Electro-Craft CompletePower Plus CPP-A12V80A-SA-USB Manuale per l'uso e la cura

CPP-A12V80A-SA-USB

Technical Reference

ElectroCraft CompletePower™ Plus Universal Servo Drive

ElectroCraft document number 198-0000023

ElectroCraft

2 Marin Way, Suite 3

Stratham, NH 03885-2578

www.electrocraft.com

Record of Revisions:

Revision

Date

Description

Comments

001

2/7/2018

Initial release

Document Released

002

8/15/2018

Phase 2&3 updates

PMDC and Stepper motor

update per ECO_000672

Read This First

While ElectroCraft believes that the information and guidance given in this manual is correct, all parties

must rely upon their own skill and judgment when making use of it. ElectroCraft does not assume any

liability to anyone for any loss or damage caused by any error or omission in the work, whether such error

or omission is the result of negligence or any other cause. Any and all such liability is disclaimed.

any means, electrical or mechanical including photocopying, recording or by any information-retrieval

system without permission in writing from ElectroCraft, Inc. The information in this document is subject to

change without notice.

About This Manual

This document is a technical reference manual for CPP-A12V80A-SA-USB hardware. This document

covers the drive hardware including technical data, connectors and wiring diagrams needed for

installation.

If you Need Assistance …

Visit ElectroCraft online

World Wide Web: www.electrocraft.com

If you want to …

• Receive general information or assistance

• Ask questions about product operation or report suspected problems

• Make suggestions or report errors in documentation

Contact ElectroCraft at …

For North America:

Tel

: (844) 338-8114

: drivesupport@electrocraft.com

Mail

: ElectroCraft

2 Marin Way, Suite 3

Stratham, NH 03885-2578

USA

For Outside North America:

Please visit

www.electrocraft.com/contact/

Contents

1Product Safety Precautions ................................................................................... 7

1.1 Operation ...................................................................................................................... 7

1.2 Storage and Transportation........................................................................................... 8

1.3 Environmental Protection .............................................................................................. 8

1.4 Installation..................................................................................................................... 9

1.5 Wiring............................................................................................................................ 9

1.6 Life Support Policy .......................................................................................................10

1.7 Checking Product on Delivery ......................................................................................11

2Product Overview.................................................................................................. 12

2.1 Key Features................................................................................................................12

2.2 Simplified System Block Diagram.................................................................................12

2.3 Hall Sensor Feedback ..................................................................................................13

2.4 Stepper motor Phase Current Waveforms for Different Step values .............................15

2.5 Encoder Feedback .......................................................................................................16

2.6 Motor and Sensor Configurations.................................................................................16

2.7 Identification Labels .....................................................................................................16

2.8 Status Indicator Lights..................................................................................................16

3Drive Specifications .............................................................................................. 17

3.1 Physical Specifications.................................................................................................17

3.2 Environmental Specifications .......................................................................................17

3.3 Electrical Specifications................................................................................................17

3.3.1 DC Supply Input .................................................................................................................... 17

3.3.2 +5VDC Supply Output ........................................................................................................... 17

3.3.3 Motor Output.......................................................................................................................... 17

3.3.4 Hall Sensor Inputs ................................................................................................................. 18

3.3.5 Encoder Inputs ...................................................................................................................... 18

3.3.6 Digital Input............................................................................................................................ 18

3.3.7 Digital Output......................................................................................................................... 18

3.3.8 Analog Input .......................................................................................................................... 18

3.3.9 Analog Output........................................................................................................................ 19

3.3.10 USB Communications ........................................................................................................... 19

3.4 De-rating ......................................................................................................................19

3.5 Peak Current Fold-back (I2t).........................................................................................20

4Hardware Installation ............................................................................................ 21

4.1 Mechanical Mounting ...................................................................................................21

4.2 Dimensions ..................................................................................................................21

4.3 Mating Connectors .......................................................................................................21

4.4 Connector Locations and Pin Numbers ........................................................................22

4.4.1 Connector Layout .................................................................................................................. 22

4.4.2 J1 Supply Connector Pinout.................................................................................................. 22

4.4.3 J2 Motor Connector Pinout.................................................................................................... 22

4.4.4 J3 Hall Connector Pinout....................................................................................................... 22

4.4.5 J4 Encoder Connector Pinout ............................................................................................... 23

4.4.6 J5 I/O Connector Pinout ........................................................................................................ 23

4.4.7 J6 USB Communications Connector Pinout ......................................................................... 23

5Connecting Power................................................................................................. 24

5.1 Power supply ...............................................................................................................24

6Connecting Motors................................................................................................ 25

6.1 Brushless DC Motor .....................................................................................................25

6.2 Permanent Magnet DC (PMDC) Motor.........................................................................25

6.3 Stepper Motor ..............................................................................................................25

7Connecting Motor Feedback Devices.................................................................. 26

7.1 Hall Sensors.................................................................................................................26

7.1.1 Hall Sensor Connections ....................................................................................................... 26

7.1.2 Hall Sensor Signal Input Circuit............................................................................................. 26

7.2 Incremental Encoder ....................................................................................................26

7.2.1 Differential Encoder ............................................................................................................... 26

7.2.2 Single-Ended Encoder .......................................................................................................... 27

7.2.3 Encoder Input Circuit............................................................................................................. 27

7.3 IxR Speed Feedback Estimator....................................................................................27

7.4 Motor Temperature Sensor ..........................................................................................28

7.4.1 Temperature Sensor Connections ........................................................................................ 28

7.4.2 Temperature Sensor Signal Input Circuit .............................................................................. 28

8Connecting I/O....................................................................................................... 29

8.1 I/O Functional Description ............................................................................................29

8.2 Minimum I/O Connections ............................................................................................30

8.2.1 Minimum I/O Connections for BLDC and PMDC motors ...................................................... 30

8.2.2 Minimum I/O Connections for Stepper motor........................................................................ 30

8.3 Digital Inputs and Outputs ............................................................................................31

8.3.1 Digital Input Circuit ................................................................................................................ 31

8.3.2 Digital Output Circuit ............................................................................................................. 31

8.4 Analog Inputs and Outputs...........................................................................................32

8.4.1 Analog Input Circuit ............................................................................................................... 32

8.4.2 Analog Output Circuit ............................................................................................................ 32

9Communication ..................................................................................................... 33

9.1 Connecting USB...........................................................................................................33

10 Introduction to ElectroCraft CompleteArchitect™ PC Software .................... 33

11 First Time Operation .......................................................................................... 33

12 Adding an External Brake Resistor .................................................................. 34

12.1 Caution Statement ....................................................................................................34

12.2 Brake Resistor Theory of Operation ..........................................................................34

12.3 Selecting External Brake Resistor.............................................................................35

12.3.1 Calculating resistance value of the braking resistor.............................................................. 35

12.3.2 Calculating power value of the braking resistor .................................................................... 36

12.4 Minimum external bulk capacitance ..........................................................................37

12.5 Connecting External Brake Resistor and Bulk Capacitor...........................................37

12.6 ElectroCraft Braking Module Assembly .....................................................................38

13 Troubleshooting ................................................................................................. 39

13.1 Status LED (Red)......................................................................................................39

13.2 Power LED (Green) ..................................................................................................40

Table of Figures

FIGURE 1: OVERALL DRIVE SYSTEM BLOCK DIAGRAM...................................................................... 12

FIGURE 2: TRAPEZOIDAL COMMUTATION WITH HALL SENSOR FEEDBACK ................................... 13

FIGURE 3: SINUSOIDAL COMMUTATION WITH HALL SENSOR FEEDBACK ...................................... 14

FIGURE 4: STEPPER MOTOR PHASE CURRENT WAVEFORM ............................................................ 15

FIGURE 5: ENCODER FEEDBACK SIGNAL............................................................................................. 16

FIGURE 6: DRIVE WITH IDENTIFYING LABEL ........................................................................................ 16

FIGURE 7: I2T ALGORITHM EXAMPLE..................................................................................................... 20

FIGURE 8: DRIVE DIMENSIONS............................................................................................................... 21

FIGURE 9: DRIVE CONNECTOR LAYOUT............................................................................................... 22

FIGURE 10: POWER SUPPLY CONNECTION TO THE DRIVE ............................................................... 24

FIGURE 11: BRUSHLESS DC MOTOR CONNECTION TO THE DRIVE ................................................. 25

FIGURE 12: PERMANENT MAGNET DC MOTOR CONNECTION TO THE DRIVE ................................ 25

FIGURE 13: STEPPER MOTOR CONNECTION TO THE DRIVE............................................................. 25

FIGURE 14: HALL SENSOR CONNECTION TO THE DRIVE................................................................... 26

FIGURE 15: HALL SENSOR SIGNAL INPUT CIRCUIT ............................................................................ 26

FIGURE 16: DIFFERENTIAL ENCODER CONNECTION TO THE DRIVE ............................................... 26

FIGURE 17: SINGLE-ENDED ENCODER CONNECTION TO THE DRIVE.............................................. 27

FIGURE 18: ENCODER SIGNAL-ENDED INPUT CIRCUIT...................................................................... 27

FIGURE 19: TEMPERATURE SENSOR CONNECTION TO THE DRIVE ................................................ 28

FIGURE 20: TEMPERATURE SENSOR SIGNAL INPUT CIRCUIT .......................................................... 28

FIGURE 21: MINIMUM DRIVE I/O CONNECTIONS NEEDED TO OPERATE BLDC AND PMDC MOTOR

............................................................................................................................................................. 30

FIGURE 22: MINIMUM DRIVE I/O CONNECTION NEEDED TO OPERATE STEPPER MOTOR ........... 30

FIGURE 23: DIGITAL INPUT CIRCUIT ...................................................................................................... 31

FIGURE 24: DIGITAL OUTPUT CIRCUIT .................................................................................................. 31

FIGURE 25: ANALOG INPUT CIRCUIT ..................................................................................................... 32

FIGURE 26: ANALOG OUTPUT CIRCUIT ................................................................................................. 32

FIGURE 24: USB CABLE CONNECTION BETWEEN COMPUTER AND DRIVE..................................... 33

FIGURE 28: BRAKE RESISTOR OPERATION GRAPH............................................................................ 34

FIGURE 29: EXTERNAL BRAKE RESISTOR AND BULK CAPACITOR CONNECTION TO THE DRIVE

............................................................................................................................................................. 37

FIGURE 30: ELECTROCRAFT BRAKING MODULE................................................................................. 38

1 Product Safety Precautions

READ THIS ENTIRE SECTION BEFORE ATTEMPTING TO USE THE CPP-A12V80A-SA-USB DRIVE!

GIVE SPECIAL ATTENTION TO ALL BOLD PRINT ITEMS.

WARNING!

ElectroCraft products are not authorized for use in safety critical applications. To operate the drive safely,

these minimum precautions MUST be followed to insure proper performance without injury to the operator

and damage to motor or drive. FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS COULD

RESULT IN SERIOUS BODILY INJURY, INCLUDING DEATH IN EXTREME CASES.

1.1 Operation

1. Do not touch any of the connector pins on connectors J1 (Supply Input) or J2 (Motor Output)

when power has been applied. Bare wires from adjacent connector pins must never be allowed to

touch one another.

2. J1 pin 3 must be connected to an external earth ground. Follow wiring procedures carefully.

3. Read ElectroCraft Life Support Policy in section 1.6 for application limitations.

4. Follow precautionary guidelines as referenced in section 12 of this manual with regard to proper

installation of an optional external brake resistor.

5. Do not operate the drive in an explosive area or near explosive or flammable materials.

6. Do not use the drive in environments where it is likely to be exposed to strong and/or frequent

static discharge.

7. Conduct trial operations on the servo drive alone with the motor shaft disconnected from the load

to avoid any unexpected motion. Motor shaft should be uncoupled and free to rotate without

coming in contact with user or any stationary object during set up and preliminary operation.

8. Under no circumstances should a phase output from the control be connected to anything other

than a passive inductive/resistive motor load. Short circuit protection for the drive is limited to

momentary conditions only! Repetitive short circuits on any of the output pins of J2 may cause

permanent damage to the drive.

9. Never touch any moving parts while the motor is running. Failure to observe this warning may

result in injury.

10. Excessive speed and current can destroy some motors and possibly injure the user. Check the

motor manufacturer's specifications to ensure that the maximum current and voltage for your

drive model, does not exceed motor limitations.

11. Whenever the drive is disabled for any reason or unpowered, the motor will be in free

spinning/coast mode. The user is responsible to analyze the application (especially in case of

servomotor for a vertical axis) and take precautionary safety measures.

12. Provide an appropriate stopping device on the machine side to ensure safety. Failure to observe

this warning may result in injury.

13. Do not parallel multiple motors off the same drive.

14. Do not make any extreme adjustments or settings changes of parameters. Failure to observe this

caution may result in injury due to unstable operation.

15. Avoid plugging connector J1 into the drive while live power is applied to the connecting cables.

Ignoring this precaution will cause electrical arcing at the connector pins, which can cause

permanent connector damage. ElectroCraft recommends using a disconnect switch ahead of J1 if

the drive must be disconnected often.

16. Do not remove the connectors on ports J1 through J6 from the drive while the motor is operating.

17. Do not service or modify this product. Only authorized personnel must perform disassembly or

repair of the drive. Failure to observe warning may result in injury or damage to product.

18. Always operate the drive within the prescribed voltage limits. Any attempt to operate outside

these bounds may result in damage to the drive.

19. Safe use of this product depends on factors specific to the end application. These factors are

outside of ElectroCraft knowledge and control. The installer of this servo drive must have a

thorough knowledge of safety precautions and practices relevant to the specific application of this

drive. In particular the installer should consider the risks associated with erroneous or non-

operation of the servo drive in the application and mitigate them appropriately.

1.2 Storage and Transportation

1. Do not store or install the product in the following places:

a. Locations subject to temperature outside of the range specified.

b. Locations subject to humidity outside the range specified.

c. Locations subject to condensation as the result of changes in temperature.

d. Locations subject to corrosive or flammable gases and liquids.

e. Locations subject to dust, salts, or electrically conductive contaminants.

f. Locations subject to exposure to water, oil, or chemicals.

g. Locations subject to shock or vibration.

Failure to observe this caution may result in fire, electric shock, or damage to the product.

2. Do not hold the product by the cables or motor shaft while transporting it. Failure to observe this

caution may result in injury or malfunction.

1.3 Environmental Protection

Waste electrical products should not be disposed of with household waste. Please recycle where facilities

exist. Check with your Local Authority or retailer for recycling.

1.4 Installation

1. Take appropriate and sufficient countermeasures when installing systems in the following

locations.

a. Locations subject to static electricity or other forms of noise.

b. Locations subject to strong electromagnetic fields and magnetic fields.

c. Locations subject to possible exposure to radioactivity.

d. Locations close to power supplies including power lines.

Failure to observe this caution may result in damage to the product.

2. Keep any external shunt/brake resistor away from flammable materials. Read section 12 carefully

for more shunt/brake resistor installation details.

3. Never use this product in an environment subject to liquids, corrosive chemicals or gases; or

combustibles; or where foreign materials can fall onto or collect inside the drive. Failure to

observe this caution may result in electric shock or fire.

4. Do not place any objects on the product. Failure to observe this warning may result in damage to

the product.

5. Do not cover the drive or prevent air from escaping or entering through the vents. Failure to

observe this caution may cause internal elements to deteriorate resulting in malfunction or fire.

6. Provide the specified clearance between the drive and other devices. Provide sufficient space

around the drive for cooling by natural convection or provide cooling fans to prevent excessive

heat. See section 4 for details. Failure to observe this caution may result in fire or malfunction.

1.5 Wiring

1. Verify ALL wiring BEFORE applying power to the drive and motor. Motor may spin or oscillate

uncontrollably if improperly wired. Drive may be damaged or improper wiring may prevent drive

from operation.

2. J1 pin 5, PE, MUST always be connected to an appropriate external Protective Earth ground in

accordance with local electrical codes. Improper grounding may result in electric shock and

damage the drive.

3. Securely connect the power supply terminals and motor output terminals. Failure to observe this

caution may result in fire.

4. Do not bundle or run power and signal lines together in the same duct. Keep power and signal

lines separated.

5. Use twisted-pair shielded wires or multi-core twisted pair shielded wires for signal and encoder

feedback lines.

6. Always use the specified power supply voltage. An incorrect power supply may result in damage

to the drive.

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