OEM CNC Installation.

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3 P/N H - Contents Section 1 - Introduction ANILAM's Commitment to You Effectivity Notation Section 2 - Theory of Operation Closed-Loop System Isolated Input/Output Overview The Closed-Loop System CNC System Overview CNC Spindle Control Section 3 - Specifications and Power Requirements Power Requirements Power Supplies OEM External Servo Power Supply for ANILAM Amplifiers Environmental Requirements The Servo System Feedback OEM Console with Liquid Crystal Display (LCD) Flat Panel Display LCD Specifications and Power Requirements LCD Environmental Requirements Handling the LCD Console VGA to OEM CNC Chassis Connection Amplifier Motors Section 4 - Amplifiers and Motors Digital Brushless Servo Amplifier AC Brushless Servo Motors AM 96 Series Motor Specifications AM 96 Series Torque Characteristic Graphs AM 96A, AM 96AB - Torque Characteristic Graph AM 96C, AM 96CB - Torque Characteristic Graph AM 96E, AM 96EB - Torque Characteristic Graph AM 130 Series Motor Specifications AM 130 Series Torque Characteristic Graphs AM 130A, AM 130AB - Torque Characteristic Graph AM 130C, AM 130CB - Torque Characteristic Graph AM 130E, AM 130EB - Torque Characteristic Graph AM Series Cables and Connectors AM Series Motors Nameplate Conventions OEM System Interconnect Section 5 - Dimensions and Installation Wiring Guidelines and Grounding Concepts General Wiring Guidelines General Grounding Guidelines Establish Bonding Points on the Machine Use Interior or Exterior Tooth Lock Washers Between Points of Contact Clean all Stand-Off and Mounting Assemblies to Bare Metal at Points of Contact All rights reserved. Subject to change without notice. iii

4 P/N H - Contents Clean all Paint to Bare Metal from the Enclosure at the Points of Contact Wiring of System Grounds Wiring Servo Amplifiers Isolation Transformer Compliance with the CE Directives Guidelines for Construction of a CE-Compliant System Major Assemblies Dimensional Data LCD Console Mounting M Console and Manual Panel OEM CNC Chassis CAN I/O Boards, Mounting Locations Digital Brushless Servo Amplifier AC Brushless Servo Motors Section 6 - Connection Overview Power Connection Fuses Amplifier Connectors Motor Connectors Console Power Requirements VGA to Single-Board Computer Connection LCD Console Power Connection LCD Setup and Adjustment Procedures Connecting the OSD Board (P/N ) Disconnecting the OSD Board Adjusting the On-Screen Display (OSD) Board Settings Keyboard Interface Board Keyboard Interface to External Keyboard Connection Manual Panel Connections Remote Floppy Disk Drive Installation and Harnesses Procedure Control Axes (X, Y, Z, U, S, and W) Single-Ended vs. Differential Axis (Jumper Settings) Cable Specifications (Control Axes) Handwheel or Readout Axes Cable Specifications (Readout Axes) Printer Connection COM2 Connection Ethernet Network Connection Probe Connection MBIO OEM Servo System Wiring Servo Control Board Use with MBIO (Option) Connectors Controller Area Network (CAN) I/O Bus Current Rating and Power Requirements Connections Mounting Additional CAN Boards Externally CAN Bus Node Addressing (S1) CAN Bus Termination iv All rights reserved. Subject to change without notice.

5 P/N H - Contents Home Switch Inputs External Cabling and Connector Specifications Cables for Motors and Amplifiers Mating Power and Encoder Connectors Section 7 - Hardware Wiring Diagrams Single-Board Computer Power Requirements VGA Connections COM Keyboard Hard Drive Printer COM Floppy Drive Setting up the BIOS for the Single Board Computer Restoring Factory Defaults Controller Area Network (CAN) Bus Nodes Connections Analog Input Configuration DSP Board Encoder and Analog Power Machine Basic I/O External START/STOP E-STOP and Manual Switches CAN Bus Interface Test Connection (P12) Probe (P15) Jumpers Firmware DSP 2 Expansion Encoder and Analog Power Jumpers Section 8 - Maintenance Balance and Signal Checks Hard Drive Filters Contamination Cabling Fuses Console Keypad Filters Environment Contamination Cabling Preventive Measures All rights reserved. Subject to change without notice. v

6 P/N H - Contents Section 9 - Troubleshooting Checking Voltages Backplane LEDs TB2 Terminal Block DSP 2 Board P LCD Troubleshooting Suggestions Amplifier Troubleshooting Suggestions Index... Index-1 vi All rights reserved. Subject to change without notice.

7 P/N H - Introduction Section 1 - Introduction ANILAM's Commitment to You As part of our ongoing commitment to our OEM partners, ANILAM is pleased to introduce our latest line of PC-based OEM CNC products designed to keep you on top and in control. Your new OEM product includes the following features: Dual Processor Design in a Highly Integrated CNC Chassis common to all products Color Liquid Crystal Display (LCD) Console Remote Manual Panel (all except 3000M) Distributed Controller Area Network (CAN) I/O System Surface Mount Design to Enhance a Compact, Powerful System At the core of the Computer Numerical Control (CNC) is a 100 MHz, 32- bit floating-point Digital Signal Processor (DSP) Motion Control Board called the DSP 2 Board. The DSP 2 Board will help you achieve an exponential increase in productivity. The DSP 2 Board single-handedly performs all the motion control real-time computations required for optimal CNC performance. The PC processor controls the Human/Machine Interface (HMI). Together, the DSP 2 Board and the PC processor provide the performance you need to meet the high-speed, high-accuracy demands of the modern machine tool market. The modular LCD color-display console and remote manual panel gives you greater flexibility to build machines for specific applications. The distributed CAN I/O system allows you to install I/O modules anywhere you need them; for example, you can install a CAN I/O module in the electrical cabinet to provide I/O for various machine needs; or, you can install a CAN I/O module in the console enclosure to provide additional operator switches, which significantly reduce wiring. The reduction in wiring makes installation simpler and more reliable. Models are available in either machinist language or ISO programming formats (G-codes) or both. ANILAM's built-in CAM system and advanced math calculators simplify programming at the control. It s easy to run programs that are generated from an off-line CAD/CAM system directly from the CNC or via ANILAM's DNC feature. The CNC's program storage capacity is at least 8.0 GB. All rights reserved. Subject to change without notice. 1-1

8 P/N H - Introduction You can also connect the CNC to Ethernet-based networks. ANILAM offers off-line versions of all our CNC products. Use off-line versions to develop and test part programs on an off-line PC. For your convenience, the off-line software operates exactly like the CNC software. Off-line systems are compatible with **Microsoft **MS-DOS or Windowsbased environments (including **Windows 3.11, Windows for Workgroups, Windows 95, **Windows NT, and **Windows XP ). The initial connection of the CNC varies depending on the product line and its number of axes. Refer to Table 1-1 for product and port connection information. Table 1-1, CNC Connection Ports Product Port M Systems X Y Z S 4200T Systems X C/S Z W 5000M Three-Axis Systems X Y Z S 5000M Four-Axis Systems X Y Z U S 5000M Five-Axis Systems X Y Z U S W Effectivity Notation Some sections do not apply to all ANILAM OEM CNC products. In these sections, icons identify products to which the information applies. Refer to Table 1-2. Table 1-2, Effectivity Notation Icon 3000M 3300M 4200T 5000M-3X 5300M 5000M-4X 5400M 5000M-5X 5500M Product 3000M Systems 4200T Systems 5000M Three-Axis Systems 5000M Four-Axis Systems 5000M Five-Axis Systems ** Microsoft, MS-DOS, Windows, Windows NT, Windows XP are registered trademarks of Microsoft Corporation in the United States and/or other countries. 1-2 All rights reserved. Subject to change without notice.

9 P/N H - Theory of Operation Section 2 - Theory of Operation Closed-Loop System Isolated Input/Output Overview The Closed-Loop System The Computer Numerical Control (CNC) is a closed-loop system that performs the following functions: Receives positioning information from highly accurate measurement transducers Compares the actual position against the programmed positions Adjusts for detected errors Simultaneously, the CNC regulates the speed and position of the controlled axis until each command is completed. Each CAN board is an I/O node. (Refer to Section 7, Nodes for details.) Multiple CAN nodes provide I/O. Two CAN I/O nodes are supplied with the standard system; up to six nodes can be implemented. Each node supports up to 10 inputs and 6 outputs, for a total I/O capacity of 60 inputs and 36 outputs. I/O signals are connected via the P5 DB-25 connector on each node. Inputs and outputs are optically isolated to prevent transmission of machine electrical noise to the processor circuits. You can configure inputs to activate functions in the CNC. Machine codes (M-codes) are normally used to control outputs. You can use an M-code to turn some outputs on and other outputs off. Outputs turned ON via an M-code can remain ON for a specified duration (pulse width) or indefinitely. Refer to the appropriate CNC Setup Utility Manual for details on I/O interface. For more advanced capability, use the ANILAM Integral Programmable Interface (IPI) feature to create a logic program that runs in the CNC. IPI accesses CNC registers and system flags to create sophisticated programs that control all types of machine functions. For example, you can use IPI to control the turret on a turning center or to control a tool changer on a machining center. Refer to the Integral Programmable Intelligence User's Guide, P/N , for details. The Closed-loop System consists of a velocity loop and a positioning loop. The velocity loop, or the velocity-controlled servo drive, maintains a constant velocity at a constant input. A transducer, such as a tachometer, must be input directly to the servo system. In contrast, a torque-controlled system maintains a constant torque. Refer to Figure 2-1, Closed-Loop System. All rights reserved. Subject to change without notice. 2-1

10 P/N H - Theory of Operation Encoder Position Loop Position Feedback Table Ballscrew Servo Motor Belt CNC Armature Voltage Velocity (Tachometer) Feedback Velocity Loop Command Signal Servo Drive CONTROLOOP Figure 2-1, Closed-Loop System 2-2 All rights reserved. Subject to change without notice.

11 P/N H - Theory of Operation The positioning loop controls command signals and all position-sensing devices as follows: 1. The CNC sends a command signal of 10 to +10 V DC to the servo drive. 2. The servo drive amplifies the signal to power the servo motor. The servo motor typically consists of a DC motor, a rotary encoder, and a tachometer, all on the same shaft. The servo motor can use motors without rotary encoders if a linear encoder or an externally mounted rotary encoder supplies feedback. Refer to Figure 2-2, Closed-Loop System with Linear Encoder. 3. The tachometer feeds a DC signal proportional to the motor velocity back to the servo drive. 4. The servo drive, in turn, continuously compares the command signal to the tachometer feedback signal and adjusts the output to the motor accordingly. 5. The servo motor mechanically drives a belt that turns a ballscrew. The ballscrew converts rotary motion to linear mechanical motion. During this process, the encoder outputs incremental position information to the CNC. 6. The CNC reads and accumulates information on the known location of the workpiece relative to the tool. It uses the positional information and the part program to compute a tool path. The CNC derives command signals for cutting and sends them to the servo drive. The CNC also corrects for geometrical and mechanical imperfections. All rights reserved. Subject to change without notice. 2-3

12 P/N H - Theory of Operation Position Loop Position Feedback Reader Head Linear Encoder Ballscrew Servo Motor Table Belt CNC Armature Voltage Velocity (Tachometer) Feedback Velocity Loop Command Signal Servo Drive CNTLOOPSCALE Figure 2-2, Closed-Loop System with Linear Encoder 2-4 All rights reserved. Subject to change without notice.

13 P/N H - Theory of Operation CNC System Overview This section provides an overview of the CNC system. Refer to Figure 2-3, 3000M CNC System Overview. Refer to Figure 2-4, 4200T CNC System Overview, and Figure 2-5, 5000M CNC System Overview, for more details. A typical CNC system consists of the following hardware: 1. The chassis, which consists of the following equipment: A single-board computer (SBC), an industrial PC that provides all PC functions A DSP 2 Motion Board that controls all machine motion, readout axes, and handwheels A 3-slot ISA backplane Two CAN I/O nodes Power supplies. Multiple power supplies prevent cross talk A hard drive 2. The console, which consists of the following equipment: A color VGA monitor The CNC keyboard The E-STOP switch (3000M only) FEEDRATE OVERRIDE switch (3000M only) A connector port for a PC keyboard (optionally provided by the builder) 4200T 5000M-3X 5000M-4X 5000M-5X 3. An external floppy drive 4. A manual panel provides handwheel control (option), axis selection, feedrate override, manual jog, E-STOP switch, and manual spindle control. 5. The OEM system is configurable to connect to each customer s servo drives and external machine control electrics, such as safety switches and machine functions. All rights reserved. Subject to change without notice. 2-5

14 P/N H - Theory of Operation Optional External QWERTY Keyboard Floppy Disk Drive Handwheel CRT/LCD CNC Console Keyboard VGA Signals Keyboard Data E-Stop Data to MBIO Floppy Data COM1 External RS-232 Comm Port COM2 External RS-232 Comm Port External Parallel Printer Port General Purpose Opto I/O Opto I/O Including Limits CAN 1 CAN 0 +24VDC I/O P/S +5,+/-15VDC Motion P/S DSP 2 Motion Control Board VGA KYBD Floppy COM1 COM2 Single Board Computer Parallel CNC Chassis 3 Slot Passive Backplane +5, +/-12DVC Computer P/S Hard Drive Power Input Floppy Power Input Handwheel Encoder Data Probe Readout Axis Encoder Data Spindle DAC and Encoder Signals MBIO Network Data Hard Disk Drive Axes Position Encoder Data Optional Network Connection Encoder Motor Amp Encoder Motor Amp Encoder Motor Amp Axes DAC Command Signals Machine Control Electrics 3000MSYSOVERVIEW Figure 2-3, 3000M CNC System Overview 2-6 All rights reserved. Subject to change without notice.

15 P/N H - Theory of Operation CRT/LCD CNC Console Keyboard Keyboard Data Optional External QWERTY Keyboard Floppy Disk Drive VGA Signals Handwheel Manual Panel COM1 Manual Panel RS-232 Data E-Stop Data to MBIO Floppy Data COM2 External RS-232 Comm Port External Parallel Printer Port General Purpose Opto I/O External CAN General Purpose Opto I/O Opto I/O Including Limits CAN 1 CAN 0 +24VDC I/O P/S +5,+/-15VDC Motion P/S DSP 2 Motion Control Board COM1 VGA KYBD Floppy COM2 Single Board Computer Parallel CNC Chassis 3 Slot Passive Backplane +5, +/-12VDC Computer P/S Hard Drive Power Input Floppy Power Input Handwheel Encoder Data MBIO Probe Readout Axis Encoder Data Spindle DAC and Encoder Signals Network Data Hard Disk Drive Axes Position Encoder Data Optional Network Connection Encoder Motor Amp Encoder Motor Amp Axes DAC Command Signals Machine Control Electrics 4200TSYSOVERVIEW Figure 2-4, 4200T CNC System Overview All rights reserved. Subject to change without notice. 2-7

16 P/N H - Theory of Operation LCD CNC Console Keyboard Optional External QWERTY Keyboard Keyboard Data Floppy Disk Drive VGA Signals Handwheel Manual Panel COM1 Manual Panel RS-232 Data E-Stop Data to MBIO Floppy Data COM2 External RS-232 Comm Port External Parallel Comm Port General Purpose Opto I/O External CAN General Purpose Opto I/O Opto I/O Including Limits CAN 1 CAN 0 +24VDC I/O P/S +5,+/-15VDC Motion P/S DSP 2 Motion Control Board COM1 VGA KYBD Floppy COM2 Single Board Computer Parallel CNC Chassis 3 Slot Passive Backplane +5, +/-12VDC Computer P/S Hard Drive Power Input Floppy Power Input Handwheel Encoder Data MBIO Probe Readout Axis Encoder Data Spindle DAC and Encoder Signals Network Data Hard Disk Drive 5000M-5X 5000M-4X Axes Position Encoder Data Optional Network Connection Encoder Encoder Encoder Encoder Encoder Machine Control Electrics Motor Amp Motor Amp Motor Amp Motor Amp Motor Amp Axes DAC Command Signals 5000MSYSOVERVIEW Figure 2-5, 5000M CNC System Overview 2-8 All rights reserved. Subject to change without notice.

17 P/N H - Theory of Operation CNC Spindle Control CNCs can control various types of spindle drives. The CNC provides DC and/or logic outputs to run the drive and can receive RPM and I/O information. The application determines the requirements of the spindle drive; the more sophisticated the application, the more intelligent the spindle drive required. The following subsections describe the CNC s outputs and inputs and spindle drive requirements. Outputs DC analog command-signal output either unipolar (0V DC to +10V DC) or bipolar (-10V DC to +10V DC) dependant on spindle drive hardware requirements. In bipolar mode, positive voltage is always forward rotation. Logical outputs are either +24V DC (source) or 24COM (sink) signals. I/O boards are either sink- or source-boardtype determined by spindle drive hardware requirements. If you require conditional logic, you must use IPI. Basic I/O supports limited only on/off control of outputs. Inputs Requires TTL quadrature with zero marker signals for RPM display and control. Maximum input speed is one million counts per second. For tapping and orientation, spindle encoder must be 1:1 with spindle. For threading, spindle to encoder ratio must be 1:1 or higher (whole number ratios only). Spindle Drive Requirements For rigid tapping and orientation, the spindle must be capable of closed-loop (servo) mode operation. IPI is required to program conditional logic. Tapping requires a floating tap head unless you use rigid tapping. For safety requirements, the spindle should have at speed and zero speed outputs. IPI is required to program conditional logic. The outputs are used by the resultant IPI program to determine: When the drive has reached speed and the machine can continue the program, and When the drive has stopped and it is safe to remove power. Some spindle drives require a braking resistor. Some braking resistors have over-heat sensors, which require IPI to detect. For cooling purposes, mount the braking resistors outside the equipment enclosure and use guarding per relevant safety codes. All rights reserved. Subject to change without notice. 2-9

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19 P/N H - Specifications and Power Requirements Section 3 - Specifications and Power Requirements Power Requirements Refer to Table 3-1 for the required input power for Liquid Crystal Display (LCD) based systems. Table 3-1, LCD Power Requirements Device Computer SVGA LCD Monitor Power Requirement VAC, 1 Phase, 2 A to 1 A 12 VDC, 2 A provided by computer power supply. CAUTION: The CNC must be plugged into a dedicated line. Voltage rating: VAC (Dedicated, no other devices attached to the line.) Power Supplies The CNC has three internal power supplies. Voltage inputs are required to meet the specifications listed in Table 3-2. Table 3-2, Power Supplies Power Supply Power Current Function Computer Power Supply P/N Motion Power Supply P/N I/O Power Supply P/N W +5 V ±12 V 6 A Supplies power to SBC, disk drives, and logic power to DSP motion control board 25 W +5 V ±15 V 1 A Supplies 5 V to encoders, ±15 V to the DSP Motion Board 24 V 2 A** 1 Supplies power to I/O **1 Required amperage determined by number and types of external devices connected to the system. When specific equipment requires more than 2 A, customers must use their own external power supply. OEM External Servo Power Supply for ANILAM Amplifiers A 160 VDC source is required for main power to the amplifiers. A schematic is shown in Figure 3-1, External Servo Power Supply. This supply will support one to five amplifiers. Because of the high current involved, #12 AWG wire should be used for all parts of this circuit except the control voltage for the Solid State Relay. For safety, the machine tool should be wired so that this voltage is removed during emergency conditions. All rights reserved. Subject to change without notice. 3-1

20 P/N H - Specifications and Power Requirements Figure 3-1, External Servo Power Supply Environmental Requirements Maintain the environmental constraints listed in Table 3-3 to ensure that the CNC performs to specification. Table 3-3, Environmental Constraints Parameter Environmental Constraints Ambient Temperature Operating 0 C to 50 C Storage and Transportation -3 C to 65 C Rise in internal temperature 10 C above ambient, maximum Humidity Operating 10% to 90% RH, non-condensing Storage and Transportation 95% RH, non-condensing for one month, maximum Shock Operating 30 g for 11-ms duration, half-sine shock pulse, maximum Storage and Transportation 50 g for 11-ms duration, half-sine shock pulse, maximum Vibration Operating 1.5 g acceleration over 5- to 300-Hz sine wave (P-P), I oct/min sine sweep. Storage and Transportation 5 g acceleration over 5- to 300- Hz sine wave (P-P), I oct/min sine sweep. Air Pressure Operating 0 10,000 ft. Storage and Transportation 0 40,000 ft. 3-2 All rights reserved. Subject to change without notice.

21 P/N H - Specifications and Power Requirements The Servo System All ANILAM CNCs require velocity-controlled servo motors and feedback devices. Typically, this would include a motor with a built-in tachometer and a rotary encoder. An external rotary encoder or linear encoder can also be used. The CNC uses feedback from either rotary encoders or linear encoders to provide the closed-loop positioning for the system. Refer to Setup Utility for details on setting each axis for the type of feedback device used. Axis resolution is set via the Machine Axis Setup. The maximum display resolution is 0.5 microns. The maximum number of line counts is 1,000,000 (one million) counts per second. NOTE: If a higher line count frequency is required, contact ANILAM Sales. Feedback The OEM CNC chassis supports both single-ended and differential feedback devices. The default configuration is single ended. NOTE: ANILAM recommends that you use differential encoders in potentially noisy environments. Encoder inputs should be TTL quadrature signals with a zero cross marker. Encoder inputs are fed to ANILAM custom ASIC counters. Counter inputs are filtered via a passive, two-stage capacitive network, and then pulled high with a 1 K resistor. The ASIC counter also incorporates an on-chip Schmidt trigger at each input to correct for input signal distortion. The input current is rated at 0.18 ma. The low input threshold is 0.8 V; the high input threshold is 2.0 V. OEM Console with Liquid Crystal Display (LCD) Flat Panel Display The Liquid Crystal Display (LCD) Console includes a color-active matrix, Thin Film Transistor (TFT) LCD panel, Analog to Digital (A/D) Controller board, On-Screen Display (OSD) board (for factory adjustments only), and Inverter. The LCD panel is a low-reflection, high-color saturation, color-active matrix display. All rights reserved. Subject to change without notice. 3-3

22 P/N H - Specifications and Power Requirements LCD Specifications and Power Requirements Table 3-4 lists the LCD specifications. Table 3-4, LCD Specifications Description Specifications Display Diagonal 12.1 inches (31 cm) Display Format Super VGA (800 x 600) Dimensions (L x W x H) 5.12 inches (130 mm) x 0.79 inches (20 mm) x 0.04 inches (13.5 mm) Active Area (W x H) 9.68 inches (240 mm) x 7.26 inches (184.5 mm) Dot Pitch (W x H) inches ( mm) x inches ( mm) Response Time (TYP) 60 ms Contrast Ratio 300:1 Bits per Color 6 Power Panel 7.2 Backlight Power 6.6 W Brightness 250 nits Table 3-5 lists the LCD inverter specifications. Table 3-5, LCD Inverter Specifications Description Specifications Input Voltage 9.6 VDC 14.4 VDC Startup Voltage 1,500 Vrms (50 70 khz) Power Requirements 9.6 VDC 14.4 VDC Output Current 6.3 marms Minimum 7.0 marms Typical 7.7 marms Maximum Power Output 7.8 W (3.9 W x 2) 3-4 All rights reserved. Subject to change without notice.

23 P/N H - Specifications and Power Requirements LCD Environmental Requirements Maintain the environmental conditions described in Table 3-6 to ensure that the LCD console performs to specification. Table 3-6, Environmental Requirements Ambient Temperature Humidity Parameter Operating Storage and Transportation Operating, Storage, and Transportation Environmental Requirements 0 C to 50 C -25 C to +60 C 95% RH, noncondensing Shock Operating 30 g for 11-ms duration, half-sine shock pulse, max. Storage and Transportation 50 g for 11-ms duration, half-sine shock pulse, max. Vibration Operating 1.5 g acceleration over Hz sine wave (P-P). Storage and Transportation Air Pressure Operating 0 10,000 ft. Storage and 0 40,000 ft. Transportation 5 g acceleration over Hz sine wave (P-P). Handling the LCD Console CAUTION: To prevent electrical shock or damage to the electrical components, turn the power off before connecting or disconnecting the cable to the LCD console. Because the connector area contains ESD-sensitive electronic components, avoid touching components. When you handle the LCD console, use all ESD precautionary measures. CAUTION: The Backlight Inverter Board operates at high voltage. To prevent electrical shock or damage to the components on the board, avoid touching any electronic components. VGA to OEM CNC Chassis Connection Use the P/N harness to connect the 15-pin connector on the back of the LCD Console labeled VGA to the labeled 15-pin VGA connector on the CNC chassis. All rights reserved. Subject to change without notice. 3-5

24 P/N H - Specifications and Power Requirements Amplifier Motors Refer to Table 4-1, Amplifier Specifications and Features, P/N Refer to Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications and Features and Table 4-3, AM 130 Series AC Brushless Servo Motor Specifications and Features. 3-6 All rights reserved. Subject to change without notice.

25 P/N H Amplifiers and Motors Section 4 - Amplifiers and Motors Digital Brushless Servo Amplifier The amplifier is illustrated in Figure 5-15, Digital Brushless Servo Amplifier, P/N It has the same footprint as earlier DC amps and should be mounted in the same orientation. It accepts a +/- 10 Volt analog signal from the motion board in the kit console or OEM chassis and drives a 3-phase AC brushless servo motor. The analog input may be either single ended or differential. The amplifier has an input connector for encoder signals from the motor. These are used for commutation and can also be fed back to the motion board for position information. Various control and status signals to communicate with the CNC are described below. The amplifier requires 160 VDC for main power. For safety, the machine tool should be wired so that this voltage is removed during emergency conditions. The amplifier also requires +5 VDC at 300mA for onboard logic. This voltage should always be present to avoid loss of position. There is a host port to connect the amplifier to the RS232 serial port of either the CNC or an external computer. This is used to upload / download parameters and for tuning and troubleshooting. Red and green LED indicators display the functional status of the unit. The amplifier has an onboard FLASH memory that stores a large number of parameters even during complete power down. This replaces the trim pots of earlier generation equipment. It is critical that the amplifier have continuous forced air cooling. Refer to Table 4-1, Amplifier Specifications and Features, P/N See Section 6, Amplifier Connectors for connector pinouts and LED indicator information: Table 6-3, Amplifier Mating Connectors Table 6-4, Amplifier J1 Host Connector Pinout Table 6-5, Amplifier J2 Signal Inputs (from Motion Board to machine interface) Connector Pinout Table 6-6, Amplifier J3 Signal Inputs (from Rotary Encoder on Motor) Connector Pinout Table 6-7, Amplifier J7 External +5 V Connector Pinout Table 6-8, Amplifier TB1 Terminal Block Connector Pinout Table 6-9, Amplifier LED Indicators All rights reserved. Subject to change without notice. 4-1

26 P/N H Amplifiers and Motors Table 4-1, Amplifier Specifications and Features, P/N Feature Specification Supply voltage VDC (typical 160 VDC) +5 volt logic keep alive 500 ma (includes: 200 ma encoder power) Peak current output ± 30 A maximum Continuous current output ± 15 A maximum (with forced air cooling) Switching frequency 25 KHz Heatsink (base) temperature 25 C to +70 C (latches disabled >+70 C) 77 F to +158 F (latches disabled >+158 F) Current loop bandwidth (programmable) 3 KHz Amplifier type (programmable) Velocity or Current mode Amplifier isolation Bus & Phase completely isolated from Low signal Input command signal (programmable gain) ± 10 V maximum Hall U, V, W Pull up to 5 V logic levels Encoder feedback Accept encoder signals up to 4.3 MHz Fault out (programmable level) TTL and 24 V compatible Current monitor out 7.5 A/V, absolute value (30 A maximum) Encoder out Can be divided from the input frequency by any integer 1 8 Low speed electronic circuit breaker (LS/ECB) Bus over voltage Bus under voltage Amplifier over temperature Green LED indicator Red LED indicator Latches when maximum programmable current and time exceed limits Trips nominally at 10% above maximum rated supply voltage Trips nominally at 10% below minimum rated supply voltage Amplifier faults and is inhibited if the heatsink temperature reaches 70 C (158 F) Run-Amplifier enabled, normal operating condition Fault-Amplifier over temperature or LS/ECB (latched condition) Operating temperature 0 C to +70 C 32 F to +158 F Storage temperature 40 C to +80 C 104 F to +176 F Humidity 5% to 95% non-condensing Dimension (L +x H x W mm) Dimension (L x H x W inches) x x x 6.00 x All rights reserved. Subject to change without notice.

27 P/N H Amplifiers and Motors AC Brushless Servo Motors The following AM series motors topics are described: AM 96 Series Motor Specifications AM 96 Series Torque Characteristic Graphs AM 130 Series Motor Specifications AM 130 Series Torque Characteristic Graphs AM Series Cables and Connectors AM Series Motors Nameplate Conventions AM 96 Series Motor Specifications The motor is illustrated in Figure 5-16, AM 96 Series AC Brushless Servo Motors. Axis motors (synchronous motors) fulfill all requirements of a Numerical Control (NC) machine tool. The B in the model number indicates that the motor has a brake. They are 3-phase, AC brushless induction servo motors with built in optical encoders. Three AM 96 Series sizes are available: 1.5 Nm, 3.3 Nm, and 5.8 Nm (refer to Table 4-2). Units with and without internal brakes are available. When fitted, the brake operates on 24 VDC and is fail-safe (that is, with no power applied, the shaft is stopped). Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications and Features Motor Without Brake AM 96A AM 96C AM 96E Motor P/N Without Brake Motor With Brake AM 96AB AM 96CB AM 96EB Motor P/N With Brake Feature Continuous stall torque when fitted to heatsink (Size 300 x 300 x 12 mm) (Size 12 x 12 x 0.5 in) Units Nm lb-in Motor weight without brake with brake kg (lb) kg (lb) 3.8 (8.4) 4.6 (10.15) 5.0 (11.0) 5.8 (12.8) 7.2 (16.0) 8.0 (17.64) Voltage gradient No Load V/1000 RPM ** Maximum motor EMF Volts Maximum speed RPM Insulation class F F F Maximum ambient temperature C ( F) 40 (104) 40 (104) 40 (104) Thermal time constant Minutes Static friction torque Nm (lb-in) 0.07 (0.62) 0.07 (0.62) 0.07 (0.62) Peak stall torque **2 Nm (lb-in) 5.5 (49) 11.1 (98) 22 (200) **1 At 25 C (77 F) **2 Note that Kt is shown as a combined value for all three phases. (Continued) All rights reserved. Subject to change without notice. 4-3

28 P/N H Amplifiers and Motors Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications & Features (Continued) Motor Without Brake AM 96A AM 96C AM 96E Motor P/N Without Brake Motor With Brake AM 96AB AM 96CB AM 96EB Motor P/N With Brake Feature Units Continuous stall current rms **3 Amps Rotor polar moment of inertia kgcm (inclusive of resolver inertia) lb-in sec Maximum current (peak) Amp Cogging torque Nm (no shaft seal fitted) lb-in Torque constant Kt Nm/Amp lb-in/amp Stator Winding Resistance Line-Line **4 Ohms Inductance Line-Line **4 MilliHenrys Thermal resistance C/Watt F/Watt **3 The temperature rise DT on the windings is 110K and applies to all continuous torque values. The maximum ambient temperature is 40 C (104 F) and therefore, the temperature on the windings should not be more than 150 C (302 F). A value higher than 150 C (302 F) would exceed the class F insulation temperature specification. **4 At 25 C (77 F) AM 96 Series Torque Characteristic Graphs The following AM 96 Series torque characteristic graphs are illustrated: Figure 4-1, AM 96A, AM 96AB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph Figure 4-2, AM 96C, AM 96CB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph Figure 4-3, AM 96E, AM 96EB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph 4-4 All rights reserved. Subject to change without notice.

29 P/N H Amplifiers and Motors AM 96A, AM 96AB - Torque Characteristic Graph Refer to Figure 4-1. AM96ATORQUE Figure 4-1, AM 96A, AM 96AB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph AM 96C, AM 96CB - Torque Characteristic Graph Refer to Figure 4-2. AM96CTORQUE Figure 4-2, AM 96C, AM 96CB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph All rights reserved. Subject to change without notice. 4-5

30 P/N H Amplifiers and Motors AM 96E, AM 96EB - Torque Characteristic Graph Refer to Figure 4-3. AM96ETORQUE Figure 4-3, AM 96E, AM 96EB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph AM 130 Series Motor Specifications The motor is illustrated in Figure 5-17, AM 130 Series AC Brushless Servo Motors. Axis motors (synchronous motors) fulfill all requirements of a Numerical Control (NC) machine tool. The B in the model number indicates that the motor has a brake. They are 3-phase, AC brushless induction servo motors with built in optical encoders. Three sizes are available: 3.3 Nm, 4.6 Nm, and 6.3 Nm (refer to Table 4-3, AM 130 Series AC Brushless Servo Motor Specifications and Features). Units with and without internal brakes are available. When fitted, the brake operates on 24 VDC and is fail-safe (that is, with no power applied, the shaft is stopped). 4-6 All rights reserved. Subject to change without notice.

31 P/N H Amplifiers and Motors Table 4-3, AM 130 Series AC Brushless Servo Motor Specifications and Features Motor Without Brake AM 130A AM 130C AM 130E Motor P/N Without Brake Motor With Brake AM 130AB AM 130CB AM 130EB Motor P/N With Brake Feature Continuous stall torque when fitted to heatsink (Size 400 x 400 x 6 mm) (Size x x 0.24 in) Units Nm lb-in Motor weight without brake with brake kg (lb) kg (lb) 6.1 (13.5) 7.7 (17.0) 7.0 (15.0) 8.6 (19.0) 7.9 (17.0) 9.5 (21.0) Voltage gradient No Load (Peak)/1000 RPM Maximum motor EMF Line Line Volts Maximum speed RPM Insulation class F F F Maximum ambient temperature C ( F) 40 (104) 40 (104) 40 (104) Thermal time constant Minutes Static friction torque Nm (lb-in) 0.14 (1.24) 0.14 (1.24) 0.14 (1.24) Peak stall torque Nm (lb-in) 8.6 (76) 13.1 (116) 17 (150) Continuous stall current rms **1 Amps Rotor polar moment of inertia kgcm (inclusive of resolver inertia) lb-in sec Maximum current (peak) Amp Cogging torque Nm (no shaft seal fitted) lb-in **3 Torque constant Kt rms**2 Nm/Amp lb-in/amp Stator Winding Resistance Line-Line **2 Ohms Inductance Line-Line MilliHenrys Thermal resistance C/Watt F/Watt **1 The temperature rise DT on the windings is 110K and applies to all continuous torque values. The maximum ambient temperature is 40 C (104 F) and therefore, the temperature on the windings should not be more than 150 C (302 F). A value higher than 150 C (302 F) would exceed the class F insulation temperature specification. **2 At 25 C (77 F) **3 Note that Kt is shown as a combined value for all three phases. All rights reserved. Subject to change without notice. 4-7

32 P/N H Amplifiers and Motors AM 130 Series Torque Characteristic Graphs The following AM 130 Series torque characteristic graphs are illustrated: Figure 4-4, AM 130A, AM 130AB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph Figure 4-5, AM 130C, AM 130CB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph Figure 4-6, AM 130E, AM 130EB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph AM 130A, AM 130AB - Torque Characteristic Graph Refer to Figure 4-4. AM130ATORQUE Figure 4-4, AM 130A, AM 130AB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph 4-8 All rights reserved. Subject to change without notice.

33 P/N H Amplifiers and Motors AM 130C, AM 130CB - Torque Characteristic Graph Refer to Figure 4-5. AM130BTORQUE Figure 4-5, AM 130C, AM 130CB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph AM 130E, AM 130EB - Torque Characteristic Graph Refer to Figure 4-6. AM130CTORQUE Figure 4-6, AM 130E, AM 130EB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph All rights reserved. Subject to change without notice. 4-9

34 P/N H Amplifiers and Motors AM Series Cables and Connectors For AM 96 Series and AM 130 Series motors see Section 6, Cables for Motors and Amplifies for: Figure 6-37, AC Brushless Motor (without Brake) Power Cable Figure 6-38, AC Brushless Motor (with Brake) Power Cable Figure 6-39, AC Brushless Motor Encoder Cable Figure 6-40, Test Cable, P/N For motor connectors, refer to the following tables: Table 6-10, Power Connector, Non-Brake Motor, MS3102E-18-10P Pinout Table 6-11 Power Connector, Brake Motor, MS3102E-20-15P Pinout Table 6-12 Encoder Connector, MS3102E-20-29P Pinout For mating power and encoder connectors, see Section 6, Mating Power and Encoder Connectors All rights reserved. Subject to change without notice.

35 P/N H Amplifiers and Motors AM Series Motors Nameplate Conventions For AM Series AC brushless motors, the nameplate is a foil/metallic label. Refer to Figure 4-7. MOTOR NAME SERIAL NO. MANUFACTURER TECHNICAL MOTOR DATA Jamestown, NY USA TYPE Tel: Fax: No C. STALL TORQUE A MAX RPM V A MOTOR PART NUMBER FEEDBACK PN:XXXXXXXX IP IC YXXXX BRAKE DETAILS WHEN USED Manufactured by SEM Ltd in England MONTH & YEAR OF SHIPPING EXAMPLE: A2006 JANUARY 2006 AMNAMEPLATE Figure 4-7, AM Series AC Brushless Motor Nameplate For correct manufacturer technical motor data information on the nameplate for motor models, refer to: Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications and Features Table 4-3, AM 130 Series AC Brushless Servo Motor Specifications and Features For Type and Part Number, refer to Table 4-4. Table 4-4, TYPE and Part Number (PN) Type PN Type PN AM 96A AM 130A AM 96C AM 130C AM 96E AM 130E AM 96AB AM 130AB AM 96CB AM 130CB AM 96EB AM 130EB All rights reserved. Subject to change without notice. 4-11

36 P/N H Amplifiers and Motors OEM System Interconnect Refer to Figure 4-8. INTERCONNECT Figure 4-8, OEM System Interconnect Diagram 4-12 All rights reserved. Subject to change without notice.

37 P/N H - Dimensions and Installation Section 5 - Dimensions and Installation Wiring Guidelines and Grounding Concepts General Wiring Guidelines IMPORTANT: For safe operation, ensure that wiring conforms to all local and national codes. IMPORTANT: The CNC, other control devices, and the enclosure must be properly grounded. An authoritative source on grounding requirements for most installations is the National Electrical Code (NEC). Follow these general wiring guidelines: 1. Do not run the signal wire and the power wire in the same conduit. Where paths must cross, make intersections perpendicular. 2. Segregate I/O wires by signal types. Route wires with different signal characteristics along separate paths whenever possible. To prevent cross talk, avoid running harnesses containing different signal types parallel to one another. 3. Establish a low-impedance, single-point ground. All noise reduction techniques depend upon proper grounding. 4. Proper routing and grounding are more important than servo wire length. 5. Make signal wiring as short and direct as possible. CAUTION: You must install E-STOP switches in the system. Make certain that the relay contacts have a sufficient rating for the application. 6. The E-STOP button and travel limit switches are wired in series. When any of them opens, the servos are de-energized. This will remove power from the machine. Ensure that they are correctly installed for safety purposes. WARNING: Never alter these circuits to defeat their function. Serious injury or machine damage could result. Observe all applicable codes as to the placement and labeling of E-STOP switches. All rights reserved. Subject to change without notice. 5-1

38 P/N H - Dimensions and Installation General Grounding Guidelines This subsection contains procedures for proper system grounding during installation. Proper grounding is the foundation of all noise control techniques. It helps limit the effects of noise due to electromagnetic interference (EMI) and is essential to proper CNC operation. WARNING: The CNC must be properly grounded. All applicable codes and ordinances must be observed when wiring the CNC. In addition to the grounding required for the CNC and its electrical cabinet, you must provide proper grounding for all controlled devices in the application. Make sure to provide each device with an acceptable grounding path. Establish Bonding Points on the Machine To establish a proper ground, remove all anodizing, paint, and other coatings down to the bare metal. Do this at points where mounting holes have been drilled into the machine to mount the electrical cabinets. A threaded hole drilled into the machine is not a proper ground. Remove the paint (or coating) around the hole, exposing bare metal. If you cannot use the mounting holes for electrical bond points, establish suitable bond points elsewhere. Use Interior or Exterior Tooth Lock Washers Between Points of Contact To ensure a good electrical path, use interior or exterior tooth star washers between each point of metal-to-metal contact. Choose interior or exterior star washers based only on mechanical concerns. Clean all Stand-Off and Mounting Assemblies to Bare Metal at Points of Contact The goal is to create a continuous metal-to-metal surface contact from the machine to the electrical cabinet. The machine builder decides which points are best suited for this task. Threaded holes are not proper grounds; just as the threads of the mounting bolts are not proper ground paths. The best path is between two bare metal surfaces, with the proper star washer between them. The closer the installation is to this model, the better the ground. Clean all Paint to Bare Metal from the Enclosure at the Points of Contact Once the bond point locations are determined, remove the paint at these points to allow bare metal-to-metal contact via internal or external tooth star washers. 5-2 All rights reserved. Subject to change without notice.

39 P/N H - Dimensions and Installation Wiring of System Grounds Wiring Servo Amplifiers Isolation Transformer Verify that building grounds adhere to local codes at the time of the installation. NOTE: If you suspect that there is no proper ground in the building, consult a qualified electrician. Electrical equipment inherently generates radio-frequency interference (RFI) and wires act as antennae that transmit this interference. Motors inherently generate electromagnetic interference (EMI). Unless the wiring is very short, shielding on the motor wires is necessary to meet FCC RFI/EMI guidelines and to protect other equipment from the adverse effects of RFI/EMI. Always use shielded wire or run the wires in a metal conduit. The shield or conduit must be connected to an earth-grounded amplifier base plate. In order to decrease shock hazard and comply with electrical codes, run a conductor of the same gauge as the motor wires (or make a direct metalto-metal connection) from the motor case to the amplifier baseplate. Earth grounding is required to meet NEC regulations and to suppress RFI/EMI. IMPORTANT: The signal wiring to the tachometer and the signal inputs to the amplifier are susceptible to noise. Excessive noise will cause erratic amplifier operation. Run each signal-input line in a separate, twisted-pair, shielded cable for optimal performance. Terminate the shield only at the amplifier end to a common terminal. Keep signal lines as far as possible from any power or motor wires. An isolation transformer is sometimes used in the AC line to the controller. This type of transformer provides isolation from the power distribution system and is often used as a step-down transformer to reduce line voltage. Any transformer used with the CNC must have a sufficient power rating for its load. This power rating is typically expressed in volt-amperes (VA). Two guidelines when determining the correct transformer and its size are as follows: ANILAM recommends an electrostatic-shielded isolation transformer rated at.5 KVA. If output devices are connected through the transformer, add their maximum VA requirements to determine the correct transformer size. All rights reserved. Subject to change without notice. 5-3

40 P/N H - Dimensions and Installation Compliance with the CE Directives The 3000M, 4200T, and 5000M are OEM products and must be installed by qualified technicians. Compliance with CE directives and the attachment of the CE mark is the responsibility of the machine builder, who assumes all liability. ANILAM has had the CNC components described herein tested for electromagnetic compatibility per the CE directives listed in Table 5-1. Table 5-1, CE Directives Directive Description EN Electromagnetic compatibility Generic emissions standard Part 1. Residential, commercial, and light industrial, EN May 1995: Generic immunity standard for industrial environment. EN Limits and methods of measurement of electromagnetic disturbance characteristics of industrial, scientific, and medical (ISM) radio-frequency equipment, Second Edition EN Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 2: Electrostatic discharge immunity test, ENV Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 3: Radiated radio frequency electromagnetic field immunity test, EN Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 4: Electrical fast transient/burst immunity test, ENV Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 6: Continuous conducted interference, EN Electromagnetic compatibility (EMC) Part 4: Voltage Dips, short interruptions, and voltage variations, EN (CISPR 22) Limits and methods of measurement techniques of radio disturbance characteristics of information technology equipment. An NRTL-certified laboratory performed CNC electromagnetic compatibility testing. Test results are chronicled in EMC test reports EMI689 and EMI621A. In accordance with the CE directives, these reports are kept on file in the USA and UK offices of ANILAM, Inc. 5-4 All rights reserved. Subject to change without notice.