Aerotech BA50 Series User manual

Revision:1.6
BA50/75/100 Series Hardware
Manual

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Copyright © 2006-2017, Aerotech, Inc., All rights reserved.

BA50/75/100 Hardware Manual Table of Contents
Table of Contents
BA50/75/100 Series Hardware Manual 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Conformity 7
Agency Approvals 8
Safety Procedures and Warnings 9
Chapter 1: Introduction 11
1.1. Product Overview 11
1.2. BA Drive Package 13
1.3. Hardware Overview and Function 14
1.3.1. Motor and AC Power Connections 15
1.3.2. DIP Switch 15
1.3.3. Potentiometers (POTs) 17
1.3.4. Connector P1 and Enable Indicator 17
1.3.5. I/O Circuitry 20
Chapter 2: Installation and Configuration 23
2.1. Jumper Selections 23
2.2. Wiring, Grounding, and Shielding Techniques 25
2.2.1. Minimizing EMI Interference 25
2.2.2. Minimizing 50/60 Hz Line Interference 27
2.3. Integrated Configurations 29
2.3.1. Velocity Command Configuration 29
2.3.2. Current Command Configuration 30
2.3.3. Dual-Phase Command Configuration 31
2.4. Control Connections 32
2.4.1. Setup - Torque Command Mode (Current) 32
2.4.2. Setup - Velocity Command Mode 32
2.4.3. Setup - Dual-Phase Command Mode 34
2.5. Motor Phasing Process 35
2.5.1. Determining Phase/Hall Sequence 35
2.6. Current Regulator Adjustment 37
Chapter 3: Technical Details 39
3.1. Electrical and Environmental Specifications 39
3.2. BA Amplifier Dimensions 43
Chapter 4: Troubleshooting 47
4.1. Amplifier Related Problems 47
4.2. Fuse Replacement 49
4.3. Cleaning 49
Appendix A: Warranty and Field Service 51
Appendix B: Revision History 53
Appendix C: Cable Drawings 55
Index 57
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Table of Contents BA50/75/100 Hardware Manual
List of Figures
Figure 1-1: BA50/75/100 Series Amplifiers 11
Figure 1-2: Functional Diagram 13
Figure 1-3: Amplifier Hardware 14
Figure 1-4: Fault Output 20
Figure 1-5: Enable/Shutdown Inputs 20
Figure 1-6: ± Limit Inputs 20
Figure 1-7: Hall and Encoder Inputs 21
Figure 2-1: BA50/75/100 Board Assembly (Jumpers Shown in Default) 24
Figure 2-2: Wiring to Minimize EMI and Capacitive Coupling 26
Figure 2-3: Back-Propagation Line Filter Connection 27
Figure 2-4: Isolation Transformer Connection (eliminates torque disturbance) 28
Figure 2-5: Velocity Command Configuration 29
Figure 2-6: Current Command Configuration 30
Figure 2-7: Dual-Phase Command Configuration 31
Figure 2-8: Command Signal Adjustment Portion of the Pre-Amplifier Circuit 33
Figure 2-9: Motor Phasing 36
Figure 2-10: Three-Phase Current Regulator Circuit 37
Figure 3-1: BA50 Dimensions (Front View) 44
Figure 3-2: BA50 Preferred Mounting (Side View) 45
Figure 3-3: BA75/100 Dimensions (Front View) 46
Figure C-1: BA Feedback Cable (PFC) 55
Figure C-2: BA Series Light Duty Brushless Motor Cable (PMC) (BA 50 only) 55
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BA50/75/100 Hardware Manual Table of Contents
List of Tables
Table 1-1: BA Models 12
Table 1-2: BA Models and Voltage Configurations 12
Table 1-3: DIP Switch Functions 15
Table 1-4: Potentiometer Functions 17
Table 1-5: Connector P1 Pinouts 18
Table 2-1: Jumper Selections 23
Table 3-1: Electrical Specifications per Model 39
Table 3-2: Additional Electrical Specifications 40
Table 4-1: Amplifier Faults, Causes, and Solutions 48
Table 4-2: Fuse Replacement Part Numbers 49
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Table of Contents BA50/75/100 Hardware Manual
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BA50/75/100 Hardware Manual Hardware Manual Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Brushless Servo Amplifier (BA50/75/100)
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2014/35/EU Low Voltage Directive LVD
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 61010-1:2001 Safety requirements for electrical equipment
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
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Declaration of Conformity BA50/75/100 Hardware Manual Hardware Manual
Agency Approvals
Aerotech, Inc. BA50/75/100 Series Amplifiers 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 04 68995 024
Standards: UL 61010-1:2012; CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-
1:2010
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Electrical Safety BA50/75/100 Hardware Manual
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 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 BA Amplifier and component parts must be restricted while connected to a
power source.
4. Residual voltages greater than 60V may be present inside BA Amplifier chassis for more
than 10 seconds after power has been disconnected.
5. 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.
6. Install the BA Amplifier inside a rack or enclosure.
7. The shunt resistor temperature can exceed 70°C during normal operation and contains
lethal voltage on its terminals and surface. It must be properly enclosed and shielded to
avoid risk of fire and operator shock.
8. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
9. All components must be properly grounded in accordance with local electrical safety
requirements.
10. Operator safeguarding requirements must be addressed during final integration of the
product.
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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. 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 this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
5. 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.
6. Operators must be trained before operating this equipment.
7. All service and maintenance must be performed by qualified personnel.
8. This product is intended for light industrial manufacturing or laboratory use. Use of this
product for unintended applications can result in injury and damage to the equipment.
BA50/75/100 Hardware Manual Electrical Safety

BA50/75/100 Hardware Manual Introduction
Chapter 1: Introduction
1.1. Product Overview
The BA (High Current) Series amplifiers are highly reliable brushless servo amplifiers that are easily
adaptable to drive brush or brushless servomotors. The amplifiers are available in three peak output current
ratings of 50, 75, and 100 amps. The BA amplifier package is a complete modular unit that includes heat
sink, metal cover, and bus power supply that operates from 200-240VAC.
The BA drives feature self-commutation with digital Hall effect feedback signals. The BA drives include a 5
VDC, 250 mA supply to power encoders, and Hall effect devices (HEDs). Each model is jumper selectable,
providing the capability to drive both brush and brushless motors. Complete electrical isolation is provided
between the control stage and the power stage for all models of the BA series. This is accomplished with a
transformer isolated control voltage power supply and opto-isolation of the drive signals, current feedback
signals and fault signal between the control and power stages. Each drive is fully protected against the fault
conditions that follow.
lControl power supply under voltage
lRMS current limit exceeded
lPower stage bias supplies under voltage
lOver temperature
lOver current
lOutput short circuits (phase to phase and phase
to ground)
lDC bus overvoltage (detected if shunt fuse is
open)
Operating modes include current command, velocity command or dual-phase command (for brushless
modes of operation only). For brush modes of operation, the available operating modes are current command
and velocity command. Differential inputs are used for better noise immunity. Velocity feedback is from
either an encoder or tachometer and logic inputs include directional current limits and shutdown. Fault,
current, and velocity outputs simplify monitoring drive status.
Figure 1-1: BA50/75/100 Series Amplifiers
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Introduction BA50/75/100 Hardware Manual
The BA50, BA75, BA100 high current drives are available in the models in the tables that follow.
Table 1-1: BA Models
Model Drive
BA50-320-S AMPLIFIER BRUSHLESS 50 A / 320 V / SHUNT
BA50-320-S-BC AMPLIFIER BRUSHLESS 50 A / 320 V / SHUNT /HEAVY DUTY CONN
BA50-320-S-FAN AMPLIFIER BRUSHLESS 50 A / 320 V / SHUNT / FAN
BA50-320-S-FAN-BC AMPLIFIER BRUSHLESS 50 A / 320 V / SHUNT / FAN / HEAVY DUTY
CONN
BA50-320-S-HS AMPLIFIER BRUSHLESS 50 A / 320 V / SHUNT / HEATSINK
BA75-320-S AMPLIFIER BRUSHLESS 75 A / 320 V / SHUNT
BA75-320-S-BC AMPLIFIER BRUSHLESS 75 A / 320 V / SHUNT / HEAVY DUTY CONN
BA75-320-S-NOFAN AMPLIFIER BRUSHLESS 75 A / 320 V / SHUNT
BA75-320-S-NOFAN-
BC
AMPLIFIER BRUSHLESS 75 A / 320 V / SHUNT / HEAVY DUTY CONN
BA100-320-S AMPLIFIER BRUSHLESS 100 A / 320 V / SHUNT
BA100-320-S-BC AMPLIFIER BRUSHLESS 100 A / 320 V / SHUNT / HEAVY DUTY CONN
Table 1-2: BA Models and Voltage Configurations
Base
Model
“Power Input” Voltage
Range (VAC)
Nominal Motor DC
Bus (VDC)
Output Cur-
rent (Peak)
Output Current (Peak
Continuous)
BA50 200…240VAC 282…340VDC 50A 25A
BA75 200…240VAC 282…340VDC 75A 37A
BA100 200…240VAC 282…340VDC 100A 50A
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BA50/75/100 Hardware Manual Introduction
1.2. BA Drive Package
The standard package includes the heat sink, cover, shunt regulator, control power supply, and the bus
power supply that operates from 200-240 VAC. The power supply is included with the standard package for
offline operation without the need for an isolation transformer. Figure 1-2 shows the standard package
configuration.
Figure 1-2: Functional Diagram
**AUX PWR INPUT "Control Power" applications, contact factory for this configuration.
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Introduction BA50/75/100 Hardware Manual
1.3. Hardware Overview and Function
The BA series consist of two power connections (motor power and input power), four potentiometers, a 10-
position DIP switch, an enable LED indicator lamp, a fault/overload indicator lamp, and a 25-pin “D” style
connector.Figure 1-3 shows locations of hardware functions.
Optional:
“AUX PWR INPUT”
(Control Power)
- or -
“External Shunt Resistor”
connector.
Contact factory for these configurations
Motor and AC
Power Connections
Fault/Overload LED
Power/Enable LED
DIP Switch
Input Pot
Tach Pot
Gain Pot
Balance Pot
Connector P1
Figure 1-3: Amplifier Hardware
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BA50/75/100 Hardware Manual Introduction
1.3.1. Motor and AC Power Connections
PWR
INPUT
MOTOR
AC1
AC2
AC3
A
B
C
G
G
The three phase motor terminal connections are made at connections A, B, and C.
This area is designated as such on the amplifier.
Input power to the BA series amplifier is made at the AC1,AC2, and AC3 terminals
with Protective Ground (PE) connected to (ground). Single or three-phase power
can be made at these connections. For single phase operation, connect the AC
power to AC1 and AC2.
N O T E : For the BA75 and BA100, three phase-input power is recommended.
1.3.2. DIP Switch
There is a 10-position DIP switch on the BA drive that provides four discrete
functions. The switch permits the user to control maximum allowable current to the motor, continuous output
current, velocity or current operational mode, and test mode. Figure 1-3 shows the location of this switch on
the BA drive. Refer to Table 1-3 for the exact switch functions.
Table 1-3: DIP Switch Functions
Current
Limit Peak
Switches Position Function
*1 closed Peak is 6% of Ipeak
*2 closed Peak is 13% of Ipeak
*3 closed Peak is 27% of Ipeak
*4 closed Peak is 54% of Ipeak
* These switches affect the GAIN adjustment of the velocity loop. Maximum gain adjustment when 1 to 4
are closed.
Continuous
Current
Peak*
5 closed Icont is 3% of Ipeak
6 closed Icont is 7% of Ipeak
7 closed Icont is 14% of Ipeak
8 closed Icont is 27% of Ipeak
* The maximum allowable continuous current is 54% of peak current.
Test 9 closed
Closing this position allows the Balance potentiometer to manually
control motor velocity or torque without the need of an input signal
depending upon the setting of switch 10.
Mode 10 Velocity/Current mode - closing this position enables the current
mode.
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Introduction BA50/75/100 Hardware Manual
Switches 1-4 affect the full-scale current output range of the amplifier when in
current (and in velocity) mode.When all four switches are closed, the peak
current range is not limited.Closing each switch effectively limits the output
range of the amplifier by a factor associated with that switch.For example
closing only SW1-4 (54%) on a BA50 limits the output current to 27 Amp.
Therefore, a 10 Volt input signal would produce a 27 Amp output; similarly, a 5
Volt input would produce a 13.5 Amp output (5V / 10V * 27A). It should be noted
that switches 1-4 have no effect in dual-phase mode.
Switches 5 through 8 determine the level where the continuous output current
the BA amp protection circuit will produce a fault. This type of protection is
known as an electronic fuse.
For low duty cycle and low acceleration system requirements, set the DIP switches equally or to the next
lower switch setting. For high duty cycle and high acceleration system requirements, set the DIP switches
equally or to the next higher switch setting.
N O T E : Closing DIP switches 1 through 4 will allow peak current. Closing switches 5 through 8 will allow
54% peak continuous current for two seconds.
The following examples should be used as guidelines for setting the DIP switches.
Example for a BA50 - Setting RMS Current Limits
To set the continuous current limit to 10A:
10A Continuous RMS x 1.414 = 14.14A continuous peak
(14.14A continuous peak/50A max peak) x 100 = 28%.
Open switches 5, 6, and 7; close switch 8.
Example for BA50 - Setting Current Limits
To set the peak current to 37A:
Peak Current
(35A peak/50A max peak) x 100 = 75%
Close switches 3 and 4; open switches 1 and 2.
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BA50/75/100 Hardware Manual Introduction
1.3.3. Potentiometers (POTs)
Potentiometers INPUT,TACH,GAIN, and BALance are associated with the
pre-amplifier circuit contained in the amplifier. Refer to Figure 1-3 for location of the
pots on the BA drive. These potentiometers are used to adjust the pre-amplifier gain
when the MODE switch is set for velocity control using an external DC tachometer
or incremental encoder for velocity feedback. Refer to Table 1-4 for pot functions.
Table 1-4: Potentiometer Functions
Potentiometer CW CCW Function
GAIN decrease increase This pot adjusts the velocity loop AC
gain of the pre-amplifier1.
INPUT increase decrease
This pot adjusts the DC gain of the
input command present at P1 Pins 8 &
21.
TACH increase decrease
This pot adjusts the DC gain of the tach
or encoder derived velocity feedback
input present at P1-Pin 3.
BALance
Provides the means of canceling small
DC offsets that may be present in the
pre-amplifier circuit.
1Velocity loop GAIN adjustment is affected by current limit peak (switches 1 to 4). Maximum gain when 1 to 4 is closed.
1.3.4. Connector P1 and Enable Indicator
Connector P1 (25-pin “D” type, female) provides the interface for input and output control connections. Refer
to Table 1-5 for connector P1 pinouts. The LED ENABLE indicator will illuminate at all times until there is a
fault or external shutdown, then the indicator will be off and motor power will be removed. Refer to Figure 1-3
for location of these items. The POWER LED will be green whenever +5V is present.
The FAULT LED energizes whenever there is a short circuit, current overload, thermal overload, etc.,
present on the drive. The unit must be powered down to clear the fault. In addition, the OVERLOAD LED
energizes whenever the RMS current limit threshold is exceeded. If the RMS threshold is exceeded for more
than two seconds, the drive becomes faulted and shuts down.
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Introduction BA50/75/100 Hardware Manual
Table 1-5: Connector P1 Pinouts
Pin # Input or
Output Signal Function
1 shield ground
Connection point to earth ground. Used for reducing electrical noise in
control and feedback signals. Typically connected to the foil shield of a
shielded cable.
2 output power On board 5V power supply. Pin 2 is intended for powering an encoder
and can supply up to 250mA of current.
3 input +tach
Tachometer input for velocity feedback, (encoder vs. tach velocity
feedback is jumper selectable). A tachometer may be used in the
velocity loop configuration to provide negative feedback to the amplifier.
This allows the amplifier to close the servo loop and control the stability
of the loop.
4input (1)
(2) Hall A
Hall effect A. One of three commutation signals used with brushless
motors. Used in conjunction with Hall effect B and Hall effect C to
provide motor rotor position information to the amplifier.
5input (1) cosine Cosine signal from encoder. Optionally used, in conjunction with sine for
deriving an electronic tachometer signal. Line receiver input
6 input cosine-N Compliment of cosine (P1 - 5). Line receiver input.
7 input ground Signal common. Electrical reference for all control circuitry on amplifier.
8input (3) +input
Non-inverting input of differential input circuit. A positive voltage on this
input causes CCW motor rotation (torque or velocity mode). For single
ended operation, connect command to the input and ground (Pin 21 of
P1).
9input (3) icmda Current command A. Jumper selectable current command input.
Bypasses differential input, pre-amplifier, and self commutation circuit.
10 input (1) shutdown Jumper selectable active high or active low input. Used to shut off
power stage and therefore remove all power to the motor.
11 input (1) +ilmt
Directional current limit input. When pulled to its active state, motion in
the positive direction (CW motor shaft rotation) is inhibited (jumper
selectable).
12 output -fdbk
Current feedback monitor. When running a brushless motor, this signal
represents the current in motor phase A. When running a brush motor;
this signal represents the entire motor current. Scaling is as follows:
lBA50 8.3 Amp/V
lBA75 12.5 Amp/V
lBA100 16.6 Amp/V
13 NC
14 signal
common ground
Electrical reference for all control circuitry on amplifier. This pin is
intended to be used as the connection point for the signal common of an
encoder. (Used in conjunction with Pin 2 as the power supply
connections to an encoder.)
15 input -tach Recommended reference input for tachometer. This point is identical to
signal common.
16 input (1)
(2) Hall B Hall effect B. One of three commutation signals used with brushless
motors. Used in conjunction with Hall effect A and Hall effect C.
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BA50/75/100 Hardware Manual Introduction
Pin #
Input
or
Output
Signal Function
17 input
(1) Hall C Hall effect C. One of three commutation signals used with brushless motors.
Used in conjunction with Hall effect A and Hall effect B.
18 input
(1) sine Sine signal from encoder. Optionally used, in conjunction with cosine for
deriving an electronic tachometer signal. Line receiver input.
19 input sine-
NCompliment of sine (P1- 18). Line receiver input.
20 output power 5V on board 5V power supply.
21 input
(3) -input
Inverting input of differential input circuit. A positive voltage on this input
causes CW motor rotation (torque or velocity mode). For single ended
command operation, ground this connection and connect signal to Pin 8 of P1.
22 input(3) icmdb Current command B. Jumper selectable current command input. Bypasses
differential input, pre-amplifier, and self commutation.
23 output -fault Jumper selectable active high or active low (open collector) output. Used to
indicate the status of the power stage (amplifier enabled or faulted).
24 input
(1) -ilmt Directional current limit input. When pulled to its active state, motion in the
negative direction (CCW motor shaft rotation) is inhibited (jumper selectable).
25 output -icmd
Preamplifier current command monitor. Used to monitor the output of the
preamplifier circuit when in current command or velocity command mode.
This signal can be used in conjunction with the peak current limiting switch
(SW1-1 through SW1-4) to determine the actual output current. When
switches SW1-1 -- SW1-4 are closed this signal has the following gain:
lBA50: 9.0 Amp/Volt
lBA75: 13.6 Amp/Volt
lBA100: 18.0 Amp/Volt
Refer to the DIP switch function description in Section 1.3.2. for more
information.
1. Denotes input pull up to internal +5 V through a 10K resistor.
2. Denotes a factory option for analog Hall commutation is available. When using analog Hall feedback, only Hall A and Hall B
connections are used.
3. Denotes that pins 21, 9, 22, and 8 also function as differential inputs for phase A and phase B current commands, respectively
(this is a factory option).
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Introduction BA50/75/100 Hardware Manual
1.3.5. I/O Circuitry
The following figures show the internal circuitry for the BA amplifier. Note that all of the logic inputs can
tolerate +24VDC.
Figure 1-4: Fault Output
SHUTDOWN/ENABLE
+5V
10K
10K
.1 UF
74HC14
P1-10
Figure 1-5: Enable/Shutdown Inputs
P1-11
+5V
10K 1%
10K 1%
+ILMT
.1 UF
.1 UF
74HC14
P1-24
10K 1%
-ILMT
74HC14
+5V
10K 1%
Figure 1-6: ± Limit Inputs
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