Cedrat Technologies CSA96 User manual

CEDRAT TECHNOLOGIES www.cedrat-technologies.com
59, Chemin du vieux chêne - Inovallée [email protected]
F-38246 MEYLAN Cedex Phone: [phone]
FRANCE Fax: [phone]
CSA96
CURRENT SWITCHING AMPLIFIER
Version : 1.0
Date: 08/09/2016

CURRENT SWITCHING AMPLIFIER
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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
CAUTION: READ BEFORE OPENING
For safety purposes these instructions must be read before use of this product.
This power amplifier is dedicated to magnetic actuators.
Only qualified personnel should work on or around this equipment
and only after becoming
thoroughly familiar with all warnings, safety notices, and procedures contained herein.
The successful and safe operation of this equipment is dependent on proper handling,
installation and operation.
A "qualified person" is one who
is familiar with the installation, construction and operation of
the equipment and the hazards involved. In addition, he/she has the following qualifications :
is trained and authorized to energize, de-
energize, clean, and ground equipment in accordance
with established practices,
is trained in the proper care and use of protective equipment in
accordance with established safety practices.

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
Table of contents
1. DESCRIPTION ........................................... 5
2. MAIN FEATURES ......................................... 5
3. APPLICATIONS .......................................... 6
4. INTENDED USE .......................................... 6
5. ELECTRICAL SAFETY INFORMATION ........................... 6
6. INFORMATION ON DISPOSAL FOR USERS OF WASTE ELECTRICAL &
ELECTRONIC EQUIPMENT (PRIVATE HOUSEHOLDS) ................. 8
7. INTERFACES............................................ 9
7.1. FRONT SIDE ................................................ 9
7.2. CONTROL PORT ............................................ 10
7.3. OPTOCOUPLERS ............................................ 11
7.4. TOP SIDE – POWER SUPPLY TERMINAL ............................ 13
7.5. BOTTOM SIDE – ACTUATOR TERMINALS ........................... 15
7.6. WIRING .................................................. 16
8. THEORY OF OPERATION................................... 18
8.1. PRINCIPLE ................................................ 18
8.2. AMPLIFIER EFFICIENCY AND COOLING............................. 19
8.3. LIMITATIONS AND PROTECTIONS ................................ 20
8.3.1. Current limitation ................................................................ 20
8.3.2. Energy recovery ................................................................. 20
8.3.3. Rheostatic braking ............................................................... 20
8.3.4. Buffer capacitor extension .......................................................... 21
8.3.5. Protections .................................................................... 22
9. MAIN VOLTAGE CONNEXIONS ............................... 22

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9.1.1. Circuit breaker .................................................................. 22
10. OPERATING INSTRUCTION FOR THE AMPLIFIER .................. 23
10.1. GENERAL INSTRUCTIONS ...................................... 23
TROUBLESHOOTING ......................................... 24
WARRANTY CONDITIONS AND EXCEPTIONS ........................ 25
INSPECTION UPON RECEIPT ................................... 26
AFTER-SALES SERVICE ....................................... 27
APPENDIX 1 : CSA96 TECHNICAL DATA SHEET ...................... 28
APPENDIX 2 : TROUBLESHOOTING FORM .......................... 31

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
1. DESCRIPTION
The CSA96 consists in a powerful and compact current switching amplifier designed to drive magnetic
actuators. It includes a power supply and as options, the possibility to connect an external power supply to
drive more voltage or a control board dedicated to advanced control of actuators (position control, velocity
control, etc.).
The external dimensions of the CSA96 are the following:
CSA96
Width : 140 mm
Length : 210 mm
Height : 59 mm
In case of optional controller, the height is 71mm.
2. MAIN FEATURES
CSA96 Included Power Supply External Power Supply
Option IS ES
Voltage 96V 200V
Current 20A 20A
Apparent Power 1920VA 4000VA
Active Power <660W 4kW max
Efficiency typ. (amplifier) 96% 96%
Efficiency typ. (supply) 93.5% -
Switching frequency 50kHz 50kHz
The CSA96-IS is characterized by an integrated power supply 110/230Vac to 96V – 660W.
Fully isolated from ground. (4.2kV between primary and secondary)
Power Factor Correction.

CURRENT SWITCHING AM
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
High apparent and active power output.
Compact.
3.
APPLICATIONS
Control
of large bipolar magnetic actuators.

High magnetic field generation.
4.
INTENDED USE
The CSA96 is intended to be use
d
5.
ELECTRICAL SAFETY IN
The following safety symbol is used in this manual
Warning
For you own safety and for your system security, be sure to carefully respect that
information.
In order to achieve a safe operation of the
information is intended to protect the user and the product and allows safe operating of the product.
The product includes two earth connections, one is intended to connect the driver to the earth, and t
is to connect the actuator to the earth.
Warning
Since the package is fully metallic, you need to connect the driver to the earth for
the user to be safe.
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
High apparent and active power output.
APPLICATIONS
of large bipolar magnetic actuators.
High magnetic field generation.
INTENDED USE
d
in electrical cabinets.
ELECTRICAL SAFETY IN
FORMATION
The following safety symbol is used in this manual
.
For you own safety and for your system security, be sure to carefully respect that
information.
In order to achieve a safe operation of the
CSA96-12
driver, some safety information must be given. This
information is intended to protect the user and the product and allows safe operating of the product.
The product includes two earth connections, one is intended to connect the driver to the earth, and t
is to connect the actuator to the earth.
Since the package is fully metallic, you need to connect the driver to the earth for
the user to be safe.
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FORMATION
For you own safety and for your system security, be sure to carefully respect that
driver, some safety information must be given. This
information is intended to protect the user and the product and allows safe operating of the product.
The product includes two earth connections, one is intended to connect the driver to the earth, and t
he other
Since the package is fully metallic, you need to connect the driver to the earth for

CURRENT SWITCHING AM
CEDRAT TECHNOLOGIES
Only qualified personnel can
install the
12.
Danger
Do not open the product during or after use, lethal voltages may be present even
after the product has been turned off.
A qualified person is a person who is entitled to p
Danger
This device
qualified personnel. Do not operate the device when there are exposed
conductors. Parts of the circuit may store charge so precautions must also be
taken when the device is not powered.
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
install the
CSA96-12
. Only Cedrat Technologies can open or
Do not open the product during or after use, lethal voltages may be present even
after the product has been turned off.
A qualified person is a person who is entitled to p
erform near electric endanger.
This device
produces hazardous potentials and should be used by suitably
qualified personnel. Do not operate the device when there are exposed
conductors. Parts of the circuit may store charge so precautions must also be
taken when the device is not powered.
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. Only Cedrat Technologies can open or
repair the CSA96-
Do not open the product during or after use, lethal voltages may be present even
erform near electric endanger.
produces hazardous potentials and should be used by suitably
qualified personnel. Do not operate the device when there are exposed
conductors. Parts of the circuit may store charge so precautions must also be

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6. INFORMATION ON DISPOSAL FOR USERS OF
WASTE ELECTRICAL & ELECTRONIC
EQUIPMENT (PRIVATE HOUSEHOLDS)
This symbol on the product(s) and / or accompanying documents means that used electrical and
electronic products should not be mixed with general household waste. For proper treatment, recovery and
recycling, please take this product(s) to designated collection points where it will be accepted free of charge.
Alternatively, in some countries you may be able to return your products to your local retailer upon purchase
of an equivalent new product.
Disposing of this product correctly will help save valuable resources and prevent any potential negative
effects on human health and the environment, which could otherwise arise from inappropriate waste
handling.
Please contact your local authority for further details of your nearest designated collection point.
Penalties may be applicable for incorrect disposal of this waste, in accordance with you national legislation.
For business users in the European Union:
If you wish to discard electrical and electronic equipment, please contact your dealer or supplier for further
information.
Information on Disposal in other Countries outside the European Union
This symbol is only valid in the European Union. If you wish to discard this product please contact your local
authorities or dealer and ask for the correct method of disposal.

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
7. INTERFACES
7.1.FRONT SIDE

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
Figure 1. Front side of the CSA96-12 with optional controller
Reference Designation
1
st
mo
dule
Current Switching Amplifier
-
CSA96
Power ON
LED (green)
–
This diode lights when the product
is connected to a power source
.
Output ON
LED (green)
–
This diode lights when the product is enabled.
Power Error
LED (red)
–
This diode lights when the
product is in fault state.
COM1
Connector SUBD9
-
M
–
This port is reserved.
Control Port
Connector SUBD9
-
F
–
Control Port.
2
nd
module
Controller Board (TBD)
ECS
Input connector for an Eddy’s Current Sensor from Cedrat Technologies.
Analog I/O
TBD
Ctrl Error
LED (red)
–
This diode lights when the controller board is in fault state.
USB
USB port.
Digital I/O
TBD
Table 1. Electrical interface assignments.
7.2.CONTROL PORT
Figure 2. Internal schematic of the Control Port.
Pin
Number Signal I/O Isolation Type Function

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Pin
Number Signal I/O Isolation Type Function
1 Enable+ Input Yes Digital Positive (Anode) of the enable optocoupler.
6 Enable- Input Yes Digital Negative (Cathode) of the enable optocoupler.
2 Fault+ Output Yes Digital Collector of the fault optocoupler.
7 Fault- Output Yes Digital Emitter of the fault optocoupler.
3 GND No
8 Imeas Output No Analog Output current sensing (offset = 2.5V, sensitivity :
56mV/A)
4 In+ Input No Analog Positive order input.
9 In- Input No Analog Negative order input.
5 GND No
Table 2. Control port pin assignements.
Note: Isolated signals can withstand 200Vrms from ground. Non-isolated signals are referenced to GND.
The order is differential to increase immunity against common mode noise.
ܱݎ݀݁ݎ=ܫ݊ା−ܫ݊ି
7.3.OPTOCOUPLERS
The series resistance of the enable optocoupler (Figure 2) has been set to allow enabling the amplifier with
a digital voltage of 5V without adding any component. In this case, the current needed is 12mA. A digital
command with a higher voltage is possible but needs the use of a higher series resistance which has to be
implemented externally. The optocoupler is AC-input and contains actually two light emitting diodes
connected inversely parallel and are optically coupled to a phototransistor (Figure 3). These diodes can also
be directly driven by current. The recommended current value is 10mA. The internal resistance is 330R as
shown on Figure 2.

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
Figure 3. Internal diagram of the ACPL-214 optocoupler with its two diodes.
The breakdown voltage of the transistor side is 80V (collector-emitter), the emitter-collector breakdown
voltage is 7V.
Figure 4. Inverting and non inverting proposed connection at the user side.

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
7.4.TOP SIDE – POWER SUPPLY TERMINAL
L E N Vb- Vb+ B+ B-
Table 3. Pin out of the power supply connector.
L
Line AC input (110/230Vac)
E
Earth
N
Neutral AC input (110/230Vac)
V
-
Negative voltage bus
V+
Positive voltage bus
B
-
Braking potential
B+
Braking potential (internally tied to
Vb+)
Table 4. Full description of the power supply connector.

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CEDRAT TECHNOLOGIES
Danger
This connector supports potential lethal voltage. Never connect/disconnect one of
these pins while the power source is
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
This connector supports potential lethal voltage. Never connect/disconnect one of
these pins while the power source is
on.
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This connector supports potential lethal voltage. Never connect/disconnect one of

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7.5.BOTTOM SIDE – ACTUATOR TERMINALS
Figure 5. Top left hand corner of the bottom side of the CSA96.
Actuator terminal
Earth Vo+ Vo-
Table 5. Pin out of the 48Vdc Fan connector and the actuator (output) connector.
Connect the magnetic actuator on this terminal. Do not connect any capacitance or capacitive actuator on
this terminal.

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CEDRAT TECHNOLOGIES
Danger
This connector supports potential lethal voltage. Neve
these pins while the power source is on.
7.6.WIRING
Figure
Note 1: The DC power supply must be connected to Phase and Neutral to supply the inte
supply of the product.
Note 2: The product allows the use of a minimum DC voltage of 36Vdc.
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
This connector supports potential lethal voltage. Neve
r connect/disconnect one of
these pins while the power source is on.
Figure
6
. Wiring of the external power supply version of the CSA96
Note 1: The DC power supply must be connected to Phase and Neutral to supply the inte
Note 2: The product allows the use of a minimum DC voltage of 36Vdc.
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r connect/disconnect one of
. Wiring of the external power supply version of the CSA96
Note 1: The DC power supply must be connected to Phase and Neutral to supply the inte
rnal, auxiliary power

CURRENT SWITCHING AM
CEDRAT TECHNOLOGIES
Figure
The recommended wire gauge for the power cable is
It is highly recommended to use shielded cable to reduce EM perturbations.
Also, it is highly recommended to use a shielded cable for the Control Port connection.
Keep all wires and cables as short as possible.
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
Figure
7
Wiring of the internal power supply version of the CSA96
The recommended wire gauge for the power cable is
14AWG
with a nominal section of
It is highly recommended to use shielded cable to reduce EM perturbations.
Also, it is highly recommended to use a shielded cable for the Control Port connection.
Keep all wires and cables as short as possible.
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Wiring of the internal power supply version of the CSA96
with a nominal section of
2.1mm².
Also, it is highly recommended to use a shielded cable for the Control Port connection.

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Warning
A circuit breaker
voltage.
Warning
It is strictly forbidden to connect the electrical output channels of several CSA96
in parallel.
Danger
This product contains components with lethal voltage, it is strictly forbidden for
the user to remove the boards from the case and to disconnect the load when
electrically powered.
8.
THEORY OF OPERATION
8.1.PRINCIPLE
The switching electronic CSA96
is dedicated to supply and control magnetic actuators. The
a power supply with a maximal power given in the attached technical data sheet.
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
A circuit breaker
must
be added to connect/disconnect the driver from main
It is strictly forbidden to connect the electrical output channels of several CSA96
This product contains components with lethal voltage, it is strictly forbidden for
the user to remove the boards from the case and to disconnect the load when
electrically powered.
THEORY OF OPERATION
is dedicated to supply and control magnetic actuators. The
a power supply with a maximal power given in the attached technical data sheet.
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be added to connect/disconnect the driver from main
It is strictly forbidden to connect the electrical output channels of several CSA96
This product contains components with lethal voltage, it is strictly forbidden for
the user to remove the boards from the case and to disconnect the load when
is dedicated to supply and control magnetic actuators. The
CSA96 includes
a power supply with a maximal power given in the attached technical data sheet.

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CEDRAT TECHNOLOGIES
The switching amplifier is built
frequency of the transistors is 25 kHz. The effective switching frequ
Warning
The output connections are floating. The amplifier is only intended to
magnetic actuator
the outputs of the CSA96
8.2.
AMPLIFIER EFFICIENCY
For the internal supply version, the maximum power losses of the am
are 40W (amplifier) and 48W (power supply). With the thermal resistance of the base plate of about
0.375K/W, the temperature difference would be low enough (33°C) to not use a heat sink and a fan
permitting a substanti
al cost reduction.
For the external supply version, the maximum power losses are 80W due to the increase of the input voltage
to 200Vdc. In this case, a heat sink may be needed
Nonetheless, the amplifier and the internal power supply are protected against
A recommended heat sink is the SK 42 (Fischer Electronik) with 150 mm x 200mm dimensions. It can be
cut to fit the dimensions of the product.
CURRENT SWITCHING AM
PLIFIER
Current Switching Amplifier
Figure 8 – Output stage principle.
The switching amplifier is built
around full bridge PWM technology for high efficiency. The switching
frequency of the transistors is 25 kHz. The effective switching frequ
ency on the actuator is 50 kHz.
The output connections are floating. The amplifier is only intended to
magnetic actuator
s
. Connecting capacitive actuators (such as piezo
the outputs of the CSA96
will
lead to the destruction of the amplifier.
AMPLIFIER EFFICIENCY
AND COOLING
For the internal supply version, the maximum power losses of the am
plifier and the internal power supply
are 40W (amplifier) and 48W (power supply). With the thermal resistance of the base plate of about
0.375K/W, the temperature difference would be low enough (33°C) to not use a heat sink and a fan
al cost reduction.
For the external supply version, the maximum power losses are 80W due to the increase of the input voltage
to 200Vdc. In this case, a heat sink may be needed
Nonetheless, the amplifier and the internal power supply are protected against
over temperature.
A recommended heat sink is the SK 42 (Fischer Electronik) with 150 mm x 200mm dimensions. It can be
cut to fit the dimensions of the product.
Contact Cedrat Technologies for more information.
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around full bridge PWM technology for high efficiency. The switching
ency on the actuator is 50 kHz.
The output connections are floating. The amplifier is only intended to
drive
. Connecting capacitive actuators (such as piezo
-actuators) on
lead to the destruction of the amplifier.
plifier and the internal power supply
are 40W (amplifier) and 48W (power supply). With the thermal resistance of the base plate of about
0.375K/W, the temperature difference would be low enough (33°C) to not use a heat sink and a fan
For the external supply version, the maximum power losses are 80W due to the increase of the input voltage
over temperature.
A recommended heat sink is the SK 42 (Fischer Electronik) with 150 mm x 200mm dimensions. It can be
Contact Cedrat Technologies for more information.

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CEDRAT TECHNOLOGIES Current Switching Amplifier 08/09/2016
8.3.LIMITATIONS AND PROTECTIONS
8.3.1.Current limitation
An onboard current limitation is implemented to stay below the maximum output current. The default
limitation is tuned to 20A.
8.3.2.Energy recovery
The switching amplifier is well suited to drive reactive load. In this case, the switching amplifier doesn’t
consume the reactive power but only the active power of the actuator plus the losses in the power switching
functions.
Example:
A CSA96 providing 20A at 200Vpp with a sinus waveform (1kVA) to an ideal inductor consumes less than
40W due only to the power components losses of the amplifier. If the inductor is non-ideal, the amplifier will
also deliver the active power (RI²). This active power cannot be higher than the maximum power of the
power supply (600W).
8.3.3.Rheostatic braking
This amplifier includes energy recovery capability which is useful to recover the energy stored in electrical
element such as inductance of magnetic actuators and the mechanical energy.
The following equations allow computing the theoretical kinetic energy (frictions are neglected). This energy
will tell you the need for a rheostat:
ܧ௞= ∆ݔܨ=ܹ
ܧ௟=
1
2ܮܫଶ
Where Δx is half of the full course, F is the maximum force. If this energy is less than 3.5J, there no need for
a rheostat.
Example:
For a MICA200, Δx = 2mm and F = 200N.
ܧ௞= 2݉݉ × 200ܰ= 0.4ܬ
ܧ௟= 0.5 × 6݉ܪ× 20ܣଶ= 1.2ܬ