2Installation CHAPTER TWO IN THIS CHAPTER

Transcription

1 CHAPTER TWO 2Installati IN THIS CHAPTER Product Ship Kit List Quick Test Motor Selecti and Wiring Drive Cfigurati DIP Switches, I/O, Potentiometers Mounting the Drive and Motor; Attaching the Load Testing the Installati Active Damping and Electric Viscosity Cfigurati ➁ Installati 5

2 WHAT YOU SHOULD HAVE (SHIP KIT) If you ordered a ZETA Drive Only (no motor), you should have: Part Part Number ZETA Drive ZETA4 Power Cable 6.6 feet (2.0 M) in length Motor Cnector 9 pin ZETA Drive Installati Guide If you ordered a ZETA System (drive and motor), you should receive all of the above, plus e of the following ZETA Motors: Part Part Number ZETA Motor ZETA57-51 ZETA83-62 ZETA57-83 ZETA83-93 ZETA ZETA The motor has a permanently attached cable, 10 feet (3 m) lg. The motor cnector is wired to the cable at the factory. PRECAUTIONS To prevent injuries to persnel and damage to equipment, observe the following guidelines: Never probe the drive. Hazardous voltages are present within the drive. Never open the drive. Opening the drive will void the warranty. Never increase the current setting to a value greater than that specified for the motor you are using. Excessive current may cause motor overheating and failure. INSTALLATION OVERVIEW 6 ZETA Drive User Guide Topics in this chapter are arranged to lead you through the installati process in a step by step manner. Complete each step before proceeding to the next. The order of topics in the installati procedure is: Quick Test Motor selecti, specificatis, and speed/torque curves Motor wiring series vs. parallel DIP switch cfigurati Indexer cnectis and 25 pin D-cnector input/output schematic Drive/Motor matching procedure Drive mounting Motor mounting Cnecting the load Cnecting AC power Testing the installati Resance, ringing, and damping discussi and theory Active Damping and Anti-Resance cfigurati Electric Viscosity cfigurati

3 INSTALLATION PROCEDURE In the following installati procedure, we assume you are using a ZETA Motor with your ZETA drive. If you are using a n-compumotor motor, csult the Appendix at the end of this user guide for informati you may need during the following installati steps. The next drawing shows locatis and names of the various cnectors, switches, etc., that you will encounter during the installati procedure. Balance & Offset Potentiometers DIP Switches Heatsink RESET+ 11 RESET 23 FLT C 9 FLT E 21 SD 17 SD + 16 DIR 15 DIR + 2 STEP 14 STEP + 1 INDEXER ZETA DRIVE POWER STEP Indexer Cnector OVER TEMP MOTOR FAULT INDEXER RESET+ 11 RESET 23 FLT C 9 FLT E 21 SD - 17 SD + 16 DIR - 15 DIR + 2 STEP - 14 STEP + 1 ZETA DRIVE Status LEDs INTERLOCK A CENTER TAP A VAC 50/60 Hz POWER STEP OVER TEMP MOTOR FAULT MOTOR INTERLOCK A CENTER TAP A+ A- EARTH B+ B- B CENTER TAP INTERLOCK ELECTRONIC VISCOSITY ACTIVE 4 8 DAMPING AC POWER Compumotor Motor Cnector Electric Viscosity Rotary Switch Active Damping Rotary Switch Power Cnector A- EARTH B+ B- B CENTER TAP INTERLOCK ELECTRONIC VISCOSITY ACTIVE DAMPING Compumotor MOTOR AC POWER VAC 50/60 Hz ZETA Drive Compent Locatis ➁ Installati 7

4 RESET+ 11 RESET 23 FLT C FLT E SD - SD + DIR - DIR + STEP - STEP B CENTER TAP DRIVE QUICK TEST Follow this procedure to have your ZETA drive perform its automatic test functi. Once you set DIP switches, cnect the motor, and cnect AC power, the automatic test will begin the motor shaft will turn in the counterclockwise directi until you remove power. This will verify that the drive, motor, and motor cable work properly as a system. POWER STEP OVER TEMP MOTOR FAULT INTERLOCK A CENTER TAP A+ A- EARTH B+ B- INDEXER MOTOR ZETA INTERLOCK ELECTRONIC VISCOSITY ACTIVE DAMPING Compumotor To AC Power Source VAC 50/60 Hz AC POWER Quick Test Setup ZETA Drive Counterclockwise (Negative) Shaft Rotati Motor This is a bench top procedure as the drawing shows, you can perform it before you cnect an indexer, mount the drive, or mount the motor. Full installati instructis follow this secti. ➀ SET DIP SWITCHES FOR Series Motor Current A -positi and a 6-positi DIP switch are located top of the ZETA drive, behind a cover. Move the cover to access the switches. Before you change them, make note of the DIP switch settings. You will restore the switches to their original settings at the end of this procedure. SW 1 1 SW First set switches 1 5 to ctrol motor current... (setting above is for series current in ZETA57-51) DIP Switch Locati...then set switches 6 11 in the positi to turn the Automatic Test functi 8 ZETA Drive User Guide Set DIP switches SW1-#1 SW1-#5 for series current for your ZETA

5 motor, according to the following table. ZETA motors ship from the factory with their cnectors wired for series current. Motor Size Current SW1-#1 SW1-#2 SW1-#3 SW1-#4 SW1-#5 ZETA A ZETA A ZETA A ZETA A ZETA A ZETA A Using a N-Compumotor Motor?: see the Appendix at the end of this user guide Later in this chapter, we will give informati about parallel motor current. If you cfigure your system for parallel operati, and then wish to repeat this automatic test, you may do so the test will work with the drive cfigured for either series or parallel current. ➁ SET DIP SWITCHES FOR THE Automatic Test Functi ➂ CONNECT THE MOTOR Set DIP switches SW1-#6 through SW1-#11 to the positi. This switch combinati selects the automatic test functi. Plug your ZETA motor cable s 9-pin cnector into the drive s MOTOR cnector. For safety, always observe the following two warnings: WARNING POWER MUST BE OFF when you cnect or discnect the motor cnector. Lethal voltages are present the screw terminals! CONNECT AC POWER WARNING You must ground the motor case. Large potentials can develop at the motor case that can create a lethal shock hazard if the motor case is not grounded. The case of a ZETA motor will automatically be grounded when you plug the cable s 9-pin cnector into the ZETA drive. The ZETA drive does not have an ON/OFF switch. When you cnect power, the automatic test will begin the drive will turn and the motor will start turning. Therefore, before you apply power to the ZETA drive: Properly secure the motor. Do not attach a load to the motor shaft. To apply power, plug e end of the power cable into the drive. Plug the other end into a grounded 0VAC power source. ➄ OBSERVE THE AUTOMATIC TEST Your ZETA Drive should now be running in the automatic test mode. The motor shaft should rotate at approximately e revoluti per secd (1 rps) in the counterclockwise (negative) directi, until you remove power. LED Operati observe the LEDs the frt panel: POWER LED should illuminate STEP LED should alternately flash red and green OVER TEMP LED and MOTOR FAULT LED should not illuminate STOP THE AUTOMATIC TEST Discnect power to stop the motor. Set DIP switches 6 11 to, or to their original settings. Return other DIP switches to their original settings. ➁ Installati 9

6 INSTALLATION The procedures in the rest of this chapter will lead you through the steps required to permanently install your ZETA Drive and motor. 1 SELECT A MOTOR We recommend that you use a ZETA motor with your ZETA drive. Because the ZETA motor s materials, design, and cstructi are matched to the drive s high performance capabilities, the ZETA motor will operate more efficiently than other motors. Furthermore, the drive s special features anti-resance, active damping, and electric viscosity were optimized to work best with ZETA motors. These features will be most effective if you use a ZETA motor. There are six ZETA motors. Speed/Torque curves, specificatis, and motor dimensis for ZETA motors are shown below. oz-in (N-m) 75 (0.53) ZETA57 51 watts (hp) oz-in (N-m) 200 (1.40) ZETA83 62 watts (hp) Parallel Torque (0.42) (0.32) (0.21) (0.11) Series Power 9 Parallel (0.18) 60 Series (0.08) Torque (1.) (0.84) (0.56) (0.28) Series Parallel 260 Parallel (0.35) Power 0 Series (0.16) Speed-RPS Speed-RPS oz-in (N-m) 5 (0.88) ZETA57 83 Parallel watts (hp) oz-in (N-m) 400 (2.80) ZETA83 93 watts (hp) Torque (0.70) (0.53) (0.35) (0.18) Series 175 Parallel (.23) Power 80 Series (0.11) Torque (2.24) (1.68) (1.) (0.56) Series Parallel Power 350 Parallel (0.47) 180 Series (0.24) Speed-RPS Speed-RPS oz-in (N-m) 150 (1.05) ZETA Parallel watts (hp) oz-in (N-m) 500 (3.50) ZETA watts (hp) Torque (0.84) (0.63) (0.42) Series 186 Parallel (0.25) Power Torque (2.80) (2.10) (1.40) Parallel Series Power 355 Parallel (0.48) 30 (0.21) 80 Series (0.11) 100 (0.70) 193 Series (0.26) = Torque Speed-RPS = Power Speed-RPS 10 ZETA Drive User Guide ZETA Motors Speed/Torque Curves

7 MOTOR SPECIFICATIONS Size 23 Size 34 ZETA57-51 ZETA57-83 ZETA ZETA83-62 ZETA83-93 ZETA Static torque oz-in (N-m) (0.46) (0.71) (0.89) (1.14) (2.14) (2.80) Rotor inertia oz-in (kg-m 2 x 10 6 ) (9.998) (20.1 ) (30.9) (63.4) (4) (191) Inductance Series mh (small signal*) mh (large signal**) Parallel mh (small signal*) mh (large signal**) Bearings Thrust load lb (kg) (11.3) (11.3) (11.3) (22.6) (22.6) (22.6) Radial load lb (kg) (6.8) (6.8) (6.8) (11.3) (11.3) (11.3) End play in Reversing load (cm) (0.013) (0.013) (0.013) (0.013) (0.013) (0.013) Equal to 1 lb Radial play in Per 0.5 lb load (cm) (0.002) (0.002) (0.002) (0.002) (0.002) (0.002) Weight (net) Motor+Cable lb Cnector (kg) (0.7) (1.1) (1.5) (1.7) (2.3) (3.8) Motor Cable Wire size AWG (mm 2 ) (0.25) (0.25) (0.25) (0.34) (0.34) (0.34) All motors: Cable length = 10 feet (3 m); attached cnector is prewired for series current; *Small Signal Inductance is found by using an inductance bridge or meter. **Large Signal Inductance is found by measuring actual generator AC flux linkage and generator short circuit current under dynamic cditis. MOTOR DIMENSIONS Size 23 frame Model ZETA57-51 ZETA57-83 ZETA A 2.0 (50.23) 3.1 (75.23) 4.0 (101.6) (5.461)dia (4) (4.953) (66.67) BC (57.66) (47.14) max 0 (305) 8 wire shielded (38.15) (38.05) ZETA Motors Frame Size 23 Dimensis 0.82(20.83) 0.72 (18.29) A 0.063(1.60) 0.83(21.08) 0.73 (18.54) (6.35) #6-32 UNC-2B Thd (6.34) 0.19 (4.83) x 0.25 (6.50) DP Shaft Dia (2) (3) Equally Spaced (47.37) BC (28.40) dia 60 Size 34 frame Model ZETA83-62 ZETA83-93 ZETA A 2.5 (62.0) 3.7 (93.98) 5.2 (9.0) 3.25 (82.55) max 3.40 (86.36) Max Casting Size 2.877(73.07)dia (72.97) 0 (305) 8 wire shielded 2.730(69.34) (69.85) ZETA Motors Frame Size 34 Dimensis (31.24) (29.21) 0.228(5.79)dia (4) (5.54) (98.42) BC A (1.60) 0.19 (4.83) (30.70) (29.72) (9.52) (9.51) Shaft Dia (2) 30 #6-32 UNC-2B Thd x 0.25 (6.50) DP (4) Equally Spaced (74.98) BC 0.750(19.05) dia x (1.27) Deep Bore Min ➁ Installati 11

8 2 CHOOSE SERIES OR PARALLEL MOTOR WIRING The ZETA motor s windings phase A and phase B are bifilar windings made from double-stranded copper wire. Each phase has two half-windings, which can be wired together in series or parallel. These two alternatives series and parallel produce different speed/ torque characteristics, affect the motor s current rating, and alter the motor s operating temperature. They are explained below. INTERLOCK TERMINALS The interlock terminals the motor cnector comprise a safety feature that protects the motor cnector. The drive checks for ctinuity between the interlock terminals. A jumper the cnector provides this ctinuity; the jumper must be in place, or the drive will not operate. If the cnector is removed when the drive is running, ctinuity between the interlock terminals is broken. The drive csiders this a fault: it illuminates the MOTOR FAULT LED, and turns power to the motor. Do not extend the interlock jumper wire beyd the cnector. The interlock circuit is designed to work with a very short jumper. Lger wires may change the electrical characteristics of the circuit, making it more susceptible to noise. Therefore, do not use a lg jumper. GROUND THE MOTOR CASE The motor case must be grounded, for safety purposes. You can cnect the ZETA motor case to the AC power ground simply by plugging in the motor cable. At the factory, e end of the cable shield is permanently wired to the motor case; the other end cnects to EARTH the drive s motor cnector. Inside the drive, EARTH cnects directly to the ground pin the AC power cnector. Thus, plugging in the motor cable will cnect the ZETA motor case to the AC power ground. SERIES WIRING The ZETA motor comes with a permanently attached motor cable. It s cnector is prewired for series motor current, as shown in the next drawing. For series operati, use the motor as it comes from the factory. INTERLOCK A CENTER TAP A+ A EARTH B+ B B CENTER TAP INTERLOCK CONNECTOR YELLOW BLUE RED BLACK WHITE GREEN ORANGE BROWN SHIELD ZETA Motor Phase A Windings PM Phase B Windings Shield is internally cnected to the motor s case ZETA Drive User Guide Motor Cnector Wired for SERIES Motor Current The center tap pins are not cnected to electrics inside the drive. They serve ly as cvenient terminals where you can cnect together wires from two half-windings. The operating temperature of a motor cnected in series will be lower than that of a motor cnected in parallel. Therefore, you should operate

9 your motor in series, if your applicati permits. Typically, series cnectis work well in high torque/low speed applicatis. PARALLEL WIRING For parallel motor current, you must rewire the cnector. Pull back the rubber boot that covers the cnector, and attach wires from the motor cable according to the following diagram. INTERLOCK CONNECTOR 1 ZETA Motor A CENTER TAP 2 A+ A EARTH B+ B B CENTER TAP 8 INTERLOCK 9 RED BLUE YELLOW BLACK WHITE BROWN ORANGE GREEN SHIELD Phase A Windings PM Shield is internally cnected to the motor s case Phase B Windings Motor Cnector Wired for PARALLEL Motor Current At higher speeds, a motor cnected in parallel will produce more torque than the same motor cnected in series. However, the operating temperature of the motor in parallel will be much higher. If you operate your motor in parallel, you must measure motor temperature under actual operating cditis. If the motor exceeds its maximum case temperature, reduce the duty cycle, or use automatic standby to reduce current at rest, or use forced air cooling to limit motor heating. ZETA motors have maximum case temperatures of 100 C (2 F). CAUTION High current in parallel cnected motors may cause motor overheating. You may need to reduce the duty cycle to 50% to decrease motor temperature, or use automatic standby. SERIES VERSUS PARALLEL SUMMARY To help you decide between series or parallel motor cnectis, the following list summarizes the points discussed above. ➀ Examine the speed/torque curves for your motor. ➁ Use series cnecti, if possible. (The motor will run cooler.) ➂ Use parallel cnecti, if you need more torque than series cnecti provides. (Typically, at higher speeds.) Parallel cnecti will cause the motor to run hotter, so measure motor temperature under operating cditis. ➄ If necessary, reduce duty cycle or use forced air cooling to keep motor temperature within acceptable limits. PRECAUTIONS Follow these precautis when you wire the motor cnector. ➀ Turn power to the drive before cnecting or discnecting the motor cnector. ➁ Verify that no wire whiskers short out motor cnectis. ➂ Do not apply power to the drive when the motor is not cnected. Never extend the interlock jumper beyd the motor cnector. ➄ Never cnect anything other than the motor to the motor terminals. After wiring the motor cnector, perform the Automatic Test, to verify that the cnector is wired correctly. ➁ Installati 13

10 3 SET DIP SWITCHES Cfigure the ZETA drive s DIP switches for your motor and applicati. The drive s 18 DIP switches are located behind the movable metal cover top of the drive. Switch 1 (SW1) is a -positi switch; Switch 2 (SW2) is a 6-positi switch. The table below summarizes switch settings. ZETA DIP SWITCH SETTINGS 1 SW 1 1 SW CURRENT STATIC TORQUE 3 S = series P = parallel ZETA57-51S ZETA57-83S ZETA57-102S ZETA83-62S ZETA57-51P ZETA83-93S ZETA57-83P (amps) ZETA57-102P ZETA83-135S ZETA83-xxP 1 RESOLUTION 2 (steps per revoluti) Default Setting WAVEFORM 2 AUTOMATIC TEST 2 S&D/CW&CCW 2 14 ZETA Drive User Guide ,800 steps 50,000 steps 36,000 steps 25,600 steps 25,400 steps 25,000 steps 21,600 steps 20,000 steps 18,000 steps,800 steps 10,000 steps 5,000 steps 2,000 steps 1,000 steps 400 steps 200 steps Default Setting % 3rd harmic -10% 3rd harmic -6% 3rd harmic Pure sine Step & Directi Indexer Clockwise & Counterclockwise Indexer Anti-res. Enabled Anti-res. Disabled Full Current 50% Current Standby 1 SW Torque Range oz-in N-m ZETA Motor: 57-51, , , P S INDUCTANCE 3 Inductance Range (mh) ZETA Motor: & greater 57-51S, 57-83S, S S, 83-93S, S P, 57-83P, P less than P, 83-93P, P ANTI-RESONANCE DISABLE AUTOMATIC STANDBY DIP Switch Settings for ZETA Motors 4 1 SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW ZETA57-51S ZETA57-83S ZETA57-102S ZETA83-62S ZETA83-93S ZETA83-135S ZETA57-51P ZETA57-83P ZETA57-102P 1. ZETA83-xxP can be ZETA83-62P, ZETA83-93P, or ZETA83-135P 2. The drive reads these switches ly up power up. It reads all other switches ctinuously. 3. These switches are read ly by active damping circuit; they are ignored if active damping is. 4. At 25,000 steps/rev, -4%, S&D, anti-res. enabled, auto standby. 83 motors in parallel not shown. Motor Part Number Suffix: S = Series Cfigurati P = Parallel Cfigurati

11 DEFAULT SETTINGS If you ordered a ZETA drive ly, the factory default positi is for all switches. If you ordered a ZETA system (drive and motor), the DIP switches were set at the factory for your particular motor, wired in series. MOTOR CURRENT Set DIP switches SW1-#1 SW1-#5 for motor current. Verify that your cnector wiring and motor current rating match the series or parallel current you set with these five switches. DRIVE RESOLUTION Set DIP switches SW1-#6 SW1-#9 for drive resoluti. There are sixteen settings, which range from 200 to 50,800 steps per revoluti. The default setting is 25,000 steps per revoluti. Be sure to set your indexer to the same resoluti as your ZETA drive. If the indexer resoluti and drive resoluti do not match, commanded acceleratis and velocities will not be properly scaled. WAVEFORM Set SW1-#10 and SW1-#11 to select a current waveform. There are four choices: e is a pure sine wave; the other three reduce the current waveform s 3rd harmic by 4%, 6%, or 10%. In most applicatis, the default setting (both switches = -4% 3rd harmic) provides the best performance. For further informati about selecting a waveform, see the secti Match the Drive to the Motor later in this chapter. NOTE: If you choose 200 steps/rev for resoluti, select any waveform except pure sine. SW1-#6 SW1-#11, when all, do not select 200 steps/rev and pure sine they select the automatic test (see below). AUTOMATIC TEST DIP switches SW1-#6 SW1-#11 have a double functi. As mentied earlier in Quick Test, they select the Automatic Test functi when they are all. For any other setting, they select resoluti and waveform. STEP & DIRECTION/CW & CCW SW1-# should be if you use a step & directi indexer. All Compumotor indexers are step and directi indexers. If you use a clockwise/counterclockwise (CW & CCW) indexer, turn this switch. AUTOMATIC STANDBY The automatic standby functi allows the motor to cool when it is not moving. Automatic standby reduces motor current by 50% if the drive does not receive a step pulse for e secd. Full current is restored up the first step pulse that the drive receives. Be aware that reduced current results in reduced holding torque. SW2-#1 should be if you do not use automatic standby. Turn this switch to use automatic standby. If you use positi maintenance, we recommend that you do not use automatic standby. ➁ Installati 15

12 ANTI-RESONANCE DISABLE SW2-#2 should be for the anti-resance circuit to be enabled. Normally, you will want anti-resance enabled; therefore, this switch should be. If you must disable anti-resance, turn SW2-#2. NOTE: If active damping is enabled via the rotary switch the frt of the drive, anti-resance is automatically disabled, regardless of the setting of SW2-#2. See Damping in the ZETA Drive later in this chapter for an explanati. INDUCTANCE The active damping circuit reads SW2-#3 and SW2-#4 to determine motor inductance. Set these switches according to your motor s large-signal inductance. The table shows the large-signal inductance range that correspds to each of the four settings. Small-signal inductance is the value read an ordinary inductance bridge or meter. Large signal inductance is found by measuring the actual generator AC flux linkage and generator short circuit current under dynamic cditis. If you ly have the small-signal inductance value available, use the formula below to approximate large-signal inductance: small signal inductance *1.5 large signal inductance NOTE: If active damping is, switches SW2-#3 and SW2-#4 are ignored by the drive, and are inactive. STATIC TORQUE The active damping circuit reads SW2-#5 and SW2-#6 to determine the motor s static torque. Set these switches according to your motor; the table shows the range of static torque that correspds to each of the four settings. NOTE: If active damping is, switches SW2-#5 and SW2-#6 are ignored by the drive, and are inactive. 16 ZETA Drive User Guide

13 RESET+ 11 RESET- FLT C FLT E SD - SD + DIR - DIR + STEP - STEP B CENTER TAP DRIVE 4 CONNECT AN INDEXER INPUTS & OUTPUTS Cnect your indexer cable to the ZETA drive s INDEXER cnector, a 25 pin D-cnector the frt of the drive. The cable that comes with Compumotor indexers is prewired for compatibility with the ZETA drive you can plug the cable directly into the ZETA drive s indexer cnector. POWER STEP OVER TEMP MOTOR FAULT INTERLOCK A CENTER TAP A+ A- EARTH B+ B- INDEXER MOTOR ZETA INTERLOCK ELECTRONIC VISCOSITY ACTIVE DAMPING Compumotor AC POWER VAC 50/60 Hz Indexer ZETA Drive Cnecting a Compumotor Indexer If you make your own cable, or use a n-compumotor indexer, csult the drawing below when you wire your cable and cnector. Reset+ Reset Fault C (FLT C) Fault E (FLT E) Shutdown (SD ) Shutdown+ (SD+) Directi (DIR ) Directi+ (DIR+) Step Step CCW 15 CCW+ CW 14 CW ZETA Drive Internal Cnectis 681Ω ILD213 ILD Ω ILD Ω 243Ω HCPL2631 If DIP SW1-# is ON HCPL Pin D-Cnector Descriptis of each functi the 25 pin D-cnector follow. STEP INPUT For every step pulse it receives its step input, the drive will commutate the motor to increment rotor positi. To send a step pulse to the drive, apply a positive voltage to STEP+ with respect to STEP. The drive registers the pulse the rising edge. The input is optically isolated. It may also be differentially driven. Step input specificatis are: ➁ Installati 17

14 18 ZETA Drive User Guide Input Current: 6.5 ma minimum 15 ma maximum Input Voltage: 3.5V minimum (min. required for or high signal) 5.2V maximum* Step Pulse: 200 nanosecd minimum pulse width 200 nanosecd minimum time 2 MHz maximum pulse rate Optically Isolated: Yes *As a custom product, Compumotor can modify drive for higher input voltage DIRECTION INPUT (DIR+ & DIR-) While a positive voltage is applied to DIR+ with respect to DIR, the drive will commutate the motor in the clockwise (positive) directi as it receives step pulses its step input. While zero voltage (or a negative voltage) is applied to DIR+ with respect to DIR, the drive will commutate the motor in the counterclockwise (negative) directi as it receives step pulses. The input is optically isolated. It may also be differentially driven. Directi input specificatis are: Input Current: 6.5 ma minimum 15 ma maximum Input Voltage: 3.5V minimum (min. required for or high signal) 5.2V maximum* Optically Isolated: Yes Directi Change: Directi input may change polarity coincident with first step pulse. *As a custom product, Compumotor can modify drive for higher input voltage CLOCKWISE AND COUNTERCLOCKWISE (CW & CCW) You can cvert the ZETA drive s step and directi inputs into clockwise and counterclockwise inputs, for use with a CW/CCW indexer. To do so, set DIP Switch 1 # to the ON positi. The following changes result: Pin # SW1 # OFF SW1 # ON 1 Step+ Clockwise+ (CW+) 1 4 Step Clockwise (CW ) 2 Directi+ Counterclockwise+ (CCW+) 1 5 Directi Counterclockwise (CCW ) Input specificatis are the same as those listed above under Step Input and Directi Input. Each positive voltage pulse applied to CW+ with respect to CW causes the drive to commutate the motor and increment rotor positi in the clockwise directi. Each positive voltage pulse applied to CCW+ with respect to CCW causes the drive to commutate the motor and increment rotor positi in the negative directi. SHUTDOWN INPUT (SD+ & SD-) You can use the shutdown input to shutdown, or disable, the ZETA drive. To activate shutdown, apply a positive voltage to SD+ with respect to SD when the motor is not moving. During shutdown, the drive turns current to the motor. The current stays as lg as the voltage is maintained the shutdown input. When you remove the voltage the input, shutdown ends. The drive restores current to the motor, in the same phase relatiship that existed before shutdown was invoked. The shutdown input may also be differentially driven. Specificatis are:

15 Input Current: 2.5 ma minimum 30 ma maximum Input Voltage: 3.5V minimum (min. required for or high signal) 13V maximum 5V maximum reverse voltage Active Level: While voltage is applied, current to motor is shut down. When voltage is removed, normal operatis resume. Time: 250 nanosecd minimum width Optically Isolated: Yes FAULT OUTPUT (FLT C & FLT E) The ZETA drive can signal, through its fault output, that it has detected a fault. Internally, the terminals FLT C and FLT E cnect to the open collector and open emitter, respectively, of an optically isolated transistor. The transistor acts like a switch: it cducts when the drive is functiing normally; it does not cduct when any of the following cditis exist. No power is applied to the drive AC line voltage is too low (less than 95VAC) Drive temperature is higher than 55 C (131 F) Drive detects a short circuit in motor or motor cable Motor is not cnected Ctinuity between interlock terminals is broken Shutdown input is active Fault output specificatis are: VCE: VCESAT: Collector Current: Dissipati: Optically Isolated: 30VDC 1 VDC 40 ma minimum 40 mw maximum Yes RESET INPUT The reset input provides a means for you to reset the ZETA drive, without actually cycling power. To activate the reset input, apply a positive voltage to RESET+ with respect to RESET when the motor is not moving. The reset will not be complete until 0.7 secds after the voltage is removed. A reset has the same effect the drive as cycling power: DIP switch settings are loaded into the drive for cfigurati. Existing faults are cleared. Current to the motor is turned while voltage is applied to the reset input. After voltage is removed from the reset input, the drive s soft start procedure will ramp current up to the startup state. The motor will move to the nearest pole positi. After voltage is removed from the reset input, there will be a 0.7 secd delay before reset is complete, and normal operatis can ctinue. Reset input specificatis are: Input Current: 2.5 ma minimum 30 ma maximum Input Voltage: 3.5V minimum (min. required for or high signal) 13V maximum 5V maximum reverse voltage Reset Voltage Pulse: 250 nanosecd minimum pulse width Active Level: While voltage is applied, reset occurs. When voltage is removed, normal operatis resume. Reset Delay: 0.7 secd delay until reset is complete, after voltage is removed from input. Optically Isolated: Yes ➁ Installati 19

16 MATCH THE DRIVE TO THE MOTOR Due to slight manufacturing variatis, each motor has its own particular characteristics. In the procedure below, you will adjust three potentiometers (pots), to match your ZETA drive to your specific motor. You will also select the best current waveform to use with your motor. If you purchased a ZETA system (drive and motor together), your drive and motor were matched to each other at the factory, with the motor cfigured for series current. If you operate the motor with parallel current, you should perform the matching procedure below. Even if you operate the motor with series current, we recommend that you perform the matching procedure, because your operating cditis temperature, line voltage, etc. may not be the same as factory cditis. If you purchased a ZETA drive ly, no matching was de at the factory. You should perform the following procedure. The ZETA drive s pots are located behind the removable metal cover top of the drive. Phase Balance Phase A Offset Phase B Offset INDEXER RESET+ 11 RESET- 23 FLT C 9 FLT E 21 SD - 17 SD + 16 DIR - 15 DIR + 2 STEP Potentiometer (Pot) Locatis The single turn potentiometers ctrol the following functis: Phase B Offset: Phase A Offset: Phase Balance: Ctrols the DC set of Phase B motor current Ctrols the DC set of Phase A motor current Adjusts the magnitude of Phase B with respect to Phase A The procedure below is a bench top procedure the drive, motor, and indexer should be temporarily cnected together, but not yet permanently mounted. Apply AC power when necessary to perform the steps below. Properly secure the motor. This procedure will be easier to perform if you do not attach the load to the motor shaft. The load is not required, because the characteristics you are matching are those ly of the drive/ motor combinati. 20 ZETA Drive User Guide

17 MATCHING PROCEDURE ➀ Apply power to the drive, and allow it to reach a stable operating temperature. This will take at least two minutes, and may take up to 30 minutes. For optimum results, perform the matching procedure at the same ambient temperature at which your applicati will operate. ➁ For each of the adjustments that follow, csult the table below to find the speed at which to run the motor. These are speeds that cause resance in the unloaded motor. When the motor is running at a resant speed, you will notice increased noise and vibrati. To make resance the most noticeable, you may need to vary the speed around the value given below for your motor. You can find the resant speed by touching the motor lightly with your fingertips as you vary the speed. When you feel the strgest vibratis, the motor is running at resant speed. Offset Balance Waveform Motor Adjust (rps) Adjust (rps) Adjust (rps) ZETA ZETA ZETA ZETA ZETA ZETA ➂ Run your motor at the resant speed listed in the Offset Adjust column. Vary the speed slightly until you find the resance point. Adjust the Phase A Offset and Phase B Offset pots for minimum motor vibrati and smoothest operati. Alternate between Phase A and Phase B to find the minimum vibrati point. ➄ Run your motor at the resant speed listed in the Balance Adjust column. Vary the speed slightly until you find the resance point. Adjust the Phase Balance pot until you find the setting that provides minimum motor vibrati and smoothest operati. Repeat steps 3 6. ➇ Run the motor at the resant speed listed in the Waveform Adjust column. Vary the speed slightly until you find the resance point. ➈ Choose the current waveform that provides minimum motor vibratis and smoothest operati at the speed you selected in step 8. To find the best waveform, compare motor performance as you select different waveforms using DIP switches SW1-#10 and SW1-#11. Waveform SW1-#10 SW1-#11-4% 3rd harmic Default from factory -10% 3rd harmic -6% 3rd harmic Pure sine Do not use with 200 step/rev resoluti The drive reads these DIP switches ly up power up or reset. Therefore, you must cycle power or reset the drive each time you change the DIP switch settings. ➉ Discnect AC power to turn the drive. Replace the cover over the pots and DIP switches. This completes the matching procedure. Proceed to the next secti to mount the drive and motor. ➁ Installati 21

18 6 MOUNT THE DRIVE Dimensis of the ZETA drive are shown below (155.9) (151.6) (25.4) (50.8) (3.4) (203.2) (218.4) (224.8) Dimensis in inches (millimeters) ZETA Drive Dimensis (.7) (25.4) 3x Ø0.156 (3.9) (clearance for #6 (M3.5) mounting screw) ENVIRONMENTAL CONSIDERATIONS 22 ZETA Drive User Guide TEMPERATURE SPECIFICATIONS Maximum Ambient Temperature: 50 C (2 F) Minimum Ambient Temperature: 0 C (32 F) Overtemperature Shutdown Fault: 55 C (131 F) The ZETA drive has an internal temperature sensor, located near the heatsink. If the sensor reaches 55 C (131 F), it will trigger an overtemperature fault, and the drive will shut down. FAN COOLING Operating the ZETA drive in high ambient temperatures may require fan cooling to keep the drive from shutting down due to an overtemperature fault. HUMIDITY Keep the relative humidity below 95%, n-cdensing. LIQUIDS Do not allow liquids or fluids to come into ctact with the ZETA drive or its cables.

19 AIRBORNE CONTAMINANTS Particulate ctaminants, especially electrically cductive material such as metal shavings or grinding dust, can damage the ZETA drive and motor. Do not allow ctaminants to come into ctact with the drive or motor. PANEL LAYOUT Follow these minimum spacing and clearance requirements when you mount multiple ZETA drives (76.2) Minimum 1.00 (25.4) Minimum Clearance 1.00 (25.4) Minimum Clearance 0.50 (.7) Minimum Clearance (218.4) 1.00 (25.4) Minimum Clearance 2.00 (50.8) Min 1.00 (25.4) Dimensis in inches (millimeters) Panel Layout Dimensis ➁ Installati 23

20 7 MOUNT THE MOTOR 24 ZETA Drive User Guide Use flange bolts to mount rotary step motors. The pilot, or centering flange the motor s frt face, should fit snugly in the pilot hole. Do not use a foot-mount or cradle cfigurati, because the motor s torque is not evenly distributed around the motor case. When a foot mount is used, for example, any radial load the motor shaft is multiplied by a much lger lever arm. ZETA motors can produce very high torques and acceleratis. If the mounting is inadequate, this combinati of high torque/high accelerati can shear shafts and mounting hardware. Because of shock and vibrati that high acceleratis can produce, you may need heavier hardware than for static loads of the same magnitude. Under certain move profiles, the motor can produce low-frequency vibratis in the mounting structure that can cause fatigue in structural members. A mechanical engineer should check the machine design to ensure that the mounting structure is adequate. WARNING Improper motor mounting can jeopardize persal safety, and compromise system performance. For ZETA motor dimensis, see Select a Motor earlier in this chapter. MOTOR TEMPERATURE & COOLING The motor s face flange is used not ly for mounting; it is also a heatsink. Mount the face flange to a large thermal mass, such as a thick steel or aluminum plate, which should be unpainted, clean, and flat. Heat will be cducted from inside the motor, through the face flange, and dissipated in the thermal mass. This is the best way to cool the motor. You can also use a fan to blow air across the motor for increased cooling, if cducti through the flange does not provide enough cooling. MOTOR MODIFICATIONS Modifying or machining the motor shaft will void the motor warranty. Ctact a Compumotor Applicatis Engineer ( ) about shaft modificatis as a custom product. EXTENDING MOTOR CABLES If you need to extend ZETA motor cables beyd the standard 10 feet (3 m), csult the table below for recommended wire sizes. Cables lger than 50 feet (15 m) may degrade system performance. Do not extend cables beyd 200 feet (61 m). Max. Current Less than 100 ft. (30 m) ft. (30 60 m) Motor Type (amps) Size: AWG mm 2 AWG mm 2 ZETA57-51S ZETA57-51P ZETA57-83S ZETA57-83P ZETA57-102S ZETA57-102P ZETA83-62S ZETA83-62P ZETA83-93S ZETA83-93P ZETA83-135S ZETA83-135P S: Series Cfigurati P: Parallel Cfigurati Rated current in wire sizes shown may result in a maximum temperature rise of 10 C (18 F) above ambient.

21 8 CONNECT THE MOTOR TO THE LOAD COUPLERS Align the motor shaft and load as accurately as possible. In most applicatis, some misalignment is unavoidable, due to tolerance buildups in compents. However, excessive misalignment may degrade your system s performance. The three misalignment cditis, which can exist in any combinati, are illustrated and described below. Aligned Angular Misalignment End Float Parallel Misalignment Misalignment Cditi Combined Parallel & Angular Misalignment Angular Misalignment: The center lines of two shafts intersect at an angle other than zero degrees. Parallel Misalignment: The set of two mating shaft center lines, although the center lines remain parallel to each other. End Float: A change in the relative distance between the ends of two shafts. The type of misalignment in your system will affect your choice of coupler. SINGLE-FLEX COUPLING Use a single-flex coupling when you have angular misalignment ly. Because a single-flex coupling is like a hinge, e and ly e of the shafts must be free to move in the radial directi without cstraint. Do not use a double-flex coupling in this situati: it will allow too much freedom and the shaft will rotate eccentrically, which will cause large vibratis and catastrophic failure. Do not use a single-flex coupling with a parallel misalignment: this will bend the shafts, causing excessive bearing loads and premature failure. DOUBLE-FLEX COUPLING Use a double-flex coupling whenever two shafts are joined with parallel misalignment, or a combinati of angular and parallel misalignment (the most comm situati). Single-flex and double-flex couplings may or may not accept end play, depending their design. RIGID COUPLING Rigid couplings are generally not recommended, because they cannot compensate for any misalignment. They should be used ly if the motor or load is some form of floating mounts that allow for alignment compensati. Rigid couplings can also be used when the load is supported entirely by the motor s bearings. A small mirror cnected to a motor shaft is an example of such an applicati. COUPLING MANUFACTURERS HUCO ROCOM CORP. HELI-CAL 70 Mitchell Blvd, Suite Engineer Drive P.O. Box1460 San Rafael, CA Huntingt Beach, CA Santa Maria, CA (415) (714) (805) ➁ Installati 25

22 9 CONNECT AC POWER At this point in your installati procedure, you should have mounted your drive and motor, coupled the motor to the load, and cnected the indexer and motor cables to the drive. The ZETA drive does not have an / switch. When you plug the power cord into the drive, the system will turn. Therefore, before you apply power to the ZETA Drive, verify the following: Motor should be properly secured Motor cable should be cnected to drive Drive should be properly mounted Indexer cable should be cnected to drive Indexer cable should not be in close physical proximity to motor cable Active Damping rotary switch should be set to zero Electric Viscosity rotary switch should be set to zero. APPLY POWER Apply power to the ZETA drive by plugging e end of the molded power cord into the drive s AC Power cnector. The cord is 6.6 feet (2 m) lg. Plug the other end of the power cord into an AC power source that meets the following specificatis: Specificatis AC Power Input Input Power: 0VAC nominal 95VAC minimum 132VAC maximum Hz Inrush Current: 25 amps maximum Fuses: No user serviceable fuses Grounding: You must provide a proper AC power ground Transformer: Not required for 0VAC operati; to size stepdown transformer, use Volt-Amp rating (see below) WARNING The motor case and drive are grounded through the AC power cnector ground pin. You must provide a proper AC power ground for safety purposes. 26 ZETA Drive User Guide PEAK POWER RATINGS The amount of power the ZETA drive requires from your AC power source depends up the motor you use, whether you wire the motor in series or parallel, and up your specific applicati. The next table shows peak power requirements. Power required for your applicati may be less. Motor Type Current Cabinet Peak Motor Peak Shaft Peak Total Volt-Amp (Amps) Loss (W) Loss (W) Power (W) Power (W) Rating (VA) ZETA57-51S ZETA57-51P ZETA57-83S ZETA57-83P ZETA57-102S ZETA57-102P ZETA83-62S ZETA83-62P ZETA83-93S ZETA83-93P ZETA83-135S ZETA83-135P S: Series Cfigurati P: Parallel Cfigurati

23 10 TEST THE INSTALLATION System installati should be complete at this point. Perform the test procedure below to verify that your system is functiing properly. (Procedures to cfigure the drive s damping features follow this test.) In the test procedure, you will command single revoluti moves in the clockwise and counterclockwise directi. If your mechanics do not permit such moves, choose a move that allows you to easily verify correct system respse. TEST PROCEDURE ➀ Apply 0VAC power. The green LED labeled POWER should illuminate. ➁ ➂ Command a slow move of e revoluti in the clockwise directi. Verify that the motor turns as commanded. The bicolor LED labeled STEP should be illuminated green while the move is in progress. Command a slow move of e revoluti in the counterclockwise directi. Verify that the motor turns as commanded. The bicolor LED labeled STEP should be illuminated green while the move is in progress. Test the shutdown input. With the motor stopped, activate the input. The motor will have no torque when shutdown is activated. You should be able to turn the motor manually (if your mechanics permit). Successful completi of this procedure will verify that your indexer and motor are correctly cnected to the ZETA drive, and that the drive is functiing properly. Proceed to the following sectis to cfigure the ZETA drive s damping features. If the test was unsuccessful, observe the LEDs the frt panel of the ZETA drive while you try the test procedure they may indicate the cause of the problem. (Chapter 3 Troubleshooting has a complete descripti of LED functis.) Review earlier sectis of this user guide, verify that you have completed each step, and try the test procedure again. If the test is still unsuccessful, proceed to Chapter 3 Troubleshooting for problem identificati and soluti procedures. ➁ Installati 27

24 11 RESONANCE, RINGING AND DAMPING DISCUSSION AND THEORY In this secti we will discuss resance and ringing in step motors. This informati will help you cfigure the ZETA drive s damping features anti-resance, active damping, and electric viscosity. All step motors have natural resant frequencies, due to the nature of their mechanical cstructi. Internally, the rotor acts very similarly to a mass suspended a spring it can oscillate about its commanded positi. Externally, the machine, mounting structure, and drive electrics can also be resant, and interact with the motor. During a move, two types of problems can arise from these causes: resance and ringing transients. RESONANCE (STEADY STATE RESPONSE) Resance is a steady state phenomen it occurs when the motor s natural resant frequencies are excited at particular velocities. It is not caused by transient commands that we give the motor. If you slowly increase your motor s speed from zero to 20 rps, for example, you may notice rough spots at certain speeds. The roughness is resance; it is depicted in the next drawing. Velocity Resances Actual Commanded Time Resance Instead of moving at the commanded velocity, the motor is oscillating between speeds faster and slower than commanded. This causes error in rotor positi. Resance points can differ in intensity. The drawing shows a typical case as motor speed increases, resances of varying levels occur. Usually, the motor can accelerate through the resance point, and run smoothly at a higher speed. However, if the resance is extreme, the rotor can be so far out of positi that it causes the motor to stall. Resance is affected by the load. Some loads are resant, and can make motor resance worse. Other loads can damp motor resance. To solve resance problems, system designers will sometimes attach a damping load, such as an inertial damper, to the back of the motor. However, such a load has the unwanted effect of decreasing overall performance, and increasing system cost. The ZETA drive has internal electrics that can damp resance, and increase system performance. No external devices are necessary. 28 ZETA Drive User Guide

25 RINGING (TRANSIENT RESPONSE) Inside a step motor, the rotor behaves like a mass a spring, as mentied above. When commanded to quickly accelerate to a given velocity, the rotor will ring about that velocity, oscillating back and forth. As shown in the next drawing, the ringing decays grows smaller over time and the rotor eventually settles at the commanded velocity. Velocity Ringing Transients Actual Commanded Time Ringing Transients Notice that ringing can be caused both by accelerating (or decelerating) to a commanded velocity, and decelerating to a stop. In all of these cases, ringing causes error in rotor positi. Ringing is a transient phenomen (unlike resance, which occurs during steady state operatis). It is a respse to a sudden change that we impose the system, such as Accelerate to Velocity or Stop. Several problems are associated with ringing. It can cause audible noise; the motor must have a margin of extra torque to overcome the ringing; and lger settling times can decrease throughput. To eliminate these problems, system designers use damping to force the ringing to decay quickly. Inertial dampers have been used as compents in passive damping methods. Accelerometers, encoders, and tachometers have been used as compents in active damping methods. These devices can have the unwanted effect of limiting performance, adding complexity, and increasing cost. The ZETA drive has internal electrics that can damp ringing transients, and cause them to decay quickly. No external devices are necessary. DAMPING IN THE ZETA DRIVE The ZETA drive has three different circuits that can damp resance and ringing. Anti-Resance General-purpose damping circuit. The drive ships from the factory with anti-resance enabled. No cfigurati is necessary. Antiresance provides aggressive and effective damping. Active Damping Extremely powerful damping circuit. The drive ships from the factory with active damping disabled. You must set four DIP switches and a rotary switch to enable active damping, and optimize it for a specific motor size and load. Electric Viscosity Provides damping at lower speeds. The drive ships with electric viscosity disabled. You must set a rotary switch to enable electric viscosity, and optimize it for the specific applicati. The first two damping circuits anti-resance and active damping work at speeds greater than three revolutis per secd (rps). Electric viscosity works at speeds from rest up to three rps. The drive will automatically switch between the damping circuits, based up the motor s speed. The next drawing shows the effective range of each circuit. ➁ Installati 29

26 Velocity Anti-Resance or Active Damping (above 3 rps) 3 rps 3 rps Electric Viscosity (below 3 rps) Time Resances, Ringing Transients, and Effective Range of Damping Circuits Above 3 rps, the drive automatically enables anti-resance or active damping but not both at the same time. They are mutually exclusive. If the rotary switch for active damping is set to the zero positi, the drive enables anti-resance. If the rotary switch is set to any positi other than zero, the drive enables active damping. This relatiship is shown in the next drawing. Notice that anti-resance can also be disabled with a DIP switch. Current Command Current Command Modulator ZETA Drive Internal Circuitry Power Amplifier Motor Terminal Voltages Motor Enable/ Disable DIP Switches Dynamic Error Modulates Current Command (above 3 rps ly) Anti- Resance (Pos. 0) Active Damping (Pos. 1-15) Scaling for System Inertia (Rotary Switch) Scaling for Motor Parameters Anti-Resance Disable Static Torque Inductance Drawing shows Anti-Resance enabled, Active Damping disabled 30 ZETA Drive User Guide Anti-Resance and Active Damping Block Diagram Differences between anti-resance and active damping are described next; refer to the block diagram above. ANTI-RESONANCE Anti-resance mitors the drive s motor terminals, and looks at power exchange between the drive and motor. From this, it extracts informati about error in rotor positi caused by resance or ringing. It modifies the internal motor current command to correct for the error. Anti-resance is a general-purpose circuit. It corrects rotor positi error, without knowledge about the system whether the motor is large or small, or the system inertia is high or low. You cannot modify the circuit s gains, or customize it for a particular applicati but, anti-resance is easy to use. When enabled via the DIP switch, it works automatically. ACTIVE DAMPING Active damping mitors the motor terminals and, like anti-resance,