MODELS 7225AC, 7425AC

LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS

WITH ±10V ANALOG U-V INPUTS

FEATURES
„ Complete line-powered servo MODEL POWER I-CONT (A) I-PEAK (A)
amplifier for AC brushless 7225AC 32~132VAC 10 20
motors with external 7425AC 32~264VAC 10 20
sinusoidal commutation
„ Off-the-line powered:
32~132VAC, 32~264VAC
50/60Hz, single-phase
No transformer required
„ Optically isolated power and
signal stages
„ Separate motor and signal
Sub-D type connectors
„ FAIL-SAFE ENABLE INPUT
Ground or +5V
active level selection
„ FAULT PROTECTIONS
Short-circuits
output to output
output to ground
Over / under voltage Current limiting is provided via an
Over temperature FEATURES internal solderless header socket or by
Self-reset or latch-off an external resistance or voltage
The 7xx5AC models are PWM applied to the signal connector.
„ CURRENT LIMIT servoamplifiers for AC brushless
servomotors that are commutated The /Enable input active logic-level is
With no loss of Phasing and externally by digital control systems that switch-selectable to ground or +5V to
alert signal for control output two +/-10V signals that represent interface with all types of control cards.
system the current command to the motor U Fail-safe operation in either polarity
and V windings. The amplifier then results from an internal jumper that
„ 3kHz Bandwidth synthesizes the current command for selects the default input level and input
the W winding. resistor pull-up or pull-down connections
„ Wide load inductance range so that the amplifier shuts down with no
Control cards take feedback from an input.
0.4~ 40 mH. encoder on the motor and use various
techniques to determine the rotor MOSFET (7225AC) and IGBT (7425AC)
position. When this has been done, the output stages deliver four-quadrant
WORKS WITH POPULAR controller is able to output two signals power for bi-directional acceleration and
that correspond to the current in the U deceleration of motors. For high-inertia
CONTROLLERS loads, an external regenerative energy
and V windings to produce torque in the
motor. The amplifier synthesizes the W dissipater is available.
„ ACS-Tech80 5651A
winding current from UV signals that are All models are protected against output
ACS-Tech80 SPiiPlus series either 120 or 90 electrical degrees short circuits (output to output and
„ PMD MC1231A Chipset apart. output to ground) and heatplate
Amplifier adjustments with this system overtemperature. With the /Reset input
„ Delta Tau PMAC open the amplifier will latch off until
consist of inductance compensation,
„ MEI DPS Series current limit, transconductance, and powered-down or the /Reset input is
offset. Thereafter, the controller does all toggled. The amplifier will reset itself
„ Galil DMC-1700 of the velocity and/or position control of automatically from faults if the /Reset
the motor. input is wired to GND.
THE OEM ADVANTAGE An internal 40-pin solderless socket lets
the user configure the various gain and
„ Internal header configures current limit settings to customize the
amplifier for plug and play amplifiers for a wide range of loads and
operation applications. Header components permit
compensation over a wide range of load
„ Conservative design for high inductance's to maximize bandwidth
with different motors.
MTBF

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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

TECHNICAL SPECIFICATIONS
MODEL 7225AC 7425AC
OUTPUT POWER
Peak power 20 A @ 110V 20 A @ 205V
Peak time 2 sec at peak power independent of polarity reversal
Continuous power 10 A @ 130V 10 A @ 250V
OUTPUT VOLTAGE
On-resistance (Ro, ohms) 0.2 0.15
Max PWM Peak Output Voltage ±Vout = (VAC X 1.41 -2)×(0.97) - (Ro)×(Io)
INPUT POWER
Mains voltage 32~132VAC, 47~63Hz 32~264VAC, 47~63Hz
Mains current @ continuous output rating 16 A 16 A
Inrush current on startup 19 A. 37 A.
External mains fuse rating 20 A/125V 20 A/250V
LOAD INDUCTANCE
Minimum inductance 400 µH. 400 µH.
Maximum inductance No maximum. See chart of load inductance values. Bandwidth varies with inductance and header parts.

BANDWIDTH Small signal -3dB @ 3kHz with minimum load at nominal supply voltage. Varies with load inductance and header values
PWM OUTPUTS
PWM frequency 25kHz
Modulation Carrier-cancellation, 50% duty cycle at 0V output
REFERENCE INPUT Differential, 94kΩ max. to 47kΩ min. between inputs, ±20V maximum
POTENTIOMETERS U Ref Fine Gain (R1) Default = Center CCW attenuates U Reference.
V Ref Fine Gain (R2) Default = Center CCW attenuates V Reference.
(Internal)
U phase current Zero (R7) Adjusts U output current to zero with U and V inputs = 0V.
V phase current Zero (R6) Adjusts V output current to zero with U and V inputs = 0V.
DIPSWITCH
S1 /Enable input active polarity. OFF (default): Gnd enables amplifier, open or +5V inhibits. ON: Gnd inhibits, open enables
UV PHASE SELECTION Internal jumper JP1-A selects UV phase of 120° or 90° (Default = 120°)
LOGIC INPUTS
/Enable Default = GND GND enables amplifier, open or >2.5V inhibits with S1 OFF. If S1 ON then GND inhibits
See following section on fail-safe operation for JP1-B settings.
Response time is 1 ms from enable active to amplifier output ON.
/Reset Default = Open GND resets latching fault condition, ground for self-reset every 50 ms.
/Motemp Default = GND Motor temperature sensor. Typically normally closed bimetal sensor. Open = overtemp
Input resistance 10kΩ to +5V, R-C filters on inputs
Logic threshold voltage 2.5V (Schmitt trigger inputs with hysteresis, 74HC14)
Input voltage range 0V to +32VDC
FAIL-SAFE ENABLE INPUT
Internal jumper JP1-B selects +5V or GND connection for input pull-up resistors to /Enable input only so that amplifier will default to
disabled condition if inputs are open-circuit, or wires are broken. (See Applications section for details)
LOGIC OUTPUTS
/Normal LO (current sinking) when status LED is green; HI when LED is red or blinking red / green.
HI output voltage +5V (no load). Output is N-channel MOSFET drain terminal with10kΩ pull-up resistor to +5V
LO output voltage On resistance Ro = 5Ω. Max sink current of 250 mA. max off-voltage = 50VDC
Amp OK Buss volts OK AND NOT (output short OR overtemp)
N-channel opto-isolator is ON when amp is OK. ON current 4 mA min. Max voltage 32 VDC
/CLIMIT HI when amplifier is not current limiting; LO when current is limit is reached.
HI output voltage +5V (No load). Output is LM339 open collector with 10kΩ pull-up resistor to +5V
LO output voltage Max sink current of 15 mA, max off voltage = 36VDC
STATUS LED
Bicolor LED changes color and flashes to indicate amplifier operating status
Green = Normal Amplifier enabled AND Amp OK (see above)
Blinking green = Ready Amplifier OK, will run when enabled
Red = Fault, non-latching Over or under-voltage condition or motor overtemp; Amplifier recovers when voltage or temp. is in normal range.
Blinking red = Latching Fault Output overcurrent (short circuit) or amp. overtemp condition. Ground /Reset or power amp. off/on to clear condition
CURRENT LIMIT INPUT
Current limit 0-5V controls current limiting (See application section for details)
MONITOR OUTPUTS
Current Monitor U Motor winding current in U phase: ±10V @ ±20 A or 2 A/V (1kΩ, 33nF R-C filter)
Current Monitor V Motor winding current in V phase: ±10V @ ±20 A or 2 A/V (1kΩ, 33nF R-C filter)
DC POWER OUTPUTS
+5V @ 200 mA max (J3-23)
+10VDC @ 5 mA (J3-24)
-10VDC @ 5 mA (J3-25)
Note: maximum power from all DC outputs not to exceed 1.4W

Copley Controls Corp, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547
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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

PROTECTIVE FEATURES
Short circuit (output to output, output to ground) Latches unit OFF (Power off/on, or ground at /Reset input resets)
OverTemperature Latches unit OFF at 70°C on heatplate (Power off/on, or ground at /Reset input resets)
Wire /Reset input to ground for automatic reset after latching fault
Undervoltage Shutdown at internal DC buss < 45VDC
Overvoltage Shutdown at internal DC buss > 195VDC (Model 7225AC), or internal DC buss > 390VDC (Model 7425AC)
(Amplifier operation resumes when internal DC buss is NOT Undervoltage or NOT Overvoltage )
Current-limiting Output current set by header component or external voltage or resistance
Current will fold-back to continuous rated current (10 A) after 2s maximum at 20 A
Relative amplitude of U/V/W phase currents maintained for no loss of commutation
AMPLIFIER DISSIPATION
Watts minimum 17W (Model 7225AC) 7W (Model 7425AC)
Watts @ continuous current 60W (Model 7225AC) 61W (Model 7425AC)
THERMAL REQUIREMENTS
Storage temperature range -30°C to +85°C
Operating temperature range 0° to 70°C baseplate temperature
Thermal resistance (heatplate to ambient): No heatsink or fan: 0.92 deg. C/W; no heatsink with fan: 0.51 deg. C/W
With heatsink, no fan: 0.6 deg. C/W; with heatsink and fan: 0.23 deg. C/W
MECHANICAL
Size 7.50 x 6.94 x 2.72 in. (190 x 174 x 69 mm) without optional heatsink
7.50 x 6.94 x 4.72 in. (190 x 174 x 120 mm) with optional heatsink
Weight 3.71 lbs. (1.69 kg) without optional heatsink. Add 3.2 lbs. (1.47 kg) for heatsink.
CONNECTORS
J1: Power & motor 9-position terminal strip
J2: Motor temperature 15-position female Sub-D type. #4-40 standoffs for cable shell lock screws
J3: Signal 25-position female Sub-D type. #4-40 standoffs for cable shell lock screws
Connector shells are connected to amplifier chassis for grounding/shielding

PANEL LAYOUT

STATUS
Model: 7425AC
Input: 32~264VAC
50/60Hz

V GAIN
J1 U GAIN

H 1
AC

S1 ENA POL
N 2
ON OFF

3
25 13
+ 4
BUSS

- 5 J3
SIGNAL
U 6
MOTOR

V 7 14 1

W 8

15 8

J2
MOTOR
9
1
Westwood, MA, USA

Copley Controls Corp, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547
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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

TYPICAL AMPLIFIER CONNECTIONS

Chan A
Chan B
Encoder
Index

U Ref(+)
2
Current Command U Ref(-)
14
Phase U
Phase V Shld
1 J3
Ground /Motemp
9
V Ref(+)
3 J2 Gnd
15
V Ref(-)
15

Signal ground Note: /Motemp must be

Note: 13 grounded for amplifier
Amplifier signal ground to operate
must be connected to
(+) 19
controller ground. Amp OK +5V
(-) 7
10k

/Normal 6

U
6
Monitor Outputs
7 V Motor
Current Mon U 10
W
8
Current Mon V 11
Shld
J1 9

L1 Fuse
/Reset 22 1 Line
L2 Filter
2
/Enable 5 J3 3 120VAC

Fuses: 20A
L1 time-delay
Blk (Brn)
Note: Circuits within Line
dashed line are HOT! L2
Filter
(At mains potential)
Grn (Grn/Yel) 230VAC
Wiring for 7425AC

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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

CONNECTORS

J1 POWER AND MOTOR WINDING CONNECTIONS

Connector type: Barrier-block. Screw-terminal connections. #6-32 locking screws with cable clamps.
PIN SIGNAL FUNCTION
1 L1 AC Power Input Hot (black or brown wire from AC mains)
2 L2 AC Power Input Neutral (white or blue wire from AC mains)
3 GND Chassis safety ground (green or green/yel wire from AC mains)
4 Buss (+) Positive terminal of internal DC power supply
5 Buss (-) Negative terminal of internal DC power supply
6 Motor U Amplifier output to “U” winding of motor
7 Motor V Amplifier output to “V” winding of motor
8 Motor W Amplifier output to “W” winding of motor
9 GND Chassis safety ground. Also for cable shield of motor cable.

J2 MOTOR TEMPERATURE CONNECTIONS

Connector type: Female Sub-D, 15 position, #4-40 locking standoffs
PIN SIGNAL FUNCTION
1 Safety GND Chassis ground. Use to ground cable shield. Not connected to internal signal ground.
2 N.C.
3 N.C.
4 N.C.
5 N.C.
6 N.C.
7 N.C.
8 N.C.
9 Motemp Note: Must be grounded for amplifier to operate (Connect to J2-10,12,14, or 15)
10 0V Signal ground
11 N.C.
12 0V. Signal ground.
13 N.C.
14 0V. Signal ground.
15 0V. Signal ground.

J3 SIGNAL CONNECTIONS
Connector type: Female Sub-D, 25-position, #4-40 locking standoffs
PIN SIGNAL FUNCTION PIN SIGNAL FUNCTION
1 Safety GND Chassis ground. Use to ground cable shield.
(Case) Not connected to internal signal ground (J3-12, 13,16).
2 Positive terminal of 14 Negative terminal of
U Ref (+) differential +/-10V analog U Ref (-) differential +/-10V analog
command input command input
3 Positive terminal of 15 Negative terminal of
V Ref (+) differential +/-10V analog V Ref (-) differential +/-10V analog
command input command input
4 N.C. 16 0V. Signal ground.
5 /Enable input Amplifier enable 17 N.C.
6 /Normal output Mosfet output amp status 18 N.C.
7 Amp OK (-) output Opto-isolator emitter (NPN) 19 Amp OK (+) output Opto-isolator collector (NPN)
8 N.C. 20 Ext. I-limit External setting of curr. limit
9 /CLIMIT Current limit status 21 N.C.
10 Current Monitor U +/-10V @ +/-20 A 22 /Reset input
11 Current Monitor V +/-10V @ +/-20 A 23 +5V @ 200 mA. Auxiliary DC power for user
devices
12 0V. Signal ground. 24 +10V @ 5 mA Auxiliary DC power
13 0V. Signal ground must be 25 -10V @ 5 mA Auxiliary DC power
connected to
the controller ground

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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

FUNCTIONAL DIAGRAM

CONTROL MOMENTARY SWITCH RESETS FAULT

R7 100k 123 JP1B
RH2 CH10 RH11 OFF = ENABLE WIRE RESET TO GROUND FOR SELF-RESET
SYSTEM CASE GND +2.5 -2.5 +5V
1 RH17 ON = ENABLE
U_REF(+) 47k 47k SW1
RESET
2 - DIFF AMP 22
2k CH12
U_REF(-)
- U
14 + CW 19.2k 10k
47k +
47k CURRENT
20.2k ERROR STATUS
RH7 120 / 90 ENABLE
AMP 5
UV &
RH3 PHASE ISOLATED CURRENT SENSE U
CONTROL GND
SELECT 12
W LOGIC
V_REF(+) 47k 47k PHASE W
3 - DIFF AMP JP1A
GENERATOR NORMAL
1
V_REF(-) 2 LED
15 + 19
47k
47k 3 G AMP OK (+)
R6 100k
GND
+2.5 -2.5
CH13 RH14 J3
16 RH8 7 AMP OK (-)
RH16 SIGNAL
23 +5V @ 200mA 2k CH15 +5V
- V
J3 24 +10V @ 5mA CW 19.2k
+ CURRENT 10k
SIGNAL 25 -10V @ 5mA 20.2k ERROR
AMP 6
CURRENT 10k /NORMAL
MONITOR U 10 ISOLATED CURRENT SENSE U
+/-10V @ +/-20A ISOLATED CURRENT SENSE V
2.2nF

CURRENT 10k
MONITOR V 11 ISOLATED CURRENT SENSE V J1 MOTOR &
+/-10V @ +/-20A
2.2nF POWER
U
6
+15V +5V PWM
STAGE V
7 MOTOR
47k 10k LM 339 ISOLATED CURRENT SENSE U MOSFET
CURRENT "H" W
8
/CLIMIT 9 LIMIT BRIDGE
SECTION ISOLATED CURRENT SENSE V
SHIELD
Gv = +HV 9
PROGRAMMABLE CURRENT 20 10
LIMITING 0 - 5V
GND
13 L1 FUSE
Inrush
94k RH18 Current 1 AC HOT
Limiting
LINE
FILTER
L2
2 AC NEUT
J2 HDR19
11 +5V @ 200mA +5 CHASSIS
MOTOR DC / DC
19 22
(CASE)
MOTOR OVER-TEMP GND 12 +15 CONVERTER GROUND
SWITCH +15 -15 3
GND 14 EARTH OR
-15 @ +/-5 mA max SAFETY GROUND
GND
15
HOT-MOT
4 BUSS (+)
9 N.C.
SHIELD
1 5 BUSS (-)
NOTE: CIRCUITS WITHIN DASHED LINE
ARE AT LINE POTENTIAL
N.C.

SIGNAL BOARD AND HEADER SOCKET LAYOUT

U Load Inductive

U Current Offset
V Load Inductive

V Current Offset
Current Gain

Compensation

Compensation
Current Gain

Current Limit

Head
er
1 20
HEADER
RH1~20 R6 R7
HDR19

L 1
JP1
R R RR C R C C R C R R R
E 2 H H HH H H H H H H H H H
3
7 8 1 1 1 1 1 1 1 1 1
D AB 2 3 0 2 3 5
DI 1 4 6 7 8
P
SW J3 SIGNAL J2 HALLS

The header socket holds components that determine the amplifier performance such as inductance compensation, offset scaling, and
peak current limit. Components are named RHn, CHn as Resistor Header n, Capacitor Header n, etc. See applications section for
details.

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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

APPLICATION INFORMATION
EXTERNAL COMMUTATION OVERVIEW SETUP FOR THE MOTOR
The motor windings and encoder are to be connected in
The model 7XX5AC amplifiers are designed to work accordance with the control card setup.
with controllers that perform external commutation to drive AC
brushless motors. Lower torque ripple can be obtained by MOTOR INDUCTANCE COMPENSATION
sinusoidal commutation of the three-phase motor than can be Header components control the amplifier compensation for
obtained by trapezoidal commutation. The figure below shows different motors. These set the gain in the current error
a typical external commutation configuration using an encoder amplifier to give the best response for different winding
for determining position. The controller uses two DAC outputs, inductance. There are two current-control loops in this series of
the U and V Phase, to drive the U and V reference inputs on amplifiers, both must have the same values in the header.
the amplifier. The amplifier then generates W Phase and The tables below give values for the header parts for the two
delivers power to all three motor windings simultaneously. models. The default values for RH11 and RH14 are indicated
below in bold & italic. If the inductance of your motor is less
The encoder data is processed by the controller, to than ½ of the value shown in the table, use the values from the
generate the sinusoidal waveform signals, which are delivered next lower inductance range. Ex., for a 4 mH motor, use the
to the amplifier. These waveforms are typically 120° phase values from the 3 mH row (1/2 of 10mH is 5mH, which is
separated, a jumper in the amplifier can be moved for 90° greater than 4mH, so the value from the next lower row, 3mH,
phase separation. The controller will perform a phase is used).
initialization routine for proper commutation. Improved phase
initialization can be achieved by using Hall sensors for For all tables: CH12 & CH15 are <out>
determining initial position.
Model 7225AC @ 115VAC; CH10 & CH13 = 15nF
L (mH) R11& RH14 (kΩ)
Amplifier 0.3 18
Controler
U
1 39
Phase U 3 75
Phase V V Motor 10 180
Phase
W Gen.
W 30 300

Encoder

Optional Halls Model 7425AC @ 230VAC; CH10 & CH13 = 10nF

L (mH) R11& RH14 (kΩ)
0.3 12.5
1 24.9
AMPLIFIER WIRING & CABLING 3 51
Power supply and motor connections should be made with wire 10 120
that has a rating to support the amplifiers continuous current. 30 200
AWG 14 wire will support all amplifiers in this series. To
minimize noise radiation from the motor and power cabling,
wires should be twisted and shielded. Motor sensor signals are
often routed near the motor phase winding cables. To minimize Model 7425AC @ 115VAC CH10 & CH13 = 10nF
coupling of PWM noise, sensor signal wiring should be L (mH) R11& RH14 (kΩ)
multiple-conductor-shielded cable.
0.3 18
GROUNDING AND ISOLATION 1 39
3 75
The signal board is fully isolated from the power section in this 10 180
series of amplifiers. For proper operation, connect the signal
30 300
ground J3-13 to the controller ground.

For safety, it is important that J1-3 be connected to earth

If the default values do not give sufficient bandwidth, contact
ground, typically through the power cable.
factory for a detailed tuning procedure.
The connections on the power board, such as the motor phase,
are at line potential.

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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

/ENABLE INPUT ACTIVE LEVEL CONTROL

DIP switch S1, ENAB POL, controls active level of the amplifier MOTOR TEMPERATURE SENSOR
enable input at J3-5. The default position is S1 OFF, this will
make the /Enable input ground-active, >2.5V will disable the The /MOTEMP (J2-9) line must be pulled to GND
amplifier. With S1 ON, this will make the /Enable input disable (J2-15) in order to enable the amplifier. The figure
amplifier if grounded, >2.5V will enable. below shows the function. A normally closed thermal
switch can be connected to protect the motor from
over temperature. When the switch opens the
S1 ENAB POL /MOTEMP line is pulled to +5V through a 10k resistor,
disabling the amplifier.
ON OFF (Default)
+5V
Motor
ENABLE INPUT FAIL SAFE CONTROL Thermalswitch 10k
J2-9
Jumper JP1-B, on the signal board, controls the /Enable input /Motemp
level control resistor. The figure below shows the function, with 10k
S1 OFF and JP1-B on pins 1-2 as the default condition. The
/Enable input must be pulled LO to enable the amplifier, and if
the input is open (disconnected or wire broken) the amplifier
J2-15
turns off as the input is pulled-up to +5V. This is called fail-safe 33nF
because the amplifier must be connected, and the input GND
actively driven to ground to turn the amplifier ON, otherwise it’s Jumper required if no thermalswitch
OFF.
REFERENCE INPUTS
JP1-B SET FOR
123 123 DIP SW S1 The reference inputs are the command signals to the amplifier.
+5V OFF (Default) There are two differential reference inputs U Ref (+), U Ref (-)
ON and V Ref (+), V Ref (-) Use all four reference wires. Connect
U Ref (-) and V Ref (-) to control system ground. Connect U
10k
Ref (+) and V Ref (+) to control system’s separate ±10V
J3-5 10k outputs. This will reject noise between control system and
amplifier grounds. Use twisted-pair cable to minimize noise
/Enable pickup between amplifier and controller.
33nF

U V PHASE CURRENT ZERO ADJUSTMENT

BALANCE ADJUSTMENT RANGE
If an active HI fail-safe operation is desired, then turn S1 ON
and move JP1-B to pin 2-3. Now the input is pulled-down to Control of the balance adjustment range can be made via
ground if it is disconnected, and must be actively pulled-up to internal components RH16 and RH17 on the header socket.
>2.5V by the control system to enable the amplifier. The full-scale can be adjusted over a typical range of 500mA to
50mA. A good first approximation would be 5% of the motors
U V PHASE ANGLE continuous current rating. See below table, for selecting
resistor values for RH16 and RH17. The default values are
Jumper JP1-A, on the signal board, sets the UV phase to either indicated in bold.
120° or 90°. The default is 120°.
U V zero adjust full-scale RH16 & RH17
JP1-A Offset Rx (Ω)
123 full-scale mA
120 Degrees UV Phase (Default) 500 200k
90 Degrees UV Phase 400 250k
300 330k
200 475k
100 1M
50 2.2M
These values are within 10%, typically. For greater accuracy,
measure current monitor and select parts for exact full-scale
value.

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 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

ZERO ADJUSTMENT GAIN FINE ADJUSTMENT

The current OFFSET potentiometers are factory set to zero The REF GAIN potentiometers are factory set to give a
current with zero input. The sum of the three currents U, V and matched transconductance of 2Amps/Volt, with RH2, RH3,
W can be set to a high degree of resolution by using the RH7, and RH8, resistors open or out of circuit. The gain of both
current monitors. After connecting and tuning the motor, U and V channels can be fine-tuned to match. The range is
ground the U and V reference inputs, then adjust the offset about +/-5%. To fine adjust the transconductance, input a
potentiometer (see below table) while monitoring the reference voltage, such as 1VDC, to the U Ref (+) (J3-2) and V
appropriate current monitor U (J3-10) and V (J3-11) with Ref (+) (J3-3), Remembering to ground Ref (-) (J3-14, J3-15)
respect to Ground (J3-13). at the source. Then while monitoring the appropriate current
monitor, adjust the REF GAIN potentiometers to match.
If the U and V currents are correctly set to zero then the W
current will also be zero: Iw = - (Iu + Iv)
POT DEFAULT DESCRIPTION POT DEFAULT DESCRIPTION
U OFFSET Center U zero output U REF GAIN Center U Fine gain control
(R7 internal) current adjustment (R1) CW increases gain
V OFFSET Center V zero output V REF GAIN Center V Fine gain control
(R6 internal) current adjustment (R2) CW increases gain

CURRENT LIMIT
TRANSCONDUCTANCE ADJUSTMENT Control of the current limit can be made internally via
component RH18 in the header socket, or externally via
OVERALL GAIN connector pin J3-20. See figure below.
A resistor can be connected between this pin and signal
The current gain or transconductance is the ratio of output ground (J3-12, 13, or 16), or the pin can be driven by a voltage
current to input voltage. The transconductance should be set to between 0 and +5VDC. Using this technique, the current limit
provide a better use of the controllers output range, typically a can be controlled over a range of 100% to 50% of the peak
+/10V DAC. The gain can be set via RH2, RH3, RH7, and command current, set by the transconductance.
RH8, see below table. All resistor values must be the same.
Use 1% tolerance for good CMRR (common mode rejection +15V
ratio).
47k Phase
It is recommended that the transconductance be set to limit the J3-20 Symmetric
peak current delivered to the motor. Most applications require
Current
peak currents of two or three times the motors continuous Limiter
current rating. Example: For a typical +/-10V DAC and a Vext R
H
94k
Rpk
required 15 Amps peak, the transconductance should be set to 0~5VDC 18

15 Amps / 10 Volt = 1.5 Amps / Volt. J3-16

The Gain (Amps / Volt) = 2 * Rx Ω / (47kΩ + Rx Ω). Τhe default Amplifier

gain is 2A/V with RH2, RH3, RH7, and RH8, resistors open or
out of circuit. (Indicated in bold & italic in the table below).
Transconductance Rx = RH2,3,7 &, 8 CURRENT LIMIT (RH18)
Default values are in bold & italic.
Gain Rx (Ω)
I-limit RH18 Vext
Amps/Volt
2 OPEN 10 31.6k 5
1.5 140k 8 16.9k 3.5
1 47k 6 10.5k 2.5
0.5 15.6k 4 5k 1.4
2 1.3k 0.4
These values are within 10%, typically. For greater accuracy,
measure current monitor and select parts for exact limit value.

Copley Controls Corp, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547
E-mail: sales@copleycontrols.com, on the Internet at http://www.copleycontrols.com Page 9 of 12
 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

STATUS SIGNALS /NORMAL OUTPUT SIGNAL

CURRENT-LIMIT OUTPUT +5V
This is an output signal which is HI (+5V) when the amplifier is
not current limiting. As the current limiting starts to take effect
the /CLIMIT output will go LO (0V). 10k
J3-6
This is very useful for a closed loop control system that expects /NORMAL
the amplifier to be operating in a linear manner. Since, the
/CLIMIT line transitions LO on the first detection of current
limiting, the controller can be alerted to non-linear behavior +NORMAL
immediately.

+5V N-channel mosfet with 10k-ohm resistor connected to +5V.

Maximum voltage: 50VDC. Maximum current 250 mA.
10k
On-resistance = 5 ohms.
Output is LO (mosfet ON) whenever amplifier is enabled and
Current limiting J3-9 NORMAL (LED Green)
detection /CLIMIT Output is HI (mosfet OFF) whenever amplifier is NOT enabled,
or FAULT occurs.
J3-12
OPTO-ISOLATED NORMAL OUTPUT
Signal GND
SIGNAL
This AMP OK signal indicates that the amplifier ready to run. It
is completely optically isolated from the amplifier. The input of
the optocoupler is driven by the amplifier logic circuits, and the
LED INDICATOR FUNCTIONS output is a floating NPN transistor with both terminals brought
to signal connector J3 as shown below.
Color and state of LED indicates amplifier operating conditions
470 J3-19
LED COLOR CONDITION ACTION to ENABLE
+5V READY(+)
Flashing Green Ready (AMP OK) Activate /ENABLE
J3-7
Green Normal None
/NORMAL READY(-)
Red Fault Power, /MOTEMP (J2-9)

Flashing Red Latching Fault /Reset, Power OFF/ON

Maximum voltage = 32VDC. ON current = 4mA. minimum
Output transistor ON voltage: 0.4 at 4mA
Ready = Amp OK AND NOT enabled
Normal = Amp OK AND enabled
Amp OK = Internal buss voltage is within limits AND
NOT Fault

Fault = Over voltage, under voltage, or motor

overtemp.
Latching Fault = Output short circuit or heatplate
overtemperature. Amplifier ‘latches’ off and
stays off until reset.

Copley Controls Corp, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547
E-mail: sales@copleycontrols.com, on the Internet at http://www.copleycontrols.com Page 10 of 12
 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

INTERFACE DIAGRAM

Driver

STATUS
Terminal block
Model: 7425AC
Input: 32~264VAC
50/60Hz
U Ref (+)
Brushless Motor J1
V GAIN
U Ref (-)
U GAIN

H 1
AC

2 S1
ENA POL
N
V Ref (+)
3
25 13
+ 4
MOTOR BUSS

V Ref (-)
- 5 J3
SIGNAL
Phase U U 6
Phase V 1
V 7 4
1 /Enable
Phase W W 8
9 /Normal
Motor temp.
8
switch
15 Sig. GND
J2
Motor
Thermal 9
1
switch Westwood, MA, USA

/Motemp /Motemp

Sig. GND

Sig. GND
Encoder signals

PC Controller ( see below table )

DSP
D/A
D/A

CONTROLLERS
Here is a list of several controllers are available that perform sinusoidal commutation. These controllers use a DSP in conjunction with
double DAC analog outputs to perform multi-axis motion control. They are configured for several buss platforms such as ISA, PC104,
VME, and STD. For more information, about controllers, please contact the below manufacturers.

Manufacturer Model Description Web site

ACS-Tech80 5651A ISA bus card for to 4 Axis www.acs-tech80.com
ACS-Tech80 SPiiPlus Series Stand-alone controller www.acs-tech80.com
PMD DK 1231A-P Developers Kit for 2 Axis www.pmdcorp.com
Motion Engineering Inc. PCX DSP ISA bus card for to 4 Axis www.motioneng.com
Delta Tau PMAC1 ISA bus card for to 4 Axis www.deltatau.com
Galil DMC-1700 ISA bus card for to 4 Axis www.galilmc.com

Copley Controls Corp, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090 Fax: 781-828-6547
E-mail: sales@copleycontrols.com, on the Internet at http://www.copleycontrols.com Page 11 of 12
 MODELS 7225AC, 7425AC
LINE-POWERED AC BRUSHLESS SERVO AMPLIFIERS
WITH +/-10V ANALOG U-V INPUTS

OUTLINE DIMENSIONS
7.50
(190.5)

0.93 (23.62)

3.00 6.22
(76.2) (158) 6.94
(176.3)

7.00
(177.8)

2.72
1.46 (69.1)
(37.08) 4.72
(119.9)

Dimensions in inches (mm)

Weight 3.71 lbs. (1.69 kg) without optional heatsink. Add 3.2 lbs. (1.47 kg) for heatsink.

CONNECTORS J1: Power & motor 9-position terminal strip

J2: Halls / Options 15-position female Sub-D type. #4-40 standoffs for cable shell lock screws
J3: Signal 25-position female Sub-D type. #4-40 standoffs for cable shell lock screws
Connector shells are connected to amplifier chassis for grounding/shielding

ORDERING GUIDE
Model 7225AC 20A peak, 10A continuous, from 32~132VAC, 50/60Hz AC mains
Model 7425AC 20A peak, 10A continuous, from 32~264VAC, 50/60Hz AC mains
Notes:
1. Add "H" to model number to specify heatsink option.

OTHER ANALOG BRUSHLESS MOTOR AMPLIFIERS

Low-drift, ±10V U-V Command Inputs, 24~180 Vdc power sources
7225X1 10 Acont, 25 Apeak,
7225X1-50 15 Acont, 50 Apeak
7225X2 2-axis, 10 Acont, 25 Apeak

Corporate Office, USA

20 Dan Road
Canton, MA 02021
Tel: 781-828-8090
Fax: 781-828-6547

Technical support: sales@copleycontrols.com, or Internet Support: http://www.copleycontrols.com

Rev B 05/19/05
Page 12 of 12