Glentek SMA8115 Installation and operating instructions

OPERATION
&
SERVICE MANUAL
Model SMA8115
Model SMA8215
Model SMA8315
Brushless Amplifier System

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TABLE OF CONTENTS
INTRODUCTION...................................................................................................6
CHAPTER ONE: DESCRIPTION, FEATURES AND SPECIFICATIONS
1.1 DESCRIPTION........................................................................................................ 7
1.2 FEATURES ............................................................................................................ 8
1.2.1 Single Amplifier Module (SMA8X15-1)..................................................... 8
1.2.2 Multi-Axis Power Supply (GP8600-70)..................................................... 9
1.3 SPECIFICATIONS.................................................................................................... 9
1.3.1 Single Amplifier Module (SMA8X15-1)..................................................... 9
1.3.1.1 Input and Output Power.................................................................. 9
1.3.1.2 Signal Inputs .................................................................................. 9
1.3.1.3 Digital Inputs ................................................................................ 10
1.3.1.4 System......................................................................................... 10
1.3.1.5 Outputs......................................................................................... 10
1.3.2 Multi-Axis Power Supply........................................................................ 10
1.3.2.1 Input and Output Power................................................................ 10
1.3.3 Mechanical............................................................................................ 10
CHAPTER TWO: THEORY OF OPERATION
2.1 INTRODUCTION.................................................................................................... 11
2.2 DRIVING DC SERVO MOTORS.............................................................................. 11
2.3 SERVO LOOPS .................................................................................................... 11
2.4 BRUSHED MOTORS VS BRUSHLESS MOTORS ........................................................ 12
2.5 SINUSOIDAL VS TRAPEZOIDAL .............................................................................. 13
2.6 THE ADVANTAGES AND DISADVANTAGES OF ATRAPEZOIDAL AMPLIFIER SYSTEM .... 14
2.7 CURRENT MODE VS VELOCITY MODE................................................................... 14
2.8 TACHOMETER (VELOCITY MODE) FEEDBACK OPTIONS........................................... 14
2.9 COMMUTATION USING A RESOLVER ..................................................................... 15
2.10 CURRENT MODE IN SINE/RESOLVER OR TRAPEZOIDAL AMPLIFIER VS TWO/THREE
PHASE INPUT CURRENT MODE AMPLIFIER ............................................................ 15
2.11 PROTECTION CIRCUITS........................................................................................ 15
CHAPTER THREE: MODEL NUMBERING
3.1 INTRODUCTION.................................................................................................... 16
3.2 SINGLE AMPLIFIER MODULES............................................................................... 16
3.2.1 Trapezoidal Mode.................................................................................. 16
3.2.2 Sine/Resolver Mode .............................................................................. 17
3.2.3 Two/Three Phase Input Current Mode................................................... 18
3.3MULTI AXIS AMPLIFIER SYSTEM ........................................................................... 19
CHAPTER FOUR: INSTALLATION
4.1 INTRODUCTION.................................................................................................... 20
4.2 MOUNTING.......................................................................................................... 20
4.3 WIRING .............................................................................................................. 20
4.3.1 RFI/EMI and Wiring Technique.............................................................. 20
4.3.2 Wire Size and Type ............................................................................... 20
4.3.3 Connector Size and Type ...................................................................... 21
4.3.3.1 The Signal Connector................................................................... 21
4.3.3.2 The Power Connector -J2 of Main Amplifier ................................ 21
4.4 SINGLE AMPLIFIER MODULE CONNECTIONS (SMA8X15-1).................................... 22
4.4.1 Buss and Motor Connections -J2.......................................................... 22
4.4.2 Signal Connections for the Trap. and Sine/Resolver Mode -J1............. 22
4.4.3 Signal Connections for the 2/3 Phase Current Mode Amplifier............... 23

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SMA8115, SMA8215, and SMA8315 MANUAL
4.4.4 Signal Connections for the Trapezoidal Mode Pre-amp......................... 23
4.4.5 Signal Connections for the Sine/Resolver Mode Pre-amp...................... 24
4.5MULTI AXIS POWER SUPPLY CONNECTIONS (GP8600-70) .................................... 24
CHAPTER FIVE: CONFIGURATION
5.1 INTRODUCTION.................................................................................................... 25
5.2 LOGIC INPUT CONFIGURATION.............................................................................. 25
5.3 TRAPEZOIDAL MODE AMPLIFIER CONFIGURATION .................................................. 25
5.3.1 +15V/+5V Logic Level Configuration...................................................... 25
5.3.2 Standard Configuration.......................................................................... 26
5.3.3 Integrator Configuration......................................................................... 26
5.3.4 Hall-Sensor Configuration...................................................................... 26
5.3.5 Motor Reverse Configuration................................................................. 26
5.3.6 Simulated Tach -Disable Configuration................................................. 26
5.3.7 Simulated Tach -Reverse Configuration ............................................... 26
5.3.8 Simulated Tach -Speed Configuration .................................................. 26
5.4 SINE/RESOLVER MODE AMPLIFIER CONFIGURATION .............................................. 27
5.4.1 +15V/+5V Logic Level Configuration...................................................... 27
5.4.2 Standard Configuration.......................................................................... 27
5.4.3 Encoder Output Resolution Configuration.............................................. 28
5.4.4 Motor Pole Configuration....................................................................... 29
5.5 TWO/THREE PHASE INPUT CURRENT MODE AMPLIFIER CONFIGURATION ................ 29
5.5.1 +15V/+5V Logic Level Configuration...................................................... 29
5.5.2 Standard Configuration.......................................................................... 29
CHAPTER SIX: START UP AND CALIBRATION
6.1INTRODUCTION.................................................................................................... 30
6.2 INITIAL START UP................................................................................................ 30
6.3 TRAPEZOIDAL MODE AMPLIFIER CALIBRATION....................................................... 30
6.3.1 Velocity and Simulated Velocity Mode Calibration Procedure................ 30
6.3.2 Current Mode Calibration Procedure...................................................... 32
6.4 SINE/RESOLVER MODE AMPLIFIER CALIBRATION ................................................... 32
6.4.1 Velocity Mode Calibration Procedure..................................................... 32
6.4.2 Current Mode Calibration Procedure...................................................... 33
6.5 TWO/THREE PHASE INPUT CURRENT MODE AMPLIFIERCALIBRATION ..................... 34
6.5.1 Two Phase Input Current Mode Calibration Procedure.......................... 34
6.5.2 Three Phase Input Current Mode Calibration Procedure........................ 34
6.6 CALIBRATION SETUP RECORD.............................................................................. 35
6.7 RESOLVER ALIGNMENT ....................................................................................... 35
6.7.1 Resolver Alignment Procedure .............................................................. 36
CHAPTER SEVEN: MAINTENANCE, REPAIR AND WARRANTY
7.1 MAINTENANCE..................................................................................................... 38
7.2 AMPLIFIER FAULTS .............................................................................................. 38
7.2.1 Table of Fault LED Conditions............................................................... 38
7.2.2 Under Voltage Fault............................................................................... 38
7.2.3 Motor Over Temp Fault.......................................................................... 38
7.2.4 High Speed Electronic Circuit Breaker (HS/ECB) Fault.......................... 39
7.2.5 Low Speed Electronic Circuit Breaker (LS/ECB) Fault........................... 39
7.2.6 Over Temp Fault.................................................................................... 39
7.2.7 Over Voltage Fault................................................................................. 39
7.2.8 Resetting A Fault................................................................................... 39
7.3 AMPLIFIER FAILURE............................................................................................. 39
7.4 FACTORY REPAIR................................................................................................ 40
7.5 WARRANTY......................................................................................................... 40

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APPENDIX A: AMPLIFIER DRAWINGS
SMA8015 BRUSHLESS POWER BOARD INSTALLATION SCHEMATIC (8015-2030).............42
SMA8015 BRUSHLESS POWER BOARD ASSEMBLY DRAWING (8015-2031).....................43
SMA8115-1 TRAPEZOIDAL SINGLE AMPLIFIER MODULE INSTALLATION(8015-1032).........44
SMA8215-1 SINE/RESOLVERSINGLE AMPLIFIER MODULE INSTALLATION(8015-1033).....45
SMA8315-1 TWO/THREE PHASE SINGLE AMPLIFIER MODULE INSTALLATION(8015-1034)46
SMA8X15-2A-2 2-AXIS INSTALLATION DRAWING (8015-1033).......................................47
SMA8X15-4A-4 4-AXIS INSTALLATION DRAWING (8015-1032).......................................48
APPENDIX B: MULTI-AXIS POWER SUPPLY
GP8600-70 60A POWER SUPPLY ASSEMBLY DRAWING (8600-7030)............................50
APPENDIX C: PERSONALITY MODULE (PRE-AMP)
SMA8115 TRAPEZOIDAL MODE INSTALLATION SCHEMATIC (8000-1130) ........................52
SMA8115 TRAPEZOIDAL MODE ASSEMBLY DRAWING (8000-1131)................................53
SMA8215 SINE/RESOLVER MODE INSTALLATION SCHEMATIC (8000-1430 PAGE 1).........54
SMA8215 SINE/RESOLVER MODE INSTALLATION SCHEMATIC (8000-1430 PAGE 2).........55
SMA8215 SINE/RESOLVER MODE ASSEMBLY DRAWING (8000-1431)............................56
SMA8215 SINE/RESOLVER MODE INSTALLATION SCHEMATIC (8000-2230 PAGE 1).........57
SMA8215 SINE/RESOLVER MODE INSTALLATION SCHEMATIC (8000-2230 PAGE 2).........58
SMA8215 SINE/RESOLVER MODE ASSEMBLY DRAWING (8000-2202)............................59
SMA8315 2Ø/3Ø CURRENT MODE INSTALLATION SCHEMATIC (8000-1330)...................60
SMA8315 2Ø/3Ø CURRENT MODE ASSEMBLY DRAWING (8000-1331)..........................61
APPENDIX D: EUROPEAN UNION EMC DIRECTIVES
ELECTROMAGNETIC COMPATIBILITY GUIDLINES FOR MACHINE DESIGN ............................63
CE CERTIFICATION ......................................................................................................68
TABLE OF CONTENTS

Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. (310) 322
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SMA8115, SMA8215, and SMA8315 MANUAL
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 SMA8115,
SMA8215, SMA8315, and the high power versions, models SMA8115HP, SMA8215HP, SMA8315HP.
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.

Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. (310) 322
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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 (SMA8115/SMA8115HP) -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 (SMA8215/SMA8215HP) -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 (SMA8315/SMA8315HP) -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.
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, 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.
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS

Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. (310) 322
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SMA8115, SMA8215, and SMA8315 MANUAL
1.2 Features:
1.2.1 Single Amplifier Module (SMA8X15-1):
•Ergonomic design: Easy access to connections, adjustments, and test points.
•Wide operating 70-340VDC.
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) control or
(8115 & 8215 only) 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, quadrature and
(8215 only) 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 directions.
Inputs: 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.
•Pseudo tach. option: For medium and high-speed, unidirectional or bidirectional applications, an
(8115 only) 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.
(8215 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.
(8115 & 8215 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 amplifier after
fault reset: a fault.
•High-Speed Electronic Instantly shuts down the amplifier in the event of a short across the motor
Circuit Breaker leads or a ground fault condition.
(HS/ECB): (i.e. amplifier exceeds 80A for 10 microseconds)
•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 120VAC, 10A for standard
(LS/ECB): 240VAC; 20A for High Power 120VAC and 15A for High Power 240VAC)
for a pre-determined period (i.e. 3 seconds).

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•Over/under voltage These circuits constantly monitor the amplifier power-supply voltages, and
and over temperature: 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 +250VDC for 120VAC line input and
+450VDC for 240VAC line 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 (GP8600-7000):
•Power supply for 2 to 4axis amplifier baseplate.
•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 resistorscan be
connected externally.
•Bridge rectifier(s) and filter capacitor.
•Cooling fans.
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 (SMA8X15-1):
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:
1.3.1.2 Signal Inputs:
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS
Input Power/
Buss Voltage(B+) Output Power (current)
Standard
R.M.S. Peak R.M.S. Peak
120VAC/170VDC 15A 25A20A 40A
240VAC/340VDC 10A 25A 15A 35A
High Power
Amplifier
Model Signal Input Maximum
Voltage
(VDC)
Minimum
Impedance
Ù
Velocity Gain
Amp./Volt Current Gain Amp./Volt
8115/8215 Differential 13 10,000 15,000(min.) 0-5
8115/8215 Single-ended ±13 10,000 15,000(min.) 0-5
8315 2/3phase input ±13 10,000 0-5

Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. (310) 322
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SMA8115, SMA8215, and SMA8315 MANUAL
1.3.1.3 Digital Inputs:
•± Limit, Inhibit & Reset: 40/-0.5V max. Terminated by 10,000 ohms.
•Fault (as input): 40/-0.5V max. Terminated by 10,000 ohms.
•Typical for all digital inputs: Digital inputs have hysteresis with thresholds at 1/3 and 2/3 of +5V
or +15Vdepending on range select jumper.
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: 10A/V.
•Tachometer : 1000Ùsource impedance, a high input impedance meter must be used
(1MÙ/volt). Maximum Tachometer output voltage for 12 bit = 0.5V/KRPM,
14 bit = 2V/KRPM.
•Encoder outputs: Standard TTL levels with 20mA sink or source capability.
(8215 only)
1.3.2Multi Axis Power Supply:
The multi-axis power supply contains all items listed under 1.2.3.
1.3.2.1 Input and Output Power:
•Input Power (Buss, B+, Control Power, Fans): 120/240VAC.
•Buss Voltage, B+: 170/340VDC.
•Output Power: 60A continuous
1.3.3Mechanical:
Model L x W x H
(inches) Weight (lbs)
SMA8X15-1(Single Amplifier Module) 7.125 x 1.38 x 4.53 1.28
SMA8X15-2A-2 (2 Axis Amplifier System) 9.00 x 10.50 x 7.70 9.36
SMA8X15-4A-4 (4 Axis Amplifier System) 13.00 x 10.50 x 7.70 15.12