Harmonic Drive YukonDrive-1021 Operating Manual Download Page 36 | Manualshive

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36

1003370 05/2016 V01

3.14.3 Connection of an external braking resistor

Attention!

•

Be sure to follow the installation instructions for the external braking resistor.

• The temperature sensor (bimetal switch) on the braking resistor must be wired in such a way that the power stage

is deactivated and the connected drive controller is disconnected from the mains supply if the braking resistor
overheats.

• The minimum permissible connection resistance of the drive controller must not be infringed – for technical data

see section A.2 on page 52.

• The braking resistor must be connected by a shielded cable.

Illustration 36.1 Connection of braking resistor - Size BG2 to BG4

Danger from electrical tension!

Danger to life! Never wire or disconnect electrical connections while they are live. Always disconnect the power before
working on the device. Dangerously high voltages of ≥ 50 V may still be present 10 minutes after the power is cut
(capacitor charging). So check that the power has been cut!

Attention!

The external braking resistor must be monitored by the control. The temperature of the braking resistor is monitored
by a temperature watchdog (Klixon). In the event of overheating the drive controller must be disconnected from the
mains supply.

Order designation

Continuous
braking power

Resistance

1)

Peak braking
power P

2)

Protection

Picture

BR-090.01.540,UR

35 W

90 Ω

6250 W

IP54

Beispiel:
BR-090.01,540,UR

BR-090.02.540,UR

150 W

6250 W

IP54

BR-090.03.540,UR

300 W

6250 W

IP54

BR-090.10.650,UR

1000 W

6250 W

IP65

1)

Tolerance ±10 %

2)

The maximum possible braking power dependent on ON-time and cycle time

Table 36.2 Technical data - braking resistors

Hinweis:

Exact specifications, in particular with regard to surface temperature, maximum system voltage and high-voltage
strength, are set out download section of our website www.harmonicdrive.de. Please consult your projecting engineer
for more detailed information on the design of braking resistors.

Available braking resistors (excerpt)

RB

L+

Braking
resistor

X1

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Summary of Contents for YukonDrive-1021

Page 1: ...Operating Manual AC Servo Controller YukonDrive More information on our servo products can be found HERE Contact us today ...

Page 2: ...brake X13 28 3 9 Specification of Ethernet port 28 3 10 Option 1 28 3 11 Option 2 28 3 12 Motor and Encoder connection 29 3 12 1 Resolver connection X6 30 3 12 2 Connection for high resolution encoders X7 30 3 13 Motor connection 31 3 13 1 Connection of Harmonic Drive Servo motors and actuators 32 3 13 2 Switching in the motor cable 34 3 14 Braking resistor RB 34 3 14 1 Protection in case of braki...

Page 3: ...est care and attention and based on the latest information available to us We should nevertheless point out that this document cannot always be updated in line with ongoing technical developments in our products Information and specifications may be subject to change at any time For information on the latest version please visit www harmonicdrive de 5 Diagnostics 45 5 1 Device states 45 5 2 Error ...

Page 4: ...following areas Areas where drive systems are installed repaired and operated Areas where motors are installed repaired and operated Motors with permanent magnets pose a particular hazard Note If it is necessary to access such areas suitability to do so must be determined beforehand by a doctor Your qualification In order to prevent personal injury and damage to property only personnel with electr...

Page 5: ...provided by Harmonic Drive would thereby be rendered void Note Deployment of the drive controllers in non stationary equipment is classed as non standard ambient conditions and is permissible only by special agreement 1 3 Responsibility Electronic devices are fundamentally not fail safe The company setting up and or operating the machine or system is itself responsible for ensuring that the drive ...

Page 6: ... master of both Optimised for the lower power range the YukonDrive offers maximum capacity in four compact designs The integration of high speed field bus systems and the latest encoder interfaces such as the digital EnDat 2 2 or HIPERFACE DSL interface ensure that future security and flexibility continue to be at the forefront of development Comprehensive motion control functions provide a variet...

Page 7: ...scription 102 1 1 3 x 230 VAC 103 104 102 2 3 x 400 480 VAC 103 104 1051 Peak current Aeff Supply voltage Ordering Code 1 x 230 VAC 3 x 230 VAC 3 x 400 VAC A 9 9 C 11 8 17 7 E 16 24 B 6 D 10 5 F 19 5 G1 36 H1 48 Feld bus Ordering Code Description A EtherCAT B Sercos II C Sercos III D CANopen E PROFIBUS F PROFINET IRT Technology Ordering Code Description A TTL Encoder simulation master encoder B TT...

Page 8: ... Axx 1031 Cxx 1041 Exx 1022 Bxx 1032 Dxx 1042 Fxx 1052 Hxx 10xx xxB 10xx xxC FHA C Mini D200 CHA C H SIE MGS ROO SIE EC RCO EC FHA C H M512P M512P EC FHA C L M512P M512P_EC CHA A H M512P M128P RES M512P EC RES EC CHA A N M128S D2048 RES M128S EC D2048 EC RES EC LynxDrive MGH MKE CHM H CDO TorkDrive auf Anfrage Combinations ...

Page 9: ... cabinet must have IP54 protection or higher To attain the best result for EMC compatible installation you should use a chromated or galvanized backing plate If backing plates are varnished remove the coating from the contact area The devices themselves have an aluminium back panel Max pollution severity 2 Further information on environmental conditions can be found in the appendix 2 2 Wall mounti...

Page 10: ... 4 applies for devices of the same power When butt mounting devices with different drive power you should arrange the devices according to their power e g viewed from the left BG4 BG3 BG2 This minimizes the thermal influence among each other When butt mounting YukonDrive controllers together with other devices you must make sure that these devices do not affect one another thermally Dimensions Not...

Page 11: ...11 V01 05 2016 1003370 Illustration 11 1 Dimensions in mm BG2 BG3 BG4 Illustration 11 2 Mounting clearances in mm C C C1 A B C1 H1 H1 A B A1 T H D D BG2 BG3 BG2 BG3 BG4 BG4 E G F F ...

Page 12: ...ts stipulated in the standard Cable type Use shielded mains motor and signal cables with double copper braiding providing 60 to 70 coverage Cable laying Lay mains motor and signal cables isolated from each other Maintain a minimum clearance of 0 2 metres wher ever possible They should not run in parallel If crossovers are unavoidable they should wherever possible be configured perpendicular at a 9...

Page 13: ...nication PE Protective conductor connection T1 T2 Pushbuttons X1 Power connection X2 Connection of control supply UV X3 AC mains connection X4 Control terminals X5 Motor temperature monitoring see page 31 X6 Resolver connection X7 Connection for high resolution encoders X8 Option 2 Technology X9 Ethernet interface X13 Connection of motor brake Table 13 2 Key to YukonDrive layout Illustration 13 1 ...

Page 14: ...RSH Diagnosis STO 12 11 1 2 14 13 I O GND Relay Digital2 RB L L Braking resistor U V W 6 n n ISD03 ISD04 ISD05 18 19 20 ISD06 21 OSD01 8 Digital1 OSD00 7 Digital0 GND GND V OSD03 2 3 4 1 5 9 10 9 DC link OSD04 5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 DGND DGND 4 3 2 1 9 8 7 6 1 1 1 1 D1 D2 T1 T2 L1 K1 L2 L3 FN L1 L2 L3 3 phase system X3 X2 X9 X4 X8 X7 X6 X5 X13 X1 Front Option 1 24V DC supply for contr...

Page 15: ...r connection Resolver incl motor temperature monitor see p 29 X7 High resolution encoder interface Sin Cos encoder TTL encoder EnDat 2 1 encoder HIPERFACE encoder SSI encoder incl motor temperature monitor see p 30 Option 1 Communication Factory installed module for field buses e g SERCOS EtherCAT see p 27 Protective conductor connection Connection diagram see section 3 5 see p 16 X8 Option 2 Tech...

Page 16: ...sented on the following pages is intended to illustrate the key measures necessary to ensure EMC compatible setup Note The specimen setup merely presents a recommendation and does not automatically guarantee compliance with ap plicable EMC directives The installer operator of a machine and or item of plant must provide proof of compliance with the protection targets stipulated in the standard Over...

Page 17: ...ied Note Ready made up motor cables are available for Harmonic Drive servo motors Detail 2 Control supply 24 V DC At the control supply connection X2 Secure the second of the two supplied shield connection plates by the screw to the mount on the bottom of the unit Ensure the plate contacts across a wide area with the heat sink of the YukonDrive and with the backing plate Use a toothed ring Slot a ...

Page 18: ...the output of the mains filter to the connection X3 of the Yukon Drive and one of the PE connections on the heat sink of the Yu konDrive via a cable of at least the same cross section to the main ground of the distributor rail Detail 4 Control cables At the control terminals X4 of the YukonDrive note the following points Strip the shielding of the control cables back only as short as absolutely ne...

Page 19: ...E terminal as leakage current 3 5 mA Use protective conductors with the same cross section as the mains power cables though at least 10 mm Also comply with local and national regulations and conditions 2 Also connect the protective conductor terminals of all other components such as line reactors filters etc in star configuration and across a wide area on the PE rail main ground in the switch cabi...

Page 20: ... in detail This concept also delivers higher operational safety and reliability of the drive controller SELV Safety Extra Low Voltage PELV Protective Extra Low Voltage Illustration 20 1 Electrical isolation method YukonDrive PE GNDµP DGND Complex non linear impedance RC element Polyswitch GNDµP GNDµP GNDµP X4 15 ISD00 ISD01 ILIM X4 21 ISD06 ILIM X4 10 ENPO ILIM X4 22 ISDSH ILIM X4 7 OSD00 X4 3 ISA...

Page 21: ...protection The power supply unit used must have a safe and reliable isolation against the mains system according to EN 50178 or EN 61800 5 1 Table 21 2 YukonDrive control supply specification Attention Suitable measures must generally be applied to provide adequate line protection Danger from electrical tension When the mains voltage is switched on at terminal X3 and there is no control supply 24 ...

Page 22: ... x 230 V AC 3 x 400 V AC Illustration 22 1 BG2 and BG3 mains supply connection 3 x 230 V YukonDrive 10x1 or 3 x 400 V YukonDrive 10x2 depending on device design Illustration 22 2 BG2 and BG3 connection to mains supply 1 x 230 V BG2 and BG3 X2 X3 L1 L2 L3 L1 N Mains filter Line reactor 1 phase system K1 F1 BG2 and BG3 X2 X3 L1 L2 L3 L1 L2 L3 Mains filter Line reactor 3 phase system K1 F1 ...

Page 23: ...e line reactor if installed Reduces the voltage distortions THD in the system and pro longs the life of the drive controller 4 Install a K1 circuit breaker power circuit breaker contactor etc Do not switch on the power 5 Use mains fuses duty class gG to isolate all poles of the drive controller from the mains supply For compliance with equipment safety requirements laid down in EN 61800 5 1 option...

Page 24: ...tor neutral point of maximum 277 V IT network not permitted In case of a ground fault the electrical stress is approximately twice as high Clearances and creepages to EN 61800 5 1 are no longer maintained Connection of the drive controllers by way of a line reactor is mandatory where the drive controller is used in applications with disturbance variables corresponding to environment class 3 as per...

Page 25: ... 10 and a start signal with control via terminal Ground the cable shields over a wide area at both ends Conductor sizes fixed 0 2 to 1 5 mm2 Flexible conductor sizes Ferrule without plastic sleeve 0 2 to 1 5 mm2 Ferrule with plastic sleeve 0 2 to 0 75 mm2 5 Keep all contacts open inputs inactive 6 Check all connections again Continue with commissioning in section 4 Note the following points Always...

Page 26: ...pprox 3 kΩ Internal signal delay time 2 μs suitable as trigger input for quick saving of actual position Yes ENPO X4 10 Disable restart inhibit STO and enable power stage High level OSSD capable Reaction time approx ca 10 ms Switching level Low High 4 8 V 18 V UIN max 24 V 20 IIN bei 24 V typ 3 mA Yes Digital outputs OSD00 OSD01 OSD02 X4 7 X4 8 X4 9 No destruction in case of short circuit 24 V DC ...

Page 27: ... cos φ 1 AC1 30 V 1 0 A DC Switching delay approx 10 ms Cycle time 1 ms X4 23 X4 24 Auxiliary voltage 24 V X4 2 X4 14 Auxiliary voltage output UH to feed the digital control inputs UH UV U U typically approx 1 2 V no destruction in case of short circuit 24 V DGND but device may briefly shut down Imax 80 mA per pin with self resetting circuit breaker polyswitch yes Digital ground DGND X4 1 X4 13 Re...

Page 28: ...ns provide detailed information on commissioning 3 11 Option 2 Option 2 can be factory configured with various technology options Additional or special encoders can be evaluated with it for example You will find all available options in the Harmonic Drive catalogue The Operating Manuals for the respective options provide detailed information on commissioning Note For the connection of the motor fe...

Page 29: ...brake Table 29 1 Cable sets Actuator Cable length Cable set Material number Feedback connection LynxDrive xxC xxx Ax L MGH B CHA xxA xxx L S1024 B CHA xxA xxx L M1024 B CHM xxxxA Ax L SDH xx B CHM xxxxA Ax L MDH xx B FHA xxC xxx L S1024 B FHA xxC xxx L M1024 B 3 m 5 m 10 m 1004153 1004154 1004155 X7 LynxDrive xxC xxx Ax H ROO B 3 m 5 m 10 m 314271 314272 314273 X6 LynxDrive xxC xxx Ax H MxE B 3 m ...

Page 30: ... compensating for the voltage drop on the cable Only use of the sen sor cable ensures that the encoder is supplied with the correct voltage The sensor cable must always be connected Ill Function Sin Cos encoder with zero pulse e g Heidenhain ERN1381 ROD486 UV 5 V 5 Imax 150 mA Heidenhain Sin Cos encoder with EnDat2 1 interface e g 13 bit single turn encoder ECN1313 EnDat01 and 25 bit multi turn en...

Page 31: ... generation of a corresponding error message when evaluating the encoder signals Attention When connected to terminal X5 the motor temperature sensor must provide basic insulation against the motor coil and when connected to terminal X6 or X7 must provide increased insulation in accordance with EN 61800 5 1 3 13 Motor connection Step Action Comment 1 Specify the cable cross section dependent on th...

Page 32: ...ors Illustration 32 1 Connection of motor 1 2 1 Motor 3 Option 2 RB L L Braking resistor U V W 6 n n 5 9 10 9 DC link 5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 4 3 2 1 9 8 7 6 1 1 1 1 X8 X7 X6 X5 X13 X1 Front Brake Brake Resolver Encoder TOP GND GND V OSD03 2 3 4 1 24V DC supply for brake ...

Page 33: ...n type L 5 Brake Brake PTC 6 Brake Brake PTC 7 PTC N C Brake 8 PTC N C Brake Table 33 1 1 Confirguration of motor cable cores 5 6 7 and 8 Attention For security reasons the connection of PTC has to be made via X5 2 Brake control can also be made external e g via SPS DC linking of multiple drive controllers is not permitted ...

Page 34: ...istor is permanently switched on because it is alloyed through by overload 0 Ω there is a protective function to protect the device against overheating You activate this function by assigning any digital output DriveManager 5 subject area Configuration of the inputs outputs Digital outputs OSD00 to OSD02 to BC_FAIL 56 In the event of a fault the selected output then switches from 24 V to 0 V This ...

Page 35: ...ff 0 2 1 1 1 K I I P N eff DBr Br T PBr DBr dt P T P 0 1 T Br DBr PBr dt P P T 0 T P P T DBr PBr BrSum dt i T I T eff 0 2 1 1 1 K I I P N eff DBr Br T PBr DBr dt P T P 0 1 T Br DBr PBr dt P P T 0 T P P T DBr PBr BrSum Marginal conditions A single braking action must not exceed the maximum pulse energy of the braking resistor WIBr PPBr x TBr The continuous braking power calculated for the device mu...

Page 36: ...tes after the power is cut capacitor charging So check that the power has been cut Attention The external braking resistor must be monitored by the control The temperature of the braking resistor is monitored by a temperature watchdog Klixon In the event of overheating the drive controller must be disconnected from the mains supply Order designation Continuous braking power Resistance1 Peak brakin...

Page 37: ...p Action Comment 1 Installing and starting the PC software see DriveManager 5 Installation Manual 2 Switching on the control supply see section 4 2 1 3 Connecting the PC and drive controller see section 4 2 2 4 Parameter setting see section4 2 3 5 Controlling the drive with DriveManager 5 see section 4 2 4 Note Details concerning STO Safe Torque Off are not taken into account for initial commissio...

Page 38: ...struction In conjunction with servo actuators and motors of Harmonic Drive AG the YukonDrive controllers are already set up motor and feedback data control limits Only application specific settings have to be done 4 2 4 Controlling the drive with DriveManager 5 Switch on the AC mains supply Then enable the power stage and activate the control The drive should be tested with no coupled mechanism DA...

Page 39: ... power stage ready closed loop control disabled Device is ready to switch on Display readout after switching on the AC mains supply Table 39 1 Readout D1 D2 after switching on the AC mains supply Table 39 2 Power up sequence Note Inputs ISDSH and ENPO For step 1 from table 39 2 the two inputs ISDSH and ENPO of terminal X4 must be configured as a minimum Manual mode dialog The best way to execute s...

Page 40: ...lt in operator control unit permits diagnosis of the YukonDrive The operator control unit comprises the fol lowing elements all located on the front of the device 2 digit 7 segment display D1 D2 2 pushbuttons T1 T2 The following functions and displays are available Display of device state see section 5 1 Device states on page 42 The device state is displayed after switching on the control supply I...

Page 41: ...lied Otherwise the new value is saved after five seconds General The button press time until an action is executed is around 1 second If no user action occurs for 60 seconds the display switches back to the device status 4 4 2 Display The following table defines various readouts and items of status information shown on the display Table 41 1 Functions of buttons T1 and T2 Table 41 2 Meaning of dis...

Page 42: ... 39 5 Ir IP reset to factory setting Reset IP address to factory default 192 168 39 5 Su b0 00 FF Subnetmask udate Byte 0 Setting of byte 0 of the IP address in exadecimal format e g 00 for 255 255 255 0 b1 00 FF Subnetmask udate Byte 1 Setting of byte 1 of the IP address in hexadecimal format e g FF for 255 255 255 0 b2 00 FF Subnetmask udate Byte 2 Setting of byte 2 of the IP address in hexadeci...

Page 43: ...ronics are subsequently restarted Illustration 43 1 Example configuration of subnet mask T1 T2 Tx Tx Back Back Back Press button Tx X 1 2 repeatedly until desired menu appears on display Press button Tx X 1 2 once Press buttons T1 and T2 simultaneously Press any button Apply 5 sec 5 sec 5 sec T2 5 sec T1 T2 T1 T2 T1 T2 Back T1 T2 Back T1 T2 T1 T2 T1 T2 T1 T2 Value NOT saved Value saved T1 T2 T1 T1...

Page 44: ...value depends on the option Po 0 3 or Transmit power Setting of fibre optic power output only with SERCOS II option otherwise display Table 44 1 Field bus address menu Example configuration of field bus address In this example the field bus address is changed from 1 to 23 Note Changes on the Field Bus Address menu are only saved when the control electronics are subsequently re started Tx Tx Back B...

Page 45: ...nitoring After approx 1 s the display jumps to ER Note The errors can be reset in accordance with their programmed reaction ER or only via a 24 V DC reset X2 ER Errors marked with a dot can only be reset when the cause of the fault has been eliminated Not a safe indication as specified in EN 61800 5 2 1 S flashes when the STO Safe Torque Off function is active display goes out when function is ina...

Page 46: ...information prior to making contact 1 Type designation serial number and software version of the device see software rating plate 2 DriveManager version in use menu Help Information Version 3 Displayed error code on 7 segment display or DriveManager 4 Description of the error symptoms how it occurred and relevant circumstances 5 Save device settings to file in DriveManager 6 Name of company and co...

Page 47: ... time s 1021 4 45 3 0 6 0 10 9 0 0 08 8 40 3 0 6 0 9 01 0 081 16 40 2 0 4 0 9 01 0 081 1031 4 45 5 9 11 8 10 8 40 16 40 1041 4 45 8 0 16 0 10 8 40 8 0 16 0 16 40 5 4 10 8 1 Automatic power stage switching frequency change to 4 kHz Data applies to motor cable length 10 m Maximum permissible motor cable length 30 m All current ratings with recommended line reactor Device Switching frequency of power...

Page 48: ...2 4 45 2 0 2 0 2 0 4 0 10 6 0 0 08 8 40 2 0 2 0 1 7 4 0 6 01 16 40 0 7 0 7 1 4 2 81 1032 4 45 5 5 4 8 4 6 7 0 10 10 5 0 08 8 40 3 5 3 5 2 6 7 0 10 51 16 40 2 2 1 3 4 4 6 61 1042 4 45 8 5 7 4 7 0 13 0 10 19 5 0 08 8 40 6 5 6 5 6 5 13 0 19 51 16 40 4 0 2 4 1 9 8 0 12 01 1 Automatic power stage switching frequency change to 4 kHz 2 Data referred to 3 x 400 V mains voltage Data applies to motor cable ...

Page 49: ...8 8 A Asymmetry of mains voltage 3 max Frequency 50 60 Hz 10 Power loss at IN 1 75 W 150W 200 W Braking chopper power electronics Peak braking power with int braking resistor 400 W in 550 Ω PTC 4 1 5 kW in 100 Ω 5 1 7 kW in 90Ω5 Minimum ohmic resistance of an externally installed braking resistor 72 Ω 72 Ω 3 72 Ω 3 1 Values referred to mains voltage 230 V AC and switching frequency 8 kHz 2 For rat...

Page 50: ...2 Ω 3 1 Values referred to mains voltage 400 V AC and switching frequency 8 kHz 2 For rated current refer to table 33 3 Connection of ext braking resistor not permitted to devices with int braking resistor 4 Braking resistor always integrated Connection of an external resistor is permissible 5 Option Table 50 1 technical data YukonDrive 1022 1032 1042 Note For more information on the braking chopp...

Page 51: ...the table must not occur simultaneously Mechanical conditions YukonDrive Vibration limit in transit as per EN 61800 2 IEC 60721 3 2 class 2M1 1 Frequency Hz Amplitude mm Acceleration m s 2 f 9 3 5 Not applicable 9 f 200 Not applicable 10 200 f 500 Not applicable 15 Shock limit in transit as per EN 61800 2 IEC 60721 2 2 class 2M1 Drop height of packed device max 0 25 m Vibration limits of the syste...

Page 52: ...e motor must be connected during operation of these drives 9 Control outputs X4 23 X4 24 and OSD00 OSD01 OSD02 Use secondary isolating source V rated 25 Vac 30 Vdc or 24 Vdc as appropriate for rating of the given output Fuse in accordance with UL248 rated 100 V must be connected between the source and the output Table 52 1 Tightening torques and mains fusing BG2 to BG4 Size Device Tightening torqu...

Page 53: ...Germany Harmonic Drive AG Hoenbergstraße 14 65555 Limburg Lahn info harmonicdrive de www harmonicdrive de Subject to technical changes T 49 6431 5008 0 F 49 6431 5008 119 05 2016 1003370 V01 ...

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