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AX-V

MAIN USER MANUAL

Release 5.2

Date: Feb. 25 2002

Supported models:

AX-V 06094

AX-V 10144

AX-V 10284

AX-V 23404

AX-V 25554

Phase Motion Control s.r.l.

Via Adamoli, 461
16141 Genova – Italy
Tel. +39 (010) 835161
Fax +39 (010) 8355355
e-mail: support@phase.it
General connection diagram

1 Analog Input 2 +
2 Analog Input 2 -
3 Analog Output 2
4 Analog Output 3
5 Ground
6 Digital Input 4
7 Digital Input 5
8 Digital Input 6
9 Digital Input 7
10 Digital Output 4
11 Digital Output 5
12 Digital Output 6
13 Digital Output 7
14 Encoder Simulator Ch. A
15 Encoder Simulator Ch. B
16 Encoder Simulator Index

1 Analog Input 0 +
2 Analog Input 0 -
3 Analog Input 1 +
4 Analog Input 1 -
5 Analog Output 0
6 Analog Output 1
7 Ground
8 Digital Input 0
9 Digital Input 1
10 Digital Input 2
11 Digital Input 3
12 Digital Output 0
13 Digital Output 1
14 Digital Output 2
15 Digital Output 3
16 Rele' Common
17 Rele' Open
18 Rele' Closed
19 +24 V Input
20 0 V Input

-2-
 Index of Contents
1 Quick Overview................................................................................................ 4
2 What is a motion control platform?.................................................................. 4
3 To get started .................................................................................................. 6
4 Hardware Description....................................................................................... 9
5 Emergency and power fail condition handling .................................................. 12
5.1 General.......................................................................................................... 12
5.2 Emergency stop with inertial loads; safety brakes ........................................... 12
5.3 Power fail with high energy load .................................................................... 13
5.4 Thermal protection delay................................................................................ 13
6 Technical Specifications.................................................................................... 14
6.1 Electrical specifications ................................................................................... 14
6.2 Physical Data.................................................................................................. 15
7 Electrical Ratings .............................................................................................. 16
7.1 Derating of output current with temperature increase .................................... 16
7.2 Area Operativa AX-V 06094........................................................................... 16
7.3 Area Operativa AX-V 10144........................................................................... 17
7.4 Area Operativa AX-V 10284........................................................................... 17
7.5 Area Operativa AX-V 23404........................................................................... 18
7.6 Area Operativa AX-V 25554........................................................................... 18
8 Electrical Connections ...................................................................................... 19
9 Mechanical Installation..................................................................................... 28
10 AX-V Fault codes .......................................................................................... 28
11 System Parameters ........................................................................................ 31
11.1 Current loop .................................................................................................. 31
11.2 Braking resistor .............................................................................................. 31
11.3 Encoder counters ........................................................................................... 32
11.4 Intradrive ....................................................................................................... 34
11.5 Analogue outputs .......................................................................................... 34
11.6 Serial link RS485 ............................................................................................ 34
11.7 Motor thermal protection............................................................................... 34
11.8 Position/Speed Loop....................................................................................... 35
11.9 Expansion board ............................................................................................ 35
11.10 Emergency braking ..................................................................................... 35
12 CE conformity of AXV platforms, Ultract, Minact, Wave motors..................... 36
12.1 Wiring recommendations and CE-typical system for conformity to EMCD and
LVD 36
12.2 EC Declaration of Conformity for the purposes of EMCD e LVD...................... 36
12.3 Introduction: EC directives.............................................................................. 36
12.4 LVD Directive ................................................................................................. 36
12.5 Product safety................................................................................................ 37
12.6 Application as directed – Scope of application ................................................ 37

-3-
 12.7 Installation ..................................................................................................... 37
12.8 EC Declaration of Conformity......................................................................... 37
12.9 The EMCD Directive (89/336EWG) ................................................................. 38
12.10 Installation as specified................................................................................ 38
12.11 EC Declaration of conformity ...................................................................... 39
13 Appendix A: ULTRACT MOTORS to DRIVE AXV Connections ....................... 40

1 Quick Overview

The AXV programmable motion control platform is characterised by an innovative

power control hardware which is fully personalised by software and configured via a PC
link.
For hardware installation information, read on in this hardware manual.
For information on the PC resident control and configuration tool AXV Cockpit, refer to
the AXV Cockpit Manual.
For information on specific functions of all applications refer to HTML help pages in
configuration tool AXV Cockpit.
For information on programming refer to the software manual “Programming AXV” in
the CD bundled with the platform.

2 What is a motion control platform?

AX-V is the first realisation of a novel concept in motion control technology. AX-V is a
configurable motion control platform, based on a very fast DSP dedicated to real time
servo control application (VECON) integrated into a versatile and innovative power
control hardware.
The result is a fully configurable IGBT drive, particularly suited for high bandwidth
brushless PM motor servo control, which can be configured, just by loading an
application from a software library, as a digital drive, an intelligent axis controller, an
electric gear, an electronic cam or, more generally, a fast motion control PLC or GPLC.

The AXV drive is fully controlled by software; no hardware adjustments are needed or
possible. The control software, which personalises the unit, as well as all the application
and tuning parameters, are stored in the unit non volatile memory and are accessed and
edited by linking the drive with a PC. Such a start-up connection is usually performed via
1
the RS 485 serial port .
The set of application data and tuning parameters, which are application specific, is the
application database. To create, inspect, edit and copy this database, the AXV Cockpit
configuration tool is supplied along with the platform. This tool is installed in the PC,
which is used to perform the installation of the AX-V drive. AXV Cockpit works as the
control centre of the drive during installation; it accesses all drive functions and
parameters, identifies the unit and its operational life, and allows copying to and from

1 The AX-V platform is equipped with a multi drop, industry standard RS 485 serial link. If only a RS 232
connection is available, a RS 232 - RS 485 converter is necessary.

-4-
stored data and to duplicate installations. It also works as a powerful diagnostic tool by
interfacing with the drive “flight recorder” function.
Cockpit also implements application security by allowing a multilevel password access
restriction.
For more information about AXV Cockpit, refer to the AXV Cockpit Application Manual.

Software enclosed in AXV platforms consists of Firmware and Application.

Firmware manages operating system and basic resources of the platform: current loop,
speed and position loop, protections and diagnostics. Parameters to configure these
functions are detailed in chapter System parameters.
Some firmware characteristics are:
y Fully digital dual direct and quadrature current control loop, updated at 16 kHz, with
4 kHz control bandwidth;
y Digital speed loop with true zero speed, PII2D controller2 with generalised
feedforward, standard servo;
y Interpolation of analogic encoder to increase resolution;
y Autophasing routine for incremental encoders which can be activated from GPLC
application;
y Configurable encoder simulation output.

Firmware is developed in Phase Motion Control and cannot be modified by the final
user. Periodically new firmware releases are available at http//www.phase.it.
New firmware is always compatible with older applications.

Application contains the motion control program and logic management. To develope
applications use the Global PLC, a programming environment which empowers the user
with the ability to create his own automation project inside the drive. Within the limits
of the available I/Os and of the program memory, all standard automation functions of
the IEC 1131-3 PLC language are available, on top of the real time motion control ability
of the AXV platforms, including the acquisition of two separate encoders. The PLC
software runs three independent tasks, a fast one used for motion control purposes,
which runs at 4 kHz, and two slow tasks, for all other uses, running at 125 Hz. The
GPLC language is so powerful that very fast functions such as position control,
electronic camshaft, trajectory control, electric gear, can be implemented together with
dedicated sensor and I/O interface. This way, the AX-V, equipped with application
specific, and private, software, can become the very control centre of an automation
application.
For detailed information on programming refer to “AXV Programming Manual” in the
CD bundled with the platform.

A set of basic Applications (with related GPLC source code) is provided with AXV
platform. These applications can be loaded into the drive by means of AXV Cockpit (see
manual).

2
PII2D controller: 4 compensation terms are available: proportional (speed), derivative (acceleration),
integral (position) integral of position (with this term, zero steady state position error can be obtained).

-5-
In every platform at the end of factory tests, the standard application Speed-V is loaded
(standard software): designed for classical applications, SpeedV turns the AXV in a
versatile digital platform for brushless servo motors.
Main features are:
y Two different control mode: current or speed control;
y Standard analogue interface +/- 10V differential or frequency input;
y Internal ramp generator;
y Capability to maintain in memory 8 different complete sets of tasks, with possibility
to switch from one to another, on the fly, by digital inputs;
y Electrical gear capability.

For detailed information on SpeedV functions and I/O refer to related HTML pages
available by opening the SpeedV3_4eng.par file with AXV Cockpit.

3 To get started

The AX-V platform is a fully digital, fully configurable drive. To interface with the drive
and to input the application parameters for the first time, a link with a PC is necessary.
After programming, the drive can be either controlled via the terminals, the serial line,
or a field bus option.
For the drive initialisation, a PC running Win 9x, Me, 2000 or Window NT 4.0 or higher
is required with a RS 485 serial line and at least 15 Mbytes free disk space is required.
If no RS 485 serial line is available on the selected PC, a RS232-485 interface converter is
required.

Supplied components:

y AX-V hardware platform

y Pre-loaded VPLC firmware (all drives are supplied, unless otherwise specified, with
the SPEED-V application set for Ultract II and SINCOS encoder)
y Application Parameter table (a default parameter set as stated above is supplied with
the original control firmware and can be modified as necessary and saved)
y AXV Cockpit configuration tool CD containing:
y Hardware manual (the present one)
y AXV Cockpit configuration program manual;
y AXV Programming manual;
y AXV Cockpit software to program, interface, install and monitor the application
in the AXV;
y GPLC software to develop dedicated applications
y copy of latest release of firmware;
y directory BONUS with samples of GPLC programming;
y Mechanical drawings of ULTRACT II motors, AXV drive in DXF format and DWF
format;
y Utilities to view and print manuals and drawings

Necessary components for first initialization:

-6-
y AXV and selected motor.
y 198-465 Vac three phase power supply (not necessary for programming and
uploading but necessary for testing the drive).
y 24-30 Vdc, > 0.6 A control power supply, unregulated (up to 1 Vpk-pk ripple)
y PC running Windows 9x, ME, 2000 or NT 4.0 or higher is required with a RS 485
serial line.
y If no RS 485 serial line is available on the selected PC, a RS232-485 interface
converter is required (available on demand).
y The browser Internet Explorer 4.0 or higher must be installed (available on CD).
y 15Mbyte free space on hard disk.

Software installation:

y Insert the supplied CD-Rom into the PC drive.

y If autorun is enabled the main application starts automatically; else, open page
index.htm in root directory of CD with any browser internet (e.g. Internet Explorer).
y It is possible also run the file setup.exe in the folder d:\setup\axvsetup\disk1.
y Install AXV Cockpit in the PC
y After the end of setup restart the PC;
y To complete installation is needed run the file Run Me First in the menù Start-
>Programs->AXV Cockpit (to do only one time after installation).

Minimum wiring requirements:

For PC connection only:

y Connect 24 V supply between +24 V and 0 V on C1 interface
y Connect RS 485 line to PC
y In this state, the drive can be queried and programmed. No high voltage power is
necessary.

Power wiring:

y Wire motor phases to A, B and C terminals of power connector, respecting scheme

enclosed with the motor. For this wiring is needed a shielded cable with a section
appropriate for the nominal current of the motor. The shield must be connected to
ground both on motor side and on AXV panel. In case of doubt, it is possible to
check the phase sequence (and the encoder phasing) by means of Test Routine
application.
y Wire external power supply to R, S and T terminals of power connector. NOTE: AXV
drives are designed to work only with three phase supply at any voltage up to 460V
(+10%).
y WARNING: A braking resistor is needed for proper use of AXV. To use internal
one, connect an insulated jumper with section appropriate to the drive current
between power terminals BR+ and DC+. To use an external braking resistor with
higher rated power connect it to DC+ and BR- terminals (without the jumper
between BR+ and DC+). Resistance values for external braking resistor must
comply with the following table:

-7-
 Model Min Max
AX-V 06094 60 Ω 80 Ω
AX-V 10144 38 Ω 50 Ω
AX-V 10284 20 Ω 25 Ω
AX-V 25554 10 Ω 13 Ω

If an external resistor is used, two system parameters must be configured: SYS_R_BRAKE

(R value in ohm) and SYS_PBRAKE_MAX (nominal power in watt). Firmware uses these
values to activate thermal protection of braking resistor. Additional details in System
Parameters paragraph.

-8-
4 Hardware Description

The drive platform is characterized by :

Power stage:

y Innovative Ac-Ac converter without DC bus electrolytic capacitor, which provides

instant availability at power-on and correct input current waveform, in line with the
future IEC 555 norm;
y Auto tuning of current limit vs. supply voltage and ambient temperature; single drive
for 198-465 Vac supply;
y 16 kHz carrier power IGBT stage, 16 kHz ripple frequency, built-in full power, limited
duty cycle brake resistor; full power braking chopper;
y Forced ventilation controlled by the drive temperature (the fan is turned on only
above 70 oC) to limit dust accumulation; the drive temperature is monitored and
available for programmable cycle self-limiting;
y Full power stage intrinsic protection (overtemperature, short circuit to ground and
between motor wires) with fault condition non volatile storage.
y Control and power stages have separate and independent power supplies for
emergency shutdown and debugging
y Real time temperature observer for each power chip, with adaptive current limit.

High speed sensor interface

two independent inputs, configurable:

a (main) 4 channel analogue/digital encoder input (200 kHz BW) which can be
programmed to receive the following signals:
1. SINCOS 5 channel encoder (2 absolute analogue tracks, 2 incremental analogue
tracks, index) (default encoder).
2. Digital 6 track encoder (3 Hall commutation + 2 incremental + index)
3. Analogue 6 track encoder (3 Hall commutation + 2 analogue incremental + index)
4. Incremental digital encoder without commutation tracks (requires autophasing)
5. Analogue SINCOS 2 tracks encoder or Resolver1
6. Hall sensors
7. Incremental 2 track analogue encoder
8. SINCOS 5 track encoder with digital incremental track

A secondary encoder I/O (500 kHz) which can be programmed as follows:

2 Digital 6 track encoder (3 Hall commutation + 2 incremental + index)

4 Incremental digital encoder without commutation tracks (requires autophasing)
6 Hall sensors

1
Resolver output signals must be connected to sine and cocine inputs of terminal S2

-9-
REMARK: to provide for long supply cables, the encoder power supply can be
programmed in the 5-15 Vdc range.

Two high speed outputs:

y Encoder emulation, any ratio with the main encoder, including index, on the S1
connector (alternative to secondary encoder input), line driver 5V differential;
y Secondary encoder replica, 24 V single ended open collector, hard wire connection
with the S1 encoder input (it is a replica of encoder emulation or of the secondary
encoder, depending on option chosen)

General purpose interface:

3 programmable differential analogue inputs

4 programmable analogue outputs
8+8 programmable digital I/Os
Programmable mechanical relay contacts 1A, 250V.

Communication:

Opto isolated, multi-drop RS 485 asynchronous serial interface;

Field bus option;
1 synchronous high speed serial line
INTRADRIVE ultra high speed (1 Mbaud) serial loop interface to link up to 4 AX-V
drives into a multi axis, multi I/O coordinated environment

Hardware:

IP 20 insulated enclosure with internal RFI shielding, book type

Power and control interfaces with removable terminal/connector
Encoder and serial interfaces via standard D connectors
Built in ground bar (4 x M4) for cable shield termination

Architecture:

Nonvolatile program memory area: 256 kByte

Processors: 40 MIPs

Task timing:

Current and drive monitor loops: 16 kHz

Servo and position loop calculations: 8 kHz
Fast task (user programmable): 4 kHz
Slow task: (user programmable): 125 Hz
Position and position targets registers: 64 bit words (232 turns with 1/232 resolution per
turn)

- 10 -
Opzioni1

Ž Digital I/O expansion board (12 inpit + 4 output)

Ž CanOpen expansion board
Ž Profibus expansion board

1
Only one option board can be installed on each drive

- 11 -
5 Emergency and power fail condition handling

5.1 General

The AX-V platform has been purpose designed with two completely separate power
supplies. The power circuit is fed from the mains voltage, without preload timing; while
the control part needs to be fed from a separate unregulated 24 V supply, which is
converted by the internal switching regulator for all internal services and for the supply
of motor encoders at the appropriate voltages.
This design solution overcomes all uncertainties of timing and synchronisation between
drive and control cabinet, by unifying the same power supply for all services, such as
sensors, PLCs, switches and latches. In this way, all data are memorised and reset at the
same time, and a simple back-up is possible for all machine information without backing
up the main power too.
The power stage without preload (and without storage capacitors) ensures that the
main power is available to the drive without delay whenever the mains power switch is
operated.

5.2 Emergency stop with inertial loads; safety brakes

Many applications involving brushless servo drives move high inertia loads in short, fast
cycles (typical example are Cartesian robots or pick and place machines). When the load
is moving at top speed, a significant amount of energy is stored in the load, so that a
sudden deenergization of the brake could be dangerous. It is therefore essential that, in
the event of an emergency, the load is braked as quickly as possible.
To resolve this problem, the use of a servo motor with a safety brake is sometimes
considered. The simple use of a safety brake, however, is wrong and dangerous for the
following reasons:

y Safety brakes designed for servo motors are stationary brakes. They are designed
exclusively to hold a motor still when deenergized, typically for vertical translations.
They are not designed to absorb any significant energy, also because their torque to
size ratio is extreme. If used to stop a motor, instead of keeping it at standstill, they
would wear quickly and eventually seize.
y The braking torque of an electrically driven brushless motor is always higher than
that of the brake and the corresponding braking time is shorter.

Consequently, the function “emergency stop” must be realized as follows:

the emergency condition, because of safety regulation, must turn off the mains power
to the drive; however, the auxiliary 24 V must be mantained, so that the drive is alive
and can brake;
at the same time, the emergency condition must generate a 0 speed reference that
brakes the motor at maximum torque, using the kinetic energy of the motor.
The drives regenerates energy from the motor to the DC bus until the motor speed is so
low that the motor back EMF is less than approximately 10 V. At this speed, the DC Bus
voltage falls, the drives locks in undervoltage and the motor is abandoned.

- 12 -
If the translation is vertical, and the motor is equipped with safety brake, only in this
moment, the safety brake can be released. To time the release, the relay contacts in the
drive can be used. The relay is switched by the DC Bus undervoltage, that corresponds
to motor almost at standstill.
When the emergency stop logic is realised as described, the machine encoders are kept
alive and no index search or initialisation is required when normal operation is resumed.

5.3 Power fail with high energy load

Mains power failure with a high kinetic energy load requires special control provisions.
In this case, the auxiliary 24 V supply may not be available for a time long enough to
stop the load. Two solutions are possible:
To back up the 24 V supply with a small battery system. This is the highest quality
solution; all encoders and sensors ride through the power failure and no reinitialization
is required when the power supply is again available.
When the back-up solution is not possible, the auxiliary 24 V should be generated with
a switching power supply fed from the drive DC Bus. The drive is equipped with a
special power fail routine that, irrespective of reference, when the DC bus falls,
regenerates energy from the motor to keep the DC bus at just above the undervoltage
level. In this way, the auxiliary power is made available to the system as long as there is
kinetic energy in the load. A 0 speed reference or a braking ramp can be programmed
as needed. Once more, a safety brake can be safely released only at the end of the
braking cycle. The 24 V supply of the brake should be thus derived from the same
switching power supply feeding the drive. The drive relay can be used to release the
brake once all the kinetic energy has been dissipated.

5.4 Thermal protection delay

When a load carries a high kinetic energy, an untimely deenergization due to a

protection tripping can be dangerous. For this reason, the thermal protection of drive
and motor is delayed (approx. 2 s) from the onset and the setting of the appropriate
terminal signal, so that the load can be braked safely before the drive trips.

- 13 -
6 Technical Specifications

6.1 Electrical specifications

AX-V AX-V AX-V AX-V AX-V

Electrical Specifications Units
06094 10144 10284 23404 25554
Supply voltage 0-506 Vac 3 phase

Supply current 1) 9 14 28 40 55 Arms

Supply Frequency 0-400 Hz

Nominal power 2) 2.8 5 5 11 11.5 KW

Output current,
6 (9*) 10 (14*) 10 (14*) 23 (36*) 25(32*) Arms
< 100 rpm speed, S1 3)
Output current, max speed
5 (6.5*) 8 (10*) 8 (10*) 18 (23*) 18.4(22*) Arms
3)
Peak current 9 14 28 40 55 Arms

Output voltage Vin × 0.95 Vac

PWM Frequency 16 KHz

Efficiency at nominal power
96.5 96.5 96.5 95 95
4)
Form factor .9
% of peak
Maximum braking current 100
current
Aux. Supply Voltage
20-30 Vdc
5)
* For 230 Vac input supply
1) Peak Value
2) Input bridge losses included
3) Vin =380Vac, Tamb=40C, Freq. Comm. 16 kHz, Vout=Vin*.95
4) Excluded auxiliary supply losses
5) Not stabilized (max. ripple 1 Vpk-pk), > 0.6 A nom.

- 14 -
6.2 Physical Data

AX-V AX-V AX-V AX-V AX-V

Physical Data Unità
06094 10144 10284 23404 25554
Average brake power with internal resistor 100 200 W

Power loss at nominal current 120 160 180 300 300 W

Thermal capacity 1400 2800 J/C

Cooling Forced cooling

Size (WxDxH) 85x225x341 182x225x341 Mm

Mass 2.4 5.3 Kg

Protection level IP20

Permissible vibrations 0.5 g in every direction, 0-10 Hz

Shocks 0.5 g

o
Operating ambient temperature 0-50 C

o
Storage temperature range -20-70 C

Relative humidity 0-95%, non condensing

0-1000 mt; derate current by 3% each 100 m
Altitude
above 1000 m

- 15 -
7 Electrical Ratings

7.1 Derating of output current with temperature increase

120
Output current, % of nominal

100

80

60
0 10 20 30 40 50

Percentage variation of output current vs.

o
room temperature ( C)

7.2 Area Operativa AX-V 06094

10
Corrente dell’azionamento [Arms] e potenza resa [kW]

0 100 200 300 400 500

1 Vo 497
Volt

Area operativa azionamento AX-V 06094 in

funzione della tensione di uscita per alimentazioni
230, 380 e 460 Vac

- 16 -
7.3 Area Operativa AX-V 10144

20

Corrente dell’azionamento, Arms, kW

15

10

0 100 200 300 400 500

Area operativa azionamento AX-V 10444 in

funzione della tensione di uscita per alimentazioni
230, 380 e 460 Vac

7.4 Area Operativa AX-V 10284

30
Corrente di uscita [Arms] e potenza resa [kW]

25

20

0 100 200 300 400 500

1 Vo 497
Volt

Area operativa azionamento AX-V 10284 in

funzione della tensione di uscita per alimentazioni
230, 380,460 Vac

- 17 -
7.5 Area Operativa AX-V 23404

50
0

Corrente dell’azionamento,
40

30

20

10

0
0 100 200 300 400 500

Area operativa azionamento AX-V 23404 in funzione della

tensione di uscita per alimentazioni 230, 380 e 460 Vac

7.6 Area Operativa AX-V 25554

60

50
Corrente dell’azionamento

40

30

20

10

0 100 200 300 400 500

Area operativa azionamento AX-V 23404 in funzione della

tensione di uscita per alimentazioni 230, 380 e 460 Vac

- 18 -
8 Electrical Connections

COMMAND TERMINAL C1 – FUNCTION AND SIGNAL DESCRIPTION

Connector Terminal Phoenix 20 pin cod. 1847301
Pin
Name Type Function Signal Description
N.
Positive signal of +/-10V, Zin = 10Kohm; if not used connect
1 R0P Analog Input
differential input to GND
Negative signal of +/-10V, Zin = 10Kohm; if not used connect
2 R0N Analog Input
differential input to GND
Positive signal of +/-10V, Zin = 10Kohm; if not used connect
3 R1P Analog Input
differential input to GND
Negative signal of +/-10V, Zin = 10Kohm; if not used connect
4 R1N Analog Input
differential input to GND
5 AO0 Analog Output Programmable Output +/-10V f.s., 5 mA

6 AO1 Analog Output Programmable Output +/-10V f.s., 5 mA

7 GND Analog Ground

8 DI0 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

9 DI1 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

10 DI2 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

11 DI3 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

12 DO0 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

13 DO1 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

14 DO2 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

15 DO3 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

16 RLM Relay Contact Common relay ouput 1A, 250 Vac resistive

17 RLO Relay Contact N.A. relay contact 1A, 250 Vac resistive

18 RLC Relay Contact N.C. relay contact 1A, 250 Vac resistive
Regulation circuit Aux Voltage: 20-30 V referred to Pin 20
19 24V Aux Supply
Alim. Absorbed current: 600mA.
20 0V Aux. Supply Neg Aux Alim.

- 19 -
 COMMAND TERMINAL C2 – FUNCTION AND SIGNAL DESCRIPTION
Connector Terminal Phoenix 16 pin cod. 1847262
Pin
Name Type Function Signal Description
N.
Positive signal of +/-10V, Zin = 10Kohm; if not used connect
1 R2P Analog Input
differential input to GND
Negative signal of +/-10V, Zin = 10Kohm; if not used connect
2 R2N Analog Input
differential input to GND
3 AO2 Analog Output Programmable Output +/-10V f.s., 5 mA

4 AO3 Analog Output Programmable Output +/-10V f.s., 5 mA

5 GND Analog Ground

6 DI4 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

7 DI5 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

8 DI6 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

9 DI7 Digital Input Programmable Input 6.6 kOhm rel. to ground, 20-30 V

10 DO4 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

11 DO5 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

12 DO6 Digital Output Programmable Output PNP open collector, 24 V, 100mA max

13 DO7 Digital Output Programmable Output PNP open collector, 24 V, 100mA max
Digital encoder
14 REA Digital Output NPN open collector 30 V, 100 mA
repetition: Ch. A
Digital encoder
15 REB Digital Output NPN open collector 30 V, 100 mA
repetition: Ch. B
Digital encoder
16 REC Digital Output NPN open collector 30 V, 100 mA
repetition: Ch. C

- 20 -
 I/O EXPANSION BOARD (Option)
Connector Terminal Phoenix 20 pin cod. 1847301
N. Pin Name Type Function Description

Insulated reference for Supply Voltage: 10-30 V to Pin 15 ( 0V )

1 +V_DO Supply Voltage
Digital Outputs

2 DO8 Digital Output Programmable output PNP open collector 100mA max

3 DO9 Digital Output Programmable output PNP open collector 100mA max

4 DO10 Digital Output Programmable output PNP open collector 100mA max

5 DO11 Digital Output Programmable output PNP open collector 100mA max

Digital outputs
6 GND_DO
Insulated gnd

7 DI8 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

8 DI9 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

9 DI10 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

10 DI11 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

11 DI12 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

12 DI13 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

13 DI14 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

14 DI15 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

15 DI16 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

16 D17 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

17 DI18 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

18 DI19 Digital Input Programmable input 6.6 kOhm to gnd (Pin 1), 20-30 V

Insulated Gnd
19 GND_IN
digital inputs
Insulated Gnd
20 GND_IN
digital inputs

- 21 -
 CAN-BUS CONNECTOR J1 (Option C)
Board connector type Cannon Sub-D 9 pin, male plug
Pin N. Name Type Signal Description

1 n.c

2 CAN-L Digital 5V Signal CAN LOW

3 SHIELD Ground

4 n.c

5 n.c.

6 GND Ground

7 CAN-H Digital 5V Signal CAN HIGH

8 n.c.

9 n.c.

PROFIBUS CONNECTOR (Option P)

Phoenix Terminal 9 pins
Pin N. Name Type Signal Description

1 Shield Ground Cable shield connection

2 n.c.

3 RX/TX – B Digitale 5 V Positive Receive/transmit Channel

4 n.c.

5 0V Ground Ground reference for data signals

6 +5V Alimentazione Supply voltage for terminating resistance

7 n.c.

8 RX/TX - A Negative Receive/transmit Channel

9 n.c.

- 22 -
 ENDAT ENCODER CONNECTOR J2 (Option C)
Board connector type Cannon Sub-D 15 pin, male plug
Pin N. Name Type Signal Description

1 0 V / PTC- Ground Connect 0 V, PTC- and shield

2 n.c.

3 CLK+ Digital 5 V Positive Clock Signal

4 CLK- Digital 5 V Negative Clock Signal

5 n.c.

6 +Vcc Power supply Encoder Supply Voltage

7 n.c.

8 PTC+ Digital 5 V Motor PTC thermal sensor input

9 DATA - Digital 5 V Negative Data Signal

10 n.c.

11 n.c.

12 n.c.

13 n.c.

14 DATA+ Digital 5 V Positive Data Signal

15 n.c.

- 23 -
 ASYNCHRONOUS SERIAL PORT X1
CARD CONNECTOR - CANNON – D 9 PIN, MALE PLUG
RS 485 multidrop, half duplex, insulated 2500 Vdc, standard speed 18.2 kB, max. hardware 1 MB
Terminate line with 120 Ohm by means of panel switch
Pin Name Type Function Description

1 Reserved

2 Reserved

3 LINE A (RS485) I/O RS485 line Channel A

4 SHIELD 0V + 100 Ohm Cable Shield

5 GND Signal Gnd

Supply voltage for
6 + 5V OUT Output Voltage Max. 20 mA
RS485 - RS232 converter
7 LINE B (RS485) I/O RS485 line Channel B

8 GND Signal Gnd

Enable RS485 Mode
9 ENABLE485 Digital input Input NPN 5 V
(Active High) *
* Jumper with pin 6 to connect to RS 485 Devices

- 24 -
 SENSOR CONNECTOR S1: FUNCTIONS AND SIGNAL DESCRIPTION1
CARD CONNECTOR - CANNON – D 15 PIN, MALE
Card Pin
Conn. Name Type Function Signal Description

1 GND+PTC 0V
Digital Negative Hall Sensor
2 H1N Square wave 0-5V
input phase 1
Digital
3 H1 Hall Sensor phase 1 Square wave 0-5V
Input
Digital
4 HALL 2 Hall Sensor phase 2 Square wave 0-5V
Input
Digital
5 HALL 3 Hall Sensor phase 3 Square wave 0-5V
Input
6 AUX +5V Aux Alim.
Digital
7 ENC A+ Encoder Ch. A Square wave 0-5V
Input
Digital Motor thermal
8 PTC
Input protection
Digital
9 ENC I- Negative Encoder Index Square wave 0-5V
Input
Digital Negative Hall Sensor
10 H2N Square wave 0-5V
Input phase 1
Digital Negative Hall Sensor
11 H3N Square wave 0-5V
Input phase 1
Digital
12 ENC A- Negative Encoder Ch. A Square wave 0-5V
Input
Digital
13 ENC B- Negative Encoder Ch. B Square wave 0-5V
Input
Digital
14 ENC I Encoder Index Square wave 0-5V
Input
Digital
15 ENC B Encoder Ch. B Square wave 0-5V
Input

1
In case of connection to Ultract motors, for encoder codes refer to Appendix A in this manual

- 25 -
 SENSOR CONNECTOR S2: FUNCTION AND SIGNAL DESCRIPTION 1
CARD CONNECTOR – CANNON – D 25 PIN, MALE
Card Pin Name Type Function Signal Description

1 AANA Ana/digi Direct Input ch A Sine 1V pk/pk / digital

2 BANA Ana/digi Direct Input ch B Sine 1V pk/pk / digital

3 IANA Ana/digi Direct Input Index Sine 1V pk/pk / digital

4 GND+PTC 0V

5 COSN Ana/digi Negative Cos Input (ch. D+) Sine 1v PK/PK absolute

6 SINN Ana/digi Negative Sin Input (ch. C-) Sine 1v PK/PK absolute

7 H1 Digital Input Hall Ch. 1 Square wave 0-5V

8 H2 Digital Input Hall Ch. 2 Square wave 0-5V

9 H3 Digital Input Hall Ch. 3 Square wave 0-5V

10 GND+PTC 0V

11 PTC+ Motor sensor terminal

12 RESEXN Analog Output Positive resolver excitation Sinusoidal, 2 V pk-pk, 8 kHz

13 GND+PTC 0V

14 ANNA Ana/digi Negative Input ch A Sine 1V pk/pk / digital

15 BNANA Ana/digi Negative Input ch B Sine 1V pk/pk / digital

16 INANA Ana/digi Negative Input Index Sine 1V pk/pk / digital

17 COS Ana/digi Direct Cos Input (ch. D-) Sine 1V pk/pk absolute

18 SIN Ana/digi Direct Sin Input (ch. C+) Sine 1V pk/pk absolute

19 GND+PTC 0V

20 H1N Digital Input Negative Hall Ch. 1 Square wave 0-5V

21 H2N Digital Input Negative Hall Ch. 2 Square wave 0-5V

22 H3N Digital Input Negative Hall Ch. 3 Square wave 0-5V

Converts encoder input S1 in
23 ABREN Digital Input Enable encoder simulation encoder simulation output, low
active
24 RESEXP Analog Output Negative resolver excitation Sinusoidal, 2 V pk-pk, 8 kHz

25 AUX + Analog Output Encoder Alim. Programmable 4.5-15V, 250 mA

1
In case of connection to Ultract motors, for encoder codes refer to Appendix A in this manual

- 26 -
 POWER CONNECTOR
CARD TERMINAL - PHOENIX PC4/10-ST 7.62 10 WAYS - FEMALE
ULTRACT Pin ULTRACT motor wire
Terminal Description
connector colour
A Motor phase A A Blue

B Motor phase B B Red

C Motor phase C C Yellow

R Mains Supply R --- ---

S Mains Supply S --- ---

T Mains Supply T --- ---

External braking resistance connection
BR- --- ---
(connect this terminal to DC+)
DC+ Positive DC bus --- ---

DC- Negative DC bus --- ---

Connect to DC+ to enable
BR+ --- ---
internal braking system

- 27 -
9 Mechanical Installation

AX-V Dimensions

Cod. a a1
AX-V 06094 85 50
AX-V 10144 85 50
AX-V 10284 85 50
AX-V 25544 182 100

φ= 5 mm

y Install inside control cabinet; do not obstruct air flow (from low side to upper side)
y Avoid proximity (<40 mm) of walls and other devices on upper and lower side
y Check distance between drive and motor; if wiring exceeds 15m, insert appropriate
snubber inductors
y Check cabinet inside temperature and cooling conditions

10 AX-V Fault codes

Remark: fault conditions are identified either with the Flight Recorder function in AX-V
Cockpit, or, when the PC is not connected, by a digital code on the signal LED. The code
meaning is as follows:
y Continuous green: normal operation
y Continuous yellow: data transfer
y flashing: fault: green=0, red=1
Example: green, green, red, red, red: 00111, motor Overtemperature
All fault conditions are latched and are reset either by Control Panel or by cycling the 24
V off and on.
Note – If Control Panel is enabled, the error code cannot be read because of the fast
communication speed with the drive; close Control Panel to allow the correct view of
red and green blinks.

- 28 -
CODE Error n. Description Possible Reason
A short circuit occurred on the motor windings or the power
00001 Error 1 Bridge Short Circuit
bridge

Over current protection. It may occur if current loop

00010 Error 2 Overcurrent
parameters are not properly tuned for the motor.

00011 Error 3 Dc-Link Overvoltage Brake resistance is not properly connected or is broken.

00100 Error 4 Heat Sink Overtemperature Too heavy work cycle

Module Junction
00101 Error 5 Too heavy work cycle
Overtemperature

00110 Error 6 Brake Short Circuit A short circuit occurred on brake resistance

Motor windings overtemperature or PTC sensor not

00111 Error 7 Motor Overtemperature
connected to the drive

01000 Error 8 Aux Power Undervoltage Supply voltage (24 V) too low

01001 Error 9 DSP Program Error Firmware error

01010 Error 10 16 KHz Interrupt Overtime Firmware error

Parameters values are not recognized. Try to click the SAVE

01011 Error 11 Invalid Flash Parameters
button in AXV-Cockpit and than reset the drive.

01100 Error 12 Bad Flash Device Firmware error

Brake resistance too hot due to excessive regenerative

01101 Error 13 Brake Overpower energy. If repeated, switch to an appropriate external
braking resistor.
The Heatsink thermal sensor could be broken or
01110 Error 14 Heatsink NTC Disconnected
disconnected

Power supply voltage is too high or clamp voltage is too

01111 Error 15 R Brake always on
low. Check parameter SYS_OV_CLM_LIM

10000 Error 16 Lock Drive Drive stopped by software

Wrong number of encoder pulses between two indexes .

10001 Error 17 Digital Encoder Count Error Check parameter Tn_CY_REV and verify all ground and
shields connections.
Wrong number of encoder pulses between two indexes.
10010 Error 18 SinCos Encoder Count Error Check parameter Tn_CY_REV and verify all ground and
shields connections.
Maximum output bandwidth of encoder simulation
10011 Error 19 Encoder Simulation
exceeded. Check parameter Tn_SE_MAX_BW

- 29 -
CODE Error n. Description Possible Reason
The check of the level in analogic/digital encoder has
10100 Error 20 Level fault in AD Encoder
reported an error

The check of the level in analogic encoder has reported an

10101 Error 21 Level fault in AN Encoder
error

Incremental to absolute
10110 Error 22 Sensor check error
sensor error

Hardware not compatible

10111 Error 23 The firmware is not compatible with the loaded application
with Software
The cooling fan didn’t start at system command. This alarm
11000 Error 24 Cooling fan locked only commutate the relay but don’t stop the drive
automatically.
System parameters values are not valid. Rewrite into the
11001 Error 25 Invalid system parameters
drive parameters of table System_eng.par.

An error was found on selected expansion board. If no

11010 Error 26 Expansion board Error expansion board is installed, verify parameter
SYS_EXP_BOARD in table System_eng.par

Only for Slave axes of Intradrive link. Indicate that the axis is
not receiving the synchronisation signals from Master axis. If
11011 Error 27 Intradrive not synchronised
you have no Intradrive link, verify parameter
SYS_ID_ADDRESS in table System_eng.par

Slow task didn’t return within 8 ms. Reduce execution time

11100 Error 28 Slow Task overtime of slowtsk. Verify that there are no infinite loops in the
code.

11110 Error 30 Relay Off Drive Relay commutated

11111 Error 31 User Alarm This alarm can be forced by the user in a GPLC program.

Auxiliary 24 V supply with excessive ripple voltage or high impedance: In this case, the
internal processor cycles between UV lockout and reset, generating an apparent error
code (no communication is possible): RED-AMBER-GREEN. In this case, increase the
filtering or stiffen the auxiliary power supply.

- 30 -
11 System Parameters

Many of firmware functions may be configurated via “System Parameters”.

To enter these parameters run AXV Cockpit and open the file SysXX_en.par (XX refers
to numeric release of firmware referred by parameter table).

11.1 Current loop

Control current loop is PID type. It is possible set three gains indipendent (Proportional,
Integral and Derivative). To obtain a good loop calibration (bandwidth 1 kHz, overshoot
<10%) many parameters may be setted as in the following table. Special motors may
require a particular calibration to closed loop step response.

Parameter Value Default

SYS_IC_P_FAK 255 * L(*) 2000
SYS_IC_I_FAK SYS_IC_P_FAK / 2 2000
SYS_IC_D_FAK SYS_IC_P_FAK / 4 1000
SYS_HIGH_RES_PHASE Enables the commutation of magnetic field orientation on high On
resolution encoder after the first reference mark latch.
These function requires that the encoder is phased according to
Phase Motion Control standard.
If a third party motor or non standard motor is used, verify encoder
phasing before enabling the function.
SYS_ABS_START If On, uses absolute encoder (if installed) to determine magnetic Off
field guidance. If Off uses absolute encoder only at reset.
(*) Where L is the inductance measured between two phases in mH

11.2 Braking resistor

Following parameters allow to calibrate braking resistor related functions:

Parameter Value Default

SYS_OV_CLM_LIM DC-Link voltage to activate braking resistor in Volt 850
SYS_P_BRAKE_MAX Nominal power of braking resistor in Watt AXV06094 = 100
AXV10144 = 100
AXV10284 = 100
AXV25554 = 200
SYS_R_BRAKE Value of braking resistor in Ohm AXV06094 = 80
AXV10144 = 40
AXV10284 = 25
AXV25554 = 12

- 31 -
11.3 Encoder counters
Following parameters allow to configure the behaviour of encoder counters:

DI encoder: Auxiliary encoder (connector S1 - Ch. A, Ch. B and Index)

Parameter Value Default

SYS_DI_ENC_FILT Digital filter for noise suppression 3
(see table 1 below)
SYS_DI_ENC_MODE Select the count mode: 0
[0] = Multiply x 4 (standard encoder);
[1] = Ch. A count up, Ch. B direction;
[2] = Ch. A count up, Ch. B count down.
SYS_INDEX_ALARM Set a function to verify index position. If count error is greater than On
number in parameter SYS_IND_DI_TOL alarm 17 is set.
SYS_IND_DI_TOL See SYS_INDEX_ALARM 2

AD Encoder: Fast encoder (connector S2 - Ch. A, Ch. B and Index)

The fast AD encoder input can handle both analogue and digital encoders. Some
parameters act on both encoders types, others are referred to a specific one.

Parameter Value Default

SYS_AD_ENC_FILT Digital filter for noise suppression see table 1 below 4
SYS_AD_RIPPLE Acceptable range of analogue levels. The drive can execute a 100
control of analogue levels (sin2 + cos2) to verify encoder or cable
failures. If limit is exceeded alarm 20 is set. Lower the value, lower
the permitted fluctuation. Value 128 disables the control.
SYS_AD_GAIN2 Set the max input range of analog input of AD encoder. Expressed 1
in differenzial Vpk-pk .
SYS_COMP_ENC_AD Enables an automatic routine to compensate offset and gain of AD Off
analog input.
SYS_INDEX_ALARM Set a function to verify index position. If count error is greater than On
number in parameter SYS_INDEX_ALARM alarm 18 is set.
SYS_IND_AD_TOL See SYS_INDEX_ALARM 2
SYS_GATED_ENC Set to On this parameter if using digital encoder with masked index Off
with high channels A and B. Set to Off if using analog encoder.

- 32 -
 Table 1: Digital filter on AD and DI encoder input

SYS_DI_ENC_FILT Suppress fronts closer than

SYS_AD_ENC_FILT
0 0 ns
1 50 ns
2 100 ns
3 200 ns
4 400 ns
5 800 ns
6 1.6 µs
7 3.2 µs

AN Encoder: Slow analogue encoder input (connector S2 - Ch. Sin and Ch. Cos).

Parameter Value Default

SYS_AN_FILT Digital filter for noise suppression see graph 1 4096
SYS_AN_RIPPLE Acceptable range of analogue levels. The drive can execute a 100
control of analogue levels (sin2 + cos2) to verify encoder or cable
failures. If limit is exceeded alarm 20 is set. Lower the value, lower
the permitted fluctuation. Value 128 disables the control.
SYS_AD_GAIN1 Set the max input range of analogue input of AN encoder. 1
Expressed in differential Vpk-pk .
SYS_COMP_ENC_AN Set an automatic routine to compensate offset and gain of AN Off
analogue input.

Graph1: Cutoff frequency for digital filter

1 .103
3
10
Filter frequency [Hz]

frq( x ) 100

10 10
3 4 5
100 1 .10 1 .10 1 .10
150 x 5
10
SPL_FILT

- 33 -
11.4 Intradrive

These parameters allow the serial synchronous connection INTRADRIVE, a fast

bidirectional data exchange through AX-V drives (16 word, 4 kHz). This link uses
RJ11connectors X3 and X4. For more information refer to manual “Intradrive”

Parameter Value Default

SYS_ID_ADDR [0] Disable Intradrive connection 0
[1] Configure AXV drive as Master Intradrive
[2..15] Configure AXV drive as Slave Intradrive
SYS_ID_ELEMENTS [0..15] Select the total number of AXV drive connected to Intradrive 0
bus. This value is necessary for the master, optional for slaves.

11.5 Analogue outputs

These parameters allow balance offset of user’s analogue outputs.

Parameter Value Default
SYS_DAC0_OFFSET Offset, analog output 0 (Connector C1/5) 0
SYS_DAC0_OFFSET Offset, analog output 1 (Connector C1/6) 0
SYS_DAC0_OFFSET Offset, analog output 2 (Connector C2/3) 0
SYS_DAC0_OFFSET Offset, analog output 3 (Connector C2/4) 0

11.6 Serial link RS485

These parameters set-up the communication over RS485 (Connector X1). Remember
AXV drive can operate only as Slave, that is answers only to a Master request.

Parameter Value Default

SYS_BAUD_RATE Set serial port RS485 baud rate. 38400
SYS_SER_DELAY Set min delay in ms before AXV drive answer. 0

11.7 Motor thermal protection

A peculiarity of brushless motor is overload. In transient, for example during an

acceleration phase, it is possible to supply 3 or 4 times the nominal current. However
strong overloads, if not monitored, may be dangerous for motor, especially if it is of
small size (ULII size 2 and 4). This may happen because local overheating of winding may
be so fast to damage it before thermal sensor works.
AXV drive holds a motor thermal model that allows to temporary feed the the max
current to the motor, but limits it to avoid damaging the motor itself.
Parameter SYS_MOTOR_TC allows this protection to take into account the motor
thermal time constant. The value of motor nominal current, used for limitation, must be
written in GPLC application into Inom variable.

- 34 -
Parameter Value Default
SYS_MOTOR_TC Motor thermal constant. 15
Note: This variable is expressed in local units: the value may be
calculated as 5000 / Ta where Ta is motor thermal constant
period in seconds.

11.8 Position/Speed Loop.

Parameter Value Default

SYS_POS_ERR_MAX Set max. position recovery. Measured as interpolated 8388610
encoder counts , that is encoder counts * ^14 (512. Enc. pulse)
SYS_SPL_ZERO Set cutoff frequency for digital low-pass filter inserted at 4096
speed loop output. Useful to cancel high frequency
vibrations (> 300Hz). See graph 1 at page 31
SYS_ACC_FFW If On uses acceleration gain only in feed-forward, that is Off
requires a current proportional to reference acceleration.
Useful to minimise the dynamic error when using internal
positioner of AXV drive.
If Off the acceleration gain needs a current proportional to
acceleration error (derivative standard contribution).
SYS_HIGH_GAINS Multiplies by 4 the scale of position and speed gain Off

11.9 Expansion board

Parameter Value Default

SYS_EXP_BOARD Select if an optional expansion board is installed (EXP. I/O, EXP. Null
CanOpen ecc.)

11.10 Emergency braking

Parameter Value Default

SYS_UV_V_MIN Voltage at which emergency braking is started 0
SYS_UV_P_FAK Voltage regulation loop gain 10

- 35 -
12 CE conformity of AXV platforms, Ultract, Minact, Wave motors

Declaration of conformity – Manufacturer’s

declaration Installation instructions
EC1.8.1.96

12.1 Wiring recommendations and CE-typical system for conformity to EMCD and LVD

12.2 EC Declaration of Conformity for the purposes of EMCD e LVD

12.3 Introduction: EC directives

The EC Directives are manufacturing prescriptions intended to guarantee a standard
level of quality, reliability and safety for all industrial goods produced and marketed
across the European Union. The EC Directives are general documents that establish base
specifications for the certifications, which are subsequently converted into national laws
by all member states. A certification issued by a member state is valid automatically in all
other member states.
Technical details are not included in the directives. They are determined by the relevant
European harmonized standards (EN).
After verification, affixing a CE mark certifies the conformity to the CE directives. Within
the EU there are no commercial barriers for a product with the CE mark. A conformity
certificate, however, is generally not required for most directives. Consequently, it is not
always evident which of the (so far) 21 EC directives is considered in the CE mark of a
product and which standards are considered in the conformity verification.

In the field of Brushless motor drives, the CE mark is referred exclusively to the Low
Voltage Directive. As for the EMCD directive, a drive is only a component and not a
system, and the conformity of the system to the EMCD remains the sole responsibility of
the system designer or user. In order to assist their Customers, Phase Motion Control
have already proved and certified the conformity of a CE-typical system to the EMC
directive (see following chapter) with the AXV digital platforms and the ULTRACT II
brushless motors.

12.4 LVD Directive

The LVD directive deals with all electrical machines operating in usual environments
between 50 and 1000 V AC, and between 75 and 1500 V DC. This directive does not
apply to applications in particular atmospheres and/or anti-explosion machines; also it
does not refer to lifting equipment.
The directive’s general purpose is to guarantee a uniform electrical safety level from the
point of view of user’s risk and of possible damage to objects; the directive dictates the
product to be supported from the point of view of safety and of application
prescriptions.

- 36 -
12.5 Product safety
1. Transport, installation and use of the drives is reserved to qualified staff (IEC 364)
2. The opening of the drive’s enclosure or motors protections, or a defective
installation, can lead to personal or material damage
3. Drives and motors can have hot, rotating and live internal parts; this can be the case
even with power supply turned off.

12.6 Application as directed – Scope of application

1. AXV, AX4 drives are intended for variable speed motion control application, inside
the entire machine control cabinets.
2. When integrating the drives into machines, they may only be commissioned (i.e.
operation as directed) if the correspondence to the EC EMC directive 89/336/EWG is
proved, EN 60204 must be observed
3. The technical data on the units nameplates must be observed
4. The drives correspond to the LVD 73/23/EWG

12.7 Installation
1. The units must be installed and cooled according to the regulations stated in the
corresponding documentation
2. Ensure that no components are bent or insulation distances changed during
transport. The electronic components and contacts must not be touched.
3. When working on an energized controller the valid national requirements for the
prevention of accidents must be observed.
4. The electrical installation must comply with applicable regulations (cable cross
sections, fuses, protective conductor connections)
5. All control inputs and outputs of the drives are insulated with a “basic” insulation
(functional). Another level of protection must be implemented for personal safety
against electrical contact..
6. When using current-operated protective devices, please note that:
The controller have internal DC rectification. A DC fault current is therefore
possible. Some differential current protection systems are made inoperative by DC
current leakage. Use only “universal” or pulse operated protection devices.
The RFI filter which is built into the drives cause a certain amount of leakage
current to flow in the ground wires. This current may cause tripping of too
sensitive differential device and need to be taken into account while sizing
differential devices.
7. Irrespective of the CE mark on both drives and motors, it is reminded that the
compliance of the required limit values with the legal EMC regulations remain the
responsibility of the manufacturer of the system or machine.

12.8 EC Declaration of Conformity

Ref. to EC Low Voltage Directive 72/23/EWG

ULTRACT and MINACT series motors and AXV series brushless amplifier are designed,
manufactured and tested in conformity with the EC Low Voltage Directive 72/23/EWG
and under the responsibility of

- 37 -
Phase Motion Control s.r.l., Lungobisagno Istria 27r, 16141 Genova

The applied standards are the following:

IEC 34-1, 34-5,34-6, 34-11, 34-14 e IEC 72;

EN 60529
IEC 249/1 10/86,
IEC 249/2 15/12/89
IEC 326/1 10/90,
EN 60097/9.93

12.9 The EMCD Directive (89/336EWG)

The EMCD directive relating to electromagnetic compatibility is effective for

“equipment” which may either cause electromagnetic disturbances or be affected by
such disturbances.
The aim is the limitation of the generation of electromagnetic disturbances so that the
operation of radio and telecommunication systems and other equipment is possible and
that a suitable immunity of the equipment against electromagnetic disturbances is
ensured so that the operation can be achieved.
Controllers cannot be driven in stand-alone operation and therefore the controllers
themselves cannot correspond to the EMC directive. The controllers must be integrated
into a drive system to check the compliance with the EC directive relating to EMC of the
“Regulation about the electromagnetic compatibility of devices”.
Phase Motion Control has verified the conformity of controllers integrated into a
“typical” drive system (see below). The user can use this example as a reference to
design a system in according to EMCD.

12.10 Installation as specified

1. The RFI filter needs a ground connection. The typical application is not operable
without ground connection.
2. The drives are not domestic appliances and are not intended for domestic use.
3. For installations different from the typical application (e.g.: use of unscreened cables,
use of multiple drives, etc.) the conformity to the CE-EMC directive requires a check
of the machine or system regarding EMC limit values.
4. The user of the machine is responsible for the compliance with the EMC directive.
5. Screen all power cables from filters to drive and from drive to motor with a shield
coverage greater than 85%
6. Signal cables must always be shielded as above.
7. In order to reduce the interference caused by the motor cable and the induced noise
in the encoder connection cable, such wiring must be shorter than 15 meters. This
limitation is necessary also for the protection of the drive itself. For longer cables, use
appropriate snubber inductors.
8. For shield and ground connections, refer to fig. 1.

- 38 -
9. It is important that the power wires are inserted in wire ways different from the
signal and supply one and that any cross between the power and signal cables is
carried out at right angle.
10. A ground cable between the motor and the drive is always necessary with a layout
similar to that of the power cables.
11. If sensitive instruments are used (for example analogue, non preamplified
transducers, load cells, thermocouples etc.) keep a safe distance between the
instrumentation ground and the power ground.
12. The RFI filter which is built into the drives, as well as the high chopper frequency,
cause a certain amount of leakage current to flow in the ground wires. This current
may cause tripping of sensitive differential device and need to be taken into account
while sizing differential protection devices. For the same reason, high frequency
noise is normally conducted through the ground wire; all sensitive devices or cables
should be wired at a distance from the ground wire and cross the same wire at a
right angle.
13. All devices (drives, filters, motors) must be grounded on a single ground bar, with
ground wires as straight and short as possible.

NOTE: As specified in the EMC IEC-22G-21/CDV norm, AXV drives are not domestic
appliances and can cause interference to radio and tv reception.

12.11 EC Declaration of conformity

Ref. to EC Directive Electromagnetic Compatibility (89/336/EWG)

NOTE: ULTRACT and MINACT series motors and AXV brushless drives series are not
stand-alone systems, and are specified to application fields 2 and 3 in accordance with
IEC-22G-21/CDV. The conformity with EMC directive cannot be verified on such
components.
To assist its own customers, Phase Motion Control declares that AXV drives running
Ultract or Minact motors assembled in accordance with the instructions above and
completed with the filter SHAFFNER FN251/16/07 or something equivalent, with up to
100 meters of shielded-conductor cable between the drive and the motor, following the
cabling normative explained in the user manual, allows the active system (PDS) to satisfy
the requirements of the IEC-EN 55011 norm Class A and EN 50022 Class B.
As Components the AXV drives comply with the IEC 1000-4-2 (IEC 801-2) and IEC
1000-4-4 (IEC 801-4), without any accessory or protection.

- 39 -
13 Appendix A: ULTRACT MOTORS to DRIVE AXV Connections

S2

to S2 or S1

S1
Encoder
connecting
terminal

SINCOS ENCODER 5 DIGITAL RESOLVER

TRACKS ENCODER (Type R)*
(Type S, P, SJ)* (Type E, F, G, GJ)*
Pin motor terminal board Pin AX-V 25 poles Pin AX-V 25 poles Pin AX-V 25 poles
(motor side) connector (S2) connector (S2) connector (S2)
1 3 Pair 1 25 Pair 1 12 Pair 1
2 16 Pair 1 10 Pair 1 24 Pair 1
3 1 Pair 2 21 Pair 2 18 Pair 2
4 14 Pair 2 8 Pair 2 6 Pair 2
5 2 Pair 3 7 Pair 3 17 Pair 3
6 15 Pair 3 20 Pair 3 5 Pair 3
7 10 Pair 4 1 Pair 4 n.c. n.c.
8 25 Pair 4 14 Pair 4 n.c. n.c.
9 17 Pair 5 16 Pair 5 n.c. n.c.
10 5 Pair 5 3 Pair 5 n.c. n.c.
11 18 Pair 6 9 Pair 6 n.c. n.c.
12 6 Pair 6 22 Pair 6 n.c. n.c.
13 n.c. n.c. 15 Pair 7 n.c. n.c.
14 n.c. n.c. 2 Pair 7 n.c. n.c.
15 11 Pair 7 11 Pair 8 11 Pair 4
16 19 Pair 7 19 Pair 8 19 Pair 4
17 Reserved (PTC+)** Reserved (PTC+)** Reserved (PTC+)**
18 Reserved (PTC-)** Reserved (PTC-)** Reserved (PTC-)**
NOTE: Always use shielded cables with twisted pairs. Connect the shield to ground on motor side
and to pin 4 of connector S2 on AX-V side. In case of use of cables with double shield, the inner
shield should be connected only on AX-V side together with outer shield.
* Encoder type is impressed on motor label (Feedback Device)
** Internally connected at factory

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