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Copley Controls 7228AC User Manual

Digital servo amplifier
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User Guide
Digital Servo Amplifier
7228AC, 7228DC, 7428AC, 7428DC
Models

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February 19, 2025

Green light is blinking & not staying on when connected to motor

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Summary of Contents for Copley Controls 7228AC

  • Page 1 User Guide Digital Servo Amplifier 7228AC, 7228DC, 7428AC, 7428DC Models...

  • Page 2: Table Of Contents

    Table Of Contents Chapter 1 Introduction ............1 - 1 Features .
  • Page 3 Chapter 3 Getting Started ........... 3 - 1 Starting Copley Motion Explorer .
  • Page 4 Chapter 5 Using Copley Explorer Motion Controller ... . . 5 - 1 Main Window ............5 - 3 File Menu .
  • Page 5 NOTES I n t r o d u c t i o n...
  • Page 6 The information in this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a committment by Copley Controls Corpo- ration. Copley Controls assumes no responsibility or liability for any errors or inaccuracies herein.

  • Page 7: Introduction

    Chapter 1 Introduction...

  • Page 8: Features

    Features...

  • Page 9: Models

    Models Table 1-1 7XX8 Models Applications...

  • Page 10: Software Requirements

    Motion Explorer Software Motion Explorer (CME) Software Requirements Motion Explorer Motion Explorer...

  • Page 11: Terminology

    Terminology s t s f i l r e i t a r i t o r o l i l e t i e s e l c i f i t a i f i e l i e l i i n i f i l...

  • Page 12: Ce Mark And Ul Conformity

    CE Mark and UL Conformity...

  • Page 13: Unpacking And Inspection

    Unpacking and Inspection Read Me First Copley Motion Explorer Technical Support...

  • Page 14: Safety

    Safety DANGER! HAZARDOUS VOLTAGES Exercise caution when installing and adjusting. WARNING! DO NOT make connections to motor or drive with power applied! WARNING! DO NOT spin motors with power off. Voltages generated by the motor can damage drives! WARNING! DO NOT switch operating modes with out using precautions. Values set for one operating mode may not be proper for another! NOTE! DO connect drives using good wiring and...
  • Page 15 Copley Motion Explorer Copley Motion Explorer At the end of this chapter, you'll find information about the amplifier's signal module and indicator.
  • Page 16 Ch. A RS-232 RS-232 Ch. /A Data Port Pulse and RS-485 Ch. B Direction Driver/ Ch. /B Format Receiver Logic Jumper Selects Ch. X Ch. /X Mode Selects Hall U Ref(+) Hall V Hall Halls Dif Amp Receiver Ref(-) Hall W &...

  • Page 17: Grounding

    Grounding ounding ounding ounding ounding Safety Grounding Safety Grounding Safety Grounding Safety Grounding Safety Grounding For safety, it is important that amplifier frame ground on J1 be connected to earth ground Signal Grounding Signal Grounding Signal Grounding Signal Grounding Signal Grounding connect the signal ground on J3 to the controller ground.
  • Page 18 V V V V V olta olta olta olta oltag g g g g e & Current Ratings of Mains e & Current Ratings of Mains e & Current Ratings of Mains e & Current Ratings of Mains e & Current Ratings of Mains Fusing Fusing Fusing...
  • Page 19 AC Model < 3ft Fuses: 20A Line Filter time-delay Blk (Brn) Wht (Blu) Corcom Grn (Grn/Yel) 120VAC Buss + Fuses: 20A time-delay Blk (Brn) Buss - Motor U Grn (Grn/Yel) 230VAC Motor V Wiring for 74XXAC Motor W Note: All lines in this power stage are HOT! Copley Amplifier (At mains potential)
  • Page 20 DC Model P DC Model P DC Model Po o o o o wer Connections wer Connections wer Connections DC Model P DC Model P wer Connections wer Connections No Transformer Required! Voltage & Current Ratings of Power Voltage & Current Ratings of Power Voltage &...
  • Page 21 DC Model Fuses Inrush limiter time-delay Buss - Buss+ Wht (Blu) Blk (Brn) Grn (Grn/Yel) 120VAC Wiring for 72XXDC Copley Amplifier Fuses time-delay Buss+ Blk (Brn) Power Buss- Supply Note: All lines in this power stage are HOT! Grn (Grn/Yel) 230VAC (At mains potential) Wiring for 74XXDC...

  • Page 22: Motor Phase Wiring Connections

    Motor Phase Wiring Connections Motor Phase Wiring Connections Motor Phase Wiring Connections Motor Phase Wiring Connections Motor Phase Wiring Connections Motor Protection: Fusing & Circuit Breakers Motor Protection: Fusing & Circuit Breakers Motor Protection: Fusing & Circuit Breakers Motor Protection: Fusing & Circuit Breakers Motor Protection: Fusing &...
  • Page 23 Motor Signal Connector (J2) Motor Signal Connector (J2) Motor Signal Connector (J2) Motor Signal Connector (J2) Motor Signal Connector (J2) Connectors & Cabling Connectors & Cabling Connectors & Cabling Connectors & Cabling Connectors & Cabling...
  • Page 24 Hall Halls Receiver Shld Case Gnd Case Gnd Twisted Pair Enc X Enc /X Encoder Enc A Receiver Encoder & Enc /A Home pulse Enc B logic Enc /B Case Gnd Case Gnd Shld +5V Power 250mA max. MOTOR Motor Overtemp /Motemp Switch Sensor...
  • Page 25 For more information about encoder formats see Chapter 3. Index Phase A Phase B Encoder Receiver Encoder Receiver Encoder Receiver Encoder Receiver Encoder Receiver Receiver circuit same for all encoder inputs 2.2k 47pF 26LS32 47pF Copley Driver...
  • Page 26 Motor Receiver circuit same for all encoder inputs Enc X Index Index Index Enc X Receiver Enc /X /Index Enc A Phase A Phase A Phase A Enc A Enc /A Phase /A Receiver Enc B Phase B Phase B Phase B Enc B Enc /B...
  • Page 27 Hall Sensors Hall Sensors Hall Sensors Hall Sensors Hall Sensors One Electrical Cycle All 6 states Phase U Phase V Phase W Typical 120 Degree Halls shown Hall Input Circuit Hall Input Circuit Hall Input Circuit Hall Input Circuit Hall Input Circuit Input circuit same for all Hall signals HCT14...
  • Page 28 Motor Phase U Phase V Hall Halls Receiver Phase W Shld Case Gnd Case Gnd Hall power +5V Power 250mA max. Copley Amplifier Temperature Sensor Input Circuit Temperature Sensor Input Circuit Temperature Sensor Input Circuit Temperature Sensor Input Circuit Temperature Sensor Input Circuit Input circuit Motor Sensor signal...
  • Page 29 Signal Connector (J3) Signal Connector (J3) Signal Connector (J3) Signal Connector (J3) Signal Connector (J3) wire that has a rating to support the current signal.
  • Page 30 * Pull-up to +5V, or pull-down to GND are selectable and may be stored in a preset. In addition, the active level (Hi or Lo) may also be selected and store as a preset. Outputs Inputs Command Inputs A mon Ch.
  • Page 31 Analog Command Inputs ( Analog Command Inputs ( Analog Command Inputs ( Analog Command Inputs ( Analog Command Inputs (± ± ± ± ± 10V) 10V) 10V) 10V) 10V) +/-10V Analog Analog input circuit Case Gnd 220pF DAC +/-10V Ref(-) +/-10V Analog Gnd Ref(+)
  • Page 32 Digital Command Receiver Digital Command Receiver Digital Command Receiver Digital Command Receiver Digital Command Receiver Receiver circuit same for all Channel inputs 2.2k 47pF 26LS32 47pF Copley Driver Pulse and Direction Receiver circuit Case Gnd same for all digital channel inputs differential configuration Ch.
  • Page 33 Pulse and Direction Receiver circuit Case Gnd same for all digital channel inputs single-ended open-collector configuration Pulse Ch. A Channel A Pulse Receiver Ch. B Channel B Receiver Copley Driver Pulse and Direction single-ended TTL configuration Receiver circuit same for all digital channel inputs Pulse Ch.
  • Page 34 Quadrature master encoder Receiver circuit same for all digital channel inputs differential configuration Ch. A Channel A Phase A Pulse Phase A Ch. /A Receiver Phase /A Ch. B Phase B Channel B Phase B Ch. /B Receiver Phase /B Ch.
  • Page 35 Analog input circuit 0-10VDC 200k Curr Limit ADCN2 200k Copley Driver...
  • Page 37 Input circuit same for all enables and home HCT14 Common Pull-up to +5V or Pull-down 0V for this group. HCT14 10nF Copley Driver Signal Gnd /Enable /Pos enable Note: Amplifier signal ground /Neg enable must be connected to /Home controller ground. Copley Amp...
  • Page 38 Input circuit same for all presets and reset HCT14 Common Pull-up to +5V or Pull-down 0V for this group. HCT14 10nF Copley Driver Connections to a Remote Computer Connections to a Remote Computer Connections to a Remote Computer Connections to a Remote Computer Connections to a Remote Computer /Preset-1 /Preset-2...
  • Page 39 +24V RELAY CLOSED WHEN (Coil supply) Relay Output Status circuit STATUS-1 IS LOW N.O. Status-1 100 min. Signal Gnd EXTREG2 +24V (Coil supply) ( supply) 4.8k Status-2 Opto Status-2 10mA EXTREG3 4N23 (24V supply) Copley Amplifier...
  • Page 40 Analog output circuit A mon 5-0V +/-10V Oscilloscope SPISMO Signal Gnd Copley Driver Figure 2-28 Analog Monitor Output...
  • Page 42 RS-232 RS-232 comm port DATA Driver / Receiver Copley Amplifer Bold & Italics RS-232 Receiver / Transmitter RS-232 JP13 Ribbon Cable DB-9 Female Copley Driver Connector DB-9 Male DB-25 Male Front view Front view...

  • Page 44: Amplifier Status Indicator

    Table 2-7 Amplifier Status Indicator...
  • Page 45 JP6 JP4 & Internal Flash RAM JP13 J4 Data Port J2 Encoder/Hall J3 Signal Jumpers Settings Function Factory installed Do not move JP13 RS-232 (Default) JP6 JP4 Force 9600 Analog Scale (Default) Baud Range +/-20Vmax.
  • Page 46 Copley Motion Explorer install a Copley supplied motor your own motor. Installation Using a Copley Motion Explorer Development Kit • Installation Using a Copley Motor Data File and a New Copley Motor • Installation Using a Vendor Specification and Motor Copley Motion Explorer...

  • Page 47: Chapter 3 Getting Started

    Getting Started...
  • Page 49 Getting Started...
  • Page 51 Copley Motion Explorer Verifying Software Parameters Verifying Software Parameters Verifying Software Parameters Verifying Software Parameters Verifying Software Parameters Copley Motion Explorer Getting Started...
  • Page 52 Halls Adjusting Calculated Motor Data...
  • Page 53 Amplifier Status Now! Getting Started...
  • Page 55 Getting Started...
  • Page 57 Tools Getting Started...

  • Page 58: Starting Copley Motion Explorer

    Copley Motion Explorer Verifying Hardware Installation Starting Copley Motion Explorer...
  • Page 59 Adjusting Calculated Motor Data Getting Started...
  • Page 60 Adjusting Calculated Motor Data...
  • Page 61 Getting Started...
  • Page 62 Verifying Hardware Installation Starting Copley Motion Explorer Copley Motion Explorer...
  • Page 63 Adjusting Calculated Motor Data Encoder Checking Auto Phasing Getting Started...
  • Page 64 calculated preliminary counts per revolution divided by pole pairs equals phase counts Commutation Mode can be set to either Trapezoidal or Sinusoidal If the motor has Hall sensors. Phase Mode can be set to either Hall-based or Algorithmic. Encoder Checking Auto Phasing.
  • Page 65 If no Halls are present, then set Phasing Mode to Algorithmic and Phase Correct Mode to ON. Also, set a Phase Init Time and set Commutation Mode to Sinusoidal. Encoder Checking, Auto Phasing Algorithmic Phasing Figure 3-8-1 Adjusting Motor Data Getting Started...
  • Page 66 free to move bi-directionally not connected to a load.
  • Page 67 percentage Manual Encoder Check Getting Started...
  • Page 69 free to move bi-directionally not connected to a load. Installation Using a Vendor Specification and Motor Encoder Checking Getting Started...
  • Page 71 "swap" a pair of wires. The swap combinations are motor wires UW, VW and UV. "rotate" Rotate left is the equivalent of shift U to W, W to V and V to U. Rotate right is the equivalent of shift W to U, U to V and V to W.
  • Page 72 and use them for all presets. other Hall offset value means there may be a problem with the alignment of the Halls on the motor. which you should not have closed earlier...
  • Page 73 Getting Started...
  • Page 74 filename.cca filename.ccm...
  • Page 75 • derived • • • • Method A: Getting Started...
  • Page 76 Method B:...
  • Page 77 > " " " I " " f i t f i t " " Getting Started...
  • Page 78 Copley Motion Explorer Copley Motion Explorer...
  • Page 79 full...
  • Page 80 filename.cca filename.ccm filename...

  • Page 81: Application Example

    Application Example: Preset 0 I/O Logic Encoder A Preset 1 Encoder /A Encoder B Encoder Encoder /B Status 0 Encoder X Encoder /X /Enable Signal ground Hall U Halls Hall V Note: Amplifier signal ground must be Hall W connected to controller ground. Phase U Motor Phase V...
  • Page 82 full...
  • Page 83 full filename.cca filenam.ccm...
  • Page 84 –– filename.
  • Page 85 Preset 0 I/O Logic Encoder A Preset 1 Encoder /A Encoder B Encoder Encoder /B Status 0 Encoder X Encoder /X /Enable Signal ground Hall U Halls Hall V Note: Amplifier signal ground must be Hall W connected to controller ground. Phase U Motor Phase V...
  • Page 86 some full...
  • Page 87 full...
  • Page 88 some full...
  • Page 89 filename.cca filename.ccm...
  • Page 90 Preset 0 I/O Logic Encoder A Preset 1 Encoder /A Encoder B Slave Encoder /B Encoder Status 0 Encoder X Encoder /X /Enable Signal ground Encoder A Hall U Halls Encoder /A Hall V Encoder B Hall W Encoder /B Master Encoder Encoder X...
  • Page 91 Notes:...
  • Page 92 Copley Motion Explorer Copley Motion Explorer...
  • Page 97 Note: These parameters are global amplifier settings and apply to all presets.
  • Page 109 calculate...
  • Page 114 Table 5-10 Motor Data Parameters...
  • Page 118 Table 5-11 Analog Monitor Signals...
  • Page 120 A preset is an instance of all the necessary motor and amplifier data necessary to make a motor perform a predefined task. Figure 5-18 Preset Manager S c r e e n...
  • Page 121 Table 5-12 Preset Manager Screen B u t t o n s...
  • Page 123 a sinusoidally or trapezoidally wound, wye or delta connected brushless motor. next...
  • Page 124 If the index is 1/4 of a line, select the correct location. Example, Index Hi when A and B are Hi. Save data as described earlier in this Motor menu section.
  • Page 125 Save data as described earlier in this Motor menu section.
  • Page 126 Save data as described earlier in this Motor menu section.
  • Page 127 Save data as described earlier in this Motor menu section.
  • Page 128 other applied...
  • Page 129 models Increment the slides and check system response.
  • Page 130 Figure 5-27 Apply Motor Data...
  • Page 133 repeatedly...
  • Page 137 Copley Motion Explorer Copley Motion Explorer...
  • Page 138 Encoder Checking...
  • Page 139 Auto Phasing...
  • Page 140 Chapter 3...
  • Page 142 (and follow some other steps described below), Copley Motion Explorer...
  • Page 144 Many of the Set Commands are buffered. Buffered commands must be followed by the update command to take effect. For more information, see the 7XX8 Series of Digital Servo Amplifier Programmer Reference Manual.
  • Page 145 Copley Motion Explorer limited...
  • Page 146 Copley Motion Explorer...
  • Page 150 filename...
  • Page 152 Model 7228AC 7428AC Output power: Output voltage:...
  • Page 153 Model 7228AC 7428AC Input Power: Mechancial 7.50 (190.5) 0.93 (23.62) 6.22 3.00 STATUS Model: 7428AC (158) 6.94 Input: 32~264VAC (76.2) 50/60Hz (176.3) DATA SIGNAL 7.00 (177.8) MOTOR Westwood, MA, USA 2.72 (69.1) 1.46 (37.08) 4.72 W/ Heat Sink Option (119.9)
  • Page 154 AC Model Connections Model 7228DC 7428DC Output power: Output voltage:...

  • Page 155: Input Power

    Model 7228DC 7428DC Input Power: Mechancial: 7.50 ( 190.5 ) 0.93 ( 23.62 ) 4.91 ( 155.5 ) 3.00 5.55 ( 76.2 ) STATUS Model: 7428DC ( 138.75 ) Input: 45~373VDC DATA ENAB SIGNAL 7.00 ( 177.8 ) MOTOR 2.00 1.00 ( 50.0 ) Westwood, MA, USA...
  • Page 156 DC Model Connectors...
  • Page 157 Other Technical Specifications for DSP Model 7XX8 Load inductance: Bandwidth: PWM outputs: Reference inputs: Motor overtemp input:...
  • Page 158 Logic Outputs: Status output: Status LED: enabled. enabled Analog monitor: DC power outputs: Data Port: Ground:...
  • Page 159 Motor encoder: Hall inputs: Logic inputs:...
  • Page 160 Thermal Requirements: ° ° ° ° Protection: °...

  • Page 161: Connection Diagram

    Connection Diagram Chapter 4, Using a New Motor Driver PC or Laptop Model: 7428AC STATUS Input: 32~264VAC 50/60Hz RS-232 Cable 120VAC Line Cord Fuse DATA Black White Green Pendant Signal Cable SIGNAL Encoder/Hall cable MOTOR Motor Power Cable SGND 7xx8 Pendant Refer to the application note for Westwood, MA, USA connection details for this kit.
  • Page 162 Appendix B Operator Pendant The Operator Pendant (Figure B-1) is a module that connects to the signal bus in place of a Programmable Logic Controller (PLC). You can use the pendant in a system to test and debug your application. The pendant has a number of components that you can use: •...
  • Page 163 . e t o i t i f i l . r e n i l l l i f i l r e i s a l , y l l i f i l . r e i t a r i d o i t l i h...
  • Page 164 Figure B-1 Pendant Module 7XX8 Series Digital Servo Amplifier User Guide...
  • Page 165 Reset Reset Preset-0 Preset-1 Preset-2 Preset-3 Analog Analog Mon Enable Enable PosEn Pos Enable NegEn Neg Enable Home Home Signal Gnd Stat-0 Stat-0 Stat-1 Stat-1 R6 200 1.21k 1.21k +12V Ext. Curr Lim Current Limit Ref(+) Input Ref(-) Input +/-10V Signal Gnd Ch.
  • Page 166 Appendix C Ordering Information Refer to this appendix when ordering accessories, cables and development kits. i f i s e l o i t 7XX8 Series Digital Servo Amplifier User Guide...

  • Page 167: Ordering Information

    t i K f i l r e i r o t l l a 0 - t i n i - n i - r 0 0 e z i " 4 / u o r 0 - t i n i - n i - r 0 0...

  • Page 168: Chapter 2 Amplifier Connections

    Index Data Connector J4 1-28 AC & DC Power & Motor Phase (J1) 2 - 4 Adjusting Calculated Motor Data 3-19 DC Model Power Connections 1 - 6 A l g o r i t h m i c P h a s e I n i t i a l i z a t i o n 3 - 2 9 Diagnostics Menu 5-47, 5-50...

  • Page 169: Software Parameter Notes

    I n i t i a t e a M o v e w i t h t h e P e n d a n t 3 - 8 On-Line Connection Screen Installation Using a Copley Motion Explorer Operating Modes 4-1, 5-15 Development Kit Motor O r d e r i n g...

  • Page 170: Auto Phasing

    Temperature Sensor Input Circuit 2-14 Terminology Tools Auto Phasing Tools > Download Firmware 5-46 Tools > Encoder Check 5-47 Tools Menu 5-41 Tools > Options Communications Screen 5-43 Tools > Options > Directories Screen 5-44 Tools > Options > Advanced Screen 5-45 Torque Mode Trace Graph...
  • Page 171 N O T E S I n d e x...

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