84855104

› BDE Pro Analog Drive Optimized for Crouzet Brush Motors Speed/Torque Control | 25A Peak | 15A Continuous Features › › › › › › › › Four Quadrant Regenerative Operation DIP Switch Selectable Modes DIP Switch Configurable Loop Tuning Selectable Inhibit Logic Adjustable Current Limits High Switching Frequency Differential Input Command Digital Fault Output Monitor › › › › › › › › On-Board Test Potentiometer Offset Adjustment Potentiometer Adjustable Input Gain Selectable 120/60 Hall Commutation Phasing Encoder Velocity Mode Velocity Monitor Output Current Monitor Output Drive Status LED Part Number: 84855104 More Technical Features Modes of Operation Command Source Feedback Supported Motors Supported › › › › › › › Current Encoder Velocity Duty Cycle (Open Loop) ±10 V Analog Hall Sensors Incremental Encoder › Three Phase (Brushless) Single Phase (Brushed, Voice Coil, Inductive Load) Compliance & Agency Approvals › UL › cUL › CE Class A (LVD) › CE Class A (EMC) › RoHS II Power Range Peak Current 25 A Continuous Current 15 A Supply Voltage 20 - 80 VDC Description The 84855104 BDE Pro is optimized to drive DC brush motors at a high switching frequency. A single red/green LED indicates operating status. The drive is fully protected against overvoltage, under-voltage, overcurrent, overheating and short circuits across motor, ground and power leads. Furthermore, the drive can interface with digital controllers or be used stand-alone, and requires only a single unregulated DC power supply. Loop gain, current limit, input gain and offset can be adjusted using 14-turn potentiometers. An offset adjusting potentiometer can also be used as an on-board input signal for testing purposes. This drive can use quadrature encoder inputs for velocity control. For more information about the 84855104 BDE Pro please visit www.crouzet-motors.com. Block Diagram Information on Approvals and Compliances US and Canadian safety compliance with UL 508c, the industrial standard for power conversion electronics. UL registered under file number E140173. Note that machine components compliant with UL are considered UL registered as opposed to UL listed as would be the case for commercial products. Compliant with European EMC Directive 2004/108/EC on Electromagnetic Compatibility (specifically EN 61000-64:2007 for Emissions, Class A and EN 61000-6-2:2005 for Immunity, Performance Criteria A). LVD requirements of Directive 2006/95/EC (specifically, EN 60204-1:2004, a Low Voltage Directive to protect users from electrical shock). The RoHS II Directive 2011/65/EU restricts the use of certain substances including lead, mercury, cadmium, hexavalent chromium and halogenated flame retardants PBB and PBDE in electronic equipment. Page 2 of 10 Specifications Power Specifications Description Units Value DC Supply Voltage Range VDC 20 - 80 DC Bus Over Voltage Limit VDC 88 DC Bus Under Voltage Limit VDC 15 Maximum Peak Output Current1 A 25 Maximum Continuous Output Current A 15 Maximum Continuous Output Power at Continuous Current W 1140 Maximum Power Dissipation at Continuous Current Minimum Load Inductance (Line-To-Line)2 W 60 µH 200 Internal Bus Capacitance µF TBD Low Voltage Supply Outputs Switching Frequency - ±10 VDC (3 mA), +6 VDC (30 mA) kHz 22 Units Value Control Specifications Description Command Sources - ±10 V Analog Feedback Supported - Hall Sensors, Incremental Encoder Commutation Methods - Trapezoidal Modes of Operation - Current, Encoder Velocity, Duty Cycle (Open Loop) Motors Supported - Three Phase (Brushless), Single Phase (Brushed, Voice Coil, Inductive Load) Hardware Protection - Over-Current, Over-Temperature, Over-Voltage, Under-Voltage, Short-Circuit (Phase-Phase & Phase-Ground) Primary I/O Logic Level - 5V TTL Mechanical Specifications Description Agency Approvals Size (H x W x D) Units mm (in) Value CE Class A (EMC), CE Class A (LVD), cUL, RoHS II, UL 129.3 x 75.8 x 25.1 (5.09 x 2.98 x 0.99) Weight g (oz) 249.5 (8.8) Heatsink (Base) Temperature Range3 °C (°F) 0 - 65 (32 - 149) Storage Temperature Range °C (°F) -40 - 85 (-40 - 185) Form Factor - Panel Mount P1 Connector - 16-pin, 2.54 mm spaced, friction lock header P2 Connector - 5-port, 5.08 mm spaced, quick disconnect terminal Notes 1. 2. 3. Maximum duration of peak current is ~2 seconds. Peak RMS value must not exceed continuous current rating of the drive. Lower inductance is acceptable for bus voltages well below maximum. Use external inductance to meet requirements. Additional cooling and/or heatsink may be required to achieve rated performance. Page 3 of 10 Pin Functions P1 - Signal Connector Pin Name Description / Notes I/O 1 +10V 3mA OUT 2 SIGNAL GND O 3 -10V 3mA OUT 4 +REF IN 5 -REF IN 6 ENCODER-B IN Single-ended encoder channel B input. +5 V logic level. I 7 ENCODER-A IN Single-ended encoder channel A input. +5 V logic level. I 8 CURRENT MONITOR Current Monitor. Analog output signal proportional to the actual current output. Scaling is 4.4 A/V. Measure relative to signal ground. O 9 INHIBIT / ENABLE TTL level (+5 V) inhibit/enable input. Pull to ground to inhibit drive (SW1-5 ON). Pull to ground to enable drive (SW1-5 OFF). Inhibit turns off all power devices. I 10 +V HALL 30mA OUT Low Power Supply for Hall Sensors (+6 V @ 30 mA). Referenced to signal ground. Short circuit protected. O 11 GND Signal Ground 12 HALL 1 13 HALL 2 14 HALL 3 15 VEL MONITOR OUT 16 FAULT OUT ±10 V @ 3 mA low power supply for customer use. Short circuit protected. Reference ground common with signal ground. GND O I Differential Reference Input (±10 V Operating Range, ±15 V Maximum Input) I GND I Single-ended Hall/Commutation Sensor Inputs (+5 V logic level). Leave open for brushed motors. I Velocity Monitor. Analog output proportional to motor speed. In Encoder Velocity mode, output is proportional to the encoder line frequency. Encoder Velocity scaling is 22 kHz/V. O TTL level (+5 V) output becomes high when power devices are disabled due to at least one of the following conditions: inhibit, invalid Hall state, output short circuit, over voltage, over temperature, power-up reset. I O P2 - Power Connector Pin Name Description / Notes I/O 1 A Motor Phase A O 2 B Motor Phase B O 3 C Motor Phase C (leave open for brushed motors) O 4 POWER GND Power Ground (Common with Signal Ground) 5 HIGH VOLTAGE DC Power Input PGND I Page 4 of 10 Hardware Settings Configuration Switch Functions SW1 Description On Setting 1 Duty Cycle mode selector. Activates internal PWM feedback. OFF by default. 2 3 Duty Cycle mode Other modes 60/120 degree commutation phasing setting. ON by default. For brushed motors, set to 60-degree phasing. 120 degrees 60 degrees Outer loop integration. Activates or deactivates integration. ON for current mode and OFF for other modes. ON by default. Inactive Active Test Offset Drive Inhibit is active low Drive Inhibit is active high Standard Inverted Test/Offset. Switches the function of the Test/Offset pot between an onboard command input for testing or a command offset adjustment. OFF by default. 4 5 Inhibit logic. Sets the logic level of inhibit pins. ON by default. Velocity feedback polarity. Changes the polarity of the internal feedback signal and the velocity monitor output signal. Inversion of the feedback polarity may be required to prevent a motor run- away condition. ON by default. 6 Off Setting Mode Selection Table Mode SW1-1 SW1-3 Encoder CURRENT OFF ON Not Connected DUTY CYCLE ON OFF Not Connected ENCODER VELOCITY* OFF OFF Connected Notes 1. Use SW1-6 to change the feedback polarity if necessary. This may be required to prevent a run-away condition. Potentiometer Functions Potentiometer Description Turning CW 1 Loop gain adjustment for duty cycle / velocity modes. Turn this pot fully CCW in Increases gain current mode. 2 Current limit. It adjusts both continuous and peak current limit while maintaining Increases limit their ratio. 3 Reference gain. Adjusts the ratio between input signal and output variables (voltage, current, or velocity). 4 Increases gain Offset / Test. Used to adjust any imbalance in the input signal or in the amplifier. Can also be used as an on-board signal source for testing purposes. Adjusts offset in negative direction Notes 1. Note: Potentiometers are approximately linear and have 12 active turns with 1 inactive turn on each end. Test points are provided on the drive PCB near each potentiometer to measure the potentiometer value. Actuating the Switches To turn on a switch, use a tool such as a small screwdriver to gently push the switch forward To turn off a switch, use a tool such as a small screwdriver to gently pull the switch backward. Tip: use the underside of the cover as a fulcrum and the screwdriver as a lever to pull the switch backward Page 5 of 10 Loop Tuning Switch Functions   In general, the drive will not need to be further tuned beyond the default configuration. However, for applications requiring more precise tuning, DIP switches can be used to adjust the current and velocity loop tuning values. Some general rules of thumb to follow when tuning the drive are: A larger resistor value will increase the proportional gain, and therefore create a faster response time. A larger capacitor value will increase the integration time, and therefore create a slower response time. Proper tuning will require careful observation of the loop response on a digital oscilloscope to find optimal DIP switch settings for the specific application. (Note: Drive cover must be removed to access SW2 and SW3) SW2 DIP switches 1-4 add additional parallel capacitance to the velocity loop integrator capacitor (see Block Diagram). The resulting velocity loop capacitance values are given in the table below along with the appropriate DIP switch settings. By default, all SW2 switches are OFF (shaded in the SW2 table below). SW2 - Velocity Loop Integrator Capacitance Options (uF) Switch .047 147 .267 .367 .517 .617 .737 .837 1.047 1.147 1.267 1.367 1.517 1.617 1.737 1.837 SW2-1 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON SW2-2 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON SW2-3 OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON SW2-4 OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON Notes 1. The velocity loop integrator capacitor can be shorted entirely by setting SW1-3 to OFF. SW3 DIP switches add additional resistance and capacitance to the current loop tuning circuitry. SW3 switches 1-5 add additional series resistance to the current loop gain resistor, and SW3 switches 6-10 add additional parallel capacitance to the current loop integrator capacitor (see Block Diagram). The resulting capacitance and resistance values are given in the tables below along with the appropriate DIP switch settings. The default switch settings are shaded in the SW3 tables below. SW3 - Current Loop Proportional Gain Resistance Options (kΩ) Switch 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 SW3-1 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF SW3-2 ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF SW3-3 ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF SW3-4 ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF SW3-5 ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON Switch 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 SW3-1 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF SW3-2 ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF SW3-3 ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF SW3-4 ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF SW3-5 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF SW3 - Current Loop Integrator Capacitance Options (uF) Switch .0047 0094 .0247 .0294 .0517 .0564 .0717 .0764 .0987 .1034 .1187 .1234 .1457 .1504 .1647 .1694 SHORT SW3-6 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON SW3-7 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON ON SW3-8 OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON ON SW3-9 OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON SW310 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON Page 6 of 10 Mechanical Information P1 - Signal Connector Recommended cable size 22-30AWG Connector Information Mating Connector 16-pin, 2.54 mm spaced, friction lock header Details Included with Drive Molex: P/N 22-01-3167 (connector) and P/N 08-50-0114 (insert terminals) Yes P2 - Power Connector Recommended cable size 12-30AWG Connector Information Mating Connector 5-port, 5.08 mm spaced, quick-disconnect terminal Details Included with Drive Phoenix: P/N 1911994 Yes Page 7 of 10 Mounting Dimensions Mounting Dimensions: 84855104 Page 8 of 10 Related Products Pre-Tuned for these Motors DCmind Brush 42mm DCmind Brush 42mm DCmind Brush 42mm 15W 24W 35W 89 810 908 89 800 908 89 850 908 DCmind Brush 62mm DCmind Brush 62mm Notes DCmind motor range is perfect for applications where silence, long life, efficiency and low EMC levels are required. They can also be provided with gearboxes. These products are certified by: 57W 100W 89 830 912 89 890 911 Recommended Tools Hand Crimp Tool (economy) Hand Crimp Tool (premium) Details Molex: P/N 0638111000 Details Description Hand Crimper Tool Rectangular Contacts, 14-24 AWG Side Entry Description Molex: P/N 0638118200 Hand Crimper Tool Rectangular Contacts, 22-30 AWG Side Entry, Ratchet Screwdriver Details Wiha: P/N 96015 Description Screwdriver Slotted 1.5mm Page 9 of 10 Settings Optimized for Crouzet Motors Duty Cycle Mode When speed control is needed without precision and load is fairly constant. No encoder feedback or external controller is necessary. SW1 - Settings Potentiometers Standard Settings Make sure to measure these values when the drive is powered off. Notes: Settings for Crouzet DCmind Brush + Encoder (89810908, 89800908, 89850908, 89830912, 89890911) up to a nominal load. If your application is outside these conditions, please refer to the information on this datasheet or contact Crouzet tech support for assistance. Encoder Velocity Mode When precise speed control is needed and load is fairly constant. Encoder feedback is necessary and external controller could be used if desired, but is not necessary SW1 - Settings Potentiometers Standard Settings Make sure to measure these values when the drive is powered off. Notes: Settings for Crouzet DCmind Brush + Encoder (89810908, 89800908, 89850908, 89830912, 89890911) and up to a nominal load. If your application is outside these conditions, please refer to the information on this datasheet or contact Crouzet tech support for assistance. All specifications in this document are subject to change without written notice. Actual product may differ from pictures provided in this document. Page 10 of 10