Model 5015 EUROCARD DC Brushless Servo Amplifier

Transcription

1 FEATURES Complete torque ( current ) mode functional block on 3U X 8HP X 160mm Eurocard Drives motors with 60 or 120 Halls Single supply voltage +18 to +55VDC Output edge filters reduce PWM noise from outputs ±5A continuous, ±10A peak More than double the power output of servo chip sets 2.5kHz bandwidth Wide load inductance range 0.2 to 40 mh. Hall power Fault protection: Short-circuits from output to output, output to ground Over/under voltage Over temperature Self-reset Separate continuous, peak, and peaktime current limits Surface mount technology APPLICATIONS X-Y stages Robotics Automated assembly machinery Component insertion machines The OEM Advantage ONLY ONE POT!: Internal component header configures amplifier for applications Conservative design for high MBTF PRODUCT DESCRIPTION is a complete PWM brushless servo amplifier for applications using DC brushless motors in torque ( current ) mode. It provides six-step commutation of three-phase DC brushless motors using 60 or 120 Hall sensors on the motor, and provides a full complement of features for motor control. These include /Pos and / Neg enable inputs using fail-safe (ground to enable) logic. Power delivery is four-quadrant for bi-directional acceleration and deceleration of motors. features 500W peak power output in a compact package using surface mount technology. An internal header socket holds components which configure the various gain and current limit settings to customize the 5015 for different loads and applications. Output edge filters slow PWM rise and fall times to greatly reduce noise coupling into adjacent cables and equipment. Separate peak and continuous current limits allow high acceleration without sacrificing protection against continuous overloads. Peak current time limit is settable to match amplifier to motor thermal limits. Header components permit compensation over a wide range of load inductances to maximize bandwidth with different motors. Package design places all connections along one edge, via the DIN connector, for easy connection, while minimizing footprint inside the enclosure. High quality components and conservative ratings insure long service life and high reliability in industrial installations. A differential amplifier buffers the reference voltage input to reject common-mode noise resulting from potential differences between controller and amplifier grounds. An output short circuit, over/under voltage, or over temperature condition will cause the amplifier to shutdown. When the fault is removed, the 5015 will self-reset. 241

2 TECHNICAL SPECIFICATIONS Typical 25 C ambient, +HV = +55VDC. Load = 200µH. in series with 1 ohm unless otherwise specified. OUTPUT POWER Peak power Unidirectional After direction change Continuous power OUTPUT VOLTAGE 50V for 0.5 second, 500W 50V for 1 second, 500W 50V, 250W Vout = (0.97) (HV) -(0.4)(Iout) MAXIMUM CONTINUOUS OUTPUT CURRENT Convection cooled, no conductive cooling 35 C ambient Fan-cooled; 400 cfm 55 C LOAD INDUCTANCE Selectable with components on header socket 200 µh to 40mH (Nominal, for higher inductances, consult factory) BANDWIDTH Small signal 2.5kHz with 200µH load Note: actual bandwidth will depend on supply voltage, load inductance, and header component selection PWM SWITCHING FREQUENCY 25kHz ANALOG INPUT CHARACTERISTICS Reference Differential, 20K between inputs with standard header values GAINS Input differential amplifier X1 as delivered. Adjustable via header components RH6, RH7 PWM transconductance stage 1 A/V ( output vs. input to current limit stage ) OFFSET Output offset current ( 0 V at inputs ) 20 ma max. ( 0.2% of full-scale ) Input offset voltage 20 mv max ( for 0 output current, RH6,7 = 10kΩ ) LOGIC INPUTS Input voltage range 0 to +24V Logic threshold voltage HI: 2.7V, LO: 1.5V (Schmitt trigger inputs with hysteresis) /Enable LO enables amplifier (/Enable Pol open), HI inhibits; 50 ms turn-on delay /POS enable, /NEG enable LO enables positive and negative output currents, HI inhibits /Enable Pol (Enable Polarity) LO reverses logic of /Enable input only (HI enables unit, LO inhibits) *Note: Do not connect /Enable Pol input to devices that operate > LOGIC OUTPUTS +Fault HI = Overtemp OR output short OR power NOT OK., OR NOT Enabled; Lo = Operation normally AND enabled. HI output (NPN transistor with collector pull-up through 10k to ) +40V max. LO output < max. current sink of 30mA. INDICATOR (LED) Green = Normal Amplifier enabled AND Normal ( Power OK, no shorts or no overtemp ) Red = Fault ( NOT Normal, see +Fault above. ) CURRENT MONITOR OUTPUT ±10A (2A/volt) DC POWER OUTPUTS DC PROTECTION Output short circuit (output to output, output to ground) Overtemperature Power supply voltage too low (Undervoltage) Power supply voltage too high (Overvoltage) POWER REQUIREMENTS DC power (+HV) Minimum power consumption Power dissipation at 5A output, 55VDC supply Power dissipation at 10A output, 55VDC supply THERMAL REQUIREMENTS Storage temperature range-30 to +85 C Operating temperature range MECHANICAL Size Weight 30mA (max current for Hall sensor) operation resumes 50mS after short circuit is removed. Shutdown at >70 C on heatplate (operation resumes 50mS after temp <70 C.) Shutdown at +HV < 18VDC (operation resumes 50mS after power >18VDC) Shutdown at +HV > 55VDC (operation resumes 50mS after power <55VDC) A peak. 2.5 W 10W 40W 0 to 70 C baseplate temperature 3U x 8HP x 160mm 0.81 Lb., (0.37 kg.) 242

3 FUNCTIONAL DIAGRAM HALLS REF(-) d 22 REF(+) d 20 CURRENT MONITOR Hall U Hall V Hall W b 16 b 18 d 2 d 4 d 6 DIF AMP RH7 RH6 - + HALL LOGIC 1nF 1nF PEAK PEAK TIME CONT CURRENT LIMIT SECTION RH5 RH4 RH3 +15 BALANCE 1M +15 Voltage Gain = 1 5K SELF-RESET WHEN FAULT IS REMOVED GREEN = NORMAL RED = FAULT - + CURRENT ERROR AMP OUTPUT CURRENT SENSE +/-5V AT +/-10A STATUS LED CH2 RH1 2.2M 15 NF 49.9K 2.2 MEG 470 PF PWM STAGE MOSFET "H" BRIDGE Gv = +HV STATUS & CONTROL LOGIC 10 +HV EDGE FILTER 750Ω z 16 +FAULT z 20 ENABLE z 22 POS ENABLE d 26 NEG ENABLE d 28 d 16 ENABLE POL b 2 z 2 b 4 z 4 b 6 z 6 Mot U Mot V Mot W +HV d 8 b 8 z 8 d 14 b 14 z 14 d 32 b 32 z 32 OPTO- COUPLER ~ 30mA b POWER GROUND AND SIGNAL GROUNDS ARE COMMON DC / DC CONVERTER TYPICAL CONNECTIONS CONTROLLER REF(-) d 22 ENCODER REF(+) d 20 SIG b 18 DC POWER SUPPLY +HV AC - AC + SIG /NEG ENAB /POS ENAB /ENABLE d 8 b 8 z 8 d 14 b 14 z 14 d 32 b 32 z 32 d 28 d 26 z 22 b 2 z 2 b 4 z 4 b 6 z 6 b 22 d 2 d 4 d 30mA Mot U Mot V Mot W Vcc Hall U Hall V Hall W MOTOR HALL SENSOR 243

4 DIN CONNECTOR TYPE F PINOUTS Pin d b z 2 Hall U input Motor phase U Motor phase U 4 Hall V input Motor phase V Motor phase V 6 Hall W input Motor phase W Motor phase W 8 +HV (+18 ~ 55VDC) +HV (+18 ~ 55VDC) +HV (+18 ~ 55VDC) Power Gnd Power Gnd Power Gnd 16 /Enable Polarity Current Monitor (2A/V) 750W in series 18 Signal Gnd 20 Ref (+ ) input +Fault 22 Ref ( -) 30mA Hall power /Enable 24 Hall Gnd 26 /Pos Enable 28 /Neg Enable Power Gnd Power Gnd Power Gnd APPLICATION INFORMATION Note: RH6 & RH7 must be 1% resistors of same value. Example: Std. value of RH6 & RH7 is 10kW, thus G = 1 A/V INPUT TO OUTPUT GAIN SETTING ( RH6, RH7 ) (A) GAIN (V) = 10 RH 6,7 ( kω) ( kω) LOAD INDUCTANCE SETTING (RH1 & CH2) Note 1 Load (mh) RH1 CH k 15 nf 1 15 k 15 nf k* 15 nf * nf nf mf PEAK CURRENT TIME-LIMIT (RH4) Note 3 Tpeak (s) RH4 (Ω) 0.5 open * M M M Times shown are for 10A step from 0A PEAK CURRENT LIMIT (RH5) Note 2 Ipeak (A) RH5 (Ω) 10 open * 8 12k 6 4.7k 4 2k CONT. CURRENT LIMIT (RH3) Icont (A) RH3 (Ω) 5 open * 4 20k 3 8.2k 2 3.9k 1 1.5k * Standard values installed at factory are shown in italics. COMPONENT HEADER WARNING! DISCONNECT POWER WHEN CHANGING HEADER COMPONENTS. FUTURE CONFIGURATION USE REFERENCE GAIN SETTING PEAK CURRENT LIMIT PEAK CURRENT TIME LIMIT CONTINUOUS CURRENT LIMIT LOAD INDUCTANCE SETTING JP8 RH7 RH6 RH5 RH4 RH3 CH2 RH1 0 Ohms 10k 10k ** ** ** 15nF 49.9k ** NOTE: Components in dotted lines are for custom configurations LED HEADER LOCATION ( UNDER HEATSINK ) BALANCE J1 Notes: 1. Bandwidth and values of RH1, CH2 are affected by supply voltage and load inductance. Final selection should be based on customer tests using actual motor at nominal supply voltage. 2. Peak current setting should always be greater than continuous current setting. 3. Peak times will double when current changes polarity. Peak times decrease as continuous current increases. BALANCE POTENTIOMETER Default position: centered. Functions to bring output current ( in torque mode ) to zero with control system outputs at zero. Adjustable range is +/- 70mA. Note: RH6 & RH7 must be 1% resistors of same value. 244

5 APPLICATION INFORMATION To use the model 5015, set up the internal header with the components that configure the transconductance, current limits, and load inductance. Current-limits and load inductance set up the amplifier for the user s particular motor, and the transconductance defines the amplifiers overall response in amps / volt that is required by the system. SETUP BASICS 1. Set RH1 and CH2 for motor load inductance (see charts in previous section). 2. Set RH3, 4, & 5 if current limits below standard values is required. 3. Set transconductance with RH6, Ground the /Enable (/Enable Pol open), /Pos Enable, and / Neg Enable inputs to signal ground. 5. Connect +HV and to a transformer-isolated source of power, +18 to +55VDC. 6. Connect the motor Hall sensors based on the manufacturers suggested signal names. Note that different manufacturers may use acronyms other than U-V-W to name their Halls. Power the Hall with the Hall power. Note that there is a 30 ma limit at. Encoders that output Hall signals typically consume ma, therefore, if these are used, they must be powered from an external power supply. 7. Turn off the amplifier and connect the motor leads to Motor U-V-W. Power up the unit. Apply a sinusoidal reference signal of ~ 1Hz, 1Vrms between Ref(+) and Ref(-). 8. Observe the operation of the motor as the current monitor signal passes through zero. When phasing is correct the speed will be smooth at zero crossing and at low speeds. If it is not, then power-down and re-connect the motor. There are six possible ways to connect the motor windings, and only one of these will result in proper motor operation. The six combinations are listed in the table below. Incorrect phasing will result in erratic operation, and the motor may not rotate. When the correct combination is found, record the new settings. b,z 2 b,z 4 b,z 6 #1 U V W #2 V W U #3 W U V #4 U W V #5 W V U #6 V U W COMPONENT HEADER SETTINGS Use the tables provided to select values for the load and system.it is recom-mended that these values be used as starting points, adjusting them later based upon tests of the amplifier in the application. 1. LOAD INDUCTANCE (RH1,CH2) Maximizes the bandwidth with the user s motor and supply voltage. First replace CH2 with a jumper (short). Adjust the value of RH1 using a step of 1A or less so as not to experience large signal slew-rate limiting. Select RH1 for the best transient response ( lowest risetime with minimal overshoot). Once RH1 has been set. Choose the smallest value of CH2 that does not cause additional overshoot or degradation of the step response. 2. CURRENT LIMITS (RH3, 4, & 5) The amplifier operates at the 5A continuous, 10A peak limits as delivered. To reduce the limit settings, choose values from the tables as starting points, and test with the motor to determine final values. Limit action can be seen on current monitor when output current no longer changes in response to input signals. Separate control over peak, continuous, and peak time limits provides protection for motors, while permitting higher currents for acceleration. 3. TRANSCONDUCTANCE (RH6, 7) The transconductance of the 5015 is the ratio of output current to input voltage. It is equal to 10kW/RH6 (Amps / Volt). RH6,and RH7 must be the same value and should be 1% tolerance metal film type for good common-mode noise rejection. ENABLE INPUTS WITH /ENABLE POL OPEN (DEFAULT) /Enable, /Pos Enable and /Neg enable must all be grounded for the amplifier to operate. If the system outputs to turn the amplifier on, then wire /Enable Pol to ground. This will invert the /Enable input only. /Pos and /Neg enable must still be grounded to run. ENABLE INPUT POLARITY The active level of the /Enable input only can be changed from ground enables to enables by grounding the /Enable Pol pin ( d16). This permits use with control cards that output to turn-on the amplifier, and ground to inhibit it. Note that this does not affect the /Pos and /Neg enable inputs. These must be grounded to enable output currents in their respective polarities ( or open will inhibit pos/neg currents). GROUNDING & POWER SUPPLIES Power ground and signal ground are common ( internally connected ) in this amplifier. Currents flowing in the power supply connections will create noise that can appear on the amplifier grounds. This noise will be rejected by the differential amplifier at the reference input, but will appear at the digital inputs. While these are filtered, the lowest noise system will result when the power-supply capacitor is left floating, and each amplifier is grounded at its power ground terminal (as shown in functional diagram, pg. 2). In multiple amplifier configurations, always use separate cables to each amplifier, twisting these together for lowest noise emission. Twisting motor leads will also reduce radiated noise from PWM outputs. If amplifiers are more than 1m. from power supply capacitor, use a small ( mF.) capacitor across power inputs for local bypassing. FAULT OUTPUT This is a logic level signal that will be HI ( ) if there is a fault condition, or if the amplifier is disabled ( inhibited ), and will go LO ( ground ) when the amplifier is operating normally. It can sink 30mA max., which can be used to drive a relay, opto-coupler, or PLC. Figure 1 below shows a relay breaking contact when a fault occurs. 245

6 RELAY CLOSED WHEN NORMAL +24V (Coil supply) 10k +FAULT z 20 2N3904 Relay 800 min. N.O. NOTE THAT THE FILTER ADDS 80ΜH IN SERIES WITH THE MOTOR. FOR LOW INDUCTANCE MOTORS, THIS HELPS REDUCE RIPPLE CURRENT AND BRING THE TOTAL LOAD INDUCTANCE INTO THE RANGE OF THE AMPLIFIER. IN MOST CASES NO ADDITIONAL INDUCTANCE WILL BE NEEDED. FIGURE 2 Figure 1 EDGE FILTER (Coil supply ) The edge filter greatly reduces the electrical noise from the power cabling that connects the PWM amplifier to the load. Typically, the output voltage from an amplifier has a rise time of about 200 ns. This is the time taken to switch from zero to the supply voltage or from the supply voltage to zero, see unfiltered output in figure 2. The edge filter greatly reduces the capacitively-coupled noise by slowing the risetime. See filtered output in figure 2. Voltage Time (ms) Filtered Output Unfiltered Output OUTLINE DIMENSIONS 1.59 (40.4) 8HP (160 ) DC Brush Servo Amplifier 5A Cont 10A Peak +18 ~ 55VDC (128.4) 3U Dimensions in inches (mm.) DIN Type F Connector Weight: 0.81 Lb., (0.37 kg.) ORDERING GUIDE 5A Continuous, 10A Peak, V DC Brushless Servoamplifier OTHER BRUSHLESS AMPLIFIERS 5001 Series Four models operating from +24~180V DC, 5~15A continuous, 10-30A peak. With optional Hall / Encoder tachometer, and brushless tachometer features. 246 Corporate Offices: 20 Dan Road Canton, MA Telephone: (781) Fax: (781) sales@copleycontrols.com