- Computers & electronics
- Audio & home theatre
- Audio amplifiers
- Copley Controls Corp.
- 306A
- User manual
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FEATURES
•
Mounts on customers printed
circuit boards.
•
Flexibility! Internal 40-pin socket configures amp with no soldering
•
Separate current limits:
Continuous, peak, and peaktime
•
No integrator windup when disabled
•
Fault protections:
Short-circuits from output to output, output to gnd
Over/under voltage
Over temperature
Self-reset or latch-off modes
•
3kHz Bandwidth
•
Wide load inductance range:
0.2-40 mH.
•
Surface mount technology construction, lower part count.
•
Optional output filter for reduced PWM noise to adjacent circuits
APPLICATIONS
•
X-Y stages
•
Robotics
•
Automated assembly machinery
•
Magnetic bearings
THE OEM ADVANTAGE
•
Minimize cabling for lowest cost products
•
Uses industry-standard connectors for solderless installation
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
MODEL FEATURES
4122P +24~90VDC, 10/20A, Standard 0-100% modulation
4212P +24~90VDC, 6/12A, Standard 0-100% modulation
FEATURES
These versions of the 4122 & 4212 models and their variants use extended pins that interface with printed circuit board mounted connectors for direct mounting of the amplifier to customers pc boards.
The active logic-level of the amplifier
Enable input is jumper selectable to
GND or +5V to interface with different control cards. /Pos and /Neg enable inputs remain ground active for fail-safe operation.
Mosfet H-bridge output stage delivers power in four-quadrants for bidirectional acceleration and deceleration of motors.
An internal solderless socket holds 17 components that configure the various gain and current limit settings to customize the amplifiers for a wide range of loads and applications.
Header components permit compensation over a wide range of load inductances to maximize bandwidth with different motors.
Individual peak and continuous current limits allow high acceleration without sacrificing protection against continuous overloads. Peak current time limit is settable to match amplifier to motor thermal or commutation limits.
All models are protected against output short circuits ( output to output and output to ground ) and heatplate overtemperature.
With the /Reset input open, output shorts or heatplate overtemperature will latch off the amplifier until power is cycled off & on, or until the /Reset input is grounded.
For self-reset from such conditions, wire
/Reset to ground and the amplifier will reset every 200ms.
Pins models also accept the “F” option card that has output ‘edge’ filters that reduce the noise coupling of PWM outputs to adjacent cabling and circuitry.
The output filter card option uses the same connectors as the popular 300 series models ( 303, 306, 306A and variants ) for easy upgrading to the
4xx2 models.
The filter is a dual section L/C/R that slows down the switching ‘edges’ ( the rise and fall times of the outputs ) for greatly reduced coupling of PWM noise to nearby cables and circuits.
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
TECHNICAL SPECIFICATIONS
MODEL
OUTPUT POWER
Test conditions: 25
°
C ambient, Load = 200µH. in series with 1
Ω
., +HV = maximum normal value
4122P 4212P
Peak time
OUTPUT VOLTAGE
LOAD INDUCTANCE
±
20A @
±
80V
±
12A @
±
120V
0.5 sec unipolar from 0A, 1 secs. after polarity reversal
±
10A @
±
80V
±
6A @
±
120V
±
Vout =
±
HV*(0.97) - (Ro)*(Io)
Ro = 0.2 Ro = 0.1
Selectable with components on header socket: 200 µH to 40mH
BANDWIDTH
PWM SWITCHING FREQUENCY
Current mode: 3kHz with 200µH load at maximum supply voltage, varies with load inductance and RH15, CH16 & CH17 values
25kHz
Differential, 94K between inputs,
±
20V maximum REFERENCE INPUT
GAINS
Input differential amplifier
PWM transconductance stage
INDICATOR (LED)
Normal
1:1 (Volt / Volt)
Ipeak / 6V ( I peak = peak rated output current; 6V measured at Current Ref J2-9 )
LOGIC INPUTS
Input voltage range
Logic threshold voltage ( LO to HI transition )
/Enable ( Internal jumper JP1 reverses logic )
Time delay on Enable
/POS enable, /NEG enable
/Reset
Input resistance
POTENTIOMETER
Balance
0 to +24V
2.5V ( Schmitt trigger inputs with hysteresis )
LO enables amplifier, HI disables
( Default function with JP-1 on pins 2-3. For +5V enable and GND inhibit, move JP1 to pins 1-2 )
0.9 ms after Enable true to amplifier ON, <1ms to disable
Gnd enables positive or negative output currents. +5V or open inhibits (<1ms delay)
( Setting of JP-1 has no effect on ground-active level of /POS and /NEG enable inputs )
LO resets latching fault condition, ground for self-reset every 200 ms.
10K pull-up to +5V, R-C filters to internal logic
Use to set output current or rpm to zero. RH1 = 10 M
Ω
for Balance function, RH1 = 100k
Ω
for Test function
LOGIC OUTPUT
+Fault ( /Normal )
HI output voltage
LO output voltage
HI = Overtemp OR output short OR power NOT-OK, OR NOT-Enabled; LO = Operating normally AND enabled
+5V ( 33k
Ω
pullup resistor to +5V ) +50V maximum
<0.5V typical, 1.25V @ 250mA max, Ro = 5
Ω
( mosfet on resistance )
Green: ON = Amplifier Enabled AND Normal ( power OK, no output shorts, no overtemp )
Red = Fault ( NOT Normal, see +Fault output above )
ANALOG MONITOR OUTPUTS
Current Ref ( current demand signal to pwm stage )
Current Monitor ( motor or load current )
DC POWER OUTPUTS
±
6V @ demands
±
Ipeak
±
6V @
±
Ipeak (1k
Ω
, 33nF R-C filter)
±
15VDC each output in series with 10k
Ω
PROTECTIVE FEATURES ( Note 1 )
Output short circuit (output to output, output to ground)
Overtemperature
Undervoltage shutdown @
Overvoltage shutdown @
<20V
>92VDC
Latches unit OFF
Latches unit OFF at 70°C on heatplate
<20V
>129VDC
POWER REQUIREMENTS
DC power (+HV) Transformer isolated from power mains
Watts @ Icont
+22 to +90VDC
2.5W
25W
THERMAL REQUIREMENTS
Storage temperature range: -30 to +85°C; operating temperature range: 0 to 70°C baseplate temperature
Notes: 1. Heatsink optional ( add “H” to model number) 2. Fan = forced air over unit @ 400 linear feet/minute
+22 to +125VDC
2.7W
41W
MECHANICAL
Amplifier case size
Heatsink
Weight
CONNECTORS
Amplifier
PC board mounting
NOTES
4.3 x 3.0 x 1.0 in. (109 x 76.2 x 25.4 mm.) + Pin height.
Adds 1.50 in. ( 38.1 mm ) to amplifier 1.0 in. dimension. Same length as amp.
0.43 lb (0.2 kg.) for amplifier alone; heatsink adds 0.78 lb. (0.35 kg)
J1 (Power & motor): 5 Pins (Methode# BA-2900-105) 0.20” centers, 1.070” long.
J2 (Signal): 16 Pins (Methode# BA-2899-116) 0.1” centers, 1.070” long.
Mating to J1: (MIL-MAX 0366-0-15-01-23-01-10-0)
Mating to J2: ( Molex: 22-14-2164 )
1. Latching faults disable amplifier until power is cycled off-on, or /Reset input is grounded. Non-latching faults re-enable amplifier when fault condition is removed. Overtemperature and short-circuits are latching faults, under or overvoltage faults are non-latching. If /Reset input is grounded, amplifier will autoreset from latching faults every 200ms.
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
FILTER OPTION DIAGRAM
R
AMPLIFIER
OUT(+)
GND
OUT(-)
L
C2
L
C1
C1
MOTOR
C2
R
FUNCTIONAL DIAGRAM
-
+
RH2 100 K
AUX
16
TACH (-)
6
GND
7
RH4
TACH LEAD
CH5
REF(+)
4
REF(-) 5
REF AMP
Gv = 1
-
+
RH3 100 K
REF LEAD
RH6 CH8
RH7 100 K
CURRENT
REF
9
CURRENT
MONITOR
8
+15V
CW
BALANCE
50K
-15V
RH1
10 MEG
1K
4.8 kHz FILTER
33NF
1K
33NF
1K
4.8 kHz FILTER
GND 2
AUXILIARY
+15
DC OUTPUTS
-15
1
3
10k
10k
+15V
-15V
CH9
INTEGRATOR
RH10
(OPEN)
CH11 *
* JP1: PINS 2-3 FOR /ENABLE AT J2-11
PINS 1-2 FOR /INHIBIT AT J2-11
INTEGRATOR RESET SWITCHES
TURN ON WHEN AMP IS DISABLED
*JP1
3 2 1
LED
GREEN = NORMAL
RED = FAULT
+5V * NOTE:
DEFAULT VALUE OF CH11 IS 0 OHMS
FOR TORQUE MODE OPERATION
FOR VELOCITY MODE ( BRUSH TACH )
REPLACE CH11 WITH 4.7NF
CH17
RH15
STATUS
&
CONTROL
LOGIC
60.4 K
-
+
SERVO
PREAMP
100PF
CURRENT LIMIT
SECTION
-
+
PEAK
CURRENT
RH12 182K
CONT
CURRENT
RH13 4.7MEG
PEAK
TIME
CH14 0.47U
Voltage gain = 1
47K
47K
CH16
-
+
CURRENT
ERROR
AMP
OUTPUT
CURRENT
SENSE
PWM
STAGE
MOSFET
"H"
BRIDGE
+/-6V for
+/-Ipeak
VOLTAGE
GAIN
Gv = +HV
10
+/-6V at
+/-Ipeak
10
GND
11
ENABLE
12
POS ENABLE
13
NEG ENABLE
*
14 +FAULT OUTPUT
15
RESET
MOMENTARY SWITCH CLOSURE RESETS FAULT
WIRE RESET TO GROUND FOR SELF-RESET
J2 SIGNAL CONNECTOR
VALUE DEPENDS ON MODEL
SEE "ARMATURE INDUCTANCE" TABLE
J1 MOTOR & POWER CONNECTOR
1
MOTOR +
MOTOR -
2
GND
3
GND
4
+HV
5
+
MOTOR
-
+5
+15
-15
+HV
DC / DC
CONVERTER
CASE MAY BE GROUNDED
FOR SHIELDING
CASE GROUND
NOT CONNECTED
TO CIRCUIT GROUND
POWER GROUND AND SIGNAL GROUNDS ARE COMMON
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
CONNECTORS AND PINOUTS
J1: MOTOR & POWER CONNECTIONS
Pin Signal Remarks
1
2
3
4
5
Motor (+)
Motor (-)
GND
GND
+HV
Amplifier output to motor (+) winding
Amplifier output to motor (-) winding
Power supply return. Connect to system ground at this pin.
Power supply return. Connect to system ground at this pin.
+HV DC power supply input
J2: AMPLIFIER BOARD CONNECTIONS
Pin Signal Remarks
1 +15V +15V in series with 10k
Ω
2 Gnd Signal
3 -15V -15V in series with 10k
Ω
4 Ref (+) Differential input positive terminal for Reference voltage
5 Ref (-)
6 Tach (-)
Differential input negative terminal for Reference voltage
Negative terminal of brush tachometer
7
8
9
Gnd / Tach (+)
Curr Mon
Curr Ref
Signal ground, or positive terminal of brush tachometer
Output current monitor:
±
6V output at
± peak output current
Current demand signal to PWM stage:
±
6V demands
± peak current
10 Gnd Signal
11 /Enable Amplifier enable input: enables or inhibits PWM switching at outputs
Default: Gnd enables amplifier, open or +5V inhibits ( JP1 @ 2-3 )
For controllers that output +5V to enable amplifier, move internal jumper JP1 to pins 1-2 ( Gnd will inhibit, +5V or open will enable )
12 /Pos Enab
13 /Neg Enab
Gnd to enable output current in one polarity, open or +5V to inhibit
Typically used with grounded, normally closed limit switches.
Gnd to enable output current in opposite polarity, open or +5V to inhibit. Typically used with grounded, normally closed limit switches.
14
15
/Normal
/Reset
Current-sinking when amplifier enabled and operating normally.
Goes to +5V when amplifier disabled or fault condition exists.
Ground to reset overtemp or output short circuit latching faults.
For automatic reset of faults every 200mS, ground permanently.
16 input.
BALANCE POTENTIOMETER
Default position: centered. Functions to bring output current ( in torque mode ) or output velocity ( in tachometer mode ) to zero with reference input voltage at zero, or control system output at zero. Normal range is
±
1% of full scale with 10Meg resistor in header location RH1. To use the pot as a wide range set-point adjustment, install a 150k
Ω
resistor at RH1. Now, full CW or CCW will have the effect of a
±
10V signal at the reference inputs.
STATUS LED
Dual color, red/green.
Color +HV
Green Normal
Red Too low or too high
X
Active None Normal
X X X
X
X
Note 1, 5 2, 5 3, 5 4, 5
Notes:
1. +HV normal >20V and <92V for model 4122P, >20V and <129V for model 4212P
2. /Enable is ground-active for JP1 on pins 2-3 ( default ). To reverse function, switch JP1 to pins 1-2.
3. Shorts detected by overcurrent circuit are between outputs, or from outputs to ground.
4. Overtemperature faults occur when heatplate temperature is >70
°
C
5. +HV and /Enable cause momentary amplifier shutdown, operation is restored when +HV is within normal limits and /Enable input is active. Output shorts, and overtemperature faults latch-off amplifier. Thus amplifier will remain off until power is cycled on/off, or /Reset input is grounded momentarily. If /Reset input is wired to ground, output short and overtemperature faults will self-reset every 200ms.
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
COMPONENT HEADER
NO PARTS INSTALLED
IN THESE LOCATIONS
5
J1
1
16
J2
JP1
3 2 1
1
COMPONENTS LABELLED "SEL"
ARE NOT INSTALLED AT FACTORY
USER SHOULD SELECT VALUES AS REQUIRED
0.47UF
4.7 MEG
182K
(O OHM)
60.4K
(SEL)
(SEL)
100K
(SEL)
(SEL)
(SEL)
100K
100K
10MEG
CH17
CH16
RH15
CH14
RH13
RH12
CH11
RH10
CH9
CH8
RH7
RH6
CH5
RH4
RH3
RH2
RH1
LOAD INDUCTANCE COMPENSATION
(SEE CHART FOR VALUES)
PEAK TIME LIMIT
CONTINUOUS CURRENT LIMIT
PEAK CURRENT LIMIT
PREAMP DC GAIN & INTEGRATOR
PREAMP HI-FREQUENCY ROLL-OFF
REF INPUT LEAD CAPACITOR
REFERENCE INPUT SCALING
REF INPUT LEAD RESISTOR
TACH INPUT LEAD NETWORK
TACH INPUT SCALING
AUX INPUT
BALANCE RANGE
ARMATURE INDUCTANCE
Model 4122P 4212P
Load 15 CH17 CH16 RH15 CH17 CH16
0.2 to 0.5
0.6 to 1.7
1.8 to 4.8
5 to 14
15 to 45
80.6k
402k
806k
2.2 nF 390 pF 69.8 k 2.2 nF 390 pF
200k 680 pF 220 pF 100 k
680 pF
680 pF
180 pF
150 pF
301 k
698 k
1 nF
470 pF
330 pF
330 pF
100 pF
82 pF
1.5M 470 pF 100 pF 1.21M 220 pF 82 pF
Note: Values in bold & italics are factory installed standard. Values shown are for 90V (4122P ) and 125V (4212P). At lower supply voltages RH15 may be increased and CH17 decreased.
PEAK CURRENT LIMIT (AMP) CONTINUOUS CURRENT LIMIT (AMP)
4122P 4212P RH13 )
16.7 10 56k
13.3 8 30k
10 6 18k
6.7 4 9.1k
3.3 2 3.9k
PEAK CURRENT TIME-LIMIT (SEC)
7.4 4.4 7.15Meg
5.7 3.4 10Meg
Notes on Current Limits:
1. Values in bold & italics are factory installed standard.
2. Peak times double after polarity reversal.
0.2 0.10
0.1 .047
2
R losses.
5. Times shown are for 100% step from 0A with default value of RH13 ( 4.7 Meg ).
When changing RH13, peak times will change. Set RH13 for continuous current limit first, then pick CH14 based on waveforms at Curr Ref ( J2-9 ).
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
APPLICATION INFORMATION
IMPORTANT! ALWAYS REMOVE POWER WHEN CHANGING
HEADER PARTS!!
OPERATING MODES
These amplifiers operate as either open-loop current sources, or feedback devices using analog tachometers.
As open-loop current sources, the
±
10V at the reference inputs produce current in the load, typically a motor. The motor acts as a transducer, and converts current into torque, the twisting force at the motor shaft. This is called torque mode. It is used most frequently in systems that have controllers taking feedback from an encoder on the motor shaft. The computer calculates both position and velocity from the encoder signal, processes them in a digital filter, and outputs a signal to the motor causing it to accelerate or decelerate.
As a feedback amplifier, a signal is generated by an analog brush tachometer mounted on the motor. This is a generator that produces an analog signal that has a polarity and amplitude proportional to the motor speed. The amplifier subtracts the tach signal from the reference signal, and amplifies the difference between them. This is called velocity mode, because the amplifier changes the motor current ( torque ) so that the motor
velocity is proportional to the reference signal.
TORQUE MODE OPERATION
Torque mode is the default configuration. For input voltages of
±
10V, the amplifier will output its peak rated current.
In torque mode, motor current is held constant, and motor speed, or velocity changes as the load changes.
In torque mode the gain of the servo preamplifier is simply 0.6 and scales the
±
10V from the reference signal down to the
±
6V that drives the PWM stage.
The servo preamplifier integrator function is disabled, and the low gain is constant over a wide range of frequencies. Thus we sometimes call this flat-gain mode.
VELOCITY MODE OPERATION
The difference between the reference and tachometer signals is amplified and used to change the torque on the motor. Ideally, the difference between the command and feedback signals would be zero, so in velocity mode operation the servo preamplifier must have much higher gain than when in torque mode.
In addition, the gain must change over a range of frequencies.
For “stiffness” that corrects for steady-state changes, the amplifier uses an integrator. For fast response the loop gain of the servo preamplifier must be tailored to the characteristics of the motor and tachometer. To control oscillations from the tachometer, the gain of the preamplifier must roll-off, or decrease at higher frequencies.
In velocity mode, motor speed is held constant, while motor current changes in response to changes in the load.
THE PARTS OF THE AMPLIFIER
DIFFERENTIAL AMPLIFIER
The reference signal ( the command signal from the control system ) is sensed by a differential amplifier. This acts like a voltmeter with two probes, measuring a voltage between two points. Current flowing in the amplifier power wiring causes voltage drops in the wires resistance. This in turn can produce a voltage at the amplifier ground that is different than the control system ground. If this voltage is added to the output of the control system, it can produce oscillation, or inconsistent operation. To eliminate this effect, you should always use both reference inputs.
Connect the Ref(+) input to the output of the controller card, and the Ref(-) input to ground at the control card. Now, the differential amplifier will measure the control signal at the control card and will reject any noise that exists between amplifier and control system grounds.
THE SERVO PREAMPLIFIER
This section processes the reference signal and any feedback signals, and generates an internal current reference signal that controls the PWM stage to produce output currents. It is here that the reference signal and tachometer signals are compared, and the difference signal produced and amplified.
Three components on the header control the behavior of the servo preamp. The chart below lists the default torque-mode and starting-point values for velocity mode operation:
CH9 out 220pF
RH10 60.4k 680k
CH11 short 4.7nF
CH9 controls the high-frequency roll-off.
RH10 controls the loop gain, and thus the step-response of the amplifier.
CH11 ( along with RH7 ) forms the integrator that gives the stiffness at a standstill, or speed regulation while running.
CURRENT LIMITING
This stage takes the output of the servo preamplifier, and processes it before sending it to the PWM stage. The amplitude of the signal is first clamped to produce peak current limiting.
This signal then goes to the continuous current-limit circuit where these functions are produced. Finally, the current-limited signal is outputted to the PWM stage as the current-reference signal.
This signal is quite useful in that the current limit action can be seen here and measured without connecting a motor, thus protecting it from overload during initial setup.
PWM STAGE
The voltage at the output of the current limit stage is called the
current reference. This signal becomes the demand signal that controls the PWM stage. Here the current demand is converted into a current in the motor. This current can be measured at the current monitor, which shows the response of the motor to the current demand signal. By operating as a current source, the
PWM stage is able to achieve faster response from the motor than if was acting only as a variable voltage.
The current error amplifier compares the current reference with the current monitor, and adjusts the output voltage such that the demanded current flows in the motor. The gain of this amplifier is controlled by RH15, CH16, and CH17, which are used to
compensate the amplifier for the motors’ inductance.
BASEPLATE OUTLINE DIMENSIONS
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
0.56
(14.2)
2.00
(50.8)
4.00
(101.6)
0.16
(4.1)
Dimensions in inches (mm.)
4.30
(109.2)
1.45
(36.8)
0.625
(15.9)
3.00
(76.2)
Optional Heat sink
2.87
(72.9)
1.00
(25.4)
1.50
(38.1)
MODELS 4122P, 4212P
“PIN” VERSIONS FOR PC BOARD MOUNTING
TYPICAL PCB ADAPTER OUTLINE DIMENSIONS
OTHER DC BRUSH SERVO AMPLIFIERS
400 Family
Model 403
Six models operating from 24-225VDC, 5-15A continuous, 10-30A peak.
Fully featured with adjustment potentiometers, voltage feedback with IR compensation.
For torque-mode only applications at low cost. +18 to +55VDC operation, 5A continuous, 10A peak
ORDERING GUIDE
Model 4122P
Model 4212P
Note: For heatsink option. Add “H” to part number. For example: 4122PH would be a model 4122P with heatsink.
For 50% modulation option. Add ”Z” to part number. For example: 4122zP.
For the PWM /DIR option Add “D” to the part number. For example: 4122PD.
20A peak, 10A continuous, +22 to +90VDC brush motor amplifier
12A peak, 6A continuous, +22 to 125VDC brush motor amplifier
ReB, 02/22/2001
Copley Controls Corp., 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax: 781-828-6547
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Table of contents
- 1 FEATURES
- 1 APPLICATIONS
- 1 THE OEM ADVANTAGE
- 1 FEATURES
- 3 FILTER OPTION DIAGRAM
- 3 FUNCTIONAL DIAGRAM
- 4 CONNECTORS AND PINOUTS
- 4 J1: MOTOR & POWER CONNECTIONS
- 5 ARMATURE INDUCTANCE
- 6 A
- 6 APPLICATION INFORMATION
- 6 OPERATING MODES
- 6 THE PARTS OF THE AMPLIFIER
- 7 BASEPLATE OUTLINE DIMENSIONS
- 8 TYPICAL PCB ADAPTER OUTLINE DIMENSIONS
- 8 OTHER DC BRUSH SERVO AMPLIFIERS
- 8 ORDERING GUIDE