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GD1 – Installation Guide

55

Part 3 -

Appendix

When using high inertia or low resistive torque machines, the user should initiate a controlled stop. To achieve a
controlled stop in accordance with stop category 1 of the EN60204-1 standard, the control system of the machine
must generate the following sequences:

-

deceleration of the load by means of the drive,

-

when the load is at standstill or almost, shutting down of the PWM by disabling the "enable/inhibit signal"
using the appropriate digital input or network signal when connected,

-

finally, activation of the STO function.

STOP

0

1

SPEED

0

0

1

ENABLE

24V

STO1

0

STO2

Deceleration ramp is
controlled by the drive

«
...
54
55
56

Summary of Contents for GD1-400/05

Page 1: ...GD1 INFRANOR Gem Drive Installation Guide gb Actuator ...

Page 2: ...s manual without notice INFRANOR June 2008 All rights reserved Issue 1 1 CAUTION Any contact with electrical parts even after power down may involve physical damage Wait for at least 10 minutes after power down before handling the drives a residual voltage of several hundreds of volts may remain during a few minutes ESD INFORMATION ElectroStatic Discharge INFRANOR drives are conceived to be best p...

Page 3: ...ED 20 3 4 X1 CONNECTOR RESOLVER 21 3 5 X2 CONNECTOR INPUTS OUTPUTS 21 3 5 1 Specification of the logic inputs INX 22 3 5 2 Specification of the AOK logic output on optorelay 22 3 5 3 Specification of the logic outputs OUTX 23 3 5 4 Specification of the analog inputs CV1 CV1 ILIM ILIM 23 3 6 X3 CONNECTOR ENCODER 24 3 6 1 X3 Connector for TTL HES incremental encoder input SUB D 25 pins female 24 3 6...

Page 4: ...USTMENT TO VARIOUS RESOLVER TYPES 37 5 2 USE OF THE AOK OUTPUT 37 5 3 ENERGY RECUPERATION VIA A BRAKING RESISTOR 38 5 4 MAINTENANCE 38 5 5 ORDER CODE 38 CONTENT PART 2 40 CHAPTER 1 SPECIFICATIONS 41 1 1 INTRODUCTION 41 1 2 MULTIAXIS POWER SUPPLY UNIT GDPS 400 16 32 41 CHAPTER 2 CONNECTORS 43 2 1 LOCATION OF THE GDPS CONNECTORS 43 2 2 J1 CONNECTOR THREE PHASE 400 V POWER INPUT FOR THE CONFIGURATION...

Page 5: ...4 Part 1 GD1 amplifier GD1 Installation Guide PART 1 ________ GD1 AMPLIFIER ...

Page 6: ...D 20 3 4 X1 CONNECTOR RESOLVER 21 3 5 X2 CONNECTOR INPUTS OUTPUTS 21 3 5 1 Specification of the logic inputs INX 22 3 5 2 Specification of the AOK logic output on optorelay 22 3 5 3 Specification of the logic outputs OUTX 23 3 5 4 Specification of the analog inputs CV1 CV1 ILIM ILIM 23 3 6 X3 CONNECTOR ENCODER 24 3 6 1 X3 Connector for TTL HES incremental encoder input SUB D 25 pins female 24 3 6 ...

Page 7: ...MMUNICATION CABLES 35 4 7 CONNECTION CABLES OF THE BRAKING RESISTOR 35 4 8 FIRST POWERING OF THE DRIVE 35 4 8 1 Very important 35 4 8 2 Switching on the 24 VDC supply 35 4 8 3 Switching on the power supply 230 VAC or 400 VAC according to the drive type 35 GD1 uuu cc PS R 35 4 9 REQUIREMENTS FOR THE COMPLIANCE WITH THE UL STANDARDS 36 4 9 1 24 V supply 36 4 9 2 Power supply and UL fuse rating 36 CH...

Page 8: ...30 to 480 VAC three phase power supply unit GDPS See Part 2 The very small dimensions allow an easy mounting in low depth cabinets Height 235 mm and depth 224 mm are the same for all voltage and current ratings The drives with current rating 45 A have a single width with 74 5 mm pitch whereas drives with 60 A and 90 A ratings have a double width with 145 mm pitch The drives with current ratings sm...

Page 9: ...king resistor INTEGRATED 400 480 VAC THREE PHASE POWER SUPPLY UNIT RATED POWER 7 kW EXTERNAL POWER SUPPLY UNIT GDPS 400 xx RATED POWER 4 kW IN 230 VAC RATED POWER 7 kW IN 400 VAC Power supply filtre braking resistor GD1 230 05 to 30 PS R Power supply filtre braking resistor GD1 400 05 to 20 PS R GDPS 400 xx GD1 400 30 to 90 230 VAC three phase or 400 VAC three phase A1 X4 Power supply filtre See P...

Page 10: ...EE PHASE POWER SUPPLY UP TO A RATED POWER 7 kW GD1 230 05 to 30 PS R Power supply filtre braking resistor A1 A2 A3 An n max 6 GD1 230 05 to 20 00 0 DC bus 320 VDC Connect the actuators from A1 to An in the decreasing order of their current ratings GD1 400 05 to 20 PS R Power supply filtre braking resistor A1 A2 A3 An n max 6 GD1 400 05 to 20 00 0 DC bus 600 VDC Connect the actuators from A1 to An ...

Page 11: ...hich the X4 cable is connected must be a GD1 230V The GD1 400 actuator s used with a 230 VAC power supply must be configured with Operating voltage 230 V in the Gem Drive Studio software Connecting the 600 VDC bus with GD1 230 actuators will destroy then immediately The use of GD1 400 cc PS drives instead of GD1 400 cc 00 will generate the FP Fault phase error For running the drive in this case th...

Page 12: ...ows to keep the position even after switching off the auxiliary 24 VDC supply The power supply is depending on the drive type GD1 230 05 A to 30 A integrated 230 VAC single phase mains operated power supply GD1 400 05 A to 20 A integrated 230 to 480 VAC three phase mains operated power supply GD1 400 30 45 60 90 A 230 to 480 VAC three phase mains operated supply with external power supply unit GDP...

Page 13: ...EFERENCE TO THE UL STANDARDS GD1 series drives have been ULUS listed according to UL508C and UL840 regarding the insulator This product was evaluated to the Third Edition of UL508C the UL Standard for Power Conversion Equipment dated May 2002 for the UL Listing USL Providing that the manual is specifying that the end user has to provide an isolated power supply for 24 VDC auxiliary input protected...

Page 14: ... for 1 sec 5 230 VAC Rated output current Arms 230 VAC Rated power kW Power losses W Rated input current Arms 230 VAC 60 Hz Max protection fuses for line circuit A60Q listed Ferraz Short circuit power of the mains UL listed Use with integrated single phase 230 VAC power supply unit Drive type GD1 230 cc PS GD1 230 05 5 2 5 1 2 5 2 A 5 kA Yes GD1 230 08 8 4 1 6 4 4 A 5 kA Yes GD1 230 11 11 5 5 2 2 ...

Page 15: ...10 V OUTPUT CURRENT RATINGS at a maximum room temperature of 40 C Output voltage range for 400 480 VAC rms three phase mains Drive type Max output current Arms for 1 sec 480 VAC Rated output current Arms 480 VAC Rated power kW Power losses W Rated input current Arms 480 VAC 60 Hz Max protection fuses for line circuit A60Q listed Ferraz Short circuit power of the mains UL listed Use with integrated...

Page 16: ... Cut off frequency for 45 phase shift 1000 Hz Internal current limitation Imax 20 to 100 and Irated 20 to 50 Authorized Imax duration 1 second Digital speed and position regulators Sampling period Anti wind up system of the integrator Adjustable digital gains Speed loop bandwidth Selectable cut off frequency for 45 phase shift 50 Hz 75 Hz or 100 Hz Max motor speed Adjustable from 100 rpm to 25 000...

Page 17: ...S 232 or 422 option Bus interface with communication protocol Automatic functions Drive adjustment to the motor AUTO PHASING Servo control adjustment AUTO TUNING Compliance with the standards CE certification 360 shield connection equipotentiality according to the wiring rules GD1 230 cc PS with FN612 20 06 mains filter GD1 400 cc PS with F400 mains filter GD1 400 cc 00 GDPSxx EMC requirements EN ...

Page 18: ...05 to 45 224 3 208 5 235 149 74 5 74 5 224 5 GD1 400 60 to 90 224 3 208 5 235 298 74 5 144 5 224 5 74 5 GDPS 400 16 175 208 5 235 149 74 5 74 5 224 5 GDPS 400 32 175 208 5 235 149 74 5 74 5 224 5 UPPER VIEW pitch between 2 axes E F SIDE VIEW Power supply unit and small current drives I 8 A A B C SIDE VIEW Drive A C FRONT SIDE Power supply Amplifiers up to 45 A B X C G FRONT SIDE Amplifiers 60 and ...

Page 19: ...INGLE AXIS WALL CROSSING MOUNTING 4 4 6 14 5 14 5 213 Slot to be cut out only if using an integrated braking resistor 2 M4 holes 225 20 20 68 5 Ø 1 4 5 Ø 14 5 DOUBLE AXIS WALL CROSSING MOUNTING 34 25 143 74 5 34 25 6 225 213 4 M4 holes MULTIAXIS WALL CROSSING MOUNTING 74 5 74 5 Slot to be cut out only if using an integrated braking resistor ...

Page 20: ...S UPPER VIEW BOTTOM VIEW X13 4 3 2 1 GND W V U X10 M O T O R 2 1 DC DC X11 D C B U S 4 3 2 1 NC NC Br Br X9 B R A K E 4 3 2 1 GND 24V 0V Br 24V Br X8 A U X I L I A R Y S U P P L Y 2 4 V 1 2 3 L1 Neutral GND X12 230 V 1 2 3 4 L1 L2 L3 GND X12 400 V X7 CAN X6 CAN Address X3 Encoder X1 Resolver X2 Inputs Outputs X5 Serial link ...

Page 21: ...SION SPEED Each drive of the network shall be configured with one single address A DIP8 switch accessible by the operator allows to configure the drive address as well as the communication speed of the CANopen bus Adressing 6 selection bits Status of the cursors Address 6 5 4 3 2 1 OFF OFF OFF OFF OFF OFF 0 OFF OFF OFF OFF OFF ON 1 OFF OFF OFF OFF ON OFF 2 ON ON ON ON ON ON 63 Communication speed ...

Page 22: ... 25 mm 2 AWG22 PIN SIGNAL I O DESCRIPTION 1 IN1 I 2 IN2 I 3 IN3 I Positive logic Optocoupled inputs 4 IN4 I 5 IN5 I Positive logic Optocoupled inputs FAST INPUT 6 IN6 I 7 IN7 I Positive logic Optocoupled inputs used for safety function STO 8 IN8 I 9 IN9 I Positive logic Optocoupled inputs MA GV1 MA GV2 10 ANA 1 AI 11 ANA 1 AI 12 ANA 2 AI 13 ANA 2 AI Differential analog inputs 10 V 14 Non connected...

Page 23: ... SPECIFICATION OF THE AOK LOGIC OUTPUT ON OPTORELAY 5 V AOK X2 32 AOK X2 31 Bidirectional Transil Opto relay polarised contact Closed if drive OK open if fault the polarity AOK positive potential with regard to AOK must be observed Pmax 10 W with Umax 50 V Imax 300 mA 24V AOK AOK AOK AOK AOK AOK AXIS 1 AXIS 2 AXIS 3 PLC input The AOK output is not made of a dry contact The polarity must be observe...

Page 24: ...ly 24 V 18 V U 30 V Maximum voltage drop 2 V Protection agains overload Available output current per output mA Number of activated outputs Cycle ratio 100 70 50 30 2 200 mA 200 mA 200 mA 200 mA 4 100 mA 150 mA 200 mA 200 mA 3 5 4 SPECIFICATION OF THE ANALOG INPUTS CV1 CV1 ILIM ILIM 100 kΩ 100 kΩ 100 kΩ 30 1 kΩ 1 5 nF 1 5 nF 1 5 nF 1 5 nF 100 kΩ 30 1 kΩ X2 10 X2 12 X2 11 X2 13 ...

Page 25: ...ut of the encoder channel A 6 Channel A Differential input of the encoder channel A 20 Channel B Differential input of the encoder channel B 7 Channel B Differential input of the encoder channel B 8 5 V Encoder supply voltage max current 300 mA 21 GND Encoder supply GND Section 0 8 mm 2 AWG18 11 HALL U Hall sensor input signal phase U 24 HALL V Hall sensor input signal phase V 12 HALL W Hall senso...

Page 26: ...hannel A 1 Channel A Differential input of the Sin Cos encoder channel A 15 Channel B Differential input of the Sin Cos encoder channel B 2 Channel B Differential input of the Sin Cos encoder channel B 8 5 V Encoder supply voltage max current 300 mA 21 GND Encoder supply GND Section 0 8 mm 2 AWG18 11 HALL U Hall sensor input signal phase U 24 HALL V Hall sensor input signal phase V 12 HALL W Hall ...

Page 27: ...lse R 14 Channel A Differential input of the Sin Cos encoder channel A 1 Channel A Differential input of the Sin Cos encoder channel A 15 Channel B Differential input of the Sin Cos encoder channel B 2 Channel B Differential input of the Sin Cos encoder channel B 16 Channel C Differential input of the Sin Cos encoder channel C 3 Channel C Differential input of the Sin Cos encoder channel C 17 Chan...

Page 28: ...ION DESCRIPTION 2 CAN L CAN L line dominant low 3 CAN GND CAN Ground 7 CAN H CAN H line dominant high 3 10 X8 CONNECTOR AUXILIARY SUPPLY AND BRAKE SUPPLY 4 pin male connector with 3 81 mm pitch female connector provided Tightening torque of the connector screws 0 22 to 0 25 Nm Section 0 8 mm 2 AWG18 check voltage drop PIN SIGNAL I O FUNCTION DESCRIPTION 4 GND I Potential reference of the 24 VDC au...

Page 29: ...ination for 2 same section wires PIN SIGNAL I O FUNCTION DESCRIPTION 1 DC I O Parallel connection of the DC bus 2 DC I O Parallel connection of the DC bus GD1 uuu 05 to 45 A section 2 5 mm 2 AWG14 GD1 uuu 60 and 90 A section 6 mm 2 AWG10 600 V 105 IMPORTANT The motor and brake cable must be shielded and connected over 360 on the cabinet rear wall as near as possible to the drives The GND reference...

Page 30: ...se L1 I 2 Phase L2 I 3 Phase L3 I Power input 400 VAC three phase 4 GND Mains ground Irms rated max 10 A 600 V 105 Section 1 mm2 AWG16 3 14 3 X13 CONNECTOR ADDITONNAL BRAKING RESISTOR 2 pins female spring contact connector no polarity Connection of the internal additional resistor 200 R 65 W or Connection of the external additional resistor type dp 50 200 for internal single phase 230 VAC supply o...

Page 31: ...ference 24 V Ext if logic outputs used CAN L CAN GND CAN H GND brake 24 Vdc brake Motor brake 24 Vdc 1 5A 24 Vdc 15 isolated See UL fuses table See UL fuses table 4 A UL listed 4 A UL listed MOTOR GND 1 CAUTION Imax 300 mA Umax 50 V see AOK output specifications Respect the AOK polarity positive potential AOK R ENABLE 24 Vdc power supply isolated from the 230 Vac mains Motor brake Motor brake OTHE...

Page 32: ... as the axis position even when moving with the mains switched off 4 4 WIRING RECOMMENDATIONS according to EN61000 4 2 3 4 5 6 and EN61800 3 Part 3 standards See diagram Shield connection on the connectors section 4 2 2 4 4 1 GROUND CONNECTIONS AND GROUNDING A shield has no effect if it is not connected to a reference potential by a connection as short as possible a few centimetres 10 centimetres ...

Page 33: ... main chassis or cabinet with a low impedance between its various elements it should be used to connect ALL references to it and also being grounded itself dfdf LEAKAGE CURRENT TO GROUND This drive may generate direct current in the protection conductor When a protection by residual current device RCD is used for the protection in case of direct or indirect contact only an RCD type B is allowed on...

Page 34: ...NNECTION ON THE CONNECTORS RULE The shield should never be interrupted or corrupted over the whole cable length NOTE When the 360 shield connection is made by means of a collar it is not necessary to connect an additional cable on the pertaining pin of the SUB D connector ...

Page 35: ... voltage drop by the half the SENSE feedback signal is not used in the GD1 range if none of both solutions above can be used the user has to supply the encoder by means of an external power supply Example The application requires an Heidenhain linear encoder supplied by 5 V 5 300 mA with 25 m cable length Min power voltage 5 V 5 Ö Umax 0 25 V ÖMin cross section S 1 2 mm 2 Such a large cross sectio...

Page 36: ... must be disabled Any braking resistor value lower than the minimum value specified in the technical specifications wil definitely damage the braking system Check for the correct groundings as well as the 360 shield connections 4 8 2 SWITCHING ON THE 24 VDC SUPPLY The red ERROR LED on the front panel must be flashing Undervolt error displayed The AOK relay pins 9 and 10 of X2 is closed It is then ...

Page 37: ...se 4 9 2 POWER SUPPLY AND UL FUSE RATING The fuse type recommended for drive application is semiconductor protection fuses The maximum short circuit power of the mains must not exceed 5000 Arms at a voltage of 480 V when protected by a UL fuse range A60Q On GD1 230 cc PS R and GD1 400 cc PS R drives power supply inside the fuse ratings must be the following GD1 400 0 5 TO 20 MULTIAXIS FERRAZ A60Q2...

Page 38: ... resolvers with a number of pole pairs N 1 all speed values displayed in the drive are equal to N times the motor rotation speed 5 2 USE OF THE AOK OUTPUT The use of the AOK output on an opto relay is mandatory in order to allow the power supply connection see section 4 1 Connection diagrams The wiring of the opto relay output must observe the AOK AOK polarity see diagram below The correct drive o...

Page 39: ... the energy reflected to the drives with parallel mounted DC busses is too high the DC bus voltage will rise up to the triggering of the Overvoltage fault A second resistor must then be mounted on the second axis which shall then be equipped with Power supply inside unit 5 4 MAINTENANCE The GD1 drive does not require any special maintenance in a specified environment The opening of the housing wil...

Page 40: ...GD1 Installation Guide 39 Part 2 GDPS power supply PART 2 ________ GDPS POWER SUPPLY ...

Page 41: ...POWER INPUT FOR THE CONFIGURATION WITH EXTERNAL POWER SUPPLY UNIT GDPS 44 2 3 J2 CONNECTOR DC BUS FOR THE CONFIGURATION IN 400 V WITH EXTERNAL POWER SUPPLY UNIT GDPS 44 2 4 X6 CONNECTOR EXTERNAL BRAKING RESISTOR 44 CHAPTER 3 CONNEXIONS 45 3 1 CONNEXION DIAGRAM OF THE SUPPLIES IN MULTIAXIS CONFIGURATION WITH GDPS 400 XX POWER SUPPLY UNIT 45 3 2 POWER SUPPLY AND UL FUSE RATING 46 CHAPTER 4 ORDER COD...

Page 42: ... or TT system with grounded neutral point 50 to 60 Hz phase ground voltage must be balanced IT system supported but not recommended Voltage unbalance Max 3 of the mains voltage fundamental 400 to 480 VAC supply 230 VAC supply Output power GDPS 16 16 kW rated 45 kW peak GDPS 32 32 kW rated 90 kW peak GDPS 16 8 kW rated 25 kW peak GDPS 32 16 kW rated 45 kW peak 400 to 480 VAC supply 230 VAC supply O...

Page 43: ...rage power in a given application The polarity DC with DC and DC with DC between the GD1 uuu cc drives and the GDPS power supply unit must be observed Otherwise the drive will be immediately destroyed When using GD1 400 cc 00 0 actuators with a 230 VAC supply voltage make sure that the operation voltage is correctly entered in the Gem Drive Studio software N 1 Paverage GDPS xxx xxx 0 4 x Prated ax...

Page 44: ...nstallation Guide 43 Part 2 Chapter 2 Connectors Chapter 2 Connectors 2 1 LOCATION OF THE GDPS CONNECTORS CONNECTION OF GDPS BRAKING RESISTOR BOTTOM VIEW X4 400 VAC MAINS GND L3 L2 L1 J1 DC BUS 2 1 DC DC J2 ...

Page 45: ...nector provided Tightening torque of the connector screws 1 2 to 1 5 Nm Section 2 5 mm 2 AWG14 for GDPS 400 16 Section 6 mm2 AWG10 for GDPS 400 32 600 V 105 PIN SIGNAL I O FUNCTION DESCRIPTION 1 DC O Parallel connection of the DC bus Connected to the X11 connector of the drives 2 DC O Parallel connection of the DC bus Connected to the X11 connector of the drives 2 4 X6 CONNECTOR EXTERNAL BRAKING R...

Page 46: ...nnection type is required when the installation rated power of the application is higher than 7 kW in 400 VAC J1 2 3 4 1 2 1 2 1 UL compliance only 3 φ 400Vac GDPS16 20 A GDPS32 40 A X4 X4 DC RB RB J2 DC GDPS 400 xx GD1 uuu cc 00 0 X6 X11 2 1 X11 2 1 X11 GND AXIS 1 AXIS 2 AXIS n GND L1 Phase L2 Phase L3 Phase dp 33 280 External braking resistor Only between GDPSxx and the 1st axis ...

Page 47: ...46 Part 2 Chapter 3 Connexions GD1 Installation Guide 3 2 POWER SUPPLY AND UL FUSE RATING For the GDPS 400 xx multiaxis power supply unit GDPS 400 16 400 32 FERRAZ A60Q20 2 A60Q40 2 ...

Page 48: ...OR dp 50 200 50 Ω 200 W braking resistor external braking resistor on GD1 230 cc with internal power supply if 200 Ω 65 W integrated braking resistor is not enough to be connected on X3 dp 33 280 33 Ω 280 W braking resistor for GDPS 16 type E 16 5 Ω 560 W braking resistor for GDPS 32 MAINS FILTER F400 for GD1 400 cc PS FN612 20 06 for GD1 230 cc PS GDPS 400 xx ...

Page 49: ...48 Part 2 Chapter 4 Order code GD1 Installation Guide PART 3 ________ APPENDIX ...

Page 50: ...rt 3 Content Content Part 3 Page 1 OPERATING ENVIRONMENT CONDITIONS 50 2 SAFE TORQUE OFF OPTION 53 2 1 DESCRIPTION 53 2 2 RECOMMENDATIONS FOR THE INTEGRATION 53 2 2 1 SAFETY INSTRUCTIONS 53 2 2 2 STO CONNECTION 54 2 2 3 TIMINGS 54 ...

Page 51: ...out hindering the heatsink and the fan The liability may be increased by installing a cooling system Other installation conditions must be specifically analysed and be subjected to a technical specification agreed by INFRANOR Mechanical mounting There are two possible mountings Normal mounting on the cabinet rear wall Wall crossing fastening see dimensions in section 2 2 of this chapter which requ...

Page 52: ...The transport packaging is not fitted for outdoor or non protected storing Climatic conditions Equipments must be stored in the environment conditions specified by the IEC 60721 3 1 standard This includes 1 Room temperature class 1K4 25 C to 55 C 2 Relative moisture class 1K3 5 to 95 Modules and panels must be protected against condensation Rough temperature and moisture variations should be avoid...

Page 53: ...sport of the equipment at temperatures lower than 25 C requires either a re heating or the removal of components sensitive to low temperature 3 Mechanical conditions The equipment may be transported in its standard package in the conditions specified by class 2M1 of the IEC 60721 3 2 standard This includes vibrations and shocks see tables below TABLE 4 Vibration limits during the transport Frequen...

Page 54: ...ATIONS FOR THE INTEGRATION 2 2 1 SAFETY INSTRUCTIONS The integration of the STO function must be the result of a risk analysis of the complete machine All control components must comply with the requirements of this risk analysis Installing and commissioning of safety functions must be performed by skilled personnel only Short circuit avoidance Install the drive in a control cabinet with a minimum...

Page 55: ...gnal and high potential 2 2 3 TIMINGS The STO function is based on forcibly guided relay technology Its response time is given by the typical Operate Time Release Time of the relay 12 ms 20 ms Refer to the following chronogram for more detailed explanation The STO function has two feedbacks the STO_OUT contact and detailed state available in object 0x3001 Only the output STO_OUT is a safe output A...

Page 56: ...andard the control system of the machine must generate the following sequences deceleration of the load by means of the drive when the load is at standstill or almost shutting down of the PWM by disabling the enable inhibit signal using the appropriate digital input or network signal when connected finally activation of the STO function STOP 0 1 SPEED 0 0 1 ENABLE 24V STO1 0 STO2 Deceleration ramp...

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