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ElectroCraft CompletePower Plus CPP-A12V80A-SA-USB, Technical Reference

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ElectroCraft CompletePower Plus CPP-A12V80A-SA-USB Technical Reference Download Page 39

 

© ElectroCraft 2018 

38 

CPP-A12V80A-SA-USB Technical Reference 

12.6  ElectroCraft Braking Module Assembly 

 

 

 

 

A Braking Module is used to divert regenerative energy from the motor and servo drive into the braking 

resistor during deceleration. The braking module will turn On when the drive side voltage increases 2 to 3 

VDC above the power supply input voltage and shunt the excess voltage to ground through the internal 

braking resistor preventing overvoltage faults in the servo drive. A blocking diode in the Braking Module 

prevents the excess voltage from feeding back to the power supply. As the drive “regenerates”, the 

module will cycle On and Off to dispose of the excess energy through the brake resistor. Care should be 

taken to ensure the brake resistor is not mounted next to any flammable material, as it could get hot. This 

braking module will also allow the user to attach a high wattage braking resistor externally. 

 

The braking module is designed to be connected between the CPP-A12V80A-SA-USB connector J1 and 

the power supply. For full and complete data including proper connection information please refer to the 

ElectroCraft Braking Module datasheet available at ElectroCraft website. 

 

Figure 30: ElectroCraft braking module

 

Summary of Contents for CompletePower Plus CPP-A12V80A-SA-USB

Page 1: ...2018 CPP A12V80A SA USB Technical Reference ElectroCraft CompletePower Plus Universal Servo Drive ElectroCraft document number 198 0000023 ElectroCraft 2 Marin Way Suite 3 Stratham NH 03885 2578 www electrocraft com ...

Page 2: ...sed by any error or omission in the work whether such error or omission is the result of negligence or any other cause Any and all such liability is disclaimed All rights reserved No part or parts of this document may be reproduced or transmitted in any form or by any means electrical or mechanical including photocopying recording or by any information retrieval system without permission in writin...

Page 3: ...al information or assistance Ask questions about product operation or report suspected problems Make suggestions or report errors in documentation Contact ElectroCraft at For North America Tel 844 338 8114 Email drivesupport electrocraft com Mail ElectroCraft 2 Marin Way Suite 3 Stratham NH 03885 2578 USA For Outside North America Please visit www electrocraft com contact ...

Page 4: ...otor and Sensor Configurations 16 2 7 Identification Labels 16 2 8 Status Indicator Lights 16 3 Drive Specifications 17 3 1 Physical Specifications 17 3 2 Environmental Specifications 17 3 3 Electrical Specifications 17 3 3 1 DC Supply Input 17 3 3 2 5VDC Supply Output 17 3 3 3 Motor Output 17 3 3 4 Hall Sensor Inputs 18 3 3 5 Encoder Inputs 18 3 3 6 Digital Input 18 3 3 7 Digital Output 18 3 3 8 ...

Page 5: ...gle Ended Encoder 27 7 2 3 Encoder Input Circuit 27 7 3 IxR Speed Feedback Estimator 27 7 4 Motor Temperature Sensor 28 7 4 1 Temperature Sensor Connections 28 7 4 2 Temperature Sensor Signal Input Circuit 28 8 Connecting I O 29 8 1 I O Functional Description 29 8 2 Minimum I O Connections 30 8 2 1 Minimum I O Connections for BLDC and PMDC motors 30 8 2 2 Minimum I O Connections for Stepper motor ...

Page 6: ...g resistance value of the braking resistor 35 12 3 2 Calculating power value of the braking resistor 36 12 4 Minimum external bulk capacitance 37 12 5 Connecting External Brake Resistor and Bulk Capacitor 37 12 6 ElectroCraft Braking Module Assembly 38 13 Troubleshooting 39 13 1 Status LED Red 39 13 2 Power LED Green 40 ...

Page 7: ...25 FIGURE 14 HALL SENSOR CONNECTION TO THE DRIVE 26 FIGURE 15 HALL SENSOR SIGNAL INPUT CIRCUIT 26 FIGURE 16 DIFFERENTIAL ENCODER CONNECTION TO THE DRIVE 26 FIGURE 17 SINGLE ENDED ENCODER CONNECTION TO THE DRIVE 27 FIGURE 18 ENCODER SIGNAL ENDED INPUT CIRCUIT 27 FIGURE 19 TEMPERATURE SENSOR CONNECTION TO THE DRIVE 28 FIGURE 20 TEMPERATURE SENSOR SIGNAL INPUT CIRCUIT 28 FIGURE 21 MINIMUM DRIVE I O C...

Page 8: ...re it is likely to be exposed to strong and or frequent static discharge 7 Conduct trial operations on the servo drive alone with the motor shaft disconnected from the load to avoid any unexpected motion Motor shaft should be uncoupled and free to rotate without coming in contact with user or any stationary object during set up and preliminary operation 8 Under no circumstances should a phase outp...

Page 9: ... control The installer of this servo drive must have a thorough knowledge of safety precautions and practices relevant to the specific application of this drive In particular the installer should consider the risks associated with erroneous or non operation of the servo drive in the application and mitigate them appropriately 1 2 Storage and Transportation 1 Do not store or install the product in ...

Page 10: ...gh the vents Failure to observe this caution may cause internal elements to deteriorate resulting in malfunction or fire 6 Provide the specified clearance between the drive and other devices Provide sufficient space around the drive for cooling by natural convection or provide cooling fans to prevent excessive heat See section 4 for details Failure to observe this caution may result in fire or mal...

Page 11: ...ide a grounded 360 degree clamp termination at both ends Provide for a large contact area between shields and the mounting plate The J5 I O port requires an external ferrite located close to the mating connector with cable passing once through the ferrite Fair Rite 0431176451 or equivalent is required for compliance 1 6 Life Support Policy READ THIS ENTIRE SECTION BEFORE ATTEMPTING TO USE THE CPP ...

Page 12: ...attempt to operate or power up the drive if there is any visible external damage or if there are loose materials inside the chassis While unpacking if you discover any loose or damaged parts notify ElectroCraft within two working days ElectroCraft recommends that all packing materials be saved in the event that the drive needs to be returned Always place the drive in the same antistatic bag used i...

Page 13: ...on input 10V Analog output configurable Encoder mode for low speed performance BLDC PMDC and Stepper motor control Halls only operation mode for BLDC motor IxR speed feedback estimator mode for PMDC motor Integrated circuit for brake regeneration Travel limit inputs Configurable ramp for current and speed 97 efficiency at full load Selectable software protection options Windows based set up and tu...

Page 14: ...rapezoidal 6 step commutation with hall sensor feedback as shown in Figure 2 and sinusoidal commutation with hall sensor feedback as shown in Figure 3 Motor Phase A Motor Phase B Motor Phase C Hall Sensor 1 Hall Sensor 2 Hall Sensor 3 60 120 180 240 300 360 60 120 180 240 300 360 Figure 2 Trapezoidal Commutation with Hall sensor feedback ...

Page 15: ...PP A12V80A SA USB Technical Reference Motor Phase A Motor Phase B Motor Phase C Hall Sensor 1 Hall Sensor 2 Hall Sensor 3 60 120 180 240 300 360 60 120 180 240 300 360 Figure 3 Sinusoidal commutation with Hall sensor feedback ...

Page 16: ...6 microsteps per step at a maximum step rate of 1MHz 50 10 The phase current wave forms for full step quarter step and 256 microsteps per step is shown in Figure 4 30 60 90 120 150 180 210 240 270 300 330 360 0 Full Step 1 Microstep per Step Quarter Step 4 Microsteps per Step 256 Microsteps per Step Motor Phase A Motor Phase B Motor Phase A Motor Phase B Motor Phase A Motor Phase B Figure 4 Steppe...

Page 17: ...nfigurations Brushless Motor PMDC Motor Stepper Motor Hall Sensors Yes No No Encoder Halls Yes No No Encoder Only No Yes No IxR Estimator No Yes No 2 7 Identification Labels Identification label with ElectroCraft serial number Figure 6 Drive with identifying label 2 8 Status Indicator Lights In normal operation the drive is either in an Enabled state or in a Disabled state When power is first appl...

Page 18: ...densing 5 95 RH 3 3 Electrical Specifications All ratings at ambient temperatures 0 to 40 C and PWM frequency of 20 kHz unless otherwise noted 3 3 1 DC Supply Input Parameter Conditions Min Typical Max Units Supply Voltage Operating Range 12 80 VDC Absolute maximum 10 5 90 Supply Current Operating at maximum load and speed 12 30 A Idle condition No external connections 12VDC 120 mA 80VDC 40 3 3 2 ...

Page 19: ...put Impedance Differential 120 Ω 3 3 6 Digital Input Parameter Conditions Min Typical Max Units Input Voltage Logic High 2 3 24 V Logic Low 0 1 Absolute maximum 26 Sinking Current Operational range when logic High 5 mA Sourcing Current Operational range when logic Low 33 µA Input Frequency Step Direction Frequency 1 MHz Pulse Width 400 nS In 0 Enable Brake Limit Limit Frequency 2 kHz Pulse Width 2...

Page 20: ...the environmental conditions This section provides guidance for application of the drive within the recommended operating conditions referenced in this manual However thermal performance of the drive is dependent on the specifics of the application and the environmental conditions The drive does not have any temperature or output PWM frequency derating in the ambient temperature range of 0 to 40 C...

Page 21: ... output current is reduced and limited to the continuous I 2 t current limit value The I 2 t time limit allowed by the software is computed using the equation given below I2 t algorithm limit IP 2 IR 2 x TP Where IP Peak phase current set by user maximum of 30 A IR Rated phase current of 12 A TP I 2 t time in mS I 2 t algorithm limit 1512000 preset The I 2 t time limit that the software allows is ...

Page 22: ...f the drives or as needed for unimpeded natural convection Install the drive using the slots provided which can accommodate up to M4 or 8 screw 4 2 Dimensions Units mm in Figure 8 Drive dimensions 4 3 Mating Connectors Connector Connector Name Manufacturer Mating Connectors P N Crimp Pin P N J1 Supply Phoenix 1757022 N A Altech SH03 5 08 J2 Motor Phoenix 1760006 N A Altech SH05 5 08 J3 Hall Molex ...

Page 23: ...pper Phase A PMDC 2 B A Output BLDC Phase B Stepper Phase A PMDC 3 C B Output BLDC Phase C Stepper Phase B 4 Brake B Output Braking Resistor Stepper Phase B 5 Frame Connected to drive chassis 4 4 4 J3 Hall Connector Pinout Pin Name I O Description 1 Hall 1 Input Hall Signal A Internal pull up to 5Vdc 2 Hall 2 Input Hall Signal B Internal pull up to 5Vdc 3 Hall 3 Input Hall Signal C Internal pull u...

Page 24: ... to drive chassis 2 A In Input Analog In Differential analog input 3 Step Input Step Digital input 4 Limit Input Limit Switch Positive Direction Digital input 5 Enable Input Enable Digital input User selectable polarity 6 Out0 Output General purpose Digital output 7 Fault Output Fault Digital output 8 5VOUT Output 5 Volts DC Power Internally generated 9 A Out Output Analog Out Analog output refere...

Page 25: ... ElectroCraft 2018 24 CPP A12V80A SA USB Technical Reference 5 Connecting Power 5 1 Power supply Drive J1 DC Power DC Power DC Power Supply Figure 10 Power supply connection to the drive ...

Page 26: ...or Shield Figure 11 Brushless DC motor connection to the drive 6 2 Permanent Magnet DC PMDC Motor Drive J2 PMDC Motor Motor Positive Motor Negative Motor Shield Figure 12 Permanent Magnet DC motor connection to the drive 6 3 Stepper Motor Drive J2 Stepper Motor Motor Phase A Motor Phase A Motor Phase B Motor Shield Motor Phase B Figure 13 Stepper motor connection to the drive ...

Page 27: ...rive 7 1 2 Hall Sensor Signal Input Circuit The Hall sensor inputs are limited to 5V logic levels Use the drive supplied 5V to supply power to the motor s hall sensors 5V 5V Hall Signal Input 1KΩ 4700pF 2 2KΩ Figure 15 Hall sensor signal input circuit 7 2 Incremental Encoder 7 2 1 Differential Encoder Drive J4 Use twisted wire pairs for and signal pairs of A B and Z B B Z Z A A Motor Encoder 5V GN...

Page 28: ...nput Figure 18 Encoder signal ended input circuit Note For single ended encoder feedback use signals A B Z and leave signals A B Z unconnected as shown in section 7 2 2 Select Single Ended Encoder in the drive configuration software 7 3 IxR Speed Feedback Estimator The IxR Speed Feedback Estimator is used to estimate motor speed when an actual speed feedback device an encoder or other sensor is un...

Page 29: ...erature is 1kΩ typical The sensor is isolated from any voltage sources the drive provides the necessary excitation This sensor is commonly a thermistor or a normally open temperature switch that closes at the desired shutdown temperature If motor over temperature function is not used the connections must be left open Contact the factory for applications with temperature sensors that do not match t...

Page 30: ...ation Out 0 Digital Output Unused do not connect In 0 Digital Input Unused do not connect Fault Digital Output Open collector output that pulls to ground when the drive is in a faulted state Ready Digital Output Open collector output that pulls to ground when the drive is ready Enable Digital Input Input which enables the drive when an active low signal is applied and disables the drive when a hig...

Page 31: ...is shown in Figure 21 Drive J5 Drive Enable Command Speed or Torque 10KΩ Command Direction Figure 21 Minimum drive I O connections needed to operate BLDC and PMDC motor 8 2 2 Minimum I O Connections for Stepper motor The drive requires an Enable Step and Direction digital input signal to operate A basic example using a switch for the Enable signal and digital pulse input for Step and Direction fro...

Page 32: ... 3 3V 3 3V Digital Input R C 100KΩ Note For Step and Direction digital inputs R 10KΩ and C 10pF For In 0 Enable Brake Limit Switch Positive and Limit Switch Negative digital inputs R 20KΩ and C 4700pF Figure 23 Digital input circuit 8 3 2 Digital Output Circuit 5V Digital Output 590Ω 47V Figure 24 Digital output circuit ...

Page 33: ...99KΩ 2 5V 34KΩ 34KΩ _ 4 99KΩ 47pF 12V 12V 12V Figure 25 Analog input circuit Note For single ended operation connect single ended analog input signals to Analog and connect Analog to analog ground 8 4 2 Analog Output Circuit The scaling for the analog output is configurable using the drive setup software Analog Output 12V 12V PTC _ 33 2KΩ 47pF 2 32KΩ Figure 26 Analog output circuit Note The single...

Page 34: ...formation required for the user to run a particular motor with CPP A12V80A SA USB drive The result will be an Application containing all of the configuration information required to operate the motor with the drive Please refer to the CompleteArchitect user manual for full documentation support to properly configure and operate the drive Windows is a registered trademark of the Microsoft Corporati...

Page 35: ...ve terminal of the supply input and ground This causes current to flow through the resistor and reduce the bus voltage When the bus voltage decreases to the brake resistor Off voltage the drive disconnects the brake resistor circuit This cycle repeats until the system dissipates enough energy beyond which the bus voltage doesn t rise up to brake resistor On voltage The resistor On time is the time...

Page 36: ...value 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑚𝑚𝑚𝑚𝑡𝑡𝑜𝑜𝑜𝑜 The next nearest resistor higher than the calculated value should be selected The table below gives the minimum resistance values for standard power supply voltages at drive continuous current of 12A Use the equation above to calculate the maximum resistance value for other supply voltage...

Page 37: ...pplication with power supply voltage of 48 V and motor deceleration current of 12 A so a 4 ohm resistor is picked according to section 12 3 1 The load accelerates for 6 seconds and brakes for 4 seconds which gives a total cycle time of 10 seconds Example parameters are referenced in the table below Parameter Value Unit Total cycle Time 10 Seconds Time in Braking 4 Seconds Volts during braking 52 V...

Page 38: ...eration current could result in an overvoltage fault condition and may result in damage to the drive 12 5 Connecting External Brake Resistor and Bulk Capacitor The braking resistor and bulk capacitor wiring is shown in Figure 29 Temperature Sensitive Device Connection The user supplied temperature sensitive device is connected in series with the brake resistor as shown in Figure 29 Generally the t...

Page 39: ...Module prevents the excess voltage from feeding back to the power supply As the drive regenerates the module will cycle On and Off to dispose of the excess energy through the brake resistor Care should be taken to ensure the brake resistor is not mounted next to any flammable material as it could get hot This braking module will also allow the user to attach a high wattage braking resistor externa...

Page 40: ...o high Drive outputs are disabled Check motor wires for shorts Verify current loop tuning for stable operation 2 Voltage Fault or Shunt Overpower Drive power is above below operational limits Braking resistor is turned ON for more than 3 seconds No Braking resistor available in the circuit or the resistor is too small for the energy dissipated Braking resistor turn ON OFF limits are set too low Dr...

Page 41: ...ON Power Indicator Drive is powered Required for drive to operate N A OFF Power Indicator Drive is not powered Drive will not operate Apply power to power input of drive Verify input power is within acceptable range Check wires for possible short circuit Verify internally generated 5Vdc power is not overloaded by I O or motor feedback devices ...

Page 42: ... ElectroCraft 2018 41 CPP A12V80A SA USB Technical Reference ...

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