MICROPHASE Mini Dc User manual

1
Service manual
www.microphase.eu
Mini Dc
Series
Precision Servodrive for DC Motors
Service Manual
MICROPHASE 36051 Creazzo (Vicenza) Italy Phone (+39) 0444 - 14.40.137 e-mail: [email protected]
MICRO
PHASE
Eurocard Servodrive
for Brush motors
Servo Amplifier for Brush DC Motors
Mini Dc

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Mini Dc
Index
Chapter 1
1.1 Safety and note ......................................................................................................................... 3
1.2 Operation mode and feedback.................................................................................................. 4
1.3 View product.............................................................................................................................. 5
1.4 Model and size .......................................................................................................................... 6
1.5Ambient conditions .................................................................................................................... 7
1.6Ventilation...............................................................................................................................7-8
1.7 Dimensions ............................................................................................................................... 8
Chapter 2
2.1 Input and output signals ............................................................................................................ 9
2.2 Ground GND ........................................................................................................................... 10
2.3 Fault output ............................................................................................................................. 10
2.4 Current request (TPRC) .......................................................................................................... 10
2.5 Current limitation (TPRC) ........................................................................................................ 11
2.6Ausiliary power supply +/-9.8V ................................................................................................ 11
2.7Analog velocity input +/-REF ................................................................................................... 12
2.8 Enable input START................................................................................................................ 12
2.9 Tachogenerator input............................................................................................................... 13
2.10 Current monitor output .......................................................................................................... 13
2.11 Encoder inputs....................................................................................................................... 13
Chapter 3
3.1 Internal adjustements.............................................................................................................. 14
3.2Adjustements with Tachogenerator feedback.......................................................................... 15
3.3Adjustements withArmature feedback ............................................................................... 16-17
3.4Adjustements with Encoder feedback ..................................................................................... 18
3.5 Current adjustments................................................................................................................ 19
3.6 Ramp time adjustments.......................................................................................................... 20
3.7 Potentiometer adjustments..................................................................................................... 21
3.8 Dynamic adjustments.............................................................................................................. 22
3.9 Indicator Leds and protections ................................................................................................ 23

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Mini Dc
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 aware ofpotentialelectrical and mechanical hazards.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 soldas end-users productsto be installed only bypractical staffin
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.
Westrongly reccomend to followtheserecommendationsinordertoavoidwrongusesoftheequipment
that may be impaired all the protections provided by the device.
1.1 Safety and note

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Mini Dc
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 tachogenerator
• DC motor with internal PWM (Armature)
• DC motor with encoder
This is a drive capable to drive DC brush motors, up to 9Nm. 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
START INPUT Start input, enable the drive with range from
>9Vdc to +30Vdc (min/max) STANDARD
FAULT OUTPUT Fault drive, open collector output 100mA max.
(Normally closed, opens when in protection
mode) STANDARD
2 ANALOG
OUTPUT
1 motor velocity monitor “V.TACHO”, with
range +/-8 Vdc output
1 current monitor "I.MOTOR", 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
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

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1.3 View product
8
DS1 7 6 5 4 3 2 1
6
5
4
3
7
1
2
Mini
(1) Product ID Label
(2) Aluminum heatsink
(3) Leds
(4) CalibrationPotentiometers
(5) Test point (V.tacho, I.Motor, GND)
(6) DIN 64 connector (32a+32c) pitch 2,54
(7) Adjustement zone
(8) Adjustement settings

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Mini Dc
1.4 Model and size
POWER SUPPLY
Model 65 19 - 84 Vdc* 60Vdc **
Model 145 39 - 184 Vdc* 140Vdc **
Model 205 54 - 276 Vdc* 200Vdc **
* Power supply min/max **Typical
CURRENT
Size Rated current (A) Peak current (A)*
3/6 3 6
4/8 4 8
7/14 7 14
10/20 10 20
14/28 14 28
20/40 20 40
*Peak current during 2 sec
Specifications
Model available
Size available
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 (+/-REF) +/-10Vdc max, impedance 20Kohm cad.
Current monitor output (I.MOTOR) +/- 8Vdc = Peak current
Velocity monitor output (V.TACHO) +/- 8Vdc = max velocity
Power supply output (+/-9.8V) +/-9.8Vdc max. 4mA
Encoder max. frequency 300Khz with level >+2,8/24Vdc min/max
Fault drive output NPN 100mA max.
Start input (Enable) >+9V/+30Vdc (min/max)
Band width (current) 2KHz
Band width (velocity) 150Hz
Minimum Inductance motor 200uH
Weight 0,42kg
Contaminants 2°or better (Norms EN60204 e EN50178)
Altitude Up to 1000m without restrictions, from 1000 to 2000m
power derating 1,5%/100m
Flammability rating 94V-0 The heatsink, the PCB and the electronic component
meet 94V-0

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Mini Dc
Mini
Mini
Mini
1.6 Ventilation
1.5 Ambient conditions
N = Standard radiator (operating ambient temperature from 0 to 45°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 +45°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
Conductive mounting panel (zinc coated)
SIZE
MODEL 3/6 4/8 7/14 10/20 14/28 20/40
65 N N N N N N2
145 N N N N N2 V
205 N N N N2 V V
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.
- 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

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Mini Dc
No
Yes
Mini
Mini
Mini
160
34
100
Mini
Dimensions in mm
Supplementary ventilation
V = Standard radiator+fan
cooling below the converter
(operating temperature 0 to
+45°C)
Mounting position
1.7 Mechanical dimensions

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Are available rack-mount installation kit and panel-mounting installation kit.
Rack and Panel mounting kit
DIN 32a+32c CONNECTOR
1ac Signal Common Ground. Corrisponds to power supply's negative GND input
2ac (OUT) Fault drive, open collector output max. 100mA
Normally closed, opens when the drive in protection mode
3ac (IN/OUT) TPRC input. Torque request and current limit
4ac (OUT) Power supply -9.8Vdc max 4mA
5ac (OUT) Power supply +9.8Vdc max 4mA
6ac (IN) Reference Positive differential input (Velocity command)
7ac (IN) Positive drive enable with range >+9Vdc min. to +30Vdc max
8ac, 10ac, 12ac (IN) Programmable inputs.
9ac (IN) Tachogenerator input
11ac (OUT) +/-4Vdc=Rated current, +/-
8Vdc=Peak current output in Volts. This
output may be used to monitor the torque the motor is producing.
14ac, 15ac,
16ac, 17ac (IN) Positive power supply +HV voltage
19ac, 20ac,
21ac, 22ac (IN) Negative power supply GND POWER
24ac, 25ac,
26ac, 27ac (OUT) Motor output +M
29ac, 30ac,
31ac, 32ac (OUT) Motor output -M
The following description refers to the 64 pin DIN connector. Wire connections must be made in
the terminal boards of the Panel mount and Rack supports.
2.1 Input and output signals

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2.4 Current request TPRC (3ac)
MINI DC
CNC
2.3 FAULT output (2ac)
MINI DC
Signal Common Ground.
Corrisponds to power supply’s negative GND power input (19ac, 20ac, 21ac, 22ac)
2.2 Signal common ground GND (1ac)
Input and output signals
Fault drive, open collector output max. 100mA
Normally closed, opens when the drive in protection mode
With a voltage (example from a CNC output) you can command the drive in torque mode.
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 .
V(TPRC) = 10 * Request current / PKcurrent Drive
V(TPRC) = 10 * 8 / 20 = 4V

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2.5 Current limitation TPRC (3ac)
MINI DC
CNC
2.6 Ausiliary power supply +/-9,8V (4ac and 5ac)
MINI DC
Input and output signals
Withan external potentiometer connected from GND andTPRCinput, you havea limitationofoutput
current (from zero to max. size) drive's.
External potentiometer (47K-100kOhm)
1-10 TURNS
The speed loop remains active and uses the input reference signal +/-VEL.
Connect between terminal and GND terminal TPRC a resistor 1/4W or 1/8W. (The figure is used a
potentiometer).Withexternalresistancetends tozeroohms,theoutputcurrenttendstozero.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.
In the terminals 5ac (+9.8V) and 6ac (-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
Potentiometer (5K-10KOhm)

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2.7 Analog reference input +REF (6ac)
Analog reference input +REF (6ac) from external
potentiometer
MINI DC
MINI DC
CNC
2.8 START input (7ac)
MINI DC
CNC
Input and output signals
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.
Thefollowing figureshows an application with speed reference connectionsusing an internal +/-9.8V
powersupply.
The speed potentiometer must have an included value between >5 and <10Kohm.
Potentiometer (5K-10KOhm)
Is possible enable the drive connected the STARTinput with +9.8V output "terminal 5ac"
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

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Mini Dc
2.9 Tachogenerator input (9ac)
2.10 Current monitor output (11ac)
MINI DC
Multimeter
1,27
2.11 Encoder inputs
Input and output signals
When the motor have a tachogenerator you can use the terminal 9ac as input for this feedback.
Connect this terminal to the negative of tachometer.
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.
In the terminals CHA and CHB (on the rack or panel-mounting) 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 signal converter.

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Mini Dc
Adjustement pads
Dip 7: Open (OFF)
Dip 6: Closed (ON)
Dip 5: Closed (ON)
Dip 4: Closed (ON)
Dip 3: Open (OFF)
Dip 2: Open (OFF)
Dip 1: Open (OFF)
DS1 7 6 5 4 3 2 1
3.1 Internal adjustements
If changes need to made to the internal drive setting powering, please wait at least 20 seconds after
the power has been removed and the OK LED is off.
All of the personalizations are located inside of the DRIVE. (See figure above)
To gain access to the adjustment pads (TOP DRIVE) and the Dip DS1 (BOTTON DRIVE)
DS1 SWITCH standard position are setting by
factory for:
- Tachogenerator feedback
- Ramp time disabled
- Standard Dynamic constant
Adjustement Dip (DS1)
standard configuration

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3.2 Setting with tachogenerator
feedback
RDT (Kohm) = Kdt * N * 9,7
1000 * Vref - 7,9
Example:Brush DC motor withthe tachogeneratorcostantKdt=10V/KRPM,max.speed2500RPMat
10V of speed reference. The result is below:
RDT (Kohm) = 10 * 2500 * 9,8
1000 * 10 - 7,9 = 16.6 Kohm
Insert the commercial value resistance 18Kohm. Prefer resistance with 1% tolerance.
Note:
RDT is the value of resistor expressed in Kohm with a power rating of 1/8 or 1/4w.
Kdt is the tachogenerator costant V/KRPM
N is the max speed express in RPM.
Vref is the max voltage +/-REF reference express in Volts.
To calculate RDT resistor, please use the following formula:
Once the resistor RDT is inserted, proceed with final speed adjustment.
Operateusing trimmer SPEED onthefront of thedrive.With Clockwise Rotationthespeedincreases.
With Counter Clockwise Rotation the speed decreases. The Range of regulation is about +/- 20%.
RDT resistor calculations
In this configuration, the drive must set with the following Dip Switch and below internal setting:
DS1 Switch set for:
- Tachogenerator feedback
- Ramp time disabled
- Standard Dynamic constant
Note: On the adjustement zone are not
considered here the other components used
to determine other calibrations "for example.
Calibration current rating etc.".
DS1 7 6 5 4 3 2 1
DS1 SWITCH ADJUSTEMENT PADS

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RA 82 68 56 47 39 33 27 20 15 12 8,2 5,6 3,9 1
65 57 53 49 45 42 38 34 28,5 23 20,5 16 12 10 5
145 121 113 105 97 88 81 72 60 50 43 33 26 20 10
205 206 193 178 165 151 138 123 103 86 74 57 44 35 18
3.3 Setting with armature feedback
In this configuration (Motor with only +M and -M armature), the drive must set with the following DS1
Switch and below internal setting:
DS1 Switch set for:
- Armature feedback
- Ramp time disabled
- Standard Dynamic constant
Note: On the adjustement zone are not
considered here the other components used
to determine other calibrations "for example.
Calibration current rating etc.".
RA resistor calculations
Vdc = Vrms * 1,41
EXAMPLE: Brush DC motor with Ke= 26V/Krpm (Vdc)
Drive model 145
Nominal speed N° =3000rpm
Risult: Vdc= 26*3000/1000= 78V
Insert on base "RA" to adapt the system to use the motor voltage.
Where:
For the Example, risult Vdc=81V. The table shows a resistor with a value of 33Kohm.
Once the resistor RA is inserted, proceed with final speed adjustment.
Operateusing trimmer SPEED onthefront of thedrive.WithClockwise Rotationthe speed increases.
With Counter Clockwise Rotation the speed decreases. The Range of regulation is about +/- 20%.
Table Vdc voltage Value of RA in Kohm
Model Voltage output Vdc
DS1 7 6 5 4 3 2 1
DS1 SWITCH ADJUSTEMENT PADS

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RCA resistor calculations
RCA (Kohm) = 0,49 * 1000 * Vmot
Vref * Ipk * Ri
Example: Drive 7/14A, Ri=0,3ohm, Vmot=36V, Reference=10V
Calculate:RCA (Kohm) = 0,49 * 1000 * 36 = 420K
10 * 14 * 0,3
Insert a 470Kohm resistance. If after insertion of the resistor the motor is unstable, increase the
Resistance value of RCA.
Where:
Vmot= Nominal voltage of the motor
Ri=Max. cold motor resistance.
Ipk =Peak drive current.
Vref= max. applied reference voltage in REF
Insert an RCA resistor on the header (ajustement zone) to compensate for voltage loss due to the
motor resistance reducing the loss of RPM.
The formula is as follows:

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3.4 Setting with encoder feedback
In this configuration, the drive must set with the following DS1 Switch and below internal setting:
DS1 7 6 5 4 3 2 1
DS1 SWITCH ADJUSTEMENT PADS
DS1 Switch set for:
- Encoder feedback
- Ramp time disabled
- Standard Dynamic constant
Note: On the adjustement zone are not
considered here the other components used
to determine other calibrations "for example.
Calibration current rating etc.".
Example: N° encoder (PPR) = 500
Motor max. speed 4000 rpm
Where:
RENC = 681*1000 / Fenc
Fenc = PPR * rpm / 60
Fenc = 500 * 4000 / 60= 33.333
RENC = 681*1000 / 33.333 = 20,4 kohm
RENC resistor calculations
The resistor RENC determine what is the max. speed of the motor at 10V of reference.
The result of RENC resistance is 20 or 22 Kohm. Prefer resistance with 1% tolerance.
Once the resistor RENC is inserted, proceed with final speed adjustment.
Operateusing trimmer SPEED onthefront of thedrive.With Clockwise Rotationthespeedincreases.
With Counter Clockwise Rotation the speed decreases. The Range of regulation is about +/- 20%.
Note: TheAand B signals may come from encoders powered by + 5V to + 24V).
The accepted logical levels are:
Minimum high logic level > + 2.8V / 24Vmax,
Minimum logical low level <1.5V
Can be connected push-pull encoders (wires A, B and GND) or line-driver encoders (wires + A, + B
and GND). Remember to combine the zero supply of the encoder with the GND (Ground of the
converter).
Connections:WireAof the encoder is connected to terminal CHA,wire B to terminal CHB to the rack-
mount or panel-mounting installation kit. The encoder supply zero must be connected to the GND
terminal. For details contact Microphase.
For calcolation this resistance apply the following formula:

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3.4
Valore RIN *56 22 12 6,8 4,7 3,9 2,7 1,8 1,5 1
3/6 32,8 2,7 2,5 2,4 2,2 21,9 1,7 1,5 1,3
4/8 43,9 3,7 3,5 3,2 32,8 2,6 2,2 2,1 1,8
7/14 76,8 6,5 65,7 5,3 54,6 43,7 3,1
10/20 10 9,7 9,2 8,7 8,1 7,6 7,1 6,5 5,7 5,3 4,4
14/28 14 13,7 13 12,3 11,4 10,7 10 9,2 87,5 6,2
20/40 20 19,4 18,4 17,4 16,2 15,2 14,2 13 11,4 10,6 8,8
Valore RIP *470 390 220 150 120 100 82 68 56 47
3/6 65,7 5,4 54,5 43,8 3,5 3,3 3,2 3
4/8 87,4 76,48 65,6 5,3 54,8 4,2 4
7/14 14 13 12,2 11,3 10,5 9,9 9,3 8,7 8,4 7,5 7
10/20 20 18,5 17,5 16,2 15 14,1 13,2 12,5 12 10,7 10
14/28 28 26 24,5 22,7 21 19,8 18,6 17,5 16,8 15 14
20/40 40 37 35 32,4 30 28,2 26,4 25 24 21,4 20
RIN resistor (rated current adjustment)
Size drive (A) Rated Current request (A)
RIP resistance limits the maximum current supplied by the converter. For the calculation see the
following table:
Resistance RIN limits the value of the rated current supplied by the drive. Normally has the same
value, of the stall current of DC motor. For the calculation see the following table:
Value of Rin in Kohm
Note * = No resistor mounted.
RIP resistor (Peak current adjustment)
Size drive (A) Peak Current request (A)
Value of RIP in Kohm
Note * = No resistor mounted.
Example: on a converter 7/14A, inserting a resistance RIP 150Kohm the maximum output current
will not be 14A, but 10.5A
Example: on a converter 7/14A, inserting a resistance RIN 6.8Kohm the rated output current will
not be 7A, but 5.7A
3.5 Current adjustement

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Mini Dc
A)
B)
VEL
MOTOR
T
T
+3,3V
-2V
VEL
MOTOR
T
T
+3,3V
-2V
Ramp disabled Rampa enabled
It is possible to modify the pre-set “range of the ramp“ by opening point DS1 (4) and inserting a
resistance (RACC) of the value indicated by the table below on the adjustement pads (see B)
DS1 4 3 2
DS1 SWITCH
DS1 4 3 2
DS1 SWITCH
DS1 4 3 2
DS1 SWITCH ADJUSTEMENT PADS
The product is standard setting with this feature is not enabled DS1 switch (2) and (3) OFF
To enable the ramp acceleration close the DS1 switch 4.
23 4FUNCTION RANGE SETTING
OFF OFF ON Ramp disabled NO SDT
ON ON ON Ramp enabled 0,1 - 1sec Variable with ramp trimmer
ON ON OFF Long ramp Insert RACC Variable with ramp trimmer
RACC resistance value 820 Kohm 1,2 Mohm 3 Mohm
TIME 0,3 - 3 sec 0,5 - 4 sec 1,1 - 12 sec
Ramp disabled (STD)
Long Ramp
Ramp enabled 0,1 - 1sec
Insert Racc
3.6 Ramp time adjustement