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OPERATING AND SERVICE MANUAL
NC400 SERIES SERVO CONTROLLER
MA1229 REV.B
NC 400 CARD AMPLIFIER
Operating and Service Manual
NC400 Series Servo Controllers
(Preliminary)
TABLE OF CONTENTS
CHAPTER 1
1.0 The NC400 Series DC Servo Controllers
1.1 Introduction
1.2 Receiving and Handling
CHAPTER II
2.0 Specifications
2.1 Servo Controller Specifications
2.2 Power Supply Specifications
2.2.1 Single Phase Power Supplies
2.2.2 Three Phase Power Supplies
2.3 Shunt Regulator Specifications
CHAPTER III
3.0 Assembly and Terminal Descriptions
3.1 Servo Controller Assemblies:
NC407, NC414, NC421
3.2 Dual-Axis Card Assemblies:
A1522, A1523
3.3 Single-Phase Power Supply Assemblies:
A1524 and A1525
3.4 Three-Phase Power Supply Assemblies:
Al526 and Al527
Shunt Regulator Assemblies:
Rack Panel Assemblies:
Power Transformers
General Precautions
Panel Mounted Assemblies
Rack Mounted Assemblies
4.4.1 Power Wiring
4.4.2 Signal Wiring and Shielding
4.4.3 Earth (Ground) Connections
Ancillary Components
4.5.1 Bus Filter Capacitor
4.5.2 Armature Inductor
Load Contactor
CHAPTER III (CONTINUED)
3.5
Al528 and Al529
3.6
Al516 and Al518
3.7
CHAPTER IV
4.0 Installation Procedures
4.1
4.2
4.3
4.4 Wiring
4.5
4.5.3
CHAPTER V
5.0
Set-Up Procedure
5.1
Power Supply Tests
5.2 Servo Controller Set-Up Procedures
5.2.1
5.2.2
5.2.3
5.2.4
Bridge Resistance Checks
Polarity (Direction) Determination
Enable and Inhibit Circuit Tests
Potentiometer Adjustments
3-13
3-14
4-1
4-2
4-3
4-3
4-5
4-5
CHAPTER V (CONTINUED)
CHAPTER VI
5.2.4
5.2.5
5.2.6
5.2.4.1 Offset Adjustment
5.2.4.2 Current Limit Adjustment
5.2.4.3 Scale Factor Adjustment
5.2.4.4 Servo Response Adjustment
Compensation Component Changes
Electronic Circuit Breaker Trip
Adjustment
6.0 Theory of Operation
6.1 Power Section Operation
6.2
Preamplifier Section Operation
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
Frequency Response Analysis
The Offset Circuit
The Current Limit Circuit
Three Signal Input Version
Miscellaneous Comments
Protection Circuit Operation
6.3.1
6.3.2
Thermal Sensor
Electronic Circuit Breaker Circuit
Overvoltage Sense Circuit
Undervoltage Protection Circuits
Primary Overcurrent Sense Circuit
6-1
6-8
6-9
6-11
6-14
6-15
6-16
6-18
6-18
6-19
6-19
6-20
6-21
Secondary Overcurrent Sense Circuit 6-22
Shunt Regulator Option
6-22
CHAPTER VII
7.0 Maintenance, Repair and Warranty
7.1 Maintenance Procedures 7-1
7.2 Fault Determination Procedures 7-1
7.2.1 In-System Check 7-2
7.2.2 Out-of-System Checks 7-3
7.2.2.1 Quadrant Resistance Tests 7-3
7.2.2.2 Signal Electronics Card Tests 7-3
7.2.2.3 Preamplifier Section Tests 7-7
7.3 Factory Repair 7-8
7.4 Spare Parts 7-9
7.4.1 Level 1 Maintenance Spare Parts 7-9
7.4.2 Level 2 Maintenance Spare Parts 7-9
7.5 Warranty 7-11
7.6 Authorized Repair Agents 7-12
APPENDIX
A.l Assembly Outline Drawings
1.0
CHAPTER 1
The NC400 Series DC Servo Controllers
1.1 Introduction
Three servo controller models, NC407, NC414 and NC421, and
associated equipment assemblies comprise the NC400 Series. These
controllers operate from a 100VDC bus and range in peak output
currents from 15 to 45 amperes.
These controllers are true plug-in card assemblies and do
not require that any wires be detached in order to remove them
from their mounting, making replacements or exchanges extremely
easy and absolutely foolproof.
The NC400 Series are switch-mode controllers employing rugged
power switching transistors, resulting in reliable, efficient
and smooth power transfer from the DC supply to the motor load.
In fact, average load current form factors are normally lower than
1.01; hence, nearly pure DC current flows in the motor. As a
result, substantially more power is obtained from SCR - rated
motors, allowing in many cases a reduction of frame size with
consequent cost savings.
In addition, an order of magnitude increase in closed-loop
velocity and position servo performance is afforded by the high
system bandwidths achievable using the NC400 Series.
Besides the three identically-sized servo controller card
assemblies, the NC400 Series also offers additional, complemen-
tary assemblies (Dual-Axis Card Assembly) in which to mount the
controllers for either panel or rack mounting. In addition, both
single and three phase Power Supply assemblies are available to
provide up to 6KW of power to the controllers. Detailed descrip-
tions of these components, as well as others, are provided in
later sections of this manual,
Page 1-1
1.0
The NC400 Series DC Servo Controllers (Continued)
1.1 Introduction (Continued)
The following sections of this manual detail installation,
operating and maintenance procedures for the NC400 Series and
have, as well, sections covering aspects of the theory of
operation of the controllers and basic applications information.
1.2 Receiving and Handling
Upon delivery of the equipment, thoroughly inspect the ship-
ping containers and contents for indications of damage incurred
in transit. If any of the items called for in the bill of lading
or express receipt are damaged or the quantity is short, do not
accept them until the freight or express agent makes an appro-
priate notation on your freight bill or express receipt. If
any concealed loss or damage is discovered later, notify your
freight or express agent within 15 days of receipt and request
that he or she make an inspection.
Claims for loss or damage in shipment must not be deducted
from your invoice, nor should payment be withheld pending adjust-
ment of any such claims.
Store the equipment in a clean, dry area. It is advisable
to leave the equipment in its shipping container until ready for
use.
Procedures for returning equipment to the factory, for any
reason, are detailed in later sections of this manual.
Page 1-2
CHAPTER 11
2.0 Specifications
2.1 Servo Controller Specifications
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
DC Bus Voltage (nominal):
Maximum Output Voltage:
Output Current:
NC407
Peak (5 sec. max) +15A
RMS +7A
Continuous +7A
Horsepower Rating (nominal):
NC407
Peak 1.5
Continuous 0.7
Power Input Voltages:
Power Section Bandwidth:
Deadband:
Efficiency:
Current Limit Range:
Form Factor (Note 1):
Gain (Note 2):
NC407
Input 1: 0 to
5000A/V
Input 2: 130 to
1300A/V
Gain Linearity:
Drift (Referred to Input):
Offset
+100VDC
+95
NC414 NC421
+30A +45A
+14A +21A
+14A +21A
NC414 NC421
3.0 4.5
1.4 2.1
+100VDC
36VAC (center-tapped) € 0.27
Small Signal: 0 to 1000HZ
Large Signal: 0 to 100H2
Zero
85%
NC407: +3A to +15A
NC414: +6A to +30A
NC421: +9A to +45A
1.01
NC414 №421
0 to 0 to
10,000A/V 15,000A/V
260 to 400 to
2600A/V 4000A/V
+5%
10uv/°c
Adjustable to zero
Page 2-1
2.0 Specifications (Continued)
2.1 Servo Controller Specifications (Continued)
15) Input Resistance (min.) Input 1: 10K Ohms
(Differential)
Input 2: 10K Ohms
16) Temperature Range:
Operating: 0°с to +50°C
Storage: -30% to +65%
ADDITIONAL FEATURES
1) Auxiliary Outputs:
a) Load Current Analogue: 1,6A/V (NC407), 3.3A/V (NC414)
4.8A/V (NC421)
b) Reference Voltages: +15VDC @25MA
c) Fault Indication: Open-Collector Transistor
Output and PCB LED Indicator
d) RMS Over-Current or Over- Open-Collector Transistor
Temp. Indication: Output with 1.5K ohm Pull-Up
to Internal +15VDC
2) Auxiliary Inputs: Positive Current Inhibit
Negative Current Inhibit
Enable (short-to-enable)
3) Protection Circuits: Over «Temperature
NOTE 1: А+ ra:ceé continuous current
2.9 mH (NC407; 14A, 1.45 mH
Over-Voltage
Over-Current (RMS)
Short-Circuit Across Armature
Short-Circuit to Ground -
either armature lead
and load inductance of 7A,
(NC414); 21A, 1.0mH (NC421)
NOTE 2: Gain ranges shown are for the standard preamplifier
configuration,
Page 2-2
2.0 Specifications (Continued)
2.2 Power
Supply Specifications
2.2.1
1)
2)
3)
4)
5)
2.2.2
1)
2)
3)
4)
5)
Single Phase Power
AC Input Voltage:
(nominal, no-load)
DC Output Voltage;
(nominal, no-load)
Power Ratings
Supplies
144VAC,
+100VDC
4,0 KW (max.
Transformer/Supply Regulation:
center- tapped
continuous)
Ripple Volts
| Transformer | No-Load @Rated PWR
T0073 +100VDC +8 4VDC 5VP-P
T0074 +100VDC +82VDC 8VP-P
T0075 +100VDC +82VDC 12VP=P
T0076 +100VDC +82VDC l6VPeP
Cooling: Convection
Three Phase Power
AC Input Voltage:
(nominal, no-load)
DC Output Voltage:
(nominal, no-load)
Power Rating:
Supplies:
72VAC line-to-line
120VAC @ lA
+100VDC
6,0 KW (max,
Transformer/Supply Regulation:
continuous)
Transformer No-Load VDC @Rated PWR Ripple Volts
T0077 +100VDC +90VDC 2VP-P
T0078 +100VDC +9 0VDC 3VP-P
T0079 +100VDC +8 8VDC 4VP-P
Cooling: Forced Air
Page 2-3
2.0 Specifications (Continued)
2.3 Shunt Regulator Specifications:
1) Peak Power Dissipated:
А1528 1000W
А1529 2000W
2) Continuous Power Dissipated:
Al528 100W
Al529 200W
3) Thresholds:
Cut-In : 117 - 118 V
Cut-Out: 112 « 113 V
Page 2-4
CHAPTER III
Assembly and Terminal Descriptions
3.1 Servo Controller Assemblies: NC407, NC414, NC421
Each of the three servo controller card assemblies
A1519 (NC407), A1520 (NC414) and A1521 (NC421) consists of
two pcb cards --- a Signal Electronics Card and a Power
Electronics Card --- mated together with a plastic handle
extrusion to form a complete controller. Only the Power
Electronics Card is different in the three different models.
The controller is a true plug-in unit. When inserted
into a Dual-Axis Card Assembly, the Signal Electronics
Card mates with a 24 pin card edge connector carrying all
signals; while the Power Electronics Card mates with a
special power card edge connector, through which all power
connections are made.
The following is a description of each of the 24 signal
inputs and outputs available at A2 on the Signal Electronics
Card, and each of the 4 power inputs and outputs available
on the Power Electronics Card (refer to Figure 3.1.)
Servo
Dual-Axis Controller
Card Assy Assembly — Terminal Descrivtion
ТВ1-1 or A2-10 NON-INVERTING SIGNAL INPUT NO. 1:
TB2-1
Non-inverting signal input point.
for signal input No, 1, when
employing differential input Stage,
Also can be used as signal No. 3
input point when not employing
differential input stage (see
Section 5.2). Input impedance is
10Ka nominal.
Page 3-1
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Servo Controller Input and Output Designations
Figure 3.1:
Page 3-2
3.0 Assembly and Terminal Descriptions (Continued).
Dual-Axis
Card Assy
TB1-2 or
TB1-3,5,9,
11,14,16,22
or
TB2-3,5,9,
11,14,16,22
TBl1-4 or
TB2-4
Servo
Controller
Assembly
A2-11
A2-D
3.1 Servo Controller Assemblies: NC407, NC414, NC421 (Cont)
Terminal Description
INVERTING SIGNAL INPUT NO, 1:
Inverting signal input No. 1,
when employing differential input
stage. Input impedance is 10Ka.
nominal, Gain is adjusted by R94
(SIG. 1 potentiometer) at the top
of the Signal Electronics Card,
CW rotation increases the signal
level,
SIGNAL COMMON:
A number of signal common connec-
tion points are provided, The sig-
nal commons are tied internally on
the NC400 Series to the power common.
SIGNAL INPUT NO, 2:
Non-differential signal input terminal
Gain set using R91 (SIG. 2) poten-
tiometer at the top of the Signal
Electronics Card. CW adjustment
increases the signal level.
Page 3-3
3.0 Assembly and Terminal Descriptionrs (Continued)
3.1 Servo Controller Assemblies: NC407, NC414, NC421 (Cont)
Dual-Axis
Card Assy
TB1=6 Or
TB2-6
TB1-7 or
TB2-7
Servo
Controller
Assembly
A2-9
A2-f
Terminal Description
AUXILIARY FUNCTION No. l:
Auxiliary Function 1, 2 and 3
terminals allow the interposition of
additional, external circuits in
the signal path of the Servo Controller,
For example, an external current-
limit circuit can be placed between
Auxiliary Function terminals 1 and 2
(jumper J4 must be removed).
Section 5.2 provides further details,
“AUXILIARY FUNCTION No,.2.
Used with Aux, Function 1 above,
or Aux. Function 3 below to imple-
ment special signal processing
functions provided by external cir-
cuitry, For example, one can inter-
pose a current-limit versus motor
speed circuit between the preamplifier
and power sections of the controller,
using Auxiliary Function No, 2 and
No. 3 terminals (jumper J3 must be
removed), See Section 5.2 for
further details.
Page 3-4
3,0 Assembly and Terminal Descriptions (Continued).
3.1 Servo Controller Assemblies: NC407, NC414, NC421 (Cont)
Dual-Axis
Card Assy
TB1-8 or
TB2-8
TB1-10 or
TB2-10
TB1-12 or
TB2-12
Servo
Controller
Assembly
A2-E
А2-Н
A2-L
Terminal Description
AUXILIARY FUNCTION NO.3:
Used with Auxiliary Function No.2,
above, to implement special signal
processing functions, See above and
Section 5.2 for details,
INHIBIT POSITIVE:
A contact closure or suitable active
device capable of sinking a peak
current of 20MA and having an off-
set or saturation characteristic of
less than 0.6V, must be present and
closed between the Inhibit Positive
terminal and signal common to allow
normal controller operation in the
positive direction, Positive direc-
tion means current flow from the
Armature (+) to Armature (-) ter-
minals, A delay of approximately 30
msec occurs between inhibit activation
and cessation of current flow,
INHIBIT NEGATIVE:
Same function as Inhibit Positive
above, except that, when activated,
current is inhibited from flowing in
the negative direction, that is, from
Armature (=) to Armature (+).
Page 3-5
3,0 Assembly and Terminal Descriptions (Continued)
3,1 Servo Controller Assemblies: NC407, NC414, NC421
Dual-Axis
Card Assy
TB1-13 or
TB2-13
TB1-15 or
TB2-15
Servo
Controller
Assembly
A2-J
A2-N
Terminal Description
SYNC SIGNAL INPUT:
This input provides a means of
synchronizing the switching frequencies
of the controller and other controllers
or devices, by injection of a triangle-
wave modulation signal from an exter-
nal source, The injected signal should
have an amplitude of from 18 to 20
volts peak-to-peak and a frequency
in the range 3 to 6 KHZ, Jumper Jl
must be removed when using an external
sychronizing signal.
Electronic Circuit Breaker/
Overtemperature Indication:
A signal low(< 0,3V) is present at this
terminal with respect to signal common
during normal controller operation.
Up to 10MA of current can be sinked by
this circuit. If either the Electronic
Circuit Breaker protection circuit or
the heat sink over-temperature sensor
should activate, this indicator ter-
minal is pulled to +15K VDC thrcugh a
1.5KQ resistor.
Page 3-6
3.0 Assembly and Terminal Descriptions (Continued)
3.1 Servo Controller Assemblies: NC407, NC414, NC421
Dual-Axis
Card As sy
TB1-17 or
TB2=17
TB1-18 or
TB2-18
Servo
Controller
Assembly
А2-С
A2-K
Terminal Description
FAULT LATCH OUTPUT:
During normal controller operation
a signal low (< 0.3V) is present
at this terminal, Up to 20MA can
be sinked. If a fault condition is
detected, such as a shorted armature
in the motor load, the internal fault
latch is set, the controller is dis-
abled and the Fault Latch Output
goes to an open state, Pull-up must
be provided by external means, as
this circuit is an open collector in
the tripped state.
CURRENT ANALOGUE OUTPUT:
An analogue of load current is
available at this terminal, The
scale factor is such that 9,3V + 10%
represents rated peak controller
current. The source impedance at
this terminal is the equivalent of
2,7K and 0.1 MF in parallel..
Page 3-7
3,0 Assembly and Terminal Descriptions (Continued)
3,1 Servo Controller Assemblies: NC407, NC414, NC421 (Cont)
Dual-Axis
Card Assy
TB1-19 or
TB2-19
TB1-20 or
TB2-20
TB1-21 or
TB2-21
Servo
Controller
Assembly
A2-M
A2-B
A2-A
Terminal Description
ENABLE:
This terminal provides a means of
disabling the controller totally,
so that the output bridge circuit
semiconductors are all in the OFF
state and current is not driven
in either direction, ‘ihe controlle:
is disabled whenever this terminal
is not connected to signal common,
A delay of approximately 30 msec
is incurred when the controller is
disabled. Virtually no delay occurs
when the controller is enabled.
+15VDC BIAS VOLTAGE:
A source of both positive and negative
15VDC bias voltage is provided by the
NC400 Series servo controllers and
made available at this terminal and
the one below, Current draw should
not exceed 25 MA, Ripple and noise
are less than 50 MV peak.to-peak,
These voltages can be used to power
auxiliary function circuits or provide
reference voltages. See Section 5.3
for further details,
=15VDC BIAS VOLTAGE:
See above for details.
3.0 Assembly and Terminal Descriptions (Continued)
3.1 Servo Controller Assemblies: NC407, NC414, NC421 (Cont)
Servo
Dual-Axis Controller
Card Assy Assembly _ Terminal Description
A2-1 36VAC INPUT)
A2-2 A source of 36 VAC, center-tapped,
at 0,2 amperes maximum is required
at these terminals to provide the
low level bias voltages for the
controller, The center tap is
connected to any of the signal
common terminals but preferrably to
terminal 22.6.
COMMON Al-1 POWER COMMON: |
Terminal for connection of the nega-
tive or common line for the 100VDC
power bus from the power supply.
+100VDC Al-2 +100VDC BUS:
Terminal for connection of the posi-
tive +100VDC line from the power supply.
Connection to this terminal and the
one above (common) is made through
0.25" FASTON terminals on the Dual-
Axis Card and through a special power
board edge connector (AMP No, 530521)
to the controller assembly,
Page 3- 9
Assembly and Terminal Descriptions (Continued)
3,1 Servo Controller Assemblies: NC407, NC414, NC421 (Cont)
Servo
Dual-Axis Controller
Card Assy Assembly Terminal Description
—
ARM (+) Al-3 ARMATURE (+):
Terminal for connection of the
positively defined armature (load)
lead. |
ARM (=) Al-4 ARMATURE (-):
Terminal for connection of the
negatively defined armature (load)
lead, As with the power common and
+100VDC connections, the armature (+)
and (-) connections are made through
FASTONS and the special four ter-
minal power board edge connector
mentioned above.
3.2 Dual-Axis Card Assemblies. Al522, Al523
A single card, available in two versions, one for rack
and one for panel mounting, serves as the holder and connection
means for the servo controller cards.
This Dual-Axis Card accommodates one or two controller cards.
Each controller card plugs into a set of two card edge connectors,
one for signal and one for power voltages Signal wire connections
are made to the Dual-Axis Card Assembly through two 22 pin ter-
minal strips, designated TBl and TB2, one strip for each axis
controller,
Page3- 10
Assembly and Terminal Descriptions (Continued)
3.2 Dual-Axis Card Assemblies-e Al522, A1523 (Cont)
Power wiring connections are made to 0,25" male FASTON
terminals, Two groups of four terminals each are provided,
one group for each axis controller,
The various terminal designations and descriptions are
given in the previous Section, 3,1, The Dual-Axis Card also
contains a cooling fan, bias voltage transformers and fusing
for the DC bus inputs and the 120VAC input,
Consult the outline drawings in Section A-1 for further
details of this assembly,
3.3 Single-Phase Power Supply Assemblies: Al524 and Al525
A single printed circuit card, the same size as the Dual-Axis
card, is employed for both the single and three phase power
supply assemblies for the NC400 Series, As with the Dual-Axis
Card, both panel and rack mounting versions are available,
The single phase versions Al524 (panel) and Al525 (rack),
when used with the appropriate transformer, can provide up to
4.0KW of average continuous power output (See Table 1), The
nominal no-load output bus voltage is +100VDC,
AC input connections are made to three screw terminals
designated ACl, AC2 and AC3. AC2 is the center-tap connection
point,
A total of 12 power output terminals (0,25" male FASTON),
six for the power commons and six for the +100VDC connections,
are provided.
Each single-phase power supply assembly has a total of 14,000
WF (nominal) of filtering. In addition, where required, an
optional Shunt Regulator Assembly (See Section 3.5) can be added
to the supply by making only two connections,
Page 3-11
Assembly and Terminal Descriptions (Continued)
3.4 Three-Phase Power Supply Assemblies: Al526 and Al527
Up to 6.0 KW of average continuous power output can be
obtained from each of the two versions, Al526 (panel) and
A1527 (rack), of the three-phase power supply assemblies for
the NC400 Series (See Table 1). |
Unlike the single-phase versions, the three-phase
assemblies contain a cooling fan to cool the three-phase
recitifier assembly.
Three-phase line connections are made to thc three screw
terminals ACl, AC2 and AC3. DC power output is available from
the 12 FASTON terminals described above in Section 3.3.
3.5 Shunt Regulator Assemblies: А1528 and Al529
As an option, a Shunt Regulator Card can be added to
either the single or three phase Power Supply Assemblies.
This card regulates the DC bus voltage during periods of
regeneration (motor deceleration), when energy returned to
the power supply filter capacitor exceeds that supplied.
The resultant voltage build-up on the capacitors activates
the Shunt Regulator Card, once a nominal voltage level of
115VDC is exceeded.
Two versions of the regulator are available. The Al528
dissipates 1000 watts peak and 100 watts continuous, while the
Al1529 dissipates 2000 watts peak and 200 watts continuous.
Both the A1528 and Al529 are the same size, mount in the
same manner as the power supply rectifier assembly, and are
connected using just two jumper wires supplied with each
regulator card.
Page 3-12
3.0
Assembly and Terminal Descriptions (Continued)
3.5 Shunt Regulator Assemblies: Al528 and A1529 (Continued)
The upper threshold or trip point on each regulator card
is factory set and should not require adjustment.
Connection is made to two 0.25" male FASTON terminals on
the power supply assembly card. These terminals are designated
REG (+) and REG (-), and mate with similarly designated
terminals on the regulator card using the jumper wires supplied.
See Section A.l for further details.
3.6 Rack Panel Assemblies: Al516 and Al518
The Rack Panel Assembly consists simply of a flat,
aluminum plate punched to mount to a standard 19" rack.
The Rack Panel Assembly can accommodate two assemblies such
as the Dual-Axis Card Assembly, which would provide controller
card slots for a four axis system.
Alternately, a Power Supply Card Assembly could be
substituted for one of the Dual-Axis Assemblies, providing
a two-axis system with power supply.
Of course, other combinations are possible, and in fact,
the A1518 assembly includes a blank plate, used to cover the
unused access hole, should only a single assembly be used
with the rack panel.
All required hardware items are supplied with either of
the two Rack Panel Assemblies. If desired, CSR can provide
assembled Rack Panel, Dual-Axis and Power Supply systems.
See Section A.l for further information.
Page 3-13
3.0
Assembly and Terminal Descriptions (Continued)
3.7 Power Transformers
A group of seven standard power transformers are available
to be used with the Power Supply Assemblies, Four single-phase
transformers provide power output ratings from 1.0 to 4.0 KW,
Three three-phase transformers provide 2.0, 4,0 and 6.0 KW of
continuous power output.
The single-phase designs have a 144VAC, center-tapped
secondary, and a dual primary of 120VAC, All the voltages are
no-load values,
The three-phase designs all have delta=-connected secondaries
of 72VAC line-to-line; a separate 120VAC, 250VA single-phase
secondary for fan and bias ciruits; and dual three-phase pri-
maries that can be connected for either 240VAC or 480VAC,
Table 1 lists the appropriate power transformer and power
supply assembly combinations, while Section A.l contains outline
drawings of the various transformers. All transformers listed
are 60HZ designs. For 50HZ units or other primary voltages
contact the factory or one of the agents listed at the end of
this manual,
Page 3-14
AVERAGE No. OF TRANSFORMER REQUIRED POWER SUPPLY ASSEMBLY
| Rack Mtg Panel Mtg
1.0 KW 1 T0073 А1525 А1524
2.0 KW 1 T0074 Al525 Al524
3.0 KW 1 T0075 A1525 A1524
4.0 KW 1 T0076 Al525 A1524
5.0 KW 3 T0077 A1527 A1526
6.0 KW 3 T0078 Al527 Al526
7.0 KW 3 70079 Al527 Al526
Table 3.1: Power Supply Combinations
Page 3-15
4.0
CHAPTER IV
Installation Procedures
4.1 General Precautions
The general installation procedures are:
l. Equipment ambient temperatures should not exceed
50% (122).
2. Equipment operational altitude should not exceed
6000 feet above sea level.
3. The equipment atmoshpere should be free of highly
€lammable or combustible vapors, corrosive chemical
fumes, oil vapor, steam, excessive moisture, and
particulants.
4.2 Panel Mounted Assemblies
The panel-mounting versions of the NC400 Series assemblies
can be mounted on either horizontal or vertical surfaces. The
plastic mounting rails on each of the assemblies provide a
convenient and consistent mounting means for each of the panel
mounted units. |
Recommended mounting hardware is 10-32 or 1/4-20 or M-6
with appropriate flat and lock washers.
During panel layout, allow sufficient clearance between
assemblies and adjacent components for wire ways and access to
connectors, terminals and fuses located on the assemblies.
Also, locate the Power Supply Assemblies centrally with respect
to the Dual-Axis Card Assemblies. This will aid in keeping
power wiring lead lengths to a minimum, which, in turn, will
obviate the need for additional bus smoothing filter capacitors
(See Section 4.4.1).
Page 4-1
4.0 Installation Procedures (Continued)
4.2 Panel Mounted Assemblies (Continued)
Consult the outline and application drawings contained
in Section A.1 for further information.
4.3 Rack Mounted Assemblies
Three assemblies, the Al523 Dual-Axis Card Assembly, the
Al525 Single-Phase and Al527 Three-Phase Power Supply
assemblies, A1516 and A1518, available in the NC400 Series,
are specially designed to mate with the Dual-Axis and
Power Supply Assemblies to form complete rack panel units.
If desired, CSR can supply completely assembled rack units
ready for mounting.
The various rack assemblies are designed to accept
wiring from the rear. Servo controller assemblies, however,
are inserted from the front in the same manner as with the
panel mounted versions of the NC400 Series.
A total of 8 screws, four on each side, are required
to mount the Al516 and Al1518 panels to a suitable rack.
If the power supply assembly is located at a distance
from the Dual-Axis Card assemblies so that power wire
lengths are greater than four feet, it is advised that
an auxiliary bus smoothing capacitor be mounted and wired
to the Dual-Axis Assembly. See Section 4.4.1 for further
details.
Section A.1 contains further information regarding
rack mounting of the NC400 Series equipment.
Page 4-2
4.0
Installation Procedures (Continued)
4.4 Wiring
4.4.1 Power Wiring
All power wiring for the armature and power supply
connections should be 12 guage (3.309 mm?) , Machine Tool
Wire (MTW), or equivalently rated wire. The wire used for
the 120VAC supply for the cooling fan and bias circuits can
be 16 guage (1.309 mm”).
It is suggested that the armature circuit wires be twisted
to minimize the loop area in the armature circuit. This
will help to reduce radiated electrical noise from the
servo controllers. When possible, the power supply wires
should also be twisted.
Wiring between the transformer secondary and the
single-phase Power Supply Assemblies should be 10 guage
(5.261 mm?) or larger (MTW). Secondary side wiring for
the three-phase power supplies should also be 10 guage.
To minimize cross talk between controllers powered
by the same power supply, it is advisable in some cases
to "strap" the power commons at the controllers (Dual-Axis
Card Assemblies) and use a single common return line to the
power supply. Figure 4.1 illustrates this technique.
Page 4-3
— «= Com
— +100VDC
Dual-Axis
Card Assembly
a | — +100VDC
— Com _
+100VDC
Power Supply
Assembly
Ebb
Com
— Com
— +100VDC
Dual-Axis
Card Assembly
— +100VDC
feed — Com
FIGURE 4.1: Technique for Cross-Talk Reduction
by Common Strapping
Page 4-4
Installation Procedures (Continued)
4.4 Wiring
4.4.2 Signal Wiring and Shielding
All signal and limit circuit wiring need not be larger
than 20 guage (0.518 mm?) For signal circuits, including
the tachometer, twisted-shielded pair wire should be employed.
Proper termination of shielded cables is important in
order to avoid creating ground loops or otherwise degrading
the noise immunity of the servo controller. In general,
cable shields should be terminated at one end only. The
other end is left floating. In most applications satisfactory
noise immunity will be realized with the signal line shields
terminated at the servo controller, to the controller signal
common terminals. In some cases, however, terminating the
individual shields at the respective signal sources will
yield better noise immunity.
In systems particularly sensitive to electrical noise,
use of shielding for the armature wiring may be required.
— It is important to maintain the continuity of cable
shields through any intervening connectors and/or terminal
blocks. Also, attempt to minimize the length of unshielded
cable at these interconnections.
4.4.3 Earth (Ground) Connections
A high quality earth connection should be made to the
common of the power supply. An unused FASTON terminal on
the Power Supply Assembly can be used for this purpose.
Alternately, connection can be made to the center-tap terminal
on single-phase transformers, although this is not recommended,
if the transformer is located at a distance of more than a
few feet from the Power Supply Assembly.
Page 4-5
Installation Procedures (Continued)
4.5 Ancillary Components
4.5.1 Bus Filter Capacitor
Each NC400 Series servo controller contains a small-
valued bus filter capacitor. Because of its value, this
capacitor is limited in its ability to provide the required
bus smoothing for proper operation of the controller, when
the wire lengths between the power supply and servo controller
exceed approximately four feet.
In most cases this requirement can be met, but, when
it cannot, it is recommended that an auxiliary bus smoothing
capacitor be added. The capacitor should be located in
close proximity to the Dual-Axis card Assembly, near the end
of the unit containing the power FASTON terminals. For rack
mounted units, a Capacitor Mounting Assembly Al603 can be supplied
by CSR, if desired.
When the auxiliary bus smoothing capacitor is supplied
by CSR, a unit having 3500uF of capacitance and a voltage
rating of 150W VDC is provided.
4.5.2 Armature Inductor
The value of the load inductance determines the peak-
to-peak ripple current in the load. For this reason,
minimum load inductance values are specified for the NC400
Series controller models. Keeping the total load inductance
-- motor inductance plus any added external inductance --
equal to or greater than the values specified will insure
that the form factors do not exceed 1.01, and that the
controller functions normally otherwise.
Page 4-6
4.5.2 Armature Inductor (Continued)
Table 4.1 lists the recommended minimum load
inductance for the three NC400 Series controller models,
and Table 4.2 lists several standard inductors available
from CSR, that can be used as auxiliary load circuit
inductors.
To determine if a load inductor is required and
what its value should be, use the following equation:
Laux 2 min 7 LMoToR
where Lux is the required auxiliary load circuit
inductance, and LMIN is minimum specified load inductance
for a particular controller. Obviously, if the calculated
difference is zero or negative in value, no auxiliary
inductor is required.
Minimum Load
Model No. Inductance MIN
NC407 2.9 mh
NC414 1.45 mh
NC421 1.0 mh
Table 4.1: NC400 Series Minimum Load Inductance
Values.
Page 4-7
INDUCTOR NOM. RATED PEAK
PART NO. VALUE CURRENT CURRENT
L0004 1.5 mh 20A 40A
1,0005 1.5 mh 30A 60A
L0007 1.5 mh 10A 30A
10009 1.0 mh 10A 30A
0015 0.5 mh 25A 75A
L0017 2.0 mh 10A 30A
Table 4.2: Standard Inductors for use as Laux
4.5.3 Load Contactor
It is a requirement in many applications that a
motor load,or "M" contactor be used to completely
disconnect the motor from the controller, whenever an
emergency stop or power-down situation arises. Additionally,
a dynamic braking resistor is often employed with such a
contactor to bring the motor to a quick halt following
contactor denergization.
Most DC contactors, such as the Ward Leonard No.
7000-2140-11, that are rated to handle the peak controller
current during contact breaking, can be used.
A typical application employing such a load contactor
ís shown in Figure 4.2. The DBR (dynamic braking resistor)
should be chosen so that the total circuit resistance, DBR
plus motor armature resistance, limits the current to less
than the demagnitization current for the motor.
Page 4-8
le 120VAC Control Voltage —
— e
LH
CRI M
J | | SM
Ÿ SES \*
CRI L“—
Other
N.C. E-Stop
Contacts
r—- = 7
NC400 BRIERE ;
| Rf |
Series |
Servo | | oa
Controller | |
| BR
paRMC- | ¿
| i
| |
“Optional
Load
Contactor
Figure 4.2: Application of Optional Load Contactor.
Page 4-9
CHAPTER V
5.0 Set-Up Procedures
5.1 Power Supply Tests
With all installation and wiring finished, perform
the following power supply tests:
5.2
Remove all servo controllers from their
respective Dual Axis Card Assemblies.
Remove one lead of the Shunt Regulator
cards, if used, and tape it securely
away from exposed circuitry and grounded
chassis parts.
Momentarily apply AC power to the power transformers,
including the 120VAC power for the fans and bias
transformers. Measure the voltage between the
+100VDC and Common terminals on the Dual-Axis
Assemblies. The polarity should be correct and
the voltage magnitude between 90 and 110VDC.
Again apply power. Check that all cooling fans
are operating and that between 105 and 125VAC
is measured between the 120VAC FASTON terminals
on the Dual-Axis Card Assemblies.
With power removed and sufficient time (15 seconds
or longer) elapsed for discharge of the supply
capacitors, reconnect the leads of the Shunt
Regulator Cards removed in (2) above.
Servo Controller Set-Up Procedures
5.2.1 Bridge Resistance Checks
Before insertion of a new or repaired servo
controller into the Dual-Axis card Assembly, make the
following power section resistance check.
Page 5-1
5.2.1
Bridge Resistance Checks (Continued)
Using a V-0-M (Volt-ohm meter), make the resistance
measurements shown below:
Test
Points Measurement
Value
Pos. Lead | Neg. Lead
Al-2 Al-3 > 2KN
Al-2 Al-4 > 2KQ
Al-3 Al-1 > 2K2
Al-4 Al-1 > 2KQ
Al-2 Al-1 > 2K£%
Al-1 Al-2 < 304
Table 5.1: Power Section Resistance Test Values
OO 0d
DON XX
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Al
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Раде 5-2
5.2.1 Bridge Resistance Checks (Continued)
Consult the fault determination precedures in Chapter VII,
if discrepancies are found in these measurements.
IMPORTANT: Each servo axis should be completely
tested for proper operation before
the next axis controller is inserted
into the Dual-Axis Card and placed in
service.
Insert the first servo controller to be set-up into
the appropriate slot in the Dual-Axis Card Assembly.
5.2.2 Polarity (Direction) Determination
The polarity of the NC400 Series servo controllers is
such that a positive input signal on the inverting signal
input terminal results in a positive voltage at the ARM (+)
terminal with respect to the ARM (-) terminal.
If the motor and tachometer polarities are known,
proper connection to the controller can be made. A
positive input signal should produce motor rotation that
yields a positive tachometer feedback signal at input No. 2.
If the motor/tachometer polarities are not known, it
is advisable to establish same before proceeding with the
controller set-up. To establish motor/tachometer polarity
use the following procedure:
1. Connect the motor through a switch directly to
the +100VDC power supply.
CAUTION: EXTREME CARE MUST BE EXERCISED WHEN
— APPLYING THIS PROCEDURE TO MACHINE-MOUNTED
MOTORS TO AVOID INCURRING DAMAGE TO THE
MACHINE, DRIVE COMPONENTS AND/OR MOTOR.
Page 5-3
5.2.1 Bridge Resistance Checks (Continued)
2. Apply power and momentarily close the switch.
Note the direction of motor rotation and the
relative polarities of the motor voltage and
the tachometer voltage.
3. Connect the motor and tachometer leads to the
controller keeping in mind the desired motor
direction and polarities.
5.2.3 Enable and Inhibit Circuit Tests
For an NC400 Series servo controller to be fully
operational, logic zeros must be present at each of the
Positive and Negative Inhibit and Enable terminals.
When only contact closures are used to realize these
functions, a V-0-M or similar instrument can be used to
check for proper closures at the appropriate terminals.
When active devices are employed to provide the
Inhibit and Enable functions, a different test using the
V-0-M must be made. Remove the DC bus fuse on the Dual-
Axis Card Assembly for the controller to be checked and
proceed as follows.
For each of the inhibits and enable, in turn, measure
the voltage present at the appropriate terminal, when,
first, system power is applied, and, second, the function
(inhibit or enable) is cycled from the active mode to the
inactive mode.
During the inactive mode, a logic zero (< 0.3V) should
appear at the desired function's terminal; while a logic
high (5.0V nominal for Enable; 1.5V nominal for either
Inhibit) should appear during the active mode.
Replace the DC bus fuse after making these tests.
Page 5-4
5.2.4 Potentiometer Adjustments
Each NC400 Series servo controller contains five
adjustment potentiometers located at the top of the
Signal Electronics Card. Normally, only these five
potentiometers need to be adjusted during the set-up
procedure. The adjustment procedure for each is explained
in the following sections.
Before the adjustment procedure is carried out, one
must establish that the servo controller is properly
attached to the motor load and is otherwise functioning
normally, although perhaps not optimally.
Assuming the procedures in the preceding sections
were carried out successfully, momentarily apply power to
the controller without any signal command applied. All |
fuses should be in place and all signal and load connections
made at this time.
If upon application of power, the motor rapidly
accelerates, a runaway condition exists, due, most
likely, to a reversal of either the motor or tachometer
polarities. Repeat the procedure in Section 5.2.2, if
this is the case.
If the motor and tachometer are properly connected,
and the controller is functioning normally otherwise,
the motor shaft should remain stationary, or at most
drift slightly in either direction, when power is applied.
5.2.4.1 Offset Adjustment
With conditions as above, adjust the OFFSET potentiometer
R90 until any rotation of the motor shaft ceases. Then,
with power to the controller OFF, obtain a zero speed
command on the signal command line, and connect the signal
lead to the controller.
Page 5-5
5.2.4.1 Offset Adjustment (Continued)
Reapply power and again adjust the OFFSET potentiometer
for a static motor shaft condition.
If the OFFSET potentiometer has insufficient range,
a lower value of resistance can be substituted for R73
to obtain a wider offset adjustment range. See Figure 5.3
for the location of R73 and other adjustment components on
the Signal Electronics Card.
5.2.4.2 Current Limit Adjustment
Each NC400 Series servo controller contains a CURRENT
LIMIT adjustment potentiometer R93 that is used to set the
peak magnitude of current supplied by the controller.
The adjustment range is from 100% to approximately 20% of
peak rated current.
7
As mentioned earlier in Section 3.1 an external current
limit function can be added by using the Auxiliary Function
No. 1 and No. 2 terminals. Figure 5.2 depicts a means of
implementing an external current limit using only a potentio-
meter. When using such a scheme, the jumper J4 on the Signal
Electronics Card must be removed. This jumper can be
removed by simply cutting its ends flush with the pcb. The
two solder terminals supporting J4 can be used if it is
ever desired to reinstall this jumper.
If peak current from the controller is desired, simply
adjust the CURRENT LIMIT potentiometer full CCW. If a
lower value of peak current is required, use the following
procedure:
Page 5-6
5.2.4.2 Current Limit Adjustment (Continued)
1. Set R93 to full CW.
Apply power.
3. Apply a low frequency (0.5Hz), 5 to 15V,
bi-directional, square wave signal to
the velocity command input (usually Signal
Input No. 1)
NOTE: Before applying this test signal, check that
R94, the Signal No. 1 gain potentiometer is
at approximately midrange; R92, the Servo
Response potentiometer is at or near the CCW
position; and R91, the Signal No. 2 potentiometer
is at the full CW position if the tachometer |
signal is returned to this input.
While the test signal is applied and the controller
operational, monitor the Current Analogue Output at
the Dual-Axis Card Assembly terminal TB1-18 (or TB2-18)
with an oscilloscope. Peak current is represented
at this terminal by a voltage magnitude of 9.3V + 10%.
Set the CURRENT LIMIT potentiometer to the desired
current level by slowly adjusting it toward the CCW
position until the desired level is achieved.
For example, if it is desired to limit the peak current
of an NC421 to 35A, the CURRENT LIMIT potentiometer
would be adjusted CCW until a peak voltage magnitude
of (35/45) x 9.3 = 7.2V is noted on the Current Analogue
Monitor during motor reversals.
Page 5-7
Dual-Axis
Card Assembly
Al522 or Al523
| |
X Л =
e - = TB1 or TB2
E
9KQ < R < 10K0
X = CW, if current limit
value increases with
CW rotation
X = CCW, if current limit
value decreases with
CW rotation
Figue 5.2: Method of Implementing External Current
Limit Control.
Page 5-8
TP4 —
J1— TPlO: IT PI
— =
tl
5 = TP6 |
= 5 | |
E TP5 TP9
д и Tp7 !
= |
6 © i
zZ — R80
= | Г)
[x]
a ocil — J4 CIRIGI
| —] DD RI7 13
CD R150
— clo — Ci — TF8 —
Г Г] > C9 — R86
CO R73
ет
Fa)
= C3 R72
i =
Ww EX
$ Г «|
© 7
=
=
— R66
—
R65 — тр?
R125 тр] — — Tp3
Nem
Figure 5.3: Component Locations on NC400 Series
Signal Electronics Card.
Page 5-9
In the standard version of the NC400 Series controller,
two scale factor adjustment potentiometers are provided in
the preamplifier section of the controller. R94 adjusts
the scale factor for Input No. 1, while R91 is used to
adjust the scaling of Input No, 2.
Both of these potentiomenters are located at the top
of the Signal Electronics Card. Both potentiomenters are
adjusted CW to increase scaling,
The normal velocity loop scaling procedure is as follows:
5.2.4.3 Scale Factor Adjustment
1.
Adjust R91 (SIG. 2) full CW.
NOTE: This procedure assumes the tachometer
signal is input Signal No. 2.
Adjust R94 (SIG. 1) full CCW.
Input a DC level (or low frequency square wave
signal) to Input No. 1 having a magnitude equal to
the maximum velocity command signal magnitude.
Apply power to the controller and monitor the
tachometer signal magnitude using a V-O-M or
oscilloscope. The oscilloscope is preferred,
if a square wave signal is being used.
Gradually adjust R94 (SIG. 1)CW until the desired
maximum motor speed is attained. The tachometer
scale factor in volts/rad/second or volts/1000 rpm
must be known in order to make this adjustment. Most
tachometers supplied by CSR are scaled at 7.0V/K rpm.
If desired maximum speed is not attained with the
Signal 1 scale factor potentiometer full CW, then
gradually adjust R91 (SIG. 2) CCW until desired motor
speed is reached,
Page 5-10
5.2.4.3 Scale Factor Adjustment (Continued)
In some cases three input signals, including the
tachometer signal, must be summed into the controller.
In this case the non-inverting input of Signal Input No. 1
is used as the third input point. Also, jumper J2
(see Figure 5.3 for location) is removed, and C44 and R162
are chosen and soldered in place.
| The value of R162 is selected first. In this case
the scale factor potentiometers R94 and R91 are adjusted
in much the same manner as described above, but R162 is
selected using a resistor substitution box or similar
instrument. The total input resistance for the third
input becomes R162 + R81. R81 is normally lOK + 1%, but
can be changed, if desired.
Then the noise filter capacitor C44 is selected for
a desired 3dB cutoff frequency о using the following
equation: 1
Css = FER
where Ro is the parallel combination of R162 and R81.
Section 6.2 provides further details regarding the
three input version of the Preamplifier Section.
5.2.4.4 Servo Response Adjustment
The NC400 Series servo controllers contain a unique,
adjustable servo response or servo stability adjustment
potentiometer R92. This potentiometer is located at the
top of the Signal Electronics Card and is labeled RESP.
Page 5-11
5.2.4.4 Servo Response Adjustment (Continued)
In most applications it is necessary to adjust only
this potentiometer to achieve optimum response. The
adjustment procedure is as follows:
1. Provide the controller with a low
frequency, bi-directional square-wave
velocity command (a 0.5Hz, *5.0V waveform
is often employed).
2. Apply power to the controller, and while
monitoring the tachometer signal*, gradually
adjust the RESP potentiometer R92 from the
CCW toward the CW position. Optimum response
(critically-damped) should be achieved at
some position before reaching full CW on R92.
Figure 5.4 illustrates the types of waveforms
observed for various settings of R92.
5.2.5 Compensation Component Changes
In some applications, especially those where the
load inertia is much smaller or larger than normally
encountered, the standard compensation components values
of 0.047uF for Cl0 and 150KQ for R77 may not allow of
an optimum setting of the RESPONSE potentiometer R92.
In fact, the velocity loop may be unstable for any
setting of R92. |
In these cases different values for C10 and R77
must be chosen. The following procedure can be used to
select these values:
1. Short circuit C10 with a short jumper wire.
2. Replace R77 with a resistor substitution box.
Initially set the box resistance at 10K.
3. Set R92, the RESPONSE potentiometer to approximately
midrange.
*If the tachometer signal is excessively noisy, the
filter network depicted in Figure 5.5 can be used to obtain
a cleaner signal waveform.
Page 5-12
5.2.5 Compensation Component Changes (Continued)
4. Input a 0.5Hz, 2V bi-directional square wave
velocity command signal to the controller.
5. Apply power, and while monitoring the tachometer
signal, gradually increase the value of the box
resistance until optimum response as depicted
in Figure 5.4 is achieved.
6 Substitute the closest standard value discrete
resistor for R77 and remove the resistor
substitution box.
7. Remove the shorting jumper across C10, and again
check the response using the squarewave test signal.
If near optimum results are obtained, trim the
response using the RESPONSE potentiometer R92 for
the optimum.
8. If step 7 does not yield satisfactory results,
substitute a larger value than 0.047 uF, if
unacceptable overshooting has been noted; or
substitute a smaller value than 0.047uF, if the
response is overdamped. Reiteration of this procedure
should yield an optimum choice for CID.
9. Finally, select a new value of Cll -- normally 0.0022ur--
so that the time constant of R77-C11 remains approx-
imately as it was with the standard value of R77.
Consult Section 6,2 for further details regarding the
compensation components.
Page 5-13
A
Ve — —
>
Command Signal t
MN
VG a
>
Overdamped: R92 too far cw t
/N
VG I
—
Critically damped: R92 optimum t
MN
\
Underdamped: R92 too far ccw
Figure 5.4: Typical Velocity Response Waveforms.
Page 5-14
NC400 Series
Servo
Controller
150K%2, 0.002uF
1/2W
Oscilloscope
Figure 5.5: RC Filter Network for Reducing Tachometer
Electrical Noise.
Page 5-15
5.2.6 Electronic Circuit Breaker Trip Adjustment
The Electronic Circuit Breaker section of each NC400
Series Servo Controller performs a function similar to an
armature circuit fuse or electro-mechanical circuit breaker.
This circuit senses output current flow with time and
after a given time disables the controller when output current
exceeds the rated current for the controller.
Unlike a fuse or actual circuit breaker, the connection
between the motor and controller is not physically broken,
instead the controller is disabled using the fault latch circuit.
If a physical break between controller and motor is required,
a load contactor should be used, as described in Section 4.5.3.
The trip-point versus current level for the Electronic
Circuit Breaker is given in Figure 5.6. The nominal trip time
at peak current is 5 seconds. This is normally acceptable for
most applications and most motors. If however, a short thermal
time constant motor is employed in the application, the time
constant of the Electronic Circuit Breaker circuit should be
changed.
This is best accomplished through experimentation, using
a resistor substitution box for resistor R66. By making R66 a
lower value, a faster trip versus current curve will result.
A procedure for adjusting the trip point follows:
1. Mechanically lock the rotor of the motor.
Set the value of R66 low, say 1l0KQ.
3. Apply a small velocity command to the controller.
4. Apply power to the controller and time the interval
between application of power and the trip of the
Electronic Circuit Breaker circuit.
Page 5-16
5.2.6 Electronic Circuit Breaker Trip Adjustment (Cont)
IMPORTANT: Resistor R161 should be in place for this
test so that the Electronic Circuit Breaker
circuit disables the controller. If Ri6l
has been removed, it should be replaced
for this procedure (standard value is 10K )
5. If the interval measured in step 4 is less than that
desired, increase the value of R66 and repeat step 4
until the desired trip time at the desired peak
current is attained.
6. Replace the substitution box with the value selected
in step 5.
7. Recheck for proper trip time.
If the decay/reset time of the Electronic Circuit Breaker
circuit is loo long the value of R65 (standard value 2MQ) can
be made smaller. Likewise, if the decay/reset time is too
short, a larger value of R65 should be used.
Page 5-17
$ Peak AN
Current )
100% |
75% |
50% |
Rated Current
25% |
VV
0 5s 10s 15s 20s 25s 30s 355 405
TIME
Figure 5.6: Electronic Circuit Breaker Trip Curve
for Continuous Output Currents.
Page 5-18
6.0
*
CHAPTER VI
THEORY OF OPERATION
6.1 Power Section Operation
The NC400 Series controllers are switching-mode servo
controllers in which the power semiconductors are either in
saturation or cut-off. This results in highly efficient
controller operation since very little power is dissipated
within the semiconductors in either of these two states.
Power transistor switches are employed as the output
semiconductors in the NC400 Series. This results in less
complicated output circuitry and a more retined, predictable
control of load power than is obtainable with silicon con-
trolled rectifiers.
The particular switching technique employed in the NC400
Series is a patented concept commonly known as TWO-STATE
MODULATION.* This technique, pioneered by CSR for DC motor
control, has advantages over other switthing techniques such
as pulse-width modulation (PWM) Some of these advantages
will be described in the following discussion of the basic
operation of the NC400 Series servo controllers.
Figure 6.1 presents a basic functional block diagram
representative of the NC400 Series circuitry. This block
diagram is employed to explain the functioning of the various
circuits.
Initially, incoming signals are processed in the pre-
amplifier section, where servo compensation normally takes
place. A detailed description of the preamplifier section is
presented in Section 6.2.
US Patent No. 3,294,981
Page 6-1
6.1 Power Section Operation (Continued)
The resultant signal A is then combined algebraically with
a feedback signal B, which is representative of the current
flowing in the load, and a relatively high, fixed frequency
triangle waveform signal C.
The resulting error signal A + B + C is applied to the Two-
State circuit, the output of which is a square wave signal
having the appropriate pulse-width and frequency modulation
characteristics for the particular load and command conditions
at that instant.
The output D of the two-state circuit is applied to identi-
cal sections containing delay and driver circuitry, as well
as interfacing circuitry for the limit and protection circuits.
As inversion takes place previous to one of the Delay/Driver
sections, however. This inversion is necessary in order to
have proper signal phasing in the output section.
The output section is a bridge, shown in simplified form
in Figure 6.1, consisting of paralleled output transistors
(for simplicity only one transistor per quadrant is shown
in Figure 6.1) and fast recovery, free wheeling diodes in
each quadrant. Emitter resistors are employed with each out-
put transistor to enhance current sharing.
Unlike linear amplifiers, where a small "idling" or
common-mode current is necessary to eliminate cross-over
distortion, common-mode conduction or switch-through must be
avoided in switching amplifiers. This condition arises
because of the unequal turn-on and turn-off times of transis-
tors; the turn-off time being longer than the turn-on time.
In the NC400 Series precise turn-on delay times are effected
in the Delay/Driver sections so that, for example, Ql has
sufficient time to turn off before 02 is allowed to turn on.
Page 6-2
6.1 Power Section Operation” (Continued)
The use of the bridge output section in the NC400
Series provides for full four quadrant dynamic motor
operation. Hence, the controller is capable not only
of delivering power to the motor, but also of removing
power from the motor (regenerative action) during periods
of deceleration.
Load current in the bridge output section is through
QI - Load - Q4 or through 03 - Load - Q2. That is, current
conduction is always diagonal in the bridge; the destruc-
tive condition of having Q1 and Q2 or Q3 and Q4 ON
simultaneously, is disallowed by the logic of the low
level circuitry.
The load current is sampled by resistors R_ in each
leg of the bridge. When the resultant signals J and K are
combined differentially by the current feedback amplifier,
a signal B results which is representative of the actual
armature current.
This current feedback loop provides the NC400 Series
servo controllers with several advantages. First, precise,
adjustable current limiting is achieved simply by limiting
the peak voltage magnitude at point A in Figure 6.1.
second, the current feedback configuration makes the
amplifier appear to the load as a controlled current source;
hence, the effect of the motor L/R time constant is sub-
stantially reduced. This is especially desirable in high
response servo drive applications.
Finally, the effects of low armature resistances or
variations of armature resistance due to heating will not
impair the performance of the NC400 Series controllers.
Page 6-3
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Page 6-4
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Page 6-5
6.1 Power Section Operation (Continued)
Figure 6.2 is a set of idealized waveforms that
appear at the various points in Figure 6.1. The wave-
forms are not to scale and certain waveforms have been
exaggerated for clarity. The waveforms are, however,
in proper time sequence. Also, Figure 6.2 represents a
specific case of input excitation , namely a DC level at
point A.
Figure 6.2 (a) depicts the input command signal to
the power section appearing at point A in Figure 6.1, and
the feedback signal B representing the current flow in
the load circuit.
These two signals are combined with the triangle
waveform C as shown in Figure 6.2 (b). For clarity,
Signals A and B are shown combined, and their sum plotted
against waveform C.
The resultant waveform A + B + C, when applied to
the two-state circuit, produces the waveform D, shown
in Figure 6.2 (Cc). This waveform contains the puise-
width and frequency modulation information required to
satisfy the input and load conditions at any instant
of time.
Waveform D when applied to the remaining delay and
quadrant driver sections produces the necessary drive
signals at points E, F, G and H for the controiler's
output quadrants represented by Q1 through Q4 in Figure
6.1. Figure 6.2 (d) and (e) depict the two lower quadrant
drive signals F and H. The two upper quadrant signals E
and G are not shown since they are similar (when shown
with respect to +V) to F and H, respectively.
Page 6-6
6.1 Power Section Operation (Continued)
Note the effect of the delay times on waveforms F
or H in Figure 6.2. After either F or H goes to zero,
a delay time t., ensues before H or F, respectively, goes
d
on. This delay ensures that common-mode conduction in
the output section does not occur.
Figure 6.2 (f) shows the load voltage У, The effect
of the delay times t, is not apparent in V because an
r
inductive load such de a motor will cause current to
"free-wheel" through diodes D1, D4 and D2, D3. Therefore,
when 02 and Q3 are turned OFF, the load voltage abruptly
changes polarity, despite the fact that Ql and Q4 have
not yet been turned ON.
In Figure 6.2 (g), waveforms J and K represent the
two constituent parts of the load current, transistor and
diode, sampled by identical resistors Rg in Figure 6.1.
These signals are added differentially and scaled to
form waveform B, the current feedback signal.
As can be seen from Figure 6.2, if the virtual signal
A+B were large enough to exceed the peak value of C, the
controller would cease to switch at the rate determined
by the period of the triangle waveform, and the process
would no longer be pulse-width modulation.
In the NC400 Series controllers this fact is used
to advantage to provide better dynamic response and higher
motor speeds than are obtainable with the PWM approach.
Greater than 100% modulation allows the load current
during transient intervals to slew at a rate limited
only by load circuit parameters.
Page 6-7
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in addition, load current regulation 1s enhancec by
maintaining a low ratio of triangle waveform amplitude
to combined signal amplitude A+B -- a situation not
possible when employing PWM, due to the constraint of
maintaining less than 100% modulation at all times.
Finally, higher motor speeds are realizeable with the
NC400 Series controllers than with PWM controllers, since
again, the constraint of less than 100% modulation for the
PWM approach implies than an average load voltage less
than full supply bus can be applied to the motor when
full speed is commanded.
6.2 Preamplifier Section Operation
Each NC400 Series servo controller contains a pre-
amplifier section, shown schematically in Figure 6.3,
that can be employed to sum velocity command and tachometer
feedback signals, and provide the necessary servo compensa-
tion and gain adjustments, resulting in stable, optimum
servo operation.
The preamplifier employs two integrated circuit
operational amplifiers as the active components. These
amplifiers have high DC gain along with good temperature
and frequency stability charcteristics.
One amplifier IC6 is configured as a differential stage
with unity gain. The purpose of this stage is to isolate
the command signal source from the signal common of the
controller. This minimizes cross-talk between controllers
operated from the same DC power supply.
Page 6-8
6.2 Preamplifier Section Operation (Continued)
The second amplifier IC5 sums the inputs from the
differential stage, the input No. 2 signal and the offset
voltage from potentiometer R90. ICS also provides the
required servo compensation and current limiting functions.
The following sections explain-in detail the function
of the various component groups in the preamplifier section.
6.2.1 Frequency Response Analysis
The preamplifier section of the NC400 Series
servo controller is configured with two feedback
paths. One in the form of a resistive tee network
controls the DC gain of the preamplifier. The other
network consisting of C10, R77 and potentiometer R32
controls the AC gain.
Using the tee network consisting of R76, R86
and R87 obviates the need for high valued resistors
in the DC feedback network. The equivalent value of
the tee network is given by the expression:
R R
Е = 2376: “87
“86
If the standard values employed in the NC400 are sub-
stituted into this expression, a value of 100 MQ
results.
The resistor Rae is mounted on solder terminals
and can be changed, if one desires to alter the DC
gain of the preamplifier. Increasing the value of
Roe lowers the gain, while decreasing Roe increases
the gain. Note that if no DC feedback is desired,
Page 6-9
6.2.1 Frequency Response Analysis (Cont)
such as would be the case if the preamplifier is to be
a pure integrator, a short circuit should be substi-
tuted for Roe:
The higher frequency (AC) gain of the preampli-
fier is a function of the components С10, R77 and the
setting of R92, the RESPONSE potentiometer. These
components form a variable lag-lead network. As can be
seen from Figure 6.3, setting R92 full CW removes the
AC feedback network and no lag in the response occurs.
The gain is then flat with frequency, being determined
by the DC feedback components; but it does begin to
roll-off in the vicinity of 1000 Hz due to the com-
bined effects of the input filter network and the
response characteristics of the operational amplifier
ICS.
Maximum AC feedback is obtained with R92 set
full CCW. This results in a lag frequency of approx-
imately 0.034 Hz. The lead frequency remains constant
for all settings of Ro and is approximately 23 Hz.
These values are calculated from the following expres-
sion for the frequency response of the preamplifier
using the standard values for the components.
Ш 1 + R 7
С. (в) = Re SC10577
RR
Roo + R75 [1 + sC,pRy7 \ + “7687 e
RgeR77
Быть >
This is the gain expression for Input No.l. The effect
of the scaling potentiometer R94 (SIG. 1) is not in-
cluded; it is, of course, a factor between 0 and 1.0
multiplying the above expression, and is linearly
related to the setting of R94. At CCW the factor is 0,
and at the CW position the factor is 1.0.
Page 6-10
The differential amplifier introduces ancthel
inversion into the above equation, so that signals
applied to the inverting terminal of the amplifier
actually experience no net phase inversion in rassing
through the preamplifier.
The gain expression for Input No. 2 is as
follows:
= Lu
0.87 Re 1 + SC, 0R-7
В. R
166 l + SC gR77 1 + ‘76 87 ©
RggR77
С. (5) мо ——
The presence of the factor 0.87 is due to the effects
of the input filter and attenuator network at Input
No. 2. The scaling potentiometer R91 (SIG.2) acts
to scale the above expression from a low at the CCW
position of 0.08 to the high value of 0.87 at the CW
position.
Figure 6.4 is a graph (Bode plot) of the gain
expression С) (5). This graph is actually a family
of asymptotic curves indicating the manner in which the
preamplifierS frequency response is altered by R92,
the RESPONSE potentiometer.
6.2.2 The Offset Circuit
The offset potentiometer R90 is connected
between the plus and minus 15V bias supplies; and, hence,
any voltage between these extremes can be applied to Ry
the offset summing resistor.
Hence, with up to 1.5 pA injected through R,
Page 6-11
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Page 6-12
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6.2.2 The Offset Circuit (Cont)
into the preamplifier, one can null up to + 45 mV of
offset an Input No.l, or + 170 mVat Input No.2. If
this offset nulling range is insufficient, R can be
73
lowered in value. is mounted on solder terminals
R 3
to facilitate this change.
6.2.3 The Current Limit Circuit
The potentiometer R93 in conjunction with zener
diodes Z1 and 72 and resistor R79 form the current
limit circuit in the NC400 Series servo controller,
The diodes limit the output voltage from IC5 to
approximately + 10.7 volts. This peak value is then
divided by R93, the CURRENT LIMIT potentiometer, and
R79.
In the standard form, where J4 and J3 are in
place and no auxiliary functions are used, the wiper
voltage at R93 is applied to the power section of the
controller and is, in fact, the current command, since
the power section is configured as a transconductance
amplifier, yielding peak current output with approx-
imately 10 volts input.
The wiper voltage of R93 is also returned to the
input of IC5 through the feedback network. Because of
this the dividing effect of R93 does not effect signal
voltages between the current limit extremes. Also, the
output impedance of the preamplifier is not appreciably
affected by the presence of R93.
Page 6-14
A
6.2.3 The Current Limit Circuit (Cont)
Component positions are available for two re-
sistors R78 and R88 to be used in applications, where
a fixed current limit is required. For these cases
R93 is removed and two appropriate values for R78 and
R88 are substituted.
Also, where an external, remote current limit
is to be employed J4 should be removed from the con-
troller and the auxiliary Function 1 and 2 input ter-
minals used to carry the external signals. Section
5.2.4.2 provides further details on this current
limit method.
6.2.4 Three Signal Input Version
When three signals must be summed into the
preamplifier section, the non-inverting input of the
differential amplifier is converted into a direct third
input.
To accomplish this, jumper J2 is removed, and
components are selected for R162 and C44 and, if
desired, for R81. The resulting third input has the
following gain expression:
qe —
Re 1 + SC RI
G,(s) = —
3 вв
Rg1* Rig2 1 + sC. R (x + 16 87 )
1077
RR
8677 7 |
L_
Note that no potentiometer is employed with the
third input to provide variable scaling, instead the
gain (dc) is fixed by the selection of R81 and R162.
Page 6-15
6.2.4 Three Signal Input Version (Cont)
Once R81 and R162 are selected, the value of
C44 is selected to provide a frequency break near
1000Hz. The value of C44 can be calculated approximately
using the following expression:
Rg1 + Rigo
6280 (Roy
C44 =
R 162)
It should be noted that in creating the third
input, the signal isolating properties of the differ-
ential amplifier stage IC6 are lost. The IC6 stage
now becomes a gain-of-one inverter for input no. 1.
6.2.5 Miscellaneous Comments
The components R72 and C9, which in the standard
form of the preamplifier are not used, can be employed
to provide a response lead network for input no. 2.
This could prove to be beneficial when, for example the
tachometer signal is returned to input no. 2.
Determination of the values of R72 and C9 1s
best done empirically. Note that the input no. 2
scaling potentiometer R91 divides the voltage applied
to R160 only and not that applied to R72 and C9.
In addition, a capacitor Cll, placed in parallel
with R77, can be selected to minimize noise carried on
the input signals. This is especially beneficial when
employing motors, such as the so-called "disc" motors,
where a significant degree of electromagnetic coupling
1s present between the tachometer and motor armatures.
This results in a noise signal, based on the switching
waveform of the controller, being amplified by the
preamplifier, and if strong enough, overcoming the
Page 6-16
6.2.5 Miscellaneous Comments (Cont)
normal triangle modulation signal. This can result in
an unstable condition in the controller.
A value of 0.0022uF is used for Cll in the
standard configuration. If Cll is changed, especially to
a larger value, the effect on the dynamic performance
of the controller should be scrutinized carefully.
Page 6-17
6.3 Protection Circuit Operation
The NC400 Series has several protection features
which act to protect the controller from conditions
that, if left unchecked, could cause catastrophic damage.
Most of these protection features are designed
into the Servo Controller assemblies. One circuit, the
(optional) Shunt Regulator, can be considered a protection
device, since it regulates the DC bus during periods of
regeneration. The servo controllers do have a secondary
high bus voltage sensing circuit, though; so that even if
the Shunt Regulator is not present the controller will
act to protect itself.
In the following sections the functioning of each
of the protection circuits is explained in detail,
6.3.1 Thermal Sensor
Attached to one of the heat sinks on each NC400
Series servo controller is a bi-metallic thermal sensor.
This sensor is intended primarily to sense the loss
of fan cooling or excessively high ambient temperatures.
The sensors contacts are connected in series
with the transistor switch employed as the output
device of the RMS Overcurrent Circuit.
If either the thermal switch or transistor
switch opens, a logic high will appear at terminal
N on the servo controller's signal connector
(TB1-15 or TB2-15 on the Dual-Axis Card Assembly
terminal strips). This point is pulled to +15VDC
through a 1.5K2? resistor.
If R161 (10K92) is in place, the controller's
fault latch will also be SET under the above
conditions, and the controller will automatically
be disabled.
Page 6-18
6.3.2 Electronic Circuit Breaker Circuit
The current feedback signal, representing
armature current, is fed to the Electronic Circuit
Breaker Circuit, which senses that a current above
the rated current of the controller is being outputted
to the load. After a given time interval at the
excessive level, the circuit turns OFF the output
transistor switch mentioned in Section 6.3.1, and
a logic HIGH appears at terminal N on the servo
controller's signal terminal strip.
The Electronic Circuit Breaker Circuit consists
of an absolute value section that converts the dual-
polarity current feedback signal to a unipolar signal.
This section 1s followed by a three section squaring
circuit, and then an integrator section.
The output of the integrator is applied to a
fixed reference comparator which drives the output
transistor switch.
The integrator section contains a dual time
constant network. The time constant for the rising
current is longer than that for the falling current
condition, since this better approximates heating
in a motor load. Section 5.2.6 contains further
information on this circuit.
6.3.3 Overvoltage Sense Circuit
As mentioned in the opening paragraphs of this
section, an Overvoltage Sense Circuit is present in
the NC400 Series servo controllers, to sense an
excessively high DC bus condition (122V or greater),
and act to disable the controller.
Page 6-19
6.3.3 Overvoltage Sense Circult (Continued)
When a high bus condition is sensed, the
Overvoltage Sense Circuit sets the fault latch.
Of course, the FAULT light-emitting diode will
glow indicating shut down, If this condition shoula
occur repeatedly during the beginning of motor
deceleration, excessive regenerated energy is indicated,
and a Shunt Regulator Assembly A1528 or A1529
(optional) should be installed.
If a Shunt Regulator is being employed, check
the fuse in this circuit, if the above conditions are
noted, since, most likely, the Regulator has ceased
to function.
6.3.4 Undervoltage Protection Circuits
Two similar circuits in the NC400 Series servo
controllers monitor both the DC bus voltage and the +15VDC
bias voltage. If either of these two circuits senses
a voltage too low to maintain proper controller operation,
the controller is disabled; but only until proper voltage
levels are restored, then the controller is enabled again.
These two circuits also function to properly sequence
turn-on of the controller, when power is first applied.
The enable-threshold for the +15VDC bias sense circuit
is approximately 13V, while that of the bus sense circuit
is approximately +55VDC. At these voltage levels and above
normal operation can take place, and so the controller is
enabled upon reaching these voltages.
Page 6-20
6.3.5 Primary Overcurrent Sense Circuit
The NC400 Series servo controllers contain two over-
current sense circuits, primary and secondary. The primary
circuit employs the principal of inductive voltage division
and the transformer effect to sense potentially catas-
trophic conditions such as a ground short to armature.
The circuit consists of a special transformer con-
taining two identical primary windings and a secondary
winding that is connected to low level processing circuitry.
The primary windings are designed to have sufficient
inductance, so that the rate of rise of current, should
the entire 100V bus voltage be place across it, will be
low enough to allow sufficient time for the controller to
disable itself.
Under normal conditions of operation, the load
inductance will be many times larger than either of the
primary windings of the special transformer mentioned above.
One primary winding is placed between each output of the
controller and the load. Most of the voltage appears
across the load inductance; and, hence, very little voltage
is induced in the transformer's secondary winding.
When a short circuit occurs, most of the voltage
appears across one or both of the primary windings, which
induces a proportionately larger voltage in the trans-
former's secondary.
This higher secondary voltage is sufficient to exceed
the threshold of the low level processing circuit, and the
fault latch is set, which disables the controller.
Page 6-21
6.3.6 Secondary Overcurrent Sense Circuit
The secondary overcurrent sense circuit monitors the
voltage drop across the emitter resistors of transistors
in the upper quadrants of the NC400 Series servo controllers.
If the primary overcurrent sense circuit should fail
to recognize a potentially catastrophic overcurrent con-
dition, or if an internal short-circuit should develop
within the controller, the secondary overcurrent circuit
will sense the condition and set the fault latch, which
disables the controller.
The secondary overcurrent sense circuit is not as fast
acting as the primary circuit, and, in fact, a higher than
peak current must appear in the emitter resistor being
monitored by this circuit before any action is taken to
disable the controller.
6.3.7 Shunt Regulator Option
As an option, a Shunt Regulator Assembly can be
added to either the single phase or three phase Power Supply
Assemblies. Two versions of the Shunt Regulator are
available; one can dissipate 1000 watts peak and 100 watts
continuously (A1528), while the other can handle 2000 watts
and 200 watts, respectively (A1529). |
The Shunt Regulator Assemblies are switching types,
wherein dissipative elements (resistors) are switched across
the DC bus, whenever the voltage reaches a predetermined
level. The switching elements employed are transistors,
identical to those used in the output sections of the
servo controllers.
The function of the Shunt Regulator is to regulate
the voltage of the DC bus during periods of motor deceler-
Page 6-22
6.3.7 Shunt Regulator Option (Cont)
ation, when there is a net energy outflow from the motor
to the controller.
The controller handles this reverse energy just as
efficiently as it provides energy to the motor, hence,
most of the energy is passed through the controller to the
power supply, where the returning energy charges the filter
capacitors above their normal voltage level, as deter-
mined by the AC incoming voltage.
When the capacitor charge-up reaches a level between
118 and 120V, the Shunt Regulator begins its regulating
action. The bus is regulated to this range until regen-
eration ceases.
Deciding if a regulator is required in a particular
application, is best done empirically, using the actual
system as a test-bed. The Shunt Regulator Option can be
added at any time to the Power Supply Assembly, merely
by making two FASTON type connections. Hence, these
units can be added in the field, whenever required.
On multiple-axis systems, if it is always the case
that the other axes are taking power from the supply
when a particular axis is regenerating, then the Shunt
Regulator is probably not required.
As a design aid, the following information is provided
so that one may estimate if a regulator will be required
in a particular case.
Page 6-23
6.3.7 Shunt Regulator Option (Cont)
It can be shown* that, neglecting friction and
other secondary power loss mechanisms, the total energy
returned to the power supply during a deceleration period
1s given by the equation:
2 2
NK I, E I_R
+ —
e = (104,7 | TE DA DÍA
e 2 2NK5
Where J = total load inertia (in-lb-sec?)
Ko = motor torque constant (in-l1lb/amp)
К = motor back emf constant (V/Krpm)
N = motor speed at the beginning of the
deceleration period (Krpm)
Ip = magnitude of the deceleration current (A)
Ra = total armature circuit resistance (0).
Once this energy value has been calculated, the
required capacitance needed to store the energy can be
found from the expression:
2E
С > Е farads.
2309
When the single or three phase Power Supply Assemblies
in the NC400 Series are used, the value of C is fixed and
the maximum allowable energy can be found. The following
ineguality results:
Ep < 16 joules.
* "The Regeneration Energy Phenomenon in Pulse-Width
Modulated DC Servo Systems," R. Schmidt, Proceedings
of the Sixth Symposium, Incremental Motion Control
Systems and Devices.
Page 6- 24
6.3.7 Shunt Regulator Option (Cont)
This 1s a maximum guaranteed value using worst-case values
for the various parameters.
Additional capacitance, added to the power supply,
is not recommended due to the higher surge currents that
must be handled by the recifiers and other components
during power-up.
Page 6-25
CHAPTER VII
Maintenance, Repair and Warranty
7.1 Maintenance Procedures
The NC400 Series servo controllers and auxiliary assemblies
have been designed to be virtually maintenance-free. It 1s only
necessary periodically to check the condition of the fuses
and cooling fans and to look for accumulations of dust and dirt
on the heat sinks and printed circuit boards.
If heavy deposits of dust or particulants are formed,
the controller should be removed from its mounting, thoroughly
but carefully cleaned, then remounted and returned to service.
No readjustment of the controller's potentiometers should be
necessary, if care is used in the cleaning procedure.
Some residue from vapors in the controller's environment
may form semi-conductive film on the printed circuit boards
and other components, which will impair the operation of the
units. If any film residue 1s noted on the boards during
inspection, the boards should be individually washed in a
suitable chemical cleaning agent such as a flurocarbon degreaser.
Care should be taken to prevent cleaning agents from washing
the thermal grease from behind the power transistors mounted to
the heat sinks; and the plastic backing bar behind the poten-
tiometers should be removed before cleaning with a solvent-type
cleaning agent.
7.2 Fault Determination Procedures
If abnormal operation occurs, a number of checks and tests
can be made to determine the area of the system in which the
fault lies.
Page 7-1
7.2.1
In-System Check
Check the following items before removing any con-
trollers,
wires or other items from the system.
Overload Devices: Check all fuses, contactors
and breakers for a blown or tripped condition.
If one or more of these devices in the bus circuits
are blown (or tripped), perform the controller
quadrant resistance tests before attempting to
reapply power.
Wiring: Are all wires to be connected to the
controller's terminal connections actually in
place, in the correct positions, and tightly
secured?
Limit Circuits: Check all limit and other disable
switches and wiring for proper operation. Check
the external function circuits, such as external
current limit, if present, for correct operation
and connection.
Input Signals: Are input signals actually
reaching the controller? Are they correct in
polarity and magnitude? Are the polarities of
the motor and tachometer correct? This latter
check is especially important if there has been a
motor replacement. A runaway condition is cause
for close scruting of polarities.
Fault Characteristics: It is especially important
to note the characteristics of a unit that demon-
strates erratic or faulty operation. For example,
does the system respond to commands in only one
direction; is there insufficient torque, but
otherwise normal operation, does the system function
Page 7-2
7.2.1
In-Systems Check (Cont)
normally for certain periods of “ime?
These characteristics can prove quite valuable in
diagnosing probable causes of failure, especially
if it becomes necessary to contact service or
factory personnel.
Out-of-System Checks
7.2.2.1 Quadrant Resistance Tests
Output section failures usually are caused by
damage to one or more output bridge transistors.
This damage is usually indicated by abnormal
resistance readings when checking the four output
section quadrants with a V-0-M or similar instrument.
For this test repeat the procedure given in
Section 5.2.1. Abnormal readinas allow one to
pinpoint the particular qguadrantí(s) in which damaged
devices are present.
It 1s normally advisable that you return at
least the Power Electronics Card for factory repair.
However, if you desire to replace damaged power
section components, the spare parts list carries
parts numbers for the power devices used.
7.2.2.2 Signal Electronics Card Tests
A number of test points are available on the
Signal Electronics Card part of the NC400 Series
servo controllers, to allow checks to be made for
proper operation of the various functional areas vi
this card.
Page 7-3
7.2.2.2 Signal Electronics Card Tests (Cont)
Figures 7.1, 7.2 and 7.3 depict waveforms at
the various test points for the condition of no
input signals present. As a precaution Auxiliary
Function terminal 3 should be jumpered to signal
common when checking these waveforms.
Also, if the Power Electronics Card 1s sus-
pected of being damaged in any way, it 1s best to
separate it from the Signal Electronics Card before
making the above measurements.
Before using an oscilloscope to observe the
waveforms in Figures 7.2, 7.2 and 7.3, measure first
the 15 volt bias supplies at TP1 (+15VDC) and TP3
(-15VDC) with respect to common (TP2). The normal
range is 14.25 to 15.75 volts. |
If abnormal waveforms are observed at TP9 and
TP5 in Figure 7.3, the fault latch or undervoltage
protection circuit may be the cause. This can be
checked by measuring the voltage at TP8 with respect
to common. This voltage is normally 0.5 to 0.8
volts for a fault and 0.1 and 0.2 volts when the
controller is enabled.
Each of Figure 7.1, 7.2 and 7.3 indicates the
particular active component(s) that could cause
an improper waveform at the particualr test point
being observed.
Page 7-4
>
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Figure 7.1: MTriangle-Wave GeneraLor: TP4
Horizontal: 50us/div
Vertical: 5V/div
: co
Devices: IC7, ICo
|| ОГ T
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N
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Figure 7.2: Comparator: TPO TP/
Horizontal: 50us Page 7-5
Vertical: 0.5V/div, 5V/div
Devices: IC1O
es
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Figure 7.35: Delay Sections: TP5, TP9
Horizontal: > 0us
Vertical: 5V/DIV, 5V /DIV
Devices: IC9, Q32, Q34, Q35
td: 18+2msec.
Page 7-6
7.2.2.3 Preamplifier Section Tests
With the load disconnected from the controller,
connect a very low level sinusoidal test signal
differentially to the inverting/non-inverting
terminals of the preamplifier.
The frequency of the test signal can be varied
over as wide a range as desired in order to check
response. With the RESPONSE potentiometer R92 set
full CW, the response should exhibit a break
between 500 and 1000Hz.
Check the operation of the SIG.1 scaling
potentiometer R94. Varying this potentiometer
sufficiently CW should cause saturation of ICS wlth
attendant clipping of the waveform at the positive
and negative extremes.
Also, check the operation of the CURRENT LIMIT
potentiometer R93. Set full CW, the clipping voltage
at J4 and J3 (if in place) shculd be approximately
2 volts. Setting R93 full CCW should produce
approximately 10.7 volts clipping level.
Finally, move the test signal to the single-
ended input number 2 and check for proper operation
of SIG.2 scaling potentiometer R91.
If, during the preceding tests the DC gain has
been found too high to allow meaningful tests to
be made, one can clip one end of R86, the DC gain
setting resistor, to obtain a lower DC gain. This
will, however, affect the frequency response break
point measurements.
Page 7-7
7.3 Factory Repair
If it 1s necessary to return an NC400 Series assembly for
repair, the following procedure should be followed:
1. If the assembly has been disassembled, reassemble 1+,
making certain that all hardware is in place.
2. Tag the assembly with the following:
a) Serial number and assembly number.
b) Company and company representative returning the item,
c) Date the item was returned.
d) Any pertinent, helpful information regarding the
malfunction.
3. Carefully package the assembly and apply appropriate
cautionary stickers (e.g. FRAGILE).
NOTE: CSR does not recommend returning items in
original shipping containers, unless the
integrity of these containers was main-
tained during the original transit.
4, Obtain a Return Authorization Number by contacting the
Customer Service Department at the factory or at an
authorized repair station. This number should appear
on all paperwork regarding the unit and on the outside
of the package containing the assembly.
5. Return the items by the best means consistent with
your requirements for a timely return of the equipment.
Page 7-8
7.4 Spare Parts
The NC400 Series equipment iS, for the most part, complex
electronic equipment, and repair requires a thorough under-
standing of electronics principles and a full complement of
electronic test equipment.
For most users, the best solution is to return any equipment
to CSR for repair. In this case only Level A maintenance
components are required.
If component level repair is attempted, Level 2 maintenance
components will most likely be required and should be stocked.
All spare parts should be ordered directly from the Customer
Service Department.
7.4.1 Level 1 Maintenance Spare Parts
NC407: MDAl0 fuse, (1) per unit.
NC414: MDA20 fuse, (1) per unit.
NC421: MDA20 fuse, (1) per unit.
. Misc: Cooling fan, Howard No. 3450
BE U N FF
or equivalent, (1) per four fan
cooled assemblies
5. Misc: MDX 1 fuse, (1) per two fan cooled assemblies.
7.4.2 Level 2 Maintenance Spare Parts
1. NC407 Power Electronics Card (Al536):
(2) 090023 Output Transistor (CSR)
(2) 090024 Output Transistor (CSR)
(2) 290036 Driver Transistor (CSR)
(2) 00037 Driver Transistor (CSR)
(4) CP5-0.1 0.1 Q, 5W Resistor (Dale)
(1) All15B Diode (General Electric)
‘О
Page 7-
7.4.2
Level 2 Maintenance Spare Parts (Cont)
2. NC414 Power Electronics Card (Al537):
(4)
(4)
(2)
(2)
(6)
(2)
Q0023
Q0024
Q0036
Q0037
CP5-0.1
А115В
Output Transistor (CSR)
Output Transistor (CSR)
Driver Transistor (CSR)
Driver Transistor (CSR)
0.1 2, 5W Resistor (Dale)
Diode (General Electric)
3. NC421 Power Electronics Card (Al538):
(6)
(6)
(2)
(2)
(8)
(3)
90023
00024
00036
90037
CP5-0.
All5B
Output Transistor (CSR)
Output Transistor (CSR)
Driver Transistor (CSR)
Driver Transistor (CSR)
0.1 9, S5W Resistor (Dale)
Diode (General Electric)
4. Signal Electronics Card (Al541):
(2)
(2)
(2)
(1)
(1)
(1)
(1)
(2)
741TC
MPS5172
63X103
63X202
MC661P
MC7815CP
MC7915CP
IN758A
Op. Amp. (Fairchild)
Small Signal Transistor
(Motorola)
10KQ potentiometer
(Spectrol)
2K? potentiometer
(Spectrol)
Hex Inverter
(Motorola)
+15V Regulator (Motorola)
-15V Regulator (Motorola)
10V Zener Diode (Motorola)
5. Single Phase Power Supply (A1524, A1525):
(1)
R4050270
Rectifier (Westinghouse)
Page 7-10
7.4.2 Level 2 Maintenance Spare Parts (Cont)
6. Three Phase Power Supply (А1526, А1527):
(3) R4040270 Rectifier (Westinghouse)
(3) R4050270 Rectifier (Westinghouse)
7.5 - Warranty
CSR warrents the NC400 Series Equipment to be free from
defects in material and workmanship, under normal conditions
of use and service, for a period of (1) year after shipment
to the original purchaser. CSR's obligation under this warranty
is expressly limited to making good at CSR's plant on equipment
authorized by CSR to be returned, freight prepaid, for repair
or replacement, after examination to CSR's satisfaction that
the equipment involved is defective and has not been subject
to misuse, negligence, accident, or failure to follow the
appropriate operating manual. THERE ARE NO IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THAT
APPLY TO THIS SALE. CSR makes no warranty whatsoever in respect
to equipment and components or systems not manufactured by 1t.
When permitted by its suppliers, CSR will transfer to Purchaser
any warranties as may be offered by such suppliers to purchasers
from CSR. This warranty is expressly made in lieu of all other
warranties, express or implied, and CSR shall, under no circum-
stances, be liable for any direct, indirect, special or con-
seguential damages, expenses, or losses resulting from operation
of or defects in the equipment covered hereby.
Page 7-11
7.6 Authorized Repair Agents
1. USA
2. European
3. United Kingdom
Control Systems Research, Inc
632 Fort Duquesne Boulevard
Pittsburgh, PA 15222
ATTN: CUSTOMER SERVICE DEPARTMENT
CONTRAVES ANTRIEBSTECHNIK AG
CSR Product Line
CH-8105 Regensdorf
Pumpwerkstrasse 23
Switzerland
CONTRAVES INDUSTRIAL PRODUCTS LTD.
Times House, Station Approach
Ruislip, Middlesex HA4 8LH
England
Page 7-12
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