MODEL 513, 513R DC BRUSHLESS SERVO AMPLIFIER (513

MODEL 513, 513R DC BRUSHLESS SERVO AMPLIFIER (513
MODEL 513, 513R
DC BRUSHLESS SERVO AMPLIFIER (513) WITH RESOLVER OPTION (513R)
FEATURES
± 180 Volts at ± 26A Peak, ± 13A
n Wide voltage range:
+24 to +190V
Model 513
n 13A continuous, 26A peak
n 25 kHz pwm frequency
n Drives motors with 60° or
120° Halls.
n Fault protections:
Output shorts
Over/under voltage
Over temperature
n 2.5kHz Bandwidth
n 0.2-40 mH load inductances
Model 513R
n +5,+15V Hall voltages
n Separate peak, peak-time,
and continuous current
limits
n Simplified compensation
adjustments
n Surface mount technology
Resolver option 513R
n Replaces Hall sensors
Tachometer emulation
Encoder emulation
n Interface motors to
microprocessor controls and
PLC's.
APPLICATIONS
n X-Y stages
n Automated assembly
machinery
n Robotics
n Component insertion
machines
THE OEM ADVANTAGE
n Component header
customizes amps for
different motors
n Conservatively rated
components for high MTBF
PRODUCT DESCRIPTION
Standard Amplifier (513)
Model 513 is a complete pwm
servoamplifier that operates from
transformer-isolated single-voltage
power supplies and provides six-step
commutation of dc brushless
servomotors.
Power output is four-quadrant for
rapid acceleration and deceleration.
Amplifier operates in torque ( current )
mode for use with microprocessor
based control cards.
Analog ( brush ) tachometers can be
used to make velocity loops. New
servo preamplifier circuits give
improved control over frequency
response for faster setup and
adjustment.
An internal header socket holds
components that configure current
limits and load-inductance
compensation to set up the Model 513
for different loads and applications.
Separate peak current, continuous
current, and peak-time limits allow
high acceleration without sacrificing
protection against continuous motor
overloads.
Over and under-voltage conditions will
cause the unit to shutdown
temporarily. Heatplate overtemperature and shorts from output to
output, or output to ground will cause
a latching disable that can be reset by
grounding the Reset input, or by
powering off & on. Self-reset will occur
if /Reset input is wired to ground.
High quality components and
conservative design insure long
service life and high reliability in
industrial installations.
Potentiometers may be replaced with
fixed resistors for OEMs which require
amplifiers that have no adjustments
(contact factory).
DC brush motors also can be driven
from the Model 513 by setting the DIP
switch to 60°, leaving the Hall inputs
open, and connecting the motor
between the U and V outputs.
Resolver Option (513R)
Provides velocity-loop operation using
resolver-derived analog tachometer
signal. Encoder outputs give position
feedback, emulate 1024 line
quadrature encoder. Both permit use
with programmable logic controls
( PLC’s ) that require speed-loops for
motion modules.
Option card installs inside drive case
and interfaces with standard twophase resolvers. A read-only memory
chip converts resolver position data to
Hall signals that control motor
commutation for motors with 1-4
electrical cycles per revolution.
Custom eproms available to interface
with most motors ( contact factory ).
Option eprom supports DC brush
motors with resolvers.
MODEL 513, 513R
DC BRUSHLESS SERVO AMPLIFIER (513) WITH RESOLVER OPTION (513R)
FUNCTIONAL DIAGRAM (513)
MOMENTARY SWITCH RESETS
WIRE RESET TO GROUND FOR SELFDIFF AMP
10K
REF(-) 8
REF(+) 9
-
REF GAIN
+
cw
RH3
SEL
10K
TACH (-)
11
22NF
CW
100K
50K
Total power from +5, -15,
BALANCE
+5V
-15V 14
-15V
+15V 15
SEL
+
CW
J2 MOTOR
CH10
1.5NF
CURRENT
SECTION
G = X1
RH7
SEL
-
CONT
SEL
49.9K
Gv = +HV
10
CURRENT
ERROR
AMP
HALL PHASE
OFF = 60
ON = 120
6
(DC-)
V
(DC+)
W
(n.c.)
2
3
J1 POWER
1
+HV
GND
2
0.25V/
SW2
OUTPUT
CURRENT
SENSE
HALL
LOGIC
W
+HV
4
GROUND CASE FOR
+5
+5 @
3
Total power from +5/+15
+15 @
+15
2
DC / DC
CONVERTER
-15
GND
1
POWER GROUND AND SIGNAL GROUNDS ARE
CONNECTOR & INTERNAL LAYOUT
HEADER LOCATION
( COVER REMOVED )
RH1
J1
CH2
J2
RH3
J3
CH4
RH5
J4
/ENABLE POLARITY
JUMPER JP-1 (NOTE 3)
CH6
RH7
S1,2
LED
BALANCE
RH8
RH9
RESP LO
RESP HI
TACH GAIN
REF GAIN
CH10
RH11
Notes:
1.
2.
MOTOR
+
RH9
301k
PWM
STAGE
MOSFE
"H"
BRIDGE
100 PF
49.9K
U
1
470 PF
RH8
3.3NF
RH11
49.9K
2.2
PEAK
PEAK
TIME
5
J4 SIGNAL
LO FREQ
-15
J3 HALLS
V
1
CURRENT REF
500K
5.6M
J4 SIGNAL
HALLS
GND
-
50K
10K
7
POS
4
ENABLE (Note
4.99K
+15V
U
NEG
3
5
GND 16
CURRENT
MONITOR 10
+/-6.5V @ +/4A/V
+5V
+15
+5V 13
Note 2
0.22UF
+
SEL
CW
outputs ( including Halls
not to exceed
CH6
RH5
12
STATUS
&
CONTROL
LOGIC
33NF
SEL
GND or TACH(+)
NORM
6
JP-1
CH2
RH1
TACH GAIN
1K
100K
1K
50K
HI FREQ
2
G
50K
-
GND 7
NORMAL
SW1
10K
TACH
CW
CH4
RESET
LED
1K
100K
10K
Components shown in dotted lines are not installed at factory.
Jumper JP-1 is delivered in non-shorting position, making /Enable input ground-active ( +5V or open inhibits ).
To invert logic of /Enable input install jumper between pins. Now, +5V or open enables, ground inhibits.
Note: the /Pos and /Neg enable inputs are not affected by this jumper, and remain ground-enable, +5V or open inhibits.
CASE
NOT
TO CIRCUIT
MODEL 513, 513R
DC BRUSHLESS SERVO AMPLIFIER (513) WITH RESOLVER OPTION (513R)
TECHNICAL SPECIFICATIONS
Typical at 25°C, +HV = +190VDC. Load = 200µH. in series with 1 ohms.
OUTPUT POWER
Peak power
2 Sec
500 mSec
Continuous power
±180V @ 20A, 3600W
±179V @ 26A, 4650W
±182V @ 13A, 2360W
OUTPUT VOLTAGE
Vout = 0.97*HV - (0.2)(Iout)
MAXIMUM CONTINUOUS OUTPUT CURRENT
At 25°C. ambient, 190VDC, perpendicular to thermally conductive mounting surface
Convection cooled, no heatsink
±9A
Fan cooled, 400 ft/min, no heatsink
±13A
At 190VDC, ±13A, fan-cooled with heatsink
50°C max. ambient
LOAD INDUCTANCE
Selectable with components on header socket
0.2mH to 40mH (Consult factory for higher inductances)
BANDWIDTH
Small signal
-3dB @ 2.5kHz with 200µH load
PWM SWITCHING FREQUENCY
25kHz
INPUT CHARACTERISTICS
Reference
Tachometer
Maximum tachometer voltage
Differential, 20KΩ between inputs
Single-ended, 33KΩ minimum with no header components installed
±100V
GAINS
Input differential amplifier
Servo preamplifier
Integrator
PWM transconductance stage
x1 to x.02 (Potentiometer adjustable)
x1 to x52 (Potentiometer adjustable, with RH3, RH4 not installed )
x1 (at f >> integrator break frequency)
4A/V
POTENTIOMETERS
Reference gain, Tachometer gain, Balance
Preamp gain, Preamp integrator break frequency
LOGIC INPUTS
/Enable, /Forward Enable, /Reverse Enable, /Reset (Ground = enabled, +5V or open inhibits)
Internal jumper inverts logic of /Enable only, so that +5V enables & ground inhibits
LOGIC OUTPUTS
/Normal ( +Fault )
LO (current sinking) when unit operating normally. 2mA maximum, +5V maximum ratings
Note: Do not connect output to devices that operate at voltages >+5V.
MONITOR OUTPUT
Current monitor
AUXILIARY POWER OUTPUTS
+5VDC
+15VDC
-15VDC
±6.5V @ ±26A (4A/volt)
30mA (Includes power for Hall sensors)
10mA
-10mA
Note: Total DC power from all auxiliary outputs and Hall outputs not to exceed 200mW
PROTECTIVE FEATURES
Output shorts: output to output, output to ground
Heatplate overtemperature
Power supply voltage too low (Undervoltage)
Power supply voltage too high (Overvoltage)
Latches unit OFF (Reset input resets, ground input for self-reset)
Shutdown at 70°C (Latches unit OFF)
Shutdown at +HV <22VDC (Operation resumes when >22V))
Shutdown at +HV >196VDC (Operation resumes when <196V)
POWER REQUIREMENTS
Model 513: 24-190VDC @ 26A peak , Model 513R: 60-190VDC @ 26A peak
Minimum power consumption
2W
Maximum power consumption
61W @ 12.5A continuous, 232W @ 26A peak
THERMAL REQUIREMENTS
Storage temperature range
Operating temperature range
-30 to +85°C
0 to 70°C baseplate temperature
MECHANICAL
Size
Weight
Amplifier: 4.4 x 7.32 x 1.29" (112 x 186 x 32.7mm), with heatsink: 4.4 x 7.32 x 2.6 (112 x 186 x 66mm)
1.32 lb (0.60 kg.) for 513, 1.48lb (0.67 kg.) for 513R, add 1.35 lb ( 0.61 kg ) for heatsink
CONNECTORS
DC power (J1)
Phoenix: MSTB 2.5/3-ST-5.08;Curtis: PA256 10.16/2
Motor (J2)
Phoenix: MSTB 2.5/5-ST-5.08; Curtis: PA256 10.16/3
Halls (J3)
Housing: Molex 22-01-3077; Terminals (7): Molex 08-50-0114
Signal (J4)
Housing: Molex: 22-01-3167; Terminals (16) Molex 08-50-0114
Note: If using Phoenix, Weidmuller or equivalent connectors, some positions are no-connects. Observe J1 and J2 to see missing pins.
Curtis connectors are delivered with unused contacts removed from connector housing.
MODEL 513, 513R
DC BRUSHLESS SERVO AMPLIFIER (513) WITH RESOLVER OPTION (513R)
RESOLVER OPTION
Reference Signal
The resolver option card installs inside
the case of the 513R. The cover has
cutouts and silkscreens for the
resolver card potentiometers, switches
and connectors.
This is the signal which excites the
rotor of the resolver. It should be
adjusted so that the Sin signal has an
amplitude of 2.0Vrms (5.6V p-p) when
the shaft is rotated to the point of
maximum output. Typical resolvers
have 2:1 ratios from Ref inputs to Sin
or Cos outputs. Thus the reference
signal from the option card will be in
the 4Vrms range in most cases.
Connections
Encoder Emulation
Power for the option card is supplied
by the DC/DC converter on the
amplifier motherboard.
The Hall signals and tachometer
emulator signals from the card
connect to the amplifier via the card
mounting connector. User-accessible
connectors on the card connect to the
resolver, and to the encoder inputs on
an external controller.
Monitor signals are provided to
measure the resolver Reference and
Sine signals. A Sync function is
provided which lets multiple amplifiers
be jumpered together to synchronize
the reference signals to eliminate
interference between them.
The position of the resolver is tracked
by a position-feedback loop in the
resolver integrated circuit. This
position is then converted into a twophase quadrature encoder signal
which can be used by position
controllers.
The electrical resolution of the position
loop is 4096 parts per revolution. Each
of these parts comprises a digital
code, and four codes constitute an
encoder 'line', giving the equivalent of
a 1024 line quadrature encoder.
Note: when using this option the
minimum supply voltage is +60VDC.
Installation
Resolver
Resolvers used must be of the type
using two stators separated by 90°
and a rotating winding that excites the
stators. These typically have 2:1 ratios
of primary ( Reference ) to secondary
( Sin & Cos ). The 1.8 to 4Vrms output
range of the Reference output permits
adjustment of the Sin/Cos signals to
the 2.0Vrms requirement of the option
card.
The 3-10kHz frequency range of the
Reference signal drives a wide range
of resolvers.
Phase adjust switches and a
potentiometer provide adjustments to
zero-out the phase difference between
the reference and Sin signals.
A two section DIP switch sets the
number of motor electrical cycles per
resolver revolution from 1 to 4.
(Consult factory for motors with other
cycles/rev ratios).
Index Signal
A once-per-revolution index signal is
part of the encoder emulation. The
width of this signal may be set to 1/4
or 1/2 of an encoder cycle using the
DIP switch S3.
( 2, 4, 6, or 8 pole motors ) To
accommodate other motors, contact
factory for custom eproms.
Synchronization
When using multiple resolvers in a
motion control system, coupling
between cables can introduce noise
due to the slightly differing frequencies
between oscillators on different
resolver cards. In such a case, the
oscillators can be wired together via a
Sync connector so that all will operate
at the same frequency. Connecting
these inputs via a ‘daisy-chain’ cable
will cause all resolvers to oscillate at
the same frequency.
Tachometer Emulation
A tach signal provided by the resolver
card makes it possible to configure the
drive as a velocity-loop. This is
particularly useful with PLC's with
motion control modules which output
position error signals. Velocity loop
operation frequently improves the
performance of microprocessor
controls which derive velocity
information from the encoder signal.
Scaling potentiometers on both the
resolver card and amplifier permit the
user to set the RPM/volt factor over a
wide range.
ENCODER SIGNALS
Cabling
CHAN A
CHAN B
1/4096 REV
1/1024 REV
INDEX
1/4 LINE
1 LINE =
4 QUADRATURE
COUNTS
1/2 LINE
Commutation
An eprom chip converts the binary
output from the resolver converter into
Hall signals for commutation. These
connect to the amplifier Hall inputs
internally to operate the motor in sixstep ( trapezoidal ) mode.
The standard eprom will drive motors
having 1,2,3, or 4 Hall cycles per
mechanical revolution of the motor
Shielded cable should be used for
connection to the resolver, and
grounded at the amplifier. The motor
case should also be grounded. This
will minimize coupling between the
motor windings and the resolver.
MODEL 513, 513R
DC BRUSHLESS SERVO AMPLIFIER (513) WITH RESOLVER OPTION (513R)
RESOLVER OPTION SPECIFICATIONS
REFERENCE OUTPUT
Frequency
Amplitude
3 to 10kHz
1.8 to 4.0 VRMS, 50mA RMS max
ENCODER EMULATION
Outputs
Accuracy
Resolution
Bandwidth
Max. speed
Index output
Ch. A,B, and Index, differential line driver (+5V CMOS, 24mA source/sink)
±10.6 arc mins. ±1 lsb (±1/2 encoder cycle ±1 lsb)
1024 lines/rev (4096 quadrature counts), non-adjustable
700 Hz. min.
375 resolver cycles/sec max (1.5M quadrature counts/sec)
Index width settable to 1/4, or 1/2 encoder cycle (1/1024 rev)
TACHOMETER OUTPUT
Connects to amplifier tachometer input internally. Tach voltage can be monitored at amplifier J4-11.
Output voltage range ±4V. Tach Gain pots on option card and amplifier interract. Adjust so that tach voltage does not
exceed the ±4V range, or clipping may occur.
POTENTIOMETERS
Reference frequency, reference amplitude, sin-ref phase adjust, tach gain
DIP SWITCHES
Sin/reference phase adjust (2 switches), motor electrical cycles (2 switches), index width (1 switch)
CONNECTORS
Sync (J5): Housing: Molex 22-01-2027, Terminals (2) Molex 08-50-0114
Encoder (J6): Housing: Molex 22-01-2077, Terminals (7): Molex 08-50-0114
Resolver (J7): Housing: Molex 22-01-2087; Terminals (8): Molex 08-50-0114
Monitor (J8): Housing Molex 22-01-2037, Terminals (3) Molex 08-50-0114
HALL OUTPUTS
U,V,W commutation signals, 120° phasing, internally connected to amplifier
MONITOR OUTPUTS
Ref & Sin signals. Used to measure amplitude, and to adjust phasing between Sin and Ref signals
SYNCHRONIZATION
Jumper resolver cards together to synchronize excitation oscillators
Oscillators will sync to lowest frequency when adjusted within ±1%.
DIP SWITCHES
S1, S2 Sin/ref phase adjust. Range will vary with frequency. Adjust so that pot can set Sin/Ref phase difference to zero°.
S3
Index pulse width; sets index pulse to 1/4096 or 1/2048 revolution (1/4 or 1/2 encoder line)
S4, S5 Motor electrical cycles per revolution setting. Standard choices are 1, 2, 3, or 4 cycles per revolution.
Other options possible, consult factory.
TYPICAL CONNECTIONS
RESOLVER OPTION (513R)
ENCODER
AMPLIFIER (513)
REF+
9
REF-
8
+18V, GND
J4
J6
HALL U
7
U
V
H
W
+5
GND
HALLS
HALL V
6
HALL W
5
4
1
2
3
4
5
6
CHAN A
7
GND
TACH
1
2
1
3
J7
5
/NEG ENABLE
4
/POS ENABLE
3
GROUND
1
TO CONTROLLER
ENCODER INPUTS
RESOLVER
J3
3
/ENABLE
CHAN /A
CHAN B
CHAN /B
INDEX
/INDEX
J4
4
5
6
7
8
SIN (+)
SIN (-)
COS (+)
COS (-)
SHIELD
REF OUT
REF RET
SHIELD
RESOLVER
R
GROUND MOTOR
CASE & USE
SHIELDED CABLE
FOR RESOLVER
MONITOR AND SYNC PINOUTS NOT SHOWN
DC POWER SUPPLY
AC
+
U
1
1
J1
2
AC
J2
LINE ISOLATED
2
V
W
3
M
NOTE: MOTOR PHASE CONNECTIONS MAY VARY
MODEL 513, 513R
DC BRUSHLESS SERVO AMPLIFIER (513) WITH RESOLVER OPTION (513R)
OUTLINE DIMENSIONS
Dimensions in inches (mm.)
ORDERING GUIDE
Model 513
Model 513R
13A Continuous, 26A Peak DC Brushless Servo Amplifier
Model 513 with Resolver option
Notes:
1. For custom configurations such as potentiometer replacement with fixed resistors, non-standard
component header parts, etc. please consult factory.
2. For heatsink add "H" to part number.
OTHER BRUSHLESS AMPLIFIERS
Model 503
Torque mode brushless amplifier. 5A continuous, 10A peak, 18-55VDC operation.
Model 505
NEW! Same power output as 503. Adds Hall / Encoder tachometer for velocity loop operation.
5001 Series
NEW! Six models covering +24 to +225VDC operation, 5-15A continuous, 10-30A peak.
With optional Hall / Encoder tachometer, and brushless tachometer features.
Corporate Office, USA
20 Dan Road
Canton, MA 02021
Tel:781-828-8090
Fax: 781-828-6547
Visit us on the web @ www.copleycontrols.com
Rev 05, 11/96
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