ADS50 5E ADSUser Manual
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maxon motor control Operating Instructions ADS 50/5 Order number 145391 June 1999 edition The ADS 50/5 is a powerful servoamplifier for driving permanent magnet DC motors up to 250 Watts. Four modes can be selected by DIP switches on the board: • Speed control using tacho signals • Speed control using encoder signals • I x R compensated speed control • Torque or current control The ADS 50/5 is protected against excess current, excess temperature and short circuit on the motor winding. With the FET power transistors incorporated in the servoamplifier, an efficiency of up to 95% is achieved. A built in motor choke combined with the high PWM frequency of 50 kHz allows the connection of motors with a very low inductivity. In most cases an external choke can be omitted. Thanks to the wide input power supply range of 12 - 50 VDC, the ADS 50/5 is very versatile and can be used with various power supplies. The aluminium housing makes installation simple, with terminal markings for easy connection. Table of Contents 1 2 3 4 5 6 7 8 9 Safety Instructions .............................................................................................................................................2 Performance Data..............................................................................................................................................3 Minimum External Wiring for Different Modes of Operation ..............................................................................4 Operating Instructions........................................................................................................................................5 Functions ...........................................................................................................................................................7 Additional Possible Adjustments......................................................................................................................10 Error Handling..................................................................................................................................................11 Block Diagram .................................................................................................................................................12 Dimension Drawing..........................................................................................................................................12 The latest edition of this operating instructions may also be found in the internet under http://www.maxonmotor.com («Downloads» in the category «Service & Support»). maxon motor 4-Q-DC Servoamplifier ADS 50/5 Operating Instructions 1 Safety Instructions Skilled Personnel Installation and starting of the equipment shall only be performed by experienced, skilled personnel. Statutory Regulations The user must ensure that the servoamplifier and the components belonging to it are assembled and connected according to local statutory regulations. Load Disconnected For primary operation the motor should be free running, i.e. with the load disconnected. Additional Safety Equipment An electronic apparatus is not fail-safe in principle. Machines and apparatus must there-fore be fitted with independent monitoring and safety equipment. If the equipment breaks down, if it is operated incorrectly, if the control unit breaks down or if the cables break, etc., it must be ensured that the drive or the complete apparatus is kept in a safe operating mode. Repairs Repairs may be made by authorised personnel only or by the manufacturer. It is dangerous for the user to open the unit or make repairs to it. Danger Do ensure that during the installation of the ADS 50/5 no apparatus is connected to the electrical supply. After switching on, do not touch any live parts. Max. Supply Voltage Make sure that the supply voltage is between 12 and 50 VDC. Voltages higher than 50 VDC or of wrong polarity will destroy the unit. Motor choke The built in motor choke allows operation with almost all maxon DC motors with an output power higher than 10 Watt. For a few exeptions (A-max ∅26, 11W as well as RE ∅25 and RE ∅26 with terminal inductance lower than 0.35 mH) an extra inductance (choke) of at least 200 µH is necessary. Electrostatic Sensitive Device (ESD) 2 maxon motor control June 1999 edition / subject to change maxon motor Operating Instructions 4-Q-DC Servoamplifier ADS 50/5 2 Performance Data 2.1 Electrical data Supply voltage Vcc (Ripple < 5%)................................................................12 - 50 VDC Max. output current Imax ............................................................................................ 10 A Continuous output current Icont ................................................................................... 5 A Switching frequency ............................................................................................. 50 kHz Efficiency................................................................................................................. 95 % Band width current controller .............................................................................. 2.5 kHz Built-in motor choke .....................................................................................160 µH / 5 A 2.2 Inputs Set value ................................................................................-10 ... +10 V (Ri = 20 kΩ) Enable ...............................................................................+4 ... + 50 VDC (Ri = 15 kΩ) Input voltage DC tacho.....................................min. 2 VDC, max. 50 VDC (Ri = 14 kΩ) Encoder signals............................................... Channel A, A\, B, B\, max. 100 kHz, TTL 2.3 Outputs Current monitor „Monitor I“ , short-circuit protected ......... -10 ...+10 VDC (RO = 10 kΩ) Speed monitor „Monitor n“ , short-circuit protected.......... -10 ...+10 VDC (RO = 10 kΩ) Status reading „READY“ Open collector ...................................................................... max. 30 VDC (IL < 20 mA) 2.4 Voltage outputs Aux. voltage, short-circuit protected............................. +12 VDC, -12 VDC, max. 12 mA Encoder supply voltage..................................................................+5 VDC, max. 80 mA 2.5 Trim potentiometers IxR Offset nmax Imax gain 2.6 LED indicator 2 colours LED....................................................................................... READY /ERROR green = ok, red = fault 2.7 Ambient temperature- / Humidity range Operating ................................................................................................... -10 ... +45 °C Storage....................................................................................................... -40 ... +85 °C noncondensating............................................................................................ 20 ... 80 % 2.8 Mechanical data Weight ...............................................................................................................ca. 360 g Dimensions .................................................................................see dimension drawing Mounting plate........................................................................................... for M4 screws 2.9 Terminal PCB-clamps .............................................................. Power (5 poles), Signal (12 poles) Pitch ...................................................................................................................3.81 mm suitable for wire cross section ............................ 0.14 - 1 mm2 multiple-stranded wire or ............................................................................................... 0.14 - 1.5 mm2 single wire Encoder................................................................................................... Plug DIN41651 for flat cable, pitch 1.27 mm, AWG 28 June 1999 edition / subject to change maxon motor control 3 4 maxon motor control 5 6 ON 1 2 ON 1 2 ON 1 2 3 4 5 6 1 2 3 4 5 6 Tacho ON Encoder IxR current mode I x R compensation EMF feedback sensor selection encoder frequency current limit mode 1 2 Current 1 2 current mode I x R compensation EMF feedback sensor selection encoder frequency current limit mode 12...50 VDC current mode I x R compensation EMF feedback sensor selection encoder frequency current limit mode Power Supply current mode I x R compensation EMF feedback sensor selection encoder frequency current limit mode 4-Q-DC Servoamplifier ADS 50/5 maxon motor Operating Instructions 3 Minimum External Wiring for Different Modes of Operation 1 1 1 1 Enable 10 kΩ 1 2 3 4 5 6 OFF 1 2 3 4 5 6 OFF OFF OFF June 1999 edition / subject to change maxon motor Operating Instructions 4-Q-DC Servoamplifier ADS 50/5 4 Operating Instructions 4.1 Determine power supply requirements You may make use of any available power supply, as long as it meets the minimal requirements spelled out below. During set up and adjustment phases, we recommend separating the motor mechanically from the machine to prevent damage due to uncontrolled motion. Power supply requirements Output voltage Vcc min. 12 VDC; max. 50 VDC Ripple <5% Output current 5 A continuous (10 A peak) The required voltage can be calculated as follows: Known values: • Operating torque MB [mNm] • Operating speed nB [min-1] • Nominal motor voltage UN [Volt] • Motor no-load speed at UN, n0 [min-1] • Speed/torque gradient of the motor ∆n/∆M [min-1 mNm-1] Sought values: • Supply voltage Vcc [Volt] Solution: Choose a power supply capable of supplying this calculated voltage under load. The formula takes a 2 Volt max. voltage drop at the ADS 50/5 into account. 4.2 Function of the potentiometers Potentiometer Function Turn to the left June 1999 edition / subject to change P1 IxR I x R compensation P2 Offset P3 nmax P4 Imax current limit P5 gain amplification Adjustment n=0 at set value 0V max. speed at 10V set value weak compensation motor turns CCW speed slower lower min. 0.5 A lower right strong compensation motor turns CW speed faster higher max. 10 A higher maxon motor control 5 maxon motor 4-Q-DC Servoamplifier ADS 50/5 Operating Instructions 4.3 Adjustment of the Potentiometers 4.3.1 Pre-adjustment With the pre-adjustment, the potentiometers are set in a preferred position. ADS units in original packing are already pre-adjusted. P1 P2 P3 P4 P5 Pre-adjustment potentiometers P1 IXR 0% P2 Offset 50 % P3 nmax 50 % P4 Imax 50 % P5 gain 10 % 4.3.2 Adjustment Encoder mode DC-Tacho mode I x R compensation Current controller mode 6 maxon motor control 1. Adjust set value to maximum (e.g. 10V) and turn potentiometer P3 nmax so far that the required speed is achieved. 2. Set potentiometer P4 Imax at the limiting value desired. Important: The limiting value lmax should be below the max. continuous current as shown on the motor data sheet. 3. Increase potentiometer P5 gain slowly until the amplification is set large enough. Caution: If the motor vibrates or becomes loud, the amplification is adjusted too high and the potentiometer must be readjusted until the instability of the closed loop of the drive under all loads disappears. 4. Adjust set value to zero, e.g. by short circuiting the set value. Then set the motor speed to zero with the potentiometer P2 Offset. In addition, only in the case of lxR compensation: 5. Slowly increase potentiometer P1 IxR until the compensation is set large enough so that in the case of high motor load the motor speed remains the same or decreases only slightly. 1. Set potentiometer P4 lmax at the limiting value desired. Important: The limiting value lmax should be below the max. continuous current as shown in the motor data sheet.. June 1999 edition / subject to change maxon motor Operating Instructions 4-Q-DC Servoamplifier ADS 50/5 5 Functions 5.1 Inputs 5.1.1 Set value The set value input is wired as a differential amplifier. Input voltage range Input resistance Positive set value Negative set value -10...+10 V 20 kΩ ( + Set Value) > ( - Set Value) ( + Set Value) < ( - Set Value) 5.1.2 Enable If a voltage is given at “Enable”, the servoamplifier switches the motor voltage to the winding connections. If the “Enable” input is not switched on or is connected to the Gnd, the power stage will be highly resistant and will be disabled. The “Enable” input is short-circuit protected. Enable Minimum input voltage Maximum input voltage Input resistance Switching time + 4,0 VDC + 50,0 VDC 15 kΩ typ 500 µsec (by 5 V) Disable Minimum input voltage Maximum input voltage Input resistance Switching time 0 VDC + 2,5 VDC 15 kΩ typ 100 µsec (by 0 V) Minimum input voltage Maximum input voltage Input resistance 2,0 V 50,0 V 14 kΩ 5.1.3 DC Tacho The nmax potentiometer allows you to adjust the motor speed for a given set value input. The lowest adjustable motor speed range is ±3850rpm with a ±10V set value and a tacho with 0.52V/1000rpm. (3850rpm x 0.52V/1000rpm = 2V ; see table above) Lower speed ranges can be achieved either by reducing the set value input range (i.e. ±5V for ±1925rpm) or using a tacho type with higher output voltage, such as 5V/1000rpm. June 1999 edition / subject to change maxon motor control 7 maxon motor 4-Q-DC Servoamplifier ADS 50/5 Operating Instructions 5.1.4 Encoder Encoder supply voltage Maximum encoder frequency Voltage value + 5 VDC max. 80 mA DIP - Switch 5 ON: 10 kHz DIP - Switch 5 OFF: 100 kHz TTL low max. 0,8 V high min. 2,0 V It is strongly recommended that the encoder be used with a built-in line driver. If the encoder is used without a line driver (without ChA\ and ChB\), speed breakdowns and max. speed limits must be expected because of the slower switching slope. The servoamplifier does not need any home impulse I and I\. Male header (front view) Pin configuration at “Encoder” input: 1 2 3 4 5 6 7 8 9 10 n.c. +5 V Gnd n.c. A\ A B\ B n.c. n.c. Not connected + 5 VDC max. 80 mA Ground Not connected Inverted Channel A Channel A Inverted Channel B Channel B Not connected Not connected This pin configuration is compatible with the flat cable plugs in Encoder HEDL 55xx (with Linedriver) 8 maxon motor control June 1999 edition / subject to change maxon motor Operating Instructions 4-Q-DC Servoamplifier ADS 50/5 5.2 Outputs 5.2.1 Current monitor „Monitor I“ The servoamplifier makes a current actual value available for monitoring purposes. The signal is proportional to the motor current. The „Monitor I“ output is short-circuit protected. Output voltage range Output resistance Gradient -10... +10 VDC 10 kΩ approx. 0,8 V / A 5.2.2 Speed monitor „Monitor n“ The speed monitor is primarily intended for the qualitative estimation of the dynamics. The absolute speed is determined by the properties of the speed sensors and by the setting of the nmax potentiometer. The output voltage of the speed monitor is proportional to the number of revolutions. The output voltage of the speed monitor is 10V when the maximum number of revolutions set by the nmax potentiometer has been reached. The “Monitor n” output is short-circuit protected. Output voltage range Output resistance -10... +10 VDC 10 kΩ 5.2.3 Status reading „Ready“ The “Ready“ signal can be used to report the state of operational readiness or a fault condition on a master control unit. The „Open Collector“ output is, in normal cases, i.e., no faults, switched to Gnd. In the case of a fault with excess temperature or excess current, , the output transistor is not conducting (high resistance). An external additional voltage is required: Input voltage range Load current max. 30 VDC < 20 mA The fault condition is stored. In order to reset the fault condition, the servoamplifier must be re-released (Enable). If the cause of the fault situation cannot be removed, the output transistor will immediately change to the not conducting state again. June 1999 edition / subject to change maxon motor control 9 maxon motor 4-Q-DC Servoamplifier ADS 50/5 Operating Instructions 6 Additional Possible Adjustments Potentiometer Function Position left right P6 ngain speed gain low high P7 Igain current gain low high P8 Icont continuous current limit lower higher P8 I cont P7 I gain P6 n gain 6.1 Adjustments potentiometer P6 ngain and potentiometer P7 Igain In most applications, regulation setting is completely satisfactory using potentiometers P1 to P5. In special cases the transient response can be optimized by setting the P6 “speed regulation gain” potentiometer. The P7 “current regulator gain” potentiometer can, in addition, be adapted to the dynamics of the current regulator. It is recommend that the success of changes to the settings of P6 ngain and P7 Igain be checked by measuring the transient response with an oscilloscope at the “Monitor n” and “Monitor I” outputs. Pre-adjustment P6 ngain = 25 % and P7 Igain = 50 %. 6.2 Adjustments potentiometer P8 Icont and current limit mode DIP-Switch 6 It is standard that a maximum current limiter is activated (DIP switch 6 OFF) as the only current limiter. In this way the motor current is limited to the value set on potentiometer P4 Imax (0.5 ... 10A). If DIP switch 6 is turned to ON, a cyclical current limiter is also activated. This current limiter method makes a certain level of motor protection against thermal overload possible. For 0.1 seconds the motor current is limited to the value set on potentiometer P4 Imax (0.5 - 10A) and then for 0.9 seconds current is limited to the value set on potentiometer P8 Icont (0.5 - 10A). After one second a current of lmax is allowed. Pre-adjustment P8 Icont = 50%. 10 maxon motor control June 1999 edition / subject to change maxon motor Operating Instructions 4-Q-DC Servoamplifier ADS 50/5 DIP-Switch 6 ON ↑ cyclical current limiter active DIP-Switch 6 OFF ↓ maximum current limit active P4 Imax Imax P4 Imax Imax P8 Icont Icont t 0.1 sec t 1 sec 6.3 Maximal encoder frequency DIP-Switch 5 DIP switch 5 permits selection of the maximum encoder input frequency. A max. encoder frequency of 100 kHz is standard. DIP-Switch 5 ON ↑ Max. Input frequency is 10 kHz Encoder pulse maximum per turn motor speed 100 6’000 rpm 500 1’200 rpm 1000 600 rpm DIP-Switch 5 OFF ↓ Max. Input frequency is 100 kHz Encoder pulse maximum per turn motor speed 100 60’000 rpm 500 12’000 rpm 1000 6’000 rpm 7 Error Handling Defect Shaft does not rotate Speed is not controlled June 1999 edition / subject to change Possible source of defect Supply voltage <12 VDC Enable not activated Set value is 0V Current limit too low Wrong operational mode Bad contacts Wrong wiring Encoder mode: encoder signals DC- Tacho mode: tacho signals I x R mode: compensation wrong Measures check power plug pin 4 check signal plug pin 3 check signal plug pin 1 and pin 2 check adjustment pot. P4 Imax check DIP switch settings check wiring check wiring check plug encoder check plug signal pin 5 and 6 (polarity) check adjustment pot. P1 maxon motor control 11 maxon motor 4-Q-DC Servoamplifier ADS 50/5 Operating Instructions 8 Block Diagram -12V OUT +12V OUT Enable Ready DIP5 +5V/80mA Gnd Encoder A Encoder A\ Encoder B Encoder B\ +5V 1K +12V 1K +12V -12V Supply -12V F/V Converter +Vcc 12-50VDC DIP6 Power Gnd +12V Current limit P8 I cont J302 DIP1 +Set value -Set value P7 I gain P5 gain DIP4 PWM, Control & Protection Logic P6 n gain P3 n max J305 MOSFET Full-Bridge J303 J304 P4 Imax -Motor -Tacho Input P1 IxR DIP2 +Motor J301 Current Detector Voltage Detector DIP3 P2 Offset 10K +12V Monitor n -12V 10K Monitor I 9 Dimension Drawing Dimensions in [mm] 12 maxon motor control June 1999 edition / subject to change
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