Copley Controls Xenus XSL-230-18 - D: Thermal Considerations

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Copley Controls Corp. 169

APPENDIX

D: THERMAL CONSIDERATIONS

This chapter describes operating temperature characteristics, heatsink options, and heatsink mounting

instructions. Contents include:

D.1: Operating Temperature and Cooling Configurations .......................................................................................................... 170

D.1.2: Heatsink and Fan Configurations .......................................................................................................................... 171

D.2: Heatsink Mounting Instructions .......................................................................................................................................... 172

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Table of Contents4
About this Manual9
Overview and Scope9
Related Documentation9
Comments9
Copyrights9
Document Validity9
Product Warnings10
Revision History11
Introduction12
Amplifier13
Cme 214
Cmo/Cml14
2: Operational Theory16
Amplifier Internal Power17
1: Logic/Signal Power17
2: High Voltage17
3: Power and Grounding Diagram18
Synchronizing PWM Switching Frequency19
Commutation Modes19
Feedback19
1: Encoder and Resolver Support19
2: Secondary Encoder Interface19
Operating Modes20
1: Modes and Control Loops20
2: Current Mode and Current Loop21
3: Velocity Mode and Velocity Loop23
4: Position Mode and Position Loop25
5: Input Command Types26
6: Analog Command Input26
7: PWM Input28
8: Digital Input29
9: CVM Program30
Canopen Operation31
1: CAN Network and Canopen Profiles for Motion31
2: Supported Canopen Modes31
3: Architecture32
4: CAN Addressing32
Limit Switches33
1: Use Digital Inputs to Connect Limit Switches33
2: Diagram: Sample Placement of Limit Switches33
3: How the Amplifier Responds to Limit Switch Activation33
4: Using Custom Output to Signal Limit Switch Activation33
Brake Operation34
1: Digital Output Controls Brake34
2: Brake/Stop Sequences34
Status Indicators35
1: Amplifier and CAN Interface Status Indicators35
2: Amplifier Status Indicator Operation35
3: CAN Interface Status Indicator Operation36
Protection37
1: Faults37
Position and Velocity Errors39
1: Error-Handling Methods39
2: Following Error Faults39
3: Following Error Warnings39
4: Position and Velocity Tracking Windows39
5: Following Error Fault Details40
6: Tracking Window Details41
Communication42
1: Communication Interfaces42
2: CME 2 and CAN Operation42
Inputs43
1: Digital Inputs43
2: Input Filters43
3: Debounce Time43
4: Configure for Pull Up/Pull down Resistors by Groups43
5: Programmable Input Functions43
Outputs45
1: Digital Outputs45
2: Standard Programmable Output Functions45
3: Custom Output Functions46
Regen Resistor Theory48
1: Regeneration48
2: Regen Resistor48
3: Regen Circuit Components48
4: Regen Circuit Protections48
5: Configurable Custom Resistor48
Specifications50
Agency Approvals51
Power Input51
Power Output51
Control Loops52
Regen Circuit Output52
Digital Command Input52
Analog Command Input53
Digital Inputs53
Digital Outputs53
Brake Output54
Encoder Power Supply Output54
Primary and Secondary Encoder Inputs54
Analog Encoder Inputs54
Hall Switch Inputs55
Resolver Interface55
Encoder Outputs55
Serial Interface55
CAN Interface56
Status Indicators56
Fault Levels56
Power Dissipation57
Thermal Impedance57
Mechanical and Environmental57
Dimensions58
Wiring60
General Wiring Instructions61
1: Electrical Codes and Warnings61
2: Grounding Considerations61
3: Connector Locations62
AC Mains (J1)63
Motor (J2)64
Regen Resistor (J3) (Optional)65
Logic Supply / Brake (J4)66
RS-232 Serial Communications (J5)67
CAN Bus (J6)68
Control (J7)69
Motor Feedback (J8)73
5: Quick Setup with CME 278
Warnings79
CME 2 Installation and Serial Port Setup80
1: Requirements80
2: Downloading Software from Web (Optional)80
3: Installing CME 2 Software80
4: Serial Port Setup81
Prerequisites83
1: Hardware and Equipment83
2: Starting CME 2 and Choosing an Amplifier84
Basic Setup85
1: Basic Setup Screen85
Motor Setup87
1: Motor Data File87
2: Rotary Motor88
3: Linear Motor89
Feedback Setup90
1: Overview90
2: Rotary Motor Feedback Setup Options91
3: Linear Motor Feedback Setup Options91
Brake/Stop (Optional)92
1: Overview92
2: Procedure92
3: Calculate93
Amplifier Configuration94
1: Digital Inputs94
2: Standard Digital Outputs96
3: Custom Digital Outputs97
4: Save Input/Output Changes97
5: Fault Latching98
6: Regen Resistor99
Command Input99
1: Analog Input100
2: PWM Input102
3: Digital Position Input103
4: CAN Interface105
Auto Phase106
1: Auto Phase Warnings and Notes106
2: Auto Phase Procedure107
3: Guidelines for Choosing Auto Phase Current and Increment Rate Values110
4: Trouble Shoot Motor Direction Setup110
5: Trouble Shoot Motor Wiring Setup110
6: Trouble Shoot Halls Wiring Setup110
7: Other Problems110
Current Loop111
1: Current Loop Settings111
2: Manually Tune Current Loop112
Velocity Loop114
1: Velocity Loop Settings114
2: Manually Tune the Velocity Loop115
Position Loop116
1: Position Loop Settings116
2: Manually Tune the Position Loop117
3: Test S-Curve Profile119
Completion Steps120
1: Objective120
2: Steps120
6: Using CME 2122
CME 2 Overview123
1: Main Screen Overview123
2: Tool Bar Overview123
3: Main Menu Overview124
4: Functional Diagram125
5: CAN Information and Status Bar126
6: Choosing an Amplifier from a List of Amplifiers126
7: Renaming an Amplifier126
Manage Amplifier and Motor Data127
1: Memory127
2: Disk Storage127
3: Data Management Tools128
4: Quick Copy Setup Procedure129
Downloading Firmware130
1: Acquiring Firmware from Web Site (Optional)130
2: Downloading Firmware to Amplifier131
Control Panel132
1: Control Panel Overview132
2: Status Indicators and Messages132
3: Monitor Functions133
4: Control Functions134
5: Jog Mode134
Scope Tool135
1: Scope Tool Overview135
2: Function Generator and Profile Tabs136
3: Scope Settings137
4: Scope Tool Controls140
5: Control Loop Parameters in the Scope Tool140
6: Scope Files142
Error Log and Communications Log143
1: Error Log143
2: Communications Log144
CME 2 Virtual Amplifier145
1: Virtual Amplifier Overview145
2: Virtual Amplifier Creation145
Manual Phasing146
1: Manual Phase Objectives146
2: Manual Phase Instructions, Standard (Non-Resolver) Xenus146
3: Manual Phase Instructions, Resolver (-R) Xenus148
4: Troubleshooting Manual Phase with Halls and Encoder149
5: Verify Motor Pole Count149
Auto Tune Current Loop150
1: Auto Tune Objective150
2: Auto Tune Instructions150
Home Function153
1: Overview153
2: Homing Functions Settings153
A: Regen Resistor Sizing and Configuration154
A.1: Sizing a Regen Resistor155
A.1.1: Gather Required Information155
A.1.2: Observe the Properties of each Deceleration During a Complete Cycle of Operation155
A.1.3: Calculate Energy Returned for each Deceleration156
A.1.4: Determine the Amount of Energy Dissipated by the Motor156
A.1.5: Determine the Amount of Energy Returned to the Amplifier156
A.1.6: Determine if Energy Returned Exceeds Amplifier Capacity157
A.1.7: Calculate Energy to be Dissipated for each Deceleration157
A.1.8: Calculate Pulse Power of each Deceleration that Exceeds Amplifier Capacity157
A.1.9: Calculate Resistance Needed to Dissipate the Pulse Power157
A.1.10: Calculate Continuous Power to be Dissipated158
A.1.11: Select Fuses158
A.2: Configuring a Custom Regen Resistor159
A.2.1: Regen Configuration Objective and Warning159
A.2.2: Regen Configuration Instructions159
B: I 2 T Time Limit Algorithm162
B.1: I 2 T Algorithm163
B.1.1: I 2 T Overview163
B.1.2: I 2 T Formulas and Algorithm Operation163
B.1.3: I 2 T Current Limit Algorithm - Application Example164
Velocity Loop Filters168
C.1: Advanced Velocity Loop Filter168
C.1.1: Filter Overview168
C.1.2: Filter Instructions and Details168
D: Thermal Considerations170
D.1: Operating Temperature and Cooling Configurations171
D.1.2: Heatsink and Fan Configurations172
D.2: Heatsink Mounting Instructions173
E: Xenus Filter174
E.1: Overview175
E.1.1: Differential and Common Mode Filtering175
E.1.2: Description and Functional Diagram175
E.1.3: PWM Output Plot175
E.2: XSL-FA-01 Edge Filter Specifications176
E.3: Thermal Considerations176
E.4: XSL-FA-01 Edge Filter Dimensions177
E.5: XSL-FA-01 Edge Filter Wiring178
E.5.2: Electrical Codes and Warnings178
E.5.2: Connector Locations179
E.5.3: Cable Notes180
E.5.4: Input (J1) from Amplifier180
E.5.5: Output (J2) to Motor180
E.5.6: Diagram: Edge Filter Wiring with Brushless Motor181
E.5.7: Diagram: Edge Filter Wiring with Brush Motor181
E.6: XSL-FA-01 Edge Filter Ordering182
F: Connecting for Serial Control184
F.1: Single-Axis and Multi-Drop185
F.1.2: Single-Axis Connections185
F.1.3: Multi-Drop Network Connections185
G: Servotube Motor Setup186
G.1: Servotube Setup and Configuration187
G.1.1: Servotube Basic Setup Screen Options187
G.1.2: Servotube Motor/Feedback Setup188
G.1.3: Calculating Servotube Initial Values189
G.1.4: Setting up the Motor over Temperature Input189
G.1.5: Other Servotube I/O and Fault Latching Setup Steps189
G.2: Servotube Auto Phase and Manual Phase190
G.2.1: Servotube Auto Phase190
G.2.2: Servotube Manual Phase193
G.3: Special Servotube Setup Completion193
H: Ordering Guide and Accessories194
H.1: Amplifier Model Numbers195
H.2: Accessory Model Numbers195
H.3: Order Example196
H.4: Control and Feedback Cable Color Codes197
Copley Controls Corp197
H.4.1: Wire Description Nomenclature197
H.4.2: Control Cable (XSL-CC-10)197
H.4.3: Feedback (XSL-FC-10)198
H.5: Regen Resistor Specifications199
H.5.1: XTL-RA-03, XTL-RA-04 Specifications199
H.5.2: XTL-RA-03, XTL-RA-04 Dimensions199
H.5.3: XSL-RA-01, 02 (Discontinued) Specifications200
H.5.4: XSL-RA-01, 02 (Discontinued) Dimensions200

Copley Controls Xenus XSL-230-18 - D: Thermal Considerations

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