Aerotech Soloist HPe 10 Hardware Manual Download Page 1

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Revision: 4.09.00

Soloist HPe 10/20/30

Hardware Manual

Summary of Contents for Soloist HPe 10

Page 1: ...Revision 4 09 00 Soloist HPe 10 20 30 Hardware Manual ...

Page 2: ...tech 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 Email Support aerotech com Phone 86 21 5508 6731 Germany Taiwan Email Support aerotech com Phone 49 0 911 967 9370 Fax 49 0 911 967 93720 Email Support aerotech com Phone 886 0 2 8751 6690 France Email ...

Page 3: ... 2 1 2 Unpowered Motor and Feedback Phasing 40 2 2 2 DC Brush Motor Connections 41 2 2 2 1 DC Brush Motor Phasing 42 2 2 3 Stepper Motor Connections 43 2 2 3 1 Stepper Motor Phasing 44 2 3 Motor Feedback Connector J207 45 2 3 1 Encoder Interface J207 46 2 3 1 1 RS 422 Line Driver Encoder Standard 47 2 3 1 2 Absolute Encoder Interface J207 48 2 3 1 3 Analog Encoder Interface 49 2 3 1 4 Encoder Phas...

Page 4: ...log Inputs TB304 86 3 5 User Power TB305 TB306 87 3 6 Opto In Connectors Digital Inputs TB305 TB306 88 3 7 Opto Out Connectors Digital Outputs TB307 TB308 91 Chapter 4 RDP Expansion Board 95 Chapter 5 Standard Interconnection Cables 99 5 1 Joystick Interface 100 5 2 Handwheel Interface 103 Chapter 6 Maintenance 105 6 1 Power Board 106 6 2 Control Board 107 6 3 Preventative Maintenance 109 Appendix...

Page 5: ...ise Motor Rotation 44 Figure 2 18 Line Driver Encoder Interface J207 47 Figure 2 19 Serial Data Stream Interface 48 Figure 2 20 Analog Encoder Phasing Reference Diagram 49 Figure 2 21 Analog Encoder Interface J207 50 Figure 2 22 Encoder Phasing Reference Diagram Standard 51 Figure 2 23 Position Feedback in the Diagnostic Display 52 Figure 2 24 Hall Effect Inputs J207 53 Figure 2 25 Thermistor Inte...

Page 6: ...cted in Current Sourcing Mode 94 Figure 3 13 Digital Outputs Connected in Current Sinking Mode 94 Figure 4 1 RDP Option Board 95 Figure 4 2 Resolver Inductosyn Recommended Wiring 97 Figure 4 3 Resolver Inputs 97 Figure 4 4 Encoder Emulation Outputs 98 Figure 5 1 Single Axis Joystick Interface to Aux I O 100 Figure 5 2 Two Axis Joystick Interface to the Aux I O of two drives 101 Figure 5 3 Two Axis...

Page 7: ...nterface Pins on the Motor Feedback Connector J207 55 Table 2 20 End of Travel Limit Input Interface Pins on the Motor Feedback Connector J207 56 Table 2 21 Brake Output Pins on the Motor Feedback Connector J207 59 Table 2 22 Electrical Noise Suppression Devices 60 Table 2 23 Mating Connector Part Numbers for the ESTOP Connector TB201 60 Table 2 24 Typical ESTOP Relay Ratings 61 Table 2 25 Auxilia...

Page 8: ...ector TB304 86 Table 3 17 User Common Pin on the Opto In Connector TB305 87 Table 3 18 5 Volt Power Pin on the Opto In Connector TB306 87 Table 3 19 Digital Input Device Specifications 88 Table 3 20 Port 1 Opto In Connector Pinout TB305 88 Table 3 21 Port 2 Opto In Connector Pinout TB306 88 Table 3 22 Mating Connector Part Numbers for the Opto In Connectors TB305 TB306 88 Table 3 23 Digital Output...

Page 9: ...tage Directive 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 supplied installation instructions EN 61800 3 2004 EMC Requirements for Power Drives EN 61010 1 2010 Safety Requirements for Electrical Equipment Authorized Representative Simon Smith European...

Page 10: ...fication 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 to view Aerotech s TÜV SÜD certificates Type the certificate number listed above in the search bar or type Aerotech for a list of all Aerotech certificates Soloist HPe 10 20 30 Declaration of Conformi...

Page 11: ...ion 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 power before servicing equipment 2 Disconnect electrical power before performing any wiring 3 Access to the Soloist HPe 10 20 30 and component parts must be restricted while connected to a power sou...

Page 12: ...ng injuries Access to all stage and motor parts must be restricted while connected to a power source 3 Cables can pose a tripping hazard Securely mount and position all system cables to avoid potential hazards 4 Do not expose this product to environments or conditions outside of the listed specifications Exceeding environmental or operating specifications can cause damage to the equipment 5 Operat...

Page 13: ...your Sales Order 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 Section 2 3 Motor Feedback Connector J207 Ethernet USB No Section Standard Connection Control Supply Section 2 1 1 Control Supply Connections TB101 Motor Supply Section 2 1 2 Motor Supply...

Page 14: ...Soloist HPe 10 20 30 Quick Installation Guide 14 www aerotech com This page intentionally left blank ...

Page 15: ... digital PID and current loops All system configuration is done using software settable parameters including control loop gains and system safety functions The Soloist HPe 10 20 30 is offered with an optional encoder interpolation feature MXH an auxiliary square wave encoder input for dual loop control dedicated analog and digital I O expandable with the IO option a resolver input and separate pow...

Page 16: ...ith Ethernet I O modules Refer to the Help file Table 1 2 Ordering Options Options Power Stage Options Section 1 2 10 10 A peak 5 A continuous 20 20 A peak 10 A continuous 30 S 30 A peak 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 three 16 bit diff...

Page 17: ...lver Options Chapter 4 RDP1 10K One channel resolver to digital converter input 10 kHz carrier frequency RDP1 7 5K One channel resolver to digital converter input 7 5 kHz carrier frequency RDP1 5K One channel resolver to digital converter input 5 kHz carrier frequency RDP2 10K Two channel resolver to digital converter input 10 kHz carrier frequency RDP2 7 5K Two channel resolver to digital convert...

Page 18: ...er 1 www aerotech com The following block diagram shows a connection summary For detailed connection information refer to Chapter 2 and Chapter 3 Figure 1 2 Functional Diagram Soloist HPe 10 20 30 Introduction ...

Page 19: ...on of the software first supported the drive Drives that list a specific version number in the Last Software Version column will not be supported after the listed version Table 1 5 Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version HPe 2 51 Current www aerotech com Chapter 1 19 ...

Page 20: ...nuous 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 mH 160 VDC 1 mH 320 VDC User Power Supply Output 5 VDC 500 mA Modes of Operation Brushless Brush Stepper Protective Features Output short circuit Peak over current DC bus over voltage RMS over current Over tem...

Page 21: ...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 sec Linear Motors 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 A...

Page 22: ...e 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 Soloist HPe 10 20 30 Mounting it to a large metal plate for extra heat sinking and providing additional fan flow are ...

Page 23: ...ion compliant for unlimited 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 Figure 1 5 Dimensions Slim Version www aerotech com Chapter 1 23 ...

Page 24: ...erotech com Figure 1 6 Dimensions Full Version with IO and RDP options Table 1 7 Physical Specifications Weight Slim 2 27 kg 5 0 lb w IO option 2 45 kg 5 4 lb w RDP option 2 45 kg 5 4 lb Soloist HPe 10 20 30 Introduction ...

Page 25: ...Temperature 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 Altitude Up to 2000 meters Pollution Pollution degree 2 normally only non conductive pollution Use Indoor use only www aerotech com Chapter 1 25 ...

Page 26: ...Soloist HPe 10 20 30 Introduction 26 Chapter 1 www aerotech com This page intentionally left blank ...

Page 27: ...nput is internally fused The AC2 input is not internally fused but can be connected to a voltage source other than Neutral if an external 2 A time delay fuse is used Although the control power supply contains an internal filter an additional external filter located as close as possible to the Soloist HPe 10 20 30 may be required for CE compliance Aerotech recommends Schaffner FN2080 or Aerotech UF...

Page 28: ...n in place W A R N I N G Do not operate the Soloist HPe 10 20 30 without proper branch protection An AC Line Filter may be required for CE compliance and should be located as close as possible to the drive For more information about the AC Line Filter refer to Section 2 1 4 Wiring between the filter and drive can be twisted and or shielded to reduce radiated emissions Figure 2 2 Motor Bus Input Co...

Page 29: ... VAC from 115 VAC 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 power TV0 3 28 Generate 28 VAC from 115 VAC or 230 VAC input source voltage When rectified by the drive it produces a 40 VDC power bus TV0 3 56 Generate 56 VAC from 115 VAC or 230 VAC...

Page 30: ...30 Chapter 2 www aerotech com Figure 2 4 40 VDC Motor Power with a TV0 3 28 56 ST Transformer Soloist HPe 10 20 30 Installation and Configuration ...

Page 31: ...Installation and Configuration Soloist HPe 10 20 30 Figure 2 5 80 VDC Motor Power with a TV0 3 28 56 ST Transformer www aerotech com Chapter 2 31 ...

Page 32: ...32 Chapter 2 www aerotech com Figure 2 6 40 Volt DC Bus from 115 and 230 VAC Source Soloist HPe 10 20 30 Installation and Configuration ...

Page 33: ...Installation and Configuration Soloist HPe 10 20 30 Figure 2 7 80 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 8 160 Volt DC Bus from 115 and 230 VAC Source TV0 3 56 Soloist HPe 10 20 30 Installation and Configuration ...

Page 35: ...Installation and Configuration Soloist HPe 10 20 30 Figure 2 9 Control and Motor Power Wiring using a TM3 or TM5 Transformer www aerotech com Chapter 2 35 ...

Page 36: ...quired for EMC compliance and are recommended during initial EMC system evaluation 1 Add clamp on ferrite to the motor feedback cable close to the drive Aerotech PN ECZ02348 Fair rite PN 0446167281 2 Add clamp on ferrite to the Motor Supply and Control Supply wires including the ground wire close to the drive Aerotech PN ECZ02347 Fair rite PN 0446164281 3 Add a ferrite core to the UFM ST AC input ...

Page 37: ...t Connections TB102 Pin Description Recommended Wire Size ØA Phase A Motor Lead 1 3 mm2 16 AWG ØB Phase B Motor Lead 1 3 mm2 16 AWG ØC Phase C Motor Lead 1 3 mm2 16 AWG Earth Ground to Motor required for safety 1 3 mm2 16 AWG 1 It is the user s responsibility to properly size external wires Table 2 8 Mating Connector Part Numbers for the Motor Output Connector TB102 Description Aerotech P N Phoeni...

Page 38: ...icates 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 the Back EMF of each motor phase be aligned with the corresponding Hall effect signal To ensure proper alignment motor Hall and encoder connections should be verified using one of the following methods powered through...

Page 39: ... Soloist HPe 10 20 30 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 11 Encoder and Hall Signal Diagnostics www aerotech com Chapter 2 39 ...

Page 40: ... Figure 2 12 Motor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined the motor can now be connected to an Aerotech system Connect motor lead A to motor connector A motor lead B to motor connector B and motor lead C to motor connector C Hall leads should also be connected to their respective feedback connector pins Hall A lead to the Ha...

Page 41: ...e 2 14 DC Brush Motor Configuration Table 2 10 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 Red Orange Red Red Orange C Yellow Blue Black Yellow Blue 1 Wire Color Set 1 is the typicalAerotech wire set used by Aerotech 2 Red Orange indicates two wires Green White indicates a ...

Page 42: ...ter to the other motor terminal 3 Rotate the motor clockwise by hand Figure 2 15 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 Soloist HPe 10 20 30 Connect t...

Page 43: ...e applied bus voltage For example an 80V motor bus supply is needed to get 40V across the motor Figure 2 16 Stepper Motor Configuration Table 2 11 Wire Colors for Aerotech Supplied Cables Stepper Pin Wire Color Set 1 1 Wire Color Set 2 Green Yellow Shield 2 Green Yellow Shield A Black Brown B Red Yellow C White White Red 1 Wire Color Set 1 is the typicalAerotech wire set used by Aerotech 2 Red Ora...

Page 44: ... 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 Figure 2 17 Clockwise Motor Rotation N OTE If using standard Aerotech motors and cables motor and encoder connection adjus...

Page 45: ...utput 7 Encoder Marker 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 Sensor C brushless motors only Input 12 Clockwise End of Travel Limit Input 13 Brake Output Output 14 Encoder Cosine Input 15 Encoder Cosine Input 16 5V Power for Limit Switches 500 mA ...

Page 46: ... to Section 2 3 1 4 for encoder feedback phasing Refer to Section 2 5 for the auxiliary encoder channel N OTE Encoder wiring should be physically isolated from motor AC power and all other power wiring Table 2 14 Encoder Interface Pins on the Motor Feedback Connector Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V Power for Encoder 500 mA max Output 6 Encoder Marker Reference Pulse Input...

Page 47: ...missing signals will cause a feedback fault when the axis is enabled An analog encoder is used with the MXH option refer to Section 2 3 1 3 for more information Table 2 15 Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec Figure 2 18 Line Driver Encoder Interface J207 www aerotech com Chapter 2 4...

Page 48: ...n via a serial data stream from the absolute encoder See Figure 2 19 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 in Section 2 3 1 Figure 2 19 Serial Data Stream Interface Soloist HPe 10 20 30 Installation and Configuration ...

Page 49: ...nalog input to quadrature output Refer to Figure 2 20 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 adjusted via controller parameters Encoder signals should be adjusted using the Feedback Tuning tab of the Digital Scope which will automatically adju...

Page 50: ...50 Chapter 2 www aerotech com Figure 2 21 Analog Encoder Interface J207 Soloist HPe 10 20 30 Installation and Configuration ...

Page 51: ...CW positive direction while observing the position of the encoder in the diagnostics display see Figure 2 23 The Motor Phasing Calculator in the Configuration Manager can be used to determine proper encoder polarity For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 23 Figure 2 22 Encoder Phasing Reference Diagram Standard N OTE Encoder manufacturer...

Page 52: ...52 Chapter 2 www aerotech com Figure 2 23 Position Feedback in the Diagnostic Display Soloist HPe 10 20 30 Installation and Configuration ...

Page 53: ...all Fault axis fault Refer to Section 2 2 1 1 for Hall effect device phasing Table 2 17 Hall Effect Feedback Interface Pins on the Motor Feedback Connector J207 Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V Power for Encoder 500 mA max Output 5 Hall Effect Sensor B brushless motors only Input 10 Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sensor C brushless motors o...

Page 54: ... 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 high triggering an over temperature fault The nominal trip value of the sensor is 1k Ohm Table 2 18 Thermistor Interface Pins on the Motor Feedback Connector J207 Pin Description In Out Bi 2 Motor Over Temperature Th...

Page 55: ...s and indicates a loss of encoder function The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active Table 2 19 Encoder Fault Interface Pins on the Motor Feedback Connector J207 Pin Description In Out Bi 23 Encoder Fault Input Input Figure 2 26 Encoder Fault Interface Input J207 www aerotech com Chapter 2 55 ...

Page 56: ...on is stopped by the counterclockwise CCW end of travel limit input The Home Limit switch can be parameter configured for use during the home cycle however the CW or CCW EOT limit is typically used instead Opto isolated user inputs 0 3 can also be used as the end of travel limit inputs see Section 2 5 4 Figure 2 27 End of Travel Limit Input Connections Table 2 20 End of Travel Limit Input Interfac...

Page 57: ...Installation and Configuration Soloist HPe 10 20 30 Figure 2 28 End of Travel Limit Interface Input J207 www aerotech com Chapter 2 57 ...

Page 58: ...r into a limit but be unable to move out To correct this swap the connections to the CW and CCW inputs at the motor feedback connector The logic level of the EOT limit inputs may be viewed in the Diagnostic Display shown in Figure 2 29 Figure 2 29 Limit Input Diagnostic Display Soloist HPe 10 20 30 Installation and Configuration ...

Page 59: ...eters refer to the Soloist Help file for more information Use either the solid state relay on the Soloist HPe 10 20 30 or the mechanical relay on the IO board when connecting a power supply to the brake outputs on J207 Do not use both relays at the same time Refer to Section 2 6 for more information on using the brake output with the solid state relay Refer to Section 3 1 for more information on u...

Page 60: ... 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 must be driven to prevent the ESTOP fault condition Figure 2 30 ESTOP Sense Input TB201 N OTE Connecting the ESTOP input to a relay or other noise producing device requires the use of noise suppression devices such as those in Table 2 22 ...

Page 61: ...e maintaining control power as shown in the Figure 2 31 The external relay must be sized based on the number of the Soloist HPe 10 20 30s connected and the peak current rating of each drive Figure 2 31 Typical Emergency Stop Circuit Table 2 24 Typical ESTOP Relay Ratings Axes AC1 AC3 Aerotech P N Third Party P N 1 32 16 ECW1018 Sprecher Schuh CA7 16C xx xxx 2 to 5 85 43 ECW1019 Sprecher Schuh CA7 ...

Page 62: ...ectional 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 Input 1 Input 18 Digital Input 1 CW EOT Input 1 Input 19 Auxiliary Marker PSO output 2 Bidirectional 20 Auxiliary Marker PSO output 2 Bidirectional 21 Common 5 Volt User Supply 500 mA max 22 Analog Output 0 Output 23 A...

Page 63: ...nator resistors Table 2 27 Auxiliary Encoder Specifications 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 directional encoder interface on the aux iliary I O connector The EncoderDivider parameter converts the auxiliary encoder interface to an output and de...

Page 64: ...64 Chapter 2 www aerotech com Figure 2 32 Auxiliary Encoder Channel J205 Soloist HPe 10 20 30 Installation and Configuration ...

Page 65: ...ation An RS 422 line receiver or opto isolator is recommended especially when using long cable lengths in noisy environments or when high frequency pulse transmission is required It is best to locate the line receiver or opto isolator close to the receiving electronics Table 2 29 PSO Specifications Specification Value Maximum Input Tracking Rate 1 Single Axis Tracking 16 6 MHz Maximum Quadrature E...

Page 66: ...66 Chapter 2 www aerotech com Figure 2 33 PSO Interface Soloist HPe 10 20 30 Installation and Configuration ...

Page 67: ...e opto isolator s common 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 31 Digital Output Specifications Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50 C Output Saturation Voltage 2 75 V at maximum current Output Resistance 33 ...

Page 68: ...puts must be connected as all sourcing or all sinking Figure 2 34 Digital Outputs Connected in Current Sourcing Mode J205 Figure 2 35 Digital Outputs Connected in Current Sinking Mode J205 Soloist HPe 10 20 30 Installation and Configuration ...

Page 69: ...ected to the drive s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 33 Digital Input Specifications Input Voltage Approximate Input Current Turn On Time Turn Off Time 5 V 1 mA 200 usec 2000 usec 24 V 6 mA 4 usec 1500 usec Table 2 34 Port 0 Digital Input Connector Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 17 Digita...

Page 70: ...uts must be connected in the all sourcing or all sinking configuration Figure 2 36 Digital Inputs Connected in Current Sourcing Mode J205 Figure 2 37 Digital Inputs Connected in Current Sinking Mode J205 Soloist HPe 10 20 30 Installation and Configuration ...

Page 71: ... 0 High Speed Digital Input Connector Pins on the Auxiliary I O Connector J205 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 Input 5 user interrupt Input Table 2 37 Input Voltage Jumper Configuration Jumper Setting Description JP3 1 2 1 24 V operation High Speed Input 5 2 3 5 V op...

Page 72: ...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 µV Table 2 39 Analog Output Connector Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 22 Analog Output 0 Output 23 Analog Common Figure 2 39 Analog Output 0 J205 Soloist HPe 10 20 30 Installation and Configuration ...

Page 73: ...eferenced to the analog common as shown in Figure 2 40 Table 2 40 Differential Analog Input 0 Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Resolution volts 305 µV 1 Signals outside of this range may damage the input Table 2 41 Analog Input Connector Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 13 Analog Input 0 Differential Input 14 Analog I...

Page 74: ...meter and the BRAKE command When TB202 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 OTE The brake power supply must be externally fused The user must verify that the brake power requirements are within the specifications of the brake control relay Table 2 42 Relay Specifications Solid State Relay Rating Maximu...

Page 75: ...1 Brake Connected to J207 N OTE The user is responsible for providing fuse protection for the brake circuit Figure 2 42 is an example of a 24 VDC brake connected to TB202 The user must connect J207 pin 13 to J207 pin 25 In this case J207 would function as an interlock to prevent the brake from releasing if the Motor Feedback connector is not connected Figure 2 42 Brake Connected to TB202 www aerot...

Page 76: ...it Output 3 RS 232 Receive Input 4 Reserved Output 5 Ground N A 6 Reserved Output 7 Reserved Input 8 Reserved Input 9 Reserved N A 1 Totaluser 5 V power is limited to 500 mA Table 2 46 Mating Connector Part Numbers for the RS 232 Port Connector J206 Mating Connector Aerotech P N Third Party P N 9 Pin D Connector ECK00137 FCI DE09P064TXLF Backshell ECK01021 Amphenol 17E 1724 2 Figure 2 43 RS 232 In...

Page 77: ...re and operator shock Table 2 47 EXTSHUNT Component Information Component Description Aerotech P N Recommended Shunt Resistor 50 Ω min 300 W Vishay Dale RBEF030050R00KFBVT ECR01039 2 Pin Mating Connector Screw Torque Value 0 5 0 6 N m Wire Size 12 30 AWG 3 3 0 0516 mm2 Phoenix 175449 ECK01110 Fuse F2 on the Power Board 2 5 A S B Littelfuse 21502 5P EIF01053 Recommended Wire Size 16 AWG 1 3 mm2 Hig...

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 the shunt resistor Equation 3 PPEAK peak power that the regeneration circuit must accommodate W tD deceleration time s Equation 4 PAV average power dissipated on shunt resistor W tCYCLE time between...

Page 79: ...st HPe 10 20 30 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 file www aerotech com Chapter 2 79 ...

Page 80: ...Soloist HPe 10 20 30 Installation and Configuration 80 Chapter 2 www aerotech com This page intentionally left blank ...

Page 81: ...Pe 10 20 30 chassis Figure 3 1 Soloist HPe 10 20 30 with IO Option Board Table 3 1 IO Expansion Board Jumper Configuration Jumper Setting Description JP2 1 2 PSO Output Active High Low Z during reset 2 3 1 PSO Output Active Low High Z during reset JP3 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 M...

Page 82: ...tact Ratings Maximum Switched Voltage 150 VDC 125 VAC Maximum Switched Current 1A Maximum Carrying Current 1A Maximum Switched Power 30 W DC 60 VA AC N OTE Do not exceed Maximum Current or Maximum Power specifications Table 3 4 Relay Connector Pinout TB301 Pin Description In Out Bi 1 Brake Relay Output Normally Closed Contact Output 2 Brake Relay Output Common Contact Output 3 Brake Relay Output N...

Page 83: ...others removed Figure 3 2 Brake Connected to J207 Figure 3 3 is an example of a 24 VDC Brake connected to TB301 In this example JP3 must be set 1 3 and all other jumpers removed Otherwise the user must connect J207 pin 13 to J207 pin 25 In this case J207 would function as an interlock to prevent the Brake from releasing if the Motor Feedback connector is not connected Figure 3 3 Brake Connected to...

Page 84: ...e shown in Table 3 9 For the JP2 jumper location refer to Figure 3 1 Table 3 7 PSO Output Interface Connector Pinout TB302 Pin Description In Out Bi 1 Reserved 2 PSO Output Output 3 Opto Isolator Common Input Table 3 8 Mating Connector Part Numbers for the PSO Output Connector TB302 Description Aerotech P N Phoenix P N Wire Size AWG mm2 3 Pin Terminal Block ECK01449 1881338 0 5 0 080 20 28 Table 3...

Page 85: ...Output 0 on J205 see Section 2 5 6 TB303 lets you connect to all of the analog outputs from one connector do not connect to AOUT0 at both TB303 and J205 Table 3 12 Analog Output Connector Pinout TB303 Pin Description In Out Bi 1 Analog Output 0 Output 2 Analog Output 1 Output 3 Analog Output 2 Output 4 Analog Output 3 Output Table 3 13 Mating Connector Part Numbers for the Analog Output Connector ...

Page 86: ...n J205 see Section 2 5 7 TB304 lets you connect to all of the analog inputs in one place do not connect to AIN0 at both TB304 and J205 Table 3 15 Analog Inputs Connector Pinout TB304 Pin Description In Out Bi 1 Analog Common N A 2 Non Inverting Analog Input 0 Input 3 Inverting Analog Input 0 Input 4 Non Inverting Analog Input 1 Input 5 Inverting Analog Input 1 Input 6 Analog Common N A 7 Non Inver...

Page 87: ...n on the Opto In Connector TB305 Pin Description In Out Bi 10 Signal Common N A Table 3 18 5 Volt Power Pin on the Opto In Connector TB306 Pin Description In Out Bi 10 Internal 5 Volt Power Supply 0 5 A max N A W A R N I N G Opto isolated inputs and outputs should not be powered by the user output power Doing so would compromise the isolation provided by the opto isolator www aerotech com Chapter ...

Page 88: ...l 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 Isolated Input 6 Digital Input 4 Optically Isolated Input 7 Digital Input 5 Optically Isolated Input 8 Digital Input 6 Optically Isolated Input 9 Digital Input 7 Optically Isolated Input 10 Signal Common N A...

Page 89: ... IO Expansion Board Soloist HPe 10 20 30 Figure 3 8 Digital Inputs www aerotech com Chapter 3 89 ...

Page 90: ...of 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 3 9 Digital Inputs Connected to a Current Sourcing Device Figure 3 10 Digital Inputs Connected to a Current Sinking Device Soloist HPe 10 20 30 IO Expansion Board ...

Page 91: ...the isolation and will reduce noise immunity Table 3 23 Digital Output Specifications TB307 TB308 Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50 C Output Saturation Voltage 2 75 V at maximum current Output Resistance 33 Ω Rise Fall Time 250 usec typical Reset State Output Off High Impedance State Suppression diodes must be installed on ou...

Page 92: ...Optically Isolated Output 9 Digital Output 6 Optically Isolated Output 10 Digital Output 7 Optically Isolated Output Table 3 25 Port 2 Opto Out Connector Pinout TB308 Pin Description In Out Bi 1 Digital Output Common Plus Input 2 Digital Output Common Minus Input 3 Digital Output 0 Optically Isolated Output 4 Digital Output 1 Optically Isolated Output 5 Digital Output 2 Optically Isolated Output 6...

Page 93: ... IO Expansion Board Soloist HPe 10 20 30 Figure 3 11 Digital Opto Isolated Outputs IO Board www aerotech com Chapter 3 93 ...

Page 94: ...94 Chapter 3 www aerotech com Figure 3 12 Digital Outputs Connected in Current Sourcing Mode Figure 3 13 Digital Outputs Connected in Current Sinking Mode Soloist HPe 10 20 30 IO Expansion Board ...

Page 95: ...he motor the alignment between the resolver and motor must be known This alignment can be determined by using the controller s software Refer to the Soloist Help file for information on configuring parameters for an axis with resolver feedback Channel 1 is on J401 and channel 2 is on J402 The RDP option can supply up to 7 VRMS reference voltage and requires 2 VRMS on the sine and cosine inputs D A...

Page 96: ...er Reference Output 8 Shield Reference Shield 7 ENC SIN Encoder Emulation Sine optional Output 11 ENC SIN Encoder Emulation Sine optional Output 1 ENC COS Encoder Emulation Cosine optional Output 6 ENC COS Encoder Emulation Cosine optional Output 2 ENC MRK Encoder Emulation Marker optional Output 12 ENC MRK Encoder Emulation Marker optional Output Table 4 3 Mating Connector Part Numbers for the Re...

Page 97: ... RDP Expansion Board Soloist HPe 10 20 30 Figure 4 2 Resolver Inductosyn Recommended Wiring Figure 4 3 Resolver Inputs www aerotech com Chapter 4 97 ...

Page 98: ... Mating Connector Part Numbers for the External Power Connector J403 Description Aerotech P N Phoenix P N Wire Size AWG mm2 3 Pin Terminal Block ECK01449 1881338 0 5 0 080 20 28 Table 4 6 Resolver Test Points Test Point Description TP4 Signal Common TP10 Sine Input Channel 1 TP11 Cosine Input Channel 1 TOP Reference Signal Channel 1 TP13 Resolver Channel 1 Error TP20 Sine Input Channel 2 TP21 Cosi...

Page 99: ...w aerotechmotioncontrol com manuals index aspx Table 5 1 Standard Interconnection Cables Cable Part Description Joystick See Section 5 1 ECZ01231 BBA32 Interconnect Cable ENET XOVER xx 1 Ethernet cross over cable USB AMBM xx 1 USB cable A male to B male 1 The xx indicates length in decimeters yy would indicate length in feet www aerotech com Chapter 5 99 ...

Page 100: ...ntrol 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 illustrate how to connect a single or two axis joystick a two axis joystick requires two Soloist HPes For cable details refer to Table 5 2 Refer to the Soloist Help file for programming informati...

Page 101: ...Accessories Soloist HPe 10 20 30 Figure 5 2 Two Axis Joystick Interface to the Aux I O of two drives www aerotech com Chapter 5 101 ...

Page 102: ...d Table 5 2 Cable Part Numbers Part Cable Description UPC C22769 XX JSXT FLY 26HD 15DU MAX300DM SOLOISTHPE DUAL AXIS 630B2276 9 C227610 XX JSXT 26HD 15DU MAX300DM SOLOISTHPE SINGLE AXIS 630B2276 10 C227611 XX JSXT 26HD 26HD 15DU MAX300DM SOLOISTHPE DUAL AXIS 630B2276 11 102 Chapter 5 www aerotech com ...

Page 103: ...ovide 5V differential quadrature signals to the Soloist HPe 10 20 30 A handwheel can be connected to the Aux I O as shown in Figure 5 4 or Figure 5 5 N OTE See the Soloist Help file for information on enabling the handwheel Figure 5 4 Handwheel Interconnection to Aux I O Figure 5 5 Handwheel Interconnection to Aux I O via a BBA32 Module www aerotech com Chapter 5 103 ...

Page 104: ...104 Chapter 5 www aerotech com Soloist HPe 10 20 30 Accessories This page intentionally left blank ...

Page 105: ...LED Description 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 fault condition MARKER Turns green to indicate that the marker input is high PWR Turns green when power is applied POS Turns green to indicate that the axis is in position If the power ligh...

Page 106: ...d on HPe30 1 Default Table 6 3 Fuse Information Fuse Description Size Aerotech P N Manufacturer s P N F1 HPe 10 VAC input at TB102 1 5 A SB 5 mm EIF00179 Wickman 1951500 HPe 20 VAC input at TB102 1 10 A SB 5 mm EIF1006 Littelfuse 218010 HPe 30 VAC input at TB102 1 10 A SB 5 mm EIF1006 Littelfuse 218010 F2 S option shunt fuse 1 A SB 5 mm EIF01052 Littelfuse 0215001 P EXTSHUNT option external shunt ...

Page 107: ...ce Soloist HPe 10 20 30 6 2 Control Board D A N G E R Always disconnect the Mains power connection before opening the Soloist HPe 10 20 30 chassis Figure 6 2 Control Board Assembly www aerotech com Chapter 6 107 ...

Page 108: ...chem MICROSMD005F 2 F4 Surface Mount Fuse 05 A EIF01028 Raychem MICROSMD005F 2 F5 Surface Mount Fuse 05 A EIF01028 Raychem MICROSMD005F 2 F6 Resettable Fuse 5 A EIF01002 Raychem MINISMDC050 Table 6 6 LED Description 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 enable...

Page 109: ...rial exposure Any fluids or electrically conductive material must not be permitted to enter the Soloist HPe 10 20 30 Visually inspect all cables and connections Tighten or re secure any loose connections Replace worn or frayed cables Replace broken connectors Cleaning The Soloist HPe 10 20 30 chassis can be wiped with a clean dry soft cloth The cloth may be slightly moistened if required with wate...

Page 110: ...110 Chapter 6 www aerotech com Soloist HPe 10 20 30 Maintenance This page intentionally left blank ...

Page 111: ...uch approval 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 available on our website www aerotech com Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than thirty...

Page 112: ...rranty 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 telephone assistance or purchased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site Field Serv...

Page 113: ... J205 l Section 2 5 2 Position Synchronized Output PSO Laser Firing J205 l Section 2 5 3 Digital Outputs 0 3 J205 l Section 2 5 4 Digital Inputs 0 3 J205 l Section 2 5 5 High Speed User Inputs 4 5 J205 l Section 2 5 6 Analog Output 0 J205 l Section 2 5 7 Differential Analog Input 0 J205 l Section 2 8 EXTSHUNT Option TB103 l Section 3 2 PSO Output Interface TB302 l Section 3 3 Analog Outputs TB303 ...

Page 114: ...Soloist HPe 10 20 30 Revision History 114 Appendix B www aerotech com This page intentionally left blank ...

Page 115: ... 25 amplifier power dissipation 22 Analog Encoder Phasing Reference Diagram 49 Analog Encoder Specifications 49 Analog Input 73 Analog Input I O Board 86 Analog Input 1 Connector 86 Analog Input Connector Pin Assignment 73 Analog Inputs Connector Pin Assignment 86 Analog Output 72 Analog Output 1 Connector 85 Analog Output 1 Connector Pin Assignment 85 Analog Outputs I O Board 85 Auxiliary Encoder...

Page 116: ...er Amplifier specifications 20 Electrical Specifications 20 Emergency Stop Sense Input 60 EN 61800 3 9 encoder absolute 48 Encoder and Hall Signal Diagnostics 39 Encoder Emulation Outputs 98 Encoder Fault Interface J207 55 Encoder Fault Interface Input 55 Encoder Fault Interface Pin Assignment 55 Encoder Interface J207 46 Encoder Interface Pin Assignment 46 Encoder Phasing 51 Encoder Phasing Refer...

Page 117: ...esign 23 Minimizing Conducted Radiated and System Noise 36 Minimum Load Inductance specifications 20 Modes of Operation 20 Motor Feedback Connections 45 Motor Feedback Connector Pinout 45 Motor Phasing Oscilloscope Example 40 Motor Supply Connections 28 Motor Supply specifications 20 N Nominal Motor Operating Voltages Required AC Voltages 29 O optional joysticks 100 Options 16 Output Specification...

Page 118: ...nt 16 Shunt fuse S option 106 Single Axis Joystick Interface 100 solid state brake control relay 74 Standard Features 16 Stepper Motor Connections 43 Stepper Motor Phasing 44 Support 2 T TB101 27 TB102 28 37 TB103 77 TB201 60 TB202 74 75 82 TB301 82 83 TB302 84 TB304 86 TB305 87 88 TB306 87 88 TB307 91 TB308 91 Technical Support 2 Thermistor Interface 54 Thermistor Interface Input 54 Transformer E...

Page 119: ...www aerotech com 119 W Wire Colors for Supplied Cables 38 41 43 Wiring Control Supply 27 Index Soloist HPe 10 20 30 ...

Page 120: ...Soloist HPe 10 20 30 Index 120 www aerotech com This page intentionally left blank ...

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