ElectroCraft CompletePower Plus CPP-A12V80A-SA-USB Technical Reference

CPP-A12V80A-SA-USB

Technical Reference

ElectroCraft CompletePower™ Plus Universal Servo Drive

ElectroCraft document number 198-0000023

© ElectroCraft 2018

ElectroCraft

2 Marin Way, Suite 3

Stratham, NH 03885-2578

www.electrocraft.com

Revision

Date

Description

Comments

001

2/7/2018

Initial release

Document Released

002

8/15/2018

Phase 2&3 updates

PMDC and Stepper motor

update per ECO_000672

Record of Revisions:

Read This First

While ElectroCraft believes that the information and guidance given in this manual is correct, all parties
must rely upon their own skill and judgment when making use of it. ElectroCraft does not assume any
liability to anyone for any loss or damage caused by any error or omission in the work, whether such error
or omission is the result of negligence or any other cause. Any and all such liability is disclaimed.

All rights reserved. No part or parts of this document may be reproduced or transmitted in any form or by
any means, electrical or mechanical including photocopying, recording or by any information-retrieval
system without permission in writing from ElectroCraft, Inc. The information in this document is subject to
change without notice.

About This Manual

This document is a technical reference manual for CPP-A12V80A-SA-USB hardware. This document
covers the drive hardware including technical data, connectors and wiring diagrams needed for
installation.

© ElectroCraft 2018 1 CPP-A12V80A-SA-USB Technical Reference

Visit ElectroCraft online

World Wide Web: www.electrocraft.com

If you want to …

Contact ElectroCraft at …

Tel

: [phone]

Email

: [e-mail]

Mail

: ElectroCraft

USA

If you Need Assistance …

• Receive general information or assistance

• Ask questions about product operation or report suspected problems

• Make suggestions or report errors in documentation

For North America:

For Outside North America:

Please visit

2 Marin Way, Suite 3
Stratham, NH 03885-2578

www.electrocraft.com/contact/

© ElectroCraft 2018 2 CPP-A12V80A-SA-USB Technical Reference

Contents

1 Product Safety Precautions ................................................................................... 7

1.1 Operation ...................................................................................................................... 7

1.2 Storage and Transportation ........................................................................................... 8

1.3 Environmental Protection .............................................................................................. 8

1.4 Installation ..................................................................................................................... 9

1.5 Wiring ............................................................................................................................ 9

1.6 Life Support Policy .......................................................................................................10

1.7 Checking Product on Delivery ......................................................................................11

2 Product Overview .................................................................................................. 12

2.1 Key Features ................................................................................................................12

2.2 Simplified System Block Diagram .................................................................................12

2.3 Hall Sensor Feedback ..................................................................................................13

2.4 Stepper motor Phase Current Waveforms for Different Step values .............................15

2.5 Encoder Feedback .......................................................................................................16

2.6 Motor and Sensor Configurations .................................................................................16

2.7 Identification Labels .....................................................................................................16

2.8 Status Indicator Lights ..................................................................................................16

3 Drive Specifications .............................................................................................. 17

3.1 Physical Specifications .................................................................................................17

3.2 Environmental Specifications .......................................................................................17

3.3 Electrical Specifications ................................................................................................17

3.3.1 DC Supply Input .................................................................................................................... 17

3.3.2 +5VDC Supply Output ........................................................................................................... 17

3.3.3 Motor Output .......................................................................................................................... 17

3.3.4 Hall Sensor Inputs ................................................................................................................. 18

3.3.5 Encoder Inputs ...................................................................................................................... 18

3.3.6 Digital Input ............................................................................................................................ 18

3.3.7 Digital Output ......................................................................................................................... 18

3.3.8 Analog Input .......................................................................................................................... 18

3.3.9 Analog Output........................................................................................................................ 19

3.3.10 USB Communications ........................................................................................................... 19

3.4 De-rating ......................................................................................................................19

2

3.5 Peak Current Fold-back (I

t) .........................................................................................20

4 Hardware Installation ............................................................................................ 21

4.1 Mechanical Mounting ...................................................................................................21

4.2 Dimensions ..................................................................................................................21

4.3 Mating Connectors .......................................................................................................21

4.4 Connector Locations and Pin Numbers ........................................................................22

4.4.1 Connector Layout .................................................................................................................. 22

© ElectroCraft 2018 3 CPP-A12V80A-SA-USB Technical Reference

4.4.2 J1 Supply Connector Pinout .................................................................................................. 22

4.4.3 J2 Motor Connector Pinout .................................................................................................... 22

4.4.4 J3 Hall Connector Pinout ....................................................................................................... 22

4.4.5 J4 Encoder Connector Pinout ............................................................................................... 23

4.4.6 J5 I/O Connector Pinout ........................................................................................................ 23

4.4.7 J6 USB Communications Connector Pinout ......................................................................... 23

5 Connecting Power ................................................................................................. 24

5.1 Power supply ...............................................................................................................24

6 Connecting Motors ................................................................................................ 25

6.1 Brushless DC Motor .....................................................................................................25

6.2 Permanent Magnet DC (PMDC) Motor .........................................................................25

6.3 Stepper Motor ..............................................................................................................25

7 Connecting Motor Feedback Devices .................................................................. 26

7.1 Hall Sensors .................................................................................................................26

7.1.1 Hall Sensor Connections ....................................................................................................... 26

7.1.2 Hall Sensor Signal Input Circuit ............................................................................................. 26

7.2 Incremental Encoder ....................................................................................................26

7.2.1 Differential Encoder ............................................................................................................... 26

7.2.2 Single-Ended Encoder .......................................................................................................... 27

7.2.3 Encoder Input Circuit ............................................................................................................. 27

7.3 IxR Speed Feedback Estimator ....................................................................................27

7.4 Motor Temperature Sensor ..........................................................................................28

7.4.1 Temperature Sensor Connections ........................................................................................ 28

7.4.2 Temperature Sensor Signal Input Circuit .............................................................................. 28

8 Connecting I/O ....................................................................................................... 29

8.1 I/O Functional Description ............................................................................................29

8.2 Minimum I/O Connections ............................................................................................30

8.2.1 Minimum I/O Connections for BLDC and PMDC motors ...................................................... 30

8.2.2 Minimum I/O Connections for Stepper motor ........................................................................ 30

8.3 Digital Inputs and Outputs ............................................................................................31

8.3.1 Digital Input Circuit ................................................................................................................ 31

8.3.2 Digital Output Circuit ............................................................................................................. 31

8.4 Analog Inputs and Outputs ...........................................................................................32

8.4.1 Analog Input Circuit ............................................................................................................... 32

8.4.2 Analog Output Circuit ............................................................................................................ 32

9 Communication ..................................................................................................... 33

9.1 Connecting USB ...........................................................................................................33

10 Introduction to ElectroCraft CompleteArchitect™ PC Software .................... 33

11 First Time Operation .......................................................................................... 33

12 Adding an External Brake Resistor .................................................................. 34

12.1 Caution Statement ....................................................................................................34

12.2 Brake Resistor Theory of Operation ..........................................................................34

© ElectroCraft 2018 4 CPP-A12V80A-SA-USB Technical Reference

12.3 Selecting External Brake Resistor .............................................................................35

12.3.1 Calculating resistance value of the braking resistor .............................................................. 35

12.3.2 Calculating power value of the braking resistor .................................................................... 36

12.4 Minimum external bulk capacitance ..........................................................................37

12.5 Connecting External Brake Resistor and Bulk Capacitor ...........................................37

12.6 ElectroCraft Braking Module Assembly .....................................................................38

13 Troubleshooting ................................................................................................. 39

13.1 Status LED (Red) ......................................................................................................39

13.2 Power LED (Green) ..................................................................................................40

© ElectroCraft 2018 5 CPP-A12V80A-SA-USB Technical Reference

Table of Figures

FIGURE 1: OVERALL DRIVE SYSTEM BLOCK DIAGRAM ...................................................................... 12

FIGURE 2: TRAPEZOIDAL COMMUTATION WITH HALL SENSOR FEEDBACK ................................... 13

FIGURE 3: SINUSOIDAL COMMUTATION WITH HALL SENSOR FEEDBACK ...................................... 14

FIGURE 4: STEPPER MOTOR PHASE CURRENT WAVEFORM ............................................................ 15

FIGURE 5: ENCODER FEEDBACK SIGNAL ............................................................................................. 16

FIGURE 6: DRIVE WITH IDENTIFYING LABEL ........................................................................................ 16

FIGURE 7: I2T ALGORITHM EXAMPLE..................................................................................................... 20

FIGURE 8: DRIVE DIMENSIONS ............................................................................................................... 21

FIGURE 9: DRIVE CONNECTOR LAYOUT ............................................................................................... 22

FIGURE 10: POWER SUPPLY CONNECTION TO THE DRIVE ............................................................... 24

FIGURE 11: BRUSHLESS DC MOTOR CONNECTION TO THE DRIVE ................................................. 25

FIGURE 12: PERMANENT MAGNET DC MOTOR CONNECTION TO THE DRIVE ................................ 25

FIGURE 13: STEPPER MOTOR CONNECTION TO THE DRIVE ............................................................. 25

FIGURE 14: HALL SENSOR CONNECTION TO THE DRIVE ................................................................... 26

FIGURE 15: HALL SENSOR SIGNAL INPUT CIRCUIT ............................................................................ 26

FIGURE 16: DIFFERENTIAL ENCODER CONNECTION TO THE DRIVE ............................................... 26

FIGURE 17: SINGLE-ENDED ENCODER CONNECTION TO THE DRIVE .............................................. 27

FIGURE 18: ENCODER SIGNAL-ENDED INPUT CIRCUIT ...................................................................... 27

FIGURE 19: TEMPERATURE SENSOR CONNECTION TO THE DRIVE ................................................ 28

FIGURE 20: TEMPERATURE SENSOR SIGNAL INPUT CIRCUIT .......................................................... 28

FIGURE 21: MINIMUM DRIVE I/O CONNECTIONS NEEDED TO OPERATE BLDC AND PMDC MOTOR

............................................................................................................................................................. 30

FIGURE 22: MINIMUM DRIVE I/O CONNECTION NEEDED TO OPERATE STEPPER MOTOR ........... 30

FIGURE 23: DIGITAL INPUT CIRCUIT ...................................................................................................... 31

FIGURE 24: DIGITAL OUTPUT CIRCUIT .................................................................................................. 31

FIGURE 25: ANALOG INPUT CIRCUIT ..................................................................................................... 32

FIGURE 26: ANALOG OUTPUT CIRCUIT ................................................................................................. 32

FIGURE 24: USB CABLE CONNECTION BETWEEN COMPUTER AND DRIVE ..................................... 33

FIGURE 28: BRAKE RESISTOR OPERATION GRAPH ............................................................................ 34

FIGURE 29: EXTERNAL BRAKE RESISTOR AND BULK CAPACITOR CONNECTION TO THE DRIVE

............................................................................................................................................................. 37

FIGURE 30: ELECTROCRAFT BRAKING MODULE ................................................................................. 38

© ElectroCraft 2018 6 CPP-A12V80A-SA-USB Technical Reference

1 Product Safety Precautions

READ THIS ENTIRE SECTION BEFORE ATTEMPTING TO USE THE CPP-A12V80A-SA-USB DRIVE!
GIVE SPECIAL ATTENTION TO ALL BOLD PRINT ITEMS.

WARNING!

ElectroCraft products are not authorized for use in safety critical applications. To operate the drive safely,
these minimum precautions MUST be followed to insure proper performance without injury to the operator
and damage to motor or drive. FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS COULD

RESULT IN SERIOUS BODILY INJURY, INCLUDING DEATH IN EXTREME CASES.

1.1 Operation

1. Do not touch any of the connector pins on connectors J1 (Supply Input) or J2 (Motor Output)
when power has been applied. Bare wires from adjacent connector pins must never be allowed to
touch one another.

2. J1 pin 3 must be connected to an external earth ground. Follow wiring procedures carefully.

3. Read ElectroCraft Life Support Policy in section 1.6 for application limitations.

4. Follow precautionary guidelines as referenced in section 12 of this manual with regard to proper
installation of an optional external brake resistor.

5. Do not operate the drive in an explosive area or near explosive or flammable materials.

6. Do not use the drive in environments where it is likely to be exposed to strong and/or frequent
static discharge.

7. Conduct trial operations on the servo drive alone with the motor shaft disconnected from the load
to avoid any unexpected motion. Motor shaft should be uncoupled and free to rotate without
coming in contact with user or any stationary object during set up and preliminary operation.

8. Under no circumstances should a phase output from the control be connected to anything other
than a passive inductive/resistive motor load. Short circuit protection for the drive is limited to
momentary conditions only! Repetitive short circuits on any of the output pins of J2 may cause
permanent damage to the drive.

9. Never touch any moving parts while the motor is running. Failure to observe this warning may
result in injury.

10. Excessive speed and current can destroy some motors and possibly injure the user. Check the
motor manufacturer's specifications to ensure that the maximum current and voltage for your
drive model, does not exceed motor limitations.

11. Whenever the drive is disabled for any reason or unpowered, the motor will be in free
spinning/coast mode. The user is responsible to analyze the application (especially in case of
servomotor for a vertical axis) and take precautionary safety measures.

12. Provide an appropriate stopping device on the machine side to ensure safety. Failure to observe
this warning may result in injury.

13. Do not parallel multiple motors off the same drive.

© ElectroCraft 2018 7 CPP-A12V80A-SA-USB Technical Reference

14. Do not make any extreme adjustments or settings changes of parameters. Failure to observe this
caution may result in injury due to unstable operation.

15. Avoid plugging connector J1 into the drive while live power is applied to the connecting cables.
Ignoring this precaution will cause electrical arcing at the connector pins, which can cause
permanent connector damage. ElectroCraft recommends using a disconnect switch ahead of J1 if
the drive must be disconnected often.

16. Do not remove the connectors on ports J1 through J6 from the drive while the motor is operating.

17. Do not service or modify this product. Only authorized personnel must perform disassembly or
repair of the drive. Failure to observe warning may result in injury or damage to product.

18. Always operate the drive within the prescribed voltage limits. Any attempt to operate outside
these bounds may result in damage to the drive.

19. Safe use of this product depends on factors specific to the end application. These factors are
outside of ElectroCraft knowledge and control. The installer of this servo drive must have a
thorough knowledge of safety precautions and practices relevant to the specific application of this
drive. In particular the installer should consider the risks associated with erroneous or non­operation of the servo drive in the application and mitigate them appropriately.

1.2 Storage and Transportation

1. Do not store or install the product in the following places:
a. Locations subject to temperature outside of the range specified.
b. Locations subject to humidity outside the range specified.
c. Locations subject to condensation as the result of changes in temperature.
d. Locations subject to corrosive or flammable gases and liquids.
e. Locations subject to dust, salts, or electrically conductive contaminants.
f. Locations subject to exposure to water, oil, or chemicals.
g. Locations subject to shock or vibration.

Failure to observe this caution may result in fire, electric shock, or damage to the product.

2. Do not hold the product by the cables or motor shaft while transporting it. Failure to observe this
caution may result in injury or malfunction.

1.3 Environmental Protection

Waste electrical products should not be disposed of with household waste. Please recycle where facilities
exist. Check with your Local Authority or retailer for recycling.

© ElectroCraft 2018 8 CPP-A12V80A-SA-USB Technical Reference

1.4 Installation

1. Take appropriate and sufficient countermeasures when installing systems in the following
locations.
a. Locations subject to static electricity or other forms of noise.
b. Locations subject to strong electromagnetic fields and magnetic fields.
c. Locations subject to possible exposure to radioactivity.
d. Locations close to power supplies including power lines.
Failure to observe this caution may result in damage to the product.

2. Keep any external shunt/brake resistor away from flammable materials. Read section 12 carefully
for more shunt/brake resistor installation details.

3. Never use this product in an environment subject to liquids, corrosive chemicals or gases; or
combustibles; or where foreign materials can fall onto or collect inside the drive. Failure to
observe this caution may result in electric shock or fire.

4. Do not place any objects on the product. Failure to observe this warning may result in damage to
the product.

5. Do not cover the drive or prevent air from escaping or entering through the vents. Failure to
observe this caution may cause internal elements to deteriorate resulting in malfunction or fire.

6. Provide the specified clearance between the drive and other devices. Provide sufficient space
around the drive for cooling by natural convection or provide cooling fans to prevent excessive
heat. See section 4 for details. Failure to observe this caution may result in fire or malfunction.

1.5 Wiring

1. Verify ALL wiring BEFORE applying power to the drive and motor. Motor may spin or oscillate
uncontrollably if improperly wired. Drive may be damaged or improper wiring may prevent drive
from operation.

2. J1 pin 5, PE, MUST always be connected to an appropriate external Protective Earth ground in
accordance with local electrical codes. Improper grounding may result in electric shock and
damage the drive.

3. Securely connect the power supply terminals and motor output terminals. Failure to observe this
caution may result in fire.

4. Do not bundle or run power and signal lines together in the same duct. Keep power and signal
lines separated.

5. Use twisted-pair shielded wires or multi-core twisted pair shielded wires for signal and encoder
feedback lines.

6. Always use the specified power supply voltage. An incorrect power supply may result in damage
to the drive.

© ElectroCraft 2018 9 CPP-A12V80A-SA-USB Technical Reference

Installation requirements for EMC CE compliance:

For EMC compliance, correct cable selection and wiring practices are mandatory. The following contains
installation instructions necessary for meeting EMC requirements.

• Power interface cable that supply power to the drive should not exceed 3m (9.84ft) in length.

• Motor cables should not exceed 10m (32.8ft) in length without consulting factory. For best results

use Electrocraft series cables.

• Shielded cables are mandatory for the motor, power and control cabling to the drive. The power
and motor cables must be bonded to earth at both ends and the control bonded to earth at one
end. The shield of the cable must be grounded at the closed ground point with the least amount
of resistance.

• Segregate the drive power wiring and motor phase cables from the control wiring and feedback
cabling. When using shielded cables for the power wiring, provide a grounded 360 degree clamp
termination at both ends. Provide for a large contact area between shields and the mounting
plate.

• The J5 I/O port requires an external ferrite located close to the mating connector, with cable
passing once through the ferrite. Fair-Rite – 0431176451 or equivalent is required for compliance.

1.6 Life Support Policy

READ THIS ENTIRE SECTION BEFORE ATTEMPTING TO USE THE CPP-A12V80A-SA-USB DRIVE!

ElectroCraft products are not authorized for use as critical components in life support devices or systems
without the express written approval from ElectroCraft, Incorporated.

1. Life support devices or systems are intended for surgical implant into the body, or support or
sustain life, and whose failure to perform, when properly used in accordance with instructions for
use provided in the User's Manual and in the labeling, can be reasonably expected to result in a
significant injury to the user.

2. A critical component is any component of a life support device or system whose failure to perform
can be reasonably expected to cause the failure of the life support device or system, or to affect
its safety or effectiveness.

© ElectroCraft 2018 10 CPP-A12V80A-SA-USB Technical Reference

1.7 Checking Product on Delivery

When your package arrives, inspect the shipping box and the unit carefully, and save ALL packing
materials. Compare the packing slip against all items included in the shipping box. Any shortages or
other inspection problems should be reported to ElectroCraft immediately.

The following procedure is used to check products upon delivery. Check the following items when your
CPP-A12V80A-SA-USB is delivered.

• Verify that the model number marked on the nameplate of the drive(s) is the correct model
ordered.

• Check the overall appearance. Check for damage or scratches that may have occurred during
shipping.

If any damage is noted, or if the unit is the wrong type, contact your ElectroCraft sales representative
immediately.

Your CPP-A12V80A-SA-USB has arrived carefully packaged from ElectroCraft, in an antistatic bag. As
you unseal this bag, inspect the contents carefully. There should not be any loose or damaged parts
inside.

Never attempt to operate or power-up the drive if there is any visible external damage or if there are loose
materials inside the chassis. While unpacking, if you discover any loose or damaged parts, notify
ElectroCraft within two working days.

ElectroCraft recommends that all packing materials be saved in the event that the drive needs to be
returned. Always place the drive in the same antistatic bag used in the original shipment. Anti-static filler
material should always be placed around the drive so that it cannot shift inside the box. Extreme care
should be exercised when placing packing material around all external connectors to prevent mechanical
stress damage.

All material to be returned to ElectroCraft must have a Return Material Authorization (RMA) tracking
number assigned before shipment. This can be obtained by contacting ElectroCraft. Any product
returned without this number will be rejected by ElectroCraft.

Always insure your shipment for the proper replacement value of its contents. ElectroCraft will not
assume responsibility for any returned goods that have been damaged outside of our factory because of
improper packaging or handling. All goods shipped to ElectroCraft must be shipped FREIGHT PREPAID.

© ElectroCraft 2018 11 CPP-A12V80A-SA-USB Technical Reference

Drive

Power Supply

I/O

PC Software

Motor

Fee dback

2 Product Overview

This manual describes the installation and operation of the CPP-A12V80A-SA-USB digital servo-amplifier
manufactured by ElectroCraft Inc.

2.1 Key Features

Features of CPP-A12V80A-SA-USB drive:

• +12 to +80 VDC power supply input.

• 12 Amps Continuous, 30 Amps Peak (2 seconds).

• 2 and 4 quadrant modes.

• Sinusoidal and Trapezoidal commutation modes.

• 20 kHz, 40 kHz and 80 kHz of programmable PWM frequency options.

• Current, Speed, Position and Position with Speed modes of operation.

• USB Communication.

• Drive status diagnostics.

• +/-10V Analog command input.

• Digital step and direction input.

• +/-10V Analog output (configurable).

• Encoder mode for low speed performance.

• BLDC, PMDC and Stepper motor control.

• Halls only operation mode for BLDC motor.

• IxR speed feedback estimator mode for PMDC motor.

• Integrated circuit for brake regeneration.

• +/- Travel limit inputs.

• Configurable ramp for current and speed.

• 97% efficiency at full load.

• Selectable software protection options.

• Windows®-based set-up and tuning utility software included.

Note: The CPP-A12V80A-SA-USB drive can be configured by the software through USB even when there
is no power supply provided.

2.2 Simplified System Block Diagram

Overall system of CPP-A12V80A-SA-USB is shown in Figure 1. The drive is configured using the
software to operate the motor according to its application.

© ElectroCraft 2018 12 CPP-A12V80A-SA-USB Technical Reference

Figure 1: Overall drive system block diagram

Motor Ph ase A

Motor Ph ase B

Motor Ph ase C

Hall Sensor 1

Hall Sensor 2

Hall Sensor 3

60° 120° 180° 240° 300° 360° 60° 120° 180° 240° 300° 360°

2.3 Hall Sensor Feedback

Drive is capable of operating the BLDC motor using trapezoidal (6-step) commutation with hall sensor
feedback as shown in Figure 2 and sinusoidal commutation with hall sensor feedback as shown in Figure

3.

Figure 2: Trapezoidal Commutation with Hall sensor feedback

© ElectroCraft 2018 13 CPP-A12V80A-SA-USB Technical Reference

Motor Ph ase A

Motor Ph ase B

Motor Ph ase C

Hall Sensor 1

Hall Sensor 2

Hall Sensor 3

60° 120° 180° 240° 300° 360° 60° 120° 180° 240° 300° 360°

Figure 3: Sinusoidal commutation with Hall sensor feedback

© ElectroCraft 2018 14 CPP-A12V80A-SA-USB Technical Reference

30° 60° 90° 120° 150° 180° 210° 240° 270° 300° 330° 360°

0°

Full Step / 1 Microstep per Step

Quarter Step / 4 Microsteps per Step

256 Microsteps per Step

Motor Ph ase A

Motor Ph ase B

Motor Ph ase A

Motor Ph ase B

Motor Ph ase A

Motor Ph ase B

2.4 Stepper motor Phase Current Waveforms for Different Step values

The drive is capable of operating the stepper motor in open-loop configuration from full step to 256
microsteps per step at a maximum step rate of 1MHz @ 50% ± 10%. The phase current wave forms for
full step, quarter step and 256 microsteps per step is shown in Figure 4.

Figure 4: Stepper motor Phase Current Waveform

© ElectroCraft 2018 15 CPP-A12V80A-SA-USB Technical Reference

Signal A leads B

by 90° Electrical

360°Electrical

Encoder Signal A

Encoder Signal B

Brushless

Motor

PMDC

Motor

Stepper

Motor

Hall Sensors

Yes

No

No

Encoder + Halls

Yes

No

No

Encoder Only

No

Yes

No

IxR Estimator

No

Yes

No

Identification label with

El ectroC ra ft serial number

2.5 Encoder Feedback

Drive counts the encoder lines in a positive direction, when encoder signal A leads encoder signal B by
90° electrical and vice-versa. This function can be reversed using the PC software. Encoder feedback
signal is shown in Figure 5.

Figure 5: Encoder feedback signal

2.6 Motor and Sensor Configurations

2.7 Identification Labels

2.8 Status Indicator Lights

In normal operation, the drive is either in an “Enabled” state or in a “Disabled” state. When power is first
applied, the green LED will be On indicating that power has been applied. The Red LED should be Off,
meaning no errors or faults. The Enable input is used to switch between “Enabled” and “Disabled” states.
Refer to section 13 for LED flash codes and possible causes.

© ElectroCraft 2018 16 CPP-A12V80A-SA-USB Technical Reference

Figure 6: Drive with identifying label

Parameter

Conditions

Typical

Units

Weight

Without mating connectors

180

g

Length x Width x Height
(without mating connectors)

109.5 x 85 x 23.33

mm

4.31 x 3.43 x 0.92

Inch

Parameter

Conditions

Min.

Typical

Max.

Units

Operating Range

0 - 40

Storage Range

-20 - 85

Ambient Humidity

Non-condensing

5 - 95

%RH

Parameter

Conditions

Min.

Typical

Max.

Units

Operating Range

12 - 80

Absolute maximum

10.5 - 90

Operating at maximum load and speed

-

12

30

A

Idle condition. No
external connections.

@ 12VDC

-

120

-

@ 80VDC

-

40

-

Parameter

Conditions

Min.

Typical

Max.

Units

Output Voltage

Operating Range

5

5.1

5.2

VDC

Total combined current on all
connectors

Parameter

Conditions

Min.

Typical

Max.

Units

Continuous with no additional heatsink

-12 - 12

Peak Current

-30 - 30

Peak Duration maximum
(see I2t section 3.5)

- 2 -

PWM Frequency

Configured by software

20 - 80

kHz

3 Drive Specifications

Using the drive outside the specified absolute maximum ratings will damage the drive. Using the drive
outside normal operating specifications may not guarantee a reliable operation.

3.1 Physical Specifications

Dimensions

3.2 Environmental Specifications

Ambient Temperature

3.3 Electrical Specifications

All ratings at ambient temperatures = 0 to 40°C and PWM frequency of 20 kHz, (unless otherwise noted)

3.3.1 DC Supply Input

Supply Voltage

Supply Current

3.3.2 +5VDC Supply Output

Output Current

- - 250 mA

3.3.3 Motor Output

°C

VDC

mA

Output Phase Current

* Values are peak of Sine

© ElectroCraft 2018 17 CPP-A12V80A-SA-USB Technical Reference

A*

s

3.3.4 Hall Sensor Inputs

Parameter

Conditions

Min.

Typical

Max.

Units

Operating Range

0 - 5.5

Logic “low” operating

0 - 1

Logic “high” operating

2.3 - 5

Logic “low” with internal 2.2K pull up to
+5V

-

-

Parameter

Conditions

Min.

Typical

Max.

Units

Logic “low” operating

0 - 1 V Logic “high” operating

2.3 - 5

Differential
(RS422)

High-threshold

- - 0.1

Low-threshold

-0.1 - -

Sinking and Sourcing
Current

Logic “low”, Sourcing

- 8 -

Logic “high”, Sinking

- 8 -

Single ended

- - 4

Differential - -

4

Minimum Pulse Width

Single ended and Differential

125 - -

nS

Input Impedance

Differential

-

120

-

Ω

Parameter

Conditions

Min.

Typical

Max.

Units

Logic High

2.3 - 24

Logic Low

0 - 1

Absolute maximum

- - 26

Sinking Current

Operational range when logic High

- - 5

mA

Sourcing Current

Operational range when logic Low

- - 33

µA

Frequency - -

1

MHz

Pulse Width

400 - -

nS

In 0, Enable,

Limit -

Frequency - -

2

kHz

Parameter

Conditions

Min.

Typical

Max.

Units

Operational range

0 5 24

Absolute Max

28

With external pull up to max operational
range voltage

150 - -

Absolute Max

112 - -

Parameter

Conditions

Min.

Typical

Max.

Units

Operational range

-10 - 10

Absolute maximum

-12 - 12

Sinking and Sourcing
Current

Input Voltage

Sourcing Current

3.3.5 Encoder Inputs

Input Voltage

Input Frequency

3.3.6 Digital Input

Input Voltage

Single ended

Single ended

2.3

V

mA

mA

MHz

V

Step, Direction

Input Frequency

Brake, Limit +,

Note: The drive registers a step pulse on the rising edge of the input pulse.

Pulse Width 200 - - µS

3.3.7 Digital Output

Output Voltage

Load impedance

3.3.8 Analog Input

Input Voltage

At operational range -0.2 - 0.2 mA

V

Ω

V

© ElectroCraft 2018 18 CPP-A12V80A-SA-USB Technical Reference

Parameter

Conditions

Min.

Typical

Max.

Units

Output Voltage

Operational range

-10 - 10

V

Load impedance

Connected to ground

10 - -

kΩ

Parameter

Conditions

Type

USB 2.0 compatible communications
interface

3.3.9 Analog Output

3.3.10 USB Communications

USB on the drive USB mini type B female

3.4 De-rating

The drive is protected against overheating. The protection mechanism employed is to shut off current to
the motor when the drive internal temperature reaches the maximum limit. The thermal performance of
the drive is dependent on the application and the environmental conditions. This section provides
guidance for application of the drive within the recommended operating conditions referenced in this
manual. However, thermal performance of the drive is dependent on the specifics of the application and
the environmental conditions.

The drive does not have any temperature or output PWM frequency derating in the ambient temperature
range of 0 to 40°C when mounted according to ElectroCraft recommendations as specified in section 4.1.
Operating the drive outside ElectroCraft recommendations or in a closed box and stagnant air may limit
maximum performance. Use of additional heatsinking or forced air may be required. For applications
outside ElectroCraft recommendations or in ambient temperature outside the limit of 0 to 40°C, please
contact ElectroCraft.

© ElectroCraft 2018 19 CPP-A12V80A-SA-USB Technical Reference

5

10

15

20

25

30

Current (A)

1

2

3

4

5 6

7

Time (S)

I2t limits c urre nt to

10 A aft er 2 seconds

3.5 Peak Current Fold-back (I2t)

Currents higher than rated continuous current may be required to achieve high momentary torques. The
drive and motor can withstand these higher peak currents for a limited time. To protect the drive and
motor, the drive will limit the time operated with peak current. The protection is implemented as an I
algorithm with a programmable peak current (I
time (T

). The values of peak current and continuous current (IC) are entered in the drive configuration

P

), rated current (IR) and I2t time which is the peak current

P

software. Rated current of the drive is set at 12A. The drive will not supply current above the peak current
value.

2

t algorithm integrates up towards the limit whenever the output current exceeds the continuous I2t

The I
current value and integrates down when the output current is below the continuous I
When the I
current limit value. The I

2

t algorithm limit is reached, the output current is reduced and limited to the continuous I2t

2

t time limit allowed by the software is computed using the equation given below.

2

t current value.

I2t algorithm limit = ((IP)2 – (IR)2) x T

P

Where, I
I
T

2

t time limit that the software allows is 2 seconds for a peak current of 30A and beyond that the drive

The I
limits the current to the I

= Peak phase current set by user (maximum of 30 A)

P

= Rated phase current of 12 A

R

2

= I

t time, in mS

P

2

t algorithm limit = 1512000 (preset)

I

2

t continuous current set in the software. The allowable I2t time limit increases

when the desired peak current value reduces.

Result of the I

2

t algorithm at maximum peak current of 30A and continuous current of 10A is shown in

Figure 7.

2

t

Figure 7: I

2

t time limit is computed by the software and any time value entered within the time limit computed is

The I
accepted by the software. If the entered time value is longer than the computed time limit, the software
defaults to the computed time limit. Additionally there is a preset maximum I

2

t algorithm example

2

t time limit of 30 seconds.

© ElectroCraft 2018 20 CPP-A12V80A-SA-USB Technical Reference

Units: mm [in]

Phoenix

1757022

Altech

SH03-5,08

Phoenix

1760006

Altech

SH05-5,08

Molex

43025-0800

43030-0007

Adam Tech

DMT-2-08

DMT-B-C-F-T-R

Adam Tech

DMT-2-10

DMT-B-C-F-T-R

Molex

43025-1600

43030-0007

Adam Tech

DMT-2-16

DMT-B-C-F-T-R

J6

USB

N/A

Miniature USB Type B - Male

N/A

-

Crimp tool for J3, J4, J5

Molex

0638190000

N/A

4 Hardware Installation

4.1 Mechanical Mounting

The drive is intended to be mounted on a metallic support which must act as a cooling heat sink, using
the provided mounting holes and the recommended mating connectors, as referenced in section 4.3.
Provide at least 25 mm (1 in) of clearance between drives or units and at least 100 mm (4 in) of clearance
above and below each drive when installing, for full rated operation of the drives or as needed for
unimpeded natural convection. Install the drive using the slots provided which can accommodate up to
M4 or #8 screw.

4.2 Dimensions

Figure 8: Drive dimensions

4.3 Mating Connectors

Connector Connector Name Manufacturer Mating Connectors P/N Crimp Pin P/N

J1 Supply

J2 Motor

J3 Hall

J4 Encoder

J5 I/O

Molex 43025-1000 43030-0007

N/A

N/A

© ElectroCraft 2018 21 CPP-A12V80A-SA-USB Technical Reference

J2

Moto r

J3

Hall

J4

Encoder

LED

J6

USBJ5I/O

J1

Supply

1

Gnd

Input

DC Power Input – Power supply return

2

Power

Input

DC Power Input – Power supply

3

PE

-

Connected to drive chassis

1

A / A+

Output

BLDC Phase A / Stepper Phase A+ / PMDC +

2

B / A-

Output

BLDC Phase B / Stepper Phase A- / PMDC -

3

C / B+

Output

BLDC Phase C / Stepper Phase B+

4

Brake / B-

Output

Braking Resistor / Stepper Phase B-

5

Frame

-

Connected to drive chassis

1

Hall 1

Input

Hall Signal A; Internal pull up to +5Vdc.

2

Hall 2

Input

Hall Signal B; Internal pull up to +5Vdc.

3

Hall 3

Input

Hall Signal C; Internal pull up to +5Vdc.

4

Temp+

Input

Motor Temperature Sensor Positive; Analog input.

5

Frame

-

Connected to drive chassis

6

+5V

OUT

Output

+5 Volts DC Power; Internally generated.

7

Gnd

-

Digital Ground; Return for hall signals.

8

Temp-

Input

Motor Temperature Negative; Return for Motor
Temperature Sensor.

4.4 Connector Locations and Pin Numbers

4.4.1 Connector Layout

Figure 9: Drive connector layout

4.4.2 J1 Supply Connector Pinout

Pin # Name I/O Description

4.4.3 J2 Motor Connector Pinout

Pin # Name I/O Description

4.4.4 J3 Hall Connector Pinout

Pin # Name I/O Description

© ElectroCraft 2018 22 CPP-A12V80A-SA-USB Technical Reference

4.4.5 J4 Encoder Connector Pinout

1

+5V

OUT

Output

+5 Volts DC Power; Internally generated.

2

+5V

OUT

Output

+5 Volts DC Power; Internally generated.

3

A+

Input

Encoder "A+" Signal; 0 to +5 Volt digital signal.

4

B+

Input

Encoder "B+" Signal; 0 to +5 Volt digital signal.

5

Z+

Input

Encoder "Z+" Signal; 0 to +5 Volt digital signal.

6

Frame

-

Connected to drive chassis

7

Gnd

-

Digital Ground; Return for encoder signals.

8

A-

Input

Encoder "A-" Signal; 0 to +5 Volt digital signal.

9

B-

Input

Encoder "B-" Signal; 0 to +5 Volt digital signal.

10

Z-

Input

Encoder "Z-" Signal; 0 to +5 Volt digital signal.

1

Frame

-

Connected to drive chassis

2

A In+

Input

Analog In+; Differential analog input.

3

Step

Input

Step; Digital input.

4

Limit+

Input

Limit Switch, Positive Direction; Digital input.

5

Enable

Input

Enable; Digital input. User selectable polarity.

6

Out0

Output

General purpose; Digital output.

7

Fault

Output

Fault; Digital output.

8

+5V

OUT

Output

+5 Volts DC Power; Internally generated.

9

A Out

Output

Analog Out; Analog output referenced to analog ground.

10

A In-

Input

Analog In-; Differential analog input.

11

Dir

Input

Direction; Digital input. User selectable polarity.

12

Limit-

Input

Limit Switch, Negative Direction; Digital input.

13

Brake

Input

Brake; Digital input.

14

In0

Input

General purpose; Digital input.

15

Ready

Output

Ready; Digital Output.

16

Gnd

-

Digital Ground; Return for digital I/O pins.

-

USB

In/Out

USB 2.0 compatible communications interface for drive
configuration.

Pin # Name I/O Description

4.4.6 J5 I/O Connector Pinout

Pin # Name I/O Description

4.4.7 J6 USB Communications Connector Pinout

Pin # Name I/O Description

© ElectroCraft 2018 23 CPP-A12V80A-SA-USB Technical Reference

5 Connecting Power

Drive

J1

+DC Po we r

-DC Po we r

DC Power

Supply

5.1 Power supply

Figure 10: Power supply connection to the drive

© ElectroCraft 2018 24 CPP-A12V80A-SA-USB Technical Reference

6 Connecting Motors

Motor Phase A

Motor Phase B

Motor Phase C

Drive

J2

Brushless

DC Motor

Motor Shield

Drive

J2

PMDC

Motor

Mo tor P osi tiv e

Motor Negative

Motor Shield

Drive

J2

Stepper

Motor

Motor Phase A+

Motor Phase A-

Motor Phase B+

Motor Shield

Motor Phase B-

6.1 Brushless DC Motor

Figure 11: Brushless DC motor connection to the drive

6.2 Permanent Magnet DC (PMDC) Motor

6.3 Stepper Motor

© ElectroCraft 2018 25 CPP-A12V80A-SA-USB Technical Reference

Figure 12: Permanent Magnet DC motor connection to the drive

Figure 13: Stepper motor connection to the drive

Hall 2

Hall 3

+5V

Drive

Ground

J3

Hall 1

Brushless

Motor

Hall Sensors

+5V

+5V

Hall

Signal

Input

1KΩ

4700pF

2.2KΩ

Drive

J4

Use twis ted w ire

pairs for + an d –

signal pairs of A, B

an d Z

B-

B+

Z+

Z-

A-

A+

Motor

Encoder

+5V
GND

7 Connecting Motor Feedback Devices

7.1 Hall Sensors

7.1.1 Hall Sensor Connections

Figure 14: Hall sensor connection to the drive

7.1.2 Hall Sensor Signal Input Circuit

The Hall sensor inputs are limited to +5V logic levels. Use the drive supplied +5V to supply power to the
motor’s hall sensors.

Figure 15: Hall sensor signal input circuit

7.2 Incremental Encoder

7.2.1 Differential Encoder

Figure 16: Differential encoder connection to the drive

© ElectroCraft 2018 26 CPP-A12V80A-SA-USB Technical Reference

7.2.2 Single-Ended Encoder

Encoder A

Encoder B

Encoder Index

Drive

Ground

+5V

J4

Motor

Encoder

+5V

Encoder +

Signal Input

120 Ω

+5V

Encoder -

Signal Input

Figure 17: Single-ended encoder connection to the drive

7.2.3 Encoder Input Circuit

The encoder inputs are limited to +5V logic levels. Use the drive supplied +5V to supply power to the
motor’s encoder.

Figure 18: Encoder signal-ended input circuit

Note: For single ended encoder feedback, use signals A+, B+, Z+ and leave signals A-, B-, Z-

unconnected as shown in section 7.2.2. Select ‘Single Ended Encoder’ in the drive configuration
software.

7.3 IxR Speed Feedback Estimator

The IxR Speed Feedback Estimator is used to estimate motor speed when an actual speed feedback
device (an encoder or other sensor) is unavailable. The drive estimates the speed of the motor using the
Motor’s Resistance and Ke. Refer CompleteArchitect
calibrating the IxR Speed Feedback Estimator.

TM

software manual for more information about

© ElectroCraft 2018 27 CPP-A12V80A-SA-USB Technical Reference

Temp Sensor

Temp Sensor

Motor

J3

Drive

J3

Motor

Temperature

Input

+5V

100KΩ

+

_

100KΩ

4700pF

100KΩ

100KΩ

1KΩ

+5V

1uF

680Ω

7.4 Motor Temperature Sensor

A motor over-temperature protection function is provided by the drive. The drive is designed to be
compatible with standard Electrocraft motors equipped with a thermistor temperature sensor. However
the drive is capable of interfacing with any resistance based temperature sensor that meets the following
criteria.

• The resistance of the temperature sensor decreases with increasing temperature.

• The resistance at the maximum motor temperature is 1kΩ (typical).

• The sensor is isolated from any voltage sources (the drive provides the necessary excitation)

This sensor is commonly a thermistor or a normally open temperature switch that closes at the desired
shutdown temperature. If motor over temperature function is not used, the connections must be left open.
Contact the factory for applications with temperature sensors that do not match these specifications.

7.4.1 Temperature Sensor Connections

Figure 19: Temperature sensor connection to the drive

7.4.2 Temperature Sensor Signal Input Circuit

Figure 20: Temperature sensor signal input circuit

© ElectroCraft 2018 28 CPP-A12V80A-SA-USB Technical Reference

8 Connecting I/O

I/O Pin Name

Type

Functional Description

Frame

-

Shield Connection.

Analog Input
Positive

-10V to +10V input signal for speed or current command. The scaling of input
voltage to motor output is configured in the setup software.

-10V to +10V input signal for speed or current command. The scaling of input

analog signal connection, this pin should be connected to ground.

-10V to +10V output signal which represents the motor speed or current. The
scaling of motor output to output voltage is configured in the setup software.

Step

Digital Input

The rising edge of each input pulse is accepted as one step pulse by the drive.

When the input signal is active low, it reverses the speed or current command.
This in turn changes the direction of motor rotation.

Out 0

Digital Output

Unused, do not connect.

In 0

Digital Input

Unused, do not connect.

Fault

Digital Output

Open collector output that pulls to ground when the drive is in a faulted state.

Ready

Digital Output

Open collector output that pulls to ground when the drive is ready.

Input which enables the drive when an active low signal is applied and

this input should be toggled from high to active low to re-enable the drive.

Brake

Digital Input

Input pin which dynamically brakes the motor when it’s active low.

Input pin which controls the positive current delivered to the motor. When the

the motor.

Input pin which controls the negative current delivered to the motor. When the

to the motor.

+5 Vout

Output

Internally generated +5 volts for customer use. Refer to section 3.3.2.

Ground

-

Referenced to supply ground.

8.1 I/O Functional Description

Analog Input

Analog Input
Negative

Analog Output

Direction

Enable

Limit Switch
Positive

Limit Switch
Negative

Analog Input

Analog Output

Digital Input

Digital Input

Digital Input

Digital Input

voltage to motor output is configured in the setup software. For a single ended

disables the drive when a high signal is applied. The signal needs to be kept
low for the drive to remain enabled. In case of any drive interruptions or faults,

Limit switch positive is active low, the drive stops delivering positive current to

Limit switch negative is active low, the drive stops delivering negative current

© ElectroCraft 2018 29 CPP-A12V80A-SA-USB Technical Reference

Drive

J5

Dri v e

Enable

Comman d

(Speed or Torque)

10K Ω

Command

Dir ec tion

Drive

J5

Dri v e

Enable

Dir ec tion

(Fr om C ont roll er)

Ste p

(Fr om C ont roll er)

8.2 Minimum I/O Connections

8.2.1 Minimum I/O Connections for BLDC and PMDC motors

The drive requires an Enable signal and speed, torque or position command signal to operate. A basic
example using a switch for the Enable signal, a potentiometer for analog speed/torque command and a
switch to change motor direction is shown in Figure 21.

Figure 21: Minimum drive I/O connections needed to operate BLDC and PMDC motor

8.2.2 Minimum I/O Connections for Stepper motor

The drive requires an Enable, Step and Direction digital input signal to operate. A basic example using a
switch for the Enable signal and digital pulse input for Step and Direction from a controller is shown in
Figure 22.

Figure 22: Minimum drive I/O connection needed to operate stepper motor

© ElectroCraft 2018 30 CPP-A12V80A-SA-USB Technical Reference

8.3 Digital Inputs and Outputs

+3.3V

+3.3V

Digital

Input

R

C

100KΩ

+5V

Digital

Output

590Ω

47V

8.3.1 Digital Input Circuit

Note: For Step and Direction digital inputs R = 10KΩ and C = 10pF. For In 0, Enable, Brake, Limit Switch
Positive and Limit Switch Negative digital inputs R= 20KΩ and C = 4700pF.

Figure 23: Digital input circuit

8.3.2 Digital Output Circuit

Figure 24: Digital output circuit

© ElectroCraft 2018 31 CPP-A12V80A-SA-USB Technical Reference

Analog +

Input

Analog -

Input

+12V

4.99K Ω

4.99K Ω

4.99K Ω

+2.5V

34K Ω

34K Ω

+

_

4.99K Ω

47pF

-12V

-12V

+12V

Analog
Output

+12V

-12V

PTC

+

_

33.2K Ω

47pF

2.32K Ω

8.4 Analog Inputs and Outputs

8.4.1 Analog Input Circuit

The scaling and offset for the analog input is configurable using the drive setup software.

Figure 25: Analog input circuit

Note: For single-ended operation, connect single ended analog input signals to Analog+ and connect
Analog– to analog ground.

8.4.2 Analog Output Circuit

The scaling for the analog output is configurable using the drive setup software.

Figure 26: Analog output circuit

Note: The single ended analog output is referenced to ground on J5 pin 16.

© ElectroCraft 2018 32 CPP-A12V80A-SA-USB Technical Reference

USB Type A - Ma le USB Mini Type B - Ma le

PC Soft ware

Drive

9 Communication

9.1 Connecting USB

An USB Type A Male to Mini USB Type B Male cable is required to connect the drive to the PC software.
Insert the USB Type A Male connector to the computer and Mini USB Type B Male to the drive as shown
in Figure 24. Follow steps as specified in the setup software user manual to establish communication
between PC software and drive.

Figure 27: USB cable connection between computer and drive

10 Introduction to ElectroCraft CompleteArchitect™ PC Software

ElectroCraft CompleteArchitect™ is a Windows-based program used for setup, configuration, system

diagnostics and motion control management. The CompleteArchitect user manual A11402 will lead the
user through a step-by-step Wizard to create the correct configuration and information required for the
user to run a particular motor with CPP-A12V80A-SA-USB drive. The result will be an “Application”
containing all of the configuration information required to operate the motor with the drive. Please refer to
the CompleteArchitect user manual for full documentation support to properly configure and operate the
drive.

Windows is a registered trademark of the Microsoft Corporation.

11 First Time Operation

To get started, proceed as follows:

1. Install ElectroCraft CompletePower Plus Universal Drive Configuration Tool onto user PC and
open the software window.

2. Connect I/O, motor phase and feedback wires to the drive. Make sure the Enable switch is in the
OFF position.

3. Supply required power to the drive (within the voltage and current range as specified in section

3) to operate the motor.

4. Establish communications between drive and PC software using the USB cable.

5. Use the configuration software to configure the drive settings. Refer to section 10 for details on
Software settings.

If the drive does not function, refer to Troubleshooting section 13.

© ElectroCraft 2018 33 CPP-A12V80A-SA-USB Technical Reference

Time (S)

On

Off

Power supply voltage (V)

On volta ge (V)

Off voltage (V)

Resistor On Ti me

Brake resi stor

Brake resi stor

12 Adding an External Brake Resistor

12.1 Caution Statement

CAUTION!

WHEN THIS PRODUCT USES THE OPTIONAL EXTERNAL BRAKE RESISTOR OR THE BRAKING
ASSEMBLY, PRECAUTIONS MUST BE FOLLOWED TO PREVENT A POSSIBLE FIRE HAZARD.

Never mount the braking resistor or braking assembly where it can make contact with flammable
materials, flammable liquid and/or flammable chemicals. Never use the drive, either with or without a
brake resistor or braking assembly of any type, in an explosive atmosphere. Never place the braking
resistor or braking assembly in the proximity of flammable materials that could melt or drop upon the
brake resistor or braking assembly body.

12.2 Brake Resistor Theory of Operation

During motor deceleration, the motor behaves as a generator i.e. mechanical energy is converted into
electrical energy. A braking resistor is used to dissipate this energy as heat.

The brake resistor is connected to the drive as shown in section 12.5. The user specifies the brake
resistor On and Off voltage in the drive configuration software. During motor deceleration, when the bus
voltage rises up to the brake resistor On voltage, the drive connects the braking resistor across the
positive terminal of the supply input and ground. This causes current to flow through the resistor and
reduce the bus voltage. When the bus voltage decreases to the brake resistor Off voltage, the drive
disconnects the brake resistor circuit. This cycle repeats until the system dissipates enough energy
beyond which the bus voltage doesn’t rise up to brake resistor On voltage.

The resistor On time is the time taken for the bus voltage to drop from the brake resistor On voltage to Off
voltage. The drive is designed such that if the resistor On time is greater than 3 seconds, it triggers a fault
condition in the drive and the drive turns off its motor outputs. The Figure 28 shows the behavior of bus
voltage in coordination with braking resistor’s On and Off time.

It is important to use an external temperature sensitive device (switch or fuse) installed in close proximity
to the brake resistor. The device opens when the braking resistor gets too hot to prevent overheating. The
drive faults due to shunt overpower when the braking resistor is disconnected from the drive while
braking. The user supplied temperature sensitive device must be rated to a current equal or more than
the maximum deceleration current. Refer section 12.5 for wiring an external temperature sensitive switch
to the drive.

© ElectroCraft 2018 34 CPP-A12V80A-SA-USB Technical Reference

Figure 28: Brake resistor operation graph

12 1 24 2 48 4 60 5 80

6.66

12.3 Selecting External Brake Resistor

For properly sizing the resistor, a complex calculation requiring detailed information about the application
and load is needed. This data is often not known or difficult to obtain, so ElectroCraft has provided the
following guideline as a starting point which has proven sufficient in the majority of applications. If further
support is needed or this recommendation does not provide the required performance please contact
ElectroCraft.

12.3.1 Calculating resistance value of the braking resistor

The resistance value of the braking resistor and the power supply voltage will determine the rate at which
energy is dissipated in it. The minimum resistance can be calculated from the following equation.

Minimum Resistance value

=

    ℎ 

The next nearest resistor higher than the calculated value should be selected.

The table below gives the minimum resistance values for standard power supply voltages at drive
continuous current of 12A. Use the equation above to calculate the maximum resistance value for other
supply voltage and drive continuous current/deceleration current.

 

Deceleration Current

(A)

12

The resistance value for appropriate power supply voltage (when brake resistor On and Off voltages are
set according to section 12.3.2) in the above table is a good starting point. Increase the resistance value
for lower deceleration current.

Drive faults due to Shunt Overpower or Bus Overvoltage (refer section 13 for drive fault codes) indicates
that the resistor is not dissipating enough power. A lower value resistor or lower deceleration current may
be required.

Power Supply Voltage

(Vdc)

Minimum Resistance value

(Ω)

© ElectroCraft 2018 35 CPP-A12V80A-SA-USB Technical Reference

Parameter

Value

Unit

Total cycle Time

10

Seconds

Time in Braking

4

Seconds

Volts during braking

52

Volts

Deceleration
current

12

Amps

12.3.2 Calculating power value of the braking resistor

The power rating of a braking resistor decides its maximum heat capacity. A brake resistor with large heat
capacity can dissipate large amount of energy without the temperature of the resistor element exceeding
the operational (safe) temperature rating.

Maximum Power value = Resistor On voltage x Maximum deceleration current of the motor

The On voltage and Off voltage of the brake resistor is programmed into the drive by the user via the PC
configuration software. Brake resistor On and Off voltages are calculated as given below:

Brake resistor On voltage = Power supply output voltage + 4 volts

Brake resistor Off voltage = Power supply output voltage + 2 volts

An example to calculate the maximum power of a braking resistor with a power supply voltage of 48 V
and motor deceleration current of 12 A is as follows:

Maximum Power value = (48 + 4) x 12 = 624 Watts

The power rating of the braking resistor need not be the maximum value as the value of power dissipated
across the resistor depends on the duty cycle of braking.

Duty Cycle = Time in Braking / Total cycle Time

Calculation for average power value of the braking resistor using duty cycle is as follows:

Average Power value = Resistor On voltage x Maximum deceleration current of the motor x Duty Cycle

For example, consider an application with power supply voltage of 48 V and motor deceleration current of
12 A, so a 4 ohm resistor is picked (according to section 12.3.1). The load accelerates for 6 seconds and
brakes for 4 seconds, which gives a total cycle time of 10 seconds. Example parameters are referenced
in the table below:

Therefore, in this example a 250 Watts resistor will be able to handle the braking power of 624 watts for 4
seconds and cools down for 6 seconds as long as the maximum current of the resistor is not exceeded
and the thermal sensitive switch does not trip.

Considering the same application as referenced in the above example but the “Total cycle Time” is 10
minutes and “Time in Braking” is 4 minutes.

A 250 watts resistor will not handle 624 watts of braking power for 4 minutes. The brake resistor will get
too hot and it will trip the user supplied temperature sensitive switch (refer to section 12.5), in turn
disconnecting the braking resistor from the drive. The drive will then fault due to shunt overpower or bus
over voltage after the braking resistor is disconnected from the drive while braking. Hence, the Average
power value of the resistor also gets affected by the duration of the braking time. The selected power
rating for any external brake resistor is application dependent. Usually a heavy-duty wire wound resistor
will work best.

© ElectroCraft 2018 36 CPP-A12V80A-SA-USB Technical Reference

Duty Cycle = 4/10 = 0.4

Average Power value = 52 x 12 x 0.4 = 250 Watts

Duty Cycle = 4/10 = 0.4

Average Power value = 250 Watts

Drive

J2

J1

+DC Po we r

-DC Po we r

DC Power

Supply

+

Bul k

Capa citor

Dio de

Br ake

Resistor

Temperature

Sen sitive Devic e

12.4 Minimum external bulk capacitance

A bulk capacitor is used to delay the bus voltage rising up to the brake resistor On voltage during braking.
This increases the braking resistor Off time, in turn giving more time for the brake resistor to cool. The
capacitor must be rated to a voltage equal or higher than the brake resistor On voltage (set in the
configuration software).

ElectroCraft recommends connecting a capacitor of 100 μF per each ampere deceleration current across
J1 pin 1 and pin 2 as shown in section 12.5. For example, the application given in section 12.3.2 has a
deceleration current of 12 A, so it will need a 1200 μF capacitor. This recommendation has proven
sufficient in the majority of applications. If further support is needed or this recommendation does not
provide the required performance please contact ElectroCraft.

WARNING!

Installing capacitance value lesser than 100 μF per each ampere deceleration current could result in an
overvoltage fault condition and may result in damage to the drive.

12.5 Connecting External Brake Resistor and Bulk Capacitor

The braking resistor and bulk capacitor wiring is shown in Figure 29.

Temperature Sensitive Device Connection: The user supplied temperature sensitive device is connected
in series with the brake resistor as shown in Figure 29. Generally the temperature sensitive device should
be mounted in contact with the surface of the brake resistor or very close to it for an effective operation.

Optional Diode connection: Adding a diode between the positive terminal of the power supply and J1 pin
2 of the drive as shown in Figure 29 will protect the power supply from any back fed overvoltage while
braking. The diode is sized by the application’s maximum reverse voltage and forward current.

Figure 29: External brake resistor and bulk capacitor connection to the drive

The ElectroCraft Braking Module is designed for this purpose and is compatible with CPP-A12V80A-SA­USB. Refer section 12.6 for application information.

© ElectroCraft 2018 37 CPP-A12V80A-SA-USB Technical Reference

Figure

12.6 ElectroCraft Braking Module Assembly

A Braking Module is used to divert regenerative energy from the motor and servo drive into the braking
resistor during deceleration. The braking module will turn On when the drive side voltage increases 2 to 3
VDC above the power supply input voltage and shunt the excess voltage to ground through the internal
braking resistor preventing overvoltage faults in the servo drive. A blocking diode in the Braking Module
prevents the excess voltage from feeding back to the power supply. As the drive “regenerates”, the
module will cycle On and Off to dispose of the excess energy through the brake resistor. Care should be
taken to ensure the brake resistor is not mounted next to any flammable material, as it could get hot. This
braking module will also allow the user to attach a high wattage braking resistor externally.

The braking module is designed to be connected between the CPP-A12V80A-SA-USB connector J1 and
the power supply. For full and complete data including proper connection information please refer to the
ElectroCraft Braking Module datasheet available at ElectroCraft website.

30: ElectroCraft braking module

© ElectroCraft 2018 38 CPP-A12V80A-SA-USB Technical Reference

Flash Code

Description

Possible cause

Result

Recovery method

Drive

inoperable.

Drive is

.

• Use the ‘Enable’ input to

outputs.

Drive

disabled.

• Use configuration software to

the drive.

Drive

disabled.

• Check motor wires for shorts.

stable operation.

• Verify temperature of drive or

over speed condition.

13 Troubleshooting

If the drive does not function as expected, check the following parameters:

• Input voltage within drive and motor range.

• Motor and I/O connections are wired correctly to the drive.

• Verify the configuration parameters were written into the drive successfully.

The table given in section 13.1 and 13.2 details the status LED flash codes and suggested recovery
steps.

13.1 Status LED (Red)

hardware or

ON

(Steady)

Software
error.
Processor is

OFF

Flicker

(fast blinking)

No Errors /
Faults.

Invalid
configuration.

1 Over Current

Voltage Fault

2

or Shunt
Overpower

• Processor fault.

• Drive is operational.

• Drive has not been

configured.

• Output current was detected
as too high.

• Drive power is above/below
operational limits.

• Braking resistor is turned ON
for more than 3 seconds.

• No Braking resistor available
in the circuit or the resistor is
too small for the energy
dissipated.

• Braking resistor turn
ON/OFF limits are set too
low.

Drive
outputs are
disabled.

operational

outputs are

outputs are

Drive
outputs are
disabled.

• Disconnect power from the
drive for 30 seconds for drive
to reset and internal
components to discharge.
Then re-apply power to drive.

enable or disable the drive

write a valid configuration into

• Verify current loop tuning for

• Verify voltage of power supply.

• Verify braking resistor is

properly sized and installed.

• Verify braking resistor turn
On/Off levels are above the
power supply input voltage.

Motor

3

Feedback
Fault

4 System Fault

Note: Detailed status information can be obtained using the drive configuration software.

© ElectroCraft 2018 39 CPP-A12V80A-SA-USB Technical Reference

• Hall / Commutation signal
Fault.

• Encoder Fault.

• Incorrect Hall and Encoder

parameters entered in the
software.

• Drive Over Temperature

• Motor Over Temperature

• Motor Over Speed

• Motor Control Error

Drive
outputs are
disabled.

Drive
outputs are
disabled.

• Verify hall / commutation
signals are present and
working correctly.

• Verify encoder signals are
present and working correctly.

• Verify Motor Pole Pairs, Hall
sensor configuration and
Encoder resolution/options.

motor.

• Check for overload conditions.

• Check for mechanical

conditions that would cause an

Required for drive
to operate.

• Apply power to power input of

feedback devices.

13.2 Power LED (Green)

Flash Code Description Possible Cause Result Recovery Method

ON Power Indicator Drive is powered.

OFF Power Indicator

Drive is not
powered.

Drive will not
operate.

N/A

drive.

• Verify input power is within
acceptable range.

• Check wires for possible
short circuit.

• Verify internally generated
+5Vdc power is not
overloaded by I/O or motor

© ElectroCraft 2018 40 CPP-A12V80A-SA-USB Technical Reference

© ElectroCraft 2018 41 CPP-A12V80A-SA-USB Technical Reference