User Manual - Galil Motion Control
Contents
1. Jumper INCOM to 5V to tie the controller s digital input common to the controller s 5 V power supply Optima series only This bypasses the optoisolation for the digital inputs EXT RESET Jumper EXT RESET to RST LSCOM to bring out the controller s Reset digital input to AUX I O J3 pin 44 LSCOM Jumper LSCOM to RST LSCOM to bring the controller s limit home switch common to AUX I O J3 pin 44 Optima series only An external DC power supply between 5 and 24 V must be connected to this pin to use the controller s limit and home switches Jumper LSCOM to 5V to tie the controller s limit home switch common to the controller s 5 V power supply Optima series only This bypasses the optoisolation for the limit and home switch inputs Analog Ground GND AG Insert jumper when using a DMC 2000 2100 or 2200 controller This ties the analog 12 V ground to digital 5 V ground PGM reserved AMP 19520 40 Jumpers e 11 External Amplifiers These jumpers must be set if external amplifiers are connected to the controller through the AMP 19520 40 Install MCM and AEN if the axis drives an external servo amplifier other than the AMP 19520 40 That axis s PWM and SGN digital outputs will be inaccessible Install PWM and SGN if the axis drives an external stepper amplifier or external PWM input servo amplifier That axis s MCM and AEN outputs will be inaccessible The SM jumper s must be installed on the controlle2. 171639 1 6 e Mating Connectors AMP 19520 40 Layout and Dimensions 8 525 m F 6 250 o 23 MY Mx POWER ooolo ont POWER GALIL a yf E N JALOG POWER ae z Y x oe a overran error 19 40 6 20 169 i i O PLCS 7 SPI AUX ENC gt _ J1 0 000 p 0 275 iial AA eee Senses O 13 O wm G 0 0 8 750 a 8 250 REF _ Figure 2 AMP 19520 40 Dimensions Overall Dimensions 8 75 x 6 80 AMP 19520 40 Mating Connectors e 7 Setup Connect an unregulated DC power supply 18 80 V to the POWER connector Before applying drive power for the first time take appropriate safety precautions set a small error limit ER 1000 set Off on Error for all axes OE 1 and set a low torgue limit TK 2 TL 2 Amplifier Setup
3. Select the amplifier gain that is appropriate for the motor The amplifier gain can be set to 0 4 A V AGO jumper 0 7 A V no AG jumper and 1 0 A V AG2 jumper This is the only jumper setting required to begin turning a motor however more jumper settings may be required to configure the optional shunt regulator amplifier error monitoring optoisolation power and external amplifiers see next section Jumpers Peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit sets the maximum voltage that will be output from the controller to the amplifier The continuous current sets what the maximum average current is over a quarter second interval The following figure captured with WSDK shows the continuous and peak operation The continuous limit was 2 V and the peak limit was 10 V if the gain is set to 0 7 A V a torque limit of 2 causes the amplifier to never exceed 1 4 A on the specified axis Storage Scope Zoom 078 016 005 797 1 1 1 1 1 1 1 1 1 1 1 1 lt ri 1 1 1 eens 108 9 145 3 181 6 Figure 3 Peak and Continuous Current Operation 8 0 Setup AMP 19520 40 Brushless Motor Setup To con
4. 00 1700 1800 2000 2100 2200 Econo Series DMC 18x2 21x2 Please use the AMP 20520 40 instead with the DMC 21x3 Electrical Specifications The AMP 19520 40 is a brush brushless trans conductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Input Voltage 18 80 VDC Continuous Current 7 amps Peak Current 10 amps Amplifier Gain 0 4 0 7 or 1 0 A V jumper adjustable Switching Freguency 60 kHz up to 175 kHz available contact Galil Minimum Load Inductance 0 5 mH low inductance option available Communtation Angle 120 60 option available Heat Transfer If all AMP 19520 40 axes run at less than 3 A thermal cooling is usually not required For axes running greater than 3 A it is up to the user to make sure that heat is adequately transferred out of the amplifier If the amplifier is not properly cooled it may reach 110 C and the amplifier will shut down All electrical components inside the amplifier that generate appreciable heat are in thermal contact with the metal back plate so consideration should be taken to mount the amplifier to a thermally conductive surface e g metal preferably with thermal grease AMP 19520 40 Introduction e 5 Viet eh T gt Figure 1 19540 Mating Connectors Connector Terminal Pins POWER 8 pin AMP 770579 1 AMP 171639 1 MX MY MZ MW 4 pin AMP 172167 1 AMP
5. 9520 40 e 13 Pinout POWER 8 pin AMP Mate n lock II ANALOG Optima Controllers Only 15 pin Male D sub AUX 1 0 44 pin Hi density Female D sub 1 Ground 1 PWM MCMD Z 1 Earth 2 Analog input 1 2 Output 6 2 VM 18 V 80 3 Analog input 3 3 Output 8 VM 18 V 80 4 Analog input 5 4 Output 5 4 VM 18 80 5 Analog input 7 5 Output 2 5 Ground 6 Ground 6 Abort 6 Ground 7 12 V 7 Input 6 7 Ground 85V 8 Latch Z Input 3 8 Ground 9 Ground 9 SIGN AEN Y 10 Analog input 2 11 Analog input 4 10 Encoder compare output MX MY MZ MW Motor Output 4 pin AMP Mate n lock II 12 Analog input 6 11 Reverse limit X 13 Analog input 8 12 Reverse limit Y 14 Ground 13 Reverse limit Z 1 Earth 15 12 V 14 Reverse limit W 2A 3C 15 Forward limit W 16 SIGN AEN W 4B 17 SIGN AEN Z X Y Z W 15 pin Hi density Female D sub 11 2B 3 A 4 AB 5 Ground 9 AA 10 Hall A 11 AA 12 AB 13 Hall B 14 Hall C 155V SPI 9 pin Female D sub 1 Reserved AUX ENC connects 18 Output 7
6. Multi axis Brushless Brush Servo Amplifier AMP 19520 40 Rev 1 0d By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet Address support galilmc com URL www galilmc com Rev 01 10 THIS PAGE LEFT BLANK INTENTIONALLY Using This Manual This user manual provides information for proper operation of the AMP 19520 and AMP 19540 multi axis amplifiers The AMP 19520 40 has been designed to work with both brushless and brush type servo motors and installation will vary depending upon which type of motor is used Although the axes are labeled X Y Z and W on the AMP 19520 40 note the following axis naming conventions Total Controller Axes Amplifier s Used Controller Axis Names per Galil software Amplifier Axis Names per AMP 19520 40 silkscreen Two AMP 19540s A B C D E F G 7 W 2 1 19520 X 2 AMP 19520 A B X Y 3 AMP 19540 X Y Z 4 AMP 19540 B C D Z W 5 19540 and AMP 19520 A B C D E X Y Z W X 6 19540 and AMP 19520 A B C D E X Y Z W X Y 7 8 Two AMP 19540s A D E F G H X 7 W 27 W WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as par
7. R digital output is brought low Insert either the 7_IN or ABORT jumper to notify the controller of these conditions OPT Reserved ELO ELO Emergency Lock Out is a jumper setting on the AMP 195x0 which configures the amplifier s behavior when the abort line goes low With the jumper absent default the behavior of the motors is subject to the OE command If the jumper is installed the amplifiers will be immediately shut down leaving the axes in a free spin state Having the ELO jumper installed is similar to OE1 except that the amplifiers are disabled in hardware rather than firmware WHEN IS INSTALLED OE SHOULD BE SET 1 To recover issue MO SH When is active the overcurrent and overvoltage lights will turn on EFGH reserved 7_IN Install this jumper to tie the amplifier s AMP ERR digital output to digital input 7 on the controller This jumper allows the controller to handle an amplifier error condition for example by issuing the ST command from ININT see in the command reference INCOM MUST BE POWERED WITH OPTIMA CONTROLLERS ABORT Install this jumper to tie the amplifier s AMP ERR digital output to the controller s Abort digital input When the Abort input is brought low the controller will stop program execution and bring all axes to an instantaneous stop OE0 or allow the motors to coast OE1 INCOM MUST BE POWERED WITH OPTIMA CONTROLLERS CHOP Install for chopper mode for low inducta
8. dy to perform closed loop motion Brush Motor Setup To configure an axis for brush motor operation connect the two motor leads to the Phase A and Phase B connections for the axis MX MY MZ MW Leave the C Phase disconnected Connect the encoders 15 pin high density X Y Z W home switches and limit switches AUX I O J3 The amplifier has no need for the Hall inputs when operating brush motors AMP 19520 40 Setup 9 Jumpers Shunt Regulator 90V 64V 33V The AMP 19520 40 has an OPTIONAL internal shunt regulator for example order AMP 19540 SR A shunt regulator is a power resistor and switch connected across the power supply used to dissipate energy fed back to the amplifier from the motor This keeps the power supply voltage from exceeding hazardous levels The shunt regulator is unused when no jumper is installed OVERVOLTAGE error condition will occur if the supply voltage exceeds 94 V Install a single jumper on the desired voltage threshold 90V 64V or 33V to use the shunt regulator The switch will close when the power supply s capacitor exceeds the voltage threshold The voltage threshold chosen should be the one just higher than the nominal supply voltage e g use the 33 V jumper when using a 24 V supply For more information see Application Note 5448 Shunt Regulator Operation Amplifier Error Monitoring When an amplifier error occurs UNDERVOLTAGE OVERCURRENT OVERVOLTAGE or OVERTEMP the AMP ER
9. figure an axis for brushless motor operation connect the encoders and Hall sensors 15 pin high density X Y Z or W home switches and limit switches AUX I O 33 The AMP 19520 40 can normally only be connected to a brushless motor with 120 degree Hall commutation 60 degree Hall commutation is an option and can be specified by ordering AMP 19540 COM60 Next connect the three motor power leads to the phase A B and C connections for the axis MX MY MZ or MW The motor wiring must correspond to the Hall wiring so if the motor manufacturer indicates how to do this simply connect the power leads as specified Otherwise you will need to try up to six motor power lead combinations keeping the hall sensor wiring fixed until smooth motion results Three of the combinations result in a stall condition no torque two result in jerky motion in one direction but smooth in the other and the last correct combination results in smooth movement in both directions The following table will help you connect all six combinations Table 1 Aid to connect all six motor power lead combinations Phase A Phase B Phase C Behavior Power Lead 1 Power Lead 2 Power Lead 3 Power Lead 1 Power Lead 3 Power Lead 2 Power Lead 2 Power Lead 3 Power Lead 1 Power Lead 2 Power Lead 1 Power Lead 3 Power Lead 3 Power Lead 1 Power Lead 2 Power Lead 3 Power Lead 2 Power Lead 1 Once the motor is wired correctly the controller is rea
10. nce motors otherwise the amplifier operates in inverter mode Rev D or newer Amplifier Gains If AG2 and AGO are not installed the amplifier gain on that axis is 0 7 A V medium 10 Jumpers AMP 19520 40 AG2 Sets the amplifier gain on that axis to 1 0 A V high AGO Sets the amplifier gain on that axis to 0 4 A V low No jumper for normal current loop gain Jumper for high current loop gain The normal current loop gain should be chosen for low inductance motors less than 5 mH with a 24V supply or 10 mH with a 48 V supply Optoisolation Power These jumpers set the power source for the controller s digital input optoisolators If an external supply is used for the general purpose inputs the Error digital output is unavailable If an external supply is used for the limit and home switch inputs the Reset digital input is unavailable NOTE If the AMP 19540 will be used with a controller that has optoisolation such as an Optima or Accelera series product and the system requires an isolated supply greater than 5V please consult Galil EROUT Jumper EROUT to ERR INCOM to bring out the controller s error digital output to AUX I O J3 pin 30 INCOM Jumper INCOM to ERR INCOM to bring the controller s digital input common to AUX I O J3 pin 30 Optima series only An external DC power supply between 5 and 24 V must be connected to this pin to use the controller s general purpose digital inputs and Abort input
11. r Jumper MCM to J3 x to bring that axis s Motor Command Analog Output to J3 AUX I O J3 connector at pin x AEN Jumper AEN to J3 x to bring that axis s motor Amplifier Enable Digital Output to the J3 AUX I O 13 connector at pin x PWM Jumper PWM to J3 x to bring that axis s Pulse Width Modulation Digital Output to the J3 AUX I O J3 connector at pin SGN Jumper SGN to J3 x to bring that axis s Sign Digital Output to the J3 AUX I O 13 connector at pin x Indicator Lights and Errors The amplifier is protected against under voltage over current over voltage and over temperature conditions which are indicated by LEDs It responds to these conditions by disabling and setting it s AMP ERR digital output low The controller can be informed of amplifier errors via AMP ERR by installing the 7_IN or ABORT jumpers POWER and Under Voltage Indicates whether amplifier power 18 80 VDC AND board level power 5 12 VDC is applied both the POWER connector and 100 pin J1 connector must be connected for this indicator to light If the power supply voltage drops below 12 V Under Voltage the amplifier disables and the POWER light will turn off The amplifier will automatically re enable once the supply rises above the 12 V OVERCURRENT If the current on any axis exceeds 10 A the amplifier will disable The amplifier will remain disabled until the controller sets all Amp Enable lines low and subsequently sets at lea
12. st one high issue MO SH to reset This fault indicates a system level problem and is usually due to a short across the motor leads or a short from a motor lead to ground OVERVOLTAGE Indicates that the amplifier power 18 80 VDC applied to the POWER connector has risen above 94 V due to regenerative energy fed back from the motor The amplifier will short the motor leads regenerative braking and will automatically return to normal operation when the supply drops below 89 V 12 Indicator Lights and Errors AMP 19520 40 OVERTEMP If the heat sink temperature rises above 110 C the amplifier disables and will automatically re enable when the temperature drops below 110 C ERROR Reflects the status of the controller s NOT the amplifier s error digital output This indicator lights under the following conditions 1 when the RESET button on the AMP 19520 40 is pushed this toggles the controller s Reset digital input 2 momentarily lights when power is applied to the controller 3 one or more of the controller s axes is not following well TE exceeds ER 4 when a controller hardware failure occurs e g 5 V supply out of tolerance corrupted firmware Note Do not hot swap the motor power connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector AMP 1
13. t of the machine Galil shall not be liable or responsible for any incidental or conseguential damages Contents ia 5 ELECTRIGAL SPECIFICATIONS 5 E AA av eat ea eee a RES 5 MATINGCONNEGTORS aa 6 SETUP SRS IA an AA E AA tt 8 Ampa KA 8 Brushless Motor Setup sasa 9 Brush MOtot Set p 9 JUMPERS POWER and Under V ltage s al kees eu a 12 OVERGURREN Fi 12 OVERVOETAGE Sirtsi ask k lina RR 12 OVERTEMP tive sive bee Sin eal teeta 13 ERROR rait Gh EE REE ag da 13 PINOUT ii TD 14 4 e Contents AMP 19520 40 Introduction The AMP 19540 four axis and AMP 19520 two axis are multi axis brush brushless amplifiers that are capable of handling 500 watts of continuous power per axis The amplifier accepts 18 80 VDC and includes breakout for all controller I O including encoders Hall effect switches digital inputs digital outputs and analog inputs Optima controllers only The AMP 19520 19540 Brushless drive module can be connected to any of the following Galil controllers via the 100 pin high density connector Optima Series DMC 1200 13x8 16
14. to controller 19 Output 4 25 pin Male D sub 20 Output 1 15V 21 Output 3 2 22 Input 7 3 ABX 23 Latch W Input 4 4 AAY 24 Latch X Input 1 5 ABY 25 PWM MCMD X 65V 26 Home X 7 AAZ 27 Home Y 8 ABZ 28 Home Z 9 AAW 29 Home W 10 ABW 30 Error 11 Reserved Output INCOM 12 Reserved 31 PWM MCMD W 13 Reserved 325 14 Ground 335 V 15 AAX 34 Ground 16 ABX 35 Ground 17 AAY 36 Input 8 18 ABY 37 Input 5 19 Ground 38 Latch Y Input 2 20 AAZ 39 PWM MCMD Y 21 ABZ 40 SIGN AEN X 22 AAW 41 Forward limit X 23 ABW 42 Forward limit Y 24 Reserved 43 Forward limit Z 14 e Pinout 25 Reserved 44 Reset LSCOM Active Low AMP 19520 40
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