Operating Instructions
Contents
1. 12 maxon motor control September 2009 edition document number 555874 04 subject to change Operating Instructions 1 Q EC Amplifier DEC 24 1 7 Potentiometers 7 1 Potentiometer P1 Speed If jumper JP3 is plugged in the set speed value is adjusted at potentiometer P1 Speed Note Left end stop of potentiometers Minimum value see chapter 6 1 Right end stop of potentiometers Maximum value see chapter 6 1 7 2 Potentiometer P2 Imax Adjusting the continuous current limit in the 0 1 1 A range The current adjusted on the potentiometer is available for an unlimited period In the short term max 1 s a higher current is permitted Imax 2 lcont in which case the time depends on the current pattern s background After that time it is limited to the continuous current leont Example 1 If the current is at less than 90 of the continuous current for more than 10 s Imax iS permitted for another second If the motor is loaded for a long time in continuous current operation leont a higher current level is not permitted A 2 kon Oo SS es EEES Leon as e o Example 2 If the maximum current is required for less than 1 s the recovery time is shortened proportionately 2 0 9 ogg gt 222 boo 1 _ A _ __ __ _ gt 0 0 5 55 6 5 t s September 2009 edition document number 555874 04 subject to change maxon motor control 132. Hall sensors are needed for detecting rotor position Hall sensor inputs are protected against overvoltage Input voltage range 0 5 V Input impedance 10 kQ pull up resistor at 5 V Voltage value low max 0 8 V Voltage value high min 2 4 V Continuous overvoltage protection 24 24 V Suitable for Hall effect sensors IC using Schmitt trigger and open collector output 5 2 Outputs 5 2 1 Vee Hall Powering the Hall sensors Output voltage 4 5 5 VDC Max output current 30 mA Note When using long thin lines the voltage drop can be so great via the lines that the supply voltage falls below the minimum for Hall sensors The maximum cable length for the Hall sensors supply voltage between motor and controller is 10 m The minimum cross section is AWG 26 10 maxon motor control September 2009 edition document number 555874 04 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 24 1 5 2 2 Monitor n The actual speed of the motor shaft is monitored at the Monitor n output of the electronics The actual speed is available as a digital signal high low and is equivalent to a third the commutation frequency Output voltage range 0 45 V Output resistance 1 kQ low level max 0 6 V high level min 4 2 V Sought values Frequency at Monitor n output Nis 2 J Monitorn Ta l Az Nist Speed rpm Zpo Number of pole pairs Sought v
3. maxon motor 1 Q EC Amplifier DEC 24 1 Operating Instructions 8 Operating Status Display The green LED shows the operating status Definition LED on o e LED off 8 1 No green LED Cause e No supply voltage e Wrong polarity of supply voltage e Hall sensors supply voltage Vcc Hall is short circuited 8 2 Green LED constantly lit up Flashing type green LED Operating status LED on Amplifier activated everything OK 8 3 Green LED flashes every second Flashing type green LED Operating status UUULULULUU Amplifier in Disable status 8 4 Green LED flickers or flashes intermittently The controller recognises invalid conditions in the Hall sensor inputs Cause e Hall sensors not connected or incorrectly connected e Intermittent Hall sensor supply lines e Excessive interference to Hall sensor supply lines Solution change supply line feeds use shielded cable e Faulty Hall sensors in motor 8 5 Green LED flashes regularly The following error messages can be distinguished depending on flashing type Flashing type green LED Error message e Motor shaft is blocked e Load too great e Imax setting too low e No winding connection When switched on the controller recognises invalid conditions in the UUU 1MM Hall sensor inputs gt check Hall sensor wiring and Hall sensor signals Note e f the motor does not turn when in
4. Enable mode the motor shaft is blocked error message will always appear e Errors and error displays are temporary and do not have to be confirmed through Disable Enable 14 maxon motor control September 2009 edition document number 555874 04 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 24 1 9 Protection 9 1 Blockage protection If the motor shaft is blocked for longer than 1 5 s the current limit is set at 0 8 A provided the current limit was not set lower via Imax potentiometer 10 Block Diagram Hall Sensor 1 Y D Power Ground Hall Sensor 2 p gt y m D Motor winding 1 D Motor winding 2 Hall Sensor 3 Q 8 Bit D Motor winding 3 Micro Controller Voc Hall D Gnd Q Disable Y Direction P gt Speed gt 11 Dimensional Drawings Dimension in mm September 2009 edition document number 555874 04 subject to change maxon motor control 15
5. B X H occcononcccnnoncnnnnonnnonononcnnnnnncnn nana nnnanencnnnns see dimension drawing chapter 11 MOUNTINO PEN E A TETTE 4 hexagonal M3 distance pins with inner winding Mounting hole Separati0N oooonicccnonnncccnnonccnnnnncncnnnncnnnnnnrnr cnn racer 49 x 28 mm 2 11 Terminals Power Signal Screw terminal iesse atr EAE E its 7 pole Plica nae nh ieee dice eel ade aR 2 54 mm suitable for wire Cross SectiON ooooocccononcccnnoncnonanancnnnornnonnnancnnnnnn nos 0 14 0 5 mm AWG 26 20 Motor and Hall sensors Flat flexible cable connector top contact Styl8 oooccccononcccnonocccononcnnnnnancnnnnnnnnnnnancnn nan ncnnnnns 8 pole Pl ci EA a ios ei Adi s 0 5 mm or Flat flexible cable connector top Contact Styl8 ooooococononicccononcccnanoncnnnoncnonnnon cnc nan nnn cnn cnn 11 pole e a stencdoasdtetiect tees pavhaatid T eevee ans A Minette tinea 1 mm or Pin connector with snap in locking device oooooccononcccnnnoncnonanancnonencnonanan cnc nana nnnonarnnn naar nnnnnnns 8 pole a a 2 5 mm or ScreW terminal siii ts oie 8 pole A A A E A E E E 2 54 mm suitable for wire Cross SectiON ooooocccononcconnoncnonnnancnnnoncncnnnancnnnnnn nos 0 14 0 5 mm AWG 26 20 September 2009 edition document number 555874 04 subject to change maxon motor control 3 maxon motor 1 Q EC Amplifier DEC 24 1 Operating Instructions 3 Minimum Wiring 3 1 Operating mode Power supply 5 24 VDC 7 9 TEOSOS
6. OONAMARWN 20 OONOARWN x o NVAO NO 0 NOONA ON Pin assignment X7 Order number 249632 Motor winding 1 Motor winding 2 Motor winding 3 Vaar 4 5 5 VDC Gnd Hall sensor 1 Hall sensor 2 Hall sensor 3 x lt ANMARWNH gt ONOanhON Pin assignment X8 Order number 381510 Motor winding 1 Motor winding 2 Motor winding 3 Vaar 4 5 5 VDC Gnd Hall sensor 1 Hall sensor 2 Hall sensor 3 DNOARON XK 00 OANOaAhONM September 2009 edition document number 555874 04 subject to change maxon motor control 5 1 Q EC Amplifier DEC 24 1 Operating Instructions 4 Operating Instruction 4 1 Power supply layout Any available power supply can be used as long as it meets the minimum requirements set out below During set up and adjustment phases we recommend separating the motor mechanically from the machine to prevent damage from uncontrolled motion Power supply requirements Output voltage Voc min 5 VDC Vcc max 24 VDC Ripple lt 2 Output current depending on load continuous max 1 A acceleration short time max 2 A The required voltage can be calculated as follows Known values Operating torque Ms mNm Operating speed ns rpm Nominal motor voltage Un V Motor no load speed at Un No rpm Speed torque gradient of motor An AM rpm mNm ugg Sought values gt Supply voltage Vcc V Solution U An V n M 1 5V CE No B AM B Choose a p
7. SO 22 P1 P2 Pin assignment X1 Pin assignment X2 1 V 5 24 VDC 1 Motor winding 1 2 Gnd 2 Motor winding 2 3 Direction 3 Motor winding 3 4 Disable 4 Vaa 4 5 5 VDC 5 Brake 5 Gnd 6 Speed 6 Hall sensor 1 7 Monitor n 7 Hall sensor 2 8 Hall sensor 3 9 n c 10 n c 38 crp E Lae E p P1 z Si O DR AR AR AAA A ACER OR RARA A AE AAC A A i OW AR A AO AAR N RA AE AAA o K 3 set value 0 5V X1 Sn FG 6 oO vines ow a xs O Ele 3 32 E e rf E a E 5 oO ON O PH o set value 0 5V X1 To eH D 2 5 a See jo mon ora O Epo 4 maxon motor control September 2009 edition document number 555874 04 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 24 1 3 2 Pin assignment Pin assignment X4 Order number 318305 Motor winding 3 Motor winding 2 Hall sensor 3 Via 4 5 5 VDC Gnd Hall sensor 1 Hall sensor 2 Motor winding 1 DAIADAADON x lt A ANOnhWNM Pin assignment X5 Order number 249630 Vaan 45 5 VDC Hall sensor 3 Hall sensor 1 Hall sensor 2 Gnd Motor winding 3 Motor winding 3 Motor winding 2 Motor winding 2 10Motor winding 1 11Motor winding 1 Pin assignment X6 Order number 249631 Motor winding 1 Motor winding 2 Motor winding 3 Vita 4 5 5 VDC Gnd Hall sensor 1 Hall sensor 2 Hall sensor 3 x lt a A B
8. V Delay time approx 20 ms Note If the jumper setting was changed the new settings are adopted through a disable enable procedure 8 maxon motor control September 2009 edition document number 555874 04 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 24 1 5 1 3 Direction When the level changes the motor slows down in an uncontrolled fashion as windings are short circuited see also chapter 5 1 4 Brake and accelerates in the opposite direction until the nominal speed is reached again The Direction input is protected against overvoltage Input voltage range 0 45 V Input impedance 33 kQ pull up resistor at 5 V Continuous overvoltage protection 24 424V Delay time approx 20 ms Clockwise CW Input open or input voltage gt 2 4 V Set input to Gnd or Counter clockwise CCW input voltage lt 0 8 V If the direction is changed with a rotating motor shaft the limitations described in chapter 5 1 4 Brake must be observed or the amplifier may be damaged 5 1 4 Brake function If the connection is not wired up or the voltage set higher than 2 4 V the brake function is inactive Brake function not active Input open or input voltage gt 2 4 V motor windings not short circuited If the connection is placed at Gnd potential or the voltage is lower than 0 8 V the brake function is active and the motor shaft slows down to a standstill short cir
9. alues Motor shaft speed wi pee 20 a ar gt rpm Z Pol fmonitor n Frequency at Monitor n output Hz Zpo Number of pole pairs Note e Interference couplings into the Monitor n output such as through long lines should be avoided e The Monitor n output also functions in disable mode September 2009 edition document number 555874 04 subject to change maxon motor control 1 1 1 Q EC Amplifier DEC 24 1 Operating Instructions 6 Built in Jumpers Operating modes are adjusted using 3 jumpers 6 1 Setting mode speed range JP1 and JP2 are used to predetermine the operating mode speed control or open loop speed control as well as the speed range Motor type Jumpers JP1 and JP2 1 pole pair 4 pole pairs 8 pole pairs l Operation as open loop speed control 0 100 500 120 000 rpm 125 30 000 rpm 63 15 000 rpm A 500 40 000 rpm 125 10 000 rpm 63 5 000 rpm JP1JP2 o aes 500 10 000 rpm 125 2 500 rpm 63 1 250 rpm 6 2 Setting set value input JP3 is used to select the type of set value input external set value input or with potentiometer P1 Jumper JP3 Set value input ti oe cae Externally with Speed value input a ESPA B ME Internally with potentiometer P1 Note If the jumper setting was changed the new settings are adopted through a disable enable procedure see chapter 5 1 2
10. anaana airain a aa id aa aiaia 8 6 Built JUMPEEFS iii ae aea aeaaea aded adedi a da iaa edad 12 He Potentiometer NN 13 8 Operating Status Display io dai iia 14 9 A O oteaseaenesaee 15 10 Block Diagrami eeno aa aA E E A laa 15 We Dimensional Drawing S ngreine aaa a E e aAA aa aa ATAA A ENa TEEN Aaa i 15 The latest edition of these operating instructions may be downloaded from the internet as a PDF file under www maxonmotor com category Service amp Downloads order numbers 249630 249631 249632 318305 381510 or in the e shop http shop maxonmotor com maxon motor ag Br nigstrasse 220 P O Box 263 CH 6072 Sachseln Tel 41 41 666 1500 Fax 41 41 666 1650 www maxonmotor com maxon motor 1 Q EC Amplifier DEC 24 1 Operating Instructions 1 Safety Instructions Skilled personnel Only skilled experienced personnel should install and start the equipment Statutory regulations The user must ensure that the amplifier and the components belonging to it are assembled and connected according to local statutory regulations Load disconnected For initial operation the motor should be free running i e with the load disconnected Additional safety equipment Any electronic equipment is in principle not fail safe Machines and apparatus must therefore be fitted with independent monitoring and safety equipment If the equipment breaks down if it is operated incorrectly if the control unit breaks
11. cuiting the motor windings The motor windings remained short circuited until the orake function is deactivated again Brake function active Set input to Gnd or motor windings short circuited input voltage lt 0 8 V The brake function will be executed even if the power stage is disabled The Brake input is protected against overvoltage Input voltage range 0 45 V Input impedance 33 kQ pull up resistor at 5 V Continuous overvoltage protection 24 24 V Max brake current 10A Delay time approx 20 ms September 2009 edition document number 555874 04 subject to change maxon motor control 9 maxon motor 1 Q EC Amplifier DEC 24 1 Operating Instructions The maximum permitted brake speed is limited through the maximum permitted short circuit current and maximum kinetic energy e lt 10A e W 20Ws The values can be calculated as follows A The maximum permitted brake speed can be calculated from the motor data max permitted brake E ae speed limited by brake Minx 10A k pcan 19 rpm current I 10 A kn speed constant rpm V Rpn ph terminal resistance phase phase Q With the given moment of inertia the maximum speed can be determined using the following formula max permitted brake speed limited by kinetic 365 energy W 20 Ws Nmax 10 000 rpm R ar L Jr rotor inertia gem J load inertia gem 5 1 5 Hall sensor 1 Hall sensor 2 Hall sensor 3
12. down or if the cables break etc it must be ensured that the drive or the complete apparatus is kept in a safe operating mode Repairs Repairs may only be carried out by authorised personnel or the manufacturer It is dangerous for the user to open the unit or carry out any repairs Danger Ensure that no apparatus is connected to the electrical supply during installation of the DEC 24 1 After switching on do not touch any live parts Max supply voltage Make sure that the supply voltage is between 5 and 24 VDC Voltages higher than 28 VDC or of the wrong polarity will destroy the unit Short circuit and earth fault The amplifier is not protected against winding short circuits against ground safety earth and or Gnd Electrostatic sensitive device ESD Pie ieee Be PP 2 maxon motor control September 2009 edition document number 555874 04 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 24 1 2 Technical Data 2 1 Electrical data Supply voltage Voc ripple lt 2 oooocincccnonicinccononanonancnannnnnancnnn cn rancio non nc nan cn nn nrnn canario 5 24 VDC Max output voltage at max Output CUITEN 2 ee eeeeeeneeeeeeeeeeeeneeeeeeeneeetesaeeeereneeeeee Vcc 1 5 V Continuous output current leont s ccceeeeceeeeeeeeeseeeeececeaeeeeseaeeeceeaeececeuseeeeseaeeeeenaaeeeseneeeesssnseetsasees 1A Max Output cut limones ai aine ea Eaa ENS 2A Switching frequency of end stage ooooonccccoccccoccc
13. is 0 rpm 2 Adjust potentiometer P2 Imax to required limiting value With potentiometer P2 the maximum current can be adjusted in a range of 0 1 1A September 2009 edition document number 555874 04 subject to change maxon motor control 7 maxon motor 1 Q EC Amplifier DEC 24 1 Operating Instructions 5 Inputs and Outputs 5 1 Inputs 5 1 1 Set value Speed The analogue set value is predetermined at the Speed input The Speed input is protected against overvoltage Input voltage range 0 5 V ref Gnd Input impedance gt 1 MQ in range 0 5 V Continuous overvoltage protection 24 424 V Note If the set value is applied using the Speed input jumper JP3 must not be plugged in 5 1 2 Disable Enabling or disabling the power stage If the Disable connection is not wired up or a voltage set higher than 2 4 V the amplifier is activated Enable Release enable Input open or input voltage gt 2 4 V motor running If the Disable connection is connected to Gnd Potential or at a voltage lower than 0 8 V the power stage is high impedant and the motor shaft freewheels and slows down Disable Block disable Set input to Gnd or power stage switched off input voltage lt 0 8 V The Disable input is protected against overvoltage Input voltage range 0 4 5V Input impedance 33 kQ pull up resistor at 5 V Continuous overvoltage protection 24 24
14. maxon motor maxon motor control 1 Q EC Amplifier DEC 24 1 Order numbers 249630 249631 249632 318305 381510 Operating Instructions September 2009 edition The DEC Digital EC Controller is a 1 quadrant amplifier for controlling electronically commutated brushless DC motors with Hall sensors with a maximum output of 24 W e Digital speed control e Maximum speed 120 000 rpm Motor with 1 pole pair e Operation as speed controller or open loop speed control e Brake Direction and Disable input e Status indicator with green LED e Set value input through built in potentiometer several speed ranges can be selected or analogue set value input 0 5 V e Adjustable maximum current limit e Integrated chokes for very low impedant motors to operate at low loss e Current limit permits temporary twice the continuous current e Attachable adapter boards enable all kinds of maxon micromotors to be used e Speed can be monitored through the speed monitor output Table of contents T Safety IST CthOMS svi saci sede sae cba ace ca ela vaad ice ees the cease ceeeae ad eeeace desde as ceadh nd gesbereadeasalt nevis hvarscteeeguiasttabengcee 2 2 gt Technical Datta iii A la 3 E WATLING ofa can lea ireadacen ce cateavt beuaedaceadesdad edvap ec cecgeus dt aea ani anaana raaa iaaa aN aa aiaia aa adea daS 4 4 Operating INSTTUCUON luiiinidcdo td cd sekehacten dass phvesisbacl Gl a RA aa aed dd 6 5 INPUTS and QUIPUES iii a dl
15. noncnonnncnoncnonncn non cn nan cnn ran nnrnn carac rra 39 kHz Max Speed 2 pole motor ococooocccononcccnononcnonononcnononcnononon cnc nano nnn nn nn o nn nn n nr rrnnrn nn nnnnnnns 120 000 rpm Internal motor chokes per phaSC ocoocccccnocccononanonononcncnanoncncnano conc nano nn ramon cncnnnnos 150 uH 1 A 0 39 Q 2 2 Input SPCC PE ET T E A E E E ada Analogue input 0 5 V Resolution 1024 steps DisSapl Eniris easan tpai enaa giana TTL CMOS 5 V or switch to Gnd A sssaaa E E A TTL CMOS 5 V or switch to Gnd Brake a3 seccdsaseesevssccageaheerteezaueads esdusenseadensedecitne s lt tdensancateseecexghastee TTL CMOS 5 V or switch to Gnd EU OI Oe 1 2 3 2 3 Output Speed MONON ses seesecties hides it Digital output signal 5 VDC 1 KQ 2 4 Voltage output Hall sensors supply voltage Voc Hall ee eeeeeeeeeneeeeeeeneeesesneeeereneeeeeeeae 4 5 5 VDC max 30 mA 2 5 Motor connections Motor winding 1 Motor winding 2 Motor winding 3 2 6 Trim potentiometers Speed Imax 2 7 LED indicator Operating and fault display green LED 2 8 Ambient temperature humidity range Operativa aia 10 45C A E 40 85 C O disap esdsseedaapesesyencepeeicectavayeadeassl oaths steendeapieatensde 20 80 2 9 Protective functions Blockage protection Motor current limit if minimum speed is not maintained for 1 5 s 2 10 Mechanical data Wells incre EG approx 20 g Dimensions L x
16. ower supply capable of supplying this calculated voltage under load The formula takes into account a 1 5 V maximum voltage drop at nominal current at the power stage Note Please note chapter 5 1 4 Brake function when using the Brake input 6 maxon motor control September 2009 edition document number 555874 04 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 24 1 4 2 Adjusting the potentiometers 4 2 1 Pre adjustment With pre adjustment the potentiometers are set in a preferred posinan Units in the original packing are already pre set Pre adjustment of potentiometers Note Left end stop of potentiometers Minimum value Right end stop of potentiometers Maximum value 4 2 2 Adjustment Digital speed control 1 Depending on operating mode selected apply set value at the Speed input or with potentiometer P1 so that required speed is reached If necessary adjust maximum speed with built in jumper JP1 and JP2 At 0 set value the speed is NOT 0 rpm It depends on the pole pair number of the connected motor see chapter 6 1 2 Adjust potentiometer P2 Imax to required limiting value With potentiometer P2 continuous current can be adjusted in a range of 0 1 1A Digital open loop speed 1 Depending on operating mode selected apply set value at the Speed control input or with potentiometer P1 so that required speed is reached At 0 set value the speed
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