800 913 Datasheet 7225x1 50

User Manual: 7225x1-50

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MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS

FEATURES

•
•
•

•

•
•

Compatible with controllers
that output +/-10V analog
torque commands for
U & V phases

I-CONT (A)
15

I-PEAK (A)
50

FAULT PROTECTIONS
Short-circuits
output to output
output to HV (+)
output to HV (-)
Over / under voltage
Over temperature
Self-reset or latch-off
No Transformer Required!
Operates from power
supplies that rectify the line
directly with full optical
isolation between signal and
power stages.
CURRENT LIMITING
2
User selectable, I T Limit
with, indicator signal for
control system
Greater than 3 kHz Bandwidth

Technology 80 5651A
PMD MC1231A Chipset
Delta Tau PMAC
MEI DPS Series
Galil DMC-1700

• THE OEM ADVANTAGE
•

POWER
24~180VDC

Reduced offset drift

WORKS WITH POPULAR
CONTROLLERS

•
•
•
•
•

MODEL
7225X1-50

Internal solderless header
configures amplifier for plug
and play operation

FEATURES
The 7225X1-50 model is a PWM servoamplifier for AC Brushless servomotors
that are commutated externally by
digital control systems that output two
+/-10V signals that represent the
current command to the motor U and V
windings. The amplifier synthesizes the
current command for the W winding.
Control cards take feedback from an
encoder on the motor and use various
techniques to determine the rotor
position. When this has been done, the
controller is able to output two signals
that correspond to the current in the U
and V windings to produce torque in the
motor. The amplifier synthesizes the W
winding current from UV signals that
are 120 electrical degrees apart.
Amplifier adjustments with this system
consist of inductance compensation,
current limit, transconductance, and
offset. Thereafter, the controller does all
of the velocity and/or position control of
the motor.

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Internal solderless sockets let the user
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 inductance's to maximize
bandwidth with different motors.
The /Enable input active logic-level is
jumper-selectable to ground or +5V to
interface with all types of control cards.
MOSFET output stage deliver four
quadrant power for bi-directional
acceleration and deceleration of
motors.
All models are protected against output
short circuits (output to output, output to
ground, output to +HV) 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 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS

TECHNICAL SPECIFICATIONS
Test conditions: 25°C. Ambient, Load = 400uH in series with 1Ω, +HV = 180V
MODEL

7225X1-50

OUTPUT POWER
Peak power
50 A @ 170 VDC
Peak time
0.25 sec at peak power independent of polarity reversal
Continuous power
15 A @ 180 VDC
OUTPUT VOLTAGE
On-resistance (Ro, ohms)
0.2
Max PWM Peak Output Voltage
±Vout = (VDC)×(0.97) - (Ro)×(Io)
INPUT POWER
DC voltage
22~186 VDC
Input current @ continuous output rating
15 A
LOAD INDUCTANCE
Minimum inductance
400 µH.
Maximum inductance
No maximum. Bandwidth varies with inductance, +HV, and header parts.
BANDWIDTH

Small signal

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

PWM OUTPUTS
PWM frequency
Modulation

25 kHz
Carrier-cancellation, 50% duty cycle at 0 V output
Differential, 94 kΩ max. to 47 kΩ min. between inputs, ±20 V maximum

REFERENCE INPUT
POTENTIOMETERS
R14
R26
R49
R41

U Ref Fine Gain
V Ref Fine Gain
U phase current Zero
V phase current Zero

Default = Centered
Default = Centered

INTERNAL JUMPER
JP1 /Enable input active polarity Pos. 1-2 (default )
Pos. 2-3

CW increases gain of U output phase current.
CW increases gain of V output phase current.
Adjusts U output current to zero with U and V inputs = 0 V.
Adjusts V output current to zero with U and V inputs = 0 V.
Gnd enables amplifier, open or +5 V inhibits.
Gnd inhibits, open or +5 V enables

LOGIC INPUTS
/Enable

Default = GND active

/Motemp

Motor temp sensor.

/Reset

Default = Open
Input resistance
Logic threshold voltage
Input voltage range

LOGIC OUTPUTS
/Normal1, /Normal2

GND enables channel open or >2.5V inhibits with JP1 on 1-2. If JP1 on 2-3 then GND inhibits
Response time is 1 ms from enable active to amplifier output ON.
HI (open) = Motor HOT, amp channel shuts down. Non-latching.
LO (gnd) = Motor OK, amp channel will operate.
GND resets latching fault condition, ground for self-reset every 1 s.
10kΩ to +5V, R-C filters on inputs
2.5V (Schmitt trigger inputs with hysteresis, 74HC14)
0V to +32VDC

HI output voltage
LO output voltage
/CurrLimit1, /CurrLimit2
HI output voltage
LO output voltage
AmpOK

LO (current sinking) when channel is Enabled AND OK
Amp OK = (NOT Short) AND (NOT Over, Undervoltage, or Basetemp) AND (MotorTemp OK)
+5V (no load). Output is N-channel MOSFET drain terminal with10kΩ pull-up resistor to +5V
On resistance Ro = 5Ω. Max sink current of 250 mA. max off-voltage = 50VDC
HI when amplifier is not current limiting; LO when current is limit is active.
+5V (No load). Output is LM339 open collector with 10kΩ pullup resistor to +5V
Max sink current of 15 mA, max off voltage = 32VDC
Opto-isolated signal: opto-transistor output stage of optocoupler
Transistor is ON when Amp is OK (see above)
One output is connected to pins 7 & 19 of both J1 & J3

Amp OK
Normal
Fault
Latching Fault

Power OK, no faults, amp will run when enabled
Amplifier OK AND Amp Enabled
Amplifier NOT OK (Over voltage OR Undervoltage OR , /Motemp not connected or open)
Heatplate ovrtemp or short ckt (output-output, output--HV, output-+HV or internal)

STATUS LEDS

MONITOR OUTPUTS
Current Monitor U
Current Monitor V

Blinking Green
Solid Green
Solid Red
Blinking Red

Motor winding current in U phase: ±10 V @ ±50 A or 5.0 A/V (2.2 kΩ, 4.7 nF R-C filter)
Motor winding current in V phase: ±10 V @ ±50 A or 5.0 A/V (2.2 kΩ, 4.7 nF R-C filter)

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 2 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
PROTECTIVE FEATURES
Short circuit
Overtemperature
Under voltage
Over voltage
Current-limiting

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 < 22 VDC
Shutdown at DC buss > 195 VDC
(Amplifier operation resumes when internal DC buss is NOT Under voltage or NOT Over voltage)
2
Continuous current and I T limit set by header components
2
Current is reduced to continuous setting when I T limit is reached.
|IU|, |IV| are hardware limited to 53A, whereas |IW | = -(IU + IV) at all times
2
Maximum I T setting (H13 = H14 = 0 ohms) will activate latching fault after 50Arms for 0.25s
2
Minimum I T setting (H13 = H14 = Open) will activate latching fault after 50Arms for 11mS
Limiting action reduces transconductance so relative amplitude of U,V,W currents is maintained for no loss of phase
/CurrLimit output indicates when current limiting is active.
Amplifier will shutdown (latching fault)if |IW | > 58A at any time.

AMPLIFIER DISSIPATION
Watts maximum at Vref = 0, amplifier enabled
Watts @ continuous current
THERMAL REQUIREMENTS
Storage temperature range
Operating temperature range
Thermal resistance (heatplate to ambient):

7W
60 W
-30°C to +85°C
0° to 70°C baseplate temperature
No heatsink or fan: 2.7 deg. C/W; With heatsink, no fan: 1.6 deg. C/W
No heatsink with fan: 1 deg. C/W; With heatsink and fan: 0.4 deg. C/W

MECHANICAL
Size
Weight

7.35 x 4.4 x 1.40 in. without optional heatsink
1.48 lb. (0.67 kg)

CONNECTORS
J1
J2

Power & Motor connections
Signal connections

6-position Euro connector
25-position female Sub-D type with #M3 standoffs for cable shell lock screws

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 3 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
FUNCTIONAL DIAGRAM

CASE GND

1
47k

U_REF(+)

-

2
U_REF(-)

DIFF
AMP

100pF

+

14
47k

H7

1-2 = /ENABLE
2-3 = ENABLE

H3

47k
47k

10k

-

CW

47k

3.01k

+
8.25k

-

V_REF(-)

15

+
47k

20.4k

806

47k

3

47k

-

18.2k

+

U Gain Trim

100pF
100pF
V_REF(+)

H4

Current Limit

DIFF
AMP

100pF

N.C.
N.C.

10k
CW
V Gain Trim

N.C.

RESET
22
+5V

10k

CURRENT
ERROR
AMP

STATUS

5

&

W

3.01k

-

12

LOGIC

19

AMP OK (+)

7

AMP OK (-)

6

/NORMAL

H11

-

H12

+

+

8.25k

+5V

V

H6

20.4k

CURRENT
ERROR
AMP

10k

ISOLATED
CURRENT
SENSE V

Current Limit

2.2k

11

J1 MOTOR &
POWER

ISOLATED CURRENT SENSE V

+5V
10k
CURRENT
LIMIT
SECTION

9
20

N.C.

8

N.C.

ISOLATED CURRENT SENSE U

PWM
STAGE
MOSFET
"H"
BRIDGE

1

2

3

W
V

MOTOR

U

ISOLATED CURRENT SENSE V

Gv = +HV
10

4

MOTOR OVER-TEMP
SWITCH

FRAME
GROUND

21

J2
SIGNAL

18.2k

4.7nF

/CLIMIT

ENABLE

GND

CONTROL

ISOLATED CURRENT SENSE U

4.7nF
CURRENT
MONITOR V
+/-10V @ +/-50A

47k

2.2k

10

+5V

H5

806

25
CURRENT
MONITOR U
+/-10V @ +/-50A

MOMENTARY SWITCH RESETS FAULT
WIRE RESET TO GROUND FOR SELF-RESET

47k
H10

23

U

PHASE W
GENERATOR

16

24

H9

ISOLATED
CURRENT
SENSE U

GND

J2
SIGNAL

JP1 Enable
Active level
select

H8

3 21

CONTROL
SYSTEM

Motor temp sense

EARTH OR
SAFETY GROUND

HV (-)
5
+5
+15

13

DC / DC
CONVERTER

-15

6

HV (+)

NOTE: CIRCUITS WITHIN DASHED LINE ARE
ISOLATED FROM SIGNAL CIRCUITS

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 4 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS

CONNECTORS
J1 POWER AND MOTOR WINDING CONNECTIONS
Connector type: Euro style terminal block.
PIN SIGNAL
FUNCTION
1
Motor W
Amplifier output to “W” winding of motor
2
Motor V
Amplifier output to “V” winding of motor
3
Motor U
Amplifier output to “U” winding of motor
4
Chassis Gnd
Chassis safety ground. Also for cable shield of motor cable.
5
HV(-)
DC Power Gnd/Return (Note: HV is isolated from 0V signal ground)
6
HV(+)
DC Power Input

J2 SIGNAL CONNECTIONS
Connector type: Female Sub-D, 25-position, #M3 locking standoffs
PIN
1

SIGNAL
Safety GND
(Case)

2
U Ref (+)
3
V Ref (+)
4
5
6
7
8
9
10
11
12
13
1.

N.C.
/Enable input
/Normal output
Amp OK (-) output
N.C.
/CLIMIT
Current Monitor U
Current Monitor V
0V.
0V.

FUNCTION
Chassis ground. Use to
ground cable shield. Not
connected to internal signal
ground (J3-12, 13,16).
Positive terminal of
differential +/-10V analog
command input
Positive terminal of
differential +/-10V analog
command input
Amplifier enable
Mosfet output amp status
Opto-isolator emitter (NPN)
Current limit status
+/-10V @ +/-50 A
+/-10V @ +/-50 A
Signal ground.
Signal ground must be
connected to the controller.

PIN

SIGNAL

FUNCTION

14
U Ref (-)
15
V Ref (-)
16
17
18
19
20
21
22
23
24
25

0V.
N.C.
N.C.
Amp OK (+) output
N.C.
Motemp
/Reset input
N.C.
N.C.
N.C.

Negative terminal of
differential +/-10V analog
command input
Negative terminal of
differential +/-10V analog
command input
Signal ground.

Opto-isolator collector (NPN)
(Note 1)

The motor temperature sensor input is supported on 7225X1-50. J2-21 must be grounded for amplifier to operate (motor temp
sensor should be a normally-closed switch that opens when motor is too hot)

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 5 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
TYPICAL AMPLIFIER CONNECTIONS
Chan A
Chan B
Index

U Ref(+)
Current Command

U Ref(-)

Phase U
Phase V

Shld

Ground
V Ref(+)
V Ref(-)

2
14
1

J2
3
15

Signal ground
Note:
13
Amplifier signal ground
must be connected to
Signal ground 16
controller ground.
AmpOK(+) 19
AmpOK(-)

7

/CurrLimit status

9

/Normal output

6

Motor temp sensor
21

J2

12
Signal ground

1
2

Monitor Outputs
Current Mon U

10

Current Mon V

11

/Reset

22

3

W
V

Motor

U

J1
HV+

Fuse

6
5

/Enable

Encoder

HV-

5
4

Note: Enable input active level is
selectable with internal jumper
JP1

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

120VAC

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

Tel: 781-828-8090

Fax: 781-828-6547
Page 6 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
PC BOARD LAYOUT

J1 = Enable input
active level control

JP1

LO = enabled ( /Enable )
(default)

Header Socket

1
2
3

HI = enabled ( Enable )

H14
H13
Do not adjust,
factory set drift
potentiometers

H11
H10
H8
H7
H5
H3
H2
H1

1
2
3

U Balance

JP1

V Balance

6 5 4 3 2 1

U Gain trim

J2
Signal

V Gain trim
Amp Normal
Fault

J1
Power & Motor

HEADER BOARD SOCKET COMPONENTS
Part
H15
H14
H13
H12
H11
H10
H9
H8
H7
H6
H5
H4
H3
H2
H1

Value
N/a
0Ω
0Ω

33.2kΩ
33nF

33.2kΩ
33nF

75kΩ

75kΩ
1.5MΩ
1.5MΩ

Remarks
No function
2
I T Current Limit select
Continuous Current Limit select
Ch. V Current Error Amp hi-frequency roll off
Ch. V Current Error Amp proportional gain
Ch. V Current Error Amp integrator
Ch. U Current Error Amp hi-frequency roll off
Ch. U Current Error Amp proportional gain
Ch. U Current Error Amp integrator
Ch. V Continuous Current Limit
Ch. V Transconductance
Ch. U Continuous Current Limit
Ch. U Transconductance
Ch. U Balance Range select
Ch. V Balance Range select

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 7 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
HEADER SOCKET COMPONENT SELECTION
LOAD INDUCTANCE
L (mH) phase-to-phase
0.4
1
3
10
30

H8, H11 @ 80V
16.5k
41.2k
124k
249K
750K

H8, H11 @ 160V
11k
33.2k
68.1k
124K
392k

H7, H10
33nF
33nF
33nF
33nF
33nF

Note: Table values apply with components H9 & H12 not installed. Values in bold and italic are factory installed.

CURRENT LIMITS
2

2

A micro controller uses an I T algorithm to monitor to protect against overload conditions. The I T overload protection for each channel
operates independent of the other. The algorithm detects when the current is any phase exceeds the continuous current limit level set
2
2
2
by the header component H13. The I T algorithm tracks the energy of the overload (A sec) and when the I T limit is reached, the
output current is limited to a level set by H4 and H6. The following tables or equations can be used to select header component values
to obtain the desired over-current protection setting.
Cont. Current (Arms)
15
12
9
6
3
2

H 4,H 6 (Ohm)

1.87k
715
301
75
2

I T Limit (A sec)
600
375
188
139
75
24

H13 (Ohm)
0 Ohms (short)
15.8k
47.5k
143k


H14 (Ohm)
0 (short)
16.9k
57.6k
86.6k
200k


(6.25 H13 = 47.5k ohms

(15 - I cont )

* (I

cont

-3)

H14 = 47.5k ohms

*

(

I 2 T limit )
15.36

I 2 Tlimit

- 1.25)

15.36
2

Example: The I T set point applies only to the energy delivered to the load over and above the continuous rating of the load. The
2
amplifier’s micro controller is informed of the continuous current rating of the load via header resistor H13. The I T set point is set via
2
2
header resistor H14. Using a 0 ohm value for H14 gives an I T set point of 600 A S. If a 0 ohm value is also used for H13, the
2
continuous current setting is 15A. This means that for a 50Arms current on either phase U, V or W, the I T protection will activate after
2
2
2
.
a time T = 600 A S/(50 - 15 )= 0.25 seconds Current is then limited to continuous limit set by H4 and H6.

BALANCE RANGE AND TRANSCONDUCTANCE SETTINGS
Header components H1 & H2 control the offset range. Default value is 1.5Mohm that gives a range of +/-350mA. The ratio between
output current, and the reference voltage at the input is the transconductance of the amplifier. It is measured in Amps/Volt, and is
controlled by components H3 & H5. The chart below gives some common settings.
Gain (A/V)
6.25
5.0
3.75
2.5
1.25

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

H3 & H5
95.3k
75k
54.9k
36.5k
17.8k

Tel: 781-828-8090

Fax: 781-828-6547
Page 8 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
DIMENSIONS

Note: Dimensions in inches (mm.)
7.35 (186,7)

1.40 (35.56)

4.40 (111,8)

V Balance

U Balance

V Gain Trim

U Gain Trim

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Pots

Amp Normal
Fault

Ph. V

Ph. W

Ph. U

HV(-)

HV(+)

J2
Signal

Leds

J1
Motor & Power

Tel: 781-828-8090

Fax: 781-828-6547
Page 9 of 10

MODEL 7225X1-50
LINE-ISOLATED AC BRUSHLESS SERVO AMPLIFIER
WITH +/-10V ANALOG U-V INPUTS
NOTES

Rev A 11/02/2001

Copley Controls Corporation. 20 Dan Rd., Canton, MA 02021
www.copleycontrols.com

Tel: 781-828-8090

Fax: 781-828-6547
Page 10 of 10



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Modify Date                     : 2001:12:11 12:29:05-05:00
Author                          : James Woodward
Title                           : 800-913 Datasheet
Create Date                     : 2001:11:02 14:31:21
Page Count                      : 10
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