Aerotech Soloist HPe 100, Hardware Manual

Page 1: ...Revision 4 09 00 Soloist HPe 50 75 100 Hardware Manual ...

Page 2: ...tech com Phone 1 412 967 6440 Fax 1 412 967 6870 101 Zeta Drive Pittsburgh PA 15238 2811 www aerotech com United Kingdom China Email Support aerotech com Phone 44 0 1256 855055 Fax 44 0 1256 855649 Email Support aerotech com Phone 86 21 5508 6731 Germany Taiwan Email Support aerotech com Phone 49 0 911 967 9370 Fax 49 0 911 967 93720 Email Support aerotech com Phone 886 0 2 8751 6690 France Email ...

Page 3: ...onnections 32 2 2 2 1 DC Brush Motor Phasing 33 2 2 3 Stepper Motor Connections 34 2 2 3 1 Stepper Motor Phasing 35 2 3 Motor Feedback Connections J207 36 2 3 1 Encoder Interface J207 37 2 3 1 1 RS 422 Line Driver Encoder Standard 38 2 3 1 2 Absolute Encoder Interface J207 39 2 3 1 3 Analog Encoder Interface 40 2 3 1 4 Encoder Phasing 42 2 3 2 Hall Effect Interface J207 44 2 3 3 Thermistor Interfa...

Page 4: ...05 TB306 77 3 6 Opto In Connector Digital Inputs TB305 TB306 78 3 7 Opto Out Connector Digital Outputs TB307 TB308 81 Chapter 4 RDP Expansion Board 85 Chapter 5 Standard Interconnection Cables 89 5 1 Joystick Interface 90 5 2 Handwheel Interface 93 Chapter 6 Maintenance 95 6 1 Power Board 96 6 2 Control Board 97 6 3 Preventative Maintenance 99 Appendix A Warranty and Field Service 101 Appendix B R...

Page 5: ...Limit Interface Input J207 48 Figure 2 22 Limit Input Diagnostic Display 49 Figure 2 23 ESTOP Sense Input TB201 51 Figure 2 24 Typical Emergency Stop Circuit 52 Figure 2 25 Auxiliary Encoder Channel J205 55 Figure 2 26 PSO Interface 57 Figure 2 27 Outputs Connected in Current Sourcing Mode J205 59 Figure 2 28 Outputs Connected in Current Sinking Mode J205 59 Figure 2 29 Inputs Connected in Current...

Page 6: ...s 88 Figure 5 1 Single Axis Joystick Interface to Aux I O 90 Figure 5 2 Two Axis Joystick Interface to the Aux I O of two drives 91 Figure 5 3 Two Axis Joystick Interface to the Aux I O and I O Board 91 Figure 5 4 Handwheel Interconnection to Aux I O 93 Figure 5 5 Handwheel Interconnection to Aux I O via a BBA32 Module 93 Figure 6 1 Power Board Assembly 96 Figure 6 2 Control Board Assembly 97 Solo...

Page 7: ...8 Mating Connector Part Numbers for the ESTOP Connector TB201 51 Table 2 19 Typical ESTOP Relay Ratings 52 Table 2 20 Auxiliary I O Connector Pinout J205 53 Table 2 21 Mating Connector Part Numbers for the Auxiliary I O Connector J205 53 Table 2 22 Auxiliary Encoder Specifications 54 Table 2 23 Auxiliary Encoder Channel Pins on the Auxiliary I O Connector J205 54 Table 2 24 PSO Specifications 56 T...

Page 8: ...r Pin on the Opto In Connector TB306 77 Table 3 19 Digital Input Device Specifications 78 Table 3 20 Port 1 Opto In Connector Pinout TB305 78 Table 3 21 Port 2 Opto In Connector Pinout TB306 78 Table 3 22 Mating Connector Part Numbers for the Opto In Connectors TB305 TB306 78 Table 3 23 Digital Output Specifications TB307 TB308 81 Table 3 24 Port 1 Opto Out Connector Pinout TB307 82 Table 3 25 Por...

Page 9: ...rective and has been designed to be in conformity with the applicable requirements of the following Standard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 61800 3 2004 EMC Requirements for Power Drives EN 61326 1 2013 EMC Requirements for Measurement Control Laboratory Use EN 61010 1 2010 Safety Requirements for Electrical Equipment Authorize...

Page 10: ...fication CUS NRTL Approving Agency TUV SUD America Inc Certificate U8 17 01 68995 023 Standards CAN CSA C22 2 No 61010 1 2012 UL 61010 1 2012 Visit https www tuev sued de product testing certificates to view Aerotech s TÜV SÜD certificates Type the certificate number listed above in the search bar or type Aerotech for a list of all Aerotech certificates Soloist HPe 50 75 100 Declaration of Conform...

Page 11: ...ion D A N G E R This product contains potentially lethal voltages To reduce the possibility of electrical shock bodily injury or death the following precautions must be followed 1 Disconnect electrical power before servicing equipment 2 Disconnect electrical power before performing any wiring 3 Access to the Soloist HPe 50 75 100 and component parts must be restricted while connected to a power so...

Page 12: ...ng injuries Access to all stage and motor parts must be restricted while connected to a power source 3 Cables can pose a tripping hazard Securely mount and position all system cables to avoid potential hazards 4 Do not expose this product to environments or conditions outside of the listed specifications Exceeding environmental or operating specifications can cause damage to the equipment 5 Operat...

Page 13: ...on your Sales Order under the heading Integration that drawing can be found on your installation device Figure 1 Quick Start Connections Topic Section Motor Output Section 2 2 Motor Output Connections Motor Feedback Section 2 3 Motor Feedback Connections J207 Ethernet USB No Section Standard Connection Control Supply Section 2 1 1 Control Supply Connections TB101 Motor Supply Section 2 1 2 Motor S...

Page 14: ...Soloist HPe 50 75 100 Quick Installation Guide 14 www aerotech com This page intentionally left blank ...

Page 15: ...tal PID and current loops All system configuration is done using software settable parameters including control loop gains and system safety functions The Soloist HPe 50 75 100 is offered with an optional encoder interpolation feature MXH an auxiliary square wave encoder input for dual loop control dedicated analog and digital I O expandable with the IO option a resolver input RDP option and separ...

Page 16: ... BASE T Ethernet port for use with Ethernet I O modules Refer to the Help file Table 1 2 Ordering Options Options Power Stage Options Section 1 2 50 S 50 A peak 25 A continuous 440 W continuous internal shunt resistor requires FAN 115 or FAN 230 option 75 S 75 A peak 37 5 A continuous 440 W continuous internal shunt resistor requires FAN 115 or FAN 230 option 100 S 100 A peak 50 A continuous 440 W...

Page 17: ...rotech if firmware calibration updates are required read write access to parameters and programs is supported Resolver Options Chapter 4 RDP1 10K One channel resolver to digital converter input 10 kHz carrier frequency RDP1 7 5K One channel resolver to digital converter input 7 5 kHz carrier frequency RDP1 5K One channel resolver to digital converter input 5 kHz carrier frequency RDP2 10K Two chan...

Page 18: ...er 1 www aerotech com The following block diagram shows a connection summary For detailed connection information refer to Chapter 2 and Chapter 3 Figure 1 2 Functional Diagram Soloist HPe 50 75 100 Introduction ...

Page 19: ...ion of the software first supported the drive Drives that list a specific version number in the Last Software Version column will not be supported after the listed version Table 1 5 Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version HPe 2 51 Current www aerotech com Chapter 1 19 ...

Page 20: ...nd 50 A 75 A 100 A Continuous Output Current 25 A 37 5 A 50 A Power Amplifier Bandwidth 2500 Hz maximum software selectable Power Amplifier Efficiency 85 95 2 PWM Switching Frequency 20 kHz Minimum Load Inductance 0 8 mH 160 VDC 1 mH 320 VDC User Power Supply Output 5 VDC 500 mA Modes of Operation Brushless Brush Stepper Protective Features Output short circuit Peak over current DC bus over voltag...

Page 21: ...r electronics or power transformer An EfficiencyFactor of approximately 90 should be used in the following equations Brushless Motor Output Power Rotary Motors Pout W Torque N m Angular velocity rad sec Linear Motors Pout W Force N Linear velocity m sec Rotary or Linear Motors Pout W Bemf V I rms 3 Ploss 3 I rms 2 R line line 2 Pin SUM Pout Ploss EfficiencyFactor DC Brush Motor Pout W Torque N m A...

Page 22: ...ld be separated from other drives and surrounded by 25 mm 1 of free air space A space of 100 mm 4 should be allowed along the front of the unit for cable connections Figure 1 3 Dimensions Table 1 7 Physical Specifications Weight Standard 6 53 kg 14 4 lb w IO option 6 93 kg 15 28 lb w RDP option 6 93 kg 15 28 lb Soloist HPe 50 75 100 Introduction ...

Page 23: ... Temperature Operating 0 to 50 C 32 to 122 F Storage 30 to 85 C 22 to 185 F Humidity Maximum relative humidity is 80 for temperatures up to 31 C Decreasing linearly to 50 relative humidity at 40 C Non condensing Altitude Up to 2000 meters Pollution Pollution degree 2 normally only non conductive pollution Use Indoor use only www aerotech com Chapter 1 23 ...

Page 24: ...Soloist HPe 50 75 100 Introduction 24 Chapter 1 www aerotech com This page intentionally left blank ...

Page 25: ...n Emergency Stop condition The control power supply requires a minimum of 85 VAC input to operate properly The AC1 input is internally fused The AC2 input is not internally fused but can be connected to a voltage source other than Neutral if an external 2 A time delay fuse is used Although the control power supply contains an internal filter an additional external filter located as close as possib...

Page 26: ...AC3 inputs The drive can be connected to a two or three phase power source Power for the cooling fan is supplied through the motor supply connection The fan connects between the AC1 and AC2 inputs and uses approximately 20W of power W A R N I N G Do not operate the Soloist HPe 50 75 100 without the safety ground connection in place W A R N I N G Do not operate the Soloist HPe 50 75 100 without pro...

Page 27: ...m to radiated emission standards The Soloist HPe 50 75 100 is a component designed to be integrated with other electronics EMC testing must be conducted on the final product configuration Ferrite beads can be used on the motor leads to reduce the effects of PWM noise Table 2 2 Ferrite Noise Suppression Part Numbers Wire Size Aerotech P N Third Party P N 13 3 mm2 6 AWG N A 2643626502 Elna Fair Rite...

Page 28: ...per see Section 2 2 3 For a complete list of electrical specifications refer to Section 1 2 Table 2 3 Motor Power Output Connections Pin Description Recommended Wire Size ØA Phase A Motor Lead 5 27 mm2 10 AWG ØB Phase B Motor Lead 5 27 mm2 10 AWG ØC Phase C Motor Lead 5 27 mm2 10 AWG Earth Ground to Motor required for safety 5 27 mm2 10 AWG Soloist HPe 50 75 100 Installation and Configuration ...

Page 29: ...wires Green White indicates a single wire N OTE Brushless motors are commutated electronically by the controller The use of Hall effect devices for commutation is recommended The controller requires that the Back EMF of each motor phase be aligned with the corresponding Hall effect signal To ensure proper alignment motor Hall and encoder connections should be verified using one of the following me...

Page 30: ...2 2 1 1 Powered Motor Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor Hall and encoder phasing Figure 2 4 Encoder and Hall Signal Diagnostics Soloist HPe 50 75 100 Installation and Configuration ...

Page 31: ... the positive direction Figure 2 5 Motor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined the motor can now be connected to an Aerotech system Connect motor lead A to motor connector A motor lead B to motor connector B and motor lead C to motor connector C Hall leads should also be connected to their respective feedback connector pins...

Page 32: ...onfiguration Table 2 5 Wire Colors for Aerotech Supplied Cables DC Brush Pin Wire Color Set 1 1 Wire Color Set 2 Wire Color Set 3 Green White Shield 2 Green Yellow Shield Green Yellow Shield A Red Orange Red Red Orange C Yellow Blue Black Yellow Blue 1 Wire Color Set 1 is the typicalAerotech wire set used by Aerotech 2 Red Orange indicates two wires Green White indicates a single wire Soloist HPe ...

Page 33: ...ive lead of the voltmeter to the other motor terminal 3 Rotate the motor clockwise by hand Figure 2 8 Clockwise Motor Rotation 4 If the voltmeter indicates a negative value swap the motor leads and rotate the motor CW by hand again When the voltmeter indicates a positive value the motor leads have been identified 5 Connect the motor lead from the voltmeter to the ØA motor terminal on the Soloist H...

Page 34: ...For example an 80V motor bus supply is needed to get 40V across the motor Figure 2 9 Stepper Motor Configuration Table 2 6 Wire Colors for Aerotech Supplied Cables Stepper Pin Wire Color Set 1 1 Wire Color Set 2 Green Yellow Shield 2 Green Yellow Shield A Black Brown B Red Yellow C White White Red 1 Wire Color Set 1 is the typicalAerotech wire set used by Aerotech 2 Red Orange indicates two wires ...

Page 35: ...ction as viewed looking at the motor from the front mounting flange the motor is phased correctly If the motor moves in a counterclockwise direction swap the motor leads and re run the command Proper motor phasing is important because the end of travel EOT limit inputs are relative to motor rotation Figure 2 10 Clockwise Motor Rotation N OTE If using standard Aerotech motors and cables motor and e...

Page 36: ...eference Pulse Input Absolute Encoder Interface Clock Output 8 Absolute Encoder Interface Data Bidirectional 9 Reserved N A 10 Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sensor C brushless motors only Input 12 Clockwise End of Travel Limit Input 13 Brake Output Output 14 Encoder Cosine Input 15 Encoder Cosine Input 16 5V Power for Limit Switches 500 mA max Output 17 Encoder Si...

Page 37: ...ameter settings Refer to Section 2 3 1 4 for encoder feedback phasing Refer to Section 2 5 for the auxiliary encoder channel N OTE Encoder wiring should be physically isolated from motor AC power and all other power wiring Table 2 9 Encoder Interface Pins on the Motor Feedback Connector J207 Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V Power for Encoder 500 mA max Output 6 Encoder Mar...

Page 38: ...use a feedback fault when the axis is enabled An analog encoder is used with the MXH option refer to Section 2 3 1 3 for more information Table 2 10 Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec Figure 2 11 Line Driver Encoder Interface J207 Soloist HPe 50 75 100 Installation and Configuratio...

Page 39: ...ncoder fault information via a serial data stream from the absolute encoder See Figure 2 12 for the serial data stream interface Refer to the Help file for information on how to set up your EnDat or Resolute absolute encoder parameters The encoder interface pinout is indicated in Section 2 3 1 Figure 2 12 Serial Data Stream Interface www aerotech com Chapter 2 39 ...

Page 40: ...ure output Refer to Figure 2 13 for the typical input circuitry The encoder interface pin assignment is indicated in Section 2 3 1 The gain offset and phase balance of the analog Sine and Cosine encoder input signals can all be adjusted via controller parameters Encoder signals should be adjusted using the Feedback Tuning tab of the Digital Scope which will automatically adjust the encoder paramet...

Page 41: ...Installation and Configuration Soloist HPe 50 75 100 Figure 2 14 Analog Encoder Interface J207 www aerotech com Chapter 2 41 ...

Page 42: ...hile observing the position of the encoder in the diagnostics display see Figure 2 16 The Motor Phasing Calculator in the Configuration Manager can be used to determine proper encoder polarity For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 16 Figure 2 15 Encoder Phasing Reference Diagram Standard N OTE Encoder manufacturers may refer to the enco...

Page 43: ...Installation and Configuration Soloist HPe 50 75 100 Figure 2 16 Position Feedback in the Diagnostic Display www aerotech com Chapter 2 43 ...

Page 44: ...efer to Section 2 2 1 1 for Hall effect device phasing Table 2 12 Hall Effect Feedback Interface Pins on the Motor Feedback Connector J207 Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V Power for Encoder 500 mA max Output 5 Hall Effect Sensor B brushless motors only Input 10 Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sensor C brushless motors only Input 21 Signal Co...

Page 45: ...s the resistance of the thermistor is low i e 100 ohms which will result in a low input signal As the increasing temperature causes the thermistor s resistance to increase the signal will be seen as a logic high triggering an over temperature fault The nominal trip value of the sensor is 1k Ohm Table 2 13 Thermistor Interface Pin on the Motor Feedback Connector J207 Pin Description In Out Bi 2 Mot...

Page 46: ... of encoder function The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active Table 2 14 Encoder Fault Interface Pin on the Motor Feedback Connector J207 Pin Description In Out Bi 23 Encoder Fault Input Input Figure 2 19 Encoder Fault Interface Input J207 Soloist HPe 50 75 100 Installation and Configuration ...

Page 47: ...it input Negative motion is stopped by the counterclockwise CCW end of travel limit input The Home Limit switch can be parameter configured for use during the home cycle however the CW or CCW EOT limit is typically used instead Opto isolated user inputs 0 3 can also be used as the end of travel limit inputs see Section 2 5 4 Figure 2 20 End of Travel Limit Input Connections Table 2 15 End of Trave...

Page 48: ...48 Chapter 2 www aerotech com Figure 2 21 End of Travel Limit Interface Input J207 Soloist HPe 50 75 100 Installation and Configuration ...

Page 49: ...be able to move further into a limit but be unable to move out To correct this swap the connections to the CW and CCW inputs at the motor feedback connector The logic level of the EOT limit inputs may be viewed in the Diagnostic Display shown in Figure 2 22 Figure 2 22 Limit Input Diagnostic Display www aerotech com Chapter 2 49 ...

Page 50: ...ist Help file for more information Use either the solid state relay on the Soloist HPe 50 75 100 or the mechanical relay on the IO board when connecting a power supply to the brake outputs on J207 Do not use both relays at the same time Refer to Section 2 6 for more information on using the brake output with the solid state relay Refer to Section 3 1 for more information on using the brake output ...

Page 51: ...to Figure 2 24 for interconnection details The ESTOP input is scaled for an input voltage of 5 24 volts If the ESTOP bit is enabled in the FaultMask axis parameter the ESTOP input must be driven to prevent the ESTOP fault condition Figure 2 23 ESTOP Sense Input TB201 N OTE Connecting the ESTOP input to a relay or other noise producing device requires the use of noise suppression devices such as th...

Page 52: ... Figure 2 24 The external relay must be sized based on the number of the Soloist HPe 50 75 100s connected and the peak current rating of each drive Figure 2 24 Typical Emergency Stop Circuit Table 2 19 Typical ESTOP Relay Ratings AC1 AC3 Aerotech P N Third Party P N HPe 50 65 30 N A Sprecher Schuh CA7 30C xx xxx HPe 75 85 43 N A Sprecher Schuh CA7 43C xx xxx HPe 100 100 60 N A Sprecher Schuh CA7 6...

Page 53: ...iliary Cosine Bidirectional 12 5 Volt 500 mA max Output 13 Analog Input 0 Differential Input 14 Analog Input 0 Differential Input 15 Output Common 16 Digital Output 3 Output 17 Digital Input 0 CCW EOT Input 1 Input 18 Digital Input 1 CW EOT Input 1 Input 19 Auxiliary Marker PSO output 2 Bidirectional 20 Auxiliary Marker PSO output 2 Bidirectional 21 Common 5 Volt User Supply 500 mA max 22 Analog O...

Page 54: ...2 22 Auxiliary Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec N OTE Use the EncoderDivider parameter to configure the bi directional encoder interface on the aux iliary I O connector The EncoderDivider parameter converts the auxiliary encoder interface to an output and defines a divisor for th...

Page 55: ...Installation and Configuration Soloist HPe 50 75 100 Figure 2 25 Auxiliary Encoder Channel J205 www aerotech com Chapter 2 55 ...

Page 56: ...ceiver or opto isolator is recommended especially when using long cable lengths in noisy environments or when high frequency pulse transmission is required It is best to locate the line receiver or opto isolator close to the receiving electronics Table 2 24 PSO Specifications Specification Value Maximum Input Tracking Rate 1 Single Axis Tracking 16 6 MHz Maximum Quadrature Encoder Output Frequency...

Page 57: ...Installation and Configuration Soloist HPe 50 75 100 Figure 2 26 PSO Interface www aerotech com Chapter 2 57 ...

Page 58: ... common connections can be directly connected to the drive s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 26 Digital Output Specifications Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50 C Output Saturation Voltage 2 75 V at maximum current Output Resistance 33 Ω Rise Fall Time ...

Page 59: ...Soloist HPe 50 75 100 N OTE Outputs must be connected as all sourcing or all sinking Figure 2 27 Outputs Connected in Current Sourcing Mode J205 Figure 2 28 Outputs Connected in Current Sinking Mode J205 www aerotech com Chapter 2 59 ...

Page 60: ... s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 28 Digital Input Specifications Input Voltage Approximate Input Current Turn On Time Turn Off Time 5 V 1 mA 200 usec 2000 usec 24 V 6 mA 4 usec 1500 usec Table 2 29 Port 0 Digital Input Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 17 Digital Input 0 CCW EOT Input 1 In...

Page 61: ...75 100 N OTE Each bank of 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 2 29 Inputs Connected in Current Sourcing Mode J205 Figure 2 30 Inputs Connected in Current Sinking Mode J205 www aerotech com Chapter 2 61 ...

Page 62: ... Digital Input Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 3 High Speed Input 4 user interrupt Input 4 High Speed Input 4 user interrupt Input 5 High Speed Input 5 user interrupt Input 6 High Speed Input 5 user interrupt Input Table 2 32 Input Voltage Jumper Configuration Jumper Setting Description JP3 1 2 1 24 V operation High Speed Input 5 2 3 5 V operation High Speed Inpu...

Page 63: ...em reset Table 2 33 Analog Output 0 Specifications TB102 B Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Resolution volts 305 µV Table 2 34 Analog Output Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 22 Analog Output 0 Output 23 Analog Common Figure 2 32 Analog Output 0 J205 www aerotech com Chapter 2 63 ...

Page 64: ...analog common as shown in Figure 2 33 Table 2 35 Differential Analog Input 0 Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Resolution volts 305 µV 1 Signals outside of this range may damage the input Table 2 36 Analog Input Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 13 Analog Input 0 Differential Input 14 Analog Input 0 Differential Input 2...

Page 65: ...eBrakeControl parameter and the BRAKE command When TB202 is used to power the solid state brake control relay the mechanical brake control relay present on the I O board should not be used N OTE The brake power supply must be externally fused The user must verify that the brake power requirements are within the specifications of the brake control relay Table 2 37 Relay Specifications Solid State R...

Page 66: ...207 N OTE The user is responsible for providing fuse protection for the brake circuit Figure 2 35 is an example of a 24 VDC brake connected to TB202 The user must connect J207 pin 13 to J207 pin 25 In this case J207 would function as an interlock to prevent the brake from releasing if the Motor Feedback connector is not connected Figure 2 35 Brake Connected to TB202 Soloist HPe 50 75 100 Installat...

Page 67: ...Power Output 1 Output 2 RS 232 Transmit Output 3 RS 232 Receive Input 4 Reserved Output 5 Ground N A 6 Reserved Output 7 Reserved Input 8 Reserved Input 9 Reserved N A 1 Totaluser 5 V power is limited to 500 mA Table 2 41 RS 232 Port Connector Mating Connector J206 Mating Connector Aerotech P N Third Party P N 9 Pin D Connector ECK00137 FCI DE09P064TXLF Backshell ECK01021 Amphenol 17E 1724 2 Figur...

Page 68: ...nent Information Component Description Aerotech P N Recommended Shunt Resistor 50 Ω min 300 W Vishay Dale RBEF030050R00KFBVT ECR01039 Fuse F1 on the Power Board 8 A S B 3 AG Littelfuse 32008 EIF00122 Recommended Wire Size 16 AWG 1 3 mm2 High Temperature NOTE Multiple resistors can be connected in parallel if required by the application If multiple resistors are used the internal fuse may also need...

Page 69: ...ximum Additional Energy 160 V 213 8 J 320 V 75 6 J If a shunt resistor is required the next step is to calculate the value of resistance necessary to dissipate the energy Use Equations 3 4 and 5 to calculate the parameters of the shunt resistor Equation 3 PPEAK peak power that the regeneration circuit must accommodate W tD deceleration time s Equation 4 PAV average power dissipated on shunt resist...

Page 70: ...Configuration and Operation Information For additional information about PC configuration hardware requirements programming utilities and system operation refer to the Soloist Help file Soloist HPe 50 75 100 Installation and Configuration ...

Page 71: ...0 chassis Figure 3 1 Soloist HPe 50 75 100 with IO Option Board Table 3 1 IO Expansion Board Jumper Configuration Jumper Setting Description JP2 1 2 PSO Output Active High Low Z during reset 2 3 1 PSO Output Active Low High Z during reset JP3 1 2 3 4 Switch Brake 5 6 7 8 1 Switch Brake 1 3 Relay Only 1 default Table 3 2 IO Option Board Fuse Information Fuse Description Size Aerotech P N Manufactur...

Page 72: ...s Maximum Switched Voltage 150 VDC 125 VAC Maximum Switched Current 1A Maximum Carrying Current 1A Maximum Switched Power 30 W DC 60 VA AC N OTE Do not exceed Maximum Current or Maximum Power specifications Table 3 4 Relay Connector Pinout TB301 Pin Description In Out Bi 1 Brake Relay Output Normally Closed Contact Output 2 Brake Relay Output Common Contact Output 3 Brake Relay Output Normally Ope...

Page 73: ...Note that JP3 is set 1 2 and 3 4 with all others removed Figure 3 2 Brake Connected to J207 Figure 3 3 is an example of a 24 VDC Brake connected to TB301 In this example JP3 must be set 1 3 and all other jumpers removed Otherwise the user must connect J207 pin 13 to J207 pin 25 In this case J207 would function as an interlock to prevent the Brake from releasing if the Motor Feedback connector is n...

Page 74: ...are shown in Table 3 9 For the JP2 jumper location refer to Figure 3 1 Table 3 7 PSO Output Connector Pinout TB302 Pin Description In Out Bi 1 Reserved 2 PSO Output Output 3 Opto Isolator Common Input Table 3 8 Mating Connector Part Numbers for the PSO Output Connector TB302 Description Aerotech P N Phoenix P N Wire Size AWG mm2 3 Pin Terminal Block ECK01449 1881338 0 5 0 080 20 28 Table 3 9 PSO O...

Page 75: ... Output 0 on J205 see Section 2 5 6 TB303 lets you connect to all of the analog outputs from one connector do not connect to AOUT0 at both TB303 and J205 Table 3 12 Analog Output Connector Pinout TB303 Pin Description In Out Bi 1 Analog Output 0 Output 2 Analog Output 1 Output 3 Analog Output 2 Output 4 Analog Output 3 Output Table 3 13 Mating Connector Part Numbers for the Analog Output Connector...

Page 76: ...205 see Section 2 5 7 TB304 lets you connect to all of the analog inputs in one place do not connect to AIN0 at both TB304 and J205 Table 3 15 Analog Inputs Connector Pinout TB304 Pin Description In Out Bi 1 Analog Common N A 2 Non Inverting Analog Input 0 Input 3 Inverting Analog Input 0 Input 4 Non Inverting Analog Input 1 Input 5 Inverting Analog Input 1 Input 6 Analog Common N A 7 Non Invertin...

Page 77: ...n on the Opto In Connector TB305 Pin Description In Out Bi 10 Signal Common N A Table 3 18 5 Volt Power Connector Pin on the Opto In Connector TB306 Pin Description In Out Bi 10 Internal 5 Volt Power Supply 0 5 A max N A W A R N I N G Opto isolated inputs and outputs should not be powered by the user output power Doing so would compromise the isolation provided by the opto isolator www aerotech co...

Page 78: ... Input Common for inputs 0 7 Input 2 Digital Input 0 Optically Isolated Input 3 Digital Input 1 Optically Isolated Input 4 Digital Input 2 Optically Isolated Input 5 Digital Input 3 Optically Isolated Input 6 Digital Input 4 Optically Isolated Input 7 Digital Input 5 Optically Isolated Input 8 Digital Input 6 Optically Isolated Input 9 Digital Input 7 Optically Isolated Input 10 Signal Common N A ...

Page 79: ... IO Expansion Board Soloist HPe 50 75 100 Figure 3 8 Digital Opto Isolated Inputs www aerotech com Chapter 3 79 ...

Page 80: ...f 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 3 9 Digital Inputs Connected to a Current Sourcing Device Figure 3 10 Digital Inputs Connected to a Current Sinking Device Soloist HPe 50 75 100 IO Expansion Board ...

Page 81: ...the isolation and will reduce noise immunity Table 3 23 Digital Output Specifications TB307 TB308 Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50 C Output Saturation Voltage 2 75 V at maximum current Output Resistance 33 Ω Rise Fall Time 250 usec typical Reset State Output Off High Impedance State Suppression diodes must be installed on ou...

Page 82: ...ptically Isolated Output 9 Digital Output 6 Optically Isolated Output 10 Digital Output 7 Optically Isolated Output Table 3 25 Port 2 Opto Out Connector Pinout TB308 Pin Description In Out Bi 1 Digital Output Common Plus Input 2 Digital Output Common Minus Input 3 Digital Output 0 Optically Isolated Output 4 Digital Output 1 Optically Isolated Output 5 Digital Output 2 Optically Isolated Output 6 ...

Page 83: ... IO Expansion Board Soloist HPe 50 75 100 Figure 3 11 Digital Opto Isolated Outputs IO Board www aerotech com Chapter 3 83 ...

Page 84: ...84 Chapter 3 www aerotech com Figure 3 12 Digital Outputs Connected in Current Sourcing Mode Figure 3 13 Digital Outputs Connected in Current Sinking Mode Soloist HPe 50 75 100 IO Expansion Board ...

Page 85: ...he motor the alignment between the resolver and motor must be known This alignment can be determined by using the controller s software Refer to the Soloist Help file for information on configuring parameters for an axis with resolver feedback Channel 1 is on J401 and channel 2 is on J402 The RDP option can supply up to 7 VRMS reference voltage and requires 2 VRMS on the sine and cosine inputs D A...

Page 86: ...ver Reference Output 8 Shield Reference Shield 7 ENC SIN Encoder Emulation Sine optional Output 11 ENC SIN Encoder Emulation Sine optional Output 1 ENC COS Encoder Emulation Cosine optional Output 6 ENC COS Encoder Emulation Cosine optional Output 2 ENC MRK Encoder Emulation Marker optional Output 12 ENC MRK Encoder Emulation Marker optional Output Table 4 3 Mating Connector Part Numbers for the R...

Page 87: ... RDP Expansion Board Soloist HPe 50 75 100 Figure 4 2 Resolver Inductosyn Recommended Wiring Figure 4 3 Resolver Inputs www aerotech com Chapter 4 87 ...

Page 88: ... Mating Connector Part Numbers for the RDP External Power Connector J403 Description Aerotech P N Phoenix P N Wire Size AWG mm2 3 Pin Terminal Block ECK01449 1881338 0 5 0 080 20 28 Table 4 6 Resolver Test Points Test Point Description TP4 Signal Common TP10 Sine Input Channel 1 TP11 Cosine Input Channel 1 TOP Reference Signal Channel 1 TP13 Resolver Channel 1 Error TP20 Sine Input Channel 2 TP21 ...

Page 89: ...les can be found on the website at http www aerotechmotioncontrol com manuals index aspx Table 5 1 Standard Interconnection Cables Cable Part Description Joystick See Section 5 1 ECZ01231 BBA32 Interconnect Cable 1 The xx indicates length in decimeters yy would indicate length in feet www aerotech com Chapter 5 89 ...

Page 90: ...ontrol will not activate unless the joystick is in the center location Third party devices can be used provided they produce a symmetric output voltage within the range of 10V to 10V The following drawings illustrate how to connect a single or two axis joystick a two axis joystick requires two Soloist HPes For cable details refer to Table 5 2 Refer to the Soloist Help file for programming informat...

Page 91: ...Accessories Soloist HPe 50 75 100 Figure 5 2 Two Axis Joystick Interface to the Aux I O of two drives Figure 5 3 Two Axis Joystick Interface to the Aux I O and I O Board www aerotech com Chapter 5 91 ...

Page 92: ...rt Cable Description UPC C22769 XX JSXT FLY 26HD 15DU MAX300DM SOLOISTHPE DUAL AXIS 630B2276 9 C227610 XX JSXT 26HD 15DU MAX300DM SOLOISTHPE SINGLE AXIS 630B2276 10 C227611 XX JSXT 26HD 26HD 15DU MAX300DM SOLOISTHPE DUAL AXIS 630B2276 11 92 Chapter 5 www aerotech com ...

Page 93: ...ovide 5V differential quadrature signals to the Soloist HPe 50 75 100 A handwheel can be connected to the Aux I O as shown in Figure 5 4 or Figure 5 5 N OTE See the Soloist Help file for information on enabling the handwheel Figure 5 4 Handwheel Interconnection to Aux I O Figure 5 5 Handwheel Interconnection to Aux I O via a BBA32 Module www aerotech com Chapter 5 93 ...

Page 94: ...94 Chapter 5 www aerotech com Soloist HPe 50 75 100 Accessories This page intentionally left blank ...

Page 95: ...1 LED Description LED Description ENB FLT Turns green to indicate that the axis is enabled Turns red to indicate a fault condition The ENB FLT LED will flash between RED and GREEN if the drive is enabled and in a fault condition MARKER Turns green to indicate that the marker input is high PWR Turns green when power is applied POS Turns green to indicate that the axis is in position If the power li...

Page 96: ...00 chassis Figure 6 1 Power Board Assembly Table 6 2 Fuse Information Fuse Description Size Aerotech P N Manufacturer s P N F1 External Shunt Fuse EXTSHUNT Option 8 A S B 3 AG EIF00109 Littelfuse 0313008 HXP F2 Fan Fuse 3 A Pico EIF01016 Littelfuse 0263003 MXL F3 Control Power 2 A S B EIF01029 Littelfuse 37212000411 96 Chapter 6 www aerotech com ...

Page 97: ...s Figure 6 2 Control Board Assembly Table 6 3 Control Board Jumper Configuration Jumper Setting Description JP2 1 2 1 Watchdog enabled 2 3 Watchdog disabled JP3 1 2 1 24 V operation High Speed Input 5 2 3 5 V operation High Speed Input 5 JP4 1 2 1 24 V operation High Speed Input 4 2 3 5 V operation High Speed Input 4 1 Default www aerotech com Chapter 6 97 ...

Page 98: ...able Fuse 5 A EIF01002 Littelfuse MINISMDC050F 2 Table 6 5 LED Description LED Description ENB FLT Turns green to indicate that the axis is enabled Turns red to indicate a fault condition The ENB FLT LED will flash between RED and GREEN if the drive is enabled and in a fault condition MARKER Turns green to indicate that the marker input is high PWR Turns green when power is applied POS Turns green...

Page 99: ...ial exposure Any fluids or electrically conductive material must not be permitted to enter the Soloist HPe 50 75 100 Visually inspect all cables and connections Tighten or re secure any loose connections Replace worn or frayed cables Replace broken connectors Cleaning The Soloist HPe 50 75 100 chassis can be wiped with a clean dry soft cloth The cloth may be slightly moistened if required with wat...

Page 100: ...100 Chapter 6 www aerotech com Soloist HPe 50 75 100 Maintenance This page intentionally left blank ...

Page 101: ...uch approval A Return Materials Authorization RMA number must accompany any returned product s The RMA number may be obtained by calling an Aerotech service center or by submitting the appropriate request available on our website www aerotech com Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than thirty...

Page 102: ...ranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply On site Non Warranty Repair If any Aerotech product cannot be made functional by telephone assistance or purchased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site Field Servi...

Page 103: ...ary Encoder Channel J205 l Section 2 5 2 Position Synchronized Output PSO Laser Firing J205 l Section 2 5 3 Digital Outputs 0 3 J205 l Section 2 5 4 Digital Inputs 0 3 J205 l Section 2 5 5 High Speed Digital Inputs 4 5 J205 l Section 2 5 6 Analog Output 0 J205 l Section 2 5 7 Differential Analog Input 0 J205 l Section 2 8 EXTSHUNT Option TB101 l Section 3 2 PSO Output Interface TB302 l Section 3 3...

Page 104: ...Soloist HPe 50 75 100 Revision History 104 Appendix B www aerotech com This page intentionally left blank ...

Page 105: ...utputs I O Board 75 Auxiliary Encoder Channel 54 55 Auxiliary Encoder Channel Pin Assignment 54 56 Auxiliary I O Connector 53 Auxiliary I O Connector Pin Assignment 53 B Brake Mechanical Relay 72 Brake Mechanical Relay Connector Pin Assignment 72 Brake Connected to J207 66 73 Brake Connected to TB20 66 Brake Connected to TB301 73 Brake Output 50 Brake Output Connector Pin Assignment 65 Brake Outpu...

Page 106: ... End Of Travel Limit Input Interface J207 47 End of Travel Limit Input Interface Pin Assignment 47 End of Travel Limit Interface Input 48 End Of Travel Limit Phasing 49 EnDat absolute encoder 39 EnDat Encoder Interface 39 Environmental Specifications 23 external emergency stop relay circuit 52 external power connector 88 External Power Pin Assignment 88 F fan 26 Fuse Information 96 G Global Techni...

Page 107: ...rrent Sourcing Mode59 84 P PC Configuration and Operation Information 70 Peak Output Current specifications 20 Pollution 23 Position Feedback in the Diagnostic Display 43 Position Synchronized Output PSO Laser Firing56 Power Amplifier Bandwidth specifications 20 Power Board 96 Power Board Assembly 96 Powered Motor Phasing 30 Preventative Maintenance 99 Protective Features 20 PS2806 4 Opto Device S...

Page 108: ... TB307 81 TB308 81 Technical Support 2 Thermistor Interface 45 Thermistor Interface Input 45 two axis joystick 90 Two Axis Joystick Interface 91 Typical Emergency Stop Circuit 52 Typical ESTOP Interface 52 U unit separation 22 unit weight 22 Unpowered Motor and Feedback Phasing 31 Use 23 User Common Connector Pin Assignment 77 User Power 77 User Power Supply specifications 20 V Voltage and Current...