Aerotech Soloist MP Series User manual

Revision: 4.10.00
Soloist MPHardware Manual

Global Technical Support
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necessary, you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts.
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Pittsburgh, PA 15238-2811
www.aerotech.com
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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
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Copyright © 2005-2019, Aerotech, Inc., All rights reserved.

Table of Contents Soloist MP
Table of Contents
Soloist MPHardware Manual 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Agency Approvals 10
Safety Procedures and Warnings 11
Quick Installation Guide 13
Chapter 1: Introduction 15
1.1. Drive and Software Compatibility 19
1.2. Electrical Specifications 20
1.2.1. System Power Requirements 21
1.2.2. Power Dissipation 22
1.3. Mechanical Design 23
1.4. Environmental Specifications 24
Chapter 2: Installation and Configuration 25
2.1. Power Connections 25
2.1.1. Control Supply Connections (TB103) 26
2.1.2. Motor Supply Connections (TB102) 27
2.1.3. External Power Supply Options 28
2.1.4. Minimizing Conducted, Radiated, and System Noise 32
2.2. Motor Output Connections 33
2.2.1. Brushless Motor Connections 34
2.2.1.1. Powered Motor Phasing 35
2.2.1.2. Unpowered Motor and Feedback Phasing 36
2.2.2. DC Brush Motor Connections 37
2.2.2.1. DC Brush Motor Phasing 38
2.2.3. Stepper Motor Connections 39
2.2.3.1. Stepper Motor Phasing 40
2.3. Motor Feedback Connections (J103) 41
2.3.1. Encoder Interface (J103) 42
2.3.1.1. RS-422 Line Driver Encoder (Standard) 43
2.3.1.2. Analog Encoder Interface 44
2.3.1.3. Encoder Phasing 46
2.3.2. Hall-Effect Interface (J103) 48
2.3.3. Thermistor Interface (J103) 49
2.3.4. Encoder Fault Interface (J103) 50
2.3.5. End Of Travel Limit Input Interface (J103) 51
2.3.5.1. End Of Travel Limit Phasing 53
2.3.6. Brake Output (J103) 54
2.3.7. Analog Input 0 (J103) 55
2.4. Emergency Stop Sense Input (TB104) 56
2.4.1. Typical ESTOP Interface 57
2.5. RS-232 Interface (TB105) 58
2.6. PC Configuration and Operation Information 59
Chapter 3: -I/O Expansion Board 61
3.1. User Power (TB201) 62
3.2. Brake Relay Connector (TB201) 63
3.3. Analog I/O Connector (TB202) 65
3.3.1. Analog Output 1 (TB202) 66
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3.3.2. Differential Analog Input 1 (TB202) 67
3.4. Opto Out Connector (Digital Outputs) (TB204) 68
3.5. Opto InConnector (Digital Inputs) (TB203) 71
3.6. Auxiliary Encoder Channel / PSO Output (J201) 74
3.6.1. Position Synchronized Output (PSO)/Laser Firing (J201) 76
Chapter 4: Standard Interconnection Cables 79
4.1. Joystick Interface 80
4.2. Handwheel Interface 82
Chapter 5: Maintenance 83
5.1. Control Board 84
5.2. Preventative Maintenance 85
Appendix A: Warranty and Field Service 87
Appendix B: Revision History 89
Index 91
Soloist MP Table of Contents

Table of Contents Soloist MP
List of Figures
Figure 1-1: Soloist MP Networked Digital Drive 15
Figure 1-2: Functional Diagram 18
Figure 1-3: Power Dissipation vs. Output Current 22
Figure 1-4: Ambient Temperature vs. Power Dissipation 22
Figure 1-5: Dimensions 23
Figure 2-1: Control Supply Connections 26
Figure 2-2: Motor Bus Input Connections 27
Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 29
Figure 2-4: PS-MP Option (2 Axis, 120 W, 48 VDCOutput, with Brake) 30
Figure 2-5: PS-MP Option (2 Axis, 240 W, 48 VDC Output, with Brake) 30
Figure 2-6: PS-MP Option (4Axis, 480 W, 48 VDC Output, with Brake) 31
Figure 2-7: Brushless Motor Configuration 34
Figure 2-8: Encoder and Hall Signal Diagnostics 35
Figure 2-9: Motor Phasing Oscilloscope Example 36
Figure 2-10: Brushless Motor Phasing Goal 36
Figure 2-11: DC Brush Motor Configuration 37
Figure 2-12: Clockwise Motor Rotation 38
Figure 2-13: Stepper Motor Configuration 39
Figure 2-14: Clockwise Motor Rotation 40
Figure 2-15: Line Driver Encoder Interface (J103) 43
Figure 2-16: Analog Encoder Phasing Reference Diagram 44
Figure 2-17: Analog Encoder Interface (J103) 45
Figure 2-18: Encoder Phasing Reference Diagram (Standard) 46
Figure 2-19: Position Feedback in the DiagnosticDisplay 47
Figure 2-20: Hall-Effect Inputs (J103) 48
Figure 2-21: Thermistor Interface Input (J103) 49
Figure 2-22: Encoder Fault Interface Input (J103) 50
Figure 2-23: End of Travel Limit Input Connections 51
Figure 2-24: End of Travel Limit Interface Input (J103) 52
Figure 2-25: Limit Input Diagnostic Display 53
Figure 2-26: Analog Input 0 (J103) 55
Figure 2-27: ESTOPSenseInput (TB104) 56
Figure 2-28: Typical Emergency Stop Circuit 57
Figure 2-29: RS-232 Interface (TB105) 58
Figure 3-1: Soloist MP with -IO Option Board 61
Figure 3-2: Brake Connected to J103 64
Figure 3-3: Brake Connected to TB201 64
Figure 3-4: Analog Output 1 Connector (TB202) 66
Figure 3-5: Analog Input Typical Connection (TB202) 67
Figure 3-6: Digital Opto-Isolated Outputs (-IOBoard) 69
Figure 3-7: Digital Outputs Connected in Current Sourcing Mode 70
Figure 3-8: Digital Outputs Connected in Current Sinking Mode 70
Figure 3-9: Digital Opto-Isolated Inputs 72
Figure 3-10: Digital Inputs Connected to a Current Sourcing Device 73
Figure 3-11: Digital Inputs Connected to a Current Sinking Device 73
Figure 3-12: Auxiliary Encoder Channel (J201) 75
Figure 3-13: PSOInterface 77
Figure 4-1: Single Axis Joystick Interface 80
Figure 4-2: Two Axis Joystick Interface 81
Figure 4-3: Handwheel Interconnection (to Aux I/O) 82
Figure 5-1: Control Board Assembly 84
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Table of Contents Soloist MP
List of Tables
Table 1-1: FeatureSummary 16
Table 1-2: Ordering Options 16
Table 1-3: MLPower Supply Options 17
Table 1-4: Accessories 17
Table 1-5: Drive and Software Compatibility 19
Table 1-6: Electrical Specifications 20
Table 1-7: Physical Specifications 23
Table 2-1: Control Supply DCInput Wiring (TB103) 26
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector (TB103) 26
Table 2-3: Motor Supply Input Wiring (TB102) 27
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector (TB102) 27
Table 2-5: ExternalPower Supply Options 28
Table 2-6: PS-MP ACPower Wiring Requirements 28
Table 2-7: Ferrite Noise Suppression Part Numbers 32
Table 2-8: Motor Power Output Connections (TB102) 33
Table 2-9: Mating Connector Part Numbers for the Motor Power Output Connector 33
Table 2-10: Wire Colors for Aerotech Supplied Cables (Brushless) 34
Table 2-11: Wire Colors for Aerotech Supplied Cables (DCBrush) 37
Table 2-12: Wire Colors for Aerotech Supplied Cables (Stepper) 39
Table 2-13: Motor Feedback Connector Pinout (J103) 41
Table 2-14: Mating Connector Part Numbers for the Motor Feedback Connector (J103) 41
Table 2-15: Encoder Interface Pins on the Motor Feedback Connector (J103) 42
Table 2-16: Encoder Specifications 43
Table 2-17: Analog Encoder Specifications 44
Table 2-18: Hall-Effect Feedback Interface Pins on the Motor Feedback Connector (J103)) 48
Table 2-19: Thermistor Interface Pin on the Motor Feedback Connector (J103) 49
Table 2-20: Encoder Fault Interface Pin on the Motor Feedback Connector (J103) 50
Table 2-21: End of Travel Limit Input Pins on the Motor Feedback Connector (J103) 51
Table 2-22: Brake Output Pins on the Motor Feedback Connector (J103) 54
Table 2-23: Differential Analog Input 0 Specifications 55
Table 2-24: Port 0 Analog Input Connector Pins on the Motor Feedback Connector (J103) 55
Table 2-25: Electrical Noise Suppression Devices 56
Table 2-26: Mating Connector Part Numbers for the ESTOPConnector (TB104) 56
Table 2-27: Typical ESTOPRelay Ratings 57
Table 2-28: RS-232 Connector Pinout (TB105) 58
Table 2-29: Mating Connector Part Numbers for the RS-232 Port Connector (TB105) 58
Table 3-1: User Common Connector Pins on the Brake Relay Connector (TB201) 62
Table 3-2: Relay Specifications 63
Table 3-3: Brake Output Connector Pinout (TB201) 63
Table 3-4: Mating Connector Part Numbers for the Brake Relay Connector (TB201) 63
Table 3-5: Port 1 Analog I/O Connector Pinout (TB202) 65
Table 3-6: Mating Connector Part Numbers for the Analog Output Connector 65
Table 3-7: Analog Output 1 Specifications (TB202) 66
Table 3-8: Port 1 Analog Output Pins on the Analog I/OConnector (TB202) 66
Table 3-9: Differential Analog Input 1 Specifications 67
Table 3-10: Differential Analog Input 1 Pins on the Analog I/OConnector (TB202) 67
Table 3-11: Digital Output Specifications (TB204) 68
Table 3-12: Opto Out Connector Pinout (TB204) 68
Table 3-13: Mating Connector Part Numbers for the Opto Out Connector (TB204) 68
Table 3-14: Digital Input Specifications 71
Table 3-15: Port 1 Opto In Connector Pinout (TB203) 71
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Table 3-16: Mating Connector Part Numbers for the Opto In Connector (TB203) 71
Table 3-17: Auxiliary Encoder Specifications 74
Table 3-18: Auxiliary Encoder Channel Pinout (J201) 74
Table 3-19: Mating Connector Part Numbers for the Auxiliary Encoder Connector (J201) 74
Table 3-20: PSO Specifications 76
Table 3-21: PSOOutput Pins on the Auxiliary Encoder Connector (J201) 76
Table 4-1: Standard Interconnection Cables 79
Table 4-2: Joystick Cable Part Numbers 80
Table 5-1: Control Board Fuse Information 84
Table 5-2: LEDDescription 84
Table 5-3: Preventative Maintenance 85
Soloist MP Table of Contents

Declaration of Conformity Soloist MP
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
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):
2014/30/EU Electromagnetic Compatibility Directive
2014/35/EU Low Voltage 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 Director
Address: Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date 11/26/2019
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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 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 MP Declaration of Conformity

Electrical Safety Soloist MP
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the Soloist MP. Read all parts of this
manual before you install or operate the Soloist MP or before you do maintenance to your system. To prevent
injury to you and damage to the equipment, obey the precautions in this manual. The precautions that follow
apply when you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury
to you or damage to the equipment can occur. If you do not understand the information in this manual,
contact Aerotech Global Technical Support.
This product has been designed for light industrial manufacturing or laboratory environments. The protection
provided by the equipment could be impaired if the product is used in a manner not specified by the
manufacturer.
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. All components must be 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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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. If the product is used in a manner not specified by the manufacturer, the protection
provided by the product can be impaired and result in damage, shock, injury, or death.
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 this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
5. Operators must be trained before operating this equipment.
6. All service and maintenance must be performed by qualified personnel.
Soloist MP Electrical Safety

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.
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.
Figure 1-1: Soloist MP Networked Digital Drive
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Table 1-1: FeatureSummary
Standard Features
l10 - 80 VDC motor supply inputs Section 2.1.2.
lOne quadrature encoder input channel Section 2.3.1.
lDedicated Home and Limit inputs Section 2.3.5.
lOne 16-bit analog differential input (±10 VDC) Section 2.3.7.
lDedicated 5-24 V Emergency Stop sense input Section 2.4.
lCalibration Refer to the Help file
lCamming Refer to theHelp file
l10/100 BASE-T Ethernet port for use with Ethernet I/O modules Refer to the Help file
Table 1-2: Ordering Options
Options
Power Stage Options (Section 2.1.1.)
10 24-80 VDC logic power input
10-LV 10-16 VDC logic power input
I/O(Chapter 3) and Feedback (Section 2.3.1.2.) Options
-IO
Expansion board with eight digital inputs (opto-isolated); eight digital outputs (opto-
isolated); one 12-bit analog input (±10 V); one 16-bit analog output (±5 V); brake
relay; auxiliary encoder channel
-MXU Programmable encoder multiplier up to x1024 (x4096 after quadrature); no real-
time output
Power Supply Option (Section 2.1.3.)
-PS-MP DC power supply for up to four axes; mounted to DIN rail
Drive Options (refer to the SoloistHelp file for more information)
-AUXENC I/O auxiliary encoder input (cannot select -IO or -MXU option with the -AUXENC
option)
-EIP Enable EtherNet/IP™ on the master drive;
-DCT Enable the Dynamic Controls Toolbox on the master drive;
-ETM Enable the Enhanced Throughput Module on the master drive
-ETC Enhanced Tracking Control for reduced dynamic following error and settling times;
effectiveness may be limited for low-resolution axes. Refer to the Help file.
-LCK
Locked drive; firmware and calibration data on the drive cannot be modified by the
user; the drive must be returned if updates are required; read/write access to
parameters and programs is supported
Soloist MP Introduction

Introduction Soloist MP
Table 1-3: MLPower Supply Options
Options
Power Supply Options
-PS-12048-A 120 W; 48 VDC; 100-120 VAC
-PS-12048-B 120 W; 48 VDC; 200-240 VAC
-PSP-24048 240 W; 48 VDC; Autoranging 100-240 VAC
-PSP-480D48-A 480 W; 48 VDC; 100-120 VAC
-PSP-480S48-B 480 W; 48 VDC; 200-240 VAC
Axes
-1AX 1 axis of wiring
-2AX 2 axes of wiring
-3AX 3 axes of wiring
-4AX 4 axes of wiring
Brake
-BRAKE-1 Axis 1 brake
-BRAKE-2 Axis 2 brake
-BRAKE-3 Axis 3 brake
-BRAKE-4 Axis 4 brake
Table 1-4: Accessories
Accessories
JI Industrial Joystick (NEMA12 (IP54) rated); refer to Section 4.1.
BRAKE24-2 24 VDC, 2 A power supply for optional brake
Joystick/Handwheel Refer to Section 4.1. or Section 4.2.
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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 MP Introduction

Introduction Soloist MP
1.1. Drive and Software Compatibility
The following table lists the available drives and which version 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
MP - 2.01 Current
A 2.55 Current
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1.2. Electrical Specifications
Table 1-6: Electrical Specifications
MP 10
Motor Supply
Input Voltage 10-80 VDC
Input Current
(Continuous) 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.
Soloist MP Introduction