drive series “onda” - mez cz · 2008. 12. 18. · drive series “onda” pag. 9 di 69 2.3...

Drive Series “ONDA”

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LIST OF CONTENTS

1. General Caution Measures Arrangements done by the Customer Safety symbols Notes on installation Terminal board- connection diagram

2. Technical Data Foreword Application field General working data

3. Safety General notes on safety Safety devices Risk zones Control zones Connecting the equipment Start Stop Emergency stop Signal and alarm devices

4. Drive Description ONDA - General description

5. Supply unit with dynamic brake Foreword Technical features of the supply unit with dynamic brake Supply group with dynamic brake Control electronics supply Power electronics supply Mains voltage configuration for the equipment Configuration Dip Switches Signal Connector P5 P2 connector for interconnection Control and brake protection board Working principle Board setting Max. Overload setting Setting of the overload ratio

6. Regenerative supply unit Foreword Technical features of the regenerative supply unit


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Diagram of the energy recovery function Recovery board — Description

7. Vector Converter Unit Converter on motor side Vector control board- Description Connector P7 Connector P6 Optional board Connector P7 – optional board Connector P8 – optional board

8. Cooling System General Description Water input to the exchanger Closed water circuit – Features

9. Anomaly Solution Guide General remarks i Alarm messages on display LED’s on the supply unit board Machine status and alarms on the supply unit

10.Serial Communication Protocol

Hardware specifications Software specifications Examples of telegram transmission Details on the communication features Examples of byte checksum calculation Baud rate parameter Setpoint ID byte encoding


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1. General Caution Measures


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1.1 Predisposizioni a carico del cliente Electrical installation and connection The electrical installation and connection must be carried out according to the voltage and frequency values indicated in the order as well as to the EN 60204-1 regulation. The wiring to be done by the Customer ends at the device terminal input as well at the mains switch input . Placement and mounting The equipment is provided with lifting bars and can be handled with a lift truck having forks that can lift up to 2000 kg. The installation does not require basements work; nevertheless the cabinet must be placed on an even surface able to bear the cabinet’s load . In order to help the cooling of the electronic components inside the cabinets anything may be placed least 1 meter away from the cooling grids that are assembled on the cabinet’s doors. 1 meter space has to be left between ceiling and cabinet’s top as well, where the cabinet fan is mounted. Storage The Customer has to store the packing in a dry place, away from heat sources, humidity, water. 1.2 Symbols regarding safety The symbols used in the manual indicate chapters or paragraphs where ranger conditions are described:

Conditions implying high danger for the operator. Also marked with CAUTION.

Conditions where voltage may cause danger for the operator. Also marked with CAUTION .


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1.3 Notes on installation In order to reduce RFI , before connecting the motor it is recommended to let the motor cables go through the six ferrite rings placed inside the cabinet, as shown in the picture below


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Ensure that the quantity of liquid inside the closet circuit respects the MIN./MAX level of the tank. Very important: in order to achieve the perfect equipment working check for the grounding of the motor and encoder cable to have been carried out in a perfect way. The grounding of the motor and encoder shields has to be carried out both on the motor and the cabinet through the bar placed on the cabinet’s lower side. In order to avoid heavy damage during the wiring and the mains connection steps the converter should be protected so that no screws or other metallic parts fall inside the drive. 1.3.1 Terminal board- connection diagram


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2. Technical Data


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2.1 Foreword The development of endothermal motors having steadily improving performances and features requires the use of highly dynamic test and measure instruments. From this point of view, a dynamic test bench like ONDA corresponds to the state of the art in the field of test benches. A test bench is considered a machine able to absorb mechanical energy Test benches are used for different purposes, such as motor power measure during a gear or transmission test. Motor tests actually require high-performance systems, since the features of the tested motor have been improving and the tests to be carried out grow more and more complex. See for instance the regulations on emissions, absorbing and noise requiring both for the project and test phase more and more efficient instruments. Another aspect regarding the test bench evolution is that many tests now are taken into the test cell, while in the past they could be carried out only on the road “Road to rig” means in fact that the final tests are transferred to the test cell. The vehicle features are simulated through a system able to brake and carry the endothermal motor. Reduced response times help simulating the features of a real vehicle . Friction, inertia, air resistance, vehicle mass can be easily modified to simulate different situations. 2.2 Application field

The system was developped for torque/speed control of a three-phase asynchronous dynamometer having a sinusoidal supply voltage of 380 – 520 VAC . N.B. The voltage delivered by the drive depends on the drive’s supply voltage itself as well as on the converter type, that means either a drive with braking group dissipating on resistors or a recovery system to the mains. Any use not corresponding to the described functions releases the manufacturer’s responsibility in case of damage to persons or things.


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2.3 General working data

Nominal current See chart Output voltage 380 – 520 Vac with regenerative bridge

380 – 420 Vac with dynamic braking Input voltage 400 – 440 Vac +/- 15% three-phase 47-63 Hz Max. output frequency 500Hz Programmable input and outputs

N°2 analog outputs +/-10V 11bit N°2 optocoupled digital outputs 18-30Vdc N°5 optocoupled inputs 18-30Vd N°2 analog inputs+/-10V 12bit

Serial line RS 485 115.200 baud. Torque Response


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General data rigen. ONDA drive

Overload [A]

Description fPWM [kHz] Nom. Current [A] 60s every 300s 30s every 300s

ONDA T10 5 180 260 320

ONDA T20 5 270 380 460

ONDA T30 5 350 490 600

ONDA T31 5 500 700 900

ONDA T40 5 560 780 960

ONDA T50 5 700 980 1200

ONDA T60 5 1250 1500 1800


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General Data ONDA drive with dynamic

braking Overload [A]

Description fPWM [kHz] Nom. Current [A] 60s every 300s 30s every 300s

brake motor brake motor brake Motor

ONDA T10 5 180 90 260 130 320 160

ONDA T20 5 270 135 380 190 460 230

ONDA T30 5 350 175 490 245 600 300

ONDA T31 5 500 250 700 350 900 450

ONDA T40 5 560 280 780 390 960 480

ONDA T50 5 700 980 1200

ONDA T60 5 1250 1500 1800


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3. Safety 3.1 General notes on safety


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All the personnel operating on the device must have read and understood what is written in the manual, especially the chapter on safety. Some necessary elementary caution measures are listed below:

• Only skilled personnel is allowed to touch and work on the device who is well aware of electrical risks.

• The personnel in charge of servicing has to stop the drive and cut off voltage from the cabinet through the mains switch with door block.

• Wait at least 15 minutes before touching the components assembled inside the cabinet after switch off for the capacitors inside the inverter to be fully discharged.

• Before connecting check for the drive to be set for the needed mains voltage value (see chapter “Mains Voltage Set) .

• Check for metal parts not belonging to the system not to be inside (screws, nuts, etc.

• Once connecting is done, it is recommended to clean the cabinet inside before start, since the cabinet is provided with cooling fans.

• The ground conductor must be carefully connected, deriving it from a ground net having requirements according to the Safety Regulation EN 60204-1.

3.2 Safety Devices


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Personnel operating near the system or being in charge for servicing must know all safety devices perfectly. Emergency button The emergency button has a mechanic lock. The device must be checked thoroughlly by export personnel in order ot remove the cause of emergency before restart . Switch with door lock and mechanical door block The mains switch with door lock makes the door open only after the switch is in off position. Thus it is not possible to have access to the mechanical blocks placed inside the cabinet so that neither the doors can be opened 3.3 Risk zones

Risk zones for the personnel in charge of service are usually those metallic parts inside the cabinet subject to high voltage. Such zones are protected and marked with the related yellow symbol For safety reasons it is strictly forbidden to remove the plastic protections inside the cabinet. 3.4 Control zones


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Commands and signals of the machine are shown below: 1= Voltage signalling lamp 2= Alarm lamp 3= Motor temperature warning lamp 4= Mains input measuring instrument 5= Diagnose Display 6= Alarm reset button 7= Emergency button 8= General mains input switch

3.5 Connecting the equipment


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Turn the general switch on position I. In order to cut off voltage turn switch on position 0. 3.6 Start After giving voltage to the system through the switch placed on the cabinet’s door, press the alarm reset button and activate the drive’s capacitor precharge (operation taking some seconds). After the precharge has ended the drive can be started. The drive can be started both through digital commands per RS 485 and hardware commands. 3.7 Stop The device is stopped through the related serial or analog commando. Cut off the drive from the mains by opening the mains input switch.

Caution: when the machine is stopped the functions are not optocoupled from high voltage sources; in order to operate on the motor or the braking resistor the supply to the drive must be cut off through the mains switch; wait for the capacitors to unload. 3.8 Emergency stop Press the emergency stop button. It deactivates the mains contactor feeding the inverter so the motor is no longer controlled by the drive. 3.9 Signal and alarm devices


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Voltage signalling lamp White lamp signalling that teh mains switch is active and voltage is given inside the equipment. Alarm lamp Yellow lamp signalling an inverter alarm or an electromechanical alarm occurring inside the equipment. Motor temperature alarm warning Yellow blinking lamp signalling the switching of the thermal sensor mounted on the motor as warning . Display The alphanumeric display shows all drive protections and the related machine status.


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4. Drive Description


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4.1 ONDA - General description Drive assembled inside a cabinet ready for connection provided with liquid cooling system and all devices needed to feed a dynamometer system. The drawing below shows a typical ONDA drive. A list of all components mounted inside the cabinet is to be founded on the following pages:


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ID Description ID Description 1 RFI filter 22 Output reactance

2 Main contactor 23 Ferrite rings

3 Mains fuses signalling device

24 Control board for dynamic braking

4 Ferrite rings 25/26 Automatic switch for motor fan

5 Mains Switch 27 Automatic switch for Plc 6 Supply converter unit 28/29/30 Auxiliary 24Vdc relay 7 Mains choke 31/32 Motor thermal protection

detector 8 Aux. Supply transformer

110/19 Vac 33 Cpu Plc

9 Aux. Supply transformer 220 Vac

34 I/O extension Plc

10 Bars 35/36 Cabinet lamps 11/12 Fuse haltering for aux.

supply 37/38 Door microswitches

13 Fuse housing for the cabinet blinking lamps

39/40 Cabinet lamp

14 Automatic transformer switch 110/19 Vac

41 Cabinet fan

15 Automatic switch 110 Vac

42 Ammeter transformer - -mains instr.

16 Autom. Transformer switch Vac

B1/B2 Connection bars for braking resistor

17 Autom. switch for cooling circuit pump

X1/X2 Terminal board

18 Autom. switch cabinet fan

OUT Motor connection bars

19 Temperature detector cabinet

20 24Vdc supply 21 Vector unit


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5.Supply Unit with Dynamic Braking


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5.1 Foreword The ONDA drives can be ordered as non regenerative equipment with supply unit having dynamic braking on external load bank ( up to T40 only) , or as regenerative equipment to the mains with IGBT input bridge. 5.2 Technical features of the supply unit with dynamic braking

Nominal supply voltage Three-phase 400/440V +/-15%

Nominal input frequency 47 ÷ 63Hz

Output voltage Voltage rectified through a Graetz bridge

Available auxiliary voltage +10Vdc IMAX 50mA - 10Vdc IMAX 50mA +24Vdc IMAX according to the module number

Capacitor charging time Constant time of two seconds Automatic SCR diodes firing

Mains dips Different solutions available

Dynamic braking On the supply unit (resistors available on demand)

LED signals 10 LEDs showing machine status and anomalies

5.3 Supply unit with dynamic braking The supply unit with dynamic braking and 6 pulse rectifier bridge allows to deliver a power to the motor quadrant equal to 50% of the power required for the brake quadrant. The supply unit has mains input connection bars R S T, bars B1 and B2 connecting the brake resistor; the higher power units have also +/- bars of the intermediate circuit for the connection to the converter module . The figure below shows a connection example between a supply with braking unit ONDA T40 and the related vector unit.


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5.3.1 Control electronics supply

Through an internal switching supply the 24 Vdc is obtained directly from the +/-dc bus to feed the whole control electronics for the drive through the interconnecting flat cable between supply and vector drive . A +5Vdc to supply the serial programming converters and +/-10Vdc for the external potentiometers is obtained as well.

CONTROL SYSTEM


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5.3.2 Power electronics supply

The input rectifier bridge ( diodes or IGBT) rectifies the ac by generating a dc voltage filtered by the capacitors that feeds the IGBT bridge of the vector converter module to which the motor is connected.

1. Input bridge: rectifies the ac 2. Capacitor group: filters the voltage of the rectifier bridge 3. and 4. vector unit : controls the motor by acting on its speed. For special multi-motor applications a solution with a single supply unit and several vector modules connected to the dc bus can be studied.


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5.4 Mains voltage configuration for the equipment

The ONDA drves can operate with variable mains voltage values between 380 and 440 Vac but the transformers DATC1 e DBTC1 taking care of the auxiliary supply must have the same supply voltage of the mains input . For safety reasons such operation must be carried out by skilled personnel and only after having cut off the drive from the mains through the main switch. To feed the drive with a transformer configuration different from the mians voltage can seriously damage the drive.

The drive with dynamic braking needs to be configurated as described below ( chapter on control board GAAP1). The auxiliary voltage transfomers and board GAAP1 are correctly configurated during the drive construction according to the required mains voltage and do not need any operating. 5.5 Configuration dip switch SW1 “mains voltage selection”

The control board of the supply unit has a dip switch called SW2 selecting the mains voltage values .

N. DIP SWITCH FUNCTION DEFAULT

1 Not used OFF 2 Not used OFF 3 Mains voltage selection ON 4 Mains voltage selection ON

The selection procedure on dip switch 3 and 4 is:

DIP 3 DIP 4 MAINS VOLTAGE

ON ON 380 - 400V ON OFF 415V OFF ON 440 – 460V OFF OFF Not used

The dip switches are shown below :


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5.6 Signal Connector (P5)

Pin Denomination Notes Technical Features

01 +10 Stabilized supply +10Vdc +10Vdc Max.Current = 50mA

02/03 SG Common for stabilized supplies +/-10V

0Vdc

04 -10 Stabilized supply -10Vdc -10Vdc Max. current = 50mA

05 IG Common for protection zener on the serial input

0V Input impedante 10Ω

06/07 +P Stabilized +24Vdc supply +25,5Vdc max. current 5,5A for version 010 and 011 1,5A for version 012 and 212 downgaded according to the number of installed modules. (see par. ”Product version”)

08/09 PG Common for stab. +24Vdc supplì Reference 0Vdc for “+P”

10 -C Common input for the optocouplers of the drive enabling

0Vdc

11 RST Optocoupled input for general reset (active for all drives at the same time )

Optocoupled OFF=


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5.7 P2- Connector for interconnection


1 +S Serial line RS485 Line driver 0 ÷ 5Vdc

2 -S Serial line RS485 Line driver 0 ÷ 5Vdc

3-4 0P Common for the stabilized +24Vdc supply

0Vdc Max. current 5,5A

5 mSR Input for the sum of the min. speed relays

0 ÷ 24Vdc Impedance 3,3KΩ

6 ALARM Input for the sum of the alarms (1 = alarm)


7 /RESFE General reset output Buffered 0 ÷ 24Vdc IMAX = 350mA

8 DRENFE General enable output ione Buffered 0 ÷ 24Vdc IMAX = 350mA

9 HV V/V converter output dc link 0 ÷ 10Vdc IMAX = 1mA Impedance 4,7Ω

10 ST Input for the sum of the thermal sensors


11 HOLD Segnalazione di “Mains failure “ signal

Buffered 0 ÷ 24Vdc IMAX = 350mA

12/13 +24 Stabilized 24Vdc supply +25,5Vdc Current depending on the installed modules (MAX 5,5A)

14/15 0P Common stabilized 24Vdc supply 0Vdc IMAX = 5,5A

Note: Do not ground the supply zero (PG, SG o 0P)


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5.8 Control and brake protection board In order to thermally protect the dynamic braking resistor ITACO has developped a GBU5 board able to detect the power being dissipated by the resistor. • The board is mounted inside the drive; there is a parallel connection to the resistor

measuring the insertion time and a interface with the electric device.

• The board signals a max. braking alarm through a double contact relay to the plc input directly. The plc cuts off the mains contactor and signals on the display mounted on the cabinet’s front.

• A single 24Vdc supply is given, taken from the stabilized supply DAAP1 .

• Alarm reset is done through the external reset command or the button on the cabinet’s front.

Connector P2 “ power connection”

PIN DENOMINATION NOTES TECHNICAL FEATURES

1 +R Connection to the positive terminal of the braking resistor ( term. B2 on

supply unit)

0 ÷ +850Vdc Impedance = 500KΩ

2 -R Connection to the negative terminal of the braking resistor (terminal B1

on the supply unit)

0Vdc Impedance = 500KΩ

Connector P1 “signal connection”

PIN DENOMINAION NOTES TECHNICAL FEATURES

1/2 +24 Pos. Supply input 20 ÷ 28Vdc

3 0V Neg. Supply Input 0Vdc

4 RST Alarm Reset Pulse command toward pos. supply

: normally not connected

NC ÷ 28Vdc Reset = 10 ÷ 28Vdc Impedance = 4KΩ

5 C2 Common enable contact NA2 Closet contact (short circuit pin 5-6 )

6 NA2 Enable contact NA2 For run enable

7 C1 Common enable contact NA1 Closet contact ( short circuit pin 7-8 )

8 NA1 Enable contact NA1 For run enabling


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5.8.1 Working principle

The board constantly detects the voltage applied at the braking resistor ends; according to the measured instant power it acts on a timer increasing it . During the resistor’s “idling” periods the timer is decreased. When the timer reaches its limit value an alarm memory is activated. The circuit has two status LEDs:

green L1 on: ready to start

green L1 off: alarm occurring

yellow L2, blinking: timer increasing

Two trimmers set the plate features of the resistor to protect:

Trimmer RV1: setting the “overload ratio”

Trimmer RV2: setting the “max. overload”

5.8.2 Board setting Foreword The dynamic braking circuit dissipates the exceeding energy on the resistor during recovery phases due to the braking of wheel masses. The energy is dissipated with high instant power peaks for a much lower efficacy value. The control task is :

− Measuring the instant power comparing it to the nominal power (resistor’s plate value);

− Calculate the overload as sum of the instant power values;

− Activate an alarm at the set value.

5.8.3 Max. overload setting “Trimmer RV2” The max. overload allowed by the resistor can be seen from the plate data or the technical data sheet of the resistor itself. The setting of ”RV2” can be seen below; the intervention time corresponds to the setting on trimmer “RV1”.


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Example: Plate Data Mains: 380Vac Resistor : 18Ω 900W 6.6Kw for 5 seconds Setting RV1 NB: mains 380V corresponds to a 660V intervention voltage Instant power = V2 = 6602 = 24,2Kw R 18 Overload ratio = PI = 24200 = 26,8 PN 900 Position of trimmer RV1 = 0% (≥ ratio 20) Setting RV2 To consider: resistor set for 6,6Kw for 5 seconds; being the instant power 24,2Kw, it can be deduced that the limit time at that power value is: 6,6 x 5 = 1,36 seconds 24,2


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Basing on the previous chart, the setting of RV2 will be:

Setting of RV2 = 88%

5.8.4 Setting of the overload ratio “trimmer RV1” The dc link voltage values at which the braking resistors is switched are:

− For mains 380÷400 = 660Vdc

− For mains 400÷440 = 780Vdc When the resistor’s ohm value is known , the instant power can be calculated with following formula:

V2 = instant power R

where: V = value of the intervention voltage R = resistor’s value in Ohm Calculate the overload ratio with formula:

PI = overload ratio PN

where: PI = instant power


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PN = nominal power (plate value ) Trimmer RV1 has to be set according to the calculated overload ratio overload ratio:

ratio ≥ 20 = trimmer on position zero ratio ≤ 3 = trimmer on position 100%

intermediate trimmer positions determine ratio values between 3 and 20


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6. Regenerative Supply Unit


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6.1 Foreword Every drive of the “ONDA” range can be ordered with dynamic braking or as regenerative unit with IGBT input bridge. The supply unit is a ac-dc converter with a PWM rectifier. A block diagram is shown below. The output capacity represents the energy cumulating and allows the decoupling between input and output steps. The control section consists of three main blocks: dc voltage control, current control, sinusoidal reference generator. This last block generates the three star connected sinusoidal voltages through a digital PLL. The current adjustment is realized with a rotating reference to operate with continuous values. Thus the current Id represents teh active component, Iq the reactive one. The Id current set is calculated by the voltage adjustment. The main technical features of the supply unit as well as an example of connection to the inverter are shown below.


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6.2 Technical features of the regenerative supply unit

Nominal Supply Voltage Three-phase 400/440V +/-15%

Nominal Input Frequency 47 ÷ 63Hz

Output Voltage Rectified through a IGBT bridge The dc bus voltage is kept at constant 750 Vdc

Available auxiliary voltage +10Vdc IMAX 50mA - 10Vdc IMAX 50mA +24Vdc IMAX depending on the number of modules

Capacitor Pre-charge At constant current Automatic insertion with IGBT

Total harmonic distortion < 4, 5%

Cos ϕϕϕϕ 1 +/- 0,5 % adjustable

LEDs 10 LED bar showing machine status and anomalies


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6.3 Diagram of the energy recovery function

6.4 Recovery board – Description

3 phase

+PGeneraz

ione if i

+PPar

+P

SV

Clarke

VD

VD*Id

*

Iq* =

Iq

Id

VdVq

Vα

Vβ

θ

VR

IR

IS

mai


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7.Vector Converter Unit


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7.1 Converter on the motor side The motor control is an indirect field oriented one, fully digital with 32bit microcontroller. Since the drive has to operate in open loop torque control mode with high accuracy, particular care was used in handling the saturated motor the motor, also depending on temperature. The control algorithm offers the possibility of closet loop control as well, through torque flange or load cell as well as the motor inertia compensation. The sensorless torque control is given as well. The converter’s main technical features are shown below: Block diagram of the field oriented converter

Clarke

Id*

Iq*

Iq

Id

θ

IR

IS

( )L is

m

1 + τ

( )LTm

τ λ1s

+ PI

+

+ PI

3 phase inverterSVM

+ PI

+ PI

AC inductio

nIq

θ

ss1 + τ

( )λ ω*

θm

ω *τ *

T

λ


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7.2 Vector control board -Description

7.2.1 Connecttor P7


01 OD Digital Zero of the board 0Vdc

02 +R1 Pos. Input analog set (differential with – R1)

0-10 Vdc input impedance 40kΩ

03 -R1 Pos. Input analog set (differential with + R1)


04 +R2 Pos. Input analog set (differential with – R1)


05 -R2 Pos. Input analog set (differential with + R2)


06 0S Common analog outputs Reference 0Vdc for “TH” and “CUR”

07 UTH Analog output proportional to speed

+/- 10Vdc output impedance 330 Ω

08 CUR Analog output proportional to the current

+/- 10Vdc output impedance 330 Ω

09 0I Common input optocouplers of the digital inputs

0Vdc

10/11 JOG1/JOG2 Configurable pulse speed input enable

Optocoupled Off=< 3 Vdc ON=15-28Vdc

12 RES Drive alarm reset input Optocoupled Off=< 3 Vdc ON=15-28Vdc

13 ON Current delivery enable input Optocoupled Off=< 3 Vdc ON=15-28Vdc

14/15 EN1/EN2 +/-R1;+/R2 set acquisition enabling input



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7.2.2 Connector P6


1 +5 Digital supply + 5Vdc

2/3 +ST/-ST Motor protection input

4 NC

5 0 Pulse/rev. Input of speed feedback

Line driver +5Vdc Max. frequency 200kHz

6 A Channel A input – speed feedback


7 B Channel B input – speed feedback


8 0 Common input for speed feedback

0Vdc

9/10/11/12

NC

13 /0 Thermal sensor sum input Line driver +5Vdc Max. frequency 200kHz

14 /A Channel /A input speed feedback Line driver +5Vdc Max. frequency 200kHz

15 /B Channel /B input speed feedback

Line driver +5Vdc Max frequency 200kHz


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7.3 Optional board

The torque flange signal is acquired through option board 5388, both as analog 0/10V signal and frequency signal, to create a torque loop inside the drive.

7.3.1 Connectore P7 – option board


1 +5 Digital supply + 5Vdc

2/3 +ST/-ST Motor protection input

4 NC

5 0 Pulse/rev of speed feedback Line driver +5Vdc Max. frequency 200kHz

6 A Channel A input torque/speed feedback

Line driver +5Vdc Max. Frequency 200kHzf

7 B Channel B input torque/speed feedback


8 0 Common speed feedback input 0Vdc

9/10/11/12

NC

13 /0 Pulse/rev. Input speed feedback Line driver +5Vdc Max. Frequency 200kHz

14 /A Channel /A input torque/speed feedback


15 /B Channel /B input torque/speed feedback



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7.3.2 Connector P8 – optional board


01 +R3 Pos. Input of anal.set (differential with – R1)

0-10 Vdc 11 bit Input impedance 40kΩ

02 -R3 Pos. Input anal. Set (differential with con + R1)

0-10 Vdc 11 bit input impedance 40kΩ

03 0A Common input speed feedback 0Vdc

04 A Channel A input torque/speed feedback


05 B Channel B input torque/speed feedback


06 Ground GND


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8. Cooling System


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8.1 General Description The ONDA driver have a liquid cooling system placed on the cabinet’s left side. It consists of a water/water exchanger to which the heatsink of both the supply and the inverter unit are connected on the secondary circuit. A pump and a tank make the cooling liquid circulate to cool the power semiconductors. A thermostat and an electro-valve open the primary circuit of the exchanger, which has to be connected to a water supply net not exceeding 30 ° C. A diagram provided with ITACO codes is shown below:


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8.2 Water input to the exchanger The cooling water on the exchanger inout must have the following features : Neutral and clean Input temp. from +5° C to +30°C Water Flow > 15 liters / min for ONDA size T10÷T30 Water Flow > 25 liters / min for ONDA size T31÷T50 Freezing to be avoided No salt water 8.3 Closed water circuit The water of the closed circuit (access through the tap on the tank) must be filtered in order to contain only parts < 0,1 mm (liquid may be added, using a 100µm filter) The drive’s closed circuit needs water with standard anti-freeze liquid used for automobiles, ratio 20%< anti-freezing liquid >30%.


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9.Anomaly Solution Guide


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9.1 General remarks The display on the plc placed on the cabinet front shows all drive alarms. They all appear a few seconds after the anomaly has occurred ( except for those regarding the inverter).

Caution: the servicing and any operation on the equipment must be carried out by skilled personnel aware of the risks of electricity . Before starting any service operation the device must be cut off from the mains; wait at least 15 minutes before touching any component inside the cabinet. 9.1.1 Alarm messages on display

Message Alarm description Anomaly FUSE ALARM

MAINS SWITCH General switch and /or overvoltage clamping fuses

Inhibiting the mains contactor ; signalled on the LED bar of teh motor control board

TEMP. ALARM CABINET

Cabinet’s thermostat Stops the motor

PUMP ALARM WATER CIRCUIT

Pump protection switch Stops the motor ; signalled on the LED bar of the motor control board

FAN ALARM CABINET

Cabinet protection switch Stops the motor

FAN ALARM ELECTRIC MOTOR

Motor protection switch Stops the motor

LIQUID LEVEL ALARM WATER

CIRCUIT

Liquid level sensor Stops the motor

TEMP. ALARM ELECTRIC MOTOR

PTC Stops the motor e

TEMP. WARNING ELECTRIC MOTOR

PTC- alarm warning electric motor

Blinking on the cabinet’s front side

DYNAMIC BRAKE ALARM

Braking protection board Inhibits the mains contactor insertion

INVERTER ALARM Drive alarm Stops the motor; signalled on the LED bar of the motor control board

EMERGENCY Emergency button open Inhibits the mains contactor


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9.2 LEDs on the supply unit board

The drive module has a 10 LED bar. Every LED is marked with the own function. They show the machine status as well as possible anomalies.

PWR

OK mSR

HLD RUN

RST TS

+/- EN

RSI PWR power if on, 24Vdc is given

OK Ready to start If off, indicates anomaly

mSR Minimum speed relay If on, indicates that at least on of the motors is rotating

HLD Hold If on, at least one of the phases is missing

RUN Run If on, the power units are enabled

RST reset Gets on only at the moment of alarm reset

TS Thermal relay If on, intervention of one of the heatsink thermal sensors

+/- +10V -10V supply If on, +/-10V supply is given

EN enable If on, “enable” input is on

RSI Input reset If on, reset inout is enabled


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The LEDs are shown below:

9.3 Machine status and supply unit alarms

Machine status: Inverter on but not enabled, following LEDs are on:

PWR; OK; +/- Inverter enabled with stopped motors: following LEDs are on:

PWR; OK; RUN; +/-; EN When the motor is rotating, mSR is on as well Anomaly Note: any alarm makes OK switch off LED “ST” means:


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w eak heat exchange

check tem perature and the cooling w ater flow check the w ater opening valve to

be w orking

too heavy w orking cycle

check average current of w orking cycle to be correct according to set param eters

Therm al sensor intervention of

therm al sensor placed on pow er dissipator

• When LED “PWR” or “+/-“ are off or low, there is overload on +/-10V or 24Vdc supply

• Are the LEDs blinking, that means a short circuit short circuit or overload on one of the supplies. In this case disconnect the loads in order to identify the short circuit, by following the steps below:

1. disconnects the output terminal board of the supply unit 2. remove the programming system and/or the serial control 3. disconnect the coloured flat cable

Remove the short circuit cause once it is found out.

• If there is no alarm on the vector unit and just LED “OK” is off, that means a undervoltage or overvoltage alarm:

supply voltage decreasing

check supply not to go below 15% of the nom inal value

drive supplied in m onophase

reset m issing phase

M im im um voltage DC pow er voltage

decreasing excessively


Pag. 54 di 69

braking resistor not connected

reset w iring

too abrupt brakingincrease deceleration

ram p

increase deceleration ram p or add braking resistors (see related

chapter)

w rong supply voltagereset nom inal value

of ac voltage

M axim um voltage DC pow er voltage

too high

too high inertial load

energy recovery not ready or not sufficient

check the drive's start-up, check

param eters of the regenerative unit


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10. Serial Communication Protocol

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10.1 Hardware specifications

− RS232

− Selectable transmission speed : 9600, 19200, 38400

− Asynchronous serial communication with 10 bit frame

− Stop bit: 1

− Number of bits: 8

Start B0 B1 B2 B3 B4 B5 B6 B7 Sincro Stop

− The first bit transmitted is the less significant one .

− A PC with RS232 interface (master) can be connected to 254 MAC/AC WAVE SUPPLY boards (slave).

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10.2- Software specifications

The slave can receive or transmit. Several stations can receive, but just one transmit.

The master can ask for or send data to the slave; the slave waits and receives data from the master or sends them only after having been asked. There is no communication between slave and slave, tha slave communicates just with the master.

There are six communication steps:

0) Demand for communication with byte 0xFE (decimal = 254)

1) Demand for communication (from master to slave)

2) Inverter selection to communicate with

3) Message encoding (from master to slave)

4) Data transmission (from master to slave or viceversa)

5) Checksum byte transmission

Step 0 sends the syncrhonism byte containing fix value 0xFE.

Step no. 1 sends one byte (SIN1) indicating which slave is concerned by communication. That byte is received by all slaves connected to the master.

Step no.2 sends a byte (SIN2) identifying the inverter, connected to the selected slave, concerned by communication. This byte contains also the info on the kind of communication (receiveing or transmitting).

Step no. 3 sends a byte (ID) indicatine the message type for the selected slave. The byte is received by trhe selected slave only and does not affect the other slaves.

During step no. 4 a variable number of bytes flows, depending on the ID byte. This step is given only if the seventh bit of byte SIN2 provides data transmission, that is ‘1’. (TX = 1).

Step no. 5 sends the checksum byte. Not all telegrams have a data exchange (for instance the setting of one or more inverter parameters). In this case the checksum byte (BCS) follows the ID byte.

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10.3 Examples of telegram transmission

Example: the master sends data to the slave

0xFE SIN1 SIN2 ID data block BCS master

0 1 2 3 4 5 n° fase

Example: the master sends a command to an inverter

0xFE SIN1 SIN2 ID ID master

0 1 2 3 5

Example: the master asks the slave for data

0xFE SIN1 SIN2 ID BCS master

0xFE data block BCS slave

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10.4 Details on communication

The six steps are examined below.

−−−− Fase 0: Device identification

The communication with the slave begins only when the information is preceded by the byte below.

7 6 5 4 3 2 1 0

1 1 1 1 1 1 1 0 SIN0

0xFE

− Fase 1: Communication demand

All slaves are receiving before this step. Communication begins with the sending of byte SIN1 containing the info on the communicating slave. If =0, the communications regards all slaves and in this case just one data sending is possible to modify the inverter parameters.

7 6 5 4 3 2 1 0

NUMERO MAC SELEZIONATA SIN1

Master → slave transmission: byte SIN1 = 0 with TX = 1 does not make any sense(would mean asking all slaves for a response), and its accidental transmission will not be considered by the slaves. Byte SIN1 = 0 is a comfortable way of sending commands or settings to all slaves at the same time.

− Step 2: Sending of byte SIN2

The inverter is selected for communication.

7 6 5 4 3 2 1 0

TX SLAVE

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Every inverter has a particular 5 ( or 4 ) bit code, settable through dip switch. The 5 less significant bits indicate the code of the regarded inverter. Communication is possible with up to 31 different inverters. Bit 7 (TX) indicates whether the slave must transmit or receive : if TX = 1 the slave must transmit.

Transmission Master → Slave, a byte SIN2 = 0 con TX = 1 does not make any sense (that would mean demand for response from all driver connected to the selected slave), and its accidental transmission will not be considered by the slaves. Byte SIN with SLAVE = 0 is a comfortable way of sending commando or settings to all slaves at the same time.

− Step 3: Message encoding

Only the slave selected by byte SIN1. takes part in this step, the other slaves are not involved. At this step the master sends a byte containing info on the telegram , especially all data being in reception/ transmission and the message length.

− Step 4: Data exchange

The inverter involved receives or sends the data specified during step 2.

− Step 5: Checksum sending

This step is always given and is carried out every time a station gives the line ( from transmitting to receiving) and attaches a checksum byte , obtained as XOR (exclusive OR “^”) of the transmitted bytes.

While calculating the BCS byte all current transmission bytes are considered, included bytes 0xFE SIN1 SIN2 ID.

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10.5 Examples of checksum byte calculation

Example: the master sends data to the slave

0xFE SIN1 SIN2 ID data block BCS master

[byte0] ... [byteN]

BCS = 0xFE ^ SIN1 ^ SIN2 ^ [byte0] ^ [byte1] ^ ... ^ [byteN]

Example: the master sends a command to the slave


BCS = 0Xfe ^ SIN1 ^ SIN2 ^ ID

Example: the master asks the slave for data


0xFE data block BCS slave

[byte1] ... [byteN]

BCS’ = 0xFE ^ [byte1] ^ [byte2] ^ ... ^ [byteN]

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10.6 ID = 33H: BAUD RATE parameter

Reading and writing of the BAUD RATE parameter

The BAUD RATE paraemter is a byte one.

Example with mac code = 1; BAUD = 2

TX = 0: sending the BAUD parameter.

0xFE 1 3 33 2 BCS

BCS = 0xFE ^ 1 ^ 3 ^ 33 ˆ 2

TX = 1: reading the BAUD parameter

0xFE 1 83 33 2 BCS master

OxFE 2 BCS’

BCS’ = 0xFE ^ 2

BAUD RATE BYTE ENCODING:

BAUD RATE = 0 : 9600 baud

1 : 19200 baud

2 : 38400 baud

3 : 57600 baud

4 : 115200 baud

The range of this variable is BAUD RATE = 0÷4

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10.7 ID = 81: Setpoint (REFERENCE)

Example with mac code = 1; codice slave = 3; ref = 500 = 1F4H

The reference variable is 2 byte long ,to value FFFFH corresponds frequency Fmax.

TX = 0

0xFE 1 3 81 1F4 BCS master

OxFE 1F4 BCS’ slave: inizio

rif.

BCS = 0xFE ^ 1 ^ 3 ^ 81 ^ 1F4

BCS’ = 0xFE 1F4

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10.8 ID byte encoding

ID TX = 0 TX = 1 DRIVE

MEANING BYTE MEANING BYTE

0 Disables the drive 0 Disables the drive 1 ac wave 2 br wave

1 Enables the drive 0 Enables the drive 1 ac wave 2 br wave

2 disables rif. 1 0 Disables rif. 1 1 ac wave 2 br wave

3 Enables rif. 1 0 enables rif. 1 1 ac wave 2 br wave

4 disables rif. 2 0 Disables rif. 2 1 ac wave 2 br wave

5 Enables rif. 2 0 enables rif. 2 1 ac wave 2 br wave

6 ---------- --- ---------- ---

7 ---------- --- ---------- ---

8 sets speed control 0 ---------- --- br wave

9 sets torque control 0 ---------- --- br wave

10 ---------- --- ---------- ---

11 ---------- --- ---------- ---

12 Cw 0 cw 1 ac wave 2 br wave

13 Ccw 0 ccw 1 ac wave 2 br wave

14 set point rifer. 2 set point rifer. 2 ac wave 2 br wave

15 ---------- --- Drive status. 1 ac wave 2 br wave

16 ---------- --- Speed 3 ac wave 2 br wave

17 ---------- --- Current 3 ac wave 2 br wave

18 ---------- --- Frequency 3 ac wave 2

19 Reserved reserved

20 software reset 0 ---------- --- ac wave 2 br wave

21 ---------- --- Alarm sending 1 ac wave 2 br wave

22 Adc setting 0 ---------- --- br wave

23 Eeprom writing 0 ---------- --- ac wave 2 br wave

24 Kp 1 kp 1 ac wave 2 br wave

25 Ki 1 ki 1 ac wave 2 br wave

26 Kd 1 kd 1 ac wave 2 br wave

27 imax 2 imax 2 br wave

28 inom 2 inom 2 br wave

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29 size 1 Size 1 br wave

30 offset adc 2 offset adc 2 br wave

31 Filter 1 filter 1 br wave

32 Setup 1 setup 1 br wave

33 baud rate 1 baud rate 1 ac wave 2 br wave

34 ---------- Run status 7 ac wave 2 br wave

35 rif. 1 max 2 rif.1 max 2 br wave

36 rif.2 max 2 rif.2 max 2 br wave

37 ---------- --- ---------- ---

38 Resolver offset 2 Resolver offset 2 br wave

39 acceleration 2 Acceleration 2 ac wave 2 br wave

40 Deceleration 2 deceleration 2 ac wave 2

41 boost v0 1 boost v0 1 ac wave 2

42 comp. Kcurr 1 comp. kcurr 1 ac wave 2

43 comp. Kslip 1 comp. kslip 1 ac wave 2

44 E2a 2 e2a 2 ac wave 2

45 E2p 2 e2p 2 ac wave 2

46 E2i 2 e2i 2 ac wave 2

47 E2d 2 e2d 2 ac wave 2

48 Secondary ramp 2 Secondary ramp 2 ac wave 2

49 Language 1 Language 1 ac wave 2 br wave

50 par. ac. wave 2 64 par. ac wave 2 64 ac wave 2

51 Reserved Reserved

52 x1 2 x1 2 ac wave 2

53 x2 2 x2 2 ac wave 2

54 t. imax 1 t. imax 1 br wave

55 g. brake 1 g. brake 1 br wave

56 Resolver setting 0 ---------- --- br wave

57 Rmv 2 rmv 2 br wave

58 an2 1 an2 1 br wave

59 en3 1 en3 1 br wave

60 fpwm 1 fpwm 1 br wave

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61 Encoder resolution 1 Encoder resolution 1 br wave

62 kappa 2 Kappa 2 ac wave 2


64 ---------- --- Drive type. 1 ac wave 2 br wave

65 en1 1 En1 1 br wave

66 en2 1 En2 1 br wave

67 on 1 on 1 br wave

68 cong.error 2 cong.error 2 br wave

69 t. err. 2 t. err. 2 br wave

70 timer brake 1 Timer brake 1 br wave

71 hold 1 Hold 1 ac wave 2

72 t. err. (word) 2 t. err. (word) 2 br wave


74 top zero 2 top zero 2 br wave

75

76 02 1 02 1 br wave

77

78

79

80 Reserved Reserved

81 set point 2 set point 2 ac wave 2


83

84

85

86

87

88

89

90

91

92

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93

94

95

96

97

98

99

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drive series “onda” - mez cz · 2008. 12. 18. · drive series “onda” pag. 9 di 69 2.3...

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