Xenus™ Regeneration Guide P/N 95-00306-000 Revision 3 June 2008

Xenus Regeneration Guide This page for notes.

Table of Contents Xenus Regeneration Guide ii Copley Controls Corp. This page for notes.

Copley Controls Corp. iii ABOUT THIS GUIDE Overview and Scope This guide describes the selection, installation, and configuration of external regen resistors for Xenus Amplifiers. Related Documentation Users should also read these Copley Controls documents: • Xenus User Guide • CME 2 User Guide Links to these publications, along with hardware manuals and data sheets, can be found under the Documents heading of http://www.copleycontrols.com/Motion/Downloads/index.html. Information on Copley Controls Software can be found at: http://www.copleycontrols.com/Motion/Products/Software/index.html Comments...

About this Guide Xenus Regeneration Guide iv Copley Controls Corp. Product Warnings Observe all relevant state, regional, and local safety regulations when installing and using this product. For safety and to assure compliance with documented system data, only Copley Controls Corporation should perform repairs to amplifiers. DANGER: Hazardous voltages. ! DANGER Exercise caution when installing and adjusting. Failure to heed this warning can cause equipment damage, injury, or death. Risk of electric shock. ! DANGER High-voltage circuits on J1, J2, and J3 are connected to mains power. Failure to...

Regen Resistor Sizing and Configuration Xenus Regeneration Guide 2 Copley Controls Corp. 1.1: Regen Resistor Theory When a load is accelerated electrical energy is converted into mechanical energy. During deceleration the conversion is reversed. This is called regeneration. Some of this regenerated energy is lost to friction in the mechanical system. More of this energy is converted to heat due to I2R losses in the motor windings, cabling and drive electronics. The remainder of the energy is added to the electrical energy already stored in the internal capacitor bank of the amplifier. The result...

Xenus Regeneration Guide Regen Resistor Sizing and Configuration Copley Controls Corp. 3 1.2: Amplifier Regen Circuit Output Specifications This section describes the amplifier’s regen resistor circuit output specifications. Model XTL-230-18 XTL-230-36 XTL-230-40 Continuous Power 2 kW 4 kW Peak Power 5 kW 10 kW Minimum Resistance 30 15 Minimum Resistor Wattage 25 W 50 W Turn On Voltage +390 Vdc Turn Off Voltage +380 Vdc DC Bus Capacitance 1760 ìF nominal Regen Energy Absorption Capacity Input Voltage 120 Vac 208 Vac 240 Vac 108 joules 57 joules 32 joules

Regen Resistor Sizing and Configuration Xenus Regeneration Guide 4 Copley Controls Corp. 1.3: Copley Standard Regen Resistors Copley Controls provides two standard regen resistors for Xenus amplifiers: XTL-RA-03 and XTL-RA-04. XTL-RA-03 and XTL-RA-04 housing is shown below. 1.3.1: Copley Standard Regen Resistor Dimensions The diagram below shows XTL-RA-03 and XTL-RA-04 mounting dimensions (in mm).

Xenus Regeneration Guide Regen Resistor Sizing and Configuration Copley Controls Corp. 5 1.3.2: Copley Standard Regen Resistor Specifications Specifications for Copley’s standard regen resistors are described below. Model Resistance Default Continuous Power Max Continuous Power Peak Power Peak Power Time For Use With XTL-RA-03 30 ohms 65 W 400 W 5 kW 1000 ms XTL-230-18 XTL-RA-04 15 ohms 65 W 400 W 10 kW 1000 ms XTL-230-36 XTL-230-40 High Temperature Risk. ! WARNING Setting Default Continuous Power for a standard Copley regen resistor to a value greater than the default of 65 W may cause the resistor...

Regen Resistor Sizing and Configuration Xenus Regeneration Guide 6 Copley Controls Corp. 1.4: Regen Circuit Wiring This section describes the wiring of the regen resistor connections. 1.4.1: Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code (NEC) or its national equivalent, and all prevailing local codes. DANGER: Hazardous voltages. ! DANGER Exercise caution when installing and adjusting. Failure to heed this warning can cause equipment damage, injury, or death. Risk of electric shock. ! DANGER High-voltage circuits on J1, J2, and J3 are connected...

Xenus Regeneration Guide Regen Resistor Sizing and Configuration Copley Controls Corp. 7 1.4.2: Amplifier Connector Locations Connector locations are shown below. The regen connector is J3. CNTRL J4 J3 J2 J1 STATUS RS232 CAN ADDR J5 S1 J6 J7 J8 FDBCK +24V BRAKE RTN REGEN+ UVW L1 L2 L3 CAN Xenus™ REGENFDBCK +24V BRAKE RTN

Regen Resistor Sizing and Configuration Xenus Regeneration Guide 8 Copley Controls Corp. 1.4.3: Regen Resistor (J3) Wiring Mating Connector Description Euro-style, 5 position, 5.0 mm pluggable male terminal block. Manufacturer PN Wago 721-605/000-043 Wire Size 22 - 14 AWG Recommended Wire 14 AWG, 600 V (Shielded cable used for CE compliance) Wire Insertion/Extraction Tool Wago 231-131 Connector and tool are included in connector kit XTL-CK Pin Description Pin Signal Function 1 Regen + + DC Bus to one side of regen resistor 2 N/C No connection 3 Regen - Collector of regen transistor to one side...

Xenus Regeneration Guide Regen Resistor Sizing and Configuration Copley Controls Corp. 9 1.4.4: Regen Resistor Configuration with CME 2 1.4.4.1 Click Configure Regen ( ) to open the Regen Resistor screen. 1.4.4.2 Select a resistor option. Option Description None No external regen resistor is used. XTL-RA-03 XTL-RA-04 Standard regen resistors supplied by Copley Controls. Custom Resistor User-supplied resistor. See Regen Resistor Sizing and Configuration (p. 11). 1.4.4.3 Click OK to save regen settings to flash memory and close the Regen Resistor screen OR click Cancel to restore to previous values...

Regen Resistor Sizing and Configuration Xenus Regeneration Guide 10 Copley Controls Corp. This page for notes.

Regen Resistor Sizing and Configuration Xenus Regeneration Guide 12 Copley Controls Corp. A.1: Sizing a Regen Resistor A.1.1: Gather Required Information Calculating the power and resistance of the regen resistor requires information about the amplifier and the rotary or linear motor application. A.1.1.1 For all applications, gather the following information: 1 Details of the complete motion profile, including times and velocities 2 Amplifier model number 3 Applied line voltage to the amplifier 4 Torque constant of the motor 5 Resistance (line-to-line) of the motor windings. A.1.1.2 For rotary...