micro rayon

Document Title: Micro Rayon_Datasheet

Document PN & Revision: RRDSH000010 Rev: 1.4

Project Name Micro Rayon

Catalog number RD000135

MICRO RAYON

Tiny Motor Controller

Tremendous Drive Power

DATASHEET

Catalog number: RD000135





2

Redler Technologies | Hagavish 5, Kfar Saba 4442211 | Israel Tel: 972-9-7672980 | Fax:972-9-8652381 | www.redler.co.il

Copyright

© 2021 Redler Technologies Ltd. No part of this document may be reproduced or

transmitted in any form or by any means without the expressed written permission of

Redler.

Disclaimer

This documentation was accurate and reliable at the time of its release. The manufacturer

may revise product specifications and/or this document at any time without specifications of

the product described in this manual without notification.

Product warranty

The Micro Rayon warranty is valid for 12 months from the date of shipment, unless

otherwise specified. The warranty will be invalidated if the customer fails to install, operate

or maintain the product in accordance with the manufacturer’s instructions.

Safety To safely operate the Micro Rayon drive, the manufacturer’s safety guidelines must be

strictly followed. These guidelines serve to keep your work area safe when operating the

Micro Rayon and accompanying equipment.

WARNING

Before assembling and commissioning the drive, read all product documentation.

Be sure to comply with all installation instructions and requirements. Improper handling of

products can cause personal injury and equipment damage.

The manufacturer takes no responsibility for any injury or damage caused by incorrect

handling or use.

• Only qualified personnel are permitted to install, commission, and maintain this drive. A

qualified person has the knowledge and permission to perform tasks such as transport,

assembly, installation, and maintenance.

• Be sure all system components are connected to earth ground. Electrical safety is

provided through a low-resistance earth ground connection.

• During operation, the drive has electrically charged components and hot surfaces. Power

cables can carry a high voltage even when the motor is not moving. To avoid the risk of

personal injury or equipment damage, keep covers (of encased drives) closed during and

after operation according to safety guidelines. After disconnecting the power source from

the drive, wait at least 30 seconds before touching the drive.

• To avoid electric arcing and hazards to personnel and electric contacts, never disconnect

or connect the product while the power source is energized.

• To prevent electrostatic damage, avoid contact with highly insulating materials, such as

plastic and synthetic materials. Place the drive on a conductive surface and ground

yourself to discharge any potential build-up of static electricity.

http://www.redler.co.il/





3

Document Control Revision # Release Date Change Description Author Approved by

1.0 11/03/2019 Release Ofer Keren Michal Munster

1.1 26/04/2020 Hight change from 9.07 to 9.6.

Improvement of GND on board.

A 6 legs connector instead of 4 to

improve mechanical.

Ofer Keren Michal Munster

1.3 18/07/2021 Update Parameters Ofer Keren Michal Munster





4

Contents

Safety ___________________________________________________ 2

Drive Features _____________________________________________ 5 Key features .................................................................................................. 5 Motors .......................................................................................................... 5 Current control .............................................................................................. 6 Speed control ................................................................................................ 6 Position control .............................................................................................. 6 Communication .............................................................................................. 6 Feedback ...................................................................................................... 6

Specifications _____________________________________________ 7 Absolute Max ................................................................................................. 7 Electrical ....................................................................................................... 7 Motor feedback .............................................................................................. 8 Mechanical .................................................................................................... 9 Environment ................................................................................................ 10 Derating ..................................................................................................... 10 Dimensions ................................................................................................. 11 PCB layout (board side) ................................................................................ 12

Wiring __________________________________________________ 13 System architecture ..................................................................................... 13 Pinout (complete) ........................................................................................ 13 Power ......................................................................................................... 14 Hall sensors ................................................................................................ 15 Incremental encoder .................................................................................... 16 Absolute encoder ......................................................................................... 17 Digital inputs ............................................................................................... 18 Digital outputs ............................................................................................. 19 Communication ............................................................................................ 20 STO input – optional ..................................................................................... 20

Micro Rayon Additional Info _________________________________ 21 Ripple capacitors .......................................................................................... 21 Voltage spikes and surges ............................................................................. 21 Reverse voltage ........................................................................................... 22 Power absorption during braking .................................................................... 22 RFI/EMI protection and emission .................................................................... 22

Micro Rayon Evaluation Board ________________________________ 24 Evaluation board layout ................................................................................ 24 Evaluation board signals ............................................................................... 25

J1 Communication connector ................................................................. 25 J2 Power and motor phases connector .................................................... 25 J3 Motor feedback connector ................................................................. 25 J4 Control connector ............................................................................. 26 J5 Analog input connector ..................................................................... 26 J6 Analog input connector ..................................................................... 27 JP1 Analog input header ........................................................................ 28 JP1 Analog input header ........................................................................ 28





5

Soldering Guidelines _______________________________________ 29

Drive Features The Micro Rayon is a complete and highly efficient motor control drive that can power up to

700W motors, and supports position, speed, and torque applications.

The Micro Rayon is a PCB-mounted controller that can be easily integrated in multi-axis

robotic applications.

Full digital control enables fast response and high bandwidth of current and position control

loops.

A dedicated GUI provides automatic control loop parameters for fast application setup,

load/read parameters, and a high-speed, Realtime graph monitor.

Key features

• PCB surface-mount technology (SMT)

• Miniature module, high power density

• Powers motors up to 700W.

• 12–48 VDC recommended operating voltage

• 10A continuous current (RMS), 15A sinusoidal

• 20A peak current 3 second (RMS), 30A sinusoidal

• Sinusoidal, flux-oriented current IQ ID vector control

• Motor calibration wizard

• Motor feedback: Hall, incremental, SSI, sin/cos absolute/incremental

• PID closed loop modes: position, speed, current, stepper.

• Autotuning and manual tuning for PID and filters

• Dedicated GUI, load/save parameters with real-time signal scope.

• RS232/422 communication (CAN optional)

• Firmware upgrade via serial

• Digital or analog ±10V command

• 5 digital inputs, 3 digital outputs

• Protection: over-temperature, over-voltage, over-current, encoder fault, motor stall, and

more

• Operating temperature -40°C to +85°C

Motors

• Brushed motors

• Brushless motors with Hall – six step commutations

• Brushless motors with Hall and incremental encoder – sinusoidal commutation

• Brushless motors with absolute SSI encoder – sinusoidal commutation





6

Current control

• Fully digital, closed loop PI at 20 kHz.

• 20kHz PWM

• Sinusoidal commutation with vector control (PID) or trapezoidal commutation with

encoder and/or digital Hall sensors

• 20 kHz sample rate, 12-bit current loop resolution

• DC bus power supply compensation

• Autotuning

Speed control

• Closed loop PID at 4 kHz.

• Programmable PID

• Feed forward

• Control filters

• Gain scheduling

• Autotuning

Position control

• Closed loop PID at 2 kHz.

• Programmable notch and low-pass filters

• External position feedback loop

Communication

Two communication options:

• RS232 serial communication with CAN, for fast communication in a multi-axis distributed

environment.

• RS422 serial communication

Feedback

• Incremental encoder – up to 1 MHz counts per second (250 kHz channel input),

differential or single-ended encoder inputs.

• Digital Hall sensors – up to 12 kHz counts per second (2 kHz channel inputs)

• Absolute analog (sine/cosine) – up to 12 bits.

• Interpolated analog (sine/cosine) encoder – up to 250 kHz (analog signal)

• Internal interpolation – up to 12 bits

• Signals offset calibration.





7

Specifications

Absolute Max

Parameter Description Units Min Typ Max

Motor voltage V 12 24-48 60

Motor current @45°C A 30

Motor current RMS A 10 20

5V output Current for encoder and Hall

sensors mA 0 200

Digital input V -0.5 5.5

Analog input 1 channel V -16 16

Operating temperature °C -40 85

Storage temperature °C -65 150

Electrical


Motor voltage Recommended working range V 12 24 48

Input capacitance µF 10

External capacitance Additional capacitance required

per motor ampere

µF/A 2.0 5

Quiescent current Logic consumption @12V mA 40 45 50

Logic consumption @24V mA 40 45 50

Logic consumption @48V mA 40 45 50

Motor current* With heat sink @45°C A 15 30

5V output Current for encoder and Hall

sensors mA 200

Serial communication Baud rate Kbit/sec 9.6 230 920

Packet rate ms 0.5

CAN Baud rate kHz 50 1000

Packet rate ms 1

Analog input Input voltage range V -10 10

Inputs 5 inputs V 0 3.3

Outputs 3 outputs mA 50

Digital inputs VIH High-level input voltage V 2.3

Digital inputs VIL Low-level input voltage V 1

ADC Resolution bit 12

Noise ARMS 0.05mV

PWM frequency kHz 20





8


Current loop Closed loop frequency kHz 20

Speed loop Closed loop frequency kHz 4

Position loop Closed loop frequency kHz 2

Current sensors Sample frequency kHz 20

Motion feedback Sample frequency kHz 20

I/Os Sample frequency kHz 0.1

Power up Power to communication sec 0.75

DSP clock MHz 59.997 60 60.003

Crystal 20 MHz accuracy ppm -50 +50

Power to motor command sec 1

Packet response µsec 25 100

Packet period from master msec 0.5

Note: See Derating specifications

Motor feedback


Incremental Resolution bit 2 30

Max input frequency kHz 250

Sin/cos incremental Resolution bit 2 30

Input frequency kHz 250

Hall Resolution in electrical turn,

60 degrees and 120 degrees

steps 6

Max input frequency kHz 20

Hall LPF RC filter and debounce kHz 72

SSI Resolution bit 4 30

Baud rate Mbit 0.5 2 4

Packet period µsec 50 500

Encoder input VIH High-differential level input

voltage

V 0.2

Encoder input VIL Low-differential level input voltage V -0.2

Encoder termination Between positive and negative

terminals Ohm 150

Hall input H High-level input voltage V 2

Hall input L Low-level input voltage V 0.8





9

Mechanical


Dimensions 30.4 X 25 X 9.6 0.1mm mm

Weight gram 8 9 10

Connector type SMT

Thermal pads Pads between covers and heatsink mm 0.9 1.0 1.1

Mounting pressure N/cm2 15 20 25





10

Environment


Operating temperature °C -40 85

Storage temperature °C -65 150

Vibration Contact Redler

EMC Contact Redler

ESS Contact Redler

Altitude Contact Redler

Derating

Temperature [°C] Current [A RMS]

25 17

45 11

71 6

85 4





11

Dimensions

Dimensions





12

PCB layout (board side)

PCB layout (board side)





13

Wiring

System architecture

System architecture

Pinout (complete)

Pin # Signal Name Signal Description

1,2,3 Ground Power return

4,5 Phase U Motor phase A

6,7 Phase V Motor phase B

8,9 Phase W Motor phase C

10,11,12 Power Power input for logic and motor 12–48V

13 Ground digital Digital ground

14 3.3 V out 10 mA max

15 SSI CLK + SSI master clock out signal MA+

16 SSI CLK - SSI master clock out signal MA-

17 SSI Data + SSI slave data out signal SLO+

18 SSI Data - SSI slave data out signal SLO-

19 RS 422 RX - Serial RS422 communication

20 RS 422 RX + Serial RS422 communication





14


21 CAN L Optional (refer to the section

Communication)

22 CAN H Optional (refer to the section

Communication)

23 RS 422 TX - Serial RS422 communication

24 RS 422 TX + Serial RS422 communication

25 RS 232 RX Serial RS232 communication

26 RS 232 TX Serial RS232 communication

27 IN5 Digital input 5

28 AI n Differential analog negative input

29 AI p Differential analog positive input

30 Reserved Do not connect

31 Ground digital Ground for digital signals

32 5V out 200 mA max

33 Hall 1 Hall sensor 1



36 Enc1 An Encoder A negative incremental/sine

37 Enc1 A Encoder A positive incremental/sine

38 Enc1 Bn Encoder B negative incremental/cosine

39 Enc1 B Encoder B positive incremental/cosine

40 Enc1 Idxn Encoder index negative

41 Enc1 Idx Encoder index positive

42 OC1 Open collector digital output 1







Power


1,2,3 Ground Power return

4,5 Phase U Motor phase A

6,7 Phase V Motor phase B

8,9 Phase W Motor phase C

10,11,12 Power Power input for logic and motor 12–48V





15

Hall sensors

• 5V supply voltage to the motor Hall components

• Supports 60-degree and 120-degree open collector Hall sensors

• Inputs contain 4.7k pullup resistor

• 72 kHz RC low pass filter with 4.7 k, 470 pF







Hall sensor wiring





16

Incremental encoder

• 5V supply voltage to encoder devices

• Supports both single-ended and differential signal

• Uses RS422 ISL32273E receivers with 150 termination

• 1 k voltage divider on negative to support single-ended configuration




36 Enc1 An Encoder A negative incremental/sine

37 Enc1 A Encoder A positive incremental/sine

38 Enc1 Bn Encoder B negative incremental/cosine

39 Enc1 B Encoder B positive incremental/cosine

40 Enc1 Idxn Encoder index negative

41 Enc1 Idx Encoder index positive

Incremental encoder wiring





17

Absolute encoder

• 5V supply voltage to encoder devices

• Supports both single-ended and differential signal

• Uses RS422 ISL3295 transmitter and SN65HVD75 receiver with 150 termination.

• 1 k voltage divider on negative to support single-ended configuration




15 SSI CLK + SSI master clock out signal MA+

16 SSI CLK - SSI master clock out signal MA-

17 SSI Data + SSI slave data out signal SLO+

18 SSI Data - SSI slave data out signal SLO-

Absolute encoder wiring





18

Digital inputs

• Digital inputs are controlled by open collector or switch input

• Digital input active signal is “0”

• Inputs contain a 4.7k pullup resistor


45 Digital input 1 Open collector or switch input (4.7K pullup to 3.3V)





Isolated ground digital input wiring

Limit switch digital input wiring





19

Digital outputs

• Digital outputs are controlled by Micro Rayon open collector NPN transistor

• Internal protection in the Micro Rayon is provided by a 1 kΩ resistor


42 Digital output 1 Open collector limit to 0.1A @24V



Isolated digital output wiring

High side digital output wiring





20

Communication

Micro Rayon provides one serial communication channel (RS232 or RS422) and one CAN bus

channel.


19 RS422 RXn RS422 receive data negative

20 RS422 RX RS422 receive data positive

21 CAN L CAN bus transceiver low signal (no termination)

22 CAN H CAN bus transceiver high signal

23 RS422 TXn RS422 transmit data negative

24 RS422 TX RS422 transmit data positive

25 RS232 RX RS232 receive data

26 RS232 TX RS232 transmit data

Note: If RS232 is selected, then RS422 signals are not active, and vice versa.

STO input – optional

STO input wiring

Micro Rayon does not have complete on-board STO functionality. However, users can easily

add the necessary hardware for STO implementation.

The carrier board components must be galvanically isolated, and the optocoupler

non-isolated side (BJT collector) is connected to the Ai- and Ai+ signals.

An optional STO interrupt input is connected to DIN4.

Contact Redler for complete ordering information.

More data on the internal protection within the Micro Rayon requires an NDA.





21

Micro Rayon Additional Info The Micro Rayon is a complete motor controller on a module. The module contains all the

logic and power parts of a motor controller.

The small dimensions and the component nature of the Micro Rayon restrict several

elements in the design. In some cases, the Micro Rayon needs some external components to

insure proper operation under a special requirement.

Ripple capacitors

The Micro Rayon is designed to be placed near a power source with a low impedance. If the

distance between the power source and the Micro Rayon is greater than 25 cm (10 inches),

a ripple capacitor must be added, close to the Micro Rayon.

The value of the ripple capacitors is ~35 µF/1 ARMS current.

Therefore, for 10 ARMS, the capacitors’ value is 350 µF, where two capacitors of 220 µF have

an equivalent value. The capacitors need to be low ESR.

Voltage spikes and surges

The Micro Rayon is rated for maximum 60V, which enables a working voltage of 48V.

Due to the high current in motor controller applications, input voltage may rise above the

working voltage. Therefore, it is mandatory to block such spikes and surges below 60V.

The easiest way to protect against over-voltage is to use a semiconductor TVS diode.

We recommend using a SMCJ48A for 48V working voltage.

TVS and motor voltage

Motor voltage 12V 24V 48V

TVS wattage 1500W 1500W 1500W

TVS type SMCJ24A SMCJ33A SMCJ48A

Place the TVS diode between the V Motor+ J1–10,11,12 and V motor return (0 V), J1–

1,2,3.

Placement of TVS

For automotive ISO7637-2 protection, consult the application note Automotive Circuit Protection using Littelfuse Automotive TVS Diodes.





22

Reverse voltage

The Micro Rayon should be protected against negative voltage.

The simplest method of protection is by connecting a diode with low V in series to the supply

V Motor+. If the motor current drawn by the Micro Rayon is less than 5A, the diode is the

best solution. If the current is greater than 5A, a MOSFET transistor is recommended.

For example, Vishay Schottky diode V8P8HM3_A/H displays a 0.5V drop @ 5A. The power

loss is 2.5W.

Placement of diode

Power absorption during braking

When the motor is braking, the energy should be absorbed by the application circuit. If the

reverse voltage blocking diode is part of the circuit, the capacitors and the local TVS serve to

absorb the power.

Users must calculate the braking power, and use the board capacitors and the TVS together.

Calculating the energy stored in a capacitor is as follows:

E=1

2𝑉²𝐶 where there are 470 µF capacitors and the working voltage is 24V

Using a 48V TVS, the energy stored in the capacitors is therefore:

𝐸 = 242 ∗ 470 ∗ 10−6 = 0.27 Joule, and the TVS will dissipate the rest

RFI/EMI protection and emission

Protection against RFI has two aspects:

• Micro Rayon – susceptibility

• Micro Rayon – emission

Micro Rayon susceptibility is low, and does not require protection against RF noise. However,

it is a good practice to shield the signals, especially for analog command signals. If the wires

are long and the induced RF field is high, the carrier board design should include ferrite

capacitors or ferrite capacitors in a configuration. The value of these components depends

on the environment RF noise. Typically, it is 47-470 µF capacitors, and 600Ω or higher

impedance at 300 Mhz ferrite.





23

Micro Rayon emission can be high if the supply, phases, and encoder wires are long and not

shielded. The high rise/fall time and the PWM frequency can generate RF noise harmonics up

to hundreds of megahertz. Power supply filtering can be done either by a Pi filter with an

inductor capable of operating in the operating current, or a common mode filter. The

common mode filter yields better filtering, but the ground voltage may rise above the 0 V

level.

The differential signals of the communication refer to CAN, RS422/485. The wide logic level

of the RS232 mitigates the problem.

Since the Micro Rayon generates a square (but not ideal) wave, the odd harmonics contain

more energy. The value of the capacitors and the inductors are subject to the system

design.

Placement of capacitors

Noise mitigation

Drive phase noise mitigation is implemented by L type filter.

Consider using Sypher Technology component SBSMD 20A.

To reduce the emission level from the encoder digital signals, use a Pi filter to the earth.

Consider using Sypher Technology component SBSPP1000103MXT

EMI filter





24

Micro Rayon Evaluation Board The Micro Rayon evaluation board enables fast implementation and testing of the motor

controller in the field.Evaluation board layout

Evaluation board layout





25

Evaluation board signals

J1 Communication connector Connector type: NORCOMP 190-009-213L569 D-type 9-pin female

Pin J1 Signal name Signal description

1 RS422 RXn RS422 receive data negative (data in)

2 RS422 RX – RS232 TX

CAN L

RS422 receive data positive (data in) or

RS232 transmit data (data out) – default state

CAN bus transceiver low signal (jumper selectable)

3 RS422 TX – RS232 RX RS422 transmit data (data out) or

RS232 receive data (data in) – default state

4 RS422 TXn Transmit data negative (data out)

5,6 GND Communication ground

7 CAN H CAN bus transceiver high signal (jumper selectable)

8,9 NC Not connected

J1-Pin 2,3,7 is jumper selectable. Refer to JP1 and JP2 description. Default signals are

RS232.

J2 Power and motor phases connector

Connector type: Molex 430451000 micro-fit 10-pin right angle male


1,6 VCC Motor 12–48 VDC

2,7 Motor Phase C Motor winding signal

3,8 Motor Phase B Motor winding signal

4,9 Motor Phase A Motor winding signal

5,10 Power GND 12–48 VDC return

7 CAN H CAN bus transceiver high signal (jumper selectable)

8,9 NC Not connected

J3 Motor feedback connector Connector type: Molex 105314-1114 nano-fit 14-pin right angle male


1 VCC 5V Hall +5 VDC supply

8 Hall 1 Hall signal input



3 GND Hall ground

10 VCC 5V Incremental encoder +5 VDC supply

4 CLK A Incremental encoder CLK A input positive

11 CLK An Incremental encoder CLK A input negative





26


5 CLK B Incremental encoder CLK B input positive

12 CLK Bn Incremental encoder CLK B input negative

6 IDX Incremental encoder index input positive

13 IDXn Incremental encoder index input negative

7 GND Incremental encoder ground

14 NC Not connected

J4 Control connector

Connector Type: Molex 105314-1116 nano-fit 16-pin right angle male


1 CAN H CAN bus transceiver high signal

9 CAN L CAN bus transceiver low signal

2 SSI CLKn SSI clock negative (RS422 signal output)

10 GND Digital ground

3 SSI DATAn SSI data negative (RS422 signal bidirectional)

11 SSI CLK SSI clock positive (RS422 signal output)

4 VCC 5V Absolute encoder +5 VDC supply

12 SSI DATA SSI data (RS422 signal bidirectional)

5 IN2 Digital input 2 (4.7 kΩ internal pullup resistor)



STO interrupt (STO version only)


7 OUT1 Open collector limit to 0.1A @24V


RS422/RS232 selector mix UART version only)



J5 Analog input connector Connector type: Molex 105314-1106 nano-fit 6-pin right angle male


1 Ai- Analog input negative

2 GND Ground

3 Ai+ Analog input positive

4,5,6 NC Not connected





27

J6 STO Connector TYPE: Molex 105314-1104 nano-fit 4-pin right angle male


1 STO-1 STO-1 switch output 12 or 24VDC

2 ISO GND Galvanically isolated ground

3 STO-2 STO-2 switch output 12 or 24VDC

4 ISO GND Galvanically isolated ground





28

P1 Communication

Header type: FCI-77313-101-14LF, use FCI 65474-002 jumper (shunt) female

Pin JP1 Signal name Signal description

1 CAN L CAN L signal to J1-2

2 CAN H CAN H signal to J1-7

3 RS232 TX RS232 transmit (output signal) to J1-2

4 RS422 RX RS422 receive (input signal) to J1-2

5 RS232 RX RS232 receive (input signal) to J1-3

6 RS422 TX RS422 transmit (output signal) to J1-3

7 CAN bus termination CAN bus termination resistor 120Ω

P2 I/O Connector type: FCI-77313-101-10LF, use FCI 65474-002 jumper (shunt) female

Pin JP2 Signal name Signal description

1 NC Not connected

2 IN5 Input 5

3 NC Not connected

4 IN4 Input 4

5 TDO Remote firmware update





29

Soldering Guidelines When performing soldering on the Micro Rayon, follow these guidelines.

• Micro Rayon is lead-free.

• No-clean soldering process is recommended.

• For manual soldering, use a soldering iron at 350°C.

• Do not repeat reflow. Use manual soldering instead.

• Visual inspection is recommended.

Soldering temperatures

micro rayon

Documents