MICROPHASE DC One XL User manual

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Service Manual
Series
Precision Servodrive for DC Motors
MICROPHASE 36051 Creazzo (Vicenza) Italy Phone (+39) 0444 - 14.40.137 e-mail: [email protected]
DC One XL
Precision Servo drive for DC Motors
MICRO
PHASE
Servoamplifier
for
dc M otors

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All the informations and concepts included in this user guide are copyright, and are supplied to the
user with the understanding that it may not be copied, disclosed or duplicated in whole or in part for
any purpose not authorised by the factory. All specifications are subject to change without prior
notification.
WARNING - Risk of damage and/or personal injury
Thisdrivesdoesn’tcontainanyuserserviceablepart. Attempting toreplaceanyinternalcomponent,
may result in damage to the unit and/or personal injury. This may also avoid the warranty.
Print in Italy rev. 08/2017
DC & BLDC SERVODRIVES
Product name: DC1C-XXX
DC1L-XXX
SP1-XXX
SP1L-XXX
MCD1-XXX
TRXL/B-XXX
TRXL/C-XXX
MUDR-XXX
Declaration of conformity
Manufacturer: MICROPHASE s.a.s.
Address: Via Palladio 23
36051 Creazzo (VI) Italy
MICROPHASEs.a.s.assuresthatthedriveslistedabovemeet the followingEuropeanNormsStandard:
in accordance with EC Directive 2014/30/EU (EMC Directive)
EN 55022, EN 61000-4-2
in accordance with EC Directive 2014/35/EU (Low Voltage Directive))
EN 61010-1

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Chapter 1
1.1 Safety and note .......................................................................................................................... 4
1.2 Operation mode and feedback................................................................................................... 5
1.3 Model and size ........................................................................................................................... 6
1.4 View product............................................................................................................................... 7
1.5Ambient conditions ..................................................................................................................... 8
1.6Ventilation................................................................................................................................8-9
1.7 Dimensions ................................................................................................................................ 9
Chapter 2
2.0 Signals input and output...................................................................................................... 10-11
2.1 Current monitor output ............................................................................................................. 12
2.2 Fault output .............................................................................................................................. 12
2.3 Current request (REQ) ............................................................................................................. 13
2.4Ausiliary power supply +/-9.8V ................................................................................................. 14
2.5 Start input ................................................................................................................................. 14
2.6Analog inputs............................................................................................................................ 15
2.7 Encoder inputs (or tachogenerator input) ................................................................................. 16
2.8Ausiliary power supply +5V....................................................................................................... 16
2.9 GND ground ............................................................................................................................. 16
Chapter 3
3.0 Power supply construction .................................................................................................. 17-18
3.1 Connections to earth and ground ............................................................................................. 19
3.2 Note about Connections........................................................................................................... 20
Chapter 4
4.0 Internal adjustements............................................................................................................... 21
4.1 Brush motor Connections with Encoder feedback .............................................................. 22-23
4.2 Brush motor Connections with Tachogenerator feedback................................................... 24-25
4.3 Brush motor Connections withArmature feedback ........................................................26-27-28
4.4 Current adjustments................................................................................................................. 29
4.5 Ramp time adjustments........................................................................................................... 30
4.6 Potentiometer adjustments...................................................................................................... 31
4.7 Dynamic adjustments............................................................................................................... 32
4.8 Indicator Leds and protections ................................................................................................. 33
4.9 Limit switch input...................................................................................................................... 34
Index

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Please read these notes carefully before powering up the drive
Simbols security standard
Caution
Warning of dangerous current present
In case of doubt or in any case you don’t know as to behave yourself, before access to the
drive, power off the device and wait until all the leds are turned off.
May you have attention when you touch the drive because it may be hot.
Danger Sign
All the circuits in the Drive are potential sources of severe electrical shock, so follow these
rules to avoiding possible personal injury.
- Power off the drive and wait until all the leds are turned off before touching, removing,
connecting or any other critical action.
- Never disconnect any connectors before powering down the drive
It is very important meet all applicable safety requirements during installation and operating of any
motion control equipment.Any installer has to assume the responsibility to ensure that he recognizes
and complies all the relevant safety standards.Any installation, not meeting the safety requirements,
may damage the equipment or injury the user.
This motion control equipment shoul be handled, installed, setted-up and maintenanced only by
competent personnel expert and trained in the installation of motion control electronic equipment.
Suchtechniciansshould be awareofpotentialelectrical and mechanicalhazards.Shallnever beliable
or have any responsability if the products have been improperly stored, installed, used or maintened,
or if the costumer has permitted any unauthorized modifications, adjustments, and/or repairs to the
products.
Users must keep well clear in mind that this motion control equipment is capable of producing high
forces and rapid movement so they must be used with attention especially during the application
program’s development.
Thismotion control equipments are soldasend-users products to beinstalledonlyby practical staff in
accordance with all local safety laws and regulations. The device have to be enclosed such that any
part is not be accessible while the system is powered on.
Westronglyreccomendtofollowtheserecommendationsinordertoavoidwrong uses of the equipment
that may be impaired all the protections provided by the device.
1.1 Safety and note

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Description
Operation mode
General characteristic
Closing the velocity feedback loop to motor may be done in several different ways to accommodate
most applications. This types of velocity feedback are available with DC brush motors.
Velocity feedback
• DC motor with encoder
• DC motor with internal PWM (Armature)
• DC motor with tachogenerator
This is a drive capable to drive DC brush motors, up to 12Nm. It's a High Performance full four
quadrant drive servo amplifier. The mosfet output power stage is controlled by a 20 Khz PWM (Pulse
Width Modulation) signal that allows it to drive servo motors where high dynamic performance and
precise speed is required.
1.2 Operation mode and feedback
DESCRIPTION
SPEED CONTROL
INPUT It is speed piloting using an analogue reference (differential or common mode) STANDARD
TORQUE CONTROL
INPUT
It is torque piloting using an analogue
reference. This function allows you to control
the current from the drive. STANDARD
DESCRIPTION
START INPUT Start input, enable the drive with range from
>9Vdc to +30Vdc (min/max) STANDARD
FAULT OUTPUT Fault drive, open collector output 50mA max. (Normally closed, opens when in protection
mode) STANDARD
2 ANALOG
OUTPUT
1 motor velocity monitor “TEST”, with range +/-
8 Vdc output
1 current monitor "CURR", with range +/-8 Vdc
output
STANDARD
LED INDICATOR Four LEDs are located just in front of the potentiometers and show the current state of
the drive STANDARD

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Specifications
Model available
Size available
The power supply voltage has to be a transformer-isolated voltage
1.3 Model and size
TECNICAL DATA CHARACTERISTICS
Supply voltage output 0,9 Vdc Input
PWM frequency 20Khz
Operating temperature 0/+45°C
Storage temperature -10/+70°C
Drift analog input 0,5uV/°C
Analog inputs (+/-VEL) +/-10Vdc max, impedance 20Kohm cad.
Current monitor output (CURR) +/- 8Vdc = Peak current
Velocity monitor output (TP1) +/- 8Vdc = max velocity
Power supply output (+5V) +5Vdcmax 130 mA
Power supply output (+/-9.8V) +/-9.8Vdc max. 4mA
Encoder max. frequency 300Khz with level >+2,8/24Vdc min/max
Fault drive output NPN 50mA max.
Start input (Enable) >+9V/+30Vdc (min/max)
Band width (current) 2KHz
Band width (velocity) 150Hz
Minimum Inductance motor 200uH
Weight 0,6kg
Contaminants 2°or better (Norms EN60204 e EN50178)
Altitude Up to 1000m without restrictions, from 1000 to 2000m
power derating 1,5%/100m
CURRENT
Size Rated current (A) Peak current (A)*
2/4 2 4
4/8 4 8
7/14 7 14
10/20 10 20
14/28 14 28
20/40 20 40
30/60 30 60
*Peak current during 2 sec
POWER SUPPLY
Model 12 8 - 28 Vdc* 12Vdc**
Model 65 20 - 84 Vdc* 65Vdc **
Model 145 39 - 184 Vdc* 145Vdc **
Model 205 55 - 275 Vdc* 205Vdc **
Model 305 60 - 320 Vdc* 250Vdc **
* Power supply min/max **Typical

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1.4 View product
1
2
346
57
8
9
10
(1) Dip switch
(2) Adjustement zone
(3) CalibrationPotentiometers
(4) Leds
(5) Test point TEST (Tacho test point)
(6) M1 Signal terminal 16 pins MC1,5/16-ST-3,81 (pitch 3,81)
(7) M2 Power Terminals 5 pins GMST 2.5/5-G-7,62 (pitch 7,62)
(8) Fixing screw
(9) Product Cover
(10) Product ID Label
(11) Fixing brackets
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Notes during the assembly
Caution: during the wiring of the servodrive in the electrical box, make sure that do not enter leading
wires of copper or iron chips through the slits. Before performing the work cover the holes with a
piece of paper tape. Naturally finished work this tape is removed.
1.6 Ventilation
Positioning in the electrical box
Follow the instructions in the positioning of the servodrive in the electrical box.
- The drive is natural convection air flow cooled.
- To ensure the drive cooling and make the installation easier for the operator it must be installed
vertically leaving a free space of at least 25 mm on each side of the device. The converter must be
mounted vertically on the electrical box. In case you want to mount it horizontally, remove the cover.
- The electrical box must have suitably filtered air vents.
- Leave the necessary space both above and below the converters.
- Keep the drive from excessive mechanical vibration
1.5 Ambient conditions
N = Standard radiator (operating ambient temperature from 0 to 40°C)
N2 = Standard radiator (operating ambient temperature from 0 to 35°C)
V = Standard radiator + supplementary ventilation (operating ambient temperature from 0 to 45°C)
This servodrive are intended only for use in close locations. Ambient characteristics: operating tem-
perature from 0 to +40°C. Humidity limits between 5% to 95% non condensing (Pollution degree 2 or
better). Supplementary ventilation may be requested in accordance to size. See the table below.
Cable duct
Cable duct
2525
50
50
181,3
Conductive mounting panel (zinc coated)
Dimensions are
expressed in
millimeters.
SIZE
MODEL 2/4 4/8 7/14 10/20 14/28 20/40 30/60
12 N N N N N N N
65 N N N N N N V
145 N N N N N2 V V
205 N N N N2 V V V
305 N N N N2 V V V

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Dimensions in mm
Supplementary ventilation
V = Standard radiator+fan
cooling below the converter
(operating temperature 0 to
+45°C)
NO
Mounting position
YES
Ifyouneed the converter mountedhorizontally,
remove the cover.
1.7 Mechanical dimensions

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2.0 Signals input and output
The figure below shows the view of the converter terminals.
M1 Signal terminal 16 pins "type MC 1,5/16-ST-3,81"
POWER Terminals 5 pins "type GMST 2,5/7,62-G-7,62"
On the test point "TEST" you can see the signal of velocity speed.The output from 0 to + /-8V is from
zeroto maximum speed.Atthis point youcan analyzethesignal when youenableone of thefollowing
velocity feedback.
•Encoder
•Armature
•Tachogenerator
Power connector
NOTE: See also the connection diagrams in Chapters 2.X
TEST M1 SIGNALS POWER
POWER CONNECTOR
+HV (IN) Positive Power supply input
GND (IN) Negative Power Supply input (GND)
-M (OUT) Motor connection -M
+M (OUT) Motor connection +M
N.C Don’t use this terminal

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Signal inputs and outputs
M1 CONNECTOR
1 CURR Current motor monitor (OUT): +/-4Vdc=Rated current, +/-8Vdc=Peak current output in Volts. This output may be used to monitor the torque the
motor is
producing (Standard setting)
2 FAULT (OUT) Fault drive, open collector output max. 50mA
Normally closed, opens when the drive in protection mode
3 REQ
REQ:, can be used in 2 distinct modes:
1) Motor Current limit mode (by REQ setting):
A motor current limit mode connect an external resistor to GND reduces
the maximun current. Connect a 1/4W o 1/8W resistor between the
TPRC (pin 3) and GND (pin 4) terminals. A 47Kohm external resistor
reduces the current by 50%. (Note: The drive velocity loop remains
active)
2) Torque request (by REQ setting):
Range: +/- 10V, which corresponds to the drives peak current output. In
this mode the velocity loop is automatically disabled.
4 GND Signal Common Ground
Corrisponds to power supply's negative GND input
5 +9.8V (OUT) Power supply +9.8Vdc max 4mA
6 –9.8V (OUT) Power supply –9.8Vdc max 4mA
7 START (IN) Positive drive enable with range >+9Vdc min. to +30Vdc max
8 +VEL (IN) Reference Positive differential input (Velocity command)
9 -VEL (IN) Reference Negative differential input (Velocity command)
10 ENC A (IN)
or
–DT (IN)
Encoder input Channel A (High logic level from >
2,8V to +24Vdc max. Low
logic level <1,5V).
Is possible setting this terminal for –DT tachogenerator input
11 ENC B (IN) Encoder input Channel B (High logic level from >
2,8V to +24Vdc max. Low
logic level <1,5V)
12 +5V (OUT) Power supply +5V max. 130mA
13 GND Signal Common Ground. Corrisponds to power supply's negative GND input.
14 +LSW Positive Limit Switch input. See page 34
15 N.A Don’t use this terminal
16 -LSW Negative Limit Switch input. See page 34

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Fault drive, open collector output max. 50mA
Normally closed, opens when the drive in protection mode
2.2 FAULT output
(Signal terminal pin 2)
DRIVE
2.1 Current monitor output
DRIVE
Multimeter
1,27
Standard product is set to the signal CURR on terminal 1 (reading of the current circulating on the
motor) and the REQ input at terminal 3.
Note:
On this terminal is available analog output "current monitor of motor" with range 0V + /-8V.The value
of 8V is the maximum current supplied by the drive. For example, if we have a size 7/14A, 8V
corresponds at 14Acirculating on the motor.
The signal can be positive or negative depending on the direction of rotation of the motor.
Output Impedance is 10Kohm. Consider the internal impedance in the case are linked external
resistive divider.
(Signal terminal pin 1)

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DRIVE
CNC
DRIVE
CNC
Witha voltage(example froma CNCoutput) you cancommand thedrive in torquemode.
Applying a signal of +/-10V at TPRC, the Drive to supply positive or negative peak current.
The formula to determine the value of Voltage to apply in TPRC in order to obtain requested current
is the following:
Example: (Drive size 10/20A, request current 8A)
NOTE:
In current reference the loop of internal velocity automatically excludes itself .
Current output limitation
Withan externalpotentiometer connected fromGND and TPRC input,you have alimitationof output
current (from zero to max. size) drive's.
Externalpotentiometer(470K-1M
Ohm) 3-10 TURNS
The speed loop remains active and uses the input reference signal +/-VEL.
Connect between terminal and GND terminal REQ a resistor 1/4W or 1/8W. (The figure is used a
potentiometer).Withexternal resistancetendstozeroohms,theoutputcurrent tends to zero.Increasing
the ohmic value of resistance, the value of current supplied increases. With 47K of the current is
limited to 50% on the Maximum size. The loop motor speed remains active.
2.3 Current request (REQ)
V(TPRC) = 10 * Request current / PKcurrent Drive
V(TPRC) = 10 * 8 / 20 = 4V
(Signal terminal pin 3)

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In the terminals 5 (+9.8V) and 6 (-9.8V) are available auxiliary supplies to power the potentiometer
reference speed. In the attached drawing below is also added a switch that allows the reversal of
the rotation motor speed .
The current capacity of the output is max + /-4mA
Output +9.8V can also be used to enable the converter
2.4 Ausiliary power supply +/-9.8V
Is possible enable the drive connected the STARTinput with +9.8V output "terminal 5"
DRIVE
CNC
The standard drive is furnished in this configuration.
Start enable input has logic range: >+9V to +30Vdc (min/max)
Unconnected Enable input = Drive Not Enabled
Enable Input +24Vdc = Drive Enabled
2.5 Start input
(Signal terminal pin 5-6)
(Signal terminal pin 7)
DRIVE

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DRIVE
CNC
DRIVE
CNC
The following diagram shows an application utilizing a differential reference from a C.N.C
The +/-VEL in differential mode has a 40Kohm of impedance input.
Differential reference
Speed potentiometer
The following diagram shows an application using speed reference connections from C.N.C in the
Common Mode. This analog in common mode has a 20Kohm of impedance input.
Common mode reference
Thefollowing figureshows an applicationwith speed referenceconnections usingan internal +/-9.8V
powersupply.
The speed potentiometer must have an included value between >5 and <10Kohm.
Speed reference from external potentiometer
2.6 Analog inputs (+/-VEL)
(Signal terminal pin 8-9)
DRIVE

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In the terminals 10 and 11 can connect the inputs from an incremental encoder for the current
feedback in response to encoder. signals can come from encoder powered from +5 V to +24 V).
Minimum high logic level> +2.8 V/24Vmax,
Minimum low logic level <1.5V
Encoder can be connected either push-pull (wiresA, B and GND) or line-driver encoder type (wires
+A+ B and GND). Remember to connect the zero encoder with the GND power converter.
View the connections and settings from encoder in chapter 4.1
2.7 Encoder inputs (or tacho input)
When the motor have a tachogenerator you can use the terminal 10 as input for this feedback.
Connect this terminal to the negative of tachometer. Do not exceed voltage as input from tacho
value of 50V.
Example: If you use a 10V/KRPM no more than 5000rpm.
View the connections and settings from tachogenerator in chapter 4.2
Tachogenerator input (Signal terminal pin 10)
2.8 Ausiliary power supply +5V
(Signal terminal pin 12)
On the terminal 12 (+ V) is available auxiliary power supply voltage +5 V (+12 V on request order).
This output can be used to power the encoder on the motor. The capacity of the output current is
130mA max.
2.9 Signal common ground
(Signal terminal pin 4-13)
Signal Common Ground. Corrisponds to power supply’s negative GND input.
(Signal terminal pin 10-11)

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Transformer
VDC = V2 * 1,41
Example: If the secondary transformer V2 is 45Vac, the VDC output is 45*1,41=64Vdc
PAYATTENTION:
- The drive has zero signal GND in conjunction with the zero power GND, thereby preventing the
following links:
- Use a standard heavy duty power transformer without center taps on the secondary as shown in the
schematic above.
- DO NOT USE AN AUTO TRANSFORMER.
Power transformer (T)
F1
V1 V2
AC
AC
VDC
F2
+HV
(T) TRANSFORMER
GND
C
+
-
AC
POWER
INPUT
3.0 Power supply construction
Normallythe power supplyisbuiltby a transformer, a bridgerectifieranda filter capacity.Alternatively,
the power supply can also be of switching type, in this case refer factory by the appropriate sizing.
The converter have to be supplied from an isolating rectified transformer secondary or a DC isolated
powersupply.
Voltage:
Theprimaryvoltagedependson whatis available locallyfor asinglephase. Thesecondary voltage is
calculated from the motor’s voltage at the required operating speed.
The secondary voltage VDC is:
The transformer's nominal power is calculated based upon the sum of power from the single motors
driven:
Where: Pn Motor =Power absorbed motor in (W)
N=Max. speed of motor in RPM.
Cn =Nominal torque of motor in (Nm).
Pn Motor = N * Cn / 9,55
P(VA)=Pn1+Pn2+..
VDC = Vdc motor / 0,83
Vdc motor = E+(Ri * In)
E = Ke * N° / 1000
Where the Vdc motor is a sum of FCEM + the drop R*I for the winding resistance motor
The FCEM of the motor "E", may be calculated by the formula:
Note: In multi-axis applications, the transformer's power can be downgraded by 30%. If the max.
power transformer calculated is over 6KVAcontact the factory.
If the secondary voltage of power supply is VDC, the Vdc motor is calculated by the formula:
Voltage motor

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Capacitor filter (C)
Capacity above the filter effect, helps to recover energy during braking of the motor.
If the converter during braking has the green LED that flashes you must increase the value of the
capacitor (eg. 10.000uF from a 20.000uF)
Fusibili
Fuses (F1) e (F2)
F1 (A) = P (VA) trasfo. / V1
Example: Brush motor with the following data:
In =5 (A)
Ri = 1 (Ohm)
E=48 (V) at nominal speed 3000 (RPM)
Vdc motor = 48 + ( 1 * 5) = 53V
VDC = 53 / 0,83 = 63,8V
63,8V is the VDC voltage request for the power supply. You'll use a transformer with the secondary
V2 = 64 / 1,41= 45Vac
When you use the transformer with V2= 44/45Vac, it is correct.
Misure unit:
E = Ke *n°/1000 (Vdc)
Im = I motor (A)
Ri = Winding resistance (Ohm)
Ke =Voltage constant (V/kRPM)
n° = MAX speed (RPM)
In regards to the capacitor filter we suggest a working voltage of:
*100VDC for Model 65
*200VDC for Model 145
*300VDC for Model 205
Fuses are required on both the primary and secondary of the transformer to protect against harm to
the system and the transformer itself. They need to be of the slow blow type to handle current in-rush
atpower-up. Locate theprimary fuse (F1)on the hotleg of theAC inputpowerand the secondaryfuse
(F2) on the + side of the secondary output, before the rectifier.
Primary of the transformer: Use the formula below to calculate the correct values:
Secondary of the transformer: Use the table below
Power supply construction (continue)
FUSE F2 (A) SIZE (A)
4 2/4
8 4/8
16 7/14
20 10/20
25 14/28
32 20/40
40 30/60

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Ground bar
Earth point connection
L bar Bar's section
0,5 .. 1m 30 x 5 mm
1..2m 40 x 5 mm
Motor and Power cable (as norm EN60204)
Control signals cable (as norm EN60204)
Feedback signals cable (as norm EN60204)
Make sure that the servodrive and the motor are connected to earth in accordance with the current
norms. This connection must be done by using a copper bar, mounted on insulating supports:
L bar
then follow these indications:
1. Connect to the ground bar:
the GND pin 4 of the Dc One
the internal "0V" zero voltage of the CNC;
the earth terminals of the PLC/CNC frames;
the "0V" of the auxiliary supply;
2. Connect the ground bar to the zinced panel of the drive by using a screw, then connect thatscrew
to earth.
3. Connect earth to the motor’s
It suggests a conductive connection as much as possible to the chassis, or the heatsink,
or the mounting panel of the electrical box.
It refers to the earth connection.
3.1 Connections to earth and ground
SECTION
0,5mm2 / 20AWG
SECTION
0,25 - 0,35mm2 / 22 -24AWG
SECTION SIZE (A)
1,5mm2 / 15AWG 2/4 4/8 7/14
2,5mm2 / 13-14AWG 10/20 14/28 20/40
4mm2 / 11-12AWG 30/60

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+ +
+
+
+
+
+
+
-
-
-
-
-
-
-
-
DC One
XL DC One XL
Powersupply Power supply
NO YES
EMC note
In the case of multiple servodrives on the same power supply, make connections-type stars, see
drawing back. Connect also feed converters using the shortest cable possible. If the cable length
exceeds 2m, twist the + and - leads together as twisted pairs.
Multiple connection
The drives have to be supplied from an isolating rectified transformer secondary or a DC isolated
powersupply.
The conformity is assured only if it is installed following the precise assembly criteria expressed
below. The fundamental assembly characteristics are summarized below:
1) The correct ground connection of predisposed parts.
2) Using the division of cables technique. Separate power cables from signal cables.
3) Use of shielded cables, both for power connection (to the transformer and the motor), and for
signal connection (also to the controller).
4) Use of appropriate network to filter the line (transformer input), from disturbances conducted or
produced by the drive. (series of filters released are available for this purpose)
3.2 Note about connections