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mannesmann Rexroth
engineering
TVD 1.3 Power Supply Module for Direct Connection to 3 x AC 380...480V Mains Supply
Applications Manual
DOK-POWER*-TVD*1.3****-ANW1-EN-P
271434
Indramat
About this documentation
Title
TVD 1.3 Supply Module for Direct Connetion to 3 x AC 380...480V Mains Supply Applicationsbeschreibung DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44 · Mappe 6 · TVD13-AN.pdf · 209-0049-4309-01 This electronic document is based on the hardcopy document with document desig.: DOK-POWER*-TVD*1.3****-ANW1-EN-P · 11.96 This document serves to: · define the applications range · support the electrical construction of the machine · support the mechanical construction of the cabinet · mounting and installation · selecting the additional components · help with the clearing of faults
Type of documentation Document code Internal file reference
Reference
The purpose of the documentation
Editing sequence
Doc. designations of previous editions 209-0049-4309-00 DE/07.96 DOK-POWER*-TVD*1.3****-ANW1-EN-P DOK-POWER*-TVD*1.3****-ANW1-EN-P DOK-POWER*-TVD*1.3****-ANW1-EN-E1,44
Status
Comments
JUL./96 Preliminary without print JUL./96 1st edition NOV./96 2nd edition Feb./97 1st edition E-Dok
Copyright
© INDRAMAT GmbH, 1996 Copying this document, and giving it to others and the use or communication of the contents thereof without express authority are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). The electronic documentation (E-doc) may be copied as often as needed if such are to be used by the consumer for the purpose intended.
Validity
All rights are reserved with respect to the content of this documentation and the availability of the product. INDRAMAT GmbH · Bgm.-Dr.-Nebel-Straße 2 · D-97816 Lohr Telefon 0 93 52 / 40-0 · Tx 689421 · Fax 0 93 52 / 40-48 85 Dept. ENA (DE, FS)
Published by
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Table of Contents
Table of Contents
1. 1.1. Construction of INDRAMAT Modular A.C. Drive System 7
Main functions of the TVD 1.3 .......................................................... 8
2. 2.1 2.2. 2.3. 2.4. 2.5.
Range of Applications
9
Functional power features of the TVD 1.3 .....................................10 Power ratings of the TVD 1.3 ......................................................... 11 Overload Capabilities of the TVD 1.3 ............................................. 11 Technical Data - TVD 1.3 ...............................................................12 Ambient Conditions ........................................................................13
3. 3.1. 3.2. 3.3 3.4. 3.5. 3.6. 3.7. 3.8. 3.9.
Electrical Connections Installation Guidelines
14
Interconnect diagram TVD 1.3 with NAM 1.3.................................15 TVD 1.3 interconnect diagram with individual, additional components ................................................................... 16 Mains connection devices ..............................................................17 Mains connection to power circuits ................................................ 19 Fuse protection for direct mains connection ..................................21 Mains supply earthing requirements ..............................................21 Commutation choke .......................................................................23 DC bus circuit .................................................................................23 DC bus smoothing choke ...............................................................24
3.10. Additional DC bus capacitance ......................................................24 3.11. Bridge circuit capacitance ..............................................................24 3.12. Additional bleeder module TBM .....................................................25 3.13. External bleeder resistor ................................................................26 3.14. Supply to electronics and blower ...................................................27 3.15. Electronics supply buffer capacitance ............................................28 3.16. Electronics supply and signal exchange connections .................................................................................... 29 3.17. Residual current operated devices ................................................ 30 3.18. Control cabinet testing ................................................................... 31 3.19. Mounting the TVD 1.3 into the control cabinet ............................... 31
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Table of Contents
3.20. Heat loss inside the control cabinet ...............................................33 3.21. Safety clearance inside the control cabinet ...................................33 3.22. Front view of the TVD 1.3 ..............................................................34
4. 4.1. 4.2. 4.3. 4.4. 4.5.
TVD 1.3 Interconnections
35
Optional Control Possibilities ......................................................... 35 TVD interconnect with DC bus dynamic braking ...........................36 TVD interconnect with E-stop relay with DC bus dynamic braking .............................................................................38 TVD interconnect without DC bus dynamic braking ...................... 40 TVD interconnect for a position-controlled braking of the drives ... 42
5. 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. 5.9.
Terminal Descriptions
44
DC bus short-circuiting ................................................................... 44 Power off ........................................................................................44 Power on ........................................................................................44 Stopping the drives in an E-stop or a power failure ....................... 45 Signal Voltages ..............................................................................46 "Ready" status ................................................................................46 Power OK .......................................................................................48 Regenerated power too high .......................................................... 48 Temperature Pre-Warning ..............................................................49
5.10. Mains contactor de-energized ........................................................ 49 5.11. Mains contactor energized .............................................................49
6. 6.1. 6.2. 6.3. 6.4.
Troubleshooting
50
Localizing the fault .........................................................................50 Diagnostic display .......................................................................... 53 Definition of the displays ................................................................54 Rating plate data ............................................................................57
7. 7.1.
Dimensional data
58
Dimension sheet TDV 1.3 power supply mdule .............................58 4
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Table of Contents
7.2. 7.3. 7.4. 7.5. 7.6. 7.7. 7.8. 7.9.
Dimension sheet NAM 1.3 power adapting module ....................... 59 Dimension sheet CZ 1.2-01-7 bus voltage capacitor ....................60 Dimension sheet KD 23/26 commutating chokes ..........................61 Dimension sheet DC bus smoothing choke GLD 16/17 ......................................................................................61 Dimension sheet CZ 1.02 auxiliary capacitance ............................62 Dimension sheet TCM 1.1 aux. capacitance mod. ........................ 62 Dimension sheet TBM aux. bleeder module ..................................63 DST Autotransformers with a secondar or output voltage of 380...460 V .....................................................................................64
8. 8.1. 8.2. 8.3. 8.4. 8.5.
Order information
65
Type codes TVD .............................................................................65 Available supply module types of the TVD 1.3 and accessories ... 65 Overview of electrical connecting accessories .............................. 66 Overview of 16-pin bus cable for NAM 1.3 ....................................66 Item list of mains supply with TVD 1.3 ...........................................67
9.
Index
68
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ty p e m ag E p
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1. Construction of the Modular AC Drive System
1.
Construction of INDRAMAT Modular A.C. Drive System
The modular AC drive system from INDRAMAT is made up of · auxilary units · supply modules and · drive modules. These can be combined depending upon the power and functionalities required.
Power Supply auxilary units
commutating reactor DC bus smoothing reactor buffer capacitor
Mains
3xAC 380 ... 460V 50 ... 60Hz L1 L2 L3
Drive Drive module
Programming module Signal voltages control, monitoring, diagnoses
Power Supply Module TVD 1.3
internal power contactor
Bleeder
internal DC bus short-circuit
n act M G feed motor
TVD/AntriebAufbau
Fig. 1.1:
The TVD 1.3 supply module as part of the INDRAMAT AC drive system
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1. Construction of the Modular AC Drive System
1.1. Main functions of the TVD 1.3
Power supply to the drives
The high-voltage link rectifies the three-phase mains AC and provides a regulated DC bus circuit voltage for the power feed to the drives. A buffer capacitor takes care of any necessary smoothing. When the drives are in generator mode, the regenerated power is absorbed by the bleeder resistor and transformed into heat. The drives can be disconnected from the mains by the TVD's internal power contactor. The TVD 1.3 provides the +24VL and +/-15VM for all connected drive modules. In the event of a power failure, the signal voltages are supplied from the DC bus circuit. Therefore, as the drives operate as a generator, the electronics of the drives remain functional. The TVD 1.3 is equipped with extensive monitoring functions. These communicate with the drive modules via the wire ribbon cable. The Bb1 contact is critical to the ready state of the drive system. The power contactor cannot be energized until the Bb1 contact is closed.
Supply to the electronics
Drive system monitoring
Bleeder
DC bus s.c.
1U1 1V1 1W1 K1 DC DC
320 V DC as power source of drives
~ =
Power source and monitoring of drives Drives ready
&
Bb1
AufbauTVR3
Power supply ready
Fig. 1.2:
The basic construction of the TVD 1.3
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2. Range of Applications
2.
Range of Applications
INDRAMAT drives up to a continuous mechanical output of 12kW can be run from the TVD line of supply modules. The TVD 1.3 operates without mains regeneration. Drives with mains regeneration for regenerated power exceeding 2 kW are, however, available.
Mains
L1 L2 L3
Input to network
Supply module
15 kW 1 kW*)
Drive module
*) By combining with auxiliary bleeder 1.5 or 2.0 kW
TVDLeistbereich
P m
P m
Continuous mechanical power up to 12 kW
Fig. 2.1:
Power range of the applications of the TVD 1.3
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2. Range of Applications
2.1
Functional power features of the TVD 1.3
· Connected load The TVD 1.3 can be operated with power systems of 3 x AC 380..480V, 50...60Hz without a transformer. Additional auxilary units are offered (NAM 1.3..) which suppress reactions on the power system. · Power shutdowns by internal contactors The contactor to shut down power to the power system of the drives is an integrated component of the TVD 1.3. · Internal DC bus dynamic braking Motors with permanent magnetic fields can be braked to a standstill by the DC bus dynamic brake in the event of fault conditions in the drive electronics. · How the drive system responds to a power failure can be programmed by inserting an external jumper: without a jumper, the drives brake at maximum torque with a jumper, a signal via a potential-free contact is transmitted to the NC control unit which can then brake the drives controlled to a standstill. Costly tools and workpieces are thus protected against damage. · Regulated DC bus voltage Drive dynamics maintained with mains undervoltage. · Charging current limit of the DC bus capacitors The inrush current does not have to be taken into consideration when selecting the switching devices of the power system. This extends the service life of these devices. · Extreme load capabilities of the control voltage Up to ten drive modules can generally mounted to one supply module. · Easy to service The signal leads are connected via plug-in screw clamps. · Two different power stages available The supply module TVD 1.3 is available with a continuous DC bus power of 7.5 kW or 15 kW. This means that the power supply can be optimally matched to the requirements of the respective application. · Overload capabilities of the TVD 1.3 The TVD 1.3 can overloaded for a short duration for the purpose of accelerating feed and main drives. The maximum possible acceleration power, as relates to the duration of acceleration, is outlined in the section "Overload Capabilities of the TVD 1.3". The values found there must be taken into account during project planning and may not be exceeded. · UL Registered The device is made according the UL-Standard.
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2. Range of Applications
2.2. Power ratings of the TVD 1.3
The TVD 1.3 is available with a DC bus continuous power of 7.5 kW and 15 kW. It can be combined with an auxiliary bleeder module. This means that the power supply can be optimally matched to the requirements of the respective application.
(1) PDC kW 7,5 7,5 15 15 (1) PDC (2) PKB-3 (3) PKB-03 (4) PBD (5) PBM (2) PKB-3 kW 15 15 30 30 (3) PKB-03 kW 22,5 22,5 45 45 (4) P BD kW 0.5 1.5 1.0 2.0 (5) PBM kW 20 60 40 80 (6) Wmax kWs 30 130 60 160 (7) Pm kW 6 6 12 12 (8) (9) Power supply components Power conn. module NAM 1.3-08 NAM 1.3-08 NAM 1.3-15 NAM 1.3-15 Auxiliary bleeder module --------------------TBM 1.2-40-W1 --------------------TBM 1.2-40-W1
PmKB-3 P mKB-03 TVD 1.3 kW kW 12 12 24 24 18 18 36 36 -08-03 -08-03 -15-03 -15-03
= continuous DC bus power = DC bus short-term power for 3s (accel. of spindle drive) = DC bus peak power for 0.3s (accel. feed drives) = Bleeder continuous power = Bleeder peak power
Fig. 2.2:
(6) Wmax (7) Pm
= maximum regenerated energy = mechanical output for ON time of > 10s
(8) P mKB-3 = mechanical short-term output for 3s (accel. of spindle drive) (9) PmKB-03 = mechanical peak output for 0.3s (accel. feed drives)
Power ratings in the TVD 1.3
2.3. Overload Capabilities of the TVD 1.3
The TVD 1.3 can be overloaded for a short duration for the purpose of accelerating feed and spindle drives. The maximum acceleration ratings must be taken into account during project planning and may not be exceeded!
300 Peak power for 0.3 s to accel feed drives
200
Power limit Short-term operating power for 3 s to accelerate the spindle drives
100 Load P/%
Continuous power for ON time exceeding 10 s 10 ON time t/s
TVRBelastungsdiagr
0.3
3
Fig. 2.3: Load diagram - TVD 1.3
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2. Range of Applications
2.4. Technical Data - TVD 1.3
Designation
Power section Input voltage Frequency DC bus voltage Continuous DC bus power Peak DC bus power (for 0.3 s) Bleeder continuous power Bleeder peak power Maximum regenerated energy Power dissipation with maximum power (without bleeder loss) Basic loss Power loss per kW continuous DC bus power Weight m (kg) U(ACN) f(N) U(DC) P(DC) P(KB-03) P(BD) P(BM) W(max) P(v) (V) (Hz) (V) (kW) (kW) (kW) (kW) (kWs) (W) (W) 17 11,2 15 45 1 40 60 330 75 14 10.5 3 x 380 ... 480 (± 10%) 50 ...60 320 (± 5%) 7.5 22.5 0.5 20 30 180
Symbol Unit
TVD 1.3-15-3
TVD 1.3-08-3
Electronics supply Input voltage Frequency Incomming power U(AC) f(N) S(el) (V) (Hz) (VA) 3 x 380 ... 480 (±10%) 50 ... 60 300
Control voltage output + 24V load voltage + 24VL continuous current + 24VL ripple ± 15V measuring voltage + 15VM continuous current - 15VM continuous current ± 15VM ripple U(M) I(+UM) I(-UM) U(L) I(UL) (V) (A) (%) (V) (A) (A) (%) 22 ... 26 7.5 2 14.9 ... 15.1 2.5 1.5 (2.0) 0.1
1)
Ambient conditions Permissible ambient temperature with rated data Maximum permissible ambient temperature with derated data Storage and transport temperatures Installation elevation with derating Permissible relative humidity Permissible absolute humidity Protection category Contamination level T(um) T(umr) T(L) (°C) (°C) (°C) +5 ... +45 55 -30 ... +85 max. 1000 meters above sea level max. 95% 25g water / m3 Luft IP 10 per DIN 40 050 non-conductive dirt, no condensate
Suitable auxilary units
NAM 1.3-15
NAM 1.3-08
1)
The -15VM can be loaded with a maximum of 2 A. The load of + 15VM and - 15VM combined may not exceed 4 A.
Fig. 2.4: Technical data of supply module TVD 1.3
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2. Range of Applications
2.5. Ambient Conditions
Increased ambient temperatures
The DC bus power and control voltage loads listed in the data sheets apply to an ambient temperature of +5 to +45oC. The maximum permissible ambient temperature may equal +55 o C. The power data, in this case, derate as per the diagram below.
Derating factor in %
100 80 60 40 20 0 0 10 20 30 40 50 60 Ambient temperature in °C
DGTemp
Fig. 2.5: The derated power data with increased ambient temperatures
Installation elevations exceeding 1000 m
The power data is derated as per the following diagrams in the case of installation of 1000 meters above sea level.
Derating factor in %
100 80 60 40 20 0 0
DGHöheDDS3
1000
2000
3000
4000
5000
Installation elevation in m
Fig. 2.6: Power data derated for installation elevations exceeding 1000 meters
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3. Electrical Connections
3.
Electrical Connections Installation Guidelines
The interconnection diagram found in this documentation is a recommendation of the equipment manufacturer. The wiring diagram of the machine builder should be used for installation.
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Circuit diagram for a TVD 1.3 with mains connection module NAM 1.3 with 380 ... 480V supply connection and internal electronics - internal power switch
central ground point for all drive modules
3xAC (380 - 480) V (50 - 60) Hz Q1
PE L3 L2 L1
X1 U1 V1 W1 X15 EB P N
11,12 13,14
X7
NAM 1.3
R1 C1
C2 R2
TBM 1 X16 L- L+ +24V 0V 2
+24V
from TVD connector X1: 16-pin bus connection for blower supply X7 X8 U2 V2 W2 1L+ 2L+ X7
0VL
P
N
RB1 RB2
1L+
2L+
EPU+ EPU -
EB
2U1 2V1 2W1
1U1 1V1 1W1
IB
3. Electrical Connections
Fig. 3.1:
+ - +
X7/EB
X7 X7 X 12 BR1 X8
for TBM with DC 24V blower power
PE
ZKS
OFF K1 power supply
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LL+
X9
ON
X2 1 ZKS 2 ZKS 3 OFF 4 OFF 5 ON 6 ON X3
NC regulated braking
DC 300V conductor rails
max. 100 mA electronics supply
max. 2 A
1 NCB 2 3 +15VM 4 0VM 5 -15VM 6 shield 7 +24V 8 0VL
Power supply for AC drives and/or main spindle drives Electronics power source, signal exchange, 16-pin bus connection
acknowledge power off
acknowledge power on
X5 K1 1 2 K1 3 4
1 UD 2 BB 3, 4 +15V 5, 6, 7, 8 0VM 9, 10 -15V 11, 12 +24V 13, 14 0VL 15 UESS 16 shield X1
3.1. Interconnect diagram TVD 1.3 with NAM 1.3
Interconnect diagram -TVD 1.3 supply module with NAM 1.3
X4 Bb1 UD BVW TVW
TVD 1.3
Supply module for direct connection of the mains - with built-in bleeder - with regulated DC bus
NAM - power connection module BR1 - bridge for switching bleeder
ready
power voltage ok
bleeder prewarning
TVD12/NAM12Anschlpl
temp. prewarning
1 2 3 4 5 6 7 8
Options R1 - Bleeder can be mounted externally R2 - auxiliary bleeder module TBM C1 - additional electronics backup C2 - additional power buffer
15
Terminal diagram for Supply Module TVD 1.3 with Individual Components with 380 ... 480V mains connection for power and electronics - internal power switch
central grounding point for all drive modules
3xAC (380 - 480) V (50 - 60) Hz
PE L3 L2 L1
Q1
U1 V1 W1
L2 X15 P N 1 2 EB
C3 R2
L1
R1
C1
C2
TBM 1 X16 L- L+ +24V 0V 2
P
N
RB1 RB2
1L+
2L+
EPU+ EPU -
EB
2U1 2V1 2W1
1U1 1V1 1W1
IB
Fig. 3.2:
U2 V2 W2
+ - +
X7/EB
for TBM with DC 24V blower power source
X7 X7 X 12 BR1
X8
PE
3. Electrical Connections
ZKS
OFF K1 power supply
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LL+
X9
ON
X2 1 ZKS 2 ZKS 3 OFF 4 OFF 5 ON 6 ON X3
Power supply DC 300V conductor rails for AC drives and/or main spindle drives
NC controlled braking
max. 100 mA electronics supply
max. 2 A
1 NCB 2 3 +15VM 4 0VM 5 -15VM 6 shield 7 +24V 8 0VL
acknowledge power off
Electronics power supply, signal exchange, 16-pin bus connection
1 UD 2 BB 3, 4 +15V 5, 6, 7, 8 0VM 9, 10 -15V 11, 12 +24V 13, 14 0VL 15 UESS 16 shield X1
acknowledge power on
X5 K1 1 2 K1 3 4
X4
TVD 1.3
Power supply module for direct connection - with built-in bleeder - with regulated DC bus
ready
Bb1
power voltage ok
BR1 - bridge for switching the bleeder C3 - Buffer capacitance L1 - DC bus smoothing reactor L2 - commutating reactor
UD
3.2. TVD 1.3 interconnect diagram with individual, additional components
Interconnect diagram of TVD 1.3 supply module with individual additonal components
TVD/KompAnschlpl
bleeder prewarning
BVW
temp. prewarning
1 2 3 4 5 6 7 8
TVW
Options R1 - bleeder, ext. mounting R2 - auxiliary bleeder module TBM C1 - additional electronics backup C2 - additional power backup
16
3. Electrical Connections
3.3
Mains connection devices
Due to regulated current consumption, the TVD 1.3 supply module offers the lowest possible mains loading without reactive current. Current regulators in switched-mode power supply system cause mains system perturbations, the level of which depend on existing system conditions, i.e., short-circuit power or mains inductance, at the installation site. To eliminate mains perturbance, the TVD 1.3 supply module is operated from the mains supply via auxilary devices. The auxilary devices are available as either compact mains connection module NAM 1.3 or in the form of individual components.
TVD 1.3 with adapter module NAM 1.3
All the necessary components like the commutation choke, storage capacitor and DC bus smoothing choke, are in the mains connection module. This keeps installation work to a minimum. Available device combinations: Supply module TVD 1.3-08-3 TVD 1.3-15-3 Mains connection module NAM 1.3-08 NAM 1.3-15
PE
stranded, max. 2 m long 3) 1)
X12 X7/2L+ X7/1L+
NAM 1.3- . . 2L+
1L+ N P U1 V1 W1 L3 U2 V2 W2
TVD 1.3
2)
X8/N X8/P
2)
L1 L2
X7/1U1 X7/1V1 X7/1W1
L+
L-
16-pin bus cable (NAM blower power supply)
IN 175/155 2 1) min. lead cross section ..........................................4 mm with TVD 1.3-08 2 min. lead cross section: .........................................16 mm with TVD 1.3-15 2 2) min. lead cross section: ........................................2.5 mm with TVD 1.3-08 2 min. lead cross section: ...........................................6 mm with TVD 1.3-15 3) 10 mm 2
Lead cross sections per EN 60204 - installation type B1 - correcting factors not taken into account
TVD / NAM 1.2
Fig. 3.3:
Connecting a TVD 1.3 supply module to the mains via adapter module NAM 1.3
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3. Electrical Connections
TVD 1.3 with separate components
If modular installation is not possible due to space restrictions, then the supply module can also be connected to the mains via separate components. Required components: Supply module Commutation choke KD 26 KD 23 Buffer DC bus capacitor smoothing choke CZ 1.2-01-7 CZ 1.2-01-7 GLD 16 GLD 17
TVD 1.3-08-3 TVD 1.3-15-3
3)
GLD . .
PE 1 2 1)
X12 X7/2L+ X7/1L+
stranded, max. X8/N 2 m long N P PE 3) PE U2 V2 W2 stranded, max. 15 m long 2) 2) 3) X8/P
TVD 1.3
CZ 1.2-01-7 KD . .
L1 L2 L3 U1 V1 W1
3)
X12 L+
X7/1U1 X7/1V1 X7/1W1
LTVD/CZ1201
1) min. lead cross section: ..........................................4 mm 2 with TVD 1.3-08 min. lead cross section: .........................................16 mm 2 with TVD 1.3-15 2) min. lead cross section: ........................................2.5 mm 2 wth TVD 1.3-08 min. lead cross section: ...........................................6 mm 2 with TVD 1.3-15 3) 10 mm 2
Lead cross sections per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.4: Connecting a TVD 1.3 to the mains with individual components
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3. Electrical Connections
3.4. Mains connection to power circuits
Direct mains connection
The TVD 1.3 can be connected to 3 x AC 380...480V,50...60Hz three-phase AC mains supplies without the need for a transformer. See section 3.5 for fuse protection information. The power and electronic supply connections are strapped at the time of delivery. Generally, a separate connection for the power source of the electronics is not required.
Supply system requirements
Mains voltage: Mains frequency: Voltage interrupt:
3x AC 380 ... 480 V; ± 10 % 50 ... 60 Hz; ± 2 Hz Maximum 8 ms at base load and 380 V mains voltage without additional capacitance. There must be a timespan of > 1s between sequential interrupts. 20 % of the peak voltage for a maximum ofone period, with 3 x 380V; a corresponding percentage with higher voltages There must be a timespan of > 1s between sequential interrupts.
Voltage dips:
3 x AC 380 ... 480 V L1 L2 L3 PE
mains fuses PE-rail in cabinet U1 V1 W1 10 mm 2 10 mm 2 U2 1 X12 PE rail V2 W2
NC control unit
NC
10 mm 2 2
1U1 1V1 1W1 1L+ X7 terminal block 2U1 2V1
2L+
RB1 RB2
2W1 EPU+ EPU-
IB
EB
TVD 1.3
drive module
drive module
drive module
1 Main lead stranded; max. 10 m long; Lead cross sections per EN 60 204 (VDE 0113) 2 10 mm 2
TVDNetzanschluß
Lead cross sections per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.5: Connecting block X7 with mutual power and electronics supply
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3. Electrical Connections
If the modular drives are to be operated in residential or light industrial areas, then it may be necessary to mount an rf interference filter to maintain the limit values for the emission of interference (rf interference suppression). Each drive module must be connected to the PE-rail of the TVD with a separate ground lead. The leakage current via the protective conductor is greater than 3.5 mA AC. A permanent connection is thus required for the TVD.
Mains connection via a transformer
A transformer is needed if the mains voltage is less than 3 x 380V or greater than 3 x 480V. The mains inductance (leakage inductance) from transformers can vary significantly depending on power and type of construction. Mains connection components are therefore still needed even if transformers are used (see section 3.3.). Required transformer power:
S
TR
P × 3×UN = DC 25,5
STr PDC UN
= = =
transformer power in VA DC bus continuous power in W transformer output voltage in V
PE
stranded, max. 2 m lang 3) 1) X7/2L+ X7/1L+ 2) X8/N X8/P 2) X7/1U1 X7/1V1 X7/1W1
3)
NAM 1.3- . . 2L+
1L+ N P PE L1 L2 L3 U1 V1 W1 U2 V2 W2
X12
TVD 1.3
L+
L-
16-pin bus cable (NAM blower power source)
IN 175/155
TVD/NAM12Trafo
1) min. lead cross section ..........................................4 mm2 with TVD 1.3-08 min. lead cross section: .........................................16 mm 2 with TVD 1.3-15 2) min. lead cross section: ........................................2,5 mm2 with TVD 1.3-08 min. lead cross section ...........................................6 mm 2 with TVD 1.3-15 3) 10 mm 2
Lead cross section per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.6: Mains connection TVD 1.3 via a transformer
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3. Electrical Connections
3.5. Fuse protection for direct mains connection
Protection for the mains input to the power section of the TVD 1.3 for direct connection to the mains can be effected by power circuit-breaker or with fusible links, utilization category gL.
Maximum fusing
The fuse rating may not exceed 35 A. The following recommendations are valid when circuit breakers are used for direct connection to mains. If fuses are used, then fuses with utilization category gL can be used. Semiconductor fuses are not required. Select the fuses in terms of the mains current.
IN =
IN PDC UN
PDC UN · 25, 5
= mains current in A = DC bus continuous power in W = mains voltage in V
DC bus contin. power 7,5 kW 15 kW
1)
Connected Mains current load at at380V 380V 480V 10 kVA 20 kVA 15 A 30 A
Power circuit breaker Siemens type
Adjust. Cross sect. of current connected load lead 3) 15 A 30 A 2.5 mm 2 6 mm 2
13.4 A 3VU1300-.MN00 1) 26.8 A 3VU1600-.MP00 2)
Max. back-up fuse as per manufacturer: 80 A (gL) for supply voltages up to 500 V Max. back-up fuse as per manufacturer: 200 A (gL) for supply voltages up to 500 V 3) Lead cross section per EN60204 - installation type B1 - without taking correction factor into account
2)
Fig. 3.7: Recommended fusing for the mains supply conductors
3.6. Mains supply earthing requirements
Earthed three-phase mains Unearthed threephase mains
The TVD 1.3 can be connected to a grounded wye or delta system without potential isolation. For ungrounded three-phase mains supplies (IT mains) there exists the increased danger that overvoltages that are not permissible can occur between the phases and the housing. The TVD 1.3 can be protected against overvoltages · if it is connected via an isolation transformer (connect the neutral point of the transformer to the TVD with a PE rail) or · if the machine is protected by overvoltage detector. Connecting the TVD 1.3 via an isolation transformer offers the best protection against overvoltage and the greatest possible operating safety.
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3. Electrical Connections
Overvoltages
· The periodic overvoltage on the TVD 1.3 between a phase (1U1, 1V1, 1W1, 2U1, 2V1, 2W1) and the housing may not exceed 1000 V (peak value). · Non-periodic overvoltages, as per VDE 0160, between the phases and the phases and the housing are permissible for the TVD 1.3 as depicted in the diagram below.
UN+U UN 3 2.6 2.4 2.3 2.2 2 1.8
UN U U 2
T
1.6 1.4 1.2 1.15 1.1 1 0.1
DGUespg
0.2
0.4 0.6
1 1.3
2
4
6 10 T (ms)
20
Fig. 3.8: Permissible non-periodic overvoltages as per VDE 0160
The TVD 1.3 can be connected to 3 x 480 V. This means that the maximum permissible overvoltage equals:
480 V x 2 · 2.3 = 1560 V
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3. Electrical Connections
3.7. Commutation choke
In an effort to keep system perturbations as low as possible, the TVD should always be operated with a commutation choke. See sections 3.3 and 3.4; for power loss see dimension sheet in section 7.
3.8. DC bus circuit
Use the busbars contained in the connection accessories kit to connect the drive modules to the TVD's DC bus circuit. Use twisted single conductors for longer connections (maximum length equals 1 meter).
L1-DC bus reactor For lead cross sections see section 3.3 max. 1 m twisted
1L+ 1L-
max. 1 m twisted 10 mm2 C1-DC bus capacitor
LL+ TVD
LL+ Drive module
LL+ Drive module
Cross section depends on the peak DC bus power to be transmitted. At least 10 mm2 with the TVD 1.3-15 and 4 mm2 with the TVD 1.3-08 (max. 1 m twisted). PDC in kW A in mm2 7,5 14 15 4 10 16 LL+ Drive module
TVRZwkreis
Lead cross section per EN 60204 - installation type B1 - correcting factors not taken into account
Fig. 3.9: Wiring the DC bus circuit
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3. Electrical Connections
3.9. DC bus smoothing choke
The TVD 1.3 must always be operated with a DC bus smoothing choke in the "L+ line". Supply Module TVD 1.3-08-3 TVD 1.3-15-3 DC bus smoothing choke GLD 16 (or NAM 1.3-08) GLD 17 (or NAM 1.3-15)
(See Section 3.3, for power loss see dimension sheet in section 7).
3.10. Additional DC bus capacitance
In plants where feed axes have to be accelerated and braked in rapid succession, e.g., nipple machines, surface grinders, roll feeds, and so on, the bleeder power and thus the power dissipation can be reduced by fitting additional capacitors to the link circuit. In a few applications, it is necessary to initiate a return of the drives with a mains failure or an E-stop. The energy stored in the DC bus circuit can be used for the return. The energy stored in the DC bus circuit can be increased by additional capacitance.
Module TVD 1.3-08 TVD 1.3-15
Maximum additional capacitance Cmax = 70 mF Cmax = 120 mF
3.11. Bridge circuit capacitance
In an effort to keep system perturbations as low as possible, the TVD must always be operated with the NAM mains connection module or the bridge capacitance CZ 1.2-01-7. See section 3.3. for details.
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3. Electrical Connections
3.12. Additional bleeder module TBM
The TVD 1.3 can be operated with an additional bleeder module of the TBM 1.2 type. The TVD and TBM combination gives the following power data:
Supply module TVD 1.3-08 TVD 1.3-15
Additional bleeder module TBM 1.2-040-W1 TBM 1.2-040-W1
(1) PBD kW 1.5 2.0
(2) PBM KW 60 80
(3) Wmax kWs 130 160
(1) PBD = Continuous bleeder power (2) PBM = Peak bleeder power (3) Wmax = Maximum regenerated energy
Caution !
In a worst case scenario, the sum of the peak regenerated power of all simultaneously braking servo drives may not exceed the peak bleeder power of the supply module. If such is not taken into account during system design, then it is possible that the DC bus voltage during an E-stop could climb to high to the point where the drive equipment could be damaged.
TVD 1.3
LX7 EB L+ 24 V 0 V X3 7 8
2 10 mm , twisted max 1 m
TBM 1.2
LL+ EB X 15 24 V 0 V
twisted
X 16
APTBM
min. 1 mm2 24 V - route leads and EB leads separately
24 V-blower power current consumption 140 mA
Fig. 3.10: Connecting the additional bleeder module TBM 1.2
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3. Electrical Connections
3.13. External bleeder resistor
Terminal block: X7/RB1/RB2 To reduce the amount of heat dissipated in the control cabinet, an external bleeder resistor can be connected. This is installed outside the cabinet, e.g., on the rear panel of the cabinet. The bleeder resistor inside the TVD 1.3 is then inoperative. The voltage across the resistor can reach 450V DC.
Caution !
L1 L2 L3 DC bus smoothing reactor external bleeder
Q1
L2 X7 1U1 2U1 1V1 2V1 1W1 2W1
L1
R1
1L+ EPU+
2L+ EPU-
RB1 IB
RB2 EB
TVD/X7/3
Fig. 3.11: Terminal block X7 when operating the TVD 1.3 with an external bleeder
Resistors can be used as indicated in the specification below: Supply module: Resistance +/- 5% Continuous power (at 450C ambient temperature) Peak power (for 1.5 s) Maximum input power Protection category TVD 1.3-08 R = 10 ohms P = 1 kW TVD 1.3-15 R = 5 ohms P = 2 kW
Ppeak = 20 kW
Ppeak = 40 kW
Umax = 450V Depends on installation site!
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3. Electrical Connections
3.14. Supply to electronics and blower
Electronics
Supply voltage: 3 x AC 380...480V, 50...60 Hz Connected load: 300 VA (for maximum utilization of supply to electronics) The mains connections for the supply to power and electronics sections are strapped when the unit is delivered. No additional mains connection is thus required for the electronics section. If a separate supply for the electronics is needed, e.g., to store the TVD's diagnostic signals with mains disconnection, then the links between power and electronics section can be removed. Short-circuit protection need only be provided in the control cabinet for the connecting cable, e.g., miniature circutbreaker 3 VU 1300 -.MF00, 0,6 ... 1A, Siemens. Tap off electronics power source between commutation chock and TVD.
L1 L2 L3 Q1 Commutation choke KD .. or choke integrated in the NAM DC bus smoothing reactor F2 K2 X7 1U1 2U1 1V1 2V1 1W1 2W1 1L+ EPU+ 2L+ EPURB1 IB RB2 EB
TVD/X7/2
L1
Fig. 3.12: Terminal block X7 for separate supplies to power and electronics sections
Blower
The TVD 1.3 needs no additional mains connection for the blower. If drive modules are used that need a mains connection for cooling, this is done on the drive module next to the TVD 1.3. The mains connector for the blower supply must be ordered separately. The order number for the socket is 219 118.
supply module
1)
2)
2)
1) Drive module without blower connection TDM ...-...-300-W0 TDM ...-...-300-W1-000 TDA, DDS 2.1-W.. 2) Drive module with blower connection TDM ...-...-300-W1-115 TDM ...-...-300-W1-220 KDA, KDS, KDF, TFM
socket part no. 219 118
Fig. 3.13: Blower connections of the drive module
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3. Electrical Connections
3.15. Electronics supply buffer capacitance
Terminal block: X7/EPU+/EPUConductor cross section: 1 mm 2 Additional electronic storage capacitance may be necessary if the drives have to be stopped under position control in the event of a mains failure. A mains failure is signalled by the UD output. Following this, the NC controller must initiate controlled stopping of the drives within 10 ms, so that the drive electronics remain operational. If the elapsed time before the drives feed back power into the DC bus circuit exceeds 10 ms, then the user can boost the supply to the electronics by means of additional capacitors. An aluminium electrolytic capacitor is recommended due to the limited space.
Caution !
The voltage between EPU+ and EPU- can reach 450V DC. The capacitor must therefore be rated for this voltage. A maximum of 680 µF may be connected otherwise the TVD 1.3 could be damaged.
Back-up time
Storage capacitance (for maximum utilitzation of supply to electronics) 150 µF 270 µF 680 µF
20 ms 50 ms 100 ms
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3. Electrical Connections
3.16. Electronics supply and signal exchange connections
Terminal connection X1 has two functions: · voltage source to the drive electronics and · signal exchange between supply and drive module(s) The wire ribbon cable on the TVD 1.3 side has 16 pins. It is included in the electrical connecting accessories of the drive module.
(2) UD BB +15V +15V 0VM 0VM 0VM 0VM -15V -15V +24V +24V 0VL 0VL free
Conn. X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
bus connection UD BB +15V 0VM 0VM 0VM 0VM -15V -15V 0VL +24V
Conn. X1 (1) 1 2 3 4 5 6 7 8 9 10 11 12
(1) Connector X1 for 12-pin units (2) Connector X1 for 16-pin units
Bus16_12
Fig. 3.14: Transition from 16-pin bus connector to 12-pin bus connector
The wire ribbon connection is completed with a terminating plug for verifying the wiring. Without it, the high voltage section cannot be powered up. The TVD 1.3 can also be installed in the middle of the drive package. In this case, it suffices if one end of the wire ribbon cable is terminated. The terminating plug is part of the connecting accessories of the supply module.
11 10
3 2
3 2
12-pin terminal conn.
16-pin terminal conn.
Endstecker
Fig. 3.15: End plug for terminating the bus connection
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3. Electrical Connections
3.17. Residual current operated devices
A current circuit breaker (fuse or power circuit breaker) should preferrably be used to switch power off in the event of a short-circuit to the housing (ground). If TT systems absolutely necessitate a residual current operated device because of the size of the grounding resistance, then the following must be taken into account. In the case of switched-mode drive controllers, capacitive leakage currents always flow to ground. The degree of the leakage current depends on · the number of drive controllers used, · the length of the motor power cable and · the grounding conditions on site. The leakage current inevitably rises if steps are taken to improve the electromagnetic compatibility of the machine (mains filter or shielded conductors). Do not use residual current operated devices with leakage currents of less than 0.3A! False tripping can occur when switching inductances and capacitances on (rf interference supression filters, transformers, contactors and magnetic valves).
Warning!
Commercial pulse-sensitive residual current operated devices (unit designation ___ ) do not guarantee that electronic equipment with a three-phase bridge circuit (B6 circuit) is sufficiently protected. The protection of the electrical equipment connected to such devices together with equipment with B6 circuits can be impaired.
~
Either residual current operated devices which switch off also with DCleakage current should be used, or an isolation transformer should be placed in the mains supply line. If isolation transformers are used, then the overcurrent protective devices must be tuned to the impedance of the ground fault loop so that there is an immediate tripping in the event of a fault. Connect the star point of the secondary windings to the protective conductor of the machine.
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3. Electrical Connections
3.18. Control cabinet testing
No voltages other than those specified in the data sheet or in the interface notes should be connected. Caution Prior to a high voltage test of the control cabinet, disconnect all connections from the TVR.
3.19. Mounting the TVD 1.3 into the control cabinet
Installation requirements
The power supply module and its associated drive modules are designed to be installed in a control cabinet or a closed housing. They correspond to protection classification IP 10, as per DIN 40 050. The unit is protected from penetration of solid, foreign matter with a diameter greater than 50 mm. The unit is not protected against · the admission of water or · intentional access, for example, a touch of the hand. However, it does keep flat surfaces away.
Arranging the drives
Arrange the drives so that the one requiring the greatest power and current is as near as possible to the power supply. With 12 pin bus connections there can be no more than a total of 16, viz., eight to the left and eight to the right. With 16 pin bus connections there can be no more than a total of 20, viz., ten to the left and ten to the right. The maximum load of the +24 V and ± 15 V may not be exceeded.
Power unit Controllers with high power Controllers with low power
Maximum number of drives
Power connection
ATTENTION! NEVER REMOVE OR INSTALL THIS PLUGS WHILE VOLTAGE IS APPLIED. BLACK CABLE ON THE BOTTOM! Verbindung nie unter Spannung lösen bzw. stecken. Schwarze Leitung immer unten!
ATTENTION! NEVER REMOVE OR INSTALL THIS PLUGS WHILE VOLTAGE IS APPLIED. BLACK CABLE ON THE BOTTOM! Verbindung nie unter Spannung lösen bzw. stecken. Schwarze Leitung immer unten!
X5b
ATTENTION! NEVER REMOVE OR INSTALL THIS PLUGS WHILE VOLTAGE IS APPLIED. BLACK CABLE ON THE BOTTOM! Verbindung nie unter Spannung lösen bzw. stecken. Schwarze Leitung immer unten!
ATTENTION! NEVER REMOVE OR INSTALL THIS PLUGS WHILE VOLTAGE IS APPLIED. BLACK CABLE ON THE BOTTOM! Verbindung nie unter Spannung lösen bzw. stecken. Schwarze Leitung immer unten!
GATVR
Fig. 3.16: Preferred arrangement of the units inside the control cabinet
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3. Electrical Connections
Spacing dimensions in the control cabinet
110 ±0.5
155 ±0.5
110 ±0.5
200 ±0.5
TVR3 TVD1
TDA
TDM1 TDM2 DDS2
TDM1 TDM2 DDS2
TDA
TVR3 TVD1
155 ±0.5
110 ±0.5
110 ±0.5
137 ±0.5
TDM1 TDM2 DDS2
TVR3 TVD1
TDA
TVR3 TVD1
TDA
TDM3 TDM4 DDS3
110 ±0.5 92 ±0.5
92 ±0.5 74 ±0.5
TVD1 TVR3
TDM1 TDM2 DDS2
TDM3 TDM4 DDS3
TVR3 TVD1
TDM3 TDM4 DDS3
TDM3 TDM4 DDS3
110 ±0.5 110 ±0.5
155 ±0.5
TVR3 TVD1
TDM1 TDM2 DDS2
TDM1 TDM2 DDS2
NAM
TVD
TVR/T eilung
Fig. 3.17: Spacing dimensions in the control cabinet
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3. Electrical Connections
3.20. Heat loss inside the control cabinet
Basic losses in the TVD 1. 3 occur as a result of the generation of signal voltages and high voltage power.
Basic losses Power losses
Basic losses equal 75 W. 14 W per kW of DC bus continuous power in the TVD 1.3-08 17 W per kW of DC bus continuous power in the TVD 1.3-15 Bleeder losses are dependent upon the rotary drive energy, the potential energy of imbalanced masses and the machine cycle in progress.
Bleeder losses
PRD =
PRD tz Wpotg Wrotg
Wrotg + W potg tz
= regenerated continous power or bleeder continuous power in kW = cycle time in s = sum of the potential energies in kWs = sum of the rotary energies in kWs
Especially when running main drives (2AD; 1MB) check to make sure that the continuous bleeder power and the maximum regenerated energy do not exceed the values as listed in the data sheets.
3.21. Safety clearance inside the control cabinet
The bleeder resistor in the TVD 1.3 is hot after power is shut down. Flammable materials such as cables and cable channels must be kept at a distance of at least 300 mm above and 40 mm to the side and to the front of the bleeder resistor.
300
40
45
40
13
5
Bleeder resistor
40
TVR/Skizze3D
Fig. 3.18: Safety clearances inside the control cabinet
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3. Electrical Connections
3.22. Front view of the TVD 1.3
Bridge capacitor connection
P N
Terminal block for mains and DC bus reactor connections
PE-conductors central ground for each drive controller
X7 X7 L-
Diagnostics Display
DC bus for the power supply of the drives
X9
TM
L+
POWER SUPPLY
Connection of bus cable of signal voltage supply and drive monitoring
X1 RESET S2
Typ: Serien-Nr.:
RESET key
X2
X3
Plug-in terminals for: · control inputs · status messages · 24V, ± 15V outputs
X5
X4
FATVD12Ver
Fig. 3.19: Front view of supply module TVD 1.3
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4. TVD 1.3 Interconnections
4.
TVD 1.3 Interconnections
The interconnections for mains and the DC bus of the TVD recommended by INDRAMAT illustrate the operating principles of the unit. This section outlines several interconnect configurations. Just which configuration is selected depends on the functions and the sequence of actions required for the entire machine and is the responsibility of the machine builder.
4.1. Optional Control Possibilities
with DC bus dynamic braking without DC bus dynamic braking by the electronics of the drive by the NC control unit
braking the drives with faulty drive electronics
controlled braking with an E-stop or a power failure
Fig. 4.1: Optional control possibilities
Stopping the drives with faulty drive electronics with or without DC dynamic braking
The DC bus is short-circuited for braking the drives to a standstill as an additional safety precaution if there is ever a fault in the drive electronics.
With DC bus dynamic braking, synchronous motors are always braked to a standstill regardless of whether the drive electronics are functional or not. Without DC bus dynamic braking, synchronous motors can not be braked with faulty drive electronics.
Asynchronous motors cannot be braked if the DC bus is short-circuited!
Braking with an E-stop or mains failure at maximum torque by the drive electronics or in a position loop by the NC control unit
Drives are generally brought to a standstill by the drive control with an E-stop or mains failure. In the event of an E-stop or if the drive-internal monitors are tripped, then drive control switches to zero command value and there is a regulated braking of the drives at maximum torque. In some cases (e.g., electronically coupled tooth gear machines), it may be necessary for the CNC to bring the drives to a standstill in an E-stop situation or a mains failure. There is then a regulated braking of the drives by the NC control unit with an E-stop or if the drive-internal monitors are tripped.
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4. TVD 1.3 Interconnections
4.2. TVD interconnect with DC bus dynamic braking
With this variant, a high level of safety with a low level of expenditure is achieved. The monitoring devices built into the drive system are used most effectively, in this case:
Application
· if the TVD 1.3 is supplying feed drives only · and if asynchronous spindle drives and synchronous feed drives are operated from the same TVD.
Features
The NCB link on the TVD (X3/1 - X3/2) must not be jumpered. It is posible to brake synchronous motors (permanently excited) with the DC bus dynamic brakes whether the drive electronics are operational or not. DC bus dynamic braking occurs only if there is a fault in the drive. Therefore, if the E-stop button is pressed, asynchronous drives are also braked. If there is an E-stop or one of the monitor circuits of the TVD is tripped, for example, by a power failure, then the drives are braked at maximum torque under drive electronic regulation.
Source of danger:
Warning!
The DC bus dynamic brake protects machines in the event of drive failure. It alone does not function to protect personnel. In the event of faults in the drive and the supply module, uncontrolled drive movements are still possible even if the DC bus dynamic brake (X2/ 2 = 0) is activated.
Possible cauess:
Injury to personnel is possible depending upon the type of machine.
How to avoid:
Additional monitoring and safety devices can be installed on the machine side.
Mode of operation
When the E-stop button is pressed, the main contactor in the TVD 1.3 drops out immediately. The drive enable signal of the drives is dropped by means of an auxiliary contact of the main contactor. This leads to a drive-internal switching of the velocity command to zero in all drives in the drive packet. All drives are braked under control. A drive fault signal to the supply module (Bb1 contact), a fault signal from the NC (servo fault), or an overtravelling of the limit switch cause the main contactor to be switched off and the DC bus dynamic brake to be applied.
DC bus short-circuit OFF ON K1 (X5/3-4) DC bus voltage UD contact Drive enable signal from control unit t1 200 ms; t2 = 1.25 ... 1,4 s; t3 40 ms
SVTVDmZW
t3 t1 t1 t1
t2
t2
Fig. 4.2: Path of the signal when powering up the TVD
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4. TVD 1.3 Interconnections
Functionalities: · with DC bus dynamic braking · regulated braking by drive electronics with an E-stop
L1 L2 L3 Q10 bridged at delivery Q1
2U1 2V1 2W1 X2/1 X4/1 Bb1 X4/2 S2 ZKS CNC X2/2 1 S1 OFF S4 X2/4 X2/5 ON S5 X2/6 K1 X2/3
1U1 1V1 1W1 X3/1 NCB open X3/2
K1
Netzschütz Haltebremse Achsendlage Verriegelung Schutztüre
X9/L+ power supply drive module X9/LDC bus dynamic braking converter release
&
ready
On delay 1.4 s
TVD
1 RF
2
3 X5/1 K4 1)
4
+24V +/- 10% TVD
K1 X5/2
X5/3 K1 X5/4 X4/3 UD X4/4 Bb RF
TVD
Y1 U U
Y2
RF U
RF drive module 0V
K4 1)
Bb1 = supply module ready (drive system) Bb = drive module ready CNC = lag error message from the control unit (use only contact that does not open when E-stop switch opens) K1 = mains contactor in supply module K4 =holding brake control 1) Q1 = power supply fuse Q10 = main switch RF = drive enable signal of the control unit S1 = E-stop S2 = axis end stop S4 = power off S5 = power on Y1 = holding brake for feed axis with electrical release; note the release delay! Speed command value 100 ms after RF on Y2 = safety door locks
1) Only with holding brakes for feed drives that are not controlled by the drive module.
SS1TVR
Fig. 4.3: Controlling the TVD 1.3 with DC bus dynamic brake
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4. TVD 1.3 Interconnections
4.3. TVD interconnect with E-stop relay with DC bus dynamic braking
Excellent safety at low cost is achieved with this variant. The monitoring devices built into the drive system are used most effectively.
Application
· in larger plants where monitoring or numerous E-stop switches are required, · if the TVD is supplying feed drives only and · if synchronous and inductance drives are operted from the same TVD.
Features
The NCB link on the TVD (X3/1 - X3/2) may not be jumpered. DC bus dynamic braking always brakes synchronous motors to a controlled standstill regardless of whether the drive electronics are still functioning or not. DC bus is short-circuited only if there is a fault in the drives. If the E-stop relay is switched off, then inductance main drives can be braked as well. If there is an E-stop or one of the monitor circuits of the TVD is tripped, for example, with a power failure, the drives are braked at maximum torque under drive regulation.
Source of danger:
Warning!
The DC bus dynamic brake protects machines in the event of drive failure. It alone does not function to protect personnel. In the event of faults in the drive and the supply module, uncontrolled drive movements are still possible even if the DC bus dynamic brake (X2/ 2 = 0) is activated.
Possible cauess:
Injury to personnel is possible depending upon the type of machine.
How to avoid:
Additional monitoring and safety devices can be installed on the machine side.
Mode of operation
When the E-stop button is pressed, the main contactor in the TVD drops out immediately. The enable signal of the drives is dropped by means of an auxiliary contact of the main contactor. This leads to a drive-internal switching of the velocity command to zero in all drives in the drive packet. All drives are braked under control. A drive fault signal to the TVD 1.3 (Bb1 contact), a fault signal from the NC (servo fault), or an overtravel signal from the overtravel limit switch cause the main contactor to be switched off and the DC bus dynamic brake to be applied.
DC bus dyn. brake OFF K1 (X5/3-4) DC bus voltage UD contact Drive enable from control unit t2 t2
SVTVDmNA
t1
t3
t1 200 ms; t2 = 1.25 ... 1.4 s; t3 40 ms
Fig. 4.4: Signal path when powering up a TVD
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4. TVD 1.3 Interconnections
Functionalities: · immediate shutdown with E-stop relay · with DC bus dynamic brake · controlled braking by drive electronics in E-stop
L1 L2 L3 Q10 bridged at delivery Q1
2U1 2V1 2W1 X2/1 X4/1 Bb1 ZKS X4/2 S2
1U1 1V1 1W1 X3/1 NCB open X3/2
K1 CNC X2/2 1 X2/3 A10 OFF X2/4 X2/5 K1 X2/6 & DC bus dynamic brake converter release X9/LX9/L+ A10 = E-stop relay Bb1 = supply module ready (drive system) Bb = drive module ready CNC = lag error message from control unit (use a contact that does not open when the E-stop switch opens) K1 = mains contactor in supply module K4 = holding brake control 1) Q1 = power supply fuse Q10 = main switch RF = drive enable signal fo the control unit S1 = E-stop S2 = axis end stop Netzschütz S4 = Power off Haltebremse S5 = Power on S11 = safety door monitoring S12 = safety door monitoring Y1 = holding brake with electrical release for feed drives; note release delay! after nach RF on
ready
ON delay 1.4 s
TVD
+24V +/- 10% RF
1
2
3
control voltage
X5/3 K1 X5/4 X4/3 UD X4/4
TVD
K4
1) K1
S11
S4
S1 Y1 U S5 S12 safety doors closed
Bb
RF RF U
RF drive module A10
K4 1) 0V 1) Only with holding brakes of feed drives that are not controlled by the drive module.
E-stop relay
Example: Depending on the safety requirements at the machine, additional monitoring devices and locks may be necessary!
SS2TVR
Fig. 4.5: TVD 1.3 interconnect with DC bus dynamic braking
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4. TVD 1.3 Interconnections
4.4. TVD interconnect without DC bus dynamic braking
Application
If the uncontrolled coasting of the drives cannot damage the plant. Typical applications · if the TVD supplies inductance drives only and · if the end-stops of the feed axes are sufficiently damped.
Features
The NCB link on the TVD (X3/1 - X3/2) may not be jumpered. The DC bus voltage is not short-circuited. In the case of inductance drives, the DC bus dynamic brake has no additional braking effect when there is a fault in the drive electronics. If the DC bus is short-circuited, inductance drives can no longer be braked under drive control. With an E-stop or if one of the monitoring circuits of the TVD is tripped, e.g., as a result of a power failure, then the drives are braked at maximum torque under drive regulation.
Mode of operation
When the E-stop key is pressed, the main contactor in the TVD drops out immediately. The drive enable signal of the drives is dropped by means of an auxiliary contact of the main contactor. This leads to a drive-internal switching of the velocity command to zero in all drives in th drive packet. All drives are braked under control.
Source of danger:
Coasting of the drives with faulty drive electronics. Caution !
Possible consequences:
Machine damage.
How to avoid:
· End stops of feed axes must be sufficiently damped. · Use motors with mechanical brakes.
OFF ON K1 (X5/3-4) DC bus voltage UD contact Drive enable signal from control unit t2 t1
t3 t1
t2
t1 200 ms; t2 = 1.25 ... 1.4 s; t3 40 ms
SVTVDoZW
Fig.4.6: Signal path when powering up the TVD
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4. TVD 1.3 Interconnections
Functionalities: · without DC bus dynamic brake · controlled braking by the drive electronics in E-stop
L1 L2 L3 Q10 bridged at delivery Q1
2U1 2V1 2W1 X2/1
1U1 1V1 1W1 X3/1 NCB open X3/2 X4/1 K1 Bb1 X4/2 for diagnostics
X2/2 1 S1 OFF S4 X2/4 X2/5 ON S5 X2/6 & K1 DC bus dynamic brake converter release X9/LX2/3 X9/L+ power supply of drive module
ready
On delay 1.4 s
TVD
+24V +/- 10% RF
1
2
3 X5/1 K4 1)
4 Bb1 = supply module ready (drive system) Bb = drive module ready K1 = mains contactor in supply module K4 =holding brake control 1) Q1 = power supply fuse Q10 = main switch RF = drive enable signal of the control unit S1 = E-stop S4 = power off S5 = power on Y1 = holding brake for feed axis with electrical release; note the release delay! Speed command value 100 ms after RF on Y2 = safety door locks
K1 X5/2
TVD
X5/3 K1 X5/4 X4/3 UD X4/4 Bb RF K4 1) 0V
TVD
Y1 U U
Y2
RF
RF drive U module
SSTVR/3
1) Only with holding brakes for feed drives that are not controlled by the drive module.
Fig. 4.7: TVD interconnect without DC bus dynamic braking
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4. TVD 1.3 Interconnections
4.5. TVD interconnect for a position-controlled braking of the drives
Application
Drives which are coupled electronically as if by gearboxes under the control of an NC cannot normally accept an angular positioning error in the event of a power failure. The NCB link on the TVD (X3/1 - X3/2) must be jumpered. The mains contactor may not switch the drive enable signal off. The DC bus voltage is not short-circuited so that energy is available for a position-controlled stopping of the drives. During E-stop or if one of the monitor circuits of the TVD, e.g., during a power failure, is tripped, then the drives will be brought to a standstill under positioncontrol through the NC. The energy stored in or regenerated to the DC bus circuit must be greater than the energy required to excite the inductance machines or for return movements.
Features
Mode of operation
When the E-stop chain opens, the main contactor in the TVD drops out immediately. The NC must bring the drives to a stop under position control.
Source of danger:
A faulty power supply is not signalled to the drives when the NCB link is installed. Caution !
Possible consequences:
There is an uncontrolled braking of the drives with a power failure. The degree of damage depends upon the type of machine.
How to avoid:
If the UD contact opens, then the NC must bring the drives to a position-controlled standstill.
OFF ON K1 (X5/3-4) DC bus voltage UD contact Drive enable from the control unit t2 t1
t3 t1
t2 1)
1) Do not switch drive enable signal off until the drives are standing stil. t1 200 ms; t2 = 1.25 ... 1.4 s; t3 40 ms
SVTVDzLBA
Fig. 4.8: Signal path when switching on a TVD
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4. TVD 1.3 Interconnections
Functionalities: · without DC bus dynamic brake · controlled braking by the NC control unit in E-stop
L1 L2 L3 Q10 bridged at delivery Q1
2U1 2V1 2W1 X2/1
1U1 1V1 1W1 X3/1 NCB X3/2 X4/1 K1 Bb1 X4/2 for diagnostics
X2/2 1 S1 OFF S4 X2/4 X2/5 ON S5 X2/6 K1 DC bus dynamic brake converter release X2/3 X9/L+ power supply drive module X9/L-
Netzschütz Haltebremse
&
On delay 1.4 s ready 1 +24V +/- 10% 2 3 X5/1 K4 1) K1 X5/2 RF Y1 RF RF RF drive module U U U Y2 control unit TVD X4/4 4 X4/3 UD 5
TVD
Bb1 = supply module ready (drive system) Bb = drive module ready K1 = mains contactor in supply module K4 =holding brake control 1) Q1 = power supply fuse Q10 = main switch RF = drive enable signal of the control unit S1 = E-stop S2 = axis end stop S4 = power off S5 = power on UD = signal from KVR; power feed working Y1 = holding brake for feed axis with electrical release; note the release delay! Speed command value 100 ms after RF on Y2 = safety door locks
Bb
K4 1) 0V
1) Only with holding brakes for feed drives that are not controlled by the drive module.
SS4TVR
Fig. 4.9: Control of theTVD for a position-controlled braking of the drives
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5. Terminal Descriptions
5.
Terminal Descriptions
5.1. DC bus short-circuiting
Terminal X2/1 - X2/2
Input ZKS
Voltage: 24 V DC
Input Operating status
Current consumption: 270 mA
open Power off, DC bus short-circuit closed closed Power on, DC bus short-circuit open
The TVD main power contactor can be pulled in only if the ZKS input is closed. The DC bus is short-circuited if the ZKS input is open. This is an additional safety feature for the machine for braking drives to a standstill with a fault in drive electronics.
Switching rate
Maximum of 25 operating cycles per minute (w/o additional capacitance with drive standing)
Z=
CZU Jg PZK
2 · P ZK Czu · 425 2 + Jg · 2
· 60
Z
= DC bus capacitance in F = Total moment of inertia of mass in kgm2 = Power of the ZK resistor in W 220W with TVD 1.3-08 440W with TVD 1.3-15 = Angular speed in rad / s = Switching rate per minute but max. 25 / min.
Fig. 5.1:Switching rate with additional capacitance and rotating motor
5.2. Power off
Terminal X2/3 - X2/4
Input OFF
Voltage: 24 V DC
Input
Current consumption: 270 mA
open Power off closed Power on
Operating status
The main power contactor in the TVD can be pulled in only if the OFF input is closed. If the OFF input is open, for example during an E-stop, then the main power contactor in the TVD opens immediately.
5.3. Power on
Terminal X2/5 - X2/6
Input ON
Voltage: 24 V DC
Input Operating status
Current consumption: 270 mA
open Power off closed or open and closed when latched Power on
If ZKS and OFF inputs are closed and the internal drive-ready signal is present, closing the ON input will cause the TVD main contactor to pull in. Next, the main contactor is latched on. The ON signal is a pulse and must hold high for at least 200 ms. Switching rate: Service life: max. 25 operating cycles per minute 2.5 million operating cycles 44
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5. Terminal Descriptions
5.4. Stopping the drives in an E-stop or a power failure
NCB Link
Input Terminal X3/1 - X3/2
jumper controlled braking with an E-stop or a power failure open by the drive electronics closed by the NC control
If the NCB link is open or not jumpered, a power failure or a drive fault in the drive ystem is signalled to all the drives. The drives are braked at maximum torque. In addition, if there is a drive fault, the internal ready signal of the TVD is dropped which leads to shutdown of the power supply. In some applications, for example, electronically coupled gear cutting machines, the drives have to be braked postion-controlled through the CNC if there is an E-stop or a power failure. Do not use the NCB link for digital drives with SERCOS interface. Position-controlled braking is done without the NCB link by programming the fault reaction directly into the drive. The NCB link prevents the signalling of a faulty power supply to the drive. With the NCB jumpered, the following faults are not signalled to the drives: · Faulty power supply mains power failure / missing phase DC bus voltage less than 270 V · Drive faults open wire-ribbon connection or missing terminating connector low-voltage faults +24 VL/±15 VM overcurrent in the TVD high-voltage section bleeder overload overtemperature in the TVD heatsink Because these monitor circuits are not tripped, the drives can be braked to a standstill under position control if there is a power failure. The power regenerated during braking must be greater than the power consumption of the TVD. The power supply of the TVD is always switched off by the internal "ready" signal in the presence of a drive fault.
Source of danger:
With the NCB link closed or jumpered, the command to zero of the drives is suppressed. Caution !
Possible consequence