Copley Controls Corp. 303 User manual

User’s Guide
Rev 08 5/00
All Rights Reserved
Models:
303,303B
306,306A,306B,306AB
312
300 Series Amplifier

The 300 Series Amplifier User’s Guide
Rev 07 9/96
All Rights Reserved

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1996~1998 Copley Controls Corporation
410 University Avenue
Westwood, MA 02090
USA
All rights reserved
The 300 Series Amplifier User' s Guide Rev 08 5/00
300 Series Amplifier
User’s Guide

300 SERIES USER GUIDE
ii
Table of Contents
Table of Contents....................................................................................................................................... ii
A Visual Guide to the 300 family:............................................................................................................. iv
Introduction................................................................................................................................................ 1
Getting Started........................................................................................................................................... 1
Functional Diagram ................................................................................................................................... 2
J17 Component Header.............................................................................................................................. 3
Location....................................................................................................................................... 3
Current-Mode Setup (Standard configuration)............................................................................ 3
Velocity Mode Setup (Use components supplied)....................................................................... 3
Technical Specifications............................................................................................................................4
Mechanical Outlines .................................................................................................................................. 5
Basic Amplifier Connectors, Signals and Pinouts...................................................................................... 6
4 Pin power connector.................................................................................................................6
22 Pin signal connector................................................................................................................6
Basic Amplifier: Current-Mode, NO Tachometer ..................................................................................... 7
Amplifier Connections................................................................................................................. 7
Basic Amplifier: Current-Mode WITH Tachometer.................................................................................. 8
Amplifier Connections................................................................................................................. 8
Amplifier with MB4 Mounting Card: Current-Mode, NO Tachometer.....................................................9
Amplifier Connections................................................................................................................. 9
Amplifier with MB4 Mounting Card: Current-Mode, WITH Tachometer............................................... 10
Amplifier Connections................................................................................................................. 10
Amplifier on Eurocard: Current-Mode, NO Tachometer........................................................................... 11
Amplifier Connections................................................................................................................. 11
Amplifier on Eurocard: Current-Mode, WITH Tachometer......................................................................12
Amplifier Connections................................................................................................................. 12
Power Supply Considerations.................................................................................................................... 13
Multiple Amplifier Power Connections.......................................................................................13
Minimum Inductance.................................................................................................................................14
Maximum Inductance ................................................................................................................................14
Bandwidth.................................................................................................................................................. 14
Enable Inputs.............................................................................................................................................15
Current Monitor......................................................................................................................................... 15
Status LED................................................................................................................................................. 15
Normal Output...........................................................................................................................................16
Reset Input.................................................................................................................................................16
Current Limit .............................................................................................................................................16
Output Voltage Swing................................................................................................................................ 16
DC Power Outputs..................................................................................................................................... 17
Mounting.................................................................................................................................................... 18
Standard Mounting...................................................................................................................... 18
PC Board Mounting (-P option) .................................................................................................. 18
MB4 Card Mounting ( -M option)............................................................................................... 18
Eurocard Mounting (-E and -ER options).................................................................................... 18
MB4 Mounting Card..................................................................................................................................19
Notes on Nomenclature ............................................................................................................... 19
P1: 4 Pin power connector........................................................................................................... 19
P2: 15 Pin signal connector......................................................................................................... 19
Status Output ............................................................................................................................... 19
Amplifier Signal Connector (J4)..................................................................................................19
MB4 Card Options ...................................................................................................................... 20
Voltage-Mode (-V option) ............................................................................................20
IR-Comp (included with -V option).............................................................................. 20
PWM Inputs (-D option)............................................................................................... 20
Edge filters (-F option).................................................................................................. 20
MB4 Card Jumper Settings..........................................................................................................21

300 SERIES USER GUIDE
iii
Notes on Modes & Jumpers...........................................................................................21
Eurocard Mount .........................................................................................................................................22
DIN Connector Pinouts................................................................................................................22
Jumper Settings............................................................................................................................22
Status Output Jumper...................................................................................................................23
Tuning and Adjustments ............................................................................................................................23
Trimpots.......................................................................................................................................23
Balance..........................................................................................................................23
Feedback........................................................................................................................23
Current Limit.................................................................................................................23
Voltage Feedback..........................................................................................................23
IR Comp ........................................................................................................................23
Mode Setting: Flat-Gain vs. Tachometer.....................................................................................24
Frequency Response with Tachometer.........................................................................................25
Tachometer Scaling .....................................................................................................................26
Voltage-Mode Gain .....................................................................................................................27
IR-Comp ......................................................................................................................................28
Setup Procedure.............................................................................................................28
Static Setup Method ......................................................................................................28
Dynamic Setup Method.................................................................................................29
Notes on IR Compensation............................................................................................29
PWM Operation...........................................................................................................................30
Appendix....................................................................................................................................................31
Connector Part Numbers..............................................................................................................31
Basic Amplifier 4-pin power/motor connector................................................31
Basic Amplifier 22-pin signal connector (housing only).................................31
MB4 Card: 4 pin power/motor connector .......................................................31
MB4 Card: 15 pin signal connector (housing only) ........................................31
Pins for 15, 22 pin signal connector................................................................31
DIN backplane connector for Eurocard mount................................................31
References....................................................................................................................................31
Standard Power Supplies ............................................................................................................31
MB4 Card Layout........................................................................................................................32
Eurocard Layout ..........................................................................................................................33
Jumper Pin Numbering..................................................................................................33
Panel Layout..................................................................................................................33
MB4 Card Schematic...................................................................................................................34
Eurocard Schematic.....................................................................................................................35
Ordering Guide for 300 Series.....................................................................................................36

300 SERIES USER GUIDE
iv
A Visual Guide to the 300 family:
Basic Amplifier, No Mounting Card, No Heatsink (30x shown)
See p. 5 for connectors & pinouts.
See pp. 7-8 for wiring.
Amplifier with MB4 Mounting Card (30xPMFDV shown)
See p. 18 for connectors & pinouts.
See pp. 9-10 for wiring.
Amplifier on Eurocard Mount with Front Panel (30xER shown)
See p. 21 for connectors & pinouts.
See. pp. 11-12 for wiring.

300 SERIES USER GUIDE
1
Introduction
The 300 Series amplifiers are second generation products designed for low cost and high
performance. They can be mounted on chassis or p.c. boards and operate from 16 to 160
volt single-output DC power supplies. A wide range of inductive loads can be driven:
64 uH to 50 mH depending on model and supply voltage.
All units feature fully differential inputs for the control, or reference voltage. Enable
inputs for output control, a status output, and a current monitor signal ease system
interfacing.
The 22 kHz. PWM switching frequency eliminates audible noise from motor windings
and fast rise and fall times give high efficiency.
A Eurocard mount is available for 3U x 220 mm. rack mounting applications. A header
socket with plug-in components makes it easy to change compensation components for
different loads.
The amplifier is protected against over-temperature, over-voltage and under-voltage, and
output short circuits.
Getting Started
To install the amplifier you will need a control, or reference voltage, a power supply, and
a load. The reference voltage can be from something as simple as a potentiometer, or as
complex as a digital control system. The power supply can be supplied by the user, or
ordered from Copley Controls along with the amplifier to create a complete amplifier
subsystem. Loads are usually motors, but magnet coils, inductors, or other non-motor
loads can also be driven.
The amplifier is typically used as a voltage-to-current converter. ±10V reference signals
will drive the amplifier's peak rated current to the load in the 'flat-gain' mode. If a
tachometer is used, the amplifier is still operated as a voltage to current converter, but
the header components are changed to increase the gain of the servo preamplifier.
Use of the MB4 and Eurocard provides additional (optional) features such as voltage-
mode operation, armature-resistance(IR) compensation, PWM inputs, and output filters.
Eurocard mounts adapt the amplifiers to 3U subrack installations. Consult the factory for
Eurocard subrack systems.

300 SERIES USER GUIDE
2
Functional Diagram

300 SERIES USER GUIDE
3
J17 Component Header
This is an 11-position socket which holds resistors and capacitors which are used for
tachometer scaling and compensation, amplifier compensation, and current limiting.
Location
Current-Mode Setup (Standard configuration)
This is the standard configuration as delivered from the factory. In this mode, a voltage
at the reference inputs will force a current at the amplifier outputs. This is also called the
flat-gain mode because it provides the maximum bandwidth which remains constant over
the 3 kHz range.
Velocity Mode Setup (Use components supplied)
Use the components supplied in the brown bag to replace R5,R7, and C6. This will setup
the amplifier for use with tachometers. See Mode Setting for further details.
4-PIN
22-PIN
J17 HEADER
AMPLIFIER WITHOUT MB4 CARD
1
2
3
4
5
6
7
8
9
10
11
22
21
20
19
18
17
16
15
14
13
12
R1
R2
C3
C4
R5
C6
R7
R8
JP9
R10
R11
10 K
Value
Component
40.2 K
OPEN
330 pF
46.4 K
.01 uF
JUMPER
10 K
JUMPER
49.9 K
49.9 K
Current Limit ; 10K = 100% of peak rated current
Enable polarity ; IN = Enable, OUT = Enable
Aux Input Gain
Ref Gain ; amplifier gain = Ipeak/10V
Function as Shown
Notes:1. R1, R2, C3 and C6 have no function in current mode.
2. Current-limiting is non-linear with respect to R8. For best results, substitute 10K pot
for R8, adjust for desired current-limit, and replace with fixed resistor.
Not used in current-mode
Flat gain
1
2
3
4
5
6
7
8
9
10
11
22
21
20
19
18
17
16
15
14
13
12
R1
R2
C3
C4
R5
C6
R7
R8
JP9
R10
R11
10 K
Value
Component
40.2 K
OPEN
330 pF
499 K
.01 uF
10 MEG
10 K
JUMPER
49.9 K
49.9 K
Tach scaling ; 10V @ Ref = 8V @ Tach
Compensation (see Mode Setting section, p. 23)
Current Limit ; 10K = 100% of peak rated current
Enable polarity ; IN = Enable, OUT = Enable
Aux Input
Ref Gain ; servo preamp DC gain = 210
Function as Shown
Notes:
1. R1, R2, and R11 interract to affect tachometer scaling and servo preamp gain.
2. Current-limiting is non-linear with respect to R8. For best results, substitute 10K pot
for R8, adjust for desired current-limit, and replace with fixed resistor.
(see Note 1 and Tachometer Scaling, p. 25)

300 SERIES USER GUIDE
4
Technical Specifications

300 SERIES USER GUIDE
5
Mechanical Outlines

300 SERIES USER GUIDE
6
Basic AmplifierConnectors, Signals and Pinouts
If you are using the MB4 or Eurocard, the pinouts will be different (refer to the sections
on the MB4 and Eurocard). Use this list when reading the following sections on hooking
up the basic amplifier.
Types of signals are listed after the pin number or letter.
P Passive Power and ground
I Input Analog or digital signal inputs
O Output Signal, logic, and power-stage outputs
Note: See appendix for complete listing of connectors and part-numbers.
4 Pin power connector
Type Remarks
AA P +HV, the high-voltage DC power input
BB O Out- , or negative output
CC O Out+, or positive output
DD P Ground and +HV power return
Table 1
22 Pin signal connector
Note that pins are referred to by letter and number. The letter refers to the functional
schematic. The number is the actual connector-pin number on the cable header that
connects to the amplifier.
-Pin- Type Signal Remarks
1 (A) I +Ref Differential (+) reference signal input
2 (B) I -Ref " (-) " " "
3 (C) P Signal Gnd Gnd for tachometer, signal gnd
4 (D) O Ref amp out Output of differential input amplifier
5 (E) I Aux input Auxiliary input
6 (F) O +11V 20K ohms in series with +11V
7 (G) P Logic gnd Gnd for Enable inputs
8 (H) O -11V 20K ohms in series with -11V
9 (I) N.C. No connection to this pin
10 (J) I /Reset LO or Gnd to reset fault condition
11 (K) O Preamp out See schematic
12 (L) Opt. ext. comp See schematic
13 (M) I Tach input Tachometer input
14 (N) Opt. ext. comp See schematic
15 (O) I /Enable LO or Gnd to enable amplifier
16 (P) I /Pos Enable LO or Gnd to enable positive output
17 (Q) I /Neg Enable LO or Gnd to enable negative output
18 (R) O +14V 1K ohms in series with +14V
19 (S) O Normal HI (+5V) when amplifier operating Normally
20 (T) O +5V 2.49K in series with internal +5V
21 (U) N.C.
22 (V) O Current monitor Outputs +/-6V at amplifier peak current
Table 2

300 SERIES USER GUIDE
7
Basic Amplifier: Current-Mode, NO Tachometer
Use this checklist for applications that don't employ a tachometer. These include
microprocessor control systems that get position feedback from an encoder on the
motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads
that require a set current from the amplifier in response to a control-voltage at the
inputs. The components on the J17 header come from the factory preset for this
operating mode. See functional diagram on page 2.
1. Connect DC power supply to amplifier +HV and GND. Check voltage to see that is is
within the amplifiers' rating.
2. Ground amplifier to chassis at GND pin DD.
3. Connect motor or load between OUT+ and OUT-. Do not ground load!
4. Connect reference voltage source to REF+ and REF- inputs.
5. Ground ENABLE,POS ENABLE, NEG ENABLE to amplifier logic ground.
6. Set FEEDBACK pot to full CW.
7. Set Vref to 0V
8.Turn power on
9.Check for green LED indicating Normal operation.
10. Adjust BALANCE trimpot for 0.0V between OUT+ and OUT-
11. Momentarily increase Reference voltage (±10V max).
12. Check motor direction: is it OK?
YES: continue
NO: remove power, reverse connections to Ref+ and Ref-.
13. Set Reference voltage to maximum value (+/-10V)
14. Check load current at CURRENT MONITOR output
15. Apply step or square-wave signal to Ref-inputs, adjust FEEDBACK CCW for
best response with no oscillation.
Amplifier Connections
Numbered terminals are on the brown 22-pin connector. Double-letter terminals are on
the orange 4-pin connector. See appendix for connector part numbers.
15
16
17
7
+HV
GND
+
-
DC
OUT+
OUT-
MOTOR
AA
DD
CHASSIS GND
1
2
AMPLIFIER
BB
CC
REF+
REF-
ENABLE
POS ENABLE
NEG ENABLE
LOGIC GND
CONTROLLER
OUT
GND
POWER
SUPPLY
22-Pin 4-Pin
Fig. 1

300 SERIES USER GUIDE
8
Basic Amplifier:Current-Mode WITH Tachometer
1.Setup J17 header components for high gain, tachometer mode (see p.3)
2. Connect DC power supply to amplifier +HV and GND. Check voltage to see that is
within the amplifiers' rating.
3.Ground amplifier to chassis at GND pin DD.
4.Connect motor or load between OUT+ and OUT-. Do not ground load!
5. Connect reference voltage source to REF+ and REF- inputs.
6. Connect Tachometer between tach input and signal ground.
7. Ground ENABLE,POS ENABLE, NEG ENABLE to amplifier logic ground.
8. Set FEEDBACK pot to full CW.
9. Set VREF to 0V
10. Turn power on.
11. Does the motor run away?:
YES: remove power, reverse tachometer leads
NO: continue
12. Check for green LED indicating Normal operation.
13. Adjust BALANCE trimpot for 0.0V between OUT+ and OUT-
14. Momentarily increase Reference voltage (±10V max).
15. Check motor direction: is it OK?
YES: continue
NO: remove power, reverse connections to Ref+ and Ref-.
16. Set Reference voltage to maximum value (+/-10V)
17. Check load current at CURRENT MONITOR output
18. Adjust CURRENT LIMIT trimpot for desired maximum current.
19. Set Reference voltage to zero, turn feedback trimpot CCW until oscillation begins
(audible squeal or noise). Back-off two turns CW or until oscillation stops.
20. Apply step or square-wave signal to Ref-inputs, adjust FEEDBACK CCW for best
response with no oscillation.
Amplifier Connections
Single-letter terminals are on the brown 22-pin connector. Double-letter terminals are on
the orange 4-pin connector.
15
16
17
7
+HV
GND
+
-
DC
OUT+
OUT-
MOTOR
AA
DD
CHASSIS GND
1
2
AMPLIFIER
BB
CC
REF+
REF-
ENABLE
POS ENABLE
NEG ENABLE
LOGIC GND
13
3
TACH +
-
+
-
CONTROLLER
POWER
SUPPLY
22-Pin 4-Pin
Fig. 2

300 SERIES USER GUIDE
9
Amplifier with MB4 Mounting Card: Current-Mode, NO Tachometer
Use this checklist for applications that don't employ a tachometer. These include
microprocessor control systems that get position feedback from an encoder on the
motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads
that require a set current from the amplifier in response to a control-voltage at the
inputs. The components on the J17 header come from the factory preset for this
operating mode. See functional diagram on page 2.
1. Connect DC power supply to MB4 card P1 (see diagram below). Check voltage to
see that is is within the amplifiers' rating.
2. Ground MB4 card to chassis at pin P1-4.
3. Connect motor or load between OUT+ and OUT-. Do not ground load!
4. Connect reference voltage source to REF+ and REF- inputs.
5. Ground ENABLE,POS ENABLE, NEG ENABLE to amplifier logic ground.
6. Set REF GAIN pot to full CW.
7. Set FEEDBACK pot to full CW.
8. Set CURRENT LIMIT pot to full CW.
9. Set Vref to 0V
10. Turn power on
11. Check for green LED indicating Normal operation.
12. Adjust BALANCE trimpot for 0.0V between OUT+ and OUT-
13. Momentarily increase Reference voltage (±10V max).
14. Check motor direction: is it OK?
YES: continue
NO: remove power, reverse connections to Ref+ and Ref-.
15. Set Reference voltage to maximum value (+/-10V)
16. Check load current at CURRENT MONITOR output
17. Apply step or square-wave signal to Ref-inputs, adjust FEEDBACK CCW for best
response with no oscillation.
Amplifier Connections
Numbered terminals are on the brown 15-pin connector(P2). Double-letter terminals are
on the orange 4-pin connector(P1). See appendix for connector part numbers.
3
2
1
11
+HV
GND
+
-
DC
OUT+
OUT-
MOTOR
1
4
CHASSIS GND
8
15
2
3
REF+
REF-
ENABLE
POS ENABLE
NEG ENABLE
LOGIC GND
CONTROLLER
OUT
GND
POWER
SUPPLY
P1
P2
MB4 Card
Fig. 3

300 SERIES USER GUIDE
10
Amplifier with MB4 Mounting Card: Current-Mode,
WITHTachometer
Use this checklist for applications that do employ a tachometer. These include
microprocessor control systems that get position feedback from an encoder on the
motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads
that require a set current from the amplifier in response to a control-voltage at the
inputs. The components on the J17 header come from the factory preset for this
operating mode. See functional diagram on page 2.
1. Connect DC power supply to MB4 card P1 (see diagram below). Check voltage to
see that is is within the amplifiers' rating.
2. Ground amplifier to chassis at pin P1-4.
3. Connect motor or load between OUT+ and OUT-. Do not ground load!
4. Connect reference voltage source to REF+ and REF- inputs.
5. Ground ENABLE,POS ENABLE, NEG ENABLE to amplifier logic ground.
6. Set REF GAIN pot to full CW.
7. Set FEEDBACK pot to full CW.
8. Set CURRENT LIMIT pot to full CW.
9. Set Vref to 0V
10. Turn power on
11. Check for green LED indicating Normal operation.
12. Adjust BALANCE trimpot for 0.0V between OUT+ and OUT-
13. Momentarily increase Reference voltage (±10V max).
14. Check motor direction: is it OK?
YES: continue
NO: remove power, reverse connections to Ref+ and Ref-.
15. Set Reference voltage to maximum value (+/-10V)
16. Check load current at CURRENT MONITOR output
17. Apply step or square-wave signal to Ref-inputs, adjust FEEDBACK CCW for best
response with no oscillation.
Amplifier Connections
Numbered terminals are on the brown 15-pin connector. Double-letter terminals are on
the orange 4-pin connector. See appendix for connector part numbers.
3
2
1
11
+HV
GND
+
-
DC
OUT+
OUT-
MOTOR
1
4
CHASSIS GND
8
15
2
3
REF+
REF-
ENABLE
POS ENABLE
NEG ENABLE
LOGIC GND
CONTROLLER
OUT
GND
POWER
SUPPLY
P2 P1
MB4 Card
6
14
TACH
Fig. 4

300 SERIES USER GUIDE
11
Amplifier on Eurocard:Current-Mode, NO Tachometer
Use this checklist for applications that don't employ a tachometer. These include
microprocessor control systems that get position feedback from an encoder on the
motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads
that require a set current from the amplifier in response to a control-voltage at the
inputs. The components on the J17 header come from the factory preset for this
operating mode. See functional diagram on page 2.
1. Connect DC power supply to amplifier +HV and GND. Check voltage to see that is is
within the amplifiers' rating.
2. Ground amplifier to chassis at GND pin DD.
3. Connect motor or load between OUT+ and OUT-. Do not ground load!
4. Connect reference voltage source to REF+ and REF- inputs.
5. Ground ENABLE,POS ENABLE, NEG ENABLE to amplifier logic ground.
6. Set REF GAIN pot to full CW.
7. Set FEEDBACK pot to full CW.
8. Set CURRENT LIMIT pot to full CW.
9. Set Vref to 0V
10. Turn power on
11. Check for green LED indicating Normal operation.
12. Adjust BALANCE trimpot for 0.0V between OUT+ and OUT-
13. Momentarily increase Reference voltage (±10V max).
14. Check motor direction: is it OK?
YES: continue
NO: remove power, reverse connections to Ref+ and Ref-.
15. Set Reference voltage to maximum value (+/-10V)
16. Check load current at CURRENT MONITOR output
17. Apply step or square-wave signal to Ref-inputs, adjust FEEDBACK CCW for best
response with no oscillation.
Amplifier Connections
Numbered terminals are on the brown 15-pin connector. Double-letter terminals are on
the orange 4-pin connector. See appendix for connector part numbers.
+HV
GND
+
-
DC
OUT+
OUT-
MOTOR
CHASSIS GND
AMPLIFIER
REF+
REF-
ENABLE
POS ENABLE
NEG ENABLE
LOGIC GND
CONTROLLER
OUT
GND
POWER
SUPPLY
+ Eurocard
C18
A18
C20
A20
C22
A22
C24
A24
C26
A26
C28
A28
C30
A30
C32
A32
C2
A2
A14
C12
A12
C16
Fig. 5

300 SERIES USER GUIDE
12
Amplifier on Eurocard: Current-Mode, WITHTachometer
Use this checklist for applications that do employ a tachometer. These include
microprocessor control systems that get position feedback from an encoder on the
motor, as well as non-motor applications such as magnet-coil, solenoids, or other loads
that require a set current from the amplifier in response to a control-voltage at the
inputs. The components on the J17 header come from the factory preset for this
operating mode. See functional diagram on page 2.
1. Connect DC power supply to amplifier +HV and GND. Check voltage to see that is is
within the amplifiers' rating.
2. Ground amplifier to chassis at GND pin DD.
3. Connect motor or load between OUT+ and OUT-. Do not ground load!
4. Connect reference voltage source to REF+ and REF- inputs.
5. Ground ENABLE,POS ENABLE, NEG ENABLE to amplifier logic ground.
6. Set REF GAIN pot to full CW.
7. Set FEEDBACK pot to full CW.
8. Set CURRENT LIMIT pot to full CW.
9. Set Vref to 0V
10. Turn power on
11. Check for green LED indicating Normal operation.
12. Adjust BALANCE trimpot for 0.0V between OUT+ and OUT-
13. Momentarily increase Reference voltage (±10V max).
14. Check motor direction: is it OK?
YES: continue
NO: remove power, reverse connections to Ref+ and Ref-.
15. Set Reference voltage to maximum value (+/-10V)
16. Check load current at CURRENT MONITOR output
17. Apply step or square-wave signal to Ref-inputs, adjust FEEDBACK CCW for best
response with no oscillation.
Amplifier Connections
Numbered terminals are on the brown 15-pin connector. Double-letter terminals are on
the orange 4-pin connector. See appendix for connector part numbers.
+HV
GND
+
-
DC
OUT+
OUT-
MOTOR
CHASSIS GND
AMPLIFIER
REF+
REF-
ENABLE
POS ENABLE
NEG ENABLE
LOGIC GND
CONTROLLER
OUT
GND
POWER
SUPPLY
+ Eurocard
TACH
C18
A18
C20
A20
C22
A22
C24
A24
C26
A26
C28
A28
C30
A30
C32
A32
C2
A2
C6
C4
A14
C12
A12
C16
Fig. 6