CXB Amplifier Operation and Service Manual (909KB PDF)
Contents
1. ENCODE ENCODEL 5 RANGE AH AL MOTOR AH AL RESET AH AL INHIBIT AH amp L LIMIT PU PD RESET FU FD INHIBIT PU PD LIMIT MMON LIMIT MPENSATION TACHOMETER DIFFERENTIAL SIG INGLE ENDED 5 46 8900 Zachary Lane N Maple Grove MN 55369 U S A 5 8900 Zachary Lane N Maple Grove MN 55369 U S A 47 1525 and 2040 MANUAL NOTES 48 8900 Zachary Lane N Maple Grove MN 55369 U S A High Bandwidth Brush Servo Amplifiers e Linear Brush type servo amplifiers to 2 25KW e PWM Pulse width modulated Brush type servo amplifiers to 70K W High Bandwidth Brushless Servo Amplifiers e Linear Brushless servo amplifiers to 2 25K W e PWM Pulse width modulated Brushless servo amplifiers to 65KW Permanent Magnet DC Brush Type Servo Motors e Continuous Torques to 335 in Ib e Peak Torques to 2100 in Ib Permanent Magnet DC Brushless Servo Motors e Continuous Torques to 1100 in Ib e Peak Torques to 2200 in Ib PHONE 612 424 7800 FAX 612 424 87342. APPENDIX PERSONALITY MODULE 8900 Zachary Lane N Maple Grove MN 55369 U S A 43 1525 and 2040 MANUAL 31 SOLON i 135 11074 1x3 amp IH 440 N3 VH Tos Joa lt NE 8900 Zachary Lane N Maple Grove MN 55369 U S A 44 3S0LUTE DIGITAL AP AA BAKA A seid T m RESOLUTION BIT 8900 Zachary Lane N Maple Grove MN 55369 U S A 45 1525 and 2040 MANUAL REF PHASE DIFFERENTIAL SIGNAL GAIN SINGLE ENDED SIGNAL GAIN TACH SIGNAL BALANCE RRENT LIMIT MOTOR INDE EXCITATION EXCITATION RTN JSINE INE INE RTN INE 2MMOM IDE INDE ENCODER B ENCODER
3. 8900 Zachary Lane N Maple Grove MN 55369 U S A
4. twisted pair shielded RESOLVER OUTPUTS and EXCITATION 22AWG three twisted pairs over all shielded 4 3 3 Connector Size and Type 4 3 3 1 The Power and Motor Connector of the Stand Alone Amplifier e Motor J2 of the Stand Alone Amplifier EE Connector PHOENIX CONTACT COMBICON Plugs in 7 62mm Itc P N GMVSTBR 2 5 3 ST 7 62 with vertical plug in direction to the conductor axis 3 positions Color green Power Input J6 of the Stand Alone Amplifier uin Connector PHOENIX CONTACT COMBICON Plugs in 7 62mm Pitc P N GMVSTBW 2 5 4 ST 7 62 with vertical plug in direction to the conductor axis 4 positions Color green 22 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 4 INSTALLATION 4 3 3 2 The Signal Connector The signal connectors are supported by the molex 100 2 54mm Centerline Connector System A of MAIN AMP B MATING CONNECTOR 2695 Series 100 2 54mm Center Crimp Terminal Housing PART 22 01 3175 red nylon housing 15 positions with polarizing rib CRIMP TERMINALS molex Crimp Terminals PART 08 55 0102 15 microinch select gold plated brass J4 and J5 of SINE RESOLVER PRE AMP J4 has and J5 has 5 pins and their corresponding mating connectors have 7 and 5 positions Their molex part numbers are as follows J4 MATING CONNECTOR PART NUMBER 22 01 3077 Js MATING CONNECTOR PART NUMB
5. 240 VAC line input 8900 Zachary Lane N Maple Grove MN 55369 U S A 9 1525 and 2040 MANUAL 1 3 SPECIFICATIONS This section contains the specifications for the brushless trapezoidal sine resolver and two or three phase input current mode D C Servo Amplifiers These specifications also include power supplies for the amplifiers NOTE All data in this section is based on the following ambient conditions 120 F 50 C maximum Forced air cooling 1 3 1 STAND ALONE ONE AXIS AMPLIFIER The stand alone one axis amplifier contains a single amplifier module a DC power supply a cooling fan fusing and shunt regulator in a sheet metal enclosure The shunt regulator within the DC power supply has a 50W internal load resistor bank which bleeds off excess DC Buss voltage when decelerating a large load inertia An external shunt regulator resistor can be connected Consult with factory NOTE Customer must specify the input AC voltage 105 120VAC 205 250VAC when ordering see chapter 3 model numbering so that the proper fan can be installed 1 3 1 1 Input and Output Power Input Power Output Power Buss Voltage B current CXB1525 CXB2040 120VAC 170VDC 1 3 1 2 Signal Inputs Signal Input Minimum Velocity Gain Current Gain Impedance Amp Volt Amp Volt 5 Series Differential 10 000 15 000 min CXB Series Single ended 10 000 15 000 min 10 8900 Zachary Lane N Maple Grove MN 55369 U
6. J4 6 Negative phase Z signal output COM J4 7 Common ground RESOLVER J5 SIN 15 1 Sine signal input COM J5 2 Sine Cosine return COS J5 3 Cosine signal input COM J5 4 Excitation return EXC J5 5 Excitation signal input 4 5 STAND ALONE AMPLIFIER INPUT POWER CONNECTIONS Aside from the single amplifier module connections a stand alone amplifier also consists of the following connections SIGNAL NAME TERMINAL NOTES GND J6 1 Ground AC J6 2 AC Power Input AC J6 3 AC Power Input Single Phase L2 AC J6 4 AC power input Single Phase L1 8900 Zachary Lane N Maple Grove MN 55369 U S A 25 1525 and 2040 MANUAL CHAPTER FIVE CONFIGURATION 5 1 INTRODUCTION Each amplifier has several configuration options This chapter describes these options and how to implement them If desired CONTREX will be happy to pre configure your amplifiers NOTE Each amplifier module is configured and shipped according to the model number instructions to construct a model number is in chapter three when the order is placed It is important for the user to realize that any adjustment on the dip switches by the user will result in discrepancies between the model number and the actual configuration of the amplifier 5 2 LOGIC INPUT CONFIGURATION There are five logic inputs Limit Limit Inhibit Reset In Motor Temp The first four may be configured for active
7. RV8 full CW Motor should be stopped or turning slowly Set Balance RV5 for 0V at ABS I J1 7 32 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 6 START UP AND CALIBRATION Connect the oscilloscope to ABS I J1 7 and the battery box to the Signal 2 Single ended Input J1 3 and J1 4 The voltage on J1 7 is a function of motor current 1V 10A While pulsing a step input voltage adjust the Current Limit for the desired peak current If the desired peak current cannot be achieved with the pot full CW increase the input voltage or increase the Signal 2 Gain RV3 With battery box still connected at J1 3 and J1 4 for single ended input or if your system uses the differential input move battery box to J1 1 and J1 2 set the battery box for a known DC voltage Apply input signal pulses and adjust the Signal 2 Gain pot or RV1 for differential input to obtain the desired current gain of the amplifier If the motor is rotating the wrong direction for a given input polarity turn the Loop Gain pot full CCW Switch MTR REVERSE 51 4 from OFF to ON or vice versa Turn the Loop Gain pot back to full CW Remove battery box and repeat step 3 Calibration complete Reconnect signal wires 8900 Zachary Lane N Maple Grove MN 55369 U S A 33 1525 and 2040 MANUAL 6 4 CALIBRATION SETUP RECORD It is good practice to keep a record of all pot settings Doing so will facilitate calibration o
8. and off time determines the average motor current Refer to figure 2 1 For example if the output is on 25 of the time and off 75 of the time the average motor current is approximately 25 of maximum A coil of wire such as the windings of a motor forms an inductor Inductors resist changes in current This resistance to change known as reactance acts to dampen or average the high current spikes that would otherwise occur when the output devices are on In fact if motor inductance is low external inductors may have to be added in series with each motor lead to ensure proper operation Figure 2 1 Pulse Width Modulation Waveform 12 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 2 THEORY OF OPERATION 2 3 SERVO LOOPS A basic velocity mode servo loop for a brush type motor is shown in figure 2 2a An external controller commands a given velocity RPM The velocity loop summing amplifier compares this command with the actual motor velocity supplied by a DC tachometer on the motor shaft and produces an error voltage proportional to the difference between the actual and commanded velocity The velocity error is used to command motor current in the inner servo loop The current loop summing amplifier compares the command current velocity error with the actual current in the motor and produces an error voltage proportional to the difference between the actual and commanded current Finally the current error signal
9. common sensor types are Hall effect sensors and an optical encoder with commutation tracks A common class of applications for trapezoidal amplifiers is for motor speed control Classically this is implemented by adding a brushless DC tachometer to the motor shaft and driving the motor through a velocity controlled servo loop A high performance velocity loop can be implemented in this manner Another way of implementating the motor speed control is by using a simulated digital tachometer synthesized by the motor commutation signals The commutation signals are used to trigger one shot signal at every transition of the commutation signals After smoothing a voltage proportional to velocity RPM is obtained Two additional system features were implementated in the synthesized tachometer design 1 At 100 of full RPM the PSEUDO TACH voltage is limited by the power supply voltage If an RPM 1 commanded above 100 RPM the servo will run away To prevent this from occuring the absolute value of the PSEUDO TACH signal 15 compared to a 95 of full RPM reference If the PSEUDO TACH signal exceeds this value an over speed latch is set and the servo is disabled The PSEUDO TACH one shot pulse is buffered and brought to the control interface The controller can use this signal to determine the exact velocity RPM of the motor 2 7 CURRENT MODE vs VELOCITY MODE The fundamental difference between current mode and velocity mode is that in cur
10. requirements as well as suppressing RFI EMI Additional RFI suppression may be obtained by placing inductors in each motor lead near the amplifier Consult a CONTREX applications engineer for inductor recommendations CONTREX stocks a complete line of inductors for virtually every application IMPORTANT The signal wiring to the resolver and the signal inputs to the amplifier are susceptible to noise pickup Excessive noise pickup will cause erratic amplifier operation We urge that each signal input be run in a twisted pair shielded cable The hall sensor signal lines the resolver excitation lines and the resolver output lines should be run in a three twisted pair shielded cable In each case the shield should be terminated at the amplifier end only to a common terminal We also recommend that the signal lines be kept as far as possible from any power or motor wires 8900 Zachary Lane N Maple Grove MN 55369 U S A 21 1525 and 2040 MANUAL 4 3 2 Wire Size and Type IMPORTANT To ensure safe operation CONTREX strongly recommends that all wiring conform to all local and national codes RECOMMENDED WIRE SIZE and TYPE MOTOR WIRES 14A WG shielded STANDARD 12AWG shielded HIGH POWER MOTOR CASE GND Same as motor wires or use metallic conduit MAIN POWER Same as motor wires SIGNAL INPUT 22AWG twisted pair shielded LOGIC INPUTS OUTPUTS 22AWG shielded with its return lead EXTERNAL TACHOMETER 22
11. OFF To measure pot settings RV8 must be set fully CCW and AC power must be off m Before making adjustments to the pot settings please consult CONTREX Inc MAX RPM 5 1650 1 TABLE OF CONTENTS and alone Amp 3 LI Input and Output 1 LZ SS Vr a a a ee ee zc 3 1 5 Digital Inputs 1 3 1 4 System 1 3 1 5 Outputs 1 3 2 Mechanical CHAPTER TWO THEORY of OPERATION 8900 Zachary Lane N Maple Grove MN 55369 U S A 1 1525 and 2040 MANUAL CHAPTER THREE MODEL NUMBERING 1 INTRODUCTION B 2 STAND ALONE AMPLIFIER 3 2 1 Sine Resolver Mode CHAPTER FOUR INSTALLATION INTRODUCTION MOUNTING WIRING 2 8900 Zachary Lane N Maple Grove MN 55369 U S A TABLE CONTENTS CHAPTER FIVE CONFIGURATION 1 15V 5V Logic Level Configuration 2 ness 83 3 on Teuration 3 5 PLD Bit CHAPTER SIX START UP AND CALIBRATION 8900 Zachary Lane N Maple Grove MN 55369 U S A 3 1525 and 2040 MANUAL 2 g 2 3 Motor Over Temp Fault 2 4 PA PRE Circuit Breaker HS ECB Fault ni ircuit Breake ECB 7 2 7 Voltage Fault 7 2 8 Resetting A Fault 3 AMPLIFIER FAILURE 4 FACTORY REPAIR 5 WARRANTY 4 8900 Zachary Lane N Maple Grove MN 55369 U S A TABLE CONTENTS APPENDIX A AMPLIFIER DRAWINGS STAND ALONE AMPLI
12. S A CHAPTER 1 DESCRIPTION FEATURES AND SPECIFICATIONS 1 3 1 3 Digital Inputs Limit Inhibit amp Reset 40 0 5 V max Terminated by 10 0008 Fault as input 40 0 5V max Terminated by 10 0005 Typical for all digital inputs Digital inputs have hysteresis with thresholds at 1 3 and and 2 3 of 5V or 15V depending on range select jumper 1 3 1 4 System Drift offset over temperature reference to input 0 01mV C max Frequency response Velocity loop 750Hz min Frequency response Current loop 2KHz min Dead band None Form factor 1 01 1 3 1 5 Outputs Fault as output Active low Open collector output can sink 500mA max Absolute motor current J1 3 10A V Tachometer 1000S source impedance a high input impedance meter must be used 1M S volt Maximum Tachometer output voltage for 12 bit 1 5V KRPM 14 bit 2V KRPM Encoder outputs Standard TTL levels with 20mA sink or source capability SMA8215 1 3 2 Mechanical Model LxWxH Weight inches 165 CXB1525 Stand Alone Amplifier 9 025 x 4 00 x 4 96 2040 Stand Alone Amplifier 9 025 x 4 00 x 4 96 8900 Zachary Lane N Maple Grove MN 55369 U S A 11 1525 and 2040 MANUAL CHAPTER TWO THEORY of OPERATION 2 1 INTRODUCTION This chapter contains the basic control theory of how brush type and brushless servo motors and amplifiers operate It also compares and contrasts the advantages and disadvantages of brush
13. TYPE MOTO Figure 2 3 Brush type and Brushless type Motors 14 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 2 THEORY OPERATION BRUSHLESS MOTORS AMPLIFIERS BRUSHED MOTORS AMPLIFIERS ADVANTAGES No scheduled maintenance and no brush dust is generated Higher RPM limits Lower inertia torque ratio Dissipates heat more efficiently due to windings being located in stator Safer for explosive atmospheres Quieter and less electrical noise generated DISADVANTAGES Amplifiers are complicated and expensive Higher torque ripple DISADVANTAGES Motor brushes must be checked periodically for wear and excess brush dust Approximately 3000RPM maximum Higher inertia to torque ratio Not as efficient at dissipating heat Heat is trapped at rotor and shortens bearing life Brushes spark and generate electrical and audible noise No Industry standard packaging ADVANTAGES Amplifiers are simpler and less expensive Lower torque ripple Industry standard packaging 2 5 SINUSOIDAL vs TRAPEZOIDAL Figure 2 4 shows the two most common waveforms used to drive a brushless motor Note that in each case there are actually three different waveforms Each waveform drives a motor winding and is 120 out of phase with the other two Again the waveform may be generated from a DC source by linear or PWM techniques Figure 2 4 Trapezoidal an
14. amp 8000 1431 for the sine resolver mode IF AMPLIFIER IS A REPLACEMENT OR ORDERED WITHIN A KIT CALIBRATION IS USUALLY NOT NEEDED Calibration requires an oscilloscope a voltmeter and a step voltage source The step source may be a flashlight battery or floating power supply with a series switch A servo system calibrator known as a Battery Box which includes an adjustable bipolar output reversing switch and pulse switch will facilitate calibration and repair A Battery Box is available from CONTREX part number BB 700 Critically Under damped Over damped damped Too much Tach Not enough Tach or not enough or too much Bandwidth Bandwidth Figure 6 1 Critically Under and Over damped waveforms 6 2 SAFETY PRECAUTIONS Before starting calibration the following safety precautions should be observed Check for any loose or damaged components Check that all connections are tight Be sure that the motor mechanism is clear of obstructions If the mechanism has limited motion e g a lead screw set the mechanism to mid position Disconnect the signal and auxiliary inputs Be sure the Loop Gain pot s are fully CCW Remove input fuses on the baseplate and apply main power Check for the correct AC voltage at fuses The motor supply voltage will be 1 4 times this value Remove power and reinstall fuses Work on only one amplifier at a time 30 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 6 START UP AND CA
15. high or active low signals and pulled up or pulled down termination type A B C and D The motor temp may be configured for active high or active low signals and is always pulled up type A and C All five logic inputs have a selectable 0 to 5VDC or 0 to 15VDC range Type A Requires grounding of input to disable the amplifier pull up active low Requires a positive voltage at input to disable the amplifier pull down active high Type C Requires grounding of input to enable the amplifier pull up active high Type D Requires a positive voltage at input to enable the amplifier pull down active low 26 8900 Zachary Lane N Maple Grove MN 55369 U S A 5 3 SINE RESOLVER MODE AMPLIFIER CONFIGURATION CHAPTER 5 CONFIGURATION The following table shows the dip switches that need to be configured for the Type A B C and D configurations The standard configuration is shown in bold LIMIT 52 8 OFF 52 5 ON 52 8 ON 52 5 OFF 82 8 OFF 52 5 OFF 52 8 ON 52 5 ON INHIBIT 82 7 OFF 52 4 ON 82 7 ON 52 4 OFF 82 7 OFF 82 4 OFF 52 7 ON 52 4 ON RESET IN 82 6 OFF 52 3 ON 52 6 52 3 52 6 52 3 52 6 52 3 52 2 ON not available 52 2 OFF not available FAULT standard not available not available not available 5 3
16. made to the 8000 14 Sine Resolver pre amp Refer to Appendix drawings 8000 1430 and 8000 1431 Connect and configure the amplifier as described in the installation section Do not apply power yet Loosen the resolver mounting screws just enough to allow the resolver to be adjusted Note the positions of S3 1 53 2 53 3 and 53 4 then set 53 1 53 2 53 3 and 53 4 for index i e S3 1 ON S3 2 OFF 53 3 and S3 4 OFF Make sure the amplifier is in current mode S1 7 OFF and S1 8 ON and set S1 4 to the ON position Apply power Adjust the motor shaft until the red index LED lights Slowly apply signal input voltage SIGNAL 1 and SIGNAL 1 1 amp 11 2 for differential input or SIGNAL 2 and COMMON J1 3 amp J1 4 for single ended input until the motor shaft becomes reasonably stiff then it can not be easily adjusted Use Caution This procedure is applying continuous current to the motor An excessive CW setting may result in motor damage The motor will rotate to the correct index position The amount of rotation will be proportional to the alignment error Slowly rotate the resolver CW or CCW until the index LED is constantly illuminated Tighten the resolver mounting screws the LED should still be on Turn the power off Restore dip switches S3 1 53 2 53 3 and 53 4 for the number of poles for the motor being used Set S1 4 OFF If the amplifier is to be operated in velocity mode then set S
17. quick and as accurately as possible 3 2 STAND ALONE AMPLIFIER MODULES 3 2 1 SINE RESOLVER MODE 3 2 2 SINE RESOLVER MODE CXB1525 CXB2040 YYYYYYY 1A 1 ZZ RRR Amplifier Model Number Pre amp Configuration Code Optional Custom Configuration Code for the amplifier module Stand alone amplifier designator 1 amplifier module mounted Optional Custom Configuration Code for the power supply and the regen circuit Power Supply Configuration CodeStand 00 120VAC 1 PHASE IN 170VDC BUSS 01 120VAC 3 PHASE IN 340VDC BUSS 02 240VAC I PHASE IN 340VDC BUSS 03 240 VAC 3 PHASE IN 340VDC BUSS 18 8900 Zachary Lane N Maple Grove MN 55369 U S A CONFIGURATION CODE CHAPTER 3 MODEL NUMBERING 4 BIT BINARY TO DIGIT CONVERSION 0000 0 1000 8 Number of S3 1 53 2 S3 3 S3 4 PLD DEVICE ENCODER RESOLUTION 0001 1 1001 9 Motor Poles CODE See section 5 3 3 0010 2 1010 A See section 5 3 4 See 5 3 3 0011 3 1011 B 2 1 1 1 1 01010 256 250 128 125 0100 4 1100 4 1 1 1 0 0 0 1 1
18. resolution may be changed at any time to a resolution which requires the same or fewer bits Increasing the bits increases the possible encoder resolution but decreases the maximum motor RPM refer to Section 5 3 5 28 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 5 CONFIGURATION 5 3 4 Motor Pole Configuration Dip switch 53 1 53 2 53 3 and 53 4 configures the pre amp for the number of poles in the motor They are also used to set up certain calibration modes Refer to the chart below and set the dip switches for the correct number of poles MOTOR 93 2 93 3 53 4 un P 2 2 POLE ON ON ON 2 4 2 6 POLE 2 8 2 10 2 12 2 O O O O O O O O 2 INDEX 5 3 5 PLD BIT Configuration MAX TACH VOLTS RPM V 1000 RPM 62 400 0 13 31 200 0 26 15 000 0 5 7 800 1 0 3 900 2 0 1 950 4 0 The Tach Volts V 1000RPM are given for the MAX RPM of the BIT resolution Consult a CONTREX applications engineer should you have any questions 8900 Zachary Lane N Maple Grove MN 55369 U S A 29 1525 and 2040 MANUAL CHAPTER SIX START UP AND CALIBRATION 6 1 INTRODUCTION This chapter contains the procedure required to calibrate and set up the amplifier All adjustments are made on the pre amp Refer to Appendix B drawing 8000 1430
19. speed command to the CXB amplifier Slowly rotate the Loop Gain pot CW from its present off full CCW position to the on position full CW The motor shaft should now hold position If the motor acts erratically or runs at high speed turn the Loop Gain pot full CCW shut off power and check wiring Consult CONTREX Inc if application assistance is needed When in doubt do not hesitate to put all adjustments back to the recorded settings and start over You may now move on to the M Series calibration SK1651 Rev 1 CALIBRATION SETUP RECORD Model CXB1525 CXB2040 Brushless Servo Amplifier System Date Model Number Serial Number Customer Order Number ENCODER Resolution DIP SWITCH CONFIGURATION Dip Switch 51 52 53 1 ON OFF ON OFF ON OFF 2 ON OFF ON OFF ON OFF 3 ON OFF ON OFF ON OFF 4 ON OFF ON OFF ON OFF 5 ON OFF ON OFF ON OFF 6 ON OFF ON OFF ON OFF 7 ON OFF ON OFF ON OFF 8 ON OFF ON OFF ON OFF POTENTIOMETER SETTING Pot Name of Pot Test Point Setting Ohms Notes RV2 SIGI J3 A to J3 F Sets MAX speed of motor Signal 1 5162 J3 B to J3 F Shipped fully CCW Signal 2 RV4 TACH J3 C to J3 F Sets system bandwidth Tach Gain RV5 BAL N A Used to null any offsets in Balance system RV6 COMP J3 D to J3 F Sets system bandwidth Compensation ILIMIT J3 E to J3 F Sets Maximum motor current Current Limit RV8 LOOP N A Shipped fully CCW Loop Gain
20. thereof manufactured by CONTREX Inc described in this manual which under normal operating conditions in the plant of the original purchaser thereof proves defective in material or workmanship within one year from the date of shipment by us as determined by an inspection by us will be repaired or replaced free of charge FOB our factory Maple Grove Minnesota U S A provided that you promptly send to us notice of the defect and establish that the product has been properly installed maintained and operated within the limits of rated and normal usage and that no factory sealed adjustments have been tampered with CONTREX liability is limited to repair or replacement of defective parts Any product or part manufactured by others and merely installed by us such as an electric motor etc is specifically not warranted by us and it is agreed that such product or part shall only carry the warranty if any supplied by the manufacturer of that part It is also understood that you must look directly to such manufacturer for any defect failure claim or damage caused by such product or part Under no circumstances shall CONTREX Inc or any of our affiliates have any liability whatsoever for claims or damages arising out of the loss of use of any product or part sold to you Nor shall we have any liability to yourself or anyone for any indirect or consequential damages such as injuries to person and property caused directly or indirectly by the produ
21. 024 1000 512 500 0101 5 1101 D 6 1 1 0 1 0 1 0 4096 4000 2048 2000 0110 6 1110 E 8 1 1 0 0 0 1 1 3600 2160 720 360 10 1 0 1 1 1 010 NA NA 625 0111 7 1111 F 12 1 0 1 0 1 041 1250 U 0 amp L 0 DEFAULT 1 1 0 NA NA NA 2500 B D 1 amp H 1 1 111 NA SPECIAL U 0 amp 1 61 10 i i D Di 51210 1 0 1 RESOLUTION Limit 0 L 1 H See 5 3 3 Limit 0 U 1 D 9 9 10 BIT 0 1 12 BIT Inhibit 02L 1 H 110 14 BIT Inhibit 0 0 1 D Reset 0 L 1 H Reset 0 0 1 D t 15V 5V on pull up 0 15 1 5V Motor Temperature 1 Type C 0 Type A DEFAULT 0 Differential or Single ended inputs 0 Single 1 Differential Velocity or Current Mode see sect 2 7 0 Velocity 1 Current Motor Reverse 1 ON 0 OFF DEFAULT 0 Tach Reverse 1 0 OFF 0 DEFAULT L1 DC BUSS VOLTAGE 0 70 240 VDC 1 240 350 VDC y m 22 SPECIAL p 8900 Zachary Lane N Maple Grove MN 55369 U S A 19 1525 and 2040 MANUAL THIS PAGE LEFT BLANK INTENTIONALLY 20 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 4 INSTALLATION CHAPTER FOUR INSTALLATION 4 1 INTRODUCTION This chapter provides the necessary information to make all the wiring connections for the amplifiers to operate properly 4 2 MOUNTING Appendix A contains all the wiring diagrams assembly drawings and mechanical information nec
22. 1 15V 5V Logic Level Configuration DEFAULT S2 1 OFF 15V 52 1 OFF 5V 52 1 5 3 2 Configuration for Sine Resolver Velocity Mode and Current ode DIP SWITCH VELOCITY MODE CURRENT MODE ENCODER 2 ENCDR 125 128 5 3 3 5 3 3 NOT USED MTR REVERSE TACH REVERSE normally OFF normally ON INTEGRATOR VEL MODE normally OFF CUR MODE 8900 Zachary Lane N Maple Grove MN 55369 U S A 27 1525 and 2040 MANUAL 5 3 3 Encoder Output Resolution Configuration Refer to Appendix B drawing 8000 1430 and 8000 1431 There are nineteen standard resolutions Up to four resolutions are contained in a single PLD To configure the pre amp for a given resolution ensure that you have the correct PLD U13 and then configure the dip switches S1 1 and S1 2 as shown below Resolution PLD PART NUMBER 8000 1212 8000 1212 8000 1212 8000 1212 F F F F O O 8000 1213 8000 1213 O 8000 1213 8000 1213 O N F N F N F N F N F F F O O O O O O O OF 8000 1218 N 8000 1218 OF 8000 1218 N 8000 1218 OF 110 ON ON 8000 1217 10 10 10 10 12 12 12 12 8000 1214 14 8000 1214 14 8000 1214 ON 14 8000 1214 14 12 12 14 14 14 The BITS refer to the Resolver to Digital resolution which must be factory configured Encoder
23. 1 7 ON and S1 8 OFF Turn the power back on and apply a signal input command while monitoring the DC voltage at the tach out J1 5 with a digital voltmeter and record this voltage Now reverse the polarity of the signal input command and record this voltage NOTE Be sure to set the tach out voltage for 1000 RPM 12 14 bit resolution 11 If the difference between both of the above readings is less than 100mV the motor is ready to operate However if the difference is greater than 100mV proceed to step12 Loosen the resolver mounting screws Alternately apply a positive and negative signal input command while monitoring the tach out voltage at J1 5 Rotate the resolver body slowly back and forth until the difference between both tach out voltage readings is less than 100mV Tighten the resolver mounting screws and turn the power off Resolver alignment complete 36 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 7 MAINTENANCE REPAIR and WARRANTY CHAPTER SEVEN MAINTENANCE REPAIR and WARRANTY 7 1 MAINTENANCE Contrex amplifiers do not require any scheduled maintenance although it is a good idea to occasionally check for dust build up or other contamination 7 2 AMPLIFIER FAULTS If an amplifier should cease to operate and one or more of the fault LED s are lit review the sections which follow on the fault in question for information and possible causes A FAULT CAN ONLY BE CAUSE
24. D BY ABNORMAL CONDITIONS LOCATE AND CORRECT THE CAUSE OF THE FAULT BEFORE REPEATED RECYCLING OF POWER TO THE AMPLIFIER TO PREVENT POSSIBLE DAMAGE 7 2 1 Table of Fault LED Conditions INPUT OR FAULT RUN HS ECB LS ECB OVER VOLT OVER TEMP FAULT CONDITION LED LED LED LED LED OUTPUT NORMAL ON OFF OFF OFF OFF OPERATION LIMIT ON ON OFF OFF OFF OFF LIMIT ON ON OFF OFF OFF OFF INHIBIT ON ON OFF OFF OFF RESET IN ON OFF OFF OFF EXT FAULT ON OFF OFF OFF UNDER VOLTAGE OFF OFF OFF 15V HS ECB LATCHED OFF OFF OFF LS ECB LATCHED ON OFF OFF OVER VOLTAGE B ON OFF LATCHED OVER TEMP ON LATCHED 8900 Zachary Lane N Maple Grove MN 55369 U S A 37 1525 and 2040 MANUAL 7 2 2 Under Voltage Fault When the 15VDC is below 12VDC a level that would cause unreliable operation the Run LED will turn off a Fault Output is generated and the amplifier is inhibited This is not a latched condition that is if the problem is resolved the amplifier will resume operation The following is a list of possible causes 1 Main AC line voltage is too low 2 Bad rectifier bridge 3 Bad DC buss filter capacitor 7 2 3 Motor Over Temp Fault When the motor temperature has reached a level that if exceeded would damage the motor the Run LED will turn off the OVER TEMP LED will turn on and a Fault Output is generated and the amplifier is
25. ER 22 01 3057 8900 Zachary Lane N Maple Grove MN 55369 U S A 23 1525 and 2040 MANUAL 4 4 SINGLE AMPLIFIER MODULE CONNECTIONS 4 4 1 Main Amplifier Module Sine Resolver Mode SIGNAL NAME TERMINAL NOTES MOTOR J2 3 Phase R of the motor MOTOR 5 J2 2 Phase S of the motor MOTOR T J2 1 Phase T of the motor SIGNAL 1 J1 1 Differential signal input SIGNAL 1 Differential signal return SIGNAL 2 Single ended signal 2 in COMMON Single ended signal2 return TACH OUT DC output proportional to RPM COMMON Tachometer common ABS I Absolute value of the motor current 10A V LIMIT Inhibits the motor in direction LIMIT Inhibits the motor in direction INHIBIT Inhibits the motor in both directions FAULT Goes low for a fault on this amplifier or inhibits the amplifier when forced low COMMON Digital common RESET IN Resets fault latch MTR TEMP Motor over temperature switch input UNUSED 24 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 4 INSTALLATION 4 4 2 Pre amp Module Sine Resolver Mode SIGNAL NAME TERMINAL ENCODER J4 J4 1 Phase A signal output J4 2 Negative phase A signal output J4 3 Phase B signal output J4 4 Negative phase B signal output J4 5 Phase Z signal output
26. FIER INSTALLATION DRAWING FOR SINE RESOLVER MODE BRUSHLESS AMPLIFIER 8015 1036 APPENDIX B PERSONALITY MODULE SINE RESOLVER MODE SCHEMATIC 8000 1430 SINE RESOLVER MODE ASSEMBLY 8000 1431 8900 Zachary Lane N Maple Grove MN 55369 U S A 5 CXB1525 and CXB2040 MANUAL INTRODUCTION CONTREX brushless motors and amplifiers offer the ultimate in low maintenance and high performance motion control CONTREX offers a full line of matched motors and amplifiers to meet virtually every motion control application This manual provides all the technical information necessary to install configure operate and maintain our TORQUE SWITCH series brushless servo motor amplifiers models CXB1525 and CXB2040 These amplifiers contain the high performance of sinusoidal motor current with the efficiency of pulse width modulation PWM We suggest that you take the time to read this manual from cover to cover before attempting to work with these amplifiers for the first time If at any time you have questions not addressed in this manual or have any special requirements please feel free to call and discuss them with a CONTREX applications engineer We are happy to provide both off the shelf and custom products With over two decades in the motion control business we have a vast pool of applications knowledge waiting to assist you Thank you for selecting CONTREX for your motion control needs It is our goal to save you time and money
27. LIBRATION 6 3 SINE RESOLVER MODE AMPLIFIER CALIBRATION 6 3 1 Overview of Potentiometer NAME OF POT SIG 1 Sets the input voltage to RPM ratio e g 10V 2000RPM velocity Signal 1 ode or input voltage to torque ratio e g 10 25 current ode required by your system for the single ended input SIG 2 Signal 2 Same as Signal 1 input TACH Tach Gain sed in conjunction with the compensation to set the system andwidth Not used in current mode Shipped at 75 BAL Balance sed to null any offsets in system COMP sed in conjunction with the tach to set the system bandwidth Compensation ot used in current mode Shipped set CW minimum andwidth I LIMIT Sets maximum motor current Shipped set CW maximum Current Limit urrent LOOP sed to shut off uncalibrated amplifiers When the loop gain is Loop Gain CW no current is delivered to the motor Shipped set CCW off 6 3 2 Sine Resolver Mode Amplifier Calibration Velocity Mode NOTE All pots except the Loop Gain are 12 turn Turn the Current Limit RV7 to mid position and the Loop Gain RV8 full CCW Apply main power and fan power Slowly turn the Loop Gain RV8 CW The Motor should be stopped or turning slowly If the motor starts running away turn Loop Gain RV8 CCW switch TACH REVERSE 51 5 from OFF to ON or vice versa or reverse the TACH OUT and COMMON at 5 and J1 6 and retest Leave the Loop Gain RV8 full CW for al
28. OPERATION amp SERVICE MANUAL for CONTREX Model CXB1525 Model CXB2040 Brushless Amplifier System MANUAL 0001 0200 REVISION E DATE 11 07 97 8900 Zachary Lane N Maple Grove MN 55369 U S A READ THIS Model CXB1525 CXB2040 Brushless Servo Motor Amplifier SETUP When a servo kit is purchased from CONTREX the resolver has been aligned and the motor amplifier tuned for a 1 1 inertia match The factory settings of the potentiometer s and switch s are recorded in the CXB1525 CXB2040 manual and on SK1650 for easy reference The only potentiometer s that may need adjustment are the Loop Gain pot which is shipped set at full CCW off and the Compensation pot if the inertia is not a 1 1 match M SERIES PRODUCT SETUP There are drawings included with the servo kit showing the proper wiring between the CXB amplifier and the M Series On the M Series set the Isolator Voltage Reference jumper to Internal Reference as shown in chapter 2 of the M Series manual Next adjust the On Board Scale Pot for a maximum output voltage of I10VDC as shown in chapter 4 of the M Series manual Reconnect all of the labeled wires between the motor and CXB amplifier Also make sure there is a good earth ground connection to the CXB amplifier chassis and from the CXB amplifier chassis to the motor AMPLIFIER SETUP Once the wiring is complete enable the CXB amplifier with the M Series powered up but NOT in RUN There is now a zero volt
29. and to provide you with a superior product 6 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 1 DESCRIPTION FEATURES AND SPECIFICATIONS CHAPTER ONE DESCRIPTION FEATURES AND SPECIFICATIONS 1 1 DESCRIPTION This brushless amplifier system has been designed to offer you our customer a large degree of flexibility and customization with a standard in stock product Each amplifier module consists of a standard power output board with one of our three types of personality modules mounted on it To help you understand the various brushless amplifier and motor system combinations and their respective advantages and disadvantages please refer to chapter two of this manual which describes the theory of operation Following is a brief description of these personality modules and their mode s of operation 1 SINE RESOLVER MODE In this mode of operation a brushless motor with an integral resolver is required The personality module contains a resolver to digital converter which provides the positional information to the amplifier that is required to commutate the motor This positional information is also used by the personality module to emulate a quadrature encoder output This personality module can be configured for the following two different types of operation a VELOCITY MODE In this mode of operation the personality module generates a tachometer signal which is used to close a velocity loop in the amplifier Pleas
30. awings in appendices A and B will enable a skilled technician to trouble shoot an amplifier to even lower levels The modular construction of the amplifier allows fast and easy repair This is especially true due to the plug in personality module card since all user adjustments and configuration changes are made on this card If an amplifier module should fail simply unplug the pre amp and plug it into a replacement amplifier 8900 Zachary Lane N Maple Grove MN 55369 U S A 39 1525 and 2040 MANUAL 7 4 FACTORY REPAIR Should it become necessary to return an amplifier to CONTREX for repair please follow the procedure described below 1 Reassemble the unit if necessary making certain that all the hardware is in place 2 Tag the unit with the following information A Serial number and model number B Company name phone number and representative returning the unit C A brief notation explaining the malfunction D Date the unit is being returned Repackage the unit with the same care and fashion in which it was received Label the container with the appropriate stickers e g FRAGILE HANDLE WITH CARE Return the unit by the best means possible The method of freight chosen will directly affect the timeliness of its return CONTREX also offers a one day repair service in the unlikely event that your system is down and you do not have a replacement amplifier module 7 5 WARRANTY Any product or part
31. ct or part sold to you and you agree in accepting our product or part to save us harmless from any and all such claims or damages that may be initiated against us by third parties 40 8900 Zachary Lane N Maple Grove MN 55369 U S A APPENDIX AMPLIFIER DRAWINGS APPENDIX A AMPLIFIER DRAWINGS 8900 Zachary Lane N Maple Grove MN 55369 U S A 41 1525 and 2040 MANUAL nM TEST HS ECB POINTS LS ECB LEDS OVER VOLT OVERTEMP _ SIGNAL 1 SIGNAL 1 125 2128 SIGNAL 2 ENCODE 2 COMMON TACH OUT ABS UP DN COMMON LIMIT OFF ON LIMIT 2 10 INHIBIT J1 HILOW 12 COMMON 13 RESET IN OFF ON 14 MTR TEMP 15 NIC SW YAGOONA NIN Gig gt gt CHASSIS GND 1 1 MOTORT 2 PEG 2 MOTORS 30 12 3 MOTOR AG INPUT MOTOR OUTPUT COMP I LIMIT LOOP INDEX CAUTION HIGH VOLTAGE gt PIN PHOENIX ITEM DESCRIPTION 42 8900 Zachary Lane N Maple Grove MN 55369 U S A
32. d sinusoidal waveform used to drive brushless motor The first waveform is known as trapezoidal or six step since the voltage is stepped from winding to winding like the Christmas light analogy This is the simplest and least expensive method of driving a brushless motor Its principal disadvantage is that the large current steps produce high torque ripple Torque ripple is a repetitive fluctuation in torque as the motor turns and is independent of load The second waveform 1 known as sinusoidal To minimize torque ripple the motor current needs to be constantly varied according to the orientation of the magnets and windings As it happens this 15 a sine function In fact a sine wave is defined as a rotating radius like a motor shaft revolving through time see figure 2 4 A sine wave is the most natural way to drive a motor and produces the minimum torque ripple 8900 Zachary Lane N Maple Grove MN 55369 U S A 15 1525 and 2040 MANUAL 2 6 THE ADVANTAGES AND DISADVANTAGES OF TRAPEZOIDAL AMPLIFIER SYSTEM A trapezoidal motor has three stator windings and together with the rotor magnets are designed so that the magnetic flux coupling between them produce a constant torque The torque of the motor is proportional to the three stator phase currents which are 120 out of phase to the other two Shaft position sensors are required to provide the commutation signals to commutate the motor The two most
33. e see section 2 3 2 5 2 8 of this manual for more detailed information b CURRENT MODE In this mode of operation which is also commonly referred to as torque mode sine wave currents in the motor are produced that are directly proportional to the input signal Please see section 2 5 2 7 2 9 of this manual for more detailed information 1 2 FEATURES 1 2 1 Stand Alone One Axis Amplifier e Line operated AC power operation Fused AC input for single or three phase input with solid state zero crossing switch which limits in rush current protection at turn on No power isolation transofrmer is required Fused Regen clamp circuit shunt regulator with LED indicator and 50W internal load resistor bank bleeds off excess DC Buss voltage when decelerating a large load inertia Additional regen resistors can be connected externally Bridge rectifier s and filter capacitor Cooling Fans 8900 Zachary Lane N Maple Grove MN 55369 U S A 7 1525 and 2040 MANUAL Surface mount technology Complete isolation Silent operation Short circuit protection LED diagnostics Encoder emulation Frequency response Velocity Loop Frequency response Current Loop Dual signal inputs Dual mode operation Current limit Digital limit enable Inputs Encoder outputs Tachometer output Fault Input Output Fault input output Constructed with surface mount components C
34. ess DC tachometer on the motor shaft which converts the velocity of the motor into DC voltage The second method is to synthesize a digital tachometer using the motor commutation signals refer to section 2 6 In the third method with a sine resolver amplifier an analogue tachometer signal is generated as part of the Resolver to Digital conversion process and is immediately available for use thru the dip switch options for velocity mode S1 7 The fourth method is to have an optical encoder installed on the motor shaft to determine the direction and position of the motor as it runs The incoming encoder signals are converted into quadrature clock pulses The frequency of this clock pulses changes with the velocity of the motor and the up down clock output signals change with the direction of which the motor is running at The frequency of the clock is then converted into the tach DC voltage signal using the Frequency to Voltage converter 2 9 COMMUTATION USING RESOLVER The Resolver to Digital converter generates the necessary excitation for the resolver and converts the resolver s sine and cosine signals into position data This position information is used to amplitude modulate the velocity error signal into three phase sinusoidal and current error signals like the one in section 2 3 2 10 CURRENT MODE IN SINE RESOLVER OR TRAPEZOIDAL AMPLIFIER vs TWO OR THREE PHASE INPUT CURRENT MODE AMPLIFIER The fundamental difference between the cu
35. essary to install the amplifiers The amplifier package should be mounted in a clean dry enclosure free of dust oil or other contaminants NEVER INSTALL THE AMPLIFIER PACKAGE IN ANY LOCATION WHERE FLAMMABLE OR EXPLOSIVE VAPORS ARE PRESENT IMPORTANT Muffin fan s are mounted along one edge of the baseplate to provide cooling At least 3 inches must be allowed between the fan side and the side opposite the fans and any other surface The clearance to any other side of the amplifier package is not critical although sufficient space should be allowed for easy wiring and servicing 4 3 WIRING 4 3 1 RFI EMI and Wiring Technique IMPORTANT All PWM equipment inherently generates radio frequency interference RFI and wiring acts as antennae to transmit this interference In addition motors inherently generate electromagnetic interference EMI Unless the wiring is very short some sort of shielding on the motor wires is necessary to meet FCC RFI EMI guidelines and to protect other equipment from the effects of RFI EMI We recommend that shielded wire be used or the wires should be run in metallic conduit The shield or conduit should be connected to the amplifier baseplate which in turn must be earth grounded In addition a conductor of the same gauge as the motor wires must be connected from the motor case to the amplifier baseplate to provide protection from shock hazard The earth grounding is necessary to meet National Electrical Code NEC
36. ields of the permanent magnets In a brush type motor this is accomplished by using a commutator and brushes The brushes which are mounted in the stator are connected to the motor wires and the commutator contacts which are mounted on the rotor are connected to the windings As the rotor turns the brushes switch the current flow to the windings which are optimally oriented with respect to the magnetic field which in turn produces maximum torque In a brushless motor there is no commutator to direct the current flow through the windings Instead an encoder hall sensors or a resolver on the motor shaft senses the rotor position and thus the magnet orientation The position data is fed to the amplifier which in turn commutates the motor electronically by directing the current through the appropriate windings to produce maximum torque The effect is analogous to a string of sequencing Christmas lights the lights seem to chase each other around the string In this case the magnets on the rotor chase the magnetic fields of the windings as the fields move around the stator The relative advantages and or disadvantages of a brush type motor amplifier combination vs a brushless motor amplifier combination can be significant On the next page is a summary of advantages and disadvantages of brush type motor amplifiers and brushless type motor amplifiers to help you decide which type to select for your applications V WIRES JRUSHLESS
37. ill turn off the OVER TEMP LED is latched on a Fault Output is generated and the amplifier is inhibited The following is a list of possible causes 1 Loss of cooling air Fans are defective or airflow is blocked 2 Excessive rise in cooling air temperature due to cabinet ports being blocked or excessive hot air being ingested 3 Extended operational duty cycle due to mechanical overload of motor or defective motor 4 The motors thermal switch has been tripped due to excessive overloading 7 2 7 Over Voltage Fault When the DC Buss voltage reaches a level that if exceeded would harm the amplifier or motor the Run LED will turn off the Over voltage LED s are latched on a Fault Output is generated and the amplifier is inhibited The following is a list of possible causes 1 Main AC line voltage is too high 2 Decelerating a large inertial load When decelerating a DC motor acts as a generator If the inertial load is large the generated voltage can pump up the DC Buss If this fault occurs you may need a Regen Clamp Consult CONTREX 7 2 8 Resetting A Fault The fault latch may be reset by pushing the Reset button activating the Reset input J1 13 or by removing power and allowing the filter capacitor s to discharge Note that the fault latch will not reset unless the fault has been cleared 7 3 AMPLIFIER FAILURE If an amplifier should fail that is if it should cease to operate with no apparent fault the dr
38. inhibited The following is a list of possible causes 1 The continuous motor current is too high 2 Binding or stalling of motor shaft due to excessive mechanical overload 3 Motor rating too small for the load 7 2 4 High Speed Electronic Circuit Breaker HS ECB Fault When the peak output of the amplifier exceeds 80A for 10 micro seconds the Run LED will turn off the HS ECB LED s are latched on a Fault Output is generated and the amplifier is inhibited The following is a list of possible causes 1 Shorted motor leads 2 Motor inductance too low 3 Short from a motor lead to ground 7 2 5 Low Speed Electronic Circuit Breaker LS ECB Fault When the RMS output of the amplifier exceeds the current set to protect the motor and or the maximum setting of the amplifier for 3 seconds the Run LED will turn off the LS ECB LED s are latched on a Fault Output is generated and the amplifier is inhibited Refer to section 1 3 1 1 for the amplifier rms settings The following is a list of possible causes 1 Binding or stalling of motor shaft due to excessive mechanical overload 2 Overload of amplifier output to motor 3 Large reflected load inertia 38 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 7 MAINTENANCE REPAIR and WARRANTY 7 2 6 Over Temp Fault When the heatsink and or motor temperature has reached a level that if exceeded would damage the output transistors or the motor the Run LED w
39. is used to produce an output linear or PWM to drive the motor The velocity loop may be bypassed and an external current command fed directly to the current loop In this case the external command signal controls the torque of the motor rather than the velocity This is known as current mode operation CURRENT ERROR SIGNAL CURRENT C 8 i Figure 2 2a Velocity mode sevo loop for a brush type motor The servo loops of a brushless amplifier figure 2 2b operate in much the same way except there are now three current loops one for each phase of the motor Z CURRENT Eli NAL H IY AL LTIPLEXEI Figure 2 2b Velocity mode sevo loop for a brushless motor 8900 Zachary Lane N Maple Grove MN 55369 U S A 13 1525 and CXB2040 MANUAL CHAPTER 2 THEORY OF OPERATION 2 4 BRUSHED MOTORS vs BRUSHLESS MOTORS There are two basic types of motor design that are used for high performance motion control systems brush type PM permanent magnet and brushless type PM As you can see in figure 2 3 a brush type motor has windings on the rotor shaft and magnets in the stator frame In a brushless type motor the magnets are on the rotor and the windings are in the stator To produce optimal torque in a motor it is necessary to direct the flow of current to the appropriate windings with respect to the magnetic f
40. l remaining adjustments Slowly move the Balance RV5 back and forth Set the Balance midway between the points where the motor begins turning in either direction Connect the oscilloscope to ABS I J1 7 and the battery box to Signal 2 Input The voltage at J1 7 is a function of motor current 1 10 While applying a step input voltage adjust the Current Limit RV7 for the desired peak current If the desired peak current cannot be achieved with the pot full CW increase the input voltage or increase the Signal Gain RV3 8900 Zachary Lane N Maple Grove MN 55369 U S A 31 1525 and 2040 MANUAL The purpose of the following procedure is to set the system bandwidth to obtain a critically damped response with the maximum possible tach gain There are many possible settings of Tach Gain and Compensation which will yield a critically damped waveform The optimum setting will occur when the Tach Gain is as CW as possible and the Compensation is as CCW as possible However the servo loop may become unstable the motor oscillates or hunts with a very low near CCW setting of Compensation In this case stability is the limiting factor At no time should the servo loop be allowed to be unstable Amplifiers are normally shipped with the Tach Gain RV4 set at 75 This is a good place to start If you are unsure of where the Tach Gain is set turn the Tach Gain fully CW up to 12 turns then CCW 3 turns Move the oscillo
41. less and brush type motors and amplifiers to help you select which is best suited for your application The following is a summary of the topics The theory behind an amplifer driving DC servo motors A comparison between brush type and brushless motors A comparison between trapezoidal mode and sinusoidal mode The advantages and disadvantages of trapezoidal amplifier systems A comparasion between velocity mode and current mode Various kinds of velocity feedback Commutation using resolver Current mode in sine resolver or trapezoidal amplifier vs two three phase input current amplifier Protection circuits 2 2 DRIVING DC SERVO MOTORS The torque of any DC motor is proportional to motor current the stronger the magnetic field the stronger the pull Motor current may be controlled in two ways linear and PWM Pulse Width Modulation Linear control is achieved by simply inserting a resistance in series with the motor This resistance is usually a partially turned on transistor The transistor is said to be in its linear region Linear amplifiers are simple accurate and effective However they are very inefficient and they generate a lot of heat Linear amplifiers are used when low electrical noise high bandwidths 2KHz or higher and or low inductance less than 1mH motors are used In pulse width modulation the control devices output transistors are rapidly turned full on and full off The ratio of the on time the pulse width
42. modes The first six modes set the number of motor poles One pole corresponds to one magnet thus a motor with two north and two south magnets has four poles The number of electrical revolutions is equal to one half the number of poles An electrical revolution refers to the arc length the motor will rotate when one complete sine wave is applied Therefore a four pole motor has two electrical revolutions and requires two sine waves to make one mechanical shaft revolution The significance of this is any motor with more than one electrical revolution will have more than one electrical index 0 A position while there is only one mechanical index From an electrical viewpoint any index may be used however from a mechanical viewpoint using a different electrical index may alter the mechanical index as much as 180 from its previous position This will show itself as a change in where the encoder index channel Z pulse occurs Note that the emulated encoder has an index per mechanical shaft revolution Of the remaining two modes the INDEX is used to generate an index output and is used for resolver alignment MOTOR un P 2 4 POLE 2 6 2 8 POLE 10 POLE 2 12 2 ZERO 2 9 9 9 9 9 999 2 INDEX 8900 Zachary Lane N Maple Grove MN 55369 U S A 35 1525 and 2040 MANUAL PROCEDURE All adjustments are
43. n future units and repair on this unit Although not a substitute for the calibration procedure it will at least get you in the ballpark Remove the power and allow all capacitors to discharge before taking measurements Note The balance pot should not be measured in this fashion set per step 4 in the calibration procedure POT DIP SWITCHES AMP1 AMP2 AMP3 AMP4 5 AMP6 TACH J3 C to J3 F S SIG 1 J3 A to J3 F S SIG 2 J3 B to J3 F S COMP J3 D to J3 F S CURRENT LIMIT J3 E to J3 F S Signal input to Tach ratio V Signal V Tach LIMIT PULL UP DN 52 8 INHIBIT PULL UP DN 52 7 RESET PULL UP DN 52 6 LIMIT ACTIVE HI LOW 52 5 INHIBIT ACTIVE HI LOW 52 4 RESET ACTIVE HI LOW 52 3 TEMP ACTIVE HI LOW 52 2 15 5 52 1 Date data taken Serial number S N Model number CXB 34 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 6 START UP AND CALIBRATION 6 5 RESOLVER ALIGNMENT Note CONTREX motors with built in resolvers are factory aligned Consult a CONTREX applications engineer prior to attempting a resolver realignment Failure to do so may void the warranty Note Consult a CONTREX applications engineer before aligning a non CONTREX motor resolver Some motor resolvers require procedures other than that described here Note Dip switches 53 1 53 2 53 3 and 53 4 allow the converter to be operated in one of eight
44. oes low in the event of a fault This input is configured so that externally forcing this output low will inhibit amplifier This allows all fault outputs in a multi axis system to be connected together wire ORed to shut down all amplifiers should any amplifier have a fault 8 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 1 DESCRIPTION FEATURES AND SPECIFICATIONS Manual and external Push button and a separate input is provided to reset the amplifier fault reset after a fault High Speed Electronic Instantly shuts down the amplifier in the event of a short across Circuit Breaker the outputs and or ground fault protection HS ECB i e amplifier exceeds 80A for 10 micro seconds Low Speed Electronic Shuts down the amplifier if the amplifier 18 operated above the Circuit Breaker maximum continuous current rating for a pre determined period LS ECB 3 seconds Fold back current limit Folds back the continuous current delivered by the amplifier to a preset value if the amplifier 1s operated above the maximum continuous current rating for a pre determined period Over under voltage These circuits constantly monitor motor and amplifier power and over temperature supply voltages and motor and amplifier heatsink temperature They will shut down the amplifier in the event of any out of specification condition The over voltage protection circuit is set to turn on at 250VDC for 120 VAC line input and 450 VDC
45. omplete isolation from input to output Carrier frequency is 20KHz Complete short circuit and ground fault protection red LED S illuminate to display various fault conditions and a green LED illuminates to indicate normal operating conditions Encoder emulation comes standard with line driver outputs quadrature and zero index 750 Hz minimum 2 KHz minimum Two single ended or one differential Both single ended inputs may be use simultaneously All inputs have up to 15 000 A V gain and all inputs will accept 13 VDC The standard amplifier may be configured for simulated velocity RPM control or current torque control Maximum motor current is adjustable Three separate logic inputs can stop the motor in either or both directions Inputs may be configured for active high or active low pull up or pull down termination and 0 to 15V or 0 to 5V range Incremental quadrature position outputs with separate index 19 different encoder counts from 125 to 4096 counts revolution are available Differential line driver output devices sink and source 40mA DC output proportional to motor RPM Open collector output goes low in the event of a fault This input is configured so that externally forcing this output low will inhibit amplifier This allows all fault outputs in a multi axis system to be connected together wire ORed to shut down all amplifiers should any amplifier have a fault Open collector output g
46. rent mode an external command signal controls the torque of the motor rather than the velocity In velocity mode an external command signal controls the velocity RPM of the motor rather than the torque In a current mode amplifier the command signal is proportional to the motor current thus it is also proportional to the torque of the motor In a velocity mode amplifier the current loop amplifier stage is preceded by a high gain error amplifier which compares the command signal and the tachometer feedback signal Current mode amplifiers are usually used in Position Control Systems where no tachometer feedback is required While velocity mode amplifiers are usually used in Classic Cascaded Contol Systems where there are position velocity and current loops in the system Velocity loops tend to have a higher bandwidth and operate better near zero speed 16 8900 Zachary Lane N Maple Grove MN 55369 U S A CHAPTER 2 THEORY OPERATION 2 8 TACHOMETER VELOCITY MODE FEEDBACK OPTIONS The following is a list of ways one can choose to implement tachometer feedback in order to drive the motor through a velocity controlled servo loop Brush type and brushless DC mechanical tachometer Simulated tachometer using the motor commutation signals PSEUDO TACH Sinusoidal resolver Simulated tachometer using the encoder signals The simplest way to simulate the actual velocity of the motor is by installing a mechanical brush type or brushl
47. rrent mode in sine resolver or trapezoidal amplifiers and the two or three phase input current mode amplifiers is that in the former case the commutation of the command and feedback signals is done within the amplifier itself The latter case accepts two or three 120 out of phase commutated drive signals In other words the user s controller has to do the commutation of the command and feedback signals themselves The user can either input two or three commutated drive signals If the user has chosen two phase input the third phase 1s generated as the negative sum of the other two inputs 2 11 PROTECTION CIRCUITS The High and Low Speed Electronic Circuit Breakers HS ECB and LS ECB protect the amplifier and motor from being damaged by high motor current specified max peak and rms current values The Over Temperature and Over Voltage detection circuits will shut off the amplifier when the temperature of the amplifier or the buss B voltage exceeds a specified limit Also there are circuits which limit the motor from running in either or both directions 8900 Zachary Lane N Maple Grove MN 55369 U S A 17 1525 and 2040 MANUAL CHAPTER THREE MODEL NUMBERING 3 1 INTRODUCTION This chapter contains the model numbering system for the stand alone one axis amplifier and applications The model numbering system is designed so that you our customer will be able to create the correct model number of the product that you need as
48. scope to the TACH OUT J1 5 set the battery box for a steady DC voltage and adjust the input voltage or Signal 2 gain for about 400RPM Pulse the input and compare the waveform with figure 6 1 Adjust the Compensation pot CCW until the waveform is critically damped or one hook overshoot Then proceed to step 10 If the desired waveform cannot be obtained by adjusting the Compensation pot back off CCW the Tach Gain pot a few turns and repeat step 8 Do not adjust the Tach Gain or Compensation pots for the rest of the calibration procedure With the battery box still connected at J1 3 and J1 4 for single ended input or if your system uses the differential input move battery box to J1 1 and J1 2 set battery box for a known DC voltage Adjust Signal 1 Gain RV3 or RV2 for differential input to obtain the desired motor velocity If the motor is rotating the wrong direction for a given input polarity turn the Loop Gain pot full CCW Switch MTR REVERSE 51 4 from OFF to ON or vice versa Turn the Loop Gain pot back to full CW 13 Remove the battery box and repeat only step 4 14 Calibration complete Reconnect signal wires NOTE All pots except the Loop Gain 12 turn See Section 5 3 2 for current mode configuration 6 3 3 Sine Resolver Mode Amplifier Calibration Current Mode Turn the current limit RV7 to mid position and the Loop Gain RV8 full CCW Apply main power and fan power Slowly turn the Loop Gain
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