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
Copley Controls Corp. 3
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
4Copley Controls Corp.
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.