artisan GA4569EPA User manual

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TABLE OF CONTENTS
Page
CHAPTER ONE: INTRODUCTION
1.1 Introduction to the GA4569EPA Manual......................................................4
CHAPTER TWO: DESCRIPTION AND INTRODUCTION
2.1 Description of the GA4569EPA ..................................................................5
2.2 Available Options and Model Numbering ....................................................5
2.2.1 Signal Input .....................................................................................5
2.2.2 Velocity-Mode or Current-Mode Options............................................5
2.2.3 Velocity-Taper Current-Mode Options ...............................................5
2.2.4 + and -Limits..................................................................................5
2.2.5 Total Inhibit......................................................................................6
2.2.6 Model Numbering.............................................................................6
2.3 Protection Circuits.....................................................................................7
2.3.1 Drive Inhibit Indicator Operation (Red LED) .......................................7
2.3.2 Low-Speed electronic Circuit Breaker (Red LED) ...............................8
2.3.3 High-Speed Electronic Circuit Breaker (Red LED)..............................8
2.3.4 Temp Indicator Operation (Red LED) ................................................8
2.3.5 Power Supply Monitor ......................................................................8
2.3.6 DC Buss Voltage Regen’ Clamp and Resistor....................................8
2.3.7 Velocity-Taper Current Limit .............................................................8
2.4 Specifications............................................................................................9
2.4.1 Output Power ..................................................................................9
2.4.2 Input Power ....................................................................................9
2.4.3 Signal Inputs..................................................................................10
2.4.4 Other Inputs and Outputs ...............................................................10
2.4.5 Other Specifications.......................................................................10
2.4.6 Mechanical (Also see Appendix B4-B6) ...........................................10
2.4.7 Typical Factory Settings.................................................................10
CHAPTER THREE: PERSONALITY PREAMP CARD
3.1 Introduction to the Personality Preamp Card.............................................11
3.1.1 Velocity -Mode Personality Preamp Card........................................11
3.1.2 Current-Mode Personality Preamp Card..........................................11
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CHAPTER THREE: PERSONALITY PREAMP CARD -Cont.
3.2 Description of Options and Adjustments....................................................11
3.2.1 Potentiometer Adjustments .............................................................11
3.2.2 Input and Output Signals.................................................................13
3.3 Removal and Installation..........................................................................13
3.4 Troubleshooting with the Personality Preamp Card....................................13
CHAPTER FOUR: THEORY OF OPERATION
4.1 Introduction to Theory of Operation...........................................................14
4.2 Operation of Output Switching Transistors.................................................14
4.3 “H Type” Output Switching Transistors......................................................15
4.4 Pulse Width Modulation (PWM.................................................................15
4.5 Current-Loop Operation...........................................................................17
4.6 Velocity-Loop Operation...........................................................................17
CHAPTER FIVE: INSTALLATION PROCEDURE
5.1 Mounting.................................................................................................18
5.2 Wiring Size and Proper Technique............................................................18
5.3 Baseplate Connections ............................................................................19
5.3.1 120 VAC 50/60 Hz for Fan(s) ..........................................................19
5.3.2 Input From Secondary of Power Transformer ...................................19
5.4 Amplifier Connections and Functions ........................................................19
5.4.1 DC Buss........................................................................................19
5.4.2 Motor.............................................................................................19
5.4.3 Signal Input....................................................................................20
5.4.4 Tachometer Input ...........................................................................20
5.4.5 Current Sense................................................................................20
5.4.6 + and -Limits.................................................................................20
5.4.7 Total Inhibit....................................................................................20
5.4.8 Fault Monitor..................................................................................20
5.4.9 External Fault-Latch Reset..............................................................21
CHAPTER SIX: START UP AND ADJUSTMENT PROCEDURE
6.1 Safety Precautions...................................................................................22
6.2 Amplifier Alignment Introduction...............................................................22
6.3 Velocity –Loop Phasing............................................................................22
6.4 Tach-Gain Adjustment .............................................................................23
6.5 Connecting Amplifier to Digital Position Loop.............................................25
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CHAPTER SEVEN: MAINTENANCE, REPAIR AND WARRANTY
7.1 Maintenance...........................................................................................27
7.2 Repair....................................................................................................27
7.2.1 Fault Tracing .................................................................................27
7.2.2 Fault Tracing Charts……………………………………………………….27
7.2.3 Part Replacement………………………………………………………….28
7.2.4 Over-Temperature Shutdown…………………………………………….28
7.2.5 Low-Speed Electronic Circuit Breaker (LS/ECB) Shutdown………… .29
7.2.6 High-Speed Electronic Circuit Breaker (HS/ECB) Shutdown……… ...29
7.3 Factory Repair……………………………………………………………………..29
7.4 Warranty…………………………………………………………………………… 30
APPENDIX A: FAULT TRACING CHARTS....................................31
Fault Chart 1 Motor does not turn in either direction……………………………… 32
Fault Chart 2 Motor only turns in one direction...............................................33
Fault Chart 3 Motor does not develop maximum output speed ........................34
Fault Chart 4 Motor does not develop maximum torque..................................35
Fault chart 5 Motor wanders and hunts or does not track smoothly..................36
Engineering Notes for Fault Tracing Charts .....................................................37
APPENDIX B: AMPLIFIER DRAWINGS........................................38
Installation Schematic GA4569EPA (4569-3400) ...........................................39
Control Board Assembly GA4569EPA (4569-3401).........................................40
Installation Diagram GA4569EPA-1A-1 (4569-3408) .......................................41
Installation Diagram GA4569EPA-2A-2 (4569-3402) .......................................42
Installation Diagram GA4569EPA-4A-4 (4569-3404) .......................................43
Installation Diagram GA4569EPA-6A-6 (4569-3406) .......................................44
APPENDIX C: PERSONALITY PREAMP.......................................45
Schematic Velocity-Mode Personality Preamp (4597-7010).............................46
Assembly Velocity-Mode Personality Preamp (4597-7012) .............................47
Schematic Current-Mode Personality Preamp (4597-5110)..............................48
Assembly Current-Mode Personality Preamp (4597-5112)..............................49
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CHAPTER ONE: INTRODUCTION
1.1 INTRODUCTION TO THE GA4569EPA MANUAL:
This manual is intended for use with Glentek’s TORQUE-SWITCHseries, model
GA4569EPA, pulse-width modulated (PWM), servo amplifiers. It provides all of the information
that is required for installation, alignment, and maintenance of the GA4569EPA. We suggest
that you take the time to read this manual from cover to cover before trying to work with a
GA4569EPA amplifier. If you have any questions that you cannot find the answer to in this
manual, please feel free to call and discuss your problem or question with a Glentek
applications engineer. Having been in the servo system business for over 35 years, we have a
vast pool of applications knowledge waiting to help you.
Thank you for using Glentek’s products. It is our goal to save you money, time, and provide
you with a superior product.
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APPENDIX C
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CHAPTER 2: DESCRIPTION
CHAPTER TWO: DESCRIPTION
2.1 DESCRIPTION OF THE GA4569EPA:
The GA4569EPA is modular, high power, high bandwidth, PWM, servo amplifier designed
for use with DC, permanent-magnet, servo motors. The GA4569EPA utilizes today’s latest
technology in power semiconductors for high efficiency, which in turn makes the amplifiers
extremely reliable in today and tomorrow’s demanding applications.
2.2 AVAILABLE OPTIONS AND MODEL NUMBERING INFORMATION:
2.2.1 SIGNAL INPUT: The GA4569EPA has two signal inputs: one single-ended and one
differential. The differential input is marked Aux., and Aux. Ret., and may be connected single-
ended by grounding Aux. Ret. (Refer to Appendix C, drawings 4597-7010 or 4597-5110).
2.2.2 VELOCITY-MODE OR CURRENT-MODE OPTIONS: The GA4569EPA is most often
used to close a critically-damped velocity-loop using a DC tachometer for velocity feedback.
However, this high-gain, summing amplifier can be bypassed to provide an input directly to the
current-loop amplifier. (Refer to Appendix C, drawings 4597-7010 & 4597-7012).
If the amplifier is ordered with the current mode option, the dedicated Current Mode
Personality Preamp Card will be used. (Refer to Appendix C, drawings 4597-5110 & 4597-5112)
2.2.3 VELOCITY-TAPER CURRENT-LIMIT OPTION: The Velocity-Taper Current-Limit
(VTCL) option limits the maximum available motor current in proportion to the motor RPM.
This protects the motor and amplifier from commutator arcing at high RPM. Refer to section
2.3.7 for additional information. Consult a Glentek applications engineer to optimize the VTCL to
your application.
2.2.4 + AND -LIMITS: The GA4569EPA may be configured for four different end-of-travel
limit circuits (refer to Appendix B, drawing 4569-3400 for implementation):
Type A: Requires grounding of pin 8 or pin 9 to disable amplifier.
Type B: Requires a positive voltage at pin 8 or pin 9 to disable amplifier.
Type C: Requires grounding of pin 8 or pin 9 to enable amplifier.
Type D: Requires a positive voltage at pin 8 or pin 9 to enable amplifier.
The amplifier is normally shipped with the type A + and -Limit configuration.
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2.2.5 TOTAL INHIBIT: The GA4569EPA may be configured for four different Total Inhibit
circuits (See 2.2.3 + AND -LIMITS above, and refer to drawings 4569-3400). The amplifier is
normally shipped with type “A” Total Inhibit.
2.2.6 MODEL NUMBERING: The following example of a GA4569EPA part number is provided
to help you better understand Glentek’s part-numbering system:
The following is a list of the standard baseplate amplifier combinations.
GA4569EPA-1Single amplifier module.
GA4569EPA-2A-1Two axis chassis with one amplifier module.
GA4569EPA-2A-2Two axis chassis with two amplifier modules.
GA4569EPA-4A-3Four axis chassis with three amplifier modules.
GA4569EPA-4A-4Four axis chassis with four amplifier modules.
GA4569EPA-6A-5Six axis chassis with five amplifier modules.
GA4569EPA-6A-6Six axis chassis with six amplifier modules.
LOGIC-INPUT CONFIGURATION:
There are four logic inputs: + Limit, -Limit, Inhibit, and Fault. The first three may be con-
figured for active-high or active-low signals, and pulled-up or pulled-down termination (type A, B,
C, and D). The fault is always active-low and pulled-up (type A). All the logic inputs on the
GA4569EPA have a + 15 range only.
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APPENDIX C
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Type A: Requires grounding of input to disable the amplifier (pull-up, active-low).
Type B: Requires a positive voltage at input to disable the amplifier (pull-down, active-high).
Type C: Requires grounding of input to enable the amplifier (pull-up, active-high).
Type D: Requires a positive voltage at input to enable the amplifier (pull-down, active-low).
The two digits of the configuration code set amplifier options, such as the inhibit configura-
tion. Most of these options are user-configurable. If you desire Glentek to pre-configure your
amplifier, a configuration code may be constructed as shown below.
When constructing the configuration code, choose the desired configuration for each option
and enter a “0” or a “1“ in the box provided. When all the boxes are filled, convert the 8-digit
number to a 2-digit number using the table provided.
2.3 PROTECTION CIRCUITS:
The following protection circuits are integral to the GA4569EPA amplifier to prevent
damage to the amplifier or your equipment. Again, Glentek is anxious to work with you in
helping to implement any circuit functions your system might require. Note: For sections 2.3.1 to
2.3.6, refer to Appendix B, drawing 4569-3400.
2.3.1 DRIVE INHIBIT INDICATOR OPERATION (RED LED): The Drive Inhibit LED indicator
light (D21) will turn ON and latch for any of the following conditions:
1. Transistor heatsink temperature in excess of 1700F (770C)
2. Low-Speed Electronic Circuit Breaker (LS/ECB) triggered.
3. High-Speed Electronic Circuit Breaker (HS/ECB) triggered.
The Drive-Inhibit indicator light will also turn ON and OFF with the Total-Inhibit input signal
(TB1-10). This is a non-latched condition.
CHAPTER
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DESCRIPTION
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2.3.2 LOW-SPEED ELECTRONIC CIRCUIT BREAKER (RED LED): The LS/ECB LED
indicator light (D24) will turn ON and latch indicating that the Low-Speed Electronic Circuit
Breaker (LS/ECB) has fired. This circuit protects the motor, amplifier, and mechanical system
from damage due to excessive mechanical bind in the system or possibly driving into a hard
mechanical stop. Circuit operation is as follows:
When the motor current exceeds the value set at TP16, typically 2 VDC (scale factor 1
VOLT= 15 AMPS), U9C switches positive and the voltage on C35 begins integrating up. If the
current remains above the set point, typically 1.5 seconds, U9D will trigger the LS/ECB latch
and the Drive Inhibited indicator.
2.3.3 HIGH-SPEED ELECTRONIC CIRCUIT BREAKER (RED LED): The HS/ECB LED
indicator light (D23) will turn ON and latch, indicating that the High-Speed Electronic Circuit
Breaker (HS/ECB) has fired. This circuit protects the amplifier from dead shorts across the
amplifier output terminals. The HS/ECB is always factory set and can not be adjusted. The
typical factory setting is 121 amps for 10 micro-seconds. Again, this circuit triggers the HS/ECB
latch and the Drive-Inhibited indicator.
2.3.4 TEMP INDICATOR OPERATION (RED LED): The Temperature LED indicator light
(D22) will turn ON and latch when the transistor heatsink temperature exceeds 1700F (770C).
This condition will also latch the Drive Inhibited indicator.
2.3.5 POWER SUPPLY MONITOR: The amplifier will automatically shut-down if the on-
board, low-voltage power supplies cannot maintain proper operating voltages. This is a non-
latched condition.
2.3.6 DC BUSS VOLTAGE REGEN’ CLAMP & RESISTOR: These components are mounted
on amplifier module A1. They function to keep DC Buss voltage surges below 170 VDC,
protecting the amplifier and DC Buss capacitor from over-voltage.
2.3.7 VELOCITY-TAPER CURRENT-LIMIT: Motor specifications often include a SOA (Safe
Operating Area) curve which is maximum motor current as a function of RPM (See figure
2.3.7). The optional VTCL (Velocity-Taper Current-Limit) ensures that the maximum available
motor current is within SOA limits. Below maximum, the motor current is still controlled by the
velocity-error (or current-command) signal. The VTCL may decrease the rate of acceleration
and deceleration. Consult a Glentek applications engineer before ordering.
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APPENDIX C
PERSONALITY PREAMP
APPENDIX C
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CHAPTER 2:
DESCRIPTION
2.4 SPECIFICATIONS
The specifications for each GA4569EPA amplifier module are as follows:
2.4.1 OUTPUT POWER
PEAK OUTPUT CURRENT: +/-60ADC
RMS OUTPUT CURRENT: +/-30ADC
OUTPUT VOLTAGE (Typical): +/-60VDC to +/-150VDC
Note: Off-line operation and/or buss voltages to 350VDC are available. Consult Glentek.
Buss voltage should be selected to be 10% to 20% above the maximum voltage re-
quired at the motor terminals for maximum system efficiency.
2.4.2 INPUT POWER:
DC BUSS (Typical): 65VDC to 170VDC
DC BUSS (Maximum): 200VDC (See note above)
A fused, single-or three-phase, full-wave rectifier and filter capacitor are provided on the
baseplate to supply the DC BUSS voltage. The AC input to this circuit is usually supplied by a
separately mounted power transformer unique to the application. The power transformer and
motor output inductors are not standard parts of the amplifier package. Glentek has power
transformers and inductors in stock to meet your system requirements.
INPUT POWER FOR FANS: 120 VAC, 50/60 Hz @ 1 AMP
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