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User Information ! WARNING ! 6000 Series products are used to control electrical and mechanical components of motion control systems. You should test your motion system for safety under all potential conditions. Failure to do so can result in damage to equipment and/or serious injury to personnel.
ABO UT Chapter 1. THIS Installation What You Should Have (ship kit) ........................................................... 2 Before You Begin ..................................................................................... 3 Recommended Installation Process ............................................. 3 Electrical Noise Guidelines ........................................................... 3 General Specifications ............................................................................
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.
1 CHAP T E R ONE 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 Mounting the APEX615n Connecting all electrical components (includes specifications) Testing the installation Motor mounting and coupling guidelines Preparing for what to do next
What You Should Have (ship kit) Part Name If an item is missing, call the factory (see phone numbers on inside front cover). Part Number One of the following line items: APEX615n standard product (with ship kit) ............................................................... APEX615n APEX615n standard product (with ship kit) ............................................................... APEX615n APEX615n standard product (with ship kit) ...............................................................
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: • Connecting any electrical device (e.g., motor, encoder, inputs, outputs, etc.
General Specifications P a r a me t e r S pe c if ic a t ion 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 .....................................................47-66 Hz Current (max. cont.).................................................
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. Change internal switch SW3 to select 4-wire. Maximum units in daisy-chain or multi-drop.........
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.
OFF SW 1 1 APEX6151 DIPs 8 SW 2 1 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 3 7 8 OFF OFF ON ON OFF ON OFF ON OFF 1 2 3 4 5 6 7 SW 1 1 APEX602 8 1 8 1 1 2 3 4 5 8 6 SW 2 2 3 4 5 6 7 7 SW 2 1 8 1 8 1 8 1 2 3 4 5 8 6 SW 3 2 3 4 5 7 8 6 7 8 8 SW 3 1 1 2 OFF 3 4 5 6 7 2 3 4 6 OFF ON OFF ON OFF ON OFF ON 7 8 OFF ON OFF ON 2 3 OFF ON 4 OFF ON (All APEX & SM motors) 5 OFF ON 6 7 8 OFF OFF OFF OFF 6 7 OFF OFF ON ON OFF ON
OFF SW 1 1 APEX6152 DIPs 8 1 2 3 4 5 6 7 8 OFF ON 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 3 OFF 25 – 40 mH (APEX605,606) 5 – 15 mH (APEX604) 15 – 25 mH Reserved 7 8 OFF OFF ON ON OFF ON OFF ON CONTINUOUS CURRENT (peak of sine wave) 3.0 amps 4.2 5.4 6.6 7.8 (APEX605, 606) 9.0 (APEX604) 10.2 12.0 PEAK CURRENT 9.0 amps 10.8 13.2 15.0 17.4 19.2 21.6 24.
OFF SW 1 1 APEX6154 DIPs 8 1 2 3 4 5 6 7 8 OFF ON 3 OFF (APEX610) (APEX620, 630, 635, 640) 7 8 OFF OFF ON ON OFF ON OFF ON 1 2 3 OFF OFF OFF OFF ON ON ON ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF ON OFF ON 1 2 3 4 5 APEX610 6 7 8 1 8 1 SW 2 2 3 4 5 6 7 8 1 8 1 SW 3 2 3 4 5 8 6 7 8 OFF SW 1 1 1 2 3 4 5 APEX620 6 7 4 5 6 OFF OFF OFF OFF ON ON ON ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF ON OFF ON 7 8 OFF OFF ON ON OFF ON OFF
Changing the COM 2 Connector from RS-232 to RS-485 RS-232C Users COM 2 Rx+ Rx– Tx+ Tx– Iso Gnd +5V Iso Gnd Rx Tx Shld RS-232 (factory default) RS-485 (optional) 1. 2. The APEX615n's COM 2 port is factory configured for RS-232C communication (use the right-hand pin descriptions). If you do not need to use RS-485 communication, you may ignore this section and proceed to the Mounting instructions. Remove the four retainer screws from the faceplate. Gently lift away the faceplate .
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. If you need to change these settings (i.e., for RS-485), refer to page 10 for instructions.
Mounting Slots and Grounding The APEX615n's mounting bracket is notched with keyhole type slots to accept four screws 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. The drive must also be grounded through the Earth terminal on the AC power connector. Dimensions APEX6151 3.0 (76.2) 9.20 (233.7) 1.055 (26.8) 0.
APEX6152 10.750 (273) 1.000 (25.4) 0.33 (8.4) 4.500 (114.3) 2.000 (50.8) 1.250 (31.7) A P E X 6 1 5 2 Unpainted for Grounding 14.250 (361.9) 15.375 (390.5) 16.250 (412.7) Dimensions in inches (millimeters) 4X clearance for #10 (M5) mounting screw APEX6154 10.750 (273) 1.000 (25.4) 5.875 (149.2) 3.000 (76.2) 0.33 (8.4) 1.438 (36.5) A P E X 6 1 5 4 Unpainted for Grounding 14.250 (361.9) 15.375 (390.5) 16.250 (412.
Airflow & Cooling Airflow a E rth a 1 E L l L 2 o tr l n o o tr C n o C E rth a rth L 2 L 1 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 bottom and upward over the internal heatsink. The air directly beneath the APEX615n must not exceed 50°C (122°F).
1.50 (38.1) (Minimum) 4.0 (102) Clearance (Minimum) 1.50 (38.1) 1.50 (38.1) Clearance (Minimum) 14.25 (362) 4.0 (102) Clearance (Minimum) 3.00 (76.2) (Minimum) 4.50 (114) Min Clearance When you design your panel layout, follow these precautions for adequate cooling: • 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).
Electrical Connections AC Input Connector DIP Switches APEX6151 mp um EX 61 51 COM 1 Co AP r o to COM1 Compumotor Rx Torque Cmd Test Point Tx Iso Gnd COM2 Limits External Encoder Connector EncoderOutput Auxiliary Sin Cos Limits Connector Ref ProgrammableInputs/Outputs Iso Rx- Gnd Rx Offset Balance Tx+ Tx- Tx Tach Output Calibration Iso Gnd Shld COM 2 Connector Auxiliary Connector External Encoder Input External Encoder Input COM 1 Connector Limits COM 2 Rx+ +5V Shield I
AC Input Connector DIP Switches COM 1 COM 1 Compumotor 2 T it ILim External Encoder Input Tx Torque Cmd Test Point Rx+ +5V COM 2 COM 2 COM 1 Connector Rx Iso Gnd COM 2 Connector Iso Rx- Gnd Rx Tx+ Tx- Tx Offset Balance Iso Gnd Shld Limits Tach Output Calibration Programmable Inputs/Outputs Limits Connector Auxiliary Connector Shield External Encoder Input EncoderOutput Auxiliary External Encoder Connector Iso Gnd ZZ+ BB+ AA+ Enable Disable Bridge Fault Drive Fault Motor Fault
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.
Earth Earth APEX6152 & APEX6154 Mounting Slot Compumotor COM 1 Chassis Ground Iso Gnd APEX6151 Iso COM 2 Gnd Shld Mounting Slot Iso Gnd Earth Earth Earth External Encoder Input Iso Gnd Limits Shield I 2 T Limit Chassis Ground Gnd Auxiliary Gnd Gnd Iso Gnd Gnd Shield Analog Ground Note: Grounding connections shown on COM 2 port are for RS-232 communications Shield 49 50 Motor Ground Isolated Ground 2 Programmable Inputs/Outputs 1 Encoder Output Gnd APEX615n Ground System
2 . If you must connect to a GND terminal, use a separate ground wire from your remote device. Do not put a jumper between GND and Iso GND. 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. Connect one wire to Iso GND, and connect the other to GND. The next drawing shows how to make these connections.
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.
AC Input Connector APEX6152 & APEX6154 Internal Connections Motor Connector L1 Phase A + 3 Phase Rectifier Phase B 3 – Phase Power Amplifier L2 – L3 Phase C V Bus + Regen Resistor V Bus – Motor Ground Earth Shield Front Panel – Right Side Earth LEDs Control L1 Controller for Power Amplifier Low Voltage Power Supply Control L2 Encoder Output Resolver ±15V Tach Output ANA GND Gnd / Resolver Shield Front Panel – Left Side Iso +5V +15V –15V Iso Ground DC-to-DC Converter +5V (isolated) COM
WIRING OPTIONS APEX6151 AC Power Source Disconnecting AC power turns off power output to motor, and turns off controller AC Power Source Disconnecting AC Power #1 turns off power output to motor; controller remains powered by AC Power #2 AC Power Source #2 Disconnecting Power to the Drive AC Input Connector AC Power Source Disconnecting Means AC Input Connector L1 L1 L2 L2 Earth L3 Earth Earth Earth Earth Control L1 Control L1 Control L2 Control L2 Disconnecting Means Disconnecting A
Disconnecting Power to the Controller Removing power to the controller portion of the APEX615n (Control L1 and Control L2) will trigger a Drive Fault, plus the controller will issue a "shutdown" signal to the drive that is equivalent to the DRIVE0 command. When power is restored to the controller, the drive will need to be reset using the either the DRESET command or the RESET Input on the Drive Auxiliary connector. (The DRESET command is the equivalent of the RESET Input.
Serial Communication RS-232C Connections RS-232C Daisy-Chain Connections* Unit 0 Unit 1 Tx Rx GND COM 1 Rx Tx Iso GND COM 2 Rx+ Rx– Tx+ Tx– Iso GND Standard 25-Pin COM Port Pin Outs: Pin 3 = Transmit (Tx) Pin 2 = Receive (Rx) Pin 5 = Ground (GND) Pin 2 = Transmit (Tx) Pin 3 = Receive (Rx) Pin 7 = Ground (GND) Rx Tx Iso GND Tx Rx GND Rx Tx Iso GND Daisy Chain to a Computer or Terminal +5V Iso GND Rx Tx SHLD Unit 0 Unit 1 Rx Tx Iso GND Serial Port Connection Standard 9-Pin COM Port Pin Outs
External Encoder CONNECTIONS & INTERNAL SCHEMATICS ENCODER Connector Internal Schematic Shield Shield Max. Cable Length is 100 feet. Use 22 AWG wire. Ground Black Z Channel – Orange/White Z Channel + Orange B Channel – Green/White B Channel + Green A Channel – Brown/White A Channel + Brown +5VDC Red SHLD Iso GND Isolated Ground ZZ+ Same Circuit B- as A Channel B+ AA+ +5V Chassis Ground +1.
End-of-Travel and Home Limit Inputs NOTES • Motion will not occur until you do one of the following: - Install end-of-travel (POS & NEG) 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 • Refer to the Basic Operations Setup chapter in the 6000 Series Programmer's Guide for in-depth discussions about using end-of-travel limits and homing.
Trigger Inputs Internal Schematic ENCODER Connector SHLD GND ZZ+ BB+ AA+ +5V TRG-A/B connected to Iso GND (normally-open switches). 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. The differences are (1) the triggers are pulled up via the AUX-P pull-up terminal; and (2) the triggers can be programmed with the INFNCi-H command to function as position capture inputs and registration inputs.
General-Purpose Programmable Inputs & Outputs VM50 ADAPTOR — for screw-terminal connections In-P 1 2 Encoder Output Out-P Aux-P CHA+ CHA CHB+ CHB CHZ+ CHZ Gnd Ref Sin Cos Programmable Inputs/Outputs Shield Red Blk 2-Foot Cable Grn Blu Brn Wht (provided with VM50) MT+ MT Flt Relay+ Flt Relay NC NC 49 50 2 4 1 6 3 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 The VM50 snaps on to any standard DIN ra
INPUT CONNECTIONS — Connecting to electronic devices such as PLCs Connection to a Sinking Output Device Electronic Device APEX615n GND ISO GND +5V The output should be able to sink at least 1mA of current. Pulled up to +5V (sourcing) Out 5-24 Volts +5VDC IN-P Output Input Connection Ground Ground Connection 6.8 KΩ 74HCxx 47 KΩ PROGRAMMING TIP Connecting to a sinking output? Set the input's active level to low with the INLVL command (Ø = active low).
OUTPUT CONNECTIONS (includes OUT-A) — for electronic devices such as PLCs Connection to a Sinking Input (active high) External Supply (up to 24VDC) Electronic Device + Connection to a Sourcing Input (active low) APEX615n – External Supply (up to 24VDC) Electronic Device + – APEX615n GND GND ISO GND +5V ISO GND +5VDC +5V +5VDC V+ OUT-P 4.7 KΩ Input Output Connection Ground Ground Connection OUT-P Output Connection Input UDK2559 UDK2559 Ground Connection Ground 4.
THUMBWHEEL CONNECTIONS — for entering BCD data Connection to the Compumotor TM8 Module TM8 Thumbwheel Module + 1 2 3 4 5 6 7 8 +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) Programmable Output #1 Programmable Output #2 Programmable Output #3 Optional Sign Bit Connection to your own Thumbwheel Module Input #9 (sign) Input #8 MSB Input #7 Input #6 Input #
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. • Use a minimum wire size of 22 AWG. • Use twisted pair shielded cables and connect the shield to the earth ground of the remote device. Leave the other end of the shield disconnected.
Drive Auxiliary Connector Pin #: 1 2 3 4 5 6 7 8 9 10 11 12 13 Reset Gnd NC Enable In Fault Out Gnd NC NC Tach Out Gnd +15 V Gnd -15 V Function: Reset Ground (tied to AC earth ground) No Connection Enable In Fault Output Ground (tied to AC earth ground) No Connection No Connection Tachometer Output Ground (tied to AC earth ground) +15V Ground (tied to AC earth ground) -15V Reset Input Internal Schematic Reset +5VDC Gnd NC Enable In 6.81K 47.
Enable Input Internal Schematic Reset Gnd NC Enable In +5VDC Fault Out Gnd 6.81K NC 47.5K NC Tach Out 74HC14 Gnd +15 V 1000 pF Gnd -15 V ANA GND • Active Low: to enable the APEX615n, hold ENABLE IN at low voltage. • Voltage Low = 1.0V maximum • Voltage High = 3.25V – 24V A switch wired between ENABLE IN and GND can be used as a manual disable switch. Opening the switch disables the APX615n, which shuts down power output to the motor, turns off the ENABLE LED, and illuminates the DISABLE LED.
Tachometer Output Internal Schematic Reset Gnd NC Enable In Fault Out Gnd 20K NC NC 20K From RDC velocity output - Tach Out Gnd +15 V + LF347 Gnd -15 V ANA GND Tachometer Output: ±10V at 15mA (max) • Use DIP Switch #3, position 5, to scale output: • OFF = 1V/1000 rpm for one speed resolvers • ON = 1V/1000 rpm for two speed resolvers.
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.
Encoder Quadrature Outputs Internal Schematic ENCODER OUTPUT Connector AM26LS31 From RDC CHA+ CHA CHB+ AM26LS31 CHB CHZ+ From RDC AM26LS31 CHZ - From RDC Gnd 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. The resolution is 1024 counts per revolution (pre-quadrature), or 4096 counts per revolution (post-quadrature).
Hall Effect Input The following circuit is internally connected to the encoder connector when DIP Switch #3, position 4 is turned ON. Internal Schematic +5VDC CHA+ +5VDC From Hall Select DIPswitch 1K (3 plcs) CHA +5V CHB+ Hall 1 CHB - Hall 2 CHZ+ Hall 3 CHZ - Gnd Gnd 74HC14 (3 plcs) 3906 10K (3 plcs) 0.1 F (3 plcs) When this circuit is active, the Encoder Output connector can be used for Hall effect sensor inputs.
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. Call Compumotor's Customer Service Department at the phone numbers provided on the inside front cover of this document.. Cable lengths in excess of 100 feet are not recommended.
Motor Temperature Sensor Input The resolver connector has two terminals through which the APEX615n can monitor motor temperature. The terminals, labeled MT+ and MT–, should be connected to the two leads of a normally-closed temperature sensor mounted on the motor. When the motor is within its temperature limits, the sensor will be closed, thus shorting together MT+ and MT–. If the motor overheats, the sensor will open. Circuit continuity will be broken, which triggers protection circuitry in the APEX615n.
Motor Braking — Fault Relay Terminals If the APEX615n faults, for any reason, the drive will be disabled and the motor will freewheel. Refer to Chapter 2: Troubleshooting for all fault conditions. If a freewheeling load is unacceptable, use the fault relay terminals Fault Relay+ and Fault Relay– to control a motor brake. The fault relay inside the APEX615n is normally open. This means that when the drive is faulted or disabled, or when the power is off, the relay will be open.
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.
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. = normally open with power removed; N.C. = normally closed with power removed) is controlled by the fault relay terminals on the APEX6151's resolver connector.
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. The connector can accept wire diameters as large as 10 AWG (6 mm2).
Regeneration Resistor 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 the two terminals labeled V Bus+ and Regen Resistor, located on the motor connector. The external resistor will double the APEX615n 's dissipation capabilities. The APEX615n's regeneration circuit works automatically—there are no adjustments to make.
Test Setup Computer or Terminal APEX6151 Compumotor COM1 Serial Connection: RS-232C or RS-485 Rx Torque Cmd Test Point Tx Iso Gnd Rx+ +5V COM2 Iso Terminal Emulation for IBM/Compatibles Tx- Tx Tach Output Calibration External Encoder Input Iso Gnd Shld Shield Iso Gnd ZZ+ BB+ Enable Disable Bridge Fault Drive Fault Motor Fault Over Voltage I2T Limit Regen Fault Regen Active A+ Limits Gnd Iso Gnd NC Home Enable In Neg Fault Out Pos Gnd NC ANI+ ANI Trg-A Auxiliary (or 120VAC for
Connections Test Procedure Response Format (left to right) End-of-travel and Home limits NOTE: If you are not using end-of-travel limits, issue the Disable Limits (LHØ) command and ignore the first two bits in each response field. TLIM response: bit 1 = POS limit bit 2 = NEG limit bit 3 = home limit 1. Enable hard limits using the LH3 command. 2. Close the end-of-travel switches and open the home switch. 3. Enter the TLIM command. The response should be *TLIM11Ø. 4.
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.
A 0.003 TIR (0.08) 1.18 ± .02 (30.0 ± .5) 2.720 (69.0) A 0.003 TIR (0.08) 2.76 + 0.06 - 0.00 (70.0 + 1.5) - 0.0) 2.11 ± 0.004 (53.6 ± 1.0) 2.76 + 0.06 - 0.00 0.07 (1.8) (70.0 + 1.5) - 0.0) Ø0.228-Ø5.80 thru four holes equally spaced on Ø2.953 (Ø75.00) Dia. B.C. 0.197 (5.00) 2.362 + (60.00 + - 0.79 (20.0) min 0.093 (2.36) 0.375 (9.54) 0.0005 0.0003 0.012) 0.007) Dimension—inches (mm) 0.551 + 0.0003 - 0.0001 (14.00 + 0.008) - 0.003) -A0.0014 (0.035) Tolerances unless otherwise specified: .XXX ±.
A 0.003 TIR (0.08) 9.30 (236.2) 4.87 (123.7) 0.12 (3.0) 1.18 ± 0.02 (30.0 ± 0.5) 0.78 (19.8) min. 3.077 (78.16) 0.44 (11.2) A 0.003 TIR (0.08) 3.150 + (80.00 + - 0.69 (17.5) 0.0005 0.0003 0.012) 0.007) 3.167 (80.44) 0.551 + 0.0003 - 0.0001 (14.00 + 0.008) - 0.003) -A0.0014 (0.035) 0.3932 (9.987) M5 x 0.8 Tap x 0.39 (10.0) Min. DP (4) holes equally spaced on 3.937 (100.0) Diameter B. C. Resolver and Thermostat Receptacle Motor Receptacle 3.14 (79.8) 0.197 (5.00) 2.56 (65.0) 3.62 + (92.
A .003 TIR (.08) 1.18 ± .02 (30.0 ± .5) 2.720 (69.0) .79 MIN (20.0) 2.11 ± 0.004 (53.6 ± 1.0) 2.76 .093 (2.36) +.06 -.00 (70.0 +1.5 -0.0 ) 2.76 +.06 -.00 (70.0 +1.5 -0.0 ) 6.48 (164) 9.61 (244.2) .375 (9.54) 2.362 +0.0005 -0.0003 (60.00 +0.012 -0.007 ) A 0.003 TIR (.08) .07 (1.8) ø.228 (ø5.80) THRU (4) HOLES EQ. SPACED ON ø2.953 (ø75.00) B.C. .551 +.0003 -.0001 (14.00 +.008 -.003 ) -A.0014 (.035) 1.53 (38.9) .197 (5.00) .196 (4.
A 0.003 TIR (0.08) A 1.18 ± 0.02 (30.0 ± 0.5) Max. 0.69 (17.5) B 0.12 (3.0) 0.78 (19.8) min. 0.44 (11.2) A 0.003 TIR (0.08) 3.150 (80.00 3.077 (78.16) 3.075 (78.11) +0.0005 -0.0003 +0.012 ) -0.007 0.551 +0.0003 -0.0001 (14.00 +0.008 -0.003 ) -A0.0014 (0.035) M5 X 0.8 Tap X 0.39 (10.0) Min. DP. (4) holes equally spaced on 3.937 (100.0) Diameter B. C. Motor APEX605 APEX606 APEX610 A Max B ± 0.06 (1.5) 9.30 (236.2) 10.86 (275.8) 12.42 (315.4) 4.87 (123.7) 6.42 (163.1) 7.23 (183.6) 3.167 (80.
A 0.004 TIR (0.10) A 1.967 ± 0.02 (50.0 ± 0.5) Max. 0.69 (17.5) B 0.14 (3.50) 1.457 (37.00) min. 0.49 (12.5) A 0.004 TIR (0.10) +0.0005 4.331 -0.0004 (110.00 +0.013 -0.009 ) 4.006 (101.75) 4.004 (101.70) 0.9449 +0.0003 -0.0002 M5 X 0.8 Tap X 0.55 (14.0) Min. DP. (4) holes equally spaced on 5.188 (130.0) Diameter B. C. (Ø24.00 +0.009 -0.004 ) 4.103 (104.22) 4.101 (104.17) 0.3932 (9.987) 0.3922 (9.962) -AA Max Motor APEX620 12.55 (318.8) APEX630 14.65 (372.1) 0.0016 (0.
A 0.004 TIR (0.10) A 1.967 ± 0.02 (50.0 ± 0.5) Max. 0.69 (17.5) B 0.14 (3.50) 1.457 (37.00) min. 0.71 (18.0) A 0.004 TIR (0.10) 5.118 +0.0006 -0.0004 +0.014 -0.011 (130.00 5.006 (127.15) 5.004 (127.10) ) 0.9449 +0.0003 -0.0002 M5 X 0.8 Tap X 0.55 (14.0) Min. DP. (4) holes equally spaced on 6.457 (164.0) Diameter B. C. (Ø24.00 +0.009 -0.004 ) 5.103 (129.62) 5.101 (129.57) 0.3932 (9.987) 0.3922 (9.962) -AA Max Motor APEX635 11.78 (299.2) APEX640 14.48 (367.8) 0.0016 (0.
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. The primary pathway through which you can remove the heat is through the motor's mounting flange. Therefore, mount the motor with its flange in contact with a suitable heatsink.
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.
What's Next? By now, you should have completed the following tasks, as instructed earlier in this chapter: 1. 2. 3. 4. 5. 6. Review the general specifications — see page 4. Perform configuration/adjustments, as necessary — see pages 6-10. Mount the APEX615n — see page 11. Connect all electrical system components — see pages 16-46. Test the installation — see pages 46-48. Mount the motor and couple the load — see pages 49-57.
2 CHAP T E R T WO 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 • Faults caused by excessive regeneration • Current foldback • Offset balance adjustment • Aligning the resolver • Commutation test mode • Product return procedure
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. You may have to dismantle your system and put it back together piece by piece to detect the problem.
LED Description How to reset the fault (see Recovering from Faults Latched (yes/no) below for additional details) Enable Indicates drive is enabled no Disable Indicates drive is disabled no Issue the DRIVE1 command Bridge Fault * Power stage over-temperature Power stage over-current Motor short circuit yes yes yes Note 1 Note 1 Note 1 Drive Fault * Control board over-temperature Under-voltage (brownout) yes yes Note 1 Note 2 Motor Fault * Resolver not connected Motor over-temperature Moto
Recovering from Faults Many of the fault conditions will shut down the APEX615n’s output current to the motor. 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 Drive Fault, the same fault will probably occur when you restart the drive—unless you first fix the problem. Most of the fault conditions are latched. Once the problem is fixed, the APEX615n will not start up again on its own.
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. • • • • Problem Erratic operation Look for the symptom that most closely resembles what you are experiencing. Look through the list of possible causes so that you better understand what may be preventing proper operation.
Problem No RS-232C Communication No Torque/Force Power-up Program does not execute Cause 1. Improper RS-232C Interface or communication parameters 2. RS-232C disabled 3. In daisy chain, unit may not be set to proper address 1. Improper wiring 2. No power to motor 3. Shutdown issued 1. ENABLE IN input is not grounded to GND 2. STARTP program is not defined Solution 1. See RS-232C Troubleshooting section 2. Enable RS-232C with the E command (all units if daisy-chained) 3.
Troubleshooting Serial Communication Problems General Notes • Power up your computer or terminal BEFORE you power up the APEX615n. • Make sure the serial interface is connected as instructed on page 25. Shield the cable to earth ground at one end only. Check to make sure you are using Iso GND as your reference, not GND. The maximum RS-232 cable length is 50 feet (15.25 meters). • RS-232: Handshaking must be disabled. Most software packages allow you to do this.
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. Either of these faults will shut down the APEX615n, to safeguard the system.
CAUTION Repeatedly cycling power or resetting the APEX615n to clear regeneration faults may damage the regeneration resistor. 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 Control L1/L2 terminals on the AC power connector, then turn the power back on; however, if the resistor has not had adequate time to cool, and the conditions leading to the regen fault persist, you may damage the regen resistor by cycling power repeatedly.
Current Foldback (I2T 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: • PEAK CURRENT—the highest current that the APEX615n will produce. Peak current can be set between 6.5A and 16.0 A for the APEX6151, between 9.0A and 24.0A for the APEX6152, and between 15A and 40A for the APEX6154..
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. NOTE This procedure—adjusting the offset balance potentiometer—was performed at the factory.
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. Adjust the potentiometer until the Tach Out signal is measured at 4 volts.
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. The current it sends to the motor will be proportional to the internal command voltage.
Appendix A Servo Tuning 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. Then you can proceed to execute your motion functions.
Closed Loop System Offset Command Digital Control Algorithm Control Signal Analog Command = Control Signal + Offset Drive Motor Load Feedback Device: Resolver, Encoder, or ANI Input Feedback Data Servo Algorithm Disabled SOFFS Offset Drive Command = Offset Drive Motor Load Feedback Device: Resolver, Encoder, or ANI Input Internally, the APEX615n has two main sections—a controller section and a drive section.
Commanded Position The commanded position is calculated by the motion profile routine based on the 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. To view the commanded position, use the TPC (Transfer Commanded Position) command; the response represents the commanded position at the instant the command is received.
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.
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.
When using the Target Zone Mode, enabled with the STRGTE command, the actual position and actual velocity must be within the target zone (that is, within the distance zone 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 APEX615n detects an error.
Gain Proportional (SGP) Integral (SGI) Velocity Feedback (SGV) Velocity Feedforward (SGVF) Acceleration Feedforward (SGAF) Stability Improve Degrade Improve ------------------------- Damping Improve Degrade Improve ------------------------- Disturbance Rejection Improve Improve ------------------------------------- Steady State Error Improve Improve ------------------------------------- Tracking Error Improve Improve Degrade Improve Improve Proportional Feedback Control (SGP) Proportional feedback is
Controlling Integral Windup If integral control (SGI) is used and an appreciable position error has persisted long enough 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. This phenomenon is called integral windup.
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).
Controller Tuning Procedure The Controller Tuning Procedure leads you through the following steps: 1. 2. 3. 4. 5. 6. 7. 8. Turn on AC power to the APEX615n. Setup up for tuning. Select the 615n's servo Sampling Frequency Ratios (SSFR). Set the Maximum Position Error (SMPER). Optimize the Proportional (SGP) and Velocity (SGV) gains. Use the Integral Feedback Gain (SGI) to reduce steady state error. Use the Velocity Feedforward Gain (SGVF) to reduce position error at constant velocity.
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. In addition to computing the APEX615n’s control signal, the DSP also computes the commanded position trajectory.
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. Larger values allow greater oscillations/motion when unstable; therefore, smaller SMPER values are safer.
START Increase SGP UNTIL OR OR Decrease SGV UNTIL Increase SGV UNTIL OR Decrease SGV UNTIL OR STOP Decrease SGP UNTIL OR Increase SGV UNTIL OR Decrease SGV UNTIL Appendix A 85
Step 6 ☞ Use the Integral Feedback Gain (SGI) to reduce steady state error: a. 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 command when the load is not moving. Steady state position error is described earlier in the Performance Measurements section.
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. NOTE The steps shown below (steps 1 - 11) represent the major steps of the process; the actual progression between these steps usually requires several iterations. The motion command used for this example is a step command with a step size of 100.
Step 5 Step 6 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 gain first. SGP = 105 SGV = 2.6 Lowering the SGV gain to 2.3 does not help reduce the chattering by much. Therefore, we should lower the SGP gain until chattering stops. SGP = 105 SGV = 2.3 Step 7 Step 8 Step 9 Chattering stops after reducing the SGP gain to 85.
Step 11 When we raised the SGV gain to 2.52, the step response became fast and very stable. SGP = 70 SGV = 2.52 Commanded Move is actually Completed Actual Time When the Target Zone Mode is not enabled, the move is considered to be complete and subsequent moves can be executed at this point in time. Velocity Under default operation (Target Zone Mode not enabled), the APEX615n’s move completion criteria is simply derived from the move trajectory.
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).
Appendix B Reducing Electrical Noise Noise-related difficulties can range in severity from minor positioning errors to damaged equipment from runaway loads crashing blindly through limit switches. In microprocessorcontrolled equipment such as the APEX615n, the processor constantly retrieves instructions from memory in a controlled sequence. If an electrical disturbance occurs, it may cause the processor to misinterpret an instruction or access the wrong data.
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.
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. This prevents noisy equipment that is grounded to Earth from sending noise into the APEX615n. When floating the signal ground is not possible, you should make the Earth ground connection at only one point.
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. 2. Shield all remote connections, use twisted pairs. Shields should be tied to Earth at one end. 3.
Appendix C Motor Specifications 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. Brake Characteristics Supply voltage Supply current Static braking torque APEX604 24 0.57 326 (2.3) APEX605/606/610 24 0.57 850 (6.0) APEX620/630/635 24 0.93 1130 (8.0) APEX640 24 1.
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; 20A rms for APEX610, 620, 630, 635, 640 motors).
oz-in (N-m) APEX604-MO at 240VAC APEX605-MO at 240VAC 1200 (8.4) oz-in (N-m) 800 (5.6) 900 (6.3) Intermittent Duty Intermittent Duty Torque Torque 600 (4.2) 400 (2.8) 300 (2.1) 2 Sin 40VAC gle Pha * se Continuous Duty 200 (1.4) 600 (4.
SM Motor Specifications Parameter Stall Torque Continuous 1 Symbol T cs Units lb.in. oz. in. Nm amperes - rms rpm rps lb.in. oz. in. Nm amperes lb.in. oz. in. Nm watts hp volts/radian/sec volts/KRPM oz. in./ amp rms Nm/amp rms ohms millihenries °C/watt oz.in./÷watt Nm/÷watt oz. in.
Value Units Tolerance 52.6 (0.37) oz-in/A rms (Nm/A rms) ± 10% 22.5 V rms/Krpm ± 10% 5.3 milliseconds nominal 1.40 milliseconds nominal 11.0 minutes nominal min. [1] oz-in (Nm) 236 (1.67) min. [2] oz-in (Nm) 223 (1.57) min. [2] oz-in (Nm) 202 (1.43) min. [1] oz-in (Nm) 630 (4.45) max. oz-in (Nm) 7.68 (0.05) max. [3] percent 5 7500 (125) rpm (rps) reference 7500 (125) rpm (rps) reference 250 Hz max. 4.2 A rms max. [1] 12.6 A rms nominal 240 V rms reference 250 V rms maximum 1.12 (1.5) kWatts (hp) min.
Value Units Tolerance 114.6 (0.81) oz-in/A rms (Nm/A rms) ± 10% 49.0 V rms/Krpm ± 10% 9.7 milliseconds nominal ----milliseconds nominal 18 minutes nominal min. [1] oz-in (Nm) 367 (2.59) min. [2] oz-in (Nm) 346 (2.44) min. [2] oz-in (Nm) 356 (2.51) min. [1] oz-in (Nm) 1046 (7.38) max. oz-in (Nm) 12.0 (0.08) max. [3] percent 5 3800 (63) rpm (rps) reference 3800 (63) rpm (rps) reference 126.7 Hz max. 3.0 A rms max. [1] 9.6 A rms nominal 240 V rms reference 250 V rms maximum 1.0 (1.3) kWatts (hp) min.
APEX604 Value Units Tolerance Torque 52.6 (0.37) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 22.5 V rms/Krpm ± 10% Electrical Time 58.7 milliseconds nominal Mechanical Time 1.30 milliseconds nominal Thermal 12 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 334 (2.36) min. [2] oz-in (Nm) 315 (2.22) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 269 (1.90) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 899 (6.35) lines 15 & 16 below.
APEX605 Value Units Tolerance Torque 68.7 (0.49) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 29.4 V rms/Krpm ± 10% Electrical Time 10.68 milliseconds nominal Mechanical Time 1.46 milliseconds nominal Thermal 18 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 367 (2.59) min. [2] oz-in (Nm) 346 (2.44) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 321 (2.27) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 1085 (7.66) lines 15 & 16 below.
APEX606 Value Units Tolerance Torque 120 (0.85) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 51.2 V rms/Krpm ± 10% Electrical Time 15.32 milliseconds nominal Mechanical Time 0.896 milliseconds nominal Thermal 20 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 672 (4.75) min. [2] oz-in (Nm) 634 (4.48) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 576 (4.07) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 1957 (13.82) lines 15 & 16 below.
APEX610 Value Units Tolerance Torque 61.4 (0.43) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 26.2 V rms/Krpm ±10% Electrical Time 13.16 milliseconds nominal Mechanical Time 0.762 milliseconds nominal Thermal 21 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 977 (6.90) min. [2] oz-in (Nm) 921.6 (6.51) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 653 (4.61) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 2630 (18.57) lines 15 & 16 below.
APEX620 Value Units Tolerance Torque 124.2 (0.877) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 53 V rms/Krpm ± 10% Electrical Time 23.4 milliseconds nominal Mechanical Time 0.82 milliseconds nominal Thermal 22 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 1974 (13.94) min. [2] oz-in (Nm) 1862 (13.15) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 1632 (11.52) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 5299 (37.42) lines 15 & 16 below.
APEX630 Value Units Tolerance Torque 175.3 (1.24) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 74.9 V rms/Krpm ± 10% Electrical Time 26.7 milliseconds nominal Mechanical Time 0.68 milliseconds nominal Thermal 28 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 2788 (19.69) min. [2] oz-in (Nm) 2630 (18.57) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 2304 (16.27) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 7488 (52.88) lines 15 & 16 below.
APEX635 Value Units Tolerance Torque 164.0 (1.158) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 70 V rms/Krpm ± 10% Electrical Time 0.77 milliseconds nominal Mechanical Time 20.8 milliseconds nominal Thermal 28 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 2605 (18.39) min. [2] oz-in (Nm) 2458 (17.36) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 2054 (14.50) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 7008 (49.49) lines 15 & 16 below.
APEX640 Value Units Tolerance Torque 291.5 (2.06) oz-in/A rms (Nm/A rms) ± 10% Voltage (Sinusoidal) 124.5 V rms/Krpm ± 10% Electrical Time 26.2 milliseconds nominal Mechanical Time 0.55 milliseconds nominal Thermal 33 minutes nominal min. [1] oz-in (Nm) Torque (s): Continuous, Stall 4640 (32.76) min. [2] oz-in (Nm) 4378 (30.92) (NOTE: Values are with Continuous, Stall min. [2] oz-in (Nm) 3955 (27.93) rated and peak current, Continuous, Rated min. [1] oz-in (Nm) 12461 (87.99) lines 15 & 16 below.
Appendix D LVD Installation Instructions For more information about LVD, see 73/23/EEC and 93/68/EEC, published by the European Economic Community (EEC). Environmental Conditions Pollution Degree APEX615n Controller/Drives are designed for pollution degree 2. Installation Category APEX615n Controller/Drives are designed for installation category II.
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. WARNING Safety Ground (Earth Ground) should never be fused.
Servo Motor Safety Earth Cable (green/yellow) Providing Protective Earth Connection for Motor 1 2 3 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. Resistance between the motor and earth must be no greater than 0.1 W.
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.
Appendix E EMC Installation Guidelines 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. These measures vary according to the type of product. The ultimate responsibility for ensuring that the EMC requirements are met rests with the systems builder.
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. This external enclosure is also required for safety reasons. There must be no user access while the equipment is operating.
Ferrite absorber specifications The absorbers described in these installation recommendations are made from a low-grade ferrite material which has high losses at radio frequencies. 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.
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. High-Frequency bonding typically involves wide, flat cabling to establish a suitable system ground.
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. Route the supply cable so that it runs close to the walls of the enclosure.
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. Motor Feedback Cables Feedback devices such as encoders, tachometers, Hall effect sensors, and resolvers also require the use of high-quality braided screen cable.
Single Phase AC Input Cable Three Phase AC Input Cable AC Control Filter AC Mains Filter Controller Cable Encoder Cable Remove Paint behind this area Braidedscreen cables A P E X 6 1 5 4 Rx Tx nd oG Is V +5 + Rx x Rx R + Tx Tx Tx Shld d n oG Is ield Sh nd G Z Z+ BB+ AA+ V +5 Iso d Gn Iso me Ho g Ne s Po I+ AN IAN -A Trg -B Trg A tOu d n G Iso +5V t-P Ou In-P x-P Au O I/ V_ t se Offnce la Ba ut tp Ou tion ch ra Ta alib C le ab En ble a Dis ault e F lt dg au Bri ve F ult Dri r Fa e to ag M
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. 5. Expose a short length of the braided screen and anchor to the panel with a P-clip.
Appendix F Configuring DIP Switches APEX6151 DIP Switches L2 Earth Earth Earth Earth Control L2 Control L2 SW1 8 1 SW2 8 1 SW3 8 1 2 3 4 5 6 7 8 1 A diagram showing DIP switch functions shown on page 7. OFF 1 OFF 1 2 3 4 5 6 7 8 Control L1 SW1 8 1 SW2 8 1 SW3 8 Control L1 1 2 3 4 5 6 7 8 Earth 1 2 3 4 5 6 7 8 Earth The default setting for all DIP switches when the APEX6151 ships from the factory is off. You must set these switches to configure the drive for your particular application.
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.
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. This switch must be OFF during normal operating conditions. See Chapter ƒ Advanced Features for more information. COMMUTATION TEST MODE — #3: Turn this switch OFF.
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). RESOLVER SPEED — #6: For a motor with a single speed resolver, turn #6 OFF. (This switch should be OFF if you use an APEX motor, all of which have single-speed resolvers.
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 Advanced Features. The following equation gives an approximate time, in minutes, for a motor that operates from a cold start.
126 APEX615n Installation Guide
Appendix G Regeneration 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 V Bus+ and Regen Resistor, located on the motor connector. The external resistor will double the dissipation capabilities of the APEX6151 and APEX6154.
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.
Peak power regeneration occurs at the moment deceleration begins, when the velocity is highest. Pshaft ( peak ) = 2πvmax T 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.
The total energy that must be dissipated in the regen resistor consists of the total regenerated energy, less copper and drive losses: Wtotal 2 T T 3 1 = 2 ( 2πvmax T ) − 2 R − 5 2 t1 kT kT To find the average power, we must consider how frequently energy is "dumped" into the resistor. The period of the move profile is the time t2.
APEX6152: (for reference only: do not install external resistor) • Resistor Size and Type • Manufacturer Name: • Manufacturer Part Number: 50 ohm, 100 watt, 5% non-inductive resistor: Memcor-Truohm Inc. FRV01006-2500-QM-NI ("NI " - Non Inductive) Memcor-Truohm Inc. Part Number 1141-006-001 • Mounting Bracket: APEX6154: • Resistor Size and Type • Manufacturer Name: • Manufacturer Part Number: 25 ohm, 100 watt, 5% non-inductive resistor: Memcor-Truohm Inc.
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. This is shown in the table above.
I N D E X A AC input power connections & specs 21 AC power jumpers 22 wiring options 23 acceleration acceleration feedforward control (SGAF) 83 acceleration range 4 accuracy velocity 4 actual position 77 address DIP switch selection 6 air-flow space, minimum 11 airborne contaminants 11 airflow 14 alignment mode 72, 123, 125 analog ground 18, 19 ANI input feedback source 75 position 77 APEX Series Motors APEX602 Motor Specifications 101 APEX603 Motor Specifications 102 APEX604 Motor Specifications 103 APEX6
motor 51 DIP switch function 125 location 6, 121, 123 DIP switch locations 6 DIP switch settings bias & termination resistors 10 motor current 6 DIP switches APEX6151 7 APEX6152 8 APEX6154 9 disassembling the APEX615n 10 dissipation heat 14 disturbance 78 rejection of 81 DRESET command 64 drive resetting 62, 64 drive auxiliary connector 36 drive specifications 4 DRPCHK command 34 E earth ground 18, 19, 95 electrical noise 3, 64 suppressing 35 enable input 65 connections & specs 37 enclosures electrical 11
internal configuration 10 N National Electric Code Handbook i negative-travel limits 27 noise defeating 96 electrical 11 externally conducted 94 ground loops 95 internal switching 94 power line 93 sensitivity 35 transmitted 95 noise, electrical 3, 64 suppression 93 suppression on I/O cables 35 O offset balance adjustments 71 open loop commutation 73 opening the APEX615n 10 oscillatory servo response 78, 82 ouput power frequency range 4 ouput power current 4 voltage range 4 output saturation 76 outputs +5V
specifications overall list of 4, 5 speed/torque curves 97 stability 78 status commands (see also back cover, and test on page 20) axis (see TASF command) limit switches (see TLIM command) motor faults (see TASXF command) programmable inputs (see TIN command) programmable outputs (see TOUT command) trigger inputs (see TIN command) steady-state 79 position error 77 support software available 60 surge suppression 93, 96 switching voltage levels 5 Switching voltage levels for HOM, POS, NEG, TRG-A , TRG-B are b
APEX6151 Servo Controller/Drive Quick Reference TROUBLESHOOTING TIPS D A N G E R HIGH VOLTAGE L2 Earth Earth Earth Control L1 1 • PROBLEM REPORT: TAS command reports problems. TFS command reports Following status.
APEX6152 &APEX6154 Servo Controller/Drive Quick Reference 8 2 3 4 5 6 15 A PE X6 SW 1 1 APEX605 APEX606 1 2 3 4 5 6 APEX610 54 for APEX Series Motors see page 7-9 OFF 1 2 3 4 5 6 APEX620 APEX630 1 2 3 1 4 5 6 COM 1 COM 2 2 3 4 5 6 COM 2 Tx Torque Cmd Test Point Rx Tx External Encoder Input LIMITS Shield Enable Iso Gnd Disable Z- Bridge Fault B- AUXILIARY Drive Fault Drive Fault Motor Fault Over Voltage B+ I 2 T Limit A- Regen Fault A+ Regen Activ
