Whittaker C159980 User manual

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NOTICE: PROPRIETARY INFORMATION OF WHITTAKERCONTROLS, INC., ABUSINESS UNIT OFMEGGITT PLC.
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WHITTAKER CONTROLS, AND SHALL NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED IN WHOLE
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THIS NOTICE SHALL APPEAR IN ANY SUCH REPRODUCTION.
REVISION 1.0 – 07/01/2005
Maintenance Manual
SERVO MOTOR CONTROLLER
60-300 VDC, RS 232, ANALOG 4-20 MA, CAN OPEN
PART NUMBERS:
C159980
C159980-1
C159980-2

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 2
LIST OF EFFECTIVE PAGES
On a revised page, the portion of text or illustrations affected by the change is indicated by a vertical line
in the outer margin of the page. When a revision is issued, the entire document is reissued with the current
revision number and date shown on all pages. For major revisions, the basic number is incremented. For
minor revisions, the number following the decimal is incremented. Dates of issue for original and subse-
quent revisions are as follows:
Original1.0 ...........................................07/01/2005
The total number of pages in this technical document is 39 consisting of the following: Title, 2 – 12, Appen-
dix A (23 pages), and Appendix B (4 pages).
TABLE OF CONTENTS
SUBJECT PAGE
Introduction ....................................................................... 5
Description and Operation ........................................................... 6
Installation ...................................................................... 11
LIST OF ILLUSTRATIONS
FIGURE PAGE
1. ServoMotorController ...................................................... 7
2. Envelope Dimensions ....................................................... 8
LIST OF TABLES
TABLE PAGE
1. Specifications/Characteristics ............................................... 10

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 3
LIST OF APPENDICES
APPENDIX NUMBER OF PAGES
A DS2000 Servodrive User’s Manual, Section 6 – Commands ................ 23
B Installation Drawing, CA24635 ........................................ 4
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS!
This manual contains important instructions that should be followed during installation and maintenance
of the Servo Motor Controller (controller). The following are general safety precautions that are not related
to specific procedures and therefore do not appear elsewhere in this publication. These are recommended
precautions that personnel must understand and apply during many phases of maintenance.
The controller is electrically energized. Wherever electricity is present, there is the hazard of electrocution.
Like any other electrical device, the controller can be dangerous if it is improperly operated or maintained.
Safety Alert Symbols
Safety alert symbols are used in this manual to identify potential or immediate personal injury hazards. The
safety alert symbol words are explained below:
DANGERindicatesanimminentlyhazardoussituationwhich,ifnot
avoided, will result in injury or serious injury.
WARNINGindicatesapotentiallyhazardous situationwhich,ifnot
avoided, could result in injury or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a poten-
tially hazardous situation which, if not avoided, may result in pro-
perty damage.
WEAR PROTECTIVE CLOTHING
!Wear protective clothing (gloves, apron, etc.) approved for the materials and tools being used.

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 4
USE APPROVED SAFETY EQUIPMENT
!When cleaners are being used, approved explosion-proof lights, blowers, and other equipment must
be used. Make sure that fire fighting equipment is readily available and in working order.
GIVE CLEANERS SPECIAL CARE
!Keep cleaners in special polyethylene bottles or in safety cans and in minimum quantities. Discard soil-
ed cleaning rags into safety cans.
Equipment Safety Information
The following safety information briefly discusses hazards peculiar to the equipment, which are likely to be
encountered during maintenance activity.
GENERAL OPERATING LOCATION PRECAUTIONS
!This manual covers equipment for use under the following atmospheric conditions:
CAn oxygen concentration not greater then 21 percent by volume
CA nominal barometric pressure of one atmosphere
!Use only authorized replacement parts or hardware.
!Observe proper Lock-Out/Tag-Out procedures when working on the controller and make sure that per-
sonnel protection equipment such as electrical grounds are installed.
!Make sure that all of the electrical wiring is properly terminated. Make sure that all of the wire terminals
are securely connected.
!Avoid hazardous voltage situations that can result from unsafe conditions such as, but not limited to
the following:
CImproper grounding
CHandling electrical leads or devices with wet hands or on wet ground
CDamaged electrical wire insulation
CImproper connection or re-connection of the power terminals.
CShort circuits to ground

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 5
INTRODUCTION
1. Purpose of Manual
This manual provides component maintenance shop instructions for the Servo Motor Controller (con-
troller).
2. Scope of Manual
This manual is intended to provide information in sufficient detail to permit proper fault isolation main-
tenance, and repair of the controller.
3. Revision Service
This manual will be revised as necessary to show the current information.
4. Weights and Measurements
Weights and measurements in this manual are expressed in both English (U.S. customary) and Metric
(SI) units.

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 6
DESCRIPTION AND OPERATION
1. Description
A. The Servo Motor Controller (see Figure 1) is installed remotely from the valve it controls, in its
own explosion proof container or in a separate customer furnished cabinet. In either case, the
controller must be located within 600 feet (182 meters) wire run length from the valve.
B. The controller consists of a servo amplifier, a position control I/O card and a power converter
packaged in a compact unit with readily accessible interface terminations. The servo amplifier
is pulse-width modulated.
C. The servo amplifier is mounted on a cold plate for improved heat conduction when enclosure
mounted.
2. Operation (Refer to Figure 2)
A. General
The controller is designed for control of high speed brushless DC servo motors for precision posi-
tioning of valves used on aero-derivative and frame DLE and SAC turbine engines.
B. Features
1) Speed and current control loops and many other functions, such as DC BUS status moni-
toring, softstart and recovery circuit management, and the protections thresholds detection,
carried out through numeric algorithms.
2) The digital mode allows a maximum stability related to the aging, the temperature and the
various application cases.
3) Settings are carried out through numbers calculated by means of analytic models and do
not depend upon analog calibrations.
C. Capabilities
1) Any 3-phase brushless DC motor can be driven by entering a set of parameters which
adjust the current loop and identify the motor’s electro-mechanical characteristics.
2) Any type of asynchronous motor can be very well driven by vector control, working as a
brushless servomotor, by entering the magnetization current (ID) and the slip gain (fre-
quency) additional parameters. Other parameters, used in connection with the hardware
features in common with brushless motors, remain active.

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 7
Figure 1. Servo Motor Controller

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 8
Figure 2. Envelope Dimensions

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 9
3) The motor transducer can be both a resolver (2 to 24 poles) and an incremental encoder
(1024 to 8192 pulses).
3. Command Interface
Appendix A contains information on the commands available from the keypad on the controller’s front
panel.
4. Configuration Switches
The Configuration Switches on the front panel allow the controller to be configured for use with specific
Whittaker Controls valves, as follows:
VALVE PART NUMBER SWITCH ID1 SWITCH ID2
C422855-1 0 F
TBD 1 TBD
TBD 2 TBD
TBD 3 TBD

WHITTAKER CONTROLS, INC.
A MEGGITT PLC COMPANY
MAINTENANCE MANUAL
SERVO MOTOR CONTROLLER – MODEL C159980
INDUSTRIAL PRODUCTS GROUP Revision 1.0 07/01/2005 Page 10
5. Specifications/Characteristics (Refer to Table 1)
Table 1. Servo Motor Controller Specifications/Characteristics
Type ............................................... Analogcontrolwithdigitalinterface
Temperatures
OperatingAmbient ......................................... 32to104°F (0 to 40°C)
Storage ............................................... –13 to 131°F (–25 to 55°C);
Excursions to 158°F (70°C) for up to 24 hours are acceptable
Electrical Data
Power Bus Input ......................................... Upto600 VDC (460 VAC)
Output Current Range ........................................... 5to140 amperes
ControlType ................................... ClosedLoop Position/Velocity Control
DigitalInput/Output..........................................................24VDC
Electrical Connections ..................................... TerminalStrip,AWG12to22
DESCRIPTION WHITTAKER PART NUMBER CONFIGURATION
Servo Motor Controller 159980 Analog, 4 to 20 milliampere,
CANBUS, CANOPEN, DS 402
159980-1 Adds Filter
159980-2 Adds Filter and Heater