Ndrive CP Hardware Manual

Transcription

1 Hardware Manual Revision: ENB/FLT MARKER PWR INPOS ENB/FLT MARKER PWR INPOS TB20 AGND AIN+ AIN- AOUT J0 FIREWIRE J02 FIREWIRE J0 J02 OP OM OPTO OUT TB202 MOTOR FEEDBACK J03 TM A3200 ESTOP TB0 AEROTECH.COM MOTOR FEEDBACK J03 ESTOP TB0 OP OM OPTO OUT TB203 TM A3200 AEROTECH.COM 240V~ MAX 50/60Hz 5A MAX MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C AUX I/O J04 TB02 DANGER! High Voltage AUX I/O J04 240V~ MAX 50/60Hz 5A MAX MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C DANGER! High Voltage TB02 C GND C V NC C NO OPTO IN TB204 OPTO IN TB205 RELAY TB206

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 Power Dissipation 2.3. Mechanical Design Environmental Specifications 23 Chapter 2: Installation and Configuration Communication Channel Settings Power Connections Control Supply Connections (TB06) Motor Supply Connections (TB02) Transformer Options Minimizing Conducted, Radiated, and System Noise 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) EnDat Encoder Interface (J03) Resolute Encoder Interface (J03) 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) Emergency Stop Sense Input (TB0) Typical ESTOP Interface Auxiliary I/O Connector (J04) Auxiliary Encoder Channel (J04) Position Synchronized Output (PSO)/Laser Firing (J04) Opto-Isolated Outputs (J04) Opto-Isolated Inputs (J04) High-Speed User Inputs 2-3 (J04)

4 Table of Contents Analog Output 0 (J04) Differential Analog Input 0 (J04) Brake Power Supply (TB03) Solid State Relay Specifications (TB03) FireWire Interface EXTSHUNT Option (TB04) PC Configuration and Operation Information 84 Chapter 3: -I/O Expansion Board Analog Output (TB20) Analog Input (TB20) Opto-Isolated Inputs (TB204, TB205) Opto-Isolated Outputs (TB202, TB203) User Power (TB204, TB205) Brake / Mechanical Relay (TB206) Brake Configuration Jumpers Mechanical Relay Specifications Brake / Mechanical Relay Interface Connector 97 Chapter 4: Standard Interconnection Cables Joystick Interface Handwheel Interface 03 Chapter 5: Maintenance Control Board Preventative Maintenance 08 Appendix A: Warranty and Field Service 09 Appendix B: Revision History Index 3 4

5 Table of Contents List of Figures Figure -: Networked Digital Drive 5 Figure -2: Functional Diagram 7 Figure -3: Power Dissipation vs. Output Current 2 Figure -4: Ambient Temperature vs. Power Dissipation 2 Figure -5: Dimensions 22 Figure 2-: Control Supply Connections 28 Figure 2-2: Motor Bus Input Connections 29 Figure 2-3: Transformer Examples 30 Figure 2-4: 40 VDC Motor Power with a TV ST Transformer 3 Figure 2-5: 80 VDC Motor Power with a TV ST Transformer 32 Figure 2-6: 40 Volt DC Bus from 5 and 230 VAC Source 33 Figure 2-7: 80 Volt DC Bus from 5 and 230 VAC Source (TV0.3-56) 34 Figure 2-8: 60 Volt DC Bus from 5 and 230 VAC Source (TV0.3-56) 35 Figure 2-9: Control and Motor Power Wiring using a TM3 or TM5 Transformer 36 Figure 2-0: AC Line Filter (UFM-ST) 37 Figure 2-: Brushless Motor Configuration 39 Figure 2-2: Encoder and Hall Signal Diagnostics 40 Figure 2-3: Motor Phasing Oscilloscope Example 4 Figure 2-4: Brushless Motor Phasing Goal 4 Figure 2-5: DC Brush Motor Configuration 42 Figure 2-6: Clockwise Motor Rotation 43 Figure 2-7: Stepper Motor Configuration 44 Figure 2-8: Clockwise Motor Rotation 45 Figure 2-9: Line Driver Encoder Interface (J03) 48 Figure 2-20: Serial Data Stream Interface 49 Figure 2-2: Serial Data Stream Interface 50 Figure 2-22: Analog Encoder Phasing Reference Diagram 5 Figure 2-23: Analog Encoder Interface (J03) 52 Figure 2-24: Encoder Phasing Reference Diagram (Standard) 53 Figure 2-25: Position Feedback in the Diagnostic Display 54 Figure 2-26: Hall-Effect Inputs (J03) 55 Figure 2-27: Thermistor Interface Input (J03) 56 Figure 2-28: Encoder Fault Interface Input (J03) 57 Figure 2-29: End of Travel Limit Input Connections 58 Figure 2-30: End of Travel Limit Interface Input (J03) 59 Figure 2-3: Limit Input Diagnostic Display 60 Figure 2-32: ESTOP Sense Input (TB0) 62 Figure 2-33: Typical Emergency Stop Circuit 63 Figure 2-34: Auxiliary Encoder Channel (J04) 66 Figure 2-35: PSO Interface 68 Figure 2-36: Outputs Connected in Current Sourcing Mode (J04) 70 Figure 2-37: Outputs Connected in Current Sinking Mode (J04) 70 Figure 2-38: Inputs Connected in Current Sourcing Mode (J04) 72 Figure 2-39: Inputs Connected in Current Sinking Mode (J04) 72 Figure 2-40: High-Speed User Inputs (J04) 73 Figure 2-4: Analog Output 0 (J04) 74 Figure 2-42: Analog Input 0 (J04) 75 Figure 2-43: Brake Connected to J03 77 Figure 2-44: Brake Connected to TB03 78 Figure 3-: with -IO Option Board 85 Figure 3-2: Analog Output Connector (TB20)

6 Table of Contents Figure 3-3: Analog Input Typical Connection (TB20) 87 Figure 3-4: Opto-Isolated Inputs 89 Figure 3-5: Inputs Connected to a Current Sourcing Device 90 Figure 3-6: Inputs Connected to a Current Sinking Device 90 Figure 3-7: Opto-Isolated Outputs (-IO Board) 93 Figure 3-8: Outputs Connected in Current Sourcing Mode 94 Figure 3-9: Outputs Connected in Current Sinking Mode 94 Figure 3-0: Brake Connected to J03 98 Figure 3-: Brake Connected to TB Figure 4-: Single Axis Joystick Interface (to Aux I/O) 00 Figure 4-2: Two Axis Joystick Interface (to the Aux I/O of two drives) 0 Figure 4-3: Two Axis Joystick Interface (to the Aux I/O and I/O Board) 0 Figure 4-4: Two Axis Joystick Interface (to the I/O board of two drives) 02 Figure 4-5: Handwheel Interconnection (to Aux I/O) 03 Figure 4-6: Handwheel Interconnection (to Aux I/O via a BBA32 Module) 04 Figure 5-: Control Board Assembly

7 Table of Contents List of Tables Table -: Feature Summary 6 Table -2: Drive and Software Compatibility 8 Table -3: Electrical Specifications 9 Table -4: Physical Specifications 22 Table 2-: Device Number Switch Settings (S) 26 Table 2-2: Control Supply AC Input Wiring 28 Table 2-3: Control Supply Mating Connector 28 Table 2-4: Motor Supply Mating Connector 29 Table 2-5: Nominal Motor Operating Voltages / Required AC Voltages 30 Table 2-6: Transformer Options 30 Table 2-7: Ferrite Noise Suppression Numbers 37 Table 2-8: UFM-ST Electrical Specifications 37 Table 2-9: Motor Power Output Connections (TB02) 38 Table 2-0: Motor Power Output Mating Connector 38 Table 2-: Wire Colors for Aerotech Supplied Cables (Brushless) 39 Table 2-2: Wire Colors for Aerotech Supplied Cables (DC Brush) 42 Table 2-3: Wire Colors for Aerotech Supplied Cables (Stepper) 44 Table 2-4: Motor Feedback Connector Pin Assignment (J03) 46 Table 2-5: Encoder Interface Pin Assignment 47 Table 2-6: Encoder Specifications 48 Table 2-7: Analog Encoder Specifications 5 Table 2-8: Hall-Effect Feedback Interface Pin Assignment (J03) 55 Table 2-9: Thermistor Interface Pin Assignment (J03) 56 Table 2-20: Encoder Fault Interface Pin Assignment (J03) 57 Table 2-2: End of Travel Limit Input Interface Pin Assignment (J03) 58 Table 2-22: Brake Output Pin Assignment (J03) 6 Table 2-23: Electrical Noise Suppression Devices 62 Table 2-24: TB0 Mating Connector 62 Table 2-25: Typical ESTOP Relay Ratings 63 Table 2-26: Auxiliary I/O Connector Pin Assignment (J04) 64 Table 2-27: Auxiliary Encoder Specifications 65 Table 2-28: Auxiliary Encoder Channel Pin Assignment (J04) 65 Table 2-29: PSO Specifications 67 Table 2-30: PSO Output Pin Assignment (J04) 67 Table 2-3: Digital Output Specifications 69 Table 2-32: Digital Output Connector Pin Assignment (J04) 69 Table 2-33: Opto-Isolated Input Specifications 7 Table 2-34: Digital Input Connector Pin Assignment (J04) 7 Table 2-35: High-Speed Input Specifications 73 Table 2-36: High Speed Digital Input Connector Pin Assignment (J04) 73 Table 2-37: Analog Output 0 Specifications (TB02 B) 74 Table 2-38: Analog Output Connector Pin Assignment (J04) 74 Table 2-39: Differential Analog Input 0 Specifications 75 Table 2-40: Analog Input Connector Pin Assignment (J04) 75 Table 2-4: Brake Output Connector Pin Assignment (TB03) 76 Table 2-42: Mating Connector (TB03) 76 Table 2-43: Brake Output Connector Pin Assignment (J03) 76 Table 2-44: Relay Specifications 79 Table 2-45: FireWire Card Part Numbers 80 Table 2-46: FireWire Repeaters (for cables exceeding 4.5 m (5 ft) specification) 80 Table 2-47: FireWire Cables (copper and glass fiber)

8 Table of Contents Table 2-48: -EXTSHUNT Component Information 8 Table 2-49: Maximum Storage Energy 82 Table 3-: -IO Expansion Board Jumper Configuration 85 Table 3-2: -IO Option Board Fuse Information 85 Table 3-3: Analog Output Specifications (TB02 B) 86 Table 3-4: Analog Output Connector Pin Assignment (TB20) 86 Table 3-5: Analog Output Mating Connector 86 Table 3-6: Differential Analog Input Specifications 87 Table 3-7: Analog Inputs Connector Pin Assignment (TB20) 87 Table 3-8: Analog Input Mating Connector 87 Table 3-9: Opto-Isolated Input Device Specifications 88 Table 3-0: Opto-Isolated Input Connector Pin Assignment (TB204) 88 Table 3-: Opto-Isolated Input Connector Pin Assignment (TB205) 88 Table 3-2: Opto-Isolated Input Mating Connector 88 Table 3-3: Output Specifications (TB202, TB203) 9 Table 3-4: Opto-Isolated Output Connector Pin Assignment (TB202) 92 Table 3-5: Opto-Isolated Output Connector Pin Assignment (TB203) 92 Table 3-6: Opto-Isolated Output Mating Connector 92 Table 3-7: User Common Connector Pin Assignment (TB204) 95 Table 3-8: +5 Volt Power Connector Pin Assignment (TB205) 95 Table 3-9: -IO Expansion Board Brake Jumper Configuration 96 Table 3-20: Voltage and Current Specifications (TB206) 96 Table 3-2: Brake / Mechanical Relay Connector Pin Assignment (TB206) 97 Table 3-22: Mating Connector for TB Table 3-23: Brake / Mechanical Relay Connector Pin Assignment (J03) 97 Table 4-: Standard Interconnection Cables 99 Table 4-2: Cable Part Numbers 02 Table 5-: LED Description 05 Table 5-2: Control Board Jumper Configuration 07 Table 5-3: Control Board Fuse Information 07 Table 5-4: LED Description 07 Table 5-5: 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): 204/30/EU 204/35/EU 20/65/EU Electromagnetic Compatibility Directive 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 550:998 EN :2004 EN :2000 EN :995 EN :995 EN :2002 EN :995 EN :995 EN :996 EN :994 EN 600-:200 RFI Limits and Measurement EMC requirements for power drives Harmonic Current Emissions Voltage Fluctuation and Flicker ESD Immunity Radiated RFI/EMI Immunity EFT/Burst Immunity Surge Immunity Conducted Immunity Voltage Dips and Interruptions 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 Digital 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-:2004; CAN/CSA-C22.2 No. 600-:2004; 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. The shunt resistor temperature can exceed 70 C during normal operation and contains lethal voltage on its terminals and surface. It must be properly enclosed and shielded to avoid risk of fire and operator shock. 7. Do not connect or disconnect any electrical components or connecting cables while connected to a power source. 8. All components must be properly grounded in accordance with local electrical safety requirements. 9. 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 9 Quick Installation Guide Quick Installation Guide This chapter describes the order in which connections and settings should typically be made to the Ndrive CP. 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. ENB/FLT MARKER PWR INPOS TB20 AGND AIN+ AIN- AOUT WARNING: DISCONNECT POWER BEFORE SERVICING HAZARDOUS VOLTAGES PRESENT UP TO 8 MIN. AFTER POWER IS DISCONNECTED SEE MANUAL FOR SWITCH SETTINGS 3 FIREWIRE J0 J02 OP OM OPTO OUT TB202 AC AC2 2 3 CONTROL SUPPLY 50/60Hz V~ 0.25A MAX TB06 5 EXTERNAL SHUNT TB MOTOR FEEDBACK J03 OP OM OPTO OUT TB CONFIG DEVICE NUMBER S OFF ON 6 ESTOP TB0 TM A3200 AEROTECH.COM + - BRAKE POWER SUPPLY TB MOTOR SUPPLY MOTOR OUTPUT AUX I/O J04 240V~ MAX 50/60Hz 5A MAX AC AC2 A B C DANGER! High Voltage TB02 C GND C V NC C NO OPTO IN TB204 OPTO IN TB205 RELAY TB S/N - P/N - 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). 5 Connect to the Control Supply (TB06). 6 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 2.8. FireWire Interface Section Control Supply Connections (TB06) Section Motor Supply Connections (TB02) User / Application dependent 3

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15 Introduction Chapter : Introduction Aerotech s (Compact PWM) network digital drive is a high performance amplifier. 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 (-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. ENB/FLT MARKER FIREWIRE J0 J02 PWR INPOS TB20 OP OM AGND AIN+ AIN- AOUT OPTO OUT TB202 WARNING: DISCONNECT POWER BEFORE SERVICING HAZARDOUS VOLTAGES PRESENT UP TO 8 MIN. AFTER POWER IS DISCONNECTED SEE MANUAL FOR SWITCH SETTINGS AC AC /60Hz V~ 0.25A MAX TB06 CONTROL SUPPLY EXTERNAL SHUNT TB04 2 MOTOR FEEDBACK J03 OP OM OPTO OUT TB ON OFF CONFIG DEVICE NUMBER S ESTOP TB0 TM A3200 AEROTECH.COM + - TB03 BRAKE POWER SUPPLY AUX I/O J04 240V~ MAX 50/60Hz 5A MAX MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C DANGER! High Voltage TB02 C GND C V NC C NO OPTO IN TB204 OPTO IN TB205 RELAY TB206 S/N - P/N - Standard Connector Description -IO/-IOH Board Option Connector Description J0 FireWire Port TB20 Analog I/O J02 FireWire Port TB202 Opto-Outputs J03 Motor Feedback TB203 Opto-Outputs J04 Auxiliary I/O TB204 Opto-Inputs TB02 Motor Supply TB205 Opto-Inputs TB02 Motor Output TB206 Relay TB06 Control Supply Output TB0 Emergency Stop Sense Input (ESTOP) TB03 Brake Power Supply TB04 External Shunt 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 Line driver square wave auxiliary quadrature encoder input or output for PSO Four opto-isolated user outputs Six opto-isolated user inputs (two high speed) One 6-bit differential analog input (± 0 V) One 6-bit analog output (±0 V) Dedicated 5-24 V Emergency Stop sense input VAC control supply inputs One fail-safe brake Single axis Position Synchronized Output (PSO) Absolute Encoder support Options -S Internal shunt resistor (standard on CP 30). 50 Ohm, 40 W Continuous; 400 W Peak (5 seconds), (Manufacturer's P/N: Ohmite F40J50RE or equivalent) -IO One 6-bit analog output (±0 V) One 2-bit differential analog input One fail-safe brake or user relay output -MXU -EXTSHUNT 6 optically isolated logic inputs (5-24 VDC), may be connected in current sourcing or sinking mode 6 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 Connection provided for an external shunt resistor network. Accessories UFM-ST AC Line Filter Module (required for CE compliance; refer to Section 2.2.) MCK-NDRIVE Mating connector kit for J03 (J04 mate is always provided) 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 Transformers Cables Interconnection Refer to Section for listings, wiring, and specifications 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. J0 / J02 J04 Aux I/O TB0 ESTOP FireWire Communication Ports Encoder +5V / Common PSO Output SIN, COS, MRK (RS422) 4 Opto Outputs 4 Opto Inputs 2 High Speed Opto Inputs Analog Input 0 +/- Analog Output 0 Emergency Stop Sense Input Analog Input +/- Analog Output 6 Opto Outputs (Sinking or Sourcing) -IO Option TB20 TB202 / TB203 Opto Out -MXU Option J03 Motor Feedback SIN, COS, MRK (RS422) CW, CCW, Home Limits; Encoder Fault; Hall A, B, C; Motor Over Temperature 6 Opto Inputs TB204 / TB205 Opto In Brake ± Encoder +5V / Common TB03 Brake Power Supply TB06 Control Supply AC AC2 AC AC2 +5V / Common Isolated Power Supply Brake Power Input or Relay (jumper configurable) + TB206 Relay TB04 -EXTSHUNT option TB02 Motor Supply AC AC2 AC AC2 Inrush Limiting Heatsink Over Temperature PWM 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 -2: Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version HEX RC Current Ndrive CL A 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 Ndrive ML 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 Table -3: Electrical Specifications Description CP 0 CP 20 CP 30 Input Voltage VAC Input Frequency Hz Inrush Current VAC; 6 5 VAC Motor Supply Maximum Continuous Input 5 A rms 0 A rms 0 A rms Current Input Current Refer to Section.2.. System Power Requirements Input Voltage VAC Control Input Frequency Hz Supply Inrush Current 26 A Input Current.25 A max Output Voltage () VDC Peak Output Current ( second) 0 A 20 A 30 A Continuous Output Current 5 A 0 A 0 A Power Amplifier Bandwidth 2500 Hz maximum (software selectable) Power Amplifier Efficiency 85% - 95% (2) PWM Switching Frequency Minimum Load Inductance User Power Supply Output Modes of Operation Protective Features Isolation () AC input voltage and load dependent. (2) Dependent on total output power: efficiency increases with increasing output power. 20 khz VDC ( 320 VDC) 5 VDC (@ 500 ma) Brushless; Brush; Stepper Output short circuit; Peak over current; DC bus over voltage; RMS over current; Over temperature; Control power supply under voltage; Power stage bias supply under voltage Optical and transformer isolation between control and power stages. 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 90% should be used in the following equations. Brushless Motor Output Power Rotary Motors Linear Motors Pout [W] = Torque [N m] * Angular velocity[rad/sec] Pout [W] = Force [N] * Linear velocity[m/sec] Rotary or Linear Motors Pout [W] = Bemf [V] * I(rms) * 3 Ploss = 3 * I(rms)^2 * R(line-line)/2 Pin = SUM ( Pout + Ploss ) / EfficiencyFactor DC Brush Motor Pout [W] = Torque [N m] * Angular velocity[rad/sec] Ploss = I(rms)^2 * R Pin = SUM ( Pout + Ploss ) / EfficiencyFactor 20 Chapter

21 Introduction.2.2. Power Dissipation The amplifier power dissipation under continuous power supply and output current conditions is shown in Figure -3. The values on the graph represent the peak current that the amplifier would provide during operation. When the bus voltage and output current are known, the amplifier power dissipation is found using this graph. Figure -4 shows the maximum recommended ambient temperature as a function of amplifier power dissipation. Use this graph along with the power dissipation obtained from the first graph to determine the maximum ambient temperature. If the result is lower than the known operating ambient temperature, additional measures are required to cool the. Mounting it to a large metal plate for extra heatsinking and providing additional fan flow are suggested. 40 Power Dissipation (W) V Bus 60V Bus 80V Bus 40V Bus Figure -3: Output Current (A) Power Dissipation vs. Output Current Ambient Temperature (C) Absolute Maximum 20 Recommended Amplifier Dissipation (W) Figure -4: Ambient Temperature vs. Power Dissipation EXAMPLE: 320 VDC Bus operation at 5 A Power Dissipation = 47 Watts Maximum Ambient Temperature = 54 C Chapter 2

22 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 [2.59] 63.5 [2.50] 3.8 [.25] 5.9 [0.63] (TYP.) Ø4.7 [Ø0.9] (TYP.) Ø0.3 [Ø0.4] (TYP.) ENB/FLT MARKER PWR INPOS TB20 AGND AIN+ AIN- AOUT FIREWIRE J0 J02 OP OM OPTO OUT TB202 MOTOR FEEDBACK J03 OP OM OPTO OUT TB [9.8] 28.6 [8.6] ESTOP TB0 TM A3200 AEROTECH.COM 98.2 [7.8] MOTOR SUPPLY MOTOR OUTPUT AUX I/O J04 240V~ MAX 50/60Hz 5A MAX AC AC2 A B C DANGER! High Voltage TB02 C GND C V NC C NO OPTO IN TB204 OPTO IN TB205 RELAY TB206 with I/O 630D987, REV H 9.8 [0.39] 4.7 [0.9] (TYP.) REC. MTG. HDWR: M4 [#8] 6. [0.64] 67.4 [6.59] 78.2 [7.02] 6.4 [0.25] Figure -5: Dimensions Table -4: Standard Physical Specifications Weight.63 kg (3.6 lb) 22 Chapter

23 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. Chapter 23

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25 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. Chapter 2 25

26 9 Installation and Configuration Table 2-: Device Number Switch Settings (S) Switch Settings (OFF is indicated by " - ") Device # ON ON ON ON ON ON ON ON ON ON 2 ON ON ON ON ON ON ON ON ON - 3 ON ON ON ON ON ON ON ON - ON 4 ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON - ON ON 6 ON ON ON ON ON ON ON - ON - 7 ON ON ON ON ON ON ON - - ON 8 ON ON ON ON ON ON ON ON ON ON ON ON ON - ON ON ON 0 ON ON ON ON ON ON - ON ON - ON ON ON ON ON ON - ON - ON 2 ON ON ON ON ON ON - ON ON ON ON ON ON ON - - ON ON 4 ON ON ON ON ON ON - - ON - 5 ON ON ON ON ON ON ON 6 ON ON ON ON ON ON ON ON ON ON ON - ON ON ON ON 8 ON ON ON ON ON - ON ON ON - 9 ON ON ON ON ON - ON ON - ON 20 ON ON ON ON ON - ON ON ON ON ON ON ON - ON - ON ON 22 ON ON ON ON ON - ON - ON - 23 ON ON ON ON ON - ON - - ON 24 ON ON ON ON ON - ON ON ON ON ON ON - - ON ON ON 26 ON ON ON ON ON - - ON ON - 27 ON ON ON ON ON - - ON - ON 28 ON ON ON ON ON - - ON ON ON ON ON ON ON ON 30 ON ON ON ON ON ON - 3 ON ON ON ON ON ON 32 ON ON ON ON ON CONFIG AC AC2 + - S/N - P/N S ON DEVICE NUMBER WARNING: DISCONNECT POWER BEFORE SERVICING HAZARDOUS VOLTAGES PRESENT UP TO 8 MIN. AFTER POWER IS DISCONNECTED SEE MANUAL FOR SWITCH SETTINGS OFF 2 3 CONFIG DEVICE NUMBER BRAKE POWER SUPPLY TB03 CONTROL SUPPLY 50/60Hz V~ 0.25A MAX TB06 S OFF ON 26 Chapter 2

27 Installation and Configuration 2.2. Power Connections The has two AC 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. Chapter 2 27

28 Installation and Configuration Control Supply Connections (TB06) 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 control power supply requires a minimum of 85 VAC input to operate properly. The AC input is internally fused. The AC2 input is not internally fused but can be connected to a voltage source other than Neutral if an external 2 A time-delay fuse is used. Although the control power supply contains an internal filter, an additional external filter located as close as possible to the may be required for CE compliance (Aerotech recommends Schaffner FN2080 or Aerotech UFM-ST). Line (L) Neutral (N) Ground Line Filter AC AC /60Hz V~ 0.25A MAX TB06 CONTROL SUPPLY Figure 2-: Control Supply Connections Table 2-2: Control Supply AC Input Wiring Recommended Wire Pin Description Size AC Line (L): VAC Control Power Input 0.8 mm 2 (#8 AWG) AC2 Neutral (0V) or VAC Control Power Input with external fuse 0.8 mm 2 (#8 AWG) Table 2-3: Protective Ground (Required for Safety) Control Supply Mating Connector 0.8 mm 2 (#8 AWG) Screw Torque Wire Size: Type Aerotech P/N Phoenix P/N Value: Nm AWG [mm 2 ] 3-Pin Terminal Block ECK [ ] 28 Chapter 2

29 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. The AC input is internally fused (5A CP0, 0A CP20/30). External fuses or a circuit breaker (5 A maximum, time delay type) are required for the AC and AC2 inputs. The AC2 input can be connected directly to Neutral without a fuse for single phase power systems. W A R N I N G : Do not operate the without the safety ground connection in place. W A R N I N G : Do not operate the without proper branch protection. An AC Line Filter may be required for CE compliance and should be located as close as possible to the drive. For more information about the AC Line Filter, refer to Section Wiring between the filter and drive can be twisted and/or shielded to reduce radiated emissions. Line (L) Neutral (N) Ground Line Filter MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C Figure 2-2: Motor Bus Input Connections TB02 Table 2-4: Motor Supply Mating Connector Tightening Wire Size: Description Aerotech P/N Phoenix P/N Torque (Nm) AWG [mm 2 ] 7-Pin Terminal Block ECK [2-30]. Recommended Wire Size:.3 mm2 (#6 AWG) Chapter 2 29

30 Installation and Configuration Transformer Options An external isolation transformer can be connected to the motor supply AC input. This is done to reduce the operating voltage of the motor and may also reduce electrical noise. Table 2-5: Nominal Motor Operating Voltages / Required AC Voltages AC Voltage DC Voltage Table 2-6: Transformer TV ST TM3 TM5 TV TV Transformer Options Description Generate 28 or 56 VAC from 5 VAC or 230 VAC input source voltage. When rectified by the drive, it produces a 40 or 80 VDC power bus. Power up to 4 drives, providing 300 watts of power Power up to 4 drives providing 500 watts of power Generate 28 VAC from 5 VAC or 230 VAC input source voltage. When rectified by the drive, it produces a 40 VDC power bus. Generate 56 VAC from 5 VAC or 230 VAC input source voltage. When rectified by the drive, it produces an 80 VDC power bus. TV.5, TV2.5, or TV5.5 kva, 2.5 kva, or 5 kva isolation transformer; 5/230 VAC input; 28, 43, 56, 70, 5 VAC output Figure 2-3: Transformer Examples 30 Chapter 2

31 Installation and Configuration Drive Motor Supply AC AC Internal Thermal Switch 28V 0V 28V Integral Fuse 3.5A Slow-Blow F-OUT 5V 00V 0V 5V 00V F-IN 4 AC HI AC LO SAFETY 5 VAC 50/60 HZ INPUT 0V 0V Frame Ground Control Supply AC AC2 6 TV ST Wiring 5 VAC INPUT Secondary = 28 VAC (40 VDC Bus) Drive Motor Supply AC AC Internal Thermal Switch 28V 0V 28V Integral Fuse 3.5A Slow-Blow F-OUT 5V 00V 0V 5V 00V F-IN AC HI AC LO SAFETY 230 VAC 50/60 HZ INPUT 0V 0V Frame Ground Control Supply AC AC2 6 HAZARDOUS VOLTAGES PRESENT TV ST Wiring 230 VAC INPUT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER Secondary = 28 VAC (40 VDC Bus) FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES.. For 00 VAC primary input, parallel the 00 VAC taps and leave the 5 VAC taps unterminated. 2. For 200 VAC primary input, series the 00 VAC taps and leave the 5 VAC taps unterminated. 3. When using an isolation transformer, earth grounding of the AC2 input tap reduces electrical and audible noise emissions and provides increased servo performance. 4. Transformer Primary Wiring: 0.8 mm 2 (#8 AWG) 300 V wire. 5. Transformer Secondary Wiring:.3 mm 2 (#6 AWG) 300 V wire. 6. AC line filters are for CE compliance. Filters may also be located on the primary side of the transformer. Drawing: 620B346-8, Rev. - Figure 2-4: 40 VDC Motor Power with a TV ST Transformer Chapter 2 3

32 Installation and Configuration Drive AC 5 Internal Thermal Switch 28V Integral Fuse 3.5A Slow-Blow 5V F-IN F-OUT AC HI AC LO SAFETY 5 VAC 50/60 HZ INPUT Motor Supply AC V 28V 00V 0V 5V 00V 4 0V 0V Frame Ground Control Supply AC AC2 6 TV ST Wiring 5 VAC INPUT Secondary = = 56 VAC (80 VDC Bus) Drive AC 5 Internal Thermal Switch 28V Integral Fuse 3.5A Slow-Blow 5V F-IN F-OUT AC HI AC LO SAFETY 230 VAC 50/60 HZ INPUT Motor Supply AC V 28V 00V 0V 5V 00V V 0V Frame Ground Control Supply AC AC2 6 HAZARDOUS VOLTAGES PRESENT TV ST Wiring 230 VAC INPUT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER Secondary = = 56 VAC (80 VDC Bus) FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES.. For 00 VAC primary input, parallel the 00 VAC taps and leave the 5 VAC taps unterminated. 2. For 200 VAC primary input, series the 00 VAC taps and leave the 5 VAC taps unterminated. 3. When using an isolation transformer, earth grounding of the AC2 input tap reduces electrical and audible noise emissions and provides increased servo performance. 4. Transformer Primary Wiring: 0.8 mm 2 (#8 AWG) 300 V wire. 5. Transformer Secondary Wiring:.3 mm 2 (#6 AWG) 300 V wire. 6. AC line filters are for CE compliance. Filters may also be located on the primary side of the transformer. Drawing: 620B346-9, Rev. - Figure 2-5: 80 VDC Motor Power with a TV ST Transformer 32 Chapter 2

33 Installation and Configuration Drive AC 7 28V RED Internal Thermal Switch #8 WHT #8 WHT 5V BLK Primary Fuse 4A Slow-Blow splice 4 AC HI AC LO SAFETY 5 VAC 50/60 HZ INPUT Motor Supply AC V GRN 28V YEL 00V ORN 0V GRY 5V BRN 00V GRN 6 0V BLK 0V BLU splice Frame Ground Control Supply AC AC2 5 TV Wiring 5 VAC INPUT Secondary = 28 VAC (40 VDC Bus) Drive AC 7 28V RED Internal Thermal Switch #8 WHT #8 WHT 5V BLK Primary Fuse 4A Slow-Blow splice 4 AC HI AC LO SAFETY 230 VAC 50/60 HZ INPUT Motor Supply AC V GRN 28V YEL 00V ORN 0V GRY 5V BRN 00V GRN 2 splice 2 6 0V BLK 0V BLU Frame Ground Control Supply AC AC2 5 HAZARDOUS VOLTAGES PRESENT TV Wiring 230 VAC INPUT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER Secondary = 28 VAC (40 VDC Bus) FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES.. For 00 VAC primary input, parallel the 00 VAC taps and leave the 5 VAC taps unterminated. 2. For 200 VAC primary input, series the 00 VAC taps and leave the 5 VAC taps unterminated. 3. When using an isolation transformer, earth grounding of the AC2 input tap reduces electrical and audible noise emissions and provides increased servo performance. 4. Additional or alternative fusing may be required for optimum protection 5. AC line filters are required for CE compliance. Filters may also be located on the primary side of the transformer. 6. Transformer Primary Wiring: 0.8 mm 2 (#8 AWG) 300 V wire. 7. Transformer Secondary Wiring:.3 mm 2 (#6 AWG) 300 V wire. Drawing: 620B346- Figure 2-6: 40 Volt DC Bus from 5 and 230 VAC Source Chapter 2 33

34 Installation and Configuration Drive AC 7 56V RED Internal Thermal Switch #8 WHT #8 WHT 5V BLK Primary Fuse 4A Slow-Blow splice 4 AC HI AC LO SAFETY 5 VAC 50/60 HZ INPUT Motor Supply AC V GRN 56V YEL 00V ORN 0V GRY 5V BRN 00V GRN 6 0V BLK 0V BLU splice Frame Ground Control Supply AC AC2 5 TV Wiring 5 VAC INPUT Secondary = 56 VAC (80 VDC Bus) Drive AC 7 56V RED Internal Thermal Switch #8 WHT #8 WHT 5V BLK Primary Fuse 4A Slow-Blow splice 4 AC HI AC LO SAFETY 230 VAC 50/60 HZ INPUT Motor Supply AC V GRN 56V YEL 00V ORN 0V GRY 5V BRN 00V GRN 2 splice 2 6 0V BLK 0V BLU Frame Ground Control Supply AC AC2 5 HAZARDOUS VOLTAGES PRESENT TV Wiring 230 VAC INPUT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER Secondary = 56 VAC (80 VDC Bus) FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES. For 00 VAC primary input, parallel the 00 VAC taps and leave the 5 VAC taps unterminated. 2. For 200 VAC primary input, series the 00 VAC taps and leave the 5 VAC taps unterminated. 3. When using an isolation transformer, earth grounding of the AC2 input tap reduces electrical and audible noise emissions and provides increased servo performance. 4. Additional or alternative fusing may be required for optimum protection 5. AC line filters are required for CE compliance. Filters may also be located on the primary side of the transformer. 6. Transformer Primary Wiring: 0.8 mm 2 (#8 AWG) 300 V wire. 7. Transformer Secondary Wiring:.3 mm 2 (#6 AWG) 300 V wire. Figure 2-7: 80 Volt DC Bus from 5 and 230 VAC Source (TV0.3-56) 34 Chapter 2

35 Installation and Configuration Drive AC 7 56V RED Internal Thermal Switch #8 WHT #8 WHT 5V BLK Primary Fuse 4A Slow-Blow splice 4 AC HI AC LO SAFETY 5 VAC 50/60 HZ INPUT Motor Supply AC V GRN splice 56V YEL 00V ORN 0V GRY 5V BRN 00V GRN 6 0V BLK 0V BLU splice Frame Ground Control Supply AC AC2 5 TV ST Wiring 5 VAC INPUT Secondary = 5 VAC (60 VDC Bus) Drive AC 7 56V RED Internal Thermal Switch #8 WHT #8 WHT 5V BLK Primary Fuse 4A Slow-Blow splice 4 AC HI AC LO SAFETY 230 VAC 50/60 HZ INPUT Motor Supply AC V GRN splice 56V YEL 00V ORN 0V GRY 5V BRN 00V GRN 2 splice 2 6 0V BLK 0V BLU Frame Ground Control Supply AC AC2 5 HAZARDOUS VOLTAGES PRESENT TV ST Wiring 230 VAC INPUT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER Secondary = 5 VAC (60 VDC Bus) FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES. For 00 VAC primary input, parallel the 00 VAC taps and leave the 5 VAC taps unterminated. 2. For 200 VAC primary input, series the 00 VAC taps and leave the 5 VAC taps unterminated. 3. When using an isolation transformer, earth grounding of the AC2 input tap reduces electrical and audible noise emissions and provides increased servo performance. 4. Additional or alternative fusing may be required for optimum protection 5. AC line filters are for CE compliance. Filters may also be located on the primary side of the transformer. 6. Transformer Primary Wiring: 0.8 mm 2 (#8 AWG) 300 V wire. 7. Transformer Secondary Wiring:.3 mm 2 (#6 AWG) 300 V wire. Drawing: 620B346-3 Figure 2-8: 60 Volt DC Bus from 5 and 230 VAC Source (TV0.3-56) Chapter 2 35

36 Installation and Configuration ST CP TM3/TM5 TRANSFORMER MODULE AC2 AC MOTOR SUPPLY MOTOR OUTPUT AC AC2 2 3 A B C TB02 CONTROL SUPPLY 50/60Hz V~ 0.25A MAX TB06 TB MAIN SUPPLY CONTROL SUPPLY TB2 28~ 0~ L 5~ N 28~ 0~ L 5~ N TB3 MAIN SUPPLY CONTROL SUPPLY TB4 AC AC2 AC AC2 3rd CP MOTOR SUPPLY TB02 CONTROL SUPPLY TB06 MOTOR SUPPLY TB02 AC AC2 MAIN SUPPLY 28~ 0~ 28~ 0~ MAIN SUPPLY AC AC2 MOTOR SUPPLY TB02 CONTROL SUPPLY TB06 AC AC2 2nd CP CONTROL SUPPLY L 5~ N L 5~ N CONTROL SUPPLY AC AC2 4th CP CONTROL SUPPLY TB06 24VDC A MAX + Use to power User-Supplied ESTOP circuitry Transformer Module AEROTECH.COM DANGER! High Voltage ON O OFF HAZARDOUS VOLTAGES PRESENT CONNECT ALL WIRING BEFORE POWERING TRANSFORMER FOLLOW ALL APPLICABLE WIRING AND SAFETY CODES.. See the TM3 or TM5 manual for input voltage configuration 2. Wiring Specifications:.3 mm 2 (#6 AWG) 300 V wire. 3. Control Supply output voltage (5 VAC in this example) is always the same as the AC Input Voltage to the unit. Figure 2-9: Control and Motor Power Wiring using a TM3 or TM5 Transformer 36 Chapter 2

37 Installation and Configuration Minimizing Conducted, Radiated, and System Noise The generates conducted (AC line) and radiated noise. Conducted emissions are minimized by using line filters and should be located as close to the drive as possible for maximum effectiveness. User connections to the product must be made using shielded cables with metal D-style connectors and back shells. The shield of the cables must be connected to the metal back shell in order for the product to conform to radiated emission standards.the is a component designed to be integrated with other electronics. EMC testing must be conducted on the final product configuration. Ferrite beads can be used on the motor leads to reduce the effects of PWM noise. Table 2-7: Ferrite Noise Suppression Numbers Wire Size Aerotech P/N Third Party P/N 3.3 mm 2 (#6 AWG) N/A # Elna Fair-Rite Products 8.3 mm 2 (#8 AWG) ECZ00285 # Elna Fair-Rite Products 2.0 mm 2 (#4 AWG) EIZ0027 # Elna Fair-Rite Products.3 mm 2 (#6 AWG) EIZ0025 # Elna Fair-Rite Products 0.8 mm 2 (#8 AWG) EIZ000 # Elna Fair-Rite Products 0.5 mm 2 (#20 AWG) EIZ000 # Elna Fair-Rite Products Aerotech's UFM-ST AC line filter and isolation transformers connected to the motor supply AC input are also effective in reducing PWM generated noise and improving performance (refer to Section ). Table 2-8: UFM-ST Electrical Specifications Specification Input Voltage Range Output Voltage Range Maximum Continuous Current Frequency Phases Leakage Current Fuse Protection Value VAC VAC 8 A rms with convection cooling 0 A rms with forced air cooling 50/60 Hz Single Phase. ma (max) Internal 0 A fuses on AC and AC2 inputs AC AC2 TB- TB-2 F2 0 ASB 3AG F 0 ASB 3AG JP4 JP3 LINE INTERNAL FILTER COMPONENTS LOAD TB2- TB2-2 AC AC2 TO MAINS GND TB-3 QVR2 V20E385P QVR V20E385P TO DRIVE TB2-3 GND Figure 2-0: AC Line Filter (UFM-ST) Chapter 2 37

38 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 2-9: Motor Power Output Connections (TB02) Pin Description Recommended Wire Size ØA Phase A Motor Lead.3 mm 2 (#6 AWG) ØB Phase B Motor Lead.3 mm 2 (#6 AWG) ØC Phase C Motor Lead.3 mm 2 (#6 AWG) Earth Ground to Motor (required for safety).3 mm 2 (#6 AWG) Table 2-0: Motor Power Output Mating Connector Tightening Wire Size: Description Aerotech P/N Phoenix P/N Torque (Nm) AWG [mm 2 ] 7-Pin Terminal Block ECK [2-30]. Recommended Wire Size:.3 mm2 (#6 AWG) 38 Chapter 2

39 Installation and Configuration Brushless Motor Connections The configuration shown in Figure 2- is an example of a typical brushless motor connection. MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C TB02 Install Aerotech FBF-3 or FBF-4 or 0 beads per wire at drive (Elna Fair-Rite # or # ). Green/Yellow & Shield Black Red White Motor Frame AC Brushless Motor NOTE: Listed wire colors are for Aerotech supplied cables. Figure 2-: Brushless Motor Configuration Table 2-: 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 N O T E : Brushless motors are commutated electronically by the controller. The use of Hall effect devices for commutation is recommended. 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. N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. Chapter 2 39

40 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 2-2: Encoder and Hall Signal Diagnostics 40 Chapter 2

41 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 2-3. 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 2-3). Wave forms are shown while moving the motor in the positive direction. CHANNEL CHANNEL 2 Figure 2-3: 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 2-4). 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 2-4: Brushless Motor Phasing Goal Chapter 2 4

42 Installation and Configuration DC Brush Motor Connections The configuration shown in Figure 2-5 is an example of a typical DC brush motor connection. Refer to Section for information on motor phasing. MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C TB02 no connection Figure 2-5: Install Aerotech FBF-5 or FBF-6 or 0 beads per wire at drive (Elna Fair-Rite # or # ). Green & White & Shield Red & Orange Yellow & Blue Motor Frame + DC Brush - Motor NOTE: Listed wire colors are for Aerotech supplied cables. DC Brush Motor Configuration Table 2-2: 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 42 Chapter 2

43 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 2-6: 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 43

44 Installation and Configuration Stepper Motor Connections The configuration shown in Figure 2-7 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. MOTOR SUPPLY MOTOR OUTPUT AC AC2 A B C TB02 Install Aerotech FBF-3 or FBF-4 or 0 beads per wire at drive (Elna Fair-Rite # or # ). Green/Yellow & Shield Black Red White NOTE: Listed wire colors are for Aerotech supplied cables. Motor Frame B B' A Stepper Motor A' Figure 2-7: Stepper Motor Configuration Note the common connection of A and B phases. Table 2-3: 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 C 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 44 Chapter 2

45 Installation and Configuration Stepper Motor Phasing 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 2-8: POSITIVE MOTION Clockwise Motor Rotation N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. N O T E : After the motor has been phased, use the ReverseMotionDirection parameter to change the direction of positive motion. Chapter 2 45

46 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 2-4: 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 Absolute Encoder Interface Data - Bidirectional 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 Absolute Encoder Interface Data + Bidirectional 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

47 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 -MXU option, the standard encoder interface can be configured for an analog encoder input via parameter settings. Refer to Section for encoder feedback phasing. Refer to Section 2.6. for the auxiliary encoder channel. 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 2-5: 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 47

48 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 -MXU option (refer to Section for more information). Table 2-6: Encoder Specifications Specification Encoder Frequency x4 Quadrature Decoding Value 0 MHz maximum (25 nsec minimum edge separation) 40 million counts/sec +3.3V +3.3V 0K 0K 0K 0K J03-7 J03-8 J03-4 J DS26LV32AT 0K 0 ADG K 0K 0K +5V ENCODER FAULT DETECTION J03-6 J03-7 SIN+ SIN- COS+ COS- MRK- MRK+ ADM485 Figure 2-9: Line Driver Encoder Interface (J03) 48 Chapter 2

49 Installation and Configuration EnDat Encoder Interface (J03) The retrieves absolute position data along with encoder fault information via a serial data stream from the absolute encoder. See Figure 2-20 for the serial data stream interface. Set up of this interface requires setting parameters EnDatEncoderResolution, EnDatEncoderSetup, and EnDatEncoderTurns. The encoder interface pin assignment is indicated in Section V ABS CLK- J03-6 ABS CLK+ J03-7 ADM485 ABS DATA- J03-8 ABS DATA+ J03-9 Figure 2-20: 80 Serial Data Stream Interface ADM485 Chapter 2 49

50 Installation and Configuration Resolute Encoder Interface (J03) The retrieves absolute position data along with encoder fault information via a serial data stream from the resolute encoder. See Figure 2-2 for the serial data stream interface. Set up of this interface requires setting parameters ResoluteEncoderResolution, ResoluteEncoderSetup, and ResoluteEncoderUserResolution. The encoder interface pin assignment is indicated in Section V ABS CLK- J03-6 ABS CLK+ J03-7 ADM485 ABS DATA- J03-8 ABS DATA+ J03-9 Figure 2-2: 80 Serial Data Stream Interface ADM Chapter 2

51 Installation and Configuration Analog Encoder Interface If the -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 2-7: Specification Input Frequency (max) Input Amplitude Analog Encoder Specifications Interpolation Factor (software selectable) Value 200 khz 0.6 to 2.25 Vpk-Vpk 4,096 Refer to Figure 2-22 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 Positive MOVE (Clockwise) Figure 2-22: CW Rotation (Positive Direction) Analog Encoder Phasing Reference Diagram Motor Mounting Flange (Front View) 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 5

52 Installation and Configuration J03-7 SIN+ K 82PF K 82PF K J03-8 SIN- K 82PF 82PF K - + AD UF 6.3V J03-4 COS+ K A 82PF K 82PF K J03-5 COS- K 82PF 82PF K - + AD UF 6.3V J03-7 MRK+ K A 82PF K 82PF K J03-6 MRK- K 82PF 82PF K - + AD UF 6.3V A Figure 2-23: Analog Encoder Interface (J03) 52 Chapter 2

53 Installation and Configuration Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-24 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 2-25). 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 2-25) SIN LINEAR MOTOR Forcer Wires Positive MOVE (Clockwise) SIN-N Magnet Track Forcer COS Vpk-pk COS-N ROTARY MOTOR MRK MRK-N Positive MOVE (Clockwise) Figure 2-24: Motor Shaft CW Rotation (Positive Direction) Encoder Phasing Reference Diagram (Standard) Motor Mounting Flange (Front View) 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 53

54 Installation and Configuration Figure 2-25: Position Feedback in the Diagnostic Display 54 Chapter 2

55 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 2-8: 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 2-26: Hall-Effect Inputs (J03) Chapter 2 55

56 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 2-9: Thermistor Interface Pin Assignment (J03) Pin# Description In/Out/Bi 2 Motor Over Temperature Thermistor Input +5V K J03-2 THERMISTOR.00 0K.0UF Figure 2-27: Thermistor Interface Input (J03) 56 Chapter 2

57 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 2-20: Encoder Fault Interface Pin Assignment (J03) Pin# Description In/Out/Bi 23 Encoder Fault Input Input +5V K J03-23 ENCODER FAULT 0K.0UF.00 Figure 2-28: Encoder Fault Interface Input (J03) Chapter 2 57

58 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 2-3). 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. Opto-isolated user inputs 8- can also be used as the end-of-travel limit inputs, see Section V Limit Com 6 20 Normally closed shown (typical). MOTOR FEEDBACK J03 CW CCW Home 22 May be a separate switch. Figure 2-29: End of Travel Limit Input Connections Table 2-2: 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 58 Chapter 2

59 0K 0K 0K Installation and Configuration +5V J03-2 J03-24 J03-22 CW LMT CCW LMT HM LMT 0K 0K 0K UF.0UF.0UF Figure 2-30: End of Travel Limit Interface Input (J03) Chapter 2 59

60 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 2-3). Figure 2-3: Limit Input Diagnostic Display 60 Chapter 2