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Analog Product Family Hardware Installation Manual

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1. 7 Brushless 10V Analog DC Drives 5 Brushless AC Supply Drives 5 Brushless PWM Input DC Drives 5 Brushless Servo Drives Brushless Servo System Bus FUSE mn titii inet C Central Point Grounding 30 Command Inputs 10 Commutation Sequence Table 13 48 Company Website li Continuous Current Limit Pin Continuous Regeneration Controller Chassis Controller based Commutation 8 Crimp Tool itn 31 Current Torque Mode 14 Current Limit Potentiometer 43 Current Limiting 46 60 Current Loop Gain 50 Current Loop Integrator 92 Current Monitor Output sa 40 Current Reference Output 41 Custom Models 5 ADVANCED 7A MOTION CONTROLS D Daisy ChainS ii 33 DC Bus Over Voltage Limit 9 DC Power Supplies 33 DC Power Supply Wiring 33 DC Supply Voltage Range 9 DIP Switch Settings 44 Drive Case Grounding 30 Drive Datasheet 4 Drive Setup Instructions 47 49 Duty Cycle Mode 14 Dwell Tine 18 E Electromagnetic Interference
2. Current Limit Current Measured Max Peak Current Limit Negative Direction I l I I I r I I I I T I l I I l I I r I I Sustained maximum current demand when switching between positive and negative maximum current without allowing sufficient time for fold back will result in drive damage Drive RMS current should be below the continuous current rating Caution e For most applications it s a rare occurrence to fully swing from peak in one direction to the other It is more likely the drive will be commanded from zero to max peak current Under this condition the drive will only sustain the maximum peak current for about one second FIGURE B 2 Peak Current Foldback Max Peak Current Limit ___ Positive Direction e Current Command Max Continuous Current Limit Current Measured e Commanding maximum peak current output starting from above zero command will also yield reduced peak current output time ADVANCED VA MOTION CONTROLS MNALHWIN 05 60 Troubleshooting Fault Conditions and Symptoms e When commanding output current less than the max peak limit but more than the max continuous limit the current output can be sustained for a longer time period than a maximum peak command before folding back FIGURE B 3 Above Continuous Current Foldback Max Peak Current Limit I Positive Direction 7777 Wi e CASS DIIS SES SEDENS IUS S
3. Specification Units Description DC Supply Voltage Range VDC Specifies the acceptable DC supply voltage range that the drive will operate within DC Bus Over Voltage Limit VDC Specifies the maximum DC supply voltage allowable If the DC bus rises above the over voltage limit the drive will automatically disable and will not re enable until the DC bus voltage falls below the over voltage limit AC Supply Voltage Range VAC Specifies the acceptable AC supply voltage range that the drive will operate within AC Supply Frequency Hz Specifies the acceptable frequency of the AC supply line Maximum Peak Output Current A Pertains to the maximum peak current the drive can output according to hardware limitations An RMS rating can be obtained by dividing this value by JA With the exception of S series drives the maximum peak output duration is inherently limited to occur for no longer than 2 seconds at which point the current output will foldback over a period of 10 seconds to the continuous current limit in order to protect the motor in stalled condition Current limiting is implemented in the drive by reducing the output voltage Most drive models feature peak current limit adjustments The maximum peak current is needed for fast acceleration and deceleration Consult the drive datasheet to see which options are available For more information on the current limit see Current Limiting Procedure on page 46 Maximum Continuous Output A Pe
4. Current Control Switching M PASAN Logic Commutation KR o i Control 1 A i i A Commutation Feedback The commutation function can also be implemented in the motion controller as in the case of ADVANCED Motion Controls sinusoidal command input drives The drive merely amplifies the controller signals 2 analog sinusoidal signals that represent 2 of the 3 motor phase currents and creates the third motor phase current the sum of the 3 currents must be zero and adjusts the phase angle to obtain maximum torque No position feedback needs to be wired into the drive The motor current amplitude is proportional to the reference signal amplitude while the reference signal frequency depends on the motor velocity and the motor pole count FIGURE 2 6 Controller based Commutation Analog Sinusoidal Motor Currents reference signals NA A AA Ju yy Controller TA mv TA CV N fasc 7 V VU senon AAAA Commutation Control NIN N au id UV AAA V Y Position and Commutation Feedback Feedback ADVANCED 7A MOTION CONTROLS MNALHWIN 05 Products and System Requirements Power Stage Specifications 2 3 Power Stage Specifications LL The drive datasheet lists the specific values for the following drive power specifications Note that not all specifications apply to every drive TABLE 2 7 Power Stage Specifications
5. 2015 ADVANCED Motion Controls All rights reserved MNALHWIN 05 Contents 1 Safety 1 1 1 General Safety Overview 00 0 saa 1 2 Products and System Requirements 4 2 1 Analog Drive Family Overview naawa Pha sicu WALL ONG YANG 4 2 1 1 Products Covered 453 iaia last ei S XS ds 4 Drive Datasheet 0 a 4 Standard and Custom Models 52 254229 esas dawa 5 2 2 Analog PWM Servo Drive Basics and Theory 6 2 2 1 Single Phase Brushed Servo Drives 7 2 2 2 Three Phase Brushless Servo Drives 7 2 3 Power Stage Specifications 65 sss orae a ERE RES 9 2 4 Command INPpUtS 51522 x a dac dor AGA AGA ANG Ee xS 10 24 DV JADOIG paa ice EIE Ric Ue XIERREr ERE Qc Ee eR 10 2 4 2 PWM and Direction odere bac CERE ERR e ees 10 225 3 SINUOSO perte 3E NG QU Pa PNK BAG EN VES e Ar 10 2 5 Feedback Specifications 5 4445 54440 404 eee deen ir 11 2 5 1 Feedback Polarity daa xk ra gw x 11 2 5 2 Incremental Encoder i c c xa e RE ed 11 2 9 9 Boll SORSOIS uo ted nee tie Re qn PP che ve dad 12 2 5 4 Tachometer x ote a d kie bd nG EET acid ats I3 2 6 Modes of Operation spiriti KAL KA C EY Ya 14 2 6 1 Current Torque Mode sis ELESSE AALAY ex 14 2 6 2 Duty Cycle Open Loop Mode sse s a 14 2 6 3 Hall Velocity Mode iude ina aspice 15 2 6 4 Encoder Velocity Mode eere 15 ADVANCED 7A MOTION CONTROLS z MNALHWIN 05 IV 2
6. 4 PE Ground zi Peak Current Fold back 60 Peak Torque 18 Pin Functions 40 42 Positive Feedback 11 Potentiometer Functions 43 Potentiometer Test Points 43 Power Ground 20 Power Outputs Low Voltage 42 Power Stage Specifications 9 Power Supply Capacitance 2 25 32 Power Supply Chassis 30 Power Supply Current 21 Power Supply Output Current 20 25 Power Supply Wiring 32 Power on Reset 59 Product Label Products Covered 4 Protective Earth 30 PWM and Direction Input Wiring 37 PWM Current Control Circuit 6 Regeneration Continuous Returns Revision History iii RMS Torque nnn 18 S Safety aa ad Scaling Factor Selection and Sizing Servo Drive Theory Shielding Shock Vibration Short Circuit Fault Shunt Fuse nee tenente restos Shunt Regulator Signal Ground Single Phase Servo Drives 7 Sinusoidal Command 10 Sinusoidal Input AC Supply Drives 5 Sinusoidal Input DC Drives 5 Sinusoidal Input Wiring
7. 2s sse o rn Single Phase AC Power Supplies Three Phase AC Power Supplies 3 44 Feedback WIS Laude baro ai PE i e bor ed d dod HELE uerus zoe tote eee tele eae at ood oe Incremental Encoder ssa e em C454 eli Res ote Y NG ADVANCED VA MOTION CONTROLS MNALHWIN 05 Tachometer 3 4 5 Input Reference Wires saos v Rd GANA PENA as 4 Operation 10V Analog Input Potentiometer Input PWM and Direction INDUS 344 esaxesedeacemksoke xtesuixs Sinusoidal Input 3 5 Mounting 4 1 Initial Setup and Features 4 1 1 Pin Function Details 4 1 8 Tuning Procedure ADVANCED VA MOTION CONTROLS Current Monitor Output LL Current Reference Output Inhibit INPUT Continuous Current Limit Pin eese Fault Output Low Voltage Power Supply Outputs Velocity Monitor Output 2s duca seu duh awed pbi oes 4 1 2 Potentiometer Function Details 25322 urhe ds 456 Test Points for Potentiometers 4 1 3 Switch FUNCTION Details 4 aa xeu KAKA ewe de de ERR 4 1 4 Adjustable Acceleration and Deceleration Rate 4 1 5 Tachometer Input Gain Sc aling 4 1 6 Current Limiting Procedure 4 1 7 Drive Set up INSIMUCHIONS siria PLA Single Phase Brush Type aa Three Phase Brushless pawa wa sisi re um ek RR Y KGG Three Pha
8. 39 Standard Drive Models 5 Switch Functions 44 Switching Frequency 9 System Requirements 17 26 System Voltage Requirement 18 T Tachometer Feedback ems 13 Velocity Mode 15 Wg aasa 36 Technical Support 62 Test Points Pots 43 Test Offset Potentiometer 43 Three Phase Servo Drives 7 Three Phase AC Supply 34 Through hole Components 54 loeo E 18 Trademarks sse li Troubleshooting 58 63 Tuning Procedure aai 49 53 Through Hole Components 54 57 Twisted Pair Wires 31 U Under Voltage Shutdown 59 V Velocity Loop Tuning Velocity Monitor Output Velocity Scaling Factor Vibration teeth Voltage Drop Interference 31 Voltage Loop Tuning Voltage Mode Voltage Ripple Ww Warning Symbols iii Warranty INfo 63 Warranty Returns 63 Wire Diameter 31 Wire Gauge reee 31 WINS san ANA 31 39 MNALHWIN 05 Analog Drives Product Family Hardware Installation Manual MNALHWIN 05 ADVANCED V4
9. 31 Encoder Velocity Mode 15 Environmental Specifications 26 Error Signal 11 External Filter Card 19 F FAC Drive Models 34 Fault Conditions 58 60 Fault Output 42 Feedback Polarity 11 Feedback Specifications 11 13 Feedback Wiring 134 36 Fokl back eee 60 Frequency Factor 25 G Ground Loops Grounding aaa anG H Hall Sensors Feedback 2 ana Wiring Hall Velocity Mode Humidity esses I Impedance 31 Incremental Encoder Feedback iii se 11 MWIEIBB es aeea E 35 Inhibit Input 41 59 Input Reference Wiring 36 39 Interference Coupling 31 Internal Bus Capacitance 2559 Internal Shunt Resistance 9 Internal Shunt Resistor Power Rating 9 Turn on Voltage 9 Invalid Hall Commutation 59 IR Compensation Mode 16 IR Feedback Loop Tuning 52 Isolated Power Supply 22 Isolation AA 22 L Linear Motor Equation 18 Lock out tag out Procedures 1 Loop Gain Potentiometer Low Voltage Power Outputs LVD Requirem
10. Outer Loop Integration Activation Activates or deactivates the outer loop integration For Current Mode outer loop integration should be deactivated but should be activated for other modes Outer Loop Integral Gain Adjustment Increases or decreases the integral gain of the outer loop Duty Cycle Feedback Enables disables the duty cycle feedback Duty cycle feedback is only enabled when the drive is configured for Duty Cycle Mode Hall Sensor Commutation Phasing Tells the drive the type of Hall sensor phasing the motor has Switches between 120 and 60 degree phasing Test Offset Switches the drive between Test mode and Offset mode In Test mode the command signal is adjustable via the Test Offset potentiometer In Offset mode the drive will accept commands via the reference inputs but a small amount of offset can be adjusted in order to compensate for offsets that may be present in the servo system PWM and Direction Test Signal Activates or deactivates the PWM and Direction internal test signal controlled by the PWM Test Signal Adjustment potentiometer Velocity Feedback Polarity Changes the polarity of the internal feedback signal and the velocity monitor output signal Inversion of the feedback polarity may be required to prevent a motor run away condition See Motor Problems on page 61 for more information IR Compensation Activates or deactivates IR feedback IR feedback should be activa
11. capacitive kinetic and potential energy The energy equations for these individual components are as follows 1 E 4 C Vrom Where E energy stored in a capacitor joules C capacitance Voom nominal bus voltage of the system ADVANCED 7A MOTION CONTROLS MNALHWIN 05 23 Products and System Requirements System Requirements l 2 E 210 E 2 Where E kinetic mechanical energy of the load joules J inertia of the load kg m 0 angular velocity of the load rads s E mgh p 8 Where Ep potential mechanical energy joules m mass of the load kg g gravitational acceleration 9 81 m s h vertical height of the load meters During regeneration the kinetic and potential energy will be stored in the power supply s capacitor To determine the final power supply voltage following a regenerative event the following equation may be used for most requirements GUAE c EUR ES 1 2 toy lo mgh tov iJo mgh nom 5 2mg h h C The Ve calculated must be below the power supply capacitance voltage rating and the drive over voltage limit If this is not the case a shunt regulator is necessary A shunt regulator is sized in the same way as a motor or drive i e continuous and RMS power dissipation must be determined The power dissipation requirements can be determined from the application move profile see Figure 2 10 ADVANCED Motion Controls offers a variety of shunt regulators
12. Current High Phase A Low High Phase B Low High Phase C ee 0 60 120 180 240 300 360 Electrical Degrees ADVANCED 7A MOTION CONTROLS MNALHWIN 05 1 2 Products and System Requirements Feedback Specifications Depending on the motor pole count there may be more than one electrical cycle for every motor revolution For every actual mechanical motor revolution the number of electrical cycles will be the number of motor poles divided by two For example e a6 pole motor contains 3 electrical cycles per motor revolution e a4 pole motor contains 2 electrical cycles per motor revolution a2 pole motor contains 1 electrical cycle per motor revolution The drive powers two of the three motor phases with DC current during each specific Hall Sensor state The table below shows the valid commutation states for both 120 degree and 60 degree phasing TABLE 2 8 Commutation Sequence Table 60 Degree 120 Degree Motor Hall 1 Hall 2 Hall 3 Hall 1 Hall 2 Hall 3 Phase A Phase B Phase C 1 0 0 1 0 0 HIGH LOW 1 1 0 1 1 0 HIGH LOW Valid 1 1 1 0 1 0 LOW HIGH 0 1 1 0 1 1 LOW HIGH 0 0 1 0 0 1 LOW HIGH 0 0 0 1 0 1 HIGH LOW Invalid 0 1 1 f 0 1 0 0 0 0 2 5 4 Tachometer A DC Tachometer can be used on some drives for velocity control The tachometer provides an analog DC voltage feedback signal that is related to the actual motor speed and direction Th
13. VA MOTION CONTROLS MNALHWIN 05 10 Products and System Requirements Feedback Specifications 2 5 Feedback Specifications 0599 There are a number of different feedback options available in the family of analog drives The feedback component can be any device capable of generating a voltage signal proportional to current velocity position or any parameter of interest Such signals can be provided directly by a potentiometer or indirectly by other feedback devices such as Hall Sensors or Encoders These latter devices must have their signals converted to a DC voltage a task performed by the drive circuitry Consult a specific drive datasheet to see which feedback devices are available for that drive 2 5 1 Feedback Polarity The feedback element must be connected for negative feedback This will cause a difference between the command signal and the feedback signal called the error signal The drive compares the feedback signal to the command signal to produce the required output to the load by continually reducing the error signal to zero This becomes important when using an incremental encoder or Hall sensors as connecting these feedback elements for positive feedback will lead to a motor run away condition In a case where the feedback lines are connected to the drive with the wrong polarity in either Hall Velocity or Encoder Velocity Mode the drive will attempt to correct the error signal by applying more command to t
14. loop gain is determined by the fixed gain of the input differential amplifier of the drive For best results the servo drive can be ordered with a higher differential gain ADVANCED 7A MOTION CONTROLS MNALHWIN 05 53 A Through hole Component Tuning P In general ADVANCED Motion Controls analog servo drives will not need to be further tuned with through hole components However for applications requiring more precise tuning than what is offered by the DIP switches and potentiometers the drive can be manually modified with through hole resistors and capacitors as denoted in Table A 1 below On most analog drives the through hole locations are not populated when the drive is shipped S Series drives however are shipped with through hole components in pin receptacles for easy removal It is recommended to contact ADVANCED Motion Controls to discuss application requirements and proper drive tuning prior to making any adjustments Any damage done to the drive while performing these modifications will void the product warranty Notice Before attempting to add through hole components to the board see Tuning Procedure on page 49 Some general rules to follow when adding through hole components are e A larger resistor value will increase the proportional gain and therefore create a faster response time e Use non polarized capacitors e Alarger capacitor value will increase the integration time and therefore create a slower resp
15. 190 40 20 BE40A201 40 190 40 20 B30A40 60 400 30 15 B40A40 60 400 40 20 TABLE 2 3 Brushless 10V Analog AC Drives Drive Number VAC Peak Current Cont Current Nominal A A B25A20AC 30 125 25 12 5 BE25A20AC 30 125 25 12 5 BX25A20AC 45 125 25 12 5 B30A40AC 45 265 30 15 B40A40AC 45 265 40 20 B060A400AC 200 240 60 30 B100A400AC 200 240 100 50 TABLE 2 4 Brushless PWM Input DC Drives Drive Number VDC Peak Current Cont Current Nominal A A BDC30A8 20 80 30 15 BDC40A20 60 190 40 20 1 Certain AC drive models can also accept a DC power supply Consult the drive datasheet to determine if DC input is allowed ADVANCED 7A MOTION CONTROLS MNALHWIN 05 5 Products and System Requirements Analog PWM Servo Drive Basics and Theory 2 2 Analog PWM Servo Drive Basics and Theory ADVANCE Analog servo drives are used extensively in motion control systems where precise control of position and or velocity is required The drive transmits the low energy reference signals from the controller into high energy signals motor voltage and current The reference signals can be either analog or digital with a x10 VDC signal being the most common The signal can represent either a motor torque or velocity demand Figure 2 2 shows the components typically used in a servo system i e a feedback system used to control position velocity and or accel
16. 6 5 Tachometer Velocity Mode ssssaa o 2 6 6 Voltage Mode pere beu od ba ORA Eas NG QUEE CIS qne 2 6 7 IR Compensation Mode eee 2 6 8 Analog Position Loop Mode 2 7 System Requirements vs x ah Sirio ERA E EXE EG 2 7 1 Analog Servo Drive Selection and Sizing Motor Current and Voltage Motor INAUCHANCE maana bo DROP Edi iei ded pe ed 2 7 2 Power Supply Selection and Sizing 422i s Power Supply Current and Voltage blonde Regeneration and Shunt Regulators Voltage Ripple 2124445446 RN du 9E d RV AG SESE x du RN 2 7 3 Environmental Specifications Shock VIDIQNONS au e qua os ron d aie bebe or ed TE 3 Integration in the Servo System 3 1 LVD Requirements uus xs PPAR ee GAWA CSS SHE ERES ES 3 2 CE EMC Wiring Requirements aeu xt px RE RH Y KA NG Ce AA AA Analog Input Drives siii GANDA eer du eR PWM Input Drives cuiua d NG Gates PAG eee EER S ho C AG MOSFET Switching Drives 2voxvasieeseisewxxI keel IGBT Switching Drives ian Fitting of AC Power Filters silice 3 2 1 Ferrite Suppression Core Setup 3 2 2 Inductive Filter Cards 34545448024 oe pane a 3 3 GUN ao dct se ceed iei deb rt bach BLG Sea eee oral 3 4 1 Wire GAUge ios uos wires Geen sees bs 655555 bee Heese E 3 4 2 Motor VINGS a v varo dei iis 3 4 3 Power Supply WIGS iii EY BAG ETE RES DC Power Supplies
17. DC supply voltage across the potentiometer Vs FIGURE 3 13 Potentiometer Input ANALOG Bi directional Control SERVO DRIVE 10V Max Potentiometer 3 REF IN 50k Y REF IN Y 10V Max A SIGNAL GROUND Uni directional Control ANALOG SERVO DRIVE 10V Max Potentiometer REF IN pd LI SIGNAL GROUND PWM and Direction Inputs On drives that accept a PWM and Direction signal for a command input the inputs are optically isolated from the power stage of the drive The PWM and Direction Inhibit and Fault I O will not provide any functionality to the drive unless the optocouplers are activated Depending on the drive model there are two methods to activate the optocouplers and thereby activate the drive e Some drive models feature a 5V input pin that is used to drive the optocoupler inputs This 5V supply must be grounded at the negative Inhibit terminal The positive terminals for the PWM Direction and Inhibit inputs are all internally connected to the 45V input Therefore the external PWM and Direction input signals should be connected at the negative PWM and Direction terminals The positive Fault output terminal can also be ADVANCED 7A MOTION CONTROLS MNALHWIN 05 3 7 Integration in the Servo System Wiring connected to the 5V input supply and when the drive enters a fault stage the negative Fault ou
18. Motion Controls drives can be found on the drive datasheet The shunt regulator turn on voltage was chosen at an appropriate level to clamp the power supply voltage so it will not exceed the drive over voltage limit during regeneration The system power supply requirement is based on the motor properties and how much voltage is needed to achieve the application move profile see Motor Current and Voltage on page 17 Keep in mind that the calculated value for V4 is the minimum voltage required to complete moves at the desired speed and torque There should be at least 1096 headroom between the calculated value and the actual power supply voltage to allow for machine changes such as increased friction due to wear change in load increased operating speed etc FIGURE 2 12 Power Supply Selection 100 rive Over Voltage Shutdown 88V 80 mmm Shunt Regulator Turn On Voltage 80V VDC Acceptable Power Supply 40 Range 26 V 72V 20 e System Power Supply Requirement 24V Drive Under Voltage Shutdown 9V Isolation In systems where an AC line is involved isolation is required between the AC line and the signal pins on the drive This applies to all systems except those that use a battery as a power supply There are two options for isolation 1 The drive can have built in electrical isolation 2 The power supply can provide isolation e g a battery or an isolation transformer The system must have at l
19. Output I Jef P FAULT GND FAULT m Y 5V INHIBIT A 5V to Inhibit Open to Enable A iNHIBIT 19 W uf uf N Ground to Inhibit Open to emm HES K gt GND INHIBIT BENG i l ADVANCED 7A MOTION CONTROLS MNALHWIN 05 38 Integration in the Servo System Mounting Sinusoidal Input The S Series of analog servo drives accept two sinusoidal command signals that are 120 degrees out of phase The sine input signals can be either differential or single ended If using a single ended signal connect the input to the REF terminal of the reference input pins and ground the negative terminal FIGURE 3 16 Sinusoidal Command Inputs Analog Servo Analog Servo Drive Drive VA Different REFIN A 40k Single ended REF IN A 40k ifferential V Sine Input A V Sine InputA REF IN A _ gt ine Input REF IN A p 40k 40k s v Y We Wy i5 REF IN B 40k Single ended REF IN B SIE Differential Sine Input B i Sine Input B X REF IN B pb De mp X REF IN B n gt V W 40k 3 40k hd bd 3 5 Mounting ADVANCED Motion Controls analog servo drives provide mounting hole locations on the baseplate allowing the drive to be mounted either vertically or horizontally Drives can be mounted to a heatsink or other plane surface or attached to a lab rail either on a test bench or as part of a larger system Consult the drive datasheet for specific mounting dimen
20. Points for Potentiometers After the potentiometer adjustments have been completed the resistance values can be measured for future adjustments or duplication on other servo drives ofthe same part number Test points for potentiometer wipers are provided and are located at the foot of all four potentiometers Resistance measurements are only to be used to duplicate drive settings since some potentiometers have other resistors in series or parallel Measure the resistance between the test point and the outer leg of the potentiometer or between the test point and an appropriate ground See the block diagram on the drive datasheet to determine which ground should be used for each potentiometer Notice Before taking potentiometer resistance measurements make sure that all potentiometers and DIP switches have been set to the desired settings and that all 1 O and Feedback cables have been removed from the drive as these can affect resistance measurements ADVANCED 7A MOTION CONTROLS MNALHWIN 05 43 Operation Initial Setup and Features 4 1 3 Switch Function Details Together with the described functions below certain switches may also be used in selecting the mode of operation while some may be used strictly for mode selection Switch implementation and functionality within the drive circuitry is included on the block diagram of the drive datasheet Consult the drive datasheet to see which switches are included on a specific dr
21. a pulsed DC current Figure 2 11 when the MOSFET switch is on it equals the motor current when the MOSFET is off it is zero Therefore the power supply current is a function of the PWM duty cycle and the motor current e g 3096 duty cycle and 12 amps motor current will result in 4 amps power supply current 3096 duty cycle also means that the average motor voltage is 3096 of the DC bus voltage Power supply power is approximately equal to drive output power plus 3 to 596 The only time the power supply current needs to be as high as the drive output current is if the move profile requires maximum current at maximum velocity In many cases however maximum current is only required at start up and lower currents are required at higher speeds Caution ADVANCED 7A MOTION CONTROLS MNALHWIN 05 20 Products and System Requirements System Requirements FIGURE 2 11 Unregulated DC Power Supply Current PWM Switching r Time MOSFET ON Vin Average Im de la DIODE BRIDGE Time Vp AC Input V Voltage PI DI eee Time SERVO DRIVE V VAC 1 41 Average Time Vm Motor Terminal Voltage Im Motor Current la Diode Current lp Power Supply Current V DC Power Supply Voltage Vp VAC AC Supply Voltage RMS Average Time The ripple current depends on the Time motor inductance and the duty
22. can be forced to go The motor shaft does through Motor A and Motor C by applying the square not need to be locked wave command signal to Ref In A only Attach the since the drive is not current probe to either Motor A or Motor C commutating 7 The drive output should follow the input command The best response will be a critically damped output waveform similar to what is shown in Figure 4 5 FIGURE 4 5 Current Loop Response Target Current Current Signal Output Current Response Time ADVANCED 7A MOTION CONTROLS MNALHWIN 05 5 1 Operation Initial Setup and Features 8 Ifneither currentloop gain DIP switch position gives a proper square wave response then the current loop gain resistors may need to be changed to optimize the response See Through hole Component Tuning on page 54 for more information 9 Whenthe proper response has been achieved remove the input signal from the drive and disconnect power Current Loop Integrator Adjustment 1 Enable the Current Loop Integrator through DIP switch or jumper settings see the drive datasheet for available options 2 Using a function generator apply a 0 5V 50 100 Hz square wave reference signal 3 Apply power to the drive Use a bus voltage that is approximate to the desired application voltage or the current loop compensation will not be correct 4 The drive should be enabled GREEN LED Observe the motor current using a current probe or resistor in s
23. drive B 1 3 Motor Problems A motor run away condition is when the motor spins rapidly with no control from the command input The most likely cause of this error comes from having the feedback element connected for positive feedback This can be solved by changing the order that the feedback element lines are connected to the drive or changing the feedback polarity switch on the DIP switch bank to the opposite setting Another common motor issue for brushless motors with Hall Sensor commutation is when the motor spins faster in one direction than in the other for the same velocity command in the opposite direction This is typically caused by improper commutation usually because the motor power wires are connected in the wrong order with respect to the Hall Sensor wiring Try all six combinations of connecting the motor power wires to the drive to find the correct commutation order The proper combination of motor wires will yield smooth motion and identical speeds in both directions Improper combinations will cause jerky motion slow movement in one direction and or audible noise As a final verification that the commutation ADVANCED 7A MOTION CONTROLS MNALHWIN 05 6 1 Troubleshooting Technical Support is correct use the Velocity Monitor Output pin to measure motor speed in both directions This can also be caused by invalid Hall phasing Check to see if the drive is set for 120 or 60 degree phasing and verify that the
24. during product commissioning Keep clear of any operational machinery and never touch them while they are working D 7A MOTION CONTROLS MNALHWIN 05 Safety General Safety Overview Keep clear of all exposed power terminals motor DC Bus shunt DC power transformer when power is applied to the equipment Follow these safety guidelines e Always turn off the main power and allow sufficient time for Warning complete discharge before making any connections to the drive e Donotrotate the motor shaft without power The motor acts as a generator and will charge up the power supply capacitors through the drive Excessive speeds may cause over voltage breakdown in the power output stage Note that a drive having an internal power converter that operates from the high voltage supply will become operative e Do not short the motor leads at high motor speeds When the motor is shorted its own generated voltage may produce a current flow as high as 10 times the drive current The short itself may not damage the drive but may damage the motor If the connection arcs or opens while the motor is spinning rapidly this high voltage pulse flows back into the drive due to stored energy in the motor inductance and may damage the drive e Donot make any connections to any internal circuitry Only connections to designated connectors are allowed e Donot make any connections to the drive while power is applied e Donotreverse the power
25. of Rsource and the drive s input impedance FIGURE 3 11 Analog Source and Drive Input 10V ANALOG ANALOG 10V ANALOG ANALOG SOURCE SERVO DRIVE SOURCE SERVO DRIVE Reource REF Resource REF V L V i O I REF p Paang s I REF 3 Rin Internal Offset Equivalent Input Reference Voltage Impedance YA MOTION CONTROLS MNALHWIN 05 36 Integration in the Servo System Wiring The drive s analog input can be simplified to a single impedance Rj as shown in Figure 3 11 If the impedance of Rgource is of the same magnitude or larger than Rip there will be a significant voltage drop across Rsource Reduced values of Rsource cause a lower voltage drop that increases signal integrity In order to avoid a voltage drop of more than 596 between the source and the drive it is recommended to use an Rsource Value of less than or equal to Zkohm If there is a large output impedance from the analog source it is recommended to use a buffer circuit between the analog source output and the drive input A unity gain op amp circuit as shown in Figure 3 12 will ensure low output impedance with minimal voltage drop FIGURE 3 12 Optimized Low Impedance Interface 10V ANALOG ANALOG SOURCE SERVO DRIVE REF I REF hi x Internal Offset Reference Voltage Potentiometer Input Analog servo drives that accept 410V analog input can be commanded with the use of an external potentiometer and a DC supply by varying the
26. on the procedure outlined in Current Limiting Procedure on page 46 Check the power and connect it to the drive Do not connect the motor lead wires Make sure the drive is in an enabled state via all inhibit enable inputs See drive datasheet for details Check that the status LED indicates normal operation GREEN Set mode according to the drive datasheet for Voltage Mode Set the Test Offset switch to Test mode Measure the voltage across the motor output with a DC voltmeter Slowly turn the Test Offset potentiometer the voltage should vary between x bus voltage Set the output voltage with the Test Offset potentiometer to a low value Verify that the load circuit meets the minimum inductance requirements and that the power supply voltage does not exceed the drive rated voltage or 15096 of the nominal motor voltage Turn the power off Connect the motor Turn the power back on Gradually turn the Test Offset potentiometer to change motor speed in both directions Set the Test Offset switch to Offset Ground both reference inputs and then using the Test Offset potentiometer set the motor for zero speed 10 Set the control mode suitable for the application Three Phase Brushless 1 Itis recommended to reduce the drive output current to avoid motor over heating during the setup procedure Make sure the current has been set appropriately based on the procedure outlined in Current Limiting Procedure on page 46 2 According
27. response Ifthe current response square wave oscillates or overshoots a larger equivalent capacitance value is necessary Ifthe current response square wave corners are too rounded a smaller equivalent capacitance value is necessary to sharpen the corners 4 Asinthe previous section using pin receptacles at the through hole locations will greatly assist in finding an acceptable capacitance value Also keep in mind that the through hole capacitor location may be in parallel with SMT capacitors on the PCB Use the block diagram on the drive datasheet to determine the equivalent integrator capacitance value capacitors in parallel add together 5 Although the ideal current loop response after integral gain tuning will be a critically damped square wave the application requirements will determine what the desired response will be i e how much overshoot steady state error oscillation is acceptable Velocity Loop Integral Gain Tuning The velocity loop proportional gain is adjusted by the ADVANCE on board Loop Gain potentiometer The velocity loop integral gain can be adjusted by DIP switch settings similar to the current loop integral gain capacitance value can be changed capacitor can be shorted out extra capacitor can be added in parallel However some drive models also include additional through hole locations where through hole capacitors can be added to further adjust the velocity loop integral gain As in tuning the curr
28. should be done for both the high and low current loop gain see drive datasheet for available current loop gain DIP switch settings Different drives need to be set up differently to view the current loop response properly as shown in the following figures ADVANCED 7A MOTION CONTROLS MNALHWIN 05 50 Operation Initial Setup and Features FIGURE 4 2 Brushed Drives Current Analog Servo Probe or Drive y Resistor Motor Square Wave Input Motor Since the two motor wires are in series the current through the wires is the same The current probe can be attached to either wire with the same results To keep the motor from turning during the tuning process the motor shaft must be locked FIGURE 4 3 Brushless Drives Current Analog Servo Probe or Drive y Resistor Square Motor A Wave Input Motor B Motor C The motor shaft does not need to be locked since the drive will not commutate without the Hall Sensors The current out of the drive can be forced to go through Motor A and Motor B by 1 Disconnecting the Hall sensors from the drive 2 Setting the 60 120 degree phasing switch to 60 degrees FIGURE 4 4 S Series Drives Current Analog Servo Probe or Drive y Resistor Square Wave Input The current out of the drive
29. the drive 1 The following two options may be used separately or in conjunction with each other to reduce the current limits Keep in mind that any current reductions enacted by the use of an external resistor will come secondary to DIP switch settings Ifavailable position any current scaling or current limit ratio DIP switches to the desired position see Potentiometer Function Details on page 43 Ifavailable use an external resistor connected to the Continuous Current Limiting Pin based on the values given on the drive datasheet see Continuous Current Limit Pin on page 41 2 If further current limiting is necessary use the Current Limit potentiometer to fine tune the current limit to a final value see Potentiometer Function Details on page 43 Example A 30A8 drive is going to be used with an application having a continuous current requirement of 1 5 amps and a continuous current limit of 2 5 amps and a peak current requirement of 6 amps and a peak current limit of 10 amps The 30A8 has a Current Scaling and Current Limit Ratio switch a Current Limit potentiometer and the option of using an external resistor to reduce the continuous current limit This example will only use the DIP switches and potentiometer 1 Typically it is recommended to set the current limits ofthe drive below the continuous and peak current limits of the motor or application allowing some headroom for safety In this case the drive cont
30. to motor current Hence the motor terminal voltage will be reduced by the voltage drop over the motor winding resistance IR resulting in a speed reduction Thus motor speed which is proportional to motor voltage terminal voltage minus IR drop varies with the load torque In order to compensate for the internal motor voltage drop a voltage proportional to motor current can be added to the output voltage An internal resistor adjusts the amount of compensation and an additional through hole resistor can be added to the location listed on the drive datasheet Use caution when adjusting the IR compensation level If the feedback voltage is high enough to cause a rise in motor voltage with increased motor current instability occurs Such a result is due to the fact that increased voltage increases motor speed and thus load current which in turn increases motor voltage If a great deal of motor torque change is anticipated it may be wise to consider the addition of a speed sensor to the motor e g tachometer encoder etc 2 6 8 Analog Position Loop Mode ADVANCE In this mode the feedback device is an analog potentiometer mechanically tied to the positioned object thus providing position feedback The wiper of the potentiometer is connected to one of the differential input terminals REF The command is an analog signal which is connected to the other differential input terminal REF It is recommended to use a tachometer to clos
31. 2 9 Environmental Specifications Environmental Specifications Parameter Description Baseplate Temperature Range See Drive Datasheet Humidity 90 non condensing Mechanical Shock 10g 11ms Half sine Vibration 2 2000 Hz 2 5g Altitude 0 3000m Shock Vibrations While analog drives are designed to withstand a high degree of mechanical shock and vibration too much physical abuse can cause erratic behavior or cause the drive to cease operation entirely Be sure the drive is securely mounted in the system to reduce the shock and vibration the drive will be exposed to The best way to secure the drive against mechanical vibration is to use screws to mount the drive against its baseplate For information on mounting options and procedures see Mounting on page 39 and the dimensional drawings and information on the drive datasheet Care should be taken to ensure the drive is securely mounted in a location where no moving parts will come in contact with the drive Caution ADVANCED 7A MOTION CONTROLS MNALHWIN 05 26 VA Integration in the Servo System P This chapter will give various details on incorporating an analog servo drive into a system such as how to properly ground the drive along with the entire system and how to properly connect motor wires power supply wires feedback wires and inputs into the analog servo drive 3 1 LVD Requirements The servo drives covered in the LVD Reference repo
32. A must match the through hole resistor values for phases B and C and the through hole capacitor value Notice for phase A must match the through hole capacitor values for phases B and C Tune the Current Loop Proportional Gain 1 Follow the steps outlined in Current Loop Proportional Gain Adjustment on page 50 up through Step 8 2 Observe the drive current response on an oscilloscope Small step tuning is different than large step tuning so adjust the function generator square wave amplitude so the drive outputs a current step similar to what will be expected in typical operation Ifthe current response does not rise quickly enough to the step input command or if it never reaches the input command the equivalent resistance of the current loop proportional gain resistor will need to be increased This will increase the current loop proportional gain and achieve a faster more aggressive response Ifthe current response overshoots the step input command the equivalent resistance ofthe current loop proportional gain resistor will need to be decreased This will decrease the current loop proportional gain and provide a slower more stable response 3 Finding an acceptable equivalent resistance may take a few iterations As outlined in the previous section using pin receptacles or an external potentiometer will make the process easier Remember to remove power from the drive prior to removing or adding any components to the PCB Al
33. ESSE eS Max Continuous 4 ho r Fr r m k i Current Limit Current Measured 1 Current Measured 2 Current Measured 3 t t 2 e The closer the commanded current is to the peak current limit the shorter the peak output time will be e Any command at or below the maximum continuous current limit can be achieved for as long as there are no fault conditions present e When the drive is configured for any of the velocity modes the user is no longer in direct control ofthe current output The current commands will be determined by the velocity loop Though internally the current loop still functions like it is described above it will do only what is necessary to meet the velocity demand The current output depends on How tight the velocity loop is tuned Theload characteristics The speed the motor is already turning Magnitude and slope of velocity step Non Foldback Current Limiting On S Series and Direct PWM BD and DD drives if the RMS current through any motor phase rises above the maximum continuous current value the over current fault output pin will trigger a fault state and the drive will be disabled until the RMS current value has returned to a value within the acceptable operating range Typically this results in the drive output rapidly switching on and off several 100 Hz until the command signal is reduced to a value below the continuous current rating of the
34. Feedback Specifications FIGURE 2 7 Encoder Feedback Signals Encoder A l Encoder A Example 1 Encoder A precedes Encoder B The pulses arrive at a certain frequency providing speed and directional information to the drive Encoder B Encoder B l l l j l aaa Encoder At l l l l l Encoder A l l l l l Example 2 Encoder B precedes Encoder A meaning the direction is opposite from Example 1 The signal frequency is also higher meaning the speed is greater than in Example 1 Encoder Bt l l l Encoder B l l l l l l 2 5 3 Hall Sensors Three Phase Brushless drives use Hall Sensors for commutation feedback and in the special case of some drives for velocity control The Hall Sensors are built into the motor to detect the position ofthe rotor magnetic field These sensors are mounted such that they each generate a square wave with either a 120 degree or 60 degree phase difference over one electrical cycle ofthe motor FIGURE 2 8 Hall Sensor Commutation and Motor Phase Current for 120 Degree Phasing Conus Note Not all ADVANCED Motion High 1 Controls servo drive series use DA the same commutation logic kainan The commutation diagrams provided here should be used Mann only with drives covered within Hall B this manual Low 0 High 1 Hall C Low 0 Electrical Degrees Motor Phase
35. For electric motors the load is typically inductive due to the windings used to generate electromagnetic fields The current can be regulated in both directions by activating the appropriate switches When switch S1 and S4 or S2 and S3 are activated current will flow in the positive or negative direction and increase When switch S1 is off and switch S4 is on or S2 off and S3 on current will flow in the positive or negative direction and decrease via one of the diodes The switch ON time is determined by the difference between the current demand and the actual current The D YA MOTION CONTROLS MNALHWIN 05 Products and System Requirements Analog PWM Servo Drive Basics and Theory current control circuit will compare both signals every time interval typically 50 usec or less and activate the switches accordingly this is done by the switching logic circuit which also performs basic protection functions Figure 2 4 shows the relationship between the pulse width ON time and the current pattern The current rise time will depend on the bus voltage HV and the load inductance Therefore certain minimum load inductance requirements are necessary depending on the bus voltage FIGURE 2 4 Output Current and Duty Cycle Relationship Current ON time Time Pulse width 2 2 1 Single Phase Brushed Servo Drives Brushed type servo drives are designed for use with permanent magnet brushed DC motors PMDC motors
36. I O cables 3 2 2 Inductive Filter Cards ADVANCE Inductive filter cards are added in series with the motor and are used to increase the load inductance in order to meet the minimum load inductance requirement of the drive They also serve to counteract the effects of line capacitance found in long cable runs and in high voltage systems These filter cards also have the added benefit of reducing the amount of PWM noise that couples onto the signal lines Visit www a m c com products filter cards html for information on purchasing ADVANCED Motion Controls inductive filter cards D VA MOTION CONTROLS MNALHWIN 05 29 Integration in the Servo System Grounding 3 3 Grounding In most servo systems all the case grounds should be connected to a single Protective Earth PE ground point in a star configuration Grounding the case grounds at a central PE ground point reduces the chance for ground loops and helps to minimize high frequency voltage differentials between components All ground wires must be of a heavy gauge and be as short as possible The following should be securely grounded at the central PE grounding point Motor chassis Controller chassis Power supply chassis Analog Servo Drive chassis FIGURE 3 1 System Grounding Case Ground Wire see Shield Ground Wire Shielded Feedback Signal Cable Shielded Power Cable PE Ground x7 Signal Ground Controller Po
37. MAR NCED MOK CONTROLS Everything s possible Analog Drives for Servo Systems Hardware Installation Manual www d Mm C cOomM VA Preface ADVANCED Motion Controls constantly strives to improve all of its products We review the information in this document regularly and we welcome any suggestions for improvement We reserve the right to modify equipment and documentation without prior notice For the most recent software the latest revisions of this manual and copies of compliance and declarations of conformity visit the company s website at www a m c com Otherwise contact the company directly at ADVANCED Motion Controls 3805 Calle Tecate Camarillo CA 93012 5068 USA Agency Compliances The company holds original documents for the following e UL 5086 file number E140173 e Electromagnetic Compatibility EMC Directive 2004 108 EC EN61000 6 2 2005 EN61000 6 4 2007 e Electrical Safety Low Voltage Directive 2006 95 EC EN 60204 1 2006 e Reduction of Hazardous Substances RoHS 2011 65 EU Trademarks ADVANCED Motion Controls the combined isosceles trapezoid right triangle logo DIGIFLEX DIGIFLEX Performance and DriveWare are either registered trademarks or trademarks of ADVANCED Motion Controls in the United States and or other countries All other trademarks are the property of their respective owners Related Documentation e Product datasheet specific for your drive available
38. NOTION CONTROLS 3805 Calle Tecate e Camarillo CA 93012 5068 Tel 805 389 1935 Fax 805 389 1165 www a m c com
39. Scaling Standard drive tachometer inputs are typically pre configured such that the standard 60k input resistance scales the maximum tach input voltage to 60V The 60k tachometer input resistance is actually populated with a 50k resistor in series with a 10k resistor Most drives with a tachometer feedback input will also have either a through hole resistor location in parallel with the 50k resistor or tachometer scaling DIP Switch options FIGURE 4 1 Tachometer Input Resistance ANALOG SERVO DRIVE Optional Through Hole Tach Gain Yo Resistor AM Tachometer Input 50k 10k This allows users to reduce the effective input resistance to a value that more closely matches their maximum application feedback voltage in order to increase the tachometer input gain An appropriate tachometer input resistance value should be at least 1000 times the maximum tachometer voltage feedback value From zero to infinite resistance open connection this through hole location can scale the tachometer s maximum input voltage range from 10V to 60V To determine the maximum feedback voltage for the application 1 Determine the absolute maximum speed required of the motor for the application Sm in kRPM 2 Look up the tachometer s voltage to speed constant K in V kRPM 3 Calculate for the tachometer s maximum voltage output in the application y E Ky Ing max Example An application s maximum motor speed is 4 7 kRPM and the ta
40. The drive construction is basically as shown in Figure 2 3 PMDC motors have a single winding armature on the rotor and permanent magnets on the stator no field winding Brushes and commutators maintain the optimum torque angle The torque generated by a PMDC motor is proportional to the current giving it excellent dynamic control capabilities in motion control systems Brushed drives can also be used to control current in other inductive loads such as voice coil actuators magnetic bearings etc 2 2 2 Three Phase Brushless Servo Drives ADVANCE Three Phase brushless servo drives are used with brushless servo motors These motors typically have a three phase winding on the stator and permanent magnets on the rotor Brushless motors require commutation feedback for proper operation the commutators and brushes perform this function on brush type motors This feedback consists of rotor magnetic field orientation information supplied either by magnetic field sensors Hall Effect sensors or position sensors encoder or resolver Brushless motors have better power density ratings than brushed motors because heat is generated in the stator resulting in a shorter thermal path to the outside environment Figure 2 5 shows a typical system configuration D 7A MOTION CONTROLS MNALHWIN 05 Products and System Requirements Analog PWM Servo Drive Basics and Theory FIGURE 2 5 Brushless Servo System HV PA i eG f
41. and a low motor speed about 20 200 RPM Without the IR feedback the motor shaft can be stalled easily Decreasing the IR feedback resistor will make the motor shaft more difficult to stop Too much IR feedback i e too low a resistor value will cause motor run away when torque is applied to the motor shaft e Velocity Loop Encoder Halls or Tachometer The velocity loop response is determined by the Loop Gain potentiometer A larger resistance value clockwise results in a faster response The velocity integrator capacitor can be used to compensate for a large load inertia A large load inertia will require a larger capacitor value Either using the DIP switches to add in an extra capacitor or installing a through hole capacitor may accomplish this see Through hole Component Tuning on page 54 for more information The need for an extra capacitor can be verified by shorting out the velocity integrator capacitor by DIP switch setting If the velocity loop is stable with the capacitor ADVANCED 7A MOTION CONTROLS MNALHWIN 05 52 Operation Initial Setup and Features shorted out and unstable with the capacitor in the circuit then a larger capacitor value is needed Analog Position Loop Use of an encoder or tachometer is recommended to obtain a responsive position loop since the position loop is closed around the velocity loop First the velocity loop must be stabilized or voltage loop for undemanding applications The position
42. ase from any model 3 Version The version number is used to track minor product upgrades with the same model number and revision letter 01 is the earliest release of any revision 4 Proto Designation When included indicates that the model is a prototype unit and model number will also begin with an X designator 5 Serial Number The serial number consists of a 5 digit lot number followed by a 4 digit sequence number Each product is assigned a unique serial number to track product life cycle history 6 Date Code The date code is a 4 digit number signifying the year and week of manufacture The first two digits designate the year and the second two digits designate the week e g the drive label shown would have been built in the year 2011 during the 18th week ADVANCED VA MOTION CONTROLS MNALHWIN 05 62 Troubleshooting Warranty Returns and Factory Help 7 Inputand Output Power Data Includes basic power parameters of the product 8 General Information Displays applicable agency approvals UL file reference number and compliance approvals More complete product information is availabe by following the listed website B 2 2 Drive Model Information DC bus voltage and range Motor type brushed brushless AC induction Motor characteristics inductance torque constant winding resistance etc Position of all DIP switches Length and make up of all wiring and cables If brushless include Hall sensor
43. chometer is rated for 7 V kRPM Using the above equation the maximum voltage from the tachometer input Vmax will be 33V Therefore the equivalent tachometer input resistance must be at least 33k Choosing an equivalent resistance value of 35k solve for the required resistance of the through hole resistor 50 Vinax 500 _ 50 35 500 60 V 60 35 max Tach Gain Through Hole Resistor in kohm 50k As solved for above the equivalent 35k resistance can be acheived by adding a 50k through hok resistor in parallel with the existing 50k resistor on the drive tachometer input Scaling the tachometer input gain is not a required procedure for alll applications Most applications will work well even with low gains The effect of low gains is only a slower velocity loop response Notice ADVANCED 7A MOTION CONTROLS MNALHWIN 05 45 Operation Initial Setup and Features 4 1 6 Current Limiting Procedure Before operating a drive the current output of the drive must be limited based on motor and system current limitations Depending on the drive model ADVANCED Motion Controls analog servo drives feature a number of different current limiting methods However the procedure for setting the current limit will essentially be the same for each drive Consult the drive datasheet to see what current limiting options are available on a specific drive The current limiting steps should be taken with no power applied to
44. come gravity The system voltage requirement is based on the motor properties and how fast and hard the motor is driven The system voltage requirement is equal to the motor voltage Vy required to achieve the move profile In general the motor voltage is proportional to the motor speed and the motor current is proportional to the motor shaft torque Linear motors exhibit the same behavior except that in their case force is proportional to current These relationships are described by the following equations Pae due TE E KS for rotary motors T KI for linear motors F K ADVANCED 7A MOTION CONTROLS MNALHWIN 05 1 8 Products and System Requirements System Requirements Where Vin motor voltage ln motor current use the maximum current expected for the application Rin motor line to line resistance E motor back EMF voltage T motor torque F motor force K motor torque constant K motor force constant Ke voltage constant Sin motor speed use the maximum speed expected for the application The motor manufacturer s data sheet contain K or Kj and K constants Pay special attention to the units used metric vs English and the amplitude specifications peak to peak vs RMS phase to phase vs phase to neutral The maximum motor terminal voltage and current can be calculated from the above equations For example a motor with a K 10V Krpm and required speed of 3000 RPM would require 30V to operate In t
45. ctance and resistance as well as the bus voltage to obtain optimum performance Brush type and Brushless drives have a single current loop while Sinusoidal S Series drives have three current loops All three loops must be tuned the same or the drive will not operate properly The loop gain and integrator capacitance of the current loop must both be adjusted for the tuning to be complete Improper current loop tuning may result in permanent drive and or motor damage regardless of drive current limits Caution ADVANCED 7A MOTION CONTROLS MNALHWIN 05 49 Operation Initial Setup and Features Since most ADVANCED Motion Controls servo drives close the current loop internally poor current loop tuning cannot be corrected with tuning from an external controller Only after the current loop tuning is complete can optimal performance be achieved with the velocity and position loops The general current loop tuning procedure follows these steps 1 Determine if additional current loop tuning is necessary 2 Ifavailable tune the drive using the current loop DIP switches 3 Ifthe current loop cannot be satisfactorily tuned with the DIP switches then the current loop components must be changed Tune the current loop proportional gain Tune the current loop integral gain 4 Oncethe current loop is tuned then the velocity and or position loops may be tuned as well if necessary Current Loop Proportional Gain Adjustment The C
46. cycle MOSFET ON vs OFF suec time A system will need a certain amount of voltage and current to operate properly If the power supply has too little voltage current the system will not perform adequately If the power supply has too much voltage the drive may shut down due to over voltage or the drive may be damaged To avoid nuisance over or under voltage errors caused by fluctuations in the power supply the ideal system power supply voltage should be at least 1096 above the entire system voltage requirement and at least 1096 below the lowest value of the following Drive over voltage External shunt regulator turn on voltage see Regeneration and Shunt Regulators on page 23 These percentages also account for the variances in K and K and losses in the system external to the drive The selected margin depends on the system parameter variations Do not select a supply voltage that could cause a mechanical over speed in the event of a drive malfunction or a runaway condition Brushed Motors may have voltage limitations due to the mechanical commutators Consult the manufacturer s data sheets Caution ADVANCED 7A MOTION CONTROLS MNALHWIN 05 2 1 Products and System Requirements System Requirements Figure 2 12 provides one possible example of an appropriate system power supply voltage for an analog drive using an external shunt regulator The over voltage and under voltage shutdown levels on ADVANCED
47. drive DIP switch setting corresponds to the Hall phasing used on the motor See Hall Sensors on page 12 for more information For a brushless drive if the opposite motor direction is desired for a given command input interchange Hall 1 and Hall 3 then Motor A and Motor B B 1 4 Causes of Erratic Operation Improper grounding i e drive signal ground is not connected to source signal ground Noisy command signal Check for system ground loops Mechanical backlash dead band slippage etc Noisy inhibit input line Excessive voltage spikes on bus B 2 Technical Support For help from the manufacturer regarding drive set up or operating problems please gather the following information B 2 1 Product Label Description The following is a typical example of a product label as it is found on the drive FIGURE B 4 Product Label Long Product Label 2 5 x 0 5 Revision Version and Proto Model Number Website Address Designation B15A8 INV www a m c com UL Logo and File Ng Rev N Ver 03 PROTO Number After Barcode E140173 SN 57532 1023 Date 1118 A US Serial Number IN 20 80Vdc for AC Ph fHz RoHS OUT 7 5A Cont 15A Peak ol CE Logo 2D Barcode Serial Input and Output Date Code RoHS Compliant 1 Model Number This is the main product identifier The model number can have a suffix designating a change from the base model 2 Revision Letter Product revision level letter A is the earliest rele
48. e For a specific gain setting turn this potentiometer fully counter clockwise and adjust the command input to 1V Then turn clockwise while monitoring motor velocity or drive output voltage depending on mode of operation until the required output is obtained for the given 1V command Turning this potentiometer counter clockwise decreases the reference in gain while setting this potentiometer in the fully clockwise position makes the whole range of drive output available This potentiometer may be left in the fully clockwise position if a controller is used to close the velocity or position loops Test Offset This potentiometer acts as an internal command source for testing when the Test Offset switch is in the ON position If the Test Offset switch is in the OFF position then this potentiometer can be used to adjust a small amount of command offset in order to compensate for offsets that may be present in the servo system Turning this potentiometer clockwise adjusts the offset in a negative direction relative to the Ref input command Before offset adjustments are made the reference inputs must be grounded or commanded to 0 volts Ramp Time This potentiometer sets the ramp time for the command input signal The ramp time can be set for up to 30 seconds in reaching the max command by adjusting the potentiometer fully clockwise Ramping rates are linear with respect to time and apply to both directions of motion Test
49. e drive subsequently adjusts the output current based on the error between the tachometer feedback and the input command voltage The maximum range of the tachometer feedback signal is 60 VDC 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 Some drive models offer a through hole location listed on the specific drive datasheet where a resistor can be added to increase the tachometer gain Use the drive s block diagram to determine an appropriate resistor value See Tachometer Input Gain Scaling on page 45 for more information ADVANCED 7A MOTION CONTROLS MNALHWIN 05 13 Products and System Requirements Modes of Operation 2 6 Modes of Operation The family of analog drives offers a variety of different control methods While some drives in the series are designed to operate solely in one mode on other drives it is possible to select the control method by DIP switch settings see Potentiometer Function Details on page 43 for more information Consult the datasheet for the drive in use to see which modes are available for use The name of the mode refers to which servo loop is being closed in the drive not the end result of the application For instance a drive operating in Current Torque Mode may be used for a positioning application if the external controller is closing t
50. e shown in the individual data sheet specifications If the drive is operated below its maximum rated voltage the minimum load inductance requirement may be reduced Most servo motors have enough winding inductance Some types of motors e g basket wound pancake etc do not have a conventional iron core rotor so the winding inductance is usually less than 50 uH If the motor inductance value is less than the minimum required for the selected drive use an external filter card D VA MOTION CONTROLS MNALHWIN 05 Products and System Requireme ii This chapter is intended as a guide and general overview in selecting installing and operating an analog servo drive Contained within are instructions on system integration wiring drive setup and standard operating methods 2 1 Analog Drive Family Overview The analog drive family contains drives that can power Single Phase Brushed and Three Phase Brushless motors Analog drives are powered off either a single DC or AC power supply and provide a variety of control and feedback options The drives accept either a 10V analog signal a PWM and Direction signal or two sinusoidal command signals as input A digital controller can be used to command and interact with analog servo drives and a number of input output pins are available for parameter observation and drive configuration 2 1 1 Products Covered The products covered in this manual adhere to the following
51. e the velocity loop The input reference gain can be increased in the drive hardware for the Analog Position Loop Mode by ordering the ANP extension The following figure is a typical wiring diagram of Analog Position Loop Mode FIGURE 2 9 Analog Position Loop Mode Configuration Analog Servo Drive Motor Outputs D VA MOTION CONTROLS MNALHWIN 05 16 Products and System Requirements System Requirements 2 7 System Requirements NENNEN To successfully incorporate an analog servo drive into your system you must be sure it will operate properly based on electrical mechanical and environmental specifications follow some simple wiring guidelines and perhaps make use of some accessories in anticipating impacts on performance Before selecting an analog servo drive a user should consider the requirements of their system This involves calculating the required voltage current torque and power requirements of the system as well as considering the operating environment and any other equipment the drive will be interfacing with 2 7 1 Analog Servo Drive Selection and Sizing Analog servo drives have a given current and voltage rating unique to each drive Based on the necessary application requirements and the information from the datasheet of the motor being used a drive may be selected that will best suit the motor capabilities A drive should be selected that will meet the peak and continuous cur
52. east one of these options to operate safely Drive with Isolation Some ADVANCED Motion Controls analog drives come with standard electrical isolation while others can be ordered with isolation as an option see Figure 2 1 Analog Product Family Part Numbering Structure To determine if a drive has isolation refer to the functional block diagram on the drive datasheet The isolation will be indicated by a dashed line through the functional block diagram separating power ground from signal ground Drives with an I after the current rating in the part number i e 30A81 drives that are rated to 400 VDC and drives that take AC line voltage for power come standard with isolation Other drives that do not fall into these categories can be ordered by special request to include isolation Power Supply with Isolation An isolated power supply is either a battery or a power supply that uses an 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 ifthere is no isolation in the drive ADVANCED 7A MOTION CONTROLS MNALHWIN 05 22 Products and System Requirements System Requirements Regeneration and Shunt Regulators Use of a shunt regulator is necessary in systems where motor deceleration or a downward motion of the motor load wi
53. ent loop integral gain use larger value equivalent capacitors to correct for overshoot or oscillation and smaller value equivalent capacitors for a quicker response time D VA MOTION CONTROLS MNALHWIN 05 57 Troubleshooting This section discusses how to ensure optimum performance and if necessary get assistance from the factory B 1 Fault Conditions and Symptoms NENNEN An inoperative drive can indicate any of the following fault conditions over temperature over voltage under voltage short circuits invalid commutation inhibit input power on reset All of the above fault conditions are self reset by the drive Once the fault condition is removed the drive will become operative again without cycling power To determine whether the drive is in a fault state measure the Fault Output pin with a digital multimeter or voltmeter A high at this pin or a low depending on the drive model and configuration see drive datasheet will indicate that the drive is subject to one of the above fault conditions and the drive will be disabled until the drive is no longer in a fault state To remove the fault condition follow the instructions in the sections below describing each possible fault state Over Temperature verify that the baseplate temperature is less than the maximum allowable baseplate temperature as denoted on the drive datasheet typically 65 C 149 F or 75 C 1679F The drive remains disabled un
54. ents Magnetic Interference Coupling 31 Max Continuous Output Current 9 Max Peak Output Current 9 Max Power Dissipation at Continuous CUrrent ince rte Mechanical Shock Minimum Load Inductance pm Model Maski aaa na Modes of Operation Analog Position Loop Current Torque Duty Cycle Open Loop Encoder Velocity Hall Velocity IR Compensation Tachometer Velocity Voltage Mode Motion Control System Motor Run AWay Motor Back EMF Voltage Motor Chassis Motor Current Motor Current Frequency Motor Force MNALHWIN 05 Overload 59 Motor Problems 61 Motor Resistance 19 Motor Run Away 61 Motor Torque Constant 18 Motor Voltage 18 20 Motor Wiring eee 32 Mounting Options 39 Move Profile 17 Multiple Power Supply Wiring 33 N Negative Feedback 11 NOISE 31 Nominal Power Supply Voltage 20 O Overload npa namamana rene 59 Over Temperature 58 Over Voltage Shutdown 58 P Part Numbering Structure
55. eration The controller contains the algorithms to close the desired servo loops and also handles machine interfacing inputs outputs terminals etc The drive represents the electronic power converter that drives the motor according to the controller reference signals The motor which can be of the brushed or brushless type rotary or linear is the actual electromagnetic actuator which generates the forces required to move the load Feedback elements are mounted on the motor and or load in order to close the servo loop FIGURE 2 2 Typical Motion Control System Reference Current Controller Servo Drive Motor Feedback Load Feedback Although there exist many ways to amplify electrical signals pulse width modulation PWM is by far the most efficient and costeffective approach At the basis of a PWM servo drive is a current control circuit that controls the output current by varying the duty cycle of the output power stage fixed frequency variable duty cycle Figure 2 3 shows a typical setup for a single phase load FIGURE 2 3 PWM Current Control Circuit HV Command l Current Switching 5 Control Logic ak i do i IE Current Feedback S3 s4 S1 S2 S3 and S4 are power devices MOSFET or IGBT that can be switched on or off D1 D2 D3 and D4 are diodes that guarantee current continuity The bus voltage is depicted by HV The resistor R is used to measure the actual output current
56. eries with the motor 10946 of motor resistance If available use any DIP switches to adjust the current loop integral gain capacitance The output should settle to a flat top with minimal current following error difference between commanded current and actual current There can be some overshoot but it should be less than 1096 Because the oscilloscope measurements are voltage representations of current the commanded and actual currents will most likely have different current to voltage scalings and tolerances Therefore even with perfect current loop tuning the two amplitudes scope traces may not Notice line up as shown in Figure 4 5 5 Ifthe square wave output overshoots too much or is over damped sluggish the current loop integrator capacitor will need to be changed to optimize the response See Through hole Component Tuning on page 54 for more information Voltage or Velocity Loop Tuning These adjustments should initially be performed with the motor uncoupled from the mechanical load Configure the drive for the desired operation mode using the DIP switch settings see the block diagram on the specific drive datasheet e Voltage Loop or Duty Cycle Loop Compensating the voltage loop requires the least amount of effort Turn the Loop Gain potentiometer clockwise until oscillation occurs then back off one turn e IR Feedback Loop Start with a very high or open IR feedback resistor with an unloaded motor shaft Comm
57. es to the Motor A Motor B and Motor C pins All six combinations must be tested to find the proper combination The correct combination should yield approximately identical motor speed in both directions If the motor runs slower in one direction or ifthe motor shaft has to be moved manually by hand to start the motor the combination is incorrect Motor speed can be verified by using the velocity monitor or by measuring the frequency of the Hall Sensors To begin connect the three motor wires in any order Apply power to the drive and slowly turn the Test Offset potentiometer in both directions Observe the motor speed for both directions Remove power from the drive and rewire the three motor wires for a different combination Test all six different combinations before proceeding Once the proper combination has been found set the Test Offset switch to Offset ground both reference inputs and then adjust the Test Offset potentiometer for zero speed Set the control mode suitable for the application If necessary to change the motor direction for a given command input interchange Hall 1 and Hall 3 then Motor A and Motor B Three Phase Brushless Drive with Brushed Motor Three Phase Brushless drives are also compatible with Single Phase Brushed motors However because there are no Hall Sensors on a brushed motor one of the following course of actions must be taken to properly commutate the drive ADVANCE Or Set the Ha
58. for download at www a m c com ADVANCED 7A MOTION CONTROLS z MNALHWIN 05 Il Attention Symbols The following symbols are used throughout this document to draw attention to important operating information special instructions and cautionary warnings The section below outlines the overall directive of each symbol and what type of information the accompanying text is relaying Note Pertinent information that clarifies a process operation or ease of use preparations regarding the product O Note Notice Required instruction necessary to ensure successful completion of a task or procedure gt Notice Caution Instructs and directs you to avoid damaging equipment Caution Warning Instructs and directs you to avoid harming yourself Warning Danger Presents information you must heed to avoid serious injury or death DANGER Revision History Document ID Revision Date Changes MNALHWIN 01 1 9 25 2009 Analog Product Family Hardware Installation Manual First Release MNALHWIN 02 2 5 13 2011 Discontinuation of B100A40 B100A40AC B60A40 B60A40AC B100A8 B100A20 MNALHWIN 03 3 5 30 2013 Addition of B060A400AC and B100A400AC MNALHWIN 04 4 6 30 2013 Discontinuation of S60A8 S100A8 S100A40AC SX30A8 MNALHWIN 05 5 1 13 2015 Discontinuation of 25A20DD 16A20AC 25A201 30A20AC 30A8DD 50A20DD 50A201 50A8DD BD15A8 BD25A20AC BD25A201 BD30A8
59. for servo drives When choosing a shunt regulator select one with a shunt voltage that is greater than the DC bus voltage of the application but less than the over voltage shutdown of the drive Verify the need ADVANCED 7A MOTION CONTROLS MNALHWIN 05 24 Products and System Requirements System Requirements for a shunt regulator by operating the servo drive under the worst case braking and deceleration conditions If the drive shuts off due to over voltage a shunt regulator is necessary Continuous Regeneration In the special case where an application requires continuous regeneration more than a few seconds then a shunt regulator may not be sufficient to dissipate the regenerative energy Please contact ADVANCED Motion Controls for 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 Voltage Ripple For the most part ADVANCED Motion Controls analog servo drives are unaffected by voltage ripple from the power supply The current loop is fast enough to compensate for 60 Hz fluctuations in the bus voltage and the components in the drive are robust enough to withstand all but the most extreme cases Peak to peak voltage ripple as high as 25 V is acceptable There are some applications where the voltage ripple can cause unacceptable performance This ca
60. he motor With the wrong feedback polarity this will result in a positive feedback run away condition To correct this either change the order that the feedback lines are connected to the drive or consult the drive datasheet for the appropriate switch on the DIP switch bank that reverses the internal feedback velocity polarity See the drive datasheet and Switch Function Details on page 44 for more information on DIP switch settings 2 5 2 Incremental Encoder Analog servo drives that use encoder feedback utilize two single ended or differential incremental encoder inputs for velocity control The encoder provides incremental position feedback that can be extrapolated into very precise velocity information The encoder signals are read as pulses that the drive uses to essentially keep track of the motor s position and direction of rotation Based on the speed and order in which these pulses are received from the two encoder signals the drive can interpret the motor velocity Figure 2 7 represents differential encoder pulse signals showing how depending on which signal is read first and at what frequency the pulses arrive the speed and direction of the motor shaft can be extrapolated By keeping track of the number of encoder pulses with respect to a known motor home position servo drives are able to ascertain the actual motor location ADVANCED 7A MOTION CONTROLS MNALHWIN 05 1 1 Products and System Requirements
61. he motor power wires with the motor feedback wires even if they are shielded Although both of these cables originate at the drive 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 10cm for every 10m of cable length ADVANCED VA MOTION CONTROLS FIGURE 3 7 Feedback Wiring Avoid running feedback and power L together Motor Feedback Motor Power Motor Feedback Motor Power Separate power and feedback wires where possible MNALHWIN 05 34 Integration in the Servo System Wiring Hall Sensors Brushless drives accept single ended Hall Sensor feedback for commutation and velocity control Most drives also include a 6V 30 mA low voltage supply output that can be used to power the Hall Sensors Verify on the motor datasheet that the voltage and current rating of the supply output will work with the Hall Sensors before connecting FIGURE 3 8 Hall Sensor Input Connections ANALOG SERVO DRIVE V HALL Power for Hall Sensors Shield HALL A gt HALL B gt HALL C gt Signal Ground NE Chassis Ground Incremental Encoder Some drive models support either single ended or differential incremental encoder feedback If using a single ended encoder with a drive that accepts differential inputs leave the negative terminal open Both the A and B channels of
62. he position loop Oftentimes mode selection will be dependent on the requirements and capabilities of the controller being used with the drive as well as the end result application 2 6 1 Current Torque Mode In Current Torque Mode the input command voltage controls the output current The drive will adjust the output duty cycle to maintain the commanded output current This mode is used to control torque for rotary motors force for linear motors but the motor speed is not controlled The output current can be monitored through an analog current monitor output pin The voltage value read at the Current Monitor Output can be multiplied by a scaling factor found on the drive datasheet to determine the actual output current While in Current Torque Mode the drive will maintain a commanded torque output to the motor based on the input reference command Sudden changes in the motor load may cause the drive to be outputting a high torque command with little load resistance causing the motor to Note spin rapidly Therefore Current Torque Mode is recommended for applications using a digital position controller to maintain system stability 2 6 2 Duty Cycle Open Loop Mode In Duty Cycle Mode the input command voltage controls the output PWM duty cycle of the drive indirectly controlling the output voltage Note that any fluctuations of the DC supply voltage will affect the voltage output to the motor This mode is recommended as a me
63. hen a few simple rules are observed As with any high efficiency PWM servo drive the possibility of noise and interference coupling through the cabling and wires can be harmful to overall system performance Noise in the form of interfering signals can be coupled e Capacitively electrostatic coupling onto signal wires in the circuit the effect is more serious for high impedance points Magnetically to closed loops in the signal circuit independent of impedance levels Electromagnetically to signal wires acting as small antennas for electromagnetic radiation From one part of the circuit to other parts through voltage drops on ground lines The main source of noise is the high DV DT typically about 1V nanosecond of the drive s output power stage This PWM output can couple back to the signal lines through the output and input wires The best methods to reduce this effect are to move signal and motor leads apart use an inductive filter card add shielding and use differential inputs at the drive Unfortunately low frequency magnetic fields are not significantly reduced by metal enclosures Typical sources are 50 or 60 Hz power transformers and low frequency current changes in the motor leads Avoid large loop areas in signal power supply and motor wires Twisted pairs of wires are quite effective in reducing magnetic pick up because the enclosed area is small and the signals induced in successive twist cancel ADVANCED Motion Controls
64. his calculation the IR term voltage drop across motor winding resistance is disregarded Maximum current is maximum torque divided by K For example a motor with K 0 5 Nm A and maximum torque of 5 Nm would require 10 amps of current Continuous current is RMS torque divided by Kj Motor Inductance The motor inductance is vital to the operation of analog servo drives as it ensures that the DC motor current is properly filtered A motor that does not meet the rated minimum inductance value of the drive may damage the drive If the motor inductance value is less than the minimum required for the selected drive use of an external filter card is necessary See Inductive Filter Cards on page 29 for more Caution information A minimum motor inductance rating for each specific drive can be found in the datasheet If the drive is operated below the maximum rated voltage the minimum load inductance requirement may be reduced In the above equations the motor inductance is neglected In brushless systems the voltage drop caused by the motor inductance can be significant This is the case in high speed applications if motors with high inductance and high pole count are used Please use the following equation to determine motor terminal voltage must be interpreted as a vector V Ry j L I E Where L phase to phase motor inductance maximum motor current frequency ADVANCED YA MOTION CONTROLS MNALHWIN 05 1 9 Products and Sys
65. information Type of controller and full description of feedback devices Description of problem instability run away noise over under shoot etc Complete part number and serial number of the product Original purchase order is helpful but not necessary B 3 Warranty Returns and Factory Help Seller warrants that all items will be delivered free from defects in material and workmanship and in conformance with contractual requirements The Seller makes no other warranties express or implied and specifically NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE The Seller s exclusive liability for breach of warranty shall be limited to repairing or replacing at the Seller s option items returned to Seller s plant at Buyer s expense within one year ofthe date of delivery The Seller s liability on any claim of any kind including negligence for loss or damage arising out of connected with or resulting from this order or from the performance or breach thereof or from the manufacture sale delivery resale repair or use of any item or services covered by or furnished under this order shall in no case exceed the price allocable to the item or service or part thereof which gives rise to the claim and in the event Seller fails to manufacture or deliver items other than standard products that appear in Seller s catalog Seller s exclusive liability and Buyer s exclusive remedy shall be release of the Buyer from the obligation to pay the p
66. inuous current limit will be chosen at 2 amps and the peak current limit at 9 amps 2 Settingthe Current Scaling switch to OFF will scale the peak and continuous current limits by half yielding a peak limit of 15 amps and a continuous limit of 7 5 amps 3 Setting the Current Limit Ratio switch to ON will change the continuous to peak current ratio to 2596 yielding a peak limit of 15 amps and a continuous limit of 3 75 amps 4 Tofurther reduce the current limits to the desired values the Current Limit potentiometer can be used Begin with the continuous current requirement using the equation to determine the number of clockwise turns for the Current Limit potentiometer 2amps ft 12 41 POST Solving for the number of turns yields approximately 7 5 turns in the clockwise direction from the fully counter clockwise position 5 Since the continuous to peak ratio was set at 25 in Step 3 the number of turns calculated above will yield a peak current limit of approximately 8 amps thereby satisfying both the continuous and peak current requirements of the application ADVANCED JA MOTION CONTROLS MNALHWIN 05 46 Operation Initial Setup and Features 4 1 7 Drive Set up Instructions Single Phase Brush Type 1 It is recommended to reduce the drive output current to avoid motor over heating during the setup procedure Make sure the current has been set appropriately within the system and motor limits based
67. ional node in the chain adds to the amount of noise and unnecessarily loads the connectors in each link Analog Servo Drive Power Suppl Analog Servo Drive Analog Servo Power Supply Capacitance For AC input amplifiers AC power should be distributed from a central AC source not a capacitor Wire pairs should be routed together and twisted all the way back to the power source DC Power Supplies For drives using a DC power supply connect the transformer isolated DC supply high voltage to the DC Power Input terminal and the DC supply ground to the power ground terminal FIGURE 3 4 DC Power Supply Wiring Isolated DC Shield ANALOG SERVO DRIVE DC Power Input Power Supply GND J power Ground YY v O AA J _L Single Point PE Ground ADVANCED 7A MOTION CONTROLS Chassis Ground mb E System Ground MNALHWIN 05 33 Integration in the Servo System Wiring Single Phase AC Power Supplies Drives that accept only single phase AC line power include a standard 3 prong pluggable AC connector for attachment to an AC supply on the underside of the drive standard AC models or on the front face of the drive FAC models Standard ACconnector underneath drive FIGURE 3 5 Pluggable AC Line Connectors FAC drive model features AC connector on drive face Three Phase AC Power Supplies Drives that acce
68. itor output can be used to determine the motor RPM through the scaling factor See Velocity Monitor Output on page 42 for the motor RPM equation The high resolution of motor mounted encoders allows for excellent velocity control and smooth motion at all speeds Encoder Velocity Mode should be used for applications requiring precise and accurate velocity control and is especially useful in applications where low speed Note smoothness is the objective 2 6 5 Tachometer Velocity Mode In Tachometer Velocity Mode the input command voltage controls the motor velocity This mode uses an external DC tachometer to close the velocity loop The drive translates the DC voltage from the tachometer into motor speed and direction information DC Tachometers have infinite resolution allowing for extremely accurate velocity control However they also may be susceptible to electrical noise most notably at low speeds Note ADVANCED VA MOTION CONTROLS MNALHWIN 05 1 5 Products and System Requirements Modes of Operation 2 6 6 Voltage Mode In Voltage Mode the input reference signal commands a proportional motor voltage regardless of power supply voltage variations This mode is recommended for velocity control when velocity feedback is unavailable and load variances are small 2 6 7 IR Compensation Mode If there is a load torque variation while in Voltage Mode the motor current will also vary as torque is proportional
69. ive TABLE 4 2 Switch Function Details Switch Description Current Scaling Changes the sensitivity of the current sense thereby reducing the peak and continuous current limits by a given amount Current Loop Proportional Gain Adjustment Adjusts the proportional gain of the current loop For drive model S16A8 there are two Current Loop Proportional Gain switches that must be set to the same setting Current Limit Ratio Sets the continuous to peak current limit ratio to a given percentage The default setting for all drives is a continuous to peak current limit ratio of 5096 i e 12 amp peak limit 6 amp continuous limit Current Loop Integral Gain Activates or deactivates the current loop integral gain This switch is OFF by default For drive model S16A8 there are two Current Loop Integral Gain switches that must be set to the same setting RMS Current Limit Setting Sets the RMS current limit setting on sinusoidal input drives used to reduce the continuous current limit to a percentage of the maximum continuous limit Two RMS Current Limit Setting switches are used to set the percentage See the drive datasheet for specific switch configuration Peak Current Limit Sets the peak current to 50 or 100 of the maximum peak current limit on sinusoidal input drives Depending on the drive model there are either two or three Peak Current Limit switches that must all be set to the same setting
70. led can generate extremely high voltage spikes which will Caution damage the drive ANALOG SERVO DRIVE Motor C 3 4 3 Power Supply Wires The PWM current spikes generated by the power outputstage are supplied by the internal power supply capacitors In order to keep the current ripple on these capacitors to an acceptable level it is necessary to use heavy power supply leads and keep them as short as possible Reduce the inductance of the power leads by twisting them Ground the power supply cable shield at one end only to the servo drive chassis ground When multiple drives are installed in a single application precaution regarding ground loops must be taken Whenever there are two or more possible current paths to a ground connection damage can occur or noise can be introduced in the system The following rules apply to all multiple axis installations regardless of the number of power supplies used see Figure 3 3 ADVANCED 7A MOTION CONTROLS MNALHWIN 05 32 Integration in the Servo System Wiring capacitor instead Run separate power supply leads to each drive directly from the power supply filter Never daisy chain any power or DC common connections Use a star connection FIGURE 3 3 Multiple Power Supply Wiring These wiring schemes are commonly practiced but often contribute to noise problems Analog Servo Drive Power Suprffy Capaciyfice Analog Servo Each addit
71. line could be a cause for a false inhibit signal being given to the drive Power On Reset All drives have a power on reset function to ensure that all circuitry on the board is functional prior to enabling the drive The board will only be disabled momentarily and will quickly enable upon power up B 1 1 Overload Verify that the minimum inductance requirement is met If the inductance is too low it could appear like a short circuit to the drive and thus it might cause the short circuit fault to trip ADVANCED 7A MOTION CONTROLS MNALHWIN 05 5 9 Troubleshooting Fault Conditions and Symptoms Excessive heating of the drive and motor is also characteristic of the minimum inductance requirement not being met See drive datasheet for minimum inductance requirements B 1 2 Current Limiting Most analog servo drives incorporate a fold back circuit for protection against over current This fold back circuit uses an approximate Pe algorithm to protect the drive see Non Foldback Current Limiting on page 61 for S Series and Direct PWM drives current limiting description e Maximum peak current output level can be sustained for about 2 seconds e To actually achieve maximum peak current output for 2 seconds requires the current command to fully swing from peak in one direction to the other FIGURE B 1 Maximum Peak Current Foldback Max Peak Current Limit Positive Direction e Current Command Max Continuous
72. ll Sensor Commutation Phasing DIP switch for 60 degree phasing Leave all the Hall Sensor inputs on the drive open These inputs are internally pulled high to 5V creating a 1 1 1 commutation state see Table 4 3 above which is a valid state in 60 degree phasing Only use Motor A and Motor B output in this configuration Tie one ofthe Hall Sensor inputs on the drive to signal ground Since the Hall Sensor inputs are by default internally brought high to 5V this will put the drive in a commutation state where two Hall inputs are high and one is low as shown in Table 4 3 having all three Hall inputs pulled high is an invalid commutation state in 120 degree phasing Depending on which Hall Sensor input is tied to ground consult Table 4 3 to determine which two motor output wires will be conducting current for that specific commutation state D 7A MOTION CONTROLS MNALHWIN 05 48 Operation Initial Setup and Features Sinusoidal Drive S Series 1 Setthe current limit to 10 of motor current to avoid high speeds See the drive datasheet for current limiting options 2 Checkthe power and connect it to the drive Do not connect the motor lead wires 3 Make sure the drive is in an enabled state via all enable inputs See drive datasheet for details 4 Since the feedback and commutation on S Series analog servo drives is fed back to the external motion controller the setup procedure will be dependent on the type of controlle
73. ll cause the system s mechanical energy to be regenerated via the drive back onto the power supply FIGURE 2 13 Four Quadrant Operation Regeneration occurs when Torque and Velocity polarity are opposite Current Torque I Torque Velocity No Regen ll Torque Velocity Regen IV I Regenerating Motoring Counterclockwise Clockwise IV Torque Velocity Regen Il Torque Velocity No Regen Voltage Velocity Ul ll Motoring Regenerating Counterclockwise Clockwise This regenerated energy can charge the power supply capacitors to levels above that of the drive over voltage shutdown level If the power supply capacitance is unable to handle this excess energy or if it is impractical to supply enough capacitance then an external shunt regulator must be used to dissipate the regenerated energy Shunt regulators are essentially a resistor placed in parallel with the DC bus The shunt regulator will turn on at a certain voltage level set below the drive over voltage shutdown level and discharge the regenerated electric energy in the form of heat The voltage rise on the power supply capacitors without a shunt regulator can be calculated according to a simple energy balance equation The amount of energy transferred to the power supply can be determined through Where E initial energy Ef final energy These energy terms can be broken down into the approximate mechanical and electrical terms
74. low level signal interconnect cables to prevent pickup from external RF fields PWM Input Drives 5 AFair Rite model 0443167251 round suppression core must be fitted to the PWM input cable to reduce electromagnetic emissions MOSFET Switching Drives 6 A Fair Rite model 0443167251 round suppression core must be fitted at the load cable connector to reduce electromagnetic emissions 7 An appropriately rated Cosel TAC series AC power filter in combination with a Fair Rite model 5977002701 torroid placed on the supply end of the filter must be fitted to the AC supply to any MOSFET drive system in order to reduce conducted emissions fed back into the supply network IGBT Switching Drives 8 An appropriately rated Cosel TAC series AC power filter in combination with a Fair Rite model 0443167251 round suppression core placed on the supply end of the filter must be fitted to the AC supply to any IGBT drive system in order to reduce conducted emissions fed back into the supply network 9 A Fair Rite model 0443164151 round suppression core and model 5977003801 torroid must be fitted at the load cable connector to reduce electromagnetic emissions Fitting of AC Power Filters It is possible for noise generated by the machine to leak onto the main AC power and then get distributed to nearby equipment If this equipment is sensitive it may be adversely affected by the noise AC power filters can filter this noise and keep it from getting o
75. ly Velocity Monitor Output This pin provides an analog voltage output that is proportional to the actual motor speed The scaling factor for each individual drive can be found on the drive datasheet e For a drive in Encoder Velocity Mode substitute the voltage value read at the velocity monitor pin Vinonitop into the below equation to determine the motor RPM V monitor Scaling Factor 60 Number of encoder lines e For a drive in Hall Velocity Mode substitute the voltage value read at the velocity monitor pin Vmonitor into the below equation to determine the motor RPM Scaling Factor 120 Motor Velocity RPM V monitor Mot locity RPM otor Velocity RPM Number of motor poles ADVANCED 7A MOTION CONTROLS MNALHWIN 05 42 Operation Initial Setup and Features 4 1 2 Potentiometer Function Details All potentiometers vary in resistance from 0 to 50 kohm over 12 turns An additional full turn that does not effect resistance is provided on either end for a total of 14 turns When the end of potentiometer travel is reached it will click once for each additional turn Consult the drive datasheet to see which potentiometers are included on a specific drive TABLE 4 1 Potentiometer Function Details Potentiometer Description Loop Gain Adjustment This potentiometer must be set completely counter clockwise in Current Mode In Velocity Voltage or Duty Cycle Mode this potentiometer adjusts
76. manual for system design and installation Standard and Custom Models The drives in the tables below are the standard product line of ADVANCED Motion Controls analog servo drives Note that not all possible part number combinations from the product family numbering structure Figure 2 1 are offered as standard drives Please contact ADVANCED Motion Controls Sales Department for further information and details on custom drive solutions TABLE 2 1 Brushed 10V Analog DC Drives TABLE 2 5 Sinusoidal Input DC Drives Drive Number VDC Peak Current Cont Current Drive Number VDC Peak Current Cont Current Nominal A A Nominal A Arms 12A8 20 80 12 6 S16A8 20 80 16 8 25A8 20 80 25 125 SX25A20 60 190 25 12 5 30A8 20 80 30 15 S30A40 60 400 30 15 50A8 20 80 50 25 S60A40 60 400 60 30 120A10 20 80 120 60 S100A40 60 400 100 50 20A20 40 190 20 10 100A40 80 400 100 50 TABLE 2 6 Sinusoidal Input AC Supply Drives TABLE 2 2 Brushless 110V Analog DC Drives Drive Number VAC Peak Current Cont Current Nominal A Arms Drive Number VDC Peak Current Cont Current S30A40AC 45 265 30 15 Somma A S60A40AC 45 270 60 30 B15A8 20 80 15 75 BE15A8 20 80 15 75 BE15A8 H 20 80 15 75 B30A8 20 80 30 15 BE30A8 20 80 30 15 BX30A8 20 80 30 15 B25A201 40 190 25 12 5 BE25A201 40 190 25 12 5 BX25A20 60 200 25 12 5 B40A201 40
77. n become apparent where constant torque or force is critical or when the bus voltage is pulled low during high speed and high current applications If necessary the voltage ripple from the power supply can be reduced either by switching from single phase AC to three phase AC or by increasing the capacitance of the power supply The voltage ripple for a system can be estimated using the equation I PS V F R C f PS Where Vn voltage ripple Cps power supply capacitance Ips power supply output current Fr frequency factor 1 hertz The power supply capacitance can be estimated by rearranging the above equation to solve for the capacitance as _ Ips QE 2 PS Vs f ADVANCED 7A MOTION CONTROLS MNALHWIN 05 25 Products and System Requirements System Requirements The frequency factor can determined from 0 42 Fe m fof where fis the AC line frequency in hertz Note that for half wave rectified power supplies f f 2 The power supply output current if unknown can be estimated by using information from the output side of the servo drive as given below Vu dy eee P Vios 0 98 Where IM current through the motor Vps nominal power supply voltage VM motor voltage see Motor Current and Voltage on page 17 2 7 3 Environmental Specifications To ensure proper operation of an analog servo drive it is important to evaluate the operating environment prior to installing the drive TABLE
78. n the AC power signal The above mentioned AC power filters should be mounted flat against the ADVANCED 7A MOTION CONTROLS MNALHWIN 05 28 Integration in the Servo System CE EMC Wiring Requirements enclosure of the product using the two mounting lugs provided on the filter Paint should be removed from the enclosure where the filter is fitted to ensure good metal to metal contact The filter should be mounted as close to the point where the AC power filter enters the enclosure as possible Also the AC power cable on the load end ofthe filter should be routed as far from the AC power cable on the supply end of the filter and all other cables and circuitry to minimize RF coupling 3 2 1 Ferrite Suppression Core Set up If PWM switching noise couples onto the feedback signals or onto the signal ground then a ferrite suppression core can be used to attenuate the noise Take the motor leads and wrap them around the suppression core as many times as reasonable possible usually 2 5 times Make sure to strip back the cable shield and only wrap the motor wires There will be two wires for single phased brushed motors and 3 wires for three phase brushless motors Wrap the motor wires together as a group around the suppression core and leave the motor case ground wire out of the loop The suppression core should be located as near to the drive as possible TDK ZCAT series snap on filters are recommended for reducing radiated emissions on all
79. ncorporate over protection in the end users equipment These items should be included in your declaration of incorporation as well as the name and address of your company description ofthe equipment a statement that the servo drives must not be put into service until the machinery into which they are incorporated has been declared in conformity with the provisions of the Machinery Directive and identification of the person signing ADVANCED 7A MOTION CONTROLS MNALHWIN 05 2 7 Integration in the Servo System CE EMC Wiring Requirements 3 2 CE EMC Wiring Requirements The following sections contain installation instructions necessary for meeting EMC requirements General 1 Shielded cables must be used for all interconnect cables to the drive and the shield of the cable must be grounded at the closest ground point with the least amount of resistance 2 The drive s metal enclosure must be grounded to the closest ground point with the least amount of resistance 3 The drive must be mounted in such a manner that the connectors and exposed printed circuit board are not accessible to be touched by personnel when the product is in operation If this is unavoidable 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 Analog Input Drives 4 AFair Rite model 0443167251 round suppression core must be fitted to the
80. o include directional inhibit pins that disable motor motion in either the positive or negative direction typically used for limit switches These pins do not cause a drive fault condition They will follow the same logic either standard or inverted as the main inhibit enable input Continuous Current Limit Pin The Continuous Current Limit pin can be used to reduce the factory preset maximum continuous current limit without affecting the peak current limit of the drive by attaching an external resistor between this pin and signal ground Values for resistors and the corresponding reduction in continuous current are given on the drive datasheet This continuous current reduction comes secondary to any reductions made by DIP switch settings on the drive and the current limiting potentiometer ADVANCED 7A MOTION CONTROLS MNALHWIN 05 4 1 Operation Initial Setup and Features Fault Output This pin provides a 5V TTL output measured relative to signal ground that will indicate when the drive is subject to one of the following fault conditions inhibit invalid Hall State output short circuit over voltage over temperature or power up reset On most drive models this pin will read 5V High when the drive is in a fault state but some drives allow the logic to be reversed so that a OV Low fault output indicates a fault Analog drives automatically self reset once all active fault conditions have been removed For instance if the DC po
81. onse time A 1 Through Hole Tuning NENNEN Proper tuning using 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 The following are some helpful hints to make the loop tuning process easier e Use pin receptacles to reduce the need for soldering Some drives have pin receptacles that make it easy to change the tuning resistors and capacitors without the need for soldering Other drives do not have these receptacles so soldering is required To avoid the need to solder every time a tuning value needs to be changed a pin receptacle can be soldered into the the through hole location of the tuning component ADVANCED 7A MOTION CONTROLS MNALHWIN 05 54 Through hole Component Tuning Through Hole Tuning Use a potentiometer to find the correct current loop gain value A potentiometer can be used to continuously adjust the gain resistance value during the tuning process Install a potentiometer in place of the gain resistor Adjust the potentiometer while viewing the current loop response on an oscilloscope When the optimal response is achieved turn off the drive remove the potentiometer and measure the potentiometer resistance Use the closest resistor value available Note This method will not work if the optimal tuning value is beyond the range of the potentiometer This method also does not work f
82. or sine drives since it is difficult to keep the tuning values in the three current loops the same Progressively double the resistance value when tuning the current loop gain for faster results If the gain resistor needs to be increased during the tuning process the fastest results are achieved by doubling the resistance from the last value tried Use this method until overshoot is observed and then fine tune from there Be aware of any components that are in parallel with the values you are trying to tune On some drives there may be one or more gain resistors in parallel with the through hole resistor location The equivalent resistance value of the SMT resistors on the board and the additional through hole resistor will be limited by the smallest resistance value ofthe group of resistors in parallel Consult the block diagram on the drive datasheet to determine the specific resistor values The same situation can occur when trying to decrease the integrator capacitor value since capacitors in parallel will be added together Safety Always remove power when changing components on the drive Caution Float the oscilloscope and function generator grounds to avoid large ground currents Caution Decouple the motor from the load to avoid being injured by sudden motor movements DANGER Table A 1 lists the different through hole components that can be used for loop tuning Some models require more than one component that mu
83. part numbering structure However additional features and or options are readily available for OEM s with sufficient ordering volume Feel free to contact ADVANCED Motion Controls for further information FIGURE 2 1 Analog Product Family Part Numbering Structure A Motor Type E Additional Options blank Brushed drive ANP Analog Position Loop BorBX Brushless drive H Available Hall Velocity Mode dT INV Inverted Inhibit QD Quick Disconnect QDI Quick Disconnect with Inverted Inhibit blank 10 V Analog DC Torque Mode PWM S or SX Commutated Sine Wave Feedback Type blank Hall Sensors or None E Encoder and or Hall Sensors Peak Current Power Supply blank DC Power Supply AC AC Power Supply FAC AC Power Connecter Located in the Front Maximum peak current rating in Amps Isolation Option Optical Isolation Peak Voltage Peak voltage rating in Volts If 2 numbers used scaled 1 10 Drive Datasheet Each analog drive has a separate datasheet that contains important information on the modes and product specific features available with that particular drive ADVANCED 7A MOTION CONTROLS MNALHWIN 05 4 Products and System Requirements Analog Drive Family Overview including the functional block diagram of the specific drive s operation The datasheet is to be used in conjunction with this
84. power wires supply power from the drive to the motor Use of a twisted shielded pair for the motor power cables is recommended to reduce the amount of noise coupling to sensitive components e Forabrushed motor or voice coil twist the two motor wires together as a group e For a brushless motor twist all three motor wires together as a group Ground the motor power cable shield at one end only to the servo drive chassis ground The motor power leads should be bundled and shielded in their own cable and kept separate from feedback signal wires DO NOT use wire shield to carry motor current or power Caution The diagrams below show how an analog servo drive connects to a Brushed single phase and Brushless three phase motor Notice that the motor wires are shielded and that the motor housing is grounded to the single point system ground PE Ground The cable shield should be grounded at the drive side to chassis ground FIGURE 3 2 Motor Power Output Wiring MOTORE SERVO DRIVE ORT MOT shield 74 Shield Y 2 74 lal O H E v Ay Motor B c8 S xi MOT Lm T ATL ra C fet cis Gro i NA Motor A A Single Point assis Groun Single Point System Ground 1 System Ground Chassis Ground PE Ground NEL PE Ground If using relays or other means to disconnect the motor leads be sure the drive is disabled before reconnecting the motor leads to the drive Connecting the motor leads to the drive while it is enab
85. pt three phase AC line power have either a 5 contact AC input screw terminal or a 4 port AC input connector Connect a three phase AC supply to AC1 AC2 and AC3 or L1 L2 and L3 depending on the drive model On certain models a single phase AC supply can be connected to any two of the three AC terminals Consult the drive datasheet to determine if a specific drive model also accepts single phase AC FIGURE 3 6 Single or Three Phase AC Line Connections ANALOG SERVO DRIVE AC1 or L1 Shield Fs 3 Phase AC ZX Nf I AC2 or L2 Power e g AC3 or L3 FTN K 43 FUSE gt FUSE gt FUSE gt Single Point System Ground PE Ground Chassis Ground For Single phase AC Supply connect AC lines to any two of AC1 AC2 and AC3 Do not connect AC line neutral to ground 3 4 4 Feedback Wires Certain drive models include internal AC line fuses On models that do not include internal AC line fuses external fuses are recommended Consult the drive datasheet for recommended values Use of a twisted shielded pair for the feedback wires is recommended Ground the shield at one end only to the servo drive chassis ground Route cables and or wires to minimize their length and exposure to noise sources The motor power wires are a major source of noise and the motor feedback wires are susceptible to receiving noise This is why it is never a good idea to route t
86. r in use Consult the instructions for the external motion controller to determine the proper setup method 4 1 8 Tuning Procedure The standard tuning values used in ADVANCED Motion Controls analog servo drives are conservative and work well in over 9096 of applications However some applications and some motors require more complete current loop tuning to achieve the desired performance The following are indications that additional current loop tuning is necessary Motor rapidly overheats even at low current Drive rapidly overheats even at low current Vibration sound comes from the drive or motor The motor has a high inductance 10mH The motor has a low inductance near minimum rating of the drive Slow system response times Excessive torque ripple Difficulty tuning position or velocity loops Electrical noise problems High power supply voltage power supply is significantly higher than the motor voltage rating or near the drive s upper voltage limit e Low power supply voltage power supply voltage is near the drive s lower voltage limit The above indicators are subjective and suggest that the current loop may need to be tuned These can also be signs of other problems not related to current loop tuning The resistors and capacitors shown under the current control block on the datasheet block diagram determine the frequency response of the current loop It is important to tune the current loop appropriately for the motor indu
87. r ground or a separate current monitor ground depending on the drive model Consult the drive datasheet to determine the correct ground connection The current monitor provides an analog voltage output signal that is proportional to the actual drive current output The scaling factor for each individual drive can be found on the drive datasheet The drive must be connected to a load in order for the drive to output actual current Example Measurement The current monitor pin on a drive with a current monitor scaling factor of 4 A V is measured to be 1 3V This would mean the drive is outputting 4 A V 1 3V 5 2A ADVANCED 7A MOTION CONTROLS MNALHWIN 05 40 Operation Initial Setup and Features Current Reference Output Measured relative to signal ground the current reference provides an analog voltage output signal that is proportional to the command signal to the internal current loop The drive does not need to be connected to a load to read the current reference output The internal command current may differ from the actual drive output current due to certain conditions such as a small load drive faults undersized power supplies inhibited drive etc The command to the internal current loop can be solved for by the following equation I peak i command V eutt nt ref y max Where I ommand command current to the internal current loop Vcurrent ref Measured voltage at current reference pin Ipeak peak cur
88. recommends using the following hand crimp tools for the appropriate I O and Feedback cable and wire preparation Consult the drive datasheet to see which connectors are used on a specific drive Drive Connector Hand Crimp Tool Manufacturer and Part Number 16 pin 2 54 mm spaced friction lock header Molex P N 0638118200 Standard Density D sub headers Tyco P N 58448 2 High Density D sub headers Tyco P N 90800 1 3 4 1 Wire Gauge As the wire diameter decreases the impedance increases Higher impedance wire will broadcast more noise than lower impedance wire Therefore when selecting the wire gauge for the motor power wires power supply wires and ground wires it is better to err on the side of being too thick rather than too thin This becomes more critical as the cable length increases The following table provides recommendations for selecting the appropriate wire size for a specific current These values should be used as reference only Consult any applicable national or local electrical codes for specific guidelines TABLE 3 1 Current and Wire Gauges Current A Minimum Wire Size AWG mm Current A Minimum Wire Size AWG mm 10 20 0 518 60 10 5 26 15 18 0 823 80 8 8 37 20 16 131 120 6 13 3 35 14 2 08 150 0 53 5 45 12 3 31 200 00 67 4 AA TAN CONTROLS MNALHWIN 05 3 1 Integration in the Servo System Wiring 3 4 2 Motor Wires The motor
89. rent requirements of the application and operate within the voltage requirements of the system Motor Current and Voltage Motor voltage and current requirements are determined based on the maximum required torque and velocity These requirements can be derived from the application move profiles Figure 2 10 FIGURE 2 10 Example Velocity Torque and Power Curves 1 Cycle Time Torque Time Power is equal to Torque x Velocity Motor Voltage Vm and Motor Current Im should be chosen where power is at a maximum Power Time ADVANCED 7A MOTION CONTROLS MNALHWIN 05 1 7 Products and System Requirements System Requirements The motor current Ij is the required motor current in amps DC and is related to the torque needed to move the load by the following equation T Torque M K T Where KT motor torque constant The motor current will need to be calculated for both continuous and peak operation The peak torque will be during the acceleration portion of the move profile The continuous torque is the average torque required by the system during the move profile including dwell times Both peak torque and continuous or RMS root mean square torque need to be calculated RMS torque can be calculated by plotting torque versus time for one move cycle Here Tj is the torque and t is the time during segment i In the case of a vertical application make sure to include the torque required to over
90. rent value of the drive Vias voltage corresponding to maximum internal current command value found on drive datasheet on most drive models V nax 7 45V Example Measurement The current reference pin on a drive with a peak current value of 12A and Vmax of 7 45V is measured to be 2 63V Following the above equation to solve for Icommang the command current to the internal current loop would be 4 24A Inhibit Input This pin provides a 5V TTL input that allows a user to enable disable the drive by either connecting this pin to ground or by applying a 5VDC voltage level to this pin referenced to signal ground By default the drive will be enabled if this pin is high and disabled if this pin is low This logic can be reversed however either through DIP switch setting or by removing a SMT jumper from the PCB consult the drive datasheet to see which option is available note that removal of the SMT jumper must be done by a person familiar with SMT soldering and that the drive warranty will be voided if the drive is damaged This will require all inhibit lines to be brought to ground to enable the drive Most drives can also be ordered with inverted inhibit logic as well INV option Some drive models allow the drive to be configured so the inhibit input does not trigger a drive fault state Typically this is achieved by DIP switch setting Consult the drive datasheet to see if this option is available Directional Inhibits Some drives als
91. rmance through damage to equipment injury or death These consequences of course can be avoided by good design and proper installation into your mechanism 1 1 General Safety Overview ADVANCE In order to install an analog drive into a servo system you must have a thorough knowledge and understanding of basic electronics computers and mechanics as well as safety precautions and practices required when dealing with the possibility of high voltages or heavy strong equipment Observe your facility s lock out tag out procedures so that work can proceed without residual power stored in the system or unexpected movements by the machine Notice Notice You must install and operate motion control equipment so that you meet all applicable safety requirements Ensure that you identify the relevant standards and comply with them Failure to do so may result in damage to equipment and personal injury Read this entire manual prior to attempting to install or operate the drive Become familiar with practices and procedures that allow you to operate these drives safely and effectively You are responsible for determining the suitability of this product for the intended application The manufacturer is neither responsible nor liable for indirect or consequential damages resulting from the inappropriate use of this product High performance motion control equipment can move rapidly with very high forces Unexpected motion may occur especially
92. rt were investigated as components intended to be installed in complete systems that meet the requirements of the Machinery Directive In order for these units to be acceptable in the end users equipment the following conditions of acceptability must be met 1 European approved overload and current protection must be provided for the motors as specified in section 7 2 and 7 3 of EN60204 1 2 Adisconnect switch shall be installed in the final system as specified in section 5 3 of EN60204 1 3 Alldrives that do not have a grounding terminal must be installed in and conductively connected to a grounded end use enclosure in order to comply with the accessibility requirements of section 6 and to establish grounding continuity for the system in accordance with section 8 of EN60204 1 4 Adisconnecting device that will prevent the unexpected start up of a machine shall be provided if the machine could cause injury to persons This device shall prevent the automatic restarting of the machine after any failure condition shuts the machine down 5 European approved over current protective devices must be installed in line before the servo drive these devices shall be installed and rated in accordance with the installation instructions the installation instructions shall specify an over current rating value as low as possible but taking into consideration inrush currents etc Servo drives that incorporate their own primary fuses do not need to i
93. rtains to the maximum continuous current the drive can output according to hardware MG limitations An RMS rating can be obtained by dividing this value by JB Most drive models feature continuous current limit adjustments by the use of DIP switches or a potentiometer Some models also allow an external resistor to be connected between a continuous current limiting pin and signal ground as an additional method of current limiting Consult the drive datasheet to see which options are available For more information on setting the current limit see Current Limiting Procedure on page 46 Maximum Continuous Sine Wave Arms Pertains to the maximum continuous RMS current that S series sinusoidal drives can output Current indefinitely If the continuous RMS current output of the drive exceeds this value the drive output will be disabled The drive will re enable once the RMS current has returned to a level below the maximum continuous sine wave current Maximum Power Dissipation at Ww The power dissipation of the drive assuming approximately 5 power loss to heat dissipation Continuous Current Calculated by taking 5 of P Vsl at continuous current and peak bus voltage Internal Bus Capacitance uF The capacitance value between the internal DC bus voltage and power ground Internal Shunt Resistance W The resistance value of the internal shunt resistor Internal Shunt Resistor Power Ww The power rating of the internal shunt resistor Rating Internal Sh
94. s with the motor disconnected there is a possible short circuit in the motor wiring 3 Measure motor armature resistance between motor leads with the drive disconnected Verify these measurements against the motor datasheet to determine if there is a short or open circuit in the motor windings Invalid Hall Sensor State Brushless Drives only See the Commutation Sequence table in Hall Sensors on page 12 for valid commutation states If the drive is disabled check the following 1 Make sure that the Hall Sensor Commutation Phasing switch is in the correct setting per motor data sheets When driving a single phase brushed type motor with a three phase brushless drive use the 60 degree phase setting see Three Phase Brushless Drive with Brushed Motor on page 48 for more information on this particular configuration 2 Checkthe voltage levels for all the Hall Sensor inputs Turn the motor by hand while measuring the Hall Sensor inputs to verify that all three Hall Sensors are changing The voltage should read approximately 5V for a high 1 Hall state and approximately OV for a low 0 Hall state 3 Make sure all Hall Sensor lines are connected properly Inhibit Input Check inhibit input for correct polarity that is pull to ground to inhibit or pull to ground to enable Inhibit configuration depends either on the DIP switch settings or a 0 ohm SMT resistor marked on the board Also keep in mind that noise on the inhibit
95. se Brushless Drive with Brushed Motor Sinusoidal Drive S Series Current Loop Proportional Gain Adjustment Current Loop Integrator Adjustment Voltage or Velocity Loop Tuning Analog Position Loop MNALHWIN 05 vi A Through hole Component Tuning A 1 Through Hole Tuning A 1 1 Procedure anice Tune the Current Loop Propo rtional Gain Tune the Current Loop Integral Gain Velocity Loop Integral Gain T B Troubleshooting B 1 Fault Conditions and Symptoms Over Temperature Over Voltage Shutdown Under Voltage Shutdown Short Circuit Fault UNING uses ER ERE eR Invalid Hall Sensor State Brushless Drives only Inhibit IDIDUT sr Power On Reset B 1 1 Overoad exis x eheu B 1 2 Current Limifing Non Foldback Current Limitin B 1 3 Motor Problems B 1 4 Causes of Erratic Operation B 2 Technical Support LL B 2 1 Product Label Description B 2 2 Drive Model Information B 3 Warranty Returns and Factory Help Index I ADVANCED VA MOTION CONTROLS o CeO ea ee AA 54 54 56 56 56 57 MNALHWIN 05 vii VU Safety This section discusses characteristics of your analog servo drive to raise your awareness of potential risks and hazards The severity of consequences ranges from frustration of perfo
96. sions and mounting hole locations FIGURE 3 17 Analog Servo Drives Mounting Options alaala Mr iii ADVANCED JA MOTION CONTROLS MNALHWIN 05 3 9 4 Operation This chapter will describe the operation and setup of an ADVANCED Motion Controls analog servo drive 4 1 Initial Setup and Features NENNEN rr To begin operation with your analog servo drive be sure to read and understand the previous chapters in this manual as well as the drive datasheet Be sure that all system specifications and requirements have been met and become familiar with the capabilities and functions of the drive Also be aware of the Troubleshooting section at the end of this manual for solutions to basic operation issues Do not install the servo drive into the system without first determining that all chassis power has been removed for at least 10 seconds Never remove a drive from an installation with power applied Carefully follow the grounding and wiring instructions in the previous chapters to make sure your system is safely and properly set up 4 1 1 Pin Function Details The family of analog drives provide a number of various input and output pins for parameter observation and drive configuration options Not all drives will have each of the following pin functions Consult the drive datasheet to see which input output pin functions are available for each drive Current Monitor Output Measured relative to signal ground powe
97. so remember that it is not just the through hole resistor value that is important but the equivalent resistance of the through hole resistor and any SMT resistors that may be in parallel with the through hole location Use the block diagram on the drive datasheet to assist in determining the equivalent gain resistance 4 Usean equivalent resistance value that brings the current response right to the point of overshoot If there is a large amount of overshoot or if there are oscillations decrease the equivalent resistance value until there is little or no overshoot Depending on the application requirements a little overshoot is acceptable but should never exceed 1096 5 Whenan acceptable resistance value has been found remove power from the drive Tune the Current Loop Integral Gain 1 Afterthe proportional gain resistance has been adjusted to an acceptable value re enable the current loop integrator capacitor either through DIP switch or jumper settings depending on the drive model ADVANCED 7A MOTION CONTROLS MNALHWIN 05 56 Through hole Component Tuning Through Hole Tuning 2 Using the same function generator input command as in the previous section apply power to the drive and observe the current loop response on an oscilloscope 3 Depending on the drive model the current loop integrator capacitor can be changed or shorted out of the circuit by DIP switch setting Test both settings while observing the current loop
98. ssis M Ground 3 4 5 Input Reference Wires Use of a twisted shielded pair for the input reference wires is recommended Connect the reference source to REF IN and the reference source or common to REF IN Connect the shield to the servo drive chassis ground The servo drive s reference input circuit will attenuate the common mode voltage between signal source and drive power grounds In case of a single ended reference signal connect the command signal to REF IN and connect the command return and REF IN to signal ground Notice Long signal wires 10 15 feet and up can also be a source of noise when driven from a typical op amp output Due to the inductance and capacitance of the wire the op amp can oscillate It is always recommended to set a fixed voltage at the controller and then check the signal at the drive with an oscilloscope to make sure that the signal is noise free 10V Analog Input When using a 10V analog signal for an input command it is important to consider the output impedance of the analog source when interfacing to input circuitry A poorly designed 10V analog input interface can lead to undesired command signal attenuation Figure 3 11 shows an external analog source connected to an analog input The ideal voltage delivered to the input is Vs However the voltage drop across Rsource will reduce the signal being delivered to the drive input This voltage drop is dependent on the value
99. st have identical values Consult the drive datasheet to see which options are available for a specific drive Please contact ADVANCED Motion Controls Applications Engineering for assistance in determining the PCB location of the through hole component options for the drive model in use TABLE A 1 Through Hole Tuning Component Component Description Current Loop Proportional Gain Resistor Through hole resistor that can be added for more precise current loop tuning Current Loop Integrator Capacitor Through hole capacitor that can be added for more precise current loop tuning Velocity Loop Integrator Capacitor Through hole capacitor that can be added for more precise velocity loop tuning ADVANCED 7A MOTION CONTROLS MNALHWIN 05 Through hole Component Tuning Through Hole Tuning A 1 1 Procedure Before changing any components on the PCB follow the steps in Tuning Procedure on page 49 to determine if any additional tuning is necessary Observe the drive output current response on an oscilloscope for all the different DIP switch gain settings if available on the drive in use If further tuning is necessary or desired please contact ADVANCED Motion Controls before proceeding through the through following steps Remember that for Sinusoidal Input S Series drives all three current loops must have identical through hole component values i e the through hole resistor value for phase
100. supply leads Severe damage will result e f using relays or other means to disconnect the motor leads be sure the drive is disabled before reconnecting the motor leads to the drive Connecting the motor leads to the drive while it is enabled can o ra generate extremely high voltage spikes which will damage the drive QUTION Use sufficient capacitance Pulse Width Modulation PWM drives require a capacitor on the high voltage supply to store energy during the PWM switching process Insufficient power supply capacitance causes problems particularly with Caution high inductance motors During braking much of the stored mechanical energy is fed back into the power supply and charges its output capacitor to a higher voltage If the charge reaches the drive s over voltage shutdown point output current and braking will cease At that time energy stored in the motor inductance continues to flow through diodes in the drive to further charge the power supply capacitance The voltage rise depends upon the power supply capacitance motor speed and inductance ADVANCED 7A MOTION CONTROLS MNALHWIN 05 Safety General Safety Overview Caution ADVANCE Make sure minimum inductance requirements are met Pulse Width modulation PWM servo drives deliver a pulsed output that requires a minimum amount of load inductance to ensure that the DC motor current is properly filtered The minimum inductance values for different drive types ar
101. t see Input Reference Wires on page 36 2 4 2 PWM and Direction PWM and Direction Input is a specialized type of command that requires a compatible controller The controller needs two high speed TTL digital outputs to control these drives one for PWM and the other for Direction The PWM duty cycle corresponds to the magnitude of the output Direct control of the PWM switching puts response times in the sub microsecond range Since these drives don t take analog inputs for command the need for a D A converter for drive control is eliminated In Torque Mode PWM e g BDC drives the PWM input goes into a PWM to Analog converter The analog signalis then used as a command into the current loop resulting in a Current Mode drive controlled with PWM and Direction 2 4 3 Sinusoidal ADVANCE The S Series of analog servo drives use sinusoidal input signals as the command input Sinusoidal Input is a specialized type of command that requires a compatible controller with specialized commutation algorithms for proper operation Two sinusoidal command signals 120 degrees out of phase from the controller control the commutation and torque of the motor The controller is effectively closing the current loop by controlling the torque angle see Figure 2 6 All feedback goes to the controller not the drive including commutation feedback This allows a wide variety of feedback options limited only by the compatibility of the controller D
102. ted for IR Compensation Mode and deactivated for other modes Inhibit Logic Sets the logic of the inhibit pins to Active High or Active Low Input Range Selection Sets the voltage range of the sinusoidal command input pins The input range can be set to 5V or 210V Drives contain two Input Range Selection switches that must set to the same setting 4 1 4 Adjustable Acceleration and Deceleration Rate On some drive models the acceleration and deceleration rates can be set independently using through hole resistors The drive datasheet contains specific resistor values and the corresponding ramping time The rates are based on 10 volts to the reference inputs The time listed in the table on the drive datasheet is the time it takes to reach the 10 volt input The ramping rates are linear with respect to time For example if the input were only 5 volts the time to ramp to this voltage would be halfthe time to ramp to 10 volts These locations are silk screened on the PCB for easy identification Two SMT jumpers 0 ohm resistors are required to be set appropriately in order to enable adjustable acceleration deceleration rate control The default setting for both jumpers is to disable adjustable rate control The specific configuration of the jumpers for a drive are given on the drive datasheet ADVANCED 7A MOTION CONTROLS MNALHWIN 05 44 Operation Initial Setup and Features 4 1 5 Tachometer Input Gain
103. tem Requirements System Requirements 2 7 2 Power Supply Selection and Sizing There are several factors to consider when selecting a power supply for an analog servo drive Power Requirements Isolation Regeneration Voltage Ripple Power Requirements refers to how much voltage and current will be required by the drive in the system Isolation refers to whether the power supply needs an isolation transformer Regeneration is the energy the power supply needs to absorb during deceleration Voltage Ripple is the voltage fluctuation inherent in unregulated supplies Power Supply Current and Voltage The power supply current rating is based on the maximum current that will be required by the system If the power supply powers more than one drive then the current requirements for each drive should be added together Due to the nature of servo drives the current into the drive does not always equal the current out of the drive However the power in is equal to the power out Use the following equation to calculate the power supply output current Ips based on the motor voltage and current requirements r mMm PS Vpg 0 98 Where Vps nominal power supply voltage Im motor current Vu motor voltage Use values of Vn and Im at the point of maximum power in the move profile Figure 2 10 when Vulm max This will usually be at the end of a hard acceleration when both the torque and speed ofthe motor is high The power supply current is
104. the encoder are required for operation Drives that accept differential signals also accept an optional index channel that can be used for synchronization and homing If using the 5V 150mA or 250mA low voltage power supply output from the drive verify that the supply output voltage and current rating is sufficient for the encoder specifications FIGURE 3 9 Incremental Encoder Connections ANALOG SERVO DRIVE la Encoder Supply Output T signal Ground v A MOTOR ENC A MOTOR ENC A EncA Incremental Encoder Shield MOTOR ENC I MOTOR ENC I MOTOR ENC B MOTOR ENC B Enc B Chassis Ground ADVANCED 7A MOTION CONTROLS MNALHWIN 05 35 Integration in the Servo System Wiring Tachometer For drives that accept a Tachometer for velocity control connect the negative tachometer input to the tachometer input on the drive and connect the positive tachometer input to signal ground The drive must be in Tachometer Velocity mode in order to properly use the tachometer input See the drive datasheet for specific DIP switch settings The tachometer has a range of 60 VDC Certain drive models allow scaling of the allowable tachometer voltage range Consult the drive datasheet for tachometer scaling instructions FIGURE 3 10 Tachometer Input Connections ANALOG SERVO DRIVE Tachometer 60 VDC Tach Pia TACHOMETER INPUT y SIGNAL GROUND Cha
105. the gain in the velocity forward position of the closed loop Turning this potentiometer clockwise increases the gain Start from the full counter clockwise position turn the potentiometer clockwise until the motor shaft oscillates then back off one turn Current Limit This potentiometer adjusts the current limit of the drive To adjust the current limit first use any available DIP switches or external current limiting resistors to set the maximum current limits and ratios consult drive datasheet to see which options are available If further adjustment is necessary use the following equation to determine the number of clockwise turns from the full counter clockwise position necessary to set the desired current limit I of turns from full CCW 12 1 Tax Isystem the desired current limit of the system typically determined by motor current rating Imax maximum current capability of the drive this value is determined after any external current limiting resistors have been used and or any current scaling or current reduction DIP switches have been set If no DIP switches or external resistors have been used then Ima is the default maximum continuous current limit set by the drive hardware See Current Limiting Procedure on page 46 for an example of how to use this potentiometer Reference Gain This potentiometer adjusts the ratio between the input signal and the output variable voltage current velocity or duty cycl
106. thod of controlling the motor velocity when precise velocity control is not critical to the application and when actual velocity feedback is unavailable Note ADVANCED VA MOTION CONTROLS MNALHWIN 05 1 4 Products and System Requirements Modes of Operation 2 6 3 Hall Velocity Mode In Hall Velocity Mode the input command voltage controls the motor velocity with the Hall Sensor frequency closing the velocity loop An analog velocity monitor output allows observation ofthe actual motor speed through a Hz V scaling factor found on the drive datasheet The voltage value read at the velocity monitor output can be used to determine the motor RPM through the scaling factor See Velocity Monitor Output on page 42 for the motor RPM equation Due to the inherent low resolution of motor mounted Hall Sensors Hall Velocity Mode is not recommended for low speed applications below 300 rpm for a 6 pole motor 600 rpm for a 4 pole motor or 900 rpm for a 2 pole motor Hall Velocity Mode is better suited for velocity control Note applications where the motor will be spinning at higher speeds 2 6 4 Encoder Velocity Mode In Encoder Velocity Mode the input command controls the motor velocity with the frequency ofthe encoder pulses closing the velocity loop An analog velocity monitor output allows observation ofthe actual motor speed through a kHz V scaling factor found on the drive datasheet The voltage value read at the velocity mon
107. til the temperature at the drive baseplate falls below this threshold Over Voltage Shutdown 1 Checkthe DC power supply voltage for a value above the drive over voltage shutdown limit If the DC bus voltage is above this limit check the AC power line connected to the DC power supply for proper value 2 Checkthe regenerative energy absorbed during deceleration This is done by monitoring the DC bus voltage with a voltmeter or oscilloscope If the DC bus voltage increases above the drive over voltage shutdown limit during deceleration or regeneration a shunt ADVANCED 7A MOTION CONTROLS MNALHWIN 05 58 Troubleshooting Fault Conditions and Symptoms regulator may be necessary See Regeneration and Shunt Regulators on page 23 for more information Under Voltage Shutdown verify power supply voltages for minimum conditions per specifications Also note that the drive will pull the power supply voltage down if the power supply cannot provide the required current for the drive This could occur when high current is demanded and the power supply is pulled below the minimum operating voltage required by the drive Short Circuit Fault 1 Checkeach motor lead for shorts with respect to motor housing and power ground If the motor is shorted it will not rotate freely when no power is applied while it is uncoupled from the load 2 Disconnect the motor leads to see if the drive will enable without the motor connected If the drive enable
108. to the the mode selection table on the drive datasheet set the drive for Duty Cycle Open Loop Mode and set the Test Offset switch to Test 3 Checkthe power and connect itto the drive Do not connect the motor lead wires 4 Make sure the drive is in an enabled state via all enable inputs See drive datasheet for details 5 Setthe Hall Sensor Commutation Switch for the appropriate phasing typically 120 degree Connect the Hall sensor inputs The drive status LED should be GREEN Manually turn the motor shaft one revolution The LED should remain green If the LED turns red or changes between green and red check the Hall Sensor Commutation Switch check power for the Hall Sensors check the voltage level of the Hall inputs see Table 4 3 for 60 degree phasing interchange Hall 1 and Hall 2 for more information see Invalid Hall Sensor State Brushless Drives only on page 59 ADVANCED Z MOTION CONTROLS MNALHWIN 05 47 Operation Initial Setup and Features TABLE 4 3 Commutation Sequence Table 60 Degree 120 Degree Motor Hall 1 Hall 2 Hall 3 Hall 1 Hall 2 Hall 3 Phase A Phase B Phase C 1 0 0 1 0 0 HIGH LOW 1 1 0 1 1 0 HIGH LOW 5 1 1 1 0 1 0 LOW HIGH Valid 0 1 1 0 1 1 LOW HIGH 0 0 1 0 0 1 LOW HIGH 0 0 0 1 0 1 HIGH LOW a 1 0 1 1 1 1 Invalid 0 1 0 0 0 0 Remove power In all there are six different ways to connect the three motor wir
109. tput terminal will rise to the 5V supply indicating a fault condition FIGURE 3 14 PWM and Direction Optocoupled Inputs 5V supply input option PWM Input Signal Direction Input Signal ANALOG SERVO DRIVE 5V 5V Input 100 3500 GPWM MW i x v KA Toon m s 5V Y Input 5V LDIR 100 Wv u DIR MEE 5V FAULT j0 Fault Monitor Output n gt T p gt FAULT J Ground to Inhibit Open to Enable 5V Supply 5V Input a 100 W ES INHIBIT ing K GND 5V tSv Input L e On drives that do not contain an additional 5V input supply pin there are two options to activate the optocouplers The positive terminals of the PWM Direction Fault and Inhibit I O can be brought to an external 5V supply or the negative terminals of the PWM Direction Fault and Inhibit I O can be brought to ground FIGURE 3 15 PWM and Direction Optocoupled Inputs ANALOG ANALOG SERVO DRIVE SERVO DRIVE 5V il A pwm 100 PWM Input Signal PWM 7 VYV LI SS N PWM Input Signal Ts HE K GND n B 25k 5V ba LDIR Hoo Direction Input Signal DIR 100 VN u u lor NG I NG Direction Input Signal HE GND DIR HE 35k 5V 1 FAULT 190 Fault Monitor Output FAULT 100 AN gt Fault Monitor
110. unt Resistor Turn on VDC The turn on voltage of the internal shunt resistor Voltage Minimum Load Inductance uH 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 ADVANCED Motion Controls provides various accessories including inductive filter cards for a wide range of drives See Inductive Filter Cards on page 29 for more information Shunt Fuse A The current rating of the internal shunt resistor fuse Bus Fuse A The current rating of the input AC line fuses Switching Frequency kHz The switching frequency of the drive output power stage ADVANCED JA MOTION CONTROLS MNALHWIN 05 Products and System Requirements Command Inputs 2 4 Command Inputs NENNEN rr The input command source for analog servo drives can be provided by one of the following options Consult the drive datasheet to see which command source is available for a specific drive 2 4 1 10V Analog A differential or single ended 10V analog reference signal can be used to command the drive by adjusting the motor current voltage or speed depending on the mode the drive is operating in For information on the proper wiring of a 10V analog inpu
111. urchase price IN NO EVENT SHALL THE SELLER BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES Buyer will take all appropriate measures to advise users and operators ofthe products delivered hereunder of all potential dangers to persons or property which may be occasioned by such use Buyer will indemnify and hold Seller harmless from all claims of any kind for injuries to persons and property arising from use of the products delivered hereunder Buyer will at its sole cost carry liability insurance adequate to protect Buyer and Seller against such claims All returns warranty or non warranty require that you first obtain a Return Material Authorization RMA number from the factory Request an RMA number by web www a m c com download form form rma html telephone 805 389 1935 fax 805 389 1165 ADVANCED 7A MOTION CONTROLS MNALHWIN 05 6 3 A Index Symbols 10V Analog Command 10 10V Analog Input Wiring 36 A AC Power Supplies AC Supply Frequency AC Supply Voltage Range Adjustable Accel and Decel 44 Agency Compliances ii Altitude 26 Analog Position Loop Mode 16 Analog Position Loop Tuning 53 Attention SymbolS lil B Baseplate Temperature Range 26 Brushed 10V Analog DC Drives 5 Brushed Servo Drives
112. urrent Loop Gain should be adjusted with the motor uncoupled from the load and the motor secured as sudden motor shaft movement may occur The following points should be kept in mind before beginning the tuning procedure Brushless drives should be configured for 60 degree phasing in order to get output current The current can be measured through either motor phase A or B For Sinusoidal S Series drives connect the function generator to REF IN A and signal ground and measure the current through motor phase A 1 Usethe DIP switches and Current Limit Potentiometer to select Current Mode the input range if applicable and to set the appropriate current limit for the motor note that S Series drives are automatically in Current Mode 2 Connectonly the motor power leads to the drive No other connections should be made at this point 3 Using a function generator apply a 0 5 V 50 100 Hz square wave reference signal to the input reference pins 4 Shortoutthe current loop integrator capacitor s using the appropriate DIP switches or jumpers see the specific drive datasheet and block diagram for details 5 Apply power to the drive Use a bus voltage that is approximate to the desired application voltage or the current loop compensation will not be correct 6 The drive should be enabled GREEN LED Observe the motor current using a current probe or resistor in series with the motor 1096 of motor resistance This observation
113. wer Ground L Chassis Earth Ground Isolated DC Power Supply Single Point System Ground PE Ground Ground cable shield wires at the drive side to a chassis earth ground point The DC power ground and the input reference command signal ground are oftentimes at a different potential than chassis PE ground The signal ground of the controller must be connected to the signal ground of the drive to avoid picking up noise due to the floating differential servo drive input In systems using an isolated DC power supply signal ground and or power ground can be referenced to chassis ground First decide if this is both appropriate and safe If this is the case they can be grounded at the central grounding point For systems using AC power referenced to chassis ground the drive must have internal optical isolation to avoid a short through the the drive s diode bridge Grounding is important for safety The grounding recommendations in this manual may not be appropriate for all applications and system machinery It is the responsibility of the system designer to follow applicable regulations and guidelines as they apply to the specific servo Warning System ADVANCED 7A MOTION CONTROLS MNALHWIN 05 30 Integration in the Servo System Wiring 3 4 Wiring Servo system wiring typically involves wiring a controller digital or analog a servo drive a power supply and a motor Wiring these servo system components is fairly easy w
114. wer supply rises above the over voltage shutdown level of the drive the Fault Output will indicate a fault and the drive will be disabled Once the DC power supply level is returned to a value below the drive over voltage shutdown level the Fault Output will return to the normal state and the drive will automatically become enabled Low Voltage Power Supply Outputs Most drives include low voltage power supply outputs meant for customer use Consult the drive datasheet to see which low voltage outputs are included on a specific drive e 10V or 5V 3mA Output Typically used as an on board 10V analog input signal for testing purposes This output can be used in conjunction with an external potentiometer to vary the input signal between 10V e 6V 30mA Output Available on three phase brushless drive only This pin provides a 6 VDC output that can be used to power Hall Sensors Consult the motor datasheet to find out which feedback wire from the motor is the Hall Sensor power supply wire Do not use this 6V supply to power an encoder An encoder will require a separate power supply Consult the encoder datasheet or specifications to determine the encoder voltage and current requirements Typical values are 5VDC at 150mA Notice e 5V 150 mA or 250mA Output Can be used as power for an encoder Consult the motor or encoder datasheet to determine the appropriate encoder voltage and current requirements before connecting this supp

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