mattke MTR 5K Parts list manual

TECHNICAL DESCRIPTION
Edition 1.00
4-QUADRANT-SERVO-AMPLIFIER
TYPE
MTR 5
MTR 20
Telefon: [phone]
Telefax: [phone]
E-Mail: [email protected]
http://www.mattke.de
MATT E AG
Leinenweberstraße 12
D-79108 Freiburg
Germany

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 2
Dear customer,
We always try to guarantee for an optimum of security measures and to inform our-
selves about the latest developments in technical research. However, it is necessary
that we pass on the following further information to you as the user of our compo-
nents:
The appliances are supply parts meant for processing by industry, trade or other fac-
tories specialized in electronics.
Safety precaution !!
Attention - do not touch! The appliances have unprotected live parts. The voltage
may be highly dangerous.
We also have to inform you that, for your own security, only an expert should work on
the appliances.
In order to comply with the safety precautions, open connections must be protected
against contact with cases, coverings or anything similar. Even after the appliance
had been disconnected, there may still be a dangerous voltage (discharges of the
capacitors).
Due to an error in handling or unfavorable conditions, the electrolytic capacitors may
explode. If you have to work on the open appliance, do protect your body (hands!)
and your face!
Make sure that there is enough ventilation because of the fire risk in case of over-
heating.

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 3
Table of Contents
TECHNICAL DESCRIPTION....................................................................................................................1
Edition 1.00 ...........................................................................................................................................1
1. Technical Description ....................................................................................................................5
1.1 General Information ...................................................................................................................5
1.2 Special Features ........................................................................................................................5
1.3 Summary of Types.....................................................................................................................6
1.4 Technical Data ...........................................................................................................................7
1.5 Functional Principles and Basic Circuit Diagrams ...................................................................10
1.5.1 Free Nominal Voltage Choice...........................................................................................10
1.5.2 Auxiliary Voltage ...............................................................................................................11
1.5.3 Function Principles of the Output Stage ...........................................................................11
1.5.4 Electrical Isolation .............................................................................................................14
1.5.5 Limit Switch Input with Automatic Braking........................................................................15
1.5.6 Blocking Protection ...........................................................................................................15
1.6 Overview of Terminals .............................................................................................................15
2. Projecting and Dimensioning.......................................................................................................19
2.1 Load Category..........................................................................................................................19
2.2 Optimizing the Drive for Given Amplifier Power.......................................................................20
2.3 Determination of the RMS Current for Dynamic Load .............................................................20
2.4 Nominal Voltage.......................................................................................................................22
2.5 Mains Transformer Calculation ................................................................................................23
2.6 Ballast Resistor ........................................................................................................................24
2.7 Commutation Current Limiting .................................................................................................25
2.8 Dynamic Brake (Option)...........................................................................................................26
2.9 Ramp Generator (Option, external) .........................................................................................27
2.10 Fuse Protection for Principal Power Supply ............................................................................27
2.11 Multiple Shaft Operation ..........................................................................................................28
2.12 Electrical Installation, Grounding, Erection ..............................................................................30
3. Commissioning and Operation ....................................................................................................34
3.1 Potentiometers, Fixed Components and Test Points (Overview)............................................34
3.2 Presetting .................................................................................................................................37
3.3 Correct Polarities......................................................................................................................37
3.4 Commissioning (First-Time Switch-On) ...................................................................................37
3.5 Current Adjustment ..................................................................................................................38
3.6 Tacho-Voltage..........................................................................................................................38
3.7 Offset Adjustment and Check for Absence of Feedback Effects.............................................39
3.8 Optimization of the Control Behavior .......................................................................................39
4. Service Information......................................................................................................................41
4.1 General Fault Tracing ..............................................................................................................41
4.2 Short Circuit in the Output Stage .............................................................................................42
4.3 Replacing the Control Electronics............................................................................................43
4.4 Replacing the Driver Electronics (with ballast circuit) ..............................................................44
4.5 Replacement Parts...................................................................................................................45

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 4
Table of Figures
Figure 1: Block Diagram, Transistor Servo Amplifier, Series 20K.......................................................... 9
Figure 2: Basic circuit diagram of the output stage .............................................................................. 11
Figure 3: Simplified basic circuit diagram............................................................................................. 12
Figure 4: Voltage waveforms in the output stage................................................................................. 13
Figure 5: maximum pulse current duration as a function of the recovery time an the current boost
factor............................................................................................................................................... 21
Figure 6: maximum pulse current duration as a function of bias and current boost factor .................. 21
Figure 7: Example of a working diagram.............................................................................................. 22
Figure 8: Standard commutation characteristics.................................................................................. 25
Figure 9: Proposed circuit for dynamic brake....................................................................................... 26
Figure 10: Fuse protection for multiple shaft operation with same nominal voltage ............................ 28
Figure 11: Power supply for unequal nominal voltages ....................................................................... 29
Figure 12: Fuse protection for mechanically coupled shafts ................................................................ 30
Figure 13: Connections diagram for series 20K units .......................................................................... 32
Figure 14: Connections diagram for series 5K units ............................................................................ 33
Figure 15: Components layout diagram for control electronics............................................................ 47
Figure 16: Circuit diagram of the preamplifier ...................................................................................... 48
Figure 17: Components layout diagram for driver electronics.............................................................. 49
Figure 18: Circuit diagram of ramp generator ...................................................................................... 50
Figure 19: Components layout diagram of ramp generator ................................................................. 50
Figure 20: Components layout diagram for electronics and ballast circuit........................................... 51
Figure 21: Components layout for driver module ................................................................................. 52
Figure 22: Dimensions of Series 20K unit ............................................................................................ 53
Figure 23: Dimensions of Series 5K..................................................................................................... 54

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
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1. Technical Description
1.1 General Information
The Series 5K and 20K transistor servo amplifiers are pulse width modulated amplifiers which have
been conceived primarily for driving DC servo motors with permanent excitation. These devices oper-
ate in four-quadrant mode, i.e. the connected motor can drive or brake in both senses of rotation,
whereby a boosted pulse torque greater than the continuous torque is available for short periods. This
feature makes these servo amplifiers particularly suitable for driving machine tool feed spindles, but
other applications are possible too (especially for the series 20K units), e.g. antenna drives.
1.2 Special Features
A new kind of modulation technique is used, in which no audible modulation sounds are emitted from
the motor or from chokes, i.e. the objectionable whistle or howl emitted by many conventional chopper
amplifiers, is here completely absent. The iron losses in the motor and chokes (magnetic hysteresis
losses in the magnetization cycle) are smaller by an order of magnitude compared with those involved
in conventional modulation methods.
The series 20K devices incorporate electrical isolation between the open loop control input side and
the load side, so that a single-wound transformer may be used instead of a double-wound transformer
for power supply. The case is electrically insulated with respect to the device.
The series 5K devices feature self-cooling, i.e. a blower is not required for forced air cooling. These
units employ essentially open construction, i.e. with no special case to contain them.
Both series of units contain a three-phase bridge rectifier for power supply and a generously dimen-
sioned ballast circuit to dissipate the braking energy. Power supply is optional with three-phase alter-
nating current or with direct current. A 230V / 50Hz auxiliary supply is required only to power the blow-
er fan in series 20K units. The control electronic circuitry is powered directly from the principal supply
via incorporated voltage converters.
Supply voltage fluctuations within wide limits are tolerated in operation (60V – 150/200V; briefly 50V –
175/230V). This permits full battery operation for the series 5K units, and an “emergency run” operat-
ing mode for the series 20K units, for example to steer to a safe position in battery operation without
blower fan on mains voltage failure. Both types of unit contain storage chokes permitting direct con-
nect-up to any motor or other kinds of load. Self-heating is very small, by virtue of the high power effi-
ciency (95 – 96% at 200V nominal voltage). Thus the required cooling facilities for the equipment cab-
inet remain within reasonable limits even when several drive shafts are incorporated.

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 6
The units incorporate protection circuits for current overload, overvoltage, undervoltage and overheat-
ing, as well as an optional plug-in commutation current limiter (IAmax = f(UA)) and standard feature I2t
current limitation. Furthermore, inputs are provided for direction-dependent limit switches, output stag-
es enable and cut-out of the integral control function. Response of the I2t current limiter is signaled via
an open collector output. When the unit is functional, a floating relay contact closes.
1.3 Summary of Types
Unit Designation Nominal Voltage
(V)
Nominal Current
(A)
Pulse Current
(Ampere, max.3s)
Series
MTR 150 / 10-B 60 – 100 10 18
5K
MTR 150 / 25-B 60 – 150 25 40
MTR 150 / 35-B 60 – 150 35 60
MTR 200 / 10-B 60 – 200 10 18
MTR 200 / 25-B 60 – 200 25 40
MTR 200 / 35-B 60 – 200 35 60
MTR 150 / 50-B 60 – 150 50 100
20K
MTR 150 / 70-B 60 – 150 70 150
MTR 150 / 100-B 60 – 150 100 200
MTR 200 / 50-B 60 – 200 50 100
MTR 200 / 70-B 60 – 200 70 150
MTR 200 / 100-B 60 – 200 100 200

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 7
1.4 Technical Data
Voltage range of control inputs ±10V
Internal impedance of the control inputs 20kOhms
Setting range of the input attenuator 0.18 … 1.1
Maximum tachovoltage for Ui= ±10V ±100V
Internal impedance of the tacho-input (min.) 11kOhms
Setting range of the tacho-attenuator 0.065 … 0.65
Maximum input drift ±15µV / °C
Output current form factor for nominal current max. 1.01
Bandwidth of subordinate current controller 1kHz
Clock frequency of output stage 8.5kHz
Isolation voltage between preamplifier and output stage ±1500V DC
Pulse currents of ballast circuit (5K / 20K) 40A / 120A
Continuous duty power dissipation of the ballast circuit (5K / 20K) 275W / 4.4kW
Contact rating of signaling relay 100V / 0.1A / 10W
Power supply outputs for external auxiliary circuits ±15V / 20mA
Action mode of inputs for limit switches and
output stage enable:
-10 / 11 / 16 -
Normal run only when contact closed.
The function of the particular input is true when the
contact is opened (e.g. pos. Stop).
Reference potential M2.
Armature current monitor output:
- 19 -
±10V corresponding to the device pulse current, Ri
= 1kOhm.
Reference potential M1.
I²t signaling:
- 20 -
For active current limiting, sinking to 0V; otherwise
open circuit voltage +15V.
Reference potential M1.
Control output for dynamic brake: Open collector, sinking to 0V only when unit is
operational and the output stage is active.
Message output for “ready for operation”:
- 23 / 24 -
Reed contact, closed when unit is ready for opera-
tion, also when output stage is switched clear.
Storage temperature: -10°C … +60°C
Ambient temperature for nominal operation: 0°C … +45°C
Ambient temperature with max. 80% load: 0°C … +55°C
Mounting instructions (only 5K): Wall mounting, cooling fins vertical, ballast resistor
at top
Tolerated further run time at nominal current
without fan (only 20K):
2 minutes starting in normal operating temperature
state
Power dissipation at nominal current: 10A: 80W
20A: 250W
35A: 280W
50A: 500W
70A: 700W
100A: 1100W
Mechanical attachment: With 4 screws on flat surface
Dimensions (length x width x height): Series 5K : 210 x 260 x 216 mm
Series 20K : 440 x 218 x 255 mm
Weight: Series 5K : 3.5kp
Series 20K : 18kp

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
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Transistor Servo Amplifier, Series 20K, Block Diagramm
1) Input 1
2) Input 2
3) Tacho-input
4) Difference amplifier
5) Difference amplifier
6) Tach-matching
7) Pulse current
8) Nominal current value
9) CW – limit switch
10) CCW – limit switch
11) Output ±15V / 20mA
12) Integral off (inv.)
13) Output stage enable (inv.)
14) Armature current monitor
15) I²t signaling
16) Relay for brake
17) Message contact for “ready” (closed
when ready)
18) Enable delay 30msec
19) External enable
20) Limit switches logic
21) Soldered jumper connection B1
22) Open an closed loop control elec-
tronics
23) Plug-in location for special circuit
24) Offset
25) Speed control amplifier with limiter
26) Electrical isolation ±1500V DC
27) Drift (for limit switches) and switch-
on jerk suppression circuit
28) Negative feedback network
29) Gain
30) Analog buffer amplifier and power
supply for preamplifier
31) Speed controller enable
32) Output stage enable
33) Optocoupler
34) Optocoupler
35) Protection circuits for current over-
load, overvoltage, undervoltage,
overtemperature, blocking (control
enable function)
36) General enable
37) Ready for operation
38) Current controller and driver enable
39) 8kHz clock generator, pulse width
modulator and delay circuit
40) Nominal current value limiter
41) PI-type current regulator
42) Armature current measuring circuit
43) Plug-in module for speed-dependent
current limiting
44) I²t measuring circuit
45) Armature voltage measuring circuit
46) Armature current actual value
47) I²t signaling
48) DC/DC voltage converter 60 – 200V
to ±15V
49) Driver electronics
50) Output stage driver circuit
51) Four-quadrant output stage
52) Safety chokes output
53) Blower, 230V
54) IAsensing lines
55) UAsensing lines
56) Control electronics for ballast circuit
57) Ballast resistor
58) Reservoir electrolytic capacitor
59) 3-phase power supply
60) 3-phase bridge rectifier, 100A

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 9
Figure 1: Block Diagram, Transistor Servo Amplifier, Series 20K

TECHNICAL DESCRIPTION „MTR 5K, MTR 20K“ Edition 1.00
Page 10
1.5 Functional Principles and Basic Circuit Dia-
grams
The following explanations are chiefly confined to the special features and technical innovations of
these units. In this section it is assumed that the reader is familiar with the general principles and pos-
sible applications of servo amplifiers. The basic circuit diagrams, respectively for the series 5K and
20K units, form the basis for the description.
1.5.1 Free Nominal Voltage Choice
The standard version servo amplifiers (150Volts) may be operated with any nominal supply voltage in
the range from 60 to 150Volts. The series with extended power supply voltage range (200V) permits
nominal supply voltages from 60 to 200Volts. The particular chosen nominal supply voltage is deter-
mined by the secondary voltage of the mains transformer. It is important to ensure that rectified volt-
age can not drop below 50V even when full pulse current is being drawn, and that the worst case open
circuit voltage is never greater then 175V (or 230V for 200V). The corresponding rms voltages for the
highest allowed values are 125V rms and 163V rms respectively in idle state. The ballast circuit may
become damaged if these limits are not observed.
Depending on the particular application, the mains transformer rating is usually much smaller than the
product of nominal current and nominal voltage, especially when speeds are required only rarely.
This is permissible because the output stage draws only the power level from the transformer which it
actually passes-on to the motor. This power is not only a function of the output current, but also of the
output voltage. The output stage of the unit performs a kind of impedance transformation, i.e. at slow
motor speed it transforms the relatively large intermediate circuit voltage at low current drain to the low
armature voltage at high armature current. Thus, for example, in the extreme case of “short circuit
across the motor terminals”, even 100Amperes output current causes only about 4.5A rms current to
flow the transformer to the rectifier circuit.
The possible saving is 50% without any problems, in the case of a single-shaft system and predomi-
nantly dynamic load. In a multiple shaft system, the saving may be much greater still, depending on
the load distribution in time. Therefore it may be useful to measure the actually required transformer
power in system operation.