Ndrive ML Hardware Manual

Transcription

1 Hardware Manual Revision: TM A3200 AEROTECH. COM TM A3200 AEROTECH. COM J20 J0 J0 FIREWIRE FIREWIRE J02 J02 ENA MRK CTL POS ENA MRK CTL POS 4 TB20 TB202 4 OPTO IN MOTOR FEEDBACK MOTOR FEEDBACK J03 J03 0 TB203 B+ RET B- MOTOR SUPPLY TB02 B+ RET B- MOTOR SUPPLY TB02 OPTO OUT A B C MOTOR OUTPUT A B C MOTOR OUTPUT 0 TB204 +/- 40VDC MAX 0AMP MAX +/- 40VDC MAX 0AMP MAX

2 Global Technical Support Go to for information and support about your Aerotech products. The website provides downloadable resources (such as up-to-date software, product manuals, and Help files), training schedules, and PC-to-PC remote technical support. You can also complete Product Return (RMA) forms and get information about repairs and spare or replacement parts. For immediate help, contact a service office or your sales representative. Have your customer order number available before you call or include it in your . Phone: Fax: service@aerotech.com United Kingdom Phone: +44 (0) Fax: +44 (0) service@aerotech.co.uk Germany Phone: +49 (0) Fax: +49 (0) service@aerotechgmbh.de France Phone: sales@aerotech.co.uk United States (World Headquarters) 0 Zeta Drive Pittsburgh, PA Japan Phone: +8 (0) Fax: +8 (0) service@aerotechkk.com.jp China Phone: +86 (2) saleschina@aerotech.com Taiwan Phone: +886 (0) service@aerotech.tw This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies. Copyright , Aerotech, Inc., All rights reserved.

3 Table of Contents Table of Contents Hardware Manual Table of Contents 3 List of Figures 5 List of Tables 7 EU Declaration of Conformity 9 Agency Approvals 0 Safety Procedures and Warnings Quick Installation Guide 3 Chapter : Introduction 5.. Drive and Software Compatibility 8.2. Electrical Specifications System Power Requirements Mechanical Design 2.4. Environmental Specifications 22 Chapter 2: Installation and Configuration Communication Channel Settings Power Connections Control Supply Connections (TB03) Motor Supply Connections (TB02) External Power Supply Options Motor Output Connections Brushless Motor Connections Powered Motor Phasing Unpowered Motor and Feedback Phasing DC Brush Motor Connections DC Brush Motor Phasing Stepper Motor Connections Stepper Motor Phasing Motor Feedback Connections (J03) Encoder Interface (J03) RS-422 Line Driver Encoder (Standard) Analog Encoder Interface Encoder Phasing Hall-Effect Interface (J03) Thermistor Interface (J03) Encoder Fault Interface (J03) End Of Travel Limit Input Interface (J03) End Of Travel Limit Phasing Brake Output (J03) Differential Analog Input 0 (J03) Emergency Stop Sense Input (TB0) Typical ESTOP Interface FireWire Interface PC Configuration and Operation Information 56 Chapter 3: -I/O Expansion Board User Power (TB20) Brake Power Supply (TB20) Solid State Relay Specifications (TB20) Analog Output (TB202) Differential Analog Input (TB202)

4 Table of Contents 3.5. Opto-Isolated Inputs (TB203) Opto-Isolated Outputs (TB204) Auxiliary Encoder Channel/PSO Output (J20) Position Synchronized Output (PSO)/Laser Firing (J20) 73 Chapter 4: Standard Interconnection Cables Joystick Interface Handwheel Interface 78 Chapter 5: Maintenance Preventative Maintenance 80 Appendix A: Warranty and Field Service 8 Appendix B: Revision History 83 Index

5 Table of Contents List of Figures Figure -: Networked Digital Drive 5 Figure -2: Functional Diagram 7 Figure -3: Dimensions 2 Figure 2-: Control Supply Connections 25 Figure 2-2: Motor Bus Input Connections 26 Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 28 Figure 2-4: PS-ML Option 29 Figure 2-5: Brushless Motor Configuration 3 Figure 2-6: Encoder and Hall Signal Diagnostics 32 Figure 2-7: Motor Phasing Oscilloscope Example 33 Figure 2-8: Brushless Motor Phasing Goal 33 Figure 2-9: DC Brush Motor Configuration 34 Figure 2-0: Clockwise Motor Rotation 35 Figure 2-: Stepper Motor Configuration 36 Figure 2-2: Clockwise Motor Rotation 37 Figure 2-3: Line Driver Encoder Interface (J03) 40 Figure 2-4: Analog Encoder Phasing Reference Diagram 4 Figure 2-5: Analog Encoder Interface (J03) 42 Figure 2-6: Encoder Phasing Reference Diagram (Standard) 43 Figure 2-7: Position Feedback in the Diagnostic Display 44 Figure 2-8: Hall-Effect Inputs (J03) 45 Figure 2-9: Thermistor Interface Input (J03) 46 Figure 2-20: Encoder Fault Interface Input (J03) 47 Figure 2-2: End of Travel Limit Input Connections 48 Figure 2-22: End of Travel Limit Interface Input (J03) 49 Figure 2-23: Limit Input Diagnostic Display 50 Figure 2-24: Analog Input 0 (J03) 52 Figure 2-25: ESTOP Sense Input (TB0) 53 Figure 2-26: Typical Emergency Stop Circuit 54 Figure 3-: with -IO Option Board 57 Figure 3-2: Brake Connected to J03 60 Figure 3-3: Brake Connected to TB20 6 Figure 3-4: Analog Output (TB202) 63 Figure 3-5: Analog Input Typical Connection (TB202) 64 Figure 3-6: Opto-Isolated Inputs 66 Figure 3-7: Inputs Connected to a Current Sourcing Device 67 Figure 3-8: Inputs Connected to a Current Sinking Device 67 Figure 3-9: Opto-Isolated Outputs (-IO Board) 69 Figure 3-0: Outputs Connected in Current Sourcing Mode 70 Figure 3-: Outputs Connected in Current Sinking Mode 70 Figure 3-2: Auxiliary Encoder Channel (J20) 72 Figure 3-3: PSO Interface 74 Figure 4-: Single Axis Joystick Interface 76 Figure 4-2: Two Axis Joystick Interface 77 Figure 4-3: Handwheel Interconnection (to Aux I/O)

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7 Table of Contents List of Tables Table -: Feature Summary 6 Table -2: Accessories 6 Table -3: Drive and Software Compatibility 8 Table -4: Electrical Specifications 9 Table -5: Physical Specifications 2 Table 2-: Device Number Switch Settings (S) 23 Table 2-2: Control Supply DC Input Wiring 25 Table 2-3: Control Supply Mating Connector 25 Table 2-4: Motor Supply Mating Connector 26 Table 2-5: External Power Supply Options 27 Table 2-6: PS-ML AC Power Wiring Requirements 27 Table 2-7: Motor Power Output Connections (TB02) 30 Table 2-8: Motor Power Output Mating Connector 30 Table 2-9: Wire Colors for Aerotech Supplied Cables (Brushless) 3 Table 2-0: Wire Colors for Aerotech Supplied Cables (DC Brush) 34 Table 2-: Wire Colors for Aerotech Supplied Cables (Stepper) 36 Table 2-2: Motor Feedback Connector Pin Assignment (J03) 38 Table 2-3: Encoder Interface Pin Assignment 39 Table 2-4: Encoder Specifications 40 Table 2-5: Analog Encoder Specifications 4 Table 2-6: Hall-Effect Feedback Interface Pin Assignment (J03) 45 Table 2-7: Thermistor Interface Pin Assignment (J03) 46 Table 2-8: Encoder Fault Interface Pin Assignment (J03) 47 Table 2-9: End of Travel Limit Input Interface Pin Assignment (J03) 48 Table 2-20: Brake Output Pin Assignment (J03) 5 Table 2-2: Differential Analog Input 0 Specifications 52 Table 2-22: Differential Analog Input Pin Assignment (J03) 52 Table 2-23: Electrical Noise Suppression Devices 53 Table 2-24: TB0 Mating Connector 53 Table 2-25: Typical ESTOP Relay Ratings 54 Table 2-26: FireWire Card Part Numbers 55 Table 2-27: FireWire Repeaters (for cables exceeding 4.5 m (5 ft) specification) 55 Table 2-28: FireWire Cables (copper and glass fiber) 55 Table 3-: User Common Connector Pin Assignment (TB20) 58 Table 3-2: Brake Output Connector Pin Assignment (TB20) 59 Table 3-3: Mating Connector (TB20) 59 Table 3-4: Brake Output Connector Pin Assignment (J03) 59 Table 3-5: Relay Specifications 62 Table 3-6: Analog Output Specifications (TB02 B) 63 Table 3-7: Analog Output Connector Pin Assignment (TB202) 63 Table 3-8: TB202 Mating Connector 63 Table 3-9: Differential Analog Input Specifications 64 Table 3-0: Differential Analog Input Pin Assignment (TB202) 64 Table 3-: TB202 Mating Connector 64 Table 3-2: Opto-Isolated Input Specifications 65 Table 3-3: Opto-Isolated Input Connector Pin Assignment (TB203) 65 Table 3-4: Opto-Isolated Input Mating Connector 65 Table 3-5: Output Specifications (TB204) 68 Table 3-6: Opto-Isolated Output Connector Pin Assignment TB204) 68 Table 3-7: Opto-Isolated Output Mating Connector 68 Table 3-8: Auxiliary Encoder Specifications 7 7

8 Table of Contents Table 3-9: Auxiliary Encoder Channel Pin Assignment (J20) 7 Table 3-20: PSO Specifications 73 Table 3-2: PSO Output Pin Assignment (J20) 73 Table 4-: Standard Interconnection Cables 75 Table 4-2: Joystick Cable Part Numbers 77 Table 5-: LED Description 79 Table 5-2: Preventative Maintenance

9 Declaration of Conformity EU Declaration of Conformity Manufacturer Address Product Model/Types Aerotech, Inc. 0 Zeta Drive Pittsburgh, PA USA All This is to certify that the aforementioned product is in accordance with the applicable requirements of the following Directive(s): 204/35/EU 20/65/EU Low Voltage Directive LVD RoHS 2 Directive and has been designed to be in conformity with the applicable requirements of the following documents when installed and used in accordance with the manufacturer s supplied installation instructions. EN 600-:200 Safety requirements for electrical equipment Name Position Location / Alex Weibel Engineer Verifying Compliance Pittsburgh, PA 9

10 Declaration of Conformity Agency Approvals Aerotech, Inc. Model Series Linear Drives have been tested and found to be in accordance to the following listed Agency Approvals: Approval / Certification: CUS NRTL Approving Agency: TUV SUD America Inc. Certificate #: U Standards: UL 600-:202; CAN/CSA-C22.2 No. 600-:202; EN 600- :

11 Electrical Safety Safety Procedures and Warnings The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure to observe these precautions could result in serious injury to those individuals performing the procedures and/or damage to the equipment. N O T E : Read this manual in its entirety before installing, operating, or servicing this product. If you do not understand the information contained herein, contact an Aerotech representative before proceeding. Strictly adhere to the statements given in this section and other handling, use, and operational information given throughout the manual to avoid injury to you and damage to the equipment. N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any time. All drawings and illustrations are for reference only and were complete and accurate as of this manual s release. Refer to for the most up-to-date information. D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of electrical shock, bodily injury, or death the following precautions must be followed.. Disconnect electrical power before servicing equipment. 2. Disconnect electrical power before performing any wiring. 3. Access to the and component parts must be restricted while connected to a power source. 4. To minimize the possibility of electrical shock and bodily injury, extreme care must be exercised when any electrical circuits are in use. Suitable precautions and protection must be provided to warn and prevent persons from making contact with live circuits. 5. Install the inside a rack or enclosure. 6. Do not connect or disconnect any electrical components or connecting cables while connected to a power source. 7. All components must be properly grounded in accordance with local electrical safety requirements. 8. Operator safeguarding requirements must be addressed during final integration of the product. D A N G E R : The case temperature may exceed 70 C in some applications.

12 Electrical Safety W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the following precautions must be followed.. Use of this equipment in ways other than described by this manual can cause personal injury or equipment damage. 2. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts must be restricted while connected to a power source. 3. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid potential hazards. 4. Do not expose this product to environments or conditions outside of the listed specifications. Exceeding environmental or operating specifications can cause damage to the equipment. 5. If the product is used in a manner not specified by the manufacturer, the protection provided by the product can be impaired and result in damage, shock, injury, or death. 6. Operators must be trained before operating this equipment. 7. All service and maintenance must be performed by qualified personnel. 8. This product is intended for light industrial manufacturing or laboratory use. Use of this product for unintended applications can result in injury and damage to the equipment. 2

13 Quick Installation Guide Quick Installation Guide This chapter describes the order in which connections and settings should typically be made to the Ndrive ML. If a custom interconnection drawing was created for your system (look for a line item on your Sales Order under the heading Integration ), that drawing can be found on your installation device. 3 TM A3200 J0 J02 AEROTECH. COM J20 FIREWIRE DEVICE NUMBER TB0 ESTOP S VDC 0.7 AMP MAX DC- DC+ TB03 CONTROL SUPPLY 5 ENA MRK CTL POS 4 TB20 TB202 S/N - P/N - ON 2 MOTOR FEEDBACK J03 4 OPTO IN 0 WARNING: DISCONNECT POWER BEFORE SERVICING SEE MANUAL FOR SWITCH SETTINGS DANGER! High Voltage TB B+ RET B- A B C MOTOR SUPPLY TB02 +/- 40VDC MAX 0AMP MAX MOTOR OUTPUT OPTO OUT 0 TB Set the Communication Channel Device Number (S). Connect the Motor Output (TB02) and Motor Feedback (J03). Connect to the FireWire (J0, J02). Connect any additional I/O as required (not shown). Connect to the Control Supply (TB03). Connect to the Motor Supply (TB02). Note: Connect to ESTOP (TB0) in this step if applicable. Figure : Quick Start Connections Topic Device Number Motor Output Motor Feedback FireWire Control Supply Motor Supply Additional I/O Section Section 2.. Communication Channel Settings Section 2.3. Motor Output Connections Section 2.4. Motor Feedback Connections (J03) Section 2.6. FireWire Interface Section Control Supply Connections (TB03) Section Motor Supply Connections (TB02) User / Application dependent 3

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15 Introduction Chapter : Introduction Aerotech s (Ultra-Compact "Micro" Linear) network digital drive is a high performance linear amplifier designed to eliminate the nonlinearities common with PWM amplifiers. The drive provides deterministic behavior, auto-identification, and easy software setup. The s high performance double precision floating point DSP controls the digital PID and current loops. All system configuration is done using software-settable parameters, including control loop gains and system safety functions. The is offered with an optional encoder interpolation feature (-MXH or -MXU), an auxiliary square wave encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -IO option), and separate power connections for motor and control supply voltages. TM A3200 AEROTECH. COM J20 J0 TB0 ESTOP 8-36 VDC 0.7 AMP MAX DC- DC+ TB03 CONTROL SUPPLY J02 FIREWIRE DEVICE NUMBER S ENA MRK MOTOR FEEDBACK J03 CTL POS 4 4 OPTO IN 0 TB20 TB202 TB203 S/N - P/N - ON WARNING: DISCONNECT POWER BEFORE SERVICING SEE MANUAL FOR SWITCH SETTINGS DANGER! High Voltage 630D2239- B+ RET B- A B C +/- 40VDC MAX 0AMP MAX MOTOR SUPPLY MOTOR TB02 OUTPUT OPTO OUT 0 TB204 Standard Connector Description -IO Board Option Connector Description J0 FireWire Port J20 Secondary Encoder J02 FireWire Port Interface J03 Motor Feedback TB20 Brake Relay TB0 Emergency Stop TB202 Analog I/O Sense Input (ESTOP) TB203 Opto-Inputs TB02 Motor Supply TB204 Opto-Outputs TB02 Motor Output TB03 Control Supply Output Figure -: Networked Digital Drive Chapter 5

16 Introduction Table -: Standard Features Feature Summary Line driver square wave quadrature encoder input for position and velocity feedback One 6-bit differential analog input (±0 V) Dedicated 5-24 V Emergency Stop sense input ±40 VDC motor supply inputs (0 A max) 8-36 VDC control supply inputs (700 ma max) Options -IO One 6-bit analog output (±5 V) One 6-bit differential analog input One fail-safe brake or user relay output -MXH or -MXU Table -2: Accessories 8 optically isolated logic inputs (5-24 VDC), may be connected in current sourcing or sinking mode 8 optically isolated logic outputs (5-24 VDC), user defined as current sourcing or sinking Interpolation circuit allowing for analog sine wave input on the standard encoder channel. Interpolation factor: 4,096 (for the -MXU option), 65,536 (for the -MXH option) Accessories JI Industrial Joystick (NEMA2 (IP54) rated); refer to Section 4.. PS24-24 VDC, A power supply for optional brake/relay output BRAKE VDC, 2 A power supply for optional brake Cables Interconnection A complete list of Aerotech cables can be found on the website at Joystick/Handwheel Refer to Section 4.. or Section 4.2. FireWire Refer to Section Chapter

17 Introduction The following block diagram shows a connection summary. For detailed connection information, refer to Chapter 2 and Chapter 3. -IO Option J0 J02 FireWire Port FireWire Port Encoder +5V / Common PSO Output, Encoder Echo SIN, COS, MRK (RS422) J20 Secondary Encoder Interface Analog Input +/- Analog Output TB202 TB0 ESTOP Emergency Stop Sense Input J03 Motor Feedback -MXH or -MXU Option SIN, COS, MRK (RS422) CW, CCW, Home Limits; Encoder Fault; Hall A, B, C; Motor Over Temperature Brake ± (with the -IO Option) Encoder +5V / Common Analog Input 0 +/- 8 Opto Outputs (Sinking or Sourcing) 8 Opto Inputs (Sinking or Sourcing) TB204 Opto Out TB203 Opto In TB03 Control Supply DC+ DC- DC- DC+ Isolated Power Supply Brake Power Input TB20 Brake Relay TB02 Motor Supply B+ RET B- B+ RET B- Heatsink Over Temperature Linear Power Amplifier A B C A B C TB02 Motor Output Figure -2: Functional Diagram Chapter 7

18 Introduction.. Drive and Software Compatibility The following table lists the available drives and which version of the software first supported the drive. Drives that list a specific version number in the Last Software Version column will not be supported after the listed version. Table -3: Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version HEX RC Current Ndrive CL A Ndrive CP A 2.0 Current B 2.9 Current Ndrive FLS Current Ndrive FLS A Current Ndrive HL Ndrive HLe Current Ndrive HP A Ndrive HPe Current Current Ndrive MP Current Ndrive QL and QLe Current Nmark CLS Current A Current Nmark GCL Current Nmark SSaM Current A Current Npaq A 2.09 Current Npaq MR with ML drives Current Npaq MR with MP drives Current Nservo Current Nstep Current 8 Chapter

19 Introduction.2. Electrical Specifications The safe operating range is load dependent. Table -4: Electrical Specifications Description ML 0 Input Voltage ±40 VDC (max) Input Current Motor Supply (continuous) 5 A Input Current (peak) 0 A Input Current Refer to Section.2.. System Power Requirements Control Supply Input Voltage 24 VDC typical (8-36 VDC) Input Current 700 ma (max) Output Voltage () 0 A Peak Output Current (2) 0 Continuous Output Current (2) 5 Power Amplifier Bandwidth Minimum Load Resistance Output Impedance User Power Supply Output Modes of Operation Protective Features Isolation 2500 Hz maximum (software selectable) 0.5 Ω 0.2 Ω (each phase) 5 VDC (@ 500 ma) Brushless; Brush; Stepper Peak current limit; Over temperature; RMS current limit; Dynamic power dissipation limit Isolation between control and power stages.. Load Dependent 2. Peak and continuous output current is load dependent (the amplifier will limit its output current based on motor speed and motor resistance). Chapter 9

20 Introduction.2.. System Power Requirements The following equations can be used to determine total system power requirements. The actual power required from the mains supply will be the combination of actual motor power (work), motor resistance losses, and efficiency losses in the power electronics or power transformer. An EfficiencyFactor of approximately 50% should be used in the following equations. Linear Motor Pdiss[W] = MotorCurrentPeak[A] * TotalBusVoltage[V] * 3 / 2 Pin = SUM ( Pdiss ) / EfficiencyFactor 20 Chapter

21 TM Introduction.3. Mechanical Design Install the unit into a construction compliant for unlimited circuits enclosure. Each unit should be separated from other drives and surrounded by 25 mm (") of free air space. A space of 00 mm (4") should be allowed along the front of the unit for cable connections. 4.5 [0.8] 3.4 [5.7] 5. [0.20] 8.3 [0.33] 630D [3.63] B+ A3200 J0 J02 MOTOR FEEDBACK RET B- A B C ENA MRK J03 4. [.62] 25.4 [.00] 8. [0.32] FIREWIRE MOTOR SUPPLY TB02 +/- 40VDC MAX 0AMP MAX MOTOR OUTPUT AEROTECH. COM CTL POS 4.0 [0.6] (TYP.) 4 4 OPTO IN 0 OPTO OUT 0 J20 TB20 TB202 TB203 TB204 REC. MTG. HDWR: M3.5 [#6] 49.2 [5.88] 57.5 [6.20] 4. [0.6] 07.0 [4.2] 2.4 [4.78] 2.5 [0.0] DIMENSIONS: MM [INCH] Dimensions apply to the standard and I/O version (shown) of the ML drive. Figure -3: Dimensions Table -5: Physical Specifications Model Weight Standard.9 kg (2 lb) w/ -IO option.99 kg (2.2 lb) w/ -MXH option.99 kg (2.2 lb) Chapter 2

22 Introduction.4. Environmental Specifications The environmental specifications for the are listed below. Ambient Temperature Operating: 0 to 50 C (32 to 22 F) Storage: -30 to 85 C (-22 to 85 F) Humidity Maximum relative humidity is 80% for temperatures up to 3 C. Decreasing linearly to 50% relative humidity at 40 C. Non condensing. Altitude Up to 2000 meters. Pollution Pollution degree 2 (normally only non-conductive pollution). Use Indoor use only. 22 Chapter

23 Installation and Configuration Chapter 2: Installation and Configuration 2.. Communication Channel Settings Use the Device Number switches to assign a communication channel number to the. If you are using multiple drives, each drive must be assigned a unique communication channel. Multiple drives are typically configured using sequential communication channels. N OT E : The drive assigned to the first communication channel number (all switches set to ON) will be configured by the Axis parameters defined in the software. The drive assigned to the second communication channel will be configured by the Axis 2 parameters, etc. Table 2-: Device Number Switch Settings (S) Device # Switch Settings (Off is indicated by "-") ON ON ON ON ON ON 2 ON ON ON ON ON - 3 ON ON ON ON - ON 4 ON ON ON ON ON ON ON - ON ON 6 ON ON ON - ON - 7 ON ON ON - - ON 8 ON ON ON ON ON - ON ON ON 0 ON ON - ON ON - ON ON - ON - ON 2 ON ON - ON ON ON - - ON ON 4 ON ON - - ON - 5 ON ON ON 6 ON ON ON - ON ON ON ON 8 ON - ON ON ON - 9 ON - ON ON - ON 20 ON - ON ON ON - ON - ON ON 22 ON - ON - ON - 23 ON - ON - - ON 24 ON - ON ON - - ON ON ON 26 ON - - ON ON - 27 ON - - ON - ON 28 ON - - ON ON ON ON 30 ON ON - 3 ON ON 32 ON Switch Location DEVICE ON NUMBER S/N - P/N - S WARNING: DISCONNECT POWER BEFORE SERVICING SEE MANUAL FOR SWITCH SETTINGS DANGER! High Voltage 0 DEVICE NUMBER TB0 ESTOP S ON Chapter 2 23

24 Installation and Configuration 2.2. Power Connections The has two DC input connectors; one for control power and a second for motor power. For a complete list of electrical specifications, refer to Section.2. N O T E : The machine integrator, OEM or end user is responsible for meeting the final protective grounding requirements of the system. W A R N I N G : All service and maintenance must be performed by qualified personnel. D A N G E R : Hazardous Voltages are present on systems. D A N G E R : and PS-ML systems must be installed inside a rack or enclosure to restrict access while energized. D A N G E R : To minimize the possibility of bodily injury or death, disconnect all electrical power prior to performing any maintenance or making adjustments to the equipment. 24 Chapter 2

25 Installation and Configuration Control Supply Connections (TB03) N O T E : This product requires two power supply connections. The Motor Supply and Control Supply must both be connected for proper operation. The control power supply input allows the to maintain communications if the motor power is removed, such as in an Emergency Stop condition. The DC+ input is internally fused. A small ferrite filter may be required to minimize radiated emissions. This should be located close to the. Core Ferrite (EIZ00286, Ferroxcube #TX22/4/6.4-3C8) DC+ Twist wires to reduce interference. DC+ DC- DC- Ground Table 2-2: 8-36 VDC 0.7 AMP MAX Figure 2-: Control Supply DC Input Wiring At Control inputs of each ML drive, wrap DC+ and DC- wires around a Ferrite Core (EIZ00286) 6 turns. Do not wrap the ground wire. Control Supply Connections Pin Description Recommended Wire Size DC+ 24 VDC (8-36 VDC) Control Power Input (700 ma max) 0.5 mm 2 (#20 AWG) DC- Control Power Common Input () 0.5 mm 2 (#20 AWG) Protective Ground (Required for Safety). For an isolated DC supply, connect DC- to protective ground at the supply. Table 2-3: Control Supply Mating Connector 0.5 mm 2 (#20 AWG) Tightening Wire Size: Description Aerotech P/N Phoenix P/N Torque (Nm) AWG [mm 2 ] 3-Pin Terminal Block ECK [ ] Chapter 2 25

26 Installation and Configuration Motor Supply Connections (TB02) N O T E : This product requires two power supply connections. The Motor Supply and Control Supply must both be connected for proper operation. Motor power is applied to the Motor Supply connector (refer to Figure 2-2 for locations). Wires must be properly matched to the fuses or circuit breakers and must be sized to meet local electrical safety codes. W A R N I N G : Do not operate the without the safety ground connection in place. B+ RET B- A B C MOTOR SUPPLY TB02 MOTOR OUTPUT B+ RET B- Ground +/- 40VDC MAX 0AMP MAX Figure 2-2: Motor Bus Input Connections Table 2-4: Motor Supply Mating Connector Tightening Wire Size () : Description Aerotech P/N Phoenix P/N Torque (Nm) AWG [mm 2 ] 8-Pin Terminal Block ECK [4-30]. Recommended Wire Size: 0.5 mm2 (#20 AWG) 26 Chapter 2

27 Installation and Configuration External Power Supply Options Two VDC power options are available to power up to four MLs. Table 2-5: External Power Supply Options Description TM3 () Power up to 4 drives, providing 300 watts of power (refer to Figure 2-3). PS-ML Din-rail mounted DC power supply for up to 2 axes (refer to Figure 2-4). The din-rail mounting clip requires 6-32 x 5/6 flat head screws to attach the ML to the din-rail clip.. Refer to the TM3 Users Manual, EDO7, for more information. An example of a wiring drawing for a typical PS-ML system showing the power inputs, as well as wiring for the optional fail-safe brake, is provided in Figure 2-4. The AC operating voltage of the PS-ML system can be configured for different operating voltages. The example system shown in Figure 2-4 is configured for 5 VAC. Purchased PS-ML systems are configured at the factory according to the users order request. System wiring and operating voltage information can be found on the System Wiring Drawing that is provided with the unit. The machine integrator, OEM, or end user is responsible for providing two fused or circuit breaker protected AC power connections and a Protective Ground connection to the system (see the table below for specifications). Table 2-6: PS-ML AC Power Wiring Requirements Connection Description Wire Size (minimum) AC AC Power.3 mm 2 (#6 AWG) 300 V wire AC2 AC Power.3 mm 2 (#6 AWG) 300 V wire GND Protective Ground (required for safety).3 mm 2 (#6 AWG) 300 V wire User must provide 0 A, 250 VAC fuse(s) or circuit breaker(s) to protect AC inputs Chapter 2 27

28 Installation and Configuration TM3 TRANSFORMER MODULE TB3 TB MOTOR SUPPLY TB02 B+ RET B- MAIN SUPPLY RET RET MAIN SUPPLY B+ RET B- MOTOR SUPPLY TB02 CONTROL SUPPLY TB03 DC+ DC- st ML P G M CONTROL SUPPLY CONTROL SUPPLY M P G DC+ DC- CONTROL SUPPLY TB03 3rd ML TB4 TB2 MOTOR SUPPLY TB02 B+ RET B- MAIN SUPPLY RET RET MAIN SUPPLY B+ RET B- MOTOR SUPPLY TB02 CONTROL SUPPLY TB03 DC+ DC- 2nd ML P G M CONTROL SUPPLY VDC A MAX CONTROL SUPPLY Transformer Module AEROTECH.COM - M P P G M DC+ G DC- CONTROL SUPPLY TB03 4th ML DANGER! High Voltage ON O OFF + - User-Provided 24 VDC 3 Amps (700 ma / Axis) HAZARDOUS VOLTAGES PRESENT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES.. The TM3 must be configured for a bipolar bus (-40B, -30B, -20B, or -0B). The TM3 depicted is labeled for -40B. 2. Transformer Wiring: 0.5 mm 2 (#20 AWG) 300 V wire. Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 28 Chapter 2

29 A B C 4 4 A B C 4 4 Installation and Configuration BRN BLU GRN/YEL The Din Rail clip kit must be installed prior to mounting rail. Use 6-32 x 5/6 flat head screws to mount the ML to the Din Rail clip. 9 User must provide 0 A, 250 VAC fuse(s) or Circuit Breaker(s) to protect AC Inputs Install A fuse (EIF000) into fuse block and spare fuse holder. GND Protective Ground (required for Safety).3 mm 2 (#6 AWG) 300 V Wire 4 System wiring shown with a neutral line configuration. If applied 8 A.C. does not contain a neutral, neutral line "N" must be properly fused by the user. AC2 AC Power.3 mm 2 (#6 AWG) 300 V Wire AC AC Power.3 mm 2 (#6 AWG) 300 V Wire 3 Din Rail should be cut such that one complete mounting hole extends beyond components on each end. Pin Description Wire Size (minimum) 7 Optional brake wiring shown on axis 2. AC INPUT REQUIREMENTS All twisted wires must be twisted at least 2 turns/inch. For 3- or 4-axes, a second PS-ML assembly will be required. 6 Only BLK and BLK/WHT wires through core assemblies. 334 [3.2] 45 [7.8] -Axis 2-Axis 2 DIMENSIONS - Millimeters [Inches] 4.5 in Cable Tie (EIZ0000) Control and Brake Power Supply Specifications 5 AC Input is fused internally Power factor correction Din Rail mountable (35 mm) RoHS Compliant Can be connected in series for increased voltage Power supply style and size may vary (this version shown for reference only). Approximately 6 In. Wrap wire 6 turns Din Rail Mounting To properly secure Din Rail to mounting surface: a) Remove components b) Use #0-32 screws spaced every 6 inches c) Re-install components Core Ferrite (EIZ00286, Ferroxcube #TX22/4/6.4-3C8) At Control inputs of each drive, wrap DC+ and DC- wires around 0 a Ferrite Core (EIZ00286) 6 turns. Do not wrap the ground wire. NOTES: Drawing Number: 620D4 Rev. B #20 GRN/YEL #6 GRN/YEL #6 BLU #6 BRN TB03 TB03 #6 GRN/YEL #6 BLU #6 BRN #22 BLK DC- DC+ DC+ #22 BLK DC- DC+ #22 GRN DC- DC+ DC- #22 GRN 6 6 +/- 40VDC MAX 0AMP MAX +/- 40VDC MAX 0AMP MAX MOTOR OUTPUT TB204 TB204 N L N L 0 MOTOR OUTPUT 0 9 TB02 BUILT TO DWG: 620D4 REV. x OPTO OUT TB02 OPTO OUT B+ RET B- MOTOR SUPPLY B+ RET B- MOTOR SUPPLY SYSTEM SERIAL NO: XXXXX -X-X-X MODEL: PS-ML/XXXXX/XXXXX /XXXXX J TB203 TB203 0 J03 5VAC 5VAC MOTOR FEEDBACK OPTO IN MOTOR FEEDBACK OPTO IN 230VAC 230VAC POWER SUPPLY INPUT = ~VAC OUTPUT = 24VDC, 5A (ECZ0443) POWER SUPPLY INPUT = ~VAC OUTPUT = 24VDC, 5A (ECZ0443) TB20 TB202 TB20 TB202 ENA MRK CTL POS ENA MRK CTL POS J02 J02 -V -V +V +V DC OK -V -V +V +V DC OK #20 GRN/YEL FIREWIRE 6 FIREWIRE J0 J0 J20 J20 TM A3200 AEROTECH. COM TM A3200 AEROTECH. COM #6 GRN/YEL #6 GRN #22 GRN #22 BLK 6 AXIS AXIS 2 #20 WHT #20 BLK #20 GRN #20 WHT 6 #20 WHT #20 BLK #20 GRN #20 WHT L N AC INPUT WIRING 6 #22 BLK #22 GRN #22 BLK Figure 2-4: PS-ML Option Chapter 2 29

30 Installation and Configuration 2.3. Motor Output Connections The is capable of controlling three motor types: Brushless (see Section 2.3..) DC Brush (see Section ) Stepper (see Section ) For a complete list of electrical specifications, refer to Section.2. Table 2-7: Motor Power Output Connections (TB02) Pin Description Recommended Wire Size ØA Phase A Motor Lead 0.5 mm 2 (#20 AWG) ØB Phase B Motor Lead 0.5 mm 2 (#20 AWG) ØC Phase C Motor Lead 0.5 mm 2 (#20 AWG) Earth Ground to Motor (required for safety) 0.5 mm 2 (#20 AWG) Table 2-8: Motor Power Output Mating Connector Tightening Wire Size () : Description Aerotech P/N Phoenix P/N Torque (Nm) AWG [mm 2 ] 8-Pin Terminal Block ECK [4-30]. Recommended Wire Size: 0.5 mm2 (#20 AWG) 30 Chapter 2

31 Installation and Configuration Brushless Motor Connections The configuration shown in Figure 2-5 is an example of a typical brushless motor connection. B+ RET B- A B C MOTOR SUPPLY TB02 +/- 40VDC MAX 0AMP MAX MOTOR OUTPUT Green/Yellow & Shield Black Red White Motor Frame AC Brushless Motor NOTE: Listed wire colors are for Aerotech-supplied cables. Figure 2-5: Brushless Motor Configuration Table 2-9: Wire Colors for Aerotech Supplied Cables (Brushless) Pin Wire Color Set () Wire Color Set 2 Wire Color Set 3 Wire Color Set 4 Green/Yellow & Shield (2) Green/Yellow & Shield Green/Yellow & Shield Green/Yellow & Shield A Black Blue & Yellow Black # Black & Brown B Red Red & Orange Black #2 Red & Orange C White White & Brown Black #3 Violet & Blue. Wire Color Set # is the typical Aerotech wire set used by Aerotech. 2. & (Red & Orange) indicates two wires; / (Green/White) indicates a single wire Brushless motors are commutated electronically by the controller, typically using Hall-effect devices. If you are using standard Aerotech motors and cables, motor phasing adjustments are not required and this section may be skipped. The controller requires that the Back-EMF of each motor phase be aligned with the corresponding Hall-effect signal. To ensure proper alignment, motor, Hall, and encoder connections should be verified using one of the following methods: powered, through the use of a test program; or unpowered using an oscilloscope. Both methods will identify the A, B, and C Hall/motor lead sets and indicate the correct connections to the controller. Refer to Section for powered motor phasing or Section for unpowered motor and feedback phasing. Chapter 2 3

32 Installation and Configuration Powered Motor Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor, Hall, and encoder phasing. Feedback Monitoring The state of the encoder and Hall-effect device signals can be observed in the Status Utility. An L for the given Hall input indicates zero voltage or logic low, where a H indicates 5V or logic high. Figure 2-6: Encoder and Hall Signal Diagnostics 32 Chapter 2

33 Installation and Configuration Unpowered Motor and Feedback Phasing Disconnect the motor from the controller and connect the motor in the test configuration shown in Figure 2-7. This method will require a two-channel oscilloscope, a 5V power supply, and six resistors (0,000 ohm, /4 watt). All measurements should be made with the probe common of each channel of the oscilloscope connected to a neutral reference test point (TP4, shown in Figure 2-7). Wave forms are shown while moving the motor in the positive direction. CHANNEL CHANNEL 2 Figure 2-7: TP TP2 TP3 TP4 Power Supply COM +5V TP5 TP6 TP7 0K OHM TYP "Wye" Configuration 0K OHM TYP Motor Lead = ØB Motor Lead 2 = ØC Motor Lead 3 = ØA COM +5V Hall Hall 2 Hall 3 Motor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined, the motor can now be connected to an Aerotech system. Connect motor lead A to motor connector A, motor lead B to motor connector B, and motor lead C to motor connector C. Hall leads should also be connected to their respective feedback connector pins (Hall A lead to the Hall A feedback pin, Hall B to Hall B, and Hall C to Hall C). The motor is correctly phased when the Hall states align with the Back EMF as shown in (Figure 2-8). Use the CommutationOffset parameter to correct for Hall signal misalignment Hall A Hall B +5V 0V Hall C ØC ØB ØA ØC ØB +V Motor Back EMF 0V -V Figure 2-8: Brushless Motor Phasing Goal Chapter 2 33

34 Installation and Configuration DC Brush Motor Connections The configuration shown in Figure 2-9 is an example of a typical DC brush motor connection. Refer to Section for information on motor phasing. B+ RET B- A B C MOTOR SUPPLY TB02 +/- 40VDC MAX 0AMP MAX MOTOR OUTPUT no connection Green & White & Shield Red & Orange Yellow & Blue Motor Frame + DC Brush - Motor NOTE: Listed wire colors are for Aerotech supplied cables. Figure 2-9: DC Brush Motor Configuration Table 2-0: Wire Colors for Aerotech Supplied Cables (DC Brush) Pin Wire Color Set () Wire Color Set 2 Wire Color Set 3 Green & White & Shield (2) Green/Yellow & Shield Green/Yellow & Shield A Red & Orange Red Red & Orange C Yellow & Blue Black Yellow & Blue. Wire Color Set # is the typical Aerotech wire set used by Aerotech. 2. & (Red & Orange) indicates two wires; / (Green/White) indicates a single wire 34 Chapter 2

35 Installation and Configuration DC Brush Motor Phasing A properly phased motor means that the positive motor lead should be connected to the ØA motor terminal and the negative motor lead should be connected to the ØC motor terminal. To determine if the motor is properly phased, connect a voltmeter to the motor leads of an un-powered motor:. Connect the positive lead of the voltmeter to the one of the motor terminals. 2. Connect the negative lead of the voltmeter to the other motor terminal. 3. Rotate the motor clockwise by hand. ROTARY MOTOR Motor Mounting Flange (Front View) Motor Shaft Figure 2-0: POSITIVE MOTION Clockwise Motor Rotation 4. If the voltmeter indicates a negative value, swap the motor leads and rotate the motor (CW, by hand) again. When the voltmeter indicates a positive value, the motor leads have been identified. 5. Connect the motor lead from the voltmeter to the ØA motor terminal on the. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the. N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. Chapter 2 35

36 Installation and Configuration Stepper Motor Connections The configuration shown in Figure 2- is an example of a typical stepper motor connection. Refer to Section for information on motor phasing. In this case, the effective motor voltage is half of the applied bus voltage. For example, an 80V motor bus supply is needed to get 40V across the motor. B+ RET B- A B C MOTOR SUPPLY TB02 +/- 40VDC MAX 0AMP MAX MOTOR OUTPUT Green/Yellow & Shield Black Red White NOTE: Listed wire colors are for Aerotech-supplied cables. Figure 2-: Motor Frame B B' Stepper Motor Configuration A Stepper Motor A' Note the common connection of A and B phases. Table 2-: Wire Colors for Aerotech Supplied Cables (Stepper) Pin Wire Color Set () Wire Color Set 2 Green/Yellow & Shield (2) Green/Yellow & Shield A Black Brown B Red Yellow RET White White & Red. Wire Color Set # is the typical Aerotech wire set used by Aerotech. 2. & (Red & Orange) indicates two wires; / (Green/White) indicates a single wire 36 Chapter 2

37 Installation and Configuration Stepper Motor Phasing N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. A stepper motor can be run with or without an encoder. If an encoder is not being used, phasing is not necessary. With an encoder, test for proper motor phasing by running a positive motion command. If there is a positive scaling factor (determined by the CountsPerUnit parameters) and the motor moves in a clockwise direction, as viewed looking at the motor from the front mounting flange, the motor is phased correctly. If the motor moves in a counterclockwise direction, swap the motor leads and re-run the command. Proper motor phasing is important because the end of travel (EOT) limit inputs are relative to motor rotation. ROTARY MOTOR Motor Mounting Flange (Front View) Motor Shaft Figure 2-2: POSITIVE MOTION Clockwise Motor Rotation N O T E : After the motor has been phased, use the ReverseMotionDirection parameter to change the direction of positive motion. Chapter 2 37

38 Installation and Configuration 2.4. Motor Feedback Connections (J03) The motor feedback connector (a 25-pin, D-style connector) has inputs for an encoder, limit switches, Halleffect devices, motor over-temperature device, 5 Volt encoder and limit power, and optional brake connection. The connector pin assignment is shown below with detailed connection information in the following sections. Table 2-2: Motor Feedback Connector Pin Assignment (J03) Pin# Description In/Out/Bi Connector Chassis Frame Ground N/A 2 Motor Over Temperature Thermistor Input 3 +5V Power for Encoder (500 ma max) Output 4 Reserved N/A 5 Hall-Effect Sensor B (brushless motors only) Input 6 Encoder Marker Reference Pulse - Input 7 Encoder Marker Reference Pulse + Input 8 Analog Input 0 - Input 9 Reserved N/A 0 Hall-Effect Sensor A (brushless motors only) Input Hall-Effect Sensor C (brushless motors only) Input 2 Clockwise End of Travel Limit Input 3 Optional Brake - Output Output 4 Encoder Cosine + Input 5 Encoder Cosine - Input 6 +5V Power for Limit Switches (500 ma max) Output 7 Encoder Sine + Input 8 Encoder Sine - Input 9 Analog Input 0 + Input 20 Signal Common for Limit Switches N/A 2 Signal Common for Encoder N/A 22 Home Switch Input Input 23 Encoder Fault Input Input 24 Counterclockwise End of Travel Limit Input 25 Optional Brake + Output Output 3 25 Mating Connector Aerotech P/N Third Party P/N 25-Pin D-Connector ECK000 FCI DB25P064TXLF Backshell ECK00656 Amphenol 7E Chapter 2

39 Installation and Configuration Encoder Interface (J03) The is equipped with standard and auxiliary encoder feedback channels. The standard encoder interface is accessible through the Motor Feedback (J03) connector. The standard encoder interface will accept an RS-422 differential line driver signal. If the has been purchased with the -MXH or -MXU option, the standard encoder interface can be configured for an analog encoder input via parameter settings. Refer to Section for encoder feedback phasing. N O T E : Encoder wiring should be physically isolated from motor, AC power, and all other power wiring. N OT E : The PSO feature is not compatible with the -MXU option. The PSO feature operates with the - MXH option and with square wave encoders. Table 2-3: Encoder Interface Pin Assignment Pin# Description In/Out/Bi Chassis Frame Ground N/A 3 +5V Power for Encoder (500 ma max) Output 6 Encoder Marker Reference Pulse - Input 7 Encoder Marker Reference Pulse + Input 4 Encoder Cosine + Input 5 Encoder Cosine - Input 7 Encoder Sine + Input 8 Encoder Sine - Input 2 Signal Common for Encoder N/A Chapter 2 39

40 Installation and Configuration RS-422 Line Driver Encoder (Standard) The standard encoder interface accepts an RS-422 differential quadrature line driver signal. Invalid or missing signals will cause a feedback fault when the axis is enabled. An analog encoder is used with the -MXH/-MXU option (refer to Section for more information). Table 2-4: Encoder Specifications Specification Encoder Frequency x4 Quadrature Decoding Value 0 MHz maximum (25 nsec minimum edge separation) 40 million counts/sec +3.3V J03-4 COS+ D IN S +3.3V ADG K 0K 0K 0K J03-5 COS- D S IN ADG72 J03-7 MRK+ D IN S ADG J03-6 MRK- D IN S DS26LV32AT ADG72 J03-7 SIN+ D IN ADG72 S 220 0K 0K 0K ENCODER FAULT DETECTION J03-8 SIN- D IN S 0K ADG72 Figure 2-3: Line Driver Encoder Interface (J03) 40 Chapter 2

41 Installation and Configuration Analog Encoder Interface If the -MXH/-MXU option has been purchased, the standard encoder channel will accept a differential analog encoder input signal. The interpolation factor is determined by the EncoderMultiplicationFactor parameter and is software selectable (refer to the A3200 Help file). Table 2-5: Analog Encoder Specifications Specification MXU MXH Input Frequency (max) 500 khz 500 khz Input Amplitude 0.6 to 2.25 Vpk-Vpk 0.6 to 2.25 Vpk-Vpk Interpolation Factor (software selectable) 4,096 65,536 MXH Interpolation Latency N/A ~ 3.25 µsec (analog input to quadrature output) Refer to Figure 2-4 for the typical input circuitry. The encoder interface pin assignment is indicated in Section The gain, offset, and phase balance of the analog Sine and Cosine encoder input signals can all be adjusted via controller parameters. Encoder signals should be adjusted using the Feedback Tuning tab of the Digital Scope, which will automatically adjust the encoder parameters for optimum performance. See the A3200 Help file for more information. SIN LINEAR MOTOR Forcer Wires Positive MOVE (Clockwise) SIN-N Magnet Track Forcer COS Vpk-pk COS-N ROTARY MOTOR MRK Motor Shaft MRK-N CW Rotation (Positive Direction) Motor Mounting Flange (Front View) Positive MOVE (Clockwise) Figure 2-4: Analog Encoder Phasing Reference Diagram N O T E : The input amplitude is measured peak to peak for any encoder signal (sin, sin-n, cos, cos-n) relative to signal common. These signals have a typical offset voltage of 2V to 2.5V. Chapter 2 4

42 Installation and Configuration J03-7 SIN+ 00 K 0PF 0PF K 00PF 2K J03-8 SIN- 00 K - + AD PF 220PF 2K 0PF UF 6.3V. A A J03-4 COS+ 00 K 0PF 0PF K 00PF 2K J03-5 COS- 00 K - + AD PF 220PF 2K 0PF UF 6.3V. A A J03-7 MRK+ K 82PF 8.06K K K J03-6 MRK- K - + AD8656 0PF - + MAX99 33 K 82PF M 0PF 33 K.. Figure 2-5: A Analog Encoder Interface (J03) A 42 Chapter 2

43 Installation and Configuration Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-6 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors). To verify, move the motor by hand in the CW (positive) direction while observing the position of the encoder in the diagnostics display (see Figure 2-7). The Motor Phasing Calculator in the Configuration Manager can be used to determine proper encoder polarity. For dual loop systems, the velocity feedback encoder is displayed in the diagnostic display (Figure 2-7) SIN LINEAR MOTOR Forcer Wires Positive MOVE (Clockwise) SIN-N Magnet Track Forcer COS Vpk-pk COS-N ROTARY MOTOR MRK MRK-N Motor Shaft CW Rotation (Positive Direction) Motor Mounting Flange (Front View) Positive MOVE (Clockwise) Figure 2-6: Encoder Phasing Reference Diagram (Standard) N O T E : Encoder manufacturers may refer to the encoder signals as A, B, and Z. The proper phase relationship between signals is shown in Figure Chapter 2 43

44 Installation and Configuration Figure 2-7: Position Feedback in the Diagnostic Display 44 Chapter 2

45 Installation and Configuration Hall-Effect Interface (J03) The Hall-effect switch inputs are recommended for AC brushless motor commutation but not absolutely required. The Hall-effect inputs accept 5-24 VDC level signals. Hall states (0,0,0) or (,,) are invalid and will generate a "Hall Fault" axis fault. Refer to Section for Hall-effect device phasing. Table 2-6: Hall-Effect Feedback Interface Pin Assignment (J03) Pin# Description In/Out/Bi Chassis Frame Ground N/A 3 +5V Power for Encoder (500 ma max) Output 5 Hall-Effect Sensor B (brushless motors only) Input 0 Hall-Effect Sensor A (brushless motors only) Input Hall-Effect Sensor C (brushless motors only) Input 2 Signal Common for Encoder N/A +5V 0K 0K 0K J03-0 J03-5 J03- HALL A HALL B HALL C 0K 0K 0K UF.0UF.0UF Figure 2-8: Hall-Effect Inputs (J03) Chapter 2 45

46 Installation and Configuration Thermistor Interface (J03) The thermistor input is used to detect a motor over temperature condition by using a positive temperature coefficient sensor. As the temperature of the sensor increases, so does the resistance. Under normal operating conditions, the resistance of the thermistor is low (i.e., 00 ohms) which will result in a low input signal. As the increasing temperature causes the thermistor s resistance to increase, the signal will be seen as a logic high triggering an over temperature fault. The nominal trip value of the sensor is k Ohm. Table 2-7: Thermistor Interface Pin Assignment (J03) Pin# Description In/Out/Bi 2 Motor Over Temperature Thermistor Input +5V 0K J03-2 THERMISTOR 0K.00.0UF Figure 2-9: Thermistor Interface Input (J03) 46 Chapter 2

47 Installation and Configuration Encoder Fault Interface (J03) The encoder fault input is for use with encoders that have a fault output. This is provided by some manufactures and indicates a loss of encoder function. The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active. Table 2-8: Encoder Fault Interface Pin Assignment (J03) Pin# Description In/Out/Bi 23 Encoder Fault Input Input +5V K J03-23 ENCODER FAULT 0K.00.0UF Figure 2-20: Encoder Fault Interface Input (J03) Chapter 2 47

48 Installation and Configuration End Of Travel Limit Input Interface (J03) End of Travel (EOT) limits are used to define the end of physical travel. The EOT limit inputs accept 5-24 VDC level signals. The active state of the EOT limits is software selectable by the EndOfTravelLimitSetup axis parameter (refer to the A3200 Help file). Limit directions are relative to the encoder polarity in the diagnostics display (refer to Figure 2-23). Positive motion is stopped by the clockwise (CW) end of travel limit input. Negative motion is stopped by the counterclockwise (CCW) end of travel limit input. The Home Limit switch can be parameter configured for use during the home cycle, however, the CW or CCW EOT limit is typically used instead V Limit Com 6 20 Normally closed shown (typical). CW 2 MOTOR FEEDBACK 4 J03 CCW Home May be a separate switch. Figure 2-2: End of Travel Limit Input Connections Table 2-9: End of Travel Limit Input Interface Pin Assignment (J03) Pin# Description In/Out/Bi 2 Clockwise End of Travel Limit Input 6 +5V Power for Limit Switches (500 ma max) Output 20 Signal Common for Limit Switches N/A 22 Home Switch Input Input 24 Counterclockwise End of Travel Limit Input 48 Chapter 2

49 Installation and Configuration +5V 0K 0K 0K J03-2 J03-24 J03-22 CW LMT CCW LMT HM LMT 0K 0K 0K UF.0UF.0UF Figure 2-22: End of Travel Limit Interface Input (J03) Chapter 2 49

50 Installation and Configuration End Of Travel Limit Phasing If the EOT limits are reversed, you will be able to move further into a limit but be unable to move out. To correct this, swap the connections to the CW and CCW inputs at the motor feedback connector. The logic level of the EOT limit inputs may be viewed in the Status Utility (shown in Figure 2-23). Figure 2-23: Limit Input Diagnostic Display 50 Chapter 2