Glentek SMA8105 Installation and operating instructions

208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
OPERATION
&
SERVICE MANUAL
for
Torque-Switch Series®
Model SMA8105
Model SMA8205
Model SMA8305
Brushless Amplifier System
MANUAL#: 8005-1040
REVISION: (A)
DATE: 10-8-96.

2Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
TABLE OF CONTENTS Page
Introduction........................................................................................................6
Chapter One: Description, Features and Specifications
1.1 Description...................................................................................................7-8
1.2 Features.......................................................................................................8-9
1.2.1 Single Amplifier Module (SMA8X05-1)...............................................8-9
1.2.2 Multi-Axis Power Supply(GP8600-4000)............................................9
1.3 Specifications...............................................................................................10-11
1.3.1 Single Amplifier Module (SMA8X05-1)...............................................10-11
1.3.1.1 Input and Output Power............................................................10
1.3.1.2 Signal Inputs.............................................................................10
1.3.1.3 Digital Inputs.............................................................................10
1.3.1.4 System......................................................................................11
1.3.1.5 Outputs .....................................................................................11
1.3.2 Multi-Axis Power Supply.....................................................................11
1.3.2.1 Input and Output Power............................................................11
1.3.3 Mechanical.........................................................................................11
Chapter Two: Theory of Operation
2.1 Introduction..................................................................................................12
2.2 Driving DC Servo Motors.............................................................................12
2.3 Servo Loops.................................................................................................13
2.4 Brushed Motors vs Brushless Motors..........................................................14-15
2.5 Sinusoidal vs Trapezoidal............................................................................15
2.6 The Advantages and Disadvantages of a Trapezoidal Amplifier System....16
2.7 Current Mode vs Velocity Mode...................................................................16
2.8 Tachometer (Velocity Mode) Feedback Options .........................................17
2.9 Commutation Using Resolver......................................................................17
2.10 Current Mode in Sine/Resolver or Trapezoidal Amplifier vs Two/Three
Phase Input Current Mode Amplifier..........................................................17
2.11 Protection Circuits......................................................................................17

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SMA8105, SMA8205, and SMA8305 MANUAL
Page
Chapter Three: Model Numbering
3.1 Introduction..................................................................................................18
3.2 Single Amplifier Modules .............................................................................18-20
3.2.1 Trapezoidal Mode...............................................................................18
3.2.2 Sine/Resolver Mode...........................................................................19
3.2.3 Two/Three Phase Input Current Mode...............................................20
3.3 Multi Axis Amplifier System .........................................................................21
Chapter Four: Installation
4.1 Introduction..................................................................................................22
4.2 Mounting......................................................................................................22
4.3 Wiring...........................................................................................................22-24
4.3.1 RFI/EMI and Wiring Technique..........................................................22
4.3.2 Wire Size and Type............................................................................23
4.3.3 Connector Size and Type...................................................................23-24
4.3.3.1 The Power Connector - J2 of Main Amplifier............................23
4.3.3.2 The Signal Connector...............................................................24
4.4 Single Amplifier Module Connections (SMA8X05-1)...................................25-27
4.4.1 Buss and Motor Connections - J2......................................................25
4.4.2 Signal Connections for the Trap. and Sine/Resolver Mode - J1........25
4.4.3 Signal Connections for the 2/3 Phase Current Mode Amplifier..........26
4.4.4 Signal Connections for the Trapezoidal Mode Pre-amp ....................26
4.4.5 Signal Connections for the Sine/Resolver Mode Pre-amp.................27
Chapter Five: Configuration
5.1 Introduction..................................................................................................28
5.2 Logic Input Configuration.............................................................................28
5.3 Trapezoidal Mode Amplifier Configuration...................................................28-30
5.3.1 +15V/+5V Logic Level Configuration..................................................28
5.3.2 Standard Configuration ......................................................................29
5.3.3 Integrator Configuration......................................................................29
5.3.4 Hall-Sensor Configuration..................................................................29
5.3.5 Motor Reverse Configuration .............................................................29

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TABLE OF CONTENTS
Page
5.3.6 Simulated Tach - Disable Configuration.............................................29
5.3.7 Simulated Tach - Reverse Configuration...........................................30
5.3.8 Simulated Tach - Speed Configuration..............................................30
5.4 Sine/Resolver Mode Amplifier Configuration...............................................30-32
5.4.1 +15V/+5V Logic Level Configuration...............................................30
5.4.2 Standard Configuration...................................................................30
5.4.3 Encoder Output Resolution Configuration ......................................31
5.4.4 Motor Pole Configuration ................................................................32
5.5 Two/Three Phase Input Current Mode Amplifier Configuration...................32
5.5.1 +15V/+5V Logic Level Configuration...............................................32
5.5.2 Standard Configuration...................................................................32
Chapter Six: Start Up and Calibration
6.1 Introduction..................................................................................................33
6.2 Initial Start Up ..............................................................................................33
6.3 Trapezoidal Mode Amplifier Calibration.......................................................33-35
6.3.1 Velocity and Simulated Velocity Mode Calibration Procedure .......34-35
6.3.2 Current Mode Calibration Procedure..............................................35
6.4 Sine/Resolver Mode Amplifier Calibration ...................................................36
6.4.1 Velocity Mode Calibration Procedure.................................................36-37
6.4.2 Current Mode Calibration Procedure..................................................37-38
6.5 Two/Three Phase Input Current Mode Amplifier Calibration.......................38-39
6.5.1 Two Phase Input Current Mode Calibration Procedure......................38
6.5.2 Three Phase Input Current Mode Calibration Procedure...................39
6.6 Calibration Setup Record.............................................................................40
6.7 Resolver Alignment Procedure....................................................................41-42
Chapter Seven: Maintenance, Repair and Warranty
7.1 Maintenance ................................................................................................43
7.2 Amplifier Faults............................................................................................43-46

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SMA8105, SMA8205, and SMA8305 MANUAL
Page
7.2.1 Table of Fault LED Conditions ...........................................................43
7.2.2 Under Voltage Fault ...........................................................................44
7.2.3 Motor Over Temp Fault......................................................................44
7.2.4 High Speed Electronic Circuit Breaker (HS/ECB) Fault.....................44
7.2.5 Low Speed Electronic Circuit Breaker (LS/ECB) Fault.......................44
7.2.6 Over Temp Fault................................................................................45
7.2.7 Over Voltage Fault .............................................................................45
7.2.8 Resetting A Fault................................................................................45
7.3 Amplifier Failure...........................................................................................45
7.4 Factory Repair .............................................................................................46
7.5 Warranty......................................................................................................46
Appendix A: Amplifier Drawings
SMA8005 Brushless Power Board Installation Schematic (8005-1030)...............48
SMA8005 Brushless Power Board Assembly Drawing (8005-1031) ....................49
SMA8105-1 Trapezoidal Single Amplifier Module Installation(8005-1032)...........50
SMA8205-1 Sine/Resolver Single Amplifier Module Installation(8005-1033).......51
SMA8305-1 Two/Three Phase Single Amplifier Module Installation(8005-1034).52
SMA8X05-2A-2 2-axis Installation Drawing (8005-1035)......................................53
SMA8X05-4A-4 4-axis Installation Drawing (8005-1036)......................................54
Appendix B: Personality Module (Pre-amp)
SMA8105 Trapezoidal Mode Installation Schematic (8000-1130)........................56
SMA8105 Trapezoidal Mode Assembly Drawing (8000-1131).............................57
SMA8205 Sine/Resolver Mode Installation Schematic (8000-1430) ....................58-59
SMA8205 Sine/Resolver Mode Assembly Drawing (8000-1431)..........................60
SMA8305 2Ø/3Ø Current Mode Installation Schematic (8000-1330)...................61
SMA8305 2Ø/3Ø Current Mode Assembly Drawing (8000-1331) ........................62
Appendix C: Custom Configurations
SMA8X05-2A-2 2-axis Installation Drawing (8005-1037)......................................64
SMA8X05-4A-4 4-axis Installation Drawing (8005-1038)......................................65

6Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
Introduction
Glentek's brushless DC 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, brushless servo-motor amplifiers, models
SMA8105, SMA8205, SMA8305, the high power versions: SMA8105HP, SMA8205HP,
SMA8305HP. These amplifiers combine the economy of trapezoidal drive current or the high
performance of sinusoidal motor current with the efficiency of pulse-width modulation (PWM).
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
not addressed in this manual, 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
and money, and to provide you with a superior product.

7Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
SMA8105, SMA8205, and SMA8305 MANUAL
Chapter One: Description, Features and Specifications
1.1 Description:
This brushless amplifier system has been designed to offer you, our customer, a large
degree of flexibility and customization with a standard, in stock product. Each amplifier
module consists of a standard power output board with one of our three types of personality
modules mounted on it. (To help you understand the various brushless amplifier and motor
system combinations and their respective advantages and disadvantages, please refer to
chapter two of this manual which describes the theory of operation). Following is a brief
description of these three personality modules and their mode(s) of operation:
• Trapezoidal Mode (SMA8105/SMA8105HP) - In this mode of operation, which is also
commonly referred to as six step, the brushless motor is commutated by hall sensors or
an encoder which contains these commutation signals. This personality module can be
configured for the following three different types of operation:
• VELOCITY MODE - In this mode of operation, a velocity signal from a brushless or
brush type tachometer is used to close a velocity loop in the amplifier. Please see
section 2.3, 2.7, 2.8 of this manual for more detailed information.
• SIMULATED VELOCITY MODE - In this mode of operation, a circuit on the
personality module looks at the hall sensors and generates a simulated velocity
signal which is used to close a velocity loop in the amplifier. This mode of operation
offers an extremely cost effective velocity mode system for medium to high velocity
applications. Please see section 2.6 of this manual for more detailed information.
• CURRENT MODE - In this mode of operation, which is also commonly referred to as
torque mode, a current in the motor is produced which is directly proportional to the
input signal. Please see section 2.2, 2.5, 2.7 of this manual for more detailed
information.
• Sine/Resolver Mode (SMA8205/SMA8205HP) - In this mode of operation, a brushless
motor with an integral resolver is required. The personality module contains a resolver to
digital converter which provides the positional information to the amplifier that is required
to commutate the motor. This positional information is also used by the personality
module to emulate a quadrature encoder output. This personality module can be
configured for the following two different types of operation:
• VELOCITY MODE - In this mode of operation, the personality module generates a
tachometer signal which is used to close a velocity loop in the amplifier. Please see
section 2.3, 2.5, 2.8 of this manual for more detailed information.
• CURRENT MODE - In this mode of operation, which is also commonly referred to as
torque mode, sine wave currents in the motor are produced that are directly
proportional to the input signal. Please see section 2.5, 2.7, 2.9 of this manual for
more detailed information.
• Two/Three Phase Input Current Mode (SMA8305/SMA8305HP) - In the two phase
current mode, the amplifier generates three sine wave currents that are proportional to
two input signals. This third command is generated on the personality module as the
negative sum of the other two signals. In the three phase current mode, the amplifier
generates three sine wave currents that are proportional to three input signals. Please
see section 2.5, 2.9 of this manual for more detailed information.

8Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS
These brushless amplifiers come with all industry standard inputs such as )limit, fault output,
etc. They are available in the following types of configurations:
• As amplifier modules where you supply the DC Buss voltage, cooling fan(s), fusing and
shunt regulator. Please see section 1.2.1 for more detailed information.
• For multi-axis applications, the multi-axis baseplate power supply can supply DC power,
cooling fans, in-rush current limit, fusing and a shunt regulator for up to 4 axis or 12
amperes continuous. Please see section 1.2.2 for more detailed information.
1.2 Features:
1.2.1 Single Amplifier Module (SMA8X05-1):
• Ergonomic design: Easy access to connections, adjustments, and test points.
• Wide operating 70-350VDC.
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 used simultaneously. All inputs have up to 15,000 A/V
gain, and all inputs will accept )13VDC.
• Dual mode operation: The standard amplifier may be configured for velocity (RPM)
(8105 & 8205 only) control or current (torque) control.
• Current limit: Maximum motor current is adjustable.
• Silent operation: Carrier frequency is 20KHz.
• Short circuit protection: Complete short circuit and ground fault protection.
• LED diagnostics: Red LED(S) illuminate to display various fault conditions and a
green LED illuminates to indicate normal operating conditions.
• Encoder emulation: Encoder emulation comes standard with line driver outputs,
(8205 only) quadrature and zero index.
• Frequency response: 750 Hz minimum.
(Velocity Loop)
• Frequency response: 2 KHz minimum.
(Current Loop)
• Digital limit/enable Three separate logic inputs can stop the motor in either or both
Inputs: directions. Inputs may be configured for active-high or active-
low, pull-up or pull-down termination, and a 0 to +5V or 0 to
+15V range.

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SMA8105, SMA8205, and SMA8305 MANUAL
• Pseudo tach. option: For medium and high-speed, unidirectional or
bidirectional (8105 only) applications, an option allows the hall
sensor inputs to produce a simulated tachometer voltage thus eliminating
the need for an external tachometer.
• Encoder outputs: Incremental (quadrature) position outputs with separate index.
(8205 only) 19 different encoder counts, from 125 to 4096 counts/revolution,
are available. Differential line-driver output devices sink and
source 40mA.
• Tachometer output: DC output proportional to motor RPM.
(8105 & 8205 only)
• Fault input/output: Open-collector output goes low in the event of a fault. This input
is configured so that externally forcing this 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.
• Manual and external Push button and a separate input is provided to reset the
fault reset: amplifier after a fault.
• High-Speed Electronic Instantly shuts down the amplifier in the event of a short across
Circuit Breaker the motor leads or a ground fault condition.
(HS/ECB): (i.e. amplifier exceeds 40A for 10 microseconds)
• Low-Speed Electronic Shuts down the amplifier if the amplifier is operated above the
Circuit Breaker maximum continuous current rating(i.e.5A for standard (LS/
ECB): 60Vac, 3A for standard 120/240Vac; 10A for High Power
60Vac and 6A for High Power 120/240Vac) for a pre-
determined period (i.e. 3 seconds).
• Over/under voltage These circuits constantly monitor the amplifier power-supply
and over temperature: voltages, and the motor and amplifier-heatsink temperatures.
They will shut down the amplifier in the event of any out-of-
specification condition. (The overvoltage protection circuit is set
to turn on at 90Vdc for 80Vdc, 250Vdc for 170Vdc line input and
450Vdc for 340Vdc buss input.)
• Multi-axis chassis: Up to four amplifier modules may be mounted on a single
baseplate. Multi-axis baseplates include a DC power supply,
cooling fan(s) and wiring for each respective amplifier module.
1.2.2 Multi-Axis Power Supply (GP8600-4000):
• Power supply for 2 to 4 axis amplifier baseplate.
• Line operated AC power operation: Fused AC input for single or three phase inputs with
in-rush current limit at turn-on. No power isolation transofrmer is required.
• Bridge rectifier(s), filter capacitor and cooling fans.

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CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS
• Fused regen circuit (shunt regulator) with a 50W internal load resistor bank bleeds off
excess DC Buss voltage when decelerating a large load inertia. Additional regen resistor
can be connected externally.
1.3 Specifications:
This section contains the specifications for the brushless trapezoidal, sine/resolver and
two or three phase input current mode D.C. Servo Amplifiers. These specifications also
include power supplies for the amplifiers.
NOTE: All data in this section is based on the following ambient conditions: 120oF (50oC)
maximum. Forced air cooling.
1.3.1 Single Amplifier Module (SMA8X05-1):
The amplifier module(s) require 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.
1.3.1.1 Input and Output Power:
Input Power/
Buss Voltage(B+) Output Power (current)
Standard High Power
R.M.S. Peak R.M.S. Peak
60VAC/80VDC 5A 10A 10A 20A
120VAC/170VDC 3A 6A 6A 12A
240VAC/340VDC 2A 6A 4A 12A
Amplifier
Model Signal Input Maximum Voltage
(VDC)
Minimum
Impedance
+
Velocity Gain
Amp./Volt Current Gain Amp./Volt
8105/8205 Differential )13 10,000 15,000(min.) 0-5
8105/8205 Single-ended )13 10,000 15,000(min.) 0-5
8305 2/3phase input )13 10,000 0-5
1.3.1.2 Signal Inputs:
1.3.1.3 Digital Inputs:
• )Limit, Inhibit & Reset: 40/-0.5V max. Terminated by 10,000+.
• Fault (as input): 40/-0.5V max. Terminated by 10,000+.
• Typical for all digital inputs: Digital inputs have hysteresis with thresholds at 1/3 and
2/3 of +5V or +15V depending on range select jumper.

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SMA8105, SMA8205, and SMA8305 MANUAL
1.3.1.4 System:
• Drift offset over temperature reference to input: 0.01mV/ oC 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 500mA max.
• Abs. motor current: 5A/V.
• Tachometer : 1000+source impedance, a high input impedance meter must
be used (1M+/volt). Maximum Tachometer output voltage for
12 bit = 1.5V/KRPM, 14 bit = 2V/KRPM.
• Encoder outputs: Standard TTL levels with 20mA sink or source capability.
(8205 only)
1.3.2 Multi Axis Power Supply:
1.3.2.1 Input and Output Power:
• Input Power
Main Power (Line Input): 60/120/240Vac
Fan Power (Line Input): 120/240Vac
• Buss Voltage, B+: 80/170/340Vdc
• Output Power: 5/3A continuous
1.3.3 Mechanical:
Model L x W x H
(inches) Weight (lbs)
SMA8X05-1(Single Amplifier Module) 4.75 x 1.38 x 4.80 1.00
SMA8X05-2A-2 (2 Axis Amplifier System) 6.75 x 6.25 x 6.5 6.00
SMA8X05-4A-4 (4 Axis Amplifier System) 11.00 x 6.75 x 6.5 9.00

12Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
Figure 2.1
CHAPTER 2: THEORY OF OPERATION
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 amplifer driving DC servo-motors.
• A comparison between brush-type and brushless motors.
• A comparison between trapezoidal mode and sinusoidal mode amplifier system.
• The advantages and disadvantages of trapezoidal mode amplifier systems.
• A comparasion between velocity mode and current mode.
• Various kinds of velocity feedback.
• Commutation using resolver.
• Current mode in sine/resolver or trapezoidal amplifier vs two/three phase input
currenamplifier.
• 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 dicusses these
waveforms.

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SMA8105, SMA8205, and SMA8305 MANUAL
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, 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.
Figure 2.2a
Figure 2.2b

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Figure 2.3
Brush-type and Brushless-type Motors
CHAPTER 2: THEORY OF OPERATION
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

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SMA8105, SMA8205, and SMA8305 MANUAL
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.
2.5 Sinusoidal vs Trapezoidal:
Figure 2.4 shows the two most common waveforms used to drive a brushless motor.
Note that in each case, there are actually three different waveforms. Each waveform drives
a motor winding and is 120 o out-of-phase with the other two. Again, the waveform may be
generated from a DC source by linear or PWM techniques.
The first waveform is known as trapezoidal or six-step since the voltage is literally
stepped from winding to winding (like the Christmas-light analogy). This is the simplest and
least expensive method of driving a brushless motor. Its principal disadvantage is that the
large current steps produce high torque ripple. (Torque ripple is a repetitive fluctuation in
torque as the motor turns and is independent of load.) The SMA8105 trapezoidal mode
amplifier produces a trapezoidal output.
The second waveform is known as sinusoidal. To minimize torque ripple, the motor
current needs to be constantly varied according to the orientation of the magnets and
windings. As it happens, this is a sine function. In fact, a sine wave is defined as a rotating
radius (like a motor shaft) revolving through time (see figure 2.4). A sine wave is the most
natural way to drive a motor and produces the minimum torque ripple. The SMA8205
sine/resolver mode amplifier produces a sinusoidal output.
Figure 2.4
Trapezoidal and sinusoidal waveform used to drive brushless motor.

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2.6 The Advantages and Disadvantages of a Trapezoidal Amplifier
System:
A trapezoidal motor has three stator windings and together with the rotor magnets are
designed so that the magnetic flux coupling between them produce a constant torque. The
torque of the motor is proportional to the three stator phase currents which are 120 o
out-of-phase to the other two. Shaft position sensors are required to provide the
commutation signals to commutate the motor. The two most common sensor types are
Hall-effect sensors and an optical encoder with commutation tracks.
A common class of applications for trapezoidal amplifiers is for motor speed control.
Classically, this is implemented by adding a brushless DC tachometer to the motor shaft and
driving the motor through a velocity controlled servo loop. A high performance velocity loop
can be implemented in this manner.
Another way of implementating the motor speed control is by using a simulated digital
tachometer synthesized by the motor commutation signals. The commutation signals are
used to trigger an one shot signal at every transition of the commutation signals. After
smoothing, a voltage proportional to velocity (RPM) is obtained.
Two additional system features were implementated in the synthesized tachometer
design:
1 At 100% of full RPM, the PSEUDO-TACH voltage is limited by the power supply
voltage. If an RPM is commanded above 100% RPM, the servo will run away. To prevent
this from occuring, the absolute value of the PSEUDO-TACH signal is compared to a 95% of
full RPM reference. If the PSEUDO-TACH signal exceeds this value, an over speed latch is
set and the servo is disabled.
2 The PSEUDO-TACH one shot pulse is buffered and brought to the control interface.
The controller can use this signal to determine the exact velocity (RPM) of the motor.
The SMA8105 is a trapezoidal brushless amplifier which contains the necessary
electronics for motor commutation and also has the PSEUDO-TACH option for better speed
control.
2.7 Current Mode vs Velocity Mode:
The fundamental difference between current mode and velocity mode is that in current
mode, an external command signal controls the torque of the motor, rather than the velocity.
In velocity mode, an external command signal controls the velocity (RPM) of the motor, rather
than the torque. In a current mode amplifier, the command signal is proportional to the motor
current, thus it is also proportional to the torque of the motor. In a velocity mode amplifier, the
current loop amplifier stage is preceded by a high gain error amplifier which compares the
command signal and the tachometer feedback signal.
Current mode amplifiers are usually used in Position Control Systems where no
tachometer feedback is required. While velocity mode amplifiers are usually used in Classic
Cascaded Contol Systems where there are position, velocity and current loops in the system.
Velocity loops tend to have a higher bandwidth and operate better near zero speed.
CHAPTER 2: THEORY OF OPERATION

17 Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
SMA8105, SMA8205, and SMA8305 MANUAL
2.8 Tachometer (Velocity Mode) Feedback Options:
The following is a list of ways one can choose to implement tachometer feedback in order
to drive the motor through a velocity controlled servo loop:
• Brush-type and brushless DC mechanical tachometer.
• Simulated tachometer using the motor commutation signals (PSEUDO-TACH).
• Sinusoidal resolver.
• Simulated tachometer using the encoder signals.
The simplest way to simulate the actual velocity of the motor is by installing a mechanical
brush-type or brushless DC tachometer on the motor shaft which converts the velocity of the
motor into DC voltage.
The second method is to synthesize a digital tachometer using the motor commutation
signals (refer to section 2.6). The SMA8105 provides this option.
In the third method, with a sine/resolver amplifier (SMA8205) an analogue tachometer
signal is generated as part of the Resolver-to-Digital conversion process and is immediately
available for use thru the dip-switch options for velocity mode(S1-7).
The fourth method is to have an optical encoder installed on the motor shaft to determine
the direction and position of the motor as it runs. The incoming encoder signals are converted
into quadrature clock pulses. The frequency of this clock pulses changes with the velocity of
the motor and the up/down clock output signals change with the direction of which the motor is
running at. The frequency of the clock is then converted into the tach DC voltage signal using
the Frequency-to-Voltage converter.
2.9 Commutation Using Resolver:
The Resolver-to-Digital converter in the SMA8205 generates the necessary excitation for
the resolver, and converts the resolver’s sine and cosine signals into position data. This
position information is used to amplitude modulate the velocity error signal into three-phase,
sinusoidal and current-error signals like the one in section 2.5.
2.10 Current Mode in Sine/Resolver or Trapezoidal Amplifier vs Two/Three
Phase Input Current Mode Amplifier:
The fundamental difference between the current mode in sine/resolver or trapezoidal
amplifiers and the two or three phase input current mode amplifiers is that in the former case,
the commutation of the command and feedback signals is done within the amplifier itself. The
latter case accepts two or three 120 o out of phase commutated drive signals. In other words,
the user’s controller has to do the commutation of the command and feedback signals
themselves. The user can either input two or three commutated drive signals. If the user has
chosen two phase input, the third phase is generated as the negative sum of the other two
inputs.
2.11 Protection Circuit:
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.

18Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
Chapter Three: Model Numbering
3.1 Introduction:
This chapter contains the model numbering system for the SMA8105, SMA8205 and
SMA8305 single module, stand alone one axis amplifier and multi-axis applications. 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 as quick and as accurately as possible.
3.2 Single Amplifier Modules:
3.2.1 Trapezoidal Mode:
SMA8105XX - YYYY - QQQ - 1
Amplifier Model Number Single Module
Power Rating Optional Custom
Omit = Standard Configuration Code
HP = High Power (A numerical code will be
assigned by Glentek to amplifiers
Pre-amp Configuration Code whose specifications vary from
the standard configuration.)
Pre-amp Configuration Code
Differential or Single-ended input:
0 = Single-ended; (Default)
1 = Differential;
Velocity or Current Mode:
0=Velocity; 1=Current;
(see section 2.7)
Sensor Select:
0 = Off = 120o/240o; (Default)
1 = On = 60o/300o;
(see 5.3.2,5.3.4)
Motor Reverse:
0 = Off; (Default)
1 = On;
(see 5.3.2, 5.3.5)
±Limit 0=L, 1=H see sect.5.2
±Limit 0=U, 1=D see sect.5.2
Inhibit 0=L, 1=H see sect.5.2
Inhibit 0=U, 1=D see sect.5.2
Reset 0=L, 1=H see sect.5.2
Reset 0=U, 1=D see sect.5.2
On Board Power Supply,
+15V/+5V on pull-up:
0 = +15V; (Default)
1 = +5V;
Motor Temperature:
(see section 5.2)
0=Type A(active-low);(Default)
1=Type C(active-high);
ESee section 5.2 E
Type A: U=0 & L=0
(Default)
Type B: D=1 & H=1
Type C: U=0 & H=1
Type D: D=1 & L=0
4 Bit Binary-to-
Digital Conversion
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
DC Buss Voltage
0 = 20 - 80 Vdc
1 = 80 - 350 Vdc
2 = Special
CHAPTER 3: MODEL NUMBERING

19 Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
SMA8105, SMA8205, and SMA8305 MANUAL
PLD Device
Code
(See 5.4.3)
Encoder Resolution
(See section 5.4.3)
0 0 0 C256 250 128 125
0 0 1 C1024 1000 512 500
0 1 0 C4096 4000 2048 2000
0 1 1 C3600 2160 720 360
1 0 0 CNA NA NA 625
1 0 1 CNA NA NA 1250
1 1 0 CNA NA NA 2500
1 1 1 CNA NA NA Special
F F F F
S1-1C0 0 1 1
S1-2C0 1 0 1
3.2.2 Sine/Resolver Mode:
Bit Resolution
(See 5.4.3)
0 0 C10 Bit
0 1 C12 Bit
1 0 C14 Bit
SMA8205XX - YYYYYYY - QQQ - 1
Amplifier Model Number Single Module
Power Rating Optional Custom
Omit = Standard Configuration Code
HP = High Power (A numerical code will be assigned by
Pre-amp Configuration Code Glentek to amplifiers whose specifications
vary from the standard configuration.)
Pre-amp Configuration Code
±Limit 0=L,1=H
±Limit 0=U, 1=D
Inhibit 0=L, 1=H
Inhibit 0=U, 1=D
Reset 0=L, 1=H
Reset 0=U, 1=D
+15V/+5V on pull-up:
0=15V,(Default); 1=5V;
Motor Temperature:
0=Type A; (Default)
1=Type C;
Diff./Single-ended input:
0=Single; (Default)
1=Differential;
Velocity or Current Mode:
0=Velocity; 1=Current;
see section 2.7.
Motor Reverse:
0=OFF, (Default); 1=ON;
see section 5.3.5.
Tach Reverse
1=ON, (Default); 0=OFF;
see section 5.3.7.
0
4 BIT Binary-to-
digital Conversion
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
Type A: U=0 & L=0 (Default)
Type B: D=1 & H=1
Type C: U=0 & H=1
Type D: D=1 & L=0
FSee section 5.2 F
DC Buss Voltage
0=20 - 80 Vdc
1=80 - 350 Vdc
2=Special
Number of
Motor Poles S3-1 S3-2 S3-3 S3-4
See section 5.4.4
2 1 1 1 1
4 1 1 1 0
6 1 1 0 1
8 1 1 0 0
10 1 0 1 1
12 1 0 1 0

20Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
3.2.3 Two/Three Phase Input Current Mode:
SMA8305XX - YYY - QQQ - 1
Amplifier Model Number Single Module
Power Rating Optional Custom
Omit = Standard Configuration Code
HP = High Power (A numerical code will be
assigned by Glentek to
Pre-amp Configuration Code amplifiers whose specifications
vary from the standard
Pre-amp Configuration Code
configuration.)
2/3 Phase Input Current:
0 = 2 Phase; (Default)
1 = 3 Phase;
see section 2.9.
Inhibit 0=L, 1=H
see section 5.2.
Inhibit 0=U, 1=D
see section 5.2.
Reset 0=L, 1=H
see section 5.2.
Reset 0=U, 1=D
see section 5.2.
On Board Power Supply
+15V/+5V on pull-up:
0 = +15V; (Default)
1 = +5V;
see section 5.2.
Motor Temperature:
0 = Type A; (Default)
1 = Type C;
section 5.2.
4 Bit Binary-to-
digital Conversion
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
0
Type A: U=0 & L=0
Default
Type B: D=1 & H=1
Type C: U=0 & H=1
Type D: D=1 & L=0
ESee section 5.2 E
DC Buss Voltage
0 = 20 - 80 Vdc
1 = 80 - 350 Vdc
2 = Special
CHAPTER 3: MODEL NUMBERING