Rev 6/95 ISP - Rev 6/95
ELMO-WARRANTY PERFORMANCE The warranty performance covers only ELMO's products and only the elimination of problems that are due to manufacturing defects resulting in impaired function, deficient workmanship or defective material. Specifically excluded from warranty is the elimination of problems which are caused by abuse, damage, neglect, overloading, wrong operation, unauthorized manipulations etc.
How to use this manual - Flow Chart The ISP amplifier is designed for OEM applications. It enables the user to adjust the amplifier for various types of motors and to save valuable adjusting time in repetitive applications. Use the following flow chart in order to determine the chapters that you should read. If you are a new user of the ISP, you should read chapters 1-4 which will familiarize you with the product.
TABLE OF CONTENTS 1. Description ................................ ........................ 6 2. Type Designation ................................ ................... 7 3. Technical specifications ................................ ...........7 4. Operation of the servo control ................................ .....8 4.1 Inputs................................ ....................... 8 4.2 Velocity mode ................................ ................ 9 4.2.1 5. 6. 7.
7.1.4 Activating the loss of tacho protection (velocity mode only) ................................ ........................... 37 8. 9. 7.1.5 Latch mode of the protective functions .............. 38 7.1.6 Activating the dynamic contouring of the current limits 38 7.2 Velocity control using tachogenerator feedback .............. 38 7.3 Velocity control using armature voltage feedback ............ 39 Amplifier adjustment and diagnostics ............................... 40 8.
1. Description The ISP is an amplifier/power supply package, assembled on a single heatsink with a Eurocard size. The rated output is up to 1500W. The integrated power supply includes a shunt regulator. The ISP is available in either panel version or rack version with a 32 poles DIN 41612 connector. Standard features * Zero deadband. * Excellent linearity. * 2 inputs. * Differential input. * Motor current monitor. * Inhibit/fault indication (free contact relay).
2. Type Designation ISP F - 15 / 65 R W 4 PWM switching frequency 20KHz when not specified 4=40KHz, 6=60KHz ISP amplifier Fan cooled Rated current Additional capacitance for ISP-10/135 only Maximum rated voltage 3. H - Panel mounting R - Rack mounting Technical specifications Current Size Size *** limits Panel types Rack ISP-8/65 14-65 8/16 SP1 3U/8T 0.7 ISP-15/65 14-65 15/30 SP1 3U/8T 0.7 ISP-5/135 80-135 5/10 SP1 3U/8T 0.
4. 4.1 Operation of the servo control Inputs The ISP has 3 inputs: 2 single ended inputs (no.1 at terminal 1 and no.2 at terminal 5) and one differential input at terminals 3,4. The current gain of inputs 1 and 2 (current mode) is given by: 8 x Ic x Ki Gc = --------------- (A/V) 15 + Ri Ic - amplifier rated continuous current. Ri - input resistor in Kohm. R1 for input 1 R2 for input 2 Ki - position of wiper of trimming potentiometer Ki=0.33 when trimmer is fully CW. Ki=1 when trimmer is fully CW.
The current gain of the differential input in velocity mode is given by: 266 x Ic Gvd = ---------------- (A/V) R3 x R6 R3,R6 in Kohm The maximum input voltage at terminals 1 or 5 is calculated by: Vinmax = 10 + 0.6Ri (Volts) Ri in Kohm The maximum input voltage at terminals 3,4 is calculated by: Vdmax = 10 + R3 (Volts), R3=R4 in Kohm 4.
easily replaced in cases when COMP trimmer range is not enough to get optimum result. The output of the error amplifier is: 1 + SxC1xR5 Vo = (V 1Gv1 + V2Gv2) x [ --------------------------- ] 1 + SxC1xR5(1 + RfxKi/R5) V1,V2, - Input signals Gv1,Gv2 - Gain of inputs. Ki = Position factor of the wiper of COMP trimmer. Full CW = Full CCW = 0.1 1 The feedback element must be connected for negative feedback.
4.4 Current loop Current loop control is obtained by op amp U1/B (Current amplifier) and R7, C2 which form a lag-lead network for current loop. The standard amp is equipped with R7 (100Kohm) and C2 (0.01 æF) to get optimum current response for an average motor in this power range. These components are mounted in solderless terminals. 4.
Ip - Iop Tp = 2.2ln ---------Ip - Ic Ic - Amplifier continuous current rating. Ip - Peak demanded (not amplifier Ip) Iop - Actual operating current before the peak demand. Example: A motor is driven by an ISP-15/65 amplifier at constant speed and constant current of 5A. What is the maximum possible duration of a 20A peak ? 20 - 5 Tp = 2.2ln -------- = 2.42 seconds 20 - 15 4.5.
4.6 Operation of the shunt regulator A shunt regulator is included in the power supply section of the ISP. The shunt regulator is a switching type, wherein dissipative elements (resistors) are switched across the DC bus, whenever the voltage reaches a predetermined level. The function of the shunt regulator is to regulate the voltage of the DC bus during the period of motor deceleration, when there is a net energy outflow from the motor to the amplifier.
4.7 Protective functions All the protective functions (excluding 4.7.6) activate internal inhibit. There are two modes of resetting the amplifier after the cause of the inhibit disappears: Self Restart and Latch. - Self restart: The amplifier is inhibited only for the period that the inhibit cause is present. - Latch: All failures latch the inhibit and only a reset signal will clear the latch. 4.7.1 Short circuit protection This protection is realized by sensing current in the DC line.
15 1 CURRENT COMMAND MONITOR. INPUT 1 C1 .022MF R5 475K R1 1000PF 100K T7 10K 4700PF 100K 100K 2 T4 10K 100 5.11K R7 100K R6 .01MF 10K .01MF 5 + 100K + R4 STAGE 100PF R3 3 4 TO POWER C2 .01MF 10K PWM + CONVERTER 10K T2 IC 10K CURRENT LIMITS T3 IP A FEEDBACK R2 INPUT 2 .1MF R8 100K T6 10K +V 4.7M T5 10K 5.
T2 IC T3 IP T4 T5 T6 T7 COMP OFFSET GAIN 2 GAIN 1 VS INH IC SO L1 L2 L3 L4 U1 U2 U3 U5 U6 U7 U8 U4 U9 U13 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 D17 R18 C1 C2 U10 U11 U12 U14 U15 U16 U19 R19A R20A ISP - CONTROL BOARD ISP - Rev 6/95 U17 14 13 12 11 10 9 8 7 6 5 4 3 2 1 U18 J3 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J1
5. 5.1 Terminal Description Terminals for Horizontal and Rack mounting versions Power stage H R Function Remark AC 2ac,4c AC input All pins are shorted on the PCB. M1 8ac,10a Armature This output will be negative when a positive signal output is fed to one of the inputs. All pins are shorted on the PCB. M2 6ac,4a Armature This output will be positive when a positive signal output is fed to one of the inputs. All pins are shorted on the PCB.
Control stage - Cont. H R Function Remark 9 24a CCW disable Two modes - see chapter 7.1.1 10 24c Inhibit input Two modes - see chapter 7.1.1 * 11 22a Circuit common 12 22c +5V 100mA 13 20a -15V + 5%, 50mA external load. 14 20c +15V + 5%, 50mA external load. 15 18a Current command monitor *** Ic Scale is = ------ (A/V) 3.75 16 18c Back EMF output See Appendix B. 17, 16a, Inhibit output A 18 16c potential free relay contact.
20 1 AC M2 M1 AC TERMINALS OF ISP - PANEL VERSION ISP - Rev 6/95
5.2 Mother Board terminals The MBA-ISP/N is designed for 19" rack systems. It has screw type terminals for both power and signals with identical designations as in the panel versions except for the following new terminals: 21 Potential free Inhibit Input (+). See 7.1.1. 22 Potential free Inhibit Input (-). See 7.1.1. The Potential Free Inhibit Input is applicable only when the "inverted inhibit logic" is used (R18 in the amplifier is inserted).
R1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 22 U1 G G VS VS AC2 AC2 M1 M2 AC1 AC1 MBA-ISP/N ISP - Rev 6/95
5.3 Terminals for ISP mounted in 3U size ENC. The MBA-ISP/3UE is designed for Elmo enclosures. It has screw type terminals for the power and D-type connectors for the signals. The Potential Free Inhibit Input is applicable only when the "inverted inhibit logic" is used (R18 in the amplifier is inserted). An opto-Coupler (IL5) is used to isolate between the Inhibit signal and the amplifier circuit.
Control connector - J1 Pin Function Remark 1 Input 2 For more details see 4.1. 2 Back EMF output See Appendix B. 3 Input 1 For more details see 4.1. 4 Negative For more details see 4.1. differential input 5 Positive For more details see 4.1. differential input 6 Current monitor Ic Scale is = ------ (A/V) 3.75 7 Current command monitor Ic Scale is = ------ (A/V) 3.75 8,15 Inhibit output A potential free relay contact. amplifier is enabled. Contact rating: 0.
Control connector - J2 Pin Function Remark 1 Inhibit input Potential free inhibit input (-). See 7.1.1 * 2 Inhibit input Potential free inhibit input (+). See 7.1.1 * 3 Inhibit input Two modes - see chapter 7.1.1 * 4 CCW disable Two modes - see chapter 7.1.1 * 5 CW disable Two modes - see chapter 7.1.1 * 6 Reset for latch low level input voltage mode (see 7.1.5). 7 Back EMF output See Appendix B. 8 Input 2 For more details see 4.1. 9 -15V + 5%, 50mA external load.
R1 IN 2 1 COM. 9 BACK EMF 2 IN 2 8 COM. COM. 15 BACK EMF 7 10 IN 1 3 +15V COM. 14 11 DIFF(-) 4 RESET 6 -15V +5V 12 13 DIFF(+) 5 C.W 5 +5V COM. 12 CURRENT MONITOR 6 COM. 11 CURRENT COMMAND 7 C.C.W 4 13 COM. INH. 3 14 +15V 10 15 INH.(+) 2 8 RELAY -15V 9 INH.
6. 6.1 Installation procedures Mounting The ISP series dissipates its heat by natural convection. For optimum dissipation the amplifier should be mounted with the fins vertical. 6.2 Wiring Proper wiring, grounding and shielding techniques are important in obtaining proper servo operation and performance. Incorrect wiring, grounding or shielding can cause erratic servo performance or even a complete lack of operation.
6.3 Load inductance The total load inductance must be sufficient to keep the current ripple within the 50% limit (10-20% of rated current is recommended). The armature current ripple (Ir) can be calculated by using the following equation: 0.5 x Vs Ir = ---------- (A) f x L L - load inductance in mH. Vs - Voltage of the DC supply in Volts. f - Switching frequency in KHz.
6.
ISP Isolating transformer +Vs Heatsink DC power common is internally connected to control common Guide lines for connecting a non isolated amplifier with an isolating power transformer Ground: DC power common Motor chassis Amplifier's heat sink Do not ground: Control common - It is internally connected to the power common. Grounding the control common will create a ground loop. Caution: - If source of motor command is Otherwise, ground loop is created.
SINGLE PHASE TRANSFORMER AC ISP AC +Vs DC power common Control common Heatsink AC AC ISP +Vs To additional ISPs CONNECTING MORE THAN ONE ISP ISP - Rev 6/95 DC power common Control common Heatsink
A 5 Tacho 2 4 Motor command + _ 3 11 1 6 A Reset 7 Current monitor 8 CW disable 9 CCW disable Twisted and shielded pair 10 Inhibit input 12 +5V 13 -15V 14 +15V 17 Relay 18 ISP CONTROL CONNECTIONS TACHOGENERATOR FEEDBACK ISP - Rev 6/95
5 A 2 4 Motor command + _ 3 11 A 1 6 7 Reset Current monitor 8 CW disable 9 CCW disable Twisted and shielded pair 10 Inhibit input 12 +5V 13 -15V 14 +15V 17 Relay 18 ISP CONTROL CONNECTIONS ARMATURE VOLTAGE FEEDBACK ISP - Rev 6/95
7. Start - Up Procedures All the operations of this chapter do not require power on the unit. The steps of paragraph 7.1 must be performed before proceeding to the appropriate feedback sensor section. 7.1 Common procedures for all amplifiers types 7.1.1 Inhibit and CW/CCW logic Select the desired Inhibit and CW/CCW logic you need: a) Disable by Low Inhibit/CW/CCW functions will be activated by connecting their inputs to a low level signal.
b) Enable by High Inhibit/CW/CCW functions will be de-activated by connecting their inputs to a high level signal. If no signal is applied to these inputs the amplifier will be disabled upon power on. For this logic insert 3.6Kohm ( +10%)resistors for R18 (Inhibit), R19a (CW), R20a (CCW).
OPTO-ISOLATED INHIBIT V +5 +5V R1 Inhibit C R18 MBA-ISP/... ISP CONTROL BOARD ISP ENABLED BY ACTIVE LOW OR CLOSED CONTACT V +5 +5V R1 Inhibit C R18 MBA-ISP/... ISP CONTROL BOARD ISP ENABLED BY ACTIVE HIGH OR CLOSED CONTACT R1 = 100 x V (ohm) V - Voltage at the inhibit input. Standard value is 2.4K (for 24V). Source must be capable to source or sink 10mA.
7.1.2 Velocity mode To operate in velocity mode the velocity loop should be enabled by converting the error amplifier to a high gain PI amplifier. Make sure that: R6 (30ohm), R5 (475Kohm) and C1 (0.022 æF), in solderless terminals, are installed on the board. 7.1.3 Current mode a) Converting the amplifier into current mode To operate in current mode the velocity loop should be disabled by converting the error amplifier to a low gain proportional amplifier.
7.1.4 Activating the loss of tacho protection (velocity mode only) Activating the loss of tacho protection is done by installing R14 (different value for 65V or 135V amplifiers),R15, and R16 as follows: 1530 R14 (65V) = ------- (Kohm) Vam 2730 R14 (135V) = ------ (Kohm) Vam 100 x Vam R15 = ----------- (Kohm) Ip x Rm R16 < 10 ohm Vam - Armature voltage at maximum application speed. Ip - Amplifiers' rated peak current limit. Rm - Total ohmic resistance of motor.
7.1.5 Latch mode of the protective functions Self Restart(D17 removed): The amplifier is inhibited only for the period that the inhibit cause is present. Latch (D17 - inserted): Failures 4.7.1-5 latch the Inhibit and the diagnostic LED. For restart (after clearing the failure source), reset has to be performed by connecting the reset input to the circuit common. 7.1.
7.3 Velocity control using armature voltage feedback The reference signal should be connected to the differential input and R3,R4 should be calculated and inserted according to: R3 = R4 = 1.33xVdm (Kohm) Vdm - maximum reference voltage at the differential input. The armature voltage feedback will enter the error amplifier by inserting R8, calculated for the two voltage types as follows: For ISP-X/65: R8 (65V) = 1.
8. Amplifier adjustment and diagnostics Important remarks: A. If all the previous steps were accomplished you may now turn on the power and continue with the following adjustments. You may omit the step for current mode or velocity mode according to your application. B.
Ic Current monitor scale (A/V) : -----3.75 8.3 Adjusting the motor speed (velocity mode only) Adjusting the speed is done by adjusting the input gain trimmer of the tacho feedback: - Increasing/decreasing the feedback gain will decrease/increase the speed. It is also possible to increase/decrease the command gain (change the fix resistors of the differential amplifier) in order to increase/decrease the speed.
8.5 Response adjustment (velocity mode only) In most applications optimum response is achieved by adjusting the compensation (COMP) trimmer. Adjustment procedure is as follows: - Provide the amplifier with a low frequency, bi-directional square wave velocity command (A 0.5Hz, ñ2.0V waveform is often employed) - Apply power to the amplifier, and while monitoring the tachometer signal, gradually adjust the COMP trimmer from the CCW toward the CW position.
- If the previous step does not yield satisfactory results, if unacceptable overshooting has been noted, substitute a larger value than 0.022æF; or, if the response is overdamped substitute a smaller value than Repetition of this procedure should yield an optimum choice for C1. Reference input signal Overdamped: T4 too far CW Critically damped: T4 optimum Underdamped: T4 too far CCW Fig. 8.1 Typical velocity response waveforms ISP - Rev 6/95 0.022æF.
9. Tables and Summaries 9.1 Adjusting trimmers Six trimmers are installed on the ISP board with the following functions: T7 (Gain 1) - CW rotation increases input 1 gain. T6 (Gain 2) - CW rotation increases input 2 gain. T5 (Balance) - see 8.1. T4 (compensation) - See 8.6. T3 (Ip) - CW rotation increases peak current limit (see 8.2). T2 (Ic) - CW rotation increases continuous current limit (see 8.2) 9.
Appendix A - Response adjustment - current loop In most applications it is not necessary to adjust the current loop to achieve the optimum response. When there are extreme electrical parameters in the armature circuit (inductance and resistance) the standard components values of 0.01æF for C2 and 100Kohm for R7 may not yield with the optimum response. The current loop should be optimized as follows: - Turn the amplifier to a current amplifier by removing C1 and R6.
Reference input signal C2 too large / R7 too small Critically damped C2 too small / R7 too large Fig.
Appendix B - Current limits contour adjustment The amplifier can be configured to have either continuous current limit or peak current limit or both which depend on motor velocity feedback. This function is enabled by calculating and inserting R11, R13. The continuous current limit is speed dependent when R11 is inserted. The peak current limit is speed dependent when R13 is inserted. The general shape of the operating envelope is given in fig.
Continuous current limit contouring: 1 - r1 R11 = 18.3 -------- (Kohm) 1 - r2 R11 R10 = 36.6 ------------- (Kohm) R11 + 20r1 Peak current limit contouring: 1 - s1 R13 = 18.3 -------- (Kohm) 1 - s2 R13 R12 = 36.6 ------------ (Kohm) R13 + 20s1 Dynamic contouring with armature voltage feedback - IxR compensation must be activated as in 7.3 - Connect the Back EMF (terminal H-16,R-18c,E-J2/7) to input 2 (terminal H-5,R28a,E-J2/8). - Remove R31.
ISP - Rev 6/95
187 169 4.0 x 4 9 85 12.5 110 111.
39 13.6 4.0 187 SP1 - SIDE VIEW 1 ISP - Rev 6/95 22.6 29.
111.76 1.6 5.
200 182 SEE DETAIL A 9 10 25.5 5 9.5 70 109 111.76 9.
13.6 62.4 74 55.
111.76 1.6 5.
187 169 4.0 x 4 9 85 12.5 110 111.
58 39 13.6 4.0 187 SP3 - SIDE VIEW 1 ISP - Rev 6/95 22.6 29.
111.76 58 1.6 5.
200 182 SEE DETAIL A 9 25.5 10 5 9.5 70 109 111.76 9.
13.6 62.4 91 55.
111.76 1.6 5.
128.7 162.54 160 J1 110 111.
2 x M3 40.64 29.4 13.6 22.6 162.
128.7 111.76 1.6 5.
+ SO IC IN VS GN1 GN2 BAL. COMP.
4 x M3 13.6 76.2 60.4 53.
128.7 111.76 1.6 5.2 12 70 40 109 ISP RACK MOUNTING (3U/15T) - SIDE VIEW 2 ISP - Rev 6/95 76.
+ SO IC IN VS GN1 GN2 BAL. COMP.
15 2.5 165 160 J1 109 111.
4 x M3 60.96 13.6 59 21.6 28.4 162.
128.7 111.76 1.6 5.2 12 59 60.
SO IC IN VS GN1 GN2 BAL. COMP.
4 x M3 96.52 13.6 89 60.4 53.
128.7 111.76 1.6 5.2 12 89 96.
SO IC IN VS GN1 GN2 BAL. COMP.
ENCLOSURE MECHANICAL OUTLINE FRONT VIEW SIDE VIEW 11 11 5 10 251.7 74.2 132.5 240 5 POWER 7.5 11 X 45.0 11 222 20 Standard Sizes 12T X 62.0 NOTE: ALL DIMENSIONS ARE IN mm. ISP - Rev 6/95 16T 20T 24T 36T 82.3 102.7 123.0 184.0 For non-standard sizes: X = 5.
List of ELMO Service Centers ISRAEL Elmo Motion Control LTD 34 Segula ST. Petah-Tikva 49103 Tel: (03)934-5059 Fax: (03)934-5126 EUROPE Elmo Motion Control 7 Stanserstrasse CH-6362 Stansstad Switzerland Tel: (041)610775 Fax: (041)610778 U.S.A Elmo Motion Control INC.
