Download PAM & SAM System User's Manual

PAM & SAM
System User’s
Manual
Part 2 - System Design
and Integration
Ordering Number: 9032 011 982
Issue October 6, 2000
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
P/n 9032 011 982
Issue October 6, 2000
© 1995 - 2000
by ACC Motion SA
All rights reserved
PART 2 - SYSTEM DESIGN AND INTEGRATION
Page: 2
TABLE OF CONTENTS
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
TABLE OF CONTENTS
Table of Contents
Table of Contents....................................................................................................3
List of Figures .........................................................................................................5
List of Tables...........................................................................................................6
Grounding and Shielding ........................................................................................7
About Protective Earth and Functional Earth Grounds .......................................7
Protective Earth Grounding Requirements..........................................................8
Grounding for Electro-magnetic Compatibility.....................................................9
Enclosure Layout ..................................................................................................12
Concept for an Entire Machine Control System ................................................12
Rules for Enclosure Layout ...............................................................................12
Recommended Layout for a PAM with SAM System ........................................13
Rules for Placement of EMC Line Filter ............................................................14
Back Panel Layout.............................................................................................14
PAM ......................................................................................................................16
PAM Full System ...............................................................................................16
PAM-ISA ............................................................................................................18
PAM for Simatic Module ....................................................................................18
EasyBus................................................................................................................19
General ..............................................................................................................19
Installation..........................................................................................................19
SAM Drive.............................................................................................................20
Mounting a SAM Drive.......................................................................................20
Interfacing AC Servomotors ..............................................................................24
Interfacing Standard Resolvers .........................................................................29
Interfacing Sine-Cosine Encoders and Rulers ..................................................32
Interfacing Multi-turn Resolvers.........................................................................34
Safety I/O & 24 VDC Supply..............................................................................35
User I/O .............................................................................................................35
Connector Pin Assignment ................................................................................38
SAM Supply ..........................................................................................................41
AC Supply Input.................................................................................................42
DC Output..........................................................................................................43
External Dynamic Braking Resistor ...................................................................43
Safety, Status and 24 VDC Supply....................................................................45
Connector Locations and Pin Assignments.......................................................47
DC Bus..................................................................................................................49
General ..............................................................................................................49
DC Bus Bar Assembly .......................................................................................49
Low Power Applications ....................................................................................51
Feeding Section ....................................................................................................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 Circuit.......................................................................................................52
Installing an EMC Line Filter..............................................................................52
Interfacing a Transformer ..................................................................................53
24 VDC Supply .....................................................................................................55
Functions ...........................................................................................................55
24 VDC Power Distribution................................................................................55
Page: 4
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
LIST OF FIGURES
List of Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Symbols for Protective Earth Ground ......................................................7
Symbol for Functional Earth Ground........................................................7
AC Supply with a Grounded Neutral ........................................................8
Machine to System Enclosure PE Conductor ..........................................9
Mesh Earthing Network Using Building Structure..................................10
Mesh Earthing Network Using Conduits and Cable Trays.....................11
Enclosure Layout Concept.....................................................................12
Enclosure Layout for a Large System....................................................13
Recommended Spacing and Clearances for SAM Drives and Supplies
...............................................................................................................15
PAM Full System....................................................................................16
PAM Chassis Mounting Dimensions and Clearances ...........................17
EMI/RFI Requirements when Installing PAM Chassis...........................17
The PAM-ISA .........................................................................................18
PAM Modules for Simatic S5-115 (left), S5-135 and S5-155 (right) ......18
Dimensions for SAM Drive 7 amp Models .............................................21
Dimensions for SAM Drive 14 & 28 amp Models...................................22
Dimensions for SAM Drive 50 amp Models ...........................................23
Shields Termination in Cable Gland ......................................................25
Wiring Diagram for “AC Servomotors” with Terminal Boxes (“C33”
option) ....................................................................................................26
Motor Windings Cable Configurations ...................................................27
Wiring Diagram for motors with Integral Mating Connectors .................28
Plug-fitted Motor Winding Cable Assembly............................................29
Resolver Feedback Interface for AC Servomotors with Terminal Boxes
...............................................................................................................30
Resolver Feedback Interface for ACC & Bautz Motors with Integral
Connectors.............................................................................................31
Wiring Diagram for Sine-cosine Encoders .............................................33
Wiring Diagram for Multi-turn Resolvers ................................................34
Safety I/O and 24 VDC Power Wiring Diagram .....................................35
User Interface to Standard I/O Configuration ........................................36
User Interface to Expanded I/O Configuration.......................................37
DC Bus, Motor Windings, Thermal Protector and Brake Control
Connectors.............................................................................................38
24 VDC Power, Safety and Position Feedback Connectors (The 14, 28
and 50 amp models are wider than shown in this figure) ......................39
EasyBus and User I/O Connectors (The 14, 28 and 50 amp models are
wider than shown in this figure) .............................................................40
Dimensions for SAM Supply 30 amp Models ........................................41
Dimensions for SAM Supply 80 amp Models ........................................42
AC Supply and DC Bus Connections to SAM Supply............................43
Dynamic Braking Resistors Dimensions (all dimensions in mm)...........44
Dynamic Braking Resistor Cable Assembly...........................................45
DB Resistor Circuit Wiring .....................................................................45
SAM Supply Status, Safety and 24 VDC Supply Connections ..............46
Connector Locations and Pin Assignments for 30 amp SAM Supply
Models (X2 connector is available only on SAM-PA-xxx-30-E type) .....47
Connector Locations and Pin Assignments for 80 amp SAM Supply
Models....................................................................................................48
DC Bus bar outlines ...............................................................................49
Page: 5
PART 2 - SYSTEM DESIGN AND INTEGRATION
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
LIST OF TABLES
Wiring Diagram for DC Bus Bar Assembly ............................................50
DC Bus Arrangement for Small Systems...............................................51
EMC Filter Dimensions ..........................................................................53
Isolation Transformer Configurations.....................................................54
Auto-transformation Wiring Configuration..............................................54
24 VDC Power Distribution ....................................................................55
List of Tables
Table 1
Page: 6
EMC Filter Information ...........................................................................52
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:
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
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 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:
Figure 2
STOP
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 additional PE grounding
requirements.
AC Supply with Grounded Neutral
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).
AC supply
PAM with SAM system
L1
L2
L3
Feeding
section
SAM
supply
PE
PE
Figure 3
Sag014_a.Cdr
AC 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.
i
Page: 8
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
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).
2. The 24 VDC supply (negative side) must be connected to PE ground.
3. 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 cable
PE Conductor
2
(min. 10 mm )
Cabinet
SAM-P
Machine
SAM-D
Motor
L
L
PE
Bus Bar
DC Bus Bar PE
Motor
LOAD
EMC Filter
LINE
From Main Supply
Figure 4
SAG013_A.CDR
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 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
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.
i
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.
i
Refer also to IEC 1000-5-2 “Installation and Mitigation Guidelines, Earthing and
Cabling”. This technical report provides valuable information.
Control cabinet
Machine structure
Mesched earthing network
Figure 5
Page: 10
EMC003_b.CDR
Mesh Earthing Network Using Building Structure
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
Control
cabinet
GROUNDING AND SHIELDING
Arial conduits
& cable trays
Machine
structure
EMC004_b.CDR
Figure 6
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Mesh Earthing Network Using Conduits and Cable Trays
Page: 11
PART 2 - SYSTEM DESIGN AND INTEGRATION
ENCLOSURE LAYOUT
Enclosure Layout
Concept for an Entire Machine Control System
Power
High Frequency
Control
Low Frequency
Control
High Frequency
LF
HF
Figure 7
Control
Power
Low Frequency
Power
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.
EMC001_b.cdr
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).
2. To be an effective ground plane, the back panel on which devices are mounted
must not be painted (nor oxidized if Aluminum is used).
3. 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.
4. Power cables must not cross the control area and control cables must not cross
power area.
5. 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.
6. 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 sevenaxes 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 distribution network) for each SAM Supply must remain
electrically isolated from the DC Bus of all other SAM Supplies in the system.
DBR
PLC
SAM
Drive
SAM
Drive
SAM
Drive
SAM
Drive
Aux.
Supply
Low frequency
low power
machine controls
EMC Filter
DC Bus bar
SAM
Supply
SAM
Drive
SAM
Drive
DC Bus bar
Fuses
Psg017_b.Cdr
Figure 8
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Enclosure Layout for a Large System
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). 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
ENCLOSURE LAYOUT
Other equipment
1.0 mm
60 mm
Cable Conduit
W
SocapelSAM
L
SocapelSAM
L
SocapelSAM
L
L
SocapelSAM
L
SocapelSAM
L
DC-Bus bar
100 mm
1.0 mm
W
SocapelSAM
L
60 mm
SocapelSAM
Cable Conduit
SocapelSAM
L
DC-Bus bar
Cable Conduit
Other equipment
PSU2_009.CDR
Figure 9
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Recommended Spacing and Clearances for SAM Drives and Supplies
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)
Fieldbus/PC104
Interface boards
PAM Module
Alphanumeric
Display
Reset button
Service connector
EasyBus IN
Power Converter
unit
EasyBus OUT
(Not used)
RS 422 connector
PAH015_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.
38
157
139
3 free 2TE 3U
front panels
287
190
All dimensions are mm
Allow min. 50 mm clearance
above and below chassis
for air flow
Allow min. 70 mm clearance
in front of chassis for
connectors
24
3
Power Supply
116
PAH008_d.cdr
Figure 11
PAM Chassis Mounting Dimensions and Clearances
Cabinet's back panel
No paint here !!!
24V DC
Source
For EMC rack must
be securely attached
to back panel at these
four mounting points
For EMC PAM Module
must be securely attached
to chassis with four
attaching screws
PAH020_a.CDR
Figure 12
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
EMI/RFI Requirements when Installing PAM Chassis
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)
Address
jumpers
Service
connector
FATAL ERROR
output
EasyBus IN
EasyBus OUT
Pah013_a.cdr
Figure 13
The 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 S5-115. The PAM module with no plastic housing is for use with Simatic
S5-135 and S5-155 models.
Run indicator (green)
Run indicator (green)
Alphanumeric
Display
Alphanumeric
Display
Reset button
Reset button
Service connector
Service connector
EasyBus IN
EasyBus OUT
(Not used)
RS 422 connector
PAH016_b.cdr
Figure 14
Page: 18
EasyBus IN
EasyBus OUT
(Not used)
RS 422 connector
PAH016_a.CDR
PAM Modules for Simatic S5-115 (left), S5-135 and S5-155 (right)
PAM with SAM System Users Handbook
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 in a 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 AND 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
STOP
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
SAM DRIVE
38
20
47
260
229
202
178
136
202
61
250
49
30
357
379
283
SocapelSAM
L
47
137
23
2
30
285
X33(Rx)
218
22
Socapel SAM
15
39
234
Figure 15
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
X24
X23
X29
l
16
202
X17
X35(Tx)
X32
X31
111
X14
X13
X12 X11
Sah076_a.cdr
Dimensions for SAM Drive 7 amp Models
Page: 21
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
140
202
2 0
38
20
47
2 0
229
202
178
136
105
49
70
357
379
283
SocapelSAM
L
47
36
137
23
2
70
285
105
X33(Rx)
X17
X32
X31
75
93
X35(Tx)
Socapel SAM
122
l
X23
X24
X29
190
02
234
Figure 16
Page: 22
X11 X12
X14
X13
Sah077_a.cdr
Dimensions for SAM Drive 14 & 28 amp Models
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
2 0
229
202
178
136
38
20
234
105
70
70
49
47
269
202
2 0
357
379
283
SocapelSAM
L
47
36
137
23
2
70
285
70
105
X33(Rx)
208
221
234
X35(Tx)
X32
X31
X17
X23
X24
Socapel SA M
X29
l
122
1 0
02
234
X11 X12
X14
X13
Sah078_a.cdr
Figure 17
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Dimensions for SAM Drive 50 amp Models
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
−
In software, modify the SAM Drive Action Masks to prevent the motor thermal
protection input (Status B7) from initiating a Stop action
i
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, AHR115, 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 Drive to motor wiring be exactly as illustrated in Figure 19.
Page: 24
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
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. On the 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
sleeve
Inner plastic
sleeve
Outer nut
EMC005_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.
i
Machine builders who prefer to fabricate 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
Protective earth rail
Motor earth
grounded through
machine structure
Green & Yellow
Cable braket
attaching screw
X12
U
Black 1
U
V
Black 2
V
W
Black 3
W
K1
Yellow
2
K2
Green
3
IGBT
Driver
X13
Θ
Θ
Thermal protector
Temperature
sensor
interface
Braun
X14
White
5
Feedback
Cable gland
Brake
control
(option)
4
Terminal box
W
V
U
Temp.ctrl
Cable gland
& bracket
Brake
Driver
2
Brake
1
PE
User
interlocks
+24 VDC
Supply
Motor windings
cable
Figure 19
Page: 26
+
Feedback
connector
SAH055_b.Cdr
- feedback cable
Wiring Diagram for “AC Servomotors” with Terminal Boxes (“C33” option)
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
SAM-DA-...-07 & 14
SAM-DA-...-28 & 50
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 & 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 threaded 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
the shield if either end is left ungrounded.
Protective earth rail
Motor earth
grounded through
machine structure
2
Green & Yellow
Cable braket
attaching screw
X12
1
Black 1
U
3
Black 2
V
4
Black 3
W
A
Yellow
2
B
Green
3
D
Braun
IGBT
Driver
X13
Θ
Θ
Thermal protector
C
X14
White
5
Feedback
Temperature
sensor
interface
Connector
shell
Brake
control
(option)
4
Connector
A
1
B C
4
2
D
Cable gland
& bracket
(as seen from the
crimp side of the
mating plug)
Driver
2
Brake
1
3
User
interlocks
+24 VDC
Supply
-
Page: 28
+
Figure 21
SAH073_b.Cdr
Wiring Diagram for motors with Integral Mating Connectors
PAM with SAM System Users Handbook
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 the cable gland
outer metal sleeve and mate it with the resolver feedback connector.
4. 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. On the 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
Shield connected
to terminal box
via cable gland
Terminal
box
X24
Resolver
5
Ua -
4
Ua+
3
1
Green
9
8
Yellow
8
4
Pink
7
3
Grey
6
1
2
Brown
2
1
terminal box
W
V
U Temp.ctrl Brake
PE
Page: 30
Sin a1
Cos a1
U Gen a1
U Gen a2
Resolver
Feedback
connector
SAH062_b.Cdr
7
8
- feedback cable
Figure 23
White
Sin a2
1
2
(motor-side connector;
pin arrangement is the
same when looking
from the crimp side
of the mating plug)
Resolver Feedback Interface for AC Servomotors with Terminal Boxes
PAM with SAM System Users Handbook
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 & AHD70 and M254 & M506), simply connect the resolver feedback cable
to its mating connectors on the motor and SAM Drive as illustrated in Figure 24.
9
8
7
12 10
1
2
6 11 3
5 4
(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
to motor case via
cable gland and
connector shell
X24
Resolver
5
Ua -
4
Ua+
3
3
Green
9
4
Yellow
8
1
Pink
7
2
Gray
6
5
6
Brown
White
2
1
Sin a2
Sin a1
Cos a1
U Gen a1
U Gen a2
SAH063_b.cdr
Figure 24
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Resolver Feedback Interface for ACC & Bautz Motors with Integral Connectors
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.
−
A statoric coupling is preferred over 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.
−
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
11 1
12 2
16 13
9 15 17 14 3
8
4
7 6 5
10
(as seen from the
crimp side of the
mating plug)
c
Shield connected to SAM drive
ase via copper banding, connector
shell and mounting screw
Shield connected
to motor case via
cable gland and
connector shell
X23
Encoder
7
Gray-Pink
18
1
Gray
17
10
4
Red-Blue
Pink
3
16
15
Green
6
16
Yellow
19
12
Blue
7
13
Red
20
14
White
2
17
Braun
15
8
Black
1
Violet
14
9
A5
S5
S0
Cos C2
Sin C2
Sin C1
Data
/ Data
Clk
/ Clk
SAH075_b.cdr
Figure 25
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Wiring Diagram for Sine-cosine Encoders
Page: 33
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
Interfacing Multi-turn Resolvers
Figure 26 shows the wiring diagram for interfacing multiturn resolvers that are
supplied together with the PAM and SAM System
(as seen from the
crimp side of the
mating plug)
11 1
10 12 2
16 13
9 15 17 14 3
8
4
7 6 5
Shield connected to SAM drive
acase via copper banding, connector
shell and mounting screw
Shield connected
to motor case via
cable gland and
connector shell
X24
5
Ua -
4
Ua+
3
15
Green
9
16
Yellow
8
Blue
7
Red
6
12
13
3
2
Braun-Green (Brown)
White-Green (White)
2
1
Sin a2
Sin a1
Cos a1
U Gen a1
U Gen a2
X23
Encoder
7
Gray-Pink
18
1
Gray
17
10
4
Red-Blue
Pink
S5
3
16
15
Green
6
16
Yellow
19
12
Blue
7
13
Red
20
14
White
2
17
Braun
15
8
Black
1
Violet
14
9
A5
S0
Cos C2
Sin C2
Sin C1
Data
/ Data
Clk
/ Clk
PSU2_003.cdr
Figure 26
Page: 34
Wiring Diagram for Multi-turn Resolvers
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
Safety I/O & 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
+
X17
SAM Drive
Power Board
1
DC
2
User STOP0 (Input)
No current activates
Stop functions
DC
Internal
Supply
3
4
10 mA
(typ.)
Stop0
Stop1
User STOP1 (Input)
5
Fatal Error relay is closed when
no fatal error condition exists
Safety chain
6
Fatal Error
SAH031_B.CDR
Figure 27
Safety I/O and 24 VDC Power Wiring Diagram
User I/O
General
Two User I/O configurations, standard and expanded I/O, are available depending
on 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 I/O Configuration (“E” option)
Figure 28 illustrates a typical interface to the standard I/O 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
Sensor
User OUT 1
9
User IN 3
8
N/C
7
User IN 2
6
N/C
5
GND ext.
4
User fast IN 1
3
GND ext.
2
24 VDC ext.
1
0L
X31
User OUT 1
5
User IN 3
4
User IN 2
3
GND ext.
2
24 VDC ext.
1
0L
-
I/O PWR
+
+24 VDC
Supply
+
-
Figure 28
Page: 36
SAH065_B.CDR
User Interface to Standard I/O Configuration
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
Expanded User I/O 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
16
User OUT 3
15
0L
0L
User OUT 2
14
0L
User OUT 1
13
0L
+24 VDC
Supply
User OUT 8
User IN 10
12
User OUT 7
User IN 9
11
User OUT 6
User IN 8
10
User OUT 5
User IN 7
9
User IN 6
8
User IN 5
7
User IN 4
6
User IN 3
5
User IN 2
4
User IN 1
3
GND ext.
2
24 VDC ext.
1
0L
0L
0L
0L
0L
Fault 4
I/O PWR
+
-
SAH066_B.CDR
Figure 29
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
User Interface to Expanded I/O Configuration
Page: 37
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
Connector Pin Assignment
DA -xxx-07x-xxx-x
X14 Brake option
X14 Brake option
1
2
3
4
5
24VDC Ext
GND Ext
n/c
Brake 1
Brake 2
X14
1
2
3
X12
1
2
3
4
5
24VDC Ext
GND Ext
n/c
Brake 1
Brake 2
X13
X13
n/c
Mot Temp 1
Mot Temp 2
DA-xxx-14x-xxx-x
X14
X13
X13
n/c
Mot Temp 1
Mot Temp 2
1
2
3
X11
X11
X12 female
Motor Phase U
1
Motor Phase V
2
Motor Phase W
3
X11 male
DC Bus -
3
DC Bus +
DC Bus PE
X12
X11 male
DC Bus -
3
DC Bus +
2
DC Bus PE
1
X12 female
Motor Phase U
1
2
Motor Phase V
2
1
Motor Phase W
3
DA-xxx-50x-xxx-x
X14 Brake option
1
2
3
4
5
24VDC Ext
GND Ext
n/c
Brake 1
Brake 2
X14
X13
n/c
Mot Temp 1
Mot Temp 2
X11 / X12
DC Bus DC Bus +
X13
1
2
3
X11/X12
+
DC Bus PE
Motor Phase 1
U
Motor Phase 2
V
Motor Phase 3
W
PSU2_004.cdr
Figure 30
Page: 38
DC Bus, Motor Windings, Thermal Protector and Brake Control Connectors
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
DA -xxx-xxx-P4N-x
X17
24 VDC Ext.
GND Ext.
STOP0
STOP1
Fatal Error
Fatal Error
1
2
3
4
5
6
X23 female
X17
n/c
n/c
n/c
n/c
n/c
n/c
n/c
n/c
n/c
Ua +10V
n/c
n/c
n/c
1
2
3
4
5
6
7
8
9
10
11
12
13
U Gen a2
U Gen a1
n/c
Ua +10V
Ua -10V
1
2
3
4
5
14 n/c
15 n/c
16 n/c
17 n/c
18 n/c
19 n/c
20 n/c
21 n/c
22 n/c
23 Ua -10V
24 n/c
25 n/c
6
7
8
9
COS a1
COS a2
SIN a1
SIN a2
DA-xxx-xxx-P5N-x
X17
1
2
3
4
5
6
24 VDC Ext.
GND Ext.
STOP0
STOP1
Fatal Error
Fatal Error
X17
X23 female
Clk 1
Data 2
A0 3
+12 VDC 4
n/c 5
Cos c2 6
Sin c2 7
Piref 2 8
Cos d2 9
Sin d2 10
Error 11
Pol Piref 12
n/c 13
14
15
16
17
18
19
20
21
22
23
24
25
1
2
3
4
5
6
7
8
9
U Gen a2
U Gen a1
n/c
Ua +10V
Ua -10V
_Clk
_Data
S0
S5
A5
Cos c1
Sin c1
Piref 1
Cos d1
Sin d1
En_latch
Mux_LR
COS a1
COS a2
SIN a1
SIN a2
PSU2_005.cdr
Figure 31
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
24 VDC Power, Safety and Position Feedback Connectors
(The 14, 28 and 50 amp models are wider than shown in this figure)
Page: 39
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM DRIVE
DA -xxx-xxx-xxx-E
DA-xxx-xxx-xxx-F
Node Address (LSB)
Node Address (LSB)
EasyBus Rx
X33
EasyBus Rx
X33
Node Address (MSB)
Node Address (MSB)
EasyBus Tx
X35
X17
X32
5
4
3
2
1
1
X32 Male
n/c
Gnd Ext.
Fast Input IN 1
Gnd Ext.
24 VDC Ext.
9
8
7
6
X31
5
4
3
2
1
EasyBus Tx
X35
X17
OUT 1
IN 3
IN 2
GND Ext.
24 VDC Ext.
n/c
IN 2
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
OUT 4
OUT 3
OUT 2
OUT 1
IN 10 / OUT 8
IN 9 / OUT 7
IN 8 / OUT 6
IN 7 / OUT 5
IN 6
IN 5
IN 4
IN 3
IN 2
IN 1
GND Ext.
24 VDC Ext.
X32
PSU2_006.cdr
Figure 32
Page: 40
EasyBus and User I/O 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
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM SUPPLY
SAM Supply
Chassis Installation in System Cabinet
STOP
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.
62
15
122
48
30
357
L
47
377
282
Socapel SAM
2
281
X7
22
Socapel SAM
15
l
106
166
X1 X5
PSU2_001.dsf
Figure 33
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
Dimensions for SAM Supply 30 amp Models
Page: 41
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM SUPPLY
136
48
140
105
48
70
357
L
47
36
377
282
Socapel SAM
2
281
X7
Socapel SAM
l
122
140
X1/X5
X2
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”).
Operating a PAM with SAM system from an ungrounded AC Supply is prohibited.
Page: 42
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM SUPPLY
SAM
Drive
L2
SAM
Supply
L1
+
L2
-
L3
L3
PE
PE
L1
Feeding
Section
X5
Figure 35
SAM
Drive
SAM
Drive
DC Bus
X1
PE Rail
On 80 amp
models, X1
and X5 are
terminal
blocks
Sah080_a.cdr
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 SAM-PA…-30-I have an internal
DB resistor. For these models, no external DB resistor is used.
DB Resistor Installation and Mounting
If the average braking power "PBRAKE_AV_TOTAL" (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 INTEGRATION
SAM SUPPLY
L
B (1600 W)
B (400 & 800 W)
E
F
H
l
Cable length: 3m
b
FWA
D
A
D
Power
FWDA
b x l Weight
L
B
H
A
D
E
F
400 W
450
60
85
430
30
404
23
5.5 x 9
2.6 kg
800 W
550
80
116
530
40
504
23
6.5 x 9
4.7 kg
1600 W
550
180
116
530
90
504
23
6.5 x 9
5.6 kg
saa004_b.dsf
Figure 36
Dynamic Braking Resistors Dimensions (all dimensions in mm)
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.
!
Page: 44
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
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.
5. Tighten the cable gland outer nut.
6. Plug the assembled cable into the mating connector X2 on the SAM Supply.
Bracket
Cable gland
Connector X2
SAH087_a.CDR
Dynamic Braking Resistor Cable Assembly
Cable gland
& bracket
X2
SAM Supply
4 Brown
3 White
IGBT
2
Black2
1
Black1
Error/Fault
Logic
RID
DB Resistor
Figure 37
to PE bar
Green-Yellow
DC Bus +
DC Bus -
PE bar
Figure 38
SAH040_b.CDR
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 Supply
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.
X7
+24 VDC
Supply
SAM Supply
1
+
DC
2
-
DC
Internal
Supply
4
Safety chain
Fatal Error relay is closed when
no fatal error condition exists
Over Voltage
5
3
Reset (Input)
6
DC Bus Low
7
n/c
Over Temp
DBR Overload
8
9
10
Machine
control PC/PLC
SAH038_C.CDR
Figure 39
Page: 46
SAM Supply Status, Safety and 24 VDC Supply Connections
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM SUPPLY
Connector Locations and Pin Assignments
PA-xxx-30x-x
DBR Overload
Over Temp
n/c
DC Bus Low
Reset In
Fatal Error
Fatal Error
Over Voltage
GND Ext.
X2 female, optional
24 VDC Ext.
DC+
1
X2
X1
X5
Bottom view
Figure 40
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
2
3
4
Shunt IGBT
-
DC Bus -
+
DC Bus +
PE
L1
L2
L3
X5 male
PE
Phase L1
Phase L2
Phase L3
ID Res
10
9
8
7
6
5
4
3
2
1
X7
X7
ID Res
Top view
PSU2_007.cdr
Connector Locations and Pin Assignments for 30 amp SAM Supply Models
(X2 connector is available only on SAM-PA-xxx-30-E type)
Page: 47
PART 2 - SYSTEM DESIGN AND INTEGRATION
SAM SUPPLY
PA-xxx-80x-E
X2 female
X2
4
3
2
1
ID Res
ID Res
Shunt IGBT
DC+
X5 / X1
X5 / X1
L1 L2 L3
- +
L1
Supply Phase 1
L2
Supply Phase 2
L3
Supply Phase 3
DC Bus PE
+
X7
DC Bus DC Bus +
X7
Bottom view
DBR Overload
Over Temp
n/c
DC Bus Low
Reset In
Fatal Error
Fatal Error
Over Voltage
GND Ext.
24 VDC Ext.
10
9
8
7
6
5
4
3
2
1
Top view
PSU2_008.CDR
Figure 41
Page: 48
Connector Locations and Pin Assignments for 80 amp SAM Supply Models
PAM with SAM System Users Handbook
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
multiple 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
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
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
Filter
SAM-PA Supply
X5
X1
X2
SAM-DA
Drive
X11
X12
SAM-DA
Drive
X11
X12
DC-bus +bar PE
PSU1_005.doc
Figure 43
!
Page: 50
D. B. Resistor
Motor
Motor
Wiring 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
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.
SAM
Drive
On 28 and 50
amp SAM Drives,
X11 is a terminal
block
-
+
SAM
Drive
-
PE
X11
Feeding
Section
L2
SAM
Supply
L1
+
L2
L3
L3
L1
PE
PE
X5
X11
+
SAM
Drive
-
PE
+
PE
X11
X1
On 80 amp
models, X1
and X5 are
terminal
blocks
PE rail
PE grounding conductors
from motor windings cables
Sah068_c.cdr
Figure 44
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
DC Bus Arrangement for Small Systems
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 Part 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
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.
STOP
If a Ground Fault Interrupter is used in the Feeding Section, The leakage current for
each EMC filter must be taken into account (see Table 1).
9032 011 149 FN 258-30/07
current rating
@ 40°°C (50°°C)
36 (30) ARMS
leakage
current
104 mA
9032 011 150 FN 258-75/34
90 (75) ARMS
113 mA
p/n
model
Table 1
Page: 52
Line side
connections
Terminals
2
1 - 10 mm
Terminals
2
10 - 25 mm
Load side
connections
Wires AWG 10
2
5.37 mm
Terminals
2
10 - 25 mm
EMC Filter Information
PAM with SAM System Users Handbook
P/n 9031 011 982, October 6, 2000
PART 2 - SYSTEM DESIGN AND INTEGRATION
FEEDING SECTION
p/n 9032 011 150
(FN258-75/34)
80
60
p/n 9032 011 149
(FN258-30/07)
150
220
35
M5
1
LINE
55
M6
314
329
335
305
320
LINE
300
1
LOAD
M6
6.5
6.5
80
9
400
LOAD
220
All dimensions in mm
Figure 45
saa002_b.dsf
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 may 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).
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 DESIGN AND INTEGRATION
FEEDING SECTION
L1a
L1
L2
L2a
L3
L3a
PE
PE
OR
L1a
L1
L2
L2a
L3
L3a
PE
PE
Sag016_a.cdr
Figure 46
Isolation Transformer Configurations
Interfacing an Auto-transformer
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
L2a
L2
L1a
L3a
L3
Figure 47
Page: 54
SAG017_a.CDR
Auto-transformation Wiring Configuration
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 & Protective
Functions
X17 Safety
I/o
X31/X32
User I/O
User
outputs
X14 Brake
ctrl.
X17
+24 VDC
Supply
X31/X32
+
-
The negative rail of the
24 VDC Supply must be
grounded
PE
PE
PE
X14
Machine Control
PC/PLC
I/O
X14
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