Leadshine iSV-B23 Series

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Overview

Function Description
Usage Features
Maintenance Features

The Leadshine iSV-B23xxx is an integrated BLDC servo motor, a compact and efficient solution for various motion control applications. This device combines a NEMA 23 brushless motor, a 1,000-line (4,000 PPR) encoder, and a servo drive into a single unit. This integration offers several advantages, including significant space savings, reduced wiring time for encoder connections and motor leads, minimized interference, and lower overall cable and labor costs. The iSV-B23xxx is designed to provide smooth low-speed performance, making it an ideal choice for applications where both precision and a small footprint are critical.

Function Description

The iSV-B23xxx operates as a closed-loop servo system, where the motor's position is continuously monitored and adjusted to match the commanded position. The integrated design simplifies the overall system architecture by eliminating the need for separate motor, encoder, and drive components.

Core Components:

BLDC Motor: A brushless DC motor provides the mechanical power for motion.
Encoder: A 1,000-line (4,000 PPR) encoder is directly integrated to provide high-resolution feedback on the motor's rotational position. This feedback is crucial for the servo system's accuracy and stability.
Servo Drive: The drive unit, also integrated, contains a comparator, amplifier, and control logic. It receives command signals, compares them to the measured position from the encoder, and amplifies the control signals to drive the BLDC motor.

Control Modes: The iSV-B23xxx can be configured and controlled in several ways:

Motion Controller: For dynamic applications requiring precise movement, the motor can be controlled by an external motion controller (indexer, pulse generator, or PLC) via pulse, direction, and enable signals.
PC Software (ProTuner): The integrated servo drive features an RS232 communication port, allowing connection to a PC for configuration and basic motor control. The ProTuner software enables users to set control modes, step resolution, current rates, and active levels of inputs/outputs. It also includes a simple emulating controller for testing purposes, allowing users to specify speed, acceleration, and move distance without an external motion controller. However, it's important to note that the performance observed in the PC software's emulating controller may not fully represent the actual performance with a dedicated motion controller.
DIP Switches: A 6-bit DIP switch on the drive case provides a quick way to configure essential parameters such as pulses/revolution settings, motor rotation direction, and self-test activation.

Input/Output Signals:

Pulse, Direction, Enable: These differential input signals are used to command the motor's movement. They can be connected to PNP (sourcing) or NPN (sinking) type controllers. The enable signal can be activated by applying 0V between ENA+ and ENA- or by leaving them unconnected to enable the motor.
Alarm, In-position Output: These isolated outputs act as electronic switches, providing feedback on the motor's status. An external resistor is required to limit the current, and the supply voltage for these outputs can be up to 24V.

Usage Features

Getting Started: To begin using the iSV-B23xxx, you need the integrated servo motor, a DC power supply, and optionally a motion controller or a PC with ProTuner software.

Power Supply Connection: The iSV-B23xxx accepts DC power input. A 2-pin pluggable screw connector is used for power supply connections. It's crucial to observe correct polarity, connecting the positive wire to the "+Vdc" terminal and the negative wire to the "GND" terminal. The power supply should always be switched off when making connections. Users must ensure the input voltage does not exceed the motor's specified range.

Motion Controller Connection: The pulse, direction, and enable inputs are differential and can be connected to NPN (sinking), PNP (sourcing), or differential type controllers. For NPN (sourcing) controllers, control signals share a common positive VCC. For PNP (sinking) controllers, control signals refer to the same ground terminal.

PC Connection: An RS232 communication port is built into the drive for configuration and control via PC software (ProTuner). A 5-pin plug-in terminal block on the drive connects to a 9-pin D-Sub female connector on the PC via an RS232 cable. If the PC lacks a serial port, a USB-to-Serial converter is required. As with power connections, the device should be powered off when connecting or disconnecting the RS232 cable.

Configuration:

DIP Switches (S1-S4): These switches set the pulses/revolution, with options ranging from 800 to 40000 pulses/rev. A "Software Configured" setting (default 4000) allows for custom resolution via ProTuner.
DIP Switch (S5): This switch reverses the motor shaft rotation direction.
DIP Switch (S6): This switch activates the self-test mode, where the motor rotates one revolution clockwise (CW) and then one revolution counter-clockwise (CCW) repeatedly until the switch is turned off.

Calculating Rotation Speed and Angle: Users can calculate the motor's rotation speed (RPM) and angle (degrees) based on the pulse frequency and pulse counts, using provided formulas:

Rotation Speed (RPM) = 60 * Pulse (Step) Frequency / (Pulse/Rev)
Rotation Angle (°) = 360 * Pulse (Step) Counts / (Pulses/Rev)

Rotating the iSV Motor:

Motion Controller: Once connected, a motion controller can be used to rotate the motor. It's recommended to disconnect the motor shaft from the load during initial setup to prevent accidents. Start with a low pulse frequency and gradually increase it. The iSV motor has no minimum speed limit, but the maximum speed is determined by input voltage and current settings.
Self-test Mode: Activating DIP switch S6 initiates a self-test, causing the motor shaft to rotate one revolution CW and then one revolution CCW repeatedly. This is a quick way to verify basic motor functionality.
PC Software: ProTuner's emulating controller allows users to specify speed, acceleration, and move distance for basic motor rotation.

Power Supply Selection: Choosing an appropriate power supply is crucial for optimal performance.

Voltage: Higher supply voltage allows for higher motor speeds but can increase noise and heating. For low-speed applications, a lower supply voltage is preferable. The recommended supply voltage should be within the drive's minimum + 10% to maximum – 10% range to account for power fluctuations and back-EMF.
Regulated vs. Unregulated: Both types can be used. Regulated supplies require a large current output rating to avoid current clamping. Unregulated supplies can often have a lower current rating (50-70% of motor current) because the drive draws current only during the PWM cycle's ON duration.
Multiple Drives: Multiple drives can share a single power supply if it has sufficient capacity. To prevent interference, drives should be connected separately to the power supply, not daisy-chained.

Maintenance Features

Wiring Notes:

Shielded Cables: To improve anti-interference performance, twisted pair shielded cables are recommended for wiring.
Signal Separation: Pulse/direction signal wires and motor wires should be separated by at least 10 cm to prevent noise from the motor from disturbing control signals, which could lead to position errors or system instability.
Power Connector: It is strictly prohibited to connect or disconnect the power connector while the drive is powered ON. High currents flowing through motor coils can cause extremely high back-EMF voltage surges, potentially damaging the drive.

Control Signal Setup Timing: For reliable operation and to prevent step loss, control signals (Pulse, Direction, Enable) must meet specific setup time requirements. These include Direction Setup Time (tDS), Pulse High/Low Level Setup Time (tPHS/tPLS), Direction Delay Time (tDD), Enable Setup Time (tES), and Enable Delay Time (tED). Specific values for these timings are provided for different iSV-B23xxx models.

Fine Tuning: While Leadshine pre-loads optimized default parameters for current and position loops, users may need to fine-tune the position loop parameters for their specific application to achieve the best performance. This tuning depends on factors such as power supply voltage, load inertia, and motion profile.

Protection Functions & Indications: The iSV-B23xxx incorporates several built-in protection functions indicated by a red LED, which blinks periodically (4-second cycle). The number of blinks signifies the type of protection activated, with higher priority errors being displayed first.

Over-current Protection (1 blink): Activated when peak current exceeds 18A, or in case of a short circuit between motor coils or between a motor coil and ground.
Over-voltage Protection (2 blinks): Activated when the drive's working voltage exceeds 60VDC.
Encoder Error (5 blinks): Activated when the encoder connection is incorrect or feedback is faulty.
Position Following Error (7 blinks): Activated when the position following error limit (default 4000 pulses, or a customer-set value) is exceeded.

Resetting Protection: When protection functions are active, the motor shaft will be free, and the LED will blink. To restore proper function, the drive must be repowered after resolving the underlying problem.

Important Safety Note: There is no protection against power lead polarity reversal. Incorrectly connecting the power supply leads can instantly damage the drive. It is critical to double-check power connections before applying power.

Troubleshooting: In case of improper operation, the first step is to determine if the problem is electrical or mechanical. Then, isolate the problematic system component. Documenting each troubleshooting step is important for future reference and for assisting technical support. Many issues often stem from electrical noise, controller software errors, or incorrect wiring.

Warranty and Service: Leadshine Technology Co., Ltd. provides a 12-month warranty against defects in materials and workmanship from the shipment date. During this period, Leadshine will repair or replace defective products at its discretion. The warranty does not cover damage due to improper handling, inadequate wiring, unauthorized modification, misuse, or operation outside electrical or environmental specifications.

To obtain warranty service, customers must acquire a Returned Material Authorization (RMA) number from customer service via email before returning the product. Customers are responsible for prepaying shipping charges for products sent to Leadshine for warranty service, while Leadshine covers the return shipping costs. The implied warranties of merchantability and fitness for a particular purpose are limited to the 12-month warranty duration. When shipping a failed product, include a written description of the problem, contact information, and details regarding the circumstances leading to the failure.