MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING MODEL FEATURES FEATURES 4122P +24~90VDC, 10/20A, Standard 0-100% modulation 4212P +24~90VDC, 6/12A, Standard 0-100% modulation • Mounts on customers printed 4122ZP +24~90VDC, 10/20A, 50% modulation circuit boards. 4212ZP +24~90VDC, 6/12A, 50% modulation • Uses output filter option for reduced PWM noise to adjacent circuits APPLICATIONS • OEM drive systems THE OEM ADVANTAGE • Minimize cabling for lowest cost products • Uses industry-standard connectors for solderless installation FEATURES The output filter card option uses the These versions of the 4122/4212 same connectors as the popular 300 models and their variants use extended series models ( 303, 306, 306A and pins that interface with printed circuit variants ) for easy upgrading to the 4xx2 board mounted connectors for direct models. mounting of the amplifier to customers The filter is a dual section L/C/R that pc boards. slows down the switching ‘edges’ ( the Pins models also accept the “F” option rise and fall times of the outputs ) for card that has output ‘edge’ filters that greatly reduced coupling of PWM noise reduce the noise coupling of PWM to nearby cables and circuits. outputs to adjacent cabling and circuitry. Copley Controls, 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax:781-828-6547 Web: http://www.copleycontrols.com Page 1 of 1 MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING FILTER DIAGRAM R AMPLIFIER C2 L OUT(+) C1 GND MOTOR L C1 OUT(-) C2 R FUNCTIONAL DIAGRAM * JP1: PINS 2-3 FOR /ENABLE AT J2-11 GND PINS 1-2 FOR /INHIBIT AT J2-11 10 ENABLE 3 2 1 * INTEGRATOR RESET SWITCHES 11 *JP1 RH2 100 K TURN ON WHEN AMP IS DISABLED POS ENABLE AUX 16 LED 12 INTEGRATOR GREEN = NORMAL STATUS NEG ENABLE RED = FAULT & 13 TACH LEAD CONTROL TACH (-) CH5 CH9 (OPEN) RH4 NOTE: +5V LOGIC - * 14 +FAULT OUTPUT 6 DEFAULT VALUE OF CH11 IS 0 OHMS FOR TORQUE MODE OPERATION RESET GND 15 7 FOR VELOCITY MODE ( BRUSH TACH ) RH3 100 K CH11 RH10 CH17 MOMENTARY SWITCH CLOSURE RESETS FAULT + * REPLACE CH11 WITH 4.7NF RH15 WIRE RESET TO GROUND FOR SELF-RESET 60.4 K REF LEAD REF AMP J2 SIGNAL CONNECTOR RH6 CH8 CURRENT LIMIT Gv = 1 CH16 SECTION REF(+) 100PF 47K 4 - - VALUE DEPENDS ON MODEL - - + SEE "ARMATURE INDUCTANCE" TABLE REF(-) + RH7 100 K 5 RH12 182K + + PEAK CURRENT CURRENT J1 MOTOR & POWER CONNECTOR SERVO ERROR PREAMP 47K AMP RH13 4.7MEG CONT CURRENT MOTOR +15V CH14 0.47U PWM PEAK STAGE CW RH1 + - TIME OUTPUT MOSFET BALANCE CURRENT "H" MOTOR + 10 MEG Voltage gain = 1 50K SENSE BRIDGE 1 -15V MOTOR - 2 +/-6V for VOLTAGE GND 1K +/-Ipeak CURRENT GAIN 3 9 REF GND 4.8 kHz FILTER Gv = +HV 33NF 4 10 +HV +/-6V at 5 1K +/-Ipeak CURRENT 8 MONITOR 4.8 kHz FILTER 33NF 1K GND 2 +HV 10k CASE MAY BE GROUNDED +5 +15 +15V 1 DC / DC FOR SHIELDING AUXILIARY +15 CONVERTER DC OUTPUTS 10k -15 3 -15V -15 CASE GROUND NOT CONNECTED TO CIRCUIT GROUND POWER GROUND AND SIGNAL GROUNDS ARE COMMON Copley Controls, 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax:781-828-6547 Web: http://www.copleycontrols.com Page 2 of 2 MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING TYPICAL CONNECTIONS TORQUE MODE ENCODER VELOCITY MODE ENCODER REF+ + 4 1 REF+ + J2 J1 4 MOTOR 1 REF- J2 J1 5 2 MOTOR REF- 5 2 6 J2 TACH + 7 GND 10 GND 10 ENABLE 11 3 ENABLE 11 3 12 POS ENABLE J1 4 GND J1 POS ENABLE 12 4 GND + NEG ENABLE 13 5 +HV NEG ENABLE + 13 5 +HV Note: JP1 on pins 2-3 ( default ) Note: JP1 on pins 2-3 ( default ) Notes 1. All amplifier grounds are common (J1-3, J1-4, J2-2, J2-7, and J2-10 ) Amplifier grounds are isolated from case & heatplate.. 2. Jumper JP1 default position is on pins 2-3 for ground active /Enable input ( J2-11 ) For /Inhibit function at J2-11 ( +5V enables ), move JP1 to pins 1-2 3. For best noise immunity, use twisted shielded pair cable for reference and tachometer inputs. Twist motor and power cables and shield to reduce radiated electrical noise from pwm outputs. Copley Controls, 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax:781-828-6547 Web: http://www.copleycontrols.com Page 3 of 3 MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING CONNECTORS AND PINOUTS J1: MOTOR & POWER CONNECTIONS Pin Signal Remarks 1 Motor (+) Amplifier output to motor (+) winding 2 Motor (-) Amplifier output to motor (-) winding 3 GND Power supply return. Connect to system ground at this pin. 4 GND Power supply return. Connect to system ground at this pin. 5 +HV +HV DC power supply input J2: AMPLIFIER BOARD CONNECTIONS Pin Signal Remarks 1 +15V +15V in series with 10kΩ 2 Gnd Signal ground 3 -15V -15V in series with 10kΩ 4 Ref (+) Differential input positive terminal for Reference voltage 5 Ref (-) Differential input negative terminal for Reference voltage 6 Tach (-) Negative terminal of brush tachometer 7 Gnd / Tach (+) Signal ground, or positive terminal of brush tachometer 8 Curr Mon Output current monitor: ±6V output at ±peak output current 9 Curr Ref Current demand signal to PWM stage: ±6V demands ±peak current 10 Gnd Signal ground 11 /Enable Amplifier enable input: enables or inhibits PWM switching at outputs Default: Gnd enables amplifier, open or +5V inhibits ( JP1 @ 2-3 ) For controllers that output +5V to enable amplifier, move internal jumper JP1 to pins 1-2 ( Gnd will inhibit, +5V or open will enable ) 12 /Pos Enab Gnd to enable output current in one polarity, open or +5V to inhibit Typically used with grounded, normally closed limit switches. 13 /Neg Enab Gnd to enable output current in opposite polarity, open or +5V to inhibit. Typically used with grounded, normally closed limit switches. 14 /Normal Current-sinking when amplifier enabled and operating normally. Goes to +5V when amplifier disabled or fault condition exists. 15 /Reset Ground to reset overtemp or output short circuit latching faults. For automatic reset of faults every 200mS, ground permanently. 16 Aux Single-ended auxiliary input. BALANCE POTENTIOMETER Default position: centered. Functions to bring output current ( in torque mode ) or output velocity ( in tachometer mode ) to zero with reference input voltage at zero, or control system output at zero. Normal range is ±1% of full scale with 10Meg resistor in header location RH1. To use the pot as a wide range set-point adjustment, install a 150kΩ resistor at RH1. Now, full CW or CCW will have the effect of a ±10V signal at the reference inputs. STATUS LED Dual color, red/green. Color +HV /Enable Short Overtemp Green Normal Active None Normal Red Too low or too high X X X X Inhibited X X X X Output short X X X X Too hot Note 1, 5 2, 5 3, 5 4, 5 Notes: 1. +HV normal >20V and <92V for model 4122, >20V and <129V for model 4212 2. /Enable is ground-active for JP1 on pins 2-3 ( default ). To reverse function, switch JP1 to pins 1-2. 3. Shorts detected by overcurrent circuit are between outputs, or from outputs to ground. 4. Overtemperature faults occur when heatplate temperature is >70°C 5. +HV and /Enable cause momentary amplifier shutdown, operation is restored when +HV is within normal limits and /Enable input is active. Output shorts, and overtemperature faults latch-off amplifier. Thus amplifier will remain off until power is cycled on/off, or /Reset input is grounded momentarily. If /Reset input is wired to ground, output short and overtemperature faults will self-reset every 200ms. Copley Controls, 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax:781-828-6547 Web: http://www.copleycontrols.com Page 4 of 4 MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING COMPONENT HEADER NO PARTS INSTALLED IN THESE LOCATIONS CH17 LOAD INDUCTANCE COMPENSATION CH16 (SEE CHART FOR VALUES) RH15 CH14 0.47UF PEAK TIME LIMIT RH13 CONTINUOUS CURRENT LIMIT 4.7 MEG 182K RH12 PEAK CURRENT LIMIT CH11 (O OHM) PREAMP DC GAIN & INTEGRATOR 60.4K RH10 CH9 PREAMP HI-FREQUENCY ROLL-OFF (SEL) (SEL) CH8 REF INPUT LEAD CAPACITOR JP1 RH7 REFERENCE INPUT SCALING 100K 3 2 1 (SEL) RH6 REF INPUT LEAD RESISTOR (SEL) CH5 J1 TACH INPUT LEAD NETWORK J2 (SEL) RH4 5 1 16 1 RH3 100K TACH INPUT SCALING 100K RH2 AUX INPUT COMPONENTS LABELLED "SEL" 10MEG RH1 BALANCE RANGE ARE NOT INSTALLED AT FACTORY USER SHOULD SELECT VALUES AS REQUIRED ARMATURE INDUCTANCE Model 4122 4212 Load (mH) RH 15 CH17 CH16 RH15 CH17 CH16 0.2 to 0.5 80.6k 2.2 nF 390 pF 69.8 k 2.2 nF 390 pF 0.6 to 1.7 200k 680 pF 220 pF 100 k 1 nF 330 pF 1.8 to 4.8 402k 680 pF 180 pF 301 k 470 pF 100 pF 5 to 14 806k 680 pF 150 pF 698 k 330 pF 82 pF 15 to 45 1.5M 470 pF 100 pF 1.21M 220 pF 82 pF Note: Values in bold & italics are factory installed standard. Values shown are for 90V (4122 ) and 125V (4122). At lower supply voltages RH15 may be increased and CH17 decreased. PEAK CURRENT LIMIT (AMP) CONTINUOUS CURRENT LIMIT (AMP) 4122 4212 RH12 (Ω) 4122 4212 RH13 (Ω) 20 12 182k 10 6 4.7Meg 16.7 10 56k 7.4 4.4 7.15Meg 13.3 8 30k 5.7 3.4 10Meg 10 6 18k 6.7 4 9.1k 3.3 2 3.9k Notes on Current Limits: PEAK CURRENT TIME-LIMIT (SEC) 1. Values in bold & italics are factory installed standard. Tpeak CH14 (μF) 2. Peak times double after polarity reversal. 1 0.47 3. Peak current limit should be set greater than continuous current limit. 0.8 0.33 If Ipeak < Icont then peak overrides continuous limit and Icont = Ipeak. Minimum setting for peak current is 0% of peak rating. 0.5 0.22 4. Continuous current sense is for average current. Symmetrical waveforms with zero 0.3 0.15 average value may cause overtemperature shutdown of amplifier or motor damage 0.2 0.10 2 due to high I R losses. 0.1 .047 5. Times shown are for 100% step from 0A with default value of RH13 ( 4.7 Meg ). When changing RH13, peak times will change. Set RH13 for continuous current limit first, then pick CH14 based on waveforms at Curr Ref ( J2-9 ). Copley Controls, 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax:781-828-6547 Web: http://www.copleycontrols.com Page 5 of 5 MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING voltage at the amplifier ground that is different than the control APPLICATION INFORMATION system ground. If this voltage is added to the output of the control IMPORTANT! ALWAYS REMOVE POWER WHEN CHANGING system, it can produce oscillation, or inconsistent operation. To HEADER PARTS!! eliminate this effect, you should always use both reference inputs. Connect the Ref(+) input to the output of the controller card, and OPERATING MODES the Ref(-) input to ground at the control card. Now, the differential These amplifiers operate as either open-loop current sources, or amplifier will measure the control signal at the control card and feedback devices using analog tachometers. will reject any noise that exists between amplifier and control As open-loop current sources, the ±10V at the reference inputs system grounds. produce current in the load, typically a motor. The motor acts as THE SERVO PREAMPLIFIER a transducer, and converts current into torque, the twisting force at the motor shaft. This is called torque mode. It is used most This section processes the reference signal and any feedback frequently in systems that have controllers taking feedback from signals, and generates an internal current reference signal that an encoder on the motor shaft. The computer calculates both controls the PWM stage to produce output currents. It is here that position and velocity from the encoder signal, processes them in the reference signal and tachometer signals are compared, and a digital filter, and outputs a signal to the motor causing it to the difference signal produced and amplified. accelerate or decelerate. Three components on the header control the behavior of the As a feedback amplifier, a signal is generated by an analog brush servo preamp. The chart below lists the default torque-mode and tachometer mounted on the motor. This is a generator that starting-point values for velocity mode operation: produces an analog signal that has a polarity and amplitude proportional to the motor speed. The amplifier subtracts the tach Part Torque Velocity signal from the reference signal, and amplifies the difference CH9 out 220pF between them. This is called velocity mode, because the RH10 60.4k 680k amplifier changes the motor current ( torque ) so that the motor CH11 short 4.7nF velocity is proportional to the reference signal. CH9 controls the high-frequency roll-off. TORQUE MODE OPERATION RH10 controls the loop gain, and thus the step-response of the amplifier. Torque mode is the default configuration. For input voltages of CH11 ( along with RH7 ) forms the integrator that gives the ±10V, the amplifier will output its peak rated current. stiffness at a standstill, or speed regulation while running. In torque mode, motor current is held constant, and motor speed, or velocity changes as the load changes. CURRENT LIMITING In torque mode the gain of the servo preamplifier is simply 0.6 and scales the ±10V from the reference signal down to the ±6V This stage takes the output of the servo preamplifier, and that drives the PWM stage. processes it before sending it to the PWM stage. The amplitude The servo preamplifier integrator function is disabled, and the low of the signal is first clamped to produce peak current limiting. This gain is constant over a wide range of frequencies. Thus we signal then goes to the continuous current-limit circuit where sometimes call this flat-gain mode. these functions are produced. Finally, the current-limited signal is outputted to the PWM stage as the current-reference signal. This VELOCITY MODE OPERATION signal is quite useful in that the current limit action can be seen here and measured without connecting a motor, thus protecting it The difference between the reference and tachometer signals is from overload during initial setup. amplified and used to change the torque on the motor. Ideally, the difference between the command and feedback signals would PWM STAGE be zero, so in velocity mode operation the servo preamplifier must have much higher gain than when in torque mode. The voltage at the output of the current limit stage is called the In addition, the gain must change over a range of frequencies. current reference. This signal becomes the demand signal that For “stiffness” that corrects for steady-state changes, the controls the PWM stage. Here the current demand is converted amplifier uses an integrator. For fast response the loop gain of into a current in the motor. This current can be measured at the the servo preamplifier must be tailored to the characteristics of current monitor, which shows the response of the motor to the the motor and tachometer. To control oscillations from the current demand signal. By operating as a current source, the tachometer, the gain of the preamplifier must roll-off, or decrease PWM stage is able to achieve faster response from the motor at higher frequencies. than if was acting only as a variable voltage. In velocity mode, motor speed is held constant, while motor The current error amplifier compares the current reference with current changes in response to changes in the load. the current monitor, and adjusts the output voltage such that the demanded current flows in the motor. The gain of this amplifier is THE PARTS OF THE AMPLIFIER controlled by RH15, CH16, and CH17, which are used to compensate the amplifier for the motors’ inductance. DIFFERENTIAL AMPLIFIER 1) The reference signal ( the command signal from the control system ) is sensed by a differential amplifier. This acts like a voltmeter with two probes, measuring a voltage between two points. Current flowing in the amplifier power wiring causes voltage drops in the wires resistance. This in turn can produce a Copley Controls, 20 Dan Road, Canton, MA 02021 Tel: 781-828-8090 Fax:781-828-6547 Web: http://www.copleycontrols.com Page 6 of 6 MODELS 4122, 4212 AND VARIANTS “P” VERSIONS FOR PC BOARD MOUNTING OUTLINE DIMENSIONS Dimensions in inches (mm.) 0.56 2.00 4.00 3.00 1.00 0.625 0.16 4.30 ORDERING GUIDE Model 4122 20A peak, 10A continuous, +22 to +90VDC brush motor amplifier Model 4212 12A peak, 6A continuous, +22 to 125VDC brush motor amplifier Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547 Web: http://www.copleycontrols.com Rev B, 06/08/2010