4xx2P - Copley Controls
Contents
1. 1 All amplifier grounds are common J1 3 J1 4 J2 2 J2 7 and J2 10 Amplifier grounds are isolated from case amp heatplate 2 Jumper JP1 default position is on pins 2 3 for ground active Enable input J2 11 For Inhibit function at J2 11 5V enables move JP1 to pins 1 2 3 For best noise immunity use twisted shielded pair cable for reference and tachometer inputs Twist motor and power cables and shield to reduce radiated electrical noise from pwm outputs Copley Controls 20 Dan Road Canton MA 02021 Tel 781 828 8090 Fax 781 828 6547 Web http www copleycontrols com Page 3 of 3 MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING CONNECTORS AND PINOUTS J1 MOTOR amp POWER CONNECTIONS Pin Signl Remaks 7 1 Motor Amplifier output to motor winding 2 Motor Amplifier output to motor winding GND Power supply return Connect to system ground at this pin 4 GND Power supply return Connect to system ground at this pin 5 Hv HV DC power supply input J2 AMPLIFIER BOARD CONNECTIONS Pin Signal Remarks 1 esv 15Vinserieswith fOkKO 2 Gnd 3 15V iBVinsereswih KO 4 Differential input positive terminal for Reference voltage 5 Differential input negative terminal for Reference voltage 6 Tach Negative terminal of brush tachometer 8 Cu2. 6547 Page 1 of 1 MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING FILTER DIAGRAM AMPLIFIER FUNCTIONAL DIAGRAM JP1 PINS 2 3 FOR ENABLE AT J2 11 PINS 1 2 FOR INHIBIT AT J2 11 321 ENABLE INTEGRATOR RESET SWITCHES 11 e RH2 100K TURN ON WHEN AMP IS DISABLED JP1 cce Es POS ENABLE aux 16 Es 2 1 INTEGRATOR GREEN NORMAL g ja STATUS pae ENABLE RED FAULT amp 43 TACH TACHLEAD 05 CONTROL NOTE 45V h LOGIC m ON CO 97 DEFAULT VALUE OF CH11 IS 0 OHMS d PAULL OUTPUT O AAN O 4 FOR TORQUE MODE OPERATION 18 RESET 100 FOR VELOCITY MODE BRUSH TACH e RH10 REPLACE CH11 WITH 4 7NF CH17 MOMENTARY SWITCH CLOSURE RESETS FAULT tov oof oe WIRE RESET TO GROUND FOR SELF RESET 60 4K BEPAMP REF LEAD Gv 1 RH6 CH8 CURRENT LIMIT o J2 SIGNAL CONNECTOR ot uut SECTION REF gt 100PF gt 47K O o 4 ot VALUE DEPENDS ON MODEL T gt SEE ARMATURE INDUCTANCE TABLE REF RH7 100K RH12 182K 2 PEAK O AA O T SERVO CURRENT CURRENT J1 MOTOR amp POWER CONNECTOR PREAMP 47K ERROR RH13 47MEG AM
3. 7UF 0 227 0 CH14 PEAK TIME LIMIT 47 MEG O RH13 CONTINUOUS CURRENT LIMIT 182K RH12 CURRENT LIMIT O C 2 0 PREAMP DC GAIN amp INTEGRATOR 60 4K 1 RH10 SEL O CH9 PREAMP HI FREQUENCY ROLL OFF JP1 SE O REF INPUT LEAD CAPACITOR mm 100K O o Ru7 REFERENCE INPUT SCALING SEL O O REF INPUT LEAD RESISTOR Ji SEL O O CHS J2 1 TACH INPUT LEAD NETWORK SEL O O 1116 1 100K TACH INPUT SCALING 100K O O RH2 AUX INPUT COMPONENTS LABELLED SEL imis d H o o BALANCE RANGE ARE NOT INSTALLED AT FACTORY USER SHOULD SELECT VALUES AS REQUIRED ARMATURE INDUCTANCE Model Load mH 80 6k 390 pF 69 8 k 390 pF Note Values in bold amp italics are factory installed standard Values shown are for 90V 4122 and 125V 4122 At lower supply voltages RH15 may be increased and CH17 decreased PEAK CURRENT LIMIT AMP CONTINUOUS CURRENT LIMIT AMP 10 6 47Meg 193 8 30k 10 6 18k 67 4 91k PEAK CURRENT TIME LIMIT SEC Notes o Current Limits 1 Values in bold amp italics are factory installed standard 2 Peak times double after polarity reversal 3 Peak current limit should be set greater than continuous current limit 08 0383 If Ipeak Icont then peak overrides continuous limit and Icont Ipeak Minimum setting for peak current is 096 of peak rating 4 Continuous curr
4. FEATURES e Mounts on customers printed circuit boards Uses output filter option for reduced PWM noise to adjacent circuits APPLICATIONS OEM drive systems THE OEM ADVANTAGE Minimize cabling for lowest cost products Uses industry standard connectors for solderless installation MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING CSS MODEL FEATURES 4122P 24 90VDC 10 20A Standard 0 100 modulation 4212 24 90VDC 6 12A Standard 0 100 modulation 41222 24 90VDC 10 20 50 modulation 4212ZP 24 90VDC 6 12A 50 modulation FEATURES These versions of the 4122 4212 models and their variants use extended pins that interface with printed circuit board mounted connectors for direct mounting of the amplifier to customers pc boards Pins models also accept the F option card that has output edge filters that reduce the noise coupling of PWM outputs to adjacent cabling and circuitry The output filter card option uses the same connectors as the popular 300 series models 303 306 306A and variants for easy upgrading to the 4xx2 models The filter is a dual section L C R that slows down the switching edges the rise and fall times of the outputs for greatly reduced coupling of PWM noise to nearby cables and circuits Copley Controls 20 Dan Road Canton MA 02021 Web http www copleycontrols com Tel 781 828 8090 Fax 781 828
5. P CURRENT O VV O 15V CHi4 0 470 Bivi MOTOR CW RHI M obo STAGE TIME BALANCE OUTPUT MOSFET ine CURRENT Hh MOTOR 50K 10 MEG Voltage gain 1 URREN 15V m 6V for VOLTAGE CURRENT Q 4 AAA Ipeak CUM 4 8 kHz FILTER Gv 4HV FAR 33NF 10 V 1K 6V at CURRENT Ipeak MONITOR 8 W 4 8 kHz FILTER GND 2 v E 54 CASE MAY BE GROUNDED AUXILIARY DC DC FOR SHIELDING DC OUTPUTS 15 4 CONVERTER c 15V 35 4 L CASE GROUND NOT CONNECTED Em POWER GROUND AND SIGNAL GROUNDS ARE COMMON TO CIRCUIT GROUND Copley Controls 20 Dan Road Canton MA 02021 Web http www copleycontrols com Tel 781 828 8090 Fax 781 828 6547 Page 2 of 2 MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING TORQUE MODE ENCODER ppr UUL VELOCITY MODE ENCODER pnr 3 REF N REF 5 2 REF J2 J1 Tt T 15 2 lt lt 6 J2 GND 10 7 GND 10 ENABLE 6 4111 3 EN ENABLE 11 3 POS ENABLE 12 J1 4 GND SAR ENABLE Pau POS ENABLE 12 J 4 Le end F L NEG ENABLE 13 5 o HV NEG ENABLE 13 2 JA 5 HV Note JP1 on pins 2 3 default Note JP1 on pins 2 3 default Notes
6. W will have the effect of a 10V signal at the reference inputs STATUS LED Dual color red green HV Enable Short Overtemp 1 5 Notes 1 HV normal 20V and 92V for model 4122 gt 20V and lt 129V for model 4212 2 Enable is ground active for JP1 on pins 2 3 default To reverse function switch JP1 to pins 1 2 3 Shorts detected by overcurrent circuit are between outputs or from outputs to ground 4 Overtemperature faults occur when heatplate temperature is gt 70 C 5 and Enable cause momentary amplifier shutdown operation is restored when HV is within normal limits and Enable input is active Output shorts and overtemperature faults atch off amplifier Thus amplifier will remain off until power is cycled on off or Reset input is grounded momentarily If Reset input is wired to ground output short and overtemperature faults will self reset every 200ms Copley Controls 20 Dan Road Canton MA 02021 Tel 781 828 8090 Fax 781 828 6547 Web http www copleycontrols com Page 4 of 4 MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING CSCS Oo NO PARTS INSTALLED 9 O IN THESE LOCATIONS Q O C 5 0 H177 LOAD INDUCTANCE COMPENSATION O C 2 9 CH16 SEE CHART FOR VALUES O RH15 O4
7. a generator that produces an analog signal that has a polarity and amplitude proportional to the motor speed The amplifier subtracts the tach signal from the reference signal and amplifies the difference between them This is called velocity mode because the amplifier changes the motor current torque so that the motor velocity is proportional to the reference signal TORQUE MODE OPERATION Torque mode is the default configuration For input voltages of 10V the amplifier will output its peak rated current In torque mode motor current is held constant and motor speed or velocity changes as the load changes In torque mode the gain of the servo preamplifier is simply 0 6 and scales the 10V from the reference signal down to the 6V that drives the PWM stage The servo preamplifier integrator function is disabled and the low gain is constant over a wide range of frequencies Thus we sometimes call this flat gain mode VELOCITY MODE OPERATION The difference between the reference and tachometer signals is amplified and used to change the torque on the motor Ideally the difference between the command and feedback signals would be zero so in velocity mode operation the servo preamplifier must have much higher gain than when in torque mode In addition the gain must change over a range of frequencies For stiffness that corrects for steady state changes the amplifier uses an integrator For fast response the loop gain of the s
8. ence signal and tachometer signals are compared and the difference signal produced and amplified Three components on the header control the behavior of the servo preamp The chart below lists the default torque mode and starting point values for velocity mode operation Torque Velocity 680k CH9 controls the high frequency roll off RH10 controls the loop gain and thus the step response of the amplifier CH11 along with RH7 forms the integrator that gives the stiffness at a standstill or speed regulation while running CURRENT LIMITING This stage takes the output of the servo preamplifier and processes it before sending it to the PWM stage The amplitude of the signal is first clamped to produce peak current limiting This signal then goes to the continuous current limit circuit where these functions are produced Finally the current limited signal is outputted to the PWM stage as the current reference signal This signal is quite useful in that the current limit action can be seen here and measured without connecting a motor thus protecting it from overload during initial setup PWM STAGE The voltage at the output of the current limit stage is called the current reference This signal becomes the demand signal that controls the PWM stage Here the current demand is converted into a current in the motor This current can be measured at the current monitor which shows the response of the motor to the curren
9. ent sense is for average current Symmetrical waveforms with zero average value may cause overtemperature shutdown of amplifier or motor damage R 5 Times shown are for 100 step from with default value of RH13 4 7 When changing RH13 peak times will change Set RH13 for continuous current limit first then pick CH14 based on waveforms at Curr Ref J2 9 Copley Controls 20 Dan Road Canton MA 02021 Tel 781 828 8090 Fax 781 828 6547 Web http www copleycontrols com Page 5 of 5 MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING APPLICATION INFORMATION IMPORTANT ALWAYS REMOVE POWER WHEN CHANGING HEADER PARTS OPERATING MODES These amplifiers operate as either open loop current sources or feedback devices using analog tachometers As open loop current sources the 10V at the reference inputs produce current in the load typically a motor The motor acts as a transducer and converts current into torque the twisting force at the motor shaft This is called torque mode It is used most frequently in systems that have controllers taking feedback from an encoder on the motor shaft The computer calculates both position and velocity from the encoder signal processes them in a digital filter and outputs a signal to the motor causing it to accelerate or decelerate As a feedback amplifier a signal is generated by an analog brush tachometer mounted on the motor This is
10. ervo preamplifier must be tailored to the characteristics of the motor and tachometer To control oscillations from the tachometer the gain of the preamplifier must roll off or decrease at higher frequencies In velocity mode motor speed is held constant while motor current changes in response to changes in the load THE PARTS OF THE AMPLIFIER DIFFERENTIAL AMPLIFIER The reference signal the command signal from the control system is sensed by a differential amplifier This acts like a voltmeter with two probes measuring a voltage between two points Current flowing in the amplifier power wiring causes voltage drops in the wires resistance This in turn can produce a voltage at the amplifier ground that is different than the control system ground If this voltage is added to the output of the control system it can produce oscillation or inconsistent operation To eliminate this effect you should always use both reference inputs Connect the Ref input to the output of the controller card and the Ref input to ground at the control card Now the differential amplifier will measure the control signal at the control card and will reject any noise that exists between amplifier and control System grounds THE SERVO PREAMPLIFIER This section processes the reference signal and any feedback signals and generates an internal current reference signal that controls the PWM stage to produce output currents It is here that the refer
11. rMon Output current monitor 6V output at peak output current 9 CurrRet 7 Current demand signal to PWM stage 6V demands speakcurrent 10 Gnd Sigmlgound 2 20 Enable Amplifier enable input enables or inhibits PWM switching at outputs Default Gnd enables amplifier open or 5V inhibits JP1 amp 2 3 For controllers that output 5V to enable amplifier move internal jumper JP1 to pins 1 2 Gnd will inhibit 5V or open will enable Gnd to enable output current in one polarity open or 5V to inhibit Typically used with grounded normally closed limit switches Gnd to enable output current in opposite polarity open or 5V to inhibit Typically used with grounded normally closed limit switches Normal Current sinking when amplifier enabled and operating normally Goes to 5V when amplifier disabled or fault condition exists Reset Ground to reset overtemp or output short circuit latching faults For automatic reset of faults every 200mS ground permanently 16 Au 7 Single ended auxiliary input BALANCE POTENTIOMETER Default position centered Functions to bring output current in torque mode or output velocity in tachometer mode to zero with reference input voltage at zero or control system output at zero Normal range is 1 of full scale with 10Meg resistor in header location RH1 To use the pot as a wide range set point adjustment install a 150kQ resistor at RH1 Now full CW or CC
12. t demand signal By operating as a current source the PWM stage is able to achieve faster response from the motor than if was acting only as a variable voltage The current error amplifier compares the current reference with the current monitor and adjusts the output voltage such that the demanded current flows in the motor The gain of this amplifier is controlled by RH15 CH16 and CH17 which are used to compensate the amplifier for the motors inductance 1 Copley Controls 20 Dan Road Canton MA 02021 Web http www copleycontrols com Tel 781 828 8090 Fax 781 828 6547 Page 6 of 6 MODELS 4122 4212 AND VARIANTS P VERSIONS FOR PC BOARD MOUNTING OUTLINE DIMENSIONS Dimensions in inches mm ORDERING GUIDE Model 4122 20A peak 10A continuous 22 to 90VDC brush motor amplifier Model 4212 12A peak 6A continuous 22 to 125VDC brush motor amplifier Copley Copley Controls 20 Dan Road Canton MA 02021 USA Controls Tel 781 828 8090 Fax 781 828 6547 Web http www copleycontrols com Rev B 06 08 2010
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