PAM & SAM System User's Manual
Contents
1. DA xxx xxx P4N x X17 1 24 VDC Ext 2 GND Ext X17 X23 female 3 STOPO 4 STOP1 ve 1 14 nic 5 Fatal Error ies 15 n c 6 Fatal Error Res 1 16 17 5 nic 5 18 nic 233 nic 6 19 n c ne MEDIO n c xa5Q nic 9 21 n c 22 n c 10V 10 23 Ua 10V 5 nic 11 24 n c n c 12 nic 13 25 X31 X24 female 9 U Gen a2 1 DE Ua sov 4 08 Ua 10V 5 DA xxx xxx P5N x X17 1 24 VDC Ext 2 GND Ext X17 X23 female 3 STOPO Clk 1 4 STOP1 Data 2 Gk 5 Fatal Error AO 3 16 80 6 Fatal Error 12 ve 17 S5 x33 Cos c2 6 15 Aes z is d 20 Sin c1 21 Piref 1 x35 42 9 22 Cos d1 5 Sin 4210 23 Sin d1 X32 Error 11 24 En latch Pol Piref 12 25 Mux LR lt X24 n c 13 x31 E B X24 female U Gen a2 1 0 e COS at Ua sto a 5 Ua 10V 5 9 SIN a2 PSU2_005 cdr Figure 31 24 VDC Power Safety and Position Feedback Connectors The 14 28 and 50 amp models are wider than shown in this figure PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 39 PART 2 SYSTEM DESIGN AND INTEGRATION DA xxx xxx xxx E Node Address LSB x33 e EasyBus Rx Node Address 5 X35 Q EasyBus Tx X32 Male n c 5 Gnd Ext 4 Fast Input 13 Ext 2 24 VDC Ext 1 320 SZE z N X31 OUT 1 IN 3 IN 2 GND Ext 24 VDC Ext RO2. Figure 26 Wiring Diagram for Multi turn Resolvers PSU2 003 cdr Page 34 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Safety amp 24 VDC Supply 24 VDC power for the SAM Drive and user safety functions interface through connector X17 Safety inputs are isolated from internal SAM Drive electronics and share a common return line Figure 27 illustrates a typical wiring diagram Refer to Part 3 Safety and Protective Functions for a functional description of User Stop inputs and the Fatal Error output Refer to Part 5 SAM Drive Technical Information for safety input output signal specifications and 24 VDC power requirements 24 VDC Supply E X17 SAM Drive 1 4 Power Board EE gt d DC Internal 2 Supply DC 217 User STOPO Input No current activates 10 mA i E Stop functions User STOP1 Input vA I gt Stop1 5 1 Fatal Error relay is closed when i l Safety chain Fatal Error no fatal error condition exists 6 Figure 27 Safety and 24 VDC Power Wiring Diagram User I O General Two User I O configurations standard and expanded are available depending on
3. 54 Auto transformation Wiring Configuration 54 24 VDC Power 55 List of Tables Table 1 4 ceto ecco heo boc de 52 Page 6 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING Grounding and Shielding About Protective Earth and Functional Earth Grounds Protective Earth Ground Protective earth ground is primarily a safety function Physically a protective earth ground is a wire connected on one end to some points in a circuit or to the exterior metal surfaces of devices The other end is connected to the earth In the event that a short circuit occurs within the device current flows in the protective earth ground preventing the voltage at the grounded point from reaching a dangerous level with respect to the earth In this manual one or both of the following symbols indicate protective earth ground connections QD PE Figure 1 Symbols for Protective Earth Ground EMC practices and safety requirements have common aspects such as earthing grounding over voltage protection and lightning protection Occasionally the two may A seem to conflict In such cases safety requirements must always have precedence over EMC practices and alternate EMC measures must be sought Functional Earth Ground Functional earth grounds
4. 9 Enclosure Layouts itd im he He pr Ope edente tds 12 Concept for an Entire Machine Control 12 Rules for Enclosure ene 12 Recommended Layout for a PAM with SAM 13 Rules for Placement of EMC Line Filter 14 Back Panel EayOUt nett ttg uris e BL IRE e ae dtd 14 netto turmis pd ee 16 PAM 2 edet ne dad 16 PAMPISA ia edd ede dade dae ded eddie dtd 18 PAM for Simatic Module sese ener 18 EaSVBUS c c n epa t Om ted deu 19 E te mir dente PURUS 19 Installation ici nr ette anes das ima lade ed desk 19 SAM Drive iii haer 20 Mounting a SAM 20 Interfacing Servomotors 2 2 00 0 24 Interfacing Standard 29 Interfacing Sine Cosine Encoders and Rulers 32 Interfacing Multi turn Resolvers sse enne 34 Safety 1 amp 24 VDC mener 35 WSO I O sino IDEE 35 Connector Pin 38 SA
5. 7 Figure Supply with a Grounded 8 Figure 4 Machine to System Enclosure PE 9 Figure 5 Mesh Earthing Network Using Building Structure 10 Figure 6 Mesh Earthing Network Using Conduits and Cable Trays 11 Figure 7 Enclosure Layout 12 Figure 8 Enclosure Layout for a Large 13 Figure9 Recommended Spacing and Clearances for SAM Drives and Supplies IEEE 15 Figure 10 PAM Full 00004000 0000 r nnd atte tans 16 Figure 11 PAM Chassis Mounting Dimensions and Clearances 17 Figure 12 EMI RFI Requirements when Installing PAM Chassis 17 Figure 13 The PAM ISA edet eet edu nicae eoe i ande 18 Figure 14 PAM Modules for Simatic S5 115 left 55 135 and 55 155 right 18 Figure 15 Dimensions for SAM Drive 7 amp 21 Figure 16 Dimensions for SAM Drive 14 amp 28 amp 22 Figure 17 Dimensions for SAM Drive 50 amp 23 Figure 18 Shields Termination in Cable Gland 25 Figure 19 Wiring D
6. X1 female DC Bus PE L L2 L3 X5 male Phase L1 Phase L2 Phase L3 XT SAM SuPPLY Top view PSU2 007 cdr Figure 400 Connector Locations and Pin Assignments for 30 amp SAM Supply Models X2 connector is available only on SAM PA xxx 30 E type PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 47 PART 2 SYSTEM DESIGN AND INTEGRATION SAM SuPPLY PA xxx 80x E X2 female 1 IDRes A 311 IDRes 1 2 1 Shunt IGBT u 1 1 DC X51X1 X5 X1 L1 12 t3 L1 L2 L3 e Supply Phase 1 X7 Supply Phase 2 Supply Phase 3 DC Bus PE DC Bus DC Bus T XT DBR Overload Over Temp n c DC Bus Low Reset In Fatal Error Fatal Error Bottom view Over Voltage GND Ext 24 VDC Ext view PSU2 008 CDR Figure 41 Connector Locations and Pin Assignments for 80 amp SAM Supply Models PAM with SAM System Users Handbook Page 48 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION DC Bus DC Bus General The DC Bus distributes DC Power at high voltage and current levels from a SAM Supply to SAM Drives The DC Bus voltage DC Bus to DC Bus can be as high as 800 VDC and the DC Bus must be totally isolated from ground In systems with multi
7. 2 24 VDC PWR Supply 1 24 VDC ext Y d T m 24 Figure 29 User Interface to Expanded I O Configuration PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 37 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Connector Pin Assignment DA xxx 07x xxx x DA xxx 14x xxx x X14 Brake option X14 Brake option 24VDC Ext 1 24VDC Ext 1 GND Ext 2 27 GND Ext 2 nic 3 3 X14 Brake 1 4 4 Brake 1 4 Brake 2 5 2 5 E X13 3 X13 X13 Mot Temp 1 me Mot Temp 2 3 MEE 11 12 X12 female X11 male Motor Phase 1 1 DC Bus E 3 Motor Phase V 2 DC Bus BEN 2 Motor Phase W 3 DC Bus WM 1 X11 male 2 N X12 female DC Bus 3 Motor Phase U D 1 DC Bus 2 DC Bus PE 2 1 DA xxx 50x xxx x X14 Brake option 24VDC Ext GND Ext n c Brake 1 Brake 2 X13 Mot Temp 1 Mot Temp 2 X11 X12 DC Bus DC Bus DC Bus PE Motor Phase 1 Motor Phase 2 Motor Phase 3 s lt c rt Motor Phase V 2 Motor Phase W D 3 a D X11 X12 PSU2 004 cdr Figure 30 DC Bus Motor Windings Thermal Protector and Brake Control Connectors Page 38 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE
8. I gt 5 terminal blocks Sah080 a cdr Feeding Figure 35 AC Supply and DC Bus Connections to SAM Supply DC Output The SAM Supply produces DC power at high voltage up to 800 VDC and current levels for use by SAM Drives in powering axis motors Distribution of this DC power to the SAM Drives is the function of the DC Bus See DC Bus page 49 External Dynamic Braking Resistor General SAM Supply models SAM PA E require an external DB resistor for dissipating excess regenerated energy from motors when it cannot be immediately reused by other SAM Drives SAM Supply models 5 30 have an internal DB resistor For these models no external DB resistor is used DB Resistor Installation and Mounting If the average braking power see Part 1 System Component Selection is high the DB resistor should be placed outside of the equipment enclosure in order to reduce the heat load within the enclosure and thus simplify its cooling Heavy wire mesh encloses the top and sides of the DB Resistor assembly to prevent accidental exposure to high temperature and high voltage present on the resistors Figure 36 shows the overall size and mounting dimensions for the various DB Resistor types PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 43 PART 2 SYSTEM DESIGN AND INTEG
9. OL gt GND ext 42 7 E UO PWR As 24 VDC ext 0 i i Y 7 gt 24 VDC Supply 1 065 B CDR Figure 28 User Interface to Standard I O Configuration PAM with SAM System Users Handbook Page 36 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Expanded User Configuration Figure 29 shows the functional schematic for the expanded user I O option With this configuration four 4 user I O X32 12 11 10 and 9 are user configurable to function as inputs or outputs X32 User OUT 4 VoL User OUT 3 ey VoL User OUT 2 gay De VoL User OUT 1 D VoL ser mm YOL 9 User OUT 7 11 gt _User IN 9 1 YOL NH E 10 serin 8 10 voL NM v User OUT 51 9 User IN 7 CI VoL z User IN 6 s User IN 5 iy S User IN 4 1 52 D UseriN 3 MN p 1 User IN 2 a4 Fy Userin 1 28 Fault 4 ser Ly 2 GND ext
10. gt 229 202 178 136 gt 1 2 lt o 269 lt gt k 202 234 250 lt 4 gt Y A e N N 5 E 8 23 e 1 8 Y Yt nln a 2 285 4 70 70 105 234 1 eN 25 X33 Rx N o X17 N X35 Tx 2 20122 c 190 5 lt 2 X11 X12 X14 234 gt Sah078 a cdr Figure 17 Dimensions for SAM Drive 50 amp Models PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 23 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Interfacing AC Servomotors General This section includes instructions and wiring diagrams specific to servomotor families that were offered together with the PAM and SAM System in the beginning of 1999 namely the AC Servomotors and the Bautz motors For interfacing other motors the information in this section may be useful but not completely applicable Motor mounted Thermal Protector The thermal protector is optional and not provided in all motors When the thermal protector is either not present or not used other steps must be taken to prevent the SAM Drive operating software from interpreting no thermal protector as a motor over temperature error The following solutions are available Simulate the thermal protector closed motor temperature in range by inserting a wire jumper from X13 2 to X13 3 n software modify the SAM Drive Action Masks to prevent the
11. 2 0 Ui m 1 1 M N RN SAHO075 b cdr Figure 25 Wiring Diagram for Sine cosine Encoders PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 33 PART 2 SYSTEM DESIGN AND INTEGRATION Interfacing Multi turn Resolvers Figure 26 shows the wiring diagram for interfacing multiturn resolvers that are supplied together with the PAM and SAM System Shield connected to motor case via Encoder Na as seen from the crimp side of the mating plug SAM DRIVE Shield connected to SAM drive acase via copper banding connector shell and mounting screw cable gland and X24 connector shell 5 2 Uz Analog input 1 4 B Ug I 3 G 15 E Sin a2 Yell 2 16 d Sin a1 3 2 1 2 2 13 m Cos a1 Braun Green Brown l wu Gen a1 2 White Green White 1 0 Gen a2 1 1 23 Gray Pink 11 X 1 im 5 Gray 117 p 55 Red Blue 13 1 10 E n 116 50 15 1 2 HE Cos C2 16 Yellow l gt Cos C1 Blue 12 mm Sin C2 43 m Sin C1 White 12 4 MN Data raun 1 gt 17 t Data 1 Black Violet 114 9 U r EN 1
12. Figure 24 Resolver Feedback Interface for ACC amp Bautz Motors with Integral Connectors PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 31 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Interfacing Sine Cosine Encoders and Rulers Guidelines for Mechanical Integration Several motors with Sine Cosine Encoders are available together with the PAM and SAM System When using a linear motor or a direct drive torque motor the user has to assemble the encoder by himself These recommendations cover this kind of applications and are valid for Rulers as well as for Encoders Users performing their own integration of a feedback device with a motor must pay close attention to the mechanical interface Misalignment backlash and other interfacing errors translate to position error at the motor shaft Any resonance should be carefully damped In order to realize the high precision and high servo stiffness possible with high resolution sine cosine encoders particular care and attention must be paid to the mechanical interface with the motor ACC offers the following recommendations Often the best solution is to install the encoder rotating and stationary parts directly onto the motor shaft and into the motor housing respectively When using a coupling between motor end encoder select a very stiff zero backlash coupling Belt coupling is to be avoided coupling is preferred over
13. The 1 0 mm horizontal spacing accommodates normal tolerances in unit width Page 14 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION DC Bus bar C Bus bar 60 I E PSU2 009 CDR ENCLOSURE LAYOUT Figure 9 Recommended Spacing and Clearances for SAM Drives and Supplies PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 15 PART 2 SYSTEM DESIGN AND INTEGRATION PAM PAM PAM Full System General The PAM Full System See Figure 10 is housed in a panel mountable chassis which requires a single 24 VDC power source An integral DC DC converter provides all other voltages required internally If the PAM Full Systems includes a fieldbus interface the system is supplied with the interface hardware and software pre installed in the chassis Normally the 24 VDC power source providing power for the remainder of the PAM with SAM system is used For PAM Full System input voltage and current requirements refer to Part 1 Selecting System Components 24V DC supply Run Indicator green Alphanumeric Display Fieldbus PC
14. Figure 32 EasyBus and User I O Connectors SAM DRIVE DA xxx xxx xxx F Q Node Address LSB x33 EasyBus Rx Node Address MSB X35 EasyBus Tx X17 X32 i OUT 4 2 OUT 3 14 OUT 2 wc eis 13 OUT 1 12 IN 10 OUT8 sso LE 11 9 OUT 7 38 10 IN 8 6 5 OUT5 8 IN 6 ur 7 IN 5 3 6 IN 4 3 5 IN 3 6 4 IN 2 3 1 2 GND Ext 1 24 VDC Ext PSU2_006 cdr The 14 28 and 50 amp models are wider than shown in this figure Page 40 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM SuPPLY SAM Supply Chassis Installation in System Cabinet See Back Panel Layout page 14 for details on laying out the mounting panel for a PAM with SAM system For effective EMI RFI shielding the SAM Supply must make metal to metal contact with the back panel over the largest possible area Therefore the back panel must be unpainted beneath the area where the SAM Drive contacts the back panel Figure 33 and Figure 34 show dimensions for 30 and 80 amp SAM Supply models Y 62 lt gt 122 g Y N S 5 e y Y Y 2 o 281 lt gt 22 PSU2 001 dsf Figure 33 Dimensions for SAM Supply 30 am
15. a rotoric type coupling such as a bellows Mechanical misalignment between motor shaft end encoder induces a periodic positioning error proportional to the severity of misalignment Design the mechanical interface to minimize misalignment and maintain the encoder securely in alignment with the motor shaft A For applications requiring very high servo stiffness please contact ACC for application assistance Electrical Interface Figure 25 shows the wiring diagram for interfacing sine cosine encoders that are supplied together with the PAM and SAM System Page 32 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE E 3X as seen from the crimp side of the mating plug Shield connected to SAM drive ase via copper banding connector shell and mounting screw 5184 connected to motor case via cable gland and connector shell occi EA E TIE X23 7 D Gray Pink 2 1 M1 Gray ue Lam Red Blue 1 0 44 16 215 Green 16 1 1 Cos C2 Yellow 16 19 2 Cos C1 d 12 Blue 17 1 Sin C2 I Red 13 E Sin C1 White 4 17 Braun l M ue 2 i m Data 8 OR 9 Violet 14 Clk
16. gt lt 136 gt Lc Yo lt gt 1885 202 250 o o N e Y K Y Y 2 285 gt 218 22 A aa 2 E 65 202 234 X31 61 lt gt 30 5 NR 9 L Y 137 D X33 Rx X35 Tx 4 X11 14 Figure 15 Dimensions for SAM Drive 7 amp Models SAM DRIVE Sah076 a cdr PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 21 PART 2 SYSTEM DESIGN AND INTEGRATION 260 229 202 178 lt 136 gt gt 0 Yo gt REGE lt 22 N 250 o amp S E 8 Y Y ENS 285 lt gt 1 1 0 o Nn 357 SAM DRIVE fs 137 Sah077_a cdr Figure 16 Dimensions for SAM Drive 14 amp 28 amp Models Page 22 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE 260 lt
17. housing is for use with Simatic 55 135 and 55 155 models Run indicator green Run indicator green Alphanumeric Display Alphanumeric Display Reset button Reset button Service connector Service connector EasyBus IN EasyBus IN EasyBus OUT Not used EasyBus OUT Not used RS 422 connector PAH016_a CDR Figure 14 PAM Modules for Simatic 55 115 left 55 135 55 155 right RS 422 connector 127277 PAHO016 b cdr PAM with SAM System Users Handbook Page 18 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION EasyBus EasyBus General The EasyBus is constructed of fiber optic cable assemblies that link a PAM and all SAM Drives ina PAM with SAM system Three types of EasyBus cable assemblies are used including Standard duty plastic fiber cables Long distance fiber cables Kevlar reinforced plastic fiber cables Refer to Part 1 Selecting System Components for more information Installation The following guidelines should be observed when handling and installing EasyBus Cables 1 Handle the cables carefully Kinks and bends below the minimum bend radius can destroy the cable 2 When making EasyBus connections finger tighten the connectors only Never use a wrench as the tightening torque would be too great PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 19 PART 2 SYSTEM DESIGN A
18. mounted must be connected to the functional earth network of the building as illustrated in Figure 5 If this is not possible metallic conduits and cable trays carrying motor and feedback cables may be utilized to create a meshed grounding network see Figure 6 8 Motor windings cables shields must be properly terminated and connected to functional earth ground see Interfacing AC Servomotors on page 23 On the motor end the motor windings cable shields are connected to the motor case and to the machine s functional earth ground A large area of metal to metal contact between the motor and the machine structure is required Motor windings cable shields may carry strong capacitively induced high frequency currents These currents are normally routed to earth ground and therefore pose no A danger Should the user fail to connect a motor cable shield to earth ground a voltage potentially dangerous to humans may be present at places that are not at least IP20 protected A mesh functional earth network throughout the machine and even throughout the building is recommended Each room should have earthing network conductors to which the machine structures enclosures cable trays etc are bonded Ground loops are not only allowed they are an effective EFI RFI mitigation measure Refer also to IEC 1000 5 2 Installation and Mitigation Guidelines Earthing and Cabling This technical report provides valuable information Control cabinet
19. n 9032 011 150 FN258 30 07 258 75 34 H e H z 150 55 Ti beh TO E a V 14 U H EY 305 320 335 300 314 329 LOAD LOAD 3 fl Pk m um t LE 01 220 saa002_b dsf All dimensions in mm Figure 45 EMC Filter Dimensions Interfacing a Transformer When a Transformer is Required A transformer is required under any of the following circumstances The AC Supply voltage exceeds the maximum rated voltage that be applied to a PAM with SAM system see Part 1 Selecting System Components The AC Supply is not a three phase four wire system with grounded neutral see AC Supply with Grounded Neutral on page 8 A Operating a PAM with SAM system from an ungrounded AC Supply is prohibited Interfacing an Isolation Transformer Figure 46 illustrates the wiring of isolation transformers The transformer secondary load side must be wired in a wye configuration and the star point which is the secondary s neutral must be solidly grounded with a low impedance connection to protective earth ground The primary may be either Delta or Wye connected PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 53 PART 2 SYSTEM DESIG
20. outer nut Plug the assembled cable into the mating connector X2 on the SAM Supply Bracket to PE bar 2 Cable gland SAHOS7 a CDR Figure 37 Dynamic Braking Resistor Cable Assembly Cable gland amp bracket SAM Supply m Brown White Y 1 4 2 Error Fault Logic DB Resistor Black1 Green Yellow PE bar SAH040 b CDR Figure 38 DB Resistor Circuit Wiring Safety Status and 24 VDC Supply Status Outputs The SAM Supply provides four 4 PLC compatible status error outputs see Figure 39 including Dynamic Braking Resistor Overload Over Temperature Over Voltage DC Bus Low PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 45 PART 2 SYSTEM DESIGN AND INTEGRATION SAM SuPPLY They are normally monitored by a PC PLC performing overall machine control Figure 39 illustrates a typical circuit The status outputs are isolated from the SAM Supply internal electronics and share a common connection to 24 VDC power For a detailed description and electrical specifications of these status outputs refer to Part 6 SAM Supply Technical Information Fatal Error Output Fatal Error is an isolated relay contact intended for use in implementing machine level safety interlocks See Part 3 Safety and Protective Functions for further information 24 VDC Supp
21. this figure 40 Figure 33 Dimensions for SAM Supply 30 amp Models 41 Figure 34 Dimensions for SAM Supply 80 amp Models 42 Figure 35 AC Supply and DC Bus Connections to SAM 43 Figure 36 Dynamic Braking Resistors Dimensions all dimensions in mm 44 Figure 37 Dynamic Braking Resistor Cable 45 Figure 38 DB Resistor Circuit Wiring 2 45 Figure 39 SAM Supply Status Safety and 24 VDC Supply Connections 46 Figure 40 Connector Locations and Pin Assignments for 30 amp SAM Supply Models X2 connector is available only on SAM PA xxx 30 E type 47 Figure 41 Connector Locations and Pin Assignments for 80 amp SAM Supply 5 DP PIG Figure 42 DC Bus bar outlines 2 2 49 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 5 PART 2 SYSTEM DESIGN AND INTEGRATION LisT TABLES Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Wiring Diagram for DC Bus Bar Assembly 50 DC Bus Arrangement for Small 51 Filter Dimensions 53 Isolation Transformer
22. 104 Interface boards Reset button Service connector PAM Module EasyBus IN Power Converter unit NE ua EasyBus OUT e e 6 Not used RS 422 connector g J 015 a CDR Figure 10 PAM Full System Fieldbus Interface Details on interfacing the PAM to a fieldbus are beyond the scope of this manual Refer to the technical manual for the selected fieldbus interface which provides hardware and software interfacing information Page 16 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION PAM Chassis Installation in System Cabinet The PAM chassis is designed to be panel mounted Figure 11 shows the chassis mounting dimensions and recommended clearances The back panel in the area beneath the chassis must paint free as illustrated in Figure 12 to provide intimate contact between the chassis and back panel for EMI RFI mitigation 157 139 A A co e 3 free 2TE 3U sss c5 I front panels Ew All dimensions mm ML 9 Allow min 50 mm clearance 9 2 above and below chassis for air flow e Allow min 70 mm clearance 9 a in front of chassis for 2 E connectors Power Supply 8 Y 5072 116 Y PAHO08 d cdr Figure 11 Chassis Mounting Dimensions and
23. Clearances Cabinet s back panel No paint here ss n For rack must be securely attached to back panel at these A 20 four mounting points 212 For PAM Module must be securely attached to chassis with four attaching screws 1 0 54 PAHO20_a CDR 9 S NL Figure 12 EMI RFI Requirements when Installing PAM Chassis o9 N PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 17 PART 2 SYSTEM DESIGN AND INTEGRATION PAM PAM ISA General The PAM ISA see Figure 13 is intended for direct installation in an ISA Bus slot of a PC For installation and interfacing information refer to Part 4 PAM Technical Information Fault Indicator red Run Indicator green ES Address jumpers FATAL ERROR Service output connector EasyBus IN EasyBus OUT Pah013 a cdr Figure 13 PAM ISA PAM for Simatic Module General The PAM for Simatic module see Figure 14 is intended for direct installation into Siemens Simatic S5 PLC chassis Two configurations of PAM module are available The PAM module integrated into a plastic housing is for use in the Simatic 55 115 The PAM module with no plastic
24. M SUpply etre dime ntm 41 AC Supply Input 0 rite 2 Ratte aree tna ae edt OR ERI he dn 42 DG Output is eme obe n 43 External Dynamic Braking 43 Safety Status and 24 VDC 45 Connector Locations and Pin Assignments sse 47 DC BUS c 49 EC 49 DC B s Bar Assembly ood seis 49 Low Power Applications ssssssssssesemeeeenen nemen 51 Feeding Section aao ccm ce Pe erbe aes ea se e ro Eb I Re deme 52 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 3 PART 2 SYSTEM DESIGN AND INTEGRATION TABLE OF CONTENTS Basic Circuits ice haat eters DAL D M i MU 52 Installing an EMC Line 52 Interfacing a 53 DAN TDG Supply trie e obo te 55 FUNRCHONS LITT I LM 55 24 VDC Power 55 PAM with SAM System Users Handbook Page 4 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION LisT FIGURES List of Figures Figure 1 Symbols for Protective Earth 7 Figure 2 Symbol for Functional Earth
25. Machine structure Mesched earthing network Figure 5 Mesh Earthing Network Using Building Structure PAM with SAM System Users Handbook Page 10 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING Control Arial conduits cabinet cabletrays Machine structure AT Aa Figure 6 Mesh Earthing Network Using Conduits and Cable Trays PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 11 PART 2 SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT Enclosure Layout Concept for an Entire Machine Control System Figure 7 illustrates a general concept for an enclosure housing a complete machine control system where power and control as well as high frequency and low frequency parts of the system are located in separate areas of the enclosure In addition the cables carrying power control high frequency and low frequency should be separated in the same manner Power Power Low Frequency High Frequency 2 oO Control Control T Low Frequency High Frequency 8 LF HF EMC001_b cdr Figure 7 Enclosure Layout Concept Rules for Enclosure Layout The following are some general rules for enclosure layout 1 Power and control devices as well as high and low frequency parts must be separated and placed in different areas which are a minimum of 30 cm apart see Figure 7 To be an effective ground plane the back panel on whic
26. N AND INTEGRATION FEEDING SECTION L1 L1a L2 L2a L3 L3a PE PE L1 L1a L2 L2a L3 L3a PE PE Figure 46 Isolation Transformer Configurations Interfacing an Auto transformer Sag016 a cdr Auto transformers are always Wye connected their star point must be solidly grounded with a low impedance connection to protective earth ground as illustrated in Figure 47 L1 L2 L3 Figure 47 Auto transformation Wiring Configuration L2a L1a L3a SAG017_a CDR Page 54 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION 24 VDC SuPPLY 24 VDC Supply Functions The 24 VDC supply provides a low voltage power source which each SAM Drive SAM Supply and PAM Full system only utilizes to develop their internal operating voltages On units equipped with cooling fans the fans are powered by 24 VDC The 24 VDC supply may also be utilized as a power source for Operating electro mechanical brakes on motors Devices controlled by the User I O on a SAM Drive Other system or machine functions 24 VDC Power Distribution General System Diagram Figure 48 is a general system level diagram illustrating distribution of 24 VDC power in a PAM with SAM system Refer to the relevant sections of this chapter for detailed information on interfacing to the PAM SAM Supply and SAM Drive Safety amp Prot
27. ND INTEGRATION SAM DRIVE SAM Drive Mounting a SAM Drive General SAM Drives are designed for panel mounting Mounting tabs above and beneath the unit are provided for securing the unit to the back panel The mounting tabs are pre punched with slots for M4 screws Setting the EasyBus Node Address Each SAM Drive must have a unique node address which assigns a physical drive to logical axis references in the application program Two sixteen position rotary switches Node Address LSB and Node Address MSB See Figure 32 on page 40 set the Node Address It is generally easier to set the Node Address switches prior to mounting the SAM Drive Chassis Installation in System Cabinet See Back Panel Layout page 14 for details on laying out the mounting panel for a PAM with SAM system For effective EMI RFI shielding the SAM Drive must make metal to metal contact with the back panel over the largest possible area Therefore the back panel must be unpainted beneath the area where the SAM Drive contacts the back panel SAM Drive dimensions are illustrated in Figure 15 Figure 16 and Figure 17 The mounting tabs for all model SAM Drives and Supplies are slotted for M4 screws Page 20 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION 260 229 gt c 202 gt lt 178
28. RATION SAM SuPPLY L B 1600 W 5 gt B 400 amp 800 W gt li EOM TEIL j C EI gt Cable length 3m b 1 oy FWA saa004 b dsf Figure 36 Dynamic Braking Resistors Dimensions all dimensions Wiring Information DB Resistors are supplied with a 3 meter long shielded cable attached to it and a connector kit for attaching to the SAM Supply plug The SAM Supply end of the cable is left unterminated to facilitate routing the cable and to permit trimming to required length before installing the supply end connector Trim the cable to the required length then assemble the connector as follows 1 Insert the cable gland components onto the cable as shown in Figure 18 2 Fold the cable shield back over the cable gland inner plastic sleeve as shown in Figure 18 There must be metallic contact between the cable shield and cable gland around the whole circumference of the shield Pigtails degrade high frequency suppression considerably and are not permitted PAM with SAM System Users Handbook Page 44 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM SuPPLY 3 Install the cable gland connector X2 and attaching screws into the bracket as shown in Figure 37 4 Terminate the conductors in connector X2 using the wiring diagram in Figure 38 Tighten the cable gland
29. This version replaces all previous versions of this document It also replaces the SAM System Designer s Guide 1995 1996 Inmotion Technologies and ACC Motion have made every effort to insure this document is complete and accurate at the time of printing In accordance with our policy of continuing product improvement all data in this document is subject to change or correction without prior notice ACC Motion SA Zone industrielle La Rippe CH 1303 Penthaz Switzerland PAM amp SAM System User s anual Part 2 System Design and Integration Ordering Number 9032 011 982 Issue October 6 2000 P n 9032 011 982 Issue October 6 2000 1995 2000 by ACC Motion SA rights reserved PART 2 SYSTEM DESIGN AND INTEGRATION TABLE OF CONTENTS PAM with SAM System Users Handbook Page 2 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION TABLE OF CONTENTS Table of Contents Contents 4 3 List Of FIgUres eni toe oe tertie ee 5 List of Tables oe ode en demam ene 6 Grounding and Shielding ankenia pR EKARA thinner 7 About Protective Earth and Functional Earth Grounds 7 Protective Earth Grounding 8 Grounding for Electro magnetic
30. ble PE Conductor Cabinet min 10 mm Machine SAM P DC Bus Bar PE Motor LOAD EMC Filter LINE From Main Supply saco13 ACDR Figure 4 Machine to System Enclosure PE Conductor Grounding for Electro magnetic Compatibility Electro magnetic compatibility EMC is the capability of a part of a system to work without perturbing emission and being perturbed by immunity the rest of the system with electromagnetic phenomena There are a few basic rules 4 The system cabinet must be designed for EMI RFI attenuation 5 The backpanel equipment mounting panel must be bare unpainted The areas beneath where the PAM SAM Drives SAM Supplies and EMI filters are mounted provide intimate metallic contact between the units and backpanel When using Aluminum backpanel avoid surface oxidation treatments 6 The back panel must be connected to functional earth ground with a high quality ground connection Normally the best way to achieve this is with a large area of metal to metal contact between the back panel and the metal structure PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 9 PART 2 SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING of the cabinet Otherwise connect the back panel to functional earth ground using braided wire cable with large surface area 7 The system cabinet and the machine on which the motors are
31. bution network for each SAM Supply must remain electrically isolated from the DC Bus of all other SAM Supplies in the system Aux Supply DC Bus bar Low frequency low power machine controls Shielded signal amp control cables DC Bus bar Contactors Fuses Psg017_b Cdr Figure 8 Enclosure Layout for a Large System PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 13 PART 2 SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT Rules for Placement of EMC Line Filter When placing an EMC line filter in the enclosure use the following guidelines 1 Keep the length of wiring between filter and SAM Supply as short as possible 2 The input line side of the EMC filter must be as close as possible to the point where the AC Supply cable enters the enclosure 3 The EMC Line Filter relies on capacitance between AC Supply conductors and functional earth Therefore the EMC Line Filter must have metal to metal contact with the ground plane back panel over the largest possible area Back Panel Layout Unit Mounting Dimensions and Spacing Figure 9 illustrates the recommended horizontal and vertical spacing between SAM Drives Supplies and adjacent units The vertical dimensions in Figure 9 indicate the minimum clearance required for connecting removing mating connectors including cable bend radius
32. dings feedback cable cable Figure 19 Wiring Diagram for AC Servomotors with Terminal Boxes C33 option PAM with SAM System Users Handbook Page 26 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Sah061 b cdr Figure 20 Motor Windings Cable Configurations Interfacing Servomotor types with Integral Mating Connectors Figure 21 is applicable for interfacing Servomotor types with integral mating connectors for motor winding connections This includes motor types AHD55 AHD70 M254 and M506 The wire colors shown in Figure 21 are for motor winding cables that are supplied with the PAM and SAM System The plug fitted motor windings cable configuration see Figure 22 is used for interfacing to the SAM SA 400 07 amp 14 models The connector assembly on the SAM Drive end is removable when necessary to pull cables through conduit or bulkheads For safety compliance with EMC regulations and satisfactory performance it is imperative that SAM Drive to motor wiring is exactly as illustrated in Figure 21 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 27 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE On the motor end there should be a large area of metallic contact bare metal where the motor s mounting face contacts the machine On the SAM Drive end the screws that secure the cable bracket and in some cases connector X12 to the SAM Drive must be th
33. ditional PE grounding requirements AC Supply with Grounded Neutral A Operating a PAM with SAM system from an ungrounded AC Supply is prohibited AC Supply system grounding is a crucial consideration The AC Supply must have a grounded neutral see Figure 3 PAM with SAM system p1 4 I L2 Feeding 1 section SAM L3 supply I I I Sag014 a Cdr Figure 3 Supply with a Grounded Neutral If a three phase 4 wire grounded neutral AC Supply is not available an isolation transformer with Wye connected secondary must be used see Figure 46 The secondary neutral star point must be solidly connected to protective earth ground in accordance with applicable regulations For additional information on AC Supply grounding refer to IEC 664 1 1992 10 Table B2 Three phase four wire systems with earthed neutral PAM with SAM System Users Handbook Page 8 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING System Cabinet and Machine 1 All SAM Drives and SAM Supplies must be connected to PE ground using the designated PE terminal on each unit see Figure 4 The 24 VDC supply negative side must be connected to PE ground The PE conductor in each motor winding cable must be connected to PE ground in the cabinet and to a PE grounding screw at the motor Motor ca
34. ective Functions er inputs User outputs X31 X32 Supply The negative rail of me 24 VDC Supply must be grounded 24 VDC 1 Machine Control PC PLC 175 E 1 SAM Supply PAM Full System SAG018_b CDR Figure 48 24 VDC Power Distribution ACC recommends not removing 24 VDC power during or immediately following a controlled or uncontrolled machine stop because valuable diagnostic information retained by the PAM Sam Drive and SAM Supply is lost with the removal of 24 VDC power PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 55
35. for motors with Integral Mating Connectors PAM with SAM System Users Handbook Page 28 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE to PE bar Sah082 b cdr Figure 22 Plug fitted Motor Winding Cable Assembly Interfacing Standard Resolvers General Information This section includes instructions and wiring diagrams specific to servomotor families that were offered together with the PAM and SAM System in the beginning of 1999 namely the AC Servomotors and the Bautz motors For interfacing other motors the information in this section may be useful but not completely applicable Interfacing Servomotor types with C33 type Terminal Boxes Figure 23 shows the resolver cable configuration for all AC Servomotors that use a terminal box for motor winding connections C33 option This includes motor types AHD92 AHD115 AHD142 AHD190 AHR92 AHR115 AHR142 and AHR190 On the motor end the resolver connections are terminated in an eight 8 pin connector in a separate compartment of the terminal box To make the resolver connections on the motor end perform the following steps 1 Remove the cable gland outer metal sleeve see Figure 18 from the feedback cable 2 Insert the cable gland outer metal sleeve into the mating hole in the terminal box and secure it to the terminal box with the locking nut 3 Insert the rectangular connector of the feedback cable through
36. h devices are mounted must not be painted nor oxidized if Aluminum is used The contact area between all devices and the ground plane back panel must be as large as possible When SAM Drives and SAM Supplies are mounted on the back panel their cases become part of the ground plane Power cables must not cross the control area and control cables must not cross power area If not shielded power and the control cables must be minimum of 30 cm apart They must be as close as possible to the ground plane back panel in order to reduce the area of the loop they make with it Shields must be connected to the ground plane or directly to the device with 360 contact using a cable gland and strain relief for example The shield must not be twisted in pig tail fashion and connected to a terminal Page 12 PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION ENCLOSURE LAYOUT 7 Where possible place devices that generate a large quantity of heat toward the top of the enclosure Recommended Layout for a PAM with SAM System Figure 8 illustrates an implementation of the enclosure layout concept for a seven axes PAM with SAM system The mating connectors for the SAM Drive and SAM Supply are strategically located to simplify wiring and cable routing with this arrangement For large systems requiring more than one SAM Supply the DC Bus output and associated DC Bus distri
37. iagram for AC Servomotors with Terminal Boxes 33 sio n 26 Figure 20 Motor Windings Cable Configurations 27 Figure 21 Wiring Diagram for motors with Integral Mating Connectors 28 Figure 22 Plug fitted Motor Winding Cable 29 Figure 23 Resolver Feedback Interface for AC Servomotors with Terminal Boxes cm C 30 Figure 24 Resolver Feedback Interface for ACC amp Bautz Motors with Integral Connectors x oet ed eee ee Re diee Den fie ed 31 Figure 25 Wiring Diagram for Sine cosine 33 Figure 26 Wiring Diagram for Multi turn 34 Figure 27 Safety I O and 24 VDC Power Wiring Diagram 35 Figure 28 User Interface to Standard I O Configuration 36 Figure 29 User Interface to Expanded I O 37 Figure 30 DC Bus Motor Windings Thermal Protector and Brake Control CONMGCIONS ui ect teen ira orte bn Leti e 38 Figure 31 24 VDC Power Safety and Position Feedback Connectors The 14 28 and 50 amp models are wider than shown in this figure 39 Figure 32 EasyBus and User I O Connectors The 14 28 and 50 amp models are wider than shown in
38. ing Diagram for DC Bus Bar Assembly DC Bus Bar plugs are not keyed It is physically possible to insert any plug into any connector The user must verify by inspection that all connections to the DC Bus Bar are correct before applying power to the SAM Supply PAM with SAM System Users Handbook Page 50 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION DC Bus Low Power Applications For small systems i e a PA 30 and 1 to 3 SAM Drives a simple DC Bus can be constructed using daisy chained wiring from the SAM Supply to SAM Drives in combination with a simple earth ground rail The PE rail can be a simple Copper bar it does not have to be IP20 protected as it is solidly at earth potential Figure 44 illustrates the circuit schematically On 28 and 50 amp SAM Drives X11 is a terminal block 1 x11 Feeding Section 13 13 ssss oss us X5 On 80 amp models X1 1 E o terminal blocks grounding conductors from motor windings cables Sah068 c cdr Figure 44 DC Bus Arrangement for Small Systems PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 51 PART 2 SYSTEM DESIGN AND INTEGRATION FEEDING SECTION Feeding Section Basic Circuit The Feeding Section includes all components of the AC Supply circuit between the AC Supply and the SAM Supply Refer to Part 1 Selecting System Components and to Par
39. ly The SAM Supply requires 24 VDC power for its internal operation All required internal voltages are derived from the 24 VDC supply Refer to Part 1 Selecting System Components for 24 VDC power supply requirements Machine control PC PLC SAM Supply 1 14 24 VDC DC E intemal 1 Supply 2 Supply T DC 1 1 Safety chain Fatal Error relay is closed when no fatal error condition exists li 1 1 1 3 1 Over Voltage p 1 1 1 K Reset Input Wa 2 Pe 1 1 DC Bus Low d 1 1 1 lt 1 IN DBR Overload d pw M 1 1 1 1 SAH038 C CDR Figure 39 SAM Supply Status Safety and 24 VDC Supply Connections PAM with SAM System Users Handbook Page 46 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION Connector Locations and Pin Assignments PA xxx 30x x Bottom view DBR Overload Over Temp n c DC Bus Low Reset In Fatal Error Fatal Error Over Voltage X2 female optional GND Ext 24 VDC Ext o 211 Shunt IGBT ID Res 4 01
40. motor thermal protection input Status B7 from initiating a Stop action Thermal modeling of the axis motor by the SAM Drive operating software is the primary motor overload protection mechanism The thermal protector mounted in the motor provides secondary protection in the event that the thermal model is incorrect due to environmental factors such as heavy accumulation of dust on the motor high ambient temperature poor air circulation etc Brake Control An external 24 VDC source is required for powering a motor mounted brake In some applications additional user interlocks are inserted in the brake control circuit The brake control connector X14 and associated wiring are options that are not present in every configuration Interfacing Servomotor types with C33 type Terminal Boxes Figure 19 is applicable for interfacing to all AC Servomotors that use a terminal box for motor winding connections C33 option This includes motor types AHD92 AHD115 AHD142 AHD190 AHR92 AHR1 15 AHR142 and AHR190 Two motor windings cable configurations see Figure 20 are used depending on the SAM Drive model The wire colors shown in Figure 19 are for motor windings cables that are supplied together with the PAM and SAM System The cable gland on the motor end is easily removable when necessary to pull cables through conduit or bulkheads For safety compliance with EMC regulations and satisfactory performance it is imperative that SAM D
41. p Models PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 41 PART 2 SYSTEM DESIGN AND INTEGRATION SAM SuPPLY 48 gt 21 co A I g ES 5 e e Lk Y Y Y Y 2 gt lt 281 lt gt y 2 122 2 X1 X5 440 gt E PSU2 002 dsf Figure 34 Dimensions for SAM Supply 80 amp Models AC Supply Input Figure 35 illustrates three phase AC Supply connections to a SAM Supply The AC Supply voltage applied to a SAM Supply must meet the following requirements 1 The voltage must be within the limits specified for the SAM Supply model see Part 1 Selecting System Components 2 The AC Supply must have a grounded neutral see Protective Earth Grounding Requirements on page 8 3 The Feeding Section must provide the necessary short circuit and over current protections i e fuses or circuit breaker 4 Necessary safety and interlocks must be built into the AC Supply input circuit see Part 3 Safety and Protective Functions A Operating a PAM with SAM system from an ungrounded AC Supply is prohibited PAM with SAM System Users Handbook Page 42 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM SuPPLY Section 13 1 X5 On 80 amp models X1
42. ple SAM Supplies the DC Bus for each SAM Supply must remain totally isolated from the DC Busses of all other SAM Supplies High DC Bus voltage ranging from 550 to 800 at high power level is present at the SAM Supply and on the DC Bus This high voltage is stored in large capacitors which retain A the high voltage after the AC Supply is switched off Wait 60 seconds after removing AC Supply before touching any component carrying DC Bus voltage DC Bus Bar Assembly General This paragraph provides installation and interfacing instructions for the PAM and SAM System Bus Bar assembly Installation E m EIE ie _ 5 BE LESSER I JHB ele e le ULLLLLBE UAE GE Eos Figure 42 DC Bus bar outlines Wiring Figure 43 shows the wiring diagram for the DC Bus Bar assembly Additional PE Ground nodes are provided on the DC Bus Bar assembly for the PE ground conductors of motor winding cables PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 49 PART 2 SYSTEM DESIGN AND INTEGRATION DC Bus L1 2 3 PE EMC SAM PA Supply Filter DC bus t bar PE PSU1_005 doc D B Resistor Motor Motor Figure 43 Wir
43. r W V U Temp ctrl Brake SAHO062 b Cdr motor side connector pin arrangement is the same when looking from the crimp side of the mating plug feedback cable Figure 23 Resolver Feedback Interface for AC Servomotors with Terminal Boxes PAM with SAM System Users Handbook Page 30 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Interfacing Servomotor types with Integral Mating Connectors For interfacing Servomotor types with integral mating connectors motor types AHD55 amp AHD70 and M254 amp M506 simply connect the resolver feedback cable to its mating connectors on the motor and SAM Drive as illustrated in Figure 24 ID 7 as seen from the crimp side of the mating plug Shield connected to SAM drive case via copper banding connector shell and mounting screw Shield connected ed to motor case via I cable gland and 1 X24 connector shell 5 m Analog input Resolver J 04 3 N Green 2 19 Sin a2 D m Yellow m Sam Sin a1 Pink m WI Cos a2 Als Gray t 1 B m om 2m U Gen at White 2 CET cr MR SAHO063 b cdr
44. readed into the captive nuts on the SAM Drive and tightened because they serve to ground the shield at the SAM Drive end The shield must be earthed grounded at both ends High voltage may be present on A the shield if either end is left ungrounded Motor earth Protective earth rail Cable braket grounded through attaching screw machine structure pd animes E 9772 Green amp Yellow 1 x12 1 Black 1 11 Em ist 2 Driver 4 Black 3 dc cb d EAST b X13 Yellow 1 5377 Temperature xe B Gron 3 ense Thermal protector H m interface Braun eee White X14 d 1 5 control 1 option Fecdback Connector 4 shell C UU rm 1 Pp Cable T E amp bracket 1 Y ri Driver as seen from the 2 mI 1 crimp side of the C mating plug Brake 1 1 User interlocks 24 VDC Supply SAHO073 b Cdr Figure 21 Wiring Diagram
45. ricate their own motor winding cables should refer to Part 1 Selecting System Components which provides some recommendations regarding cable and mating plug selection PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 25 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE 9 4 Protective earth rail Cable braket Motor earth grounded through machine structure D d r lt lt D ID ini Green amp Yellow X12 Black 1 U ram Black 2 V IGBT Driver Black 3 IW o 1X13 T K1 n Yellow 2 1 o e Temperature l K2 Green 3 Freie Thermal protector Or cm interface Ix Braun l White X14 2 SN re 1 5 Brake a control option Feedback Cable gland 124 C Terminal box Cable m Dri i amp bracket Ta iia A Brake 1 2 User SE e E NES interlocks 24 VDC aA Feedback Supply connector 2 SAH055_b Cdr Motor win
46. rive to motor wiring be exactly as illustrated in Figure 19 PAM with SAM System Users Handbook Page 24 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE gt gt Please note and observe the following instructions and precautions when performing SAM Drive to motor wiring 1 On the motor flange end there should be a large area of metallic contact bare metal where the motor s mounting face contacts the machine 2 The motor end of the motor windings cable shields must be properly terminated in a cable gland and the cable gland must make good metallic contact with the terminal box Figure 18 shows correct preparation of the cable shields for termination in a cable gland 3 Onthe SAM Drive end the screws that secure the cable bracket and in some cases connector X12 to the SAM Drive must be threaded into the captive nuts on the SAM Drive and tightened because they serve to ground the shield at the SAM Drive end Outer metal Inner plastic Outer nut sleeve sleeve EMCO05 B cdr Figure 18 Shields Termination in Cable Gland There must be metallic contact between the cable shield and cable gland around the whole circumference of the shield Pigtails degrade the high frequency noise suppression considerably and are not permitted The shield must be earthed grounded at both ends High voltage may be present on the shield if either end is left ungrounded Machine builders who prefer to fab
47. serve primarily to neutralize the electrical charge that develops in the shields and metal cases enclosing system components The currents flowing in functional earth grounds are high frequency therefore conductors with a large surface area such as flat braided cable must be used for making high quality low impedance functional earth ground connections In this manual functional earth ground connections are indicated by the following symbol eI Figure 2 Symbol for Functional Earth Ground Functional earth grounding is not simply connecting a wire to ground Since perturbations are high frequency current flow is concentrated at the outside surface of the conductor Therefore to have a good functional earth ground connection a conductor with a large surface area such as flat braided cable must be used PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 7 PART 2 SYSTEM DESIGN AND INTEGRATION GROUNDING AND SHIELDING Protective Earth Grounding Requirements General This section describes the protective earth PE grounding requirements for a PAM with SAM system Local national and international regulations may specify additional PE grounding requirements These regulations also specify other aspects of protective earth grounds including conductor cross section and color connection means at the device and manner of connecting to the earth PAM with SAM system users must be aware of and comply with any ad
48. t 3 Safety and Protective Functions for details on sizing and selecting Feeding Section components The AC Supply to a PAM with SAM system must have a grounded neutral Operating a A PAM with SAM system from an ungrounded AC Supply is prohibited Installing an EMC Line Filter When installing an EMC filter refer to Rules for Placement of EMC Line Filter on page 14 The connection method for making load and line side connections is via wire leads or terminal blocks depending on the model Table 1 lists the connection method and conductor cross section for each model Refer to Figure 45 for EMC filter dimensions The EMC filter relies on capacitance between AC Supply conductors and functional earth Therefore the EMC line filter must have metal to metal contact with the ground plane back panel over the largest possible area each EMC filter must be taken into account see Table 1 current rating leakage Line side Load side 40 C 50 C current connections connections 9032 011 149 FN 258 30 07 36 30 Arus Terminals Wires AWG 10 If a Ground Fault Interrupter is used the Feeding Section The leakage current for 1 10 mm 5 37 9032 011 150 FN 258 75 34 90 75 Arus Terminals Terminals 10 25 mm 10 25 Table 1 EMC Filter Information PAM with SAM System Users Handbook Page 52 P n 9031 011 982 October 6 2000 PART 2 SYSTEM DESIGN AND INTEGRATION FEEDING SECTION p n 9032 011 149 p
49. the SAM Drive model SAM Drive models SAM DA 400 E incorporate the standard User I O configuration and SAM DA 400 F models have the expanded User I O configuration All user inputs and outputs are isolated from the internal SAM Drive electronics and share common power and ground return lines LED indicators located on the SAM Drive front panel display the state of each input output Refer to Part 5 SAM Drive Technical Information for user input and output signal specifications PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 35 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE Standard User Configuration option Figure 28 illustrates a typical interface to the standard configuration For all signals except USER FAST IN 1 the user connection may be made to either connector X31 or X32 Signals applied to USER FAST IN 1 should be high quality clean signals with sharp rising and falling edges no bounce and no ringing They require shielded connections and can be thus connected only to X32 D sub type connector X32 User OUT 119 User IN 1 8 N C User IN 2 N C 5 GND ext 3 Sensor User fast IN 1 a GND ext 1 2 X 24 VDC ext C User OUT 1 4 NL User IN 3 gt __User IN 2
50. the cable gland outer metal sleeve and mate it with the resolver feedback connector Insert the cable gland inner plastic sleeve into the cable gland outer sleeve For satisfactory performance and compliance with EMC regulations it is imperative that the feedback cable shield is terminated as illustrated in Figure 18 There must be metallic contact between the cable shield and cable gland around the whole circumference of the shield Pigtails degrade the high frequency noise suppression considerably and are not permitted PAM with SAM System Users Handbook P n 9031 011 982 October 6 2000 Page 29 PART 2 SYSTEM DESIGN AND INTEGRATION SAM DRIVE 5 Tighten cable gland outer nut 6 Onthe SAM Drive end plug the mating connector into X24 Cable gland Shield connected to SAM drive case via copper banding connector shell and mounting screw po n Terminal Shield connected box to terminal box X24 via cable gland 5 p Uk Analog input Resolver 4 2 Uat 3 Pm Sin a2 Yellow LU Sin at 4 17 t 2 N 3 G 1 6 1 m Y Cos at pa m Brown LZ U Gen at 2 White 1 U Gen a2 0 5 terminal box Resolver Feedback connecto
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