AMC AnalogDrives InstallManual

Everythings possible.
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
Notice - Required instruction necessary to ensure successful completion of a task or procedure.
Caution - Instructs and directs you to avoid damaging equipment.
Warning - Instructs and directs you to avoid harming yourself.
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
2011 ADVANCED Motion Controls. All rights reserved.
iii
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Contents
1 2
Safety
1.1 General Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Products and System Requirements
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
Integration in the Servo System

3.1 LVD Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 CE-EMC Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PWM Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOSFET Switching Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . IGBT Switching Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting of AC Power Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Ferrite Suppression Core Set-up . . . . . . . . . . . . . . . . . . . . . 3.2.2 Inductive Filter Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Motor Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 Power Supply Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4 Feedback Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hall Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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Through-hole Component Tuning

A.1 Through-Hole Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tune the Current Loop Proportional Gain . . . . . . . . . . . . . Tune the Current Loop Integral Gain . . . . . . . . . . . . . . . . . Velocity Loop Integral Gain Tuning . . . . . . . . . . . . . . . . . .
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
Thissectiondiscussescharacteristicsofyouranalogservodrivetoraiseyourawarenessofpotentialrisksand hazards.Theseverityofconsequencesrangesfromfrustrationofperformance,throughdamagetoequipment, injuryordeath.Theseconsequences,ofcourse,canbeavoidedbygooddesignandproperinstallationintoyour mechanism.
1.1 General Safety Overview

Inordertoinstallananalogdriveintoaservosystem,youmusthaveathoroughknowledge andunderstandingofbasicelectronics,computersandmechanicsaswellassafetyprecautions andpracticesrequiredwhendealingwiththepossibilityofhighvoltagesorheavy,strong equipment. Observeyourfacilityslockout/tagoutproceduressothatworkcanproceedwithoutresidual powerstoredinthesystemorunexpectedmovementsbythemachine. You must install and operate motion control equipment so that you meet all applicable safety requirements. Ensure that you identify the relevant standards and comply with them. Failure to do so may result in damage to equipment and personal injury. Read this entire manual prior to attempting to install or operate the drive. Become familiar with practices and procedures that allow you to operate these drives safely and effectively. You are responsible for determining the suitability of this product for the intended application. The manufacturer is neither responsible nor liable for indirect or consequential damages resulting from the inappropriate use of this product. High-performance motion control equipment can move rapidly with very high forces. Unexpected motion may occur especially during product commissioning. Keep clear of any operational machinery and never touch them while they are working.
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Safety / General Safety Overview
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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Safety / General Safety Overview
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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Products and System Requirements
Thischapterisintendedasaguideandgeneraloverviewinselecting,installing,andoperatingananalogservo drive.Containedwithinareinstructionsonsystemintegration,wiring,drivesetup,andstandardoperating methods.
2.1 Analog Drive Family Overview

TheanalogdrivefamilycontainsdrivesthatcanpowerSinglePhase(Brushed)andThree Phase(Brushless)motors.AnalogdrivesarepoweredoffeitherasingleDCorACpower supply,andprovideavarietyofcontrolandfeedbackoptions.Thedrivesaccepteithera10V analogsignal,aPWMandDirectionsignal,ortwosinusoidalcommandsignalsasinput.A digitalcontrollercanbeusedtocommandandinteractwithanalogservodrives,andanumber ofinput/outputpinsareavailableforparameterobservationanddriveconfiguration.
2.1.1 Products Covered

Theproductscoveredinthismanualadheretothefollowingpartnumberingstructure. However,additionalfeaturesand/oroptionsarereadilyavailableforOEMswithsufficient orderingvolume.FeelfreetocontactADVANCEDMotionControlsforfurtherinformation. FIGURE 2.1 Analog Product Family Part Numbering Structure
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
Drive Datasheet Eachanalogdrivehasaseparatedatasheetthatcontainsimportantinformation

onthemodesandproductspecificfeaturesavailablewiththatparticulardrive,includingthe
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Products and System Requirements / Analog Drive Family Overview
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
Standard and Custom Models Thedrivesinthetablesbelowarethestandardproductline
Cont. Current (A) 15 25 12.5 25
TABLE 2.6 Brushless PWM Input DC Drives

Drive Number BD15A8 BD30A8 BDC30A8 BD25A20 BD25A20I BDC40A20 VDC (Nominal) 20-80 20-80 20-80 40-190 40-190 60-190 Peak Current (A) 15 30 30 25 25 40 Cont. Current (A) 7.5 15 15 12.5 12.5 20
TABLE 2.2 Brushless 10V Analog DC Drives

Drive Number B15A8 BE15A8 BE15A8-H B30A8 BE30A8 BX30A8 B100A8 B25A20I BE25A20I BX25A20 B40A20 B40A20I BE40A20I B30A40 B40A40 B60A40 B100A40 VDC (Nominal) 20-80 20-80 20-80 20-80 20-80 20-80 20-80 40-190 40-190 60-200 40-190 40-190 40-190 60-400 60-400 60-400 60-400 Peak Current (A) 15 15 15 30 30 30 100 25 25 25 40 40 40 30 40 60 100 Cont. Current (A) 7.5 7.5 7.5 15 15 15 50 12.5 12.5 12.5 20 20 20 15 20 30 50
TABLE 2.7 Brushless PWM Input AC Drives

Drive Number BD25A20AC VAC (Nominal) 45-140 Peak Current (A) 25 Cont. Current (A) 12.5
TABLE 2.8 Sinusoidal Input DC Drives

Drive Number S16A8 SX30A8 S60A8 S100A8 SX25A20 S30A40 S60A40 S100A40 VDC (Nominal) 20-80 20-80 20-80 20-80 60-190 60-400 60-400 60-400 Peak Current (A) 16 30 60 100 25 30 60 100 Cont. Current (Arms) 8 15 30 50 12.5 15 30 50
TABLE 2.3 Brushed 10V Analog AC Drives

Drive Number 16A20AC 30A20AC VAC (Nominal) 30-130 30-130 Peak Current (A) 16 30 Cont. Current (A) 8 15
TABLE 2.4 Brushless 10V Analog AC Drives

Drive Number B25A20AC BE25A20AC BX25A20AC B30A40AC B40A40AC B60A40AC B100A40AC VAC (Nominal) 30-130 30-130 45-140 45-270 45-270 45-270 45-270 Peak Current (A) 25 25 25 30 40 60 100 Cont. Current (A) 12.5 12.5 12.5 15 20 30 50
TABLE 2.9 Sinusoidal Input AC Supply Drives

Drive Number S30A40AC S60A40AC S100A40AC VAC (Nominal) 45-265 45-270 45-270 Peak Current (A) 30 60 100 Cont. Current (Arms) 15 30 50
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Products and System Requirements / Analog PWM Servo Drive Basics and Theory
2.2 Analog PWM Servo Drive Basics and Theory

Analogservodrivesareusedextensivelyinmotioncontrolsystemswhereprecisecontrolof positionand/orvelocityisrequired.Thedrivetransmitsthelowenergyreferencesignalsfrom thecontrollerintohighenergysignals(motorvoltageandcurrent).Thereferencesignalscan beeitheranalogordigital,witha10VDCsignalbeingthemostcommon.Thesignalcan representeitheramotortorqueorvelocitydemand. Figure2.2showsthecomponentstypicallyusedinaservosystem(i.e.afeedbacksystemused tocontrolposition,velocity,and/oracceleration).Thecontrollercontainsthealgorithmsto closethedesiredservoloopsandalsohandlesmachineinterfacing(inputs/outputs,terminals, etc.).Thedriverepresentstheelectronicpowerconverterthatdrivesthemotoraccordingto thecontrollerreferencesignals.Themotor(whichcanbeofthebrushedorbrushlesstype, rotary,orlinear)istheactualelectromagneticactuator,whichgeneratestheforcesrequiredto movetheload.Feedbackelementsaremountedonthemotorand/orloadinordertoclosethe servoloop. FIGURE 2.2 Typical Motion Control System
Controller Reference Servo Drive Current Motor Feedback Load Feedback
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
Command + Current Control Switching Logic
I Motor
D3
D4
Current Feedback
S3 Rc
S4
S1,S2,S3,andS4arepowerdevices(MOSFETorIGBT)thatcanbeswitchedonoroff.D1,D2, D3,andD4arediodesthatguaranteecurrentcontinuity.Thebusvoltageisdepictedby+HV. TheresistorRcisusedtomeasuretheactualoutputcurrent.Forelectricmotors,theloadis typicallyinductiveduetothewindingsusedtogenerateelectromagneticfields.Thecurrentcan beregulatedinbothdirectionsbyactivatingtheappropriateswitches.WhenswitchS1andS4 (orS2andS3)areactivated,currentwillflowinthepositive(ornegative)directionand increase.WhenswitchS1isoffandswitchS4ison(orS2offandS3on)currentwillflowin thepositive(ornegative)directionanddecrease(viaoneofthediodes).Theswitch"ON"time isdeterminedbythedifferencebetweenthecurrentdemandandtheactualcurrent.The
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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
ON time Time Pulse width
2.2.1 Single Phase (Brushed) Servo Drives

BrushtypeservodrivesaredesignedforusewithpermanentmagnetbrushedDCmotors (PMDCmotors).ThedriveconstructionisbasicallyasshowninFigure2.3.PMDCmotorshave asinglewinding(armature)ontherotor,andpermanentmagnetsonthestator(nofield winding).Brushesandcommutatorsmaintaintheoptimumtorqueangle.Thetorque generatedbyaPMDCmotorisproportionaltothecurrent,givingitexcellentdynamiccontrol capabilitiesinmotioncontrolsystems. Brusheddrivescanalsobeusedtocontrolcurrentinotherinductiveloadssuchasvoicecoil actuators,magneticbearings,etc.
2.2.2 Three Phase (Brushless) Servo Drives

ThreePhase(brushless)servodrivesareusedwithbrushlessservomotors.Thesemotors typicallyhaveathreephasewindingonthestatorandpermanentmagnetsontherotor. Brushlessmotorsrequirecommutationfeedbackforproperoperation(thecommutatorsand brushesperformthisfunctiononbrushtypemotors).Thisfeedbackconsistsofrotormagnetic fieldorientationinformation,suppliedeitherbymagneticfieldsensors(HallEffectsensors)or positionsensors(encoderorresolver).Brushlessmotorshavebetterpowerdensityratings thanbrushedmotorsbecauseheatisgeneratedinthestator,resultinginashorterthermal pathtotheoutsideenvironment.Figure2.5showsatypicalsystemconfiguration.
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FIGURE 2.5 Brushless Servo System

+HV S1 Current Control Switching Logic Commutation Control S1 S2 S3 S S2 S3
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
Position and Commutation Feedback
Feedback
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Products and System Requirements / Power Stage Specifications
2.3 Power Stage Specifications

Thedrivedatasheetliststhespecificvaluesforthefollowingdrivepowerspecifications.Note thatnotallspecificationsapplytoeverydrive. TABLE 2.10 Power Stage Specifications
Specification DC Supply Voltage Range DC Bus Over Voltage Limit Units VDC VDC Description Specifies the acceptable DC supply voltage range that the drive will operate within. Specifies the maximum DC supply voltage allowable. If the DC bus rises above the over voltage limit, the drive will automatically disable, and will not re-enable until the DC bus voltage falls below the over voltage limit. Specifies the acceptable AC supply voltage range that the drive will operate within. Specifies the acceptable frequency of the AC supply line. Pertains to the maximum peak current the drive can output according to hardware limitations. An RMS rating can be obtained by dividing this value by 2 . With the exception of S-series drives, the maximum peak output duration is inherently limited to occur for no longer than 2 seconds, at which point the current output will foldback over a period of 10 seconds to the continuous current limit in order to protect the motor in stalled condition. Current limiting is implemented in the drive by reducing the output voltage. Most drive models feature peak current limit adjustments. The maximum peak current is needed for fast acceleration and deceleration. Consult the drive datasheet to see which options are available. For more information on the current limit see Current Limiting Procedure on page 46. Maximum Continuous Output Current A Pertains to the maximum continuous current the drive can output according to hardware limitations. An RMS rating can be obtained by dividing this value by
AC Supply Voltage Range AC Supply Frequency Maximum Peak Output Current
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
Shunt Fuse Bus Fuse Switching Frequency
A A kHz
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Products and System Requirements / Command Inputs
2.4 Command Inputs

Theinputcommandsourceforanalogservodrivescanbeprovidedbyoneofthefollowing options.Consultthedrivedatasheettoseewhichcommandsourceisavailableforaspecific drive.
2.4.1 10V Analog

Adifferentialorsingleended10Vanalogreferencesignalcanbeusedtocommandthedrive byadjustingthemotorcurrent,voltage,orspeed,dependingonthemodethedriveisoperating in.Forinformationontheproperwiringofa10Vanaloginput,seeInputReferenceWires onpage35.
2.4.2 PWM and Direction

PWMandDirectionInputisaspecializedtypeofcommandthatrequiresacompatible controller.ThecontrollerneedstwohighspeedTTLdigitaloutputstocontrolthesedrives,one forPWMandtheotherforDirection.ThePWMdutycyclecorrespondstothemagnitudeofthe output.DirectcontrolofthePWMswitchingputsresponsetimesinthesubmicrosecond range.SincethesedrivesdonttakeanaloginputsforcommandtheneedforaD/Aconverter fordrivecontroliseliminated. APWMandDirectiondrivecanbeoperatedineitherDirectPWMorTorqueModePWM.
InDirectPWM(e.g."BD"drives)thePWMinputdirectlycontrolsthePWMoutput,giving directcontroloftheswitchingfrequencyanddutycycle. InTorqueModePWM(e.g."BDC"drives)thePWMinputgoesintoaPWMtoAnalog converter.Theanalogsignalisthenusedasacommandintothecurrentloop,resultingina CurrentModedrivecontrolledwithPWMandDirection.
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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Products and System Requirements / Feedback Specifications
2.5 Feedback Specifications

Thereareanumberofdifferentfeedbackoptionsavailableinthefamilyofanalogdrives.The feedbackcomponentcanbeanydevicecapableofgeneratingavoltagesignalproportionalto current,velocity,position,oranyparameterofinterest.Suchsignalscanbeprovideddirectly byapotentiometerorindirectlybyotherfeedbackdevicessuchasHallSensorsorEncoders. TheselatterdevicesmusthavetheirsignalsconvertedtoaDCvoltage,ataskperformedbythe drivecircuitry. Consultaspecificdrivedatasheettoseewhichfeedbackdevicesareavailableforthatdrive.
2.5.1 Feedback Polarity

Thefeedbackelementmustbeconnectedfornegativefeedback.Thiswillcauseadifference betweenthecommandsignalandthefeedbacksignal,calledtheerrorsignal.Thedrive comparesthefeedbacksignaltothecommandsignaltoproducetherequiredoutputtothe loadbycontinuallyreducingtheerrorsignaltozero.Thisbecomesimportantwhenusingan incrementalencoderorHallsensors,asconnectingthesefeedbackelementsforpositive feedbackwillleadtoamotor"runaway"condition.Inacasewherethefeedbacklinesare connectedtothedrivewiththewrongpolarityineitherHallVelocityorEncoderVelocityMode, thedrivewillattempttocorrectthe"errorsignal"byapplyingmorecommandtothemotor. Withthewrongfeedbackpolarity,thiswillresultinapositivefeedbackrunawaycondition.To correctthis,eitherchangetheorderthatthefeedbacklinesareconnectedtothedrive,or consultthedrivedatasheetfortheappropriateswitchontheDIPswitchbankthatreverses theinternalfeedbackvelocitypolarity.SeethedrivedatasheetandSwitchFunctionDetailson page44formoreinformationonDIPswitchsettings.
2.5.2 Incremental Encoder

Analogservodrivesthatuseencoderfeedbackutilizetwosingleendedordifferential incrementalencoderinputsforvelocitycontrol.Theencoderprovidesincrementalposition feedbackthatcanbeextrapolatedintoveryprecisevelocityinformation.Theencodersignals arereadas"pulses"thatthedriveusestoessentiallykeeptrackofthemotorspositionand directionofrotation.Basedonthespeedandorderinwhichthesepulsesarereceivedfromthe twoencodersignals,thedrivecaninterpretthemotorvelocity. Figure2.7representsdifferentialencoder"pulse"signals,showinghowdependingonwhich signalisreadfirstandatwhatfrequencythe"pulses"arrive,thespeedanddirectionofthe motorshaftcanbeextrapolated.Bykeepingtrackofthenumberofencoder"pulses"with respecttoaknownmotor"home"position,servodrivesareabletoascertaintheactualmotor location.
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FIGURE 2.7 Encoder Feedback Signals

Encoder A+
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-
2.5.3 Hall Sensors

ThreePhase(Brushless)drivesuseHallSensorsforcommutationfeedback,andinthespecial caseofsomedrives,forvelocitycontrol.TheHallSensorsarebuiltintothemotortodetectthe positionoftherotormagneticfield.Thesesensorsaremountedsuchthattheyeachgeneratea squarewavewitheithera120degreeor60degreephasedifferenceoveroneelectricalcycle ofthemotor. FIGURE 2.8 Hall Sensor Commutation and Motor Phase Current for 120-Degree Phasing
Hall Sensor Commutation
High (1)
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
Motor Phase Current

High
Phase A
Low High
Phase B
Low High
Phase C
Low 0 240 300 360
60
120
180
Electrical Degrees
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Dependingonthemotorpolecount,theremaybemorethanoneelectricalcycleforevery motorrevolution.Foreveryactualmechanicalmotorrevolution,thenumberofelectricalcycles willbethenumberofmotorpolesdividedbytwo.Forexample:
a6polemotorcontains3electricalcyclespermotorrevolution a4polemotorcontains2electricalcyclespermotorrevolution a2polemotorcontains1electricalcyclepermotorrevolution
ThedrivepowerstwoofthethreemotorphaseswithDCcurrentduringeachspecificHall Sensorstate: Thetablebelowshowsthevalidcommutationstatesforboth120degreeand60degree phasing. TABLE 2.11 Commutation Sequence Table

60 Degree Hall 1
1 1 1 0 0 0 1 0
120 Degree Hall 3

0 0 1 1 1 0 1 0
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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Products and System Requirements / Modes of Operation
2.6 Modes of Operation

Thefamilyofanalogdrivesoffersavarietyofdifferentcontrolmethods.Whilesomedrivesin theseriesaredesignedtooperatesolelyinonemode,onotherdrivesitispossibletoselectthe controlmethodbyDIPswitchsettings(seePotentiometerFunctionDetailsonpage43for moreinformation).Consultthedatasheetforthedriveinusetoseewhichmodesareavailable foruse. Thenameofthemodereferstowhichservoloopisbeingclosedinthedrive,nottheendresult oftheapplication.Forinstance,adriveoperatinginCurrent(Torque)Modemaybeusedfora positioningapplicationiftheexternalcontrollerisclosingthepositionloop.Oftentimes,mode selectionwillbedependentontherequirementsandcapabilitiesofthecontrollerbeingused withthedriveaswellastheendresultapplication.
2.6.1 Current (Torque) Mode

InCurrent(Torque)Mode,theinputcommandvoltagecontrolstheoutputcurrent.Thedrive willadjusttheoutputdutycycletomaintainthecommandedoutputcurrent.Thismodeisused tocontroltorqueforrotarymotors(forceforlinearmotors),butthemotorspeedisnot controlled.Theoutputcurrentcanbemonitoredthroughananalogcurrentmonitoroutput pin.ThevoltagevaluereadattheCurrentMonitorOutputcanbemultipliedbyascaling factorfoundonthedrivedatasheettodeterminetheactualoutputcurrent.
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.
2.6.2 Duty Cycle (Open Loop) Mode

InDutyCycleMode,theinputcommandvoltagecontrolstheoutputPWMdutycycleofthe drive,indirectlycontrollingtheoutputvoltage.NotethatanyfluctuationsoftheDCsupply voltagewillaffectthevoltageoutputtothemotor. This mode is recommended as a method of controlling the motor velocity when precise velocity control is not critical to the application, and when actual velocity feedback is unavailable.
Note
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2.6.3 Hall Velocity Mode

InHallVelocityMode,theinputcommandvoltagecontrolsthemotorvelocity,withtheHall Sensorfrequencyclosingthevelocityloop.Ananalogvelocitymonitoroutputallows observationoftheactualmotorspeedthroughaHz/Vscalingfactorfoundonthedrive datasheet.Thevoltagevaluereadatthevelocitymonitoroutputcanbeusedtodeterminethe motorRPMthroughthescalingfactor.SeeVelocityMonitorOutputonpage42forthemotor RPMequation. Due to the inherent low resolution of motor mounted Hall Sensors, Hall Velocity Mode is not recommended for low-speed applications below 300 rpm for a 6-pole motor, 600 rpm for a 4-pole motor, or 900 rpm for a 2-pole motor. Hall Velocity Mode is better suited for velocity control applications where the motor will be spinning at higher speeds.
Note
2.6.4 Encoder Velocity Mode

InEncoderVelocityMode,theinputcommandcontrolsthemotorvelocity,withthefrequency oftheencoderpulsesclosingthevelocityloop.Ananalogvelocitymonitoroutputallows observationoftheactualmotorspeedthroughakHz/Vscalingfactorfoundonthedrive datasheet.Thevoltagevaluereadatthevelocitymonitoroutputcanbeusedtodeterminethe motorRPMthroughthescalingfactor.SeeVelocityMonitorOutputonpage42forthemotor RPMequation.
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.
2.6.5 Tachometer Velocity Mode

InTachometerVelocityMode,theinputcommandvoltagecontrolsthemotorvelocity.This modeusesanexternalDCtachometertoclosethevelocityloop.ThedrivetranslatestheDC voltagefromthetachometerintomotorspeedanddirectioninformation.
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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2.6.6 Voltage Mode

InVoltageModetheinputreferencesignalcommandsaproportionalmotorvoltageregardless ofpowersupplyvoltagevariations.Thismodeisrecommendedforvelocitycontrolwhen velocityfeedbackisunavailableandloadvariancesaresmall.
2.6.7 IR Compensation Mode

IfthereisaloadtorquevariationwhileinVoltageMode,themotorcurrentwillalsovaryas torqueisproportionaltomotorcurrent.Hence,themotorterminalvoltagewillbereducedby thevoltagedropoverthemotorwindingresistance(IR),resultinginaspeedreduction.Thus, motorspeed,whichisproportionaltomotorvoltage(terminalvoltageminusIRdrop)varies withtheloadtorque. Inordertocompensatefortheinternalmotorvoltagedrop,avoltageproportionaltomotor currentcanbeaddedtotheoutputvoltage.Aninternalresistoradjuststheamountof compensation,andanadditionalthroughholeresistorcanbeaddedtothelocationlistedon thedrivedatasheet.UsecautionwhenadjustingtheIRcompensationlevel.Ifthefeedback voltageishighenoughtocauseariseinmotorvoltagewithincreasedmotorcurrent,instability occurs.Sucharesultisduetothefactthatincreasedvoltageincreasesmotorspeedandthus loadcurrentwhich,inturn,increasesmotorvoltage.Ifagreatdealofmotortorquechangeis anticipated,itmaybewisetoconsidertheadditionofaspeedsensortothemotor(e.g. tachometer,encoder,etc.).
2.6.8 Analog Position Loop Mode

Inthismodethefeedbackdeviceisananalogpotentiometermechanicallytiedtothe positionedobject,thusprovidingpositionfeedback.Thewiperofthepotentiometeris connectedtooneofthedifferentialinputterminals(REF).Thecommandisananalogsignal, whichisconnectedtotheotherdifferentialinputterminal(+REF). Itisrecommendedtouseatachometertoclosethevelocityloop.Theinputreferencegaincan beincreasedinthedrivehardwarefortheAnalogPositionLoopModebyorderingtheANP extension.ThefollowingfigureisatypicalwiringdiagramofAnalogPositionLoopMode. FIGURE 2.9 Analog Position Loop Mode Configuration
Analog Servo Drive
Motor Outputs
Tach+ Tach-
Tach Motor
Load
Pot1 (>20k)
+10V +Ref -Ref -10V GND Return Command
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Products and System Requirements / System Requirements
2.7 System Requirements

Tosuccessfullyincorporateananalogservodriveintoyoursystem,youmustbesureitwill operateproperlybasedonelectrical,mechanical,andenvironmentalspecifications,follow somesimplewiringguidelines,andperhapsmakeuseofsomeaccessoriesinanticipating impactsonperformance.Beforeselectingananalogservodrive,ausershouldconsiderthe requirementsoftheirsystem.Thisinvolvescalculatingtherequiredvoltage,current,torque, andpowerrequirementsofthesystem,aswellasconsideringtheoperatingenvironmentand anyotherequipmentthedrivewillbeinterfacingwith.
2.7.1 Analog Servo Drive Selection and Sizing

Analogservodriveshaveagivencurrentandvoltageratinguniquetoeachdrive.Basedonthe necessaryapplicationrequirementsandtheinformationfromthedatasheetofthemotorbeing used,adrivemaybeselectedthatwillbestsuitthemotorcapabilities. Adriveshouldbeselectedthatwillmeetthepeakandcontinuouscurrentrequirementsofthe application,andoperatewithinthevoltagerequirementsofthesystem.
Motor Current and Voltage Motorvoltageandcurrentrequirementsaredeterminedbased

onthemaximumrequiredtorqueandvelocity.Theserequirementscanbederivedfromthe applicationmoveprofiles(Figure2.10). FIGURE 2.10 Example Velocity, Torque, and Power Curves
1 Cycle Velocity
Dwell Dwell
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
Themotorcurrentwillneedtobecalculatedforbothcontinuousandpeakoperation.Thepeak torquewillbeduringtheaccelerationportionofthemoveprofile. Thecontinuoustorqueistheaveragetorquerequiredbythesystemduringthemoveprofile, includingdwelltimes.Bothpeaktorqueandcontinuous,orRMS(rootmeansquare)torque needtobecalculated.RMStorquecanbecalculatedbyplottingtorqueversustimeforonemove cycle.
T RMS =
Ti ti
i ---------------ti
HereTiisthetorqueandtiisthetimeduringsegmenti.Inthecaseofaverticalapplication makesuretoincludethetorquerequiredtoovercomegravity. Thesystemvoltagerequirementisbasedonthemotorpropertiesandhowfastandhardthe motorisdriven.Thesystemvoltagerequirementisequaltothemotorvoltage,VM,requiredto achievethemoveprofile.Ingeneral,themotorvoltageisproportionaltothemotorspeedand themotorcurrentisproportionaltothemotorshafttorque.Linearmotorsexhibitthesame behaviorexceptthatintheircaseforceisproportionaltocurrent.Theserelationshipsare describedbythefollowingequations:
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.
Motor Inductance Themotorinductanceisvitaltotheoperationofanalogservodrives,asit

ensuresthattheDCmotorcurrentisproperlyfiltered. A motor that does not meet the rated minimum inductance value of the drive may damage the drive! If the motor inductance value is less than the minimum required for the selected drive, use of an external filter card is necessary. See Inductive Filter Cards on page 29 for more information. Aminimummotorinductanceratingforeachspecificdrivecanbefoundinthedatasheet.Ifthe driveisoperatedbelowthemaximumratedvoltage,theminimumloadinductance requirementmaybereduced. Intheaboveequationsthemotorinductanceisneglected.Inbrushlesssystemsthevoltagedrop causedbythemotorinductancecanbesignificant.Thisisthecaseinhighspeedapplicationsif motorswithhighinductanceandhighpolecountareused.Pleaseusethefollowingequationto determinemotorterminalvoltage(mustbeinterpretedasavector).
V m = ( R m + jL )I m + E
Where: L phasetophasemotorinductance maximummotorcurrentfrequency
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2.7.2 Power Supply Selection and Sizing

Thereareseveralfactorstoconsiderwhenselectingapowersupplyforananalogservodrive.
PowerRequirements Isolation Regeneration VoltageRipple
PowerRequirementsreferstohowmuchvoltageandcurrentwillberequiredbythedrivein thesystem.Isolationreferstowhetherthepowersupplyneedsanisolationtransformer. Regenerationistheenergythepowersupplyneedstoabsorbduringdeceleration.Voltage Rippleisthevoltagefluctuationinherentinunregulatedsupplies.
Power Supply Current and Voltage Thepowersupplycurrentratingisbasedonthe
maximumcurrentthatwillberequiredbythesystem.Ifthepowersupplypowersmorethan onedrive,thenthecurrentrequirementsforeachdriveshouldbeaddedtogether.Duetothe natureofservodrives,thecurrentintothedrivedoesnotalwaysequalthecurrentoutofthe drive.However,thepowerinisequaltothepowerout.Usethefollowingequationtocalculate thepowersupplyoutputcurrent,IPS,basedonthemotorvoltageandcurrentrequirements.
VM IM I PS = ----------------------------V PS ( 0.98 )
Where: VPS IM VM nominalpowersupplyvoltage motorcurrent motorvoltage
UsevaluesofVmandImatthepointofmaximumpowerinthemoveprofile,Figure2.10 (whenVMIM=max).Thiswillusuallybeattheendofahardaccelerationwhenboththetorque andspeedofthemotorishigh. ThepowersupplycurrentisapulsedDCcurrent(Figure2.11):whentheMOSFETswitchis on,itequalsthemotorcurrent;whentheMOSFETisoffitiszero.Therefore,thepowersupply currentisafunctionofthePWMdutycycleandthemotorcurrent(e.g.30%dutycycleand12 ampsmotorcurrentwillresultin4ampspowersupplycurrent).30%dutycyclealsomeans thattheaveragemotorvoltageis30%oftheDCbusvoltage.Powersupplypoweris approximatelyequaltodriveoutputpowerplus3to5%.
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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FIGURE 2.11 Unregulated DC Power Supply Current

PWM Switching Time Vm MOSFET ON
DIODE BRIDGE Vp
Ip Vm
Im
MOSFET OFF Average Time Im Ripple Current
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
Asystemwillneedacertainamountofvoltageandcurrenttooperateproperly.Ifthepower supplyhastoolittlevoltage/currentthesystemwillnotperformadequately.Ifthepower supplyhastoomuchvoltagethedrivemayshutdownduetoovervoltage,orthedrivemaybe damaged. Toavoidnuisanceoverorundervoltageerrorscausedbyfluctuationsinthepowersupply, theidealsystempowersupplyvoltageshouldbeatleast10%abovetheentiresystemvoltage requirement,andatleast10%belowthelowestvalueofthefollowing:
Driveovervoltage Externalshuntregulatorturnonvoltage(seeRegenerationandShuntRegulatorson page23)
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
Acceptable Power Supply Range (26 V-72V)

System Power Supply Requirement (24V) Drive Under Voltage Shutdown (9V)
Isolation InsystemswhereanAClineisinvolved,isolationisrequiredbetweentheAClineandthe
signalpinsonthedrive.Thisappliestoallsystemsexceptthosethatuseabatteryasapower supply.Therearetwooptionsforisolation: 1. 2. Thedrivecanhavebuiltinelectricalisolation. Thepowersupplycanprovideisolation(e.g.abatteryoranisolationtransformer).
Thesystemmusthaveatleastoneoftheseoptionstooperatesafely.
Drive with Isolation

SomeADVANCEDMotionControlsanalogdrivescomewithstandardelectricalisolation,while otherscanbeorderedwithisolationasanoption(seeFigure2.1,AnalogProductFamilyPart NumberingStructure,).Todetermineifadrivehasisolationrefertothefunctionalblock diagramonthedrivedatasheet.Theisolationwillbeindicatedbyadashedlinethroughthe functionalblockdiagramseparatingpowergroundfromsignalground. Driveswithan"I"afterthecurrentratinginthepartnumber(i.e.30A8I),drivesthatarerated to400VDCanddrivesthattakeAClinevoltageforpowercomestandardwithisolation.Other drivesthatdonotfallintothesecategoriescanbeorderedbyspecialrequesttoinclude isolation.
Power Supply with Isolation

Anisolatedpowersupplyiseitherabatteryorapowersupplythatusesanisolation transformertoisolatetheAClinevoltagefromthepowersupplyground.Thisallowsboththe powergroundonanisolatedpowersupplyandthesignalgroundonanonisolateddrivetobe safelypulledtoearthground.Alwaysuseanisolatedpowersupplyifthereisnoisolationinthe drive.
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Regeneration and Shunt Regulators Useofashuntregulatorisnecessaryinsystems

wheremotordecelerationoradownwardmotionofthemotorloadwillcausethesystems mechanicalenergytoberegeneratedviathedrivebackontothepowersupply. FIGURE 2.13 Four Quadrant Operation - Regeneration occurs when Torque and Velocity polarity are opposite
Current/Torque I II IV Regenerating Counterclockwise I Motoring Clockwise III IV Torque + Torque Torque Torque + Velocity + Velocity + Velocity Velocity No Regen Regen No Regen Regen
Voltage/Velocity III Motoring Counterclockwise II Regenerating Clockwise
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
Theseenergytermscanbebrokendownintotheapproximatemechanicalandelectricalterms capacitive,kinetic,andpotentialenergy.Theenergyequationsfortheseindividual componentsareasfollows:
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)
Duringregenerationthekineticandpotentialenergywillbestoredinthepowersupplys capacitor.Todeterminethefinalpowersupplyvoltagefollowingaregenerativeevent,the followingequationmaybeusedformostrequirements:
( Ec Er Ep ) = ( Ec Er Ep ) i f 1 2 1 2 1 2 1 2 -- CV nom + -- J i + mgh i = -- CV f + -- J f + mgh f 2 2 2 2

Whichsimplifiesto:
Vf =
2mg ( h i h f ) 2 2 J 2 V nom + --- ( i f ) + -----------------------------C C
TheVfcalculatedmustbebelowthepowersupplycapacitancevoltageratingandthedriveover voltagelimit.Ifthisisnotthecase,ashuntregulatorisnecessary.Ashuntregulatorissizedin thesamewayasamotorordrive,i.e.continuousandRMSpowerdissipationmustbe determined.Thepowerdissipationrequirementscanbedeterminedfromtheapplication moveprofile(seeFigure2.10). ADVANCEDMotionControlsoffersavarietyofshuntregulatorsforservodrives.When choosingashuntregulator,selectonewithashuntvoltagethatisgreaterthantheDCbus voltageoftheapplicationbutlessthantheovervoltageshutdownofthedrive.Verifytheneed
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forashuntregulatorbyoperatingtheservodriveundertheworstcasebrakingand decelerationconditions.Ifthedriveshutsoffduetoovervoltage,ashuntregulatorisnecessary.
Continuous Regeneration
Inthespecialcasewhereanapplicationrequirescontinuousregeneration(morethanafew seconds)thenashuntregulatormaynotbesufficienttodissipatetheregenerativeenergy. PleasecontactADVANCEDMotionControlsforpossiblesolutionstosolvethiskindof application.Someexamples:
Webtensioningdevice Electricvehiclerollingdownalonghill Spinningmasswithaverylargeinertia(grindingwheel,flywheel,centrifuge) Heavyliftgantry
Voltage Ripple Forthemostpart,ADVANCEDMotionControlsanalogservodrivesare

unaffectedbyvoltageripplefromthepowersupply.Thecurrentloopisfastenoughto compensatefor60Hzfluctuationsinthebusvoltage,andthecomponentsinthedriveare robustenoughtowithstandallbutthemostextremecases.Peaktopeakvoltagerippleashigh as25Visacceptable. Therearesomeapplicationswherethevoltageripplecancauseunacceptableperformance. Thiscanbecomeapparentwhereconstanttorqueorforceiscriticalorwhenthebusvoltageis pulledlowduringhighspeedandhighcurrentapplications.Ifnecessary,thevoltageripple fromthepowersupplycanbereduced,eitherbyswitchingfromsinglephaseACtothree phaseAC,orbyincreasingthecapacitanceofthepowersupply. Thevoltagerippleforasystemcanbeestimatedusingtheequation:
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)
2.7.3 Environmental Specifications

Toensureproperoperationofananalogservodrive,itisimportanttoevaluatetheoperating environmentpriortoinstallingthedrive. TABLE 2.12 Environmental Specifications
Environmental Specifications Parameter
Baseplate Temperature Range Humidity Mechanical Shock Vibration Altitude
Description
0 - 65 C 90%, non-condensing 10g, 11ms, Half-sine 2 - 2000 Hz @ 2.5g 0-3000m
Shock/Vibrations Whileanalogdrivesaredesignedtowithstandahighdegreeofmechanical
shockandvibration,toomuchphysicalabusecancauseerraticbehavior,orcausethedriveto ceaseoperationentirely.Besurethedriveissecurelymountedinthesystemtoreducethe shockandvibrationthedrivewillbeexposedto.Thebestwaytosecurethedriveagainst mechanicalvibrationistousescrewstomountthedriveagainstitsbaseplate.Forinformation onmountingoptionsandprocedures,seeMountingonpage39andthedimensional drawingsandinformationonthedrivedatasheet.
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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Integration in the Servo System
Thischapterwillgivevariousdetailsonincorporatingananalogservodriveintoasystem,suchashowto properlygroundthedrivealongwiththeentiresystem,andhowtoproperlyconnectmotorwires,power supplywires,feedbackwires,andinputsintotheanalogservodrive.
3.1 LVD Requirements

TheservodrivescoveredintheLVDReferencereportwereinvestigatedascomponents intendedtobeinstalledincompletesystemsthatmeettherequirementsoftheMachinery Directive.Inorderfortheseunitstobeacceptableintheendusersequipment,thefollowing conditionsofacceptabilitymustbemet. 1. Europeanapprovedoverloadandcurrentprotectionmustbeprovidedforthemotorsas specifiedinsection7.2and7.3ofEN60204.1. 2. Adisconnectswitchshallbeinstalledinthefinalsystemasspecifiedinsection5.3of EN60204.1. 3. Alldrivesthatdonothaveagroundingterminalmustbeinstalledin,andconductively connectedtoagroundedenduseenclosureinordertocomplywiththeaccessibility requirementsofsection6,andtoestablishgroundingcontinuityforthesystemin accordancewithsection8ofEN60204.1. 4. Adisconnectingdevicethatwillpreventtheunexpectedstartupofamachineshallbe providedifthemachinecouldcauseinjurytopersons.Thisdeviceshallpreventthe automaticrestartingofthemachineafteranyfailureconditionshutsthemachinedown. 5. Europeanapprovedovercurrentprotectivedevicesmustbeinstalledinlinebeforethe servodrive,thesedevicesshallbeinstalledandratedinaccordancewiththeinstallation instructions(theinstallationinstructionsshallspecifyanovercurrentratingvalueaslow aspossible,buttakingintoconsiderationinrushcurrents,etc.).Servodrivesthat incorporatetheirownprimaryfusesdonotneedtoincorporateoverprotectionintheend usersequipment. Theseitemsshouldbeincludedinyourdeclarationofincorporationaswellasthenameand addressofyourcompany,descriptionoftheequipment,astatementthattheservodrivesmust notbeputintoserviceuntilthemachineryintowhichtheyareincorporatedhasbeendeclared inconformitywiththeprovisionsoftheMachineryDirective,andidentificationoftheperson signing.
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Integration in the Servo System / CE-EMC Wiring Requirements
3.2 CE-EMC Wiring Requirements

ThefollowingsectionscontaininstallationinstructionsnecessaryformeetingEMC requirements.
General
1. Shieldedcablesmustbeusedforallinterconnectcablestothedriveandtheshieldofthe cablemustbegroundedattheclosestgroundpointwiththeleastamountofresistance. 2. Thedrivesmetalenclosuremustbegroundedtotheclosestgroundpointwiththeleast amountofresistance. 3. Thedrivemustbemountedinsuchamannerthattheconnectorsandexposedprinted circuitboardarenotaccessibletobetouchedbypersonnelwhentheproductisin operation.Ifthisisunavoidabletheremustbeclearinstructionsthatthedriveisnottobe touchedduringoperation.Thisistoavoidpossiblemalfunctionduetoelectrostatic dischargefrompersonnel.
Analog Input Drives

4. AFairRitemodel0443167251roundsuppressioncoremustbefittedtothelowlevel signalinterconnectcablestopreventpickupfromexternalRFfields.
PWM Input Drives

5. AFairRitemodel0443167251roundsuppressioncoremustbefittedtothePWMinput cabletoreduceelectromagneticemissions.
MOSFET Switching Drives

6. AFairRitemodel0443167251roundsuppressioncoremustbefittedattheloadcable connectortoreduceelectromagneticemissions. 7. AnappropriatelyratedCoselTACseriesACpowerfilterincombinationwithaFairRite model5977002701torroid(placedonthesupplyendofthefilter)mustbefittedtotheAC supplytoanyMOSFETdrivesysteminordertoreduceconductedemissionsfedbackinto thesupplynetwork.
IGBT Switching Drives

8. AnappropriatelyratedCoselTACseriesACpowerfilterincombinationwithaFairRite model0443167251roundsuppressioncore(placedonthesupplyendofthefilter)must befittedtotheACsupplytoanyIGBTdrivesysteminordertoreduceconductedemissions fedbackintothesupplynetwork. 9. AFairRitemodel0443164151roundsuppressioncoreandmodel5977003801torroid mustbefittedattheloadcableconnectortoreduceelectromagneticemissions.
Fitting of AC Power Filters

Itispossiblefornoisegeneratedbythemachineto"leak"ontothemainACpower,andthen getdistributedtonearbyequipment.Ifthisequipmentissensitive,itmaybeadverselyaffected bythenoise.ACpowerfilterscanfilterthisnoiseandkeepitfromgettingontheACpower signal.TheabovementionedACpowerfiltersshouldbemountedflatagainsttheenclosureof
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Integration in the Servo System / CE-EMC Wiring Requirements
theproductusingthetwomountinglugsprovidedonthefilter.Paintshouldberemovedfrom theenclosurewherethefilterisfittedtoensuregoodmetaltometalcontact.Thefiltershould bemountedasclosetothepointwheretheACpowerfilterenterstheenclosureaspossible. Also,theACpowercableontheloadendofthefiltershouldberoutedasfarfromtheACpower cableonthesupplyendofthefilterandallothercablesandcircuitrytominimizeRFcoupling.
3.2.1 Ferrite Suppression Core Set-up

IfPWMswitchingnoisecouplesontothefeedbacksignalsorontothesignalground,thena ferritesuppressioncorecanbeusedtoattenuatethenoise.Takethemotorleadsandwrap themaroundthesuppressioncoreasmanytimesasreasonablepossible,usually25times. Makesuretostripbackthecableshieldandonlywrapthemotorwires.Therewillbetwo wiresforsinglephased(brushed)motorsand3wiresforthreephase(brushless)motors. Wrapthemotorwirestogetherasagrouparoundthesuppressioncoreandleavethemotor casegroundwireoutoftheloop.Thesuppressioncoreshouldbelocatedasneartothedrive aspossible.TDKZCATseriessnaponfiltersarerecommendedforreducingradiated emissionsonallI/Ocables.
3.2.2 Inductive Filter Cards

Inductivefiltercardsareaddedinserieswiththemotorandareusedtoincreasetheload inductanceinordertomeettheminimumloadinductancerequirementofthedrive.Theyalso servetocounteracttheeffectsoflinecapacitancefoundinlongcablerunsandinhighvoltage systems.ThesefiltercardsalsohavetheaddedbenefitofreducingtheamountofPWMnoise thatcouplesontothesignallines. Visitwww.amc.com/products/filter_cards.htmlforinformationonpurchasingADVANCED MotionControlsinductivefiltercards.
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Integration in the Servo System / Grounding
3.3 Grounding
InmostservosystemsallthecasegroundsshouldbeconnectedtoasingleProtectiveEarth (PE)groundpointina"star"configuration.GroundingthecasegroundsatacentralPEground pointreducesthechanceforgroundloopsandhelpstominimizehighfrequencyvoltage differentialsbetweencomponents.Allgroundwiresmustbeofaheavygaugeandbeasshort aspossible.ThefollowingshouldbesecurelygroundedatthecentralPEgroundingpoint:
Motorchassis Controllerchassis Powersupplychassis AnalogServoDrivechassis FIGURE 3.1 System Grounding

Case Ground Wire Shield Ground Wire Shielded Feedback/Signal Cable Shielded Power Cable
+VDC
+VDC
Command Signal
Command Signal
PE Ground Signal Ground Power Ground
Controller
Analog Servo Drive Isolated DC Power Supply
Chassis Earth Ground
Motor
Single Point System Ground (PE Ground)
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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Integration in the Servo System / Wiring
3.4 Wiring
Servosystemwiringtypicallyinvolveswiringacontroller(digitaloranalog),aservodrive,a powersupply,andamotor.Wiringtheseservosystemcomponentsisfairlyeasywhenafew simplerulesareobserved.AswithanyhighefficiencyPWMservodrive,thepossibilityof noiseandinterferencecouplingthroughthecablingandwirescanbeharmfultooverall systemperformance.Noiseintheformofinterferingsignalscanbecoupled:
Capacitively(electrostaticcoupling)ontosignalwiresinthecircuit(theeffectismore seriousforhighimpedancepoints). Magneticallytoclosedloopsinthesignalcircuit(independentofimpedancelevels). Electromagneticallytosignalwiresactingassmallantennasforelectromagneticradiation. Fromonepartofthecircuittootherpartsthroughvoltagedropsongroundlines.
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
3.4.1 Wire Gauge

Asthewirediameterdecreases,theimpedanceincreases.Higherimpedancewirewill broadcastmorenoisethanlowerimpedancewire.Therefore,whenselectingthewiregauge forthemotorpowerwires,powersupplywires,andgroundwires,itisbettertoerrontheside ofbeingtoothickratherthantoothin.Thisbecomesmorecriticalasthecablelength increases.Thefollowingtableprovidesrecommendationsforselectingtheappropriatewire sizeforaspecificcurrent.Thesevaluesshouldbeusedasreferenceonly.Consultany applicablenationalorlocalelectricalcodesforspecificguidelines. TABLE 3.1 Current and Wire Gauges
Current (A) 10 15 20 35 45 Minimum Wire Size (AWG) #20 #18 #16 #14 #12 mm2 0.518 0.823 1.31 2.08 3.31 Current (A) 60 80 120 150 200 Minimum Wire Size (AWG) #10 #8 #6 #0 #00 mm2 5.26 8.37 13.3 53.5 67.4
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3.4.2 Motor Wires

Themotorpowerwiressupplypowerfromthedrivetothemotor.Useofatwisted,shielded pairforthemotorpowercablesisrecommendedtoreducetheamountofnoisecouplingto sensitivecomponents.
Forabrushedmotororvoicecoil,twistthetwomotorwirestogetherasagroup. Forabrushlessmotor,twistallthreemotorwirestogetherasagroup.
Groundthemotorpowercableshieldatoneendonlytotheservodrivechassisground.The motorpowerleadsshouldbebundledandshieldedintheirowncableandkeptseparatefrom feedbacksignalwires.
DO NOT use wire shield to carry motor current or power!
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
ANALOG SERVO DRIVE MOT +
BRUSHLESS MOTOR Shield Motor
ANALOG SERVO DRIVE Motor C Motor B Motor A Chassis Ground
3.4.3 Power Supply Wires

ThePWMcurrentspikesgeneratedbythepoweroutputstagearesuppliedbytheinternal powersupplycapacitors.Inordertokeepthecurrentrippleonthesecapacitorstoan acceptablelevelitisnecessarytouseheavypowersupplyleadsandkeepthemasshortas possible.Reducetheinductanceofthepowerleadsbytwistingthem.Groundthepowersupply cableshieldatoneendonlytotheservodrivechassisground. Whenmultipledrivesareinstalledinasingleapplication,precautionregardinggroundloops mustbetaken.Whenevertherearetwoormorepossiblecurrentpathstoaground connection,damagecanoccurornoisecanbeintroducedinthesystem.Thefollowingrules applytoallmultipleaxisinstallations,regardlessofthenumberofpowersuppliesused(see Figure3.3): 1. Runseparatepowersupplyleadstoeachdrivedirectlyfromthepowersupplyfilter capacitor. 2. Never"daisychain"anypowerorDCcommonconnections.Usea"star"connection instead.
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FIGURE 3.3 Multiple Power Supply Wiring

These wiring schemes are commonly practiced but often contribute to noise problems. Each additional node in the chain adds to the amount of noise and unnecessarily loads the connectors in each link.
Analog Servo Drive
Analog Servo Drive
Analog Servo Drive
Analog Servo Drive
Analog Servo Drive
Analog Servo Drive
DC Power Supply
Power Supply Capacitance
DC Power Supply
Analog Servo Drive
Analog Servo Drive
Analog Servo Drive
DC Power Supply
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
DC Power Supplies FordrivesusingaDCpowersupply,connectthetransformerisolatedDC

supplyhighvoltagetotheDCPowerInputterminal,andtheDCsupplygroundtothepower groundterminal. FIGURE 3.4 DC Power Supply Wiring
ANALOG SERVO DRIVE Isolated DC +HV Power GND Supply Shield DC Power Input Power Ground
Chassis Ground Single Point System Ground (PE Ground)
AC Power Supplies DrivesthatacceptonlysinglephaseAClinepowerincludeastandard3

prongpluggableACconnectorforattachmenttoanACsupplyontheundersideofthedrive (standardACmodels),oronthefrontfaceofthedrive(FACmodels). FIGURE 3.5 Pluggable AC Line Connectors
StandardACconnector underneathdrive
FACdrivemodel featuresACconnector ondriveface
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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
3-Phase AC Power Supply*
Shield
AC1 AC2 AC3
FUSE FUSE FUSE
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!
3.4.4 Feedback Wires

Useofatwisted,shieldedpairforthefeedbackwiresisrecommended.Groundtheshieldatone endonlytotheservodrivechassisground.Routecablesand/orwirestominimizetheirlength andexposuretonoisesources.Themotorpowerwiresareamajorsourceofnoise,andthe motorfeedbackwiresaresusceptibletoreceivingnoise.Thisiswhyitisneveragoodideato routethemotorpowerwireswiththemotorfeedbackwires,eveniftheyareshielded. Althoughbothofthesecablesoriginateatthedriveandterminateatthemotor,trytofind separatepathsthatmaintaindistancebetweenthetwo.Aruleofthumbfortheminimum distancebetweenthesewiresis10cmforevery10mofcablelength. FIGURE 3.7 Feedback Wiring
Motor Feedback Avoid running feedback and power wires together Motor Feedback Analog Servo Drive
Analog Servo Drive
Motor
Separate power and feedback wires where possible
Motor
Motor Power Motor Power
Hall Sensors BrushlessdrivesacceptsingleendedHallSensorfeedbackforcommutationand
velocitycontrol.Mostdrivesalsoincludea+6V,30mAlowvoltagesupplyoutputthatcanbe usedtopowertheHallSensors.Verifyonthemotordatasheetthatthevoltageandcurrent ratingofthesupplyoutputwillworkwiththeHallSensorsbeforeconnecting. FIGURE 3.8 Hall Sensor Input Connections

ANALOG SERVO DRIVE +V HALL (Power for Hall Sensors) Shield Motor HALL A + HALL B + HALL C + Signal Ground Chassis Ground
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Incremental Encoder Somedrivemodelssupporteithersingleendedordifferential
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
+ -
MOTOR ENC A+ MOTOR ENC A-
Incremental Encoder Shield Motor + Enc I MOTOR ENC I+ MOTOR ENC I-
+ Enc B -
MOTOR ENC B+ MOTOR ENC BChassis Ground
Tachometer FordrivesthatacceptaTachometerforvelocitycontrol,connectthenegative
tachometerinputtothetachometerinputonthedrive,andconnectthepositivetachometer inputtosignalground.ThedrivemustbeinTachometerVelocitymodeinordertoproperlyuse thetachometerinput.SeethedrivedatasheetforspecificDIPswitchsettings.Thetachometer hasarangeof60VDC. FIGURE 3.10 Tachometer Input Connections

Tachometer ( 60 VDC) Motor SIGNAL GROUND Tach+ Chassis Ground ANALOG SERVO DRIVE TachTACHOMETER INPUT
3.4.5 Input Reference Wires

Useofatwisted,shieldedpairfortheinputreferencewiresisrecommended.Connectthe referencesource"+"to"+REFIN",andthereferencesource""(orcommon)to"REFIN". Connecttheshieldtotheservodrivechassisground.Theservodrivesreferenceinputcircuit willattenuatethecommonmodevoltagebetweensignalsourceanddrivepowergrounds.
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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.
Longsignalwires(1015feetandup)canalsobeasourceofnoisewhendrivenfromatypical opampoutput.Duetotheinductanceandcapacitanceofthewiretheopampcanoscillate.Itis alwaysrecommendedtosetafixedvoltageatthecontrollerandthencheckthesignalatthe drivewithanoscilloscopetomakesurethatthesignalisnoisefree.
10V Analog Input Whenusinga10Vanalogsignalforaninputcommand,itisimportantto
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 + -
+REF -REF Rin
Internal Offset Reference Voltage
Equivalent Input Impedance
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
Internal Offset Reference Voltage
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Potentiometer Input Analogservodrivesthataccept10Vanaloginputcanbecommanded
withtheuseofanexternalpotentiometerandaDCsupplybyvaryingtheDCsupplyvoltage acrossthepotentiometer. FIGURE 3.13 Potentiometer Input

Bi-directional Control
ANALOG SERVO DRIVE
+/- VDC Power Supply
+10V
+10V Max Potentiometer (~50kO) +REF IN -REF IN
GND
-10V
-10V Max SIGNAL GROUND
Uni-directional Control
+VDC Power supply
+10V
+10V Max Potentiometer (~50kO)
ANALOG SERVO DRIVE +REF IN -REF IN
GND SIGNAL GROUND
PWM and Direction Inputs OndrivesthatacceptaPWMandDirectionsignalforacommand

input,theinputsareopticallyisolatedfromthepowerstageofthedrive.ThePWMand Direction,Inhibit,andFaultI/Owillnotprovideanyfunctionalitytothedriveunlessthe optocouplersareactivated.Dependingonthedrivemodel,therearetwomethodstoactivate theoptocouplersandtherebyactivatethedrive.
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
GND +5V +5V Input
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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
Direction Input Signal GND

5k
DIR+ DIR-
100k
5k
100k
Fault Monitor Output GND
FAULT+ FAULTINHIBIT+ INHIBIT-
100k
100k
+5V to Inhibit / Open to Enable GND
100k
Sinusoidal Input TheSSeriesofanalogservodrivesaccepttwosinusoidalcommandsignalsthat

are120degreesoutofphase.Thesineinputsignalscanbeeitherdifferentialorsingleended. Ifusingasingleendedsignal,connecttheinputtothe+REFterminalofthereferenceinput pins,andgroundthenegativeterminal. FIGURE 3.16 Sinusoidal Command Inputs
Analog Servo Drive + REF-IN-A - REF-IN-A 40k 40k Single-ended Sine Input A Analog Servo Drive + REF-IN-A - REF-IN-A 40k 40k
Differential Sine Input A
Differential Sine Input B
+ REF-IN-B - REF-IN-B
40k 40k
Single-ended Sine Input B
+ REF-IN-B - REF-IN-B
40k 40k
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Integration in the Servo System / Mounting
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.
4.1 Initial Setup and Features

Tobeginoperationwithyouranalogservodrive,besuretoreadandunderstandtheprevious chaptersinthismanualaswellasthedrivedatasheet.Besurethatallsystemspecifications andrequirementshavebeenmet,andbecomefamiliarwiththecapabilitiesandfunctionsof thedrive.Also,beawareoftheTroubleshootingsectionattheendofthismanualfor solutionstobasicoperationissues. Donotinstalltheservodriveintothesystemwithoutfirstdeterminingthatallchassispower hasbeenremovedforatleast10seconds.Neverremoveadrivefromaninstallationwith powerapplied.Carefullyfollowthegroundingandwiringinstructionsintheprevious chapterstomakesureyoursystemissafelyandproperlysetup.
4.1.1 Pin Function Details

Thefamilyofanalogdrivesprovideanumberofvariousinputandoutputpinsforparameter observationanddriveconfigurationoptions.Notalldriveswillhaveeachofthefollowingpin functions.Consultthedrivedatasheettoseewhichinput/outputpinfunctionsareavailablefor eachdrive.
Current Monitor Output Measuredrelativetosignalground,powerground,oraseparate
currentmonitorground,dependingonthedrivemodel.Consultthedrivedatasheetto determinethecorrectgroundconnection.Thecurrentmonitorprovidesananalogvoltage outputsignalthatisproportionaltotheactualdrivecurrentoutput.Thescalingfactorforeach individualdrivecanbefoundonthedrivedatasheet.Thedrivemustbeconnectedtoaloadin orderforthedrivetooutputactualcurrent.
Example Measurement
Thecurrentmonitorpinonadrivewithacurrentmonitorscalingfactorof4A/Vismeasured tobe1.3V.Thiswouldmeanthedriveisoutputting:(4A/V)(1.3V)=5.2A.
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Operation / Initial Setup and Features
Current Reference Output Measuredrelativetosignalground,thecurrentreference
providesananalogvoltageoutputsignalthatisproportionaltothecommandsignaltothe internalcurrentloop.Thedrivedoesnotneedtobeconnectedtoaloadtoreadthecurrent referenceoutput.Theinternalcommandcurrentmaydifferfromtheactualdriveoutput currentduetocertainconditionssuchasasmallload,drivefaults,undersizedpowersupplies, inhibiteddrive,etc.Thecommandtotheinternalcurrentloopcanbesolvedforbythe followingequation:
I peak I command = V current ref -----------V

Where:
max
Icommand commandcurrenttotheinternalcurrentloop Vcurrentref measuredvoltageatcurrentreferencepin Ipeak peakcurrentvalueofthedrive Vmax voltagecorrespondingtomaximuminternalcurrentcommand,value foundondrivedatasheet;onmostdrivemodelsVmax=7.45V
Example Measurement
Thecurrentreferencepinonadrivewithapeakcurrentvalueof12AandVmaxof7.45Vis measuredtobe2.63V.FollowingtheaboveequationtosolveforIcommand,thecommand currenttotheinternalcurrentloopwouldbe4.24A.
Inhibit Input Thispinprovidesa+5VTTLinputthatallowsausertoenable/disablethedriveby
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.
Continuous Current Limit Pin TheContinuousCurrentLimitpincanbeusedtoreducethe
factorypresetmaximumcontinuouscurrentlimitwithoutaffectingthepeakcurrentlimitof thedrivebyattachinganexternalresistorbetweenthispinandsignalground.Valuesfor resistorsandthecorrespondingreductionincontinuouscurrentaregivenonthedrive datasheet.ThiscontinuouscurrentreductioncomessecondarytoanyreductionsmadebyDIP switchsettingsonthedriveandthecurrentlimitingpotentiometer.
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Fault Output Thispinprovidesa+5VTTLoutputmeasuredrelativetosignalgroundthatwill
indicatewhenthedriveissubjecttooneofthefollowingfaultconditions:inhibit,invalidHall State,outputshortcircuit,overvoltage,overtemperature,orpowerupreset.Onmostdrive modelsthispinwillread+5V(High)whenthedriveisinafaultstate,butsomedrivesallowthe logictobereversed,sothata0V(Low)faultoutputindicatesafault. Analogdrivesautomaticallyselfresetonceallactivefaultconditionshavebeenremoved.For instanceiftheDCpowersupplyrisesabovetheovervoltageshutdownlevelofthedrive,the FaultOutputwillindicateafault,andthedrivewillbedisabled.OncetheDCpowersupply levelisreturnedtoavaluebelowthedriveovervoltageshutdownlevel,theFaultOutputwill returntothenormalstate,andthedrivewillautomaticallybecomeenabled.
Low Voltage Power Supply Outputs Mostdrivesincludelowvoltagepowersupply

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.
+5V,150mA(or250mA)OutputCanbeusedaspowerforanencoder.Consultthe motororencoderdatasheettodeterminetheappropriateencodervoltageandcurrent requirementsbeforeconnectingthissupply.
Velocity Monitor Output Thispinprovidesananalogvoltageoutputthatisproportionalto
ForadriveinEncoderVelocityMode,substitutethevoltagevaluereadatthevelocity monitorpin,Vmonitor,intothebelowequationtodeterminethemotorRPM:
theactualmotorspeed.Thescalingfactorforeachindividualdrivecanbefoundonthedrive datasheet.
V monitor Scaling Factor 60 Motor Velocity [RPM] = --------------------------------------------------------------------Number of encoder lines
ForadriveinHallVelocityMode,substitutethevoltagevaluereadatthevelocitymonitor pin,Vmonitor,intothebelowequationtodeterminethemotorRPM:
V monitor Scaling Factor 120 Motor Velocity [RPM] = -----------------------------------------------------------------------Number of motor poles
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4.1.2 Potentiometer Function Details

Allpotentiometersvaryinresistancefrom0to50kohm,over12turns.Anadditionalfullturn thatdoesnoteffectresistanceisprovidedoneitherend,foratotalof14turns.Whentheendof potentiometertravelisreached,itwillclickonceforeachadditionalturn.Consultthedrive datasheettoseewhichpotentiometersareincludedonaspecificdrive. TABLE 4.1 Potentiometer Function Details
Potentiometer Loop Gain Adjustment Description This potentiometer must be set completely counter-clockwise in Current Mode. In Velocity, Voltage, or Duty Cycle Mode, this potentiometer adjusts the gain in the velocity forward position of the closed loop. Turning this potentiometer clockwise increases the gain. Start from the full counter-clockwise position, turn the potentiometer clockwise until the motor shaft oscillates, then back off one turn. This potentiometer adjusts the current limit of the drive. To adjust the current limit, first use any available DIP switches or external current limiting resistors to set the maximum current limits and ratios (consult drive datasheet to see which options are available). If further adjustment is necessary, use the following equation to determine the number of clockwise turns from the full counter-clockwise position necessary to set the desired current limit:
Current Limit
I system # of turns (from full CCW) = ---------------- 12 + 1 I max

Isystem = the desired current limit of the system (typically determined by motor current rating) Imax = maximum current capability of the drive; this value is determined after any external current limiting resistors have been used and/or any current scaling or current reduction DIP switches have been set. If no DIP switches or external resistors have been used, then Imax is the default maximum continuous current limit set by the drive hardware. See Current Limiting Procedure on page 46 for an example of how to use this potentiometer. Reference Gain This potentiometer adjusts the ratio between the input signal and the output variable (voltage, current, velocity, or duty cycle). For a specific gain setting, turn this potentiometer fully counterclockwise, and adjust the command input to 1V. Then turn clockwise while monitoring motor velocity or drive output voltage (depending on mode of operation) until the required output is obtained for the given 1V command. Turning this potentiometer counter-clockwise decreases the reference in gain, while setting this potentiometer in the fully clockwise position makes the whole range of drive output available. This potentiometer may be left in the fully clockwise position if a controller is used to close the velocity or position loops. This potentiometer acts as an internal command source for testing when the Test/Offset switch is in the ON position. If the Test/Offset switch is in the OFF position, then this potentiometer can be used to adjust a small amount of command offset in order to compensate for offsets that may be present in the servo system. Turning this potentiometer clockwise adjusts the offset in a negative direction relative to the +Ref input command. Before offset adjustments are made, the reference inputs must be grounded or commanded to 0 volts.
Test/Offset
Test Points for Potentiometers Afterthepotentiometeradjustmentshavebeencompleted,
theresistancevaluescanbemeasuredforfutureadjustmentsorduplicationonotherservo drivesofthesamepartnumber.Testpointsforpotentiometerwipersareprovidedandare locatedatthefootofallfourpotentiometers.Resistancemeasurementsareonlytobeusedto duplicatedrivesettings,sincesomepotentiometershaveotherresistorsinseriesorparallel. Measuretheresistancebetweenthetestpointandtheouterlegofthepotentiometeror betweenthetestpointandanappropriateground.Seetheblockdiagramonthedrive datasheettodeterminewhichgroundshouldbeusedforeachpotentiometer.
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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4.1.3 Switch Function Details

Togetherwiththedescribedfunctionsbelowcertainswitchesmayalsobeusedinselectingthe modeofoperation,whilesomemaybeusedstrictlyformodeselection.Switchimplementation andfunctionalitywithinthedrivecircuitryisincludedontheblockdiagramofthedrive datasheet.Consultthedrivedatasheettoseewhichswitchesareincludedonaspecificdrive. TABLE 4.2 Switch Function Details
Switch Current Scaling Current Loop Proportional Gain Adjustment Current Limit Ratio Description Changes the sensitivity of the current sense, thereby reducing the peak and continuous current limits by a given amount. Adjusts the proportional gain of the current loop. For drive model S16A8, there are two Current Loop Proportional Gain switches that must be set to the same setting. Sets the continuous-to-peak current limit ratio to a given percentage. The default setting for all drives is a continuous-to-peak current limit ratio of 50% (i.e., 12 amp peak limit, 6 amp continuous limit). Activates or deactivates the current loop integral gain. This switch is OFF by default. For drive model S16A8, there are two Current Loop Integral Gain switches that must be set to the same setting. Sets the RMS current limit setting on sinusoidal input drives, used to reduce the continuous current limit to a percentage of the maximum continuous limit. Two RMS Current Limit Setting switches are used to set the percentage. See the drive datasheet for specific switch configuration. Sets the peak current to 50% or 100% of the maximum peak current limit on sinusoidal input drives. Depending on the drive model, there are either two or three Peak Current Limit switches that must all be set to the same setting. Activates or deactivates the outer loop integration. For Current Mode, outer loop integration should be deactivated, but should be activated for other modes. Increases or decreases the integral gain of the outer loop. Enables/disables the duty cycle feedback. Duty cycle feedback is only enabled when the drive is configured for Duty Cycle Mode. Tells the drive the type of Hall sensor phasing the motor has. Switches between 120 and 60 degree phasing. Switches the drive between Test mode and Offset mode. In Test mode, the command signal is adjustable via the Test/Offset potentiometer. In Offset mode, the drive will accept commands via the reference inputs, but a small amount of offset can be adjusted in order to compensate for offsets that may be present in the servo system. Activates or deactivates the PWM and Direction internal test signal, controlled by the PWM Test Signal Adjustment potentiometer. Changes the polarity of the internal feedback signal and the velocity monitor output signal. Inversion of the feedback polarity may be required to prevent a motor run-away condition. See Motor Problems on page 60 for more information. Activates or deactivates IR feedback. IR feedback should be activated for IR Compensation Mode, and deactivated for other modes. Sets the logic of the inhibit pins to Active High or Active Low. Sets the voltage range of the sinusoidal command input pins. The input range can be set to 5V or 10V. Drives contain two Input Range Selection switches that must set to the same setting.
Current Loop Integral Gain
RMS Current Limit Setting
Peak Current Limit
Outer Loop Integration Activation Outer Loop Integral Gain Adjustment Duty Cycle Feedback Hall Sensor Commutation Phasing Test/Offset
PWM and Direction Test Signal Velocity Feedback Polarity
IR Compensation Inhibit Logic Input Range Selection
4.1.4 Adjustable Acceleration and Deceleration Rate

Onsomedrivemodels,theaccelerationanddecelerationratescanbesetindependentlyusing throughholeresistors.Thedrivedatasheetcontainsspecificresistorvaluesandthe correspondingrampingtime.Theratesarebasedon10voltstothereferenceinputs.The "time"listedinthetableonthedrivedatasheetisthetimeittakestoreachthe10voltinput. Therampingratesarelinearwithrespecttotime.Forexample,iftheinputwereonly5volts, thetimetoramptothisvoltagewouldbehalfthetimetorampto10volts.Theselocationsare silkscreenedonthePCBforeasyidentification.TwoSMTjumpers(0ohmresistors)are requiredtobesetappropriatelyinordertoenableadjustableacceleration/decelerationrate control.Thedefaultsettingforbothjumpersistodisableadjustableratecontrol.Thespecific configurationofthejumpersforadrivearegivenonthedrivedatasheet.
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4.1.5 Tachometer Input Gain Scaling

Standarddrivetachometerinputsaretypicallypreconfiguredsuchthatthestandard60kinput resistancescalesthemaximumtachinputvoltageto60V.The60ktachometerinputresistance isactuallypopulatedwitha50kresistorinserieswitha10kresistor.Mostdriveswitha tachometerfeedbackinputwillalsohaveathroughholeresistorlocationinparallelwiththe 50kresistor. FIGURE 4.1 Tachometer Input Resistance
ANALOG SERVO DRIVE
Optional Through-Hole Tach Gain Resistor
Tachometer Input 50k 10k
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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4.1.6 Current Limiting Procedure

Beforeoperatingadrive,thecurrentoutputofthedrivemustbelimitedbasedonmotorand systemcurrentlimitations.Dependingonthedrivemodel,ADVANCEDMotionControlsanalog servodrivesfeatureanumberofdifferentcurrentlimitingmethods.However,theprocedure forsettingthecurrentlimitwillessentiallybethesameforeachdrive.Consultthedrive datasheettoseewhatcurrentlimitingoptionsareavailableonaspecificdrive. Thecurrentlimitingstepsshouldbetakenwithnopowerappliedtothedrive. 1. Thefollowingtwooptionsmaybeusedseparatelyorinconjunctionwitheachotherto reducethecurrentlimits.Keepinmindthatanycurrentreductionsenactedbytheuseof anexternalresistorwillcomesecondarytoDIPswitchsettings. Ifavailable,positionanycurrentscalingorcurrentlimitratioDIPswitchestothe desiredposition(seePotentiometerFunctionDetailsonpage43). Ifavailable,useanexternalresistorconnectedtotheContinuousCurrentLimitingPin basedonthevaluesgivenonthedrivedatasheet(seeContinuousCurrentLimitPin onpage41). 2. Iffurthercurrentlimitingisnecessary,usetheCurrentLimitpotentiometerto"finetune" thecurrentlimittoafinalvalue(seePotentiometerFunctionDetailsonpage43).
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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4.1.7 Drive Set-up Instructions Single Phase (Brush Type)

1. Itisrecommendedtoreducethedriveoutputcurrenttoavoidmotoroverheatingduring thesetupprocedure.Makesurethecurrenthasbeensetappropriatelywithinthesystem andmotorlimitsbasedontheprocedureoutlinedinCurrentLimitingProcedureon page46. 2. Checkthepowerandconnectittothedrive.Donotconnectthemotorleadwires. 3. Makesurethedriveisinanenabledstateviaallinhibit/enableinputs.Seedrivedatasheet fordetails. 4. CheckthatthestatusLEDindicatesnormaloperation(GREEN). 5. SetmodeaccordingtothedrivedatasheetforVoltageMode. 6. SettheTest/OffsetswitchtoTestmode.Measurethevoltageacrossthemotoroutputwith aDCvoltmeter.SlowlyturntheTest/Offsetpotentiometer;thevoltageshouldvarybetween busvoltage.SettheoutputvoltagewiththeTest/Offsetpotentiometertoalowvalue. 7. Verifythattheloadcircuitmeetstheminimuminductancerequirementsandthatthe powersupplyvoltagedoesnotexceedthedriveratedvoltageor150%ofthenominal motorvoltage. 8. Turnthepoweroff.Connectthemotor.Turnthepowerbackon.Graduallyturnthe Test/Offsetpotentiometertochangemotorspeedinbothdirections.SettheTest/Offset switchtoOffset. 9. GroundbothreferenceinputsandthenusingtheTest/Offsetpotentiometer,setthemotor forzerospeed. 10. Setthecontrolmodesuitablefortheapplication.
Three Phase (Brushless)

1. Itisrecommendedtoreducethedriveoutputcurrenttoavoidmotoroverheatingduring thesetupprocedure.Makesurethecurrenthasbeensetappropriatelybasedonthe procedureoutlinedinCurrentLimitingProcedureonpage46. 2. Accordingtothethemodeselectiontableonthedrivedatasheet,setthedriveforOpen LoopMode,andsettheTest/OffsetswitchtoTest. 3. Checkthepowerandconnectittothedrive.Donotconnectthemotorleadwires. 4. Makesurethedriveisinanenabledstateviaallenableinputs.Seedrivedatasheetfor details. 5. SettheHallSensorCommutationSwitchfortheappropriatephasing(typically120 degree).ConnecttheHallsensorinputs.ThedrivestatusLEDshouldbeGREEN.Manually turnthemotorshaftonerevolution.TheLEDshouldremaingreen.IftheLEDturnsredor changesbetweengreenandred: checktheHallSensorCommutationSwitch checkpowerfortheHallSensors checkthevoltageleveloftheHallinputs(seeTable4.3) for60degreephasinginterchangeHall1andHall2 (formoreinformationseeInvalidHallSensorState(BrushlessDrivesonly)onpage58)
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TABLE 4.3 Commutation Sequence Table

60 Degree Hall 1
1 1 1 0 0 0 1 0
120 Degree Hall 3

0 0 1 1 1 0 1 0
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.
Three Phase (Brushless) Drive with Brushed Motor ThreePhase(Brushless)drives
arealsocompatiblewithSinglePhase(Brushed)motors.However,becausetherearenoHall Sensorsonabrushedmotor,oneofthefollowingcourseofactionsmustbetakentoproperly commutatethedrive:
SettheHallSensorCommutationPhasingDIPswitchfor60degreephasing.Leaveallthe HallSensorinputsonthedriveopen.Theseinputsareinternallypulledhighto+5V, creatinga"111"commutationstate(seeTable4.3above)whichisavalidstatein60 degreephasing.OnlyuseMotorAandMotorBoutputinthisconfiguration.
or:
TieoneoftheHallSensorinputsonthedrivetosignalground.SincetheHallSensorinputs arebydefaultinternallybroughthighto+5V,thiswillputthedriveinacommutationstate wheretwoHallinputsarehigh,andoneislow(asshowninTable4.3,havingallthreeHall inputspulledhighisaninvalidcommutationstatein120degreephasing).Dependingon whichHallSensorinputistiedtoground,consultTable4.3todeterminewhichtwomotor outputwireswillbeconductingcurrentforthatspecificcommutationstate.
Sinusoidal Drive (S-Series)

1. Setthecurrentlimitto10%ofmotorcurrenttoavoidhighspeeds.Seethedrivedatasheet forcurrentlimitingoptions.
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2. Checkthepowerandconnectittothedrive.Donotconnectthemotorleadwires. 3. Makesurethedriveisinanenabledstateviaallenableinputs.Seedrivedatasheetfor details. 4. SincethefeedbackandcommutationonSSeriesanalogservodrivesisfedbacktothe externalmotioncontroller,thesetupprocedurewillbedependentonthetypeofcontroller inuse.Consulttheinstructionsfortheexternalmotioncontrollertodeterminetheproper setupmethod.
4.1.8 Tuning Procedure

ThestandardtuningvaluesusedinADVANCEDMotionControlsanalogservodrivesare conservativeandworkwellinover90%ofapplications.Howeversomeapplicationsand somemotorsrequiremorecompletecurrentlooptuningtoachievethedesiredperformance. Thefollowingareindicationsthatadditionalcurrentlooptuningisnecessary:
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.
SincemostADVANCEDMotionControlsservodrivesclosethecurrentloopinternally,poor currentlooptuningcannotbecorrectedwithtuningfromanexternalcontroller.Onlyafterthe currentlooptuningiscompletecanoptimalperformancebeachievedwiththevelocityand positionloops.
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Thegeneralcurrentlooptuningprocedurefollowsthesesteps: 1. Determineifadditionalcurrentlooptuningisnecessary. 2. Ifavailable,tunethedriveusingthecurrentloopDIPswitches. 3. IfthecurrentloopcannotbesatisfactorilytunedwiththeDIPswitches,thenthecurrent loopcomponentsmustbechanged. Tunethecurrentloopproportionalgain. Tunethecurrentloopintegralgain. 4. Oncethecurrentloopistuned,thenthevelocityand/orpositionloopsmaybetunedas wellifnecessary.
Current Loop Proportional Gain Adjustment TheCurrentLoopGainshouldbe
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.
FIGURE 4.2 Brushed Drives

Analog Servo Drive
Square Wave Input Motor + +Ref Motor Current Probe or Resistor
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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FIGURE 4.3 Brushless Drives

Analog Servo Drive
Square Wave Input Motor A +Ref Motor B Motor C Current Probe or Resistor
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
FIGURE 4.4 S-Series Drives

Analog Servo Drive
Square Wave Input Motor A Ref In A Motor B Motor C Current Probe or Resistor
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.
7. Thedriveoutputshouldfollowtheinputcommand.Thebestresponsewillbeacritically dampedoutputwaveform,similartowhatisshowninFigure4.5. FIGURE 4.5 Current Loop Response

Current Target Current Signal Output Current Response
Time
8. IfneithercurrentloopgainDIPswitchpositiongivesapropersquarewaveresponse,then thecurrentloopgainresistorsmayneedtobechangedtooptimizetheresponse.See ThroughholeComponentTuningonpage53formoreinformation. 9. Whentheproperresponsehasbeenachieved,removetheinputsignalfromthedrive,and disconnectpower.
Current Loop Integrator Adjustment

1. EnabletheCurrentLoopIntegratorthroughDIPswitchorjumpersettings(seethedrive datasheetforavailableoptions).
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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.
Voltage or Velocity Loop Tuning Theseadjustmentsshouldinitiallybeperformedwith

themotoruncoupledfromthemechanicalload. ConfigurethedriveforthedesiredoperationmodeusingtheDIPswitchsettings(seetheblock diagramonthespecificdrivedatasheet).
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.
Analog Position Loop Useofanencoderortachometerisrecommendedtoobtaina
responsivepositionloop,sincethepositionloopisclosedaroundthevelocityloop.Firstthe velocityloopmustbestabilized(orvoltageloopforundemandingapplications).Theposition loopgainisdeterminedbythefixedgainoftheinputdifferentialamplifierofthedrive.For bestresultstheservodrivecanbeorderedwithahigherdifferentialgain.
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Through-hole Component Tuning
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:
Alargerresistorvaluewillincreasetheproportionalgain,andthereforecreateafaster responsetime. Usenonpolarizedcapacitors. Alargercapacitorvaluewillincreasetheintegrationtime,andthereforecreateaslower responsetime.
A.1 Through-Hole Tuning

Propertuningusingthroughholecomponentswillrequirecarefulobservationoftheloop responseonadigitaloscilloscopetofindtheoptimalthroughholecomponentvaluesforthe specificapplication. Thefollowingaresomehelpfulhintstomakethelooptuningprocesseasier:
UsepinreceptaclestoreducetheneedforsolderingSomedriveshavepinreceptacles thatmakeiteasytochangethetuningresistorsandcapacitorswithouttheneedfor soldering.Otherdrivesdonothavethesereceptacles,sosolderingisrequired.Toavoidthe needtosoldereverytimeatuningvalueneedstobechangedapinreceptaclecanbe solderedintothethethroughholelocationofthetuningcomponent.
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Through-hole Component Tuning / Through-Hole Tuning
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.
Tune the Current Loop Proportional Gain

1. FollowthestepsoutlinedinCurrentLoopProportionalGainAdjustmentonpage50up throughStep8. 2. Observethedrivecurrentresponseonanoscilloscope.Smallsteptuningisdifferentthan largesteptuning,soadjustthefunctiongeneratorsquarewaveamplitudesothedrive outputsacurrentstepsimilartowhatwillbeexpectedintypicaloperation. Ifthecurrentresponsedoesnotrisequicklyenoughtothestepinputcommand,orif itneverreachestheinputcommand,theequivalentresistanceofthecurrentloop proportionalgainresistorwillneedtobeincreased.Thiswillincreasethecurrent loopproportionalgain,andachieveafaster,moreaggressiveresponse. Ifthecurrentresponseovershootsthestepinputcommand,theequivalentresistance ofthecurrentloopproportionalgainresistorwillneedtobedecreased.Thiswill decreasethecurrentloopproportionalgain,andprovideaslower,morestable response. 3. Findinganacceptableequivalentresistancemaytakeafewiterations.Asoutlinedinthe previoussection,usingpinreceptaclesoranexternalpotentiometerwillmaketheprocess easier.Remembertoremovepowerfromthedrivepriortoremovingoraddingany componentstothePCB.Alsorememberthatitisnotjustthethroughholeresistorvalue thatisimportant,buttheequivalentresistanceofthethroughholeresistorandanySMT resistorsthatmaybeinparallelwiththethroughholelocation.Usetheblockdiagramon thedrivedatasheettoassistindeterminingtheequivalentgainresistance. 4. Useanequivalentresistancevaluethatbringsthecurrentresponserighttothepointof overshoot.Ifthereisalargeamountofovershoot,orifthereareoscillations,decreasethe equivalentresistancevalueuntilthereislittleornoovershoot.Dependingonthe applicationrequirements,alittleovershootisacceptable,butshouldneverexceed10%. 5. Whenanacceptableresistancevaluehasbeenfound,removepowerfromthedrive.
Tune the Current Loop Integral Gain

1. Aftertheproportionalgainresistancehasbeenadjustedtoanacceptablevalue,reenable thecurrentloopintegratorcapacitor(eitherthroughDIPswitchorjumpersettings, dependingonthedrivemodel).
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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).
Velocity Loop Integral Gain Tuning Thevelocityloopproportionalgainisadjustedbythe

onboardLoopGainpotentiometer.ThevelocityloopintegralgaincanbeadjustedbyDIP switchsettingssimilartothecurrentloopintegralgain(capacitancevaluecanbechanged, capacitorcanbeshortedout,extracapacitorcanbeaddedinparallel).However,somedrive modelsalsoincludeadditionalthroughholelocationswherethroughholecapacitorscanbe addedtofurtheradjustthevelocityloopintegralgain.Asintuningthecurrentloopintegral gain,uselargervalueequivalentcapacitorstocorrectforovershootoroscillation,andsmaller valueequivalentcapacitorsforaquickerresponsetime.
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Troubleshooting
Thissectiondiscusseshowtoensureoptimumperformanceand,ifnecessary,getassistancefromthefactory.
B.1 Fault Conditions and Symptoms

Aninoperativedrivecanindicateanyofthefollowingfaultconditions:
overtemperature overvoltage undervoltage shortcircuits invalidcommutation inhibitinput poweronreset
Alloftheabovefaultconditionsareselfresetbythedrive.Oncethefaultconditionisremoved thedrivewillbecomeoperativeagainwithoutcyclingpower.Todeterminewhetherthedrive isinafaultstate,measuretheFaultOutputpinwithadigitalmultimeterorvoltmeter.Ahigh atthispin(oralow,dependingonthedrivemodelandconfigurationseedrivedatasheet)will indicatethatthedriveissubjecttooneoftheabovefaultconditions,andthedrivewillbe disableduntilthedriveisnolongerinafaultstate.Toremovethefaultcondition,followthe instructionsinthesectionsbelowdescribingeachpossiblefaultstate.
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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Troubleshooting / Fault Conditions and Symptoms
regulatormaybenecessary.SeeRegenerationandShuntRegulatorsonpage23formore information.
Under-Voltage Shutdown Verifypowersupplyvoltagesforminimumconditionsper
specifications.Alsonotethatthedrivewillpullthepowersupplyvoltagedownifthepower supplycannotprovidetherequiredcurrentforthedrive.Thiscouldoccurwhenhighcurrent isdemandedandthepowersupplyispulledbelowtheminimumoperatingvoltagerequired bythedrive.
Short Circuit Fault

1. Checkeachmotorleadforshortswithrespecttomotorhousingandpowerground.Ifthe motorisshorteditwillnotrotatefreelywhennopowerisappliedwhileitisuncoupled fromtheload. 2. Disconnectthemotorleadstoseeifthedrivewillenablewithoutthemotorconnected.If thedriveenableswiththemotordisconnected,thereisapossibleshortcircuitinthe motorwiring. 3. Measuremotorarmatureresistancebetweenmotorleadswiththedrivedisconnected. Verifythesemeasurementsagainstthemotordatasheettodetermineifthereisashortor opencircuitinthemotorwindings.
Invalid Hall Sensor State (Brushless Drives only) SeetheCommutationSequence
tableinHallSensorsonpage12forvalidcommutationstates.Ifthedriveisdisabledcheck thefollowing:
1. MakesurethattheHallSensorCommutationPhasingswitchisinthecorrectsettingper motordatasheets.Whendrivingasinglephase(brushedtype)motorwithathreephase (brushless)driveusethe60degreephasesetting(seeThreePhase(Brushless)Drive withBrushedMotoronpage48formoreinformationonthisparticularconfiguration). 2. CheckthevoltagelevelsforalltheHallSensorinputs.Turnthemotorbyhandwhile measuringtheHallSensorinputstoverifythatallthreeHallSensorsarechanging.The voltageshouldreadapproximately+5Vfora"high(1)"Hallstate,andapproximately0V fora"low(0)"Hallstate. 3. MakesureallHallSensorlinesareconnectedproperly.
Inhibit Input Checkinhibitinputforcorrectpolarity(thatis,pulltogroundtoinhibitorpullto
groundtoenable).InhibitconfigurationdependseitherontheDIPswitchsettingsora0ohm SMTresistormarkedontheboard.Also,keepinmindthatnoiseontheinhibitlinecouldbea causeforafalseinhibitsignalbeinggiventothedrive.
Power-On Reset Alldriveshaveapoweronresetfunctiontoensurethatallcircuitryonthe
boardisfunctionalpriortoenablingthedrive.Theboardwillonlybedisabledmomentarily, andwillquicklyenableuponpowerup.
B.1.1 Overload
Verifythattheminimuminductancerequirementismet.Iftheinductanceistoolowitcould appearlikeashortcircuittothedriveandthusitmightcausetheshortcircuitfaulttotrip.
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Excessiveheatingofthedriveandmotorisalsocharacteristicoftheminimuminductance requirementnotbeingmet.Seedrivedatasheetforminimuminductancerequirements.
B.1.2 Current Limiting

WiththeexceptionofSSeries(sinusoidalcommandinput)andDirectPWMcommand(e.g. "BD")drives,analogservodrivesincorporateafoldbackcircuitforprotectionagainstover current.ThisfoldbackcircuitusesanapproximateI2talgorithmtoprotectthedrive.
Maximumpeakcurrentoutputlevelcanbesustainedforabout2seconds. Toactuallyachievemaximumpeakcurrentoutputfor2secondsrequiresthecurrent commandtofullyswingfrompeakinonedirectiontotheother. FIGURE B.1 Maximum Peak Current Foldback

Max Peak Current Limit (Positive Direction) Current Command Max Continuous Current Limit
Current Measured 0
Max Peak Current Limit (Negative Direction) t t+2
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!
Formostapplications,itsarareoccurrencetofullyswingfrompeakinonedirectionto theother.Itismorelikelythedrivewillbecommandedfromzerotomaxpeakcurrent. Underthiscondition,thedrivewillonlysustainthemaximumpeakcurrentforaboutone second. FIGURE B.2 Peak Current Foldback

Max Peak Current Limit (Positive Direction) Current Command Max Continuous Current Limit
Current Measured 0 t t+1
Commandingmaximumpeakcurrentoutputstartingfromabovezerocommandwillalso yieldreducedpeakcurrentoutputtime.
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Whencommandingoutputcurrentlessthanthemaxpeaklimit,butmorethanthemax continuouslimit,thecurrentoutputcanbesustainedforalongertimeperiodthana maximumpeakcommandbeforefoldingbackalongthesamecurve. FIGURE B.3 Above Continuous Current Foldback

Max Peak Current Limit (Positive Direction)
Max Continuous Current Limit
Current Measured 1 0 t t+2 Current Measured 2 Current Measured 3
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.
B.1.3 Motor Problems

Amotorrunawayconditioniswhenthemotorspinsrapidlywithnocontrolfromthe commandinput.Themostlikelycauseofthiserrorcomesfromhavingthefeedbackelement connectedforpositivefeedback.Thiscanbesolvedbychangingtheorderthatthefeedback elementlinesareconnectedtothedrive,orchangingthefeedbackpolarityswitchontheDIP switchbanktotheoppositesetting. AnothercommonmotorissueforbrushlessmotorswithHallSensorcommutationiswhenthe motorspinsfasterinonedirectionthanintheotherforthesamevelocitycommandinthe oppositedirection.Thisistypicallycausedbyimpropercommutation,usuallybecausethe motorpowerwiresareconnectedinthewrongorderwithrespecttotheHallSensorwiring. Tryallsixcombinationsofconnectingthemotorpowerwirestothedrivetofindthecorrect commutationorder.Thepropercombinationofmotorwireswillyieldsmoothmotionand identicalspeedsinbothdirections.Impropercombinationswillcausejerkymotion,slow movementinonedirection,and/oraudiblenoise.Asafinalverificationthatthecommutation iscorrect,usetheVelocityMonitorOutputpintomeasuremotorspeedinbothdirections.This
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Troubleshooting / Technical Support
canalsobecausedbyinvalidHallphasing.Checktoseeifthedriveissetfor120or60degree phasing,andverifythatthedriveDIPswitchsettingcorrespondstotheHallphasingusedon themotor.SeeHallSensorsonpage12formoreinformation. Forabrushlessdrive,iftheoppositemotordirectionisdesiredforagivencommandinput, interchangeHall1andHall3,thenMotorAandMotorB.
B.1.4 Causes of Erratic Operation

Impropergrounding(i.e.drivesignalgroundisnotconnectedtosourcesignalground). Noisycommandsignal.Checkforsystemgroundloops. Mechanicalbacklash,deadband,slippage,etc. Noisyinhibitinputline. Excessivevoltagespikesonbus.
B.2 Technical Support

Forhelpfromthemanufacturerregardingdrivesetuporoperatingproblems,pleasegather thefollowinginformation.
B.2.1 Product Label Description

Thefollowingisatypicalexampleofaproductlabelasitisfoundonthedrive: FIGURE B.4 Analog Product Label 1 4 2
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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Troubleshooting / Warranty Returns and Factory Help
B.2.2 Drive Model Information

DCbusvoltageandrange Motortype(brushed,brushless,ACinduction) Motorcharacteristics(inductance,torqueconstant,windingresistance,etc.) PositionofallDIPswitches Lengthandmakeupofallwiringandcables Ifbrushless,includeHallsensorinformation Typeofcontrollerandfulldescriptionoffeedbackdevices Descriptionofproblem:instability,runaway,noise,over/undershoot,etc. Completepartnumberandserialnumberoftheproduct.Originalpurchaseorderis helpful,butnotnecessary
B.3 Warranty Returns and Factory Help

Sellerwarrantsthatallitemswillbedeliveredfreefromdefectsinmaterialandworkmanship andinconformancewithcontractualrequirements.TheSellermakesnootherwarranties, expressorimpliedandspecificallyNOWARRANTYOFMERCHANTABILITYORFITNESSFOR APARTICULARPURPOSE.TheSeller'sexclusiveliabilityforbreachofwarrantyshallbe limitedtorepairingorreplacingattheSeller'soptionitemsreturnedtoSeller'splantatBuyer's expensewithinoneyearofthedateofdelivery.TheSeller'sliabilityonanyclaimofanykind, includingnegligence,forlossordamagearisingoutof,connectedwithorresultingfromthis order,orfromtheperformanceorbreachthereoforfromthemanufacture,sale,delivery, resale,repairoruseofanyitemorservicescoveredbyorfurnishedunderthisordershallin nocaseexceedthepriceallocabletotheitemorserviceorpartthereofwhichgivesrisetothe claimandintheeventSellerfailstomanufactureordeliveritemsotherthanstandardproducts thatappearinSeller'scatalog.Seller'sexclusiveliabilityandBuyer'sexclusiveremedyshallbe releaseoftheBuyerfromtheobligationtopaythepurchaseprice.INNOEVENTSHALLTHE SELLERBELIABLEFORSPECIALORCONSEQUENTIALDAMAGES.Buyerwilltakeall appropriatemeasurestoadviseusersandoperatorsoftheproductsdeliveredhereunderofall potentialdangerstopersonsorproperty,whichmaybeoccasionedbysuchuse.Buyerwill indemnifyandholdSellerharmlessfromallclaimsofanykindforinjuriestopersonsand propertyarisingfromuseoftheproductsdeliveredhereunder.Buyerwill,atitssolecost,carry liabilityinsuranceadequatetoprotectBuyerandSelleragainstsuchclaims. Allreturns(warrantyornonwarranty)requirethatyoufirstobtainaReturnMaterial Authorization(RMA)numberfromthefactory.RequestanRMAnumberby: web telephone fax e-mail www.a-m-c.com/download/form/form_rma.html (805) 389-1935 (805) 389-1165 amcsupport@a-m-c.com
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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
MNALHWIN-01
MotorCurrentFrequency .............19 MotorForce ....................................19 MotorInductance .......................3, 19 Overload .....................................58 MotorProblems .............................60 MotorResistance............................19 MotorRunAway ............................60 MotorTorqueConstant..................18 MotorVoltage ...........................18, 20 MotorWiring..................................32 MountingOptions ..........................39 MoveProfile ...................................17 MultiplePowerSupplyWiring......33 N NegativeFeedback......................... 11 Noise...............................................31 NominalPowerSupplyVoltage ....20 O Overload .........................................58 OverTemperature..........................57 OverVoltageShutdown .................57 P PartNumberingStructure...............4 PEGround ......................................30 PeakCurrentFoldback .................59 PeakTorque ...................................18 PinFunctions ...........................4042 PositiveFeedback .......................... 11 PotentiometerFunctions ...............43 PotentiometerTestPoints .............43 PowerGround................................30 PowerOutputs,LowVoltage..........42 PowerStageSpecifications..............9 PowerSupplyCapacitance ..2, 25, 32 PowerSupplyChassis ...................30 PowerSupplyCurrent...................21 PowerSupplyOutputCurrent 20, 25 PowerSupplyWiring ....................32
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
II
MNALHWIN-01
Analog Drives Product Family Hardware Installation Manual

MNALHWIN-01
3805 Calle Tecate Camarillo, CA 93012-5068 Tel: (805) 389-1935 Fax: (805) 389-1165 www.a-m-c.com

AMC AnalogDrives InstallManual

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Everythings possible.

Notice - Required instruction necessary to ensure successful completion of a task or procedure.

Caution - Instructs and directs you to avoid damaging equipment.

Warning - Instructs and directs you to avoid harming yourself.

2011 ADVANCED Motion Controls. All rights reserved.

1.1 General Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Products and System Requirements

Integration in the Servo System

Through-hole Component Tuning

Thissectiondiscussescharacteristicsofyouranalogservodrivetoraiseyourawarenessofpotentialrisksand hazards.Theseverityofconsequencesrangesfromfrustrationofperformance,throughdamagetoequipment, injuryordeath.Theseconsequences,ofcourse,canbeavoidedbygooddesignandproperinstallationintoyour mechanism.

1.1 General Safety Overview

Safety / General Safety Overview

Safety / General Safety Overview

Products and System Requirements

Thischapterisintendedasaguideandgeneraloverviewinselecting,installing,andoperatingananalogservo drive.Containedwithinareinstructionsonsystemintegration,wiring,drivesetup,andstandardoperating methods.

2.1 Analog Drive Family Overview

2.1.1 Products Covered

Drive Datasheet Eachanalogdrivehasaseparatedatasheetthatcontainsimportantinformation

Products and System Requirements / Analog Drive Family Overview

Standard and Custom Models Thedrivesinthetablesbelowarethestandardproductline

Cont. Current (A) 15 25 12.5 25

TABLE 2.6 Brushless PWM Input DC Drives

TABLE 2.2 Brushless 10V Analog DC Drives

TABLE 2.7 Brushless PWM Input AC Drives

TABLE 2.8 Sinusoidal Input DC Drives

TABLE 2.3 Brushed 10V Analog AC Drives

TABLE 2.4 Brushless 10V Analog AC Drives

TABLE 2.9 Sinusoidal Input AC Supply Drives

2.2 Analog PWM Servo Drive Basics and Theory

Command + Current Control Switching Logic

ON time Time Pulse width

2.2.1 Single Phase (Brushed) Servo Drives

2.2.2 Three Phase (Brushless) Servo Drives

FIGURE 2.5 Brushless Servo System

Position and Commutation Feedback

Products and System Requirements / Power Stage Specifications

2.3 Power Stage Specifications

AC Supply Voltage Range AC Supply Frequency Maximum Peak Output Current

Shunt Fuse Bus Fuse Switching Frequency

Products and System Requirements / Command Inputs

2.4 Command Inputs

2.4.1 10V Analog

2.4.2 PWM and Direction

Products and System Requirements / Feedback Specifications

2.5 Feedback Specifications

2.5.1 Feedback Polarity

2.5.2 Incremental Encoder

Products and System Requirements / Feedback Specifications

FIGURE 2.7 Encoder Feedback Signals

2.5.3 Hall Sensors

Motor Phase Current

Products and System Requirements / Feedback Specifications

Dependingonthemotorpolecount,theremaybemorethanoneelectricalcycleforevery motorrevolution.Foreveryactualmechanicalmotorrevolution,thenumberofelectricalcycles willbethenumberofmotorpolesdividedbytwo.Forexample:

a6polemotorcontains3electricalcyclespermotorrevolution a4polemotorcontains2electricalcyclespermotorrevolution a2polemotorcontains1electricalcyclepermotorrevolution

ThedrivepowerstwoofthethreemotorphaseswithDCcurrentduringeachspecificHall Sensorstate: Thetablebelowshowsthevalidcommutationstatesforboth120degreeand60degree phasing. TABLE 2.11 Commutation Sequence Table

120 Degree Hall 3

Products and System Requirements / Modes of Operation

2.6 Modes of Operation

2.6.1 Current (Torque) Mode

2.6.2 Duty Cycle (Open Loop) Mode

Products and System Requirements / Modes of Operation

2.6.3 Hall Velocity Mode