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Agito AGD200 Product Manual

Dual axis controller with integrated drives
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AGD200
Dual Axis Controller
with Integrated Drives
Product Manual

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Summary of Contents for Agito AGD200

  • Page 1 AGD200 Dual Axis Controller with Integrated Drives Product Manual...
  • Page 2 Agito Akribis Systems Ltd. Products Rights AGDx, AGCx, AGMx, AGAx, AGIx, and AGLx are products designed by Agito Akribis Systems Ltd. in Israel. Sales of the products are licensed to Akribis Systems Pte Ltd. under intercompany license agreement.

  • Page 3: Table Of Contents

    Safety Guidelines _______________________________________________________________ 12 Compliance ____________________________________________________________________ 13 Installation ___________________________________________________________ 15 Unpacking and Packing ___________________________________________________________ 15 Mounting _____________________________________________________________________ 15 3.2.1 Mounting the AGD200 ____________________________________________________ 15 3.2.2 Mounting Multiple Power Amplifiers ________________________________________ 16 Electrical Installation ____________________________________________________________ 17 3.3.1 Power Wiring ___________________________________________________________ 17 Regeneration ____________________________________________________________ 17 3.3.2...
  • Page 4 Tuning ________________________________________________________________________ 46 4.3.1 Commissioning __________________________________________________________ 46 4.3.2 Current Loop Tuning ______________________________________________________ 47 4.3.3 Auto Velocity and Position Loop Tuning ______________________________________ 48 4.3.4 Manual Velocity and Position Loop Tuning ____________________________________ 51 Maintenance and Servicing ______________________________________________ 53 AGD200 Product Manual Rev.2.1 Page 4...

  • Page 5: Product Description

    AGD200 controllers are ideal for any tightly coordinated motion systems. AGD200 has two integrated amplifiers, enabling it to drive two motors directly. It can also control a third axis through an external driver. It can drive all types of motors, such as steppers, voice coils, brushed or brushless motors, and including direct-drive linear and rotary motors.

  • Page 6: System Design

    Output power @ 90 VDC 0.12 kVA 0.24 kVA 0.48 kVA Peak current time 2 sec Output frequency 0–599 Hz Isolated digital inputs Isolated digital outputs Differential inputs Differential outputs Analog inputs Analog outputs Brake outputs AGD200 Product Manual Rev.2.1 Page 6...
  • Page 7 * EnDat 2.2 is not supported in the standard FPGA version due to space constraints. The default production FPGA supports BiSS-C only. If you are interested in a FPGA version that supports EnDat 2.2, contact Technical Support. AGD200 Product Manual Rev.2.1 Page 7...
  • Page 8 Hardware: Differential RS422 Termination: 120 Ω Propagation delay: 100 ns Max. frequency: 5 MHz Direction: Input or output, set by Agito PCSuite Functionality: Any differential input or output functionality. Analog inputs Operational voltage: ±12V Resolution: 12 bit (16 bit with extension board) Analog outputs Operational voltage: ±12V...
  • Page 9 Mechanical Specifications Feature Specification Unit dimensions (max) H=107 mm, W=50 mm, D=88 mm Package dimensions H=150 mm, W=120 mm, D = 120 mm Unit weight 0.2 kg Shipping weight 0.24 Figure 3. Product Dimensions (mm) AGD200 Product Manual Rev.2.1 Page 9...

  • Page 10: Motion Control Specifications

    Standalone user programs  Multi-threaded with priority setting environment, up to 8 threads  Execution time: 50 low script commands in 1 millisecond  High level C-language-like script programming language integrated  in Agito PCSuite AGD200 Product Manual Rev.2.1 Page 10...

  • Page 11: Environmental Specifications

    ASCII string commands or binary CAN format  1.6 Environmental Specifications Environmental Specifications Feature Specification Operating temperature 0°C to 50°C Storage temperature -20°C to 70°C Operating humidity < 90% Operating conditions Protection class: IP20 AGD200 Product Manual Rev.2.1 Page 11...

  • Page 12: Safety

    Attention All power connectors must be securely tightened before any operation. Warning Connectors X22, X21, X24, X25 are high power. Do not touch these connectors when the product is powered. AGD200 Product Manual Rev.2.1 Page 12...

  • Page 13: Compliance

    It is the responsibility of the machine or end-product manufacturer to ensure the final machine or end-product meets the requirement of any safety and EMC regulations. AGD200 Product Manual Rev.2.1 Page 13...
  • Page 14 Compliance AGD200 Product Manual Rev.2.1 Page 14...

  • Page 15: Installation

    3.2.1 Mounting the AGD200 The heatsink on the back of the AGD200 includes 4 holes for mounting the unit. The AGD200 can be mounted vertically (book mounting) or horizontally (shelf mounting). The AGD200 is mounted using 4 M4 screws. It is important to mount the product on metal panel for both grounding and secure connections.

  • Page 16: Mounting Multiple Power Amplifiers

    If controller are mounted on a backplane, the backplane temperature must not exceed the 50°C. It is recommended to install a cooling fan at the bottom of the cabinet for best circulation. Figure 4. Vertical Mounting multiple amplifiers within cabinet Figure 5. Horizontal mounting multiple amplifiers within cabinet AGD200 Product Manual Rev.2.1 Page 16...

  • Page 17: Electrical Installation

    3.3 Electrical Installation 3.3.1 Power Wiring AGD200 is designed to operate on voltage ranging from 12V VAC to 90 VDC, which is supplied to bus voltage, to motor, and to logic power. Regeneration AGD200 uses the main DC power input to output a controlled electrical power through the phases of the motor.

  • Page 18: Grounding

    3.3.2 Grounding It is recommended to install the AGD200 on a metal plate for better power dissipation, reduced EMI, and grounding connection. Make sure the plate is not painted. The heatsink of the AGD200 is electrically conductive and serves as the protective earth (PE) ground of the product.

  • Page 19: Grounding Policy

    The enclosures and other external parts that may be touched by the user are in the safe domain.  The AGD200 must be connected to protective earth (PE) and connected to the building’s ground.  PE is protected with an earth-leakage circuit breaker (ELCB); hence it is safe to touch. Refer to Figure 6.

  • Page 20: Electrical Interfaces

    Make sure you connect power input according to the connector pinout below. Optional schemes for isolated power supplies The AGD200 can support fully isolated power supplies, one for the power circuitry to drive the motor, and one for the digital logic. If you are interested in such a scheme, contact Technical Support.

  • Page 21: Interface X1: Backup Power

    Warning - Hot plugging is forbidden! Plug or unplug the power connector only when power is off! Plugging the power connector when power is on may cause power surges through connected devices and possibly damage them. AGD200 Product Manual Rev.2.1 Page 21...

  • Page 22: Interface X22: Motor

    14–18 AWG, insulation rated for 300V Notes: Brushless/Brush/Voice Coil Motors – PE: Use for motor ground and cable shield.  Stepper Motors – Pin 3/Pin 8: Two motor wires are connected to a single pin of the connector.  AGD200 Product Manual Rev.2.1 Page 22...

  • Page 23: Interface X23: Safety

    A bipolar stepper motor has two independent phases (a total of 4 wires). When using the AGD200, you need to connect the (-) wire of both phases together, into pin 3 of the connector (for motor A) or pin 8 (for motor B).

  • Page 24: Safety Circuitry

    The electrical characteristics of the Safety_Input_1 and Safety_Input_2 are identical to those of  all other isolated digital inputs of the controller. The safety inputs implemented in the product are currently pending certification Functional  Safety Standards. AGD200 Product Manual Rev.2.1 Page 24...

  • Page 25: Interface X24: Brakes

    Brake_Power for direct connection into inductive load. Up to 4A operation. Brake_Power_RTN Return for Brake_Power. Connector manufacturer Phoenix Mating connector part number 1840382 Connector pitch 3.5 mm Wiring 18–20 AWG, insulation rated for 160V AGD200 Product Manual Rev.2.1 Page 25...

  • Page 26: Brakes Circuitry

    Connect the Motor Brake- wire to X24 pin 2 for motor A brake, or to pin 3 for motor B brake. AGD200 includes flyback diodes; therefore, an external diode is not required.  Motor brake functionality can be configured in Agito PCSuite to automatic mode: Brake released  on motor on, and Brake engaged on motor off.
  • Page 27 Note – 5V supply limitation The 5V supply provided on each connector (X6, X7, and X8) is limited to 0.5A per connector. The maximum current provided by all 5V power supplies combined is 1.5A. AGD200 Product Manual Rev.2.1 Page 27...

  • Page 28: Interface X25: Regen

    The return line for VIN. Do not connect or use this pin for the regeneration function. Connector manufacturer Phoenix Mating connector part number 1779990 Connector pitch 5.08 mm Wiring 14–18 AWG, insulation rated for 300 V AGD200 Product Manual Rev.2.1 Page 28...

  • Page 29: Interface X2: Ethernet (Lan)

    BI-_D4 Bi-directional - Connector type RJ45 LAN 10/100Base-T connector Mating connector part number Any CAT5e compatible shielded connector Cable CAT5e or higher, standard Ethernet straight cable Wiring 26 AWG, insulation rated for 100 V AGD200 Product Manual Rev.2.1 Page 29...

  • Page 30: Interfaces X3, X4: Can, Rs232, Rs485

    CAN bus chain. The RS485 lines have a built-in (not optional) 120Ω terminator. Communication performance may be degraded if too many units are placed on the RS485 chain. AGD200 Product Manual Rev.2.1 Page 30...

  • Page 31: Interface X5: Micro-Usb

    USB to RS232 bridge The Micro-USB connection is implemented using an internal converter/adapter from USB to RS232 (UART). Typically, the Windows OS contains a built-in driver for the convertor/adapter. If necessary, you can access drivers at: http://www.ftdichip.com/Drivers/D2XX.htm. AGD200 Product Manual Rev.2.1 Page 31...

  • Page 32: Interface X9: General I/Os-1

    Electrical Interfaces 3.4.11 Interface X9: General I/Os–1 Connector X9 is used for connecting external I/O devices to the AGD200. For schematics and more information about these interfaces, refer to the section I/O Interfaces – Circuitry. Figure 18: General I/O–1 connector...
  • Page 33 Analog_Output_2 AOutPort[2] ±12V, 16 bit Analog_Output_2_Return Must connect to GND if analog input is single- ended. Analog_Output_3 AOutPort[3] ±12V, 16 bit Analog_Output_3_Return Analog_Output_4 AOutPort[4] ±12V, 16 bit Analog_Output_4_Return Analog_Input_1 AInPort[1] ±12V, 12 bit AInPort[5] AGD200 Product Manual Rev.2.1 Page 33...

  • Page 34: Interface X10: General I/Os-2

    CC03R-2830-01-G Wiring 24-26 AWG, insulation rated for 100V 3.4.12 Interface X10: General I/Os–2 Connectors X10 is used for connecting external I/O devices to the AGD200. Figure 19: General I/O–2 connector Connector X10: General l/O – 2 Pin # Name Software...
  • Page 35 Differential_Output_8+ DOutPort.bit(7) Differential output 4 Differential_Output_8- GND for differential I/Os GND for differential I/Os Connector manufacturer Samtec Inc. Mating connector part number ISDF-15-D-M Crimp contact part number CC03R-2830-01-G Wiring 26 AWG, insulation rated for 100V AGD200 Product Manual Rev.2.1 Page 35...

  • Page 36: I/O Interfaces - Circuitry

    Each group is fully isolated and independent of the other groups. The AGD200 has three groups of inputs: digital inputs 1 to 4, digital inputs 5 to 8, and digital  inputs 9 to 11.

  • Page 37: Isolated Digital Outputs

    When using 5V Digital_Output_Common_Power, higher current (but less than the absolute maximum value of 250 mA) can be driven. However, the output high voltage will drop significantly. To maintain output high voltage at >4.5V, limit the current to 60 mA. AGD200 Product Manual Rev.2.1 Page 37...

  • Page 38: Analog Input

    Analog output reflects the internal value of a user selected parameter (position, position  error, velocity, current, or any parameter/status of the controller), with a user defined scaling factor, for easy monitoring using an external oscilloscope. AGD200 Product Manual Rev.2.1 Page 38...

  • Page 39: Differential Inputs

    The same electrical signal is sent as a differential pair, each in its own conductor. The pair is wired  as a twisted pair. The differential inputs in the AGD200 are implemented according to the RS422 standard.  Each differential input has a 120 Ω terminator.

  • Page 40: Dip Switches

    Electrical Interfaces 3.4.14 DIP Switches The AGD200 includes 8 DIP switches to define CAN or Ethernet address offset, to connect a 120Ω CAN terminator resistor, to activate firmware download mode, and set other functions. These are hardware configurations that are typically done only once, during product installation. The DIP switches are located inside the product housing, and are not generally used.
  • Page 41 CAN address: the actual CAN address of the unit is equal to: CANAddr + offset * 16 Note: Requires power cycle or reset. Reserved for Future Use Always keep at OFF state. Reserved for Future Use Always keep at OFF state. AGD200 Product Manual Rev.2.1 Page 41...

  • Page 42: Operation

    Electrical Interfaces section. Make sure the safety port is connected before any operation. 2. Open Agito PCSuite software. Select CFG in CONFIG below and setup the parameters as follows: Figure 28. Configuration Figure 29. Operation Mode Configuration 3.
  • Page 43 Figure 32. Position and Velocity Protection 6. Click Next to configure current and voltage limits. It is important to refer to motor’s specifications. The limits entered here must be within the motor operating limits to avoid damaging the motor. AGD200 Product Manual Rev.2.1 Page 43...

  • Page 44: Drive/Motor Overload Protection

    Drive/Motor Overload Protection Figure 33. Current and Voltage Protection 4.2 Drive/Motor Overload Protection The following methods are used to protect the AGD200 from overload:  Motor stuck  4.2.1 In a transient condition, the motor can sustain a certain amount of energy that exceeds the continuous limit.

  • Page 45: Motor Stuck

    Drive/Motor Overload Protection In Agito PCSuite, the following parameters define the ���� ���� characteristics: Peak current  Continuous current  Peak time  Figure 35. I2T Settings Note – The I2T algorithm does not support thermal memory protection or thermal memory during power loss.

  • Page 46: Tuning

    3. After the auto-phasing is completed successfully, change the Auto-Phasing method to Encoder with Halls/Encoder switching and save all parameters to flash. After reset or power cycle of the controller, auto-phasing will be done by Hall sensors. AGD200 Product Manual Rev.2.1 Page 46...

  • Page 47: Current Loop Tuning

    Click Calculate PI to calculate the current loop gains. Check both checkboxes for auto data recording and user predefined data recording. Click Apply Current Command to test the current loop performance. Figure 39. Current Loop Tuning AGD200 Product Manual Rev.2.1 Page 47...

  • Page 48: Auto Velocity And Position Loop Tuning

    Click Begin Identification to perform system identification. Figure 41. Begin System Identification When the identification is completed successfully, the plant’s transfer function will be displayed, as shown in the following figure. Figure 42. Typical Plant Transfer Function AGD200 Product Manual Rev.2.1 Page 48...
  • Page 49 PIV gains for this plant. Figure 44. Start Auto-Tuning calculation 4. Once Auto-Tuning is completed, click Write to Controller to download the calculated gains into the controller. Figure 45. Download the parameters to the controller AGD200 Product Manual Rev.2.1 Page 49...
  • Page 50 5. Check the motion performance in the Motions Tab, set the required motion profile, and click Go 1 or Go 2 to move to Target 1 or Target 2. Record the motion data to analyze the motion performance in detail. Figure 46. Testing Motion AGD200 Product Manual Rev.2.1 Page 50...

  • Page 51: Manual Velocity And Position Loop Tuning

    Figure 47. Manual Velocity Loop Tuning Figure 48. Typical Velocity Loop Performance Similarly, adjust proportional gain of position loop. In addition, adjust acceleration and velocity feedforward to improve performance. Click Apply Pos Command to check performance. AGD200 Product Manual Rev.2.1 Page 51...
  • Page 52 Figure 50. Typical Position Loop performance Repeat the configuration and tuning steps for all the axes connected to the product. Finally, test the motion according to the required motion profile, as shown in Figure 46. Testing Motion. AGD200 Product Manual Rev.2.1 Page 52...

  • Page 53: Maintenance And Servicing

    (free wheel) Position feedback sensor is Go to Agito PCSuite’s CONFIG > FDBK page, toggle configured in wrong direction the Invert direction setting. Encoder signal is interfered Verify if the encoder signal is drifting even when the by EMI noise in the system, motor is physically locked or not moving.
  • Page 54 Check software position limits and velocity limits at Agito PCSuite’s CONFIG > POS page. If the FLS or RLS signal is active when the digital input is changed, the FLS or RLS status will remain ON. In this case, set the...

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