Glentek SMA7115HP Installation and operating instructions

OPERATION
&
SERVICE MANUAL
Model SMA7115
Model SMA7115HP
Brush Type Amplifier System

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SMA7115 MANUAL
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................5
CHAPTER ONE: DESCRIPTION, FEATURES AND SPECIFICATIONS
1.1 Description...........................................................................................................6
1.2 Features...............................................................................................................6
1.2.1 Single Amplifier Module (SMA7115-1)................................................................6
1.2.2 Stand Alone One Axis Amplifier (SMA7115-1A-1)...............................................6
1.2.3 Multi-Axis Power Supply (GP8600-70)................................................................7
1.3 Specifications.......................................................................................................7
1.3.1 Single Amplifier Module (SMA7115-1)................................................................7
1.3.1.1 Input and Output Power ..........................................................................8
1.3.1.2 Signal Inputs............................................................................................8
1.3.1.3 Digital Inputs............................................................................................8
1.3.1.4 System.....................................................................................................8
1.3.1.5 Outputs....................................................................................................8
1.3.2 Stand Alone One Axis Amplifier (SMA7115-1A-1)...................................................8
1.3.3 Multi-Axis Power Supply (GP8600-70) ...................................................................9
1.3.3.1 Input and Output Power................................................................................9
1.3.4 Mechanical ............................................................................................................9
CHAPTER TWO: THEORY OF OPERATION
2.1 Introduction........................................................................................................10
2.2 Driving DC Servo Motors ...................................................................................10
2.3 Servo Loops.......................................................................................................10
2.4 Brushed Motors vs Brushless Motors.................................................................11
2.5 Operation of Output Switching Transistors.........................................................12
2.6 “ H ” Type Output Bridge Configuration..............................................................12
2.7 Pulse-Width-Modulation (PWM).........................................................................13
2.8 Current-Loop Operation.....................................................................................13
2.9 Velocity-Loop Operation.....................................................................................14
2.10 Protection Circuits..............................................................................................14
CHAPTER THREE: MODEL NUMBERING
3.1 Introduction........................................................................................................15
3.2 Single Amplifier Module .....................................................................................15
3.3 Stand Alone One Axis Amplifier.........................................................................16
3.4 Multi-axis Amplifier.............................................................................................16
CHAPTER FOUR: INSTALLATION
4.1 Introduction........................................................................................................17
4.2 Mounting............................................................................................................17
4.3 Wiring ................................................................................................................17
4.3.1 RFI/EMI and Wiring Technique.........................................................................17
4.3.2 Wire Size and Type..........................................................................................17
4.3.3 Connector Size and Type.................................................................................17
4.3.3.1 The Power Connector of the Single Amplifier Module.............................17
4.3.3.2 The Signal Connector.............................................................................18
4.3.3.3 The Power & Motor Connectors of the Stand Alone Amplifier .................18
4.3.4 Amplifier Module Connections..........................................................................18
4.3.4.1 The Power Connections.........................................................................18
4.3.4.2 The Signal Connections.........................................................................19
4.3.5 Stand Alone One Axis Amplifier Connections ...................................................19
4.3.6 Multi-Axis Amplifier Connections ......................................................................19

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CHAPTER FIVE: CONFIGURATION
5.1 Introduction ....................................................................................................... 20
5.2 Logic Input Configuration................................................................................... 20
5.2.1 15V/+5 Logic Level Configuration..................................................................... 20
5.2.2 Velocity Mode and Current Mode Configuration ............................................... 20
5.2.3 Integrator Configuration ................................................................................... 20
5.2.4 Stop Function .................................................................................................. 20
CHAPTER SIX: START UP AND CALIBRATION
6.1 Introduction ....................................................................................................... 21
6.2 Initial Start Up.................................................................................................... 21
6.3 Calibration of the Velocity Mode Amplifier......................................................... 21
6.4 Calibration of the Current Mode Amplifier.......................................................... 23
6.5 Calibration Setup Record .................................................................................. 24
CHAPTER SEVEN: MAINTENANCE, REPAIR, AND WARRANTY
7.1 Maintenance...................................................................................................... 25
7.2 Amplifier Faults ................................................................................................. 25
7.2.1 Table of Fault LED Conditions ......................................................................... 25
7.2.2 Under Voltage Fault......................................................................................... 25
7.2.3 High Speed Electronic Circuit Breaker (HS/ECB) Fault..................................... 25
7.2.4 Low Speed Electronic Circuit Breaker (LS/ECB) Fault...................................... 26
7.2.5 Over Temp Fault.............................................................................................. 26
7.2.6 Over Voltage Fault........................................................................................... 26
7.2.7 Resetting A Fault............................................................................................. 26
7.3 Amplifier Failure ................................................................................................ 26
7.4 Factory Repair................................................................................................... 26
7.5 Warranty ........................................................................................................... 27
APPENDIX A: AMPLIFIER DRAWINGS
SMA7115 & SMA7115HP Installation Schematic (7015-4042) .................................. 29
SMA7115 Installation Drawings (7015-4043)............................................................. 30
SMA7115-1A-1 Installation Drawing for the Stand Alone Amplifier (7015-4044)........ 32
SMA7115-2A-2 2 AXIS Amplifier Installation Drawing (7115-1033).......................... 33
SMA7115-4A-4 4 AXIS Amplifier Installation Drawing (7115-1032).......................... 34
APPENDIX B: POWER SUPPLY
GP8600-70 60A Power Supply Assembly Drawing (8600-2030)................................ 36
APPENDIX C: EUROPEAN UNION EMC DIRECTIVES
Electromagnetic Compatibility Guidelines for Machine Design................................... 38
CE Certification.......................................................................................................... 43
TABLE OF CONTENTS

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SMA7115 MANUAL
Introduction
Glentek's brush type and brushless DC servo motors and amplifiers offer the ultimate in low maintenance and high
performance motion control. Glentek offers a full line of matched motors and amplifiers to meet virtually every motion
control application.
This manual provides all the technical information necessary to install, configure, operate, and maintain our
TORQUE-SWITCH™ series, brush type servo amplifier, model SMA7115. There is also an informative theory-of-
operation chapter.
We suggest that you take the time to read this manual from cover-to-cover before attempting to work with
these amplifiers for the first time. If at any time you have questions, or have any special requirements, please feel
free to call and discuss them with a Glentek applications engineer. We are happy to provide both off-the-shelf and
custom products. With over three decades in the servo-motor/amplifier business, we have a vast pool of applications
knowledge waiting to assist you.
Thank you for selecting Glentek for your motion control needs. It is our goal to save you time, money, and to provide
you with a superior product.
iNTRODUCTION

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Chapter One: Description, Features and Specifications
1.1 Description:
This brush type servo amplifier system has been designed to offer you, our customer, a large degree of flexibility and
customization with a standard, in stock product. The amplifier is of a modular, ‘open’ construction for ease of
installation and service.
The amplifier system is available in the following types of configurations:
•As amplifier modules, SMA7115-1, where you supply the DC Buss voltage, cooling fan(s), fusing and shunt
regulator. Please see section 1.2.1 for more detailed information.
•As a stand alone one axis amplifier, SMA7115-1A-1, which contains a DC power supply, cooling fan, soft
start circuitry, fusing and a shunt regulator. Please see section 1.2.2 for more detailed information.
•For multi-axis applications, the multi-axis baseplate power supply can supply DC power, cooling fans, zero
crossing solid state relays, fusing and a shunt regulator for up to 4axis or 60 amperes continuous. Please
see section 1.2.3 for more detailed information.
Each amplifier accepts a bipolar DC control input. The polarity of this signal determines the direction of rotation. This
signal may be used to control either the velocity (RPM) or the current (torque) of the motor (see Servo Loops, section
2.3). The amplifier provides Pulse-Width Modulated (PWM) power to the motor in proportion to the input signal.
Each amplifier has several ‘logic’ inputs to stop the motor in one or both directions. These inputs are very useful for
connecting to mechanical limit switches or digital equipment.
Each amplifier has several protection circuits to protect the amplifier, motor, and operator from almost any kind of
fault. LED’s show what fault has occurred, and a separate output can be used to signal other equipment.
1.2 Features:
1.2.1 Single Amplifier Module (SMA7115-1):
•Ergonomic design: Easy access to connections, adjustments, and test points.
•Wide operating 30-220VDC.
buss voltage:
•Complete isolation: Complete isolation from input to output.
•Dual signal inputs: Two single-ended or one differential. Both single-ended inputs may be use
simultaneously. All inputs have up to 15,000A/V gain (velocity mode), and
inputs will accept up to ±13VDC.
•Dual mode operation: The amplifier may be field configured for velocity (RPM) control or current
torque control.
•Current limit: Maximum peak motor current is adjustable.
•Digital limit/enable Three separate logic inputs can stop the motor in either or both directions.
Inputs: Inputs may be configured for active-high or active-low, pull-up termination,
and a 0 to +5VDC or 0 to +15VDC range. See Logic Input Configuration,
section 5.2.
•Fault input/output: Open-collector output goes low in the event of a fault. Externally forcing the
output low will inhibit the amplifier. This allows all fault outputs in a multi-
axis system to be connected together (wire-ORed) to shut down all
amplifiers should any amplifier have a fault.
•Silent operation: Carrier frequency is 20KHz.
•Short circuit protection: Complete short circuit and ground fault protection.
•LED diagnostics: A Red LED flashes to display various fault conditions and a green LED
illuminates to indicate normal operating conditions.
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS

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CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS
•Frequency response 750 Hz minimum.
(Velocity Loop):
•Frequency response 2 KHz minimum.
(Current Loop):
•External fault reset: Aseparate input is provided to reset the amplifier after a fault.
•High-Speed Electronic Instantly shuts down the amplifier in the event of a short across outputs and
Circuit Breaker or ground fault condition.
(HS/ECB): (i.e. amplifier exceeds 80A for 10microseconds)
•Low-Speed Electronic Shuts down the amplifier if the amplifier is operated above the maximum
Circuit Breaker continuous current rating (i.e. 15A for standard, 20A for high power) for
(LS/ECB): 3seconds.
•Over/under voltage These circuits constantly monitor amplifier power-supply voltages, and
and over temperature: amplifier-heatsink temperature. They will shut down the amplifier in the
event of any out-of-specification amplifier condition.
•Surface mount technology: Constructed with surface mount components.
•Current fold back: A factory option; Allows the motor current to “fold back” i.e. drop to a safe
(Factory option) level after a pre-determined time.
•Multi-axis chassis: Up to four amplifier modules may be mounted on a single baseplate. Multi-
axis baseplate includesa DC power supply, cooling fan(s) and wiring for
each respective amplifier module.
1.2.2 Stand Alone One Axis Amplifier (SMA7115-1A-1):
The stand alone amplifier includes all of the features that the single amplifier module has, and also includes the
following additional features.
•Line operated AC power operation, 110-130VAC: Fused single or three phase AC input with in-rush
current protection at turn-on. No power isolation transformer is required.
•Fused regen clamp circuit (shunt regulator) with LED indicator and 50W internal load resistor bank bleeds
off excess DC Buss voltage when decelerating a large load inertia. The regen clamp circuit is set to turn
on at 215VDC.
•All faults can be monitored through isolated logic signals.
•Bridge rectifier(s) and filter capacitor.
•Cooling fans.
1.2.3 Multi-Axis Power Supply (GP8600-70):
•Power supply for 2 to 4axis amplifier baseplates. Line operated AC power operation: Fused single or
three phase AC inputs with a solid state zero-crossing switch which limits in-rush current at turn-on. No
power isolation transformer is required.
•Fused regen clamp circuit (shunt regulator) with LED indicator and 95W internal load resistor bank bleeds
off excess DC Buss voltage when decelerating a large load inertia. Additional regen resistors can be
connected externally. The regen clamp circuit is set to turn on at 215VDC.
•All faults can be monitored through isolated logic signals.
•Bridge rectifier(s) and filter capacitor.
•Cooling fans.
1.3 Specifications:
1.3.1 Single Amplifier Module (SMA7115-1):
The amplifier module requires an external DC power supply which must include a bridge rectifier, buss
capacitor, solid-state relay and shunt regulator. Forced air cooling is required to meet the maximum
power ratings specified below.

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1.3.1.1 Input and Output Power:
•Buss Voltage, B+: 30-220VDC.
•Output Current:Standard: 15A(continuous), 25A(peak).
High Power:20A(continuous), 40A(peak).
1.3.1.2 Signal Inputs:
1.3.1.3 Digital Inputs:
•±Limit, Inhibit and Reset: +24V max. Terminated by 10K ohms.
•Fault (as input): +40V/-5v max. Terminated by 10K ohms.
•Typical for all digital inputs: Digital inputs have hysteresis with thresholds at 1/3 and 2/3 of +5V or +15V
depending on range selected.
1.3.1.4 System:
•Drift offset over temperature reference to input: 0.01mV/ o C max.
•Frequency response (Velocity loop): 750Hz min.
•Frequency response (Current loop): 2KHz min.
•Dead band: None.
•Form factor: 1.01.
1.3.1.5 Outputs:
•Fault (as output): Active low. Open-collector output can sink 75mA max. through 10 ohms.
•Absolute motor current: Bipolar output. 1V=5A. 10mA max.
•LS/ECB, HS/ECB Open-collector outputs can sink 40mA max.
Overvolt, Overtemp:
1.3.2 Stand Alone One Axis Amplifier (SMA7115-1A-1):
The stand alone one axis amplifier contains a single amplifier module, a DC power supply, a cooling fan, fusing
and shunt regulator in a sheet metal enclosure. It has the same specifications as the single amplifier module,
refer to 1.3.1, except the DC power supply and cooling fan are included. The shunt regulator within the DC
power supply has a 50W internal load resistor bank which bleeds off excess DC Buss voltage when
decelerating a large load inertia.
•Input Voltage: 110-130VAC (internally fused for 20A).
•Output Current:Standard: 15A (continuous), 25A (peak).
High Power: 20A (continuous), 40A (peak).
NOTE: Customer must specify Single or Three Phase AC input when ordering (see chapter 3: model
numbering), so that the proper power supply module can be installed.
Signal Input Voltage VDC
(maximum)
Impedance
(minimum)
ohms
Velocity Gain
Amp./Volt Current Gain Amp./Volt
Differential ±13 10,000 15,000 0-5
Single-ended ±70 4,000 15,000 0-5
Tachometer input ±50 10,000 7,000
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS

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1.3.3 Multi-Axis Power Supply (GP8600-70):
The multi-axis power supply contains all items listed under 1.2.3.
1.3.3.1 Input and Output Power:
•Input Voltage: 95-135VAC, 50 or 60Hz.
•Fan Voltage: 110-130VAC, 50 or 60Hz, 0.12A.
•Output Voltage, (B+): 133-189 VDC.
•Output Current:60A (continuous).
1.3.4 Mechanical:
Model L x W x H
(inches) Weight (lbs)
SMA7115-1(Single Amplifier Module) 7.12 x 1.36 x 4.79 1.28
SMA7115-1A-1 (Stand Alone Amplifier) 9.03 x 4.00 x 4.96 4.83
SMA7115-2A-2 (2-axis Amplifier System) 9.00 x 10.50 x 7.70 10.00
SMA7115-4A-4 (4-axis Amplifier System) 13.00 x 10.50 x 7.70 15.00
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS

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Chapter Two: Theory of Operation
2.1 Introduction:
This chapter contains the basic control theory of how brush type and brushless servo motors and amplifiers operate.
It also compares and contrasts the advantages and disadvantages of brushless and brush type motors and amplifiers
to help you select which is best suited for your application. The following is a summary of the topics:
•The theory behind an amplifier driving DC servo motors.
•A comparison between brush type and brushless motors.
•Operation of output switching transistors.
•“H Type” output bridge configuration.
•Pulse-Width-Modulation (PWM).
•Current-Loop and Velocity-Loop operation.
•Protection circuits.
2.2 Driving DC Servo-Motors:
The torque of any DC motor is proportional to motor current: the stronger the magnetic field, the stronger the pull.
Motor current may be controlled in two ways: linear and PWM (Pulse-Width Modulation). Linear control is achieved
by simply inserting a resistance in series with the motor. This resistance is usually a partially turned on transistor.
The transistor is said to be in its "linear" region. Linear amplifiers are simple, accurate, and effective. However, they
are very inefficient and they generate a lot of heat. Linear amplifiers are used when low electrical noise, high
bandwidths (2KHz or higher) and or low inductance (less than 1mH) motors are used. In pulse-width modulation the
control devices (output transistors) are rapidly turned full on and full off. The ratio of the on time (the pulse width) and
off time determines the average motor current. Refer to figure 2.1. For example: if the output is on 25% of the time
and off 75% of the time, the average motor current is approximately 25% of maximum.
A coil of wire, such as the windings of a motor, forms an inductor. Inductors resist changes in current. This
resistance to change, known as reactance, acts to dampen or average the high-current spikes that would otherwise
occur when the output devices are on. In fact, if motor inductance is low, external inductors may have to be added in
series with each motor lead to ensure proper operation.
A brush type motor may be run from a steady DC voltage since the brushes and commutator switch the current from
winding to winding. However, a brushless motor requires that the voltage be switched from winding to winding
externally; the voltage that drives a brushless motor is a constantly changing AC waveform. Section 2.5 discusses
these waveforms.
2.3 Servo Loops:
A basic velocity mode servo loop for a brush type motor is shown in figure 2.2a. An external controller commands a
given velocity (RPM). The velocity loop summing amplifier compares this command with the actual motor velocity,
supplied by a DC tachometer on the motor shaft, and produces an error voltage proportional to the difference
between the actual and commanded velocity.
The velocity error is used to command motor current in the inner servo-loop. The current loop summing amplifier
compares the command current (velocity error) with the actual current in the motor and produces an error voltage
proportional to the difference between the actual and commanded current.
Finally, the current error signal is used to produce an output (linear or PWM) to drive the motor.
The velocity loop may be bypassed, and an external current command fed directly to the current loop. In this case,
Figure 2.1
Pulse Width Modulation Waveform
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SMA7115 MANUAL
the external command signal controls the torque of the motor, rather than the velocity. This is known as current-
mode operation.
The servo-loops of a brushless amplifier (figure 2.2b) operate in much the same way, except there are now three
current loops, one for each phase of the motor.
2.4 Brushed Motors vs. Brushless Motors:
There are two basic types of motor design that are used for high-performance motion control systems: brush type PM
(permanent magnet), and brushless type PM. As you can see in figure 2.3, a brush type motor has windings on the
rotor (shaft) and magnets in the stator (frame). In a brushless type motor, the magnets are on the rotor and the
windings are in the stator.
To produce optimal torque in a motor, it is necessary to direct the flow of current to the appropriate windings with
respect to the magnetic fields of the permanent magnets. In a brush-type motor, this is accomplished by using a
commutator and brushes. The brushes, which are mounted in the stator, are connected to the motor wires, and the
commutator contacts, which are mounted on the rotor, are connected to the windings. As the rotor turns, the brushes
switch the current flow to the windings which are optimally oriented with respect to the magnetic field, which in turn
produces maximum torque.
In a brushless motor there is no commutator to direct the current flow through the windings. Instead, an encoder, hall
sensors or a resolver on the motor shaft senses the rotor position (and thus the magnet orientation). The position
data is fed to the amplifier which in turn commutates the motor electronically by directing the current through the
appropriate windings to produce maximum torque. The effect is analogous to a string of sequencing Christmas lights:
the lights seem to chase each other around the string. In this case, the magnets on the rotor "chase" the magnetic
fields of the windings as the fields "move" around the stator.
The relative advantages and/or disadvantages of a brush type motor/amplifier combination vs. a brushless motor/
amplifier combination can be significant. On the next page is a summary of advantages and disadvantages of brush
type motor/amplifiers and brushless type motor/amplifiers to help you decide which type to select for your
applications.
Figure 2.2a
Velocity mode sevo loop
for a brush type motor
Figure 2.2b
Velocity mode sevo loop
for a brushless motor
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2.5 Operation of Output Switching Transistors:
The output transistors, for all intents and purposes, operate in only two states. They are analogous to ON/OFF
switches. When an output transistor is OFF , there is no current flowing through it (its resistance is infinite). When an
output transistor is ON, current flows through it (its resistance is near zero). When the transistor is ON, it is
technically referred to as being in saturation.
2.6 “H” Type Output Bridge Configuration:
The output configuration of the amplifier is an “H TYPE” bridge (see figure 2.4 for schematic representation of an
output bridge with a motor connected).
Figure 2.3
Brush type and Brushless type Motors
Figure 2.4
Schematic representation of
an output bridge with a
motor connected.
Brushless Motors/Amplifiers Brushed Motors/Amplifiers
Advantages Disadvantages
No scheduled maintenance and no brush dust
is generated. Motor brushes must be checked periodically for wear and excess brush dust.
Higher RPM limits. Approximately 3000RPM maximum.
Lower inertia/torque ratio. Higher inertia to torque ratio.
Dissipates heat more efficiently due to windings
being located in stator. Not as efficient at dissipating heat. Heat is trapped at rotor and shortens bearing life.
Safer for explosive atmospheres. Quieter and
less electrical noise generated. Brushes spark and generate electrical and audible noise.
Disadvantages Advantages
Amplifiers are complicated and expensive. Amplifiers are simpler and less expensive.
Higher torque ripple. Lower torque ripple.
No Industry standard packaging. Industry standard packaging.
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The advantage of an “H TYPE” output bridge configuration is that by controlling the switching of the opposite pairs of
transistors, current can be made to flow through the motor in either direction using a single-polarity power supply.
To provide motor current in one direction, transistor A and C are turned ON, while B and D remain in the OFF state.
To provide motor current in the other direction, B and D are turned ON, while A and C remain in the OFF state.
2.7 Pulse-Width-Modulation (PWM):
Pulse-width-modulation is the technique used for switching opposite pairs of output transistors ON and OFF to control
the motor drive current. When zero current is commanded to the current loop, the opposite pairs of transistor are
turned ON and OFF as shown in figure 2.5. Note that since the pulse widths are equal, the net DC current in the
motor is equal to zero.
When a non-zero current is commanded to the current loop, the transistor switching waveform is as shown in figure
2.6A. Since there is a non-zero current command, the output transistor pulse widths will change and the motor will
see a net DC current flowing from A through C.
If the input to the current loop had been changed in polarity, the output transistor switching waveform would be as
shown in figure 2.6B.
If a larger current of the same polarity was commanded to the output transistor (see figure 2.6B) the ON-time widths
of B and D would automatically increase to provide more current.
From the previous examples it is easy to understand why this output transistor switching technique is referred to as
pulse-width-modulation.
To change the magnitude and polarity of the current flow in the motor, the pulse widths of the opposite pairs of
transistors are modulated. The frequency at which these output transistors are switched ON and OFF is referred to
as the ‘carrier frequency’.
Now that we have a good understanding of how the current is provided from an “H TYPE” pulse-width-modulated
(PWM) bridge, let’s analyze the operation of the current loop.
2.8 Current Loop Operation:
Please refer to figure 2.2A for a diagram of the current loop. In control electronics the symbol Sigma (with the circle
around it) is referred to as a ‘summing junction’. The manner in which this summing junction operates is as follows:
The current-command signal (also referred to as the velocity error signal when received from the output of the
Figure 2.6A
Transistor switching
waveform when current
flows from A through C
Figure 2.5
Transistor switching
waveform at zero
current
Figure 2.6B
Transistor switching
waveform when current
flows from B through D

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velocity loop, as shown in figure 2.2A) is added to the current feedback signal. The signal resulting from this addition,
is referred to as the “current error” signal. This current-error signal is fed into the current amplifier, which in turn
produces a current in the motor. A voltage which is proportional to the motor current is developed across Rs (shunt
resistor). This voltage is referred to as the “current feedback” signal. The current in the motor increases until the
current-command signal. At this point the current error signal drops to zero. and the actual current is equal to the
commanded current. If anything happens to disturb either the current command signal, or the current feedback
signal, the same process occurs again until the current feedback signal is equal in magnitude to the current command
signal, but opposite in polarity.
The type of loop described above is referred to as a “servo loop” because the current servos about a commanded
value.
We are surrounded in our everyday lives by a multitude of servo loops. For example, many of today’s luxury cars
have what is called ‘automatic climate control’. To operate this servo loop, you set the climate control to the
temperature that you wish to be maintained in the interior of the car (current command signal). The selected
temperature is then summed with the actual temperature from a thermometer (current feedback), and the output
(current error signal) activates either the heater or the air conditioner until the actual temperature as measured by the
thermometer (current feedback signal) is equal in magnitude, but opposite in polarity, to the set temperature.
2.9 Velocity Loop Operation:
Please refer to figure 2.2A for a diagram of a typical velocity loop. The velocity loop’s operational description is
analogous to the current loop description, except for the fact that the input signal is called the Velocity Command and
the feedback signal from the DC tachometer is called the Velocity Feedback.
2.10 Protection Circuits:
The High and Low Speed Electronic Circuit Breakers (HS/ECB and LS/ECB) protect the amplifier and motor from
being damaged by high motor current (specified max. peak and rms current values). The Over Temperature and
Over Voltage detection circuits will shut off the amplifier when the temperature of the amplifier or the buss (B+)
voltage exceeds a specified limit. Also, there are circuits which limit the motor from running in either or both
directions.
CHAPTER
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THEORY OF OPERATION

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Chapter Three: Model Numbering
3.1 Introduction:
This chapter contains the model numbering system for the SMA7115 single amplifier module, stand alone one axis
amplifier and multi-axis amplifier system. The model numbering system is designed so that you, our customer,will be
able to create the correct model number of the product that you need quickly and as accurate as possible.
3.2 Single Amplifier Module:
Optional Custom
Configuration Code.
(A numerical code will be assigned
by Glentek to amplifiers whose
specifications vary from the stan-
dard configuration.)
Power Rating
Omit = Standard
HP = High Power
Amplifier Model Number Single Module
Amplifier Configuration Code
SMA7115XX—YYY—QQQ—1
Amplifier Configuration Code
±Limit 0=L, 1=H see sect.5.2
±Limit 0=U see sect.5.2
Inhibit 0=L, 1=H see sect.5.2
Inhibit 0=U see sect.5.2
Reset 0=L, 1=H see sect.5.2
Reset 0=U see sect.5.2
See section 5.2 
Type A: U=0 & L=0
(Default)
Type C: U=0 & H=1
00 000
0000=0 1000=8
0001=1 1001=9
0010=2 1010=A
0011=3 1011=B
0100=4 1100=C
0101=5 1101=D
0110=6 1110=E
0111=7 1111=F
4 Bit Binary-to-Digital
Conversion
Differential or Single-ended input:
0 = Single-ended; (Default)
1 = Differential.
Velocity or Current Mode:
0=Velocity; 1=Current.
(see section 2.8 & 2.9)
On Board Power Supply
+15V / +5V on pull-up:
0 = +15V (Default)
1 = +5V
DC Buss Voltage
0 = 30-220VDC; (Default)
1 = Special.
CHAPTER 3: MODEL NUMBERING

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3.3 Stand Alone One Axis Amplifier:
3.4Multi-Axis Amplifier:
NOTE: The multi-axis amplifier label will be mounted on the baseplate and each amplifier module will contain
its own label and serial number.
SMA7_15XX -__ -7_15XX/_ -___ -_A -_ -ZZ -RRR
Type of Amplifier Model
Power Rating
Omit = Standard
HP = High Power
Pre-amp & Custom Configuration
Code (See sect. 3.2)
Optional Custom Con-
figuration Code for the
Power Supply and Regen
Circuit
Power Supply Configuration
Code
00 = 110-130VAC
01 = 208-240VAC
02 = Special
The total number of amplifier
modules mounted on the base-
plate
Maximum number of amplifier
modules the baseplate will hold.
2 = 2 axis baseplate
4= 4 axis baseplate
Second type of amplifier module on
baseplate.
Number of this type of amplifier
module(s) used
Pre-amp configuration code for second type
of amplifier if it is different from the first am-
plifier’s configuration code. NOTE: This will
be omitted if they are the same.
When there is only one type of amplifier used on the baseplate,
this part of the model number will be omitted. If there are more
than two types of amplifier modules on the baseplate, this part
of the model number will be repeated for each amplifier type.
SMA7115XX -YYY -QQQ -1A -1 -ZZ -RRR
Amplifier Model Number
Power Rating
Omit = Standard
HP = High Power
Optional Custom Configuration
Code for the Power Supply and
Regen Circuit
Power Supply Configuration
Code
00 = 110-130VAC, Single Phase
01 = 110-130VAC, Three Phase
02 = Special
Amplifier Configuration Code
Optional Custom Configuration Code
for the amplifier module
Stand alone amplifier designator
1 amplifier module mounted
CHAPTER 3: MODEL NUMBERING

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SMA7115 MANUAL
Chapter Four: Installation
4.1 Introduction:
This chapter provides the necessary information to make all the wiring connections for the amplifiers to operate
properly.
4.2 Mounting:
Appendix A contains all the wiring diagrams, assembly drawings, and mechanical information necessary to install the
amplifiers. The amplifier package should be mounted in a clean, dry enclosure, free of dust, oil, or other
contaminants.
NEVER INSTALL THE AMPLIFIER PACKAGE IN ANY LOCATIONWHERE FLAMMABLE OR EXPLOSIVE
VAPORS ARE PRESENT.
IMPORTANT: Muffin fan(s) are mounted along one edge of the baseplate to provide cooling. At least 3 inches must
be allowed between the fan side and the side opposite the fans and any other surface. The clearance to any other
side of the amplifier package is not critical, although sufficient space should be allowed for easy wiring and servicing.
4.3 Wiring:
DO NOT APPLY POWER UNTIL INSTRUCTED TO DO SO.
4.3.1 RFI/EMI and Wiring Technique:
IMPORTANT: All PWM equipment inherently generates radio-frequency interference (RFI), and wiring acts as
antennae to transmit this interference. In addition, motors inherently generate electromagnetic interference
(EMI). Unless the wiring is very short, some sort of shielding on the motor wires is necessary to meet FCC
RFI/EMI guidelines and to protect other equipment from the effects of RFI/EMI. We recommend that shielded
wire be used, or the wires should be run in metallic conduit. The shield or conduit should be connected to the
amplifier baseplate, which in turn must be earth grounded. In addition, a conductor of the same gauge as the
motor wires must be connected from the motor case to the amplifier baseplate to provide protection from
shock hazard. The earth grounding is necessary to meet National Electrical Code (NEC) requirements as well
as suppressing RFI/EMI.
Additional RFI suppression may be obtained by placing inductors in each motor lead near the amplifier.
Consult a Glentek applications engineer for inductor recommendations. Glentek stocks a complete line of
inductors for virtually every application.
IMPORTANT: The signal wiring to the tachometer (if used) and the signal inputs to the amplifier are
susceptible to noise pickup. Excessive noise pickup will cause erratic amplifier operation. We urge that each
signal input line each be run in separate, twisted-pair, shielded cable. In each case the shield should be
terminated at the amplifier end only to a common terminal. We also recommend that the signal lines be kept
as far as possible from any power or motor wires.
4.3.2 Wire Size and Type:
IMPORTANT: To ensure safe operation, Glentek strongly recommends that all wiring conform to all local and
national codes.
Recommended Wire Size and Type:
•Motor Wires: 14AWG, shielded -Standard Version.
12AWG, shielded -High Power Version.
•Motor Case Ground: Same as motor wires, or use metallic conduit.
•Main Power: 14AWG (single axis) or 12AWG (multi-axis), twisted.
•Fan Power: 16AWG, twisted.
•Signal & Tach Input: 22AWG, twisted-pair, shielded.
•Logic Inputs/Outputs: 22AWG, shielded with its return lead.
4.3.3 Connector Size and Type:
4.3.3.1 The Power Connector of the Single Amplifier Module:
All amplifiers are shipped with the right angle AUGAT terminal block mounted as it power connector .
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The vertical angle AUGAT terminal block and the PHOENIX connector are two options one can choose
to use for the power connector. The specifications of all the mentioned connectors are listed as follows:
•AUGAT®RDI 6 Series Tri-Barrier Terminal Blocks(AUGAT P/N: 6PCR-04) -Default :
-Screw Size/Spacing: 6 (#6-32 on .375" centers).
-Terminal Style: PC (Printed Circuit Pin).
-Terminal Orientation: R (Right Angle).
-Number of Screw Terminals: 04 (4 screw positions).
-Terminal lugs: Thomas & Betts (T&B P/N: A116 for 18awg wire, B19 for 14awg wire and C133 for
12/10awg wire).
•AUGAT®RDI 6 Series Tri-Barrier Terminal Blocks(AUGAT P/N: 6PCV-04):
-Screw Size/Spacing: 6 (#6-32 on .375" centers).
-Terminal Style: PC (Printed Circuit Pin).
-Terminal Orientation: V (Vertical Angle).
-Number of Screw Terminals: 04 (4 screw positions).
-Terminal lugs: Thomas & Betts (T&B P/N: A116 for 18awg wire, B19 for 14awg wire and C133 for
12/10awg wire).
•PHOENIX CONTACT, COMBICON Headers and Plugs with 7.62mm pitch
(HEADER PART# GMSTBA 2,5/4-G-7,62),
(PLUG PART# GMVSTBR 2,5/4-ST-7,62):
-header with side panels, plug-in direction parallel to PCB.
-4 positions.
-color: green.
4.3.3.2 The Signal Connector -J1:
The signal connector is supported by the molex®KK .100" (2,54mm) Centerline Connector System.
•Mating Header: molex®7478 Series Right Angle Square Pin Friction Lock Header
(molex P/N: 22-12-2164):
-16 pins.
-.025" (0,64mm) right angle square brass pins.
-94V-0 nylon housing.
•Mating Connector: molex®2695 Series .100" (2,54mm) Center Crimp Terminal Housing
(molex P/N: 22-01-3167):
-red nylon housing.
-16 positions.
-with polarizing rib.
•Crimp Terminals: molex®Crimp Terminals (molex P/N: 08-55-0102):
-15 microinch select gold plated.
-brass.
4.3.3.3 The Power and Motor Connectors of the Stand Alone Amplifier -TB1 &2:
•PHOENIX CONTACT, COMBICON Headers and Plugs with 7.62mm pitch
(Header P/N: GMSTBA 2,5/4-G-7,62, Plug P/N: GMVSTBW 2,5/4-ST-7,62),
(Header P/N: GMSTBA 2,5/2-G-7,62, Plug P/N: GMVSTBR 2,5/4-ST-7,62):
-header with side panels, plug-in direction parallel to PCB.
-2 and 4 positions.
-color: green.
4.3.4 Amplifier Module Connections:
4.3.4.1 The Power Connections -TB1:
Signal Name Terminal Notes
BUS RETURN, B-TB1-1DC Buss -
BUSS, B+ TB1-2DC Buss +
MOTOR -TB1-3Motor -
MOTOR + TB1-4Motor +
CHAPTER 4: INSTALLATION

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CHAPTER 4: INSTALLATION
4.3.4.2 The Signal Connections -J1:
4.3.5 Stand Alone One Axis Power Connections:
4.3.6 Multi-Axis Chassis Power Connections:
Main Voltage:Connect 95-135VAC line input, single or three phase at TB1 (see Power Supply Sub-
assembly drawing 8600-7030).
Fan Voltage:Connect 110-130VAC, 50/60Hz for fans to TB1-5 and TB1-6.
Signal Name Terminal Notes
GND TB2-1Ground.
AC (OMIT FOR SINGLE PHASE) TB2-2110-130VAC power input.
AC TB2-3110-130VAC power input.
AC TB2-4110-130VAC power input.
Signal Name Terminal Notes
DIFF SIG IN (+) J1-1Differential signal input.
DIFF SIG RET (-) J1-2Differential signal return.
SIG IN (+) J1-3Single-ended signal input.
COMMON J1-4Common for all signals and shields.
TACH IN J1-5Tachometer input. Not used in current-mode.
MTR CUR J1-6Scale factor: 1V=5A.
LIMIT + J1-7Inhibits the motor in the + direction.
LIMIT -J1-8Inhibits the motor in the -direction.
INHIBIT J1-9Inhibits the motor in both directions.
FAULT J1-10 Goes low if there is a fault in the amplifier. May be
externally forced low to stop motor rotation in both
COMMON J1-11 Common for all signals and shields.
RESET J1-12 Resets the fault latch. May also be used as an inhibit
input.
LS/ECB J1-13 Goes high if the Low Speed Electronic Circuit Breaker
turns on.
HS/ECB J1-14 Goes high if the High-Speed Electronic Circuit Breaker
turns on.
OVERVOLT J1-15 Goes high if the buss voltage rises above 250VDC.
OVERTEMP J1-16 Goes high if the temperature of the amplifier rises above
the specified temp.

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Chapter Five: Configuration
5.1 Introduction:
Each amplifier has several configuration options. This chapter describes these options and how to implement them.
If desired, Glentek will be happy to pre-configure your amplifiers.
NOTE: Each amplifier module and multi-axis amplifier is configured and shipped according to the model number
(instructions to construct a model number is in chapter three) when the order is placed. It is important for the user to
realize that any changes to the jumpers (micro-shunts) by the user will result in discrepancies between the model
number and the actual configuration of the amplifier.
5.2 Logic Input Configuration:
There are four logic inputs: Limit +, Limit -, Inhibit and Reset In. They may be configured for active-high or active-low
signals, and all are pulled-up termination (type A or C). All logic inputs have a selectable 0 to +5VDC or 0 to +15VDC
range.
Type "A": Requires grounding of input to disable the amplifier (pull-up, active-low).
Type "C": Requires grounding of input to enable the amplifier (pull-up, active-high).
The following table shows how to configure the jumpers (micro-shunts) for the inputs selected. The standard
configuration is shown in bold.
5.2.1 +15V/+5V Logic Level Configuration (Default: J9 = Omit Jumper):
•+15V: J9 = Omit Jumper.
•+5V: J9 = Install Jumper.
5.2.2 Velocity Mode and Current Mode Configuration:
•Velocity Mode: J4 = Install Jumper, J5 = Omit Jumper.
•Current Mode: J4 = Omit Jumper, J5 = Install Jumper.
5.2.3 Integrator Configuration (Default: J6 = Omit Jumper):
The integrator circuit is used to lower the integration proportional break point in the velocity PID loop. The
lower break point may be required with motors having high inductance armatures. This jumper should remain
omitted unless instructed to install by a Glentek engineer.
5.2.4Stop Function (Default: J8-D = Omit Jumper):
If the stop function is enabled (jumper installed), when the amplifier is inhibited at J1-9, the amplifier will
actively decelerate the motor for 150 ms, then all current output from the amplifier will cease until the inhibit is
de-activated. This function only works when the amplifier is in velocity mode (see above). If the stop function is
disabled (jumper omitted), when the amplifier is inhibited, all amplifier current output immediately ceases.
Type A Type C
LIMIT ± J8–A = Install Jumper J8–A = Omit Jumper
INHIBIT J8–B = Install Jumper J8–B = Omit Jumper
RESET IN J8–C = Install Jumper J8–C = Omit Jumper
CHAPTER
5
:
CONFIGURATION

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SMA7115 MANUAL
Chapter Six: Start Up and Calibration
6.1 Introduction:
This chapter contains the procedure required for initial start up and amplifier calibration. The SMA7115 amplifier can
be configured to run in velocity mode (6.3) and current mode (6.4).
Required Equipment: Oscilloscope, voltmeter & battery box. The battery box serves as a step input voltage
command, applying and removing a flashlight battery can also be used for this function. Glentek sells a battery box,
BB-700, which is ideal for this function.
6.2 Initial Start Up:
When applying power to start up your amplifier system for the first time, we recommend you follow this procedure. If
you have already gone through this procedure you can skip to the appropriate calibration procedure.
1. Check for any loose or damaged components.
2. Check that all connections are tight. Be sure that the motor mechanism is clear of obstructions. If the
mechanism has limited motion,e.g:, a lead-screw, set the mechanism to mid-position.
3.Disconnect the signal and/or auxiliary inputs.
4.Be sure the Loop-Gain pot(s) are fully CCW.
5.Apply main power. Check for the correct AC voltage at power supply TB1. The DC Bus (amplifier supply-
voltage) will be 1.4 times this value.
6.Work on only one amplifier at a time.
6.3 Calibration of the Velocity Mode Amplifier:
The amplifier, in this configuration, receives an analog, bi-polar input command which is proportional to the required
motor velocity. The amplifier receives velocity feedback from a tachometer which is usually mounted to the rear of
the motor. The following pots will be set during calibration: (Note: RV7-RV11 are single turn pots and RV1-RV6are
20-turn pots.)
Note: RV8-RV11 are factory set and should not be adjusted. Adjusting these pots voids warranty.
Pots Name of Pot Notes
RV1 Differential Gain,
DIFF GAIN Sets the input voltage to velocity ratio for differential signal
input.
RV2Signal Gain,
SIG GAIN Sets the input voltage to velocity ratio for single-ended signal
input.
RV3Balance,
BAL Used to null any offsets in system.
RV4Tach. Gain,
TACH Sets the DC tachometer gain.
RV5Compensation,
COMP Used in conjunction with tach. gain to set the system
bandwidth.
RV6Current Limit,
CUR LIMIT Sets the maximum peak motor current. Shipped set CW
(max. current).
RV7LOOP GAIN Used to shut off uncalibrated amplifiers. When the loop gain
is full CCW, no current is delivered to the motor.
CHAPTER 6: START UP AND CALIBRATION