7x28AC - Copley Controls
Contents
1. 3 00 Ma o o a Ob 6 158 6 94 500090000000000090000000000090000 102 176 3 oo o o n o o o a a o 6 ag 1 Qi i e 4 v Q Y Q 7 00 o lt 177 8 d NENNEN e 2 72 gt ME 69 1 As 37 08 4 72 W Heat Sink Option 119 9 Heat Sink Option CONNECTORS J1 Power amp motor 9 position terminal strip J2 Motor J3 Signal J4 RS 232 485 Connector shells are connected to amplifier chassis for grounding shielding 15 position female Sub D type 4 40 standoffs for cable shell lock screws 37 position female Sub D 4 40 standoffs for cable shell lock screws 9 position female Sub D 4 40 standoffs for cable shell lock screws Cople lt Controls Corp Model 7XX8 Digital Brushless Driver MODEL 7228DC 7428DC OUTPUT POWER Peak power 20A 180V 20A 370V Peak time 1 second at peak power Continuous power 10A 180V 10A 370V OUTPUT VOLTAGE On resistance Ro ohms 0 2 0 15 Max PWM Peak Output Voltage Vout VDC X 0 97 Ro X Io INPUT POWER Mains voltage 45 186VDC 45 373VDC Mains current continuous output rating 16A 16A Inrush current on startup 19A max 37A max External mains fuse rating 20A 125V 20A 250V MECHANICAL Weight 2 71 Ib 1 23 kg without optional Heatsink Add 3 2 Ib 1 47 kg for heatsink MECHANICAL OUTLINE DC MODEL 10 5 Y PT 0 93 23 622. Connect button to connect to the driver Verify Serial Port to test the amplifier data that is indicated on the screen Desired Baud then press the Continue button If pus PDA 3400 communication is lost then press Amplifier S600 Connect to Host to load the communication 9600 Baud Rate Detected at 19200 C 57600 form fi 15200 Baud Rate Set to 115200 Before the Copley software can communicate do eye exa with the 7X X8 amplifier the RS 232 or RS 458 port must be connected If communication 15 T228 amp C Sar ae successful then the amplifier found indicator on Connect 000001 Serial Number this form will be illuminated green 2 Firmware Version The bar graph indicates that the presets are I uploading from the driver to the computer zd Ine Fig 2 Communication form Connect and upload data Software and firmware updates As time progresses into the future new features and enhancements will be added to the Copley Motion explorer software and DSP firmware Typically a new release will contain a software and a firmware update The firmware can be updated through the Copley Motion Explorer by selecting Tools Download firmware then select the appropriate cplyX XXX bin filename containing the latest firmware to download The Download form will display Erasing and then the downloading bargraph The firmware version can be verified on the communication form after re establishing communication
3. Preset O Sachin Motor Overtemp Motemp Switch Preset 1 Preset 2 M Preset 3 Reset Signal Gnd lt Enable Iv lE us 7 Pos enable inpi 8 w Neg enable Shlid Fuse 20A 1 11 time delayBIk Brn 2 L2 Wnt Blu Outputs Analog monite 3 Grn Iring Tor Status G db 7228AC Status limiter L1 Fuses 20A Bik Brn time delay Signal Gn 4 Note Circuits within dashed line are EE HOT At mains potential t 7428AC Cople Controls Corp m Model 7XX8 Digital Brushless Driver J1 Connections PIN SIGNAL Function AC Power Input Hot black or brown wire from AC mains AC Model AC Power Input Neutral white or blue wire from AC mains Euro J 1i Chassis safety ground green or green yel wire from AC mains Positive terminal of internal DC power supply N C Motor U Negative terminal of internal DC power supply N C 6 Moru Amplifier output to U winding of motor Motor V Amplifier output to V winding of motor Motor W 8 Motor W Amplifier output to W winding of motor 9 Chassis safety ground Also for cable shield of motor cable Fuses 25A time delayBik Brn 120VAC Fuses 25A time delay Brn Note All lines in this power stage are HOT Grn Grn Y At mains potential an 230VAC Wiring for 7AXX PIN SIGNAL Function Chassis
4. Accessories Ordering Guide Control Pendant Hand controler with switches potentiometers and connections for testing Software CD CD rom with Copley Motion Explorer Software Printed Users Manual for the 7XX8 Digital Amplifier Series 18 AWG USA power cord Cople E Controls Corp 18 Model 7XX8 Digital Brushless Driver Connection Diagram The diagram below can be used for quick connection of a development kit If alternative components are used such as a user supplied motor consult the users guide for connection details using a new motor and first time phasing instructions Driver PC or Laptop Model 7428AC STAT Input 32 264VAC U 50 60Hz o RS 232 Cable 120VAC Line Cord 5 Black ES H 1 PN T c 8 2 Pendant Signal Cable a 5 5405 3 D 8 2 9 5 og Encoder Hall cable J2 Copley Controls Motor Power Cable c 9 1 SGND 7xx8 Pendant A A J 5V H B E E 1 sTAT 0 GND X L STATUS RESET Refer to the application note for connection details for this kit 1 1 D OV 5V Brushless Motor Control Pendant Development Kit Ordering Guide Kit 001 7228AC CBL 162BE 001 6000rpm 1 4 round Kit 002 7428 CBL 232AE 001 45
5. Cople lt Controls Corp Model 7XX8 Digital Brushless Driver Drive status The Amplifier Status Now form presents the latest status data retrieved from the driver See Fig 3 The Status Updates check box located under the communication button can be checked to continuously retrieve fresh data The driver s current preset operating mode and other critical data are indicated These settings can be modified by pressing the More button When all indicators are illuminated green the drive 1s enabled and running If an in indicator is illuminated red then a fault condition has occurred Press the Amp OK button to diagnose and correct the fault A mpi Sloe Ail Motor Pr Postion oe on ENMEE Cont Lint oos HEEL Too EINEN Lint Source _Conuricaion __ M ras noces i Statue Lipdates F PullipssSy Enable sy Pos biie r FF Neg LiibsGnd Mode Pori Torque Profle data dree molor Torque kimani funalog Moritur Motor Date Text and rol No Stop Stop Hode Mult pie a cara Continus Cun Limit Postion 2047337 Peak Cunent Limit 37 Pu Lira x fo inbegr Larmi 1 01 Dommutsbon Accslmalion ie Statur Direi T irek xui 5 MIT EE mon Sh
6. Otherwise use the Auto Phasing routine for proper phasing of a new motor This screen is located under Diagnostics gt Specail gt More gt Auto Phase See Fig 11 B Prior to phasing the amplifier must have values set either from an amplifier file or model calculation Torque mode with 0 command is good and 3 command can be used after phasing to test Cople lt Controls Corp 10 Model 7XX8 Digital Brushless Driver Auto phasing Pacey The Auto phasing screen can be used to phase the motor Halls encoder and UVW Hall Shanes Hal tee power wires Check the Auto update box to A read the present Hall state If the motor is ca rotated through 1 electrical cycle then all 6 Hall states can be viewed if the motor Halls are phased correctly then the Hall j angle Green LED will make 1 congruent kiaiu Cormar rotation Press Attempt Phasing to initiate the routine The default motor command will be 10 of continuous current setting Phase init tire the phase init time will be in the range of 1 Upisa to 10 seconds and the phase counts settings will be used Ifall goes well then the Output Angle will track the Hall angle and any Hall offset detected will be indicated Fig 11B Adjustments to initial tuning calculations Intuitive Tuning Slides After the model calculates the initial tuning parameters the slides can be used to adjust the model parameters much
7. installed on the hot line Signal Board Layout JP6JP4 Jumpers Settings Function Factory installed JP13 Do not move U LIIBBBBD 85222 Default JP1 JP6JP4 DSP 8765432 1 7 8 n HHHBH mH Internal 87 654 32 1 Force Flash RA JP2 Tach Scale Default E Range 20Vmax 8 7 Eu 1 JP2 Tach Scale JP2 m Range 120Vmax Q wu Copley Controls Corp 5 Model 7XX8 Digital Brushless Driver Software installation To install the Copley software load the CD and run setup exe after the Copley software is installed the Copley icon will appear on the Windows Program file list To run the Copley software double click on the Copley icon Splash screen When the Copley Motion Explorer software is initiated the splash screen will appear See Fig 1 Copley Wekome to Press the On Line button to work live If a new C Controls Copley Motion Explorer motor is being used and no amplifier or motor file Ex Corp Bata Veraian 1 1 24 is available then the motor data file can be Click the buona below select the sms vou sani to wor created off line by pressing OFF Line and using the motor data form Communication Form The Communication form will appear on screen On Line Connection after loading See Fig 2 Press the COMM Double click Seral Communications Port buttons button for the proper serial port Press the below to test for amplifier present at that port
8. like a mechanical engineer would understand the system See Fig 11C The slides make intuitive tuning adjustments possible with the motor and load connected in a system Current Loop Slides Current Loop Position Loop a Ls di Bandwidh J The Bandwidth slide can be used to Ie LI increase or decrease the current loop laa 19 5909 response If proper values of motor 34310 LT inductance and resistance are entered for je the calculations then the default current iE Raf loop response is typically gt 1kHz The sum m mm Peaking slide be used to effect the 195 Cont Cur Lin A EL amount of overshoot of the current loop 2047 Fink Cun Lim amp Ti response Typical peaking is about 596 The E ii ie 1000 Pesk Time ms Baw Position Eao Lii default current loop values calculated by Linit Tracking Windom the model are excellent so it is unnecessary IH E to change them m Cancel Position Loop Slides Fig 11C Adjustments to initial tuning calculations The Bandwidth slide can be used to change the system bandwidth effecting the PID values Term and D term mostly The Gain slide changes the overall system gain by effecting term The stiffness slide changes the system stiffness by effecting the P term The Kaff slide changes the acceleration feed forward by effecting the
9. to 0 or set the integration term to 0 i Dersive Time 2 Increase the derivative term D for a sufficiently low position error 480 Position Emor Lim 3 Increase the proportional gain P for a sufficiently stiff position loop 0 4 Increase the integration limit and integration term T for sufficient Urs holding torque under load 1 oo Indes Capus Dounce The position error limit is the number of encoder counts allowed before a position error occurs T rine Poln Ena Kout is a multiplier at the end of the digital position loop so must not be jo Tearing window set to zero B5 Pere Tae Refer to Users Guide for more details on other position loop values Fig 6 Position loop values Cople Controls Corp Model 7XX8 Digital Brushless Driver Trace The Trace form can be used to display measured signals and events Located on the toolbar at Tools Trace M Example The Position Error trace can be displayed by selecting the appropriate item in the Trace Var pull down menu and commanding the motor to a new position See Fig 7 The trace can be initiated upon updating the driver with new instruction by selecting the Update option in the condition options The trace display can be armed for capturing a trace by pressing the Arm button For continuous arming on a condition check the Auto Arm box Fig 7 Trace of trapezoidal motion profile with positio
10. 00rpm 3 8 round Kit 003 7228AC CBL 232BE 001 6000rpm 3 8 round Notes 1 Kit Includes Power cord Data cable Motor signal cable Motor power cable Connector Kit Pendant cable Pendant Software CD Users Manual 2 Size 16 amp 23 motors have flying leads with connector Size 34 motors have military style connectors Corporate Offices 20 Dan Road Telephone 781 282 8090 Corp 19 02021 Fax 781 828 1750 www copleycontrols com
11. 4 91 1929 76 2 5 55 138 75 o O v 200 Gn t 1 00 50 0 Westwood MA USA 250 4 A t 4 00 w Heat Sink Option Heat Sink Option 100 0 Y CONNECTORS J1 Power amp motor 7 position terminal strip J2 Motor 15 position female Sub D type 24 40 standoffs for cable shell lock screws J3 Signal 37 position female Sub D 74 40 standoffs for cable shell lock screws J4 RS 232 485 9 position female Sub D 74 40 standoffs for cable shell lock screws Connector shells are connected to amplifier chassis for grounding shielding Cople Controls C Corp Model 7XX8 Digital Brushless Driver LOAD INDUCTANCE Minimum inductance 400 H Maximum inductance No maximum Bandwidth varies with inductance and supply BANDWIDTH Small signal 3dB 2kHz with minimum load at nominal supply voltage Varies with load inductance and PID filter values 205uS rate PWM OUTPUTS PWM frequency 20kHz Modulation Center weighted 50 duty cycle at output REFERENCE INPUTS Torque or velocity Analog 10V Differential 94k Ohms between inputs 20V maximum Position Digital 2 signal TTL Any of three formats CW CCW Pulse Dir A amp B quadrature pulse
12. 7X X8AC Models operate directly from the AC mains while 7X X8DC Models operate form directly rectified line models have full isolation between signal and power stages No power transformers are required All models take industry standard 10V analog control signals for torque or velocity control In addition stepper motor command pulses in CW CCW or PLS DIR format can be used for position control External devices such as sensors or PLC connections can initiate presets Presets can include a profiled move to a specific position a change in tuning parameters or a complete change in operating mode Through the 4 preset logic lines up to 16 distinct presets can be initiated Each driver will contain configuration information stored in nonvolatile Flash Memory on the driver Through the RS 232 port a single driver can be configured for an unlimited number of axis in a system The Copley Motion Explorer software a windows 95 98 visual basic interface can be used to tune configure and analyze the drive The configuration data can be uploaded and saved to disk for replicated usage Consequently the modularity of the 7XX8 driver provides the user with a single spares inventory that can be configured over all the needs of a system Windows 95 98 amp NT DLLs Dynamic Link Libraries work with virtually all windows programing languages including Visual Visual Basic and others A growing database of motor models and a continuou
13. Kaff term this is used to reduce position error during acceleration The Kvff slide changes the velocity feed forward by effecting the Kvff term this is used to reduce position error during velocity Cople Controls lt Corp Model 7XX8 Digital Brushless Driver Operating Mode Briefs At the time of this printing there are several operating modes available such as position mode velocity mode stepper mode and torque mode Future releases will make more modes of operation available Position mode By selecting Pos gt Torque from the Operating mode pull down list the drive can be configured for a position loop driving a current loop The current loop gains and limits apply to the torque loop that operates inside the position loop With the position loop selected the motion profile and position loop values are applicable Velocity mode The velocity loop operates as a position loop that never reaches the destination position By selecting Pos gt Torque from the Operating mode pull down list and then selecting velocity from the profile mode pull down list the drive can be configured for a velocity loop in a position loop driving a current loop The current loop gains and limits apply to the torque loop that operates inside the position loop With the velocity loop selected some of the motion profile and all of the position loop values are applicable By selecting 10V gt Pos gt Torque from the Operating mode pull down list
14. Model 7XX8 Digital Brushless Driver FEATURES DSP controlled torque velocity or position mode using encoder feedback from the motor Windows 98 software 9 Command sources Analog 10V inputs Digital PLS DIR CW CCW Digital Presets Data RS 232 RS 485 Select up to 16 preset modes using a PLC or Logic Hi Lo line 9 Programmable S curve and trapezoidal motion profiles RS 232 or RS 485 digital interface used to store all settings in internal FLASH memory for selecting preset modes Separate motor signal and control signal Sub D type connectors for simpler cabling 9 Terminals for DC Buss connect to external regenerative energy dissipator Input for motor temperature sensor protects motor No Transformer Required AC Version operates directly from AC mains DC Version operates from rectified line with full optical isolation between signal and power stages 32 132VAC 7228 32 264VAC 7428 9 Fault protections Short circuits from output to output output to gnd Over under voltage Over temperature APPLICATIONS e Linear Brushless Motors e Automated assembly machinery e Packaging Equipment ee ee L 4 7228DC 45 186VDC 20 10 T4mpc 4arvoc 9 PRODUCT DESCRIPTION The 7XXS series are DSP Digital Signal Processor controlled PWM servo amplifiers from Copley Controls Corp for control of AC brushless motors that require sinusoidal commutation
15. OK see above Red Buss Fault non latching Over or under voltage condition Amplifier recovers when in normal range Blinking red Latching Fault Output overcurrent short circuit following error or overtemp condition Clear with software control Ground Reset or power amp off on to clear condition ANALOG MONITOR 10V Full scale 1k Ohms source resistance Programmable monitor functions DC POWER OUTPUTS 5VDC 250mA 12VDC 25mA 12VDC 25mA Cople E Controls Corp Model 7XX8 Digital Brushless Driver DATA PORT RS232 or RS485 jumper selectable Permits programming parameters from PC Settings held in flash memory RS232 3 wire TxD RxD Gnd RS485 5 wire XMT XMT RCV RCV Gnd differential full duplex CONTROLLER GND Floating Gnd externally Power stage optically isolated THERMAL REQUIREMENTS Storage temperature range 30 C to 85 C Operating temperature range 0 to 70 C baseplate temperature Thermal resistance heatplate to ambient No heatsink or fan 0 92 deg C W no heatsink with fan 0 51 deg C W With heatsink no fan 0 6 deg C W with heatsink and fan 0 23 deg C W PROTECTION Output to output short Latches unit OFF will reset if Reset input is wired to ground or when power is cycled Output to ground short Latches unit OFF will reset if Reset input is wired to ground or when power is cycled Overtemperature Latches unit OFF at 70 C on heatplate will reset if Reset input is momen
16. abu T 5 etie Tine B M ask 100 atthe leeches amp HFFFF i T ach Digital Position impu Command Motion Done Mode Loop E f Df len Poston Eno e000 _ Tisckang Window 5 Loop rs Fig 3 Status Now form with More values for current preset displayed Applying changes amp saving presets to the amplifier Changes to the displayed settings are highlighted in yellow These changes can be immediately applied to the amplifier by pressing the Apply Now button The displayed settings can be downloaded to a preset for later execution by pressing the Save as Preset button and selecting the desired preset number Use the Void Preset to terminate the values in an amplifier preset Use the Load Preset button to view a preset from the amplifier Cople CC S9 Corp Model 7XX8 Digital Brushless Driver First Move To make a move the amplifier must be configured for the motor Typically the demo kit 1s factory configured for position mode Refer to the kit application note to verify all preset values Example If the application note says Operating mode is POS gt TORQUE then verify that this 1s true If values are not correct then make changes as appropriate apply and save to the desired preset Some important values are the P and I values for the current loop tuning if the current loop gain is too low then poor operation and motor overheating may occur if too h
17. and then selecting velocity from the profile mode pull down list the drive can be configured for a velocity loop in a position loop driving a current loop that uses the external 10V reference to command velocity The current loop gains and limits apply to the torque loop With the velocity loop selected some of the motion profile and all of the position loop values are applicable Torque mode By selecting Torque from the Operating mode pull down list the drive can be configured for a torque or current loop The current loop gains and limits apply to the torque loop With the torque loop selected the Command and Current loop values are applicable The motion profile and position loop values are not applicable By selecting 10 gt Torque from the Operating mode pull down list the drive can be configured for a torque or current loop that uses the external 10V reference to command current The current loop gains and limits apply to the torque loop With the 10V gt torque loop selected the Current loop values are applicable The command motion profile and position loop values are not applicable Digital position mode By selecting Pos gt Torque from the Operating mode pull down list and then selecting Gear from the profile mode pull down list the drive can be configured for a Digital position loop driving a current loop The current loop gains and limits apply to the torque loop that operates inside the digital position lo
18. ed J CBL341FE 001 Motor Performar T TLEN Buss 160VDC 1 4 1A 1 12 4 PET EL LE ET A _ cpntingods _ o LORI 0 1k 2k 3k 1k 2k 3k 4k 5k Speed rpm Speed rpm 25C Ambient w Heat sink 25C Ambient w Heat sink 1k 2k 3k 4k 5k 6k 0 56 0 125 Speed rpm CBL343GE 001 Motor Performan Y 05 25C Ambient w Heat sink Buss 160VDC Ic 5 8A Ip 15 4A Ya _olLWw0NOTT ve Sod Torque oz in NL D LENE 1k 2k 3k 4k 5k Speed rpm 0 002 bus codi 0 5000 02 p 4 0 250 ga 25C Ambient w Heat sink 5 On d 3675 Bolt Circle lt 343G 6 94 For 10 Bolt Controls Corp iz Model 7XX8 Digital Brushless Driver Amplifier Ordering Guide Amplifier 7228AC 20A peak 10A continuouse from 32 132VAC 50 60Hz AC mains 7428AC 20A peak 10A continuouse from 32 264VAC 50 60Hz AC mains 7228DC 20 peak 10A continuouse from 45 186VDC 32 132VAC rectified 7428DC 20 peak 10A continuouse from 45 373 VDC 32 264VAC rectified 1 Add to model number to specify heatsink option 2 Add F to model number to specify filter option Example 7228ACFH Notes Value Package Ordering Guide Notes 1 Value packages do not include accessories see development kits for a complete set of all accessories
19. h the Preset Manager An amplifier configuration can be saved to a file use the File Save As form to save the file with an appropriate name such as Demo343GR 001 cca Cople Controls C Corp Model 7XX8 Digital Brushless Driver Using a new motor Downloading an Amplifier Configuration To open the cca file containing a previously configured amplifier data use the File Open form to locate and open a file Existing motor and amplifier files are available on disk or through the Internet Motor data file it Moto Daba S peche adian To create a new ccm motor file use the Motor Feedback Motor Data form to enter the motor s type Erico feedback electrical and mechanical data See Fig 10 When all the data has been entered Fe face press the Save button to save the file with an D Bruch Tan feaa appropriate name ccm After the motor data 3 A f yas Ae form has been filled press the Calculate Amp EE 00 Typa Data button This will generate initial tuning parameters form a mathematical model for initial testing Fig 10A Motor data used for initial tuning calculations Press the Apply to Amp button to apply the calculated initial tuning values to the Status Now form Motor Data After the motor data is loaded whether from an amplifier file or from a model calculation verify that the values are correct See Fig 11A Motor Data Irt aa iater Lr The cu
20. igh then oscillations may occur Enable the drive To enable the amplifier switch the Enable line low with the hardware or check the Enable 5V box to change the active level of the enable line See Fig 4 Apply change but do not save this change to a preset unless necessary Pul Up In this default fail safe mode if the line is cut then the amplifier is disabled x dox 4 Enable the drive at this time and verify that the green LED on the drive 15 v Neg Limit Gnd on Refer to the Kit application note for details of factory configured Presets and there function Enables Fig 4 Enable polarities Motion Profiles The Profile Mode can be trapezoidal S curve velocity or gearing If a sinusoidal S curve profile is chosen then a value Jerk must be set The velocity profile is actually a position loop that never gets to the destination If no value for deceleration is entered than the acceleration value will be used See Fig 5 After a move the position count will settle in the settle window then after the settle time the settled status will change Position loop Fig 5 Motion Profile values The position loop tuning parameters are determined by a math model and Petition Loop are initialized Soft and with out loading of the motor For proper operation with a load the PID values for the Position Loop may need to be changed See Fig 6 E B A method for tuning 1 Adjust the integral Limit
21. n error of 10 counts E I J T P 3 LM F P Ir i Ii I EU KIL Le AN T P LR E ua T Temperature Sensor If no temperature sensor is used then do not check the Temp Sensor box If a temperature sensor 1s used then the operation thresholds can be set using the Temp Sensor form See Fig 8 Press he temp Sensor button to view the form Status Output The status output Stat 0 and Stat 1 can be programed to indicate that a fault condition has occurred or a motion profile 1s active Press the Status Output button located on the Status Now More form to open the Status Output form See Fig 9 Check the appropriate status box True False button and On Hi On Low option End of Move The Status line can be used to indicate the end of a move This is useful for a PLC that 1s monitoring a line for the end of move indicator before initiating another preset move AAA AAA RE EEEEEEEEEEEEEEEE Saving an Amplifier Configuration Fig 9 Status form truth table During initial communication with the amplifier all the presets are uploaded to the computer If the amplifier has not been pre configured then all the presets will be void If the Copley amplifier has been pre configured to operate with a particular motor then some or all of the presets will be configured These presets can be viewed wit
22. op With the gear profile mode selected some of the motion profile and all of the position loop values are applicable The digital input source can be set to any one of the below listed modes A B Encode Where quadrature encoder pulses are used as a master encoder to position the motor CW CCW Where pulses on the clock wise line produce CW rotation and pulses on the counter clockwise line produces CCW rotation Pls Dir Where stepper pulse and direction are used to position the motor Gear Ratio The gear ratio can be set to scale the number of digital input counts to the number of encoder counts Cople E Controls Corp 12 Model 7XX8 Digital Brushless Driver Amplifier Connections Functional Diagram AC Model Command Inputs L Pulse Ch A Tx ee Direction Ch A Data Port 35 3 Pulse cua Millia Pulse CW Directio Driver 5 Pulse CCW E Ch B Receive Jumper Selec A Quadrature Ch X LI B Quadrature Ch X Hall U OVW 10V Anolo amp C Hall m Hall V E _ Ref t sna cs Enc A i Signal ground Enc A d E Enc B Enc B UN F T Enc X IN Enc X Note Amplifier signal ground must Buffered Enc BufferedEnc BufferedEnc Bolt Buffered Enc 5V Buffered Enc X out Shia ov Inputs Shld
23. rrent limit source can be external where a voltage or resistance 1s used to VOR outa n 4 13 Continuous Cun Limit set the peak current limit or internal where the continuous current limit and peak dee 25 Paak Cureni Lim current limit values are used e The average voltage can be limited to the motor by setting the PWM limit Trapezo il Phasing Made An important value to get correct is the Phase counts the number of encoder Phos Couris counts per electrical cycle Parte Consent w M Mode If the motor has Halls then Trapezoidal or Sinusoidal commutation and Hall based Algorithmic phasing can be used If no Halls present then use 6000 ini Tine algorithmic phasing mode with Phase correction mode ON Phase initialization Encoder Polanty time set and sinusoidal commutation 11 AE Index aD Hij Temp Seren Encoder polarity normally low pulse high index or normally high pulse low 0 nda i Lo Tanp Sensor index _ must be set correctly for proper algorithmic phasing or phase correction Also the timing of the index pulse with respect to the state of the i Fig 11A Motor data A B pulses must be selected correctly for proper detection of the index pulse values First time phasing If a motor has been previously phased for commutation with a Copley amplifier then the same wiring of the Halls and motor phases will apply
24. rushless Driver 18 Flying lead CBL162BE 001 Motor Performa Buss 75VDC Ic 4A Ip 20 s Peal 460 6 o Ve BRR e eS deese ups gt VU SES 2 A0 L o 1k 2k 3k 4k 5k 6k 2509 0999 Speed rpm 0005 25 Ambient w Heat sink 1 30 SQ 4 79 CBL232BE 001 Motor Performan 4x00 218 Buss 160VDC Ic 4 1A 20 thru holes equ spaced TES on O 2 625 bolt circle 0 0000 14 075 18 Leads 0 3750 0 0005 B 0 1k 2k 3k 4k 5k 6k Speed rpm 25C Ambient w Heat sink 232 001 Motor Performance CBL233BE 001 Motor Performa Buss 160VDC Ic 2 1A Ip 10 5A Buss 250VDC Ic 2 1A Ip 10 5A Buss 160VDC Ic 4 1A Ip 20A 600 600 69 WO FEET ORES sod tt 4 N Pe POT LLNAILLLLISSULTTELLLLLLIN 84 TT TTT 300 300 33 e EE EOD a 5 4 6 toe IRL too Lemos 224 jeonimisus 1 e 0 1k 2k 3k 4k E 1k K ok 1k 2k 3k 4k 5k 6k peed rpm peed rpm Speed rpm CBL233AE 001 Motor Performance 25C Ambient w Heat sink Buss 160VDC Ic 2 1A Ip 10 5 Buss 250VDC Ic 2 1A 10 5A TT TT TT T
25. s Preset Digital 4 line 28V max Group programmable 22k Ohms internal pull up to 5V or pull down to OV The four inputs initiate 16 predefined modes ANALOG TACHOMETER INPUT 120V or 20V maximum Jumper selectable Load 240k Ohms MOTOR OVERTEMP INPUT Analog input Sk Ohms internal pull up to 5V for thermistor or IC sensor Thresholds programable MOTOR ENCODER INPUTS A B X 2 2k Ohms internal pull up to 5V differential or single ended 4Meg Counts Sec maximum BUFFERED OUTPUTS Enc Buffout A HCMOS Differential line driver Buffered encoder output A Enc Buffout HCMOS Differential line driver Buffered encoder output B Enc Buffout X HCMOS Differential line driver Buffered encoder output X HALL INPUTS U V W Single ended 10k Ohms internal pull up to 5V LOGIC INPUTS Enable Enables amplifier within Sms when active Pos Enable Enables CW rotation Neg Enable Enables CCW rotation Reset Resets latching fault condition recovers in 1ms TTL 28V max Group programmable 22k Ohms internal pull up to 5V or put down to OV Software programmable active Lo or Hi LOGIC OUTPUTS Status output 1 2 Software function programmable N channel MOSFET 10k Ohms pull up to 5V Max 50V off voltage Max 250mA sink 5 Ohms On resistance STATUS LED Bicolor LED changes color and flashes to indicate amplifier operating status Blinking green Ready Amplifier OK will run when enabled Green Normal Amplifier enabled AND Amp
26. safety ground green or green yel wire from AC mains DC power input positive terminal from DC power supply DC power input negative terminal from DC power supply Amplifier output to U winding of motor Amplifier output to V winding of motor 6 MoetrW Amplifier output to W winding of motor Chassis safety ground Also for cable shield of motor cable Fuses time delay A Blk Brn Inrush limiter 120VAC Wiring for 72XXI Fuses time delay E BIk Brn mE Grn Grn Ye Note All lines in this power stage are HOT At mains potential Cople lt Controls Corp 230VAC Wiring for 7AXX 14 Model 7XX8 Digital Brushless Driver LED Indicator functions Color and state of LED indicates amplifier operating conditions COLOR CONDITION ACTION REQUIRED TO ENABLE Flashing Green Ready Enable amplifier J3 3 Note 1 Flashing Red Latching Fault Ground Reset input or cycle AC power OFF ON Signal Wiring Signal connections should be made with wire that has a rating to support the signal current AWG 24 wire will support all motor signals in this series Additional recommendations for wire insulation are for a voltage rating of 300V and a temperature range of 80 C To minimize coupling of PWM noise sensor signal wiring should be multiple conductor twisted pair shielded cable Further more all cable shields should be case grounded at both ends for compliance with CE emi
27. sly evolving collection of amplifier operating modes are available as resources for the 7X X8 Driver Cople lt Controls Corp Model 7XX8 Digital Brushless Driver Tech nical specifications Test conditions 25 C ambient Load 400 in series with 1 Ohms MODEL 7228AC 7428AC OUTPUT POWER Peak power 20A 110V 20A 205V Peak time 1 second at peak power Continuous power 10A 130V 10A 250V OUTPUT VOLTAGE On resistance Ro ohms 0 2 0 15 Max PWM Peak Output Voltage Vout VAC X 1 41 2 X 0 97 Ro X Io Maximum effective output voltage at continuous power 130V 10A 250V 10A Maximum effective output voltage at peak power 110V 20A 205V 20A INPUT POWER Mains voltage 32 132VAC 47 63Hz 32 264VAC 47 63Hz Mains current continuous output rating 16A 16A Inrush current on startup 37A max 37A max External mains fuse rating 20A 125V 20A 250V MECHANICAL Weight 3 71 Ib 1 69 kg without optional Heatsink Add 3 2 Ib 1 47 kg for heatsink 7 50 MECHANICAL OUTLINE 190 5 AC MODEL A A M 2909090909000050000000000909909 0 93 23 62 3 6 22
28. ssions limits J2 Motor Hall and Encoder Signal Connections PIN SIGNAL Function Digital Hall inputs for U Digital Hall inputs for V s aa e ooa a _ Notes 5VDC 250mA connects to 13 15 J3 27 and 12 11 Combined not to exceed 250 Cople Controls Corp Model 7XX8 Digital Brushless Driver User amp Control Signals Connections J3 Signal Connections SIGNAL Function PIN SIGNAL Function Ref 10V analog command input Ref 10V analog command input Enable input Amplifier enable Pos Enable Positive direction enable og command _ Posie don ematie J4 Communications Data Connections 7xx8 models support RS 232 and RS 485 Jumpers on the signal PC board set the configuration for either type of communication protocol Data connections should be made with wire that has a rating to support the signal current AWG 24 wire will support all data signals in this series Ribbon cable is acceptable for short distances and baud rates less than 9600 however to minimize coupling of PWM noise data signal wiring should be multiple conductor twisted pair shielded cable The amplifier looks like DCE Data Communications Equip ment and does not require a null modem cable RS 232 Connection PIN SIGNAL Function 3 en R522 Seia Daa mou Cono gt Ang lt Controls Corp 16 Model 7XX8 Digital B
29. tarily grounded or when power is cycled off on Undervoltage shutdown at internal DC buss lt 45VDC Overvoltage shutdown buss gt 195VDC 7228 or buss gt 390VDC 7428 Current limiting Output current peak continuous amp peak time limits programmed via RS232 port CE CONFORMITY EN 55011 1992 CISPR 11 1990 Edition 2 Amendment 2 Limits and Methods of Measurement of Radio Disturbance Characteristics of Industrial Scientific and Medical ISM Radio Frequency Equip EN 50082 1 1992 Electromagnetic Compatibility Generic Immunity Standard EN 61010 1 1993 Safety Requirements for Electrical Equip for Measurement Control and Lab Use Recommendations A line filter such as Corcom P N20VDK6 can be installed at least 3 feet from the driver s power entry terminal strip to reduce line noise This will reduce the systems line noise for compliance with CE emissions limits Power supply and motor connections should be made with wire that has a rating to support the amplifiers continuous current AWG 14 wire will support all amplifiers in this series Additional recommendations for wire insulation are for a voltage rating of 600V and a maximum temperature of 105 C Fusing should be time delayed and install on any hot lines coming from the mains The fusing for the high voltage units should be rated for 250VDC at 25Amps and are to be installed on both hot lines The fusing for the low voltage units should be rated for 120VDC at 25 Amps and 1s to be
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