Elmo ISP Emanuisp User Manual To The 55c601e8 0f4c 460d 9437 D9e38e620371
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1 Rev 6/95 ISP - Rev 6/95 2 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 effective. ISP - Rev 6/95 Standard Acknowledge Form, than the later shall prevail and be 3 How to use this manual - Flow Chart The ISP amplifier is designed for OEM applications. It enables the user to adjust the amplifier for various types of motors and to save valuable adjusting time in repetitive applications. Use the following flow chart in order to determine the chapters that you should read. If you are a new user of the ISP, you should read chapters 1-4 which will familiarize you with the product. Read chapters 1,2,3,4 no Familiar with the ISP ? Panel (H) version or Rack (R) w/o Elmo mother board ? Read chapter 5.1 Terminals no Rack (R) with Elmo mother board? Read chapters 5.1+5.2 Terminals no Elmo enclosure ? Read chapter 5.3 Terminals Read chapter 6 - Installation Read chapter 7.1 - Start-Up no Brush Tacho ? Read 7.2 Armature voltage feedback ? Read 7.3 Read chapter 8 - Adjustments Read chapter 9 - Summaries ISP - Rev 6/95 no (Current mode) 4 TABLE OF CONTENTS 1. Description ................................ ........................ 6 2. Type Designation ................................ ................... 7 3. Technical specifications ................................ ...........7 4. Operation of the servo control ................................ .....8 4.1 Inputs................................ ....................... 8 4.2 Velocity mode ................................ ................ 9 4.2.1 5. 6. 7. Velocity control using armature voltage feedback .....10 4.3 Current mode ................................ ................. 10 4.4 Current loop ................................ ................. 11 4.5 Current limits ................................ ............... 11 4.5.1 Time dependent peak current limit .................... 11 4.5.2 Dynamic contouring of continuous and peak current limits 12 4.6 Operation of the shunt regulator ............................. 13 4.7 Protective functions ................................ .........14 4.7.1 Short circuit protection ............................. 14 4.7.2 Under/over voltage protection ........................ 14 4.7.3 Temperature protection ............................... 14 4.7.4 Insufficient load inductance ......................... 14 4.7.5 Loss of velocity feedback signal ..................... 14 4.7.6 Shunt regulator duty cycle ........................... 14 Terminal Description ................................ ............... 17 5.1 Terminals for Horizontal and Rack mounting versions ..........17 5.2 Mother Board terminals ................................ .......20 5.3 Terminals for ISP mounted in 3U size ENC. .................... 22 Installation procedures ................................ ............ 26 6.1 Mounting................................ ..................... 26 6.2 Wiring................................ ....................... 26 6.3 Load inductance ................................ .............. 27 6.4 AC power supply ................................ .............. 27 6.5 Wiring diagrams ................................ .............. 28 Start - Up Procedures ................................ .............. 33 7.1 Common procedures for all amplifiers types ................... 33 7.1.1 Inhibit and CW/CCW logic ............................. 33 7.1.2 Velocity mode ................................ ........36 7.1.3 Current mode ................................ .........36 ISP - Rev 6/95 5 7.1.4 Activating the loss of tacho protection (velocity mode only) ................................ ........................... 37 8. 9. 7.1.5 Latch mode of the protective functions .............. 38 7.1.6 Activating the dynamic contouring of the current limits 38 7.2 Velocity control using tachogenerator feedback .............. 38 7.3 Velocity control using armature voltage feedback ............ 39 Amplifier adjustment and diagnostics ............................... 40 8.1 Balance adjustment ................................ .......... 40 8.2 Current limit adjustment ................................ .... 40 8.3 Adjusting the motor speed (velocity mode only) .............. 41 8.4 Adjustment of the IxR compensation .......................... 41 8.5 Response adjustment (velocity mode only) .................... 42 Tables and Summaries ................................ ............... 44 9.1 Adjusting trimmers ................................ .......... 44 9.2 LED diagnostics ................................ ............. 44 Appendix A - Response adjustment - current loop ........................ 45 Appendix B - Current limits contour adjustment ......................... 47 List of ELMO Service Centers ................................ ........... 77 ISP - Rev 6/95 6 1. Description The ISP is an amplifier/power supply package, assembled on a single heatsink with a Eurocard size. The rated output is up to 1500W. The integrated power supply includes a shunt regulator. The ISP is available in either panel version or rack version with a 32 poles DIN 41612 connector. Standard features * Zero deadband. * Excellent linearity. * 2 inputs. * Differential input. * Motor current monitor. * Inhibit/fault indication (free contact relay). * Remote control functions: Inhibit and CW/CCW disable. * Adjustable compensation. * Adjustable continuous and peak current limits. * Dynamic contouring of continuous and peak current limits. * Input balance (offset) adjustment. * Operation in two velocity modes (Tacho or armature voltage feedback) or current mode. * LEDs diagnostics. * Option - Personality board for ease of replacement: the board includes all the adjusting trimmers. Protective functions: The following protections cause an inhibit which is latched (for manual reset) selectable by the user: * Under / over voltage. * Short circuit: between outputs or each output to ground. * Low inductance. * RMS current limit. * Loss of tacho feedback. * Over temperature. * Duty cycle limit of the power supply's shunt regulator. ISP - Rev 6/95 either self-restart or 7 2. Type Designation ISP F - 15 / 65 R W 4 PWM switching frequency 20KHz when not specified 4=40KHz, 6=60KHz ISP amplifier Fan cooled Rated current Additional capacitance for ISP-10/135 only Maximum rated voltage 3. H - Panel mounting R - Rack mounting Technical specifications Current Size Size *** limits Panel types Rack ISP-8/65 14-65 8/16 SP1 3U/8T 0.7 ISP-15/65 14-65 15/30 SP1 3U/8T 0.7 ISP-5/135 80-135 5/10 SP1 3U/8T 0.7 ISPF-10/135_W 28-135 10/20 SP3 3U/12T 0.8 ISP-10/135_W 28-135 10/20 SP4 3U/19T 1.6 Type AC Supply Weight * DC output voltage is 130% of AC input voltage. * 20KHz, 40KHz or 60KHz switching frequency. * 2KHz current loop response (minimum) * Outputs voltages of +5V/100mA, +15V/50mA each, for external use. * Efficiency at rated current - 97%. * Drift: 10æV/§C (referred to input) * Operating temperature: 0-50 §C. * Storage temperature: -10 - +70 §C. * The W version includes additional 3000 æF in the bus filter. *** These are the absolute minimum-maximum AC supply voltages under any condition. ISP - Rev 6/95 8 4. 4.1 Operation of the servo control Inputs The ISP has 3 inputs: 2 single ended inputs (no.1 at terminal 1 and no.2 at terminal 5) and one differential input at terminals 3,4. The current gain of inputs 1 and 2 (current mode) is given by: 8 x Ic x Ki Gc = --------------- (A/V) 15 + Ri Ic - amplifier rated continuous current. Ri - input resistor in Kohm. R1 for input 1 R2 for input 2 Ki - position of wiper of trimming potentiometer Ki=0.33 when trimmer is fully CW. Ki=1 when trimmer is fully CW. The current gain of the differential input for R3=R4 (current mode) is given by: 5.33 x Ic Gcd = ------------- (A/V) R3 R3 in Kohm The current gain of the single ended inputs in velocity mode is given by (place the appropriate Gc for each input): 400 x Ic x Ki Gv = ----------------(15+Ri)xR6 Ri,R6 in Kohm ISP - Rev 6/95 (A/V) 9 The current gain of the differential input in velocity mode is given by: 266 x Ic Gvd = ---------------- (A/V) R3 x R6 R3,R6 in Kohm The maximum input voltage at terminals 1 or 5 is calculated by: Vinmax = 10 + 0.6Ri (Volts) Ri in Kohm The maximum input voltage at terminals 3,4 is calculated by: Vdmax = 10 + R3 (Volts), R3=R4 in Kohm 4.2 Velocity mode In this mode op amp U1/A is employed as a high gain error amplifier The amplifier sums velocity command and the tachogenerator feedback signal, and provides the necessary servo compensation and gain adjustments, resulting in stable, optimum servo operation. This op amp is configured with two feedback paths: One, in the form of a resistive T network, controls the DC gain of this amplifier. The equivalent value of a T network is given by: 10 10 Rf= -------R6 Resistor R6 is mounted in solderless terminals so it can be changed easily whenever the DC gain of the error amplifier is to be changed. The AC gain is controlled by C1, R5 and COMP trimmer. Maximum AC gain is obtained with COMP trimmer set fully CW. Setting COMP trimmer fully CCW removes AC gain and no lag in response occurs. R5 and C1 are mounted in solderless terminals and can be ISP - Rev 6/95 10 easily replaced in cases when COMP trimmer range is not enough to get optimum result. The output of the error amplifier is: 1 + SxC1xR5 Vo = (V 1Gv1 + V2Gv2) x [ --------------------------- ] 1 + SxC1xR5(1 + RfxKi/R5) V1,V2, - Input signals Gv1,Gv2 - Gain of inputs. Ki = Position factor of the wiper of COMP trimmer. Full CW = Full CCW = 0.1 1 The feedback element must be connected for negative feedback. The polarity of the ISP servo amplifiers is such that a positive input signal results in a negative voltage at terminal M1 with respect to terminal M2. 4.2.1 Velocity control using armature voltage feedback By inserting R8 to its solderless terminals, the armature voltage is fed into the error amplifier to be used as a velocity feedback. This feature is useful for all cases when low regulation ratio and low speed accuracy are acceptable. 4.3 Current mode In order to operate the servo amplifier as a current amplifier, the velocity loop should be disabled. This is done by converting the error amplifier into a low gain DC amplifier which has a flat response beyond the desired current bandwidth. In this mode, R6 and C1 have to be removed from the circuit. ISP - Rev 6/95 11 4.4 Current loop Current loop control is obtained by op amp U1/B (Current amplifier) and R7, C2 which form a lag-lead network for current loop. The standard amp is equipped with R7 (100Kohm) and C2 (0.01 æF) to get optimum current response for an average motor in this power range. These components are mounted in solderless terminals. 4.5 Current limits The servo amplifier can operate in the following voltage-current plane: +V -Ip -Ic Ic Intermittent Continuous zone zone Ip -V Ic - Continuous current Ip - Peak current Fig. 4.1: Voltage-Current plane Each amplifier is factory calibrated to have this shape of voltage-current operating area with rated values of continuous and peak current limits. In addition the peak current limit is time dependent as explained in 4.5.1. 4.5.1 Time dependent peak current limit The peak current is so designed that its duration is a function of the peak amplitude and the motor actual operating current before the peak demand. The maximum peak current is available for 1.6 second. The duration of Ip is given by: ISP - Rev 6/95 12 Ip - Iop Tp = 2.2ln ---------Ip - Ic Ic - Amplifier continuous current rating. Ip - Peak demanded (not amplifier Ip) Iop - Actual operating current before the peak demand. Example: A motor is driven by an ISP-15/65 amplifier at constant speed and constant current of 5A. What is the maximum possible duration of a 20A peak ? 20 - 5 Tp = 2.2ln -------- = 2.42 seconds 20 - 15 4.5.2 Dynamic contouring of continuous and peak current limits Most of the servo motors have reduced continuous current limits at high speeds (Fig. 4.2). This phenomenon is due to commutation limits and iron looses which become significantly high as speed increases and this leads to reduction of the continuous current limit. The ISP amplifiers have the features which enable the user to define the current limit envelope as closely as possible to the motor operating envelope defined by the motor manufacturer. Velocity Cont. zone Interm. zone Torque Fig. 4.2: Typical operating envelope of a brush servo motor ISP - Rev 6/95 13 4.6 Operation of the shunt regulator A shunt regulator is included in the power supply section of the ISP. The shunt regulator is a switching type, wherein dissipative elements (resistors) are switched across the DC bus, whenever the voltage reaches a predetermined level. 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. On multi-axis systems, it is recommended to parallel the DC bus of all the ISPs. SHUNT specifications Type Reg. Voltage (Vr) Reg. Current (A) ISP-8/65 91 11 ISP-15/65 91 22 ISP-5/135 191 6 ISPF-10/135_W 191 12 ISP-10/135_W 191 12 ISP - Rev 6/95 14 4.7 Protective functions All the protective functions (excluding 4.7.6) activate internal inhibit. There are two modes of resetting the amplifier after the cause of the inhibit disappears: Self Restart and Latch. - Self restart: The amplifier is inhibited only for the period that the inhibit cause is present. - Latch: All failures latch the inhibit and only a reset signal will clear the latch. 4.7.1 Short circuit protection This protection is realized by sensing current in the DC line. Every current peak above a certain value will inhibit the amplifier for a period of approx. 30mS (if in restart mode). The amplifier is protected against shorts between outputs and either output to ground. 4.7.2 Under/over voltage protection Whenever the DC bus voltage is under or over the limits indicated in the technical specifications, the amplifiers 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. 4.7.4 Insufficient load inductance Whenever the load inductance is too small, the current spikes will be very high. In such cases the amplifier will be disabled. 4.7.5 Loss of velocity feedback signal If the amplifier loses the velocity feedback signal it will inhibit itself. In the "Self Restart" mode it will restart after a delay of 6-8 seconds. 4.7.6 Shunt regulator duty cycle Whenever the ratio between "ON" time to "OFF" time of the shunt exceeds 5-10% the shunt will be inhibited. ISP - Rev 6/95 15 15 1 CURRENT COMMAND MONITOR. INPUT 1 C1 .022MF R5 475K R1 1000PF 100K T7 10K 4700PF 100K 100K 2 T4 10K 100 5.11K R7 100K R6 .01MF 10K .01MF 5 + 100K + R4 STAGE 100PF R3 3 4 TO POWER C2 .01MF 10K PWM + CONVERTER 10K T2 IC 10K CURRENT LIMITS T3 IP A FEEDBACK R2 INPUT 2 .1MF R8 100K T6 10K +V 4.7M T5 10K 5.11K 7 CURRENT offset -V MONITOR CURRENT CONTOURS R9 17 R10 RELAY R11 18 R12 R13 16 BACK EMF OUTPUT A CW 8 PROTECTIONS R19a 9 inhibit latch D17 CCW loss of tacho R16 loss of tacho R15 R20a 5V INHIBIT 5.11K INPUT loss of tacho R14 100 10 + R18 2.8V +5V -15V +15V RESET 11 ISP - Rev 6/95 CURRNET 12 13 14 6 FROM POWER STAGE A ARMATURE VOLTAGE 16 T2 IC T3 IP T4 T5 T6 T7 COMP OFFSET GAIN 2 GAIN 1 VS INH IC SO L1 L2 L3 L4 U1 U2 U3 U5 U6 U7 U8 U4 U9 U13 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 D17 R18 C1 C2 U10 U11 U12 U14 U15 U16 U19 R19A R20A ISP - CONTROL BOARD ISP - Rev 6/95 U17 14 13 12 11 10 9 8 7 6 5 4 3 2 1 U18 J3 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J1 17 5. 5.1 Terminal Description Terminals for Horizontal and Rack mounting versions Power stage H R Function Remark AC 2ac,4c AC input All pins are shorted on the PCB. M1 8ac,10a Armature This output will be negative when a positive signal output is fed to one of the inputs. All pins are shorted on the PCB. M2 6ac,4a Armature This output will be positive when a positive signal output is fed to one of the inputs. All pins are shorted on the PCB. AC 12ac,10c AC input All pins are shorted on the PCB. Control stage H R Function Remark 1 32a Input 1 For more details see 4.1. 2 32c Circuit common 3 30a Negative For more details see 4.1. differential input 4 30c Positive For more details see 4.1. differential input 5 28a Input 2 6 28c Reset For more details see 4.1. for latch mode 7 26a low level input voltage *** enables the amplifier (see 7.1.5). Current monitor Ic Scale is = ------ (A/V) 3.75 8 *** 26c CW disable -1V < Vil < 1V ; 2V < Vih < 30V Source sink capability - 2mA. ISP - Rev 6/95 Two modes - see chapter 7.1.1 *** 18 Control stage - Cont. H R Function Remark 9 24a CCW disable Two modes - see chapter 7.1.1 10 24c Inhibit input Two modes - see chapter 7.1.1 * 11 22a Circuit common 12 22c +5V 100mA 13 20a -15V + 5%, 50mA external load. 14 20c +15V + 5%, 50mA external load. 15 18a Current command monitor *** Ic Scale is = ------ (A/V) 3.75 16 18c Back EMF output See Appendix B. 17, 16a, Inhibit output A 18 16c potential free relay contact. Closed when amplifier is enabled. Contact rating: 0.5A, 200V, 10W 19 14a DC power voltage 5A max. output - common 20 14c DC power voltage 5A max. output - positive Remark: In the following paragraphs the terminals will be related to all the mounting types as in the the following example: H-18,R-16c,E-J1/8. *** -1V < Vil < 1V ; 2V < Vih < 30V Source sink capability - 2mA. ISP - Rev 6/95 19 20 1 AC M2 M1 AC TERMINALS OF ISP - PANEL VERSION ISP - Rev 6/95 20 5.2 Mother Board terminals The MBA-ISP/N is designed for 19" rack systems. It has screw type terminals for both power and signals with identical designations as in the panel versions except for the following new terminals: 21 Potential free Inhibit Input (+). See 7.1.1. 22 Potential free Inhibit Input (-). See 7.1.1. The Potential Free Inhibit Input is applicable only when the "inverted inhibit logic" is used (R18 in the amplifier is inserted). An opto-Coupler (IL5) is used to isolate between the Inhibit signal and the amplifier circuit. Activating this opto-coupler is done by inserting R1 on the mother board according to the following relation: R1 = 100 x Vinh (ohm) Vinh - voltage in the inhibit input. Standard value is 2.4K (For 24 volts) Source must be capable of source or sink 10mA. ISP - Rev 6/95 21 R1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 22 U1 G G VS VS AC2 AC2 M1 M2 AC1 AC1 MBA-ISP/N ISP - Rev 6/95 22 5.3 Terminals for ISP mounted in 3U size ENC. The MBA-ISP/3UE is designed for Elmo enclosures. It has screw type terminals for the power and D-type connectors for the signals. The Potential Free Inhibit Input is applicable only when the "inverted inhibit logic" is used (R18 in the amplifier is inserted). An opto-Coupler (IL5) is used to isolate between the Inhibit signal and the amplifier circuit. Activating this opto-coupler is done by inserting R1 on the mother board according to the following relation: R1 = 100 x Vinh (ohm) Vinh - voltage in the inhibit input. Standard value is 2.4K (For 24 volts) Source must be capable of source or sink 10mA. Power Terminals Terminal Function AC AC input M1 Armature This output will be negative when a positive signal output is fed to one of the inputs. Armature This output will be positive when a positive signal output is fed to one of the inputs. M2 AC AC input GND Ground ISP - Rev 6/95 Remark 23 Control connector - J1 Pin Function Remark 1 Input 2 For more details see 4.1. 2 Back EMF output See Appendix B. 3 Input 1 For more details see 4.1. 4 Negative For more details see 4.1. differential input 5 Positive For more details see 4.1. differential input 6 Current monitor Ic Scale is = ------ (A/V) 3.75 7 Current command monitor Ic Scale is = ------ (A/V) 3.75 8,15 Inhibit output A potential free relay contact. amplifier is enabled. Contact rating: 0.5A, 200V, 10W 9,10 Circuit common 11 +15V + 5%, 50mA external load. 12 -15V + 5%, 50mA external load. 13 +5V 100mA 14 Circuit common ISP - Rev 6/95 Closed when 24 Control connector - J2 Pin Function Remark 1 Inhibit input Potential free inhibit input (-). See 7.1.1 * 2 Inhibit input Potential free inhibit input (+). See 7.1.1 * 3 Inhibit input Two modes - see chapter 7.1.1 * 4 CCW disable Two modes - see chapter 7.1.1 * 5 CW disable Two modes - see chapter 7.1.1 * 6 Reset for latch low level input voltage mode (see 7.1.5). 7 Back EMF output See Appendix B. 8 Input 2 For more details see 4.1. 9 -15V + 5%, 50mA external load. 10 +15V + 5%, 50mA external load. 11,12 Circuit common 13 +5V 14,15 Circuit common *** enables the amplifier 100mA Remark: In the following paragraphs the terminals will be related to all the mounting types as in the the following example: H-18,R-16c,E-J1/8. *** -1V < Vil < 1V ; 2V < Vih < 30V Source sink capability - 2mA. ISP - Rev 6/95 25 R1 IN 2 1 COM. 9 BACK EMF 2 IN 2 8 COM. COM. 15 BACK EMF 7 10 IN 1 3 +15V COM. 14 11 DIFF(-) 4 RESET 6 -15V +5V 12 13 DIFF(+) 5 C.W 5 +5V COM. 12 CURRENT MONITOR 6 COM. 11 CURRENT COMMAND 7 C.C.W 4 13 COM. INH. 3 14 +15V 10 15 INH.(+) 2 8 RELAY -15V 9 INH.(-) 1 J1 FEMALE J2 MALE AC M2 M1 AC MBA - ISP/3UE ISP - Rev 6/95 GND GND 26 6. 6.1 Installation procedures Mounting The ISP series dissipates its heat by natural convection. For optimum dissipation the amplifier should be mounted with the fins vertical. 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. d) Use twisted and shielded wires for connecting all signals (command and feedback). Avoid running these wires 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 joints etc. A reliable connection with the spring type connectors is achieved with wires of 0.5mm 2 (AWG 20) stripped to a length of 11mm (.043"). ISP - Rev 6/95 27 6.3 Load inductance The total load inductance must be sufficient to keep the current ripple within the 50% limit (10-20% of rated current is recommended). The armature 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 - Switching frequency in KHz. If motor inductance does not exceed this value, a choke should be added (on the motor branch) summing together the required inductance Lch = L - Larm Lch - Choke inductance Larm - Armature inductance 6.4 AC power supply AC power supply can be at any voltage in the range defined within the technical specifications (chapter 3). However, if the power source to the power supply is the AC line (through a transformer), safety margins have to be considered to avoid activating the under/over voltage protection due to line variations and/or voltage drop under load. The nominal DC bus voltage should be in the following range: 1.2V dcmin < Vdc < 0.9V dcmax Vdcmin - Minimum DC bus in the table of chapter 3 Vdcmax - Maximum DC bus in the table of chapter 3 ISP - Rev 6/95 28 6.5 Wiring diagrams A Motor M1 B M2 ISP Chassis GND Minimum acceptance ============================================================= Power wires twisted together Motor A M1 B Chassis ISP M2 GND Acceptable for most applications ============================================================ Power wires twisted and shielded Motor A M1 B Chassis M2 ISP GND Optimum wiring, minimum RFI ISP - Rev 6/95 29 ISP Isolating transformer +Vs Heatsink DC power common is internally connected to control common 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 Otherwise, ground loop is created. ISP - Rev 6/95 grounded, use amplifier's differential input. 30 SINGLE PHASE TRANSFORMER AC ISP AC +Vs DC power common Control common Heatsink AC AC ISP +Vs To additional ISPs CONNECTING MORE THAN ONE ISP ISP - Rev 6/95 DC power common Control common Heatsink 31 A 5 Tacho 2 4 Motor command + _ 3 11 1 6 A Reset 7 Current monitor 8 CW disable 9 CCW disable Twisted and shielded pair 10 Inhibit input 12 +5V 13 -15V 14 +15V 17 Relay 18 ISP CONTROL CONNECTIONS TACHOGENERATOR FEEDBACK ISP - Rev 6/95 32 5 A 2 4 Motor command + _ 3 11 A 1 6 7 Reset Current monitor 8 CW disable 9 CCW disable Twisted and shielded pair 10 Inhibit input 12 +5V 13 -15V 14 +15V 17 Relay 18 ISP CONTROL CONNECTIONS ARMATURE VOLTAGE FEEDBACK ISP - Rev 6/95 33 7. Start - Up Procedures All the operations of this chapter do not require power on the unit. The steps of paragraph 7.1 must be performed before proceeding to the appropriate feedback sensor section. 7.1 Common procedures for all amplifiers types 7.1.1 Inhibit and CW/CCW logic Select the desired Inhibit and CW/CCW logic you need: a) Disable by Low Inhibit/CW/CCW functions will be activated by connecting their inputs to a low level signal. If no signal is applied to these inputs the amplifier will be enabled upon power on. For this logic, R18 (for Inhibit), R19a (for CW), R20a (for CCW) should not be installed. +5V C ISP DISABLED BY ACTIVE LOW OR CLOSED CONTACT -1V < Vil < 1V 2V < Vih < 30V ISP - Rev 6/95 34 b) Enable by High Inhibit/CW/CCW functions will be de-activated by connecting their inputs to a high level signal. If no signal is applied to these inputs the amplifier will be disabled upon power on. For this logic insert 3.6Kohm ( +10%)resistors for R18 (Inhibit), R19a (CW), R20a (CCW). The power of these resistors is calculated according to: Pmin=V 2/1500 (Watt) +v 2V < +V < 30V +5V C INHIBIT R18 +5V C CW R19a +5V C CCW R20a ISP ENABLED BY ACTIVE HIGH OR CLOSED CONTACT ISP - Rev 6/95 35 OPTO-ISOLATED INHIBIT V +5 +5V R1 Inhibit C R18 MBA-ISP/... ISP CONTROL BOARD ISP ENABLED BY ACTIVE LOW OR CLOSED CONTACT V +5 +5V R1 Inhibit C R18 MBA-ISP/... ISP CONTROL BOARD ISP ENABLED BY ACTIVE HIGH OR CLOSED CONTACT R1 = 100 x V (ohm) V - Voltage at the inhibit input. Standard value is 2.4K (for 24V). Source must be capable to source or sink 10mA. ISP - Rev 6/95 36 7.1.2 Velocity mode To operate in velocity mode the velocity loop should be enabled by converting the error amplifier to a high gain PI amplifier. Make sure that: R6 (30ohm), R5 (475Kohm) and C1 (0.022 æF), in solderless terminals, are installed on the board. 7.1.3 Current mode a) Converting the amplifier into current mode To operate in current mode the velocity loop should be disabled by converting the error amplifier to a low gain proportional amplifier. - Remove R6 (in solderless terminals). - Remove C1 (in solderless terminals). In addition, you must make sure that the velocity feedback signal is not entering the error amplifier. If a tachogenerator is used, make sure that it is not connected to the amplifier. b) Selecting the reference signal gain The ISP has 2 single ended inputs (terminals H-1,R-32a,E-J1/3 and H-5,R-28a,EJ1/1) and a differential input (terminals H-3,R-30a,E-J1/4, and H-4,R-30c,E- J1/5). The standard procedure recommends to use the differential input for the reference signal. Following are the input maximum voltage and impedance with the standard values of input resistors: INPUT - RESISTOR STANDARD MAX. Current Gain(A/V) INPUT VALUE VOLTAGE (in current mode) IMPEDANCE Input 1 - R1 2.49Kohm 11V 0.46xIc 17.5 Kohm Input 2 - R2 15Kohm 19V 0.27xIc 30Kohm Differential - R3,4 20Kohm 30V 0.27xIc 30 Kohm See chapter 4.1 for calculation of other values ISP - Rev 6/95 37 7.1.4 Activating the loss of tacho protection (velocity mode only) Activating the loss of tacho protection is done by installing R14 (different value for 65V or 135V amplifiers),R15, and R16 as follows: 1530 R14 (65V) = ------- (Kohm) Vam 2730 R14 (135V) = ------ (Kohm) Vam 100 x Vam R15 = ----------- (Kohm) Ip x Rm R16 < 10 ohm Vam - Armature voltage at maximum application speed. Ip - Amplifiers' rated peak current limit. Rm - Total ohmic resistance of motor. R9 should be calculated and inserted according to the tacho voltage at maximum application velocity (Vtm): For Vtm > 7.5V: insert R9 = 301Kohm. For Vtm < 7.5V: 2250 R9 = ------Vtm ISP - Rev 6/95 (Kohm) 38 7.1.5 Latch mode of the protective functions Self Restart(D17 removed): The amplifier is inhibited only for the period that the inhibit cause is present. Latch (D17 - inserted): Failures 4.7.1-5 latch the Inhibit and the diagnostic LED. For restart (after clearing the failure source), reset has to be performed by connecting the reset input to the circuit common. 7.1.6 Activating the dynamic contouring of the current limits If you do not use this feature make sure that R11 and R13 are not installed on the board. If you want to activate this function refer to appendix B. 7.2 Velocity control using tachogenerator feedback When using tacho feedback, it is recommended to use the single ended input no.2 for the tacho signal and to use the differential input for the reference signal in order to reduce common mode noises. R2,R3 and R4 are calculated and inserted for two tacho voltage ranges: For Vtm > 7.5V R3 = R4 = 1.33xVdm (Kohm) Vdm - maximum reference voltage at the differential input. R2 = 2xVtm - 15 (kohm) Vtm - Voltage generated by the tacho at maximum velocity. For Vtm < 7.5V R3 = R4 = 10xVdm/Vtm (Kohm) Vdm - maximum reference voltage at the differential input. Vtm - Voltage generated by the tacho at maximum velocity. R2 = 470 Ohm ISP - Rev 6/95 39 7.3 Velocity control using armature voltage feedback The reference signal should be connected to the differential input and R3,R4 should be calculated and inserted according to: R3 = R4 = 1.33xVdm (Kohm) Vdm - maximum reference voltage at the differential input. The armature voltage feedback will enter the error amplifier by inserting R8, calculated for the two voltage types as follows: For ISP-X/65: R8 (65V) = 1.3xVam (Kohm) Vam - armature voltage at maximum application speed For ISP-X/135: R8 (135V) = 0.73xVam (Kohm) Vam - armature voltage at maximum application speed IxR compensation In order to improve the speed stability in various load conditions, an IxR compensation is required. This is achieved by: - Connect the Current Feedback Monitor (terminal H-7,R-26a,E-J1/6) to input 1 (terminal H-1,R-32a,E-J1/3). - Rotate T7 to max. CCW position (minimum IxR compensation). - Insert R1 as follows: 3 x Vam R1 = ---------- (Kohm) Rm x Ip Vam - Armature voltage at maximum application speed. Ip - Amplifiers' rated peak current limit. Rm - Total ohmic resistance of motor. ISP - Rev 6/95 40 8. Amplifier adjustment and diagnostics Important remarks: A. If all the previous steps were accomplished you may now turn on the power and continue with the following adjustments. You may omit the step for current mode or velocity mode according to your application. B. In some applications, especially those where the motor electrical parameters (total inductance and resistance in the armature circuit) are much smaller or larger than normally encountered, the current loop response should be optimized before proceeding with the following steps - See Appendix A. 8.1 Balance adjustment If the motor is rotating with the command signal at zero voltage, a balance adjustment will be necessary. Turn the balance trimmer (T5) as required until the motor stops. As a rule, have the command signal connected and set to zero when balancing the amplifier. This way, any offset in the command signal will be canceled. 8.2 Current limit adjustment The amplifiers' current limits can be adjusted without the need for loading. Disconnect motor leads and connect a voltmeter between the Current Command Monitor (terminal H-15,R-18a,E-J1/7) and the circuit common. Apply maximum input voltage to one of the inputs to cause an error at the error amplifier (input gain trimmer should be fully CW). In order to adjust the continuous limit - turn T3 (Ip) fully CCW to disable Ip, then use T2 (Ic) to adjust the continuous limit by monitoring the meter readout. Full CW rotation of T2 will result in rated current limit. After adjusting the continuous limit, turn T3 up to the desired peak level. The current monitor range is up to 7.5V and its scale depends on the amplifier rated continuous current (Ic) and is given by: ISP - Rev 6/95 41 Ic Current monitor scale (A/V) : -----3.75 8.3 Adjusting the motor speed (velocity mode only) Adjusting the speed is done by adjusting the input gain trimmer of the tacho feedback: - Increasing/decreasing the feedback gain will decrease/increase the speed. It is also possible to increase/decrease the command gain (change the fix resistors of the differential amplifier) in order to increase/decrease the speed. Best performance is achieved when the feedback gain is as close as possible to its maximum value. Therefore, the final adjustment should yield with Ki of the tacho input trimmer over 0.8. 8.4 Adjustment of the IxR compensation If you do not use this feature, skip this chapter. After following all the instructions in 7.3, you may improve the speed stability in various load conditions by performing the following procedure: a. Run motor at 2/3 of nominal speed. b. Apply nominal load. c. Increase IxR compensation (CW rotation of gain 1 - trimmer T7) until motor's speed reaches the no load speed. d. Notice that a high compensation may result in unstable operation of the amplifier. Reducing the DC and AC gains of the error amplifier by increasing C1 and R5 is recommended. The final values depend on the type of motor and mechanical load, so optimum results will be achieved by the empirical method. ISP - Rev 6/95 42 8.5 Response adjustment (velocity mode only) In most applications optimum response is achieved by adjusting the compensation (COMP) trimmer. Adjustment procedure is as follows: - Provide the amplifier with a low frequency, bi-directional square wave velocity command (A 0.5Hz, ñ2.0V waveform is often employed) - Apply power to the amplifier, and while monitoring the tachometer signal, gradually adjust the COMP trimmer from the CCW toward the CW position. Optimum response (critically-damped) should reaching full CW on T4. Fig 8.1 be achieved at some position before illustrates the types of waveforms observed for various setting o T4. In some applications, especially those where the load inertia is much smaller or larger than normally encountered, the standard compensation components values of 0.022æF for C1 and 470Kohm for R5 may not allow an optimum setting of the COMP trimmer T4. In fact, the velocity loop may be unstable for any setting of T4. In these cases different values for C1 and R5 must be chosen. The following procedure can be used to select these values: - Short circuit C1 with a short jumper wire. - Replace R5 with a decade resistance box. Initially set the box resistance at 20Kohm. - Set T4, the COMP trimmer to approximately midrange. - Input a 0.5Hz, ñ2V bi-directional square wave velocity command signal to the amplifier. - Apply power, and while monitoring the tachometer signal, gradually increase the value of the box resistance until optimum response a depicted in Fig 8.1 is achieved. - Substitute the closest standard value discrete resistor for R6 and remove the decade resistance box. - Remove the shorting jumper across C1, and again check the response using the squarewave test signal. If near optimum result are obtained, trim the response using the COMP trimmer T4 for the optimum. ISP - Rev 6/95 43 - If the previous step does not yield satisfactory results, if unacceptable overshooting has been noted, substitute a larger value than 0.022æF; or, if the response is overdamped substitute a smaller value than Repetition of this procedure should yield an optimum choice for C1. Reference input signal Overdamped: T4 too far CW Critically damped: T4 optimum Underdamped: T4 too far CCW Fig. 8.1 Typical velocity response waveforms ISP - Rev 6/95 0.022æF. 44 9. Tables and Summaries 9.1 Adjusting trimmers Six trimmers are installed on the ISP board with the following functions: T7 (Gain 1) - CW rotation increases input 1 gain. T6 (Gain 2) - CW rotation increases input 2 gain. T5 (Balance) - see 8.1. T4 (compensation) - See 8.6. T3 (Ip) - CW rotation increases peak current limit (see 8.2). T2 (Ic) - CW rotation increases continuous current limit (see 8.2) 9.2 LED diagnostics Four LEDs are installed on the ISP with the following designations: Ic, In, Vs, SO. Under normal operation only Vs should illuminate (Vs indicates the existence of supply voltages). The following table represents the faults indications of the LEDs: 1 Ic 2 3 X In X Vs X X SO X X X - Illuminated LED 1. One or more of: external inhibit, under/over voltage, short circuit, excess temperature, loss of tacho or insufficient load inductance. 2. Continuous current limit. 3. The shunt is "ON". ISP - Rev 6/95 45 Appendix A - Response adjustment - current loop 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 0.01æF for C2 and 100Kohm for R7 may not yield with the optimum response. The current loop should be optimized as follows: - Turn the amplifier to a current amplifier by removing C1 and R6. - Provide the amplifier with a bi-directional square wave current command (100- 200Hz, ñ2.0V waveform is often employed). - Apply power to the amplifier, and 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 C2 with a short jumper wire. - Replace R7 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 a depicted in Fig A-1 is achieved. - Substitute the closest standard value discrete resistor for R7 and remove the decade resistance box. - Remove the shorting jumper across C2, 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 æF; or, if the response is overdamped, substitute smaller value than 0.01 æF. Repetition of this procedure should yield an optimum choice for C2. ISP - Rev 6/95 46 Reference input signal C2 too large / R7 too small Critically damped C2 too small / R7 too large Fig. A-1 Typical current response waveforms ISP - Rev 6/95 47 Appendix B - Current limits contour adjustment The amplifier can be configured to have either continuous current limit or peak current limit or both which depend on motor velocity feedback. This function is enabled by calculating and inserting R11, R13. The continuous current limit is speed dependent when R11 is inserted. The peak current limit is speed dependent when R13 is inserted. The general shape of the operating envelope is given in fig. B-1 Velocity N1 N2 T2 Tc T3 Tp Torque Tc - Max continuous torque up to velocity N1 T2 - Continuous torque at max velocity (Nmax). Tp - Max peak torque up to velocity N2. T3 - Peak torque at maximum velocity. Fig. B-1: Current limits contour The user should derive the relations r1=N1/Nmax, r2=T2/Tc, s1=N2/Nmax and s2=T3/Tp from the motor data sheet. R11 and R10 (for continuous limit) and/or R13/R12 (for peak limit) should be installed according to the following relations: ISP - Rev 6/95 48 Continuous current limit contouring: 1 - r1 R11 = 18.3 -------- (Kohm) 1 - r2 R11 R10 = 36.6 ------------- (Kohm) R11 + 20r1 Peak current limit contouring: 1 - s1 R13 = 18.3 -------- (Kohm) 1 - s2 R13 R12 = 36.6 ------------ (Kohm) R13 + 20s1 Dynamic contouring with armature voltage feedback - IxR compensation must be activated as in 7.3 - Connect the Back EMF (terminal H-16,R-18c,E-J2/7) to input 2 (terminal H-5,R28a,E-J2/8). - Remove R31. - Insert R2 = 470 Ohm - Insert R9 = 301 Kohm - Calculate and insert R14 as in 7.1.4. ISP - Rev 6/95 49 ISP - Rev 6/95 50 187 169 4.0 x 4 9 85 12.5 110 111.76 SP1 - TOP VIEW ISP - Rev 6/95 51 39 13.6 4.0 187 SP1 - SIDE VIEW 1 ISP - Rev 6/95 22.6 29.4 52 111.76 1.6 5.2 39 12 5 SP1 - SIDE VIEW 2 ISP - Rev 6/95 9 53 200 182 SEE DETAIL A 9 10 25.5 5 9.5 70 109 111.76 9.5 DETAIL A SP2 - TOP VIEW ISP - Rev 6/95 54 13.6 62.4 74 55.6 200 SP2 - SIDE VIEW 1 ISP - Rev 6/95 GROUNDING SCREW M4 55 111.76 1.6 5.2 12 72 M4 42 2 SP2 - SIDE VIEW 2 ISP - Rev 6/95 56 187 169 4.0 x 4 9 85 12.5 110 111.76 SP3 - TOP VIEW ISP - Rev 6/95 57 58 39 13.6 4.0 187 SP3 - SIDE VIEW 1 ISP - Rev 6/95 22.6 29.4 58 111.76 58 1.6 5.2 12 5 SP3 - SIDE VIEW 2 ISP - Rev 6/95 9 59 200 182 SEE DETAIL A 9 25.5 10 5 9.5 70 109 111.76 9.5 DETAIL A SP4 - TOP VIEW ISP - Rev 6/95 60 13.6 62.4 91 55.6 200 SP4 - SIDE VIEW 1 ISP - Rev 6/95 GROUNDING SCREW M4 61 111.76 1.6 5.2 12 91 M4 42 2 SP4 - SIDE VIEW 2 ISP - Rev 6/95 62 128.7 162.54 160 J1 110 111.76 ISP RACK MOUNTING (8T and 15T) - TOP VIEW ISP - Rev 6/95 63 2 x M3 40.64 29.4 13.6 22.6 162.54 188 ISP RACK MOUNTING (3U/8T) - SIDE VIEW 1 ISP - Rev 6/95 39 64 128.7 111.76 1.6 5.2 38 12 8 ISP RACK MOUNTING (3U/8T) - SIDE VIEW 2 ISP - Rev 6/95 65 + SO IC IN VS GN1 GN2 BAL. COMP. IP IC + FRONT PANEL FOR ISP 3U/8T ISP - Rev 6/95 66 4 x M3 13.6 76.2 60.4 53.6 160 188 ISP RACK MOUNTING (3U/15T) -SIDE VIEW 1 ISP - Rev 6/95 70 67 128.7 111.76 1.6 5.2 12 70 40 109 ISP RACK MOUNTING (3U/15T) - SIDE VIEW 2 ISP - Rev 6/95 76.2 68 + SO IC IN VS GN1 GN2 BAL. COMP. IP IC FRONT PANEL FOR ISP 3U/15T ISP - Rev 6/95 69 15 2.5 165 160 J1 109 111.76 ISP RACK MOUNTING (3U/12T and 3U/19T) - TOP VIEW ISP - Rev 6/95 70 4 x M3 60.96 13.6 59 21.6 28.4 162.45 188 ISP RACK MOUNTING (3U/12T) -SIDE VIEW 1 ISP - Rev 6/95 71 128.7 111.76 1.6 5.2 12 59 60.96 8 109 ISP RACK MOUNTING ( 3U/12T) - SIDE VIEW 2 ISP - Rev 6/95 72 SO IC IN VS GN1 GN2 BAL. COMP. IP IC FRONT PANEL FOR ISP 3U/12T ISP - Rev 6/95 73 4 x M3 96.52 13.6 89 60.4 53.6 160 188 ISP RACK MOUNTING (3U/19T) -SIDE VIEW 1 ISP - Rev 6/95 74 128.7 111.76 1.6 5.2 12 89 96.52 40 109 ISP RACK MOUNTING ( 3U/19T) - SIDE VIEW 2 ISP - Rev 6/95 75 SO IC IN VS GN1 GN2 BAL. COMP. IP IC FRONT PANEL FOR ISP 3U/19T ISP - Rev 6/95 76 ENCLOSURE MECHANICAL OUTLINE FRONT VIEW SIDE VIEW 11 11 5 10 251.7 74.2 132.5 240 5 POWER 7.5 11 X 45.0 11 222 20 Standard Sizes 12T X 62.0 NOTE: ALL DIMENSIONS ARE IN mm. ISP - Rev 6/95 16T 20T 24T 36T 82.3 102.7 123.0 184.0 For non-standard sizes: X = 5.08 x n + 1mm 77 List of ELMO Service Centers ISRAEL Elmo Motion Control LTD 34 Segula ST. Petah-Tikva 49103 Tel: (03)934-5059 Fax: (03)934-5126 EUROPE Elmo Motion Control 7 Stanserstrasse CH-6362 Stansstad Switzerland Tel: (041)610775 Fax: (041)610778 U.S.A Elmo Motion Control INC. 1200 Woodruff Road, Suite C-22, Greenville, SC 29607 -5731 Tel: (803) 288-9316 Fax: (803) 288-9318 ISP - Rev 6/95
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