DMCLDC Closed Loop DC Drive User Guide
Contents
1. 20 20 20 Adjustments Setting the Potentiometers ee 21 Gain Potentiometer nennen nenne nnn nnns 21 Damping Potentiometer 21 Overcurrent Trip 21 CONTENTS Technical Specifications DMCLDC Drive Moduler 200 01 4 0 22 BITES MN RE 24 Mounting Information aE 25 RT PR EROR IE 25 Recommended Motors 26 IS 27 Motor TAC OI CG TNI UTRUM 27 MOTOR SOCCI Ca 1 28 231 nnn nnn nna an 28 Milsiogio d 22522 29 MRE SA 29 RE 30 PULA 2s 30 sale enc E ect een ees 31 arcas me EH 31 2 31 Blake 31 Introduction About This Manual The Axidyne Closed Loop Dc Drive Sy2. TOL O MATIC P N 36009070 RESET AND FAULT J1 has 12 terminal points User connections are required for a 5 30Vdc 1 J 1 4 source used in conjunction with Reset J 1 8 after fault Reset requires a normally closed contact to the external Vdc I O GND Vdc I O is usually derived from the controller providing the step and direction inputs Opening the contact resets the drive A form C solid state relay provides and contacts for fault indication 1 10 11 12 CTORS INDICATORS AND TIOMETERS ENCODER TERMINALS J2 has sixterminal points 2 1 and 6 provide 45V and ground for driving the encoder 2 2 3 4 5 are connections for the encoder pulses MOTOR TERMINALS J3 has four terminal points J 3 2 and are motor positive red motor lead and negative black motor lead terminals respectively FAULT INDICATORS LED s to indicate Position Error and Overcurrent Trip are located on the motor drive board at J4 J5 respectively POSITION ERROR LED The position error detector circuit shuts off faults the drive if the position error exceeds the preset limit The PD Proportional amp Derivative control loop in the closed loop dc drive calculates error by comparing the commanded position of the motor with its actual position provided via encoder feedback If that error is greater than 127 encoder counts then the position error will be active and will fault the driv
3. and connect them to the positive terminal of the 5 to 30Vdc power supply Vdc on the controller If the controller has sourcing outputs use steps 2a 3a and 4a for wiring SYSTEM WIRING CONTROLLER INTERFACE BOARD 2a Connect the Step or Pulse output on the controller to the PUL input on the drive Connect the Direction or CW CCW output on the stepper dic controller to the DIR input on the drive 4a Jumper the DIR and PUL inputs on the drive and connect SINKING OUTPUTS them to the negative terminal of the 5 to 30 Vdc power supply DIRECTION on the controller CD PULSE Theremaining terminals on the Controller Interface Board are wired at the factory as follows Dir Out is the isolated direction signal connected to J 1 7 the motor drive board Pulse Out is the isolated pulse signal connected to J 1 6 on the Motor Drive board TOL O MATIC 5V isthe 5Vdc supply to J 1 1 on the motor drive board GND is the ground for Vdc and also for the drive power bus connected to J 3 4 and also J 1 3 on the motor drive board V is the positive of the power bus 48Vdc connected to J 3 1 on the motor drive board SYSTEM WIRING Control Wiring to the Motor Drive Board RESET If the drive faults due to position error or overcurrent drive current will be shut off with no motor holding torque To reset this condition itis necessary to open a normally closed conne
4. EQ 0 187 4 75 2 498 2 495 Spacedona Square Key X MRBN Tip 01 06 63 45 63 37 0 3250 B C 4 1 00 25 4 Long 04 00 01 Encoders Encoder Overview Thisis a revolutionary modular type encoder using SMT technology to provide high reliability Sensors are set up differentially under a single LED light source Installation is simple usinga slide lock mechanism to align center and gap for maximum performance No adjustments are required and no mechanical rubbing occurs once installed The cover has an integral positive locking system which eliminates the usually required mounting hardware NOTE To extend the encoder leads use a grounded metal junction box Ensure continuity of the shield which should be single point grounded Features Self aligning Self centering Self gapping Frequency response to 100 KHz all channels Differential Index e Positivelock on cover Dimensions SLIDE LOCK ENCODER MECHANISM TOP 1 53 2 56 CLEARANCE HOLE COVER 4 40 CLEARANCE HOLE Notes Hamel MN 55340 612 478 8000 Telephone 612 478 8080 Fax http www tolomatic com
5. PECIFICATIONS Normally closed momentary contact for resetting faults Encoder Resolution 1000 counts per revolution 500 line encoder POTENTIOMETER INPUTS Current Trip Adjustment of torque limit Gain Position error adjustment between command and actual feedback signals Damping System settling time adjustment between the system natural frequency and operating frequency OUTPUTS Fault Output Form C solid state relay output for position or current trip setting Fault L E D Output Diagnostic indication of current trip or position error 45 Vdc L E D Output indicates power to DMCLDC Drive Module ENVIRONMENTAL Temperature 0 50 degrees C 32 122 degrees F Humidity 10 9596 non condensing TECHNICAL SPECIFICATIONS Module Dimensions 0 15 4 VR p i TECHNICAL SPECIFICATIONS DMCLDC Mounting LOCATION TheDMLDC moduleis designed to operate in an industrial environment however severe atmospheric contamination electrical noise or temperature extremes can affect system performance To avoid performance problems operate the DMCLDC system within the following environmental guidelines Operating Temperature 0 50 C 32 122 F Humidity 10 95 percent non condensing Leave sufficient room to the side of the module for screwdriver access to the gain damping and current trip adjustment potentiometers When mounting system components care should be taken not to place heat produ
6. R MOTION PRODUCTS DMCLDC Closed Loop DC Drive USER S MANUAL INC cellence in Motion 3600 4078 Copyright 1997 Tol O Matic Incorporated All rights reserved Axidyne and Tol O Matic are registered trademarks of Tol O Matic Incorporated All other products or brand names are trademarks of their respective holders Contents Introduction About this Manual nennen nnn nnns l S VNO 1 E ane aa 1 System Descriptions Scal m T T ence 2 Closed Loop 4 Closed Loop Dc DriveModule een 5 t 6 Connectors Indicators and Potentiometers Gaul mc c 7 Ac Power 1npUt ee 7 Controller Interface 8 Motor Drive Board 9 ET 9 POSU ON Error ED 10 Overcurrent TIP LED m 11 a 12 crm 12 12 Overcurrent TED 13 System Wiring Safety 7 15 OUR 15 assan ESEE 15 Encoder Motor Connection ee 17 ENCO TETTE 17 19 Wiring to the Controller 18 Control Wiring to the Motor Drive
7. cators Potentiometers Overview This section is intended to provide a comprehensive description of the DMCLDC Drive Module inputs outputs indicators connectors and adjustments Details on system wiring and adjustments follow Ac Power Input 115 Vac Neutral GND Terminals for ac power see Installation for wiring diagrams are mounted adjacent to the transformer on the main chassis plate CTORS INDICATORS AND TI OMETERS Controller Interface Board The controller interface board provides opto isolation for step and direction inputs from the controller It also provides the regulated 5V Vdc for use by the Motor Drive Board The stepper controller source must provide a non inverting pulse input either sinking or sourcing User collections required are pulse and direction signals with a 5 30 Vdc source NY CONNECTORS INDIC POTEN d Motor Drive Board The motor drive board regulates the voltage of the dc power buss to that required for the motor speed and load There arethree connectors for user hook up See system wiring for details L LI 27 slelo 84 R7 ce HP R9 C 2 R34 5 30 Vdc ve e eoooeceoo GL LHL OL 6 8 9 GS p Eje 1 42 Q 6 O O Q
8. cing devices underneath or near the DM CLDC unit Recommended Motors Recommended Motors OVERVIEW Axidyne brushed dc motors for use with closed loop drives are brush type permanent magnet servo motors with encoders A selection of motor speed torque characteristics is available to match Axidyne actuator applications The motors have permanent magnet poles on the stators and apply continuous power to the rotor through the brushes and commutator DC Motor Cross Section Feld fig 8 These motors are all complete with a 500 count per revolution two channel A amp B differential incremental encoder for feedback The encoder is used in the dual 2x mode providing resolution of 1 000 counts per revolution Axidyne Closed Loop Dc Drive systems have a typical final position error of 4 2 encoder counts System resolution is a function of screw pitch or belt drive wheel circumference any drive reduction ratio and the encoder resolution RECOMENDED MOTORS FEATURES Precision balanced rotors ABEC classbearings Ferrite magnetics Quiet motor designs Precision machined dimensions Common NEMA mechanical flanges simplify interfacing to standard gearboxes Two channel differential encoder 500 count used in dual 2x mode Motor Mounting Axidyne brush dc motors have Nema faces for in line applications mounting kits are used to attach Axidyne motors to Axidyne screw drive act
9. ction that is required to run between the Reset terminal J 1 8 and the ground of the external Vdc I O probably on the controller source of the 5 24dc Vdc 1 supply must be connected to 1 4 FAULT RELAY Jiterminals 10 11 12 are the connectors to a form C contact of a solid state relay which change state at error or overcurrent faults and can be used to provide remote indication of drive shut down NOTE Connection terminals not identified for interconnection on the motor drive board as on the controller interface board are not used Connection to them may cause damage to the drive module or Adjustments connected apparatus SETTING POTENTIOMETERS All three 25 turn pots The ranges and factory settings of the three potentiometers are Range Factory Setting Gain 0 35 to 1 75 Volts Encoder Count Full CCW 0 35 V Count Damping Oto 25 turns 10 turns back from full CW Current Trip 2 Amps to 15 Amps 2 Amps GAIN POTENTIOMETER The 25 turn gain pot can be set at maximum fully CW for most conditions The gain may need to be reduced for heavy load applications DAMPING POTENTIOMETER The 25 turn damping pot is best at maximum fully CW then turned back 5 to 10 turns CCW This gives the best compromise between good velocity regulation and overly aggressive velocity regulation Less damping will result in degraded velocity loop performance and may result in instability More damping may result in in
10. ding torque Using the latest pulse width modulation PWM drive technology Axidyne closed loop dc drives provide smooth quiet motor operation at low speed prolonged motor brush life reduced heat build up and reliable repetitive solid state reversing Dc Drive Module Configuration SYSTEM DESCRIPTION Features 10 Amp continuous 15 Amp peak power supply rating Position feedback accomplished via two channel amp B differential incremental encoder Proportional Derivative PD feedback loop for closing the loop around the motor Final position error of 2 encoder counts with repeatability typically 1 encoder count Position error 127 encoder counts and current trip faults Current trip point potentiometer for setting torque fault limit Fault status via solid state Form C output Current trip or Position error No motor holding torque whilein a fault condition Fault condition indication via 2 L E D sto indicate current trip and position error faults for field diagnostics Opto isolated external 1 0 power Vdc I O Potentiometer for Damping and Gain adjustment Opto isolated inputs pulse and reset and quad full Dedicated reset input for clearing fault condition Dedicated pulseand direction inputs for remote stepper type controller interface Five catalog dc brush servo motors in three frame sizes with encoders Connections Indi
11. e and light the LED 4 CONNECTORS INDIC POTEN d OVER CURRENT TRIP LED The over current trip circuit protects against overloading of the motor and actuator system while allowing high starting torque for systems with high inertial load The overcurrent detection circuit monitors motor current build up above a set value at any time during operation Refer to Installation for adjustment information When activated the circuit faults the drive and lights the Current Trip LED J5 fig 6 FAULT N C fo FAULT COM 1 FAULT LT CURRENT m TRIP L E D POSITION ERROR L E D gt CTORS INDICATORS AND TIOMETERS Potentiometers ONIdNVG fig 7 There are three adjustment potentiometers on the motor drive board GAIN Position error adjustment between the commanded and actual position feedback signal Proportional gain is the response to the current value of the error signal It is analogous to a spring constant where the larger the value the stiffer the spring The gain potentiometer is 25 turns CW CCW increases decreases the system gain respectively DAMPING System settling time adjustment between the system s natural operating frequency This is generally considered the damping of perturbations in position and velocity It is analogous to a shock absorber in a automobile The gain potentiometer is 25 turns CW CCW increases decreases the system damping respect
12. eed Torque 48 Volts mum 100 Duty KE 15 12 Volts 1000 r p m KE 15 83 Volts 1000 r p m 19 75 oz in Amp 20 35 oz in Amp Ha 0 97 Ohms Ha 0 51 Ohms Rotor Inertia 15 36 oz in 2 Rotor Inertia 20 48 oz in 2 Max Temp 105 Temp 105 F Weight 6 0 Ibs Weight 8 4 Ibs Dimensions MRB 341 342 MOTOR Leadwires MRB341 5 80 61 147 3 1 25 03 rom Frame MRB342 7 00 31 8 177 8 0 218 1383 20 8 42 4 Holes 0500 5 5 12 7 RECOMENDED MOTORS Model MRB 401 Model MRB 402 Speed Torque Characteristics Speed Torque Characteristics 4000 2000 3500 1750 gt 3000 gt 1500 2500 i 1250 2000 4000 1500 750 1000 500 500 250 0 0 0 100 200 300 0 200 400 600 TORQUE 2 TORQUE oz in 20 Duty 20 Duty Speed Torque 48 Volts p q mum 100 Duty Speed Torque 48 Volts mum 100 Duty KE 22 5 Volts 1000 r p KE 35 8 Volts 1000 m KT 30 5 oz in Amp KT 48 4 oz in Amp Ha 0 6 Ohms Ha 0 87 Ohms Rotor Inertia 100 67 oz in 2 Rotor Inertia 122 28 oz in 2 Temp 105 F 105 Weight 17 16 Weight 20 Ibs Dimensions Encoder Wire Hamess MRBN Models Only Motor Wire 16 Ga Red amp Black 24 610 Long Typical 1 2 NPT Lead Exit 0 512 502 13 00 12 75 3 251 623 05 15 88 15 82 101 6 1 4 20 UNC 28 0 10 L 101 6 401 402 085 06 Drill Depth
13. ively CONNECTORS INDIC POTEN d OVER CURRENT TRIP Used to adjust the maximum current allowed before faulting the drive Thisallows protection against overloading of motor and actuator system while allowing high starting torque for systems with high inertial load The overcurrent detection circuit monitors motor current build up above a set value at any time during operation The current trip pot is 25 turns CW CCW increases decreases the current trip level respectively This pot should be set after the system is tuned and programmed See page 19 for information about setting these potentiometers Notes System Wiring Safety Considerations When installing any motion control system safety should bea primary concern Axidyne hardware should be installed to conform with local and national electrical safety codes Failure to observe safe working practices when installing or servicing this equipment can expose you to dangerous voltages Grounding In general all electrical chassis and enclosures must be connected to earth ground through a grounding electrode conductor to provide alow impedance path for ground fault or noise induced currents A single point grounding setup is recommended and all earth ground connections must be continuous and permanent Prepare all other components and mounting surfaces prior to installation so that good electrical contact is made between the component enclosure and the mo
14. lack GND 6 White A 2 Yellow A 3 Green B 4 Blue B 5 Orange not used Brown not used SYSTEM WIRING MOTOR Connect the red and black motor leads to terminals 2 and Motor and Motor respectively of terminal block J3 on the Motor drive board Wiring to the Control Interface Instructions for connecting the DM CLDC drive to a generic stepper controller are provided below and are illustrated The pulse MANI and direction inputs to the drive are opto isolated on the Controller Interface Board 1 TheAxidyne DMCLDC drive has a non inverting pulse input A CONTROLLER non inverting pulse is alow going signal that advances the motor step when a high pulse is encountered Follow the directions sent with the stepper controller to send a non inverting pulse signal to the drive CD PULSE TheCLDC drive module can take either a sinking or a sourcing 45 30 DC 1 0 pulseindexer Consult the manual that is shipped with your stepper controller to see which one your controller has Most stepper controllers have sinking outputs for step and direction For sinking outputs use steps 2 3 and 4 for wiring 2 Connectthe Step or Pulse output on the controller to the PUL inputon the controller interface 0 3 Connect the Direction CW CCW output on the stepper controller to the DIR input on the controller interface 4 Jumper the DIR and PUL inputs on the drive
15. motion control systems consist of the following elements Motor Provides the torque and speed necessary for an actuator to meet application requirements Drive Converts the signal received from the controller or PLC to actually move the motor In addition the drive must convert the local power source typically 115 Vac 60 Hz to the power input required by the motor The power ratings watts of the motor and the drive must match the peak and RM S requirements of the application Controller Features I O connections to receive inputs from programmable logic controller PLC or other operator interface and convert them to output signalsto the drive moduleto properly control the motor and to achieve the required motion profile s Operator Interface An optional device used by the system operator to program tr signal the controller remotely The performance of an electric linear actuator system is determined by thetype of control system used with the actuator i e dc open loop brush servo stepper or ac brushless servo In general dc systems represent a low cost mature technology easily applied to meet basic linear motion needs SYSTEM DESCRIPTION Closed Loop Dc Drive System Theclosed loop dc drive system comprises a closed loop dc drive module DM CLDC and a dc brush servo motor The system requires step and direction signal inputs from a controller to operate as a positioning drive The motor embodies an encoder which pro
16. stability at low speeds OVER CURRENT TRIP POTENTIOMETER After the system is tuned and programmed the current trip should beset This is done by adjusting the 25 turn current trip pot CCW until the drive current trips while running at maximum load Then turn the pot 2 to 4 turns CW to allow operating margin Figure 7 on page 11 shows the potentiometers on the motor drive board Technical Specifications DMCLDC Drive Module Specifications POWER Input Voltage 85 132 Vac Frequency 60 Hz Current 7 Amp max Output Voltage 48 Vdc Continuous Current 10 Amp Peak Current 15 Amp Note 1 European Input power available on request as a modification 2 48Vdc is no load output 3 1 second operating at peak condition PERFORMANCE System Resolution 1000 counts per revolution Position Range Limited by remote step direction controller Velocity Range 50 000 pulses per second 3000 RPM when used With Tol O Matic MRB motors and encoders requires 1000 step rev for motor speed as shown Accel Range Limited by remote step direction controller Over Current Rating 125 of continus rating INPUTS Pulse step and Direction Signal Circuit Optically isolated Ohm input impedance Current 5 mA min 25 mA max 25 UDC max Direction Input Direction changed on transition Pulse step Input Drive steps on positive going transition Minimum step pulse width 10 microseconds Reset TECHNICAL S
17. stem is designed to provide Cost effective solutions for linear motion profiling and positioning where a separate source of step and direction input is available The Tol O Matic SSC controllers are appropriate as are stepper controllers within a host PLC This manual provides information necessary to configure install and operate these Axidyne system components in the selected application If you have difficulty configuring or installing your system please contact your local distributor for help or call Tol O Matic at 1 800 328 2174 SAFETY SYMBOLS The following symbols are used throughout this manual to alert the user to potential safety hazards Caution When this symbol appears exercise care to avoid the possibility of sustaining slight operator injury or equipment damage A WARNING When this symbol appears exercise extreme caution to avoid an IMMEDIATE DANGER of sustaining severe operator injury or irreparable equipment damage NOTE Failureto comply with cautions and requirements in this manual may result in damage to equipment not covered under Tol O Matic warranties CW CCW DEFINITION For all references in this manual clockwise or counterclockwise rotation of the motor shaft is as viewed when looking at the motor mounting face If the motor is direct coupled to aright hand screw actuator CCW rotation will move the carrier toward the motor System Description Overview Typical electronic linear
18. uators The kits include standard mounting plate spacer and fasteners NOTE Aflexible coupler between the motor shaft and the load is recommended to isolate the motor from vibration and to compensate for possible slight shaft misalignment Reverse parallel motor mountingis also available on screw actuators using an enclosed toothed belt drive with 1 1 or 2 1 ratio Motors may be direct coupled to belt drive actuators or drive through a 3 1 reduction box See Axidyne product catalog no 3600 4077 for details RECOMENDED MOTORS Model MRB 231 Speed Torque Characteristics KE 12 7 Volts 1000 m 4000 17 1 oz in Amp 3500 Ha 1 7 Ohms 3000 Rotor Inertia 1 92 oz in 2 2500 Temp 105 F 2000 Weight 3 5 Ibs 1500 1000 500 0 50 100 150 TORQUE oz in 20 Duty Speed Torque 48 Volts ENEN 100 Duty Dimensions ENCODER WITH INDEX AND 0 195 THRU 4 LINE DRIVERS EQ SPD ASSHOWN 551 082 ON A Q 2 625 B C PA 20 8 a ENCODER CABLE 2 91 18 457 2 LONG 733 1 500 1 498 38 1 38 0 FLAT 015 38 DP X 63 16 0 RECOMENDED MOTORS Model MRB 341 Model MRB 342 Speed Torque Characteristics Speed Torque Characteristics 4000 4000 3500 3500 gt 3000 gt 3000 2500 i 2500 2000 2000 1500 1500 1000 1000 500 500 0 0 0 100 200 TORQUE oz in TORQUE oz in 20 Duty 20 Duty Speed Torque 48 Volts mum 100 Duty Sp
19. unting surface Remove the paint from equipment surfaces where the ground contact will be bolted to a panel and use star washers to ensure solid bare metal contact Wiring AC Power To connect the DM CLDC to an ac power supply consult the wiring diagram WARNING AC power must be disconnected prior to installation of wiring Failureto observe safe working practices when installing or servicingthis equipment can expose you to dangerous volta ges SYSTEM WIRING 1 Connectthe BLACK lead to 115 Vac terminal 2 Connect WHITE wire to NEUTRAL terminal 3 Connect GREEN wire to ground NOTE The 115V source should be fused or breakered at no more than 15 Amps SYSTEM WIRING Encoder Wires ENCODER R47 i 2442 2 M OL 6 8 2 9 S t Ele OO QW J2 6 2 6 TOL O MATIC 777 36009070 There are six wires connecting the Encoder to the Drive Module Terminal connections are 45Vdc to power the encoder encoder GND and the other four are connected to the A and B channels and serve as the encoder feedback to the dc closed loop drive module Use of shielded cable is strongly recommended with the shield grounded at one end only WiretheTol O Matic encoder to the drive board terminal 2 as follows Wire Color Code Encoder Terminal Terminal Block Red 45V 1 B
20. vides speed and position feedback to the drive module to implement proportional and derivative closed loop control in a position controlling mode Tol O Matic offers a range of dc brush servo motors with torque speed characteristics to match the Axidyne family of actuators OPPEN CHASSIS OPTIONAL OPERATOR De DRIVE D C MOTOR ENCODER open chassis PLC closed loop via 1 PRC 222 drive cable Axidyne Power Suppl stepper Controller 48 vdc NOTE EUROPEAN SUPPLY VOLTAGE INPUT AVAILABLE 115 VAC 60 HZ BY REQUEST AS A MODIFICATION SYSTEM DESCRIPTION Closed Loop Dc Drive Module Available in an open chassis configuration the closed loop dc drive module consists of a closed loop dc drive and a 48 Vdc power supply Itis designed for single or multi axis applications with a positioning controller being supplied remotely It hasinputs for a pulsetrain and direction signal to be provided by an external stepper controller or PLC Tol O Matic s closed loop drive utilizes a PD proportional and derivative feedback loop for closing the loop around the motor TheClosed Loop Dc Drive module has three main functions 1 convert 115V 60 Hz supply power to the voltage and current level the motor requires to produce the desired speed and torque 2 respond appropriately to the controllers pulse train and an encoder feedback input to ensure that the desired motor profile position is achieved and 3 provide position hol
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