AutomationDirect AC Servo User Manual

1-800-633-0405

3 Standard Drives ... 8 Standard Motors ... 100W to 3kW
... over 50 gearboxes (both inline and right angle) with four ratios

For the latest prices, please check AutomationDirect.com.

®

AC Servo Systems

Drive features

• Main Power and Control Power Inputs

» Main Power: 230 VAC 1-phase/3-phase (2kW and 3kW systems

are 3-phase only)

» Control Power: 230 VAC Single Phase; 50/60 Hz

• Fully digital with up to 450 Hz velocity loop response

• Easy setup and diagnostics with built-in keypad/display or the
SureServo Pro PC-based software

• Five-in-one command options include:

» ± 10V torque or velocity command
» Pulse train or master encoder position command (accepts

line driver or open collector) with electronic gearing

» Built-in indexer for position control using 8 preset positions

and/or position setpoint with serial Modbus

• Tuning aids include inertia estimation and easy tuning for up to 10
levels of response

• Optically isolated digital inputs (8) and outputs (5), analog outputs
for monitor signals (2), and line driver output for encoder (with
scalable resolution)

SureServo

SureServo

tuning technology

The SureServo drive closes the loop on
current, velocity, and position
(depending on control mode selection).
Proportional gain, integral gain, feed
forward compensation, command low
pass filter, and a notch filter for reso­nance suppression are available. There
are three tuning modes:

1. “Manual Mode” for user-defined

adjustments

2. “Easy Mode” for default settings over

a wide range of programmed inertia
with 10 response levels

3. “Auto Mode” for automatic adjust-

ment using an estimated (or
measured) value of inertia

built-in motion controller

While the SureServo drives can accept
traditional commands from host controls,
they can also provide their own internal
motion control. For example, up to
eight index moves can be pre-defined
and stored in the drive and then selected
and executed using up to three discrete
inputs. The predefined index profiles can
also be changed via serial communica­tions. The motion can be incremental or
absolute (homing routines are available
in the drive) and acceleration can be
linear or S-curve.

Multiple drives can be daisy-chained
and addressed separately using the
drive’s serial port. This allows very
simple yet powerful control of multi-axis
processes that do not need precise path
control but only precise starting and stop­ping points. Applications include press
feeds, auger fillers, rotary tables, robots
for pick and place, test or assembly
operations, drilling, cutting, tapping, and
similar applications using simple index
moves for single or multi-axis motion.

Motor features

• Low inertia models:

» 100W, 200W, 400W, 750W and 1kW
» Speeds up to 5,000 rpm.

• Medium inertia models:

» 1kW, 2kW and 3kW
» Speeds up to 3,000 rpm.

• Square flange mounting with metric dimensions:

» 40, 60, 80, 100, 130 and 180 mm flanges

• Permanent magnet 3-phase synchronous motor

• Keyless drive shafts support clamp-on style coupling

• Integrated encoder with 2,500 (x4) pulses/revolution plus marker
pulse (once per revolution)

• Optional 24 VDC spring-set holding brakes

• Standard hook-up cables for motor power/brake and encoder

• Standard DIN-rail mounted ZIPLink break-out kit for the drive’s
CN1 connector (with screw terminal connections)

SureServo
Optional Holding Brake

Each SureServo motor can be ordered
with an optional 24VDC spring-set
holding brake that holds the motor in
place when power is removed.

SureGear® Precision
Gearboxes for
Servo motors

Inertia
balancing
issue in
your design?

The SureGear PGA
series easily mates to SureServo
motors. Everything you need to mount
your SureServo motor is included!

• Four gear ratios available (5, 10, 15, 25:1)

• Mounting hardware included for attaching
to SureServo motors

• Industry-standard mounting dimensions

• Thread-in mounting style

• Best-in-class backlash (5 arc-min)

• 5-year warranty

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Motion Control

tMNC-166

1-800-633-0405

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®

AC Servo Systems

• Pulse Train Positions:

• Step and direction

• CW and CCW

• Encoder follower

• Analog Velocity (±10V)

• Analog Torque (±10V)

• Mode Switching

• “On-the-Fly” Control Mode
Switching

mMNC-6

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Motion Control

Stand-alone operation
using internal presets

• Preset selection with
digital inputs

• Ability to change preset
values with serial bus
(RTU/ASCII Modbus
protocols)

1-800-633-0405

Motion Control

tMNC-167

1-800-633-0405

®

AC Servo Systems

How to select and apply SureServo systems

The primary purpose of the AC servo system is to precisely
control the motion of the load. The most fundamental
considerations in selecting the servo system are
“reflected” load inertia, servo system maximum speed
requirement, servo system continuous torque require­ment, and servo system peak torque requirement. In a
retrofit application, select the largest torque SureServo
system that most closely matches these parameters for

Motion Profile

Desired

Load

Velocity

Required

Motor

Torque

time

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the system being replaced. In a new application, these
parameters should be determined through calculation and/or
measurement.

AutomationDirect has teamed with Copperhill Technologies
to provide free servo-sizing software. “VisualSizer-SureServo”
software will assist in determining the correct motor and drive
for your application by calculating the reflected load inertia
and required speed and torque based on the load configura­tion. “VisualSizer-SureServo” software can be downloaded
from www.sureservo.com/downloads.htm.

Information for selecting SureServo systems is also included
in Appendix B of the SureServo User Manual, which can be
downloaded from the AutomationDirect.com website.

Servo

System

Mechanical

Transmission

Load

1. “Reflected” load inertia

The inertia of everything attached to the servo motor drive­shaft needs to be considered and the total “reflected” inertia
needs to be determined. This means that all elements of any
mechanical transmission and load inertia need to be trans­lated into an equivalent inertia as if attached directly to the
motor driveshaft. The ratio of “reflected” load inertia to motor
inertia needs to be carefully considered when selecting the
servo system.

In general, applications that need high response or band­width will benefit from keeping the ratio of load inertia to

motor inertia as low as possible and ideally under 10:1.
Systems with ratios as high as 200:1 can be implemented,
but corresponding lower bandwidth or responsiveness must
be accepted. The servo response including the attached load
inertia is determined by the servo tuning. SureServo systems
may be tuned manually, adaptively with measurement of the
load inertia, or set with default tuning based on a programmed
value of load inertia.

2. Torque and speed

With knowledge of the motion profile and any mechanical transmis­sion between the motor and load, calculations can be made to deter­mine the required servo motor continuous torque, peak torque, and
maximum motor speed. The required amount of continuous torque
must fall inside the continuous operating region of the system torque­speed curve (you can check the continuous torque at the average
speed of the motion profile). The required amount of peak torque
must also fall within the servo system’s intermittent operating region
of the system torque-speed curve (you need to check this value at the
required maximum speed).

300%

Torque

200%

100%

Peak Torque

Limited by Current

Limit

Intermittent Operating

Region

Continuous Operating

Region

Limited by Voltage

Peak Torque

Limit

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1000 2000 3000 4000

Speed (r.p.m.)

Motion Control

5000

tMNC-168

1-800-633-0405

®

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AC Servo Systems

Application tip -
coupling considerations

The SureServo motors have keyless shafts that are designed for
use with clamp-on or compression style couplings. Couplings
using keys and/or set screws should NOT be used with
SureServo motors as they are likely to come loose or damage
the motor shaft. “Servo-grade” clamp-on or compression
style couplings are usually the best choice when you consider

Coupling Suppliers: www.sureservo.com/couplingconsiderations.htm

Mechanical transmissions

Common mechanical transmissions include leadscrews, rack
& pinion mechanisms, conveyors, gears, and timing belts. The
use of leadscrew, rack & pinion, or conveyor are common

the stiffness, torque rating, and inertia. Higher stiffness
(lb-in/radian) is needed for better response but there is a
trade-off between the stiffness and the added inertia of the
coupling. Concerning the torque rating of the coupling, use a
safety factor of 1.25 over the SureServo peak torque require­ment of your application.

ways to translate the rotary motion of the servo motor into
linear motion of the load. The use of a speed reducer such
as a gearbox or timing belt can be very beneficial as follows:

1. Reduction of reflected
load inertia

As a general rule, it is beneficial to
keep the reflected load inertia as low as
possible while using the full range of servo
speed. SureServo systems can go up to
5,000 rpm for the low inertia motors and
up to 3,000 rpm for the medium inertia
motors.

Example: A gearbox reduces the required
torque by a factor of the gear ratio, and
reduces the reflected load inertia by a
factor of the gear ratio squared. A 10:1
gearbox reduces output speed to 1/10,
increases output torque 10 times, and
decreases reflected inertia to 1/100.

However, when investigating the effect
of different speed reduction ratios DO
NOT forget to include the added inertia
of couplings, gearbox, or timing belt
pulleys. These added inertias can be
significant, and can negate any inertia
reduction due to the speed reduction.

www.sureservo.com/mechanical_trans.htm

2. Low speed and high torque
applications

If the application requires low speed and
high torque then it is common to intro­duce a speed reducer so that the servo
system can operate over more of the
available speed range. This could also
have the added benefit of reducing the
servo motor torque requirement which
could allow you to use a smaller and
lower cost servo system. Additional
benefits are also possible with reduction
in reflected inertia, increased number of
motor encoder counts at the load, and
increased ability to reject load distur­bances due to mechanical advantage of
the speed reducer.

3. Space limitations and motor
orientation

SureServo motors can be mounted in
any orientation, but the shaft seal should
not be immersed in oil (open-frame
gearbox, etc.). Reducers can possibly
allow the use of a smaller motor or
allow the motor to be repositioned. For
example, some reducers would allow for
in-line, right angle, or parallel mounting
of the motor.

For more information, refer to the
website listed below.

Ordering guide instructions

The following four pages are your ordering guide for the
eight standard SureServo systems. Each of the eight standard
systems has a torque-speed curve including the motor inertia
for reference. This is the fundamental information that you
need to select the servo drive and matching motor for your
application.

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Don’t forget the cables and ZIPLink break-out board kit!

Included in the ordering guide are the available connection
cables from the drive to motor in standard lengths from 10 to
60 feet. The break-out board kit includes a 0.5m (19 inch)
cable for the CN1 I/O interface, and is listed for your conve­nience. We highly recommend all five items per system as a
minimum. All cables are 100% factory tested to make your
system installation as easy and quick as possible. See the
Accessories section for regeneration resistors, AC line filters,
fuses, contactors, and RF noise filters.

Motion Control

tMNC-169

SV A - 2 04 0

2: 230VAC; 50/60 Hz

1-800-633-0405

®

AC Servo System Configuration

SureServo series drives and motors part numbering system

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Series

SV: SureServo AC servo

Component Type

A: Drive

L: Low inertia motor

M: Medium inertia motor

Component Option

0: Drive
Blank: Motor without brake
B: Motor with brake

Rated Output Power

01: 100W 10: 1000W
02: 200W 20: 2000W
04: 400W 30: 3000W
07: 750W

Nominal Input Voltage

Here is what you will need to order a complete servo system:

Servo Drive

Servo Motor Motor Power

Cable

Motor Encoder

Cable

ZIPLink I/O

Interface

Note: uNit caN be programmed via keypad.

optioNal programmiNg software (free dowNload) aNd optioNal programmiNg cable available.

Note: if you Need a gear box for your coNfiguratioN, you caN do it easily oNliNe:

http://www.sureservo.com/gearbox/selector

SureServo AC servo drive, motor, and cable combinations

Inertia

& Power

Inertia

Low inertia

Medium inertia

Drive and Motor

Servo

Servo

Motor

Motor

without

Power

Servo Drive

100W

200W SVL-202 SVL-202B

400W SVL-204 SVL-204B

750W

1000W SVL-210 SVL-210B

1000W SVM-210 SVM-210B

2000W

3000W SVM-230 SVM-230B

SVA-2040

SVA-2100

SVA-2300

with

brake

brake

(note)

(note)

SVL-201 SVL-201B

SVL-207 SVL-207B

SVM-220 SVM-220B

10 ft 20 ft 30 ft 60 ft 10 ft 20 ft 30 ft 60 ft

SVC­PFL-010

SVC­PHM-010

SVC­PHH-010

Note: each servo motor requires aN eNcoder feedback cable aNd a power cable.

the motor power cable iNcludes brake power wires for the optioNal motor brake.

Power Cables

(from Drive to Motor)

SVC-

SVC­PFL-030

SVC­PHM-030

SVC­PHH-030

SVC­PFL-060

SVC­PHM-060

SVC­PHH-060

PFL-020

SVC­PHM-020

SVC­PHH-020

Encoder Feedback Cables Miscellaneous

SVC­EFL-010

SVC­EHH-010

SVC­EFL-020

SVC­EHH-020

SVC­EFL-030

SVC­EHH-030

SVC­EFL-060

SVC­EHH-060

ZIPLink I/O
Interface

ZL-RTB50

and

ZL-SVC-CBL50
or
ZL-SVC-CBL50-1
or
ZL-SVC-CBL50-2

RS-422/485
Serial Com­munication
Cable

SVC-MDCOM-CBL

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Motion Control

tMNC-170

Torque

Torque

(rpm)

Torque

Torque

Torque

1-800-633-0405

100W Low Inertia System

(N-m)

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®

AC Servo System Configuration

For all systems:

Order programming software &

programming cable if needed.

See pgs. tMNC-171 & 45.

Torque
(in-lb)

8.9

7.1

Intermittent
Duty Zone

Continuous

5.3

3.5

1.8

Duty Zone

0

100W Low Inertia

Speed

(rpm)

SVA-2040 $483.00

Jm= Motor Inertia = 0.000027 lb-in-s2 (0.000003 kg - m2)

200W Low Inertia System

(N·m)

2.5

2.0

1.5

1.0

0.5

Intermittent
Duty Zone

Continuous Duty Zone

0

0

1000 2000

3000 4000

200W Low Inertia

Jm= Motor Inertia = 0.00016 lb-in-s2 (0.000018 kg - m2)

(in·lb)

5000

Speed

22.1

17.7

13.3

8.9

4.4

0

SVA-2040 $483.00

SVL-201 $322.00
SVL-201B (w/brake) $567.00

SVC-EFL-010 (10’) $56.00
SVC-EFL-020 (20’) $92.00
SVC-EFL-030 (30’) $108.00
SVC-EFL-060 (60’) $137.00

SVL-202 $425.00
SVL-202B (w/brake) $629.00

SVC-EFL-010 (10’) $56.00
SVC-EFL-020 (20’) $92.00
SVC-EFL-030 (30’) $108.00
SVC-EFL-060 (60’) $137.00

SVC-PFL-010 (10’) $33.50
SVC-PFL-020 (20’) $63.00
SVC-PFL-030 (30’) $79.00
SVC-PFL-060 (60’) $143.00

ZL-RTB50 $52.00
and one cable below:
ZL-SVC-CBL50 (0.5m) $34.00
ZL-SVC-CBL50-1 (1m) $35.00
ZL-SVC-CBL50-2 (2m) $40.50

SVC-PFL-010 (10’) $33.50
SVC-PFL-020 (20’) $63.00
SVC-PFL-030 (30’) $79.00
SVC-PFL-060 (60’) $143.00

ZL-RTB50 $52.00
and one cable below:
ZL-SVC-CBL50 (0.5m) $34.00
ZL-SVC-CBL50-1 (1m) $35.00
ZL-SVC-CBL50-2 (2m) $40.50

400W Low Inertia System

35.4

26.6

17.7

Speed

(rpm)

(in-lb)

44.3

8.9

0

(N·m)

Intermittent
Duty Zone

Continuous
Duty Zone

400W Low Inertia

Jm= Motor Inertia =0.0003 lb-in-s2 (0 .000034 kg - m2)

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SVA-2040 $483.00

SVL-204 $520.00
SVL-204B (w/brake) $733.00

SVC-EFL-010 (10’) $56.00
SVC-EFL-020 (20’) $92.00
SVC-EFL-030 (30’) $108.00
SVC-EFL-060 (60’) $137.00

SVC-PFL-010 (10’) $33.50
SVC-PFL-020 (20’) $63.00
SVC-PFL-030 (30’) $79.00
SVC-PFL-060 (60’) $143.00

ZL-RTB50 $52.00
and one cable below:
ZL-SVC-CBL50 (0.5m) $34.00
ZL-SVC-CBL50-1 (1m) $35.00
ZL-SVC-CBL50-2 (2m) $40.50

Motion Control

tMNC-171