5x34AC

User Manual: 5x34AC

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MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
FEATURES

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•
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•

•

•

POWER
32~132VAC
32~264VAC

I-CONT (A)
15
15

I-PEAK (A)
30
30

Drives DC brushless
motors with 60°° or 120°° Halls
in six-step (trapezoidal) mode
Independent settings for
peak and continuous current,
and peak-time.
External or hardwired
control of peak and
continuous current limits.
DriveTorque mode
switches from velocity to
torque mode for fastenerdriving, bottle capping, etc.

FEATURES
Separate motor and
signal Sub-D type connectors
for simpler cabling
+5V @ 200mA powers
motors with “commutating
encoders”
FAIL-SAFE ENABLE INPUT
Ground or +5V level select
Pull-up or pull-down select
Dual Status outputs (amp
NORMAL and amp READY)
FAULT PROTECTIONS
Short-circuits
output to output
output to gnd
Over / under voltage
Over temperature
Self-reset or latch-off
3kHz bandwidth
Wide load inductance range
0.4~40 mH.

THE OEM ADVANTAGE

•

MODEL
5234AC
5434AC

Operates directly from AC
mains with full optical
isolation between signal and
power stages.

Production amplifiers can
be pre-configured at the
factory for volume production

The 5xx4AC models are PWM
servoamplifiers for Hall commutated DC
brushless motors operating in six-step
(trapezoidal) mode. Models operate
from 115 or 230VAC single-phase AC
mains. Signal, logic, Halls, encoder,
and monitor signals are all optically
isolated from the mains.
Built with surface-mount technology,
these amplifiers offer a full complement
of features for DC brushless motor
control. Torque-mode operation is
standard, and there are two modes of
velocity-loop operation. Frequency to
voltage conversion of Hall or encoder
signals gives tachless velocity-loop
operation. Output voltage control gives
velocity loop operation without the use
of encoder or Hall signals.
Torque mode is used typically with
digital controllers that calculate position
and velocity from the motors encoder.
Hall tach operation works well for high
speed applications such as spindles.
Encoder tach velocity loops give a wide
speed range and lower ripple near zero
velocity. Voltage mode is smooth
around zero, and has enough speed
regulation to work well with PLC’s, or
motion control IC’s.
An internal solderless sockets permits
users to configure the various gain and
current limit settings to customize the
amplifiers for a wide range of loads and
applications. Header components
permit compensation over a wide range
of load inductances to maximize
bandwidth with different motors.

Built in power supply!

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Separate current-limits provide
protection for motors while optimizing
acceleration characteristics. Peak
current, continuous current, and peaktime are individually settable via the
internal header, or by external signals.
DriveTorque mode for fastener driving
applications permits external switching
between velocity and torque mode.
Screws are driven in at constant speed
using voltage-mode feedback until the
external controller senses increased
current. Then, mode is switched to
torque mode to set screw at
programmed torque.
The /Enable input active logic-level is
switch-selectable to ground or +5V to
interface with all types of control cards.
Fail-safe operation in either polarity
results from an internal jumper that
selects the default input level and input
resistor pull-up or pull-down
connections so that the amplifier shuts
down with no input.
IGBT output stages deliver fourquadrant power for bi-directional
acceleration and deceleration of
motors. For high-inertia loads, an
external regenerative energy dissipater
is available.
All models are protected against output
short circuits (output to output and
output to ground) and heatplate
overtemperature. With the /Reset input
open the amplifier will latch off until
powered-down or the /Reset input is
toggled.The amplifier will reset itself
automatically from faults if the /Reset
input is wired to GND.

Tel: 781-828-8090

Fax: 781-828-6547
Page 1 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
TECHNICAL SPECIFICATIONS
MODEL

5234AC

5434AC

OUTPUT POWER
Peak power
30A @ 100V
30A @ 200V
Peak time
1 sec at peak power or 2 secs. after polarity reversal
Continuous power
15A @ 120V
15A @ 240V
OUTPUT VOLTAGE
On-resistance (Ro, ohms)
0.1
0.15
Max PWM Peak Output Voltage
±Vout = (VAC X 1.41 -2)×(0.97) - (Ro)×(Io)
Maximum effective output voltage at continuous power
120V @ 15A
240V @ 15A
Maximum effective output voltage at peak power
100V @ 30A
200V @ 30A
INPUT POWER
Mains voltage
32~132VAC, 47~63Hz
32~264VAC, 47~63Hz
Mains current @ continuous output rating
16A
16A
Inrush current on startup
37 A max
37 A max
External mains fuse rating
30A/125V
30A/250V
LOAD INDUCTANCE
Minimum inductance
400 µH.
400 µH.
Maximum inductance
No maximum. See chart of load inductance values. Bandwidth varies with inductance and header parts.
BANDWIDTH

Small signal

-3dB @ 3kHz with minimum load at nominal supply voltage. Varies with load inductance and header values

PWM OUTPUTS
PWM frequency
Modulation

25kHz
Center-weighted, 50% duty cycle at 0V output
Differential, 94KΩ between inputs, ±20V maximum

REFERENCE INPUT
POTENTIOMETERS
(15 turn)

DIP SWITCHES

Ref Gain
Tach Gain
Loop Gain
Integ Freq
Balance/Test
S1:
S2, S3:
S4:

Default = CW
Default = CCW
Default = CCW
Default = CCW
Default = center

CCW attenuates Reference input from x1 to 0
CW increases speed ( decreases feedback from tachometer ). Note: fully CW = 5% of max
CW increases loop gain in velocity mode, current gain in torque mode
Integrator zero-gain frequency in velocity mode. CW increases stiffness
Use to set output current or rpm to zero; or use as ±10V test input if RH9 set to 50kΩ

Velocity loop integrator control. ON: Torque mode, integrator disabled. OFF: Velocity mode, integrator enabled.
Feedback mode control. See Applications section for details.
/Enable input active polarity. OFF (default): Gnd enables amplifier, open or +5V inhibits. ON: Gnd inhibits, open enables

LOGIC INPUTS
/Enable

Default = GND

/POS enable, /NEG enable
/Reset
/Motemp
/Force

Default = GND
Default = Open
Default = GND
Default = Open

Input resistance
Logic threshold voltage
Input voltage range

GND enables amplifier, open or >2.5V inhibits with S1 OFF. If S4 ON then GND inhibits
See following section on Fail-Safe operation for JP4 settings.
Response time: 1 ms. From enable active to amplifier output ON
GND enables, open or >2.5V inhibits positive/negative output currents ( S4 has no effect )
GND resets latching fault condition, ground for self-reset every 50 ms.
Motor temperature sensor. Typically normally closed bimetal sensor. Open = overtemp
Velocity to torque mode switching control. Ground disconnects velocity loop
components (Ref Gain, Tach Gain, Loop Gain, Integ Freq, and Balance pots,
and all related header parts). Mode changes to torque, RH10 controls transconductance.
See application section for details.
)
10kΩ (Jumper J1-A selects connection to +5V or ground , R-C filters on inputs
2.5V (Schmitt trigger inputs with hysteresis, 74HC14)
0V to +32VDC

FAIL-SAFE ENABLE INPUT
Internal jumper JP4 selects +5V or GND connection for input pull-up resistors to /Enable input only so that amplifier will default to
disabled condition if inputs are open-circuit, or wires are broken. (See Applications section for details)
LOGIC OUTPUTS
/Normal
HI output voltage
LO output voltage
Amp OK

LO (current sinking) when Normal LED is ON; HI when LED is OFF
+5V (no load). Output is N-channel mosfet drain terminal with10kΩ pullup resistor to +5V
On resistance Ro = 5Ω. Max sink current of 250mA. max off-voltage = 50VDC
N-channel opto-isolator is ON when amp is OK:
Buss volts OK AND NOT (output short OR overtemp) AND NOT Motemp switch open.
4 mA.
32 VDC

ON current
Max voltage
STATUS LED

Bicolor LED changes color and flashes to indicate amplifier operating status
Green = Normal
Amplifier enabled AND Amp OK (see above)
blinking green = Ready
Amplifier OK, will run when enabled
Red = Buss Fault, non-latching
Over or under-voltage condition. Amplifier recovers when voltage is in normal range OR Motemp switch open.
Red/blinking = Latching Fault
Output overcurrent (short circuit) or overtemp condition. Ground /Reset or power amp off/on to clear condition
MONITOR OUTPUTS
Current Ref
Current Monitor
Feedback

Current demand signal to PWM stage: ±10V = ±Ipeak
Motor winding current: ±10V @ ±Ipeak (1kΩ, 33nF R-C filter)
Monitor signal for Hall/encoder tachometer, voltage feedback. ±5V = 100% of feedback signal normal range

DC POWER OUTPUTS
+5V @ 250 mA max (J2-11, J3-23). Power for Halls and/or encoder.
+10VDC @ 5 mA (J3-24) -10VDC @ 5mA (J3-25)
Note: maximum power from all dc outputs not to exceed 1.4W

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 2 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
PROTECTIVE FEATURES
Short circuit (output to output, output to ground)
OverTemperature
Undervoltage
Overvoltage
Current-limiting (foldback)

Latches unit OFF (Power off/on, or ground at /Reset input resets)
Latches unit OFF at 70°C on heatplate ( Power off/on, or ground at /Reset input resets)
Wire /Reset input to ground for automatic reset after latching fault
Shutdown at DC buss < 45VDC
Shutdown at DC buss > 195VDC (5234AC), or DC buss > 390VDC (5434AC)
( Amplifier operation resumes when power is NOT undervoltage or NOT overvoltage )
Output current set by header components (peak, continuous, & peak-time)

THERMAL REQUIREMENTS
Storage temperature range -30°C to +85°C
Operating temperature range 0° to 70°C baseplate temperature
Thermal resistance (heatplate to ambient):
No heatsink or fan: 0.92 deg C/W, no heatsink with fan: 0.51 deg C/W
With heatsink: no fan: 0.6 deg C/W; with heatsink and fan: 0.23 deg C/W.
MECHANICAL
Size
Weight

7.50 x 7.0 x 2.72 in. (190 x 178 x 69 mm) without optional heatsink
7.5 x 7.0 x 4.72 in. (190 x 178 x 120mm) with optional heatsink
3.71 lbs (1.69 kg) without optional heatsink. Add 3.2 lb ( 1.47 kg ) for heatsink.

CONNECTORS
J1: Power & motor
J2: Halls / Options
J3: Signal

9-position terminal strip
15-position female Sub-D type. #4-40 standoffs for cable shell lock screws
25-position female Sub-D type. #4-40 standoffs for cable shell lock screws
Connector shells are connected to amplifier chassis for grounding/shielding

PANEL LAYOUT

STATUS

Model: 5434AC
Input: 32~264VAC
50/60Hz

REF GAIN
TACH GAIN
LOOP GAIN
INT FREQ

AC

J1

BALANCE

H

1

N

2

S1
S2
S3
S4

TRQ/VEL
MODE 0
MODE 1
ENAB POL

BUSS

3

+

4

-

5

25

13

J3

MOTOR

SIGNAL

U

6

V

7

W

8

14

1

15

8

9

J2
MOTOR
9
1

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 3 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
J1 POWER AND MOTOR WINDING CONNECTIONS
Connector type: Barrier-block. Screw-terminal connections. #6-32 locking screws with cable clamps.
PIN SIGNAL
FUNCTION
1
H
AC Power Input Hot (black or brown wire from AC mains)
2
N
AC Power Input Neutral (white or blue wire from AC mains)
3
GND
Chassis safety ground (green or green/yel wire from AC mains)
4
Buss (+)
Positive terminal of internal DC power supply (N.C.)
5
Buss (-)
Negative terminal of internal DC power supply (N.C.)
6
Motor U
Amplifier output to “U” winding of motor
7
Motor V
Amplifier output to “V” winding of motor
8
Motor W
Amplifier output to “W” winding of motor
9
GND
Chassis safety ground. Also for cable shield of motor cable.

J2 MOTOR HALL AND ENCODER CONNECTIONS
Connector type: Female Sub-D, 15-position, #4-40 standoffs for cable shell
PIN SIGNAL
FUNCTION
1
Safety GND
Chassis ground. Use to ground cable shield. Not connected to internal signal ground.
2
Hall U
Digital Hall inputs for “U”
3
Hall V
Digital Hall inputs for “V”
4
Hall W
Digital Hall inputs for “W”
5
Analog Tach
Brush tachometer input
6
N.C.
7
Encoder B channel
8
Encoder A channel
9
Motemp
Note: Must be grounded for amplifier to operate (Connect to J2-12, 14 or 15)
10
N.C.
11
+5V @ 200 mA.
DC power for encoders and Halls (Note 1)
12
0V.
Signal ground for +5V and Halls.
13
N.C.
14
0V.
Signal ground for +5V and Halls.
15
0V.
Signal ground for +5V and Halls.

J3 SIGNAL CONNECTIONS
Connector type: Female Sub-D, 25-position, #4-40 standoffs for cable shells
PIN SIGNAL
FUNCTION
PIN SIGNAL
FUNCTION
1
Safety GND
Chassis ground. Use to
ground cable shield. Not
connected to internal signal
ground (J3-12,13,15,16).
2
Ref (+)
Positive terminal of
14
Ref (-)
Negative terminal of
differential +/-10V analog
differential +/-10V analog
command input
command input
3
Analog Tach
Brush tachometer input
15
0V.
Signal ground.
4
Feedback
Hall, encoder, or Vout FB
16
0V.
Signal ground.
5
/Enable input
Amplifier enable
17
/Pos Enable input
6
/Normal output
Mosfet output amp status
18
/Neg Enable input
7
Amp OK (-) output
Opto-isolator emitter (NPN)
19
Amp OK (+) output
Opto-isolator collector (NPN)
8
Current Ref output
20
Ext Ipeak
External setting of peak curr
9
Aux input
21
Ext Icont
External setting of cont curr
10
Current Monitor Out
22
/Reset input
11
/DrivTorq
Ground enables Drive23
+5V @ 200 mA.
Auxiliary DC power for user
Torque mode.
devices (Note 1)
12
0V.
Signal ground.
24
+10V @ 5 mA
Auxiliary DC power
13
0V.
Signal ground.
25
-10V @ 5 mA
Auxiliary DC power
Notes:
1. +5V @ 200mA connects to both J3-23 and J2-11. Combined current from both pins must not exceed 200mA.

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 4 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
AMPLIFIER CONNECTIONS
2
Ref(+)
Ref(-)
Shld

2

3

14

4

1

11

Signal ground

Note:
Amplifier signal ground
must be connected to
controller ground.

13

12

U
V
W

Halls

+5V
0V

J2

+5V

Monitor Outputs
Feedback

4

Current Ref

8

Current Mon

10

0V

J3

7
8
1

(+)

19

(-)

7

9

6

15

Amp OK

/Normal

Ch. B

Encoder

Ch. A
Shld
/Motemp
Gnd
Note: /Motemp must be
grounded for amplifier to
operate

6
Velocity

7 V

11

Mode switch
DriveTorque

8

/Reset

22

/Enable

5

/Pos enable

17

J1

9

Motor

W
Shld

4

BUSS (+) N.C.

5

BUSS (-) N.C.

1
18

/Neg enable

U

2

H

Fuse

N

3
Fuses: 30A

L1

time-delay

Blk (Brn)

L2

Grn (Grn/Yel)
230VAC Wiring for

Note: Circuits within
dashed line are HOT!
(At mains potential)

5434AC

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 5 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
FUNCTIONAL DIAGRAM
JP1-A
AUX

9

100K
1K

CONTROL
SYSTEM
REF(+)

SJ From RH22

REF(-)

To Drive Torque Ref

47K

-

2

47K

+

14

RH3

100 PF

47K
50K

REF GAIN

4

50K

33NF

TACH GAIN

GND
-10V @
5mA
CURRENT
REFERENCE
+/-10V @ +/-Ipk

+5
C
W

5K

24

+10V

INTEG FREQ

25

GND

+

12

1K

BALANCE
RH9

Normal J3-11 Open

10M
CURRENT
LIMIT

-5
-10V
1K

8

IC from drive torque
when J3-11 Grouded

SECTION

PEAK
RH15

CONT
RH14

PEAK TIME
RH17

SEL

SEL

301k

CH18
1.5NF

RH20
49.9K

G = X1

CURRENT REF

TACH (-)

12.1K
CH. B

ENCODER

CH. A
U
V
W

HALLS

+5V @
200mA

TEMP

7

60 / 120
DEGREE
SELECTION
IS
AUTOMATIC

8
2

12

GND

14

GND

SHIELD

19

+

+5V@200mA

RH19

1

H

2

N

3
Earth GND

4

Buss (+)
N.C.

5

Buss (-)
N.C.

22

+15 -15
+/-5 mA
To IC
max

-

Drive Torque Ref

4
11

GND

HOT-MOT

RH 10

HALL
LOGIC

3

MOTOR

W

8

Power Stage
at Line
Potential and
Isolated from
Signal Stage

CURRENT
ERROR
AMP

5

V

7

Rectifier and
Capacitors

-

33NF

U

6

12.1K

10

+

J2 MOTOR

J1 MOTOR & POWER

OUTPUT
CURRENT
SENSE
Inrush
Limiting

33NF
1K

J3 SIGNALS

PWM
STAGE
MOSFET
"H"
BRIDGE
Gv = +HV
10

470 PF
CURRENT
MONITOR
+/-10V @ +/-Ipk

DRVTORQ

11

G

-

C
W

100K

50K

13

ENABLE

5

NORMAL
LED

RH1
CW

POS ENABLE

17

LOGIC

RH6

15

18

CONTROL

CH8

TACH
GND or TACH(+)

NEG ENABLE

&
0.22UF

+

RH7

NORMAL

6

STATUS

CH2

500K

3

+10V @
5mA

50K

1K

TACH (-)

J3 SIGNALS

SW
1

RESET

22

LOOP GAIN

100K

1K

0.1

WIRE RESET TO GROUND FOR SELF-RESET

+5V

10k

C
W

47K

FEEDBACK

1K

100K

RH12
CH5

RH4
cw

220 PF

CH13

RH11

33NF
DIFF AMP

MOMENTARY SWITCH RESETS FAULT

123

OFF = ENABLE
ON = ENABLE
SW
4

+HV

GROUND CASE FOR SHIELDING

+5
DC / DC
CONVERTER

+15

CASE GROUND
NOT CONNECTED
TO CIRCUIT GROUND

-15

15
9

POWER GROUND AND SIGNAL GROUNDS ARE
COMMON

1

FEEDBACK MODES FUNCTIONAL DIAGRAM

TO
J2 MOTOR
Ch. A
Ch. B
ENCODER

+5V
GND

4 PULSES
PER
ENCODER
100K
LINE

8
7
11

+5V

CH23

+5V

HALL U

FILTERS &
STATE
DECODER

A

U

E
VO

LT

AG

C
TA

E
H

AL

L

EN

DIP SW S2

OFF

ON

ON

OFF

DIP SW S3

ON

OFF

ON

OFF

K1

X

X

B

A

K2

X

B

A

A

K3

B

A

A

A

C

O

D

ER

C

H

FEEDBACK

J3
4

K1
T

4538

B

A
B

HALL V
3

HALL W
4

CH24

Q

2

GND

Q

TA

12

15

HALLS

R

H

6 PULSES
PER
HALL CYCLE

OUTPUT
VOLTAGE
SENSE

14

LOW-PASS FILTER

K2
A

K3

100K

100K

-

POLARITY
SWITCHING

+

RH22

TO SJ

B
CH25

JP1-B
NORM
REV
FEEDBACK POLARITY
SELECTION

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 6 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
DIP SWITCH FUNCTIONS
The default configuration for the amplifier is torque mode (no feedback). To enable the velocity feedback modes described below, set
the DIP switches according to the chart below.
Note: Default positions shown in bold & italics (ON is toward PC board, OFF is away from PC board)
SW

NAME

S1

INTEG

S2
S3
S4

MODE 0
MODE 1
EN POL

SEL
ON
OFF
OFF
ON
ON
OFF

DESCRIPTION
Torque Mode (velocity integrator OFF)
Velocity feedback mode (integrator ON)
Amplifier operating mode selection (Default = torque mode)
See table below for functions
/Enable input disables amplifier if ground. Open or >2.5V enables.
/Enable input ground-active. Open or >2.5V disables amplifier.

Note: “X” in table below means that switch setting doesn’t matter.
S2
OFF
ON
ON
OFF
X

S3
ON
OFF
ON
OFF
X

J3-11
HI
HI
HI
HI
LO

FUNCTION
Torque-Mode
Output voltage feedback
Hall speed control mode
Encoder speed control mode
DriveTorque mode

DESCRIPTION
No internal feedback
Output voltage control
Frequency to voltage conversion of Halls
Frequency to voltage conversion of encoder
RH10 sets current-gain. All pots out of circuit.

POTENTIOMETER FUNCTIONS
POT
REF GAIN

DEFAULT
CW

TACH
GAIN

CCW

LOOP
GAIN
INTEG
FREQ

CCW
CCW

BALANCE

Center

DESCRIPTION
Input reference signal attenuation. Controls overall amplifier gain
(amps/volt or rpm/volt) without affecting response.
Full CCW attenuates reference signal to zero.
Tachometer feedback control. CCW = maximum feedback (lowest
speed, fastest response), CW = minimum feedback (highest speed,
slowest response). Range = 20:1 (maximum to minimum speed).
Response control for velocity loop: CW increases bandwidth, CCW
decreases. In torque mode: CW increases amps/volt.
DIP switch S1 must be OFF for this pot to function.
In velocity mode, CW increases stiffness, makes loop less stable,
CCW decreases stiffness, makes loop more stable.
Too much CW leads to violent oscillation.
Sets velocity to zero, or output current to zero with zero input.

LED INDICATOR FUNCTIONS
Color and state of LED indicates amplifier operating conditions:
LED COLOR
Flashing Green
Green
Red
Flashing Red
Notes:
1.

2.

CONDITION (Note 2)
Ready
Normal
Power Fault
Latching Fault

ACTION REQUIRED TO ENABLE
Ground /Enable input (J3-5) (Note 2)
None. Normal “RUN” condition.
Bring AC voltage into range.
Ground /Reset input, or cycle AC power OFF/ON

Fault = output short circuit or heatplate overtemperature. Amplifier ‘latches’ off and stays off until reset.
Amp OK = Internal buss voltage is within limits AND NOT-Fault
Ready = Amp OK AND NOT-enabled
Normal = Amp OK AND enabled
With S4 OFF and jumper J1-A on pins 1-2 (default), grounding /Enable will enable amplifier.
If S4 is ON, grounding J3-5 inhibits the amplifier: voltage must be >2.5V to enable amplifier.
If J1-A is on pins 1-2 (default), amplifier will be enabled whenever J3-5 is open or >2.5V.
With J1-A on pins 2-3, the enable input is pulled to ground via a 10k resistor, disabling the amplifier when J35 is open (Fail-Safe operation). To enable the amplifier, the controller must pull-up the 10k resistor to >2.5V to
enable amplifier.

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 7 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
FAIL-SAFE JUMPER FUNCTION
J1-A

123

123

OFF
ON

+5V

SET FOR DIP
SW S4

10k

J3-5

DRIVETORQUE MODE

10k

/Enable

33nF

Internal jumper J1-A sets the open-pin voltage for the /Enable
input (J3-5). For FAIL-SAFE operation, the amplifier should
shut down if J3 is disconnected, or if the wire to the /Enable
input is broken.
For this to work, J1-A should be set according to the position
of DIP switch S4 as follows:
S4 OFF (default): /Enable input is ground active. J1-A set to
pins 1-2 so that input pulls up to +5V, disabling amplifier.
S4 ON: /Enable input functions as +Enable, /Disable. Set J1A to pins 2-3 so that input voltage is pulled-down to ground if
input is open.

AMP-NORMAL OUTPUT
+5V

This mode is most useful in fastener-drive applications where
the amplifier is operated in a velocity mode to drive the
fastener in at a constant speed until the controller senses that
the current has reached a set value. Then the controller
grounds the /DRVTRQ input switching the amplifier into torque
mode that applies a set current to the fastener to drive it into
position at a constant torque value.
With J3-11 open (default) amplifier operates in velocity mode.
This can be switch-selected to be Hall, encoder, output
voltage, or analog tachometer controlled.
When J3-11 is grounded, DriveTorque mode is enabled, and
amplifier switches to torque mode with transconductance
controlled by RH10. The REF GAIN, LOOP GAIN, INTEG
FREQ, and BALANCE pots have no effect in this mode. The
current gain is controlled by this simple equation:

Gain =
(A/V)

RH10 (kOhms)
10

PEAK CURRENT LIMIT SET
Control of the peak current limits can be made externally via
connector pin J3-20. A resistor can be connected between this
pin and signal ground (J3-12, 13, 15, or 16), or the pin can be
driven by a voltage between 0 and +10VDC. Using this
technique, the current limit can be controlled over a range of
100% to 10% of the amplifiers peak rated current. The figure
below shows the circuit. RH15 internal.

10k
+15V

J3-6

/NORMAL
47k
J3-20

+NORMAL

N-channel mosfet with 10k ohm resistor connected to +5V.
Maximum voltage: 50VDC. Maximum current 250mA. Onresistance = 5 ohms.
Output is LO (mosfet ON) whenever amplifier is enabled and
NORMAL (LED green).
Output is HI (mosfet OFF) whenever amplifier is NOT-enabled,
or FAULT occurs.

OPTOISOLATED AMP OK OUTPUT
The Amp OK signal indicates amplifier ready to run status. It is
completely optically isolated from the amplifier. The input of
the optocoupler is driven by the amplifier logic circuits, and the
output is a floating NPN transistor with both terminals brought
to signal connector
J3 as shown below.

470
+5V

J3-19
AMP OK(+)

J3-7
/NORMAL
AMP OK(-)
Maximum voltage = 32VDC. ON current = 4mA. minimum
Output transistor ON voltage: 0.4 at 4mA

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

0~10VDC

Rpk

+10V = 100%
Ipeak
R
H
15

94k

J3-16

Amplifier

The table below give values of the external control voltage, or
external control resistor for various values of peak current:
Ipeak
30
27
24
21
18
15
12
9
6
3

Rext

180k
91k
56k
39k
24k
15k
10k
5k
1.2k

Vext
10
8.8
7.7
6.6
5.6
4.6
3.5
2.5
1.4
0.4

These values are within 10%, typically. For greater accuracy,
measure Current Ref and select parts for exact limit value.

Tel: 781-828-8090

Fax: 781-828-6547
Page 8 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
ENCODER TACH OPERATION

the response of the loop to a step input. This will give the
widest rpm range.

HALL TACH VS. ENCODER TACH

VELOCITY LOOP TUNING

Digital Hall or encoder signals are converted into an analog
tachometer signal by f/v (frequency to voltage) conversion.
Encoder tachometer mode gives the widest speed useable
speed range and fastest velocity-loop response. Use Halltachometer mode for high-speed operation where no encoder
feedback exists. Example: a 4-pole brushless motor with a 500
line encoder operating at 1500 rpm. The f/v clock pulse rate is
50,000 Hz for encoder feedback, and 300 Hz for Hall
feedback. As speed drops, ripple will increase. At a standstill,
there will be no feedback between Hall or encoder transitions,
resulting in jitter. This may be acceptably small for an encoder
application, or unacceptably rough for a Hall tach. Use the
/Enable or /Brake inputs to disable the amplifier if zero-output
is required.

Begin with S1 ON (integrator disabled), REF GAIN pot fully
CW, TACH GAIN and LOOP GAIN pots fully CCW. Previous
steps must be performed to insure that motor is properly
phased and rotates smoothly in both directions.

MAXIMUM F/V PULSE RATE
An f/v clock signal is generated that is 4X the encoder line
frequency. The maximum f/v clock rate is 600kHz. First check
to make sure that your f/v clock will be in limits.
Lines × rpm
f/v Encoder =
15
Poles × rpm
f/v Hall =
20
If the rate is greater than 600kHz, then maximum rpm must be
reduced. If the rate is acceptable, select the f/v capacitor
CH23 as follows:

HALL TACHOMETER
Set DIP switches S2 & S3 ON. Choose CH23 based on this
equation:
1400
( C = CH23 in µF )
C=
Poles × rpm

ENCODER TACHOMETER
Set DIP switches S2 and S3 OFF. Choose CH23 based on this
equation:
1 × 10e 9
(CH23 = pF)
C=
Lines × rpm
Choose a capacitor with the closest value. This should
produce a tach-voltage of about ±5V at the rpm used in the
equations. With the default value of 49.9k for RH22 (feedback
scaling header resistor), this would correspond to the
maximum reference input of ±10V.

LOW-PASS FILTER
The choice of low-pass filter will determine both the useable
rpm range of the f-v converter and the effective response time
of the velocity-loop ( or effective bandwidth ). For widest speed
range, set the low-pass filter frequency to a lower value. For
faster response times ( higher velocity loop bandwidth ) set the
frequency to a higher value.
Because Hall pulse rates will typically be as much as 100X
less than encoder pulse rates, a low-pass filter frequency that
gives satisfactory results at lower speeds may noticeably slow
down the step response of the motor. The default filter
frequency is 16Hz for Hall tach operation. This gives a
frequency of 159Hz, which is a good starting point for many
motors. CH24 & CH25 may be removed for fastest response
and best stiffness with smaller motors. In general, use the
lowest frequency possible that does not begin to slow down
Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

STATIC SETUP
Apply a ±10V signal to Ref inputs Measure feedback voltage at
J3-4 This should be about ±5V if CH23 has been chosen
correctly. Motor rpm can be measured by viewing any Hall
signal and calculating as follows:
120
RPM =
Th × Poles
Where Th is the period of one Hall signal (U, V, or W ).

DYNAMIC SETUP
Set switch S1 ON (integrator disabled). Use a function
generator with a square wave output set to a small voltage
(±0.5V). Connect to reference inputs and adjust frequency so
that motor can change direction and settle to a set speed (1
Hz). Connect oscilloscope to J3-4 to monitor voltage. If
possible, also connect to J2-10, current monitor. Adjust Loop
Gain pot for fastest response that does not produce oscillation
or excessive ringing of either tach signal, or current monitor.
When Loop Gain is adjusted, set S1 OFF. Adjust Integ Freq
pot CW until overshoot on tach signal rings and then back off
for stable response. CW adjustment increases stiffness
(speed stability), but too much will produce oscillation. With
Loop Gain and Integ Freq adjusted properly, response to step
inputs will be smooth, and free from oscillation.

FEEDBACK POLARITY
Jumper J1-B switches the polarity of the feedback signal.
Once the amplifier is adjusted in torque mode to compensate
for load inductance, the velocity loop is closed by setting DIP
switches 2 & 3 to one of the three possible choices: Hall,
encoder, or output voltage. If the initial setting produces runaway (positive feedback), disable the amplifier and set the
jumper to the alternate position. This should produce a stable
velocity loop which can then be ‘tuned’ using the
potentiometers.

VOLTAGE FEEDBACK MODE
Set DIP switches S1 OFF, S2 ON, and S3 OFF. Set Ref Gain
pot fully CW, Tach Gain, Loop Gain, and Integ Freq pots fully
CCW. With the default components, the voltage gain is X40.
Thus, a ±5V input will produce a ±200V-output voltage swing.

Tel: 781-828-8090

Fax: 781-828-6547
Page 9 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
CONTINUOUS CURRENT LIMIT SET

MOTOR INDUCTANCE SETTING

Control of the peak current limits can be made externally via
connector pin J3-21. A resistor can be connected between this
pin and signal ground (J3-12, 13, 15, or 16), or the pin can be
driven by a voltage between 0 and +5VDC. Using this
technique, the current limit can be controlled over a range of
10% TO 100% of the amplifiers rated continuous current. The
figure below shows the circuit. RH14 internal.

Header components RH20, CH18, and CH16 control the
amplifier compensation for different motors. These set the gain
in the current error amplifier to give the best response for
different winding inductances.
The tables below give values for the header parts for the two
models. If the inductance of your motor is less than ½ of the
value shown in the table, use the values from the next lower
inductance range. E.g., for a 4mH motor, use the values from
the 3 mH row (1/2 of 10mH is 5mH, which is greater than 4mH,
so the value from the next lower row, 3mH, is used).
For all tables, CH18 is 15nF, and CH16 is .
Model 5234AC @ 115VAC
L (mH)
RH20 (kΩ)
0.3
10
1
30
3
100
10
300
30
1 Meg

+10V

Vext
0~5VDC

10k
Rext

J3-21

+5V = 100%
of Icont

RH
14

9.76k

J3-16
Amplifier

The table below lists values for Vext and Rext to control the
continuous current limit externally.
Icont
15
13.5
12
10.5
9
7.5
6
4.5
3.1

Rext

30k
15k
7.5k
4.7k
2.7k
1.5k
560
0

Vext
4.9
4.29
3.66
3.0
2.4
1.78
1.16
0.54
0

These values will give results within 10%, typically. For greater
accuracy, measure Current Ref signal, and select parts for
desired value.

Model 5434AC @ 230VAC
L (mH)
0.3
1
3
10
30

RH20 (kΩ)
4.7
15
47
150
470

Model 5434AC @ 115VAC
L (mH)
0.3
1
3
10
30

RH20 (kΩ)
10
30
100
300
1 Meg

SIGNAL BOARD AND HEADER SOCKET LAYOUT
20
HEADER "A"
RH1~20

JP-1

FEEDBACK
POLARITY

1 } REV
2 } NORM
3

1
2
GND {
3
+5V {

"A" Header

R
R CR R CR R C R R
H
H HH H HH H H H H
1
1 23 4 5 6 7 8 9 0 1
1

R
H
1
2

C
H
1
3

R
H
1
4

R
H
1
5

C
H
1
6

R
H
1
7

C
H
1
8

R
H
2
0

A B
25
RH21
RH22

BALANCE

LOOP GAIN

21

INTEG FREQ

TACH GAIN

LED

REF GAIN

HEADER "B"
RH21~25

ENABLE
INPUT
RESISTOR

HDR19

1

DIP
SW

J3 SIGNAL

JP1

J2 HALLS

CH23
CH24
CH25

"B" Header

The A and B header sockets hold the components that determine the amplifiers performance such as operating mode, current limits, and
feedback type. Components are named RHn, CHn as Resistor Header n, Capacitor Header n, etc. The table above lists values that cover a wide
range of motor winding inductances. Note: RH22 is temporally installed in the RH19 position as default from factory. For velocity operation,
after current mode commutation is verified working, install RH22.

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547

Page 10 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
SETTING LOAD INDUCTANCE COMPENSATION
Header components RH20, CH18, and CH16 control the frequency response of the current error amplifier. Determining the correct
values for these parts with your motor is called tuning the current loop, or setting the inductance compensation for the amplifier.
This proceeds in two parts: adjustment of the DC gain in the current error amplifier, and adjustment of the integrator frequency. Header
component RH20 controls the DC gain, and is selected with CH18 replaced by a jumper. When this is complete, CH18 is re-installed,
and the best value is then selected. In most applications, CH16 is not needed, but can be added to lower the high-frequency response.
Important: always power-down when changing components in the header socket.

DC GAIN ADJUSTMENT (RH20)
1. Use a square-wave reference signal of ±0.5V, 50Hz.. Set the power supply to the anticipated operating voltage.
2. Replace the compensation capacitor (CH18) with a short ( jumper )
3. Observing the signal at the current monitor, pick a value for RH20 that gives a clean step response. Do not consider the
‘flat-top’ portion of the waveform, the ‘tilt’ will disappear when CH18 is adjusted.
OSCILLATION, RESISTOR VALUE TOO HIGH!
GOOD RESPONSE, BEST RISETIME WITHOUT OSCILLATION

COMPENSATION RESISTOR
SETTING
( COMPENSATION CAPACITOR = SH

RESISTOR TOO SMALL, POOR RESPONSE

INTEGRATOR ADJUSTMENT (CH18)
1.
2.

Begin with the default value of 15nF. Check step waveform. If overshoot >10% and ringing occur, CH18 is too small. If
response is sluggish, CH18 is too big. When changing CH18, use a factor of 3X (or 1/3) to see significant effect.
Thereafter-smaller changes can be used to converge on best setting.
When CH18 is properly chosen, some overshoot (<10%) will occur, but waveform will settle cleanly to a ‘flat-top’ with
little undershoot.
> 10% OVERSHOOT AND/OR OSCILLATION, CAPACITOR TOO SMALL
GOOD RESPONSE, SAME RISETIME WITH <10% OVERSHOOT

COMPENSATION CAPACITOR
SETTING
CAPACITOR TOO BIG,
SLUGGISH RESPONSE

( USE VALUE OF RESISTOR CHOSEN IN PREVIOUS

BANDWIDTH TESTING
1.
2.

Change reference signal to sinusoidal waveform. Begin at 100Hz, adjust amplitude for a 0.35V peak-to-peak waveform at the
current monitor. This should be seven vertical divisions on an oscilloscope that is set to 0.05V/division.
Sweep the frequency upward. When the peak-to-peak amplitude drops to 5 divisions this is the –3dB frequency. This method will
permit testing of 10mH loads to 3kHz BW at 120VAC or a 20mH load to 3kHz at 240VAC. For higher inductance values, slew rate
limiting will force p-p current amplitude to be lowered for observation without error.

Copley Controls Corp., 20 Dan Road Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547

Page 11 of 12

MODELS 5234AC, 5434AC
LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS
OUTLINE DIMENSIONS
7.50
(190.5)

0.93 (23.62)

3.00
(76.2)

6.22
(158)

6.94
(176.3)

7.00
(177.8)

2.72
(69.1)
1.46
(37.08)

4.72 Heat sink option
(119.9)

Optional heat sink

Dimensions in inches (mm.)
WEIGHT

3.71 lb. (1.69 kg) without optional heatsink. Add 3.2 lb. (1.47 kg) for heatsink.

CONNECTORS

J1: Power & motor
J2: Motor signal
J3: Control Signal

9-position barrier strip; #6-32 screws have wire protector washers
15 position female sub-D type; with #4-40 standoffs for cable shell
25 position female sub-D type; with #4-40 standoffs for cable shell

ORDERING GUIDE
Model 5234AC
Model 5434AC

30A peak, 15A continuous, 115VAC, 50/60Hz nominal input power
30A peak, 15A continuous, 115/230VAC, 50/60Hz nominal input power

Notes: 1. Add "H" to model number to specify heatsink option.
Example: Model 5434AC with heatsink would be ordered as a 5434ACH
No user serviceable parts. Contact Copley for service.

OTHER BRUSHLESS AMPLIFIERS
7000 Series
5xx1 Series
Model 503
Model 505

Five different model types for driving AC brushless motors with sinusoidal commutation using a variety
of feedback and control card schemes
Six models operating from +24 to +225VDC, 10~20A peak, 5~15A continuous.
CE compliance available (5xx1CE models), Hall/encoder velocity feedback option
Brushless tachometer option.
Torque-mode brushless amplifier. +18 to +55VDC, 5A continuous, 10A peak.
Same power output as 503. Adds Hall / Encoder tachometer feature for velocity loop operation.

www.copleycontrols.com

Copley Controls Corp.
20 Dan Road Canton, MA 02021

Tel: 781-828-8090
Fax: 781-828-6547
Rev. F 04/01/05
Page 12 of 12



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