SureServo2 AC Servo Systems

Drive Features

• Power Options: Available in single-phase 110VAC or 220VAC (100W-2kW) and three-phase 220VAC (3kW-15kW).
• High Performance: Features fully digital control with up to 3.1 kHz velocity loop response.
• User-Friendly: Easy setup and diagnostics via built-in keypad/display or the SureServo2 Pro PC-based software.
• Upgradeable Firmware: Allows for field upgrades to the latest operating system.
• Command Options: Supports ±10V torque/velocity command, pulse train, master encoder position command (line driver/open collector), and built-in motion controller with serial Modbus, Modbus TCP, or Ethernet/IP options.
• Internal Sequencing: Capable of handling position/speed commands, registration, electronic camming, homing, jumps, and arithmetic statements.
• Advanced Tuning: Features high-level automatic tuning with modes like One Touch Auto Tuning, Normal Auto Tuning, Assisted Tuning, and Manual Tuning. It can estimate load inertia and fine-tune systems with up to 60:1 inertia mismatch.
• I/O Capabilities: Includes optically isolated digital inputs (10) and outputs (6), analog outputs (2), and line driver output for encoders.
• Safety Features: Includes Safe Torque Off (STO) for E-stop situations.
• Advanced Diagnostics: Features an Advanced Scope for monitoring command and status signals.

Motor Features

SureServo2 motors are permanent magnet 3-phase synchronous motors available in three inertia classes:

• Low Inertia Models: 100W to 1kW, speeds up to 6,000 rpm.
• Medium Inertia Models: 1kW to 3kW, speeds up to 3,000 rpm.
• High Inertia Models: 4.5kW to 15kW, speeds up to 3,000 rpm.

All motors feature keyed drive shafts, integrated encoders (16,777,216 pulses/revolution), and optional 24 VDC spring-set holding brakes.

Tuning and Control Capabilities

The SureServo2 drive provides precise control of current, velocity, and position with a 3.1 kHz bandwidth for accurate tuning. It offers advanced tuning methods and an inertia estimation function.

Built-in Motion Controller: Drives can execute up to 99 preset index moves, controlled via digital inputs or communication protocols. This allows for applications like press feeds, rotary tables, and pick-and-place robots.

Selecting and Applying SureServo2 Systems

Key considerations for selecting a SureServo2 system include reflected load inertia, required speed, continuous torque, and peak torque. The system's performance is influenced by the ratio of load inertia to motor inertia, with lower ratios generally preferred for higher response.

Reflected Load Inertia

The inertia of all connected components must be translated to an equivalent inertia at the motor driveshaft. Keeping the reflected load inertia low (ideally under 10:1 ratio to motor inertia) is beneficial for high-response applications. Ratios up to 200:1 are possible but may require adjustments to bandwidth or responsiveness.

Torque and Speed Considerations

Calculations based on the motion profile and mechanical transmission determine the required servo motor torque and speed. Continuous torque must be within the drive's continuous operating region, and peak torque must be within the intermittent operating region. The SureServo2 Pro software's Scope feature can capture these values.

(Diagram Description: A torque-speed curve graph illustrates the relationship between motor speed and torque, showing continuous and intermittent operating regions, and peak torque limits.)

Mechanical Transmissions

Common transmissions include leadscrews, rack & pinion, conveyors, gears, and timing belts. Speed reducers like gearboxes or timing belts can be beneficial for low-speed, high-torque applications, reducing reflected inertia and improving load disturbance rejection. Proper selection must account for the added inertia of couplings and pulleys.

Coupling Considerations

Keyed shafts accommodate keyed or clamp-on/compression couplings. Servo-grade couplings are recommended for stiffness and torque rating. A safety factor of 1.25 over the peak torque requirement is advised.

System Configuration and Ordering

A complete SureServo2 system typically requires a Servo Drive, Servo Motor, Motor Power Cable, Motor Encoder Cable, and I/O Interface components. Optional accessories like Ethernet cards and breakout boards are also available.

Part Numbering System

The part numbering system (e.g., SV2A-2040) indicates component type (Drive/Motor), power rating, input voltage, inertia class, and series.

Torque to SureServo2 System Quick Reference

Detailed charts for SureServo2 AC servo drive, motor, and cable combinations across various power ratings (100W to 15kW) are available, specifying compatible drives, motors, power cables, encoder cables, and I/O breakout options.

SureServo2 Drive Specifications

SureServo2 drives offer a range of specifications including:

• Power Ratings: 400W up to 15kW.
• Input Voltage: Single-phase 100-120 VAC or 200-230 VAC, and three-phase 200-230 VAC.
• Output Current: Continuous output current ranges from 2.60A to 78A (rms).
• Cooling: Fan cooling is standard.
• Encoder Resolution: 24-bit (16,777,216 p/rev).
• Control Modes: Includes SVPWM control, Manual/Auto, and various pulse types (Pulse+Direction, CCW+CW, AB Quadrature).
• Interfaces: USB for PC configuration, RS-485 for Modbus communication, and I/O interface options.
• Protection Functions: Comprehensive protection including STO (Category 3/SIL 2), overcurrent, overvoltage, overheat, and more.
• Environmental: Operating temperature 0°C to 55°C, IP20 rating.

Detailed specification tables are available for each model, covering electrical characteristics, control modes, environmental factors, and approvals.

Wiring and Dimensions

Standard Wiring Example

A comprehensive wiring diagram illustrates typical connections for the SureServo2 drive, including power input, motor output (U, V, W), encoder connections (A, B, Z), digital inputs/outputs, Safe Torque Off (STO), and communication interfaces (USB, RS-485). It also shows connections for regenerative resistors and optional holding brakes.

Drive Dimensions

Dimensional drawings are provided for each SureServo2 drive model (e.g., SV2A-2040, SV2A-2075/2150, SV2A-2200/2300, SV2A-2550, SV2A-2750, SV2A-2F00). These diagrams detail mounting hole locations, overall unit dimensions in millimeters and inches, and specify required air flow clearances (2 inches above and below the drive) and cabinet depth considerations for cable bend radius.