Aerotech Soloist MP User manual

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SM
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Revision: 4.08.00
Soloist MP
Hardware Manual
J201
TB201
TB202
TB203
TB204
OPTO OUTOPTO IN
1
4
1
4
1
10
1
10
AEROTECH.
COM
TM
ETHERNET
J102
AEROTECH.
COM
TM
ETHERNET
J102
MOTOR
FEEDBACK
J103
MOTOR
SUPPLY
MOTOR
OUTPUT
TB102
DC+
DC-
A
B
C
80VDC MAX
10AMP MAX
ENA
MRK
CTL
POS
MOTOR
FEEDBACK
J103
MOTOR
SUPPLY
MOTOR
OUTPUT
TB102
DC+
DC-
A
B
C
80VDC MAX
10AMP MAX
ENA
MRK
CTL
POS
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Global Technical Support
Go to www.aerotech.com/global-technical-support for information and support about your Aerotech products. The website
provides downloadable resources (such as up-to-date software, product manuals, and Help files), training schedules, and PC-
to-PC remote technical support. You can also complete Product Return (RMA) forms and get information about repairs and
spare or replacement parts. For immediate help, contact a service office or your sales representative. Have your customer
order number available before you call or include it in your email.
United States (World Headquarters)
Phone: [phone]
Fax: [phone]
Email: [e-mail]
101 Zeta Drive
Pittsburgh, PA 15238-2897
www.aerotech.com
United Kingdom Japan
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Germany China
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
France Taiwan
Phone: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the
express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and
may be trademarks of their respective companies.
Copyright © 2005-2015, Aerotech, Inc. All rights reserved.
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Table of Contents Soloist MP
Table of Contents
Table of Contents iii
List of Figures v
List of Tables vii
EC Declaration of Conformity ix
Agency Approvals x
Safety Procedures and Warnings xi
Quick Installation Guide xiii
Chapter 1: Introduction 1
1.1. Drive and Software Compatibility 4
1.2. Electrical Specifications 5
1.2.1. System Power Requirements 6
1.2.2. Power Dissipation 7
1.3. Mechanical Design 8
1.4. Environmental Specifications 9
Chapter 2: Installation and Configuration 11
2.1. Power Connections 11
2.1.1. Control Supply Connections (TB103) 12
2.1.2. Motor Supply Connections (TB102) 13
2.1.3. External Power Supply Options 14
2.1.4. Minimizing Conducted, Radiated, and System Noise 16
2.2. Motor Output Connections 17
2.2.1. Brushless Motor Connections 18
2.2.1.1. Powered Motor Phasing 19
2.2.1.2. Unpowered Motor and Feedback Phasing 21
2.2.2. DC Brush Motor Connections 24
2.2.2.1. DC Brush Motor Phasing 25
2.2.3. Stepper Motor Connections 26
2.2.3.1. Stepper Motor Phasing 27
2.3. Motor Feedback Connections (J103) 28
2.3.1. Encoder Interface (J103) 29
2.3.1.1. RS-422 Line Driver Encoder (Standard) 30
2.3.1.2. Analog Encoder Interface 31
2.3.1.3. Encoder Phasing 33
2.3.2. Hall-Effect Interface (J103) 35
2.3.3. Thermistor Interface (J103) 36
2.3.4. Encoder Fault Interface (J103) 37
2.3.5. End Of Travel Limit Input Interface (J103) 38
2.3.5.1. End Of Travel Limit Phasing 40
2.3.6. Brake Output (J103) 41
2.3.7. Analog Input 0 (J103) 42
2.4. Emergency Stop Sense Input (TB104) 43
2.4.1. Typical ESTOP Interface 44
2.5. RS-232 Interface (TB105) 45
2.6. PC Configuration and Operation Information 46
Chapter 3: -I/O Expansion Board 47
3.1. User Power (TB201) 48
3.2. Brake Power Supply (TB201) 49
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3.2.1. Solid State Relay Specifications (TB201) 52
3.3. Analog Output (TB202) 53
3.4. Analog Input (TB202) 54
3.5. Opto-Isolated Inputs (TB203) 55
3.6. Opto-Isolated Outputs (TB204) 58
3.7. Auxiliary Encoder Channel/PSO Output (J201) 62
3.7.1. Position Synchronized Output (PSO)/Laser Firing (J201) 64
Chapter 4: Standard Interconnection Cables 67
4.1. Joystick Interface 68
4.2. Handwheel Interface 70
Chapter 5: Maintenance 71
5.1. Control Board 72
5.2. Preventative Maintenance 74
Appendix A: Warranty and Field Service 75
Appendix B: Revision History 77
Index 79
Soloist MP Table of Contents
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Table of Contents Soloist MP
List of Figures
Figure 1-1: Soloist MP Networked Digital Drive 1
Figure 1-2: Functional Diagram 3
Figure 1-3: Power Dissipation vs. Output Current 7
Figure 1-4: Ambient Temperature vs. Power Dissipation 7
Figure 1-5: Dimensions 8
Figure 2-1: Control Supply Connections 12
Figure 2-2: Motor Bus Input Connections 13
Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 14
Figure 2-4: PS-MP Option 15
Figure 2-5: Brushless Motor Configuration 18
Figure 2-6: Encoder and Hall Signal Diagnostics 20
Figure 2-7: Motor Phasing Oscilloscope Example 21
Figure 2-8: Hall Phasing with Oscilloscope 22
Figure 2-9: Brushless Motor Phasing Goal 23
Figure 2-10: DC Brush Motor Configuration 24
Figure 2-11: Clockwise Motor Rotation 25
Figure 2-12: Stepper Motor Configuration 26
Figure 2-13: Clockwise Motor Rotation 27
Figure 2-14: Line Driver Encoder Interface (J103) 30
Figure 2-15: Analog Encoder Phasing Reference Diagram 31
Figure 2-16: Analog Encoder Interface (J103) 32
Figure 2-17: Encoder Phasing Reference Diagram (Standard) 33
Figure 2-18: Position Feedback in the DiagnosticDisplay 34
Figure 2-19: Hall-Effect Inputs (J103) 35
Figure 2-20: Thermistor Interface Input (J103) 36
Figure 2-21: Encoder Fault Interface Input (J103) 37
Figure 2-22: End of Travel Limit Input Connections 38
Figure 2-23: End of Travel Limit Interface Input (J103) 39
Figure 2-24: Limit Input Diagnostic Display 40
Figure 2-25: Analog Input 0 (J103) 42
Figure 2-26: ESTOPSenseInput (TB104) 43
Figure 2-27: Typical Emergency Stop Circuit 44
Figure 2-28: RS-232 Interface (TB105) 45
Figure 3-1: Soloist MP with -IO Option Board 47
Figure 3-2: Brake Connected to J103 50
Figure 3-3: Brake Connected to TB201 51
Figure 3-4: Analog Output 1 Connector (TB202) 53
Figure 3-5: Analog Input Typical Connection (TB202) 54
Figure 3-6: Opto-Isolated Inputs 56
Figure 3-7: Inputs Connected to a Current Sourcing Device 57
Figure 3-8: Inputs Connected to a Current Sinking Device 57
Figure 3-9: Opto-Isolated Outputs (-IOBoard) 59
Figure 3-10: Outputs Connected in Current Sourcing Mode 60
Figure 3-11: Outputs Connected in Current Sinking Mode 61
Figure 3-12: Auxiliary Encoder Channel (J201) 63
Figure 3-13: PSOInterface 65
Figure 4-1: Single Axis Joystick Interface 68
Figure 4-2: Two Axis Joystick Interface 69
Figure 4-3: Handwheel Interconnection (to Aux I/O) 70
Figure 5-1: Control Board Assembly 72
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Soloist MP Table of Contents
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Table of Contents Soloist MP
List of Tables
Table 1-1: FeatureSummary 2
Table 1-2: Accessories 2
Table 1-3: Soloist Drive and Software Compatibility 4
Table 1-4: Electrical Specifications 5
Table 1-5: Physical Specifications 8
Table 2-1: PS-MP ACPower Wiring Requirements 11
Table 2-2: Control Supply DCInput Wiring 12
Table 2-3: Control Supply Mating Connector 12
Table 2-4: Motor Supply Mating Connector 13
Table 2-5: ExternalPower Supply Options 14
Table 2-6: Motor Supply Input Wiring 16
Table 2-7: Motor Power Output Connections (TB102) 17
Table 2-8: Motor Power Output Mating Connector 17
Table 2-9: Wire Colors for Aerotech Supplied Cables (Brushless) 18
Table 2-10: Wire Colors for Aerotech Supplied Cables (DCBrush) 24
Table 2-11: Wire Colors for Aerotech Supplied Cables (Stepper) 26
Table 2-12: Motor Feedback Connector Pin Assignment (J103) 28
Table 2-13: Encoder Interface Pin Assignment 29
Table 2-14: Analog Encoder Specifications 31
Table 2-15: Hall-Effect Feedback Interface Pin Assignment (J103) 35
Table 2-16: Hall-Effect Feedback Interface Pin Assignment (J103) 36
Table 2-17: Encoder Fault Interface Pin Assignment (J103) 37
Table 2-18: End of Travel Limit Input Interface Pin Assignment (J103) 38
Table 2-19: Brake Output Pin Assignment (J103) 41
Table 2-20: Port 0 Analog Input Connector Pin Assignment (J103) 42
Table 2-21: Electrical Noise Suppression Devices 43
Table 2-22: Electrical Noise Suppression Devices 43
Table 2-23: TB104 Mating Connector 43
Table 2-24: Typical ESTOPRelay Ratings 44
Table 2-25: RS-232 Connector Pin Assignment (TB105) 45
Table 2-26: RS-232 Port Connector Mating Connector (TB105) 45
Table 3-1: User Common Connector Pin Assignment (TB201) 48
Table 3-2: Brake Output Connector Pin Assignment (TB201) 49
Table 3-3: Mating Connector (TB201) 49
Table 3-4: Brake Output Connector Pin Assignment (J103) 49
Table 3-5: Relay Specifications 52
Table 3-6: Port 1 Analog Output Connector Pin Assignment (TB202) 53
Table 3-7: Analog Output Mating Connector 53
Table 3-8: Port 1 Analog Inputs Connector Pin Assignment (TB202) 54
Table 3-9: Analog Input Mating Connector 54
Table 3-10: PS2806-4 Opto-Device Specifications 55
Table 3-11: Port 1 Opto-Isolated Input Connector Pin Assignment (TB203) 55
Table 3-12: Opto-Isolated Input Mating Connector 55
Table 3-13: Port 1 Opto-Isolated Output Connector Pin Assignment (TB204) 58
Table 3-14: Opto-Isolated Output Mating Connector 58
Table 3-15: Output Specifications (TB204) 60
Table 3-16: Auxiliary Encoder Channel Pin Assignment (J201) 62
Table 3-17: PSOOutput Pin Assignment (J201) 64
Table 3-18: PSO Output Sources 64
Table 4-1: Standard Interconnection Cables 67
Table 4-2: Cable Part Numbers 69
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Table 5-1: LEDDescription 71
Table 5-2: Control Board Fuse Information 73
Table 5-3: LEDDescription 73
Table 5-4: Preventative Maintenance 74
Soloist MP Table of Contents
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Declaration of Conformity Soloist MP
EC Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Soloist MP
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2004/108/EC Electromagnetic Compatibility Directive
2006/95/EC Low Voltage Directive
2011/65/EU RoHS2 Directive
and has been designed to be in conformity with the applicable requirements of the following documents
when installed and used in accordance with the manufacturer’s supplied installation instructions.
EN 55011 RFI Limits and Measurement
EN 61800-3 EMC requirements for power drives
EN 61000-3-2 Harmonic Current Emissions
EN 61000-3-3 Voltage Fluctuation and Flicker
EN 61000-4-2 ESD Immunity
EN 61000-4-3 Radiated RFI/EMI Immunity
EN 61000-4-4 EFT/Burst Immunity
EN 61000-4-5 Surge Immunity
EN 61000-4-6 Conducted Immunity
EN 61000-4-11 Voltage Dips and Interruptions
EN 61010-1 Safety requirements for electrical equipment
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date July 9, 2015
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Agency Approvals
Aerotech, Inc. Model Soloist MP Series Digital Drives have been tested and found to be in accordance to the
following listed Agency Approvals:
Approval / Certification: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 13 11 68995 013
File / Report #: 090-1309372-000
Standards: UL 61010-1; CAN/CSA-C22.2 No. 61010-1
Soloist MP Declaration of Conformity
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Electrical Safety Soloist MP
Safety Procedures and Warnings
The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure
to observe these precautions could result in serious injury to those individuals performing the procedures
and/or damage to the equipment.
N O T E : Read this manual in its entirety before installing, operating, or servicing this product. If you do
not understand the information contained herein, contact an Aerotech representative before proceeding.
Strictly adhere to the statements given in this section and other handling, use, and operational information
given throughout the manual to avoid injury to you and damage to the equipment.
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of
electrical shock, bodily injury, or death the following precautions must be followed.
1. Disconnect electrical power before servicing equipment.
2. Disconnect electrical power before performing any wiring.
3. Access to the Soloist MP and component parts must be restricted while connected to a
power source.
4. To minimize the possibility of electrical shock and bodily injury, extreme care must be
exercised when any electrical circuits are in use. Suitable precautions and protection must
be provided to warn and prevent persons from making contact with live circuits.
5. Install the Soloist MP inside a rack or enclosure.
6. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
7. Make sure the Soloist MP and all components are properly grounded in accordance with
local electrical safety requirements.
8. Operator safeguarding requirements must be addressed during final integration of the
product.
D A N G E R : The Soloist MP case temperature may exceed 70°C in some applications.
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xii www.aerotech.com
W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the
following precautions must be followed.
1. Use of this equipment in ways other than described by this manual can cause personal
injury or equipment damage.
2. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts
must be restricted while connected to a power source.
3. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid
potential hazards.
4. Do not expose the Soloist MPto environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
5. If the Soloist MP is used in a manner not specified by the manufacturer, the protection
provided by the Soloist MP can be impaired and result in damage, shock, injury, or death.
6. Operators must be trained before operating this equipment.
7. All service and maintenance must be performed by qualified personnel.
8. The Soloist MP is intended for light industrial manufacturing or laboratory use. Use of the
Soloist MP for unintended applications can result in injury and damage to the equipment.
Soloist MP Electrical Safety
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Quick Installation Guide Soloist MP
Quick Installation Guide
This chapter describes the order in which connections and settings should typically be made to the Soloist
MP. If a custom interconnection drawing was created for your system (look for a line item on your Sales
Order under the heading “Integration”), that drawing can be found on your installation device.
J201
TB201
TB202
TB203
TB204
OPTO OUTOPTO IN
1
4
1
4
1
10
1
10
AEROTECH.
COM
TM
ETHERNET
J102
MOTOR
FEEDBACK
J103
MOTOR
SUPPLY
MOTOR
OUTPUT
TB102
DC+
DC-
A
B
C
80VDC MAX
10AMP MAX
ENA
MRK
CTL
POS
High Voltage
DANGER!
WARNING:
DISCONNECT POWER
BEFORE SERVICING
S/N -
P/N -
TB104 ESTOP
TB105
RS232 TX
RS232 RX
GND
TB103
CONTROL
SUPPLY
24-80VDC
1AMP MAX
DC+
DC-
Connect the Motor Outputs (TB102) and Motor Feedback (J103).
Connect the PC to the Ethernet (J102).
Connect any additional I/O as required (not shown).
Connect to the Control Supply (TB103).
Connect to the Motor Supply (TB102).
Note: Connect to ESTOP (TB101) in this step if applicable.
1
5
1
1
2
3
4
5
2
5
4
Figure 1: Quick Start Connections
Topic Section
Motor Output Section 2.2. Motor Output Connections
Motor Feedback Section 2.3. Motor Feedback Connections (J103)
Ethernet / USB No Section / Standard Connection
Control Supply Section 2.1.1. Control Supply Connections (TB103)
Motor Supply Section 2.1.2. Motor Supply Connections (TB102)
Additional I/O User / Application dependent
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Soloist MP Quick Installation Guide
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Introduction Soloist MP
Chapter 1: Introduction
Aerotech’s Soloist MP(Ultra-Compact "Micro"PWM) network digital drive is a high performance
amplifier.The drive provides deterministic behavior, auto-identification, and easy software setup. The Soloist
MP’s high performance double precision floating point DSP controls the digital PID and current loops. All
system configuration is done using software-settable parameters, including control loop gains and system
safety functions.
The Soloist MP is offered with an optional encoder interpolation feature (-MXU), an auxiliary square wave
encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -IO option), and
separate power connections for motor and control supply voltages.
J201
TB201
TB202
TB203
TB204
OPTO OUTOPTO IN
1
4
1
4
1
10
1
10
AEROTECH.
COM
TM
ETHERNET
J102
MOTOR
FEEDBACK
J103
MOTOR
SUPPLY
MOTOR
OUTPUT
TB102
DC+
DC-
A
B
C
80VDC MAX
10AMP MAX
ENA
MRK
CTL
POS
High Voltage
DANGER!
WARNING:
DISCONNECT POWER
BEFORE SERVICING
S/N -
P/N -
TB104 ESTOP
TB105
RS232 TX
RS232 RX
GND
TB103
CONTROL
SUPPLY
24-80VDC
1AMP MAX
DC+
DC-
Standard
Connector Description
J102 Ethernet Port
J103 Motor Feedback
TB102 Motor Supply
TB102 Motor Output
TB103 Control Supply
TB104 Emergency Stop
Sense Input (ESTOP)
TB105 RS-232
-IO Board Option
Connector Description
J201 Auxiliary Encoder
Interface
TB201 Brake Relay
TB202 Analog I/O
TB203 Opto-Inputs
TB204 Opto-Outputs
Figure 1-1: Soloist MP Networked Digital Drive
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2 Chapter 1 www.aerotech.com
Table 1-1: FeatureSummary
Standard Features
lLine driver square wave quadrature encoder input for position and velocity feedback
lOne 16-bit differential analog input (±10 V)
lDedicated 5-24 V Emergency Stop sense input
l10 - 80 VDC motor supply inputs
l24 - 80 VDCcontrol supply inputs
lCalibration (refer to the SoloistHelp file for more information)
lCamming (refer to the SoloistHelp file for more information)
l10/100 BASE-T Ethernet port for use with Ethernet I/O modules
Options
-IO lOne 16-bit analog output (±5 V)
lOne 12-bit differential analog input
lOne fail-safe brake or user relay output
l8 optically isolated logic inputs (5 - 24 VDC), may be connected in current
sourcing or sinking mode
l8 optically isolated logic outputs (5 - 24 VDC), user defined as current
sourcing or sinking
-MXU Interpolation circuit allowing for analog sine wave input on the standard encoder
channel. Interpolation factor: 4,096
Table 1-2: Accessories
Accessories
JI Industrial Joystick (NEMA12 (IP54) rated); refer to Section 4.1.
PS24-1 24 VDC, 1Apower supply for optional brake/relay output
BRAKE24-2 24 VDC, 2 A power supply for optional brake
External Power Supply Options
Refer to Section 2.1.3. for more information
Cables
Interconnection A complete list of Aerotech cables can be found on the website at
http://www.aerotechmotioncontrol.com/manuals/index.aspx
Joystick/Handwheel Refer to Section 4.1. or Section 4.2.
Soloist MP Introduction
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Introduction Soloist MP
The following block diagram shows a connection summary. For detailed connection information, refer to
Chapter 2 and Chapter 3.
Isolated
Power Supply
TB103
Control Supply
Encoder +5V / Common
Analog Input 0 +/-
Brake ± (with the -IO Option)
SIN, COS, MRK (RS422)
CW, CCW, Home Limits;
Encoder Fault; Hall A, B, C;
Motor Over Temperature
-MXU
Option
J103
Motor
Feedback
SIN, COS, MRK (RS422)
Encoder +5V / Common
PSO Output, Encoder Echo
Emergency Stop Sense Input
J201
Secondary
Encoder
Interface
Ethernet Port
J102
Analog Input 1 +/-
Analog Output 1 TB202
-IO Option
8 Opto Outputs
(Sinking or Sourcing)
TB204
Opto Out
8 Opto Inputs
(Sinking or Sourcing)
TB203
Opto In
Brake Power
Input or Relay
TB201
Brake
Relay
TB105
RS232
RS232
+5V / Common
PWM Power
Amplifier
Heatsink Over
Temperature A
B
C
TB102
Motor
Supply
TB102
Motor
Output
TB104
ESTOP
DC+
DC-
DC+
DC-
A
B
C
DC+
DC-
DC+
DC-
Figure 1-2: Functional Diagram
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4 Chapter 1 www.aerotech.com
1.1. Drive and Software Compatibility
The following table lists the available Soloist drives and which version of the Soloist software first provided
support for a given drive. Drives that list a specific version number in the Last Software Version column will
not be supported after the listed version.
Table 1-3: Soloist Drive and Software Compatibility
Drive Type Firmware Revision First Software Version Last Software Version
CL - 2.06 Current
A 2.55 Current
CP
- 1.00 Current
A 2.01 Current
B 2.54 Current
HLe - 2.51 Current
HPe - 2.51 Current
ML - 3.00 Current
MP - 2.01 Current
A 2.55 Current
Soloist MP Introduction
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Introduction Soloist MP
1.2. Electrical Specifications
Table 1-4: Electrical Specifications
MP 10
Motor Supply Input Voltage 10-80 VDC
Maximum Continuous
Input Current
5 Arms
Input Current Refer to Section 1.2.1. System Power Requirements
Control
Supply
Input Voltage 24-80 VDC (±10%)
Input Current 1 Amax
Output Voltage (1) 10-80 VDC
Peak Output Current (1 second) 10 A
Continuous Output Current 5 A
Power Amplifier Bandwidth 2500 Hz maximum (software selectable)
Power Amplifier Efficiency 85% - 95%(2)
PWM Switching Frequency 20 kHz
Minimum Load Inductance 0.1 mH @ 80 VDC
User Power Supply Output 5 VDC (@ 500 milliamps)
Modes of Operation Brushless; Brush; Stepper
Protective Features Output short circuit; Peak over current, DCbus over
voltages; RMSover current; Over temperature; Control
power supply under voltage; Power stage bias supply under
voltage
Isolation Optical and transformer isolation between control and power
stages.
(1) AC input voltage and load dependent.
(2) Dependent on total output power: efficiency increases with increasing output power.
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