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ElectroCraft CompletePower Plus CPP-A24V80A-SA-CAN, User Manual

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ElectroCraft CompletePower Plus CPP-A24V80A-SA-CAN User Manual Download Page 22

 

© ElectroCraft 2022 

21 

High Power Universal Drive User Manual 

5 

Hardware Installation 

5.1 

Mechanical Mounting 

 

The drive is intended to be mounted at least on a 300 mm (12 in) x 300 mm (12 in) metallic support which 
is  not  connected  to  any  other  heat  generating  source  and  must  act  as  a  cooling  heat  sink.  Use  the 
provided mounting holes and the recommended mating connectors, as referenced in section 5.3. Provide 
at  least  125  mm  (5  in)  of  clearance  between  drives  or  units  and  at  least  250  mm  (10  in)  of  clearance 
above  and  below  each  drive  when  installing,  for  full  rated  operation  of  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. 

 

5.2 

Dimensions 

 

Figure 8: Drive dimensions (for both CPP-A24V80A-SA-CAN & CPP-A40V24A-SA-CAN) 

5.3 

Mating Connectors 

 

Connector 

Connector Name 

Manufacturer 

Mating Connectors P/N 

Crimp Pin P/N 

J1 

Supply 

Phoenix 

1804933* 

N/A 

FCI / Amphenol 

20020516-M051B01LF 

ET0501500000G 

J2 

Motor 

Phoenix 

1804920* 

N/A 

FCI / Amphenol 

20020516-M041B01LF 

ET0401500000G 

J3 

Hall 

Molex 

43025-0800 

43030-0007 

Adam Tech 

DMT-2-08 

DMT-B-C-F-T-R 

J4 

Encoder 

Molex 

43025-1000 

43030-0007 

Adam Tech 

DMT-2-10 

DMT-B-C-F-T-R 

J5 

I/O 

Molex 

43025-1600 

43030-0007 

Adam Tech 

DMT-2-16 

DMT-B-C-F-T-R 

J6 

USB 

N/A 

Miniature USB Type B - Male 

N/A 

J7 

CAN Input 

Amp 

RJ45 

N/A 

J8 

CAN Output 

Amp 

RJ45 

N/A 

- 

Crimp tool for J3, J4, J5 

Molex 

0638190000

 

N/A 

*Phoenix parts listed must be used only for applications less than or equal to 20A continuous current. 

Summary of Contents for CompletePower Plus CPP-A24V80A-SA-CAN

Page 1: ... ElectroCraft 2022 CPP A24V80A SA CAN CPP A40V24A SA CAN Drive User Manual ElectroCraft CompletePower Plus Universal Servo Drive ElectroCraft document number 198 0000084 ...

Page 2: ... 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 writing from ElectroCraft Inc The information in this document is subject to change without notice About This Manual This document is a Drive User Manu...

Page 3: ...ed problems Make suggestions or report errors in documentation Contact ElectroCraft For regional technical application and sales support for ElectroCraft and Hansen Products North America USA Mexico South America Central America Contact 844 338 8114 sales electrocraft com Europe except Germany Middle East Africa Australia Contact EMEA Sales Team 44 0 1270 508800 EMEAsales electrocraft com Germany ...

Page 4: ...nsor Configurations 15 3 6 Identification Labels 15 3 7 Status Indicator Lights 15 4 Drive Specifications 16 4 1 Physical Specifications 16 4 2 Environmental Specifications 16 4 3 Electrical Specifications 16 4 3 1 DC Supply Input for CPP A24V80A SA CAN 16 4 3 2 DC Supply Input for CPP A40V24A SA CAN 16 4 3 3 5VDC Supply Output 16 4 3 4 Motor Output 17 4 3 5 Hall Sensor Inputs 17 4 3 6 Encoder Inp...

Page 5: ... 2 Hall Sensor Signal Input Circuit 26 8 2 Incremental Encoder 27 8 2 1 Differential Encoder 27 8 2 2 Single Ended Encoder 27 8 2 3 Encoder Input Circuit 28 8 3 IxR Speed Feedback Estimator 28 8 4 Motor Temperature Sensor 29 8 4 1 Temperature Sensor Connections 30 8 4 2 Temperature Sensor Signal Input Circuit 30 9 Connecting I O 31 9 1 I O Functional Description 31 9 2 I O Connections 32 9 2 1 Typ...

Page 6: ...ry of Operation 39 13 3 Selecting External Brake Resistor 40 13 3 1 Calculating resistance value of the braking resistor 40 13 3 2 Calculating power value of the braking resistor 41 13 4 Minimum external bulk capacitance 42 13 5 Connecting External Brake Resistor and Bulk Capacitor 42 13 6 ElectroCraft Braking Module Assembly 43 14 Troubleshooting 44 14 1 Status LED Red 44 14 2 Power LED Green 45 ...

Page 7: ...DIFFERENTIAL ENCODER CONNECTION TO THE DRIVE 27 FIGURE 16 SINGLE ENDED ENCODER CONNECTION TO THE DRIVE 27 FIGURE 17 ENCODER SIGNAL ENDED INPUT CIRCUIT 28 FIGURE 18 TEMPERATURE SENSOR CONNECTION TO THE DRIVE 30 FIGURE 19 TEMPERATURE SENSOR SIGNAL INPUT CIRCUIT 30 FIGURE 20 TYPICAL DRIVE I O CONNECTIONS NEEDED TO OPERATE BLDC AND PMDC MOTORS 32 FIGURE 21A DIGITAL INPUT CIRCUIT FOR CAPTURE ENABLE BRA...

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: ...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 5 for details Failure to observe this caution may result in fire or malfunction 1 5 Wiring 1 Verify ALL wiring BEFOR...

Page 11: ...e port must be covered by non conductive rubber plug tape or label 1 6 Life Support Policy READ THIS ENTIRE SECTION BEFORE ATTEMPTING TO USE THE CPP A24V80A SA CAN DRIVE ElectroCraft products are not authorized for use as critical components in life support devices or systems without the express written approval from ElectroCraft Incorporated 1 Life support devices or systems are intended for surg...

Page 12: ...ted by ElectroCraft Always insure your shipment for the proper replacement value of its contents ElectroCraft will not assume responsibility for any returned goods that have been damaged outside of our factory because of improper packaging or handling All goods shipped to ElectroCraft must be shipped FREIGHT PREPAID 2 Introduction to ElectroCraft CompleteArchitect PC Software ElectroCraft Complete...

Page 13: ...ostics 10V Analog command input Digital step and direction input 10V Analog output configurable Encoder mode for low speed performance Capture digital input for Encoder location Digital output to signal to engage eBrake BLDC and PMDC 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 ...

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: ...igh Power Universal Drive User Manual 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: ... feedback signal 3 5 Motor and Sensor Configurations Brushless Motor PMDC Motor Hall Sensors Yes No Encoder Halls Yes No Encoder Only No Yes IxR Estimator No Yes None No Yes 3 6 Identification Labels Figure 5 Drive with identifying label 3 7 Status Indicator Lights In normal operation the drive is either in an Enabled state or in a Disabled state When power is first applied the green LED will be O...

Page 17: ...RH 4 3 Electrical Specifications All ratings at ambient temperatures 0 to 40 C and PWM frequency of 20 kHz unless otherwise noted 4 3 1 DC Supply Input for CPP A24V80A SA CAN 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 24 60 A Idle condition No external connections 12VDC 127 mA 80VDC...

Page 18: ...puts Parameter Conditions Min Typical Max Units Input Voltage Operating Range 0 5 5 V Logic low operating 0 1 Logic high operating 2 3 5 Sourcing Current Logic low with internal 2 2K pull up to 5V 2 3 mA 4 3 6 Encoder Inputs Parameter Conditions Min Typical Max Units Input Voltage Single ended Logic low operating 0 1 5 V Logic high operating 3 5 5 Differential RS422 High threshold 0 2 Low threshol...

Page 19: ...rising edge of the input pulse 4 3 8 Digital Output Parameter Conditions Min Typical Max Units Output Voltage Ready Fault Operational range 0 5 24 1 V Absolute Max 28 1 eBrake Operational range 0 48 1 Absolute Max 53 1 Sourcing Current 2 Ready Fault eBrake 7 mA Sinking Current Ready Fault 2 4 A eBrake 1 0 External Load Impedance 3 Ready Fault 10 eBrake 48 1 Note When voltage is applied externally ...

Page 20: ...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 temperature derating for different PWM frequencies in the ambient temperature range of 0 to 40 C and supply voltage of 80VDC is shown in Figure 6 when mounted according to ElectroCraft...

Page 21: ... the equation given below I2 t algorithm limit IP 2 IR 2 x TP Where for A24V80A IP Peak phase current set by user maximum of 60 A IR Rated phase current of 24 A TP I2t time in ms I2t algorithm limit 6048000 preset Where for A40V24A IP Peak phase current set by user maximum of 100 A IR Rated phase current of 40 A TP I2t time in ms I2t algorithm limit 16800000 preset The I2t time limit that the soft...

Page 22: ...using the slots provided which can accommodate up to M4 or 8 screw 5 2 Dimensions Figure 8 Drive dimensions for both CPP A24V80A SA CAN CPP A40V24A SA CAN 5 3 Mating Connectors Connector Connector Name Manufacturer Mating Connectors P N Crimp Pin P N J1 Supply Phoenix 1804933 N A FCI Amphenol 20020516 M051B01LF ET0501500000G J2 Motor Phoenix 1804920 N A FCI Amphenol 20020516 M041B01LF ET0401500000...

Page 23: ...rive chassis 5 4 3 J2 Motor Connector Pinout Pin Name I O Description 1 A Output BLDC Phase A PMDC 2 B Output BLDC Phase B PMDC 3 C Output BLDC Phase C 4 Frame Connected to drive chassis 5 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 up to ...

Page 24: ...ial analog input 3 1 Step Input Step Digital input A In2 Input Analog Input2 Differential analog input 4 Limit Input Limit Switch Positive Direction Digital input 5 Enable Input Enable Digital input 6 eBrake Output Digital output 7 Fault Output Fault Digital output 8 5VOUT Output 5 Volts DC Power Internally generated 9 A Out Output Analog Output 10 A In1 Input Analog Input1 Differential analog inp...

Page 25: ...nput Isolated return for Enable In 6 Shield CAN Shield pass thru to J8 pin 6 7 GND CAN GND digital GND 8 CAN V Pass thru no connection 5 4 9 J8 CAN Communications Output Pinout Pin Name I O Description 1 CAN H In Out CAN high differential signal 2 CAN L In Out CAN low differential signal 3 GND CAN GND digital GND 4 5VOUT Output 5 Volts DC Power Internally generated 5 EN Out Output Digital output f...

Page 26: ...y connection to the drive 7 Connecting Motors 7 1 Brushless DC Motor Motor Phase A Motor Phase B Motor Phase C Drive J2 Brushless DC Motor Motor Shield Figure 11 Brushless DC motor connection to the drive 7 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 ...

Page 27: ...2 Hall 3 5V Drive Ground J3 Hall 1 Brushless Motor Hall Sensors Figure 13 Hall sensor connection to the drive 8 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 Hall Signal Input 1K 4700pF 2 2K Figure 14 Hall sensor signal input circuit ...

Page 28: ...coder Drive J4 Use twisted wire pairs for and signal pairs of A B and Z B B Z Z A A Motor Encoder 5V GND Figure 15 Differential encoder connection to the drive 8 2 2 Single Ended Encoder Encoder A Encoder B Encoder Index Drive Ground 5V J4 Motor Encoder Figure 16 Single ended encoder connection to the drive ...

Page 29: ...feedback use signals A B Z and leave signals A B Z unconnected as shown in section 8 2 2 Select Single Ended Encoder in the drive configuration software 8 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 unavailable The drive estimates the speed of the motor using the Motor s Resistanc...

Page 30: ...is can be enabled in CompleteArchitectTM and doesn t require to set any thresholds Threshold Level Temperature Sensing A custom configurable threshold set in CompleteArchitectTM Consult factory Negative Temperature Coefficient NTC Temperature Sensing An NTC sensor is a resistive element whose resistance decreases with temperature The values of R25 and B25 Tref are inherent to the NTC sensor being ...

Page 31: ... 1 Temperature Sensor Connections Temp Sensor Temp Sensor Motor J3 Drive J3 Figure 18 Temperature sensor connection to the drive 8 4 2 Temperature Sensor Signal Input Circuit _ 3 3V 1K Motor Temp Input BAV99 3 3V 1mF Figure 19 Temperature sensor signal input circuit ...

Page 32: ...hould be connected to ground eBrake Digital Output Open drain output that can be used to engage electromechanical brake See section 12 for more details Capture Digital Input When the capture input pin has been triggered it provides an instantaneous encoder count location The trigger occurs on a falling edge input The count location is stored in memory and can be accessed via USB or CAN Fault Digit...

Page 33: ...leteArchitectTM To run the drive in a basic no I O connection mode the drive needs to be configured to ignore the enable input set a fixed direction and set a fixed speed or torque setting See the CompleteArchitectTM manual for more details 9 2 1 Typical I O Connections for BLDC and PMDC motors A basic example using a switch for the Enable signal a potentiometer for analog speed torque command and...

Page 34: ...ake and Limit Switch Inputs For Enable Brake Limit Switch Pos Limit Switch Neg R 20KΩ and C 4700pF For Capture R 10KΩ and C 5pF Step Direction Inputs See section 9 1 for functional application regarding step direction inputs The states of these pins can be monitored in CompleteArchitect There is the option to set the steps per revolution in CompleteArchitect The software will divide the Desired St...

Page 35: ...operation connect single ended analog input signals to Analog and connect Analog to analog ground 9 4 2 Analog Output Circuit The scaling for the analog output is configurable using the drive setup software Analog Output 100 _ 100pF 69 8K 10K PTC 10V 69 8K Figure 25 Analog output circuit Note The single ended analog output is referenced to ground on J5 pin 16 The primary analog output circuit is l...

Page 36: ...5V External Output Internally generated 5 volts for customer use Refer to section Error Reference source not found Shield Pass through for CAN cable shield ground Ground Referenced to supply ground CAN V Pass thru no connection 10 1 2 CAN Physical Layer Circuit CAN TRx CAN_P CAN_N 24V 5pF Figure 26 CAN Physical Layer Circuit Important Note CAN bus termination of 120 Ohms between CAN high and low s...

Page 37: ...is achieved by connecting the CAN enable output circuit of one drive to the CAN EN circuit to the next drive See Figure 30 below Note that the 5V external supply is provided from the first drive to the second drive for CAN enable high input The second drive and subsequent drives can also be pulled up by an external source See section 4 3 12 for electrical specifications Figure 29 Drive Daisy Chain...

Page 38: ... range 1 15 are available by this method See table below SW ID Name Description ID1 ADDR0 Hardware CAN Axis ID bit 0 ID2 ADDR1 Hardware CAN Axis ID bit 1 ID3 ADDR2 Hardware CAN Axis ID bit 2 ID4 ADDR3 Hardware CAN Axis ID bit 3 c CAN Axis ID configured in CompleteArchitectTM as a base address plus hardware switches d Dynamically assigned at power up over the CAN bus As shipped from the factory sta...

Page 39: ...ettings If the drive does not function refer to Troubleshooting section 14 12 eBrake Control The drive includes an output circuit that can be used to control an external electromechanical brake There are two options for this as indicated below Option 1 For high current applications a relay or switch can be driven by the output Option 2 For low current applications the eBrake can be driven directly...

Page 40: ...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 41: ...n Minimum Resistance value 𝑆𝑢𝑝𝑝𝑙𝑦 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑑𝑒𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑜𝑡𝑜𝑟 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 24 A Use the equation above to calculate the maximum resistance value for other supply voltage and drive continuous curr...

Page 42: ...pplication with power supply voltage of 48 V and motor deceleration current of 24 A so a 2 ohm resistor is picked according to section 13 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 43: ...ent could result in an overvoltage fault condition and may result in damage to the drive 13 5 Connecting External Brake Resistor and Bulk Capacitor The braking resistor and bulk capacitor wiring is shown in Figure 33 Temperature Sensitive Device Connection The user supplied temperature sensitive device is connected in series with the brake resistor as shown in Figure 33 Generally the temperature s...

Page 44: ...cking 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 watta...

Page 45: ...oo 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 D...

Page 46: ...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 47: ... ElectroCraft 2022 46 High Power Universal Drive User Manual ...

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