OPERATION & SERVICE MANUAL Torque Switch
Contents
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4. JOY LO3dSNI 340250111250 5 LOSdSNI ATHLOOWS MOVYL LON 5300 51 SH3ONVM SOLON GLENTEK 208 Standard Street El Segundo California 90245 U S A 310 322 3026 26 GA4567PA and GA4568PA MANUAL APPENDEX A FAULT TRACING CHARTS ENGINEERING NOTES FOR FAULT TRACING CHARTS NOTE 1 To measure the DC buss voltage carefully connect a voltmeter across the bleeder resistor attached to the DC buss filer capacitor The proper DC buss voltage for your amplifier is calculated by multiplying the AC power input voltage on the main DC buss transformer by 1 4 e g For 70 VAC input you should read 70 x 1 4 or approx 100 VDC buss voltage The DC buss voltage will vary depending on if the motor is under a heavy or light load The DC buss voltage will sag under heavy loads This is normal for unregulated DC power supplies NOTE 2 The output voltage to the motor can be checked by alternately applying a positive and then negative voltage to the signal input and observing the voltage swing at the amplifier motor output terminals Keep in mind that the Loop Gain and Signal potentiometers must be set at least somewhat CW This test can be made with motor disconnected from amplifier NOTE 3 A low but not zero DC buss voltage could indicate an open or defective DC buss filter capacitor To check capacitor remove from circuit and check with an ohmmeter A visual check of the ca
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10. 2 Wrong power transformer installed 3 Aspinning DC motor is basically DC generator which produces back EMF in proportion to the RPM This BEMF voltage adds to the DC Buss voltage regen voltage when the amplifier is commanded to decelerate a motors inertial load If the regen voltage is high enough to cause Over Voltage condition consult with Glentek about adding a Regen Clamp to your system 7 2 5 LOW SPEED ELECTRONIC CIRCUIT BREAKER LS ECB SHUTDOWN The LS ECB is tripped when a preset current threshold is exceeded for a preset length of time See Typical Settings section 2 4 7 Possible causes 1 Binding or stalling of motor shaft 2 Overload of amplifier output to motor 3 Large reflected load inertia See section 2 3 6 on resetting the fault latch Note The fault latch will not reset unless the fault has been removed 7 2 6 HIGH SPEED ELECTRONIC CIRCUIT BREAKER HS ECB SHUTDOWN The HS ECB is tripped when a preset current threshold is exceeded for a preset length of time See Typical Settings section 2 4 7 Possible causes 1 Shorted motor leads 2 Intermittent motor short 3 Motor inductance too low 4 Motor commutator flash over See section 2 3 6 on resetting the fault latch Note The fault latch will not reset unless the fault has been removed FACTORY REPAIR Should it become necessary to return a GA4567PA or GA4568PA to Glentek for repair please follow the procedure described be
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12. The basic model number for these amplifiers is GA4567PA and GA4568PA Several suffixes may be added to provide various options These options are described below Glentek will be happy to discuss any special requirements you may have 2 2 22 VELOCITY MODE or CURRENT MODE OPTIONS The GA4567PA and GA4568PA are most often used to close a critically damped velocity loop using a DC tachometer for velocity feedback However the high gain input summing amplifier can be bypassed to provide an input directly to the current loop amplifier The part number designator for this Current Mode option is CM and follows next in the sequence of the part number e g GA4567PAOM If the CM is absent from the part number the amplifier will be configured for Velocity Mode Refer to Appendix C drawings 4597 7010 amp 4597 7012 If the amplifier is ordered with a CM option the dedicated CM Personality Preamp Card will be used Refer to Appendix C drawings 4597 5110 amp 4597 5112 2 2 3 LOGICGNPUTS The Limit and Inhibit inputs may setup in four different configurations refer to Appendix B drawings 4567 3106 4567 3107 4568 2105 and 4568 2106 for implementation Type A Requires grounding of input to disable amplifier Type B Requires a positive voltage at input to disable amplifier Type C Requires grounding of input to enable amplifier Type D Requires a positive voltage at input to enable amplifier The amplifier is normally shipped with the
13. indicating that the High Speed Electronic Circuit Breaker HS ECB has fired This circuit protects the amplifier from dead shorts across the amplifier output terminals The HS ECB is factory set and should not be adjusted 2 3 3 LOW SPEED ELECTRONIC CIRCUIT BREAKER RED LED The LS ECB LED indicator light will turn ON and latch indicating that the Low Speed Electronic Circuit Breaker LS ECB has fired This circuit protects the motor amplifier and mechanical system from damage due to excessive mechanical bind in the system or possibly driving into a hard mechanical stop 2 3 4 OVER TEMP INDICATOR OPERATION RED LED The Over Ternp LED indicator light will turn ON and latch when the heatsink temperature exceeds 170 F 770 2 3 5 DC BUSS OVER VOLTAGE MONITOR RED LED The Over Volt LED indicator will turn on and latch when the DC Buss voltage exceeds 155VDC This protects the amplifier and motor from high DC Buss voltages 2 3 6 RESETTING the FAULT LATCH The fault latch may be reset by pressing the Reset pushbutton on the amplifier board or by removing power and allowing the power supply filter capacitors to discharge Note that the fault latch will not reset unless the fault has been corrected 2 3 7 LOW VOLTAGE POWER SUPPLY MONITOR An under voltage detector circuit monitors the low voltage power supply input and will shut down the amplifier GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310
14. transistors are modulated The frequency at which these output transistors are switched ON and OFF is referred to as the Aarrier frequency o After realizing how the PWM amplifier output works it becomes apparent that some inductance must be added to the motor circuit to prevent excessively high AC ripple current and heating in the servomotor Consult a Glentek applications engineer for recommended inductance Now that we have a good understanding of how the current is provided from an TYPE pulse width modulated PWM bridge lets analyze the operation of the current loop 45 CURRENT LOOP OPERATION Please refer to figure 4 1 for a diagram of the current loop In control electronics the symbol Sigma with the circle around it is referred to as a summing junction The manner in which this summing junction operates is as follows The current command signal also referred to as the velocity error signal when received from the output of the velocity loop as shown in fig 4 1 is added to the current feedback signal The signal resulting from this addition is referred to as the Aurrent error ignal This current error signal is fed into the current amplifier which in turn produces a current in the motor A voltage which is proportional to the motor current is developed across Rs shunt resistor This voltage is referred to as the Acurrent feedback ignal The current in the motor increases until the current feedback signal is exactly equal in ma
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16. 322 3026 7 GA4567PA and GA4568PA MANUAL CHAPTER 2 DESCRIPTION and SPECIFICATIONS the voltage falls below 11VDC This is a non latched condition The amplifier will return to normal operation when the voltages return to normal 2 3 8 VELOCITY TAPER CURRENT LIMIT Motor specifications often include a SQA Safe Operating Area curve which is maximum motor current as a function of RPM See figure 2 3 On the 4568 an optional VTCL Velocity Taper Current Limit ensures that the maximum available motor current is within SOA limits Below maximum the motor current is still controlled by the velocity error or current command signal The VTCL may decrease the rate of acceleration and deceleration Consult a Glentek applications engineer before ordering SAFE OPERATING AREA VELOCITY TAPER MOTOR CURRENT LIMIT CURRENT figure 2 3 SPECIFICATIONS 2 4 4 OUTPUT POWER Each amplifier GA4567PA GA4568PA PEAK OUTPUT CURRENT 25ADC 40ADC RMS OUTPUT CURRENT 15ADC 20ADC OUTPUT VOLTAGE Typical 100VDC 100VDC Note Buss voltage should be selected to be 10 to 20 above the maximum voltage required at the motor terminals for maximum system efficiency Higher buss voltages available consult Glentek 242 INPUT POWER DC BUSS Typical 70VDC to 100VDC DC BUSS Maximum 150VDC The DC Buss voltage and control voltages are provided to each amplifier by power supplies on the baseplate Input power to the base plate
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18. Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 42 PERSONALITY PREAMP DRAWINGS APPENDEX C GA4567PA and GA4568PA MANUAL Hoa pe 04 46 BONG 1 165 9 131vV30DAADINI 5434 A18W3SSV 8272 o TINO 72291 2 OL 1 221 82484 94 14 g m 21 071 628141 9628 ____ 64 1 Hunde ma vl 002 naf XOLMM89 NO 014 89 109 AOL 914 218 G ASUJI xSHX 9 104 14469 NO XOlNMC9 104 gly ML 296 __ 05614 2 po 6 X HOON 523 728 124 5 o ZI 669 77545047241 1 00 zz XL 2 2 cz 1 2 1 ETC TA cc 1n 69 craf yq e 621 945 1 091531 2 601 410 n 2017 ISN IVNNVIN 304 34 2002 1669 5303553915 SIHL 8 265 a 00 466 ASSV 8 100 665 834 d 0002 1669 W3HOS asimisyyo sse un jn s suyo SouDasisey Jayyo j nsuoj A6 6y 8 9 Gv VO PUL 6S4NL ZMO 9 LYO 227 902 10 HZT 6Y Buimojjoy ayy osjo
19. and Output Signals 3 8 Removal and Installation 3 4 Troubleshooting with the Personality Preamp Card CHAPTER FOUR THEORY OF OPERATION Introduction to Theory of Operation Operation of Output Switching Transistors H Type Output Bridge Configuration Pulse Width Modulation PWM Current Loop Operation Velocity Loop Operation CHAPTER FIVE INSTALLATION PROCEDURE Mounting Wiring Size and Proper Technique Baseplate Connections 5 31 120 VAC 50 60 Hz for Fan s and Low Voltage Power Supply 5 3 2 Input from Secondary of Power Transformer Amplifier Connections and Functions GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 3 GA4567PA GA4568PA MANUAL TABLE OF CONTENTS 5 4 1 5 4 2 5 4 3 Signal Input 5 4 4 Tachometer Input 5 4 5 Current Sense 5 4 6 and Limits 5 4 7 Total Inhibit 5 4 8 Fault Input Output 5 4 9 Low Voltage Power Supply CHAPTER SIX START UP AND ADJUSTMENT PROCEDURE Safety Precautions Amplifier Alignment Introduction Velocity Loop Phasing Tach Gain Adjustment Connecting Amplifier to Digital Position Loop CHAPTER SEVEN MAINTENANCE REPAIR AND WARRANTY 71 Maintenance 7 2 Repair Fault Tracing Charts Part Replacement Over Temperature Shutdown Over Voltage Shutdown Low Speed Electronic Circuit Breaker LS ECB 2 High Speed Electronic Circuit Breaker HS ECB 7 3 Factory Repair 7 4 Warranty APPENDIX A FAULT TRACING CHARTS Fault Chart 1
20. e e 533814 SIN 9920 2 601 01 Y3MOd 39 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL 4 MODEL 0010 8967 ES ON DA ZEYVNGZ ted ES 00 9 V9 VdBOG VO Q31V30d3D2NI Wv3ovia G3IN31O NOLVTWISNI SIXV 9 1517 YO WIVI 30 1511 142531 31193578 19896 310008 53319 WOPENSS 83111234 20758 10058 WNNOVA 49 915 10781 201611 30405 XV 7201051 0310018 NOLIOYdYO ISNI ONY 0 3503 202311004 dive ISNA ONY 530 10 3504 003 1909 05 OvAOZL COCNYJ LOZNY3 83 035 1 0661 219 XlddfiS 33MOd ASIF 72011 90 1821 JSYHd 1029 OVASOL ZI MOLE 53015538 TOZA INANI 35984 1 10681 123456789 100121314 15 T T 123456789 10111213141 39V9vd 1029 SSVTOIXTId NO P NIORY TWNOLLdO HUM 0319905 38 NYO 39 90Yd S 97 TINGON 334180 SUNO 9 9 11009 5 0 9 S3I3NOHOVL TWNOIS OL 193NNO9 50931 33L3NOHOVL ONY TNOIS 304 318v 030135 36 5 JHL 30 5104100
21. most styles and sizes are in stock at Glentek IT IS IMPERATIVE THAT YOU DO NOT USE GROUNDED TEST EQUIPMENT ON THE MOTOR ARMATURE NOR CONNECT EITHER END OF THE MOTOR ARMATURE TO SIGNAL GROUND OR DC BUSS RETURN 5 4 3 SIGNAL INPUT Each amplifier has two Signal Inputs one single ended Signal Input TB1 3 amp TB1 4 4567 or TB2 3 amp TB1 4 4568 and one differential Auxiliary Signal Input and Auxiliary Return TB1 1 amp TB1 2 4567 or 2 1 amp TB2 2 4568 respectfully Typically when operating in the velocity mode the input signal range is 10VDC The input voltage is summed with a precision DC tachometer to provide accurate velocity control at the servo motor shaft see fig 4 1 The Signal Gain potentiometer R12 and Auxiliary Gain potentiometer R13 adjust the motor velocity desired for a given input voltage velocity command 5 4 4 TACHOMETER INPUT The Tachometer is connected to TB1 5 amp TB1 6 4567 or TB2 5 amp TB2 6 4568 5 4 5 CURRENT SENSE The Current Sense output signal can be monitored at TB1 7 4567 or TB2 7 4568 It is an isolated output signal that is proportional to motor current The scale factor is 1V 10A 5 4 6 and LIMITS The and Limits are located at TB1 8 amp TB1 9 4567 or TB2 8 amp TB2 9 4568 respectively Please refer to 2 2 3 for a description of the different configurations of limits that are available Amplifier modules are normally shipped with type AA imits
22. type A mput configuration Designation letter A B C or D is added next to the part number to indicate the type of input circuit desired e g GA4567PACMA would have type A inputs 224 MULTI AXIS CONFIGURATIONS Up to six amplifiers may be mounted on a single baseplate Following are the part numbers for each configuration GA4567PA 1 or GA4568PA 1 Single amplifier module GA4567PA 1A 1 or GA4568PA 1A 1 One axis baseplate with one amplifier module GA4567PA 2A 1 or GA4568PA 2A 1 Two axis baseplate with one amplifier module GA4567PA 2A 2 or GA4568PA 2A 2 Two axis baseplate with two amplifier modules GA4567PA 4A 3 or GA4568PA 4A 3 Four axis baseplate with three amplifier modules GA4567PA 4A 4 or GA4568PA 4A 4 Four axis baseplate with four amplifier modules GA4567PA 6A 5 or GA4568PA 6A 5 Six axis baseplate with five amplifier modules GA4567PA 6A 6 or GA4568PA 6A 6 Six axis baseplate with six amplifier modules 2 2 5 EXAMPLE MODEL NUMBERING The following example of GA4567PA part number is provided to help you better understand Glentek s part numbering system 6 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 2 DESCRIPTION and SPECIFICATIONS Example GA4567PACMTA 6A 5 GA4567PA Glentek Amplifier model 4567 Plug in preamp version A CM Current Mode option T Velocity Taper Current Limit option 4568 only A Type A logic input option 6A 5
23. which means that when a limit input is pulled to common by some external circuit the amplifier is inhibited in the or direction 5 4 7 TOTAL INHIBIT The Total Inhibit is located at TB1 10 4567 or TB2 10 4568 Please refer to 2 2 3 for a description of the different configurations of inhibit that are available Amplifier modules are normally shipped with type AA nhibit which means that when the inhibit input is pulled to common by some external circuit the amplifier is totally inhibited 5 4 8 FAULT INPUT OUTPUT The fault input output is on TB1 12 4567 or TB2 12 4568 Please refer to chapters 2 3 and 7 fora description of the protection circuits that will generate a fault When there is a fault this open collector output will go to ground Externally pulling this pin to ground will inhibit the amplifier 5 4 9 LOW VOLTAGE POWER SUPPLY The common from the low voltage power supply is connected to TB1 13 4567 or TB2 13 4568 the 15VDC is connected to TB1 14 4567 or TB2 14 4568 and the 15VDC is connected to TB1 15 4567 or TB2 15 4568 On our multi axis baseplates these connections are made for you GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 6 START UP and ADJUSTMENT PROCEDURE CHAPTER SIX START UP and ADJUSTMENT PROCEDURE 6 1 SAFETY PRECAUTIONS Before starting the adjustment and alignment procedure please be sure to obse
24. 1 located on the baseplate DO NOT APPLY ANY POWER YET 5 3 2 INPUT from SECONDARY of POWER TRANSFORMER The AC voltage that is used to form the DC buss of the amplifier package is supplied from a separately mounted transformer that has been selected by Glentek for your application Connect the secondary of the power transformer to input terminals 1 amp 2 of TB201 for a single phase input and terminals 1 2 amp 3 fora three phase input DO NOT APPLY ANY POWER YET GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 15 GA4567PA and GA4568PA MANUAL CHAPTER 5 INSTALLATION PROCEDURE 54 AMPLIFIER CONNECTIONS and FUNCTIONS 16 5 4 1 DC BUSS The DC Buss from the filter capacitor is connected to terminals 1 and 2 of terminal strip TB2 4567 or TB1 4568 on each amplifier This connection is already made for you on our multi axis packages The power transformer is not a standard part of the amplifier package and must be selected for your application Many sizes and styles are in stock at Glentek 5 4 2 MOTOR The motor is connected to terminals 1 and 2 of terminal strip TB2 4567 or TB1 4568 of the amplifier module In most cases if the motor inductance is less than 1 millihenry an inductor should be connected in series with the motor leads The inductor is considered to be a separate part from the amplifier package Glentek can advise on the inductor specifications and
25. 78 075 vel 33M09 D o 13 281 SNDISIA3Y LINDYIS PS BEES ES AOT MERI 3SN3S 1439919 DMAS 2 Q LAST sree IT AST sessi T 0 36901013 207 o lt 3 13538 395 2 or e 3000914 ANOUN PBA THA E NOWNO9D ae Lv NOWWOO 0 389010005 daa 98 7941041 A aawo 2 369010902 oor su 38m vs SINO x ISE3N yr O HOVL 9915 31002 26895 1 05834 29 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL MODEL I H 1 4 96 99 1511 50 30 1511 v c01c Z9c 243 8 1012 1999 v 0010 2969 OLLWW3HOS SIHONI NI SNOISNOWIT 0131315395 3SIAGHIU SSIM 40113153539 7581 0782 581 0 02 58 061 581 58 XVN NI 8 X NI X NI GELLI NI 8 X NI X OTI XVN NI 8 X NI X NI 06 XV NI 8 X NI OGOL X NI OZ HX1XM 9 V9 Vd 96tv5 95 79 0 0 495 9 1 90 9 39vXOvd 9 9 2 96 9 907 9 2 2 419 0 1 1 49
26. 9 6 ZW TINON SLINO L vc va 9srv9 13000 l t 109 Y3LIWOHOYL 915 OL 13 5 123 02 750431 YILINOH YL TWNOIS 31882 03013 5 351 7 30 Sindino IHL ONNOYI N3 3N C 5 TY 303 WOIdKL SI OL 9NPIIM I SALON Qva 01 01 OL 01 32 Usi 40 30 WA 35 4 6 OL 104 53404 CI NVHO 43 08449 3194 5 0151 38 was Py WOO HOWL SFA H2v1 sy DIS 1fidNI 915 2 ANNI 1 CWIIdAL 2 0 1 0 1 359 4 1 51 09 1531 TE 2000 HA 1 N 94 SH 10281 01 S3OVd 91W 9929 19 2H09 0G 2 021 CWIIdA 1 gt 2 9 0 1 0 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 32 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL B D A WOO 9 JITO DINnO3S 7 133815 15 802 013494040121 YO VIA 1917 15 51 9 S 1517 51594 MO Wl1s31vM 30 1511 SIXY 319143598 9001 9581 1
27. E IN ANY LOCATION WHERE FLAMMABLE OR EXPLOSIVE VAPORS ARE PRESENT 5 2 WIRING SIZE and PROPER TECHNIQUE Please refer to the installation diagrams in Appendix B These installation diagrams show the necessary external connections to ensure proper amplifier operation Glentek recommends that your wiring be in accordance with all national and local codes that are applicable to your system Wire size must be sufficient to accommodate the maximum continuous current that will be run through it Recommended wire sizes for the amplifier are as follows MOTOR ARMATURE 14AWG 4567 or 12AWG 4568 shielded twisted pair or run in metallic conduit for RFI suppression MAIN AC POWER INPUT 12AWG twisted pair 120VAC and 15VDC 16AWG twisted pair SIGNAL INPUT 22AWG shielded twisted pair Terminate shield at amplifier end only to Tachometer Common TB1 6 TACHOMETER INPUT 22AWG shielded twisted pair Terminate shield at amplifier end only to Tachometer Common TB1 6 LOGIC INPUT OUTPUT 22AWG Twist with return lead When wiring to and from the drive cabinet it is considered good technique to route the power lines 16 AWG and larger along different paths than the signal and tachometer lines This minimizes the amount of stray noise pick up that is injected into the amplifier 5 3 BASEPLATE CONNECTIONS 5 3 1 120 VAC 50 60 Hz FOR FANS and LOW VOLTAGE POWER SUPPLY Connect the 120VAC to terminals 5 and 6 of terminal barrier strip TB20
28. Motor does not turn in either direction Fault Chart 2 Motor only turns in one direction Fault Chart 3 Motor does not develop maximum output speed Fault Chart 4 Motor does not develop maximum output torque Fault Chart 5 Motor wanders and hunts or does not track smoothly Engineering Notes for Fault Tracing Charts APPENDIX B AMPLIFIER DRAWINGS Installation Schematic GA4567PA 4567 3107 Amplifier Board Assembly GA4567PA 4567 3106 Installation Drawing GA4567PA Single Axis 4567 3111 Installation Drawing GA4567PA Two Axis 4567 3108 Installation Drawing GA5467PA Four Axis 4567 3109 Installation Drawing GA4567PA Six Axis 4567 31 10 Installation Schematic GA4568PA 4568 2105 Amplifier Board Assembly GA4568PA 4568 2106 Installation Drawing GA4568PA Single Axis 4568 2107 Installation Drawing GA4568PA Two Axis 4568 2108 Installation Drawing GA5468PA Four Axis 4568 2109 Installation Drawing GA4568PA Six Axis 4568 21 10 APPENDIX C PERSONALITY PREAMP Schematic Velocity Mode Personality Preamp 4597 7010 Assembly Velocity Mode Personality Preamp 4597 7012 Schematic Current Mode Personality Preamp 4597 51 10 Assembly Current Mode Personality Preamp 4597 51 12 4 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 1 INTRODUCTION CHAPTER ONE INTRODUCTION 1 1 INTRODUCTION to the GA4567PA and GA4568PA MANUAL This manual is in
29. O 14 69 109 AOI SANTAN 21 366 54 1 21 700 92 5 Mw ixL oo ___ L L Zi By vi e amp ev 13 68 747 110 1511 lo ezi rods 1s31 6541 1411 40 21 2245 1 04 1531 41 eL 210 ANO ISN 304 V 33 2006 1669 5303543405 SIHL v 2015 466 143 v 2015 1669 ASSV v 1018 2669 894 v 0019 1669 W3HOS peyloeds ssejun jn ul SUYO SOUDISISOY 23318599 Cud9 GvV9 4 9 0 43 dz9Sv v9 Vd369Gt V9 gt dZ9Svvo 1 843 vd3 vd89StV9 dSSSvvo 94 24 94 SAI 74794 TAT LY 9 SINIDA 40451594 YUI UND ysanbas uo s 66 9 v 0005 65 nbueu s S 46Gvv9 sepesjedns G 6Sy v9 sul SILON TONI INVIJA S310H GaLVOIGNI ISN IN3ALSDPQV IVINOZIJOH 11 52424 IJON 1N333NM9 45 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL NOTES 46 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 Omega Series Digital PWM Brushless Servo Amplifiers e PWM Pulse Width Modulated Brushless servo amplifiers to 20KW Analog Brush T
30. Od W3LSAS 1I8IHNI NVI N3939 ONY BOVLIOA 55018 A93H9 93 MOT4HIV SNV4 NMOQ1009 53 213 403 W3LSAS H93N 53H29 JOYAS OL 1133 YOLOW 15340934 dWv JHL QNIJ OL V 1Y 3NO NV H2V3 193NNO934 310N 22345 1021 SI 1021 M3ASHOJSNVML 30V1d3u YIVd3Y 303 YILNI 01 1013 ONAY 24 NO 1 cz dW3133A0 4 031 823 03345 M01 N3d0 INV NO 35114 1 4 NO LIBIHNI SI 319 8380 3lvld 3Svd NO SdAV Y3HLO 09 SLN3LLINS3LNI SLYOHS 303 5 080 YOLOW 893 03345 SINGOW NO 13 3503 30v1d34 SOLON 193NNOOSIQ 1021 WO 10254 193NNOO2SIG 310N 43345 1021 51 49345 Alddns SI N3dO 023 3503 JOSIF N04 10254 WO34 S YILAIANV 193 03510 HO 10258 40 108100 SI 334005 2 021 310N HO 39V110A 5508 24 SIXV ILIAW NI 3I dv 93 H3HII3 NI LON 5304 MOLON 29 431935 SI 303 31N319 OL M3llldWv 0133 2 310N JOVLIOA 1022 YOLIOWIVO 5508 93338 32 143 23HO 3311234 39v1434 YOLOW N3dO 303 A93H9 YMO ONY I
31. S Sig and Aux Gain 5V Sig 7V Tach Tach Gain 5096 Loop Gain CCW OFF Comp CW min bandwidth GA4567PA GA4568PA LS ECB 15A for 1 5s 20A for 1 5s HS ECB 35A for 1005 60A for 1005 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 9 GA4567PA and GA4568PA MANUAL CHAPTER 3 PERSONALITY PREAMP CARD CHAPTER THREE PERSONALITY PREAMP CARD 3 1 INTRODUCTION to the PERSONALITY PREAMP CARD The Personality Preamp card is a modular plug in card that comes in two versions velocity mode and current mode Schematic and board assembly prints for these cards are found in Appendix C drawing numbers 4597 7010 4597 7012 4597 5110 and 4597 5112 and will be referred to in the following description The Personality card contains the main high gain preamp with all associated system alignment adjustments This card greatly enhances system trouble shooting and repair If an amplifier should fail simply remove the Personality card which has all of the original system constants adjusted in and re place it on a spare amplifier This eliminates system realignment when changing out amplifiers Also a motor tach load may be aligned at the factory and then just the Personality card sent to the field for system test 3 1 1 VELOCITY MODE PERSONALITY PREAMP CARD The Velocity Mode Preamp card contains the main high gain preamp with all the associated system alignment adjustments to close a velocity
32. Segundo California 90245 U S A 310 322 3026 38 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL Y Y 4 y O 730 T L5 6012 8997 269152 GINOUINTOSS 13 133515 0994 915 802 2 STIONW 99 15 SNOL Wai 131 990 0 532444301 31 1435 8 TINTON 83 VOPSNGE 83141234 WANOVIN 99 4315 20 641 39805 20 061 03 00 8 10198492 01 40151538 3604 8 3503 VON de 3504 ONY N3T10H350 2909 05 2 021 YANYOISNVYL 6661 ALI 9915 W3MOd ASLT 2011 9 6 LHOISH WLOL JOVHOWd 1029 33 0 43 09 SSVIDIXTIA YO 9 4812 3934 7740130 0319915 38 AV 31000 SUNO C vr vdegorv9 T300W SIXV e t NONWOO 3313NOHOVL ONY IVN9IS OL 5 123 02 Saval M3I3WOHOVI TWNOIS 804 3189 Q301lHS 3SN 53331148 JHL JO 5104100 IHL 050089 3 2 SUSI TW 303 SI OL ONISIM L S310N AAA AD ddY 3194 39 WA 7 WIN IVAGOL ZI ANNI Y3MOd 39d 1 159 511 Ens pe e e
33. Six axis baseplate with five amplifier modules mounted In this example each of the amplifiers would be labeled GA4567PA 1 with a serial number and CMTA designator at the bottom of the label The six axis baseplate would be labeled GA4567PA 6A 5 with a serial number and CMTA designator at the bottom of the label 23 PROTECTION CIRCUITS The following protection circuits are integral to the GA4567PA and GA4568PA amplifiers to prevent damage to the amplifier or your equipment Again Glentek is anxious to work with you in helping to implement any circuit functions your system might require Note For sections 2 3 1 to 2 3 7 refer to Appendix B drawings 4567 3107 and 4568 2105 2 3 1 FAULT INPUT OUTPUT The open collector fault output at TB1 12 4567 or TB2 12 4568 will go low and latch for any of the following fault conditions 1 High Speed Electronic Circuit Breaker HS ECB triggered 2 Low Speed Electronic Circuit Breaker LS ECB triggered 3 Transistor heatsink temperature in excess of 170 77 C 4 DC Buss over voltage condition The Fault output may also be externally pulled low to force a fault condition When the Fault output is on all output current is removed from the motor and the loop gain is reduced It is analogous to applying the Total Inhibit input Refer to section 2 3 6 on resetting the fault latch 2 3 2 HIGH SPEED ELECTRONIC CIRCUIT BREAKER RED LED The HS ECB LED indicator light will turn ON and latch
34. TAL INHIBIT CURR SENSE TACH COM SIG CUM AUX RET ND1108 HSNd HOLIAS 13334 ex a Eu CRLIF 684567PR MADE INC SLENTEK L L6Svv9 0492 5534 U S 8 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 30 AMPLIFIER DRAWINGS APPENDEX B 4 4 y O GA4567PA GA4568PA MANUAL KOS 9 2690 va 008 ng 206 311 200 935 13 133415 QAYANYIS 802 NOLLVTIVISN AINSTO SIXY 11143145 ASIAN 1517 514 4 50 30 157 o oo sw SIXY 31VIdISV8 2116 1999 i vdroewo 310008 333089 tw t TOSCYON 0311238 10238 49 91015 TVNIAY3L 10281 2011 195849 20461 ATddNS YIMOd 5661 ALO YINYOISNVYL OQAG L 39805 O0A01 0300 8 4 2 MOL NOL 3019634 015 dhvOz 3504 ONY H3TI0H350i 015 ISNA ONY YINIOHISN 14 09 06 OVAOZL NIB LHOIZH WLOL JOVIOVd asli 9551 Y3MOd 1022 SSVIOIXTIA YO P 3939 WNOlLdO NV 03114405 38 39vM Vd NONWOO YJLIWOH YL ONY WNOIS OL 5 193NNOO 50 31 USISNOHOWL ANY WNOIS 404 318v9 Q3013lHS 350 W3ridAv JHL 30 514100 JHL 0 010849 N3A3N I SALON
35. The optimum waveform for most systems is the critically damped waveform If the waveform that you are observing is critically damped proceed to step 9 If your waveform is under damped make the following adjustments Turn the Compensation potentiometer R16 CCW until the waveform becomes critically damped Note here that the limiting factor will be motor oscillation or Auunting You must always leave the Compensation potentiometer far enough CW so that the velocity loop remains stable If the waveform is still under damped after adjusting the Compensation potentiometer for maximum bandwidth turn the Tachometer Gain potentiometer R14 2 turns CCW and then adjust Compensation potentiometer R16 CCW until waveform becomes critically damped Repeat procedure if necessary Again the servo velocity loop must at all times remain stable Consult the factory if necessary If the waveform is over damped make the following adjustments Turn the Tachometer Gain potentiometer R14 CW until a slight overshoot appears on the waveform then turn the Compensation potentiometer R16 CCW until a critically damped waveform is observed Now that the waveform is critically damped leave the Compensation R16 and Tachometer Gain R14 at these settings for all remaining adjustments and operations Next set the Signal potentiometer R12 or R13 to the gain required by your system e g 10 volts 2000 RPM Adjust Balance potentiometer R15 one more time
36. VAOZ Aldd SOLON LOSNNOOSY QVOT43AO YO LYOHS IN3LLINS3LNI 303 YOLINOW ONY OL LINN 1139 YOLOM 391438 4 340 NMO18 2023 MO 1023 SI 310N HO 1028 SI HO 170 1 Y3MOd NIVW YMOS NIV Aldd 53504 N3dO YOLOW 193NNOOSIQ M3W4OJSNVML M3MOd 3971933 324005 4 1004 LYOHS 303 ONIJIM ONY YOLOW S3A 310N LIOA 5508 7213 SHOLIOVdYS SSn8 543141234 340 3103 3 2 40 NMO18 2024 MO 1023 SI SHOLINVdVO 5508 583131234 Q3LMOHS 403 93H29 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 24 FAULT TRACING CHARTS APPENDEX A GA4567PA and GA4568PA MANUAL 804 31N319 OL 0133 W3iSAS IVNS3LX3 JAONIY SIVN9IS LIN 93 9 NOILI3YI0 3NO NI SNYNL AINO SOLOW YOLOW 1434 YO TVOINVHO3N 03 AOSHI AMOIOV3 LINSNOO 40 M313AOHOV1 1933309 OL NOLLO3MIG YIHLIA NI QvO1 ON 03395 LAdLNO WAWIXVW dOT3A30 LON 5304 YOLOW 303 3LN3T19 OL NYNLIY 310 HO 104100 10100 39V110A HOWL ALON FJOVLIOA 5508 790 31 4330 31 1435 8 NO SSdWV Y3HLO 09 39VAIVd
37. al Gain potentiometer sets the input voltage to output current required by your system for the differential signal input e g 5 volts input 20 amps current R16 Current Limit potentiometer sets the maximum acceleration and deceleration current Loop Gain potentiometer is factory set to prevent amplifier maximum rated current from being exceeded when the current limit potentiometer is fully CW Balance potentiometer is used to null out any DC offset in the amplifier e g 0 volts input 0 current output INPUT and OUTPUT SIGNALS NAME FUNCTION SIGNAL Single ended signal input 15VDC 15VDC power 15VDC 15VDC power COMMON 15VDC and signal common AUXILIARY differential signal input AUXILIARY RETURN differential signal input OUTPUT Velocity error or current command CLAMP Reduces gain of the summing amplifier TACHOMETER Tachometer signal input 3 3 REMOVAL and INSTALLATION When removing or installing the Personality Preamp card care must be taken not to damage any of the components on the Amplifier card or on the Personality card 2168 3 N Removal Hold the Personality card by its edges and pull straight away from the Amplifier Controller board Do not pull on the components For amplifiers with the Personality card mounted vertically remove amplifier module first before unplugging Personality card Installation Hold the Personality card by its edges and car
38. card Refer to Appendix C drawings 4597 7010 amp 4597 7012 6 3 VELOCITY LOOP PHASING For proper servo operation it is necessary for the amplifier to receive negative feedback from the tachometer If the tachometer leads are reversed positive feedback the amplifier will run away To check the phasing of the motor and tachometer proceed as follows Make sure Loop Gain potentiometer R18 is full CCW as shipped from factory Make sure that nothing is connected to the Signal Input TB1 3 4567 or TB2 3 4568 or the Auxiliary Signal Input TB1 1 amp TB1 2 4567 or TB2 1 amp TB2 2 4568 Apply the main power and the 120 volt power Slowly turn the Loop Gain potentiometer R18 CW If the motor starts to run away turn the Loop Gain potentiometer full CCW and reverse the tachometer leads do not move the shield lead Again slowly turn the Loop Gain potentiometer CW The motor should be stopped or rotating slowly Leave the Loop Gain potentiometer R18 full CW for all remaining adjustments and operations TACH GAIN ADJUSTMENT At this point the motor will be stopped or rotating slowly Adjust the Balance potentiometer R15 until the motor rotation is stopped While observing the tachometer output voltage with an oscilloscope apply a step voltage at the Signal Input terminal of the amplifier A step voltage can be simulated by applying and removing a flashlight battery to the Signal Input For this purpose the battery is us
39. d ALIIvNOSH3d IINIID OILVW3HOS ISN WANVW 304 38 0008 1669 5343583405 SIHL 016 766 193 v 2014 1569 ASSV v 1014 1669 824 v 0016 1669 N3HOS y SvtivNLU payloads asimisyjo 55 jn 5 40 120405 9 SUYO si 92 0 5 5984 dS8Srv9 1 zMdlgecrvo 8 8 d89Sv v9 2449 5 9 8d3 vd3 1 96 9 239116799 957 70 4369 6 dc9Gvvo 843 vd3 3555995 LM 954 10 40351594 Ne senbej uo SI G 6Gt V9 v 0005 265 noueu s 6 66 sepesjedns G 6Sv v9 9 L 14 SrLYNL VOSZNL OOL YONA N gt 6 2 MOL 95 OL V9SZNL NIVO XAY 138 0 0L 5 53454 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 44 PERSONALITY PREAMP DRAWINGS APPENDEX C GA4567PA and GA4568PA MANUAL 1334 30 133HS MES Tr 16 60 a het AV 31 3Ud302NI dWV3add ALlIVNOSM3d ATBNISSV 0 08 Sri 80 2 268 0 GYOONOD Nid 64 14 6 534 7 Nid 8 1VM Lj X018M89 YO 14 89 109 AOL 6 30134469 M
40. e feedback signal from the DC tachometer is called the Velocity Feedback 14 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 5 INSTALLATION PROCEDURE CHAPTER FIVE INSTALLATION PROCEDURE 5 1 MOUNTING The installation diagrams in Appendix B show the bolt hole mounting pattern to support the amplifier The mounting holes will accept 1 4 inch dia bolts The base material is cadmium plated 094 inch thick aluminum THE MOUNTING BOLTS SHOULD PROVIDE AN ELECTRICAL GROUND FOR THE CHASSIS TO MINIMIZE SHOCK HAZARD The surface that the amplifier package will be mounted on must be able to support its weight but does not need to provide Acold plate ooling for the amplifier One two or three standard muffin fans are mounted on the baseplate to cool the amplifiers It is IMPORTANT to allow a minimum of three inches between both the fan side and the module side opposite fans of the amplifier baseplate and the cabinet wall The distance between the other two sides and top of the amplifier and the cabinet walls are not critical However some space should be provided for wire routing and terminal strip access The amplifier package should be mounted in a clean dry enclosure with a maximum ambient temperature of 122 50 To ensure maximum reliability keep the amplifier cabinet cool and free from dust oil and other contaminates NEVER INSTALL THE AMPLIFIER PACKAG
41. efully align the nine pins with their mating sockets and push straight toward the amplifier controller board until it is firmly seated Do not press on any of the components 3 4 TROUBLESHOOTING with the PERSONALITY CARD If your system exhibits a problem and a working amplifier module is available fault tracing can be expedited by removing the Personality Preamp card from the malfunctioning amplifier plugging it into the replacement amplifier and testing the system If the system does not work with the new amplifier module refer to Chapter Seven on Maintenance and Repair for a more detailed fault tracing procedure However if the system does work with the new amplifier module check the malfunctioning unit for loose connections and retest the suspected unit in the system to verify the malfunction GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 11 GA4567PA and GA4568PA MANUAL CHAPTER 4 THEORY OF OPERATION CHAPTER FOUR THEORY of OPERATION 4 1 INTRODUCTION to THEORY of OPERATION A velocity mode servo amplifier is essentially comprised of two control loops fig 4 1 VELOCITY CURRENT CURRENT ERROR SIGNAL LOOP AMPLIFIER VELOCITY COMMAND SIGNAL Figure 4 1 The inside control loop is referred to as the Acurrent loop and the outside loop is referred to as the Arelocity loop Before we begin our analysis of the current loop let us review some basic concepts which will hel
42. gnitude but opposite in polarity to the current command signal At this point the current error signal drops to zero and the actual current is equal to the commanded current If anything happens to disturb either the current command signal or the current feedback signal the same process occurs again until the current feedback signal is equal in magnitude to the current command signal but opposite in polarity The type of loop described above is referred to as a Aservo loop d ecause the current servos about a commanded value We are surrounded in our everyday lives by multitude of servo loops For example many of todays luxury cars have what is called Automatic climate control 9To operate this servo loop you set the climate control to the temperature that you wish to be maintained in the interior of the car current command signal The selected temperature is then summed with the actual temperature from a thermometer current feedback and the output currenterror signal activates either the heater or the air conditioner until the actual temperature as measured by the thermometer current feedback signal is equal in magnitude but opposite in polarity to the set temperature 46 VELOCITY LOOP OPERATION Please refer to figure 4 1 for a diagram of a typical velocity loop The velocity loop s operational description is analogous to the current loop description except for the fact that the input signal is called the Velocity Command and th
43. is as follows FANS LOW VOLTAGE POWER SUPPLY 120VAC 50 60Hz MAIN POWER for DC Buss 12VAC to 105VAC 50 60Hz single or three phase Note This power is supplied by a separately mounted power transformer selected for your application This transformer is not considered a standard part of the amplifier package Glentek stocks a complete line of power transformers to meet any application 2 4 5 SIGNAL INPUTS VOLTAGE MAXIMUM Aux Input 13 volts Sig Input 70 volts Tach Input 90 volts Input impedance 10K ohms minimum 8 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 2 DESCRIPTION and SPECIFICATIONS GAIN MAXIMUM Sig and Aux Inputs 15 000 amps volt Tachometer 7 000 amps volt Drift ref to input maximum 0 01mV C Frequency response minumum 750 Hz Dead band none Form factor 1 01 244 OTHER INPUTS OUTPUTS Limits and Inhibit inputs Terminated by 8K ohms minumum to com or 15V Thresholds at 4 2V and 10 3V Fault input output As input Terminated by 3 3K ohms to 15VDC Threshold at 1 5VDC As output Can sink 500mA through 100 ohms 2 4 5 OTHER SPECIFICATIONS Carrier frequency 20Khz 2 4 6 MECHANICAL SEE APPENDIX B DRAWINGS 4567 3111 amp 4567 3109 Mounting Any Position Temperature 120 50 ambient max Weight 8 Dimensions See Appendix 247 TYPICAL FACTORY SETTING
44. is isolated The charts are to be used only as a guide to identify the parts or assemblies that Glentek recommends as the lowest level of repair The fault tracing procedures assume that only a single failure mode exists Fault Chart 1 Motor does not turn in either direction Fault Chart 2 Motor only turns in one direction Fault Chart 3 Motor does not develop maximum output speed no load applied in either direction Fault Chart 4 Motor does not develop maximum output torque in either direction Fault Chart 5 Motor wanders and hunts or does not track smoothly 7 2 2 PART REPLACEMENT The removal and replacement of the defective assembly can be accomplished with standard shop procedures The assemblies that may be easily removed are as follows Fuses F201 F203 the base plate and F1 on each amplifier Rectifiers BR201 and BR202 Capacitor C201 Fans 201 203 Amplifier modules A1 A6 Low voltage power supply PS201 After reviewing the fault tracing charts you may conclude that the complete amplifier should be returned to Glentek for failure analysis repair and retesting to specifications This is particularly true with failure modes in the amplifier power section FAULT SHUT DOWNS CAN ONLY BE CAUSED BY ABNORMAL CONDITIONS THE CAUSE SHOULD BE INVESTIGATED BEFORE REPEATED RECYCLING OF THE MOTOR DRIVE TO PREVENT POSSIBLE DAMAGE TO THE AMPLIFIER 7 2 5 OVER TEMPERATURE SHUTDOWN When the heatsink temperature has reached a level
45. ith the Digital Loop operating turn the Loop Gain potentiometer R18 fully CW and command a small move Slowly increase or decrease the Signal Gain potentiometer R12 or R13 until the servo is operating as required It should be noted here that too much Signal Gain can cause instability oscillation Do not stay in this oscillating condition long as it may result in system mechanical or electrical damage Be sure when all signal adjustments are made that the Balance is re checked and adjusted for zero rotation for zero signal input It should also be noted here that the GA4567PA and GA4568PA is designed to operate with many different systems and if after reading this manual you have further questions do not hesitate to call a Glentek applications engineer ENGINEERING NOTE After all systems are aligned and functioning it is good practice to remove power from the amplifier and using a digital ohm meter measure the impedance value of the following potentiometer wiper settings with respect to signal ground These values may be useful for the next machine you align or for maintenance of this system at a later date Make these measurements on each amplifier on a multi axis baseplate For your convenience a table has been provided below AMP1 2 AMP3 AMP4 5 AMP6 Tach Gain potentiometer wiper to common ohms Signal gain potentiometer wiper to common ohms Compensation potentiometer wiper to common ohms Cur
46. loop using a D C tachometer for velocity feedback Refer to Appendix C drawings 4597 7010 and 4597 7012 3 12 CURRENT MODE PERSONALITY PREAMP CARD The Current Mode Personality card contains all the system alignment adjustments to control a current mode amplifier Refer to Appendix C drawings 4597 5110 and 4597 5112 3 2 DESCRIPTION of OPTIONS and ADJUSTMENTS The Personality Preamp card is a small printed circuit card 2 7 2 3 standing on nine pins 0 6 ong that mate with appropriate sockets on the amplifier control board The Personality card is most often used to close a velocity loop by using a DC tachometer for velocity feedback However the high gain input summing amplifier can be bypassed providing an input directly to the current loop amplifier Current Mode option If the Current Mode CM option is specified the committed Current Mode Personality Preamp card will be supplied 3 2 1 POTENTIOMETER ADJUSTMENTS The following is a description of the potentiometer adjustments used for the two modes of operation Please refer to Chapter Six on Start Up and Adjustment Procedures for a detailed description of how to set these potentiometers VELOCITY MODE Refer to Appendix C drawings 4597 7010 and 4597 7012 R12 Signal Gain potentiometer sets the input voltage to output RPM required by your system for the single ended input e g 10 volt input 2000 RPM R13 Auxiliary Signal Gain potentiometer sets the input voltage
47. low 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 assembly unit B Company name 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 Contact a Glentek representative confirm the unit is being returned to the factory and obtain an RMA Return Material Authorization number Return the unit by the best means possible The method of freight chosen will directly affect the timeliness of its return GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 21 GA4567PA and GA4568PA MANUAL CHAPTER 7 MAINTENANCE REPAIR and WARRANTY 74 WARRANTY Any product or part thereof manufactured by Glentek Inc described in the manual which under normal operation 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 El Segundo California 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
48. ornia 90245 U S A 310 322 3026 36 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL 30 133HS v N VS was 1012 8969 ame NSI 5 904 992206 7206 311 200 0935 13 010 500 3003 RHS 29394 133315 48 0 915 802 ST 31V30d302NI WYNIA Sjutog 159 NOLVTIVISNI SIXV L auis SIM 1112 8947 MOL E 80151534 VOW 4 02 3504 930103503 VON 4 3504 ONY 3301083503 1809 06 OVAOZL NYJ YAWYOISNVAL 5661 ALI AlddNS Y3MOd ASL 011 96 10 89 WIAA 2 601 01 1NANI 43 04 wo 7 4 4 y O 6 WLOL 39volovd 1002 M3A0 43A00 558191 314 MO 9 393 TWNOLLdO NY 0319905 38 4 6 NOWAOS WNOIS OL QTI3IHS 193NNOO SQY31 YJLINOHOWL 7 5 803 37870 034113 5 351 2 MSNA 30 5104110 IHL 0 008490 YIAN SALON 43 08449 3194 SNOISIA3Y HAS 37 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL S q 4 4 y O Rem 896 KSI 6906 awa
49. osite pairs of output transistors ON and OFF to control the motor drive current When zero current is commanded to the current loop the opposite pairs of transistors are turned ON and OFF as shown in figure 4 3 Note that since the pulse widths are equal the net DC current in the motor is equal to zero QA amp QC ON OFF QB amp QD ON Figure 4 3 When a non zero current is commanded to the current loop the transistor switching waveform is as shown in figure 4 3A Since there is a non zero current command the output transistor pulse widths will change and the motor will see a net DC current flowing from A through C QA amp QC 0 OFF QB amp QD 0 Figure 4 3A If the input to the current loop had been changed in polarity the output transistor switching waveform would be as shown in figure 4 3B QA amp QC OFF QB amp QD ON Figure 4 3B GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 13 GA4567PA and GA4568PA MANUAL CHAPTER 4 THEORY OF OPERATION If a larger current of the same polarity was commanded to the output transistors see fig 4 3B the ON time widths of B and D would automatically increase to provide more current From the previous examples it is easy to understand why this output transistor switching technique is referred to as pulse width modulation To change the magnitude and polarity of the current flow in the motor the pulse widths of the opposite pairs of
50. p you to better understand the amplifier operation 4 2 OPERATION of OUTPUT SWITCHING TRANSISTORS The output transistors for all intents and purposes operate in only two states They are analogous to ON OFF switches When an output transistor is OFF there is no current flowing through it its resistance is infinite When an output transistor is ON current flows through it its resistance is near zero When the transistor is ON it is technically referred to as being in saturation 43 TYPE OUTPUT BRIDGE CONFIGURATION The output configuration of the amplifier is an Ad TYPE pridge see fig 4 2 for schematic representation of output bridge with motor connected D C BUSS FILTER CAPACITOR Figure 4 2 12 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 4 THEORY OF OPERATION The advantage of an TYPE utput bridge configuration is that by controlling the switching of the opposite pairs of transistors current can be made to flow through the motor in either direction using a single polarity power supply as shown in figure 4 2 To provide motor current in one direction transistors A and C are turned ON while B and D remain in the OFF state To provide motor current in the other direction B and D are turned ON while A and C remain in the OFF state 44 PULSE WIDTH MODULATION PWM Pulse width modulation ds the technique used for switching opp
51. pacitor port seal could show a blown pressure seal caused by a failed overheated capacitor NOTE 4 If the 120VAC fuse F204 is blown it may indicate a defective low voltage power supply a shorted fan or possible a defective low voltage transformer This transformer is located on the baseplate near the low voltage power supply The transformer wires are color coded as follows Red amp Brn Primary 120VAC Yel and Grn Secondary 32 center tapped GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 27 GA4567PA and GA4568PA MANUAL APPENDEX B AMPLIFIER DRAWINGS APPENDIX B AMPLIFIER DRAWINGS 28 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL 4 MODEL ess i mox ETE qa Be Na UE 94 9 99 suy TINTO NOLWTWISN 2 Ed 55 62 1113913 3 WA 1 105 9 3091 lo 3dAL yr Ste ERI gt 3189510 OL 3991 10A 3189510 01 9 1112212 39 9110 24 61 LIGIHNI OND Xie 1119415 79101 JAVNDILO33IG AI IHNI lt IND LISIHNI lt IND 1115412 299110 33A d 5010 gt 0
52. rated and normal usage Glenteks liability is limited to repair or replacement of defective parts Any product or part manufactured by others and merely installed by us such as electric motors 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 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 including power transistors Under no circumstances shall Glentek 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 product 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 22 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL APPENDEX A FAULT TRACING CHARTS APPENDIX A FAULT TRACING CHARTS GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 23 FAULT TRACING CHARTS APPENDEX A GA4567PA GA4568PA MANUAL J10N MO JOSIF SI 10254 14405 W3M
53. rd Street El Segundo California 90245 U S A 310 322 3026 AMPLIFIER DRAWINGS APPENDEX B GA4567PA and GA4568PA MANUAL Hl s 016299 m 18 9 V9 VdZ9Sv VO 131 v30d3D2NI 119711915 WOO HOWL 9 SILNITO SIXV 9 E cn gl 1511 51894 30 WISILVH 30 1511 SIXv 9 31 1435 8 2201 1959 1 1 4 95 99 JINGOW 313114 99 19 2 062 0 43131 339 20238 10238 2 181 NIg9 9181 i 2011 9 ATddNS N3 Dd 5661 319 3HNOJSNVMI JV AObT 0 24 1002 0 0026 01129493 LNdNI 43404 3SvHd I 01 40151933 1024 1 075 dWvo2 3513 430103513 2023 2023 2 075 ISNA I301OH3SN3 ______ 1024 1 Z183H 09 05 1 SINIDd 1531 Tm 1021 y XVN NIB 1H9IH 1101 JDWIOVA Biens i E ne 167 8 6 lt e e i e e x 5 9 8 e a 5 o CIV2IdA15 29 10 1 0 INANI 1022 55 1015114 dAVIO 3938 NNOILdO 0319905 38 NYO 39 0 4 9 dL96vV9 OL JIBILVANOO Nid SI Vd 96tV9 G V 310001 3 SLINO S V9 WdZ9SP 9 13000 SIXY 5 7 WOO HOWL Y
54. rent limit potentiometer wiper to common ohms Signal input to Tach input voltage ratio volts Signal volts Tach Date data taken ___ Note any changes to compensation components etc GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 19 GA4567PA and GA4568PA MANUAL CHAPTER 7 MAINTENANCE REPAIR and WARRANTY CHAPTER SEVEN MAINTENANCE REPAIR and WARRANTY 7 1 MAINTENANCE The GA4567PA and GA4568PA amplifiers do not require any scheduled maintenance The only wear out items are the cooling fans which are specified to have in excess of 15 000 hours MTBF by their manufacturer 7 2 REPAIR If your system exhibits a problem this manual should assist you to identify the fault and to replace the defective component sub assembly It is Glentek s recommendation that only major assemblies be replaced in the field and the assemblies be returned to Glentek for failure analysis and repair However appendices B and C contain complete System schematics that in case of extreme emergency should permit a skilled electronic technician to troubleshoot the circuit boards to levels lower than those recommended as replaceable 7 2 1 FAULT TRACING CHARTS The fault tracing charts in Appendix A start with an observable fault listed at the top of each chart Follow the line connections between blocks by your answers to the questions noted the diamond shape blocks until the defective part
55. rve the following precautions Be certain that there are no visibly loose or damaged components Check that all connections are tight Check all power and signal wiring Remove power input fuses apply power and measure that the correct power voltage is being applied Your DC buss voltage will be 1 4 times the AC voltage applied Refer to Appendix A note 1 Be sure that the motor mechanism is clear of all obstructions If motor is connected to an axis lead screw or other device with limited motion place at mid position Make sure Loop Gain potentiometer on Preamp card is turned fully CCW before applying power DO NOT use grounded test equipment on motor leads or power section of amplifier 62 AMPLIFIER ALIGNMENT INTRODUCTION The following procedure must be done to each amplifier in a multi axis system Work on only one amplifier at a time When adjusting an amplifier for optimum velocity loop operation it is desirable to achieve a critically damped stable step velocity response with maximum Tach Gain The following discussion will describe how to best achieve this result Your amplifier has been run at the factory with a known motor tachometer and inertial load In testing at the factory we try to simulate the same conditions you will have in your system For this reason it is a good idea to start with the initial settings as shipped from the factory Note All of the following adjustments are to be made on the Personality Preamp
56. tended for use with Glenteks TORQUE SWITCH series models GA4567PA and GA4568PA pulse width modulated PWM servo amplifiers It provides all of the information that is required for installation alignment and maintenance of these amplifiers We suggest that you take the time to read this manual from cover to cover before trying to work with these amplifiers If you have any questions that you cannot find the answer to in this manual please feel free to call and discuss your problem or question with a Glentek applications engineer Having been in the servo system business for over 28 years we have a vast pool of applications knowledge waiting to help you Thank you using Glentek s products It is our goal to save you money time and provide you with a superior product GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 5 GA4567PA and GA4568PA MANUAL CHAPTER 2 DESCRIPTION and SPECIFICATIONS CHAPTER TWO DESCRIPTION and SPECIFICATIONS 2 1 DESCRIPTION of the GA4567PA and GA4568PA The GA4567PA and GA4568PA are modular medium power high bandwidth PWM servo amplifiers designed for use with DC permanent magnet servo motors These amplifiers utilize todays latest technology in power semiconductors for high efficiency which in turn makes them extremely reliable in today and tomorrows demanding applications 22 MODEL NUMBERING INFORMATION and AVAILABLE OPTIONS 2 2 1 BASIC MODEL NUMBER
57. that if exceeded would damage the output transistors the Temp indicator LED is latched ON and the amplifier will be inhibited Possible causes Loss of cooling air Fans are defective or airflow is blocked Excessive rise in cooling air temperature due to cabinet ports being blocked or excessive hot air being ingested Extended operational duty cycle due to mechanical overload of motor or defective motor Defective power output section due to component failure Return to Glentek for repair Noisy Tachometer Signal A noisy tachometer causes a considerable amount of random switching of the power output transistors thus increasing the amount of heat developed in the output section The higher the bandwidth the more the heating due to a noisy tachometer A noisy tachometer can be 20 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 7 MAINTENANCE REPAIR and WARRANTY identified by a large amount of rumbling and twitching of the motor at low or zero shaft speeds See section 2 3 6 on resetting the fault latch Note The fault latch will not reset unless the fault has been removed 7 2 A OVER VOLTAGE SHUTDOWN When the DC Buss voltage has exceeded 155VDC the Over Voltage indicator will latch on and the amplifier will be inhibited This circuit protects the motor and amplifier from high DC Buss voltages Possible causes 1 AC main voltage too high
58. to null out any offset with O volt input For all remaining adjustments when placing the amplifier in your system only the Signal potentiometer R12 or R13 and Balance potentiometer R15 should be adjusted Tach Voltage RPM Critically Under Damped Over Damped Damped Too much Tach Not enough Tach or not enough Bandwidth Figure 6 4 65 CONNECTING AMPLIFIER to a DIGITAL POSITION LOOP 1 Before connecting the amplifier to a digital position loop be sure the adjustments of section 6 4 have been made Start out with Loop Gain potentiometer R18 fully CCW and activate the digital position loop Slowly 18 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 6 START UP and ADJUSTMENT PROCEDURE turn Loop Gain potentiometer CW If servo runs away immediately adjust Loop Gain fully CCW and turn power OFF It is possible at this time that the digital loop is reverse phased An example of this would be if a positive voltage from the velocity DAC digital to analog converter required the motor to turn CW However it turned CCW instead causing the encoder feedback signal to count up instead of down This would cause a run away condition If you are out of phase as described be sure power is OFF and reverse the motor leads at the amplifier This will cause the motor to rotate in the opposite direction than it did before properly phasing the digital loop W
59. to output RPM required by your system for the differential signal input e g 10 volt input 2000 RPM R14 Tachometer Gain potentiometer sets the amount of tach signal required by your system Use in conjunction with the Compensation potentiometer R16 to adjust the system bandwidth R15 Balance potentiometer is used to null out any DC offset in the amplifier e g 0 volt input 0 RPM R16 Compensation potentiometer sets the amount of bandwidth frequency response required by your system Use in conjunction with the Tachometer Gain potentiometer R14 to adjust the system bandwidth Current Limit potentiometer sets the maximum acceleration and deceleration current Loop Gain potentiometer is used to reduce the velocity loop gain to zero when the system is first turned on to prevent run away operation Before turning the system on for the first time this potentiometer is set fully CCW to command zero current to the motor Once the system is correctly phased this potentiometer is set fully CW for all further system adjustments 10 GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 GA4567PA and GA4568PA MANUAL CHAPTER 3 PERSONALITY PREAMP CARD CURRENT MODE Refer to Appendix C drawings 4597 5110 and 4597 5112 R14 Signal Gain potentiometer sets the input voltage to output current required by your system for the single ended input e g 5 volt input 20 amp output current R15 Auxiliary Sign
60. ually mounted inside of a small box with a switch Common names used to describe this DC signal voltage source are Battery Box or DC Simulator Elaborate signal sources made for this purpose often include bipolar output potentiometer output adjust and polarity reversing GLENTEK Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 17 GA4567PA and GA4568PA MANUAL CHAPTER 6 START UP and ADJUSTMENT PROCEDURE switches etc You often hear the phrase Box the velocity loop servo ised by people working on servo systems This Signal Box may be purchased from Glentek Inc Part Number BB700 At this point the motor should be running smoothly While applying and removing the DC input signal adjust the Current Limit potentiometer R17 for desired maximum acceleration and deceleration Motor current should be observed by using an oscilloscope at TB1 7 4567 or TB2 7 4568 The scale factor of this voltage is 1V 10A Leave the Current Limit potentiometer at this setting for all remaining adjustments Adjust the Signal Gain potentiometer R12 or the Aux Signal Gain potentiometer R13 depending on the input you are using so that when you apply the DC signal the motor rotates at approximately 400 RPM Observe the tachometer voltage with an oscilloscope while applying and removing the DC input signal You will observe one of three possible waveforms critically damped under damped or over damped see figure 6 4
61. ype Servo Amplifiers e Linear Brush type servo amplifiers to 2 6KW e PWM Pulse Width Modulated Brush type servo amplifiers to 28KW Analog Brushless Servo Amplifiers e Linear Brushless servo amplifiers to 3 5KW e PWM Pulse Width Modulated Brushless servo amplifiers to 51KW Permanent Magnet DC Brush Type Servo Motors Continuous Torques to 335 in Ib e Peak Torques to 2100 in Ib Permanent Magnet DC Brushless Servo Motors Continuous Torques to 1100 in Ib e Peak Torques to 2200 in Ib MANUAL 4567 31 40 000 GLENTEK REVISION C DATE 15 May 2002 Solutions for Motion Control 208 Standard Street El Segundo California 90245 USA Telephone 310 322 3026 Fax 310 322 7709 www glentek com e mail sales glentek com
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