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Summary of Contents for Copley Controls Corp. Xenus XTL-230-18
- Page 1 Xenus™ Regeneration Guide P/N 95-00306-000 Revision 3 June 2008...
- Page 2 Xenus Regeneration Guide This page for notes.
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Page 3: Table Of Contents
TABLE OF CONTENTS About This Guide....................................iii Overview and Scope................................iii Related Documentation ...............................iii Comments ...................................iii Copyrights ...................................iii Document Validity................................iii Product Warnings ................................iv Revision History.................................. iv Regen Resistors for Xenus ................................. 1 1.1: Regen Resistor Theory................................2 1.2: Amplifier Regen Circuit Output Specifications ........................3 1.3: Copley Standard Regen Resistors............................ - Page 4 Table of Contents Xenus Regeneration Guide This page for notes. Copley Controls Corp.
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Page 5: About This Guide
BOUT UIDE 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. -
Page 6: Product Warnings
About this Guide Xenus Regeneration Guide 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. -
Page 7: 1: Regen Resistors For Xenus
CHAPTER 1: R EGEN ESISTORS FOR ENUS This chapter provides an overview of regeneration and using regen resistors with Xenus. The contents of this chapter include: Title Page 1.1: Regen Resistor Theory................................2 1.2: Amplifier Regen Circuit Output Specifications ........................3 1.3: Copley Standard Regen Resistors............................ -
Page 8: Regen Resistor Theory
Regen Resistor Sizing and Configuration Xenus Regeneration Guide 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 I R losses in the motor windings, cabling and drive electronics. -
Page 9: Amplifier Regen Circuit Output Specifications
Xenus Regeneration Guide Regen Resistor Sizing and Configuration 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 Minimum Resistor Wattage 25 W... -
Page 10: Copley Standard Regen Resistors
Regen Resistor Sizing and Configuration Xenus Regeneration Guide 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). Copley Controls Corp. -
Page 11: 2: Copley Standard Regen Resistor Specifications
Xenus Regeneration Guide Regen Resistor Sizing and Configuration 1.3.2: Copley Standard Regen Resistor Specifications Specifications for Copley’s standard regen resistors are described below. Model Resistance Default Peak Peak For Use With Continuous Continuous Power Power Power Power Time XTL-RA-03 30 ohms 65 W 400 W 5 kW... -
Page 12: Regen Circuit Wiring
Regen Resistor Sizing and Configuration Xenus Regeneration Guide 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. -
Page 13: 2: Amplifier Connector Locations
Xenus Regeneration Guide Regen Resistor Sizing and Configuration 1.4.2: Amplifier Connector Locations Connector locations are shown below. The regen connector is J3. ™ Xenus STATUS RS232 ADDR CNTRL REGEN+ REGEN- FDBCK FDBCK +24V +24V BRAKE BRAKE Copley Controls Corp. -
Page 14: 3: Regen Resistor (J3) Wiring
Regen Resistor Sizing and Configuration Xenus Regeneration Guide 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... -
Page 15: 4: Regen Resistor Configuration With Cme 2
Xenus Regeneration Guide Regen Resistor Sizing and Configuration 1.4.4: Regen Resistor Configuration with CME 2 Click Configure Regen ( ) to open the Regen Resistor screen. 1.4.4.1 Select a resistor option. 1.4.4.2 Option Description None No external regen resistor is used. XTL-RA-03 Standard regen resistors supplied by Copley Controls. - Page 16 Regen Resistor Sizing and Configuration Xenus Regeneration Guide This page for notes. Copley Controls Corp.
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Page 17: A: Regen Resistor Sizing And Configuration
APPENDIX A: R EGEN ESISTOR IZING AND ONFIGURATION This chapter describes the formulas used to determine if a regen resistor is required and what the optimal resistor characteristics would be for a given application. The contents of this chapter include: Title Page A.1: Sizing a Regen Resistor............................... -
Page 18: A.1: Sizing A Regen Resistor
Regen Resistor Sizing and Configuration Xenus Regeneration Guide 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. For all applications, gather the following information: A.1.1.1 Details of the complete motion profile, including times and velocities Amplifier model number... -
Page 19: A.1.3: Calculate Energy Returned For Each Deceleration
Xenus Regeneration Guide Regen Resistor Sizing and Configuration A.1.3: Calculate Energy Returned for Each Deceleration Use the following formulas to calculate the energy returned during each deceleration: Rotary motor: = ½ J Where: = Energy returned by the deceleration, in joules. Jt = Load inertia on the motor shaft plus the motor inertia in kg m I1 = Shaft speed at the start of deceleration in radians per second. -
Page 20: A.1.6: Determine If Energy Returned Exceeds Amplifier Capacity
Regen Resistor Sizing and Configuration Xenus Regeneration Guide A.1.6: Determine if Energy Returned Exceeds Amplifier Capacity Compare the amount of energy returned to the amplifier in each deceleration with the amplifier's energy absorption capacity. For related amplifier specifications, see Amplifier Regen Circuit Output Specifications (p. -
Page 21: A.1.10: Calculate Continuous Power To Be Dissipated
Xenus Regeneration Guide Regen Resistor Sizing and Configuration A.1.10: Calculate Continuous Power to be Dissipated Use the following formula to calculate the continuous power that must be dissipated by the regen resistor. Use each deceleration where energy is dissipated by the regen resistor. -
Page 22: A.2: Configuring A Custom Regen Resistor
Regen Resistor Sizing and Configuration Xenus Regeneration Guide A.2: Configuring a Custom Regen Resistor A.2.1: Regen Configuration Objective and Warning Configure the amplifier to operate properly with the custom resistor. Incorrect values may damage amplifier or external regen resistor. For the I T algorithms to work correctly, the values entered in the following steps must be correct. - Page 23 Xenus Regeneration Guide Regen Resistor Sizing and Configuration Enter a Continuous Power within the range described. Click Next for Step 3. A.2.2.4 Enter a Peak Power within the range described. Click Next for Step 4. A.2.2.5 Click Next for Step 5. A.2.2.6 Review the configuration.
- Page 24 Xenus™ Regeneration Guide 95-00306-000 Revision 3 June 2008 2003, 2004, 2006, 2007, 2008 Copley Controls Corporation 20 Dan Road Canton, MA 02021 USA All rights reserved...
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