Glentek SMA8130 Installation and operating instructions

OPERATION
&
SERVICE MANUAL
Model SMA8130
Model SMA8230
Model SMA8330
Brushless Amplifier System

SMA8130, SMA8230, and SMA8330
2
Glentek 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 Amplifier Module (SMA8X30-1A-1)....................................................8-8
1.3 Specifications...............................................................................................10-11
1.3.1 Amplifier Module (SMA8X30-1A-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 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 A 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
TABLE OF CONTENTS

SMA8130, SMA8230, and SMA8330
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Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
Page
Chapter Three: Model Numbering
3.1 Introduction..................................................................................................18
3.2 Amplifier Module..........................................................................................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
Chapter Four: Installation
4.1 Introduction..................................................................................................21
4.2 Mounting......................................................................................................21
4.3 Wiring...........................................................................................................21-23
4.3.1 RFI/EMI and Wiring Technique..........................................................21
4.3.2 Wire Size and Type............................................................................22
4.3.3 Connector Size and Type...................................................................22-23
4.3.3.1 The Power and Motor Connector - TB1 of Amplifier.................22
4.3.3.2 The Signal Connector...............................................................23
4.4 Amplifier Module Connections (SMA8X30-1A-1).........................................24-26
4.4.1 Power and Motor Connections - TB1.................................................24
4.4.2 Signal Connections for the Trap. and Sine/Resolver Mode - J1 ........24
4.4.3 Signal Connections for the 2/3 Phase Current Mode Amplifier..........25
4.4.4 Signal Connections for the Trapezoidal Mode Pre-amp.....................25
4.4.5 Signal Connections for the Sine/Resolver Mode Pre-amp.................26
Chapter Five: Configuration
5.1 Introduction..................................................................................................27
5.2 Logic Input Configuration.............................................................................27
5.3 Trapezoidal Mode Amplifier Configuration...................................................27-29
5.3.1 +15V/+5V Logic Level Configuration..................................................27
5.3.2 Standard Configuration ......................................................................28
5.3.3 Integrator Configuration......................................................................28
5.3.4 Hall-Sensor Configuration..................................................................28
5.3.5 Motor Reverse Configuration .............................................................28
TABLE OF CONTENTS

SMA8130, SMA8230, and SMA8330
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Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
Page
5.3.6 Simulated Tach - Disable Configuration.............................................28
5.3.7 Simulated Tach - Reverse Configuration ...........................................29
5.3.8 Simulated Tach - Speed Configuration ..............................................29
5.4 Sine/Resolver Mode Amplifier Configuration...............................................29-31
5.4.1 +15V/+5V Logic Level Configuration...............................................29
5.4.2 Standard Configuration...................................................................29
5.4.3 Encoder Output Resolution Configuration ......................................30
5.4.4 Motor Pole Configuration ................................................................31
5.5 Two/Three Phase Input Current Mode Amplifier Configuration...................31
5.5.1 +15V/+5V Logic Level Configuration...............................................31
5.5.2 Standard Configuration...................................................................31
Chapter Six: Start Up and Calibration
6.1 Introduction..................................................................................................32
6.2 Initial Start Up ..............................................................................................32
6.3 Trapezoidal Mode Amplifier Calibration.......................................................32-34
6.3.1 Velocity and Simulated Velocity Mode Calibration Procedure.......33-34
6.3.2 Current Mode Calibration Procedure ..............................................34
6.4 Sine/Resolver Mode Amplifier Calibration ...................................................35
6.4.1 Velocity Mode Calibration Procedure.................................................35-36
6.4.2 Current Mode Calibration Procedure..................................................36-37
6.5 Two/Three Phase Input Current Mode Amplifier Calibration .......................37-38
6.5.1 Two Phase Input Current Mode Calibration Procedure .....................37
6.5.2 Three Phase Input Current Mode Calibration Procedure...................38
6.6 Calibration Setup Record.............................................................................39
6.7 Resolver Alignment Procedure....................................................................40-41
Chapter Seven: Maintenance, Repair and Warranty
7.1 Maintenance ................................................................................................42
7.2 Amplifier Faults............................................................................................42-45
TABLE OF CONTENTS

SMA8130, SMA8230, and SMA8330
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Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
Page
7.2.1 Table of Fault LED Conditions ...........................................................42
7.2.2 Under Voltage Fault ...........................................................................43
7.2.3 Motor Over Temp Fault......................................................................43
7.2.4 High Speed Electronic Circuit Breaker (HS/ECB) Fault.....................43
7.2.5 Low Speed Electronic Circuit Breaker (LS/ECB) Fault ......................43
7.2.6 Over Temp Fault ................................................................................44
7.2.7 Over Voltage Fault .............................................................................44
7.2.8 Resetting A Fault................................................................................44
7.3 Amplifier Failure...........................................................................................44
7.4 Factory Repair.............................................................................................45
7.5 Warranty......................................................................................................45
Appendix A: Amplifier Drawings
SMA8030 Brushless Power Board Installation Schematic (8030-1037)...............47
SMA8030 Brushless Power Board Assembly Drawing (8030-1032)....................48
SMA8130 Trapezoidal Amplifier Module Installation (8030-1033)........................49
SMA8230 Sine/Resolver Amplifier Module Installation (8030-1034) ....................50
SMA8330 2Ø/3Ø Amplifier Module Installation (8030-1035)................................51
Appendix B: Personality Module (Pre-amp)
SMA8130 Trapezoidal Mode Installation Schematic (8000-1130)........................53
SMA8130 Trapezoidal Mode Assembly Drawing (8000-1131).............................54
SMA8230 Sine/Resolver Mode Installation Schematic (8000-1430) ....................55-56
SMA8230 Sine/Resolver Mode Assembly Drawing (8000-1431) .........................57
SMA8330 2Ø/3Ø Current Mode Installation Schematic (8000-1330)...................58
SMA8330 2Ø/3Ø Current Mode Assembly Drawing (8000-1331)........................59
TABLE OF CONTENTS

SMA8130, SMA8230, and SMA8330
6
Glentek 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
SMA8130, SMA8230, SMA8330. 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.

SMA8130, SMA8230, and SMA8330
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Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
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
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 (SMA8130) - 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 (SMA8230) - 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 (SMA8330) - 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.
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS

SMA8130, SMA8230, and SMA8330
8
Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS
1.2 Features:
1.2.1 Amplifier Module (SMA8X30-1A-1):
• Ergonomic design: Easy access to connections, adjustments, and test points.
• Wide operating 120-340VDC.
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 except single-ended,
which will accept ±10VDC.
• Dual mode operation: The standard amplifier may be configured for velocity (RPM)
(8130 & 8230 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 flashes 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,
(8230 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.

SMA8130, SMA8230, and SMA8330
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Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
• Pseudo tach. option: For medium and high-speed, unidirectional or bidirectional
(8130 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.
(8230 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.
(8130 & 8230 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 100A for 10 microseconds)
• Low-Speed Electronic Shuts down the amplifier if the amplifier is operated above the
Circuit Breaker maximum continuous current rating for a pre-determined
(LS/ECB): 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.
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS

SMA8130, SMA8230, and SMA8330
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Glentek Inc., 208 Standard Street, El Segundo, California 90245, U.S.A. [phone]
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.
NOTE: All data in this section is based on the following ambient conditions: 120oF (50oC)
maximum. Forced air cooling.
1.3.1 Amplifier Module (SMA8X30-1A-1):
The amplifier module includes an integral DC power supply which includes a bridge
rectifier, buss capacitors, in rush current protection, cooling fans and a 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)
CONTINUOUS PEAK
120VAC/170VDC 30A 60A
240VAC/340VDC 30A 60A
Amplifier
Model Signal Input Maximum Voltage
(VDC)
Minimum
Impedance
W
Velocity Gain
Amp./Volt Current Gain Amp./Volt
8130/8230 Differential ±13 10,000 15,000(min.) 0-5
8130/8230 Single-ended ±10 10,000 15,000(min.) 0-5
8330 2/3 phase 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 10,000W.
• Fault (as input): 40/-0.5V max. Terminated by 10,000W.
• 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.
CHAPTER 1: DESCRIPTION, FEATURES AND SPECIFICATIONS