Aerotech SOLOIST User manual

SOLOIST
HARDWARE MANUAL
P/N: EDU180 (Ver. 1.4)
AEROTECH, Inc. 101 Zeta Drive Pittsburgh, PA. 15238-2897 USA
Phone [phone] Fax [phone]
Product Service: [phone]; [phone] (Fax)
http://www.aerotech.com/

Product Registration
To register your Soloist, use the product registration form that is available online at:
http://www.aerotech.com/prodreg.cfm
Technical Support
For technical support, contact one of the following:
United States (Headquarters):
Phone: [phone]
Fax: [phone]
Email: [email protected]
United Kingdom:
Phone: [phone]
Fax: [phone]
Email: [email protected]
Germany:
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Product names mentioned herein are used for identification purposes only and may be trademarks of their respective
companies.
Soloist™is a trademark of Aerotech, Inc.
The Soloist User’s Manual Revision History:
Ver. 1.0 October 12, 2004
Ver. 1.1 December 8, 2004
Ver. 1.2 December 23, 2004
Ver. 1.3 February 28, 2005
Ver. 1.4 April 12, 2005
©Aerotech, Inc., 2005

Soloist Hardware Manual Table of Contents
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TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION.............................................................................1-1
1.1 Chapter Overview ...............................................................................1-1
1.2 Feature Summary ................................................................................1-2
1.2.1 Power Amplifier................................................................... 1-2
1.2.2 Dual Encoder Feedback Channels ....................................... 1-2
1.2.3 Inputs and Outputs............................................................... 1-2
1.2.4 -IO Option Feature Summary............................................... 1-2
1.3 Soloist Connections.............................................................................1-3
1.4 Soloist Power Features........................................................................1-4
1.5 Soloist Voltage Configurations...........................................................1-5
1.6 Electrical Specifications......................................................................1-6
1.7 Physical Dimensions ...........................................................................1-8
1.8 Environmental Specifications..............................................................1-9
CHAPTER 2: INSTALLATION AND CONFIGURATION.................................2-1
2.1 Introduction.........................................................................................2-1
2.2 Safety Procedures and Warnings.........................................................2-2
2.3 Motor and AC Power Connections .....................................................2-3
2.4 Wiring, Grounding, and Shielding Techniques...................................2-4
2.4.1 Minimizing EMI Interference.............................................. 2-4
2.4.2 AUXPWR (Auxiliary Power) Option.................................. 2-5
2.4.3 40/80 VDC Power Transformers ......................................... 2-5
2.5 Typical AC Wiring with the -AUXPWR Option and an
External Transformer ..........................................................................2-6
2.5.1 Minimizing 50/60 HZ Line Interference.............................. 2-9
2.5.2 I/O and Signal Wiring Requirements................................... 2-9
2.6 Emergency Stop Sense Input (TB101)..............................................2-10
2.6.1 Typical ESTOP Interface................................................... 2-11
2.7 Motor Connections............................................................................2-12
2.7.1 DC Brush Motor Connections in Torque Mode................. 2-12
2.7.1.1 DC Brush Motor Phasing .................................... 2-12
2.7.2 Brushless Motor Connections............................................ 2-13
2.7.2.1 Brushless Motor Phasing..................................... 2-14
2.7.2.2 Brushless Motor Hall Effect Feedback
Connections......................................................... 2-15
2.7.2.3 Hall Effect Phasing.............................................. 2-16
2.7.3 Stepper Motor Connections ............................................... 2-18
2.7.3.1 Stepper Motor Phasing Process........................... 2-18
2.8 Encoder Feedback Connections........................................................2-19
2.8.1 Encoder Phasing ................................................................ 2-20
2.9 End of Travel Limit Connections......................................................2-21
2.9.1 End of Travel Limit Phasing.............................................. 2-21
2.10 Communication Channel Settings .....................................................2-22
2.11 Soloist Help Information...................................................................2-24
CHAPTER 3: TECHNICAL DETAILS..................................................................3-1
3.1. Port 0 I/O and the Secondary Encoder Channel (J104).......................3-1

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3.1.1. Secondary Encoder Channel (J104)..................................... 3-3
3.1.2. Port 0 User Digital Outputs (J104) ...................................... 3-5
3.1.3. Port 0 User Digital Inputs (J104)......................................... 3-8
3.1.4. User Analog Output 0 (J104)............................................. 3-11
3.1.5. User Analog Input 0 (J104)................................................ 3-12
3.2. Position Synchronized Output (PSO)................................................3-13
3.3. Motor Feedback (J103).....................................................................3-15
3.3.1. MXU Option...................................................................... 3-17
3.3.2. Brake / Relay Interface (J103, TB103).............................. 3-18
3.4. RS-232 Serial Port (TB103)..............................................................3-19
3.5. USB Port (J101)*..............................................................................3-20
CHAPTER 4: SOLOIST OPTIONS ....................................................................... 4-1
4.1. Introduction.........................................................................................4-1
4.2. -IO Option Board ................................................................................4-2
4.2.1. Analog Input 1 (TB201)....................................................... 4-2
4.2.2. Analog Output 1 (TB201).................................................... 4-3
4.2.3. Port 1 and Port 2 Opto-Isolated Outputs (TB202,
TB203)................................................................................. 4-4
4.2.4. Port 1 and Port 2 Opto-Isolated Inputs (TB204,
TB205)................................................................................. 4-6
4.2.5. User Power (TB204, TB205)............................................... 4-9
4.2.6. Brake / Relay (TB206)......................................................... 4-9
4.2.6.1. Brake Configuration Jumpers.............................. 4-10
CHAPTER 5: ACCESSORIES................................................................................ 5-1
5.1. Standard Interconnection Cables.........................................................5-1
5.2. Joystick Interface.................................................................................5-5
5.3. Handwheel Interface............................................................................5-7
CHAPTER 6: TROUBLESHOOTING................................................................... 6-1
6.1. Problems, Causes, and Solutions.........................................................6-1
6.2. Soloist Test Points...............................................................................6-3
6.3. Fuse Replacement................................................................................6-4
6.4. Soloist Board Assembly......................................................................6-5
6.5. Preventative Maintenance ...................................................................6-7
6.5.1. Cleaning............................................................................... 6-7
APPENDIX A: GLOSSARY OF TERMS................................................................A-1
APPENDIX B: WARRANTY AND FIELD SERVICE...........................................B-1
APPENDIX C: TECHNICAL CHANGES...............................................................C-1
C.1. Current Changes.................................................................................C-1
C.2. Archive of Changes............................................................................C-2
INDEX
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Soloist Hardware Manual List of Figures
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LIST OF FIGURES
Figure 1-1 Soloist in TwoVersions.......................................................................1-1
Figure 1-2 Soloist Hardware.................................................................................1-3
Figure 1-3 Soloist Block Diagram........................................................................1-4
Figure 1-4 Soloist Physical Dimensions...............................................................1-8
Figure 2-1 -AUXPWR Option..............................................................................2-5
Figure 2-2 40 Volt DC Bus from 115 and 230 VAC Source................................2-6
Figure 2-3 80 Volt DC Bus from 115 and 230 VAC Source................................2-7
Figure 2-4 160 Volt DC Bus from 115 and 230 VAC Source..............................2-8
Figure 2-5 Back-Propagation Line Filter Connection...........................................2-9
Figure 2-6 ESTOP Sense Input (TB101)............................................................2-10
Figure 2-7 Typical Emergency Stop Circuit.......................................................2-11
Figure 2-8 DC Brush Motor (Torque Mode) Connections .................................2-12
Figure 2-9 Brushless Motor Connections ...........................................................2-13
Figure 2-10 Hall Effect Feedback Connections....................................................2-15
Figure 2-11 Hall Effect Feedback Inputs in the Soloist HMI Program.................2-15
Figure 2-12 Motor Phasing...................................................................................2-17
Figure 2-13 Stepper Motor Connections...............................................................2-18
Figure 2-14 Encoder Feedback Connections........................................................2-19
Figure 2-15 Encoder Phasing Reference Diagram................................................2-20
Figure 2-16 Encoder Feedback in the Soloist HMI ..............................................2-20
Figure 2-17 Limit Inputs in the Soloist HMI Program..........................................2-21
Figure 2-18 Limit Inputs in the Soloist HMI Program..........................................2-21
Figure 3-1. PSO Interface (J104)...........................................................................3-3
Figure 3-2. Primary / Secondary Encoder Channels (J103, J104) .........................3-4
Figure 3-3. User Outputs (J104)............................................................................3-6
Figure 3-4. Outputs Connected as Current Sinking ...............................................3-7
Figure 3-5. Outputs Connected as Current Sourcing .............................................3-7
Figure 3-6. Connecting Current Sinking Inputs.....................................................3-9
Figure 3-7. Connecting Current Sourcing Inputs...................................................3-9
Figure 3-8. Low Speed and High Speed User Inputs (J104)................................3-10
Figure 3-9. Analog Output 0 (J104).....................................................................3-11
Figure 3-10. Analog Input 0 (J104) .......................................................................3-12
Figure 3-11. PSO Block Diagram..........................................................................3-14
Figure 3-12. Data Capture/Data Update Modes.....................................................3-14
Figure 3-13. Limit, Thermistor and Hall-Effect Inputs (J103)..............................3-16
Figure 3-14. Optional -MXU Analog Encoder Interface (J103)............................3-17
Figure 3-15. Brake Connector (TB103).................................................................3-18
Figure 3-16. RS-232 Connector (TB103)..............................................................3-19
Figure 4-1. –IO Option Board (690D1611 Rev. 0)................................................4-2
Figure 4-2. Optional Analog Input Connector (TB201) ........................................4-2
Figure 4-3. Analog Output Connector (TB201).....................................................4-3
Figure 4-4. Connecting Outputs in Current Sinking Mode....................................4-5
Figure 4-5. Connecting Outputs in Current Sourcing Mode..................................4-5
Figure 4-6. Inputs Connected in Current Sourcing Mode......................................4-7
Figure 4-7. Inputs Connected in Current Sinking Mode........................................4-8

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Figure 4-8. Brake Connected to TB206...............................................................4-11
Figure 4-9. Brake Connected to J103 ..................................................................4-11
Figure 4-10. Suppression for DC Brake Systems...................................................4-13
Figure 5-1. Joystick Interface.................................................................................5-5
Figure 5-2. Single Axis Joystick Interface to J104 of the Soloist ..........................5-6
Figure 5-3. Single Axis Joystick Interconnect to J104 of the Soloist.....................5-6
Figure 5-4. Handwheel Interconnection to J104 of the Soloist..............................5-7
Figure 5-5. Handwheel with Flying Leads (No Connector)...................................5-8
Figure 5-6. BBA32 Interface Used to Connect a Handwheel with Flying
Leads (No Connector).........................................................................5-9
Figure 6-1. Soloist Board Assembly (690D1591 Rev. -).......................................6-5
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Soloist Hardware Manual List of Tables
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LIST OF TABLES
Table 1-1 Soloist Voltage Configurations................................................................1-5
Table 1-2 Electrical Specifications...........................................................................1-6
Table 2-1 Main AC Power Input and Motor Output (TB102)..................................2-3
Table 2-2 -AUXPWR AC Input Option (when TB102 AC input < 85 VAC)..........2-3
Table 2-3 Wire Part Numbers ..................................................................................2-4
Table 2-4 ESTOP Input Voltage Jumper ...............................................................2-10
Table 2-5. Electrical Noise Suppression Devices....................................................2-10
Table 2-6 Soloist Switch Settings (S1)...................................................................2-23
Table 3-1. Auxiliary I/O Connector Mating Connector (J104) .................................3-1
Table 3-2. Auxiliary I/O Connector Pin out (J104)...................................................3-2
Table 3-3. Secondary Encoder Connector Pin-out (J104).........................................3-3
Table 3-4. Port 0 Digital Output Connector Pin-out (J104) ......................................3-5
Table 3-5. Opto Outputs 0-3 Specifications..............................................................3-5
Table 3-6. Port 0 Digital Input Connector Pin out (J104).........................................3-8
Table 3-7. Analog Output Connector Pin-outs (J104).............................................3-11
Table 3-8. Optional Analog Input Connector Pin-outs (J104).................................3-12
Table 3-9. PSO Output Source................................................................................3-13
Table 3-10. Motor Feedback Connector Mating Connector (J103) ..........................3-15
Table 3-11. Motor Feedback Connector Pin out (J103)............................................3-16
Table 3-12. Brake Power Input Pin-out on Connector TB103..................................3-18
Table 3-13. Brake/Relay Output Pin-out on Connector J103....................................3-18
Table 3-14. TB103 RS-232 Connector Pin-out.........................................................3-19
Table 3-15. RS-232 Port Connector Mating Connector (TB103) .............................3-19
Table 4-1. Soloist Options.........................................................................................4-1
Table 4-2. Optional Analog Input Connector Pin-out (TB201) ...............................4-2
Table 4-3. Analog Output Connector Pin-out (TB201).............................................4-3
Table 4-4. Port 1 Opto-Isolated Output Connector Pin-out (TB202)........................4-4
Table 4-5. Port 2 Opto-Isolated Output Connector Pin-out (TB203)........................4-4
Table 4-6. Output Specifications (TB202, TB203)...................................................4-4
Table 4-7. Port 1 Opto-Isolated Input Connector Pin-out (TB204) .........................4-6
Table 4-8. Port 2 Opto-Isolated Input Connector Pin-out (TB205) .........................4-7
Table 4-9. User Common Connector Pin out (TB204) .............................................4-9
Table 4-10. +5 Volt Power Connector Pin out (TB205).............................................4-9
Table 4-11. –IOPSO Option Board Jumpers...............................................................4-9
Table 4-12. Voltage and Current Specifications (TB206).........................................4-10
Table 4-13. Brake / Relay Connector Pin-out (TB206).............................................4-10
Table 4-14. Brake / Relay Connector Pin-out (J103)................................................4-10
Table 5-1. Standard Interconnection Cables .............................................................5-1
Table 5-2. Combined Motor & Feedback Cables......................................................5-2
Table 5-3. Individual Motor Cables..........................................................................5-3
Table 5-4. Individual Feedback Cables.....................................................................5-4
Table 6-1. Amplifier Faults, Causes, and Solutions..................................................6-2
Table 6-2. Soloist Control Board Test Points............................................................6-3

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Table 6-3. -IO Option Board Test Points ..................................................................6-3
Table 6-4. Soloist Fuse Information..........................................................................6-4
Table 6-5. -IO Board Fuse Information.....................................................................6-4
Table 6-6. Soloist Jumper Selections ........................................................................6-6
Table 6-7. Preventative Maintenance........................................................................6-7
Table C-1. Current Changes......................................................................................C-1
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Soloist Hardware Manual Regulatory Information
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DECLARATION OF CONFORMITY
Manufacturer’s Name and Address
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2897
Declares that the product:
Product Name: Soloist
Conforms to the following product specifications, with the exceptions listed below.
Safety: EN 61010-1:1993 Safety Requirements
and complies with EMC directive 89/336/EEC and 73/23/EEC low voltage directive.
General notes concerning the test setup.
Safety related requirements to ensure compliance:
Soloist must be installed within an enclosure with construction compliant
unlimited circuits.
Pittsburgh, PA David F. Kincel_________________________
September, 2004 Quality Assurance Manager
Alex Weibel ___________________________
Engineer Verifying Compliance
General notes concerning the test setup.
Safety related requirements to ensure compliance:
Exceptions to EN 61010-1:
Soloist must be installed within an enclosure with construction compliant for
unlimited circuits.
End user is responsible for meeting final protective ground requirements.
AC power disconnect is AC power cord located on front panel of Soloist. End
user is responsible for determining and providing supply disconnect for system.
End user is responsible for preventing unexpected startup.
Connection requirements are described in the technical documentation provided
with the system. End user is responsible for making proper connections and
meeting any required interlock requirements for application.

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Voltages greater than 60 Volts may be present inside Soloist after a discharge
time of 5 seconds.
End user must provide protection concerning power interruption / restoration if
required.
End user must provide earth fault current protection if required.
"  End user must provide protection against lightning and switching surges if
required.
Control and EStop requirements are determined and provided by the end user.
"  Wire and cabling provided with the Soloist meets Aerotech’s electrical and listed
environmental requirements. End user must meet final requirements.
Failure to follow the described procedures could result in serious injury and/or damage to
the equipment.
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Soloist Hardware Manual Introduction
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CHAPTER 1: INTRODUCTION
In This Section:
Chapter Overview......................................................1.1
Feature Summary.......................................................1.2
Soloist Connections ..................................................1.3
Soloist Power ............................................................1.4
Voltage Configurations..............................................1.5
Electrical Specifications ............................................1.6
Physical Dimensions .................................................1.8
Environmental Specifications ....................................1.9
1.1 Chapter Overview
Use this chapter to become familiar with the features on your Soloist™. This chapter
includes electrical, mechanical, and environmental specifications.
Figure 1-1 Both Versions of the Soloist

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1.2 Feature Summary
Review the following summary of the standard and optional features of the Soloist.
1.2.1 Power Amplifier
Configure for brush, brushless, and stepper motor operation
Standard 100 VDC –320 VDC, optional 10 VDC –320 VDC bus operation
Fully isolated power stage
Full protection against the following failure modes:
1. Control supply under voltage
2. Continuous current overload
3. Power stage bias supply under voltage
4. Power stage output short circuit (phase to phase and phase to ground)
5. DC bus over voltage
6. IGBT (isolated gate bipolar transistor) device over temperature sense
Keep alive and -AUXPWR option for emergency stop (estop) applications
Inrush current limiting
Internal or external shunt option
1.2.2 Dual Encoder Feedback Channels
Primary Channel: Line driver square wave or optional analog sine wave
quadrature encoder primary position and velocity feedback
Secondary Channel: Line driver square wave auxiliary quadrature encoder input
1.2.3 Inputs and Outputs
Four opto-isolated user outputs standard
Six opto-isolated user inputs standard, two of which are high speed
One differential analog input standard
One analog output standard
Dedicated 24 V E-stop sense input standard (5 V optional)
Integral 24 V brake output interface
5 VDC, 500 mA user output power for encoder and Hall effect signals
1.2.4 -IO Option Feature Summary
16 additional opto-isolated user outputs
16 additional opto-isolated user inputs
One additional differential analog input
One additional analog output
One additional Brake/Relay Output

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1.3 Soloist Connections
The Soloist AC power, motor power, feedback, and communications connections are
detailed in Figure 1-2.
Figure 1-2 Soloist Hardware

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1.4 Soloist Power Features
If you purchased the Soloist with the standard set of features, it includes the bus power
supply that operates from 70-240 VAC (100 –340 VDC). The power supply provides
off-line operation without the need for an isolation transformer. A soft start circuit is
included to prevent high inrush currents. These features are detailed in the following
diagram. Note: Figure 1-3 includes power options.
Figure 1-3 Soloist Block Diagram

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1.5 Soloist Voltage Configurations
The Soloist is available in three models with continuous power, ranging from 1,100 to
2,300 watts. The available voltage configurations and power options for these models are
shown in Table 1-1.
Table 1-1 Soloist Voltage Configurations
Model Peak Output Current Continuous Output Current (peak)
Soloist10 10A 5A
Soloist20 20A 10A
Soloist30-S 30A 15A
Options
-S Shunt resistor network, standard on Soloist30
-AUXPWR Auxiliary 115/230 VAC input to power logic circuitry; required for “keep alive” or 10-40 VDC bus operation. 10-40 VDC operation requires external
transformer to generate 7-28 VAC bus power input.
-IO I/O option, adds 16 digital opto-inputs, 16 digital opto-outputs, 18-bit analog
output and 16-bit analog input and a brake/relay output.
-LB Low bus voltage option for 40-100 VDC bus; doesn’t support keep-alive functionality; not available with -AUXPWR option; 40-100 VDC bus operation
requires external transformer to generate 28-70 VAC bus power input
-MXU x512 (total) software encoder resolution multiplication (primary channel only)
-S Shunt option (standard on Soloist30)

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1.6 Electrical Specifications
The electrical specifications for the Soloist are listed in Table 1-2.
Table 1-2 Electrical Specifications
Description Units Soloist10 Soloist20 Soloist30
Main Supply 70 - 240 VAC
Input Volts -AUXPWR (1) VAC
Input Frequency Main Supply Hz 50-60
Current (Max Peak)
Main Supply Amps 42
Max Continuous
Input Power Main Supply Watts 1200 2400 2400
Supply Input Volts VAC 70-240
-AUXPWR Supply Input Frequency (1) Hz 50-60
-AUXPWR Supply Maximum Input
Power (1) Watts 100
-AUXPWR Supply Input Current
Maximum (1) A (RMS) .25
Output Voltage (2) VDC 15-350
Peak Output Current (2 sec) A (peak) 10 20 30
Continuous Output Current A (peak) 5 10 15
Peak Power Output (3) Watts 2300 4800 4800
Continuous Power Output (3) Watts 1100 2300 2300
Efficiency % 97
Current Loop Bandwidth (4) kHz 5 kHz max
PWM Switching Frequency kHz 20
Minimum Load Inductance mH 0.8 @ 160 VDC bus
(1 mH @320 VDC)
Maximum Optional Shunt Regulator
Dissipation (-S opt.) Watts 40
Maximum Heat Sink Temperature "C 75
Heat Sink Size (typical) Volume 25.4 x 50.8 x 6.35 (1 x 2 x .25)
Weight (standard) lb (kg) 3.6 (1.63)
Notes:
1. –AUXPWR is optional
2. AC input voltage dependant. See 2.4.2.
3. Includes AC line droop
4. See the Digital Current Loop Parameters in the Soloist Help.

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Table 1-2 Electrical Specifications
Feature Description
Modes of Operation - Brush (torque mode) - Brushless
- Stepper
Feedback Inputs
Hall A-Pin 10, Hall B-Pin 5, Hall C-Pin 11: Hall effect device
inputs for commutation, 0 to 5 VDC, internal pull-up, 10K input.
Commutation signals used with brushless motors to provide
motor rotor position information to the controller. This allows
the three motor phase’s currents to be varied (commutated) to
rotate the motor in the desired direction at the desired speed.
TTL level input.
Sine/Sine-N-Pin 17, Pin 18, Cosine/Cosine-N-Pin 14, Pin 15:
Encoder input 0 to 5VDC, internal pull-up, 10K input.
Auxiliary Power
Outputs
5V-Pin 16: On board 5V power supply. 250 mA maximum
output.
5V-Pin 3: On board 5V power supply. 500 mA maximum output
(for encoder).
- Output short circuit - Peak over current
- DC bus over voltage - RMS over current
- Over temperature - Control power supply under
voltage
Protective Features
- Power stage bias supply
under voltage - Designed to EN61010/UL3101
Isolation - Optical and transformer isolation between control and power
stages.
Indicator (power) - LED indicates drive power.
Indicator (enabled) - LED indicates drive enabled.

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1.7 Physical Dimensions
The physical dimensions for the Soloist are shown in Figure 1-4. Separate Soloist’s from
each other and provide 25 mm (1 inch) of free air space.
167.4 [6.59]
178.2 [7.02]
6.4 [0.25]
9.8 [0.39]
4.7 [0.19]
(TYP.)
233.0 [9.18]
218.6 [8.61]
63.5 [2.50]
31.8 [1.25] 15.9 [0.63]
(TYP.)
Mounting
Hole
Layout
Each unit should be surrounded by
25mm (1 inch) of free air space.
Ø10.3 [Ø0.41] (TYP.)
Ø4.7 [Ø0.19] (TYP.)
15.9 [0.63]
(TYP.)
16.1 [0.64] 198.2 [7.81]
218.6 [8.61]
233.0 [9.18]
9.8 [0.39]
4.7 [0.19]
(TYP.)
63.5 [2.50]
65.7 [2.59]
31.8 [1.25]
Figure 1-4 Soloist Physical Dimensions

The Soloist case temperature may exceed 75 °C in some applications.


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1.8 Environmental Specifications
The environmental specifications for the Soloist are listed in the following table.
Temperature: Ambient
Operating: 5"- 50"C (41"- 122"F)
Storage: -20 - 70"C (-4 - 158"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 (on-conductive pollution)
Use: Indoor use only
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