Elmo ISP User Manual

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.

The following maximum warranty period applies:

12 months from the time of operational startup but not later than 18 months from shipment by the manufacturing plant.

Units repaired under warranty have to be treated as an entity. A breakdown of the repair procedure (for instance of the repair of a unit into repair of cards) is not permissible.

Damage claims, including consequential damages, which exceed the warranty obligation will be rejected in all cases.

If any term or condition in this warranty performance shall be at variance or inconsistent with any provision or condition (whether special or general) contained or referred to in the Terms and Conditions of Sales set out at the back of Elmo's Standard Acknowledge Form, than the later shall prevail and be effective.

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 of the ISP, you should read chapters 1-4 which will familiarize you with the product.

Familiar with the ISP ?

Panel (H) version or Rack (R) w/o Elmo mother board ?

Read chapter 5.1 Terminals

Read chapter 6 - Installation

Read chapter 7.1 - Start-Up

Brush Tacho ?

Read

7.2

Rack (R) with Elmo mother board?

Read chapters 5.1+5.2

Terminals

Armature voltage feedback ?

Read

7.3

Read chapters

1,2,3,4

Elmo enclosure ?

Read chapter 5.3 Terminals

(Current mode)

ISP - Rev 6/95

Read chapter 8 - Adjustments

Read chapter 9 - Summaries

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 Velocity control using armature voltage feedback .....10

4.3 Current mode................................ .................10

4.4 Current loop................................ .................11

4.5 Current limits................................ ...............11

4.5.1 Time dependent peak current limit ....................11

4.5.2 Dynamic contouring of continuous and peak current limits 12

4.6 Operation of the shunt regulator ............................. 13

4.7 Protective functions.........................................14

4.7.1 Short circuit protection .............................14

4.7.2 Under/over voltage protection ........................14

4.7.3 Temperature protection ...............................14

4.7.4 Insufficient load inductance .........................14

4.7.5 Loss of velocity feedback signal .....................14

4.7.6 Shunt regulator duty cycle ...........................14

5. Terminal Description ................................ ...............17

5.1 Terminals for Horizontal and Rack mounting versions ..........17

5.2 Mother Board terminals.......................................20

5.3 Terminals for ISP mounted in 3U size ENC. ....................22

6. Installation procedures ................................ ............26

6.1 Mounting................................ .....................26

6.2 Wiring.......................................................26

6.3 Load inductance................................ ..............27

6.4 AC power supply................................ ..............27

6.5 Wiring diagrams................................ ..............28

7. Start - Up Procedures ................................ ..............33

7.1 Common procedures for all amplifiers types ...................33

7.1.1 Inhibit and CW/CCW logic .............................33

7.1.2 Velocity mode ................................ ........36

7.1.3 Current mode ................................ .........36

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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 Velocity control using armature voltage feedback ............ 39

8. Amplifier adjustment and diagnostics ............................... 40

8.1 Balance adjustment .......................................... 40

8.2 Current limit adjustment ................................ .... 40

8.3 Adjusting the motor speed (velocity mode only) .............. 41

8.4 Adjustment of the IxR compensation .......................... 41

8.5 Response adjustment (velocity mode only) .................... 42

9. Tables and Summaries ................................ ............... 44

9.1 Adjusting trimmers .......................................... 44

9.2 LED diagnostics ............................................. 44

Appendix A - Response adjustment - current loop ........................ 45

Appendix B - Current limits contour adjustment ......................... 47

List of ELMO Service Centers ................................ ........... 77

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 deadband. * Excellent linearity. * 2 inputs. * Differential input. * Motor current monitor. * Inhibit/fault indication (free contact relay). * Remote control functions: Inhibit and CW/CCW disable. * Adjustable compensation. * Adjustable continuous and peak current limits. * Dynamic contouring of continuous and peak current limits. * Input balance (offset) adjustment. * Operation in two velocity modes (Tacho or armature voltage feedback) or current

mode. * LEDs diagnostics. * Option - Personality board for ease of replacement: the board includes all the

adjusting trimmers.

Protective functions:

The following protections cause an inhibit which is either self-restart or latched (for manual reset) selectable by the user: * Under / over voltage. * Short circuit: between outputs or each output to ground. * Low inductance. * RMS current limit. * Loss of tacho feedback. * Over temperature. * Duty cycle limit of the power supply's shunt regulator.

ISP - Rev 6/95

2. Type Designation

ISP F - 15 / 65 R W 4

ISP amplifier

PWM switching frequency

20KHz when not specified

Fan cooled

4=40KHz, 6=60KHz

Rated current

Additional capacitance for ISP-10/135 only

Maximum rated voltage

H - Panel mounting R - Rack mounting

3. Technical specifications

Type AC Supply

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 0.7 ISPF-10/135_W 28-135 10/20 SP3 3U/12T 0.8

Current limits

Size Panel types

Size Rack

Weight

ISP-10/135_W 28-135 10/20 SP4 3U/19T 1.6

* DC output voltage is 130% of AC input voltage. * 20KHz, 40KHz or 60KHz switching frequency. * 2KHz current loop response (minimum) * Outputs voltages of +5V/100mA, +15V/50mA each, for external use. * Efficiency at rated current - 97%. * Drift: 10æV/§C (referred to input) * Operating temperature: 0-50§C. * Storage temperature: -10 - +70§C. * The W version includes additional 3000 æF in the bus filter.

These are the absolute minimum-maximum AC supply voltages under any condition.

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 - 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 for R3=R4 (current mode) is given

by:

5.33 x Ic Gcd = ------------- (A/V) R3

R3 in Kohm

The current gain of the single ended inputs in velocity mode is given by (place

the appropriate Gc for each input):

400 x Ic x Ki Gv = ----------------- (A/V) (15+Ri)xR6

Ri,R6 in Kohm

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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

Ri in Kohm

The maximum input voltage at terminals 3,4 is calculated by: Vd

R3=R4 in Kohm

= 10 + 0.6Ri (Volts)

max

= 10 + R3 (Volts),

max

4.2 Velocity mode

In this mode op amp U1/A is employed as a high gain error amplifier The amplifier sums velocity command and the tachogenerator feedback signal, and provides the necessary servo compensation and gain adjustments, resulting in stable, optimum servo operation.

This op amp is configured with two feedback paths: One, in the form of a resistive T network, controls the DC gain of this amplifier. The equivalent value of a T network is given by:

10 Rf= ------- R6

Resistor R6 is mounted in solderless terminals so it can be changed easily whenever the DC gain of the error amplifier is to be changed. The AC gain is controlled by C1, R5 and COMP trimmer. Maximum AC gain is obtained with COMP trimmer set fully CW. Setting COMP trimmer fully CCW removes AC gain and no lag in response occurs. R5 and C1 are mounted in solderless terminals and can be

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 = (V1Gv1 + 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 = 0.1 Full CCW = 1

The feedback element must be connected for negative feedback. The polarity of the ISP servo amplifiers is such that a positive input signal

results in a negative voltage at terminal M1 with respect to terminal M2.

4.2.1 Velocity control using armature voltage feedback

By inserting R8 to its solderless terminals, the armature voltage is fed into the error amplifier to be used as a velocity feedback. This feature is useful for all cases when low regulation ratio and low speed accuracy are acceptable.

4.3 Current mode

In order to operate the servo amplifier as a current amplifier, the velocity loop should be disabled. This is done by converting the error amplifier into a low gain DC amplifier which has a flat response beyond the desired current bandwidth. In this mode, R6 and C1 have to be removed from the circuit.

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 (0.01æF) to get optimum current response for an average motor in this power range. These components are mounted in solderless terminals.

4.5 Current limits

The servo amplifier can operate in the following voltage-current plane:

-Ip -Ic

Intermittent zone

Each amplifier is factory calibrated to have this shape of voltage-current operating area with rated values of continuous and peak current limits. In addition the peak current limit is time dependent as explained in 4.5.1.

Continuous zone -V

Ic - Continuous current Ip - Peak current

Fig. 4.1: Voltage-Current plane

Ic Ip

4.5.1 Time dependent peak current limit

The peak current is so designed that its duration is a function of the peak amplitude and the motor actual operating current before the peak demand. The maximum peak current is available for 1.6 second. The duration of Ip is given by:

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 - 5 Tp = 2.2ln -------- = 2.42 seconds 20 - 15

4.5.2 Dynamic contouring of continuous and peak current limits

Most of the servo motors have reduced continuous current limits at high speeds (Fig. 4.2). This phenomenon is due to commutation limits and iron looses which become significantly high as speed increases and this leads to reduction of the continuous current limit. The ISP amplifiers have the features which enable the user to define the current limit envelope as closely as possible to the motor operating envelope defined by the motor manufacturer.

Velocity

Cont. zone

Interm. zone

Torque

ISP - Rev 6/95

Fig. 4.2:

Typical operating envelope of a brush servo motor

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. The amplifier handles this reverse energy just as efficiently as it provides energy to the motor, hence, most of the energy is passed through the amplifier to the power supply, where the returning energy charges the filter capacitors above their normal voltage level, as determined by the AC incoming voltage.

When the capacitors charge-up reaches the predetermined voltage level (Vr), the shunt regulator begins its regulating action. The bus is regulated to this range until regeneration ceases.

On multi-axis systems, it is recommended to parallel the DC bus of all the ISPs.

SHUNT specifications

Type Reg. Voltage (Vr) Reg. Current (A) ISP-8/65 91 11 ISP-15/65 91 22 ISP-5/135 191 6 ISPF-10/135_W 191 12 ISP-10/135_W 191 12

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 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. Every current peak above a certain value will inhibit the amplifier for a period of approx. 30mS (if in restart mode).

The amplifier is protected against shorts between outputs and either output to ground.

4.7.2 Under/over voltage protection

Whenever the DC bus voltage is under or over the limits indicated in the technical specifications, the amplifiers will be inhibited.

4.7.3 Temperature protection

Temperature sensor is mounted on the heatsink. If, for any reason, the temperature exceeds 85§C the amplifier will be inhibited. The amplifier will restart when the temperature drops below 80 §C.

4.7.4 Insufficient load inductance

Whenever the load inductance is too small, the current spikes will be very high. In such cases the amplifier will be disabled.

4.7.5 Loss of velocity feedback signal

If the amplifier loses the velocity feedback signal it will inhibit itself. In the "Self Restart" mode it will restart after a delay of 6-8 seconds.

4.7.6 Shunt regulator duty cycle

Whenever the ratio between "ON" time to "OFF" time of the shunt exceeds 5-10% the shunt will be inhibited.

ISP - Rev 6/95

CURRENT COMMAND MONITOR.

INPUT 1

4700PF

3 4

.01MF

10K

100K

5.11K

100K

475K

1000PF

100K

CURRENT LIMITS

100

100K

.022MF

10K

100K 100PF

.01MF

TO POWER STAGE

PWM

CONVERTER

CURRNET FEEDBACK

INPUT 2

CURRENT

MONITOR

BACK EMF OUTPUT

CCW

INHIBIT INPUT

.1MF

RELAY

R18

+5V

5.11K

R19a

R20a

100

10K

2.8V

-15V

100K

10K

5.11K +

-V

4.7M

offset

PROTECTIONS

+15V

CURRENT CONTOURS

R10

R11 R12 R13

inhibit latch

D17

loss of tacho

R16

loss of tacho

R15

loss of tacho

R14

RESET

FROM POWER STAGE

ARMATURE

VOLTAGE

ISP - Rev 6/95

11 13

U13

T2 T3 T4

COMPIPIC

U10

OFFSET

R1 R2 R3 R4 R5 R6 R7 R8

R9 R10 R11 R12 R13 R14 R15 R16 D17 R18

C1 C2

U11

T6 T7

GAIN 1GAIN 2

U12

U14

U15

U16

ICINH

14 13 12 11 10

9 8 7 6 5 4 3 2 1

U17

U18

U19

R19A R20A

ISP - CONTROL BOARD

14 13 12 11 10

9 8 7 6 5 4 3 2 1

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

This output will be positive when a positive signal is fed to one of the inputs. All pins are shorted on the PCB.

AC 12ac,10c AC input All pins are shorted on the PCB.

Control stage H R Function Remark 1 32a Input 1 For more details see 4.1.

2 32c Circuit common 3 30a Negative

For more details see 4.1. differential input

4 30c Positive

For more details see 4.1. differential input

5 28a Input 2 For more details see 4.1.

6 28c Reset for latch

mode

low level input voltage

(see 7.1.5).

enables the amplifier

7 26a Current monitor Ic

Scale is = ------ (A/V)

3.75

8 26c CW disable Two modes - see chapter 7.1.1

-1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA.

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 18c Back EMF output See Appendix B. 17,1816a,

16c

Inhibit output A potential free relay contact. Closed when

amplifier is enabled. Contact rating: 0.5A, 200V, 10W

19 14a DC power voltage

5A max.

output - common

20 14c DC power voltage

5A max.

output - positive

Remark: In the following paragraphs the terminals will be related to all the mounting types as in the the following example: H-18,R-16c,E-J1/8.

-1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA.

ISP - Rev 6/95

AC M2 M1 AC

120

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). An opto-Coupler (IL5) is used to isolate between the Inhibit signal and the amplifier circuit. Activating this opto-coupler is done by inserting R1 on the mother board according to the following relation:

R1 = 100 x Vinh (ohm)

Vinh - voltage in the inhibit input. Standard value is 2.4K (For 24 volts) Source must be capable of source or sink 10mA.

ISP - Rev 6/95

10 11 12 13 14 15 16 17 18 21 22

1 2 3 4 5 6 7 8 9

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.

R1 = 100 x Vinh (ohm)

Vinh - voltage in the inhibit input. Standard value is 2.4K (For 24 volts) Source must be capable of source or sink 10mA.

Power Terminals Terminal Function Remark AC AC input

M1 Armature

output

M2 Armature

output AC AC input GND Ground

This output will be negative when a positive signal is fed to one of the inputs. This output will be positive when a positive signal is fed to one of the inputs.

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

5 Positive

differential

input

6 Current monitor Ic

7 Current command

monitor

8,15 Inhibit output A potential free relay contact. Closed when

9,10 Circuit common

For more details see 4.1.

Scale is = ------ (A/V)

3.75 Ic Scale is = ------ (A/V)

3.75

amplifier is enabled. Contact rating: 0.5A, 200V, 10W

11 +15V + 5%, 50mA external load. 12 -15V + 5%, 50mA external load. 13 +5V 100mA 14 Circuit common

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

low level input voltage

enables the amplifier

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. 10 +15V + 5%, 50mA external load. 11,12 Circuit common 13 +5V 100mA 14,15 Circuit common

Remark: In the following paragraphs the terminals will be related to all the mounting types as in the the following example: H-18,R-16c,E-J1/8.

-1V < Vil < 1V ; 2V < Vih < 30V

Source sink capability - 2mA.

ISP - Rev 6/95

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Elmo ISP User Manual

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User Manual