Parker Compumotor APEX615 Series Installation Manual
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Parker Compumotor APEX615 Series Installation Manual

Servo controller / drive
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  • Page 1 (217) 352-9330 | Click HERE Find the Parker / Compumotor APEX6152 at our website:...
  • Page 2 G rn B lu B rn la y F lt la y la y F lt F lt Compumotor Division Parker Hannifin Corporation p/n 88-016148-01 A March 1997 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 3 Since Parker Hannifin constantly strives to improve all of its products, we reserve the right to change this user guide and software and hardware mentioned therein at any time without notice.

  • Page 4: Table Of Contents

    • Mechanical motion control concepts, such as inertia, torque, velocity, distance, force. • Serial communication and terminal emulator experience: RS-232C and/or RS-485 Related Publication • 6000 Series Software Reference, Parker Hannifin Corporation, Compumotor Division; part number 88-012966-01 • 6000 Series Programmer’s Guide, Parker Hannifin Corporation, Compumotor Division;...
  • Page 5 APEX615n CONTROLLER/DRIVE: LVD Installation Instructions Product Type: APEX6151, APEX6152 and APEX6154 Servo Controller/Drives The above products are in compliance with the requirements of directives • 72/23/EEC Low Voltage Directive • 93/68/EEC CE Marking Directive APEX615n Controller/Drives, when installed according to the procedures in the main body of this installation guide, may not necessarily comply with the Low Voltage Directive (LVD) of the European Community.

  • Page 6: Installation

    C H A P T E R O N E Installation IN THIS CHAPTER • Product ship kit list • Things to consider before you install the APEX615n • General specifications table • Optional pre-installation alterations DIP switch settings – motor current, device address, autobaud feature Changing the COM 2 port from RS-232C to RS-485 •...

  • Page 7: What You Should Have (Ship Kit)

    What You Should Have (ship kit) Part Name Part Number One of the following line items: If an item is missing, APEX615n standard product (with ship kit) ............... APEX615n call the factory (see APEX615n standard product (with ship kit) ............... APEX615n phone numbers on APEX615n standard product (with ship kit) ...............

  • Page 8: Before You Begin

    Before You Begin WARNINGS The APEX615n is used to control your system's electrical and mechanical components. Therefore, you should test your system for safety under all potential conditions. Failure to do so can result in damage to equipment and/or serious injury to personnel. Always remove power to the APEX615n before: •...

  • Page 9: General Specifications

    General Specifications P a r a m e t e r S p e c i f i c a t i o n Input Power Voltage Range............APEX6151: 85-252VAC (1-phase) APEX6152: 205-252 VAC (1- or 3- phase) APEX6154: 205-252 VAC (1- or 3- phase) Frequency Range .............
  • Page 10 Serial Communication RS-485 requires internal jumper and DIP switch configuration (see page 10). Connection Options..........RS-232C (3-wire); RS-485 (2- or 4-wire); Change internal switches SW1, SW2, and SW3, and internal jumper JU2 to position 3 to select RS-485 communication for COM 2 port.. Default for RS-485 is 2-wire.

  • Page 11: Pre-Installation Adjustments

    Pre-installation Adjustments DIP Switch Settings – Motor Current, Feedback Options, Drive Features The APEX615n has three 8-position DIP switches. The switches are located behind a small metal cover on top of the APEX615n. Loosen the two screws that hold the access cover. Move the cover out of the way to expose the DIP switches.
  • Page 12 SW 1 SW 2 SW 3 APEX6151 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 DIPs REGEN FAULT Enable Disable HALL DEGREES 120° Hall motor 60°...
  • Page 13 SW 1 SW 2 SW 3 APEX6152 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 DIPs REGEN FAULT Enable Disable HALL DEGREES 120° Hall motor 60°...
  • Page 14 SW 1 SW 2 SW 3 APEX6154 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 DIPs 1 2 3 4 5 6 7 8 REGEN FAULT Enable Disable HALL DEGREES 120° Hall motor 60°...

  • Page 15: Changing From Rs-232 To Rs-485

    Changing the COM 2 Connector from RS-232 to RS-485 RS-232C Users The APEX615n's port is factory configured for RS-232C COM 2 Rx– communication (use the right-hand pin descriptions). If you do Tx– not need to use RS-485 communication, you may ignore this Iso Gnd Shld section and proceed to the Mounting instructions.

  • Page 16: Mounting The Apex615N

    Mounting the APEX615n Before you mount the APEX615n Make sure you have performed all the necessary configuration tasks that require accessing internal components (DIP switches and jumpers). • Select motor current (DIP switches). See pages 6-9. • Select serial communication method (jumper & DIP switches). If you are using RS-232C to communicate with the APEX615n, use the factory settings.

  • Page 17: Dimensions

    Mounting Slots and The APEX615n's mounting bracket is notched with keyhole type slots to accept four screws Grounding for surface mounting on a flat panel. One of the slots—upper right—is unpainted. You can use a star washer between the mounting screw and this slot to help provide additional electrical grounding between the APEX615n and the mounting surface.
  • Page 18 APEX6152 10.750 (273) 1.000 0.33 4.500 (114.3) (25.4) (8.4) 2.000 1.250 (31.7) (50.8) A P E X 6 1 5 2 Unpainted Grounding 14.250 (361.9) 15.375 (390.5) 16.250 (412.7) 4X clearance for Dimensions in inches (millimeters) #10 (M5) mounting screw APEX6154 10.750 (273) 1.000...

  • Page 19: Airflow & Cooling

    Airflow & Cooling Airflow The APEX615n can operate in an ambient temperature environment of 0°C to 50°C (32°F to 122°F). It is cooled by an internal fan mounted at the top of the drive. The fan draws air in through the in t in t o to...
  • Page 20 When you design your panel layout, 1.50 1.50 4.0 (102) (38.1) (38.1) follow these precautions for adequate Clearance (Minimum) cooling: (Minimum) • The vertical distance between the APEX615n and other equipment, or the top and bottom of the enclosure, should be no less than 4 inches (100 mm).

  • Page 21: Electrical Connections

    Electrical Connections AC Input Connector DIP Switches A P E X 6 1 5 1 Compumotor Torque Cmd Test Point Iso Gnd COM 1 Offset Balance Connector Tach Output Calibration Iso Gnd Shld COM 2 Enable Connector Disable Bridge Fault Shield Drive Fault Iso Gnd...
  • Page 22 AC Input Connector DIP Switches Compumotor Torque Cmd Iso Gnd Test Point COM 1 Connector COM 2 Offset Connector Balance Iso Gnd Shld Tach Output Calibration External Encoder Enable Shield Connector Disable Iso Gnd Bridge Fault Limits Drive Fault Motor Fault Connector Over Voltage T Limit...

  • Page 23: Ground Connections

    Ground Connections The APEX615n has three internal ground systems: two floating ground systems (Isolated Ground and Analog Ground) and one Earth ground system (Chassis Ground). The table below identifies the terminals that are associated with each ground system. Refer to the following drawings to locate the grounding points.
  • Page 24 APEX6152 & APEX6154 Mounting Slot Chassis Ground Compumotor Iso Gnd APEX6151 Shld Mounting Slot Shield Iso Gnd Chassis Ground T Limit Iso Gnd Iso Gnd Shield Isolated Ground Analog Note: Grounding connections shown Ground on COM 2 port are for RS-232 communications 49 50 APEX615n Ground Systems...
  • Page 25 2 . If you must connect to a terminal, use a separate ground wire from your remote device. Do not put a jumper between I s o G N D If you connect signals from an external device to terminals on both the left row of connectors and the right row of connectors, then run two separate ground wires from the remote device to the APEX615n.

  • Page 26: Ac Input Connector

    AC Input Connector Connect AC power to the APEX615n's AC Input connector, which is an 8-pin removable connector located on top of the unit. The connector can accept wire diameters as large as 10 AWG (6mm) The AC power requirements for each model of the APEX615n are as follows: APEX6151: 85-252VAC, Single Phase, (SM Motor - 120VAC only) APEX6152:...
  • Page 27 APEX6152 & APEX6154 Internal Connections AC Input Connector Motor Connector Phase A 3 Phase Phase B Rectifier 3 – Phase Phase C Power Amplifier V Bus + – Regen Resistor V Bus – Earth Motor Ground Shield Front Panel – Right Side Earth LEDs Control L1...
  • Page 28 WIRING OPTIONS APEX6151 APEX6152 and APEX6154 AC Power Disconnecting AC Input AC Power Disconnecting AC Input Source Means Connector Source Means Connector Disconnecting AC power turns off power output to motor, and turns off controller Earth Earth Earth Earth Earth Control L1 Control L1 Control L2...
  • Page 29 Disconnecting Removing power to the controller portion of the APEX615n ( ) will Control L1 Control L2 Power to the trigger a Drive Fault, plus the controller will issue a "shutdown" signal to the drive that is Controller equivalent to the command.

  • Page 30: Serial Communication

    Serial Communication RS-232C Connections RS-232C Daisy-Chain Connections* Unit 0 Unit 1 Unit 2 Iso GND Iso GND Iso GND Iso GND Daisy Chain to a Computer or Terminal Rx– Unit 0 Unit 1 Unit 2 Tx– Iso GND SHLD Serial Port Connection Iso GND Iso GND Iso GND...

  • Page 31: External Encoder

    External Encoder CONNECTIONS & INTERNAL SCHEMATICS ENCODER Connector Internal Schematic Shield Shield SHLD Ground Black Iso GND Chassis Ground Max. Cable Length is 100 feet. Orange/White Isolated Ground Z Channel – Use 22 AWG wire. Z Channel + Orange Same Circuit +1.8VDC B Channel –...

  • Page 32: End-Of-Travel And Home Limit Inputs

    End-of-Travel and Home Limit Inputs NOTES • Motion will not occur until you do one of the following: - Install end-of-travel ( & ) limit switches - Disable the limits with the LHØ command (recommended only if load is not coupled) - Change the active level of the limits with the LHLVL command •...

  • Page 33: Trigger Inputs

    Trigger Inputs Internal Schematic ENCODER Connector SHLD TRG-A/B connected to Iso GND (normally-open switches). Chassis Ground The active level (default is active low) can be changed with the INLVL command. These inputs are like the general-purpose inputs on the 50-pin header.

  • Page 34: General-Purpose Prog. Inputs & Outputs

    General-Purpose Programmable Inputs & Outputs VM50 ADAPTOR — for screw-terminal connections Out-P CHA+ In-P CHA - Aux-P CHB+ CHB - CHZ+ CHZ - Shield 2-Foot Cable (provided with VM50) M T + M T - Flt Relay+ Flt Relay - Flt Relay - 2 4 6 8 10 12 14 16 18 20 22 24 26...
  • Page 35 INPUT CONNECTIONS — Connecting to electronic devices such as PLCs Connection to a Electronic APEX615n Sinking Output Device D e v i c e ISO GND +5VDC Pulled up to +5V The output should IN-P (sourcing) be able to sink at least 1mA of current.
  • Page 36 OUTPUT CONNECTIONS (includes OUT-A) — for electronic devices such as PLCs Connection to a Sinking Input (active high) Connection to a Sourcing Input (active low) External Supply Electronic APEX615n (up to 24VDC) External Supply – Device Electronic APEX615n (up to 24VDC) –...

  • Page 37: Rp240 Remote Operator Panel

    THUMBWHEEL CONNECTIONS — for entering BCD data Connection to the Compumotor TM8 Module TM8 Thumbwheel Module +5 GND I5 I4 I3 I2 I1 O5 O4 O3 O2 O1 APEX615n Programmable Input #1 Programmable Input #2 Programmable Input #3 Programmable Input #4 Programmable Input #5 Pin #49 (+5VDC) Pin #48 (ISO GND)

  • Page 38: Lengthening I/O Cables

    Lengthening I/O Cables Bear in mind that lengthening cables increases noise sensitivity. (The maximum length of cables is ultimately determined by the environment in which the equipment will be used.) If you lengthen the cables, follow the precautions below to minimize noise problems. •...

  • Page 39: Drive Auxiliary Connector

    Drive Auxiliary Connector Pin #: Function: Reset Reset Ground (tied to AC earth ground) No Connection Enable In Enable In Fault Output Fault Out Ground (tied to AC earth ground) No Connection No Connection Tach Out Tachometer Output Ground (tied to AC earth ground) +15 V +15V Ground (tied to AC earth ground)
  • Page 40 Enable Input Internal Schematic Reset +5VDC Enable In Fault Out 6.81K 47.5K Tach Out 74HC14 +15 V 1000 pF -15 V ANA GND • Active Low: to enable the APEX615n, hold at low voltage. ENABLE IN • Voltage Low = 1.0V maximum •...
  • Page 41 Tachometer Output Internal Schematic Reset Enable In Fault Out From RDC velocity output Tach Out +15 V LF347 ANA GND -15 V Tachometer Output: ±10V at 15mA (max) • Use DIP Switch #3, position 5, to scale output: • OFF = 1V/1000 rpm for one speed resolvers •...

  • Page 42: Encoder Output Connector

    Encoder Output Connector The encoder output connector is a dual use connector. It can be used for either Encoder Output or for Hall Effect Input. Use DIP Switch #3, position 4, to select desired function. OFF = Encoder Output (derived from the resolver input) ON = Hall Effect Input mode Encoder Output Hall Effect Input...
  • Page 43 Encoder - nternal Schematic Quadrature Outputs ENCODER OUTPUT Connector AM26LS31 From RDC CHA+ CHA - AM26LS31 CHB+ From RDC CHB - CHZ+ AM26LS31 CHZ - From RDC The APEX615n’s encoder outputs are pseudo-quadrature outputs. These quadrature outputs are called pseudo because they are hardware–derived from resolver information and not from an actual encoder.
  • Page 44 Hall Effect Input The following circuit is internally connected to the encoder connector when DIP Switch #3, position 4 is turned ON. nternal Schematic +5VDC +5VDC From Hall Select CHA+ DIP switch (3 plcs) CHA - 74HC14 (3 plcs) 3906 CHB+ CHB - Hall 1...

  • Page 45: Resolver Connector

    Resolver Connector Connect the motor end of the resolver cable to the motor. Cables are available for SM motors in 10 and 25 foot lengths; and for APEX Series motors in 10, 25, 50, and 100 foot lengths. The cables have MS-type connectors on the motor end of the cable. You can also order custom cables of any length.
  • Page 46 Motor Temperature The resolver connector has two terminals through which the APEX615n can monitor motor Sensor Input temperature. The terminals, labeled , should be connected to the two leads of a MT– normally-closed temperature sensor mounted on the motor. When the motor is within its temperature limits, the sensor will be closed, thus shorting together .
  • Page 47 Motor Braking — If the APEX615n faults, for any reason, the drive will be disabled and the motor will Fault Relay freewheel. Refer to Chapter 2: Troubleshooting for all fault conditions. If a freewheeling load Terminals is unacceptable, use the fault relay terminals to control a motor Fault Relay+ Fault Relay–...
  • Page 48 EXAMPLE 1: APEX Series motors are available from Compumotor with an optional mechanical brake. Call Compumotor’s Customer Service Department (800-722-2282) for more information. The next drawing shows how to connect the brake to the fault relay terminals. +5VDC to +24VDC Internal Schematic Drive Relay...
  • Page 49 EXAMPLE 2: The next drawing illustrates how to connect auxiliary resistors to control motor braking. The drawing shows that during normal operations, the motor contactor is energized and provides a direct connection between the motor and drive. The motor contactor (N.O.

  • Page 50: Connecting The Motor

    Connecting the Motor The motor cable connects the APEX615n’s power output, located on the bottom of the drive, to the motor's power input. APEX and SM motor cables have an MS style connector on the end that attaches to the motor. You must wire the other end of the cable to the APEX615n’s motor connector, which is a 8-pin removable connector located on the bottom of the cabinet.

  • Page 51: Testing The Installation

    Regeneration The APEX615n can dissipate regenerated energy in its internal regeneration resistor. If an Resistor APEX615n system regenerates more energy than the internal resistor can dissipate, you can connect an external resistor between the two terminals labeled V Bus+ Regen Resistor located on the motor connector.
  • Page 52 Test Setup Computer Terminal A P E X 6 1 5 1 Serial Connection: Compumotor Torque Cmd RS-232C Test Point RS-485 Iso Gnd Offset Balance Tach Output Calibration Terminal Emulation for IBM/Compatibles Connect to 240VAC Iso Gnd Shld and ground Enable To communicate with the APEX615n, you will Disable...
  • Page 53 Connections Test Procedure Response Format (left to right) End-of-travel NOTE: If you are not using end-of-travel limits, issue the Disable Limits (LHØ) command and TLIM response: and Home ignore the first two bits in each response field. bit 1 = POS limit limits bit 2 = NEG limit bit 3 = home limit...

  • Page 54: Mounting & Coupling The Motor

    Mounting & Coupling the Motor WARNINGS • Improper motor mounting and coupling can jeopardize personal safety, and compromise system performance. • Never disassemble the motor; doing so will cause contamination, significant reduction in magnetization, and loss of torque. • Improper shaft machining will destroy the motor’s bearings, and void the warranty. Consult a factory Applications Engineer (see phone number on inside of front cover) before you machine the motor shaft.
  • Page 55 A 0.003 TIR ( 0.08 ) 1.18 ± .02 (30.0 ± .5) 0.093 (2.36) 0.375 2.720 0.79 (20.0) (9.54) (69.0) A 0.003 TIR ( 0.08 ) 0.0005 2.362 + 0.06 2.76 0.0003 0.00 0.012) (60.00 + 1.5) (70.0 0.007) 2.11 ± 0.004 0.0) (53.6 ±...
  • Page 56 A 0.003 TIR ( 0.08 ) 9.30 1.18 ± 0.02 (236.2) 0.69 (30.0 ± 0.5) 4.87 (17.5) (123.7) 0.12 (3.0) 0.78 (19.8) min. 3.077 (78.16) 0.44 (11.2) A 0.003 TIR ( 0.08 ) 0.0005 3.150 + 0.0003 3.167 (80.44) 0.012) (80.00 + 0.007) 0.0003...
  • Page 57 A .003 TIR (.08) 9.61 (244.2) 1.18 ± .02 6.48 (30.0 ± .5) (164) .093 (2.36) .375 2.720 (9.54) (69.0) .79 MIN (20.0) 2.11 ± 0.004 (53.6 ± 1.0) +0.0005 2.362 -0.0003 +.06 2.76 +0.012 -.00 (60.00 -0.007 +1.5 (70.0 A 0.003 TIR -0.0 (.08)
  • Page 58 (0.08) A 0.003 TIR 1.18 ± 0.02 Max. (30.0 ± 0.5) 0.69 (17.5) 0.12 (3.0) 0.78 (19.8) min. 0.44 (11.2) A 0.003 TIR (0.08) 3.077 (78.16) 3.167 (80.44) +0.0005 3.150 -0.0003 3.075 (78.11) 3.165 (80.39) +0.012 (80.00 -0.007 0.3932 (9.987) +0.0003 M5 X 0.8 Tap X 0.39 (10.0) Min.
  • Page 59 A 0.004 TIR (0.10) 1.967 ± 0.02 Max. (50.0 ± 0.5) 0.69 (17.5) 0.14 (3.50) 1.457 (37.00) min. 0.49 (12.5) A 0.004 TIR (0.10) +0.0005 4.331 4.006 (101.75) 4.103 (104.22) -0.0004 4.004 (101.70) 4.101 (104.17) +0.013 (110.00 -0.009 0.3932 (9.987) +0.0003 0.3922 (9.962) 0.9449...
  • Page 60 A 0.004 TIR (0.10) 1.967 ± 0.02 (50.0 ± 0.5) Max. 0.69 (17.5) 0.14 (3.50) 1.457 (37.00) min. 0.71 (18.0) A 0.004 TIR (0.10) 5.118 +0.0006 5.006 (127.15) 5.103 (129.62) -0.0004 5.004 (127.10) 5.101 (129.57) +0.014 (130.00 -0.011 0.3932 (9.987) +0.0003 0.3922 (9.962) 0.9449...

  • Page 61: Motor Heatsinking

    Motor Heatsinking Performance of a servo motor is limited by the amount of current that can flow in the motor's coils without causing the motor to overheat. Most of the heat in a brushless servo motor is dissipated in the stator - the outer shell of the motor.
  • Page 62 Double-Flex Coupling Use a double-flex coupling whenever two shafts are joined with parallel misalignment, or a combination of angular and parallel misalignment (the most common situation). Single-flex and double-flex couplings may or may not accept end play, depending on their design. Rigid Coupling Rigid couplings are generally not recommended, because they cannot compensate for any misalignment.

  • Page 63: What's Next

    What's Next? By now, you should have completed the following tasks, as instructed earlier in this chapter: 1. Review the general specifications — see page 4. 2. Perform configuration/adjustments, as necessary — see pages 6-10. 3. Mount the APEX615n — see page 11. 4.

  • Page 64: Troubleshooting

    C H A P T E R T W O Troubleshooting IN THIS CHAPTER • Troubleshooting basics: Diagnostic LEDs for hardware problems Reducing Electrical Noise Error message and debug tools Technical support • Solutions to common problems • RS-232C troubleshooting •...

  • Page 65: Troubleshooting Basics

    Troubleshooting Basics When your system does not function properly (or as you expect it to operate), the first thing that you must do is identify and isolate the problem. When you have accomplished this, you can effectively begin to resolve the problem. The first step is to isolate each system component and ensure that each component functions properly when it is run independently.
  • Page 66 How to reset the fault (see Recovering from Faults Description Latched (yes/no) below for additional details) Enable Indicates drive is enabled Disable Indicates drive is disabled Issue the DRIVE1 command Bridge Fault * Power stage over-temperature Note 1 Power stage over-current Note 1 Motor short circuit Note 1...

  • Page 67: Reducing Electrical Noise

    Recovering from Many of the fault conditions will shut down the APEX615n’s output current to the motor. Faults Before trying to restart your system, you should first solve the problem that caused the fault. For example, if a short circuit in a motor cable caused a , the same fault will Drive Fault probably occur when you restart the drive—unless you first fix the problem.

  • Page 68: Common Problems & Solutions

    Common Problems & Solutions The following table presents some guidelines to help you isolate problems with your motion control system. Some common symptoms are listed along with a list of possible causes and remedies. • Look for the symptom that most closely resembles what you are experiencing. •...
  • Page 69 Problem Cause Solution No RS-232C 1. Improper RS-232C Interface or 1. See RS-232C Troubleshooting section Communication communication parameters 2. RS-232C disabled 2. Enable RS-232C with the E command (all units if daisy-chained) 3. Verify proper application of the ADDR command 3.

  • Page 70: Troubleshooting Serial Communication Problems

    1. Power up the computer or terminal and launch the terminal emulator. 2. Power up the APEX615n. A power-up message (similar to the following) should be displayed, followed by a prompt (>): ∗PARKER COMPUMOTOR 615n SERVO CONTROLLER ∗RP240 CONNECTED >...

  • Page 71: Faults Caused By Excessive Regeneration

    Faults Caused by Excessive Regeneration The APEX615n’s protection circuitry monitors regeneration activity, and can trigger one of two fault conditions if excess regeneration occurs. Exceeding the regeneration resistor’s continuous power rating will cause a Regen Fault. Exceeding the resistor’s peak power rating will cause an Overvoltage Fault.

  • Page 72: Overvoltage Fault

    You can clear the regen fault by cycling power or by resetting the drive. To cycle power, turn off AC power to the to the terminals on the AC power connector, then turn the Control L1/L2 CAUTION power back on; however, if the resistor has not had adequate time to cool, and the conditions Repeatedly cycling leading to the regen fault persist, you may damage the regen resistor by cycling power or resetting the...

  • Page 73: Current Foldback (I2T Limit)

    Current Foldback (I T Limit) The purpose of the current foldback circuit is to protect the motor from overheating due to prolonged high currents. The eight switches of DIP Switch#2 are used to set the parameters for the current foldback circuit. These parameters are: •...

  • Page 74: Offset Balance Adjustments

    Offset Balance Adjustments The offset balance potentiometer (offset pot) adjusts the offset voltage of the APEX615n’s internal command signal. The offset is zeroed at the factory, with the pot set near the middle of its range of travel. Normally, you do not need to adjust it. However, if you suspect the pot’s setting has been altered, the procedure below will explain how to adjust it to zero the offset balance.

  • Page 75: Tachometer Output Calibration

    Tachometer Output Calibration Use the Tachometer Output Calibration potentiometer to precisely calibrate the APEX615n Controller/Drive's tachometer output, while monitoring the actual tachometer output at the Tach Out pin on the Drive Auxiliary connector. For example, a commanded velocity of 4000 rpm should produce Tach Out signal of 4 volts.

  • Page 76: Commutation Test Mode

    Commutation Test Mode You can operate the APEX615n in commutation test mode to help identify and isolate problems. When it runs in commutation test mode, the APEX615n does not use any motor feedback information for commutation. It ignores the resolver or the Hall effect sensor input, and commutates the motor in an open loop fashion at one revolution per second.
  • Page 77 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 78: Appendix A (Servo Tuning)

    Appendix A S e r v o T u n i n g In a Hurry? We strongly recommend tuning the APEX615n before attempting to execute any motion functions. If you must execute motion quickly (e.g., for testing purposes), you should at least complete this appendix’s Controller Tuning Procedure and find a proportional feedback gain that gives a stable response for your system.
  • Page 79 Closed Loop System Offset Control Analog Command = Signal Digital Control Signal + Offset Command Drive Motor Load Control Algorithm Feedback Device: Feedback Data Resolver, Encoder, or ANI Input Servo Algorithm Disabled SOFFS Drive Command = Offset Offset Drive Motor Load Feedback Device: Resolver, Encoder,...
  • Page 80 Commanded The commanded position is calculated by the motion profile routine based on the Position acceleration (A, AA), deceleration (AD, ADA), velocity (V) and distance (D) command values and it is updated every servo sampling period. Therefore, the commanded position is the intended position at any given point of time.
  • Page 81 Servo Response Terminology Stability The first objective of tuning is to stabilize the system. The formal definition of system stability is that when a bounded input is introduced to the system, the output of the system is also bounded. What this means to a motion control system is that if the system is stable, then when the position setpoint is a finite value, the final actual position of the system is also a finite value.
  • Page 82 These three measurements are made before or shortly after the motor stops moving. When it is moving to reach and settle to the setpoint, we call such a period of time the transient. When it is not moving, it is defined as steady-state. A typical stable position response plot in preset mode (MCØ) is shown below.
  • Page 83 When using the Target Zone Mode, enabled with the STRGTE command, the actual Target Zone Mode Enable STRGTE position and actual velocity must be within the target zone (that is, within the distance zone Target Zone Distance STRGTD defined by STRGTD and within the velocity zone defined by STRGTV). If the motor/load does not settle into the target zone before the timeout period set by STRGTT, the Target Zone Velocity STRGTV...
  • Page 84 Disturbance S t e a d y Tracking G a i n Stability Damping Rejection State Error Error Improve Improve Improve Improve Improve Proportional ( Degrade Degrade Improve Improve Improve Integral ( Improve Improve ------------- ------------- Degrade Velocity Feedback ( ------------- ------------- -------------...
  • Page 85 Controlling Integral If integral control (SGI) is used and an appreciable position error has persisted long enough Windup during the transient period (time taken to reach the setpoint), the control signal generated by the integral action can end up too high and saturate to the maximum level of the controller’s analog control signal output.
  • Page 86 Velocity Feedforward Control (SGVF) The purpose of velocity feedforward control is to improve tracking performance—that is, reduce the position error when the system is commanded to move at constant velocity. The tracking error is mainly attributed to three sources—friction, torque load, and velocity feedback control (SGV).
  • Page 87 Controller Tuning Procedure The Controller Tuning Procedure leads you through the following steps: 1. Turn on AC power to the APEX615n. 2. Setup up for tuning. 3. Select the 615n's servo Sampling Frequency Ratios (SSFR). 4. Set the Maximum Position Error (SMPER). 5.
  • Page 88 Higher sampling frequencies improve the accuracy of the derived velocity and integral values. A higher sampling frequency can also improve the tracking of a rapidly changing or oscillating position. Therefore, the servo sampling frequency is a key parameter that influences the servo system’s stability and closed loop bandwidth.
  • Page 89 Step 4 Set the Maximum Position Error ( SMPER The SMPER command allows you to set the maximum position error allowed before an error condition occurs. The position error, monitored once per system update period, is the difference between the commanded position and the actual position as read by the feedback device selected with the last SFB command.
  • Page 90 START Increase SGP UNTIL Decrease SGV Increase SGV UNTIL UNTIL Decrease SGV UNTIL STOP Decrease SGP UNTIL Increase SGV UNTIL Decrease SGV UNTIL Appendix A Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 91 Step 6 Use the Integral Feedback Gain (SGI) to reduce steady state error: Determine the steady state position error (the difference between the commanded position and the actual position). You can determine this error value by the TPER Steady state position error is described earlier in the command when the load is not moving.
  • Page 92 Tuning Scenario This example shows how to obtain the highest possible proportional feedback (SGP) and velocity feedback (SGV) gains experimentally by using the flow diagram illustrated earlier in Step 5 of the Tuning Procedure. N O T E The steps shown below (steps 1 - 11) represent the major steps of the process; the actual progression between these steps usually requires several iterations.
  • Page 93 Step 5 After the SGV gain is raised to 2.6, the overshoot was reduced but chattering is still quite pronounced. This means either one or both of the gains is too high. The next step should be to lower the SGV SGP = 105 gain first.
  • Page 94 Step 11 When we raised the SGV gain to 2.52, the step response became fast and very stable. SGP = 70 SGV = 2.52 Target Zone (Move Completion Criteria) Under default operation (Target Zone Mode not enabled), the APEX615n’s move completion criteria is simply derived from the move Commanded trajectory.
  • Page 95 Damping is critical To ensure that a move settles within the distance zone, it must be damped to the point that it will not move out of the zone in an oscillatory manner. This helps ensure the actual velocity falls within the target velocity zone set with the STRGTV command (see illustration below). Failed Move Completion Successful Move Completion STRGTD...

  • Page 96: Appendix B (Reducing Elec. Noise)

    Appendix B R e d u c i n g E l e c t r i c a l N o i s e Noise-related difficulties can range in severity from minor positioning errors to damaged equipment from runaway loads crashing blindly through limit switches. In microprocessor- controlled equipment such as the APEX615n, the processor constantly retrieves instructions from memory in a controlled sequence.
  • Page 97 Internal Switching Noise This noise directly relates to the high dv/dt from the internal switching of the IGBT power block of the APEX615n's drive. This high dv/dt creates a large earth ground di/dt through the motor case. This may cause the ground to jump if a solid earth connection is not present. Depending on how the drive and other equipment are connected to the earth ground, users may experience voltage spikes on I/O lines.
  • Page 98 Multiple devices on the same circuit should be grounded together at a single point. Furthermore, power supplies and programmable controllers often have DC common tied to Earth (AC power ground). As a rule, it is preferable to have the APEX615n Iso GND floating with respect to Earth.
  • Page 99 Defeating Noise The best time to handle electrical noise problems is before they occur. When a motion system is in the design process, the designer should consider the following set of guidelines for system wiring (in order of importance): 1. Put surge suppression components on all electrical coils: Resistor/capacitor filters, MOVs, Zener and clamping diodes.

  • Page 100: Appendix C (Motor Specifications)

    Appendix C M o t o r S p e c i f i c a t i o n s Motor Specifications Speed/torque curves, motor specifications, and dimensions are shown on the following pages. Motor Brakes Motor brakes are mounted directly behind the motor and are pre-assembled at the factory. When ordering the brake option, specify the motor type.
  • Page 101 Continuous Duty means steady state operation for drive ambient temperatures of 0°C to 50°C. Intermittent Duty means operation for shorter periods of time. 240VAC SINGLE PHASE OPERATION: You must limit single phase operations to current levels that do not blow the AC input fuse. Dotted lines on the speed torque curves show maximum single phase current (8A rms for APEX604, 605, 606 motors;...
  • Page 102 APEX604-MO at 240VAC oz-in (N-m) APEX605-MO at 240VAC 1200 (8.4) oz-in (N-m) (5.6) (6.3) (4.2) Intermittent Duty Intermittent Duty (4.2) (2.8) (2.1) (1.4) Continuous Duty Continuous Duty 2000 4000 6000 8000 1200 2400 3600 4800 6000 7200 (33) (67) (100) (133) (rps) (20)
  • Page 103 SM Motor Specifications Parameter Symbol Units SM231AR SM232AR SM233BR lb.in. 10.2 Stall Torque Continuous oz. in. 0.40 0.76 1.15 amperes - rms Stall Current Continuous Rated Speed 7500 4250 6000 1, 6 lb.in. 17.5 33.4 50.9 Peak Torque oz. in. 1.98 3.78 5.76...
  • Page 104 Motor Size: A P E X 6 0 2 Value Units Tolerance ± 10% Constant (s): Torque 52.6 (0.37) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 22.5 V rms/Krpm Electrical Time milliseconds nominal Mechanical Time 1.40 milliseconds nominal Thermal 11.0 minutes nominal...
  • Page 105 Motor Size: A P E X 6 0 3 Value Units Tolerance ± 10% Constant (s): Torque 114.6 (0.81) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 49.0 V rms/Krpm Electrical Time milliseconds nominal Mechanical Time ----- milliseconds nominal Thermal minutes nominal Torque (s):...
  • Page 106 Motor Size: A P E X 6 0 4 Value Units Tolerance ± 10% Constant (s): Torque 52.6 (0.37) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 22.5 V rms/Krpm Electrical Time 58.7 milliseconds nominal Mechanical Time 1.30 milliseconds nominal Thermal minutes nominal...
  • Page 107 Motor Size: A P E X 6 0 5 Value Units Tolerance ± 10% Constant (s): Torque 68.7 (0.49) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 29.4 V rms/Krpm Electrical Time 10.68 milliseconds nominal Mechanical Time 1.46 milliseconds nominal Thermal minutes nominal...
  • Page 108 Motor Size: A P E X 6 0 6 Value Units Tolerance ± 10% Constant (s): Torque 120 (0.85) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 51.2 V rms/Krpm Electrical Time 15.32 milliseconds nominal Mechanical Time 0.896 milliseconds nominal Thermal minutes nominal...
  • Page 109 Motor Size: A P E X 6 1 0 Value Units Tolerance ± 10% Constant (s): Torque 61.4 (0.43) oz-in/A rms (Nm/A rms) ±10% Voltage (Sinusoidal) 26.2 V rms/Krpm Electrical Time 13.16 milliseconds nominal Mechanical Time 0.762 milliseconds nominal Thermal minutes nominal Torque (s):...
  • Page 110 Motor Size: A P E X 6 2 0 Value Units Tolerance ± 10% Constant (s): Torque 124.2 (0.877) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) V rms/Krpm Electrical Time 23.4 milliseconds nominal Mechanical Time 0.82 milliseconds nominal Thermal minutes nominal Torque (s):...
  • Page 111 Motor Size: A P E X 6 3 0 Value Units Tolerance ± 10% Constant (s): Torque 175.3 (1.24) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 74.9 V rms/Krpm Electrical Time 26.7 milliseconds nominal Mechanical Time 0.68 milliseconds nominal Thermal minutes nominal...
  • Page 112 Motor Size: A P E X 6 3 5 Value Units Tolerance ± 10% Constant (s): Torque 164.0 (1.158) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) V rms/Krpm Electrical Time 0.77 milliseconds nominal Mechanical Time 20.8 milliseconds nominal Thermal minutes nominal Torque (s):...
  • Page 113 Motor Size: A P E X 6 4 0 Value Units Tolerance ± 10% Constant (s): Torque 291.5 (2.06) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 124.5 V rms/Krpm Electrical Time 26.2 milliseconds nominal Mechanical Time 0.55 milliseconds nominal Thermal minutes nominal...

  • Page 114: Appendix D (Lvd Installation)

    Appendix D L V D I n s t a l l a t i o n I n s t r u c t i o n s For more information about LVD, see 73/23/EEC and 93/68/EEC, published by the European Economic Community (EEC).
  • Page 115 Line Fuses Line fuses need to be added to protect the transformer and associated wiring. If the live wire cannot be readily identified, fuse both phase conductors. The value of fuse required is given by: (1.5 x VA)/(supply volts) [amps] Fuse types should be anti-surge HBC.
  • Page 116 Servo Motor Safety Earth Cable (green/yellow) Providing Protective Earth Connection for Motor Use a spade lug in combination with a star washer and mounting bolt to make good contact with the bare metal surface of the motor's mounting flange. Use a green and yellow striped wire to make the connection between the motor and earth. Wire gauge must be no thinner than the current carrying wire in the motor's power cable.
  • Page 117 Table of Graphic Symbols and Warnings The following symbols may appear in this user guide, and may be affixed to the products discussed in this user guide. Symbol Description Earth Terminal Protective Conductor Terminal Frame or ChassisTerminal Equipotentiality Caution, Risk of Electric Shock Caution, Refer to Accompanying Text Hot Surface 1 1 2...

  • Page 118: Appendix E (Emc Installation Guide)

    Appendix E E M C I n s t a l l a t i o n G u i d e l i n e s General Product Philosophy Compumotor products that were not designed originally for EMC compliance, such as the APEX615n, will require specific measures to be taken during installation.
  • Page 119 General Considerations Applicable to all Products External enclosures The measures described in these recommendations are primarily for the purpose of controlling conducted emissions. To control radiated emissions, all drive and control systems must be installed in a steel equipment cabinet which will give adequate screening against radiated emissions.
  • Page 120 They therefore act like a high impedance in this waveband. The recommended components are produced by Parker Chomerics (617-935-04850) and are suitable for use with cable having an outside diameter up to 10—13mm. The specification is...
  • Page 121 P-Clip Installation Details The function of the P-Clip is to provide a 360 degree metallic contact and thus a convenient means of ensuring a proper R.F. ground. When dealing with EMI issues, it is important to remember that continuity, a DC connection, does not at all speak to the integrity of an AC (high-frequency) connection.
  • Page 122 Mount the filter within 2 inches (50mm) of the drive as shown in Figure 4. Ensure that there is no paint on the mounting panel under the filter mounting lugs - it is vital that there is large-area conductive contact between the filter and the panel. Connect the incoming AC supply cable to the push-on or screw type terminals on the filter, with the earth lead connected to a local earth stud, bus bar or metal back-plane.
  • Page 123 Within the cabinet itself, all the motor cables should lie in the same trunking as far as possible. They must be kept separate from any low-level control signal cables. This applies particularly where the control cables are unscreened and run close to the drive or other sources of electrical noise.
  • Page 124 Single Phase AC Input Cable Three Phase AC Input Cable AC Control Filter AC Mains Filter Controller Cable Encoder Cable Remove Braided- Paint behind screen this area cables f s e la n Is o t p u io n r a t li b D is...
  • Page 125 Control Signal Wiring High-quality braided screen cable should be used for control connections. In cases where the signal transmission is in differential mode, it is preferable to use cable with twisted pairs to minimize magnetic coupling. No connection is made to the cable screen at the drive itself. Fit a ferrite absorber close to the I/O connector and run the cable down to the mounting panel as shown in Fig.

  • Page 126: Appendix F (Dip Switches)

    Appendix F C o n f i g u r i n g D I P S w i t c h e s APEX6151 DIP Switches The APEX6151 has three 8-position DIP switches. The switches are located behind a small metal cover on top of the APEX6151.
  • Page 127 CURRENT LOOP COMPENSATION — #7 & #8: These two switches control the dynamics of the APEX6151's current feedback loop. Use these switches to match the drive's performance to your particular motor's characteristics. For Compumotor APEX and SM motors, set the switches according to the table below. If you use a motor from another vendor, call Compumotor's Applications Department for instructions on setting these two DIP switches for your motor.
  • Page 128 Switch 3 (SW 3) RESERVED — #1: Set this switch in the OFF position. ALIGNMENT MODE — #2: Turn this switch OFF. If you need to align the resolver, you will turn this switch ON during the alignment procedure, and turn it OFF when you have finished aligning the resolver.
  • Page 129 Switch 1 (SW 1) RESERVED — #1, #2, #3: Set these three switches in the OFF position. MOTOR POLE PAIR NUMBER — #4, #5: Set these two switches according to the number of pole pairs your motor has. All APEX motors have two pole pairs (four poles), except the APEX635 and APEX640, which have three pole pairs (six poles).
  • Page 130 The time constant is NOT the time until foldback occurs. It is a parameter based upon the motor's physical characteristics. Three variables (continuous current, actual current, and time constant) affect the amount of time that the foldback circuit allows operations to continue before foldback occurs. For a full explanation of the foldback circuit, see Chapter ƒ...
  • Page 131 1 2 6 APEX615n Installation Guide Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 132: Appendix G (Regeneration Resistors)

    Appendix G R e g e n e r a t i o n The APEX615n can dissipate regenerated energy in its internal regeneration resistor. If an APEX615n system regenerates more energy than the internal resistor can dissipate, you can connect an external resistor between two terminals labeled , located V Bus+...
  • Page 133 By changing the move profile—less torque, slower velocities, or a longer time between moves, for example—you may be able reduce the regeneration to a lower level, so that the fault no longer occurs. By installing an external resistor, you can double the regeneration circuit’s power dissipation capabilities.
  • Page 134 Peak power regeneration occurs at the moment deceleration begins, when the velocity is highest. = 2πv shaft ( peak ) Not all of this peak power must be dissipated in the power resistor. Some of it will be dissipated in the copper windings of the motor—these power losses are known as copper losses.
  • Page 135 The total energy that must be dissipated in the regen resistor consists of the total regenerated energy, less copper and drive losses:         − 3 2 R − 5 2    ...
  • Page 136 APEX6152: (for reference only: do not install external resistor) • Resistor Size and Type 50 ohm, 100 watt, 5% non-inductive resistor: • Manufacturer Name: Memcor-Truohm Inc. • Manufacturer Part Number: FRV01006-2500-QM-NI ("NI " - Non Inductive) • Mounting Bracket: Memcor-Truohm Inc. Part Number 1141-006-001 APEX6154: •...
  • Page 137 The APEX615n controller/drive's internal IGBT power switch is the component that determines the above specifications. With the standard external resistors discussed previously, the switch is already at its peak power dissipation level. However, the switch can dissipate more continuous power than the standard resistors allow. Your network, therefore, can dissipate additional continuous power, but must not dissipate more peak power.
  • Page 138 I N D E X internal connections 22 lengthening cables 35 APEX615n motor cable 47 panel layout 14 multi-drop 25 AC input power connections & specs PLC inputs 33 PLC outputs 32 AC power power (VAC) input 21 jumpers 22 balance—offset adjustments 71 programmable inputs 32 wiring options 23...
  • Page 139 motor 51 ground mounting (see mounting) DIP switch ANA GND 18, 19 precautions 3 function 125 Chassis Ground 18, 19 process overview 3 location 6, 121, 123 connection diagram 19 test 48 DIP switch locations 6 floating 18 integral feedback control (SGI) 81 DIP switch settings I/O GND 18, 19 integral windup limit (SGILIM) 82...
  • Page 140 internal configuration 10 error 65, 77 response – servo 78 overshoot 82 return procedure 73 response (servo) 77 rise time 78 types 78 RP240 National Electric Code Handbook i setpoint 77 connections negative-travel limits 27 tracking error 77 test 50 noise position range 4 RP240, connections 34...
  • Page 141 specifications timeout error 91 two-speed resolver 121, 124 overall list of 4, 5 temperature range 4, 11 speed/torque curves 97 temperature sensors 11 stability 78 terminal emulation, set up 49 under-damped servo response 78 status commands (see also back termination resistors undervoltage fault 62 cover, and test on page 20) calculating 25...
  • Page 142 APEX6151 Servo Controller/Drive Quick Reference AC INPUT TROUBLESHOOTING TIPS SW 1 SW 2 SW 3 85–252 VAC; • TO ALLOW MOTION: 47–66 Hz; 1-phase; APEX602 Earth – Power must be on. (Is at least one LED on?) Earth Earth L1/L2 for high-power –...
  • Page 143 APEX6152 &APEX6154 Servo Controller/Drive Quick Reference TROUBLESHOOTING TIPS AC INPUT SW 1 SW 2 SW 3 202 – 252 VAC • TO ALLOW MOTION: APEX 47 – 66 Hz – Power must be on. (Is at least one LED on?) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8...

This manual is also suitable for:

Compumotor apex6151Compumotor apex6152Compumotor apex6154

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