PDK 205481 KW26-S5-FSE-4Q en
PDK 205481 KW26-S5-FSE-4Q en
PDK 205481 KW26-S5-FSE-4Q en
RACING KIT
4 wheel drive
"Formula Student Electric"
Version:
2015/13
Part-no.: 205481
Translation of the "Original Dokumentation"
Imprint
Name:
Version:
PDK_205481_KW26-S5-FSE-4Q
Version: 2015/13
Chapter / Topic
l
l
Previous version:
Product version:
CAN
Project
planning
Change
l
l
l
Letter
symbol
KoJ
2015/10
Product AMK part no. Firmware Version (AMK part no.)
RACING KIT 1
(E1208)
RACING KIT 2
(E1209)
Hardware
Version
(AMK part
no.)
Copyright notice:
Reservation:
We reserve the right to modify the content of the documentation as well as the delivery options for
the product.
Publisher:
Service:
Internet address:
www.amk-antriebe.de
2 / 83
Content
Imprint
1 About this documentation
1.1 Where is what?
1.2 Keeping this document
1.3 Target group
1.4 Purpose
1.5 Related documents
1.6 Display conventions
2 For your safety
2.1 Intended use
2.2 Basic notes
2.3 Safety rules for handling electrical systems
2.4 Presenting safety messages
2.5 Class of hazard
2.6 Requirements for the personnel and their qualification
2.7 Warranty
3 Product overview
3.1 Product name and ordering data
3.2 Product description
3.2.1 Inverter overview
3.2.2 Servo motor overview
3.2.3 AMK AIPEXPRO software
3.2.4 AMK RACINGKIT product training
3.2.5 Defined level of support
3.3 Product view inverter
3.4 Product view motor
3.5 System overview (diagram)
4 Technical data
4.1 Technical data inverter
4.2 Technical data motor
5 Dimensional drawings
5.1 Dimensional drawings - Inverter
5.1.1 Top view
5.1.2 Side view
5.2 Dimensional drawings - Motor
5.2.1 Side view
5.2.2 Front and rear view
6 Project planning
6.1 Mechanics
6.1.1 Mounting options motor
6.1.2 Spline overview
6.1.3 Spline (dimensional drawing)
6.2 Liquid cooling
6.2.1 Drive system cooling circuit
6.2.2 Liquid cooling
6.2.3 Liquid cooling inverter
6.2.4 Coolant
6.2.5 Cooling circuit
6.2.6 Measures to protect the cooling circuit
6.2.7 Dew point table
6.3 Elektric
2
6
6
6
6
7
7
7
9
9
9
9
9
10
10
10
11
11
11
11
11
12
12
12
12
15
16
17
17
18
19
19
19
19
20
20
20
21
21
21
22
22
23
23
24
25
27
27
27
28
29
3 / 83
29
29
31
32
32
33
33
34
35
36
37
37
37
38
39
40
40
42
42
43
43
44
46
47
48
49
50
52
53
53
54
55
56
56
56
56
58
60
61
61
62
63
63
64
66
66
67
68
68
70
70
71
71
73
74
74
75
78
82
83
5 / 83
Chapter
Chapter
number
Details
Safety
Product overview
Technical data
Dimensional drawings
Planning
l
Mechanics
l
l
l
Connection technology
Functionality
Startup
l
l
Liquid cooling
Electrics
Configuration
Glossary
6 / 83
1.4 Purpose
This document is addressed to any person who handles the product. It gives information about the following topics:
l
Safety messages which are absolutely necessary to take care of during handling the product
l
Product identification
l
Projecting, planning and dimensioning of the application
l
Environmental conditions for storage, transportation and operation
l
Assembly
l
Electrical connections
l
Startup and operation
l
Maintenance
l
Replacement
l
Diagnosis
l
Technical data
Device descriptions
AMK part no.
Title
202276
Motors DT / DTK / DP
27859
Motor encoders
204260
Functional descriptions
AMK part no.
Title
202234
203771
203704
25786
Diagnostic messages
Meaning
This symbol points to parts of the text to which particular attention should be paid!
The red hand symbol indicates the button or menu item to click on.
The red hand symbol indicates the option to be selected.
RMB
0x
'Names'
7 / 83
Display
Meaning
'Text'
IDxxxxx - x
8 / 83
Environments that do not meet the climatic conditions specified in this documentation
l
l
l
l
l
At electrical drive systems, hazards are present in principle that can result in death or fatal injuries:
o Electrical hazard (e. g. electric shock due to touch on electrical connections)
o Mechanical hazard (e. g. crush, retract due to the rotation of the motor shaft)
o Thermal hazard (e. g. burns due to touch on hot surfaces)
These hazards are present while starting up and operating the unit, and also during servicing or maintenance work.
Safety instructions in the documentation and on the product warn about the hazards.
Personnel must have read and understood the safety instructions before installing and operating the product. In the
documentation about the product the usage warnings pertain to direct hazards and must therefore be followed directly
when operating or handling the product by the operator.
AMK products must be kept in their original order, that means it is not allowed to do a significant constructional change
on hardware side and software is not allowed to be decompiled and change the source code.
Damaged or faulty products are not allowed to be integrated or put into operation.
Do not start the system in which the AMK products are installed (begin of intended use) until you can determine that all
relevant standards, laws, and directives have been complied with, e. g. low voltage directive, EMC directive, and the
machinery directive, and possible further product standards. The plant manufacturer is responsible for the compliance
with the laws, directives, and standards.
SIGNAL WORD
Type and source of risk
Consequence(s) of non-observance
Steps to prevent:
l
...
9 / 83
DANGER
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury
CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury
NOTICE
NOTICE is used to address preventions to avoid material damage, but not related to personal
injury.
2.7 Warranty
l
l
l
l
10 / 83
All information in the documents accompanying the product must be complied with for a safe and trouble-free
operation.
The assertion of warranty claims is excluded if the information in the documents is not observed completely.
Hardware and firmware may not be modified except by personnel authorised by AMK and after consultation with AMK.
The company AMK Arnold Mller GmbH & Co. KG is not liable for damages from unintended use, incorrect installation
or operation, exceeding rated values and non-observance with the environmental conditions.
3 Product overview
3.1 Product name and ordering data
Product name
AMK RACING KIT 1
Order number
1)
E1208
1) DYNASYN
A2370DD
2) DYNASYN
A2371ED
47541
O907
47058
N308
FSE doc. CD
tbd
N307
11 / 83
l
l
l
Configuration
Startup, optimization (test generator and oscilloscope)
Diagnosis
Interface to inverter: EtherCAT or USB
Connection technology
CAN interface
Working with the AMK AIPEX PRO startup software
Configuration and startup
Question and answer session with AMK employees from the power electronics and motor engineering development
departments
With respect to the illustrations shown in the documentation, please pay attention to the label 'Cooling circuit connection side'.
12 / 83
I1
P1
C1
SL
QB
13 / 83
14 / 83
Motor W3
Motor W4
HVvoltage
CAN
1
2
3
4
5
6
15 / 83
16 / 83
4 Technical data
4.1 Technical data inverter
Terminal / strand
HV+, HV-
KW26-S5-FSE-4Q
(data per inverter)
540 VDC
Input current
Power supply for HV = 540 VDC
48 A
75 F
Supply voltage
for logic supply LV
X08
(X09)
24 VDC 15%,
The 0V potential must be connected to the vehicle ground
(vehicle chassis).
Input current
for logic supply LV
500 mA
1,500 F
Efficiency
Approx. 98%
Ground
Control method
Switching frequency
PWM
8 kHz
Output frequency
U, V, W
0 - 599 Hz
26 KVA
43 A
105 A
10 s
1s
X12
Cooling
Liquid cooling
Flow rate
40 C
Protection class
IP00
17 / 83
Terminal / strand
Approx. 11 kg
KW26-S5-FSE-4Q
(data per inverter)
Prerequisite for the automatic transfer of the data from the encoder database:
l
Encoder cable connected
l
Motor parameters have not already been changed manually
l
The data has been stored in the encoder at the factory
18 / 83
5 Dimensional drawings
5.1 Dimensional drawings - Inverter
5.1.1 Top view
19 / 83
Dimensional drawing of spline: See ' Spline (dimensional drawing)' on page 22.
20 / 83
6 Project planning
6.1 Mechanics
6.1.1 Mounting options motor
The motor can be mounted either at the rear via the 8 x M4 threads or at the front.
Front mounting
The mounting plates indicated in the drawing are required for front mounting. The mounting plates are not included in the
scope of delivery and must be provided by the user.
The mounting plates can be fastened in the front end of the motor at the 4 x 10 mm wide notches.
Rear mounting
Fixation via 8 x M4 threads.
21 / 83
Material Damage!
Pressure on the motor shaft can damage the motor bearings or cause the motor shaft to move
out of its fixing and into the motor casing.
Preventive measures:
Mounting parts such as toothed wheels or shafts must be attached without force (not pressed in)
and must then be secured with a screw or a retaining ring.
The motor shaft contains a spline in accordance with DIN 5480 W11 x 0.8 x 30 x 12 x 7h
22 / 83
Material Damage!
Preventive measures:
l
Only operate the drive system with the specified cooling system
l
Connect the PTC thermistor from the servo motor to the temperature monitoring
equipment
l
Activate the It monitoring of the servo motor in ID32773 'Service bits', bit 14
WARNING
Warning against pressurised lines!
Closed cooling circuits are under high pressure. Opening the circuit while it is under high
pressure can result in injuries from escaping coolant. The sudden pressure change can cause
lines to rip loose or make uncontrolled movements.
Steps to prevent:
l
Never open a line system that is under high pressure!
l
Drain the coolant at the provided point, e.g. drain valve. Pay attention to the instructions
of the manufacturer of the cooling device.
l
Collect the cooling liquid in a proper containment. Store or dispose it according to the
local instructions.
l
Wear adequate protective clothing, e.g. goggles, gloves, safety shoes.
Inverters:
The inverters are mounted on an aluminum cold plate with liquid cooling. The maximum permissible surface temperature of
the cold plate is 40 C. The cold plate can be connected directly to a cooling circuit.
Boundary conditions for the inverter cold plate:
l
The maximum permissible surface temperature of the cold plate is 40 C
l
The flow rate must be approx. 10 l/min
l
The coolant must be < 30 C at the inlet
23 / 83
Motors:
The thermal losses incurred in the motor are generated from power loss PV , which must be dissipated. The cooling jacket for
the motor must be designed and constructed by the user.
Boundary conditions for the motor:
l
The coolant temperature must not exceed the maximum permissible inlet temperature of 40 C
l
The minimum flow rate must be 2 l/min
l
The maximum temperature increase of the coolant must be < 5 K
The coolant temperature must be adapted to the environment in accordance with the dew point table.
Condensation must not be allowed to form on the motor surface or cold plate.
The requirements regarding the cooling circuit and the quality of the coolant must be observed.
M
n
1
1
30
Torque
Speed
24 / 83
Efficiency
The torque, speed, and efficiency can be obtained from the efficiency curve on the motor data sheet.
In the case of liquid-cooled motors, the power loss that can be dissipated is proportional to the flow rate of the coolant. The
minimum coolant flow rate over a period of time is calculated as follows:
P [W ] 60
l
Q
= V
min T[C ] C
T:
C:
Permissible temperature increase of the coolant between flow and return T < 5 K
Specific thermal capacity of the coolant, e.g., water: 4187 J/(kgK)
+5 C to +40 C
Relative humidity
5% to 85%, non-condensing
AlMgSi 0.5
Dimensions
339 x 180 mm
Coolant connection
1) At 25 C and 10 l/min
25 / 83
26 / 83
6.2.4 Coolant
Requirements to the quality of the water used as coolant
Components
Quantities
Chloride ions
< 40 ppm1)
Sulphate ions
< 50 ppm
Nitrate ions
< 50 ppm
pH value
6...12
Quantities
Frost protection
Solutes
< 100 m
1) The antifreeze protection quantity has to be < 30 %, else derating is required. Consult the AMK customer service.
NOTICE
Damage to the cooling plate due to electrolysis
Material Damage!
The cooling plate is made of an AlMgSi0.5 aluminium alloy. If components such as supply line
pipes and heat exchangers that are made of more precious materials (e.g. copper) are used
within the cooling circuit, they can be affected and damaged due to electrolytic processes.
Steps to prevent:
l
Only use components made of the same or a comparable aluminium alloy within the
cooling circuit
The installation of a closed cooling circuit with the following properties is recommended:
l
No constant addition of freshwater, through this the water quality is controllable and consistent
l
Light-proof cooling system in order to hinder the growth of algae
l
Negligible loss through evaporation
If there are critical water circumstances, an expert institute should be contacted for a water analysis.
27 / 83
When using aluminium in the cooling circuit, it must be guaranteed that there is no direct contact of the aluminium with the
copper parts. In order to avoid selective corrosion, the possible copper decontamination must be removed carefully through
customer handling or through miscellaneous modifications (for example, by flushing out the cooling canal).
Scale formation
In order to avoid to formation of scale, for example, the hardness of the water should be limited or the use of hardness
stabilizers may make sense.
Algae growth
In closed systems without the addition of oxygen or with light-proof installations not critical, otherwise it must be worked with
suitable biocides.
Biological attack, formation of mucus bacteria
An attack, or the constant addition of materials promoting the growth of bacteria must be avoided.
Frost
If there are possible temperatures below the freezing point (transport, storage....), measures against frost damage must be
taken.
Environment tolerability
The environment tolerability of the protective material used must received special value.
Material Damage!
Steps to prevent:
l
Observe the dew point table!
l
Switch off the cooling circuit when the systems are idle!
l
Check the temperature of the coolant after longer downtimes!
l
At high levels of humidity, it is recommended to use a dehumidifier!
The dew point table specifies at which surface temperature condensate forms. This depends on the temperature of the air and
the relative humidity.
Example:
28 / 83
Ambient
air temperature
in C
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
-7,70
-6,26
-5,43
-4,40
-3,16
-2,48
-1,77
-0,98
-0,26
0,47
1,20
-6,11
-4,88
-3,69
-2,61
-1,79
-0,88
-0,09
0,78
1,62
2,44
3,20
-4,49
-3,07
-2,10
-1,05
-0,08
0,85
1,86
2,72
3,62
4,48
5,38
-2,69
-1,61
-0,44
0,67
1,80
2,83
3,82
4,77
5,66
6,48
7,32
10
-1,26
0,02
1,31
2,53
3,74
4,79
5,82
6,79
7,65
8,45
9,31
12
0,35
1,84
3,19
4,46
5,63
6,74
7,75
8,69
9,60
10,48
11,33
14
2,20
3,76
5,10
6,40
7,58
8,67
9,70
10,71
11,64
12,55
13,36
15
3,12
4,65
6,07
7,36
8,52
9,63
10,70
11,69
12,62
13,52
14,42
16
4,07
5,59
9,98
8,29
9,47
10,61
11,68
12,66
13,63
14,58
15,54
17
5,00
6,48
7,62
9,18
10,39
11,48
12,54
13,57
14,50
15,36
16,19
18
5,90
7,43
8,83
10,12
11,33
12,44
13,48
14,56
15,41
16,31
17,25
19
6,80
8,33
9,75
11,09
12,26
13,37
14,49
15,47
16,40
17,37
18,22
20
7,73
9,30
10,72
12,00
13,22
14,40
15,48
16,46
17,44
18,36
19,18
21
8,60
10,22
11,59
12,92
14,21
15,36
16,40
17,44
18,41
19,27
20,19
22
9,54
11,16
12,52
13,89
15,19
16,27
17,41
18,42
19,39
20,28
21,22
23
10,44
12,02
13,47
14,87
16,04
17,29
18,37
19,37
20,37
21,34
22,23
24
11,34
12,93
14,44
15,73
17,06
18,21
19,22
20,33
21,37
22,32
23,18
25
12,20
13,83
15,37
16,69
17,99
19,11
20,24
21,35
22,27
23,30
24,22
26
13,15
14,84
16,26
17,67
18,90
20,09
21,29
22,32
23,32
24,31
25,16
27
14,08
15,68
17,24
18,57
19,83
21,11
22,23
23,31
24,32
25,22
26,10
28
14,96
16,61
18,14
19,38
20,86
22,07
23,18
24,28
25,25
26,20
27,18
29
15,85
15,58
19,04
20,48
21,83
22,97
24,20
25,23
26,21
27,26
28,18
30
16,79
18,44
19,96
21,44
23,71
23,94
25,11
26,10
27,21
28,19
29,09
32
18,62
20,28
21,90
23,26
24,65
25,79
27,08
28,24
29,23
30,16
31,17
34
20,42
22,19
23,77
25,19
26,54
27,85
28,94
30,09
31,19
32,13
33,11
36
22,23
24,08
25,50
27,00
28,41
29,65
30,88
31,97
33,05
34,23
35,06
38
23,97
25,74
27,44
28,87
30,31
31,62
32,78
33,96
35,01
36,05
37,03
40
25,79
27,66
29,22
30,81
32,16
33,48
34,69
35,86,
36,98
38,05
39,11
45
30,29
32,17
33,86
35,38
36,85
38,24
39,54
40,74
41,87
42,91
44,03
50
34,76
36,63
38,46
40,09
41,58
42,99
44,33
45,55
46,75
47,90
48,98
The use of a dehumidifier in the switch cabinet is recommended in case of high levels of humidity.
6.3 Elektric
6.3.1 Charging the intermediate circuit capacitors
The intermediate circuit capacitors in the inverters must be charged via an external charging device.
The intermediate circuit capacity is 300 F in total (75 F per inverter).
The charging device does not form part of the RACING KIT and must be designed by the user.
29 / 83
t
R
C
=
=
=
=
0.2 s
100 ohms
300 F
R x C ( = 0.03 s)
t
R
C
=
=
=
=
Uc = Uo 1 e I
Uc = 499.364 V
Capacitor voltage
Ur = Uo - Uc
Ur = 0.636 V
Voltage at charging
resistor
Ur = 0.636 V
Voltage at charging
resistor
Ur = Uo e I
t
Uo
i = e I
R
t
Uo
t
Er = t e I Uo e I dt
0 R
Er = 37.5 J
Charging energy
t
t
Uo
Ec = t e I Uo 1 e I dt
0 R
Ec = 37.405 J
Charging energy
Pr = 187.5 W
Peak power
Prm = 3.75 W
Average power
Pr =
Er
t
f = 0.1 Hz ; T = 10 s
Prm = Er f
When = 5 (5 = 5 x 0.03 s = 0.15 s), the capacitors are charged by 99.33% of Uo. Reserves of 0.05 s are available. The
selected 100 ohm resistor must be designed for an average power of 3.75 watts and a peak power of 187.5 watts.
30 / 83
Motor cable
The motor cable must be a shielded cable with tinned copper braiding. The motor cable shield must be connected to the
shield for the unconnected cable end of the motor across the surface. Use non-adhesive heat-shrink tubing for this. Press the
two pieces of shielding firmly together.
At the inverter, the shield must be placed across the surface of the cold plate. Ensure good contact with the cold plate.
The motor cable shield can prevent interference to a large extent.
(Large diameter skin effect)
HV cable
When greater than 1m, the HV cable must have a copper shield.
The end of the shield must be connected to the designated casing ground on the cold plate and on the battery side.
The end of the shield must NOT be connected to the negative terminal (-) of the HV battery.
31 / 83
The PE connection is established in the same way for I1 + I2 and for I3 + I4 (on the rear of the device in the illustration).
6.4 Configuration
All AMK parameters are based on the SERCOS standard and are described as identification (ID) numbers. They are
described in the Parameter descriptionKW-R06 / -R16 / -R07 / -R17.
The inverter parameters are configured using the AMK AIPEX PRO startup software.
32 / 83
The FSE function is a special item of firmware in which some of the functionality and setting options for the
parameters differ from the default parameter description and the selection options in AIPEXPRO.
Please refer to the following chapters for settings relevant to the FSE function.
Prerequisite for the automatic transfer of the data from the encoder database:
l
Encoder cable connected
l
l
33 / 83
Dec value
Scaling
Meaning
32798 - 2
1 2)
32798 - 3
720
1,2)
32798 - 4
250 1,2)
32798 - 5
500 2)
0.1 C
32798 - 6
600 2)
0.1 C
1,2)
32798 - 7
670
32798 - 8
1150 2)
0.1 C
32798 - 9
1250 2)
0.1 C
1,2)
32798 - 10
300
32798 - 11
1250 2)
0.1 C
32798 - 12
1400 2)
0.1 C
34 / 83
Enter the length of the list (maximum length of the list 245).
35 / 83
The 'System parameters' group is used to set the controller enable RF source hardware.
ID32796 'Source RF'
Default value: 0 dec
Input value: 5 dec (meaning: RF via fieldbus)
To activate motor control, you always require the RF hardware signal (X140 BE1) and the AMK_bEnable
and AMK_bInverterOn CAN signals.
The 'System parameters' group is used to activate the FSE special function.
ID32901 'Global service bits'
Default value: 0x240
Input value: 0x10240 (meaning: FSE special function active)
The 'General parameters' group is used to activate It motor monitoring.
ID32773 'Service bits'
Default value: 0000 0000 0000 0000 0001 0000 0000 0101 (0x1005)
Input value: 0000 0000 0000 0000 0101 0000 0000 0101 (0x5005) (also set 'Motor monitoring active' for default bit 14 It)
The 'Motor parameters' group is used to enter the maximum speed.
ID113 'Maximum speed'
Default value: 6000
Input value: application-specific
If the actual speed value increases to the value in ID113 x 1.25, the output stage is blocked automatically
and the motor runs down. The user must define the value for ID113 subject to the process without
exceeding the maximum speed of the motor.
The 'Speed controller parameters' group is used to enter the speed limit.
ID38 'Positive velocity limit'
ID39 'Negative velocity limit'
Default value: +(-) 5000
Input value: application-specific (meaning: ID38/ID39 limits the speed setpoint)
The 'Inverter parameters' group is used to enter minimum allowed battery voltage.
ID32837 'DC bus voltage monitoring'
Default value: device specific
Input value: ID32798 - 4 'Minimum allowed battery voltage'
Exceeds the HV voltage the value in ID32798 - 4, the internal signal AMK 'QUE' will be set and the motor control can be
activated.
36 / 83
This is due to with the speed increasing induced voltage of the motor.
When approaching the induced voltage at the maximum output voltage of the inverter, the torque-generating current Iq
reduced. Sequence, the motor torque decreases.
The maximum output voltage of the inverter is limited by the HV voltage.
When operating points on the 'characteristic speed point', the control reserve for the current controller is severely limited.
If you are using a battery, the HV voltage can vary by acceleration or recuperation. The HV voltage has a direct influence on
the 'characteristic speed point' .
The induced voltage can be calculated using the following formula:
Induced voltage =
1000
37 / 83
During the transition to the field weakening, the inverter injects in the winding a negative magnetization current Id.
Thereby, the field of the permanent magnet is weakened. The 'voltage constant Ke' decreases, which reduces the induced
voltage.
A torque-generating current Iq can flow.
The magnetization current Id caused losses. The maximum motor current "Imax" must not be exceeded.
Imax
I q + I d
38 / 83
The transition into the field weakening (characteristic speed point) collaborates with reduced HV voltage earlier.
The maximum motor torque falls generally in field weakening. In addition, the torque falls with reduced HV voltage.
Example: Motor torque at 600 VDC and 500 VDC / - - - field weakening area
Possible consequences:
l
Output terminal overcurrent (diagnoses-no. 2334), drive runs down
l
Drive runs down (induced voltage > HV voltage = DC braking)
Steps to prevent:
l
Calculate maximum nominal torque specification and limit online
The maximum motor torque in the field weakening depends on the HV voltage. Change in the HV voltage,
especially when accelerating must be taken into account by the user.
Msoll max =
P [W ]
2
N ist [1 / min]
60
Locate on a test bench, the maximum motor power. Start the measurement series with a reduced motor
power.
Determining field-weakening
The motor is in field weakening, if
Msollmax < Mmax
The desired torque setpoint (in field weakening) by the CAN variables AMK_TorqueLimitPositiv or AMK_
TorqueLimitNegativ
must be : Msetpoint < Msollmax < Mmax.
39 / 83
7 Electrical connections
7.1 Interface overview and connections inverter
40 / 83
Overview of terminals
Interfaces
Number
Function
X08 / X09
X12
X13
Reserved
X14
Reserved
X15
X16
Reserved
X85
X86
Reserved
X131
X140
Binary inputs
X235
USB
(connection to PC for AMK AIPEX PRO software (startup, diagnosis, and
configuration) and ATF (firmware update)
Number
Function
HV+
Battery connection + 1)
HV-
Battery connection - 1)
Motor phase U
Motor phase V
Motor phase W
T-mot
CAN bus
41 / 83
Status LED H2
Class
Status
Note
Drive status
Green
Green flashing
Orange flashing
Orange
Red
Pins
Length
3x1
Type
Manufacturer
Description
Unitron
LiYCY
(shielded)
Assignment:
Signal
Color
mark
Description
CAN High
White
CAN Low
Brown
CAN GND
Green
GND
Black
Cable shielding
42 / 83
Design:
Design
Pins
Length
Type
Manufacturer
10mm2
2x1
Approx.
30 cm
Silicone wire
Multi Contact
single
conductors,
screw-type
Assignment:
Signal
Color
mark
Description
HV +
Red
HV voltage +
HV -
Blue
HV voltage -
Connection:
Cable
Shield connection
Cold plate
Connect the end of the shield on the battery side to the designated casing ground.
Pins
Length
Type
Manufacturer
Description
0.34mm2
2x1
Approx. 30
cm
Shielded cable
Unitron
LiYCY
(shielded)
single conductors,
screw-type
Assignment:
Signal
Color
mark
Description
RT1 (+)
Brown
KTY + connection
RT2 (-)
White
KTY - connection
Black
Cable shielding
43 / 83
WARNING
Danger from uncontrolled movements of the motor shaft!
An incorrect phase sequence with the motor connection can lead to uncontrolled movements of
the motor shaft after being powered on.
Steps to prevent:
l
Ensure that the motor phases are correctly connected.
Description:
Connection of the U, V, W phases of the motor
Technical data:
l
See 'Technical data inverter' on page 17.
Design:
Design
Pins
Length
Type
Manufacturer
Description
6mm2
3x1
Approx. 30
cm
Stranded wire
RADOX
single conductors,
soldered
Assignment:
Signal
Color
mark
Description
Brown
Blue
Black
Connection:
Cable
Shield connection
7.1.5 [X08] / [X09] 24 VDC supply voltage (on-board supply) and looping
NOTICE
Overload of the terminal and the internal circuit board!
The connected rating of the terminals X08, X09 is restricted. The terminals X08 or X09 are
designed for a current of at most 8 A.
Material Damage!
Steps to prevent:
l
A looping of the 24 VDC supply voltage is permitted for a total of 5 modules at the most.
l
If more than 5 devices are installed, each group of five needs to be supplied separately
with 24 VDC.
NOTICE
Material damage caused by incorrect handling!
Mechanical damage to terminals!
Disconnected signal lines.
Material Damage!
44 / 83
Steps to prevent:
l
The plug connectors are partially encoded. Do not push in with force.
l
Never pull on the cable, but rather on the connector casing.
l
For service purposes, use the control tap.
Description:
For supplying the internal switched-mode power supply
X08: connection to 24 VDC supply voltage
X09: voltage looping
Technical data:
l
24 VDC 15%
l
Ripple max. 5% with integrated inrush current limitation
l
The 0V potential of the power supply is to be grounded at the central PE
Design:
Design
Pins
Type
Single-row
pin strip
Assignment:
[X08]/ [X09]
Connection Signal
Description
0 VDC
24 VDC
Connection:
Recommended
cable type
2-wire, unshielded
Cable assembly
0.75 mm
AWG 18
9 mm
Terminal
FK-MCP 1.5/2-ST-3.80
Note
A failure of the 24 VDC supply that lasts > 10ms will result in a fault
45 / 83
Material Damage!
Steps to prevent:
l
Connect the PTC thermistor of the servo motor for temperature monitoring
l
Activate the It monitoring of the servo motor in ID32773 'Service bits' Bit 14.
NOTICE
Material damage caused by incorrect handling!
Mechanical damage to terminals!
Disconnected signal lines.
Material Damage!
Steps to prevent:
l
The plug connectors are partially encoded. Do not push in with force.
l
Never pull on the cable, but rather on the connector casing.
l
For service purposes, use the control tap.
Description:
Connection for monitoring the temperature of a servo motor (can be configured via ID34166 'Temperature sensor motor').
The X12 terminal is prewired with two strands. See 'Stranded wires motor temperature sensor' on page 43.
Technical data:
l
Temperature sensor (KTY)
Design:
Design
Pins
Connection Signal
Description
RT1 (+)
RT2 (-)
Connection:
Recommended
cable type
2-wire, shielded
Cable assembly
Shield connection
0.5 mm
AWG 20
8 mm
Terminal
FK-MC 0.5/2-ST-2.5
46 / 83
Material Damage!
Steps to prevent:
l
The plug connectors are partially encoded. Do not push in with force.
l
Never pull on the cable, but rather on the connector casing.
l
For service purposes, use the control tap.
Description:
During normal operation, the inputs 'EF' and 'EF2' must be set simultaneously. This enables the power output stage.
An interruption to 'EF' and 'EF2' leads to the clock pulses for the power output stage being immediately and reliably blocked. If
the controller enable (RF) is set, an error message is generated and the power output stage is blocked. See 'Drive behavior in
the event of an error' on page 64.
Technical data:
l
Electrically isolated via optocoupler
l
Rated input voltage: +24 VDC ext.
l
Pin 3 coding
Design:
Design
Pins
Assignment:
[X15]
Connection Signal
Description
EF2
2,4
EF
WEF
Connection:
Recommended
cable type
4-wire, unshielded
Cable assembly
Recommended
cable cross section
0.5 mm2
AWG 20
8 mm
Terminal
FK-MC 0.5/4-ST-2.5
47 / 83
Pins
Type
RJ45
Socket
Assignment:
[X85] / [X86]
Pin
Signal
Description
Tx+
Transmit data +
Tx-
Transmit data -
Rx+
Receive data +
Reserved
Reserved
Rx-
Receive data -
Reserved
Reserved
Connection:
Cable type
On both sides
Cable assembly
RJ45 plug
Note
48 / 83
Material Damage!
Steps to prevent:
l
Avoid touching electrical connections and contacts.
l
During handling the electronic component discharge yourself by touching PE.
l
Pay attention to the ESD-notes (electrostatic discharge).
Description
AMK type P motor encoders are installed in the RACING KIT. For further information: See 'Motor encoders' on page 68.
Technical data
l
Input signals as per RS485 specification
l
Encoder cable lengths:
Encoder description
ECI 1118
AMK encoder
description
100
The specified cable lengths are valid in conjunction with the specified voltage ranges and the cable cross
sections recommended by AMK.
Design
Design Pins Type
D-SUB
15
Socket
Assignment
[X131]
Connection P-encoder
5 VDC1)
GND
-EN_DAT
10
+EN_DAT
11
-EN_CLK
12
+EN_CLK
13
5 VDC1)
14
GND
15
1)
49 / 83
Connection
P
Shield connection
Cable assembly
Note
Cable
Material Damage!
50 / 83
Steps to prevent:
l
Avoid touching electrical connections and contacts.
l
During handling the electronic component discharge yourself by touching PE.
l
Pay attention to the ESD-notes (electrostatic discharge).
Description
At terminal X140, the controller card has 2 binary inputs and 1 binary output. The FSE firmware uses the 2 binary inputs.
Technical data
l
Norm IEC 61131-2 type 3 binary inputs:
Rated input voltage 0-30 VDC, maximal input current at 30 VDC = 15 mA
Level 0-5 VDC: low, 11-30 VDC: high
Electrically delay of Ton = 3-8 s, Toff = 48-57 s
l
Norm IEC 61131-2 binary outputs:
Rated output voltage 24 VDC, rated output current maximal 0.5 A, short-circuit safe, electrically isolated, electrically
delay of Ton 8-20 s, Toff = 50-55 s at 200 mA load
Design
Design
Pins Type
Assignment:
[X140]
Connection Signal
Description
1A
BA3
1B
BGND
2A
BGND
2B
BE2
3A
BVCC
3B
BE1
Connection
Cable
Shield connection
Cable assembly
51 / 83
Circuit
Pins
Type
Port
Assignment:
[X235]
Connection Signal
Description
5 VDC
input
D-
Data -
D+
Data +
5 VDC
GND
Ground
Connection:
Cable type
Cable assembly
Assembled cables
Note
52 / 83
Black
Blue
Brown
DT5
U
V
W
-
Brown
Blue
Black
Material Damage!
Steps to prevent:
l
Avoid touching electrical connections and contacts.
l
During handling the electronic component discharge yourself by touching PE.
l
Pay attention to the ESD-notes (electrostatic discharge).
Description
Connection socket for encoder signals and temperature monitoring
Technical data
AMK type P motor encoder, EnDat 2.2 light (digital) 1)
53 / 83
EnDat 2.2 light means, that the encoder supports EnDat 2.2, which is used only with the commands of EnDat
2.1 from the AMK controller.
Design
Design
Pins Type
M12 socket 8
Connection Signal
Terminal on inverter
Name of
connection
on inverter
Description
KTY-
RT2 (-)
KTY+
X12
(unconnected cable
end present)
RT1 (+)
Data+
X131
+EN_DAT
Data-
-EN_DAT
GND
GND
Ground
Clock-
-EN_CLK
Clock signal
Clock+
+EN_CLK
Up
5 VDC 5%
Max. 350 mA
Voltage supply
Connection
Recommended cable type:
M12 plug, 8-pin, tightening torque 0.4 Nm
Minimum cross section 0.25 mm, shielded
The connection cable with angled plug and data cables is available for order from:
Phoenix Contact, description: SAC-8P-M12MR/5,0-PUR SH
(not part of the AMK RACING KIT)
54 / 83
Technical data:
l
See 'Technical data inverter' on page 17.
Design:
Design
Pins
Length
3x1
Type
Color
mark
Description
Black
Blue
Brown
Color
mark
Description
Brown
Blue
Black
Connection:
Cable
Shield connection
The cable shield must be continuous between the motor and inverter and applied on both sides.
Unshielded cables can be shielded with a shielding braid. Allow transitions to overlap to a large extent.
7.2.3 PE connection
DANGER
Danger to life from electric shock!
In the event of an interruption to the PE connection, hazardous voltages may be present on the
casing.
Preventive measures:
l
The PE connection must be designed with a cable cross section of at least 10 mm2 .
l
The PE connection is screwed into the motor casing with a ring cable lug and an M5
screw.
Connection:
Recommended
cable type
Cable assembly
Connection
M5 x 12
55 / 83
8 Functionality
8.1 CAN bus
8.1.1 Wiring for two CAN BUS lines
It is intended that one inverter pair (I1 + I2, or I3 + I4) will be operated at one common CAN.
A fieldbus cable approx. 30 cm in length is soldered in each inverter pair (I1 + I2, or I3 + I4). A 120 ohm bus terminator is
integrated in the I2 and I4 inverters.
56 / 83
57 / 83
The different inverters (node addresses) are addressed with the aid of the base address + offset (corresponding ID34023
'BUS address participant').
58 / 83
Example:
Calculating the CAN identifier (COB-ID) for AMK Actual Values 1 from the inverter with node address 2
0x282 (AMK actual values 1) + 0x2 (node address) = 0x284 (CAN identifier)
The ID34023 'BUS address participants' must be selected so that multiple identical COB-IDs cannot occur
in the same CAN bus system.
Inverter CAN configuration: See 'CAN bus communication parameters' on page 33.
Description of the data telegrams
The following data telegrams are available for exchanging data between the inverter and CAN controller:
Base address
Name
Direction
Meaning
0x282
0x284
0x183
AMK Setpoints 1
Offset
Length in bits
Value type
Unit
Meaning
AMK_Status
16
Unsigned
Status word
See the table below: Content of the
'AMK_Status' status word
AMK_ActualVelocity
16
16
Signed
rpm
AMK_TorqueCurrent
32
16
Signed
AMK_MagnetizingCurrent
48
16
Signed
59 / 83
Offset
Length in bits
Meaning
AMK_bReserve
Reserved
AMK_bSystemReady
AMK_bError
Error
AMK_bWarn
10
Warning
AMK_bQuitDcOn
11
HV activation acknowledgment
AMK_bDcOn
12
HV activation level
AMK_bQuitInverterOn
13
AMK_bInverterOn
14
AMK_bDerating
15
Offset
Length in bits
Value type
Unit
Meaning
AMK_TempMotor
16
Signed
0.1 C
Motor temperature
AMK_TempInverter
16
16
Signed
0.1 C
AMK_ErrorInfo
32
16
Unsigned
Diagnostic number
AMK_TempIGBT
48
16
Signed
0.1 C
IGBT temperature
Offset
Length in bits
Value type
Unit
Meaning
AMK_Control
16
Unsigned
Control word
See the table below: Content of the
'AMK_Control' control word
AMK_TargetVelocity
16
16
Signed
rpm
Speed setpoint
AMK_TorqueLimitPositiv
32
16
Signed
AMK_TorqueLimitNegativ
48
16
Signed
Offset
Length in bits
Meaning
AMK_bReserve
Reserved
AMK_bInverterOn
Controller enable
AMK_bDcOn
HV activation
AMK_bEnable
10
Driver enable
AMK_bErrorReset
11
Remove error*
AMK_bReserve
12
Reserved
*Setpoints must have the value 0, as otherwise the 'Remove error' command will not be executed.
60 / 83
Device
FSE inverter
Description
Errors that occur when initializing the CAN are declared with 'Additional info 1'.
Errors that occur when operating the CAN are declared with 'Additional info 2'.
Category
Error
Drive behavior
Device behavior
Additional information (AMK Service information)
Info 1
Decimal Bit
0
Decimal Bit
1
16
32
64
16
61 / 83
Label
Description
CAN variable
Speed setpoint
AMK_
TargetVelocity
nactual
AMK_ActualVelocity
Mmax,
pos
AMK_
TorqueLimitPositiv
Mmax,
neg
AMK_
TorqueLimitNegativ
KP
KI
Speed controller integration constant (I value) (as reset time Tn in ID101 'Integral-action
time speed control TN')
Msoll
Torque setpoint
kt
Motor torque constant (ID32771 'Nominal torque'/ ID111 'Motor nominal current IN')
KPQ
Current controller gain (P value) (ID34151 'Current path Q proportional gain KP')
KIQ
Current controller integration constant (I value) (as reset time Tn in D34050 'Current path Q
integral-action time TN')
GE (S)
GM(S)
setpoint
Material damage!
Preventive measures:
When defining the acceleration and braking torque, it must be ensured that the permissible
charging and discharging currents of the battery are observed.
Driving mode
Description
CAN Variable
Forward
acceleration
AMK_TargetVelocity
AMK_TorqueLimitPositiv
Brakes on 0 1/min
with positive speed value
AMK_TargetVelocity
AMK_TorqueLimitPositiv
AMK_TorqueLimitNegativ
AMK_TargetVelocity
AMK_TorqueLimitPositiv
AMK_TorqueLimitNegativ
Brakes on 0 1/min
Speed setpoint = 0 [1/min]
with negative speed value Positive torque limitation =
required positive deceleration torque [0,1 %MN]
Reverse
acceleration
AMK_TargetVelocity
AMK_TorqueLimitPositiv
AMK_TorqueLimitNegativ
Speed setpoint =
(negative sign) required speed [1/min]
AMK_TargetVelocity
AMK_TorqueLimitPositiv
AMK_TorqueLimitNegativ
1) Exceeds the actual speed the speed setpoint, for example when driving downhill the motor brakes with the given
deceleration torque.
62 / 83
Device
FSE inverter
Description
Category
Error
Drive behavior
Device behavior
Additional information (AMK Service information)
Info 1
Info 2
Info 3
Info 3
Info 3
Info 3
Info 3
Info 2
Info 3
Info 2
Info 3
8.2.4 Units
Torque
All system torque values refer to ID32771 'Nominal torque' and are specified to 0.1 % MN of its value. Please refer to the type
plate or data sheet for the motor for the parameter value. The key reference for the torque data is ID111 'Motor nominal current
IN'.
Speed
All speed values are specified in rpm.
Temperature
All temperature values are specified to 0.1 C.
Id and Iq
The currents are related to the device-specific value in ID110 'Converter peak current'. The actual current in A is calculated as
follows:
63 / 83
Transmission rate
N... Number of messages
X... Number of devices in the network
64 / 83
AMK_
bError
(CAN)
AMK_
bQuitInverterOn
(CAN)
Induced
voltage
> HV voltage
Behavior
No
Yes
No
Yes
No
Yes
1) The trigger signals for activating the power output stages are blocked at two channels.
It is only ever the drive system of the inverter that generates the error that is switched to torque-free
operation; the other drive systems continue to be controlled as normal.
The program for the higher-level CAN controller must be designed so that errors are detected and the other
drive systems are switched off based on the current situation.
65 / 83
1) Optional
66 / 83
Derating calculates a limit for the torque current. To ensure that this limit is not exceeded, the torque limits are influenced. Only
the positive or negative torque limit that is currently active during operation is influenced.
No error messages are issued when the voltage limits are exceeded. However, torque cannot be taken from the motor that
would cause the limits to be exceeded further.
If power is being reduced, this is signaled via the CAN bus with the 'AMK_bDerating' CAN variable.
Configuring torque limitation:
Temperature
Motor
Temperature measured by KTY in the motor winding, connected to terminal X12 at the
inverter
ID32798 'User list 1'
Temperature
Inverter power supply (IGBT)
ID32798 - 11
ID32798 - 12
ID32798 - 9
67 / 83
Temperature
Inverter cold plate
ID32798 - 6
Overload
as per inverter current
integral
Overload
as per motor current integral
Activate the It monitoring of the servo motor in ID32773 'Service bits', bit 14
1)
Undervoltage or
overvoltage in the HV circuit
ID32798 - 4
ID32798 - 7
ID32798 - 10
1) The
magnetizing current is not taken into account in the calculation. If high speeds occur in the field
weakening range, this can lead to increased heating in the motor.
68 / 83
To ensure correct commutation for synchronous motors, the encoder must be adjusted after it has been
mounted on the motor shaft. The encoder adjustment function is started with a command (ID32843 'Service
command'). The commutation offset defined during the encoder adjustment is stored in the encoder if it has
an encoder store. If the position of the encoder changes in relation to the motor shaft (e.g., if the encoder is
replaced), the commutation offset must be redefined, as otherwise it will not be possible to control the
motor. AMK motors with absolute encoders and encoder stores are adjusted at the factory and delivered
with a valid commutation offset.
69 / 83
9 Startup
9.1 Wiring the motor and supply cables
70 / 83
71 / 83
Step
To do
Detailed description
Install AIPEX PRO on a PC with a Windows operating system and Ethernet Software description AIPEXPRO
and / or USB interface.
V3 chapter:
AIPEX PRO Installation
instructions
Components required
l
l
l
The following AIPEX PRO functions are required for startup, maintenance,
service, etc. Test the functions.
l
Log in
l
Read and save the device data
l
Load an offline project on a device
l
Perform diagnosis with AIPEX PRO
l
Test generator
l
Configure oscilloscope
72 / 83
(*1) Each inverter delivers an 'AMK_bSystemReady' status signal (AMK SBM signal). All status signals have to be
evaluated in a higher-level CANcontroller.
(*2) The internal QUE status signal is set as soon as the HV DC voltage > ID32837 'DC bus voltage monitoring'.
73 / 83
(*3) The EF / EF2 output stage enable may only be removed when the RF controller enable is switched off and when the
motor is at a standstill. Switching off EF / EF2 during operation will generate an error message in the drive and the
motor will coast down.
Interrupting the EF / EF2 control inputs blocks the trigger signals for activating the power output stages at two
channels. The motor is then in a torque-free state but the drive system is not completely disconnected. If, in the event
of an interruption, the motor speed is in the field weakening range, this can cause the motor to be braked. See 'Drive
behavior in the event of an error' on page 64.
The power output stage is unblocked by setting the EF and EF2 signals.
Following the enable, the drive can be supplied with power by setting the RF controller enable (X140 BE1 = 1, 'AMK_
bEnable' = 1, 'AMK_bInverterOn' = 1).
If the function is not used, the EF / EF2 control inputs can be permanently connected to 24 VDC.
(*4) Activating the controller enable also requires the hardware input BE1 to be set in addition to the CAN signals ('AMK_
bInverterOn' and 'AMK_bEnable'). BE1 is similar to the terminal designation X15 (ignition key) in the automotive
sector.
BE1 = 1 : controller enable RF possible
BE1 = 0 : controller enable RF blocked
If the function is not used, the BE1 hardware input can be permanently connected to 24 VDC.
(*5) The 'AMK_bEnable' control signal must be set and reset, but does not activate any function.
(*6) Activating the predefined torque limits requires the BE2 hardware input to be set.
BE2 = 1 : torque limits active
BE2 = 0 : torque limits deactivated, motor without torque
If the function is not used, the BE2 hardware input can be permanently connected to 24 VDC.
74 / 83
75 / 83
For an optimally set PID controller, the actual speed value may overshoot a setpoint step-change by no more than 20%.
Two PT1 filters can be configured at the output of the speed controller.
See ID32928'Time filter 1' and ID32929'Time filter 2'
Relevant parameters:
Parameter
Name
ID100
ID101
ID102
ID32928
ID32929
76 / 83
Halve the determined value for 'Speed controlproportional gain KP' KP and enter the halved value in ID100.
Setting the reset time Tn
Using the integral proportion (I-proportion) in the controller, the controller deviation resulting from the P controller is adjusted.
The integration time is reduced (starting at an initial value e.g. 100ms) until the settling time is minimal. If the reset time is set
optimally, the actual speed value curve (jump answer) roughly follows the curve with the solid line:
For an optimally set PI controller, the actual speed value may overshoot a setpoint jump by no more than 20% as an answer.
77 / 83
78 / 83
CH1:
l
l
CH2:
l
l
CH3:
l
l
Activate the configured signals by the pull-down menu 'CH - ID Parameter name'
79 / 83
Configure your 'Own list' by entering a name and the parameter IDs which are relevant for the controller settings.
We recommend the following input:
>own list name<,38,39,82,83,100,101,102
Display own list 'Tuning':
80 / 83
81 / 83
After the measurement has finished, the results are transferred to the PC and displayed automatically.
Interpret the measurement.
By means of 'Temporary parameters', you can optimise the P part (ID100), I part (ID101), and D part (ID102).
The button 'HOLD' saves the selected value so that you can compare it to the next measurement.
82 / 83
83 / 83