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1. Motor B Pouer supplu 09 470 VDC N e S d d E E 4 AS sS A ef IP S 2 O S O O O Ake ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 17 oF oo ee gt ANS ElectroCraft powering innovation User Manual EA4709 EA4718 4 4 1 Adjustment procedure for PWM mode 1 Potentiometer pre setting refer chapter 5 2 2 Choose the maximum set value e g 10 V Turn the potentiometer Scale until the desired maximum speed is reached If the red LED is flashing 5x s the maximum speed is reached depending on the supply voltage Then reduce the Scale potentiometer slightly till the red LED is lit off 3 Adjust the current limiter to a value requested by you with the max potentiometer It is of major importance that this value is lower than the maximum admissible constant current see motor data sheet To measure the motor current use a current probe in one of the motor cables with a oscilloscope If the red LED is lit the current limitation is activated 4 This PWM mode is an open loop mode The Gain potentiometer has no function 5 Set the set value to zero and adjust the Offset potentiometer to the standstill of the motor 6 The ramp function is deactivated if the potentiometer Time is set to the left ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 18 ElectroCraft powering innovation User Manual EA4709 EA4718 4 5
2. 100 mA max source and sink Note The logical state of this output is clearly visible by the green Power Error LED on the front panel ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 32 ElectroCraft powering innovation User Manual EA4709 EA4718 7 3 Analog Inputs Set val Set val Inputs for Set Values An external 10 10 V analog signal for speed or for current is entered using Set val and Set val inputs If the effective voltage is OV the motor stops If the effective voltage is positive the motor moves in one direction If the input is negative the motor consequently will be move in the opposite direction These inputs are given in form of a differential amplifier so each of them can be related to ground This offers the possibility to preset the level control in only one direction Additional information about the schematic refer chapter 3 2 Range of Input Voltage 10 V to 10 V Input Impedance 20 kOhm Permanent Input Protection 30 V to 30 V As an alternative the set value can be entered using an external potentiometer 10 kOhm For this purpose connect the slide resistance to Set val the left stop to 10V and the right stop to 70V This procedure requires the Set val input to be bridged to GND The admissible range for the set value is limited by the programmed Scale speed value In this case the desired maximum speed can be selected according to th
3. Amplifier Set val T Brushless DC Motors ElectroCraft Set val Supply Voltage 9 70V 2 Offset Cont Current 09 18A www electrocraft com 3 Peak Current 18 36A a Scale DIN ISO EN 9001 2000 Cain Design Made in EAA7 8 Ej Patent Germany mox IPC A 610 class 2 G RoHS C PWM Time Hall Encoder Torque Set val Phase peak Enable S N E HEIEREN Power GND Motor C Motor B I I I I I I I I I I I I Hall B L Hall EH Enc fi Pouer supplu 09 7B8 UDC I I I I I I I I I I I I I I I I I I I I I I I J N Q S ot L e Q qv Q SO g SPP e q e e SOSIO ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 13 s ei ElectroCraft powering innovation User Manual EA4709 EA4718 4 2 1 Adjustment procedure for Encoder mode 1 Potentiometer pre setting refer chapter 5 2 2 Choose the maximum set value e g 10 V Turn the potentiometer Scale until the desired maximum speed is reached If the red LED is flashing 5x s the maximum speed is reached depending on the supply voltage Then reduce the Scale potentiometer slightly till the red LED is lit off 3 Adjust the current limiter to a value requested by you with the max potentiometer It is of major importance that this value is lower than the maximum admissible constant current see motor data sheet To measure the motor current use a current pro
4. Mail info electrocraft com www electrocraft com May 2009 24 ElectroCraft powering innovation User Manual EA4709 EA4718 6 Glossary Offset There are two distinct functions for the Offset Potentiometer 1 Levelling the position at which the motor stands still 2 Selection of the Set Value This task requires the switch S1 3 Set val to be in Off position In any mode this feature is available and offers the possibility of a quick functional test It is advisable to begin the subsequent levelling procedure with an idle run of the motor However you cannot expect this calibration to be stable in the long term because the motor as well as the controller are always subject to thermal influences Scale Use this potentiometer to adapt the desired maximum speed to the amplitude of the present set value For Example if maximum of 5V is to be used for maximum Speed then send 5V and adjust that maximum with the Scale potentiometer Take care not to exceed meaningful limits An exaggerated value may entail problems for the control of the servo amplifier making it impossible e g to line up the system in speed control operation under load Gain The dynamical behaviour of the servo amplifier must be compatible to the particular connected motor The adjusting procedure is performed using the Gain potentiometer A bad adaptation i e if the Gain value has been selected too high can be easily recognized by excessive motor
5. WMd B ee VWOL AOL VUJO L AO V AOL Kant E o qeu3 z JeAos D Fenes x E Mail info electrocraft com www electrocraft com May 2009 ElectroCraft ElectroCraft powering innovation User Manual EA4709 EA4718 3 2 Input amp Output Schematics Input Hall A B C Input Encoder A B 220 X4 4 X4 3 Output Monitor Output Monitor n X3 6 Diff Input SetValue Output Error ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 8 ElectroCraft powering innovation User Manual EA4709 EA4718 3 3 Control Elements 3 4 Operation Modes PWM Mode In the PWM mode the input voltage of the set value is directly converted to a PWM signal at the output The drive works in open loop and the complete regulation circuit is switched off In this mode the drive is used e g as a power amplifier for a positioning system Hall Mode At hall mode the feedback information is coming from hall switches which are mounted in the motor or a hall encoder which is mounted at the motor The speed regulation is good at each load condition and qualified for each application to control the speed of a system also for high speed application Encoder Mode At encoder mode feedback information is coming from the encoder signals The encoder is mounted at the motor The speed regulation has got a high performance at each load condition and qualified for each appli
6. signals or in an environment with strong magnetic interference e Connect the shield on either end of the cable For 50 60 Hz interference remove the shield on one side Digital Signals Enable Error e No shielding required To verify a trouble free operation and the conformity to CE regulation it makes only sense to test the system as a whole with all components installed motor amplifier supply pack EMC filters cables etc se Note To improve the resistance to the noise immunity always connect unused e logical inputs to a fix potential GND or 5V Do not connect the CAT5 connectors to any network ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 10 ElectroCraft powering innovation User Manual EA4709 EA4718 4 1 Wiring Example I Hall Mode gr Power Error 4 Q Servo Amplifier Brushless DC Motors ElectroCraft red Status Supply Voltage 9 70V Offset Cont Current 09 18A www electrocraft com Peak Current 18 36A 480 ida EA4709 DIN ISO EN 9001 2000 Patent Germany y Beien IPC A 610 class 2 RoHS PWM Time Hall Encoder Torque Set val Phase peak Enable Gain Motor C Motor B e Z CD s U 3 O A Power supply 09 7B8 UDC L N S a g d JA sf X S 2 WW ef WKS e SOSI ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 11 Ki e e ElectroCraft po
7. 7 050 8800 Email EMEAsales electrocraft com Customer Support Germany Customer service at 49 0 711 727205 0 Email info electrocraft de ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 38 ElectroCraft powering innovation User Manual EA4709 EA4718 11 Dimensions BE 85 0 119 0 112 0 All dimensions in mm 12 Mounting Din rail adapter wd DIN7982 3 5x9 5 zang EA47xx E09 Subject to change without prior notice ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 39
8. Potentiometer pre setting refer chapter 5 2 2 Adjust the current limiter to a value requested by you with the max potentiometer It is of major importance that this value is lower than the maximum admissible constant current see motor data sheet If the red LED is lightning the current limitation is activated 3 Choose the maximum set value e g 10 V Turn the potentiometer Scale until the desired maximum current is reached 4 To optimize the response time slowly raise the value of the Gain potentiometer If the motor begins to work unsteadily to vibrate or to cause excessive noise carefully lower the gain factor again until the instability symptoms have disappeared for all load selections 5 Set the Set Value to zero and adjust the Offset potentiometer to the standstill of the motor 6 The ramp function is deactivated if the potentiometer Time is set to the left ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 16 ElectroCraft powering innovation User Manual EA4709 EA4718 4 4 Wiring Example IV PWM Mode gr Power Error 4 Q Servo Amplifier Brushless DC Motors ElectroCraft Supply Voltage 9 70V Cont Current 09 184 Wwww electrocraft com Peak Current 18 36A Manufactured under EA4 7 09 LJ scale DIN ISO EN 9001 2000 E4718 B red Status Offset ean Germany y IPC A 610 class 2 Bai RoHS PWM Time Hall Encoder Torque Set val Phase peak Enable
9. User Manual EA4709 EA4718 ElectroCraft powering innovation 4 Q PWM Servo 09 18 A For Brushless Commutated DC Motors up to 1260 W EA4709 EA4718 Le E 4 CT H 0 ase Mon oY i go AA SR yO d nope B mo Aw E 0 p Servo amplifier in a small size rugged aluminium housing in bookshelf form Different methods of mounting for fast installation Tool free connections for power terminations Inputs and outputs via RJ45 CAT5 plug Operation mode with simple DIP switch setting User adjustable current limit and ramp function Wide range supply voltage between 9 and 70 VDC for different kinds of DC power supplies Protected against overtemperature and over current MOSFet technology efficiency 97 Continuous current up to 9 18 A model dependent Basic drive description The EA4709 EA4718 servo amplifiers are designed to drive DC brushless type motors They require a single DC power supply for operation The drives are to be used with a single motor They have the functionality to operate as an independent speed control or high performance servo The drives are protected against short circuits under voltage over temperature and over current It has multiple modes of operation and serves as a reliable choice for your motion control needs ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 1 ElectroCraft powering innovation User Manual EA4709 EA4718 Tab
10. Wiring Example V gr Power Error 4 Q Servo Amplifier 1QU toet Val Brushless DC Motors ElectroCraft ane ser val eee Cont Current 09 18A Www electrocraft com GND Enable ee Peak Current 18 36A 1 QU Manufactured under EA4709 LJ Scale O DIN ISO EN 9001 2000 Uerror i Design Made in a E SE Patent Germany r rror T IPC A 610 class 2 ROHS C PWM Time Hall Encoder Torque Set val Phase peak Enable fe Off7 On Motor C Motor B m ES s U 3 O A 4 I i I I i I Pouer supplu tO en VOC L _ Only need in encoder mode Setting of S1 Hall Mode Encoder Mode Torque Mode PWM Mode gt GN o gt E M We o gt GM oc PF e s A e e CVS OE ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 19 ElectroCraft powering innovation User Manual EA4709 EA4718 4 6 Wiring Example VI gr Power Error 4 Q Servo Arnplifier ElectroCraft ETSI ene Brushless DC Motors ElectroCratt__ supply Voltage 9 70V Set val ss Cont Current 09 184 www electrocratt com Enable Peak Current 18 36A 10U Manufactured under EA4709 MN scale DIN ISO EN 9001 2000 10U om Design Made in Ens B Uerror Patent Germany Error IPC A 610 class 2 A RoHS C Ava 2002 95 EC GND PWM Time Hall Encoder Torque Set val Phase peak Enable Motor C Motor B
11. aft powering innovation User Manual EA4709 EA4718 10 Warranties amp Disclaimers e Contents are subject to change without notice e Electrocraft will not be liable in any way for direct indirect incidental or consequential damages caused by the use of this product or document e Per Electrocrafts Terms amp Conditions the user of Electrocrafts accepts all responsibility and risks involved with applying this product into their machinery and indemnifies Electrocraft against all damages e Any reproduction of this product and document is strictly prohibited Limited Warranty Electrocraft products unless otherwise stated in specifications are warranted for a period of 18 months from date of shipment to be free from defects in materials workmanship and to conform to the specifications Liability under this warranty shall be limited to the repair or replacement but not to the installation of any defective product at Seller s option Products will be repaired or replaced at the Sellers option Under no circumstance shall the user repair or modify the product Failure to adhere to this will void all warranty For Warranty Repair or Technical Assistance contact Customer Support North America USA amp Canada Motion Control Technologies 800 697 6715 Email info electrocraft com Customer Support Europe except Germany Middle East Africa Australia Central amp South America Customer service at 44 0 12
12. al selection using a voltage between X3 1 and X3 2 Setting of the Hall arrangement The halls in the motor have an arrangement of 120 The halls in the motor have an arrangement of 60 Pulsed Current The feature is disabled The output delivers a pulsed current to the double value of max The time is defined by the Time potentiometer Setting range is between 50 ms and 500ms Enabling of the output The enable is following the signal at the input X3 3 With high the output stage will be activated Refer chapter 7 1 With switching the switch from Off to On the output stage will be activated ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 23 User Manual EA4709 EA4718 ElectroCraft powering innovation Setting Hall Mode Encoder Mode Torque Mode PWM Mode Set value intern o ap Ou a x Phase 120 Ipeak off S S d Se xX xX 48 Q8 ef QU AP Z aue Ze a Ss Sade oe e 23 aue Ze Pd 2 Set value extern Phase 120 Ipeak off Set value intern Phase 120 Ipeak on Set value extern Phase 120 Ipeak on Set value intern Phase 60 Ipeak off Set value extern oae Oo ae s xs Ng xs WW ef d AS QS Es af e x Pd Zo we RS e y Sae we Le e e Pd ue Phase 60 Ipeak off Set value intern Qoae OP ae X 2 Z s 2 QS 2 gt e e SMS FO e F af ll af Phase 60 lpeak on Set value extern Phase 60 adult urina lpeak on 2 3 41 5 6 213141516 ElectroCraft E
13. atic refer chapter 3 2 Range of Input Voltage 0 to 24 VDC Input Impedance 4 7 kOhm to GND Permanent Input Protection 0 6 to 50 VDC Enable activated gt 3 5 VDC Enable disabled lt 0 6 V open or connected to GND ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 31 ElectroCraft powering innovation User Manual EA4709 EA4718 7 2 Digital Outputs Error Monitoring Output Whenever a system failure occurs i e overtemperature or hall error the Error output responds LO position and the green LED on the front panel is switch off The drive output stage is switched off and the error will not reset until the user resets the drive by switching the enable input If the error occurs again the problem still exists The output is applicable in three different modes A As Open Collector LO active TTL compatible or up to 30 V industrial logic B As Push Pull output with an output impedance 50 Ohm when connecting the upper voltage signal to input Verror With Verror 24V an SPS with photocoupler inputs can directly be controlled C Together with a bridge between the 5V output and Verror input applicable as Push Pull output for a connection to TTL or CMOS Logics without external upper voltage signal Additional information about the schematic refer chapter 3 2 Range of Output Voltage 0 6 V Verror 0 6 V with Verror 5 V to 30 V Output Impedance 50 Ohm Permanent Output Current
14. be in one of the motor cables with a oscilloscope If the red LED is lit the current limitation is activated 4 Slowly raise the value of the Gain potentiometer If the motor begins to work unsteadily to vibrate or to cause excessive noise carefully lower the gain factor again until the instability symptoms have disappeared for all load selections 5 Set the set value to zero and adjust the Offset potentiometer to the standstill of the motor 6 The ramp function is deactivated if the potentiometer Time is set to the left ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 14 ElectroCraft powering innovation User Manual EA4709 EA4718 4 3 Wiring Example Ill Torque Mode gr Power Error 4 Q Servo Amplifier Brushless DC Motors ElectroCraft red Status Supply Voltage 9 70V Cont Current 09 18A www electrocraft corn Peak Current 18 36A Manufactured under EA4 7 09 GJ Scale DIN ISO EN 9001 2000 Gain Design Made in Patent Germany mox IPC A 610 class 2 RoHS C PWM Hall Encoder Torque Set val Phase peak Enable Offset Time Motor B Pouer supplu 09 470 VDC N P L ae 9 d E E 4 AS sS WH IP SS 2 lglslzlelebkk ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 15 oF oo ee gt ANS ElectroCraft powering innovation User Manual EA4709 EA4718 4 3 1 Adjustment procedure for Torque mode 1
15. cation to control exactly the speed of a system especially for low speed application The maximum achievable speed in this mode is limited through the encoder input frequency Torque Mode At torque mode the drive does only control the current of the motor This control loop is very fast but the speed is moving with the load due to the constant current This mode is used in application with force control or as a fast power amplifier for positioning systems ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 9 ElectroCraft powering innovation User Manual EA4709 EA4718 4 Wiring According to the safety directives a correct cable selection is mandatory Regular inspection is advisable Damaged burned or kinked items have immediately to be exchanged Power Power e Power GND e Normally no shielding required e When connecting several amplifiers to the same supply pack use star point wiring Motor Wiring gt 30 cm e Only shielded cables are recommended e Connect the shield to the ground lug of the servo amplifier e A separate cable has to be used e Choke modules are useful to reduce PWM pulses Connection to hall and encoder 30 cm e Only shielded cables are recommended e Connect the shield to the controller e A separate cable has to be used Analog Signals max Set val Set val Mon I Mon n e n most cases no shielding required This may be different for low level
16. dation is 1 5 mm AWG16 the minimum is 0 13 mm AWG28 Maximum wire diameter with respect to the plug contact is 2 5 mm AWG14 otrip the wire insulation of the cables on a length of 10mm For stranded wire use end sleeves with the corresponding length Wire ends have to be inserted into the contact until they reach the stop For the cabling of the RJ45 plugs we recommended shielded CAT5 cables The cables are available in different colours and lengths in the system accessories ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 User Manual EA4709 EA4718 2 2 Mechanical Data Mechanical Dimensions L x W x H Weight Mounting 2 3 Ambient Conditions Operation Temperature Storage Temperature Humidity Non Condensing Overtemperature Protection 2 4 Digital and Analog Inputs Enable Hall A B C Encoder Channel A B Set value 2 5 Outputs Auxiliary Voltage Outputs 5V Auxiliary Voltage Output 70V Auxiliary Voltage Output 70V Error Mon Mon n ElectroCraft powering innovation 120 x 85 x 27 5 mm 210g M3 screws or Din Rail Mounting 10 to 45 C 40 to 85 C 20 to 80 RH 80 C TTL 24 VDC Resistance 10 kOhm TTL 5 VDC Resistance 1 kOhm TTL 5 VDC Resistance 1 kOhm max 78 kHz Analog 10 10 VDC Resistance 20 kOhm 5 V 50 mA for each 100 mA if connected in parallel 10 V 10 mA 10 V 10 mA Open Collector Push P
17. e maximum input voltage Note If the motor does not stop at input voltage 0 V fine tuning has to be performed using Offset potentiometer ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 33 ElectroCraft powering innovation User Manual EA4709 EA4718 7 4 Analog Outputs Mon n Motor Speed Output This feature shows the motor speed as a voltage signal The maximum output voltage depends on the Scale potentiometer After adjusting the Scale potentiometer at maximum Set val refer chapters 4 x 1 the drive has to be reset by switching Enable OFF and ON The voltage that is then measured is the maximum voltage with setting above Additional information about the schematic refer chapter 3 2 Range of Output Voltage 0 to 10 V Output Impedance 200 Ohm Permanent Output Current 20 mA max source and sink Mon I Motor Current Output Monitor delivers a result representing the actual value of the average motor current The proportionality factor is fixed to 1V EA4709 0 5V EA4718 per 1A motor current Additional information about the schematic refer chapter 3 2 Range of Output Voltage 0 to 10 V Output Impedance 200 Ohm Permanent Output Current 20 mA max source and sink ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 34 ElectroCraft powering innovation User Manual EA4709 EA4718 8 Basic Troubleshooting The servo amplifier ha
18. ectors 87654321 ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 21 ElectroCraft powering innovation User Manual EA4709 EA4718 5 2 Potentiometers Rw Q e 2 SN e I Potentiometer Function Turning to the Left Turning to the Right ccw cw Zero Offset motor stands Motor rotates Clockwise rotation Offset still counterclockwise Scale Definition of max number Value is decreased Value is increased of revolutions Gain Gain Factor lowered Factor raised max Set value for max current Upper limit lowered Upper limit raised Set the time constant for Time constant Time constant raised Time ramp or the peak current lowered Potentiometer setting for start up Offset Scale Gain max Time Middle Right stop Middle Middle Left stop 5 3 Dip switches N 77 O O WL GB AN WP WPF Oe ollie S1 1 1 2 Function Mode Off Off Speed Control by Encoder On Off Speed Control by Hall Off On Torque Control On On Open loop PWM Mode ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 22 User Manual EA4709 EA4718 1 3 Off S1 4 Off 51 6 Off Sel val Set val intern Set val extern Phase Phase 120 Phase 60 peak peak Off peak On Enable Enable Off Enable On ElectroCraft powering innovation Methods of entering the set value The internal Offset potentiometer is used Extern
19. ectroCraft powering innovation User Manual EA4709 EA4718 NTC Negative Temperature Coefficient A negative temperature coefficient thermistor is used to detect and protect a motor winding from exceeding its maximum temperature rating it is also used in a servo amplifier Resistance of the device decreases with an increase in temperature Open loop A system in which there is no feedback Motor motion is expected to faithfully follow the input command Stepping motor systems are an example of open loop control Pulse Width Modulation PWM 1 A PWM controller amplifier switches DC supply voltage on and off at fixed frequencies The length of the on off interval or voltage waveform is variable 2 Pulse width modulation PWM describes a switch mode as opposed to linear control technique used in amplifiers and drivers to control motor voltage and current PWM offers greatly improved efficiency compared to linear techniques Regeneration The action during motor braking in which the motor acts as a generator and takes kinetic energy from the load converts it to electrical energy and returns it to the amplifier Resonance Oscillatory behavior caused by mechanical limitations Ringing Is an oscillation of a system following a sudden change in state Speed Describes the linear or rotational velocity of a motor or other object in motion Tachometer A small generator normally used as a rotational speed sens
20. equency is to high use an encoder with a lower resolution No motion even though enable is on e Check power supply and the wiring e Overheating protection is active e Check the polarity of the motor windings and hall signals e Is the phasing 120 or 60 of the hall correct e The polarity of the motor windings or hall signals is permuted e The feedback loop is open Check wiring Over temperature e Use an additional heatsink See accessories e Reset the amplifier Note e Beware that the maximal working temperature of 80 C in the driver is not reached otherwise the drive will be switched off ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 36 User Manual EA4709 EA4718 9 Accessories amp Options Mounting adaptor for Din rail Connecting module Choke modules Heatsink No Fan MA0025 WA2509 IA3100 with 3 x 50 uH and 1A3101 with 3 x 100 uH HA3008 ElectroCraft powering innovation TM e Heatsink 1 Fan HA3018 e Heatsink 2 Fans HA3028 e Shielded CAT5 Cables CA2005 Red 5 CA2010 Red 10 CA2020 Red 20 CA2030 Red 30 CA8005 Yellow 5 CA8010 Yellow 10 CA8020 Yellow 20 CA8030 Yellow 30 CA4005 Grey 9 CA4010 Grey 10 CA4020 Grey 20 CA4030 Grey 30 CA6005 Blue 9 CA6010 Blue 10 CA6020 Blue 20 CA6030 Blue 30 e Braking module ASO BM 70 30 ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 37 ElectroCr
21. ing device The tachometer feeds its signal to a control which adjusts its output to the motor accordingly called closed loop feedback control ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 30 ElectroCraft powering innovation User Manual EA4709 EA4718 Thermal protection A thermal sensing device mounted to the motor to protect it from overheating This is accomplished by disconnecting the motor phases from the drive in an over temperature condition Torque Is a measure of angular force which produces rotational motion This force is defined by a linear force multiplied by a radius e g lb in or Nm Torque is an important parameter of any motion control system Two Quadrants Refers to a motion system which can operate in two quadrants by changing the direction of the motor speed ore in one quadrant with active accelerate and decelerate Watt One horsepower equals 746 watts 7 Description of Inputs and Outputs 7 1 Digital Inputs Enable Activating or Disabling the Output Stage If the Enable input is at GND potential or not wired at all the output stage remains in the locked state The motor stands still or slow down without brake To reactivate the output stage a voltage signal gt 3 5V to the Enable input is necessary If the ramp function is applied as well it will immediately be carried out after the activation of the connector Additional information about the schem
22. le of Contents 1 Safety amp Installation mo 3 2 SSDOCHICallOfiS uuu ua E 4 2285 7107 eu 7 EE dic e 10 5 Explanation of Terminals Dip Switches amp Potentiometers 21 O GOSSA RE 25 7 Description of Inputs and Outputs 31 8 Basic Troubleshooting J 35 9 Accessories amp Options T 37 10 Warranties amp Disclaimers 38 Mtg DIMENSIONS e 39 12 Mounting Din rail adapter 39 Used Symbols Indicates a warning or caution concerning operations that may lead to A death or injury to persons or damage to property if not performed correctly In order to use the drive safely always pay attention to these warnings or operational requirements for a procedure Reading these notes is much Indicates a clarification of an operation or contains additional explanations et recommended ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 2 ElectroCraft powering innovation User Manual EA4709 EA4718 1 Safety amp Installation The EA4709 EA4718 requires installation by qualified personal which must pay attention to significant safety and other regulatory sta
23. m ES s U 3 O A Power supply PBO VDC L Only need in encoder mode Setting of S1 For Enable switch S1 6 from off to on Hall Mode Encoder Mode Torque Mode PWM Mode o Q We Qo A Q x Oe FPF FHF S af ue FEF ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 20 ElectroCraft powering innovation User Manual EA4709 EA4718 5 Explanation of Terminals Dip Switches amp Potentiometers 5 1 Terminals Terminal Label Description S1 1 S1 2 select mode PWM Hall 51 3 change set value to Offset pot Encode S1 Torque S1 4 select the phase of the halls Set val pee i S1 5 select Ipeak on or off Encble S1 6 set switch on enables the drive Power Motor X1 x CND 6 C B A Pin 1 amp 2 connect to power supply Pin 3 amp 4 amp 5 connect to motor Hall A a Enc B Pin 1 amp 2 amp 3 input for hall signals X Hall B D D 4 5V i 4 amp 5 input encoder feedback Hall C 5V Pin 6 amp 7 voltage output 5 VDC Enc AD D snp Pin 8 GND Pin 1 amp 2 input set value Pin 3 input Enable extern Pin 4 amp 5 voltage output 10 VDC Pin 6 voltage input for Error X3 Pin 7 output signal Error Pin 8 GND Pin 1 amp 5 amp 6 amp 7 do not contact Pin 2 voltage output 5 VDC X4 Pin 3 voltage output speed monitor Pin 4 voltage output for current Pin 8 GND X2 X3 XA Pinning of CAT5 conn
24. ndards They should be thoroughly familiar with the entire system before beginning installation Before final operation of machine be sure to test hookup with motor but disconnected from the load Improper wiring could cause a motor run away condition and cause serious injury or damage to the machine and personal Before starting installation of the EA4709 EA4718 be sure that main power is disconnected After powering the drive it should not be touched by hand or risk shock Take care that in case of regeneration or in brake operation the energy recovery must be buffered by the power supply and or a braking module Ensure with electronically stabilized power supplies that protection circuit isn t react Dont switch off the power supply while the motor is turning in this case the drive could be destroyed by regeneration We recommend connecting a capacitor of 1000 uF per each ampere output current close to power input in parallel Do not repair or open drives enclosure Result would result in personal injury and would void all warranties The EA4709 EA4718 comply with the European directive EN61800 3 1996 The followings points must followed e Ametal mounting plate with correct grounding is mandatory e For installation purposes tooth lock washers have to be used e For most wiring schemes only shielded cables are admissible to suppress interference with other devices Damaged items have to be replaced e Pr
25. ode without a speed feedback Brushless motor A Class of motors that operate using electronic commutation of phase currents rather than electromechanical brush type commutation Brushless motors typically have a permanent magnet rotor and a wound stator Commutation Is a term which refers to the action of steering currents or voltages to the proper motor phases so as to produce optimum motor torque In brush type motors commutation is done electromechanically via the brushes and commutator In brushless motors commutation is done by the switching electronics using rotor position information obtained by Hall sensors Hall sensor Is a feedback device which is used in a brushless servo system to provide information for the amplifier to electronically commutate the motor The device uses a magnetized wheel and hall effect sensors to generate the commutation signals ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 27 ElectroCraft powering innovation User Manual EA4709 EA4718 Encoder Is a feedback device which converts mechanical motion into electronic signals The most commonly used rotary encoders output digital pulses corresponding to incremental angular motion For example a 1000 line encoder produces 1000 pulses every mechanical revolution The encoder consists of a glass or metal wheel with alternating transparent and opaque stripes detected by optical sensors to produce the digital
26. on is deactivated if the potentiometer Time is set to the left If the potentiometer set to the right is the ramp time 2s The ramp time defines the increasing time to reach the scheduled value defined by Scale The ramp is active after the drive is enabled also after changing the Set value for both directions The function is linear and works in all modes Time lpeak If this potentiometer set to the left the peak current time is 50 ms is it set to the right the peak current time is 500 ms If set switch S1 6 to on the drive is to be able to deliver a peak current up to the double of value that is defined by max The time for this peak current is adjusted with the potentiometer Time The dead time for the next peak current is 4 times longer than the time of the defined peak current time ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 26 ElectroCraft powering innovation User Manual EA4709 EA4718 Hall mode This is a closed loop speed mode which is using the hall signals as a feedback input for the speed Encoder mode This is a closed loop speed mode that receives the speed information from the encoder The advantage of a better speed regulation is given especially at lower speed Torque mode In this mode the driver controls only the current into the motor The speed of the motor depends on the load because only the output force of the motor is regulated PWM mode A open loop m
27. outputs Back EMF The voltage generated when a permanent magnet motor is rotated This voltage is proportional to motor speed and is present regardless of whether the motor winding s are energized or de energized Closed loop This is broadly applied term relating to any system in which the output is measured and compared to the input The output is then adjusted to reach the desired condition In motion control the term typically describes a system utilizing a velocity and or position transducer to generate correction signals in relation to desired parameters Cogging A term used to describe non uniform angular velocity Cogging appears as jerkiness especially at low speeds Continuous rated current The maximum allowable continuous current a motor can handle without exceeding the motor temperature limits Continuous stall torque Is the amount of torque at zero speed which a motor can continuously deliver without exceeding its thermal rating To determined by applying DC current through two windings with locked rotor while monitoring temperature It s specified with motor windings at maximum rated temperature and 25 C ambient temperature motor mounted to a heat sink Refer to individual specs for heat sink size Controller This term describes a functional block containing an amplifier power supplies and possibly position control electronics for operating a servomotor or step motor ElectroCraft E Mail info electrocraf
28. ovide for a large contact area between shields and mounting plate e The motor has to be grounded in the prescribed manner e The drive is an Electrostatic Sensitive Device ESD Electrostatic discharge needs to be avoided NOTE Certain applications may involve special requirements Consult Factory ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 3 User Manual EA4709 EA4718 2 2 1 Specifications Electrical Data Power Supply Voltage Auxiliary Voltage Input Nominal Current Peak Current Maximum Power only achievable with additional heatsink amp proper mounting See accessories Switching Frequency Efficiency Induction Specification amp caution for low inductance motors Power connector Signal terminals ElectroCraft powering innovation 9 to 70 VDC Residual ripple lt 5 The lower limit is monitored by integrated undervoltage trip WARNING Do not exceed 70V Overvoltage will damage the drive 5 to 30 VDC Supply voltage for the Error output Refer chapter 7 2 9 18 A model dependent 18 36 A model dependent 630 1260 W model dependent 50 kHz 97 96 Optional choke modules are often an economical solution for low inductance or other motors if an overheating situation occurs in regular intervals Contact factory service for details The diameter must be suited for the connecting wires of the current load The recommen
29. s included some different protective functions Over voltage over temperature hall error encoder error and over current are monitored and shown in an error trap with the two LED s at the front side which error has occurred The table is described in chapter 2 7 The under voltage protection switches off the power output stage and reset the complete system The motor starts only by resetting the Enable Important Before resetting an error by resetting the Enable make sure that the cause of the failure is eliminated Motor oscillates e The gain of the servo amplifier is too high Motor runaway e The polarity of the encoder is permuted e No load in torque mode e Reduce the maximal speed with pot Scale e Input frequency of feedback has been exceeded Motor noise e Reduce gain with gain pot e Use additional choke in the motor Motor has no torque e Increase the admissible current with max pot Motor drifts at standstill e Adjust the offset with the offset pot e The input value for the set value isn t stable Motor is going hot e Use an additional choke in series with the motor see accessories ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 35 ElectroCraft powering innovation User Manual EA4709 EA4718 Motor speed too low e Increase the range with pot Scale e Increase the admissible current with max pot e Supply voltage too low e Encoder input fr
30. t com www electrocraft com May 2009 28 ElectroCraft powering innovation User Manual EA4709 EA4718 Demag current Is the current level at which the motor magnets will start to be demagnetized This is an irreversible effect which will alter the motor characteristics and degrade performance Drive Its an electronic device that controls torque speed and or position of an AC or brushless motor Typically a feedback device is mounted in or on the motor for closed loop control of velocity and position Driver Is the electronics which convert step and direction inputs to high power currents and voltages to drive a step motor The step motor driver is analogous to the servomotor amplifier s logic Efficiency The ratio of power output to power input Feedback It is a signal which is transferred from the output back to the input for use in a closed loop system Four quadrants Refers to a motion system which can operate in all four quadrants i e velocity in either direction and torque in either direction This means that the motor can accelerate run and decelerate in either direction Inductance The electrical equivalent to mechanical inertia that is the property of a circuit which has a tendency to resist current flow when no current is flowing and when current is flowing has a tendency to maintain that current flow ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 29 El
31. ull TTL 24 VDC Resistance 50 Ohm Analog 0 10 VDC Resistance 200 Ohm max 20 mA Analog 0 10 VDC Resistance 200 Ohm max 20 mA ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 ElectroCraft powering innovation User Manual EA4709 EA4718 2 6 Control LEDs Power Error LED green Status LED red 2 Status Table State LED green LED red Error Output Reset Reset Selftest Off On Off LOW Normal On Off HIGH Hall error Off Flash 5x s LOW Enable Encoder error Off Long flash 1x s LOW Enable Duty cycle 9096 Overtemperature Off Flash 1x s LOW Enable Current limiter On On HIGH Auto Out of control On Flash 5x s HIGH Auto ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 6 ou3jjewog useJ6 sneg po Slqeu3 eed eseyd anjer jeg c9po N L9polN d d MEIN wae ElectroCraft powering innovation lnpouu jndino Jejibiq c 9jnpouu jndur ey6iq lnpouu jndur jey6iq ma WWOS AS Fa WWOS AG AS j npouu Jopo2u4 gaug 3 B E B e npouu Jo4juo2 ze jnpow UEL pram einpouu indui Bojeuy einpouu jndjno Bo euv LN memi ind JOJON Jewod Hes J lJi duuv ONE mod D LX Ajddns J8Mod yndu Drive Overview Block Diagram cO T N er t LLI O N er t LLI c x d 3 3 1 19IuS H ON 2 c JO1137 no JSAO0d lnpouu JeAup
32. vibration or noise Consequential mechanical damages cannot be excluded furthermore an overtemperature situation may arise due to high currents inside the motor When setting the Gain value during a stop the result most probably will have to be accommodated one more time because the dynamical reaction of the motor at a higher speed will not be sufficient Always remember that this potentiometer does not only act on the gain itself but also on the frequency of the entire control loop ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 25 ElectroCraft powering innovation User Manual EA4709 EA4718 I max The following action requires the motor to be operated with maximum load The motor current may be measured e g using current probe with effective value display or by means of an ammeter located in the motor line max decides on the maximum possible motor current The following limits have to be observed Left stop 5 96 of rated current of 09A 18 A model dependent Right stop 100 96 of rated current 0 10 96 Note Do not overheat the motor For this reason the max limit should always be selected lower than the maximum admissible constant current Time This potentiometer has two different properties e f peak 81 5 off the potentiometer is setting the ramp time e f peak 81 5 on the potentiometer is setting the peak current time Time Hamp The ramp functi
33. wering innovation User Manual EA4709 EA4718 4 1 1 Adjustment procedure for Hall mode 1 Potentiometer pre setting refer chapter 5 2 2 Choose the maximum set value e g 10 V Turn the potentiometer Scale until the desired maximum speed is reached If the red LED is flashing 5x s the maximum speed is reached depending on the supply voltage Then reduce the Scale potentiometer slightly till the red LED is lit off 3 Adjust the current limiter to a value requested by you with the max potentiometer It is of major importance that this value is lower than the maximum admissible constant current see motor data sheet To measure the motor current use a current probe in one of the motor cables with a oscilloscope or a multimeter If the red LED is lit the current limitation is activated 4 Slowly raise the value of the Gain potentiometer If the motor begins to work unsteadily to vibrate or to cause excessive noise carefully lower the gain factor again until the instability symptoms have disappeared for all load selections 5 Set the set value to zero and adjust the Offset potentiometer to the standstill of the motor 6 The ramp function is deactivated if the potentiometer Time is set to the left ElectroCraft E Mail info electrocraft com www electrocraft com May 2009 12 ElectroCraft powering innovation User Manual EA4709 EA4718 4 2 Wiring Example Il Encoder Mode X3 gr Power Error 4 Q Servo

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