Control Techniques MiniAx 60 x 5/10 User manual

MiniAx
60 x 5/10
60 x 10/20
300/600W Six-step
brushless
Variable Speed Drive
Codice: 01.0056.0 Issue 1 November 99

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Index
1.0 Product information________________________________ _______________________ 3
1.1 Introduction________________________________ _____________________________ 4
1.2 Technical data ________________________________ __________________________ 4
1.3 Drive Description ________________________________ ________________________ 5
1.4 Drive Label Description________________________________ ____________________ 6
1.5 Drive Dimensions ________________________________ ________________________ 7
1.6 Connections ________________________________ ____________________________ 7
1.7 Signal inputs and outputs ________________________________ __________________ 8
1.8 Power inputs and outputs ________________________________ __________________ 9
2.1 Potentiometer adjustments ________________________________ ________________ 10
2.2 Protections ________________________________ ____________________________ 11
2.3 L.E.D. indicators ________________________________ ________________________ 11
2.4 Personalizations and settings ________________________________ ______________ 12
2.5 Solder Links ________________________________ ___________________________ 13
3.1 Power supply (rating) considerations ________________________________ ________ 14
3.2 Multiple Connections ________________________________ ____________________ 16
3.3 Electro-magnetic Compatibilty Standards________________________________ _____ 17
3.4 Connection and Wiring System________________________________ _____________ 20
3.5 Connecting Ground and Screen.________________________________ ____________ 21
3.6 Examples of Signal Connections ________________________________ ___________ 22
3.7 Power Connections________________________________ ______________________ 28
4.1 Logic Hall Signals 120° and 60° ________________________________ ____________ 29
4.2 Practical example of Hall, Motor and MiniAx phasing.____________________________ 30
5.1 Speed Adjustment with Encoder Feedback. ________________________________ ___ 31
5.2 PWM Speed feedback adjustment________________________________ __________ 32
5.3 Hall Effect Sensor Speed Adjustment________________________________ ________ 33
5.4 Adjusting Speed Balance ________________________________ _________________ 34
5.5 Nominal Current Adjustment________________________________ _______________ 34
5.6 Peak current adjustment________________________________ __________________ 34
5.7 Ramp time adjustment ________________________________ ___________________ 35
5.8 Dynamic constant adjustment________________________________ ______________ 36
6.1 Troubleshooting ________________________________ ________________________ 37

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1.0 Product information
The MiniAx amplifier series is distributed with the CE mark, because they are in accordance with th
European Directives on EMC and Low Voltage.
ATTENTION!
ELECTRICAL AND CONTROL EQUIPMENT CAN BE DANGEROUS IF HANDLED IMPROPERLY
This manual describes the mechanical and electrical characteristics of the MiniAx servoamplifier series.
It is important that the installation procedures are performed by only qualified personnel in accordance with
local safety guidelines.
Whoever installs the equipment must follow all of the technical instructions printed in this manual.
All rights reserved. Reproduction in whole or in part is prohibited without prior written permission of th
copyright owner. All specifications are subject to change without prior written permission of the copyright
owner. All specifications are subject to change without prior notification.

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Chapter 1 Description
1.1 Introduction
The MiniAx BRUSHLESS is a very small bi-directional, four quadrant drive.
the output power stage (MOSFET) is controlled using the PWM technique with 22 Khz modulation frequency
which allows it to drive small to medium sized brushless servomotors (up to 2Nm) where dynamic
performance and noticeable rotation regularity is required.
MiniAx, is a drive with a one source power range of 20-80 Vdc along with a differential type reference input.
Drive enable is furnished through continuous voltage between +10Vdc/30Vdc. It is also possible to enable
through GND connection.
The velocity feedback may be through:
-Hall sensor + encoder.
-Internal PWM (Armature), + Hall sensor.
Exist the possibility to change any default setting of parameters just substituting existing components with
different value.
The selection of various prearranged values setting is easily realized by opening and closing solder points.
The intervention of drive protections are all visible with LEDs on the front of the drive.
5-10A 10-20A
The nominal current, as well as peak current is adjusted through resistance on the base pcb. The drive
dimensions are 135,5x82x 28,5mm. Listed below are the 2 principle sizes of the MiniAx product line:
The operating temperature is from 0 to 40 °C (32° to 104°F) and no ventilating system is required as long as
the spacing between the drives allow for adequate air flow.
1.2 Technical data
Input voltage Range 20-80 Vdc
Output voltage max. 0,93 V input
PWM frequency 22 kHz
Operating Temperature 0/40 C°
Storage Temperature -10/70 C°
Drift +/-18 uV/C°
Analogue input +/-10 Vdc
Current monitor +/-7 Vdc=Pk. curr.
Encoder and Hall Effect +5 Vdc max130 mA
Auxilary power supply +/-10 Vdc max 4mA
Max. Encoder frequency 250 kHz
Logic signals +10/30 Vdc **
Band Width of current loop 2.5 kHz
Humidity 10/95 % w/o
No condensation
Weight 350 gr.
Altitude 2000 m.slm
** The MiniAx can also be setted in negative logic.

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1.3 Drive Description
1 Calibration component area (socket and links)
2 Calibration Potentiometers
3 Signal terminals
4 Power terminals
5 Fixing screws
6 Module cover
7 Module Label
8 Serial number

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1.4 Drive Label Description
TYPE MiniAx 060-5/10-PWM- 0
ADJ 5/10A RA
Date 27/04/98 Ord.365 /98
The Product Label is on all MiniAx Drives. The Label printed above is a typical example. To identify the
various options see below: Product type and Identification.
TYPE MiniAx 60 5/10
Model 5/10
10/20
I nom/I Peak
ADJ is the identification of specific adjustments on the product for specific motors. If the product is furnished
Standard, the ADJ will show the disbursed current.
ADJ 55MM 2048step/rev 3000RPM
Motor
Encoder pulse
Nominal speed
ORD is CONTROL TECHNIQUES's internal order number which relates to product distribution. Always
reference this number for eventual requests.

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1.5 Drive Dimensions
NOTE:Dimensions ( ” Inch - mm).
1.6 Connections
135.50
28.50
82.00
19.50
64.50
18.00
5.33”
1.20”
3.22”
0.76”
2.53”
0.70”

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1.7 Signal inputs and outputs
The following is the Signal Connector Description.
1 IMOT(OUT). Current Monitor: +/-7 V corresponds to drive's Peak current. A 5K6 Kohm resistor is
inserted in series on the output driver.
2 OK (OUT). Drive Ok, Open collector with 50mA max. current. (Normally closed, it opens for any
type of protection intervention).
3 TPRC (IN). (OUT). This command can be used in 2 distinct modes:
A. Current Output Limitation;
happens by connecting an external resistor to zero; linear re-partitioning with R
internal = 47K (the internal velocity loop remains functional). Ex. with ext. R of 47K
the curent is limited 50% of the size I Max.
B. Current Reference (Torque Input): low impedance voltage drive with a signal of
+/- 10V max., which corresponds to the drives peak current output.
In this case the velocity loop is automatically excluded and doesn't interfere with the
system.
The TPRC terminal could be used (as an alternative in cases A and B) as a signal
monitor of the drive's demand current (output impedence 50k)
4 GND DriveCommon Zero Signal. Internally connected with to power supply's negative -AT
input.
5 +10V (OUT). Auxilary voltage+10V max 4mA
6 -10V (OUT). Auxilary voltage-10V max 4mA
7 ENABLE (IN). Functional enabling of the drive. (Range included between +10V and 30Vdc max.
positive logic).
It's also possible to enable the drive with negative logic by connecting a GND input
(to enable such a function, close solder links S12-S13).
8 +REF(IN). Positive (hot) differential Reference input.
9 -REF (IN). Negative (cold) differential Reference input.
10 CHA (IN) Encoder input Chanel A (include high logic level between +5V/24Vdc max)
High logic level >3,2V Low logic level <1,5V.
11 CHB (IN) Encoder input Chanel B. (include high logic level between +5V /24Vdc max).
High logic level >3,2V Low logic level <1,5V.
12 +V (OUT). Auxilary voltage +5V max 130mA.
13 GND. DriveCommon Zero Signal. Internally connected with to power supply's negative -AT
input.
14-15-16 HALL A-B-C (IN). Hall Sensor inputs internally connected to the motor. Each input has a pull-up
resistor 1 Kohm at 5V.
High logic level>3,2V , Low logic level<1,5V.


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NOTE !: Always power the motor's hall sensors using the auxilary power supply intrnally generated by the
MiniAx SMPS (Terminal 12 +V).
If an external power supply is used, open solder bridge S11.
WARNING: Such an external power supply, if used to supply the incremental encoder + hall effect sensors,
must be applied to the motor at the same time the the MiniAx is switched on.
1.8 Power inputs and outputs
+AT (Input). Positive continuous power supply. (allowed range between 20V and 80V).
-AT (Input). Negative Continuous power supply. Internally connected to the Common Zero
Signal GND.
U (Output). Motor connection U phase
V (Output). Motor connection V phase
W (Output). Motor connection W phase

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Chapter 2 Adjustments
2.1 Potentiometer adjustments
SPEED
Speed potentiometer.Turn the potentiometer clockwise (cw) to increase the
maximum speed and counter-clockwise (ccw) to reduce the maximum
speed.
The range of the adjustment is +/-20%.
OFFSET
Offset adjustment.Adjust this potentiometer to cancel any offset in the
external speed ref. signal.
(Max ref. compensation +/- 200mV).
GAIN
With this adjustment we can improve the dynamic behaviour of the servomotor.With a clockwise turn (cw)we
increase the gain of the PI “speed stage”, therefore, improving the response.
DER (DAMP)
Turn the potentiometer clockwise (cw)to increase the derivative (damping) effect,reducing the amount of
overshoot in the system response.
ACC
The solder bridges S1-S3 allow insertion of the acc/dec function (ramp). With this potentiometer we can
adjust the slope of the ramp in acceleration and deceleration. Turning the potentiometer clockwise
(cw) increases the ramp time from 0,1 to 1 Sec (with 10 V reference).
It is also possible to increase or decrease the pre-set max time of acc/decby opening solder bridge S2 and
inserting resistance RAMP.
(See chapter RAMP TIME ADJUSTMENT)
SPEED
OFFSET
GAIN
DER
ACC
(DAMP)

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2.2 Protections
The MiniAx is equipped with a series of protections to safeguard both the drive and the motor, in case of
malfunctions.
All protections are visualized using LEDs on the front of the drive. (See the next page).
The two types of interventions are Reversible and Irreversible.
Reversible Protection Intervention:
The drive is automatically reset/restarted when the cause of interventionhas been corrected.
-Current limitation
-Min max voltage
Irreversible Protection Intervention:
The drive is reset but not restarted. The power supply must be removed and the cause of intervention
eliminated, then the power supply can be replaced. *Note: A mininum amount of time must pass in order to
ensure that the drive is completely off prior to replacing the power supply.
-Over Current
-Drive thermal switch
-Missing Hall Effect Signals
2.3 L.E.D. indicators
FiveLEDs are available on the drive and they signify the following:
- (GREEN) OK Normally ON, means proper operation of the drive. When
the LED is OFF, it indicates that at least one of the drive protection functions
is active.
- (RED) IN Normally OFF,it become lit when the nominal motor I-t limit is
exceeded.
(Reversible alarm)
- (RED) ST Normally OFF. May come ON,because of a short circuit between
motor terminals and short circuit to ground.It cannot be reset and the fault
activate the memorization of the alarm.
Switch off the system,eliminate the cause and then re-start the power
supply.
- (RED) OC Normally OFF,it represents overheating of the drive heatsink.
This fault activate and memorize the alarm. To reset it is necessary to turn
off the power supply, wait until the heatsink temperature is lower, and then
re-start the power supply.
- (RED) AH Normally OFF. The light status indicate either missing Hall signals or incorrect 60° or 120°
settings.
It cannot be reset and the fault cause the memorization of the alarm. S11 is Normally (default) closed.If
Open, the alarm protection for missing Hall Effect Signals will not disable the drive.

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2.4 Personalizations and settings
WARNING: After switching off to do the adjustments, please wait for at least 10 sec before working inside
the drive.
If the drive isn’t adjusted with the proper servomotor, follow these procedures.
All of the personalizations are located inside of the MiniAx. To gain access to the adjustment components
and the solder bridges , unscrew (A) , and remove the cover (B). (See fig. below)
All of the adjustments are located in the area behind the potentiometers .It’s there that a header containing
all of the adjustment components is located..
The header is made of a double rowand 9 locations of components with 10.00mm/0.4" pitch (resistors) and
a double row 3 locations of components with 5.08 mm/0.2” pitch (capacitors).
The resistors may be either 1/4W or 1/8W.
RENC Low Scale Speed Adjustment with Encoder or Hall Effect feedback.
RA Low Scale Speed adjustment with Armature Feedback
RCA Droop compensation of internal Motor Resistance (RI)
RIN Nominal Current limitation resistor.
RIP Peak current limitation resistor.
GAIN Determines static gain of the speed loop. Insertion of new values is possible by
opening Solder bridge S6 (Disable internal Constant Standard from 22Ohm).
CDER By inserting a capacitor on the extractable card in CDER you can increase th
internal pre-set speed loop's deriative constant.
RKV- CKV resistor and capacitor values that respectively form the proportional/integral network
of the Speed Loop. Substitution may be done by opening Solder bridge S5(Dynamic
Constant Standard Disablement ;100 Kohm-47nF).
RKI- CKI Resistor and capacitor values that respectively form the proportional/integral network
of the current Loop. Substitution may be done by opening Solder Bridge S7
(Dynamic Constant Standard Setting; 220Kohm- 2.2nF).

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2.5 Solder Links
13 Solder Links are present (in the Adj. Zone) with which it's possible to enable or disable funcitons or parts
of the MiniAx. Verify the corresponding solder links closings required by the drive.
The Drive is furnished with the following Standard configuration of closed solder links:
Indicated below are the solder links that are to be opened or closed in accordance with the desired funtions.
S1 e S3 Normally open. (See Chapter 5.7 “Ramp Time Adjustment”).
S2 Normally closed. (See Chapter 5.7 ““Ramp Time Adjustment”).
S4 Normally closed. If Open - disable the Encoder or Hall Effect speed feedback if selected.
S5 Normally closed. (Standard constant RKV=100Kohm , CKV= 47nF)
If Open - You must insert the NEW Dynamic Constant CKV, RKV on the persalization base.
(Adjustment reserved for Qualified Personnel Only ! )
S6 Normally closed. If Open - you must insert the New GAIN resistor. (Static Gain). Standard value= 22ohm
S7 Normally closed. If Open - you must insert the Dynamic Constant CKI, RKI on the personalization base.
(Standard constant RKI=220 Kohm , CKI= 2,2nF)
(Adjustments Reserved for Qualified Personnel Only!)
S8 Normally open. If Closed, when the IN protection is activated the green OK LED goes off and is unable to
allow the Drive OK LED to come on.
S9 Normally closed.(Encoder Feedback option). If open, you must configure the Speed feedback from the
Hall Effect Signal.
S10 Normally open. (Hall Effect 120° option). If Closed - you must enable the drive for Hall Effect 60°.
S11 Normally closed. If Open, the alarm protection for missing Hall Effect Signals will not disable the drive.
S12 - S13 Normally open. (Configured for Drive signal with positive logic >+8V max 24V.). If Closed -
configure signal with negative logic. (Enable with zero GND Voltage).

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Chapter 3 Installation
3.1 Power supply (rating) considerations
WARNING:Use the following scheme and equation shown below to calculate the power supply rating.
The drive doesn’t need auxiliary voltage ,all of the voltages requested come from an internal flyback
DC-DC converter.
Transformer
The drive has the internal zero signal connected
with the negative (power), consequently:
-- Do Not use auto transformers
--If the transformer is connected using Center-Star,
Do not connect to Ground
--Do Not connect any points of Transformer Primary or Secondary to Ground
Therefore, use the MiniAx power supply for these.
- Keep the +AT and -AT between the power supply and the MiniAx as short as possible. If shielded cable is
not used twist the 2 cables together.
Voltage: The primary voltage depends on the available main voltage. The secondary voltage will be
calculated according to the motor’s characteristics and according to the voltage drive range.
The Value will be:
V2 (Dc) = VM / 0,8
Where: VM = E+ (Ri x Im) E = Ke x n° / 1000
VM=Motor voltage(V)
E =motor BEMF(V)
Im = I motor(A)
Ri =Winding resistance(Ohm)
Ke =Voltage constant (V/kRPM)
n° = Max. speed(RPM)
Considering you must keep a certain margin during the motor's breaking phase, you should never exceed a
voltage of 60Vdc (44 Vac from transformer).
The max. value is 80Vdc and the min. value is 20Vdc.
Example:Brushless DC Motor with the following data:
Im =3,8 (A)
Ri = 2,5 (Ohm)
Ke =12 (V/kRPM)
n° = 3000(RPM) E = 12 x 3000 / 1000 = 36 (V)
VM = 36 + ( 2,5 x 3,8 )= 45 (V)
V2 = 45 / 0,8 = 56 (V) V1= 56 / 1,41 = 39,8 (Vac)
You'll use a transformer with the secondary V1= 39 Vac OK 44Vac.
AC
Power

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Transformer power
The transformer's nominal power is calculated based upon the sum of power from the single motors driven.
Or Better:
P(VA)=Power absorbed by motor 1 + Power absorbed by motor 2+....etc)
Note; however, that in multi-axis applications, the transformer's power can be derated to 30% of its initial
power.
In regards to the filter capacitor we suggest a 100Vdc working voltage. It's capacity value is derived using
the following formula:
C (uF) = P (VA) trafo. / V2 x 2000
V2 = DC Voltage present on capacitor without load.
Such a capacitor is used to filter the straightened voltage from the power supply and to recover energy
during the motor's braking phase..
Discharge resistor
This resistor,discharge the capacitor also when the amplifier is disconnected after the power supply is switch
off.
The value can be calculatedwith the following formula:
RS (Ohm) = 20 x 1.000.000 / C (uF)
P (W) = V22 / RS
Fuses
Determination of the primary and secondary F1 and F2 transformer fuses.
Such fuses can be replaced with thermomagnetic switches of the same value.
The F1 fuse inserted on the primary protects the transformer from current overloads caused by th
secondary. This fuse is the “Slow” type.
The F2 fuse inserted on the secondary protects the transformer from short circuits caused by the charge or
on the rectifier bridge itself. This fuse is the“Slow”type.
F 1 = P (VA) trafo. x 1,1 / V (primary) ac
F2 for MiniAx 5/10 = 8A
for MiniAx 10/20 = 20A
MAIN-AC

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3.2 Multiple Connections
In case of Multi-axis application from a single power supply, use the "STARY" type of power supply
distribution. DO NOT use cascade type connections such as "SEQUENCE".
DO NOT USE THIS WIRING!
USE THIS WIRING!
Connect the MiniAx to the power supply using the shortest route possible. Max. 1m. (Contact CONTROL
TECHNIQUES for additional information.
+Vdc
-Vdc
+AT +AT +AT
- AT - AT - AT
Power Supply
MiniAx
+Vdc
-Vdc
+AT +AT +AT
- AT - AT - AT
Power Supply
MiniAx

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3.3 Electro-magnetic Compatibilty Standards
The regulated standard in accordance with conformity of electromagnetic compatiibilty is summarized in
Italian Regulation CEI EN 61800 (complete).
MiniAx conformity is assured only if it is installed following the precise assembly criteria expressed below:
The fundamental assembly characteristics are summarized below:
1) Use of appropriate network filters to filter the line (transformer input), from disturbances conducted or
produced by the drive.
A series of filters released by CONTROL TECHNIQUES are available for this purpose.
2) Use of shielded cables, both for power connection (to the transformer and the motor), and for signal
connection (also to the controller).
3) Using the separation of cables technique. (Separate power cables from signal cables).
4) the correct ground connection of predisposed parts.
Network filters
Of all of the mentioned sistems, the use of network filters is without a doubt fundamental in suppressing
disturbances.
During product testing Control Techniques found optimal solutions for their products. Other eveutual choices
of filtering by End-Users cannot be guaranteed by CONTROL TECHNIQUES.
Below is a graphic example of disturbance levels measured with and without using the type of filter indicated
in the following pages.
These filters are produced by SCHAFFNER. Other products with the same characteristics may be sufficient,
but have notbeen tested or evaluated by CONTROL TECHNIQUES.
In choosing the filter, we also considered the current absorption of its connecting devices. CONTROL
TECHNIQUES recommends connecting the filter before the power supply transformer. This method,
besides offering better disturbance suppression results, also allows for the use of filters capable of
supporting a lot less current, consequently they're cheaper.(takes advantage of the transformers ratio).
Follow the formula below for the filter dimensions for use with the MiniAx.
I(A)= P tot. / ( 1.73 * 380 )
Where: --I is the net current expressed in Amperes for the necessary filter.
--380 is the 3 Phase Transformer primary voltage.
--P tot. is the motor's max. power absorption in VA.
P(VA)=Motor1 power absorption + Motor 2 power absorption + .....etc.
Withou t filter
With filter
Rule Lim it

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WARNING:
For filter connection (divert to ground or earth the unwanted frequency) considering such devices can
produce small leakage current towards earth or ground (this current amounts to "some" amount of
milliapmeres). For these precautionary reasons, it is necessary to connect the filter to earth prior t
connecting the power supply.
In relations to leakage current, remember that it must be considered when sizing differential switch, thus
avoiding undesired interventions. The precise data relative to our filters can be found below.
Mechanical and Electrical Characteristics
Below is a table showing the electrical characteristics of our recommended filters. Pay particular attention to
Leakage, differential adjustments, and nominal current in accordance with operational temperature.:
Type Current Rating Leakage Current Power Loss Weight
(A) (mA) (W) (Kg)
FN355-3 3 (40°) /3.2 (25°) 0.41(400V 50HZ) 1.5 0.25
FN251-4 4 (40°) /4.6 (25°) 1.31(400V 50HZ) 5.5 0.75
FN251-8 8 (40°) /9.2 (25°) 1.31(400V 50HZ) 7 0.75

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In this section fundamental mechanical characteristics of the filters are shown:
The FN355-3 Series Filtersare furnished with Fast-on connectors for both input and output.
Max Voltage: 420Vac
Max. Current: 3A @ 40°C
Working Temp: -25° +85°C
the FN251-4 and FN251-8 Filters are furnished with connector terminals forinput and Flying leads for output.
Max. Voltage: 440Vac
Max. Current: 8A @ 40°C
Working Temp.: -25° +85°C

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3.4 Connection and Wiring System
The wiring technique is important for gaining excellent results without disturbances. Shown below are
connection schemes.
As shown, the filter must be placed before the transformer (where required).
--All connections of the Net filters must be shielded and shouldn't be longer than the length shown in the
scheme.
--the cable shield must cover the entire length of the wire and be as close as possible to the connection
terminals.
--the shielded earth connection cable should be accomplished.
--Always use shielded cable (twisted) to connect the motor and drive.
--Avoid passing signal and power cables through the same channels.
It is very important that the panel where the filter is mounted is connected to earth.
Power and Command/Signal conductors should not be placed in the same channels (keep separate). Avoid
twisting, crossing, and etc.. It crossing is inevitable, try to cross at a 90 degree angle. Where possible use
metallic channels connected to earth.
This typeof shielding (pressed cable) is better when used on conductors close to the filters and drives.
Ground and Screen Connections
It is important that the drive's ground connections are done using the shortest possible method.
These connections shouldn't be longer than 15cm. the next page shows the connection using terminals
fixed to the drive's base (bottom). this connection also reduces disturbances in the net.
Filter Rectifier
bridge
Transformer
AC
Power
MiniAx MOTOR
Shield
Panel connection