Aerotech Soloist CP User manual

P/N:EDU180
Revision: 4.05.00
Soloist CP
Hardware Manual
MOTOR FEEDBACK
J103
ESTOP
TB101
ENB/FLT
MARKER
AUX I/O
J104
MOTOR FEEDBACK J103
ESTOP TB101
ENB/FLT
MARKER
RELAY TB206
NC
C
NO
OPTO IN TB205
OPTO IN TB204
C
0
1
2
3
4
5
6
7
GND
OPTO OUT TB203
OPTO OUT TB202
OP
OM
0
1
2
3
4
5
6
7
TB201
AGND
AIN+
AIN-
AOUT
AUX I/O J104
AEROTECH.
COM
TMTM
AEROTECH.
COM
TMTM
C
0
1
2
3
4
5
6
7
+5V
OP
OM
0
1
2
3
4
5
6
7
ETHERNET J102
ETHERNET
J102
High Voltage
DANGER!
MOTOR SUPPLY MOTOR OUTPUT
AC1
AC2
A
B
C
240V~
MAX
50/60Hz
15A MAX
PWR
INPOS
TB102
High Voltage
DANGER!
MOTOR SUPPLY MOTOR OUTPUT
AC1
AC2
A
B
C
240V~
MAX
50/60Hz
15A MAX
PWR
INPOS
TB102

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 © 2004-2015, Aerotech, Inc. All rights reserved.

Table of Contents Soloist CP
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 5
1.2. Electrical Specifications 6
1.2.1. System Power Requirements 7
1.2.2. Power Dissipation 8
1.3. Mechanical Design 9
1.4. Environmental Specifications 10
Chapter 2: Installation and Configuration 11
2.1. Power Connections 11
2.1.1. Control Supply Connections (TB106) 12
2.1.2. Motor Supply Connections (TB102) 13
2.1.3. Transformer Options 14
2.1.4. Minimizing Conducted, Radiated, and System Noise 21
2.2. Motor Output Connections 22
2.2.1. Brushless Motor Connections 23
2.2.1.1. Powered Motor Phasing 24
2.2.1.2. Unpowered Motor and Feedback Phasing 26
2.2.2. DC Brush Motor Connections 29
2.2.2.1. DC Brush Motor Phasing 30
2.2.3. Stepper Motor Connections 31
2.2.3.1. Stepper Motor Phasing 32
2.3. Motor Feedback Connections (J103) 33
2.3.1. Encoder Interface (J103) 34
2.3.1.1. RS-422 Line Driver Encoder (Standard) 35
2.3.1.2. EnDat Encoder Interface (J103) 36
2.3.1.3. Resolute Encoder Interface (J103) 37
2.3.1.4. Analog Encoder Interface 38
2.3.1.5. Encoder Phasing 40
2.3.2. Hall-Effect Interface (J103) 42
2.3.3. Thermistor Interface (J103) 43
2.3.4. Encoder Fault Interface (J103) 44
2.3.5. End Of Travel Limit Input Interface (J103) 45
2.3.5.1. End Of Travel Limit Phasing 47
2.3.6. Brake Output (J103) 48
2.4. Emergency Stop Sense Input (TB101) 49
2.4.1. Typical ESTOP Interface 50
2.5. Auxiliary I/O Connector (J104) 51
2.5.1. Auxiliary Encoder Channel (J104) 52
2.5.2. Position Synchronized Output (PSO)/Laser Firing (J104) 54
2.5.3. Opto-Isolated Outputs (J104) 56
2.5.4. Opto-Isolated Inputs (J104) 58
2.5.5. High Speed User Inputs 4-5 (J104) 60
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2.5.6. Analog Output 0 (J104) 61
2.5.7. Analog Input 0 (J104) 62
2.6. Brake Power Supply (TB103) 63
2.6.1. Solid State Relay Specifications (TB103) 66
2.7. RS-232 Interface (TB103) 67
2.8. -EXTSHUNT Option (TB104) 68
2.9. PC Configuration and Operation Information 71
Chapter 3: -I/O Expansion Board 73
3.1. Analog Output (TB201) 74
3.2. Analog Input (TB201) 75
3.3. Opto-Isolated Inputs (TB204, TB205) 76
3.4. Opto-Isolated Outputs (TB202, TB203) 79
3.5. User Power (TB204, TB205) 83
3.6. Brake / Mechanical Relay (TB206) 84
3.6.1. Brake Configuration Jumpers 84
3.6.2. Mechanical Relay Specifications 84
3.6.3. Brake / Mechanical Relay Interface Connector 85
Chapter 4: Standard Interconnection Cables 87
4.1. Joystick Interface 88
4.2. Handwheel Interface 91
Chapter 5: Maintenance 93
5.1. Control Board 94
5.2. Preventative Maintenance 96
Appendix A: Warranty and Field Service 97
Appendix B: Revision History 99
Index 101
Soloist CP Table of Contents

Table of Contents Soloist CP
List of Figures
Figure 1-1: Soloist CP Networked Digital Drive 1
Figure 1-2: Functional Diagram 4
Figure 1-3: Power Dissipation vs. Output Current 8
Figure 1-4: Ambient Temperature vs. Power Dissipation 8
Figure 1-5: Dimensions 9
Figure 2-1: Control Supply Connections 12
Figure 2-2: Motor Bus Input Connections 13
Figure 2-3: Transformer Examples 14
Figure 2-4: 40 VDC Motor Power with a TV0.3-28-56-ST Transformer 15
Figure 2-5: 80 VDC Motor Power with a TV0.3-28-56-ST Transformer 16
Figure 2-6: 40 Volt DC Bus from 115 and 230 VAC Source 17
Figure 2-7: 80 Volt DC Bus from 115 and 230 VAC Source (TV0.3-56) 18
Figure 2-8: 160 Volt DC Bus from 115 and 230 VAC Source (TV0.3-56) 19
Figure 2-9: Control and Motor Power Wiring using a TM3 or TM5 Transformer 20
Figure 2-10: ACLine Filter (UFM-ST) 21
Figure 2-11: Brushless Motor Configuration 23
Figure 2-12: Encoder and Hall Signal Diagnostics 25
Figure 2-13: Motor Phasing Oscilloscope Example 26
Figure 2-14: Hall Phasing with Oscilloscope 27
Figure 2-15: Brushless Motor Phasing Goal 28
Figure 2-16: DC Brush Motor Configuration 29
Figure 2-17: Clockwise Motor Rotation 30
Figure 2-18: Stepper Motor Configuration 31
Figure 2-19: Clockwise Motor Rotation 32
Figure 2-20: Line Driver Encoder Interface (J103) 35
Figure 2-21: Serial Data Stream Interface 36
Figure 2-22: Serial Data Stream Interface 37
Figure 2-23: Analog Encoder Phasing Reference Diagram 38
Figure 2-24: Analog Encoder Interface (J103) 39
Figure 2-25: Encoder Phasing Reference Diagram (Standard) 40
Figure 2-26: Position Feedback in the DiagnosticDisplay 41
Figure 2-27: Hall-Effect Inputs (J103) 42
Figure 2-28: Thermistor Interface Input (J103) 43
Figure 2-29: Encoder Fault Interface Input (J103) 44
Figure 2-30: End of Travel Limit Input Connections 45
Figure 2-31: End of Travel Limit Interface Input (J103) 46
Figure 2-32: Limit Input Diagnostic Display 47
Figure 2-33: ESTOPSenseInput (TB101) 49
Figure 2-34: Typical Emergency Stop Circuit 50
Figure 2-35: Auxiliary Encoder Channel (J104) 53
Figure 2-36: PSOInterface 55
Figure 2-37: Outputs Connected in Current Sinking Mode (J104) 57
Figure 2-38: Outputs Connected in Current Sourcing Mode (J104) 57
Figure 2-39: Inputs Connected in Current Sinking Mode (J104) 59
Figure 2-40: Inputs Connected in Current Sourcing Mode (J104) 59
Figure 2-41: High Speed User Inputs (J104) 60
Figure 2-42: Analog Output 0 (J104) 61
Figure 2-43: Analog Input 0 (J104) 62
Figure 2-44: Brake Connected to J103 64
Figure 2-45: Brake Connected to TB103 65
Figure 2-46: RS-232 Interface (TB103) 67
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Figure 3-1: Soloist CP with -IO Option Board 73
Figure 3-2: Analog Output 1 Connector (TB201) 74
Figure 3-3: Analog Input Typical Connection (TB201) 75
Figure 3-4: Opto-Isolated Inputs 77
Figure 3-5: Inputs Connected to a Current Sourcing Device 78
Figure 3-6: Inputs Connected to a Current Sinking Device 78
Figure 3-7: Opto-Isolated Outputs (-IOBoard) 80
Figure 3-8: Outputs Connected in Current Sourcing Mode 81
Figure 3-9: Outputs Connected in Current Sinking Mode 82
Figure 3-10: Brake Connected to J103 85
Figure 3-11: Brake Connected to TB206 86
Figure 4-1: Single Axis Joystick Interface (to Aux I/O) 88
Figure 4-2: Two Axis Joystick Interface (to the Aux I/O of two drives) 89
Figure 4-3: Two Axis Joystick Interface (to the Aux I/O and I/O Board) 89
Figure 4-4: Two Axis Joystick Interface (to the I/Oboard of two drives) 90
Figure 4-5: Handwheel Interconnection (to Aux I/O) 91
Figure 4-6: Handwheel Interconnection (to Aux I/O via a BBA32 Module) 91
Figure 5-1: Control Board Assembly 94
Soloist CP Table of Contents

Table of Contents Soloist CP
List of Tables
Table 1-1: FeatureSummary 2
Table 1-2: Accessories 3
Table 1-3: Soloist Drive and Software Compatibility 5
Table 1-4: Electrical Specifications 6
Table 1-5: Physical Specifications 9
Table 1-6: Heat Sink Specifications 9
Table 2-1: Control Supply ACInput Wiring 12
Table 2-2: Control Supply Mating Connector 12
Table 2-3: Motor Supply Mating Connector 13
Table 2-4: Nominal Motor Operating Voltages / Required ACVoltages 14
Table 2-5: TransformerOptions 14
Table 2-6: Motor Supply Input Wiring 21
Table 2-7: UFM-STElectrical Specifications 21
Table 2-8: Motor Power Output Connections (TB102) 22
Table 2-9: Motor Power Output Mating Connector 22
Table 2-10: Wire Colors for Aerotech Supplied Cables (Brushless) 23
Table 2-11: Wire Colors for Aerotech Supplied Cables (DCBrush) 29
Table 2-12: Wire Colors for Aerotech Supplied Cables (Stepper) 31
Table 2-13: Motor Feedback Connector Pin Assignment (J103) 33
Table 2-14: Encoder Interface Pin Assignment 34
Table 2-15: Analog Encoder Specifications 38
Table 2-16: Hall-Effect Feedback Interface Pin Assignment (J103) 42
Table 2-17: Hall-Effect Feedback Interface Pin Assignment (J103) 43
Table 2-18: Encoder Fault Interface Pin Assignment (J103) 44
Table 2-19: End of Travel Limit Input Interface Pin Assignment (J103) 45
Table 2-20: Brake Output Pin Assignment (J103) 48
Table 2-21: Electrical Noise Suppression Devices 49
Table 2-22: Electrical Noise Suppression Devices 49
Table 2-23: TB101 Mating Connector 49
Table 2-24: Typical ESTOPRelay Ratings 50
Table 2-25: Auxiliary I/O Connector Pin Assignment (J104) 51
Table 2-26: Auxiliary Encoder Channel Pin Assignment (J104) 52
Table 2-27: PSOOutput Pin Assignment (J104) 54
Table 2-28: PSO Output Sources 54
Table 2-29: Port 0 Digital Output Connector Pin Assignment (J104) 56
Table 2-30: Digital Output Specifications 56
Table 2-31: Port 0 Digital Input Connector Pin Assignment (J104) 58
Table 2-32: PS2806-4 Opto-Device Specifications 58
Table 2-33: Port 0 High Speed Digital Input Connector Pin Assignment (J104) 60
Table 2-34: Input Voltage Jumper Configuration 60
Table 2-35: Analog Output Connector Pin Assignment (J104) 61
Table 2-36: Analog Input Connector Pin Assignment (J104) 62
Table 2-37: Brake Output Connector Pin Assignment (TB103) 63
Table 2-38: Mating Connector (TB103) 63
Table 2-39: Brake Output Connector Pin Assignment (J103) 63
Table 2-40: Relay Specifications 66
Table 2-41: RS-232 Connector Pin Assignment (TB103) 67
Table 2-42: RS-232 Port Connector Mating Connector (TB103) 67
Table 2-43: Recommended Shunt Resistors and Wire Gauge 68
Table 2-44: External Shunt Mating Connector 68
Table 2-45: Maximum Storage Energy 69
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Table 3-1: -IO Expansion Board Jumper Configuration 73
Table 3-2: -IO Option Board Fuse Information 73
Table 3-3: Analog Output Connector Pin Assignment (TB201) 74
Table 3-4: Analog Output Mating Connector 74
Table 3-5: Analog Inputs Connector Pin Assignment (TB201) 75
Table 3-6: Analog Input Mating Connector 75
Table 3-7: PS2806-4 Opto-Device Specifications 76
Table 3-8: Port 1 Opto-Isolated Input Connector Pin Assignment (TB204) 76
Table 3-9: Port 2 Opto-Isolated Input Connector Pin Assignment (TB205) 76
Table 3-10: Opto-Isolated Input Mating Connector 76
Table 3-11: Port 1 Opto-Isolated Output Connector Pin Assignment (TB202) 79
Table 3-12: Port 2 Opto-Isolated Output Connector Pin Assignment (TB203) 79
Table 3-13: Opto-Isolated Output Mating Connector 79
Table 3-14: Output Specifications (TB202, TB203) 81
Table 3-15: User Common Connector Pin Assignment (TB204) 83
Table 3-16: +5 Volt Power Connector Pin Assignment (TB205) 83
Table 3-17: -IO Expansion Board Brake Jumper Configuration 84
Table 3-18: Voltage and Current Specifications (TB206) 84
Table 3-19: Brake / Mechanical Relay Connector Pin Assignment (TB206) 85
Table 3-20: Mating Connector 85
Table 3-21: Brake / Mechanical Relay Connector Pin Assignment (J103) 85
Table 4-1: Standard Interconnection Cables 87
Table 4-2: Cable Part Numbers 90
Table 5-1: LEDDescription 93
Table 5-2: Control Board Jumper Configuration 95
Table 5-3: Control Board Fuse Information 95
Table 5-4: LEDDescription 95
Table 5-5: Preventative Maintenance 96
Soloist CP Table of Contents

Declaration of Conformity Soloist CP
EC Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Soloist CP
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 CP 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 CP Declaration of Conformity