Everything’s possible.

AxCent™ Panel Mount Drives

for Servo Systems

Hardware
www.a-m-c.com Installation Manual
MNACHWIN-06
 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 company’s 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:

• UL 508c, UL 61800-5-1 file number E140173
• Electromagnetic Compatibility, EMC Directive - 2014/30/EU
EN61000-6-2:2005
EN61000-6-4:2007/A1:2011
Electrical Safety, Low Voltage Directive - 2014/35/EU
EN 60204-1:2006/A1:2009
• Reduction of Hazardous Substances (RoHS III), 2015/863/EU

Trademarks

ADVANCED Motion Controls®, the combined isosceles trapezoid/right triangle logo, DIGIFLEX®,
DIGIFLEX® Performance™, DriveWare® and AxCent™ 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.

MNACHWIN-06 ii
/

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 ease-

of-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 Revision # Date Changes
MNACHWIN-01 1 3/2016 AxCent Product Family Hardware Installation Manual First Release
MNACHWIN-02 2 9/2016 Added AB50A200 Drive Model Information
MNACHWIN-03 3 11/2016 Added AB30A100, AB50A100 and AB30A200 Drive Model Information
MNACHWIN-04 4 3/2017 Added ABDC30A100 and AB50A200I Drive Model Information
MNACHWIN-05 5 4/2017 Added AB30A200I Drive Model Information
MNACHWIN-06 6 8/2017 Added AB30A200AC Drive Model Information

© 2018 ADVANCED Motion Controls. All rights reserved.

iii MNACHWIN-06
 Contents

1 Safety 1

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

2 Products and System Requirements 4

2.1 AxCent™ Drive Family Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Products Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Analog PWM Servo Drive Basics and Theory . . . . . . . . . . . . . . . . . 5
2.2.1 Single Phase (Brushed) Servo Drives . . . . . . . . . . . . . . . . . . 6
2.2.2 Three Phase (Brushless) Servo Drives . . . . . . . . . . . . . . . . . . 6
2.3 Power Stage Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Command Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.1 ±10V Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.2 PWM and Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.1 Feedback Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.2 Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.3 Hall Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.4 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.1 Current (Torque) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.2 Duty Cycle (Open Loop) Mode . . . . . . . . . . . . . . . . . . . . . 13
2.6.3 Hall Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.4 Encoder Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.5 Tachometer Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.6 Voltage Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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2.6.7 IR Compensation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.7 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7.1 Analog Servo Drive Selection and Sizing . . . . . . . . . . . . . 15
Motor Current and Voltage . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7.2 Power Supply Selection and Sizing . . . . . . . . . . . . . . . . . . 18
Power Supply Current and Voltage . . . . . . . . . . . . . . . . . . 19
Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Regeneration and Shunt Regulators . . . . . . . . . . . . . . . . . 22
Voltage Ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.7.3 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . 25
Ambient Temperature Range and Thermal Data . . . . . . 25
Shock/Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Integration in the Servo System 28

3.1 LVD Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2 CE-EMC Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Analog Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PWM Input Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MOSFET Switching Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
IGBT Switching Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fitting of AC Power Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.1 Ferrite Suppression Core Set-up . . . . . . . . . . . . . . . . . . . . . 30
3.2.2 Inductive Filter Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.1 Wire Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.2 Motor Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.3 Power Supply Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Three Phase AC Power Supplies . . . . . . . . . . . . . . . . . . . . . 35
Single Phase AC Power Supplies . . . . . . . . . . . . . . . . . . . . 35
3.4.4 Feedback Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hall Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Incremental Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.5 Input Reference Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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±10V Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PWM and Direction Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Potentiometer Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4 Operation 39

4.1 Initial Setup and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1.1 Pin Function Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Current Monitor Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Current Reference Output . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inhibit / Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fault Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Low Voltage Power Supply Outputs . . . . . . . . . . . . . . . . . 41
Velocity Monitor Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.2 Potentiometer Function Details . . . . . . . . . . . . . . . . . . . . . 41
Test Points for Potentiometers . . . . . . . . . . . . . . . . . . . . . . . 42
Potentiometer Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.3 Switch Function Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1.4 Tachometer Input Gain Scaling . . . . . . . . . . . . . . . . . . . . . 43
4.1.5 Current Limiting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1.6 Drive Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Single Phase (Brush Type) . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Three Phase (Brushless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Three Phase (Brushless) Drive with Brushed Motor . . . . . . 47
4.1.7 Current Loop Tuning Procedure . . . . . . . . . . . . . . . . . . . . 47
Current Loop Proportional Gain Adjustment . . . . . . . . . . 48
Current Loop Integrator Adjustment . . . . . . . . . . . . . . . . . 49
Voltage or Velocity Loop Tuning . . . . . . . . . . . . . . . . . . . . 50
Analog Position Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

A Additional Tuning 51

A.1 Tuning DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

A.2 Through-Hole Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
A.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tune the Current Loop Proportional Gain . . . . . . . . . . . . . 53

MNACHWIN-06 vi
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Tune the Current Loop Integral Gain . . . . . . . . . . . . . . . . . 54

Velocity Loop Integral Gain Tuning . . . . . . . . . . . . . . . . . . 55

B Troubleshooting 56

B.1 Fault Conditions and Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Over-Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Over-Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Under-Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Short Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Invalid Hall Sensor State (Brushless Drives only) . . . . . . . . . 57
Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Power-On Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
B.1.1 Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
B.1.2 Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Non-Foldback Current Limiting . . . . . . . . . . . . . . . . . . . . . . 59
B.1.3 Motor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
B.1.4 Causes of Erratic Operation . . . . . . . . . . . . . . . . . . . . . . . . 60
B.2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
B.2.1 Drive Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
B.3 Warranty Returns and Factory Help . . . . . . . . . . . . . . . . . . . . . . . 61
Index I

MNACHWIN-06 vii
 1 Safety

This section discusses characteristics of your analog servo drive to raise your awareness of potential risks and
hazards. The severity of consequences ranges from frustration of performance, through damage to equipment,
injury or death. These consequences, of course, can be avoided by good design and proper installation into your
mechanism.

1.1 General Safety Overview

In order to install an analog drive into a servo system, you must have a thorough knowledge
and understanding of basic electronics, computers and mechanics as well as safety
precautions and practices required when dealing with the possibility of high voltages or heavy,
strong equipment.

Observe your facility’s lock-out/tag-out procedures so that work can proceed without residual
power stored in the system or unexpected movements by the machine.

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.

Over current protective devices recognized by an international safety

agency must be installed in line before the servo drive. These devices
shall be installed and rated in accordance with the device installation
instructions and the specifications of the servo drive (taking into
consideration inrush currents, etc.). Servo drives that incorporate their
own primary fuses do not need to incorporate over current protection in
the end user’s equipment.

MNACHWIN-06 1
 Safety / General Safety Overview

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.

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!
• If using relays or other means to disconnect the motor leads, be sure
the drive is disabled before reconnecting the motor leads to the
drive. Connecting the motor leads to the drive while it is enabled can
generate extremely high voltage spikes which will damage the drive.

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 drive’s over-
voltage 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.

MNACHWIN-06 2
 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.

MNACHWIN-06 3
 2 Products and System Requirements

This chapter is intended as a guide and general overview in selecting, installing, and operating an AxCent™
family servo drive. Contained within are instructions on system integration, wiring, drive-setup, and standard
operating methods.

2.1 AxCent™ Drive Family Overview

The AxCent drive family contains drives that power both Single Phase (Brushed) and Three
Phase (Brushless) motors. AxCent drives are powered off either a single DC or AC power
supply, and accept either ±10V analog or PWM and Direction signals. A digital controller can be
used to command and interact with AxCent servo drives, and a number of input/output pins
are available for parameter observation and drive configuration.

2.1.1 Products Covered

The drives in the tables below are the standard product line of ADVANCED Motion Controls’
AxCent servo drives. Please contact ADVANCED Motion Controls’ Sales Department for further
information and details on custom drive solutions.
TABLE 2.1 DC Drives TABLE 2.2 AC Drives1
Drive Number VDC Peak Current Cont. Current Drive Number VAC Peak Current Cont. Current
(Nominal) (A) (A) (A) (A)
(Nominal)
AB15A100 20-80 15 7.5 AB30A200AC 30-125 30 15
AB25A100 20-80 25 15 B30A40AC 45-265 30 15
AB30A100 20-80 30 15 B060A400AC 200-240 60 30
ABDC30A100 20-80 30 15 B100A400AC 200-240 100 50
AB50A100 20-80 50 25
AB20A200 40-175 20 12
AB30A200 40-175 30 15
AB30A200I 40-175 30 15
AB50A200 40-175 50 25
AB50A200I 40-175 50 25
B30A40 60-400 30 15

1.Certain AC drive models can also accept a DC power supply. Consult the drive datasheet to determine if DC input is allowed.

Drive Datasheet 2.Each AxCent drive has a separate datasheet that contains important
information on the modes and product-specific features available with that particular

MNACHWIN-06 4
 Products and System Requirements / Analog PWM Servo Drive Basics and Theory

drive, including the functional block diagram of the specific drive’s operation. The
datasheet is to be used in conjunction with this manual for system design and installation.

2.2 Analog PWM Servo Drive Basics and Theory

Analog servo drives are used extensively in motion control systems where precise control of
position and/or velocity is required. The drive transmits the low-energy reference signals from
the controller into high-energy signals (motor voltage and current). The reference signals can
be either analog or digital, with a ±10 VDC signal being the most common. The signal can
represent either a motor torque or velocity demand.

Figure 2.1 shows the components typically used in a servo system (i.e. a feedback system used
to control position, velocity, and/or acceleration). The controller contains the algorithms to
close the desired servo loops and also handles machine interfacing (inputs/outputs, terminals,
etc.). The drive represents the electronic power converter that drives the motor according to
the controller reference signals. The motor (which can be of the brushed or brushless type,
rotary, or linear) is the actual electromagnetic actuator, which generates the forces required to
move the load. Feedback elements are mounted on the motor and/or load in order to close the
servo loop.

FIGURE 2.1 Typical Motion Control System

Reference Current
Controller Servo Drive Motor Feedback Load Feedback

Although there exist many ways to "amplify" electrical signals, pulse width modulation (PWM)
is by far the most efficient and cost-effective approach. At the basis of a PWM servo drive is a
current control circuit that controls the output current by varying the duty cycle of the output
power stage (fixed frequency, variable duty cycle). Figure 2.2 shows a typical setup for a single
phase load.

FIGURE 2.2 PWM Current Control Circuit

+HV

S1 S2
D1 D2

I
Command Motor
+ Current Switching
- Control Logic

D3 D4

Current Feedback S3 S4
Rc

S1, S2, S3, and S4 are power devices (MOSFET or IGBT) that can be switched on or off. D1, D2,
D3, and D4 are diodes that guarantee current continuity. The bus voltage is depicted by +HV.
The resistor Rc is used to measure the actual output current. For electric motors, the load is
typically inductive due to the windings used to generate electromagnetic fields. The current can
be regulated in both directions by activating the appropriate switches. When switch S1 and S4

MNACHWIN-06 5
 Products and System Requirements / Analog PWM Servo Drive Basics and Theory

(or S2 and S3) are activated, current will flow in the positive (or negative) direction and
increase. When switch S1 is off and switch S4 is on (or S2 off and S3 on) current will flow in
the positive (or negative) direction and decrease (via one of the diodes). The switch "ON" time
is determined by the difference between the current demand and the actual current. The
current control circuit will compare both signals every time interval (typically 50 sec or less)
and activate the switches accordingly (this is done by the switching logic circuit, which also
performs basic protection functions). Figure 2.3 shows the relationship between the pulse
width (ON time) and the current pattern. The current rise time will depend on the bus voltage
(+HV) and the load inductance. Therefore, certain minimum load inductance requirements are
necessary depending on the bus voltage.

FIGURE 2.3 Output Current and Duty Cycle Relationship

Current

ON time

Time

Pulse
width

2.2.1 Single Phase (Brushed) Servo Drives

Brushed type servo drives are designed for use with permanent magnet brushed DC motors
(PMDC motors). The drive construction is basically as shown in Figure 2.2. PMDC motors have
a single winding (armature) on the rotor, and permanent magnets on the stator (no field
winding). Brushes and commutators maintain the optimum torque angle. The torque
generated by a PMDC motor is proportional to the current, giving it excellent dynamic control
capabilities in motion control systems.

Brushed drives can also be used to control current in other inductive loads such as voice coil
actuators, magnetic bearings, etc.

2.2.2 Three Phase (Brushless) Servo Drives

Three Phase (brushless) servo drives are used with brushless servo motors. These motors
typically have a three-phase winding on the stator and permanent magnets on the rotor.
Brushless motors require commutation feedback for proper operation (the commutators and
brushes perform this function on brush type motors). This feedback consists of rotor magnetic
field orientation information, supplied either by magnetic field sensors (Hall Effect sensors) or
position sensors (encoder or resolver). Brushless motors have better power density ratings
than brushed motors because heat is generated in the stator, resulting in a shorter thermal
path to the outside environment. Figure 2.4 shows a typical system configuration.

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 Products and System Requirements / Analog PWM Servo Drive Basics and Theory

FIGURE 2.4 Brushless Servo System

+HV

S1 S2 S3

Current
Control
N
Switching
Logic
Commutation S
Control
S1 S2 S3

Commutation Feedback

MNACHWIN-06 7
 Products and System Requirements / Power Stage Specifications

2.3 Power Stage Specifications

The drive datasheet lists the specific values for the following drive power specifications. Note
that not all specifications apply to every drive.
TABLE 2.3 Power Stage Specifications
Specification Units Description
DC Supply Voltage Range VDC Specifies the acceptable DC supply voltage range that the drive will operate within.
DC Bus Over Voltage Limit VDC 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.
AC Supply Voltage Range VAC Specifies the acceptable AC supply voltage range that the drive will operate within.
AC Supply Frequency Hz Specifies the acceptable frequency of the AC supply line.
Maximum Peak Output Current A 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 44.
Maximum Continuous Output A Pertains to the maximum continuous current the drive can output according to hardware
Current
limitations. An RMS rating can be obtained by dividing this value by 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 44.
Maximum Power Dissipation at W The power dissipation of the drive, assuming approximately 5% power loss to heat dissipation.
Continuous Current Calculated by taking 5% of P=V•I at continuous current and peak bus voltage.
Internal Bus Capacitance F The capacitance value between the internal DC bus voltage and power ground.
Internal Shunt Resistance  The resistance value of the internal shunt resistor.
Internal Shunt Resistor Power W The power rating of the internal shunt resistor.
Rating
Internal Shunt Resistor Turn-on VDC The turn-on voltage of the internal shunt resistor.
Voltage
Minimum Load Inductance H 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 30 for more information.
Shunt Fuse A The current rating of the internal shunt resistor fuse.
Bus Fuse A The current rating of the input AC line fuses.
Switching Frequency kHz The switching frequency of the drive output power stage.

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2.4 Command Inputs

The input command source for AxCent servo drives is provided by the following.

2.4.1 ±10V Analog

A differential or single-ended ±10V analog reference signal can be used to command the drive
by adjusting the motor current, voltage, or speed, depending on the mode the drive is
operating in. For information on the proper wiring of a ±10V analog input, see “Input
Reference Wires” on page 37.

2.4.2 PWM and Direction

PWM and Direction Input is a specialized type of command that requires a compatible
controller. The controller needs two high speed TTL digital outputs to control these drives, one
for PWM and the other for Direction. The PWM duty cycle corresponds to the magnitude of the
output. Direct control of the PWM switching puts response times in the sub-microsecond
range. The PWM input goes into a PWM-to-Analog converter. The analog signal is then used as
a command into the current loop, resulting in a Current Mode drive controlled with PWM and
Direction. For information on the proper wiring of a PWM and Direction input, see “PWM and
Direction Inputs” on page 38.

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 Products and System Requirements / Feedback Specifications

2.5 Feedback Specifications

There are a number of different feedback options available in the family of analog drives. The
feedback component can be any device capable of generating a voltage signal proportional to
current, velocity, position, or any parameter of interest. Such signals can be provided directly
by a potentiometer or indirectly by other feedback devices such as Hall Sensors or Encoders.
These latter devices must have their signals converted to a DC voltage, a task performed by the
drive circuitry.

Consult a specific drive datasheet to see which feedback devices are available for that drive.

2.5.1 Feedback Polarity

The feedback element must be connected for negative feedback. This will cause a difference
between the command signal and the feedback signal, called the error signal. The drive
compares the feedback signal to the command signal to produce the required output to the
load by continually reducing the error signal to zero. This becomes important when using an
incremental encoder or Hall sensors, as connecting these feedback elements for positive
feedback will lead to a motor "run-away" condition. In a case where the feedback lines are
connected to the drive with the wrong polarity in either Hall Velocity or Encoder Velocity
Mode, the drive will attempt to correct the "error signal" by applying more command to the
motor. With the wrong feedback polarity, this will result in a positive feedback run-away
condition. To correct this, either change the order that the feedback lines are connected to the
drive, or consult the drive datasheet for the appropriate switch on the DIP switch bank that
reverses the internal feedback velocity polarity. See the drive datasheet and “Switch Function
Details” on page 43 for more information on DIP switch settings.

2.5.2 Incremental Encoder

Analog servo drives that use encoder feedback utilize two single-ended or differential
incremental encoder inputs for velocity control. The encoder provides incremental position
feedback that can be extrapolated into very precise velocity information. The encoder signals
are read as "pulses" that the drive uses to essentially keep track of the motor’s position and
direction of rotation. Based on the speed and order in which these pulses are received from
the two encoder signals, the drive can interpret the motor velocity.

Figure 2.5 represents differential encoder "pulse" signals, showing how depending on which
signal is read first and at what frequency the "pulses" arrive, the speed and direction of the
motor shaft can be extrapolated. By keeping track of the number of encoder "pulses" with
respect to a known motor "home" position, servo drives are able to ascertain the actual motor
location.

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FIGURE 2.5 Encoder Feedback Signals

Encoder A+

Encoder A-
Example 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

Three Phase (Brushless) drives use Hall Sensors for commutation feedback, and in the special
case of some drives, for velocity control. The Hall Sensors are built into the motor to detect the
position of the rotor magnetic field. These sensors are mounted such that they each generate a
square wave with either a 120-degree or 60-degree phase difference over one electrical cycle
of the motor.

FIGURE 2.6 Hall Sensor Commutation and Motor Phase Current for 120-Degree Phasing
Hall Sensor
Commutation Note: Not all ADVANCED Motion
High (1) Controls’ servo drive series use
the same commutation logic.
Hall A
The commutation diagrams
Low (0)
provided here should be used
High (1)
only with drives covered within
Hall B this manual.
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 60 120 180 240 300 360 Electrical Degrees

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Depending on the motor pole count, there may be more than one electrical cycle for every
motor revolution. For every actual mechanical motor revolution, the number of electrical cycles
will be the number of motor poles divided by two. For example:
• a 6-pole motor contains 3 electrical cycles per motor revolution
• a 4-pole motor contains 2 electrical cycles per motor revolution
• a 2-pole motor contains 1 electrical cycle per motor revolution

The drive powers two of the three motor phases with DC current during each specific Hall
Sensor state:

The table below shows the valid commutation states for both 120-degree and 60-degree
phasing.
TABLE 2.4 Commutation Sequence Table
60 Degree 120 Degree Motor
Hall 1 Hall 2 Hall 3 Hall 1 Hall 2 Hall 3 Phase A Phase B Phase C
1 0 0 1 0 0 HIGH - LOW
1 1 0 1 1 0 - HIGH LOW
1 1 1 0 1 0 LOW HIGH -
Valid
0 1 1 0 1 1 LOW - HIGH
0 0 1 0 0 1 - LOW HIGH
0 0 0 1 0 1 HIGH LOW -
1 0 1 1 1 1 - - -
Invalid
0 1 0 0 0 0 - - -

2.5.4 Tachometer
A DC Tachometer can be used on some drives for velocity control. The tachometer provides an
analog DC voltage feedback signal that is related to the actual motor speed and direction. The
drive subsequently adjusts the output current based on the error between the tachometer
feedback and the input command voltage. The maximum range of the tachometer feedback
signal is ±60 VDC.

Some applications may require an increase in the gain of the tachometer input signal. This
occurrence will be most common in designs where the tachometer input has a low voltage to
RPM scaling ratio. Some drive models offer a through-hole location listed on the specific drive
datasheet where a resistor can be added to increase the tachometer gain. Use the drive’s block
diagram to determine an appropriate resistor value.

See “Tachometer Input Gain Scaling” on page 43 for more information.

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 Products and System Requirements / Modes of Operation

2.6 Modes of Operation

The AxCent drive family offers a variety of different control methods. While some drives in the
series are designed to operate solely in one mode, on other drives it is possible to select the
control method by DIP switch settings. Consult the datasheet for the drive in use to see which
modes are available for use.

The name of the mode refers to which servo loop is being closed in the drive, not the end-
result of the application. For instance, a drive operating in Current (Torque) Mode may be used
for a positioning application if the external controller is closing the position loop. Oftentimes,
mode selection will be dependent on the requirements and capabilities of the controller being
used with the drive as well as the end-result application.

2.6.1 Current (Torque) Mode

In Current (Torque) Mode, the input command voltage controls the output current. The drive
will adjust the output duty cycle to maintain the commanded output current. This mode is used
to control torque for rotary motors (force for linear motors), but the motor speed is not
controlled. The output current can be monitored through an analog current monitor output
pin. The voltage value read at the “Current Monitor Output” can be multiplied by a scaling
factor found on the drive datasheet to determine the actual output current.

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
Note 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

In Duty Cycle Mode, the input command voltage controls the output PWM duty cycle of the
drive, indirectly controlling the output voltage. Note that any fluctuations of the DC supply
voltage will affect the voltage output to the motor.

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

2.6.3 Hall Velocity Mode

In Hall Velocity Mode, the input command voltage controls the motor velocity, with the Hall
Sensor frequency closing the velocity loop. An analog velocity monitor output allows

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observation of the actual motor speed through a Hz/V scaling factor found on the drive
datasheet. The voltage value read at the velocity monitor output can be used to determine the
motor RPM through the scaling factor. See “Velocity Monitor Output” on page 41 for the motor
RPM equation.

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
Note applications where the motor will be spinning at higher speeds.

2.6.4 Encoder Velocity Mode

In Encoder Velocity Mode, the input command controls the motor velocity, with the frequency
of the encoder pulses closing the velocity loop. An analog velocity monitor output allows
observation of the actual motor speed through a kHz/V scaling factor found on the drive
datasheet. The voltage value read at the velocity monitor output can be used to determine the
motor RPM through the scaling factor. See “Velocity Monitor Output” on page 41 for the motor
RPM equation.

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
Note smoothness is the objective.

2.6.5 Tachometer Velocity Mode

In Tachometer Velocity Mode, the input command voltage controls the motor velocity. This
mode uses an external DC tachometer to close the velocity loop. The drive translates the DC
voltage from the tachometer into motor speed and direction information.

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

2.6.6 Voltage Mode

In Voltage Mode the input reference signal commands a proportional motor voltage regardless
of power supply voltage variations. This mode is recommended for velocity control when
velocity feedback is unavailable and load variances are small.

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2.6.7 IR Compensation Mode

If there is a load torque variation while in Voltage Mode, the motor current will also vary as
torque is proportional to motor current. Hence, the motor terminal voltage will be reduced by
the voltage drop over the motor winding resistance (IR), resulting in a speed reduction. Thus,
motor speed, which is proportional to motor voltage (terminal voltage minus IR drop) varies
with the load torque.

In order to compensate for the internal motor voltage drop, a voltage proportional to motor
current can be added to the output voltage. An internal resistor adjusts the amount of
compensation, and an additional SMT or through-hole resistor can be added to a location on
the drive. Consult the drive datasheet to see which IR Compensation resistor option is
available. Use caution when adjusting the IR compensation level. If the feedback voltage is high
enough to cause a rise in motor voltage with increased motor current, instability occurs. Such
a result is due to the fact that increased voltage increases motor speed and thus load current
which, in turn, increases motor voltage. If a great deal of motor torque change is anticipated, it
may be wise to consider the addition of a speed sensor to the motor (e.g. tachometer, encoder,
etc.).

2.7 System Requirements

To successfully incorporate an analog servo drive into your system, you must be sure it will
operate properly based on electrical, mechanical, and environmental specifications, follow
some simple wiring guidelines, and perhaps make use of some accessories in anticipating
impacts on performance. Before selecting an analog servo drive, a user should consider the
requirements of their system. This involves calculating the required voltage, current, torque,
and power requirements of the system, as well as considering the operating environment and
any other equipment the drive will be interfacing with.

2.7.1 Analog Servo Drive Selection and Sizing

Analog servo drives have a given current and voltage rating unique to each drive. Based on the
necessary application requirements and the information from the datasheet of the motor
being used, a drive may be selected that will best suit the motor capabilities.

A drive should be selected that will meet the peak and continuous current requirements of the
application, and operate within the voltage requirements of the system.

Motor Current and Voltage Motor voltage and current requirements are determined based
on the maximum required torque and velocity. These requirements can be derived from the
application move profiles (Figure 2.7).

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FIGURE 2.7 Example Velocity, Torque, and Power Curves

1 Cycle
Velocity
Dwell Dwell

Time

Torque

RMS

Time

Power is equal to Torque x Velocity. Motor

Power Voltage (Vm) and Motor Current (Im) should
be chosen where power is at a maximum.

Time

The motor current IM is the required motor current in amps DC, and is related to the torque
needed to move the load by the following equation:
Torque
I M = -------------------
KT

Where:
KT -motor torque constant

The motor current will need to be calculated for both continuous and peak operation. The
peak torque will be during the acceleration portion of the move profile.

The continuous torque is the average torque required by the system during the move profile,
including dwell times. Both peak torque and continuous, or RMS (root mean square) torque

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 Products and System Requirements / System Requirements

need to be calculated. RMS torque can be calculated by plotting torque versus time for one move
cycle.

2
 Ti ti
T RMS = i
----------------
-
 ti
i
Here Ti is the torque and ti is the time during segment i. In the case of a vertical application
make sure to include the torque required to overcome gravity.

The system voltage requirement is based on the motor properties and how fast and hard the
motor is driven. The system voltage requirement is equal to the motor voltage, VM, required
to achieve the move profile. In general, the motor voltage is proportional to the motor speed
and the motor current is proportional to the motor shaft torque. Linear motors exhibit the
same behavior except that in their case force is proportional to current. These relationships
are described by the following equations:

Vm = Im Rm + E

E = Ke Sm

for rotary motors T = Kt Im

for linear motors F = Kf Im

Where:
Vm -motor voltage
Im -motor current (use the maximum current expected for the application)
Rm -motor line-to-line resistance
E -motor back-EMF voltage
T -motor torque
F -motor force
Kt -motor torque constant
Kf -motor force constant
Ke -voltage constant
Sm -motor speed (use the maximum speed expected for the application)

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 Products and System Requirements / System Requirements

The motor manufacturer’s data sheet contain Kt (or Kf) and Ke constants. Pay special attention
to the units used (metric vs. English) and the amplitude specifications (peak-to-peak vs. RMS,
phase-to-phase vs. phase-to-neutral).

The maximum motor terminal voltage and current can be calculated from the above equations.
For example, a motor with a Ke = 10V/Krpm and required speed of 3000 RPM would require
30V to operate. In this calculation the IR term (voltage drop across motor winding resistance)
is disregarded. Maximum current is maximum torque divided by Kt. For example, a motor with
Kt = 0.5 Nm/A and maximum torque of 5 Nm would require 10 amps of current. Continuous
current is RMS torque divided by Kt.

Motor Inductance The motor inductance is vital to the operation of analog servo drives, as it
ensures that the DC motor current is properly filtered.

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 30 for more
information.

A minimum motor inductance rating for each specific drive can be found in the datasheet. If
the drive is operated below the maximum rated voltage, the minimum load inductance
requirement may be reduced.

In the above equations the motor inductance is neglected. In brushless systems the voltage
drop caused by the motor inductance can be significant. This is the case in high-speed
applications if motors with high inductance and high pole count are used. Please use the
following equation to determine motor terminal voltage (must be interpreted as a vector).

V m =  R m + jL I m + E

Where:
L -phase-to-phase motor inductance
 -maximum motor current frequency

2.7.2 Power Supply Selection and Sizing

There are several factors to consider when selecting a power supply for an analog servo drive.
• Power Requirements
• Isolation
• Regeneration
• Voltage Ripple

Power Requirements refers to how much voltage and current will be required by the drive in
the system. Isolation refers to whether the power supply needs an isolation transformer.

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 Products and System Requirements / System Requirements

Regeneration is the energy the power supply needs to absorb during deceleration. Voltage
Ripple is the voltage fluctuation inherent in unregulated supplies.

Power Supply Current and Voltage The power supply current rating is based on the
maximum current that will be required by the system. If the power supply powers more than
one drive, then the current requirements for each drive should be added together. Due to the
nature of servo drives, the current into the drive does not always equal the current out of the
drive. However, the power in is equal to the power out. Use the following equation to calculate
the power supply output current, IPS, based on the motor voltage and current requirements.
VM  IM
I PS = ----------------------------
-
V PS   0.98 

Where:
VPS -nominal power supply voltage
IM -motor current
VM -motor voltage

Use values of Vm and Im at the point of maximum power in the move profile, Figure 2.7 (when
VMIM = max). This will usually be at the end of a hard acceleration when both the torque and
speed of the motor is high.

The power supply current is a pulsed DC current (Figure 2.8): when the MOSFET switch is on,
it equals the motor current; when the MOSFET is off it is zero. Therefore, the power supply
current is a function of the PWM duty cycle and the motor current (e.g. 30% duty cycle and 12
amps motor current will result in 4 amps power supply current). 30% duty cycle also means
that the average motor voltage is 30% of the DC bus voltage. Power supply power is
approximately equal to drive output power plus 3 to 5%.

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 2.8 Unregulated DC Power Supply Current

PWM
Switching
Time
MOSFET ON
Vm

MOSFET OFF
Im
Ip
DIODE BRIDGE Average
Time
Vp Vm
Im Ripple Current
Id
Motor

AC Input
Voltage

Time
SERVO DRIVE
Id

Vp = VAC*1.41
Average

Time

Ip

Vm = Motor Terminal Voltage

Im = Motor Current
Average
Id = Diode Current
Time
Ip = Power Supply Current
Vp = DC Power Supply Voltage Vp
VAC = AC Supply Voltage (RMS)

The ripple current depends on the Time

motor inductance and the duty
cycle (MOSFET ON vs. OFF 50usec
time)

A system will need a certain amount of voltage and current to operate properly. If the power
supply has too little voltage/current the system will not perform adequately. If the power
supply has too much voltage the drive may shut down due to over voltage, or the drive may be
damaged.

To avoid nuisance over- or under-voltage errors caused by fluctuations in the power supply,
the ideal system power supply voltage should be at least 10% above the entire system voltage
requirement, and at least 10% below the lowest value of the following:
— Drive over voltage
— External shunt regulator turn-on voltage (see “Regeneration and Shunt Regulators” on
page 22)

These percentages also account for the variances in Kt and Ke, and losses in the system
external to the drive. The selected margin depends on the system parameter variations.

Do not select a supply voltage that could cause a mechanical over-

speed in the event of a drive malfunction or a runaway condition.
Brushed Motors may have voltage limitations due to the mechanical
commutators. Consult the manufacturer’s data sheets.

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 Products and System Requirements / System Requirements

Figure 2.9 provides one possible example of an appropriate system power supply voltage for
an analog drive using an external shunt regulator. The over voltage and under voltage
shutdown levels on ADVANCED Motion Controls drives can be found on the drive datasheet.
The shunt regulator turn-on voltage was chosen at an appropriate level to clamp the power
supply voltage so it will not exceed the drive over voltage limit during regeneration. The
system power supply requirement is based on the motor properties and how much voltage is
needed to achieve the application move profile (see “Motor Current and Voltage” on page 15).
Keep in mind that the calculated value for Vm is the minimum voltage required to complete
moves at the desired speed and torque. There should be at least 10% headroom between the
calculated value and the actual power supply voltage to allow for machine changes such as
increased friction due to wear, change in load, increased operating speed, etc.

FIGURE 2.9 Power Supply Selection

100
Drive Over Voltage Shutdown (88V)
80 Shunt Regulator Turn-On Voltage (80V)

60
VDC Acceptable Power Supply
40 Range (26 V-72V)
System Power Supply Requirement (24V)
20
Drive Under Voltage Shutdown (9V)
0

Isolation In systems where an AC line is involved, isolation is required between the AC line and the
signal pins on the drive. This applies to all systems except those that use a battery as a power
supply. There are two options for isolation:
1. The drive can have built in electrical isolation.
2. The power supply can provide isolation (e.g. a battery or an isolation transformer).

The system must have at least one of these options to operate safely.

Drive with Isolation

Some ADVANCED Motion Controls AxCent drives come with standard electrical isolation, while
others can be ordered with isolation as an option To determine if a drive has isolation refer to
the functional block diagram on the drive datasheet. The isolation will be indicated by a dashed
line through the functional block diagram separating power ground from signal ground.

Drives with an "I" after the current rating in the part number (i.e. AB50A200I), drives that are
rated to 400 VDC and drives that take AC line voltage for power come standard with isolation.
Other drives that do not fall into these categories can be ordered by special request to include
isolation.

Power Supply with Isolation

An isolated power supply is either a battery or a power supply that uses an isolation
transformer to isolate the AC line voltage from the power supply ground. This allows both the
power ground on an isolated power supply and the signal ground on a non-isolated drive to be
safely pulled to earth ground. Always use an isolated power supply if there is no isolation in the
drive.

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Regeneration and Shunt Regulators Use of a shunt regulator is necessary in systems

where motor deceleration or a downward motion of the motor load will cause the system’s
mechanical energy to be regenerated via the drive back onto the power supply.

FIGURE 2.10 Four Quadrant Operation - Regeneration occurs when Torque and Velocity polarity are opposite
Current/Torque

I Torque + Velocity + No Regen

II Torque - Velocity + Regen
IV I Torque - No Regen
III Velocity -
Regenerating Motoring
Counterclockwise Clockwise IV Torque + Velocity - Regen

Voltage/Velocity

III II
Motoring Regenerating
Counterclockwise Clockwise

This regenerated energy can charge the power supply capacitors to levels above that of the
drive over-voltage shutdown level. If the power supply capacitance is unable to handle this
excess energy, or if it is impractical to supply enough capacitance, then an external shunt
regulator must be used to dissipate the regenerated energy. Shunt regulators are essentially a
resistor placed in parallel with the DC bus. The shunt regulator will "turn-on" at a certain
voltage level (set below the drive over-voltage shutdown level) and discharge the regenerated
electric energy in the form of heat.

The voltage rise on the power supply capacitors without a shunt regulator, can be calculated
according to a simple energy balance equation. The amount of energy transferred to the power
supply can be determined through:

Ei = Ef

Where:
Ei -initial energy
Ef -final energy

These energy terms can be broken down into the approximate mechanical and electrical terms
- capacitive, kinetic, and potential energy. The energy equations for these individual
components are as follows:

1 2
E c = --- CV nom
2

Where:
Ec -energy stored in a capacitor (joules)
C -capacitance
Vnom -nominal bus voltage of the system

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 Products and System Requirements / System Requirements

1 2
E r = --- J
2

Where:
Er -kinetic (mechanical) energy of the load (joules)
J -inertia of the load (kg-m2)
 -angular velocity of the load (rads/s)

E p = mgh

Where:
Ep -potential mechanical energy (joules)
m -mass of the load (kg)
g -gravitational acceleration (9.81 m/s2)
h -vertical height of the load (meters)

During regeneration the kinetic and potential energy will be stored in the power supply’s
capacitor. To determine the final power supply voltage following a regenerative event, the
following equation may be used for most requirements:

 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

Which simplifies to:

2 J 2 2 2mg  h i – h f 
Vf = V nom + ----   i –  f  + ------------------------------
-
C C

The Vf calculated must be below the power supply capacitance voltage rating and the drive
over voltage limit. If this is not the case, a shunt regulator is necessary. A shunt regulator is
sized in the same way as a motor or drive, i.e. continuous and RMS power dissipation must be
determined. The power dissipation requirements can be determined from the application
move profile (see Figure 2.7).

ADVANCED Motion Controls offers a variety of shunt regulators for servo drives. When
choosing a shunt regulator, select one with a shunt voltage that is greater than the DC bus
voltage of the application but less than the over voltage shutdown of the drive. Verify the need

MNACHWIN-06 23
 Products and System Requirements / System Requirements

for a shunt regulator by operating the servo drive under the worst-case braking and
deceleration conditions. If the drive shuts off due to over-voltage, a shunt regulator is
necessary.

Continuous Regeneration

In the special case where an application requires continuous regeneration (more than a few
seconds) then a shunt regulator may not be sufficient to dissipate the regenerative energy.
Please contact ADVANCED Motion Controls for possible solutions to solve this kind of
application. Some examples:
• Web tensioning device
• Electric vehicle rolling down a long hill
• Spinning mass with a very large inertia (grinding wheel, flywheel, centrifuge)
• Heavy lift gantry

Voltage Ripple For the most part, ADVANCED Motion Controls analog servo drives are
unaffected by voltage ripple from the power supply. The current loop is fast enough to
compensate for 60 Hz fluctuations in the bus voltage, and the components in the drive are
robust enough to withstand all but the most extreme cases. Peak to peak voltage ripple as high
as 25 V is acceptable.

There are some applications where the voltage ripple can cause unacceptable performance.
This can become apparent where constant torque or force is critical or when the bus voltage is
pulled low during high speed and high current applications. If necessary, the voltage ripple
from the power supply can be reduced, either by switching from single phase AC to three
phase AC, or by increasing the capacitance of the power supply.

The voltage ripple for a system can be estimated using the equation:
I PS
V R = ---------- F f
C PS

Where:
VR -voltage ripple
CPS -power supply capacitance
IPS -power supply output current
Ff -frequency factor (1/hertz)

The power supply capacitance can be estimated by rearranging the above equation to solve for
the capacitance as:
I PS
C PS = -------- F f
VR

MNACHWIN-06 24
 Products and System Requirements / System Requirements

The frequency factor can determined from:

0.42
F f = ----------
f

where f is the AC line frequency in hertz. Note that for half wave rectified power supplies, f =
f/2.

The power supply output current, if unknown, can be estimated by using information from the
output side of the servo drive as given below:
VM  I
M
I PS = ----------------------------
-
V PS   0.98 

Where:
IM -current through the motor
VPS -nominal power supply voltage
VM -motor voltage (see “Motor Current and Voltage” on page 15)

2.7.3 Environmental Specifications

To ensure proper operation of an AxCent servo drive, it is important to evaluate the operating
environment prior to installing the drive.
TABLE 2.5 Environmental Specifications
Environmental Specifications
Parameter Description
Ambient Temperature Range See Figure 2.11
Baseplate Temperature Range See Drive Datasheet
Humidity 90%, non-condensing
Mechanical Shock 10g, 11ms, Half-sine
Vibration 2 - 2000 Hz @ 2.5g
Altitude 0-3000m

Ambient Temperature Range and Thermal Data AxCent drives contain a built-in
over-temperature disabling feature if the baseplate temperature rises above a certain value.
For a specific continuous output current, the graphs below specify an upper limit to the
ambient temperature range AxCent drives can operate within while keeping the baseplate
temperature below the over-temperature value. It is recommended to mount the baseplate of
the AxCent drive to a heatsink for best thermal management results. For mounting instructions
and diagrams see “Mounting” on page 34.

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 Products and System Requirements / System Requirements

FIGURE 2.11 AxCent Drives Maximum Ambient Temperature

Maximum Ambient °C Maximum Ambient °C
AB15A100 Drive Models at 80VDC AB25A100 Drive Models at 80VDC

70 70

60 60

50 50

40 40
°C °C
30 30

20 20

10 10

0 0
0 1 2 3 4 5 6 7 8 0 2 4 6 8 10 12 14 16

Continuous Output Current (Amps) Continuous Output Current (Amps)

No Heatsink W/ Heatsink (see note 1) No Heatsink W/ Heatsink (see note 1)

Maximum Ambient °C Maximum Ambient °C

AB20A200 Drive Models at 190VDC AB50A200 Drive Models at 175VDC

70 70

60 60

50 50

40 40
°C °C
30 30

20 20

10 10

0 0
0 2 4 6 8 10 12 0 5 10 15 20 25 30

Continuous Output Current (Amps) Continuous Output Current (Amps)

No Heatsink W/ Heatsink (see note 1) No Heatsink W/ Heatsink (see note 1)

Maximum Ambient °C Maximum Ambient °C

B060A400AC Drive Models at 208VAC B100A400AC Drive Models at 208VAC

90 80

80 70
70 60
60
50
50
°C °C40
40
30
30
20
20
10 10

0 0
0 5 10 15 20 25 30 35 0 10 20 30 40 50 60

Continuous Output Current (Amps) Continuous Output Current (Amps)

W/ Heatsink (see note 1) With Fans W/ Heatsink (see note 1) With Fans

1. The heatsink used in the above tests is a 15" x 22" x 0.65" aluminum plate.
2. Contact ADVANCED Motion Controls for the thermal data of drive models not included in Figure 2.11.

Shock/Vibrations While AxCent drives are designed to withstand a high degree of mechanical
shock and vibration, too much physical abuse can cause erratic behavior, or cause the drive to
cease operation entirely. Be sure the drive is securely mounted in the system to reduce the
shock and vibration the drive will be exposed to. The best way to secure the drive against
mechanical vibration is to use screws to mount the drive against its baseplate. For information

MNACHWIN-06 26
 Products and System Requirements / System Requirements

on mounting options and procedures, see “Mounting” on page 38 and the dimensional
drawings and information on the drive datasheet.

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.

MNACHWIN-06 27
 3 Integration in the Servo System

This chapter will give various details on incorporating an AxCent servo drive into a system, such as how to
properly ground the drive along with the entire system, and how to properly connect motor wires, power
supply wires, feedback wires, and inputs into the analog servo drive.

3.1 LVD Requirements

The servo drives covered in the LVD Reference report were investigated as components
intended to be installed in complete systems that meet the requirements of the Machinery
Directive. In order for these units to be acceptable in the end users’ equipment, the following
conditions of acceptability must be met.
1. European approved overload and current protection must be provided for the motors as
specified in section 7.2 and 7.3 of EN60204.1.
2. A disconnect switch shall be installed in the final system as specified in section 5.3 of
EN60204.1.
3. All drives that do not have a grounding terminal must be installed in, and conductively
connected to a grounded end use enclosure in order to comply with the accessibility
requirements of section 6, and to establish grounding continuity for the system in
accordance with section 8 of EN60204.1.
4. A disconnecting device that will prevent the unexpected start-up of a machine shall be
provided if the machine could cause injury to persons. This device shall prevent the
automatic restarting of the machine after any failure condition shuts the machine down.
5. European approved over current protective devices must be installed in line before the
servo drive, these devices shall be installed and rated in accordance with the installation
instructions (the installation instructions shall specify an over current rating value as low
as possible, but taking into consideration inrush currents, etc.). Servo drives that
incorporate their own primary fuses do not need to incorporate over protection in the
end users’ equipment.

These items should be included in your declaration of incorporation as well as the name and
address of your company, description of the equipment, a statement that the servo drives must
not be put into service until the machinery into which they are incorporated has been
declared in conformity with the provisions of the Machinery Directive, and identification of the
person signing.

MNACHWIN-06 28
 Integration in the Servo System / CE-EMC Wiring Requirements

3.2 CE-EMC Wiring Requirements

The following sections contain installation instructions necessary for meeting EMC
requirements.

Contact the factory for assistance in determining the type of drive in use.

General
1. Shielded cables must be used for all interconnect cables to the drive and the shield of the
cable must be grounded at the closest ground point with the least amount of resistance.
2. The drive’s metal enclosure must be grounded to the closest ground point with the least
amount of resistance.
3. The drive must be mounted in such a manner that the connectors and exposed printed
circuit board are not accessible to be touched by personnel when the product is in
operation. If this is unavoidable there must be clear instructions that the drive is not to be
touched during operation. This is to avoid possible malfunction due to electrostatic
discharge from personnel.

Analog Input Drives

4. A Fair Rite model 0443167251 round suppression core must be fitted to the low level
signal interconnect cables to prevent pickup from external RF fields.

PWM Input Drives

5. A Fair Rite model 0443167251 round suppression core must be fitted to the PWM input
cable to reduce electromagnetic emissions.

MOSFET Switching Drives

6. A Fair Rite model 0443167251 round suppression core must be fitted at the load cable
connector to reduce electromagnetic emissions.
7. An appropriately rated Cosel TAC series AC power filter in combination with a Fair Rite
model 5977002701 torroid (placed on the supply end of the filter) must be fitted to the
AC supply to any MOSFET drive system in order to reduce conducted emissions fed back
into the supply network.

IGBT Switching Drives

8. An appropriately rated Cosel TAC series AC power filter in combination with a Fair Rite
model 0443167251 round suppression core (placed on the supply end of the filter) must
be fitted to the AC supply to any IGBT drive system in order to reduce conducted
emissions fed back into the supply network.
9. A Fair Rite model 0443164151 round suppression core and model 5977003801 torroid
must be fitted at the load cable connector to reduce electromagnetic emissions.

Fitting of AC Power Filters

It is possible for noise generated by the machine to "leak" onto the main AC power, and then
get distributed to nearby equipment. If this equipment is sensitive, it may be adversely

MNACHWIN-06 29
 Integration in the Servo System / CE-EMC Wiring Requirements

affected by the noise. AC power filters can filter this noise and keep it from getting on the AC
power signal. The above mentioned AC power filters should be mounted flat against the
enclosure of the product using the two mounting lugs provided on the filter. Paint should be
removed from the enclosure where the filter is fitted to ensure good metal to metal contact.
The filter should be mounted as close to the point where the AC power filter enters the
enclosure as possible. Also, the AC power cable on the load end of the filter should be routed as
far from the AC power cable on the supply end of the filter and all other cables and circuitry to
minimize RF coupling.

3.2.1 Ferrite Suppression Core Set-up

If PWM switching noise couples onto the feedback signals or onto the signal ground, then a
ferrite suppression core can be used to attenuate the noise. Take the motor leads and wrap
them around the suppression core as many times as reasonable possible, usually 2-5 times.
Make sure to strip back the cable shield and only wrap the motor wires. There will be two
wires for single phased (brushed) motors and 3 wires for three phase (brushless) motors.
Wrap the motor wires together as a group around the suppression core and leave the motor
case ground wire out of the loop. The suppression core should be located as near to the drive
as possible. TDK ZCAT series snap-on filters are recommended for reducing radiated
emissions on all I/O cables.

3.2.2 Inductive Filter Cards

Inductive filter cards are added in series with the motor and are used to increase the load
inductance in order to meet the minimum load inductance requirement of the drive. They also
serve to counteract the effects of line capacitance found in long cable runs and in high voltage
systems. These filter cards also have the added benefit of reducing the amount of PWM noise
that couples onto the signal lines.

Visit www.a-m-c.com/products/filter_cards.html for information on purchasing ADVANCED

Motion Controls inductive filter cards.

MNACHWIN-06 30
 Integration in the Servo System / Grounding

3.3 Grounding
In most servo systems all the case grounds should be connected to a single Protective Earth
(PE) ground point in a "star" configuration. Grounding the case grounds at a central PE ground
point reduces the chance for ground loops and helps to minimize high frequency voltage
differentials between components. All ground wires must be of a heavy gauge and be as short
as possible. The following should be securely grounded at the central PE grounding point:
• Motor chassis
• Controller chassis
• Power supply chassis
• AxCent Servo Drive chassis

FIGURE 3.1 System Grounding

Case Ground Wire

Shield Ground Wire
Shielded Feedback/Signal Cable
Command Command Shielded Power Cable
Signal Signal +VDC
+VDC PE Ground
Controller
Signal Ground

Power Ground
AxCent Servo Drive
Chassis Earth Ground

Isolated DC
Power Supply

Motor

Single Point System

Ground (PE Ground)

Ground cable shield wires at the drive side to a chassis earth ground point.

The DC power ground and the input reference command signal ground are oftentimes at a
different potential than chassis/PE ground. The signal ground of the controller must be
connected to the signal ground of the drive to avoid picking up noise due to the "floating"
differential servo drive input. In systems using an isolated DC power supply, signal ground
and/or power ground can be referenced to chassis ground. First decide if this is both
appropriate and safe. If this is the case, they can be grounded at the central grounding point.
For systems using AC power referenced to chassis ground, the drive must have internal optical
isolation to avoid a short through the the drive’s diode bridge.

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
Servo system wiring typically involves wiring a controller (digital or analog), a servo drive, a
power supply, and a motor. Wiring these servo system components is fairly easy when a few
simple rules are observed. As with any high efficiency PWM servo drive, the possibility of noise
and interference coupling through the cabling and wires can be harmful to overall system
performance. Noise in the form of interfering signals can be coupled:
• Capacitively (electrostatic coupling) onto signal wires in the circuit (the effect is more
serious for high impedance points).
• Magnetically to closed loops in the signal circuit (independent of impedance levels).
• Electromagnetically to signal wires acting as small antennas for electromagnetic radiation.
• From one part of the circuit to other parts through voltage drops on ground lines.

The main source of noise is the high DV/DT (typically about 1V/nanosecond) of the drive’s
output power stage. This PWM output can couple back to the signal lines through the output
and input wires. The best methods to reduce this effect are to move signal and motor leads
apart, use an inductive filter card, add shielding, and use differential inputs at the drive.

Unfortunately, low-frequency magnetic fields are not significantly reduced by metal enclosures.
Typical sources are 50 or 60 Hz power transformers and low frequency current changes in the
motor leads. Avoid large loop areas in signal, power-supply, and motor wires. Twisted pairs of
wires are quite effective in reducing magnetic pick-up because the enclosed area is small, and
the signals induced in successive twist cancel.

ADVANCED Motion Controls recommends using the following hand crimp tools for the
appropriate I/O and Feedback cable and wire preparation. Consult the drive datasheet to see
which connectors are used on a specific drive.
Drive Connector Hand Crimp Tool Manufacturer and Part Number
16-pin, 2.54 mm spaced friction lock header Molex: P/N 0638118200
Standard Density D-sub headers Tyco: P/N 58448-2
High Density D-sub headers Tyco: P/N 90800-1

3.4.1 Wire Gauge

As the wire diameter decreases, the impedance increases. Higher impedance wire will
broadcast more noise than lower impedance wire. Therefore, when selecting the wire gauge
for the motor power wires, power supply wires, and ground wires, it is better to err on the
side of being too thick rather than too thin. This becomes more critical as the cable length
increases. The following table provides recommendations for selecting the appropriate wire
size for a specific current. These values should be used as reference only. Consult any
applicable national or local electrical codes for specific guidelines.
TABLE 3.1 Current and Wire Gauges
Current (A) Minimum Wire Size (AWG) mm2 Current (A) Minimum Wire Size (AWG) mm2
10 #20 0.518 60 #10 5.26
15 #18 0.823 80 #8 8.37
20 #16 1.31 120 #6 13.3
35 #14 2.08 150 #0 53.5
45 #12 3.31 200 #00 67.4

MNACHWIN-06 32
 Integration in the Servo System / Wiring

3.4.2 Motor Wires

The motor power wires supply power from the drive to the motor. Use of a twisted, shielded
pair for the motor power cables is recommended to reduce the amount of noise coupling to
sensitive components.
• For a brushed motor or voice coil, twist the two motor wires together as a group.
• For a brushless motor, twist all three motor wires together as a group.

Ground the motor power cable shield at one end only to the servo drive chassis ground. The
motor power leads should be bundled and shielded in their own cable and kept separate from
feedback signal wires.

DO NOT use wire shield to carry motor current or power!

The diagrams below show how an AxCent servo drive connects to a Brushless (three-phase)
and Brushed (single-phase) motor. Notice that the motor wires are shielded, and that the
motor housing is grounded to the single point system ground (PE Ground). The cable shield
should be grounded at the drive side to chassis ground.

FIGURE 3.2 Motor Power Output Wiring

BRUSHLESS AXCENT BRUSHED AXCENT
MOTOR SERVO DRIVE MOTOR SERVO DRIVE

Motor C
MOT +
Shield Shield
Motor Motor B
Motor
Motor A MOT -
Single Point Chassis Ground
System Ground Chassis Ground Single Point
(PE Ground) System Ground
(PE Ground)

If using relays or other means to disconnect the motor leads, be

sure the drive is disabled before reconnecting the motor leads to
the drive. Connecting the motor leads to the drive while it is
enabled can generate extremely high voltage spikes which will
damage the drive.

3.4.3 Power Supply Wires

The PWM current spikes generated by the power output-stage are supplied by the internal
power supply capacitors. In order to keep the current ripple on these capacitors to an
acceptable level it is necessary to use heavy power supply leads and keep them as short as
possible. Reduce the inductance of the power leads by twisting them. Ground the power supply
cable shield at one end only to the servo drive chassis ground.

When multiple drives are installed in a single application, precaution regarding ground loops
must be taken. Whenever there are two or more possible current paths to a ground
connection, damage can occur or noise can be introduced in the system. The following rules
apply to all multiple axis installations, regardless of the number of power supplies used (see
Figure 3.3):

MNACHWIN-06 33
 Integration in the Servo System / Wiring

1. Run separate power supply leads to each drive directly from the power supply filter
capacitor.
2. Never "daisy-chain" any power or DC common connections. Use a "star"-connection
instead.

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.

AxCent AxCent AxCent AxCent AxCent AxCent

Servo Servo Servo Servo Servo Servo
Drive Drive Drive Drive Drive Drive

DC DC
Power Power
Supply Supply
Power Supply Power Supply
Capacitance Capacitance

AxCent AxCent AxCent

Servo Servo Servo
Drive Drive Drive

DC
Power
Supply

Power Supply
Capacitance

For AC input amplifiers, AC power

Wire pairs should be routed
should be distributed from a
together and twisted all the
central AC source, not a capacitor
way back to the power source

DC Power Supplies For drives using a DC power supply, connect the isolated DC supply high
voltage to the DC Power Input terminal, and the DC supply ground to the power ground
terminal.

FIGURE 3.4 DC Power Supply Wiring

Appropriately rated over current protective

devices (fuses or other) must be installed AXCENT
before or after the power supply! SERVO DRIVE

Isolated DC Shield DC Power Input

+HV
Power
Supply GND Power Ground

Chassis Ground
Single Point
System Ground
(PE Ground)

An external electrolytic capacitor connected between high voltage and power ground as close
to the drive as possible is recommended on some drive models. Consult the datasheet for the
drive in use to determine the recommended capacitance value, if necessary.

MNACHWIN-06 34
 Integration in the Servo System / Wiring

Three Phase AC Power Supplies Drives that accept three-phase AC line power have either
a 5-contact AC input screw terminal or a 4-port AC input connector. Connect a three phase AC
supply to AC1, AC2, and AC3, or L1, L2, and L3, depending on the drive model. On certain
models, a single phase AC supply can be connected to any two of the three AC terminals.
Typically using a single phase AC supply in these cases will result in a 30% derating of current
output. Consult the drive datasheet to determine if a specific drive model also accepts single
phase AC with current derating.

FIGURE 3.5 Single or Three Phase AC Line Connections

AXCENT
SERVO DRIVE

**
AC1 or L1 FUSE
Shield
3-Phase AC
AC2 or L2 FUSE
Power
Supply*
AC3 or L3 FUSE

Single Point
Chassis Ground
System Ground
(PE Ground)

*For Single-phase AC Supply, connect AC

lines to any two of AC1, AC2, and AC3. Do **Certain drive models include internal AC line
not connect AC line neutral to ground! fuses. On models that do not include internal AC line
Using a single-phase AC supply typically fuses, external fuses are recommended. Consult the
results in a 30% derating of current output. drive datasheet for recommended values.

Single Phase AC Power Supplies Drive models that accept only single-phase AC line
power (i.e. AB30A200AC) include a standard 3-prong pluggable AC connector for attachment
to an AC supply on the underside of the drive.

3.4.4 Feedback Wires

Use of a twisted, shielded pair for the feedback wires is recommended. Ground the shield at one
end only to the servo drive chassis ground. Route cables and/or wires to minimize their length
and exposure to noise sources. The motor power wires are a major source of noise, and the
motor feedback wires are susceptible to receiving noise. This is why it is never a good idea to
route the motor power wires with the motor feedback wires, even if they are shielded.
Although both of these cables originate at the drive and terminate at the motor, try to find
separate paths that maintain distance between the two. A rule of thumb for the minimum
distance between these wires is 10cm for every 10m of cable length.

FIGURE 3.6 Feedback Wiring

Avoid running
Motor Feedback feedback and power
wires together
Motor Feedback

AxCent AxCent Separate power and

Servo Motor Servo feedback wires Motor
Drive Drive where possible

Motor Power
Motor Power

Hall Sensors AxCent drives accept single-ended Hall Sensor feedback for commutation. Most
drives also include a +6V, 30 mA low voltage supply output that can be used to power the Hall
Sensors. Verify on the motor datasheet that the voltage and current rating of the supply output
will work with the Hall Sensors before connecting.

MNACHWIN-06 35
 Integration in the Servo System / Wiring

FIGURE 3.7 Hall Sensor Input Connections

AXCENT
SERVO DRIVE

+V HALL (Power for Hall Sensors)

Shield HALL A +

Motor HALL B +

HALL C +

Signal Ground

Chassis Ground

Incremental Encoder AxCent drives support either single-ended incremental encoder

feedback for velocity control. The drive must be in Encoder Velocity mode for proper operation
with the encoder. See the drive datasheet for specific DIP switch settings. Both the "A" and "B"
channels of the encoder are required for operation. If using the +5V, 150mA (or 250mA) low
voltage power supply output from the drive, verify that the supply output voltage and current
rating is sufficient for the encoder specifications.

FIGURE 3.8 Incremental Encoder Connections

AXCENT SERVO
DRIVE

+5V Encoder Supply Output

Signal Ground
Incremental
Encoder Enc A MOTOR ENC A
Shield

Motor
MOTOR ENC B
Enc B
Chassis
Ground

Tachometer For drives that accept a Tachometer for velocity control, connect the negative
tachometer input to the tachometer input on the drive, and connect the positive tachometer
input to signal ground. The drive must be in Tachometer Velocity mode in order to properly
use the tachometer input. See the drive datasheet for specific DIP switch settings. The
tachometer has a range of ±60 VDC. Certain drive models allow scaling of the allowable
tachometer voltage range. Consult the drive datasheet for tachometer scaling instructions.

FIGURE 3.9 Tachometer Input Connections

AXCENT SERVO
DRIVE
Tachometer
(± 60 VDC) Tach- TACHOMETER INPUT

Motor

SIGNAL GROUND
Tach+
Chassis
Ground

MNACHWIN-06 36
 Integration in the Servo System / Wiring

3.4.5 Input Reference Wires

Use of a twisted, shielded pair for the input reference wires is recommended. Connect the
reference source "+" to "+REF IN", and the reference source "-" (or common) to "-REF IN".
Connect the shield to the servo drive chassis ground. The servo drive’s reference input circuit
will attenuate the common mode voltage between signal source and drive power grounds.
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.

Long signal wires (10-15 feet and up) can also be a source of noise when driven from a typical
op-amp output. Due to the inductance and capacitance of the wire the op-amp can oscillate. It
is always recommended to set a fixed voltage at the controller and then check the signal at the
drive with an oscilloscope to make sure that the signal is noise free.

±10V Analog Input When using a ±10V analog signal for an input command, it is important to
consider the output impedance of the analog source when interfacing to input circuitry. A
poorly designed ±10V analog input interface can lead to undesired command signal
attenuation. Figure 3.10 shows an external analog source connected to an analog input. The
ideal voltage delivered to the input is VS. However, the voltage drop across Rsource will reduce
the signal being delivered to the drive input. This voltage drop is dependent on the value of
Rsource and the drive’s input impedance.

FIGURE 3.10 Analog Source and Drive Input

+/- 10V ANALOG AXCENT +/- 10V ANALOG AXCENT
SOURCE SERVO DRIVE SOURCE SERVO DRIVE

Rsource Rsource
+REF +REF
-
Vs + Vs + Rin
- -REF + - -REF

Internal Offset Equivalent Input

Reference Voltage Impedance

The drive’s analog input can be simplified to a single impedance, Rin, as shown in Figure 3.10.
If the impedance of Rsource is of the same magnitude or larger than Rin, there will be a
significant voltage drop across Rsource. Reduced values of Rsource cause a lower voltage drop
that increases signal integrity. In order to avoid a voltage drop of more than 5% between the
source and the drive, it is recommended to use an Rsource value of less than or equal to 2kohm.
If there is a large output impedance from the analog source, it is recommended to use a buffer
circuit between the analog source output and the drive input. A unity gain op-amp circuit as
shown in Figure 3.11 will ensure low output impedance with minimal voltage drop.

FIGURE 3.11 Optimized Low Impedance Interface

+/- 10V ANALOG AXCENT
SOURCE SERVO DRIVE

- +REF
Rsource -
+
Vs + -REF +
-

Internal Offset
Reference Voltage

MNACHWIN-06 37
 Integration in the Servo System / Mounting

PWM and Direction Inputs The PWM and Direction inputs should be connected to the PWM
and DIR input pins on the drive.

FIGURE 3.12 PWM and Direction Input Wiring

AXCENT
SERVO DRIVE

Controller PWM
PWM

DIR
DIR
GND

SIGNAL GROUND

Potentiometer Input AxCent servo drives that accept ±10V analog input can be commanded
with the use of an external potentiometer and a DC supply by varying the DC supply voltage
across the potentiometer.

FIGURE 3.13 Potentiometer Input

AXCENT
Bi-directional Control SERVO DRIVE

+/- VDC +10V Max

+10V
Power
Supply Potentiometer +REF IN
(~50k)
-REF IN
-10V
GND -10V Max

SIGNAL GROUND

Uni-directional Control
AXCENT
SERVO DRIVE
+VDC +10V Max
+10V
Power
supply Potentiometer +REF IN
(~50k)
-REF IN
GND

SIGNAL GROUND

3.5 Mounting
ADVANCED Motion Controls’ AxCent servo drives provide mounting hole locations on the
baseplate allowing the drive to be mounted either vertically or horizontally. Drives can be
mounted to a heatsink or other plane surface, or attached to a lab rail either on a test bench or
as part of a larger system. Consult the drive datasheet for specific mounting dimensions and
mounting hole locations.

MNACHWIN-06 38
 4 Operation

This chapter will describe the operation and setup of an ADVANCED Motion Controls’ AxCent servo drive.

4.1 Initial Setup and Features

To begin operation with your AxCent servo drive, be sure to read and understand the previous
chapters in this manual as well as the drive datasheet. Be sure that all system specifications
and requirements have been met, and become familiar with the capabilities and functions of
the drive. Also, be aware of the “Troubleshooting” section at the end of this manual for
solutions to basic operation issues.
Do not install the servo drive into the system without first determining that all chassis power
has been removed for at least 10 seconds. Never remove a drive from an installation with
power applied. Carefully follow the grounding and wiring instructions in the previous
chapters to make sure your system is safely and properly set up.

4.1.1 Pin Function Details

The family of AxCent drives provide a number of various input and output pins for parameter
observation and drive configuration options. Not all drives will have each of the following pin
functions. Consult the drive datasheet to see which input/output pin functions are available for
each drive.

Current Monitor Output Measured relative to signal ground, power ground, or a separate
current monitor ground, depending on the drive model. Consult the drive datasheet to
determine the correct ground connection. The current monitor provides an analog voltage
output signal that is proportional to the actual drive current output. The scaling factor for each
individual drive can be found on the drive datasheet. The drive must be connected to a load in
order for the drive to output actual current. Note that the polarity of the current monitor
measurement will be reversed from the current command.

Example Measurement

The current monitor pin on a drive with a current monitor scaling factor of 4 A/V is measured
to be -1.3V. With the polarity reversed on the current monitor pin, this would mean the drive is
outputting: (4 A/V)(1.3V) = 5.2A.

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Current Reference Output Measured relative to signal ground, the current reference
provides an analog voltage output signal that is proportional to the command signal to the
internal current loop. The drive does not need to be connected to a load to read the current
reference output. The internal command current may differ from the actual drive output
current due to certain conditions such as a small load, drive faults, undersized power supplies,
inhibited drive, etc. The command to the internal current loop can be solved for by the
following equation:
I peak
I command = V current ref  -------------
V max

Where:
Icommand -command current to the internal current loop
Vcurrent ref -measured voltage at current reference pin
Ipeak -peak current value of the drive
Vmax -voltage corresponding to maximum internal current command, value
found on drive datasheet; on most drive models Vmax = 7.45V

Example Measurement
The current reference pin on a drive with a peak current value of 12A and Vmax of 7.45V is
measured to be 2.63V. Following the above equation to solve for Icommand, the command
current to the internal current loop would be 4.24A.

Inhibit / Enable Input This pin provides a +5V TTL input that allows a user to enable/disable
the drive by either connecting this pin to ground or by applying a +5VDC voltage level to this
pin, referenced to signal ground. By default, the drive will be enabled if this pin is high, and
disabled if this pin is low. This logic can be reversed, however, either through DIP switch
setting or by removing a SMT jumper from the PCB (consult the drive datasheet to see which
option is available; note that removal of the SMT jumper must be done by a person familiar
with SMT soldering, and that the drive warranty will be voided if the drive is damaged). This
will require all inhibit lines to be brought to ground to enable the drive. Some drives can also
be ordered with inverted inhibit logic as well (-INV option). Some drive models allow the drive
to be configured so the inhibit input does not trigger a drive fault state. Typically this is
achieved by DIP switch setting. Consult the drive datasheet to see if this option is available.

Directional Inhibits

Some drives also include directional inhibit pins that disable motor motion in either the
positive or negative direction, typically used for limit switches. These pins do not cause a drive
fault condition. They will follow the same logic (either standard or inverted) as the main
inhibit/enable input.

Fault Output This pin provides a +5V TTL output measured relative to signal ground that will
indicate when the drive is subject to one of the following fault conditions: inhibit, invalid Hall
State, output short circuit, over voltage, under voltage, over temperature, or power-up reset.
On most drive models this pin will read +5V (High) when the drive is in a fault state, but some
drives allow the logic to be reversed, so that a 0V (Low) fault output indicates a fault.

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AxCent drives automatically self-reset once all active fault conditions have been removed. For
instance if the DC power supply rises above the over-voltage shutdown level of the drive, the
Fault Output will indicate a fault, and the drive will be disabled. Once the DC power supply
level is returned to a value below the drive over-voltage shutdown level, the Fault Output will
return to the normal state, and the drive will automatically become enabled.

Low Voltage Power Supply Outputs Most drives include low voltage power supply
outputs meant for customer use. Consult the drive datasheet to see which low voltage outputs
are included on a specific drive.
• ±10V (or ±5V), 3mA Output - Typically used as an on-board ±10V analog input signal for
testing purposes. This output can be used in conjunction with an external potentiometer
to vary the input signal between ±10V.
• +6V, 30mA Output - Available on three phase (brushless) drive only. This pin provides a
+6 VDC output that can be used to power Hall Sensors. Consult the motor datasheet to find
out which feedback wire from the motor is the Hall Sensor power supply wire.

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, 150 mA (or 250mA) Output - Can be used as power for an encoder. Consult the
motor or encoder datasheet to determine the appropriate encoder voltage and current
requirements before connecting this supply.

Velocity Monitor Output This pin provides an analog voltage output that is proportional to
the actual motor speed. The scaling factor for each individual drive can be found on the drive
datasheet.
• For a drive in Encoder Velocity Mode, substitute the voltage value read at the velocity
monitor pin, Vmonitor, into the below equation to determine the motor RPM:

V monitor  Scaling Factor  60

Motor Velocity [RPM] = ---------------------------------------------------------------------
-
Number of encoder lines
• For a drive in Hall Velocity Mode, substitute the voltage value read at the velocity monitor
pin, Vmonitor, into the below equation to determine the motor RPM:
V monitor  Scaling Factor  120
Motor Velocity [RPM] = ------------------------------------------------------------------------
-
Number of motor poles

4.1.2 Potentiometer Function Details

All potentiometers vary in resistance from 0 to 50 kohm, over 12 turns. An additional full turn
that does not effect resistance is provided on either end, for a total of 14 turns. It is
recommended to turn the potentiometer 14 counter-clockwise turns before adjusting the
potentiometer to a specific setting. Consult the drive datasheet to see which potentiometers
are included on a specific drive.

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TABLE 4.1 Potentiometer Function Details

Potentiometer Description
Loop Gain Adjustment 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.
Current Limit 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:
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 44 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 counter-
clockwise, 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.
Test/Offset 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.
Ramp Time This potentiometer sets the ramp time for the command input signal. The ramp time can be set for
up to 30 seconds in reaching the max command by adjusting the potentiometer fully clockwise.
Ramping rates are linear with respect to time and apply to both directions of motion.

Test Points for Potentiometers After the potentiometer adjustments have been completed,
the resistance values can be measured for future adjustments or duplication on other servo
drives of the same part number. Test points for potentiometer wipers are provided and are
located at the foot of all four potentiometers. Resistance measurements are only to be used to
duplicate drive settings, since some potentiometers have other resistors in series or parallel.
Measure the resistance between the test point and the outer leg of the potentiometer or
between the test point and an appropriate ground. See the block diagram on the drive
datasheet to determine which ground should be used for each potentiometer.
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.

Potentiometer Tool ADVANCED Motion Controls offers a tool for adjusting the potentimeters,
part number PT01. This tool features an exposed stainless steel blade on one end and a
recessed stainless steel blade on the other end. Contact customer service for ordering
information.

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4.1.3 Switch Function Details

Together with the described functions below certain switches may also be used in selecting the
mode of operation, while some may be used strictly for mode selection. Switch implementation
and functionality within the drive circuitry is included on the block diagram of the drive
datasheet. Consult the drive datasheet to see which switches are included on a specific drive.
TABLE 4.2 Switch Function Details
Switch Description
Current Scaling Changes the sensitivity of the current sense, thereby reducing the peak and continuous current
limits by a given amount.
Current Loop Proportional Gain Adjusts the proportional gain of the current loop.
Adjustment
Current Limit Ratio 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).
Current Loop Integral Gain Activates or deactivates the current loop integral gain. This switch is OFF by default.
Outer Loop Integration Activation Activates or deactivates the outer loop integration. For Current Mode, outer loop integration should
be deactivated, but should be activated for other modes.
Outer Loop Integral Gain Adjustment Increases or decreases the integral gain of the outer loop.
Duty Cycle Feedback Enables/disables the duty cycle feedback. Duty cycle feedback is only enabled when the drive is
configured for Duty Cycle Mode.
Hall Sensor Commutation Phasing Tells the drive the type of Hall sensor phasing the motor has. Switches between 120 and 60
degree phasing.
Test/Offset 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.
Velocity Feedback Polarity 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 59 for more information.
IR Compensation Activates or deactivates IR feedback. IR feedback should be activated for IR Compensation Mode,
and deactivated for other modes.
Inhibit Logic Sets the logic of the inhibit pins to Active High or Active Low.

4.1.4 Tachometer Input Gain Scaling

Standard drive tachometer inputs are typically pre-configured such that the standard 60k input
resistance scales the maximum tach input voltage to 60V. The 60k tachometer input resistance
is actually populated with a 50k resistor in series with a 10k resistor. Most drives with a
tachometer feedback input will have an SMT resistor location in parallel with the 50k resistor
or tachometer scaling DIP Switch options. Contact the factory for instructions and assistance
for SMT resistor additions.

FIGURE 4.1 Tachometer Input Resistance

AXCENT
SERVO DRIVE Optional SMT
Tach Gain
Resistor(s) or
DIP Switch
Selectable
Resistors

Tachometer Input

50k 10k

This allows users to reduce the effective input resistance to a value that more closely matches
their maximum application feedback voltage in order to increase the tachometer input gain.
An appropriate tachometer input resistance value should be at least 1000 times the maximum
tachometer voltage feedback value. From zero to infinite resistance (open connection), this

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 Operation / Initial Setup and Features

through-hole or SMT location can scale the tachometer’s maximum input voltage range from
10V to 60V.

To determine the maximum feedback voltage for the application:

1. Determine the absolute maximum speed required of the motor for the application (Sm, in
kRPM).
2. Look up the tachometer’s voltage to speed constant (Kv, in V/kRPM).
3. Calculate for the tachometer’s maximum voltage output in the application:
V max = K v  S m

Example
An application’s maximum motor speed is 4.7 kRPM, and the tachometer is rated for 7
V/kRPM. Using the above equation, the maximum voltage from the tachometer input, Vmax,
will be 33V. Therefore, the equivalent tachometer input resistance must be at least 33k.
Choosing an equivalent resistance value of 35k, solve for the required resistance of the SMT
resistor.
 50  V max  – 500  50  35  – 500- = 50k
Tach Gain Additional Resistor (in kohm) = ----------------------------------------- = -----------------------------------
60 – V max 60 – 35

As solved for above, the equivalent 35k resistance can be acheived by adding a 50k SMT
resistor in parallel with the existing 50k resistor on the drive tachometer input.

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.

4.1.5 Current Limiting Procedure

Before operating a drive, the current output of the drive must be limited based on motor and
system current limitations. Depending on the drive model, ADVANCED Motion Controls’ AxCent
servo drives feature a number of different current limiting methods. However, the procedure
for setting the current limit will essentially be the same for each drive. Consult the drive
datasheet to see what current limiting options are available on a specific drive.

The current limiting steps should be taken with no power applied to the drive.
1. The following option may be used to reduce the current limits:
— If available, position any current scaling or current limit ratio DIP switches to the
desired position (see “Potentiometer Function Details” on page 41).
2. If further current limiting is necessary, use the Current Limit potentiometer to "fine tune"
the current limit to a final value (see “Potentiometer Function Details” on page 41).

Example

A drive is going to be used with an application having a continuous current requirement of 1.5
amps and a continuous current limit of 2.5 amps, and a peak current requirement of 6 amps,

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and a peak current limit of 10 amps. The drive has a Current Scaling and Current Limit Ratio
switch, a Current Limit potentiometer.
1. Typically it is recommended to set the current limits of the drive below the continuous
and peak current limits of the motor or application, allowing some headroom for safety. In
this case, the drive continuous current limit will be chosen at 2 amps, and the peak
current limit at 9 amps.
2. Setting the Current Scaling switch to OFF will scale the peak and continuous current limits
by half, yielding a peak limit of 15 amps, and a continuous limit of 7.5 amps.
3. Setting the Current Limit Ratio switch to OFF will change the continuous-to-peak current
ratio to 25%, yielding a peak limit of 15 amps, and a continuous limit of 3.75 amps.
4. To further reduce the current limits to the desired values, the Current Limit potentiometer
can be used. Begin with the continuous current requirement, using the equation to
determine the number of clockwise turns for the Current Limit potentiometer:
2amps
# of turns = ------------------------ 12 + 1
3.75amps

Solving for the number of turns yields approximately 7.5 turns in the clockwise direction
from the fully counter-clockwise position.
5. Since the continuous-to-peak ratio was set at 25% in Step 3, the number of turns
calculated above will yield a peak current limit of approximately 8 amps, thereby
satisfying both the continuous and peak current requirements of the application.

4.1.6 Drive Set-up Instructions

Single Phase (Brush Type)

1. It is recommended to reduce the drive output current to avoid motor over heating during
the setup procedure. Make sure the current has been set appropriately within the system
and motor limits based on the procedure outlined in “Current Limiting Procedure” on
page 44.
2. Check the power and connect it to the drive. Do not connect the motor lead wires.
3. Make sure the drive is in an enabled state via all inhibit/enable inputs. See drive datasheet
for details.
4. Check that the status LED indicates normal operation (GREEN).
5. Set mode according to the drive datasheet for Voltage Mode.
6. Set the Test/Offset switch to Test mode. Measure the voltage across the motor output with
a DC voltmeter. Slowly turn the Test/Offset potentiometer; the voltage should vary
between ± bus voltage. Set the output voltage with the Test/Offset potentiometer to a low
value.
7. Verify that the load circuit meets the minimum inductance requirements and that the
power supply voltage does not exceed the drive rated voltage or 150% of the nominal
motor voltage.
8. Turn the power off. Connect the motor. Turn the power back on. Gradually turn the
Test/Offset potentiometer to change motor speed in both directions. Set the Test/Offset
switch to Offset.
9. Ground both reference inputs and then using the Test/Offset potentiometer, set the motor
for zero speed.

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 Operation / Initial Setup and Features

10. Set the control mode suitable for the application.

Three Phase (Brushless)

1. It is recommended to reduce the drive output current to avoid motor over heating during
the setup procedure. Make sure the current has been set appropriately based on the
procedure outlined in “Current Limiting Procedure” on page 44.
2. According to the the mode selection table on the drive datasheet, set the drive for Duty
Cycle (Open Loop) Mode, and set the Test/Offset switch to Test.
3. Check the power and connect it to the drive. Do not connect the motor lead wires.
4. Make sure the drive is in an enabled state via all enable inputs. See drive datasheet for
details.
5. Set the Hall Sensor Commutation Switch for the appropriate phasing (typically 120
degree). Connect the Hall sensor inputs. The drive status LED should be GREEN. Manually
turn the motor shaft one revolution. The LED should remain green. If the LED turns red or
changes between green and red:
— check the Hall Sensor Commutation Switch
— check power for the Hall Sensors
— check the voltage level of the Hall inputs (see Table 4.3)
— for 60 degree phasing interchange Hall 1 and Hall 2
(for more information see “Invalid Hall Sensor State (Brushless Drives only)” on page 57)
TABLE 4.3 Commutation Sequence Table
60 Degree 120 Degree Motor
Hall 1 Hall 2 Hall 3 Hall 1 Hall 2 Hall 3 Phase A Phase B Phase C
1 0 0 1 0 0 HIGH - LOW
1 1 0 1 1 0 - HIGH LOW
1 1 1 0 1 0 LOW HIGH -
Valid
0 1 1 0 1 1 LOW - HIGH
0 0 1 0 0 1 - LOW HIGH
0 0 0 1 0 1 HIGH LOW -
1 0 1 1 1 1 - - -
Invalid
0 1 0 0 0 0 - - -

6. Remove power. In all, there are six different ways to connect the three motor wires to the
Motor A, Motor B, and Motor C pins. All six combinations must be tested to find the
proper combination. The correct combination should yield approximately identical motor
speed in both directions. If the motor runs slower in one direction, or if the motor shaft
has to be moved manually by hand to start the motor, the combination is incorrect. Motor
speed can be verified by using the velocity monitor or by measuring the frequency of the
Hall Sensors.
7. To begin, connect the three motor wires in any order.
8. Apply power to the drive, and slowly turn the Test/Offset potentiometer in both
directions. Observe the motor speed for both directions. Remove power from the drive,
and rewire the three motor wires for a different combination. Test all six different
combinations before proceeding.
9. Once the proper combination has been found, set the Test/Offset switch to Offset, ground
both reference inputs, and then adjust the Test/Offset potentiometer for zero speed.
10. Set the control mode suitable for the application. If necessary, to change the motor
direction for a given command input, interchange Hall 1 and Hall 3, then Motor A and
Motor B.

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Three Phase (Brushless) Drive with Brushed Motor Three Phase (Brushless) drives
are also compatible with Single Phase (Brushed) motors. However, because there are no Hall
Sensors on a brushed motor, one of the following course of actions must be taken to properly
commutate the drive:
• Set the Hall Sensor Commutation Phasing DIP switch for 60-degree phasing. Leave all the
Hall Sensor inputs on the drive open. These inputs are internally pulled high to +5V,
creating a "1-1-1" commutation state (see Table 4.3 above) which is a valid state in 60-
degree phasing. Only use Motor A and Motor B output in this configuration.

or:
• Tie one of the Hall Sensor inputs on the drive to signal ground. Since the Hall Sensor
inputs are by default internally brought high to +5V, this will put the drive in a
commutation state where two Hall inputs are high, and one is low (as shown in Table 4.3,
having all three Hall inputs pulled high is an invalid commutation state in 120-degree
phasing). Depending on which Hall Sensor input is tied to ground, consult Table 4.3 to
determine which two motor output wires will be conducting current for that specific
commutation state.

4.1.7 Current Loop Tuning Procedure

The standard tuning values used in ADVANCED Motion Controls AxCent servo drives are
conservative and work well in over 90% of applications. However some applications and some
motors require more complete current loop tuning to achieve the desired performance. The
following are indications that additional current loop tuning is necessary:
• Motor rapidly overheats even at low current
• Drive rapidly overheats even at low current
• Vibration sound comes from the drive or motor
• The motor has a high inductance (+10mH)
• The motor has a low inductance (near minimum rating of the drive)
• Slow system response times
• Excessive torque ripple
• Difficulty tuning position or velocity loops
• Electrical noise problems
• High power supply voltage (power supply is significantly higher than the motor voltage
rating or near the drive’s upper voltage limit)
• Low power supply voltage (power supply voltage is near the drive’s lower voltage limit)

The above indicators are subjective and suggest that the current loop may need to be tuned.
These can also be signs of other problems not related to current loop tuning.

The resistors and capacitors shown under the current control block on the datasheet block
diagram determine the frequency response of the current loop. It is important to tune the
current loop appropriately for the motor inductance and resistance, as well as the bus voltage

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 Operation / Initial Setup and Features

to obtain optimum performance. The loop gain and integrator capacitance of the current loop
must both be adjusted for the tuning to be complete.

Improper current loop tuning may result in permanent drive and/or

motor damage regardless of drive current limits.

Since most ADVANCED Motion Controls servo drives close the current loop internally, poor
current loop tuning cannot be corrected with tuning from an external controller. Only after the
current loop tuning is complete can optimal performance be achieved with the velocity and
position loops.

The general current loop tuning procedure follows these steps:

1. Determine if additional current loop tuning is necessary.
2. If available, tune the drive using the current loop DIP switches.
3. If the current loop cannot be satisfactorily tuned with the DIP switches, then the current
loop components must be changed.
- Tune the current loop proportional gain.
- Tune the current loop integral gain.
4. Once the current loop is tuned, then the velocity and/or position loops may be tuned as
well if necessary.

Current Loop Proportional Gain Adjustment The Current Loop Gain should be
adjusted with the motor uncoupled from the load, and the motor secured as sudden motor
shaft movement may occur. The following points should be kept in mind before beginning the
tuning procedure:
— Brushless drives should be configured for 60 degree phasing in order to get output
current. The current can be measured through either motor phase A or B.
1. Use the DIP switches and Current Limit Potentiometer to select Current Mode, the input
range (if applicable) and to set the appropriate current limit for the motor.
2. Connect only the motor power leads to the drive. No other connections should be made at
this point.
3. Using a function generator, apply a ±0.5 V, 50-100 Hz square wave reference signal to the
input reference pins.
4. Short out the current loop integrator capacitor(s) using the appropriate DIP switches or
jumpers (see the specific drive datasheet and block diagram for details).
5. Apply power to the drive. Use a bus voltage that is approximate to the desired application
voltage or the current loop compensation will not be correct.
6. The drive should be enabled (GREEN LED). Observe the motor current using a current
probe or resistor in series with the motor (<10% of motor resistance). This observation
should be done for both the high and low current loop gain (see drive datasheet for
available current loop gain DIP switch settings). Different drives need to be set up
differently to view the current loop response properly, as shown in the following figures.

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 Operation / Initial Setup and Features

FIGURE 4.2 Brushed Drives

Current
Analog Servo Probe or
Resistor
Drive

Square Motor +
Wave Input +Ref Motor
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.

FIGURE 4.3 Brushless Drives

Current
Analog Servo Probe or
Resistor
Drive

Square Motor A
Wave Input +Ref
Motor B Motor
Motor C

The motor shaft does

The current out of the drive can be forced to go
not need to be locked
through Motor A and Motor B by:
since the drive will not
1) Disconnecting the Hall sensors from the drive
commutate without
2) Setting the 60/120 degree phasing switch to 60 degrees
the Hall Sensors.

7. The drive output should follow the input command. The best response will be a critically
damped output waveform, similar to what is shown in Figure 4.4.

FIGURE 4.4 Current Loop Response

Current Target Current

Signal

Output Current
Response

Time

8. If neither current loop gain DIP switch position gives a proper square wave response, then
the current loop gain resistors may need to be changed to optimize the response. See
“Additional Tuning” on page 51 for more information.
9. When the proper response has been achieved, remove the input signal from the drive, and
disconnect power.

Current Loop Integrator Adjustment

1. Enable the Current Loop Integrator through DIP switch or jumper settings (see the drive
datasheet for available options).
2. Using a function generator, apply a ±0.5V, 50-100 Hz square wave reference signal.

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 Operation / Initial Setup and Features

3. Apply power to the drive. Use a bus voltage that is approximate to the desired application
voltage or the current loop compensation will not be correct.
4. The drive should be enabled (GREEN LED). Observe the motor current using a current
probe or resistor in series with the motor (<10% of motor resistance). If available, use any
DIP switches to adjust the current loop integral gain capacitance. The output should settle
to a flat top with minimal current following error (difference between commanded
current and actual current). There can be some overshoot, but it should be less than 10%.
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 4.4.
5. If the square wave output overshoots too much or is over-damped (sluggish), the current
loop integrator capacitor will need to be changed to optimize the response. See
“Additional Tuning” on page 51 for more information.

Voltage or Velocity Loop Tuning These adjustments should initially be performed with
the motor uncoupled from the mechanical load.

Configure the drive for the desired operation mode using the DIP switch settings (see the block
diagram on the specific drive datasheet).
• Voltage Loop or Duty Cycle Loop- Compensating the voltage loop requires the least
amount of effort. Turn the Loop Gain potentiometer clockwise until oscillation occurs,
then back off one turn.
• IR Feedback Loop - Start with a very high (or open) IR feedback resistor with an
unloaded motor shaft. Command a low motor speed (about 20-200 RPM). Without the IR
feedback the motor shaft can be stalled easily. Decreasing the IR feedback resistor will
make the motor shaft more difficult to stop. Too much IR feedback, i.e. too low a resistor
value, will cause motor run-away when torque is applied to the motor shaft.
• Velocity Loop (Encoder, Halls, or Tachometer) - The velocity loop response is
determined by the Loop Gain potentiometer. A larger resistance value (clockwise) results
in a faster response. The velocity integrator capacitor can be used to compensate for a
large load inertia. A large load inertia will require a larger capacitor value. Either using the
DIP switches to add in an extra capacitor or installing a through-hole capacitor may
accomplish this (see “Additional Tuning” on page 51 for more information). The need for
an extra capacitor can be verified by shorting out the velocity integrator capacitor by DIP
switch setting. If the velocity loop is stable with the capacitor shorted out, and unstable
with the capacitor in the circuit, then a larger capacitor value is needed.

Analog Position Loop Use of an encoder or tachometer for velocity feedback is recommended
to obtain a responsive position loop, since the position loop is closed around the velocity loop.
First the velocity loop must be stabilized (or voltage loop for undemanding applications). The
position loop gain is determined by the fixed gain of the input differential amplifier of the
drive. Contact ADVANCED Motion Controls for additional information on configuration for
analog position loop mode.

MNACHWIN-06 50
 A Additional Tuning

In general, ADVANCED Motion Controls’ AxCent servo drives will not need further tuning adjustments. However,
for applications requiring more precise tuning than what is offered by the configuration DIP switches and
potentiometers, adjustments to the tuning circuirtry can be made either with on-board tuning DIP switches or
with through-hole resistors and capacitors as denoted in Table A.1 below. Consult the drive datasheet to see
which option is available. On most drives, the through-hole locations are not populated when the drive is
shipped.
It is recommended to contact ADVANCED Motion Controls to discuss application requirements and proper drive
tuning prior to adding and through-hole components.

Any damage done to the drive while performing these modifications will
void the product warranty.

Before adjusting the tuning DIP switches or attempting to add through-hole components to the board, see
“Current Loop Tuning Procedure” on page 47. Some general rules to follow when adjusting the tuning circuitry
are:
• A larger resistor value will increase the proportional gain, and therefore create a faster
response time.
• Use non-polarized capacitors.
• A larger capacitor value will increase the integration time, and therefore create a slower
response time.

MNACHWIN-06 51
 Additional Tuning / Tuning DIP Switches

A.1 Tuning DIP Switches

Certain drive models feature DIP switches on the drive PCB that are used for tuning
adjustments. Note that these tuning DIP switches are different from the drive configuration
DIP switch bank (SW1). The configuration DIP switch bank is accesible from the connector
side of the drive, while the tuning DIP switches are only accessible if the drive cover is
removed.

Tuning DIP switches are available for the following functions:

• Adding additional current loop proportional gain resistance
• Adding additional current loop integrator gain capacitance
• Adding additional velocity loop integrator gain capacitance

Consult the drive datasheet for a table of the resistance and capacitance values that can be
achieved using the tuning DIP switches. Follow the procedure in “Procedure” on page 53 to
properly tune the drive.

A.2 Through-Hole Tuning

Proper tuning using through-hole components will require careful observation of the loop
response on a digital oscilloscope to find the optimal through-hole component values for the
specific application.

The following are some helpful hints to make the loop tuning process easier:
• Use pin receptacles to reduce the need for soldering - Some drives have pin receptacles
that make it easy to change the tuning resistors and capacitors without the need for
soldering. Other drives do not have these receptacles, so soldering is required. To avoid the
need to solder every time a tuning value needs to be changed a pin receptacle can be
soldered into the the through hole location of the tuning component.
• Use a potentiometer to find the correct current loop gain value - A potentiometer can
be used to continuously adjust the gain resistance value during the tuning process. Install
a potentiometer in place of the gain resistor. Adjust the potentiometer while viewing the
current loop response on an oscilloscope. When the optimal response is achieved turn off
the drive, remove the potentiometer, and measure the potentiometer resistance. Use the
closest resistor value available. (Note: This method will not work if the optimal tuning
value is beyond the range of the potentiometer. This method also does not work for sine
drives since it is difficult to keep the tuning values in the three current loops the same).
• Progressively double the resistance value when tuning the current loop gain for
faster results - If the gain resistor needs to be increased during the tuning process the
fastest results are achieved by doubling the resistance from the last value tried. Use this
method until overshoot is observed and then fine tune from there.
• Be aware of any components that are in parallel with the values you are trying to
tune - On some drives, there may be one or more gain resistors in parallel with the
through-hole resistor location. The equivalent resistance value of the SMT resistors on the
board and the additional through-hole resistor will be limited by the smallest resistance
value of the group of resistors in parallel. Consult the block diagram on the drive datasheet

MNACHWIN-06 52
 Additional Tuning / Procedure

to determine the specific resistor values. The same situation can occur when trying to
decrease the integrator capacitor value, since capacitors in parallel will be added together.
• 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.

Table A.1 lists the different through-hole components that can be used for loop tuning. Consult
the drive datasheet to see which options are available for a specific drive. Please contact
ADVANCED Motion Controls Applications Engineering for assistance in determining the PCB
location of the through-hole component options for the drive model in use.
TABLE A.1 Through-Hole Tuning Component
Component Description
Current Loop Proportional Gain Resistor Through-hole resistor that can be added for more precise current loop tuning.
Current Loop Integrator Capacitor Through-hole capacitor that can be added for more precise current loop tuning.
Velocity Loop Integrator Capacitor Through-hole capacitor that can be added for more precise velocity loop tuning.

A.3 Procedure
Before adjusting the tuning DIP switches or changing any components on the PCB, follow the
steps in “Current Loop Tuning Procedure” on page 47 to determine if any additional tuning is
necessary. Observe the drive output current response on an oscilloscope for all the different
DIP switch gain settings (if available on the drive in use). If further tuning is necessary or
desired, please contact ADVANCED Motion Controls before proceeding through the following
steps.

Tune the Current Loop Proportional Gain

1. Follow the steps outlined in “Current Loop Proportional Gain Adjustment” on page 48 up
through Step 8.

MNACHWIN-06 53
 Additional Tuning / Procedure

2. Observe the drive current response on an oscilloscope. Small step tuning is different than
large step tuning, so adjust the function generator square wave amplitude so the drive
outputs a current step similar to what will be expected in typical operation.
— If the current response does not rise quickly enough to the step input command, or if
it never reaches the input command, the equivalent resistance of the current loop
proportional gain resistor will need to be increased. This will increase the current
loop proportional gain, and achieve a faster, more aggressive response.
— If the current response overshoots the step input command, the equivalent resistance
of the current loop proportional gain resistor will need to be decreased. This will
decrease the current loop proportional gain, and provide a slower, more stable
response.
3. Finding an acceptable equivalent resistance may take a few iterations. If using a drive
model with through-hole tuning components, using pin receptacles or an external
potentiometer will make the process easier. Remember to remove power from the drive
prior to changing the tuning DIP swithces, or removing or adding any components to the
PCB. Also remember that it is not just the through-hole resistor value that is important,
but the equivalent resistance of the through-hole resistor and any SMT resistors that may
be in parallel with the through-hole location. Use the block diagram on the drive datasheet
to assist in determining the equivalent gain resistance.
4. Use an equivalent resistance value that brings the current response right to the point of
overshoot. If there is a large amount of overshoot, or if there are oscillations, decrease the
equivalent resistance value until there is little or no overshoot. Depending on the
application requirements, a little overshoot is acceptable, but should never exceed 10%.
5. When an acceptable resistance value has been found, remove power from the drive.

Tune the Current Loop Integral Gain

1. After the proportional gain resistance has been adjusted to an acceptable value, re-enable
the current loop integrator capacitor (either through DIP switch or jumper settings,
depending on the drive model).
2. Using the same function generator input command as in the previous section, apply
power to the drive and observe the current loop response on an oscilloscope.
3. Depending on the drive model, the current loop integrator capacitor can be changed or
shorted out of the circuit by DIP switch setting. Test both settings while observing the
current loop response.
— If the current response square wave oscillates or overshoots, a larger equivalent
capacitance value is necessary.
— If the current response square wave corners are too rounded, a smaller equivalent
capacitance value is necessary to sharpen the corners.
4. As in the previous section, using pin receptacles at the through-hole locations will greatly
assist in finding an acceptable capacitance value. Also keep in mind that the through-hole
capacitor location may be in parallel with SMT capacitors on the PCB. Use the block
diagram on the drive datasheet to determine the equivalent integrator capacitance value
(capacitors in parallel add together).
5. Although the ideal current loop response after integral gain tuning will be a critically
damped square wave, the application requirements will determine what the desired
response will be (i.e. how much overshoot, steady-state error, oscillation, is acceptable).

MNACHWIN-06 54
 Additional Tuning / Procedure

Velocity Loop Integral Gain Tuning The velocity loop proportional gain is adjusted by the
on-board Loop Gain potentiometer. The velocity loop integral gain can be adjusted by DIP
switch settings similar to the current loop integral gain (capacitance value can be changed,
capacitor can be shorted out, extra capacitor can be added in parallel). However, some drive
models also include additional through-hole locations where through-hole capacitors can be
added to further adjust the velocity loop integral gain. As in tuning the current loop integral
gain, use larger value equivalent capacitors to correct for overshoot or oscillation, and smaller
value equivalent capacitors for a quicker response time.

MNACHWIN-06 55
 B Troubleshooting

This section discusses how to ensure optimum performance and, if necessary, get assistance from the factory.

B.1 Fault Conditions and Symptoms

An inoperative drive can indicate any of the following fault conditions:
• over-temperature
• over-voltage
• under-voltage
• short-circuits
• invalid commutation
• inhibit input
• power-on reset

All of the above fault conditions are self-reset by the drive. Once the fault condition is removed
the drive will become operative again without cycling power. To determine whether the drive
is in a fault state, measure the “Fault Output” pin with a digital multimeter or voltmeter. A high
at this pin (or a low, depending on the drive model and configuration - see drive datasheet) will
indicate that the drive is subject to one of the above fault conditions, and the drive will be
disabled until the drive is no longer in a fault state. To remove the fault condition, follow the
instructions in the sections below describing each possible fault state.

Over-Temperature Verify that the baseplate temperature is less than the maximum allowable
baseplate temperature as denoted on the drive datasheet, typically 65ºC (149ºF) or 75ºC
(167ºF). The drive remains disabled until the temperature at the drive baseplate falls below
this threshold.

Over-Voltage Shutdown
1. Check the DC power supply voltage for a value above the drive over-voltage shutdown
limit. If the DC bus voltage is above this limit, check the AC power line connected to the DC
power supply for proper value.
2. Check the regenerative energy absorbed during deceleration. This is done by monitoring
the DC bus voltage with a voltmeter or oscilloscope. If the DC bus voltage increases above
the drive over-voltage shutdown limit during deceleration or regeneration, a shunt

MNACHWIN-06 56
 Troubleshooting / Fault Conditions and Symptoms

regulator may be necessary. See “Regeneration and Shunt Regulators” on page 22 for
more information.

Under-Voltage Shutdown Verify power supply voltages for minimum conditions per
specifications. Also note that the drive will pull the power supply voltage down if the power
supply cannot provide the required current for the drive. This could occur when high current
is demanded and the power supply is pulled below the minimum operating voltage required by
the drive.

Short Circuit Fault

1. Check each motor lead for shorts with respect to motor housing and power ground. If the
motor is shorted it will not rotate freely when no power is applied while it is uncoupled
from the load.
2. Disconnect the motor leads to see if the drive will enable without the motor connected. If
the drive enables with the motor disconnected, there is a possible short circuit in the
motor wiring.
3. Measure motor armature resistance between motor leads with the drive disconnected.
Verify these measurements against the motor datasheet to determine if there is a short or
open circuit in the motor windings.

Invalid Hall Sensor State (Brushless Drives only) See the “Commutation Sequence”
table in “Hall Sensors” on page 11 for valid commutation states. If the drive is disabled check
the following:
1. Make sure that the Hall Sensor Commutation Phasing switch is in the correct setting per
motor data sheets. When driving a single phase (brushed type) motor with a three phase
(brushless) drive use the 60-degree phase setting (see “Three Phase (Brushless) Drive
with Brushed Motor” on page 47 for more information on this particular configuration).
2. Check the voltage levels for all the Hall Sensor inputs. Turn the motor by hand while
measuring the Hall Sensor inputs to verify that all three Hall Sensors are changing. The
voltage should read approximately +5V for a "high (1)" Hall state, and approximately 0V
for a "low (0)" Hall state.
3. Make sure all Hall Sensor lines are connected properly.

Inhibit Input Check inhibit input for correct polarity (that is, pull-to-ground to inhibit or pull-to-
ground to enable). Inhibit configuration depends either on the DIP switch settings or a 0 ohm
SMT resistor marked on the board. Also, keep in mind that noise on the inhibit line could be a
cause for a false inhibit signal being given to the drive.

Power-On Reset All drives have a power-on reset function to ensure that all circuitry on the
board is functional prior to enabling the drive. The board will only be disabled momentarily,
and will quickly enable upon power up.

B.1.1 Overload
Verify that the minimum inductance requirement is met. If the inductance is too low it could
appear like a short circuit to the drive and thus it might cause the short circuit fault to trip.

MNACHWIN-06 57
 Troubleshooting / Fault Conditions and Symptoms

Excessive heating of the drive and motor is also characteristic of the minimum inductance
requirement not being met. See drive datasheet for minimum inductance requirements.

B.1.2 Current Limiting

Most analog servo drives incorporate a “fold-back” circuit for protection against over-current.
This “fold-back” circuit uses an approximate “I2t” algorithm to protect the drive. (see “Non-
Foldback Current Limiting” on page 59 for S-Series and Direct PWM drives current limiting
description)
• Maximum peak current output level can be sustained for about 2 seconds.
• To actually achieve maximum peak current output for 2 seconds requires the current
command to fully swing from peak in one direction to the other.

FIGURE B.1 Maximum Peak Current Foldback

Max Peak Current Limit

(Positive Direction)

Current Command
Max Continuous
Current Limit
Current Measured

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 fold-
back, will result in drive damage. Drive RMS current should be below the
continuous current rating!

• For most applications, it’s a rare occurrence to fully swing from peak in one direction to
the other. It is more likely the drive will be commanded from zero to max peak current.
Under this condition, the drive will only sustain the maximum peak current for about one
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

• Commanding maximum peak current output starting from above zero command will also
yield reduced peak current output time.

MNACHWIN-06 58
 Troubleshooting / Fault Conditions and Symptoms

• When commanding output current less than the max peak limit, but more than the max
continuous limit, the current output can be sustained for a longer time period than a
maximum peak command before folding back.

FIGURE B.3 Above Continuous Current Foldback

Max Peak Current Limit

(Positive Direction)

Max Continuous
Current Limit
Current Measured 1
Current Measured 2
0 Current Measured 3
t t+2

• The closer the commanded current is to the peak current limit, the shorter the peak
output time will be.
• Any command at or below the maximum continuous current limit can be achieved for as
long as there are no fault conditions present.
• When the drive is configured for any of the velocity modes, the user is no longer in direct
control of the current output. The current commands will be determined by the velocity
loop. Though internally the current loop still functions like it is described above, it will do
only what is necessary to meet the velocity demand. The current output depends on:
— How tight the velocity loop is tuned
— The load characteristics
— The speed the motor is already turning
— Magnitude and slope of velocity step

Non-Foldback Current Limiting On S-Series and Direct PWM ("BD" and "DD") drives, if the
RMS current through any motor phase rises above the maximum continuous current value,
the over current fault output pin will trigger a fault state, and the drive will be disabled until
the RMS current value has returned to a value within the acceptable operating range. Typically
this results in the drive output rapidly switching on and off (several 100 Hz) until the
command signal is reduced to a value below the continuous current rating of the drive.

B.1.3 Motor Problems

A motor run-away condition is when the motor spins rapidly with no control from the
command input. The most likely cause of this error comes from having the feedback element
connected for positive feedback. This can be solved by changing the order that the feedback
element lines are connected to the drive, or changing the feedback polarity switch on the DIP
switch bank to the opposite setting.

Another common motor issue for brushless motors with Hall Sensor commutation is when the
motor spins faster in one direction than in the other for the same velocity command in the
opposite direction. This is typically caused by improper commutation, usually because the
motor power wires are connected in the wrong order with respect to the Hall Sensor wiring.
Try all six combinations of connecting the motor power wires to the drive to find the correct
commutation order. The proper combination of motor wires will yield smooth motion and
identical speeds in both directions. Improper combinations will cause jerky motion, slow
movement in one direction, and/or audible noise. As a final verification that the commutation

MNACHWIN-06 59
 Troubleshooting / Technical Support

is correct, use the Velocity Monitor Output pin to measure motor speed in both directions .
This can also be caused by invalid Hall phasing. Check to see if the drive is set for 120- or 60-
degree phasing, and verify that the drive DIP switch setting corresponds to the Hall phasing
used on the motor. See “Hall Sensors” on page 11 for more information.

For a brushless drive, if the opposite motor direction is desired for a given command input,
interchange Hall 1 and Hall 3, then Motor A and Motor B.

B.1.4 Causes of Erratic Operation

• Improper grounding (i.e. drive signal ground is not connected to source signal ground).
• Noisy command signal. Check for system ground loops.
• Mechanical backlash, dead-band, slippage, etc.
• Noisy inhibit input line.
• Excessive voltage spikes on bus.

B.2 Technical Support

For help from the manufacturer regarding drive set-up or operating problems, please gather
the following information.
1. Model Number: This is the main product identifier. The model number can have a suffix
designating a change from the base model.
2. Revision Letter: Product revision level letter (’A’ is the earliest release from any model).
3. Version: The version number is used to track minor product upgrades with the same
model number and revision letter (’01’ is the earliest release of any revision).
4. Proto Designation: When included, indicates that the model is a prototype unit and model
number will also begin with an ’X’ designator.
5. Serial Number: The serial number consists of a 5-digit lot number followed by a 4-digit
sequence number. Each product is assigned a unique serial number to track product life
cycle history.
6. Date Code: The date code is a 4-digit number signifying the year and week of manufacture.
The first two digits designate the year and the second two digits designate the week (e.g.
the drive label shown would have been built in the year 2011 during the 18th week).
7. Input and Output Power Data: Includes basic power parameters of the product.
8. General Information: Displays applicable agency approvals, UL file reference number, and
compliance approvals. More complete product information is availabe by following the
listed website.

B.2.1 Drive Model Information

• DC bus voltage and range
• Motor type (brushed, brushless, AC induction)
• Motor characteristics (inductance, torque constant, winding resistance, etc.)
• Position of all DIP switches

MNACHWIN-06 60
 Troubleshooting / Warranty Returns and Factory Help

• Length and make-up of all wiring and cables

• If brushless, include Hall sensor information
• Type of controller and full description of feedback devices
• Description of problem: instability, run-away, noise, over/under shoot, etc.
• Complete part number and serial number of the product. Original purchase order is
helpful, but not necessary

B.3 Warranty Returns and Factory Help

Seller warrants that all items will be delivered free from defects in material and workmanship
and in conformance with contractual requirements. The Seller makes no other warranties,
express or implied and specifically NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. The Seller's exclusive liability for breach of warranty shall be
limited to repairing or replacing at the Seller's option items returned to Seller's plant at Buyer's
expense within one year of the date of delivery. The Seller's liability on any claim of any kind,
including negligence, for loss or damage arising out of, connected with or resulting from this
order, or from the performance or breach thereof or from the manufacture, sale, delivery,
resale, repair or use of any item or services covered by or furnished under this order shall in
no case exceed the price allocable to the item or service or part thereof which gives rise to the
claim and in the event Seller fails to manufacture or deliver items other than standard products
that appear in Seller's catalog. Seller's exclusive liability and Buyer's exclusive remedy shall be
release of the Buyer from the obligation to pay the purchase price. IN NO EVENT SHALL THE
SELLER BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES. Buyer will take all
appropriate measures to advise users and operators of the products delivered hereunder of all
potential dangers to persons or property, which may be occasioned by such use. Buyer will
indemnify and hold Seller harmless from all claims of any kind for injuries to persons and
property arising from use of the products delivered hereunder. Buyer will, at its sole cost, carry
liability insurance adequate to protect Buyer and Seller against such claims.

All returns (warranty or non-warranty) require that you first obtain a Return Material
Authorization (RMA) number from the factory. Request an RMA number by:

web www.a-m-c.com/download/form/form_rma.html
telephone (805) 389-1935
fax (805) 389-1165

MNACHWIN-06 61
 Index

Symbols Drive Case Grounding....................31 IR Compensation Mode .................15

±10V Analog Command ..................9 Drive Datasheet ...............................4 IR Feedback Loop Tuning .............50
±10V Analog Input Wiring............37 Drive Set-up Instructions........45–47 Isolated Power Supply...................21
Duty Cycle Mode ............................13 Isolation..........................................21
A Dwell Time .....................................16
AC Supply Frequency ...................... 8 L
AC Supply Voltage Range ................ 8 E Linear Motor Equation ..................17
Agency Compliances .......................ii Electromagnetic Interference.......32 Lock-out/tag-out Procedures .........1
Altitude...........................................25 Encoder Velocity Mode .................14 Loop Gain Potentiometer ..............42
Analog Position Loop Tuning .......50 Environmental Specifications.......25 Low Voltage Power Outputs .........41
Attention Symbols ..........................iii Error Signal ....................................10 LVD Requirements.........................28
External Filter Card .......................18
B M
Baseplate Temperature Range .....25 F Magnetic Interference Coupling ...32
Brushed Servo Drives...................... 6 Fault Conditions.......................56–58 Max. Continuous Output Current ...8
Brushless AC Supply Drives............4 Fault Output ...................................40 Max. Peak Output Current...............8
Brushless DC Supply Drives............4 Feedback Polarity ..........................10 Max. Power Dissipation at Continuous
Brushless Servo Drives ................... 6 Feedback Specifications ..........10–12 Current .............................8
Brushless Servo System ..................7 Feedback Wiring......................35–36 Mechanical Shock ..........................25
Bus Fuse ...........................................8 Fold-back........................................58 Minimum Load Inductance.............8
Frequency Factor...........................24 Modes of Operation .................13–15
C Current (Torque) .......................13
Capacitive Interference Coupling .32 G Duty Cycle (Open Loop) ............13
CE-EMC Wiring Requirements .....29 Ground Loops ..........................31, 33 Encoder Velocity........................14
Grounding ......................................31 Hall Velocity ...............................13
Central Point Grounding ...............31 IR Compensation .......................15
Command Inputs .............................9 Tachometer Velocity ..................14
Commutation Sequence Table 12, 46 H Voltage Mode..............................14
Company Website............................ii Hall Sensors Motion Control System....................5
Continuous Regeneration .............24 Feedback .................................... 11 Motor "Run-Away".........................10
Controller Chassis .........................31 Wiring.........................................35 Motor Back-EMF Voltage...............17
Crimp Tool......................................32 Hall Velocity Mode.........................13 Motor Chassis.................................31
Current (Torque) Mode.................13 Humidity ........................................25 Motor Current ..........................16, 19
Current Limit Potentiometer........42 Motor Current Frequency .............18
Current Limiting ...................... 44, 58 I Motor Force....................................17
Current Loop Gain .........................48 Impedance......................................32 Motor Inductance ......................3, 18
Current Loop Integrator ...............49 Incremental Encoder Overload .....................................57
Current Monitor Output................39 Feedback ....................................10 Motor Problems .............................59
Current Reference Output.............40 Wiring.........................................36 Motor Resistance ...........................17
Inhibit Input.............................40, 57 Motor Run-Away ............................59
D Input Reference Wiring........... 37–?? Motor Torque Constant .................16
Daisy Chains...................................34 Interference Coupling ...................32 Motor Voltage...........................17, 19
DC Bus Over Voltage Limit.............. 8 Internal Bus Capacitance ................8 Motor Wiring .................................33
DC Power Supplies ........................34 Internal Shunt Resistance ...............8 Mounting Options ..........................38
DC Power Supply Wiring...............34 Internal Shunt Resistor Move Profile ...................................15
DC Supply Voltage Range ................ 8 Power Rating................................8 Multiple Power Supply Wiring .....34
Turn-on Voltage ...........................8
DIP Switch Settings .......................43 Invalid Hall Commutation.............57

MNACHWIN-06 I
/

N R Test/Offset Potentiometer ............42

Negative Feedback.........................10 REF IN, -..........................................37 Three Phase Servo Drives ...............6
Noise...............................................32 REF IN, +.........................................37 Three-Phase AC Supply .................35
Nominal Power Supply Voltage ....19 Reference Gain Potentiometer .....42 Through-hole Components...........51
Regeneration..................................22 Torque.............................................16
O Continuous .................................24 Trademarks ..................................... ii
Overload .........................................57 Returns ...........................................61 Troubleshooting ......................56–61
Over-Temperature .........................56 Revision History ............................ iii Tuning
Over-Voltage Shutdown ................56 RMS Torque....................................17 Procedure .............................47–50
Through-Hole Components 51–55
P S Twisted Pair Wires ........................32
PE Ground ......................................31 Safety ............................................1–3
Scaling Factor.................................14 U
Peak Current Fold-back.................58
Peak Torque ...................................16 Selection and Sizing.................15–25 Under-Voltage Shutdown ..............57
Pin Functions ........................... 39–41 Servo Drive Theory.................... 5–??
Positive Feedback ..........................10 Shielding...................................31, 32 V
Potentiometer Functions ..............41 Shock/Vibration ............................26 Velocity Loop Tuning.....................50
Potentiometer Test Points ............42 Short Circuit Fault .........................57 Velocity Monitor Output................41
Potentiometer Tool........................42 Shunt Fuse........................................8 Velocity Scaling Factor ..................41
Power Ground................................31 Shunt Regulator .......................20, 22 Vibration.........................................25
Power Outputs, Low Voltage ........41 Signal Ground ................................31 Voltage Drop Interference.............32
Power Stage Specifications ............. 8 Single Phase Servo Drives ...............6 Voltage Loop Tuning......................50
Power Supply Capacitance.. 2, 24, 33 Switch Functions ...........................43 Voltage Mode..................................14
Power Supply Chassis ...................31 Switching Frequency .......................8 Voltage Ripple ................................24
Power Supply Current...................20 System Requirements .............15–25
Power Supply Output Current 19, 24 System Voltage Requirement........17 W
Power Supply Wiring ....................33 Warning Symbols........................... iii
Power-on Reset..............................57 T Warranty Info.................................61
Products Covered ............................ 4 Tachometer Warranty Returns ..........................61
Protective Earth.............................31 Feedback ....................................12 Wire Diameter ...............................32
PWM Current Control Circuit .........5 Velocity Mode.............................14 Wire Gauge .....................................32
Wiring.........................................36 Wiring ....................................... 32–??
Technical Support..........................60
Test Points (Pots)...........................42

II MNACHWIN-06
 AxCent™ Panel Mount Drives
Hardware Installation Manual
MNACHWIN-06

3805 Calle Tecate  Camarillo, CA 93012-5068

Tel: (805) 389-1935 Fax: (805) 389-1165 www.a-m-c.com