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Hardware AZ Analog Drives - Advanced Motion Controls

1. TABLE 2 7 Three Phase Power Connectors AZ 6A8 AZ 12A8 AZ 20A8 AZ 40A8 AZ_60A8 AZ 10A20 AZ 25A20 AZ 6A8 AZ 12A8 P2 AZ 20A8 AZ 10A20 P2 P1 Analog Input PWM Input Analog Input Analog Input AZ 40A8 AZ_60A8 AZ 25A20 P2 P3 Encoder Vel Hall Vel Pin Description Pin Description Pin Description Description Description Description 1 1b 1a B 2 p acts HIGH VOLTAGE 1 REF IN PWM IN REF IN REF IN 2 VOLTAGE 2b 2a 2 SIGNAL GND SIGNAL GND SIGNALGND SIGNAL GND RESERVED 3b 3 NC KEY 3b 3a 3 REF IN DIR IN REF IN REF IN NC KEY P2 3a 4 CURRENT CURRENT CURRENT CURRENT 4 POWER 4b 4a POWER GROUND MONITOR MONITOR MONITOR MONITOR 5 GROUND 5b 5a INHIBIT IN INHIBIT IN INHIBIT IN INHIBIT IN 6b 6a V HALL V HALL V HALL V HALL 7 MOTOR C 7b 75 MOTOR C OUT OUT OUT OUT 7 SIGNAL GND SIGNAL GND SIGNALGND SIGNAL GND 5 MOTOR B Ba so MOTOR B 8 HALL 1 HALL 1 HALL 1 HALL 1 ii 2b sa 10 10b 10a 9 HALL 2 HALL 2 HALL 2 HALL 2 MOTORA MOTOR A 10 HALL3 HALL 3 HALL 3 HALL 3 M Mg i 11 CURRENT CURRENT CURRENT CURRENT AZ 10A4 P2 REF OUT REF OUT REF OUT REF OUT 12 FAULT OUT FAULT OUT FAULT OUT FAULT OUT Pin Description 13 RESERVED RESERVED ENCODER B RESERVED 1 14 RESERVED RESERVED ENCODER A RESERVED 5 ORs 15 RESERVED RESE
2. Motor Wires either Motors Supported Mounting n Mounting Cards PCB Mounting Options Mating Connectors Soldering Screw Mounting Mounting Cards Mounting Diagrams da Move Profile N Nominal Power Supply Voltage 19 Non AZ Drive Replacement 33 ADVANCED 7A MOTION CONTROLS 0 Offset INput 45 Offset Potentiometer 50 Operation renes 48 Overload AA 69 Over Temperature 68 Over Voltage sss 68 Over Voltage Shutdown 68 P Part Numbering Structure 7 PCB Circuitry Design Examples Tachometer Input 45 PCB Design iii 40 Circuitry Examples 41 DC Power 41 Encoder anand 43 Hall Sensors 43 Motor Power 42 Offset Input 45 Trace Routing 40 Trace Width 40 PCB Mounting Options 37 PE Groufid iraniana 30 Peak Current Fold back 69 Peak Output Current 7 62 Peak Torque 17 Physical Dimensions 64 Pin Layouts 13 AZ 10A20 sse 13 AZ T0A4
3. Positive Direction Current Command Max Continuous Current Limit Current Measured Max Peak Current Limit Negative Direction I I I I I I r I I l l I I I I I 7 l I Sustained maximum current demand when switching between positive and negative maximum current without allowing sufficient time for fold back will result in drive damage Drive RMS current should be below the continuous current setting Caution e For most applications it s a rare occurrence to fully swing from peak in one direction to the other It is more likely the drive will be commanded from zero to max peak current Under this condition the drive will only sustain the maximum peak current for about one second FIGURE C 2 Peak Current Fold Back Max Peak Current Limit ___ Positive Direction em Current Command Max Continuous Current Limit Current Measured tot e Commanding maximum peak output current starting from above zero command will also yield reduced peak current output time e When commanding output current less than the max peak limit but more than the max continuous limit the current output can be sustained for a longer time period than a maximum peak command before folding back FIGURE C 3 Above Continuous Current Foldback Max Peak Current Limit I Positive Direction 7777 LN gx EFE ED C MDC A EDUC TE Max Continuous Current Limit Current Measure
4. 49 68 69 Input Reference Wires 33 Input Output Pin Functions 48 50 Current Monitor 48 MNALAZIN 13 Current Reference 48 Fault 1 49 Hall Power 49 Inhibit m49 Tachometer Velocity Monitor Interface Circuitry Exampks Interference Coupling z CapacltiVe iier eie 31 Electromagnetic 31 Magnetic s Voltage Drops wl Invalid Commutation s68 Invalid Hall Commutation 69 Isolated Power Supply 21 Isobti on certes 21 L Linear Motor Equation 17 Lock out tag out Procedures 1 Loop Gain Potentiometer 50 M Mating Connectors Max Power Dissipation me Mechanical Shock Minimum Load Inductance 7 62 Model Information Model Mask Motion Control System Motor Run Away su Motor Back EMF Voltage Motor Current Motor Current Frequency 18 Motor Force sss Overload Motor Power Output pa Motor Problems Motor Resistance Motor Torque Constant Motor Voltage
5. Fault Conditions and Symptoms on page 68 for more information on hardware protection ADVANCED 7A MOTION CONTROLS MNALATIN 13 62 I Specifications Tables FIGURE B 1 AZ Ambient Temperature Ranges MasimumAnbient C Maximum Ambient C AZ 6 8 Drive Models at 80VDC AZ 10A4 Drive Models at 24VDC 80 Co 70 70 pete 60 Co 50 a a C40 Cao 30 EJ 20 2 10 40 0 0 9 is 3 4 o 1 2 3 4 5 6 7 Continuous Output Current Amps Continuous Output Current Arps No Heatsink Noheasirk W Haasirk see rale 1 MasimumAnbient C MaximumAnbient C AZ 12 8 Drive Models at 80VDC AZ 20 8 Drive Models at 80VDC 8 8 m T to amp ak BR 0E E E BG TESI co ca EJ E uu D 10 10 9 0 G 1 2 3 4 7 o 2 4 6 8 10 12 4 Continuous Output Current Ans Continuous Output Current Arps ottica W reek Goro 1 No Heatsink W Heetsirk ecercie 1 Mainimine Maximum Ambient C AZ 4008 Drive Models at 80VDC AZ_60A8 Drive Models at 80VDC x 80 70 de ee 60 a Co S d aa a 5 50 c40 DS C40 d ic 30 la 9 20 v 10 0 0 D 5 pa pa 2 0 5 10 15 20 25 30 35 Continuous Ouiput Curent Arps Continuous Output Current Amps No Heetsirk W Hedsirk oe role 1 No Heatsink amp Wi Heatsink see no
6. iei 13 AZ 12A8 eo aede 13 AZ 2048 eet 13 AZ 25A20 ane retten 13 AZ 40A8 endisse Anda 13 AZ 6048 aseceetidelues 13 AZ 6A8 iae eite 13 PIHOUIS encre etn n 15 Signal Connectors 15 Positive Feedback 10 Potentiometers sss 50 POWER GROUND 15 Power Ground 31 Power Specifications 7 62 Power Supply Capacitance 2 24 32 Power Supply Current 20 Power Supply Output Current 19 24 Power Supply Wires 32 Power on Reset 68 69 Product Label 72 Products Covered 7 PWM Current Control Circuit 5 PWMIN 2 5 hbri 15 R REE IN ete edens 15 33 REFINsE vige 15 33 Regeneration 21 22 Continuous sss 24 Ab eoo eee Te odere 73 Revision History iv RMS Torque ee 17 S Safety cese reete teet ees 1 3 Scaling Factor a39 Screw Mounting sss 38 Selection and Sizing 16 25 Selective Wave Soldering 38 Servo Drive Theory 5 6 Shielding m Shock Vibration Short Circuit Fault Short Circuit Shunt Regulator SIGNAL
7. Spacer not included with AZ drive or mounting card Spacer shown is standard 3 16 hex 4 40 thread male female 7 16 length ADVANCED JA MOTION CONTROLS MNALATIN 13 38 Integration in the Servo System Mounting FIGURE 3 14 Screw Mount Diagram Remove drive mounting screw ng and align spacer over empty screw hole on drive PCB Use a 4 40 thread 1 screw to secure mounting card to drive from the bottom of the mounting card through the spacer after drive has been inserted in mounting card socket connectors Drive Mounting Screw Spacer not included with AZ drive or mounting card Spacer shown is 4 clear 7 16 length Larger model AZ drives can also be screw mounted through two 4 40 thread screw holes on either side of the AZ baseplate onto an external heatsink or other mounting plate for added stability and resiliency against mechanical vibration Mounting to an external heatsink also provides better thermal management behavior than other mounting options See Ambient Temperature Range and Thermal Data on page 25 for more info Direct Cabling AZ 10A4 models can be directly cabled to using the recommended mating connector Samtec P N SLM 112 01 L S or SLM 114 01 L S as shown in Figure 3 15 FIGURE 3 15 AZ 10A4 Direct Cabling ADVANCED VA MOTION CONTROLS MNALATIN 13 39 Integration in the Servo System PCB Design 3 6 PCB Design When designing a PCB board to interface with an
8. 27 Environmental Specifications 25 64 Error Signal eben 10 External Filter Card 18 32 F Fault Conditions Inhibit INput Invalid Hall Commutation Over Temperature Over Voltage Shutdown Power on Reset Short Circuit Fault Under Voltage Shutdown FAULT OUT Fault Output Feedback Polarity Feedback Supported 10 12 62 Na atol AA 12 Halll Sensors 10 Tachometer 12 Feedback Wires 33 Folk back eh ett 69 Frequency Factor 24 G Ground Loops 30 32 Grounding 30 31 Controller Chassis 30 Drive Caspian anan 30 Motor ChassisS 30 PCB Interface Chassis 30 Power Supply Chassis Shielding H Hall Sensor Inputs 43 Hall Sensor Power Supply 49 Hall Sensors 10 52 62 Hall Velocity Mode 9 Hand Soldering 38 Hardware Protection 62 HIGH VOLTAGE eee 15 Hurridity 2 tertie 25 I Impedance e 32 Inhibit Input
9. ADVANCED MOTION CONTROLS Everything s possible AZ Analog Drives for Servo Systems Hardware Installation Manual WWW O M C COM VA Preface ADVANCED Motion Controls constantly strives to improve all of its products We review the information in this document regularly and we welcome any suggestions for improvement We reserve the right to modify equipment and documentation without prior notice For the most recent software the latest revisions of this manual and copies of compliance and declarations of conformity visit the company s website at www a m c com Otherwise contact the company directly at ADVANCED Motion Controls 3805 Calle Tecate Camarillo CA 93012 5068 USA Agency Compliances The company holds original documents for the following e UL 5086 file number E1401 73 e Electromagnetic Compatibility EMC Directive 2004 108 EC EN61000 6 2 2005 EN61000 6 4 2007 e Electrical Safety Low Voltage Directive 2006 95 EC EN 60204 1 2006 e Reduction of Hazardous Substances RoHS 2011 65 EU Trademarks ADVANCED Motion Controls the combined isosceles trapezoid right triangle logo DIGIFLEX DIGIFLEX Performance and DriveWare are either registered trademarks or trademarks of ADVANCED Motion Controls in the United States and or other countries All other trademarks are the property of their respective owners Related Documentation e Product datasheet specific for your dri
10. Baseplate Thickness mm in 6 35 0 25 5 79 0 228 5 79 0 228 2X6 120 FIGURE B 2 AZ 10A4 Mounting Dimensions inches and mm 1 260 ADVANCED JA MOTION CONTROLS 1 200 MNALATIN 13 64 I Specifications Tables FIGURE B 3 AZ 10A4IC Mounting Dimensions inches and mm 3 05 2X 120 38 10 1 500 3 05 120 7 12 1 80 280 071 E 14 75 3 05 581 38 10 1 500 FIGURE B 4 AZBE H D10A4 Mounting Dimensions inches and mm 320 1 260 alabang 15 1 700 ADVANCED YA MOTION CONTROLS MNALAZIN 13 65 Specifications Tables FIGURE B 5 AZ 12A8 AZ 6A8 Mounting Dimensions inches and mm 2X 4 40 UNC 2B THRU 1597 24 5 74 55 88 15 220 1 535 FIGURE B 6 AZ 2048 AZ 10420 Mounting Dimensions inches and mm 2X 4 40 UNC 28 THRU ADVANCED VA MOTION CONTROLS MNALATIN 13 66 Specifications Tables FIGURE B 7 AZ 40A8 AZ 6048 AZ 25A20 Mounting Dimensions inches and mm 2X 4 40 UNC 2B THRU ADVANCED JA MOTION CONTROLS MNALATIN 13 67 Troubleshooting This section discusses how to ensure optimum performance and if necessary get assistance from the factory C 1 Fault Conditions and Symptoms HTH arr An inoperative drive can indicate any of the following fault conditions over t
11. Due to the inductance and capacitance of the wire the OP AMP can oscillate It is always recommended to set a fixed voltage at the controller and then check the signal at the drive with an oscilloscope to make sure that the signal is noise free ADVANCED 7A MOTION CONTROLS MNALATIN 13 33 Integration in the Servo System Mounting 3 5 Mounting This section provides information on the different ways to mount an AZ drive to a PCB board 3 5 1 Mounting Cards Mounting cards are available to interface directly with certain AZ servo drives TABLE 3 1 Mounting Card Drive Compatibility Mounting Card Compatible Drive Models Connector Type MC1XAZ01 AZ 6A8 AZ 12A8 AZ 20A8 AZ 10A20 AZ 25A20 Vertical Entry Quick Disconnect MC1XAZ01 HR AZ 6A8 AZ 12A8 AZ 20A8 AZ 40A8 AZ 60A8 AZ 10A20 AZ 25A20 Side Entry Quick Disconnect I O Fixed Screw Terminal Motor Power MC1XAZ02 AZB10A4 AZBDC10A4 AZBE10A4 AZBH10A4 AZBD10A4 Side Entry Fixed Screw Terminal Do not command more than 24A continuous current if using the MC1XAZ01 HR with the AZ_60A8 models Pinouts dimensions and ordering information for the mounting cards are obtainable on the mounting card datasheets available for download at www a m c com The mounting cards are shipped with the following included connectors TABLE 3 2 MC1XAZ01 Included Quick Disconnect Connectors MC1XAZ01 Included Quick Disconnect Connectors Description Qty
12. Included Manufacturer and Part Number 3 position 5 08mm spaced plug terminal 1 Phoenix Contact 1757022 4 position 5 08mm spaced plug terminal 1 Phoenix Contact 1757035 8 position 3 5mm spaced plug terminal 2 Phoenix Contact 1840421 TABLE 3 3 MC1XAZ01 HR Included Quick Disconnect Connectors MC1XAZ01 HR Included Quick Disconnect Connectors Description Qty Included Manufacturer and Part Number 8 position 3 5mm spaced plug terminal 2 Phoenix Contact 1863217 FIGURE 3 3 MCIXAZ01 FIGURE 3 4 Mating Connectors FIGURE 3 5 MC1XAZ01 HR if All four mating connectors shown are included with the MC1XAZ01 Side entry versions of the two 8 position connectors are included with the MC1XAZ01 HR FIGURE 3 6 MC1xAZ02 ADVANCED 7A MOTION CONTROLS MNALAZIN 13 34 Integration in the Servo System Mounting The mounting cards can be secured to a panel heatsink or other surface with the use of standoffs or spacers The following figures show some possible mounting configurations using AZ drives and the MC1XAZ01 and MC1XAZ01 HR mounting cards Figure 3 7 below shows an AZ 20A8 drive attached to a MC1XAZ01 mounted to a panel Four threaded spacers are used to secure the mounting card to the panel Note that when using an MC1XAZ01 with the included mating connectors the wire connections to the mounting card will be from the top FIGURE 3 7 AZ 2048 attached to MCIXAZ01 mounted on panel shown w
13. MNALATIN 13 36 Integration in the Servo System Mounting 3 5 2 PCB Mounting Options AZ servo drives can be directly integrated onto a PCB either by mounting the board on socket connectors or by actually soldering the AZ drive to the board Except for the AZ 10A4 models AZ drives are designed with a common pin layout throughout the entire drive family providing the user with the option of designing only one mounting card or PCB interface that is compatible with the different power levels For an application that may have different versions with higher or lower power requirements the same mounting card or PCB interface can be used for each application version with the appropriate AZ drive FIGURE 3 12 AZ Drives PCB Footprint not to scale 80V and 200V Drive Models P1 Signal Connector PIN 6 40V Drive Models P3 Power P2 Power A Connector Connector PIN1b PIN 1a f 1 20in PIN 1 30 48mm PIN 1a PIN 1b P2 3a Keyed PIN 7 Keyed 24X 0 018in 0 46mm SQ Post Thru 60X 0 025in 0 64mm SQ Post Thru in 0 64mm SQ Post Thru BENT P2 Power IG IQ Connector PIN 11a y gt PIN 11b PIN 1 P1 Signal Connector PIN 11b PIN 11a 0 39in 2 20in 10 00mm 55 88mm For the 80V and 200V drive versions AZ 6A8 and AZ 12A8 drive models connect to P1 and the A row of P2 while AZ 20A8 and AZ 10A20 drives connect to P1 and both rows of P2 AZ 40A8 AZ 60A8 and AZ 25A20 mod
14. MNALAZIN 13 58 FA Loop Tuning In general ADVANCED Motion Controls AZ servo drives will not need to be further tuned However for applications requiring more precise tuning the drive can be manually modified with resistors and capacitors as denoted in Table A 1 below It is recommended to contact ADVANCED Motion Controls to discuss application requirements and proper drive tuning prior to making any adjustments Any damage done to the drive while performing these modifications will void the product warranty Nofice Before attempting to change components on the board see Tuning Procedure on page 54 Some general rules to follow when changing components are e A larger resistor value will increase the proportional gain and therefore create a faster response time e Use non polarized capacitors e Alarger capacitor value will increase the integration time and therefore create a slower response time A 1 Loop Tuning Proper tuning will require careful observation of the loop response on a digital oscilloscope to find the optimal component values for the specific application The following are some helpful hints to make the loop tuning process easier e Usea potentiometer to find the correct current loop gain value A potentiometer can be used to continuously adjust the gain resistance value during the tuning process Install a potentiometer in place of the gain resistor Adjust the potentiometer while viewing
15. grinding wheel flywheel centrifuge Heavy lift gantry Voltage Ripple For the most part ADVANCED Motion Controls AZ servo drives are unaffected by voltage ripple from the power supply The current loop is fast enough to compensate for 60 Hz fluctuations in the bus voltage and the components in the drive are robust enough to withstand all but the most extreme cases Peak to peak voltage ripple as high as 25 V is acceptable There are some applications where the voltage ripple can cause unacceptable performance This can become apparent where constant torque or force is critical or when the bus voltage is pulled low during high speed and high current applications If necessary the voltage ripple from the power supply can be reduced either by switching from single phase AC to three phase AC or by increasing the capacitance of the power supply The voltage ripple for a system can be estimated using the equation I PS V F R C f PS Where VR voltage ripple Cps power supply capacitance Ips power supply output current Fr frequency factor 1 hertz The power supply capacitance can be estimated by rearranging the above equation to solve for the capacitance as _ Ips QE 2 PS Vs f ADVANCED 7A MOTION CONTROLS MNALAZIN 13 24 Products and System Requirements System Requirements The frequency factor can determined from 0 42 Fe fof where fis the AC line frequency in hertz Note that for half wave rectif
16. 1 2 toy lo mgh tov iJo mgh nom 5 2mg h h C The Ve calculated must be below the power supply capacitance voltage rating and the drive over voltage limit If this is not the case a shunt regulator is necessary A shunt regulator is sized in the same way as a motor or drive i e continuous and RMS power dissipation must be determined The power dissipation requirements can be determined from the application move profile see Figure 2 13 ADVANCED Motion Controls offers a variety of shunt regulators for servo drives When choosing a shunt regulator select one with a shunt voltage that is greater than the DC bus voltage of the application but less than the over voltage shutdown of the drive Verify the need ADVANCED 7A MOTION CONTROLS MNALAZIN 13 23 Products and System Requirements System Requirements for a shunt regulator by operating the servo drive under the worst case braking and deceleration conditions If the drive shuts off due to over voltage a shunt regulator is necessary Continuous Regeneration In the special case where an application requires continuous regeneration more than a few seconds then a shunt regulator may not be sufficient to dissipate the regenerative energy Please contact ADVANCED Motion Controls for possibk solutions to solve this kind of application Some examples Web tensioning device Electric vehicle rolling down a long hill Spinning mass with a very large inertia
17. B precedes Encoder A meaning the direction Encoder A E is opposite from Example 1 The signal frequency is also higher Encoder B meaning the speed is greater than in Example 1 EE 2 5 4 Tachometer Feedback AZBE and most AZBH drives offer the option of using a DC Tachometer for velocity control The tachometer provides an analog DC voltage feedback signal that is related to the actual motor speed and direction The drive subsequently adjusts the output current based on the error between the tachometer feedback and the input command voltage The maximum range of the tachometer feedback signal is 60 VDC ADVANCED 7A MOTION CONTROLS MNALAZIN 13 1 2 Products and System Requirements Pin Layout 2 6 Pin Layout The diagrams below show the pin layout and location on AZ drives as seen from the PCB where the drive is mounted Note that some drives use a double row for the power header and other drives have two power connectors More detailed dimensional information can be found in Physical Dimensions on page 64 and in Mating Connectors on page 37 FIGURE 2 8 AZ series Pin Layouts AZB10A4 and AZBDC10A4 Drives P1 Signal Connector PINI P2 Power Connector PIN 12 PIN 12 fs 0 50in 1 27mm 3 120in 30 48mm Note that P1 and P2 are identical 12 pin headers on AZB10A4 and AZBDC10A4 drive models To avoid damage to the drive be sure when plugging or soldering the drive into
18. Cable t Shielded Power Cable PE Ground lt Signal Ground Controller Power Ground Chassis Earth Ground Isolated DC Power Supply Single Point System Ground PE Ground Ground cable shield wires at the mounting card or PCB interface side to a chassis earth ground point The DC power ground and the input reference command signal ground are oftentimes at a different potential than chassis PE ground The signal ground of the controller must be connected to the signal ground of the AZ drive to avoid picking up noise due to the floating differential servo drive input On all AZ drives the DC power ground and the input command signal ground are referenced to each other internally In systems using an isolated DC power supply signal ground and or power ground can be referenced to chassis ground First decide if this is both appropriate and safe If this is the case they can be grounded at the central grounding point Grounding is important for safety The grounding recommendations in this manual may not be appropriate for all applications and system machinery It is the responsibility of the system designer to follow applicable regulations and guidelines as they apply to the specific servo Warning System 3 4 Wiring Servo system wiring typically involves wiring a controller digital or analog a servo drive a power supply and a motor Wiring these servo syst
19. MNALAZIN 13 46 Integration in the Servo System Interface Circuitry Examples Fault Output AZ drives feature a 5V TTL Fault output that will become high when the drive is subject to a fault condition see Fault Output on page 49 for a list of fault conditions The Fault output should be measured relative to Signal Ground The Fault output can also be used with an external LED as shown in Figure 3 30 FIGURE 3 30 Fault Output Wiring INTERFACE AZ SERVO Nee INTERFACE AZ SERVO PCB DRIVE 45V Y PCB DRIVE 5V t FAULTOUTPUT 7 FAULT OUTPUT Controller External LED l SIGNAL GROUND i A SIGNAL GROUND I L Lb ADVANCED 7A MOTION CONTROLS MNALAZIN 13 47 P Operation This chapter will present a brief introduction on how to test and operate an AZ servo drive Read through this entire section before attempting to test the drive or make any connections 4 1 Getting Started To begin operation with your AZ drive be sure to read and understand the previous chapters in this manual as well as the drive datasheet Be sure that all system specifications and requirements have been met and become familiar with the capabilities and functions ofthe AZ drive Also be aware of the Troubleshooting section at the end of this manual for solutions to basic operation issues 4 1 1 Input Output Pin Functions The family of AZ drives provides a number of various input and output pins for
20. PWM drives require a capacitor on the high voltage supply to store energy during the PWM switching process Insufficient Dower supply capacitance causes problems particularly with Caution high inductance motors During braking much of the stored mechanical energy is fed back into the power supply and charges its output capacitor to a higher voltage If the charge reaches the drive s over voltage shutdown point output current and braking will cease At that time energy stored in the motor inductance continues to flow through diodes in the drive to further charge the power supply capacitance The voltage rise depends upon the power supply capacitance motor speed and inductance ADVANCED 7A MOTION CONTROLS MNALAZIN 13 Safety General Safety Overview Caution ADVANCE Make sure minimum inductance requirements are met Pulse Width modulation PWM servo drives deliver a pulsed output that requires a minimum amount of load inductance to ensure that the DC motor current is properly filtered The minimum inductance values for different drive types are shown in the individual data sheet specifications If the drive is operated below its maximum rated voltage the minimum load inductance requirement may be reduced Most servo motors have enough winding inductance Some types of motors e g basket wound pancake etc do not have a conventional iron core rotor so the winding inductance is usually less than 50 uH If the m
21. The feedback element must be connected for negative feedback This will cause a difference between the command signal and the feedback signal called the error signal The drive compares the feedback signal to the command signal to produce the required output to the load by continually reducing the error signal to zero For AZ drives this becomes important when using Encoder Feedback and Hall Sensors as connecting these feedback elements for positive feedback will lead to a motor run away condition In a case where the feedback lines are connected to the drive with the wrong polarity in either Hall Velocity or Encoder Velocity Mode the drive will attempt to correct the error signal by applying more command to the motor With the wrong feedback polarity this will result in a positive feedback run away condition To correct this either change the order that the feedback lines are connected to the drive or change Switch 4 on the DIP switch bank to the opposite setting to reverse the internal feedback velocity polarity See the drive datasheet for more information on DIP switch settings 2 5 2 Hall Sensors AZ drives use single ended Hall Sensors for commutation feedback and in the special case of the AZBH drives for velocity control The Hall Sensors typically three are built into the motor to detect the position of the rotor magnetic field These sensors are mounted such that they each generate a square wave with 120 degree phase
22. These relationships are described by the following equations Pae due TE E KS for rotary motors T KI for linear motors F K ADVANCED 7A MOTION CONTROLS MNALAZIN 13 1 7 Products and System Requirements System Requirements Where Vin motor voltage ln motor current use the maximum current expected for the application Rin motor line to line resistance E motor back EMF voltage T motor torque F motor force K motor torque constant K motor force constant Ke voltage constant Sin motor speed use the maximum speed expected for the application The motor manufacturer s data sheet contain K or Kj and K constants Pay special attention to the units used metric vs English and the amplitude specifications peak to peak vs RMS phase to phase vs phase to neutral The maximum motor terminal voltage and current can be calculated from the above equations For example a motor with a K 10V Krpm and required speed of 3000 RPM would require 30V to operate In this calculation the IR term voltage drop across motor winding resistance is disregarded Maximum current is maximum torque divided by K For example a motor with K 0 5 Nm A and maximum torque of 5 Nm would require 10 amps of current Continuous current is RMS torque divided by Kj Motor Inductance The motor inductance is vital to the operation of AZ servo drives as it ensures that the DC motor current is properly filtered A motor that doe
23. a PCB or interface card that the drive orientation is correct P1 and P2 are labeled on the PCB silkscreen Pin 7 on P2 is keyed removed to differentiate it from P1 AZBE D H10A4 Drives P1 Signal Connector P2 Power i Connector PIN 12 PIN 14 0 50in 127mm 1 20in 30 48mm ADVANCED 7A MOTION CONTROLS AZ_6A8 and AZ_12A8 Drives P1 Signal Connector PIN 16 P2 Power Connector PINA 0 19in 254mm 2 20in 55 88mm AZ 10A20 and AZ 20A8 Drives P1 Signal Connector P2 Power Connector 0 10in 2 54mm 0 10in 2 54mm AZ 25A20 AZ 40A8 and AZ 60A8 Drives P1 Signal Connector PIN 16 P2 Power P3 Power Connector cdnnector PIN 1b PIN 1a 0 10in 2 54mm 2 20in 55 88mm 0 39in 10mm MNALATIN 13 13 Products and System Requirements Features and Control Specifications 2 7 Features and Control Specifications NENNEN 2 7 2 AZBDC 2 7 1 AZB Designed to drive brushless brushed motors with a 210 V analog input Current Torque Mode HallSensor trapezoidal Commutation 2 7 3 AZBE Designed to drive brushless brushed motors with a 210 V analog input DIPSwitch selectable modes Current Torque Duty Cycle Encoder Velocity Tachometer Velocity HallSensor trapezoidal commutation Single ended incremental encoder feedback for velocity control External potentio
24. as a group around the suppression core and leave the motor case ground wire out of the loop The suppression core should be located as near to the drive as possible TDK ZCAT series snap on filters are recommended for reducing radiated emissions on all I O cables 3 2 2 Inductive Filter Cards Inductive filter cards are added in series with the motor and are used to increase the load inductance in order to meet the minimum load inductance requirement of the drive They also serve to counteract the effects of line capacitance found in long cable runs and in high voltage systems These filter cards also have the added benefit of reducing the amount of PWM noise that couples onto the signal lines 3 3 Grounding In most servo systems all the case grounds should be connected to a single Protective Earth PE ground point in a star configuration Grounding the case grounds at a central PE ground point reduces the chance for ground loops and helps to minimize high frequency voltage differentials between components All ground wires must be of a heavy gauge and be as short as possible The following should be securely grounded at the central PE grounding point e Motor chassis e Controller chassis e Power supply chassis e PCB Interface chassis ADVANCED 7A MOTION CONTROLS MNALATIN 13 30 Integration in the Servo System Wiring FIGURE 3 1 System Grounding Case Ground Wire sn Shield Ground Wire RN Shielded Feedback Signal
25. difference over one electrical cycle of the motor Depending on the motor pole count there may be more than one electrical cycle for every motor revolution For every actual mechanical motor revolution the number of electrical cycles will be the number of motor poles divided by two For example e a6 pole motor contains 3 electrical cycles per motor revolution e a4 pole motor contains 2 electrical cycles per motor revolution e a2 pole motor contains 1 electrical cycle per motor revolution The drive powers two of the three motor phases with DC current during each specific Hall Sensor state ADVANCED VA MOTION CONTROLS MNALATIN 13 1 0 Products and System Requirements Feedback Supported FIGURE 2 6 Hall Sensor Commutation and Motor Phase Current for 120 Degree Phasing i Note Not all ADVANCED Motion ommutation p j Controls servo drive series use the same commutation logic The commutation diagrams provided here should be used only with drives covered within this manual High 1 Hall A Low 0 High 1 Hall B Low 0 High 1 Hall C Low 0 Motor Phase Current High Phase A Low High Phase B Low High Phase C Low Electrical Degrees The table below shows the valid commutation states for both 120 degree and 60 degree phasing TABLE 2 5 Commutation Sequence Table 60 Degree 120 Degree Motor Hall 1 Hall 2 Hall 3 Hall 1 Hall 2 Hall 3 Phase A Phase B Phase C 1 0
26. included indicates that the model is a prototype unit and model number will also begin with an X designator 5 Serial Number The serial number consists of a 5 digit lot number followed by a 4 digit sequence number Each product is assigned a unique serial number to track product life cycle history 6 Date Code The date code is a 4 digit number signifying the year and week of manufacture The first two digits designate the year and the second two digits designate the week e g the drive label shown would have been built in the year 2011 during the 18th week 7 General Information Displays applicable agency approvals UL file reference number compliance approvals and EtherCAT capability More complete product information is availabe by following the listed website ADVANCED VA MOTION CONTROLS MNALATIN 13 72 I Warranty Returns and Factory Help C 3 Warranty Returns and Factory Help Seller warrants that all items will be delivered free from defects in material and workmanship and in conformance with contractual requirements The Seller makes no other warranties express or implied and specifically NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE The Seller s exclusive liability for breach of warranty shall be limited to repairing or replacing at the Seller s option items returned to Seller s plant at Buyer s expense within one year of the date of delivery The Seller s liability on any claim of any ki
27. information D 7A MOTION CONTROLS MNALAZIN 13 68 Fault Conditions and Symptoms Under Voltage Shutdown Verify power supply voltages for minimum conditions per specifications Also note that the drive will pull the power supply voltage down if the power supply cannot provide the required current for the drive This could occur when high current is demanded and the power supply is pulled below the minimum operating voltage required by the drive Short Circuit Fault 1 Check each motor lead for shorts with respect to motor housing and power ground If the motor is shorted it will not rotate freely when no power is applied while it is uncoupled from the load 2 Disconnect the motor leads to see if the drive will enable without the motor connected 3 Measure motor armature resistance between motor leads with the drive disconnected Invalid Hall Sensor State See the Commutation Sequence table in Hall Sensors on page 10 for valid commutation states If the drive is disabled check the following 1 Make sure that the 60 or 120 degree phasing jumper JE2 is in the correct setting per motor data sheets If driving a single phase brushed type motor use the 60 degree phase setting see Using a Single Phase Motor on page 11 for more information on this particular configuration 2 Check the voltage levels for all the Hall sensor inputs 3 Make sure all Hall Sensor lines are connected properly Inhibit Input
28. parameter observation and drive configuration options Consult the drive datasheet to see which input output pin functions are available for each drive Current Monitor Output The current monitor pin is available on all AZ drive models Measured relative to signal ground it provides an analog voltage output signal that is proportional to the actual current output The scaling factor for each individual drive can be found on the drive datasheet Example Measurement The current monitor pin on an AZ drive with a current monitor scaling factor of 4 A V is measured to be 1 3V This would mean the drive is outputting 4 A V 1 3V 5 2A Current Reference Output The current reference pin is available on 80V and 200V drive models Measured relative to signal ground it provides an analog voltage output signal that is proportional to the command signal to the internal current loop When the drive output ADVANCED JA MOTION CONTROLS MNALATIN 13 48 Operation Getting Started reaches the maximum peak current value the current reference pin will read 7 45V The command to the internal current loop can be solved for by the following equation I peak command current ref 745V Where I ommand command current to the internal current loop Vourrent ref Measured voltage at current reference pin Ipeak peak current value of AZ drive Example Measurement The current reference pin on an AZ drive with a peak current value of
29. response then the current loop gain resistors may need to be changed to optimize the response See Loop Tuning on page 59 for more information When the proper response has been achieved remove the input signal from the drive and disconnect power Current Loop Integrator Adjustment 1 Notice 5 Enable the Current Loop Integrator by removing the jumper previously used to short it during the proportional gain adjustment and start with the default capacitor Using a function generator apply a 0 5V 50 100 Hz square wave reference signal Apply power to the drive Use a bus voltage that is approximate to the desired application voltage or the current loop compensation will not be correct The drive should be enabled Observe the motor current with an oscilloscope by using a current probe or resistor in series with the motor lt 10 of motor resistance The output should settle to a flat top with minimal current following error difference between commanded current and actual current There can be some overshoot but it should be less than 10 Because the oscilloscope measurements are voltage representations of current the commanded and actual currents will most likely have different current to voltage scalings and tolerances Therefore even with perfect current loop tuning the two amplitudes scope traces may not line up as shown in Figure 4 4 If the square wave output overshoots too much or is over damped sluggis
30. the potentiometer and a negative DC voltage 10V max to the other end of the potentiometer a analog signal can be sent through the potentiometer s wiper into the REF input pin on the mounting card or PCB interface see drive datasheet or Pinouts on page 15 for pin labels The voltages applied to the external reference potentiometer ADVANCED 7A MOTION CONTROLS MNALAZIN 13 51 Operation Initial Setup should come from a test power supply that is different than the main DC power This separate VDC test power supply should be referenced to the AZ drive signal ground FIGURE 4 1 Reference Input Potentiometer INTERFACE AZ SERVO PCB DRIVE 10V Max E VDC Test Power Supply e 10V Max Potentiometer 4 REF IN gt 50kO 3 SIGNAL GROUND Power Supply HIGH VOLTAGE Y PowER GROUND Main DC H a KA Without connecting the potentiometer wiper to the mounting card or PCB interface apply the test VDC to the two sides of the potentiometer Measure the wiper of the potentiometer with a voltmeter or digital multimeter and verify that by turning the potentiometer in both directions the full range of VDC is observable on the potentiometer wiper This voltage will serve as a test command Once the full range of VDC has been verified turn the potentiometer so that approximately 0 VDC is observed on the potentiometer wiper then turn off the tes
31. torque or velocity demand Figure 2 1 shows the components typically used in a servo system i e a feedback system used to control position velocity and or acceleration The controller contains the algorithms to close the desired servo loops and also handles machine interfacing inputs outputs terminals etc The drive represents the electronic power converter that drives the motor according to the controller reference signals The motor which can be of the brushed or brushless type rotary or linear is the actual electromagnetic actuator which generates the forces required to move the load Feedback elements are mounted on the motor and or load in order to close the servo loop FIGURE 2 1 Typical Motion Control System Reference Current Controller Servo Drive Motor Feedback Load Feedback Although there exist many ways to amplify electrical signals pulse width modulation PWM is by far the most efficient and cost effective approach At the basis of a PWM servo drive is a current control circuit that controls the output current by varying the duty cycle of the output power stage fixed frequency variable duty cycle Figure 2 2 shows a typical setup for a single phase load FIGURE 2 2 PWM Current Control Circuit Command Current Switching Control Logic Current Feedback S1 S2 53 and S4 are power devices MOSFET or IGBT that can be switched on or off D1 D2 D3 and D4 are diodes that guara
32. user should consider the requirements of their system This involves calculating the required voltage current torque and power requirements of the system as well as considering the operating environment and any other equipment the drive will be interfacing with AZ servo drives are shipped with no other connectors or mounting components other than the signal and power header pins on the drive PCB itself However mounting cards and mating connectors are readily available See Mounting Cards on page 34 for the ADVANCED Motion Note Controls AZ mounting cards Customized mounting options are also available for orders with sufficient volume 2 8 1 Analog Servo Drive Selection and Sizing AZ servo drives have a given current and voltage rating unique to each drive Based on the necessary application requirements and the information from the datasheet of the motor being used a drive may be selected that will best suit the motor capabilities A drive should be selected that will meet the peak and continuous current requirements of the application and operate within the voltage requirements of the system Motor Current and Voltage Motor voltage and current requirements are determined based on the maximum required torque and velocity These requirements can be derived from the application move profiles Figure 2 13 FIGURE 2 13 Example Velocity Torque and Power Curves 1 Cycle Time Torque Time Power is equal to Torqu
33. 0 1 0 0 HIGH 2 LOW 1 1 0 1 1 0 i HIGH LOW Valid 1 1 1 0 1 0 LOW HIGH 0 1 1 0 1 1 LOW HIGH 0 0 1 0 0 1 LOW HIGH 0 0 0 1 0 1 HIGH LOW Invalid 2 0 1 0 0 0 0 By default AZ drives are always set to 120 degree phasing However AZ drives feature either a surface mount jumper JE2 on the drive PCB that can be removed to manually set the drive to 60 degree phasing or a DIP Switch that can configure the drive for 60 degree phasing Using a Single Phase Motor AZ drives are also compatible with Single Phase Brushed motors However because there are no Hall Sensors on a brushed motor one of the following course of actions must be taken to properly commutate the drive e Remove the JE2 jumper to set the drive for 60 degree phasing Leave all the Hall Sensor inputs on the drive open These inputs are internally pulled high to 5V creating a 1 1 1 commutation state see Table 2 5 above which is a valid state in 60 degree phasing Connect only two of the motor output wires Motor A and Motor B ADVANCED 7A MOTION CONTROLS MNALAZIN 13 1 1 Products and System Requirements Feedback Supported or e Tie one of the Hall Sensor inputs on the AZ drive to signal ground Since the Hall Sensor inputs are by default internally brought high to 5V this will put the AZ drive ina commutation state where two Hall inputs are high and one is low as shown in Table 2 5 having all three Hall input
34. 04443 Current Monitor OUtpUt 24 sd eine Caes Vos ek on PAGA e ea Current Reference Output Fault OUtPU 2 cbeeus ot weeded deen aan AIO Ut ae ELI a Low Power Supply Output gt is sissseriarinsiaseneni Velocity Monitor Output LL Tachometer NOU ca aano ANA KG GB ABAKA GAGA Er LAG 4 1 2 Potentiometer Function Details 2 2 Illo SelUE 2 cis busta pa dome Hee Reseed KG dee tO intesa 4 2 1 Current Torque Mode Test Connections Test AA PP ood be AA Power Supply 20202 GG ma as DA S sane adu ed m ADVANCED 7A MOTION CONTROLS MNALAZIN 13 vii Input Command Wiring 4 aho E REP PEE RARE 5 EI SES DES S saeua dE RS dU eau ROL 52 MOTOT PRA APPEAR dei bie dg cq ee ees 53 Applying a Command Analog Input 53 Motor Direction gary x xo dede e x dx AKDA awe AKA 54 4 3 Tuning Procedure 2 2 6 pletri 54 Current Loop Proportional Gain Adjustment 55 Current Loop Integrator Adjustment 57 Duty Cycle or Velocity Loop Tuning 57 A Loop Tuning 59 Al LOCO TUNING SSH exa YARD tile 59 A 1 1 Procedure Licia EE Ra E Bra n a d 60 Tune the Current Loop Proportional Gain 60 Tune the Current Loop Integral Gain 61 Velocity Loop TUNING siii 61 B Specifications 62 B I Specifications Tables a eed Shee NGARAN Fa Dawn 62 C Troubleshooting 68 C 1 Fault Condi
35. 12A is measured to be 2 63V Following the above equation to solve for I ommand the command current to the internal current loop would be 4 24A Fault Output The fault output is available on all AZ drive models This pin provides a 5V TTL output that will become high when the drive is subject to one of the following fault conditions inhibit invalid Hall State output short circuit over voltage over temperature or power up reset This pin will remain low when the drive is enabled AZ drives automatically self reset once all active fault conditions have been removed For instance if the DC power supply rises above the over voltage shutdown level of an AZ drive the Fault Output will go high and the drive will be disabled Once the DC power supply level is returned to a value below the drive over voltage shutdown level the Fault Output will become low and the drive will automatically become enabled Inhibit Input The inhibit input pin is available on all AZ drive models This pin provides a 5V TTL input that allows a user to enable disable the drive by either connecting this pin to ground or by applying a 5VDC voltage level to this pin referenced to signal ground By default all AZ drives will be enabled if this pin is high and disabled if this pin is low This logic can be reversed however by removing the jumper JE1 from the drive PCB Low Power Supply Output The low power supply provides a 6 VDC 30 mA output that can be used to power
36. 16 Keep in mind that the calculated value for V is the minimum voltage required to complete moves at the desired speed and torque There should be at least 1096 headroom between the calculated value and the actual power supply voltage to allow for machine changes such as increased friction due to wear change in load increased operating speed etc FIGURE 2 15 AZ 20A8 Power Supply Selection 100 AZ Drive Over Voltage Shutdown 88V O 6O0 eR _ _ _ _ _ _ Shunt Regulator Turn On Voltage 80V 60 VDC Acceptable Power Supply 40 Range 26 V 72V 20 e M System Power Supply Requirement 24V AZ Drive Under Voltage Shutdown 9V 0 Isolation In systems where an AC line is involved isolation is required between the AC line and the signal pins on the drive This applies to all systems except those that use a battery as a power supply There are two options for isolation 1 The drive can have built in electrical isolation 2 The power supply can provide isolation e g a battery or an isolation transformer The system must have at least one of these options to operate safely Isolation Ordering Option ADVANCED Motion Controls AZ drives can be ordered with isolation as an option Specify an I after the current rating in the part number i e AZB20A8T to order a drive with isolation Power Supply with Isolation An isolated power supply is either a battery or a power supply that uses an isolation transformer to i
37. 5A Current Mode AZB10A4 AZB6AB AZB12A8 AZB20A8 AZBAOAB AZB60A8 AZB10A20 AZB25A20 Analog 210V Command AZB10A4IC Current Mode AZBDC10A4 AZBDC6A8 AZBDC12A8 AZBDC20A8 AZBDC40A8 AZBDC60A8 AZBDC10A20 AZBDC25A20 Three Phase PWM DirCommand AZBDC10A4IC EM Hall Velocity AZBH10A4 AZBHGA8 AZBH12A8 AZBH20A8 AZBH40A8 AZBH60A8 AZBH10A20 AZBH25A20 n Analog 10V Command Single Phase Brushed Encoder Velocity AZBE10A4 AZBEGA8 AZBE12A8 AZBE20A8 AZBE40A8 AZBEGOA8 AZBE10A20 AZBE25A20 Analog 210V Command Duty Cycle Mode AZBD10A4 Analog 210V Command 2 1 1 Drive Datasheet Each AZ analog drive has a separate datasheet that contains important information on the modes and product specific features available with that particular drive The datasheet is to be used in conjunction with this manual for system design and installation ADVANCED 7A MOTION CONTROLS MNALAZIN 13 4 Products and System Requirements Analog PWM Servo Drive Basics and Theory 2 2 Analog PWM Servo Drive Basics and Theory ADVANCE Analog servo drives are used extensively in motion control systems where precise control of position and or velocity is required The drive transmits the low energy reference signals from the controller into high energy signals motor voltage and current The reference signals can be either analog or digital with a 10 VDC signal being the most common The signal can represent either a motor
38. 75VDC 80 80 1 70 70 S IC 60 tes 60 a 50 so le a lic m c C 40 Ss 40 m 30 30 20 20 10 10 0 0 0 1 a 3 4 0 2 4 6 8 10 12 Continuous Output Current Amps Continuous Output Current Amps e No Heatsink a W Heatsink see note 1 4 No Heatsink s W Heatsink see note 1 3 The heatsink used in the above tests is a 15 x 22 x 0 65 aluminum plate ADVANCED VA MOTION CONTROLS MNALATIN 13 26 Products and System Requirements System Requirements Shock Vibrations While AZ drives are designed to withstand a high degree of mechanical shock and vibration too much physical abuse can cause erratic behavior or cause the drive to cease operation entirely Be sure the drive is securely mounted in the system to reduce the shock and vibration the drive will be exposed to The best way to secure the drive against mechanical vibration is to use screws to mount the AZ drive against its baseplate For information on mounting options and procedures see Mounting on page 34 Care should be taken to ensure the drive is securely mounted in a location where no moving parts will come in contact with the drive Caution ADVANCED 7A MOTION CONTROLS MNALAZIN 13 27 VA Integration in the Servo System _ This chapter will give various details on incorporating an AZ servo drive into a system such as how to design the PCB traces on an interf
39. 7A MOTION CONTROLS MNALAZIN 13 73 A Index A Agency Compliances li Alde ettet pte 25 Ambient Temperature Range 25 63 Attention Symbols iii AZ 10A20 Dimensions iss Pin Layout eet AZ 10A4 Pin L yott eate 13 AZ 12A8 Dimensions eens 66 Pin LayOUt 13 AZ 20A8 Dimensions 66 Pin Layout AZ 25A20 Dimensions 67 Pin LayOUt 13 AZ 40A8 Dimensions eee 67 Pin LayOUt ii 13 AZ 60A8 Dimensions 67 Pin bayout ua naaa 13 AZ 6A8 Dimensions 66 Pin Layout ss 13 AZB etes zie 14 Block Diagram 14 Pinout auld AZB 10A4IC 36 AZBDC 14 Block Diagram li Pinout wals AZBE 14 Block Diagram l4 Pinout 15 AZBH 14 Block Diagram 14 PINOUT rnat 15 B Baseplate Temperature Range 25 Brushed Motors 6 Brushless Motors 6 Brushless Servo System 6 ADVANCED 7A MOTION CONTROLS C Central Point Grounding 30 Command Sources 7 62 Commutation Methods 7 62 Commutation Phasing 11 Commutation Sequence
40. 9 2 5 Feedback Supported Hapag seuss sown e EX WERPSERAR R43 10 2 5 1 Feedback Polarity 2 2 25 aoa Ren 10 2 5 2 ON SONGS serros dior duo BALANG NG DAS HERUER eee dod ad 10 Using a Single Phase Motor 0 c ce eee ee eee 11 2 5 3 Encoder Feedback 2 ouo an ka NAAN AG ted bowed 12 2 5 4 Tachometer Feedback nunn neer 12 26 PIN LOGO uus cys ty eee LIA KAN S 13 2 7 Features and Control Specifications ss rr a 14 27 VAB na KANA AE ANNA GG ated Xue ek de AL 14 AAAH PSP USO TA 14 ADVANCED JA MOTION CONTROLS MNALAZIN 13 v 2 7 3 AZBE 2 7 4 AZBH 2 7 5 Block DIAgraMmsS suut iae esae v SR E E exped 2 7 6 Pinouts 2 8 System Requirements 0 4gb aska rh a e Y SR 2 8 1 Analog Servo Drive Selection and Sizing Motor Current and Voltage Motor NQUCIONCS associata dace bo DROP Edi d dr ieee pea 2 8 2 Power Supply Selection and Sizing siii Power Supply Current and Voltage 22 2 222224 22 2 8 3 Environment Isolation Regeneration and Shunt Regulators Voltage Ripple diues d ES ENG GANG Re RU NEC C du Ambient Temperature Range and Thermal Data SHOCK VIDI asili 3 Integration in the Servo System 3 1 LVD Requirements 3 2 CE EMC Wiring Requirements arie a 3 3 Grounding 3 4 Wiring 3 4 1 Wire Gauge 3 4 2 Motor Wires General Analog Input Drives 4 333 a4 baci dne ir NG heeds S NG PWM Input Drives uuu oteys eeu GR bees d
41. A MOTION CONTROLS MNALATIN 13 Products and System Requirements Products Covered 2 3 Products Covered The products covered in this manual adhere to the following part numbering structure However additional features and or options are readily available for OEM s with sufficient ordering volume Feel free to contact ADVANCED Motion Controls for further information FIGURE 2 5 AZ Part Numbering Structure AZ A AZ Analog Drive Series J Additional Options INV Inverted Inhibit Logic Drive Type B Brushless Brushed BDC Brushless Brushed PWM Command Interface Card Option Current Mode 40V Mode of Operation Models only Blank Current Mode D Duty Cycle Open Loop Mode E Encoder Velocity Mode Available H Hall velocity Mode Available IC Interface Card Drive Assembly Max DC Bus Voltage 1 10 in Volts Peak Current Amps Continuous Current output typically 50 a y i of Peak Current value Options available for orders with sufficient volume Contact ADVANCED Motion Controls for more information In general the AZ family of analog drives can be divided into top level categories based on the peak current rating of the drive These categories can be further separated into subdivisions based on specifications such as whether a drive uses analog or PWM input and the feedback available on the drive TABLE 2 2 Power Specifications Power Specifications D
42. AZ drive there are some key features that must be kept in mind to ensure proper operation 3 6 1 Trace Width and Routing ADVANCE The proper design and implementation of the PCB traces on an interface card is essential in maximizing drive efficiency and noise reduction Keep high and low power signals separated Although AZ servo drives have an internal connection between power and signal ground the traces emitting from the Power Connector P2 carry high currents and voltages while the traces emitting from the Signal Connector P1 carry low currents voltages Refrain from routing traces from P2 near traces from P1 and never route them in parallel If power traces and signal traces need to cross they should do so at right angles Keep high current traces short Traces carrying high current such as the DC Power traces and Motor Signal traces should be kept short and close together to minimize noise emissions Also keep DC Power traces separate from Motor Signal traces where possible Design for maximum values Adjacent traces can carry a voltage potential equal to the maximum DC power supply value and carry current of both the AZ servo drive s peak and continuous current ratings The trace width and copper plating thickness will need to take these maximum values into account Also be aware that AZ servo drive pin headers have a maximum current rating of 3 amps DC per pin In order to achieve a higher overall peak current capability som
43. C Input Power connections Refer to the datasheet of the specific model being used The maximum current capacity per pin is 3A continuous Notice ADVANCED 7A MOTION CONTROLS MNALAZIN 13 41 Integration in the Servo System Interface Circuitry Examples Motor Power Output The diagram below shows how an AZ servo drive connects to a motor through a mounting card interface PCB Both brush type and brushless motors should follow this general setup Notice that the motor wires are shielded and that the motor housing is grounded to the single point system ground PE Ground The cable shield should be grounded at the mounting card or PCB interface side to chassis ground FIGURE 3 17 Three Phase Motor Power Output Wiring INTERFACE PCB AZ SERVO DRIVE Motor C Shield rj Motor Y Motor B CG Motor A Chassis Ground Single Point L System Ground PE Ground FIGURE 3 18 Single Phase Motor Power Output Wiring INTERFACE PCB AZ SERVO DRIVE Motor B pep Motor A Use only Motor A and Motor B if using 60 degree Hall phasing If using 120 degree Hall phasing consult the Commutation Sequence Table Table 2 5 to determine which two motor phase outputs to connect Single Point System Ground PE Ground fal Depending on the power capacity of the AZ drive model being used there may be multiple pins for Motor Power connections Refer
44. Check inhibit input for correct polarity that is pull to ground to inhibit or pull to ground to enable Inhibit configuration depends on JE1 on the PCB Also keep in mind that noise on the inhibit line could be a cause for a false inhibit signal being given to the drive Power On Reset All drives have a power on reset function to ensure that all circuitry on the board is functional prior to enabling the drive The board will only be disabled momentarily and will quickly enable upon power up C 1 1 Overload Verify that the minimum inductance requirement is met If the inductance is too low it could appear like a short circuit to the drive and thus it might cause the short circuit fault to trip Excessive heating of the drive and motor is also characteristic of the minimum inductance requirement not being met See drive data sheets for minimum inductance requirements C 1 2 Current Limiting AZ drives incorporate a fold back circuit for protection against over current This fold back circuit uses an approximate Pe algorithm to protect the drive e Maximum peak current output level can be sustained for about 2 seconds e To actually achieve maximum peak current output for 2 seconds requires the current command to fully swing from peak in one direction to the other ADVANCED 7A MOTION CONTROLS MNALATIN 13 69 Fault Conditions and Symptoms FIGURE C 1 Maximum Peak Current Fold Back Max Peak Current Limit
45. GROUND Signal Ground Single Phase Motors Soldering inn Specifications Tables Switching Frequency System Requirements 16 27 System Voltage Requirement 17 T Tachometer Feedback 12 Tachometer Input 45 50 Tachometer Velocity Mode 9 Technical Support 72 Three Phase Motors 6 TOEQUE cs csset peer eed Emi 17 Trace Routing sss 40 Trace Width xn 40 Troubleshooting 68 73 TUDITIB sete teret tee 59 Twisted Pair Wires 32 U Under Voltage 68 Under Voltage Shutdown 69 V V HALL OUT eee 15 Velocity Control 10 62 Velocity Monitor Output 50 Vibration Voltage Ripple Ww Warning Symbols iii Warranty Info 73 Warranty Returns eee 73 Wave Soldering 38 Wire Diameter 32 Wire Gauge n 32 Wiring 31 33 Feedback Wires 33 Input Reference Wires 33 Motor Wires Power Supply Wires Wire Gauge MNALAZIN 13 AZ Analog Drives Hardware Installation Manual MNALAZIN 13 ADVANCED
46. Hall Sensors on three phase drives consult the motor datasheet to find out which feedback wire is the Hall Sensor power supply wire or for other user requirements on single phase drives Do not use this 6V supply to power an encoder An encoder will require a separate external power supply Consult the encoder datasheet or specifications to determine the encoder voltage and current requirements Typical values are 5VDC at 150mA Notice ADVANCED 7A MOTION CONTROLS MNALAZIN 13 49 Operation Getting Started Velocity Monitor Output The velocity monitor output pin is available on AZBE and AZBH drive models only This pin provides an analog voltage output that is proportional to the actual motor speed e For AZBE drives in Encoder Velocity Mode substitute the voltage value read at the velocity monitor pin Vinonitop into the below equation to determine the motor RPM V DIE 60 monitor V t t PAPA TY NG otor Velocity Number of encoder lines e For AZBH drives in Hall Velocity Mode substitute the voltage value read at the velocity monitor pin Vmonitor into the below equation to determine the motor RPM Hz V 100 120 monitor V Mot locity RPM S otor Velocity Number of motor poles Tachometer Input For AZBE and AZBH drive models when the drive is set to Tachometer Velocity mode by DIP switch setting the Velocity Monitor Output pin is used as a DC Tachometer Input The drive must be in T
47. IN 05 5 10 2010 Added AZ_10A20 and AZ_25A20 drive model information MNALAZIN 06 6 1 2011 Added AZ_25A20 data to Ambient Temperature Range and Thermal Data MNALAZIN 07 7 4 2011 Added AZBE25A20 and AZBH25A20 drive model information MNALAZIN 08 8 5 2013 Added AZ_60A8 drive model information MNALAZIN 09 9 1 2014 Added AZ_10A4 drive model information MNALAZIN 10 10 5 2014 Added MC1XAZ02 mounting card information MNALAZIN 11 11 2 2015 Added AZ 10A4IC drive model information MNALAZIN 12 12 5 2015 Added AZBH10A4 and AZBD10A drive model information MNALAZIN 13 13 9 2015 Added AZBE10A4 drive model information 2015 ADVANCED Motion Controls All rights reserved ADVANCED 7A MOTION CONTROLS MNALAZIN 13 Contents 1 Safety 1 1 1 General Safety Overview 00 0 saa 1 2 Products and System Requirements 4 2 1 AZ Drive Family Overview sperano deeds 4 2 1 1 Drive Datasheet 6 2 AABANG iso bee 4 2 2 Analog PWM Servo Drive Basics and Theory 5 2 2 1 Single Phase Brushed Motors 6 2 2 2 Three Phase Brushless Motors 6 2 3 Pr od cis KG AA AA AA 7 2 4 Control Modes sassoni iddio added ABA HANG edel ERAS 8 2 4 1 Current Torque es ahahhaha kawa da Sevens bane ES 8 242 Duty Cycle Open Loop either Dhan ees 8 2 4 3 Hall Velocity print AA he ipa 9 2 4 4 Encoder Velocity illa aaa 9 2 4 5 Tachometer Velocity oss BUGA WANG ND EN VS I XE MG
48. Input For AZBDC drive models the PWM and Direction inputs should be connected to the PWM and DIR input pins on the drive FIGURE 3 24 PWM and Direction Input Wiring INTERFACE AZ SERVO PCB DRIVE PWM J i DIR gt GROUND lt Tachometer Input For drive models that allow an external DC Tachometer for velocity control the tachometer is connected between the Velocity Monitor Output Tachometer Input pin P1 15 and signal ground either P1 7 or P1 2 The tachometer is limited to a feedback voltage range of 60 VDC The diagram below shows the recommended connection method FIGURE 3 25 DC Tachometer Input Wiring INTERFACE AZ SERVO PCB DRIVE Tach Ive MONITOR OUT TACH IN yy uf Tachometer 60 VDC SIGNAL GROUND Tach Ewa Offset Input For drive models that have an external offset input option a potentiometer can be used in addition to the input command signal when an input offset adjustment is desired The diagram below shows one possible connection method using a potentiometer for the offset input FIGURE 3 26 Offset Input Wiring INTERFACE AZ SERVO 10V Max PCB DRIVE Offset gt OFFSET P1 16 Potentiometer 7 10V Max REF IN P1 1 40k 20k 200k Input Command gt 5k Signal E REF IN P1 3 40k RI ADVANCED JA MOTION CONTROLS MNALAZIN 13 45 Integration in the Servo System Interface Circuitry Examples Inhibit Input A
49. Once certain that all these steps have been safely and properly followed turn on the main DC power supply Use a voltmeter or digital multimeter to once again check the DC power supply level Analog Input Drives 1 Turn on the test power supply connected to the external potentiometer 2 Slowly turn the potentiometer in one direction while observing the motor shaft Only make very slight adjustments to the reference potentiometer to avoid causing damage to the motor Since the drive is in Current Torque Mode and there is no load on the motor shaft even a small potentiometer adjustment can create high speeds at the motor shaft Caution Exercise caution when adjusting the potentiometer e For single phase motors this should cause the motor shaft to energize in one direction Slowly turning the potentiometer further in that same direction and also in the opposite direction should cause the motor shaft to move smoothly in response to the input e For three phase motors the three motor wires may have to be changed in order to properly commutate the motor There are six different ways that the three motor wires can be attached to the mounting card or PCB interface All six will have to be tested in order to find the right commutation Before removing the motor wires turn off both the main DC power supply and the test power supply Never remove or make any connections to the drive while power is applied Warning The proper combi
50. RVED VEL MON VEL MON 3 OUT or OUT or MOTOR B TACH IN TACH IN 4 5 16 RESERVED RESERVED OFFSET REF IN MOTOR C AZ 10A4xx 7 RESERVED P1 P3 Analog Input PWM Input vr paa 8 POWER 9 GROUND Pin Description Description Description Description 10 HIGH 1 REF IN DIR IN ENCODER B RESERVED A VOLTAGE 2 REF IN PWM IN ENCODER A RESERVED 12 RESERVED 3 SIGNAL GND SIGNAL GND REF IN REF IN 4 FAULT OUT FAULT OUT REF IN REF IN AZ 10A4IC P7 5 INHIBIT IN INHIBIT IN SIGNAL GND SIGNAL GND 6 CURRENT CURRENT Pin Description FAULT OUT FAULT OUT MONITOR MONITOR 1 POWER HALL 3 HALL 3 INHIBIT IN INHIBIT IN 2 GROUND CURRENT CURRENT 3 HALL 2 HALL 2 HIGH MONITOR MONITOR 3 VOLTAGE HALL 1 HALL 1 HALL 3 HALL 3 10 V HALL V HALL HALL 2 HALL 2 AZ_10AAIC P8 OUT OUT 11 SIGNAL GND SIGNAL GND HALL 1 HALL 1 Pin Description 12 RESERVED RESERVED V HALL V HALL 1 OUT OUT 7 MOTOR A 13 N A N A SIGNAL GND SIGNAL GND 3 14 N A N A VEL MON VEL MON 4 MOTORE OUT OUT 5 MOTOR C 6 7 s RESERVED ADVANCED 7A MOTION CONTROLS MNALAZIN 13 15 Products and System Requirements System Requirements 2 8 System Requirements To successfully incorporate an AZ servo drive into your system you must be sure it will operate properly based on electrical mechanical and environmental specifications follow some simple wiring guidelines and perhaps make use of some accessories in anticipating impacts on performance Before selecting an AZ servo drive a
51. Table 11 Company Website ii Continuous Output Current 7 62 Continuous Regeneration 24 Control Modes 7 8 9 62 Current Torque 8 Duty Cycle Open Loop 8 Encoder Velocity 9 Hall Velocity 9 Tachometer Velocity 9 Control Specifications 7 62 Current Torque 8 Current Torque Mode Test 51 54 Current Limiting 69 Current Loop Gain 55 Current Loop Integrator 57 CURRENT MONITOR 15 Current Monitor Output 48 CURRENT REF OUT Current Reference Output D DC Bus Over Voltage Limit 7 62 DC Bus Under Voltage Limit 7 62 DC Power Input 41 DC Supply Voltage Range 7 62 Differential Inputs 32 DIP Switch Settings 10 DIRIN iocis dic rci 15 Drive Datasheet 4 Duty Cycle Mode 8 Dwell Time sess 17 E Eticoder incus 10 62 Encoder Feedback 12 Encoder Inputs 43 Encoder Velocity Mode 9 Environment Shock Vibration
52. V4 NOTION CONTROLS 3805 Calle Tecate e Camarillo CA 93012 5068 Tel 805 389 1935 Fax 805 389 1165 www a m c com
53. Z drives feature an Inhibit Input pin that is used to either enable or disable the drive By default the Inhibit Input pin should be left open to enable the drive and brought to Signal Ground to disable the drive This logic can be reversed if jumper JE1 is removed however FIGURE 3 27 Inhibit Input Wiring INTERFACE AZ SERVO INTERFACE AZ SERVO PCB DRIVE PCB DRIVE INHIBIT INPUT l INHIBIT INPUT Controller O Controller Default Logic JE1 Removed Open to Enable Short to Enable Short to Disable Open to Disable SIGNAL GROUND ASIGNAL GROUND 7 I X Current Monitor Output AZ drives feature a Current Monitor output that provides an analog voltage output signal that is proportional to the actual current output The Current Monitor output should be measured relative to Signal Ground FIGURE 3 28 Current Monitor Output Wiring INTERFACE AZ SERVO PCB DRIVE CURRENT MONITOR DVM or O ANN gt Controller 10K SIGNAL GROUND DI ST Current Reference Output Some AZ drives feature a Current Reference output that provides an analog voltage output signal that is proportional to the command signal to the internal current loop The Current Reference output should be measured relative to Signal Ground FIGURE 3 29 Current Reference Output Wiring INTERFACE AZ SERVO PCB DRIVE CURRENT REFERENCE DVM or Controller C SIGNAL GROUND X ADVANCED 7A MOTION CONTROLS
54. ace board how to properly ground both the AZ drive along with the entire system and how to properly connect motor wires power supply wires feedback wires and inputs into the AZ drive 3 1 LVD Requirements The servo drives covered in the LVD Reference report were investigated as components intended to be installed in complete systems that meet the requirements of the Machinery Directive In order for these units to be acceptable in the end users equipment the following conditions of acceptability must be met 1 European approved overload and current protection must be provided for the motors as specified in section 7 2 and 7 3 of EN60204 1 2 A disconnect switch shall be installed in the final system as specified in section 5 3 of EN60204 1 3 All drives that do not have a grounding terminal must be installed in and conductively connected to a grounded end use enclosure in order to comply with the accessibility requirements of section 6 and to establish grounding continuity for the system in accordance with section 8 of EN60204 1 4 A disconnecting device that will prevent the unexpected start up of a machine shall be provided if the machine could cause injury to persons This device shall prevent the automatic restarting of the machine after any failure condition shuts the machine down 5 European approved over current protective devices must be installed in line before the servo drive these devices shall be installed and rate
55. achometer Velocity Mode in order to properly use the tachometer input The maximum input allowed at the tachometer input pin is 60 VDC When using a DC Tachometer in Tachometer Velocity mode the velocity monitor output function is inactive Notice 4 1 2 Potentiometer Function Details AZBE and AZBH drive models utilize two 0 to 50 kohm potentiometers for Loop Gain and Offset functions Both potentiometers vary in resistance from 0 to 50 kohm over 12 turns An additional full turn that does not effect resistance is provided on either end for a total of 14 turns When the end of potentiometer travel is reached it will click once for each additional turn TABLE 4 1 Potentiometer Function Details Potentiometer Description Loop Gain Adjustment located closest This potentiometer must be set completely counter clockwise in Current Mode In Velocity or Duty to corner of PCB Cycle Mode this potentiometer adjusts the gain in the velocity forward position of the closed loop Turning this potentiometer clockwise increases the gain Start from the full counter clockwise position turn the potentiometer clockwise until the motor shaft oscillates then back off one turn Offset located furthest from corner of This potentiometer is used to adjust a small amount of command offset in order to compensate for PCB offsets that may be present in the servo system Turning this potentiometer clockwise adjusts the offset in a negative direction rela
56. age limit e Low power supply voltage power supply voltage is near the drive s lower voltage limit The above indicators are subjective and suggest that the current loop may need to be tuned These can also be signs of other problems not related to current loop tuning The resistors and capacitors shown under the current control block on the datasheet block diagram determine the frequency response of the current loop It is important to tune the current loop appropriately for the motor inductance and resistance as well as the bus voltage to obtain optimum performance The loop gain and integrator capacitance of the current loop must both be adjusted for the tuning to be complete Improper current loop tuning may result in permanent drive and or motor damage regardless of drive current limits Caution Since most ADVANCED Motion Controls servo drives close the current loop internally poor current loop tuning cannot be corrected with tuning from an external controller Only after the current loop tuning is complete can optimal performance be achieved with the velocity and position loops The general current loop tuning procedure for AZ drives follows these steps 1 Determine if additional current loop tuning is necessary 2 If tuning is necessary then the current loop components must be changed Tune the current loop proportional gain Tune the current loop integral gain 3 Once the current loop is tuned then the velocity and or p
57. and practices required when dealing with the possibility of high voltages or heavy strong equipment Observe your facility s lock out tag out procedures so that work can proceed without residual power stored in the system or unexpected movements by the machine Notice Notice You must install and operate motion control equipment so that you meet all applicable safety requirements Ensure that you identify the relevant standards and comply with them Failure to do so may result in damage to equipment and personal injury Read this entire manual prior to attempting to install or operate the drive Become familiar with practices and procedures that allow you to operate these drives safely and effectively You are responsible for determining the suitability of this product for the intended application The manufacturer is neither responsible nor liable for indirect or consequential damages resulting from the inappropriate use of this product High performance motion control equipment can move rapidly with very high forces Unexpected motion may occur especially during product commissioning Keep clear of any operational machinery and never touch them while they are working D 7A MOTION CONTROLS MNALAZIN 13 Safety General Safety Overview Keep clear of all exposed power terminals motor DC Bus shunt DC power transformer when power is applied to the equipment Follow these safety guidelines e Always turn off the main
58. ay available from Phoenix Contact www phoenixcontact com part number 2952020 UM72 10 16 GN6021 Figure 3 10 below shows an AZ 20A8 drive mounted on a MC1XAZ01 that is installed on a DIN tray FIGURE 3 10 MCIXA701 and AZ 2048 Drive Mounted on MCIXAZOI and Phoenix Contact DIN Tray mating connectors shown are included with MC1XAZ01 DIN tray shown for reference only available from Phoenix Contact n In addition users may design their own mounting card to mate with an AZ servo drive For more information on designing an AZ compatible PCB interface card see PCB Design on page 40 AZB 10A4IC The AZB 10A4IC models are a servo drive and inteface mounting card soldered together to provide quick access to all drive features All drive I O supply power and motor power pins are accessible via connectors on the interface card Mating connectors for the interface card connections are included and listed below in Table 3 4 TABLE 3 4 AZB 10A4IC Included Quick Disconnect Connectors MC1XAZ01 Included Quick Disconnect Connectors Description Qty Included Manufacturer and Part Number 12 port 2 0mm spaced plug terminal 1 Molex P N 51110 1260 housing 50394 8051 crimp pins 4 port 2 0mm spaced plug terminal 1 Molex P N 51110 0460 housing 50394 8051 crimp pins 8 port 2 0mm spaced plug terminal 1 Molex P N 51110 0860 housing 50394 8051 crimp pins FIGURE 3 11 AZB 10A4IC ADVANCED JA MOTION CONTROLS
59. caused by improper commutation usually because the motor power wires are connected in the wrong order Try all six combinations of connecting the motor power wires to the drive to find the correct commutation order The proper combination of motor wires will yield smooth motion and identical speeds in both directions Improper combinations will cause jerky motion slow movement in one direction and or audible noise As a final verification that the commutation is correct use the Velocity Monitor Output pin to measure motor speed in both directions This can also be caused by invalid Hall Commutation Check to see if the drive is set for 120 or 60 degree phasing and whether this setting corresponds to the type of motor being used typically 120 degree for three phase motors and 60 degree for single phase motors See Hall Sensors on page 10 for more information For a brushless motor if the opposite motor direction is desired for a given command input interchange Hall 1 and Hall 3 then Motor A and Motor B C 1 4 Causes of Erratic Operation e Improper grounding for example drive signal ground is not connected to source signal ground e Noisy command signal Check for system ground loops e Mechanical backlash dead band slippage etc e Noisy inhibit input line e Excessive voltage spikes on bus ADVANCED JA MOTION CONTROLS MNALATIN 13 71 I Technical Support C 2 Technical Support For help from the manufacturer r
60. d 1 Current Measured 2 Current Measured 3 t t42 e The closer the commanded current is to the peak current limit the shorter the peak output time will be ADVANCED 7A MOTION CONTROLS MNALAZIN 13 70 Fault Conditions and Symptoms e Any command at or below the maximum continuous current limit can be achieved for as long as there are no fault conditions present e When the drive is configured for any of the velocity modes the user is no longer in direct control of the current output The current commands will be determined by the velocity loop Though internally the current loop still functions like it is described above it will do only what is necessary to meet the velocity demand The current output will be heavily dependent on How tight the velocity loop is tuned The load characteristics The speed the motor is already turning Magnitude and slope of velocity step C 1 3 Motor Problems A motor run away condition is when the motor spins rapidly with no control from the command input The most likely cause of this error comes from having the feedback element connected for positive feedback This can be solved by changing the order that the feedback element lines are connected to the drive or for AZBH and AZBE drives changing Switch 4 on the DIP switch bank to the opposite setting Another common motor issue is when the motor spins faster in one direction than in the other This is typically
61. d in accordance with the installation instructions the installation instructions shall specify an over current rating value as low as possible but taking into consideration inrush currents etc Servo drives that incorporate their own primary fuses do not need to incorporate over protection in the end users equipment These items should be included in your declaration of incorporation as well as the name and address of your company description of the equipment a statement that the servo drives must not be put into service until the machinery into which they are incorporated has been declared in conformity with the provisions of the Machinery Directive and identification of the person signing ADVANCED VA MOTION CONTROLS MNALATIN 13 28 Integration in the Servo System CE EMC Wiring Requirements 3 2 CE EMC Wiring Requirements The following sections contain installation instructions necessary for meeting EMC requirements General 1 Shielded cables must be used for all interconnect cables to the drive and the shield of the cable must be grounded at the closest ground point with the least amount of resistance 2 The drive s metal enclosure must be grounded to the closest ground point with the least amount of resistance 3 The drive must be mounted in such a manner that the connectors and exposed printed circuit board are not accessible to be touched by personnel when the product is in operation If this is unavoidable t
62. e the drive will maintain a commanded torque output to the motor based on the input reference command Sudden changes in the motor load may cause the drive to be outputting a high torque command with little load resistance causing the motor to Note spin rapidly Therefore Current Torque Mode is recommended for applications using a digital position controller to maintain system stability 2 4 2 Duty Cycle Open Loop In Duty Cycle Mode the input command voltage controls the output PWM duty cycle of the drive indirectly controlling the output voltage However any fluctuations of the DC power supply voltage will affect the voltage output to the motor This mode is available as a DIP switch selectable mode on AZBE and AZBH drives and is the sole mode of operation on the AZBD10A4 model This mode is recommended as a method of controlling the motor velocity when precise velocity control is not critical to the application and when actual velocity feedback is unavailable Note ADVANCED VA MOTION CONTROLS MNALATIN 13 8 Products and System Requirements Control Modes 2 4 3 Hall Velocity In Hall Velocity Mode the input command voltage controls the motor velocity with the Hall Sensor frequency closing the velocity loop An analog velocity monitor output allows observation of the actual motor speed through a Hz V scaling factor found on the drive datasheet The voltage value read at the velocity monitor output can be used to det
63. e aggressive response Ifthe current response overshoots the step input command the resistance of the current loop proportional gain resistor will need to be decreased This will decrease the current loop proportional gain and provide a slower more stable response Finding an acceptable resistance may take a few iterations As outlined in the previous section using an external potentiometer will make the process easier Remember to remove power from the drive prior to removing or adding any components to the PCB Use a resistance value that brings the current response right to the point of overshoot If there is a large amount of overshoot or if there are oscillations decrease the resistance value until there is little or no overshoot Depending on the application requirements a little overshoot is acceptable but should never exceed 10 When an acceptable resistance value has been found remove power from the drive Tune the Current Loop Integral Gain 1 2 After the proportional gain resistance has been adjusted to an acceptable value re enable the current loop integrator capacitor Using the same function generator input command as in the previous section apply power to the drive and observe the current loop response on an oscilloscope The current loop integrator capacitor can be changed or shorted out of the circuit Test both settings while observing the current loop response Ifthe current response square wave o
64. e high current signals share a group of pins to spread the current between them High current traces running to these pin groups should be inter connected on the PCB board Consult the drive s datasheet or the Pinouts section in Products Covered on page 7 for these pin groupings D VA MOTION CONTROLS MNALAZIN 13 40 Integration in the Servo System Interface Circuitry Examples 3 7 Interface Circuitry Examples 2g S0 Arr The following sections show examples of how an interface board could be designed to work with an AZ servo drive and also contain general connection rules and instructions DC Power Input The diagram below shows how an AZ servo drive connects to an isolated DC Power Supply through a mounting card interface PCB Notice that the power supply wires are shielded and that the power supply case is grounded at the single point system ground PE Ground The cable shield should be grounded at the mounting card or PCB interface side to chassis ground FIGURE 3 16 DC Power Input Wiring INTERFACE AZ SERVO PCB DRIVE Isolated DC High Voltage NG Power HV Supply GND GC Power Ground Chassis Ground Single Point System Ground PE Ground External electrolytic capacitor required between High Voltage and Power Ground Consult the drive datasheet for the required value Depending on the power capacity of the AZ drive model being used there may be multiple pins for D
65. e tee MOSFET Switching Drives i iii IGBTSWICNINO DINVGES pece e ea Fitting or AC Power Filters 22464 5 o1445544 444 5944045 3 2 1 Ferrite Suppression Core Set Up 3 2 2 Inductive Filter Cards Ce cria er ea d E EE dee ee CE 3 4 3 Power Supply Wires 22er REX wa 3 4 4 Feedback Wires ard ox p a kee ly bees steer tees 3 4 5 Input Reference Wires 0 00 ee eee 3 5 Mounting 3 5 1 Mounting OOS 2a aid d doe haha GL ie ADVANCED VA MOTION CONTROLS AZB 10A4IC MNALATIN 13 vi 3 5 2 PCB Mounting ODIO EE xESSERPRa Pak kaa ed es Mating CONNeEcCtOrS za Baa vines RR e OP d 4 Operation Soldering Screw MOUNING sassinoro Drect Ob iB PROSPERO PERE E POT PITT TR TITTI TOI 3 6 PCB Design 3 6 1 Trace Width and Routing 4444 46 440404 in 3 7 Interface Circuitry Examples 0 ccc ee ees DC Power NPU quos haah us aula ace ee ees Motor Power Output waaahh xx ERES ODE EEXS Hall Sensor INPU S 221 dX rich uk inten ERA Halata s Bl 42d s ve PAP AA 110V Analog Reference Input Potentiometer Input 0 ccc cc ee eens PWM and Direction Input silla pe TOCHOMeICNINDUT s sca qx ida ERU RR EEG Offset Input Inhibit Input Current Monitor OUTDUT vss sis REX Y s Current Reference Output Fault Output 4 1 Getting Started cas doodccegerbure Riera ead CC beer ne ed 4 1 1 Input Output Pin FUNCTIONS lt ik xe ERPERE 85454
66. e x Velocity Motor Voltage Vm and Motor Current Im should be chosen where power is at a maximum Time ADVANCED 7A MOTION CONTROLS MNALAZIN 13 1 6 Products and System Requirements System Requirements The motor current Iy is the required motor current in amps DC and is related to the torque needed to move the load by the following equation T Torque M K T Where KT motor torque constant The motor current will need to be calculated for both continuous and peak operation The peak torque will be during the acceleration portion of the move profile The continuous torque is the average torque required by the system during the move profile including dwell times Both peak torque and continuous or RMS root mean square torque need to be calculated RMS torque can be calculated by plotting torque versus time for one move cycle Here Tj is the torque and t is the time during segment i In the case of a vertical application make sure to include the torque required to overcome gravity The system voltage requirement is based on the motor properties and how fast and hard the motor is driven The system voltage requirement is equal to the motor voltage Vy required to achieve the move profile In general the motor voltage is proportional to the motor speed and the motor current is proportional to the motor shaft torque Linear motors exhibit the same behavior except that in their case force is proportional to current
67. egarding drive set up or operating problems please gather the following information C 2 1 Drive Model Information DC bus voltage and range Motor type including inductance torque constant and winding resistance Position of all DIP switches Length and make up of all wiring and cables If brushless include Hall sensor information Type of controller plus full description of feed back devices Description of problem instability run away noise over under shoot or other description e Complete part number and serial number of the product Original purchase order is helpful but not necessary C 2 2 Product Label Description The following is a typical example of a product label as it is found on the drive FIGURE C 4 Product Label Square Product Labels 0 375 x 0 375 2D Barcode Serial Model Number Number UL Logo Revision Version and Proto Designation UL File Number D 1118 S 57574 1007 Date Code CE Logo RoHS Serial Number Compliant AMC Website Address 1 Model Number This is the main product identifier The model number can have a suffix designating a change from the base model 2 Revision Letter Product revision level letter A is the earliest release from any model 3 Version The version number is used to track minor product upgrades with the same model number and revision letter 01 is the earliest release of any revision 4 Proto Designation When
68. els connect to P1 P2 and P3 The MC1XAZ01 and MC1XAZ01 HR mounting cards contain a keyed socket connector on P2 to coincide with the keyed power header on AZ drives It is recommended to include this feature on user designed mounting cards to avoid connecting the drive with the wrong Notice orientation Mating Connectors AZ drives use square post male headers for signal and power pins that are designed for fast and easy removal from PCB mount socket connectors making this option particularly useful when prototyping The socket mating connectors compatible with AZ drives are shown in the tabk below TABLE 3 5 AZ Drives Socket Mating Connectors Connector Pins Manufacturer and Part Number Signal Connector AZB10A4 AZBDC10A4 12 Samtec RSM 112 02 L S Signal Connector AZBE10A4 AZBH10A4 AZBD10A4 14 Samtec RSM 114 02 L S Signal Connector AZ_6A8 AZ_12A8 AZ_20A8 AZ_40A8 AZ_60A8 AZ_10A20 AZ_25A20 16 Samtec BCS 116 L S PE Power Connector AZ_10A4 12 Samtec RSM 112 02 L S Power Connector AZ_6A8 and AZ_12A8 11 Samtec BCS 111 L S PE Power Connector AZ_20A8 AZ_40A8 AZ_60A8 AZ_10A20 AZ_25A20 22 Samtec BCS 111 L D PE AZ_40A8 AZ_60A8 and AZ_25A20 drive models will require two BCS 111 L D PE mating connectors for the power connectors ADVANCED 7A MOTION CONTROLS MNALATIN 13 37 Integration in the Servo System Mounting Soldering Soldering an AZ board directly to a PCB prov
69. em components is fairly easy when a few simple rules are observed As with any high efficiency PWM servo drive the possibility of noise and interference coupling through the cabling and wires can be harmful to overall system performance Noise in the form of interfering signals can be coupled e Capacitively electrostatic coupling onto signal wires in the circuit the effect is more serious for high impedance points e Magnetically to closed loops in the signal circuit independent of impedance levels e Electromagnetically to signal wires acting as small antennas for electromagnetic radiation e From one part ofthe circuit to other parts through voltage drops on ground lines ADVANCED 7A MOTION CONTROLS MNALAZIN 13 31 Integration in the Servo System Wiring Experience shows that the main source of noise is the high DV DT typically about 1V nanosecond of the drive s output power stage This PWM output can couple back to the signal lines through the output and input wires The best methods to reduce this effect are to move signal and motor leads apart add shielding and use differential inputs at the drive For extreme cases use of an inductive filter card is recommended Unfortunately low frequency magnetic fields are not significantly reduced by metal enclosures Typical sources are 50 or 60 Hz power transformers and low frequency current changes in the motor leads Avoid large loop areas in signal power supply and
70. emperature over voltage under voltage short circuits invalid commutation inhibit input power on reset All of the above fault conditions are self reset by the drive Once the fault condition is removed the drive will become operative again without cycling power To determine whether the drive is in a fault state measure the Fault Output pin with a digital multimeter or voltmeter A high at this pin will indicate that the drive is subject to one of the above fault conditions and the drive will be disabled until the drive is no longer in a fault state To remove the fault condition follow the instructions in the sections below describing each possible fault state Over Temperature Verify that the baseplate temperature is less than 75 C 167 F The drive remains disabled until the temperature at the drive baseplate falls below this threshold Over Voltage Shutdown 1 ADVANCE Check the DC power supply voltage for a value above the drive over voltage shutdown limit If the DC bus voltage is above this limit check the AC power line connected to the DC power supply for proper value Check the regenerative energy absorbed during deceleration This is done by monitoring the DC bus voltage with a voltmeter or oscilloscope If the DC bus voltage increases above the drive over voltage shutdown limit during deceleration or regeneration a shunt regulator may be necessary See Regeneration and Shunt Regulators on page 21 for more
71. er Input Interface Wiring INTERFACE AZ SERVO PCB DRIVE 5V 10k Encoder A Encoder A In Shield 5V A ti Encoder B In 3 ane Encoder B Signal Ground LA VDC Power Chassis Ground Supply for Encoder ADVANCED 7A MOTION CONTROLS MNALAZIN 13 43 Integration in the Servo System Interface Circuitry Examples 10V Analog Reference Input When using a 10V analog signal for an input command it is important to consider the output impedance of the analog source when interfacing to input circuitry A poorly designed 10V analog input interface can lead to undesired command signal attenuation Figure 3 21 shows an external analog source connected to an analog input The ideal voltage delivered to the input is Vs However the voltage drop across Rsource Will reduce the signal being delivered to the drive input This voltage drop is dependent on the value of Resource and the drive s input impedance FIGURE 3 21 Analog Source and Drive Input 10V INTERFACE AZ 10V INTERFACE AZ SERVO ANALOG PCB SERVO ANALOG PCB DRIVE SOURCE DRIVE SOURCE Fei A REF ha REF O I O 1 1 A I REF A REF Rin w Equivalent Internal Offset i Input Reference Voltage Impedance The drive s analog input can be simplified to a single impedance Rin as shown in Figure 3 21 If the impedance of Rgource is of the same magnitude or larger than Rin there will be a significa
72. erface headers and the AZ drive pins Check for any shorts or open circuits At this point also check the ground connection of the whole system AZ drive mounting card Motor All these elements should have their case or chassis connected to a central grounding point ina star configuration For review see Grounding on page 30 Power Supply 1 Before wiring the DC power supply to the mounting card and AZ drive use a voltmeter or digital multimeter to make sure the DC voltage level is within specifications 2 Do not turn on the DC power supply yet Connect the DC power supply wires to the mounting card or PCB interface Do not connect directly to the AZ drive header pins Be sure the high voltage and ground connections do not get reversed as this will damage the drive 3 Turn on the DC power supply Monitor the DC voltage on the mounting card test points or PCB interface to be sure the voltage level is within specifications Once certain that power is being properly applied to the AZ drive turn the DC power supply off Input Command Wiring Follow the instructions below to properly wire the input command of the AZ drive but do not apply any power or input signal yet e For drives that use 10 V analog input one method of testing the functionality of the AZ drive within the system is by using an external reference potentiometer approximately 50 KQ as an input command signal By applying a positive DC voltage 10V max to one end of
73. ermine the motor RPM through the scaling factor See Velocity Monitor Output on page 50 for the motor RPM equation This mode is available as a DIP switch selectable mode on AZBH drives and is the sole mode of operation on the AZBH10A4 model Due to the inherent low resolution of motor mounted Hall Sensors Hall Velocity Mode is not recommended for low speed applications below 300 rpm for a 6 pole motor 600 rom for a 4 pole motor or 900 rom for a 2 pole motor Hall Velocity Mode is better suited for velocity control Note applications where the motor will be spinning at higher speeds 2 4 4 Encoder Velocity In Encoder Velocity Mode the input command controls the motor velocity with the frequency of the encoder pulses closing the velocity loop An analog velocity monitor output allows observation of the actual motor speed through a kHz V scaling factor found on the drive datasheet The voltage value read at the velocity monitor output can be used to determine the motor RPM through the scaling factor See Velocity Monitor Output on page 50 for the motor RPM equation This mode is available as a DIP switch selectable mode on AZBE drives The high resolution of motor mounted encoders allows for excellent velocity control and smooth motion at all soeeds Encoder Velocity mode should be used for applications requiring precise and accurate velocity control and is especially useful in applications where low speed Note smoothnes
74. escription Units AZ_10A4xx AZ 6A8 AZ 12A8 AZ 20A8 AZ 40A8 AZ 60A8 AZ 10A20 AZ 25420 DC Supply Voltage Range VDC 10 36 20 80 10 80 40 175 DC Bus Over Voltage Limit VDC 40 88 195 193 DC Bus Under Voltage Limit VDC 8 18 9 36 Maximum Peak Output Current A 10 6 12 20 40 60 10 25 Maximum Continuous Output Current A 5 3 6 12 20 30 6 12 5 Maximum Power Dissipation at Continuous Current W 9 12 24 48 80 120 53 110 Minimum Load Inductance uH 100 100 250 Switching Frequency kHz 40 31 20 7 1 Switching frequency for AZBE AZBH 40A8 and AZBE AZBH_60A8 drive models is 33 kHz Switching frequency for AZBE AZBH_10A20 and AZBE AZBH_25A20 is 22 kHz TABLE 2 3 Control Specifications Control Specifications Description AZB AZBDC AZBE AZBH2 AZBD Command Sources 10V Analog PWM and Direction 10V Analog 10V Analog 10V Analog Commutation Methods Trapezoidal Trapezoidal Trapezoidal Trapezoidal Trapezoidal Current Duty Cycle Encoder Current Duty Cycle Hall Control Modes Current Current Velocity Tachometer Velocity Velocity Tachometer Velocity Duty Cycle Three Phase Three Phase Three Phase Three Phase Three Phase Motors Supported j ij Single Phase Single Phase Single Phase Single Phase Single Phase 1 AZBE10A4 models operate solely in Encoder Velocity mode 2 AZBH10A4 models operate solely in Hall Velocity mode ADVANCED 7A MOTION CONTROLS MNALAZIN 13 7 Products and System Requi
75. h the current loop integrator capacitor will need to be changed to optimize the response See Loop Tuning on page 59 for more information Duty Cycle or Velocity Loop Tuning For AZBE and AZBH drives the velocity loop proportional gain can be tuned for the system requirements by adjusting the Loop Gain potentiometer These adjustments should initially be performed with the motor uncoupled from the mechanical load Configure the drive for the desired operation mode using the DIP Switchs see the drive datasheet for the specific settings ADVANCE Duty Cycle Loop Compensating the duty cycle loop requires the least amount of effort Turn the Loop Gain potentiometer clockwise until oscillation occurs then back off one turn D 7A MOTION CONTROLS MNALATIN 13 57 Operation Tuning Procedure ADVANCE e Velocity Loop Encoder Halls or Tachometer The velocity loop response is determined by the Loop Gain potentiometer as well A larger resistance value clockwise results in a faster response A smaller resistance value counter clockwise results in a slower response Adjust the Loop Gain potentiometer as necessary for the desired application performance If adjustments to the Loop Gain potentiometer do not result in the desired performance the velocity loop integrator capacitor may need to be changed to optimize the response See Loop Tuning on page 59 for more information D VA MOTION CONTROLS
76. he proper combination of motor wires will yield smooth motion and identical speeds in both directions Improper combinations will cause jerky motion slow movement in one direction and or audible noise Once the proper combination has been found varying the duty cycle should cause the motor shaft to rotate appropriately in response to the input Motor Direction For brushless motors if it is desired to change the motor direction for a given command input interchange Hall 1 and Hall 3 then Motor A and Motor B 4 3 Tuning Procedure NENNEN The standard tuning values used in ADVANCED Motion Controls AZ servo drives are conservative and work well in over 9096 of applications However some applications and some motors require more complete current loop tuning to achieve the desired performance The following are indications that additional current loop tuning is necessary Motor rapidly overheats even at low current Drive rapidly overheats even at low current Vibration sound comes from the drive or motor The motor has a high inductance 10mH The motor has a low inductance near minimum rating of the drive Slow system response times Excessive torque ripple Difficulty tuning position or velocity loops Electrical noise problems ADVANCED VA MOTION CONTROLS MNALATIN 13 54 Operation Tuning Procedure e High power supply voltage power supply is significantly higher than the motor voltage rating or near the drive s upper volt
77. hed Motors AZ servo drives are designed for use with permanent magnet brushed DC motors PMDC motors PMDC motors have a single winding armature on the rotor and permanent magnets on the stator no field winding Brushes and commutators maintain the optimum torque angle The torque generated by a PMDC motor is proportional to the current giving it excellent dynamic control capabilities in motion control systems AZ drives can also be used to control current in other inductive loads such as voice coil actuators magnetic bearings etc 2 2 2 Three Phase Brushless Motors AZ servo drives are used with brushless servo motors These motors typically have a three phase winding on the stator and permanent magnets on the rotor Brushless motors require commutation feedback for proper operation the commutators and brushes perform this function on brush type motors This feedback consists of rotor magnetic field orientation information supplied either by magnetic field sensors Hall Effect sensors or position sensors encoder or resolver Brushless motors have better power density ratings than brushed motors because heat is generated in the stator resulting in a shorter thermal path to the outside environment Figure 2 4 shows a typical system configuration FIGURE 2 4 Brushless Servo System HV Current Control Switching Logic Commutation Control Commutation Feedback ADVANCED Y
78. here must be clear instructions that the amplifier is not to be touched during operation This is to avoid possible malfunction due to electrostatic discharge from personnel Analog Input Drives 4 A Fair Rite model 0443167251 round suppression core must be fitted to the low level signal interconnect cables to prevent pickup from external RF fields PWM Input Drives 5 A Fair Rite model 0443167251 round suppression core must be fitted to the PWM input cabk to reduce electromagnetic emissions MOSFET Switching Drives 6 A Fair Rite model 0443167251 round suppression core must be fitted at the load cable connector to reduce electromagnetic emissions 7 An appropriately rated Cosel TAC series AC power filter in combination with a Fair Rite model 5977002701 torroid placed on the supply end of the filter must be fitted to the AC supply to any MOSFET drive system in order to reduce conducted emissions fed back into the supply network IGBT Switching Drives 8 An appropriately rated Cosel TAC series AC power filter in combination with a Fair Rite model 0443167251 round suppression core placed on the supply end of the filter must be fitted to the AC supply to any IGBT drive system in order to reduce conducted emissions fed back into the supply network 9 A Fair Rite model 0443164151 round suppression core and model 5977003801 torroid must be fitted at the load cable connector to reduce electromagnetic emissions Fitting of AC Power Fil
79. ides added support against mechanical shocks and vibration It is recommended to solder AZ drives to a PCB following the industry standard for Acceptability of Electronic Assemblies IPC A 610D Use solder with no clean flux AZ drives can be soldered by any of the following methods e wave soldering e hand soldering e selective wave soldering To clean the PCB and drive after soldering it is recommended to gently apply isopropyl alcohol or a cleaning agent with a soft bristled brush Use care not to apply downward pressure but rather lightly brush the PCB and drive Do not immerse the drive in a cleaning agent Screw Mounting For added stability and support AZ drives can be mounted with screws in tandem with one of the options above Figure 3 13 shows how AZ 20A8 AZ 40A8 AZ 60A8 AZ 10A20 and AZ 25A20 drives can be mounted to a mounting card using a spacer and Figure 3 14 shows the mounting procedure for AZ 6A8 and AZ 12A8 drives AZ 10A4 models feature two screw mounting locations on opposite corners of the PCB See Physical Dimensions on page 64 and or the specific drive s datasheet for exact screw locations and dimensions FIGURE 3 13 Screw Mount Diagram Remove drive mounting screw and replace with spacer Use the removed drive mounting screw to secure mounting card to drive from the bottom of the mounting card through the spacer after drive has been inserted in mounting card socket connectors Drive Mounting Screw
80. ied power supplies f f 2 The power supply output current if unknown can be estimated by using information from the output side of the servo drive as given below Vu dy eee PS Vios 0 98 Where IM current through the motor Vps nominal power supply voltage VM motor voltage see Motor Current and Voltage on page 16 2 8 3 Environment To ensure proper operation of an AZ servo drive it is important to evaluate the operating environment prior to installing the drive TABLE 2 8 Environmental Specifications Environmental Specifications Parameter Description Ambient Temperature Range See Figure 2 17 Baseplate Temperature Range See drive datasheet Humidity 90 non condensing Mechanical Shock 10g 11ms Half sine Vibration 2 2000 Hz 2 5g Altitude 0 3000m Ambient Temperature Range and Thermal Data AZ drives contain a built in over temperature disabling feature if the baseplate temperature rises above a certain value For a specific continuous output current the graphs below specify an upper limit to the ambient temperature range AZ drives can operate within while keeping the baseplate temperature below the over temperature value It is recommended to mount the baseplate of the AZ drive to a heatsink for best thermal management results For mounting instructions and diagrams see Mounting on page 34 ADVANCED 7A MOTION CONTROLS MNALAZIN 13 25 Products and System Require
81. ith mating connectors installed Vertical entry wire connections MC1XAZ01 Customer Panel Figure 3 8 below shows an AZ_40A8 drive attached to an MC1XAZ01 HR mounted to a panel Four threaded spacers are used to secure the mounting card to the panel Note that when using an MC1XAZ01 HR with the included mating connectors the wire connections to the mounting card will be from the side FIGURE 3 8 AZ_40A8 attached to MC1XAZ01 HR mounted on panel shown with mating connectors installed l l MC1XAZ01 HR Side entry wire connections Customer Panel The MC1XAZ01 HR is useful in system setups for both AZ_40A8 and lower current AZ drives where wire connections from above the mounting card would be difficult due to enclosed spaces or certain mounting configurations such as Figure 3 9 below Notice Figure 3 9 below shows an AZ 40A8 drive attached to an MC1XAZ01 HR The drive is secured by two screws through its baseplate to an external heat sink and the mounting card is secured with four threaded spacers to the external heat sink for additional stability FIGURE 3 9 AZ 4048 drive attached to MC1XAZ01 HR mounted to heat sink shown with mating connectors installed Customer Heat Sink Side entry wire connections MC1XAZ01 HR ADVANCED 7A MOTION CONTROLS MNALAZIN 13 35 Integration in the Servo System Mounting The mounting cards are also designed for easy mounting and installation on a standard DIN rail tr
82. le level it is necessary to use heavy power supply leads and keep them as short as possible Reduce the inductance of the power keads by twisting them Ground the power supply cabk shield at one end only to the mounting card or PCB interface chassis ground When multiple drives are installed in a single application precaution regarding ground loops must be taken Whenever there are two or more possible current paths to a ground ADVANCED 7A MOTION CONTROLS MNALAZIN 13 32 Integration in the Servo System Wiring connection damage can occur or noise can be introduced in the system The following rules apply to all multiple axis installations regardless of the number of power supplies used 1 Run separate power supply leads to each drive directly from the power supply filter capacitor 2 Never daisy chain any power or DC common connections Use a star connection instead 3 4 4 Feedback Wires Use of a twisted shielded pair for the feedback wires is recommended Ground the shield at one end only to the mounting card or PCB interface chassis ground Route cables and or wires to minimize their length and exposure to noise sources The motor power wires are a major source of noise and the motor feedback wires are susceptible to receiving noise This is why it is never a good idea to route the motor power wires with the motor feedback wires even if they are shielded Although both of these cables originate at the drive and ter
83. ltage should be at least 1096 above the entire system voltage requirement and at least 1096 below the lowest value of the following Drive over voltage External shunt regulator turn on voltage see Regeneration and Shunt Regulators on page 21 These percentages also account for the variances in K and K and losses in the system external to the drive The selected margin depends on the system parameter variations Do not select a supply voltage that could cause a mechanical over speed in the event of a drive malfunction or a runaway condition Brushed Motors may have voltage limitations due to the mechanical commutators Consult the manufacturer s data sheets Caution ADVANCED 7A MOTION CONTROLS MNALAZIN 13 20 Products and System Requirements System Requirements AZ servo drives operate off an isolated unregulated DC Power Supply see Table 2 2 for drive model power supply ranges and over voltage shutdown values Figure 2 15 provides one possible example of an appropriate system power supply voltage for an AZ 20A8 drive using an external shunt regulator The shunt regulator turn on voltage was chosen at an appropriate level to clamp the power supply voltage so it will not exceed the drive over voltage limit during regeneration The system power supply requirement is based on the motor properties and how much voltage is needed to achieve the application move profile see Motor Current and Voltage on page
84. ments System Requirements FIGURE 2 17 AZ Ambient Temperature Ranges MasimumAnbient C Maximum Ambient C AZ 628 Drive Models at 80VDC AZ 10A4 Drive Models at 24VDC 80 0 70 7 p 60 amp 50 m MSc TN C40 cao 30 EJ 20 2 10 10 0 0 o 3 ui 6 o 1 2 3 4 5 6 7 Continuous Output Current Amps Continuous Output Current Arps No Heatsink Noheatsirk W Heatsirk sendte 1 MasimumAnbient C MaximumAnbient C AZ 1288 Drive Models at 80VDC AZ 2028 Drive Models at 80VDC m 8 WILL zz E n at oe E pi TESI Cao c40 bu a E ca a D hi 10 9 0 o 4 2 5 0 2 4 6 8 10 2 Continuous Output Current Anpa Continuous Output Current Arps viso Fieiirk sec Wbesisek serve No Heatsink W Heetsirk seerote 1 Mairum ntent e Maximum Ambient C AZ 4008 Drive Models at 80 DC AZ 60A8 Drive Models at 80VDC 80 A 70 de ee 60 Co S d aa a pa 50 Ma DS C40 NET 3 ic 30 m 20 m 10 0 0 i 5 pa pa 5 0 5 10 15 20 25 30 35 Continuous Output Curent Arps Continuous Output Current Amps No Heetsirk W Heatsirk seerote 1 No Heatsink amp Wi Heatsink see note 1 Maximum Ambient C Maximum Ambient C AZ 10A20 Drive Models at 175VDC AZ 25A20 Drive Models at 1
85. meter input pin for command offset adjustment 2 7 5 Block Diagrams FIGURE 2 9 AZB Drive Structure AZ SERVO DRIVE Fall Sensor 9 E o E 5 IS B 5 5 5 5 o Current Feedback FIGURE 2 11 AZBE Drive Structure Encoder or Tachometer Feedback Hall Sensor Commutation Velocity Command Current Command Power Stage Brushless or Brushed Current Motor Feedback ADVANCED 7A MOTION CONTROLS Designed to drive brushless brushed motors with a PWM input command Current Torque Mode Hall Sensor trapezoidal Commutation 2 7 4 AZBH Designed to drive brushless brushed motors with a 10 V analog input DIP Switch selectable modes Current Torque Duty Cycle Hall Velocity Tachometer Velocity Hall Sensor trapezoidal commutation Single ended Hall Sensor feedback for velocity control External potentiometer input pin for command offset adjustment FIGURE 2 10 AZBDC Drive Structure AZ SERVO DRIVE Hall Sensor Brushless or Brushed Motor Current Command Power Stage Current Feedback FIGURE 2 12 AZBH Drive Structure AZ SERVO DRIVE Hall Sensor or Tachometer Feedback Hall Sensor Commutation Velocity Command Current Command Power Stage Brushless or Brushed Motor Current Feedback MNALAZIN 13 14 Products and System Requirements Features and Control Specifications 2 7 6 Pinouts TABLE 2 6 Signal Connectors
86. minate at the motor try to find separate paths that maintain distance between the two A rule of thumb for the minimum distance between these wires is 10cm for every 10m of cable length Motor Feedback t Separate power and feedback wires where possible FIGURE 3 2 Feedback Wiring Avoid running Motor Feedback feedback and power wires together Motor Power Motor Power 3 4 5 Input Reference Wires Use of a twisted shielded pair for the input reference wires is recommended Connect the reference source to REF IN and the reference source or common to REF IN Connect the shield to the mounting card or PCB interface chassis ground The servo drive s reference input circuit will attenuate the common mode voltage between signal source and drive power grounds In case of a single ended reference signal connect the command signal to REF IN and connect the command return and REF IN to signal ground If you are using an AZ drive to replace an ADVANCED Motion Controls panel mount drive the same command input to the REF IN input pins on the AZ drive will result in the motor spinning in the opposite direction as with the panel mount drive This can be changed by swapping the Note command input wiring REF IN to Pin 3 Pin 2 for AZ 10A4 models instead of Pin 1 and REF IN to Pin 1 instead of Pin 3 Long signal wires 10 15 feet and up can also be a source of noise when driven from a typical OP AMP output
87. motor wires Twisted pairs of wires are quite effective in reducing magnetic pick up because the enclosed area is small and the signals induced in successive twist cancel 3 4 1 Wire Gauge As the wire diameter decreases the impedance increases Higher impedance wire will broadcast more noise than lower impedance wire Therefore when selecting the wire gauge for the motor power wires power supply wires and ground wires it is better to err on the side of being too thick rather than too thin This recommendation becomes more critical as the cable length increases 3 4 2 Motor Wires The motor power wires supply power from the drive to the motor Use of a twisted shielded pair for the motor power cables is recommended to reduce the amount of noise coupling to sensitive components e For a brushed motor or voice coil twist the two motor wires together as a group e Fora brushless motor twist all three motor wires together as a group Ground the motor power cabk shield at one end only to the mounting card or PCB interface chassis ground The motor power leads should be bundled and shielded in their own cable and kept separate from feedback signal wires DO NOT use wire shield to carry motor current or power Caution 3 4 3 Power Supply Wires The PWM current spikes generated by the power output stage are supplied by the internal power supply capacitors In order to keep the current ripple on these capacitors to an acceptab
88. nation of motor wires will yield smooth motion and identical speeds in both directions Improper combinations will cause jerky motion slow movement in one ADVANCED 7A MOTION CONTROLS MNALAZIN 13 53 Operation Tuning Procedure direction and or audible noise Once the proper combination has been found turning the potentiometer slowly in both directions should cause the motor shaft to rotate appropri ately in response to the input PWM Input Drives Turn on the function generator to apply the PWM signal to the PWM IN pin 2 Monitor the Function Generator PWM signal on an oscilloscope Be sure to keep the PWM frequency within the 10 25 kHz range By varying the duty cycle of the PWM input signal the motor shaft should rotate in response to the input e For single phase motors this should cause the motor shaft to energize in one direction Slowly varying the PWM duty cycle should cause the motor shaft to move smoothly in response to the input e For three phase motors the three motor wires may have to be changed in order to properly commutate the motor There are six different ways that the three motor wires can be attached to the mounting card or PCB interface All six will have to be tested in order to find the right commutation Before removing the motor wires turn off both the main DC power supply and the Function Generator Never remove or make any connections to the drive while power is applied Warning T
89. nd including negligence for loss or damage arising out of connected with or resulting from this order or from the performance or breach thereof or from the manufacture sale delivery resale repair or use of any item or services covered by or furnished under this order shall in no case exceed the price allocable to the item or service or part thereof which gives rise to the claim and in the event Seller fails to manufacture or deliver items other than standard products that appear in Seller s catalog Seller s exclusive liability and Buyer s exclusive remedy shall be release of the Buyer from the obligation to pay the purchase price IN NO EVENT SHALL THE SELLER BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES Buyer will take all appropriate measures to advise users and operators of the products delivered hereunder of all potential dangers to persons or property which may be occasioned by such use Buyer will indemnify and hold Seller harmless from all claims of any kind for injuries to persons and property arising from use of the products delivered hereunder Buyer will at its sole cost carry liability insurance adequate to protect Buyer and Seller against such claims All returns warranty or non warranty require that you first obtain a Return Material Authorization RMA number from the factory Request an RMA number by web www a m c com download form form_rma html telephone 805 389 1935 fax 805 389 1165 ADVANCED
90. nt W 9 12 24 48 80 120 53 110 Minimum Load Inductance uH 100 100 250 Switching Frequency kHz 40 31 20 7 1 Switching frequency for AZBE AZBH 40A8 and AZBE AZBH_60A8 drive models is 33 kHz Switching frequency for AZBE AZBH 10A20 and AZBE AZBH 25A20 is 22 kHz TABLE B 2 Control Specifications Description AZB AZBDC AZBE AZBH2 AZBD Command Sources 10V Analog PWM and Direction 10V Analog 10V Analog 10V Analog Commutation Methods Trapezoidal Trapezoidal Trapezoidal Trapezoidal Trapezoidal Current Duty Cycle Encoder Current Duty Cycle Hall Control Modes Current Curent Velocity Tachometer Velocity Velocity Tachometer Velocity Duty Cycle Three Phase Three Phase Three Phase Three Phase Three Phase Motors Supported A i i Single Phase Single Phase Single Phase Single Phase Single Phase 1 AZBE10A4 models operate solely in Encoder Velocity mode 2 AZBH10A4 models operate solely in Hall Velocity mode TABLE B 3 Feedback Supported Description AZB AZBDC AZBE AZBH AZBD Hall Sensors for Commutation v v v v v Hall Sensors for Velocity Control v Single Ended Incremental Encoder v TABLE B 4 Hardware Protection Description All AZ Drives 1 Over Current Over Temperature Over Voltage Under Voltage Short Circuit Phase Phase Short Circuit Phase Ground v Invalid Hall Commutation v See
91. nt voltage drop across Rsource Reduced values of R purce cause a lower voltage drop that increases signal integrity In order to avoid a voltage drop of more than 596 between the source and the drive it is recommended to use an Rsource Value of less than or equal to Zkohm If there is a large output impedance from the analog source it is recommended to use a buffer circuit between the analog source output and the drive input A unity gain op amp circuit as shown in Figure 3 22 will ensure low output impedance with minimal voltage drop FIGURE 3 22 Optimized Low Impedance Interface 10V ANALOG INTERFACE AZ SERVO SOURCE PCB DRIVE ANA E A REF y source T did We 5 I L Vs 2 I REF Internal Offset Reference Voltage Potentiometer Input AZ servo drives can be commanded with the use of an external potentiometer and a DC supply by varying the DC supply voltage across the potentiometer FIGURE 3 23 Potentiometer Input INTERFACE AZ SERVO Bi directional Control PCB DRIVE Uni directional Control INTERFACE AZ SERVO 10V Max 4VDC 10V Max PCB DRIVE 10V Power Potentiometer S4 _ REE IN supply Potentiometer S 1 REF IN is 50k 7 I 50k lt 2 REF IN gt REFIN x PA GROUND LI i SIGNAL GROUND I l E ADVANCED 7A MOTION CONTROLS MNALAZIN 13 44 Integration in the Servo System Interface Circuitry Examples PWM and Direction
92. ntee current continuity The bus voltage is depicted by HV The resistor R is used to measure the actual output current For electric motors the load is typically inductive due to the windings used to generate electromagnetic fields The current can be regulated in both directions by activating the appropriate switches When switch S1 and S4 or S2 and S3 are activated current will flow in the positive or negative direction and increase When switch S1 is off and switch S4 is on or S2 off and S3 on current will flow in the positive or negative direction and decrease via one of the diodes The switch ON time is determined by the difference between the current demand and the actual current The current control circuit will compare both signals every time interval typically 50 usec or less and activate the switches accordingly this is done by the switching logic circuit which also D VA MOTION CONTROLS MNALATIN 13 Products and System Requirements Analog PWM Servo Drive Basics and Theory performs basic protection functions Figure 2 3 shows the relationship between the pulse width ON time and the current pattern The current rise time will depend on the bus voltage HV and the load inductance Therefore certain minimum load inductance requirements are necessary depending on the bus voltage FIGURE 2 3 Output Current and Duty Cycle Relationship Current ON time Time Pulse width 2 2 1 Single Phase Brus
93. or 1096 of motor resistance Depending on the motor type the drives need to be set up differently to view the current loop response properly as shown in the following figures FIGURE 4 2 Brushed Motors Current AZ Servo Drive Probe or y Resistor Square Motor Wave Input Motor Motor Since the two motor wires are in series the current through the wires is the same The current probe can be attached to either wire with the same results To keep the motor from turning during the tuning process the motor shaft must be locked FIGURE 4 3 Brushless Motors Current AZ Servo Drive Probe or y Resistor C Bc The motor shaft does not need to be locked since the drive will not commutate without the Hall Sensors Square Wave Input The current out of the drive can be forced to go through Motor A and Motor B by 1 Disconnecting the Hall sensors from the drive 2 Jumper Hall 2 input to Signal Ground 7 The drive output should follow the input command The best response will be a critically damped output waveform similar to what is shown in Figure 4 4 ADVANCED 7A MOTION CONTROLS MNALAZIN 13 56 Operation Tuning Procedure 8 FIGURE 4 4 Current Loop Response Current Target Current Signal Output Current Response Time If the drive output did not result in a proper square wave
94. osition loops may be tuned as well if necessary Equipment Necessary for Tuning Function Generator Oscilloscope Current Probe or Resistor high powered low resistance Soldering Iron Current Loop Proportional Gain Adjustment The Current Loop Gain should be adjusted with the motor uncoupled from the load and the motor secured as sudden motor shaft movement may occur To keep the motor from commutating during tuning make sure the Hall Sensor wires are not connected to the drive at this point 1 Use the DIP switches on Velocity Mode capable AZ drives to select Current Mode other AZ drives are automatically in Current Mode 2 Connect only the motor power leads to the drive No other connections should be made at this point ADVANCED 7A MOTION CONTROLS MNALAZIN 13 55 Operation Tuning Procedure 3 Using a function generator apply a 0 5 V 50 100 Hz square wave reference signal to the input reference pins 4 Short out the current loop integrator capacitor s Consult ADVANCED Motion Controls for capacitor location Any damage done to the drive while performing these modifications will void the product warranty Nofice 5 Apply power to the drive Use a bus voltage that is approximate to the desired application voltage or the current loop compensation will not be optimized 6 The drive should be enabled Observe the motor current with an oscillscope by using a current probe or resistor in series with the mot
95. otor inductance value is less than the minimum required for the selected drive use an external filter card D 7A MOTION CONTROLS MNALATIN 13 Products and System Requireme i This document is intended as a guide and general overview in selecting installing and operating an AZ servo drive Contained within are instructions on system integration wiring drive setup and standard operating methods 2 1 AZ Drive Family Overview go r l e e e l e lb l1 The family of AZ analog drives are designed to offer the same high performance and accuracy of larger drives but in a space saving PCB mount architecture By utilizing high density power devices dual sided PCB boards and creative design AZ drives are ideal for applications with limited size and weight constraints The AZ drive family contains drives that can power Single Phase brushed and Three Phase brushless motors AZ drives are powered off a single unregulated DC power supply and provide a variety of control and feedback options The drives accept either a 10V analog signal or a PWM and Direction signal as input A digital controller can be used to command and interact with AZ drives and a number of input output pins are available for parameter observation and drive configuration TABLE 2 1 Standard AZ Drive Family Part Numbers Voltage 10 40V 10 80V 40 175V Peak Current 10A 6A 12A 20A 40A 60A 10A 2
96. power and allow sufficient time for Warning complete discharge before making any connections to the drive e Do not rotate the motor shaft without power The motor acts as a generator and will charge up the power supply capacitors through the drive Excessive speeds may cause over voltage breakdown in the power output stage Note that a drive having an internal power converter that operates from the high voltage supply will become operative e Donot short the motor leads at high motor speeds When the motor is shorted its own generated voltage may produce a current flow as high as 10 times the drive current The short itself may not damage the drive but may damage the motor If the connection arcs or opens while the motor is spinning rapidly this high voltage pulse flows back into the drive due fo stored energy in the motor inductance and may damage the drive e Do not make any connections to any internal circuitry Only connections to designated connectors are allowed e Donot make any connections to the drive while power is applied e Do not reverse the power supply leads Severe damage will result e If using relays or other means to disconnect the motor leads be sure the drive is disabled before reconnecting the motor leads to the drive Connecting the motor leads to the drive while it is enabled can o ra generate extremely high voltage spikes which will damage the drive QUTION Use sufficient capacitance Pulse Width Modulation
97. put power plus 3 to 596 The only time the power supply current needs to be as high as the drive output current is if the move profile requires maximum current at maximum velocity In many cases however maximum current is only required at start up and lower currents are required at higher speeds Caution ADVANCED JA MOTION CONTROLS MNALATIN 13 1 9 Products and System Requirements System Requirements FIGURE 2 14 Unregulated DC Power Supply Current PWM Switching r Time MOSFET ON Vin Average Im de la DIODE BRIDGE Time Vp gt AC Input V Voltage PI DI eee Time SERVO DRIVE V VAC 1 41 Average Time Vm Motor Terminal Voltage Im Motor Current la Diode Current lp Power Supply Current Vp DC Power Supply Voltage Vp VAC AC Supply Voltage RMS Average Time The ripple current depends on the Time motor inductance and the duty cycle MOSFET ON vs OFF M suec time A system will need a certain amount of voltage and current to operate properly If the power supply has too little voltage current the system will not perform adequately If the power supply has too much voltage the drive may shut down due to over voltage or the drive may be damaged To avoid nuisance over or under voltage errors caused by fluctuations in the power supply the ideal system power supply vo
98. rements Control Modes 2 4 Control Modes D NNNM e The AZ family of analog drives offers a variety of different control methods While some drives in the series are designed to operate solely in one mode on other drives it is possible to select the control method by DIP switch settings Consult the datasheet for the drive in use to see which modes are available for use The name of the mode refers to which servo loop is being closed in the drive not the end result of the application For instance a drive operating in Current Torque Mode may be used for a positioning application if the external controller is closing the position loop Oftentimes mode selection will be dependent on the requirements and capabilities of the controller being used with the drive as well as the end result application 2 4 1 Current Torque In Current Torque Mode the input command voltage controls the output current The drive will adjust the output duty cycle to maintain the commanded output current This mode is used to control torque for rotary motors force for linear motors but the motor speed is not controlled The output current can be monitored through an analog current monitor output pin The voltage value read at the Current Monitor Output can be multiplied by a scaling factor found on the drive datasheet to determine the actual output current All AZ drives are able to operate in Current Torque Mode While in Current Torque Mod
99. rtional Gain Resistor Resistor that can be changed for more precise current loop tuning Current Loop Integrator Capacitor Capacitor that can be changed for more precise current loop tuning Velocity Loop Integrator Capacitor Capacitor that can be changed for more precise velocity loop tuning A 1 1 Procedure Before changing any components on the PCB follow the steps in Tuning Procedure on page 54 to determine if any additional tuning is necessary Observe the drive output current response on an oscilloscope If further tuning is necessary or desired please contact ADVANCED Motion Controls before proceeding through the through following steps Tune the Current Loop Proportional Gain 1 Follow the steps outlined in Current Loop Proportional Gain Adjustment on page 55 up through Step 8 2 Observe the drive current response on an oscilloscope Small step tuning is different than large step tuning so adjust the function generator square wave amplitude so the drive outputs a current step similar to what will be expected in typical operation Ifthe current response does not rise quickly enough to the step input command or if it never reaches the input command the resistance of the current loop proportional ADVANCED 7A MOTION CONTROLS MNALAZIN 13 60 Loop Tuning Loop Tuning 5 gain resistor will need to be increased This will increase the current loop proportional gain and achieve a faster mor
100. s is the objective 2 4 5 Tachometer Velocity In Tachometer Velocity Mode the input command voltage controls the motor velocity This mode uses an external DC tachometer to close the velocity loop The drive translates the DC voltage from the tachometer into motor speed and direction information This mode is available as a DIP switch selectable mode on AZBE and most AZBH drives DC Tachometers have infinite resolution allowing for extremely accurate velocity control However they also may be susceptible to electrical noise most notably at low speeds Note ADVANCED 7A MOTION CONTROLS MNALAZIN 13 9 Products and System Requirements Feedback Supported 2 5 Feedback Supported There are a number of different feedback options available in the AZ family of analog drives The feedback element can be any device capabk of generating a voltage signal proportional to current velocity position or any parameter of interest Such signals can be provided directly by a potentiometer or indirectly by other feedback devices such as Hall Sensors or Encoders These latter devices must have their signals converted to a DC voltage a task performed by the AZ drive circuitry TABLE 2 4 Feedback Supported Feedback Supported Description AZB AZBDC AZBE AZBH AZBD Hall Sensors for Commutation v v v v v Hall Sensors for Velocity Control v Single Ended Incremental Encoder v 2 5 1 Feedback Polarity
101. s not meet the rated minimum inductance value of the drive may damage the drive If the motor inductance value is less than the minimum required for the selected drive use of an external filter card is necessary See Inductive Filter Cards on page 30 for more Caution information A minimum motor inductance rating for each specific drive can be found in the drive datasheet If the drive is operated below the maximum rated voltage the minimum load inductance requirement may be reduced In the above equations the motor inductance is neglected In brushless systems the voltage drop caused by the motor inductance can be significant This is the case in high speed applications if motors with high inductance and high pole count are used Please use the following equation to determine motor terminal voltage must be interpreted as a vector V Ry j L I E Where L phase to phase motor inductance maximum motor current frequency ADVANCED A MOTION CONTROLS MNALAZIN 13 1 8 Products and System Requirements System Requirements 2 8 2 Power Supply Selection and Sizing There are several factors to consider when selecting a power supply for an AZ servo drive Power Requirements Isolation Regeneration Voltage Ripple Power Requirements refers to how much voltage and current will be required by the drive in the system Isolation refers to whether the power supply needs an isolation transformer Regeneration is the energy the po
102. s pulled high is an invalid commutation state in 120 degree phasing Depending on which Hall Sensor input is tied to ground consult Table 2 5 above to determine which two motor output wires will be conducting current for that specific commutation state e On AZB10A4 IC drives set DIP Switch 1 to ON internally pulls Hall 2 to ground and leave all the Hall Sensor inputs on the drive open This creates a 1 0 1 commutation state which is valid for 120 degree phasing Connect only Motor A and Motor B 2 5 3 Encoder Feedback AZBE drives utilize two single ended incremental encoder inputs for velocity control The encoder provides incremental position feedback that can be extrapolated into very precise velocity information The encoder signals are read as pulses that the AZ drive uses to essentially keep track of the motor s position and direction of rotation Based on the speed and order in which these pulses are received from the two encoder signals the drive can interpret the motor velocity The diagram below represents encoder pulse signals showing how dependent on which signal is read first and at what frequency the pulses arrive the speed and direction of the motor shaft can be extrapolated FIGURE 2 7 Encoder Feedback Signals i Example 1 Encoder A precedes Engager Encoder B The pulses arrive at a certain frequency providing speed and directional Encoder B information to the drive Example 2 Encoder
103. scillates or overshoots a larger capacitance value is necessary Ifthe current response square wave corners are too rounded a smaller capacitance value is necessary to sharpen the corners Although the ideal current loop response after integral gain tuning will be a critically damped square wave the application requirements will determine what the desired response will be i e how much overshoot steady state error oscillation is acceptable Velocity Loop Tuning The velocity loop proportional gain is adjusted by the on board Loop Gain potentiometer The velocity loop integral gain can be adjusted similar to the current loop integral gain capacitance value can be changed capacitor can be shorted out As in tuning the current loop integral gain use larger value capacitors to correct for overshoot or oscillation and smaller value capacitors for a quicker response time ADVANCED 7A MOTION CONTROLS MNALAZIN 13 61 Bf Specifications B 1 Specifications Tables TABLE B 1 Power Specifications Description Units AZ_10A4xx AZ 6A8 AZ 12A8 AZ 20A8 AZ 40A8 AZ 60A8 AZ 10A20 AZ 25A20 DC Supply Voltage Range VDC 10 36 20 80 10 80 40 175 DC Bus Over Voltage Limit VDC 40 88 195 193 DC Bus Under Voltage Limit VDC 8 18 9 36 Maximum Peak Output Current A 10 6 12 20 40 60 10 25 Maximum Continuous Output Current A 5 3 6 12 20 30 6 12 5 Maximum Power Dissipation at Continuous Curre
104. shunt regulator will turn on at a certain voltage level set below the drive over voltage shutdown level and discharge the regenerated electric energy in the form of heat The voltage rise on the power supply capacitors without a shunt regulator can be calculated according to a simple energy balance equation The amount of energy transferred to the power supply can be determined through Where E initial energy Ef final energy These energy terms can be broken down into the approximate mechanical and electrical terms capacitive kinetic and potential energy The energy equations for these individual components are as follows 1 E c 9 C Vrom Where E energy stored in a capacitor joules C capacitance Vadin nominal bus voltage of the system ADVANCED YA MOTION CONTROLS MNALAZIN 13 22 Products and System Requirements System Requirements l 2 E 210 oA Where E kinetic mechanical energy of the load joules J inertia of the load kg m 0 angular velocity of the load rads s E mgh p 8 Where Ep potential mechanical energy joules m mass of the load kg g gravitational acceleration 9 81 m s h vertical height of the load meters During regeneration the kinetic and potential energy will be stored in the power supply s capacitor To determine the final power supply voltage following a regenerative event the following equation may be used for most requirements GUAE c EUR ES
105. solate the AC line voltage from the power supply ground This allows both the power ground on an isolated power supply and the signal ground on a non isolated drive to be safely pulled to earth ground Always use an isolated power supply ifthere is no isolation in the drive Regeneration and Shunt Regulators Use of a shunt regulator is necessary in systems where motor deceleration or a downward motion of the motor load will cause the system s mechanical energy to be regenerated via the drive back onto the power supply ADVANCED 7A MOTION CONTROLS MNALAZIN 13 21 Products and System Requirements System Requirements FIGURE 2 16 Four Quadrant Operation Regeneration occurs when Torque and Velocity polarity are opposite Current Torque Torque Velocity No Regen ll Torque Velocity Regen IV I Torque No Regen Regenerating Motoring A q Velocity gi Counterclockwise Clockwise IV Torque Velocity Regen Voltage Velocity Ul ll Motoring Regenerating Counterclockwise Clockwise This regenerated energy can charge the power supply capacitors to levels above that of the drive over voltage shutdown level If the power supply capacitance is unable to handk this excess energy or if it is impractical to supply enough capacitance then an external shunt regulator must be used to dissipate the regenerated energy Shunt regulators are essentially a resistor placed in parallel with the DC bus The
106. t power supply With no voltage command applied to the potentiometer connect the wiper to the REF IN input pin on the mounting card or PCB interface Connect the test power supply ground or common to the AZ drive signal ground on the mounting card or PCB interface e For drives that use PWM and Direction input a Function Generator should be set up to generate a simple 5V square wave at a frequency of 10 25 kHz Connect the Function Generator signal to the PWM input pin on the AZ drive see drive datasheet or Pinouts on page 15 for pin labels and the common to the signal ground pin on the AZ drive Hall Sensors 1 For brushless motors With the DC power supply still turned off connect the Hall Sensors to the Hall input pins on the mounting card or PCB interface Also connect the V HALL OUT 6V supply from the AZ drive to the Hall Power line consult the motor datasheet to see which wires from the motor are the Hall Input lines and Hall Power line For brushed motors If using 60 degree Hall phasing leave all Hall input pins open If using 120 degree Hall phasing tie one of the Hall inputs to ground and leave the other two open 2 Turn on the DC power supply to the system 3 Use a digital multimeter or voltmeter to monitor the Fault Output pin see Fault Output on page 49 for more information 4 Manually rotate the motor shaft by hand a few revolutions If all the Hall Sensors are functioning properly the Faul
107. t Output signal should stay low If the Fault Output signal ADVANCED 7A MOTION CONTROLS MNALATIN 13 52 Operation Initial Setup goes high this could indicate either a short or bad connection in the Hall Sensor wires or an invalid commutation state See Hall Sensors on page 10 for information on Hall commutation 5 Once verified turn off the DC power supply Motor With the DC power supply still turned off connect the motor wires to the appropriate motor output pins on the mounting card or PCB interface e For three phase brushless motors there will be three wires to connect For now connect the wires in any order to the motor output pins on the mounting card or PCB interface These may need to be changed later in order to properly commutate the motor e For single phase brushed motors there will be two wires to connect If using 60 degree Hall phasing connect the wires to motor output phases A and Bin any order If using 120 degree Hall phasing then the proper motor output phases will depend on the Hall commutation state See Using a Single Phase Motor on page 11 for more information Applying a Command Analog Input Atthis stage everything that is needed to test operation should be connected to the AZ drive through the mounting card or PCB interface all the elements should be properly grounded in a central point location and no power or input command should be applied to any element in the system
108. te 1 Maximum Ambient C Maximum Ambient C AZ_10A20 Drive Models at 175VDC AZ_25A20 Drive Models at 175VDC 80 80 1 70 70 ak _ ee 60 a 50 50 Fa Sa lic E c C 40 Sa 40 m 30 30 20 20 10 10 0 0 0 a 2 3 4 0 2 4 6 8 10 12 14 Continuous Output Current Amps Continuous Output Current Amps e No Heatsink a W Heatsink see note 1 4 No Heatsink s W Heatsink see note 1 1 The heatsink used in the above tests is a 15 x 22 x 0 65 aluminum plate ADVANCED VA MOTION CONTROLS MNALATIN 13 63 Specifications Tables TABLE B 5 Standard Environmental Specifications Parameter Description Ambient Temperature Range See Figure B 1 Baseplate Temperature Range See drive datasheet Humidity 90 non condensing Mechanical Shock 10g 11ms Half sine Vibration 2 2000 Hz 2 5g Altitude 0 3000m TABLE B 6 Physical Dimensions Description Units AZ 10A4 AZ 10A4IC AZ 6A8 AZ 20A8 AZ 40A8 AZ 60A8 AZ 12A8 AZ 10A20 AZ 25A20 Height mm in 38 1 1 50 38 1 1 50 63 50 2 50 63 50 2 50 76 20 3 00 Width mm in 38 1 1 50 38 1 1 50 50 80 2 00 50 80 2 00 50 80 2 00 Depth not including pin lengths mm in 7 34 0 29 16 6 0 65 16 84 0 66 22 86 0 90 22 86 0 90 Weight g oz 8 5 0 3 17 0 6 84 9 3 0 94 5 3 3 119 7 4 2
109. ters It is possible for noise generated by the machine to leak onto the main AC power and then get distributed to nearby equipment If this equipment is sensitive it may be adversely affected by the noise AC power filters can filter this noise and keep it from getting on the AC power signal The above mentioned AC power filters should be mounted flat against the ADVANCED 7A MOTION CONTROLS MNALAZIN 13 29 Integration in the Servo System Grounding enclosure of the product using the mounting lugs provided on the filter Paint should be removed from the enclosure where the filter is fitted to ensure good metal to metal contact The filter should be mounted as close to the point where the AC power filter enters the enclosure as possible Also the AC power cable on the load end of the filter should be routed far from the AC power cable on the supply end of the filter and all other cables and circuitry to minimize RF coupling 3 2 1 Ferrite Suppression Core Set up If PWM switching noise couples onto the feedback signals or onto the signal ground then a ferrite suppression core can be used to attenuate the noise Take the motor leads and wrap them around the suppression core as many times as reasonable possible usually 2 5 times Make sure to strip back the cable shield and only wrap the motor wires There will be two wires for single phased brushed motors and 3 wires for three phase brushless motors Wrap the motor wires together
110. the current loop response on an oscilloscope When the optimal response is achieved turn off the drive remove the potentiometer and measure the potentiometer resistance Use the closest resistor value available Note This method will not work if the optimal tuning value is beyond the range of the potentiometer e Ifno potentiometer is available progressively double the resistance value when tuning the current loop gain for faster results If the gain resistor needs to be ADVANCED VA MOTION CONTROLS MNALATIN 13 59 Loop Tuning Loop Tuning increased during the tuning process the fastest results are achieved by doubling the resistance from the last value tried Use this method until overshoot is observed and then fine tune from there e Safety Always remove power when changing components on the drive Caution Float the oscilloscope and function generator grounds to avoid large ground currents Caution Decouple the motor from the load to avoid being injured by sudden motor movements DANGER Table A 1 lists the different components that can be used for loop tuning Consult the drive datasheet to see which options are available for a specific drive Please contact ADVANCED Motion Controls Applications Engineering for assistance in determining the PCB location of the component options for the drive model in use TABLE A 1 Through Hole Tuning Component Component Description Current Loop Propo
111. tions and Symptoms LL 68 Over Temperature eee 68 Over Voltage Shutdown LL 68 Under Voltage Shutdown eese 69 SIOFLC ela CPP X BER REX Ee 69 Invalid Hall Sensor State 4 24 Vice ca s RR ERROR RE pi 69 Inhibit OU APA APP APA EUER RR E Es 69 Power On Reset 2b 03555 NG Sd QE VAR osi HAGGANG 69 C 1 1 Overload siii peri CE eee GSS ee eee 69 em ABO AU SA oe oe eae ee eta T ro 69 C 1 3 Motor Problems 4 aub Sh oe Ga NG PAL Ur KAKA 71 C 1 4 Causes of Erratic Operation iii 71 ADVANCED 7A MOTION CONTROLS MNALAZIN 13 Vill C 2 Technical SUpport 4 7a BAWANG bob do cee hed GAL AWA X3 72 C2 Drive Model Information maawa Panda Soe NGREAD OR ne 72 C 2 2 Product Label Description 0 0 0 cee eee eee 72 C 3 Warranty Returns and Factory Help 73 Index ADVANCED 7A MOTION CONTROLS MNALAZIN 13 IX VU Safety This section discusses characteristics of your AZ Analog Drive to raise your awareness of potential risks and hazards The severity of consequences ranges from frustration of performance through damage to equipment injury or death These consequences of course can be avoided by good design and proper installation into your mechanism 1 1 General Safety Overview ADVANCE In order to install an AZ drive into a servo system you must have a thorough knowledge and understanding of basic electronics computers and mechanics as well as safety precautions
112. tive to the Ref input command Before offset adjustments are made the reference inputs must be grounded or commanded to 0 volts ADVANCED 7A MOTION CONTROLS MNALAZIN 13 50 Operation Initial Setup 4 2 Initial Setup Carefully follow the grounding and wiring instructions in the previous chapters to make sure your system is safely and properly set up For initial testing purposes it is not necessary to use a controller to provide a command input or to have any load attached to the motor The items required will be AZ Servo Drive attached to Mounting Card or PCB Interface Motor DC Power Supply for supplying power to system Digital Multimeter or ohmmeter and voltmeter 4 2 1 Current Torque Mode Test Initially the AZ drive should be placed in Current Torque Mode By default all AZ drives are shipped already set for Current Torque Mode However AZBE and AZBH drives have the option of using DIP switches to configure the drive for other modes If using an AZBE or AZBH drive mode check the DIP switch configuration to be certain the drive is in Current Torque Mode Mode configuration tables can be found on the drive datasheet Connections Test Before applying power to the drive connect the AZ drive to the mounting card or PCB interface using any of the mounting options from Mounting on page 34 Using an ohmmeter or digital multimeter test the connections between the mounting card or PCB int
113. to the datasheet of the specific model being used The maximum current capacity per pin is 3A continuous Notice If using relays or other means to disconnect the motor leads be sure the drive is disabled before reconnecting the motor leads to the drive Connecting the motor leads to the drive while it is enabled can generate extremely high voltage spikes which will Caution damage the drive ADVANCED 7A MOTION CONTROLS MNALAZIN 13 42 Integration in the Servo System Interface Circuitry Examples Hall Sensor Inputs A7 drives allow singk ended Hall Sensor inputs both for commutation and in the special case of AZBH drives for velocity feedback AZ drives provide a 6V low power supply to power the Hall Sensors Below is the recommended circuitry when designing a mounting card to interface with an AZ drive FIGURE 3 19 Hall Sensor Interface Wiring INTERFACE AZ SERVO PCB DRIVE 5V 5k Hall A Hall 1 gt 5V Shield 5k Hall B Hall 2 gt 5V 5k Hall C Hall 3 Hall Power bag V Hall Out Hall Ground Signal Ground Chassis Ground Nu Encoder Inputs AZBE drives support single ended incremental encoder inputs The encoder must be powered by an external power supply Check the motor and encoder specifications for the encoder voltage and current requirements Below is the recommended circuitry when designing a mounting card to interface with an AZ drive FIGURE 3 20 Encod
114. ve available for download at www a m c com ADVANCED 7A MOTION CONTROLS m MNALAZIN 13 Il Attention Symbols The following symbols are used throughout this document to draw attention to important operating information special instructions and cautionary warnings The section below outlines the overall directive of each symbol and what type of information the accompanying text is relaying Note Pertinent information that clarifies a process operation or ease of use preparations regarding the product O Note Notice Required instruction necessary to ensure successful completion of a task or procedure gt Notice Caution Instructs and directs you to avoid damaging equipment A Caution Warning Instructs and directs you to avoid harming yourself Warning Danger Presents information you must heed to avoid serious injury or death DANGER ADVANCED 7A MOTION CONTROLS MNALAZIN 13 Revision History Document ID Revision Date Changes MNALAZIN 01 1 9 2008 AZ Install Manual First Release MNALAZIN 02 2 10 2008 Updated Pads Layout Diagram Figure 3 12 Updated Pin Layout Diagram Figure 2 8 Added Tachometer Velocity information also see page 12 page 45 and page 50 MNALAZIN 03 3 6 2009 Added AZ 40A8 drive model information MNALAZIN 04 4 11 2009 Added MC1XAZ01 HR information to Mounting Cards section MNALAZ
115. wer supply needs to absorb during deceleration Voltage Rippk is the voltage fluctuation inherent in unregulated supplies Power Supply Current and Voltage The power supply current rating is based on the maximum current that will be required by the system If the power supply powers more than one drive then the current requirements for each drive should be added together Due to the nature of servo drives the current into the drive does not always equal the current out of the drive However the power in is equal to the power out Use the following equation to calculate the power supply output current Ips based on the motor voltage and current requirements r mMm PS Vpg 0 98 Where Vps nominal power supply voltage Im motor current Vu motor voltage Use values of Vn and Im at the point of maximum power in the move profile Figure 2 13 when Vulm max This will usually be at the end of a hard acceleration when both the torque and speed of the motor is high The power supply current is a pulsed DC current Figure 2 14 when the MOSFET switch is on it equals the motor current when the MOSFET is off it is zero Therefore the power supply current is a function of the PWM duty cycle and the motor current e g 3096 duty cycle and 12 amps motor current will result in 4 amps power supply current 3096 duty cycle also means that the average motor voltage is 30 of the DC bus voltage Power supply power is approximately equal to drive out

Hardware AZ Analog Drives - Advanced Motion Controls

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