Unitek TVD6.2-RS Manual

Unitek TVD6.2-RS is a transistor-based, 3-phase servo drive that is specifically designed to work with AC-Synchro servomotors. It is a compact and efficient device that is suitable for a wide range of applications, including those that require high dynamic acceleration and deceleration cycles, precise speed and torque regulation, and smooth travel.

The Unitek TVD6.2-RS has a number of features that make it an excellent choice for a variety of applications. These features include:

Direct power supply of 400V~
Electronic starting current limitation
Two differential reference inputs
Acceleration and deceleration ramp with second nominal value

PDF

Document

MANUAL

3-Phase-Transistor-Servo-Drive

for

AC-Synchro-Servomotors with

Resolver

G m b H

Industriestraße 1

D-71397

Leutenbach 3 - Nellmersbach

Version

0899-1

Transistor-Servo-Drive TVD6.2-RS

1 Basic-Information

Safety Advice

General Information

Application

Characteristics

Technical Data

2 Mechanical Installation

Dimensions

Structure of Device

Mounting Advice

3 Electrical Installation

Connection Overview

Connection Plan

Earthing Plan EMC-Advice

Mains Connection

Motor Connection

Control Connection

Signals

Connector Plan

4 Device Overview

Resolver

Component Positions

Block Diagram

Frontpanel

Adjustment Functions

Signals

5 Adjustment

Adjustment Advice

Nominal Value

Actual Value

Current

Speed Controller

6 Getting Started

Default Setup

Getting Started

7 Fault Finding

LED Indications

Function Faults

Function Diagram

Encoder Signals

8 Guarantee

9 Protocol

Seite

8, 9

18 to 23

15,16

24, 25

26, 27, 28

39 to 41

1Basic-Information

Electronic devices always involve the risk of failure.

Caution High Voltage

AC 460V~, DC 750V=

This manual has to be read carefully and must be understood by experts before installing or starting the device.

If there are any doubts call your trader or the manufacturer.

The TVD6 series is designed to regulate electrical currents; protection standard IP00.

Instructions and rules:

the devices and accessory components must be set up and connected according to the local technical regulations. In Germany they are:

- EU-machine guide lines 89/392/EWG,84/528/EWG,86/663/EWG

- VDE-regulation VDE 100, VDE 110, VDE 160 und VDE 0113

- TÜV-regulations

- Regulations of the professional guild.

The user has to assure that: after

- a failure of the device

- an incorrect handling

- a failure of the control unit etc.

he drive is brought to a secure operating condition.

Machines and installations are to be provided with supervisory and safety equipment, that is independent of the device.

Adjustment

only by qualified personnel

- adher to safety regulations

Installation work

only when disconnected from all power lines.

The devices are archived by the manufacturer with serial number and their test specifications.

The EU-guide line 89/336/EWG with the EMC-Regulations EN50081-2 and

EN50082-2 are observed.

TVD6.2-400-x-RS 3

Transistor-Servo-Drive TVD6.2-RS

The transistor 3-phase current servo amplifier SERVO-TVD6 .

2 forms together with the brushless direct current motor (synchro-servo (EC-) motor) a propulsion unit distinguished by its rear-zero maintenance and by its high dynamic control range.

The drive displays the wellknown good regulation characteristics of the direct current drives without the disadvantages of the carbon brush wear and of the communication limits.

The rotor intertia is notably lower and the power envelope is greater than with equally constructed DC-motors. The result are up to 5 times higher acceleration values. As the generated heat in the motor occurs in the stator, the ec-motors are always designed to the protection standard IP

65.

The brushless direct current motor is electrically a synchro-motor with a permanent magnet rotor and 3-phase stator.

The physical characteristics correspond to those of the direct current motors, that is, the current is proportional to the torque and the voltage is proportional to the speed. As both values can be measured precisely, the servo-control unit can be mounted easily. It is possible to control the speed from the motor voltage, but in order to achieve exact regulation it is preferable touse atways a tachometer regulation.

The tachometer actual value is generated from the sensor unit (resolver).

In the speed controller (P-I-controller) of the servo-drive is the differenz of nominal value and actual value amplified. The result is the current nominal value, which is transferred by the resolver signal onto the three phase current controllers such that the stator magnetic field leads ca. 90° electrically the rotor magnetic field.

This field frequency is not a controlled variable, it adjusts istself automatically. The motor currents, following the resolver interpretation, form a sine-waved rotating field.

As occurs in all DC-, AC or ec-servo-amplifiers which are supplied by the dc-bus, the feed-back of the energy must be observed when braking in the dc-bus (especially where stroke or eccentric cycles are concerned). The bleeder switch is set for a 3 % duty cycle. The ballast-resistors have to be mounted externally.

Information:

For lower power >>> UNITEK Serie TVD3.2

100V upto 10/20A

For higher power >>> UNITEK Serie MODULA

400V upto 100/200A

1 Basic-Information

Application :

for all kinds of machines up to 8KW drive power especially as 4Q-servodrive in travel axes with

-high dynamic acceleration and deceleration cycles

- great regulation range

- high efficiency

- small motor size

- even and smooth travel for speed or torque regulation or combined speed-torque regulation with or without superposed position controller.

Drives with constand speed as in conveyors, lead screw drives, pumps or divider units.

Synchro-Servo-drives are smaller than other drives.

For Use in:

componenet insertation machines, metall-sheet working machines machine tools, plastic working machines, assembly machines, knitting and sewing machines, textile working machines, grinding machines, wood and stone working machines, food processing machines, robots and manipulators, storage across machines, Extruder, Kalander, and many other machines and installations

Notice:

In bl-drives which mainly require deceleration for example:

- winding machines, lifts, great centrifugal masses the braking energy will be annihilated in the ballast circuit or re-feded to the mains using an external dc-bus converter.

With multiple-axes an energy compensation is possible.

The motors are

- designed to protection standard IP 65

- compact

- suitable in rough surroundings

- suitable with high dynamic overload

- service-free

TVD6.2-400-x-RS 5

Transistor-Servo-Drive TVD6.2-RS

Construction:

- cubicle-mount or 6HE-plug-in unit according to the

VDE- DIN- and EU- regulations.

- standard analog regulation electronics.

- power electronics for 5A, 10A, 16A and 25A.

- wide-band chopper supply unit for the auxiliary voltages.

- power supply unit on the back circuit board .

Galvanic isolation between

- power section and covering

- power section and regulation electronics

- regulation electronics and contol inputs

The leakage distances are according to the VDE regulations.

There are used:

- fully isolated six-pack IGBT-power semiconductors, generous dimensioning.

- only industrial standard components are used

- All ICs with external connections are mouted on high-quality sockets

- LED displays

- 16 digit binary switches for PI-setup of the speed regulator

- precision trimers for fine adjustment

- plug-in jumpers for system setup.

Characteristics:

* Direct power supply 400V~

* Electronic starting current limitation

* 2 differential reference inputs

* Accelleration and decelleration ramp with second nominal value

* Speed and torque regulation

* Static and dynamic current limit

* Current nominal value output

* Test connectors for current and speed

* Galvanic isolated logic in- and outputs

* Enable and end-switch logic

* Integral disabling

* Quick stop

* Mains failure braking

* Temperature control for motor and device

* Parameter adjustments without soldering

* 10 pin control plug

* Incremental encoder output

1Basic-Information

Power connection :

directly on the mains 1x 400V~

3x 400V~ maximum: 460V~

Option :connection voltage < 300V~ >>> notice the advise

Technical data:

type TVD6.2-400output voltage max.

V~eff.

output standstill current duration A= peak A= electrical power max kW rapid fuses built-in measurements plug-in device

BxH cooling 60% ED

100% ED fan switch cabinet mounting BxHxT

400

6,4

400

16TE

24TE 6HE convect convect fan convect fan fan fan see illustrations of the dimensions

Common specifications:

protection standard device layout humidity stress operation altitude operation range expanded operation range bearing reach speed controller control precision (excl. tacho error) control range reference inputs logic inputs logic outputs

Caution:

When order please specify: notice cyclic duration factor several axes with >=10A within one rack input voltages <300V~ exact torque control high centrifugal mass

>>>

IP 00

VDE 0100 group C

VDE 0160 class F according to DIN 40040

< 1000m above NN

0 ... 45°C (with external fan 0 ... 35°C) up to 60° C red. 2%/ °C

-30°C up to + 80°C

± 0,1%

> 1: 1000

± 10V=

+10 ... +30V=

>+14V, 6mA external cooling system with 100% external cooling system recommended modify power supply unit current controller with PI-wiring external ballast resistor

TVD6.2-400-x-RS 7

Transistor-Servo-Drive TVD6.2-RS

2 Mechanical Installation

Multi-axes combinations

Dimensions 6HE [mm] dimension

Unit-grid dimension

10 and 16 A Device

25 A Device

Mounting height 255 mm plug-in units

1 2 3 4 5

1xE+3 2xE+3 3xE+3 4xE+3 5xE+3

1xE+40 2xE+40 3xE+40 4xE+40 5xE+40

1xE+55 2xE+55 3xE+55 4xE+55 5xE+55

81,28 mm

121,92 mm

TVD6.2-400-x-RS 9

Transistor-Servo-Drive TVD6.2-RS

TVD6

X31

Entfernen bei externem

Ballastwiederstand

X11

X8 nur bei

Ausführung

IN, RS

D15 X7,X8

80,0

Power supply unit back panel with plug-in-device (without rack)

Power supply unit setup

Incremental encoder output X8 external ballast resistor

Jumper J2

Bridge D open

IC I7 cable 1

Rack

Hight unit : 6HE

Wide unit : 10/16A = 16TE, 25A = 24TE

Mixed 6HE, 3HE (TVD3) racks on request

2 Mechanical Installation mounting height 255mm Compact device 10/16A

Compact device 25A (w)

Compakt device 25A (sw)

Multi-axes combination

Free space to switch-cabinet wall min. 100mm

Fixing dimensions [mm] compact device current

5,10, 16 Wanne

5-w Wanne

25 sw

190,555 M5

A B C

135

335

335 mounting angles 180

D E

158 screw

M4 multi-axes combinations mounting angles wall mounting

A n x E+60 front mounting with19" systems

E at <=16A = 81,28 mm

E at 25A = 121,92

C n x E+40

D E

190,5 55 mm n =number of plug-in units

Dissipation power at maximum power rated dissipation power[W] current Device supply unit

70 20 5A xx

10A

16A

25A

125

180

43 fuse xx xx xx xx

M-choke xx xx xx xx screw

M5 filter xx xx xx

TVD6.2-400-x-RS 11

Transistor-Servo-Drive TVD6.2-RS

Chokes devicemains filter rated current 1ph 3ph

10A

16A

25A

FE1-10

FE1-16

FE3-10

FE3-16

FE3-25 motor chokes ferrite core

MDD 1,3 a

MDD 1,6 a

MDD 2 b

MDD 2,5 b

EMI742 70107

3 Electrical Installation

TVD6.2-400-x-RS 13

Transistor-Servo-Drive TVD6.2-RS

The devices are according to EU-regulation 89/336/EWG, the standards EN 50081-2 and prEN 50082-2 will be observed under the following conditions.

Device,transformer,motor chokes and mains filter fixed on a 500 x 500 x 2 mm mounting board.

Mounting board and motor frame connected to gnd with a 10mm² wire.

Devices reference X1:13 connected to mounting board with a 2,5mm² wire.

Device-PE-screw connected to mounting board with a 50mm long 4mm² line.

Single-phase power supply: mains filter Type : linelength device - mains filter <100mm

Three-phase power supply: mains filter Type : up to 16A = FE1-16 up to 16A = FE3-16 up to 25A = FE3-25 linelength transformer - mains filter <500mm linelength device - mains filter <100mm

Motor connection: motor chokes Type :

25A = MDDxx-30 motor line 1,5m long, 4core shielded. Shielding on device side fixed to mounting board and on motor side flächig connected to PE.

10A = MDD1,6-10

16A = MDDxx-20

3 Electrical Installation

Caution:

The connection advice concerning the individual attachments of the connections to the plug numbers or terminals are binding.

All further advices to this are not binding.

The input and output lines can be altered or completed in consideration of the electrical regulations.

Notice:

- connection advice and operation advice

local technical regulations

- EU-machine regulation 89/392/EWG

Input filter:

see CE-advice (page 14) short line length between input filter and device or shielded line

FI-switch

- design to DIN VDE 0664

- tripping current > 200mA

- only combined with other protective measure

Connection to 400 V~ mains

Alternating voltage connection 1x400V~ compact device up to 10A.

multi axis combination up to 20A

50/60Hz

Three-phase current-connection 3x400V~ 50/60Hz with >10A (multi axes rack >20A) necessary dimensioning 5/10A 16A 25A max. 30A wire cross section mm² fusing blow-out fuse AF

0.75

1.5

2.5

10 16 25 30 automatic circuit breaker A 10 16 25 25 electronical starting current limitation >>> max. current 7A~

TVD6.2-400-x-RS 15

Transistor-Servo-Drive TVD6.2-RS

Connection at 400 V mains

AC or three-phase voltage supply autotransformer or isolation transformer one transformer for several devices

Notice:

-set safety contacts on transformer inrush current.

-slow fuses in front of the transformer

-fuse value corresponding to the transformer rated current

-quick fuses after the transformer

-fuse value for each power supply unit max. 30AF

Transformer capacity:

primary voltage secondary voltage 400V~

500V~

Autotransformer transformer rated power [VA]=

Isolation transformer transformer rated power [VA]=

IM = total power of the motors

GLF = coincidence factor nF = speed ratio factor

0,2 x

400 x

IM x

GLF x nF

1,25 x

430 x

IM x

GLF x nF

GLF =

0,5 ... 0,7

0,4 ... 0,6 with one motor with 2 motors with >2 motors nF = effective speed maximum speed

AC three phase current

3 Electrical Installation

Motor connections

wire number PE M1 M2 M3 connection X3:6 X3:7 X3:8 X3:9

X3:6 is internally connected with the devices PE-bolt.

motor line at cross section kind of cable

5A 10A 16A

0,75 1,5 1,5

3x motor line shielded + PE

25A

2,5

+ (if required: 2x thermo + 2x brake) thermo brake

0,75 0,75

Shielding with earth clamp connected directly with the entry of the switch cabinet and the motor earth manifold if there are long lines .

Ferrit core

- against HF-failure

Motor chokes

- against HF-failure

- against high discharge current

- for high efficiency of the motor

- for the duration of the motors life

External ballast resistor

dimensioning : average of the brake power per axis

1 x

Jg x n² Jg² x a x n

P ballast [ W] =

Jg =

2 M

M motor- and effective load torque f n max =

M M = a =

= x maximum speed maximum motor torque deceleration repeating frequency of the braking[s ¹] f

To change on back panel power supply unit:

- remove jump wire connection D

- mount cable 1(external ballast resistor) external ballast resistor >>> internal ballast resistor

[kgm²]

[s ¹]

[Nm]

[s ²] smallest resistance value 40 W

/ 50W, at 3%ED = 1,5 kW

TVD6.2-400-x-RS 17

Transistor-Servo-Drive TVD6.2-RS

The connecting advices are for general information and without obligation.

Notice:

- Connecting- and operating instructions

- Local regulations

- EU-machine regulation 89/392/EWG

Clamp terminal pin numbers

X1: 1 to X1:16 and X2 : 17 to X2 : 32

Signal lines shielded and seperated from power lines nominal value lines paired twisted and shielded

Logical connections

Relay with golden pins or reed relay. Maximum currency on contact 6mA.

Internal logical voltage15V=

- Potential connection

- With relay control

- Jumper J1 and J3 plugged

External logical voltage

- Galvanic isolation

- With SPS or CNC

- UEXT +15 up to 30V= on clamp X2:27

- GNDE on clamp X1:11

jumper J1 and J3 unplugged

- residual ripple of the logical voltage <20%

Default setup: jumper J1 and J3 plugged.

Inputs and outputs with optocoupler.

Input

Output

3 Electrical Installation

Enable >>>active with forward voltage

jumper SW1 position 2-3 (default setup) enable -internal logical voltage

- internal logical voltage

- chain of contacts between

X1:1 +15V/10mA

X1:1 and X1:2

Enable -external logical voltage

- enable voltage +10 ... +30V X1:2

Enable >>> active at zero point

Jumper position 1-2

Enable -internal logical voltage

- logical zero point

- chain of contacts between

X1:11

Enable -external logical voltage

- enable voltage 0V

(US-version)

X1:11

X1:2 and

X1:2 enable

Enable switching on

- nominal value and torque control are cleared immediately

- LED D1B bright

Enable switching off

jumper J2 plugged (quick stop) (default setup)

- nominal value immediately set to zero internally (deceleration)

- LED D1B dark.

- after five seconds >>> speed controller locked jumper J2 unplugged (no braking)

- speed controller immediately locked.

- LED D1B dark

Notice:

Jumper SW1 Pos: 2-3 >> enable active with > +10V (default setup)

Pos: 1-2 >> enable active at zero point

Jumper J2 plugged unplugged

>> quick stop

>> free run out

(default setup)

TVD6.2-400-x-RS 19

Transistor-Servo-Drive TVD6.2-RS

Limit switch

L i mi t s wi t ch i np ut s

enable for

- positive nominal value LED 1D >>>contact between X2:27 and

X1:16

- negative nominal value LED 1H >>>contact between X2:27 and X2:32

Limit switch direction contact locked direction lock function enable>LED bright endswitchendswitch+ open

> limit switch is occupied

- drive decelerates

>>> contact open

> change of the nominal value

- drive moves from limit switch

- limit switch cleared >>> contact closed

Caution:

Without limit switch >>> connection between X2:27, X2:32 and X1:16

Integral switching off

Function - relay contact contact open locked speed controller

P-I regulation

P- regulation

Function - external logical voltage voltage X2:31 speed controller

< 2V

> 10V

P-I regulation

P- regulation

Caution:

Notice optimization advices.

Mains failure-braking

braking function

- nominal value is set immediately to zero

Generatoric rear feed into the intermediate circuit.

3 Electrical Installation

Speed-nominal value

voltage source for nominal values ±10V, 10mA

+10V X1:3

-10V

GND

X1:5

X1:8 with internal voltage source >>> Jumper S11, S12 plugged

Nominal value inputs

- maximum nominal value voltage ±10V=

- input resistance 50 k

- relay contacts: gold or reed contacts

Nominal value lines paired twisted and shielded. Shield connection one sided

Connection connection nominal X1:4 (signal) value 1 X1:8 (GND) nominal X2:17(signal) value 2

X2:28 (GND) jumper function directly

SW2 1-2 directly

SW2 2-3 ramp measuring point

X4:1

X4:10

X4:2

X4:10

Jumper positions function nominal value1 differential input with internal voltage source nominal value 2 differential input with internal voltage source with ramp (integrator) without ramp without nominal value 2 jumper position

S12

S12 unplugged plugged

S11

SW2

SW3

SW2 unplugged plugged

Pos. 2-3

Pos. 1-2 unplugged

Resistors for nominal value current 0 ... ±20mA nominal value 1 nominal value 2 i nternal supply

R121

CNC/SPS default setup

***

500

W nominal value current

TVD6.2-400-x-RS 21

Transistor-Servo-Drive TVD6.2-RS

External current limitation

voltage source for external current limit

+10V/10mA X1:3

Control range:

0 ... + 5V >>>

0 ... +10V >>> internal overcurrent control >>>

0 up to 100% rated current

0 up to 200% rated current max. 5 sec.

Inputs maximum input voltage +10V input resistance 10 k

W internal attenuatiuon with trimer I max1

, I max2 relay contacts: gold or reed contacts

Connection current limit positve negative internal supply conection jumper

X1:9 (signal)

X1:7 (GND)

X1:10 (signal)

X1:7 (GND) measuring point

S19 unplugged X4:3

X4:10

S20 unplugged

CNC/SPS

X4:3

X4:10 nominal value current

Caution: with internal current limit adjustment >>> jumper S19, S20 plugged.

3 Electrical Installation

Actual Value-Connection

Connector X7

- D-connector 15 pins

- Case metallized plastic

- Shielding on case

Line : resolver line

3x (2x 0,25 drilled and shielded) + 2x 0,5 shielded

Pin assignment X7

Function reference A (R1) reference B (R2) sine sine cosine cosine

A (S1)

B (S2)

A (S3)

B (S4) colour white brown yellow green pink grey

X7: 4

Pin-No

X7: 13

X7: 2

X7: 15

X7: 14

X7: 3 temperature sensor temperature sensor

X7: 6

X7: 12 with motors without temperature sensor >>>>>> bridge between pin 6 and 12

Incremental encoder- output

Connector X8

- D-connector 9 pins

- Case metallized plastic

- Shielding on case

Line: until10m

> 10m

Pin assignment X8

Function channel channel channel channel null pulse null pulse

6x 0,14 + 2x 0,5 shielded

6x 0,25 + 2x 0,5 shielded

Colour red black brown green grey pink

Pin-No

4 supply supply

+5V, 150mA violet 0,5

GND blue 0,5 connect allways supply!

Caution: Notice motorspecific connection sheets. Appendix A.

TVD6.2-400-x-RS 23

Transistor-Servo-Drive TVD6.2-RS

Ready for operation- BTB signal

Relay RL2 signal contact contact values

X2:21 - X2:22 max. 48V, 0.5A

The ready for operation signal (BTB) shows the control (CNC/SPS) that the drive is in working order.

Connect BTB-signals of several axes in series.

delay after switching on the mains >>> max. 1sec.

Indication ready for operation error

LED D1A bright contact closed

LED D1A dark contact open

BTB turns off with individual error BTB-LED D1A actual value error overtemperature dark dark short, line-to-earth fault dark voltage error dark buffer circuit error dark single signal- LED

LED D2H bright

LED D2G bright

LED D2F bright

LED D2B bright

LED D2A bright

Caution:

In any case use BTB-contact with CNC/SPS -Control !

Analogue measuring outputs

function connection measuring tage value

Output-

Resistance motor currency

X2:20 - X2:24

2,5V= current limit

5,0V= peak current unipolar positiv

1 k

W speed

X1:6 - X1:7 tachometer volbipolar before divider

4,7 k

3 Electrical Installation

Signal output logical outputs with opto-coupler

- wire break secure in case of error output is locked

- output voltage 10 ... 30V=

- output voltage

- output resistance

5mA

1k

Overview of signal outputs signal function intermediate circuit power supply unit error overload standstill overtemperature blocked speed motor heat sink

< 1% output

X1:14

X2:18

X2:25 indication stored

>150°C X2:26

> 75°C X2:26

LED 2A yes

LED 1F no

LED 1E no

— no

— no heat sink > 80°C X2:26 LED 2G yes warning reference earth motor, heat sink too hot

GND

X2:19

X2:23

— no memory reset: enable main s off/o n jumper

S6 off/on jumper S6 plugged ( default setup ) unplugged

TVD6.2-400-x-RS 25

Transistor-Servo-Drive TVD6.2-RS

Control Connection X1,X2

Function tor

No.

+ 15 Volt (for enable) enable input (+10 ... +30 Volt)

+ 10 Volt (for nominal value) nominal value 1-input (signal)

- 10 V (for nominal value)

DC-tachometer -input (signal)

DC-tachometer-input (AGND) nominal value 1-input (AGND) external current limit I

1 external current limit I

2 external GNDE

-15V (external electronics) device ground GND intermediate circuit error amplification 1:1 limit switch (-) nominal value 2-input (signal) overload signal

Terminal No.

X1: 9

X1: 10

X1: 11

X1: 12

X1: 13

X1: 14

X1: 15

X1: 16

X2: 17

X2: 18

X1: 1

X1: 2

X1: 3

X1: 4

X1: 5

X1: 6

X1: 7

X1: 8

Intern. Connec-

overload tacho error or temperature error current (I-actual) ready/operational BTB ready/operational BTB device ground GND (mass) analogue device ground (AGND) standstill signal over-temperature external voltage UEXT

X2: 19

X2: 20

X2: 21

X2: 22

X2: 23

X2: 24

X2: 25

X2: 26

X2: 27

X11: 28a

X11: 26a

X11: 24a

X11: 22a

X11: 20a

X11: 18a

X11: 16a

X11: 14a

X11: 12a nominal value 2 (AGND) input nominal current value

+15V (external electronics) integral component interlock X2: 31 limit switch (+)

X2: 28

X2: 29

X2: 30

X2: 32

X11: 10a

X11: 8a

X11: 6a

X11: 4a

X11: 2a

X11: 32c

X11: 30c

X11: 28c

X11: 26c

X11: 24c

X11: 22c

X11: 20c

X11: 18c

X11: 16c

X11: 14c

X11: 12c

X11: 10c

X11: 8c

X11: 6c

X11: 4c

X11: 2c

X11: 32a

X11: 30a

3 Electrical Installation

Power connection X3

Function Terminal No.

intermediate circuit ex. load resistor X3:1 intermediate circuit + X3:2 power L1 power L2

400V~

X3:3

X3:4

400V~ power L3 earth PE motor 1 motor 2 motor 3

X3:5

X3:6

X3:7

X3:8

X3:9

Control Connector X4

(front panel)

Function

1st nominal value according to the differential amplifier

2nd nominal value according to the diff. amplifier or integrator

I-nominal value

+10 V

-10 V

I-actual value n-actual value (normalised) enable device ground GND

Intern.Connector

No.

X31: 18,2 0 abc

X31: 14, 16 abc

X31: 10, 12 abc

X31: 6, 8 abc

X31: 2, 4 abc

X31: 22, 24 abe

X31: 26, 28 abe

X31: 30, 32 abe

Pin-No.

X4: 1

X4: 2

X4: 3

X4: 4

X4: 5

X4: 6

X4: 7

X4: 8

X4: 9, 10

TVD6.2-400-x-RS 27

Transistor-Servo-Drive TVD6.2-RS

Encoder Connector to Motor X7

Function Colour reference reference sine sine cosine cosine

A (R1)

B (R2)

A (S1)

B (S2)

A (S3)

B (S4) white brown yellow green pink grey temperature sensor temperature sensor

X7: 6

X7: 12

Kabel: 3x (2x 0,25 twisted and shielded) + 2x 0,25 (Temp)

Schield on connector case.

D-Connector-No.

X7: 13

X7: 4

X7: 2

X7: 15

X7: 14

X7: 3

Encoder Connector to CNC\SPS X8

Function colour D-Connector-No.

channel channel channel channel

X8: 5 zero pulse zero pulse

+5V/50mA external

GND red black brown green grey pink violet 0,5 internal/external blue 0,5

Notice motorspecific connection sheets. Appendix A.

X8: 2

X8: 9

X8: 3

X8: 8

X8: 7

X8: 4

X8: 1

4 Device Overview

TVD6.2-400-x-RS 29

Transistor-Servo-Drive TVD6.2-RS

4 Device Overview

TVD6.2-400-x-RS 31

Transistor-Servo-Drive TVD6.2-RS

Indicator LEDs 2x actual value error temperature error short detection rotor position 3 rotor position 2 rotor position 1 voltage error intermediate circuit error

Adjustment potentiometer

- I

+I max max current limit current limit

Control Connector X4

1.nominal value after the diff. amplifier

2.nominal value after the integrator nominal current value

+ 10V

- 10V current - actual value speed - actual value enable n.c.

device ground GND

Indicator LEDs 1x end limit switch + end limit switch overload - blocked standstill current direction current direction + enable enable ready/operational BTB

Adjustment Potentiometer

D continous current limit

INT amplification

Integrator-time n max speed

Offset zero point

4 Device Overview

Adjustment functions

Function

Adjustment functions bl tachometer

Component poti P4 (n max) actual value adjustment Option DC-tacho binary switch S9 + poti P4 internal current limit external current limit steady current integrator amplification P-component jumper S19, S20 poti P5 (I max

1), S19 poti P6 (I max2

), S20 poti P5 (I max

1) poti P6 (I max2

) poti P7 (I

) jumper SW2 (2-3) poti P2 (INT) binary switch S4 poti P3 (Xp) amplification I-component

Nullabgleich binary switch S5

Poti P8 (Offset)

Jumpers

Function

1st nominal value input (zero referenced)

2nd nominal value input (zero referenced) ramps 2nd nominal value on/off actual value differentiation actual value smoothing internal current limit 2 internal current limit 1 amplification 1=1 ext. +UL = int. +15V ext GND = int. GND quick stop (delayed controller interlock) actual value-bl-tacho enable - reset enable positive/negative logic temperature controller

TVD6.2-400-x-RS

Jumper

S 12

S 11

SW2 2-3/1-2

S 14

S 3

S 19

S 20

S 2

J 1

J 3

J 2

S 6

SW1 2-3/1-2

S 18

Transistor-Servo-Drive TVD6.2-RS

LED- indicators

Function

Control electronics limit switch + limit switch blocked standstill speed controller output speed controller output + enable nominal value ready/operational (BTB)

Power section actual value error temperature short detection rotor position R3 rotor position R2 rotor position R1 voltage error intermediate circuit error

LED-No.

LED D1x

LED H

LED G

LED F

LED E

LED D

LED C

LED B

LED A

(stored)

(optional)LED G

(stored)

LED D2x

LED H

LED F

LED E

LED D

LED C

LED B

(not stored).

LED A

5 Adjustment

Adjustment Advice

adjustments

- only by qualified personnel

- adhered to safety regulations

- notice adjusting sequence

Presettings actual value >>> nominal value inputs, >>> logical inputs/outputs >>>

P-I parameter switch >>> jumper, networks jumper, differential input jumper, int/ext. supply jumper, switch

Optimization actual valueadjustment current regulator current limits torque controller slope limitation zero point position controller n max adjustment adjustment by the factory (P- or PI-Controller)

I max

, I

-adjustment

P-I-switch, Xp-adjustment

INT-adjustment (only nominal value 2) offset-adjustment in CNC\SPS

Caution:

control systems have to be optimized from inside to outside.

sequence: current controller>> torque controller>>position controller

(CNC\SPS)

Measuring values

control connector X4 point measuring value max.value

1st nominal value after input amplifier

2nd nominal value after input amplifier

±10V

±10V nominal value current (speed controller) ±10V actual value current unipolar + 5V torque actual value after divider ± 5V measuring

X4:1

X4:2

X4:3

X4:6

X4:7

TVD6.2-400-x-RS 35

Transistor-Servo-Drive TVD6.2-RS

Function lue input amplifier input voltage differential input input according to GND input signal input GND measuring point control pin measuring value

1st nominal value 2nd nominal vaconstant 1 max.

±10V= jumper S12 unplugged jumper S12 plugged

X1:4 max.

X1:8

X4:1

±10V=

S11 unplugged

S11 plugged

X2:17

X2:28

X4:2

±10V= integrator function does not exist jumper SW2

Input in relation to GND with nominal value potentiometer with internal supply voltage jumper S11, S12 plugged notice GND connection

Differential input with nominal value of SPS/CNC foreign external voltage jumper S11, S12 open signal- and GND-connection exchangeable default setup

Both nomimal values connected:

- 1st and 2nd nominal value are added internally

- notice signs

- sum of nominal values not over ±10V

Only with 2nd nominal value

-acceleration and deceleration-ramp linear integrator

2nd nominal value jumper Poti without integrator with integrator

SW2 pos. 1-2 —-

SW2 pos. 2-3

0,1 up to 4,5sec.

without 2nd nom.value SW2 unplugged range

——

INT(P2)

—-

Nominal value current nominal value from external supply 0 to ±20mA internal compliance resistors 0 to max. ±10V

1st nominal value resistor R121

2nd nominal value resistor R4

Resistance value [

]

= nominal value voltage / nominal value current

(max. 500

)

5 Adjustment

Actual Value-Speed

Caution:

Please pay attention to the motor specific connection sheets.

see Appendix A coarse adjustment see page 29

.

Fine adjustment with potentiometer n max

(P4) with nom. value from potentiometer: with 1V Sollwert adjust to 10% maximum speed with 10V Sollwert fine adjust to 100% .

with nom. value from CNC\SPS: with 0,8V Sollwert adjust to 10% maximum speed

Direction of rotation (looking at motor backside-DIN) change nominal value polarity at the differtial input

TVD6.2-400-x-RS 37

Transistor-Servo-Drive TVD6.2-RS

Current Limitation

peek current steady current range 0 up to 200% rated current reset time max. 5 sec.

range 5 up to 100% rated current

Poti P5/P6

Poti P7

Internal reducing current limits current limit overload function time heat sink motor temperature temperature

The lowest current limit is active!

limit steady current

50% rated current

Peek current internal current limit (default setup)

I adjustment max1

Jumper

S19 plugged

S20 plugged I max2 external current limit

I adjustment max1 input

X1:9

I max2

X1:10 0 .. +10VS20 unplugged

The external current limit can be internally reduced with the I max

-potentiometer.

Jumper

0 .. +10VS19 unplugged

Steady current motor protection adjustment for both torque directions to motor rated current potentiometer I

(P6)

Poti

I max1

(P5)

I max2

(P6)

Poti

I max1

(P5)

I max2

(P6)

Measure adjusted values:

- motor not connected

- predetermine nominal value and enable >> turn on/off

- measuring value at connector X4:3 (5V=rated current) nom.value measuring value I max

(2 sec.) measuring value I

+5V 0 bis max.10V

0,25 bis max. 5V

- 5V 0 bis max.10V

0,25 bis max. 5V

Current-actual value measuring value at connector X4:6 >>> Imax = 0 up to +5V,

= 0,12 up to +2,5V

Caution: for exact torque regulation:

-changing of adjustment from P-toPI-regulation in the current regulator by the manufacturer

5 Adjustment

Speed control switching

- two 16 pole binary switches S4, S5

- amplification trimmer P3 (Xp)

- D-component with jumper S14

- in case of exchanging the devices>>> take over adjustment values.

Default setup

- binary switch S4 und S5 on position 4

- amplification trimmer Xp on 50%

- no D-component, jumper S14 open

- optimal for most drives.

Adjustment P-component with the binary switch

S4 switch S4 position 0 1 2 3 4 5 6 7

R-value 1000 450 280 209 180 148 123107 k

W position 8 9 A B C D E F

R-value 90 82 73 67 64 59 55 52 k

W adjustment I-component with the binary switch S5 switch S5 position 0 1 2 3 4 5 6 7

C-value 0,01 0,02 0,03 0,04 0,08 0,09 0,1 0,11 m

F position 8 9 A B C D E F

C-value 0,11 0,12 0,13 0,14 0,18 0,19 0,2 0,21 m

Caution: with the input INTAB (X2:31) the I-component can be switched off.

TVD6.2-400-x-RS 39

Transistor-Servo-Drive TVD6.2-RS

Proportional amplification

function binary switch S4 function potentiometer X

P proportional amplification = Xp x Fxp

Adjustment with osciloscope

Adjust

- nominal value jump ± 0,5V

- input INTAB X2:31 activated

Effect D-component

- nominal value -differentiation

- jumper S14 plugged

Caution:

In case of position control (CNC/SPS) do not use D-component

Measuring value nominal value X4:1 reply of the controller nominal value current X4:3

5 Adjustment

Adjustment without measuring instruments

connect the motor, nominal value = 0

Xp = 50% switch S4 switch S5

= position 4

= position 4 enable the device, turn potentiometer Xp clockwise until the drive swings.

if there is no oscillation

-turn switch S4 back to a lower value

-set to swinging with potentiometer Xp

-turn the potentiometer Xp anti-clockwise until the swinging fades out

-turn potentiometer Xp another two positions anti-clockwise.

Setup switch S5 so, that the drive runs smoothly after about two oscillations when there was a nominal value jump off 50%.

Responce of the drive: amplification too low long wave oscillation 1 ... 0,1Hz long ballistic factors overshoots target position amplification too high short wave oszillation 30 ... 200Hz vibrates >in case of acceleration, vibrates >in case of deceleration and in position

Caution: operation with CNC\SPS - control

-ad maximum speed >>> speed nominal value from 8 up to 9V

TVD6.2-400-x-RS 41

Transistor-Servo-Drive TVD6.2-RS

Default setup

check connections before putting into operation

- mains connection

- protective conductor clamps X3:3, X3:4, X3:5 earth screw at case max. 460V~

- motor connection clamps X3:7, X3:8, X3:9

- motor earth connection clamps X3:6

- option

- external ballast resistor clamps X3:1 and X3:2 mind connection advices on page 12.

Encoder connection X7 pay attention to the motor specific connection sheets. See appendix A

Basic connections-supply lines

- protective conductor

- mains

- motor

- encoder

1x oder 3x 400V~

3x motorline + earth conductor + screen pay attention to the motor specific connection sheets.

Basic connections - control lines enable contact betweem X1:1 and X1:2 nominal value limit switch signal X1:4, GND X1:8 limit switch at X1:16 and X2:32 or bridge X2:27 to X1:16, X2:32

Default adjustment for first putting into operation switch switch

P-amplification

I-component position 4 position 4 potentiometer potentiometer potentiometer potentiometer potentiometer potentiometer

INT n max1 max2

D max peak current peak current steady current amplification integrator speed

10%

100%

50% anti-clockwise stroke anti-clockwise stroke

Jumper unplugged

S2, S14, S18

SW1 Pos.1-2

SW2 Pos.1-2 plugged

J1, J2, J3, J4

S3, S6, S11, S12, S19, S20

SW1 Pos.2-3

SW2 Pos.2-3

6 Getting Started turn on mains yes

LED D1A bright

LED D1E bright yes

LED D1H bright

LED D1G bright yes enable drive yes

LED D1B bright yes increase nom.value to 10% yes motor turns with about 10% of maximum speed yes motor run smooth not jerky yes adjust speed with poti n max to 10% no no no no no adjust nom. dcvalue value to 0V drive stands still yes increase nom.value to 50% turn poti X clockwise until the drive oszillates, then turn anti-clockwise until the drive runs smooth no adjust current limits with poti I max1 and

I max2 to the peek current and with poti I

D to the steady current acording to the motor data

Getting started finished turn off mains optimize drive and record the adjustment dates in the protocol

TVD6.2-400-x-RS check mains connection turn off mains check power supply unit fuse turn off mains check limit switches connect limit switches or thread bridges turn off mains check enable voltage and chain of enable contacts motor speeds up>> motor stands still >> turn off mains check motor and encoder lines amplification too high Xp >> turn anticlockwise turn off mains check motor and encoder lines adjust speed with poti Offset to standstill

Transistor-Servo-Drive TVD6.2-RS

Switch on mais

All LED dark no

LED D1A dark

LED D2A bright yes yes

No mains V0ltage fuse on power supply unit blown out

Check power supply unit

LED D1A dark

LED D2A dark no yes

LED D2B bright yes internal or external power supply overloaded

LED D2F bright yes short or line-to-earth fault in motor line or outputstage error

LED D2G bright yes connect limit switches

LED D1G dark

LED D1H dark yes connect enable yes

LED D1B dark no preset nom.v alue ± no

LED D1C dark

LED D1D dark no

LED D1F bright no let device be checked by the manufactorer yes yes yes yes let device be checked by the manufactorer check limit switches or bridge limit switches check enable voltage and jumpers check nom.value

and jumper motor mech. blocked motor- or encoder line wrong yes heatsink-temperature >80°C

7 Fault Finding

Faults

Fault motor is fixed in one position, runs jerkey or swings in one position motor speeds up motor runs restless

Causes transmittercable or motorcable connection wire changed or interrupted.

Switchposition S1: pos3 and pos4 wrong(pole-number adaption) motor- or rotor positon- line wire in rotating field 120° leading or lagging.

tachometer- connection wires exchanged or interrupted amplification too high.

nominal value failure braking energy too high power supply unit goes while braking to failure

LED D2-A glows power supply unit goes while switching on to failure

LED D2-A glows amplifier switches to failure speed is not adjustable with potentiometer n max power supply phase is missed or the mains voltage is too low.

overtemperature, phase- or line-to-earth fault . BTB-fault power amplifier mistake.

resistor R19 or switchposition S1-1, S1-2 on RESO2-x wrong

TVD6.2-400-x-RS 45

Transistor-Servo-Drive TVD6.2-RS

7 Fault Finding

Resolver Signals

Motor voltage

Motor current

TVD6.2-400-x-RS 47

Transistor-Servo-Drive TVD6.2-RS

UNITEK

products have a warranty against defects in material and workmanship for a period of one year from the date of shipment. All values from the pre- and final quality control checks are archivied with the devices’ serial numbers. UNITEK does not guarantee the suitability of the device for any specific application.

During the warranty period, UNITEK will, at its option, either repair or replace products that prove to be defective, this includes guaranteed functional attributes. UNITEK specifically disclaims the implied warranties or merchantability and fitness for a particular purpose. For warranty service or repair, this product must be returned to a service facility designated by

UNITEK.

For products returned to UNITEK for warranty service, the Buyer shall prepay shipping charges to UNITEK and UNITEK shall pay shipping charges to return the product to the Buyer.

However, the Buyer shall pay all shipping charges, duties, and taxes for products returned to UNITEK from another country.

The foregoing warranty shall not apply to defects resulting from:

* improper or inadequate repairs effected by the Buyer or a third party,

* non-observance of the manual which is included in the all consignments,

* non-observance of the electrical standards and regulations

* improper maintenance

* acts of nature

All further claims on transformation, diminution and replacement of any kind of damage, especially damage, which does not affect the UNITEK device, cannot be considered. Follow-on damage within the machine or system, which may arise due to malfunction or defect in the device cannot be claimed. This limitation does not affect the product liability laws as applied in the place of manufacture (i. e. Germany).

UNITEK reserves the right to change any information included in this

MANUAL. All connection circuitry discribed is meant for general information purposes and is not mandatory.

The local legal regulations, and those of the Standards Authorities have to be adhered to. UNITEK does not assume any liability, expressively or inherently, for the information contained in this MANUAL, for the functioning of the device or its suitability for any specific application.

All rights are reserved.

Copying, modifying and translations lie outside UNITEK’s liability and thus are not prohibited. UNITEK’s products are not authorized for use as critical components in the life support devices or systems without express written approval.

The onus is on the reader to verifiy that the information here is current.

9 Protocol

Customer: . . . . . . . . . . . . . . . . . . . . . . . . .

Maschine-No . . . . . . . . . ..

Device: . . . . . . . . . . . . . . . . . . . . . . . . .

Series-No . . . . . . . .. . . . . . .

Anschlußspannung [ V=,V~]. . . . . . . . . . . .

Eingänge

Enable

Nom. value1

Contact ?

Type

Nom.value 2 additional Type current nom.value I max1 external current nom.value I max2 external voltage [V=] voltage [V=] voltage [V=] voltage [V=] voltage [V=]

Adjustments speed controller

Act.value coarse adjustment

DC-Tacho

Switch positions

P-component

I-component

S5 position position position

Potistellungen

Speed

Peek current

Steady current

Integrator

Amplification

Offset n max

I max1

I max2

INT

Offset

Jumper (plug-in bridges) soldjumper plugged Nr. . . . . . . . . . . . . . . .

Unplug Nr. . . . . . . . . . . . . .

P8 position position position position position position position

TVD6.2-400-x-RS 49

Transistor-Servo-Drive TVD6.2-RS

Adjustment power section

Amplification current controller

Resistors current controller

Measuring values

Motor voltage max.

Motor current

DC-Tacho voltage max

Acceleration

Deceleration peek steady

[ k W]. . . . . . . . . . . . . . . . .

[V~] 3x

[A~] 3x

[V=]

[V/ms]

Motor data

Identification plate specifications

Producer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . .

Motor voltage [V~] . . . . . . . . . .

Brake [V] . . . . . . . . . .

Series No. . . . . . . . .

Motor current[A~] . . . . .

Fan[V]

Stuttgart

UNITEK Industrie Elektronik GmbH Industriestr.1

D-71397 Leutenbach-Nellmersbach b.

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