Elmo Servo Amplifier Dbp Series Users Manual Emanudbp

SERVO AMPLIFIER DBP SERIES MAN_DBP_

DBP SERIES to the manual 99089bd7-80ef-45b2-9a4d-224e6c003172

2015-02-06

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DBP - Rev 6/93

Rev 6/93

DBP - Rev 6/93

ELMO-WARRANTY PERFORMANCE

The warranty performance covers only ELMO's products and only the

elimination of problems that are due to manufacturing defects resulting in

impaired function, deficient workmanship or defective material. Specifically

excluded from warranty is the elimination of problems which are caused by

abuse, damage, neglect, overloading, wrong operation, unauthorized

manipulations etc.

The following maximum warranty period applies:

12 months from the time of operational startup but not later than 18 months

from shipment by the manufacturing plant.

Units repaired under warranty have to be treated as an entity. A breakdown

of the repair procedure (for instance of the repair of a unit into repair of

cards) is not permissible.

Damage claims, including consequential damages, which exceed the warranty

obligation will be rejected in all cases.

If any term or condition in this warranty performance shall be at variance

or inconsistent with any provision or condition (whether special or general)

contained or referred to in the Terms and Conditions of Sales set out at the

back of Elmo's Standard Acknowledge Form, than the later shall prevail and be

effective.

DBP - Rev 6/93

How to use this manual - Flow Chart

The DBP HARDWARE MANUAL will lead you toward a successful start-up of your

digital amplifier. Please review carefully the following flow chart and write

down the chapters that you have to follow in the right order. Only after

performing all the steps you may proceed to the software manual.

If you are a new user of the DBP, you better not skip chapters 1-4 which

will familiarize you with the product.

Read chapter 5.1

Read chapter 6 - Installation

Read chapter 7.1 - Start-Up

Read chapters

1,2,3,4

Familiar with the DBP ? no

Resolver ?

Read chapter 8 - Applying power - Adjustments

Read chapter 9 - Summaries

Hall sensors with

Rack (R) with Elmo mother board ? Elmo enclosure ?

no no

Panel (H) version or Rack (R)

w/o Elmo mother board ?

Terminals

Read chapter 5.3

Terminals

Read chapter 5.2

Terminals

optical encoder ?

Adding velocity loop ? Read Appendix B

yes

DBP - Rev 6/93

TABLE OF CONTENTS

1.Description ................................ .......................... 7

2. Type Designation ................................ ................... 8

3. Technical Specification ................................ ............ 9

3.1 Digital I/O specification ................................ ... 10

3.2 Analog input specification ................................ .. 13

3.3 Sensors specification ................................ ....... 14

3.3.1 Encoder ................................ ............. 14

3.3.2 Resolver ................................ ............ 14

3.4 Communication ................................ ............... 16

3.4.1 RS232 Configuration ................................ . 16

3.4.2 RS485 Configuration ................................ . 16

3.5 Battery backup ................................ .............. 16

3.6 Performance ................................ ................. 16

4. System Operation ................................ ................... 18

4.1 RS485 and Checksum Protocol ................................ . 18

4.2 Current Control ................................ ............. 18

4.2.1 Current feedback, Current feedback multiplier (CFM) and

Current loop ................................ ............... 19

4.3 Digital current limits ................................ ...... 20

4.3.1 Time dependent peak current limit ................... 20

4.4 Digital position and speed control .......................... 21

4.5 Operation of the shunt regulator ............................ 25

4.6 Commutation signals format ................................ .. 26

4.7 Protective functions ................................ ........ 27

4.7.1 Short circuit protection ............................ 27

4.7.2 Under/over voltage protection ....................... 27

4.7.3 Temperature protection .............................. 27

4.7.4 Internal power supply failure ....................... 27

4.7.5 Loss of commutation feedback ........................ 27

4.7.6 Low back-up Battery voltage ......................... 27

5. Terminal Description ................................ ............... 33

5.1 Terminals for Horizontal and Rack mounting versions ......... 33

5.2 Mother Boards terminals (MBA-DBP/3U and MBA-DBP/6U) ......... 43

5.3 Terminals for DBP mounted in ENCD. .......................... 54

5.4 Communication Port Connector ................................ 64

DBP - Rev 6/93

6. Installation procedures ................................ ............65

6.1 Mounting................................ .....................65

6.2 Wiring................................ ....................... 65

6.3 Load inductance................................ ..............66

6.4 AC power supply................................ ..............66

6.5 Wiring diagrams................................ ..............67

6.5.1 Motor's windings ................................ .....67

6.5.2 AC power wiring ................................ ......68

6.5.3 Hall sensors wiring ................................ ..77

6.5.4 RS232 Communication wiring ........................... 78

6.5.5 RS485 Communication wiring ........................... 79

6.5.6 Main encoder wiring ................................ ..81

6.5.7 Resolver wiring ................................ ......82

6.5.8 Auxiliary encoder wiring ............................. 83

6.5.9 Pulse/Direction signals wiring ....................... 84

7. Start - Up Procedures ................................ ..............85

7.1 Common procedures for all amplifiers types ................... 85

7.1.1 Commutation signals format ........................... 85

7.1.2 CFM function ................................ .........85

7.1.3 Abort logic ................................ ..........85

7.1.4 Setting the auxiliary position input format ..........86

7.1.5 Selecting the communication bus ...................... 86

7.1.6 Preparing the automatic baud rate selection ..........86

7.2 Setting the main optical encoder format ...................... 87

7.3 Setting the R/D circuit ................................ ......87

8. Applying power - Adjustments ................................ .......94

Step 1 - Applying Power ................................ .....94

Step 2 - Establishing the communication ..................... 95

Step 3 - Checking the feedback elements ..................... 95

Step 4 - Adjusting the current limits ....................... 95

Step 5 - Latch mode of the protective functions .............96

Step 6 - Connecting the Motor ............................... 96

9. Tables and Summaries ................................ ...............97

9.1 Display diagnostics ................................ ..........97

9.2 Summary of DIP switches ................................ ......98

Appendix A - Current loop response ................................ .....99

DBP - Rev 6/93

Appendix B - Adding a velocity feedback ............................... 101

Appendix C - Differential amplifier connection ........................ 102

DIMENSIONAL DRAWINGS ................................ ................... 103

PANEL (H), DBP1 ................................ .................. 104

PANEL (H), DBP2 ................................ .................. 107

PANEL (H), DBP3 ................................ .................. 110

PANEL (H), DBP4 ................................ .................. 113

PANEL (H), DBP6 ................................ .................. 116

RACK 3U/13T ................................ ...................... 119

RACK 3U/20T ................................ ...................... 122

RACK 6U/14T ................................ ...................... 125

RACK 6U/21T ................................ ...................... 128

ENCD - 3U/... ................................ .................... 130

ENCD - 6U/... ................................ .................... 131

EXTERNAL SHUNT RESISTOR ................................ .......... 132

List of ELMO Service Centers ................................ ........... 133

DBP - Rev 6/93

1.Description

The DBP series are digital, full wave, three phase servo amplifiers designed

for high performance brushless servo motors in the range of up to 7KW. They

utilize power MOSFETs and Surface Mounting Technology which contribute to its

high efficiency and compact design. The DBP operates from a single AC supply

(either single or three phase) and, when using the galvanic isolation option,

it can be connected directly to the Mains.

The DBP is constructed from two main PCBs mounted on a heat sink plate. The

lower board contains the rectifying bridge, the power switching transistors

which drive the motor, terminals for the power stage, the switch mode power

supply, the protection logic and commutation logic. The upper PCB is the

Digital Control Board (DCB) which contains the digital control logic, terminals

for the control stage, D-type connector for the communication and a 4-digit

display.

The DBP requires a position sensor in order to enable its operation. It can

be either a Resolver or a combination of an optical encoder and Hall effect

sensors. When using a Resolver, a small interface card is mounted on top of the

DCB.

The DBP is available in either panel version or rack version with two DIN

41612 connectors. The rack version can be fitted in a panel mount enclosure

(ENCD-3U or ENCD-6U), that is specially designed for a simple hook-up

procedure.

The amplifiers are fully protected against the following faults:

* Under/over voltage

* Shorts between the outputs or between the outputs to ground.

* RMS current limit.

* Insufficient load inductance.

* Loss of commutation signals.

* Excess temperature.

* Excess position error.

Analog Section Standard Features:

* Single AC supply (single or three phase)

* Zero Deadband.

* Motor current monitor.

* Motor speed monitor.

* Extra differential operational amplifier.

DBP - Rev 6/93

* Standard commutation sensors: Hall effect sensors or a Resolver.

* Galvanic isolation of the control stage - option.

Digital Section Standard Features

* Accepts motion commands via RS232 or RS485

* Buffering for pipe lining instructions prior to execution

* Battery-backed RAM for storing user programs and parameters

* Conditional statements for controlling program execution real- time.

* Programmable time and position trip points

* Variables for entering and changing system parameters

* 5 Uncommitted inputs

* 2 uncommitted high speed inputs.

* 10 Uncommitted outputs

* Arithmetic and logic functions for manipulating parameters

* Digital filter with programmable gain, damping and integrator

* Error handling, end of travel, emergency stop, status reporting.

* 0-600,000 quadrature counts/second speed range

* One analog input - 11 bit resolution

* Master/slave operation with programmable following ratio (master information

from an optical encoder or from Pulse and Direction inputs)

* Dual-loop capability

* Adjustable continuous and peak current limits

* 4-digit display for diagnostics.

2. Type Designation

R - Resolver

E - Optical encoder + Hall sensors

I - Isolation *

O - Off line:

Rated continuos current

Max. operating AC voltage

R - Rack mounting

H - Panel mounting

DBP F- 24 / 270 R R O

DBP series amplifier

Fan cooling required for full rating Isolation + Inrush current limit

DBP - Rev 6/93

3. Technical Specification

Type AC Supply*

min max

Current

limits

Size

Panel(H)

Size

Rack(R)

Weight

(Kg)

DBP-12/135 28- 135 12/24 DBP2 3U/20T 1.4

DBP-20/135 28- 135 20/40 DBP3 6U/21T 3

DBP- 8/270 100- 270 8/16 DBP2 3U/20T 1.4

DBP-16/270 100- 270 16/32 DBP3 6U/21T 3

DBPF-12/135 28- 135 12/24 DBP1 3U/13T 0.7

DBPF-20/135 28- 135 20/40 DBP4 6U/13T 1.3

DBPF-30/135 28- 135 30/60 DBP6 6U/21T 3

DBPF- 8/270 100- 270 8/16 DBP1 3U/13T 0.7

DBPF-16/270 100- 270 16/32 DBP4 6U/13T 1.3

DBPF-24/270 100- 270 24/48 DBP6 6U/21T 3

* These are the absolute minimum-maximum AC supply voltage under any condition.

DBP - Rev 6/93

General

* DC output voltage is 130% of AC input voltage.

* 2KHz current loop response

* Outputs voltages of +5V/0.2A, +15V/0.1A for external use.

* Efficiency at rated current - 97%.

* Operating temperature: 0 - 50 °C.

* Storage temperature: -10 - +70 °C.

3.1 Digital I/O specification

Digital Inputs:

High/Low input definition: Vil<1V, Vih>2.4V

Maximum input voltage: 30V

Input impedance: 3-7Kohm

Input hysteresis: typ 1V.

When left open: low level.

Input threshold level can be shifted on request.

The fast inputs capture events (input voltage level

going from low to high) of less then 10 µsec duration.

Digital Outputs:

High/Low output definition: Vol<0.4V, Voh>4V

Output level: 0-5V

Recommended output current: Iol=Ioh=5mA

Maximum output current +10mA

The outputs are normally at low level.

DBP - Rev 6/93

13b

14b

15b

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

16b

17b

D0 Q0 2

D1 Q1 5

D2 Q2 6

D3 Q3 9

D4 Q4 12

D5 Q5 15

D6 Q6 16

D7 Q7 19

OC VCC 20

U17

74HCT373A

+5V

OUT 7

OUT 8

OUT9

3 2

U11A

74HCT4050

5 4

U11B

74HCT4050

7 6

U11C

74HCT4050

6a OUT10

MOTION

COMPLETE

DIGITAL OUTPUTS

DBP - Rev 6/93

1 3

U100A

SN75C189AD

LIMIT SWITCH

FORWARD

REVERSE

LIMIT SWITCH

10a 4 6

U100B

SN75C189AD

10 8

U100C

SN75C189AD

13 11

U100D

SN75C189AD

12a

HOME INPUT

ABORT INPUT 13a

18b 1 3

U102A

SN75C189AD

4 6

U102B

SN75C189AD

19b

I3 20b 10 8

U102C

SN75C189AD

13 11

U102D

SN75C189AD

1 3

U103A

SN75C189AD

21b

INDEX SLAVE

22b

4 6

U103B

SN75C189AD

15a

I7 16a 10 8

U103C

SN75C189AD

DIGITAL INPUTS

DBP - Rev 6/93

3.2 Analog input specification

Maximum input voltage:

- When R1 (470ohm) is inserted, the absolute value of the input voltage should be

less than 5V.

- When the absolute value is higher than 5V, R1(Kohm) = 2Vi-10 should be inserted.

The µP reads always +5V.

Resolution of the digital conversion: 11 bit full scale.

Typical offset: 5 bits

470K

300

4700PF 4700PF

U1\10

VREF

4700PF

10 8

U8C

470k

18a

ANALOG 1 2 R1

*470k 6

5 7

U8B

DIGITAL GND

470k 1000PF

20K VREF

DIGITAL GND

300

4700PF 4700PF

U1\11

DIGITAL GND

20K 13

12 14

U8D

DIGITAL GND

10K

DIGITAL GND

INPUT

ANALOG INPUT

DBP - Rev 6/93

3.3 Sensors specification

3.3.1 Encoder

The encoder must be incremental with two TTL channels in quadrature and 90 °

phase shift.

High/Low input definition: Vil<1.5V, Vih>3V

Input voltage range: 0-15V

Input hysteresis 1.5V

Input impedance: 1Kohm to 5V.

Maximum frequency main encoder: 150KHz

Maximum frequency auxiliary encoder: 250KHz

Noise protection by analog and digital filters

When left open the input is internally pulled to high level.

3.3.2 Resolver

Resolver Option Feature:

* 10,12,14 and 16 bit resolution set by the user.

* Maximum tracking rate 1040 rps (10 bits).

* Velocity output.

* Encoder A, B, outputs + programmable index output.

Reference parameters:

Max. voltage: 20Vptp or 7Vrms

Minimum output voltage: 2Vrms

Max. current: 80mA

Max frequency: 20KHz outputs:

DBP - Rev 6/93

REMARK:

R704 - 708 ARE NOT INSTALLED IN FACTORY STANDARD SETTING.

+5v

2.49K

+5v +5v

1000P

100K

2 U107

+5v +5v

1000P 1K

100

R707

22a

AY/PULSE

21a

DS5 301K

BY/DIR

BY/DIR 24a

100

23a

+5v +5v +5v

1000P

100K

+5v

2.49K

2 U106

+5v

301K

DS4

R706*

+5v +5v +5v +5v

+5V

5 6

U121B

1000P 301K

100K 11

10 13

U31D

1000P 1K

100

R708

32a

31a

INDEX

DS6

+5v

+5v+5v

1000P

100K

2 U104

+5v +5v

1000P 1K

100

30a

29a

CH A

R704

301K

DS2

ENCODER INPUTS

+5V

+5v +5v

1000P

100K

2 U105

+5v+5v

1000P 1K

100

R705

28a

27a

CH B

CH B DS3 301K

Vref

DBP - Rev 6/93

3.4 Communication

3.4.1 RS232 Configuration

The RS232 is configured for 8-bit, no parity, full duplex and it will echo all

the transmissions.

Baud rates: 300,600,1200,2400,4800,9600,19200,38400,57600

No hardware handshaking is required.

3.4.2 RS485 Configuration

The RS485 is configured for 8-bit, no parity, half duplex.

Baud rates: 300,600,1200,2400,4800,9600,19200,38400,57600

No hardware handshaking is required.

3.5 Battery backup

180mAH battery that at rated operating and storage condition will last for

at least 40,000 non operating hours.

3.6 Performance

Position range: +230 quadrature counts

Velocity range: +600,000 counts/sec

Velocity resolution: 1 count/s

Acceleration range: 91 - 11.8x10 6 count/s

Acceleration resolution: 91 counts/s 2

DBP - Rev 6/93

COMMUNICATION

-15V

DZ13v

300

0.1MF 0.1MF

+15V

DZ13v

300

+5v

DS9

RS232-OFF

-V

GND

4 RTC 6

RY 3

DA 2

+V 8

U115

SN75155

+5v

TRANSMIT

RECEIVE

GND

+5V

RS232

T/R-

RS485 +5v 0.1MF

VCC

GND

5 D 4

DE 3

RE 2

R 1

U114

SN75LS176

RS485-ON

R119

T/R+

TRANSMIT/

RECEIVE CONTROL

RS485/RS232

R119 - LINE TERMINATION RESISTOR, USED ON BOTH ENDS OF LONG LINES. NORMALLY NOT MOUNTED.

* R802

* R802 - SMD RESISTOR. NORMALLY NOT MOUNTED

Notes:

120

ohm

DBP - Rev 6/93

4. System Operation

4.1 RS485 and Checksum Protocol

The RS485 in the DCB is configured as 8-bit, no parity, 1 stop bit, half

duplex. The following baud rates are available: 300, 600, 1200, 2400, 4800,

9600, 19200, 38400, 57600. No hardware handshaking is required.

In the RS-485, which is a Half Duplex system, all the Transmitters and all

the Receivers share the same Multidrop wire. Therefore, each character that is

transmitted on the line, is automatically received by all the Receivers. This

is an inherently "confused" way to transmit data and no "Echo" procedure can

assure reliable communication.

In order to solve this reliability problem, it is necessary to use standard

protocols procedures.

It is important to understand that using RS485 with the DCB products without

any protocol is possible. This is also the default condition whenever the RS485

is activated. However, the reliability of the communication is only assured

when activating the protocol. This is done by sending the command CK1 from the

host to the DCB.

Chapter 1.2.1 in the DCB Software manual explains the standard protocol used

and supplied by Elmo.

4.2 Current Control

The analog part of the DBP is actually a standard amplifier that operates in

current mode. However, the DCB receives continuously analog information about

the current magnitude, direction and ripple. This information is processed to

obtain digital control of the following features:

* Continuous current limit

* Peak current limit

* Time dependent peak current limit

* Current ripple

DBP - Rev 6/93

4.2.1 Current feedback, Current feedback multiplier (CFM) and

Current loop

Three current feedbacks are obtained by measuring the voltage drop across

current sensing resistors or by current transformers (when using the isolation

option). These three signals are synthesized and multiplexed which result in a

single voltage signal proportional to phases currents. It is then compared to

the current command. The error is processed by the current amplifier to provide

a voltage command to the PWM section.

Current loop control is obtained by op amp U21/A (current amplifier) and R4,

C1 which form a lag-lead network for current loop. The standard amp is equipped

with R4 and C1 to get optimum current response for an average motor in this

power range. These components are mounted in solderless terminals.

Error amplifier Current amplifier

Current feedback

CFM

The amplifier is equipped with a Current Feedback Multiplier (CFM). By

turning DIP switch 2 (on the upper board of the power stage) to ON, the signal

of the current feedback is multiplied by 2 and consequently the following

changes occur:

- Current gains are multiplied by 2.

- Current monitor is divided by 2.

- Current limits are divided by 2.

- Dynamic range is improved.

- Commutation ripple is reduced.

DBP - Rev 6/93

This function should be activated whenever the rated current AND the peak

current of the motor are less than 20% of the amplifier rated continuous and

peak limits respectively.

Sometimes, oscillations may occur in the current loop due to the fact that

the feedback gain was multiplied. This can be resolved by substituting R4 with

a lower value.

4.3 Digital current limits

The servo amplifier can operate in the following voltage-current plane:

-Ip -Ic

Ic Ip

Intermittent

zone

Continuous

zone -V

Ic - Continuous current Ip - Peak current

Fig. 4.1: Voltage-Current plane

Each amplifier is factory adjusted to have this shape of voltage-current

operating area with rated values of continuous and peak current limits. By

using the command CL(n) for the continuous and PL(n) for the peak it is

possible to adjust the current limits (continuous and peak independently) from

the rated values down to 10% of the rated values.

4.3.1 Time dependent peak current limit

The peak current duration is a programmable parameter which is also a

function of the peak amplitude and the motor operating current before the peak

demand. The user defines the maximum duration of the full amplitude peak by the

instruction PDn - n cannot be more than 2 seconds. In addition to this

definition, a digital filter is employed to ensure that the RMS value of the

current will not exceed the continuous current limit. The duration of Ip is

given by:

DBP - Rev 6/93

Ip - Iop

Tp = 2.2ln ----------

Ip - Ic

Iop - Actual operating current before the peak demand.

The result of this filter is that the maximum peak can last for a maximum of

2 seconds. A lower peak can last longer.

Example: A motor is driven by an DBPF-10/135 amplifier at constant speed and

constant current of 5A. What is the maximum possible duration of a 20A peak ?

20 - 5

Tp = 2.2ln -------- = 0.892 seconds

20 - 10

4.4 Digital position and speed control

The DCB accepts motion commands via an RS232 or RS485 communication line and

receives position feedback in an incremental encoder format either from an

encoder or from the resolver/digital circuit. The DCB derives the closed-loop

position error by comparing the command position and the feedback position. The

error is processed by a digital filter to yield with an analog motor command.

The analog +5 volt range motor command is then amplified by the power

amplifier.

Following is a summary of all the operating modes of the DCB and a detailed

discussion of each of them.

Control Modes

Holding Modes.

Start Modes

Program Mode

Termination Modes

Status reporting

Define origin modes

DBP - Rev 6/93

Control Modes

The DCB can be commanded to control the position of a motor, its torque or

its velocity using three basic control modes:

- Position Mode

- Velocity Mode

- Position Follower Mode

Position Mode

In the position mode the motor will advance a specified distance and then

stop. This distance can be represented as an absolute position (PA n) or as a

relative distance from the current position (PR n). The motion will follow a

trapezoidal or triangular profile with the acceleration (AC n) and slew

velocity (SP n) set by the user.

Velocity Mode

In the velocity mode the motor will accelerate to a specified slew speed. It

will hold this speed until a stop condition is received (see termination

modes), or a new velocity/direction is commanded.

Position Follower

It can also control the motor as a position follower of a master encoder or

a pulse and direction signals.

Holding Modes.

The holding modes describe the behavior of the system after it has stopped.

There are three holding modes:

- Servo

- Motor Off

Servo Mode

In the servo mode (SV) the system maintains stopping position by using its

control law to correct for any position errors.

Motor Off Mode

In the Motor Off mode is, the power bridge and the position control are shut

off and there no torque is generated by the amplifier. The Motor Off mode is

useful in robotics applications in the teaching mode.

DBP - Rev 6/93

Start Modes

There are three start modes to begin a move:

Direct command

A move can be initiated directly by a command from the host or a terminal.

Program

A move can be initiated by a command included in the user program.

Input condition

Another alternative is to have the move started by a conditional statement

specified by the user program.

Program Mode

A set of commands can be implemented as a user program to allow for

automatic and/or complex types of moves. The user may specify software

variables, conditional statements, subroutines and error routines which enable

enhanced motion control.

Termination Modes

A motion can be terminated in a variety of ways. In all but emergency

termination modes the motor will be decelerated gradually to a stop and then

will enter one of the stationary modes (Servo, or Motor Off). In a position

mode move, the motion will terminate naturally upon reaching the desired final

position. In all of the control modes the motion can be terminated by a command

from the host. An additional means of termination is from one of the local

inputs.

Activating the forward and reverse limit switch inputs can be another means

of terminating a move. Upon contacting the switch, the #[ routine will be

activated. This is a user programmed routine that should normally include a

stop command to decelerate the motor to a full stop.

There are two methods of generating an emergency stop. The first is by an

abort command from the host, and the other is by the local abort input. Upon

receipt of either of these commands the system will go immediately to its

stationary mode.

Another "unnatural" way to terminate a motion is whenever an internal

amplifier inhibit (due to one of the protections) occurs. This turns off the

power stage and the motor will decelerate to a stop by friction only. There are

two modes of handling the internal amplifier inhibit:

Latch Mode

The power stage is disabled and only a reset will release it.

DBP - Rev 6/93

Auto restart

The power stage inhibit will automatically be released upon clearing the

cause of the inhibit.

Status Reporting

Status is available to the user in several ways.

Communication

In response to the Tell Status command (TS) the DCB sends a coded message

describing the status of the amplifier.

In addition, the host may request certain information at any time. This

consists of the state of the system (GN?, ZR?, PL?, KI?), the state of the

local inputs (TI), the torque level (TT), the current motor position (TP), the

current motor velocity (TV) and the reason for a stop condition (TC).

Refer to the DCB Software Manual for further details.

Hardware signal

Motion complete signal

This output will go to high when motion is complete.

Inhibit output

Whenever the amplifier is inhibited, this open collector output goes to low.

When using Elmo's mother boards a potential free relay replaces the open

collector output.

4-digit display

Whenever a fault occurs, a fault message will be displayed for easy visual

information. See chapter 9.1 for a summary of all amplifier's fault

indications.

Define origin modes

The origin is that location at which the absolute position of the motor

equals zero. This special location may be defined in two ways. First, the user

may send a command (DH) which defines the current motor position to be the

origin. The alternate method is to request the DCB to perform the homing

sequence by commanding HM.

DBP - Rev 6/93

4.5 Operation of the shunt regulator

A shunt regulator is included in the power supply section of the DBP. The

shunt regulator is a switching type, wherein dissipative elements (resistors)

are switched across the DC bus, whenever the voltage reaches a predetermined

level (Vr). The function of the shunt regulator is to regulate the voltage of

the DC bus during the period of motor deceleration, when there is a net energy

outflow from the motor to the amplifier. The amplifier handles this reverse

energy just as efficiently as it provides energy to the motor, hence, most of

the energy is passed through the amplifier to the power supply, where the

returning energy charges the filter capacitors above their normal voltage

level, as determined by the AC incoming voltage.

When the capacitors charge-up reaches the predetermined voltage level (Vr),

the shunt regulator begins its regulating action. The bus is regulated to this

range until regeneration ceases.

All the double Eurocard size amplifiers are equipped with two outputs for

connecting an external shunt resistor , hence increasing the power dissipation

capability.

SHUNT specifications

Type Reg.

Voltage

(Vr)

Internal

Reg.

Current (A)

External Reg.

Current (A)

DBP-12/135 193 13 N/A

DBP-20/135 193 26 21

DBP-8/270 383 8 N/A

DBP-16/270 383 16 12

DBPF-12/135 193 13 N/A

DBPF-20/135 193 26 N/A

DBPF-30/135 193 26 21

DBPF-8/270 383 8 N/A

DBPF-16/270 383 16 12

DBPF-24/270 383 16 12

DBP - Rev 6/93

4.6 Commutation signals format

300 60 120 180 240 300 360 600

(0)

(360)

300 60 120 180 240 300 360 600

(0)

(360)

300 60 120 180 240 300 360 600

(0)

(360)

Vac

Vba

Vcb

60 FORMAT (120)

30 FORMAT

MOTOR BEMF

DBP - Rev 6/93

4.7 Protective functions

All the protective functions except "Low Back-up Battery Voltage" activate

an interrupt to the main processor which inhibits the power bridge and disable

current flow to or from the motor. The user can interrogate the processor in

order to verify the cause of the inhibit. An indication of the fault will

appear on the display. The following protections are processed by the DCB:

4.7.1 Short circuit protection

The amplifier is protected against shorts between outputs, or either output

to ground, or either output to the positive supply line.

4.7.2 Under/over voltage protection

Whenever the DC bus voltage is under or over the limits indicated in the

technical specifications, the amplifier will be inhibited.

4.7.3 Temperature protection

Temperature sensor is mounted on the heatsink. If, for any reason, the

temperature exceeds 85°C the amplifier will be inhibited. The amplifier will

restart when the temperature drops below 80 °C. The user can always interrogate

the DCB about the heatsink temperature by using the command T?.

4.7.4 Internal power supply failure

In any case that the sum of the internal power supplies is below 13V or its

difference higher than 1V, the amplifier will be inhibited.

4.7.5 Loss of commutation feedback

Lack of either of the commutation signals will inhibit the amplifier.

4.7.6 Low back-up Battery voltage

When the battery voltage goes below 2.4V the DCB will send a message on the

communication line and will display "BATT" on the display.

DBP - Rev 6/93

MOTOR OUTPUTS

+VS

SHUNT D1 D2 D3

D6D5

CURRENT SENSING

CONTROL

RECTIFING,

CURRENT

INRUSH LIMIT

POWER

COMMON

D5 D6

COMMUTATION

CURRENT PROCESSING

D1 D2 D3 D4

SUPPLIES

SMPS

SUPPLIES

CONTROL

PROTECTIONS

CURRENT FEED BACK

PWM SIGNALS

"HALLS" SIGNALS

ISOLATION

PWM SIGNAL

CURRENT FEED BACK

PROTECTIONS

"HALL" SIGNAL

PROCESSING

DBP 3U - BLOCK DIAGRAM

DBP - Rev 6/93

RS232

Display

RS485

Outputs

Buffers Master

Processor TEMP SIGNAL

SHORT SIGNAL

UNDER / OVER - SIGNAL

Current

Feedback

Inputs

Buffer

Aux

Buffer

Encoder

Analog in

Position

ProcessorBuffer

option

MOTOR COMMAND

Current

limits

TACH INPUT (OPTION) R7

10K

100K

PWM

option

100K 100K

619K

VELOCITY/ CURRENT MODE

-V

OFFSET

OPTION 1M

R800

100K

POWER

STAGE

100K

.01UF

ERROR AMPLIFIER

100K

MEMORY BATTERY

BACK UP

10K

DCB BLOCK DIAGRAM

RESOLVER

OPTION

VELOCITY

FEEDBACK

SIGNAL

(TACH OUTPUT WITH RESOLVER OPTION)

ENCODER OUTPUTS

TO POSITION

PROCESSOR

CURRENT

AMPLIFIER

INH. OUT 10MA/30V

DBP - Rev 6/93

DCB COMPONENTS LAYOUT

T1T2

U120

U114

N80C196KB-12

U115

U123

R713

R712

R119

R802

U130

U25

U22

R566

U108

U109

U27

U112

U113

U28

C313

C312

OFF ON

U17

U10

U101

U18

R R

C1C2 U21

U26

R R R R

U20

JPR

U9 U21

U29

U11

C139

U31

R800

R500

R501

R502

R503

R508

R509

R510

R511

U100

U103

R705

506

507

R504

R505

U102 R708

706

704

C300

513

518

519

U106

R707

U107

D7 U8

U116

1 2 34 5 6 7

DBP - Rev 6/93

DCB RESOLVER OPTION BLOCK DIAGRAM

DS14

DS13

DS12

HALLS + ENCODER

PROCESSOR

POSITION

BITS

RESOLVER TO

DIGITAL CONVERTER

R201

R200

C68

C67

R197

Velocity feedback

DS11

ENCODER A

ENCODER B

ENCODER I

R242

R243

R244

R193

R194

Ref. oscillator output

R192

R228

R233

C60

C61

R196

C62

SIN. INPUT

COS. INPUT

JR/1

JR/2

JR/3

JPR/10

JPR/9

JPR/8

JR/8

JR/7

JR/10

JR/9

JR/5

JR/6 Ref. osc. common

JR/4 1K

DBP - Rev 6/93

RESOLVER BOARD

COMPONENTS LAYOUT

U25

U24

DS2

OFF 11

U22

61 R

192

200

197

195

196

201

U30

233

228

193

194

U23

U28 U29

c c c c c

JPR

DBP - Rev 6/93

5. Terminal Description

5.1 Terminals for Horizontal and Rack mounting versions

POWER BOARD - 3U size

H R Function

1 (32a,c) Motor phase A output. With the DIN connector both pins must be

connected.

2 (30a,c Motor phase B output. With the DIN connector both pins must be

connected.

3 (28a,c) Motor phase C output. With the DIN connector both pins must be

connected.

4 (26a,c) AC supply-phase A. With the DIN connector both pins must be

connected.

5 (24a,c) AC supply-phase B. With the DIN connector both pins must be

connected.

6 (22a,c) AC supply-phase C. With the DIN connector both pins must be

connected.

7 (20a,c) DC power positive (+Vs)

(18a,c

16a,c)

DC power common

10 (14c) Hall sensor A *

11 (12c) Hall sensor B *

12 (10c) Hall sensor C *

13 (8c) +15VDC for Hall sensors supply.

14 (6c) Circuit common for the Hall sensors supply (Control common).

15 (4c) 24V common - for the fan supply only.

16 (2c) +24VDC, 400mA for use with brushless fan

* -1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA min.

DBP - Rev 6/93

Power Board - 6U size - Supplies terminals

H R FUNCTION

+VS 4ac,2ac External shunt resistor connection / +VS.

NC NOT CONNECTED

SO 8ac External shunt resistor connection.

NC NOT CONNECTED

POW

COM

14ac,12ac POWER COMMON

NC NOT CONNECTED

AC 20ac,18ac AC supply-phase A. With the DIN connector all pins must be

connected.

AC 26ac,24ac AC supply-phase B. With the DIN connector all pins must be

connected.

AC 32ac,30ac AC supply-phase C. With the DIN connector all pins must be

connected.

Power Board - 6U size - Motor terminals

H R FUNCTION

HC 2c Hall sensor C *

HB 4c Hall sensor B *

HA 6c Hall sensor A *

-FAN 8c 24V common - for the fan supply only

+FAN 10c +24VDC, 400mA for use with brushless fan

MC 18ac,16ac,14a Motor phase C output. With the DIN connector all pins must

be connected.

MB 26c,24ac,22ac Motor phase B output. With the DIN connector all pins must

be connected.

MA 32ac,30ac,28c Motor phase A output. With the DIN connector all pins must

be connected.

* -1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA min.

DBP - Rev 6/93

Control board

H & R Function Remarks

1a Output 6 *

1b Current monitor This analog output represents the actual current

in the motor. The scale (in A/V) is: Ip / 7.5

Ip - Rated peak current of amplifier.

2a Output 7 *

2b Velocity / current mode

selection

When input is left open (low level) the analog

part of the amplifier is working in current mode.

when a high level signal is applied (>2V), the

analog part of the amplifier is working as a high

gain velocity amplifier.**

3a Output 8 *

3b Motion command (+5V) This analog output represents the current command

from the position loop to the power amplifier. It

is useful for monitoring the position loop

response.

4a Circuit common

4b Circuit common

5a Fast output 9 *

5b +5V output There are several +5V terminals. The accumulative

external load should not exceed 200mA.

6a Fast output 10 *

6b Circuit common

7a Motion Complete This output will go to high when motion is

complete. *

7b +15V output 100mA.

8a Inhibit output Whenever the amplifier is inhibited, this open

collector output goes low.

8b -15V output 100mA.

* Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

** Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Control board - cont.

H & R Function Remarks

9a Forward limit switch This committed input activates the #[ subroutine. *

9b positive input of a

differential amplifier.

See Appendix C.

10a Reverse limit switch This committed input activates the #[ subroutine.*

10b Negative input of a

differential amplifier.

See Appendix C.

11a Circuit common

11b Output of a

differential amplifier.

See Appendix C.

12a Home switch *

12b Tachogenerator

output/input

When using the resolver option this output is the

velocity monitor with a scale of 8V for maximum

speed. See 7.3.

13a Abort input This input must be connected to high level voltage

to enable the amplifier.*

13b Output 1 **

14a Circuit common

14b Output 2 **

15a Fast input 6 This fast response input can capture events with a

duration of less than 10µs. An event is defined as

an input voltage transition from low to high. *

15b Output 3 **

16a Fast input 7 Same function as Fast Input 6 (15a). *

16b Output 4 **

17a Reset input *

17b Output 5 **

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

** Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Control board - cont.

H & R Function Remarks

18a Analog input This input is monitored by the main µP. When |Vi|

< 5V, R1=470ohm should be inserted. When |Vi|> 5V,

R1(Kohm)=2Vi-10 should be inserted. The µP always

reads a range of +5V.

18b Input 1 *

19a +5V output There are several +5V terminals. The accumulative

external load should not exceed 200mA.

19b Input 2 *

20a Circuit common

20b Input 3 *

21a Auxiliary encoder input

(Ay) or pulse input for

Pulse and Direction

mode.

21b Input 4 *

22a Auxiliary encoder

complementary input (-

Ay) or complementary

Pulse and Direction

mode

22b Input 5 or Index Input. If a homing sequence is required, the Index Input

must be connected to Input 5 *

23a Auxiliary encoder input

(By) or Direction input

for Pulse and Direction

mode

23b Resolver reference Max. voltage: 20Vptp or 7Vrms

Max current: 80mA

Max frequency: 20KHz

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Control board - cont.

H & R Function Remarks

24a Auxiliary encoder

complementary input (-

By) or Complementary

Direction input for

Pulse and Direction

mode

24b Resolver reference

common.

The reference voltage to the resolver must be

taken from terminals 23b and 24b only.

25a +5V output There are several +5V terminals. The accumulative

external load should not exceed 200mA.

25b Cosine signal input. See 7.3

26a Circuit common For the auxiliary encoder

26b Cosine signal common. See 7.3

27a Channel B input

27b Sine signal input. See 7.3

28a Channel -B input

28b Sine signal common See 7.3

29a Channel A input

29b Circuit common For the main encoder

30a Channel -A input

30b Index output For resolver option only.

31a -Index input

31b Channel B output

32a Index input

32b Channel A output

Remark: In the following paragraphs the terminals will be related to all the

mounting types as in the following sample:

H/R-2a,E-J4/13.

DBP - Rev 6/93

TERMINALS OF DBP

RACK VERSION - 3U SIZE

CONTROL BOARD 1

32 b

32 POWER BOARD

DBP - Rev 6/93

DBP - PANEL (H) MOUNTING TYPE

TERMINALS LAYOUT

EUROCARD SIZE TYPES

CONTROL BOARD

1 2 3 4

+VS

AC input

5 6 7 8

B C

MOTOR OUT

910 11 12 13

COM. ABC

POWER HALL

14 15 16

SUPPLY FAN

~ ~ ~C+15

DBP - Rev 6/93

DBP - PANEL (H) MOUNTING TYPE

DOUBLE EUROCARD SIZE TYPE

ba1

+FAN

-FAN

POW

COM.

N.C

S.O

N.C

+VS

DBP - Rev 6/93

DBP-6U RACK TYPE

POWER

CONTROL

CONNECTORS

ba1

DBP - Rev 6/93

5.2 Mother Boards terminals (MBA-DBP/3U and MBA-DBP/6U)

Use: For all DBP amplifiers (3U/6U size) with Resolver or optical encoder

feedback. The encoder outputs are driven by line drivers to improve noise

immunity.

Termination: Screw type terminals for the power and D-type connectors for the

signals.

POWER TERMINALS FOR MBA-DBP/3U

H R Function

1 (32a,c) Motor phase A output. With the DIN connector both pins must be

connected.

2 (30a,c Motor phase B output. With the DIN connector both pins must be

connected.

3 (28a,c) Motor phase C output. With the DIN connector both pins must be

connected.

4 (26a,c) AC supply-phase A. With the DIN connector both pins must be

connected.

5 (24a,c) AC supply-phase B. With the DIN connector both pins must be

connected.

6 (22a,c) AC supply-phase C. With the DIN connector both pins must be

connected.

7 (20a,c) DC power positive (+Vs)

(18a,c

16a,c)

DC power common

10 Ground, this terminal is connecred through a screw to the rack

chassis.

15 (4c) 24V common - for the fan supply only.

16 (2c) +24VDC, 400mA for use with brushless fan

DBP - Rev 6/93

POWER TERMINALS FOR MBA-DBP/6U

Terminal Function

M1 Motor phase A output.

M2 Motor phase B output.

M3 Motor phase C output.

GND Ground. This terminal is connected to the ENC chassis.

AC AC supply-phase A.

AC AC supply-phase B.

AC AC supply-phase C.

COM DC power common

VS DC power positive

SO Auxiliary shunt output, for external shunt resistor.

DBP - Rev 6/93

Signals connector - J1 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function Remarks

1 Channel A input

2 Channel -A input

3 Channel B input

4 Channel -B input

5 -Index input

6 Index input

7 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

8 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

9 Circuit common

Signals connector - J2 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function Remarks

1 Resolver reference Max. voltage: 20Vptp or 7Vrms

Max current: 80mA

Max frequency: 20KHz

2Resolver reference

common.

The reference voltage to the resolver must be

taken from pins 1 and 2 only.

3 Cosine signal input. See 7.3

4 Cosine signal common. See 7.3

5 Sine signal input. See 7.3

6 Sine signal common See 7.3

7 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

8 -15V output There are several -15V pins. The accumulative

external load should not exceed 100mA.

9 Circuit common

DBP - Rev 6/93

Signals connector - J3 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function Remarks

1positive input of a

differential amplifier.

See Appendix C.

2Negative input of a

differential amplifier.

See Appendix C.

3Output of a

differential amplifier.

See Appendix C.

4 Circuit common

5 Analog input This input is monitored by the main µP. When |Vi|

< 5V, R1=470ohm should be inserted. When |Vi|>

5V, R1(Kohm)=2Vi-10 should be inserted. The µP

always reads a range of +5V.

6 Circuit common

7 Circuit common

8 Current monitor This analog output represents the actual current

in the motor. The scale (in A/V) is: Ip / 7.5

Ip - Rated peak current of amplifier.

9 Circuit common

10 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

11 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

12 -15V output There are several -15V pins. The accumulative

external load should not exceed 100mA.

13 Channel B output

14 Channel A output

15 Index output For resolver option only.

16 Not connected

17 Inhibit output Relay contact (potential free).

The relay contact is closed whenever the

amplifier is enabled. Contact rating: 0.5A, 200V,

10W.

DBP - Rev 6/93

Signals connector - J3 - cont.

Pin Function Remarks

18 Inhibit output Relay contact (potential free).

The relay contact is closed whenever the

amplifier is enabled. Contact rating: 0.5A, 200V,

10W.

19 Motion command (+5V) This analog output represents the current command

from the position loop to the power amplifier. It

is useful for monitoring the position loop

response.

20 Circuit common

21 Reset input *

22 Circuit common

23 Tachogenerator

output/input

When using the resolver option this output is the

velocity monitor with a scale of 8V for maximum

speed. See 7.3.

24 Circuit common

25 Velocity / current mode

selection

When input is left open (low level) the analog

part of the amplifier is working in current mode.

when a high level signal is applied (>2V), the

analog part of the amplifier is working as a high

gain velocity amplifier. *

26 Not connected

Signals connector - J4 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function Remarks

1 Input 1 *

2 Input 2 *

3 Circuit common

4 Input 3 *

5 Input 4 *

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function Remarks

6 Input 5 or Index Input. If a homing sequence is required, the Index Input

must be connected to Input 5.

7 Circuit common

8 Fast input 6 This fast response input can capture events with

a duration of less than 10µs. An event is defined

as an input voltage transition from low to high. *

9 Fast input 7 Same function as Fast Input 6 (8).

10 Circuit common

11 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

12 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

13 Output 7 **

14 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

15 Output 1 **

16 Output 2 **

17 Output 3 **

18 Circuit common

19 Output 4 **

20 Output 5 **

21 Output 6 **

22 Circuit common

23 Output 9 **

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

** Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function Remarks

24 Output 10 *

25 Motion Complete This output will go to high when motion is

complete. *

26 Output 8 *

Signals connector - J6 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function Remarks

1Auxiliary encoder

complementary input (-

By) or Complementary

Direction input for

Pulse and Direction

mode

2 Auxiliary encoder input

(By) or Direction input

for Pulse and Direction

mode

3 Auxiliary encoder input

(Ay) or pulse input for

Pulse and Direction

mode.

4Auxiliary encoder

complementary input (-

Ay) or complementary

Pulse and Direction

mode

* Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J6 - cont.

Pin Function Remarks

5 Auxiliary encoder index

input

6 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

7 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

8 Circuit common

9 Home switch *

10 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

11 Abort input This input must be connected to high level

voltage to enable the amplifier. *

12 +5V output 200mA

13 Forward limit switch This committed input activates the #[ subroutine.

14 Reverse limit switch This committed input activates the #[ subroutine.

15 Circuit common

J1A, FAN TERMINALS - (MBA-DBP/6U ONLY)

10 24VDC common - fan only.

11 +24VDC isolated supply for fan (max. 400mA)

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J8 (MBA-DBP/3U and MBA-DBP/6U)

1 Channel A output Main encoder buffered output (20mA, 0-5V)

2 Channel -A output Main encoder buffered output (20mA, 0-5V)

3 Channel B output Main encoder buffered output (20mA, 0-5V)

4 Channel -B output Main encoder buffered output (20mA, 0-5V)

5 Encoder index output For resolver option only buffered output

(20mA, 0-5V)

6 Encoder -index output For resolver option only buffered output

(20mA, 0-5V)

7 Circuit common

8 Circuit common

9 Circuit common

10 Hall A *

11 Hall B *

12 Hall C *

13 +15V There are several +15V pins. The accumulative

external load should not exceed 100mA.

14 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

15 Circuit common

Remark: In the following paragraphs the terminals will be related to all the

mounting types as in the following sample:

H/R-2a,E-J4/13.

* -1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA min.

DBP - Rev 6/93

MBA - DBP/3U

J3 J7

815 26

815

DBP - Rev 6/93

J1A

25 26 11

25 26

J4 8

MBA-DBP/6U

POW. COM.

+VS

DBP - Rev 6/93

5.3 Terminals for DBP mounted in ENCD.

POWER TERMINALS FOR MBA-DBP/3UE (3U size)

Terminal Function

1Motor phase A output.

2Motor phase B output.

3Motor phase C output.

4AC supply-phase A.

5AC supply-phase B.

6AC supply-phase C.

7DC power positive (+Vs)

8,9 DC power common

10 Ground

11 Ground

POWER TERMINALS FOR MBA-DBP/6UE (6U size)

Terminal Function

MA Motor phase A output.

MB Motor phase B output.

MC Motor phase C output.

GND Ground

AC AC supply-phase A.

AC AC supply-phase B.

AC AC supply-phase C.

POW COM POWER COMMON

+VS External shunt resistor connection / +VS.

SO External shunt resistor connection.

Attention:

DC power commons, control commons and fan common are floating with respect to each

other. Do not short them unless specified.

For isolated amplifiers connecting control common to ground is accomplished by

inserting R2 (short resistor) on the mother board.

DBP - Rev 6/93

Signals connector - J1 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function Remarks

1 Channel A input

2 Channel -A input

3 Channel B input

4 Channel -B input

5 -Index input

6 Index input

7 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

8 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

9 Circuit common

Signals connector - J2 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function Remarks

1 Resolver reference Max. voltage: 20Vptp or 7Vrms

Max current: 80mA

Max frequency: 20KHz

2Resolver reference

common.

The reference voltage to the resolver must be

taken from pins 1 and 2 only.

3 Cosine signal input. See 7.3

4 Cosine signal common. See 7.3

5 Sine signal input. See 7.3

6 Sine signal common See 7.3

7 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

8 -15V output There are several -15V pins. The accumulative

external load should not exceed 100mA.

9 Circuit common

DBP - Rev 6/93

Signals connector - J3 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function Remarks

1positive input of a

differential amplifier.

See Appendix C.

2Negative input of a

differential amplifier.

See Appendix C.

3Output of a

differential amplifier.

See Appendix C.

4 Circuit common

5 Analog input This input is monitored by the main µP. When |Vi|

< 5V, R1=470ohm should be inserted. When |Vi|>

5V, R1(Kohm)=2Vi-10 should be inserted. The µP

always reads a range of +5V.

6 Circuit common

7 Circuit common

8 Current monitor This analog output represents the actual current

in the motor. The scale (in A/V) is: Ip / 7.5

Ip - Rated peak current of amplifier.

9 Circuit common

10 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

11 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

12 -15V output There are several -15V pins. The accumulative

external load should not exceed 100mA.

13 Channel B output

14 Channel A output

15 Index output For resolver option only.

16 Not connected

17 Inhibit output Relay contact (potential free).

The relay contact is closed whenever the

amplifier is enabled. Contact rating: 0.5A, 200V,

10W.

DBP - Rev 6/93

Signals connector - J3 - cont.

Pin Function Remarks

18 Inhibit output Relay contact (potential free).

The relay contact is closed whenever the

amplifier is enabled. Contact rating: 0.5A, 200V,

10W.

19 Motion command (+5V) This analog output represents the current command

from the position loop to the power amplifier. It

is useful for monitoring the position loop

response.

20 Circuit common

21 Reset input *

22 Circuit common

23 Tachogenerator

output/input

When using the resolver option this output is the

velocity monitor with a scale of 8V for maximum

speed. See 7.3.

24 Circuit common

25 Velocity / current mode

selection

When input is left open (low level) the analog

part of the amplifier is working in current mode.

when a high level signal is applied (>2V), the

analog part of the amplifier is working as a high

gain velocity amplifier. *

Signals connector - J4 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function Remarks

1 Input 1 *

2 Input 2 *

3 Circuit common

4 Input 3 *

5 Input 4 *

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function Remarks

6 Input 5 or Index Input. If a homing sequence is required, the Index Input

must be connected to Input 5.

7 Circuit common

8 Fast input 6 This fast response input can capture events with

a duration of less than 10µs. An event is defined

as an input voltage transition from low to high. *

9 Fast input 7 Same function as Fast Input 6 (8).

10 Circuit common

11 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

12 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

13 Output 7 **

14 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

15 Output 1 **

16 Output 2 **

17 Output 3 **

18 Circuit common

19 Output 4 **

20 Output 5 **

21 Output 6 **

22 Output 8 **

23 Output 9 **

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

** Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function Remarks

24 Output 10 *

25 Motion Complete This output will go to high when motion is

complete. *

Signals connector - J6 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function Remarks

1Auxiliary encoder

complementary input (-

By) or Complementary

Direction input for

Pulse and Direction

mode

2 Auxiliary encoder input

(By) or Direction input

for Pulse and Direction

mode

3 Auxiliary encoder input

(Ay) or pulse input for

Pulse and Direction

mode.

4Auxiliary encoder

complementary input (-

Ay) or complementary

Pulse and Direction

mode

* Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J6 - cont.

Pin Function Remarks

5 Auxiliary encoder index

input

6 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

7 +15V output There are several +15V pins. The accumulative

external load should not exceed 100mA.

8 Circuit common

9 Home switch *

10 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

11 Abort input This input must be connected to high level

voltage to enable the amplifier. *

12 +5V output 200mA

13 Forward limit switch This committed input activates the #[ subroutine.

14 Reverse limit switch This committed input activates the #[ subroutine.

15 Circuit common

J1A, FAN TERMINALS - (MBA-DBP/3UE and MBA-DBP/6UE)

10 24VDC common - fan only.

11 +24VDC isolated supply for fan (max. 400mA)

* Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J8 (MBA-DBP/3UE and MBA-DBP/6UE)

1 Channel A output Main encoder buffered output (20mA, 0-5V)

2 Channel -A output Main encoder buffered output (20mA, 0-5V)

3 Channel B output Main encoder buffered output (20mA, 0-5V)

4 Channel -B output Main encoder buffered output (20mA, 0-5V)

5 Encoder index output For resolver option only buffered output

(20mA, 0-5V)

6 Encoder -index output For resolver option only buffered output

(20mA, 0-5V)

7 Circuit common

8 Circuit common

9 Circuit common

10 Hall A *

11 Hall B *

12 Hall C *

13 +15V There are several +15V pins. The accumulative

external load should not exceed 100mA.

14 +5V output There are several +5V pins. The accumulative

external load should not exceed 200mA.

15 Circuit common

Remark: In the following paragraphs the terminals will be related to all the

mounting types as in the following sample:

H/R-2a,E-J4/13.

* -1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA min.

DBP - Rev 6/93

8 CIRCUIT COM.

+15V 13

CIRCUIT COMMON 9

HALL A 10

HALL B 11

HALL C 12

CIRCUIT COM. 15

4 CH B

+5V 14

1 CH A OUT

2 CH A

3 CH B

5 INDEX

6 INDEX

7 CIRCUIT COM.

OUT

CIRCUIT COMMON 9

+15V 8

INDEX INPUT 6

+5V 7

MOTION COMPLETE 25 13 OUT 7

CURRENT/VELOCITY MODE 25

4 CH. B INPUT

3 CH. B INPUT

2 CH. A INPUT

1 CH. A INPUT

13 CHA. B OUTPUT

11 +15V

7 CIRCUIT COM.

9 CIRCUIT COMMON

6 CIRCUIT COM.

8 CURRENT MONITOR

10 +5V

12 -15V

CIRUIT COMMON 24

CIRUIT COMMON 22

CIRUIT COMMON 20

TACHO COMMON 23

RESET INPUT 21

MOTOR COMMAND OUT 19

9 INPUT 7

11 +5V

7 CIRCUIT COMMON

6 INPUT 5

8 INPUT 6

10 CIRCUIT COMMON

12 +5V

OUT 5 20

OUT 10 24

OUT 4 19

OUT 6 21

OUT 9 23

CIRCUIT COMMON 18

6 +5V

7 +15V

8 CIRCUIT COMMON

FORWARD LIMIT SW 13

REVERSE LIMIT SW 14

CIRCIT COMMON 15

HOME INPUT 9

+5V 10

ABROT INPUT 11

+5V 12 5 INDEX

4 CH. A AUX. INPUT

3 CH. A AUX. INPUT

2 CH. B AUX. INPUT

1 CH. B AUX. INPUT

+5V 14

OUT 2 16

OUT 1 15

0UT 3 17

1 INPUT 1

5 INPUT 4

3 CIRCUIT COMMON

2 INPUT 2

4 INPUT 3

CHA. A OUTPUT 14

N.C. 16

INHIBIT OUTPUT 18

INHIBIT OUTPUT 17

INDEX OUTPUT 15

1 DIFF. IN (+)

5 ANALOG INPUT

3 OUT DIFF. AMP.

2 DIFF IN(-)

4 CIRCUIT COM.

5 INDEX INPUT

4 COS. SIGNAL COMMON

+15V 7

-15V 8

SIN. SIGNAL COMMON 6

CIRCUIT COMMON 9

2 Vref COMMON

1 Vref OUTPUT

3 COS. SIGNAL INPUT

5 SIN. SIGNAL INPUT

CONTROL

COMMON

J1A

FAN

GROUND

118 9

POWER

COMMON

6 7

POWER

POSITIVE

4 5

AC INPUT

2 31

MOTOR OUTPUT

R2< 1ohm IS USED TO SHORT

CONTROL COMMON TO

GROUND WHEN USING

ISOLATED AMP.

+VS

ABC

MBA-DBP/3UE

OUT 8 22

DBP - Rev 6/93

8 CIRCUIT COM.

+15V 13

CIRCUIT COMMON 9

HALL A 10

HALL B 11

HALL C 12

CIRCUIT COM. 15

4 CH B

+5V 14

1 CH A OUT

2 CH A

3 CH B

5 INDEX

6 INDEX

7 CIRCUIT COM.

OUT

CIRCUIT COMMON 9

+15V 8

INDEX INPUT 6

+5V 7

MOTION COMPLETE 25 13 OUT 7

CURRENT/VELOCITY MODE 25

4 CH. B INPUT

3 CH. B INPUT

2 CH. A INPUT

1 CH. A INPUT

13 CHA. B OUTPUT

11 +15V

7 CIRCUIT COM.

9 CIRCUIT COMMON

6 CIRCUIT COM.

8 CURRENT MONITOR

10 +5V

12 -15V

CIRUIT COMMON 24

CIRUIT COMMON 22

CIRUIT COMMON 20

TACHO COMMON 23

RESET INPUT 21

MOTOR COMMAND OUT 19

9 INPUT 7

11 +5V

7 CIRCUIT COMMON

6 INPUT 5

8 INPUT 6

10 CIRCUIT COMMON

12 +5V

OUT 5 20

OUT 8 22

OUT 10 24

OUT 4 19

OUT 6 21

OUT 9 23

CIRCUIT COMMON 18

6 +5V

7 +15V

8 CIRCUIT COMMON

FORWARD LIMIT SW 13

REVERSE LIMIT SW 14

CIRCIT COMMON 15

HOME INPUT 9

+5V 10

ABROT INPUT 11

+5V 12 5 INDEX

4 CH. A AUX. INPUT

3 CH. A AUX. INPUT

2 CH. B AUX. INPUT

1 CH. B AUX. INPUT

+5V 14

OUT 2 16

OUT 1 15

0UT 3 17

1 INPUT 1

5 INPUT 4

3 CIRCUIT COMMON

2 INPUT 2

4 INPUT 3

CHA. A OUTPUT 14

N.C. 16

INHIBIT OUTPUT 18

INHIBIT OUTPUT 17

INDEX OUTPUT 15

1 DIFF. IN (+)

5 ANALOG INPUT

3 OUT DIFF. AMP.

2 DIFF IN(-)

4 CIRCUIT COM.

FAN

5 INDEX INPUT

4 COS. SIGNAL COMMON

+15V 7

-15V 8

SIN. SIGNAL COMMON 6

CIRCUIT COMMON 9

2 Vref COMMON

1 Vref OUTPUT

3 COS. SIGNAL INPUT

5 SIN. SIGNAL INPUT

CONTROL COMMON

R2<1ohm, is used to short control common to

ground only when ISOLATED amplifier

is used.

MA MB MC GND AC AC AC POW

COM. +VS SO

MBA-DBP/6UE

DBP - Rev 6/93

5.4 Communication Port Connector

The serial communication is available via a 9 pins D connector (Jc) with the

following pin assignment:

RS232

Pin Function

2 Receive

3 Transmit

5 Common

When using an IBM XT as an host, pins 4 and 5 should be connected together on the 25

pins D connector (computer side). When using an IBM AT as an host, pins 7 and 8

should be connected together on the 9 pins D connector (computer side).

RS485

Pin Function

5 Common

6,7 T/R -

8,9 T/R +

DBP - Rev 6/93

6. Installation procedures

6.1 Mounting

The DBP series dissipates its heat by natural convection except DBPF types

which are fan cooled. For optimum dissipation the amplifiers have to be mounted

with the fins in vertical position.

6.2 Wiring

Proper wiring, grounding and shielding techniques are important in obtaining

proper servo operation and performance. Incorrect wiring, grounding or

shielding can cause erratic servo performance or even a complete lack of

operation.

a) Keep motor wires as far as possible from the signal level wiring (feedback

signals, control signals, etc.).

b) If additional inductors (chokes) are required, keep the wires between the

amplifier and the chokes as short as possible.

c) Minimize lead lengths as much as is practical. Although the amplifier is

protected against long (inductive) supply wires it is recommended to keep

the leads as short as possible.

d) Use twisted and shielded wires for connecting all signals (command and

feedback). Avoid running these leads in close proximity to power leads or

other sources of EMI noise.

e) Use a 4 wires twisted and shielded cable for the motor connection.

f) Shield must be connected at one end only to avoid ground loops.

g) All grounded components should be tied together at a single point (star

connection). This point should then be tied with a single conductor to an

earth ground point.

h) After wiring is completed, carefully inspect all conditions to ensure

tightness, good solder joint etc.

DBP - Rev 6/93

6.3 Load inductance

The total load inductance must be sufficient to keep the current ripple

within the limits - 50% of the adjusted continuous current limit. The current

ripple (Ir) can be calculated by using the following equation:

0.5 x Vs

Ir = ---------- (A)

f x L

L - load inductance in mH.

Vs - Voltage of the DC supply in Volts.

f - Frequency in KHz.

If motor inductance does not exceed this value, 3 chokes should be added (to

each motor phase) summing together the required inductance

Lch = L - Lp

Lch - Choke inductance

Lp - Total inductance between two phases (in Y connection it is the sum of two

phases).

6.4 AC power supply

AC power supply can be at any voltage in the range defined within the

technical specifications. It must have the capability to deliver power to the

amplifier (including peak power), without significant voltage drops. Any

voltage below the minimum or above the maximum will disable the amplifier.

The recommended AC voltage are:

1.2 x VAC(min) < VAC < 0.9 x VAC(max)

Note - Single phase connection:

When using a single phase supply, voltage drop due to loading is expected.

The magnitude of the voltage drop depends on the load current, motor velocity,

stiffness of the power source and total bus capacitance. It is recommended not

to use single phase connection for output current higher than 20A.

For 3U size amplifiers it is recommended to add external capacitance as

follows:

For 135V units up to 1200µF

For 270V units up to 600µF

DBP - Rev 6/93

6.5 Wiring diagrams

6.5.1 Motor's windings

DBP

Motor

Heatsink / GND

Chassis

Minimum acceptance

======================================================================

DBP

Motor

Heatsink / GND

Chassis

Power wires twisted together

Acceptable for most applications

======================================================================

DBP

Motor

Heatsink / GND

Chassis

Power wires twisted and shielded

Optimum wiring, minimum RFI

DBP - Rev 6/93

6.5.2 AC power wiring

+Vs

DC power common

Control common

Heatsink

Fuse

A. Direct connection to the

three phase mains

B. External fuses are needed for 3U size only

DBP + O option

======================================================================

+Vs

DC power common

Control common

Heatsink

Fuse

B. Using autotransformer with

Autotransformer

three phase mains

DBP + O option

A. External fuses are needed for 3U size only

DBP - Rev 6/93

Guide lines for connecting non-isolated AC supplies

Ground:

Control common

Motor chassis

Amplifier's heatsink

Do not ground:

Power common

(The power common is a hot point and any grounding will cause an input

rectifier failure).

Caution:

- If source of motor command is grounded, use amplifier's differential input.

Otherwise, a ground loop is created.

DBP - Rev 6/93

+Vs

DC power common

Control common

Heatsink

Fuse

Isolating transformer

A. Extenal fuses are needed for 3U size only

DBP + I option

Guide lines for connecting an Isolated amplifier with an isolating power transformer

Ground:

DC power common

Control common

Motor chassis

Amplifier's heat sink.

Caution:

- If source of motor command is grounded, use amplifier's differential input.

Otherwise, a ground loop is created.

DBP - Rev 6/93

+Vs

DC power common is internally

connected to control common

Heatsink

Fuse

Isolating transformer

NON-ISOLATED DBP

A. External fuses are needed for 3U size only

Guide lines for connecting a non isolated amplifier with an isolating power transformer

Ground:

DC power common

Motor chassis

Amplifier's heat sink

Do not ground:

Control common - It is internally connected to the power common. Grounding the

control common will create a ground loop.

Caution:

- If source of motor command is grounded, use amplifier's differential input.

Otherwise, a ground loop is created.

DBP - Rev 6/93

+Vs

DC power common

Control common

Heatsink

Fuse

+Vs

DC power common

Control common

Heatsink

To additional

DBPs

CONNECTING MORE THAN ONE DBP

DIRECT CONNECTION TO

THE THREE PHASE MAINS

NOTE: DC POWER TERMINALS ARE

CONNECTED IF SINGLE PHASE

IS USED OR IF SHUNT CURRENT

HAS TO BE INCREASED DBP

DBP

O option

A. External fuses are needed

for 3U size only

DBP - Rev 6/93

+Vs

DC power common

Control common

Heatsink

Fuse

+Vs

DC power common

Control common

Heatsink

To additional

DBPs

CONNECTING MORE THAN ONE DBP

ISOLATING

TRANSFORMER

NOTE: DC POWER TERMINALS ARE

CONNECTED IF SINGLE PHASE

IS USED OR IF SHUNT CURRENT

HAS TO BE INCREASED

DBP

A. External fuses are needed

for 3U size only

I option

DBP - Rev 6/93

+Vs

Heatsink

Fuse

+Vs

Heatsink

To additional

DBPs

CONNECTING MORE THAN ONE DBP

ISOLATING

TRANSFORMER

ISOLATED DBP

NON

NOTE: DC POWER TERMINALS ARE

CONNECTED IF SINGLE PHASE

IS USED OR IF SHUNT CURRENT

HAS TO BE INCREASED

DC POWER COMMON IS

INTERNALLY CONNECTED

TO CONTROL COMMON

DC POWER TERMINAL IS

INTERNALLY CONNECTED

TO CONTROL COMMON

A. External fuses are needed

for 3U size only

DBP - Rev 6/93

+Vs

DC power common

Control common

Heatsink

Fuse

Fuse DBP

External

capacitance

SINGLE PHASE CONNECTION

See chapter 6.4 for details

All rules about supply connections described in the previous pages are also valid

for multi-IBP and/or single phase connection.

DBP - Rev 6/93

+Vs

Control common

Heatsink

DBP

CONNECTING THE EXTERNAL SHUNT RESISTOR

DOUBLE EUROCARD SIZE ONLY

For 135V types the standard value of

For 270V types the standard value of

Rex

Rex is 9.1ohm/225Watt

Rex is 33ohm/225Watt

DBP - Rev 6/93

6.5.3 Hall sensors wiring

HALL A

HALL SENSORES

HALL SENSORES CONNECTION

HALL B

HALL C

+15V

GND

REMARK:

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.4 RS232 Communication wiring

RS232 COMMUNICATION

TCOMPUTER

TXD

RXD

RST CTS

NOTE:

SHIELDING MUST BE CONNECTED AT COMPUTER END ONLY

SYMBOLS:

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.5 RS485 Communication wiring

RS 485 COMMUNICATION

AMP. No 1

T/R+

T/R-

COMPUTER

NOTES:

1. SHIELDING MUST BE CONNECTED AT COMPUTER END ONLY

2. PIN No.1 TRANSMIT/RECEIVE CONTROL

3. PIN No.4 +5V

SYMBOLS:

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

RS485 COMMUNICATION

COMPUTER

T/R+

T/R-

AMP. No 1

AMP. No 2

AMP. No 32

NOTES:

2. PIN No.1 TRANSMIT/RECEIVE CONTROL

3. PIN No.4 +5V

1. SHIELDING MUST BE CONNECTED AT COMPUTER

END ONLY.

SYMBOLS:

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.6 Main encoder wiring

ENCODER CONNECTION

ENCODER

DIFFERENTIAL ENCODER CONNECTION

ENCODER

NOTES:

1.THIS CONNECTION IS FOR AN ENCODER WITH +5V SUPPLY.

SYMBOLS:

COMMON. THE SHIELDING SHOULD BE CONNECTED EITHER

2.THE METAL FRAME OF J1 IS INTERNALLY CONNECTED TO THE DCB

FOR AN ENCODER OF +15V SUPPLY, USE J1 PIN 8 INSTEAD OF PIN 7.

TO J1 PIN 9 OR TO THE METAL FRAME OF J1.

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.7 Resolver wiring

RESOLVER CONNECTION

RESOLVER

4S4

NOTES:

1. PIN No 7 = +15V

2. PIN No 8 = -15V

3. PIN 9 AND THE METAL FRAME OF J2 ARE INTENALLY CONNECTED

TO THE DCB COMMON. THE SHIELDINGS OF ALL THE PAIRS

SYMBOLS:

FRAME OF J2.

SHOULD BE CONNECTED EITHER TO J2 PIN 9 OR TO THE

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.8 Auxiliary encoder wiring

AUXILIARY ENCODER CONNECTION

IENCODER

DIFFERENTIAL AUXILIARY

ENCODER CONNECTION

ENCODER

NOTES:

1.THIS CONNECTION IS FOR AN ENCODER WITH +5V SUPPLY.

SYMBOLS:

FOR AN ENCODER OF +15V SUPPLY, USE J6 PIN 7 INSTEAD OF PIN 6.

TO J6 PIN 8 OR TO THE METAL FRAME OF J6.

2.THE METAL FRAME OF J6 AND PIN 8 ARE INTERNALLY CONNECTED TO

THE DCB COMMON. THE SHIELDING SHOULD BE CONNECTED EITHER

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.9 Pulse/Direction signals wiring

PULSE & DIRECTION INPUT CONNECTION

CONTROLLER

DIRECTION

DIFFERENTIAL PULSE & DIRECTION

INPUT CONNECTION

- PULSE

PULSE

DIRECTION

- DIRECTION

CONTROLLER

NOTES:

SYMBOLS:

TO J6 PIN 8 OR TO THE METAL FRAME OF J6.

1.THE METAL FRAME OF J6 AND PIN 8 ARE INTERNALLY CONNECTED TO

THE DCB COMMON. THE SHIELDING SHOULD BE CONNECTED EITHER

TWISTED PAIR

SHIELDING

PULSE

DBP - Rev 6/93

7. Start - Up Procedures

7.1 Common procedures for all amplifiers types

7.1.1 Commutation signals format

Select the position of DIP switch 1 on the upper board of the power stage

according to the commutation signal format the motor has.

DS1 positions: ON (down): 30°OFF (up): 60°

For all Resolver versions it should be 60 °.

7.1.2 CFM function

Select the position of DIP switch 2 on the upper board of the power stage

according to the motor's rated current. If it is less than 20% of the

amplifier's rated current select:

DS2 to ON (down)

Otherwise,

DS2 to OFF (up) - No CFM

7.1.3 Abort logic

Make sure that the Abort input is connected to a High (logic) voltage

source.

DBP - Rev 6/93

7.1.4 Setting the auxiliary position input format

This step is valid only for those applications that need to use the auxiliary

position input. You may skip this step if you do not use it.

When using an Optical encoder

Set DS 7 to OFF

When a the encoder has differential outputs:

Set DS 4 and 5 to OFF

Otherwise they should be ON.

When using Pulse and Direction signals

Set DS 7 to ON

7.1.5 Selecting the communication bus

Select the desired communication bus as follows:

For RS232: Set DS9 to OFF

For RS485: Set DS9 to ON

7.1.6 Preparing the automatic baud rate selection

The DCB baud rate will automatically match the host baud rate when DS1 is

set to ON.

Set DS1 to ON

DBP - Rev 6/93

7.2 Setting the main optical encoder format

When a differential encoder is used:

Set DS 2,3,6 to OFF

Otherwise they should be ON.

7.3 Setting the R/D circuit

Set DS 2,3,6 to ON

The Resolver interface circuit consists of three basic blocks:

R/D converter

The R/D conversion is done by a variable resolution, monolithic converter

type 2S82 of Analog Devices. It accepts two signals from the Resolver (sine and

cos.) and converts them into binary position data bits. The resolution of the

position bits is user selectable 10, 12 ,14 and 16 (only for standard encoder

resolution). In addition, the R/D creates a signal that is proportional to the

Resolver velocity. This signal is being used as a velocity feedback.

EPROM

The EPROM creates "Hall" signals by mapping the position data bits accepted

from R/D into suitable Hall signals to operate a specific brushless motor. In

addition, the encoder index (marker) signal is also produced from the EPROM.

The EPROM is designated as follows:

2 4 X S STD

Resolver's poles number

Ratio of motor/resolver

poles numbers

Encoder resolution

Commutation address

R/D resolution

X=User selectable, 0=10 bits

2=12 bits, 4=14 bits, 6=16 bits

In the S (standard) version zero crossing of phases B C occurs at position

address "0" of the Resolver.

DBP - Rev 6/93

Oscillator

Creates sinusoidal waveform signal to excite the primary of the Resolver.

Oscillator Frequency/Amplitude Selection (R228,R233)

The frequency (fr) and amplitude (Vr) needed to excite the Resolver are

taken from the Resolver data sheet.

Selecting the frequency:

R228 = 110/fr (Kohm)

0.1KHz < fr (KHz) < 20KHz

Selecting the amplitude:

Pay attention that the RMS amplitude does not exceed 7Vrms or that the peak-

to-peak (ptp) value is within the range of 2V < Vrptp < 20V. For Vr in

peak-to-peak value:

R233 = 6/(Vr - 2) (Kohm)

For Vr in RMS value:

R233 = 6/(2.82Vr - 2) (Kohm)

Reference Voltage level to R/D (R192)

In order to adjust the reference voltage input level to 2Vrms, select R192

as follows:

R192 = 50 x (Vrrms - 2) (Kohm)

For Vrrms <2V, install R192=100 ohm.

DBP - Rev 6/93

Signal input level (R193,R194)

The R/D inputs (Vinrms) are adjusted to the sin/cos. Resolver outputs by:

Resolver output = Vinrms = Vrrms x Transformation ratio

R193 = R194 = Vinrms - 2 - Rstator (Kohm)

(Rstator in Kohm).

When Vinrms<2V, install R193=R194=100 ohm.

The standard R/D converter will not operate for Vin rms<1.8V. Consult factory

for OEM applications.

Velocity Signal

The tracking converter technique generates an internal signal at the output of

the integrator that is proportional to the rate of change of the input angle.

This dc analog output (velocity signal) is buffered and represented at terminal

H/R-12b,E-J3/23. Max output voltage is +8V.

This velocity signal can be internally connected to the summing junction of

the error amplifier by inserting R7 - see Appendix B for more details. However,

the standard procedure does not require closing the velocity loop.

Select maximum actual velocity of the application and calculate the maximum

tracking rate T of the Resolver as follows:

T = rpm x Q / 120

T unit is rps: Resolver electrical revolution per second

Q - number of poles of Resolver ;

rpm - mechanical revolution per minute.

Selecting the Resolution

The resolution can be selected to be 10,12,14 or 16 bits by use of DIP

switches 13 and 14. When selecting the resolution the rps limits should not be

exceeded:

DBP - Rev 6/93

10 bit = 1040 rps

12 bit = 260 rps

14 bit = 65 rps

16 bit = 16.5rps

Resolution DS13 DS14

10 ON ON

12 ON OFF

14 OFF ON

16 OFF OFF

Note:

- Each resolution change must be followed by new components selection

procedure.

- When changing resolution under dynamic conditions, a period of uncertainty

will exist before position and velocity data is valid.

Encoder resolution

In the STD mode (DS12 OFF), the encoder signals A,B are created by the EPLD

and can have only the following basic resolutions (for 2 pole Resolver):

256 for 10 bits

1024 for 12 bits

4096 for 14 and 16 bits

When the Resolver is more than 2 poles, the resolution for one shaft

rotation will be:

Er = QxS / 8

Q = number of Resolver poles ;

S = resolution of converter (2 10,212,or 214)

When different encoder resolution is needed the encoder signals are

generated by the EPROM and the R/D resolution is no longer user selectable.

This option requires

- DS12 at ON

- Special EPROM which is programmed for this resolution.

DBP - Rev 6/93

HF Filter (R195, R196, C61, C62)

The function of the HF filter is to reduce the amount of noise present on

the signal inputs to the 2S82, reaching the Phase Sensitive Detector and

affecting the outputs. Values should be chosen so that

15Kohm < R195=R196 < 30Kohm

160x103

C61 = C62 = ------------ (pF)

R195 x fr

fr = Reference frequency in KHz

R195 in Kohm

This filter gives an attenuation of 3 times at the input to the phase

sensitive detector.

AC Coupling of Reference Input (C60)

Select C60 so that there is no significant phase shift at the reference

frequency. That is,

106 100 x R192

C60 = -------------- (pF) Rx = ------------ (Kohm)

fr(KHz) x Rx 100 + R192

R192 in Kohm

If Rx yields less than 50K, install a value of Rx=50K in the C60 equation.

Maximum Tracking Rate (R201)

The VCO input resistor R201 sets the maximum tracking rate of the converter

and hence the velocity scaling as at the maximum tracking rate, the velocity

output will be 8V.

Decide on your required maximum tracking rate, "T" , in revolutions per

second. Note that "T" must not exceed the specified maximum tracking rate or

1/16 of the reference frequency.

DBP - Rev 6/93

R201 = 5.92 x 107 / T x p (Kohm)

where p = bit per rev

= 1,024 for 10 bits resolution

= 4,096 for 12 bits

= 16,384 for 14 bits

= 65,536 for 16 bits

Closed Loop Bandwidth Selection (C67, C68, R200)

a. Choose the Closed Loop 3dB Bandwidth (f bw) required ensuring that

fref > 10 x fbw

Recommended bandwidth values:

250Hz for 3KHz

300Hz for 5KHz

500Hz for 10KHz

b. Select C67 so that

2.5x109

C67 = ------------- (pF)

R201 x fbw2

with R201 in Kohm and fbw in Hz as selected above.

c. C68 is given by

C68 = 40 x C67 (pF)

DBP - Rev 6/93

d. R200 is given by

127 x 107

R200 = ------------- (Kohm)

fbw x C68

fbw in Hz, C68 in pF

R200 value should be at least three times R197.

Gain Scaling Resistor (R197)

R197 should be installed according the following table:

536Kohm for 10 bits resolution

130Kohm for 12 bits

33Kohm for 14 bits

8.2Kohm for 16 bits

DBP - Rev 6/93

8. Applying power - Adjustments

Important remarks:

A. If all the previous steps were accomplished you may now disconnect the motor

leads, turn the power on and continue with the following adjustments.

Step 1 - Applying Power

Apply power and check for LED Vs of the DCB that should be "ON", indicating

that the system supplies are present. The display should read: "F-OK". If you

get another message, refer to the following table to find the cause of the

problem. Turn the power off, clear the cause of the problem and re-power the

unit.

Event Display Display

after

Recurring

DIP switch 1 - ON BAUD OK

Load is under cont. current limit CLIM C-OK

Battery Low BATT B-OK

Abort condition (hardware only) ABRT A-OK

Amplifier's power stage disabled *AMPD H-OK

-15V out of limits -15V F-OK

Under or Over Voltage VOLT F-OK

+15V out of limits +15V F-OK

Over Temperature TEMP F-OK

Commutation problem CMMT F-OK

Short condition at the power outputs SHRT F-OK

* The AMPD message appears in two cases:

1. When MO (Motor Off) command is given.

2. Position error exceeds the allowed value.

DBP - Rev 6/93

Step 2 - Establishing the communication

Press CR (carriage return) in the host several times until the DCB sends the

message "Communication OK".

If you want to "lock" the baud rate in the DCB:

- Turn off the power and remove the amplifier from the rack if it is a rack

version.

- Set DS1-OFF.

Now the baud rate you selected is stored in the SRAM.

It is possible to change DS1 at any time. However, the DCB will notice the change

only upon power on or hardware reset.

Step 3 - Checking the feedback elements

- Turn on the power.

- Rotate the motor shaft manually and interrogate the position with the

instruction:

TP (CR)

The controller response should vary as the motor is turned. If this does not

occur, check the feedback signals.

- When using the auxiliary encoder input, rotate the auxiliary encoder and

interrogate the position with the instruction: PY.

The controller response should vary as the encoder is turned. If this does

not occur, check the feedback signals. The DCB is counting quadrature pulses.

This means that for encoders or resolvers the answer for a TP command will be 4

times the number of basic encoder pulses and for Pulse/Direction mode it will

be twice the number of pulses.

Step 4 - Adjusting the current limits

Defining the amplifier type

- Define the maximum current of the amplifier by the instruction:

MCn

n - rated peak current of the amplifier in A as given in the table of chapter

For example: n is 48 for DBPF-24/270

DBP - Rev 6/93

Current limit adjustments

- Define the continuous current limit by the instruction:

CLn.m (n.m - current in A)

- Define the peak current limit by the instruction:

PLn.m (n.m - current in A)

- Define the maximum peak current duration by the instruction:

PDn.m (n.m - seconds)

Step 5 - Latch mode of the protective functions

All the protective functions activate internal inhibit. There are two modes

of resetting the amplifier after the cause of the inhibit disappears:

Self Restart: (LM0)

The amplifier is inhibited only for the period that the inhibit cause is

present.

Latch (LM1)

Each failure latches the Inhibit and the failure message on the display. For

restart (after clearing the failure source), reset has to be performed by

applying logic 0 at the reset input (H/R-17a,E-J3/21), or by turning the power

off and on.

For safety reason it is recommended to use the amplifier in the LATCH MODE - LM1

Step 6 - Connecting the Motor

- Turn off the power.

- Connect the leads of the motor.

- Turn on the power.

For proper operation, the system must have negative feedback. If the motor

remains in the same position and returns to the same position when you turn the

motor shaft and let go, then the position feedback is negative as required. If

the motor runs away you have positive feedback. To correct the feedback, just

reverse the encoder leads.

DBP - Rev 6/93

9. Tables and Summaries

9.1 Display diagnostics

Each amplifier's fault is stored immediately in the DCB RAM. In addition to

that, a Failure Message is displayed. Following are all the valid Display

Messages:

Event Display Display

after

Recurring

DIP switch 1 - ON BAUD OK

Load is under cont. current limit CLIM C-OK

Battery Low BATT B-OK

Abort condition (hardware only) ABRT A-OK

Amplifier's power stage disabled *AMPD H-OK

-15V out of limits -15V F-OK

Under or Over Voltage VOLT F-OK

+15V out of limits +15V F-OK

Over Temperature TEMP F-OK

Commutation problem (for brushless drives

only)

CMMT F-OK

Short condition at the power outputs SHRT F-OK

* The AMPD message appears in two cases:

1. When MO (Motor Off) command is given.

2. Position error exceeds the allowed value.

DBP - Rev 6/93

9.2 Summary of DIP switches

Power stage board

(2 poles DIP switch)

DIP switch OFF (UP) ON (DOWN)

DS1 60° commutation signals format 30° commutation signals format

DS2 No CFM Activate CFM

Control stage board

(9 poles DIP switch)

DIP switch ON OFF

DS1 Auto-selection of Baud rate Latch last value

DS2 Non-differential channel A Diff. input of channel A

DS3 Non-differential channel B Diff. input of channel B

DS4 Non-differential channel Ay Diff. input of channel Ay

DS5 Non-differential channel By Diff. input of channel By

DS6 Non-differential index Diff. index

DS7 Pulse/Direction format Encoder channels format

DS8 N/C

DS9 RS485 RS232

4 poles DIP switch (for Resolver)

Switch OFF ON

DS11 Tacho signal disconnected Tacho signal connected to error

amplifier.

DS12 Standard encoder resolution Non-standard encoder resolution

DS13 14 bit resolution (DS14-ON)

16 bit resolution (DS14-OFF)

10 bit resolution (DS14-ON)

12 bit resolution (DS14-OFF)

DS14 12 bit resolution (DS13-ON)

16 bit resolution (DS13-OFF)

10 bit resolution (DS13-ON)

14 bit resolution (DS13-OFF)

DBP - Rev 6/93

Appendix A - Current loop response

In most applications it is not necessary to adjust the current loop to

achieve the optimum response. When there are extreme electrical parameters in

the armature circuit (inductance and resistance) the standard components values

of 0.01µF for C1 and 100Kohm for R4 may not yield with the optimum response.

The current loop should be optimized as follows:

- Insert R7 (1K) to connect the tacho input to the error amplifier. The

amplifier must not be configured into velocity mode. If the resolver option

is used, make sure that DS11 is OFF.

- Apply power to the amplifier and send the command BA.

- Provide the tacho input H/R-12b,E-J3/23 with a bi-directional square wave

current command (100-200Hz, +2.0V waveform is often employed).

- Monitor the load current either by a current probe or by the current monitor.

If the current response is not critically damped, use the following

procedure:

- Short circuit C1 with a short jumper wire.

- Replace R4 with a decade resistance box. Initially set the box resistance at

10Kohm.

- Apply the square wave test signal to the amplifier input.

- Apply power, and while monitoring the load current, gradually increase the

value of the box resistance until optimum response as depicted in Fig A-1 is

achieved.

- Substitute the closest standard value discrete resistor for R4 and remove the

decade resistance box.

- Remove the shorting jumper across C1, and again check the response using the

square wave test signal.

- If the previous step does not yield satisfactory results, if unacceptable

overshooting has been noted, substitute a larger value than 0.01 µF; or, if

the response is overdamped, substitute a smaller value than 0.01 µF.

Repetition of this procedure should yield an optimum choice for C1.

DBP - Rev 6/93

Reference input signal

C1 too large / R4 too small

Critically damped

C1 too small / R4 too large

Fig. A-1

Typical current response waveforms

100

DBP - Rev 6/93

Appendix B - Adding a velocity feedback

THIS PAGE IS BLANK

101

DBP - Rev 6/93

Appendix C - Differential amplifier connection

The differential amplifier is provided for your optional use. It can be used

for buffering, inverting or elimination of common mode signals.

The differential amplifier inputs are available at terminals H/R-9b,E-J3/1,

H/R-10b,E-J3/2. Terminal H/R-10b,E-J3/2 is the inverting input, terminal H/R-

9b,E-J3/1 is the non-inverting input. The output is on terminal H/R-11b,E-J3/3.

The differential amplifier can be internally connected to the summing junction

by inserting R800.

The differential amplifier may be used as a buffer or as an eliminator of

common mode signals. For a non-inverting buffer amplifier, connect the positive

signal lead to terminal H/R-9b,E-J3/1 and the negative signal lead to terminal

H/R-10b,E-J3/2, and connect terminal H/R-10b,E-J3/2 to the circuit common. For

an inverting buffer amplifier, connect the positive signal lead to terminal

H/R-10b,E-J3/2, the negative signal lead to terminal H/R-9b,E-J3/1, and connect

terminal H/R-9b,E-J3/1 to the circuit common. The output of the differential

amplifier is given by:

10xV1 10 10xV 2

Vo = ----------- x ( 1 + --- ) - -------

10 + R3 R2 R2

V1 - Input voltage of terminal H/R-9b,E-J3/1.

V2 - Input voltage of terminal H/R-10b,E-J3/2.

V1max < 10 + R3; V2max < 100/R2

See schematic in chapter 4.

102

DBP - Rev 6/93

DIMENSIONAL DRAWINGS

IN THE FOLLOWING DRAWINGS ALL THE DIMENSIONS ARE IN MILLIMETERS.

PANEL (H), DBP1................................ ................... 104

PANEL (H), DBP2................................ ................... 107

PANEL (H), DBP3................................ ................... 110

PANEL (H), DBP4................................ ................... 113

PANEL (H), DBP6................................ ................... 116

RACK 3U/13T................................ ....................... 119

RACK 3U/20T................................ ....................... 122

RACK 6U/14T................................ ....................... 125

RACK 6U/21T................................ ....................... 128

ENCD - 3U/................................... ..................... 130

ENCD - 6U/................................... ..................... 131

EXTERNAL SHUNT RESISTOR ................................ ...........132

103

DBP - Rev 6/93

PANEL (H), DBP1

187 169

12.5 110

DBP1 - TOP VIEW

BATTERY

104

DBP - Rev 6/93

18.6

52.5

9.6

4.0 187

DBP1 - SIDE VIEW 1

1 2 ON

OFF

105

DBP - Rev 6/93

111.76

32.3

1.6

DBP1 - SIDE VIEW 2

6 7 8 910 11

3 4 51 21213 14 1516

106

DBP - Rev 6/93

PANEL (H), DBP2

200 182

109

DBP2 - TOP VIEW

BATTERY

107

DBP - Rev 6/93

OFF

1 2

85.5

9.6

51.2

GROUNDING

SCREW M4

200

DBP2 - SIDE VIEW 1

OFF

1 2

102

108

DBP - Rev 6/93

111.76

1 2 3 4 5 6 7 8 9 10 11

32.3

1.6

9.64

DBP2 - SIDE VIEW 2

102

12 13 14 15 16

109

DBP - Rev 6/93

PANEL (H), DBP3

200 182

205

245

DBP3 - TOP VIEW

DETAIL A

DETAIL A.

SEE

BATTERY

110

DBP - Rev 6/93

9.64

1 2

14.64

56.64

GROUNDING

200

SCREW M4

102

DBP3 - SIDE VIEW 1

OFF

111

DBP - Rev 6/93

245.11

+-HA HB HC

FAN

111.76

AC AC AC

NC P.C NC SO NC +VS

32.3

1.6

14.6

105

DBP3 - SIDE VIEW 2

112

DBP - Rev 6/93

PANEL (H), DBP4

187 173.5

215

245

DBP4 - TOP VIEW

BATTERY

113

DBP - Rev 6/93

14.64

9.64

23.64

4.0

187

72.54

14.64

DBP4 - SIDE VIEW 1

SIDE VIEW

1 2 ON

OFF

114

DBP - Rev 6/93

245.11

+-HA HB HC

FAN

111.76

AC AC AC

NC P.C NCSO NC +VS

32.3

1.6

14.64

72.54

DBP4 - SIDE VIEW 2

115

DBP - Rev 6/93

PANEL (H), DBP6

DBP6 - TOP VIEW

SEE DETAIL A

294205

POWER

CONN.

182

AIR FLOW

FAN

200

DETAIL A.

BATTERY

116

DBP - Rev 6/93

FRONT VIEW

182

200

130

DBP6 - SIDE VIEW 1

117

DBP - Rev 6/93

DBP6 - SIDE VIEW 2

294

130

118

DBP - Rev 6/93

RACK 3U/13T

DBP RACK MOUNTING (3U/ 13T)

OFF

51.54

17.64

2.4

9.64

162.54 KEYING PIN

OFF

1 2

65.84

SIDE VIEW 1

119

DBP - Rev 6/93

DBP RACK MOUNTING (3U/ 13T)

111.76

32.3 65.84

9.64 1.6

KEYING PIN

5.5

SIDE VIEW 2

120

DBP - Rev 6/93

POWER

ELMO

FRONT PANEL FOR DBP 3U/13T

121

DBP - Rev 6/93

RACK 3U/20T

DBP RACK MOUNTING (3U/20T)

9.64

2.4

83.54

49.64

KEYING PIN

162.54

OFF

1 2

101.4

SIDE VIEW 1

122

DBP - Rev 6/93

DBP RACK MOUNTING (3U/ 20T)

111.76

32.3

32 C

9.64

1.6

KEYING PIN

5.5

132

101.4

SIDE VIEW 2

123

DBP - Rev 6/93

101.4

128.7

POWER

ELMO

FRONT PANEL FOR DBP 3U/ 20T

124

DBP - Rev 6/93

RACK 6U/14T

189

OFF

1 2

9.64

14.64

1.6

14.64

32.3

22.64

56.54

162.5

180

8.5

DBP RACK MOUNTING (6U/14T)

70.92

SIDE VIEW 1

125

DBP - Rev 6/93

32 2C

A32 C

32.3

1.6

14.6

111.76

262

DBP RACK MOUNTING (6U/14T)

SIDE VIEW 2

126

DBP - Rev 6/93

70.92

262

FRONT PANEL FOR DBP 6U/14T

POWER

ELMO

127

DBP - Rev 6/93

RACK 6U/21T

DBP RACK MOUNTING (6U/21T)

9.64

14.64

1.6

88.54

54.64

162.5

32.3

SIDE VIEW 1

180

2.4

8.5

OFF

106.5

128

DBP - Rev 6/93

POWER

ELMO

FRONT PANEL FOR DBP 6U/21T

129

DBP - Rev 6/93

ENCD - 3U/...

SIDE VIEW

FRONT VIEW

ENCD - 3U/...

132.5

265.5

272.5

222

45.0

11 X

POWER

7.5

NOTE:

ALL DIMENSIONS ARE IN mm.

X102.7

12T 20T16T

62.0 82.3

24T 36T

123.0 184.0

Standard Sizes

For non-standard sizes:

X = 5.08 x n + 1mm

POWER

ELMO

130

DBP - Rev 6/93

ENCD - 6U/...

SIDE VIEW

11 FRONT VIEW

5POWER

7.5

NOTES: 1. ALL DIMENSIONS ARE IN mm.

2. X = n x 5.08+1, n = number of T

ENCD - 6U/...

222

400

234

406.5

POWER

ELMO

131

DBP - Rev 6/93

EXTERNAL SHUNT RESISTOR

TOP VIEW

11.9

15.9

SIDE VIEW

.508

31.75

FRONT VIEW

9.5

4.4

15.9

22.2

293.7

EXTERNAL SHUNT RESISTOR (ESR)

14.3

7.14

316

132

DBP - Rev 6/93

List of ELMO Service Centers

ISRAEL

Elmo Motion Control LTD

34 Segula ST.

Petah-Tikva 49103

Tel: (03)934-5059

Fax: (03)934-5126

U.S.A

Elmo Motion Control INC.

1200 Woodruff Road, Suite C-22,

Greenville, SC 29607

Tel: (803) 288-9316

Fax: (803) 288-9318

EUROPE

Elmo Motion Control

Stanserstr. 7

CH-6362 Stansstad, Switzerland

Tel: (041) 610775

Fax: (041) 610778

================================================================

AUSTRIA

Kwapil

POB 64

A-1091 Wien

Tel: (0222) 342597

Fax: (0222) 311203

BENELUX

Eltromat B.V.

Looierij 26

4760 AB Zevenbergen

The Netherlands

Tel: (01680) 25925

Telefax: (01680) 28485

134

DBP - Rev 6/93

FINLAND

OY Scandrive

Elsankuja 2 K

SF-02231 Espoo

Tel: 358-0-8035044

Fax: 358-0-8035055

FRANCE

A 2 V SA

11-12 Rue Eugene HENAFF,

78190 Trappes,

Tel: (1) 30620101

Fax: (1) 30626204

GERMANY

IME GmbH

Brugger str. 8

D-78628 Rottweil

Tel: 0741/22091

Fax: 0741/22060

ITALY

Servotecnica SRL

Viale Lombardia 20

20095 Cusano Milanino (MI)

Tel: (02) 66401010

Fax: (02) 66401020

SWEDEN

Aratron AB

P.O.B 20087,

Kratsbodavagen 50,

S-16120 Bromma

Tel: 8-981875

Fax: 8-984281

UNITED KINGDOM

INMOCO Limited

4 Brunel Close

Drayton Fields

Daventry NN11 5LE

Tel: 0327/300320

Fax: 0327/300319

Elmo Servo Amplifier Dbp Series Users Manual Emanudbp

SERVO AMPLIFIER DBP SERIES MAN_DBP_

DBP SERIES to the manual 99089bd7-80ef-45b2-9a4d-224e6c003172

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