Hudson M-341 Series User manual

U SER M ANUAL
Hudson Motor User Manual
Rev. 1.30 April 18, 2022

Hudson Manual Rev. 1.30 2
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Table of Contents
Table of Contents..............................................................................................................2
Introduction ....................................................................................................................... 4
What's in This Document .......................................................................................................4
Information on the Web .........................................................................................................4
What are Hudson Motors?..................................................................................................... 5
Safety and Safe Handling Information ............................................................................ 6
General Precautionary Statement ......................................................................................... 6
Symbols Used in this Manual ................................................................................................ 6
Important Safe Handling Practices ........................................................................................ 7
Parts of a Hudson Motor.................................................................................................. 8
Interconnect and Wiring ................................................................................................... 9
Motor Connector Options.......................................................................................................9
Molex Mini-Fit Jr. Connector .................................................................................................. 9
Souriau Trim-Trio Connector ................................................................................................. 9
Connector Pinouts and Mating Parts................................................................................... 11
Molex Mini-Fit Jr. Pinout ......................................................................................................11
Souriau Trim-Trio Pinout...................................................................................................... 12
Servo Drive Selection ..................................................................................................... 13
Drive Compatibility ............................................................................................................... 13
Supported Commutation Methods ....................................................................................... 13
Six-Step (Trapezoidal) Commutation ................................................................................... 13
Sine wave Commutation (Better) ......................................................................................... 14
Sine wave commutation with Vector Torque Control (Best)................................................. 14
Encoder and Commutation Signals............................................................................... 16
Encoder & Commutation Board Power Requirements ........................................................ 16
Encoder Signaling................................................................................................................ 17
Differential............................................................................................................................ 17
Single-Ended ....................................................................................................................... 17
Commutation (Hall) Signaling .............................................................................................. 18
Commutation Signal and Motor Phase Relationship............................................................ 18
Wiring Hudson Motors To Third-Party Drives ...................................................................... 19

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Hudson Motor FAQ..........................................................................................................20
Q: Are Hudson Motors UL and CE certified?........................................................................20
Q: How are Hudson Motors tested? .....................................................................................20
Q: What type of servo drives will work with a Hudson Motor?..............................................20
Q: Which connector should I use?........................................................................................20
Q: Which motor winding option should I pick?......................................................................20
Q: Do I need the optional motor shaft seal? .........................................................................21
Q: How do I tune a Hudson motor? ......................................................................................21
Q: How can I change a motor’s “sense of direction”?...........................................................21
Q: Why is the motor warm during operation? .......................................................................22
Q: Where can I find 3D drawings of Hudson motors? ..........................................................22
Appendix A: Hudson Part Number Key .........................................................................23
Appendix B: Specifications ............................................................................................24
NEMA 23 Common Specifications....................................................................................... 24
NEMA 23 Individual Specifications ...................................................................................... 25
NEMA 34 Common Specifications....................................................................................... 26
NEMA 34 Individual Specifications ...................................................................................... 27
Appendix C: Motor Dimensions .....................................................................................28
Hudson Motor 3D Models .................................................................................................... 28
NEMA 34 Series Dimensions ..............................................................................................28
NEMA 23 Series Dimensions ..............................................................................................29
Appendix D: Motor Extension Cables............................................................................30
HDSN-CABLE-120 (Sold by Teknic) ...................................................................................30
Example Motor Cable Drawings (Flex-rated)....................................................................... 30
Golden Rules for Motor Cable Construction........................................................................31
Cable Making Guidelines.....................................................................................................32

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Introduction
What's in This Document
This document contains technical information on the Hudson family of
brushless DC servo motors, including:
x Wiring information
x Mechanical drawings
x Application tips
x Specifications
Information on the Web
Please visit Teknic's website for more information on the Hudson family of
brushless servo motors: https://www.teknic.com/products/hudson-motors/

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What are Hudson Motors?
Hudson motors have been called (more or less correctly) all of the following:
x BLDC motors
x Three-phase, permanent magnet motors
x Synchronous, permanent magnet motors
x AC servomotors (AC because electronic commutation requires a
sinusoidal current to produce constant torque, not to be confused
with AC induction motors)
x DC servomotors (presumably to distinguish them from AC induction
motors)
x 3-phase servomotors
Technically speaking, Hudson motors are:
Three-phase, synchronous, permanent magnet,
brushless servo motors.
Definition or Terms
"Servo Motor" refers to a motor that uses one or more feedback devices
(encoder, Hall effect sensors, etc.) to control torque, velocity, and/or position
in a closed loop manner.
"Brushless", aside from the obvious, means the motor requires a drive
(amplifier) that supports electronic, non-contact commutation.
"Permanent Magnet" means that the motor has permanent magnets affixed
to the rotor (brush motors typically have permanent magnets affixed to the
stator).
"Synchronous" means that the rotational speed of the electromagnetic field
is the same as (i.e. synchronous with) the speed of the rotor. There is no “slip”
between them like there is with an AC induction motor.
“3-phase" means the motor has three separate stator windings connected
together in a delta or wye configuration.

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Safety and Safe Handling Information
General Precautionary Statement
Always follow appropriate safety precautions when installing and operating
motion control devices. Automated equipment should be designed to prevent
personnel from coming into contact with moving parts and electrical contacts
that could potentially cause injury or death.
Read all cautions, warnings and notes before attempting to operate or service
motion control devices. Follow all applicable codes and standards when using
this equipment. Failure to use this equipment as described may impair or
neutralize protections built into the product.
Symbols Used in this Manual
The following symbols and conventions are used on the equipment and in this
manual.
Caution, risk of danger
Identifies information about practices or circumstances that can lead to
equipment damage, personal injury, or loss of life.
Shock hazard
Identifies presence of hazardous electrical voltages and currents.
Protective earth terminal
Indicates points that must be connected to a reliable earth system for safety
compliance. Protective earth connections should never be omitted.
Earth ground terminal
Frame or chassis terminal (shield)
Direct current
Note
Identifies information that is critical for successful application and
understanding of the product.
Tip
Identifies additional information that may be helpful in supporting certain
applications.

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Important Safe Handling Practices
x Do not hammer pulleys, pinions, etc. onto the motor shaft.
x Do not wrench or pry pulleys, pinions, or other accessories off the
motor shaft. Use a gear puller that pushes on the center of the shaft,
offsetting the applied force, when removing accessories from the
shaft. Maximum axial force limits are listed below.
x Do not exceed the axial force limits when pulling or pushing on the
motor shaft. Bearing damage will occur! See table below.
x Do not touch the bare pins on a Hudson motor connector unless you
are working in a static-safe area.
x Do not pick up a Hudson motor by its pigtail. Note: Maximum
pigtail pull force is 7 lbs.
x Do not allow the Hudson pigtail to flex during routine operation. The
Hudson pigtail is not flex-rated. Use cable ties or other means to
immobilize the motor pigtail during operation.
x Do not install a Hudson motor such that the pigtail is pulled taut (i.e.
has a constant tension applied to it). Allow for some slack in the
pigtail when securing the motor to a machine.
Motor Shaft Axial Force Limits
Pushing into shaft Pulling out of shaft
NEMA 23 N (Lbs.) NEMA 34 N (Lbs.) NEMA 23 N (Lbs.) NEMA 34 N (Lbs.)
Continuous (operating) 90 (20.2) 115 (25.9) 22 (4.9) 32 (7.2)
Static, short term 224 (50.4) 360 (80.9) 112 (25.2) 135 (30.3)
Shock / Impact 45 (10.1) 68 (15.3) 45 (10.1) 68 (15.3)

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Parts of a Hudson Motor
1 16-inch pigtail eliminates costly motor cables in many
applications.
11 Compression-fit aluminum stator housing channels heat
out of the motor.
2 Single cable, single connector pigtail results in neater,
lower cost installations.
12 Sintered, nickel-plated, rare-earth magnets generate
maximum power.
3 Connector choices: lower cost automotive-style, and
sealed, bayonet-style, M12 on-body.
13 Architectural-quality, anodized finish will look great for
years.
4 All Hudson motors come with connectors. 14 Oversized, permanently lubricated front bearing extends
bearing life.
5 Zero-clearance pigtail allows bigger motors to fit into
smaller spaces.
15 Long-stroke, wave spring imparts consistent bearing
preload.
6 Shatter-proof encoder disk eliminates shock-induced
failures.
16 Optional high-performance shaft seal for more protection
against dirt and dust.
7 Industry-standard encoder and commutation signals. 17 Smooth, radiused transition from external shaft diameter
results in a stronger shaft.
8 Low-profile encoder allows you to fit motors into tighter
spaces.
18 Feather keyway allows easy assembly (and the key
can’t work its way out).
9 Precision brass balancing tabs for smoother motion and
less vibration.
19 Helically skewed stator laminations improve smoothness
of motion.
10 Epoxy insulation layer allows the use of higher operating
voltages.
20 Tightly formed and laced end-turns heat more evenly for
higher reliability and longevity.

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Interconnect and Wiring
This section discusses:
x Hudson connector styles/options
x Motor pinouts
x Mating connector parts
Motor Connector Options
Hudson motor connector options include: Molex MiniFit Jr. and Souriau
Trim-Trio connectors.
Molex Mini-Fit Jr.
Free-Hanging Souriau Trim-Trio
Free-Hanging Souriau Trim-Trio Bulkhead-Mount
Hudson motor connector options
Molex Mini-Fit Jr. Connector
The Mini-Fit Jr. family provides a gas tight link with four points of contact per
circuit. This low cost, rugged connector is rated for up to 10A continuous and
600V per circuit. The connector includes a positive locking mechanism, and
fully isolated, low engagement-force terminals.
Use Molex Mini-Fit Jr. connectors when:
x Lower cost is required.
x The operating environment is relatively clean and dry (typical dust
and dirt is OK).
x No more than 10A continuous current per circuit is required.
Souriau Trim-Trio Connector
This bayonet-style connector is keyed, sealed, and positive locking in nature,
derived from the MIL-C 26482 specification.
Use Souriau Trim-Trio connectors when:

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x The pollution level at the connector is higher (light spray, mists,
fumes, chips, etc.).
x A water resistant seal at the connector is required.
x Higher current-carrying capacity (up to 20A continuous) is required.

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Connector Pinouts and Mating Parts
Molex Mini-Fit Jr. Pinout
1
2345
6
78
9
10111213
14
1516
WIRE ENTRY VIEW
Pin# AWG Color Signal Name Notes
1 16 TIN P DRAIN Drain wire for Phase Cable
2 NO CONNECT
3 26 GRN COMM S-T commutation (Hall) sensor
4 26 GRN/WHT COMM R-S commutation (Hall) sensor
5 26 GRY/WHT COMM T-R commutation (Hall) sensor
6 26 TIN E DRAIN drain wire for Logic Cable shield
7 26 BLK GND +5VDC ground (encoder/Hall board return)
8 26 BLU/WHT ENC A~ encoder out (A~)
9 16 BLK or WHT/BLK PHASE R MOTOR PHASE
10 16 RED or WHT/RED PHASE S MOTOR PHASE
11 16 WHT PHASE T MOTOR PHASE
12 26 RED +5VDC IN +5VDC input (encoder/Hall board power)
13 26 BRN ENC I encoder out (index)
14 26 ORN ENC B encoder out (B)
15 26 BLU ENC A encoder out (A)
16 26 ORN/WHT ENC B~ encoder out (B~)
Mating Parts
Part Description Mfg. / Part Number
Connector Housing, panel mount Molex / 39-01-2166
Terminal, male, 24 AWG (logic
signals) Molex / 39-00-0049 (loose) -0048 (reel)
Terminal, male, 16 AWG (motor
phases) Molex / 39-00-0082 (loose) -0081 (reel)
Crimp tool, 22-28AWG Molex / 11-01-0198
Crimp tool, 16AWG Molex / 2002182200
Extraction Tool Molex / 11-03-0044

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Souriau Trim-Trio Pinout
A
B
R
V
U
T
S
PC
D
E
F
G
H
J
K
L
M
N
Front View
A
B
R
V
U
T
S
P
C
D
E
FG
H
J
K
L
M
N
Wire Entry View
Pin# AWG Color Signal
Name Notes
A NO CONNECT
B 16 BLK or WHT/BLK PHASE R MOTOR PHASE
C 16 RED or WHT/RED PHASE S MOTOR PHASE
D 16 WHT PHASE T MOTOR PHASE
E NO CONNECT
F 26 ORN/WHT ENC B~ encoder out (B~)
G 26 GRN COMM S-T commutation (Hall) sensor
H 26 GRN/WHT COMM R-S commutation (Hall) sensor
J 26 BLU ENC A encoder out (A)
K 26 BLU/WHT ENC A~ encoder out (A~)
L 26 GRY/WHT COMM T-R commutation (Hall) sensor
M 26 TIN E DRAIN Drain wire for Logic Cable shield
N NO CONNECT
P NO CONNECT
R 16 TIN P DRAIN Drain wire for Phase Cable
S 26 BLK GND +5VDC return
T 26 RED +5VDC IN +5VDC input (encoder/hall power)
U 26 BRN ENC I encoder out (index)
V 26 ORN ENC B encoder out (B)
Mating Parts
Part Description Mfg. / Part Number
Connector Housing, w/ flange (for free-hanging pigtail) Souriau / UTG016-19S
Connector Housing, for panel-mount pigtail Souriau / UTG616-19S
Terminal, female, 24 AWG (logic signals) Souriau / SC24M1TK6
Terminal, female, 16 AWG (motor phases) Souriau / RC16M23T
Backshell / Clamp Souriau / UTG16AC

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Servo Drive Selection
Drive Compatibility
Servo drives intended for use with a Hudson motor must have the capabilities
listed below.
Supported Methods of Commutation (see section below for details)
x Six-Step (trapezoidal)
x Sine Wave
x Sine Wave with Vector Torque Control
Hudson motor electronics
x 5VDC differential or single-ended encoder signals. (Note: single-
ended encoders not available for webstore purchases).
x 5VDC, 120q optical commutation sensors (analogous to Hall effect
sensors)
x 8 poles
x 4 electrical cycles per revolution
Supported Commutation Methods
Each Hudson motor has a precision optical encoder disk with 120º optical
commutation sensors (analogous to Hall effect sensors). During assembly the
disk is precisely locked into position such that the commutation tracks line up
with the rotor in a known orientation.
Six-Step (Trapezoidal) Commutation
Note: Six-step commutation (aka "trapezoidal commutation") can be used
with Hudson motors though it is generally not preferred for high precision, low
speed applications due to higher torque ripple and lower operating efficiency.
Six-step is often used in cost-sensitive, lower precision applications, and for
high speed applications where the mechanical system and motor have
enough inertia combined that the effect of torque ripple is minimal.
During six-step commutation, the servo drive interprets the rotating
commutation sensor codes from the motor to determine relative rotor to stator
position and uses this information to sequence and time the switching of
current into the motor phases.
Step# Commutation Sensor State
3 channels, 120º separation Current Flow
1 1 0 1 From phase R to phase S
2 1 0 0 From phase R to phase T
3 1 1 0 From phase S to phase T
4 0 1 0 From phase S to phase R
5 0 1 1 From phase T to phase R
6 0 0 1 From phase T to phase S

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oning tasks.
During six-step commutation, current flows in only two phases at a time (the
third phase is always off). Example: In Step #1 above, when the commutation
sensors read binary (1 0 1) the drive sends current through Phases R and S,
while Phase T remains off.
It is useful to understand that the commutation “code” changes state six times
per electrical cycle1, and thus provides a less precise fix on rotor position
than a typical sine wave drive with encoder-based commutation. While this
may be sufficient for less demanding motion applications, a high resolution
feedback device—such as an encoder—is a better choice for high
performance positi
Pros and Cons of Six-Step Commutation
Pro: Lower cost of implementation (six-step drives may be cheaper)
Con: High torque ripple
Con: No torque control loop, though does have a current loop
Con: Lower torque efficiency (at high speeds)
Sine wave Commutation (Better)
Sine wave commutation is generally better suited to midrange applications
where greater precision of control over position, velocity and/or current is
required.
Most sine wave drives use the commutation sensors to initialize the
commutation process. First, the commutation code is read from the motor to
establish the initial rotor vs. stator position. Then the drive applies current to
the motor windings to achieve the desired relationship between the
permanent and electromagnetic fields. After this relationship is established,
the electromagnetic vector is “locked” to the encoder position, and
commutation continues based on encoder feedback (and not on the Halls).
Though more efficient than six-step drives, sine wave drives run open loop
with respect to torque control. While the current in each motor phase is
individually servo controlled, the actual torque produced at the shaft is not. In
most sine wave drives, torque errors are only corrected indirectly—after they
have resulted in velocity and position errors. This generally means sine wave
drives operate with a wider positioning error band than sine wave drives with
true vector torque control (see next topic).
Sine wave commutation with Vector Torque Control (Best)
Sine wave drives with Vector Torque Control (VTC) are often the drive of
choice for high precision, high throughput positioning and contouring
applications. A sine wave VTC drive is wired, and operates, in basically the
same way as a sine wave drive without VTC. The key difference is how
torque is controlled. While most sine wave drives servo control only the
1Note: Hudson motors are 8-pole motors that have four electrical cycles per mechanical
revolution. This means that Hudson commutation sensors transition (6 states x 4
electrical cycles) 24 times per motor revolution.

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individual motor phase currents, VTC drives servo control the actual torque
produced at the motor shaft.
The drive simultaneously takes calibrated current measurements from all
motor phases, combines this data with information about rotor position, phase
resistance, inductance and back-EMF, and then applies advanced vector
mathematics to calculate the exact torque being produced at the shaft. This
tight torque feedback loop allows for very rapid corrections in torque error,
resulting in superior dynamic tracking performance.

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Encoder and Commutation Signals
Hudson motors have single-ended* or differential encoder outputs, and
single-ended commutation signal (Hall) outputs.
* Note: single-ended encoder signals not available on motors sold on the
Teknic webstore.
Encoder and commutation tracks are optically read from the Hudson encoder
disk and then translated to driven signals present at the motor connector.
Encoder Track
Glass encoder
At left is a Hudson encoder disk. At right is a glass encoder disk on a motor that
was dropped on the floor.
Encoder & Commutation Board Power Requirements
Hudson motors require a 5VDC supply voltage to power the combined
encoder & commutation sensor board.
Input voltage (at motor connector) 4.5-5.5VDC (6.0VDC absolute max.)
Current draw, loaded* 180mA @ 5VDC
Current draw, unloaded 125mA @ 5VDC
*This value is based on a 200 ohm test load.

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Encoder Signaling
Differential
Differential encoder outputs are balanced, driven outputs intended to drive
terminated, twisted pair transmission lines. Differential signals offer excellent
common-mode noise immunity and support longer cable runs than single-
ended signaling.
Technical Note
The differential outputs are driven from an AM26C31 differential line driver
optimized for 120Ω transmission lines. Refer to the AM26C31 data sheet for
complete specifications.
Differential encoder
To Servo Drive
74HC14
AM26C31
24Ω
ENC I
ENC A
ENC A
ENC B
ENC B
encoder disk
Motor
read head
(one pulse per revolution)
Differential encoder output
Differential encoder signals provide excellent common mode noise immunity,
especially over longer transmission ranges (up to 100 feet). In many
applications, such as plasma cutting.
If your third-party drive requires a differential index pulse, please contact
Teknic for wiring recommendation.
Single-Ended
The single-ended encoder features 5VDC TTL, totem pole driven (i.e.
“push/pull”) outputs at 10mA max. Note: single-ended encoder option not
available for motors purchased at Teknic’s webstore.
Single-ended encoder
To Servo Drive
24Ω
ENC A
24Ω
24Ω
74HC14
ENC B
ENC I
encoder disk
Motor
read head
(one pulse per revolution)
Single-ended encoder output

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Commutation (Hall) Signaling
The Hudson optical commutation sensors are 5V TTL, totem pole driven
outputs with 10mA maximum current.
Commutation Signal and Motor Phase Relationship
The diagram below illustrates the relationship between commutation (Hall)
outputs and motor phases for properly wired Hudson motors. Refer to this
diagram when wiring third-party servo drives to Hudson motors. When using
the diagram below, bear in mind the following:
x The waveforms below apply to sine wave drives that can process
120° commutation sensor (Hall) signals and use encoder-based
commutation.
x The drive must be wired to count up as the motor shaft is turned
CCW (looking into the shaft).
x The commutation sequence shown in gray below is read from right
to left. When spinning the shaft CCW, a properly wired motor should
report commutation codes in the following sequence: 100, 101, 001,
011, 010, 110.
0° 30° 60° 90° 120° 150° 180° 210° 240° 270° 300° 330° 360°
0° 30° 60° 90° 120° 150° 180° 210° 240° 270° 300° 330° 360°
PHASE T
PHASE R
PHASE S
Back EMF
Waveforms
Commutation Sensor
(Hall Effect) Signals
COMM. T-R
COMM. S-T
COMM. R-S
110 010 011 001 101 100
(6) (2) (3) (1) (5) (4)
(referenced to phase R)
(referenced to phase S)
(referenced to phase T)
(Decimal)
Binary
Commutation
Sensor Codes
(read rIght to left
for CCW rotation)
Note: Motor phase zero-crossings must line up
with commutation sensor transitions as shown
motor phase
zero crossing
commutation
sensor transition
The above diagram illustrates the idealized back-EMF waveforms one would
observe if the motor shaft was spun counterclockwise (looking into the shaft)
with an oscilloscope probe attached to the phase of interest and the ground
clip attached to the reference phase. The lower part of the diagram illustrates
how the commutation signals would appear on an oscilloscope when probed
from signal to ground.

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The motor is phased correctly when the zero-crossings of motor phases line
up with the transition points of the commutation sensor signals as shown in
the previous illustration.
Wiring Hudson Motors To Third-Party Drives
When wiring a Hudson to a third-party drive, start with a motor that is wired to
show positive encoder counts when spun CCW (viewed looking into the motor
shaft). If this is not the case, swap encoder signals A and A~ (for differential
encoders).
Important: the motor phases must align with their associated commutation
signal as follows (refer to phase diagram on previous page):
x Phase T and Comm. T-R
x Phase R and Comm. R-S
x Phase S and Comm. S-T
Note: Within the motion control industry, there is no standardized convention
for the labeling of encoder signals, motor phases or commutation (Hall)
signals. Consult the servo drive manufacturer for questions regarding
the wiring of encoder outputs, commutation (Hall) outputs and motor
phases.

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Hudson Motor FAQ
Q: Are Hudson Motors UL and CE certified?
A: Yes.
Q: How are Hudson Motors tested?
A: Each Hudson motor is rigorously tested before shipment. The tests
include:
x 100% HASS tested (Highly Accelerated Stress Screening)
x Mechanical compliance tests
x Encoder integrity test
x Commutation sensor accuracy test
x Full electrical compliance test
x Full functional test
Q: What type of servo drives will work with a Hudson Motor?
A: Hudson servo motors are 3-phase, synchronous, permanent magnet,
brushless, servo motors with an incremental encoder that outputs standard
differential encoder signals and standard 120º optical commutation (Hall)
sensor signals. Hudson BLDC motors will work with the following drive types:
x Six-step (trapezoidal)
x Sine wave
x Sine wave with vector torque control
Q: Which connector should I use?
A: A Hudson motor can be fitted with either a Molex MiniFit Jr. or Souriau
Trim-Trio connector.
For most applications, the Molex MiniFit Jr. connector is a good choice. Use
this type of connector in relatively clean, dry environments (general dust is
OK), and when 10 amps or less motor phase current will be applied.
Consider using Souriau Trim-Trio connectors where the connector may be
subject to water spray, mist or fumes, or when more than 10 amps per phase
may be present. Note: Trim-Trio connectors have a longer lead time.
Q: Which motor winding option should I pick?
A: Hudson motors are available in Series or Parallel winding configurations.
Select the winding that best matches your torque and speed requirements.
Torque-speed graphs are available in the Hudson motor section of our
website.