Cedrat Technologies CSA96 User manual

CEDRAT TECHNOLOGIES www.cedrat-technologies.com
59, Chemin du vieux chêne - Inovallée [e-mail]
F-38246 MEYLAN Cedex Phone: [phone]
FRANCE Fax: [phone]
CSA96
CURRENT SWITCHING AMPLIFIER
Version: 1.0.8
Date: 18/12/2017

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CEDRAT TECHNOLOGIES Current Switching Amplifier 18/12/2017
CAUTION: READ BEFORE USE
For safety purposes these instructions must be read before use of this product.
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,
•is trained in the soldering process and wiring of connectors,
•is familiar with the EMC and safety requirements.
To comply with the safety and EMC regulation, the user must install and configure the product
correctly. Qualified person, who is familiar with the EMC and safety requirements, must install the
product and is responsible for ensuring that the end product complies with the relevant laws in
the country, where it is going to be used. Special care should be taken regarding electrical safety
since the product is capable of providing high voltages.

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CEDRAT TECHNOLOGIES Current Switching Amplifier 18/12/2017
Table of contents
1. DESCRIPTION ........................................... 5
2. MAIN FEATURES ......................................... 5
3. INTENDED USE .......................................... 6
4. ELECTRICAL SAFETY INFORMATION ........................... 7
5. INFORMATION ON DISPOSAL FOR USERS OF WASTE ELECTRICAL &
ELECTRONIC EQUIPMENT (PRIVATE HOUSEHOLDS) ................. 9
6. DISCLAIMER........................................... 10
7. INTERFACES........................................... 11
7.1. FRONT SIDE ............................................... 11
7.2. CONTROL PORT ............................................ 11
7.3. COMMUNICATION PORT ....................................... 13
7.3.1. Command list .................................................................. 13
7.4. OPTOCOUPLERS ............................................ 14
7.5. TOP SIDE –POWER SUPPLY TERMINAL ............................ 15
7.6. BOTTOM SIDE –ACTUATOR TERMINALS ........................... 17
7.7. WIRING .................................................. 18
7.7.1. CSA96 Internal Supply version ....................................................... 18
7.7.2. CSA96 External Supply version....................................................... 19
7.7.3. EMC considerations .............................................................. 19
8. THEORY OF OPERATION................................... 20
8.1. PRINCIPLE ................................................ 20
8.2. EFFICIENCY AND COOLING ..................................... 20
8.3. LIMITATIONS AND PROTECTIONS ................................ 21

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CEDRAT TECHNOLOGIES Current Switching Amplifier 18/12/2017
8.3.1. Current limitation ................................................................ 21
8.3.2. Energy recovery ................................................................. 21
8.3.3. Rheostatic braking ............................................................... 22
8.3.4. Buffer capacitor extension .......................................................... 23
8.3.5. Minimum output inductance value .................................................... 24
8.3.6. Protections .................................................................... 24
9. MAIN VOLTAGE CONNEXIONS ............................... 24
9.1. CIRCUIT BREAKER........................................... 24
10. OPERATING INSTRUCTION FOR THE AMPLIFIER .................. 25
10.1. GENERAL INSTRUCTIONS ...................................... 25
TROUBLESHOOTING ......................................... 26
WARRANTY CONDITIONS AND EXCEPTIONS ........................ 27
INSPECTION UPON RECEIPT ................................... 28
AFTER-SALES SERVICE ....................................... 29
APPENDIX 1 : TROUBLESHOOTING FORM .......................... 30

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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,
increasing output voltage and power capability, and 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.
The bottom plate is also a thermal interface used to dissipate the heat of the converter. The packaging also
features side openings for air circulation in order to enhance the heat dissipation.
2. MAIN FEATURES
The CSA96 is available in two versions, the first one features a powerful internal AC/DC converter which allows
to connect directly the amplifier on mains. The second permits to use a DC input voltage source.
CSA96
Included Power Supply
Version
External Power Supply
Version
Option
IS
ES
Voltage
96V
200V
Current
20A
20A
Apparent Power
1920VA
4000VA
Active Power
<660W
4kW max
Efficiency typ. (amplifier)
98%
98%
Efficiency typ. (supply)
(power supply)
93.5%
-
Switching frequency
50kHz
50kHz
The CSA96-IS is characterized by an integrated power supply 110/230Vac to 96V –660W.

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Fully isolated from ground. (4.2kV between primary and secondary)
Active Power Factor Correction (meets EN 61000-3-2).
High apparent and active power output.
Compact size.
3. INTENDED USE
The CSA96 is intended to be used in electrical cabinets.

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4. ELECTRICAL SAFETY INFORMATION
The following safety symbols are used in this manual.
Warning
For you own safety and for your system security, be sure to carefully respect that
information.
Danger
This symbol alerts you about an electrical hazard.
Failure to follow these instructions will result in death or serious injury.
In order to achieve a safe operation of the CSA96 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 the other
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.

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Only qualified personnel can install and use the CSA96. Only Cedrat Technologies can open or repair the
CSA96.
Danger
Do not open the product during or after use, lethal voltages may be present even
after the product has been turned off.
Do not short the DC voltage bus or the braking resistor terminals.
Do no touch unshielded components or terminals with voltage present.
Avoid all contact with the product when powered on. If the user need to operate on
the product follow the following guideline :
-Turn off the product and disconnect the power source.
-Wait 1 min to allow the DC bus to discharge.
-Measure the voltage on the DC bus with a properly rated voltmeter to verify
that the voltage is below 42Vdc.
Danger
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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Danger
Before powering on, ensure that enable input is turned off to help prevent an
accidental startup.
5. 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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6. DISCLAIMER
All product, product specifications and data are subject to change without notice to improve reliability,
function or design or otherwise.
Cedrat Technologies makes no warranty, representation or guarantee regarding the suitability of the products
for any particular purpose or the continuing production of any product.
Except as expressly indicated in writing, Cedrat Technologies products are not designed for use in medical,
life-saving, or life-sustaining applications or for any other application in which the failure of the Cedrat
Technologies product could result in personal injury or death.

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7. INTERFACES
7.1.FRONT SIDE
Figure 1. Front side of the CSA96 with optional controller
Reference
Designation
1st module
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.
2nd module
Controller Board (TBD)
Analog I/O
TBD
CAN/Profibus
Ctrl Error
LED (red) –This diode lights when the controller board is in fault state.
Ethernet
USB
USB port.
Digital I/O
TBD
Table 1. Electrical interface assignments.
7.2.CONTROL PORT
The User Port permits to control the amplifier with a differential analog signal (±10V), to monitor the output
current and to enable the amplifier.

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Figure 2. Internal schematic of the Control Port.
Pin
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. (±10V)
9
In-
Input
No
Analog
Negative order input. (±10V)
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.
  
1
2
3
4
5
6
7
8
9
330R
33R
15V
Fault
Enable
Enable+
Enable-
Fault+
Fault-
Imes Imes
10k
5V
10k
10k
10k
10k
In+
In-
In+
In-
15V
15V
User Port
Reserved (Do Not Connect)
GND

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7.3.COMMUNICATION PORT
In order to drive different actuators, the PI parameters of the internal current control may need tuning. This
can be done on a PC using the TTL serial communication link and a FTDI TTL to USB converter (part number:
TTL-232R-5V-WE) through the Com. 1 port.
RX, TX and CTS can be used to communicate with the amplifier in order to tune the PI controller parameters.
Figure 3. Internal schematic of the Com. 1 Port
Pin
Signal
I/O
Isolation
Type
Function
5
GND
9
RX
Input
No
Digital
Receive signal - Serial communication
4
TX
Output
No
Digital
Transmit signal - Serial communication
8
CTS
Output
No
Digital
Clear To Send - Serial communication
3
Reserved
Do not connect
7
GND
2
OT
Output
No
Digital
OverTemp fault
6
OV
Output
No
Digital
OverVoltage/UnderVoltage fault
1
OC
Output
No
Digital
OverCurrent fault
All digital inputs/outputs are TTL 5V signals.
7.3.1.Command list
The list of available digital commands for the CSA96 is in the following table:
5
4
3
1
9
8
7
6
GND
RX
TX
CTS
GND
OverTemp
OverVoltage
Com. 1
Reserved (Do Not Connect)
2
Overcurrent

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Character
Description
Parameter range
Example
‘A’
This command prints the current parameters.
0-255
Value is a ‘don’t
care’
‘A1E’
‘P’
Sets the proportional term P of the PI controller
0-235
‘P150E’
Sets the proportional
gain to 150.
‘I’
Sets the integral term I of the PI controller
8310-96700
‘I13300E’
Sets the integral gain
to 13300.
P and I command are made to be intelligible and proportional gains to usual Kp and Ki gain. Internally, those
values are 8bits values, some differences may appears between entered values and effective values.
The internal current loop is presented in the Figure 4.
When a parameter of the CSA96 is modified, the new parameter value is automatically saved in a non-volatile
memory. The parameters of the CSA96 are automatically recalled on startup, so that the user does not have
to reconfigure the board on every power-up.
Since those commands write the memory, their execution time is longer.
Figure 4. Internal current loop diagram.
7.4.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
P
0…235
I
8.3k…93k
ActVbus/6.2
0.056A/V
Ampli
Corrector
Gain Delay
~1/50kHz
120kHz
0.112
Current
I
47
Order

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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 5). 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.
Figure 5. 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 6. Inverting and non-inverting proposed connection at the user side.
7.5.TOP SIDE –POWER SUPPLY TERMINAL
Figure 7. 16XXX Side panel.
P
E
N
Vb-
Vb+
B+
B-
Table 3. Pin out of the power supply connector. (16XXX version)

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P
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 V+)
Table 4. Full description of the power supply connector.
A recommended mating connector is the BLF 5.08HC/07/180F (Weidmueller):
Figure 8. BLF 5.08HC/03/180F
Danger
This connector supports potential lethal voltage. Never connect/disconnect one of
these pins while the power source is on.

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7.6.BOTTOM SIDE –ACTUATOR TERMINALS
Figure 9. Top left hand corner of the bottom side of the CSA96.
E
+
-
Table 5. Pin out of the actuator (output) connector.
Connect the magnetic actuator on this terminal. Do not connect any capacitance or capacitive actuator on
this terminal.
A recommended mating connector is the BLF 5.08HC/03/180F (Weidmueller).
Danger
This connector supports potential lethal voltage. Never connect/disconnect one of
these pins while the power source is on.

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7.7.WIRING
7.7.1.CSA96 Internal Supply version
Figure 10. Wiring of the internal power supply version of the CSA96
Warning
A circuit breaker must be added to connect/disconnect the driver from main
voltage.
CSA96
Amplifier
(Internal Supply version)
In+
In-
Differential Inputs ±5V
Neutral
Phase
Earth Earth
Vo+
Vo-
B+
B-
Braking
Rheostat
Mains
V+
V-
Actuator
Protective
Earth
Protective
Earth

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7.7.2.CSA96 External Supply version
Figure 11. Wiring of the external power supply version of the CSA96
The DC power supply shall be connected to Phase and Neutral to supply the internal, auxiliary power supply
of the product. It must include current limitation in order to limit the inrush current in the internal capacitors.
There is no polarity since a full wave rectifier is used inside. The minimum DC voltage is 40Vdc and the
maximum is 190Vdc.
The recommended wire gauge for the power cable is 14AWG with a nominal section of 2.1mm².
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.
7.7.3.EMC considerations
It is highly recommended to use shielded cable to connect the actuator to the CSA96 and for the Control Port
connection. Keep all wires and cables as short as possible.
CSA96
Amplifier
(External Supply version)
In+
In-
Differential Inputs ±5V
Neutral
Phase
Earth Earth
Vo+
Vo-Actuator
B+
B-
Braking
Rheostat
V+
V-
DC Power
Supply
Protective
Earth
Protective
Earth

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8. THEORY OF OPERATION
8.1.PRINCIPLE
The switching electronic CSA96 is dedicated to supply and control magnetic actuators. The CSA96 includes a
power supply with a maximal power given in the technical data sheet.
Figure 12 –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 frequency on the actuator is 50 kHz.
Warning
The output connections are floating.
The amplifier is only intended to drive magnetic actuators. Connecting capacitive
actuators (such as piezo-actuators) on the outputs of the CSA96 will lead to the
destruction of the amplifier.
8.2.EFFICIENCY AND COOLING
For the internal supply version, the maximum power losses of the amplifier and the internal power supply are
40W (amplifier) and 65W (power supply). With the thermal resistance of the base plate of 0.375K/W, it leads
V+
V-
+
-
Actuator
96V
AC
DC
P
N
B+
B-