Danaher Motion SuperDrive ACS24 Series, User Manual

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Introduction

26.04.2005

Version History

Revision

Edition date

Reason for revision

Trademark information here

Product was developed under one or more US patents

Printed in Sweden. All rights reserved.

Danaher Motion is a registered trademark of Danaher Corporation. Danaher Motion makes every attempt to
ensure accuracy and ratability of the specification in this publication. Specifications are subject to change
without notice. Danaher motion provides this information “AS IS” and declines all warranties, express or
implied, including, but not limited to, implied warranties of mechanic ability and fitness for a particular purpose.
It is the responsibility of the product user to determine the suitability of this product for a specific application.

©2005 Danaher Motion

Item No.

89Y05120A

User's Guide 1.0

2

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Summary of Contents for SuperDrive ACS24 Series

Page 1: ...AC SuperDrive The AC motor controller Generation 5 User s Guide 1 0 Item No 89Y05120A 26 04 2005 Solution by...

Page 2: ...o ensure accuracy and ratability of the specification in this publication Specifications are subject to change without notice Danaher motion provides this information AS IS and declines all warranties...

Page 3: ...terface 14 2 1 3 Speed control 14 2 1 4 Flux control 15 2 1 5 Slip and stator frequency estimation 15 2 1 6 Current control and SPWM sym 15 2 1 7 Power conversion section 15 2 1 8 Speed sensor interfa...

Page 4: ...9 3 13 4 ACS ID1 and ID2 inputs 30 3 13 5 Temperature sensor 31 3 14 Can bus communications 32 4 Start up commissioning 35 4 1 General 35 4 2 Checks prior to initial power up 35 4 3 Verifying AC Super...

Page 5: ...65 6 14 How the AC SuperDrive handles parameters 66 6 14 1 General 66 6 14 2 Parameter verification at startup 66 6 14 3 Saving parameters 67 6 14 4 Duplicating a configuration 67 6 14 5 Reverting to...

Page 6: ...93 8 2 Current and power output ratings 93 8 3 DC supply voltage requirement 94 8 4 Isolation 94 8 5 CAN communications interface 94 8 6 Safety system 94 8 7 Operating environment 94 8 8 EMC 95 8 9 S...

Page 7: ...ly powered vehicle utilizing the CAN Bus and CANopen protocol for communications and control 1 1 4 WARNING CAUTION AND INFORMATION NOTICES Special attention must be paid to the information presented i...

Page 8: ...nstallation that the AC SuperDrive model is correct for the vehicle s battery supply voltage The DC Supply nominal voltage is stated on a label on the cover of each AC SuperDrive 1 2 2 OEM S RESPONSIB...

Page 9: ...CONFIGURATIONS The AC SuperDrive is manufactured in the following two configurations Convection cooled models see Figure 1 employing a heat sink with cooling fins that transfer heat to the surrounding...

Page 10: ...umber within a production lot Manufacture date Year month and day of manufacture Table 1 AC SuperDrive Product expressions 1 4 STANDARD FEATURES AND CAPABILITIES The AC SuperDrive incorporates a numbe...

Page 11: ...software configurability eliminates all operator adjustments and assures absolutely reproducible performance of identically configured AC SuperDrives All heat generating components mounted on a massi...

Page 12: ......

Page 13: ...ersion section A PTC Positive Temperature Coefficient resistance limits inrush current to a bank of filter capacitors when power is first turned on via the disconnect switch The key start contactor co...

Page 14: ...ls on each functional block Figure 4 AC SuperDrive Block Diagram 2 1 2 CAN INTERFACE The CAN Interface manages communications between the AC SuperDrive and the CAN Bus The CAN controller provides the...

Page 15: ...ture and frequency related changes in motor winding impedance as well as variations in the DC supply voltage thereby providing precise control of motor flux and torque over a wide range of operating c...

Page 16: ...as a generator supplying power to the battery The change from motor to generator is smooth and instant when rotor speed exceeds synchronous speed The AC SuperDrive supplies a magnetizing current at th...

Page 17: ...t continued operation of the AC SuperDrive Less serious problems that permit continued AC SuperDrive operation often at reduced capacity produce warnings For some items monitored the AC SuperDrive pro...

Page 18: ...oadcast periodically by the master to all slaves to synchronize network devices and processes with the master NETWORK MANAGEMENT NMT Transmitted by the master to control network boot up initialization...

Page 19: ...tion from liquids and particles dripping splashing or spraying onto the unit however the AC SuperDrive is not environmentally sealed It should not be located in a place where it is subjected to liquid...

Page 20: ...94 3 3 CLEARANCES FOR ACCESS AND AIR CIRCULATION For all AC SuperDrive models 50 mm clearances in front of and behind the AC SuperDrive are required for airflow 50 mm clearance above the AC SuperDrive...

Page 21: ...EQUIPMENT REQUIRED The following tools and hardware are recommended for mounting an AC SuperDrive Four 4 bolt M6S M6 x yy 8 8 fzb yy mm see Figure 8 internal hex head bolts pos 1 Four 4 washer BRB 6...

Page 22: ...8 8 fzb mm bolts or equivalent 5 16 UNC bolts pos 1 Four 4 washer BRB 8 8 HB 200 fzb 16 x 8 4 x 1 5 Pos 2 13 mm Box wrench Thermal grease type of grease is typically Electrolube HTC or Dow Corning 34...

Page 23: ...motor This configuration utilizes an on board fuse and main contactor under direct control of the truck controller Table 2 provides a description of the six terminal post connections on the AC SuperDr...

Page 24: ...or and battery currents otherwise overheating will occur Crimp ring lugs onto the motor wires then secure the lugs to terminal posts using bolts M8 x 25 pos no 1 and pos 7 in Figure 14 and lock washer...

Page 25: ...G AND SELECTION i An on board fuse is not supplied with the AC SuperDrive This component must be ordered separately An on board fuse installed between the B and terminals on each AC SuperDrive protect...

Page 26: ...1 KEY START FUSE F2 Fuse F2 should be sized according to the number of AC SuperDrives in the circuit Refer to Table 3 the current consumption of the KEY START input Refer to Figure 11 for A CAN based...

Page 27: ...th the PTC resistance prevents the energy stored in the SuperDrive s internal capacitors from powering the truck controller when the start key is switched off See Figure 11 The configuration shown in...

Page 28: ...AL Connector K1 Plug AMPseal 23P 770680 1 Contact 770854 1 provides the electrical interface for all control and I O connections to an AC SuperDrive Figure 16 illustrates wiring of the mating interfac...

Page 29: ...Output CAN_H One for IN and one for OUT to the next device 7 8 Output CAN GND One for IN and one for OUT to the next drive From November 2004 9 Output CAN 120R CAN 120 ohm termination resistor To use...

Page 30: ...ity of electrical noise coupling into encoder lines avoid routing encoder cables next to conductors carrying high currents or high current pulses Noise immunity may also be improved by using twisted c...

Page 31: ...manufacturer provides a means for the AC SuperDrive to monitor motor temperature The connector on the AC SuperDrive side is an AMP Superseal 282080 1 Table 6 lists the color coding and signal names f...

Page 32: ...in a Daisy chain arrangement as shown in Figure 18 Twisted pair wiring is required for the CAN_H and CAN_L signals Both physical ends of the CAN Bus must be terminated with 120 ohm resistances A servi...

Page 33: ...d these should all be grouped together at one end on the CAN bus and the GND connection to these units should be taken from one common point star connection if possible see Figure 19 Under no circumst...

Page 34: ......

Page 35: ...ge to equipment prior to applying power for the first time Make sure that the motor and battery cables are connected correctly Incorrect motor or battery connections may destroy the AC SuperDrive 4 2...

Page 36: ...the AC SuperDrive at page 41 The general procedure for obtaining the correct configuration in the final product requires normally that the established parameter values are used as default values in th...

Page 37: ...pump Make sure that the motor and battery cables are connected correctly Incorrect motor or battery connections may destroy the AC SuperDrive 1 With the main contactor open not enabled apply battery...

Page 38: ......

Page 39: ...e due to voltage transients the AC SuperDrive s internal filter capacitors must be discharged as described in Drive Removal on page 40 Do not short the to B terminal 5 1 PERIODIC PREVENTIVE MAINTENANC...

Page 40: ...latch on connector housing and remove mating connector from K1 5 Remove on board fuse if applicable for use in replacement drive 6 On units with fins loosen four bolts securing drive to its mounting...

Page 41: ...tics of the controlled motor and define the operating envelope of the motor drive combination A step in each new design is to establish the parameter values for the motor drive in its application This...

Page 42: ...egularly to the ACS with a constant frequency the speed of the motor and the status of the ACS can be controlled In its basic configuration the Command Word and the Command Speed is sent to the ACS vi...

Page 43: ...e CANopen state of the ACS becomes OPERATIONAL via the NMT message Start Remote Node PDO communication must start within one second Once the first PDORx is received subsequent PDORx s must be received...

Page 44: ...error condition has occurred the NMT message Reset Node has to be sent After that the procedure from point 1 and forward has to be repeated A restart of the ACS can also be done by turning off and the...

Page 45: ...ilteredValue FilteredValue FilterGain 256 RawValue FilteredValue Filter gain 256 means no filtering 2050h 5 Acceleration Read only variable rpm 20ms Table 8 Speed Measurement Parameters 6 3 1 TUNING O...

Page 46: ...ommand Speed is the input to the speed controller and the limited Torque Current is the output It is also possible to disable the speed controller and use torque control instead The input then is the...

Page 47: ...or 5 During constant speed and acceleration 2092h 1 2 Speed PI Controller I gain Medium Set 0 1 Speed Control Mode 1 Not used Speed Control Mode 4 or 5 During rollback 2093h 1 2 Speed PI Controller I...

Page 48: ...erating in an steep uphill slope Bit 2 Enter Rollback Mode At Zero Speed If set to true the truck stops before it eventaully starts to roll Only used if Rollback Speed is NOT zero 2095h 9 Speed Change...

Page 49: ...faster than the Internal Speed Reference In order to allow the truck to decelerate faster than the ramp the ramp is adjusted to the actual speed when decelerating in a steep slope as can be seen in F...

Page 50: ...n uphill slope the truck will reach zero speed and then start rolling backwards down the slope with a speed larger than zero but less than or equal to the Rollback Speed value The bit 9 Rollback disab...

Page 51: ...ctionality it is also possible to include the parameters 2000h 7 and 2000 8 shown in Table 15 in the PDO The receive PDO then looks as in Table 14 1 2 3 4 5 6 7 8 Command Word Command Speed Accelerati...

Page 52: ...according to bits 11 12 in the Command Word 1 Parameter Set 0 2 Parameter Set 1 3 Parameter Set 2 Forward Deceleration 2101h and Reverse Deceleration 2103h 4 Parameter Set 3 Used according to bits 11...

Page 53: ...A Torque Current and a Speed give each point Figure 25 Best Performance CurveOption 6 5 2 SPEED PI CONTROLLER The Speed PI controller is a normal PI controller with two inputs the Internal Speed Refer...

Page 54: ...2095h 6 Reverse Max Acceleration Torque Current Unit ARMS 2095h 7 Forward Max Brake Torque Current Unit ARMS 2095h 8 Forward Max Brake Torque Current Unit ARMS Table 17 Torque Current Limitation Para...

Page 55: ...mp modes Table 9 explains during which operation conditions the Small Medium and Large I gain respectively are used The Torque Current Limitation parameters Table 17 also have to be set to appropriate...

Page 56: ...etization Current i e the rotor flux is kept constant up to the Base Speed Above the Base Speed the Magnetization Current is reduced Since the Slip Gain is reciprocally proportional to the Magnetizati...

Page 57: ...0 C change in rotor temperature The motor manufacturer or Danaher Motion usually supplies this parameter 2070h 2 Nominal Magnetization Current Nominal magnetization current for the motor connected to...

Page 58: ...tion Angle is computed as the sum of the Actual Speed electrical and the Slip Speed Figure 27 Slip and Stator Frequency Estimation 6 9 1 PARAMETERS AND VARIABLES The Number of Motor Poles is the only...

Page 59: ...oid damage of the drive if a too high magnetization current is set via the CANopen object dictionary From the measured current in phase U and V the current in phase W is computed based on that the sum...

Page 60: ...ices of the variables read only within the Current Control that are accessible via CANopen Index Sub Index Name Description 2070h 1 Iq Measured instantaneous torque current in deciA Iq is sampled ever...

Page 61: ...r s c 3 256 f 1 4 I 3 U R R f 2 Igain s base dc r s c where fc Current control bandwidth 200 Hz fs Sampling execution frequency of the current control 4000 Hz Ls Lr Stator and rotor leakage inductanc...

Page 62: ...n gives the switching instants The frequency of the triangular carrier wave determines the PWM switching frequency Nominally the switching frequency is equal to 8 kHz but with the parameter SPWM Switc...

Page 63: ...er wave during a number of PWM switching periods i e the MOSFETs are mainly switching during the zero crossings of the reference voltages The use of over modulation will increase the harmonic content...

Page 64: ...pen drain output 1 on and bit 7 Open drain ouput 2 on in the Command Word The Open Drain Outputs are voltage controlled in both modes and the voltage is defined as the voltage between B and Pin 2 in K...

Page 65: ...l Time During this time in ms the Pull Voltage is generated 2060h 3 Open Drain Output 1 Pull Voltage Initial voltage in centiV between B and output Pin 2 in K1 when output is enabled 2060h 4 Open Drai...

Page 66: ...copies parameter values from EEPROM memory into a segment of RAM memory reserved for parameters The operating software then performs several checks to verify the validity of the parameter set in RAM...

Page 67: ...e value 65766173h to CANopen object Store All Parameters 1010h 1 Saving parameters shall be performed with the vehicle at standstill Figure 34 Procedure for saving Parameters to Flash Memory 6 14 4 DU...

Page 68: ...rs stored in flash memory along with the AC SuperDrive software using a procedure similar to saving parameters i e by writing the value 64616F6Ch to CANopen object Restore All Default Parameters 1011h...

Page 69: ...r the vehicle We can provide this troubleshooting information on electronic media in various formats for OEMs who wish to import it into their documentation 7 3 ERRORS The AC SuperDrive continuously m...

Page 70: ...shing light 1Hz A warning is active Figure 36 The LED status indicator placement 7 6 USING THE TROUBLESHOOTING GUIDE CAUTION Do not manually operate main contactor or override system control of main c...

Page 71: ...chart Symptom code See page Main contactor doesn t close within 10 seconds after switching on key switch 73 Fuse to Power Stage is blown 74 AC SuperDrive Status indicator is blinking or off 75 Motor...

Page 72: ...emperature sensor 1 not connected short circuit 87 0x0200 Heat sink temperature 2 low 20 C 88 0x0400 Heat sink temperature 2 high 85 C 80 0x0800 Heat sink temperature sensor 2 not connected short circ...

Page 73: ...26 04 2005 Troubleshooting guide 7 7 1 MAIN CONTACTOR DOESN T CLOSE Symptom User s Guide 1 0 Item No 89Y05120A 73...

Page 74: ...l operation Replace fuse and restart drive Replace drive start end Increased friction heavier load high speed and rapid start stop all increase average current drawn by the drive Vehicle may have been...

Page 75: ...26 04 2005 Troubleshooting guide 7 7 3 AC SUPERDRIVE STATUS INDICATOR IS FLASHING OR OFF Symptom User s Guide 1 0 Item No 89Y05120A 75...

Page 76: ...Troubleshooting guide 26 04 2005 7 7 4 MOTOR RUNS ONLY AT LOW SPEED Symptom Item No 89Y05120A User s Guide 1 0 76...

Page 77: ...26 04 2005 Troubleshooting guide 7 7 5 SPEED FEEDBACK SENSOR NOT CONNECTED Warning Code 0x4000 User s Guide 1 0 Item No 89Y05120A 77...

Page 78: ...26 04 2005 7 7 6 MOTOR TEMPERATURE ERROR Error Code 0x4210 POWER LIMITED DUE TO OVER TEMPERATURE Warning Code 0x2000 POWER REDUCTION DUE TO MOTOR OVER TEMPERATURE Warning Code 0x0010 Item No 89Y05120...

Page 79: ...26 04 2005 Troubleshooting guide User s Guide 1 0 Item No 89Y05120A 79...

Page 80: ...TSINK OVER TEMPERATURE ERROR Error Code 0x4310 POWER LIMITED DUE TO HEATSINK OVER TEMPERATURE 1 2 85 O C Warning Code 0x0080 1 0x0400 2 POWER REDUCTION DUE TO TEMPERATURE Warning Code 0x2000 See next...

Page 81: ...26 04 2005 Troubleshooting guide User s Guide 1 0 Item No 89Y05120A 81...

Page 82: ...Troubleshooting guide 26 04 2005 Item No 89Y05120A User s Guide 1 0 82...

Page 83: ...26 04 2005 Troubleshooting guide 7 7 8 AC CURRENT OVER CURRENT Error Code 0x2310 AC CURRENT SHORT CIRCUIT Error Code 0x2340 User s Guide 1 0 Item No 89Y05120A 83...

Page 84: ...Troubleshooting guide 26 04 2005 7 7 9 DC BUS HIGH HARDWARE DETECTED Error Code 0x3212 DC BUS HIGH SOFTWARE DETECTED Error Code 0x3211 Item No 89Y05120A User s Guide 1 0 84...

Page 85: ...26 04 2005 Troubleshooting guide 7 7 10 DC BUS LOW Error Code 0x3221 NO CHARGING DC BUS Error Code 0x3120 User s Guide 1 0 Item No 89Y05120A 85...

Page 86: ...Troubleshooting guide 26 04 2005 7 7 11 CAN TIME OUT Error Code 0x8100 Item No 89Y05120A User s Guide 1 0 86...

Page 87: ...26 04 2005 Troubleshooting guide 7 7 12 HEATSINK TEMPERATURE SENSOR 1 2 OPEN CIRCUIT SHORT CIRCUIT Warning Code 0x0100 1 0x0800 2 User s Guide 1 0 Item No 89Y05120A 87...

Page 88: ...leshooting guide 26 04 2005 7 7 13 MOTOR TEMP 50 C Warning Code 0x0008 HEATSINK MOTOR TEMP 1 2 20 C Warning Code 0x0040 1 0x0200 2 POWER REDUCTION Warning Code 0x2000 Item No 89Y05120A User s Guide 1...

Page 89: ...26 04 2005 Troubleshooting guide 7 7 14 MOTOR TEMPERATURE SENSOR OPEN CIRCUIT SHORT CIRCUIT Warning Code 0x0020 User s Guide 1 0 Item No 89Y05120A 89...

Page 90: ...shooting guide 26 04 2005 7 7 15 15 V SUPPLY LOW VOLTAGE Error Code 0x5111 15 V SUPPLY LOW OR HIGH VOLTAGE Error Code 0x5113 CURRENT CALIBRATION ERROR Error Code 0x5210 Item No 89Y05120A User s Guide...

Page 91: ...26 04 2005 Troubleshooting guide 7 7 16 REVERTED TO DEFAULT PARAMETERS Warning Code 0x1000 User s Guide 1 0 Item No 89Y05120A 91...

Page 92: ......

Page 93: ...24 36 450 200 18 2 8 1 3615 675 xxx 24 36 675 300 27 3 12 1 3620 900 xxx 36 900 400 36 4 16 2 4810 350 xxx 48 350 150 19 3 8 3 4815 525 xxx 48 525 225 28 9 12 4 4820 700 xxx 48 700 300 38 6 16 5 4825...

Page 94: ...okay LED indicator is steady green When error condition s exist LED is flashing fast 10Hz When warning condition s exist LED is flashing slow 1Hz OVERCURRENT Power Conversion section disabled on over...

Page 95: ...iated immunity emission ESD ELECTRICAL FAST TRANSIENT BURST EN61000 4 4 level 2 8 9 SAFETY AND TESTING STANDARDS COMPLIANCE SAFETY INDUSTRIAL TRUCKS EN 1175 1 BASIC ENVIRONMENTAL TESTING PROCEDURES IE...

Page 96: ...ion Y1 Y2 Y3 Y4 ACSxx 10 165 120 9 ACSxx 15 233 6 150 41 8 ACSxx 20 302 2 215 107 5 43 6 ACSxx 25 370 8 250 125 60 4 Finned version Y1 X1 X2 X3 ACSxx 10 165 25 5 114 ACSxx 15 233 6 25 5 182 6 ACSxx 20...

Page 97: ...26 04 2005 AC SuperDrive specifications Figure 37 Dimensions for AC SuperDrive with finned heatsink mm User s Guide 1 0 Item No 89Y05120A 97...

Page 98: ...AC SuperDrive specifications 26 04 2005 Figure 38 Dimensions and surface roughness for flat heatsink mm Item No 89Y05120A User s Guide 1 0 98...

Page 99: ...rompt attention to customers needs Call the nearest office listed for ordering and application information or for the address of the closest authorized distributor SWEDEN Danaher Motion Stockholm AB S...

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