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USER MANUAL: - Allied Motion

1. ccccccseeeeessesesesesssseseseeeeeessseseeseeeeeeeeeeees 36 5 9 Soi DA EEE 38 540 Toning the Current LOOP srera n nea Die oeaiei 40 SJ L Current Compensator LOOP ssrsisr ireann EE n rE OEE ERIRE NER TERA EN ARAE 40 TEL BT 41 5 10 3 Calculating Filter Coefficients rrrrrrrrrrrrrrrrrrrrrrrrrnrrrrrsrrrrrsrrsrsrssrsrssssssrssssssssssssnne 41 TL TN 45 5 11 1 Velocity Compensator Loop rrrrnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 45 511 2 Bm 46 5 11 3 Calculating Filter Coefficients rrrrrrrrrrrrrrrrrrrrrrrrrrrrrererrrrnrrnrrrnnnrnrnrnnnnnnnnnnnnnnennee 46 ER ED Go EEE 50 5 13 Viewing and Configuring Faults rrrorrrrrrrrrrrrrrrrnrrrrrrnrnrnrnrrnnrnrrnnnnrnrnrrrrrrrrrrrnrrrrnnnsnnnnns 51 5 14 Deploying DPFlex Applications rrrrrrrrrrrnrrrrrrnrrnnnrnrrrnnnnnnnnrnnnrrnnnnnrnrnnrnrnrnrnnsnssrssnnnnnssnns 52 Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 3 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive This manual describes the installation and operation of the DPFlex sensorless brushless DC motor drive manufactured by Allied Motion Technologies Every effort has been made to ensure the accuracy of the information in this manual However Allied Motion assumes no responsibility for any errors or omissions The information contained in this document is subject to change without prior notice We welcome your crit
2. Figure A 1 DPFlex PCB dimensions In addition to the clearance requirement on the edge of the PCB board there is a minimum supporting outer edge requirement that is necessary for proper mechanical support of the assembly Failure to include this edge may lead to additional stresses being placed on the PCB which could cause component failures A maximum of 0 635mm 0 025in supporting edge must extend underneath the PCB starting from the nominal board edge location This edge must not extend any further under the PCB or risk of an electrical short may occur and minimum creepage and clearance specifications may be breached for specified regulatory agencies Please refer to Figure A 2 for details on edge dimensions and tolerances Note that the supporting edge requirement is optional for the two edges that are perpendicular to the connector side edge of the PCB so the use of an economical extrusion can be used to decrease manufacturing costs if desired Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 58 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive M ar mr 1 ENE LL OAJ JH 4 Q E35mrm MAX LET TIL ATT F Didin MN F B Edge for supporting FCB latim MRI ail H FANN Ari k i Thermally Conductive Mounfing Surface Figure A 2 DPFlex PCB edge dimensions and tolerances Because the primary reason for providing a mounting surface is to give an adequate path for heat removal from
3. Phase A rd e mme f i N Phase B i i 7 G fam F Phase C f SL 0 60 170 180 740 300 360 Electrical Degrees Figure 1 Six Step Commutation Phase Current amp Back EMF Diagram Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 11 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 2 3 Sensorless Six step Commutation Once the shaft of the motor is spinning sufficiently fast the induced back emf speed voltage caused by the time varying magnetic flux linking the stator windings can be measured by the drive The magnetic flux is produced from the permanent magnets contained in the rotor It is possible to use this information to commutate the motor without any other position feedback information This is what is meant by the term sensorless it is the absence of any physical position feedback devices in the motor For trapezoidal commutation only two coils of the three motor coils are energized at any one time The coils that are energized are the two that yield the maximum developed electromagnetic torque For a Y WYE connected motor the third coil is off and the speed voltage can be sensed at its phase terminal Each of the three coils is energized ON for 120 electrical degrees and is then de energized OFF for 60 electrical degrees This pattern is repeated again and again every 180 electrical degrees and the current is switched in direction each 180
4. and other application parameters DP D enables you to create and store multiple configurations To create a configuration Click Start gt Programs gt Allied Motion gt DP D DP D opens the navigation tree ioj xi File View Tools Help To create a new configuration e In the navigation tree double click System DP D displays the Interact form which lists defined connections mr ox Connections Add Delete Propet lice as e Choose Add DP D displays the Connection Info form e Ifthe port to which the DPFlex controller is connected is not displayed in the Port drop down list choose Scan Ports DP D scans the PC for serial ports or the USB to serial adapter e Ifthe USB port does not appear in the list check the following items and re scan Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 36 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive That the USB to serial driver is installed That the USB to serial cables are properly connected e In the Port drop down list choose the port to which the DPFlex controller is connected Connection Info E x Serial Fort Virtual Scan Forts Part Communications Port COM1 Communications Port COM CP210x USB to UART Bridge Controller COME panel e Choose Test to confirm the connection to the controller is working e Ifthe test fails check the following items and re
5. gt DPFlex Port gt Registers DP D displays the Registers form x Auto Start Update Registers to Flash Update Registers Save Registers to File from Flash Save Register Load Registers from File to Flash Load Registers Figure 21 DP D Registers form e Choose Update Registers DP D saves the current configuration parameters into the drive s non volatile memory e Click to close the Registers form 5 10 Tuning the Current Loop Once you have configured DPFlex for the target motor you can tune the current loop for the application A well tuned current loop is the first step to acceptable velocity and torque control Without proper current tuning satisfactory velocity and torque control cannot be achieved 5 10 1 Current Compensator Loop The current loop is a control loop inside the velocity loop which ensures the desired current setpoint is achieved and maintained Refer to the block diagram shown in Figure 22 below Except for the plant the motor and its load all of the blocks are parts of the drive For the sake of simplicity the plant is just an R L transfer function of a BLDC motor In the control loops two main tasks must be achieved Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 40 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Keeping the output in this case current in the motor coil as close as possible to the input
6. in this case a current setpoint This is called steady state response Proper response to the change in the setpoint This is called dynamic response To achieve these two goals a second order infinite impulse response filter biquad compensator is used to approximate a classic PID control loop Discrete Foer Competsa tor converte Plant Input jur m O Gutput sae a Te we JJ EN y ea ar i i Sensor S Figure 22 Current loop block diagram 5 10 2 Biquad Compensator A classic PID control loop can be approximated in the discrete time domain by a 2nd order IIR filter with the following z domain transfer function v z Bg B JE hz Diz 5 y KIZ 1 A 2 Age Which has the following block diagram Figure 23 Biquad filter structure 5 10 3 Calculating Filter Coefficients DP D automatically calculates the biquad filter coefficients Bn and An from the on screen representation gains Kp Ki and Kd Biquad coefficients are values described in Q1 15 format with exponent value Most good digital signal processing texts contain a description of the Q1 15 numerical format The transfer function of the PID compensator in the s domain is Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 41 of 64 Pied Motion DPFlex Sensorless Brushless Motor Drive PID a SE kp kes 2 e To find out how PID gains are related to Biquad gain
7. 11 2 Biquad Compensator A classic PID control loop can be approximated in the discrete time domain by a 2nd order IIR filter with the following z domain transfer function 2 v z Bg B ee baz Diz lt Which has the block diagram Xin wN vin T le ad Y A 1 2 ON fa y 1 2 pl lt Figure 28 Biquad filter structure 5 11 3 Calculating Filter Coefficients DP D automatically calculates the biquad filter coefficients Bn and An from the on screen representation gains Kp Ki and Kd Biquad coefficients are values described in Q1 15 format with exponent value Most good digital signal processing texts contain a description of the Q1 15 numerical format The transfer function of the PID compensator in the s domain is VIs k pirga a ep ee 2 Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 46 of 64 DPFlex Sensorless Brushless Motor Drive Pied Motion 5 To find out how PID gains are related to Biquad gains let s assume that 7271 which is an approximation of the bilinear transformation Then by substituting z in 2 apa ko ski shale kp aka ekaj xiz 1 3 3 and by comparing 1 and 3 BESE 4 m f 5 Bo k tki k a 6 Bj k 2k q 7 2 8 Equations 4 through 8 show how each of the 5 biquad filter coefficients are calculated from the screen PID representation in DP D To tune the velocity loo
8. Additional Information Document Title Edition or Date of issue Notified Body Certificate of Conformity Technology International Inc Documentation supporting this Declaration and the Notified Body Certificate of Conformity is kept on file at the Headquarters location listed above Issued at Waterloo Ontario Canada yy mmm dd Place Date Signature Name Title Function Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 64 of 64
9. Motor Phase B pin J6 Motor Phase C pin J7 The other ends connect to the corresponding motor phases The DPFlex USB to UART Communication Cable Kit part number 10 0099 connects the drive to a USB port on a PC It includes the following cables e A 6 foot USB A to B Cable part number 40 0098 e A USB UART adapter cable part number 40 0094 Note You can make your own cables For details see Making Cables for DPFlex Drives 4 4 3 Connecting DPFlex to a PC 1 Plug one end of the USB A to B cable into the USB port of the USB UART adapter cable 2 Plug the free end of the USB A to B cable into a USB port on the PC Note If you did not install the USB to serial driver when you installed DP D the PC will launch a device driver install wizard when it detects the adapter cable Use the wizard to install the driver from the driver directory on the DP D CD 3 Plug the free end of the adapter cable into the serial communications connector on the DPFlex drive Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 24 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive Power connector pins Motor connector pins UART Connector Analog amp Digital Inputs connectors Enable pin Figure 11 DPFlex connector locations 4 44 Connecting DPFlex to power 1 Plug the power cable into DPFlex s power connector 2 Wire the other end of the power cable to your power supp
10. Registers from File to Flash Load Registers e Choose Update Registers DP D saves the current configuration parameters into the drive s non volatile memory e Click to close the Registers form To save configuration parameters to a file e Inthe DP D navigation tree choose System gt DPFlex Port gt Registers DP D displays the Registers form Registers DPFlex1 COM4 x Start on Enable Input v Update Registers Save Registers to File from Flash Save Registers m Load Registers from File to Flash Load Registers e Choose Save Registers DP D opens a browser Update Registers to Flash j e Select the path and file name and choose Save e Click to close the Registers form Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 53 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive To load configuration parameters from a file into DPFlex s non volatile memo e Inthe DP D navigation tree choose System gt DPFlex Port gt Registers DP D displays the Registers form Registers DPFlex1 COM4 xj Start on Enable Input v Fixed Torque 4 30 00 Update Registers m Save Registers to File from Flash Save Registers Update Registers to Flash Load Registers from File to Flash Load Registers e Choose Load Registers DP D opens a browser e Select the path
11. Up DEPRE oie aE a E a 20 4 1 As Ans tbe SOLU WIG enea aa eee dende 20 4 2 Installation Requremensaauvv v lt vecacmmvnssssoreooaansnnaanda sementere 20 4 3 Using the ee ee OD eee ete nee emt ee ent mene ee ne ene EER ne 20 4 4 Connectme the DPV ex DE ancuei e EEAO E 23 271 VU 23 4 42 Connecting DPFlex with the Cable Kit rrrrrrrrrrrrrrrrrnrrrrrrrrnrnrnnnnnnnnnrrrrrsrrsrrsrsrsssnn 24 AAS DNO cease nn A E nas sass sane 24 444 Connecting DPEICK to POW el sscesiecescvoncessseetacessvsiedsaicaneannhestadwascardenateanatenstanecvabortadends 25 4 4 5 Connecting DPFlex to a motor rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrsrsrrrrsrssrssssssnssssnsnns 25 4 5 Making Cables for DPFlex Drives sicicsscoveseauaersseusquucieinaansesasiansssarncasivaoxcegenesesstiueciansenee 25 S Prom DK NON 28 5 1 Developing DPFlex A ppleatdns nrare4raaserassassamendnmmemb nlnnminind ie 28 5 1 1 Steps To Develop a DPFlex Application rrrrnooooooonooonnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 28 52 Usm DP D rirerire E EE NEERA EN EE E O 28 5 3 PTO LO Nyce E A 28 5 4 Using the DP D Navigation 1S S ceo aedcceec orccceneosecemeeoteataneetducmesenecteneoancneencneoianeoitesnencnacts 29 5 5 Using DPFlex s Det Oscilloscope vvs 31 Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 2 of 64 tilied Motion DPFlex Sensorless Brushless Motor Drive Mange no SW Saran E N 35 5 7 i JE 35 5 8 Creating and Managing Configurations
12. a browser Select a path and file name for the configurations and choose Save e Ifyou want to discard the current configurations choose No e Ifyou want to cancel the creation of the new configurations choose Cancel To open a set of configurations e Choose File gt Open DP D displays a browser e Select a path and file name for the configurations and choose Open 5 9 Configuring DPFlex You configure DPFlex by setting motor parameters and running the configuration tool After the tool has finished you can save the configuration parameters to the controller s non volatile memory so that they are not lost if the controller loses power To set motor parameters e Inthe DP D navigation tree double click System gt DPFlex Port gt Motor DP D displays the Motor parameters form Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 38 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive x Motor Type Motor Settings Number of Pole Pairs 0 pairs Motor Peak Curent 0 00 A Motor Venficaton Tool M Automatically calculate current loop gaire Use 7000 se of motor peak currert Figure 20 Motor parameters form e From the motor s data sheet set the following parameters To set this parameter take this action Number of Pole Pairs Enter the number of pairs Motor Peak Current Enter the number of Amperes e Choose Apply to update the motor paramet
13. alliedmotion com March 29 2012 Version R1 Page 51 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e Click to close the Faults form To view the operational status of the drive and motor e Inthe Faults form choose the Status tab Faults DPFlex1 COM4 x Status Corfigure A Refresh Clear Faults e Check the current status Choose Refresh to update the display with the current status Choose Clear Faults to clear the display and update the status e Click to close the Faults form 5 14 Deploying DPFlex Applications At any time during application development you can update a connected DPFlex drive s non volatile memory with the current configuration parameters You can also save DPFlex configuration parameters to a file and load these parameters into a connected DPFlex drive s non volatile memory You can also define in which mode to run the motor when the drive powers up Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 52 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive To update DPFlex with the current configuration parameters e Inthe DP D navigation tree choose System gt DPFlex Port gt Registers DP D displays the Registers form Registers DPFlex1 COM4 x Start on Enable Input v Update Registers to Flash Update Registers Save Registers to File from Flash i Save Registers Load
14. and file name and choose Open DP D loads the parameters into the drive s non volatile memory e Click to close the Registers form To set the drive to Auto Start or Start on Enable Input e Inthe DP D navigation tree choose System gt DPFlex Port gt Registers DP D displays the Registers form Registers DPFlex1 COM4 i x Start on Enable Input v m Update Registers to Flash Update Registers Save Registers to File from Flash j Save Registers Load Registers from File to Flash Load Registers Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 54 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive e Select Auto Start or Start on Enable Input from the first drop down list box Registers DPFlex1 COM4 maset v Start on Enable Input Fixed Torque al 30 00 Update Registers to Flash Update Registers Save Registers to File from Flash Save Registers Load Registers from File to Flash Load Registers e Select from one of four motor start up parameter from the second drop down list box DP D displays the motor start up parameters drop down list box Registers DPFlex1 COM4 i x Start on Enable Input v Startup with fixed torque setpoint v Start up with analog input velocity setpoint Start up with fired velocity setpoint Start up with analog input lorgue setpoint Start up with fixed
15. degree segment The speed voltage induced in the OFF phase undergoes a polarity reversal during the time the phase is OFF The bias voltage is the voltage of the neutral point of the WYE connection Ideally the drive should shut OFF a coil as the induced speed voltage across that coil is undergoing a polarity reversal The coil should then be re energized once the voltage has changed polarity and that coil can contribute to torque production In order to do this the controller samples the voltage of the OFF phase once the current in that phase has dropped to zero Once it detects that the rotor flux is generating a speed voltage of the proper polarity it shuts OFF the coil that is just beginning to go through this voltage reversal process and energizes the one that just finished this process The drive uses a physical constant of the motor in order to assess when the time is appropriate The motor constant related to the volts per rpm Ke of the motor is used to calculate how much flux there is per pole By integrating the induced speed voltage in the OFF phase and waiting for the proper amount of flux to accumulate the drive can commutate at the appropriate time Since this is a motor constant it is speed independent and it is applicable at all speeds at which the back emf of the motor can be detected by the drive Figure 2 Six Step Commutation Sequence Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page
16. driver e In the installation utility choose Install USB to serial Driver The installation utility launches the driver installation wizard 5 DP D v10 84 ER sitatic E gt sik Swf a _ PAR es The installer will install DP D v10 84 to the following folder To install in this folder click Next To install to a different folder enter it below or click Browse Folder C Program Files x86 Allied Motion Canada Inc DP D v10 84 Browse Disk Cost Install DP D v10 84 for yourself or for anyone who uses this computer Everyone C Justme The installer is ready to install DP D v10 84 on your computer Click Next to start the installation Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 22 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e Choose Next to install the driver or Cancel to abort the operation DP D v10 84 has been successfully installed Click Close to exit 4 4 Connecting the DPFlex Drive To use the DPFlex drive in an application you must connect it to power and to a motor To configure DPFlex and to monitor its performance you must also connect it to a PC 4 4 1 DPFlex safety To ensure safe operation of DPFlex your application must meet the following requirements CAUTION Failure to comply with the requirements listed below may create an electrical hazard in y
17. is used it is highly recommended that a pre charge circuit be used to limit the inrush current required to charge this capacitance The limiting resistor should then be shorted out using a relay or other appropriate means If not using the DPFlex aluminum cover an alternative enclosure providing similar or better attenuation between 30 MHz and 1 GHz must be used Use of this product in environments other than those defined as EN 55011 Class A may require the user to apply additional EM suppression techniques to meet the EMC requirements of the final installation environment NOTE This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense This ISM device complies with Canadian ICES 001 Cet appareil ISM est conforme la norme NMB 001 du Canada Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 62 of 64 Pied Moti
18. points to plot The trigger settings enable you to specify the timing and type of trigger The cursor position indicators show the coordinates of the current cursor position To use the tool bar Clicking on buttons in the tool bar performs the actions listed in the table below Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 32 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Choose button to perform this action Zoom in on the selected segment of the graph Zoom out of the selected segment of the graph Rescale the display to the input signals range Show or hide the cursor Open an oscilloscope configuration Save the current oscilloscope configuration Print the captured data points Copy all captured data points to the clipboard Display inputs as graphs Display inputs in a table Display scaled data gare Position the cursor on the selected input Zoom out on the graph to show all captured data points anand Table 8 DP D oscilloscope tool bar buttons To view or change a channel s settings e Click the channel s settings button Ts Drive Current Setpoint Sid DFFes1 COM 4 e DP D displays the channel settings form Channel Settings x Controller ss To Log 4xis Register To Log D waite Current Setpoint fe Avis Velocity Actual Velocity Setpoint Cancel Figure 17 Channel settings form e Choose Ax
19. test That the communication cables are properly connected That the DPFlex controller is powered e Choose OK to accept the connection or Cancel to abort the operation The Interact form now lists the connection to the controller Interact ae Connections COM4 Enabled Delete Properties OF Cancel e Choose OK to accept the controller connection configuration or Cancel to abort the operation DP D updates the navigation tree for the new configuration pr D dpe DPD 51 x File View Tools Help A DPFIex1 COM H A Stimulus Tools Motor Current Compensator Velocity Compensator Inputs i Faults i Registers Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 37 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive To save the current configurations e Choose File gt Save If you have not previously saved the configurations DP D displays a browser e Select a path and file name for the configurations and choose Save To save the current configurations to a different file e Choose File gt Save As DP D displays a browser e Select a path and file name for the configurations and choose Save To create a new set of configurations e Choose File gt New If you have not previously saved the current configurations DP D prompts you to save or discard them e Ifyou want to save the current configurations Choose Yes DP D displays
20. the PCB the surface directly beneath the power semiconductors located between the two mounting hole locations must maintain flatness and spatial dimensional as listed in the figures listed in this document Please refer to Figure A 3 for these details Failure to meet the flatness specification will lead to a poor thermal heat transfer out of the PCB and may lead to premature shutdowns of the drive or complete failure of the assembly Adequate thermally conductive material beneath the drive is essential for proper operation of the product Failing to provide either increased surface area capable of dissipating the maximum expected power dissipation or a sufficient bulk thermally conductive material will require the de rating of the DPFlex for reliable operation Please refer to the power dissipation curve for the product assembly that the mounting surface is being designed for Please note that the recommended minimum thermal area is only for meeting the thermal transfer requirements This surface can be extended to the outer edges of the PCB along the centerline of the mounting holes If this extension is made the thermal interface material will need to be extended to those additional areas as well Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 59 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Thermal Interface Surface must comply with flatness and surface finish specifications FLAT O 0
21. the maximum and minimum velocity pulse stimulus to percentages of the value you set in Maximum Velocity Set the frequency of the velocity pulse stimulus In the Frequency field or using the matching slider enter the frequency of the velocity pulse stimulus Start or stop the motor Choose Start or Stop e Inthe Velocity stimulus form choose Start to apply the velocity setpoints to the motor e In the Oscilloscope form choose Auto to start triggering Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 49 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive After a few seconds the Oscilloscope form will display the velocity stimulus setpoints and the actual velocity of the motor Ex H aaf na 1 EN EEE Time based sampling Time Base Trigger Settings 100ms On ve Stimulus Ed T Drive Velocity Actual l DPFIex COM 4 ee Ta 3 a LG ra beak 2 lms 105 20 00 me Div Position of 200 me You can vary the settings in the Velocity stimulus form to see how it affects the actual velocity achieved by the motor e In the Oscilloscope form choose Auto to stop triggering e Inthe Velocity stimulus form choose Stop to stop the motor 5 12 Viewing DPFlex Inputs When DPFlex is connected to a PC you can use DP D to check the signals at the input pins Note that while you are checking the inputs with DP D the drive is disabled
22. to see how it affects the current the motor draws Inthe Oscilloscope form choose Auto to stop triggering Inthe Current stimulus form choose Stop to cut current to the motor 5 11 Tuning the Velocity Loop Once you have configured DPFlex for the target motor you can tune the velocity loop for the application 5 11 1 Velocity Compensator Loop The velocity loop ensures the desired velocity setpoint is achieved and maintained Refer to the block diagram in Figure 27 below Except for the plant a motor and its load all of the blocks are parts of the drive For the sake of simplicity the plant is just an R L transfer function of a DC motor In the control loops two main tasks must be achieved Keeping the output in this case velocity of the motor as close as possible to the input in this case a velocity setpoint This is called steady state response Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 45 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Proper response to the change in the setpoint This is called dynamic response To achieve these two goals a second order infinite impulse response filter biquad compensator is used to approximate a classic PID control loop Discrete Power Conpensa tor converte Plant Input Output pi jp guad we bl pa Lp r aks r i il oe Sensor A B 5 Figure 27 Velocity loop block diagram 5
23. 04 1IN OVERALL MAX 0 012 SURFACE FINISH 3RMS or BETTER DSO MAM 83 90 eri MN 23 W432 OF M3 5 metriz Tapped Hole Tas mea represents the smallest recommended sutaze RA for mounting the DPFlex against 2 4D0mim AIM F oe aP Laim fall ST lare aii Figure A 3 DPFlex PCB mounting surface considerations In addition to observing the constraints on the mechanical clearances and interface surfaces as explained above it is necessary to use a thermally conductive electrically isolating interface material inserted between the PCB located at the specified thermal transfer surface underneath the PCB and a compression clip to guarantee proper operation of the DPFlex The thermal interface material must be selected to have a low thermal resistance while filling in all voids between the mounting surface and the PCB and providing 1100VDC of electrical isolation Allied Motion recommends using the Berquist GAP PAD GPVOS 0 020 AC 0 5mm 0 02in thick thermal interface material The material must extend pass the mounting surface by a minimum of 1 27mm 0 05in or the PCB edge whichever is less to ensure that no contact will occur between the PCB traces and the thermally conductive mounting surface The thermal interface material should provide close fit clearance holes for the mounting screws to allow sufficient insulation material around those locations Once the thermal interface material has been installed a compression clip mu
24. 12 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 2 4 Special Considerations for Sensorless Commutation During the process of commutation current in one phase must drop to zero and be transferred to the phase that is just coming ON Because of the fact that the coils are not mutually coupled 100 and that each coil has its own leakage reactance there will be a portion of time albeit brief where all three coils have current in them During this period of time an accurate back EMF or speed voltage cannot be obtained from the voltage sense circuit on the controller Immediately after commutation the drive will shut OFF the phase voltage and wait until it determines that an accurate back EMF signal can be obtained from the analog input dedicated to BEMF sensing in the OFF phase It is only after this has been successfully detected that the drive will begin to use the measured speed voltage for commutation purposes Since DPF lex itself monitors the speed voltage feedback and activates the back EMF sensing itself there is no parameter associated with the coil coil current transfer 2 5 Sensorless Startup As the back EMF is proportional to speed a sensorless controller needs a means of finding the initial rotor position in order to start the motor and accelerate it to sufficient speed to be able to detect the back EMF voltage Startup is undoubtedly the biggest hurdle any sensorless control algorithm must overcome Conventi
25. Allied Motion Technologies Inc Piked 455 Commerce Drive Suite 5 Amherst NY 14228 dled Motion gr a USER MANUAL DPFlex Sensorless Brushless Motor Drive Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 1 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Contents LL e i PN 5 TL GUTS E E E A EOE I EEE OEA E E EO OA E E A 6 MN EEA A ITE EAEE E S E SEREIS E E EE ATA 7 Iy AS PCCIIOM npon RKeCeip issiria EA AE EA S 8 1 h ve MIN Gar 9 1 1 VDA oE A A OAE E OAOA NE 9 1 2 Rv 9 1 3 DP FICK Evaluation Kis viiscsarscscnssarsvacaventnacsaasvadsoventesdanetsinsananiutinyarsadbadeoasatsacssainvsasvasawec 10 2 Sensorless Drive Technology sccccecchcasccsceasacecusvacecetscacuessas execs tvcaneseenasvecenseasssvavaeeeestevasesasoasecseseuss 11 2 1 Understanding Commutation and DPFIex rrrrrrrornnnnrnrrrnrrrnrsrnrsrrnsnsrssrssnsssssssssssrsssssssne 11 AD Six Step or Trapezoidal Commutation rrrrrrrrrrrrrnnrnrrnnrrnnrnrrnnrnrnnnnrrnnrnrnnsrnnrnrnsnnnsnsssne 1 2 3 Sensorless Six step Commutation cccccccccccccssccceccsccesecccscsccccsscssscsacccsecccseeeeecceaeeeees 12 2 4 Special Considerations for Sensorless Commutat10n rrrrrrrrrrrnrrrnnnnrnrrrrrnrnnrrrrsnssssnn 13 2 5 ML 13 SED GLED EE E E 14 3 1 PIN ee nn cee eee ee en neers ee 14 a I Ge E AEE 17 3 3 PD 17 3 4 PI ve 18 3 5 DPFlex Power Dissipation sanavvavqeqcsaqsasemeaammaaeremnemmmsitmmnee 18 d Sene
26. Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 50 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive To monitor DPFlex inputs e In DP D s navigation tree double click Inputs DP D displays the Inputs form Inputs DPFlex1 COM4 E x Digital Input Analog Input One Ege rv Input One Input Two g Figure 32 DP D Inputs form The Digital Input One and Digital Input Two indicators turns ON when signal voltage is applied across the corresponding inputs The Analog Input One indicator shows the percentage of input voltage across the analog input Click to close the Inputs form 5 13 Viewing and Configuring Faults DP D enables you to view and configure faults while the DPFlex drive is running To view and configure fault thresholds e In DP D s navigation tree double click Faults DP D displays the Faults form Faults DPFlex1 COM4 E x Status Configure Temperature Wam when temperature exceeds OG Shut down when temperature reaches 90 C Current Wam when the curent exceeds f 31 50 4 Shut down when the curer reaches 24 50 Voltage Wam when the voltage exceeds f 31 Shut down when the voltage reaches AV Figure 33 DP D Faults form e Set the thresholds by entering values for temperature current and voltage in degrees Celsius amperes and volts respectively e Choose Apply Allied Motion Technologies Inc www
27. D 35 Figure 19 DP D About ScreGisssinesrsscrina anden 36 Figure 20 Motor parameters TOP Luunnsenmseivsdnndnenmniesnmnugensgeiedandennadesrege 39 Mr TTPDR ESN 40 Figure 22 Current loop block diagram rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrsrrrrsrrnsssnnnnne 41 Figure 23 Biquad filter MATE Lara 41 Figure 24 Current Compensator form rrrnnnnnnnnnnnrnnnnnnnrvrrnnnnnnnnnnnnnnnnnsssnnnnnnnnns 42 Figure 25 DP D Oscilloscope and Current stimulus forms rrrrrrrrrrrrnnnnnnnnnn 43 Figure 26 Current stimulus form rrrrrrrrvrrrrrrrrrrsrsrrnnnnnnnnnrrrrrrnnnnnnnsrssssssrrnnnnnnnnnns 43 Figure 27 Velocity loop block diagram rrrnrnnnnnnnnrrrvrrvnnvvvnrrrrrsrrsrnnnnnnnnrrrvrnnsssee 46 Figaro 28 Biguad ME ae 46 Figure 29 Velocity Compensator form rrrnnnnnnnnnnrrrvvrrnnnvnrrrrnnrrrnrnnnnnnnnnnvvvnnsssee 47 Figure 30 DP D Oscilloscope and Velocity stimulus forms 48 Figure 31 Velocity stimulus form rrrrrrrrrrrrrrrrrrrrrnnnnnnnnnrrrvrvrnnnnnrrrrssssssrnnnnnnnnnns 48 Ube ET EEE SE SA 51 Allied Motion Technologies Inc si iW www alliedmotion com March 29 2012 Version R1 Page 6 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive lll Safety Read all provided documentation before assembly and commissioning Failure or incorrect or improper use of this equipment can cause death personal injury and consequential damage Allied Motion disclaims any responsibility for such occurrence wh
28. Pulse r Control Source Host C Analog Input Stop m Start Pulse amplitude sliders Pulse frequency slider Direction Frequency Eros iHz I s srny oon 10mHz 100mHz 1Hz 10Hz 100Hz Figure 31 Velocity stimulus form e Inthe Velocity stimulus form Choose Pulse Set the desired values for starting current maximum velocity maximum and minimum velocity setpoints and velocity pulse stimulus frequency Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 48 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive To do this take this action Set the starting current In Starting Current enter the starting current in Amps The starting current is the current needed to move the motor from an a standing still position This current has to be sufficient to generate enough torque to overcome the static inertia of the motor plus the load Set the maximum velocity In Maximum Velocity enter the maximum permitted velocity in revolutions minute Control the velocity from DP D In Control Mode choose Host Control the velocity from an external analog input In Control Mode choose Analog Input Set the type of stimulus Choose DC for a constant velocity stimulus or Pulse for a varying velocity stimulus Set the range of the velocity pulse stimulus In the Maximum and Minimum fields or using their matching sliders enter
29. conveyors office and medical equipment automotive subsystems and many others 1 2 DPFlex Components The DPFlex product family includes the following components e The DPFlex drive Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 9 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e The DP D software for Microsoft Windows 2000 XP Vista 7 e Cables and connectors for connecting a DPFlex drive to power motor and e A personal computer e This user manual 1 3 DPFlex Evaluation Kits Allied Motion offers DPFlex evaluation kits that contain all the components you need to design and test the DPFlex in your application Contact us for more information Voltage Current Part Number 16V 30A 11 F0012 30 16 V 15A 11 F0012 15 Table 1 DPFlex Evaluation Kits DPFlex Drive 16 V Maximum 30A 10 F0012 30 15A 10 F0012 15 10A 10 FO012 10 DPFlex Drive 30 V Maximum 30A 10 F0024 30 15A 10 F0024 15 10A 10 F0024 10 Table 2 DPFlex Evaluation Kit Contents Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 10 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 2 Sensorless Drive Technology 2 1 Understanding Commutation and DPFlex Controlling current in a motor to produce torque is called commutation Torque in an electric motor is the interaction between two magnetic fields one from a rotor and the other one from a stator These two ma
30. d Frequency Direction 1H ee ee Tt OT ee mi H tombe 100mhz THe 10H2 100H2 Velocity Compensator DPHlex1 COM4 I Velocity Gains K f 0000 lt f ooo Kaf ooo 4 Tuning Tools Apply x Drive Velocity Setpoint Time Dased samping Zj DPFlex1 COM4 Time Base Trigger Settings i 71 50ms on ve Stimulus Ede Drive Velocity Actual owh st DPFlex1 COM4 ins J 5C0ms SJ x Position of 100 ms ca NONE 40 50 g0 4 S00us 30 f A i j 10 00 ms Div EM SS Datalog R p J i Rate 1 00 ms Y 0 ic Manual Trigger Single Auto Points 100 0 00 me Figure 30 DP D Oscilloscope and Velocity stimulus forms Tip You can arrange the forms as you like and save their positions using the View gt Save Windows command You can restore the forms to their saved positions at any time including the next time you run DP D with the View gt Restore Windows command Note that DP D automatically sets the controls and fields in the Oscilloscope and Velocity stimulus forms to default values appropriate for tuning the velocity loop The Velocity stimulus form enables you to vary the velocity stimulus to the motor x Velocity DPHex1 COM4 Axis1 1 m Starting Current 350 A Maximum 100 60 00 m Maximum Velocity J 2500 RPM m Actual Velocity oc g 0 00
31. drive disconnect it from the computer and restore power to the drive to start using the auto start function Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 56 of 64 Pified Motion DPF Sensores Brustiess Motor Drive Appendix A Mounting Guidelines for Stand Alone DPFlex Controller PCB Assembly A 1 Introduction DPFlex is a fully operational sensorless BLDC motor controller that requires a functional heatsink to realize the full product power rating This document has been written to provide guidance to OEM designers who desire to incorporate the DPFlex controller within packaging of their own design so that the product will achieve maximum mechanical robustness and greatest electrical performance The section is organized into two sections that focus on the mechanical clearances and the electrically insulated thermally conductive interface A 1 1 Mechanical Integration The DPFlex BLDC sensorless controller assembly has been designed to allow OEM installation of the controller with minimum skilled technical involvement There are three items to be aware of during the design of the mounting surface for the PCB assembly e Mechanical clearance between the printed circuit board PCB and surrounding areas must be checked to ensure that interferences do not occur at maximum PCB tolerances as this might induce unexpected stresses on the PCB that could affect component reliability e Mechanical clearanc
32. e 5 4 Refer to schematic shown in Figure 6 Allied Motion Technologies Inc March 29 2012 Version R1 www alliedmotion com Page 14 of 64 Pied Motion DPFlex Sensorless Brushless Motor Drive CMPD7000 02 naii IN IA RO 13 1211 SF mana om i Inside the DPFlex drive g DIN 18 Ermit m i R12 Digital Input 1 i D4 14 sw De O41 12k1 3V3 3v3 Supply Ground d pin JVB EEE PWR_GNO Figure 3 Connecting passive circuit to enable line DI 1 p m ne R18 R19 I D IN i Ur 1K 1K RAB Digital Input 2 2 pin J1 5 a 0 01uF i 12k1 12k1 i i aus i i Supply Ground pin JAB Inside the DPFlex drive PWR GND i eee Figure 4 Digital input 2 motor direction circuitry Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 15 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive BATDC R4 ih 475R Q1 R8 12k1 ost dd a D3 Inside the DPFlex drive PWR_GND a Digital Output A i 2 pin J1 6 I R13 AS R14 12k1 D OUT i 475R Supply Ground pin J4 B PWR_GND i Figure 5 Digital output circuitry Analog Input Svde or pin 4 4 Inside the DPFlax drive Analog Input 40K ohm pin J1 2 sy potentometer Analog Common pin J 3 Figure 6 Example of connecting passive circuitry to DPFlex s analog input Allied Motion Technologies Inc www alliedmotion com Marc
33. e 5109K15 1 Figure A 5 Compression rubber strip dimensions A 1 2 Testing After completing the integration of the DPFlex into the target location an insulation test should be performed to verify that the electrical insulation has not been breached Further functionally tests can be done for verification of the thermal interface in addition to the insulation tests Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 61 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Appendix B Compliance A 2 EMC Related Installation Instructions In order to maintain compliance with the EMC Directive 2004 108 EC in EN 55011 Class A Industrial and Commercial environments the following guidelines must be observed The signal cables for J1 must be less than Im in length Drive dc power supply cables connected to J3 J4 should be made as short as possible and should be twisted together using one 1 twist or more per cm Motor cables connected to J5 J6 J7 should be as short as possible and should be twisted together using one 1 twist or more per cm An additional electrolytic capacitor placed as close as possible to the J3 J4 power connectors is recommended Approximate sizing for this capacitor is 30uF per amp Wiring for the added capacitor cables connected to J3 J4 should be made as short as possible and should be twisted together using one 1 twist or more per cm If extra capacitance
34. ep Commutation Sequence rrrrrrnrnnnnnnnnnrrrrrrrnnrnrrrrrrrrrrrrnrnnnnnnnnr 12 Figure 3 Connecting passive circuit to enable line DI 1 0 eee 15 Figure 4 Digital input 2 motor direction circultry rrrrrrrrrnnrrnnrrrrrrrrsrrnnnnnnnnnnr 15 Figure 5 Digital output Cru LaKuKmsasnearearmeqmnaiaviuenemidenmsaumnndea 16 Figure 6 Example of connecting passive circuitry to DPFlex s analog input 16 Fiore 7 DPFIEX dimensions 100 VEN vassere 17 Figure 8 DPFlex dimensions Side vIeW J rrrrrrrrrrrrrrrrrrnrnrnrnnnrnnnnnrssrrrsrsrsnssssssnn 18 Figure 9 DPFlex power dissipation isisccscssrscdnewssectasseescsavadactaneanssdnewstectasseercaaas 19 Figure 10 DPFlex safe operating area rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrsrsssssnsnnne 19 Figure 11 DPFlex connector locations sassarrrnnnsnnnnnnnsssnsvvnvennssnsvnnnnnnnnennnnnnnnse 25 Figure 12 DPFlex connection points rrrrrrrrrnnnnnnnnnnnnrrvrvrrnnnnnnnnnrrrrsssssrrnnnnnnnnnns 26 Figure 13 DP D navigation tree with two configurations rrrrrrrrrrrrrrrrrrrrrrnnnn 29 Feel System properes TOGA Lae E teins 30 F re 15 DPD Intoract Ori ys ccc 0s sescvecsntasanaveediesconcestannseieedaiesindentasnedxnnstsaeceses 31 Figure 16 DP D digital oscilloscope rrrrrrrrrnrrrrrrnrnrrrnnrrnrnrnrrnnnnrsnsnnnnnsnnsnnnsssnne 32 Figure 17 Channel settings TOT s sserssornscssascccatonsttuswntessivsdouritanascedenedselimeubersen 33 Fig re 18 Setting the trigger N
35. ereby unskilled and or untrained personnel have incorrectly installed the equipment Do not apply power to the motor without checking for proper wiring The final responsibility for the safe use of this motor is solely that of the user Allied Motion has used its best effort in the preparation of this manual We reserve the right to make modifications and alterations to improve the content and amend errors may be made to it without notice Check the appendices for errata and revisions Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 7 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive IV Inspection upon Receipt All Allied Motion products are thoroughly inspected and tested before leaving the factory Although our products are packaged with extreme care it is important that the user complete a thorough inspection of the product upon arrival Examine the condition of the shipping container and materials If damage is found notify the commercial carrier involved It is the user s responsibility to file any necessary damage claims with the carrier Our products are shipped EXW ex works unless other arrangements have been made Allied Motion is not responsible for carrier mishandling Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 8 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 1 Introducing DPFlex This chapter provides an o
36. ers To run the configuration tool e Inthe Motor parameters form choose Start The DP D configuration tool displays the configuration instructions Motor Verification Tool Press the continue button to begin setup process The motor verification tool wall Determine ph to ph motor resistance and inductance Determine startup parameters Caution Motor vill move during the setup process The motor frame should be ted down The motor shaft should be able to move freely Pressing the STOF button at any time wall immediately halt any motor movement Please press Continue to proceed Continue Stop CAUTION Failure to ensure that the motor is fixed in place not connected to a load and that the shaft can turn freely may result in improper configuration and damage to equipment or personnel Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 39 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e Choose Continue to start the configuration operation Choose Stop at any time to immediately halt the configuration operation e Follow the instructions in the configuration tool to complete the configuration Note that the configuration operation can take several minutes to complete e Click to close the configuration tool To save configuration parameters to DPFlex s non volatile memory e Inthe DP D navigation tree double click System
37. es between the mounting planar surface and specified PCB locations must meet minimum required regulatory agency specifications for electrical clearances or 1 0mm 0 0394in e The mechanical mounting surface designated as the thermal transfer surface must meet specified flatness specifications to prevent raised surfaces from interfering with heat transfer To address the mechanical clearance requirements between the mounting area and the edge of the PCB it is recommended that provisions be made to allow a minimum of 1 0mm 0 03941n of clearance from the edge of the PCB to the area surrounding the PCB mounting location The DPFlex PCB will typically have a tolerance of 0 762mm 0 030in 0 0mm 0 0in on the outer edge dimensions Please refer to Figure A 1 for details on clearance and tolerance requirements By providing the recommended clearance it will accommodate any variations in manufacturing process that might occur and will facilitate the installation of the PCB during assembly while ensuring PCB reliability Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 57 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive md la Caine Clearcnce requirement from edge of PCB r FA ed Tren Fe mi h l OO 0 O TE Ga A 39 KN Umm MS serge tS 2 750 0 ae aarm n r d Claarance requirement from edge of PCB Si Far irrar h l 3 aein pi i ss0mm 07
38. forms or re starting DP D e You can set whether DP D displays a status bar To toggle displaying DP D forms on top e Choose View gt Always on Top To save the currently displayed forms positions e Choose View gt Save Windows To restore forms to their displayed positions e Choose View gt Restore Windows To toggle display of the status bar e Choose View gt Status Bar 5 7 Getting Help DP D provides online help for all procedures and forms To display online help take one of the following actions e Right click a node in the navigation tree and choose Help e Choose Help gt DP D Help Topics e Press the F1 key To view information about DP D e Choose Help gt About DP D DP D displays the About DP D form Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 35 of 64 Pied Motion About DP D DPFlex Sensorless Brushless Motor Drive DP D v10 81build20081210 141638 MAXCLIb v11 16 Warning This computer program is protected by MAXComm v10 52 copyright law and international treaties Unauthorized MAXComm mpR5232 v10 51 reproduction or distribution of this program or any portion of it nay result in severe civil and criminal penalties ard will be prosecuted to the maximun extent possible under law Copyright 2008 Agile Systems lac Figure 19 DP D About screen 5 8 Creating and Managing Configurations A configuration stores controller and motor settings
39. gnetic fields must move relative to each other to maintain torque There are two ways to produce a moving magnetic field One way is to apply AC current to stationary windings The other is to change the physical path of DC current in a stator A DC motor uses the latter approach to commutation DPFlex changes the path of current in motor coils in the following manner Electrical commutation is done using an external controller to change the current path Current 1s directed through various wires in the stator creating a moving magnetic field To control the paths for current DPFlex uses a six step sensorless method that relies on back electromotive force sensing 2 2 Six Step or Trapezoidal Commutation In this method there are only two phases of the stator coils energized by the DC source To complete one electrical cycle 360 degrees for magnetic field rotation every phase would be energized four times two times in the positive polarity and the other two in the negative polarity Because the transition from one step to the next is discrete the waveform of the field is like a trapezoid This method is simple and can be used for different types of BLDC motors The simplicity and effectiveness of this method makes it an attractive choice for commutation even at high speed BLDC motors are commutated in six 60 steps during each full 360 electrical cycle Only two of the three motor coils are energized during each step i Wo 1 Uf
40. h 29 2012 Version R1 Page 16 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 3 2 DPFlex Connectors Keystone Horizontal Quick Fit Terminals P N 4907 Tab Size 187 4 75 Keystone Horizontal Quick Fit Terminals P N 4907 Tab Size 187 4 75 Horizontal Quick Fit Terminals P N 4907 Tab Size 187 4 75 Analog amp Digital I O JST P N SM06B GHS TB USB UART Communication JST P N SM04B GHS TB Table 3 DPFlex connectors For connector pinouts for DPFlex see Making Cables for DPFlex Drives 3 3 DPFlex Dimensions 94 2 96 9 101 6 66 7 9 5 Figure 7 DPFlex dimensions top view Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 17 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 23 1 BR 8 3 6 3 4 8 Figure 8 DPFlex dimensions side view 3 4 DPFlex Safety To ensure safe operation of DPFlex your application must meet the following requirements CAUTION Failure to comply with the requirements listed below may create an electrical hazard in your application e Use two AWG 16 twisted with one twist per cm cables 3 ft 1 m long to connect the DC power supply to DPFlex e Use three AWG 16 twisted with one twist per cm cables 1 ft 3 m long to connect the motor to DPFlex e Connect a fuse between the positive voltage from the DC power supply and pin J3 B on DPFlex s power ter
41. ical evaluation and suggestions for improvements to be made in future revisions This manual is supplied to the user with the understanding that it will not be reproduced duplicated or disclosed in whole or in part without the express written permission of Allied Motion Technologies Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 4 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive I Tables Table 2 DPFlex Evaluation Kit Contents rrnnnnnnrrrrrrrnnvrrrrrrrnrsrnrnnnnnnnnnrrvvrnnnene 10 Te NN 17 Table 4 Analog amp digital I O connector pinout J1 orrrrrrrrrrrrrnrrrrrnrrnnnrnnnr 26 Table 5 Serial communication connector pinout J2 rrrrrrrrrnrrrnrrrnrnrnrnnnnnnr 26 Table 6 Power connector pins Keystone Terminals P N 4907 J rrrrrrrornrnnrr 27 Table 7 Motor connector pins Keystone Terminals P N ft 4907 J rrrrrrrnnnnnnnrr P Table 8 DP D oscilloscope tool buttons rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrnrrrrnnsnnnn 33 Table 9 Change oscilloscope display rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrnrnrrnrrssnssrnn 34 Table 10 Manas er Captured dauer verre ad 34 Allied Motion Technologies Ine 00000000 www alliedmotion com March 29 2012 Version R1 Page 5 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive ll Figures Figure 1 Six Step Commutation Phase Current amp Back EMF Diagram 11 Figure 2 Six St
42. ick the DPFlex Port leaf in the navigation tree and choose Interact e Double click the leaf DP D displays the system properties form DPHex1 COM4 DPAlex1 COMA E X MDC Bus Voltage DC Fink h l er PYNT Controller Information Sr DPDFIex Software version 8 14 Tue Dec 09 11 12 23 2008 5057 lt lt Hide Details Current rating 30 4 Voltage rating 30 Load New Firmware Figure 14 System properties form The system properties form displays the following controller information e The current supply voltage e The firmware version and its date and time of compilation e The drive s current and voltage ratings To display or hide a configuration s system properties e Click Show Details or Hide Details To rename a configuration e Right click the DPFlex Port branch in the navigation tree and choose Rename Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 30 of 64 Pied Motion T DPFlex Sensorless Brushless Motor Drive o add delete or change the properties of configurations take one of the following steps Right click the System branch in the navigation tree and choose Connection Double click the System branch DP D displays the Interact form which lists defined connections x Connections Add Delete Properties panel Figure 15 DP D Interact form For details about using the Interact form see Creating and Managing Config
43. imiting resistor should then be shorted out using a relay or some other appropriate means The following tables list the pinouts and connector type for each connector on the drive Figure 12 below shows how external devices are connected to DPFlex Note The serial communications connector on the drive uses TTL signals If you want to communicate with the drive from a device using standard RS 232 signals you must provide a means to convert the signal levels between the two devices Purpose Analog 5V Analog Input 0 5V DC Analog Common Digital Input 1 motor enable disable Referenced to J4 B J1 5 DI2 Digital Input 2 motor direction Referenced to J4 B J1 6 DO Digital Output Referenced to J4 B Table 4 Analog amp digital I O connector pinout J1 Communication Ground Transmit Communication 5V Table 5 Serial communication connector pinout J2 Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 26 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive Pin Pin Nam J3 B DC Voltage J4 B DC Voltage Table 6 Power connector pins Keystone Terminals P N 4907 Pin Pin Namo JS APH A Motor Phase J6 BPH B Motor Phase J7 CPH C Motor Phase Table 7 Motor connector pins Keystone Terminals P N 4907 Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 27 of 64 lied Motion DPFlex Sensor
44. is to log data or None to disable logging Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 33 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e Choose the data to log from the list in the Axis Register To Log panel e Choose OK to save the settings or Cancel to abort the operation To change the oscilloscope display take the following actions To take this action Choose this button Display inputs as graphs Display inputs in a table Display scaled data Position the cursor on the select the input channel Zoom out to show all captured data points Zoom in on the selected segment of the graph Zoom out of the selected segment of the graph Rescale the display to the input signals range E Se EE Show or hide the cursor Table 9 Change oscilloscope display To manage captured data take the following actions To take this action choose this button Open an oscilloscope configuration Save the current oscilloscope configuration Print the captured data points Copy all captured data points to the clipboard Table 10 Manager captured data To select the trigger type choose one of the following commands e Choose Manual to trigger input logging once immediately e Choose Single to trigger input logging once at the point set with the trigger settings controls e Choose Auto to enable the oscilloscope to trigger continuously and d
45. isplay captured data To set the time base e Using the mouse rotate the time base control to the desired period To set the data logging frequency e In the Datalog Rate field enter the sampling period in seconds e In the Datalog Points field enter the number of points to log during the time base period To change the trigger settings Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 34 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e In the Trigger Settings area choose one of the following triggers from the drop down list Choose this setting to set this trigger No Auto Trigger None On Stimulus Edge On the edge of the current or velocity stimulus On ve Stimulus Edge On the positive edge of the current or velocity stimulus On ve Stimulus Edge On the negative edge of the current or velocity stimulus On Enable When the motor is enabled Figure 18 Setting the trigger type e In the Trigger Settings area set the point in time to trigger by rotating the Position at of 50 ms control or entering a value in milliseconds in the field below 5 6 Managing Views DP D provides several options for managing its display e You can set DP D to always display DP D forms on top of other application windows and forms e Ifyou have multiple parameter forms open you can save their current display positions and restore them to those positions after closing the
46. less Brushless Motor Drive 5 Creating DPFlex Applications This chapter describes how to develop and deploy the DPFlex in your application How to configure it for a motor how to check the analog and digital inputs how to set motor performance parameters and how to check application performance 5 1 Developing DPFlex Applications Once you have installed the DP D software and connected a motor and power to DPFlex you can start developing your application 5 1 1 Steps To Develop a DPFlex Application 1 Create a configuration A configuration stores controller and motor settings and other application parameters DP D enables you to create and store multiple configurations For details see Creating and Managing Configurations 2 Configure DPFlex for the motor you want to use in the application For details see Configuring DPFlex Tune the current loop for the application For details see Tuning the Current Loop Tune the velocity loop for the application For details see Tuning the Velocity Loop Check DPFlex s inputs For details see Viewing DPFlex Inputs a Se Configure thresholds and check for faults For details see Viewing and Configuring Faults 7 Save the application parameters and deploy them to other DPFlex controllers For details see Deploying DPFlex Applications 5 2 Using DP D You use the DP D application software for Microsoft Windows 2000 XP Vista 7 to develop and deploy DPFlex applications For de
47. ls e Choose Tools DP D displays the Oscilloscope and the Current stimulus forms ef Eit M EE AR EN nn Rated Current Maximum 30 00 A sf 5000 nO m Motor Peak Current 30 00 Control Made Current Mode Pulse m C Torque Mode z Control Source vi Host inimun c cin inea 40 00 Stop m T Start i terte Frequency r m Direction vanam ronm rn nfe anoi 100 H I I I m 3 Z O 10mHz 100mHz 1Hz 10Hz 100Hz Calculate Gains Based On Motor Parameters Current Gains Kof 0 000 kif 0000 Kaf ooo 4 Tuning Tools Apply x j Time based sampling v x Time Base gt r Trigger Settings Drive Current Setpoint DPFlex1 COM4 No Auto Trigger v Drive Current Actual sls DPFlex1 COM4 agi Position of 25 ms F H e f J emae iE 30 gt Y 70 2 50 ms Div CH4 Datalog a J 5 A AE es 1 L c Rate 1 0 25 ms 0 100 Manual Trigger ill Single Auto 1 Points 100 fe 0 00 ms Figure 25 DP D Oscilloscope and Current stimulus forms Tip You can arrange the forms as you like and save their positions using the View gt Save Windows command You can restore the forms to their saved positions at any time including the next time you run DP D wi
48. ly referring to their labels for pin number and signal name CAUTION Failure to connect a properly rated fuse between DPFlex s high voltage input pin J5 on the power connector and the power supply may create an electrical hazard Size the fuse to 150 of DPFlex s rated current 4 4 5 Connecting DPFlex to a motor 1 Plug the motor cable into DPFlex s motor connector 2 Wire the other end of the motor cable to the motor 4 5 Making Cables for DPFlex Drives You can make your own cables for DPFlex as long as the following points are adhered to e The signal cables for J1 must be less than Im in length e Drive dc power supply cables connected to J3 J4 should be made as short as possible and should be twisted together using 1 twist or more per cm e Motor cables connected to J5 J6 J7 should be as short as possible and should be twisted together using twist or more per cm Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 25 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e An additional electrolytic capacitor placed as close as possible to the J3 J4 power connectors is recommended Rule of thumb sizing for this capacitor is 30uF per amp Cables running to and from the added capacitor should follow the above cabling practices e If extra capacitance is used it is highly recommended that a pre charge circuit be used to limit the inrush current required to charge this capacitance The l
49. minal Size the fuse to 150 of DPFlex s rated current e Spot ground the DPFlex drive itself e Use a USB cable to connect the PC to the USB UART adapter e Heat sink the DPFlex drive using the power dissipation curve shown in Figure 3 8 to guide the heat sink s design 3 5 DPFlex Power Dissipation DPFlex generates heat as its consumption of power increases Use the graphs in Figure 9 and Figure 10 below to determine safe operating conditions Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 18 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive 50 45 ad te on Oo tio Qo Total Power Dissipation Watts M M ov 0 5 10 15 20 25 30 Peak Current per Phase Amps Figure 9 DPFlex power dissipation Note The power dissipation curve was generated with balanced 3 phase sinusoidal current at a 100 Hz fundamental and a 20 KHz switching frequency Peak Phase current Amps Base temperature C Figure 10 DPFlex safe operating area Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 19 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 4 Setting Up DPFlex This chapter describes how to set up DPFlex and configure it for a motor 4 1 Installing the Software The software provided with the DPFlex drive includes DP D an application for Microsoft Windows that enables you to configure and monitor the dri
50. on This device complies with part 15 of the FCC Rules Operation is subject to the following two conditions DPFlex Sensorless Brushless Motor Drive 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 63 of 64 Pfied Motion vrreSesesbusnes Molor Drve DECLARATION OF CONFORMITY in accordance with ISO IEC 17050 1 Declaration Number A unique number or other identification is required Manufacturer Agile Systems Inc Headquarters A12 550 Parkside Drive Waterloo Ontario N2L 5V4 CANADA Phone 1 519 886 2000 Fax N A Web http www alliedmotion com EU Address Contact Address for the EU Office or EU distributor Product Type DP Flex Model 10 FX10 XX XX Starting Serial Number The products described above are in conformity with the requirements of the following documents Document Title Edition or Date of issue 2004 108 EC ELECTROMAGNETIC COMPATIBILITY 2004 DIRECTIVE EN 55011 INDUSTRIAL SCIENTIFIC AND MEDICAL ISM 2007 RADIO FREQUENCY EQUIPMENT ELECTROMAGNETIC DISTURBANCE CHARACTERISTICS LIMITS AND METHODS OF MEASUREMENT EN 55011 A2 AMENDMENT A2 TO BS EN 55011 2007 2007 EN 61326 1 ELECTRICAL EQUIPMENT FOR 2006 MEASUREMENT CONTROL AND LABORATORY USE EMC REQUIREMENTS PART 1 GENERAL REQUIREMENTS
51. onal methods drive a current through the motor windings in order to force the motor rotor into a known position to ensure proper motor start This can cause up to 180 of 2 pole motor rotation opposite to the desired direction adding to acceleration and startup time The current required to orient the rotor depends on the inertial and frictional load of the motor If the initial current to orient the motor is too high there may be overshoot and ringing in the system If the current is too low the motor may not start at all Such a system is not robust with respect to system load conditions More advanced methods determine motor rotor position based on the motor phase saturation inductance change The drive generates 6 short opposing current pulses that drive the motor phases into saturation The drive calculates the motor rotor position based on the saturation inductance change in each phase We refer to this procedure as the ping method The motor rotor remains stationary during the initial ping period because the current pulses are short and in opposing sequence In most cases the motor reaches sufficient speed before the next commutation sector change for the back EMF commutation algorithm to take over In a few cases usually if the load on the motor is extremely heavy the ping process repeats while the motor rotates at low speeds below the back EMF commutation threshold This is possible because the ping period time 1s negligible with respec
52. our application Use two AWG 16 twisted with one twist per cm cables 3 ft 1 m long to connect the DC power supply to DPFlex Use three AWG 16 twisted with one twist per cm cables 1 ft 3 m long to connect the motor to DPFlex Connect a fuse between the positive voltage from the DC power supply and pin J3 B on DPFlex s power terminal Size the fuse to 150 of DPFlex s rated current Spot ground the DPFlex drive itself Use a USB cable to connect the PC to the USB UART adapter Heat sink the DPFlex drive using the power dissipation curve shown in Figure 3 8 to guide the heat sink s design Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 23 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive 4 42 Connecting DPFlex with the Cable Kit The easiest way to connect a DPFlex drive is to use cables offered by Allied Motion The DPFlex Power Cable part number 40 0105 connects the drive to power One end fitted with Amp 8 520182 1 of the red wire in the cable connects to J3 B the positive pin One end also fitted with Amp 8 520182 1 of the white wire in the cable connects to J4 B the ground pin The other ends connect to the power supply The DPFlex Motor Cable 40 0106 connects the drive to a motor One end fitted with Amp 8 520182 1 of each of the red white and black wires in the cable connects to the motor pins Motor Phase A pin J5
53. p Make sure the motor shaft is connected to the required load that the load is free to move and can move safely and that the motor itself will not move when turning CAUTION You risk damaging equipment or personnel during tuning if you do not ensure that the load can move safely and that the motor will not move when rotating In DP D s navigation tree double click System gt DPFlex Port gt Velocity Compensator DP D displays the Velocity Compensator form Velocity Compensator DPFlexi COM4 E x Ke Mim H Kif oo Kaf oom Tuning Tools i Apply Figure 29 Velocity Compensator form The Velocity Compensator form displays the current gains set for the target motor It also enables you to re calculate the gains based on the motor parameters and to open DP D s tuning tools Choose Tuning Tools DP D displays the Oscilloscope and the Velocity stimulus forms Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 47 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive SHS 2 tt PEO AQ h 1 gt coos x Starting Current 1 350 A Maximum 100 a 60 00 Maximum Velocity g0 2500 RPM Actual Velocity DC m 50 0 00 1 40 mr Pulse 7 Control Source Host J a Analog Input Minimum ox f 30 00 Ds Bs 10s Stop Start ae 2
54. s e The DC command sets the current to direct e The Pulse command sets the current to a square wave e The Frequency field and slider sets the frequency of the square wave e The Maximum and Minimum fields and sliders set the maximum and minimum values of the current pulse as percentages of the motor peak current These values can be negative zero Or positive Inthe Current stimulus form e Choose Current Mode e Choose Pulse e Set the desired values for current pulse frequency and amplitude Inthe Current stimulus form choose Start to apply current to the motor Inthe Oscilloscope form choose Auto to start triggering Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 44 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive After a few seconds the Oscilloscope form will display the current stimulus in green and the actual current drawn by the motor in red Oscilloscope S El S Bs A 22 25 S Pll Ea ii Lm v Se eee E CH1 Drive Curent Setpoint Time BEA anining El DPFlex COM4 Time Base Trigger Settings 1CD0ms Mo Auto Trigger CH Drive Curent Actual lg sel DFFIext COMA ji J Position of 50 ms TE lms 105 6 00 me Div Datalog Rate 0 25 me Manual Trigger Single Point 200 You can vary the settings in the Current stimulus form including the slider controls for the frequency and amplitude of the current stimulus
55. s let s assume that el which is an approximation of the bilinear transformation Then by substituting z 1n 2 k kil l k jat fe Ja ppg Ye e ki k is Ik 4 2 5 and by comparing 1 and 3 Br 4 fa 5 Bg kp k k q 6 B k 2k4 7 B k 2 d 8 Equations 4 through 8 show how each of the 5 biquad filter coefficients are calculated from the screen PID representation in DP D To tune the current loop Make sure the motor shaft is connected to the required load that the load is free to move and can move safely and that the motor itself will not move when turning CAUTION You risk damaging equipment or personnel during tuning if you do not ensure that the load can move safely and that the motor will not move when rotating In DP D s navigation tree double click System gt DPFlex Port gt Current Compensator DP D displays the Current Compensator form Current Compensator DPHex1 COM4 Z Calculate Gains Based On Motor Parameters Current Gains Kp 0000 kif 0000 kaf 0000 Tuning Tools Apply Figure 24 Current Compensator form Allied Motion Technologies Inc March 29 2012 www alliedmotion com Version R1 Page 42 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive The Current Compensator form displays the current gains set for the target motor It also enables you to re calculate the gains based on the motor parameters and to open DP D s tuning too
56. st be fitted on top of the PCB board above the power MOSFETS to ensure that adequate pressure is maintained on the PCB board to minimize thermal resistance and to provide mechanical restraint An example design of a compression metal clip can be found in Figure A 4 and the compression rubber strip in Figure A 5 Alternately mounting hardware kits can be ordered from Allied Motion which contain the compression clip the Berquist thermal interface material and two 6 32 3 16 inch machine screws When mounting the DPFlex care must be taken that no more than 113 N cm 10 in Ib of torque be applied to the screws during assembly Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 60 of 64 4 led Motion DPFlex Sensorless Brushless Motor Drive Ilin ho DLA mm pr I SSS ee ares j SLOT DIMENSIONS m an 7 Ae ts ee len a ene 127 IT sem i se Dan Sn rarae 010 m PP Sin Pl Sein Seer E D 25 ror or a a N DETAIL A N J SCALE 4 1 pa I iial LL j EP hamme 2 de i Sad alin Biren Zamm Tain i lamm 12 97mm Arn Ep L 2 5000 D ame 5 mm a 23 simm E E E E ea PEPE FE E DOM EEE KE RESES amp ME EE Se ME E BESS kS GaSSES RE egsa 42 G G 7 r kler de dt bk mF eS Figure A 4 Compression metal clip design considerations l 1775n m 45 O rnim tb Odin 1 7 8mm i 1 08tin MeMaster Carr Silicone foam tape with IE ATM adhesiv
57. t to the time between sector transitions at low motor speeds The ping method guarantees unidirectional motor start which is independent of motor loading conditions The system is robust with respect to system load conditions Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 13 of 64 Pied Motion 3 DPFlex Specifications 3 1 DPFlex Specifications Specification DC Supply Voltage Acceptable Motor Type Output Phase Current Motor phase to phase inductance Motor time constant Trip temperature Digital Input motor direction enable disable Digital output Analog input Analog Input Sampling Frequency Input Sampling Frequency Commutation Type Commutation Period Diagnostics Protection USB UART communications DPFlex Sensorless Brushless Motor Drive Value 15 V min 24 V typ 30 V max 8 V min 12 V typ 16 V max Brushless AC DC WYE connected 10 15 30 A peak 100 uH min 150 usec 90 C 0 V min 30 V max 0 V min 30 V max 5 V single ended 100 Hz 20 kHz Six step back emf 250 usec min 400 point data logger Over under voltage over current over temperature Digital TX 115 kbps 1 Refer to the power dissipation curve shown in Figure 3 8 to properly heat sink the drive 2 Digital inputs require isolation if connected to active circuitry Refer to schematic shown in Figure 3 and Figure 4 3 Refer to schematic shown in Figur
58. tails about installing DP D see Installing the Software e To start DP D On your Windows Desktop choose Start gt Programs gt Allied Motion gt DP D e To exit DP D In DP D choose File gt Exit 5 3 About DP D DP D enables you to perform the following tasks e Configure DPFlex for a motor e Tune the current and velocity loops for your application e Configure thresholds and view faults over temperature over current and over voltage e Monitor DPFlex inputs e Save configuration parameters to a file on the PC and to DPFlex s non volatile memory e Create save and open sets of DPFlex configurations Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 28 of 64 4 lied Motion DPFlex Sensorless Brushless Motor Drive 5 4 Using the DP D Navigation Tree When you start DP D it opens a navigation tree that you use to create and manage multiple DPFlex configurations z View Tools Help System P DPD1 COM3 B A Stimulus Tools E Motor E Current Compensator Velocity Compensator amp Inputs amp Faults Registers 3 BB DPFIex2 Virtual B A Stimulus Tools E Motor Current Compensator Velocity Compensator Inputs Faults Registers I Digital Output Figure 13 DP D navigation tree with two configurations DP D displays each DPFlex configuration as a branch in the navigation tree It displays the parameters for each configuration as leaves on the branch Each DPFlex config
59. th the View gt Restore Windows command DP D automatically sets the controls and fields in the Oscilloscope and Current stimulus forms to default values appropriate for tuning the current loop based on the values you set in the Motor parameters form The Current stimulus form enables you to vary the current available to the motor x m Rated Current Maximum r 100 30 00 60 00 Do l Motor Peak Current 30 00 Control Mode pc Curent Mode Pulse C Torque Mode Control Source ar Pulse amplitude sliders f Host Analog Input Stop Start Direction LL Pulse frequency slider Frequency J 4 100 H I FER KI it ELEU I BEELI II OT E 3 10mHz 100mHz2 1Hz2 10Hz 100Hz Figure 26 Current stimulus form Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 43 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive The Rated Current field shows the maximum current available from the DPFlex drive The Motor Peak Current field shows the value previously set for the motor s peak current rating To change this value see To set motor parameters The Control Mode section enables you to set Current or Torque as the control mode The Stop Start control enables you to turn the current to the motor on or off The current controls enable you to set the following characteristic
60. to Serial Driver electronics digital controls and network communications into small compact and cost effective packages Agile has established customers in a broad range of industries and is based in Waterloo Ontario Canada This version of DP D supports as Copyright 2008 e Windows 2000 with Service Pack 4 and above jed Motion Canada Inc e Windows XP Home Professional with Service Pack 2 and above Please contact us for more information Allied Motion Canada Inc 550 Parkside Drive Unit A12 Waterloo ON If the installation utility does not automatically run run the Setup exe program found in the root of the CD To install DP D e In the installation utility choose Install DP D The installation utility launches the DP D installation wizard 8 DP D v10 84 3 v10 84 SS P tt Me S TA The installer will guide you through the steps required to install DP D v10 84 on your computer C Copyright 2008 Allied Motion Canada Inc amet ee e Follow the instructions in the wizard to install DP D Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 21 of 64 Pied Motion DPFlex Sensorless Brushless Motor Drive Note DP D requires an Open Database Connectivity driver to be installed on the PC If you do not have one you can install one by running the MDAC_TYP EXE program in the MDAC2_S8 directory found on the CD To install the USB to serial
61. torque setpoint Update Registers to Flash Update Registers Save Registers to File from Flash Save Registers Load Registers from File to Flash Load Registers e You can choose to start the motor using a torque or velocity set point You can also choose a fixed set point or one set by the analog input e Ifyou chose to use a fixed set point enter the required set point value in the Fixed Velocity or Fixed Torque field Star on Enable Input hl Star us with fired velocity setpoint Figed Velocity 1 2500 RPM Starting Current 3 50 A Stan on Enable Input v Start up with fired torque setpoint Fixed Torque 30 00 Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 55 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e Ifyou chose to use a set point set by the analog input enter the maximum permitted set point value in the Maximum Velocity or Maximum Torque field Start on Enable Input Star on Enable Input Start up with analog input velocity setpoint Startu with analog input torque setpoint v Maximum velocity 2500 RPM Maximum Torque 30 00 A Starting Curent 350 e Enter the Starting Current in amperes e Choose Update Registers DP D saves the current configuration parameters into the drive s non volatile memory e Click to close the Registers form Note that you must cut power to the
62. uration shows which port the controller is connected to and provides access to the following configuration parameters e The Stimulus Tools forms enable you to vary motor current or velocity e The Motor Parameters form enables you to set motor ratings and command DPFlex to configure itself for that motor e The Current Compensator form enables you to define the gains for the application s current loop and provides access to DPFlex current loop tuning tools Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 29 of 64 lied Motion DPFlex Sensorless Brushless Motor Drive e The Velocity Compensator form enables you to define the gains for the application s velocity loop and provides access to DPFlex velocity loop tuning tools e The Inputs form enables you to view the current values of DPFlex digital and analog inputs e The Faults form enables you to configure and view fault settings states warnings and error messages e The Registers form enables you to store and retrieve DPFlex settings in files and to save those settings to DPFlex s non volatile memory It also enables you to configure the drive autostart mode To open a parameters form take one of the following steps e Right click the desired parameters leaf in the navigation tree and choose Interact or e Double click the leaf DP D displays the form To view system configuration properties take one of the following steps e Right cl
63. urations 5 5 Using DPFlex s Digital Oscilloscope DPFlex features a four channel digital oscilloscope that enables you to view your application s set points and the motor s actual performance To display the digital oscilloscope take one of the following actions e Inthe Tools menu choose Oscilloscope In the Current Compensator form or Velocity Compensator form choose Tuning Tools Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 31 of 64 Allied Motion DPFlex Sensorless Brushless Motor Drive Oscilloscope PEER fel ee JE x RAAT NT EE Mo Auto Trigger z CH1 Drive Current Setpoint Time BA n anni El DPFlex1 COM4 i Trigger Settings 6 00 mesDiy Datalog Fate 0 25 ms Manual Trigger Single Points 200 Figure 16 DP D digital oscilloscope The digital oscilloscope features the following controls The tool bar enables you to manage oscilloscope settings examine captured signals and control the display The signal display traces the signal on each channel after the trigger occurs and for the selected time base The channel controls enable you to assign a signal to a channel The trigger type controls enable you to select the type of triggering to use The time base control enable you to specify the time base used in the display The datalog controls enable you to specify the rate at which inputs are logged and the number of data
64. ve and a USB to serial driver that enables a PC to communicate with the drive over a USB port For details about installing the DP D software see the upcoming topics 4 2 Installation Requirements To install and run the DPFlex software you need a personal computer that meets the following minimum requirements e Windows 2000 with SP4 or Windows XP with SP2 e A USB port or an RS 232 serial communication port capable of 115200 bps e 133 MHz or higher Pentium compatible microprocessor e Atleast 64 megabytes MB RAM e 50 MB available storage e SVGA or higher resolution monitor Note A personal computer equipped with more RAM or a faster microprocessor will provide significantly better performance 4 3 Using the Installation CD The DPFlex software is packaged on a CD ROM part number 35 0028 containing the DP D software To run the installation utility e Insert the CD in your CDROM drive e Wait for the Install Application to run Allied Motion Technologies Inc www alliedmotion com March 29 2012 Version R1 Page 20 of 64 DPFlex Sensorless Brushless Motor Drive Pied Motion Welcome to Allied Motion amp Thank You for choosing our Digital Power DP product Home Allied Motion Canada is a world leader in the design development and Install DP D manufacturing of advanced motion control technology including motor control and power conversion Our team is highly skilled in integrating power Install USB
65. verview of the DPFlex its features functions and specifications 1 1 What is DPFlex The DPFlex provides sensorless control of rotary brushless DC motors at performance levels that exceed those of conventional Hall commutated drives DPFlex detects motor rotor position at motor stand still through an innovative algorithm based on motor phase inductance measurement You can integrate the DPFlex into a motor e g into the bell end or mount it separately from the motor DPFlex features include e Enables a brushless DC motor to provide controlled torque or speed without the need for motor commutation sensors e One non isolated analog input to adjust torque or speed e One non isolated digital input to select the direction of motor rotation e One non isolated digital input to enable or disable the drive and motor e One non isolated digital output e Over temperature and over current protection e Auto start programming function e Models for motors requiring up to 30 A peak e Allied Motion s DP D software for Microsoft Windows 2000 XP Vista 7 enables you to tune configure and program the drive It provides the following features Motor set up and configuration tools Inputs set up and configuration tools Motor verification and performance analysis tools Integrated online help DPFlex is suitable for a wide range of applications including control of fans pumps compressors centrifuges drills and mills

USER MANUAL: - Allied Motion

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