Ndrive MP 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 MOTOR FEEDBACK 4 J03 OPTO IN MOTOR FEEDBACK J03 0 TB203 MOTOR SUPPLY MOTOR TB02 OUTPUT DC+ DC- A B C DC+ DC- A B C MOTOR SUPPLY MOTOR TB02 OUTPUT OPTO OUT 0 TB204 80VDC MAX 0AMP MAX 80VDC 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 PCto-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 Table of Contents List of Figures List of Tables EC Declaration of Conformity Agency Approvals Safety Procedures and Warnings Quick Installation Guide Chapter : Introduction.. Drive and Software Compatibility 4.2. Electrical Specifications System Power Requirements Power Dissipation 7.3. Mechanical Design 8.4. Environmental Specifications 9 Chapter 2: Installation and Configuration 2.. Communication Channel Settings 2.2. Power Connections Control Supply Connections (TB03) Motor Supply Connections (TB02) External Power Supply 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) 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) Analog Input 0 (J03) Emergency Stop Sense Input (TB0) Typical ESTOP Interface FireWire Interface PC Configuration and Operation Information 48 Chapter 3: -I/O Expansion Board User Power (TB20) 50 iii v vii ix x xi xiii iii

4 Table of Contents 3.2. Brake Power Supply (TB20) Solid State Relay Specifications (TB20) Analog Output (TB202) Analog Input (TB202) Opto-Isolated Inputs (TB203) Opto-Isolated Outputs (TB204) Auxiliary Encoder Channel/PSO Output (J20) Position Synchronized Output (PSO)/Laser Firing (J20) 66 Chapter 4: Standard Interconnection Cables Joystick Interface Handwheel Interface 72 Chapter 5: Maintenance Control Board Preventative Maintenance 76 Appendix A: Warranty and Field Service 77 Appendix B: Revision History 79 Index 8 iv

5 Table of Contents List of Figures Figure -: Networked Digital Drive Figure -2: Functional Diagram 3 Figure -3: Power Dissipation vs. Output Current 7 Figure -4: Ambient Temperature vs. Power Dissipation 7 Figure -5: Dimensions 8 Figure 2-: Device Number (S) Location Figure 2-2: Control Supply Connections 4 Figure 2-3: Motor Bus Input Connections 5 Figure 2-4: Control and Motor Power Wiring using a TM3 Transformer 6 Figure 2-5: PS-MP Option 7 Figure 2-6: Brushless Motor Configuration 20 Figure 2-7: Encoder and Hall Signal Diagnostics 22 Figure 2-8: Motor Phasing Oscilloscope Example 23 Figure 2-9: Hall Phasing with Oscilloscope 24 Figure 2-0: Brushless Motor Phasing Goal 25 Figure 2-: DC Brush Motor Configuration 26 Figure 2-2: Clockwise Motor Rotation 27 Figure 2-3: Stepper Motor Configuration 28 Figure 2-4: Clockwise Motor Rotation 29 Figure 2-5: Line Driver Encoder Interface (J03) 32 Figure 2-6: Analog Encoder Phasing Reference Diagram 33 Figure 2-7: Analog Encoder Interface (J03) 34 Figure 2-8: Encoder Phasing Reference Diagram (Standard) 35 Figure 2-9: Position Feedback in the Diagnostic Display 36 Figure 2-20: Hall-Effect Inputs (J03) 37 Figure 2-2: Thermistor Interface Input (J03) 38 Figure 2-22: Encoder Fault Interface Input (J03) 39 Figure 2-23: End of Travel Limit Input Connections 40 Figure 2-24: End of Travel Limit Interface Input (J03) 4 Figure 2-25: Limit Input Diagnostic Display 42 Figure 2-26: Analog Input 0 (J03) 44 Figure 2-27: ESTOP Sense Input (TB0) 45 Figure 2-28: Typical Emergency Stop Circuit 46 Figure 3-: with -IO Option Board 49 Figure 3-2: Brake Connected to J03 52 Figure 3-3: Brake Connected to TB20 53 Figure 3-4: Analog Output Connector (TB202) 55 Figure 3-5: Analog Input Typical Connection (TB202) 56 Figure 3-6: Opto-Isolated Inputs 58 Figure 3-7: Inputs Connected to a Current Sourcing Device 59 Figure 3-8: Inputs Connected to a Current Sinking Device 59 Figure 3-9: Opto-Isolated Outputs (-IO Board) 6 Figure 3-0: Outputs Connected in Current Sourcing Mode 62 Figure 3-: Outputs Connected in Current Sinking Mode 63 Figure 3-2: Auxiliary Encoder Channel (J20) 65 Figure 3-3: PSO Interface 67 Figure 4-: Single Axis Joystick Interface 70 Figure 4-2: Two Axis Joystick Interface 70 Figure 4-3: Handwheel Interconnection (to Aux I/O) 72 Figure 5-: Control Board Assembly 74 v

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7 Table of Contents List of Tables Table -: Feature Summary 2 Table -2: Accessories 2 Table -3: A3200 Drive and Software Compatibility 4 Table -4: Electrical Specifications 5 Table -5: Physical Specifications 8 Table 2-: Device Number Switch Settings (S) 2 Table 2-2: PS-MP AC Power Wiring Requirements 3 Table 2-3: Control Supply DC Input Wiring 4 Table 2-4: Control Supply Mating Connector 4 Table 2-5: Motor Supply Mating Connector 5 Table 2-6: External Power Supply Options 6 Table 2-7: Motor Supply Input Wiring 8 Table 2-8: Motor Power Output Connections (TB02) 9 Table 2-9: Motor Power Output Mating Connector 9 Table 2-0: Wire Colors for Aerotech Supplied Cables (Brushless) 20 Table 2-: Wire Colors for Aerotech Supplied Cables (DC Brush) 26 Table 2-2: Wire Colors for Aerotech Supplied Cables (Stepper) 28 Table 2-3: Motor Feedback Connector Pin Assignment (J03) 30 Table 2-4: Encoder Interface Pin Assignment 3 Table 2-5: Analog Encoder Specifications 33 Table 2-6: Hall-Effect Feedback Interface Pin Assignment (J03) 37 Table 2-7: Hall-Effect Feedback Interface Pin Assignment (J03) 38 Table 2-8: Encoder Fault Interface Pin Assignment (J03) 39 Table 2-9: End of Travel Limit Input Interface Pin Assignment (J03) 40 Table 2-20: Brake Output Pin Assignment (J03) 43 Table 2-2: Analog Input Connector Pin Assignment (J03) 44 Table 2-22: Electrical Noise Suppression Devices 45 Table 2-23: Electrical Noise Suppression Devices 45 Table 2-24: TB0 Mating Connector 45 Table 2-25: Typical ESTOP Relay Ratings 46 Table 2-26: FireWire Card Part Numbers 47 Table 2-27: FireWire Repeaters (for cables exceeding 4.5 m (5 ft) specification) 47 Table 2-28: FireWire Cables (copper and glass fiber) 47 Table 3-: User Common Connector Pin Assignment (TB20) 50 Table 3-2: Brake Output Connector Pin Assignment (TB20) 5 Table 3-3: Mating Connector (TB20) 5 Table 3-4: Brake Output Connector Pin Assignment (J03) 5 Table 3-5: Relay Specifications 54 Table 3-6: Analog Output Connector Pin Assignment (TB202) 55 Table 3-7: Analog Output Mating Connector 55 Table 3-8: Analog Inputs Connector Pin Assignment (TB202) 56 Table 3-9: Analog Input Mating Connector 56 Table 3-0: PS Opto-Device Specifications 57 Table 3-: Opto-Isolated Input Connector Pin Assignment (TB203) 57 Table 3-2: Opto-Isolated Input Mating Connector 57 Table 3-3: Opto-Isolated Output Connector Pin Assignment (TB204) 60 Table 3-4: Opto-Isolated Output Mating Connector 60 Table 3-5: Output Specifications (TB204) 62 Table 3-6: Auxiliary Encoder Channel Pin Assignment (J20) 64 Table 3-7: PSO Output Pin Assignment (J20) 66 Table 3-8: PSO Output Sources 66 vii

8 Table of Contents Table 4-: Standard Interconnection Cables 69 Table 4-2: Cable Part Numbers 7 Table 5-: LED Description 73 Table 5-2: Control Board Fuse Information 75 Table 5-3: LED Description 75 Table 5-4: Preventative Maintenance 76 viii

9 Declaration of Conformity EC 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): 2004/08/EC 2006/95/EC 20/65/EU Electromagnetic Compatibility Directive Low Voltage Directive 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 EN EN EN EN EN EN EN EN EN EN 600- 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 / Alex Weibel Position Engineer Verifying Compliance Location Pittsburgh, PA Date July 9, ix

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 File / Report #: Standards: UL 600-; CAN/CSA-C22.2 No x

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. Make sure the and all components are 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. xi

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 the to environments or conditions outside of the listed specifications. Exceeding environmental or operating specifications can cause damage to the equipment. 5. If the is used in a manner not specified by the manufacturer, the protection provided by the 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. The is intended for light industrial manufacturing or laboratory use. Use of the for unintended applications can result in injury and damage to the equipment. xii

13 Quick Installation Guide Quick Installation Guide This chapter describes the order in which connections and settings should typically be made to the Ndrive MP. 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. TM A3200 AEROTECH. COM J20 TB0 ESTOP VDC AMP MAX DC- 3 J0 J02 FIREWIRE CFG DEVICE NUMBER S DC+ TB03 CONTROL SUPPLY ENA MRK CTL POS 4 TB20 TB202 S/N - P/N - ON 2 4 WARNING: DISCONNECT POWER BEFORE SERVICING MOTOR FEEDBACK J03 OPTO IN 0 SEE MANUAL FOR SWITCH SETTINGS DANGER! High Voltage TB DC+ DC- A B C MOTOR SUPPLY MOTOR TB02 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). 80VDC MAX 0AMP MAX 5 Connect to the Control Supply (TB03). 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 2.6. FireWire Interface Section Control Supply Connections (TB03) Section Motor Supply Connections (TB02) User / Application dependent xiii

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15 Introduction Chapter : Introduction Aerotech s (Ultra-Compact "Micro" PWM) network digital drive is a high performance amplifier.the drive provides deterministic behavior, auto-identification, and easy software setup. The Ndrive MP 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. TM A3200 AEROTECH. COM J20 TB0 ESTOP 24-80VDC AMP MAX DC- J0 J02 FIREWIRE CFG DEVICE NUMBER S TB03 CONTROL SUPPLY DC+ 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 DC+ DC- A B C 80VDC MAX 0AMP MAX MOTOR MOTOR SUPPLY TB02 OUTPUT OPTO OUT 0 TB204 Standard Connector Description J0 FireWire Port J02 FireWire Port J03 Motor Feedback TB0 Emergency Stop Sense Input (ESTOP) TB02 Motor Supply TB02 Motor Output TB03 Control Supply -IO Board Option Connector Description J20 Auxiliary Encoder Interface TB20 Brake Relay TB202 Analog I/O TB203 Opto-Inputs TB204 Opto-Outputs Figure -: Networked Digital Drive Chapter

16 Introduction Table -: Feature Summary Standard Features Line driver square wave quadrature encoder input for position and velocity feedback One 2-bit differential analog input (±0 V) Dedicated 5-24 V Emergency Stop sense input 0-80 VDC motor supply inputs VDC control supply inputs Options -IO One 6-bit analog output (±5 V) One 2-bit differential analog input One fail-safe brake or user relay output -MXU 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 Table -2: Accessories 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 External Power Supply Options Refer to Section for more information 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 -MXU Option SIN, COS, MRK (RS422) 8 Opto Outputs (Sinking or Sourcing) TB204 Opto Out J03 Motor Feedback 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 Inputs (Sinking or Sourcing) TB203 Opto In TB03 Control Supply DC+ DC- DC- DC+ Isolated Power Supply Brake Power Input or Relay TB20 Brake Relay TB02 Motor Supply DC+ DC- DC- DC+ Heatsink Over Temperature PWM Power Amplifier A B C A B C TB02 Motor Output Figure -2: Functional Diagram Chapter 3

18 Introduction.. Drive and Software Compatibility The following table lists the available A3200 drives and which version of the A3200 software first provided support for a given drive. Drives that list a specific version number in the Last Software Version column will not be supported after the listed version. Table -3: A3200 Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version CL Current A 2.55 Current CP A 2.0 Current B 2.9 Current FLS Current FLS A Current HL HLe Current HP A HPe Current ML Current MP Current Nmark CLS Current Nmark CLS A Current Nmark SSaM Current Nmark SSaM A Current Npaq () A 2.09 Current Nservo Current Nstep Current QL/QLe Current () This section does not apply to the Npaq MR. The Npaq MR contains multiple ML or MP drives. Refer to either the ML or MP drive type to determine the value for your Npaq MR. 4 Chapter

19 Introduction.2. Electrical Specifications Table -4: Electrical Specifications MP 0 Motor Supply Input Voltage 0-80 VDC Maximum Continuous Input Current 5 A rms Input Current Refer to Section.2.. System Power Requirements Control Supply Output Voltage () Input Voltage VDC (±0%) Input Current A max 0-80 VDC Peak Output Current ( second) 0 A Continuous Output Current 5 A Power Amplifier Bandwidth 2500 Hz maximum (software selectable) Power Amplifier Efficiency 85% - 95% (2) PWM Switching Frequency 20 khz Minimum Load Inductance VDC User Power Supply Output 5 VDC (@ 500 milliamps) Modes of Operation Brushless; Brush; Stepper Protective Features Output short circuit; Peak over current, DC bus over voltages; RMS over current; Over temperature; Control power supply under voltage; Power stage bias supply under voltage Isolation Optical and transformer isolation between control and power stages. () AC input voltage and load dependent. (2) Dependent on total output power: efficiency increases with increasing output power. Chapter 5

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 6 Chapter

21 Introduction.2.2. Power Dissipation The first figure below shows the amplifier power dissipation under continuous power supply and output current conditions. 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. The second figure 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 heat-sinking and providing additional fan flow are suggested. Power Dissipation (W) V Bus 40V Bus Output Current (A) Figure -3: Power Dissipation vs. Output Current Ambient Temperature (C) Absolute Maximum Recommended Amplifier Dissipation (W) Figure -4: Ambient Temperature vs. Power Dissipation EXAMPLE: 80 VDC Bus operation at 2.4 A Power Dissipation = 7.5 Watts Maximum Ambient Temperature = 53 C Chapter 7

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. 7.6 [0.30] 4. [.62] 25.4 [.00] DIMENSIONS: MM [INCH] Dimensions apply to the standard and I/O version (shown) of the MP drive. TM A3200 AEROTECH. COM J20 J0 FIREWIRE J02 ENA MRK CTL POS 4 TB20 TB [6.20] 49.2 [5.88] 4. [0.6] DC+ DC- A B C MOTOR FEEDBACK J03 80VDC MAX 0AMP MAX MOTOR SUPPLY MOTOR TB02 OUTPUT OPTO IN 0 OPTO OUT [0.6] (TYP.) TB203 TB204 REC. MTG. HDWR: M3.5 [#6] 8. [0.32] 4.2 [5.56] 07.0 [4.2] 2.4 [4.78] Drawing Number: 630D [0.0] Figure -5: Dimensions Table -5: Physical Specifications Weight Standard kg (.0 lb) w/ -IO option kg (.2 lb) w/ -MXH option kg (.2 lb) Typical Size 00 mm x 25 mm x 2.4 mm (4 in x 5 in x in) 8 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 9

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25 Installation and Configuration Chapter 2: Installation and Configuration 2.. Communication Channel Settings Use the Device Number switches of S 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. S CFG DEVICE NUMBER ON TB0 ESTOP CFG DEVICE NUMBER S ON S/N - P/N - WARNING: DISCONNECT POWER BEFORE SERVICING SEE MANUAL FOR SWITCH SETTINGS DANGER! High Voltage Figure 2-: Device Number (S) Location Chapter 2

26 Installation and Configuration 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 Chapter 2

27 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. An example of a wiring drawing for a typical PS-MP system showing the power inputs, as well as wiring for the optional fail-safe brake, is provided in Figure 2-5. The AC operating voltage of the PS-MP system can be configured for different operating voltages. The example system shown in Figure 2-5 is configured for 5 VAC. Purchased PS-MP 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 2-2: PS-MP 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 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-MP 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. Chapter 2 3

28 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 control power supply operates from VDC (±0%). The DC+ input is internally fused. A small ferrite filter may be required to minimize radiated emissions. This should be located close to the. TB03 CONTROL SUPPLY Core Ferrite (EIZ00286, Ferroxcube #TX22/4/6.4-3C8) DC+ Twist wires to reduce interference. DC+ DC- DC- Ground 24-80VDC AMP MAX At Control and Motor Supply inputs of each MP drive, wrap DC+ and DC- wires around a Ferrite Core (EIZ00286) 6 turns. Do not wrap the ground wire. Figure 2-2: Control Supply Connections Table 2-3: Control Supply DC Input Wiring Pin Description Recommended Wire Size DC VDC (±0%) Control Power Input (20 Watt Max) 0.5 mm 2 (#20 AWG) DC- Control Power Common Input () 0.5 mm 2 (#20 AWG) Protective Ground (Required for Safety) 0.5 mm 2 (#20 AWG) () For an isolated DC supply, connect DC- to protective ground at the supply. Table 2-4: Control Supply Mating Connector Tightening Type Aerotech P/N Phoenix P/N Torque (Nm) Wire Size: mm 2 [AWG] 3-Pin Terminal Block ECK [4-30] 4 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 2-3 for locations). The recommended wire size is 0.5 mm 2 (#20 AWG). For an isolated DC supply, connect DC- to Protective Ground at the supply. The wire must be properly matched to the fuses or circuit breakers and must be sized to meet local electrical safety codes. A small ferrite filter may be required to minimize radiated emissions. This should be located close to the MP. See Figure 2-3 for more details. W A R N I N G : Do not operate the without the safety ground connection in place. Core Ferrite (EIZ00286, Ferroxcube #TX22/4/6.4-3C8) 0-80 VDC MOTOR SUPPLY Twist wires to reduce interference. DC+ DC+ DC- DC- A B C TB02 MOTOR OUTPUT At Control and Motor Supply inputs of each MP drive, wrap DC+ and DC- wires around a Ferrite Core (EIZ00286) 6 turns. Do not wrap the ground wire. Ground Figure 2-3: Motor Bus Input Connections Table 2-5: Motor Supply Mating Connector Tightening Type Aerotech P/N Phoenix P/N Torque (Nm) Wire Size: mm 2 [AWG] 7-Pin Terminal Block ECK [4-30] Chapter 2 5

30 Installation and Configuration External Power Supply Options Two VDC power options are available to power up to four MPs. Table 2-6: External Power Supply Options Description TM3 () Power up to 4 drives, providing 300 watts of power (refer to Figure 2-4). PS-MP Din-rail mounted DC power supply for up to 4 axes (refer to Figure 2-5). The din-rail mounting clip requires 6-32 x 5/6 flat head screws to attach the MP to the din-rail clip. () Refer to the TM3 Users Manual, EDO7, for more information. st MP TM3 Transformer Module DC+ TB03 CONTROL SUPPLY DC+ DC- DC- MOTOR SUPPLY TB TB MAIN SUPPLY CONTROL SUPPLY TB3 MAIN SUPPLY CONTROL SUPPLY 3rd MP DC+ DC- DC+ DC- Motor Control Supply Supply 2nd MP DC+ DC- Motor Supply TB2 MAIN SUPPLY TB4 MAIN SUPPLY 4th MP DC+ DC- Motor Supply Control Supply DC+ DC- CONTROL SUPPLY CONTROL SUPPLY DC+ DC- Control Supply Use to power User-Supplied ESTOP circuitry 24VDC A MAX + 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 manual for input voltage configuration. 2.The TM3 must be configured for ±40 VDC or ±80 VDC output. 3. Transformer Wiring: 0.5 mm 2 (#20 AWG) 300 V wire. 4. The Auxiliary Supply has been relabeled Control Supply as of April Figure 2-4: Control and Motor Power Wiring using a TM3 Transformer 6 Chapter 2

31 A B C 4 4 A B C 4 4 A B C 4 4 A B C Installation and Configuration 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 Only BLK and BLK/WHT wires through core assemblies. Connection Description Wire Size (minimum) 4.5 in Cable Tie (EIZ0000) AC INPUT REQUIREMENTS 3C Controls Terminal Block WTB2-W4 (ECK0400) 3C Controls Terminal Block Ground WTB2-W2/4G (ECK0402) 3C Controls Terminal Block End Cover WTB2-EPW2/4 (ECK0403) 3C Controls End Barrier Clamp WTB2-EB (ECK0404) All A dimensions are approximate. Dimensions: Millimeters [Inches] Approximately 6 In. Wrap wire 6 turns A: [8.83] A: [3.88] A: [20.49] A: [23.] B: [6.87] B: [.9] B: [8.52] B: [2.5] 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 -Axis 2-Axis 3-Axis 4-Axis DIMENSIONS (without Brake Option) Core Ferrite (EIZ00286, Ferroxcube #TX22/4/6.4-3C8) 5 -Axis 2-Axis 3-Axis 4-Axis A: [2.2] A: [7.4] A: [23.75] A: [26.38] B: [0.5] B: [5.7] B: [2.78] B: [24.4] 4 The Din Rail clip kit (MP-DIN) must be installed prior to mounting rail. Use 6-32 x 5/6 flat head screws to mount the MP to the Din Rail clip. 8 At Control and Motor Supply inputs of each MP drive, wrap DC+ and DC- wires around a Ferrite Core (EIZ00286) 6 turns. Do not wrap the ground wire. DIMENSIONS (with Brake Option) TERMINAL BLOCK DEFINITION (For Reference Only) 3 All twisted wires must be twisted at least 2 turns/inch. Din Rail should be cut such that one complete mounting hole extends beyond components on each end. System wiring shown with a neutral line configuration. If applied A.C. does not contain a neutral, neutral line "N" must be properly fused by the user. 9 TWIST 3 7 TB03 CONTROL SUPPLY DC+ DC- 2 TWIST 3 Control and Brake Power Supply Specifications 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) VDC AMP MAX TWIST 3 Before Crimping After Crimping TWIST 3 CONTROL SUPPLY CONNECTOR DETAIL 6 Ferrule Crimping Due to the small size of the MP power connectors, twin type ferrules should be crimped as shown below #6 BRN #6 GRN/YEL #6 BLU #6 BLU #6 GRN/YEL #6 BRN #22 BLK #22 BLK/WHT #22 BLK #22 BLK/WHT #22 BLK #22 BLK/WHT #22 BLK #22 BLK/WHT TWIST TWIST TWIST TWIST TWIST TWIST #20 GRN/YEL #20 BLK #20 BLK/WHT #20 GRN/YEL 80VDC MAX 0AMP MAX 80VDC MAX 0AMP MAX 80VDC MAX 0AMP MAX 80VDC MAX 0AMP MAX MOTOR OUTPUT TB204 MOTOR OUTPUT TB204 MOTOR OUTPUT TB204 MOTOR OUTPUT TB204 0 #20 BLK #20 BLK/WHT #20 GRN/YEL 0 #20 BLK #20 BLK/WHT #20 GRN/YEL 0 #20 BLK #20 BLK/WHT #20 GRN/YEL 0 DIN RAIL (EAM0094) N L N L LED -V -V +V +V 8 TB02 OPTO-OUT 8 TB02 OPTO-OUT 8 TB02 OPTO-OUT 8 TB02 OPTO-OUT INPUT OUTPUT P/N DC+ DC- MOTOR SUPPLY DC+ DC- MOTOR SUPPLY DC+ DC- MOTOR SUPPLY DC+ DC- MOTOR SUPPLY TB203 TB203 TB203 TB INPUT: ~00-240VAC OUTPUT: 24VDC, 3.2A (ALTECH-PS-7524) 2 J03 J03 J03 J03 5VAC INPUT OUTPUT P/N ~00-20 VAC or ~ VAC +48 VDC, 2.5 A ALTECH-PS-2048-A 2-AXIS POWER SUPPLY ~ VAC +48 VDC, 5 A ALTECH-PS A INPUT OUTPUT P/N INPUT OUTPUT P/N ~00-20 VAC or ~ VAC +48 VDC, 0 A ALTECH-PS-480S48-A 4-AXIS POWER SUPPLY ~00-20 VAC or ~ VAC +48 VDC, 0 A ALTECH-PS-480S48-A MOTOR FEEDBACK OPTO-IN MOTOR FEEDBACK OPTO-IN MOTOR FEEDBACK OPTO-IN MOTOR FEEDBACK OPTO-IN OPTIONAL BRAKE POWER SUPPLY 230VAC -AXIS POWER SUPPLY 3-AXIS POWER SUPPLY 2 POWER SUPPLY TB20 TB202 TB20 TB202 TB20 TB202 TB20 TB202 ENA MRK CTL POS ENA MRK CTL POS ENA MRK CTL POS ENA MRK CTL POS BRN BLU GRN/YEL J02 J02 J02 J02 +V +V -V -V LED FIREWIRE FIREWIRE FIREWIRE FIREWIRE J0 J0 J0 J0 J20 J20 J20 J20 AEROTECH. COM TM A3200 AEROTECH. COM TM A3200 AEROTECH. COM TM A3200 AEROTECH. COM TM A TWIST AC 5 VAC AC2 5 VAC PROTECTIVE GROUND AXIS AXIS 2 AXIS 3 AXIS 4 #22 BLU/WHT #22 BLU DIMENSION B 9 DIMENSION A DIN RAIL (EAM0094) Figure 2-5: PS-MP Option Chapter 2 7

32 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 the 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 (Aerotech s FBF- or FBF-2 filter adapters) can be used on the motor leads to reduce the effects of PWM noise. Table 2-7: Motor Supply Input Wiring 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 8 Chapter 2

33 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 2-8: 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 2-9: Motor Power Output Mating Connector Tightening Type Aerotech P/N Phoenix P/N Torque (Nm) Wire Size: mm 2 [AWG] 7-Pin Terminal Block ECK [4-30] Chapter 2 9

34 Installation and Configuration Brushless Motor Connections The configuration shown in Figure 2-6 is an example of a typical brushless motor connection. DC+ DC- A B C MOTOR SUPPLY TB02 MOTOR OUTPUT Install Aerotech FBF- or FBF-2, 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 2-6: Brushless Motor Configuration Table 2-0: 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 drive 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. There are two methods for verifying motor connections: powered, through the use of a test program; and an unpowered method using an oscilloscope. Both methods will identify the A, B, and C Hall/motor lead sets and indicate the correct connections to the drive. N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. 20 Chapter 2

35 Installation and Configuration Powered Motor Phasing To test the initial set of motor connections, run the MsetDebug.Pgm test program. The program will attempt to move the motor forward in a positive (CW) direction. Depending on the information that the program gathers during the test, you may be prompted to rearrange motor lead connections and run the test again. Refer to Section for connector pin output information. W A R N I N G : The MsetDebug.Pgm program moves the motor in Open-Loop mode, bypassing many of the standard safety faults. W A R N I N G : It is recommended that rotary motors be disconnected from the stage/load before running this test. Linear motor systems must be free from obstruction to prevent damage to other components. Operators must remain clear of all moving parts during the test. Hall Signal Phasing (connections to J03): With the information gathered while the program is running, the Hall signal wires may have to be swapped. After the Hall sequence is correct, the program will determine if a commutation offset is required (and calculate a value for the CommutationOffset 2 parameter that will have to be entered into the parameter editor). Refer to Section for more information and connector pin output assignments. Encoder Phasing (connections to J03): The MsetDebug.Pgm program also determines if the feedback wiring is correct. Follow the program prompts to establish the correct feedback wiring. Refer to Section 2.4. for connector pin output assignments and Section for phasing information. Feedback Monitoring: The state of the encoder and Hall-effect device signals can be observed in the Status Utility. A L for the given Hall input indicates zero voltage or logic low, where a H indicates 5V or logic high. MotorVerification.pgm has replaced MSetDebug.pgm in software version CommutationOffset has replaced CfgMotOffsetAng in software version Chapter 2 2

36 Installation and Configuration Figure 2-7: Encoder and Hall Signal Diagnostics 22 Chapter 2

37 Installation and Configuration Unpowered Motor and Feedback Phasing Disconnect the motor from the controller and connect the motor in the test configuration (as shown in Figure 2-8). 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 2-8). To determine the relative phasing/order of the three motor lead signals in relation to each other, connect channel of the oscilloscope to TP. Connect channel 2 to TP2 and move the motor in the positive direction (CW) by hand. Note the peak of the sine wave signal of channel in comparison to the peak of the sine wave signal of channel 2. Next, disconnect channel 2 from TP2 and reconnect it to TP3 and again move the motor in the positive direction. Note the peak of the sine wave signal of channel 3 in comparison to the peak of the sine wave signal of channel. Aerotech phasing configuration expects ØC to be the lead signal (in time), ØB to follow it, and ØA to follow ØB. This means that whichever signal has its sine wave peak farthest to the left should be designated as the ØC signal. Channel at TP and Channel 2 at TP2 Channel at TP and Channel 2 at TP3 CH2 (TP2) CH2 (TP3) CH (TP) CH (TP) Signals Combined for Comparison ØC ØB ØA ØC ØB CHANNEL CHANNEL 2 TP TP2 TP3 TP4 Power Supply COM +5V TP5 TP6 TP7 In this example: The peak of the sine wave signal at TP2 precedes the peaks of the sine wave signals at TP and TP3. The peak of the sine wave signal at TP precedes the peak of the sine wave signals at TP3. TP2 = Motor Lead 2 = ØC signal TP = Motor Lead = ØB signal TP3 = Motor Lead 3 = ØA signal After the phasing process is complete, the ØA, ØB, and ØC signal motor leads should be connected to their respective Motor Outputs (A to A, B to B and C to C). 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 DC+ DC- A B C MOTOR SUPPLY MOTOR TB02 OUTPUT Figure 2-8: Motor Phasing Oscilloscope Example Chapter 2 23

38 Installation and Configuration After the motor leads have been tested, the next step is to determine the phase of the Hall signals. The required (by an Aerotech system) relationship between motor and Hall leads is that the peak of a motor lead signal should correspond to the low voltage phase of the Hall signal (as shown in Figure 2-9). With channel still connected to one of the motor leads, connect channel 2 of the oscilloscope to TP5, TP6, and then TP7, while advancing the motor in the positive direction after each connection. Note which of the three Hall signals has the complimentary phase relationship to the motor lead that channel is connected to (as shown in Figure 2-9). Move channel of the oscilloscope to the second motor lead and repeat the steps from above. Note which Hall signal corresponds to the currently selected motor lead and repeat the process for the 3rd motor lead. Channel at TP and Channel 2 at TP5, TP6, and TP7 TP TP5 (CH2) TP6 (CH2) TP7 (CH2) Hall B CHANNEL TP2 TP3 TP4 TP (CH) ØB Power Supply COM +5V Channel at TP2 and Channel 2 at TP5, TP6, and TP7 TP5 (CH2) TP6 (CH2) TP7 (CH2) TP2 (CH) Channel at TP3 and Channel 2 at TP5, TP6, and TP7 TP5 (CH2) TP6 (CH2) TP7 (CH2) TP3 (CH) Hall C ØC Hall A ØA TP5 TP6 CHANNEL 2 TP7 In this example: The low voltage phase of the TP6 Hall signal corresponds with the peak phase of the motor sine wave of TP (in the previous example designated as ØB). The signal at TP6 should be designated as Hall B. Motor Feedback Hall Pin Assignemt The low voltage phase of the TP7 Hall signal corresponds with the peak phase of the motor sine wave of TP2 (in the previous example designated as ØC). The signal at TP7 should be designated as Hall C. The low voltage phase of the TP5 Hall signal corresponds with the peak phase of the motor sine wave of TP3 (in the previous example designated as ØA). The signal at TP5 should be designated as Hall A. After the phasing process is complete, the Hall A, Hall B, and Hall C signal leads should be connected to their respective Motor Feedback connector inputs (Hall A to Pin 0, Hall B to Pin 5, and Hall C to Pin ). Pin Hall C Hall A Hall B Hall Positions Hall A Hall B Hall C Figure 2-9: Hall Phasing with Oscilloscope 24 Chapter 2

39 Installation and Configuration 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. Connect Hall lead A to Pin 0 of the feedback connector. Hall lead B should connected to Pin 5 and Hall lead C should connect to Pin of the feedback connector. The motor is correctly phased when the Hall states correspond to the states at each of the electrical angles. The Hall signal leads must be associated with its corresponding motor leads Hall A Hall B +5V 0V Hall C ØC ØB ØA ØC ØB +V Motor Back EMF 0V -V Motor Feedback Connector Hall Positions Corresponding Motor Lead Motor Output Connector Pin 0 Pin 5 Pin Hall A Hall B Hall C ØA ØB ØC Figure 2-0: Brushless Motor Phasing Goal Chapter 2 25

40 Installation and Configuration DC Brush Motor Connections The configuration shown in Figure 2- is an example of a typical DC brush motor connection. Refer to Section for information on motor phasing. DC+ DC- A B C MOTOR SUPPLY TB02 MOTOR OUTPUT no connection Install Aerotech FBF- or FBF-2, 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. Figure 2-: DC Brush Motor Configuration Table 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 26 Chapter 2

41 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 POSITIVE MOTION Figure 2-2: 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 27

42 Installation and Configuration Stepper Motor Connections The configuration shown in Figure 2-3 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. DC+ DC- MOTOR SUPPLY Install Aerotech FBF- or FBF-2, or 0 Beads per wire at drive (Elna Fair-Rite # , or # ) Motor Frame A A' A B C TB02 MOTOR OUTPUT Green/Yellow & Shield Black Red White NOTE: Listed wire colors are for Aerotech supplied cables. B B' Stepper Motor Note the common connection of A and B phases. Figure 2-3: Stepper Motor Configuration Table 2-2: 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 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 28 Chapter 2

43 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 POSITIVE MOTION Figure 2-4: Clockwise Motor Rotation N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. N OT E : After the motor has been phased, use the ReverseMotionDirection 2 parameter to change the direction of positive motion. CountsPerUnit has replaced CntsPerMetricUnit, CntsPerEnglishUnit, and CntsPerRotaryUnit in software version ReverseMotionDirection has replaced the functionality of reversing the sign on the CntsPer*Unit to change the direction of positive motion in software version Chapter 2 29

44 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 2-3: 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

45 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. 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 2-4: 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 3

46 Installation and Configuration RS-422 Line Driver Encoder (Standard) The standard encoder interface accepts an RS-422 differential quadrature line driver signal in the range of 0 to 5 Volts. It accepts a 0 MHz (max) encoder signal frequency (25 nsec minimum edge separation), producing 40 million counts per second after times four (x4) quadrature decoding. An analog encoder is used with the -MXU option (refer to Section for more information). +3.3V +3.3V 0K 0K 0K 0K J03-7 J03-8 SIN+ MRK+ MRK- COS+ COS- SIN- 80 J03-7 J03-6 J03-4 J DS26LV32AT ENCODER FAULT DETECTION Figure 2-5: Line Driver Encoder Interface (J03) 32 Chapter 2

47 Installation and Configuration Analog Encoder Interface If the -MXU option has been purchased, the standard encoder channel will accept an analog encoder input signal. The multiplication (interpolation) factor is determined by the EncoderMultiplicationFactor parameter. Table 2-5: Analog Encoder Specifications Specification Description Input Frequency (max) 200 khz Input Amplitude 0.6 to 2.25 Vpk-Vpk Interpolation Factor (software selectable) 4,096 Refer to Figure 2-6 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) CW Rotation (Positive Direction) Motor Mounting Flange (Front View) Figure 2-6: 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. EncoderMultiplicationFactor has replaced CfgFbkEncMultFactorMxu in software version Chapter 2 33

48 Installation and Configuration J03-7 MRK+ K 82PF 82PF J03-6 MRK- K K 82PF 82PF A 82PF 82PF K K - + AD822 K UF 6.3V A J03-7 SIN+ K 82PF 82PF J03-8 SIN- K K 82PF 82PF A 82PF 82PF K K - + AD822 2K UF 6.3V A J03-4 COS+ K 82PF 82PF K 82PF K J03-5 COS- K 82PF A 82PF 82PF K - + AD822 2K UF 6.3V A Figure 2-7: Analog Encoder Interface (J03) 34 Chapter 2

49 Installation and Configuration Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-8 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 2-9). The MsetDebug.Pgm program can be used if the motor can not be moved by hand. If the program causes the Position Feedback to count more negative, swap the connections to the controllers SIN and the SIN-N encoder inputs. For dual loop systems, the velocity feedback encoder is displayed in the diagnostic display (Figure 2-9) 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 2-8: 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 35

50 Installation and Configuration Figure 2-9: Position Feedback in the Diagnostic Display 36 Chapter 2

51 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. 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 2-20: Hall-Effect Inputs (J03) Chapter 2 37

52 Installation and Configuration Thermistor Interface (J03) The thermistor input is used to detect an over temperature condition in a motor 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. If the increasing temperature causes the thermistor s resistance to increase, the signal will be seen as a logic high, triggering an over temperature fault. Table 2-7: Hall-Effect Feedback Interface Pin Assignment (J03) Pin# Description In/Out/Bi 2 Motor Over Temperature Thermistor Input +5V 0K J03-2 THERMISTOR 0K.00.0UF Figure 2-2: Thermistor Interface Input (J03) 38 Chapter 2

53 Installation and Configuration Encoder Fault Interface (J03) The encoder fault input is used with encoders having a fault output. Each manufacturer uses this signal to indicate different faults. 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 2-22: Encoder Fault Interface Input (J03) Chapter 2 39

54 Installation and Configuration End Of Travel Limit Input Interface (J03) End of Travel (EOT) limits are required to define the end of the physical travel on linear axes. Positive or clockwise motion is stopped by the clockwise (CW) end of travel limit input. Negative or counterclockwise 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. All of the end-of-travel limit inputs accept 5-24 VDC level signals. Limit directions are relative to the encoder polarity in the status display (refer to Figure 2-25). The active state of the EOT limits is software selectable (by the EndOfTravelLimitSetup parameter) V Limit Com 6 20 Normally closed shown (typical). CW 2 MOTOR FEEDBACK 4 J03 CCW Home May be a separate switch. Figure 2-23: 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 EndofTravelLimitSetup has replaced LimitLevelMask in software version Chapter 2

55 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 2-24: End of Travel Limit Interface Input (J03) Chapter 2 4

56 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 J03 connector. The logic level of the EOT limit inputs may be viewed in the diagnostic display (shown in Figure 2-25). Figure 2-25: Limit Input Diagnostic Display 42 Chapter 2