Operating Instructions
Contents
1. October 2008 Edition Doc No 544910 06 subject to change maxon motor control 13 maxon motor 1 Q EC Amplifier DEC 50 5 Operating Instructions 9 Operating Status Display Red and green LEDs show the operating status 9 1 No LED Reason e No supply voltage e Fuse blown e Wrong polarity of supply voltage e Hall sensors supply voltage Vcc Hall is short circuited 9 2 Green LED lED Amplifier active Disable function active 9 3 Red LED flickers or flashes intermittently The controller recognises invalid conditions in the Hall sensor inputs Reason 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 9 4 Red LED flashes regularly The following error messages can be distinguished depending on flashing type Flashing type red LED AAA Thermal overload protection is active e Motor shaft is blocked 1n irr e Load too great e Imax setting too low e No winding connection When switched on the controller recognises invalid conditions in the Hall sensor inputs gt check Hall sensor wiring and Hall sensor signals An invalid operating mode was set on UUUU LEILPLILI switches S3 S6 14 maxon motor control October 2008 Edition Doc No 544910 06 subject to chang2. om om om Lo mm TEN I am E E i mO LIS O e e g e 2 e lt 2 DW os E E E i ES e a f x E z amp 5 E gt ES gt lt 4 LO lt 4 H LO 29 g Gg eo Set value 0 maxon motor control 5 October 2008 Edition Doc No 544910 06 subject to change maxon motor 1 Q EC Amplifier DEC 50 5 Operating Instructions 4 Operating Instructions 4 1 Power supply layout Any available power supply can be used as long as it meets the minimum re quirements 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 Vcc min 10 VDC Veco max 50 VDC Ripple lt 5 Output current depending on load continuous max 5 A acceleration short time max 10 A The required voltage can be calculated as follows Known values Operating torque Ms mNm Operating speed ng rpm Nominal motor voltage Uy V Motor no load speed at Uy no rpm Speed torque gradient of motor An AM rpm mNm Uuuu Sought values gt Supply voltage Vcc V Solution U An 1 Vig np M 1V on Os AM e 095 Choose a power supply capable of supplying this calculated voltage under load The formula takes into account a max PWM cycle of 95 96 and a 1 volt max voltage drop at DEC 50 5
3. o o 0 x x x 5 u s c 2 ul 3 E o cos 6 5 9 e go OH E c D O 510 E o A Q9 E o c 2 o O o T co eo October 2008 Edition Doc No 544910 06 subject to change 4 maxon motor control maxon motor 1 Q EC Amplifier DEC 50 5 Operating Instructions 3 2 Current control and open loop speed control sbumes oBuei poods 38 om EC spou 75 c mL ueb zs Im XEUJ Ed dwey z peeds Zd L peeds Ld AreBuny ul ape AS 0 peeds GL Xnv vL e exelg L 2 unload ZL aiqesid LL puo e2S0 amp c WS AOS S 0S O3Q Tedy 93 0 1 1011002 10 OUI UOXBUI 10 0W uoxeuuJ vUlQ XBW eH 99A 40sues e H z 10sues eH 10sues JeH o ojojojo a ojo 2 J9MOg Bulpuim 100 z Bu puim 1040 Bulpuim 100 OGAO0S OL 99A pu JeMog olo o QO 2 o o D o o Power Supply 10 50VDC N T S 4T 5 Motor windings Hall sensors maxon EC motor 4 033009 uano 011u09 peeds doo uado Ast 0 en eA 19S Jeyeuionuejod eu181xe UM eul9yxe uim d AS 0 en eA 19S ejyeujonuejod ENE eul9yxe uli Set value O e
4. Note Please note chapter 5 1 5 Brake function when using the brake input 6 maxon motor control October 2008 Edition Doc No 544910 06 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 50 5 4 2 Adjusting the potentiometers 4 2 1 Pre adjustment With the pre adjustment the potentiometers are set in a preferred position DEC units in the original packing are already pre set P1 Speed 1 P2 Speed 2 Ramp P3 Imax Pre adjustment of potentiometers Per see 50 P2 Spe0s2 Ramp 50 Dm Ww 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 predetermine set value so that required speed is reached If necessary adjust max speed with switch S5 and S6 see chapter 7 Speed Ranges 2 Adjust potentiometer P3 Imax to required limiting value Maximum current in the 0 10 A range can be adjusted in linear fashion with potentiometer P3 3 Adjust switch S2 gain to required amplification S2 OFF gain high S2 ON gain low Important If the motor is unsteady vibrates or makes noises the se lected amplification is too high Switch S2 must be set at ON Digital current control 1 Adjust potentiometer P1 Speed 1 to required speed limit Maximum speed in the 500 25 000 rpm range motor with 1 pole pair can be adjus
5. 0 8 V min 2 4 V 50 50 V Suitable for Hall effect sensors IC using Schmitt trigger and open collector out put Powering the Hall sensors Output voltage Max output current 7 12 VDC 30 mA current limited October 2008 Edition Doc No 544910 06 subject to change maxon motor control 11 1 Q EC Amplifier DEC 50 5 maxon motor Operating Instructions 6 Switch Functions 123456 LL OFF 500 rpm 6 000 rpm 123456 L OFF Speed control with 2 different speeds 123456 L OFF Input Speed change between 2 speeds 7 Speed Ranges 123456 123456 123456 L LI o OFF OFF OFF Os SA Ben rpm 500 rpm soo EPR e mid oo e 25 000 rpm 60 000 rpm 120 000 rpm aee Br lc ene a UN EE OFF OFF Speed control Speed control Current control or with internal with external open loop potentiometer P1 set value speed controller Mc n E UM E city tye eas M LL Ld rum SU L Gain OFF high 123456 I Connection AUX OFF Output 5 V In the speed control mode the set value range 0 5 V is equal to the fol lowing speed ranges Type of motor Switch S5 and S6 Motor with 1 pole pair Motor with 4 pole pairs Motor with 8 pole pairs 123456 en an 500 6 000 rpm 125 1 500 rpm 67 750 rpm 123456 500 25 000 rpm 125 6 250 rom 67 8 125 rpm 123456 500 60 000 rpm 125 15 000 rpm 67 7 500 rpm 123
6. 456 500 120 000 rpm 125 30 000 rpm 67 15 000 rpm OFF Note e Independent of the position of the switches S5 and S6 the maximum speed can with the help of P1 Speed be adjusted only in the range 500 25 000 rpm 2 pole motors in current control mode For multi pole motors the speed range is shown in the table above e Operating as an open loop speed control the O V set value is equal to a motor voltage of O V and thus a speed of 0 rpm Independent of the posi tion of the switches S5 and S6 the maximum speed is given by the supply voltage and the speed constant of the motor 12 maxon motor control October 2008 Edition Doc No 544910 06 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 50 5 8 Potentiometer Functions The following table shows which potentiometer is active in which operating mode Mode Speed control Open loo p Current control p p closed loop speed control co x o no x 0 x o UE OE a g OE T OE a eg Eg co gt 2 8 co gt ee coo Fundionofpoen F 54 25 239 29 55 Leo 55 23 o o o x S 5 oH o xs occ gt tiometers 305 2397 o gt E sO o Lok 3 i geej 30 co 0 q 2 cot Ge co gt gt wT O o gt gt i nO gt gt k NO ae wt E se st z og n gt as og xt P1 Speed1 S S ii NIS Speed2 M S s S P2 Ramp E S S S S S S P3 max
7. 8 Edition Doc No 544910 06 subject to change maxon motor control 3 Operating Instructions maxon motor 1 Q EC Amplifier DEC 50 5 01Ju09 pasads ion ASO i sp ds PROC Jejeuionuejod anjen yas juelewip z euJejul uw euJe Xo uM i y x LI P ISP CS UlIM UUM 5 xew eq E o a o dwey z peeds Zd E FH Mom om om K EE Ke z BL EL EL om o i 7 ERN I Far mm O REE zi Erg ais am zi Ss peeds Ld MILI R MENS c mo mO ESI 2 A870 pads SL E 2 y po Sl I c Xnv vL lt i o e Vg EL EN i e uomoeig ZL 3 3 T me se aqsa Lt fo Sos jum eBunp ul apen 1 a k f uem ZZ5082 VS AOS S 05 O3Q pu OL o 9 2 lt y 7 1g 1g 29 jeyidui 23 07 ywog xeu eH 9A 6 o S lo E A K O onus T0190 Vore Y o ou uoxeu pesesie 8 0 O i9 go Ej E i A oa c 10SU9S eH 7 o O SE z E c Q PEA qc T A d Josues eH 9 o lt o E 5 gt 5 JeMog Buipuim Jojo S o lt 5 _ p o Oo z Bulpuim 100 y o lt 2 ES Duipuim Jojo o S8 ei a ol Eo a OGA0S 0L99A Z o 8 o g z UE J9MO o gt puo J8MOY o E 5 c e amp o gt
8. able x 30 cm on DEC 50 5 e Shield casing over motor Hall connection cable e Connect shielding on both sides or e Lowest resistive connection of motor housing and bottom of DEC 50 5 housing e Cable design of motor Hall connection cable as close as possible with aforementioned connection Analogue signals AUX Speed e No shielding normally required e Use cable shielding with analogue signals with small signal level and electromagnetically harsh environment e Normally connect shielding on both sides Place shielding on one side if there are 50 60 Hz interference problems Digital signals Disable Direction Brake e No shielding necessary See also block diagram in chapter 12 In practical terms only the complete equipment comprising all individual components mo tor amplifier power supply unit EMC filter cabling etc can undergo an EMC test to ensure interference free CE approved operation October 2008 Edition Doc No 544910 06 subject to change maxon motor control 15 maxon motor 1 Q EC Amplifier DEC 50 5 Operating Instructions 12 Block Diagram Case Ground t 5V 7 412Vg Safety Hall Sensor 1 gt 5VA earth optional v 10 50V Power Ground Hall Sensor 2 m Power Motor winding 1 Driver L 1 bo ho Motor winding 2 bo 1 I Motor winding 3 Hall Sensor 3 gt 8 Bit Micro Control
9. aueessceseeensuanssecesetensuaneseseserenseanersneees 1 2 3 2 3 Inputs outputs AUX Configurable sic 2 icit ierit cierto testes tot eere rtc teg digital input 5 VDC output 2 4 Voltage outputs Hall sensors supply voltage Voc Hall oooonococononacacononcninanancninarcnananancnnnno 7 12 VDC max 30 mA 2 5 Motor connections Motor winding 1 Motor winding 2 Motor winding 3 2 6 Trim potentiometers Speed 1 Speed 2 Ramp Imax gain 2 7 LED indicator Operating indicator green LED Error indicator red LED 2 8 Ambient temperature humidity range Operation inince alin 10 45 C ef LIE 40 85 C NES 20 80 2 9 Protective functions Heat monitoring of power stage sseesse eene emen T 100 Blockage protection Motor current limit if motor shaft is blocked for longer than 1 5 s 2 10 Mechanical data Wells E approx 155 y Dimensions LX W x H oooononnccnnnonicononcccnononononononcncnanencnnnnn cnn see dimension drawing chapter 13 Mounting plate civic aia for 4 screws M3 Mounting hole SeparatiON oococcnnnccccnnoncccnnnoncnnnnnnnonononnnnnnnn enne nnns 87 x 39 mm 2 11 Terminals PCB clamps plug in terminal clamps eseeeeeeeneneeeneneenn enn 15 poles Pit o Ehe Uter eee ed et 3 5 mm suitable for wire cross section 0 14 1mm multiple stranded or 0 14 1 3mm single wire AWG 16 26 October 200
10. celerates in the opposite direction until the nominal speed is reached again A speed ramp is only used during acceleration The Direction input is protected against overvoltage Input voltage range 0 5V Input impedance 33 kQ pull up resistor at 5 V Continuous overvoltage protection 50 50 V Delay time approx 12 ms Clockwise CW pull oper o input voltage gt 2 4 V Set input to Gnd or Counter clockwise CCW input voltage 0 8 V in chapter 5 1 5 Brake function must be observed or the amplifier may be If the direction is changed with a rotating motor shaft the limitations described damaged 5 1 4 Ramp function The ramp function enables the motor speed to have a controlled run up when it starts up and if set values change Acceleration time is adjusted at the potentiometer P2 Ramp and relates to the maximum speed in the currently chosen speed range see chapter 7 Speed Ranges adjustable acceleration time on the potentiometer P2 Ramp approx 20 ms approx 10 s Left end stop approx 20 ms Right end stop approx 10 s Pitch linear approx 1 0 s pitch Example Potentiometer P2 Ramp 40 Change in Speed set value 0 V to 3V Acceleration time to rated speed Acceleration time 40 10 s approx 2 4 s Note The minimum acceleration time can only be reached if the gain is high and the drive sufficiently dynamic October 2008 Edition Doc No 544910 06 subject to c
11. e maxon motor Operating Instructions 1 Q EC Amplifier DEC 50 5 10 Protection 10 1 Protection against heat overload If the power stage temperature exceeds a limit of around 100 C for longer than 1 5 s the output stage is switched off The error mode is shown in diagram form see chapter 9 Operating Status Display If the power stage temperature falls below 80 C the motor is restarted A speed ramp will be performed during acceleration 10 2 Blockage protection If the motor shaft is blocked for longer than 1 5 s the current limit is set at 4 2 A pro vided the current limit was not set at a lower value via the Imax potentiometer Note The blockage protection is not active in current control mode 11 EMC compliant installation Power supply Vcc Power Gnd e No shielding normally required e Star point shaped wiring if several amplifiers are supplied by the same power supply Motor cable gt 30 cm e Shielded cable highly recommended e Connect shielding on both sides DEC 50 5 side Bottom of housing Motor side Motor housing or with motor housing mechanical design with low resis tive connection e Use separate cable Hall sensor cable gt 30 cm e Shielded cable highly recommended e Connect shielding on both sides DEC 50 5 side Bottom of housing Motor side Motor housing or with motor housing mechanical design with low resis tive connection e Use separate cable Direct connection motor Hall c
12. g the following formula max permitted brake speed limited by kinetic 365 energy W 20 Ws Nmax al y 10000 rpm rt Jr Rotor inertia g cm J Load inertia gcm 10 maxon motor control October 2008 Edition Doc No 544910 06 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 50 5 5 1 6 AUX Switch S1 closed Switch S1 opened The AUX terminal can be used as input or output depending on the switch position The AUX terminal is only protected against overvoltage if switch S1 is open Function Output voltage Internal resistance Output current designed for an exter nal potentiometer gt 10 kQ Function Input voltage range Input impedance Continuous overvoltage protection Speed setting with potentiometer Speed 1 Speed setting with potentiometer Speed 2 Hall sensor 1 Hall sensor 2 Hall sensor 3 Hall sensors are needed for detecting rotor position Hall sensor inputs are protected against overvoltage 5 1 7 5 2 Outputs 5 2 1 Vcc Hall Input voltage range Input impedance Voltage value low Voltage value high Continuous overvoltage protection Voltage output 5 VDC 15 2200 500 pA Speed change 0 5V 33 kQ pull up resistor at 5 V 50 50 V Input open or input voltage gt 4 0 V Set input to Gnd or input voltage lt 1 0 V 0 45V 15 kQ pull up resistor at 5 V max
13. hange maxon motor control 9 maxon motor 1 Q EC Amplifier DEC 50 5 Operating Instructions 5 1 5 Brake function If the input is not wired or the applied voltage is greater than 2 4 V the brake function is deactivated If the input is placed at Gnd potential or the applied voltage is lower than 0 8 V the brake function is activated and the motor shaft slows down to a halt short circuiting the motor windings The motor windings remain short circuited until the brake function is deactivated The brake function is also used with an active disable function The Brake input is protected against overvoltage Input voltage range 0 45V Input impedance 33 kQ pull up resistor at 5 V Continuous overvoltage protection 50 50 V Max brake current 30A Delay time approx 12 ms Input open or input voltage gt 2 4 V Set input to Gnd or input voltage lt 0 8 V Brake inactive Brake active The maximum permitted brake speed is limited by the maximum permitted short circuit current and maximum kinetic energy e lt 30A e W lt 20 Ws the values can be calculated as follows The maximum permitted brake speed can be calculated from the motor data max permitted brake speed limited by brake n 30 A k Rpp 0 05Q rpm current MS dus Speed constant rpm V Rpp ph Terminal resistance phase phase With the given moment of inertia the maximum speed can be determined usin
14. hing on do not touch any live parts Max supply voltage Make sure that the supply voltage is between 10 and 50 VDC Voltages higher than 60 VDC or of wrong polarity will destroy the unit Short circuit and earth fault The amplifier is not protected against winding short circuits winding short circuits against ground safety earth or Gnd Electrostatic sensitive device ESD ie ie ee P PF RE 2 maxon motor control October 2008 Edition Doc No 544910 06 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 50 5 2 Performance Data 2 1 Electrical data Supply voltage Voc Ripple lt 5 96 10 50 VDC Max output voltage rerne eere eenean e E aaa eaae Eaa naaa E A aaisan ENNA 0 95 Vcc Continuous output current leoni ssccceeeeeeeeeeeeeeeeaeececeeeeeeecaeeecseaeeeeseeeeeeseeeeeecaeeesenseeesssnseeeseaees 5A Max output current Ima ooo toi eee eei iIIa ie 10A Switching TTequenCy oooconncconoccconaccnoncnonononononnnncnnnnc crac nn rara nr nn nennen nennen tenente tenens enne nnne 39 kHz Max speed motor with 1 pole pair 120 000 rpm 2 2 Inputs SI A deetpendchsnees date E EE EA analogue input 0 5 V Resolution 1024 steps Dial eet t e UU TTL CMOS 5V or switch against Gnd DISCO Micol car TTL CMOS 5V or switch against Gnd IBrake tnter tete chiens TTL CMOS 5V or switch against Gnd Hall sensor cccccccsssseceecccccsseesecccececceeesseceeeeeceeansececeeee
15. ler V Hall A Gnd gt Note A 5V Disable gt P1 Speed 1 gt taphole on DEC 50 5 Qe earth optional A 5V Direction gt P2 Speed 2 Ramp Brake gt gt AUX lt gt Speed 39 13 Dimension Drawing Dimensions in mm Power Gnd Vcc 10 50VDC Motor winding 3 Motor winding 2 Motor winding 1 Power Hall sensor 3 D H GITA Hall sensor 2 Hall sensor 1 maxon motor maxon motor control Vcc Hall max 30mA 1Q EC Amplifier DEC 50 5_50V 5A_ 230572 10 Gnd aana ea Made in Hungary 11 Disable ee 12 Direction ee 4 13 Brake wet 14 AUX 15 Speed 0 5V Signal P1 Speed 1 St AUX S2 gain S3 E mode P2 Speed 2 Ramp 8 speed range AN On ARUN o DIVND DID P D D P P D P P O ojojojojojojojojojojojojojojo Settings 16 maxon motor control October 2008 Edition Doc No 544910 06 subject to change
16. maxon motor maxon motor control 1 Q EC Amplifier DEC 50 5 Order number 230572 Operating Instructions October 2008 Edition The DEC Digital EC Controller is a 1 quadrant amplifier for controlling electronically commutated brushless DC motors e Digital speed control e Maximum speed 120 000 rpm motor with 1 pole pair e Operates as speed control current control or open loop speed control e Brake direction and disable input e AUX connection adjustable function 5 V output or input for changing speed e Status indicator with red and green LED e Set value input through built in potentiometer several speed ranges can be selected or through analogue set value input 0 5 V e Maximum current limit adjustable e Gain can be adjusted in two stages e Adjustable speed ramp e Protection against heat overload e Blockage protection current limit for blocked motor e Plug in terminal clamp Table of Contents 1 Safety Instructions circo enh ih Ale ae edhe ee AI aaa aaa iae 2 2 Perlormance Data si nike se eae A ae 3 3 Minimum External Wiring for Different Modes of Operation 4 4 Operating INStrUCTIONS RM 6 D Inputs and Outputs T 8 SEI FUNCIONS EP EE 12 7 Speed RANGES E E 12 8 Potentiometer FUNCHIONS cccnnncinnnnnnnnnnnnncccnnncn caca 13 9 Operating Status Display iia EET 14 TO Protectio CR E M 15 11 EMG compliant install tion isolated td iaidd 15 12 BlOCK DIAN suscita lia 16 13 DIMENSION BICIS vecina
17. nuous overvoltage protection 50 50 V Use of external potentiometer When using an external potentiometer the AUX output switch S1 AUX ON can be used as 5 V reference Recommended resistance value of potentiometer 10 kQ Note 0 V equals the minimum speed see chapter 7 Speed Ranges 5 1 2 Disable Disabling or blocking the power stage If the input is not wired or the applied voltage is greater than 2 4 V the amplifier is activated A speed ramp will be performed during acceleration If the input is placed at Gnd potential or the applied voltage is lower than 0 8 V the power stage is blocked and the motor shaft freewheels and slows down The Disable input is protected against overvoltage Input voltage range 0 45V Input impedance 33 kQ pull up resistor at 5 V Continuous overvoltage protection 50 50 V Delay time approx 12 ms Input open or input voltage gt 2 4 V Set input to Gnd or input voltage lt 0 8 V Disable active Disable inactive Note If the switch adjuster was changed the new settings are adopted through a disable enable procedure 8 maxon motor control October 2008 Edition Doc No 544910 06 subject to change maxon motor Operating Instructions 1 Q EC Amplifier DEC 50 5 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 5 Brake function and ac
18. s 16 The latest edition of these operating instructions may be found in the internet as a PDF file under www maxonmotor com category Service amp Downloads Order number 230572 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 50 5 Operating Instructions 1 Safety Instructions Skilled Personnel Only experienced skilled 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 apparatus 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 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 50 5 After switc
19. ted in linear fashion with potentiometer P1 and is independent of the position of the switches S5 and S6 see chapter 7 Speed Ranges 2 Predetermine set value at Speed input so that required torque is reached Note A set value in the 0 5 V range at the Speed input is equal to a current adjustment range of approx 0 5 A Band width of current control approx 15 Hz Digital open loop 1 Predetermine set value at Speed input so that required speed is speed control reached The set value range of 0 5 V is equal to a motor voltage range of 0 V Vcc The maximum speed is determined by the supply voltage and the speed constant of the motor and is independent of the position of the switches S5 and S6 2 Adjust potentiometer P3 Imax to required limiting value Maximum current in the O 10 A range can be adjusted in linear fashion with potentiometer P3 October 2008 Edition Doc No 544910 06 subject to change maxon motor control 7 maxon motor 1 Q EC Amplifier DEC 50 5 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 set value input is used for the following operating modes speed control current control and open loop speed control The Speed input is protected against overvoltage Input voltage range 0 5 V ref Gnd Input impedance gt 1 MO in the 0 5 V range Conti
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