Copley Controls Xenus XSL-230-36 User manual

Xenus™Regeneration Guide
P/N 95-00306-000
Version 1.1
November 2004

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: Regen Specifications.............................................................................................................................................................. 2
1.2.1: Amplifier Regen Circuit Output Specifications............................................................................................................ 2
1.2.2: Copley Standard Regen Resistor Specifications ........................................................................................................ 2
1.2.3: Regen Dimensions .................................................................................................................................................... 3
1.3: Regen Circuit Wiring............................................................................................................................................................... 4
1.3.1: Electrical Codes and Warnings.................................................................................................................................. 4
1.3.2: Connector Locations.................................................................................................................................................. 5
1.3.3: Regen Resistor (J3) Wiring........................................................................................................................................ 6
1.3.4: Regen Resistor Configuration with CME 2 ................................................................................................................. 7
A: Regen Resistor Sizing and Configuration ................................................................................................................................. 9
A.1: Sizing a Regen Resistor....................................................................................................................................................... 10
A.2: Configuring a Custom Regen Resistor ................................................................................................................................. 14
A.2.1: Regen Configuration Objective and Warning........................................................................................................... 14
A.2.2: Regen Configuration Instructions ............................................................................................................................ 14

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 of the CANopen features should also read these Copley Controls documents:
•Xenus User Guide
•Using CME 2 with Xenus
Information on Copley Controls Software can be found at:
http://www.copleycontrols.com/motion/software
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
Release Date Applies to Comments
1.0 July 2003 Xenus firmware version 2.16
CME 2 Software version 3.1
Initial publication.
1.1 November 2004 Xenus firmware version 4.0.
CME 2 Software version 4.0.
Corrected model number in specifications table
(p. 2).

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: Regen Specifications.............................................................................................................................................................. 2
1.3: Regen Circuit Wiring............................................................................................................................................................... 4

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. 9).
The amplifier protects the regen circuit against short circuit, and uses I2Tpeak current/time
algorithms to protect both the external resistor and internal transistor.
1.2: Regen Specifications
This section describes the regen resistor specifications.
1.2.1: Amplifier Regen Circuit Output Specifications
Model XSL-230-18 XSL-230-36 XSL-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
1.2.2: Copley Standard Regen Resistor Specifications
Model Resistance Continuous Power Peak Power For Use With
XSL-RA-01 30 ohms 167 W 5 kW XSL-230-18
XSL-RA-02 15 ohms 200 W 10 kW XSL-230-36
XSL-230-40

Xenus Regeneration Guide Regen Resistor Sizing and Configuration
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1.2.3: Regen Dimensions
The following diagram describes the mounting dimensions (in inches) of both of the Copley-
supplied resistors.
.244 TYP
.50 TYP
2X 2.75
.25 TYP
5
9.25
10
4.125

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
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1.3: Regen Circuit Wiring
This section describes the wiring of the regen resistor connections.
1.3.1: 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
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1.3.2: 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

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1.3.3: 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 XSL-CK or XSL-CA
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
XSL-RA-01 Cooper Bussman KLM-8 or equivalent
XSL-RA-02 Cooper Bussman KLM-12 or equivalent
User Supplied See Regen Resistor Sizing and Configuration (p. 9).

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1.3.4: Regen Resistor Configuration with CME 2
1.3.4.1 Click Configure Regen ( )to open the Regen Resistor screen.
1.3.4.2 Select a resistor option.
Option Description
None No external regen resistor is used.
XSL-RA-01
XSL-RA-02
Standard regen resistors supplied by Copley Controls.
Custom Resistor User-supplied resistor. See Regen Resistor Sizing and Configuration (p. 9).
1.3.4.3 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
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This page for notes.

Copley Controls Corp. 9
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....................................................................................................................................................... 10
A.2: Configuring a Custom Regen Resistor ................................................................................................................................. 14

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
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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.

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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(H1
2-H2 2)
Where:
Edec = Energy returned by the deceleration, in joules.
Jt = Load inertia on the motor shaft plus the motor inertia in kg m2.
H1 = Shaft speed at the start of deceleration in radians per second.
H2 = Shaft speed at the end of deceleration in radians per second.
H= 2IRPS.
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

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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. 2).
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. 2).
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. 2).

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A.1.10: Calculate Continuous Power to be Dissipated
Use the following formula to calculate the continuous power that must be dissipated by the regen
resistor. Use each deceleration where energy is dissipated by the regen resistor.
Pcont = ( Eregen 1 + Eregen 2 + Eregen …) / Tcycle
Where:
Pcont = The continuous power that will be dissipated by the resistor in watts.
Eregen n = Energy being dissipated during decelerations, in joules.
Tcycle = Total cycle time in seconds.
Choose a resistor with a power rating equal to or greater than the calculated continuous power.
Verify that the calculated power value is less than the continuous regen power rating specified in
Amplifier Regen Circuit Output Specifications (p. 2).
A.1.11: Select Fuses
For custom regen resistors, Cooper Bussman KLM fuses, or equivalent, should be selected. The
peak and continuous currents, as well as the peak current time, must be taken into consideration
for proper fuse selection. The duration of the peak current is the deceleration time (Tdecel)
associated with the maximum pulse power regen event.
Use the following formulas to determine the minimum peak and continuous current ratings of the
fuse. For related amplifier specifications, see Amplifier Regen Circuit Output Specifications (p. 2).
The peak current is determined by the chosen regen resistor value.
Ipeak = Vregen / Rregen
Where:
Ipeak = The current though the regen resistor during regeneration in amps.
Vregen =The voltage at which the regen circuit turns on.
Rregen = The resistance value of the chosen regen resistor in ohms.
The continuous current is determined by the continuous regen power.
Icont = Pcont / Vregen
Where:
Icont = The minimum continuous current rating the fuse requires in amps.
Pcont = The continuous power calculated in the previous step,in watts.
Vregen =The voltage at which the regen circuit turns on.

Regen Resistor Sizing and Configuration Xenus Regeneration Guide
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A.2: Configuring a Custom Regen Resistor
A.2.1: Regen Configuration Objective and Warning
Configure the amplifier to operate properly with the custom resistor.
Incorrect values may damage amplifier or external regen resistor.
!
WARNING
For the I2Talgorithms to work correctly, the values entered in the following steps
must be correct. Damage to the external regen resistor may result from incorrect
values entered. Damage to the amplifier may result if an incorrect resistance value is
entered.
Failure to heed this warning can cause equipment damage.
A.2.2: Regen Configuration Instructions
A.2.2.1 On the Main screen, click Configure Regen ( )to open the Regen Resistor
screen.
A.2.2.2 Select Custom Resistor and then click Configure to open the Custom Regen
Configuration screen.
A.2.2.3 Enter a Resistance within the range described on the screen. Click Next for Step 2.