Trust TA333 Operating Manual

Trust Automation, Inc. TA333 High Power Linear Drive

TA333

High Power Linear Servo Amplifier

PRELIMINARY Operating Manual

Revision 0.13

6-Feb-09 Operating Manual

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

Copyright Information

© 2009 Trust Automation, Inc. All rights reserved.

This document is provided for Trust Automation, Inc. customers, solely for the purpose of assisting our
customers in the use and installation of our products. Other uses are unauthorized without the written
permission of Trust Automation, Inc. The text and graphics included are for purpose of illustration only
and information is subject to change without notice. Trust Automation, Inc. and the Trust Automation,
Inc. logo are trademarks of Trust Automation, Inc. – a California corporation.

For information regarding re-use of this material or to report errors, omissions, inconsistencies, etc,
please contact Technical Support at:

Trust Automation, Inc.

143 Suburban Road, Bldg. 100
San Luis Obispo, CA 93401
E-mail Technical Support: [e-mail]
Web: www.trustautomation.com
Phone: [phone]
FAX: [phone]

Handling and Safety Information

Trust Automation products contain static sensitive parts that may be damaged if handled improperly.
We strongly encourage you to follow proper ESD procedures when handling electronic components.
Removing component covers, except where expressly permitted, may expose products to static
damage and increase the risk of premature failure.

High voltages are present in some Trust Automation products. Maintenance or repair should only be
performed by qualified personnel and only under power down conditions. Maintenance and repair shall
be limited to those items described in this operating manual as user approved. All other repair and
maintenance shall be performed by Trust Automation, Inc.

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

Table of Contents

1.0 Features and Setup ........................................................................................................... 7

1.1 Introduction...................................................................................................................................7

1.2 Setup..............................................................................................................................................8

1.3 Drive Modes...................................................................................................................................8

1.4 Command Input.............................................................................................................................9

1.5 Upgrading from a TA320 or TA330..............................................................................................9

1.6 Transconductance Ratio..............................................................................................................9

1.7 Thermal Limits ............................................................................................................................10

1.8 Dynamic Transconductance Selection.....................................................................................10

1.9 Enable Input ................................................................................................................................11

1.10 Fault Output...............................................................................................................................11

1.11 Ground Connections................................................................................................................12

1.12 Drive Power Supply..................................................................................................................12

1.13 Optional External 24VDC Supply.............................................................................................13

1.14 Power Dissipation Calculations ..............................................................................................13

1.15 Motor Connections...................................................................................................................14

1.16 Serial Monitoring.......................................................................................................................15

2.0 General Specifications.................................................................................................... 18

2.1 Electrical Specifications.............................................................................................................18

2.2 Mechanical Specifications.........................................................................................................18

2.3 Environmental Specifications....................................................................................................18

2.4 TA333 Safe Operating Area Curve (SOA) .................................................................................19

2.5 TA333 Output Frequency Response.........................................................................................22

3.0 Mechanical Information................................................................................................... 23

3.1 Dimensions..................................................................................................................................23

4.0 Connector and Switch Information................................................................................ 24

4.1 Front Panel Connector and Switch Layout ..............................................................................24

4.2 Connector Types.........................................................................................................................24

4.3 J1 – External 24VDC Supply......................................................................................................24

4.4 J2 – Serial Monitoring Port ........................................................................................................24

4.5 J3 – Command Signals...............................................................................................................25

4.6 J4 – Hall Sensor Input ................................................................................................................25

4.7 J5 – Motor Signals......................................................................................................................25

4.8 J6 – Motor Power........................................................................................................................25

4.8 SW1 – Switch Settings ...............................................................................................................26

4.9 SW1 – Switch 3 and 4, Fixed Gain and DTS Settings..............................................................26

4.10 SW1 – Switch 5-8 Motor type...................................................................................................27

4.11 Isolation Diagram......................................................................................................................28

5.0 Application Examples ..................................................................................................... 30

5.1 Brushless Motor, Sinusoidal (Differential Command Input)...................................................30

5.2 Brushless Motor, Sinusoidal (Single Ended Command Input)...............................................31

5.3 Brushless Motor, Trapezoidal, Hall Commutation...................................................................32

5.4 Brush Motor, Bridge Mode.........................................................................................................33

5.5 Brush Motor, Dual Motor Mode .................................................................................................34

5.6 Stepper Motor, Sinusoidal Commutation .................................................................................35

6.0 Warranty........................................................................................................................... 36

7.0 TA333 Hardware Revision History ................................................................................. 37

8.0 TA333 Manual Revision History ..................................................................................... 38

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

Figures

Figure 1 – Enable Circuit ......................................................................................................... 11

Figure 2 – Fault Circuit ............................................................................................................ 11

Figure 3 – Drive Power Connection......................................................................................... 12

Figure 4 – Com Port Settings for Serial Communication ......................................................... 15

Figure 5 – Data Transmission Format, HyperTerminal............................................................ 16

Figure 6 – Sample Fault Printout ............................................................................................. 17

Figure 7 – TA333 SOA Curve.................................................................................................. 19

Figure 8 – Output Current vs. Time Graph for Time to Fault @ ~30°C.................................... 20

Figure 9 – Dissipation Wattage vs. Time for Time to Fault @ ~30°C ...................................... 20

Figure 10 – Temperature De-rating, Time to Fault for Dissipation Wattages vs. Heatsink

Temperature ............................................................................................................................ 21

Figure 11 – TA333 Frequency Response ................................................................................ 22

Figure 12 – TA333 Mechanical Dimensions ............................................................................ 23

Figure 13 – TA333 Front Panel ............................................................................................... 24

Figure 14 – Fixed Gain and DTS Settings ............................................................................... 26

Figure 15 – SW1 Motor Type settings ..................................................................................... 27

Figure 16 – TA333 Isolation Diagram ...................................................................................... 28

Figure 17 – Application Example 1 .......................................................................................... 30

Figure 18 – Application Example 2 .......................................................................................... 31

Figure 19 – Application Example 3 .......................................................................................... 32

Figure 20 – Application Example 4 .......................................................................................... 33

Figure 21 – Application Example 5 .......................................................................................... 34

Figure 22 – Application Example 6 .......................................................................................... 35

Tables

Table 1 – Data Transmission Format ...................................................................................... 16

Table 2 – Fault Codes ............................................................................................................. 16

Table 3 – Electrical Specifications ........................................................................................... 18

Table 4 – Mechanical Specifications ....................................................................................... 18

Table 5 – Environmental Specifications................................................................................... 18

Table 6 – Connector Types ..................................................................................................... 24

Table 7 – External 24VDC Supply Connector.......................................................................... 24

Table 8 – Serial Monitoring Connector .................................................................................... 24

Table 9 – Motor Command Signals Connector........................................................................ 25

Table 10 – Hall Sensor Input Connector.................................................................................. 25

Table 11 – Motor Signals Connector ....................................................................................... 25

Table 12 – Motor Power Connector......................................................................................... 25

Table 13 – SW1 Settings .........................................................................................................26

Table 14 – Fixed Gain and DTS Switch Settings..................................................................... 26

Table 15 – SW1 Motor Type Selection .................................................................................... 27

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

1.0 Features and Setup

1.1 Introduction

The TA333 is a 4
with pure analog throughput at virtually infinite resolution and is free from digital conversion losses. This
versatile linear drive is an excellent choice for a variety of different servo motors and applications that
require high resolution positioning and/or ultra low noise applications with sensitive measuring
equipment, (e.g., transducers, sensors).

The TA333 is a highly configurable device with four common configuration modes:

• Drive one brushless motor using external sinusoidal commutation.

• Use Hall Effect sensor feedback for smooth internally commutated trapezoidal operation.

• Supports one or two brush or voice coil type motors.

• Drive a two coil stepper motor under sinusoidal control.

The TA333 features digital on-the-fly gain control (Dynamic Transconductance or DTS). This allows an
application to modify the drive transconductance on-the-fly, permitting both high acceleration control
and high resolution control. Normally one of these parameters is sacrificed in favor of the other due to
DAC limitations at the driving motion controller.

Why use a Trust Automation linear amplifier?

The majority of motion control applications use PWM (Pulse Width Modulated) drives. PWM drives are
very efficient, but are electrically noisy as they operate by pulsing the motor at full supply voltage at
typical frequencies of 4 kHz to 30 kHz. This pulsing tends to saturate everything electrically in the
surroundings, often including the intended operation. A second side effect of using PWM drives shows
up in ultra-high precision systems requiring nanometer precision. Due to the pulsing nature of the PWM
drive, the motor will tend to dither causing position error that cannot be tuned out.

The TA333 features a true Class-AB linear power stage with a fast current feedback loop to put it in
torque mode. This means that the output is a pure current signal with virtually no distortion around zero,
eliminating all of the side effects of a PWM drive. Some Class-C linear designs, which have a dead
band at zero volts out, attempt to mask this with a fast current loop. This works for some applications,
but performance will suffer in ultra-high precision applications.

Two important considerations where linear servo amplifiers are utilized are cooling and power supply
selection. A linear servo amplifier acts similarly to a large electronic variable resistor. Any power supply
voltage not delivered to the load is dumped as heat into the heatsink. Power supply voltages should be
matched closely to the required load voltage with a small margin for overhead. Excessive supply
voltage will result in amplifier overheating. Cooling linear servo amplifiers is often overlooked or not well
understood. Many products are available with similar current output specifications, but require the user
to supply heatsinks or fans. The TA333 incorporates a large heatsink with integral cooling fans to
accommodate most demanding applications provided there is adequate air space around the chassis
and the ambient temperature does not exceed specification. The TA333 intelligently monitors
temperature and compensates its internal dissipation to protect the drive from damage due to high
temperatures. The TA333 has a serial diagnostics port to monitor application performance and power
levels to aid in assuring optimal performance and a long life.

All Trust Automation drive products are built for safety, installation ease and long life. The TA333 offers
a fully isolated user interface for safe operation in high voltage applications. In addition the TA333

th

generation Trust Automation Linear Drive featuring a true Class-AB linear amplifier

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

housing reduces the risk of operator injury and protects the drive, ensuring longer useful life. All
connections utilize pluggable terminal connectors making them easy to install and remove while
reducing the risk of connection errors.

1.2 Setup

The TA333 is configurable for several drive motor type options and configurations. All configurations
require the use of bipolar supplies that can be in the range of 24 to 100V. Current outputs are
adjustable from 10 to 25A.

Some of these options are shown in the application example section.

1.3 Drive Modes

Sinusoidal

Sinusoidal commutation of three-phase brushless servo motors plus a linear drive power stage
eliminates the familiar cogging and torque ripple problems that plague most trapezoidal digital drives.
Control is consistent and smooth at any velocity.

In sinusoidal mode, the TA333 is designed to accept two command signals (A and B @ ±10V) from a
motion controller that is performing the commutation based upon encoder feedback. The TA333 derives
the third phase internally (C = - (A+B)). (See application example 5.1 and 5.2)

Trapezoidal

Trapezoidal operation is the simplest configuration used to drive a DC brushless motor. The TA333
reduces the audible tick often associated with Hall commutation by smoothing the transitions without
sacrificing performance. As a practical limitation, Hall commutation is limited to ~ 3 kHz throughput. In
this mode, the motors Hall Sensors are connected to J4. If the motor has differential Hall outputs, only
connect the “+” Hall outputs to J4 and leave the “–” Hall signals unconnected. (Do not tie to ground, the
motor will be damaged.)

The motion command signal (±10V) is connected to the “A” command input. (See application example

5.3)

Brushed-Bridge

Brushed-bridge mode supports operating a traditional brushed or voice coil-type motor, bridged across
the A & C output phases. The command signal (±10V) is connected to the “A” command input. (See

application example 5.4)

Brushed-Dual

This mode supports driving two independent brushed or voice coil-type motors. This mode could also
be used to drive a stepper motor in sinusoidal mode. The first motor (winding) would be connected to
the “A” phase output and the common ground of the bipolar power supply. The second motor (winding)
would connect to the “B” phase output and the common ground. The command inputs (±10V) are
connected to the “A” and “B” command inputs. (See application examples 5.5 and 5.6)

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

1.4 Command Input

Motion command connections to the TA333 are made at J3. Inputs are provided for two of the three
phases (A and B) and the TA333 can derive the third phase (C = - (A+B)) in sinusoidal applications.
The inputs are common mode terminated at 10K and there is no need to ground an input if it is unused.

The input range is set to ±10V commands.

Differential Inputs

Using differential input helps reduce or eliminate potential noise susceptibility from other sources.
Connect the motion controller ± command outputs to the TA333 ± inputs at J3. For best immunity use a
twisted pair cable. Terminate the motion controller signal ground to the TA333 ISO ground connection
at J3. (See application examples 5.1)

Single-Ended Inputs

Many motion controllers only offer single-ended command signals with a common ground. Single­ended configurations are accommodated by referencing the A+ and B+ signals to the command output
and referencing the A- and B- signals to the motion controller signal ground. It is good practice to use a
twisted pair cable for the “+” command, terminating the “-” command at the controller signal ground.
Terminate the motion controller signal ground to the TA333 ISO ground connection at J3.

(See application example 5.2)

1.5 Upgrading from a TA320 or TA330

When changing a preexisting application from a TA320 or TA330, the command signal polarity must be
reversed to maintain the applications direction of motion.

The original TA320 and TA330 linear amplifiers operated with inverted outputs, meaning a positive
command induces a negative current. The TA333 is a non-inverting amplifier (positive command =
positive current).

Examples:

• Differential inputs would place the motion controller’s “+” signal on the TA333 “–” command
input and the controller’s “–” signal on the TA333 “+” command input.

• Single-ended configurations place the motion controller’s command output on the TA333 “–”
command inputs and terminate the TA333’s “+” command inputs to the motion controller’s
signal ground and the TA333 ISO ground connection.

1.6 Transconductance Ratio

The TA333 operates in current mode (commonly referred to as Torque mode). For a given input
voltage, the TA333 will output a proportional current by raising the output voltage until the commanded
current is drawn. As current flow in a motor is directly proportional to torque, it is common to refer to this
as “Torque mode”. The ratio between the command voltage and the output current is referred to as the
“Transconductance Ratio,” which is measured in amps per volt and is expressed by the following
equation:

g

= Io / Vc

m

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

g

= current gain (Transconductance)

m

I

= output current

o

V

= command voltage

c

Example:

If: I
Then: g

desired = 15A and Vc (max) = 10V

o

= 15 / 10 or 1.5A/V

m

For every 1 volt of command 1.5A of current will be driven.

Note: Current output is limited by Ohm’s Law (I = V

supply

/ R

motor

)

TA333 is factory configured for 10A, 15A, 20A and 25A for a commanded input voltage of ±10V, set at
SW1, positions 3 and 4. (See table 4.9

)

Note: 25A output duration is limited by the SOA graph and temperature. (See SOA section 2.4)
Custom Transconductance ratios can be preset by the factory. Please contact

[e-mail]

to discuss your requirements.

1.7 Thermal Limits

The TA333 is internally thermally protected with integral variable speed cooling fans. The heatsink
temperature is monitored and the fan speed is automatically adjusted to maintain a safe operating
temperature. If the heatsink temperature rises to 70°C, a FAULT output is generated but the drive will
continue to operate. If FAULT is ignored and the heatsink temperature rises to 90°C, the drive will
shutdown. When the heatsink temperature drops below 40°C, the drive can be re-enabled by toggling
the enable line.

1.8 Dynamic Transconductance Selection

A feature pioneered by Trust Automation, Dynamic Transconductance, or DTS, enables on-the-fly
changes to the transconductance settings. This feature is advantageous in frictionless systems (i.e., air
bearing systems) where start, stop and turn around currents are high, but moving currents are very low.

Due to the digital nature of most motion controllers there is limited DAC resolution to cover both the
high and low currents with sufficient resolution. By switching the transconductance on the fly, the
motion controller’s DAC can be utilized at its full resolution for both high current moves and precision
motion.

The DTS inputs are logically “OR”ed with the DTS switch inputs. In this way a highest current setting
can be chosen by the switches and logic can “OR” with this data to set a lower setting.

The TA333 accomplishes this by allowing the motion controller to logically control the DTS bits D0 and
D1 through pins 5 and 6 of J3 (5V TTL). (See application example 5.4)

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

1.9 Enable Input

The ENABLE input can be selected as active-high or active-low logic at SW1 position 1. (See table 4.8

The input must be pulled to logic low (ISO GND) or logic high (ISO +5) for the TA333 to operate. The
ENABLE line is pulled up internally to ISO +5. The TA333 provides an isolated +5V source at connector
J3 and J4 with a maximum draw of 100mA. If the application requires more current, the user must
supply an external 5V that must be referenced to the ISO ground connection.

The TA333 must not be enabled during power up.

If the drive is powered up when enabled, the drive
will not enable and will assert FAULT. The ENABLE input must then be cleared and re-asserted to
enable the drive.

Note: A minimum sinking capability (I

) of 5mA is required.

OL

Note: Logic low input minimum voltage (V

) is 0.8V. Logic high input minimum voltage (VIH) is 2.0V with

IL

a maximum on 5.2V.

See circuit in the following figure:

)

Figure 1 – Enable Circuit

1.10 FAULT Output

The TA333 FAULT output is selectable as active-high or active-low logic, set at SW1 position 2. (See

table 4.8

graph. (See section 2.4)
the serial monitoring port. (See section 1.16)

Note: Logic output high minimum voltage (V

0.8V.

See circuit in the following figure:

) The TA333 will assert FAULT upon over-current or thermal overload based on the SOA

Past FAULT information is stored in internal memory and may be accessed at

) is 2.5V. Logic output low maximum voltage (VOL) is

OH

Figure 2 – Fault Circuit

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Trust Automation, Inc. TA333 High Power Linear Servo Amplifier

1.11 Ground Connections

Command and Signal Logic

Connections to a motion controller must be referenced to ISO ground at J2. These signals include
Enable, FAULT, DTS and the analog command inputs. For single-ended command signals, reference
the TA333 command A- and B- inputs to ISO ground on connector J2.

ISO Ground and all user interface signals on J2, J3 and J4 are isolated from drive power GND and the
External 24V GND with a minimum 1500V hipot separation.

1.12 Drive Power Supply

A pair of matching power supplies (24V to 100V) must be used to power the TA333. A high quality
switching supply is suitable for most applications. These supplies tend to be small, affordable, and
highly available. Trust Automation recommends supplies with an output ripple less than 100mV. Some
high quality supplies available offer less than 50mV. In some cases, particularly where there is great
concern for noise interference, a linear power supply, regulated or unregulated, will be required. For
unregulated supplies, verify that the voltage supplied either at V+ or at V- does not exceed the absolute
maximum supply voltage of 100V. Also note that the supplies must be within 12V of each other or a
supply fault will be generated.

When using the TA333 or any linear servo amplifier, power supply voltage that is not delivered to the
motor will be lost as heat in the amplifier. (See section 1.14)

When selecting supplies for a given motor application it is recommended that the total voltage be
approximately 20V more than the required motor voltage. (The TA333 can drive to within ~ 8V of the
supply). Excessive supply voltages will result in higher peak wattage dissipation. Reference the SOA
graph for actual currents allowed. (See section 2.4)

Figure 3 – Drive Power Connection

Connect the positive supply positive “+” to V+ and the positive supply negative “-” to GND. Connect the
negative supply positive “+” to GND and the negative supply negative “-” to V-. This is shown in Figure
3 above.

Note: When designing a system E-stop, never cut the motor leads. Doing so will result in a runaway
condition and may damage the TA333. Always cut the incoming DC supply (crowbar with a low value
resistor) to the TA333 to produce a rapid stop.

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