Elmo SERVO AMPLIFIER DBP User Manual

Rev 6/93

DBP - Rev 6/93

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.

DBP - Rev 6/93

How to use this manual - Flow Chart

The DBP HARDWARE MANUAL will lead you toward a successful start-up of your digital amplifier. Please review carefully the following flow chart and write down the chapters that you have to follow in the right order. Only after performing all the steps you may proceed to the software manual.

If you are a new user of the DBP, you better not skip chapters 1-4 which will familiarize you with the product.

Familiar with the DBP ?

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

Hall sensors with optical encoder ?

Rack (R) with Elmo mother board ? Elmo enclosure ?

Read chapter 5.2 Terminals

Resolver ?

Read chapters

1,2,3,4

Read chapter 5.3 Terminals

DBP - Rev 6/93

Adding velocity loop ? Read Appendix B

Read chapter 8 - Applying power - Adjustments

Read chapter 9 - Summaries

yes

TABLE OF CONTENTS

1.Description .......................................................... 7

2. Type Designation ................................ ................... 8

3. Technical Specification ............................................ 9

3.1 Digital I/O specification ................................ ... 10

3.2 Analog input specification .................................. 13

3.3 Sensors specification ................................ ....... 14

3.3.1 Encoder ................................ ............. 14

3.3.2 Resolver ................................ ............ 14

3.4 Communication ............................................... 16

3.4.1 RS232 Configuration ................................. 16

3.4.2 RS485 Configuration ................................. 16

3.5 Battery backup .............................................. 16

3.6 Performance ................................ ................. 16

4. System Operation ................................ ................... 18

4.1 RS485 and Checksum Protocol ................................. 18

4.2 Current Control ............................................. 18

4.2.1 Current feedback, Current feedback multiplier (CFM) and

Current loop ................................ ............... 19

4.3 Digital current limits ................................ ...... 20

4.3.1 Time dependent peak current limit ................... 20

4.4 Digital position and speed control .......................... 21

4.5 Operation of the shunt regulator ............................ 25

4.6 Commutation signals format .................................. 26

4.7 Protective functions ................................ ........ 27

4.7.1 Short circuit protection ............................ 27

4.7.2 Under/over voltage protection ....................... 27

4.7.3 Temperature protection .............................. 27

4.7.4 Internal power supply failure ....................... 27

4.7.5 Loss of commutation feedback ........................ 27

4.7.6 Low back-up Battery voltage ......................... 27

5. Terminal Description ................................ ............... 33

5.1 Terminals for Horizontal and Rack mounting versions ......... 33

5.2 Mother Boards terminals (MBA-DBP/3U and MBA-DBP/6U) ......... 43

5.3 Terminals for DBP mounted in ENCD. .......................... 54

5.4 Communication Port Connector ................................ 64

DBP - Rev 6/93

6. Installation procedures ............................................65

6.1 Mounting.....................................................65

6.2 Wiring....................................................... 65

6.3 Load inductance................................ ..............66

6.4 AC power supply................................ ..............66

6.5 Wiring diagrams................................ ..............67

6.5.1 Motor's windings ................................ .....67

6.5.2 AC power wiring ................................ ......68

6.5.3 Hall sensors wiring ................................ ..77

6.5.4 RS232 Communication wiring ...........................78

6.5.5 RS485 Communication wiring ...........................79

6.5.6 Main encoder wiring ................................ ..81

6.5.7 Resolver wiring ................................ ......82

6.5.8 Auxiliary encoder wiring .............................83

6.5.9 Pulse/Direction signals wiring .......................84

7. Start - Up Procedures .............................................. 85

7.1 Common procedures for all amplifiers types ...................85

7.1.1 Commutation signals format ...........................85

7.1.2 CFM function ................................ .........85

7.1.3 Abort logic ................................ ..........85

7.1.4 Setting the auxiliary position input format ..........86

7.1.5 Selecting the communication bus ......................86

7.1.6 Preparing the automatic baud rate selection ..........86

7.2 Setting the main optical encoder format ......................87

7.3 Setting the R/D circuit......................................87

8. Applying power - Adjustments ................................ .......94

Step 1 - Applying Power ................................ .....94

Step 2 - Establishing the communication .....................95

Step 3 - Checking the feedback elements .....................95

Step 4 - Adjusting the current limits .......................95

Step 5 - Latch mode of the protective functions .............96

Step 6 - Connecting the Motor ...............................96

9. Tables and Summaries ............................................... 97

9.1 Display diagnostics................................ ..........97

9.2 Summary of DIP switches......................................98

Appendix A - Current loop response ................................ .....99

DBP - Rev 6/93

Appendix B - Adding a velocity feedback ............................... 101

Appendix C - Differential amplifier connection ........................ 102

DIMENSIONAL DRAWINGS ................................ ................... 103

PANEL (H), DBP1 ................................ .................. 104

PANEL (H), DBP2 ................................ .................. 107

PANEL (H), DBP3 ................................ .................. 110

PANEL (H), DBP4 ................................ .................. 113

PANEL (H), DBP6 ................................ .................. 116

RACK 3U/13T ................................ ...................... 119

RACK 3U/20T ................................ ...................... 122

RACK 6U/14T ................................ ...................... 125

RACK 6U/21T ................................ ...................... 128

ENCD - 3U/... ................................ .................... 130

ENCD - 6U/... ................................ .................... 131

EXTERNAL SHUNT RESISTOR ................................ .......... 132

List of ELMO Service Centers ........................................... 133

DBP - Rev 6/93

1.Description

The DBP series are digital, full wave, three phase servo amplifiers designed for high performance brushless servo motors in the range of up to 7KW. They utilize power MOSFETs and Surface Mounting Technology which contribute to its high efficiency and compact design. The DBP operates from a single AC supply (either single or three phase) and, when using the galvanic isolation option, it can be connected directly to the Mains.

The DBP is constructed from two main PCBs mounted on a heat sink plate. The lower board contains the rectifying bridge, the power switching transistors which drive the motor, terminals for the power stage, the switch mode power supply, the protection logic and commutation logic. The upper PCB is the Digital Control Board (DCB) which contains the digital control logic, terminals for the control stage, D-type connector for the communication and a 4-digit display.

The DBP requires a position sensor in order to enable its operation. It can be either a Resolver or a combination of an optical encoder and Hall effect sensors. When using a Resolver, a small interface card is mounted on top of the DCB.

The DBP is available in either panel version or rack version with two DIN 41612 connectors. The rack version can be fitted in a panel mount enclosure (ENCD-3U or ENCD-6U), that is specially designed for a simple hook-up procedure.

The amplifiers are fully protected against the following faults:

* Under/over voltage * Shorts between the outputs or between the outputs to ground. * RMS current limit. * Insufficient load inductance. * Loss of commutation signals. * Excess temperature. * Excess position error.

Analog Section Standard Features:

* Single AC supply (single or three phase) * Zero Deadband. * Motor current monitor. * Motor speed monitor. * Extra differential operational amplifier.

DBP - Rev 6/93

DBP F- 24 / 270 R R O

* Standard commutation sensors: Hall effect sensors or a Resolver. * Galvanic isolation of the control stage - option.

Digital Section Standard Features

* Accepts motion commands via RS232 or RS485 * Buffering for pipe lining instructions prior to execution * Battery-backed RAM for storing user programs and parameters * Conditional statements for controlling program execution real- time. * Programmable time and position trip points * Variables for entering and changing system parameters * 5 Uncommitted inputs * 2 uncommitted high speed inputs. * 10 Uncommitted outputs * Arithmetic and logic functions for manipulating parameters * Digital filter with programmable gain, damping and integrator * Error handling, end of travel, emergency stop, status reporting. * 0-600,000 quadrature counts/second speed range * One analog input - 11 bit resolution * Master/slave operation with programmable following ratio (master information

from an optical encoder or from Pulse and Direction inputs) * Dual-loop capability * Adjustable continuous and peak current limits * 4-digit display for diagnostics.

2. Type Designation

DBP series amplifier

Fan cooling required for full rating

Rated continuos current

Max. operating AC voltage

I - Isolation *

O - Off line:

Isolation + Inrush current limit

E - Optical encoder + Hall sensors R - Resolver

R - Rack mounting

H - Panel mounting

DBP - Rev 6/93

3. Technical Specification

Type AC Supply

min max

Current limits

Size Panel(H)

Size Rack(R)

Weight

(Kg) DBP-12/135 28- 135 12/24 DBP2 3U/20T 1.4 DBP-20/135 28- 135 20/40 DBP3 6U/21T 3 DBP- 8/270 100- 270 8/16 DBP2 3U/20T 1.4 DBP-16/270 100- 270 16/32 DBP3 6U/21T 3

DBPF-12/135 28- 135 12/24 DBP1 3U/13T 0.7 DBPF-20/135 28- 135 20/40 DBP4 6U/13T 1.3 DBPF-30/135 28- 135 30/60 DBP6 6U/21T 3 DBPF- 8/270 100- 270 8/16 DBP1 3U/13T 0.7 DBPF-16/270 100- 270 16/32 DBP4 6U/13T 1.3 DBPF-24/270 100- 270 24/48 DBP6 6U/21T 3

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

DBP - Rev 6/93

General

* DC output voltage is 130% of AC input voltage. * 2KHz current loop response * Outputs voltages of +5V/0.2A, +15V/0.1A for external use. * Efficiency at rated current - 97%. * Operating temperature: 0 - 50°C. * Storage temperature: -10 - +70°C.

3.1 Digital I/O specification

Digital Inputs:

High/Low input definition: Vil<1V, Vih>2.4V Maximum input voltage: 30V Input impedance: 3-7Kohm Input hysteresis: typ 1V. When left open: low level. Input threshold level can be shifted on request. The fast inputs capture events (input voltage level going from low to high) of less then 10 µsec duration.

Digital Outputs:

High/Low output definition: Vol<0.4V, Voh>4V Output level: 0-5V Recommended output current: Iol=Ioh=5mA Maximum output current +10mA The outputs are normally at low level.

DBP - Rev 6/93

U17

VCC

74HCT373A

2 5 6 9 12 15 16 19

+5V

3 2

U11A 74HCT4050

5 4

13b

14b

15b

16b

17b

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

OUT 8

OUT9

OUT10

U11B 74HCT4050

7 6

U11C

MOTION COMPLETE

74HCT4050

DIGITAL OUTPUTS

DBP - Rev 6/93

FORWARD

LIMIT SWITCH

REVERSE

LIMIT SWITCH

HOME INPUT

ABORT INPUT

10a

12a

13a

18b

19b

20b

21b

1 3

4 6

SN75C189AD

10 8

13 11

1 3

4 6

10 8

13 11

U100A SN75C189AD

U100B

U100C

SN75C189AD

U100D

SN75C189AD

U102A SN75C189AD

U102B

SN75C189AD

U102C

SN75C189AD

U102D

SN75C189AD

DBP - Rev 6/93

22b

1 3

INDEX SLAVE

15a

16a

4 6

10 8

DIGITAL INPUTS

U103A SN75C189AD

U103B

SN75C189AD

U103C

SN75C189AD

3.2 Analog input specification

Maximum input voltage:

- When R1 (470ohm) is inserted, the absolute value of the input voltage should be

less than 5V.

- When the absolute value is higher than 5V, R1(Kohm) = 2Vi-10 should be inserted. The µP reads always +5V.

Resolution of the digital conversion: 11 bit full scale.

Typical offset: 5 bits

470K

VREF

4700PF

VREF

300

4700PF 4700PF

300

4700PF

DIGITAL GND

U1\10

U1\11

ANALOG INPUT

18a

1 2

10K

DIGITAL GND

470k

6 5

U8B

DIGITAL GND

470k

9 10

DIGITAL GND

20K

4700PF

U8C

1000PF

20K

13 12

U8D

DIGITAL GND

DBP - Rev 6/93

ANALOG INPUT

3.3 Sensors specification

3.3.1 Encoder

The encoder must be incremental with two TTL channels in quadrature and 90 ° phase shift. High/Low input definition: Vil<1.5V, Vih>3V Input voltage range: 0-15V Input hysteresis 1.5V Input impedance: 1Kohm to 5V. Maximum frequency main encoder: 150KHz Maximum frequency auxiliary encoder: 250KHz Noise protection by analog and digital filters When left open the input is internally pulled to high level.

3.3.2 Resolver

Resolver Option Feature:

* 10,12,14 and 16 bit resolution set by the user. * Maximum tracking rate 1040 rps (10 bits). * Velocity output. * Encoder A, B, outputs + programmable index output.

Reference parameters:

Max. voltage: 20Vptp or 7Vrms Minimum output voltage: 2Vrms Max. current: 80mA Max frequency: 20KHz outputs:

DBP - Rev 6/93

CH B

27a

R705

28a

1000P

100

+5v+5v

1K 1000P

DS3

+5v

100K

+5V

3 2

U105

301K

Vref

CH A

AY/PULSE

INDEX

29a

30a

21a

22a

31a

32a

R704

R707

R708

100

1000P

100

1000P

100

1000P

+5v

+5v +5v

+5v

1K 1000P

1000P

1K 1000P

DS5

+5v+5v

+5v

DS6

+5v+5v

DS2

+5v

100K

100K 11

+5v

3 2

301K

U104

U107

U31D

+5v

2.49K

+5V

4 5 6U121B

REMARK:

R704 - 708 ARE NOT INSTALLED IN FACTORY STANDARD SETTING.

DBP - Rev 6/93

BY/DIR

23a

24a

+5v +5v

+5v

1000P

100

R706*

100

DS4

1000P

+5v

3 2

100K

301K

ENCODER INPUTS

+5v

2.49K

U106

3.4 Communication

3.4.1 RS232 Configuration

The RS232 is configured for 8-bit, no parity, full duplex and it will echo all the transmissions. Baud rates: 300,600,1200,2400,4800,9600,19200,38400,57600 No hardware handshaking is required.

3.4.2 RS485 Configuration

The RS485 is configured for 8-bit, no parity, half duplex. Baud rates: 300,600,1200,2400,4800,9600,19200,38400,57600 No hardware handshaking is required.

3.5 Battery backup

180mAH battery that at rated operating and storage condition will last for

at least 40,000 non operating hours.

3.6 Performance

Position range: +230 quadrature counts Velocity range: +600,000 counts/sec Velocity resolution: 1 count/s Acceleration range: 91 - 11.8x106 count/s Acceleration resolution: 91 counts/s

DBP - Rev 6/93

RS232

DZ13v

TRANSMIT RECEIVE GND

RS485

T/R-

T/R+

TRANSMIT/ RECEIVE CONTROL

+5V

3 2 5

-15V

120

ohm

300

0.1MF

* R802

+5v

R119

U115

-V

GND

SN75155

0.1MF U114

VCC

GND

SN75LS176

+5v

RE DE

RTC

+15V

300

DZ13v

0.1MF

2 3 6

+5v

DS9

RS232-OFF RS485-ON

RS485/RS232

1 2 3 4

Notes:

R119 - LINE TERMINATION RESISTOR, USED ON BOTH ENDS OF LONG LINES. NORMALLY NOT MOUNTED.

* * R802 - SMD RESISTOR. NORMALLY NOT MOUNTED

DBP - Rev 6/93

COMMUNICATION

4. System Operation

4.1 RS485 and Checksum Protocol

The RS485 in the DCB is configured as 8-bit, no parity, 1 stop bit, half duplex. The following baud rates are available: 300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600. No hardware handshaking is required.

In the RS-485, which is a Half Duplex system, all the Transmitters and all the Receivers share the same Multidrop wire. Therefore, each character that is transmitted on the line, is automatically received by all the Receivers. This is an inherently "confused" way to transmit data and no "Echo" procedure can assure reliable communication.

In order to solve this reliability problem, it is necessary to use standard protocols procedures.

It is important to understand that using RS485 with the DCB products without any protocol is possible. This is also the default condition whenever the RS485 is activated. However, the reliability of the communication is only assured when activating the protocol. This is done by sending the command CK1 from the host to the DCB.

Chapter 1.2.1 in the DCB Software manual explains the standard protocol used and supplied by Elmo.

4.2 Current Control

The analog part of the DBP is actually a standard amplifier that operates in current mode. However, the DCB receives continuously analog information about the current magnitude, direction and ripple. This information is processed to obtain digital control of the following features:

* Continuous current limit * Peak current limit * Time dependent peak current limit * Current ripple

DBP - Rev 6/93

4.2.1 Current feedback, Current feedback multiplier (CFM) and Current loop

Three current feedbacks are obtained by measuring the voltage drop across current sensing resistors or by current transformers (when using the isolation option). These three signals are synthesized and multiplexed which result in a single voltage signal proportional to phases currents. It is then compared to the current command. The error is processed by the current amplifier to provide a voltage command to the PWM section.

Current loop control is obtained by op amp U21/A (current amplifier) and R4, C1 which form a lag-lead network for current loop. The standard amp is equipped with R4 and C1 to get optimum current response for an average motor in this power range. These components are mounted in solderless terminals.

Error amplifier Current amplifier

Current feedback

CFM

The amplifier is equipped with a Current Feedback Multiplier (CFM). By turning DIP switch 2 (on the upper board of the power stage) to ON, the signal of the current feedback is multiplied by 2 and consequently the following changes occur:

- Current gains are multiplied by 2.

- Current monitor is divided by 2.

- Current limits are divided by 2.

- Dynamic range is improved.

- Commutation ripple is reduced.

DBP - Rev 6/93

This function should be activated whenever the rated current AND the peak current of the motor are less than 20% of the amplifier rated continuous and peak limits respectively.

Sometimes, oscillations may occur in the current loop due to the fact that the feedback gain was multiplied. This can be resolved by substituting R4 with a lower value.

4.3 Digital current limits

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

-Ip -Ic

Intermittent zone

Ic - Continuous current Ip - Peak current

Each amplifier is factory adjusted to have this shape of voltage-current operating area with rated values of continuous and peak current limits. By using the command CL(n) for the continuous and PL(n) for the peak it is possible to adjust the current limits (continuous and peak independently) from the rated values down to 10% of the rated values.

Continuous zone -V

Fig. 4.1: Voltage-Current plane

Ic Ip

4.3.1 Time dependent peak current limit

The peak current duration is a programmable parameter which is also a function of the peak amplitude and the motor operating current before the peak demand. The user defines the maximum duration of the full amplitude peak by the instruction PDn - n cannot be more than 2 seconds. In addition to this definition, a digital filter is employed to ensure that the RMS value of the current will not exceed the continuous current limit. The duration of Ip is given by:

DBP - Rev 6/93

Ip - Iop Tp = 2.2ln --------- Ip - Ic

Iop - Actual operating current before the peak demand.

The result of this filter is that the maximum peak can last for a maximum of

2 seconds. A lower peak can last longer.

Example: A motor is driven by an DBPF-10/135 amplifier at constant speed and constant current of 5A. What is the maximum possible duration of a 20A peak ?

20 - 5 Tp = 2.2ln -------- = 0.892 seconds 20 - 10

4.4 Digital position and speed control

The DCB accepts motion commands via an RS232 or RS485 communication line and receives position feedback in an incremental encoder format either from an encoder or from the resolver/digital circuit. The DCB derives the closed-loop position error by comparing the command position and the feedback position. The error is processed by a digital filter to yield with an analog motor command. The analog +5 volt range motor command is then amplified by the power amplifier.

Following is a summary of all the operating modes of the DCB and a detailed discussion of each of them.

Control Modes Holding Modes. Start Modes Program Mode Termination Modes Status reporting Define origin modes

DBP - Rev 6/93

Control Modes

The DCB can be commanded to control the position of a motor, its torque or

its velocity using three basic control modes:

- Position Mode

- Velocity Mode

- Position Follower Mode

Position Mode

In the position mode the motor will advance a specified distance and then stop. This distance can be represented as an absolute position (PA n) or as a relative distance from the current position (PR n). The motion will follow a trapezoidal or triangular profile with the acceleration (AC n) and slew velocity (SP n) set by the user.

Velocity Mode

In the velocity mode the motor will accelerate to a specified slew speed. It will hold this speed until a stop condition is received (see termination modes), or a new velocity/direction is commanded.

Position Follower

It can also control the motor as a position follower of a master encoder or a pulse and direction signals.

Holding Modes.

The holding modes describe the behavior of the system after it has stopped. There are three holding modes:

- Servo

- Motor Off

Servo Mode

In the servo mode (SV) the system maintains stopping position by using its control law to correct for any position errors.

Motor Off Mode

In the Motor Off mode is, the power bridge and the position control are shut off and there no torque is generated by the amplifier. The Motor Off mode is useful in robotics applications in the teaching mode.

DBP - Rev 6/93

Start Modes

There are three start modes to begin a move:

Direct command

A move can be initiated directly by a command from the host or a terminal.

Program

A move can be initiated by a command included in the user program.

Input condition

Another alternative is to have the move started by a conditional statement

specified by the user program.

Program Mode

A set of commands can be implemented as a user program to allow for automatic and/or complex types of moves. The user may specify software variables, conditional statements, subroutines and error routines which enable enhanced motion control.

Termination Modes

A motion can be terminated in a variety of ways. In all but emergency termination modes the motor will be decelerated gradually to a stop and then will enter one of the stationary modes (Servo, or Motor Off). In a position mode move, the motion will terminate naturally upon reaching the desired final position. In all of the control modes the motion can be terminated by a command from the host. An additional means of termination is from one of the local inputs.

Activating the forward and reverse limit switch inputs can be another means of terminating a move. Upon contacting the switch, the #[ routine will be activated. This is a user programmed routine that should normally include a stop command to decelerate the motor to a full stop.

There are two methods of generating an emergency stop. The first is by an abort command from the host, and the other is by the local abort input. Upon receipt of either of these commands the system will go immediately to its stationary mode.

Another "unnatural" way to terminate a motion is whenever an internal amplifier inhibit (due to one of the protections) occurs. This turns off the power stage and the motor will decelerate to a stop by friction only. There are two modes of handling the internal amplifier inhibit:

Latch Mode

The power stage is disabled and only a reset will release it.

DBP - Rev 6/93

Auto restart

The power stage inhibit will automatically be released upon clearing the

cause of the inhibit.

Status Reporting

Status is available to the user in several ways.

Communication

In response to the Tell Status command (TS) the DCB sends a coded message

describing the status of the amplifier.

In addition, the host may request certain information at any time. This consists of the state of the system (GN?, ZR?, PL?, KI?), the state of the local inputs (TI), the torque level (TT), the current motor position (TP), the current motor velocity (TV) and the reason for a stop condition (TC).

Refer to the DCB Software Manual for further details.

Hardware signal

Motion complete signal

This output will go to high when motion is complete.

Inhibit output

Whenever the amplifier is inhibited, this open collector output goes to low. When using Elmo's mother boards a potential free relay replaces the open collector output.

4-digit display

Whenever a fault occurs, a fault message will be displayed for easy visual information. See chapter 9.1 for a summary of all amplifier's fault indications.

Define origin modes

The origin is that location at which the absolute position of the motor equals zero. This special location may be defined in two ways. First, the user may send a command (DH) which defines the current motor position to be the origin. The alternate method is to request the DCB to perform the homing sequence by commanding HM.

DBP - Rev 6/93

4.5 Operation of the shunt regulator

A shunt regulator is included in the power supply section of the DBP. The shunt regulator is a switching type, wherein dissipative elements (resistors) are switched across the DC bus, whenever the voltage reaches a predetermined level (Vr). 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.

All the double Eurocard size amplifiers are equipped with two outputs for connecting an external shunt resistor , hence increasing the power dissipation capability.

SHUNT specifications

Type Reg.

Voltage

(Vr) DBP-12/135 193 13 N/A DBP-20/135 193 26 21 DBP-8/270 383 8 N/A DBP-16/270 383 16 12 DBPF-12/135 193 13 N/A DBPF-20/135 193 26 N/A DBPF-30/135 193 26 21 DBPF-8/270 383 8 N/A DBPF-16/270 383 16 12 DBPF-24/270 383 16 12

Internal Reg. Current (A)

External Reg. Current (A)

DBP - Rev 6/93

4.6 Commutation signals format

60 FORMAT (120)

300

Vac

(360)

60 120 180 240 300 360 600

(0)

30 FORMAT

60 120 180 240 300 360 600

(0)

Vba

Vcb

300

(360)

DBP - Rev 6/93

MOTOR BEMF

60 120 180 240 300 360 600

(0)

4.7 Protective functions

All the protective functions except "Low Back-up Battery Voltage" activate an interrupt to the main processor which inhibits the power bridge and disable current flow to or from the motor. The user can interrogate the processor in order to verify the cause of the inhibit. An indication of the fault will appear on the display. The following protections are processed by the DCB:

4.7.1 Short circuit protection

The amplifier is protected against shorts between outputs, or either output to ground, or either output to the positive supply line.

4.7.2 Under/over voltage protection

Whenever the DC bus voltage is under or over the limits indicated in the technical specifications, the amplifier 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. The user can always interrogate the DCB about the heatsink temperature by using the command T?.

4.7.4 Internal power supply failure

In any case that the sum of the internal power supplies is below 13V or its difference higher than 1V, the amplifier will be inhibited.

4.7.5 Loss of commutation feedback

Lack of either of the commutation signals will inhibit the amplifier.

4.7.6 Low back-up Battery voltage

When the battery voltage goes below 2.4V the DCB will send a message on the communication line and will display "BATT" on the display.

DBP - Rev 6/93

+VS

MOTOR OUTPUTS

AC AC AC

CONTROL

HA HB HC

RECTIFING, CURRENT INRUSH LIMIT

POWER COMMON

SUPPLIES

PWM SIGNAL PROTECTIONS CURRENT FEED BACK

SHUNT CONTROL

SMPS

ISOLATION

"HALL" SIGNAL

PROCESSING

D1 D2 D3

SUPPLIES

PWM SIGNALS PROTECTIONS CURRENT FEED BACK "HALLS" SIGNALS

CURRENT SENSING

D1 D2 D3 D4

COMMUTATION

CURRENT PROCESSING

D6D5

D5 D6

DBP - Rev 6/93

DBP 3U - BLOCK DIAGRAM

Display

RS232 RS485

Outputs Buffers

Inputs Buffer

Aux Encoder Buffer

Analog in

Encoder

MOTOR COMMAND

VELOCITY/ CURRENT MODE

TO POSITION

PROCESSOR

ENCODER OUTPUTS

Master Processor

Position ProcessorBuffer

MEMORY

SHORT SIGNAL UNDER / OVER - SIGNAL TEMP SIGNAL

Current limits

CURRENT

AMPLIFIER

100K R4

BATTERY

BACK UP

POWER

STAGE

Current Feedback

PWM

.01UF

RESOLVER

OPTION

VELOCITY FEEDBACK

SIGNAL

TACH INPUT (OPTION)

(TACH OUTPUT WITH RESOLVER OPTION)

INH. OUT 10MA/30V

10K

R800

100K option

OFFSET OPTION

100K

-V

100K

10K

100K

ERROR

option

619K

100K

AMPLIFIER

DCB BLOCK DIAGRAM

DBP - Rev 6/93

U120

U114

N80C196KB-12

U115

U123

R713 R712

R119

T1T2

R802

U116

U130

U25

U22

U109

R566

U108

U102

R504 R505

U10

U17

R705

506 507

518 519

U18

C300

513

C313

C312

U101

U100

C139

U103

U106

OFF

R500 R501

R502

R503 R508

R509 R510 R511

R708

706 704

U28

R R

R 1 234 5 6 7

C1C2

R800

U31

U107

R707

U27

R R R R

U21

U9 U21

U11

U112

U113

U26

U29

HC HB HA

U20

JPR

DCB COMPONENTS LAYOUT

DBP - Rev 6/93

JR/5

JR/6

JR/9

SIN. INPUT

JR/10

JR/7

COS. INPUT

JR/8

Ref. oscillator output

R192

Ref. osc. common

C60

R193

R194

R228

R233

C62

R196

RESOLVER TO

DIGITAL CONVERTER

C61

R196

POSITION BITS

R197

R201

C67

R200

C68

JPR/8

JPR/9 JPR/10

JR/2 JR/3

JR/1

JR/4

HA HB HC

ENCODER A ENCODER B ENCODER I

R242 R243 R244

DS11

Velocity feedback

HALLS + ENCODER

PROCESSOR

DS12

DS13

DS14

DCB RESOLVER OPTION BLOCK DIAGRAM

DBP - Rev 6/93

U24

OFF

12 13

DS2

U25

c c c c

686762

195

197

U22

201

196

200

192

233

228

194

JPR

193

U30

U28

U29

U23

RESOLVER BOARD

COMPONENTS LAYOUT

DBP - Rev 6/93

5. Terminal Description

5.1 Terminals for Horizontal and Rack mounting versions

POWER BOARD - 3U size

H R Function 1 (32a,c)

2 (30a,c

3 (28a,c)

4 (26a,c)

5 (24a,c)

6 (22a,c)

7 (20a,c) 8 9

(18a,c 16a,c)

10 (14c)

Motor phase A output. With the DIN connector both pins must be connected. Motor phase B output. With the DIN connector both pins must be connected. Motor phase C output. With the DIN connector both pins must be connected. AC supply-phase A. With the DIN connector both pins must be connected. AC supply-phase B. With the DIN connector both pins must be connected. AC supply-phase C. With the DIN connector both pins must be connected. DC power positive (+Vs) DC power common

Hall sensor A

11 (12c) 12 (10c) 13 (8c) 14 (6c) 15 (4c) 16 (2c)

Hall sensor B * Hall sensor C * +15VDC for Hall sensors supply. Circuit common for the Hall sensors supply (Control common). 24V common - for the fan supply only. +24VDC, 400mA for use with brushless fan

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

Source sink capability - 2mA min.

DBP - Rev 6/93

Power Board - 6U size - Supplies terminals

H R FUNCTION

+VS 4ac,2ac NC SO 8ac NC POW

14ac,12ac

External shunt resistor connection / +VS. NOT CONNECTED External shunt resistor connection. NOT CONNECTED POWER COMMON

COM NC AC 20ac,18ac

NOT CONNECTED AC supply-phase A. With the DIN connector all pins must be connected.

AC 26ac,24ac

AC supply-phase B. With the DIN connector all pins must be connected.

AC 32ac,30ac

AC supply-phase C. With the DIN connector all pins must be connected.

Power Board - 6U size - Motor terminals

H R FUNCTION HC 2c

HB 4c HA 6c

-FAN 8c +FAN 10c MC 18ac,16ac,14a

Hall sensor C Hall sensor B * Hall sensor A 24V common - for the fan supply only +24VDC, 400mA for use with brushless fan Motor phase C output. With the DIN connector all pins must be connected.

MB 26c,24ac,22ac

Motor phase B output. With the DIN connector all pins must be connected.

MA 32ac,30ac,28c

Motor phase A output. With the DIN connector all pins must be connected.

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

Source sink capability - 2mA min.

DBP - Rev 6/93

Control board H & R Function Remarks

1a Output 6 1b Current monitor

2a Output 7 2b Velocity / current mode

selection

3a Output 8 3b Motion command (+5V)

4a Circuit common

This analog output represents the actual current in the motor. The scale (in A/V) is: Ip / 7.5 Ip - Rated peak current of amplifier. * When input is left open (low level) the analog part of the amplifier is working in current mode. when a high level signal is applied (>2V), the analog part of the amplifier is working as a high gain velocity amplifier.

* This analog output represents the current command from the position loop to the power amplifier. It is useful for monitoring the position loop response.

4b Circuit common 5a Fast output 9 5b +5V output

* There are several +5V terminals. The accumulative external load should not exceed 200mA.

6a Fast output 10

6b Circuit common 7a Motion Complete

This output will go to high when motion is complete. *

7b +15V output 8a Inhibit output

100mA. Whenever the amplifier is inhibited, this open collector output goes low.

8b -15V output

100mA.

Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Control board - cont.

H & R Function Remarks

9a Forward limit switch 9b positive input of a

differential amplifier. 10a Reverse limit switch 10b Negative input of a

differential amplifier. 11a Circuit common 11b Output of a

differential amplifier. 12a Home switch 12b Tachogenerator

output/input

13a Abort input

13b Output 1

This committed input activates the #[ subroutine.

See Appendix C.

This committed input activates the #[ subroutine.* See Appendix C.

See Appendix C.

* When using the resolver option this output is the velocity monitor with a scale of 8V for maximum speed. See 7.3. This input must be connected to high level voltage to enable the amplifier.*

14a Circuit common 14b Output 2 15a Fast input 6

** This fast response input can capture events with a duration of less than 10µs. An event is defined as an input voltage transition from low to high. *

15b Output 3 16a Fast input 7 16b Output 4 17a Reset input 17b Output 5

** Same function as Fast Input 6 (15a). * ** * **

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Control board - cont.

H & R Function Remarks

18a Analog input

18b Input 1 19a +5V output

19b Input 2 20a Circuit common 20b Input 3 21a Auxiliary encoder input

(Ay) or pulse input for Pulse and Direction

mode. 21b Input 4 22a Auxiliary encoder

This input is monitored by the main µP. When |Vi| < 5V, R1=470ohm should be inserted. When |Vi|> 5V, R1(Kohm)=2Vi-10 should be inserted. The µP always reads a range of +5V. * There are several +5V terminals. The accumulative external load should not exceed 200mA. *

complementary input (-

Ay) or complementary

Pulse and Direction

mode 22b Input 5 or Index Input.

If a homing sequence is required, the Index Input must be connected to Input 5 *

23a Auxiliary encoder input

(By) or Direction input

for Pulse and Direction

mode 23b Resolver reference

Max. voltage: 20Vptp or 7Vrms Max current: 80mA Max frequency: 20KHz

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Control board - cont.

H & R Function Remarks 24a Auxiliary encoder

complementary input (By) or Complementary Direction input for Pulse and Direction mode

24b Resolver reference

common.

25a +5V output

25b Cosine signal input. 26a Circuit common 26b Cosine signal common. 27a Channel B input 27b Sine signal input. 28a Channel -B input 28b Sine signal common 29a Channel A input 29b Circuit common 30a Channel -A input 30b Index output 31a -Index input

The reference voltage to the resolver must be taken from terminals 23b and 24b only. There are several +5V terminals. The accumulative external load should not exceed 200mA. See 7.3 For the auxiliary encoder See 7.3

See 7.3

For the main encoder

For resolver option only.

31b Channel B output 32a Index input 32b Channel A output

Remark: In the following paragraphs the terminals will be related to all the mounting types as in the following sample: H/R-2a,E-J4/13.

DBP - Rev 6/93

CONTROL BOARD

POWER BOARD

b a

c a

TERMINALS OF DBP

RACK VERSION - 3U SIZE

DBP - Rev 6/93

TERMINALS LAYOUT

CONTROL BOARD

FAN 24

C+15

- +

14 15 16

b a

MOTOR OUT

B C

1 2 3 4

AC input

~ ~

5 6 7 8

POWER

+VS

COM.AB

HALL

SUPPLY

91011 12 13

DBP - PANEL (H) MOUNTING TYPE

DBP - Rev 6/93

EUROCARD SIZE TYPES

17 18 19

+FAN

-FAN HA HB HC

5 6

7 8 9

11 12 13

N.C POW COM.

N.C S.O

N.C +VS

DBP - PANEL (H) MOUNTING TYPE

DOUBLE EUROCARD SIZE TYPE

DBP - Rev 6/93

POWER

CONTROL

DBP-6U RACK TYPE

CONNECTORS

DBP - Rev 6/93

5.2 Mother Boards terminals (MBA-DBP/3U and MBA-DBP/6U)

Use: For all DBP amplifiers (3U/6U size) with Resolver or optical encoder feedback. The encoder outputs are driven by line drivers to improve noise immunity. Termination: Screw type terminals for the power and D-type connectors for the signals.

POWER TERMINALS FOR MBA-DBP/3U

H R Function 1 (32a,c)

2 (30a,c

3 (28a,c)

4 (26a,c)

5 (24a,c)

6 (22a,c)

7 (20a,c) 8 9 10

(18a,c 16a,c)

Ground, this terminal is connecred through a screw to the rack

15 (4c) 16 (2c)

DBP - Rev 6/93

chassis. 24V common - for the fan supply only. +24VDC, 400mA for use with brushless fan

POWER TERMINALS FOR MBA-DBP/6U

Terminal Function M1 Motor phase A output.

M2 Motor phase B output. M3 Motor phase C output. GND Ground. This terminal is connected to the ENC chassis. AC AC supply-phase A. AC AC supply-phase B. AC AC supply-phase C. COM DC power common VS DC power positive SO Auxiliary shunt output, for external shunt resistor.

DBP - Rev 6/93

Signals connector - J1 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function 1 Channel A input

2 Channel -A input 3 Channel B input 4 Channel -B input 5 -Index input 6 Index input 7 +5V output

8 +15V output

9 Circuit common

Signals connector - J2 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function 1 Resolver reference

Remarks

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +15V pins. The accumulative external load should not exceed 100mA.

Remarks Max. voltage: 20Vptp or 7Vrms

2 Resolver reference

common. 3 Cosine signal input. 4 Cosine signal common. 5 Sine signal input. 6 Sine signal common 7 +15V output

8 -15V output

9 Circuit common

Max current: 80mA Max frequency: 20KHz The reference voltage to the resolver must be taken from pins 1 and 2 only. See 7.3 See 7.3 See 7.3 See 7.3 There are several +15V pins. The accumulative external load should not exceed 100mA. There are several -15V pins. The accumulative external load should not exceed 100mA.

DBP - Rev 6/93

Signals connector - J3 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function 1 positive input of a

differential amplifier.

2 Negative input of a

differential amplifier.

3 Output of a

differential amplifier. 4 Circuit common 5 Analog input

6 Circuit common 7 Circuit common 8 Current monitor

Remarks See Appendix C.

See Appendix C.

This input is monitored by the main µP. When |Vi| < 5V, R1=470ohm should be inserted. When |Vi|> 5V, R1(Kohm)=2Vi-10 should be inserted. The µP always reads a range of +5V.

This analog output represents the actual current in the motor. The scale (in A/V) is: Ip / 7.5

9 Circuit common 10 +5V output

11 +15V output

12 -15V output

13 Channel B output 14 Channel A output 15 Index output 16 Not connected 17 Inhibit output

Ip - Rated peak current of amplifier.

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +15V pins. The accumulative external load should not exceed 100mA. There are several -15V pins. The accumulative external load should not exceed 100mA.

For resolver option only.

Relay contact (potential free). The relay contact is closed whenever the amplifier is enabled. Contact rating: 0.5A, 200V, 10W.

DBP - Rev 6/93

Signals connector - J3 - cont.

Pin Function 18 Inhibit output

19 Motion command (+5V)

20 Circuit common 21 Reset input 22 Circuit common 23 Tachogenerator

output/input

24 Circuit common

Remarks Relay contact (potential free).

The relay contact is closed whenever the amplifier is enabled. Contact rating: 0.5A, 200V, 10W. This analog output represents the current command from the position loop to the power amplifier. It is useful for monitoring the position loop response.

When using the resolver option this output is the velocity monitor with a scale of 8V for maximum speed. See 7.3.

25 Velocity / current mode

selection

When input is left open (low level) the analog part of the amplifier is working in current mode. when a high level signal is applied (>2V), the analog part of the amplifier is working as a high gain velocity amplifier. *

26 Not connected

Signals connector - J4 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function 1 Input 1

2 Input 2

Remarks *

3 Circuit common 4 Input 3 5 Input 4

* *

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function 6 Input 5 or Index Input.

7 Circuit common 8 Fast input 6

9 Fast input 7 10 Circuit common 11 +5V output

12 +5V output

13 Output 7 14 +5V output

Remarks If a homing sequence is required, the Index Input

must be connected to Input 5.

This fast response input can capture events with a duration of less than 10µs. An event is defined as an input voltage transition from low to high. Same function as Fast Input 6 (8).

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +5V pins. The accumulative external load should not exceed 200mA.

There are several +5V pins. The accumulative external load should not exceed 200mA.

15 Output 1 16 Output 2 17 Output 3

** **

18 Circuit common 19 Output 4 20 Output 5 21 Output 6

** ** **

22 Circuit common 23 Output 9

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function 24 Output 10

25 Motion Complete

26 Output 8

Remarks *

This output will go to high when motion is complete.

Signals connector - J6 (MBA-DBP/3U and MBA-DBP/6U)

Pin Function

Remarks

1 Auxiliary encoder

complementary input (By) or Complementary Direction input for Pulse and Direction mode

2 Auxiliary encoder input

(By) or Direction input for Pulse and Direction mode

3 Auxiliary encoder input

(Ay) or pulse input for Pulse and Direction mode.

4 Auxiliary encoder

complementary input (Ay) or complementary Pulse and Direction mode

Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J6 - cont.

Pin Function 5 Auxiliary encoder index

input

6 +5V output

7 +15V output

8 Circuit common 9 Home switch 10 +5V output

11 Abort input

12 +5V output 13 Forward limit switch

Remarks

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +15V pins. The accumulative external load should not exceed 100mA.

There are several +5V pins. The accumulative external load should not exceed 200mA. This input must be connected to high level voltage to enable the amplifier. * 200mA This committed input activates the #[ subroutine. *

14 Reverse limit switch

This committed input activates the #[ subroutine. *

15 Circuit common

J1A, FAN TERMINALS - (MBA-DBP/6U ONLY)

10 11

24VDC common - fan only. +24VDC isolated supply for fan (max. 400mA)

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J8 (MBA-DBP/3U and MBA-DBP/6U)

1 Channel A output 2 Channel -A output 3 Channel B output 4 Channel -B output 5 Encoder index output

6 Encoder -index output

7 Circuit common 8 Circuit common 9 Circuit common 10 Hall A 11 Hall B 12 Hall C 13 +15V

Main encoder buffered output (20mA, 0-5V) Main encoder buffered output (20mA, 0-5V) Main encoder buffered output (20mA, 0-5V) Main encoder buffered output (20mA, 0-5V) For resolver option only buffered output (20mA, 0-5V) For resolver option only buffered output (20mA, 0-5V)

* * There are several +15V pins. The accumulative external load should not exceed 100mA.

14 +5V output

There are several +5V pins. The accumulative external load should not exceed 200mA.

15 Circuit common

Remark: In the following paragraphs the terminals will be related to all the mounting types as in the following sample: H/R-2a,E-J4/13.

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

Source sink capability - 2mA min.

DBP - Rev 6/93

7 6

5 4

2 1

DBP - Rev 6/93

MBA - DBP/3U

+VS

25 26

10 11

J1A

POW. COM.

MBA-DBP/6U

DBP - Rev 6/93

5.3 Terminals for DBP mounted in ENCD.

POWER TERMINALS FOR MBA-DBP/3UE (3U size)

Terminal Function

1 2 3 4 5 6 7 8,9 10 11

POWER TERMINALS FOR MBA-DBP/6UE (6U size)

Terminal Function MA

MB MC

Motor phase A output. Motor phase B output. Motor phase C output. AC supply-phase A. AC supply-phase B. AC supply-phase C. DC power positive (+Vs) DC power common Ground Ground

Motor phase A output. Motor phase B output. Motor phase C output.

GND AC AC AC POW COM +VS SO

Attention: DC power commons, control commons and fan common are floating with respect to each

other. Do not short them unless specified. For isolated amplifiers connecting control common to ground is accomplished by inserting R2 (short resistor) on the mother board.

Ground AC supply-phase A. AC supply-phase B. AC supply-phase C. POWER COMMON External shunt resistor connection / +VS. External shunt resistor connection.

DBP - Rev 6/93

Signals connector - J1 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function 1 Channel A input

2 Channel -A input 3 Channel B input 4 Channel -B input 5 -Index input 6 Index input 7 +5V output

8 +15V output

9 Circuit common

Signals connector - J2 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function 1 Resolver reference

Remarks

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +15V pins. The accumulative external load should not exceed 100mA.

Remarks Max. voltage: 20Vptp or 7Vrms

2 Resolver reference

common. 3 Cosine signal input. 4 Cosine signal common. 5 Sine signal input. 6 Sine signal common 7 +15V output

8 -15V output

9 Circuit common

DBP - Rev 6/93

Signals connector - J3 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function 1 positive input of a

differential amplifier.

2 Negative input of a

differential amplifier.

3 Output of a

differential amplifier. 4 Circuit common 5 Analog input

6 Circuit common 7 Circuit common 8 Current monitor

Remarks See Appendix C.

See Appendix C.

This input is monitored by the main µP. When |Vi| < 5V, R1=470ohm should be inserted. When |Vi|> 5V, R1(Kohm)=2Vi-10 should be inserted. The µP always reads a range of +5V.

This analog output represents the actual current in the motor. The scale (in A/V) is: Ip / 7.5

9 Circuit common 10 +5V output

11 +15V output

12 -15V output

13 Channel B output 14 Channel A output 15 Index output 16 Not connected 17 Inhibit output

Ip - Rated peak current of amplifier.

For resolver option only.

Relay contact (potential free). The relay contact is closed whenever the amplifier is enabled. Contact rating: 0.5A, 200V, 10W.

DBP - Rev 6/93

Signals connector - J3 - cont.

Pin Function 18 Inhibit output

19 Motion command (+5V)

20 Circuit common 21 Reset input 22 Circuit common 23 Tachogenerator

output/input

24 Circuit common

Remarks Relay contact (potential free).

When using the resolver option this output is the velocity monitor with a scale of 8V for maximum speed. See 7.3.

25 Velocity / current mode

selection

Signals connector - J4 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function 1 Input 1

2 Input 2

Remarks *

3 Circuit common 4 Input 3 5 Input 4

* *

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function 6 Input 5 or Index Input.

7 Circuit common 8 Fast input 6

9 Fast input 7 10 Circuit common 11 +5V output

12 +5V output

13 Output 7 14 +5V output

Remarks If a homing sequence is required, the Index Input

must be connected to Input 5.

This fast response input can capture events with a duration of less than 10µs. An event is defined as an input voltage transition from low to high. Same function as Fast Input 6 (8).

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +5V pins. The accumulative external load should not exceed 200mA.

There are several +5V pins. The accumulative external load should not exceed 200mA.

15 Output 1 16 Output 2 17 Output 3

** **

18 Circuit common 19 Output 4 20 Output 5 21 Output 6 22 Output 8 23 Output 9

** ** ** ** **

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J4 - cont.

Pin Function 24 Output 10

25 Motion Complete

Remarks *

This output will go to high when motion is complete.

Signals connector - J6 (MBA-DBP/3UE and MBA-DBP/6UE)

Pin Function

Remarks

1 Auxiliary encoder

complementary input (By) or Complementary Direction input for Pulse and Direction mode

2 Auxiliary encoder input

(By) or Direction input for Pulse and Direction mode

3 Auxiliary encoder input

(Ay) or pulse input for Pulse and Direction mode.

4 Auxiliary encoder

complementary input (Ay) or complementary Pulse and Direction mode

Vol<0.4V, Voh>4V, Output level: 0-5V, max output current +5mA

DBP - Rev 6/93

Signals connector - J6 - cont.

Pin Function 5 Auxiliary encoder index

input

6 +5V output

7 +15V output

8 Circuit common 9 Home switch 10 +5V output

11 Abort input

12 +5V output 13 Forward limit switch

Remarks

There are several +5V pins. The accumulative external load should not exceed 200mA. There are several +15V pins. The accumulative external load should not exceed 100mA.

14 Reverse limit switch

This committed input activates the #[ subroutine. *

15 Circuit common

J1A, FAN TERMINALS - (MBA-DBP/3UE and MBA-DBP/6UE)

10 11

24VDC common - fan only. +24VDC isolated supply for fan (max. 400mA)

Vil<1V, Vih>2.4V, Maximum input voltage: +30VDC

DBP - Rev 6/93

Signals connector - J8 (MBA-DBP/3UE and MBA-DBP/6UE)

1 Channel A output 2 Channel -A output 3 Channel B output 4 Channel -B output 5 Encoder index output

6 Encoder -index output

7 Circuit common 8 Circuit common 9 Circuit common 10 Hall A 11 Hall B 12 Hall C 13 +15V

* * There are several +15V pins. The accumulative external load should not exceed 100mA.

14 +5V output

There are several +5V pins. The accumulative external load should not exceed 200mA.

15 Circuit common

Remark: In the following paragraphs the terminals will be related to all the mounting types as in the following sample: H/R-2a,E-J4/13.

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

Source sink capability - 2mA min.

DBP - Rev 6/93

MBA-DBP/3UE

CIRCUIT COM. 15

+5V 14

+15V 13

HALL C 12 HALL B 11

HALL A 10

CIRCUIT COMMON 9

CIRCIT COMMON 15

REVERSE LIMIT SW 14

FORWARD LIMIT SW 13

+5V 12

ABROT INPUT 11

+5V 10

HOME INPUT 9

4 CH. A AUX. INPUT

3 CH. A AUX. INPUT 2 CH. B AUX. INPUT 1 CH. B AUX. INPUT

8 CIRCUIT COM. 7 CIRCUIT COM. 6 INDEX

OUT

5 INDEX 4 CH B

OUT

3 CH B

OUT

2 CH A

1 CH A OUT

8 CIRCUIT COMMON

7 +15V

6 +5V

5 INDEX

CIRCUIT COMMON 9

INDEX INPUT 6

COMPLETE

MOTION

OUT 10 24

OUT 9 23

OUT 8 22

OUT 6 21

OUT 5 20

OUT 4 19

CIRCUIT COMMON 18

0UT 3 17

OUT 2 16

OUT 1 15

+15V 8

+5V 7

+5V 14

5 INDEX INPUT

4 CH. B INPUT

3 CH. B INPUT

2 CH. A INPUT 1 CH. A INPUT

13 OUT 7

12 +5V

11 +5V

10 CIRCUIT COMMON

9 INPUT 7

8 INPUT 6

7 CIRCUIT COMMON

6 INPUT 5

5 INPUT 4

4 INPUT 3

3 CIRCUIT COMMON

2 INPUT 2

1 INPUT 1

CURRENT/VELOCITY MODE 25

CIRCUIT COMMON 9

-15V 8

+15V 7

SIN. SIGNAL COMMON 6

CIRUIT COMMON 24 TACHO COMMON 23 CIRUIT COMMON 22

RESET INPUT 21

CIRUIT COMMON 20

MOTOR COMMAND OUT 19

INHIBIT OUTPUT 18

INHIBIT OUTPUT 17

N.C. 16

INDEX OUTPUT 15

CHA. A OUTPUT 14

5 SIN. SIGNAL INPUT 4 COS. SIGNAL COMMON

3 COS. SIGNAL INPUT 2 Vref COMMON 1 Vref OUTPUT

13 CHA. B OUTPUT 12 -15V

11 +15V 10 +5V 9 CIRCUIT COMMON

8 CURRENT MONITOR

7 CIRCUIT COM.

6 CIRCUIT COM.

5 ANALOG INPUT

4 CIRCUIT COM.

3 OUT DIFF. AMP.

2 DIFF IN(-) 1 DIFF. IN (+)

MOTOR OUTPUT

CONTROL COMMON

J1A

FAN

R2< 1ohm IS USED TO SHORT

CONTROL COMMON TO GROUND WHEN USING

ISOLATED AMP.

+VS

AC INPUT

2 31

4 5

POWER

POSITIVE

6 7

POWER

COMMON

GROUND

118 9

DBP - Rev 6/93

MBA-DBP/6UE

CIRCUIT COM. 15

+5V 14

+15V 13

HALL C 12

HALL B 11

HALL A 10

CIRCUIT COMMON 9

CIRCIT COMMON 15

REVERSE LIMIT SW 14

FORWARD LIMIT SW 13

+5V 12

ABROT INPUT 11

+5V 10

HOME INPUT 9

3 CH. A AUX. INPUT 2 CH. B AUX. INPUT 1 CH. B AUX. INPUT

8 CIRCUIT COM. 7 CIRCUIT COM. 6 INDEX

OUT

5 INDEX

4 CH B

OUT

3 CH B

OUT

2 CH A 1 CH A OUT

8 CIRCUIT COMMON

7 +15V 6 +5V 5 INDEX

4 CH. A AUX. INPUT

MOTION

CIRCUIT COMMON 18

CONTROL COMMON

CIRCUIT COMMON 9

+15V 8

+5V 7

INDEX INPUT 6

COMPLETE

OUT 10 24

OUT 9 23 OUT 8 22

OUT 6 21

OUT 5 20

OUT 4 19

0UT 3 17

OUT 2 16

OUT 1 15

+5V 14

5 INDEX INPUT

4 CH. B INPUT

3 CH. B INPUT

2 CH. A INPUT

1 CH. A INPUT

13 OUT 7

12 +5V

11 +5V

10 CIRCUIT COMMON

9 INPUT 7

8 INPUT 6

7 CIRCUIT COMMON

6 INPUT 5

5 INPUT 4

4 INPUT 3

3 CIRCUIT COMMON

2 INPUT 2

1 INPUT 1

CURRENT/VELOCITY MODE 25

CIRCUIT COMMON 9

-15V 8

+15V 7

SIN. SIGNAL COMMON 6

CIRUIT COMMON 24 TACHO COMMON 23 CIRUIT COMMON 22

RESET INPUT 21

CIRUIT COMMON 20

MOTOR COMMAND OUT 19

INHIBIT OUTPUT 18

INHIBIT OUTPUT 17

N.C. 16

INDEX OUTPUT 15

CHA. A OUTPUT 14

5 SIN. SIGNAL INPUT 4 COS. SIGNAL COMMON

3 COS. SIGNAL INPUT 2 Vref COMMON 1 Vref OUTPUT

13 CHA. B OUTPUT

12 -15V 11 +15V

10 +5V 9 CIRCUIT COMMON

8 CURRENT MONITOR

7 CIRCUIT COM.

6 CIRCUIT COM.

5 ANALOG INPUT

4 CIRCUIT COM.

3 OUT DIFF. AMP.

2 DIFF IN(-) 1 DIFF. IN (+)

FAN

MA MB MC

R2<1ohm, is used to short control common to

ground only when ISOLATED amplifier

GND

is used.

AC AC AC POW

COM.

+VS SO

DBP - Rev 6/93

5.4 Communication Port Connector

The serial communication is available via a 9 pins D connector (Jc) with the

following pin assignment:

RS232

Pin Function 2 Receive

3 Transmit 5 Common

When using an IBM XT as an host, pins 4 and 5 should be connected together on the 25 pins D connector (computer side). When using an IBM AT as an host, pins 7 and 8 should be connected together on the 9 pins D connector (computer side).

RS485

Pin Function 5 Common

6,7 T/R 8,9 T/R +

DBP - Rev 6/93

6. Installation procedures

6.1 Mounting

The DBP series dissipates its heat by natural convection except DBPF types which are fan cooled. For optimum dissipation the amplifiers have to be mounted with the fins in vertical position.

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.

a) Keep motor wires as far as possible from the signal level wiring (feedback

signals, control signals, etc.).

b) If additional inductors (chokes) are required, keep the wires between the

amplifier and the chokes as short as possible.

c) Minimize lead lengths as much as is practical. Although the amplifier is

protected against long (inductive) supply wires it is recommended to keep the leads as short as possible.

d) Use twisted and shielded wires for connecting all signals (command and

feedback). Avoid running these leads in close proximity to power leads or

other sources of EMI noise. e) Use a 4 wires twisted and shielded cable for the motor connection. f) Shield must be connected at one end only to avoid ground loops. g) All grounded components should be tied together at a single point (star

connection). This point should then be tied with a single conductor to an

earth ground point. h) After wiring is completed, carefully inspect all conditions to ensure

tightness, good solder joint etc.

DBP - Rev 6/93

6.3 Load inductance

The total load inductance must be sufficient to keep the current ripple within the limits - 50% of the adjusted continuous current limit. The 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 - Frequency in KHz.

If motor inductance does not exceed this value, 3 chokes should be added (to each motor phase) summing together the required inductance

Lch = L - Lp Lch - Choke inductance Lp - Total inductance between two phases (in Y connection it is the sum of two phases).

6.4 AC power supply

AC power supply can be at any voltage in the range defined within the technical specifications. It must have the capability to deliver power to the amplifier (including peak power), without significant voltage drops. Any

voltage below the minimum or above the maximum will disable the amplifier.

The recommended AC voltage are:

1.2 x VAC(min) < VAC < 0.9 x VAC(max)

Note - Single phase connection:

When using a single phase supply, voltage drop due to loading is expected. The magnitude of the voltage drop depends on the load current, motor velocity, stiffness of the power source and total bus capacitance. It is recommended not to use single phase connection for output current higher than 20A.

For 3U size amplifiers it is recommended to add external capacitance as follows:

For 135V units up to 1200µF

For 270V units up to 600µF

DBP - Rev 6/93

6.5 Wiring diagrams

Power wires twisted together

Power wires twisted and shielded

6.5.1 Motor's windings

Motor

Chassis

MA MB MC

DBP

Heatsink / GND

Minimum acceptance

======================================================================

Motor

Chassis

MA MB MC

DBP

Heatsink / GND

======================================================================

Motor

Chassis

DBP - Rev 6/93

Acceptable for most applications

DBP MC Heatsink / GND

Optimum wiring, minimum RFI

6.5.2 AC power wiring

Fuse Fuse Fuse

AC AC AC

DBP + O option

+Vs DC power common Control common Heatsink

A. Direct connection to the

three phase mains

B. External fuses are needed for 3U size only

======================================================================

Fuse Fuse

AC AC

DBP + O option

Fuse

Autotransformer

A. External fuses are needed for 3U size only

B. Using autotransformer with

three phase mains

DBP - Rev 6/93

AC +Vs

DC power common Control common Heatsink

Guide lines for connecting non-isolated AC supplies

Ground: Control common Motor chassis Amplifier's heatsink

Do not ground:

Power common (The power common is a hot point and any grounding will cause an input rectifier failure).

Caution:

- If source of motor command is grounded, use amplifier's differential input. Otherwise, a ground loop is created.

DBP - Rev 6/93

Isolating transformer

Fuse Fuse Fuse

DBP + I option

AC AC +Vs

DC power common Control common

Heatsink

A. Extenal fuses are needed for 3U size only

Guide lines for connecting an Isolated amplifier with an isolating power transformer

Ground:

DC power common Control common Motor chassis Amplifier's heat sink.

Caution:

- If source of motor command is grounded, use amplifier's differential input. Otherwise, a ground loop is created.

DBP - Rev 6/93

Isolating transformer

Fuse Fuse Fuse

AC AC

NON-ISOLATED DBP AC +Vs

DC power common is internally connected to control common

Heatsink

A. External fuses are needed for 3U size only

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 grounded, use amplifier's differential input. Otherwise, a ground loop is created.

DBP - Rev 6/93

DIRECT CONNECTION TO

THE THREE PHASE MAINS

NOTE: DC POWER TERMINALS ARE

CONNECTED IF SINGLE PHASE IS USED OR IF SHUNT CURRENT

HAS TO BE INCREASED

A. External fuses are needed

for 3U size only

Fuse Fuse Fuse

To additional DBPs

AC AC

DBP

O option

AC +Vs DC power common Control common Heatsink

AC AC

DBP

O option

AC +Vs DC power common Control common Heatsink

DBP - Rev 6/93

CONNECTING MORE THAN ONE DBP

ISOLATING

TRANSFORMER

NOTE: DC POWER TERMINALS ARE

CONNECTED IF SINGLE PHASE IS USED OR IF SHUNT CURRENT

HAS TO BE INCREASED

A. External fuses are needed

for 3U size only

Fuse Fuse

Fuse

To additional DBPs

AC AC

DBP

I option

AC +Vs DC power common Control common Heatsink

AC AC

DBP

I option

AC +Vs DC power common Control common Heatsink

DBP - Rev 6/93

CONNECTING MORE THAN ONE DBP

ISOLATING

TRANSFORMER

NOTE: DC POWER TERMINALS ARE

CONNECTED IF SINGLE PHASE IS USED OR IF SHUNT CURRENT HAS TO BE INCREASED

A. External fuses are needed

for 3U size only

Fuse Fuse Fuse

To additional DBPs

AC AC

NON

ISOLATED DBP

AC +Vs

DC POWER COMMON IS INTERNALLY CONNECTED TO CONTROL COMMON

Heatsink

AC AC AC

NON

ISOLATED DBP

+Vs

DC POWER TERMINAL IS INTERNALLY CONNECTED TO CONTROL COMMON

Heatsink

DBP - Rev 6/93

See chapter 6.4 for details

Fuse Fuse

AC AC

DBP

External

capacitance

+Vs DC power common Control common Heatsink

SINGLE PHASE CONNECTION

All rules about supply connections described in the previous pages are also valid for multi-IBP and/or single phase connection.

DBP - Rev 6/93

For 135V types the standard value of

AC AC AC +Vs

DBP

Rex is 9.1ohm/225Watt

For 270V types the standard value of

Rex is 33ohm/225Watt

Rex

SO Control common Heatsink

CONNECTING THE EXTERNAL SHUNT RESISTOR

DOUBLE EUROCARD SIZE ONLY

DBP - Rev 6/93

6.5.3 Hall sensors wiring

HALL SENSORES CONNECTION

HALL SENSORES

HALL A

HALL B

HALL C

REMARK:

14 13 12 11 10 9

+15V

GND

8 7 6 5 4 3 2 1

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.4 RS232 Communication wiring

RS232 COMMUNICATION

COMPUTER

RXD TXD

RST CTS

DBP - Rev 6/93

NOTE:

SHIELDING MUST BE CONNECTED AT COMPUTER END ONLY

SYMBOLS:

TWISTED PAIR

SHIELDING

6.5.5 RS485 Communication wiring

RS 485 COMMUNICATION

AMP. No 1

COMPUTER

T/R-

T/R+

DBP - Rev 6/93

NOTES:

1. SHIELDING MUST BE CONNECTED AT COMPUTER END ONLY

2. PIN No.1 TRANSMIT/RECEIVE CONTROL

3. PIN No.4 +5V

SYMBOLS:

TWISTED PAIR

SHIELDING

RS485 COMMUNICATION

AMP. No 1

COMPUTER

T/RT/R+

AMP. No 2

AMP. No 32

SYMBOLS:

NOTES:

1. SHIELDING MUST BE CONNECTED AT COMPUTER END ONLY.

2. PIN No.1 TRANSMIT/RECEIVE CONTROL

3. PIN No.4 +5V

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.6 Main encoder wiring

ENCODER CONNECTION

DIFFERENTIAL ENCODER CONNECTION

ENCODER

NOTES:

1.THIS CONNECTION IS FOR AN ENCODER WITH +5V SUPPLY. FOR AN ENCODER OF +15V SUPPLY, USE J1 PIN 8 INSTEAD OF PIN 7.

2.THE METAL FRAME OF J1 IS INTERNALLY CONNECTED TO THE DCB COMMON. THE SHIELDING SHOULD BE CONNECTED EITHER TO J1 PIN 9 OR TO THE METAL FRAME OF J1.

SYMBOLS:

DBP - Rev 6/93

TWISTED PAIR

SHIELDING

6.5.7 Resolver wiring

RESOLVER CONNECTION

RESOLVER

NOTES:

1. PIN No 7 = +15V

2. PIN No 8 = -15V

3. PIN 9 AND THE METAL FRAME OF J2 ARE INTENALLY CONNECTED TO THE DCB COMMON. THE SHIELDINGS OF ALL THE PAIRS SHOULD BE CONNECTED EITHER TO J2 PIN 9 OR TO THE FRAME OF J2.

SYMBOLS:

TWISTED PAIR

SHIELDING

DBP - Rev 6/93

6.5.8 Auxiliary encoder wiring

AUXILIARY ENCODER CONNECTION

DIFFERENTIAL AUXILIARY

ENCODER

8 7

NOTES:

1.THIS CONNECTION IS FOR AN ENCODER WITH +5V SUPPLY. FOR AN ENCODER OF +15V SUPPLY, USE J6 PIN 7 INSTEAD OF PIN 6.

2.THE METAL FRAME OF J6 AND PIN 8 ARE INTERNALLY CONNECTED TO THE DCB COMMON. THE SHIELDING SHOULD BE CONNECTED EITHER TO J6 PIN 8 OR TO THE METAL FRAME OF J6.

SYMBOLS:

ENCODER CONNECTION

TWISTED PAIR

ENCODER

DBP - Rev 6/93

SHIELDING

6.5.9 Pulse/Direction signals wiring

PULSE & DIRECTION INPUT CONNECTION

DIFFERENTIAL PULSE & DIRECTION

CONTROLLER

PULSE

DIRECTION

8 7

NOTES:

1.THE METAL FRAME OF J6 AND PIN 8 ARE INTERNALLY CONNECTED TO THE DCB COMMON. THE SHIELDING SHOULD BE CONNECTED EITHER TO J6 PIN 8 OR TO THE METAL FRAME OF J6.

SYMBOLS:

INPUT CONNECTION

TWISTED PAIR

CONTROLLER

- PULSE PULSE DIRECTION

- DIRECTION

DBP - Rev 6/93

SHIELDING

7. Start - Up Procedures

7.1 Common procedures for all amplifiers types

7.1.1 Commutation signals format

Select the position of DIP switch 1 on the upper board of the power stage

according to the commutation signal format the motor has.

DS1 positions: ON (down): 30° OFF (up): 60°

For all Resolver versions it should be 60 °.

7.1.2 CFM function

Select the position of DIP switch 2 on the upper board of the power stage according to the motor's rated current. If it is less than 20% of the amplifier's rated current select:

DS2 to ON (down)

Otherwise,

DS2 to OFF (up) - No CFM

7.1.3 Abort logic

Make sure that the Abort input is connected to a High (logic) voltage source.

DBP - Rev 6/93

7.1.4 Setting the auxiliary position input format

This step is valid only for those applications that need to use the auxiliary position input. You may skip this step if you do not use it.

When using an Optical encoder

Set DS 7 to OFF

When a the encoder has differential outputs:

Set DS 4 and 5 to OFF

Otherwise they should be ON.

When using Pulse and Direction signals

Set DS 7 to ON

7.1.5 Selecting the communication bus

Select the desired communication bus as follows:

For RS232: Set DS9 to OFF For RS485: Set DS9 to ON

7.1.6 Preparing the automatic baud rate selection

The DCB baud rate will automatically match the host baud rate when DS1 is

set to ON.

Set DS1 to ON

DBP - Rev 6/93

7.2 Setting the main optical encoder format

When a differential encoder is used:

Set DS 2,3,6 to OFF

Otherwise they should be ON.

7.3 Setting the R/D circuit

Set DS 2,3,6 to ON

The Resolver interface circuit consists of three basic blocks:

R/D converter

The R/D conversion is done by a variable resolution, monolithic converter type 2S82 of Analog Devices. It accepts two signals from the Resolver (sine and cos.) and converts them into binary position data bits. The resolution of the position bits is user selectable 10, 12 ,14 and 16 (only for standard encoder resolution). In addition, the R/D creates a signal that is proportional to the Resolver velocity. This signal is being used as a velocity feedback.

EPROM

The EPROM creates "Hall" signals by mapping the position data bits accepted from R/D into suitable Hall signals to operate a specific brushless motor. In addition, the encoder index (marker) signal is also produced from the EPROM. The EPROM is designated as follows:

2 4 X S STD

Encoder resolution

Resolver's poles number

Commutation address R/D resolution

Ratio of motor/resolver poles numbers

X=User selectable, 0=10 bits 2=12 bits, 4=14 bits, 6=16 bits

In the S (standard) version zero crossing of phases B C occurs at position address "0" of the Resolver.

DBP - Rev 6/93

Oscillator

Creates sinusoidal waveform signal to excite the primary of the Resolver.

Oscillator Frequency/Amplitude Selection (R228,R233)

The frequency (fr) and amplitude (Vr) needed to excite the Resolver are

taken from the Resolver data sheet.

Selecting the frequency:

R228 = 110/fr (Kohm)

0.1KHz < fr (KHz) < 20KHz

Selecting the amplitude:

Pay attention that the RMS amplitude does not exceed 7Vrms or that the peakto-peak (ptp) value is within the range of 2V < Vr peak-to-peak value:

R233 = 6/(Vr - 2) (Kohm)

For Vr in RMS value:

R233 = 6/(2.82Vr - 2) (Kohm)

Reference Voltage level to R/D (R192)

In order to adjust the reference voltage input level to 2Vrms, select R192 as follows:

For Vr

R192 = 50 x (Vr

<2V, install R192=100 ohm.

rms

- 2) (Kohm)

rms

< 20V. For Vr in

ptp

DBP - Rev 6/93

Signal input level (R193,R194)

The R/D inputs (Vin

Resolver output = Vin

R193 = R194 = Vin

stator

When Vin The standard R/D converter will not operate for Vin for OEM applications.

Velocity Signal The tracking converter technique generates an internal signal at the output of the integrator that is proportional to the rate of change of the input angle. This dc analog output (velocity signal) is buffered and represented at terminal H/R-12b,E-J3/23. Max output voltage is +8V.

in Kohm).

<2V, install R193=R194=100 ohm.

rms

) are adjusted to the sin/cos. Resolver outputs by:

rms

= Vr

rms

- 2 - R

x Transformation ratio

rms

stator

(Kohm)

<1.8V. Consult factory

rms

This velocity signal can be internally connected to the summing junction of the error amplifier by inserting R7 - see Appendix B for more details. However, the standard procedure does not require closing the velocity loop.

Select maximum actual velocity of the application and calculate the maximum tracking rate T of the Resolver as follows:

T = rpm x Q / 120

T unit is rps: Resolver electrical revolution per second Q - number of poles of Resolver ; rpm - mechanical revolution per minute.

Selecting the Resolution

The resolution can be selected to be 10,12,14 or 16 bits by use of DIP switches 13 and 14. When selecting the resolution the rps limits should not be exceeded:

DBP - Rev 6/93

10 bit = 1040 rps 12 bit = 260 rps 14 bit = 65 rps 16 bit = 16.5rps

Resolution DS13 DS14

10 ON ON 12 ON OFF 14 OFF ON 16 OFF OFF

Note:

- Each resolution change must be followed by new components selection procedure.

- When changing resolution under dynamic conditions, a period of uncertainty will exist before position and velocity data is valid.

Encoder resolution

In the STD mode (DS12 OFF), the encoder signals A,B are created by the EPLD

and can have only the following basic resolutions (for 2 pole Resolver): 256 for 10 bits 1024 for 12 bits 4096 for 14 and 16 bits

When the Resolver is more than 2 poles, the resolution for one shaft

rotation will be:

Er = QxS / 8

Q = number of Resolver poles ; S = resolution of converter (210,212,or 214)

When different encoder resolution is needed the encoder signals are

generated by the EPROM and the R/D resolution is no longer user selectable. This option requires

- DS12 at ON

- Special EPROM which is programmed for this resolution.

DBP - Rev 6/93

HF Filter (R195, R196, C61, C62)

The function of the HF filter is to reduce the amount of noise present on the signal inputs to the 2S82, reaching the Phase Sensitive Detector and affecting the outputs. Values should be chosen so that

15Kohm < R195=R196 < 30Kohm

160x10 C61 = C62 = ------------ (pF) R195 x fr

fr = Reference frequency in KHz R195 in Kohm

This filter gives an attenuation of 3 times at the input to the phase sensitive detector.

AC Coupling of Reference Input (C60)

Select C60 so that there is no significant phase shift at the reference frequency. That is,

106 100 x R192 C60 = -------------- (pF) Rx = ------------ (Kohm) fr(KHz) x Rx 100 + R192

R192 in Kohm

If Rx yields less than 50K, install a value of Rx=50K in the C60 equation.

Maximum Tracking Rate (R201)

The VCO input resistor R201 sets the maximum tracking rate of the converter and hence the velocity scaling as at the maximum tracking rate, the velocity output will be 8V.

Decide on your required maximum tracking rate, "T" , in revolutions per second. Note that "T" must not exceed the specified maximum tracking rate or 1/16 of the reference frequency.

DBP - Rev 6/93

R201 = 5.92 x 107 / T x p (Kohm)

where p = bit per rev = 1,024 for 10 bits resolution = 4,096 for 12 bits = 16,384 for 14 bits = 65,536 for 16 bits

Closed Loop Bandwidth Selection (C67, C68, R200) a. Choose the Closed Loop 3dB Bandwidth (fbw) required ensuring that

> 10 x f

ref

Recommended bandwidth values: 250Hz for 3KHz 300Hz for 5KHz 500Hz for 10KHz

b. Select C67 so that

2.5x10 C67 = ------------- (pF) R201 x f

with R201 in Kohm and fbw in Hz as selected above.

c. C68 is given by

DBP - Rev 6/93

C68 = 40 x C67 (pF)

d. R200 is given by

127 x 10 R200 = ------------- (Kohm) fbw x C68

fbw in Hz, C68 in pF

R200 value should be at least three times R197.

Gain Scaling Resistor (R197) R197 should be installed according the following table: 536Kohm for 10 bits resolution 130Kohm for 12 bits 33Kohm for 14 bits

8.2Kohm for 16 bits

DBP - Rev 6/93

8. Applying power - Adjustments

Important remarks: A. If all the previous steps were accomplished you may now disconnect the motor leads, turn the power on and continue with the following adjustments.

Step 1 - Applying Power

Apply power and check for LED Vs of the DCB that should be "ON", indicating that the system supplies are present. The display should read: "F-OK". If you get another message, refer to the following table to find the cause of the problem. Turn the power off, clear the cause of the problem and re-power the unit.

Event Display Display

after

Recurring DIP switch 1 - ON BAUD OK Load is under cont. current limit CLIM C-OK Battery Low BATT B-OK Abort condition (hardware only) ABRT A-OK Amplifier's power stage disabled

AMPD H-OK

-15V out of limits -15V F-OK Under or Over Voltage VOLT F-OK +15V out of limits +15V F-OK Over Temperature TEMP F-OK Commutation problem CMMT F-OK Short condition at the power outputs SHRT F-OK

The AMPD message appears in two cases:

1. When MO (Motor Off) command is given.

2. Position error exceeds the allowed value.

DBP - Rev 6/93

Step 2 - Establishing the communication

Press CR (carriage return) in the host several times until the DCB sends the

message "Communication OK".

If you want to "lock" the baud rate in the DCB:

- Turn off the power and remove the amplifier from the rack if it is a rack version.

- Set DS1-OFF.

Now the baud rate you selected is stored in the SRAM.

It is possible to change DS1 at any time. However, the DCB will notice the change only upon power on or hardware reset.

Step 3 - Checking the feedback elements

- Turn on the power.

- Rotate the motor shaft manually and interrogate the position with the instruction: TP (CR)

The controller response should vary as the motor is turned. If this does not

occur, check the feedback signals.

- When using the auxiliary encoder input, rotate the auxiliary encoder and interrogate the position with the instruction: PY.

The controller response should vary as the encoder is turned. If this does not occur, check the feedback signals. The DCB is counting quadrature pulses. This means that for encoders or resolvers the answer for a TP command will be 4 times the number of basic encoder pulses and for Pulse/Direction mode it will be twice the number of pulses.

Step 4 - Adjusting the current limits

Defining the amplifier type

- Define the maximum current of the amplifier by the instruction: MCn n - rated peak current of the amplifier in A as given in the table of chapter

3. For example: n is 48 for DBPF-24/270

DBP - Rev 6/93

Current limit adjustments

- Define the continuous current limit by the instruction: CLn.m (n.m - current in A)

- Define the peak current limit by the instruction: PLn.m (n.m - current in A)

- Define the maximum peak current duration by the instruction: PDn.m (n.m - seconds)

Step 5 - Latch mode of the protective functions

All the protective functions activate internal inhibit. There are two modes

of resetting the amplifier after the cause of the inhibit disappears:

Self Restart: (LM0)

The amplifier is inhibited only for the period that the inhibit cause is

present.

Latch (LM1)

Each failure latches the Inhibit and the failure message on the display. For restart (after clearing the failure source), reset has to be performed by applying logic 0 at the reset input (H/R-17a,E-J3/21), or by turning the power off and on.

For safety reason it is recommended to use the amplifier in the LATCH MODE - LM1

Step 6 - Connecting the Motor

- Turn off the power.

- Connect the leads of the motor.

- Turn on the power. For proper operation, the system must have negative feedback. If the motor

remains in the same position and returns to the same position when you turn the motor shaft and let go, then the position feedback is negative as required. If the motor runs away you have positive feedback. To correct the feedback, just reverse the encoder leads.

DBP - Rev 6/93

9. Tables and Summaries

9.1 Display diagnostics

Each amplifier's fault is stored immediately in the DCB RAM. In addition to that, a Failure Message is displayed. Following are all the valid Display Messages:

Event Display Display

after Recurring

DIP switch 1 - ON BAUD OK Load is under cont. current limit CLIM C-OK Battery Low BATT B-OK Abort condition (hardware only) ABRT A-OK Amplifier's power stage disabled

AMPD H-OK

-15V out of limits -15V F-OK Under or Over Voltage VOLT F-OK +15V out of limits +15V F-OK Over Temperature TEMP F-OK Commutation problem (for brushless drives

CMMT F-OK only) Short condition at the power outputs SHRT F-OK

The AMPD message appears in two cases:

1. When MO (Motor Off) command is given.

2. Position error exceeds the allowed value.

DBP - Rev 6/93

9.2 Summary of DIP switches

Power stage board (2 poles DIP switch)

DIP switch OFF (UP) ON (DOWN) DS1 60° commutation signals format 30° commutation signals format

DS2 No CFM Activate CFM

Control stage board (9 poles DIP switch)

DIP switch ON OFF DS1 Auto-selection of Baud rate Latch last value

DS2 Non-differential channel A Diff. input of channel A DS3 Non-differential channel B Diff. input of channel B DS4 Non-differential channel Ay Diff. input of channel Ay DS5 Non-differential channel By Diff. input of channel By DS6 Non-differential index Diff. index DS7 Pulse/Direction format Encoder channels format DS8 N/C DS9 RS485 RS232

4 poles DIP switch (for Resolver)

Switch OFF ON DS11 Tacho signal disconnected Tacho signal connected to error

amplifier. DS12 Standard encoder resolution Non-standard encoder resolution DS13 14 bit resolution (DS14-ON)

16 bit resolution (DS14-OFF)

DS14 12 bit resolution (DS13-ON)

16 bit resolution (DS13-OFF)

10 bit resolution (DS14-ON)

12 bit resolution (DS14-OFF)

10 bit resolution (DS13-ON)

14 bit resolution (DS13-OFF)

DBP - Rev 6/93

Appendix A - Current loop response

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 0.01µF for C1 and 100Kohm for R4 may not yield with the optimum response. The current loop should be optimized as follows:

- Insert R7 (1K) to connect the tacho input to the error amplifier. The amplifier must not be configured into velocity mode. If the resolver option is used, make sure that DS11 is OFF.

- Apply power to the amplifier and send the command BA.

- Provide the tacho input H/R-12b,E-J3/23 with a bi-directional square wave current command (100-200Hz, +2.0V waveform is often employed).

- Monitor the load current either by a current probe or by the current monitor.

If the current response is not critically damped, use the following

procedure:

- Short circuit C1 with a short jumper wire.

- Replace R4 with a decade resistance box. Initially set the box resistance at 10Kohm.

- Apply the square wave test signal to the amplifier input.

- Apply power, and while monitoring the load current, gradually increase the value of the box resistance until optimum response as depicted in Fig A-1 is achieved.

- Substitute the closest standard value discrete resistor for R4 and remove the decade resistance box.

- Remove the shorting jumper across C1, and again check the response using the square wave test signal.

- If the previous step does not yield satisfactory results, if unacceptable overshooting has been noted, substitute a larger value than 0.01 µF; or, if the response is overdamped, substitute a smaller value than 0.01 µF. Repetition of this procedure should yield an optimum choice for C1.

DBP - Rev 6/93

C1 too small / R4 too large

Reference input signal

C1 too large / R4 too small

Critically damped

Fig. A-1

Typical current response waveforms

DBP - Rev 6/93

Elmo SERVO AMPLIFIER DBP User Manual

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