R30. Bantam R30. Actual Size. Current monitor Current reference. Model Vdc Ic Ip R ~ R ~

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1 Bantam Analog Inputs ± Vdc current reference Peak, continuous current & peak-time set Analog Outputs Current monitor Current reference Digital Inputs Amp Enable Fwd/Rev Enable (limit switches) Hi/Lo load inductance Digital Outputs Amp OK Regen control Brake control Feedback Digital Halls from brushless motors Dimensions. x.7 x. mm. x.8 x.6 in description is a compact, DC powered analog current amplifier for torque control of DC brush or brushless motors. It operates as a standalone driver taking a ±V input from an external controller. Mounting to a PC board with solderless connectors facilitates lowcost, multi-axis designs. The Amp Enable input interfaces to active LO signals up to Vdc. Another digital input switches the current-loop gain from a high to low for load inductance compensation. Forward and Reverse Enable inputs are provided for limit switches. A digital output for Amp-OK indicates the amplifier s status. There are two other digital outputs one of which can activate an external regenerative energy dissipator circuit and another for motor brake control. RUGGEDIZED trapezoidal Torque amplifier for BRUSHLESS/BRUSH MOTORS Actual Size Model Vdc Ic Ip -- ~ -9- ~9 Digital Hall feedback enables trapezoidal drive of DC brushless motors. For driving DC brush motors, these inputs are left unconnected and the motor connected between the U & V outputs. Protections include IT current limiting for peak and continuous current as well as peak time. Short circuits between outputs or to ground and amplifier over-temperature produce latching faults. ruggedized standards conformance Ambient Temperature non-operating -ºC to 8ºC operating -ºC to 7ºC Thermal Shock operating -ºC to 7ºC in minute Relative Humidity non-operating 9% non-condensing at 6ºC operating 9% non-condensing at 6ºC Vibration operating Hz to Hz, up to.8 grms Altitude N non-operating - m to, m operating - m to, m Shock Crash Safety 7 g peak acceleration operating g peak acceleration MIL-STD specifications MIL-STD- 6, 7, 8, 7, 99 IEC specifications IEC- 668, 679 development kit A Development Kit is available that provides mounting and easy connectivity for the. Tech Support: sales@copleycontrols.com, Internet: Page of 8

2 Bantam GENERAL SPECIFICATIONS Test conditions: Load = Wye connected load: mh + Ω line-line. Ambient temperature = C, +HV = HV max MODEL Output Power Peak Current Adc, ±% Peak time Sec Continuous current Adc, ±% Peak Output Power 8 w Continuous Output Power 7 w Output resistance.7.7 Rout (Ω) Maximum Output Voltage Vout = HV*.97 - Rout*Iout INPUT POWER HV min to HV max + to + + to +9 Vdc, Transformer-isolated Ipeak Adc ( sec) peak Icont Adc continuous (Note ) PWM OUTPUTS Type Commutation Control Analog Reference Input Bandwidths Minimum load inductance feedback Digital Halls Power -phase MOSFET, khz Trapezoidal using digital Hall feedback ± Vdc, kω differential input impedance Current loop:. khz typical, bandwidth will vary with tuning & load inductance µh line-line, non-isolated, for brushless motor commutation kω to + Vdc pull-up with µs RC filter to 7HC Schmitt trigger + ma max. (J-, ) to power Hall sensors or commutating encoder digital inputs Number [IN] /Enable Amplifier enable, LO active, HI disables /PosEnab, /NegEnab Forward and reverse direction limit switch/enable inputs: HI will disable output current in direction Type 7HC Schmitt trigger operating from + Vdc with RC filter on input Vin-LO <. Vdc, Vin-HI >.6 Vdc, input voltage range to + Vdc kω to + Vdc pull-up, 7HC Schmitt trigger operating from + Vdc with RC filter on input 7HCT, Vil =.8 Vdc max, Vih =. Vdc min, input voltage range to + Vdc [LoInd] Low Inductance HI or open: for higher inductance loads, LO or grounded: for lower inductance loads analog inputs Number Ref(+), Ref(-) Command input for output current demand, ± Vdc Peak Current Limit. to.8 Vdc sets peak current limit from ~% of rated peak current Continuous Current Limit. to.87 Vdc sets continuous current limit from ~% of rated continuous current IT Limit. to. Vdc sets ~% of IT time Balance ±. Vdc from the. Vdc quiescent state will adjust output current ±% of peak rated current digital outputs Number: type [AOK] [OUT] [OUT] analog output Current Monitor Current Ref : N-channel MOSFET, open-drain, Vdc max, ma max for [AOK] and [OUT], ma for [OUT] Amp OK: active LO when amplifier has no faults and will operate when enabled Configured as external regen switch controller: will be LO to turn on regen switch Brake control (external flyback diode required): will be LO when AOK and is enabled to release brake ±. ±Ipeak Monitor for current-loop command: ±. Vdc = ±% of rated peak current Notes ) Heatsink is required for continuous current rating. Tech Support: sales@copleycontrols.com, Internet: Page of 8

3 Bantam motor connections Phase U, V, W Hall U, V, W Hall power PWM outputs to -phase ungrounded Wye or delta wound brushless motors, or DC brush motors (U-V) Digital Hall signals, single-ended + Vdc madc max protections HV Overvoltage HV Undervoltage +HV > HV max, Amplifier outputs turn off until +HV < HV max (See Input Power for HV) -9-: +HV < + Vdc, Amplifier outputs turn off until +HV > + Vdc --: +HV < + Vdc, Amplifier outputs turn off until +HV > + Vdc Amplifier over temperature Heat plate > 8 C Short circuits output to output, output to ground, internal PWM bridge faults I T Current limiting Programmable: continuous current, peak current, peak time MECHANICAL & ENVIRONMENTAL Size. x.8 x.6 [. x.7 x.] in [mm] Weight Amplifier:.8 lb [.7 kg], heatsink. lb [. kg] Contaminants Pollution degree Environment IEC68-: 99 Cooling Conduction through heatplate on amplifier chassis, or convection amplifier DIMEnsions. [.].8 [.7] Dimensions in inches [mm].6 [.] Tech Support: sales@copleycontrols.com, Internet: Page of 8

4 Bantam control inputs and outputs enable input The Enable input [IN] is LO-active and pulled up to +V by an internal k resistor. This provides fail-safe operation by disabling the amplifier if the Enable input is open, or a wire from the controller should break. /Enable +V k J-8 k 7HCG nf fwd/rev enable inputs Two inputs are provided for limit switches. These should be LO for normal operation, and open or HI to inhibit current of positive or negative polarity. /PosEnab /NegEnab +V k J-9 J- k 7HCG nf Load inductance input The /LowInd input controls the gain of the current error amplifier to compensate the amplifier for lower or higher inductance loads. With the input open, the bandwidth will be ~. khz for a mh (line-line) load. Grounding the input reduces the gain to / of the input-open gain for the same bandwidth with µh loads. /LowInd +V k J- k 7HCT nf analog reference input The amplitude and polarity of the amplifier output current is controlled by a ±V analog signal from an external controller..m + -.V Ref(+) J- 9.9k k - balance input The output current of the amplifier can be adjusted to Adc by connecting the balance input to a potentiometer with an adjustment range of to + Vdc. This will produce an offset adjustment range of ±.8% of the Ipeak rating of the amplifier. The table below shows the offset adjustment range in ma. Ref(-) Balance Analog Gnd J-7 J-9 J- 9.9k + k.m + - k.v Model ±Ioffset (ma) V digital outputs Three N-channel MOSFETs sink current from loads connecting to + Vdc maximum. Outputs [AOK] and [OUT] can sink ma maximum. The brake output [OUT] can sink ma. An external flyback diode is required with driving inductive loads like a brake, or relays. k J-7 J- J- [AOK] [OUT] [OUT] Tech Support: sales@copleycontrols.com, Internet: Page of 8

5 Bantam motor connections Motor connections are of two types for brushless motors: phases and Halls. For brush motors, only the armature connections are needed. The phase or armature connections carry the amplifier output currents that drive the motor to produce motion. The Hall signals are three digital signals used for commutating a brushless motor. When using a brush motor the Hall inputs should be unconnected and the motor armature connections made between the U & V phase outputs. motor phase connections: brushless The amplifier output is a three-phase PWM inverter that converts the DC buss voltage (+HV) into DC voltage waveforms that drive two motor phase-coils at a time (trapezoidal commutation). Cable should be sized for the continuous current rating of the amplifier. Motor cabling should use twisted, shielded conductors for CE compliance, and to minimize PWM noise coupling into other circuits. The motor cable shield should connect to motor frame and the equipment frame ground for best results. P- P- P- P- P- P- P- P- P-9 P- P- P- U V W Brushless Motor motor phase connections: brush The amplifier output is an H-bridge PWM inverter that converts the DC bus voltage (+HV) into a DC voltage waveform that drives the motor armature. Cable should be sized for the continuous current rating of the amplifier. Motor cabling should use twisted, shielded conductors for CE compliance, and to minimize PWM noise coupling into other circuits. The motor cable shield should connect to motor frame and the equipment frame ground for best results. P- P- P- P- P- P- P- P- (+) (-) Brush Motor P-9 P- P- P- No connections MOTOR HALL SIGNALS Hall signals are single-ended signals that provide absolute feedback within one electrical cycle of the motor. There are three of them (U, V, & W) and they may be sourced by magnetic sensors in the motor, or by encoders that have Hall tracks as part of the encoder disc. They typically operate at much lower frequencies than the motor encoder signals, and are used for commutation. When driving DC brush motors, the Hall inputs should be left unconnected. Hall U Hall V Hall W J-6 J- J- +V k k.nf 7HC Tech Support: sales@copleycontrols.com, Internet: Page of 8

6 Bantam current limit inputs Two inputs are provided for setting the peak and continuous current limits. The I-Peak and I-Cont inputs each have equivalent circuits shown below. Limits can be set either by applying a voltage (Vset) to the input or by connecting a resistor (Rset) between input and signal ground. The tables below show values for Rset and Vset that give ~% of the rated peak and continuous current ratings. amplifier models and ratings Model I-Peak I-Cont T-Peak IT peak current limit settings equivalent circuit Example I-Peak setting % Vpeak Rpeak.8 <out> Vpeak Rpeak J- +.8 V Ipeak Control 96 Vpeak If a voltage Vpeak is used to control the peak-limit current, it can be found like this: Vpeak =.8 * PeakLimitCurrent AmpPeakCurrent Example: find Vpeak for a 6 A PeakLimitCurrent using a -9-: Vpeak =.8 * 6 =. V To use a resistor for setting Peak-Limit current, calculate the value as follows: Rpeak = 96 * PeakLimitCurrent (AmpPeakCurrent - PeakLimitCurrent) Example: find Rpeak for a A PeakLimitCurrent: Rpeak = 96 * =, ohms ( - ) To use the table, find the % value as follows: % = PeakLimitCurrent * AmpPeak Current continuous current limit settings equivalent circuit Example Icont setting % Vcont Rcont.87 <out> Vcont Rcont J V Icont Control 9799 Vcont If a voltage Vcont is used to control the peak-limit current, it can be found like this: Vpeak =.8 * ContLimitCurrent AmpContCurrent Example: find Vcont for a A ContLimitCurrent using a -9-: Vpeak =.87 * =.9 V To use a resistor for setting Cont-Limit current, calculate the value as follows: Rpeak = 9799 * ContLimitCurrent (AmpContCurrent - ContLimitCurrent) Example: find Rcont for a A ContLimitCurrent: Rpeak = 9799 * = 6, ohms ( - ) To use the table, find the % value as follows: % = ContLimitCurrent * AmpContCurrent Tech Support: sales@copleycontrols.com, Internet: Page 6 of 8

7 Bantam pwm limiting input IT limit settings equivalent circuit Example IT setting % Vit Rit. <out> Vit Rit J- + V IT Control IT If a voltage Vpeak is used to control the IT, it can be found like this: Vit =. * ITSecs AmpITLimit Example: find Vit for a 6 A PeakLimitCurrent using a -9-: Vpeak =.8 * 6 =. V To use a resistor for setting Peak-Limit current, calculate the value as follows: Rpeak = 96 * PeakLimitCurrent (AmpPeakCurrent - PeakLimitCurrent) Example: find Rpeak for a A PeakLimitCurrent: Rpeak = 96 * =, ohms ( - ) about pwm limiting PWM limiting sets a maximum value for the on vs. off time of the outputs of the amplifier. While the peak voltage seen by the load remains about the same as the supply voltage (HV), the average voltage seen by the motor can be limited. A common use of this is to limit the maximum RPM of a motor even though it s operating in torque mode. PWM limit settings equivalent circuit Example PWM setting % Rset (K) Vset 97 <out>.9 The table shows duty cycles measured with some choices of Rset for the PWM limits Vpwm Rset + k J-8 Vset Amplifier Tech Support: sales@copleycontrols.com, Internet: Page 7 of 8

8 Bantam PC BOARD DESIGN Printed circuit board layouts for amplifiers should follow some simple rules:. Install a low-esr electrolytic capacitor not more than inches from the drive. PWM amplifiers produce ripple currents in their DC supply conductors. amplifiers do not use internal electrolytic capacitors as these can be easily supplied by the printed circuit board. In order to provide a good, lowimpedance path for these currents a low- ESR capacitor should be mounted as close to the drive as possible. µf is a minimum value, with a voltage rating appropriate to the drive model and power supply.. Connect P signals (U,V,W outputs, +HV, and +HV Common) in pin-groups for current-sharing. The signals on P are all high-current types (with the exception of the + Vdc Aux HV supply). To carry these high currents (up to Adc peak) the pins of P must be used in multiples to divide the current and keep the current carrying capacity of the connectors within specification. The diagram on page 9 shows the pin groups that must be inter-connected to act as a single connection point for pc board traces.. Follow IPC- rules for conductor thickness and minimum trace width of P signals. The width and plating should depend on the model of drive used, the maximum voltage, and maximum current expected to be used for that model. Power supply traces (+HV, +HV Common) should be routed close to each other to minimize the area of the loop enclosed by the drive DC power. Noise emission or effects on nearby circuitry are proportional to the area of this loop, so minimizing it is good layout practice. Motor signals (U,V,W) should also be routed close together. All the motor currents sum to zero, and while the instantaneous value in a given phase will change, the sum of currents will be zero. So, keeping these traces as closely placed as possible will again minimize noise radiation due to motor phase currents. circuit grounds are electrically common, and connect internally. However, the P signals carry high currents while the grounds on J (signal ground) carry low currents. So, J signals should be routed away from, and never parallel to the signals on P. Encoder signal pairs (A, /A, B, /B, and X, /X) should be routed close together for good transmission-line effect to reduce reflections and noise. The amplifier heatplate is electrically isolated from all drive circuits. For best noiseimmunity it is recommended to connect the standoffs to frame ground and to use metal mounting screws to maintain continuity between heatplate and standoffs. Tech Support: sales@copleycontrols.com, Internet: Page 8 of 8

9 PC BOARD MOUNTING FOOTPRINT Bantam Top View Dimensions in inches...9 Note.7 J P.99. MOT U MOT V 6X Ø. ±. THRU AFTER PLATING.787 (TYP).8 MOT W Pgnd.787 (TYP) 6 +HV X Ø.66 +./-. THRU AFTER PLATING.787 (TYP) Accelnet Mounting Hardware: qty Description Mfgr Part Number Remarks Socket Strip Samtec SQW---L-D J Socket Strip Samtec SQW-8--L-D P Notes. P signals must be connected for current-sharing.. To determine copper width and thickness for P signals refer to specification IPC-. (Association Connecting Electronic Industries, Standoffs should be connected to etches on pc board that connect to frame ground for maximum noise suppression and immunity. Tech Support: sales@copleycontrols.com, Internet: Page 9 of 8

10 Bantam amplifier PC BOARD CONNECTORS Top View Pin Drive viewed from above looking down on the pc board on which it is mounted. Pins shown in grey are unused locations in PC board socket J: Signal Dual row, mm centers position female header Samtec: SQW---L-D P: Motor & HV Dual row, mm centers 6 position female header Samtec: SQW-8--L-D Pin Pin 6 J signals & pins Signal Pin Signal IT Time Current Ref Peak Curr Limit Ref(+) Cont Curr Limit 6 Agnd PWM Limit 8 7 Ref(-) /LowInd 9 Balance Hall W Current Monitor Hall V [OUT] Hall U 6 [OUT] /Enable 8 7 [AOK] /NegEnab 9 /PosEnab Hall +V Hall +V Pgnd Pgnd P signals & pins Signal Pin Signal Motor U Motor U Motor U Motor U N/C 6 N/C N/C 8 7 N/C N/C 9 N/C Motor V Motor V Motor V Motor V N/C 6 N/C N/C 8 7 N/C Motor W 9 Motor W Motor W Motor W N/C N/C Pgnd 6 Pgnd Pgnd 8 7 Pgnd N/C 9 N/C N/C N/C +HV +HV +HV 6 +HV Notes. Grey-shaded signal are N.C. (No Connection). Signals are grouped for current-sharing on the power connector. When laying out pc board artworks, all pins in groups having the same signal name must be connected.. The total current current from J- and J- cannot exceed ma. Tech Support: sales@copleycontrols.com, Internet: Page of 8

11 Bantam amplifier connections Amplifier Motion Controller DAC ±V Enable /Enable J/8 [AOK] J/7 Ref(+) J/ Ref(-) J/7 Agnd J/ J Hall U J/6 Hall V J/ Hall W J/ Hall +V J/ Sgnd J/ U V W HALLS Hall +V J/ Balance k Balance J/9 J/ Curr Ref J/ CurrMon J/ Motor U P/,,, U Note: Brush motors connect to U & V outputs /PosEnab J/9 /NegEnab J/ Motor V P/,,, V BRUSHLESS MOTOR [OUT] J/ [OUT] J/ /LowInd J/ PWM Limit J/8 Cont Curr Limit J/6 Peak Curr Limit J/ IT Time J/ Motor W P/9,,, P +HV P/,,,6 Pgnd P/,6,7,8 W Mount external capacitor <= ( cm) from amplifier µf Minimum per drive + - DC Power Heatsink grounding Notes. Total output current from +V pins (J-,) cannot exceed ma.. When Balance potentiometer is used, it should connect to amplifier +V and ground for best stability. Tech Support: sales@copleycontrols.com, Internet: Page of 8

12 Bantam amplifier AMBIEnt operating TEMPERATURE vs output current and HV Data shown for temperatures below C are calculated based on power dissipation and thermal resistance -- HV = Vdc -9- HV = Vdc = Forced air, LFM, with HS = Forced air, LFM, with HS = Forced air, LFM, no HS = Convection, with HS = Convection, no HS Ambient Temperature (C) Continuous Output Current (Adc) Ambient Temperature (C) Continuous Output Current (Adc) -- HV = Vdc -9- HV = Vdc Ambient Temperature (C) Ambient Temperature (C) Continuous Output Current (Adc) Continuous Output Current (Adc) -- HV = Vdc -9- HV = 9 Vdc Ambient Temperature (C) Ambient Temperature (C) Continuous Output Current (Adc) Continuous Output Current (Adc) Tech Support: sales@copleycontrols.com, Internet: Page of 8

13 Bantam HEATSINK INSTALLATION If a heatsink is used it is mounted using the same type of screws used to mount the drive without a heatsink but slightly longer. Phase change material (PSM) is used in place of thermal grease. This material comes in sheet form and changes from solid to liquid form as the drive warms up. This forms an excellent thermal path from drive heatplate to heatsink for optimum heat transfer. STEPS TO INSTALL. Remove the PSM (Phase Change Material) from the clear plastic carrier. Phase Change Material. Place the PSM on the aluminum heatplate taking care to center the PSM holes over the holes in the drive body.. Mount the heatsink onto the PSM again taking care to see that the holes in the heatsink, PSM, and drive all line up.. Torque the #- mounting screws to 8~ lb-in (.9~. N m). Transparent Carrier (Discard) Tech Support: sales@copleycontrols.com, Internet: Page of 8

14 Bantam development kit development kit top view The graphic below shows the placement of components and connectors on the Development Kit PC board. The amplifier is not shown, but mounts in the outline that contains connectors J & J. J J J Socketed components P/P Remarks IT Time setting resistor Ipeak setting resistor Icont setting resistor No function Tech Support: sales@copleycontrols.com, Internet: Page of 8

15 Bantam development kit Connectors These charts show the pins and signals for the Development Kit connectors. J Motor and HV power Pin Signal Mot U J Mot V Mot W HV Gnd +HV Input Euro position J Halls Signal Pin Signal Sgnd 9 n.c. Hall U Sgnd Hall V + Vdc output Hall W Sgnd Sgnd n.c. n.c. 6 n.c. n.c. 7 n.c. n.c. 8 J 8 9 D-Sub female J Control Signal Pin Signal Sgnd Ref(-) Ref(+) Sgnd Ext Balance 6 Sgnd /NegEnab 7 /PosEnab /Enable 8 Gain Select J [OUT] 6 9 Sgnd Current Cont Limit 7 n.c. Current Ref 8 Curr Peak Limit IT Time 9 [AOK] D-Sub female Current Monitor + Vdc Output [OUT] n.c. Sgnd n.c. Sgnd notes ) The combined current from J- and J- cannot exceed ma. Tech Support: sales@copleycontrols.com, Internet: Page of 8

16 Bantam development kit Connections In the diagram below, connectors inside the outline are the amplifier connectors, their signal names, and pin numbers. All connectors and components outside of the are on the Development Kit. J 7 6 SW JP-B JP-D SW JP-A JP-E SW JP-C JP-E JP-A JP-C Bantam 8 /Enable [AOK] /NegEnable [OUT] 9 /PosEnable [OUT] /LowInd 7 JP-B JP-C JP-D DS DS DS J 6 9 +V +V +V JP-B Ref(+) 7 Ref(-) Agnd Hall U 6 J R k +V J cw R k JP-A JP-E JP-D 9 Balance J Hall V Hall W Hall +V Pgnd Pgnd 9 P- P- JP-A JP-B P- P- IT Time Peak Curr Limit P Mot U J 7 P- JP-D P- 6 Cont Curr Limit Mot V Mot W 9 8 Current Ref Pgnd Current Monitor +HV 6 notes ) The combined current from J- and J- cannot exceed ma. Tech Support: sales@copleycontrols.com, Internet: Page 6 of 8

17 Bantam development kit jumper functions The functions shown in the tables below are in effect when the jumper is in place. When a jumper is removed, the stated function is disabled. J connects to an external controller jp JP A B C D E Remarks Shorts k balance scaler Ref(-) input is grounded Ref(+) input is grounded Connects J- to Amp: Balance R controls Amp: Balance jp JP A B C D E Remarks Gain Select to Sgnd Amp: [AOK] drives DS Amp: [OUT] drives DS Amp: [OUT] drives DS Connects J- to Amp: /NegEnab jp JP A B C D E Remarks Connects SW to Amp: /NegEnab Connects SW to Amp: /Enable Connects SW to Amp: /PosEnab Connects J- to Amp: /Enable Connects J-7 to Amp: /PosEnab jp JP A B C D E Remarks Connects J-9 to Amp: IT Time Connects J- to Amp: Current Peak Limit No connections Connects J-7 to Amp: Current Cont Limit Connects J-8 to Amp: Gain Select Tech Support: sales@copleycontrols.com, Internet: Page 7 of 8

18 Bantam MASTER ORDERING GUIDE BDK-9- BDK-CK analog current amplifier, / Adc analog current amplifier, / Adc Development kit Connector Kit for Development Kit ordering example Example: Order -- current amplifier and development kit: Qty Item Remarks -- current amplifier BDK-9- Development Kit for amplifier BDK-CK Connector Kit for Development Kit ACCESSories ORDER NUMBER Qty Ref DESCRIPTION BDK-CK Connector kit for BDK-9- Development Kit (includes next items shown below) heatsink (optional) J Connector,, Euro style plug, position, Tyco (AMP) J Connector, D-Sub, -position, male,, Tyco (AMP) J Backshell, D-Sub,, metallized, -position, Norcomp 979--R J Connector, D-Sub, -position, male,, Tyco (AMP) J Backshell, D-Sub,, metallized, -position, Norcomp 979--R Heatsink Kit BTM-HK Heatsink kit (for field-installation by customer) Heatsink Thermal Phase-change Material Heatsink hardware (#- screws) Note: Specifications subject to change without notice Rev 6.-fr // Tech Support: sales@copleycontrols.com, Internet: Page 8 of 8