[TO SERIES MANUAL SDFPO 1525-17 SERVO DYNAMICS 21541 D Nordholf St, Chatsworth, CA 91311 (618) 700-8600 * FAX (818) 718-6719 eesThis is a general purpose manual describing the Model SDFPO1525-17 series of servo power amplifier. For ease of wiring refer to the enclosed installation drawing and information manual supplied with each unit, for proper electrical connections. CAUTION THE ELECTRICAL CONNECTIONS AND ADJUSTMENTS PROVIDED HEREIN SHOULD BE ATTEMPTED ONLY BY A SKILLED TECHNICIAN USING PROPER EQUIPMENT SO AS TO NOT VOID YOUR WARRANTY. WARRANTY PROVISION CLAUSE WARRANTY - The Seller warrants that the articles to be delivered under this purchase order will be free from defects in material and workmanship under normal use and are limited to replacing or repairing, at its option, at its factory. any of said articles which within one (1) year after shipment be returned to the Seller's factory of origin, transportation charges prepaid, and which are, after examination, disclosed to the Seller's satisfaction to be thus defective. THIS WARRANTY IS EXPRESSED IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON THE SELLER'S PART AND IT NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR THE SELLER ANY OTHER LIABILITIES IN CONNECTION WITH THE SALE OF THE SAID ARTICLES. This warranty shall not apply to any of such articles which shall have been subjected to misuse, negligence, or accident. The aforementioned provisions do not extend the original warranty period of any article which has either been repaired or replaced by Seller.TABLE OF CONTENTS SECTION PAGE FOREWARD SPECIFICATIONS DIMENSIONS BLOCK DIAGRAM (FIG.1) DISCUSSION OF BLOCK DIAGRAM SIMPLIFIED BOARD LAYOUT (FIG. 2) CONNECTOR INFORMATION TEST POINT INFORMATION PROTECTION ADJUSTMENTS INSTALLATION INSTRUCTIONS INSTALLATION DRAWINGS (Figures 3, 4, 5) SIMPLIFIED SYSTEM SET UP SYSTEM COMPENSATION WITH OSCILLOSCOPE TACH PICTORIAL SECTION (FIG. 6 & 7) MODIFIED COMPENSATION TROUBLE SHOOTING SHUNT REGULATOR BOARD LAYOUT (FIGURE 8) SUMMING AMPLIFIER SCHEMATIC (Figure 9) POTENTIOMETER SETTINGS SIMPLIFIED AMPLIFIER SCHEMATIC (Figure 10) APPENDIX a) MOTOR SERIES INDUCTANCE DISCUSSION b) VARIOUS TACH GRADIENTS c) PROCEDURE FOR SETTING RMS CURRENT POT d) SYSTEMS THAT DO NOT USE TACHOMETERS OR TENSION (TORQUE) CONTROL SYSTEMS e) CURRENT FOLD BACK OPTION £) RECOMMENDATION FOR USING DIFFERENTIAL SIGNAL INPUT FIGURES FIGURE 1 BLOCK DIAGRAM FIGURE 2 SDFPO1525 TEST AND LAYOUT INFORMATION FIGURE 3 INSTALLATION DRAWING SDFPO1525-17 PIGURE 4 INSTALLATION DRAWING SDFPO1-1525-17-1 PIGURE 5 INSTALLATION DRAWING SDFPO4-1525-12-4 FIGURE 6 TACH PICTORIAL SECTION FIGURE 7 TACH PICTORIAL SECTION FIGURE 8 PRINTED CIRCUIT BOARD LAYOUT FIGURE 9 SDFPO AMPLIFIER FIGURE 10 SDFPO1525 AMPLIFIER SCHEMATIC 13 16 19 22 25 27 40FOREWARD This manual is a general purpose manual describing the theory of operation, product specification, installation instructions and adjustment procedure. for the SDFP01525-17 of Servo Amplifier The amplifier, in addition to the other features listed in the specification sheet and common to other amplifiers, does not require an isolation transformer and can derive its 170 vde power directly from a 120 vac source. The Servo Amplifier described herein is a Pulse Width Modulated (PWM) type used for controlling DC brush type servo motors. A complete chassis assembly consists of one or more amplifier modules mounted on a sub panel, containing a bus power rectifier, filter capacitor, fans and associated wiring“agra EE TOES ESTOS, SPECIFICATIONS MODEL. SSDFPO 1825-17 Peak Voliage #170 voc Peak Current 25 Amps (See Note 1) Continuous Vollage 160 VOC (yp) Continuous Current 15 Amps (See Note 2) Horsepower (cont) 2 HP Input Power Re, ‘Bus 1/3 peak to peak VOC nom.) (Peak OC Vals cepends on Mocel) ‘Signal Input Vohages £10 Vols (yp) 2 £235 voits (max) ‘Signal Inputs (ad) 1) Aue Single Enaes 2) Sighal Dit or Singie Ended 3) Tach Single Enaes Gain 0 to 6000 ampsivott ‘Signal Input Impecance 20K mn Signal Balance Ad Drit (refer to inp) ALVIS Switching Freq A KHZ Etlecive Banawiath 15 KHz, Current Limit (ap Oto peak amps RMS limit (ac) (0% to 100% cont. amps PROTECTION with LED incication (See note 3) RED LED 1 Overvotage LED 2 Motor ground faults LED 3 Over temperature Excessive RMS current LED « Excessive vransisor curren Shortes motor output GREEN LED ‘Ampllier operational SERVO DYNAMICS 21841 O Norahott St. Chatsworth, CA 9191 (618) 700-8600 + FAx (B18) 718-6719 System Compensation Adjustable “Ambient Tom. (oper) 010 S0%C ‘Asilary Inputs Gain Reduction/Gain Increase [Umit Swatch Overtavel NOLIN. Remote On-Ot Programmabte Current Limit Remote Reset Load Current Monitor (Gee Note ¢) Fault Monitor Options Special Compensation Internal Reset Current Foldback—No Shut Of ‘with internal ieset ‘Asiiary Outouts Notes: 1. Max. peak current is avaiable for 1 second, 2. The ampilier has a bultin AMS protect cut. the continuous current level s exceeded for an extended ‘ime the ampitier wil tnp-off ane stay off win LED incicaton 3. The amolitor when tnpped will tay off wih LED incicaton. 4, Butlered curent output can drive a SK or greater load 10 Vols: = Peak Amps. (Uni- TeaydAn : ae (9 383 003 20d reubrs} yy 002 UTEB door UOT a Ho, 30 HOD 3e} 003 YDeL eeaeee Mag aod yey, 20 fig aod yeubys wang 5 (raiar uy uye6 ura) swaaske 10149 Buynortos Teas oy aanaoyd 3991309 oq PINOD STyL 30 AInd 03 SquoMMOD 2eFTTU door uoyaysou Meuse ele Suysora e103aq (door wos aysod uado)_xoq £19714 UO A1q391209 dn 398 sen doot yoey aya SUNESE saanioyy 2ouI09 243 99s 03 AeTdsyp quayauos © 38 Teo;949n pue UO;sTa;psoas {° ye poads doons exe sesuodsas oTsas VIGOISTT TTL 25MODIFIED COMPENSATION(See Figs. 2. 8, & 9) Before modifying the amplifier compensation section, one should try to anticipate what is going to happen when a particular part value is changed. IT IS ALSO NECESSARY TO TURN THE “CMP “ POT FULLY CCW AND SLOWLY TURN IT CW AFTER ANY COMPENSATION PART VALUE IS CHANGED It is also a good practice before changing any compensation values to check for mechanical problems such as backlash, misalignment, damaged couplings, lost motion, lead screw binding or machine wind up. 1) UNABLE TO STOP THE SYSTEM FROM OSCILLATING AT A HIGH FREQUENCY EVEN THOUGH THE "CMP" POT FULL CCW This type of system, is due to the ratio of the gains and break frequencies, that have to much bandwidth. They may be exciting system resonances or the motor may be highly inductive, typically 9 MHY or greater Note: Motors of 2 and 3 inch diameters with torque constants(Kt) of 2 in lb/amp or greater, are typically high inductive motors. If the system is unstable increase the value of capacitor "C10" to .033 mfd and adjust the "CMP" pot fully CCW. It may also be necessary to decrease the tach gain by turning the tach pot CCW. If the system ig still unstable increase the value of resistor"R27" to 33K. Note: Add 100pfd in parallel with R27 when R27 is greater than 10K. If the system oscillation is due to a mechanical resonance it may be necessary to add capacitance at R/C. If the resonance is above 700HZ increase value of R5 to 200 ohms and let C5 equal 1 ufd and. R/C equal 033 ufd, Another idea ig to decr the Betucrnde REE Seuebz2°mzatand aclete Cs and “Ryc.” (Eonsule the factory for the explanation of this change) 262) IF THE MACHINE IS HAVING TROUBLE NULLING OR COMING INTO POSITION, DUE TO NOT ENOUGH GAIN: Increase C4 to .1 mfd and decrease R@ to 2K, and turn the tach pot CW to increase the tach gain. You can also increase the internal forward loop gain of the Servo Amplifier by decreasing the value of R32 from 100 ohms to 10 ohms . 3) A HIGH INERTIA SYSTEM WHICH USUALLY HAS A LOW MECHANICAL BREAK FREQUENCY. It may be necessary to increase C4 to .1 mfd and decrease R8 to 2K 27TROUBLE SHOOTING SECTION If the amplifier does not "turn-on", please read the comments below and read the "Protective Circuit Section" of your manual If a fault indicator is “ON” carefully look at which LED is lit for a proper indentification, and again look at the “Protective Section" for appropriate comment. Other reasons for the drive not “turning-on" even though input power appears to be present 1. Check limit switches, if using normally closed limit lines Ji-14 & 15, must be pulled low for the amplifier to operate Note: The amplifier is factory shipped with a shorting jumper on J6. This jumper is removed only if normally closed limit switches are connected at J1-14 and J1-15. 2. Measure the voltage on the large Bus cap if it is less than 30 volts DC the drive will not turn-on. Increase the bus voltage. 3. Check to see that all motor leads are connected to appropri- ate terminals. Motor runs away. Check and see if the tachometer voltage is really getting to Jl Pin 3 on the amplifier. A convenient place to check this is on TP6 with respect to TP1 Nuisance tripping of the voltage LED. Check and see if the shunt regulator fuses are blown. If a shunt regulator is not present on the amplifier chassis, one may be required for this particular system. 28SHUNT REGULATOR — (optional) On some applications where several axis decelerate with a lot of inertia at the same time, energy is pumped back into the main bus capacitor. This energy can cause the main bus capacitor to charge up to a voltage level beyond the capability of the ampli- fier. The amplifier is protected against this Over-voltage condition. Model SDFPO1525-17 will shut-off at 200 VDC. To avoid nuisance tripping it may be necessary to install a shunt regulator across the DC Bus Capacitor The shunt regulator turns on at 194 VDC for Model SDFPO 1525-17. The shunt regulator will dissipate excessive voltage thru voltage dropping resistors mounted on the amplifier chassis. The shunt regulator is protected against excessive dissipation by means of a fuse. 298 aunora wnoxv1 ods osm a a omue ma =(@) arie agente a @ Boe toe) asec dll on FENG one ome 8 & Berea oa oe alee Om Oo ‘ 2 Boe, Ca A i ae], oese Gas id «98 2). [0] 2 geass s/f | oh SoS oa ee a SB a 23 2s OFIG| oo 3 @ @ ofmo am a = solo ° (2 @ sie am ; J eae, oie 9, Pied ont Ba geese" ae TARR oe 8, «ol BBBBBEB ° oe bae fo oye 2 Bn, ormd a8 Be woocda’ Se" me SfelS (ageoaea B88 33" s000 @) , 7 m ° 8 = = eye] 8888) “eo oO => offo a Ela) @ @ oo = o 000%,° GBB So fg 888888 _ el" | et ‘i So BBQSABEIS & Oropootere gi gts See G9. Q Cao n° fe) Bg 8888888 mace ° BERBBBB fe 3 pea ie _——~ “aa eg gt nc. bree gene Seta6 gunora MaIaITdHY ONINKAS ogaas 11-1 now 6-10 NoHo pur Nowii0D 1S I-1e NI xny e-1e IW z-1r NE IS ee ez Oz i# NI gata ee “ez z# NI gala ze PA-RI-ERECORD OF POTENTIOMETER SETTINGS USE OHMETER SET ON 20K OHM SCALE REMOVE INPUT CONNECTORS FROM J1 AND/OR J2 TPT W.R.T. TPL MAX. CCW LOW LIMIT 70 NOTE: TP1 IS AT GROUND POTENTIAL. TP2-TPS & TF7 GO TO ‘THE AFORMENTIONED POTENTIOMETER WIPERS. ** If this SDFPO module is used as a replacement for an SD, SDF, or SDFO series modul the same signal potentiometer setting (ohmic value TP1-TP3) on the SDFPO module probably will not produce the same performance because of the differences in front end circuit layout. ‘When adjusting the compensation pot.for the desired ohmic reading, start with the pot fully CW and turn CCW for the desired reading. Because of the pots. function in the circuit, the ohmic reading goes from a minimum to a maximum and back to a minimum, from one end of the adjustment to the other. To assure correct resistance setting of the compensation pot it is necessary to have the current limit pot fully CCW. "W.R.T." = With Respect To. 32ot aunora WWUOWIG OTL WNaOS eon Have suaaraa a uoswas ‘yous 33APPENDIX 34MOTOR SERIES INDUCTANCE DISCUSSION The amplifier has an electronic rate of rise detector for ouput current. This circuit can sense if inductance is too far below the minimum safe value and shut off the amplifier with a “SURGE” LED indication. Hence an external buffer current inductor may not be required. It should be pointed out that in particular with the 170 VDC model amplifier when used with motors that have 140 VDC commuta— tors that an external inductor under many operating conditions will increase the motor brush life VARIOUS TACH GRADIENTS As a general rule the amplifiers are set up to work with the “tach pot" in mid-position, for use with 7 Volt/1000 RPM tachometers. In order to keep the tach pot in “mid position" a tach divider may be required for some tach gradients If a high voltage tach is used, the motor/amplifier may not attain full speed, and a tach divider will be required. See Scale Below: VOLTAGE DIVIDER IN TACH CIRCUIT TACH GRADIENT IN R/C SLOT INSTALL V/1000 RPM THE RESISTOR LISTED 31.5V 2.4K 20V 3.9K 1sv 6.8K 12.5V 9.1K Nw NONE 35APPLICATION NOTES PROCEDURE FOR SETTING THE RMS CURRENT POT (R60) 1) Disconnect all power to the circuit board. 2) Connect an OHM meter (set on 20K OHM scale) to TP7 with respect to ground TP1. (Reference Figure 2.) 3) Set to values shown below for the desired RMS current. MODEL SDFPO-1525-17 RMS CURRENT “OHMIC READING 15 10.K 128 9.4K 10A 8.5K 7.95R 6.5K 5A 4.1K 2.58 2.1K *As measured from TP7 with respect to TP1 ground. 36APPLICATION NOTE A) SYSTEMS THAT DO NOT USE TACHOMETER FEEDBACK OR B) TENSION (TORQUE) CONTROL SYSTEMS USUALLY REQUIRE A POWER STAGE AS PART OF THE CONTROL SYSTEM THAT PROVIDES A PROPORTIONAL OUTPUT RELATIVE TO A COMMAND HOW TO CONVERT A STANDARD SDFPO1525-17 CURRENT SOURCE AMPLIFIER MODULE INTO A POWER STAGE WHICH HAS THE APPROPRIATE LINEAR AND PROPORTIONAL GAIN 1) INSTALL A JUMPER LINK AT J3 BETWEEN PINS 1 & 2 (THIS REDUCES GAIN OF FRONT END OP AMP SO THAT IT HAS A MAX GAIN OF 2). 2) TURN ANY UNUSED SIGNAL INPUTS (AUX & TACH) FULLY ccW. 3) TURN COMPENSATION POT FULLY cw. 4) ADJUST SIGNAL INPUT POT FOR APPROPRIATE SCALING OF THE POWER AMPLIFIER TO HAVE LINEAR & PROPORTIONAL GAIN FOR EXAMPLE: IF 10 VOLTS IS THE MAXIMUM SIGNAL COMMAND ADJUST THE SIGNAL POT SO THAT 10 VOLTS = 25 AMPS. 37CURRENT FOLDBACK APPLICATION NOTE Servo Dynamics Amplifiers reduce output current in either of two ways when RMS or continuous ouput is exceeded; 1. The unit shuts off and remains off until reset. 2. The unit reduces the maximum allowable current to a preselected level. If the second (foldback) system is installed, the value of a single resistor in the amplifier determines the maximum output current during foldback. Assume an amplifier has a peak rating of 25 amperes and a continuous rating of 15 amperes. This means that. if the amplifier has been at rest, it will deliver 25 amps for a second or two and then fold back to a lower level when the contin- uous level set by the RMS pot is exceeded. IN SELECTING THE RESISTOR WHICH CONTROLS THE FOLD BACK LEVEL IT IS STRONGLY RECOMMENDED THAT THE LEVEL BE GREATER THAN THE LEVEL WHICH IS SELECTED BY THE RMS POT.* If the reverse were true, the current would fold back to a level lower than the RMS trip level. This would let the RMS circuit go back to an “untripped" condition and the current would suddenly go back to the 25 amp level. The current would oscillate between the 25 amp level and the foldback level, a condition which should be avoided. If, on the other hand, the current folds back to a level higher than the RMS trip point, the RMS circuit remains "tripped", and the current remains steady until an external command calls for lower current. " See Current Foldback Selection Table (next page). 38CURRENT FOLDBACK SELECTION TABLE AMP PEAK FOLDBACK LIMIT (AMPERES) R95 RESISTOR VALUE (OHMS 15 1.82K 10 740 5 240 AMP PEAK 15 3.2K 10 i 5 150 AMP PEAK 10 1.5K 5 210 AMP PEAK 5 400 * As part of Current Foldback Selection 1. Remove resistor R62. 2. Add R37, 100K ohms 3. Add R38, 10 K ohms 4. Add Q22, 2N5461 5. Select R35 value per table for foldback limit to match up with peak current setting. 39APPLICATION NOTE For the SDFPO 1525-17 SDFPO using the differential input to J2, Pins 1 and 2 The standard method is to use a twisted pair of shielded wires for connecting the controller to the amplifier. The procedure is to connect the appropriate wire of the shielded pair to the controller output and to connect the other wire to the controller ground with the shield grounded at the controller end. Most controllers output's are single-ended for the signal com- mand. The controller's signal command output can be connected to the differential input of the SDFPO amplifier. In general, using the differential signal input of the amplifier will give cleaner amplifier performance than using the single~ ended signal input of the amplifier. However, when using the differential input (J2, Pins 1 and 2) of the SDFPO amplifier, ONE MUST BE AWARE THAT THIS AMPLIFIER HAS NO INTERNAL CONNECTION FROM THE J1 COMMONS TO METALWORK AND AT LEAST ONE OF THE "COMMON" PINS 4, 9 OR 11 NEED TO BE CONNECTED TO CONTROLLER GROUND. Failure to make this connection can result in large 60 Hz voltages which will overload the differential input. If the reset or fault status/inhibit Pin J1 is used, a ground return for it will normally go to Pin 9 or 11 will suffice for the required grounding. Proper housekeeping calls for these wires to be bundled with the signal cable to J2. If routed as a separate cable, magnetic fields can put a large common-mode voltage between the ground wire and the signal wires. If the only other connection to J1 is the tachometer input to Jl. Pins 3 and 4, the shield of the signal cable, which is normally only connected at the controller's end, can also be connected at the amplifier to Ji, Pin 4 to obtain the required ground connec— tion and there will not be a ground loop. Servo Dynamics Rev. 1/5/95 40APPLICATION NOTES and SDFPO SERIES Limit Switch Inputs TI Pins 6 & 7 (N.O.) or JI Pins 14945 (N.C.) ‘The limit switch feature on these series is different than the SD series. If a limit switch input is activated on the SDFP and SDFPO the amplifier will not deliver power to the motor in the direction the amplifier was inhibited. If the command for the original direction is still present and the limit switch input is de-activated the amplifier will stil not deliver power in the original direction. However the amplifier will deliver power in the opposite direction. If commanded in the opposite direction. ‘Once the amplifier has delivered power in the opposite direction and the command is flipped again the amplifier will deliver power in the original direction. Because of the design of this limit switch feature it is not advisable to tie Pins 6 & 7 or Pins 14 & 15 together because there is a lot of flipping of a command line after the pair of inputs Pins 6 & 7 or Pins 14 & 15 are released to get the amplifier to become bi directional again. THRESHOLD LEVELS TH, Pins 6, 7, 8, 14 & 15 inputs have CMOS logic (7 volts) threshold. For Pins 14 & 15(N.C. limit switch inputs) the signal has to get to +7 volis for the amplifier to shut of. However if oné wanted to tie Pins 14 & 15 to the -15 volts (J1, Pin 12) which is not really necessary one could, ‘The model SDFP requires an external +15 volt supply which is connected to J4. ‘The model SDFPO does not need an external supply for Pins 10 & 12 of J1. Do not forget the 1K buffer resistor in series with the -15 volts (J1, Pin 12) retum, line for the limit switches if you use the -15 volt as the return line. JLPIN 8 This Pin can be pulled up to +24 volts, However a IK extemal resistor must be installed in series with Pin 8 to prevent excessive dissipation in Q15. T9195 SERVO DYNAMICS 21641 D NORDHOFF STREET CHATSWORTH, CA91311