SilverNugget Closed-Loop Hybrid Servo Motor Controller/Driver

SilverNugget Closed-Loop Hybrid Servo Motor Controller/Driver
Datasheet: QCI-DS035
Date: 08 August 2017
QuickSilver Controls, Inc.
www.QuickSilverControls.com
SilverNugget N3-MX – X Series Controller
The SilverNugget™ N3-MX servo motor controller includes a controller/indexer, digital driver,
active power clamp, and cabling to drive 3rd party NEMA 34 frame bipolar microstep motors
with high resolution encoders. The SilverNugget has two integrated cables for interfacing with
the primary encoder as well as the microstep motor. Serial communications and IO, as well as
processor power are accessed through a High Density DB15 connector. CANopen is available
on a separate DB 9 connector. Power and external Clamp resistor are available through a 5
pin 5W5 connector.
The 15 pin SMI interface includes 7 I/O, all of which support both LVTTL and analog signals,
and one of which also supports 0 to 10v analog input. A hardware drive enable are also
included. Communication is available via CANopen and RS-485 serial, which may be operated
simultaneously. The driver is rated to 20A continuous per phase. The system is designed for
use at +12 to +72 VDC for driver power and 12-48v for processor power.
The X series SilverNugget includes dual internal clamp circuits. An external primary clamp
allows the clamp resistor to be connected externally to handle the required power level. A
secondary internal clamp comes on at a slightly higher internal voltage to protect the driver if
the primary clamp is not connected, and for those low inertia designs and or lower speeds, or
which are not back-driven, the 50w internal clamp may eliminate the need for an external
clamp resistor, according to the application. (Note: Dump resistors are 50W average, allow up
to 250W for up to 5 seconds). The internal clamp may also be bypassed for use with batteries
to allow capture of regenerated power.
Property of QuickSilver Controls, Inc.
Page 1 of 15
This document is subject to change without notice.

QuickControl® and QCI® are Registered Trademarks of QuickSilver Controls, Inc.
SilveNugget™, PVIA™, QuickSilver Controls™, and AntiHunt™ are trademarks of QuickSilver Controls, Inc..
QuickSilver Controls, Inc.
Datasheet:QCI-DS035
System Overview
Point-to-Point Moves
• Relative or Absolute
• Velocity or Time Based
• S-Curve
Advanced Motion Profile Moves
• Profile Move Commands
• Register Based
o Position/Accel/Decel/Velocity
o Modify On-the-Fly
Input/Output
• 7 LVTTL Digital I/O
o Bi-Directional
o Set While In Motion
• 7 Analog Inputs (Joystick)
• 1 Analog 0-10v Input
• 1 Output supports PWM out
• 1 Input supports PWM in
• Programmable Logic Switch out
• Secondary Encoder In
• Encoder Out (single ended and
differential available)
Program and Data Storage
• 32K Non-Volatile Memory
• 2000-3000 Program Lines
• Expanded 8191 word program buffer
• 4K User Registers
• User Data Examples
o CAM Tables
o Motion Profiles
o Lookup Tables
Electronic Gearing/Camming
• Follow External Signals
o Encoder (A/B Quadrature)
o Step and Direction
• Gearing plus Trapezoid motion
• Electronic Cam
o Import Cam Table from File
• Gearing with extended precision:
o A/B gearing
o xxx.xxxxxxxx multiplier
QuickSilver Controls, Inc.
Page 2 of 15
(8 places behind decimal
point)
Electronic Slip Clutch/Brake
• Variable Torque
• Wind/Unwind Applications
Communications
• RS-485 @ up to 230K Baud
• ASCII, Binary, Modbus®, DMX512
• Host Control While Servo in Motion
• CANopen® (Rev 03 SW and higher)
Programming Language
• Easy, Menu Driven Interface
• Command Parameter Prompts
• No Syntax Errors
• User Namable I/O and Registers
Advance PVIA™ Servo Loop
• Improvement Stability
• Simulated Viscous Inertial Damper
• 100:1 Inertial Mismatch
• Direct Drive Oversized Inertial Loads
o Flywheels
o Belt Drives
o Typically eliminates need for
Gearheads
Anti-Hunt™
• Optionally transition to open loop
while in position – automatically
changes back to full servo if position
is disturbed.
• No Servo Dither While at Rest
Multi-Task/Multi-Thread
• Two programs plus a motion
simultaneously
• Multiple background protection
settings
Based on QCI’s Hybrid Servo Motors:
NEMA 34 Frame
o 16000 Counts/Rev Encoder
o Up to 2600 oz-in (18.6 Nm)
(continuous)
QuickSilver Controls, Inc.
Datasheet:QCI-DS035
SMI Interface – Processor power, IO, Serial Communications
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P1
Signal
Drive Enable
RS-485 A
+5v Out
I/O #3
I/O #6
Power Ground
V+
Logic Ground
I/O #2
I/O #5
Power Ground
RS-485 B
I/O #1
I/O #4
I/O #7
Output
+
DC
Control
Input
Solid
State
Relay
To Load
Input
Input Power
Processor Power
V+ Processor:+12 VDC to +48 VDC, regulated. Processor Power should have no larger than
an 8A fuse to limit power.
Driver Power
V+Driver: +12 VDC to +72 VDC. Device must be initialized for the actual operating voltage.
Driver Power, Power Ground, Chassis Ground, Clamp+ and Clamp- are provided on a
separate 5 pin 5W5 connector: The Driver power should be fused with not more than a 25A
slow blow fuse unless power supply current is limited to same.
Pin
1
2
3
4
5
Signal
V+ Clamp
V+ Driver
V- Clamp
V- Driver
Chassis Gnd
QuickSilver Controls, Inc.
Wire color for QCI-XC-P10
Yellow
External Clamp resistor (according to need)
Red
Normal V+ connection
Orange External Clamp resistor (according to need)
Black
Normal V- Connection
Drain1,2
Page 3 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Built-in Clamps
Two stages of Clamp circuits are built into the system. The primary clamp allows the clamp
resistor to be mounted external to the system for easy heat elimination. This provides for very
large inertias and for systems that are back driven. The secondary clamp provides up to 50W
average clamping, and comes on at a slightly higher voltage than the primary clamp, actuating
only if the primary clamp is not sufficient or is not connected (or opens). The secondary clamp
includes over temperature monitoring to shut down the motor if the internal resistors are
dissipating excessive energy. Connecting the V+ Clamp and the +VP signals together will
bypass the internal clamp, allowing regenerated power to be used to recharge batteries, for
example. Care must be taken to prevent overvoltage.
Driver Power Input Current
20 Amps DC maximum for any input voltage, +12.5 VDC to +72 VDC per controller. This input
must be fused no more than 25A slow blow. The Driver Power is isolated from the processor
power to minimize the influence of the high currents for the driver upon the input voltages.
The processor power and the driver power isolation
The processor power and driver power are galvanically isolated. The processor ground, the
driver ground, and the chassis ground should be connected at the power supply, with the
negative side of the power supply strapped to chassis ground at that point, for best noise
characteristics.
Inputs & Outputs
Digital Inputs
0 to +3.3 VDC. LVTTL level compatible. All inputs have a light pull-up (~100k ohm to 3.3v).
All I/O have an optional programmable pull-up/pull-down of 2.2 k ohm; the source to these
resistors may also be floated if no pull-up or pull-down is needed. The seven IO are protected
to +/- 40v.
5v output
Rated to 100mA. Do not back drive. Do not short out.
Digital Output Voltage
0 / +3.3 VDC.
Digital Output Current
Sinking or Sourcing: 2mA
Analog Inputs
All 7 I/O may be used as Analog Inputs: 0 to +3.3 VDC input signal range.
IO7 has a secondary circuit to handle 0 to +10v input signal range; the input protection will
isolate the normal 3.3 v input channel allowing the 0 to 10v operation.
Resolution: 12 bits (before filtering)
Analog signals are read every servo cycle (120 μsec.) and the converted analog data is
processed through a (default) 5 ms filter to reduce noise & transients.
QuickSilver Controls, Inc.
Page 4 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Drive Enable Input
This hardware drive enable input must be connected to +10 VDC to +48 VDC for the drive
electronics to be enabled. The Drive enable voltage is measured with respect to the processor
power ground, not the driver power ground.
Communications
Serial Interface
RS-485 multi-drop, Reduced unit load accommodates up to 255 nodes.
Protected up to +/- 70v.
Note: RS-485 requires a nominal 120 ohm ½ W termination resistor at each end of the network
for longer runs. This termination is not provided onboard and must be provided by the user.
Protocols
8-bit ASCII, 9-bit binary, Modbus, and DMX512
Hardware Configuration Settings
Available Baud Rates: 2400, 4800, 9600, 19.2k, 28.8k, 57.6k, 115.2k or 230.4k
(250k only for DMX512)
Data Bits: 8 (9 bits for binary)
Stop Bits: 1.5 or 2
Parity Bit: None (Modbus supports None, Even, Odd)
CAN interface
CAN connections
The CANopen connections are made via a 9 pin male DSub connector.
2 = CAN-L
3 = GND
6 = GND
7 = CAN-H
The CAN bus connection is not isolated, but does include transceivers which have an
extended +/- 70v fault protection range. The CANopen® communications protocol allows the
unit to function as a master, slave, or peer on a CANopen network. See the CANopen User
Manual for details on the CANopen protocol. This protocol operates simultaneously and
independently from the standard serial protocols.
Note that a 120 ohm ½ W termination resistor is required at each end of the CAN network
(only two per system). This termination is not provided onboard the controller and must be
provided by the user. For the CAN bus operation, this termination is not optional.
CANopen® and CiA® are registered community trademarks of CAN in Automation e.V.
QuickSilver Controls, Inc.
Page 5 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Wiring and Cable Specifications
Encoder Feedback Connection: 8-Wire Encoder Cable
Designation
Encoder +5V
Encoder Gnd
Encoder A+
Encoder AEncoder B+
Encoder BZ+ (index +)
Z- (index -)
•
Wire Color
Red
Black
White
Yellow
Green
Blue
Orange
Brown
Wire Gauge
26 AWG
26 AWG
26 AWG
26 AWG
26 AWG
26 AWG
26 AWG
26 AWG
For a back mounted encoder, the encoder’s A Channel should lead B Channel
when the front motor shaft rotates clockwise.
Encoder Cable Specifications
Nominal Cable Diameter =
0.25 inches
Minimum Bend Radius =
1.8 inches
Each Wire Pair Has A Shield
Shields Connected To SilverNugget Case
Driver Winding Signals: 4-Wire Motor Cable
Designation
Winding A+
Winding AWinding B+
Winding BDrain †
Wire Color
Red
Yellow
Black
Orange
Bare Wire
Wire Gauge
14 AWG
14 AWG
14 AWG
14 AWG
2x16 AWG ‡
Motor Cable Specifications
Nominal Cable Diameter =
0.4 inches
Minimum Bend Radius =
2.8 inches
Wire Pairs Are Not Shielded
Each Wire Pair Wrapped with 16 AWG Drain Wire
† The Drain is connected to the SilverNugget case. QCI recommends connecting the Drain to
the motor chassis.
‡ The Drain is composed of two 16 AWG wires in parallel.
QuickSilver Controls, Inc.
Page 6 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Stepper Motor Wiring Configuration
A+
Ideally, the SilverNugget will be interfaced with a four
wire bipolar motor. Then the SilverNugget four wire
motor cable will match up with the leads from the
micro-step motor. Although, the SilverNugget will
work with motors that have more than 4 wires.
M
A-
B+
B-
4 Wire Bipolar Configuration
Some bipolar micro step motors are
8 wires. Typically, an eight wire motor is
wired in a parallel configuration for use with
the SilverNugget. However, a series wiring
configuration
is
acceptable.
Either
configuration is perfectly legitimate to obtain
the best motor characteristics and achieve
optimum performance.
A+
manufactured
M
A+
A-
M
B+
B-
A-
8 Wire Parallel
Bipolar Configuration
8 Wire Series
Bipolar
B+Configuration
B-
A
M
V+
Unipolar motors are not suggested with the SilverNugget, as
they are typically higher inductance and higher resistance
than equivalent bipolar configurations.
B
C
V+
D
Unipolar Configuration
QuickSilver Controls, Inc.
Page 7 of 15
with
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
SilverNugget Part Number Cabling Interface Designation:
Q CI -N2 -MX -BB0 1
Cable length (feet)
Encoder Connector
Motor Connector
The first letter specifies the type of connector placed on the end of the motor cable. The
second letter specifies the type of connector placed on the end of the encoder cable. Options
for the motor and encoder cable are interchangeable. For example, ordering a SilverNugget,
with the ABxx option, would mean the motor cable has flying leads and the encoder cable has
a TE or Molex compatible connector.
Cable lengths are available from 1 foot to 25 feet in one-foot increments. For longer lengths,
contact QCI Support.
A – Cable has flying leads.
The AA option comes with flying leads on
both the Motor and Encoder cables.
B–
Motor Cable: 5-pin Single Row Socket Connector
•
TE or Molex compatible connector, with crimped pins, attached to end of cable.
Encoder Cable: 10-pin Dual Row, 0.1" Socket Connector
•
Molex compatible connector, with crimped
pins, attached to end of cable.
The -BB option (standard SilverNugget N3-MX option)
comes with a TE or Molex compatible connector on the
motor cable and Molex compatible connector on the
encoder cable.
QuickSilver Controls, Inc.
Page 8 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
B Option on Motor Cable
Motor Cable Connector Pinout
Pin Number
Signal
Wire Color
1
Winding AYellow
2
Winding A+
Red
3
Winding BOrange
4
Winding B+
Black
5
Chassis Gnd Green/Yellow
White
Motor Cable Connector Face View.
A short length (approx. 1 inch) of 16 AWG wire is soldered between the Drain and the
Chassis Ground Pin on the SilverNugget B option motor connector.
Motor Cable Connector Part Numbers
Description Molex Part #
Series Total Used
Housing
44441-2005
44441
1
Female Pins 43375-1001
43375
5
Recommended Crimping Tool
Description Molex Part #
Series
Crimper
63811-0500
63811
63811-7300
Mating Connector Part Numbers
Description Molex Part #
Series Total Used
Housing
43680-2005
43680
1
Male Pins
43178-2002
43178
5
Recommended Crimping Tool
Description Molex Part #
Series
63811-3100
Crimper
63811-0700
63811
The 43375 and 43178 series pins, with 14 AWG wire, are rated for 18 Amps each.
QuickSilver Controls, Inc.
Page 9 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
B Option on Encoder Cable
The B option for the encoder cable interfaces with a US Digital 10 pin, dual row differential
encoder connector.
Encoder Cable Connector Face View.
Encoder Cable Connector Pinout
Pin Number
Signal
Wire Color
1
Not Used
2
Encoder Gnd
Black
3
Z- (Index -)
Brown
4
Z+ (Index +)
Orange
5
Encoder AYellow
6
Encoder A+
White
7
Encoder +5V
Red
8
Not Used
9
Encoder BBlue
10
Encoder B+
Green
Encoder Cable Connector Part Numbers
Description Molex Part #
Series Total Used
Housing
15-04-5104
70013
1
Insert
22-55-2103
70450
1
Female Pins 16-02-0104
70058
8
Mating Connector Part Numbers
Description Molex Part #
Series Total Used
Housing
50-65-0010
70022
1
Insert
22-55-2103
70450
1
Male Pins
16-02-0117
70021
8
•
The 70058 and 70021 series pins, with 26 AWG wire, are rated for 1.8 Amps
each.
Recommended Crimping Tool
Description
Molex Part #
Crimper
11-01-0208
QuickSilver Controls, Inc.
Page 10 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
STATUS LIGHTS
Three status lights are provided on the back of the SilverMax.
The Comm LED (normally Red) indicates the unit is ready (no
program running) by a dim level, it is off between
communications if a program is running. It blinks brightly during
each incoming communications frame. The Status light
(normally Green) varies in intensity with the motor torque
(negative torque dimmer, positive torque brighter); if Done Bit is
configured the LED lights to indicate Done (See Set Done Bit
command), is also used to blink error codes if a fault is
detected (and the Done bit is not configured). The Driver power
present LED is normally Green; It becomes amber if driver is
disabled (either by hardware or by software).
Power
Comm Status
Environmental Specifications
Operational Temperature
-40 C to +70 C. Continuous torque curves taken at 20C; derating may be needed at higher
temperatures. 100% torque requires motor affixed to thermally conductive structure, and may
need air flow. Must be verified in final application.
Storage Temperature
- 40 C to +85 C
Humidity
Continuous specification is 95% RH non-condensing.
Shock
Limitation is approximately 50g/11ms.
Specifications subject to change without notice. See www.QuickSilverControls.com for current
information.
QuickSilver Controls, Inc.
Page 11 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Mechanical Dimensions
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Page 12 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Recommended Components
SilverNugget N3-MX Start-Up Materials
For first time users, QCI recommends purchasing the following items to aid with use of the
SilverMax X-series servo motor:
•
•
•
SilverNugget N3 X-series Breakout Board (QCI-BO-X3)
USB to RS485 converter (QCI-USB-RS485)
Desired 3rd party motor with 1000, 2000, or 4000 line encoder.
o Contact factory for more supported encoder resolutions.
• 10’ Power cable (QCI-EC-P10)
Optionally:
1000W, +48V Power Supply (SE-1000-48)
• Power Supply Cord w/ Flying Leads (QCI-C-ACP-FLY-6)
• 50W Clamp Resistors (QCI-R4-50) (may need multiple in series/parallel for needed
dissipation – contact Support for more details)
Configuration Software: QuickControl™ is free and available from our website.
Typical System Setup
Note: Power cable is not fused as the power supply is current limited to ~20A; higher power supplies or batteries require a fuse in the positive lead.
4. USB to RS485
QCI-USB-RS485
Note: Power cable is not fused as the power supply is
current limited to ~20A; higher rated power supplies
or batteries require a fuse in the positive lead.
6. Power Supply
SE-1000-48
7. Resistor
Bank
QCI-U
3. N3 X-series Breakout
QCI-BO-X3
5. N3 Power Cable
QCI-EC-Pnn
1. SilverNugget MX Controller
QCI-N3-MX
1. SilverNugget MX controller
Controller with digital driver and integral Clamp.
QuickSilver Controls, Inc.
Page 13 of 15
2. Generic 3rd party motor
with encoder feedback
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
2. Generic 3rd Party Micro Step Motor with Encoder Feedback
SilverNugget N3-MX is specifically designed to drive 100 poles, 1.8° step motors. To best
utilize the capabilities of the SilverNugget, select a motor that has been optimized for micro
stepping.
3. Breakout (QCI-BO-X3)
The breakout board breaks out the SilverNugget N3’s processor power input, drive enable
input, RS-485 communication lines, 7 LVTTL digital/analog I/Os, local +5v supply, and CAN
bus onto pluggable terminal connector blocks.
4. USB to RS485 Converter (QCI-USB-RS485)
USB-RS-485 converter provides a USB powered serial port with RS-485 signaling. See QCITD073 USB-RS485 Converter Setup Guide for information on network termination and
shielding recommendations.
5. SilverNugget Power Cable (QCI-EC-Pnn)
This connector provides power conductors for V+, V-, and Clamp resistor, in addition to a
chassis ground connection.
6. Power Supply
Power supply selection is motor dependent, but the following will work with all SilverNugget Xseries controllers.
SE-1000-48 (48V, 20A, 1000 Watt)
RS-1000-48 (48V, 20A, 1000 Watt)
7. External Regenerative Clamp Resistor
Rapid deceleration of larger loads may require the use of the Primary Clamp circuit, requiring
adding external power resistors between Clamp+ and Clamp-. Do not connect Clamp- to
Clamp+ except through a clamp resistor of sufficient power rating. Resistance should be such
that at operating voltage the resistor current will not exceed 20A when the clamp is active.
Changes from N3-MG:
Please see the N3 Product Change Notice for a full description of differences for the previous
N3-MG design.
QuickSilver Controls, Inc.
Page 14 of 15
QuickSilver Controls, Inc.
Datasheet: QCI-DS035
Part Numbers
SilverNugget MX
X-Series M-Grade controller with cables for encoder and Motor.
A single firmware version handles varying encoder division (including
none) and different encoder index styles; these are configured at
initialization time. The single version firmware also handles ASCII,
Modbus, 9Bit, DMX, CANopen.
QCI-N3-MX-BB01
QCI-N3-MX-BB04
QCI-N3-MX-S0001
1 foot cables, Encoder cable has locking 10 pin connector compatible
with differential US-Digital™ style encoders. Motor cable has 5 pin
Molex/TE style connector
4 foot cables, Encoder cable has locking 10 pin connector compatible
with differential US-Digital™ style encoders. Motor cable has 5 pin
Molex/TE style connector
1 foot cables. Encoder cable has locking 10 pin connector compatible
with differential US-Digital™ style encoders. Motor cable is flying lead
only. Processor power is internally connected to Driver power (voltage
limited to 48v).
Contact Information
QuickSilver Controls, Inc.
990 N Amelia Ave
San Dimas, CA 91773
+1 (909) 599-6291 or (888) 660-3801
+1 (909) 599-6289 FAX
www.QuickSilverControls.com
QuickSilver Controls, Inc.
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