300 Series Amplifier User’s Guide Rev 08 5/00 All Rights Reserved Models: 303,303B 306,306A,306B,306AB 312
The 300 Series Amplifier User’s Guide Rev 07 9/96 All Rights Reserved
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300 Series Amplifier User’s Guide 1996~1998 Copley Controls Corporation 410 University Avenue Westwood, MA 02090 USA All rights reserved The 300 Series Amplifier User' s Guide Rev 08 5/00
300 SERIES USER GUIDE Table of Contents Table of Contents....................................................................................................................................... ii A Visual Guide to the 300 family: ............................................................................................................. iv Introduction................................................................................................................................................
300 SERIES USER GUIDE Notes on Modes & Jumpers........................................................................................... 21 Eurocard Mount ......................................................................................................................................... 22 DIN Connector Pinouts................................................................................................................ 22 Jumper Settings...............................................................
300 SERIES USER GUIDE A Visual Guide to the 300 family: Basic Amplifier, No Mounting Card, No Heatsink (30x shown) See p. 5 for connectors & pinouts. See pp. 7-8 for wiring. Amplifier with MB4 Mounting Card (30xPMFDV shown) See p. 18 for connectors & pinouts. See pp. 9-10 for wiring. Amplifier on Eurocard Mount with Front Panel (30xER shown) See p. 21 for connectors & pinouts. See. pp. 11-12 for wiring.
300 SERIES USER GUIDE Introduction The 300 Series amplifiers are second generation products designed for low cost and high performance. They can be mounted on chassis or p.c. boards and operate from 16 to 160 volt single-output DC power supplies. A wide range of inductive loads can be driven: 64 uH to 50 mH depending on model and supply voltage. All units feature fully differential inputs for the control, or reference voltage.
300 SERIES USER GUIDE Functional Diagram 2
300 SERIES USER GUIDE J17 Component Header This is an 11-position socket which holds resistors and capacitors which are used for tachometer scaling and compensation, amplifier compensation, and current limiting. Location AMPLIFIER WITHOUT MB4 CARD 4-PIN 22-PIN J17 HEADER Current-Mode Setup (Standard configuration) This is the standard configuration as delivered from the factory. In this mode, a voltage at the reference inputs will force a current at the amplifier outputs.
300 SERIES USER GUIDE Technical Specifications 4
300 SERIES USER GUIDE Mechanical Outlines 5
300 SERIES USER GUIDE Basic Amplifier Connectors, Signals and Pinouts If you are using the MB4 or Eurocard, the pinouts will be different (refer to the sections on the MB4 and Eurocard). Use this list when reading the following sections on hooking up the basic amplifier. Types of signals are listed after the pin number or letter.
300 SERIES USER GUIDE Basic Amplifier: Current-Mode, NO Tachometer Use this checklist for applications that don't employ a tachometer. These include microprocessor control systems that get position feedback from an encoder on the motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads that require a set current from the amplifier in response to a control-voltage at the inputs. The components on the J17 header come from the factory preset for this operating mode.
300 SERIES USER GUIDE Basic Amplifier: Current-Mode WITH Tachometer 1. Setup J17 header components for high gain, tachometer mode (see p.3) 2. Connect DC power supply to amplifier +HV and GND. Check voltage to see that is within the amplifiers' rating. 3. Ground amplifier to chassis at GND pin DD. 4. Connect motor or load between OUT+ and OUT-. Do not ground load! 5. Connect reference voltage source to REF+ and REF- inputs. 6. Connect Tachometer between tach input and signal ground. 7.
300 SERIES USER GUIDE Amplifier with MB4 Mounting Card: Current-Mode, NO Tachometer Use this checklist for applications that don't employ a tachometer. These include microprocessor control systems that get position feedback from an encoder on the motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads that require a set current from the amplifier in response to a control-voltage at the inputs.
300 SERIES USER GUIDE Amplifier with MB4 Mounting Card: Current-Mode, WITH Tachometer Use this checklist for applications that do employ a tachometer. These include microprocessor control systems that get position feedback from an encoder on the motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads that require a set current from the amplifier in response to a control-voltage at the inputs.
300 SERIES USER GUIDE Amplifier on Eurocard: Current-Mode, NO Tachometer Use this checklist for applications that don't employ a tachometer. These include microprocessor control systems that get position feedback from an encoder on the motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads that require a set current from the amplifier in response to a control-voltage at the inputs. The components on the J17 header come from the factory preset for this operating mode.
300 SERIES USER GUIDE Amplifier on Eurocard: Current-Mode, WITH Tachometer Use this checklist for applications that do employ a tachometer. These include microprocessor control systems that get position feedback from an encoder on the motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads that require a set current from the amplifier in response to a control-voltage at the inputs. The components on the J17 header come from the factory preset for this operating mode.
300 SERIES USER GUIDE Power Supply Considerations 1. Determine the maximum voltage required to drive your motor or load at peak current and peak RPM (in the case of a motor). Add extra for losses in the amplifier (see p. 10, Output Voltage Swing). Add an extra 5-10% for power supply ripple. Use this value, and the amplifier's continuous current rating as your nominal power supply specification at normal line voltage. 300 series peak currents of 2-2.
300 SERIES USER GUIDE Minimum Inductance Table 3 lists the minimum inductance required for various amplifier and buss voltage combinations. Model 303,303B 306,306A,306AB 312 20V 63 uH 30 uH N/A 40V 125 uH 63 uH 175uH 80V 250 uH 125 uH 350uH 160V N/A N/A 700 uH Table 3 Maximum Inductance There is no maximum inductance specified for the 300 series, however larger inductances can reduce the bandwidth and produce excessive ringing in the amplifier's response.
300 SERIES USER GUIDE Enable Inputs The polarity of the amplifier's output can be controlled with the Positive and Negative enable inputs, and the outputs can be completely disabled with the Enable input. Output polarity control is usually used on motion control systems that use travel -limit switches. If a moving member hits one of these switches, it is supposed to disable the amplifier, preventing further travel into a mechanical stop.
300 SERIES USER GUIDE Normal Output This is a +5V CMOS output signal in series with an internal 1.87K resistor. It will be HI (+5V) when the Normal LED is on, and LO (ground) when the Normal LED is off. It can drive an external low-current LED, or CMOS logic compatible inputs to user equipment. Reset Input A +5V CMOS logic input which is normally pulled-up to +5V by an internal 100K resistor. Ground this signal momentarily to reset a fault condition caused by overtemp, or output short-circuit.
300 SERIES USER GUIDE DC Power Outputs All internal supply voltages are derived from the high-voltage supply. These internal voltages are available at the signal connector for certain user applications. All are current-limited by series resistors (Rser) and are intended for low-power applications. Table 8 lists the connector pin, voltage, and series resistance for each of these outputs: Vout +5 +11 -11 +14 -14 Std 22 pin 20 6 8 18 n/a MB4 P2 n/a n/a n/a 5 13 Eur DIN n/a n/a n/a C8 A8 Rser Iout 2.
300 SERIES USER GUIDE Mounting Standard Mounting The standard model comes with plug-in cable connectors. (See appendix for a list of connector types) The chassis can be mounted to flat surfaces with four #6 screws that go through four holes in the amplifier chassis. The mounting surface may provide adequate heat-sinking, or the amplifier can be ordered with a standard (-H option) or extended -HX option) heatsink.
300 SERIES USER GUIDE MB4 Mounting Card The MB4 card adds features and options to the 300 series amplifiers that are not available on the basic unit. These include PWM inputs, voltage-mode amplification, IR compensation, and output 'edge' filters. The MB4 card connects to the amplifier via connectors J3 & J4. The user makes connections to the amplifier/card assembly via connectors P1 (motor, and high voltage DC supply) , and P2 (reference, tach, and aux inputs, and Enable signals).
300 SERIES USER GUIDE They are listed here for information only. The type of signal (output, input, passive) is relative to the MB4 card, i.e. pin A is the Ref+ signal that is an output from the card to the amplifier. Pin A B C D E F G H I J K L M N O P Q R S T U V Type O O P P O I P I O I O O P O O O I I I I Description +Ref -Ref Signal Ground Ref Amp Output Aux. Input +11V Output from Amplifier Logic Ground -11V Output from Amplifier N.C.
300 SERIES USER GUIDE MB4 Card Jumper Settings Table 15 shows the settings of the on-card jumpers for the various card and setup options. Jumpers consist of two-pin shorting connectors on three-pin p.c. board headers. The shorting connector can connect pins 1-2, or 2-3, as shown below.
0 SERIES USER GUIDE Eurocard Mount All connections to the amplifier are made via the DIN connector. The Eurocard may be ordered with the same additional options as the MB4 card: Voltage-Mode operation with IR compensation (-V option) PWM Inputs (-D option) Edge Filters (-F option) Heatsink options available with the Eurocard mounting are the -H, and -HX, for standard and extended heatsink. The 10HP spacing will accept the -H heatsink, but a wider spacing is required for the -HX extended heatsink.
300 SERIES USER GUIDE Status Output Jumper JP-103: 1-2 for open-drain MOSFET output, 2-3 for HCTTL output. Normal = HI (HCTTL), or off (MOSFET), fault = LO (HCTTL), or ON (MOSFET). Tuning and Adjustments First we describe the operation of the trimpots on the basic amplifier, and the MB4 and Eurocard. Next are more detailed sections on particular subjects such as tachometer scaling, voltage-gain, and so on. For more detailed theory and practice, a list of references is included in the appendix.
300 SERIES USER GUIDE Mode Setting: Flat-Gain vs. Tachometer In current mode operation, the amplifier functions as a single-input, single-output transducer that converts an input voltage to an output current. Use of a tachometer is optional. When no tachometer is used, the amplifier is operated in the flat gain mode. This configuration gives the maximum bandwidth. When driving motors, it is usually preferred over voltage-mode operation because it makes the motor respond faster.
300 SERIES USER GUIDE Frequency Response with Tachometer The curves below show the gain and phase for the servo preamplifier when using the J17 components setup for normal tachometer mode, and for the 1/3 and 1/5 gain modes as shown in the table on the preceding page.
300 SERIES USER GUIDE Tachometer Scaling As delivered, a +/-10V reference signal will drive the motor to a speed at which the tachometer produces a -/+8V signal, regardless of RPM. Tachometer scaling refers to the selection of components on the J17 header so that a particular signal at the reference inputs will drive a motor to a particular RPM. Before you begin, you must know the RPM of the motor when your control system is delivering its' maximum signal to the amplifier.
300 SERIES USER GUIDE Voltage-Mode Gain This setup applies to MB4 and Eurocards that have been ordered with the -V option, for voltage feedback. A voltage-sensing circuit attenuates the amplifier's output voltage by a factor of 22. This voltage is then fed-back into the Tach input. Setting the voltage-gain then is similar to setting-up a system with a tachometer.
300 SERIES USER GUIDE IR-Comp Setup Procedure Two methods are presented here. Use the one that seems to be the most appropriate to your installation, and equipment available. First, remember that IR-comp is used in the voltage mode. So determine that the voltage gain of the amplifier has been set correctly (see proceeding section).
300 SERIES USER GUIDE Dynamic Setup Method Equipment required: Oscilloscope, signal generator (square wave, 1 Hz.) 1. Adjust the Feedback pot CCW until oscillation appears (squealing sound). Turn pot 2 turns CW. Oscillation should cease. 2. Apply square wave to Reference voltage inputs. Monitor current monitor test point (TP2) with oscilloscope. 3. Adjust IR comp pot (R51) CCW while monitoring waveform on the oscilloscope. 4. Response time of current to square wave should gradually decrease.
300 SERIES USER GUIDE PWM Operation PWM signals are of two distinct types that we refer to as 0-100% and 50%. The 0-100% type uses two signals: one to control the amplitude and the other to control direction. The 50% type uses only one signal that is at 50% duty cycle for a zero output from the amplifier, and changes to 0, or 100% for full output in the positive, or negative directions. The table of jumper setting shows how to setup the MB4 card for the different modes.
300 SERIES USER GUIDE Appendix Connector Part Numbers Here are the Copley Controls Corp.(CCC), and OEM part numbers for the connectors used with the 300 series amplifiers: Basic Amplifier 4-pin power/motor connector CCC No. 57-0073 (Weidmuller BL4.12593.6) Basic Amplifier 22-pin signal connector (housing only) CCC No. 57-0074 (Molex 22-01-3227) MB4 Card: 4 pin power/motor connector CCC No. 57-0073 (Weidmuller BL4.12593.6) MB4 Card: 15 pin signal connector (housing only) CCC No.
300 SERIES USER GUIDE MB4 Card Layout 32
300 SERIES USER GUIDE Eurocard Layout JP106 R21 JP103 JP104 R11 R18 R19 R12 JP109 JP101 JP102 JP108 JP107 JP105 S1 P1 Jumper Pin Numbering PINS 1 2 3 Panel Layout BALANCE REF GAIN CURR LIMIT FEEDBACK ARM FB. NORMAL RESET CURR MON.
300 SERIES USER GUIDE MB4 Card Schematic 34
300 SERIES USER GUIDE Eurocard Schematic 35
300 SERIES USER GUIDE Ordering Guide for 300 Series 36
The 300 Series Amplifier User' s Guide Rev 07 5/98
The 300 Series Amplifier User’s Guide Rev 07 5/98 All Rights Reserved C o rp o r a t e O f fi c e, U S A 4 1 0 U n i v er s ity A v e . W e s tw o o d , M A 0 2 0 9 0 Tel: 6 1 7 - 3 2 9-8 2 0 0 F a x : 6 1 7 -3 2 9 -4 0 5 5 W e s t C o a st , U S A S an J o s e, C A Tel: 4 0 8 - 9 9 7-9 2 0 9 F a x : 4 0 8 -9 9 7 -9 2 1 8 Vis it u s o n th e w e b @ h ttp ://w w w.c o p le y c o n tro ls .
