Model 505 DC Brushless Servo Amplifier FEATURES

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1 FEATRES CE Compliance to 9//EEC Recognized Component to L 0C elocity mode operation from motor Hall sensors or quadrature encoder 00mA powers Hall sensors and encoder Drives motors with 0 or 0 Halls Enable polarity selectable to + or ground active Single supply voltage: -DC A continuous, 0A peak more than double the power output of servo chip sets Fault protections: Short-circuits from output to output, output to ground Over/under voltage Over temperature Self-reset or latch-off.khz bandwidth ide load inductance range: mh. +,+ Hall power Separate continuous, peak, and peak-time current limits Surface mount technology APPLICATIONS elocity loops for PLC s or for speed controls Belt, fan, or spindle drives THE OEM ADANTAGE Conservative design for high MTBF Low cost solution for small brushless motors to / HP Small size, SMT technology DESCRIPTION Model 0 operates three-phase DC brushless motors in tachless velocity loops using Hall signals, or A&B signals from incremental encoders. A 00mA, + output drives both Halls and encoders, or commutating encoders that output both Hall and A/B signals. Frequency to voltage conversion of encoder signals provides velocity feedback in applications that do not require smooth operation around zero speed, where the velocity feedback becomes discontinuous. Spindle drives and other speed controls benefit from this form of velocity control. For highest speeds, use Hall feedback. For widest speed range, use encoder feedback. Commutation is six-step ( trapezoidal ) using 0 or 0 Hall sensors on the motor. Power delivery is four-quadrant for bi-directional acceleration and deceleration of motors. The Model 0 features 00 peak power output in a compact package using surface mount technology. An internal header socket holds components which configure the various gain and current limit settings to customize the 0 for different loads and applications. Separate peak and continuous current limits allow high acceleration without sacrificing protection against continuous overloads. Peak current time limit is settable to match amplifier to motor thermal limits. Header components permit compensation over a wide range of load inductances to maximize bandwidth with different motors. Logic inputs include remote inhibit/enable, and Pos/Neg enable inputs for connection to limit switches. Amplifier Enable input has selectable polarity for easy interface to all types of motion-control cards. Directional ( Pos & Neg ) enables always use fail-safe (ground to enable) logic. Package design places all connectors along one edge for easy connection and adjustment while minimizing footprint inside enclosures. High quality components and conservative ratings insure long service life and high reliability in industrial installations. A differential amplifier buffers the reference voltage input to reject common-mode noise resulting from potential differences between controller and amplifier grounds. Output short circuits and heatplate overtemperature cause the amplifier to latch into shutdown. Grounding the /Reset input will enable an autoreset from such conditions when this feature is desired.

2 FNCTIONAL DIAGRAM TEST POINTS CH CH 0 OERSPEED ENCODER 00mA XPLS 9 CH CH7 CHAN-B HALL- HALL- CHAN-A MAX PLSE RATE LO-PASS FILTER HALL- 7 +H HALL / ENCODER HALL-ENCODER S: OTPT AND HIGH-POER DC/DC CONERTER OFF = ELOCITY MODE ON = CRRENT MODE INTEGRATOR RESET SITCHES J7 TRN ON HEN AMP IS DISABLED SORCE SELECT 0.F K LEAD RH7 INTEGRATOR CH - S CH 0 PF K GAIN 0K C RH 00 K CH 0. F + RH C LOOP ANALOG BRSH 0. K GAIN OMETER REF AMP REF LEAD 0K NF Gv = RH CH 00PF REF(+) REF(-) + RH + C 00 K + 0K REF GAIN SERO INTEG PREAMP FREQ K TEST / BALANCE C 00K J HALL-ENCODER S RH K + 0 K C BALANCE 0K RH9 0 MEG - NF CIRCITS IN THIS AREA K RH 00 K ARE ON BOARD AX CRRENT MONITOR 9 OPEN = 0 DEG. = 0 DEG. HALL SELECT 7 0mA max + HALLS + K 0mA max NF HALL LOGIC HALL- HALL- HALL- HALLS CONNECT INTERNALLY TO BOARD CIRCITS IN THIS AREA CRRENT LIMIT SECTION PEAK RH CONT RH PEAK TIME RH oltage gain = ARE ON AMPLIFIER BOARD INTEGRATOR RESET SITCHES TRN ON HEN AMP IS DISABLED 00K CH 0K. NF RH 99K 70 PF - + CRRENT ERROR AMP + + LED'S SHORT/O.T. R POER OK R NORMAL G +. MEG 00 PF OTPT CRRENT SENSE +/- AT +/-0A - POER GROND AND SIGNAL GRONDS ARE COMMON STATS & CONTROL LOGIC PM STAGE MOSFET "H" BRIDGE Gv = +H 0 +H DC / DC CONERTER MOMENTARY SITCH RESETS FALT IRE RESET TO GROND FOR SELF-RESET RESET NORM NEG ENABLE POS ENABLE ENABLE J SIGNAL CONNECTOR J MOTOR & POER CONNECTOR MOTOR +H GROND CASE FOR SHIELDING CASE GROND NOT CONNECTED TO CIRCIT GROND TYPICAL CONNECTIONS CONTROLLER +/-0 ENCODER TRANSFORMER-ISOLATED DC POER SPPLY - DC REF(+) REF(-) SIG AX EXT INT ENC CHAN-A ENC CHAN-B 00 ma +H J J SIG /0 DEG /RESET /NEG ENABLE /POS ENABLE /ENABLE /ENABLE POL +NORMAL CRR MON +/-0A N.C. N.C. 0mA 0mA + HALL SENSORS MOTOR J

3 TECHNICAL SPECIFICATIONS AMPLIFIER SPECIFICATIONS Typical C ambient, +H = +DC. Load = 00µH. in series with ohm unless otherwise specified. OTPT POER Peak power nidirectional After direction change Continuous power 0 for 0. second, 00 0 for second, 00 0, 0 OTPT OLTAGE out = ±H * ( 0.97 ) - (Ro)(Iout) Ro = amplifier output resistance, 0.Ω MAXIMM CONTINOS OTPT CRRENT Convection cooled, no conductive cooling C ambient Mounted on narrow edge, on steel plate, fan-cooled 00 ft/min C LOAD INDCTANCE Selectable with components on header socket 00 µh to 0mH (Nominal, for higher inductances consult factory) BANDIDTH Small signal with 00µH load Note: actual bandwidth will depend on supply voltage, load inductance, and header component selection PM SITCHING FREQENCY khz ANALOG INPTS Reference +/- Inputs Differential, 9kΩ between inputs, ±0 max Auxiliary Input Single-ended, kω/nf input filter to RH on header Tachometer Single-ended, kω/0.µf input filter to 0kΩ pot with tap to RH, RH7 on header LOGIC INPTS Logic threshold voltage HI:., LO:.0 Input voltage range Gnd to + maximum /Enable LO enables amplifier (/Enable Pol open), HI inhibits; 0 ms turn-on delay /POS enable, /NEG enable LO enables positive output currents, HI inhibits /Reset LO resets latching fault condition, ground for self-reset every 0 ms. /Enable Pol (Enable Polarity) LO reverses logic of /Enable input (HI enables unit, LO inhibits) LOGIC OTPTS +Normal HI when unit operating normally, LO if overtemp, output short, disabled, or power supply (+H) out of tolerance Definitions: HI output voltage =. min at -. ma max., LO output voltage = 0. max at ma max. + maximum, do NOT connect to devices operating at greater than + INDICATORS (LED s) Normal (green) ON = Amplifier enabled, no shorts or overtemp, power within limits Power fault (red) ON = Power fault: +H < OR +H > Short/Overtemp (red) ON = Output short-circuit or over-temperature condition MONITOR OTPT Current monitor ±0A (A/volt), 0kΩ,.nF R-C filter DC POER OTPTS Hall +DC ( J- ) 0mA (Includes power for Hall sensors) Hall +DC ( J- ) 0mA Encoder +DC ( J-9 ) 00mA PROTECTION Output short circuit (output to output, output to ground) Latches unit OFF (self-reset if /RESET input grounded) Overtemperature Shutdown at >70 C on heatplate (Latches unit OFF) Power supply voltage out of tolerance Shutdown at +H <DCor +H >DC ( operation resumes when supply in tolerance ) POER REQIREMENTS DC power (+H) - 0A peak. Minimum power consumption. Power dissipation at A output, DC supply 0 Power dissipation at 0A output, DC supply 0 THERMAL REQIREMENTS Storage temperature range -0 to + C Operating temperature range 0 to 70 C baseplate temperature OMETER SPECIFICATIONS MAXIMM FREQENCIES F/ clock internal pulse rate 00,000 /sec Encoder lines/sec 0,000 /sec Hall cycles/sec 00,000 /sec Note: F/ clock internal pulse-rate = encoder lines/sec X, or Hall cycles/sec X LINEARITY < 0.% of full scale over a 000: rpm range SPEED RANGE 000: typical

4 INTERNAL SOCKETS & JMPERS AMPLIFIER PC BOARD HALL- PC BOARD J J J J9 ABCDEF A C B D J7 OERSPEED TEST POINT F- TEST POINT HEADER AMPLIFIER HEADER LOAD INDCTANCE RH CH CRRENT LIMITS RH RH RH FIXED 0K RH RH7 CH7 FILTER CH CIRCIT CH PLSE RATE CH CH RH LOOP GAINR-C RH AX GAIN RH9 CH RH7 RH CH RH RH CH RH BALANCE RANGE GAIN & LEAD R-C REF GAIN & LEAD R-C INTEGRATOR ABCDEF HALL J9 ABCDEF ENCODER POLARITY J A POS - NEG - C JMPER - JMPER - JMPER POSITIONS B D HALL & ENCODER ANALOG BRSH J7 MODE AMPLIFIER LAYOT ON DIP SITCH OFF J 0 REF GAIN GAIN LOOP GAIN INTEG FREQ BALANCE BALANCE/TEST INTEGRATOR J J J Motor & Power Supply position Euro: eidmuller BL-9., Phoenix MSTB./-ST-.0 J Amplifier Signals position 0. centers: Molex -0-7 with terminals J Tach Card Signals 0 position 0. centers: Molex with terminals

5 CONNECTORS AND PINOTS J: MOTOR & POER CONNECTIONS Pin Signal Remarks Motor phase Amplifier output to motor windings Motor phase Amplifier output to motor windings Motor phase Amplifier output to motor windings +H - DC power supply input Power supply return. Connect to system ground at this pin. J: AMPLIFIER BOARD CONNECTIONS Pin Signal Remarks Signal ground ( Note ) /0 HALL Ground for 0 Hall phasing, open for 0 /RESET Normally open. Ground to clear overtemp or short circuit fault. ire to ground for self-reset from fault every 0 ms. /NEG ENAB Negative rotation enable (ground to enable, open inhibits) /POS ENAB Positive rotation enable (ground to enable, open inhibits) /ENABLE Amplifier enable. Ground to enable amp, open inhibits. 0 ms delay between Enable active and amp outputs ON 7 /ENABLE POL /Enable polarity ith J-7 open, J- enables amp. ith J-7 grounded: + or open enables amp, ground inhibits + NORMAL HI (+ ) if amplifier operating normally (No faults) LO if amp disabled, +H over or undervoltage, overtemp, or output short circuit. 9 CRR MON A/olt current monitor output (bipolar) 0 No connection. Pins used by tach card.( Note. ) No connection. Pins used by tach card. ( Note.) Signal ground ( Note ) + + at 0 ma Hall power ( total power from + and at 0 ma Hall power outputs not to exceed 00m) HALL Hall input HALL Hall input 7 HALL Hall input Hall ground ( Note ) J: BOARD CONNECTIONS Pin Signal Remarks Ref(+) Input ±0 reference input. Ref(-) Input Reference ground ( connect to gnd at reference voltage source ) Gnd Brush tachometer (+), or reference cable shield Aux Input Auxiliary input ( single-ended analog input ) Ext. Tach Input External brush tachometer (-), or analog velocity feedback Int. Tach Output Hall-encoder tach output ( ±0 at max pulse-rate ) 7 Encoder A Chan Quadrature encoder channel-a Encoder B Chan Quadrature encoder channel B 9 Encoder + 00mA powers encoder, or encoder and Halls 0 Encoder Gnd 0 or ground for encoder ( also connect to encoder cable shield ) Model 0 Notes. For motors with separate Halls and encoder, connect Hall + to J- ( J- if Halls require + ). Connect Hall ground to J-. Connect encoder to J ( +, gnd, and channels A, B ) For motors with commutating encoders, or with Halls and encoders operating from same + supply, use + from J-9 & ground to J-0.. Pins J-0, are Ref inputs on model 0. DO NOT SE on model 0, these connect to tachometer board internally. Reference inputs are on tach card, J pins and.. All amplifier grounds are electrically common. J-, J-, J-, J-, J-, & J-0 are all connected inside the amplifier. The amplifier circuitry is isolated from the case.

6 APPLICATION INFORMATION Follow these steps to place amplifier into service:. Setup amplifier header for motor inductance and current limits.. Establish correct phasing for motor & Hall connections.. Select tachometer header components for maximum motor speed.. Select tach card header components for low-pass filter.. Test & adjust potentiometers for optimal operation.. MOTOR INDCTANCE Note: for procedures &, remove jumper from J7 on tach card, set switch S ON, and turn Loop Gain pot fully CC. Ground J-,, to J- to enable amplifier. RH & CH on amplifier header socket match amplifier to motor inductance. For easy setup, use chart to select values closest to your motor inductance. To optimize compensation using function generator and oscilloscope: First replace CH with a jumper (short). se reference input of square wave at ±, 0Hz. Select RH for the best transient response ( lowest risetime with minimal overshoot). Once RH has been set. choose the smallest value of CH that does not cause additional overshoot or degradation of the step response. Select values of RH, RH, and RH if motor current limits are less than amplifiers A continuous, 0A peak rating. Pick starting values from charts. Fine-tune limits by using current monitor and adjusting values for exact limit desired.. MOTOR-HALL PHASING. Connect the motor Hall sensors to J based on the manufacturers suggested signal names. (A-B-C, R-S-T, and -- are all used to name the Hall signals by different manufacturers). se the required Hall supply voltage (+ from J- or + from J-). If Halls are connected to encoder, or if they come from a commutating encoder, use + from J-9, ground to J-0.. ith the motor windings disconnected, apply power and slowly rotate the motor shaft. Observe the Normal (green) led. If the lamp blinks while turning then the 0/ 0 setting is incorrect. If J- is open, then ground it and repeat the test. In order to insure proper operation, the correct Hall phasing of 0 or 0 must be made..turn off the amplifier and connect the motor leads to J-,, in -- order. Power up the unit. Apply a sinusoidal reference signal of about Hz. and rms between J- & ( Reference inputs ).. Observe the operation of the motor as the current monitor signal passes through zero. hen phasing is correct the speed will be smooth at zero crossing and at low speeds. If it is not, then power-down and re-connect the motor. There are six possible ways to connect the motor windings, and only one of these will result in proper motor operation. The six combinations are listed in the table below. Incorrect phasing will result in erratic operation, and the motor may not rotate. hen the correct combination is found, record your settings. J- J- J- # # # # # #. OMETER SETP Note: for procedures -, install jumper at J7 pins - on tach card, set switch S OFF. Begin with Loop Gain and Integ Freq pots fully CC. If motor runs away, reverse position of jumper J. GENERAL CONSIDERATIONS Encoder tachometer mode gives the widest speed useable speed range combined the fastest velocity-loop response. se Hall-tachometer mode for high-speed operation where no encoder feedback exists. Example: a -pole brushless motor with a 00 line encoder operating at 00 rpm. The f/v clock pulse rate is 0,000 Hz for encoder feedback, and 00 Hz for Hall feedback. As speed drops, ripple will increase. At a standstill, there will be no feedback between Hall or encoder transitions, resulting in jitter. This may be acceptably small for an encoder application, or unacceptably rough for a Hall tach. se the Enable input to disable the amplifier if zero-output is required. MAXIMM PLSE RATE An f/v clock signal is generated that is X the Hall cycle frequency, or X the encoder line frequency. The maximum f/v clock rate is 00kHz. Before proceeding, check to make sure that your f/v clock will be in limits. If the rate is greater than 00kHz, then maximum rpm must be reduced. If the rate is acceptable, select the f/v capacitors CH & CH as follows: HALL OMETER Install jumpers at J9-A,B,C. Choose CH & CH based on this equation: 00 C = ( C = µf ) Poles rpm ENCODER OMETER Install jumpers at J9-D,E,F. Choose CH & CH based on this equation: 0e9 C = ( C =pf ) Lines rpm Choose a capacitor with the closest value. This should produce a tach-voltage of about ± at the rpm used in the equations.

7 . LO-PASS FILTER The choice of low-pass filter will determine both the useable rpm range of the f-v converter and the effective response time of the velocity-loop ( or effective bandwidth ). For widest speed range, set the low-pass filter frequency to a lower value. For faster response times ( higher velocity loop bandwidth ) set the frequency to a higher value. Hall tach applications may require much larger values of capacitor in the filter. Because Hall pulse rates will typically be as much as 00X less than encoder pulse rates, a lowpass filter frequency that gives satisfactory results at lower speeds may noticeably slow down the step response of the motor. Thus, Hall tach applications will be most useful for higher speeds such as spindle drives, blowers, and geardrives. As delivered, the 0 has a filter frequency of 9Hz. This should work well for encoder-tach modes with a wide variety of motors in the size range that the 0 can drive. This frequency is high enough so that the velocity loop response will be affected mainly by the rpm / volt gain, and tuning of the Loop Gain, and Integ Freq potentiometers. In general, use the lowest frequency possible that does not begin to slow down the response of the loop to a step input. This will give the widest rpm range. GRONDING & POER SPPLIES Power ground and signal ground are connected internally in the Model 0. These grounds are isolated from the amplifier case which can then be grounded for best shielding while not affecting the power circuits. Currents flowing in the power supply connections will create noise that can appear on the amplifier grounds. This noise will be rejected by the differential amplifier at the reference input, but will appear at the digital inputs. These are filtered, but for lowest noise, leave the power-supply capacitor floating, and ground each amplifier at its power ground terminal. In multiple amplifier configurations, always use separate cables to each amplifier, twisting these together for lowest noise emission. Twisting motor leads will also reduce radiated noise from pwm outputs. If amplifiers are more than m. from power supply capacitor, use a small (00-00µF.) capacitor across power inputs for local bypassing.. ELOCITY LOOP TNING Begin with S ON, Ref Gain pot fully C, Tach Gain pot fully CC, Loop Gain pot fully CC. Previous steps must be performed to insure that motor is properly phased and rotates smoothly in both directions. Rotate shaft slightly. If motor runs away, reverse position of jumper JA. Motor should now be stable with no reference inputs. Static Setup Set switch S ON. Rotate Balance pot fully C. This will be equivalent to applying +0 to Ref inputs. Measure tach voltage at J-. This should be about + if CH & have been chosen correctly. Motor rpm can be measured by viewing any Hall signal and calculating as follows: here Th is the period of one Hall signal ( can be,, or ). Dynamic Setup Set switch S OFF. se a function generator with a square wave output. Connect to reference inputs and adjust frequency so that motor can change direction and settle to a set speed. Connect oscilloscope to J- to monitor tachometer voltage. If possible, also connect to J-9, current monitor. Adjust Loop Gain pot for fastest response that does not produce oscillation or excessive ringing of either tach signal, or current monitor. hen Loop Gain is adjusted, set S OFF. Adjust Integ Freq C until overshoot on tach signal rings and back off for stable response. C adjustment increases stiffness ( speed stability ), but too much will produce oscillation. ith Loop Gain and Integ Freq adjusted properly, response to step inputs will be smooth, and free from oscillation. 7

8 AMPLIFIER COMPONENT HEADER CRRENT-LIMITS I-Peak RH I-Cont RH T-Peak RH 0A Open A Open 0.s Open A k A 0k 0.s 0 Meg A.7k A.k 0.s. Meg A k A.9k 0.s Meg A 70 A.k LOAD INDCTANCE Load (mh) RH CH k. nf 0 k. nf 99 k. nf * 0 99 k. nf 99 k. nf 0 99 k 0 nf * alues in bold & italics are factory standard. OTPT TRTH TABLE The table below shows the relationship between the signals at the Hall inputs and the drive outputs. Note that only two outputs are active at any time, the third output is off and neither sources nor sinks current. Outputs: + = HI/LO active PM output - = active LO output 0 = OFF Current flow is from + to - when + terminal is HI (+H), and recirculates through + and - when the + output is LO during a PM cycle. The table shown is for a negative voltage at the Ref(+) input. hen the reference input voltage is reversed, the same two outputs remain active, but their polarities are reversed. This changes the direction of current through the motor windings, producing torque and rotation in the opposite direction. Elec. Deg. 0 S = OFF 0 S = ON Output States ORDERING GIDE Model 0 A Continuous, 0A Peak, DC Brushless Servoamplifier with Hall-Encoder Tach Corporate Offices: 0 Dan Road Canton, MA 00 Telephone: (7) -090 Fax: (7) -7 sales@copleycontrols.com