DG2S series
Contents
1. 4 Overheat indicates that the drive s metal case reached 65 C Green LED on Red LED blinking Description This is a fault condition and indicates an overtemperature of the drive s metal case When this fault happens the drive cannot be reset until it cools down to under 65 5 Overcurrent indicates that the current on the motor outputs cannot be limited Green LED off Red LED off Description This is a fault condition and indicates a short circuit on the motor output or a too low resistance inductance of the motor coil Note Point 2 to 5 are error conditions and the error line of the drive actives in these cases 5 1 Installation of Drive and Physical dimensions Figure 4 Drive mounting dimensions All dimensions in mm The drive has four 3 5mm mounting holes in the 3mm thick aluminium backplate The drive s metal base plate acts as a heat sink for the drive and can become hot under heavy current operation It is recommended to install the drive on a thermally conductive frame for example an aluminum plate of at least 1 5mm thickness to improve cooling and power dissipation Use heat transfer paste or a silicon heat transfer sheet to get the best thermal connection between the drive s metal backplate and external mounting metal frame The drive has builtin thermal protection but it is adviced to keep the metal frame as cool as possible to avoid overheating and shutdowns 5 2 Motor2. Typ Notes Motor supply voltage model 08020 12 l Optimal U rated 10 20 Motor supply voltage model ve WinOuE Stag 12 Optimal U rated 10 20 braking circuit Motor supply voltage model 10035 witht using 12 Optimal U rated 10 20 braking circuit Motor current 0 Limited by drive at set threshold model 08020 maximum at 20A Motor current 0 Limited by drive at set threshold model 16035 maximum at 35A Logic supply voltage 11 5 12 Logic supply current 100 200 Operating temperature Automatic shutdown at 65 Opto isolator input Voltage 3 Use external series resistor in case of input Voltage gt 5VDC For 12V input use 1kKOhm For 24V input use 2 2kOhm Opto isolator current 3 5 Step input frequency 0 Direction signal stabile state 1 1 Step signal active and inactive minimum allowed valid time edges can be configured in after step signal active edge software by user Encoder maximum frequency 1 1 With 4x decoding Error line output current 10 10 20mA continiously is destructive Switching frequency 20 20 20 kHz PID loop sampling time 1 65535 60usec User setable in 60usec steps Minimum allowed motor coil 0 4 Ohm If resistance is lower it should be resistance extended with inductor or with resistor resistor wire Minimum allowed motor coil s 200 If inductance of the motor coil is inductance lower it should be extended with series coil
3. Error line connection options Note A Stop signal can be sent on the Reset line or on the Error line Grounding either of these pins will stop the drive but in different ways See Chapter 4 2 for Error line function 3 1 4 Encoder Interface The plug labeled Encoder is a standard RJ45 jack and contains the following connections as shown in red numbers in Figure 2 1 Ground 2 5V DC power for encoder 3 Not used Encoders must be an incremental and TTL level type with square waves Absolute encoders are not supported An encoder with differential A A and B B_ channels Ground must be used for position feedback from the motor A A single ended encoder can be converted to differential 5 Volt by using our DTSE differential to single ended encoder B interface board Mount the interface board near the encoder and connect the encoder wires to the interface screw terminals as shown Figure 3 Encoder interface The other end of the board contains an RJ45 jack for connecting a standard Ethernet patch cable to the Encoder jack on the DG2S drive 3 1 5 USB interface A 4 pin RM2 0 socket connector is provided for tuning and for making diagnostics on the drive This connector plugs directly into our PRG1 programming cable and this cable contains the USB driver electronics For tuning connect the drive s 4 pin socket to the PRG1 programming cable s 4 pin socket with the cables supplied with the programming cable And connect th
4. and motor power supply s ground are floating to each other not connected inside the drive to avoid ground loops and therefore noise problems in communication Do not use the same power supply for the motor power and the digital control power for example a high voltage power supply that also has a low voltage output included which takes its primary power from the high voltage side To protect your new drives and also for the most reliable communications between the computer and the CNC electronics always use separated Power Supplies for the digital power and the motor power and do not connect the two GND points together keep them separated and run the ground lines back to their respective power supplies Use shielded cables for the Main connector and Encoder connector if possible Connect the cable shields to an earth GROUND point at one end only preferably at the Control box and not at the machine tool If you connect both ends of a cable shield to ground then current can flow thru the shield creating communication problems and also can carry high voltage back to your control box electronics in the event of a short circuit at the machine tool 5 5 Error Line wiring The Error line is a bidirectional line and when looking to it as an output it acts as an open collector output While the drive is running in normal operation the error line is released by the drive and only the internal 100KOhm pullup resistors pulling the line to
5. but do not connect a PSU with an overvoltage absolute maximum motor Voltage ratings of the drive is 160VDC If your motor has higher Voltage it will operate from 160VDC but with limited maximum torque The best way is to use a higher Voltage rated drive in this case For more information visit http www cncdrive com e mail info cncdrive Es Please consider the enviroment before printing this document
6. the internal 5 Volts potential The error line acts as an open collector output means that any number of error lines can be paralleled connected together which allows the user to create a common error line When paralleling the error lines of all drives in a setup if any of the drive has an internal fault it pulls the error line low indicating the fault and stopping all other drives An external optical isolator may be used to interface the error line to the control computer or to a PLC or to any type of external control circuit The external optical isolator may be connected as drawn on Figure 5 An external pushbutton or NPN transistor may be used to trigger the error line by external circuits Take care to not to overstress the Error line output and never connect the error line to any other potential than GND 0 Volts of the digital powersupply The error line can sink maximum 10mAmpers of current and can live throu 20mA in peaks Overstressing the error line may cause permanent damage to the device 5V from AUX port pin 1 V Optoisolator TE i ox Drive 1 PC GND Internal control External External control logic pushbutton logic a GND from AUX port pin 2 Internal control logic aox Drive n Internal control logic Figure 5 Interfacing the error line 5 6 Reset Line wiring The reset line is a TTL level input The line is help on 5Volts potential referenced to the digital
7. to the drives The device should not be used where it can cause personal injury death or high financial loss Never open the drive s chassis and never touch inner circuitry even if it s unpowered Take care of power supply s correct polarity connection wrong polarity connection of the Motor Power supply will cause permanent damage to the device Never disconnect the motor from the drive when power supply is connected to the drive and is under Voltage Do not short the motor output terminals it may cause permanent damage to the device The drives are in enclosure but this metal case is not meant to protect the drive from dust and falling chips liquid or other moisture material Please take care to protect the drives from taint damage 1 2 Policy CNCdrive cannot take responsibility for any personal injury and or financial loss caused by their drives failure or caused by following an error in this documentation 1 3 Warranty We give 12 months of standard warranty period with our DG2S series drives Customers may send back the drives within 15 days from reception date if they are not satisfied with the performance Using the drive outside of the specified electrical ranges may cause permanent damage to the device and void warranty Opening the drive s metal frame and making any modification in it voids warranty 2 Electric specifications and limitations 2 1 Operation ranges Property Min
8. wiring If possible use twisted pair of wires to connect motors to the drives to minimize radiated EMI from the wires Use as high gauge wire as possible to minimize wire resistance 5 3 Encoder wiring To connect a differential encoder to the RJ45 style encoder plug on the DG2S drive there are two options 1 Cut one end off of a standard Ethernet patch cable expose the individual wires and connect them to the appropriate terminals or plug on the encoder Ethernet cables normally have clear plastic connectors allowing the wire colors can be readily seen so you can figure out which color wires go to what pins on the cable plug 2 If the encoder vendor supplied pre made cable of sufficient length then simply connect those wires to an RJ45 plug These plugs are readily available at electronics supply stores in both crimp and IDS types If using our ENCD encoder interface board a standard CAT5 grade Ethernet cable is all that is needed A shielded cable is preferable The cable length must be between 1 meter and 100 meters Cables less than 1 meter in length or above 100 meters in length may not meet the cable driver circuit s impedance requirements Use separate cables for motor power and for encoder signals and do not route them close to each other or in a common conduit 5 4 Shielding techniques in general The drive has isolated motor power supply and digital power supply sections This means the digital power supply ground
9. 3 1 Connectors 3 1 1 Motor and Motor Power supply connector These are heavy duty high current bare screw connectors with M4 diameter Connect the motor to Motor Arm1 and Motor Arm2 It is OK if polarity is not known at this stage It will be determined during first startup and tuning Connect the power supply to Power and Power Polarity MUST be correct Be very careful to get the Power polarity correct Always put the drives into a closed box Never touch the terminals 3 1 2 Using external braking circuit connector The background When a DC motor is rapidly deccelerating it acts as a generator The generated energy pumps back into the drive possibly higher the voltage in the motor power supply Therefore if the used power supply rated voltage is greater than 80VDC it is strongly recommended to use an external braking circuit which dumps and dissipates the generated extra Voltage and energy Working of braking circuits A braking circuit monitors the motor power supply voltage If the voltage level rises above a set level the braking circuit activates and powers a braking resistor The braking resistor is used to dissipate the generated extra energy We supply braking circuit products which fits our drives and can be used to protect the drives and the system from regenerative overvoltage events For more information please check our BRKC xxx braking circuit devices datasheet 3 1 3 Main Connector The socket l
10. DG2S series DC Servo drive User s Manual and Installation Guide Contents 1 Electric specifications Connections and pinouts Safety policy and warranty 1 1 Safety notes 1 2 Policy 1 3 Warranty 2 1 Operation ranges Connectors 1 Motor and PSU connector a 2 External braking circuit lt A J rr 3 Main connector A 15 COMPLIANT RESTRICTION OF HAZARDOUS SUBSTANCES Encoder interface 3 1 3 1 3 1 3 1 3 1 3 1 5 USB programming cable Indicators and faults 4 1 LED indicators 4 2 Fault Conditions and Error Handling Installation guide 5 1 Installation of drive frame 5 2 Motor wiring 5 3 Encoder Wiring 5 4 Shielding Techniques 5 5 Error Line Wiring 5 6 Reset line wiring 5 7 Mixing the Reset and Error lines Power Supply selection and filtering Troubleshooting 1 1 Safety Notes Please read through this documentation before operating the device The devices can operate on low and medium DC bus Voltages the model 08020 operates upto 80VDC and the model 16035 operates upto 160VDC Above 50VDC the drive s metal case must be connected to safety ground for safety purpose Above 80VDC motor supply Voltage an external braking circuit must be used on the powersupply Moving objects like machine axis can be hazardous avoid touching and keep distance from mechanic moving parts of the machine while the motor power supply is on and connected
11. abeled Main is a standard RJ45 socket and contains the following connections as show in white numbers in Figure 2 Figure 2 Control Connections Step signal input Direction signal input Ground for Step and Direction signals NOT for power Not used Reset input and Stop input Error output and Stop input DC Power 11 5V to 14V tipically 12V for digital processor DC Power Signal descriptions The DC Power must be smoothed with capacitor An example is a typical low power universal power supply set to 12VDC voltage Step and Direction source signals are fed to the DG2S drive through built in high speed 10Mbit sec optoisolators The step and direction inputs interface includes an analog and also a digital filer these filters out short pulses and noise spikes Reset and Stop signal is referenced to the digital power supply ground pin8 This is a dual purpose signal which is active low which means the drive normally keeps the signal high and the drive is stopped by pulling the line low grounding the pin After the pin is pulled low releasing the pin initiates a reset Note The drive is also reset by turning the digital power off and back on Error conditions must be cleared and an encoder must be connected and functioning properly before the drive will start working successfully Error and Stop See Chapter 4 2 for features and function of the Error line See Chapter 5 4 for
12. e PRG1 circuit to the PC USB port via a standard USB A B cable The USB connection is provided for configuration and monitoring purposes These lines are optically isolated from the device s other parts and from the PC Note The USB A B cable is not the part of the D2GS drive package and also not the part of the PRG1 programming cable package This cable must be supplied by the user but it is easy to get it in most of electric or informatic stores The drives can be configured tuned with our Servoconfigurator3 software which can be downloaded from our website for free of charge The software documentation can be found in the software package Download the latest tuning software from our website 4 1 LED indicators Indicator lights are visible on the edge of the board to give visual feedback on the drive operation There are 2 pieces of LEDs one with green and one with red with color The LED states and the combination of the states gives clear information about the drive operation Please read section 4 2 below for more information about the possible LED states 4 2 Fault conditions and Error handling Error line is pin number 6 in the Main connector and is a dual purpose bi directional line This pin is active low meaning that the line is normally high indicating no problems and normal operation The drive will stop if this pin is pulled ow grounded by one of these sources EXTERNAL activation The line can be pulled lo
13. onnection of the error and reset lines and with this connection there is no need to use any external logic to force the drives to reset after a fault Ofcourse individual reset and error line handling is also possible it is only an option to mix the error and reset lines It depends on the application if this connection mode is useful or not 6 Power Supply selection and filtering The drive needs 2 power supplies for operation one to feed the digital circuit and one to feed the motor The digital power supply can be tipically a 12V DC voltage source with that has smoothed and regulated output and meets the other electrical requirements The motor power supply should be a linear power transformer with continuous current capability at least of motor s rated continuous current rating The DC output should be smoothed with capacitors downstream of the rectifier using the following sizing rules 1000uF per amp up to 80V 2000uF per amp over 80V Connect each drive with separate feed wires from these main capacitors Do not daisy chain or connect the motors in series Keep the wires from the power supply to the drives under 30cm 12 inches in length If that is not possible then install an additional 1000uf or greater capacitor directly across the power terminals on the drive Do not use switching mode power supplies for motor power unless a properly designed power resistor capacitor network is installed on the outpu
14. powersupply ground by internal weak pullup resistors with an approximate value of 100kOhm The reset line can be activated by external logic with pulling the line low Releasing the line returns the line to a high 5V state 5 7 Mixing the Reset and Error lines The error line acts as an opencollector output which means that many error lines can be connected together paralelled or in other words OR wired The reset line is an input and therefor any number of reset lines may be also wired together It is also allowed to wire the error lines and the reset lines together With making this connection we get a common error reset line for a drive or for any number of drives in the setup If this common error reset line is pulled to GND potential by external logic it works as if it was just a reset line and the drive stops operation If the line is released by the external logic the drive s automaticly resets and starts operation again If an internal fault occurs in any of the drives in this chain the commoned error reset line is pulled to GND potential by the drive which got the fault but because the reset line is also connected to the same wire the drive automaticly resets itself In this automatic reset procedure a short approximately 300msec long low pulse is generated on the common error reset line which an external logic may read and may do the required steps of operation As mentioned the drives automaticly resets with this mixed c
15. t otherwise the SMPS may destroy the drive and or the drive may destroy the SMPS O Power Drive Transformer Rectifier Power O Power Figure 6 Ideal basic motor power supply configuration 7 Troubleshooting Q When powering up the drive the motor runs with full speed to one direction and stops after a while with error limit reached LED on A Encoder is wired up in reverse exchange motor Arm1 with Arm2 to reverse direction of the motor Q The motor is oscillating over the nullpoint when powerup A Tune the PID controller with the Servoconfigurator3 software Q like to control my motor with a PLC which has 24V I Os is it possible A The step and direction pins are feed through optoisolators Use a series resistor with the step and with the direction signal from the PLC Resistor must be sized so that the opto isolator current is limited under 10mA Q like to control an AC servomotor with the drive is it possible A No The drive can only control brush type DC servomotors Q have a disk type servomotor with coil resistance of lower than 0 4 Ohms and an inductance of lower than 200uH what to do A Use a resistor wire and or inductor in series with the motor coil to extend resistance to at least 0 4 Ohm and inductance to at least 200uH otherwise the motor and or drive may damage Q have a motor that have a rated Voltage greater than 160VDC can used it with the drive A Yes
16. w by an external source CNC software E stop etc In this case the drive will stop and remain stopped When the pin is released the drive will remain stopped but can then be reset CNC software should be set for active low to use the Error line to stop the drive INTERNAL activation The line is pulled low by the drive itself due to a fault condition Once stopped by an internal fault condition the drive will remain stopped until the fault is cleared and the drive is reset This line may be monitored by your CNC software to trigger an e stop in the event of a fault See Chapter 5 4 for details on Error line connection options Fault handling by the DG2S series drives The possible operation states and their indications are as follows 1 Controller running indicates normal operation of the controller Red LED off Green LED Flashing Description This is the indication when there is no fault and the drive is up and running 2 Limit override indicates that the set servo error limit is reached Red LED blinking Green LED blinking Description This is a fault condition and occurs if the following servo error gets greater than the user set value 3 Unconnected or faulty encoder indicates that the encoder is not working properly Green LED off Red LED blinking rapidly Description This is a fault condition The drive detects unconnected and faulty encoder signals if it Sensing an encoder fault it stops operation
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