of power loss and driver disable. It is very important for proper operation to sequence the driver servo lock and mechanical brake to avoid loss of holding torque during the transition. The driver in conjunction with an external relay and brake power supply provide for the optimum sequencing to prevent loss of holding torque or driver damage. The brake mode and brake threshold are configured through the MacroPro II analyzer, Parameters, Current Drive Parameters menu item.

11.1

NO MECHANICAL BRAKING

If a mechanical brake is not used, tie BRAKE CONFIRM input ON for the DMAX-1.5 through DMAX-17.5 driver sizes. For the DMAX-35 and larger drivers, a jumper must be provided between B11 and B12. The factory installs a jumper from B11 to B12. Set the Brake Mode to No Brake.

11.2

MECHANICAL BRAKING WITH SOFT DECELERATION

The driver sequencing can be set to apply the mechanical brake after the driver has reduced the motor speed to a programmable set point. The speed when the brake applied is determined by the Holding Brake Threshold parameter. This value is scaled in % of rated speed. The mechanical brake is applied immediately upon loss of power or a drive alarm. Connect the braking relay and power supply as shown in Figures 11.1 or 11.2 and set the Brake Mode to Mechanical Brake. The sequencing will be as shown in Figure 11.3.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Figure 11.1 - Mechanical Brake Connection for the DMAX-1.5 Through DMAX-17.5 Drivers with a Sourcing I/O Board

PAGE 11 - 2

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IB-19B003 USER’S GUIDE

Figure 11.2 - Mechanical Brake Connection for the DMAX-35 Through DMAX-115 Drivers

JUNE 2003

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

Figure 11.3 - Mechanical Brake Sequencing for Soft Decel

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11.

DRIVE ENABLE may be turned ON within 0.6 seconds of SERVO NORMAL. BRAKE turns on within 800usec. of DRIVE ENABLE. BRAKE CONFIRM must be returned within 100ms or AL-14 will be generated. The servo will become active within 800usec of sensing BRAKE CONFIRM. When an alarm is sensed, the SERVO NORMAL and BRAKE outputs are turned OFF and the servo becomes inactive. The BRAKE CONFIRM turns ON indicating the braking relay has toggled. The mechanical brake engages after a delay in the braking mechanism. The DRIVE ENABLE must be turned OFF before alarm clearing can be accomplished. ALARM RESET causes driver to check for clearing of the alarm condition and if all alarm states are clear the SERVO NORMAL will turn ON within 30 ms. ALARM RESET should be turned OFF before DRIVE ENABLE is turned ON. The servo starts to decelerate within 800usec of DRIVE ENABLE being turned OFF. The servo becomes inactive and the BRAKE output turns OFF within 800usec of the motor speed dropping below the brake threshold set point. The BRAKE CONFIRM turns ON indicating the braking relay has toggled.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

12. The mechanical brake engages after a delay in the braking mechanism.

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11.3

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

MECHANICAL BRAKE POWER SUPPLY

DRAWING NUMBER

DESCRIPTION

DMBPS-115/24 DMBPS-220/24 DMBPS-220/220

Mechanical Brake Power Supply Mechanical Brake Power Supply Mechanical Brake Power Supply

** CAUTION ** The DMBPS-XXX mechanical brake power supply does not have enough capacity to operate the brake in the 7500 W and 10 KW size motors. Use properly rated 24 VDC power supply and relay (Ry) per Figure 11.2.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

JUNE 2003

IB-19B003 USER’S GUIDE

PAGE 11 - 7

Error! Not a valid link.

IB-19B003 USER’S GUIDE

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

JUNE 2003

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

SECTION 12 - ALARM & STATUS CODES

12.1

ALARM CODES

ALARM CODE HALt AL -01 Internal Power Module Error

DESCRIPTION Driver fatal fault Driver has detected the following:  Overcurrent  Overheat  Gate voltage drop

AL -02 Overvoltage

DC power bus exceeds 420 VDC.

AL -03 Under Voltage

DC power bus below 200 VDC.

AL -06 Resolver Open

Resolver feedback signal (R1, R2) drops below 0.34 VAC. Main control unit identifies a fault in the power stage of the driver. Excessive regen energy being dissipated by the internal or external regeneration resistor. Regen transistor is ON for more than 50ms.

AL -07 Power Stage Error AL -09 Regen Resistor Over Temperature AL -10 Regen Resistor Open (DMAX-35 and above only)

AL -12 Watchdog timer AL -14 Brake Alarm

Internal CPU clock has stopped. Sequencing of the static or dynamic brake is faulty.

AL -15 Excessive Current

Motor current exceeds the rating by 120%.

JUNE 2003

REMEDY Replace driver. Check if the motor wire (A/B/C) is shorted or grounded. Ambient temperature over 55 C. Indicates a fatal fault in the driver power stage. If motor wires are not shorted and temperature is below 55 C contact IIS factory. Power line voltage fluctuation above 264 VAC for “A” model drivers or 126 VAC for “B” model drivers. Excessive regeneration energy. Check line voltage fluctuations. Add additional external regeneration resistor. Power line voltage fluctuation below 170 VAC for “A” model drivers or 85 VAC for “B” model drivers. Check line voltage fluctuations. Check for missing phase of AC line power for 3 phase models DMAX-35 and above. Check for broken resolver wire or loose connection. Voltage between R1-R2 must be above 0.34VAC. Indicates a fatal fault in the driver power stage. Contact IIS factory. The frequency or rate of acceleration/deceleration may be too high. Excessive power line voltage. Add additional regen resistor capacity. WITH POWER OFF: If an internal regen resistor is used, check that the resistance from P to JP2 is less than 20-30 ohms and that a jumper is installed from JP1 to JP2. If an external regen resistor is used, verify the regen resistor is the proper value and that all wiring to the resistor is secure. Unit is damaged. Contact IIS factory. Check wiring connections of the static or dynamic brake. Verify that the external braking relay is functional. Check if the motor wire (A/B/C) is shorted or grounded. Verify that motor shaft or machine system is not jammed. Check that the motor code in the Analyzer is set for the proper motor.

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IB-19B003 USER’S GUIDE

12.1

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

ALARM CODES (cont’d)

ALARM CODE AL -16 Speed amp Saturated

DESCRIPTION Internal speed loop is saturated and max. torque is applied for more than 3 sec.

AL -17 Motor overload

Calculated motor temperature exceeds rating 110%.

REMEDY Verify that motor shaft or machine system is not jammed. Check that the motor code in the Analyzer is set for the proper motor. Acel/decel rate is too large for the inertia load on the motor causing maximum torque during acel/decel. Verify that the average torque required to drive the load does not exceed the motor/driver continuous rating. Check if the duty cycle of the machine is too high. Check motor code UP-02 is set for the proper motor. t = -Tm

Where:

t I IR TM

= = = =

1.052 I 1IR

(

( )

)

time in minutes motor current motor rated current thermal time constant of motor

Status display oL is I x 100 IR See Section 3. AL -18 Driver Overload

Motor current exceeds intermittent rating of driver or motor whichever is less.

Verify that motor shaft or machine system is not jammed. Check motor code UP-02 is set for the proper motor. Acel/decel rate is too large for the inertia load on the motor causing maximum torque during acel/decel. K t= I -1 IR*1.2

(

Where:

t I IR K

= = = =

)

time in seconds motor current motor rated current 1.5 for Delta-D30HRA 2.0 for Delta-120HRA & Delta-D50HRA 2.5 for Delta-200HRA & Delta-D100HRA 3.0 for Delta-D200HRA 3.5 for Delta-400HRA 4.0 for Delta-D400HRA 6.0 for all others

See Overload Protection Characteristic Curve in Section 3.

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INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

12.1

IB-19B003 USER’S GUIDE

ALARM CODES (cont’d)

ALARM CODE AL -19 Resolver Error

DESCRIPTION Resolver feedback error.

AL -20 Overspeed

Motor speed exceeds maximum rating by 120%.

AL -21 Deviation counter overflow

Motor is unable to follow the commanded profile. Deviation counter exceed 221.

AL-22 Absolute encoder phase error AL-23 Absolute encoder disconnected AL-25 Option AL-26 Parameter setting error

Absolute encoder CHA and CHB have been detected out of phase.

Replace motor.

Absolute encoder connection is broken.

Check absolute encoder/resolver cable C-253YYY. If cable is OK, replace motor.

Self-diagnostic checks of options failed. Motor code is not set or is set improperly.

14-bit A/D converter not functioning to specification. Return to factory. Motor code must be set to operate. Set UP-02 then cycle power to have the parameters take effect.

AL-27 Absolute encoder fault AL-32 Absolute Home Position not set

CHA or CHB of absolute encoder is non-functional.

Check absolute encoder/resolver cable C-253YYY. If cable is OK, replace motor.

Absolute Home Position has not been established using the MacroPro II Software tools. Also set with AL-6, 19, 22, 23.

Check for cause of fault in the case of AL-6, 19, 22, 23. Correct fault and set Absolute Home Position using MacroPro II Software tools.

AL-33 Absolute Home Position setting error

Absolute Home setting procedure is not correctly completed. Also set with AL-6, 19, 22, 23, 27.

Check for cause of fault in the case of AL-6, 19, 22, 23, 27. Correct fault and set Absolute Home Position using MacroPro II Software tools.

AL-36 Battery missing

Battery has been disconnected when the power was OFF. A, B, Z, U, W or V phases of encoder not functional.

Check for detached battery or cable short.

AL-40 Encoder Signal Short

JUNE 2003

REMEDY Check resolver cable and connectors. Check if resolver is loose on motor shaft. Verify that resolver cable is separated from power wiring to prevent noise coupling to resolver signals. Check resolver cable and connectors. Check if resolver is loose on motor shaft. Verify that resolver cable is separated from power wiring to prevent noise coupling to resolver signals. Overshoot is generated due to improper setting of AJ2, AJ3 & AJ4 parameters. Excessive load. Load inertia is too large for acceleration/deceleration rate. Position gain (AJ4) is too high. Torque limit is too low.

Check encoder cable and connections.

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IB-19B003 USER’S GUIDE

12.1

ALARM CODES (cont’d)

ALARM CODE AL-41 Encoder Communication error AL-42 Encoder Power AL-43 Encoder Checksum AL-44 Battery low AL-45 Absolute encoder error

12.2

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

DESCRIPTION Communication problem with absolute encoder

REMEDY Check encoder cable, replace driver, motor.

Absolute encoder backup power low Encoder communication checksum error at power up

Replace battery.

Absolute battery voltage has fallen below 2.8 V. Signal sequencing problem in the absolute encoder.

Replace absolute battery.

Replace motor/encoder.

Replace motor.

CONTROLLER STATUS

Figure 12.1 - Controller Status

PAGE 12 - 4

JUNE 2003

APPENDIX A (MOTOR/DRIVER SPECIFICATIONS) AND APPENDIX B (CABLES AND ACCESSORIES) DOCUMENTS ARE SAVED UNDER IB-19B001.

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

IB-19B003 USER’S GUIDE

APPENDIX C - ABSOLUTE DELTAMAX MOTOR AND DRIVE APPLICATION NOTE OVERVIEW The DeltaMax Absolute Motor and Drive system consists of the following: 1) DeltaMax Controller with integral Absolute Motor Driver. 2) Motor with integral Absolute Encoder. 3) Battery pack with cable. 4) Cabling between Controller and Drive. 5) MacroPro II Tool Kit Software Package. As shipped the absolute position may not be set. This will be indicated by an alarm condition from the drivers display: Display Al 27 Al 32 Al 33 Al 36

Description Alarm 27: ABS encoder error Alarm 32: Absolute position not set or lost. Alarm 33: ABS home position invalid. Alarm 36: Battery missing.

Prior to setting the ABS HOME POSITION, errors 27 and 36 must be corrected by proper installation of the battery and cabling. The battery plugs into the three-prong connector down the side of the controller below the resolver/encoder connector. Connections should be made with the power off to the controller. Also the power must be cycled to the controller to clear most alarm conditions. The controller will come up with alarm 32 as long as the ABS HOME POSITION has not been set. Setting the ABS HOME POSITION is accomplished through the Macropro II Tool Kit version 2.3 or higher.

JUNE 2003

APPENDIX C - 1

IB-19B003 USER’S GUIDE

INDUSTRIAL INDEXING SYSTEMS, Inc. DELTAMAX

SETTING ABS HOME POSITION Connect the MacroPro II Analyzer to the DeltaMax controller per procedures in the DeltaMax Manual. Once connected the ABS HOME POSITION may be successfully set as long as the motor is not busy as follows:

Position the motor to the correct home position manually or otherwise. It is possible to run a program implementing indexes to get to the exact position using the tool kit. To manually get to a position the drive shall have to be off, issue a RESET to the controller using the Tool Kit to accomplish this.

From the Parameters pull down menu select Set Home Position; verify that the default selection bullet of Clear Rotation & Angle is selected. If not it must be changed from NO EFFECT. To change this setting it may be necessary to RESET the controller from the tool bar first.

From the Set Home Position window, with the mouse click on the Set Home button.

Within less than a minute the controllers single seven segment display should start flashing a “P”, to indicate that power should be cycled at this point.

Cycle power to the DeltaMax.

Verify that there are no alarm conditions on the displays.

If alarm conditions persist after a couple of attempts, record the alarms, and then refer to the DeltaMax manual for a corrective procedure. If it is unclear on how to correct the alarm condition or other problems exist, please contact Industrial Indexing System for assistance.

APPENDIX C- 2

JUNE 2003

IB-19B003

INDUSTRIAL INDEXING SYSTEMS INC. 626 FISHERS RUN VICTOR, NEW YORK 14564 (585) 924-9181 FAX: (585) 924-2169

IB-19B003

INDUSTRIAL INDEXING SYSTEMS INC. 626 FISHERS RUN VICTOR, NEW YORK 14564 (585) 924-9181 FAX: (585) 924-2169