5x34AC
User Manual: 5x34AC
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MODELS 5234AC, 5434AC LINE-POWERED DC BRUSHLESS SERVO AMPLIFIERS FEATURES • • • • • • • • • • • • 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 Rext180k 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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