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-IO Expansion Board

Soloist CP

Chapter 3: -I/O Expansion Board

The -IO option board is 16 digital opto-inputs, 16 digital opto-outputs, 1 analog input, 1 analog output, and a
brake/relay output.

D A N G E R : Always disconnect the Mains power connection before opening the Soloist CP
chassis.

Figure 3-1:

Soloist CP with -IO Option Board

Table 3-1:

-IO Expansion Board Jumper Configuration

Jumper

Setting

Description

JP1

1-2, 3-4

Switch Brake +

5-6, 7-8

(1)

Switch Brake -

1-3

Relay Only

(1) default

Table 3-2:

-IO Option Board Fuse Information

Fuse

Description

Size

Aerotech P/N

Manufacturer's P/N

+5 VDC User Power

3 A, resettable

EIF01001

Raychem RGE300

www.aerotech.com

Chapter 3

Summary of Contents for Soloist CP 10

Page 1: ...Revision 4 09 00 Soloist CP Hardware Manual...

Page 2: ...ech com Phone 1 412 967 6440 Fax 1 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 2811 www aerotech com United Kingdom China Email Support aerotech com Phone 44 0 1256 855055 Fax 44 0 1256 855649 Ema...

Page 3: ...tor and Feedback Phasing 39 2 2 2 DC Brush Motor Connections 40 2 2 2 1 DC Brush Motor Phasing 41 2 2 3 Stepper Motor Connections 42 2 2 3 1 Stepper Motor Phasing 43 2 3 Motor Feedback Connections J10...

Page 4: ...l Analog Input TB201 84 3 2 Opto Out Connectors Digital Outputs TB202 TB203 85 3 3 Opto In Connectors Digital Inputs TB204 TB205 89 3 4 User Power TB204 TB205 92 3 5 Relay Connector TB206 93 Chapter 4...

Page 5: ...ation 43 Figure 2 19 Line Driver Encoder Interface J103 46 Figure 2 20 Serial Data Stream Interface 47 Figure 2 21 Analog Encoder Phasing Reference Diagram 48 Figure 2 22 Analog Encoder Interface J103...

Page 6: ...o a Current Sinking Device 91 Figure 3 10 Brake Connected to J103 94 Figure 3 11 Brake Connected to TB206 94 Figure 4 1 Single Axis Joystick Interface to Aux I O 96 Figure 4 2 Two Axis Joystick Interf...

Page 7: ...e 2 21 Encoder Fault Interface Pin on the Motor Feedback Connector J103 54 Table 2 22 End of Travel Limit Input Interface Pins on the Motor Feedback Connector J103 55 Table 2 23 Brake Output Pins on t...

Page 8: ...Connector Pinout TB203 86 Table 3 12 Mating Connector Part Numbers for the Opto Out Connectors TB202 TB203 86 Table 3 13 Digital Input Device Specifications 89 Table 3 14 Port 1 Opto In Connector Pin...

Page 9: ...ive 2011 65 EU RoHS 2 Directive and has been designed to be in conformity with the applicable requirements of the following Standard s when installed and used in accordance with the manufacturer s sup...

Page 10: ...ication CUS NRTL Approving Agency TUV SUD America Inc Certificate U8 17 01 68995 023 Standards CAN CSA C22 2 No 61010 1 2012 UL 61010 1 2012 Visit https www tuev sued de product testing certificates t...

Page 11: ...on 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 1 Disconnect electrical...

Page 12: ...earing 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 pote...

Page 13: ...rder under the heading Integration that drawing can be found on your installation device Figure 1 Quick Start Connections Topic Section Motor Output Section 2 2 Motor Output Connections Motor Feedback...

Page 14: ...Soloist CP Quick Installation Guide 14 www aerotech com This page intentionally left blank...

Page 15: ...e digital PID and current loops All system configuration is done using software settable parameters including control loop gains and system safety functions The Soloist CP is offered with an optional...

Page 16: ...ak 10 A continuous 40 W continuous internal shunt resistor I O Chapter 3 and Feedback Section 2 3 1 3 Options IO Expansion board with 16 digital inputs opto isolated 16 digital outputs opto isolated o...

Page 17: ...oduction Soloist CP The following block diagram shows a connection summary For detailed connection information refer to Chapter 2 and Chapter 3 Figure 1 2 Functional Diagram www aerotech com Chapter 1...

Page 18: ...ware first supported the drive Drives that list a specific version number in the Last Software Version column will not be supported after the listed version Table 1 3 Drive and Software Compatibility...

Page 19: ...0 A Continuous Output Current 5 A 10 A 10 A Power Amplifier Bandwidth 2500 Hz maximum software selectable Power Amplifier Efficiency 85 95 2 PWM Switching Frequency 20 kHz Minimum Load Inductance 0 1...

Page 20: ...r electronics or power transformer An EfficiencyFactor of approximately 90 should be used in the following equations Brushless Motor Output Power Rotary Motors Pout W Torque N m Angular velocity rad s...

Page 21: ...ture 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...

Page 22: ...d circuits enclosure Each unit should be separated from other drives and surrounded by 25 mm 1 of free air space A space of 100 mm 4 should be allowed along the front of the unit for cable connections...

Page 23: ...Operating 0 to 50 C 32 to 122 F Storage 30 to 85 C 22 to 185 F Humidity Maximum relative humidity is 80 for temperatures up to 31 C Decreasing linearly to 50 relative humidity at 40 C Non condensing...

Page 24: ...Soloist CP Introduction 24 Chapter 1 www aerotech com This page intentionally left blank...

Page 25: ...t CP has two AC input connectors one for control power and a second for motor power For a complete list of electrical specifications refer to Section 1 2 N OTE The machine integrator OEM or end user i...

Page 26: ...contains an internal filter an additional external filter located as close as possible to the Soloist CP may be required for CE compliance Aerotech recommends Schaffner FN2080 or Aerotech UFM ST Figu...

Page 27: ...nd connection in place W A R N I N G Do not operate the Soloist CP without proper branch protection An AC Line Filter may be required for CE compliance and should be located as close as possible to th...

Page 28: ...or 230 VAC input source voltage When rectified by the drive it produces a 40 or 80 VDC power bus TM3 Power up to 4 drives providing 300 watts of power TM5 Power up to 4 drives providing 500 watts of p...

Page 29: ...Installation and Configuration Soloist CP Figure 2 4 40 VDC Motor Power with a TV0 3 28 56 ST Transformer www aerotech com Chapter 2 29...

Page 30: ...30 Chapter 2 www aerotech com Figure 2 5 80 VDC Motor Power with a TV0 3 28 56 ST Transformer Soloist CP Installation and Configuration...

Page 31: ...Installation and Configuration Soloist CP Figure 2 6 40 Volt DC Bus from 115 and 230 VAC Source www aerotech com Chapter 2 31...

Page 32: ...32 Chapter 2 www aerotech com Figure 2 7 80 Volt DC Bus from 115 and 230 VAC Source TV0 3 56 Soloist CP Installation and Configuration...

Page 33: ...Installation and Configuration Soloist CP Figure 2 8 160 Volt DC Bus from 115 and 230 VAC Source TV0 3 56 www aerotech com Chapter 2 33...

Page 34: ...34 Chapter 2 www aerotech com Figure 2 9 Control and Motor Power Wiring using a TM3 or TM5 Transformer Soloist CP Installation and Configuration...

Page 35: ...on Numbers Wire Size Aerotech P N Third Party P N 13 3 mm2 6 AWG N A 2643626502 Elna Fair Rite Products 8 3 mm2 8 AWG ECZ00285 2643626502 Elna Fair Rite Products 2 0 mm2 14 AWG EIZ01027 2643002402 Eln...

Page 36: ...Power Output Connections TB102 Pin Description Recommended Wire Size A Phase A Motor Lead 1 3 mm2 16 AWG B Phase B Motor Lead 1 3 mm2 16 AWG C Phase C Motor Lead 1 3 mm2 16 AWG Earth Ground to Motor r...

Page 37: ...Green White indicates a single wire N OTE Brushless motors are commutated electronically by the controller The use of Hall effect devices for commutation is recommended The controller requires that t...

Page 38: ...com 2 2 1 1 Powered Motor Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor Hall and encoder phasing Figure 2 12 Encoder and Hall Signal Diagnostics Soloist CP Insta...

Page 39: ...sitive direction Figure 2 13 Motor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined the motor can now be connected to an Aerotech system...

Page 40: ...tor Configuration Table 2 12 Wire Colors for Aerotech Supplied Cables DC Brush Pin Wire Color Set 1 1 Wire Color Set 2 Wire Color Set 3 Green White Shield 2 Green Yellow Shield Green Yellow Shield A R...

Page 41: ...egative lead of the voltmeter to the other motor terminal 3 Rotate the motor clockwise by hand Figure 2 16 Clockwise Motor Rotation 4 If the voltmeter indicates a negative value swap the motor leads a...

Page 42: ...age For example an 80V motor bus supply is needed to get 40V across the motor Figure 2 17 Stepper Motor Configuration Table 2 13 Wire Colors for Aerotech Supplied Cables Stepper Pin Wire Color Set 1 1...

Page 43: ...s 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 p...

Page 44: ...ker Reference Pulse Input Absolute Encoder Interface Clock Output 8 Absolute Encoder Interface Data Bidirectional 9 Reserved N A 10 Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sens...

Page 45: ...n 2 5 for the auxiliary encoder channel N OTE Encoder wiring should be physically isolated from motor AC power and all other power wiring N OTE The PSO feature is not compatible with the MXU option Th...

Page 46: ...ll cause a feedback fault when the axis is enabled An analog encoder is used with the MXU option refer to Section 2 3 1 3 for more information Table 2 17 Encoder Specifications Specification Value Enc...

Page 47: ...Figure 2 20 for the serial data stream interface Refer to the Help file for information on how to set up your EnDat or Resolute absolute encoder parameters The encoder interface pinout is indicated i...

Page 48: ...1 for the typical input circuitry The encoder interface pin assignment is indicated in Section 2 3 1 The gain offset and phase balance of the analog Sine and Cosine encoder input signals can all be ad...

Page 49: ...Installation and Configuration Soloist CP Figure 2 22 Analog Encoder Interface J103 www aerotech com Chapter 2 49...

Page 50: ...ion while observing the position of the encoder in the diagnostics display see Figure 2 24 The Motor Phasing Calculator in the Configuration Manager can be used to determine proper encoder polarity Fo...

Page 51: ...Installation and Configuration Soloist CP Figure 2 24 Position Feedback in the Diagnostic Display www aerotech com Chapter 2 51...

Page 52: ...lt Refer to Section 2 2 1 1 for Hall effect device phasing Table 2 19 Hall Effect Feedback Interface Pins on the Motor Feedback Connector J103 Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V...

Page 53: ...esistance of the thermistor is low i e 100 ohms which will result in a low input signal As the increasing temperature causes the thermistor s resistance to increase the signal will be seen as a logic...

Page 54: ...loss of encoder function The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active Table 2 21 Encoder Fault In...

Page 55: ...ut Negative motion is stopped by the counterclockwise CCW end of travel limit input The Home Limit switch can be parameter configured for use during the home cycle however the CW or CCW EOT limit is t...

Page 56: ...56 Chapter 2 www aerotech com Figure 2 29 End of Travel Limit Interface Input J103 Soloist CP Installation and Configuration...

Page 57: ...e to move further into a limit but be unable to move out To correct this swap the connections to the CW and CCW inputs at the motor feedback connector The logic level of the EOT limit inputs may be vi...

Page 58: ...Soloist Help file for more information Use either the solid state relay on the Soloist CP or the mechanical relay on the IO board when connecting a power supply to the brake outputs on J103 Do not us...

Page 59: ...tor Supply Refer to Figure 2 32 for interconnection details The ESTOP input is scaled for an input voltage of 5 24 volts If the ESTOP bit is enabled in the FaultMask axis parameter the ESTOP input mus...

Page 60: ...rol power as shown in the Figure 2 32 The external relay must be sized based on the number of the Soloist CPs connected and the peak current rating of each drive Figure 2 32 Typical Emergency Stop Cir...

Page 61: ...y Cosine Bidirectional 12 5 Volt 500 mA max Output 13 Analog Input 0 Differential Input 14 Analog Input 0 Differential Input 15 Output Common 16 Digital Output 3 Output 17 Digital Input 0 CCW EOT Inpu...

Page 62: ...s Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec N OTE Use the EncoderDivider parameter to configure the bi direction...

Page 63: ...Installation and Configuration Soloist CP Figure 2 33 Auxiliary Encoder Channel J104 www aerotech com Chapter 2 63...

Page 64: ...ency pulse transmission is required It is best to locate the line receiver or opto isolator close to the receiving electronics Table 2 31 PSO Specifications Specification Value Maximum Input Tracking...

Page 65: ...Installation and Configuration Soloist CP Figure 2 34 PSO Interface www aerotech com Chapter 2 65...

Page 66: ...ommon connections can be directly connected to the drive s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 33 Digital Output Specifications O...

Page 67: ...ion Soloist CP N OTE Outputs must be connected as all sourcing or all sinking Figure 2 35 Outputs Connected in Current Sourcing Mode J104 Figure 2 36 Outputs Connected in Current Sinking Mode J104 www...

Page 68: ...power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 35 Digital Input Specifications Input Voltage Approximate Input Current Turn On Time Turn Of...

Page 69: ...N OTE Each bank of 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 2 37 Inputs Connected in Current Sourcing Mode J104 Figure 2 38 Inputs Connected in Current Sinkin...

Page 70: ...he Auxiliary I O Connector J104 Pin Description In Out Bi 3 High Speed Input 4 user interrupt Input 4 High Speed Input 4 user interrupt Input 5 High Speed Input 5 user interrupt Input 6 High Speed Inp...

Page 71: ...ble 2 40 Analog Output 0 Specifications TB102 B Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Resolution volts 305 V Table 2 41 Analog Output Connector Pi...

Page 72: ...analog common as shown in Figure 2 41 Table 2 42 Differential Analog Input 0 Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Resolution volts 305 V 1 Signals outside of...

Page 73: ...the EnableBrakeControl parameter and the BRAKE command When TB103 is used to power the solid state brake control relay the mechanical brake control relay present on the I O board should not be used N...

Page 74: ...connected to the Motor Feedback connector In this example the external 24 VDC power source is connected to TB103 Figure 2 42 Brake Connected to J103 N OTE The user is responsible for providing fuse p...

Page 75: ...DC brake connected to TB103 The user must connect J103 pin 13 to J103 pin 25 In this case J103 would function as an interlock to prevent the brake from releasing if the Motor Feedback connector is not...

Page 76: ...1 Output 2 RS 232 Transmit Output 3 RS 232 Receive Input 4 Signal Common N A 5 Brake Power Supply Output 6 Brake Power Supply Output 1 Totaluser 5 V power is limited to 500 mA Table 2 48 RS 232 Port...

Page 77: ...d operator shock Table 2 49 EXTSHUNT Component Information Component Description Aerotech P N Recommended Shunt Resistor 50 min 300 W Vishay Dale RBEF030050R00KFBVT ECR01039 2 Pin Mating Connector Scr...

Page 78: ...160 V 71 3 J 320 V 25 2 J If a shunt resistor is required the next step is to calculate the value of resistance necessary to dissipate the energy Use Equations 3 4 and 5 to calculate the parameters of...

Page 79: ...oloist CP 2 9 PC Configuration and Operation Information For additional information about PC configuration hardware requirements programming utilities and system operation refer to the Soloist Help fi...

Page 80: ...Soloist CP Installation and Configuration 80 Chapter 2 www aerotech com This page intentionally left blank...

Page 81: ...er connection before opening the Soloist CP chassis Figure 3 1 Soloist CP with IO Option Board Table 3 1 IO Expansion Board Jumper Configuration Jumper Setting Description JP1 1 2 3 4 Switch Brake 5 6...

Page 82: ...onnector Pinout TB201 Pin Description In Out Bi 1 Analog Common N A 2 Non inverting Analog Input 1 Input 3 Inverting Analog Input 1 Input 4 Analog Output 1 Output Table 3 4 Mating Connector Part Numbe...

Page 83: ...s TB201 Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Resolution volts 305 V N OTE Analog Output 0 is available on J104 refer to Section 2 5 7 Table 3 6 A...

Page 84: ...Figure 3 3 Table 3 7 Differential Analog Input Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 12 bits Resolution volts 4 88 mV 1 Signals outside of this range may damage the...

Page 85: ...isolation and will reduce noise immunity Table 3 9 Digital Output Specifications TB202 TB203 Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50...

Page 86: ...5 Optically Isolated Output 9 Digital Output 6 Optically Isolated Output 10 Digital Output 7 Optically Isolated Output Table 3 11 Port 2 Opto Out Connector Pinout TB203 Pin Description In Out Bi 1 Di...

Page 87: ...IO Expansion Board Soloist CP Figure 3 4 Digital Outputs TB202 TB203 www aerotech com Chapter 3 87...

Page 88: ...88 Chapter 3 www aerotech com Figure 3 5 Outputs Connected in Current Sourcing Mode TB202 TB203 Figure 3 6 Outputs Connected in Current Sinking Mode TB202 TB203 Soloist CP IO Expansion Board...

Page 89: ...igital Input Common for inputs 0 7 Input 2 Digital Input 0 Optically Isolated Input 3 Digital Input 1 Optically Isolated Input 4 Digital Input 2 Optically Isolated Input 5 Digital Input 3 Optically Is...

Page 90: ...90 Chapter 3 www aerotech com Figure 3 7 Digital Inputs Soloist CP IO Expansion Board...

Page 91: ...TE Each bank of 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 3 8 Inputs Connected to a Current Sourcing Device Figure 3 9 Inputs Connected to a Current Sinking De...

Page 92: ...TB205 5V terminal and TB204 GND terminal Table 3 17 User Common Connector on the Opto In Connector TB204 Pin Description In Out Bi 10 Signal Common N A Table 3 18 5 Volt Power Connector Pin on the Op...

Page 93: ...150 VDC 125 VAC Maximum Switched Current 1A Maximum Carrying Current 1A Maximum Switched Power 30 W DC 60 VA AC N OTE The maximum power that may be switched is voltage dependent Initial Contact Resis...

Page 94: ...t JP1 is set 1 2 and 3 4 with all others removed Figure 3 10 Brake Connected to J103 Figure 3 11 is an example of a 24 VDC Brake connected to TB206 In this example JP1 must be set 1 3 and all other ju...

Page 95: ...be found on the website at http www aerotechmotioncontrol com manuals index aspx Table 4 1 Standard Interconnection Cables Cable Part Description Joystick See Section 4 1 ECZ01231 BBA32 Interconnect...

Page 96: ...will not activate unless the joystick is in the center location Third party devices can be used provided they produce a symmetric output voltage within the range of 10V to 10V The following drawings...

Page 97: ...Accessories Soloist CP Figure 4 2 Two Axis Joystick Interface to the Aux I O of two drives Figure 4 3 Two Axis Joystick Interface to the Aux I O and I O Board www aerotech com Chapter 4 97...

Page 98: ...Cable Description UPC C22763 XX JSXT FLY 26HD 15DU MAX300DM SOLOISTCP DUAL AXIS 630B2276 3 C22764 XX JSXT 26HD 15DU MAX300DM SOLOISTCP SINGLE AXIS 630B2276 4 C22765 XX JSXT 26HD 26HD 15DU MAX300DM SOL...

Page 99: ...vide 5V differential quadrature signals to the Soloist CP A handwheel can be connected to the Aux I O as shown in Figure 4 5 or Figure 4 6 N OTE See the Soloist Help file for information on enabling t...

Page 100: ...100 Chapter 4 www aerotech com Soloist CP Accessories This page intentionally left blank...

Page 101: ...tion LED Description ENB FLT Turns green to indicate that the axis is enabled Turns red to indicate a fault condition The ENB FLT LED will flash between RED and GREEN if the drive is enabled and in a...

Page 102: ...Soloist CP Maintenance 5 1 Control Board D A N G E R Always disconnect the Mains power connection before opening the Soloist CP chassis Figure 5 1 Control Board Assembly 102 Chapter 5 www aerotech com...

Page 103: ...ittelfuse 3721200041 F4 Soloist CP 10 VAC Input at TB102 1 5 A S B 5 mm EIF01023 Littelfuse 215005 P SoloistCP 20 VAC Input at TB102 1 10 A S B 5 mm EIF01006 Littelfuse 218010 SoloistCP 30 VAC Input a...

Page 104: ...onductive material exposure Any fluids or electrically conductive material must not be permitted to enter the Soloist CP Visually inspect all cables and connections Tighten or re secure any loose conn...

Page 105: ...proval A Return Materials Authorization RMA number must accompany any returned product s The RMA number may be obtained by calling an Aerotech service center or by submitting the appropriate request a...

Page 106: ...t warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply On site Non Warranty Repair If any Aerotech product cannot be made functional by tele...

Page 107: ...2 8 EXTSHUNT Option TB104 4 08 00 Revision changes have been archived If you need a copy of this revision contact Aerotech Global Technical Support 4 07 00 4 05 00 4 04 00 4 03 00 4 02 00 4 01 00 4 0...

Page 108: ...Soloist CP Revision History 108 Appendix B www aerotech com This page intentionally left blank...

Page 109: ...Input I O Board 84 Analog Input 1 Connector 84 Analog Input Connector Pin Assignment 72 Analog Inputs Connector Pin Assignment 84 Analog Output 71 Analog Output 1 Connector 83 Analog Output 1 Connect...

Page 110: ...Interface Pin Assignment 54 Encoder Interface J207 45 Encoder Interface Pin Assignment 45 Encoder Phasing 50 Encoder Phasing Reference Diagram 50 End of Travel Limit Input Connections 55 End Of Trave...

Page 111: ...nputs 68 89 90 Opto Isolated Output Connector Pin Assignment 86 Opto Isolated Outputs 66 85 Opto Isolated Outputs IO Board 87 Output Specifications 85 Output Voltage specifications 19 Outputs Connecte...

Page 112: ...Interface Input 53 Transformer Examples 28 Transformer Options 28 TV0 3 28 56 ST Transformer 30 TV0 3 56 33 two axis joystick 96 Two Axis Joystick Interface 97 Typical Emergency Stop Circuit 60 Typica...

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