Copley Controls Corp. Xenus XTL-230-18 User manual

Xenus™Regeneration Guide
P/N 95-00306-000
Revision 3
June 2008

Xenus Regeneration Guide
This page for notes.

Copley Controls Corp. i
TABLE OF CONTENTS
About This Guide.................................................................................................................................................................................. iii
Overview and Scope............................................................................................................................................................iii
Related Documentation .......................................................................................................................................................iii
Comments...........................................................................................................................................................................iii
Copyrights ...........................................................................................................................................................................iii
Document Validity................................................................................................................................................................iii
Product Warnings............................................................................................................................................................... iv
Revision History.................................................................................................................................................................. iv
1: Regen Resistors for Xenus......................................................................................................................................................... 1
1.1: Regen Resistor Theory........................................................................................................................................................... 2
1.2: Amplifier Regen Circuit Output Specifications ........................................................................................................................ 3
1.3: Copley Standard Regen Resistors.......................................................................................................................................... 4
1.3.1: Copley Standard Regen Resistor Dimensions ........................................................................................................... 4
1.3.2: Copley Standard Regen Resistor Specifications ........................................................................................................ 5
1.3.3: Copley Standard Regen Resistor Thermal Characteristics ........................................................................................ 5
1.4: Regen Circuit Wiring............................................................................................................................................................... 6
1.4.1: Electrical Codes and Warnings.................................................................................................................................. 6
1.4.2: Amplifier Connector Locations ................................................................................................................................... 7
1.4.3: Regen Resistor (J3) Wiring........................................................................................................................................ 8
1.4.4: Regen Resistor Configuration with CME 2 ................................................................................................................. 9
A: Regen Resistor Sizing and Configuration ............................................................................................................................... 11
A.1: Sizing a Regen Resistor....................................................................................................................................................... 12
A.1.1: Gather Required Information ................................................................................................................................... 12
A.1.2: Observe the Properties of Each Deceleration During a Complete Cycle of Operation ............................................. 12
A.1.3: Calculate Energy Returned for Each Deceleration................................................................................................... 13
A.1.4: Determine the Amount of Energy Dissipated by the Motor ...................................................................................... 13
A.1.5: Determine the Amount of Energy Returned to the Amplifier .................................................................................... 13
A.1.6: Determine if Energy Returned Exceeds Amplifier Capacity ..................................................................................... 14
A.1.7: Calculate Energy to be Dissipated for Each Deceleration........................................................................................ 14
A.1.8: Calculate Pulse Power of Each Deceleration that Exceeds Amplifier Capacity........................................................ 14
A.1.9: Calculate Resistance Needed to Dissipate the Pulse Power ................................................................................... 14
A.1.10: Calculate Continuous Power to be Dissipated ....................................................................................................... 15
A.1.11: Select Fuses ......................................................................................................................................................... 15
A.2: Configuring a Custom Regen Resistor ................................................................................................................................. 16
A.2.1: Regen Configuration Objective and Warning........................................................................................................... 16
A.2.2: Regen Configuration Instructions ............................................................................................................................ 16

Table of Contents Xenus Regeneration Guide
ii Copley Controls Corp.
This page for notes.

Copley Controls Corp. iii
ABOUT THIS GUIDE
Overview and Scope
This guide describes the selection, installation, and configuration of external regen
resistors for Xenus Amplifiers.
Related Documentation
Users should also read these Copley Controls documents:
•Xenus User Guide
•CME 2 User Guide
Links to these publications, along with hardware manuals and data sheets, can be found
under the Documents heading of
http://www.copleycontrols.com/Motion/Downloads/index.html.
Information on Copley Controls Software can be found at:
http://www.copleycontrols.com/Motion/Products/Software/index.html
Comments
Copley Controls Corporation welcomes your comments on this guide. See
http://www.copleycontrols.com for contact information.
Copyrights
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of Copley
Controls Corporation.
Xenus and CME 2 are registered trademarks of Copley Controls Corporation.
Document Validity
We reserve the right to modify our products. The information in this document is subject
to change without notice and does not represent a commitment by Copley Controls
Corporation. Copley Controls Corporation assumes no responsibility for any errors that
may appear in this document.

About this Guide Xenus Regeneration Guide
iv Copley Controls Corp.
Product Warnings
Observe all relevant state, regional, and local safety regulations when installing and using
this product. For safety and to assure compliance with documented system data, only
Copley Controls Corporation should perform repairs to amplifiers.
DANGER: Hazardous voltages.
!
DANGER
Exercise caution when installing and adjusting.
Failure to heed this warning can cause equipment damage, injury, or
death.
Risk of electric shock.
!
DANGER
High-voltage circuits on J1, J2, and J3 are connected to mains power.
Failure to heed this warning can cause equipment damage, injury, or
death.
Use equipment as described.
!
DANGER
Operate amplifiers within the specifications provided in this manual.
Failure to heed this warning can cause equipment damage, injury, or
death.
Revision History
Revision Date DECO # Comments
1.0 July 2003 Initial publication.
1.1 November
2004
Corrected model number in specifications table (p. 5).
2February 2007 14988 Updated to describe new Copley regen resistor models.
3June 2008 17137 Updated Web page references.

Copley Controls Corp. 1
CHAPTER
1: REGEN RESISTORS FOR XENUS
This chapter provides an overview of regeneration and using regen resistors with Xenus.
The contents of this chapter include:
Title Page
1.1: Regen Resistor Theory........................................................................................................................................................... 2
1.2: Amplifier Regen Circuit Output Specifications ........................................................................................................................ 3
1.3: Copley Standard Regen Resistors.......................................................................................................................................... 4
1.4: Regen Circuit Wiring............................................................................................................................................................... 6

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
2Copley Controls Corp.
1.1: Regen Resistor Theory
When a load is accelerated electrical energy is converted into mechanical energy. During
deceleration the conversion is reversed. This is called regeneration. Some of this
regenerated energy is lost to friction in the mechanical system. More of this energy is
converted to heat due to I2Rlosses in the motor windings, cabling and drive electronics.
The remainder of the energy is added to the electrical energy already stored in the
internal capacitor bank of the amplifier. The result of this energy being added is an
increase in the voltage on the capacitor bank.
If too much energy is added to the capacitor bank, the voltage will rise to a point where
the amplifier's over voltage protection will shut down the amplifier. To prevent this, a
regen circuit shunts some of the energy into an external resistor, known as a regen
resistor, when the voltage rises too high.
Xenus provides an internal transistor that is used in combination with an external resistor.
Copley Controls supplies compatible external resistors. When using a resistor acquired
from another source, be sure it meets the specifications described in
Regen Resistor Sizing and Configuration (p. 11).
The amplifier protects the regen circuit against short circuit, and uses I2Tpeak
current/time algorithms to protect both the external resistor and internal transistor.
NOTE: The Xenus micro panel model has its own internal regen circuit and does not use
an external regen resistor.

Xenus Regeneration Guide Regen Resistor Sizing and Configuration
Copley Controls Corp. 3
1.2: Amplifier Regen Circuit Output Specifications
This section describes the amplifier’s regen resistor circuit output specifications.
Model XTL-230-18 XTL-230-36 XTL-230-40
Continuous Power 2 kW 4 kW
Peak Power 5 kW 10 kW
Minimum Resistance 30 15 
Minimum Resistor Wattage 25 W 50 W
Turn On Voltage +390 Vdc
Turn Off Voltage +380 Vdc
DC Bus Capacitance 1760 µFnominal
Regen Energy Absorption Capacity
Input Voltage 120 Vac
208 Vac
240 Vac
108 joules
57 joules
32 joules

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
4Copley Controls Corp.
1.3: Copley Standard Regen Resistors
Copley Controls provides two standard regen resistors for Xenus amplifiers:
XTL-RA-03 and XTL-RA-04. XTL-RA-03 and XTL-RA-04 housing is shown below.
1.3.1: Copley Standard Regen Resistor Dimensions
The diagram below shows XTL-RA-03 and XTL-RA-04 mounting dimensions (in mm).

Xenus Regeneration Guide Regen Resistor Sizing and Configuration
Copley Controls Corp. 5
1.3.2: Copley Standard Regen Resistor Specifications
Specifications for Copley’s standard regen resistors are described below.
Model Resistance Default
Continuous
Power
Max
Continuous
Power
Peak
Power
Peak
Power
Time
For Use With
XTL-RA-03 30 ohms 65 W 400 W 5 kW 1000 ms XTL-230-18
XTL-RA-04 15 ohms 65 W 400 W 10 kW 1000 ms XTL-230-36
XTL-230-40
High Temperature Risk.
!
WARNING
Setting Default Continuous Power for a standard Copley regen resistor to a value greater
than the default of 65 W may cause the resistor casing to heat to temperatures that could
cause injury. If higher settings are required, contact Copley Controls customer support.
Failure to heed this warning can cause equipment damage or injury.
1.3.3: Copley Standard Regen Resistor Thermal Characteristics
The following graph shows surface temperature rise vs. dissipated power for the XTL-RA-
03 and XTL-RA-04 mounted to a control panel with the long surface of the resistor
oriented vertically. Results may vary if the resistor is mounted differently.
XTL-RA-03/XTL-RA-04
Surface Temperature Rise
vs. Dissipated Power
0
25
50
75
100
125
150
175
200
0 25 50 75 100 125 150 175 200 225 250
Dissipated Power (W)
Temperature Rise above Ambient (C)

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
6Copley Controls Corp.
1.4: Regen Circuit Wiring
This section describes the wiring of the regen resistor connections.
1.4.1: Electrical Codes and Warnings
Be sure that all wiring complies with the National Electrical Code (NEC) or its national
equivalent, and all prevailing local codes.
DANGER: Hazardous voltages.
!
DANGER
Exercise caution when installing and adjusting.
Failure to heed this warning can cause equipment damage, injury, or
death.
Risk of electric shock.
!
DANGER
High-voltage circuits on J1, J2, and J3 are connected to mains power.
Failure to heed this warning can cause equipment damage, injury, or
death.
Do not ground mains-connected circuits.
!
WARNING
With the exception of the ground pins on J1, J2, and J3, all of the other
circuits on these connectors are mains-connected and must never be
grounded.
Failure to heed this warning can cause equipment damage.

Xenus Regeneration Guide Regen Resistor Sizing and Configuration
Copley Controls Corp. 7
1.4.2: Amplifier Connector Locations
Connector locations are shown below. The regen connector is J3.
CNTRL
J4
J3
J2
J1
STATUS
RS232
CAN
ADDR
J5
S1
J6
J7
J8
FDBCK
+24V
BRAKE
RTN
REGEN+
U
V
W
L1
L2
L3
CAN
Xenus
™
REGEN-
FDBCK
+24V
BRAKE
RTN

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
8Copley Controls Corp.
1.4.3: Regen Resistor (J3) Wiring
Mating Connector
Description Euro-style, 5 position, 5.0 mm pluggable male terminal block.
Manufacturer PN Wago 721-605/000-043
Wire Size 22 - 14 AWG
Recommended Wire 14 AWG, 600 V
(Shielded cable used for CE compliance)
Wire Insertion/Extraction Tool Wago 231-131
Connector and tool are included in connector kit XTL-CK
Pin Description
Pin Signal Function
1Regen + + DC Bus to one side of regen resistor
2N/C No connection
3Regen - Collector of regen transistor to one side of regen resistor
4N/C No connection
5Ground Enclosure ground and cable shield
Regen Resistor Wiring Diagram
Regen +
Regen -
+ DC Bus
- DC Bus
Fus es
Regen
Resistor
Enclosure
Amplifier J3
J3-5
J3-4
J3-3
J3-2
J3-1
Regen Resistor Fusing
Recommended Fuses:
Regen Resistor Fuse type
XTL-RA-03 Cooper Bussman KLM-8 or equivalent
XTL-RA-04 Cooper Bussman KLM-12 or equivalent
User Supplied See Regen Resistor Sizing and Configuration (p. 11).

Xenus Regeneration Guide Regen Resistor Sizing and Configuration
Copley Controls Corp. 9
1.4.4: Regen Resistor Configuration with CME 2
1.4.4.1 Click Configure Regen ( )to open the Regen Resistor screen.
1.4.4.2 Select a resistor option.
Option Description
None No external regen resistor is used.
XTL-RA-03
XTL-RA-04
Standard regen resistors supplied by Copley Controls.
Custom Resistor User-supplied resistor. See Regen Resistor Sizing and Configuration (p. 11).
1.4.4.3 Click OK to save regen settings to flash memory and close the Regen Resistor screen
OR
click Cancel to restore to previous values and close the screen.

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
10 Copley Controls Corp.
This page for notes.

Copley Controls Corp. 11
APPENDIX
A:REGEN RESISTOR SIZING AND
CONFIGURATION
This chapter describes the formulas used to determine if a regen resistor is required and
what the optimal resistor characteristics would be for a given application.
The contents of this chapter include:
Title Page
A.1: Sizing a Regen Resistor....................................................................................................................................................... 12
A.2: Configuring a Custom Regen Resistor ................................................................................................................................. 16

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
12 Copley Controls Corp.
A.1: Sizing a Regen Resistor
A.1.1: Gather Required Information
Calculating the power and resistance of the regen resistor requires information about the
amplifier and the rotary or linear motor application.
A.1.1.1 For all applications, gather the following information:
1Details of the complete motion profile, including times and velocities
2Amplifier model number
3Applied line voltage to the amplifier
4Torque constant of the motor
5Resistance (line-to-line) of the motor windings.
A.1.1.2 For rotary motor applications, gather this additional information:
1Load inertia seen by the motor
2Inertia of the motor.
A.1.1.3 For linear motor applications, gather this additional information:
1Mass of the moving load
2Mass of the motor forcer block if the motor rod is stationary
OR
Mass of the motor rod if the motor forcer block is stationary.
A.1.2: Observe the Properties of Each Deceleration During a Complete Cycle
of Operation
A.1.2.1 For each deceleration during the motion cycle, determine:
1Speed at the start of the deceleration
2Speed at the end of the deceleration
3Time over which the deceleration takes place.

Xenus Regeneration Guide Regen Resistor Sizing and Configuration
Copley Controls Corp. 13
A.1.3: Calculate Energy Returned for Each Deceleration
Use the following formulas to calculate the energy returned during each deceleration:
Rotary motor:
Edec=½Jt(I1
2-I2 2)
Where:
Edec = Energy returned by the deceleration, in joules.
Jt = Load inertia on the motor shaft plus the motor inertia in kg m2.
I1 = Shaft speed at the start of deceleration in radians per second.
I2 = Shaft speed at the end of deceleration in radians per second.
I= 2JRPS.
Linear motor:
Edec=½Mt(V1
2- V2 2)
Where:
Edec = Energy returned by the deceleration, in joules.
Mt=Total mass of the load and the moving part of the motor in kg.
V1=Velocity at the start of deceleration in meters per second.
V2=Velocity at the end of deceleration in meters per second.
A.1.4: Determine the Amount of Energy Dissipated by the Motor
Calculate the amount of energy dissipated by the motor due to current flow though the
motor winding resistance using the following formulas.
Pmotor = 3/4 Rwinding (F / Kt)2
Where:
Pmotor = Power dissipated in the motor in watts.
Rwinding = Line to line resistance of the motor.
F = Force needed to decelerate the motor:
Nm for rotary applications
N for linear applications
Kt = Torque constant for the motor:
Nm/Amp for rotary applications
N/Amp for linear applications
Emotor = Pmotor Tdecel
Where:
Emotor = Energy dissipated in the motor in joules
Tdecel = Time of deceleration in seconds
A.1.5: Determine the Amount of Energy Returned to the Amplifier
Calculate the amount of energy that will be returned to the amplifier for each deceleration
using the following formula.
Ereturned = Edec - Emotor
Where:
Ereturned = Energy returned to the amplifier, in joules
Edec = Energy returned by the deceleration, in joules
Emotor = Energy dissipated by the motor, in joules

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
14 Copley Controls Corp.
A.1.6: Determine if Energy Returned Exceeds Amplifier Capacity
Compare the amount of energy returned to the amplifier in each deceleration with the
amplifier's energy absorption capacity. For related amplifier specifications, see Amplifier
Regen Circuit Output Specifications (p. 3).
For mains voltages not listed in the specification table, use the following formula to
determine the energy that can be absorbed by the amplifier.
Wcapacity = ½ C (Vregen
2-(1.414 Vmains)2)
Where:
Wcapacity = The energy that can be absorbed by the bus capacitors, in joules.
C = Bus capacitance in farads.
Vregen = Voltage at which the regen circuit turns on, in volts.
Vmains = Mains voltage applied to the amplifier, in volts AC.
A.1.7: Calculate Energy to be Dissipated for Each Deceleration
For each deceleration where the energy exceeds the amplifier’s capacity, use the
following formula to calculate the energy that must be dissipated by the regen resistor:
Eregen = Ereturned - Eamp
Where:
Eregen = Energy that must be dissipated in the regen resistor, in joules.
Ereturned = Energy delivered back to the amplifier from the motor, in joules.
Eamp = Energy that the amplifier will absorb, in joules.
A.1.8: Calculate Pulse Power of Each Deceleration that Exceeds Amplifier
Capacity
For each deceleration where energy must be dissipated by the regen resistor, use the
following formula to calculate the pulse power that will be dissipated by the regen resistor:
Ppulse = Eregen / Tdecel
Where:
Ppulse = Pulse power in watts.
Eregen = Energy that must be dissipated in the regen resistor, in joules.
Tdecel = Time of the deceleration in seconds.
A.1.9: Calculate Resistance Needed to Dissipate the Pulse Power
Using the maximum pulse power from the previous calculation, calculate the resistance
value of the regen resistor required to dissipate the maximum pulse power: For related
amplifier specifications, see Amplifier Regen Circuit Output Specifications (p. 3).
R = Vregen
2/ Ppulse max
Where:
R = Resistance in ohms.
Ppulse max =The maximum pulse power.
Vregen =The voltage at which the regen circuit turns on.
Choose a standard value of resistance less than the calculated value. This value must be
greater than the minimum regen resistor value specified in Amplifier Regen Circuit Output
Specifications (p. 3).