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OPERATION & SERVICE MANUAL Model SMA7115

1. Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 15 SMA7115 MANUAL CHAPTER 3 MODEL NUMBERING 3 3 Stand Alone One Axis Amplifier pe iad YYY QQQ 1A 1 ZZ RRR Amplifier Model ai l Spiona Custom Configuration Code for the Power Supply and Power Rating Regen Circuit Omit gege HP High Power Power Supply Configuration Amplifier Configuration Code Code 00 110 130VAC Single Phase Optional Custom Configuration Code 01 110 130VAC Three Phase for the amplifier module 02 Special Stand alone amplifier designator 1 amplifier module mounted 3 4 Multi Axis Amplifier SMA7_15XX _ p7_ _ ZZ RRR Type of Amplifier Model eee Custom Con figuration Code for the Power Rating Power Supply and Regen Omit Standard Circuit HP High Power Power Supply Configuration Pre amp amp Custom Configuration Code Code See sect 3 2 x eae 02 Special Second type of amplifier module on baseplate The total number of amplifier modules mounted on the base Number of this type of amplifier plate module s used Maximum number of amplifier Pre amp configuration code for second type modules the baseplate will hold of amplifier if it is different from the first am 2 2 axis baseplate plifier s configuration code NOTE This will 4 4 axis baseplate be omitted if they are the same When there is only one type of am
2. AC INPUT 1 AC INPUT 2 AC INPUT 3 CHASSIS GND FAN POWER ISOMETRIC VIEW SCALE DN 34 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL APPENDIX B POWER SUPPLY Appendix C POWER SUPPLY Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 35 POWER SUPPLY APPENDIX B SMA7115 MANUAL QT SVS E eo MI1NI19 0700584 mm Lee OZ GAN UD 31W1S ONOS INISSOYI OYIZ 20 20 CE SI HOVIS 8 NJHM SINNHS N3933 OOASCE SIHOWIS 8 NAHM SINNHS N3933 ld Cd OL SLOAJNNOD Zd G4aSN LON JYY rd ONY vd OL SIOINNOS Zd GNV Cd OL SLOANNOO ld CYSS ONY LYSS NOISYJA IVAO Z NOISY A IVAOEL NOISHSA IVAOPZ NOIS8JA OVAOZL Lenz YO DWAOZL 3DWIIOA ININI IVNINON 3NINY3130 OL 138v1 NA XSL KR M3IA OIJIINOS Die DWAOGZ vz VON OvAOSZ voz 3 94 G3 ti Nig OwAosz vos Sa Z3 ld 318V1 3SN4 zo Seil e x Z TINO and Nei NI d Mei Oz azr 381 171007 YMA Mei LUN SM Nei UNI Cias N3938 MS 0 0C y Sixv B vON voz Hr SIXxW 9 D ip 3 Sixv 8 TR ap Sixw 9 Os z sixv 8 O aie air z Sixv 8 V Sei Si Or wer 3181 OND SISSYHO 0181 AML Aa AML ee v a i ER VOLNS UNI Ov
3. O e 3181 VOCNE Z NANI OW YO ga HEI VOCNE ELA NIT DW os zz IC rS 60 9 AlddNS 33003 04 0098d9 MAINZ i 39V1 OA HOIH NOLLNYO s 6sz Leo ET k J1 3 B AX J1 2 B AX J1 1 B AX J J J Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 36 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES Appendix C European Union EMC Directives Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 37 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES Electromagnetic Compatibility Guidelines For Machine Design This document provides background information about Electromagnetic Interference EMI and machine design guidelines for Electromagnetic Compatibility EMC Introduction Perhaps no other subject related to the installation of industrial electronic equipment is so misunderstood as electrical noise The subject is complex and the theory easily fills a book This section provides guidelines that can minimize noise problems The majority of installations do not exhibit noise problems However these filtering and shielding guidelines are pro vided as counter measures The grounding guidelines provided below are simply good grounding practices They should be followed in all installations Electrical noise has two characteristics the genera
4. Goes high if the temperature of the amplifier rises above OVERTEMP the specified temp 4 3 5 Stand Alone One Axis Power Connections er GND Ground AC OMIT FOR SINGLE PHASE 110 130VAC power input AC 110 130VAC power input AC 110 130VAC power input 4 3 6 Multi Axis Chassis Power Connections Main Voltage Connect 95 135VAC line input single or three phase at TB1 see Power Supply Sub assembly drawing 8600 7030 Fan Voltage Connect 110 130VAC 50 60Hz for fans to TB1 5 and TB1 6 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 19 SMA7115 MANUAL CHAPTER 5 CONFIGURATION Chapter Five Configuration 5 1 Introduction Each amplifier has several configuration options This chapter describes these options and how to implement them If desired Glentek will be happy to pre configure your amplifiers NOTE Each amplifier module and multi axis amplifier is configured and shipped according to the model number instructions to construct a model number is in chapter three when the order is placed It is important for the user to realize that any changes to the jumpers micro shunts by the user will result in discrepancies between the model number and the actual configuration of the amplifier 5 2 Logic Input Configuration There are four logic inputs Limit Limit Inhibit and Reset In They may be configured for active high or active low signals and all are pulled
5. IMPORTANT All PWM equipment inherently generates radio frequency interference RFI and wiring acts as antennae to transmit this interference In addition motors inherently generate electromagnetic interference EMI Unless the wiring is very short some sort of shielding on the motor wires is necessary to meet FCC RFI EMI guidelines and to protect other equipment from the effects of RFI EMI We recommend that shielded wire be used or the wires should be run in metallic conduit The shield or conduit should be connected to the amplifier baseplate which in turn must be earth grounded In addition a conductor of the same gauge as the motor wires must be connected from the motor case to the amplifier baseplate to provide protection from shock hazard The earth grounding is necessary to meet National Electrical Code NEC requirements as well as suppressing RFI EMI Additional RFI suppression may be obtained by placing inductors in each motor lead near the amplifier Consult a Glentek applications engineer for inductor recommendations Glentek stocks a complete line of inductors for virtually every application IMPORTANT The signal wiring to the tachometer if used and the signal inputs to the amplifier are susceptible to noise pickup Excessive noise pickup will cause erratic amplifier operation We urge that each signal input line each be run in separate twisted pair shielded cable In each case the shield should be terminated at the amplifier e
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7. 1 Input and Output Power Input Voltage 95 135VAC 50 or 60Hz Fan Voltage 110 130VAC 50 or 60Hz 0 12A Output Voltage B 133 189 VDC Output Current 60A continuous 1 3 4 Mechanical LxWxH SMA7115 1 Single Amplifier Module 7 12 X 1 36 x 4 79 SMA7115 1A 1 Stand Alone Amplifier 9 03 x 4 00 x 4 96 SMA7115 2A 2 2 axis Amplifier System 9 00 x 10 50 x 7 70 SMA7115 4A 4 4 axis Amplifier System 13 00 x 10 50 x 7 70 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 9 SMA7115 MANUAL CHAPTER 2 THEORY OF OPERATION Chapter Two Theory of Operation 2 1 Introduction This chapter contains the basic control theory of how brush type and brushless servo motors and amplifiers operate It also compares and contrasts the advantages and disadvantages of brushless and brush type motors and amplifiers to help you select which is best suited for your application The following is a summary of the topics The theory behind an amplifier driving DC servo motors A comparison between brush type and brushless motors Operation of output switching transistors H Type output bridge configuration Pulse Width Modulation PWM Current Loop and Velocity Loop operation Protection circuits 2 2 Driving DC Servo Motors The torque of any DC motor is proportional to motor current the stronger the magnetic field the stronger the pull Motor current may be controlled in two ways lin
8. 16 OVERTEMP HE sz 18 oze AC CHASSIS GND I 3 qa AC INPUT SMA7115 1A 1 BRUSHTYPE AMPLIFIER GLENTEK MOTOR MOTOR OUTPUT n ve 21 srs gt NOlLdIYIS3O SNOISIZY oe Sz6 L 6z s9 eez NMOHS SV S30V1ld Z d33q zz sez x 100S z8 p ee AIR FLOW Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 32 SMA7115 MANUAL APPENDIX A AMPLIFIER DRAWINGS 340 322 3026 FAX 310 3227709 TA Sanderi Steet El Segundo CA 9234 USA Hetto foe Metien Contre vum gloriak com GLENTEK 9 00 228 6 w SMA7115 2A 2 INSTALLATION AAN 8 25 209 6 B AXIS 2 B AXIS 1 B AXIS 1 FES GE DEE oaae onanan A ER EPP Y AC INPUT 1 I AC INPUT 2 AC INPUT 3 CHASSIS GND FAN POWER AIR FLOW 6 83 173 5 ISOMETRIC VIEW SCALE 625X Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 33 SMA7115 MANUAL APPENDIX A AMPLIFIER DRAWINGS M USA 208 Standard Sres Segunda CA 902 390 322 3026 FAX 310 322 7708 wea lant com 4x 9 266 6 76 Sehattons tor Matton Contre GSLENTEK e POWER SUPPLY A y 8 i e il B r iiy Det Keel DOCUMENT WAS 13 00 330 2 ____ _ 12 25 311 2
9. 310 322 3026 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES EUROPEAN UNION DECLARATION OF INCORPORATION VAY MOTION CONTROL SYSTEMS C Classified as Components of Machinery Model Series SMA7115 Council Directive 89 392 EEC Machinery Directive The Products cited below and their accessories comply with the following Safety of Machinery Standards when installed and operated in accordance with the Instructions provided in the Operation amp Installation Manuals The products are declared to comply by virtue of Design Third Party Evaluations and Testing EMC Testing and Product Safety Evaluations and Risk Assessments were conducted by NATIONAL TECHNICAL SYSTEMS an independent Nationally Recognized Test Laboratory located in Fullerton CA 92631 USA As components of Machinery please be advised that 1 These are not individually classified as machinery within the scope of directive 89 392 EEC 2 These are intended to be incorporated into machinery or to be assembled with other machinery to constitute machinery covered by directive 89 392 EEC as amended 3 As such do therefore not in every respect comply with the provisions of directive 89 392 EEC SAFETY STANDARDS EN60292 2 Safety of Machinery Basic Principals EN60204 Electrical Equipment of Industrial Machines Collateral Test Standards Specified by EN60204 EN50011 1991 Emissions Limits for Industrial Scientific Class A And Medical ISM RF Equipment Con
10. Advantages Disadvantages No scheduled maintenance and no brush dust Motor brushes must be checked periodically for is generated wear and excess brush dust Higher RPM limits Approximately 3000RPM maximum Lower inertia torque ratio Higher inertia to torque ratio Dissipates heat more efficiently due to windings Not as efficient at dissipating heat Heat is being located in stator trapped at rotor and shortens bearing life Safer for explosive atmospheres Quieter and Brushes spark and generate electrical and less electrical noise generated audible noise Disadvantages Advantages Amplifiers are complicated and expensive Amplifiers are simpler and less expensive Higher torque ripple Lower torque ripple No Industry standard packaging Industry standard packaging 2 5 Operation of Output Switching Transistors The output transistors for all intents and purposes operate in only two states They are analogous to ON OFF switches When an output transistor is OFF there is no current flowing through it its resistance is infinite When an output transistor is ON current flows through it its resistance is near zero When the transistor is ON it is technically referred to as being in saturation 2 6 H Type Output Bridge Configuration The output configuration of the amplifier is an H TYPE bridge see figure 2 4 for schematic representation of an output bridge with a motor connected Figure 2 4
11. DC Buss voltage when decelerating a large load inertia Additional regen resistors can be connected externally The regen clamp circuit is set to turn on at 215VDC All faults can be monitored through isolated logic signals Bridge rectifier s and filter capacitor Cooling fans 1 3 Specifications 1 3 1 Single Amplifier Module SMA7115 1 The amplifier module requires an external DC power supply which must include a bridge rectifier buss capacitor solid state relay and shunt regulator Forced air cooling is required to meet the maximum power ratings specified below Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 7 SMA7115 MANUAL CHAPTER 1 DESCRIPTION FEATURES AND SPECIFICATIONS 1 3 1 1 Input and Output Power e Buss Voltage B 30 220VDC e Output Current Standard 15A continuous 25A peak High Power 20A continuous 40A peak 1 3 1 2 Signal Inputs Voltage aa Signal Input VDC minimum maximum ohms p p Differential 13 10 000 Single ended 4 000 Tachometer input 10 000 1 3 1 3 Digital Inputs Limit Inhibit and Reset 24V max Terminated by 10K ohms Fault as input 40V 5v max Terminated by 10K ohms Typical for all digital inputs Digital inputs have hysteresis with thresholds at 1 3 and 2 3 of 5V or 15V depending on range selected 1 3 1 4 System Drift offset over temperature reference to input 0 01mV C max Frequency response V
12. DC current flowing from A through C QA amp QC ON Figure 2 5 Transistor switching OFF waveform at zero current QB amp QD ON If the input to the current loop had been changed in polarity the output transistor switching waveform would be as shown in figure 2 6B QA amp QC ON Figure 2 6B Transistor switching OFF TIME waveform when current flows from B through D QB amp QD ON If a larger current of the same polarity was commanded to the output transistor see figure 2 6B the ON time widths of B and D would automatically increase to provide more current From the previous examples it is easy to understand why this output transistor switching technique is referred to as pulse width modulation To change the magnitude and polarity of the current flow in the motor the pulse widths of the opposite pairs of transistors are modulated The frequency at which these output transistors are switched ON and OFF is referred to as the carrier frequency Now that we have a good understanding of how the current is provided from an H TYPE pulse width modulated PWM bridge let s analyze the operation of the current loop 2 8 Current Loop Operation Please refer to figure 2 2A for a diagram of the current loop In control electronics the symbol Sigma with the circle around it is referred to as a summing junction The manner in which this summing junction operates is as follows The current command signal also re
13. and MIL STD 461 Also in industrial environments you should use encoders with differential driver outputs rather than single ended outputs and digital inputs outputs with electrical isolation such as those provided with optocouplers The EMI model provides only three options for eliminating the EMC problem e Reduce the EMI at the source e Increase the victim s immunity to EMI harden the victim e Reduce or eliminate the coupling mechanism In the case of servo drives reducing the EMI source requires slowing power semiconductor switching speeds How ever this adversely affects drive performance with respect to heat dissipation and speed torque regulation Harden ing the victim equipment may not be possible or practical The final and often the most realistic solution is to reduce the coupling mechanism between the source and victim Filtering shielding and grounding can achieve this 38 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES Filtering As mentioned above high frequency energy can be coupled between circuits via radiation or conduction The AC power wiring is one of the most important paths for both types of coupling mechanisms The AC line can conduct noise into the drive from other devices or it can conduct noise directly from the drive into other devices It can also act as an antenna and transmit or receive radiated noise
14. circuits should not pass within 300 mm 1 ft of the drive The length or parallel runs between other circuit cables and the motor or power cable should be minimized A rule of thumb is 300 mm 1 ft of separation for each 10 m 30 ft of parallel run The 300 mm 1 ft separation can be reduced if the parallel run is less than 1 m 3 ft Cable intersections should always occur at right angles to minimize magnetic coupling The encoder mounted on the brushless servomotor should be connected to the amplifier with a cable using multiple twisted wire pairs and an overall cable shield Encoder cables are offered in various lengths that have correct terminations Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 41 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES Persistent EMI problems may require additional countermeasures The following suggestions for system modification may be attempted 1 A ferrite toroid or doughnut around a signal cable may attenuate common mode noise particularly RS 232 communication problems However a ferrite toroid will not help differential mode noise Differential mode noise requires twisted wire pairs Suppress each switched inductive device near the servo amplifier Switch inductive devices include sole noids relay coils starter coils and AC motors such as motor driven mechanical timers DC coils should be suppressed with a free wheeling diod
15. is also important to separate HF grounds from sensitive circuit grounds Single Point Ground Types shows single point grounds for both series daisy chain and parallel separate connec tions A single point parallel connected ground system is recommended CIRCUIT CIRCUIT CIRCUIT CIRCUIT CIRCUIT CIRCUIT 1 2 3 1 2 3 SERIES CONNECTION PARALLEL CONNECTION GROUND BUS BAR Figure 3 Single Point Ground Types A ground bus bar or plane should be used as the single point where circuits are grounded This will minimize com mon ground impedance noise coupling The ground bus bar GBB should be connected to the AC ground and if necessary to the enclosure All circuits or subsystems should be connected to the GBB by separate connections These connections should be as short as possible and straps should be used when possible The motor ground con ductor must return to the ground terminal on the drive not the GBB 40 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES Shielding and Segregation The EMI radiating from the drive enclosure drops off very quickly over distance Mounting the drive in an enclosure such as an industrial cabinet further reduces the radiated emissions The cabinet should have a high frequency ground and the size of the openings should be minimized In addition the drive is considered an open device that does
16. not provide the proper IP rating for the environment in which it is installed For this reason the enclosure must provide the necessary degree of protection An IP rating or Nema rating which is similar to IP specifies the degree of protection that an enclosure provides The primary propagation route for EMI emissions from a drive is through cabling The cables conduct the EMI to other devices and can also radiate the EMI For this reason cable segregation and shielding are important factors in re ducing emissions Cable shielding can also increase the level of immunity for a drive For example Shield termination at both ends is extremely important The common misconception that shields should be terminated at only one end originates from audio applications with frequencies lt 20 kHz RF applications must be terminated with the shield at both ends and possibly at e Intermediate points for exceptionally long cables e When shielded cables are not terminated at the cable connection and pass through the wall of a cabinet the shield must be bonded to the cabinet wall to prevent noise acquired inside the cabinet from radiating outside the cabinet and vice versa When shielded cables are terminated to connectors the shield must be able to provide complete 360 cov erage and terminate through the connector backshell The shield must not be grounded inside the connec tor through a drain wire Grounding the shield inside the connector couples th
17. the SMA7115 single amplifier module stand alone one axis amplifier and multi axis amplifier system The model numbering system is designed so that you our customer will be able to create the correct model number of the product that you need quickly and as accurate as possible 3 2 Single Amplifier Module SMA7115XX YYY QQQ 1 Amplifier Model Number gt Single Module Optional Custom Power Rating Configuration Code Omit Standard A numerical code will be assigned HP High Power by Glentek to amplifiers whose specifications vary from the stan Amplifier Configuration Code EES Amplifier Configuration Code tLimit O L 1 H see sect 5 2 Differential or Single ended input Limit O U see sect 5 2 i lt 0 Single ended Default Inhibit O L 1 H see sect 5 2 1 Differential Inhibit O U see sect 5 2 Velocity or Current Mode Reset 0 L 1 H see sect 5 2 0 Velocity 1 Current Reset 0 U see sect 5 2 see section 2 8 amp 2 9 On Board Power Supply See section 5 2 15V 5V on pull up Type A U 0 amp L 0 0 15V Default Default 1 5V Type C U 0 amp H 1 DC Buss Voltage 0 30 220VDC Default 1 Special 4 Bit Binary to Digital Conversion 0000 0 1000 8 0001 1 1001 9 0010 2 1010 A 0011 3 1011 B 0100 4 1100 C 0101 5 1101 D 0110 6 1110 E 0111 7 1111 F
18. up termination type A or C All logic inputs have a selectable 0 to 5VDC or 0 to 15VDC range Type A Requires grounding of input to disable the amplifier pull up active low Type C Requires grounding of input to enable the amplifier pull up active high The following table shows how to configure the jumpers micro shunts for the inputs selected The standard configuration is shown in bold LIMIT J8 A Install Jumper J8 A Omit Jumper INHIBIT J8 B Install Jumper J8 B Omit Jumper RESET IN J8 C Install Jumper J8 C Omit Jumper 5 2 1 15V 5V Logic Level Configuration Default J9 Omit Jumper e 15V J9 Omit Jumper 5V J9 Install Jumper 5 2 2 Velocity Mode and Current Mode Configuration e Velocity Mode J4 Install Jumper J5 Omit Jumper e Current Mode J4 Omit Jumper J5 Install Jumper 5 2 3 Integrator Configuration Default J6 Omit Jumper The integrator circuit is used to lower the integration proportional break point in the velocity PID loop The lower break point may be required with motors having high inductance armatures This jumper should remain omitted unless instructed to install by a Glentek engineer 5 2 4 Stop Function Default J8 D Omit Jumper If the stop function is enabled jumper installed when the amplifier is inhibited at J1 9 the amplifier will actively decelerate the motor for 150 ms then all current output from the amplifier will cease unti
19. CATIONS Chapter One Description Features and Specifications 1 1 Description This brush type servo amplifier system has been designed to offer you our customer a large degree of flexibility and customization with a standard in stock product The amplifier is of a modular open construction for ease of installation and service The amplifier system is available in the following types of configurations As amplifier modules SMA7115 1 where you supply the DC Buss voltage cooling fan s fusing and shunt regulator Please see section 1 2 1 for more detailed information As a stand alone one axis amplifier SMA7115 1A 1 which contains a DC power supply cooling fan soft start circuitry fusing and a shunt regulator Please see section 1 2 2 for more detailed information For multi axis applications the multi axis baseplate power supply can supply DC power cooling fans zero crossing solid state relays fusing and a shunt regulator for up to 4 axis or 60 amperes continuous Please see section 1 2 3 for more detailed information Each amplifier accepts a bipolar DC control input The polarity of this signal determines the direction of rotation This signal may be used to control either the velocity RPM or the current torque of the motor see Servo Loops section 2 3 The amplifier provides Pulse Width Modulated PWM power to the motor in proportion to the input signal Each amplifier has several logic inputs to stop th
20. DURE 22 Apply the main power and fan power Slowly turn the Loop Gain pot RV7 CW The motor should be stopped or turning slowly If the motor starts running away remove the power reverse the tach leads and retest Set the Balance pot RV3 for zero motor rotation Connect an oscilloscope to J1 6 MTR l and a battery box to J1 3 J1 4 is common for both The voltage on J1 6 is a function of motor current 1V 5A While applying a step input voltage adjust the Current Limit pot RV6 for the desired peak current The purpose of the following procedure is to set the system bandwidth to obtain a critically damped response or a one hook overshoot response with the maximum possible Tach Gain There are many possible settings of Tach Gain and Compensation which will yield the desired waveform The optimum setting will occur when Tach Gain is as CW as possible and Compensation is as CCW as possible However the servo loop may become unstable the motor oscillates or hunts with a very low near CCW setting of Compensation In this case stability is the limiting factor At no time should the servo loop be allowed to be unstable Amplifiers are normally shipped with the Tach Gain pot RV4 set at 100 This is a good place to start If you are unsure of where the Tach Gain is set turn the Tach Gain RV4 fully CW up to 20 turns Connect an oscilloscope to J1 5 TACH IN and J1 4 common Set the battery box for a DC signal output to o
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22. ON 6 4 Calibration of the Current Mode Amplifier The amplifier in this configuration receives an analog bi polar input command which is proportional to the required motor current motor torque The following potentiometers pots will be set during calibration Note RV7 RV11 are single turn pots and RV1 RV6 are 20 turn pots Note RV8 RV11 are factory set and should not be adjusted Adjusting these pots voids warranty Differential Gain ee DIFF GAIN Sets the input voltage to current ratio for differential signal input Signal Gain Sets the input voltage to current ratio for single ended signal SIG GAIN input Balance BAL Current Limit Sets the maximum peak motor current Shipped set at full CW CUR LIMIT Max current Used to shut off uncalibrated amplifiers When the loop gain is full LOOP GAIN CCW no current is delivered to the motor Used to null any offsets in system PROCEDURE Apply the main power and fan power Slowly turn the Loop Gain pot RV7 CW The motor should be stopped or turning slowly Set the Balance pot RV3 for zero motor rotation Connect an oscilloscope to J1 6 MTR CUR and a battery box to J1 3 J1 4 is common for both The voltage on J1 6 is a function of motor current 1V 5A While applying a step input voltage adjust the Current Limit pot RV6 for the desired peak current If the desired peak current cannot be achieved with the Current Limit pot full CW increa
23. OPERATION amp SERVICE MANUAL Model SMA7115 Model SMA7115HP Brush Type Amplifier System GLENTEK Solutions for Motion Control SMA7115 MANUAL TABLE OF CONTENTS INTRODUCTION CHAPTER ONE DESCRIPTION FEATURES AND SPECIFICATIONS 1 1 Description 1 2 Features 1 2 1 Single Amplifier Module SMA7115 1 1 2 2 Stand Alone One Axis Amplifier SMA7115 1A 1 1 23 Multi Axis Power Supply GP8600 70 1 3 Specifications 1 3 1 SE Amplifier Module SMA7115 1 Input and Output Power 1 3 3 Multi Axis Power Supply GP8600 70 1 3 3 1 Input and Output Power 1 3 4 Mechanical CHAPTER TWO THEORY OF OPERATION Introduction Driving DC Servo Motors Servo Loops Brushed Motors vs Brushless Motors Operation of Output Switching Transistors H Type Output Bridge Configuration Pulse Width Modulation PWM Current Loop Operation Velocity Loop Operation 2 10 Protection Circuits CHAPTER THREE MODEL NUMBERING 3 1 Introduction 3 2 Single Amplifier Module 3 3 Stand Alone One Axis Amplifier 3 4 Multi axis Amplifier CHAPTER FOUR INSTALLATION Introduction Mounting Wiring 4 3 1 RFI EMI and Wiring Technique 4 3 2 Wire Size and Type 4 3 3 Connector Size and Type 4 3 3 1 The Power Connector of the Single Amplifier Module 4 3 3 2 The Signal Connector 4 3 3 3 The Power 8 Motor Connectors of the Stand Alone Amplifier 4 3 4 Amplifier Module Connections 4 3 4 1 The Power Connections 4 3 4 2 The Signal Connections 4 3 5 Stand Alo
24. POWER ON RESET AMPLIFIER INHIBIT 7 2 2 Under Voltage Fault When the 15VDC power supply is below 12VDC a level that would cause unreliable operation the Run LED will turn off a Fault Output is generated and the amplifier is inhibited This is not a latched condition that is if the problem is resolved the amplifier will resume operation The following is a list of possible causes Main AC line voltage is too low Bad rectifier bridge Bad DC buss filter capacitor 7 2 3 High Speed Electronic Circuit Breaker HS ECB Fault When the peak output of the amplifier exceeds 80A for 10 microseconds the Run LED will turn off the HS ECB LED will turn on and a Fault Output is generated and the amplifier is inhibited NOTE This is a latched condition Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 25 SMA7115 MANUAL CHAPTER 7 MAINTENANCE REPAIR and WARRANTY The following is a list of possible causes e Shorted motor leads Motor inductance too low e Shortfrom a motor lead to ground 7 2 4 Low Speed Electronic Circuit Breaker LS ECB Fault When the RMS output of the amplifier exceeds 15A for standard or 20A for high power for 3 seconds the Run LED will turn off the LS ECB LED will turn on and a Fault Output is generated and the amplifier is inhibited NOTE This is a latched condition The following is a list of possible causes e Binding or stalling of mot
25. Schematic representation of an output bridge with a motor connected D C BUSS FILTER CAPACITOR 12 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 2 THEORY OF OPERATION The advantage of an H TYPE output bridge configuration is that by controlling the switching of the opposite pairs of transistors current can be made to flow through the motor in either direction using a single polarity power supply To provide motor current in one direction transistor A and C are turned ON while B and D remain in the OFF state To provide motor current in the other direction B and D are turned ON while A and C remain in the OFF state 2 7 Pulse Width Modulation PWM Pulse width modulation is the technique used for switching opposite pairs of output transistors ON and OFF to control the motor drive current When zero current is commanded to the current loop the opposite pairs of transistor are turned ON and OFF as shown in figure 2 5 Note that since the pulse widths are equal the net DC current in the motor is equal to zero QA amp QC ON Figure 2 6A Transistor switching OFF TIME waveform when current flows from A through C QB amp QD ON When a non zero current is commanded to the current loop the transistor switching waveform is as shown in figure 2 6A Since there is a non zero current command the output transistor pulse widths will change and the motor will see a net
26. URRENT AMPLIFIER CURRENT T Figure 2 2a VELOCITY COMMAND Velocity mode sevo loop COMMAND Nera for a brush type motor SIGNAL ERROR SIGNAL The servo loops of a brushless amplifier figure 2 2b operate in much the same way except there are now three current loops one for each phase of the motor VELOCITY LOOP r Figure 2 2b VELOCITY AN Velocity mode sevo loop COMMAND ELO for a brushless motor SIGNAL VELOCITY FEEDBACK SIGNAL ULTIPLEXE 2 4 Brushed Motors vs Brushless Motors There are two basic types of motor design that are used for high performance motion control systems brush type PM permanent magnet and brushless type PM As you can see in figure 2 3 a brush type motor has windings on the rotor shaft and magnets in the stator frame In a brushless type motor the magnets are on the rotor and the windings are in the stator To produce optimal torque in a motor it is necessary to direct the flow of current to the appropriate windings with respect to the magnetic fields of the permanent magnets In a brush type motor this is accomplished by using a commutator and brushes The brushes which are mounted in the stator are connected to the motor wires and the commutator contacts which are mounted on the rotor are connected to the windings As the rotor turns the brushes switch the current flow to the windings which are optimally oriented with respect to the magnetic
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28. between the drive and other devices One method to improve the EMC characteristics of a drive is to use isolation AC power transformer to feed the ampli fier its input power This minimizes inrush currents on power up and provides electrical isolation In addition it pro vides common mode filtering although the effect is limited in frequency by the interwinding capacitance Use of a Faraday shield between the windings can increase the common mode rejection bandwidth shield terminated to ground or provide differential mode shielding shield terminated to the winding In some cases an AC line filter will not be required unless other sensitive circuits are powered off the same AC branch circuit NOTE Common mode noise is present on all conductors that are referenced to ground Differential mode noise is present on one conductor referenced to another conductor The use of properly matched AC line filters to reduce the conducted EMI emitting from the drive is essential in most cases This allows nearby equipment to operate undisturbed The basic operating principle is to minimize the high fre quency power transfer through the filter An effective filter achieves this by using capacitors and inductors to mis match the source impedance AC line and the load impedance drive at high frequencies For drives brought into use in Europe use of the correct filter is essential to meet emission requirements Detailed information on filters is in
29. btain approximately 400RPM The RPM may be set by measuring the tach voltage at J1 5 e g 2 8VDC for a 7V KRPM tach is 400RPM Pulse the input and compare the waveform with figure 6 1 Critically damped One Hook Overshoot Under damped Over damped Too much Tach or Not enough Tach or not enough Bandwidth too much Bandwidth Figure 6 1 Critically damped One Hook Overshoot Under and Over damped waveforms Adjust the Compensation pot RV5 CCW until the waveform is critically damped or one hook overshoot Then proceed to step 9 If the desired waveform cannot be obtained by adjusting the Compensation pot back off CCW the Tach Gain pot RV4 a few turns and repeat step 7 Do not adjust the Tach Gain or Compensation pots for the rest of the calibration procedure With the battery box still connected at J1 3 and J1 4 for single ended input or if your system uses the Differential input move battery box to J1 1 and J1 2 set the battery box for a known DC voltage Adjust the Signal Gain pot RV2 or RV1 for differential input to obtain the desired motor velocity If the motor is rotating in the wrong direction for a given input polarity remove power and reverse both the motor leads and the tach leads Remove the battery box and repeat step 3 Calibration complete Reconnect signal wires Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 6 START UP AND CALIBRATI
30. cluded in the manual and transformers should be used where specified in the manual AC Line Filter Selection Selection of the proper filter is only the first step in reducing conducted emissions Correct filter installation is crucial to achieving both EMIL attenuation and to ensure safety All of the following guidelines should be met for effective fil ter use The filter should be mounted to a grounded conductive surface The filter must be mounted close to the drive input terminals particularly with higher frequency emissions 5 30 MHz If the distance exceeds 600mm 2 feet a strap should be used to connect the drive and fil ter rather than a wire The wires connecting the AC source to the filter should be shielded from or at least separated from the wires or strap that connects the drive to the filter If the connections are not segregated from each other then the EMI on the drive side of the filter can couple over to the source side of the filter thereby reducing or eliminating the filter effectiveness The coupling mechanism can be radiation or stray capacitance be tween the wires The best method of achieving this is to mount the filter where the AC power enters the en closure AC Line Filter Installation shows a good installation and a poor installation POOR CONDUCTED EMI lt AC CONDUCTED EMI ag a RADIATED EMI lt NS y RADIATED EMI RADIATED EMI FILTER CONDUCTED EMI Figure 2 AC Line Fil
31. ducted and Radiated EN61000 4 2 Electrostatic Discharge Immunity Level 2 EN61000 4 3 Radiated Emission Immunity Level 2 EN61000 4 4 Electric Fast Transients Burst Level 3 Manufacturers Name GLENTEK INC Manufacturers Address 208 Standard Street El Segundo CA 90245 USA Description of Equipment Motion Control Systems including Amplifiers and Servo Motors Model Number s SMA7115 SMA7115HP The above amplifier modules packaged in the following configurations 1 1A 1 2A 1 2A 2 4A 4 6A 5 6A 6 3U 1 and all power supply configurations 00 01 02 accordance with The Machinery Directives Refer to Technical Construction File GTK 99408 MANUFACTURER HELEN M VASAK SECRETARY TREASURER 4 19 99 Prepared By National Technical Systems Fullerton CA Confirmed By Chuck Helton Director of Product Safety Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 43 SMA7115 MANUAL NOTES 44 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 Omega Series Digital PWM Brushless Servo Amplifiers e PWM Pulse Width Modulated Brushless servo amplifiers to 20KW Analog Brush Type Servo Amplifiers e Linear Brush type servo amplifiers to 2 6KW e PWM Pulse Width Modulated Brush type servo amplifiers to 28KW Analog Brushless Servo Amplifiers e Linear Brushless servo amplifiers to 3 5KW e PWM Pulse Width Modulated Brushless servo amplifiers to 51KW P
32. e connected across the coil AC coils should be suppressed with RC filters a 200 Ohm 1 2 Watt resistor in series with a 0 5 uF 600 Volt capacitor is common Following these guidelines can minimize noise problems However equipment EMC performance must meet regula tory requirements in various parts of the world specifically the European Union Ultimately it is the responsibility of the machine builder to ensure that the machine meets the appropriate requirements as installed RECOMMENDATIONS FOR GLENTEK AMPLIFIERS All amplifiers installed in a NEMA 12 enclosures or equivalent with wiring in metal conduit or enclosed metal wire trough see Shielding and segregation Use Glentek shielded feedback and motor cables An AC line filter properly installed ina NEMA 12 enclosure or equivalent see Filtering AC line filters for single phase applications 1A 15A input current 120 250VAC use Corcom 15ET1 or equivalent 15A 25A input current 120 250VAC use Corcom 25FC10 or equivalent 25A 36A input current 120 250VAC use Corcom 36FC10 or equivalent AC line filters for 3 phase applications 1A 25A input current 120 250VAC use Corcom 25FCD10 or equivalent 25A 36A input current 120 250VAC use Corcom 36FCD10 or equivalent 36A 50A input current 120 250VAC use Corcom 50FCD10 or equivalent 50A 80A input current 120 250VAC use Corcom 80FCD10 or equivalent 42 Glentek Inc 208 Standard Street El Segundo California 90245 U S A
33. e motor in one or both directions These inputs are very useful for connecting to mechanical limit switches or digital equipment Each amplifier has several protection circuits to protect the amplifier motor and operator from almost any kind of fault LED s show what fault has occurred and a separate output can be used to signal other equipment 1 2 Features 1 2 1 Single Amplifier Module SMA7115 1 Ergonomic design Easy access to connections adjustments and test points Wide operating 30 220VDC buss voltage Complete isolation Complete isolation from input to output Dual signal inputs Two single ended or one differential Both single ended inputs may be use simultaneously All inputs have up to 15 000A V gain velocity mode and inputs will accept up to 13VDC Dual mode operation Current limit Digital limit enable Inputs Fault input output Silent operation Short circuit protection LED diagnostics The amplifier may be field configured for velocity RPM control or current torque control Maximum peak motor current is adjustable Three separate logic inputs can stop the motor in either or both directions Inputs may be configured for active high or active low pull up termination and a 0 to 5VDC or 0 to 15VDC range See Logic Input Configuration section 5 2 Open collector output goes low in the event of a fault Externally forcing the output low will inhibit the amplifier This allow
34. e noise on the shield to the signal conductors sharing the connector and virtually guarantees failure to meet European EMC require ments The shield must be continuous Each intermediate connector must continue the shield connection through the backshell e Al cables both power and signal should use twisted wire pairing The shield termination described above provides a coaxial type of configuration which provides magnetic shielding and the shield provides a return path for HF currents that are capacitively coupled from the motor windings to the frame If power frequency circulating currents are an issue a 250 VAC capacitor should be used at one of the con nections to block 50 60 Hz current while passing HF currents Use of a properly shielded motor cable is essential to meet European EMC requirements The following suggestions are recommended for all installations 1 Motor cables must have a continuous shield and be terminated at both ends The shield must connect to the ground bus bar or drive chassis at the drive end and the motor frame at the motor end Use of a prop erly shielded motor cable is essential to meet European EMC requirements Signal cables encoder serial and analog should be routed away from the motor cable and power wiring Separate steel conduit can be used to provide shielding between the signal and power wiring Do not route signal and power wiring through common junctions or raceways Signal cables from other
35. ear and PWM Pulse Width Modulation Linear control is achieved by simply inserting a resistance in series with the motor This resistance is usually a partially turned on transistor The transistor is said to be in its linear region Linear amplifiers are simple accurate and effective However they are very inefficient and they generate a lot of heat Linear amplifiers are used when low electrical noise high bandwidths 2KHz or higher and or low inductance less than 1mH motors are used In pulse width modulation the control devices output transistors are rapidly turned full on and full off The ratio of the on time the pulse width and off time determines the average motor current Refer to figure 2 1 For example if the output is on 25 of the time and off 75 of the time the average motor current is approximately 25 of maximum A coil of wire such as the windings of a motor forms an inductor Inductors resist changes in current This resistance to change known as reactance acts to dampen or average the high current spikes that would otherwise occur when the output devices are on In fact if motor inductance is low external inductors may have to be added in series with each motor lead to ensure proper operation A brush type motor may be run from a steady DC voltage since the brushes and commutator switch the current from winding to winding However a brushless motor requires that the voltage be switched from winding to winding exter
36. elocity loop 750Hz min Frequency response Current loop 2KHz min Dead band None Form factor 1 01 1 3 1 5 Outputs Fault as output Active low Open collector output can sink 75mA max through 10 ohms Absolute motor current Bipolar output 1V 5A 10mA max LS ECB HS ECB Open collector outputs can sink 40mA max Overvolt Overtemp 1 3 2 Stand Alone One Axis Amplifier SMA7115 1A 1 The stand alone one axis amplifier contains a single amplifier module a DC power supply a cooling fan fusing and shunt regulator in a sheet metal enclosure It has the same specifications as the single amplifier module refer to 1 3 1 except the DC power supply and cooling fan are included The shunt regulator within the DC power supply has a 50W internal load resistor bank which bleeds off excess DC Buss voltage when decelerating a large load inertia e Input Voltage 110 130VAC internally fused for 20A e Output Current Standard 15A continuous 25A peak High Power 20A continuous 40A peak NOTE Customer must specify Single or Three Phase AC input when ordering see chapter 3 model numbering so that the proper power supply module can be installed 8 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 1 DESCRIPTION FEATURES AND SPECIFICATIONS 1 3 3 Multi Axis Power Supply GP8600 70 The multi axis power supply contains all items listed under 1 2 3 1 3 3
37. er no circumstances shall Glentek Inc or any of our affiliates have any liability whatsoever for claims or damages arising out of the loss of use of any product or part sold to you Nor shall we have any liability to yourself or anyone for any indirect or consequential damages such as injuries to person and property caused directly or indirectly by the product or part sold to you and you agree in accepting our product or part to save us harmless from any and all such claims or damages that may be initiated against us by third parties Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 27 SMA7115 MANUAL APPENDIX A AMPLIFIER DRAWINGS Appendix A Amplifier Drawings 28 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 AMPLIFIER DRAWINGS APPENDIX A SMA7115 MANUAL two ya ue ma vente uopow 104 suolinjos BOLLZZEOLE XWA OZOE ZZE OLE YSN 6206 vO opunBeg 13 A 31 N 31 9 1804S PIEPUEIS 807 NIv9 91S 4 gt rs ver 10 OL SOO SS3NHONOY 30vsUNS 3003 d s TV 229 l ELE G p p Z soon ni auv snosnama JOON O3LJIDIJS ISIMYIHAO_SSTINN NOILdINISIO IMIYSIIVA 32v80103 et ana EES ut E mu mem wu om EI Me DIS orl Aggecp ASE Ase ASI AlddNS JIMOJ 39V1 OA si soi Weg 9IS 4410 SINIOd 1S31 ZP ps ee s ae e 3OV80333 1N383809 YOLOW AUTO JAG NO
38. ermanent Magnet DC Brush Type Servo Motors e Continuous Torques to 335 in Ib e Peak Torques to 2100 in Ib Permanent Magnet DC Brushless Servo Motors e Continuous Torques to 1100 in Ib e Peak Torques to 2200 in lb MANUALE 7015 4040 000 GLENTEK REVISION A DATE 14 May 2002 Solutions for Motion Control 208 Standard Street El Segundo California 90245 USA Telephone 310 322 3026 Fax 310 322 7709 www glentek com e mail sales glentek com
39. ferred to as the velocity error signal when received from the output of the Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 13 SMA7115 MANUAL CHAPTER 2 THEORY OF OPERATION velocity loop as shown in figure 2 2A is added to the current feedback signal The signal resulting from this addition is referred to as the current error signal This current error signal is fed into the current amplifier which in turn produces a current in the motor A voltage which is proportional to the motor current is developed across Rs shunt resistor This voltage is referred to as the current feedback signal The current in the motor increases until the current command signal At this point the current error signal drops to zero and the actual current is equal to the commanded current If anything happens to disturb either the current command signal or the current feedback signal the same process occurs again until the current feedback signal is equal in magnitude to the current command signal but opposite in polarity The type of loop described above is referred to as a servo loop because the current servos about a commanded value We are surrounded in our everyday lives by a multitude of servo loops For example many of today s luxury cars have what is called automatic climate control To operate this servo loop you set the climate control to the temperature that you wish to be maintained in t
40. field which in turn produces maximum torque In a brushless motor there is no commutator to direct the current flow through the windings Instead an encoder hall sensors or a resolver on the motor shaft senses the rotor position and thus the magnet orientation The position data is fed to the amplifier which in turn commutates the motor electronically by directing the current through the appropriate windings to produce maximum torque The effect is analogous to a string of sequencing Christmas lights the lights seem to chase each other around the string In this case the magnets on the rotor chase the magnetic fields of the windings as the fields move around the stator The relative advantages and or disadvantages of a brush type motor amplifier combination vs a brushless motor amplifier combination can be significant On the next page is a Summary of advantages and disadvantages of brush type motor amplifiers and brushless type motor amplifiers to help you decide which type to select for your applications Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 11 SMA7115 MANUAL CHAPTER 2 THEORY OF OPERATION MAGNETS Seas WINDINGS 22 WINDINGS BRUSHES k MAGNETS ARMATURE COMMUTATOR BEAR MOTOR WIRE BRUSH TYPE MOI BRUSHLESS TYPE Figure 2 3 Brush type and Brushless type Motors Brushless Motors Amplifiers Brushed Motors Amplifiers
41. he interior of the car current command signal The selected temperature is then summed with the actual temperature from a thermometer current feedback and the output current error signal activates either the heater or the air conditioner until the actual temperature as measured by the thermometer current feedback signal is equal in magnitude but opposite in polarity to the set temperature 2 9 Velocity Loop Operation Please refer to figure 2 2A for a diagram of a typical velocity loop The velocity loop s operational description is analogous to the current loop description except for the fact that the input signal is called the Velocity Command and the feedback signal from the DC tachometer is called the Velocity Feedback 2 10 Protection Circuits The High and Low Speed Electronic Circuit Breakers HS ECB and LS ECB protect the amplifier and motor from being damaged by high motor current specified max peak and rms current values The Over Temperature and Over Voltage detection circuits will shut off the amplifier when the temperature of the amplifier or the buss B voltage exceeds a specified limit Also there are circuits which limit the motor from running in either or both directions 14 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 3 MODEL NUMBERING Chapter Three Model Numbering 3 1 Introduction This chapter contains the model numbering system for
42. ibility Guidelines for Machine Design CE Certification 4 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL INTRODUCTION Introduction Glentek s brush type and brushless DC servo motors and amplifiers offer the ultimate in low maintenance and high performance motion control Glentek offers a full line of matched motors and amplifiers to meet virtually every motion control application This manual provides all the technical information necessary to install configure operate and maintain our TORQUE SWITCH series brush type servo amplifier model SMA7115 There is also an informative theory of operation chapter We suggest that you take the time to read this manual from cover to cover before attempting to work with these amplifiers for the first time If at any time you have questions or have any special requirements please feel free to call and discuss them with a Glentek applications engineer We are happy to provide both off the shelf and custom products With over three decades in the servo motor amplifier business we have a vast pool of applications knowledge waiting to assist you Thank you for selecting Glentek for your motion control needs It is our goal to save you time money and to provide you with a superior product Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 5 SMA7115 MANUAL CHAPTER 1 DESCRIPTION FEATURES AND SPECIFI
43. l the inhibit is de activated This function only works when the amplifier is in velocity mode see above If the stop function is disabled jumper omitted when the amplifier is inhibited all amplifier current output immediately ceases 20 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 6 START UP AND CALIBRATION Chapter Six Start Up and Calibration 6 1 Introduction This chapter contains the procedure required for initial start up and amplifier calibration The SMA7115 amplifier can be configured to run in velocity mode 6 3 and current mode 6 4 Required Equipment Oscilloscope voltmeter amp battery box The battery box serves as a step input voltage command applying and removing a flashlight battery can also be used for this function Glentek sells a battery box BB 700 which is ideal for this function 6 2 Initial Start Up When applying power to start up your amplifier system for the first time we recommend you follow this procedure If you have already gone through this procedure you can skip to the appropriate calibration procedure Check for any loose or damaged components Check that all connections are tight Be sure that the motor mechanism is clear of obstructions If the mechanism has limited motion e g a lead screw set the mechanism to mid position Disconnect the signal and or auxiliary inputs Be sure the Loop Gain pot s are fully CCW A
44. ll reduce emission coupling through the drive back to the AC line However the motor cable still carries a large HF voltage and current Therefore it is very important to segregate the motor cable from the AC power cable More information on cable shielding and segregation is contained in the section on shielding Grounding High frequency HF grounding is different from safety grounding A long wire is sufficient for a safety ground but is completely ineffective as a HF ground due to the wire inductance As a rule of thumb a wire has an inductance of 8 nH in regardless of diameter At low frequencies it acts as constant impedance at intermediate frequencies as an in ductor and at high frequencies as an antenna The use of ground straps is a better alternative to wires However the length to width ratio must be 5 7 or better yet 3 1 to remain a good high frequency connection The ground system s primary purpose is to function as a return current path It is commonly thought of as an equipo tential circuit reference point but different locations in a ground system may be at different potentials This is due to the return current flowing through the ground systems finite impedance In a sense ground systems are the sewer systems of electronics and as such are sometimes neglected The primary objective of a high frequency ground system is to provide a well defined path for HF currents and to mini mize the loop area of the HF current paths It
45. mount components A factory option Allows the motor current to fold back i e drop to a safe level after a pre determined time Multi axis chassis Up to four amplifier modules may be mounted on a single baseplate Multi axis baseplate includes a DC power supply cooling fan s and wiring for each respective amplifier module 1 2 2 Stand Alone One Axis Amplifier SMA7115 1A 1 The stand alone amplifier includes all of the features that the single amplifier module has and also includes the following additional features e Line operated AC power operation 110 130VAC Fused single or three phase AC input with in rush current protection at turn on No power isolation transformer is required Fused regen clamp circuit shunt regulator with LED indicator and 50W internal load resistor bank bleeds off excess DC Buss voltage when decelerating a large load inertia The regen clamp circuit is set to turn on at 215VDC All faults can be monitored through isolated logic signals Bridge rectifier s and filter capacitor Cooling fans 1 2 3 Multi Axis Power Supply GP8600 70 Power supply for 2 to 4 axis amplifier baseplates Line operated AC power operation Fused single or three phase AC inputs with a solid state zero crossing switch which limits in rush current at turn on No power isolation transformer is required Fused regen clamp circuit shunt regulator with LED indicator and 95W internal load resistor bank bleeds off excess
46. nally the voltage that drives a brushless motor is a constantly changing AC waveform Section 2 5 discusses these waveforms ON TIME m ei CARRIER FREQ MOTOR VOLTAGE MOTOR CURRENT Figure 2 1 Pulse Width Modulation Waveform 2 3 Servo Loops A basic velocity mode servo loop for a brush type motor is shown in figure 2 2a An external controller commands a given velocity RPM The velocity loop summing amplifier compares this command with the actual motor velocity supplied by a DC tachometer on the motor shaft and produces an error voltage proportional to the difference between the actual and commanded velocity The velocity error is used to command motor current in the inner servo loop The current loop summing amplifier compares the command current velocity error with the actual current in the motor and produces an error voltage proportional to the difference between the actual and commanded current Finally the current error signal is used to produce an output linear or PWM to drive the motor The velocity loop may be bypassed and an external current command fed directly to the current loop In this case 10 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 2 THEORY OF OPERATION the external command signal controls the torque of the motor rather than the velocity This is known as current mode operation VELOCITY CURRENT CURRENT ERROR SIGNAL LOOP C
47. nd only to a common terminal We also recommend that the signal lines be kept as far as possible from any power or motor wires 4 3 2 Wire Size and Type IMPORTANT To ensure safe operation Glentek strongly recommends that all wiring conform to all local and national codes Recommended Wire Size and Type e Motor Wires 14AWG shielded Standard Version 12AWG shielded High Power Version Motor Case Ground Same as motor wires or use metallic conduit Main Power 14AWG single axis or 12AWG multi axis twisted Fan Power 16AWG twisted Signal amp Tach Input 22AWG twisted pair shielded Logic Inputs Outputs 22AWG shielded with its return lead 4 3 3 Connector Size and Type 4 3 3 1 The Power Connector of the Single Amplifier Module All amplifiers are shipped with the right angle AUGAT terminal block mounted as it power connector Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 17 SMA7115 MANUAL CHAPTER 4 INSTALLATION The vertical angle AUGAT terminal block and the PHOENIX connector are two options one can choose to use for the power connector The specifications of all the mentioned connectors are listed as follows AUGAT RDI 6 Series Tri Barrier Terminal Blocks AUGAT P N 6PCR 04 Default Screw Size Spacing 6 6 32 on 375 centers Terminal Style PC Printed Circuit Pin Terminal Orientation R Right Angle Number of Screw Terminals 04 4 screw posi
48. ne One Axis Amplifier Connections 4 3 6 Multi Axis Amplifier Connections Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 3 SMA7115 MANUAL TABLE OF CONTENTS CHAPTER FIVE CONFIGURATION 5 1 Introduction 5 2 Logic Input Configuration 5 2 1 15V 5 Logic Level Configuration 5 2 2 Velocity Mode and Current Mode Configuration 5 2 3 Integrator Configuration 5 2 4 Stop Function CHAPTER SIX START UP AND CALIBRATION Introduction Initial Start Up Calibration of the Velocity Mode Amplifier Calibration of the Current Mode Amplifier Calibration Setup Record CHAPTER SEVEN MAINTENANCE REPAIR AND WARRANTY 7 1 Maintenance 7 2 Amplifier Faults Table of Fault LED Conditions Under Voltage Fault High Speed Electronic Circuit Breaker HS ECB Fault Low Speed Electronic Circuit Breaker LS ECB Fault Over Temp Fault 2 Over Voltage Fault 7 2 7 Resetting A Fault 7 3 Amplifier Failure 7 4 Factory Repair 7 5 Warranty APPENDIX A AMPLIFIER DRAWINGS SMA7115 8 SMA7115HP Installation Schematic 7015 4042 SMA7115 Installation Drawings 7015 4043 SMA7115 1A 1 Installation Drawing for the Stand Alone Amplifier 7015 4044 SMA7115 2A 2 2 AXIS Amplifier Installation Drawing 7115 1033 SMA7115 4A 4 4 AXIS Amplifier Installation Drawing 7115 1032 APPENDIX B POWER SUPPLY GP8600 70 60A Power Supply Assembly Drawing 8600 2030 APPENDIX C EUROPEAN UNION EMC DIRECTIVES Electromagnetic Compat
49. or shaft due to excessive mechanical overload e Overload of amplifier output to motor e Large reflected load inertia 7 2 5 Over Temp Fault When the amplifier heatsink temperature has reached a level that if exceeded would damage the output transistors the Run LED will turn off the OVER TEMP LED is latched on a Fault Output is generated and the amplifier is inhibited NOTE This is a latched condition The following is a list of possible causes Loss of cooling or fans are defective or airflow is blocked Excessive rise in cooling air temperature due to cabinet ports being blocked or excessive hot air being ingested Extended operational duty cycle due to mechanical overload of motor or defective motor 7 2 6 Over Voltage Fault When the DC Buss voltage reaches 250VDC the Run LED will turn off the Overvoltage LED will turn on anda Fault Output is generated and the amplifier is inhibited NOTE This is a latched condition The following is a list of possible causes e Main AC line voltage is too high e Decelerating a large inertial load When decelerating a DC motor acts as a generator If the inertial load is large the generated voltage can pump up the DC Buss If this fault occurs you may need a Regen Clamp Consult Glentek 7 2 7 Resetting A Fault The fault latch may be reset by pushing the Reset button activating the Reset input J1 12 or by removing power and allowing the filter capacitor s to discharge Note
50. ot wiper J2 4 to common ohms Compensation pot wiper J2 5 to common ohms Current Limit pot wiper J2 6 to common ohms Foldback Current Limit pot wiper J2 7 to common ohms Date data taken Serial number S N Model number SMA7115 Note Tach voltage is measured at J1 5 Common for all measurements is at J1 11 Note any changes to components or any special features in the space below 24 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 7 MAINTENANCE REPAIR and WARRANTY Chapter Seven Maintenance Repair and Warranty 7 1 Maintenance Glentek amplifiers do not require any scheduled maintenance although it is a good idea to occasionally check for dust build up or other contamination 7 2 Amplifier Faults If an amplifier should cease to operate and one or more of the fault LED s are lit review the sections which follow on the fault in question for information and possible causes A FAULT CAN ONLY BE CAUSED BY ABNORMAL CONDITIONS LOCATE AND CORRECT THE CAUSE OF THE FAULT BEFORE REPEATED RECYCLING OF POWER TO THE AMPLIFIER TO PREVENT POSSIBLE DAMAGE 7 2 1 Table of Fault LED Conditions Input or Fault RED LED GREEN FAULT Condition FLASHES LED OUTPUT NORMAL OPERATION CURRENT FOLBACK OVER TEMP LATCHED LIMITS OVER VOLT LATCHED LS ECB LATCHED HS ECB LATCHED EXT FAULT OR
51. plifier used on the baseplate this part of the model number will be omitted If there are more than two types of amplifier modules on the baseplate this part of the model number will be repeated for each amplifier type NOTE The multi axis amplifier label will be mounted on the baseplate and each amplifier module will contain its own label and serial number 16 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 4 INSTALLATION Chapter Four Installation 4 1 Introduction This chapter provides the necessary information to make all the wiring connections for the amplifiers to operate properly 4 2 Mounting Appendix A contains all the wiring diagrams assembly drawings and mechanical information necessary to install the amplifiers The amplifier package should be mounted in a clean dry enclosure free of dust oil or other contaminants NEVER INSTALL THE AMPLIFIER PACKAGE IN ANY LOCATIONWHERE FLAMMABLE OR EXPLOSIVE VAPORS ARE PRESENT IMPORTANT Muffin fan s are mounted along one edge of the baseplate to provide cooling At least 3 inches must be allowed between the fan side and the side opposite the fans and any other surface The clearance to any other side of the amplifier package is not critical although sufficient space should be allowed for easy wiring and servicing 4 3 Wiring DO NOT APPLY POWER UNTIL INSTRUCTED TO DO SO 4 3 1 RFI EMI and Wiring Technique
52. pply main power Check for the correct AC voltage at power supply TB1 The DC Bus amplifier supply voltage will be 1 4 times this value Work on only one amplifier at a time 6 3 Calibration of the Velocity Mode Amplifier The amplifier in this configuration receives an analog bi polar input command which is proportional to the required motor velocity The amplifier receives velocity feedback from a tachometer which is usually mounted to the rear of the motor The following pots will be set during calibration Note RV7 RV11 are single turn pots and RV1 RV6 are 20 turn pots Note RV8 RV11 are factory set and should not be adjusted Adjusting these pots voids warranty Differential Gain Sets the input voltage to velocity ratio for differential signal DIFF GAIN input Signal Gain Sets the input voltage to velocity ratio for single ended signal SIG GAIN input Balance BAL Used to null any offsets in system Tach Gain TACH Sets the DC tachometer gain Compensation Used in conjunction with tach gain to set the system COMP bandwidth Current Limit Sets the maximum peak motor current Shipped set CW CUR LIMIT max current Used to shut off uncalibrated amplifiers When the loop gain LOOP GAIN is full CCW no current is delivered to the motor Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 21 SMA7115 MANUAL CHAPTER 6 START UP AND CALIBRATION PROCE
53. s all fault outputs in a multi axis system to be connected together wire ORed to shut down all amplifiers should any amplifier have a fault Carrier frequency is 20KHz Complete short circuit and ground fault protection A Red LED flashes to display various fault conditions and a green LED illuminates to indicate normal operating conditions Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL Frequency response Velocity Loop Frequency response Current Loop External fault reset High Speed Electronic Circuit Breaker HS ECB Low Speed Electronic Circuit Breaker LS ECB Over under voltage and over temperature CHAPTER 1 DESCRIPTION FEATURES AND SPECIFICATIONS 750 Hz minimum 2 KHz minimum A separate input is provided to reset the amplifier after a fault Instantly shuts down the amplifier in the event of a short across outputs and or ground fault condition i e amplifier exceeds 80A for 10microseconds Shuts down the amplifier if the amplifier is operated above the maximum continuous current rating i e 15A for standard 20A for high power for 3 seconds These circuits constantly monitor amplifier power supply voltages and amplifier heatsink temperature They will shut down the amplifier in the event of any out of specification amplifier condition Surface mount technology Current fold back Factory option Constructed with surface
54. se either the input signal or the Signal Gain pot RV2 for single ended input or Differential Gain pot RV1 for differential input With the battery box still connected at J1 3 and J1 4 for single ended input or if your system uses the Differential input move battery box to J1 1 and J1 2 set the battery box for a known DC voltage Apply input signal pulses and adjust the Signal Gain pot RV2 or RV1 for differential input to obtain the desired current gain of the amplifier If the motor is rotating in the wrong direction for a given input polarity remove the power and reverse the motor leads Remove the battery box and repeat step 2 Calibration complete Reconnect signal wires Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 23 SMA7115 MANUAL CHAPTER 6 START UP AND CALIBRATION 6 5 Calibration Setup Record It is good practice to keep a record of all pot settings Doing so will facilitate calibration on future units and repair on this unit Although not a substitute for the calibration procedure it will at least get you in the ballpark Remove the power and allow all capacitors to discharge before taking measurements Note The balance pot should not be measured in this fashion set per step 3 in the calibration procedure Differential Gain pot wiper J2 1 to common ohms Signal Gain pot wiper J2 2 to common ohms Tach Gain pot wiper J2 3 to common ohms IR Compensation p
55. tch Header P N GMSTBA 2 5 4 G 7 62 Plug P N GMVSTBW 2 5 4 ST 7 62 Header P N GMSTBA 2 5 2 G 7 62 Plug P N GMVSTBR 2 5 4 ST 7 62 header with side panels plug in direction parallel to PCB 2 and 4 positions color green 4 3 4 Amplifier Module Connections 4 3 4 1 The Power Connections TB1 BUS RETURN B DC Buss BUSS B DC Buss MOTOR Motor MOTOR Motor 18 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 4 INSTALLATION 4 3 4 2 The Signal Connections J1 DIFF SIG IN Differential signal input DIFF SIG RET Differential signal return SIG IN Single ended signal input COMMON Common for all signals and shields TACH IN Tachometer input Not used in current mode MTR CUR Scale factor 1V 5A LIMIT Inhibits the motor in the direction LIMIT Inhibits the motor in the direction INHIBIT Inhibits the motor in both directions Goes low if there is a fault in the amplifier May be FAULT externally forced low to stop motor rotation in both COMMON Common for all signals and shields Resets the fault latch May also be used as an inhibit RESET en Goes high if the Low Speed Electronic Circuit Breaker LS ECB turns on Goes high if the High Speed Electronic Circuit Breaker HS ECB turns on OVERVOLT Goes high if the buss voltage rises above 250VDC
56. ter Installation Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 39 SMA7115 MANUAL APPENDIX C EUROPEAN UNION EMC DIRECTIVES When multiple power cables enter an enclosure an unfiltered line can contaminate a filtered line external to the en closure Therefore all lines must be filtered to be effective The situation is similar to a leaky boat All the holes must be plugged to prevent sinking SE WARNING f a Large leakage currents exist In AC line filters They must be grounded properly before applying power Filter capacitors retain high voltages after power removal Before handling the equipment voltages should be measured to determine safe levels prior to handling the equipment Failure to observe this precaution could result in severe bodily injury If the filter is mounted excessively far from the drive it may be necessary to mount it to a grounded conductive sur face such as the enclosure to establish a high frequency HF connection to that surface To achieve the HF ground direct contact between the mounting surface and the filter must be achieved This may require removal of paint or other insulating material from the cabinet or panel The only reasonable filtering at the drive output terminals is the use of inductance Capacitors would slow the output switching and deteriorate the drive performance A common mode choke can be used to reduce the HF voltage at the drive output This wi
57. that the fault latch will not reset unless the fault has been cleared 7 3 Amplifier Failure If an amplifier should fail that is if it should cease to operate with no apparent fault the drawings in appendix A will enable a skilled technician to troubleshoot an amplifier to even lower levels The modular construction of the amplifier allows for fast and easy repair The lowest level parts or modules which Glentek recommends for field replacement are e Fuses In the power supply e Fans e Amplifier modules 7 4 Factory Repair Should it become necessary to return an amplifier to Glentek for repair please follow the procedure described below T Reassemble the unit if necessary making certain that all the hardware is in place 26 Glentek Inc 208 Standard Street El Segundo California 90245 U S A 310 322 3026 SMA7115 MANUAL CHAPTER 7 MAINTENANCE REPAIR and WARRANTY Tag the unit with the following information A Serial number and model number B Company name phone number and representative returning the unit C A brief notation explaining the malfunction D Date the unit is being returned Repackage the unit with the same care and fashion in which it was received Label the container with the appropriate stickers e g FRAGILE HANDLE WITH CARE Contact a Glentek representative confirm that the unit is being returned to the factory and obtain an RMA Return Material Authorization number The RMA number m
58. tion or emission of electromagnetic interference EMI and re sponse or immunity to EMI The degree to which a device does not emit EMI and is immune to EMI is called the de vice s Electromagnetic Compatibility EMC Equipment which is to be brought into the European Union legally requires a specific level of EMC Since this ap plies when the equipment is brought into use it is of considerable importance that a drive system as a component of a machine be correctly installed EMI Source Victim Model shows the commonly used EMI model The model consists of an EMI source a coupling mechanism and an EMI victim A device such as servo drives and computers which contain switching power supplies and microprocessors are EMI sources The mechanisms for the coupling of energy between the source and victim are conduction and radiation Victim equipment can be any electromagnetic device that is adversely affected by the EMI coupled to it CONDUCTED EMI gt EMI EMI SOURCE sZ VICTIM RADIATED EMI EMI VICTIM Figure 1 EMI Source Victim Model Immunity to EMI is primarily determined by equipment design but how you wire and ground the device is also critical to achieving EMI immunity Therefore it is important to select equipment that has been designed and tested for in dustrial environments The EMI standards for industrial equipment include the EN61000 4 X series IEC 1000 4 X and IEC801 X EN55011 CISPR11 ANSI C62 and C63
59. tions Terminal lugs Thomas amp Betts T amp B P N A116 for 18awg wire B19 for 14awg wire and C133 for 12 10awg wire AUGAT RDI 6 Series Tri Barrier Terminal Blocks AUGAT P N 6PCV 04 Screw Size Spacing 6 6 32 on 375 centers Terminal Style PC Printed Circuit Pin Terminal Orientation V Vertical Angle Number of Screw Terminals 04 4 screw positions Terminal lugs Thomas amp Betts T amp B P N A116 for 18awg wire B19 for 14awg wire and C133 for 12 10awg wire PHOENIX CONTACT COMBICON Headers and Plugs with 7 62mm pitch HEADER PART GMSTBA 2 5 4 G 7 62 PLUG PART GMVSTBR 2 5 4 ST 7 62 header with side panels plug in direction parallel to PCB 4 positions color green 4 3 3 2 The Signal Connector J1 The signal connector is supported by the molex KK 100 2 54mm Centerline Connector System Mating Header molex 7478 Series Right Angle Square Pin Friction Lock Header molex P N 22 12 2164 16 pins 025 0 64mm right angle square brass pins 94V 0 nylon housing Mating Connector molex 2695 Series 100 2 54mm Center Crimp Terminal Housing molex P N 22 01 3167 red nylon housing 16 positions with polarizing rib Crimp Terminals molex Crimp Terminals molex P N 08 55 0102 15 microinch select gold plated brass 4 3 3 3 The Power and Motor Connectors of the Stand Alone Amplifier TB1 amp 2 PHOENIX CONTACT COMBICON Headers and Plugs with 7 62mm pi
60. ust accompany the unit upon return to Glentek Return the unit by the best means possible The method of freight chosen will directly affect the timeliness of its return Glentek also offers a 24 48hr repair service in the unlikely event that your system is down and you do not have a replacement amplifier module 7 5 Warranty Any product or part thereof manufactured by Glentek Inc described in this manual which under normal operating conditions in the plant of the original purchaser thereof proves defective in material or workmanship within one year from the date of shipment by us as determined by an inspection by us will be repaired or replaced free of charge FOB our factory El Segundo California U S A provided that you promptly send to us notice of the defect and establish that the product has been properly installed maintained and operated within the limits of rated and normal usage and that no factory sealed adjustments have been tampered with Glentek s liability is limited to repair or replacement of defective parts Any product or part manufactured by others and merely installed by us such as an electric motor etc is specifically not warranted by us and it is agreed that such product or part shall only carry the warranty if any supplied by the manufacturer of that part It is also understood that you must look directly to such manufacturer for any defect failure claim or damage caused by such product or part Und

OPERATION & SERVICE MANUAL Model SMA7115

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OPERATION &amp; SERVICE MANUAL Model SMA7115

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OPERATION & SERVICE MANUAL Model SMA7115