ds160 series servo and dsr/dsrf rack
Contents
1. DC Bus Shunt Regeneration Set Point VDC max 190 Table 3 2 Control Input Power Specifications Units Value Pin Comment Voltage 115VAC VAC max 130 J2 1 2 240VAC and 220VAC VAC min 95 European Service are 230VAC VAC max 260 considered nominal values for VAC min 190 230VAC configuration Frequency Hz min 50 J2 1 2 60Hz is typically the standard Hz max 400 input frequency for North American Service Current 115VAC mA max 70 J2 1 2 Power draw is typically less 230VAC mA max 35 than 5 Watts 3 6 Aerotech Inc Version 1 1 DS160 User s Manual DSR and DSRF Mounting Racks Table 3 3 Motor Output Power Specifications Units Value Pin Comment Motor Connection Output J4 1 2 3 4 5 6 See Table 2 2 through Table 2 8 for DS160 Series Servo Module specifications Table 3 4 Control Interface Specifications Units Value Pin Comment Auxiliary 12VDC Output Connections mA max 50 33 11 12 This is maximum draw for J3 5 12 external use Motor Shutdown Connection Volts max 5to 20 J3 4 10 16 Connection is separate for each motor axis Pulling this input to signal common Kohn 10 inhibits switching of impedance respective Servo Amp This input is pulled up internally to 12 System Fault Output Connection mA max 50 J3 20 7 Open Collector output driver Drives low if any DS160 module is current tri2. sse 1 1 Figure 2 1 DS160 Series Servo Amplifier Module a 2 2 Figure 2 2 Mechanical Diagram of DS160 Series Servo Module some detail omitted for clarity a 2 2 Figure 2 3 Outline of Quick Connect Mating Connector for Connector Jl of DS160 Senes sont rete baton tee Tea desa ede elites 2 3 Figure 2 4 Simplified Block Diagram of the DS160 Series Servo Amplifier Module sinen itte tete ett seksis souin Guts 2 6 Figure 2 5 Detailed Electrical Diagram of the DS160 Series Pre Amplifier Circuit actual circuit eee eee 2 7 Figure 2 6 Transfer Function of Pre Amplifier Circuit esses 2 9 Figure 2 7 Outline of Personality Module RCN4 eese 2 10 Figure 2 8 Detailed Electrical Diagram of DS160 Post Amplifier Circuit 2 11 Figure 2 9 Wiring Diagram for One or More DS160 Servo Modules when not used with the Optional DSR Mounting Rack 2 12 Figure 3 1 Three Axis Mounting Rack DSR sese 3 2 Figure 3 2 Six Axis Mounting Rack DSR sss sees eee 3 2 Figure 3 3 Side View of DSR DSRF Mounting Rack esee 3 3 Figure 3 4 DSR DSRF Mounting Dimensions eee 3 4 Figure 3 5 DSR DSRF Fan Dimensions eee 3 5 Figure 3 6 Front View of DSR 1 2 DSRE Showing Locations of Input Output C
3. 2 2 e Elec ncaliSpeciticatiomns asas 2 4 extbauleOutput e sun sa 2 4 e Ppersonality Medule2 n eE 2 5 5 2 5 AECA Md S 2 5 ASMA munan 2 8 e Pre Amplifier Gain Characteristics sss 2 8 O Tiho P SAD CR ek ee 2 8 e Wiring DS160 into A System a 2 8 e Troubleshooting the DS160 Sertes 2 13 2 1 Introduction The DS160 Series Servo Amplifiers are shown in Figure 2 1 and Figure 2 2 Also shown in these figures are the various locations for potentiometer adjustments the personality module labeled RCN4 the motor load fuse and the pin out specification for the main control and power connector J1 located at the rear of the unit Details of the various items are included in this chapter 2 2 Mounting Specifications The DS160 Series is designed to slide into any standard 3U or partitioned 6U user supplied card rack Integrated power supply 3U card racks for the DS160 Series can be supplied by Aerotech see Chapter 3 for details A sampling of 3U 6U card rack manufacturers are listed below in Table 2 1 Table 2 1 3U 6U Card Rack Manufacturers Manufacturer Address BICC VERO 40 Lindeman Drive Trumbull CT 06611 USA SCHROFF 179 Commerce Drive Warwilk RI 02886 USA KNURRAG USA Representative Panel Components Corp 335 Tesconi Circle Santa Rosa CA 95406 Version 1 1 Aerotech
4. JaMod 1ndu sng 94 lt e n d DC Bus B Rack ing Electrical Block Diagram of DSR 1 2 DSRF Mount Figure 3 7 3 9 Aerotech Inc Version 1 1 DSR and DSRF Mounting Racks DS160 User s Manual DS160 Series Servo Amplifier Modules plug in here Shunt adjust pot factory set to 190VDC Jumpers for selecting control power input voltage 115 or 230 VAC See Figures 3 3 3 7 and 3 9 Figure 3 8 Inside View of DSR Mounting Rack DS160 Amplifiers and Power Supply Module Removed 3 10 Aerotech Inc Version 1 1 DS160 User s Manual DSR and DSRF Mounting Racks 3 9 Wiring DSR DSRF into System An interconnect diagram for input power and output motor wiring is shown in Figure 3 9 The input DC bus power wiring J1 allows for three configurations single phase full wave single phase center tap or 115VAC off line The internally generated DC bus voltage relationship to input AC voltage can be derived with the following equation this equation applies to both center tap and non center tap configurations DC BUS VDC INPUT VAC RMS x 1 414 Connections JI pin 4 and J3 pin 7 must both be connected to earth ground see Figure 3 9 5 An outline and pin out specification for the control interface connector J3 is shown in Figure 3 11 Connector J3 accommodates a standard 37 pin D type male mate 3 10 The TV 2 5 DC Bus Power Transformer An outlin
5. Two control sections pre amplifier and post amplifier in dotted lines are shown in Figure 2 4 These control sections are detailed in Figure 2 5 and Figure 2 8 2 5 Fault Output The DS160 Series Servo Amplifier Module when equipped with the DS Series motherboard is configured with a Fault Output of active low If the DS160 Series Servo Amplifier is not equipped with the DS Series motherboard and the motherboard is to be user supplied the Servo Amplifier Module may be selectively configured for a Fault Output of active high This is accomplished by removing the Fault Output Select jumper see Figure 2 4 from JP1 1 to 2 and connecting the jumper to JP1 2 to 3 both are P C B trace jumpers Aerotech Inc Version 1 1 DS160 Series Users Manual DS160 Servo Amplifier Module The active high Fault Output must not be used in conjunction with the DS Series motherboard 5 2 6 Personality Module The Personality Module pre amplifier circuit RCN4 shown in Figure 2 5 is used to interface input and tach feedback signals if any exist Figure 2 2 shows the location of this module The user may reconfigure this module An outline of the module is shown in Figure 2 7 2 7 Control Modes The input speed command Vcom see Figure 2 5 is usually connected to the output command signal of the Motion Controller through J1 pin 16 The motor tachometer feedback connection Vfb is then connected to JI pin 18 The component values
6. voltage which controls J1 30 current flow to the DC motor The output switching frequency is 20kHz Internal short Volts min 0 a circuit protection is provided if these outputs are shorted together or to earth ground Heatsink ground J1 4 Earth grounding point for heatsink Table 2 9 Troubleshooting Guide Condition Possible Cause References Active LED is de energized even with 12VDC applied to pins 20 and 22 of J1 Shutdown input pin 6 JI is pulled low See Figure 2 4 see also Table 2 7 High DC bus voltage pins 28 32 or J1 See Figure 2 4 Figure 2 9 12VDC input pin 20 JI is below 11VDC See Figure 2 4 Figure 2 9 see also Table 2 7 Short circuit exists at motor connections pin 26 30 or J1 See Figure 2 4 Figure 2 9 Active LED is energized but no torque is present at motor shaft Motor load fuse FI is open See Figure 2 2 Figure 2 4 I limit pin 12 J1 and or I limit pin 14 JI contact closed to signal common See Figure 2 4 Figure 2 9 see also Table 2 7 No DC bus voltage on B B return pins 28 32 of J1 See Figure 2 4 Figure 2 9 Current limit pot turned full CW See Figure 2 2 Figure 2 4 Figure 2 5 Motor accelerated to full speed when 12VDC power and DC bus power was applied Tach feedback wires reversed pin 18 24 of J1 See Figure 2 4 Figure 2 9 see also Table 2 7 Personality module remo
7. N C N C ek ek ik yon a WwW N Signal Common Motor 3 Shutdown N C Motor 3 Limit N C ci 22b Ok 2 o on Oo 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 System Fault Motor 1 Tach Feedback Vra Motor 1 Input Command Vcom Motor 1 Current Monitor Irs N C Motor 1 Limit N C Motor 2 Tach Feedback Vra Motor 2 Input Command Vcom Motor 2 Current Monitor Irs N C Motor 2 Limit N C Motor 3 Tach Feedback Vra Motor 3 Input Command Vcom Motor 3 Current Monitor Ira N C Motor 3 Limit Alternate Tachometer connections can be made at J5 See Figure 3 6 and Figure 3 9 Figure 3 11 Pinout Definitions for Control Connector J13 3 14 Aerotech Inc Version 1 1 DS160 User s Manual DSR and DSRF Mounting Racks Input Voltage Primary Jumper PRIMARY AQ o o m Input Connection 104 115 208 230 273 1 10 J8B e Weight 12 73 Kg 51 lbs A B C D A B E F mo mum Figure 3 12 A amp D A amp F A amp D A amp F TITA MECHANICAL SPECIFICATIONS SECONDARY 115VAC 70VAC 56VAC 43VAC 28VAC 0 Volts C T 0 Volts C T 28VAC 43VAC 56VAC 70VAC 115VAC 120VAC See Section 3 10 for DC Bus Equivalent 10A 15A J1 1 16 5A 17A 19A E NEUTRAL J1 4 19A 17A 16 5A J1 2 15A 10A J2 2 4 0A J2 1 Connections to DSR F Figure 3 9 Dimensions Millimeter
8. SARMA m4 eseug ejBuis uonejos 1euu0JsueJ Ajddns sng Sq peuinbaJ sy 1ON JO ue4 OvAOEZ 1 V g g 14 ees paso Zdr Indio for W alon ees uedo edr Lar T e USC uonejedo OVA0862 TM Jun y ued OVASL J MO uo Be so epo uedo zdf han e sixy pesojo edr Lap puewwog ZHO9 0S WES UONEISd0 OVASLL 101 U09 uio9 bis OVAS L L 0 u wl q I oq ues JWA aseym H 09 08 OVAOEZ 10 OVASI LL ZA OVA SNE OG 9A0qe UMOUS z sixy sjusuleBueJe uloq 104 yoey Gununon puewwo9g punoi uue3 pub yueg mwodilndui dHSQ 7 4 10 ysa uo9 Bis sng Oq 1 sixy puewwog uio BIS eoepelu o41U09 Interconnection for DSR 1 2 DSRF Mounting Rack Figure 3 9 Version 1 1 Aerotech Inc 3 12 DS160 User s Manual DSR and DSRF Mounting Racks View is with rear cover and shunt resistor removed PAD A PAD C Jumper B C with 115VAC off line operation Jumper A B with transformer isolation See Figure 3 9 Figure 3 10 Rear View of DSR 1 2 DSRF Mounting Rack Version 1 1 Aerotech Inc 3 13 DSR and DSRF Mounting Racks DS160 User s Manual Outline of Connector J3 O 000000000000000000 O QOOOOOOOOO0O0O00QO00O0QQ0 par Shield N C Signal Common Motor 1 Shutdown 12VDC for external use Motor 1 Limit Signal Common N C o ON O Q on Signal Common Motor 2 Shutdown gt n o0 12VDC for external use Motor 2 Limit
9. 2 D Blower Assembly Blower Assembly 43 2 1 70 L i 92 7 3 65 lt 119 6 4 71 EN sb 50 9 2 01 Dimensions millimeters inches Figure 3 5 DSR DSRE Fan Dimensions Version 1 1 Aerotech Inc 3 5 DSR and DSRF Mounting Racks DS160 User s Manual 3 7 Electrical Specifications Electrical specifications for the DSR and DSRF mounting racks are listed in the tables below Each specification contains reference information regarding input output connector pin numbers Comments are also included for each specification An outline of the DSR three axis mounting rack is shown in Figure 3 6 This outline provides reference information for user terminated input and output control and power wiring A rear view of the DSRF rack is shown in Figure 3 10 This outline shows the location of jumpers A B or B C which vary depending on the type of DC bus input power see Figure 3 9 Table 3 1 Input Output For DS160 Series DC Bus Power Specifications Units Value Pin Comment Peak DC Bus Output Current Amps DC max 60 Pi P2 P3 28 32 Assume equal distri bution of total current over all 3 sets of connections Continuous DC Bus Output Current Amps DC max 30 P1 P2 P3 28 32 Max current per connection is 15 amps DC Bus Input Supply AC Voltage VAC max 115 JI 1 2 3 4 Max is nominal line value Max allowable VAC min 5 high line is 10 i e 127 VAC
10. 23 O O 101 6 4 00 O O DSR DSRF SIDE O O 56 6 2 23 O O O e e S lo al 2 2 al L J 7 250 5 9 86 l 19 5 0 583 T 240 0 8 45 V 63 5 2 50 I 268 2 10 56 wi DSRF Power Supply M5 10 Clearance Typ DSRF FRONT 32 0 1 26 pwason pwann ed 2227 Teea kizek Hea m 2 ero Te L ere 22 5 0 89 132 8 5 23 e o o o 3 l k O o 9 o i 101 6 4 00 O o o 3 O 8 O 56 6 2 23 O O O e e L e eo e J 2 A eo kid 465 6 18 33 Ls 483 4 19 03 Dimensions millimeters inches Figure 3 4 DSR DSRF Mounting Dimensions 3 4 Aerotech Inc Version 1 1 DS160 User s Manual DSR and DSRF Mounting Racks DSR FRONT VIEW dada M ZZ 210 o YD DSR DSRF SIDE VIEW O e o o o Ie a da IS 9 v 2 el 2 2 2 x Blower Assembly 43 2 1 70 33 0 1 30 119 6 a MEE 4 71 e 1 95 La DSRF FRONT VIEW riera ae 222222 aTa e e e aT e e o lo o o o o O O O O O O o o o o o o O O O O O O e Ka ka Q e a o 2 D
11. 3 8 Aerotech Inc Version 1 1 DSR and DSRF Mounting Racks DS160 User s Manual Semnbiy pou B pun 6 8 KE s ede Lar Edf 1 MOd JAAZI 031002 E SIXY IonuoO z SIXY 033002 SIxV jndino yney wo sAS Jojo ejoo uedo eoepielul 6 8 37 34 3 15 10 Lo Or ou a b 23 o 31 25 o N NaO OAC LT ue OWADEZ peso zdf uedo df Ldr uonejedo ZHO9 09 OVAOEC ue OWASLL uedo zdf pasol9 Edf Ldr uonejedo ZHO9 OS DWA SLE AcL Ajddns UQUILIO jeus CH m 0330053 uMopinus e Q jer euJajul 91807 yned 0311n8y qUISILOH dIWV ureyo Asteq H on 114 dwy T Axis 1 Inhibit Lola AN a c c3 00 N SOsao SEI ez eu ge S Cerca JO s e q umopinys 3ne4 esny4 uedo MOOL z 7512 unus 0 IWAOEZ SL iCoOQi0 pajejos Jemog du OJUOD OUA LT Connection N C8 cx o e N ot e ise N Ce c N 8SVSI esn z indu gSVSI esny Indu uomnejedo dej Jajueo ALM nj eseud ajBuis uM Awwnq asny z indu gsvog esny Indu deuejueo ou uonejedo eAew n eseud ejBuis ul Jo uonejedo aui YO OVASL L YUM 9 pue 6 Sounbi4 eoueJeJeH N 9G VYE L LAN JOMOd NANO Jojo 1sis H junus 2dA00Z g 4rioooz B Return DC Bus Return
12. Inc 2 1 DS160 Servo Amplifier Module DS160 Series User s Manual 2 3 Power and Control Connections A quick connect mating connector is supplied with the DS160 Series Servo Amplifier when the amplifier is supplied less the DSR mounting rack An outline of this connector is shown in Figure 2 3 This connector will mount in any 3U card rack section of DIN mounting specification 41612 Ds 16030 Figure 2 1 DS160 Series Servo Amplifier Module 40 3 1 59 173 8 6 84 7 T 171 1 6 74 F Personality Module RCN4 d 1 K T T a 100 1 3 94 128 4 5 06 e O i y Connector Ji L Fuse F1 Dimensions millimeters inches Front View Side View Back View Figure 2 2 Mechanical Diagram of DS160 Series Servo Module some detail omitted for clarity 2 2 Aerotech Inc Version 1 1 DS160 Series User s Manual DS160 Servo Amplifier Module 25 Quick Connect Lugs Typical Mounting Hole BACK VIEW OF CONNECTOR SIDE VIEW OF CONNECTOR Figure 2 3 Outline of Quick Connect Mating Connector for Connector J1 of DS160 Series If the user wants the DS160 Servo to be integrated into a user designed PC motherboard DIN mounting specification 41617 a different connector designed for PC board mounting must be used Aerotech will supply this connector as an option P N ECK352 or the user m
13. T Use a 30A slow blow 3AG 125V fuse with non center tap transformer or off line See Figure 3 7 and Figure 3 9 Use 15A slow blow 3AG 125V fuse with center tap transformer DC bus input 2 fuse DS16020 or DS16030 Use dummy fuse bus bar with non center tap transformer or off line See Figure 3 7 and Figure 3 9 Shunt regulator Use 3 amp slow blow 3AG 125V fuse overload fuse F1 Do Not Exceed 3 Amp 3 18 Aerotech Inc Version 1 1 DS160 Series Users Manual Appendix A APPENDIX A WARRANTY AND FIELD SERVICE In This Section e Laser Product Warranty e Return Products Procedure e Returned Product Warranty Determination e Returned Product Non warranty Determination e Rush Service e On site Warranty Repair e On site Non warranty Repair Aerotech Inc warrants its products to be free from defects caused by faulty materials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repairing or issuing credit at its option for any products which are returned by the original purchaser during the warranty period Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided or whether or not Aerotech s products are specifica
14. bus and pins 28 and 32 must be twisted tightly together and be of no less htan 14 AWG gauge 21x10 CM Failure to observe the considerations listed above may result in permanent damage to the power stage of the Servo Amplifier 2 8 Aerotech Inc Version 1 1 DS160 Series User s Manual DS160 Servo Amplifier Module Input Pot Full CCW P ui Input Pot Full CW 80 Gain dB 60 y Gain Pot Center Gain Pot Full CW 40 Transfer Function 20 Icom Vcom 0 A 1 10 100 1000 10000 100000 Frequency Hz 80 z Tach Pot Full CCW Gain Tach Pot Full CW dB pro 60 Gain Pot Center 40 Transfer Function 20 Icom Vfb 0 A 1 10 100 1000 10000 100000 Frequency Hz Note Transfer functions shown above are with respect to values of RCN4 shown in Figure 2 5 Figure 2 6 Transfer Function of Pre Amplifier Circuit Version 1 1 Aerotech Inc 2 9 DS160 Servo Amplifier Module DS160 Series User s Manual 16 Pin DIP Wafer snap on cover removed i i i i i RCN4 1 16 Resistor 1 4 Watt RCN4 2 15 Resistor 14 Watt RCN4 3 14 Resistor 1 4 Watt RCN4 4 13 Resistor 14 Watt RCN4 5 12 Ceramic Capacitor 50V RCN4 6 11 Resistor 1 4 Watt RCN4 7 10 Resistor 1 4 Watt RCN4 8 9 Resistor 1 4 Watt Figure 2 7 Outline of Personality Module RCN4 Table 2 4 Personality Module RCN4 Modes DS16
15. bus shunt regulator circuit integral to the mounting rack is supplied to clamp an elevated DC bus voltage caused by excess motor power regeneration during deceleration The shunt adjust pot P1 see Figure 3 8 is factor set for 190 VDC If a lower clamping level is required this pot may be turned CCW appropriately 3 4 Control amp Power Connections to Mounting Racks Control and power connections to the mounting rack are accessed via an extension board at the rear of the mounting rack The mounting rack base height is 3U in accordance with international DIN standards The control and power extension board is less than 1U in additional height Version 1 1 Aerotech Inc 3 1 DSR and DSRF Mounting Racks DS160 User s Manual DS1 6020 2816020 DS16020 mo mu Figure 3 1 Three Axis Mounting Rack DSR Figure 3 2 Six Axis Mounting Rack DSRF 3 2 Aerotech Inc Version 1 1 DS160 User s Manual DSR and DSRF Mounting Racks 3 5 Six Axis Mounting Rack DSRF The six axis mounting rack DSRF is shown in Figure 3 2 This rack consists of two three axis racks joined together To simplify this chapter provides only those specifications that are pertinent to the three axis rack Specifications for the six axis rack are provided only for those specific items that differ from the three axis version 3 6 Mounting Specifications Mounting specifications for the DSR and DSRF mounting racks are shown in Fig
16. of RCN4 are set to those values depicted in Figure 2 5 As previously stated there are five potentiometers that are used to tune the amplifier to a particular motor and load See Table 2 3 for descriptions Table 2 3 Potentiometer Descriptions Potentiometer Description Input Provides the means of adjusting the DC gain of the input command present at J1 Pin16 Turning this pot CW increases gain Tach Provides the means of adjusting the DC gain of the tach feedback signal present at J1 Pin18 Turning this pot CW increases gain Balance Provides the means of canceling small DC offsets that may be present in the pre amplifier circuit Current Limit Provides a means of adjusting the clamp levels of the current command signal produced by the output of the pre amplifier Turning this pot CCW increases the clamp levels increases the peak current Gain Provides the means of adjusting the AC Gain of the pre amplifier Turning this pot CCW increases gain Pots are only used in velocity mode se For the physical position of these pots see Figure 2 2 For the circuit position and effect see Figure 2 5 and Figure 2 6 Modern motion controllers often provide tach feedback internally to the control The result is that the output control signal from the motion controller is usually a current command signal rather than the traditional speed command signal described above For this control mode the tach connection pi
17. the DS160 Series Amplifier the DSR and the DSRF The three axis mounting rack DSR is shown in Figure 3 1 The six axis mounting rack is shown in Figure 3 2 Both mounting racks have a totally integrated DC bus and control power supplies Shunt regulators for controlling DC bus motor regeneration are standard Isolation transformers to supply power to the DC bus may be supplied as an option for both mounting racks Both mounting racks provide easy termination of control and power connections to the motion controller and DC motors These mounting racks are designed for panel mounting reversing the mounting flanges on the six axis DSRF rack will permit 19 rack mounting The major difference between the DSR rack and the DSRF rack is the inherent mounting hardware The six axis DSRF rack is in actuality two three axis racks joined together The six axis DSRF rack contains two separate three axis power supplies each identical to the power supply on the three axis DSR mounting rack All mounting rack specifications listed in Chapter 3 except those specifying dimensional data are in reference to the three axis DSR mounting rack 1 2 Aerotech Inc Version 1 1 DS160 Series User s Manual DS160 Servo Amplifier Module CHAPTER 2 DS160 SERVO AMPLIFIER MODULE In This Section e Introduction UIT 2 1 e Mounting Specifications ee eee eee 2 1 e Power and Control Connections
18. 020 DS16030 Torque Mode Velocity Mode Torque Mode Velocity Mode 1 16 10KQ 10KQ 10KQ 10KQ 2 15 Open 39KQ Open 39KQ 3 14 Open 3902 Open 3902 4 13 0Q 100KQ 00 100KQ 5 12 Open JuF Open luF 6 11 10KQ 100KQ 10KQ 100KQ 7 10 Open 150KQ Open 150KQ 8 9 1 2KQ 1 2KQ 22KQ 22K The surface mount version of this module has a 0 ohm resistor in series with each CS component listed 2 10 Aerotech Inc Version 1 1 DS160 Series User s Manual DS160 Servo Amplifier Module A I gt 0 E l F e Ke r ke e i _ __ E m d o o Ete lt m o zt 00 gt gt E amp 02 a A z 3 o gt gt E o o d x 2 e S o c gt o e o o o L N N S o gt c o cv o 2 Sc G 2 o o e L E S o bel O ha S rO 20 o O9 F Xx G a gt s 9 28 s CR gt 8 a o z OLS 8 8 lt G N 1 o zc Q d O o o e L N a 5 9 e Figure 2 8 Detailed Electrical Diagram of DS160 Post Amplifier Circuit Version 1 1 Aerotech Inc 2 11 DS160 Series User s Manual DS160 Servo Amplifier Module pesn si uonejedo 1eu0Jsue4 uollelosi ON 9 eut jo DWASLL J jurod siyi ye punoub quee 19euuoo JOU oq i LNV LHOdMI punou9 y ey 0 ewe JOJO 199uuoo y a x punog uue3 oi Jd T LP JO y Uld 10euuoo GINO 0L X v1 eDner 9 1see1 1v eg PINOYS SIM 1010 punog A yey ol pal eg W ii pinous WOO DIS Sur I A84 usn Ag paliddns D
19. 5 31 and 37 of J3 are pulled to signal common Current limit pots on DS160 Series servo module are full CW No DC bus input voltage J1 or input DC bus fuse open Figure 3 7 Figure 3 11 Table 2 6 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 3 6 Figure 3 7 Figure 3 9 Motor s accelerate to full speed when 12VDC power 32 DC bus power Jl is applied Tach feedback connected pin 21 27 and 33 of J3 are required with respect to signal common Figure 3 7 Figure 3 9 Figure 3 11 Table 2 6 DC bus shunt regulator fuse opens periodically Excessive motor regeneration due to deceleration of high inertia load DC input power gt 115VAC Figure 3 7 Table 3 1 Figure 3 7 Figure 3 9 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Fault LED is energized Shunt regulator fuse is shunt option open 1 or more DS160 Series servo s have a short circuit cruuent trip condition at motor output connections J4 DC bus voltage in excess of 195VDC Figure 3 6 Figure 3 7 Figure 3 7 Figure 3 9 Version 1 1 Aerotech Inc 3 17 DSR and DSRF Mounting Racks DS160 User s Manual 3 12 DSR amp DSRF Spare Parts Table 3 6 Replacement Parts for the DSR and DSRF Item Aerotech Part Comment DSR 3 axis mounting rack EFA471 Use 15A slow blow 3AG 125V fuse with center tap transformer DC bus input 1 fuse DS16020 or DS16030
20. DS160 SERIES SERVO AND DSR DSRF RACK USER S MANUAL P N EDA119 V1 1 AEROTECH AEROTECH Inc s 101 Zeta Drive e Pittsburgh PA 15238 2897 e USA Phone 412 963 7470 e Fax 412 963 7459 Product Service 412 967 6440 412 967 6870 Fax www aerotechinc com If you should have any questions about the DS160 Series Servo Amplifier the DSR DSRF racks or comments regarding the documentation please refer to Aerotech online at http www aerotechinc com For your convenience a product registration form is available at our web site Our web site is continually updated with new product information free downloadable software and special pricing on selected products DS160 Series Servo Amplifiers and DSR DSRF racks are products of Aerotech Inc DS160 Series Servo Amplifier Manual Revision History Rev 1 0 November 1990 Rev 1 1 September 28 2000 DS160 Series User s Manual Table of Contents TABLE OF CONTENTS CHAPTER 1 DESCRIPTION sse 1 1 1 1 Introductions t SE ERO bh epe asb 1 1 CHAPTER2 DS160 SERVO AMPLIFIER MODULE 2 1 2 1 Introduction a see teer Pei eet masse 2 1 2 2 Mounting Specifications eren 2 1 2 3 Power and Control Connections esee 2 2 2 4 Electrical Specifications ses eee ee eee eee 2 4 25 Fault Output u p ie Bae eens Be ie es 2 4 2 6 Personality Module eogoeep oerte obe mene 2 5 2 7 Contro
21. Josues 91607 nouo umoq pous igiuuj eDeyoA sng ubi inus O PA 02T 99 Z uonejos gt Nau queuing sng yBIH Jedunp y T oy 91607 ieles z oi jne4 ines indno o nes m yney Lar o umopinus ME i Version 1 1 Simplified Block Diagram of the DS160 Series Servo Amplifier Module Aerotech Inc Figure 2 4 2 6 UOISIBA oul u991019V LC S C ANSIA 141 enjoe WIAD Jogijdury a44 SILOS 091Sd t JO ure1gerq Ie rn li PIVA J1 Vcom iE GWO 3 150K Ur G E v0 UE A poe RCN4 RCN4 RCN4 100K 100K J1 Vfb TACH POT CW 39K 2 Y V VAS 9 8 Icom 0 O See Figure RCN4 k 6 RONG 25 10K 1 e av A V A l CW V Balance 6 8V cw J1 12 po V C t E urren LIMIT Limit Pot 12 Ji ILIMIT 14 V Note Typical 741EN OP AMP WARNING Do not use a resistor value Open Loop Gain Is 200 V MV smaller than 1 2K for RCN4 9 for the nuE 01uF DS16020 Amplifier Do not use a resistor value smaller than 2 2K for RCN4s 9 for the Personality Module RCN4 DS16030 Amplifier Shown in the Velocity Mode See Table 2 4 enuey S 19Sf seues 091Sa a npoyy Jayijdwy ouss 09 1 90 DS160 Servo Amplifier Module DS160 Series User s Manual WARNING 2 8 Setting the Current Limit The RCN4 resistor component 8 9 is used to set the maximum current that can be obtained by the current limit potentiometer full CW for zero current full CCW for maximum current 2 9 Pre Amplifier Gai
22. OUA ZL iddns DGA ZL WOO DIS OGA L MO 9g PION 89S INVLYOdINI puewwoj p ds y sixy Ot DWASLLOLO A omes 18d A002 sng OQAO91 01 0 4no002 09ISd m E y GINO 0L X L2 obne tL 18EOT 1y eg pinous abe9 eJIM NIVHO ASIV LON OQ e2inog ol sies ulog Duo s youl 8 Ajayesedag ejeuiuJe eg peisiM eg 1snN UBy l SON 88 JON ISNIN S91NOS 0 ajnpoyy wouy y Bue7 BuurM juejloduu ional for One or More DS160 Servo Modules when not used with the Opt iagram DSR Mounting Rack D iring Wi Figure 2 9 Version 1 1 Aerotech Inc 2 12 DS160 Series User s Manual DS160 Servo Amplifier Module 2 12 Troubleshooting the DS160 Series A troubleshooting guide for the DS160 Series Servo Amplifier module is provided in Table 2 9 A list of recommended spare parts for the DS160 Series Servo Amplifier Module is shown in Table 2 10 Table 2 5 Environmental Specifications Unit Value Comment Operating Temp C 50 max 0 min Ambient temp of the servo module heatsink not the enclosure Storage Temp C 85 max 30 min Shelf storage only not stand by use Humidity 10 90 Non condensing Table 2 6 Power Stage Specifications Unit Value Pin Comment Short Circuit Trip Amps min 40 J1 26 30 Requires power down reset Max may be as high as 60 amps Typical input output impedance Ohms max 3 J1 26 28 30 32 From bus connection 28 or 32 t
23. a aaaassssssss 2 15 Troubleshooting Guide sss esse esse eee 2 15 DS160 Series Replacement Parts esse 2 16 Input Output For DS160 Series DC Bus Power Specifications 3 6 Control Input Power Specifications asss 3 6 Motor Output Power Specifications eee 3 7 Control Interface Specifications ass 3 7 Troubleshooting w teet eter e ve stent eten be 3 17 Replacement Parts for the DSR and DSREF esses 3 18 V V V vi Aerotech Inc Version 1 1 DS160 Series User s Manual Description CHAPTER 1 DESCRIPTION In This Section SiO 1 1 1 1 Introduction The Aerotech DS16020 and DS16030 Servo Amplifiers hereafter denoted as DS160 Servo Amplifiers mark an advance in brush DC motor power control technology High output power small size and standardized mounting standard 160 mm 3U Euro card make these Servo Amplifiers two of the most versatile on the market today The DS160 Series Amplifier uses a patented PWM drive scheme allowing them to produce high output power at very high efficiency The DS16020 has a nominal rating of 160 VDC at 20 amps peak 2 seconds 10 amps continuous with fan cooling at up to 50 C ambient The DS16030 has a nominal rating of 160 VDC at 30 amps peak 2 seconds 15 amp continuous with fan cooling at up to 50 C ambient The patented drive scheme allows operation
24. ay purchase this connector independently One supplier of this mating connector is Schroff see Table 2 1 Version 1 1 Aerotech Inc 2 3 DS160 Servo Amplifier Module 2 4 DS160 Series User s Manual Electrical Specifications Electrical specifications are listed in Table 2 2 Table 2 2 Electrical Specifications Units DS16020 DS16030 Peak Current Output 2 sec Amps 20 30 Continuous Output Current Amps 10 15 5 without fan 5 without fan Output Fuse F1 3 AG slow blow Amps 10 5 w o fan 15 5 w o fan Peak Output Voltage Volts 160 160 Minimum Voltage Output Volts 10 10 Peak Power Output Watts 2920 4200 Continuous Power Output Watts 1530 2300 765 w o fan 765 w o fan Efficiency 93 Pre Amplifier Voltage Gain max open loop dB 100 Drift referred to input u V C 10 Offset Volts Adjustable to Zero Power Amplifier Gain continuous output Amps Volt 1 2 Bandwidth kHz 1 PWM Switching Frequency kHz 20 Output Current Limit Amps max Adjustable Zero to Peak Shutdown Input Tristates Motor Output Minimum Load Inductance mH 2 Operating Temperature C 0 to 50 Storage Temperature C 30 to 85 Weight kg Ib 0 5 1 A block diagram of the DS160 Series Servo Amplifier Module is shown in Figure 2 4 All input and output power and control connections are passed through connector JI see Figure 2 3 also
25. between O and 160 VDC bus levels without component adjustments A motor output load fuse is provided Ds 16030 Figure 1 1 The DS160 Series Servo Amplifiers The PWM output switching frequency is 20 KHz well above the audible frequency range The PWM output stage utilizes hermetically sealed power MOSFET switching devices providing very high reliability and long life Five potentiometers are provided at the front of the DS160 Servo Amplifier for easy access when adjusting the input and tach feedback gain balance and current limit A Version 1 1 Aerotech Inc 1 1 Description DS160 Series User s Manual parameter adjustment module known as the personality module or RCN Resistor Capacitor Network provides a means of modifying all gain and current limit adjustment parameters usually adjusted with the potentiometers The user may set predetermined gains and current limits and match specific DC motors to the DS160 Series Amplifier without adjusting the potentiometers themselves The DS160 Series Amplifiers are self contained except for the user supplied AC voltage source needed to generate the internal DC bus voltage of O to 160 VDC and 12 VDC control voltages Motor load short circuit protection is provided intemally A typical interconnection diagram for wiring two or more DS160 Series Amplifiers into a system is shown in Figure 2 9 Aerotech provides two types of integrated power supply mounting racks for
26. d Well illustrated Would you like to see more illustrations Would you like to see more text How do you use this document in your job Does 1t meet your needs What improvements if any would you like to see Please be specific or cite examples Y our name Y our title Company name Address Remove this page from the document and fax or mail your comments to the technical writing department of Aerotech AEROTECH INC Technical Writing Department 101 Zeta Drive Pittsburgh PA 15238 2897 U S A Fax number 412 963 7009 AEROTECH
27. e of the optional TV2 5 DC bus power supply transformer P N EAX159 is shown in Figure 3 12 This transformer is supplied as an option to the DSR and DSRF mounting racks The transformer allows the generation of a 40 VDC bus 28 VAC taps 60 VDC bus 43 VAC taps 80 VDC 56 VAC taps 100 VDC 70 VAC taps and 160 VDC 115 VAC taps Figure 3 13 shows the typical DC bus droop characteristics of the TV2 5 transformer connected to the DC bus input power connection J1 of the DSR rack see Figure 3 9 DC bus voltage level Vo of Figure 3 13 is in respect to the filter capacitors 2000ufx3 with given value of output current Ip distributed to the three DS160 Series Amplifier modules 115 VAC operation can be derived directly from the line eliminating the need for the TV2 5 transformer TS Version 1 1 Aerotech Inc 3 11 DS160 User s Manual DSR and DSRF Mounting Racks 0L g aN paeoquoujou HSG y uo pej eisui aq snw g 0 v Jeduunf uonejos JoUOJSUBJ UNM V 01 amp e1n614 preoquayjou usq ay uo pejeisur eq snw 9 0 g Jedunp uonejedo auij yo OvASLL UIM Y 9dA09 JOZAX OVASLL SNG DA JuawsBue Je aaoqe 104 punog yue3 ANNOYS AL34WS TVHIR3N OV eut HO OVASLL UONB OS JOUWOJSUBJI ON iddns sng 5q SARMA m4 eseyq ejBuis SAem my eseyq ejBuis L JOJOIN S1ON e SN e Bu orm yonn Pm uonejos 1euuoJsueJ iddns sng 9q de 191082
28. ection Kohms impedance 5 J1 8 This connection provides a point at which the output current level flowing from pin 26 to 30 of J1 signal may be monitored Scaling is Samp volt for DS 16030 and 3 amp volt for DS 16020 Fault output connection mA max 50 J1 10 This output is used for external fault open collector indication This connection is field programmable to drive low to signal common or open if a short circuit condition motor load high VDC max 30 DC bus voltage or low 12VDC input condition exists Jumper points 1 to 2 at JPI for active low Jumper points 2 to 3 at JPI for active high 12VDC source connection VDC min 11 Voltage below 11VDC will inhibit VDC max 13 J1 20 output switching mA max loading 50 2VDC source connection VDC min 11 VDC max 13 J1 22 mA max loading 50 Signal Common J1 24 2 14 Aerotech Inc Version 1 1 DS160 Series User s Manual DS160 Servo Amplifier Module Table 2 8 Power Connection Specifications Unit Value Pin Comment B B return connection VDC max 165 JI 28 B The DC bus voltage for the power stage of DS160 Servo is applied here Warning Interconnect wiring between these points VDC max 7 TES must never be more than 18 inches in B return length Both wires must be twisted together See Figure 2 9 for more information Motor connections Volts max 165 J1 26 Provide PWM
29. for DS16020 16030 2 13 F Fault output 2 4 Field Service Information A 1 Field Service Policy A 1 Introduction 1 1 J13 pinouts 3 14 L Load connections 3 3 3 12 M Motor output specifications for DSR F 3 7 Mounting specifications for the DSR F 3 3 Mounting the DS160 series 2 1 P Parts DS160 series 2 16 DSR F 3 18 Personality module 2 5 2 10 2 16 Pinouts for J13 3 14 Post amplifier specifications for DS 16020 16030 2 8 Potentiometer Description 2 5 Overview 1 1 Power connection specifications 2 15 Pre amplifier Gain characteristics 2 8 2 9 PWM 1 1 Output stage 1 1 Output switching frequency 1 1 R Replacement parts for the DSR F 3 18 S Shunt regulator option 3 1 Six axis mounting rack DSRF 3 2 3 3 Specifications 2 1 Version 1 1 Aerotech Inc i Index DS160 Series User s Manual T W Three axis mounting rack DSR 3 1 3 2 Warranty Information A 1 Transformer TV2 5 3 11 Warranty Policy A 1 Specifications 3 15 Wiring into a system Troubleshooting DS160 2 8 DS160 series 2 13 2 15 DSR F 3 11 DSR E 3 17 TV2 5 transformer 3 11 V V V 11 Aerotech Inc Version 1 1 READER S COMMENTS AEROTECH DS160 Series Servo Amplifier User s Manual P N EDA119 September 2000 Please answer the questions below and add any suggestions for improving this document Is the information Adequate to the subject Well organized Clearly presente
30. l La san den ence oi peo dean e ee cedet 2 5 2 8 Setting the Current Limit eee 2 8 2 9 Pre Amplifier Gain Characteristics eee 2 8 2 10 The PostAmplifier nece te eei erg a oars 2 8 2 11 Wiring DS160 into A System sse sese eee 2 8 2 12 Troubleshooting the DS160 Series essen 2 13 CHAPTER 3 DSR AND DSRF MOUNTING RACKS 3 1 3 1 ItrO y s te terere a eie ei eats 3 1 3 2 Three Axis Mounting Rack DSR eee 3 1 313 Shunt Regulatory nennen nne 3 1 3 4 Control amp Power Connections to Mounting Racks 3 1 3 5 Six Axis Mounting Rack DSRF seen 3 3 3 6 Mounting Specifications nennen 3 3 3 7 Electrical Specifications ses sese eee eee 3 6 3 8 Functional Diagram eee Deseret eben 3 8 3 9 Wiring DSR DSRF into System esee 3 11 3 10 The TV 2 5 DC Bus Power Transformer sss esse esse sees sees eee 3 11 3 11 Troubleshooting eee u SS u puas 3 17 3 12 DSR amp DSRF Spare Parts eee etit 3 18 APPENDIX A WARRANTY AND FIELD SERVICE POLICY A 1 INDEX Version 1 1 Aerotech Inc iii Table of Contents Aerotech Inc DS160 Series User s Manual Version 1 1 DS160 Series User s Manual List of Figures and Tables LIST OF FIGURES Figure 1 1 The DS160 Series Servo Amplifiers
31. lly designed and or manufactured for buyer s use or purpose Aerotech s liability or any claim for loss or damage arising out of the sale resale or use of any of its products shall in no event exceed the selling price of the unit gt E 3 X p Aerotech Inc warrants its laser products to the original purchaser for a minimum period Laser Products of one year from date of shipment This warranty covers defects in workmanship and material and is voided for all laser power supplies plasma tubes and laser systems subject to electrical or physical abuse tampering such as opening the housing or removal of the serial tag or improper operation as determined by Aerotech This warranty is also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or concealed must be filed with the carrier by the Return Procedure buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty without first obtaining approval from Aerotech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product ret
32. n 18 of JI remains open The current command signal is brought into pin 16 of JI In this case personality module RCN4 is usually reconfigured for unity gain by replacing RCN4 12 to 5 and RCN4 7 to 10 with 4 7Kzx resistors The input tach and gain potentiometer positions are set full CCW Version 1 1 Aerotech Inc 2 5 DS160 Series User s Manual DS160 Servo Amplifier Module uney g zc LP suonoeuuoo M JOJOIN Loc 9c sz Ir sng g ls Ir HOA due 0209190 40A dws 0 09LSA g pue y JeAleooy 1eAuq uo z Jouydwe 104 sureb qu ZLS PGS py ON 1lu led y9eqpaa jueuno pue uuoo PUEWWOJ JUOJINI yy xx 0 uonoeuuoo JOJOU 0 109d sa zz z peoqieuioui sales yo eui ym pesn UIA 9z uonoeuuoo JOJOU uo eBeyoA aq jou jsnw ndino yney uBiu SANDY 3 LON snjd jou e seonpoud uowwoo jeufis oj jpodsau Ir ndino yne uBiu 3AN 10 01 Z LAP POUUOJ UUM uoejo ndui Jouje uo eyon snjd y punoJt jndino jnej Mo BANDE JO Z O LAP JOBUUOD doo7 uedo uonue uo 1eJsueJ 1ndinoAndu SH y yuls eoH A LP vz uio Bis A Ir 8 z enBi4 u 9 z pue g z seunbi4 Sire eq 1eyiduy 1sod u sirejeq Jeyijdwy elq oz elt LP uonejos zi JOJIUON queuing S 1eyiduiy wyo xS TF dad queuing FSA mE nm x 8 JeAuq LS al g 19419994 V J9NSI9Y I pe pem xx V JeAug e I l NOH 4 V JOAloJOy g enlovoy i S19Al9J9Y pue sjeAug GUneoj4 abejs 1 MOd
33. n Characteristics The open loop transfer function for the input connection Vcom pin 16 J1 and tach feedback connection Vfb pin 18 J1 to internal current command signal Icom is shown in Figure 2 6 The gain curves shown in Figure 2 6 are in relation to the values of RCN4 shown in Figure 2 5 2 10 The Post Amplifier A detailed circuit description of the post amplifier shown by dotted lines in Figure 2 4 is outlined in Figure 2 8 The circuitry shown in Figure 2 8 is for reference only and is not intended to be altered by the user Figure 2 8 shows the control relationships of the internal current command Icom with the internal current feedback signal Ifb see also Figure 2 4 and Figure 2 5 A brief outline of the PWM circuit used to control the MOFSET switches of the output power stage is also shown in this figure 2 41 Wiring DS160 into A System A typical user interconnect wiring diagram for two DS160 Servo s operating from a common DC bus and 12 VDC control supply is shown in Figure 2 9 Exercise caution when wiring the DS160 Servo Amplifiers to the DC bus and control power supplies Most important of the wiring considerations is the length of the interconnect wiring between the DC bus power supply and connector J1 pins 28 and 32 of the DS160 Servo Amplifier This interconnect wiring must never exceed 18 inches between 0 45 meter between these two points see Figure 2 9 Also the interconnect wiring between the DC
34. nual DSR and DSRF Mounting Racks CHAPTER 3 DSR AND DSRF MOUNTING RACKS In This Section ex Introduction USE 3 1 e Three Axis Mounting Rack DSR 3 1 AS UR eR EC 3 1 e Control amp Power Connections to Mounting Racks 3 1 e Six Axis Mounting Rack DSRF 3 3 Mountine Specilications umu 3 3 em ElectricaliSpecifications waamwaumanmamawsawaaaaaiymaa 3 6 AECI nasa e SR SO 3 8 e Wiring DSR DSRF into System 1 3 11 e The TV 2 5 DC Bus Power Transformer 3 11 ew RRIT T STS TT 3 17 e DSR amp DSRE Spare parts n 3 18 3 1 Introduction Two types of mounting racks for the DS160 Series Servo Amplifier module may be supplied as an option see Figure 3 1 and Figure 3 2 3 2 Three Axis Mounting Rack DSR The three axis mounting rack DSR shown in Figure 3 1 contains all necessary functions for interfacing up to three DS160 Series Servo Modules with three DC motors If isolation from the AC line is required the only additional item necessary is a transformer for generating power for the internal DC bus power supply A 2 5 KVA transformer is usually all that is necessary for driving up to three DS160 Series amplifier in a typical servo application The control voltages 12 VDC supply are derived internally from an external 115 230 VAC 50 to 400Hz power source 3 3 Shunt Regulator A DC
35. o motor connection 26 or 30 DC bus high voltage trip Volts DC 205 J1 28 32 Requires power down reset min Typical switching efficiency min 93 Efficiency based on switching and resistance losses Version 1 1 Aerotech Inc 2 13 DS160 Servo Amplifier Module DS160 Series User s Manual Table 2 7 Control Interface Specifications Unit Value Pin Comment Input command connection Volts max 20 J1 16 This connection is for the speed Kohms impedance 6 current command input control to the servo module Tach feedback connection Volts max 40 J1 18 This connection is for velocity Kohms impedance 6 feedback to the servo module Shutdown connection Volts max 5to 20 J1 6 Provides shutdown to the power stage of the servo module Pulling Kohms impedance 10 this input to signal common inhibits switching at the power stage I Limit connection VDC 0 JI 12 Provides directional current limit to the servo module via limit switch When pin J1 12 is connected Kohms impedance 10 through a dry contact to signal common current flow from J1 30 to J1 26 is limited to lamp I limit connection VDC 0 JI 14 Provides directional current limit to the servo module via limit switch Kohms impedance 10 When pin J1 14 is connected through a dry contact to signal common current flow from J1 26 to J1 30 is limited to lt lamp Current monitor conn
36. ontrol and Power Connections 3 8 Figure 3 7 Electrical Block Diagram of DSR 1 2 DSRF Mounting Rack 3 9 Figure 3 8 Inside View of DSR Mounting Rack DS160 Amplifiers and Power Supply Module Removed esee 3 10 Figure 3 9 Interconnection for DSR 1 2 DSRF Mounting Rack 3 12 Figure 3 10 Rear View of DSR 1 2 DSRF Mounting Rack 3 13 Figure 3 11 Pinout Definitions for Control Connector J13 3 14 Figure 3 12 TV2 5 Transformer Specifications sese 3 15 Figure 3 13 Typical DC Bus Voltage Characteristics of TV2 5 amp DSR F Mounting Rack stre erit tbe Pe D ebbe UE eibi n 3 16 Version 1 1 Aerotech Inc V List of Figures and Tables DS160 Series User s Manual LIST OF TABLES Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 2 6 Table 2 7 Table 2 8 Table 2 9 Table 2 10 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 3U 6U Card Rack Manufacturers sss sees sees eee ee eee 2 1 Electrical Specifications imita id 2 4 Potentiometer Descriptions 2 5 Personality Module RCN4 Modes eee 2 10 Environmental Specifications essere 2 13 Power Stage Specifications 2 13 Control Interface Specifications sese ee ee ee eee 2 14 Power Connection Specifications
37. pped or VDC max 430 if DC bus is too high loss of shunt regulator or if 12VDC supply is low For electrical specifications on all other connections to internal connector J3 see Table 2 6 Control Interface Specifications Version 1 1 Aerotech Inc E 3 7 DSR and DSRF Mounting Racks DS160 User s Manual 3 8 Functional Diagram A functional diagram of the DSR mounting rack is shown in Figure 3 7 Locations of input and output connectors JI through J4 are shown in Figure 3 6 Pertinent information concerning the location of key items shown in the function diagram Figure 3 7 1s shown in Figure 3 8 AC Power 115 or 230 VAC DC Bus Power Fault Indicator for Control Power J2 Connections LED DS1 41 Axis 1 2 and 3 Axis 1 2 and 3 Motor Control Connections Connections J4 J3 O L y o Optional Stand off SANGER DC BUS POWER 20 INTERFACE 37 CONTROL Hani te WERDE for Plastic Guard AC AC typical 4 DON voltage n eriom d ee Ji 1 19 J4 Ssss pe 85 S amp SS SS SS O 1 2 3 4 J2 2 3 4 5 O O Input 1 Fuse O a d Input 1 Fuse Shunt O Ol DC BUS SHUNT REGULATOR INPUT FUSES OVERLOAD FUSE SEE FIGURE 3 7 FOR DETAILS DANGER HIGH VOLTAGE EXISTS ON CARDRACK BACKPLANE AS SHOWN ABOVE Figure 3 6 Front View of DSR 1 2 DSRF Showing Locations of Input Output Control and Power Connections
38. s Inches 42 154 9 6 10 180 3 7 10 56 70 115 Top amp Bottom gu E 140 5 50 e TV2 5 Transformer Specifications 148 5 81 Use 14 20 Mounting Hardware Version 1 1 Aerotech Inc 3 15 DSR and DSRF Mounting Racks DS160 User s Manual 50 DC AMPS Curves shown are for center tap and full wave configurations see Figure 3 9 Figure 3 13 Typical DC Bus Voltage Characteristics of TV2 5 amp DSR F Mounting Rack 3 16 Aerotech Inc Version 1 1 DS160 User s Manual DSR and DSRF Mounting Racks 3 11 Troubleshooting A troubleshooting guide for the DSR F mounting racks appears below in Table 3 5 Table 3 5 Troubleshooting Condition Possible Cause Reference Shutdown inputs pins 4 10 16 of _ x J3 are pulled to signal common ki PSD ecl Daple ust 115 230 VAC control input Active LED s on DS160 a Figure 3 7 Figure 3 9 Series servo are de energized with 115 230 VAC applied at connector J2 power below minimum level Motor short circuit condition at motor output power connections pin 1 through 6 on J4 12VDC power supply fuse F2 open Figure 3 7 Figure 3 9 Figure 3 7 Figure 3 8 If fuse is open do not attempt repair Active LED s on DS160 Series servo module s are energized but no torque is present on motor shaft Directional current limit contacts limit and I limit pins 6 12 18 2
39. service cost Rush service is subject to Aerotech s approval If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs For warranty field repairs the customer will not be charged for the cost of labor and material If service is rendered at times other than normal work periods then special service rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply 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 service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs and the prevailing labor cost including travel time necessary to complete
40. the repair Aerotech Inc Phone 412 963 7470 101 Zeta Drive Fax 412 963 7459 Pittsburgh PA 15238 2897 TWX 710 795 3125 USA V VV Aerotech Inc Version 1 1 DS160 Series User s Manual Index C Control and power connections DS160 2 2 DSR F 3 1 Control input power specifications for DSR F 3 6 Control interface specifications DS160 2 14 DSR F 3 7 Control modes of DS160 Series 2 5 Current limit 2 4 2 5 2 8 3 17 D Description DS160 series 2 1 DSR 3 1 DSRF 3 3 DS16020 DS16030 Control interface specifications 2 14 Control modes 2 5 Electrical specifications 2 4 Environmental specifications 2 13 Fault output 2 4 Mounting specifications 2 1 Personality module 2 5 Pictures of 1 1 2 2 Post amplifier specifications 2 8 2 11 Power and control connections 2 2 Power connection specifications 2 15 Power stage specifications 2 13 Pre amplifier Specifications 2 4 Spare parts 2 16 Troubleshooting guide 2 15 DSR DSRF Control and power connections 3 1 Control input power specifications 3 6 Control interface specifications 3 7 Electrical specifications 3 6 Functional diagram 3 8 Interconnection 3 12 Introduction 3 1 Motor output specifications 3 7 Mounting specifications 3 3 3 4 3 5 Shunt regulator option 3 1 Spare Parts 3 18 Troubleshooting 3 17 Wiring into a system 3 11 E Electrical specifications DS16020 16030 2 4 DSR F 3 6 Environmental specifications
41. ure 3 4 and Figure 3 5 Adequate ventilation space must be provided above and below the mounting rack for adequate convection cooling of the D S160 series amplifiers see Figure 3 4 for minimum airflow space WARNING A side view of the DSR DSRF mounting racks is shown in Figure 3 3 The sides of both mounting racks can be reversed in the field by removing the six screws from both sides as shown This feature allows for field selectable panel mounting or rack mounting The DSRF six axis mounting rack is the standard 19 width allowing it to be panel or rack mounted Mounting ears can be reversed for rack or panel mounting by removing screws both sides Mounting ear in rear when panel mounted N Mounting ear in front when rack mounted VOLTS SERIAL TAG MODEL TAG d i VOLTS TAG gt Indicates requirement for control input power see Figure 3 7 and Figure 3 9 Figure 3 3 Side View of DSR DSRF Mounting Rack Version 1 1 Aerotech Inc 3 3 DSR and DSRF Mounting Racks DS160 User s Manual Allow Sufficient Space For Air Flow Top And Bottom DSR Power Supply M5 10 Clearance Typ DSR FRONT 32 0 1 26 FA T 8 2 Baz fo wem 2222 ZZ 157 5 6 20 50 i 2 00 4 8 av 9 9 22 5 0 89 t ka 132 8 5
42. urned later than 30 days after the issuance of a return authorization number will be subject to review After Aerotech s examination warranty or out of warranty status will be determined If Returned Product upon Aerotech s examination a warranted defect exists then the product s will be Warranty Determination repaired at no charge and shipped prepaid back to the buyer If the buyer desires an air freight return the product s will be shipped collect Warranty repairs do not extend the original warranty period Version 1 1 Aerotech Inc A 1 Appendix A 4020 LS User s Manual Returned Product Non warranty Determination Rush Service On site Warranty Repair On site Non warranty Repair Company Address After Aerotech s examination the buyer shall be notified of the repair cost At such time the buyer must issue a valid purchase order to cover the cost of the repair and freight or authorize the product s to be shipped back as is at the buyer s expense Failure to obtain a purchase order number or approval within 30 days of notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Replacement components are warranted for one year from date of shipment At times the buyer may desire to expedite a repair Regardless of warranty or out of warranty status the buyer must issue a valid purchase order to cover the added rush
43. ved See Figure 2 2 Figure 2 5 Motor has high pitch oscillation sound when 12VDC and DC bus power is applied Tach and or Gain pot turned too high See Figure 2 2 Figure 2 5 Motor gets excessively hot when running at minimum load condition reference current monitor pin 8 of JI Ripple current peak to peak in excess of 2096 of continuous return of motor due to too high pre amplifier gains See Figure 2 5 Ripple current peak to peak in excess of 20 of continuous return of motor due to too low motor inductance See Figure 2 5 Version 1 1 Aerotech Inc 2 15 DS160 Servo Amplifier Module DS160 Series User s Manual Table 2 10 DS160 Series Replacement Parts Item Aerotech Part Comment DS16020 Servo Amplifier EFA465 Module DS16030 Servo Amplifier EFA469 Motor load fuse FI Use any slow blow fuse no greater than 10 amp for DS16020 and 15 amp for DS16030 current with no less than 250Volt rating Fuse size 3 AG Personality Module EIK135 Used for pre selection of gain and parameters for other motor EIK 162 combinations Quick connect mating connector ECK381 Mating connector for discrete for connector J1 back plane termination Solder type mating connector for ECK352 Mating connector for printed connector J1 circuit motherboard termination VV V 2 16 Aerotech Inc Version 1 1 DS160 User s Ma
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