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Servo Motor Guide
Servo Motor Guide
Servo Motor Guide
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fabrication (CNC machinery), and equipment upgrades. Many OEM customers request that we "private-label" the
Servo Motor, so that their customers stay loyal to them for servicing, replacements and repairs.
What Industries are Servo Motors used in?
Servo motors are seen in applications such as factory automation, robotics, CNC machinery, and packaging. The
feedback lets the drive know its position, speed, and torque to detect unwanted motion. Pharmaceutical industries
are driven be the need to create smaller devices; ones that are easier to operate and function more efficiently.
How Does a Servo Motor Work?
Typical servo motor mechanism is not complex. The servo motor has control circuits and a potentiometer that is
connected to the output shaft. The shaft, which is the output device, links to a potentiometer and control circuits
that are located inside the servo. The potentiometer, coupled with signals from the control circuits, control the
angle of the shaft anywhere from 0 to 180 degrees, sometimes further. The potentiometer allows the control
circuitry to monitor the current angle of the servo motor. If the shaft is at the correct angle, the servo motor idles
until next positioning signal is received. The servo motor will rotate the correct direction until the angle is correct.
Each servo motor works off of modulation known as Pulse Coded Modulation, or PCM. The motor has a control
wire that is given a pulse application for a certain length of time. The angular degree of the shaft is determined by
the length of the pulses, which the servo motor anticipates every couple seconds. A normal servo is mechanically
not capable of rotating further due to a mechanical stop built into the main output gear. The amount of power
applied to the motor is proportional to the distance it needs to travel. So if the shaft of the servo motor needs to
turn a large distance, the servo motor will run at full speed. If the servo motor needs to rotate only a small amount,
the motor will run at a slower speed. This is referred to as Proportional Control. The servo motor expects to see a
pulse every 20 milliseconds, (.02 seconds) and the length of each pulse will determine how far the servo motor
will rotate.
How to Select a Servo Motor
The simplified definition of a servo system is that it consists of several components which together control or
regulate speed/position of a load. The servo motor is one of these components in the system. When it comes time
to select an appropriate servo motor for an application some people may be nave in thinking that they can just
check size the motor based on the horsepower rating of the presently installed motor, or exclusively based on the
applications torque requirements. The following factors must all be taken into account when selecting the
appropriate motor: inertia ratio, speed, and max torque at desired speed.
Any rotating object has a moment of inertia which is a measurement of how difficult it is to change the rotating
velocity of that object. Moment of inertia in a servo system can be divided into two parts; load inertia and motor
inertia. The motor inertia is part of the servo design and is typically listed in the manufacturers specification sheet.
Load inertia is more complicated because it involves every component that is moved by the motor, and is
calculated using proper equations for each component. A typical inertia ratio for most applications is 5:1, but the
lower the ratio is, the higher performance will be, and vice versa.
Since there may be a variety of servo motors that meet the required inertia ratio specifications, the next step is to
find the smallest, most cost-effective servo motor that will meet the speed and torque demands. Servo motor
manufacturers normally provide speed-torque curves for each series of motors, which illustrate several interesting
points of the servo motors characteristics. The speed-torque curve contains two regions; continuous and
intermittent, which can translate to correct match or incorrect match (respectively) for the application. If the speed-
torque required for a specific application falls into the continuous region of the speed-torque curve, then that motor
can produce that torque and speed without overheating. If the speed-torque required for the application falls into
the intermittent region of the speed-torque cure, then that motor can only produce that speed and torque for a
limited amount of time before overheating.
How are Servo Motors controlled?
Servo motors operate on negative feedback, meaning that the control input is closely compared to the actual
position via a transducer. If there is any variance between physical and wanted values, an error signal is
amplified, converted, and used to drive the system in the direction necessary to reduce or eliminate error. Servo
motors are controlled by a pulse of variable width that is sent from a micro-controller output pin to the servo
motors control wire. The shaft angle is determined by the duration of the pulse, also known as pulse width
modulation (pwm). This pulse has to have specific parameters such as; minimum pulse, a maximum pulse, and a
repetition rate. Given these constraints, neutral is defined to be the position where the servo has exactly the same
amount of potential rotation in the clockwise direction as it does in the counter clockwise direction. It is important
to note that different servo motors will have different constraints on their rotation, but they all have a neutral
position, and that position is always around 1.5 milliseconds (ms).
Anaheim Automation offers AC Servo Drives providing high speed DSP. These servo motors are equipped with
auto disturbance rejection control and speed observation control algorithm, in addition to compensation servo
delays, forward feed control, and reference smoothing techniques. Anaheim Automation Servo Drives are
equipped with a range of dynamic features:
High Overload Capacity
The industrial grade Intelligent Power Modules (IPM) utilized in the EDB/EDC AC Servo Drivers are one
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step higher in capacity than other servo products that are specified at the same power.
Communication Interface
Standard CAN bus interfaces are available in the EDC AC Servo Driver, simplifying the integration
process. Based on Modbus protocols from either RS485 or RS232 interfaces, up to 32 servo motors can
be connected together. When RS485 interface is used, the transmission distance can reach up to 4000
feet. Anaheim Automation AC Servo Drivers can also communicate with a PLC, DCS, intelligent
instruments, touch screens, and more.
ESView Communication Software
Anaheim Automation software is capable of the following:
- Parameter Management - Fast and convenient operations to all parameters available, including
editing, transmission, comparison, and initialization.
- Monitoring - Real time monitoring of all I/O signals, alarms of the present and history records,
and system status
- Real Time Management - Real time sampling of the torque vs. speed curves for simple, rapid
analysis.
- Adjusting - Quick adjustment of gains.
Servo Motor Types
There are two main types of Servo Motors: Rotary and Linear.
Rotary Servo Motor
A rotary Servo Motor is what most people think
of when they think of a Servo Motor. The three
types of Rotary Servo Motors are: AC Servo
Motor, Brush DC Servo Motor, and Brushless
DC Servo Motor. The motion of a rotary Servo
Motor is often converted into linear motion by
the use of a screw thread (ball screw or lead
screw), or with the use of belts and pulleys.
A Rotary AC Servo Motor is an AC type motor that is used with a feedback device. These are typically
used in smaller applications, because a large AC Servo Motor is typically inefficient when compared to its
DC or Brushless counterparts.
Linear Servo Motor
A linear Servo Motor is a flattened out Servo
Motor where the rotor is on the inside, and the
coils are on the outside of a moveable u-channel.
Both Servo Motor types are becoming more
popular as Servo Motor prices continue to come
down.
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high temperature range, and is inherently shock-resistant due to its design. A resolver is mostly used in harsh
environments.
The optical encoder on the Servo Motor uses a rotating shutter to interrupt a beam of light across an air gap
between a light source and a photodetector, over time the wear associated with the rotating shutter reduces the
longevity and reliability of the encoder. The application will determine whether a resolver or an encoder is
needed. Encoders are more accurate and are easier to implement so they should be the first choice for any
application. The only reason to choose a resolver is environmental concerns and longevity requirements.
Servo Motor Accessories
Anaheim Automation provides many different accessories for its Servo Motor product line. These accessories
include brakes, encoders, connectors, cables and a handheld interface unit, as well as a full line of servo motor
drives.
The Servo Motor brake is a 24VDC system. These Servo Motor brakes are perfect for holding applications and
are available for Anaheim Automation Servo Motors. They can be purchased separately or are attached to the
rear of the Servo Motor. The Servo Motor brakes have a low voltage design for applications that are susceptible to
weak batter, brown out, or long wiring runs. When electric power is applied to the Servo Motor brake, the armature
is pulled by the electromagnet force in the magnet body assembly, which overcomes the spring action. This
allows the friction disc to rotate freely. When electrical power is interrupted, the electromagnetic force is removed
and the pressure spring mechanically forces the armature plate to clamp the friction disc between itself and the
pressure plate.
Anaheim Automation's Servo Motor is designed with a 2500 counts per revolution quadrature encoder, with a
resolution of 10,000 pulses per revolution.
Anaheim Automation's Servo Motor comes with the necessary connectors to connect to another company's servo
drive or an Anaheim Automation servo drive. These Servo Motor connectors can also be purchased separately
should they become lost. Please refer to the servo motor user's guide for a specific part numbers.
Servo Motor cables can be made with the supplied Servo Motor connector, or can be purchased from Anaheim
Automation. The Servo Motor cable comes with a standard length of 5M but can be adjusted to any length
required.
NOTE: Anaheim Automation strongly recommends the purchasing of the cables with servo motors and
drives to ensure cable integrity. These cables are perfectly matched and a stable form of connection.
Servo Motor History
The steam engine governor is considered the first powered feedback system that used a gain value so it is
considered the first servo mechanism. The word Servo Motor comes from the French phrase "Le Servomoteur" or
the "slave motor". The first known record of its use was by JJL Farcot in 1868 to describe steam engines and
hydraulics for use in steering a ship.
Servo Motor Customization
Anaheim Automation was established in 1966 as a manufacturer of "turnkey" motion control systems. Its'
emphasis on R&D has ensured the continued introduction of advanced motor drivers and controllers, such as the
Servo Motor product line. Today, Anaheim Automation ranks among the leading manufacturers and distributor of
motion control products; a position enhanced by its excellent reputation for quality products at competitive prices.
The Servo Motor product line is no exception to the Company's goal.
Anaheim Automation offers a wide variety of standard Servo Motor products. Occasionally, OEM customers with
mid to large quantity requirements prefer to have a Servo Motor that is custom or modified to meet their exact
design requirements. Sometimes the customization is as simple as a shaft modification, brake, oil seal for an IP65
rating, mounting dimensions, wire colors, or simple label requirement. Other times, a customer might require that
a Servo Motor meet an ideal specification such as, speed, torque, and/or voltage. Engineers appreciate that
Anaheim Automation's Servo Motor product line can answer their desire for creativity, flexibility and system
efficiency. Buyers appreciate the simplicity of the "one-stop shop," and the cost savings of a custom Servo Motor
design, while engineers are pleased with Anaheim Automation's dedicated involvement in their specific servo
motor system. Note: There are minimum purchase requirements for all special/custom orders.
Anaheim Automation's standard Servo Motor product line is a cost-effective solution; they are known for their
rugged construction and excellent performance. This is a result of dedicated engineering, friendly customer
service and professional application assistance, often surpassing the customer's expectations for fulfilling their
custom requirements. Anaheim Automation takes pride in its standard stock base located in Anaheim, California,
USA. To make customization of a Servo Motor affordable, a minimum quantity and/or a Non-Recurring
Engineering (NRE) fee is required. Contact the factory for details, should you require a custom Servo Motor in
your design.
All Sales for a customized or modified Servo Motor are Non-Cancelable-Non-Returnable, and a NCNR
Agreement must be signed by the customer, per each request. All Sales, including a customized Servo Motor, are
made pursuant to Anaheim Automation's standard Terms and Conditions, and are in lieu of any other expressed
or implied terms, including but not limited to any implied warranties.
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PLEASE NOTE: Technical assistance regarding its Servo Motor product line, as well as all the products
manufactured or distributed by Anaheim Automation, is available at no charge. This assistance is offered to help
the customer in choosing Anaheim Automation products for a specific application. However, any selection,
quotation, or application suggestion for a Servo Motor, or any other product, offered from Anaheim Automation's
staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of the
Servo Motor in a specific system design is solely the customers' responsibility. While every effort is made to offer
solid advice regarding the Servo Motor product line, as well as other motion control products, and to produce
technical data and illustrations accurately, such advice and documents are for reference only, and subject to
change without notice.
Servo Motor Mounting
Mounting - Introduction
Proper installation will achieve the best results from the production capability of the servo motor and drive
system. This can only be accomplished if several important steps are implemented and some precautions
are taken. Note: Local codes may suggest different requirements, but those given in this section must be
satisfied as much as possible.
CAUTION - Only qualified personnel should be allowed to open and work on the servo motor and
drive and other components inside electrical enclosures.
Equipment and machinery should never be run unless the electrical enclosure door is closed and locked.
The electronics inside the main electrical enclosure are sensitive to metal chips and filings. During the
installation and use of the servo motor and drive system, great care must be given to make sure metal
chips or filings cannot fall onto or into any of the electrical devices.
Electrical Installation
Safety is the number one concern when performing the electrical connection of the servo motor and drive,
as well as all motion control products and electrical equipment. Therefore, check every step at least once
after it has been taken. During the installation of the servo motor and drive, it is important to minimize the
possibility of electrical noise entering critical sensitive circuits. This is best accomplished by following the
electrical installation procedures precisely. Considerable attention has been given to noise immunity in the
basic design and manufacture of the servo motor and drive system. However, it is essential that great care
and attention be given during the installation of the servo motor and drive in your machine or in your
facility.
Plan Ahead
Before attempting any electrical installations, gather any drawings, instructions, or procedural documents
you have on the servo motor and drive, as well as other components in your system. Reading and studying
the servo motor and drive documentation before starting the project will alert you to any special situations,
such as the need for specific tools. Also, you will know where to begin and where to go from there. Always
keep the specific servo motor and drive documentation with you while completing the installation, as you
should regularly refer to them. Documentation among servo motor and drive manufacturers will vary
greatly, as their design, layout, and connections are not the same. Match the part numbers to the
documentation before attempting the installation. Even seasoned professionals need guidance and advice
while performing complicated electrical installations. This ensures the safest results for everyone.
Safety
Human safety and equipment safety must be the first considerations when performing the installation
procedures for the servo motor and drive system. When it comes to electronics in your factory or
workplace, you want to make sure both your facility and the employees in it are safe. The following is an
electrical safety checklist, courtesy of the National Electric Safety Foundation:
General Electrical Safety Checklist:
Cords and Cables: Make sure cords and cables are in good condition. Check cords, cables and
other wiring for frays and cracks. Make sure that all wiring and cabling is placed out of reach and
out of traffic areas. Cords/cables should never be nailed or stapled to the wall, baseboard or to
another object. Do not place cords under carpets or rugs. Anaheim Automation recommends using
its product-specific cables for its servo motors and drives product line, and extreme care should be
taken if the installer decides to use their own cabling system.
Plugs and Terminals: Make sure that all plugs fit the outlets, and that the terminals of the servo
motor and drive are correctly matched and fit snug. Never remove the ground pin (the third prong) to
make a three-prong fit a two-conductor outlet, because it could lead to an electrical shock. Avoid
overloading outlets with too many electronic components. Never force a plug into an outlet if it
doesn't fit, nor should you ever modify terminal blocks or cables for the servo motor and drive.
Electrical Outlet Safety: Routinely check for loose-fitting plugs, which can overheat and lead to
fire. Replace broken or missing wall plates
Ground Fault Circuit Interrupters (GFCIs): These can help prevent electrocution and are used in
any areas where water and electricity may come into contact. When a CFCI senses leakage in an
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electrical circuit, it assumes a ground fault has occurred. It then interrupts power fast enough to help
prevent serious injury from electrical shock. Test GFCIs regularly, according to the manufacturer's
instructions to make sure they are working properly.
Circuit Breakers/Fuses: Should be the correct size current rating for their circuit. If you do not
know the correct size, have an electrician identify and label the size to be used. Always replace a
fuse with the same size fuse.
Computer, Controller, HMI, PLC and Drive Products: Check to see that the equipment is in good
condition and working properly. Look for cracks or damage in wiring, terminals, plugs and
connectors. Use a surge protector bearing the seal of a nationally recognized certification agency.
Lightning: During an electrical storm, make sure you use surge protectors on electronic devices.
Mounting, Bonding and Grounding
After establishing all layouts, you can begin mounting, bonding, and grounding each chassis/enclosure.
Bonding is the connecting together of metal parts of chassis, assemblies, frames, shields, and enclosures
to reduce the effects of EMI and ground noise. Grounding is the connection to the grounding-electrode
system to place equipment at earth ground potential.
IMPORTANT NOTE: These guidelines assume that you follow surge-suppression guidelines. While these
guidelines apply to the majority of servo motor and drive installations, as well as other motion control
applications, certain electrically harsh environments may require additional precautions.
Grounding of equipment and machinery is required for two reasons.
1. To prevent hazards to personnel in case of a breakdown between current electrical components and the
exposed metal surfaces.
2. To minimize the effects of electrical noise on the control system.
Mounting and Bonding the Enclosure General Practices
Generally speaking, you can mount the chassis with either bolts or welded stud:
Stud-mounting a ground bus or chassis to the back panel of the enclosure
Stud-mounting a back panel to the enclosure
Bolt-mounting a ground bus or enclosure to the back panel of the enclosure
If the mounting brackets of a chassis do not lay flat before the nuts are tightened, use additional washers
as shims so that the chassis does not bend when you tighten the nuts.
Important Note: Do not bend the chassis. Bending the chassis might damage the backplane and result in
poor connections. Make good electrical connection between each chassis, back-panel, and enclosure
through each mounting bolt or stud. Wherever contact is made, remove paint or other non-conductive finish
from around studs or tapped holes.
With motors, drives and controls, proper bonding and grounding helps reduce the effects of EMI and
ground noise. Also, since bonding and grounding are important for safety in electrical installations, local
codes and ordinances dictate which bonding and grounding methods are permissible. Anaheim
Automation supplies motion control components only, therefore, it is imperative that the user know all
pertinent safety practices and local codes and ordinances for where the machinery or system is built,
and/or their machinery is shipped.
For example, for U.S. installations, the National Electrical Code (NEC) will provide the requirements for
safe bonding and grounding, such as information about the size and types of conductors and methods of
safely grounding electrical components.
Use a steel enclosure to guard against EMI. If the enclosure door has a viewing window, it should be a
laminated screen or a conductive optical substrate to block EMI.
Important Note: Do not rely on the hinge for electrical contact between the door and the enclosure; install a
bonding wire.
How Good Is Your Earth Grounding System?
The existing factory earth and power systems of the plant, into which a new machine or motion control
system is to be installed, should be checked for at least 24 hours before the machine/system arrives. This
should be done as soon as the location is known to allow as much time as possible to make any changes
that may be required. A good and reliable system that has been used for this purpose for many years is a
Dranetz line analyzer. The power line disturbances should not exceed + or - 15% of the machine, or
motion control components specification power requirements. This includes all forms of noise, voltage
drop out or voltage spikes. While most machinery and motion control systems can usually tolerate more
deviation than this, it is best to maintain these limits to protect people and the machine/system
performance.
Water Pipes May Not work
Although a utility ground, such as a cold water pipe or the metal frame of a building, is generally an
adequate ground for safety purposes, IT IS NOT usually recommended for minimizing the effects of
electrical noise.
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Sources of Noise
Normally, other electrical equipment is connected to water pipe grounds or building steel and, therefore,
carries the transient electrical noise currents associated with all of the attached equipment. These
combined electrical noise currents cause a voltage gradient to be developed within the pipe or structural
member because of its inherent resistance and reactance. Therefore, a function of the total noise current
flowing at any one instant may cause a disturbance. This transient ground shift voltage disturbances are
set up which may be coupled into the electronics and cause the drives and controllers to malfunction.
What Is An Earth Rod?
A separate earth ground should always be used to ground a computer-controlled machine tool, or motion
control system that uses drives, controllers, PLCs and/or HMIs. It may consist of a driven rod, driven pipe,
buried plate, or any other device approved for this purpose. However, they should be kept out of any oily
areas.
It is preferred that Earth Rods are located where saltwater can periodically be poured down the side of the
rod. If a parallel water pipe is provided, the rod should be located where it can easily be filled. This type of
ground usually provides the low-impedance, stable, noise-free ground required for minimizing the effects
of electrical noise on the control system and will also provide personnel safeguards. At no time should
more than one machine be connected to one ground rod. The cable connecting the control panels ground
point to the earth rod should be continuous, as short as practical, and of at least the size of the conductors
used to connect the electrical power to the machine tool or process line.
Installation of Earth Ground Rod
The length and diameter of the ground rod is dependent upon the soil in the area of machine site. A good
starting point would be to use a ten foot long by 5/8 diameter rod. The actual length and diameter of the
earth ground rod should be determined by the length, and hence the diameter, required to reach the water,
or moisture table in the subsoil. However, the local grounding conditions should be well-known by the
plant electrical engineers and local electric company or electrical authority engineers; Anaheim
Automation recommends consulting with them. It is best to weld a steel spike or cone to the end of the rod
to help it penetrate the soil.
Sizing the Transformer - General Practices
To determine the required rating of the transformer, add the external-transformer load of the power supply
and all other power requirements (input circuits, output circuits). The power requirements must take into
consideration the surge currents of devices controlled by the processor. Choose a transformer with the
closest standard transformer rating above the calculated requirements. For example, a 500VA transformer
should be used if there were 360VA of load.
Isolation Transformer For applications near excessive electrical noise generators, an isolation
transformer (for the second transformer) provides further suppression of electromagnetic interference (EMI)
from other equipment.
Constant-Voltage Transformer In applications where the AC power source is especially soft and
subject to unusual variations, a constant-voltage transformer can stabilize the AC power source to the
processor and minimize shutdowns. The constant-voltage transformer must be of the harmonic
neutralizing type. If the power supply receives its AC power through a constant-voltage transformer, the
input sensors connected to the I/O chassis should also receive their AC power from the same constant-
voltage transformer. If the inputs receive their AC power through another transformer, the AC source
voltage could go low enough that erroneous input data enters memory while the constant-voltage
transformer prevents the power supply from shutting down the processor. The output actuators being
controlled should draw power form the same AC sources as the constant-voltage transformer, but not from
the secondary of the constant-voltage transformer.
The following information is intended as a general guideline for the installation and mounting of a Servo
Motor. WARNING - Dangerous voltages capable of causing injury or death may be present in the Servo
Motor system. Use extreme caution when handling, testing, and adjusting during installation, set-up,
tuning, and operation. It is very important that the wiring of the Servo Motor be taken into consideration
upon installation and mounting.
Subpanels installed inside the enclosure for mounting Servo Motor system components, must be a flat,
rigid surface that will be free from shock, vibration, moisture, oil, vapors, or dust. Remember that the Servo
Motor and drive will produce heat during work. Therefore, heat dissipation should be considered in
designing the system layout. Size the enclosure so as not to exceed the maximum ambient temperature
rating. It is recommended that the servo drive be mounted in an upright position, providing adequate
airflow. The Servo Motor should be mounted in a stable fashion, secured tightly.
NOTE: There should be a minimum of 10mm between the servo drive and any other devices mounted in
the system/electric panel or cabinet. There should be at least 10mm space in the lateral direction and
50mm space in the longitudinal direction, between the servo motor drive and other electronic/electrical
devices. For multi-axis systems, mount in the panel left to right according to power utilization (highest to
lowest). If power utilization is unknown, mount from left to right based on Amp rating.
NOTE: In order to comply with UL and CE requirements, the servo motor drive must be grounded in a
grounded-conducive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP55
such that they are not accessible to the operator or unskilled person. As with any moving part in a system,
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the Servo Motor should be kept out of the reach of the operator. A NEMA 4X enclosure exceeds those
requirements providing protection to IP66. To improve the bond between the power rail and the subpanel,
construct your subpanel out of zinc-plated (paint-free) steel. Additionally, it is strongly recommended that
the servo motor drive be protected against electrical noise interferences. Noise from signal wires can
cause mechanical vibration and malfunctions.
Servo Motor Environmental Considerations
The following environmental and safety considerations must be observed during all phases of operation, service,
and repair of a Servo Motor system. Failure to comply with these precautions violates safety standards of design,
manufacture, and intended use of the Servo Motor and drive. Please note that even well-built servo motor
products operated and installed improperly can be hazardous. Precaution must be observed by the user with
respect to the load and operating environment. The customer is ultimately responsible for the proper selection,
installation, and operation of the Servo Motor system.
The atmosphere in which a Servo Motor is used must be conducive to good general practices of
electrical/electronic equipment. Do not operate the Servo Motor in the presence of flammable gases, dust, oil,
vapor, or moisture. For outdoor use, the Servo Motor and drive must be protected from the elements by an
adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrical shock
hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and
vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install the
Servo Motor and drive in an environment which is free from dust, metal chips, condensation, electrical noise,
vibration and shock.
Additionally, it is preferable to work with the Servo Motor and Drive system in a non-static protective environment.
Exposed circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact
with live circuitry. No work should be performed while power is applied. Do not plug in or unplug the connectors
when power is ON. Wait for at least 5 minutes before doing inspection work on the Servo Motor system after
turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining
in the capacitors of the internal circuit of the servo motor drive.
Plan the installation of the Servo Motor and drive in a system design that is free from debris, such as metal debris
from cutting, drilling, tapping, and welding, or any other foreign material that could come in contact with circuitry.
Failure to prevent debris from entering the Servo Motor system can result in damage and/or shock.
NOTE: Meeting CE Requirements mandates a ground system; and the method of grounding the AC line filter and
the servo motor drive must match. Failure to do this renders the filter ineffective and may result in damage.
Servo Motor Wiring - Safety First!
Extension Cord Safety
When installing new technology, you may be dealing with extension cords to help plug your Anaheim
Automation products on a test bench for prototyping. Use them on a temporary basis. Extension cords are
not meant for permanent wiring.
Here are some general electrical cord safety tips when dealing with extension cords, in part, courtesy of
the National Electrical Safety Foundation, which develops safety policies and procedures for electronics.
Extension Cords:
NOTE: Water and electricity don't mix: don't leave plugged-in electronics where they might come into
contact with water. If they do fall in water, never reach in and pull them out, even if they are turned off. First,
turn off the power source and then unplug the unit. If you have a servo motor, drive or controller that has
gotten wet, don't use it until it has been checked by our qualified repair staff.
High-Temperature Braided Sleeving
The life of cables, wires and hoses can be greatly extended with high-temperature braided sleeving.
Braided sleeving is a protective cover for the vulnerable material of common wires. High temperatures can
cause cracks, frays, or fires, especially for wires and cables that are used in industrial settings or exposed
to outdoor elements. In addition to protecting the wires from high temperatures, braided sleeving can
shield wires and cables from abrasions, chemicals, dirt, and even freezing temperatures.
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An emphasis on safety is largely due to the fear of what an arc flash can do. An arc flash is a short circuit
through the air that can happen when conductors can't support the voltage. An arc flash can be as hot as
5,000 F and creates a brilliant flash of light and loud noise. As radiant energy explodes out of the electrical
equipment, hot gases and melted metal can endanger human life. This is why there are four separate
industry standards or electrical safety requirements in place to protect workers against arc flashes and
electrical safety equipment on the market in the form of boots, suits, gloves and more. It is the responsibility
of the installer/user of servo motors and drives, and all other Anaheim Automation products, to become
familiar with all safety requirements.
Avoid Working with Live Wires
A live wire is one that has electricity running through it. If you are installing or repairing anything
electrical, always isolate the equipment from the power source. In addition to turning any circuit breakers
off, it is always good to test any circuit or conductor before you touch it. This can be done very simply with
a hand-held voltage tester. Use this multi-meter every time you must handle something that is potentially
live.
Electrical Hazards
The following are the four main hazards involved with the installation of electrical equipment:
1. Electric Shock- An electric shock or burn occurs when an electric current comes
into contact with the skin and conducts through the body. If high-voltage electricity
runs through the head or chest, death can occur instantly.
2. Arc Flash Burn- An arc flash occurs when a conductive object gets too close to a
high voltage, electrified object. This flash can cause intense heat in the
surrounding air, possibly causing clothes to catch fire.
3. Arc Blast Impact- When a metal object triggers an arc flash, a subsequent blast
can cause hearing loss and concussion. Also, this blast can cause lacerations
from flying metal pieces. Falling- Shocks and arc blasts can easily knock a worker
off a high platform, such as a ladder or pole.
Surge-Suppression General Practices
Transient Electromagnetic Interference (EMI) can be generated whenever inductive loads such as relays,
solenoids, motor starters, or motors are operated by hard contacts such as pushbutton or selector switches. The
wiring guidelines are based on the assumption that you guard your system against the effects of transient EMI by
using surge-suppressors to suppress transient EMI at its source. Inductive loads switched by solid-state output
devices alone do not require surge-suppression. However, inductive loads of AC output modules that are in
series or parallel with hard contacts require surge-suppression to protect the module output circuits as well as to
suppress transient EMI.
Electrical noise from any source, whether it is the power line, an electrical arc generated in an adjacent machine
or process, or crosstalk within the control, is transmitted by conduction, inductive or capacitive coupling, or
radiation. It is extremely important to maintain the electrical enclosures and panels, conduits, wiring shields, and
machine members at zero potential and to provide a return path to the earth for noise currents so as to effectively
shield the sensitive logic from electrical noise.
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Make the servo motor and drive and other components in the system less susceptible to EMI
emissions
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IMPORTANT NOTE: EMC is an important field in electronics with strict regulations, and motors and their
circuits are significant sources of EMI. It is therefore essential that engineers take the appropriate actions
to reduce EMI improve EMC as much as possible.
Power Line Interference
This section provides basic information that should help achieve a safe, successful and reliable servo motor and
drive installation. It does not cover all possibilities, but does give good basic information and guidance to servo
motor and drive applications, as well as other motion control systems.
Power lines are one of the most troublesome sources of electrical noise. The power lines to which the motion
control components are connected, may also supply power to equipment such as arc welders, high current
(induction) furnaces, or large horsepower electric motors. Starting or stopping these large consumers of power, or
changing the load conditions on them, may cause transient voltages, which may take the form of voltage surges
or dips accompanied by high frequency noise superimposed on the incoming voltage waveform. This electrical
noise may cause a digital electronic control system to count incorrectly, lose stored data, store incorrect data, or
lose axis synchronization.
Power lines in an ungrounded Delta power system are inherently noisy. This system floats with respect to ground
and may also cause excessively high voltages to be applied to equipment connected to it. For these reasons, a
grounded Wye power system is preferred for supplying power to a computer controlled machine tool or other
motion system.
To minimize the effects of power line noise on computer-controlled machine tools or other motion control system
components, the power wiring is physically and electrically separated from the logic signal wiring. Also, shielded
cables are used for logic signal wiring where appropriate, and an effective common point ground system is
provided. Even though these precautions have been taken, power line noise may still be coupled into the logic in
extreme cases and cause the control to malfunction as described above.
Possible Solutions
To eliminate controller, HMI, PLC, and computer malfunctions that are caused by excessive power line noise, one
or more of the following may be necessary:
1.
2.
3.
Reduce existing power line noise or install a separate incoming power line to the machine or
process.
If the only available power source is an ungrounded Delta type, install a Delta-to-Wye isolation
transformer ahead of the control and ground the neutral of the Wye to improve noise rejection
and to better regulate the input voltage to the controls.
Install a motor alternator set ahead of the control to isolate it from the incoming power line.
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visible damage, shaft can be rotated by hand, the brake works correctly, and there are no loose bolts. Operators
should periodically check the motor for vibration and noise while the motor is not rotating, rotating at low speeds,
and accelerating and decelerating. Inspect the motor for scratches or cracks on the motor casing. If crevices or
cracks are found on the motor, action should be taken immediately by repairing or replacing the damaged unit.
Check the motor casing for oil or cutting fluid because this can corrode the coating possibly leading to future
failure. Use an insulation level tester to check insulation resistance between motor coil and motor frame and refer
to the owners manual to see if insulation value falls within an operable range. Observe the normal voltage
waveforms on an oscilloscope periodically and take notes for future comparison purposes and report any
inconsistencies to manufacturer. Check cables and wiring for cracks and frays. Replace if found worn, as this
could be dangerous (See the Wiring section in this guide for more details).
Servo Motor Applications
Technical assistance regarding the Servo Motor product line is available at no charge. This assistance is offered
to help the customer in choosing Anaheim Automation products for a specific application. However, any selection,
quotation, or application suggestion for a Servo Motor, or any other product, offered from Anaheim Automation's
staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of the
Servo Motor in a specific system application is solely the customers' responsibility. While every effort is made to
offer solid advice regarding the Servo Motor in a specific application, and to produce technical data and
illustrations accurately, such advice and documents are for reference only, and subject to change without notice.
Anaheim Automation is in no event responsible or liable for indirect or consequential damages resulting from the
use or application of the Servo Motor. Improper use of a Servo Motor in an application can result in personal injury
or death, property damage, and/or economic loss. Persons not familiar with servo motor systems installation might
be better served to use a qualified systems integrator.
Does Not Require Feedback: The stepper motor also Encoder: Determines the accuracy and
acts as the position transducer
resolution of the servo motor
Price: Relatively inexpensive
Higher cost
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