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1. 17 17 OPERATION 19 9 OEM300 21 AC INPUT SPECIFICATIONS 21 Voltage pe 21 ajon a E P mE 21 UU dence 22 0 0 22 Output Voltage deterret dnd a tans 22 Qutput Cuktrent 22 Output ROWer lees 22 Output Grounds noie ter Lee egere serpere oreste ed dee ete nte 22 0 0 22 mure ETE 22 1 OEM300 Preface 23 Power D mbp 3 iere eerte e Per Pre REIN ET 23 Short Circuit Protection erae iea endrina 23 23 Overvoltage Protection OPERATING TEMPERATURES 4 24 Maximum Ambient Still Air ee 24 Maximum Ambient Moving Air Ne 24 Maximum Heatplate Temperature pp 24 Minimum Ambient ene enn 24 Protective Circuits in the OEM300 25 4 eene ener 25 SHORT CIRCUIT PROTECTION OVER TEMPERATURE PROTECTION esee 27 Trip Ternperatire iter e eor ere er tie rere rrr erro tp dne date 27 Hysteresis 2 27 POWER DUMP E
2. MAYBE YOU SHOULDN T READ THIS MANUAL Perhaps you are wondering How hard can it be to operate this Power Module Why do I need a manual Can t I just hook up AC power plug in some output cables and power up my sys tem You may be right If you have experience designing motion control systems then perhaps the only information you need can be found in Chapter Installation amp Operation You may already know how to cool power supplies You will have calcu lated the power your system requires and you will connect the right number of drives to the Power Module You will know about the hazards of load regeneration and improper equip ment grounding And you will probably take the proper steps to ensure electrical noise is not a problem in your system So if you are confident in your preparations o ahead and plug away And best of luck with the OEM300 The rest of the information in this manual gives details about the issues mentioned above Special benefits of using the are also discussed such as the protective circuits that guard equipment from damage by short circuits load regenera tion or high temperatures A troubleshooting section will help you locate problems So browse through the manual you might find other topics of interest too FOR THOSE WHO NEVER READ MANUALS At least look at the next illustration We have attempted to put all the critical information you need in this drawing It is also
3. User Guide OEM300 Power Module Parker Hannifin Corporation Compumotor Division p n 88 013513 01 C Jojoundwiod Important User Information Installation amp Operation of Compumotor Equipment It is important that Compumotor motion control equipment is installed and operated in such a way that all applicable safety requirements are met It is your responsibility as a user to ensure that you identify the relevant standards and comply with them Failure to do so may result in damage to equipment and personal injury In particular you should review the contents of the user guide carefully before installing or operating the equipment Under no circumstances will the suppliers of the equipment be liable for any incidental consequential or special damages of any kind whatsoever including but not limited to lost profits arising from or in any way associated with the use of the equipment or this user guide Safety Warning High performance motion control equipment is capable of producing rapid movement and very high forces Unexpected motion may occur especially during the development of controller programs KEEP CLEAR of any machinery driven by stepper or servo motors and never touch them while they are in operation High voltages exist within enclosed units on rack system backplanes and on transformer terminals KEEP CLEAR of these areas when power is applied to the equipment Parker Compumotor constantly strives to improv
4. 0 102 2 6 5 00 127 2 000 Dimensions OEM300 Power Module Installation amp Operation 0 Panel Layout and Minimum Spacing Do not obstruct the openings in the top and bottom of the OEMS300 Provide space for air circulation between the Power Module and other equipment The figure below shows the minimum spacing required D d 2 50 8 Clearance 2 50 8 50 8 Clearance Minimum ah 2 50 8 Clearance Minimum 9 7 0 375 9 5 Typ Dimensions in inches millimeters Panel Layout OEM300 Power Modules with OEM Series Drives If you are using several OEM30O0s in an equipment cabinet mount them side by side This configuration provides good heat dissipation Do not mount units above each other in a vertical configuration heat rises from the lower units to the upper units which may cause excessive heat buildup in the upper units This is shown in the next drawing OEM300 Q Installation amp Operation Mount Power Modules Side by Side Not One Above the Other Side by Side Mounting is Preferred When you position equipment and components place those that produce the most heat above those that are cooler The figure below illustrates this Mount Heat Sensitive Equipment Below the Power Module Not Above It Heat Sensitive Equipment Preferred Mounting Q Installation
5. 20W where T is the ambient temperature is your heatsink s thermal resistance to ambient conditions in C W ths 20W in this equation is the amount of heat the Power Module will dissipate through its heatplate when it operates at its maximum continuous output power This is a worst case condition If your application uses less power the Power Module will dissipate less heat In this case you can use a number smaller than 20W in the equation above HEATSINK PROBLEMS Several problems with heatsinks can cause poor heat transfer Warped Heatsink Many heatsinks are made from aluminum extrusions During the extrusion process the aluminum is hot When it cools it sometimes warps A warped heatsink will not make good con tact with the Power Module Heat transfer may be inadequate Ensure that your heatsink is flat 35 Heat amp Thermal Management Issues OEM300 Voids in Thermal Interface The heatsink should be in full contact with the Power Module s heatplate Use silicone thermal joint compound or a thermal gasket to ensure full contact Make sure that there are no air pockets empty spaces or voids in the thermal grease Voids can severely reduce the amount of surface area available for heat transfer Paint Paint on a heat sinking surface can cause poor thermal trans fer If you attach the Power Module to the wall of an equipment cabinet make sure that any paint has been removed from the area where the P
6. 28 OVERVOLTAGE PROTECTION 9 31 5 Heat amp Thermal Management Issues 33 HEAT MUST BE REMOVED FROM THE 33 HEATPEATE COOLING ree treno t ettet a ia dd TR ERO 33 Heatplate Temperature 34 Heatsink Calculations ee 35 Heatsink Problems riri eterne 35 CONVECTION COOLING essere 36 Ambient Air Temperature Limits ee 37 Providing Additional Ventilation 37 OVER TEMPERATURE PROTECTION pe 38 Calculating How Many Drives amp Motors The OEM300 Operate 39 GENERAL GUIDELINES STEP MOTOR SYSTEMS 39 WORST CASE METHOD essere nennen nnetetenein 40 CALCULATION METHOD 41 Where Power is Used in a Motion Control System 41 Power Requirements During a Typical 45 Calculating the Power Required pp 47 A Design Example 48 Unusual Power Requirements pp 52 MEASUREMENT METHOD eese nennt emet entrent 53 9 Troubleshooting 2 cio teine ener 57 POSSIBLE PROBLEMS 57 RETURNING THE OEM300 TO 59 61 PREFACE
7. NUMBER OEM57 40 MO 1 2 Stack 57 51 Stack OEM57 83 MO 2 Stack 83 62 Stack 83 93 2 Stack 83 135 3 Stack li OEM300 Calculating How Many Drives CALCULATION METHOD In most applications the worst case situation described above never occurs Conditions where all motors in a system produce maximum shaft power all at the same time are extremely rare Instead it is more common for the motors to use power at different levels one may be accelerating another stopped and others moving at constant velocity or decelerating If you consider the move profiles of all motors in your system and evaluate the amount of peak and average power the motors require you will probably find that you can operate more drives and motors from one OEM300 than the worst case numbers suggest Details on how to perform these calculations are given below WHERE POWER IS USED IN A MOTION CONTROL SYSTEM A motor can be in one of four states stopped accelerating slewing or decelerating The power supply must satisfy the motor s power requirements which are very different during each of these states A sketch of a typical move profile is shown below 2 AS RS amp e X S 0 6 gx S Velocity Time Typical Move Profile In the following sections we will see how the drive and motor use the power they get from the power supply Then we will examin
8. Two provided GROUND Three provided RESERVED One provided Do not use Output Connector 6 Pin Removable connector Phoenix P N MVSTBR 1 5 6 ST Wire Size 16 AWG 1 5 mn if less than 10 ft 3m 14 AWG 2 5 mm if more than 10 ft Q Installation amp Operation OEM300 The following drawing illustrates typical power cabling for various OEM Series drives AC POWER GROUND MICROSTEPPING SERVO OEM Series Drive OEM Series Drive POWER RESERVED FAULT REMOTE le REF e e CURRENT e DUMP e renes VDC 9 9 At e i 9 POWER jie Power Connections to Various Drives OurPUT POWER CABLE LENGTH Make the output power cables as short as possible Voltage drops occur in cables over 3 feet long and cause a reduction in power delivered to the drive To minimize cable length mount the OEM300 close to the drive The next drawing shows that the 75VDC output pins are con nected together internally It also shows the internal connec tions of the ground pins and cover 14 OEM300 Installation amp Operation RESERVED GND AC GND Pins EARTH Pin 475VDC 2 7A and COVER are 29 7 Internally Connected GND EARTH 5 a JUMPER FOR 90 132 VAC 50 1 JUMPER FOR 180 265 VAC 50 60 CO 0 RESERVED GND 27 75VDC Pins are Internally Connected fono POWER Int
9. are not blocked If you have high ambient temperature conditions or heat producing equipment near the OEM300 you may need to provide a fan for air circulation and cooling For more informa tion about ventilation refer to Chapter Heat amp Thermal Man agement Issues AC POWER CONNECTION Use AC input power in the range of 90 132VAC or 180 265VAC to operate the OEM300 and configure the jumper wire on the power connector to match your input voltage Voltage in the intermediate range 132 180VAC MUST NOT BE USED There are two terminals on the 5 pin AC input connector that require the installation or removal of a jumper wire depending upon the input voltage you use The following illustration shows how to configure the jumper for your voltage No Jumper 120VAC 240VAC Install jumper Remove Jumper AC Input Connector Jumper Configurations 11 Q Installation amp Operation OEM300 120VAC Operations The OEM300 is shipped from the factory configured for input voltage in the 90 132VAC range with the jumper in place on the connector Leave the jumper in place if you operate in this range Operating without a jumper will cause poor system performance Line voltage is present on the jumper For safety reasons use only insulated wire for the jumper WARNING High voltage is present on the jumper Use insulated wire for safety 240VAC Operations If you use input power in the 180 265VAC range remove the
10. determine how many step motor drives you can connect to one OEM300 A reference has been added to Chapter that says similar information about servo motor drives can be found in Compumotor s OEM670T Torque Servo Drive User Guide CONTENTS Diii IV D Introduction 7 7 nnnnnns 1 1 Compumotor s OEM Series A Family of Motion Control Products 1 Original Equipment Manufacturers Decide How to Use OEM Products 1 OEMS300 POWER MODULE FEATURES esse ene 2 PROTECTIVE CIRCUITS octo engeren epe rore EORR Pn nai 3 SPECIAL DESIGN ISSUES eres eene trentaine etant 3 Cooling the OEM300 Power Module pp 4 How Many Drives can the OEM300 Operate 4 2 Installation amp Operation M se BEFORE YOU BEGIN 2 2 5 OEMS00 SHIP Roi Reni eae redd 6 BENGH rM 6 INSTALLATION eer 7 7 AC Power Connection eevee 11 DC Output Connection pp 13 Output Power Cable Length 14 Grounding for Safety oerte nant 15 How Many Drives Can Be Connected to One 16 Connecting Multiple Drives to the 16 Using More than One OEM300 Power Module
11. is a LATCHED condition To resume normal operations turn off AC power cool the Power Module below 30 C 86 F and then turn on AC power PowER DUMP The OEM300 has a power dump circuit that can dissipate excess energy from load regeneration conditions THRESHOLD VOLTAGE 85VDC x 3VDC ENERGY DISSIPATION Consult Power Dump sec tion in Chapter Protective Circuits AVERAGE POWER DISSIPATION RATE 8 Watts PEAK POWER DISSIPATION RATE 722 5 Watts EQUIVALENT ENERGY Two 83 135 motors each turning loads with 10 1 Rotor Inertia at 50 rps simultaneously decelerate to a full stop in 0 3 sec SHORT CIRCUIT PROTECTION The Power Module shuts down the 75VDC output if there is a short circuit in output cables or drives This is a LATCHED condition Cycle AC power to resume normal operations Short Circuit Current Response Time 9 Amps Immediate output shuts down 6 Amps Responds in 3 seconds OVERVOLTAGE PROTECTION Patita The Power Module has an output overvoltage protection circuit It shuts down the Power Module if the power dump stays on continuously for more than one half second This is a LATCHED condition Correct the problem then cycle AC power to resume normal operations 23 OEM300 Specifications 0 OPERATING TEMPERATURES MAXIMUM AMBIENT STILL AIR 35 C 95 F 40 C 104 F MAXIMUM AMBIENT MOVING AIR 45 113 F 50 C 122 F MAXIMUM HEATPLATE TEMPERATURE 60 C 140 F MIN
12. measure the power requirements 39 Calculating How Many Drives OEM300 For the simplest and most conservative way to proceed use the worst case numbers However in almost every application you can operate more drives than these numbers suggest Use the information in the other sections below to see if you can save money by operating additional drives with each Power Module The following sections use Compumotor OEM Series motors as examples If you are using other motors obtain information about the relevant motor specifications copper losses core losses peak shaft power etc and follow the same type of procedure as explained below NOTE The techniques presented in this chapter apply to step motor systems For information on how to determine the num ber of servo drives you can connect to an OEM300 consult your servo drive user s manual WORST CASE METHOD A system of drives and motors places the greatest demand on a power supply when each motor produces the maximum shaft power it can deliver and all motors turn at the same time For the power supply this is the worst case situation There are no other times when the power supply must provide this much power The table below lists the maximum number of drives that can be connected to the OEM300 Power Module in the worst case situation each drive operating a motor at maximum shaft power all motors turning simultaneously WORST CASE NUMBER OF DRIVES
13. or more It should be 5 to 10 inches away from the OEM300 and posi tioned so that it blows air from the bottom up through the OEM300 Heat amp Thermal Management Issues OEM300 EXAMPLE Suppose you want to power a 170 watt system with an and you need to place your equipment in a sealed equipment cabinet You mount the Power Module in a cabinet that has no fan or ventilation holes After you power up your system and let it run long enough to reach stable temperatures you check the temperature in the still air near the OEM300 You find it is 45 C 113 F which is higher than the 40 C 104 F recommended limit for still air So you install a fan in the cabinet and verify that it circulates air through the Power Module Once again you measure the air temperature near the OEM300 and find that it is still 45 C 113 F But because the air is moving the ambient air tem perature is now within recommended limits You can still use a sealed cabinet without ventilation holes OVER TEMPERATURE PROTECTION The OEM300 has a circuit that protects the Power Module from damage due to over temperature conditions This circuit shuts down the Power Module if the heatplate temperature rises above 60 C 140 F For more information about the over temperature circuit refer to Chapter Protective Circuits in the OEM300 38 CHAPTER Calculating How Many Drives amp Motors The OEM300 Can Operate You c
14. shaft power is no longer required to accelerate the load During slew the power supply must replace losses caused by core losses it must supply shaft power to overcome friction in the load and it must replace power dissipated in copper losses and in the drive itself Decelerating During deceleration the motor becomes a generator and produces regenerated energy The motor sends regenerated energy onto the power bus this energy will be used to replace core losses copper losses and drive losses If there is still excess energy the power supply must be able to absorb this energy CALCULATING THE POWER REQUIRED To calculate the power your system will require from the power supply you need to know three numbers power required at peak power required for slew and power required when the motor is stopped The table below lists the power required by each OEM Series step motor POWER REQUIREMENTS OEM SERIES MOTORS STOP SLEW oem ae 83 62 83 93 83 135 57 40 SE D STNO 57 83 These figures for motors that are operating at maximum power If your motors operate at less than maximum power the figures for peak and slew power will be lower 47 Calculating How Many Drives OEM300 To determine the power that the OEM300 must deliver to your system at any given time first determine where each motor is in its move profile stopped accelera
15. shown on the back cover Use it for quick reference Consult the rest of the manual for detailed information IV OEM300 Preface OEM300 POWER MODULE The OEM300 is NOT a WARNING general purpose power NO USER SERVICEABLE PARTS INSIDE supply Use it only with The OEM300 contains potentially lethal Compumotor OEM voltages Do not attempt to repair it Return Series Microstepping or the OEM300 to Compumotor for repairs Servo Drives HEATPLATE COOLING IHEATSINK You must provide a Thermal FUERO Wo Interface to cool the heatplate Module s heatplate Use silicone thermal joint com to a heatsink or pound or thermal gasket heat sinking Maximum Temp 60 C 140 F surface A AMBIENT AiR COOLING E Keep 2 clearance around top bot tom and sides AIR TEMP LIMITS STILL AIR 35 C 95 F 200W 40 104 170W MOVING AIR 45 C 113 F 200W 50 C 122 F 170W 22 RES VD GND 75VDC 75VDC GND GM NEL A 90 132VAC with Jumper EARTH Installed 180 265VAC with Jumper Removed 75VDC 5 DO NOT USE 132 180VAC 2 7A 200W Continuous INPUT CONNECTOR 4 0A 300W Peak 5 Pin Removable Connector 30 sec 10 Duty Cycle at Peak 16 AWG Recommended Two 75VDC pins internally connected You must connect the EARTH OUTPUT CONNECTOR terminal to EARTH GROUND 6 Pin Removable Connector Chassis cover EARTH GND e Use16 AWG if gt 10 ft 14
16. 00 s power dump will always turn on first Therefore there is usually no need to use the power dump in the drive as long as your system s stored energy can be safely dissipated in the OEM300 s power dump However if you design a system that has enough stored energy to overwhelm the power dump in the OEM300 you may want to use the drive s power dump to protect the drive Regenerating this much energy should be avoided however It is beyond the specified energy dissipation limits and can damage the OEM3OO OVERVOLTAGE PROTECTION An overvoltage protection circuit guards your drives and equip ment from excessively high voltages produced by a damaged It also protects your system from excessive regenera tion If a damaged element within the Power Module causes it to produce an output voltage in excess of 85VDC the power dump threshold voltage is exceeded and the power dump turns on The overvoltage circuit monitors the power dump If the power dump stays on for more than one half second the overvoltage circuit will shut down the output terminals The overvoltage circuit also monitors the power dump when load regeneration occurs In this case if the power dump stays on longer than one half second excessive regeneration is occurring To protect the OEMSOO the overvoltage circuit will shut down the output terminals TROUBLESHOOTING NOTE There are no separate indicators to distinguish between an excessive regeneration
17. 75VDC OUTPUT Should Measure 75VDC 5 If the above conditions are not true there are three possible problems PROBLEM SOLUTION No AC power Check AC at OEM300 AC Input Thermal Shutdown Cool OEM300 below 30 C 86 F Cycle AC Power Defective OEM300 Return OEM300 to Compumotor 57 Troubleshooting 0 DRIVE IS CONNECTED OEM300 WILL NOT POWER DRIVE Check to see if the LED is illuminated If it is not use the information in the first table below If it is illuminated use the information in the second table LED is OFF OEM300 Does Not Power Drive PROBLEM No AC Power SYMPTOM System will not turn on SOLUTION Use an AC voltmeter to verify presence of AC power at AC input of OEM300 Wrong Jumper Configuration System will not turn on or will not stay on 120VAC Install jumper 240VAC Remove jumper Thermal Shutdown due to Over Temperature System ran properly but shut down unexpectedly when heatplate exceeded 60 C 140 F LED is off OEM300 will not restart Cool OEM300 below 30 C 86 F Cycle AC power Restart OEM300 Damaged OEM300 OEM300 will not turn on even though AC power is present at input and heatplate temp is below 30 C 86 F Return OEM300 to Compumotor LED is OEM300 Does Not Power Drive PROBLEM Short Circuit in Cables or Drive SYMPTOM When system is turned on OEMS300 shuts down immediat
18. AWG if gt 10 ft pins are connected internally PARALLEL They will not share the load SHORT CIRCUIT PROTECTION Latched POWER DUMP Turns on at 85VDC OVER TEMPERATURE Unit shuts down 60 C Latched Cool to 30 C OVERVOLTAGE Shuts down output after 0 5 sec overvoltage Latched Preface 0 WARNINGS 8 CAUTIONS Warning and caution notes alert you to problems that may occur if you do not follow the instructions correctly Situations that may cause bodily injury are presented as warnings WARNING NO USER SERVICEABLE PARTS INSIDE THE OEM300 The OEM300 contains potentially lethal voltages Do not attempt to repair it Return it to Compumotor for any repairs Situations that may cause system damage are presented as cautions CAUTION Do not use AC input voltage in the range of 182 180VAC AC voltage in this range can cause excessive voltages to be generated within the OEM300 and may damage the unit cHAPTER D Introduction DESIGN INTENTIONS CoMPUMOTOR s OEM SERIES A FAMILY OF MOTION CONTROL PROD UCTS The OEM Series is a collection of high performance motion control modules The product line consists of stepper and servo drives indexers motors and the OEM300 Power Module The products are intended to be used as embedded systems around which the Original Equipment Manufacturer OEM can design a motion control system THE ORIGINAL EQUIPMENT MANUFACTURER DECIDES Ho
19. IMUM AMBIENT TEMPERATURE 32 24 With 200W Load With 170W Load With 200W Load With 170W Load CHAPTER 9 Protective Circuits in the OEM300 Extreme conditions can damage power supplies The OEM300 Power Module contains several circuits that will protect it from threatening conditions such as short circuits in drives exces sive heat buildup in equipment cabinets or energy regenerated by high inertial loads The OEM300 s protective circuits are built in and work auto matically You do not need to do anything to turn them on in fact you cannot alter them in any way Because they are auto matic they can cause unexpected results if you do not under stand how they work For example if there is a short circuit in a drive connected to the Power Module the Power Module will shut down If you are unaware of the short circuit protection feature you might think the shutdown is caused by a defective Power Module and waste time trying to fix it If you know about the protective circuitry however you can find the root cause of the problem the short circuit in the drive more quickly You can proceed straight to locating and fixing the short circuit and getting your system running again The following information about the protective circuits will help you understand how they work when they take effect and the results they produce This will aid your troubleshooting efforts and help you locate t
20. Issues CAUTION Do not obstruct the openings in the top and bottom of the OEM300 Ensure adequate space for air circulation between the OEM300 and other equipment AMBIENT AIR TEMPERATURE LIMITS The ambient air temperature must remain below these limits to adequately cool internal components STILL AIR 35 C 95 F with a 200W load 40 C 104 F with a 170W load Movinc AIR 45 113 F with a 200W load 50 C 122 F with a 170W load To measure ambient air temperature position your thermal probe below the OEM300 approximately one inch away from it Make measurements after your system has run long enough to reach a stable operating temperature PROVIDING ADDITIONAL VENTILATION If you have heat producing equipment near the OEM300 you may need to provide additional ventilation to keep the ambient air temperature within limits Additional ventilation can be provided by vent holes in the equipment cabinet a fan to move air in the cabinet a combination of fans and ventilation ducts or some other method Simply by moving air past the OEM300 you can raise the maximum ambient temperature limit by 10 C 18 F from 35 C to 45 C for a 200 watt load or from 40 C to 50 C for a 170 watt load 95 F to 113 F at 200W or 104 F to 122 F at 170W You may wish to include a fan in your system to take advan tage of this extended temperature range The fan should be rated at approximately 20 cfm cubic feet minute
21. Power Module A variety of filters are commercially available from many different vendors Q Installation amp Operation 0 Output Filter We recommend that no external filters be placed between the output of the OEM300 Power Module and any equipment connected to it The OEM300 Power Module should be connected directly to Compumotor OEM Series drives It is designed to respond rapidly to power demands from drives and their loads Any external filters such as EMI filters or extra capacitors may seriously impede the response and performance of the Power Module Output Cables Noise can be coupled from the output cables to sensitive equip ment by means of electromagnetic radiation This type of noise problem is known as Electro Magnetic Interference or EMI If you need to reduce EMI emanating from the power cables use shielded power cables and properly ground the shield You can achieve additional reductions in EMI if you run cables in con duit or steel pipe Cables should be as short as possible Keep cables away from sensitive equipment If you run separate wires for power cables POS and GND or and both wires should be parallel immediately adjacent to each other and twisted together This will minimize circuit inductance and radiated noise Proper Application of the OEM300 In extreme cases and unusual applications sensitive equipment can be highly susceptible to electrical noise problems In situa tions like th
22. a ture limits you must use two methods to remove this heat heatplate cooling and convection cooling HEATPLATE COOLING The OEM300 uses a HEATPLATE technique to provide a heat dissipation path The heatplate is the entire back surface of the it is the unpainted metal plate you see when you look at the back of the Power Module Internally many of the components that produce the most heat are thermally bonded to the heatplate The heat they produce can be removed through the heatplate pathway This means that if you can cool the heatplate these components will stay cool too To cool the heatplate you must mount it to a thermal mass such as a heatsink or a heat sinking surface Make sure that the surface of the heatsink is clean and flat not warped There should be good contact between the heatplate and heatsink with no voids or empty spaces between them Use silicone thermal joint compound or a thermal gasket to ensure good heat transfer across the thermal interface 33 Heat amp Thermal Management Issues OEM300 CAUTION The heatplate must be mounted to a heatsink or proper heat sinking surface Ensure good contact between the heatplate and the mounting surface Use silicone thermal joint compound or a thermal gasket to ensure heat transfer from the heatplate to the mounting surface HEATPLATE TEMPERATURE LIMIT Maximum Heatplate Temperature 60 C 140 F To check the heatplate temperature in
23. abinets To remove excess heat from within the OEM300 uses a heat plate technique and convection cooling PROTECTIVE CIRCUITS Several circuits in the OEM300 automatically provide protection for the Power Module and the equipment it powers OVER TEMPERATURE The Power Module monitors the temperature of its heatplate and will automatically shut down if the heatplate temperature exceeds 60 C 140 F To restart the Power Module turn off AC power cool the Power Module below 30 C 86 F and cycle AC power SHORT CIRCUIT PROTECTION The Power Module moni tors current going to the drive and will shut down its output if it detects a short circuit in the drive Cycle AC power to resume normal operations INTERNAL POWER DUMP Power Module has internal power dump circuit This circuit can dissipate excess energy during load regeneration conditions Q OVERVOLTAGE The Power Module will shut down if there is excessive voltage at its output terminals For more information about these circuits refer to Chapter Protective Circuits in the OEM300 SPECIAL DESIGN ISSUES You can use the Power Module in many different ways To use it effectively however you must solve several design issues Two of the most important are Introduction OEM300 COOLING THE OEM300 POWER MODULE The OEM300 Power Module dissipates some power as internal heat This excess heat must be removed from the Power Module When you des
24. ach product They are available upon request Please order user guides as needed BENCH TEST Power Modules are tested at the factory before they are shipped Ordinarily there is no need to perform a bench test on the Power Module before you install it in your system If you want to test the Power Module you can perform the tests listed below CAUTION If you operate the without adequate cooling it may be damaged Mount the OEMSOO to a heatsink Make sure there is good thermal contact between the Power Module s heatplate and the heatsink Do not block the openings in the cover Allow adequate air movement so that convection can cool the Power Module Remove AC power to the Power Module when you complete your tests To test a Power Module 1 Connect AC power to the OEM300 120VAC with jumper installed or 220VAC with jumper removed 2 LED the green LED should be illuminated This indicates that the 75VDC power supply in the Power Module is operat ing correctly OEM300 Installation amp Operation 3 Use a voltmeter to measure the voltage at the 75VDC output terminals It should be 75VDC 5 INSTALLATION MOUNTING The OEM300 Power Module is designed to minimize panel area or footprint in an equipment cabinet Dimensions are shown in the drawing below 4x 20 187 4 75 Thru Clearance for 8 PHP Screw Dimensions in inches millimeters 4 31 109 4 177 106
25. amp Operation 0 Attachment to Heatsink You must attach the heatplate of the Power Module to a heatsink or suitable heat sinking surface The heatplate is the pathway through which you can remove much of the excess heat generated by the Power Module Use silicone thermal joint compound or thermal gasket between heatplate and heatsink HEATPLATE Attaching Heatplate to Heatsink When you attach the Power Module to a heatsink observe the following guidelines Q Use silicone thermal joint compound or a thermal gasket to ensure good thermal contact between the heatsink and the Power Module s heatplate 4 Make sure there are no voids or air pockets between the heatsink and heatplate Q Verify that the heatsink is not warped a warped surface will not make a good thermal interface CAUTION You must attach the heatplate of the Power Module to a heatsink or suitable heat sinking surface Use silicone thermal joint compound or a thermal gasket to provide a good thermal interface For more information about choosing a heatsink refer to Chap ter Heat amp Thermal Management Issues 10 OEM300 Q Installation amp Operation Ventilation The OEM300 depends on ventilation to remove much of its excess heat Mount the Power Module so that air can circulate around it Follow the guidelines for minimum spacing that were shown earlier in this section Make sure the openings in the top and bottom of the cover
26. an use the OEM300 Power Module to power Compumotor s OEM Series servo motor drives OEM670T OEM670X 6705 etc OEM Series step motor drives OEM650 OEM650X OEM350 OEM350X etc This chapter will explain how to determine the number of step motor drives you can connect to the OEM300 For a similar discussion about servo motor drives see Chapter Power Supply Selection in the OEM670T User Guide part number 88 013599 01 The section of that chapter called Peak Power Curves for OEM Series Motors may be particularly useful for using the OEM300 Power Module with OEM670 drives GENERAL GUIDELINES STEP MOTOR SYSTEMS The OEM300 Power Module can deliver power to many different combinations of drives indexers and the motors they run How many drives can one Power Module operate The answer de pends on several factors 1 The size of each motor in the system The work each motor must do what its move profile looks like Q The time when each move profile occurs There are three methods you can use to determine how many drives to connect to one OEM300 Q WORST CASE METHOD If you want all your motors to be able to simultaneously produce full power connect the number of motors specified in the Worst Case Table below CALCULATION METHOD Based on figures for peak and average power requirements calculate the number of drives to connect MEASUREMENT METHOD Make a prototype of your system and directly
27. application include answers to the follow ing questions What is the extent of the failure reason for return How long did it operate How many units are still working How many units failed What was happening when the unit failed i e installing the unit cycling power starting other equipment etc How was the product configured in detail What if any cables were connected and how With what equipment is the unit connected What was the application What was the system sizing speed acceleration duty cycle inertia torque friction etc What was the system environment temperature enclosure spacing unit orientation contaminants etc What upgrades are required hardware user guide 3 Call Parker Compumotor s Applications Engineering Depart ment at 800 358 9070 for a Return Material Authorization RMA number Returned products cannot be accepted without an RMA number 4 Ship the unit to Parker Compumotor Corporation 5500 Business Park Drive Rohnert Park CA 94928 Attn RMA XXXXXXX 59 Troubleshooting 0 60 DE X A AC Input Ground 15 AC Input Secifications 21 24 AC Input Voltage 12 AC Power Connection 11 Accelerating Power Requirements 46 Additional Ventilation 37 38 Ambient Temperature Limits 24 37 B Bench test 6 Bus 14 C Cable Length 14 Calculating of Drives to Connect 39 55 Calculating Power Requiremen
28. city Notice that they can change rapidly during accelera tion or deceleration and are constant when the motor is slewing Shaft Power During Acceleration Slew and Deceleration To accelerate a load the motor s shaft produces torque The power required to accelerate the load is called shaft power since torque multiplied by velocity equals power During slew a system with little friction will not require shaft power If there is friction in the system the motor must produce shaft power to overcome the friction Shaft power is shown in the drawing below Power 4 Acceleration NK Profile Friction Regeneration Shaft Power Notice that shaft power rises at a constant rate during accelera tion and if friction is negligible will be close to zero during slew During deceleration shaft power is negative This means that the drive is not delivering power to the motor In fact the opposite happens the motor delivers power to the drive and power supply This is called regeneration 44 OEM300 Calculating How Many Drives POWER REQUIREMENTS DURING A TYPICAL MOVE If we make a graph of all the places power is used as we have done in the next drawing we can see where power goes during a move Velocity Time Shaft Power During Acceleration Core Losses During Slew Deceleration Regeneration Power b Time Copper L
29. e all of its products We reserve the right to modify equipment and user guides without prior notice No part of this user guide may be reproduced in any form without prior consent from Parker Compumotor Compumotor For assistance in the United States contact For assistance in Europe contact Compumotor Division of Parker Hannifin Parker Digiplan 5500 Business Park Drive 21 Balena Close Rohnert Park CA 94928 Poole Dorset Telephone 800 358 9070 England 17 70 Fax 707 584 8015 Telephone 0202 690911 Fax 0202 600820 88 013513 01 C Compumotor Division of Parker Hannifin 1995 All rights reserved OEMS300 Power Module User Guide Revision C Change Summary The following is a summary of the primary technical changes to this user guide since the last version was released This user guide p n 88 013513 01 C released on January 3 1995 supersedes 88 013513 01 B JUMPER SELECTABLE AC INPUT VOLTAGE RANGE PG 11 The OEM300 Power Module AC power input circuitry is no longer auto ranging A jumper on the AC power connector will now configure the OEM300 for 120VAC or 240VAC operation as follows 120VAC Operation Jumper must be installed 240VAC Operation Jumper must be removed The OEM300 ships from the factory pre configured for 120VAC operation with a jumper installed on the connector You must remove the jumper if you operate the OEM300 at 240VAC SYSTEM SIZING PG 45 Chapter explains how to
30. e peak demand periods and find their duty cycles is to connect the current probes to a storage oscilloscope For any given time you can then add up the demand from each drive to obtain the total demand You can also measure the duration of the peak demand find how frequently it occurs and calculate its duty cycle The OEM300 is rated to deliver current at these levels RATED CURRENT 2 7A Continuous 4 0A Peak 30 sec 10 duty 54 OEM300 Calculating How Many Drives Current levels that activate the OEM300 s short circuit protec tion are shown in the next table SHORT CIRCUIT PROTECTION Current Level Shutdown Within 6A 3 seconds 9A Immediate With the results of your current probe measurements and the current levels listed above determine how many drives you can connect to each OEM300 Try to keep the current produced by the OEM300 within the rated levels What happens when your system operates on the borderline and occasionally requires more than 4 Amps of current The answer depends on the duration and level of the excess current demand If asked to deliver excess current the OEMSOO will do so for brief periods Voltage will stay very near the rated voltage of 75VDC However there are two possible consequences if the OEM300 operates outside its specified range The first is related to over temperature protection If the OEM300 continually provides current in excess of 4 0 Amps it may become exces
31. e the amount of power required by the drive and motor during each part of a move 41 Calculating How Many Drives OEM300 Copper Losses and Drive Losses Two types of power losses always exist whether a motor is in motion or stopped copper losses and drive losses Their values remain approximately constant regardless of the speed at which the motor turns If the motor is not moving these are the only losses present Copper losses are caused by resistance to current flow in the copper windings of the motor A step motor that is stopped has a current flowing in it to maintain holding torque approxi mately the same amount of current flows when the motor is in motion The copper losses are calculated as I2R the square of the current in the windings multiplied by the resistance of the windings Since the current stays the same whether the motor is moving or stopped the copper losses are constant They are usually small approximately 10 to 15 Watts because the resistance of the windings is low Drive losses occur during normal operation of the drive The drive receives power from the power supply and sends most of that power to the motor Some of the power however is lost as heat in the drive when resistors and other components heat up Power dissipated as heat in the drive constitutes the drive losses These are usually small approximately equal to the copper losses They are proportional to the current the drive del
32. ecided on a method for ventilating the Power Module and keeping ambient air temperatures within specified limits Q NUMBER OF DRIVES You have calculated the power re quired by your system and have decided how many drives you can connect to each Power Module If you need more information about heatsinks and cooling refer to Chapter amp Heat amp Thermal Management Issues For informa tion on how many drives you can connect to the Power Module refer to Chapter Calculating How Many Drives amp Motors the Can Operate NOTE The OEM300 is not a general purpose power supply nor is it a laboratory bench supply It was designed specifically for use with OEM Series drives it is unsuitable for other purposes CAUTION The OEM300 Power Module should only be used with OEM Series drives Do not connect it to any other products or equipment OQ Installation amp Operation OEM300 OEM300 SHIP KIT Inspect the OEM300 upon receipt for obvious damage to its shipping container Report any damage to the shipping com pany Parker Compumotor cannot be held responsible for damage incurred in shipment You should receive one or more OEM300 Power Modules depending upon what you ordered Compare your order with the units shipped Component Part Number OEM300 Power Module OEM300 5 Pin Connector 43 014298 01 6 Pin Connector 43 006606 01 Accessories OEM300 User Guide 88 013513 01 User guides are not sent with e
33. ed if your system unexpectedly stops the voltage at the 75VDC terminals is Volts but the LED is illuminated There is prob ably a short circuit fault in your equipment Remember the LED will remain illuminated even when the 75VDC output is shut down due to a short circuit fault Find and fix the problem in your equipment then cycle power to the OEM300 and restart your system Other possible causes D Excessive load regeneration see the Power Dump description below Overvoltage see the description below 26 OEM300 Protective Circuits in the OEM300 OVER TEMPERATURE PROTECTION The OEM300 has a circuit that protects it from damage due to over temperature conditions This circuit monitors the tempera ture of the Power Module s heatplate A temperature rise above 60 C 140 F will trigger a thermal switch when this happens the protection circuit shuts down the Power Module and turns off the green LED This is a latched condition Before the Power Module can operate again its heatplate must cool below ap proximately 30 C 86 F and AC power must be cycled The Power Module will cool faster if you turn off AC power while it cools If AC power is on several bleeder resistors will continue to dissipate their heat into the heatplate and keep it warm even though the Power Module is off It will cool much faster with the power off Therefore design your system so that if an over temperature shutdown occurs AC po
34. ed regeneration The energy produced by regeneration is proportional to the kinetic energy of the moving parts of the motor and its load For some configurations of motors and loads the energy can be quite high and has the potential to damage any connected drives and power supplies The OEM300 has a circuit that protects drives connected to it from excessive load regeneration The protective circuit is called a power dump The power dump works by sensing the voltage at the 75VDC output terminals A voltage rise above a threshold value ap proximately 85VDC indicates the is receiving too much regenerated energy The power dump circuitry closes an internal switch and diverts the extra energy through a large power resistor The energy is dissipated as heat in the resistor and voltage at the output terminals falls When the voltage falls to approximately 82VDC the power dump turns off If energy is still being regenerated voltage at the output terminals will start to rise When the voltage reaches 85VDC the power dump turns on and the whole process begins again To dissipate the entire amount of regenerated energy the power dump will switch on and off over and over again until the voltage no longer rises above 85VDC The resistor in the power dump can absorb a maximum of 400 joules of energy within a short period of time And after the resistor converts the energy to heat it needs time to transfer the heat to the ambi
35. ely LED stays on SOLUTION Solve short circuit problem in connected equipment Cycle AC power to restart system Overvoltage or Damaged OEM300 When turned on with motor not moving system runs for approx 1 2 second then OEM300 shuts down LED stays on Return OEM300 to Compumotor Excessive When turned on system runs Adjust move profile or load Regeneration until regeneration occurs characteristics to keep OEM300 shuts down during regeneration within regeneration LED stays on specifications Cycle AC power and restart system Drive is not OEM300 is on 75VDC output Check cable connections connected measures 75VDC LED is on Use a voltmeter to verify But drive is off 75VDC is present at drive input Wrong Jumper Configuration 58 Motor operates poorly or does not run at all 120VAC Install jumper 240VAC Remove jumper OEM300 Troubleshooting RETURNING THE OEM300 TO COMPUMOTOR If your OEM300 has failed you must return it for replacement or repair If you return your OEM300 for repairs or upgrades use the following steps 1 Get the serial number and the model number of the defective unit s and a purchase order number to cover repair costs in the event Parker Compumotor determines the unit is out of warranty 2 Before you ship the unit to Parker Compumotor have some one from your organization with a technical understanding of the OEM300 and its
36. ent air before it can absorb more energy Therefore there is a repetition rate or period that determines how frequently energy can be dumped into the power resistor The maximum average power dissipation rate during this period is 8 watts For example suppose 400 joules is dissipated in the power 28 OEM300 Protective Circuits in the OEM300 dump in one second How long must we wait before we can repeat the regeneration event Average power dissipation must be 8 watts or less during the total regeneration event dump on plus time waiting We find the repetition rate by dividing 400 joules by 8 watts this gives us 50 seconds Remember 1 watt is equal to 1 joule per second So 400 joules 8 watts 50 seconds We must wait 49 seconds before regenerating again 1 second ON plus 49 seconds OFF 50 seconds Another factor to consider in power dump performance is the peak power dissipation rate 722 5 watts If your system sends power to the power dump at a rate higher than 722 5 watts the power dump cannot dissipate the power fast enough to lower the voltage at the output terminals It will stay on continuously After one half second the overvoltage circuit will shut down the output of the OEM300 See the next section for an explanation of the overvoltage protection circuit For example suppose a moving system of motors contains 200 joules that must be dissipated in the power dump How quickly can it decelerate without ov
37. ernal Connections GROUNDING FOR SAFETY Inside the OEM300 the 75VDC output grounds are connected to each other to the AC input ground which is labeled EARTH and to the cover of the OEM300 For safety considerations connect the EARTH terminal of the Power Module to an external EARTH GROUND Do not create ground loops when you connect cables to your system 15 Installation amp Operation 0 How MANY DRIVES CAN BE CONNECTED TO ONE OEM300 The OEM300 can deliver power to many different combinations of drives indexers and the motors they operate Determine the power demanded by your application and verify that the will supply the amount of power needed You may need multiple OEM300 Power Modules or you may be able to use fewer Power Modules than anticipated For details on how to calculate the power output required of the OEM300 refer to Chapter Calculating the Number of Drives amp Motors the OEM300 Can Operate CONNECTING MULTIPLE DRIVES TO THE OEM300 Consult the following figure for guidelines on how to connect more than one drive to the OEM300 You can make a single power bus or you can use the extra pins in the DC output connector to make a second power bus AC POWER EARTH GROUND Power Cabling Options 16 OEM300 2 Installation amp Operation You can connect OEM650 Microstepping Drives and OEM670 Servo Drives to the same OEM300 Power Module USING MORE THAN ONE OEM300 P
38. erwhelming the power dump If energy is dissipated at the peak rate of 722 5 watts we find that the deceleration time is 200 joules 722 5 watts or 0 3 seconds The repetition rate will be 200 joules 8 watts or 25 seconds Power dump information is summarized below POWER DUMP CHARACTERISTICS Peak 722 5 Watts POWER DISSIPATION RATE Average 8 Watts PEAK ENERGY ABSORBED x xx Joules within y yy seconds Amount Joules Absorbed Time Off sec Repetition Rate sec 400 Joules 5 0 sec 45 000 sec 50 000 sec 400 2 5 47 500 50 000 400 1 0 49 000 50 000 400 0 554 49 446 50 000 361 25 0 5 44 656 45 156 144 5 0 2 17 863 18 063 72 25 0 1 8 931 9 031 36 125 0 05 4 466 4 516 On 85 VDC THRESHOLD VOLTAGE Off 82 VDC 29 Protective Circuits the OEM300 OEM300 The numbers in the table show the energy that can safely be absorbed the OEM300 s power dump When a motor regener ates energy much of the energy is dissipated as heat in the motor and drive Therefore total energy contained in the mov ing parts of the motor and load can be higher than the numbers shown in the table After motor and drive losses the energy left over will be sent into the power dump this is the energy that is listed in the table above For a discussion of motor and drive losses see the section Where Power is Used in a Motion Control System in Chapter Ca
39. fault a dam aged Power Module or a short circuit fault Any of these condi tions will shut down your system and the green LED will remain illuminated 31 Q Protective Circuits in the OEM300 OEM300 When you attempt to restart your equipment you should be able to isolate the cause If the problem is due to a short circuit fault in connected equipment the Power Module will shut down instantly when it is turned on If the problem is due to a dam aged Power Module it will run for 1 2 second and shut down even with no load regeneration If the problem is due to exces sive regeneration the Power Module will power your system until load regeneration occurs then it will shut down These conditions are summarized below Power Module Shuts Down Probable Cause instantly when turned on Short circuit fault in drive after running 1 2 second Damaged OEM300 when regeneration occurs Excessive regeneration 32 CHAPTER Heat amp Thermal Management Issues HEAT MUST BE REMOVED FROM THE OEM300 The OEM300 will operate over a broad range of ambient tem peratures As it delivers power to connected equipment it also produces heat internally During load conditions where the 5 1300 is supplying its maximum output power internally generated heat can be as much as 35 watts In the small space enclosed by the Power Module 35 watts is a significant amount of heat To keep the Power Module within its operating temper
40. friction in the system 48 OEM300 Calculating How Many Drives Move Profile 27 of All Three Motors gt t Time 110W 48W F Motor 1 22W 110W 48W Motor 2 22W 110W 48W J gt Motor 3 22W i t 2 Total Power 330W at Time P 144W at Time ty Simultaneous Move Profiles At time f7 each motor requires peak power From the table listing power requirements for OEM Series motors we find a 49 Calculating How Many Drives OEM300 value of 110W at peak for the OEM57 83 motor Next we add together the power required by each motor Motor 1 110W Motor 2 110W Motor 3 110W TOTAL 330W We find the total power required at time t7 is 330W The is specified as a 300W power supply Can it provide 330W Yes because the duration of time that 330W is required is very brief the will use extra power stored in its capacitors to meet this demand Notice that every motor s peak power requirements occur at the same time Because of this we can only run three motors of this size This is the same number that is listed in the worst case table for OEM57 83 motors The method discussed in this section was used to find the numbers in the worst case table At time t2 each motor is slewing and requires 48W The total power required to operate the system at this time is 144W This means that most of the time this sys
41. g or the OEM300 to Compumotor for repairs Servo Drives HEATPLATE COOLING CESENA 2d s You must provide a Thermal rmn cuts Mee Interface to cool the heatplate Module s heatplate Use silicone thermal joint com to a heatsink or pound or thermal gasket heat sinking 4 E Maximum Temp 60 C 140 F surface lt a AMBIENT AIR COOLING 65 OF Se Keep 2 clearance around top bot tom and sides AIR TEMP LIMITS STILL AIR 35 C 95 F 200W 40 C 104 F 170W MOVING AIR 45 C 113 F 9 200W 50 C 122 F 170W 90 132VAC with Jumper EARTH Installed 180 265VAC with Jumper Removed 75VDC 5 DO NOT USE 132 180VAC 2 7A 200W Continuous INPUT CONNECTOR 4 0A 300W Peak 5 Pin Removable Connector 30 sec 10 Duty Cycle at Peak 16 AWG Recommended Two 75VDC pins internally connected You must connect the EARTH OUTPUT CONNECTOR terminal to EARTH GROUND 6 Pin Removable Connector Chassis cover EARTH GND Use16 AWG if 10 ft 14 AWG if gt 10 ft PARALLEL They will not share the load PROTECTIVE CIRCUITS SHORT CIRCUIT PROTECTION Latched POWER DUMP Turns on at 85VDC OVER TEMPERATURE Unit shuts down 60 C Latched Cool to 30 C OVERVOLTAGE Shuts down output after 0 5 sec overvoltage Latched
42. he cause of unexpected behavior SHORT CIRCUIT PROTECTION The OEM300 continuously monitors output current at the 75VDC terminals If it detects a rapid current rise to excessive levels it interprets the current rise as a short circuit fault in the drive It shuts off power to the 75VDC output terminals Inter 25 Q Protective Circuits in the OEM300 OEM300 nally the 75VDC power supply section of the Power Module continues to function and the green LED remains illuminated If the OEM300 detects a short circuit current in excess of 9 amps it will shut down the output immediately It will monitor a 6 amp current and shut down the output if the current lasts longer than 3 seconds This is summarized in the table below Current Level Response Time of Protection 9 amps Respond Immediately 6 amps Respond In 3 seconds 4 6 amps No Response Beyond specified operating range 2 7 4 amps No Response Intermittent operat ing range 0 2 7 amps No Response Continuous range When the 75VDC output is shut down the shutdown is a LATCHED condition the 75VDC output will remain off until power is cycled To CYCLE POWER turn off the AC power to the OEM300 wait approximately 30 seconds the green LED will turn off then turn on AC power The output is latched in the OFF condition for safety reasons Short circuit protection guards people from injury and equip ment from damage IMPORTANT TROUBLESHOOTING NOTE You may be confus
43. ign your system keep in mind three things you can do to remove heat COOL THE HEATPLATE Make sure heat can pass through the Power Module s heatplate and into a suitable heat sink ing surface Q PROVIDE SPACE AROUND THE POWER MODULE Allow convection to transfer heat to the ambient air KEEP AMBIENT AIR WITHIN ITS TEMPERATURE LIM ITS Otherwise it will not adequately cool the Power Mod ule For more information about cooling the Power Module refer to Chapter Heat amp Thermal Management Issues How MANY DRIVES CAN THE OEM300 OPERATE The can deliver power to many different combinations of OEM Series products You can save money if you analyze your system determine how much power each drive needs and then connect the right number of drives to use the full power capability of the OEM300 For information on calculating power required by different motors and drives see Chapter Calculating How Many Drives amp Motors The OEM300 Can Operate CHAPTER GO Installation amp Operation BEFORE YOU BEGIN This chapter tells you how to test install and operate your OEM300 Power Module Before you begin installation we assume you have addressed and solved the following design issues Q HEATSINK You have chosen a heatsink or a suitable heat sinking surface You have selected a way to make good thermal contact between the heatsink and the Power Module s heatplate COOLING You have d
44. is a switching power supply might be the wrong type of power supply to use If your system cannot tolerate the amount of electrical noise generated by the OEM300 and noise reduction techniques fail to reduce noise to tolerable levels then you may need to con sider using a linear power supply such as the Compumotor DC 4 Linear supplies are virtually noise free and give excellent results in noise sensitive applications Unfortunately in com parison to switching supplies linear supplies are large heavy and dissipate more power They also suffer from poor output regulation which may affect the high speed performance of your system 18 OEM300 Installation amp Operation OPERATION The OEM300 Power Module is intended to be hardwired within your system Therefore it does not have an ON OFF switch AC input cables or DC output cables You should provide a means for turning the OEM300 on and off connecting input AC power and delivering DC output power to your drives During operation a green LED on the front panel is illuminated to indicate the 75VDC section is functioning 19 Q Installation amp Operation OEM300 20 cHAPTER 9 OEM300 Specifications WARNING NO USER SERVICEABLE PARTS INSIDE THE OEM300 The OEM300 contains potentially lethal voltages Do not attempt to repair it Return it to Compumotor for any repairs AC INPUT SPECIFICATIONS INPUT VOLTAGE Low Range Jumper instal
45. ivers Since this current is fairly constant drive losses are also constant they do not change when motor speed changes Copper losses and drive losses are shown in the drawing below Notice that these losses are constant whether the motor is moving or stopped 42 OEM300 Calculating How Many Drives Power Dissipated in Motor s Copper Windings amp Power Dissipated in Drive Power N 7 Copper Losses and Drives Losses The following table lists the values for drive losses and copper losses COPPER LOSSES and DRIVE LOSSES Copper Drive TOTAL 57 40 9 9 18 57 51 11 11 22 OEM57 83 MO 9 13 22 050656200 13 15 28 34 42 OEM83 93 MO 83 135 Core Losses Caused by Motion When the motor is in motion some power is lost because of the movement of the motor The moving magnetic fields in the motor will induce eddy currents in the motor s iron core these eddy currents cause heating in the core The power supply delivers the power that ends up as heat in the motor s core The power losses caused by eddy current induction are called core losses they are also known as iron losses Core losses are shown in the drawing below 43 Calculating How Many Drives 0 Power Dissipated as Heat in Motor s Core Caused by Moving Motor Inducing Eddy Currents Power Core Losses Core losses are proportional to v2 the square of the motor s velo
46. jumper Do not operate the OEM300 in the 180 265VAC range with the jumper in place Doing so can produce high internal voltages which could cause severe system damage CAUTION Do not use a jumper when using AC input voltage in the 180 265VAC range If a jumper is in place input voltage in this range will cause the OEM300 to generate high internal voltages which could result in system damage AC input information is summarized below Input Voltage 90VAC 132VAC Jumper installed 180VAC 265VAC Jumper removed Forbidden Range 132VAC 180VAC Wire Size 16 AWG 1 5 mm minimum Input Connector 5 pin removable connector Phoenix P N GMVSTBR 2 5 5 ST The following illustration shows the AC input connector prop erly configured for both voltage ranges OEM300 2 Installation amp Operation 120VAC 240VAC EARTH EARTH GROUND GROUND Note Note Line and Neutral Line 1 and Line 2 are Interchangeable are Interchangeable AC Input Connections 0 CAUTION Do not use AC input voltage in the range of 132 180VAC AC voltage in this range can cause excessive voltages to be generated within the OEM300 and may damage the unit DC OurPUT CONNECTION For convenience multiple pins are provided for 75VDC and for GROUND GND The two 75VDC pins are identical use either one or use both whichever your needs require Similarly the three GROUND pins are identical use as many as you need Output Pins 75VDC
47. lculating How Many Drives amp Motors the OEM300 Can Oper ate The power dump in the OEM300 is designed to dissipate as much regenerated energy as would occur in a worst case situa tion where two 83 135 motors each operate loads with 10 1 rotor inertia Under these conditions when regeneration occurs the power dump will turn on and dissipate the excess energy EXAMPLE A single OEM83 135 MO motor turns a load that has ten times the motor s rotor inertia Speed of the system is 50 rps The kinetic energy in the moving parts of the system can be calculated as follows Kinetic Energy 1 2 0 1 2 1 10 1 87 kg cm2 103 21 50 101 5 joules Where J inertia in kg cm 1 87 kg cm is the motor s rotor inertia It can be found in the OEM650 User Guide 10 is a conversion factor to convert from kg cm to kg m units which are compatible with joules o velocity in radians sec o 2n rps Kinetic energy in this system is 101 5 joules Kinetic energy in a similar system with two motors would be approximately 200 joules which can be absorbed in 0 3 sec 200J 722 5W 0 3 sec See previous page 30 OEM300 Protective Circuits in the OEM300 Compumotor s OEM650 Microstepping Drive also has a power dump circuit To use it you must connect an external power resistor to the drive However the threshold voltage for the power dump in the OEM300 is much lower than the threshold in the OEM650 The OEM3
48. led 90VAC to 132VAC High Range Jumper removed 180VAC to 265VAC Forbidden Range 132VAC to 180VAC WARNING High voltage is present on the jumper Use insulated wire for safety CAUTION Do not use AC input voltage in the range 132 180VAC Voltage in this range can cause excessive voltages to be generated within the OEM300 and may damage the unit INPUT FILTER The Power Module has a line filter at the AC input that mini mizes noise energy sent out to the power line 21 OEM300 Specifications OEM300 INRUSH CURRENT The Power Module has an initial power up current limiter Input Limit 40A Maximum Inrush Current DC OUTPUT SPECIFICATIONS OUTPUT VOLTAGE 75VDC 5 Fixed Not Adjustable OUTPUT CURRENT 2 7A at 75VDC Continuous Current 4 0A at 75VDC Peak Current OuTPUT POWER 200W Continuous 300W Peak 30 seconds maximum at peak 10 duty cycle at maximum Example 30 seconds at 300W followed by a minimum of 270 seconds at 200W or less OuTPUT GROUNDS Output grounds are internally connected to each other to the AC input ground labeled EARTH and to the cover of the OEM300 VOLTAGE REGULATION 5 maximum EFFICIENCY The Power Module has a minimum of 80 efficiency at full output load 22 OEM300 OEM300 Specifications OVER TEMPERATURE PROTECTION The Power Module will shut down if its heatplate reaches a temperature of 60 C 140 F This
49. ments If your system has unusual power requirements you must make appropriate adjustments to the figures given earlier for power required by OEM Series motors Or use the measure ment method discussed in the next section and determine the actual current requirements MEASUREMENT METHOD The measurement method empirically measures actual current flowing from a power supply to each drive To use the measure ment method you must first make a working prototype of your system and measure the current required by each drive as the motors operate You can then compare the total current re quired with that available from the OEM300 For your prototype system use a large temporary power supply capable of providing enough current for all drives in your system at 75VDC Once you determine the current require ments you will replace the temporary power supply with one or more OEM300 Power Modules 53 Calculating How Many Drives 0 Use a DC current probe to measure the current going from the power supply to each drive Currents going from the drive to the motor are not relevant in this procedure you do not need to measure them Current Voltage Probe Probe Probe Amplifier Oscilloscope Setup for Current Measurement You need to find two values the total peak current demand and the duration or duty cycle of that total peak demand The total current demand will probably be changing continuously One way to locate th
50. n 28 M Maximum Ambient Temperature 24 Maximum Heatplate Temperature 24 27 Maximum number of drives 40 Measurement Method 53 55 Measuring Heatplate Temperature 34 Minimum Ambient Temperature 24 62 Minimum Spacing 8 Motors Power Requirements 47 Mounting 7 11 Air circulation 11 Attachment to Heatsink 10 Heat producing equipment 9 Minimum Spacing 7 Multiple OEM300s 8 Panel Layout 7 Ventilation 11 Moving Air Temperature Limits 24 Multiple pins 13 N Noise reduction 17 Input Filter 17 Linear power supply 18 Output Cables 18 Output Filter 18 Switching power supply 17 0 OEM Series 1 basic features 1 design intentions 1 OEM Series Step Motors Power Requirements 47 ON OFF switch 19 Output Connection 3 Output Connector 13 Output Current 22 Output Filter 18 Output Grounds 15 22 Output Pins 13 Output Power See Power Output Output Specifications 22 Output Voltage 22 Over Temperature Protection 23 27 Overvoltage Protection 23 31 32 threshold values 31 troubleshooting 31 P Paint and heatsink 36 Panel Layout 8 Parallel OEM300s 17 Peak Power Output 22 Plug AC input 12 DC output 13 Power Bus 14 Power cabling 14 Power Connection 11 Power Dump 23 28 31 OEM650 power dump 31 Power Output 22 continuous 22 duty cycle at peak 22 peak 22 Power Required During Move 45 Power Requirements TABLE 47 Problems Troubleshooting 57 Protective Circuits 3 25 32 Providing Additional Ventila
51. osses amp Drive Losses Power During a Move And if we add up the values for the various losses shaft power regeneration etc we get a graph of the power that the power supply must deliver This is shown in the next drawing 45 Calculating How Many Drives 0 Velocity Time Power Required at Peak Power Required for Slew Power Power Required When Stopped Regeneration Power Required During a Move Using the drawings above we can discuss the power required during each part of a move profile Stopped When the motor is not moving power is dissipated in copper losses and drive losses The power supply must deliver power to replace these losses Accelerating During acceleration the motor develops shaft power Because the motor is moving core losses start to dissipate power and play a larger role as speed increases Copper losses and drive losses are still present The power supply must deliver enough power for all these purposes In most applications the period of time peak power is actually required is very brief often just a few thousandths of a second There is usually enough stored energy in the power supply s capacitors to meet this brief power demand 46 OEM300 Calculating How Many Drives Slewing When the motor is slewing the load moves at a constant speed Demand placed on the power supply drops sharply because
52. owER MODULE The is not designed for current sharing Each unit is designed as a standalone Power Module Do not attempt to connect multiple OEM300s together in parallel Instead con nect drives directly to individual Power Modules CAUTION Do not connect multiple OEM300 Power Modules in parallel Connect drives directly to individual Power Modules ELECTRICAL NoisE CONTROL The OEM300 Power Module contains a switching power supply Internally it rapidly switches several high voltage components on and off This rapid switching creates electrical noise which is a standard characteristic of switching power supplies You may need to reduce electrical noise depending on your application and the sensitivity of the equipment in your system The following information is provided to help with your noise reduction efforts For additional information about controlling electrical noise consult the technical reference section in Compumotor s catalog Switching Frequencies Primary Switching Frequency 118 kHz 9 kHz AC Line Switching Frequency 48 72 Hz plus harmonics AC line frequency varies by country Input Filter Internally the OEM300 has an AC input filter This filter re duces the electrical noise that is conducted from the Power Module to the AC power line If you need to further reduce the noise sent out over the AC lines you can install an external filter at the point where AC power is connected to the
53. ower Module attaches to the wall Thermal Contact Only Around Fasteners Flexible or non rigid heat sinking surfaces such as equipment cabinet walls are prone to a particular problem The pressure of the bolts or screws that attach the Power Module to the wall can cause the wall to warp slightly There may be thermal contact in the circular area immediately surrounding the bolt but nowhere else If you use the wall of an equipment cabinet for a heat sinking surface make sure there is good thermal contact everywhere between the heatplate and your surface not just around the bolts CONVECTION COOLING Several heat producing components inside the OEM300 are not attached to the heatplate They must dissipate their heat to the surrounding air The open top and bottom of the OEM300 allow air to circulate and carry heat away from these components If the openings are blocked air cannot circulate through the Power Module Heated air is not replaced by cooler air instead the air is motionless and heat builds up around the hot compo nents Mount the OEM300 properly to ensure adequate air circulation and to keep temperatures within acceptable limits Refer to Chapter Installation amp Operation for information on recom mended mounting patterns spacing between the Power Module and adjacent equipment and other issues Make sure the open top and bottom of the OEM300 are not obstructed 36 OEM300 Heat amp Thermal Management
54. quire at time t3 is 206W By staggering the move profiles we have substantially reduced the peak power requirements of the total system A fourth motor and drive could be added The OEM300 would easily have the capability to provide the necessary power no matter when the fourth motor s peak power demand occurred Even more drives and motors can be added If the moves are organized so that some motors are stopped while others are running the peak demand will be reduced Remember that a stopped motor still requires power in this example 22W The peak demand will also be reduced if some motors operate at a level that requires less than full peak or full slew power UNUSUAL POWER REQUIREMENTS So far the explanation of the calculation method has assumed that the power required during slew is substantially less than that required at peak acceleration This is not always the case For example the following drawing shows a graph of the power required by a motor while it moves a load against a large amount of friction 52 OEM300 Calculating How Many Drives Moving a load against a large amount of friction slew power is much greater m than when friction is negligible Unusual Power Requirements The demand for power rises as the load accelerates and stays near the peak level while the load moves at constant velocity A motor lifting a load against gravity would have a similar graph for its power require
55. sively hot The OEM300 will not be damaged but when its heatplate temperature exceeds 60 C the over temperature protection circuit will shut down the output of the OEM300 The second potential problem is related to the short circuit protection feature The OEM300 will produce currents above 4 0 Amps to satisfy brief demands but if it produces 6 0 Amps the short circuit protection feature will shut down the output within seconds If the current reaches 9 0 Amps how ever briefly the OEM300 will shut down immediately Operating the OEM300 beyond its specified range can cause unpredictable results Therefore to achieve optimum perfor mance from the Power Module connect the appropriate number of drives 55 Calculating How Many Drives 0 56 CHAPTER Troubleshooting WARNING NO USER SERVICEABLE PARTS INSIDE THE OEM300 The OEM300 contains potentially lethal voltages Do not attempt to repair it Return it to Compumotor for any repairs POSSIBLE PROBLEMS The first section below gives troubleshooting information for an that does not have drives connected to it Use the information in the second section to help you diagnose prob lems in a system with motors drives and an OEM300 No DRIVE IS CONNECTED OEM300 wiLL NOT TURN ON With AC power connected to the OEM300 the LED and 75VDC output should be as follows NORMAL OPERATION WITH PowER CONNECTED LED Should be Illuminated
56. tem operates less than half of the capability of the Power Module is being used The next section shows how to use the full capabilities of the Power Module and operate additional drives Independent Moves In this example we consider the same three motors as in the previous example This time however the move profiles are staggered so that the peak power requirements of each motor occur at different times Move profiles and power requirements for each motor are shown in the next drawing We assume there is no friction during slew 50 OEM300 Calculating How Many Drives Motor 1 Motor 2 K IN m Fe Motor 3 a Velocity 48W Motor 1 asaw 4o Motor 2 Motor 3 Total Power 206W at Time t3 Independent Move Profiles In this system when Motor 1 reaches its peak power at time t1 Motor 2 is beginning to accelerate and Motor 3 is stopped At time t3 Motor 3 accelerates to its peak power and Motors 1 and 2 are slewing 51 Calculating How Many Drives OEM300 The peak power required by this system occurs at time t3 Motors 1 and 2 each require 48W while slewing Motor 3 requires 110W during its moment of peak power These num bers can be found in the Power Requirements table We add each motor s power requirements Motor 1 48W Motor 2 48W Motor 3 110W TOTAL 206W The total power the three motors and drives re
57. ting slewing or decelerating Use the numbers from the table above to approximate the number of Watts each motor requires at that time Add up the Watts required by each motor to obtain the total power demand The OEM300 can provide 200W on a continuous basis and 300W peak for up to 30 seconds with a 1096 duty cycle Iden tify the periods when your system requires the most power and compare the power required with the amount of power the can deliver Remember there is a reservoir of additional power stored in the capacitors of the OEM300 If the peak power demand during acceleration of some motors briefly exceeds 300W the OEM300 may still be able to deliver enough power provided that the period of peak demand is short enough A DESIGN EXAMPLE To illustrate the calculation method we will determine how many OEM650 drives can be connected to one OEM300 Power Module when each drive runs an OEM57 83 motor a 23 frame size 2 stack step motor Because the number of drives that can be connected depends on the motors move profiles we will look at two situations The first example has move profiles that occur simultaneously The second example has move profiles that occur at different times Simultaneous Moves The drawing below shows the move profile and power require ments in a system where three motors simultaneously acceler ate until they reach maximum power then move at constant velocity We assume there is no
58. tion 37 38 R Reducing electrical noise 17 Regeneration 28 Removable connector AC input 12 DC output 13 Reserved pin 13 Returning OEM300 to Compumotor 59 RMA number 59 S Safety considerations 15 75VDC output grounds 15 75VDC pins 3 Shaft Power 44 Shielded power cables 18 Ship Kit 6 Short Circuit Protection 23 25 26 current levels 26 response time 26 Shutdown temperature 27 OEM300 Index 6 Pin Connector 6 13 Slewing Power Requirements 47 Spacing 8 Specifications for OEM300 21 24 Step Motors Power Requirements 47 Still Air Temperature Limits 24 Stopped Power Requirements 46 Switching Frequencies 17 Switching power supply 17 T Temperatures operating 24 Thermal hysteresis 27 Thermal interface 33 Thermal mass 33 Thermal probe 34 Thermal switch 27 Trip Temperature 27 Troubleshooting 57 59 Turning OEM300 on 19 Typical move profile 41 U Unusual Power Requirements 52 User Guide 6 V Ventilation 37 38 Voids in Thermal Interface 36 Voltage Range AC Input 12 Voltage Regulation 22 Warnings VI Warped Heatsink 35 Where Power is Used 41 Wire Size AC Input 12 Wire Size DC Output 13 Worst Case Method 40 63 OEM300 POWER MODULE The OEM300 is NOT a WARNING general purpose power NO USER SERVICEABLE PARTS INSIDE supply Use it only with The OEM300 contains potentially lethal Compumotor OEM voltages Do not attempt to repair it Return Series Microsteppin
59. ts 47 Calculation Method 41 53 Cautions VI Compumotor DC 4 18 Conduit 18 Connecting Multiple Drives 16 Connectors 6 Continuous Power Output 22 Controlling electrical noise 17 Convection Cooling 36 38 Copper Losses 42 Core Losses 43 Current limiter 22 Current probes 54 Current sharing 17 Cycle power definition 26 D DC 4 18 DC Output Connector 13 DC Output Specifications 22 Decelerating Power Requirements 47 Description of OEM300 2 Design Issues 3 cooling 4 how many drives 4 Dimensions 7 Drive Losses 42 Drives How many can OEM300 operate 39 55 Duty cycle 22 E EARTH ground 15 Efficiency 22 Electrical Noise Control 17 Electro Magnetic Interference 18 Electromagnetic radiation 18 EMI 18 EMI filters 18 External filter 17 Extra capacitors 18 F Fan for ventilation 37 Features of OEM300 2 Filters 17 5 Pin Connector 6 12 67 index 0 6 Green LED 9 Ground loops 15 Ground pins 13 Grounding 15 H Heat sinking surface 35 Heatplate Cooling 33 36 Heatplate Temperature Limit 24 34 Heatsink Calculations 35 Heatsink Problems 35 36 How Many Drives to Connect 39 55 Hysteresis 27 Input Connector 12 Input Filter 17 21 Input ground 15 Input Specifications 21 24 Input Voltage 21 Inrush Current 22 Installation 7 18 Internal connections 14 J Jumper wire 11 58 L Latched Definition 26 LED 19 Linear power supply 18 Load regeneratio
60. w To Use OEM PRODUCTS The products have a basic set of features that the OEM can configure to meet varied needs The products are not shipped as ready to use units Compumotor assumes that the OEM system designer will make design and engineering decisions to properly use the equipment THIS MANUAL PROVIDES INFORMATION NECESSARY TO MAKE ENGINEERING AND DESIGN DECISIONS ABOUT PROPER USE OF THE OEM300 POWER MODULE Introduction OEM300 OEM Series Drives OEM300 Power Module OEM Series Motors OEM Series Products A Typical System OEM300 POWER MODULE FEATURES The OEM300 Power Module is optimized to provide power to Compumotor s OEM Series of microstepping drives and servo products It contains a dual range power supply that can oper ate at 120VAC or 240VAC at 50 60 Hz The voltage output of the OEM3OO is fixed at 75VDC It can produce 2 7A continuous and 4 0A peak and provides power for drives and motors The OEM300 will power two OEM650 Drives each running a Compumotor 83 135 step motor It can power as many as five OEM650 Drives each running 57 40 step motors It can power OEMO70 Servo Drives running servo motors as large as 1 2 OEM300 Introduction horsepower 373 watts The total number of servo drives is limited by the total power demand The Power Module is compact It occupies the space of two OEM drives and mounts similarly to the drives Its small footprint conserves space in equipment c
61. wer is turned off while the Power Module cools down TRIP TEMPERATURE 65 C x 5 149 F x 9 F DESIGN TIP Use 60 C 140 F as the maximum heatplate temperature allowed for continuous operation of the Power Module Because of the manufacturing tolerance on the thermal switch different units will shut down at different temperatures in the 60 C to 70 C range 140 F to 158 F For predictability use 60 C 140 F as the shutdown temperature HYSTERESIS The thermal switch used by the over temperature protection circuit has built in thermal hysteresis The switch will open at 65 C x 5 149 F x 9 F and shut down power to the OEM300 It will not close until it has cooled to approximately 30 C 86 F This means that the OEM300 will not operate again until it has had adequate time to cool TROUBLESHOOTING NOTE If the OEM300 shuts down be cause of excessive heatplate temperature the heatplate must cool below 30 C 86 F before the unit can be restarted Turn off AC power while the OEM300 cools 27 Q Protective Circuits in the OEM300 OEM300 POWER DUMP During normal use a motor consumes power from a power supply During deceleration or a free wheeling shutdown however the motor becomes a generator and produces energy This energy must go somewhere It travels through the cables and drive and back to the power supply where it enters the supply through the output terminals This phenomenon is call
62. your system take mea surements after the system has run long enough to reach steady temperatures As the next drawing shows place your thermal probe directly on the heatplate not the heatsink to which it is attached amp For accurate temperature measurements do not place thermal probe on heatsink Instead position thermal probe on the heatplate HEATPLATE Measuring Heatplate Temperature Do not assume that the heatplate and heatsink are at the same temperature If the thermal interface between them is not good heat may not transfer from the heatplate to the heatsink If heat is not leaving the heatplate its temperature can become very high while just a few inches away the heatsink is much cooler 34 OEM300 Heat amp Thermal Management Issues In this situation if you place a thermal probe on the heatsink you might read an acceptable temperature This could lead you to think your system is within limits but it is not Therefore make sure you place the probe on the heatplate This will give you the most accurate temperature information about your system HEATSINK CALCULATIONS To cool the heatplate of the OEM300 mount the Power Module to a heatsink Or you may prefer to mount the Power Module directly to a heat sinking surface such as the metal wall of an equipment cabinet Your heatsink or heat sinking surface should satisfy this equa tion 60 C T lt

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