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Agito AGD301 Product Manual

3-axis controller with integrated drives
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AGD301
3-Axis Controller
with Integrated Drives
Product Manual

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Summary of Contents for Agito AGD301

  • Page 1 AGD301 3-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 ____________________________________________________________________ 16 3.2.1 Mounting the AGD301 ___________________________________________________ 16 3.2.2 Mounting Multiple Power Amplifiers ________________________________________ 16 Electrical Installation ___________________________________________________________ 18 3.3.1 Power Wiring___________________________________________________________ 18 3.3.2 Regeneration ___________________________________________________________ 18 3.3.3...
  • Page 4 Commissioning _________________________________________________________ 56 4.3.2 Current Loop Tuning _____________________________________________________ 57 4.3.3 Auto Velocity and Position Loop Tuning ______________________________________ 58 4.3.4 Manual Velocity and Position Loop Tuning ____________________________________ 61 Maintenance and Servicing ______________________________________________ 63 Troubleshooting _______________________________________________________________ 63 AGD301 Product Manual Rev.2.0 Page 4...

  • Page 5: Product Description

    AGD301 controllers are ideal for any tightly coordinated motion systems. AGD301 has three integrated amplifiers, enabling it to drive three motors directly. 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 504 kVA 504 kVA Peak current time 3 sec Output frequency 0–599 Hz Isolated digital inputs Isolated digital outputs Differential inputs Differential outputs Analog inputs 4 (12 bit) Analog outputs 4 (16 bit) AGD301 Product Manual Rev.2.0 Page 6...
  • Page 7 Commutation: Auto-phasing, by absolute offset Absolute EnDat 2.2 Hardware: Differential RS422/RS485, clock, data Clock frequency: 2 MHz Max. position bits: 32 bits Commutation: Auto-phasing, by absolute offset Hall sensors Opto-isolated 5V with internal or external power supply AGD301 Product Manual Rev.2.0 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 or 16 bit Analog outputs Operational voltage: ±12V...
  • Page 9 Feature Specification Unit dimensions (max) H=57 mm, W=188 mm, D=105 mm Package dimensions H=70 mm, W=235 mm, D = 145 mm Unit weight 0.4 kg Shipping weight 0.5 kg Figure 3. Product Dimensions (mm) AGD301 Product Manual Rev.2.0 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 AGD301 Product Manual Rev.2.0 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 AGD301 Product Manual Rev.2.0 Page 11...

  • Page 12: Safety

    Do not attempt to hinder or override the product’s or system’s fault detection or protection circuits. You must determine the cause of a fault and correct it before you attempt to operate the system. Failure to correct the fault could result in personal AGD301 Product Manual Rev.2.0 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. AGD301 Product Manual Rev.2.0 Page 13...
  • Page 14 Compliance AGD301 Product Manual Rev.2.0 Page 14...

  • Page 15: Installation

    3. After unpacking, locate the part number label on the product, and make sure it matches the product your ordered, and that the voltage meets your specific requirements. AGD301 Product Manual Rev.2.0 Page 15...

  • Page 16: Mounting

    3.2.1 Mounting the AGD301 The AGD301 includes 6 slots for mounting the unit, as shown in Figure 3. The unit can be mounted using either the 2 side slots or the 4 bottom slots. The AGD301 is mounted using M4 screws. It is important to mount the product on metal panel for both grounding and secure connections.
  • Page 17 Mounting Figure 5. Vertical mounting multiple amplifiers within cabinet (mm) AGD301 Product Manual Rev.2.0 Page 17...

  • Page 18: Electrical Installation

    Electrical Installation 3.3 Electrical Installation 3.3.1 Power Wiring AGD301 is designed to operate on voltage ranging from 12 VDC to 90 VDC, which is supplied to bus voltage, to motor, and to logic power. 3.3.2 Regeneration AGD301 uses the main DC power input to output a controlled electrical power through the phases of the motor.

  • Page 19: Safe Operating Area

    Each of the power/voltage/current absolute maximal ratings is valid over the overall operating temperature range, subject to the safe operating area (SOA). Attention Operating (or storing) the product contrary to the defined absolute maximal ratings is not allowed and will damage the product. AGD301 Product Manual Rev.2.0 Page 19...
  • Page 20 Electrical Installation AGD301-ET-2D05 Safe operating area (SOA) @90 VDC AGD301-ET-2D09 Safe operating area (SOA) @90 VDC PWM power Overall PWM power to motors is the sum of PWM power to all three motors. PWM power = 0.95 × Main_Power_Supply_Voltage [V] ×...

  • Page 21: Grounding

    3.3.4 Grounding It is recommended to install the AGD301 on a metal plate for better power dissipation, reduced EMI, and grounding connection. Make sure the plate is not painted. The heatsink of the AGD301 is electrically conductive and serves as the protective earth (PE) ground of the product.

  • Page 22: Ground Domains

    The enclosures and other external parts that may be touched by the user must be in the safe  domain. The AGD301 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 23: Electrical Interfaces

    3.4.1 Interface X5: Main Power Connector X5 (MAIN PWR) is used to supply 12–90 VDC to the AGD301. The input voltage is directly connected to the amplifier power bridge, to drive the motors. In addition, it is used to generate internal logic power to the controller board and to external devices such as encoders and I/Os.

  • Page 24: Interface X6: Backup Power

    Optional schemes for isolated power supplies The AGD301 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 25: Interface X7: I/O Power And Brake Power

    Warning - Hot plugging is not supported! Plug or unplug the power connector only when power is off. Plugging in the power connector when power is on may cause power surges through connected devices and possibly damage them. AGD301 Product Manual Rev.2.0 Page 25...

  • Page 26: Brake Circuitry

    AGD301 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. AGD301 Product Manual Rev.2.0...

  • Page 27: Interfaces A4, B4, C4: Motors

    Interfaces A4, B4, C4: Motors Connectors A4, B4, and C4 (MOTOR) are used to connect to the motor phases of Axes A, B, and C, respectively. The AGD301 supports any combination of 3-phase brushless motors, 1-phase brushed motors, and voice coil motors.

  • Page 28: Interface X3: Safety

    Safety_Feedback positive (collector) output Safety_Input_2+ Safety_Input_2 positive input Safety_Input_1+ Safety_Input_1 positive input Connector manufacturer Samtec Inc. Mating connector part number IPD1-04-D-K Crimp contact part number CCC79L-2630-01-L (or equivalent) Wiring 26 AWG, insulation rated for 100 V AGD301 Product Manual Rev.2.0 Page 28...

  • Page 29: 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. AGD301 Product Manual Rev.2.0 Page 29...

  • Page 30: Interface X10: Regeneration

    The external regeneration resistor should be connected between this pin (pin 2) and the Internal DC Bus pin (pin 1). Connector manufacturer Phoenix Mating connector part number 1777989 Connector pitch 5.08 mm Wiring 14–16 AWG, insulation rated for 300 V AGD301 Product Manual Rev.2.0 Page 30...

  • Page 31: Interfaces A1, B1, C1: Encoders

    Each encoder port supports various encoder types: digital quadrature incremental encoders (AqB), analog sin/cos incremental encoders, absolute BiSS-C encoders, and absolute EnDat2.2 encoders. The type of encoder connected to the AGD301 is configured in the Agito PCSuite software. Figure 15: Encoder Connector...

  • Page 32: Interfaces A2, B2, C2: Hall Sensors And Static Brake

    Additional I/Os are available on interfaces A3, B3, C3 (Digital and Analog I/Os), and on interface X4 (General I/Os) For schematics and more information about these interfaces, refer to the section I/O Interfaces – Circuitry. Figure 16: Brake and Hall Sensors Connector AGD301 Product Manual Rev.2.0 Page 32...
  • Page 33 Hall_A DInPort.bit(18) Hall A signal. To use Hall input, go to the Agito PCSuite Digital Input page, and configure input 18 as Hall A. The following inputs (19 and 20) will be set automatically as Hall B and Hall C.
  • Page 34 Hall_A DInPort.bit(2 Hall A signal. To use Hall input, go to the Agito PCSuite Digital Input page, and configure input 24 as Hall A. The following inputs (25 and 26) will be set automatically as Hall B and Hall C.

  • Page 35: Hall Sensors Circuitry

    Hall sensor is an open collector (NPN) type and requires a 5 VDC power supply. Any three consecutive digital inputs can be used as Hall sensor inputs.  Motor Hall sensors are wired as standard digital inputs.  AGD301 Product Manual Rev.2.0 Page 35...

  • Page 36: Interfaces A3, B3, C3: Digital And Analog I/Os

    DOutPort.bit(2) Isolated digital output 3, programmable sink or source Analog_Input_1+ AInPort[1] ±12V, 12-bit resolution. Analog_Input_1- Analog input 1 return. Must be connected to GND if analog input is single-ended. 5V power supply, limited to 0.5A Ground for 5V and differential signals AGD301 Product Manual Rev.2.0 Page 36...
  • Page 37 DOutPort.bit(5) Isolated digital output 6, programmable sink or source Analog_Input_2+ AInPort[2] ±12V, 12-bit resolution. Analog_Input_2- Analog input 2 return. Must be connected to GND if analog input is single-ended. 5V power supply, limited to 0.5A Ground for 5V and differential signals AGD301 Product Manual Rev.2.0 Page 37...
  • Page 38 DOutPort.bit(8) Isolated digital output 9, programmable sink or source Analog_Input_3+ AInPort[2] ±12V, 12-bit resolution. Analog_Input_3- Analog input 3 return. Must be connected to GND if analog input is single-ended. 5V power supply, limited to 0.5A AGD301 Product Manual Rev.2.0 Page 38...
  • Page 39 I/O power output. Connected internally to X7: IO PWR pin 1 IO_Power_Return Connected internally to X7: IO PWR pin 2 Connector manufacturer Mating connector part number 10120-3000PE + 10320-52A0-008 Wiring AWG 26, insulation rated for 100 V AGD301 Product Manual Rev.2.0 Page 39...

  • Page 40: 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 AGD301 Product Manual Rev.2.0 Page 40...

  • Page 41: Interfaces X8, X9: Can, Rs232, Rs485

    Two ports are provided to support daisy chain connection of a CAN bus or RS485. It can be also used to connect two types of communication channels at the same time, instead of splitting a cable from a single RJ45 connector. AGD301 Product Manual Rev.2.0 Page 41...

  • Page 42: Interface X1: 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. AGD301 Product Manual Rev.2.0 Page 42...

  • Page 43: Interface X4: General Purpose I/Os

    Electrical Interfaces 3.4.13 Interface X4: General Purpose I/Os Connector X4 (GENERAL I/O) provides I/Os for the connection of external devices to the AGD301: 1 analog input, 1 analog output and 8 bi-directional differential I/Os, configurable as either input or output by software.
  • Page 44 GND for 5V and differential signals Analog_Output_4 AOutPort[4] Analog output 4, +/-12V, 16 bits Bi-Dir_Diff_IO_5+ DInPortHigh.bit(0) Bi-directional differential I/O 5+ DOutPort.bit(21) Software configurable: BiDirConfig.bit(0) = 0 for input BiDirConfig.bit(0) = 1 for output Bi-Dir_Diff_IO_5- Bi-directional differential I/O 5- AGD301 Product Manual Rev.2.0 Page 44...
  • Page 45 26 AWG, insulation rated for 100V Note – 5V supply limitation The 5V supply provided at pin 7 is limited to 0.5A. The maximum total current provided by all the 5V pins in the product is limited to 1.5A. AGD301 Product Manual Rev.2.0 Page 45...

  • Page 46: I/O Interfaces - Circuitry

    Isolated Digital Outputs Figure 24. Isolated digital outputs The AGD301 has 5 groups of digital output , digital outputs 1 to 3, 4 to 6, 7 to 9, 10 to 13 , and 14  to 17.

  • Page 47: Analog Input

    For single-ended analog inputs, be sure to connect the return line to GND. Do not leave it  unconnected. Input circuit bandwidth: 1 kHz, -40 dB/decade  The controller software provides the following parameters to control the analog input reading:  Filter  Offset  Deadband  Gain  AGD301 Product Manual Rev.2.0 Page 47...

  • Page 48: Analog Output

    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 AGD301 are implemented according to the RS422 standard.  Each differential input has a 120 Ω terminator.

  • Page 49: Bi-Directional Differential I/Os

     3.4.15 DIP Switches The AGD301 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.
  • Page 50 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. AGD301 Product Manual Rev.2.0 Page 50...

  • Page 51: Status Led

    Electrical Interfaces 3.4.16 Status LED A bi-colored LED, marked ST, shows the operational status of the AGD301. ST - Status LED indicator Color Meaning – Powered off On steady Fault Green On steady Normal operation Green Blinking fast In Boot mode...

  • Page 52: 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 32. Configuration Figure 33. Operation Mode Configuration 3.
  • Page 53 Figure 36. 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. AGD301 Product Manual Rev.2.0 Page 53...

  • Page 54: Drive/Motor Overload Protection

    Drive/Motor Overload Protection Figure 37. Current and Voltage Protection 4.2 Drive/Motor Overload Protection The following methods are used to protect the AGD301 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 55: Motor Stuck

    Drive/Motor Overload Protection In Agito PCSuite, the following parameters define the �� �� characteristics: Peak current  Continuous current  Peak time  Figure 39. I2T Settings Note – The I2T algorithm does not support thermal memory protection or thermal memory during power loss.

  • Page 56: 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. AGD301 Product Manual Rev.2.0 Page 56...

  • Page 57: 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 43. Current Loop Tuning AGD301 Product Manual Rev.2.0 Page 57...

  • Page 58: Auto Velocity And Position Loop Tuning

    Click Begin Identification to perform system identification. Figure 45. Begin System Identification When the identification is completed successfully, the plant’s transfer function will be displayed, as shown in the following figure. Figure 46. Typical Plant Transfer Function AGD301 Product Manual Rev.2.0 Page 58...
  • Page 59 PIV gains for this plant. Figure 48. Start Auto-Tuning calculation 4. Once Auto-Tuning is completed, click Write to Controller to download the calculated gains into the controller. Figure 49. Download the parameters to the controller AGD301 Product Manual Rev.2.0 Page 59...
  • Page 60 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 50. Testing Motion AGD301 Product Manual Rev.2.0 Page 60...

  • Page 61: Manual Velocity And Position Loop Tuning

    Figure 51. Manual Velocity Loop Tuning Figure 52. 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. AGD301 Product Manual Rev.2.0 Page 61...
  • Page 62 Figure 54. 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 50. Testing Motion. AGD301 Product Manual Rev.2.0 Page 62...

  • Page 63: 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 64 Check software position limits and velocity limits at position and velocity limits. 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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