Aerotech DR500 User manual

Artisan Technology Group is your source for quality
new and certied-used/pre-owned equipment
• FAST SHIPPING AND
DELIVERY
• TENS OF THOUSANDS OF
IN-STOCK ITEMS
• EQUIPMENT DEMOS
• HUNDREDS OF
MANUFACTURERS
SUPPORTED
• LEASING/MONTHLY
RENTALS
• ITAR CERTIFIED
SECURE ASSET SOLUTIONS
SERVICE CENTER REPAIRS
Experienced engineers and technicians on staff
at our full-service, in-house repair center
WE BUY USED EQUIPMENT
Sell your excess, underutilized, and idle used equipment
We also offer credit for buy-backs and trade-ins
www.artisantg.com/WeBuyEquipment
REMOTE INSPECTION
Remotely inspect equipment before purchasing with
our interactive website at www.instraview.com
LOOKING FOR MORE INFORMATION?
Visit us on the web at www.artisantg.com for more
information on price quotations, drivers, technical
specications, manuals, and documentation
Contact us: (888) 88-SOURCE | [e-mail] | www.artisantg.com
SM
View
Instra

DR500
DRIVE CHASSIS
OPERATION & TECHNICAL MANUAL
P/N: EDA120 (V1.6)
AEROTECH, Inc. •101 Zeta Drive •Pittsburgh, PA. 15238-2897 •USA
Phone [phone] •Fax [phone]
Product Service: [phone]; [phone] (Fax)
www.aerotech.com
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

If you should have any questions about the DR500 and/or comments regarding the documentation, please refer to
Aerotech online at:
http://www.aerotech.com.
For your convenience, a product registration form is available at our web site.
Our web site is continually updated with new product information, free downloadable software, and special pricing
on selected products.
The DR500 Drive Chassis Operation and Technical Manual Revision History:
Rev 1.1 January 31, 1994
Rev 1.2 May 4, 1995
Rev 1.3 November 6, 1996
Rev 1.3a June 2, 1997
Rev 1.4 March 12, 1998
Rev 1.4a February 15, 2000
Rev 1.5 December 12, 2000
Rev 1.6 May 28, 2002
© Aerotech, Inc., 2002
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DR500 Operation and Techincal Manual Table of Contents
Version 1.6 Aerotech, Inc. iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION............................................................................ 1-1
1.1. Product Overview............................................................................... 1-1
1.1.1. DR500 Functions ................................................................. 1-2
1.1.2. DR500 Configurations ......................................................... 1-2
1.2. DR500 Options................................................................................... 1-3
1.2.1. The SHUNT500 Regulator Board........................................ 1-3
1.2.2. DRC I/O Cable..................................................................... 1-5
1.2.3. DR500 Brake Option............................................................ 1-7
1.3. Safety Procedures and Warnings........................................................ 1-8
CHAPTER 2: SET UP.............................................................................................. 2-1
2.1. Unpacking the DR500 Drive Package................................................ 2-1
2.2. DR500 Jumper Selections and Configurations...................................2-2
2.2.1. Rear Panel Interface Board Internal Jumpers....................... 2-3
2.2.2. Drive Interface Board Internal Jumpers............................... 2-3
2.2.3. Bus Configuration ................................................................ 2-8
2.2.3.1. Bus Type (Unipolar/Bipolar Configuration) ...... 2-8
2.2.3.2. Bus #1, Unipolar ................................................ 2-8
2.2.3.3. Bus #1, Bipolar................................................... 2-8
2.2.3.4. Bus #2, Unipolar ................................................ 2-8
2.2.3.5. Bus #2, Bipolar................................................... 2-8
2.2.3.6. Bus Voltage Configuration................................. 2-9
2.2.4. Installing A Drive Module in the DR500........................... 2-10
2.2.5. Brush Drive Configuration (DS16020 or DS16030).......... 2-11
2.2.5.1. Electrical Specifications................................... 2-12
2.2.5.2. Fault Output...................................................... 2-12
2.2.5.3. Personality Module........................................... 2-13
2.2.5.4. Setting the Current Limit.................................. 2-16
2.2.5.5. Pre-Amplifier Gain Characteristics .................. 2-16
2.2.5.6. The Post-Amplifier........................................... 2-16
2.2.5.7. Troubleshooting the DS160 Series................... 2-20
2.2.6. Stepper Drive Configuration (AM16007) ..........................2-22
2.2.7. AC Brushless Drive Configuration (AS32020 or
AS32030)........................................................................... 2-24
2.2.8. AC Brushless Linear Drive Configuration (AS3005)......... 2-26
2.2.9. Internal System Wiring....................................................... 2-27
2.3. Power Supply Fusing........................................................................ 2-28
2.4. Motor Fusing.................................................................................... 2-29
2.5. External Device Power..................................................................... 2-30
2.6. Mechanical Installation..................................................................... 2-30
2.7. Electrical Installation........................................................................ 2-31
2.7.1. DR500 Power Up............................................................... 2-32
2.8. DR500 Interface............................................................................... 2-33
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Table of Contents DR500 Operation and Technical Manual
iv Aerotech, Inc. Version 1.6
CHAPTER 3: TECHNICAL DETAILS..................................................................3-1
3.1. Connector Pinouts and OP500 Interconnect Cable
Specifications......................................................................................3-1
3.1.1. Pin Descriptions ...................................................................3-3
3.2. DR500 Rear Panel Connectors.........................................................3-10
3.2.1. Motor Axis Connectors ......................................................3-10
Pin # 3-10
3.2.2. Joystick Connector.............................................................3-11
3.2.3. Miscellaneous Input/Output Connector..............................3-12
3.2.4. Brake Connector.................................................................3-12
3.2.5. Digital I/O Connector.........................................................3-13
3.2.6. The Opto-22 Connector......................................................3-14
3.2.7. DAC Outputs Connector ....................................................3-14
3.2.8. Motor Power Connector Pinouts........................................3-15
3.2.9. DR500 Test Points .............................................................3-16
3.3. DR500 Outline Drawings and Mechanical Specifications...............3-17
3.4. Electrical Specifications ...................................................................3-19
3.5. Environmental Specifications...........................................................3-20
3.6. Emergency Stop Sense Input............................................................3-21
CHAPTER 4: SOFT-START / VOLTAGE SELECTOR BOARD ......................4-1
4.1. Soft-Start / Voltage Selector Overview ..............................................4-1
4.2. Soft-Start Operation............................................................................4-2
4.3. Voltage Selector Function ..................................................................4-3
4.4. Connector Pinouts...............................................................................4-4
4.4.1. AC Input Power Connector (J1)...........................................4-4
4.4.2. +24 VDC Power Connector (J2)..........................................4-4
4.4.3. Transformer Interface Connectors (J3, J5)...........................4-4
4.4.4. Fan Interface Connector (J4)................................................4-5
4.5. Fuse Information.................................................................................4-6
CHAPTER 5: TROUBLESHOOTING...................................................................5-1
5.1. Warning and Cautions ........................................................................5-1
5.2. Amplifier Related Problems ...............................................................5-2
5.3. Power Related Problems.....................................................................5-3
5.4. Fuse Replacement...............................................................................5-4
5.5. Preventative Maintenance...................................................................5-5
5.6. Cleaning..............................................................................................5-6
APPENDIX A: WARRANTY AND FIELD SERVICE.......................................... A-1
INDEX
REVISION HISTORY
∇∇∇
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DR500 Operation and Technical Manual List of Figures
Version 1.6 Aerotech, Inc. v
LIST OF FIGURES
Figure 1-1. DR500 Drive Chassis......................................................................... 1-1
Figure 1-2. UNIDEX 500 / UNIDEX 600 System Diagram................................. 1-3
Figure 1-3. SHUNT500 Wiring ............................................................................ 1-4
Figure 1-4. Mounting of the Shunt Board............................................................. 1-4
Figure 1-5. SHUNT500 Board.............................................................................. 1-5
Figure 1-6. DRC I/O Cable................................................................................... 1-6
Figure 1-7. Sample Uses of the DRC Cable.......................................................... 1-6
Figure 1-8. BRAKE OPTION Wiring................................................................... 1-7
Figure 2-1. Rear Panel Interface Board Jumper Locations ...................................2-2
Figure 2-2. Drive Interface Board Internal Jumper Locations .............................. 2-4
Figure 2-3. Drive Module Installation................................................................. 2-10
Figure 2-4. DS16020 / DS16030 Brush Drive Modules..................................... 2-11
Figure 2-5. Simplified Block Diagram of the DS160 Series Servo
Amplifier Module............................................................................. 2-14
Figure 2-6. DS16020 / DS16030 Brush Drive Modules Pre-Amp
Schematic ......................................................................................... 2-15
Figure 2-7. Transfer Function of Pre-Amplifier Circuit...................................... 2-17
Figure 2-8. Outline of Personality Module RCN4 .............................................. 2-18
Figure 2-9. Detailed Electrical Diagram of DS160 Post-Amplifier Circuit ........ 2-19
Figure 2-10. AM16007 Stepper Drive Modules ...................................................2-22
Figure 2-11. AS32020 / AS32030 AC Brushless Drive Modules......................... 2-24
Figure 2-12. AS3005 Brushless Linear Drive Module..........................................2-26
Figure 2-13. Power Supply Fusing 5V Adjust Potentiometer............................... 2-28
Figure 2-14. Drive Module Fuse Mounting ..........................................................2-29
Figure 2-15. DR500 Rear Panel Connector Layout .............................................. 2-30
Figure 2-16. DR500 Electrical Connections ......................................................... 2-31
Figure 2-17. U500/U600 Generic System Interconnect........................................ 2-34
Figure 3-1. DR500 Rear Panel Connector Layout ................................................ 3-1
Figure 3-2. CW Motor Rotation Viewed from Mounting Flange End .................. 3-4
Figure 3-3. Linear Motor (Forcer) CW Direction................................................. 3-4
Figure 3-4. Joystick Interface.............................................................................. 3-11
Figure 3-5. DR500 Desktop Package.................................................................. 3-17
Figure 3-6. DR500 Rack Mount Package ........................................................... 3-18
Figure 4-1. Soft-Start / Voltage Select Board ....................................................... 4-1
∇∇∇
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

List of Figures DR500 Operation and Technical Manual
vi Aerotech, Inc. Version 1.6
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DR500 Operation and Techincal Manual List of Tables
Version 1.6 Aerotech, Inc. vii
LIST OF TABLES
Table 2-1. Rear Panel Interface Board Jumper Selections................................... 2-3
Table 2-2. Drive Interface Board Jumper Selections........................................... 2-5
Table 2-3. Drive Interface Bd. Jumper Selections for AM16007 Stepper
Drive................................................................................................... 2-7
Table 2-4. Drive Interface Bd. Jumper Selections for DS16020 /
DS16030 Servo Drive ........................................................................ 2-7
Table 2-5. Drive Interface Bd. Jumper Selections for AS32020 /
AS32030 Brushless Drive .................................................................. 2-7
Table 2-6. Drive Interface Board Jumper Selections for AS3005
Brushless Drive .................................................................................. 2-8
Table 2-7. DS160 Series Electrical Specifications ............................................ 2-12
Table 2-8. DS160 Series Potentiometer Descriptions........................................ 2-13
Table 2-9. DS160 Series Personality Module RCN4 Modes............................. 2-18
Table 2-10. DS160 Series Environmental Specifications .................................... 2-20
Table 2-11. Power Stage Specifications...............................................................2-20
Table 2-12. DS160 Series Troubleshooting Guide .............................................. 2-21
Table 2-13. DS160 Series Replacement Parts......................................................2-21
Table 2-14. AM16007 Series Electrical Specifications....................................... 2-23
Table 2-15. AM16007 Series Test Points............................................................ 2-23
Table 2-16. AS32020 / AS32030 Series Electrical Specifications ......................2-25
Table 2-17. AS32020/AS32030 Series Test Points............................................. 2-25
Table 2-18. AS3005 Series Electrical Specifications........................................... 2-27
Table 2-19. AS3005 Series Test Points ............................................................... 2-27
Table 3-1. Pinouts for Connector J1 (Interface to U500/U600 Connector
P1) ...................................................................................................... 3-2
Table 3-2. Pinouts for Axis 1 Through Axis 4 (J2 - J5)..................................... 3-10
Table 3-3. Pinouts for the Joystick Interface Connector (J12)........................... 3-11
Table 3-4. Pinouts for the Miscellaneous I/O Connector (J13).......................... 3-12
Table 3-5. Pinouts for Optional Brake Connector (J14) .................................... 3-12
Table 3-6. Pinouts for the Digital I/O Connector (J10)...................................... 3-13
Table 3-7. Pinouts for the I/O Bus or Opto-22 Connector (J11)........................ 3-14
Table 3-8. Pinouts for the DAC Outputs Connector (J16)................................. 3-14
Table 3-9. Motor Connector (Stepper)...............................................................3-15
Table 3-10. Motor Connector (Brush)................................................................. 3-15
Table 3-11. Motor Connector (Brushless) ........................................................... 3-15
Table 3-12. DR500 Rear Panel InterfaceTest Points........................................... 3-16
Table 3-13. DR500 Drive InterfaceTest Points, Fuses, and L.E.D.s.................... 3-16
Table 3-14. Weights for DR500 Packages (not including drives)........................ 3-18
Table 3-15. Electrical Specifications................................................................... 3-19
Table 4-1. Voltage Selector Switch Settings........................................................ 4-3
Table 4-2. AC Input Power Connector (J1) Pinouts ............................................ 4-4
Table 4-3. +24 VDC Power Connector (J2) Pinouts............................................4-4
Table 4-4. Transformer Interface Connectors (J3, J5) Pinouts............................ 4-4
Table 4-5. Fan Interface Connector (J4) Pinouts................................................. 4-5
Table 4-6. Fuse Replacement Part Numbers........................................................ 4-6
Table 5-1. Amplifier Problems ............................................................................ 5-2
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

List of Tables DR500 Operation and Technical Manual
viii Aerotech, Inc. Version 1.6
Table 5-2. Power Checks.....................................................................................5-3
Table 5-3. Fuse Replacement Part Numbers........................................................5-4
Table 5-4. Preventative Maintenance...................................................................5-5
Table R-1. Revisions ............................................................................................R-1
∇∇∇
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DR500 Operation and Technical Manual Regulatory Information
Version 1.6 Aerotech, Inc. ix
DECLARATION OF CONFORMITY
Manufacturer’s Name and Address
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2897
Declares that the product:
Product Name: DR500
Conforms to the following product specifications:
• Electrostatic Discharge in accordance with IEC 1000-4-2
as specified by EN50082-2
• Electrical Fast Transients in accordance with
IEC 1000-4-3 as specified in EN50082-2
• Immunity to radiated electromagnetic fields in accordance
with IEC 1000-4-3 as specified in EN50082-2
• Immunity to conducted RF in accordance with EN 501041
• Radiated emission in accordance with EN55011; Group 1,
Class A
• Conducted Emission in accordance with EN550100;
Group 1, Class A
• EN61010-1:93 - safety of electrical equipment for
measurement, control, and laboratory use
and complies with EMC directive 89/336/EEC and 73/23/EEC low voltage directive.
Pittsburgh, PA David F. Kincel_________________________
March, 1998 Quality Assurance Manager
Alex Weibel__________________________
Engineer Verifying Compliance
General notes concerning the test setup.
This product was tested at Compliance Labs in Middlefield, Ohio on December 16, 1997.
The report number is 1050.
The DR500 was tested with a CE-compliant, class B personal computer and it controlled
four brushless AC motors. The DR500 requires a line filter (Aerotech P/N UFM) to meet
conducted emission requirements. This filter may not be necessary if the DR500 is used
by the OEM in a system that has a line filter.
Not all configurations of the DR500 are CE compliant. Compliant versions are indicated
by the "CE" symbol on the back of the unit.
∇∇∇
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com