User Manual for QuickStart BL3416E2-A04
Contents
1. 7 TN SS m DL i m 1 amp 9 9 n i Fog p FA C2 D CO CO EIC di LA 2 Ne 2 D l lt a EE Fa lt 002 ome scr xj L CU ue A as 22 m Sc CO D 2 2 2 E m OU LH i 2 6 O QJ s E hd LI J Release Date Revision Advanced Motion Controls 3805 Calle Tecate Camarillo 93012 3 5 2010 2 01 ph 805 389 1935 fx 805 389 1165 www a m c com Page Cre 4 ADVANCED A MOTION CONTROLS Analog Servo Drive BX25A20AC PART NUMBERING INFORMATION BX 25 A 20 AC Drive Additional Options B or BX Brushless drive BE Encoder Velocity Mode Available BD PWM Command Revision BDC PWM Command Closed Current Loop Assigned a letter A through Z by manufacturer S or SX Commutated Sine Command Power Supply DC Power Supply Peak Current AC AC Power Supply Maximum peak current rating in Amps FAC AC Power Connecter Relocated to the Front Peak Voltage Isolation Option Peak voltage rating scaled 1 10 in Volts Optical Isolation ADVANCED Motion Controls analog series of servo drives are available in many configurations All models listed in the selection tables of the website are readily available standard product offerings ADVANCED Motion Controls also has the capability to pr2. ENCODER CABLE 7 1005 FOUL SHIELD 1 CLOCKWISE SHAFT ROTATION 4 ADVANCED MOTION CONTROLS 3805 Calle Tecate Camarillo CA 93012 Tel 805 389 1935 Fax 805 389 1165 Quick Start Cable CBL D02 DRIVE CABLE WIRING SPECIFICATIONS ow tn i d LO 8 dO ordo o E oO 2 n o c NEN 2226072 9 2 D s ue E e E 2 E a a 5 5 O 9 D S tor ioi tot 12 101 12 9 E a H H BE HB Be HE 5 otS Stor ts Si 5 1 CU 101 1 fot CO tor tor o C D 8 icq xw 7 2 5 a gt 7 lt M O c allo Cizioixisiz oe LIGILO gt e LG PLI 2 11 lt 1 51 oc 3 it T gt O gt lt o 2 Qe A T LiL Li Vi ViVi 010 010101 G we 1919 454 C O OI OI 0 D IDO 5 _ gt DENM gt oS i i o D 8 Ca t 5 v 8 2 8 gt O 9 9 52 o x N Qo lt gt c c ooo90 60
3. ol 4 15 Curr Ref caji 1 1 16 u fC 4 c EL 2 32 16 Fault Out i B ml T 5 CEEI 56 5 LI II j S 18 22 22 19 SGND Encoder 2i 25 25 20 5 Encoder 28 28 21 Encoder Channel 22 Encoder Channel A 23 Encoder Channel B 24 Encoder Channel B 25 Encoder Channel 26 Encoder Channel MOTION CONTROLS MNQSA4UM 01 38
4. 5 5 8284 995 835 T T e c 9o z1D 98 5 2 5 81 5 1541 LL a m 9 EO V 10 0 2 ul Z A L Oa Z DIAGRAM 805 389 1165 805 389 1935 Fax 4 ADVANCED MOTION CONTROLS 3805 Calle Tecate Camarillo CA 93012 Tel Quick Start Cable CBL F01 10 FEEDBACK CABLE WIRING SPECIFICATIONS CBL F01 10 CABLE O c O 9 o O o o o c im c O O c c o O Connector D 9 Sis o O 2102 6 Molex Connector P N 43020 0601 Twisted Pair Terminals P N 43031 0002 15 Pin AMP D SUB Plug P N 748364 1 Twisted Pair Housing P N 748677 1 isted Pair Tw 8 Pin Molex Terminals P N 748333 4 Connector P N 70107 0007 isted Pair Tw Terminals P N 16 02 0077 isted Pair Tw DIAGRAM Connector C Single Wires Twisted Pairs Twisted Pairs y 10 99UUOD Twisted Pairs 10 0 2 4 ADVANCED MOTION CONTROLS 805 389 1165 805 389 1935 Fax 3805 Calle Tecate Camarillo CA 93012 Tel Quick Start Cable N N 56 C T Z O S Connector x c T 2 a LLI 1 tQ lt o D o ur d S 0 1 tQ O Si
5. ADVANCED MOTION CONTROLS MNQSA4UM 01 8 Integrate QuickStart into Your System Wiring 3 1 2 Command Signal Command signal and mode selection are dictated by the capabilities of your controller and the desired operation of your system Analog 10V command signals are suited for torque and velocity modes 10V Command Signal Single Ended Signal SIB Available Drive Modes SGND C3 2 SGND Command C3 4 Ref Torque Mode Velocity Mode 10V Command Signal Differential Signal SIB Available Drive Modes Command C3 4 Command C3 5 Ref Torque Mode Velocity Mode More Information on Mode Selection Drive modes can be separated into three basic categories Torque Velocity and Position The name of the mode describes what servo loops are being closed in the drive They don t describe the end result of the operation For example a drive in Torque mode can still be in a positioning application if the external controller closes the position loop In fact most high performance positioning systems use a drive in torque mode with the controller closing the velocity and position loops The correct mode is determined by the requirements of the controller Some controllers require that the drive be in torque mode Other controllers require that the drive be in velocity mode Check the documentation on your controller or contact the manufacturer of your controller to
6. SENSOR CONNECTOR PIN 43025 0600 CONTACTS MOLEX P N 43030 0002 OR EQUIV AMP CONNECTOR P N 103650 7 OR EQUIVALENT ENCODER LEADS 28 AWG 18 LONG SHIELDED CABLE EH 2 w PHASE 5 PHASE T 4 BARE SHIELD TO CASE MOTOR SHIELDED CABLE 16 AWG 5 218 THRU 4 EG ecu FIN COLOR FUNCTION GROUND x SHIELD EXC ODER CONNECTIONS RED o vbG O were BLuE OuTPUTB GREEN ouTPUTB wo I pn i BLACK WHITE CASE GROUND DRAIN WIRE CABLE SHIELD 4 ADVANCED MOTION CONTROLS 3805 Calle Tecate Camarillo CA 93012 Tel 805 389 1935 Fax 805 389 1165 Quick Start Motor ENCODER 2500 lines revolution 8000 RPM 0 250 0 0000 0 0005 RADIAL SHAFT MOVEMENT 0 007 TIR AXIAL SHAFT MOVEMENT 0 030 MAX HOUSING Carbon Fiber Composite case ground via cable TERMINATION 15 conductor cable 28 AWG 18 long MOUNTING 1 812 Bolt Circle MOMENT OF INERTIAL 1 5 x 10 oz in s ACCELERATION 1 x 10 Radians s ACCURACY 1 0 Arc Minutes Mechanical OutlIne 30 ROTATION ADJUSTMENT CW ROTATION FOR OUTPUT WAVEFORMS pe 40 ELECTRICAL TYP a hes 150 ELECTRICAL 10 OUTPUT OUTPUT A LJ orure LU LULU ULL OUTPUT B l l OUTPUT I 2 OUTPUT B AE WITH B LONG
7. over heating and short circuits The drive interfaces with digital controllers or can be used as a stand alone drive and requires only a single AC power supply A single red green LED indicates operating status Loop gain current limit input gain and offset can be adjusted using 14 turn potentiometers The offset adjusting potentiometer can also be used as an on board input signal for testing purposes when SW1 DIP switch is ON The drive can use quadrature encoder inputs or Hall sensors for velocity control Four Quadrant Regenerative Operation 4 Adjustable Current Limits Selectable Inhibit Enable Logic Built in Shunt Regulator Circuit 4 On Board Test Potentiometer Offset Adjustment Potentiometer 4 Adjustable Input Gain MODES OF OPERATI ON Current Duty Cycle Open Loop Hall Velocity Velocity COMMAND SOURCE 10 V Analog Revision 2 01 Release Date 3 5 2010 Advanced Motion Controls 3805 Calle Tecate Camarillo 93012 ph 805 389 1935 fx 805 389 1165 www a m c com Analog Servo Drive BX25A20AC Power Range Peak Current 25A Continuous Current 12 5A Supply Voltage 45 140 VAC A ADVANCED MOTION CONTROLS LLL E UTE com MADE IN U S A BRUSHLESS PWM SERVO AMPLIFIER Features Selectable 120 60 Hall Commutation Phasing Hall Velocity Mode Encoder Velocity Mode Selectable Fault Level Fault Latching Option Built in brake shunt regulator bbb bb Internal
8. Drive MECHANICAL INFORMATION 1 Signal Connector 16 pin 2 54 mm spaced friction lock header Connector Information Molex P N 22 01 3167 connector and P N 08 50 0114 insert terminals Details Mating Connector Included with Drive Yes 15 CURR REFERENCE r 13 HALL 2 11 SIGNAL GND 9 INHIBIT IN 7 VEL MONITOR OUT 5 REFIN 3 10V 3mA OUT _ r 1 10V 3mA OUT 2 SIGNAL GND REF 6 8 CURR MONITOR OUT 10 5V 12 HALL 1 14 HALL 3 16 FAULT OUT P2 Motor Power Connector 3 port 5 08 mm spaced screw terminal Details Not applicable Included with Drive Not applicable Connector Information Mating Connector 1 2 MOTORB 3 MOTORC P3 Feedback Connector 5 pin 2 54 mm spaced friction lock header Connector Information Molex P N 22 01 3167 connector and P N 08 50 0114 insert terminals Details Mating Connector Included with Drive Yes 2 CHANNEL A 1 5V 3 NC 4 CHANNEL B 5 SIGNAL GND Release Date Revision Advanced Motion Controls 3805 Calle Tecate Camarillo 93012 3 5 2010 2 01 ph 805 389 1935 fx 805 389 1165 www a m c com BX2
9. Manual Brochure 1 1 2 Additional Requirements Item Notes Power Supply Requirements 120 VAC 60 hz Single Phase Acceptable Operating Range 30 125 VAC Controller 10V Command Signal ADVANCED Z MOTION CONTROLS MNQSA4UM 01 5 Minute QuickStart Let s Spin the Motor This quick setup procedure will get the motor moving in a short amount of time without the need for a controller The drive has been pre configured in Encoder Velocity Mode with a slight offset This will turn the motor at a slow steady speed on power up to demonstrate operation Once the system is shown to be operational the next section Integrate QuickStart into Your System will guide you through the process of integrating the system into your application 2 1 Wiring In Section 2 4 you will find the cables and connections sheet Use this as a reference when following the steps in this section 2 1 1 Drive Connect cable CBL D02 to the P1 and connectors on the drive Connect the other end to the C2 connector on the System Interface Board SIB 2 1 2 Feedback CBL F01 10 is the feedback cable Connect the black connectors and shield drain wire on this cable to the corresponding connectors on the motor Connect the 15 pin D sub to the C1 connector on the System Interface Board SIB 2 1 3 Motor Connect the white connector on the motor power cable CBL P02 10 to the corresponding conne
10. brake shunt resistor FEEDBACK SUPPORTED Halls Incremental Encoder Tachometer 60 VDC COMPLIANCES amp AGENCY APPROVALS UL cUL CE Class LVD Class ROHS Page 1 of 9 ADVANCED MOTION CONTROLS BLOCK DIAGRAM Analog Servo Drive BROKEN LINE REPRESENTS BX25A20AC Pi 1 FUNCTIONAL BLOCK DIAGRAM 18 1140 OPTICAL ISOLATION 50 TNA 50 FAULT 3H1 2 CURRENT REFERENCE 10k OFFSET 5006 OUTPUTS a 5 5 SW 1 2 re Lik 11 SIGNAL GMD 541 1 5k 2 Eo SH1 10 51 7 Pi 4 REF IM rae 100k 0 01 20k REF IM GAIN CURRENT CH l k 60 120 VEL 5 REF IN LIMIT MOTOR 22 3 cH 50k gt 40k L CURRENT POTS LIMIT 20k 1 MOTOR 2 8 d _ CONTROL SW1 5 Sk MOTOR Pe 1 alk 10k HALL 1 1 100 Paes WEBS 2 UELOCITY INTERNAL Hy EE ee il IC TO DC 10k conv 1 3 CONVERTER k P1 10 50 amp 200 CR ENCODER Parl w _ VELOCITY SENSE SW2 3 2 6 P3 5 SIGNAL GND bs 5 pm e r1 x3 GROUNDS ARE HOT CONNECTED 2 a al a SEE TABL
11. drive s block diagram to determine an appropriate resistor value Tuning With Through hole Components In general the drive will not need to be further tuned with through hole components However for applications requiring more precise tuning than what is offered by the potentiometers and dipswitches the drive can be manually modified with through hole resistors and capacitors as denoted in the above table By default the through hole locations are not populated when the drive is shipped Before attempting to add through hole components to the board consult the section on loop tuning in the installation notes on the manufacturer s website Some general rules of thumb to follow when adding through hole components are e larger resistor value will increase the proportional gain and therefore create a faster response time larger capacitor value will increase the integration time and therefore create a slower response time Proper tuning using the through hole components will require careful observation of the loop response on a digital oscilloscope to find the optimal through hole component values for the specific application t Note Damage done to the drive while performing these modifications will void the warranty Release Date Revision Advanced Motion Controls 3805 Calle Tecate Camarillo CA 93012 3 5 2010 2 01 ph 805 389 1935 fx 805 389 1165 www a m c com Page 4 ADVANCED A MOTION CONTROLS Analog Servo
12. either with clamps or bolted down using its mounting holes Caution ADVANCED MOTION CONTROLS MNQSA4UM 01 5 Minute QuickStart Cables and Connections 2 4 Cables and Connections User Power BL3416E2 A04 AC120 120VAC Cables and Connections BX25A20AC USER SUPPLIED CONTROLLER E ED PC Based Controller Stand Alone Controller USER INTERFACE AS CBL D02 Pd Do not ground both this wire and the motor case Grounding both will cause a ground loop Choose one or the other CBL P02 10 424 S4 LS System Interface Board 0278 5 lt CBL F01 10 Caution The motor will move on initial power up See the manual to remove offset Ground Bring all ground connections to a central point or common plane that has solid contact with Earth ground Note Actual cables are longer than they appear in these images MBL3416E2 NCED CONTROLS ADVANCED MOTION CONTROLS MNQSA4UM 01 5 Minute QuickStart Inhibit Line Test optional 2 5 Inhibit Line Test optional Follow this step only if you installed the inhibit switch described in Section 2 3 This is to verify that the optional inhibit switch is functioning and the drive is initially powered up ina disabled state 1 Disconnect the motor power by unplugging the white connector on CBL P02 10 Unplugging this connection allows you to power up the system without the possibil
13. 3mA OUT O 2 SIGNAL GND 10 V 3 mA low power supply for customer use Short circuit protected Reference SGND ground common with signal ground 3 10V 3mA OUT O CN Differential Reference Input 10 V Operating Range 15 V Maximum Input 6 Negative Tachometer Input Maximum 60 Use signal ground for positive input Velocity Monitor Analog output proportional to motor speed In Encoder Velocity mode output is proportional to the encoder line frequency In Hall Velocity mode output is 1 proportional to the electrical cycle frequency Encoder Velocity scaling is 25 2 Hall M Velocity scaling is 125 Hz V Current Monitor Analog output signal proportional to the actual current output Scaling is 4 8 CURR MONITOR OUT A V by default but may be reduced to half this value by setting DIP switch SW 3 to OFF see O Hardware Settings section below Measure relative to signal ground 9 TNHIBIT IN TTL level 5 V inhibit enable input Leave open to enable drive Pull to ground to inhibit drive Inhibit turns off all power devices 10 45V Low Power Supply For Feedback 5 V 200 mA Referenced to signal ground Note O the combined current on all 5V outputs on this drive should not exceed 200 mA 11 SIGNAL GND Signal Ground SGND 12 HALL 1 13 HALL 2 Single ended Hall Commutation Sensor Inputs 5 V logic level 14 HALL 3 Measures the command signal to the internal current loop This has a maximum output 1
14. 5 CURR REFERENCE of 7 25 V when the drive outputs maximum peak current Measure relative to signal O ground TTL level 5 V output becomes high when power devices are disabled due to at least one 16 FAULT OUT of the following conditions inhibit invalid Hall state output short circuit over voltage over O temperature power up reset P2 Motor Power Connector Pin Name Description Notes I O 1 MOTOR A Motor Phase A O 2 MOTOR B Motor Phase B O 3 MOTOR C Motor Phase C O P3 Feedback Connector Pin Name Description Notes I O 1 Low Power Supply For Encoder 5 150 mA Referenced to signal ground Short circuit protected 2 CHANNEL A Single ended encoder channel A input 5 V logic level 3 NC Not Connected Reserved 4 CHANNEL B Single ended encoder channel B input 5 V logic level 5 SIGNAL GND Signal Ground GND Release Date Revision Advanced Motion Controls 3805 Calle Tecate Camarillo 93012 Page 4 of 9 3 5 2010 2 01 ph 805 389 1935 fx 805 389 1165 www a m c com 9 ADVANCED MOTION CONTROLS Analog Servo Drive BX25A20AC HARDWARE SETTINGS Switch Functions 5 1 Switch Description Off Test Offset Switches the function of the Test Offset pot between 1 an on board command input for testing or a command offset Test Offset adjustment OFF by default 2 Current loop proportional gain adjustment ON by default Decrease Increase Current scaling When OFF increases sensitivity of
15. 5A20AC Page 7 of 9 ADVANCED MOTION CONTROLS Analog Servo Drive BX25A20AC MOUNTING DIMENSIONS BL Fa UU dias 1 es f zx oe Wd AO Qd o cu C Li ju we 4 x x Y X AX WD D 7 A A p 0 CU fe i AO 1 Ld ab 2 E p t3 lt gt Y N E pA N 0 LJ E CY si an x a Es lt N 2 aA D E Z B Ma E FE LL ro Q ie AL amp y m LJ pe LJ 2 Li E D 0 CO e M EX we 5 _ P Eg CO gt lt 255 NE 9 M gt 1 52 NS D gt o lt
16. ADVANCED MOTION CONTROLS Everything s possible cKS BL3416E2 A04 AC120 gt User Manual Plug n Play Servo System with Analog Drive Brushless Motor and Cables Continuous 16 Ib in 4500 rom WWW BL3416E2 A04 AC120 Thank you for purchasing this QuickStart package QuickStart makes it easy to set up Advanced Motion Controls drives to get your system running quickly The drive and motor have been matched with each other the cables are custom made for this system and an interface board simplifies integration with your controller Remember if you need us we are here for you Our goal is to get you up and running as quickly as possible If at any point you have a question a team of applications engineers and our customer service staff are just a phone call away We are available weekdays from 8am to 5pm Pacific Time at 805 389 1935 We can also be contacted via email through our website www a m c com go to Contact Us 4 Steps to Success 1 2 3 4 Getting Started 5 Minute Integrate Going into QuickStart QuickStart into Production Your System What s included Let s spin the motor Get your machine Transitioning from with QuickStart and working prototype to what to expect production This manual has been laid out in four sections to guide you through the process of setting up and integrating your QuickStart system By following each step in success
17. ES BELOW gt L a i H EE oa Es a L E d LL tL tL LL tL _ SELECTION 11 2 CURRENT MODE Cor om FF HALL VELOCITY CONNECTED LED GREEN NORMAL OPERATION LED RED FAULT OFF FF CONN orr or CONN orr or oF 5 1 5 31 6 5 2 1 sie e o LEWEL SELECT FAULT IMHIBIT RELATION RECOMMENDED SETTING FOR CURRENT MODE FULLY CCW POTS FULLY CH AMPLIFIERS ARE SHIPPED IN CURRENT MODE WITH MAXIMUM CURRENT SETTINGS FOR OTHER SWITCH FUNCTIONS SEE SWITCH DESCRIPTION OPTIONAL USER INSTALLED THROUGH HOLE COMPONENTS Release Date 11 30 2011 Revision 2 01 Information on Approvals and Compliances FAULT LEWEL FAULT COPMDITIOH SHe 3 Pul P1 9 te GND to 542 9 INHIBIT FAULT 5 OUT 1 6 6 LATCH Orr ENABLE OFF Orr active Lo ofr INHIBIT active Hi Lon FAULT LATCH 1 VOLTAGE UNDER VOLTAGE SHORT CIRCUIT 2 3 4 OUER TEMPERATURE US and Canadian safety compliance with UL 508c the industrial standard for power conversion electronics UL registered under file number E140173 Note that machine components compliant with UL are considered UL registered as opposed to UL listed as would be the case for commercial p
18. ave the green wire disconnected Grounding the motor at both the green wire and at the motor case causes a ground loop that has been shown to disrupt the feedback signals Choose one or the other ADVANCED MOTION CONTROLS MNQSA4UM 01 Integrate QuickStart into Your System Configuration 3 1 10 Load Coupling non rigid coupling must be used between the motor shaft and the load to minimize mechanical stress due to radial loads axial loads or misalignment If you feel that the radial load on the motor is excessive you may want to consider connecting the motor to an idler shaft that is supported by pillow block bearings or similar Then the load can be coupled to the idler shaft without risking damage to the motor bearings 3 2 Configuration BX25A20AC Capabilities Mode Category Mode Name Torque Current Velocity Estimation Duty Cycle Velocity Encoder Velocity Hall Velocity Duty Cycle Mode does not use direct feedback to close the velocity loop therefore it can t be considered a true velocity mode Duty Cycle Mode produces velocity that is roughly proportional to the input command but is not as precise as using a Tachometer or Encoder Hall Velocity Mode 15 not recommended with this system since Encoder Velocity Mode is available with superior velocity control The correct mode is determined by the requirements of the controller Some controllers require that the drive be in torque m
19. ctive High Active Low Sets whether or not the fault output should latch When non latching the fault output clears as soon as all fault conditions are 6 released When latching the fault output clears only once all fault Non latching Faults Latching Faults conditions have been released and the drive is either power cycled or the inhibit input is toggled Mode Selection Table SW1 4 SW1 5 SW1 6 SW2 1 SW2 2 Encoder Tachometer CURRENT ON OFF OFF Not Connected Not Connected DUTY CYCLE OFF ON OFF Not Connected Not Connected HALL VELOCITY OFF OFF ON OFF ON Not Connected Not Connected ENCODER VELOCITY OFF OFF ON ON OFF Connected Not Connected TACHOMETER OFF OFF OFF Not Connected Connected NOTE See details of switch SW1 7 for further Hall Velocity or Encoder Velocity configuration information Release Date Revision Advanced Motion Controls 3805 Calle Tecate Camarillo CA 93012 3 5 2010 2 01 ph 805 389 1935 fx 805 389 1165 www a m c com Page ure ADVANCED MOTION CONTROLS Analog Servo Drive BX25A20AC Potentiometer Functions Potentiometer Description Turning CW Loop gain adjustment for duty cycle velocity modes Turn this pot fully CCW in current mode Current limit It adjusts both continuous and peak current limit while maintaining their ratio Reference gain Adjusts the ratio between input signal and output variables voltage current or velocity Offset Test Used to adjust any imbalanc
20. ctor on the motor Connect the green connector to the P2 connector on the drive Red Motor A P2 1 White Motor B P2 2 Black Motor C P2 3 CBL AC IEC supplies AC to the drive Do not apply power at this time An AC power strip or other switch can be used to make cycling power more convenient during testing ADVANCED MOTION CONTROLS MNQSA4UM 01 4 5 Minute QuickStart Grounding 2 2 Grounding Bring all ground wires to central point ground such as a ground bus ground plane single ground bolt Also don t forget to ground the drive chassis Use the silver screw marked PE on the case 2 2 1 Motor Ground The green wire coming from the motor power cable is the motor chassis ground If the motor case is already grounded through direct contact with the machine housing then leave the green wire disconnected Grounding the motor at both the green wire and at the motor case causes a ground loop that has been shown to disrupt the feedback signals Choose one or the other 2 3 Inhibit Switch optional for this section An inhibit switch not included can be connected between pins 9 and 11 the Interface Board This switch disables power to the motor until you are ready Opening the switch Enables the drive closing the switch Disables the drive To avoid the motor from jumping unexpectedly and causing damage the motor should be secured
21. current sense thus reducing both peak and continuous current limit by 50 3 3 Full current Half current The scaling of the current monitor output signal becomes its ordinary value when this switch is OFF A Outer loop integration Activates or deactivates integration ON by default for current mode and OFF for other modes 5 Mode selection See mode selection table below 6 Mode selection See mode selection table below Velocity feedback polarity Changes the polarity of the internal 7 feedback signal and the velocity monitor output signal Inversion Standard of the feedback polarity may be required to prevent a motor run away condition 8 Current ratio Used to set continuous to peak current ratio Cont Peak Ratio 50 Cont Peak Ratio 25 Default is ON Outer loop integral gain adjustment It is recommended to leave 9 this switch OFF for most applications but ON for Hall Velocity Decrease Increase Mode Hall sensor phasing Selects 120 60 commutation phasing ON P 10 120 60 by default SW2 Switch Description setung On Off 1 Mode selection See mode selection table below 2 Mode selection See mode selection table below 3 Inhibit logic Sets the logic level of inhibit pins Active Low Active High 4 Sets whether or not the inhibit input activates the fault output Inhibit In Fault Out Inhibit In Fault Out 5 Fault logic Sets the logic level of fault output A
22. determine the correct mode for your drive Once the command signal and mode have been selected connect the controller to the signals as indicated in the above tables The proper gains and command settings must also be configured This will be explained later in the configuration section 3 1 3 Drive Inhibit Recommended The inhibit line is used to turn off power to the motor while the drive is still powered on Sometimes this is necessary if power to the motor needs to be removed quickly or if the user needs to manually move the load in a freewheeling condition If your controller has an inhibit function then we highly recommend that you use it Inhibit Connection Controller SIB Inhibit C3 9 Inhibit Note that the inhibit input is configured to disable the drive when pulled low active low The control logic can be inverted by setting SW2 3 to the OFF position ADVANCED MOTION CONTROLS MNQSA4UM 01 9 Integrate QuickStart into Your System Wiring 3 1 4 Feedback The feedback on the motor is an incremental encoder with two Channels A and B and an Index I The signals are differential but are compatible with single ended circuitry simply leave the complimentary signals open A B and I The resolution is 10000 counts per revolution quadrature Power Requirements Encoder power is supplied by the drive 5VDC 125mA The screw terminals on the System Interface Board SIB provide easy acce
23. drive integration into a servo system Visit www a m c com to see which accessories will assist with your application design and implementation Za Filter Cards To Motor AADYANCED Bk Ni Wh m Drive s All specifications in this document are subject to change without written notice Actual product may differ from pictures provided in this document Release Date Revision Advanced Motion Controls 3805 Calle Tecate Camarillo 93012 3 5 2010 2 01 ph 805 389 1935 fx 805 389 1165 www a m c com Page 9 of 9 System Specifications This page intentionally left blank ADVANCED YA NOTION CONTROLS MNQSA4UM 01 31 Quick Start Motor MBL3416E2 BRUSHLESS SERVO MOTOR FEATURES 3 25 Inch NEMA 34 w Heavy Duty Shaft Continuous Torques up to 15 63 Ib in Speeds up to 4500 rom Voltage Rating up to 170 Vdc Integrated Hall Effect Commutation 30 Lb Radial Load Capacity 1 2 from Front Face High Precision Optical Encoders 10000 count SPECIFICATIONS SPECIFICATIONS CONTINUOUS TORQUE PEAK TORQUE SPEED RATED VOLTAGE RATED VOLTAGE CONTINUOUS CURRENT PEAK CURRENT TORQUE CONSTANT VOLTAGE CONSTANT RESISTANCE 9 40 0 224 NDUCTNACE NERTIA kg cm Ib in s 2 034 0 0018 WEIGHT Kg Ib 3 54 7 8 MOTOR CONNECTIONS MOTOR CONNECTOR COLORI FUNCTION PIN 1 430702 0 PHASE R CONTACTS AMP PIN 350550 1 OR EQUIV
24. e in the input signal or in 4 the amplifier Can also be used as an on board signal source for Adjusts offset in negative direction testing purposes Note Potentiometers are approximately linear and have 12 active turns with 1 inactive turn on each end 1 Increases gain 2 Increases limit 3 Increases gain Through hole Components Location Description Velocity Loop Integrator Through hole capacitor that can be added for more precise velocity loop tuning See section CF1 below on Tuning with Through hole components for more details Current Loop Integrator Through hole capacitor that be added for more precise current loop tuning See section CF2 i below on Tuning with Through hole components for more details Tachometer Input Scaling Through hole resistor that be added to change the gain of the tachometer input See section below on Tachometer Gain for more details RF2 Current Loop Proportional Gain Through hole resistor that can be added for more precise current loop tuning See section below on Tuning with Through hole components for more details Tachometer Gain Some applications may require an increase in the gain of the tachometer input signal This occurrence will be most common in designs where the tachometer input has a low voltage to RPM scaling ratio The drive offers a through hole location listed in the above table where a resistor can be added to increase the tachometer gain Use the
25. e the drive e Turn the Loop Gain pot clockwise e When the system begins to make a loud buzzing noise turn the pot in the counterclockwise direction until the buzzing stops e Turn the pot one more turn in the counter clockwise position Reference Gain Potentiometer 3 The gain of the drive velocity out volts in can be adjusted using the Reference Gain Potentiometer Pot 3 Turning the pot clockwise increases the gain while turning the pot counter clockwise decreases the gain ADVANCED MOTION CONTROLS MNQSA4UM 01 15 4 Going into Production 4 1 Prototype to Production Once you have completed your proof of concept you will be ready to design for production If you decide that the QuickStart drive and motor are perfect for you then you re in luck Both are popular off the shelf items that are readily available Drives can be ordered directly from us and we can put you in touch with the appropriate motor supplier If your servo system requires a drive that better fits your application such as e Additional features e Different power range e Smaller size e Different form factor such as plug style drives e Network connectivity Then our applications engineers can help optimize your system by selecting the best drive for your needs ra i You will also be in contact with local representative to help you with the selection of motors and other system compone
26. et in the Appendix The SIB can be mounted using the mounting holes or a DIN tray such as from Phoenix Contact If using the mounting holes standoffs must be used to keep the bottom of the SIB from shorting with the mounting surface 3 1 8 Cable Routing Cable Datasheets can be found in the Appendix QuickStart cables come with excellent shielding and make proper grounding easy This makes proper cable routing less critical however proper routing practices should still be followed Route cables to minimize length and minimize 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 practice to route the motor power wires close to the motor feedback wires even if they are shielded Although both of these cables originate at the amplifier and terminate 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 1cm for every 1m of cable length 3 1 9 Grounding Bring all ground wires to a central point ground such as a ground bus ground plane or a single ground bolt Also don t forget to ground the drive chassis Use the silver screw marked PE on the case Motor Ground The green wire coming from the motor power cable is the motor chassis ground If the motor case is already grounded through direct contact with the machine housing then le
27. ion you will first be introduced to QuickStart then hook up the system for a simple bench test and then integrate QuickStart into your machine and finally transition into the production stage ADVANCED MOTION CONTROLS MNQSA4UM 01 Getting Started 1 1 What to Expect What is QuickStart QuickStart is a system offering including a drive a motor all necessary cables and an interface board with screw terminal connections all in one box ready for fast delivery What purpose does QuickStart serve QuickStart is intended to introduce OEMs to Advanced Motion Controls servo drives and provide a positive first experience Why is Advanced Motion Controls offering a QuickStart package We realize that many OEMs today are faced with trying to get their machinery to market using the fastest possible methods Our solution is to provide a means by which motion control can be quickly proven How does QuickStart benefit potential customers QuickStart is designed to make system prototyping easier to include Advanced Motion Controls servo drives The attraction to OEM s is a savings of time money and the personnel needed to move from conception to production Upon receipt everything will plug in and operate within 5 minutes All systems are initially configured in velocity or voltage mode to turn the motor shaft at 30 20 rpm This is an indication that when put together it works out of the box No pots to t
28. ity of spinning the motor Apply power to the drive Toggle the inhibit switch and verify that you can cause the LED color to change from Red to Green Set the switch so the LED is Red Remove power from the drive and reconnect the white connector on CBL P02 10 2 6 System Power Up 1 2 Apply power to the drive If an inhibit switch has been installed enable the drive by toggling the inhibit switch so the LED turns Green The motor should turn at a smooth controlled speed If the motor turns then the system has been hooked up correctly Remove power and continue to the next section If not then go to Troubleshooting To stop the motor from turning turn the Test Offset switch SW1 1 to the OFF position Then use the offset pot Pot 4 to set the speed to zero The motor may continue to creep very slowly when in velocity mode True zero speed can be achieved once a controller is used to close the loop around the servo drive 2 6 1 Troubleshooting LED not lit Verify that power has been applied to the drive Motor doesn t have holding torque Verify that the LED is Green LED doesn t turn Green Verify all cables are connected If an Inhibit Switch has been installed toggle the Inhibit switch Motor doesn t turn but has holding torque Turn Pot 4 Test Offset in either direction This will change the amount of offset in the drive Contact Factory If you can t get the motor turning within a few minutes p
29. lease call and ask for technical support 805 389 1935 We want to get you up and running quickly ADVANCED MOTION CONTROLS MNQSA4UM 01 Integrate QuickStart into Your system The following instructions are a continuation of the previous chapter This section explains controller wiring drive configuration drive mounting motor mounting SIB mounting and load coupling 3 1 Wiring 3 1 1 Signal Ground Almost all signals between the drive and the controller are referenced to signal ground Without this reference the drive and the controller would not be able to transmit signals to each other To ensure that the signals between the drive and the controller are referenced to the same potential the signal grounds on the controller and the drive must be connected together This is especially important for e Single ended command signals e Inhibit line e Other inputs and outputs You will need to identify the signal ground on your controller and connect it to the signal ground on the drive For your convenience the Signal Ground is accessible at three locations on the SIB However to avoid ground loops there should only be one connection between the drive signal ground and the controller signal ground Don t add a connection if there is already continuity between the two grounds Available Signal Ground Locations on the SIB Controller SIB Signal Ground C3 2 SGND C3 11 SGND C3 19 SGND
30. ngle Wire Single Wire Single Wire A 4 Pin AMP P N 350873 1 Connector Terminals P N 1 480703 0 Wiring Scheme Function Wire Contact WIRING SPECIFICATIONS DIAGRAM Connector B Connector A Single Wires Spade 2 1 Single Wires 4 ADVANCED MOTION CONTROLS 805 389 1165 805 389 1935 Fax 3805 Calle Tecate Camarillo CA 93012 Tel System Specifications This page intentionally left blank ADVANCED YA NOTION CONTROLS MNQSA4UM 01 37 5 System Interface Board SIB rti Ik 3 12325567 589101112 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Dimensions 72mm x 72mm C1 Connector 15 pin to motor C2 Connector 26 pin to drive C3 Connector 26 pin user interface C3 Pin Functions Pin Function 15 Pin Dsub EM Gi ins 3 10V 3mA C2 Shell NI 4 Ref In 5 Ref in 6 Tach In P L 5 Vel Mon Out 4 11 13 LI Jl 8 Curr Mon Out 4 LI UT MOR AU 5 9 Inhibit 5 1111 n 1 1 41 3 10 5 lll J a 11 SGND 46 C2 j kek CLr i _ 12 Hall 1 4 eee 45 5 13 Hall 2 ae s 5 2 E 14 14 14 Hall 3 4
31. nts such as cables gear boxes slides bearings and more Feedback Your feedback is important to us Your comments can make QuickStart better and help us improve our processes technical support customer support and product offering Please go here to provide us your feedback ADVANCED MOTION CONTROLS MNQSA4UM 01 6 Going into Production Prototype to Production This page intentionally left blank ADVANCED YA NOTION CONTROLS MNQSA4UM 01 7 4 Appendix ADVANCE System Specifications Drive Datasheet Motor Datasheet Cable Datasheets System Interface Board D AMOTION CONTROLS MNQSA4UM 01 18 ADVANCED YA NOTION CONTROLS MNQSA4UM 01 This page intentionally left blank 19 System Specifications A 1 System Specifications Torque peak 35 Ib in 3 975 Nm Torque continuous 15 63 Ib in 1 77 Nm Velocity Maximum 4500 rom Supply Voltage 120 VAC Encoder Resolution 10000 counts rev Speed Torque Curve BL3416E2 AD4 ACT2U 2000 3000 4000 Speed rpm ADVANCED YA MOTION CONTROLS MNQSA4UM 01 20 System Specifications This page intentionally left blank ADVANCED YA NOTION CONTROLS MNQSA4UM 01 21 y ADVANCED MOTION CONTROLS Description The BX25A20AC PWM servo drive is designed to drive brushless DC motors at a high switching frequency It is fully protected against over voltage over current
32. ode Other controllers require that the drive be in velocity mode Check the documentation on your controller or contact the manufacturer of your controller to determine the correct mode for your drive Advanced Motion Controls Analog Servo Drives are configured using Switches and Potentiometers There is no software to download or configure The basic setup of these servo drives is straightforward and user friendly These instructions will walk you through the steps necessary to configure your drive to your system e Configure the drive mode Torque Mode Configuration Velocity Mode Configuration gt Encoder Velocity gt Hall Velocity gt Duty Cycle ADVANCED YA NOTION CONTROLS MNQSA4UM 01 12 Integrate QuickStart into Your System Configuration 3 2 1 Torque Mode Configuration The terms Torque Mode and Current Mode are synonymous They can be interchanged and you may see either of these terms throughout this document and other motion control documents The Switches and Potentiometers set the mode on the drive Use the Mode Selection Table for the correct configuration Mode Selection Table Torque Mode Switch SW1 1 OFF Bank1 Sw12 ON SW1 3 ON SW1 4 ON SW1 5 OFF SW1 6 OFF SW1 7 ON SW1 8 ON SW1 9 ON SW1 10 ON Switch SW2 1 OFF Bank2 sw2 2 OFF SW2 3 ON SW2 4 ON SW2 5 ON SW2 6 ON Pots Pot 1 Loop Gain Full CCW Po
33. ommand Common units are rpm V and counts per second V The three velocity modes available in this system offer varying degrees of performance Starting with the highest performance they are listed below Encoder Velocity Uses the encoder as the velocity feedback This mode is very accurate over the widest range of speeds Hall Velocity This mode uses the Hall sensors for velocity feedback This mode is not accurate at slow velocities but as the speed increases beyond 1000 rpm this mode becomes more usable This mode is popular in systems where the cost of an encoder is prohibitive and the operating velocity is above 1000 rpm Duty Cyc le This mode does not use any feedback to determine velocity Velocity is estimated by the duty cycle of the PWM Duty Cycle Mode is the least accurate of these velocity modes The Switches and Potentiometers set the mode on the drive Use the Mode Selection Table for the correct configuration Mode Selection Table Velocity Mode Encoder Velocity Hall Velocity Duty Cycle Switch SW1 1 OFF OFF OFF Bank 1 SW1 2 ON ON ON SW1 3 ON ON ON SW1 4 OFF OFF OFF SW1 5 OFF OFF ON SW1 6 ON ON OFF SW1 7 ON ON ON SW1 8 ON ON ON SW1 9 OFF ON OFF SW1 10 ON ON ON Switch SW2 1 ON OFF OFF Bank2 Sw2 2 OFF ON OFF SW2 3 ON ON ON SW2 4 ON ON ON SW2 5 ON ON ON SW2 6 ON ON ON Pots Pot 1 Loop Gain 8 turns 10 turns 9 5 turns Po
34. omptly develop and deliver specified products for OEMs with volume requests Our Applications and Engineering Departments will work closely with your design team through all stages of development in order to provide the best servo drive solution for your system Equipped with on site manufacturing for quick turn customs capabilities ADVANCED Motion Controls utilizes our years of engineering and manufacturing expertise to decrease your costs and time to market while increasing system quality and reliability Examples of Customized Products Integration of Drive into Motor Housing Integrate OEM Circuitry onto Drive PCB Mount OEM PCB onto Drive Without Cables Custom Control Loop Tuned to Motor Characteristics Multi axis Configuration for Compact System Custom Interface for System Compatibility Custom PCB and Baseplate for Optimized Footprint Preset Switches and Pots to Reduce User Setup RTV Epoxy Components for High Vibration Optimized Switching Frequency OEM Specified Connectors for Instant Compatibility Ramped Velocity Command for Smooth Acceleration OEM Specified Silkscreen for Custom Appearance Remove Unused Features to Reduce OEM Cost Increased Thermal Limits for High Temp Operation Application Specific Current and Voltage Limits aaa aR aR RED maa aR RR ERD Feel free to contact Applications Engineering for further information and details Available Accessories ADVANCED Motion Controls offers a variety of accessories designed to facilitate
35. roducts Compliant with European CE for both the Class A EMC Directive 2004 108 EC on Electromagnetic Compatibility specifically EN 61000 6 4 2007 and EN 61000 6 2 2005 and LVD requirements of directive 2006 95 EC specifically EN 60204 1 2006 a low voltage directive to protect users from electrical shock RoHS Reduction of Hazardous Substances is intended to prevent hazardous substances such as lead from being manufactured in electrical and electronic equipment ADVANCED Motion Controls 3805 Calle Tecate Camarillo 93012 ph 805 389 1935 fx 805 389 1165 www a m c com Page 2 of 9 ADVANCED Release Date Revision 3 5 2010 2 01 Advanced Motion Controls 3805 Calle Tecate Camarillo CA 93012 ph 805 389 1935 fx 805 389 1165 www a m c com A MOTION CONTROLS Analog Servo Drive BX25A20AC SPECIFICATIONS Power Specifications Description Units Value AC Supply Voltage Range VAC 45 140 DC Supply Voltage Range VDC 60 200 DC Bus Over Voltage Limit VDC 205 Maximum Peak Output Current A 25 Maximum Continuous Output Current A 12 5 Maximum Continuous Output Power at Continuous Current W 2375 Internal Bus Capacitance UF 3600 Internal Shunt Resistance 10 Internal Shunt Resistor Power Rating W 50 Internal Shunt Resistor Turn on Voltage VDC 185 Minimum Load Inductance Line To Line uH 250 Switching Frequency kHz 22 Shunt Fuse A 3 Bus Fuse A 16 Control Specifications Description Units Value Command So
36. ss to the encoder signals Encoder Connection Signal SIB SGND C3 19 5VDC C3 20 Channel C3 21 Channel A C3 22 Channel B C3 23 Channel B C3 24 Channel C3 25 Channel l C3 26 3 1 5 Drive Mounting Mounting Dimensions are found in the drive datasheet in the Appendix The drive can be mounted flat against the base plate or along the spine Mounting the drive flat on the base plate against a large thermally conductive surface for cooling will provide the most natural heat dissipation for the drive A metal back plane in a cabinet on the machine often makes a good surface Drives mounted on the spine can be mounted next to each other Maintain a minimum separation of 1 inch between drives to provide adequate convection cooling Additional cooling may be necessary to dissipate the heat generated by the drive depending on ambient temperatures duty cycle and natural ventilation Note ADVANCED MOTION CONTROLS MNQSA4UM 01 0 Integrate QuickStart into Your System Wiring 3 1 6 Motor Mounting Mounting Dimensions are found in the motor datasheet in the Appendix The mounting surface must be stiff enough so it does not deflect when radial loads are applied to the motor shaft The mounting surface should also have good thermal conductivity especially if peak performance is demanded of the motor 3 1 7 SIB Mounting Mounting Dimensions can be found in the SIB datashe
37. t 2 Current Limit Full CW Pot 3 Reference Gain Full CW Pot 4 Offset Mid 7 turns Current Limit with these settings 12 5A continuous 25A peak Potentiometer Instructions CW is the clockwise direction CCW is the counterclockwise direction Full CW or Full CCW means the pot has been turned to the end of its travel where it begins to click on every turn These potentiometers have a 14 turn range before they start to click The number of potentiometer turns on the Mode Selection Table is referenced from the full counterclockwise position To maintain consistency in the number of turns the initial Starting point is defined as follows 1 Turn the pot CCW until the pot begins to click on every turn 2 Continue to slowly turn the pot CCW until the next click is heard then stop 3 Now turn the pot in the CW direction the number of turns indicated in the Mode Selection Table Gain Setting The gain of the drive amps out volts in can be adjusted using the Reference Gain Potentiometer Pot 3 Turning the pot to the full clockwise position results in a gain of roughly 2 5A V Turning the pot counter clockwise reduces the gain down to a minimum of zero ADVANCED MOTION CONTROLS MNQSA4UM 01 13 Integrate QuickStart into Your System Configuration 3 2 2 Velocity Mode Configuration Velocity mode outputs a velocity that is proportional to a given input command The gain can be expressed as output velocity input c
38. t 2 Current Limit Full CW Full CW Full CW Pot 3 Reference Gain Full CW Full CW Full CW Pot 4 Offset Mid 7 turns Mid 7 turns Mid 7 turns Current limit with these settings 12 5A continuous 25A peak ADVANCED MOTION CONTROLS MNQSA4UM 01 14 Integrate QuickStart into Your System Configuration Potentiometer Instructions CW is the clockwise direction CCW is the counterclockwise direction Full CW or Full CCW means the pot has been turned to the end of its travel where it begins to click on every turn These potentiometers have a 14 turn range before they start to click The number of potentiometer turns on the Mode Selection Table is referenced from the full counterclockwise position To maintain consistency in the number of turns the initial starting point is defined as follows 1 Turn the pot CCW until the pot begins to click on every turn 2 Continue to slowly turn the pot CCW until the next click is heard then stop 3 Now turn the pot in the CW direction the number of turns indicated in the Mode Selection Table Loop Gain Potentiometer 1 In Velocity Mode the loop gain increases the responsiveness of the system The loop gain settings in the mode Selection table are a good starting point However once the drive is in the system the loop gain will need to be adjusted to match the system dynamics To adjust the Loop Gain e Turn the Loop Gain pot to the full counterclockwise position e Enabl
39. urces 10 V Analog Feedback Supported Halls Incremental Encoder Tachometer 60 VDC Commutation Methods Trapezoidal Modes of Operation Current Hall Velocity Duty Cycle Velocity Motors Supported Single Phase Brushed Voice Coil Inductive Load Three Phase Brushless Hardware Protection _ Invalid Commutation Feedback Over Current Over Temperature Over Voltage Short Circuit Phase Phase amp Phase Ground Primary I O Logic Level 5V TTL Internal Shunt Regulator Yes Internal Shunt Resistor Yes Mechanical Specifications Description Units Value Agency Approvals CE Class A EMC CE Class A LVD cUL RoHS UL Size H x W x D mm in 186 7 x 107 4 x 62 2 7 4 x 4 2 x 2 4 Weight 02 1140 40 2 Heatsink Base Temperature Range C F 0 65 32 149 Storage Temperature Range C F 40 85 40 185 Form Factor Panel Mount P1 Connector 16 pin 2 54 mm spaced friction lock header P2 Connector 3 port 5 08 mm spaced screw terminal P3 Connector 5 pin 2 54 mm spaced friction lock header Notes 1 Maximum duration of peak current is 2 seconds 2 Lower inductance is acceptable for bus voltages well below maximum Use external inductance to meet requirements 3 Additional cooling and or heatsink may be required to achieve rated performance Page 3 of 9 ADVANCED A MOTION CONTROLS Analog Servo Drive BX25A20AC PIN FUNCTIONS 1 Signal Connector Pin Name Description Notes I O 1 10V
40. weak or software to configure Are QuickStart program motors available for individual resale Quite simply not from Advanced Motion Controls The motors in these packages are meant to represent what is commonly available from many different manufacturers Your local Advanced Motion Controls representative can handle requests for motor model information for additional purchases How is QuickStart pricing important to me Careful selection of systems incorporate popular Advanced Motion Control s drives in order to maximize exposure and minimize costs What other considerations should you know about QuickStart Although it will be hard to find easy to configure systems like these at lower prices anywhere QuickStart isn t intended for multiple pre packaged system selling Initial exposure to Advanced Motion Controls drives is the key Each project will be followed up by our Sales department to determine overall progress and assist in determining the next step ADVANCED MOTION CONTROLS MNQSA4UM 01 2 Getting Started What to Expect 1 1 1 Package Contents LiBrushless Servo Drive BX25A20AC LlBrushless NEMA 34 Motor w encoder MBL3416E2 LlScrew Terminal Board SIB System Interface Board LlFeeback Commutation Cable 10 foot CBL F01 10 _I Motor Power Cable 10 foot CBL P02 10 Drive Power Cable CBL AC IEC LIDrive Cable 1 5 foot CBL D02 LJ Documentation Quick Connect Sheet User
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