Elmo ISP manual

1 ISP - Rev 6/95 Rev 6/95[...]

2 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, dam[...]

3 ISP - Rev 6/95 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 o[...]

4 ISP - Rev 6/95 TABLE OF CONTENTS 1. Description ................................ ........................ 6 2. Type Designation ................................ ................... 7 3. Technical specifications ................................ ........... 7 4. Operation of the servo control ................................ ..... 8 4.1 Inputs ....[...]

5 ISP - Rev 6/95 7.1.4 Activating the loss of tacho protection (velocity mode only) ................................ ........................... 37 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 V[...]

6 ISP - Rev 6/95 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 deadban[...]

7 ISP - Rev 6/95 2. Type Designation ISP F - 15 / 65 R W 4 ISP amplifier Fan cooled 4=40KHz, 6=60KHz R - Rack mounting Rated current 20KHz when not specified PWM switching frequency H - Panel mounting Maximum rated voltage for ISP-10/135 only Additional capacitance 3. Technical specifications Type AC Supply * * * Current limits Size Panel types Siz[...]

8 ISP - Rev 6/95 4. Operation of the servo control 4.1 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 -[...]

9 ISP - Rev 6/95 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: Vin max = 10 + 0.6Ri (Volts) Ri in Kohm The maximum input voltage at terminals 3,4 is calculated by: Vd max = 10 + R3 (Volts), R3=R4 in [...]

10 ISP - Rev 6/95 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 1 G v1 + V 2 G v2 ) x [ --------------------------- ] 1 + SxC1xR5(1 + RfxKi/R5) V 1 ,V 2 , - Input signals G v1 ,G v2 - Gain of inputs. Ki = Position factor of the wiper of COMP trimmer. F[...]

11 ISP - Rev 6/95 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 æ F) to get optimum current response for an average motor in this power range. These components are mounted in solderless termi[...]

12 ISP - Rev 6/95 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 - [...]

13 ISP - Rev 6/95 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 volt[...]

14 ISP - Rev 6/95 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[...]

15 ISP - Rev 6/95 T4 10K 100 C1 .022MF 1000PF R5 475K 100K 4700PF T7 10K R1 INPUT 1 CURRENT COMMAND MONITOR. 15 1 2 3 R3 100K 5.11K .01MF 10K - 100K + - R6 100K 10K R7 100K 100PF + - C2 .01MF PWM TO POWER STAGE CONVERTER CURRNET FEEDBACK A 10K T3 IP CURRENT LIMITS T2 IC + R2 INPUT 2 10K .01MF R4 4 5 CURRENT T6 10K .1MF 5.11K +V T5 10K 100K -V offse[...]

16 ISP - Rev 6/95 U1 T2 T3 T4 COMP IP IC U5 T6 T7 GAIN 1 GAIN 2 T5 OFFSET R1 R2 U12 L1 L2 L3 IC INH VS L4 SO J1 12 13 14 1 2 3 4 5 6 7 8 9 10 11 U17 R3 R4 R5 R6 R7 R8 R9 U14 U15 R10 R11 R12 R13 R14 U7 U6 U2 U3 U4 U13 R15 R16 R18 C1 C2 U10 U9 U8 D17 U16 U11 U18 J3 U19 R19A R20A 3 4 5 6 7 8 9 10 11 12 13 14 1 2 ISP - CONTROL BOARD[...]

17 ISP - Rev 6/95 5. Terminal Description 5.1 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 output This output will be negative when a positive signal is fed to one of the inputs. All pins are shorted on the PCB. M2 6ac,4a Armature output T[...]

18 ISP - Rev 6/95 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 18[...]

19 ISP - Rev 6/95 TERMINALS OF ISP - PANEL VERSION AC M2 M1 AC 1 20[...]

20 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 Pote[...]

21 ISP - Rev 6/95 R1 22 21 18 17 16 AC1 M2 AC1 15 14 13 12 11 10 M1 AC2 AC2 VS VS 9 8 7 6 5 4 G G U1 3 2 1 MBA-ISP/N[...]

22 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 [...]

23 ISP - Rev 6/95 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 differential input For more details see 4.1. 5 Positive differential input For more details see 4.1. 6 Current monitor Ic Scale is = ------ (A/V) 3.75 7 Current command mon[...]

24 ISP - Rev 6/95 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 mode low[...]

25 ISP - Rev 6/95 R1 J1 FEMALE J2 MALE GND AC GND M1 M2 AC MBA - ISP/3UE 9 COM. 1 IN 2 BACK 2 3 4 IN 1 DIFF(-) EMF 10 11 12 COM. +15V -15V 13 14 15 +5V COM. RELAY 5 6 7 DIFF(+) CURRENT MONITOR CURRENT COMMAND 8 8 7 6 IN 2 RESET BACK EMF 15 14 COM. COM. 13 12 11 +5V COM. COM. +15V 5 4 3 C.W C.C.W INH. 2 1 INH.(+) INH.(-) 10 9 -15V[...]

26 ISP - Rev 6/95 6. Installation procedures 6.1 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, groundin[...]

27 ISP - Rev 6/95 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 i[...]

28 ISP - Rev 6/95 6.5 Wiring diagrams Motor A B GND Chassis ISP M1 M2 Minimum acceptance ============================================================= Motor A B GND Chassis Power wires twisted together ISP M1 M2 Acceptable for most applications ============================================================ Motor A B GND Chassis Power wires twisted an[...]

29 ISP - Rev 6/95 DC power common is internally connected to control common Heatsink Isolating transformer ISP +Vs 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. Gr[...]

30 ISP - Rev 6/95 AC AC +Vs DC power common Control common Heatsink AC AC +Vs DC power common Control common Heatsink To additional ISPs CONNECTING MORE THAN ONE ISP SINGLE PHASE TRANSFORMER ISP ISP[...]

31 ISP - Rev 6/95 ISP CONTROL CONNECTIONS TACHOGENERATOR FEEDBACK Reset Motor command A -15V CW disable Twisted and shielded pair 1 3 + _ 4 14 13 +15V 12 +5V 7 Current monitor 10 5 11 2 8 Tacho 6 9 Inhibit input CCW disable A Relay 18 17[...]

32 ISP - Rev 6/95 ISP CONTROL CONNECTIONS ARMATURE VOLTAGE FEEDBACK Reset Motor command A -15V CW disable Twisted and shielded pair 1 3 + _ 4 14 13 +15V 12 +5V 7 Current monitor 10 5 11 2 8 6 9 Inhibit input CCW disable A Relay 18 17[...]

33 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:[...]

34 ISP - Rev 6/95 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). The power of these resistors is calculate[...]

35 ISP - Rev 6/95 OPTO-ISOLATED INHIBIT +5V ISP ENABLED BY ACTIVE LOW OR CLOSED CONTACT C R18 V +5 R1 MBA-ISP/... ISP CONTROL BOARD Inhibit +5V ISP ENABLED BY ACTIVE HIGH OR CLOSED CONTACT C R18 +5 R1 MBA-ISP/... ISP CONTROL BOARD Inhibit V R1 = 100 x V (ohm) V - Voltage at the inhibit input. Standard value is 2.4K (for 24V). Source must be capable[...]

36 ISP - Rev 6/95 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 æ F), in solderless terminals, are installed on the board. 7.1.3 Current mode a) Converting the amplifier into current mode To op[...]

37 ISP - Rev 6/95 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 oh[...]

38 ISP - Rev 6/95 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 re[...]

39 ISP - Rev 6/95 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 inser[...]

40 ISP - Rev 6/95 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. In some applications, especially those where the motor electr[...]

41 ISP - Rev 6/95 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[...]

42 ISP - Rev 6/95 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, ñ 2.0V waveform is often employed) - Apply power to th[...]

43 ISP - Rev 6/95 - 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 0.022æF. Repetition of this procedure should yield an optimum choice for C1. Reference input signal Overdamped: T4 too [...]

44 ISP - Rev 6/95 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.[...]

45 ISP - Rev 6/95 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 0.01 æ F for C2 and 100Kohm for R7 may not yield wi[...]

46 ISP - Rev 6/95 Reference input signal C2 too large / R7 too small Critically damped C2 too small / R7 too large Fig. A-1 Typical current response waveforms[...]

47 ISP - Rev 6/95 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[...]

48 ISP - Rev 6/95 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[...]

49 ISP - Rev 6/95[...]

50 ISP - Rev 6/95 187 169 85 12.5 4.0 x 4 9 110 111.76 SP1 - TOP VIEW[...]

51 ISP - Rev 6/95 39 22.6 29.4 13.6 4.0 187 SP1 - SIDE VIEW 1[...]

52 ISP - Rev 6/95 111.76 12 39 5.2 1.6 5 9 SP1 - SIDE VIEW 2[...]

53 ISP - Rev 6/95 200 182 SEE DETAIL A 9.5 9 10 9.5 DETAIL A 5 25.5 109 70 111.76 SP2 - TOP VIEW[...]

54 ISP - Rev 6/95 55.6 62.4 13.6 GROUNDING SCREW M4 200 SP2 - SIDE VIEW 1 74[...]

55 ISP - Rev 6/95 111.76 5.2 12 1.6 M4 42 72 2 SP2 - SIDE VIEW 2[...]

56 ISP - Rev 6/95 187 169 85 12.5 4.0 x 4 9 110 111.76 SP3 - TOP VIEW[...]

57 ISP - Rev 6/95 39 22.6 29.4 13.6 4.0 187 SP3 - SIDE VIEW 1 58[...]

58 ISP - Rev 6/95 5 9 SP3 - SIDE VIEW 2 111.76 5.2 12 1.6 58[...]

59 ISP - Rev 6/95 200 182 70 SEE DETAIL A 9.5 25.5 9 10 9.5 DETAIL A 5 109 111.76 SP4 - TOP VIEW[...]

60 ISP - Rev 6/95 91 55.6 62.4 13.6 GROUNDING SCREW M4 200 SP4 - SIDE VIEW 1[...]

61 ISP - Rev 6/95 111.76 5.2 12 1.6 M4 42 91 2 SP4 - SIDE VIEW 2[...]

62 ISP - Rev 6/95 128.7 ISP RACK MOUNTING (8T and 15T) - TOP VIEW 160 162.54 110 J1 111.76[...]

63 ISP - Rev 6/95 ISP RACK MOUNTING (3U/8T) - SIDE VIEW 1 2 x M3 40.64 39 29.4 22.6 13.6 162.54 188[...]

64 ISP - Rev 6/95 ISP RACK MOUNTING (3U/8T) - SIDE VIEW 2 111.76 128.7 1.6 8 5.2 12 38[...]

65 ISP - Rev 6/95 + SO IC IN VS COMP. GN1 GN2 BAL. IP IC + FRONT PANEL FOR ISP 3U/8T[...]

66 ISP - Rev 6/95 ISP RACK MOUNTING (3U/15T) -SIDE VIEW 1 4 x M3 70 60.4 53.6 13.6 76.2 160 188[...]

67 ISP - Rev 6/95 ISP RACK MOUNTING (3U/15T) - SIDE VIEW 2 128.7 111.76 1.6 5.2 12 70 76.2 40 109[...]

68 ISP - Rev 6/95 FRONT PANEL FOR ISP 3U/15T + SO IC IN GN1 GN2 BAL. VS IP IC COMP.[...]

69 ISP - Rev 6/95 ISP RACK MOUNTING (3U/12T and 3U/19T) - TOP VIEW 2.5 15 160 165 J1 109 111.76[...]

70 ISP - Rev 6/95 4 x M3 ISP RACK MOUNTING (3U/12T) -SIDE VIEW 1 60.96 28.4 59 21.6 13.6 162.45 188[...]

71 ISP - Rev 6/95 ISP RACK MOUNTING ( 3U/12T) - SIDE VIEW 2 128.7 111.76 12 59 60.96 5.2 1.6 8 109[...]

72 ISP - Rev 6/95 FRONT PANEL FOR ISP 3U/12T SO IC IN VS GN1 GN2 BAL. COMP. IP IC[...]

73 ISP - Rev 6/95 4 x M3 ISP RACK MOUNTING (3U/19T) -SIDE VIEW 1 96.52 60.4 89 53.6 13.6 160 188[...]

74 ISP - Rev 6/95 ISP RACK MOUNTING ( 3U/19T) - SIDE VIEW 2 128.7 111.76 12 89 96.52 5.2 1.6 40 109[...]

75 ISP - Rev 6/95 FRONT PANEL FOR ISP 3U/19T SO IC IN VS GN1 GN2 BAL. COMP. IP IC[...]

76 ISP - Rev 6/95 SIDE VIEW FRONT VIEW ENCLOSURE MECHANICAL OU TLINE 11 11 10 5 74.2 132.5 240 251.7 222 45.0 20 5 11 11 X POWER 7.5 NOTE: ALL DIMENSIONS ARE IN mm. X 102.7 12T 20T 16T 62.0 82.3 24T 36T 123.0 184.0 Standard Sizes For non-standard sizes: X = 5.08 x n + 1mm[...]

77 ISP - Rev 6/95 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. 1200 Woodruff Road, Suite C-22, Greenville, SC 29607 -5731 Tel: ([...]