1 A6951e21
1 A6951e21
1 A6951e21
AXPERT Eazy
High Frequency Drive
INSTRUCTION MANUAL
IMAE-02, Rev: 1.4
(September, 2010)
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TABLE OF CONTENTS
PREFACE
Precautions For Safety
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PREFACE
THANK YOU for purchasing the “AMTECH AXPERT Eazy Series High Frequency Drive”.
AXPERT Eazy Series High Frequency Drive is a modern Digital Signal Processor based highly
functional AC Drive for high-speed application and that is easy to use. It employs latest generation
IGBT as a switching device and pwm control technique to apply commanded output to the Spindle to
control the Spindle speed.
PLEASE READ THIS MANUAL THOROUGHLY before use, and keep the manual at hand for later
reference. Also make sure that this manual is delivered to the final users.
The purpose of this Instruction Manual is to provide basic information on Installation, Start-up,
Operational and Troubleshooting for the AXPERT Eazy Series High Frequency Drive.
WARNING
The safety precautions are ranked as "DANGER" and "CAUTION" in this instruction manual.
CAUTION
Note that some items described as may lead to major problems depending
on the situation. In any case, important information that must be observed is described.
This instruction manual is written on the presumption that the user has an understanding of the AC
Drive. A qualified person must do installation, operation, maintenance and inspection of this product.
Even qualified persons must undergo periodic training.
Qualified refers to satisfying the following conditions.
9 The person has thoroughly read and understood this instruction manual.
9 The person is well versed in the installation, operation, maintenance and inspection of this
product, and understands the possible dangers.
9 The person is informed on matters related to starting, stopping, installation, locks and tag
displays, and has been trained in the operation and remedies.
9 The person has been trained on the maintenance, inspection and repairs of this product.
9 The person has been trained on protective tools used to ensure safety.
AMTECH puts the maximum effort into making products better and more reliable, but there is always
the possibility that trouble may occur with them. Trouble with AC Drive may lead to personal injury,
fire or property damage. Remember to give due consideration to safety when making your system,
with appropriate measures such as isolating devices, mechanical brakes, prevention against any
malfunction or mishap.
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CHAPTER- 1: DELIVERY, INSPECTION AND STORAGE
CAUTION
9 Always transport the product with an appropriate method according to the products weight.
Failure to observe this could lead to injuries.
9 Do not place the product near inflammable items.
Failure to observe this could lead to fires.
9 Do not hold the product with front cover while transporting the product.
Failure to observe this could lead to injuries from dropping.
9 Do not let conductive materials such as screws or metal pieces and inflammable materials such
as oil enter the product.
Failure to observe this could lead to fires.
9 Install the product in a place that can withstand the weight of the product, and follow the
instruction manual.
Failure to do so could lead to injuries from dropping.
9 Do not install and operate an AC Drive that is damaged or that has missing parts.
Failure to observe this could lead to injuries.
9 Always observe the conditions described in the instruction manual for the installation
environment.
Failure to observe this could lead to faults.
The AXPERT Eazy Series High Frequency Drive should be kept in the shipping carton before
installation. In order to retain the warranty coverage, the AC Drive should be stored properly when it is
not to be used for an extended period of time. Some storage suggestions are:
(1) Store in a clean, dry location.
(2) Store within an ambient temperature range of -20°C (-4°F) to +70°C (158°F).
(3) If possible, store in an air-conditioned environment where the relative humidity is less than 95%,
non-condensing.
(4) Do not store the High Frequency Drive in places where it could be exposed to corrosive gases.
(5) Do not store the High Frequency Drive on a shelf or on an unstable surface.
(6) If the High Frequency Drive is not to be used for a while (more than 2 months) after purchasing,
store it in a place with no humidity or vibration in the packaged state.
(7) Always inspect the High Frequency Drive before using after storing for a long period.
Series name
Capacity 22kW
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CHAPTER- 2: INSTALLATION AND WIRING
This chapter provides the information needed to properly install and wire the AC Drive. Make sure
that the AC Drive is wired according to the instructions contained in this chapter. The instructions
should be read and understood before the actual installation begins.
CAUTION
9 Install the AC Drive, dynamic braking unit and resistor, and other peripheral devices on
noncombustible material such as metal.
Failure to observe this could lead to fires.
9 Do not place the product near inflammable items.
Failure to observe this could lead to fires.
9 Do not let conductive materials such as screws or metal pieces and inflammable materials such
as oil enter the product.
Failure to observe this could lead to fires.
9 Install the product in a place that can withstand the weight of the product.
Failure to do so could lead to injuries from dropping.
9 Do not install and operate AC Drive that is damaged or that is missing parts.
Failure to observe this could lead to injuries.
9 Always observe the conditions described in the instruction manual for the installation
environment.
Failure to observe this could lead to faults.
9 Install an overheating protection device on the dynamic braking resistor, and shut off the power
with this fault signal.
Failure to do so could lead to fires in the event of abnormal overheating.
50mm (1.97")
200mm (7.87")
DANGER
¾ Always turn the device's input power OFF before starting wiring.
Failure to do so could lead to electric shocks or fires.
¾ Carry out grounding that complies with the standards of the country where the AC Drive is being
installed.
Failure to do so could lead to electric shocks or fires.
¾ Wiring must always be done by a qualified electrician
Failure to observe this could lead to electric shocks or fires.
¾ Always install the device before starting wiring.
Failure to do so could lead to electric shocks or injuries.
¾ Use circuit breaker or fuses that match with the capacity of AC Drive power supply.
Failure to do so could lead to fires.
CAUTION
9 Do not connect an AC power supply to the output terminals (U, V, W) and DC terminals (L+1,
L+2, and L–).
Failure to observe this could lead to injuries or fires.
9 Confirm that the product's rated input voltage and frequency match the power supply voltage and
frequency.
Failure to do so could lead to injuries or fires.
9 Install an overheating protection device on the dynamic braking resistor, and shut off the power
with this fault signal.
Failure to do so could lead to fires in the event of abnormal overheating.
9 Do not directly connect a resistor to the DC terminals (L+1, L+2, and L–).
Failure to observe this could lead to fires.
9 Tighten the terminal screws with the designated tightening torque.
Failure to do so could lead to fires.
9 Correctly connect the output (U, V, W) to Spindle terminals to ensure proper phase sequence.
Failure to do so could cause the Spindle to rotate in reverse and the machine to be damaged.
Refer to below figure and wire the main circuits for the power supply and Spindle, etc.
Always observe the following precautions for wiring.
CAUTION
9 Wait at least 20 minutes after turning the power off before starting work. Make sure that the
displays on the Digital Operation Panel have gone out before removing the cover.
9 After removing the cover, confirm that the “DC BUS CHARGE LED“ in the unit on bleeder board
has gone out. Also check that the voltage between terminals L+1 or L+2 and L- is 15V or less
before starting the inspections.
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DCL
(Note 9) DB UNIT
(Note 2) AXPERT
L2
EAZY
V
M
L3 W
(Note 7)
(Note 3) (Note 4)
E E
(Note 7)
(Note 5) (Note 1)
AXPERT Eazy AMT- HF 1P5 2P2 4P0 5P5 7P5 011 015 018 022 030 037
Rated Capacity kW 1.5 2.2 4.0 5.5 7.5 11 15 18 22 30 37
Hp 2.0 3.0 5.0 7.5 10 15 20 25 30 40 50
Rated Current (A) 3.6 5.5 8.6 13 17 23 31 37 44 60 73
Applicable Spindle kW 1.5 2.2 4.0 5.5 7.5 11 15 18 22 30 37
2
Applicable wire for mm 0.8 0.8 2 3.5 5.5 5.5 8 14 14 35 35
Input / Output AWG 18 18 14 12 10 10 8 6 6 2 2
If improperly sized, the voltage drop on a line reactor can reduce the voltage on drive terminals
especially at high load. In that case the Spindle current will also increase and DC Bus under
voltage fault may occur.
Drive’s terminal.
• When using the control circuit wiring and power circuit wiring in parallel, separate the wiring
by 300mm (11.8”) or more or pass each of the wiring through separate metal conduits. If the
control circuit wiring and main circuit wiring intersect, make sure that they intersect at a right
angle.
(Note 7) Grounding
Always ground the AC Drive unit according to the regulations of the country where the AC Drive is
being used.
(Note 9) DCL
Always short across L+1 and L+2 when not using the DCL (factory setting state). When
connecting the optional DCL, connect it to L+1 and L+2. Twist the wiring to the DCL, and keep the
wiring length to 5 meters (16.4”) or less.
When using the external DB unit, use the overload detection relay or thermal relay to protect the
DB resistor and AC Drive.
(Note 12) Voltage Selection for the auxiliary equipment Power Supply (Applicable to models
above 22kW)
Ensure appropriate tapping for the control transformer, which provides the power supply to the
auxiliary equipments like fan/blower, soft charge contactor etc. Note that this not applicable to the
models up to 22kW.
460V
YELLOW
440V
Fuse GRAY
415V 230V
To L2 YELLOW YELLOW VIOLET RED
380V
ORANGE
0V 0V
To L3 BLACK BLACK RED
TR1
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(Note 13) Output Transformer
Output transformer must be custom designed for each drive and required voltage frequency of
Spindle. If the output transformer is not properly sized, drive and/or spindle may damage.
¾ In high frequency application when spindle voltage is significantly lower (360V) than the line
voltage available.
¾ For increasing the output current without increasing the drive current rating (output voltage
reduction).
9 Use a 0.13mm2 (AWG 26) to 0.8mm² (AWG 18) wire for wiring to the control circuit. The
tightening torque must be 0.6N.m (5.3lb-inch).
9 Use a twisted pair wire or twisted pair shield wire for wiring to the analog signal circuit such as
the analog references and meters. Connect the shield wire to the 0V terminal of the unit. The
wire length must be 30 meters (98.4”) or less.
9 The length of the sequence input/output contact wire must be 50 meters (164”) or less.
9 The sequence input can be changed between sink logic and source logic by changing the jumper
position JP1 in PCA-2014A between “SINK” and “SOURCE” position respectively. Open cover
designated as “Control Unit” to access this jumper.
9 At this time do not carry out a megger check or buzzer check on the control circuit.
• Are there any wire scraps or foreign matter left around the terminals?
• Are any screws loose?
• Is the wiring correct?
• Is any terminal contacting any other terminal?
If so, take the necessary corrective measures before proceeding further.
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CHAPTER- 3: DIGITAL OPERATION PANEL (LCD KEYPAD MODULE)
The configuration of the Digital Operation Panel is shown in the below figure. The structure of it is as
shown below.
The Digital Operation Panel is equipped with 8-keys as shown in the above figure. The function of
each key is described below.
This key is utilized to reach to the normal screen of digital operator panel from any
parameter, group or mode. The normal screen displays different parameters and status.
This is the screen displayed at power on.
This key when pressed, passes the control to next successive modes i.e. NORM
(Normal), MODE-M (Monitor), MODE-A, MODE-B, MODE-C, MODE-D & Meter mode.
After the end of all modes, it will carry the control again to first mode. When changing the
mode, the last accessed parameter of last accessed group of successive mode will be
displayed.
This key passes the control to next group in the same mode. The groups can be
accessed only in the incremental direction. At last it will again come to the first group.
These keys are used to change parameter numbers & parameter value. When ENTER
key is pressed, these keys are used to change the parameter value, otherwise it is used
to navigate the parameters in upward / downward direction in the group.
This key is used to start the AC Drive when the start control is through Digital Operation
Panel. The key is equipped with the status indicating LED. It will glow, when the AC
Drive is running.
This key is used to stop the AC Drive irrespective of the start control source. It is also
used to reset the fault. The stop key is equipped with status indicating LED. It will glow
when the AC Drive is off.
The Digital Operation Panel is also equipped with the fault indicating LED. It will flash in the fault
condition. It is also equipped with four lines, 20-character LCD display for the user-friendly parameter
navigation, monitoring and setting.
N o r m
Norm 1 0 . 0 H z 0 . 0 A m p Norm 3
Norm 2 5 0 . 0 H z * 0 0 % L Norm 4
F w d , L c l , D r i v e S t o p
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The above figure also indicates the selected direction of rotation, start selection and drive status. The
four user selectable parameters can be configured using A601 ~ A604.
3- 1 Drive Status
The fourth line of the Digital Operation Panel (LCD Keypad Module) is used to display different status
of the unit as shown above. More than one status can exist at one time. In this case, the status having
higher priority will be displayed. The priority is as shown in the figure. Fault has the highest priority
and mains on have least priority.
NO NAME DESCRIPTION
1 Fault It indicates that some fault has occurred in the unit.
2 Emergency Stop It shows that the unit is stopped due to emergency stop command.
3 Gap Elimi On It shows gap eliminator output is on.
4 Start Delay It shows that the start is delayed by the programmed start delay.
5 Jogging It shows that the jog select input is active and present operation is jogging.
6 Auto Restart It shows that auto restart function is in operation.
7 Current Limit It shows that the current limit function is active.
8 Voltage Limit It shows that the dc bus voltage control function is active.
9 Speed Search It shows that the speed search operation is in progress.
10 PLCT Active It shows that the Power-Loss-Carry-Through function is in progress.
11 Normal Run It shows that ramp up / down action is over and unit is running in normal
condition.
12 Acceleration It shows that the unit is accelerating to the set speed.
13 Deceleration It shows that the unit is decelerating.
14 DC Breaking It shows that the dc breaking is active.
15 Drive Stop It shows that the AC Drive is in stop condition.
16 Mains On It shows that the mains power supply is on.
When first time MODE key is pressed, lastly accessed parameter of lastly accessed group of Mode-M
will appear with its data. Below figure shows the parameter M101 of Group-1 of Mode-M.
Mode-M Group-1
M o d e - M G r o u p - 1
M 1 0 1 O u t p u t F r e q
0 . 0 H z
F w d , L c l , D r i v e S t o p
Parameter Data
Parameter Number and Name
The first line indicates the present mode and group. The second line indicates the parameter number
with its name and the third line shows its value. The fourth line shows the present status and remains
all the time except fault condition, contact information and fault history.
The parameters are grouped into Modes and Groups according to their functions.
The configuration of the parameters is as under.
NORM
MODE-C
MODE-D
Meter Mode
CAUTION
9 Do not remove or insert the display cable between PCA-2014A (Main Control Card) and PCA-
2012 (Display Card) in power-energized condition.
Failure to observe this could lead to component failure and tripping of the unit.
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CHAPTER- 4: TEST OPERATION AND ADJUSTMENT
DANGER
¾ Always install the front cover before turning the input power ON. Never remove the cover while
the power is ON. There are sections in the front PCB that are charged with high voltages.
Failure to observe this could lead to electric shocks.
¾ Never touch the switches with wet hands.
Failure to observe this could lead to electric shocks.
¾ Never touch the AC Drive’s terminals while the AC Drive power is ON even if the operation is
stopped.
Failure to observe this could lead to electric shocks.
¾ Selection of the restart function could lead to unexpected restarting when a fault occurs. The
machine may start suddenly if the power is turned ON, if the run command is present. Do not go
near the machine.
(Design the machine so that physical safety can be ensured even if the machine restarts.)
Failure to do so could lead to injuries.
¾ The machine may not stop according to the set deceleration time when a stop command is issued
if the ramp down to stop function is selected and the voltage / current limit function is activated.
Prepare a separate emergency stop switch in such cases.
Failure to do so could lead to injuries.
¾ Resetting of a fault while the run signal is input could lead to restarting. Always confirm that the
run signal is OFF before resetting the fault.
Failure to do so could lead to injuries.
CAUTION
9 The heat sink, chokes and dynamic braking resistor are heated to high temperatures, so never
touch them.
Failure to observe this could lead to burns.
9 Do not block the AC Drive’s ventilation holes.
Failure to observe this could lead to fires.
9 The AC Drive operation can easily be set from low speeds to high speeds, so confirm that the
operation is within the tolerable range for the Spindle or machine before making settings.
Failure to do so could lead to injuries.
9 Prepare holding brakes when necessary. Holding is not possible with the AC Drive’s brake
functions.
Failure to do so could lead to injuries.
9 Confirm the operation of the Spindle as a single unit before operating the machine.
Failure to do so could lead to injuries or machine damage due to unforeseen movements.
9 Always prepare a safety backup device so that the machine is not placed in a hazardous situation
when an error occurs in the AC Drive.
Failure to do so could lead to injuries or machine damage or fires.
Start
↓
Installation and wiring
Refer Chapter-2
↓
Preparation before turning
power ON
↓
Initialization of Spindle
parameters in Mode-B
↓
Test operation with operation
panel
↓
Setting of parameters for
external control
↓
Test operation including
external control
↓
End of test operation
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Make sure that there is no abnormal noise, smoke or odors at this time. If any abnormality is found,
turn the power OFF immediately.
4-1-1 Selection of Start Control
The Axpert Eazy HF Drive can be controlled from various places like Digital Operation Panel (Local),
Terminal or from PC. Select appropriate start control in A301. Use Digital Operation Panel (Local)
during the test operation.
A301: Start Control
=1: Local
=2: Terminal
=3: Serial
4-1-2 Selection of Frequency Reference Input
The Axpert Eazy AC Drive accepts frequency reference from various places like Digital Operation
Panel (Local), Terminal or from PC. Select appropriate frequency reference input in A106. Use Digital
Operation Panel (Local) during the test operation.
A106: Frequency Reference Input
=1: Local (Digital Operation Panel) =2: FSV 0-10V
=3: FSI 4-20mA =4: FSV 0-5V
=5: FSI 0-20mA =6: FSV 10-0V
=7: FSI 20-4mA =8: FSV 5-0V
=9: FSI 20-0mA =10: Static pot
=11: Serial =12: PID Output
=13: IIN 4-20mA
Refer the diagram of selection process of frequency reference diagram for the better understanding of
the flow frequency reference signal priorities.
4-1-3 Output Transformer Selections
Output transformer must be custom designed for each drive and the required voltage/frequency of the
spindle. If the output transformer is not properly sized, drive and / or spindle damage may result.
Output transformer is required when spindle voltage is significantly lower than the line voltage.
4-2 Initialization of Spindle parameters in Mode-B
Input the Spindle rating parameters. Set the following parameters in Mode-B.
B101: Rated Input Voltage (V)
B102: Spindle Voltage (V)
B103: Spindle Current (A)
B104: Spindle Frequency (Hz)
B105: Spindle Speed (KRPM)
B106: Spindle Output (kW)
B107: Spindle Poles
4-4
Preset i/p-1 B403 RUN
Ramp Freq Limiter
Preset i/p-2 Command
=9: FSI 20-0mA On (PSI) On
B407
Freq Increase On
(PSI) =10: Static pot
Freq
Freq Decrease Off Command
(PSI) =11: Serial A102 A103
Serial Jog Select A104
RUN Command has higher priority
=12: PID Output
Internal signal (PID Output) then Jog Select
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CHAPTER- 5: CONTROL INPUT / OUTPUT TERMINALS
5-1 Input / Output Terminal Functions Of PCA-2014A (Control Unit)
VIEW OF PCA-2014A
JP3
NLD LD
LD
SOURCE
JP1 NLD
SINK
JP5
K1 K2 K3
Fault Relay Prog Relay-1 Prog Relay-2
TB1
TB2
P15 0V VIN IIN VO2 IO1 CANH RUN PSI6 COM PSI2 PSI4 +24V PSO1 PSO3 COM RX PB PA +5V
FSV FSI 0V VO1 0V IO2 CANL STOP +24V PSI1 PSI3 PSI5 COM PSO2 PSO4 TX COM PBN PAN COM
R1A Programmable This is programmable relay and its function is assigned to “Run”
Relay 1 condition in default. When a programmed condition occurs, the section
R1C contacts R1A-R1C will close and the section R1B-R1C will open. Other internal
signals can also be output with the help of C111.
R1B
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R2A Programmable This is programmable relay and its function is not assigned to any
R2C Relay 2 internal signal in default. When any function is assigned using C112
contacts and the programmed condition occurs, the section R2A-R2C is closed
R2B and the section R2B-R2C is open.
The control circuit wiring is shown as under. The described precautions must be observed during
wiring. Changing the jumper position JP1 in PCA-2014A between “SINK” and “SOURCE” position can
change the sequence input between sink logic and source logic. Open cover designated as “Control
Unit” to access this jumper. The unit is shipped with sink logic.
+24V +24V
+24V
PSI 5.6k
PSI 5.6k
L<50m
(164')
COM
L<50m
(164')
SOURCE
SOURCE
JP1 JP1
SINK
SINK
Precautions
10k
2k/2W 0V IIN
20mA
L<30m (98.4') 270R
0V
L<30m (98.4')
VO1 270R
Output Frequency
(0-10V)
VO2 270R
Output Current
(0-10V)
0V
Ground
IO1 50R
Output Power
(4-20mA)
IO2 50R
Output Voltage
(4-20mA)
L<30m (98.4')
Precautions
PSO
L<50m (164')
Precautions
1. To drive an L load, such as a coil, insert the flywheel diode shown in the drawing.
2. Keep the wiring length to 50meters (164’) or less.
3. Use within the 30VDC, 50mA ratings range.
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5-6 Programmable Sequence Output (PSO) Wiring (Relay)
FA R1A R2A
FC R1C R2C
FB R1B R2B
PROGRAMMABLE FAULT
PROGRAMMABLE RELAY1 PROGRAMMABLE RELAY2
RELAY
Precautions
PSI1
Emergency Stop
PSI2
Fault Reset
PSI3
Preset Input-0
PSI4
Preset Input-1
PSI5
COM
TB1
(Sink logic operation is considered in this diagram)
Jumper Position
1. The equipment is shipped with sink logic (JP1 is kept on Sink position) for the programmable
sequence inputs. To change the sink logic to source, change the jumper JP1 position to Source.
2. The equipment is shipped with JP3 in NLD position. This means the terminating resistors are not in
picture. To insert the terminating resistors, keep the jumper to LD position.
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PSO1
PSO2
Programmable Sequence
Outputs
PSO3
PSO4
COM
TX
RS-485 P
RX C
COM A
PB -
2
PBN
0
Encoder Connections
(Reserved)
PA 1
PAN 4
+5V A
COM
TB1
FA
Programmable
FC P
Fault Relay
C
FB
A
R1A -
Programmable
Relay 1
R1C 2
R1B 0
1
R2A
Programmable
4
Relay 2
R2C A
R2B
NC
TB2
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CHAPTER- 6: PARAMETER SETTINGS & FUNCTIONS
MODE-M: Monitor Parameters
The monitor mode sequentially displays the frequency, power supply, etc., parameters.
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WP: Indicates that this parameter is Write Protected during RUN condition.
MODE-A Parameters
No Parameter Unit Def Min Max Res. Description WP
GROUP-1: FREQUENCY SETTING
A101 Local Set Hz 50.0 0.1 1800.0 0.1 This is the frequency set from Digital Operation
Frequency Panel (LCD Keypad Module). It can be set in
Hz (0.1 resolution) or in KRPM (0.01
resolution) according to selection in A107.
A102 Minimum Hz 0.1 0.1 1800.0 0.1 These two parameters are used to configure
Frequency Minimum and Maximum Frequency of the AC
A103 Maximum Hz 50.0 0.1 1800.0 0.1 Drive. It can be set in Hz (0.1 resolution) or in
Frequency KRPM (0.01 resolution) according to selection
in A107.
A104 Jog Frequency Hz 5.0 0.1 A103 0.1 This is frequency setting for jog input.
A105 Line Speed Setting rpm 0 0 108000 1 RPM line speed display. The entered value will
be displayed as Spindle speed in M102 at
Maximum Frequency (A103). At zero value
(default), Spindle speed (B105) will be displayed
as Spindle speed in M102 at Maximum
Frequency (A103).
A106 Frequency 1 1 13 1 This is used to select the speed reference.
Reference Input =1: Local =2: FSV 0-10V
=3: FSI 4-20mA =4: FSV 0-5V
=5: FSI 0-20mA =6: FSV 10-0V
=7: FSI 20-4mA =8: FSV 5-0V
=9: FSI 20-0mA =10: Static pot
=11: Serial =12: PID Output
=13: IIN 4-20mA
A107 Set frequency Unit 0 0 1 This parameter is for frequency unit selection. If
it is 0 then in A101 set point can be set in
frequency (Hz) unit with 0.1 resolution. And if it
is 1 then in A101 set point can be set in KRPM
with 0.01 resolution.
=0: Hz =1: KRPM
GROUP-2: ACCELERATION / DECELERATION TIME
A201 Acceleration Sec 10.0 0.1 1200.0 0.1 Time needed to change the output frequency
Time-1 from zero to maximum.
A202 Deceleration Sec 20.0 0.1 1200.0 0.1 Time needed to change the output frequency
Time-1 from maximum to zero.
A203 Acceleration Sec 10.0 0.1 1200.0 0.1 The acceleration time and deceleration time for
Time-2 the second ramp function.
A204 Deceleration Sec 20.0 0.1 1200.0 0.1
Time-2
A205 S-Curve Selection 0 0 1 1 This will enable the s-curve shape during
acceleration /deceleration.
=0: Disable
=1: Enable
A206 S-Curve Time-1 Sec 0.1 0.1 600.0 0.1 The maximum value will depend on the currently
selected ramp time.
A207 S-Curve Time-2 Sec 0.1 0.1 600.0 0.1 The maximum value will depend on the currently
selected ramp time.
A208 Current Limit Sec 10.0 0.5 1200.0 0.1 This is ramp up time during the stall current
Acceleration Time limit.
A209 Current Limit Sec 5.0 0.5 1200.0 0.1 This is ramp down time during the stall current
Deceleration Time limit.
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NO Parameter Unit Def Min Max Res. Description WP
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NO Parameter Unit Def Min Max Res. Description WP
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NO Parameter Unit Def Min Max Res Description WP
C218 IIN Time Constant mS 50 0 1000 1 This parameter set the filter time constant for
the VIN and IIN analog inputs.
C219 Vout-1 Bias 87 0 1000 1 This is bias setting for the VO1 analog output.
C220 Vout-2 Bias 82 0 1000 1 This is bias setting for the VO2 analog output.
C221 Spindle Thermistor 1.000 0.100 1.500 0.001 This is gain setting for the Spindle thermistor
Gain input.
C222 Spindle Thermistor 0 0 1000 1 This is bias setting for the Spindle thermistor
Bias input.
GROUP-3: STATUS OUTPUT DETECTION LEVEL
C301 Frequency % 1.0 0.0 20.0 0.1 The attained frequency output (Freq Attain)
Attainment operation width is set.
Detection Width
C302 Crush current % 100.0 5.0 200.0 0.1 The crush current level (current detection) is
Level set. Set with a percentage of the rated current
(current detection) (B103). A 5% hysteresis will occur with the
current-Detection operation.
C303 Speed Detection % 95.0 1.0 105.0 0.1 The speed detection operation level is set. Set
Level-1 with a percentage to the max frequency A103.
The output frequency or the Spindle speed will
C304 Speed Detection % 50.0 1.0 105.0 0.1
be the comparison target. A 1% hysteresis will
Level-2
occur with speed detection operation.
C305 Zero Speed % 1.0 0.0 50.0 0.1 The Zero speed detection operation level is set.
Detection Level Set with a percentage to the max frequency
(A103). The output frequency or the Spindle
speed will be the comparison target. A 1%
hysteresis will occur with zero speed operation.
C306 4-20mA Reference 2 1 7 1 This parameter configures the AC Drive’s
Loss response to a failure of 4-20mA Frequency
reference input signal.
=1: No action at fault detection
=2: Minor fault alarm & run at minimum speed
=3: Minor fault alarm & run at max speed
=4: Minor fault alarm & run at set speed
=5: Minor fault alarm & run at preset speed-1
=6: Fault, ramp down to stop
=7: Fault, coast to stop
C307 Output Phase Loss 1 0 1 1 Output open-phase is detected if one phase
current is <5% and other two phase currents
are >10% of Spindle rated current, when this
protection is enabled.
=0: Disable
=1: Enable
C308 Timer Output 0 0 1 1 Set the ON/OFF control for the timer output.
Selection =0: ON only when AC Drive is ON
=1: ON whenever power is ON
C309 Timer output Off Sec 60 0 3000 1 Set the time in seconds to delay turning OFF
Delay time the timer output after the AC Drive OFF
command is received.
C310 Temperature 1 0 1 1 This parameter controls the automatic change
Control selection of carrier frequency in case of temperature rise
above the predefined level.
=0: Disable
=1: Enable
Amtech
6-10
NO Parameter Unit Def Min Max Res Description WP
D205 Spindle Type kW M304 0.1 315.0 0.1 The Spindle’s rated output at the base speed is
set from the nameplate.
D206 Local Set Hz 50.0 0.1 1800.0 0.1 This is the frequency set from Digital Operation
Frequency Panel (LCD Keypad Module) for this auxiliary
Spindle. It can be set in Hz (0.1 resolution) on in
KRPM (0.01 resolution) according to selection
in A107.
D207 Min Frequency Hz 0.1 0.1 1800.0 0.1 These two Parameters are used to configure
Minimum and Maximum Frequency of the AC
D208 Max Frequency Hz 50.0 0.1 1800.0 0.1
Drive for this auxiliary Spindle. It can be set in
Hz (0.1 resolution) on in KRPM (0.01 resolution)
according to selection in A107
D209 Line Speed rpm 1500 0 108000 1 The set value will be displayed as Spindle
Setting speed in M102 at Maximum Frequency (D208)
when this auxiliary drive is selected. At zero
value (default), Spindle speed (D204) will be
displayed as spindle speed in M102 at
Maximum Frequency (D208)
D210 Acceleration Time- Sec 10.0 0.1 1200.0 0.1 Time needed for the speed to change from zero
1 to maximum.
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6-12
NO Parameter Unit Def Min Max Res Description WP
D211 Deceleration Time- Sec 20.0 0.1 1200.0 0.1 Time needed for the speed to change from
1 maximum to zero.
D212 Manual Torque % 0.0 0.0 20.0 0.1 When setting manually, set the boost voltage at
Boost 0Hz as a percentage in respect to the rated
Setting output voltage. When programmed to zero, it
will be disabled.
D213 Gap Eliminator % 0.0 0.0 20.0 0.1 This is % of Spindle rated power.
Threshold
D214 V/F Selection 1 1 3 1 Select the appropriate v/f curve.
=1: Linear Curve
=2: Square Curve
=3: Custom setting
D215 VF1 Frequency Hz 30.0 30.0 100.0 0.1 These parameters are used to create the
custom V/Hz profile. Three different points for
D216 VF2 Frequency Hz 40.0 30.0 100.0 0.1 the curve can be defined to get the profile
D217 VF3 Frequency Hz 50.0 30.0 100.0 0.1 suitable for the application.
D218 VF1 Voltage Vac 100 50 460 1 D215 <= D216 <= D217 <= D203
D219 VF2 Voltage Vac 210 50 460 1 & D218 <= D219 <= D220 <= D201 <=B101
Amtech
6-14
FUNCTION EXPLANATIONS
GROUP-1
GROUP-2
6-16
M208: Heat sink Temperature (°F)
This parameter displays the actual heat sink temperature. When selected for the normal parameter
display in A601~A608, the value will be displayed with “°F” unit.
GROUP-3
M o d e - M G r o u p - 3
M 3 0 6 P S I - 1 2 3 4 5 6 7 8
0 1 0 0 0 0 0 0
F w d , L c l , N o r m a l R u n
As shown above, line-2 shows the programmable sequence input and line-3 shows the status of
respective input. The zero value indicates that the programmable sequence input is OFF and 1
indicates ON. In the above screen, only PSI-2 is ON and the others are OFF.PSI-7 shows status of
PSI-RUN and PSI-8 shows status of PSI-STOP.
M o d e - M G r o u p - 3
M 3 0 7 P S O - 1 2 3 4 5 6 7
0 1 0 0 0 1 0
F w d , L c l , N o r m a l R u n
PAGE-1
M o d e - M F L T - 1 G r o u p - 4
E x t e r n a l F a u l t
5 8 5 V d c 0 . 0 A m p
1 0 . 0 H z 3 5 ° C
PAGE-2
M o d e - M F L T - 1 G r o u p - 4
E x t e r n a l F a u l t
4 2 0 V r y 6 0 1 1 0 H r
1 1 0 M W H 7 3 5 k W H
As shown above, in the first page, line-2 shows the fault code, line-3 shows the DC Bus Voltage &
Output Current and line-4 shows the Output Frequency & Heat sink Temperature. In the second page
also, line-2 shows the fault code, line-3 shows Input Voltage (Vry) & Total Conductivity Time (Hr) and
line-4 shows the Energy Meter (MWH & kWH). If no fault is detected since shipment, line-2 in both the
pages will display “No previous fault” and the value of different parameters will be read as zero.
Same way FLT-2 ~ FLT10 shows the previous fault codes and parameters at the time of fault
occurrence.
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6-18
MODE – A
2. FSV 0-10V
When this option is selected, the set frequency M105 corresponds to analog input FSV. The output
frequency will be zero at 0V and maximum at 10V.
F F
A103 A103
V I
0 10V 0 4mA 20mA
FSV 0-10V FSI 4-20mA
3. FSI 4-20mA
When this option is selected, the set frequency M105 corresponds to analog input FSI. Zero
frequency will be available at 4mA and maximum at 20mA.
4. FSV 0-5V
When this option is selected, the set frequency M105 corresponds to analog input FSV. Zero
frequency will be available at 0V and maximum at 5V.
5. FSI 0-20mA
When this option is selected, the set frequency M105 corresponds to analog input FSI. Zero
frequency will be available at 0mA and maximum at 20mA.
6. FSV 10-0V
This is an inverse to option-2. When this option is selected, the set frequency M105 corresponds to
analog input FSV. Zero frequency will be available at 10V and maximum at 0V.
7. FSI 20-4mA
This is an inverse to option-3. When this option is selected, the set frequency M105 corresponds to
analog input FSI. Zero frequency will be available at 20mA and maximum at 4mA. The maximum limit
is decided by A103.
Amtech
6-20
F F
A103 A103
V I
0 FSV 10-0V 10V 0 4mA FSI 20-4mA 20mA
8. FSV 5-0V
This is an inverse to option-4. When this option is selected, the set frequency M105 corresponds to
analog input FSV. Zero frequency will be available at 5V and maximum at 0V.
9. FSI 20-0mA
This is an inverse to option-5. When this option is selected, the set frequency M105 corresponds to
analog input FSI. Zero frequency will be available at 20mA and maximum at 0mA.
11. Serial
In this option, the set frequency M105 can be assigned from serial link.
13 IIN 4-20mA
When this option is selected, the set frequency M105 corresponds to analog input IIN. Zero frequency
will be available at 4mA and maximum at 20mA.
F
A103
I
0 4mA 20mA
IIN 4-20mA
Max.Frequency
(A103)
0 t
Acceleration Deceleration
Time-1(A201) Time-1(A202)
Amtech
6-22
F
Deceleration
Time-1 (A202)
Ramp Select = OFF
Acceleration Deceleration
Time-1 (A201) Time-2 (A204)
Ramp Select = ON
ON
Ramp Select
A206 A207
t
A206 A207
Acceleration Deceleration
time-1 (A201) time-1 (A202)
t
F
M105
Output Freq.
Current Limit
(M101) Current Limit
Decel Time (A209)
Accel Time (A208)
t
Vdc
740Vdc
DC Bus voltage
Control (B307=1)
t
RUN
Output frequency
COM
RUN
If A302=1: The start / stop control is momentary type as described in below figure.
Amtech
6-24
Output frequency
RUN
STOP
RUN
COM
STOP
Vout
Spindle voltage
(B102)
Linear curve
(A401=1)
Square curve
(A401=2)
Fout
Spindle frequency
(B104)
Custom three-point v/f characteristics as shown in the below figure can be set for the Spindles having
special v/f characteristics. Choose custom v/f curve in A401.
Vout
(A403)
(A409)
(F3,V3)
(F2,V2)
(A408)
(A407)
(F1,V1)
Fout
(A404) (A405) (A406) (A402)
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6-26
A501: Manual Torque Boost setting (%)
When setting manually, set the boost voltage at 0Hz as a percentage in respect to the Spindle voltage
(B102). When programmed to zero, it will be disabled.
Vout
Spindle voltage
(B102)
Output voltage
with manual
torque boost
Output voltage
with no torque
A501 boost
Fout
Spindle frequency
(B104)
This parameter can be set individually for 15 different auxiliary spindles. (D213, D313,….., DG13).
Gap eliminator function is disable, when gap eliminator threshold value is 0.0% (default) or “16: Gap
Eli Det” option is not selected in programmable output.
The gap eliminator function is useful in applications where it is necessary to “close the gap” between a
spindle’s tool and the work piece using a fast feed rate. When the tool hits the part face and the load
threshold is exceeded, the relay is activated and the feed rate is reduced (by the user).
Volt compensation gain (A504) compensates the effect of input supply voltage variation in power
when spindle is in “Normal Run” condition but the tool is not yet in contact with the part.
Any time the spindle reaches to the “Normal Run” condition, the present load (output power) is
sampled and stored as the base load. The sampling and storage of the base load level occurs 3 sec
after “Normal Run” condition is reached.
Note:
1. It is important that the frequency reference input (0~10V or 4-20mA) remain stable during the
entire operation. Fluctuation in frequency reference may cause malfunction of gap eliminator
function.
2. Machining must not start until 3 sec after “Normal Run” condition has been reached.
Changing the spindle load during this period will cause the sampling of an improper base load
level.
Base load
RUN
command
applied 3 sec
Load applied
Digital oputput
"Gap Eli Detect"
The base load sample can alternatively be taken from digital input (PSI “16: Base Load Input”) by user
after reaching at set speed (“Normal Run” condition). The feature is useful in applications where the
speed is constant. By periodically taking a base load sample input, machine load variations
(temperature, time, etc.) are eliminated. This is momentary type input and once this digital input is
active, the base load sample will be taken after 1 second. Note that if the digital input is kept ON all
the time, it will not update the base load sample again. Reapply the digital input to take next sample.
When “Gap Eli Det” is selected in digital programmable sequence output (PSO) or programmable
relay output, it will activate on the output power crosses the programmed threshold level (A502) form
base load sample taken. It will deactivate with Hysteresis (0.5 of A502).
Amtech
6-28
GROUP – 6: DISPLAY PARAMETER SELECTION
N o r m
Norm 1 0 . 0 H z 4 2 . 0 A m p Norm 3
Norm 2 5 0 . 0 H z * 9 5 % L Norm 4
F w d , L c l , D r i v e S t o p
To display the Output Frequency M101 (Hz) parameter at Norm 1 position as shown in the above
screen, select option 1 (M101 Hz) in parameter A601 Norm Parameter1.
M o d e - A G r o u p - 6
A 6 0 1 N o r m P a r a m e t e r 1
1 : M 1 0 1 H z
F w d , L c l , D r i v e S t o p
Similarly, to display the desired parameters at positions Norm 2, Norm 3 and Norm 4, select the
appropriate option in A602, A603 and A604 respectively.
Parameters A605~A608 selects parameters for Norm-5 to Norm-8 positions for the meter screen and
are not applicable for the normal screen. Below is the meter screen with eight parameters.
User Selectable eight parameters
Norm 5 4 1 5 V r y 2 2 k W Norm 7
Norm 1 5 0 . 0 H z 4 4 . 0 A m p Norm 3
Norm 2 5 0 . 0 H z * 1 0 0 % L Norm 4
Norm 6 5 8 5 V d c 3 5 ° C Norm 8
Amtech
6-30
GROUP – 2: SPINDLE CONSTANT
t
F
M105
Output freq.
Current limit decel
(M101) Current limit accel
time (A209)
time (A208)
t
Vdc
740Vdc
DC bus voltage
control (B307=1)
t
Set the current limit as a percentage of Spindle rated current.
Output freq.
(M101)
Note: In pump applications, if the flow decreases below a minimum speed there will be cavitations.
This feature becomes useful to turn off the pump in such case.
Vdc
B307=1
740Vdc
30V hysteresis
t
F
M105
Output freq.
(M101)
Amtech
6-32
B308: Reverse Direction Lock
Set this to prevent unintentional reverse direction operation. When enabled it will prevent the AC Drive
to start in reverse direction. This parameter cannot be changed during running condition.
Not: If reverse direction is locked and run command is given with reverse direction selection,
the AC Drive will not start in reverse direction.
Note that the value entered in B311 will not be memorized. If correct value is entered, appropriate
action will be taken and “00” will be displayed. If incorrect value is entered, no action will be taken and
“00” will be displayed.
The Start Control A301 determines the direction of rotation. If Local (Digital Operation Panel) is
selected as start control, the direction can be change only through parameter A305. When Terminal is
selected as start control, the status of sequence input terminal would decide the direction.
The preset speed can be set higher than max frequency A103 up to 1800Hz. However, the output
frequency will not exceed the maximum frequency A103.
Amtech
6-34
Operation
frequency
B503
B502
B501 B504
Set frequency
6 Preset i/p-2
7 Freq Increase The currently selected frequency setting is increased or decreased.
When the ON state continues, the frequency is incremented
8 Freq Decrease /decremented with 0.1Hz at every 100msec. This is valid only if static
potentiometer is selected as frequency reference source in A106
9 E-Stop (NO) This is used as emergency stop. This is Normally Open type. When
the digital input (connected to COM in case of sink logic or to +24V in
case of source logic) is close, Emergency stop occurs as per the
selection in C503.
10 Fault Reset This is used for the fault reset. If RUN input is present at the time of
fault reset, the AC Drive will not start after fault reset. Issue fresh
RUN command to start the AC Drive after fault reset.
11 Ext Flt (NO) This is used for the external fault function. This is Normally open
type. When the digital input (connected to COM in case of sink logic
and to +24V in case of source logic) is close, external fault occurs.
12 Terminal When this input is selected, the operation control will be switched
over to terminal.
13 Ref Select 0 These two inputs Ref Select 1 Ref Select 0 Freq reference
are used to select 0 0 A106
the frequency
14 Ref Select 1 reference as shown 0 1 FSI 4-20mA
in the side table. 1 0 Static Pot
1 1 Serial
15 Reverse This input is used to select reverse direction of rotation in terminal
mode.
16 Base Load This is used to sample the power for the gap eliminator function from
Sample i/p the digital input. Sample is taken after 1 second the activation of the
digital input in normal run condition. This is momentary type input, so
reapply the digital input to take the next sample.
Amtech
6-36
17 Spindle Sel 1 These four Spindle Spindle Spindle Spindle Selected Spindle
inputs are Sel 4 Sel 3 Sel 2 Sel 1
used to 0 0 0 0 Main Spindle
select the
auxiliary 0 0 0 1 Auxiliary Spindle 1
Spindle as 0 0 1 0 Auxiliary Spindle 2
shown in the
18 Spindle Sel 2 side table. 0 0 1 1 Auxiliary Spindle 3
0 1 0 0 Auxiliary Spindle 4
0 1 0 1 Auxiliary Spindle 5
0 1 1 0 Auxiliary Spindle 6
19 Spindle Sel 3 0 1 1 1 Auxiliary Spindle 7
1 0 0 0 Auxiliary Spindle 8
1 0 0 1 Auxiliary Spindle 9
1 0 1 0 Auxiliary Spindle 10
20 Spindle Sel 4 1 0 1 1 Auxiliary Spindle 11
1 1 0 0 Auxiliary Spindle 12
1 1 0 1 Auxiliary Spindle 13
1 1 1 0 Auxiliary Spindle 14
1 1 1 1 Auxiliary Spindle 15
21 E-Stop (NC) This is used as emergency stop. This is Normally Close type. When the
digital input (connected to COM in case of sink logic or to +24V in case of
source logic) is open, Emergency stop occurs as per the selection in
C503.
22 Ext Flt (NC) This is used for the external fault function. This is Normally Close type.
When the digital input (connected to COM in case of sink logic and to
+24V in case of source logic) is open, external fault occurs.
23 RUN This is used to give RUN command from terminal.
24 STOP This is used to give STOP command from terminal.
25 Enable (NO) This is used for the “Enable” function. It allows drive output when RUN
command is given. When “Enable” is not active, output will not come even
though RUN command is present. This is Normally open type. When link
(connected to COM in case of sink logic and to +24V in case of source
logic) is closed, “Enable” function activates.
26 Enable (NC) This is used for the “Enable” function. It allows drive output when RUN
command is given. When “Enable” is not active, output will not come even
though RUN command is present. This is Normally Closed type. When link
(connected to COM in case of sink logic and to +24V in case of source
logic) is open, “Enable” function activates.
19 Spindle Sel 3
20 Spindle Sel 4
21 Thermal Trip This output will be turned ON when the resistance of the Spindle
thermister is measured outside the range of 30R ~ 4k2.
22 Temp Alarm The output is ON when the heat sink temperature exceeds the set
Temperature Alarm Level in C311.
Amtech
6-38
23 Ready The output is ON when the unit is ready to start. The soft charge
contactor is energized and no fault condition persists.
24 Fault The output is ON when fault occurs.
Selected Spindle Spindle Sel 4 Spindle Sel Spindle Sel Spindle Sel
3 2 1
Main Spindle 0 0 0 0
Auxiliary Spindle 1 0 0 0 1
Auxiliary Spindle 2 0 0 1 0
Auxiliary Spindle 3 0 0 1 1
Auxiliary Spindle 4 0 1 0 0
Auxiliary Spindle 5 0 1 0 1
Auxiliary Spindle 6 0 1 1 0
Auxiliary Spindle 7 0 1 1 1
Auxiliary Spindle 8 1 0 0 0
Auxiliary Spindle 9 1 0 0 1
Auxiliary Spindle 10 1 0 1 0
Auxiliary Spindle 11 1 0 1 1
Auxiliary Spindle 12 1 1 0 0
Auxiliary Spindle 13 1 1 0 1
Auxiliary Spindle 14 1 1 1 0
Auxiliary Spindle 15 1 1 1 1
Amtech
6-40
This is bias setting for the IO2 analog output.
M105
C301
Freq Attain
Iout
5%
C302
I-Detection
The speed detection operation level is set. Set with a percentage to the maximum frequency A103.
The output frequency or the Spindle speed will be the comparison target. When the output frequency
reaches the set level, the output will be ON. When the frequency reduces below the 1% hysteresis
level, the output will be OFF.
Amtech
6-42
F
1%
C304
C303
Speed
Detect1
Speed
Detect2
C305
1%
t
Zero Speed
Temp
2°C (35.6°F)
C310
M208
Temp Alarm
1: 1200 4: 9600
2: 2400 5: 19200
3: 4800
Refer the detail manual for the ModBus protocol and other information.
Amtech
6-44
C402: Station Number
This parameter defines the address of the unit when connected to the serial network. This AC Drive
supports the ModBus protocol. The station number can be assigned to 1 ~ 247.
C403: Parity
This parameter is used to set the parity. Parity is error-checking code to prevent from erroneous data
transformation between drive unit and terminal.
For detail information on the ModBus protocol and register assignment, please refer “Serial
Communication Guide, Version 1.0”.
Note: Put jumper JP3 to “LD” position to use terminating resistors. Remove the cover
designated as “Control Unit” to access this jumper on PCA-2014A.
Programming 0 in C501 disables the restart feature. Number of restart C501 defines the number of
attempts to restart during the fault condition.
When a fault is detected, the AC Drive output is shut off for the restart wait time C502. The operation
panel displays the fault while the AC Drive output is OFF.
When the restart wait time elapses, a fault is reset automatically and speed search operation is
performed.
When the number of such attempts exceeds the number of restart C501, the faults are not reset
automatically and the AC Drive output remains OFF. At this time a fault relay is activated and the fault
data will be stored in fault history. The RUN relay will also be deactivated.
A103
OC OC OC
M105
t
C502
Amtech
6-46
operation starts after the speed search wait time C508 after the start command. The following figure
explains the sequence of operation.
Speed search current limit C505 is applicable only during the speed search operation. The output
frequency deceleration time and output voltage acceleration time during the SSF can be adjusted
using C506 and C507 respectively as per the application.
Note: The time in C509 must be less than the time for which the control power supply remains
stable during the power outage or under voltage condition.
Fout
Maximum Frequency
A103
C506 Set Frequency
M101
A201
Motor
speed
Iout
M104
Vout
C507
t
C508
6-48
C608: PID deviation
C610: PID Offset Upper Limit
Adjustment
C602=1
+ +
C603: PID
Reference Input
PID PID Output
- +
C604: PID
C609: PID deviation
Feedback Input
Lower Limit
C605: Proportional Gain
C606: Integral Time
C607: Derivative Gain
PID Controller
When multi-Spindle operation is selected the inverter output & different sequence output commands
will be as shown in the below figure.
RUN RUN
RUN RUN
Amtech
6-50
MODE – D
In default condition, at zero value Spindle speed (D204) will be displayed as spindle speed in M102 at
Maximum Frequency (D208).
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6-52
D211: Deceleration Time-1 (Sec)
Deceleration Time-1 is the time taken by AC Drive output frequency to ramp down from maximum
frequency D208 to zero frequency.
Short deceleration time can result in excessive output current and if it exceeds the Stall current limit
B301, the deceleration will cease until the current reduces below the B301 value. In such case, the
actual deceleration time will differ from programmed value. The AC Drive may trip in timed over
current / dc bus over voltage fault if the condition persists for long time. Increase deceleration time in
such cases.
Vout
Spindle voltage
(D201)
Linear curve
(D214=1)
Square curve
(D214=2)
Fout
Spindle frequency
(D203)
(D201)
(D220)
(F3,V3)
(F2,V2)
(D219)
(D218)
(F1,V1)
Fout
(D215) (D216) (D217) (D203)
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6-54
This page is intentionally left blank.
It uses 32-bit High-Performance Digital Signal Processor TMS320F2811. The control board
generates the necessary pwm control signals for AC Drive operation. It accepts various inputs from
different circuits, gate drive board and Digital Operation Panel (LCD Keypad Module) to generate the
necessary control and gate signals.
The TMS320F2811 (U1) is the heart of this board. It handles the user interfaces and core algorithm
and generates IGBT gate signals. The PCA-2014A is connected to PCA-2012 Display Card with RS-
485 link. PCA-2012 displays various parameters of the drive.
It has LPC2368 controller. When interfaced with main control board PCA-2014A, this becomes master
and the main control boards works as slave. The master and slave communication is based on RS-
485 (Modbus-RTU Protocol).
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7-2
CHAPTER- 8: MAINTENANCE, INSPECTION & PART REPLACEMENT
DANGER
¾ Always wait at least 20 minutes after turning the input power OFF before starting inspection.
Wait at least 20 minutes after turning the input power OFF before starting work. Make sure that
the displays on the operation panel have gone out before removing the front cover.
Remove the front cover, and confirm that the “DC BUS CHARGE LED” on bleeder board has
gone out. Also check that the voltage between terminals L+1 or L+2 and L– is 15V or less before
starting the inspections.
Failure to observe this could lead to electric shocks.
¾ Maintenance, inspections and part replacement must be done by a designated person.
(Remove all metal accessories such as watches, bracelets, etc., before starting the work.)
(Always use an insulation measure tool.)
Failure to observe this could lead to electric shocks and injuries.
¾ Always turn the power OFF before inspecting the Spindle or machine. A potential is applied on
the Spindle terminal even when the Spindle is stopped.
Failure to do so could lead to electric shocks and injuries.
¾ Do not use parts other than those designated for the replacement parts.
Contact your AC Drive dealer for replacement parts.
Failure to observe this could lead to fires.
¾ Never modify the product.
Failure to observe this could lead to electric shocks or injuries or product failure.
CAUTION
9 Vacuum the AC Drive with a vacuum cleaner to clean it. Do not use water or organic solvents.
Failure to observe this could lead to fires or damage.
9 Do not megger the unit.
Failure to observe this could lead to damage to semiconductor devices.
Daily inspections
Inspection of spares
The inspection shown in above table must also be performed for spare AC Drives that are left
connected but are not used in normal operation. The operation of the AC Drive must be checked
every six months by turning the power on.
Amtech
8-2
CHAPTER- 9: OPTIONS
Besides the standard features available in the Axpert Eazy HF series AC Drive, which satisfies most
of the industrial applications, AMTECH offers its users a spectrum of optional products designed to
match their requirement.
The list of optional products offered by AMTECH herewith is all developed, field tested and
commissioned at various locations in India. A brief description of the option is given. Contact
AMTECH with relevant data to design one for you.
Non-linear loads like AC Drive, UPS, Converters etc. draw power from mains in a way, which
introduce harmonic currents into the mains. They behave like harmonic source, which feeds harmonic
to all the equipments, connected with the power source. IEEE STD 519: 1992; IEEE Recommended
Practices and Requirements for Harmonic Control in Electric Power System states that it is the
responsibility of the consumer to curb this mains ‘Pollution’ at the source point itself within acceptable
limits.
AMTECH offers Input Harmonic Converter as a solution for this problem. As per the requirement and
acceptable limits of induced harmonics such converters can be tailor made for you. Contact AMTECH
for details on Input Harmonic Converter.
Output of any AC Drive is Sine PWM (Pulse Width Modulation) modulated at high frequency carrier
wave. When this kind of waveform encounters Spindle load, it tends to create very high dV/dt stress
for the stator winding. After a long time the stator insulation gets weakened up and ultimately the
stator flashover takes place. The problem is particularly severe in places where the location of Spindle
and AC Drive is at large distance. This happens because of the impedance mismatch between cable
and the Spindle surge impedance. This can reach as high as 1.9 times the DC bus voltage.
Output Sinus Filter helps to outcome this problem. The output after sinus filter becomes sinusoidal
and the Spindle gets relieved from excessive dV/dt stress. Spindle can be placed far away from AC
Drive. The Spindle loss due to harmonic heating also reduces considerably.
Output Sinus Filter also helps in controlling the EMI and RFI generated by the power cable and
Spindle. That means an added advantage for equipments operating with small voltages and high
frequencies. Contact AMTECH for details on Output Sinus Filter.
Input filter is installed before the converter stage of the any AC Drive to smoothen the current drawn
from mains power supply. This also improves the wave shape at the input, as the peak value of drawn
current is restricted and the mains transformer do not goes towards saturation.
Output filter with around 3% impedance helps in changing the characteristic impedance of the
Spindle. Now the AC Drive sees the output filter as the reflecting impedance and the filtering choke
bears the dV/dt spikes. Thus the dV/dt transient do not hampers the Spindle thereby increasing its
insulation life and reduced heating. Alternatively RC Filters and LC Filters and other passive
component combinations are also designed to suit a particular requirement. For sizing and best filter
selection for your system, contact AMTECH.
Metering
At times there may be need of monitoring the internal AC Drive data. Optional analog or digital
metering of AC Drive operating data like various voltages, currents, rpm etc can be provided in the
panel. For the AC Drive data, which can be monitored, and the extra hardware, contact AMTECH for
details.
Some applications may demand enclosures, which suit the environment where the unit is to be
installed. Protection against water or ingress or against some harmful ambient gas can be provided
within the scope of the manufacturer. The enclosure can be modified for required degree of protection
like IP54/ 55. Occasionally the shape and size of the enclosure can also be discussed for
incorporating the unit in some other predefined structure. Contact AMTECH for details on Enclosure
options.
For critical applications where the equipment can’t bare the stoppage due to interruptions in the power
supply or its complete failure, AMTECH offers battery backup AC Drives. This is also applicable at
locations where the input power provided for AC Drive is DC. Contact AMTECH for details on Battery
Backup AC Drive.
Remote box for operation from near the actual driven Spindle site can be provided for the user with
optional controls and displays. We remind you here that our standard keypad control box can be
taken up to 1000 feet without any problem. Contact AMTECH for details on Remote Operator Box.
EMI Filter
AC Drive output carries high frequency carrier wave generates electromagnetic radiations. AMTECH
offers EMI filters to minimize the affect of AC Drive generated EMI noise on other equipments, which
are microprocessor based, and are placed very near to such EMI sources.
Dynamic breaking up 100% of the unit rating can be provided for high inertia loads, which require fast
deceleration. The mechanical inertial rotating energy is converted into electrical energy and dissipated
at dynamic breaking resistors. Contact AMTECH for details on Dynamic Braking.
AC Drive Bypass
A bypass with Direct-On-Line or Star-Delta bypass start can be provided for Spindle at critical places
where the process cannot bear any eventuality arising out of AC Drive failure. Contact AMTECH for
the scheme of bypass and other details on AC Drive bypass option.
Amtech
9-2
CHAPTER- 10: SERIAL COMMUNICATION SET-UP
The AXPERT Eazy Drive is equipped with a serial communication function using RS485 as a
standard. It acts as a Modbus slave in the network. The unit can be controlled with a host computer
(master) using this function.
10-1 Connection method
This network is configured of one host computer (master) and 1 to 247 max AXPERT Eazy units
(slaves). TB1 on main control board is used for the connection.
Refer to Chapter-2 Installation and Wiring for wiring the control signal and for the wiring methods.
The total length of the connected cable must be within 300mt (1000ft).
By using a commercially available RS485-RS232C converter or USB converter unit, the inverter can
be connected to a host computer equipped with a serial port or USB, such as a commercially
available personal computer.
The details of the TB1 terminal section are shown below.
TB1 RX
P15 0V VIN IIN VO2 IO1 CANH RUN PSI6 COM PSI2 PSI4 +24V PSO1 PSO3 COM PB PA +5V
FSV FSI 0V VO1 0V IO2 CANL STOP +24V PSI1 PSI3 PSI5 COM PSO2 PSO4 COM PBN PAN COM
TX
RS232
RS232 RS232/RS485
RS485 Converter
VCC GND DATA+ DATA-
RX
PSO3 COM PB
PSO4 COM PBN
TB1
TX
RS232 USB
AXPERT Shielded
AXPERT RS232/RS485 AXPERT USB/RS485
Converter Converter
EAZY EAZY RS485 EAZY RS485
twisted
cable
TB1 TB1 TB1
9 Separates the communication cable from the main circuit cable and other power cables.
9 A shielded twisted pair cable should be used for connecting TB1 and the host computer.
Connect the shielded twisted pair cable's shield to the COM terminal of TB1.
9 When connecting the TB1 and shielded twisted pair cable, do not solder the wires, which are
exposed after the sheath is peeled off.
9 If the communication is distorted and not carried out properly because of noise, etc., connect
a ferrite core, etc., to the cable, and increase the noise resistance.
9 When connecting several Axpert Eazy units, connect two wires to each TB1 terminal, and
couple the Axpert Eazy units. An example of the connection is shown below.
HOST
COMPUTER
(Master)
RS485
TX
COM RX
TB1
Shield
To host computer
To next unit
or unit
Shielded twisted cable Shielded twisted cable
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CAUTION
9 Separates the communication cable from the main circuit cable and other power cables.
9 A shielded twisted pair wire should be used for connecting TB1 and the host computer.
Connect the twisted pair cable's shield to the COM terminal of TB1.
9 When using several slave units, set JP3 of last unit to ‘LD’ position to connect the terminating
resistors as shown in the above fig.
9 When connecting the TB1 and shielded twisted pair cable, do not solder the wires, which are
exposed after the sheath is peeled off.
9 If the communication is distorted and not carried out properly because of noise, etc., connect
a ferrite core, etc., to the cable, and increase the noise resistance.
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Digital inputs 8-Programmable Sequence Inputs, Sink / Source changeable
Programmable to 26 different options: Not Used, Jog Select, Ramp Select,
Preset i/p-0, Preset i/p-1, Preset i/p-2, Freq Increase, Freq Decrease,
Emergency Stop (NO), Fault Reset, Ext Fault (NO), Terminal, Ref Select 0,
Ref Select 1, Reverse, Base Ld I/P, Spindle Sel 1, Spindle Sel 2, Spindle
Sel 3, Spindle Sel 4, Emergency stop (NC), Ext Fault (NC), RUN, STOP,
Enable (NO), Enable (NC)
Digital outputs 4-Programmable Sequence Outputs, open collector type
Operation Specifications
Protective Function Current Limit, Over current fault, Timed over current fault, Load side short
circuit fault, Under current fault, Over voltage fault, Under voltage fault,
Temperature fault, Spindle Hot/Short, Output phase loss fault, Ground
fault, External fault, Charging fault, Current sensor fail fault, EEPROM
Specifications
Note1: Indicates the total effective value including the higher harmonics
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Appendix-B: Fault Codes
In case of fault condition, first ensure that the mains voltage applied at L1, L2 and L3 are ok.
Then check the control supply voltage in PCA-2014A.
If the above voltages are correct, check the following jumper positions.
Jumper Position
1. The equipment is shipped with sink logic (JP1 is kept on Sink position) for the programmable
sequence inputs. To change the sink logic to source, change the jumper JP1 position to Source.
2. The equipment is shipped with JP3 in NLD position. This means the terminating resistors are not in
picture. To insert the terminating resistors, keep the jumper to LD position.
If the above jumper positions are correct, check the following as per the fault displayed on the
Operation Panel (LCD Display)
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parameters and current limit may result in over current or damage to
the power devices.
2. Increase the acceleration time (A201 / A203).
3. Reduce torque boost settings (A501)
A-10
2. One or more current sensor may have problem.
Remove the current sensor feedback and check.
3. If still fault persists, replace PCA-2014A; otherwise replace the
problematic current sensor.
17 Communication Loss 1. Check the communication cable between master (LCD Display unit)
and slave (Main control unit).
2. Disable the fault using C405. This will allow the inverter to run in case
of communication loss between the PCA-2014A DSP control board
and PCA-2012 LCD display board.
3. There may be problem in display board PCA-2012.
Replace the display board PCA-2012 and check again.
4. There may be problem in control board PCA-2014A. If +5V supply or
+3.3V supply is not coming then also this fault will come.
Check the power supply unit and if found problem replace it or replace
the DSP control board PCA-2014A and check again.
18 Output Current 1. Check the setting of B313. Correct the setting if it is too low.
Unbalance 2. Go through the below steps and if it does not help, disable it by setting
0% to B313.
B C
10mm (0.4" )
D
127mm
F (5")
H
KEYPAD 72mm
CUTOUT (2.8")
A E
10mm (0.4")
SIDE VIEW
10mm (0.4")
TOP VIEW
AMT 4P0
AMT 5P5
AMT 7P5
AMT 011
AMT 015 585 250 300 196.5 565 61.5 186 61.5 29
AMT 018 (23.0) (9.8) (11.8) (7.7) (18.1) (2.4) (7.3) (2.4) (63.9)
AMT 022
AMT 030 700 322 365 217 680 97.5 144 97.5 40
AMT 037 (27.5) (12.7) (14.4) (8.5) (26.8) (3.8) (5.7) (3.8) (88.2)
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