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AMC AnalogDrives InstallManual
AMC AnalogDrives InstallManual
Analog Drives
for Servo Systems
Hardware
MNALHWIN-01
www.a-m-c.com
Installation Manual
Preface
ADVANCED Motion Controls constantly strives to improve all of its products. We review the information in this document regularly and we welcome any suggestions for improvement. We reserve the right to modify equipment and documentation without prior notice. For the most recent software, the latest revisions of this manual, and copies of compliance and declarations of conformity, visit the companys website at www.a-m-c.com. Otherwise, contact the company directly at: ADVANCED Motion Controls 3805 Calle Tecate Camarillo, CA 93012-5068 USA Agency Compliances The company holds original documents for the following:
Trademarks
UL 508c, file number E140173 Electromagnetic Compatibility, EMC Directive - 2004/108/EC EN61000-6-2:2001 EN61000-6-4:2001 EN61000-3-2:2000 EN61000-3-3:1995/A1:2001 Electrical Safety, Low Voltage Directive - 2006/95/EC EN 60 204-1 (IEC 60 204-1) Reduction of Hazardous Substances (RoHS), 2002/95/EC
ADVANCED Motion Controls, the combined isosceles trapezoid/right triangle logo, DIGIFLEX, DIGIFLEX Performance and DriveWare are either registered trademarks or trademarks of ADVANCED Motion Controls in the United States and/or other countries. All other trademarks are the property of their respective owners. Related Documentation
Product datasheet specific for your drive, available for download at www.a-m-c.com.
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Attention Symbols The following symbols are used throughout this document to draw attention to important operating information, special instructions, and cautionary warnings. The section below outlines the overall directive of each symbol and what type of information the accompanying text is relaying.
Note - Pertinent information that clarifies a process, operation, or easeof-use preparations regarding the product.
Note
Danger - Presents information you must heed to avoid serious injury or death.
Revision History
Document ID
MNALHWIN-01
Revision #
1
Date
9/25//2009
Changes
Analog Product Family Hardware Installation Manual First Release
iii
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Contents
1 2
Safety
2.1 Analog Drive Family Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1.1 Products Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Drive Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Standard and Custom Models . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Analog PWM Servo Drive Basics and Theory . . . . . . . . . . . . . . . . . 6 2.2.1 Single Phase (Brushed) Servo Drives . . . . . . . . . . . . . . . . . . 7 2.2.2 Three Phase (Brushless) Servo Drives . . . . . . . . . . . . . . . . . . 7 2.3 Power Stage Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.4 Command Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.4.1 10V Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.4.2 PWM and Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.4.3 Sinusoidal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.5 Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.5.1 Feedback Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.5.2 Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.5.3 Hall Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.5.4 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.6 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.6.1 Current (Torque) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.6.2 Duty Cycle (Open Loop) Mode . . . . . . . . . . . . . . . . . . . . . 14 2.6.3 Hall Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.6.4 Encoder Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2.6.5 Tachometer Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . 2.6.6 Voltage Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.7 IR Compensation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.8 Analog Position Loop Mode . . . . . . . . . . . . . . . . . . . . . . . . 2.7 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1 Analog Servo Drive Selection and Sizing . . . . . . . . . . . . . Motor Current and Voltage . . . . . . . . . . . . . . . . . . . . . . . . Motor Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.2 Power Supply Selection and Sizing . . . . . . . . . . . . . . . . . . Power Supply Current and Voltage . . . . . . . . . . . . . . . . . . Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regeneration and Shunt Regulators . . . . . . . . . . . . . . . . . Voltage Ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . Shock/Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 16 16 16 17 17 17 19 20 20 22 23 25 26 26
27
27 28 28 28 28 28 28 28 29 29 30 31 31 32 32 33 33 34 34 35 35
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3.4.5 Input Reference Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10V Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Potentiometer Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PWM and Direction Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . Sinusoidal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 36 37 37 38 39
Operation
4.1 Initial Setup and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Pin Function Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Monitor Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Reference Output . . . . . . . . . . . . . . . . . . . . . . . . . Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous Current Limit Pin . . . . . . . . . . . . . . . . . . . . . . . . Fault Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Power Supply Outputs . . . . . . . . . . . . . . . . . Velocity Monitor Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Potentiometer Function Details . . . . . . . . . . . . . . . . . . . . . Test Points for Potentiometers . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Switch Function Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Adjustable Acceleration and Deceleration Rate . . . . . . 4.1.5 Tachometer Input Gain Scaling . . . . . . . . . . . . . . . . . . . . . 4.1.6 Current Limiting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.7 Drive Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Phase (Brush Type) . . . . . . . . . . . . . . . . . . . . . . . . . . Three Phase (Brushless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three Phase (Brushless) Drive with Brushed Motor . . . . . . Sinusoidal Drive (S-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.8 Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Loop Proportional Gain Adjustment . . . . . . . . . . Current Loop Integrator Adjustment . . . . . . . . . . . . . . . . . Voltage or Velocity Loop Tuning . . . . . . . . . . . . . . . . . . . . Analog Position Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40 40 40 41 41 41 42 42 42 43 43 44 44 45 46 47 47 47 48 48 49 50 51 52 52
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53
53 55 55 55 56
Troubleshooting
B.1 Fault Conditions and Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . Over-Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over-Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . Under-Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . Short Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Invalid Hall Sensor State (Brushless Drives only) . . . . . . . . . Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-On Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.1 Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.2 Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3 Motor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.4 Causes of Erratic Operation . . . . . . . . . . . . . . . . . . . . . . . . B.2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1 Product Label Description . . . . . . . . . . . . . . . . . . . . . . . . . B.2.2 Drive Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3 Warranty Returns and Factory Help . . . . . . . . . . . . . . . . . . . . . . .
57
57 57 57 58 58 58 58 58 58 59 60 61 61 61 62 62
Index I
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Safety
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Keep clear of all exposed power terminals (motor, DC Bus, shunt, DC power, transformer) when power is applied to the equipment. Follow these safety guidelines:
Always turn off the main power and allow sufficient time for complete discharge before making any connections to the drive. Do not rotate the motor shaft without power. The motor acts as a generator and will charge up the power supply capacitors through the drive. Excessive speeds may cause over-voltage breakdown in the power output stage. Note that a drive having an internal power converter that operates from the high voltage supply will become operative. Do not short the motor leads at high motor speeds. When the motor is shorted, its own generated voltage may produce a current flow as high as 10 times the drive current. The short itself may not damage the drive but may damage the motor. If the connection arcs or opens while the motor is spinning rapidly, this high voltage pulse flows back into the drive (due to stored energy in the motor inductance) and may damage the drive. Do not make any connections to any internal circuitry. Only connections to designated connectors are allowed. Do not make any connections to the drive while power is applied.
Do not reverse the power supply leads! Severe damage will result!
Use sufficient capacitance! Pulse Width Modulation (PWM) drives require a capacitor on the high voltage supply to store energy during the PWM switching process. Insufficient power supply capacitance causes problems particularly with high inductance motors. During braking much of the stored mechanical energy is fed back into the power supply and charges its output capacitor to a higher voltage. If the charge reaches the drives overvoltage shutdown point, output current and braking will cease. At that time energy stored in the motor inductance continues to flow through diodes in the drive to further charge the power supply capacitance. The voltage rise depends upon the power supply capacitance, motor speed, and inductance.
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Make sure minimum inductance requirements are met! Pulse Width modulation (PWM) servo drives deliver a pulsed output that requires a minimum amount of load inductance to ensure that the DC motor current is properly filtered. The minimum inductance values for different drive types are shown in the individual data sheet specifications. If the drive is operated below its maximum rated voltage, the minimum load inductance requirement may be reduced. Most servo-motors have enough winding inductance. Some types of motors (e.g. "basket-wound", "pancake", etc.) do not have a conventional iron core rotor, so the winding inductance is usually less than 50 H. If the motor inductance value is less than the minimum required for the selected drive, use an external filter card.
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A
Motor Type
(blank): Brushed drive. B or BX: Brushless drive.
Additional Options
ANP : H: INV: QD: QDI: Analog Position Loop Available Hall Velocity Mode Inverted Inhibit Quick Disconnect Quick Disconnect with Inverted Inhibit
Command Type
(blank): D: DC: S or SX: +/- 10 V Analog Direct PWM Torque Mode PWM Commutated Sine Wave
Revision
Assigned a letter (A through Z) by manufacturer.
Feedback Type
(blank): Hall Sensors or None E: Encoder and/or Hall Sensors
Power Supply
(blank): DC Power Supply AC: AC Power Supply FAC: AC Power Connecter Located in the Front
Peak Current
Maximum peak current rating in Amps.
Peak Voltage
Peak voltage rating scaled 1:10 in Volts.
Isolation Option
I: Optical Isolation
Command Type
(blank): Non-PWM Command DD: Brushed PWM Command
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functionalblockdiagramofthespecificdrivesoperation.Thedatasheetistobeusedin conjunctionwiththismanualforsystemdesignandinstallation.
ofADVANCEDMotionControlsanalogservodrives.Notethatnotallpossiblepartnumber combinationsfromtheproductfamilynumberingstructure(Figure2.1)areofferedas standarddrives.PleasecontactADVANCEDMotionControlsSalesDepartmentforfurther informationanddetailsoncustomdrivesolutions. TABLE 2.5 Brushed PWM Input DC Drives TABLE 2.1 Brushed 10V Analog DC Drives
Drive Number 12A8 25A8 30A8 50A8 120A10 20A20 25A20I 50A20I 100A40 VDC (Nominal) 20-80 20-80 20-80 20-80 20-80 40-190 40-190 40-190 60-400 Peak Current (A) 12 25 30 50 120 20 25 50 100 Cont. Current (A) 6 12.5 15 25 60 10 12.5 25 50 Drive Number 30A8DD 50A8DD 25A20DD 50A20DD VDC (Nominal) 20-80 20-80 40-190 40-190 Peak Current (A) 30 50 25 50
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Products and System Requirements / Analog PWM Servo Drive Basics and Theory
Althoughthereexistmanywaysto"amplify"electricalsignals,pulsewidthmodulation(PWM) isbyfarthemostefficientandcosteffectiveapproach.AtthebasisofaPWMservodriveisa currentcontrolcircuitthatcontrolstheoutputcurrentbyvaryingthedutycycleoftheoutput powerstage(fixedfrequency,variabledutycycle).Figure2.3showsatypicalsetupforasingle phaseload. FIGURE 2.3 PWM Current Control Circuit
+HV S1
D1
S2
D2
I Motor
D3
D4
Current Feedback
S3 Rc
S4
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Products and System Requirements / Analog PWM Servo Drive Basics and Theory
currentcontrolcircuitwillcomparebothsignalseverytimeinterval(typically50secorless) andactivatetheswitchesaccordingly(thisisdonebytheswitchinglogiccircuit,whichalso performsbasicprotectionfunctions).Figure2.4showstherelationshipbetweenthepulse width(ONtime)andthecurrentpattern.Thecurrentrisetimewilldependonthebusvoltage (+HV)andtheloadinductance.Therefore,certainminimumloadinductancerequirementsare necessarydependingonthebusvoltage. FIGURE 2.4 Output Current and Duty Cycle Relationship
Current
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Products and System Requirements / Analog PWM Servo Drive Basics and Theory
Commutation Feedback
Thecommutationfunctioncanalsobeimplementedinthemotioncontroller,asinthecaseof ADVANCEDMotionControlssinusoidalcommandinputdrives.Thedrivemerelyamplifiesthe controllersignals(2analogsinusoidalsignalsthatrepresent2ofthe3motorphasecurrents) andcreatesthethirdmotorphasecurrent(thesumofthe3currentsmustbezero)andadjusts thephaseangletoobtainmaximumtorque.Nopositionfeedbackneedstobewiredintothe drive.Themotorcurrentamplitudeisproportionaltothereferencesignalamplitude,whilethe referencesignalfrequencydependsonthemotorvelocityandthemotorpolecount. FIGURE 2.6 Controller-based Commutation
Analog Sinusoidal reference signals Motor Currents
Controller:
Position Control Velocity Control Commutation Control
Servo Drive
Motor
Feedback
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VAC Hz A
2.
Most drive models feature continuous current limit adjustments by the use of DIP switches or a potentiometer. Some models also allow an external resistor to be connected between a continuous current limiting pin and signal ground as an additional method of current limiting. Consult the drive datasheet to see which options are available. For more information on setting the current limit see Current Limiting Procedure on page 46. Maximum Continuous Sine Wave Current Arms Pertains to the maximum continuous RMS current that S-series (sinusoidal) drives can output indefinitely. If the continuous RMS current output of the drive exceeds this value, the drive output will be disabled. The drive will re-enable once the RMS current has returned to a level below the maximum continuous sine wave current. The power dissipation of the drive, assuming approximately 5% power loss to heat dissipation. Calculated by taking 5% of P=VI at continuous current and peak bus voltage. The capacitance value between the internal DC bus voltage and power ground. The resistance value of the internal shunt resistor. The power rating of the internal shunt resistor. The turn-on voltage of the internal shunt resistor. The minimum inductance needed at the output of the drive for proper operation. For a brushless motor, this corresponds to the phase-to-phase inductance. If this minimum inductance is not met, a filter card should be used to add additional inductance. Some motors may operate with slightly less than the required inductance if the bus voltage is low enough. ADVANCED Motion Controls provides various accessories including inductive filter cards for a wide range of drives. See Inductive Filter Cards on page 29 for more information. The current rating of the internal shunt resistor fuse. The current rating of the input AC line fuses. The switching frequency of the drive output power stage.
Maximum Power Dissipation at Continuous Current Internal Bus Capacitance Internal Shunt Resistance Internal Shunt Resistor Power Rating Internal Shunt Resistor Turn-on Voltage Minimum Load Inductance
W F W W VDC mH
A A kHz
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2.4.3 Sinusoidal
The"SSeries"ofanalogservodrivesusesinusoidalinputsignalsasthecommandinput. SinusoidalInputisaspecializedtypeofcommandthatrequiresacompatiblecontrollerwith specializedcommutationalgorithmsforproperoperation.Twosinusoidalcommandsignals (120degreesoutofphase)fromthecontrollercontrolthecommutationandtorqueofthe motor.Thecontrolleriseffectivelyclosingthecurrentloopbycontrollingthetorqueangle(see Figure2.6).Allfeedbackgoestothecontroller,notthedrive,includingcommutationfeedback. Thisallowsawidevarietyoffeedbackoptions,limitedonlybythecompatibilityofthe controller.
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Encoder AExample 1: Encoder-A precedes Encoder-B. The pulses arrive at a certain frequency, providing speed and directional information to the drive.
Encoder B+ Encoder B-
Encoder A+ Encoder A-
Example 2: Encoder-B precedes Encoder-A, meaning the direction is opposite from Example 1. The signal frequency is also higher, meaning the speed is greater than in Example 1.
Encoder B+
Encoder B-
Hall A
Low (0) High (1)
Hall B
Low (0) High (1)
Hall C
Low (0) 0 60 120 180 240 300 360
Electrical Degrees
Phase A
Low High
Phase B
Low High
Phase C
Low 0 240 300 360
60
120
180
Electrical Degrees
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Motor Hall 3
0 0 0 1 1 1 1 0
Hall 2
0 1 1 1 0 0 0 1
Hall 1
1 1 0 0 0 1 1 0
Hall 2
0 1 1 1 0 0 1 0
Phase A
HIGH LOW LOW HIGH -
Phase B
HIGH HIGH LOW LOW -
Phase C
LOW LOW HIGH HIGH -
Valid
Invalid
2.5.4 Tachometer
ADCTachometercanbeusedonsomedrivesforvelocitycontrol.Thetachometerprovidesan analogDCvoltagefeedbacksignalthatisrelatedtotheactualmotorspeedanddirection.The drivesubsequentlyadjuststheoutputcurrentbasedontheerrorbetweenthetachometer feedbackandtheinputcommandvoltage.Themaximumrangeofthetachometerfeedback signalis60VDC. Someapplicationsmayrequireanincreaseinthegainofthetachometerinputsignal.This occurrencewillbemostcommonindesignswherethetachometerinputhasalowvoltageto RPMscalingratio.Somedrivemodelsofferathroughholelocationlistedonthespecificdrive datasheetwherearesistorcanbeaddedtoincreasethetachometergain.Usethedrivesblock diagramtodetermineanappropriateresistorvalue. SeeTachometerInputGainScalingonpage45formoreinformation.
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Note
While in Current (Torque) Mode, the drive will maintain a commanded torque output to the motor based on the input reference command. Sudden changes in the motor load may cause the drive to be outputting a high torque command with little load resistance, causing the motor to spin rapidly. Therefore, Current (Torque) Mode is recommended for applications using a digital position controller to maintain system stability.
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Note
Note
The high resolution of motor mounted encoders allows for excellent velocity control and smooth motion at all speeds. Encoder Velocity Mode should be used for applications requiring precise and accurate velocity control, and is especially useful in applications where low-speed smoothness is the objective.
DC Tachometers have infinite resolution, allowing for extremely accurate velocity control. However, they also may be susceptible to electrical noise, most notably at low speeds.
Note
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Tach+ Tach-
Tach Motor
Load
Pot1 (>20k)
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Time
Torque
RMS Time
Power
Power is equal to Torque x Velocity. Motor Voltage (Vm) and Motor Current (Im) should be chosen where power is at a maximum.
Time
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ThemotorcurrentIMistherequiredmotorcurrentinampsDC,andisrelatedtothetorque neededtomovetheloadbythefollowingequation:
I M = Torque -----------------KT
Where: KT motortorqueconstant
T RMS =
Ti ti
i ---------------ti
Vm = Im Rm + E E = Ke Sm
forrotarymotors
T = Kt Im F = Kf Im
forlinearmotors
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Where: Vm Im Rm E T F Kt Kf Ke Sm motorvoltage motorcurrent(usethemaximumcurrentexpectedfortheapplication) motorlinetolineresistance motorbackEMFvoltage motortorque motorforce motortorqueconstant motorforceconstant voltageconstant motorspeed(usethemaximumspeedexpectedfortheapplication)
ThemotormanufacturersdatasheetcontainKt(orKf )andKeconstants.Payspecialattention totheunitsused(metricvs.English)andtheamplitudespecifications(peaktopeakvs.RMS, phasetophasevs.phasetoneutral). Themaximummotorterminalvoltageandcurrentcanbecalculatedfromtheaboveequations. Forexample,amotorwithaKe=10V/Krpmandrequiredspeedof3000RPMwouldrequire 30Vtooperate.InthiscalculationtheIRterm(voltagedropacrossmotorwindingresistance)is disregarded.MaximumcurrentismaximumtorquedividedbyKt.Forexample,amotorwithKt =0.5Nm/Aandmaximumtorqueof5Nmwouldrequire10ampsofcurrent.Continuous currentisRMStorquedividedbyKt.
V m = ( R m + jL )I m + E
Where: L phasetophasemotorinductance maximummotorcurrentfrequency
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VM IM I PS = ----------------------------V PS ( 0.98 )
Where: VPS IM VM nominalpowersupplyvoltage motorcurrent motorvoltage
The only time the power supply current needs to be as high as the drive output current is if the move profile requires maximum current at maximum velocity. In many cases however, maximum current is only required at start up and lower currents are required at higher speeds.
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DIODE BRIDGE Vp
Ip Vm
Im
Id AC Input Voltage
Motor
Time
SERVO DRIVE
Id
Vp = VAC*1.41
Average Time Ip
Vm = Motor Terminal Voltage Im = Motor Current Id = Diode Current Ip = Power Supply Current Vp = DC Power Supply Voltage VAC = AC Supply Voltage (RMS) The ripple current depends on the motor inductance and the duty cycle (MOSFET ON vs. OFF time)
Average Time Vp
Time
50usec
ThesepercentagesalsoaccountforthevariancesinKtandKe,andlossesinthesystem externaltothedrive.Theselectedmargindependsonthesystemparametervariations.
Do not select a supply voltage that could cause a mechanical overspeed in the event of a drive malfunction or a runaway condition. Brushed Motors may have voltage limitations due to the mechanical commutators. Consult the manufacturers data sheets.
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Figure2.12providesonepossibleexampleofanappropriatesystempowersupplyvoltagefor ananalogdriveusinganexternalshuntregulator.Theovervoltageandundervoltage shutdownlevelsonADVANCEDMotionControlsdrivescanbefoundonthedrivedatasheet.The shuntregulatorturnonvoltagewaschosenatanappropriateleveltoclampthepowersupply voltagesoitwillnotexceedthedriveovervoltagelimitduringregeneration.Thesystempower supplyrequirementisbasedonthemotorpropertiesandhowmuchvoltageisneededto achievetheapplicationmoveprofile(seeMotorCurrentandVoltageonpage17).Keepin mindthatthecalculatedvalueforVmistheminimumvoltagerequiredtocompletemovesat thedesiredspeedandtorque.Thereshouldbeatleast10%headroombetweenthecalculated valueandtheactualpowersupplyvoltagetoallowformachinechangessuchasincreased frictionduetowear,changeinload,increasedoperatingspeed,etc. FIGURE 2.12 Power Supply Selection
100 80 Drive Over Voltage Shutdown (88V) Shunt Regulator Turn-On Voltage (80V)
VDC
60 40 20 0
Isolation InsystemswhereanAClineisinvolved,isolationisrequiredbetweentheAClineandthe
signalpinsonthedrive.Thisappliestoallsystemsexceptthosethatuseabatteryasapower supply.Therearetwooptionsforisolation: 1. 2. Thedrivecanhavebuiltinelectricalisolation. Thepowersupplycanprovideisolation(e.g.abatteryoranisolationtransformer).
Thesystemmusthaveatleastoneoftheseoptionstooperatesafely.
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Thisregeneratedenergycanchargethepowersupplycapacitorstolevelsabovethatofthe driveovervoltageshutdownlevel.Ifthepowersupplycapacitanceisunabletohandlethis excessenergy,orifitisimpracticaltosupplyenoughcapacitance,thenanexternalshunt regulatormustbeusedtodissipatetheregeneratedenergy.Shuntregulatorsareessentiallya resistorplacedinparallelwiththeDCbus.Theshuntregulatorwill"turnon"atacertain voltagelevel(setbelowthedriveovervoltageshutdownlevel)anddischargetheregenerated electricenergyintheformofheat. Thevoltageriseonthepowersupplycapacitorswithoutashuntregulator,canbecalculated accordingtoasimpleenergybalanceequation.Theamountofenergytransferredtothepower supplycanbedeterminedthrough:
Ei = Ef
Where: Ei Ef initialenergy finalenergy
1 2 E c = -- CV nom 2
Where: Ec C Vnom energystoredinacapacitor(joules) capacitance nominalbusvoltageofthesystem
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1 2 E r = -- J 2
Where: Er J kinetic(mechanical)energyoftheload(joules) inertiaoftheload(kgm2) angularvelocityoftheload(rads/s)
E p = mgh
Where: Ep m g h potentialmechanicalenergy(joules) massoftheload(kg) gravitationalacceleration(9.81m/s2) verticalheightoftheload(meters)
Vf =
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forashuntregulatorbyoperatingtheservodriveundertheworstcasebrakingand decelerationconditions.Ifthedriveshutsoffduetoovervoltage,ashuntregulatorisnecessary.
Continuous Regeneration
Inthespecialcasewhereanapplicationrequirescontinuousregeneration(morethanafew seconds)thenashuntregulatormaynotbesufficienttodissipatetheregenerativeenergy. PleasecontactADVANCEDMotionControlsforpossiblesolutionstosolvethiskindof application.Someexamples:
I PS V R = --------- F f C PS
Where: VR CPS IPS Ff voltageripple powersupplycapacitance powersupplyoutputcurrent frequencyfactor(1/hertz)
Thepowersupplycapacitancecanbeestimatedbyrearrangingtheaboveequationtosolvefor thecapacitanceas:
I PS C PS = ------- F f VR
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Thefrequencyfactorcandeterminedfrom:
0.42 F f = --------f
wherefistheAClinefrequencyinhertz.Notethatforhalfwaverectifiedpowersupplies,f= f/2. Thepowersupplyoutputcurrent,ifunknown,canbeestimatedbyusinginformationfromthe outputsideoftheservodriveasgivenbelow:
VM I M I PS = ---------------------------V PS ( 0.98 )
Where: IM VPS VM currentthroughthemotor nominalpowersupplyvoltage motorvoltage(seeMotorCurrentandVoltageonpage17)
Description
0 - 65 C 90%, non-condensing 10g, 11ms, Half-sine 2 - 2000 Hz @ 2.5g 0-3000m
Shock/Vibrations Whileanalogdrivesaredesignedtowithstandahighdegreeofmechanical
Care should be taken to ensure the drive is securely mounted in a location where no moving parts will come in contact with the drive.
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General
1. Shieldedcablesmustbeusedforallinterconnectcablestothedriveandtheshieldofthe cablemustbegroundedattheclosestgroundpointwiththeleastamountofresistance. 2. Thedrivesmetalenclosuremustbegroundedtotheclosestgroundpointwiththeleast amountofresistance. 3. Thedrivemustbemountedinsuchamannerthattheconnectorsandexposedprinted circuitboardarenotaccessibletobetouchedbypersonnelwhentheproductisin operation.Ifthisisunavoidabletheremustbeclearinstructionsthatthedriveisnottobe touchedduringoperation.Thisistoavoidpossiblemalfunctionduetoelectrostatic dischargefrompersonnel.
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3.3 Grounding
InmostservosystemsallthecasegroundsshouldbeconnectedtoasingleProtectiveEarth (PE)groundpointina"star"configuration.GroundingthecasegroundsatacentralPEground pointreducesthechanceforgroundloopsandhelpstominimizehighfrequencyvoltage differentialsbetweencomponents.Allgroundwiresmustbeofaheavygaugeandbeasshort aspossible.ThefollowingshouldbesecurelygroundedatthecentralPEgroundingpoint:
+VDC
Command Signal
Command Signal
Controller
Motor
Groundcableshieldwiresatthedrivesidetoachassisearthgroundpoint. TheDCpowergroundandtheinputreferencecommandsignalgroundareoftentimesata differentpotentialthanchassis/PEground.Thesignalgroundofthecontrollermustbe connectedtothesignalgroundofthedrivetoavoidpickingupnoiseduetothe"floating" differentialservodriveinput.InsystemsusinganisolatedDCpowersupply,signalground and/orpowergroundcanbereferencedtochassisground.Firstdecideifthisisboth appropriateandsafe.Ifthisisthecase,theycanbegroundedatthecentralgroundingpoint. ForsystemsusingACpowerreferencedtochassisground,thedrivemusthaveinternaloptical isolationtoavoidashortthroughthethedrivesdiodebridge. Grounding is important for safety. The grounding recommendations in this manual may not be appropriate for all applications and system machinery. It is the responsibility of the system designer to follow applicable regulations and guidelines as they apply to the specific servo system.
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3.4 Wiring
Servosystemwiringtypicallyinvolveswiringacontroller(digitaloranalog),aservodrive,a powersupply,andamotor.Wiringtheseservosystemcomponentsisfairlyeasywhenafew simplerulesareobserved.AswithanyhighefficiencyPWMservodrive,thepossibilityof noiseandinterferencecouplingthroughthecablingandwirescanbeharmfultooverall systemperformance.Noiseintheformofinterferingsignalscanbecoupled:
ThemainsourceofnoiseisthehighDV/DT(typicallyabout1V/nanosecond)ofthedrives outputpowerstage.ThisPWMoutputcancouplebacktothesignallinesthroughtheoutput andinputwires.Thebestmethodstoreducethiseffectaretomovesignalandmotorleads apart,useaninductivefiltercard,addshielding,andusedifferentialinputsatthedrive. Unfortunately,lowfrequencymagneticfieldsarenotsignificantlyreducedbymetalenclosures. Typicalsourcesare50or60Hzpowertransformersandlowfrequencycurrentchangesinthe motorleads.Avoidlargeloopareasinsignal,powersupply,andmotorwires.Twistedpairsof wiresarequiteeffectiveinreducingmagneticpickupbecausetheenclosedareaissmall,and thesignalsinducedinsuccessivetwistcancel. ADVANCEDMotionControlsrecommendsusingthefollowinghandcrimptoolsforthe appropriateI/OandFeedbackcableandwirepreparation.Consultthedrivedatasheettosee whichconnectorsareusedonaspecificdrive.
Drive Connector 16-pin, 2.54 mm spaced friction lock header Standard Density D-sub headers High Density D-sub headers Hand Crimp Tool Manufacturer and Part Number Molex: P/N 0638118200 Tyco: P/N 58448-2 Tyco: P/N 90800-1
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Forabrushedmotororvoicecoil,twistthetwomotorwirestogetherasagroup. Forabrushlessmotor,twistallthreemotorwirestogetherasagroup.
ThediagramsbelowshowhowananalogservodriveconnectstoaBrushed(singlephase)and Brushless(threephase)motors.Noticethatthemotorwiresareshielded,andthatthemotor housingisgroundedtothesinglepointsystemground(PEGround).Thecableshieldshouldbe groundedatthedrivesidetochassisground. FIGURE 3.2 Motor Power Output Wiring
BRUSHED MOTOR Shield Motor MOT Single Point System Ground (PE Ground) Chassis Ground
Single Point System Ground (PE Ground)
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DC Power Supply
Power Supply Capacitance
DC Power Supply
Power Supply Capacitance
DC Power Supply
Power Supply Capacitance
For AC input amplifiers, AC power should be distributed from a central AC source, not a capacitor
Wire pairs should be routed together and twisted all the way back to the power source
StandardACconnector underneathdrive
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DrivesthataccepteithersinglephaseorthreephaseAClinepowerhavea5contactACinput screwterminal.ConnectathreephaseACsupplytoAC1,AC2,andAC3.AsinglephaseAC supplycanbeconnectedtoanytwoofthethree(AC1,AC2,AC3)ACterminals. FIGURE 3.6 Single or Three Phase AC Line Connections
ANALOG SERVO DRIVE
Shield
Chassis Ground
*For Single-phase AC Supply, connect AC lines to any two of AC1, AC2, and AC3. Do not connect AC line neutral to ground!
Motor
Motor
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incrementalencoderfeedback.Ifusingasingleendedencoderwithadrivethataccepts differentialinputs,leavethenegativeterminalopen.Boththe"A"and"B"channelsofthe encoderarerequiredforoperation.Drivesthatacceptdifferentialsignalsalsoacceptan optional"index"channelthatcanbeusedforsynchronizationandhoming.Ifusingthe+5V, 150mA(or250mA)lowvoltagepowersupplyoutputfromthedrive,verifythatthesupply outputvoltageandcurrentratingissufficientfortheencoderspecifications. FIGURE 3.9 Incremental Encoder Connections
ANALOG SERVO DRIVE +5V Encoder Supply Output Signal Ground
Enc A
+ -
+ Enc B -
Tachometer FordrivesthatacceptaTachometerforvelocitycontrol,connectthenegative
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In case of a single-ended reference signal, connect the command signal to "+ REF IN" and connect the command return and "- REF IN" to signal ground.
considertheoutputimpedanceoftheanalogsourcewheninterfacingtoinputcircuitry.A poorlydesigned10Vanaloginputinterfacecanleadtoundesiredcommandsignal attenuation.Figure3.11showsanexternalanalogsourceconnectedtoananaloginput.The idealvoltagedeliveredtotheinputisVS.However,thevoltagedropacrossRsourcewillreduce thesignalbeingdeliveredtothedriveinput.Thisvoltagedropisdependentonthevalueof Rsourceandthedrivesinputimpedance. FIGURE 3.11 Analog Source and Drive Input
+/- 10V ANALOG SOURCE ANALOG SERVO DRIVE +/- 10V ANALOG SOURCE ANALOG SERVO DRIVE
Rsource Vs + -
+REF -REF
Rsource + Vs + -
Thedrivesanaloginputcanbesimplifiedtoasingleimpedance,Rin,asshowninFigure3.11. IftheimpedanceofRsourceisofthesamemagnitudeorlargerthanRin,therewillbea significantvoltagedropacrossRsource.ReducedvaluesofRsourcecausealowervoltagedrop thatincreasessignalintegrity.Inordertoavoidavoltagedropofmorethan5%betweenthe sourceandthedrive,itisrecommendedtouseanRsourcevalueoflessthanorequalto2kohm. Ifthereisalargeoutputimpedancefromtheanalogsource,itisrecommendedtouseabuffer circuitbetweentheanalogsourceoutputandthedriveinput.Aunitygainopampcircuitas showninFigure3.12willensurelowoutputimpedancewithminimalvoltagedrop. FIGURE 3.12 Optimized Low Impedance Interface
+/- 10V ANALOG SOURCE ANALOG SERVO DRIVE
Rsource Vs + -
+REF -REF
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+10V
GND
-10V
Uni-directional Control
+10V
Somedrivemodelsfeaturea+5Vinputpinthatisusedtodrivetheoptocouplerinputs. This+5VsupplymustbegroundedatthenegativeInhibitterminal.Thepositiveterminals forthePWM,Direction,andInhibitinputsareallinternallyconnectedtothe+5Vinput. Therefore,theexternalPWMandDirectioninputsignalsshouldbeconnectedatthe negativePWMandDirectionterminals.ThepositiveFaultoutputterminalcanalsobe connectedtothe+5Vinputsupply,andwhenthedriveentersafaultstage,thenegative Faultoutputterminalwillrisetothe+5Vsupplyindicatingafaultcondition. FIGURE 3.14 PWM and Direction Optocoupled Inputs, +5V supply input option
ANALOG SERVO DRIVE +5V Input PWM+ PWM Input Signal PWM+5V Input DIR+ Direction Input Signal +5V FAULT+ Fault Monitor Output FAULT+5V Input INHIBIT+ Ground to Inhibit / Open to Enable INHIBIT5k 100k 100k 100k 100k
+5V
500
+5V
DIR5k
+5V
+5V Supply
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Ondrivesthatdonotcontainanadditional+5Vinputsupplypin,therearetwooptionsto activatetheoptocouplers.ThepositiveterminalsofthePWM,Direction,Fault,andInhibit I/Ocanbebroughttoanexternal+5Vsupply,orthenegativeterminalsofthePWM, Direction,Fault,andInhibitI/Ocanbebroughttoground. FIGURE 3.15 PWM and Direction Optocoupled Inputs
ANALOG SERVO DRIVE +5V PWM+ PWM Input Signal PWM5k 100k
ANALOG SERVO DRIVE PWM Input Signal GND PWM+ PWM5k 100k
+5V DIR+ Direction Input Signal +5V FAULT+ Fault Monitor Output +5V INHIBIT+ Ground to Inhibit / Open to Enable INHIBITFAULTDIR-
100k
DIR+ DIR-
100k
5k
100k
100k
100k
100k
+ REF-IN-B - REF-IN-B
40k 40k
+ REF-IN-B - REF-IN-B
40k 40k
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3.5 Mounting
ADVANCEDMotionControlsanalogservodrivesprovidemountingholelocationsonthe baseplateallowingthedrivetobemountedeitherverticallyorhorizontally.Drivescanbe mountedtoaheatsinkorotherplanesurface,orattachedtoalabraileitheronatestbenchor aspartofalargersystem.Consultthedrivedatasheetforspecificmountingdimensionsand mountingholelocations. FIGURE 3.17 Analog Servo Drives Mounting Options
MOTION
ADVAN C CO NT ED RO
LS
MOTIO
ADVAN C
N CONT
RO LS
ED
MO TIO NC ON T RO LS
AD V
ANC E
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Operation
ThischapterwilldescribetheoperationandsetupofanADVANCEDMotionControlsanalogservodrive.
Example Measurement
Thecurrentmonitorpinonadrivewithacurrentmonitorscalingfactorof4A/Vismeasured tobe1.3V.Thiswouldmeanthedriveisoutputting:(4A/V)(1.3V)=5.2A.
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max
Example Measurement
Thecurrentreferencepinonadrivewithapeakcurrentvalueof12AandVmaxof7.45Vis measuredtobe2.63V.FollowingtheaboveequationtosolveforIcommand,thecommand currenttotheinternalcurrentloopwouldbe4.24A.
eitherconnectingthispintogroundorbyapplyinga+5VDCvoltageleveltothispin, referencedtosignalground.Bydefault,thedrivewillbeenabledifthispinishigh,and disabledifthispinislow.Thislogiccanbereversed,however,eitherthroughDIPswitch settingorbyremovingaSMTjumperfromthePCB(consultthedrivedatasheettoseewhich optionisavailable;notethatremovaloftheSMTjumpermustbedonebyapersonfamiliar withSMTsoldering,andthatthedrivewarrantywillbevoidedifthedriveisdamaged).This willrequireallinhibitlinestobebroughttogroundtoenablethedrive.Mostdrivescanalsobe orderedwithinvertedinhibitlogicaswell(INVoption).Somedrivemodelsallowthedriveto beconfiguredsotheinhibitinputdoesnottriggeradrivefaultstate.Typicallythisisachieved byDIPswitchsetting.Consultthedrivedatasheettoseeifthisoptionisavailable.
Directional Inhibits
Somedrivesalsoincludedirectionalinhibitpinsthatdisablemotormotionineitherthe positiveornegativedirection,typicallyusedforlimitswitches.Thesepinsdonotcauseadrive faultcondition.Theywillfollowthesamelogic(eitherstandardorinverted)asthemain inhibit/enableinput.
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outputsmeantforcustomeruse.Consultthedrivedatasheettoseewhichlowvoltageoutputs areincludedonaspecificdrive. 10V(or5V),3mAOutputTypicallyusedasanonboard10Vanaloginputsignalfor testingpurposes.Thisoutputcanbeusedinconjunctionwithanexternalpotentiometerto varytheinputsignalbetween10V. +6V,30mAOutputAvailableonthreephase(brushless)driveonly.Thispinprovidesa +6VDCoutputthatcanbeusedtopowerHallSensors.Consultthemotordatasheettofind outwhichfeedbackwirefromthemotoristheHallSensorpowersupplywire. Do not use this +6V supply to power an encoder. An encoder will require a separate power supply. Consult the encoder datasheet or specifications to determine the encoder voltage and current requirements. Typical values are +5VDC at 150mA.
ForadriveinEncoderVelocityMode,substitutethevoltagevaluereadatthevelocity monitorpin,Vmonitor,intothebelowequationtodeterminethemotorRPM:
theactualmotorspeed.Thescalingfactorforeachindividualdrivecanbefoundonthedrive datasheet.
ForadriveinHallVelocityMode,substitutethevoltagevaluereadatthevelocitymonitor pin,Vmonitor,intothebelowequationtodeterminethemotorRPM:
V monitor Scaling Factor 120 Motor Velocity [RPM] = -----------------------------------------------------------------------Number of motor poles
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Current Limit
Test/Offset
Before taking potentiometer resistance measurements, make sure that all potentiometers and DIP switches have been set to the desired settings, and that all I/O and Feedback cables have been removed from the drive, as these can affect resistance measurements.
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Outer Loop Integration Activation Outer Loop Integral Gain Adjustment Duty Cycle Feedback Hall Sensor Commutation Phasing Test/Offset
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Thisallowsuserstoreducetheeffectiveinputresistancetoavaluethatmorecloselymatches theirmaximumapplicationfeedbackvoltageinordertoincreasethetachometerinputgain.An appropriatetachometerinputresistancevalueshouldbeatleast1000timesthemaximum tachometervoltagefeedbackvalue.Fromzerotoinfiniteresistance(openconnection),this throughholelocationcanscalethetachometersmaximuminputvoltagerangefrom10Vto 60V. Todeterminethemaximumfeedbackvoltagefortheapplication: 1. Determinetheabsolutemaximumspeedrequiredofthemotorfortheapplication(Sm,in kRPM). 2. Lookupthetachometersvoltagetospeedconstant(Kv,inV/kRPM). 3. Calculateforthetachometersmaximumvoltageoutputintheapplication: V max = K v S m
Example
Anapplicationsmaximummotorspeedis4.7kRPM,andthetachometerisratedfor7 V/kRPM.Usingtheaboveequation,themaximumvoltagefromthetachometerinput,Vmax, willbe33V.Therefore,theequivalenttachometerinputresistancemustbeatleast33k. Choosinganequivalentresistancevalueof35k,solvefortherequiredresistanceofthe throughholeresistor. ( 50 V max ) 500 ( 50 35 ) 500 Tach Gain Through-Hole Resistor (in kohm) = ----------------------------------------- = ----------------------------------- = 50k 60 35 60 V max Assolvedforabove,theequivalent35kresistancecanbeacheivedbyaddinga50kthrough holeresistorinparallelwiththeexisting50kresistoronthedrivetachometerinput.
Scaling the tachometer input gain is not a required procedure for all applications. Most applications will work well even with low gains. The effect of low gains is only a slower velocity loop response.
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Example
A30A8driveisgoingtobeusedwithanapplicationhavingacontinuouscurrentratingof2.5 amps,apeakcurrentrequirementof6amps,andapeakcurrentlimitof10amps.The30A8 hasaCurrentScalingandCurrentLimitRatioswitch,aCurrentLimitpotentiometer,andthe optionofusinganexternalresistortoreducethecontinuouscurrentlimit.Thisexamplewill onlyusetheDIPswitchesandpotentiometer. 1. Typicallyitisrecommendedtosetthecurrentlimitsofthedrivebelowthecontinuousand peakcurrentratingsoftheapplication,allowingsomeheadroomforsafety.Inthiscase, thedrivecontinuouscurrentlimitwillbechosenat2amps,andthepeakcurrentlimitat 9amps. 2. SettingtheCurrentScalingswitchtoOFFwillscalethepeakandcontinuouscurrentlimits byhalf,yieldingapeaklimitof15amps,andacontinuouslimitof7.5amps. 3. SettingtheCurrentLimitRatioswitchtoONwillchangethecontinuoustopeakcurrent ratioto25%,yieldingapeaklimitof15amps,andacontinuouslimitof3.75amps. 4. Tofurtherreducethecurrentlimitstothedesiredvalues,theCurrentLimitpotentiometer canbeused.Beginwiththecontinuouscurrentrequirement,usingtheequationto determinethenumberofclockwiseturnsfortheCurrentLimitpotentiometer: 2amps # of turns = ----------------------- 12 + 1 3.75amps Solvingforthenumberofturnsyieldsapproximately7.5turnsintheclockwisedirection fromthefullycounterclockwiseposition. 5. Sincethecontinuoustopeakratiowassetat25%inStep3,thenumberofturns calculatedabovewillyieldapeakcurrentlimitofapproximately8amps,thereby satisfyingboththecontinuousandpeakcurrentrequirementsoftheapplication.
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Motor Hall 3
0 0 0 1 1 1 1 0
Hall 2
0 1 1 1 0 0 0 1
Hall 1
1 1 0 0 0 1 1 0
Hall 2
0 1 1 1 0 0 1 0
Phase A
HIGH LOW LOW HIGH -
Phase B
HIGH HIGH LOW LOW -
Phase C
LOW LOW HIGH HIGH -
Valid
Invalid
6. Removepower.Inall,therearesixdifferentwaystoconnectthethreemotorwirestothe MotorA,MotorB,andMotorCpins.Allsixcombinationsmustbetestedtofindtheproper combination.Thecorrectcombinationshouldyieldapproximatelyidenticalmotorspeed inbothdirections.Ifthemotorrunsslowerinonedirection,orifthemotorshafthastobe movedmanuallybyhandtostartthemotor,thecombinationisincorrect.Motorspeedcan beverifiedbyusingthevelocitymonitororbymeasuringthefrequencyoftheHall Sensors. 7. Tobegin,connectthethreemotorwiresinanyorder. 8. Applypowertothedrive,andslowlyturntheTest/Offsetpotentiometerinbothdirections. Observethemotorspeedforbothdirections.Removepowerfromthedrive,andrewire thethreemotorwiresforadifferentcombination.Testallsixdifferentcombinations beforeproceeding. 9. Oncethepropercombinationhasbeenfound,settheTest/OffsetswitchtoOffset,ground bothreferenceinputs,andthenadjusttheTest/Offsetpotentiometerforzerospeed. 10. Setthecontrolmodesuitablefortheapplication.Ifnecessary,tochangethemotor directionforagivencommandinput,interchangeHall1andHall3,thenMotorAand MotorB.
or:
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Motorrapidlyoverheatsevenatlowcurrent Driverapidlyoverheatsevenatlowcurrent Vibrationsoundcomesfromthedriveormotor Themotorhasahighinductance(+10mH) Themotorhasalowinductance(nearminimumratingofthedrive) Slowsystemresponsetimes Excessivetorqueripple Difficultytuningpositionorvelocityloops Electricalnoiseproblems Highpowersupplyvoltage(powersupplyissignificantlyhigherthanthemotorvoltage ratingornearthedrivesuppervoltagelimit) Lowpowersupplyvoltage(powersupplyvoltageisnearthedriveslowervoltagelimit)
Theaboveindicatorsaresubjectiveandsuggestthatthecurrentloopmayneedtobetuned. Thesecanalsobesignsofotherproblemsnotrelatedtocurrentlooptuning. Theresistorsandcapacitorsshownunderthecurrentcontrolblockonthedatasheetblock diagramdeterminethefrequencyresponseofthecurrentloop.Itisimportanttotunethe currentloopappropriatelyforthemotorinductanceandresistance,aswellasthebusvoltage toobtainoptimumperformance.BrushtypeandBrushlessdriveshaveasinglecurrentloop, whileSinusoidal(SSeries)driveshavethreecurrentloops.Allthreeloopsmustbetunedthe sameorthedrivewillnotoperateproperly.Theloopgainandintegratorcapacitanceofthe currentloopmustbothbeadjustedforthetuningtobecomplete. Improper current loop tuning may result in permanent drive and/or motor damage regardless of drive current limits.
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adjustedwiththemotoruncoupledfromtheload,andthemotorsecuredassuddenmotorshaft movementmayoccur.Thefollowingpointsshouldbekeptinmindbeforebeginningthetuning procedure: Brushlessdrivesshouldbeconfiguredfor60degreephasinginordertogetoutput current.ThecurrentcanbemeasuredthrougheithermotorphaseAorB. ForSinusoidal(SSeries)drives,connectthefunctiongeneratorto+REFINAand signalground,andmeasurethecurrentthroughmotorphaseA. UsetheDIPswitchesandCurrentLimitPotentiometertoselectCurrentMode,theinput range(ifapplicable)andtosettheappropriatecurrentlimitforthemotor(notethatS SeriesdrivesareautomaticallyinCurrentMode). Connectonlythemotorpowerleadstothedrive.Nootherconnectionsshouldbemadeat thispoint. Usingafunctiongenerator,applya0.5V,50100Hzsquarewavereferencesignaltothe inputreferencepins. Shortoutthecurrentloopintegratorcapacitor(s)usingtheappropriateDIPswitchesor jumpers(seethespecificdrivedatasheetandblockdiagramfordetails). Applypowertothedrive.Useabusvoltagethatisapproximatetothedesiredapplication voltageorthecurrentloopcompensationwillnotbecorrect. Thedriveshouldbeenabled(GREENLED).Observethemotorcurrentusingacurrent probeorresistorinserieswiththemotor(<10%ofmotorresistance).Thisobservation shouldbedoneforboththehighandlowcurrentloopgain(seedrivedatasheetfor availablecurrentloopgainDIPswitchsettings).Differentdrivesneedtobesetup differentlytoviewthecurrentloopresponseproperly,asshowninthefollowingfigures.
1.
2. 3. 4. 5. 6.
Motor
Since the two motor wires are in series, the current through the wires is the same. The current probe can be attached to either wire with the same results. To keep the motor from turning during the tuning process the motor shaft must be locked.
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Motor The motor shaft does not need to be locked since the drive will not commutate without the Hall Sensors.
The current out of the drive can be forced to go through Motor A and Motor B by: 1) Disconnecting the Hall sensors from the drive 2) Setting the 60/120 degree phasing switch to 60 degrees
Motor
The current out of the drive can be forced to go through Motor A and Motor C by applying the square wave command signal to Ref In A only. Attach the current probe to either Motor A or Motor C.
The motor shaft does not need to be locked since the drive is not commutating.
Time
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2. Usingafunctiongenerator,applya0.5V,50100Hzsquarewavereferencesignal. 3. Applypowertothedrive.Useabusvoltagethatisapproximatetothedesiredapplication voltageorthecurrentloopcompensationwillnotbecorrect. 4. Thedriveshouldbeenabled(GREENLED).Observethemotorcurrentusingacurrent probeorresistorinserieswiththemotor(<10%ofmotorresistance).Ifavailable,useany DIPswitchestoadjustthecurrentloopintegralgaincapacitance.Theoutputshouldsettle toaflattopwithminimalcurrentfollowingerror(differencebetweencommanded currentandactualcurrent).Therecanbesomeovershoot,butitshouldbelessthan10%. Because the oscilloscope measurements are voltage representations of current, the commanded and actual currents will most likely have different current to voltage scalings and tolerances. Therefore, even with perfect current loop tuning, the two amplitudes (scope traces) may not line up as shown in Figure 4.5. 5. Ifthesquarewaveoutputovershootstoomuchorisoverdamped(sluggish),thecurrent loopintegratorcapacitorwillneedtobechangedtooptimizetheresponse.SeeThrough holeComponentTuningonpage53formoreinformation.
VoltageLooporDutyCycleLoopCompensatingthevoltagelooprequirestheleast amountofeffort.TurntheLoopGainpotentiometerclockwiseuntiloscillationoccurs,then backoffoneturn. IRFeedbackLoopStartwithaveryhigh(oropen)IRfeedbackresistorwithan unloadedmotorshaft.Commandalowmotorspeed(about20200RPM).WithouttheIR feedbackthemotorshaftcanbestalledeasily.DecreasingtheIRfeedbackresistorwill makethemotorshaftmoredifficulttostop.ToomuchIRfeedback,i.e.toolowaresistor value,willcausemotorrunawaywhentorqueisappliedtothemotorshaft. VelocityLoop(Encoder,Halls,orTachometer)Thevelocityloopresponseis determinedbytheLoopGainpotentiometer.Alargerresistancevalue(clockwise)results inafasterresponse.Thevelocityintegratorcapacitorcanbeusedtocompensatefora largeloadinertia.Alargeloadinertiawillrequirealargercapacitorvalue.Eitherusingthe DIPswitchestoaddinanextracapacitororinstallingathroughholecapacitormay accomplishthis(seeThroughholeComponentTuningonpage53formore information).Theneedforanextracapacitorcanbeverifiedbyshortingoutthevelocity integratorcapacitorbyDIPswitchsetting.Ifthevelocityloopisstablewiththecapacitor shortedout,andunstablewiththecapacitorinthecircuit,thenalargercapacitorvalueis needed.
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Ingeneral,ADVANCEDMotionControlsanalogservodriveswillnotneedtobefurthertunedwiththroughhole components.However,forapplicationsrequiringmoreprecisetuningthanwhatisofferedbytheDIPswitches andpotentiometers,thedrivecanbemanuallymodifiedwiththroughholeresistorsandcapacitorsasdenoted inTableA.1below.Onmostanalogdrives,thethroughholelocationsarenotpopulatedwhenthedriveis shipped.SSeriesdriveshoweverareshippedwiththroughholecomponentsinpinreceptaclesforeasy removal. ItisrecommendedtocontactADVANCEDMotionControlstodiscussapplicationrequirementsandproperdrive tuningpriortomakinganyadjustments. Any damage done to the drive while performing these modifications will void the product warranty.
Beforeattemptingtoaddthroughholecomponentstotheboard,seeTuningProcedureonpage49.Some generalrulestofollowwhenaddingthroughholecomponentsare:
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UseapotentiometertofindthecorrectcurrentloopgainvalueApotentiometercan beusedtocontinuouslyadjustthegainresistancevalueduringthetuningprocess.Installa potentiometerinplaceofthegainresistor.Adjustthepotentiometerwhileviewingthe currentloopresponseonanoscilloscope.Whentheoptimalresponseisachievedturnoff thedrive,removethepotentiometer,andmeasurethepotentiometerresistance.Usethe closestresistorvalueavailable.(Note:Thismethodwillnotworkiftheoptimaltuning valueisbeyondtherangeofthepotentiometer.Thismethodalsodoesnotworkforsine drivessinceitisdifficulttokeepthetuningvaluesinthethreecurrentloopsthesame). Progressivelydoubletheresistancevaluewhentuningthecurrentloopgainfor fasterresultsIfthegainresistorneedstobeincreasedduringthetuningprocessthe fastestresultsareachievedbydoublingtheresistancefromthelastvaluetried.Usethis methoduntilovershootisobservedandthenfinetunefromthere. Beawareofanycomponentsthatareinparallelwiththevaluesyouaretryingto tuneOnsomedrives,theremaybeoneormoregainresistorsinparallelwiththe throughholeresistorlocation.TheequivalentresistancevalueoftheSMTresistorsonthe boardandtheadditionalthroughholeresistorwillbelimitedbythesmallestresistance valueofthegroupofresistorsinparallel.Consulttheblockdiagramonthedrivedatasheet todeterminethespecificresistorvalues.Thesamesituationcanoccurwhentryingto decreasetheintegratorcapacitorvalue,sincecapacitorsinparallelwillbeaddedtogether. Safety Always remove power when changing components on the drive.
Float the oscilloscope and function generator grounds to avoid large ground currents.
Decouple the motor from the load to avoid being injured by sudden motor movements.
TableA.1liststhedifferentthroughholecomponentsthatcanbeusedforlooptuning.Some modelsrequiremorethanonecomponentthatmusthaveidenticalvalues.Consultthedrive datasheettoseewhichoptionsareavailableforaspecificdrive.PleasecontactADVANCED MotionControlsApplicationsEngineeringforassistanceindeterminingthePCBlocationofthe throughholecomponentoptionsforthedrivemodelinuse. TABLE A.1 Through-Hole Tuning Component
Component Current Loop Proportional Gain Resistor Current Loop Integrator Capacitor Velocity Loop Integrator Capacitor Description Through-hole resistor that can be added for more precise current loop tuning. Through-hole capacitor that can be added for more precise current loop tuning. Through-hole capacitor that can be added for more precise velocity loop tuning.
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A.1.1 Procedure
BeforechanginganycomponentsonthePCB,followthestepsinTuningProcedureon page49todetermineifanyadditionaltuningisnecessary.Observethedriveoutputcurrent responseonanoscilloscopeforallthedifferentDIPswitchgainsettings(ifavailableonthe driveinuse).Iffurthertuningisnecessaryordesired,pleasecontactADVANCEDMotion Controlsbeforeproceedingthroughthethroughfollowingsteps.
Remember that for Sinusoidal Input (S-Series) drives, all three current loops must have identical through-hole component values (i.e. the through-hole resistor value for phase A must match the through-hole resistor values for phases B and C, and the through-hole capacitor value for phase A must match the through-hole capacitor values for phases B and C.
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2. Usingthesamefunctiongeneratorinputcommandasintheprevioussection,apply powertothedriveandobservethecurrentloopresponseonanoscilloscope. 3. Dependingonthedrivemodel,thecurrentloopintegratorcapacitorcanbechangedor shortedoutofthecircuitbyDIPswitchsetting.Testbothsettingswhileobservingthe currentloopresponse. Ifthecurrentresponsesquarewaveoscillatesorovershoots,alargerequivalent capacitancevalueisnecessary. Ifthecurrentresponsesquarewavecornersaretoorounded,asmallerequivalent capacitancevalueisnecessarytosharpenthecorners. 4. Asintheprevioussection,usingpinreceptaclesatthethroughholelocationswillgreatly assistinfindinganacceptablecapacitancevalue.Alsokeepinmindthatthethroughhole capacitorlocationmaybeinparallelwithSMTcapacitorsonthePCB.Usetheblock diagramonthedrivedatasheettodeterminetheequivalentintegratorcapacitancevalue (capacitorsinparalleladdtogether). 5. Althoughtheidealcurrentloopresponseafterintegralgaintuningwillbeacritically dampedsquarewave,theapplicationrequirementswilldeterminewhatthedesired responsewillbe(i.e.howmuchovershoot,steadystateerror,oscillation,isacceptable).
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Troubleshooting
Thissectiondiscusseshowtoensureoptimumperformanceand,ifnecessary,getassistancefromthefactory.
Over-Temperature Verifythatthebaseplatetemperatureislessthanthemaximumallowable
baseplatetemperatureasdenotedonthedrivedatasheet,typically65C(149F)or75C (167F).Thedriveremainsdisableduntilthetemperatureatthedrivebaseplatefallsbelow thisthreshold.
Over-Voltage Shutdown
1. ChecktheDCpowersupplyvoltageforavalueabovethedriveovervoltageshutdown limit.IftheDCbusvoltageisabovethislimit,checktheACpowerlineconnectedtotheDC powersupplyforpropervalue. 2. Checktheregenerativeenergyabsorbedduringdeceleration.Thisisdonebymonitoring theDCbusvoltagewithavoltmeteroroscilloscope.IftheDCbusvoltageincreasesabove thedriveovervoltageshutdownlimitduringdecelerationorregeneration,ashunt
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regulatormaybenecessary.SeeRegenerationandShuntRegulatorsonpage23formore information.
tableinHallSensorsonpage12forvalidcommutationstates.Ifthedriveisdisabledcheck thefollowing:
boardisfunctionalpriortoenablingthedrive.Theboardwillonlybedisabledmomentarily, andwillquicklyenableuponpowerup.
B.1.1 Overload
Verifythattheminimuminductancerequirementismet.Iftheinductanceistoolowitcould appearlikeashortcircuittothedriveandthusitmightcausetheshortcircuitfaulttotrip.
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Excessiveheatingofthedriveandmotorisalsocharacteristicoftheminimuminductance requirementnotbeingmet.Seedrivedatasheetforminimuminductancerequirements.
Current Measured 0
Sustained maximum current demand, when switching between positive and negative maximum current without allowing sufficient time for foldback, will result in drive damage. Drive RMS current should be below the continuous current setting!
Commandingmaximumpeakcurrentoutputstartingfromabovezerocommandwillalso yieldreducedpeakcurrentoutputtime.
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Ifthecurrentcommandsstartfromadifferentcommandlevel(inFigureB.3,allthree commandsbeginfromzeroamps)thepeaktimesandfoldbackcurveswillbedifferent. Thecloserthecommandedcurrentistothepeakcurrentlimit,theshorterthepeak outputtimewillbe. Anycommandatorbelowthemaximumcontinuouscurrentlimitcanbeachievedforas longastherearenofaultconditionspresent. Whenthedriveisconfiguredforanyofthevelocitymodes,theuserisnolongerindirect controlofthecurrentoutput.Thecurrentcommandswillbedeterminedbythevelocity loop.Thoughinternallythecurrentloopstillfunctionslikeitisdescribedabove,itwilldo onlywhatisnecessarytomeetthevelocitydemand.Thecurrentoutputdependson: Howtightthevelocityloopistuned Theloadcharacteristics Thespeedthemotorisalreadyturning Magnitudeandslopeofvelocitystep OnSSeriesdrives,iftheRMScurrentthroughanymotorphaserisesabovethemaximum continuoussinewavecurrentvalue,theovercurrentfaultoutputpinwilltriggerafault state,andthedrivewillbedisableduntiltheRMScurrentvaluehasreturnedtoavalue withintheacceptableoperatingrange.
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1. EIADateCode:Thedatecodeisa4digitnumbersignifyingtheyearandweekthatthe drivewasmanufactured.Thefirsttwodigitsdesignatetheyearandthesecondtwodigits designatetheweek.Forexample,theabovepartwouldhavebeenbuiltduringthetwenty secondweekof2009. 2. SerialNumber:Theserialnumberisa5digitnumberfollowedbya4digitnumber. 3. VersionNumber:Threedigitcodethatreferstoproductversion.Differentversionsreflect minorcomponentvaluechanges.RsignifiesRoHScompliancy. 4. PartNumber:Refertothedrivedatasheetfortypicalpartnumbers.Thelastletterrefersto therevision(intheaboveexampleB).ThepartnumbercanbeproceededbyanX,which signifiesaprototypeunit.Thepartnumbercanalsohaveasuffix(e.g.B30A40BAMC), whichdesignatesaspecialversionofthestandarddrive(B30A40Bisthestandarddrive, AMCdesignatesthespecialversion).
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Index
Symbols 10VAnalogCommand.................10 10VAnalogInputWiring ............36 A ACPowerSupplies ........................33 ACSupplyFrequency ......................9 ACSupplyVoltageRange.................9 AdjustableAccel.andDecel. ..........44 AgencyCompliances .......................ii Altitude............................................26 AnalogPositionLoopMode...........16 AnalogPositionLoopTuning........52 AttentionSymbols ...........................iii B BaseplateTemperatureRange ......26 Brushed10VAnalogDCDrives ....5 BrushedACSupplyDrives ..............5 BrushedPWMInputDCDrives ......5 BrushedServoDrives......................7 Brushless10VAnalogDCDrives ..5 BrushlessACSupplyDrives ............5 BrushlessPWMInputDCDrives ....5 BrushlessServoDrives....................7 BrushlessServoSystem...................8 BusFuse ...........................................9 C CapacitiveInterferenceCoupling .31 CEEMCWiringRequirements......28 CentralPointGrounding ...............30 CommandInputs............................10 CommutationSequenceTable.13, 48 CompanyWebsite ............................ii ContinuousCurrentLimitPin.......41 ContinuousRegeneration..............25 ControllerChassis ..........................30 ControllerbasedCommutation.......8 CrimpTool......................................31 Current(Torque)Mode .................14 CurrentLimitPotentiometer.........43 CurrentLimiting ......................46, 59 CurrentLoopGain .........................50 CurrentLoopIntegrator ................51 CurrentMonitorOutput ................40
CurrentReferenceOutput.............41 CustomModels .................................5 D DaisyChains...................................32 DCBusOverVoltageLimit ..............9 DCPowerSupplies ........................33 DCPowerSupplyWiring...............33 DCSupplyVoltageRange.................9 DIPSwitchSettings........................44 DriveCaseGrounding ...................30 DriveDatasheet................................4 DriveSetupInstructions.........4749 DutyCycleMode.............................14 DwellTime .....................................18 E ElectromagneticInterference........31 EncoderVelocityMode ..................15 EnvironmentalSpecifications .......26 ErrorSignal .................................... 11 ExternalFilterCard........................19 F FACDriveModels ...........................33 FaultConditions .......................5759 FaultOutput....................................42 FeedbackPolarity .......................... 11 FeedbackSpecifications .......... 1113 FeedbackWiring......................3435 Foldback.........................................59 FrequencyFactor ...........................25 G GroundLoops ..........................30, 32 Grounding ......................................30 H HallSensors Feedback ....................................12 Wiring.........................................34 HallVelocityMode..........................15 Humidity.........................................26 I Impedance ......................................31
IncrementalEncoder Feedback ....................................11 Wiring .........................................35 InhibitInput .............................41, 58 InputReferenceWiring...........3538 InterferenceCoupling....................31 InternalBusCapacitance.................9 InternalShuntResistance................9 InternalShuntResistor PowerRating ................................9 TurnonVoltage ...........................9 InvalidHallCommutation .............58 IRCompensationMode .................16 IRFeedbackLoopTuning .............52 IsolatedPowerSupply ...................22 Isolation ..........................................22 L LinearMotorEquation...................18 Lockout/tagoutProcedures..........1 LoopGainPotentiometer...............43 LowVoltagePowerOutputs...........42 LVDRequirements .........................27 M MagneticInterferenceCoupling ...31 Max.ContinuousOutputCurrent....9 Max.PeakOutputCurrent ...............9 Max.PowerDissipationatContinuous Current .............................9 MechanicalShock ..........................26 MinimumLoadInductance .............9 ModelMask ......................................4 ModesofOperation..................1416 AnalogPositionLoop .................16 Current(Torque) .......................14 DutyCycle(OpenLoop).............14 EncoderVelocity.........................15 HallVelocity................................15 IRCompensation........................16 TachometerVelocity...................15 VoltageMode ..............................16 MotionControlSystem.....................6 Motor"RunAway" .........................11 MotorBackEMFVoltage ...............19 MotorChassis .................................30 MotorCurrent ..........................18, 20
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PoweronReset..............................58 ProductLabel .................................61 ProductsCovered .............................4 ProtectiveEarth .............................30 PWMandDirectionCommand .....10 PWMandDirectionInputWiring.37 PWMCurrentControlCircuit..........6 R REFIN,..........................................35 REFIN,+.........................................35 ReferenceGainPotentiometer ......43 Regeneration ..................................23 Continuous .................................25 Returns ...........................................62 RevisionHistory............................. iii RMSTorque....................................18 S Safety ............................................13 ScalingFactor .................................15 SelectionandSizing .................1726 ServoDriveTheory......................68 Shielding ...................................30, 31 Shock/Vibration ............................26 ShortCircuitFault..........................58 ShuntFuse........................................9 ShuntRegulator........................21, 23 SignalGround ................................30 SinglePhaseServoDrives ...............7 SinglePhaseACSupply.................34 SinusoidalCommand.....................10 SinusoidalInputACSupplyDrives .5 SinusoidalInputDCDrives .............5 SinusoidalInputWiring ................38 StandardDriveModels .....................5 SwitchFunctions............................44 SwitchingFrequency .......................9 SystemRequirements ..............1726 SystemVoltageRequirement ........18
T Tachometer Feedback ....................................13 VelocityMode .............................15 Wiring .........................................35 TechnicalSupport..........................61 TestPoints(Pots) ...........................43 Test/OffsetPotentiometer.............43 ThreePhaseServoDrives ...............7 ThreePhaseACSupply .................34 ThroughholeComponents............53 Torque.............................................18 Trademarks ..................................... ii Troubleshooting .......................5762 Tuning Procedure .............................4952 ThroughHoleComponents .5356 TwistedPairWires.........................31 U UnderVoltageShutdown ...............58 V VelocityLoopTuning .....................52 VelocityMonitorOutput.................42 VelocityScalingFactor ...................42 Vibration.........................................26 VoltageDropInterference .............31 VoltageLoopTuning ......................52 VoltageMode ..................................16 VoltageRipple.................................25 W WarningSymbols ........................... iii WarrantyInfo.................................62 WarrantyReturns ..........................62 WireDiameter................................31 WireGauge .....................................31 Wiring .......................................3138
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