ZDCR300EE User Manual
Contents
1. OTION CONTROLS ZDCR300EE User Manual Figure 4 Output Stage Dissipation vs Output Current 14 13 12 11 10 e 9 S 8 Vbus 24V 8 7 Vbus 48V Ce Vbus 72V 4 3 2 1 0 0 1 2 3 4 5 6 lour A 1 19 2006 Advanced Motion Controls 3805 Calle Tecate Camarillo CA Page 22 of 34 Tel 805 389 1935 Fax 805 389 1165 www a m c com ADVANCED ZDCR300EE User Manual 8 CUSTOM DRIVES If an application requires a drive in a different form or if custom labeling is desired a custom drive may be possible To request information regarding custom products contact a local Advanced Motion Controls representative or the factory directly Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com PE MAR VANGER ZDCR300EE User Manual 9 WARRANTY INFORMATION ALL RETURNS WARRANTY OR NON WARRANTY REQUIRE THAT THE CUSTOMER FIRST OBTAIN AN RMA NUMBER FROM THE FACTORY RMA number requests may be made by telephone at 805 389 1935 by fax at 805 389 1165 or via our web site http www a m c com ADVANCED MOTION CONTROLS warrants its products to be free from defects in workmanship and materials under normal use and is limited to replacing or repairing at its factory any of its products which within one year after shipment are returned to the factory of origin transportation charges prepaid and which are determined to be defective This warra2. Var ay PS TV 0 98 9 3 Ips Power Supply Output Current A Vos Nominal Power Supply Voltage V IER Motor Current A from Eq 9 2 Vu Motor Voltage V from Eq 9 1 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 27 of 34 MAR VANGER ZDCR300EE User Manual Use values of Mu and I at the point of maximum power in the move profile when V xIy max This will usually be at the end of a hard acceleration when both the torque and speed of the motor are high see Figure 6 Figure 6 Power is equal to Torque x Velocity Vu and Im should be chosen where power is at a maximum A 1 cycle Velocity I I Dwell Dwell bn bn Time 4 Torque Time Time Note 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 10 3 Regeneration During motor deceleration or a downward motion of the motor load conversion of the system s mechanical energy kinetic and potential will be regenerated via the servo drive back to the supply in the form of electrical energy This regenerative process can charge the capacitors in the power supply to potentially dangerous voltages o
3. possible since the length of cable between the two is a source of noise If this distance is greater than 3 feet then a 1000 uF capacitor should be added within 1 foot of the drive This capacitance stabilizes the voltage supplied to the drive as well as filters noise on the power supply line 5 5 Drive to Motor Wiring Always verify that the line to line inductance of the motor meets the requirements of the drive see Table 1 Sufficient inductance is required to filter the switching output of the drive and supply the motor with a smooth current waveform If the drive is operated below its maximum operating voltage the minimum load inductance requirement may be reduced In general most motors will have sufficient inductance however motors without a conventional iron core such a basket wound or pancake tend to have particularly low inductance An inductive filter card may be wired in series with a low inductance motor Inductive filter cards can also help with noise suppression In case of relatively long motor cables placing the filter card at the drive side can help reduce EMI problems For more information on inductive filter cards see Section 10 6 of the Appendix Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 16 of 34 Ale A GE ZDCR300EE User Manual 5 5 1 Brushless Motor A brushless motor will have 3 motor power wires and possibly
4. 2 3 GND v 5V 5V 5K HALL A B C 5K PDO 1 2 3 GND ral v SGND Eo o 1K MOT ENC A B SREE 6 67K MOT ENC A B I REF 6 67K 1K Int Refr PDI 4 5 DIFF PDI 4 5 DIFF MOTOR A MOTOR B CAN BAUD CAN ADDR 0 MOTOR C CAN ADDR 1 500K HIGH VOLTAGE GND RX TX GND GND LOGIC POWER CAN RX CAN TX Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 19 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com raser ONA ed ZDCR300EE User Manual 3 CONNECTOR INFORMATION 3 1 Pin Function Summary Table 2 P1 I O Connector Pin Name Description Section I O CAN ADDR 0 CAN bus address selector 0 3 V range 3 2 1 CAN ADDR 1 Differential analog command input or programmable analog 3 2 4 5 e caN BAUD CAN bus bit rate selector sui 1 8 pPpoz S Programmable digital output 3 2 6 PDI 1 PDI 2 Programmable digital input 3 2 5 PDI 3 C 5 ne frame 525 o Loan f can transmit eaures eieiei 522 o PDI 4 Programmable differential digital input or Step Step or Aux PDI 4 Enc A A 3 2 5 PDI 5 Programmable differential digital input or Direction Direction aa PDI 5 or Aux Enc B B HALL A 23 HALL B Hall sensor commutation inputs Internal 5 kQ pull up to 5 Voc HALL C ENC I Differential encoder index input For single ended encoder leave ENC I the I P1 26 terminal open 27 ENC A Differential encoder channel A input For single ended encoder
5. AADIYANCED ZDCR300EE User Manual GLOSSARY Brushed DC Motor Refers to a brushed DC or simply brushed motor which uses conductive brushes for commutation the brush makes a physical contact between the stator and the rotor Brushed DC motors can be split into two categories standard DC or permanent magnet DC PMDC Standard DC motors have an electromagnet or winding on the rotor and another electromagnet on the stator often referred to as the field winding The stator winding and field winding can be wired in series or in parallel resulting in different motor characteristics Standard DC motors tend not be used in servo systems due to their non linearity PMDC motors replace the field winding with a permanent magnet resulting in motor characteristics which are more linear Brushless Motor Refers to a brushless permanent magnet or simply brushless motor Brushless motors are part of the AC synchronous motor family with permanent magnets on the rotor and multiphase windings on the stator They are available as rotary or linear motors Control over the torque angle between the electromagnetic stator field and magnetic rotor field allow the motor to be commutated Brushless motors have several advantages over brushed motors including no maintenance requirements longer life spans higher efficiency higher power density and lower electrical noise For these reasons brushless motors are often the motor of choice in high performance serv
6. ADDR 0 and 1 inputs are used to set the CAN node address The formula below shows the voltages and corresponding address 7 Addr0 7 Addrl CANAddress 8 Table 4 CAN ADDR 0 Value CAN ADDR 1 Value CAN ADDR V V Tolerance V CAN Address Node 0 0 RE Address stored in non volatile memory 0 100 3 7 0 43 0 40 100 1 0 100 6 7 0 86 0 0 100 2 0 100 9 7 1 3 0 0 100 3 0 100 18 7 2 57 21 7 3 0 hee 62 0 100 21 7 3 0 21 7 3 0 As 63 CAN ADDR 0 and 1 are integer multiples of 3 7 V between OV and 3V Examples of how to set some CAN addresses are given in Table 4 Note that the CAN address 0 will utilize the address stored in non volatile memory Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 19 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 9 of 34 fa ADVANCED ZDCR300EE User Manual The CAN bit rate is set by applying the appropriate voltage to the CAN BAUD pin as given in Table 5 Table 5 CAN BAUD Value V CAN BAUD Tolerance V CAN Bus Bit Rate bits s 0 REH Bit rate stored in non volatile memory 0 388 S 0 388 200K 0 388 S 0 388 SE 0 388 3 0 000 Gase 3 2 2 CAN Interface A CAN interface is provided through a transmit pin CAN_TX and a receive pin CAN RX which conform to the CAN standard In order to access the CAN bus an external transmitter which meets a CAN physical laye
7. Considerations seen AL 7 1 Internal Logic eee 21 7 2 Power EE 21 Custom Drives ssssssssssssssncsscsssnsscoatsossoveseassesecensousecoossesedsooussesensonseevesovsecsoussoessossowasinese 20 Warranty Information 24 APD NOIX serres cesse ces era tester iles este lens A 2D LOT NEE 25 10 2 Power Supply Sizing amp Selection 25 UNE 28 Advanced Motion Controls 3805 Calle Tecate Camarillo CA Tel 805 389 1935 Fax 805 389 1165 www a m c com User Manual Page 2 of 34 ADVANCED AMOTION CONTROLS ZDCR300EE User Manual 10 4 Shunt Regulators eee 30 10 5 Voltage Ripple eiert Ta 30 10 6 TE 31 TOL PCB EE 32 GIOSSAFY E 33 Advanced Motion Controls 3805 Calle Tecate Camarillo CA Page 3 of 34 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com AD VANCED MOTION CONTROLS LIST OF ABBREVIATIONS ZDCR300EE User Manual AC Alternating Current CAN Controller Area Network CE Conformit Europ enne European Conformity CFM Cubic Feet per Minute DC Direct Current EMI Electromagnetic Interference UC Inputs amp Outputs LVD Low Voltage Directive MOSFET Metal Oxide Surrounded Field Effect Transistor PCD Printed Circuit Board PDI Programmable Digital Input PDO Programmable Digital Output PE Protective Earth RMA Return Material Authorization RMS Root Mean Square RPM Revolutions Per Minute VDC Volts DC 1 19 2006 Advanced Motion Controls 3805 Calle Tecate Camarillo CA Page 4 of 34 Te
8. Selection 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 because of over voltage or worse the drive and or motor may be damaged The processes of calculating the voltage and current requirements are described below 10 2 1 Selecting the Supply Voltage The ideal voltage is defined by the following constraints Upper Constraints o Drive over voltage limit o Shunt regulator voltage if available Lower Constraints o System voltage requirements Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 25 of 34 MAR VANGER ZDCR300EE User Manual o Drive under voltage limit Figure 5 illustrates the constraints when selecting a power supply voltage for a drive with power specification as shown in Table 8 and for a system that requires 100 Vpc to operate Figure 5 In this case the acceptable power supply voltage is between 110V and 170V Voltage 250 Over Voltage Region gt 195 V 200 Shunt Voltage 185 V 150 e Recommended Operating Range 110 170 V 100 System Voltage Requirement 100 V 50 Under Voltage Region lt 40 V 0 Table 8 Under Voltage 40 V Over Voltage 195 V 10 2 2 Cal
9. ferrite suppression cores also know as torroids can further help reduce the effects of EMI Although unnecessary for many systems ferrite cores can play a critical role in systems with higher bus voltages gt 200 VDC Ferrite cores are used at the drive side of a motor power cable where the motor wire leads are wrapped 2 5 times around the core as a group common mode Case ground or shield leads should never be wrapped in the ferrite core as this would counteract its effectiveness If necessary strip back the shield of the motor power cable such that you have sufficient length to use the ferrite Table 7 shows some characteristics of ferrite cores typically used in servo systems This table can be used to select an appropriate core according to the gauge of the motor power wires Note that higher impedance will yield more EMI suppression Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1113 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 15 of 34 AAR KANGER ZDCR300EE User Manual Table 7 Impedance Q Wire Gauge Manufacturer Part Number Type AWG 10MHz 25MHz 100MHz 2631102002 2643800502 Piece Core 4 82 0443164151 Snapon 156 250 C on Farre 2643802702 1Piececore 48 s C zs rte 2643626202 1PieceCore 195 3s 10 6 Farke 2643803802 i piece core ss 108 5 4 Power Supply Sufficient capacitance is needed within 1
10. requirement of the drive The filter card must also be rated to the required current 2 To reduce the dV dt of the motor outputs The main source of emitted drive noise is the high dV dt typically about 1 V per nanosecond of the drive s output power stage Unfiltered motor outputs can introduce noise in analog and digital signals For applications with noise sensitive devices e g video cameras magnetic or capacitive sensors the use of an external inductive filter card may reduce emitted noise 10 7 PCB Design This section will give some general recommendations regarding the design of the PCB to which a drive or drives will be mounted Specific information such as minimum trace distances and widths will not be covered since these parameters will vary according to the design requirements of an application ex UL compliance 10 7 1 Signal amp Power Traces Whenever possible route low level signals away from high power traces and noiSe sources such as power devices and power traces Also ensure that high power traces will be large enough to handle the current that will be drawn by the drive 10 7 2 Recommended Components A DC bus capacitor should be added near the power input connector to reduce voltage ripple Select an aluminum electrolytic capacitor rated for at least 100 VDC and 33 pF Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 32 of 34
11. to Controller Wiring 5 6 1 Reference Input If you will be using an analog input as a reference command input use the differential inputs REF IN and REF IN of the I O connector P1 For single ended inputs use only REF IN while leaving REF IN open A single ended connection will function correctly in this fashion because REF IN is connected to an internal reference point see Figure 1 of Section 2 5 6 2 Programmable Digital I O PDI amp PDO A controller can interface with the drive through PDIs and PDOs All single ended PDIs and PDOs are internally pulled to logic high In order to activate such a PDI you must pull it to ground To use a differential PDI as a regular single ended PDI pull the negative terminal to ground and supply the positive terminal with 0 5 Voc 5 7 Drive to Computer Wiring The drive supports standard RS232 data transmission Connect the PC transmit pin Tx to the drive receive pin Rx the PC receive pin Rx to the drive transmit pin Tx and connect the PC RS232 ground to the drive signal ground 5 8 CE EMC Requirements Additional installation instructions may be necessary to meet EMC requirements For reference purposes the Technical Construction File Number is TCF No J97001250 007 Rev 1 5 8 1 General 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 The dri
12. with longer motor power wire lengths Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 14 of 34 Ale A GE ZDCR300EE User Manual 5 2 3 Twisted Wires Twisted wires effectively increasing noise immunity The successive twists cancel noise transients along the length of the cable Both signal cables and power cables should be of the twisted and shielded type Differential signal wires should be twisted as a pair The combination of twisted pair wires and a differential signal significantly adds to noise immunity Power wires should be twisted as a group along with the ground or chassis wire if available For example the power leads of a brushless motor with a ground wire would all be twisted together as a bundle of 4 wires 5 2 4 Cable Shielding All signal wires should be bundled and shielded separately from drive power and motor power wires Power wires should also be bundled and shielded When grounding a shield the rule of thumb is to do so at the source of power while leaving the other shield end open For example in the case of motor power wires this would be the drive side Ideally twisted pairs should be individually shielded and isolated from the outer shield which encompasses all wires within the cable However since this type of stringent shielding practice is often not required typical cables do not provide isolation between inner an
13. 3 2 9 ENC A leave the A P1 28 terminal open ENC B Differential encoder channel B input For single ended encoder 30 ENC B leave the B P1 30 terminal open For more detailed information on an I O pin function refer to the corresponding section as given in Table 3 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2 25 26 27 28 29 30 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 19 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 8 of 34 MEGA ZDCR300EE User Manual Table 3 P2 Power Connector Name Description I O Wess 5V logic supply 5 Input current is 0 4A current consumption of feedback and I O POWER GROUND Power ground current rating of 3A per pin DC power input current rating of 3A per pin ES SS MOTOR C Motor phase C connection current rating of 3A per pin e MOTOR B Motor phase B connection current rating of 3A per pin e 10 TC MOTOR A Motor phase A connection current rating of 3A per pin 12 3 2 Pin Function Details This section describes the pin functions of Table 3 in more detail For TTL logic I O 5 Vpc represents a logic high and 0 V represents a logic low digital signal polarity can be configured via software 3 2 1 CAN Configuration The CAN configuration pins are comprised of two pins for CAN bus addressing CAN ADDR 0 amp CAN ADDR 1 and one pin for selecting the CAN bus bit rate CAN BAUD The CAN
14. ADVANCED G MOTION CONTROLS ZDCRSOOEE User Manual Rev 1 0 EE ZDCR300EE TABLE OF CONTENTS 1 19 2006 1 10 Detailed Specifications sseeeeeneneseesessesseenenensensee D 1 1 Specification Summary onteebasivntesiesbateaarunveadetenteeds 5 1 2 Power Stage Specification Details 3 1 3 Control Specification Details 6 Block Diagram csccccssscssscssesssessssscesscsssscsesssssssscssesssesssessenssenessssssssssecssessccssoesee 7 Connector Information ssssssssssssesessssesssssessessesceseseeensiesessessesesseseesseiss eessissiessese O 3 1 Pin Function Summary ui eeccccccessesceseeseeeessesecaceesceceescaecseesecasescceeaeeseesenascaeeeseeaes 8 d2 Pin Funcion Details nn ee eer 9 Mechanical Information LL 4 1 Connector Information sise 11 4 2 Mounting Dimensions inner 12 Wiring Instructions sense LO GT System Ch eruten tte ere dentiste de 13 0 2 System WING eet EE instituts 14 5 3 Grounding Guidelines amp Noise Prevention 15 5 4 Power Supply inner 16 5 5 Drive to Motor Wiring sise 16 5 6 Drive to Controller Wiring ss 17 5 7 Drive to Computer Wiring sise 17 5 8 CE EMC Requirements rennes 17 5 9 Filter and Ferrite Supplier ss 18 5 10 CE LVD Requirements nr 18 Setup Instructions ssssssssssssssssssssssssssssosssssssosissosssossssssssssosssosssossassssnssosss ssssssosssassssss DU Dt Software EE Meder need nement 20 Thermal
15. CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 29 of 34 ADVANCED AAMOTION CONTROLS ZDCR300EE User Manual 1 J 1 2 1 2 1 2 7 CVnon EE mgh e WEE mgh 9 9 Which simplifies to J 2mg h h V A 1o a 9 10 The V 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 Alternatively capacitance can be added to the system in order to increase C and hence reduce Ve However adding capacitance can often be cost and size prohibitive 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 calculated from the application move profile see Figure 6 10 3 2 Special Case Continuous regeneration If the application requires continuous regeneration more than a few seconds then the shunt regulator may not be sufficient to dissipate the regenerative energy Please contact Advanced Motion Controls for possible 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 grinding wheel flywheel centrifuge Heavy lift gantry 10 4 Shunt Regulators Advanced Motion Controls offers a variety of shunt regulators for servo drives Shunt regulators are sometimes necessary because brakin
16. LIFIERS 3805 Calle Tecate Camarillo CA 93012 NS Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 12 of 34 LE KANGED ZDCR300EE User Manual 5 WIRING INSTRUCTIONS This section starts with an overview of servo system wiring and finishes with CE wiring requirements In general the main components of a servo system will include a controller drive motor and power supply Wiring and requirements for all these components are discussed in this section 5 1 System Overview A typical servo system involves a controller drive and motor These components can create one of two different system types open loop or closed loop see Figure 2 Since open loop systems have inherent control restrictions most servo systems tend to be closed loop Because a closed loop system is just an extension of an open loop system this document focuses on closed loop systems without loss of information regarding open loop systems Figure 2 OPEN LOOP wwe ome nm CLOSED LOOP COMMAN LS FEEDBAC The wiring method for coupling the components of a servo system will depend upon the power supplies used and the isolation available on both the power supplies and the servo components Since this manual is for a non isolated drive with DC power input only this scenario see Figure 3 will be covered A
17. able itself The storage temperature range of the drive is 40 to 85 C Temperature is measured on the heat sink near the location of the power stage of the drive 1 2 7 Power Dissipation The power dissipation of the drive assuming approximately 5 power loss to heat dissipation Calculated by taking 5 of P V I at continuous current and peak bus voltage 1 3 Control Specification Details 1 3 1 Commutation Method The method by which the drive controls the motor phase currents Trapezoidal commutation is also commonly referred to as brushless DC or 6 step commutation Sinusoidal commutation is commonly referred to as brushless AC 1 3 2 Loop Sample Times The time interval at which the drive updates the corresponding loop according to the available internal or external feedback Disturbances that occur more rapidly than these rates will be transparent to the corresponding control loop 1 3 3 Maximum Encoder Frequency The highest frequency at which the drive can interpret encoder feedback This frequency corresponds to pre quadrature encoder lines per second To convert this frequency to RPM use the following formula RPM Max Encoder Freq x 60 encoder line count Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 6 of 34 ed ZDCR300EE User Manual 2 BLOCK DIAGRAM Figure 1 5V 5K PDI 1
18. al impedance of the power output stage is approximately Zo 4 3 C Watt However unlike with the internal logic the heat generation of the power output stage Wo is not a constant value and varies depending upon the output current and bus voltage of the drive as given in Figure 4 To calculate ATo simply extract the appropriate value of Wo from Figure 4 and then multiply it by Zo Example A system with Vous 24 Vpc and Lu 5 A results in Wo 8 5 Watts Hence the temperature change due to the power output stage is ATo Zo a Wo 36 55 C Thus the total base plate temperature change AT ATo iS approximately 48 8 C Hence in a 25 C ambient the drive would reach 73 8 C and shut down due to drive over temperature gt 65 C In this situation additional heat sinking and or cooling is required such that the base plate temperature stays below 65 C to avoid over temperature drive shutdown The thermal impedance of the power output stage can be reduced by using additional heat sinking and or cooling For example an additional heat sink of dimensions 2 1 x 2 1 x 0 4 inches clamped to the existing heat sink can reduced Zo to 3 8 C Watt whereas a 110 CFM fan placed near the drive within 1 foot can reduced Zo to 1 13 C Watt Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 21 of 34 AD VANCED
19. an additional motor chassis wire Connect the 3 motor power wires to pins MOTOR A MOTOR B and MOTOR C of the drive power connector P2 in any desired order If you will be using more than 3 Amperes continuous in your application be sure to use both supplied pins If a motor chassis wire is provided connect it to the systems central PE and ensure that the motor chassis itself will be isolated from PE 5 5 2 Brushed Motor A brushed motor will have two motor power wires and possibly an additional motor chassis wire Connect the 2 motor power wires to any two MOTOR pins of the drive power connector P2 If you will be using more than 3 Amperes continuous in your application be sure to use both supplied pins If a motor chassis wire is provided connect it to the system s central PE and ensure that the motor chassis itself will be isolated from PE 5 5 3 Motor Feedback Connect the motor feedback wires to the appropriate pins of the drive I O connector P1 Hall sensor inputs can be connected in any particular order Leave the negative Hall terminals HALL A HALL B HALL C open for single ended Hall sensor outputs Single ended encoders should use only the positive terminals I A and B while leaving the other terminals open If you are using a brushed motor with a tachometer you may use a programmable analog input for tachometer feedback provided the tachometer maximum voltage falls within the limits of the analog input 5 6 Drive
20. culations Over Voltage The over voltage level on Advanced Motion Controls drives can be found in the drive data sheet In the example from Table 8 the data sheet would state that the over voltage shut down point is 195 VDC Shunt Regulator Voltage From Figure 5 a shunt regulator was chosen with a 185 VDC shunt voltage The purpose of a shunt regulator is to clamp the power supply voltage so it doesn t exceed the drive over voltage levels during regeneration See Section 10 3 Regeneration to determine if a shunt regulator is required and how to select the correct voltage System Voltage Requirement 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 required to achieve the move profile The motor voltage is determined as Vu K S y Uy Ryu 9 1 Where Ma Motor Voltage V I Motor Current A use the maximum current expected for the application Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 26 of 34 TA GA ZDCR300EE User Manual Ky Motor Back EMF Constant Ry Motor Line to Line Resistance Q Ges Motor Speed use the maximum speed expected for the application If Ly is not known you can use the maximum current rating of the motor or drive or you can calculate it as Torque M TK T I 9 2 where K is the
21. d outer shields 5 3 Grounding Guidelines amp Noise Prevention Good grounding practices help reduce the majority of noise present in a system Therefore this section covers both grounding guidelines and other noise prevention techniques 5 3 1 System Grounding All common grounds within an isolated system should be tied to PE through a single low resistance point that is a central point grounding should always be carried out For example if the power supply ground is pulled to PE as shown in Figure 3 then no other point common to the power supply ground such as signal ground should be connected to PE at a separate location Avoiding such repetitive links to PE will prevent ground loops which are a frequent source of noise Central point grounding should also be applied to cable shielding shields should be open on one end and grounded on the other Close attention should also be given to chassis wires For example motors are typically supplied with a chassis wire If this chassis wire is connected to PE but the motor chassis itself is attached to the machine frame which is also connected to PE a ground loop will be created Wires used for grounding should be of a heavy gauge and as short as possible Unused wiring should also be grounded when safe to do so since wires left floating can act as large antennas which contribute to EMI 5 3 2 Ferrite Suppression Cores In addition to the recommendations given above Section 5 2
22. d to establish grounding continuity for the system in accordance with section 8 of EN60204 1 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 18 of 34 MAR VANGER ZDCR300EE User Manual D 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 E European approved over current protective devices must be installed in line before the drive these devices shall be installed and rated in accordance with the installation instructions the installation instructions shall specify an over current protection rating value as low as possible but taking into consideration inrush currents etc Drives that incorporate primary fuses do not need to incorporate over current 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 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 Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fa
23. dvanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 13 of 34 TA GA ZDCR300EE User Manual Figure 3 Controller AMC HV Servo Drive PwrGnd Q rive z D 9 Feedback MA MB MC Chassis Brushless Motor Wiring Diagram With Isolated Supply and Differential Reference Input These connections should each join the main Earth ground in a star connection at one central point using thick wire 5 2 System Wiring This section discusses wiring recommendations applicable to the overall system as opposed to the coupling of particular components 5 2 1 Wire Gauge As wire diameter decreases increased gauge impedance increases Higher impedance wire will broadcast more noise than lower impedance wire Therefore when selecting the wire gauge it is preferable to select lower gauge i e larger diameter wire This recommendation becomes more critical as the cable length increases Use the following table to select the appropriate wire size to use in your application Table 6 Current A Minimum wire size AWG 10 20 15 18 20 16 35 14 45 12 60 10 80 8 120 6 5 2 2 Cable Routing All content sensitive signal wires should be routed as far away from motor power wires as possible Power wires are a major source of noise and can easily corrupt a nearby signal This issue becomes increasingly important
24. e I Regenerating SCH Torque Velocity No Regen Goeres come Fir Torque Veotcty Regen Ci Torque Velocity No Regen Valage Velocity Ill Il Motoring Regenerating Counterclockwise Clockwise The initial and final energy of Eq 9 4 can be separated into capacitive kinetic and potential energy The energy equations for these individual components are as follows 1 E Va 9 5 nom 1 where E is the energy stored in a capacitor in joules J C is the size of the capacitor in Farads F and V m is the nominal bus voltage of the system in volts V 1 E Jo 9 6 2 where E is the kinetic mechanical energy of the load in joules J J is the inertia of the load in kg m and is the angular velocity of the load in radians per second rad s E mgh 9 7 where E is the potential mechanical energy in Joules J m is the mass of the load in kilograms kg g is gravitational acceleration 9 81m s and his the vertical height of the load in meters m Similar equations can be applied to linear motor system 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 see below for variable definitions E E E E e 9 8 Advanced Motion Controls 3805 Calle Tecate Camarillo
25. en collector of a Hall sensor See Section 5 5 3 for wiring instructions 3 2 9 Differential Encoder Input Used with differential or single ended encoder outputs Both channel A and channel B are required whereas the index channel is optional See Section 5 5 3 for wiring instructions 1 19 2006 Advanced Motion Controls 3805 Calle Tecate Camarillo CA Page 10 of 34 Tel 805 389 1935 Fax 805 389 1165 www a m c com MEGA ZDCR300EE User Manual 4 MECHANICAL INFORMATION 4 1 Connector Information P1 I O Connector Connector Information Dual Row 30 pin 0 1 in 2 54 mm pitch Mating Connector Example Samtec SSM 115 L DV P2 Power Connector Connector Information Single Row 12 pin 0 1 in 2 54 mm pitch Mating Connector Example Samtec BCS 112 L S PE ENC B ENC A ENC l 5V INPUT HALL C GND HALL A GND PDI5 HV PDI4 CS HV CAN TX TX CAN RX RX MOTOR C PDI3 PDI2 MOTOR C PDI PDO3 MOTOR B PDO2 PDO1 a MOTOR B CAN BAUD GND MOTOR A REF REF MOTOR A CAN ADDR 1 CAN ADDR 0 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 19 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 11 of 34 MAR VANGER ZDCR300EE User Manual 42 Mounting Dimensions CRIP erc ADVANCE MOTION CONTROLS PWM SERVO AMP
26. foot of wire length and in parallel with the power supply of the drive There should always be at least 1000 uF of capacitance at the power supply However some systems may require more Capacitance is required during braking or deceleration of a motor because energy is transferred back through the drive into the power supply this is known as regeneration see Section 10 3 of the Appendix If the capacitance at the power supply is insufficient in size its terminal voltage will rise beyond the operating voltage of the drive and as a result of over voltage protection the drive will disable itself and braking deceleration will cease To ensure that there is sufficient capacitance carefully test the system under worst case braking deceleration situations while monitoring the bus voltage If the bus voltage becomes too high use more capacitance If the system cannot be tested or it is unsafe to do so the required capacitance can be estimated given that the change in energy at the load can be calculated For more information on making this calculation see Section 10 3 of the Appendix As an alternative to additional capacitance a shunt regulator may be used to bleed off i e dissipate regenerative energy Shunt regulators are added in parallel with the DC bus voltage of the drive For more information on shunt regulators see Section 10 4 of the Appendix The distance between the DC power supply of the drive and the drive itself should be as short as
27. g or deceleration of a mechanical load results in its energy being fed back into the power supply which causes a rise in bus voltage This phenomenon is known as regeneration see Section 10 3 If the charge reaches the drive s over voltage shutdown point motor control and braking will cease To ensure smooth deceleration of large inertial loads the use of a shunt regulator is recommended Verify the need for a shunt regulator by operating the servo under the worst case braking and deceleration conditions If the drive shuts off due to over voltage a shunt regulator is necessary Shunt regulators operate by dissipating energy through a resistor placed in parallel with the DC bus voltage When the bus voltage reaches the shunt voltage as specified by the shunt regulator a voltage comparator unit turns on an electronic switch that connects the shunt resistor across the DC bus This power resistor dissipates the energy from the DC bus After the bus voltage is reduced to less than the shunt voltage setting the resistor is disconnected from the bus A small hysteresis loop allows time between switching When choosing a shunt regulator choose 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 10 5 Voltage Ripple For the most part Advanced Motion Controls drives are unaffected by voltage ripple from the power supply The current loop is usually fast enough to compen
28. he output side of the servo drive as given below Vm Im PS a 9 14 Ves 0 98 SS where Im is the current through the motor as defined by Eq 9 2 Vrs is the nominal power supply voltage in volts V and Vm is the motor voltage defined as Vu Ke Su Im Ru 9 15 In Eq 9 15 Ke is the motor back EMF constant also known as the voltage constant in volts per thousands of RPM V kRPM SM is the motor speed in thousands of RPM kRPM Rm is the line to line resistance of the motor in ohms Q and Im is defined by Eq 9 2 10 6 Filter Cards Advanced Motion Controls offers a selection of inductive filter cards These filters contain two inductors for single phase loads and three inductors for three phase loads Filter cards have two typical applications Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 31 of 34 MAR VANGER ZDCR300EE User Manual 1 To increase the inductance to meet the minimum load inductance requirement of Advanced Motion Controls drives Some motors have inductances that are less than the minimum load inductance requirement for the drive For example basket wound and pancake motors do not have a conventional iron core so the winding inductance is usually less than 25 uH For this type of application the filter card should be sized so the total inductance of the motor plus filter card meets or exceeds the inductance
29. l 805 389 1935 Fax 805 389 1165 www a m c com ed ZDCR300EE User Manual 1 DETAILED SPECIFICATIONS 1 1 Specification Summary Table 1 Power Stage Specifications DC Supply Voltage Peak Output Current Maximum Continuous Output Current Minimum Load Inductance Switching Frequency Heatsink Base Temperature Range Power Dissipation at Continuous Current Internal Bus Capacitance Logic Supply Voltage Under Voltage Limit Over Voltage Limit Commutation Method Max Encoder Line Frequency Current Loop Sample Time Velocity Loop Sample Time Position Loop Sample Time Power Connector P2 Signal Connector P1 Size Lx W x H Weight 1 2 Power Stage Specification Details 1 2 1 DC Supply Voltage 20 80 V 12 A 8 6 Arms 6 A 4 3 Arms 250 uH 20 kHz 0 to 65 C disables if gt 65 C 18 W 33 UF 5 VDC 5 0 4A current consumption of feedback and 1 0 17V 86 V Control Specifications Sinusoidal or Trapezoidal programmable 1 25 MHz 50 us 100 ps 100 ps Mechanical Specifications Single row header 0 1 inch 2 54 mm spacing Dual row header 0 1 inch 2 54 mm spacing 2 5 x 2 0 x 0 73 inches 63 5 x 50 8 x 18 5 mm 3 4 oz 95 2 g Corresponds to the bus voltage of the drive The drive accepts DC input power only of which the voltage may vary anywhere within the range of 20 80 VDC As a protection feature the drive will disable itself upon an under over voltage A
30. ly fail when the drive signal ground is pulled to earth ground 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 10 1 1 Drive With Isolation Some Advanced Motion Controls drives come with standard electrical isolation others have isolation as an option and some do not have isolation To determine if an Advanced Motion Controls drive has isolation refer to the functional block diagram Figure 1 Section 2 The isolation will be indicated by a dashed line through the functional block diagram and labeled as isolation If there is no dashed line through the functional block diagram separating power ground from signal ground the drive does not have isolation The following are some of the Advanced Motion Controls drives that come standard with isolation Products that are rated to 400 VDC Drives that take AC line voltage for power 10 1 2 Power Supply With Isolation Either a battery or power supply that uses a isolation transformer to isolate 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 if there is no isolation in the drive 10 2 Power Supply Sizing amp
31. motor torque constant Keep in mind that the calculated value for Vu is the minimum voltage required to complete moves at the desired speed and torque There should be at least 20 head room 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 and other changes Under Voltage Limit The under voltage level on Advanced Motion Controls drives can be found in the drive data sheet In the example from Table 8 the data sheet would state that the under voltage shut down point is 40 VDC Acceptable Power Supply Voltage The power supply voltage needs to be at least 20 above the system voltage requirement and at least 10 below the lowest value of the following Shunt regulator voltage Drive over voltage Power supply over voltage 10 2 3 Selecting the Supply Current The power supply current rating is based on the maximum current that will be required by the system If the power supply provides power to more than one drive then the current requirements for each drive should be added together Due to the nature of PWM drives the current into the drive does not always equal the current out of the drive but the power in is approximately minus the power losses in the drive equal to the power out Use the following equation to calculate the drive current requirements based on the motor current requirements
32. n under voltage corresponds to lt 17 VDC while an over voltage corresponds to gt 86 VDC 1 2 2 Peak Current Pertains to the maximum peak current the drive can output according to hardware limitations The maximum peak output duration is also internally limited to occur for no longer than 2 seconds An RMS rating can be obtained by dividing this value by v2 1 19 2006 Advanced Motion Controls 3805 Calle Tecate Camarillo CA Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 5 of 34 TA GA ZDCR300EE User Manual 1 2 3 Continuous Current Pertains to the maximum continuous current the drive can output according to hardware limitations An RMS rating can be obtained by dividing this value by 2 1 2 4 Minimum Load Inductance The minimum inductance needed at the output of the drive for proper operation For a brushless motor this corresponds to the phase to phase inductance If this minimum inductance is not met a filter card should be used to add additional inductance Some motors may operate with slightly less than the required inductance if the bus voltage is low enough AMC provides various accessories including inductive filter cards for a wide range of AMC drives for more information visit www a m c com 1 2 5 Switching Frequency The switching frequency of the drive output power stage MOSFET drive 1 2 6 Temperature Range The drive operating temperature range If operated above 65 C the drive will dis
33. nty supersedes all other warranties expressed or implied including any implied warranty or fitness for a particular purpose and all other obligations or liabilities on ADVANCED MOTION CONTROLS part and it neither assumes nor authorizes any other person to assume for the seller any other liabilities in connection with the sale of the said articles The original warranty period is not extended by the above mentioned provisions for any replaced or repaired articles This warranty shall not apply to any of ADVANCED MOTION CONTROLS products that have been subjected to misuse negligence accident or modification by the user Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 24 of 34 TA GA ZDCR300EE User Manual 10 APPENDIX The information in this appendix is intended to be generic and is not specific to any one product Asa result some sections may not pertain to the drive intended for this installation manual Read the beginning of each section to know if it applies your product Furthermore refer to the product datasheet when relating your product to examples which use product specific ratings 10 1 Isolation In systems where an AC line is involved there needs to be isolation 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 If there is no isolation the drive will immediate
34. o systems Commutation The method used to maintain a phase relationship between the stator and rotor magnetic field in order to obtain optimal torque production Controller The system function that is responsible for the final output The controller can be a separate device or be part of the drive It can be as complex as a processor based device that controls the multi axis position trajectories or as simple as a potentiometer that sets the speed of the motor Differential Signal When two wires are used to transmit a single signal In general one wire transmits the signal whereas the other transmits its complement Signals transmitted in this manner are much more immune to noise than when a single wire is utilized Drive The servo drive or simply drive is the component of a servo system that translates a low power input command signal to a higher power output This input is generally used to adjust a quantitative attribute of a motor such as torque velocity or position Electrical Revolution Cycle An electrical revolution corresponds to one cycle of phase to phase back EMF from the motor In one mechanical revolution there are as many electrical revolutions as there are pole pairs EMI Electro Magnetic Interference Noise present on a signal due to an electromagnetic source The source is generally in the form of a high frequency oscillating potential Encoder A feedback device used to measure the velocity or relative position
35. of a mechanical load These devices typically utilize a photo emitter and detector to encode two sets of tracks on a glass disk These tracks are identical in terms of the number of lines per revolution but slightly offset The offset allows for increased effective resolution A reference or index track consisting of one line per revolution is also typically supplied Ferrite Ferrite suppression cores known simply as ferrites or torroids are used to suppress the electromagnetic field radiating from a source of EMI Hall Effect Sensors A feedback device used in brushless motors to allow an external device to commutate that motor Hall sensors are typically found in one of two forms 120 or 60 degree separation However 1200 degree separation is the most common Hall sensors consist of three sensors on the stator of a motor that detect 6 different positions of the rotor over each electrical cycle Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1113 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 33 of 34 TA GA ZDCR300EE User Manual Isolation Used in this documentation to express the fact that one reference point is electrically isolated from another reference point That is all signals on one side of an isolation barrier will be taken relative to one point whereas all signals on the other side of the isolation will be taken relative to a different point Kinetic Energy The mechanical energy acqui
36. r Holding AG Fair Rite Products Corp Nordstrasse 11 PO Box J 1 Commercial Row Wallkill NY 12589 CH 4542 Luterbach Phone 888 324 7748 Switzerland Fax 888 337 7483 Phone 41 32 6816 626 Fax 41 32 6816 630 EUROPE Fair Rite Europe SAS NORTH AMERICA 3 RN 19 Schaffner EMC Inc F 77166 52 Mayfield Ave Grisy Suisnes France Edison NJ 08837 Telephone 33 0 1 60 62 71 84 Phone 1 800 367 5566 Fax 33 0 1 64 05 96 15 Phone 732 225 9533 Fax 732 225 4789 ASIA Fair Rite Asia Pte Ltd Adress 61 Kaki Bukit Avenue 1 03 38 Shun Li Industrial Park Singapore 417943 Telephone 65 6846 1998 Fax 65 6846 1918 5 10 CE LVD Requirements Instructions Necessary for Meeting 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 A European approved overload and over current protection must be provided for the motors as specified in section 7 2 and 7 3 of EN60204 1 B A disconnect switch shall be installed in the final system as specified in section 5 3 of EN60204 1 C 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 an
37. r standard ex ISO 11898 2 is required This transceiver acts as a medium between CAN chip level signals CAN_TX amp CAN_RX and CAN bus level signals CAN H amp CAN_L used on the two wire differential bus When choosing a transceiver make sure it matches with the physical layer standard of the CAN bus being used It is also recommended to isolate the transceiver from the drive 3 2 3 RS232 Interface The RS232 interface of the drive consists of a transmit data TX and receive data RX pin often referred to as Tx and Rx Connect these pins to the appropriate locations on a serial cable connector as specified by the RS232 standard The reference point for the RS232 signals is common with the signal ground GND of the drive 3 2 4 Reference Input 12 bit differential analog input with a range of 10 V Use with a single ended or differential reference signal see Section 5 6 1 for wiring instructions If not needed for a reference input may be used as a programmable analog input 3 2 5 Digital Input Internally pulled high through a current limiting 5 kQ resistor Pull to ground in order to activate 3 2 6 Digital Output Internally pulled high through a current limiting 5 kQ resistor The transistor is turned ON upon activation 3 2 7 Signal Ground Signal ground and power ground are equivalent and interchangeable for this drive 3 2 8 Hall Sensor Input Internally pulled high through a current limiting 5 kQ resistor Connects to the output op
38. r voltages that may cause a drive over voltage shutdown Consequently power supplies should have sufficient capacitance to absorb this energy without causing an over voltage fault If it is not practical to supply enough capacitance use of a shunt regulator may be necessary to dissipate the kinetic and potential energy of the load The shunt regulator is connected to the DC power supply to monitor the voltage When a preset trip voltage is reached a power resistor R is connected across the DC power supply by the shunt regulator circuit to discharge the power supply capacitor The electric energy stored in the capacitor is thereby transformed into heat UR 10 3 1 Calculations The voltage rise on the power supply capacitors assuming no 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 E E 9 4 1 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 28 of 34 MAR VANGER ZDCR300EE User Manual where E represents initial energy and E represents final energy These energy terms can be broken down into the approximate mechanical and electrical terms Note use the metric kg m s system of units for calculation Figure 7 Four quadrant operation Regeneration occurs when Torque and Velocity polarity are opposite Current Torqu
39. red by a mass due to motion PE Protective Earth The point often supplied on the chassis of an electronic unit with the intention of it being tied to Earth ground for the purpose of safety Poles The magnets or electromagnets in a motor are often referred to as pole pairs A motor must have at least two poles one pole pair to function but most motors have multiple pairs A higher number of poles is typically found in higher power motors Potential Energy The mechanical energy acquired by a mass due to a change in height PMDC Permanent Magnet Direct Current Motor See Brushed Motor PWM Pulse Width Modulation When a signal is varied modulated by changing the width or duty cycle of repetitive pulses in the signal In terms of motion control this often refers to a square waveform of constant frequency with the square pulses varying in width Regeneration The phenomenon of having the mechanical energy of a load of a servo system transferred to the power supply of that servo system in the form of electrical energy Servo To control the motion of a mechanical load Shunt Regulator A component often found in servo systems to help dissipate the electric energy delivered back to a power supply due to regeneration Tachometer A feedback device used to measure the velocity of a mechanical load Essentially a small rotary generator attached to the load that outputs a voltage dependent upon the speed of the load Torroid See Fe
40. rrite Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 34 of 34
41. sate for 60Hz 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 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 14272008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 30 of 34 MAR VANGER ZDCR300EE User Manual 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 10 5 1 Calculations The voltage ripple for a system can be estimated using the equation Vk lrs Fe 9 11 PS where Ve is the voltage ripple Ces is the power supply capacitance and F is the frequency factor The power supply capacitance can be estimated by rearranging the above equation to solve for the capacitance C as Ips Crs Fr 9 12 VR The variables for this equation are defined below 0 42 Fy _ 9 13 f where f is the AC Line Frequency in hertz Hz Note that for half wave rectified power supplies f f 2 IPs is the power supply output current which if not known can be estimated by using information from t
42. software Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1 13 2006 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 20 of 34 Ale A GE ZDCR300EE User Manual 7 THERMAL CONSIDERATIONS The ZDCR300 drive has two sources of heat generation heat generated by the internal logic and heat generated by the power output stage The base plate temperature change caused by these two sources is different due to the internal construction of the drive Both heat sources are discussed below with all thermal impedance values being relative to temperatures as seen by the drive in an open ambient environment Note that the drive uses a thermal sensor located near the power output stage to measure heat sink temperature changes 7 1 Internal Logic The thermal impedance of the internal logic section is approximately Z 5 1 C Watt with the heat generation of the logic section given by W 2 4 Watts Heat Dissipated in I O Circuit Watts The heat dissipation in the I O circuit can be calculated from the current through the input and output impedances This is typically very small and negligible Thus the temperature change due to the logic circuit is approximately ATL Z xXxW 12 24 C As a result a powered but disabled ZDCR300 can be expected to reach a temperature of about 12 C above ambient 7 2 Power Output Stage The temperature change due to the power output stage is given by ATo Zo X Wo where the therm
43. ve s metal enclosure if available must be grounded to the closest ground point with the least amount of resistance Advanced Motion Controls 3805 Calle Tecate Camarillo CA 1422008 Tel 805 389 1935 Fax 805 389 1165 www a m c com Page 17 of 34 TA GA ZDCR300EE User Manual 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 there must be clear instructions that the drive is not to be touched during operation This is to avoid possible malfunction due to electrostatic discharge from personnel A Fair Rite model 0443167251 round suppression core must be fitted to the motor cable connector to reduce electromagnetic emissions An appropriately rated Schaffner 2080 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 of any MOSFET drive system in order to reduce conducted emissions fed back into the supply network 5 8 2 Analog Input Drives 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 59 Filter and Ferrite Supplier Below is the contact information for a suggested filter and ferrite supplier Schaffner Fair Rite EUROPE HEADQUARTERS NORTH AMERICA HEADQUARTERS Schaffne
44. x 805 389 1165 www a m c com Page 13 of 34 MAD VANGER ZDCR300EE User Manual 6 SETUP INSTRUCTIONS Setup and configuration of all DigiFlex drives is done strictly through software This section will discuss how this software can be acquired and installed For additional help on using the software refer to the software help content 6 1 Software Setup DigiFlex drives use the DriveWare300 application program for setting up and configuring the drive This application is readily available online at the Advanced Motion Controls website or contact us directly for information on how to obtain this software This application can be downloaded as a compressed zip file If you don t already have an application for uncompressing such file types you ll need to download one also freely available online Once the zip file has been downloaded uncompress it and run the software setup application Complete the installation process and then run the resulting software Be sure to view the installation notes These notes are particularly important if you are running the latest version of DriveWare300 with an older drive In some situations a firmware update will be required before you can correctly configure a drive Note that you can run DriveWare300 without having a drive connected however the oscilloscope tool will not be available When opening DriveWare300 without a drive open an existing project file or use the default file provided with the
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