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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2.4.3 SIGNAL INPUTS:
VOLTAGE, MAXIMUM
Aux. Input: ± 13 volts.
Sig. Input and Tach. input: ± 70 volts.
Input impedance, minimum:10K ohms.
GAIN, MAXIMUM
Sig., and Aux., Inputs: 15,000 amps/volt.
Tachometer: 7,000 amps/volt.
Drift (ref., to input), maximum: 0.01 mV/°C.
Frequency response, minimum: 750 Hz.
Dead band: none.
Form factor: 1.01.
2.4.4 OTHER INPUTS AND OUTPUTS
+ and -Limits (type “A”): Activated by a 2mA contact closure to
common.
Total Inhibit (Type “A”): Activated by a 2mA contact closure to
common.
Fault Monitor: Ground on fault. Open collector transistor can
sink 500mA max. Output is pulled up to 15V by
5K ohms.
Ground to Reset Activated by a 15mA contact closure to
common.
+ to Reset Activated by 10 to 15VDC, 1 mA max.
2.4.6 MECHANICAL (SEE APPENDIX B4-B6)
Mounting: Any Position.
Cooling: 1220F (50°C) ambient max.
Baseplate: GA4569EPA-16 lbs.
GA4569EPA-2A-210.5 in. x 14.0 in. x 8in. 26lbs.
GA4569EPA-4A-420.0 in. x 14.0 in. x 8in. 421lbs.
GA4569EPA-6A-627.1 in. x 14.0 in. x 8in. 58lbs.
2.4.6 TYPICAL FACTORY SETTINGS
Sig. and Aux. Gain: 5V(Sig.)/7V(Tach) Comp: CW (mm. bandwidth).
Tach. Gain: 50% LS/ECB: 30A @ 1.5 sec.
Loop Gain: CCW (OFF) HS/ECB: 121A @ 10 micro-sec.
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APPENDIX B
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CHAPTER
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PERSONALITY PREAMP CARD
CHAPTER THREE: PERSONALITY PREAMP CARD
3.1 INTRODUCTION TO THE PERSONALITY PREAMP CARD:
The Personality Preamp card is a modular plug-in card that comes in two versions: velocity
mode and current mode. Schematic and board-assembly prints for these cards are found in
Appendix C, drawing numbers 4597-7010, 4597-7012, 4597-5110, 4597-5112 and will be
referred to in the following description.
The Personality card contains the main high-gain preamp with all associated system
alignment adjustments. This card greatly enhances system trouble shooting and repair. If an
amplifier should fail, simply remove the Personality card (which has all of the original system
constants adjusted in) and replace it on a spare amplifier. This eliminates system realignment
when changing out amplifiers. Also, a motor-tach-load may be aligned at the factory and then
just the Personality card sent to the field for system test.
3.1.1 VELOCITY-MODE PERSONALITY PREAMP CARD: The Velocity-Mode Preamp card
contains the main high-gain preamp with all the associated system alignment adjustments to
close a velocity loop using a D.C. tachometer for velocity feedback (Refer to Appendix C,
drawings 4597-70 10 and 4597-7012).
3.1.2 CURRENT-MODE PERSONALITY PREAMP CARD: The Current-Mode Personality
card contains all the system alignment adjustments to control a current-mode amplifier (Refer to
Appendix C, drawings 4597-5110 and 4597-5112).
3.2 DESCRIPTION OF OPTIONS AND ADJUSTMENTS:
The Personality Preamp card is a small printed-circuit card (2.7” x 2.3”) standing on nine
pins (0.6” long) that mate with appropriate sockets on the amplifier control board.
The Personality card is most often used to close a velocity loop by using a DC tachometer
for velocity feedback. However, the high-gain, summing amplifier can be bypassed providing an
input directly to the current-loop amplifier (Current-Mode option). If the Current-Mode (CM)
option is specified, the committed Current-Mode Personality Preamp card will be supplied.
3.2.1 POTENTIOMETER ADJUSTMENTS: The following is a description of the potentiometer
adjustments used for the two modes of operation. Please refer to Chapter Six on Start Up and
Adjustment Procedures for a detailed description of how to set these potentiometers.
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VELOCITY MODE: (Refer to Appendix C, drawings 4597-7010 and 4597-7012)
R12 -Signal-Gain potentiometer sets the input voltage to output RPM required by your
system for the single-ended input (e.g. 10 volt input = 2000 RPM).
R13 -Auxiliary Signal-Gain potentiometer sets the input voltage to output RPM required by
your system for the differential signal input (e.g. 10 volt input 2000 RPM).
R14 -Tachometer-Gain potentiometer sets the amount of tach’ signal required by your
system. Use in conjunction with the Compensation potentiometer, R16, to adjust the
system bandwidth.
R15 -Balance potentiometer is used to null out any DC offset in the amplifier (e.g. 0 volt input
=0 RPM).
R16 -Compensation potentiometer sets the amount of bandwidth (frequency response)
required by your system. Use in conjunction with the Tachometer-Gain potentiometer,
R14, to adjust the system bandwidth.
R17 -Current-Limit potentiometer sets the maximum acceleration and deceleration current.
R18 -Loop-Gain potentiometer is used to reduce the velocity-loop gain to zero when the
system is first turned on to prevent run away operation. Before turning the system on
for the first time, this potentiometer is set fully CCW to command zero current to the
motor. Once the system is correctly phased this potentiometer is set fully CW for all
further system adjustments.
CURRENT MODE: (Refer to Appendix C, drawings 4597-5110 and 4597-5112)
R14 -Signal-Gain potentiometer sets the input voltage to output current required by your
system for the single-ended input (e.g. 5 volt input = 20 amp output current).
R15 -Auxiliary Signal-Gain potentiometer sets the input voltage to output RPM required by
your system for the differential signal input (e.g. 5 volts input = 20 amps current).
R16 -Current-Limit potentiometer sets the maximum acceleration and deceleration current.
R17 -Loop-Gain potentiometer is factory set to prevent amplifier maximum rated current
from being exceeded when the current-limit potentiometer is fully CW.
R21 -Balance potentiometer is used to null out any DC offset in the amplifier (e.g. 0 volts
input = 0 current output)
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APPENDIX B
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CHAPTER
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PERSONALITY PREAMP CARD
3.2.2 INPUT AND OUTPUT SIGNALS ON PERSONALITY CARD:
Pin No.
1SIGNAL: Single-ended signal input.
2+ 15 VDC: + 15 VDC power.
3-15 VDC: -15 VDC power.
4COMMON: +/-15 VDC and signal common.
5AUXILIARY: + differential signal input.
6AUXILIARY RETURN: -differential signal input.
7OUTPUT: Velocity-error or current-command output.
8CLAMP: Reduces gain of the summing amplifier when
drive isinhibited.
9TACHOMETER: Tachometer signal input.
3.3 REMOVAL AND INSTALLATION:
When removing or installing the Personality Preamp card, care must be taken not to
damage any of the components under the card on the Amplifier Controller board or on the
Personality card.
Removal: Hold the Personality card by its edges and pull straight away from the Amplifier
Controller board (Do not pull on the components). For amplifiers with the Personality card
mounted vertically, remove amplifier module first before unplugging Personality card.
Installation: Hold the Personality card by its edges and carefully align the nine pins with
their mating sockets and push straight toward the amplifier controller board until it is firmly
seated (Do not press on any of the components).
3.4 TROUBLE SHOOTING WITH THE PERSONALITY CARD:
If your system exhibits a problem and a working amplifier module is available, fault tracing
can be expedited by removing the Personality Preamp card from the malfunctioning amplifier,
plugging it into the replacement amplifier, and testing the system. If the system does not work
with the new amplifier module, refer to Chapter Seven on Maintenance and Repair for a more
detailed fault tracing procedure. However, If the system does work with the new amplifier
module, check the malfunctioning unit for loose connections arid retest the suspected unit in the
system to verify the malfunction.
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CHAPTER FOUR: THEORY OF OPERATION
4.1 INTRODUCTION TO THEORY OF OPERATION:
A velocity-mode servo amplifier is essentially comprised of two control loops (see fig. 4.1).
The inside control loop is referred to as the “current loop” and the outside loop is referred
to as the “velocity loop”. Before we begin our analysis of the current loop, let us review some
basic concepts which will help you to better understand the amplifier’s operation.
4.2 OPERATION OF OUTPUT SWITCHING TRANSISTORS:
The output transistors, for all intents and purposes, operate in only two states. They are
analogous to ON/OFF switches. When an output transistor is OFF, there is no current flowing
through it (its resistance is~infinite). When an output transistor is ON, current flows through it (its
resistance is near zero). When the transistor is ON, it is technically referred to as being in
saturation.
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APPENDIX B
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APPENDIX B
AMPLIFIER DRAWINGS
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4.3 “H TYPE” OUTPUT BRIDGE CONFIGURATION:
The output configuration of the amplifier is an “H TYPE” bridge (see fig. 4.2 for schematic
representation of output bridge with motor connected).
The advantage of an “H TYPE” output bridge configuration is that by controlling the
switching of the opposite pairs of transistors, current can be made to flow through the motor in
either direction using a single-polarity power supply as shown in figure 4.2.
To provide motor current in one direction, transistors A and C are turned ON, while B and
D remain in the OFF state. To provide motor current in the other direction, B and D are turned
ON, while A and C remain in the OFF state.
4.4 PULSE-WIDTH-MODULATlON (PWM):
“Pulse-width modulation” is the technique used for switching opposite pairs of output transistors
ON and OFF to control the motor drive current. When zero current is commanded to the current
loop, the opposite pairs of transistors are turned ON and OFF as shown in figure 4.3. Note that
since the pulse widths are equal, the net DC current in the motor is equal to zero.
CHAPTER 4:
THEORY OF OPERATION
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When a non-zero current is commanded to the current loop, the transistor switching
waveform is as shown in figure 4.3A. Since there is a non-zero current command, the output
transistor pulse widths will change and the motor will see a net DC current flowing from A
through C.
If the input to the current loop had been changed in polarity, the output transistor switching
waveform would be as shown in figure 4.3B.
If a larger current of the same polarity was commanded to the output transistors (see fig.
4.3B) the ON-time widths of B and D would automatically increase to provide more current.
From the previous examples it is easy to understand why this output transistor switching
technique is referred to as pulse-width modulation.
To change the magnitude and polarity of the current flow in the motor, the pulse widths of
the opposite pairs of transistors are modulated. The frequency at which these output transistors
are switched ON and OFF is referred to as the ‘carrier frequency’.
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ENGINEERING NOTES FOR FAULT TRACING CHARTS:
NOTE 1: To measure the DC buss voltage, carefully connect a voltmeter
across the bleeder resistor attached to the DC buss filter capacitor. The
proper DC buss voltage for your amplifier is calculated by multiplying the
AC power input voltage on the main DC buss transformer by 1.4 (e.g. For
70 VAC input you should read 70 x 1.4 or approx. 100 VDC buss voltage).
The DC buss voltage will vary depending on if the motor is under a heavy
or light load. The DC buss voltage will sag under heavy loads. This is nor-
mal for unregulated DC power supplies.
NOTE 2: The output voltage to the motor can be checked by alternately
applying a positive and then negative voltage to the signal input and ob-
serving the voltage swing at the amplifier motor output terminals. Keep in
mind that the Loop Gain and Signal potentiometers must be set at least
somewhat CW. This test can be made with motor disconnected from am-
plifier.
NOTE 3: A low, but not zero, DC buss voltage could indicate an open or
defective DC buss filter capacitor. To check capacitor, remove from circuit
and check with an ohmmeter. A visual check of the capacitor port seal
could show a blown pressure seal caused by a failed, overheated capaci-
tor.
APPENDIX A
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CHAPTER 4:
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After realizing how the PWM amplifier output works, it becomes apparent that some induc-
tance must be added to the motor circuit to prevent excessively high AC ripple current and heat-
ing in the servomotor. Consult a Glentek applications engineer for recommended inductance.
Now that we have a good understanding of how the current is provided from an “H TYPE”
pulse-width modulated (PWM) bridge, let’s analyze the operation of the current loop.
4.5 CURRENT-LOOP OPERATION:
Please refer to figure 4.1 for a diagram of the current loop. In control electronics the symbol
Sigma (with the circle around it) is referred to as a “summing junction”. The manner in which this
summing junction operates is as follows:
The current-command signal (also referred to as the velocity-error signal when received
from the output of the velocity loop, as shown in fig. 4.1) is added to the current-feedback signal.
The signal resulting from this addition, is referred to as the “current-error” signal. This current-
error signal is fed into the current amplifier, which in turn produces a current in the motor. A volt-
age which is proportional to the motor current is developed across Rs (shunt resistor). This volt-
age is referred to as the “current-feedback” signal. The current in the motor increases until the
current-feedback signal is exactly equal in magnitude, but opposite in polarity, to the current-
command signal. At this point the current-error signal drops to zero, and the actual current is
equal to the commanded current. If anything happens to disturb either the current-command sig-
nal, or the current-feedback signal, the same process occurs again until the current-feedback
signal is equal in magnitude to the current-command signal, but opposite in polarity.
The type of loop described above is referred to as a “servo loop” because the current ser-
vos about a commanded value.
We are surrounded in our everyday lives by a multitude of servo loops. For example, many
of today’s luxury cars have what is called “automatic climate control”. To operate this servo loop,
you set the climate control to the temperature that you wish to be maintained in the interior of
the car (current-command signal). The selected temperature is then summed with the actual
temperature from a thermometer (current-feedback), and the output (current-error signal) acti-
vates either the heater or the air-conditioner until the actual temperature as measured by the
thermometer (current-feedback signal) is equal in magnitude, but opposite in polarity, to the set
temperature.
4.6 VELOCITY-LOOP OPERATION:
Please refer to figure 4.1 for a diagram of a typical velocity loop. The velocity-loop’s opera-
tional description is analogous to the current-loop description, except for the fact that the input
signal is called the Velocity Command and the feedback signal from the DC tachometer is called
the Velocity Feedback.
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CHAPTER FIVE: INSTALLATION PROCEDURE
5.1 MOUNTING:
The installation diagrams in Appendix B show the bolt hole mounting pattern to support the
amplifier. The mounting holes will accept 1/4 inch bolts. The base material is cadmium
plated, .060-inch-thick steel.
THE MOUNTING BOLTS SHOULD PROVIDE AN ELECTRICAL GROUND FOR THE
CHASSIS TO MINIMIZE SHOCK HAZARD.
The surface that the amplifier package will be mounted on must be able to support its
weight, but does not need to provide ”cold plate” cooling for the amplifier.
Standard 100 CFM muffin fans are mounted on the baseplate to cool the amplifiers. It is
IMPORTANT to allow a minimum of three inches between both the fan side and the module
side (opposite fans) of the amplifier baseplate and the cabinet wall. The distance between
the other two sides and top of the amplifier and the cabinet walls are not critical. However, some
space should be provided for wire routing and terminal strip access.
The amplifier package should be mounted in a clean, dry enclosure with a maximum ambi-
ent temperature of 122°F (50°C). To ensure maximum reliability, keep the amplifier cabinet cool
and free from dust, oil and other contaminates.
NEVER INSTALL THE AMPLIFIER PACKAGE IN ANY LOCATION
WHERE FLAMMABLE OR EXPLOSIVE VAPORS ARE PRESENT
5.2 WIRING SIZE AND PROPER TECHNIQUE:
Please refer to Appendix B, GA4569EPA installation diagrams. These installation diagrams
show the necessary external connections to ensure proper amplifier operation.
Glentek recommends that your wiring be in accordance with all national and local codes
that are applicable to your system. Wire size must be sufficient to accommodate the maximum
continuous current that will be run through it.
Recommended wire sizes for the GA4569EPA are as follows:
MOTOR ARMATURE -12 AWG.
0-105 VAC POWER INPUT (from secondary of power transformer) -10 AWG.
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120 VAC FOR FANS -16 AWG twisted pair.
SIGNAL INPUT -22 AWG mm., 2-conductor, shielded.
TACHOMETER INPUT -22 AWG mm. 2-conductor, shielded. Terminate shield at amplifier
end only, to Tachometer Common, TB1 terminal-strip.
When wiring to-and-from the drive cabinet, it is considered good technique to route the
power lines (16 AWG and larger) along different paths than the signal and tachometer lines.
This minimizes the amount of stray noise pick-up that is injected into the amplifier.
5.3 BASEPLATE CONNECTIONS:
5.3.1 120 VAC 50/60 Hz FOR FAN(S): Connect the 120 VAC to terminals 1 and 2 of terminal
barrier-strip TB201 located on the baseplate.
DO NOT APPLY ANY POWER YET.
5.3.2 INPUT FROM SECONDARY OF POWER TRANSFORMER: The AC voltage that is
used to form the DC buss of the amplifier package, is supplied from a separately mounted trans-
former that has been selected by Glentek for your application. Connect the secondary of the
power transformer to input terminals of fuses F201, F202, and F203.
DO NOT APPLY ANY POWER YET.
5.4 AMPLIFIER CONNECTIONS AND FUNCTIONS:
5.4.1 DC BUSS: The DC buss from the filter capacitor is connected to terminals 1 (+) and 2
(-) of terminal strip TB3. This connection is already made for you on our multi-axis packages.
The power transformer for the DC buss is not a standard part of the amplifier package. Glentek
can advise on transformer specifications required. Most styles and sizes are in stock at
Glentek.
5.4.2 MOTOR: The motor is connected to terminals 3 (-) and 4 (+) of terminal strip TB3 of the
amplifier module. In most cases, if the motor inductance is less than 1 millihenry, an inductor
should be connected in series with the motor leads. The inductor is considered to be a separate
part from the amplifier package. Glentek can advise on the inductor specifications, and most
styles and sizes are in stock at Glentek.
IT IS IMPERATIVE THAT YOU DO NOT USE GROUNDED TEST EQUIPMENT ON
THE MOTOR ARMATURE NOR CONNECT EITHER END OF THE MOTOR ARMATURE
TO SIGNAL GROUND OR DC BUSS RETURN.
CHAPTER
5
:
INSTALLATION PROCEDURE
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