Parker COMPAX series compact servo controller: integrated motion control and drive

Parker COMPAX series compact servo controller: integrated motion control and drive

Product positioning and core philosophy

In modern automated manufacturing systems, the accuracy and response speed of motion control, as well as the simplicity of system integration, directly determine the performance limit of production equipment. Parker Hannifin's COMPAX series compact servo controllers are integrated products designed to address this core requirement. It integrates servo drives and programmable positioning controllers into the same chassis, eliminating the need to separately install motion control modules and power amplifiers in the control cabinet, greatly simplifying the system architecture, reducing wiring workload, and improving overall reliability.

The design philosophy of the COMPAX series can be summarized as "fast and stable". This concept runs through the development process of all digital controllers. By integrating position control, speed control, and torque control into a single device and using a high-speed digital signal processor (DSP) for unified computation, COMPAX achieves better dynamic response and rigidity than traditional discrete solutions. Users do not need to be proficient in complex control theory, as the system can automatically calculate the optimal control parameters based on input motor model, load inertia, transmission ratio, and other parameters, greatly reducing the threshold for servo system debugging.

Breakthrough in Integrated Control Technology

2.1 Fully digital closed-loop control

Unlike traditional servo systems that rely on analog input and potentiometer adjustment, COMPAX achieves fully digital closed-loop control from setting value generation to power output stage. The digital signal processor operates with a cycle time of 100 microseconds and processes real-time algorithms for the three loops of current, velocity, and position. The direct benefit of this high-speed processing capability is that the driver can respond to load changes in a very short amount of time, reduce tracking errors, and lower peak current and torque requirements. Due to the discontinuation of analog potentiometers and the storage of control parameters in digital form, parameter deviation caused by temperature drift or vibration is completely avoided, resulting in extremely high consistency during long-term operation.

2.2 Automatic Control Parameter Setting

One of COMPAX's major innovations is its intelligent parameter self-tuning function. Users only need to input physical parameters such as motor type, external load inertia, and transmission ratio during debugging, and the controller will automatically calculate and set the optimal core control parameters such as PID gain and filter time constant. This means that on the first power on, the three control loops can operate in a fast and stable state without the need for repeated trial and error. For higher-order applications, users only need to adjust up to two independent optimization parameters - damping coefficient and rigidity coefficient - to further match specific process requirements. This design compresses the servo debugging work that originally required hours or even days into a few minutes, making it particularly suitable for multi variety, small batch equipment manufacturing scenarios.

2.3 Monitoring Control and Adaptive Control

COMPAX integrates real-time monitoring capabilities for various system state parameters, including motor temperature, intermediate circuit voltage, actual current, external load inertia, and output stage temperature. Based on this information, the controller can adopt advanced monitoring control and adaptive control strategies. For example, when a significant change in load inertia is detected, the system can dynamically adjust the speed loop gain to maintain the same dynamic response performance. This adaptive capability enables COMPAX to perform well in situations where load characteristics vary with process steps, such as when a robotic arm grabs workpieces of different weights.

Comprehensive product range and power coverage

The COMPAX series is divided into multiple sub series based on power levels, power supply methods, and installation forms to meet different application requirements ranging from 1kW to 35kW.

3.1 COMPAX 1000SL

This is an entry-level model in the series, suitable for single-phase 230V AC power supply environments. Its rated output current is 2.5A effective value, and the peak current can reach 5A effective value (with a duration of less than 5 seconds), with an apparent power of 1.0kVA. This model adopts a fully enclosed metal shell, with built-in EMC shielding and heat dissipation fins, and supports panel installation. Despite its compact size, it still provides complete positioning control and 16 digital I/O (8 inputs/8 outputs), and comes standard with an RS232 interface. Regenerated energy is absorbed through a built-in 660 μ F capacitor, and if necessary, an external 100 Ω/60W braking resistor can be connected.

3.2 COMPAX 25XXS

This model supports single-phase or three-phase 230V AC power supply, with a rated current of 6.3A effective value, a peak value of 12.6A, and a power of 2.5kVA. Its design is compact and can be installed side by side or wall mounted through the accompanying mounting plate, significantly saving control cabinet space. The internal energy storage capacitor is 1100 μ F and can absorb 27Ws of regenerative energy. The recommended external braking resistor is 56 Ω/180W. It is suitable for small and medium-sized packaging machinery, textile machinery, and simple handling systems.

3.3 COMPAX 45XXS / 85XXS

These two models are designed for 400V/460V three-phase industrial power grids. 45XXS rated current 6.5A (400V) or 5.4A (460V), peak value 13.0A, power 4.5kVA; 85XXS provides a rated current of 12.5A (400V) or 10.5A (460V), with a peak value of 25.0A and a power of 8.6kVA. They are equipped with a 300W continuous power braking resistor (peak 3kW for 1 second) and reserve an external 22 Ω/450W resistor interface. Its heat dissipation design and installation dimensions are suitable for more demanding heating environments, and are commonly used in machine tools, flying shears, and heavy-duty conveying equipment.

3.4 COMPAX-M series (P1XXM, 02XXM, 05XXM, 15XXM)

COMPAX-M adopts a modular design, and the controller itself does not include a rectifier unit, but is powered by a central power module (NMD10 or NMD20). This architecture allows one power module to simultaneously drive multiple COMPAX-M drivers (up to 15kW), significantly reducing the cost of multi axis systems. The power of each sub model is P1XXM (3.8kVA, peak 8.5A), 02XXM (4.5kVA, peak 8.5A), 05XXM (8.0kVA, peak 17.0A), and 15XXM (17.0kVA, peak 50.0A). The power supply voltage range is 100V-650V DC, and the regenerated energy is centrally processed through the power module.

3.5 COMPAX 35XXM

As a high-power flagship in the series, the 35XXM is directly connected to a 400V/460V three-phase power grid, with a rated current of up to 50A effective value, a peak value of 100A, and an output power of 35kVA. Its built-in energy storage capacitor reaches 3450 μ F, which can absorb 542Ws of regenerative energy. The external braking resistor is 10 Ω/2kW. This model is suitable for large presses, injection molding machine parts taking robots, or centrifugal equipment with high inertia loads. All COMPAX models feature a fully enclosed metal casing with a protection level of IP20 (customizable to IP54), and are equipped with LED status display or a 3-digit 7-segment digital tube (excluding 1000SL) for fault diagnosis.

Core control functions and software variants

In addition to the standard positioning type (XX00), the COMPAX series also offers various specialized software variants, which can achieve specific motion control functions through firmware without the need for additional hardware.

4.1 COMPAX XX30- Cone Control

This variant is specifically designed for circular positioning applications such as indexing tables and rotating tables. The position coordinates are programmed in degrees and support both forward and reverse directions. Its feature lies in the "pitch calculator" instruction, which can divide the frustum into up to 1000 angle segments, suitable for multi station assembly machines. The system supports external position monitoring and can compensate for mechanical transmission errors by adding encoders to improve the final positioning accuracy. Typical applications include rotary combination machine tools, rotary filling machines, and indexing cutting equipment.

4.2 COMPAX XX50- Synchronous Cycle Control

This variant is designed for continuous operation of flying shears, cross cutting machines, and follow-up machining equipment. Its core function is to achieve synchronous tracking between the axis and the moving material. When the material is running at a certain speed, COMPAX controls the saw or moving worktable to accelerate to the material speed, and detects the "synchronous operation" state with a relative speed of zero, and then triggers the cutting or processing action through digital output. After processing, decelerate from the shaft and return to the standby position, waiting for the next cutting length signal. This variant also handles boundary logic such as "waste length" and "short material length": when the material speed is too high or the cutting length is too short, causing the standby time to approach zero, the system automatically switches to a longer alternative length to ensure reliable processing. In addition, the marking related processing (color code positioning) function allows for fixed length cutting or trimming through external input signals, suitable for positioning cutting of printing and packaging materials.

4.3 COMPAX XX60- Electronic Gearbox

The XX60 variant achieves electronic synchronization between the spindle and the external spindle. The signal of the external spindle can be provided by encoders, other COMPAX simulation outputs, or servo drivers. Users can freely set the transmission ratio (greater than 1, equal to 1, or less than 1) through two parameters, and support negative ratios to change the direction of rotation. There are two real-time inputs available for switching between the preset two transmission ratios. This variant provides two coordinate reference modes: in the "internal reference" mode, external pulses only serve as relative positioning superposition and do not change the internal zero point of the axis; In the "main position reference" mode, the external position values will be offset in real-time from the axis coordinate system, achieving superimposed motion, that is, the internal positioning program can still be executed when machining moving workpieces. Typical applications include synchronous angle control, color group synchronization of printing machines, and drilling or dispensing on continuous materials.

4.4 COMPAX XX70- Electronic Cam Control

This is the most powerful software variant in the COMPAX series, designed to electronically replace mechanical camshafts and camshafts. The system collects the real-time angle of the spindle through an incremental encoder, and COMPAX calculates the target position of the spindle based on the cam curve set by the user - stored in non-volatile memory in the form of up to 2500 reference points - and drives the servo motor (synchronous or asynchronous) to accurately follow. The controller performs linear interpolation between reference points, with a repeatability accuracy of up to 0.02 degrees. Multiple cam curves can be stored simultaneously and support dynamic switching of external signals, achieving the function of "curve linking".

In addition to position following, each reference point can also be associated with auxiliary functions: simulating the travel switch or analog feedback on the mechanical cam through 8 digital outputs and 2 analog outputs (± 10V range). Users can use the "CamEditor" Windows software to create cam curves graphically. After entering key points, the software automatically interpolates and displays position, velocity, and acceleration curves. Auxiliary functions can also be intuitively assigned on the timeline. In addition, XX70 provides multiple engagement/disengagement modes: static engagement, engagement at a designated synchronous position through external signals during spindle rotation, or automatic engagement when the spindle reaches a specific angle. The system also has a "lag warning" function, which outputs an alarm when the deviation between the actual position of the axis and the theoretical curve exceeds the set value. For complex curve design, Parker's technical support department can use the "Optimus Motus" design tool to generate optimized curves, balancing acceleration requirements and motor power. This variant is particularly suitable for reciprocating sealing and cutting machines in packaging machinery, die-cutting machines, and electronic jacquard weaving in textile machinery.

Flexible communication and bus integration

The COMPAX series provides a wide range of interface options for integration into modern industrial networks. All models come standard with an RS232 serial port for parameter settings, program downloads, and point-to-point control, with communication rates of 9600 or 4800 baud. For multi axis systems, users can choose from the following bus interfaces (all with optoelectronic isolation):

RS485: Supports 2 or 4 wires, up to 115k baud, and up to 99 stations.

Interbus S: Twisted pair remote bus, 500k baud, with a maximum of 64 participants per loop.

Profibus DP/FMS: 1.5M baud, compatible with Simatic S7 module.

CANbus/CANopen: up to 1M baud, following the CiA DS301 communication protocol and DS402 driver specifications.

CS31: Dedicated to interface with ABB PLC.

In addition, the HEDA real-time interface (options A1/A4) is a synchronous serial real-time bus that enables high-precision synchronization between the COMPAX master station and up to 16 slave stations, with a synchronization accuracy of ± 2.5 microseconds. HEDA can be used to transmit position settings or actual values between multiple axes, or to connect with HAISER's interpolation module (IPM) to achieve interpolation and tracking of up to 9 axes and 100000 contour points, with a data exchange cycle of only 1 millisecond.

For digital I/O, the standard configuration provides 16 channels of 24V DC input and 16 channels of output (8 channels each for 1000SL), with short-circuit protection for the output and a maximum of 100mA per channel. All I/O are connected through pluggable terminals. In addition, 5 binary inputs/outputs are provided for programmable controller data interfaces (excluding 1000SL). The encoder interface (standard or optional) supports RS422 differential input, can be connected to incremental encoders with 120 to 5000 lines/rpm, and has encoder simulation output (512 or 1024 pulses/rpm). Absolute position detection can be achieved through either a Resolver (standard configuration) or a SinCos encoder (options S1/S2/S3), the latter supporting single or multiple turns (4096 turns) absolute values. Option S2 also has a programmable transmission ratio, while S3 is suitable for linear motors.

EMC measures and peripheral accessories

To meet the requirements of CE certification (EN61800-3) and electromagnetic compatibility in industrial sites, COMPAX provides a complete EMC solution. The AC inlet filter (models NFI01/02, 01/03, 01/05) is used to suppress RF interference and meet the conducted emission limits. The connection line between the filter and the driver should be as short as possible: the unshielded line should be less than 0.5 meters, and the shielded line should be less than 5 meters. When the length of the motor cable exceeds 20 meters, a motor output filter (MDR01 series) must be installed, and the specifications of 16A/2mH, 30A/1.1mH, or greater than 30A/0.64mH should be selected according to the rated current.

The processing of regenerated energy is an important part of servo system selection. COMPAX models are equipped with different capacity energy storage capacitors and discharge circuits, but continuous or frequent deceleration processes require external braking resistors. The selection guide is as follows: COMPAX 1000SL recommends BRM8/01 (100 Ω, 60W continuous, 253W peak); 25XXS recommends BRM5/01 (56 Ω, 180W continuous); 45XXS/85XXS recommends BRM6/01 (22 Ω, 450W continuous, 6.9kW peak); 35XXM recommends BRM7/01 (10 Ω, 2kW continuous, 56kW peak); Choose the BRM4 series (15 Ω, providing continuous power from 0.57kW to 1.5kW) for the NMD20 power module. All braking resistors are equipped with 1.5-meter connecting wires, with a maximum allowable extension of 2 meters.

Software Tools and Development Support

The ServoManager software that comes with the COMPAX series is the core tool for configuration, debugging, and diagnosis. This Windows program provides features such as axis manager, parameter download/upload, error tracking and history, variable monitoring, and direct terminal access. Users can easily edit 250 motion commands (stored in non-volatile memory) through ServoManager. The instruction language is based on a BASIC like structure, including ACCEL (acceleration), SPEED (velocity), POSA (absolute positioning), POSR (relative positioning) WAIT、GOTO、GOSUB、IF-THEN-ELSE、OUTPUT、REPEAT、 Mathematical operations such as addition, subtraction, multiplication, division, and parameter assignment. The program supports sequential execution and can be interrupted by an external Break signal to stop at the set deceleration and continue running from another location.

For the design of electronic cam curves, HAISER CamEditor provides a graphical Windows interface. After the user inputs key points, the software automatically interpolates to generate up to 2500 reference points and displays position, velocity, and acceleration curve graphs. Auxiliary functions (digital output or analog voltage) can be arbitrarily specified to the reference point. The cam curve can be stored as a linear graph or displayed as a polar coordinate graph.

In addition, a handheld terminal BDF2/01 is also provided, which can be connected via RS232 for menu guided configuration, parameter and program viewing/editing, direct command input, and status value display, making it very suitable for rapid on-site diagnosis and trial operation.

Technical specifications and installation requirements

The control power supply of the COMPAX series is 24V DC, with a permissible fluctuation of ± 10% and a ripple of less than 1Vpp. The current consumption of different models is as follows: 35XXM is about 1.3A, 45XXS/85XXS is about 1A, and other models are about 0.8A; in addition, the maximum digital output per channel is 100mA, the fan is about 100mA, the motor brake is 0.35-1.6A, and the absolute value encoder is 0.3A. In terms of positioning accuracy, the motor shaft resolution is 16 bits (about 0.3 arcminutes), and the absolute accuracy is ± 15 arcminutes. The motion trajectory supports linear, quadratic, or smooth curves, and the acceleration and deceleration time can be set within the range of 10ms to 60s. Position units can be selected in steps, millimeters, inches, or customized through scale factors. The monitoring functions include power supply voltage, motor/power level temperature, stall protection, tracking error monitoring, and ready contact output (0.5A/60V/30W). Environmental conditions: Working temperature 0-45 ℃, relative humidity ≤ 75%, no condensation.

The installation size and weight vary depending on the model: 1000SL weighs 1.6kg, 25XXS weighs 4.6kg, 45XXS/85XXS weighs 6.5kg, P1XXM weighs 5.6kg, 02XXM weighs 7.1kg, 05/15XXM weighs 7.8kg, 35XXM weighs 22.5kg, NMD10/20 weighs 7.6kg and 8.1kg respectively. All models are suitable for panel installation of industrial control cabinets, and the connection methods include terminal blocks (motors, power supplies, I/O) and double row connectors (sensors and communication interfaces). Random attachments include user manual, matching connectors, and ServoManager software CD.

Summary of Typical Application Fields

With a wide power coverage from 1kW to 35kW, flexible bus integration, and specialized software variants, the COMPAX series has been widely used in the following industrial fields:

Assembly system: Rotating worktable, continuous assembly conveyor line, utilizing circular table control or electronic gears to achieve multi station collaboration.

Specialized machine tools: measuring units, electronic gearboxes, flying saws, achieve fixed length or calibrated cutting through synchronous cycle control.

Handling system: palletizing, loading and unloading, material removal, using automatic parameter tuning to adapt to different loads.

Machine tool: tool positioning, synchronous machining, spindle drive, leveraging high dynamic response and high rigidity advantages.

Textile machinery: laying, cutting, and sewing require electronic camshafts to achieve non sinusoidal motion patterns.

Packaging machinery: roller feed, electronic cam, main drive, especially for trademark synchronization and color compensation.

Production machinery: flying saw, winding, rotating cutter, using XX70 to achieve flexible electronic cam curves.

Measurement and testing: Sensor positioning, continuous path control, utilizing HEDA interface to achieve multi axis high-precision interpolation.

COMPAX servo controller series models

Basic model and power version:

COMPAX 1000SL (also known as COMPAX 10XXSL)

COMPAX 25XXS

COMPAX 45XXS

COMPAX 85XXS

COMPAX P1XXM (or COMPAX P100M)

COMPAX 02XXM

COMPAX 05XXM

COMPAX 15XXM

COMPAX 35XXM

Software functional variants (based on the aforementioned hardware):

COMPAX XX00 (Universal Positioning Type)

COMPAX XX30 (cone control)

COMPAX XX50 (synchronous cycle control)

COMPAX XX60 (Electronic Gearbox)

COMPAX XX70 (Electronic Cam Control)

Power module and peripheral accessories

Central power module (for COMPAX-M):

NMD10

NMD20

Communication input filter:

NFI01/02

NFI01/03

NFI01/05

Motor output filter:

MDR01/01（16A / 2mH）

MDR01/02（30A / 1.1mH）

MDR01/03（>30A / 0.64mH）

External braking resistor:

BRM4/01, BRM4/02, BRM4/03 (for NMD20, 15 Ω)

BRM5/01 (for COMPAX 25XXS, 56 Ω)

BRM6/01 (for COMPAX 45XXS/85XXS, 22 Ω)

BRM7/01 (for COMPAX 35XXM, 10 Ω)

BRM8/01 (for COMPAX 1000SL, 100 Ω)