I eeMOTION UMC HE AFETY INFORMATION DANGER HIGH VOLTAGE Several of the product's components are under high voltage and could constitute a serious safety risk, Do not touch excosed connections with the power supply connected. Disconnect power supply and wait § minutes before accessing internal components. Only technically qualified personnel should install this equipment after reading and understanding this instruction manual. The user should ensure that the installation complies with current safety regulations. With effect from purchase date, the product is covered by the UMC S.1.). guarantee and subject to its general conditions. Such guarantee becomes invalid in the case of damage caused by negligence, misuse or incorrect installation. 1 MINIBI Stand AloneUMC HEEB) eoirro. This manual contains all information required to enable correct use of the product. Its use Is intended for technically qualified personnel with appropriate knowledge of the management control technology employed as well as sufiicient familiarity with the generai concepts of automation safety. To ensure a clear and easy understanding of the manual, it does not cover every single programming particular and cannot consider ail of the products possible types of ‘application or operating modes. Therefore, for specific enquiries please contact your supplier, This manual makes use of special terms to highlight essential inforrnation requiring particular attention. These terms have a twofold purpose; firstly fo guarantee mojor safety in the workplace and secondly to prevent the occurrence of damage to the system. The following terms are used: DANGER Paragraphs are labelled in this manner whenever serious safety risks exist fo personnel should the safety rules not be respected. carefully followed if camage to the product is to be » WARNING This term ernphasises important instructions that should be avoided The user must preserve the manual for further consultation and can annotate the configuration of the controller in the last page of the manual. Revision Date f File nome. [June 1998, Thnbsaeng.doc The manufacturer reserves the right to modify without notice the following manual andior product specifications whilst accepting no responsibility resulting from its incorrect use. With effect from purchase date, the product is covered by the UMC S.r.. guarantee and subject fo lis general conditions. Such guarantee becomes invalid in the case of damage coused by negligence, misuse or incorrect installation. MINIBI Stand Alone 2UMC HE) eSiieoe INDEX 1 (GENERAL CHARACTERISTICS 1) Models. .2) Electrical .3) Calibrations... 4) Control Inputs and Outputs. 1. 1 1 1 6 2) INSTALLATION 2.1) Witing standards... 2.2) Power Supply dimensioning. 2.3) Mechanical ........... 2.4) Wiring Examples... 3) STARTING AND ADJUSTING 3.1) Description ... 3.2) Adjusting Preset 3.3) Initial start-up. 3.4) Test Points... 4) DIAGNOSTIC 4,1) Leds .. 4,2) Fault Finding .. 5) OPTION CIRCUIT DESCRIPTION 5.1) ETT Option Board .. APPEND... 3 MINIBI Stand Alone:UMC HE) Corea 1) GENERAL 1.1) MODELS The MINIBI series is a line of four-quadrant converlers and accessories, available in wo different current levels, specially designed for driving smal DC motors within the range 0.2 to 1kW. \With MOSFET output stage driven by a 20 KHz PWM signal, the converter is reliable and can be feadly inserted into any system. The range of products of the MINIBI seties includes a version of the converter in Eurocard 100 x 160mm format and single-oxis version; an isolation module for using the converter with DC motor voltages exceeding 75 Volts; 2 or 4-axs rack; option cards for implementing auxiliary functions. SINGLE-AXIS CONVERTER The converter is contained in a compact enclosure that allows a “stand alone” installation. It has an intemal focilty for isolation module and option cards, and can also house a power- supply module comprising bridge rectifier, capacitor bank and clamping circuit. EUROCARD FORMAT CONVERTER The converter can be installed in any Eurocard format rock. It requires a DC supply for the Power section and 24Vcc for the isolated operating voltages. It can accept the isolation Module and options cards. Please refer to the specific manual for the installation of the single-axis convertor. ISOLATION MODULE It allows the converter to be used with DC Bus voltages exceeding 75 Volt (motor terninal voltages exceeding 70 Vec) thus guaranteeing the isolation spectications requested by the Low Voltage Directives. i DS Allow the folowing functions to be impiemented on the converter. © Ramp/t ti rt Allows separate adjustment of motor acceleration and deceleration time and houses the circuit offering protection in the case of absence of the feedback control signal from the tachogeneraior. © Rams bs cord Allows separate adjustment of motor acceleration and deceleration time and houses the circuit that converts the signals emitted by the encoder info a signal proportional to the speed (itis useful if an encoder is alieady used on the motor in order to control the postion, ‘thus avoiding the need for a tachogenerator). MINIBI Stand Alone 4UMC HS) CSieoe 2 OR 4-AXIS RACK The MINIBI series dedicated racks allow easy installation of 2, 3 or 4 axes at a very reasonable ice since they notabyy reduce wing and power-supply costs, Each rack comes complete with rectifier, Capacitor bank and clamping circuit. They require a three-phase input voltage for the power section, 24 Vec operating voltage and an externally- mounted clamp resistor. They are fied with fan in order to allow delivery of rated current to all ‘axes up to an ambient temperature of 40°C, Accessories are also availabe for the MINIBI series convertors including power transformers nd inductors to be placed in series at the motor if required. MODEL Motor DC supply voltage | Current rating at 40°C of Peak current }ambient Temperature (max. 2 seconds) (see note) MNIBI 8/16 20 - 110V. BA 168 ‘MNIBI 5/10 20 - 110V BA TOA Notes: ‘© Output current rating can be set between 0 and the rated value. ‘With ambient temperature exceeding 40°C or without forced ventilation, the values of Current delivered by the converter are reduced. MINIBI 8/16 always requires forced ventilation. 6 MINIBI Stand AloneUMC HE |) contro. 1.2) ELECTRICAL CHARACTERISTIC © Supply voltage: altemating direct as * Supply voltage of 2/4-axisrack —_altemating * Operating voltage... + Speed SET POINT... ‘= Auxiliary power supply outputs... © DRIVE OK output... * Temperature drift of eror amplifier... * Peak voltage of tachogenerator... '* Adjustment range with tachogenerator. © Adjustment range with armature feedback. ‘+ Enable signal. * Extemal clamping resistor for single-anis converter ....... © Operating temperature... * Storage temperature, © Humidity... © SaFeQUAS..ssssten * Degree of protection ‘Single axis converter. 2/4-axis rack MINIBI Stand Alone é 20 - 85Vac three phase 30 -120Vec 20 - 85Vac three phase 24Vee +/- 10% + 10V, impedance 10« +£18V mA max conlact 10W 100Vmax. 0.54 max. uve +65 1 - 5000 rom 200 - 3000 rpm 24V (active at high logic level) ohm, 100W 0... + 40°C -2B.ut 70°C 80% without condensation ~ Heatsink over temperature 60°C = undervottage 30VDC -overvoltage 1 80VDC min. = CLAMP intervention 165VDC max. - overcurrent 29, - Tachogenerator failure 1P20 1P20UMCHEM BE 1.3) CALIBRATION COMPONENTS Potentiometers can be used to adjust the end scale of maximum speed, the derivative action of the PID present in the circuit, reduction of any input speed reference signal offset, Proportional action of PID. = 5 OF Sf F | | + | | Adjustable parameter Description Dynamic gain of Multum potentiometer (GAIN). PID filter Allows motor response to be acapted fo suit the fequirements of the system Clearing speed reference Multitum potentiometer (OFFSEN. signal lows the elimination of any speed reference signal offset due to slow rotation of the clive shaft with zero input reference, Derivative action Multi-tum potentiometer (DERIV) Increase the dervative action of the PID filter with increase or decrease of the response. a MINIBI Stand AloneUMC HEE Maximum speed Multi-turn potentiometer (SPEED). Allows adiusiment of max. motor speed (approximately between -20% and +20% of speed end scale value). Please refer to paragraph 2.6. for the setting of motor maximum speed of rotation CONTROL Accel/decel ramps Mutt-tum potentiometer (RAMP). ‘Allows the value of the acceleration and ‘deceleration ramp to be adjusted between 0 and 8 seconds SIGNAL LEDS FITIED TO CONVERTER Yellow LED POWER If lit incicates that converter is powered up. Green LED Dr. OK Indicates the state of the converter. The LED remains it whist converter is operating normaly. The intervention of the converters intemal protections causes the LED fo go out. Red LEDI xt Indicates the intervention of the current limiter circuit. The lighting up of the Red LED signals that the set time limit for supplying peak current has been exceeded. When the LED is lt, the converter no longer supplies the motor with peak current, but the set tated current, Red LED TACHO BREAK Indicates the intervention of the Tacho Breok protection circuit, Such protection is the ieversibie type and is signalled by the lighting up of the fed LED on the front panel, Red CLAMP LED Indicates the intervention of the clicult for the dissipation of clamping energy (CLAMP). MINIBI Stand Alone 6PROTECTION CIRCUITS UMC HES) Contos The MINIBI converter is fitted with a series of protections for safeguarding the motor and converter in case of malfunction or incorect connection. When a protection happens, the converter Is dsabled and the OK contact is opened, The GREEN LED on the front panel goes out. In this state the converter does not supply current, The protections are of two types: reversible and immeversible. Inthe cose of reversible protection the converter is automatically re-enabled as scon as the cause of the problem has been resolved. (nthe cose of irreversible protection the converter is not re-enabled, The power supply must be disconnected and the cause of the problem resolved, after which the power should be restored, Reversible protections: Undervoltage intervenes when supply-vollage value on the bus is below 20V. Temperature [overheat intervenes when the heatsink temperature exceeds orc intemal operating voltages intervenes wnen supply voliages for ihe electionic cliculty generated by the intemal DC/DC converter are absent or of an inconect level. Whilst the intervention of such protections will disable the converter, an extemal signal of this fact is not given. reversible protections: Overvoliage intervenes when the supply-voliage value on the bus (rectified and filtered) exceeds allowable peak of 180V. Tachogenerator Failure intervenes in case of jachogenerator falure. intervenes in Case of shot circuit of the motor cables. Power Siage Failure 9 MINIBI Stand AloneUMCHE CONTROL 1.4) CONTROL INPUTS AND OUTPUTS Signal In/Out [Function ‘Connection | A in |Phose A of encoder Conn. [1 A\ In | Phase A\ of encoder 2 8 in | Phase B of encoder 3 B\ in _] Phose B\ of encoder 4 z in Phose Z of encoder 5 a in| Phose 2\ of encoder 6 - NC. 7 : N.C. 8 +2av out | + 24vec output 9 ow out___|24v.Commen 10 [Same ]OurTexiemat clamp reststor Cone [1 Clamp — Out _| External clamp resistor 2 +DC In | Power positive 3 -DC In| Power negative 4 R In| Power supply phase R 5 s In | Power supply phase $ 6 T tn | Power supply phase T 7 TERRA : Converter earthing point 8 In Power positive Conn. C }1 in Power negative 2 in Power negative 3 Out | Motor + se, short-circult protected 4 Out ___|Motor - side, short-circuit protected 5 Tachogenerator signal Conn, D 1 Tachogenerator signal 2 Earth reference signal 3 Speed reference signal input (inverting) 4 Speed reference signal input (non inverting) 5 =15VDC max, 10mA 6 +18VDC max. 10rmA 7 Conveter-status signal. Normally closed contact that 3.9 ‘opens when a protection intervenes ABIL in | Converter enable signal. 10 ‘OV = disables the delivery of current. The motor can rotate freely, 24V = enables the delivery of current. PROT In _| Disables the flow of curent to the motor when earthed. n The motor can rotate tree! +2ay in | 24V Operating power supply input 12 ov n___] 24V Operating power supply common 13 MINIBI Stand Alone 10UMC HEE 9!) Contes. POSITION OF THE CONNECTORS ON THE CONVERTER. VW MINIBI Stand AloneUMC HES 1!) Contras 2) INSTALLATION 2.1) Wiring standards Some considerations follow regarding the creation of connections to the MINIBI converter within an application. The considerations regard the following themes: @} Compliance with the Low Voltage Directives. b) Choice and size of cables. ¢)} Compliance with EMC Directives: + Earthing © Fiteting = Screening d) —_Exampies of connection. Compliance with the Low Voltage Directives The Low Voltage Directive 73/23/EEC and subsequent amendment 93/68/EEC requires that all electical and electronic materials destined for use at voltages between 50-1000 Vea and 75- 1800 Vee be manufactured in full compliance with safety standards, both in domestic and industrial environments. The drective refe's to the safety provisions stipulated in the Harmonised Standards issued by CENELEC, if they exist for such product; otherwise it refers to IEC international standards. The MINIBI drive conforms fo the Low Voltage Directive and more specifically compies with operating and safety requirements of the following reference standards: = PEN 60178 (a draft}; Electionic equipment for use in power installations. = CEI EN 60204-1 (|EC204-1}; Safety of machinery - Electrical equipment of machines, In order to respect these Directives without excessively penclising low-voltage applications, UMC 3... has inserted in his circuits an * Isolation module” that must be used with bus voltage exceding 75Vde Several precautions must be taken whist prepating the connections, In order to ensure correct wiring, please refer to the connection examples. MINIBI Stand Alone 12UMC HEEB |! Contaoe Cable sizes ‘Contiol/signal cables Signal cables should be of size 0.5 mm’ with PVC coating. ‘The analogue signal cables, (speed reference, tachogenerator signal) should be shielded twisted pals of size 0.5 mm . Power cables ‘ Motor egbles should be shielded and of size 1.5 mm’ for current ratings up to 5 amperes and 2.5. mm for higher current ratings. ing sho} retained in the screw terminal. 13 MINIBI Stand Alone:UMC HE) contro. ELECTROMAGNETIC COMPATIBILITY (EMC) The European Directive on Electromagnetic Compatibility (89/336/ EEC and subsequent ‘amendments 92/31/EEC and 93/68/EEC} requires every electic and/or electionic product to be manufactured in such a way that it wil not cause harmful electromagnetic interference and that it have adequate levels of immunity against such interference, Therefore, all electrical/electronic products must comply with EMC (Electromagnetic ompatibilty) legislation by noticeably limiting ernission levels of electromagnetic interference (EMI) and increasing immunity to the same, so as to ensure that in most situations both simple and more compiex electric/electronic systems will operate correctly. The following Intemational Standard deals specifically with this problem and must be respected by the drives IEC 1800-3 [CEI EN 61800-3] * EMC product standard including specific test methods", This standard replaces the exsting Generic Standards in all respects and defines EMC spectications for variable-speed electtic dives with DC and AC motors and effective supoly voltage of up to 1000\, it therefore defines test methods, requirements and limits regarding electiomagnetic emission and immunity for PDS (Power Drive Systems}, as well as giving a few Pointers on safety problems. When correctly installed, MINIB| comply with the basic requirements of the previous stanciards listed nere below. Emisson of electromagnetic interference: — ENS501 1/CISPR1 1; Emission of conducted and radiated RF interference. Group 1, Class A. —IEC 1000-3-2; Harmonic current emissions. —IEC 1000-3-3; Emission of voltage fluctuations and flicker in low-voltage supply systems. Immunity from electiomagnetic interference: —IEC 1000-4-2; Electrostatic discharge (ESD) immunity test. IEC 1000-4-3; Electromagnetic field immunity test (26-1000) MHz. —IEC 1000-4-4; Fast ransents/burst immunity test. =IEC 1000-4-5; Surges immunity test. In order fo effect a correct installation, its necessary to keep under control Radiated Interference, emanating from motor cable, signal cable and converter, and Conducted Interference that propagates through power cables and signal cables. In order to achieve this objective it is necessary to consider the following aspects of installation: * Correct earthing. + Input and output fitering of the interference source. '* Screening of sources and paris subject to interference. Since radiated energy is rapidly lost as it moves away, having good screening and maintaining a gap from sources greatly eliminate these probiems; ‘* Correct postioning of components inside the switchboard; by arranging power components in separate sections of the switchboard away from those reserved for switchgear, immunity to system interference increases; MINIBI Stand Alone 14UMC HB |) Conroe routes followed uld be kept well apart in order to avoi it nce. Bonding and earthing When usi it how to corr rect f ‘and MINIBI © Earthing of the power retum (connector b pin 8) shoud only be caried out if using the Converter without isolation module (operating voltages below 75 Vcc} ‘© Onno account should it be carried out if using the isolation module, since in this manner the isolation cleated between the signal and power sections would be lost. © The retum of the +24V operating power supply should always be led to common earth. The way in which earthing is carried out can have a significant effect on drive EMC performance. Infact, good earthing provides: * a suitable signal reference within the system, * a low-impedance conductor for fault cument, * reduced free-flowing of EMI. A ist follows of procedures for ensuring correct earthing. + Use wide metallic surfaces as ground conductors, * Use low-impedance connections. A rectangular conductor (copper bar or plait) has a lower high-frequency impedance than a circular conductor. Connections to bars with saps constructed from insulated plait (the insulation prevents common impedance) ‘cre preferable; any difficulty in finding such materials can be overcome by using a circular conductor of greater size (210mm?) or with more than one connection in parallel, * The signal and power cables must be led separately to a single suitably-sized earth terminal situated as close to the converters as possible (e.g. it may be a low- Inductance copper bar, size 3x10 mm, of sufficient length to house the connections), © Keep the earth connections as short as possible. * Do not limit oneself to just the mechanical contacts, but create safe electrical contacts. Cary out regular routine checks on system earthing, the reduction of, ® licorrectly bonded, MINIBI series converters make a most important contribution 15 MINIBI Stand AloneUMC HD) correo. Filtering When properly used, filers prevent the flow of EMI. The use of the isolation transformer, with screening between primary and secondary allows an intial important reduction of conducted EMI to be obtained, When instaling filters, the following points should be borne in mind: ) Filter require some time before being fully dischar it Interference filers should be placed in series at the three-phase or single-phase power supply, directly connected to converters and down-ine from the transformer. Their function is both that of isolating the device from any interference on the power lines, as well as preventing any EM generated by the device Iseff from spreading to the power line. The fiers are earth bonded at every fiter terminal; both these connections are earthed on the filter housing, MOTOR FILTERS The use of motor filters in suppiessing EMI has the purpose of preventing interference from passing fo the power lines in both directions, as well as drastically reducing ripple current due to PWM Spectiications of single-phase input filters. FERRITE CHOKES Ferrite chokes are used to reduce the flow of EMI through the power and/or signal cables, since their core provides excellent absorption of high frequency EMI In addition they are very effective against common mode EMI without adversely effecting signal quality They are generally of assistance in increasing product Immunity and reducing radiated ‘emissions but are of virtually no use in combating conducted emissions Ferrite chokes can be easly installed, since the foroid is divided in two symmetrical parts and. enclosed in a plastic housing. The type of choke to be used has to be decided according to the diameter of the cable it is destined for. They should be positioned as close as possible to the source of interference, taking particular care not to interupt the flaw of EMI through the screening, by bonding said screening pior to the ferite core. They are useful for ftering the brush discharge, by placing the choke close to the motor MINIBI Stand Alone 16UMC HEISE) CGntroe Screening The purpose of screening is to prevent any unwanted electromagnetic radiation from entering or leaving the system. Screening of high-frequency cables shoud be carried out on both sides The screen of the cables leading fo the motor should become a continuation of the converter ‘and motor housing without interuptions. In order to achieve good screening of our system, the following 1ules should be taken into consideration: © The ctive with its switching elements Is the main source of EMI and it should therefore be mounted inside o metal cabinet that acts as a scieen, * The motor housing itsetf is an effective EMI screen. + The metalic parts of system components (converter/switchboard/motor) should be connected in an efficient manner in oxder to form a single uninterupted screen. * The motor cable should be as short as possible. In order to be efficient, absolute bonding of the cable screen should be carried ou, /.e. 360°. 60°-BONDED SCREEN 7 MINIBI Stand AloneUMC HEE 8!) Contra. 2.2) POWER SUPPLY DIMENSIONING If placed before the thiee-phase voltage input connector, the fuses should be of the retarded type since elevated current peaks can occur when switching on that originate from the Charge of tne fitters intemal capacitors, The following diagram and formulas can help with the correct sizing of power supply. Before deciding on the power supply, it is Important that the rated output required by the motor be defined, Maximum allowable voltage levels on the secondary of the transformer: MINIBI 110. 30...85 Vac PRIMARY SECONDARY a —) =F ral SAFETY | FUSES Se i OF ‘ Me ft . ——) = ¥ Oo SIZING THE TRANSFORMER ‘One or more converters may be powered using a thiee-phase transformer. Obviously, if more than one converter is utilised, the sizing of the transformer will be canied out on the basis of the sum of required power of the Individual converters. The secondary windings of the transformer must be delta-connected, whilst the primary winding may be star-connected or detia- connected, ‘When sizing the transformer, take account of variations to mains power! and maximum speed of rotation of the motor. Total power of the transformer can be calculated using the following empiiical formula: Pn =1.JeVcaeinen Where: Pn iransformer minimum power Vea = Transformer secondary voltage In Motor rated current n lumber of motors operating at the same time It is to be remembered that transformer secondary voltage should be around Vea=Vec/1.41 The overload capacity factor of the transformers is around Ipiin = 2.5 For the more exacting tasks it may be necessary to Increase transformer power by 20%, MINIBI Stand Alone 18UMC HEEB) Conta. INDUCTORS In some coses it will be necessary to place an inductor between converter and motor in order to impreve system performance. The cases that most often call for an inductor are: * The motors used have an inductance of less than 2 mH; * The motors are subjected fo particularly exacting work cycles. By placing an inductor between converter and motor a “cleaner current is obtained thus reducing the noise that can cause overheating of the motor; The transformers and inductors necessary for a correct installation may be ordered dliectty from UMC s.r. 9 MINIBI Sand Alone:UMC HEIN 9!) Contec. 3) MECHANICAL INSTALLATION The converters require an environment free trom dust, liquids or gas. The absence of condensate must also be guaranteed. Converters should be mounted in such a way as to assist the loss of heat on the part of the heatsink. The assembly should carried out in such a way as to ensure the absence of vibration, Installation Of Clamp Resistor Inside The Switchboard Inthe presence of acceleration and deceleration cycles with high inertial ioads, connect the clamp resistor to the special connector, In this case it should be remembered that: 2: Under | in. ting or fail litions, the Le ean reach 200°C. I in rous bus voitages. For this reason, care should be taken as tof Mere! (6 the ituated on the rack. VENTILATION erating factors. The converters are protected from damage that would be caused i the heatsink were subjected to excessively high temperatures by way of a sensor that disables the supply of current until such time as the temperature retums to within the permitted range. MINIBI Stand Alone 20UMC HES 9) eStieon 2.4) WIRING AND DISPLACING EXAMPLES INDUCTOR OF FILTER_ 21 MINIBI Stand AloneUMC HEED! Contec. acsst0e ot} —- € NB: tormninal 8 of connector B should only be led to the earth bar if the converter is not fitled with isolation module (motor terminal voltage below 70 Volts). SIGNAL CONNECTOR MINIBI Connection of speed reference in differential mode. MINIBI Stand Alone 22UMC HEI Bi) Conrad Connection of speed reference in common mode EXTERNAL POWER-SUPPLY SIGNAL CONNECTOR +10V MINIBI ND JUMPER J} SHORTHED MINIBI Connection of speed reference for using converter as a current ampifier. 23 MINIBI_ Stand AloneUMC EEE 3) STARTING AND ADJUSTING CIRCUIT DESCRIPTION Its possible to Control either speed or current of MINEBI series converters. In addition, the speed input can be driven in common mode or differential mode in the presence of the optional isolation module. We would remind you that the isolation modue, situated on the speed reference signal coupled with the isolators situated on the Enable, Protection and Dr. OK commands, allows the converters live components to be completely isolated from the application. Therefore, in the case of converter power supplies exceeding 75Vcc or SOVCA, the product complies with the safety measures requested by the Low Voltage Directives. The MINIBI series converters exercise control using two feedback circuits: the speed loop (A2) ‘and current loop (A3). The speed reference signal is supplied to the converter from an extemal NC, PLC or potential divider. The signal is compared (Al) with the sgnal emitted by the tachogenerator, modified bby RT resisior, or in its absence win the armature feedback control signal (A4) before being sent to the speed-error amplifier (A2). Through the use of multtum potentiometers it is possible to modify the Ortset, Maxmum speed, Detivative and Gain parameters. The A2 output is the current signal, The value of this signal (between +/-10 Volt) is proportional to the value of the cunent supplied to the motor. At +10 Volt the converter is delivering peak current, If wishing to use the converter as a current ampiffier from the speed reference input (le. in order to control torque of the motor father than the speed of same), it will be necessary to short Jumper J1; in this manner, with a constant input signal there will still be constant torque regardless of the motors speed of rotation, The Output signal of ampifier A2 is compared with the current limiter circuit in order to keep it within any limit that may nave been set. If the peak value of the cument is requested for a pertod exceeding 2 seconds, the circuit intervenes by reducing the value of the current to 50% of the current rating. If the red LED is lit, this is in fact confirmation as to the intervention of the current limiter clrcult, The current loop is closed by the ampifier of the current signal delivered to the motor (A5). The curent signal emitted by cmpifier Ad is used to generate the PWM signal (Pulse Wicth Modulation) that drives the power stage. The correct operation of the power stage is regulated by the protection circuits that intervene in case of short circuit or converter failure. The Intervention of the protection cicuits is signalled by the switching off of the green LED and the opening of the converler status OK contact. MINIBI Stand Alone 24UMC HEED) Contra 25 MINIBI Stand AloneUMC HEE 3.2) ADJUSTING PRESETS * Tachogenerator feedback with a 51.1K2 resistor fitted allowing a speed of +3000 revolutions with 1 OV reference having a 10V/1000 revolutions tachagenerator, ‘+ The continuously available current is the rated one. Any different converter configurations should only be set following careful reading of the instruction manual. MINIBI Stand Alone 26UMC HB)! estrron SUMMARY OF JUMPERS REF. | Details Specifications Notes A 1C6 Isolation module The Isolation module must be fitted with bus voltages exceeding 75Vec 8 JI Jumper to be connected if wishing to use | Not usually fitted the converter as a cunent ampifier. Cc RT Resistors for the configuration of RT fitted RA tachogenerator (RT + RA}and armature | RA not fit feedback (RA only} values Sos feaoning paagioh c RX Resistors for configuing the values of See following paragraph RN fated current and operating lime of the Curent control circuit, c RY Resistors for configuing peak-current Do not touch. delivery time Please contact UMC s.r. for further information D 3 Feedback selection jumper In order to position the x jumper correctly, keep the Card pointing in the sarne n Tachogenerator feedback cheotion oh the faite on| n the preceding page. ‘Amature feedback n n x E J2 Jumper allowing the enabling or disabling | Normally fited between of the acceleration/deceleration ramps. | pins 1-2. (with option card ony). Ramps disabled. F Option Conn | Connector for housing option cards. See Options 6 R42 Resisiors for configuring vottage level at [Do not touch. R43 which the converter must operate See folowing paragraph for further information H Screw to remove and replace with a threaded spacer when fiting an option ‘card. 27 MINIBI Stand AloneUMC HERES! Contra. ADJUSTMENT OF THE MAXIMUM SPEED OBTAINABLE FROM THE CONVERTER-MOTOR SYSTEM. In order that the converter may drive the motor at the speed requested by the application, it is necessary that a signal arrive from the motor indicating the speed of rotation. In systems using permanent-magnet DC motors there are two possible ways of supplying the converter with this signal: * Fit the motor with a tachogenerator that supplies a signal proportional to the speed of rotaton of the motor. * Use the motor itsalf as a generator of this signal. Having adopted one of these two solutions so as fo generate the feedback signal, in order to allow the motor fo teach maximum speed it will be necessary to modify the speed reference signal (at value of +10V it will comespond to the maximum clockwise speed of the motor) whilst it will be possible to alter the maximum speed of the system (within a fange of +20%) using the SPEED potentiometer. In the presence of a good-quality tachogenerator, i.e. with reduced signal ripple and good linearity, the control obtainable is certainly more precise than the feedback that uses the amature of the motor as a source of the feedback signal. Obviously the cost of the ‘application will be increased by the expense of the tachogenerator itself. Details follow regarding ways of adapting the specifications of tachogenerator (kt = voltage Constant of tachogenerator) and motor ( Ke = voltage constant of motor) to suit converter. On the other hand, by usng the OFFSET adjusiment potentiometer it is possible to control the diift of motor speed. Drift is generally caused by interference from connection cables o: from ‘thermal dirits of the electronic components utiized. CONFIGURATION OF TACHOGENERATOR SIGNAL » 10 stort with mi val The converter is normally supplied with settings for tachogenerator feedback with voltage ‘constant value of 10V/1000RPM. If using a tachogenerator with different constant, the values of the RT configuration ressstors will need to be recalculated, whilst the configuration jumpers of the card must not be altered. * The RT resistor allows the tachogenerator chosen to be adapted to suit the converter. If the calculation resutts in a negative value, it will not be possible to obtain the desired speed without altering the specifications of the tachogenerator ( Kt ). MINIBI Stand Alone 28UMC HS 1) Contec Configuration of tachogenerator or armature feedback signal. The J3 jumper must be correctly positioned in order to choose between tachogenerator or armature feedback, The RT of RA resistors must be on. JUMPER POSTION Tachogenerator Be sure to adjust the tachogenerator settings correctly. Sizing the RT resistor The formula stated below should be used for sizing RT. RT(KQ) = Kt” 19 v «50 where Kt = Vottage constant of tachogenerator (V/1000 revolutions) Maximum motor speed (RPM) Analogue speed reference input signal (Volt), EXAMPLE : If the maximum desired speed is 2500 RPM and the tachogenerator specications are 10V/1000 1,.m., by introducing the data into the formula, an RT value of 40KQ is obtained nd therefore the custom card standard resistor wil have to be replaced accordingly. Speed requested 2500 RPM Kt tachogenerator 10 Vde/1 000% Speed reference signal 10 Vde 10*2500 _ 19 = 40a 10*50 Once a suitable value for the tachogenerator voltage constant has been obtained, it will be Possible to set the maximum speed of the system with more accuracy using the calibration ‘obtainable from the SPEED potentiometer and with the help of a rev counter. 29 MINIBI Stand AloneUMC HES BE) Contra Selecting the RA resistor The RA tesistor must only be fitted if armature feedback has been chosen hr DANGER: An err Id. Cause th with mc Ke*ntK RA(KQ) = “Vaso 10 dove Ke = Motor voltage constant (Volt/1 000 revolutions) nN = Maximum motor speed (RPM) V = Analogue speed reference input signal (Volt), K = constant supply voltage 30V K=0.26 supply voltage 60V K=0.145 supply voltage 110V kK = 0.08 Please contact UMC s.r.l. should the requested speed produce a negative value for the resistor to be fitted. Selecting current rating The RN and RX resistors are utlized to adjust the rated current output of the converter whilst operating. RN 5600. 1KQ. 15kQ 2.2KQ RX. 3.3KQ. 5.1KQ. 68KQ 8.2KQ model Rated current in Ampere MINIBI 5/10 25 3.5 45 "5.5 MINIBI 8/16 3.6 5.1 6.7 *8 “Factory setting ING: yf the rc rent: fe fe tion of the than the peak current of the drive. Setting the operating time of the current limiter The RY resistor must be used to adjust the operating time of the current limiter circult RN fied 5602 1Ka T5KQ 2.2KQ Time (sec) 05 T50KA T20KQ BIKA 6RKQ 1 270KQ 220KQ T8OKQ 120KQ 15 390KQ. 330KQ. 220KQ 180K 2 560KQ 470KQ 330KQ_ | 270KQ* RY RY RY ry *Factory setting MINIBI Stand Alone 30UMC HEEB |) Contec. Selecting the converter operating voltage The resistors R42 and R43 are used to adjust the converter voltage to around that of iis rated operating voltage, E.g. with a rated voltage of 70V the converter will be configured for 60V. They are normally configured by UMC 5.1.1. and therefore do not require alteration. MINIBI 30 VOLT 60 VOLT 110 VOLT OPERATING VOLIAGE RAD 39.2K 22.1K 121K R43 99.2K 22.1K 121K Lee Configuration of the Clamp operating voltage The clamp operating voltage (dissipation of clamping energy on the clamp resistor’ is preset by the manufacturer and should not be altered. 31 MINIBI Stand Alone:UMC HEEB i!) ESnteo. 3,3) INITIAL START-UP we i motor during the initial start-up phase. Checks on motor Before energizing: — Check the absence of short circuits between windings and the motor chassis. — Check that the motor and inductor are correctly connected. — Ensure that the motor brushes are correctly posttioned.- IGER: the OF OF | wired incorre the drive shoft at high. re¢ if me de Yr Checks on converter Canty out a visual check on the converter connections. If tachogenerator feedback is employed, itis necessary to check that the polarity of motor ‘and tachogenerator coincide since incorrect wiring could cause system failure. It should also be pointed out that if connecting the M+ terminal of the connector to the positive terminal of the motor, this wil make the drive shaft rotate clockwise (as seen from the front) with a positive speed reference signal. Itshould also be bome in mind that if wishing to obtain anticlockwise rctation of the diive shaft wih a positive speed reference signal, it will be necessary fo invert the connections of both motor and tachogenerator. Switching on the system q) Disconnect the signal terminal block. b) Supply power to converter, the PW LED should light up. The drive shaft should be able to tum freely. ¢) _ Disconnect power from converter and affer 10 seconds reconnect the signal terminal block: The speed reference signal should be set for low speed (<1). @) _ Enable the converter using the +24V enable signal. ‘The motor will turn slowly, ) _Inciease speed reference signal and observe the direction of rotation of the motor. f) If the motor tums in the opposite direction to that requested, disconnect the power supply and swap over both the motor cables and the tachogenerator cables In case of malfunction, please refer to the paragraph FAULT FINDING. MINBI Stand Alone 32UMC HEI 8) nro Adjustment using the potentiometers SPEED Potentiometer for maximum speed adjustment In the presence of motor feedback control signal by adjusting the potentiometer it is possible to set maximum speed value to between +/- 20% of the value reached. With the speed reference signal set for maximum speed ( + 10V }, adjust the potentiometer to give the motor the required speed. The speed is teduced by ‘uming the adjuster screw anticlockwise OFFSET Potentiometer for clearing reference signal ‘Any speed reference signal offsst will cause the crive shaff to tum slowy: the P5 potentiometer ‘allows this effect to be cancelled out. The calibration of the input ampifier is usually cared ‘out during final testing of the converter; however, it may be necessary to reset this parameter shoud an error be caused by the reference signal generator that needs to be eliminated. In this case one should: * check that generator is emitting the correct signal by disconnecting the signal teminal block and if necessary adjust generator offset; * connect signal to terminal block and enable converter; * with generator speed feference signal set for zero speed (OV), tum the OFFSET potentiometer until the drive shatt remains siationary. © if the stop option is present, this must be disabled before camying out any Offset adjustment. 33 MINIBI Stand AloneUMC HEE EI)! Contron DYNAMIC ADJUSTMENT OF THE CONVERTER The adjustment of dynamic behaviour allows the response of the converter-motor systern to be more fully adapted, To modify the dynamic behaviour of the system, the following components must be adjusted: DERIV Potentiometer - Reduces any overshoot and increases derivative action. GAIN Potentiometer - Increases motor slew rate, but at the same time makes its behaviour more "nervous". suc left just as they are. In order to reguiate your system, after having controled the operating parameters of the motor-converter system ond remembering that the inctease in the proportional action offers stability and the increase in the derivative action offers prompiness, with the load applied to the drive shaff, one can test system response on various positioning cycles. It should also be remembered that the agjustment Proportional + Detivative (PD) Is useful for processes that are characterised by notable inettio, but are not very sensitive fo the problems of Offset. \What is more, in the case of applications that are not particularly exacting, in order to optimise parameters, it wil be possible fo Increase the proportional gain parameter. uit yf iii if In the presence of applications with particular load or friction characteristics it s necessary to check the dynamic behaviour of the system using the signal originating from the techogenerator, thus enabling the converter-motor system fo be adapted to the paricular application. The following insttuments are required: A function generator A duattrace storage oscilloscope Before energizing the converter, position the probes of the oscilloscope and function generator in the following manner. Connect the speed reference signal (Vin+) io function generator output. * Connect the terminal Vin- to eatth by attaching a jumper to OV terminal. * Connect the probe of an oscilloscope to the tachogenerator signal ( Tacho +) and its earth to the earth signal ( 0 V). * Connect the second escilloscope probe to the | Mot signal (cuent supplied to the motor) present on the test point, situated behind the motor connector and close to the options Connector, and its earth to the earth signal (0 V) obtainable on the central terminal of the motor connector (please 1efer to the description in the paragraph Test Point). MINIBI Stand Alone: 34UMC HEE!) Contras Power up and enable the converter, send a Square-wave signal of amplitude 3VDC at 0.5 sneer f \ ignal He. Two waveforms will be visible on the oscilloscope screen as demonstrated by the figures that reveal the systern’s dynamic behaviour to be less than optimal (insufficient dynamic gain). Signal of current circulating in the motor Tum the Gain potentiometer clockwise in order to increase system gain, faking care fo avoid an excessive Increase In tne value of the noise ( R)) present on the motor current signal, Elevated gain would bing about a high level of noise in the cuntent circulating in the motor thus causing ‘overheating of the motor itself and the likely intervention of the current limiter circuit (ht). The presence of overshoot can be noted, indicating a poor derivative action, In order to eliminate the overshoot present on the tachogenerator signal it is in fact necessary to adjust the Deriv potentiometer, bearing in mind that the previous comments regarding the GAIN potentiometer are valid, An excessive derivative action wil cause an increase in motor noise wth subsequent loss in performance and system response. 35 MINIBI Stand AloneUMC HERES B! CSereo. 3.4) TEST POINT The most important parameters for checking the correct running of the converter are to be found on the connector designed to house the signals required for operating the optional cards. They should only be used by qualified personnel solely for the purpose of functional tests. Under no circumstances should these signals be used for the implementation of circuits or systems, Terminal Description Notes pin on? RIFT speed reference downline from input ampiier. ph 2cn7 RIF2 pin 3cn7 Motor voltage Motor terminal voltage pin 4en7 LIMIT signal normally in high logic state (+ T5V]; wil go to low when curent limiter circuit is triggered. pin Sony Tashogenerator | Signal emiied by tachogenerator pin 6cn7 -15V pin 7cn7 EARTH ‘Only use this Test Point as earth reference for Monitoring the signals described herewith pin 8cn7, IRREV. pin 9cn7 Motor current Current circulating in the moior pin 10 cn7, +15V pin 1 cné + 24v Supply voltage pin 2cn6 +15Vis Insulated supply voliage pin Sond INSULATED EARTH [Insulated power supply earth reference pin 40n6 ~15Vis Insulated supply voliage MINIBI Stand Alone 36UMC HIE 8 || Conteoe 4) DIAGNOSTIC 4.1) LEDS Red LED Ix? Indicates the infervention of the current limiter clout, The lighting up of the Red LED signals that the set time limit for supplying peak current has been exceeded, This is normally due to the system being subjected to particularly exacting work cycles as a resut of * frequent acceleration/deceleration: * changes in direction of rotation; * unit of insufficient size; * presence of inertia or friction in the system, either unforeseen or caused by fatigue. It shouid also be remembered that when the LED is lt, the converter no longer supplies the motor with peak current, but the set rated current in order to safeguard the motor itself. Yellow LED Power Indicates that converter is powered up. Green LED D.0K indicaies the siaie of the converter. The LED rernains lit whilst converter is operating normally. The triggering of the converter’ intemal protections causes the LED to go out and cutting of the power suppk Red LED iff, the red LED indicates a malfunction of the signal issued TACHO BREAK by the tachogenerator. The fault may be caused by: «absence of signal trom tachogenerator * failure of tachogenerator itself; «cables non connected properly or at all 37 MINIBI Stand AloneUMCHEI EE 4.2) FAULT FINDING PROBLEM MOTION CONTROL POSSIBLE CAUSE REMEDY The motor does non start when the converter is enabled ‘Two coses: © The GREEN LED is It, © The GREEN LED is off The Green LED is lit « Absence of speed reference signal. * Motor not connected. Check the presence of signal on terminal 5 of CONN. D. The Green LED is off The Enable signal is not connected. ‘Comect Enable signal (pin 10 CONN. D) at +15V The PROT signals earthed. Disconnect PROT signal from earth {pin 11 CONN, D). Short circuit on terminals. Check motor terminals for Possible short circult. Tipping of protections. The motor runs for just a short The intervention threshold of ‘Check value of RN. time, then stops. the curent limiter has been set incorrectly. Motor overload, Ensure that armature current Values are within those specified, The motor only turns over at | Absence of tachogenerator Check the presence of maximum speed. signal. tachogenerator signal. ‘Check the tachogenerator signals on terminals 1,2 CONN.D The tachogenerator cables —_| Swap over the tachogenerator have been Inverted, cables on the input connectors, The motor furs over slowly |The value set on the Reduce the signal, even with speed reference ‘at low level potentiometer (offset) is too high. The motor does not remain stationary when requested Incorrect calibration of potentiometer (offset ) Adjust potentiometer in order to remove converter speed offset. MINIBI Stand Alone 38UMC HEE | Conteoe 9) OPTION CIRCUIT DESCRIPTION 5.1) ETT OPTION CARD In low cost applications where notable precision is not required at low speed, this option may be installed in order to effect speed negative feedoack using an encoder instead of the tachogenerator. Such option may be installed on all converters of the MINIBI series. It has to be calibrated using a resistor that is fitted into special supports; the value of this resistor depends on the resolution of the encoder ullised and the maximum speed reauited (see Table 1), if calculating that the resistor size falls somewhat short of a standard value, use the next lowest one, It cso assumed that the reference signal to the converter is £10V. Encoder Frequency (Hz) | RZ (Ka) 4000 TOK 9000, 7.5K 10000 68K 12500. 5.6K 17500. 3.3K 22500 2.2K 35000 1K 50000 1200 Table 1 itis worth remembering that frequency of encoder signals is given by the following relation: Freq. (Hz) = P24 stories Example: If using @ 500 pulses/revolution encode and the maximum required speed is 3000 RPM, the encoder output frequency will be: Freq,(Hz) = 3000 * 500 60 =25000 Therefore, for interpolation RZ = 2KQ_: it is necessary to fit a 1.8KQ Using the speed ttimmer to be found on the converter it is therefore possible to obtain the maximum with accuracy. The encoder used may be line cfiver, TIL or push-pull type. A pail of jumpers inside the card { J! ) allow it to be selected, 39 MINIBI Stand AloneUMC HEEB BF) Cone In this case only two signals will be employed and it is therefore necessary to use inouts Aneg. and B neg. ( pin 2, pin 4). The encoder may be powered by an external power source. > Connector CN10 Signal Pin T A Pin 2 Aneg. Pin 3 B Pin 4 B neg. Pin 5. Z: Pin 6 Zneg. Pin 7 Ke Pin 8. NC. Pin? +24V Pin 10 Ov Table 2 List of signals for CNTO Ji FUNCTION pos. 2-3_| LINE DRIVER pos. 1-2 [OTHER ENCODERS NB: inputs Z and Z neg. (encoder zero pulse signal) are not managed by this option. MINBI Stand Alone 40UMC HEEB |) Conroe APPENDIX CONVERTER Model Serial number Notes MOTOR Model Serial number Notes motor Kiconstant [Stall torque No. revolutions [EMF Rated current MA Nm Rpm V.krpm A TACHOGENERATOR Model Serial number Ke ViKipm CALIBRATION EFFECTED Description | Specification Notes JT RANP—_ |Rarnps disabled. indicate the configuration chosen Ramps enabled. B Tachogenerator negaive feedback _| State if fited Ke Indicate tachogenerator values Kt Amature negative feedback RX Indicate its value Rr RKW RN 4) MINIBI Stand Alone