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1. NOTES Solois PRIMARY FUSE AUXPWR OPTION 4A SLO BLO 1 THE AUXPWR OPTION IS USED WHEN THE MAIN SUPPLY POWER IS BELOW U TRANSFORMER 18 WHT ACHI 100VAC TYPICALLY 28 56VAC INPUT THIS COREESPONDS TO A BUS INTERNAL AG VOLTAGE OF 40 80VDC THE CONFIGURATION SHOWN IS FOR ISOLATED THERMAL CS uis WHT splice ACLO 50 60 HZ 115VAC 160VDC BUS OPERATION INPUT REDS56v 115vBLK SAETEY 2 FOR 100VAC PRIMARY INPUT PARALLEL THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED 100v ORN AN GRN ov 3 FOR 200VAC PRIMARY INPUT SERIES THE 100VAC TAPS AND LEAVE THE zz 0v GRAY 115VAC TAPS UNTERMINATED go splice 2 28 Xov BEN 4 WHEN USING AN ISOLATION TRANSFORMER EARTH GROUNDING OF AC2 YEL 56v e INPUT TAP REDUCES ELECTRICAL AND AUDIBLE NOISE EMMISSIONS AND id PROVIDES INCREASED SERVO PERFORMANCE Ov BLU 5 ITIS RECOMMENDED THAT THE OPTIONAL AND MAIN SUPPLIES ARE CONNECTED TO THE SAME SOURCE AS SHOWN THIS WILL ENSURE PROPER SOFT START OPERATION 6 ADDITIONAL OR ALTERNATIVE FUSING MAY BE REQUIRED FOR OPTIMUM FRAME GROUND PERFORMANCE 22 Sa K3 N TV0 3 56 WIRING PRIMARY 115VAC SECONDARY 115VAC 160VDC BUS TRANSFORMER P N EAX01006 Soloist PRIMARY FUSE 3A SLO BLO AUXPWR OPTION TRANSFORMER 18 WHT JU ACHI INTERNAL THERMAL 230VAC SWITCH S 18 WHT Splice ACLO 50 60 HZ RED 56v 115v BLK RIT SAFTEY 100v OR
2. mn 9 Q 1B207 2 2 gt ps 1 FS Figure 4 1 Option Board 690D1611 Rev 0 4 2 1 Analog Input 1 TB201 Analog input 1 is differential and buffered by a precision unity gain differential AD622 instrumentation amplifier and converted to digital by a 12 bit ADS7816 analog to digital converter allowing an input voltage in the range of 10 volts This produces a resolution of 4 88 millivolts per bit of the A D Refer to Figure 4 2 To interface to a single ended non differential voltage ground the negative input and connect your signal to the positive input Analog input 0 is available at J104 see section 3 1 5 The analog input has a 10 Giga ohm input impedance Table 4 2 Optional Analog Input Connector Pin out TB201 Pin Label Description In Out Bi 1 AGND Analog Common N A 2 AIN1 Non Inverting Analog Input 1 Input 3 AINI Inverting Analog Input 1 Input 12V EF AD622 _ys 12V Figure 4 2 Optional Analog Input Connector TB201 4 2 www aerotech com Soloist Hardware Manual Soloist Options 4 2 2 Analog Output 1 TB201 Analog output 1 is driven by a 16 bit DAC8531 digital to analog converter and buffered by 084 op amp producing a single ended output voltage in the range of 10 volts This produces a resolution of 305 uVolts per bit of the D A The output current is limited to less
3. 3 18 Figure 3 16 RS 232 Connector 103 046000 7 3 19 Figure 4 1 Option Board 69001611 Rev 0 4 2 Figure 4 2 Optional Analog Input Connector TB201 4 2 Figure 4 3 Analog Output Connector TB201 esee 4 3 Figure 4 4 Connecting Outputs in Current Sinking 2 2 2 2 4 5 Figure 4 5 Connecting Outputs in Current Sourcing Mode 4 5 Figure 4 6 Inputs Connected in Current Sourcing Mode 4 7 Figure 4 7 Inputs Connected in Current Sinking Mode 4 8 WWW aerotech com List of Figures Soloist Hardware Manual Figure 4 8 Figure 4 9 Figure 4 10 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 6 1 Brake Connected to 206 4 11 Brake Connected 1 103 4 11 Suppression for DC Brake 5 22 441 211 4 13 Joystick Interface citet pti or e ERES PER 5 5 Single Axis Joystick Interface to J104 of the Soloist 5 6 Single Axis Joystick Interconnect to J104 of the Soloist 5 6 Handwheel Interconnection to J104 of the Soloist 5 7 Handwheel with Flying Lea
4. 26HD FEMALE I O Soloist JOYSTICK INTERCONNECT 19792 CABLE JOYSTICK 620B1345 2 620B1345 201 DWG Figure 5 3 Single Axis Joystick Interconnect to J104 of the Soloist 5 6 www aerotech com Soloist Hardware Manual Accessories 5 3 Handwheel Interface The user may connect a handwheel or any device producing differential quadrature signals for manual positioning of the axes See the Soloist Help for information on the Gear command to enable the handwheel The handwheel may be connected to J104 of the Soloist as shown in Figure 5 4 below The following drawing Figure 5 4 is shown for reference only and was complete and accurate as of this manual s release The most recent Dwg files and a viewer may be found on your software CD 3 AUET OR ARILENGIH 1 INSTALL LABEL TO BACK OF HANDWHEEL To Soloist HANDWHEEL MODEL HWASR 26HD Xx XX CABLE LENGTH IN DECIMETERS ETT RED SIN XXXXXX WORK ORDER NUMBER COM 21 2 ov 4 424 SUMTAK SIN 1 3 A LGF 043 100 2 BLU 4 AN ECZ00201 2 CABLE LENGTH WF 100 LINES REV CAUTION CABLE LENGTHS XX ARE IN DECIMETERS COSN t 5 EXAMPLE HWA32 26HD 30 COST id GRN 30 30 DECIMETERS 3 METERS 10FT 4 3 CONNECTOR VIEW FROM SOLDER SIDE ECX00570 CABLE 3
5. Off is indicated by O 0 The shaded cells columns 9 through 5 should be left in their factory preset positions normally all on www aerotech com 2 23 Installation and Configuration Soloist Hardware Manual 2 11 Soloist Help Information For additional information about the Soloist and PC configuration hardware requirements programming utilities and system operation and the Soloist HMI application see the Getting Started in the Soloist Help 2 24 WWW aerotech com Soloist Hardware Manual Technical Details CHAPTER 3 TECHNICAL DETAILS In This Section e Port 0 I O and the Secondary Encoder Channel J104 3 1 e Secondary Encoder Channel 104 3 3 e Port 0 User Digital Outputs J104 3 5 e Port 0 User Digital Inputs 104 2 2 2 224242 2 1 3 8 User Analog Output 0 1104 s 3 11 e User Analog Input 0 104 0 3 12 e Position Synchronized Output 3 13 euxaivIotonbeedbackdil 3 15 e Brake Relay Interface 103 TB103 3 18 REZ GEIEN coooa 3 19 USB OLONE 3 20 Planned Option Consult Aerotech Inc for availability 3 1 Port 0 I O and the Secondary Encoder Channel J104 The J104 connect
6. C19360 xx BL MTR FL 4DU MAX450DM PMCHPDNT yy Obsolete Used On Any brushless motor stage having a 4 pin D style connector for motor power BM BMS motors with D25 option ABL2000 amp 8000 series ABR1000 Series ADR160 240 series ADRT series ALA1000 series Motor Output ALS130 135 2200 3600 5000 5000WB 20000 amp 25000 series Motor 125 series ASR1000 1100 amp 2000 series with LHPD option ATS1100 H series LMA amp LMAC series The length measured in decimeters length measured in feet www aerotech com 5 3 Accessories Soloist Hardware Manual Table 5 4 Individual Feedback Cables Soloist Part Number s Description Stage Motor C16501 xx BL FB 25DU 25DU MAX120DM C16505 xx BL FB 25DU 25DU MAX240DM BFCMX yy Obsolete Used On Motor Feedback Any brushless motor stage having a 25 pin 10 istyle connector for encoder limits halls and brake BM BMS motors with D25 option ABL2000 amp 8000 series ABR1000 Series ADR160 240 series ADRT series ALA1000 series ALS130 135 2200 3600 5000 5000WB 20000 amp 25000 series 125 series 1000 1100 amp 2000 series with HPD option ATS1100 H series Encoder Limits Halls Brake Motor Feedback LMA
7. ES 65 7 2 59 I 63 5 2 50 I2 63 5 2 50 31 8 1 25 pt 159100981 31801 25 pt AES Each unit should be surrounded by 25mm 1 inch of free air space __1 947 90 19 TYP i 910 3 0 41 TYP Mounting i Hole 5 5 Layout 5 E as s p laa ce E 4 7 0 19 4 7 0 19 3 4 6 40 25 5 2 MTG HDWR 5 10 6 m a 2 Figure 1 4 Soloist Physical Dimensions The Soloist case temperature may exceed 75 C in some applications 1 8 www aerotech com Soloist Hardware Manual Introduction 1 8 Environmental Specifications The environmental specifications for the Soloist are listed in the following table Temperature Ambient Operating 50 SOLC 417 122 Storage 20 70CC 4 158 Humidity Maximum relative humidity is 80 for temperatures up to decreasing linearly to 50 relative humidity at 40 C Non condensing Altitude Up to 2000 meters Pollution Pollution degree 2 on conductive pollution Use Indoor use only WWW aerotech com 1 9 Introduction Soloist Hardware Manual 1 10 www aerotech com Soloist Hardware Manual Installation and Configuration CHAPTER2 INSTALLATION AND CONFIGURATION In This Section Introduction eU 2 1 e Safety Procedures and Warnings
8. 3 1 WWW aerotech com Table of Contents iii Table of Contents Soloist Hardware Manual CHAPTER 4 CHAPTER 5 CHAPTER 6 APPENDIX A APPENDIX B APPENDIX C INDEX 3 2 3 4 3 9 4 1 4 2 5 1 5 2 9 3 1 CA 3 1 1 Secondary Encoder Channel 104 3 3 3 1 2 Port 0 User Digital Outputs J104 2 2 22 2 44 2 2 3 5 3 1 3 Port 0 User Digital Inputs J104 esses 3 8 3 1 4 User Analog Output 0 J104 esses 3 11 3 1 5 User Analog Input 0 J104 sss 3 12 Position Synchronized Output PSO sess 3 13 Motor Feedback J103 sese 3 15 3 3 1 MXU Option nein ee ates 3 17 3 3 2 Brake Relay Interface J103 103 3 18 5 232 Serial Port TB1O09 iet ttt er temi enn 3 19 USB Port beret e ce erp ied 3 20 SOLOIST OPTIONS eere 0 4 1 e ote tette eter uli tee istae ehe iti eap tee ue 4 1 IO Option Boatd e 4 2 4 2 1 Analog Input 1 TB201 see 4 2 4 2 2 Analog Output 1 201 0 4 3 4 2 3 Port 1 and Port 2 Opto Isolated Outputs TB202 TB203 E S 4 4 4 2 4 Port 1 and Port 2 Opto
9. 4 6 Table 4 8 Port 2 Opto Isolated Input Connector Pin out TB205 4 7 Table 4 9 User Common Connector Pin out TB204 sess 4 9 Table 4 10 5 Volt Power Connector Pin out 205 4 9 Table 4 11 IOPSO Option Board Jumpers esee 4 9 Table 4 12 Voltage and Current Specifications 206 4 10 Table 4 13 Brake Relay Connector Pin out 206 4 10 Table 4 14 Brake Relay Connector Pin out J103 sese 4 10 Table 5 1 Standard Interconnection Cables 5 1 Table 5 2 Combined Motor amp Feedback Cables sese 5 2 Table 5 3 Individual Motor Cables sssini saa iaeiei 5 3 Table 5 4 Individual Feedback Cables seen 5 4 Table 6 1 Amplifier Faults Causes and Solutions sees 6 2 Table 6 2 Soloist Control Board Test Points eese 6 3 WWW aerotech com vii List of Tables Soloist Hardware Manual Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 6 7 Table C 1 Option Board Test 6 3 Soloist Fuse Information eeeeeeeececeeeee nnn nnn nennen nnne 6 4 IO Board Fuse Information eese 6 4 Soloist Jumper Selec
10. LU Chassis Frame Ground OPTIONAL Secondary Feedback SIN J104 SIN N 2 OPTIONAL Optional 10 Secondary Feedback ndar Secondary cos 11 Line Driver 20 Encoder annel 19 Qr Analog Sine Wave 5V 12 With MXH Multiplier COM Chassis Frame Ground Typical limit encoder cables are the BFC BFCMX or BFCD cables For full cable drawings refer to your software CD ROM Figure 2 14 Encoder Feedback Connections www aerotech com 2 19 Installation and Configuration Soloist Hardware Manual 2 8 Encoder Phasing Tthe required encoder phasing for CW motor rotation or positive forcer movement Postne through the stationary magnet track is illustrated in Figure 2 15 If the motor is not visible or cannot be manually moved by hand it can be actively driven open loop by 88 Motor Shaft running the Soloist Programs Samples MsetDebug Ab program This program moves the motor in a positive direction allowing the position of the encoder to be monitored in the Soloist HMI as shown in Figure 2 16 The program causes the encoder to produce a more positive position If it counts negative swap the connections to the controllers SIN and the SIN N encoder inputs or the sign of the CfgFbkVelMultiplier and CfgFbkPosMultiplier parameters However if this axis is configured for dual loop two feedback devices one for position and one for velocity feedback invert the sign o
11. 1 1 1 1 Feature dete oret tette Cer eben tees 1 2 12 11 Power 1 2 1 2 23 Dual Encoder Feedback Channels 1 2 1 2 3 Inputs and 1 2 124 IO Option Feature 1 2 Soloist 8 enne enne nnne en nnne entren 1 3 Soloist Power Features 1 4 Soloist Voltage Configurations 2 1 5 Electrical Specifications 1 6 Physical Dimensions nennen enne ens 1 8 Environmental 1 9 INSTALLATION AND 2 1 oce ete ttu terii ee eR bes 2 1 Safety Procedures and Warnings sese 2 2 Motor AC Power Connections esee 2 3 Wiring Grounding and Shielding Techniques 2 4 2 4 1 Minimizing EMI 2 4 2 4 2 AUXPWR Auxiliary Power Option 2 5 2 4 5 40 80 VDC Power Transformers eee 2 5 Typical AC Wiring with the AUXPWR Option and an Exte
12. 1 4 Voltage ElectnicallS peciticationsm 22222277 7 1 6 2 22 1 8 e Environmental Specifications 1 9 1 1 Chapter Overview Use this chapter to become familiar with the features on your Soloist This chapter includes electrical mechanical and environmental specifications ENB FLT MARKER ETHERNET 1102 MOTOR FEEDBACK 103 Soloist ESTOP TB101 AUX I O J104 Standard with I O Option Figure 1 1 Both Versions of the Soloist www aerotech com 1 1 Introduction Soloist Hardware Manual 12 Feature Summary Review the following summary of the standard and optional features of the Soloist 12 1 Power Amplifier e Configure for brush brushless and stepper motor operation e Standard 100 VDC 11320 VDC optional 10 VDC 0320 VDC bus operation e Fully isolated power stage e Full protection against the following failure modes 1 Control supply under voltage Continuous current overload Power stage bias supply under voltage Power stage output short circuit phase to phase and phase to ground DC bus over voltage 6 IGBT isolated gate bipolar transistor device over temperature sense e Keep alive AUXPWR option for emergency stop estop applications e Inrush current limiting e Internal or external shunt option 1 2 2 Dual Encoder Feedb
13. esee 2 2 Motor and AC Power Connections 2 3 Wiring Grounding and Shielding Techniques 2 4 Typical AC Wiring with the AUXPWR Option 2 6 e Emergency Stop Sense Input TB101 2 10 Motor Connections nr reer eee eee 2 12 Communication Channel Settings 2 2 2 22 e Soloist Help 2 24 2 1 Introduction This chapter describes hardware configurations including switches jumpers connectors and power connections used with a brush brushless or stepper motors Wiring grounding shielding techniques and motor phasing are also described www aerotech com 2 1 Installation and Configuration Soloist Hardware Manual 2 2 Safety Procedures and Warnings The following statements define the Warning and Danger symbols that appear in this manual If you fail to observe these precautions serious personal injury or damage to the equipment results If you use the equipment in a manner not specified by the manufacturer the protection provided by the equipment is impaired You must practice caution when following the given procedures Deviation from given procedures results in damage to the equipment or machinery To minimize the possibility of electrical shock and bodily injury if the motor begins to spin you must ensure that the motor is decoup
14. EOE c e c Lm 4 2 Analog 4 2 e Analog 4 3 e Port 1 and Port 2 Opto Isolated Outputs TB202 203 4 4 Port 1 and Port 2 Opto Isolated Inputs 204 TB205 4 6 e User Rowen 2 4 9 e Brake Relay 206 41 Introduction The following options are available for the Soloist Table 4 1 Soloist Options Option Capabilities CAUXPWR Separate control power input for the 20 80VDC bus as described in Chapter 2 section 2 4 2 Analog encoder x512 encoder resolution multiplier option See Chapter MXU 3 LS Shunt option standard on Soloist30 Option Board add 16 digital opto inputs 16 digital opto outputs 1 analog input 1 analog output and brake relay output LS Shunt regulator for regenerative energy dissipation Low bus voltage option for 40 100 VDC bus does not support keep LB alive functionality not available with AUXPWR option 40 100 VDC bus operation requires external transformer to generate 28 70 V AC bus power input JI Industrial Joystick www aerotech com 4 Soloist Options Soloist Hardware Manual 42 Option Board See the following sections for details on the connector Pin out and technical information for the IO options 18206 18205 T8204 18203 18202 4 T8201
15. DS26LV32AT 7 10 5 aq 4 RN32 D 1 11 10K 6 apn 3 RN32 C 2 74LCX86 M37 B 10K 7 2_RN32 B 4 7 10K_8 RI 5 74LCX86 10K 4 RN29 D 9 10K 6 5 29 10 MW Dim 10 7 RN29 B 12 10K B aal RN29 A 15 Yo ia 74LCX86 5V 3 3V C74 e C220 10UF 6 3V cmp R312444 0_ OHM MN RN4 A AD OHM 180 74 1614 R313 C381 1 1 m CJ104 19 4 2 104 1 AUXMRK R314AAQ OHM 74 1614 ADM485 Figure3 2 Primary Secondary Encoder Channels J103 J104 3 4 www aerotech com Soloist Hardware Manual Technical Details 3 1 2 Port 0 User Digital Outputs J104 The digital outputs see Figure 3 3 are software configurable by the DrivelOConfig axis parameter as sourcing or sinking and are driven by a PS2802 4 opto isolator See Table 3 4 for the pin numbers and Table 3 5 for the PS2802 4 device specifications See Figure 3 4 and Figure 3 5 for user connections to the outputs in current sourcing and current sinking modes All outputs can be connected as sourcing or as all sinking as defined by the DriveIOConfig axis parameter See section 3 1 1 for the mating connector part number Additional I O is provided by the IO option as described in Chapter 4 Sixteen additional digital inputs and outputs are provided by Ports 1 and 2 on the on the IO Option board as described in Chapter 4 9 0 oO OXO
16. Figure 3 12 Data Capture Data Update Modes 3 14 WW aerotech com Soloist Hardware Manual Technical Details 3 3 Motor Feedback J103 The 25 pin DUstyle connector contains all of the necessary feedback inputs to complete a servo loop This connector has inputs for a 3 channel encoder three end of travel limit switches thermistor over temperature sense input and three Hall effect devices The three line driver encoder signals consists of the following sine SIN cosine COS and marker MKR as well as their complimentary signals sine n SIN N cosine n COS N and marker n MKR N The encoder input is defined for a differential line driver encoder in the range of 0 to 5 volts It allows up to an 8 MHz encoder signal 31 nsec minimum edge separation producing 32 million counts per second after multiplying by four x 4 quadrature decoding See Figure 3 2 for typical input circuitry of the encoder signals The Soloist standardly accepts a line driver encoder or with the MXU option an analog sine wave encoder see Section 3 3 1 See Section 2 8 1 Encoder Phasing for information on interfacing to non Aerotech motors Two of the three limit inputs are end of travel sensing CW Limit and CCW Limit while the third is an optional reference limit Home Limit Alternatively opto isolated user inputs 8 10 may be used as the end of travel limit inputs see Section 3 1 3 The Hall effect switch inputs are recommen
17. Index S 1 5 S Option 4 1 Safety Procedures 2 2 Shield Connection 2 3 Shielding Techniques 2 4 Signal Wiring Requirements 2 9 Soft Start Circuit 1 4 Specifications Opto Isolated Output Connector 4 4 Standard Encoder Input 3 15 Standard Interconnection Cables 5 1 Standard Package 1 4 Stepper Motor Configuration 2 18 T TB101 2 10 TB102 2 3 TB301 4 3 TB301 Brake Relay Current Specifications 4 10 TB301 Brake Relay Voltage Specifications 4 10 TB304 4 4 www aerotech com TB4 4 2 TB7 4 6 Test Points 6 3 Three Phase Motor Terminal Connections 2 3 Three Phase Power Input optional 2 3 Troubleshooting 6 1 0 3 28 power transformer optional 2 5 0 3 56 power transformer optional 2 5 Typical AC Wiring AUXPWR Option 2 6 Typical ESTOP Citcuit 2 11 Typical ESTOP Interface 2 11 U Unknown Phase Hall Sequence 2 16 User Power Connector Pinouts 4 9 Warnings 2 2 Warranty Policy B 1 Wiring Techniques 2 4 iii Index Soloist Hardware Manual www aerotech com READER S COMMENTS Soloist User s Manual P N EDU180 April 2005 Please answer the questions below and add any suggestions for improving this document Is the information Adequate to the subject Well organized Clearly presented 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
18. Inertia Lead Error Lead Screw A standard protocol analogous to RS 232 for transmitting digital information The G P I B interface IEEE 488 transmits data in parallel instead of serial format See IEEE 488 Comparison or ratio of the output signal and the input signal In general the higher the system gain the higher the response Actual distance between graduations on an encoder Feedback device HED used in a brushless servo system to provide information for the amplifier to electronically commutate the motor Hall Effect Device See Hall Effect Sensors Human Machine Interface Used as a means of getting operator data into the system See MMI Reference position for all absolute positioning movements Usually defined by a home limit switch and or encoder marker A sensor used to determine an accurate starting position for the home cycle A component of bidirectional repeatability Hysteresis is the deviation between actual and commanded position and is created by the elastic forces in the drive systems Input Output The reception and transmission of information between control devices using discrete connection points A set of codes and formats to be used by devices connected via a parallel bus system This standard also defines communication protocols that are necessary for message exchanges and further defines common commands and characteristics See G P I B A move referenced from its start
19. User 5 Volt Power Output Total user 5V power is limited to 500mA by an internal re settable fuse 50291 NI OldO 4 2 6 Brake Relay TB206 The relay output is typically used to automatically drive a fail safe brake on a vertical axis however it may also be used as general purpose relay See the BrakeOnDriveDisable axis parameter for information on activating the brake output automatically or the BRAKE command for manually toggling the output both in the Soloist help The brake relay output is available at the J103 connector and TB206 In order to help the user to interface to the brake relay the remainder of this section will be presented as a step by step procedure lt un m lt E 09 N en The N C terminal is the Normally Closed relay contact the N O terminal is the normally open contact and the C terminal is the Common contact switched between the other two terminals Table 4 11 Option Board Jumpers Description Switch Brake Output at J103 Pin 13 Remove 1 3 5 6 and 7 8 Switch Brake Output at J103 Pin 25 Remove 1 3 1 2 and 3 4 Auxiliary relay Output Option at TB206 Remove 1 2 3 4 5 6 and 7 8 factory default setting www aerotech com 4 9 Soloist Options Soloist Hardware Manual 4 2 6 1 Brake Configuration Jumpers The configuration of JP1 as shown in the table above allows either the Brake or the
20. Table 3 4 Port 0 Digital Output Connector Pin out J104 0909 Pin Label Description In Out Bi O50 Output 0 Output OQ Output 1 Output Q OQ Output 2 Output 950 Output 0 3 opto isolator common connection Output 3 Output Table 3 5 Opto Outputs 0 3 Specifications Specification Value Maximum Output Current 80 milli Amperes Maximum Frequency 1 kilo Hertz Maximum Voltage 40 Volts DC Maximum Power Dissipation 90 milli Watts per output channel Typical Rise Time 250 micro Seconds Saturation Voltage 85 Volt 9 80mAmps 7 Volt 1mAmps www aerotech com 3 5 Technical Details Soloist Hardware Manual M43 is OPTOOUTO o4 7 V SAK Lis i OPTOOUT y 4 2 8 6 1 x OPTOQUTJ 8 52802 4 3 M42 1 16 R262 OPTOCOM TN e V 510 2 15 R276 3 14 10K V Shy 84 83 4 15 R281 6 Y 74 1014 74 1014 57214 0 V Shy 8 9 SINK SOURCE N PS2802 4 Figure 3 3 User Outputs J104 3 6 www aerotech com Soloist Hardware Manual Technical Details OPTO_OUTPUT_O OPTO_OUTPUT_1 80 milliamps maximum OPTO_OUTPUT_2 52802 4 5 24VDC Figure 3 4 Outputs Connected as Current Sinking Be sure to set the DrivelOConfig axis parameter to configure the outputs as current sinking or current sourcing
21. amp LMAC series C18391 xx BL FB 25DU 25DU 9DU MAX120DM C18393 xx BL FB 25DU 25DU 9DU MAX240DM BFCD yy Obsolete Encoder Halls Used On Any Brushless motor stage having a 25 pin 0 istyle connector for encoder halls amp brake and a 9 pin connector for limits BM BMS motors with D25 option Brake Motor Feedback C15291 xx BL FB 25DU 17MS 9DU MAX120DM C15297 xx BL FB 25DU 17MS 9DU MAX240DM BFC yy Obsolete Nu 22 Encoder Halls Used On Any stage having a BM BMS motor with a 17 pin MS style connector for encoder halls amp brake and a 9 pin D for limits Limits The 2xx indicates length measured in decimeters Gyy indicates length measured in feet 5 4 WW aerotech com Soloist Hardware Manual Accessories 5 2 Joystick Interface The user may connect an Aerotech JI not JBV or JP4 joystick or their own joystick and switches to the Soloist Refer to Figure 5 1 The joystick interlock input in the logic low state may be used to detect the presence of the joystick The zero velocity null point for each joystick is approximately 2 5 volts A two axis joystick requires 2 analog inputs Each Soloist has only one analog input unless the IO option board is present so two Soloists may be used for a two axis joystick Subsequent drawings illustrate how to connect the joystick both single and two axis to the Soloist in vari
22. user is responsible for preventing unexpected startup e Connection requirements are described in the technical documentation provided with the system End user is responsible for making proper connections and meeting any required interlock requirements for application www aerotech com ix Regulatory Information Soloist Hardware Manual e Voltages greater than 60 Volts may be present inside Soloist after a discharge time of 5 seconds e user must provide protection concerning power interruption restoration if required e user must provide earth fault current protection if required user must provide protection against lightning and switching surges if required e Control and EStop requirements are determined and provided by the end user Wire and cabling provided with the Soloist meets Aerotech s electrical and listed environmental requirements End user must meet final requirements Failure to follow the described procedures could result in serious injury and or damage to the equipment x www aerotech com Soloist Hardware Manual Introduction CHAPTER 1 INTRODUCTION In This Section 1 1 SUMIN Aly gene 1 2 1 3 EE 9
23. A 2 Thermistor Input 3 5 4 NC N A 5 B Input 6 Mkr Input 7 Mkr Input 8 Reserved N A 9 Reserved N A 0 Input u HC Input 12 CW Limit Input Brake N A 14 Cost Input 18 Cos Input 16 5 Volt Output 17_ Sint Input 18 Input 19 Reserved N A 20 Common N A 21 Common N A 22 Home Limit Input 23 Enc Fit Input 24 CCW Limit Input 25 Brake N A Total user 5 V power is limited to 500 mA by an internal re settable fuse All external power provided by the Soloist to the user is protected by a re settable fuse Should an over current condition occur the fusing device would open to provide protection against the overload To reset the device remove the over current condition RN39 C RN39 D WM WM WW 10K 74LCX16244 Figure 3 13 Limit Thermistor and Hall Effect Inputs J103 3 16 www aerotech com Soloist Hardware Manual Technical Details 3 3 1 MXU Option The MXU encoder input option is designed for a differential analog encoder in the range of 0 6 to 2 volts Peak to Peak The maximum input frequency is limited to 200 kHz The MXU option multiplies the resolution programmatically up to 512 times total The multiplication factor is defined by the CfgFbkEncMultFactorMXU axis parameter The encoder input should be adjusted for optimum performance by the CfgFbkEncCosGain CfgFbkEncCosOffset Cfg
24. Bidirectional repeatability refers to the value established by moving toward a position in the same or opposite direction The smallest change in distance that a device can measure An optical element with the property that an input light beam is reflected and returns along the same angle as the input beam Used with laser interferometers Angular motion of a carriage around an axis parallel to the motion direction and perpendicular to the yaw axis Positioning error resulting from a roll motion The rotating part of a magnetic structure In a motor the rotor is connected to the motor shaft Industry standard for sending signals utilizing a single ended driver receiver circuit As such the maximum distance is limited based on the baud rate setting but is typically 50 100 feet This standard defines pin assignments handshaking and signal levels for receiving and sending devices Industry standard programming language Also referred to as G code machine programming A command set specific for the machine tool industry that defines geometric moves Industry communication standard for sending signals over distances up to 4000 feet Standard line driver encoder interfaces utilize RS 422 because of the noise immunity The deviation from the desired form of a surface during full rotation 360 degrees about an axis Runout is measured as total indicated reading TIR For a rotary stage axis runout refers to the deviation of the
25. Brake output to be switched by the relay and connected at the J103 motor feedback mE connector or for the brake to be connected at TB206 See Figure 4 8 in section 4 2 2 for more information Step 1 Brake Relay Specifications So oloist The user must verify that the application will be within the specifications of the Brake Relay contacts These specifications are provided below in Table 4 12 Table 4 12 Voltage and Current Specifications TB206 Relay K1 Contact Ratings Maximum Switched Voltage 150 VDC 125 VAC Maximum Switched Current 1A Maximum Carrying Current 1A Maximum Switched Power 30W DC 60 VA AC Note The maximum power that may be switched is voltage dependent Initial Contact Resistance 50 milliohms max 10 mA 6 VDC The user must not exceed the Maximum Current or Maximum Power specifications Step 2 Select Brake Interface Connector The Normally Open Brake Relay Contacts are accessible through TB206 and the Motor Feedback connector J103 The Brake Relay Normally Closed Contact is only accessible through TB206 see Figure 4 8 The Motor Feedback connector J103 allows the brake wires to be included in the motor feedback cable and eliminate the need for a separate brake cable The Brake Relay connections to TB206 are listed in Table 4 13 and the Brake Relay connections to the Motor Feedback connector J103 are listed in Table 4 1
26. Does it meet your needs What improvements if any would you like to see Please be specific or cite examples Your name Your 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 412 967 6870 AEROTECH Motion Control Positioning Systems Components Aerotech Products Catalogs and Brochures UK Francais Deutsch Dutch News In Europe Featured Products and News gt F Actuators Air Bearings Amplifiers Drive Racks Gantry Systems Goniometers Lift Stages Linear Motors Linear Stages Manual Positioners Motion Controllers Optical Mounts Fiberoptics Positioners Rotary Motors Rotary Stages Spindles Accessories Engineering Reference Engineered Systems Glossary VascuLathe High Performance Stent Cutting System VascuLathe is a single machine platform for the production of neurovascular cardiovascular and peripheral stents Get our new free brochure and find out how the VascuLathe can increase your stent manufacturing throughput up to 5 times ASR1200 Rotary Stage The ASR1200 series is an extension of the successful ASR1100 series direct drive rotary stage The ASR1200 includes the integral pneumatically operated collet chuck for automated ma
27. Fuse Description Size PN PN RAYCHEM F1 5 VDC User Power 3A resettable EIF01001 RGE300 www aerotech com Soloist Hardware Manual Troubleshooting 6 4 Soloist Board Assembly Figure 6 1 highlights the important components located on the control board The Soloist has a few jumper selectable items none of which normally need to be changed by the user since all of the important configurable items are software selectable Table 6 6 lists the jumpers and the default configurations for the Soloist board S1 defines the Soloist communication channel number and is the only user configured switch jumper on the control board see Table 2 3 2 A 78102 1810 HM 101 e F4 F6 FS F5 e 2 52 pg TP16 TP17 8 TP19 TP21 2 7 TP18 CL 20 Fi F3 F2 11 Figure 6 1 Soloist Board Assembly 69001591 Rev 1 www aerotech com 6 5 Troubleshooting Soloist Hardware Manual Table 6 6 Soloist Jumper Selections Jumpers Positions Function 1 2 No Shunt Option Present Standard Soloist10 20 2 3 Shunt Option Present Optional except Soloist30 5 1 2
28. Input Volts Poo VAC AUXPWR P Input Frequency Main Supply Hz 50 60 Current Max Peak Main Supply Amps 42 Max Continuous Input Power Main Supply Watts 1200 2400 2400 Supply Input Volts VAC 70 240 AUXPWR Supply Input Frequency 4 Hz 50 60 AUXPWR Supply Maximum Input Watts 100 a Power AUXPWR Supply Input Current Maximum A RMS 25 Output Voltage VDC 15 350 Peak Output Current 2 sec A peak 10 20 30 Continuous Output Current A peak 5 10 15 Peak Power Output Watts 2300 4800 4800 Continuous Power Output Watts 1100 2300 2300 Efficiency 97 Current Loop Bandwidth kHz 5 kHz max PWM Switching Frequency kHz 20 Minimum Load Inductance mH aus 2 Regulator Watts 40 Maximum Heat Sink Temperature 75 Heat Sink Size typical Volume 25 4 x 50 8 x 6 35 1 x 2 x 25 Weight standard 3 6 1 63 Notes 1 AUXPWR is optional 2 AC input voltage dependant See 2 4 2 3 Includes AC line droop 4 See the Digital Current Loop Parameters in the Soloist Help 1 6 www aerotech com Soloist Hardware Manual Introduction Table 1 2 Electrical Specifications Feature Description Brush torque mode Modes of Operation Brushless Stepper Hall A Pin 10 Hall B Pin 5 Hall C Pin 11 Hall effect device inputs for commutation 0 to 5 VDC interna
29. Isolated Inputs TB204 1 209 4 6 4 2 5 User Power TB204 205 4 0 4 2 6 Brake Relay TB206 sese 4 0 4 2 6 1 Brake Configuration Jumpers 4 10 ACCESSORIES eeeeee eee eee enses enses ense sritis 5 1 Standard Interconnection 2 04004 0 000 5 1 Joystick Interface i e cette tet rete tt Re REFER REDE 5 5 Handwheel Interface eese eene 5 7 TROUBLESHOOT ING eese 6 1 Problems Causes and Solutions ccccecsecececeesecseceeececsessssneeeeeeees 6 1 Soloist TEST ben et tote 6 3 Ino uEvSrI M 6 4 Soloist Board 6 5 Preventative Maintenance esses nennen enne 6 7 Ua EEEEG Unum 6 7 GLOSSARY OF TERMS esses eese entes eene neta stn sens ts tosta sone ta an A 1 WARRANTY AND FIELD 4 B 1 TECHNICAL CHANGES sesessesesosoroesesesoesosossesesseoososossesesoeoesoeossese C 1 Current Changes ese elie Ru eo Ple boca a be Ey C 1 Archive of 22 C 2 eee iv www aerotech com Soloist Hardware Manual List of Figures LIST OF FIGURES Figure 1 1 Soloist in
30. Risk of electric shock Residual voltages inside the Soloist controller may exceed 60 Volts after AC power has been disconnected for 10 seconds DANGER gt gt DANGER gt DANGER gt DANGER a DANGER WW w aerotech com 6 1 Troubleshooting Soloist Hardware Manual ENB FLT MARKER 9 POWER INPOS Table 6 1 Amplifier Faults Causes and Solutions Symptom Possible Cause and Solution Motor rotates uncontrollably Brushless motor will not rotate Amplifier faults ENB 0 LED turns red when motor decelerates Encoder sine and cosine signals are improperly connected See Section 2 8 for motor phasing information Motor phases A B and C connected incorrectly relative to Hall A Hall B and Hall C inputs See Section 2 8 for motor phasing information Bus over voltage detected Soloist10 20 This condition indicates an excessive bus supply regeneration condition The Soloist10 20 requires that a shunt regulator option be mounted in the unit Amplifier Faults ENB LED turns red 1 RMS current exceeded run at lower current 2 Over temperature condition Remove power and let the drive cool down and or provide better ventilation 3 Defective on board power supply Return for repair 6 2 www aerotech com Soloist Hardware Manual Troubleshooting 6 2 Soloist Test Points The following test points are available interna
31. Runout Ramp Time Device that allows the operator to communicate with a machine A keyboard or thumbwheel is used to enter instructions into a machine See HMI or MMI A linear or angular position feedback device using light fringes to develop position information System or circuit that transmits signal with no direct electrical connections using photoelectric coupling between elements The condition of a surface or axis which is perpendicular offset 90 degrees to a second surface or axis Orthogonality specification refers to the error from 90 degrees from which two surfaces of axes are aligned In a servo system referred to the amount of velocity and or position overrun from the input command Overshoot is a result of many factors including mechanical structure tuning gains servo controller capability and inertial mismatch A group of gain terms in classical control theory Proportional Integral Derivative used in compensation of a closed loop system The terms are optimally adjusted to have the output response equal the input command Aerotech controllers utilize the more sophisticated PID FVFA loop which incorporates additional terms for greater system performance Angular motion of a carriage around an axis perpendicular to the motion direction and perpendicular to the yaw axis Positioning error resulting from a pitching motion Programmable Logic Controller A programmable device that utilizes ladder logic
32. Watch dog enabled Standard 2 3 Watch dog disabled 6 1 2 24 Volt Emergency Stop Standard 2 3 5 Volt Emergency Stop ESTOPO5 option Factory Default All jumpers are factory configured and should not be changed by the user See Table 6 4 for fuse replacement information 6 6 www aerotech com Soloist Hardware Manual Troubleshooting 6 5 Preventative Maintenance The Soloist and external wiring should be inspected monthly Inspections may be required at more frequent intervals depending on the environment and use of the system Table 6 7 lists the recommended checks that should be made during these inspections The Soloist all Aerotech equipment is not to be used in a manner not specified by Aerotech Inc Table 6 7 Preventative Maintenance Check Action to be Taken Visually Check chassis for loose or damaged parts hardware Note Internal inspection is not required Parts should be repaired as required If internal damage is suspected these parts should be checked and repairs made if necessary Inspect cooling vents Remove any accumulated material from vents Check for fluids or electrically conductive material exposure Any fluids or electrically conductive material must not be permitted to enter the Soloist Note Disconnect power to avoid shock hazard Visually inspect all cables and connections Tighten or re secure any loose c
33. a positive direction as shown in Figure 2 15 To correct a reversed motor rotation swap any two motor lead connections The second method is a non powered method The motor is disconnected from the controller and connected in the test configuration as shown in Figure 2 12 identifying 4motor leads A B and C and Hall signals These sequences and the generated output motor phase voltages motor output connections OB and OC are shown in Figure 2 12 Generate the voltages by moving the motor and forcer by hand in a positive CW direction 2 14 www aerotech com Soloist Hardware Manual Installation and Configuration 2 7 2 2 Brushless Motor Hall Effect Feedback Connections The Hall effect feedback signals on an AC brushless motor are correctly phased when the CBee m y Positive Direction Hall states correspond to the states at each of the electrical angles as shown in Figure 2 12 A value of 0 for the given Hall input indicates zero voltage or logic low and a value of Motor Shaft 1 indicates five volts or logic high You can view these logic levels in the Soloist HMI in the Axis I O section of the Diagnostic panel of the screen as shown in Figure 2 11 Soloist Motor Mounting J103 Flange Front View Primary Hall A Hall Hall Effect Channel 5 HallC 44 Feedback Encoder 5V 3 Encoder Com 21 Chassis Frame Ground Typical hall limit encoder cables a
34. axis of rotation from the theoretical axis of rotation Refers to a closed loop control system where a command is issued for a change in position and the change is then verified via a feedback system www aerotech com Soloist Hardware Manual Glossary of Terms Settling Time Shaft Radial Load Shaft Runout Slotless Stator Stiction Straightness of Travel Torque Torque Continuous Torque Peak Torque rms Torque Stall Total Indicated Reading TIR Tuning Unidirectional Repeatability Velocity Command Time required for a motion system to cease motion once the command for motion has ended Maximum radial load that can be applied to the end of the motor shaft at maximum motor speed Deviation from straight line travel Describes the type of laminations used in a motor that eliminates cogging torque due to magnetic attraction of the rotor to the stator slots Non rotating part of a magnetic structure In a motor the stator usually contains the mounting surface bearings and non rotating windings Friction encountered when accelerating an object from a stationary position Static friction is always greater than moving friction and limits the smallest possible increment of movement Measure of the side to side deviation of a stage as it travels in a horizontal plane Rotary equivalent to force Equal to the product of the force perpendicular to the radius of motion and distance
35. ed ee ui 620B1343 101 DWG Figure 5 6 BBA32 Interface Used to Connect a Handwheel with Flying Leads No Connector www aerotech com 5 9 Accessories Soloist Hardware Manual 5 10 www aerotech com Soloist Hardware Manual Troubleshooting CHAPTER 6 TROUBLESHOOTING In This Section e Problems Causes and Solutions 6 1 6 3 6 4 e Soloist Board Assembly sess 6 5 e Preventative Maimtenance mo 6 7 6 1 This Problems Causes and Solutions section covers symptoms probable causes and solutions related to Soloist operation Table 6 1 lists the most common symptoms of irregular operation and the possible causes and solutions for these faults More information can be found in the Soloist HMI help Before performing the tests described in Table 6 1 be aware of lethal voltages inside the controller and at the input and output power connections A qualified service technician or electrician should perform these tests No user serviceable parts inside Motor Soloist chassis may exceed 50 C Disconnect power to the Soloist main supply and optional supply before servicing Hazardous voltages may be present at Mains inlet and motor connectors Voltages must be mechanically secured before applying power Motors must be mechanically secured before applying power
36. external emergency stop circuit is required as illustrated in Section 2 6 1 This option also allows the Soloist to operate at bus voltages less than 120 VDC 85 VAC If the Soloist was purchased with the AUXPWR option a separate AC input has been included on the amplifier for the control power and must be powered The internal power supply of the Soloist requires a minimum of 85 VAC input to properly operate The following figure displays the required connection to the AUXPWR option The AUXPWR connection is made to a three terminal connector Aerotech Part ECK213 provided See Section 2 5 for AC wiring options Twist 85 VAC HI Y AC Keep Alive TO LO x X laco CONTROL 240 Ground L AC2 may require external fuse or circuit breaker 3 Amps time delay Twist HI Y AC1 BUS _ 240 vac LO X X m Max Ground L AC1 AC2 require external fuses or circuit breaker 15 Amps Max time delay Figure 2 1 AUXPWR Option 2 4 5 40 80 VDC Power Transformers The 0 3 56 power transformer is an optional accessory for the Soloist The transformer allows the generation of 56 VAC from either a 115 VAC or 230 VAC source When rectified by the Soloist 56 VAC yields an 80 VDC power bus The 0 3 28 power transformer is an optional accessory available for the Soloist The transformer changes a 115 VAC or 230 VAC source to 28 VAC When rectified by the Soloist 28 VAC yi
37. force at the motor output Brushless motors can be commutated directly from a controller that can output current phase A and B commands An allowable current to run a motor above its rated load usually during starting conditions Peak current listed on a data sheet is usually the highest current safely allowed to the motor Root Mean Square Average of effective currents over an amount of time This current is calculated based on the load and duty cycle of the application www aerotech com A 3 Glossary of Terms Cycle DC Brushless Servo Deceleration Duty Cycle Dwell Time Efficiency Electronic Gearing Encoder Marker Encoder Resolution Encoder Incremental Feedback Flatness of travel Force Continuous Force Peak Friction Soloist Hardware Manual When motion is repeated move and dwell such as repetitive back and forth motion A servomotor with stationary windings in the stator assembly and permanent magnet rotor See AC Brushless Servo The change in velocity as a function of time For a repetitive cycle the ratio of on Itime to total cycle time used to determine a motor s rms current and torque force Time in a cycle at which no motion occurs Used in the calculation of rms power Ratio of input power vs output power Technique used to electrically simulate mechanical gearing Causes one closed loop axis to be slaved to another open or closed loop axis with a va
38. gt 5 8 0 3 28 WIRING 6 ADDITIONAL OR ALTERNATIVE FUSING MAY BE REQUIRED FOR OPTIMUM PRIMARY 115VAC PROTECTION SECONDARY 28VAC 40VDC BUS TRANSFORMER P N EAX01007 Soloist PRIMARY FUSE SLO BLO AUXPWR OPTION TRANSFORMER 18 WHT on p THERMAL A 230VAC SWITCH 6 18wHT_ Splice AC LO 50 80 Hz RED28v 115v BLK SAFTEY 100v ORN A Ov GRAY 115v BRN splice MAIN SUPPLY YEL28v 100v GRN FRAME GROUND Soloist AUXPWR INTERCONNECT TV0 3 28 WIRING 40VDC BUS TVO 3 28 PRIMARY 230VAC 620B1346 1 SECONDARY 28VAC 40VDC BUS TRANSFORMER P N EAX01007 620B1346 101 DWG OPTIONAL SUPPLY gt gt 8 6 88 Figure 2 2 40 Volt DC Bus from 115 and 230 VAC Source Figure 2 2 is shown only for reference For the most recent Dwg files see your software CD ROM which includes a Dwg file viewer 2 6 www aerotech com Soloist Hardware Manual Installation and Configuration Soloist PRIMARY FUSE 4A SLO BLO AUXPWR OPTION TRANSFORMER 18 WHT ACHI 115 318 WHT 5 ACLO 50 60 HZ INPUT RED 56v 115v BLK SAFTEY 100v ORN A z Ov GRAY EE Jaca 115v BRN YELS6v 100v GRN splice FRAME GROUND 21 25 of ES EZ 0 3 56 WIRING PRIMARY 115 SECONDARY 56VAC 80VDC BUS TRANSFORMER P N 01006 Soloist PRIMARY FUSE SLO B
39. is available in three models with continuous power ranging from 1 100 to 2 300 watts The available voltage configurations and power options for these models are shown in Table 1 1 Table 1 1 Soloist Voltage Configurations Model Peak Output Current Continuous Output Current peak SoloistlO 10A 5A Soloist20 20A 10A Soloist30 S 30A 15A Options S Shunt resistor network standard on Soloist30 Auxiliary 115 230 VAC input to power logic circuitry required for keep alive AUXPWR 10 40 VDC bus operation 10 40 VDC operation requires external transformer to generate 7 28 VAC bus power input I O option adds 16 digital opto inputs 16 digital opto outputs 18 bit analog ae output and 16 bit analog input and a brake relay output Low bus voltage option for 40 100 VDC bus doesn t support keep alive LB functionality not available with AUXPWR option 40 100 VDC bus operation requires external transformer to generate 28 70 VAC bus power input MXU x512 total software encoder resolution multiplication primary channel only S Shunt option standard on Soloist30 www aerotech com 1 5 Introduction 1 6 Electrical Specifications Soloist Hardware Manual The electrical specifications for the Soloist are listed in Table 1 2 Table 1 2 Electrical Specifications Description Units Soloist10 Soloist20 Soloist30 Main Supply 70 240 VAC
40. method using a two channel oscilloscope and three resistors 10 K ohm 1 2 watt wired in a Wye configuration The motor is disconnected from the controller and connected in the test configuration as shown in Figure 2 12 The motor leads A B and C and the Hall signals are identified Before performing the test in Figure 2 12 you must completely disconnect the motor leads from the amplifier To perform the following tests you do not need to turn the amplifier on because Figure 2 12 provides the generated output voltage data of the amplifier as determined by the input Hall sequences Connect the ends of the three resistors to three motor leads Use one channel of the oscilloscope to monitor motor terminal A with a Wye neutral that is the point where all three resistors are connected together Turn the shaft of the motor CW and record the generated voltage This voltage represents the Phase A to neutral counter With the second oscilloscope probe determine the Hall switch that is in phase with this voltage Similarly Phases B and C must be aligned with the other two Hall switches This identifies the motor and Hall lead that are in phase with each other Any motor and Hall lead set can be designated as Phase A The phasing between this set and the other two sets determines which set is designated as Phase B or C Refer to Figure 2 12 and note the generated output voltages of the amplifier applied to the Hall A B and C co
41. recent Dwg files and a viewer may be found on your software CD ROM To 00570 Sor LENGTH AA SEE NOTE 2 BLU on dd CONNECTOR SHIELDING 5 2 EXT_INCOM 24 BLK 18 WoT 2 s2 WRAP 6 COPPER FOIL EIA281 ANALOG IN 13 3 xpot OVER GROMMET SHIELD amp DRAIN WIRE Er 5 GROMMET SUPPLIED ANALOG IN 14 gt SAN 4 W BACKSHELL AGND 23 Inputa 7 RED 7 51 Inputto 25 BRN 13 INTERLOCK T i SHIELD TA FOLD BACK FOIL SHIELD A SUCH THAT THE SILVER PART IS OUTSIDE 26 HD MALE K86 AA 26P 01259 15 LINE FEMALE D FOLD BACK amp TWIST BACKSHELL 17 1725 2 01022 745493 2 ECK00783 D DEAN RE SEE NOTE 3 FOR CONNECTOR VIEW BACKSHELL 17 1725 2 1022 EE gene COVER JACKSOCKETS 207719 3 00129 e H AR 2 CABLE LENGTH Soloist Joystick EXAMPLE C19782 30 30 30 DECIMETERS 8 METERS 10FT EXTENSION CABLE JSXT 26HD XX C19792 XX 630B1 979 2 630B1979 201 DWG 3 CONNECTOR VIEW FROM SOLDER SIDE Figure 5 2 Single Axis Joystick Interface to J104 of the Soloist Soloist NOTES JOYSTICK INTERFACE 1 USING C19792 XX CABLE WILL ONLY PROVIDE 1 AXIS OF SLEWING 2 THE JI JOYSTICK MUST BE USED WITH THE Soloist JBV OR JP4 JOYSTICK VERSIONS ARE NOT COMPATIBLE 19792 JOYSTICK EXT CABLE J104 AUX
42. than 240 ohms use 240 ohm resistor If the resistance of R is too low the relay contacts may weld together If the resistance of R is too high the contacts may be damaged due to excessive arching Capacitor C 1 uF rated for AC and a voltage rating of not less than 250 Volts If the voltage rating of the capacitor is too low the Varistor may not be able to protect it and it may fail Varistor V Rated for the maximum voltage of the external supply being used Typically a varistor rated for a standard 120 VAC line should work Verify that the capacitor voltage rating is greater than the clamping voltage of the varistor If the voltage rating of the varistor is too low it may conduct during normal operation and overheat If the voltage rating of the varistor is too high it may not protect the capacitor C against over voltage conditions 4 12 WWW aerotech com Soloist Hardware Manual Soloist Options VDC OR VAC RLYNV23026N SMT Figure 4 10 Suppression for DC Brake Systems www aerotech com 4 13 Soloist Options Soloist Hardware Manual 4 14 www aerotech com Soloist Hardware Manual Accessories CHAPTER 5 ACCESSORIES In This Section e Standard Interconnection Cables 5 1 6 Joystick Interface an 5 5 5 7 5 1 Standard Interconnection Cables The following three tables show a summary
43. than 50 mA Note that the analog outputs are referenced to TB201 1 Analog output 0 is present on J104 see Section 3 1 4 The analog outputs will be zero volts during reset Table 4 3 Analog Output Connector Pin out TB201 Pin Label Description In Out Bi AGND Analog Common N A AOUT I Analog Output 1 Output The analog output common may be found at J103 pin 23 or TB201 pin 1 5VA 412V Figure 4 3 Analog Output Connector TB201 www aerotech com 4 3 Soloist Options Soloist Hardware Manual 4 2 3 Port 1 and Port 2 Opto Isolated Outputs TB202 TB203 The digital outputs are software configurable by the DrivelOConfig axis parameter as sourcing or sinking All outputs must all be connected as sourcing or all as sinking The outputs are driven by PS2802 4 opto isolators that are rated for 40 volts maximum and up to 80 mA channel not to exceed 90 mW per channel Figure 4 4 and Figure 4 5 illustrate how to connect to an output in current sinking and current sourcing modes respectively Four additional outputs are on J104 Note that the connection must always be made to both the OP and OM connections to prevent glitches on the outputs as shown in Figure 4 4 and Figure 4 5 Table 4 4 Port 1 Opto Isolated Output Connector Pin out TB202 Label Description In Out Bi Output Common Plus for TB202 Input M Output Common Minus for TB202 Input ut
44. 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 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 returned 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 upon Aerotech s examination a warranted defect exists then the product s will be 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 Warr
45. 12 2005 6 06 36 PM New Resource Guide of Motion and Positioning Control Components and Systems Automation Solutions for Semiconductor and Flat Panel Display Manufacturing Click to view brochure Deutsche Version Automation Solutions for Electronic Manufacturing Test and Inspection and Data Storage Click to view brochure Deutsche Version Automation Solutions for the cam Automotive Machine Tool LE a Assembly and Packaging Industries Click to view brochure Deutsche Version Automation 3200 The Intelligent 32 Axis Motion Vision PLC Robotics amp I O Platform Aerotech Products o About Aerotech News Tradeshows Literature Request Select a Market Sales Support Customer Service Contact Us Site Index Motion Control Positioning Systems Components Aerotech payloads It eliminates the mechanical instability of high load inertia multi axis systems through a proprietary design that significantly increases stage stiffness Engineered System Aerotech has over 30 years of experience manufacturing turnkey and complete motion subsystems for some of the largest companies in the world Our engineers and technicians have developed an array of systems for applications ranging from semiconductor medical laboratory photonics and fiberoptics laser machining automotive packaging pick and place and more We are wel
46. 2 on the on the IO Option board as described in Chapter 4 Note that there are no input bits 6 7 or output bits 4 7 on J104 Port 0 3 2 WWW aerotech com Soloist Hardware Manual 3 1 1 Secondary Encoder Channel J104 This encoder channel may be used as an input for master slave operation handwheel or for dual loop systems This encoder must be a 5 volt RS 422 line driver encoder It allows up to an 8 MHz encoder signal 31 nanosecond minimum edge separation producing 32 million counts per second after times four x4 quadrature decoding See Figure 3 2 for typical input circuitry of the encoder signals See section 3 1 1 for the mating connector part number See Table 3 3 for the pin numbers on J104 related to the secondary encoder channel See section 2 8 1 Encoder Phasing for more information The Auxiliary Marker output is also the PSO output which has a 02 micro sec typical propagation delay Pull up and pull down resistors are required on this output when used as the PSO output The EncoderDivider axis parameter should be set to 0 to configure the Auxiliary Marker as an output Table 3 3 Secondary Encoder Connector Pin out J104 Pin Label Description In Out Bi Auxiliary Sine Secondary Encoder Channel Input 2 Auxiliary Sine Secondary Encoder Channel Input 10 Auxiliary Cosine Secondary Encoder Channel Input 11 Auxiliary Cosine Secondary En
47. 3 10 www aerotech com Soloist Hardware Manual Technical Details 3 1 4 User Analog Output 0 J104 Analog output 0 is driven by a 16 bit DAC8531 digital to analog converter and buffered by TL082 op amps producing a single ended output voltage in the range of 10 volts cos This produces a resolution of 305 uVolts per bit of the D A The output current is limited 1104 to less than 50 mA See Table 3 7 for the pin numbers Note that the analog output is z referenced to J104 21 or 23 See Section 3 1 1 for the mating connector part number A second analog output is provided on the IO option board AN Table 3 7 Analog Output Connector Pin outs J104 Pin Label Description In Out Bi 22 Analog 0 Out Analog Output 0 Output me 21 Common Common N A oO O 23 Common Common N A O80 OXO R208 12V 412V x 8 2 E ol wW 10K C282 1 1 C43 6 3V R200 5VA R210 20K 20K 1 TLOB2 2 Ratt RE 2 3 T pu i E 4 8209 4 99 2 Ms t VFB i 33 i375 M37 A DAC8531 wW lt C273 Figure 3 9 Analog Output 0 J104 WWW aerotech com 3 11 Technical Details Soloist Hardware Manual TI 3 1 5 User Analog Input 0 J104 Analog input 0 is differ
48. 3 18 www aerotech com Soloist Hardware Manual 3 4 RS 232 Serial Port TB103 The RS 232C port is shown in Figure 3 16 Connecting the RS 232 port to a user s PC requires only a standard 9 pin cable not a null modem Table 3 14 103 RS 232 Connector Pin out Pin Label Description In Out Bi 1 5 Volt 5 Volt Power Output Output 2 RS232TXD RS 232 Transmit Output Output 3 RS232RXD RS 232 Receive Input Input 4 Common Signal Common N A Total user 5 V power is limited to 500 mA by an internal re settable fuse Table 3 15 RS 232 Port Connector Mating Connector TB103 Aerotech Third Party Source 6 pin connector ECK01364 Phoenix FK MC0 5 6 ST 2 5 1881367 TB105 1 Figure 3 16 RS 232 Connector TB103 WWW aerotech com Technical Details 5V 0 5A RS232 TX RS232 RX GND 6 BRAKE PS BRAKE PS Technical Details Soloist Hardware Manual 3 5 USB Port J101 The USB port has all of the same functionality as the Ethernet interface for Aerotech s utilities The Ethernet port however does have some additional features for non Aerotech devices Planned Feature Consult Aerotech Inc for availability 3 20 www aerotech com Soloist Hardware Manual Soloist Options CHAPTER 4 SOLOIST OPTIONS In This Section INtrOdUCTL OMe este S 4 1
49. 4 Table 4 13 Brake Relay Connector Pin out TB206 Pin Label Description In Out In Out 3 Relay N C Brake Relay Output Normally Closed Contact Output 4 Relay Com Brake Relay Output Common Contact Output 5 Relay N O Brake Relay Output Normally Open Contact See JP1 Output Table 4 14 Brake Relay Connector Pin out J103 Pin Label Description In Out Bi BRK Brake Relay Output Normally Open Contact See JP1 Output Brake Power connection See JP1 Output Figure 4 8 is an example of a 24 VDC Brake connected to TB206 In this example JP1 must be set 1 3 and all other jumpers removed Otherwise the user must connect J103 pin 13 to J103 pin 25 In this case J103 would function as an interlock to prevent the Brake from releasing if the Motor Feedback connector is not connected 4 10 www aerotech com Soloist Hardware Manual Soloist Options RELAY NC 3 1 TB206 ES RELAY COMMON 5 206 2 Bs 10 i RLY V23026 SMT VARISTOR AEROTECH PN ECR180 Harris PN V33ZA1 jumpers to JP1 1 3 In 1 2 Out 3 4 Out 5 6 Out 7 8 Out Figure 4 8 Brake Connected to TB206 Figure 4 9 is an example of a 24 VDC Brake connected to J103 the Motor Feedback connector In this example the external 24 power source is connected to TB206 Also note that JP1 is set 1 2 and 3 4 with all others removed RLYNV23026N SMT Fig
50. 5DU FL 25DU E C18982 xx MAX107DM BENGDNIAY Obsolete Used On Mot tput ss pu Any brushless motor stage having a single 25 pin D style connector for motor power encoder limits and halls ABL1000 series ALS130 amp ALS135 series Single connector version ANT series AVL125 amp ADRI75 Pats Motor Feedback ASR1000 1100 amp 2000 series with 25D option DC MTR FB 5DU FL 24MS x 13803 MAX107DM Motor Output Used On Any stage having a DC brush motor with a single 24 pin MS I style connector for motor power encoder limits and brake Motor Encoder Limits Brake o Motor Feedback SM amp FB 25DU 23 20251 MAX107DM Used On Any stage having a stepper motor with a single 23 pin Burndy style connector for motor power encoder limits and brake Motor Encoder Limits Brake Motor Feedback The indicates length measured in decimeters Gyy indicates length measured in feet 5 2 www aerotech com Soloist Hardware Manual Accessories Table 5 3 Individual Motor Cables Soloist Part Number s Description Stage Motor C15805 xx BL MTR FL 4MS MAX450DM CN PMCNT yy Obsolete Used On Any brushless motor stage having a 4 pin MS style connector for motor power Motor Output BM BMS motors with MS option BMxxxE motors HJ
51. 6 Inputs 4 Outputs and Line Driver Secondary Encoder Input for Master Slaving Camming Etc 8 3104 TEES 16 Digital Opto In 52 TB204 TB205 240 VAC Max 50 60 Hz 3 Phase 40 340 VDC Motor Output 10 30A pk Auxpwr Option Connector 50281 NI OLdO Brake Relay Output TB206 90281 Figure 1 2 Soloist Hardware www aerotech com 1 3 Introduction Soloist Hardware Manual 1 4 Soloist Power Features If you purchased the Soloist with the standard set of features it includes the bus power supply that operates from 70 240 VAC 100 0340 VDC The power supply provides off line operation without the need for an isolation transformer A soft start circuit is included to prevent high inrush currents These features are detailed in the following diagram Note Figure 1 3 includes power options 70 240 VAC Control Voltage 5 Power Module Integrated Protection Short Circuit Under Voltage va J104 Line Driver x4 Line Driver x4 Voltage Detect gt A secondary 70 240 VAC connection is necessary if the DC bus power is required to J202 J203 operate below 100 VDC AC input below 70 VAC J201 The shunt regulator is optional on the Soloist 10 20 and standard on the Soloist 30 IO Option Figure 1 3 Soloist Block Diagram 1 4 WWW aerotech com Soloist Hardware Manual Introduction 1 5 Soloist Voltage Configurations The Soloist
52. 8 COND 24 SHIELDED No 26 PIN HD MALE K86 AA 26P 01259 171726 2 ECKO a SEE NOTE 3 FOR CONNECTOR TERMINAL 462849 00294 TYP 6 PLS ADD BRADY WIRE MARKERS TO TERMINALS Soloist HANDWHEEL 3 HWA32 26HD XX H AR HWA32 26HD XX 630B1 983 2 630B1983 201 DWG Figure 5 4 Handwheel Interconnection to J104 of the Soloist A handwheel with flying leads no connector may also be connected to the Soloist through the Aerotech BBA32 to J104 per the next two drawings The following drawings Figure 5 5 and Figure 5 6 are shown for reference only and were complete and accurate as of this manual s release The most recent dwg files and a viewer may be found on your software CD ROM www aerotech com 5 7 Accessories Soloist Hardware Manual F 10 FT OR AR TO A LENGTH Soloist J104 VIA HANDWHEEL BBA32 N 5V 12 q RED 1 5V COM 21 exp BLK 2 ov SUNTAK SIN 1 O PEN 3 A LGF 043 100 BLU ECZ00201 SINN 2 q 4 A N 100 LINES REV COS N 11 5 B COS 10 6 B N GND G m 3j 00570 FERRULE 3200014 01001 TYP 7 ADD BRADY WIRE MARKERS TO WIRI CABLE NC 8 COND 24 SHIELDED PLS ES TERMINAL 52949 AMP EIK00234 TYP 6 PLS ADD BRADY WIRE MARKERS TO TERMINALS HWA32 FLY XX Fo 6in Figure 5 5 1 INSTALL LABEL TO BACK OF HAN
53. All outputs on a port 0 1 or 2 must be connected as all sourcing or all sinking outputs COMMON OPTO OUTPUT 0 80 milliamps maximum J104 220 OPTO OUTPUT 1 5 24VDC 52802 4 Figure 3 5 Outputs Connected as Current Sourcing www aerotech com 3 7 Technical Details Soloist Hardware Manual AUX 1104 1 0 3 1 3 Port 0 User Digital Inputs J104 The high speed inputs 12 and 13 Figure 3 8 are scaled for a 5 volt input voltage Using a higher input voltage requires adding external series resistors to limit the current to 20 milliamps For example for 24 volt operation add a 1 000 ohm watt resistor in series with each opto input pin See Table 3 6 for the pin numbers The high speed inputs inputs 4 and 5 are isolated by an HCPL 0630 opto isolator and have a typical delay of 50 nanoseconds The lower speed inputs numbered 0 3 are isolated by a PS2806L 4 opto isolator Inputs 0 2 may also be used as Home and CW CCW end of travel limit inputs respectively by setting bit 22 of the DrivelOConfig axis parameter Figure 3 6 illustrates interfacing an active device or a switch to the inputs In either case an external power supply is required to maintain the isolation provided by the opto couplers See Section 3 1 1 for the mating connector part number Additional I O is pro
54. Configuration Manager assign a name to each Soloist on the network The configuration parameters used the assigned name If you do not specify a name the configuration parameters the name Drive_ where reflects the number assigned by the communication connection For additional information about connecting analog and digital I O see Chapter 3 Technical Details Disconnect power to the Soloist main supply and optional AUXPWR supply before changing the communication channel settings DANGER 2 22 www aerotech com Soloist Hardware Manual Installation and Configuration Table 2 6 Soloist Switch Settings S1 Switch Settings RA 3 2 1 0 1 Ist ON ON ON ON ON 2nd ON ON ON ON 3rd ON ON ON z ON 4th ON ON ON RRL Sth ON ON ON ON ON 7th ON ON 5 ON 8th ON ON 7 z 9th ON ON ON ON 10th ON 5 ON ON 11th ON ON ON 12th ON ON 13th ON ON ON 14th ON 2 ON 2 15th ON p ON 16th ON 17th ON ON ON ON 18th ON ON ON 19th ON ON ON 20th ON ON 214 ON ON ON 22nd ON z ON z 23rd ON ON 24th ON 25th ON ON ON 26th 5 ON ON 27th 5 ON ON 28th ON 29th ON ON 30th ON 31st 2 z p ON 32nd 3
55. Current Changes Version Section s Affected General Information 1 6 Corrected Input and Output power Specifications in Table 1 2 in Section 1 6 2 6 Added E STOP noise suppression requirement note and Table 2 5 2 10 Added note to remove power before changing communication channel settings 3 1 1 Clarified PSO output text in paragraph 2 and updated Figure 3 1 to show interface to a single ended device 1 4 3 1 3 Corrected high speed input voltage spec from 5 24 to 5 volts only Updated Figure 3 6 3 7 to show 2 inputs connected Removed errant Window array reference in Figure 3 11 Fixed schematic picture in Figure 4 6 and corrected text to indicate T these inputs are scaled for 5 24 volt logic High speed inputs in Sec 3 1 3 are 5 volt only 6 3 Corrected fuse F4 for the Soloist30 to LittleFuse P N from 2184010 to 218010 www aerotech com C 1 Technical Changes Soloist Hardware Manual C 2 Archive of Changes Version Section s Affected General Information 1 0 All New First release of the manual 1 1 Formatting changes non technical Digital I O renumbered from 0 to Port 0 0 7 Port un 1 0 7 and Port 2 0 7 Chap 4 Picture updated Relay always present not just with IO opt and re 1 3 3 3 2 4 2 6 worded entire section normally open was incorrectly indicated as normally closed
56. DWHEEL E MODEL HWAS2 FLY XX 630B1983 1 REV S N XXXXXX XX CABLE LENGTH DECIMETERS XXXXXX WORK ORDER NUMBER TYPE 4 MIA00424 2 CABLE LENGTH CAUTION CABLE LENGTHS XX ARE IN DECIMETERS EXAMPLE HWA32 FLY 30 30 30 DECIMETERS 3 METERS 10FT 3 THIS HANDWHEEL IS INTENDED TO BE USED WITH THE BBA32 BREAK OUT BLOCK REFERENCE 620B1344 1 Soloist HANDWHEEL HWA32 FLY XX 630 1983 1 630B1983 101 DWG HWA32 FLY XX Handwheel with Flying Leads No Connector 5 8 www aerotech com Soloist Hardware Manual Accessories NOTES Soloist THE BBA32 CONSISTS OF THE FOLLOWING PARTS 2 AUX I O INTERFACE 1 ECZ01230 PHOENIX BREAK OUT MODULE pei j 1 ECZ01231 26 PIN HD M F CABLE 2 5FT 26 PIN HD J 1 04 M F CABLE S ECZ01231 26HD FEMALE PHOENIX 26 PIN HD BREAKOUT MODULE ECZ01230 SHOWN FOR REFERENCE 5 6888266068 19060000600 9 C6 1 AUX_SIN 10 AUX_COS 19 AUX_MRK 2 AUX SIN 11 AUX COS 20 AUX_MRK 3 OPTO1 12 5V 21 COM 4 OPTO1 18 ANALOG_IN 22 ANALOG1 OUT BBA32 5 OPTO2 14 ANALOG IN 23 AGND AUX 1 0 6 OPTO2 15 EXT_OUTCOM 24 EXT_INCOM 7 EXT_OUT1 16 EXT_OUT4 25 INTERFACE 8 EXT_OUT2 17 26 4 9 EXT C IG EXT IN2 Soloist BBA32 AUX I O INTERCONNECT SS SS ae eee pease 62081343 1 7 5 9 1 53
57. FbkEncPhase CfgFbkEncSineGain CfgFbkEncSineOffset CfgFbkEncMultFactorMXU axis parameters This can be done automatically using the Encoder Feedback Configuration utility See the Soloist HMI help for more information The LMXU option is not compatible with PSO firing capabilities because it does not generate a serial pulse stream as required by the PSO Position Synchronized Output option A standard differential line driver encoder must be used if this option is not present see Section 3 3 for more information See the figure below for MXU typical input circuitry The pin out is indicated in Table 3 11 R319 R294 C405 SIN COS MKR Typical SIN COS MKR Typical C409 33PF 1 10UF 6 3V Figure 3 14 Optional MXU Analog Encoder Interface J103 MOTOR FEEDBACK J103 Soloist O a www aerotech com 3 17 Technical Details Soloist Hardware Manual 3 3 2 Brake Relay Interface J103 103 The brake relay is typically used to power a failsafe electromagnetic brake on a vertical axis This causes the brake to be engaged holding the axis in position unless it is powered Note that the axis may move slightly as the brake is enabled and disabled but will never drift or fall down The design also allows the brake to be powered throu
58. Input Connector Pin out 104 222 222 2 3 8 Table 3 7 Analog Output Connector Pin outs J104 sss 3 11 Table 3 8 Optional Analog Input Connector Pin outs J104 3 12 Table 3 9 PSO Output SOUEGe oe sert 3 13 Table 3 10 Motor Feedback Connector Mating Connector J103 3 15 Table 3 11 Motor Feedback Connector Pin out 7103 sess 3 16 Table 3 12 Brake Power Input Pin out on Connector 103 3 18 Table 3 13 Brake Relay Output Pin out on Connector 103 3 18 Table 3 14 103 RS 232 Connector 0 3 19 Table 3 15 RS 232 Port Connector Mating Connector 103 3 19 Table 4 1 Soloist C 4 1 Table 4 2 Optional Analog Input Connector Pin out 201 4 2 Table 4 3 Analog Output Connector Pin out TB201 sss 4 3 Table 4 4 Port 1 Opto Isolated Output Connector Pin out TB202 4 4 Table 4 5 Port 2 Opto Isolated Output Connector Pin out TB2023 4 4 Table 4 6 Output Specifications TB202 TB2023 sse 4 4 Table 4 7 Port 1 Opto Isolated Input Connector Pin out TB204
59. LO AUXPWR OPTION TRANSFORMER 18 WHT ACHI 230VAC THERMAL 18 WHT __ Splice AC LO 50 60 HZ RED 56v 115v BLK bur SAFTEY 100v ORN Ov GRAY 115v BRN MAIN SUPPLY gt o N YEL56v 100v GRN splice FRAME GROUND OPTIONAL SUPPLY 0 3 56 WIRING PRIMARY 230VAC SECONDARY 56VAC 80VDC BUS TRANSFORMER P N EAX01006 Figure 2 3 NOTES 1 THE AUXPWR OPTION IS USED WHEN THE MAIN SUPPLY POWER IS BELOW 100VAC TYPICALLY 28 56VAC INPUT THIS COREESPONDS TO A BUS VOLTAGE OF 40 80VDC 2 FOR 100VAC PRIMARY INPUT PARALLEL THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED 3 FOR 200VAC PRIMARY INPUT SERIES THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED 4 WHEN USING AN ISOLATION TRANSFORMER EARTH GROUNDING OF AC2 INPUT TAP REDUCES ELECTRICAL AND AUDIBLE NOISE EMMISSIONS AND PROVIDES INCREASED SERVO PERFORMANCE 5 IT IS RECOMMENDED THAT THE OPTIONAL AND MAIN SUPPLIES ARE TURNED ON AT THE SAME TIME TO ENSURE PROPER SOFT START OPERATION 6 ADDITIONAL OR ALTERNATIVE FUSING MAY BE REQUIRED FOR OPTIMUM PROTECTION Soloist AUXPWR INTERCONNECT 80VDC BUS TVO 3 56 620B1346 2 620B1346 201 DWG 80 Volt DC Bus from 115 and 230 VAC Source Figure 2 3 is shown only for reference For the most recent Dwg files see your software CD ROM which includes a Dwg file viewer WWW aerotech com 2 7 Installation and Configuration Soloist Hardware Manual
60. N GRN ov A z 5 GRAY splice zg Ac2 splice 115v BRN 2 YEL 56v_ 100v GRN splice FRAME GROUND a 25 Soloist ES AUXPWR INTERCONNECT N 160VDC BUS 0 3 56 TV0 3 56 WIRING PRIMARY 230VAC 620B1346 3 SECONDARY 115VAC 160VDC BUS 620B1346 301 DWG TRANSFORMER P N EAX01006 Figure 2 4 160 Volt DC Bus from 115 and 230 VAC Source Figure 2 4 is shown only for reference For the most recent Dwg files see your software CD ROM which includes a Dwg file viewer 2 8 www aerotech com Soloist Hardware Manual Installation and Configuration 2 5 1 Minimizing 50 60 HZ Line Interference If you are operating the Soloist from an off line power source of 115 VAC or 230 VAC there is a potential problem of EMI electromagnetic interference generated from the Soloist switching power stage propagating through the bridge rectifier and out through the and AC2 input AC line connections Use a line filter to minimize back propagation of noise into the AC lines An example of a line filter and its proper connection to the Soloist is shown in Figure 2 5 Toraue to Use 14 AWG 300V Copper Wire rated for sr indb at least 80 C 115 230 Soloist Schaffner FN2070 10 50 60Hz A 06 includes common Ground mode choke and ferrite Ground AC2 AC1 Protective TB102 3 Ground This configuration is especially important if the Soloist is operati
61. Output 14 AWG 2C Phase C Motor Output 14 AWG External fuses or circuit breakers 15 Amps maximum time delay type are required for the ACI and AC inputs for protection and must be located near the Soloist For optimum protection use 10 Amp protection devices 15 Amp devices are required in applications requiring maximum power The AUXPWR input is an option but if present must be powered For example if the AC bus input voltage is less than 85 VAC at 102 AC2 the optional AUXPWR control power input must be present and powered for keep alive operation This feature can also be used when an external emergency stop circuit is present which removes bus power as illustrated in Section 2 6 1 In either case the AUXPWR input provides keep alive or control power to the drive at all times The AUXPWR input is located on the side of the unit as shown in the previous illustration The supply connections to the ACI and AC2 AUXPWR inputs and the protective ground must be at least 18 AWG wire rated 300 V 3 Amp external fusing is required for AC2 The AC1 is fused internally at 3 Amps Table 2 2 AUXPWR AC Input Option when TB102 AC input lt 85 VAC Pin Description Wire Gauge 85 240 VAC Control Power Input 18 AWG AC2 85 240 VAC Control Power Input 18 AWG GND Protective Ground Required for Safety 18 AWG DANGER High Voltage CE www aerotech com 2 3 Installation and Configura
62. SOLOIST HARDWARE MANUAL P N EDU180 Ver 1 4 U Standard with 1 0 Option AEROTECH Inc e 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 http www aerotech com AEROTECH Product Registration To register your Soloist use the product registration form that is available online at http www aerotech com prodreg cfm Technical Support For technical support contact one of the following United States Headquarters Phone 412 967 6440 Fax 412 967 6870 Email service aerotech com United Kingdom Phone 44 0 118 940 9420 Fax 44 0 118 940 9428 Email service aerotech co uk Germany Phone 49 911 967937 0 Fax 49 911 967937 21 Email service aerotechgmbh de Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Soloist is a trademark of Aerotech Inc The Soloist User s Manual Revision History Ver 1 0 October 12 2004 Ver 1 1 December 8 2004 Ver 1 2 December 23 2004 Ver 1 3 February 28 2005 Ver 1 4 April 12 2005 Aerotech Inc 2005 Soloist Hardware Manual TABLE OF CONTENTS CHAPTER 1 1 1 1 2 CHAPTER 2 2 1 2 2 2 3 24 2 5 2 6 2 7 2 8 2 9 2 10 2 11 CHAPTER 3 3 1 9 4 04 4 0
63. Technical Details Soloist Hardware Manual Software Primary Encoder 4 Marker Trigger or Secondary Encoder Tracking Distance Trigger 2 4 gt Pulse Switching Generator Pulse Multiplex Output Lang nable PSO Output High Speed 4 Input 12 Window Window High Speed and Output Input 13 Enter Exit Detection y Switching Count 1 Multiplex i i N Trigger Data AN Reset Inside Window Capture Update Marker Mode Only See other Block Diagram Figure 3 11 PSO Block Diagram The window modes allow firing to occur or be enabled based upon axes being within a user defined window The and Enter Exit Detection block within the block diagram is used to prevent false triggering due to one bit dither on an axis etc Window modes may not be pre scaled as indicated in the block diagram Data Capture mode allows the encoder position to be captured at the PSO trigger locations Data Update mode allows analog or digital outputs to be set by the same trigger The capture and update modes are defined in Figure 3 12 For a full description of these modes refer to the Soloist HMI help From Pulse or lt gt PSO Output Window Switching High Speed Input 12 Multiplexors lt gt High Speed Input 13 Capture Primary Encoder 32 Bit Secondary Encoder 32 Bit Window
64. TwoVersions essere eene 1 1 Figure 1 2 Soloist HardWate 1 3 Figure 1 3 Soloist Block Diagram 2 4242400 0 1 4 Figure 1 4 Soloist Physical Dimensions 1 8 Figure 2 1 AUXPWR 2 5 Figure 2 2 40 Volt DC Bus from 115 and 230 VAC 2 6 Figure 2 3 80 Volt DC Bus from 115 and 230 VAC 2 7 Figure 2 4 160 Volt DC Bus from 115 and 230 VAC 2 8 Figure 2 5 Back Propagation Line Filter Connection sess 2 9 Figure 2 6 ESTOP Sense Input TB101 eee 2 10 Figure 2 7 Typical Emergency Stop Circuit esee 2 11 Figure 2 8 DC Brush Motor Torque Mode Connections 2 12 Figure 2 9 Brushless Motor 2 13 Figure 2 10 Hall Effect Feedback Connections sese 2 15 Figure 2 11 Hall Effect Feedback Inputs in the Soloist HMI Program 2 15 Figure 2 12 Motor Phasing sser A 2 17 Figure 2 13 Stepper Motor 2 18 Figure 2 14 Encoder Feedback Connections 2 19 Figure 2 15 Encoder Phasing Reference Diagram esee 2 20 Figure 2 16 Encoder Feedback i
65. Uu Du C 2 www aerotech com Soloist Hardware Manual Index RS 232 RS 422 3 19 Continuous Output Current 1 5 Control Board 6 5 lt 85 VAC AC Bus Input Power 2 3 Assembly 6 5 40 80 VDC Power Transformer 2 5 Jumpers 6 5 6 6 A D AC Power Connections 2 3 DC Brush Motor Configuration 2 12 AUXPWR 2 3 Determining Proper Connections to the NDrive ACI Input Terminal 2 3 2 9 Test 2 16 AC2 AUXPWR 2 3 Dimensions 1 8 AC2 Input Terminal 2 3 2 9 Drive Package 1 4 Amplifier Faults 6 2 Analog Inputs TB302 4 2 E Analog Output Connector Pinouts 3 11 4 3 Auxiliary I O Electircal Noise Reduction 2 4 Connector Pinouts 3 2 Electrical Specifications 1 6 Secondary Encoder 3 3 Emergency Stop Sense Input TB101 2 10 User Digital Inputs 3 8 EMI Interference 2 4 User Digital Outputs 3 5 Environmental Specifications Auxiliary Power Option 2 5 Altitude 1 9 AUXPWR 1 5 2 3 2 5 4 1 Humidity 1 9 ACI 2 3 Pollution 1 9 AC2 2 3 Temperature 1 9 Ground 2 3 Operating 1 9 Storage 1 9 B Use Indoor 1 9 ESTOP TB101 2 10 Back Propagation Line Filter Connection 2 9 Brake Relay TB301 Current Specifications 4 10 Brake Relay TB301 Voltage Specifications 4 10 Brake Relay Connector Pinouts 4 10 Feature Summary 1 2 Brake Configuration Jumpers 4 10 Feedback Connections 2 12 2 15 2 19 2 21 Brushless Motor Configuration 2 13 Field Service Policy B 1 Bus Power Supply 1 4 Fuse R
66. ack Channels e Primary Channel Line driver square wave or optional analog sine wave quadrature encoder primary position and velocity feedback e Secondary Channel Line driver square wave auxiliary quadrature encoder input 1 2 3 Inputs and Outputs e Four opto isolated user outputs standard e Six opto isolated user inputs standard two of which are high speed e differential analog input standard e Oneanalog output standard e Dedicated 24 V E stop sense input standard 5 V optional Integral 24 V brake output interface e 5 VDC 500 mA user output power for encoder and Hall effect signals 1 2 4 IO Option Feature Summary e 16 additional opto isolated user outputs e 16 additional opto isolated user inputs e One additional differential analog input e One additional analog output e One additional Brake Relay Output 1 2 www aerotech com Soloist Hardware Manual Introduction 1 3 Soloist Connections The Soloist AC power motor power feedback and communications connections are detailed in Figure 1 2 Features in this box are only Brake Power Input p available with the IO Option and RS232 TB103 E 1 Analog In LED Indicators ls z 1 Analog Out TB201 gt Ethernet J102 20781 LNO O1dO Motor Feedback 16 Digital Opto Out Line Driver Encoder BY Halls Limits z TB202 TB203 J103 5 Emergency Stop Sense Input TB101 Auxiliary I O
67. anty repairs do not extend the original warranty period Laser Products Return Procedure Returned Product Warranty Determination www aerotech com B 1 Warranty and Field Service Soloist Hardware 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 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 w
68. are CD A viewer is included WWW aerotech com 2 11 Installation and Configuration Soloist Hardware Manual 2 7 Motor Connections The Soloist can be integrated into a system using three basic configurations DC brush torque mode brushless and stepper motors 2 7 1 DC Brush Motor Connections in Torque Mode When you connect a DC brush motor in torque mode use the configuration shown in Figure 2 8 Note No connection is made to the Soloist terminal as shown Figure 2 8 Motor A Green White amp Shield Frame Red amp Orange V Typical motor cables used are the C13802 BADC MSO or BADC MSONT DC Brush No Connection Motor Yellow amp Blue For full cable drawings refer to your software CD ROM Figure 2 8 DC Brush Motor Torque Mode Connections 2 7 1 1 DC Brush Motor Phasing If you are using an Aerotech motor and cabling no motor phasing is required A DC brush motor is phased correctly when a positive motion command causes clockwise CW motor rotation as viewed when looking at the motor from the front mounting flange See previous illustration The PosScaleFactor parameter must be set to a positive value Motor phasing is unrelated to the direction of motion commanded from within a user task Instead it is determined solely by which motor lead is connected to the C motor terminals After correctly phasing the motor you can reverse the moto
69. coder Channel Input 12 5 Volt 5 Volt 500mA max Output 19 Auxiliary Marker Secondary Encoder Channel PSO Output Bidir 20 Auxiliary Marker Secondary Encoder Channel PSO Output Bidir 21 Common Common 5V Supply Return 23 Common Common 5V Supply Return Total user 5 V power is limited to 500 mA by an internal re settable fuse User Provided Pull Up and Pull Down Resistors 10k Ohm 20 19 5 VDC User Provided Pull Up Resistor 10k Ohm 104 NOTE Si pin 20 will onl Signal at pin 20 will only TT 20 vary from 1 4 volts DC Aux Marker Pin 19 No 19 Connection Opto 4 Isolator User Device 23 Figure 3 1 PSO Interface J104 www aerotech com Opto Isolator gt 1 2 Double Ended amp ooooooQ amp Ooooooooe Technical Details 3 3 Technical Details Soloist Hardware Manual 3 3V 3 3V S 3s E C34 al 2 10UF_6 3V ol rl ol C376 1 344 377 11 01 4 dd 85858 886 E RN40 B 24 70 OHM J103 18 3IN RN40 A 1 80 OHM OS RN40 D 444 50 OHM 403 15 05 RN40 C 3 A60 OHM AUXSIN RN33 A 14 80 OHM BA RN33 B 70 OHM Gips ip AUXCOS RN33 C 34 60 OHM Cyj94 1p AUXCOS RN33 D 4A A5 0 OHM 8 6
70. d causes the motor to rotate in a CW direction assuming a positive scaling factor as determined by the PosScaleFactor parameter To correct the phasing reverse the connections to the 0A and terminals on the Soloist This is important because the inputs for the end of travel EOT limit are determined by motor rotation After correctly phasing the motor you can reverse the motor direction when commanding a positive move from a user task by changing the PosScaleFactor parameter to a negative value 2 18 WW aerotech com Soloist Hardware Manual Installation and Configuration 2 8 Encoder Feedback Connections The same encoder feedback device is used for brush and brushless motor types Each of the encoder channels in the Soloist accepts a differential line driver encoder DC Brush and brushless motors may have a separate position and a velocity feedback device Use an analog sine wave encoder with the Aerotech MXH multiplier box to multiply the encoder resolution and simultaneously convert it to a differential line driver encoder signal that can be accepted by the Soloist To shield signals you must physically isolated wiring from motor AC power and all other power wiring Primary Feedback Soloist Sin J103 Sin N 2 Line Driver Encoder Primary Cos with hall feedback Encoder Cos N Or Channel Mkr O N Analog Sine Wave It du Encoder With MXH Mkr N E Multiplier Encoder 5V
71. ded for AC brushless motor commutation but not absolutely required The Hall effect and limit inputs accept 5 24 VDC logic signals The Pin outs for the connector are shown in Table 3 11 The thermistor input is used to detect an over temperature condition in the motor by a positive temperature coefficient device That is as the temperature of the device increases so does the resistance of the device Under normal operating conditions the resistance of the thermistor is low i e 100 ohms This will be seen as a low input signal After the temperature causes the thermistor s resistance to increase above 1K ohms the signal will be seen as a logic high triggering an over temperature fault by the controllers FaultMasks See the Soloist HMI help for more information on configuring these FaultMasks Table 3 10 Motor Feedback Connector Mating Connector J103 Aerotech Third party Source Connector ECK00101 Cinch P N DB25P Back shell ECK00656 Amphenol P N 17 1726 2 The Soloist is factory configured for either a square wave differential encoder default OR an analog encoder with the MXU option MOTOR FEEDBACK J103 Soloist 1 j N OC E WWW aerotech com 3 15 Technical Details Soloist Hardware Manual Table 3 11 Motor Feedback Connector Pin out J103 Pin Label In Out Bi 1 Frame N
72. ds No 5 8 BBA32 Interface Used to Connect a Handwheel with Flying Leads No Connector eese enne nennen 5 9 Soloist Board Assembly 69001591 Rev 6 5 e vi www aerotech com Soloist Hardware Manual List of Tables LIST OF TABLES Table 1 1 Soloist Voltage Configurations essere 1 5 Table 1 2 Electrical 1 6 Table 2 1 Main AC Power Input and Motor Output 102 2 3 Table 2 2 AUXPWR AC Input Option when TB102 AC input lt 85 VAC 2 3 Table 2 3 Wire Part NUfIDetS eiie coiscese et con ete ates te end ce ete eU EE ve PERF eee 2 4 Table 2 4 ESTOP Input Voltage Jumper esee 2 10 Table 2 5 Electrical Noise Suppression Devices esee 2 10 Table 2 6 Soloist Switch Settings 50 2 23 Table 3 1 Auxiliary I O Connector Mating Connector J104 3 1 Table 3 2 Auxiliary I O Connector Pin out 7104 sse 3 2 Table 3 3 Secondary Encoder Connector Pin out 104 3 3 Table 3 4 Port 0 Digital Output Connector Pin out J104 sess 3 5 Table 3 5 Opto Outputs 0 3 3 5 Table 3 6 Port 0 Digital
73. e Manual Warranty and Field Service APPENDIX B WARRANTY AND FIELD SERVICE In This Section Laser PrOdUGtS 22222 222220 B 1 o Return Procedurer ee B 1 Returned Product Warranty Determination B 2 e Returned Product Non warranty Determination B 2 Rush Service eee e B 2 e On site Warranty 2 2 B 2 e On site Non warranty B 2 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 that 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 specifically 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 Aerotech Inc warrants its laser products to the original purchaser for a minimum period of one year from date of shipment This
74. elds a 40 VDC power bus AUXPWR 50 60Hz 85 240V 0 25 A MAX A www aerotech com 2 5 Installation and Configuration Soloist Hardware Manual 2 5 Typical AC Wiring with the AUXPWR Option and External Transformer To generate a 40 80 160 VDC Bus for the motor power connect your Soloist to a 115 230 VAC source The following three figures illustrate the six combinations available for both AC input voltages and all three DC bus voltages when the AUXPWR option is used Soloist PRIMARY FUSE AUXPWR OPTION Mawur AS10810 AC HI 115VAC ACLO 50 60 HZ INPUT 18WHT__ SPlice 115v BLK SAFTEY 100v ORN NOTES Ov GRAY 115v BRN 1 THE AUXPWR OPTION IS USED WHEN THE MAIN SUPPLY POWER IS BELOW 100VAC TYPICALLY 28 56VAC INPUT THIS COREESPONDS TO A BUS VOLTAGE OF 40 80VDC 28 100v GRN 2 FOR 100VAC PRIMARY INPUT PARALLEL THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED 3 FOR 200VAC PRIMARY INPUT SERIES THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED FRAME GROUND 4 WHEN USING AN ISOLATION TRANSFORMER EARTH GROUNDING OF THE AC2 INPUT TAP REDUCES ELECTRICAL AND AUDIBLE NOISE EMMISSIONS AND PROVIDES INCREASED SERVO PERFORMANCE 5 IT IS RECOMMENDED THAT THE OPTIONAL AND MAIN SUPPLIES ARE CONNECTED TO THE SAME SOURCE AS SHOWN THIS WILL ENSURE PROPER SOFT START OPERATION OPTIONAL SUPPLY gt
75. ential buffered by a TL082 op amp and converted to digital by 12 bit ADS7816 analog to digital converter allowing an input voltage in the range of 10 volts Signals outside this range may damage the input The 12 bit ADC produces a resolution of 4 88 mVolts per bit of the A D Refer to Figure 3 10 See Table 3 8 for the pin numbers To interface to a single ended non differential voltage ground the negative input and connect your signal to the positive input See Section 3 1 1 for the mating connector part number A second analog input is provided on the IO option board Table 3 8 Optional Analog Input Connector Pin outs J104 Pin Label Description In Out Bi 13 Analog0 In Positive Analog Input 0 Input 14 Analog0 In Negative Analog Input 0 Input 21 Common Common N A 23 Common Common TP51 ANALOG_IN ANALOG_IN Figure 3 10 Analog Input 0 J104 3 12 www aerotech com Soloist Hardware Manual Technical Details 3 2 Position Synchronized Output PSO The Soloist includes a Position Synchronized Output PSO option This feature may be programmed to generate an output synchronized to the axis position based upon a user defined trigger condition The Soloist provides only single axis tracking of one of the two encoder input channel Encoder signals may come from the primary or secondary encoder channels These input channels allow a 40 Mhz inp
76. eplacement 6 4 C G Cable Interconnections 5 1 Grounding Techniques 2 4 Cleaning 6 7 Connector Pinouts H Auxiliary I O 3 2 Secondary Encoder 3 3 Handwheel Interface 5 7 User Digital Inputs 3 8 Hardware Function 1 3 User Digital Outputs 3 5 Hardware Overview 1 3 J103 3 16 High Inrush Currents 1 4 J104 3 2 Secondary Encoder 3 3 I User Digital Inputs 3 8 User Digital Outputs 3 5 Wiring Requirements 2 9 J206 3 19 Input Power Motor Feedback 3 16 AC2 2 9 www aerotech com Index Soloist Hardware Manual AC2 2 3 Main Supply 2 3 Motor Frame Connections 2 3 Shield Connection 2 3 Three Phase Power Input 2 3 Input Power Wiring Techniques 2 4 Installation 2 1 Integrated Configurations 2 12 2 15 2 19 2 21 IOPSO 4 5 IOPSO Option Jumpers 2 10 4 9 IOPSO Option Board 4 2 Analog Inputs TB302 4 2 Analog Outputs 4 3 Opto Isolated Inputs TB305 4 6 Opto Isolated Outputs TB304 4 4 J J103 3 15 Connector Pinouts 3 16 J104 Connector Pinouts 3 2 Secondary Encoder 3 3 User Digital Inputs 3 8 User Digital Outputs 3 5 J206 Connector Pinouts 3 19 J207 4 10 JI Option 4 1 Joystick Interface 5 5 Jumpers IOPSO 2 10 4 9 L Laser Output Opto Isolator Specifications 3 13 Limit and Hall Effect Inputs 3 16 Line Filter Connection 2 9 Line Interference 2 9 Logic High 2 14 Logic Low 2 14 M Models 1 5 Motor and Feedback Connection Basic Conf
77. er stage of the drive while maintaining power to the control section Figure 2 7 This is accomplished by the use of an external relay The ESTOP sense input TB101 notifies you of the setting of the ESTOP fault The controllers response to the ESTOP fault is determined by the Soloist FaultMask axis parameters For additional information see Soloist Help The external relay must be sized to handle the peak inrush current of the Soloist For additional information see Table 1 3 Soloist AUXPWR OPTION A A MAIN SUPPLY gt N AC HI 115 230VAC ACLO 50 60 HZ SAFTEY TB101 ESTOP PORT d 4 NOTES 2 24 A THE AUXPWR OPTION CAN BE USED WHEN THE MAIN SUPPLY BUS POWER MUST BE REMOVED DURING AN EMERGENCY STOP CONDITION WHILE LOGIC ENCODER POWER MUST BE MAINTAINED 77 control relay USER SUPPLIED crt db 24VDC e SUPPLY A FOR THE E STOP INPUT TO BE ACTIVE SETUP THE APPROPRIATE FAULTMASK IN THE AXIS PARAMETERS FOR THE DESIRED ACTION WHEN AN E STOP CONDITION IS ENVOKED 501015110 Slo Blo Soloist20 10A Slo Blo Soloist30 10A Slo Blo Soloist AUXPWR OPTION 1 A Soloist AUXPWR INTERCONNECT A AC2 WITH E STOP lt 620B1358 4 Figure 2 7 Typical Emergency Stop Circuit Figure 2 47 is shown only for reference For the most recent Dwg files see your softw
78. f the Motor Mounting parameter that is associated with the incorrectly phased feedback device Flange Front View cos MOVE Ciockwise FORCER WIRES COS N SIN SIN N MKR MKR N MOVE Clockwise Me Figure 2 15 Encoder Phasing Reference Diagram Diagnostics q Drive 1 0 ChkOut_14 7 gt Position Command 0 PositionFeedock o _ Curent Command Auxiliary Encoder Input jo Amplifier Temperature 26 9607849 Diaital Input 0 000000 Figure 2 16 Encoder Feedback in the Soloist HMI 2 20 www aerotech com Soloist Hardware Manual Installation and Configuration CW Rotation Positive Direction 2 9 End of Travel Limit Connections EOT limits define the end of physical travel of the axis and are used for homing which defines absolute reference for the user coordinate system EOT limits are clockwise rotary motion or positive linear motor motion Positive or clockwise motion is stopped by the CW EOT limit input Soloist Motor Mounting 16 Flange Front View end MOVE Clockwise J103 cw 12 Primary 24 FORCER WIRES Encoder Channel 22 N May bee separate switch Normally Closed Typical Or Normally Open not shown For full cable drawings refer to your software CD ROM Figure 2 17 Limit Inputs in the Soloi
79. from the center of rotation to the point where the force is applied Torque needed to drive a load over a continuous time Maximum amount of torque a motor can deliver when the highest allowable peak currents are applied Root Mean Square is a mathematical method to determine a steadfast or average torque for a motor The maximum torque without burning out the motor The full indicator reading observed when a dial indicator is in contact with the part surface during one full revolution of the part about its axis of rotation In a servo system the process of optimizing loop gains usually PID terms to achieve the desired response from a stage or mechanism from an input command See Repeatability Motor driver or amplifier configuration where the input signal is commanding motor velocity Motors with analog tachometers are normally driven by this driver configuration www aerotech com Glossary of Terms Soloist Hardware Manual Wobble An irregular non repeatable rocking or staggering motion of the table top of a rotary stage Wobble is defined as an angular error between the actual axis of rotation and the theoretical axis of rotation Yaw of travel Rotation about the vertical axis perpendicular to the axis of travel Angular movement error that affects straightness and positioning accuracy Yaw Error Positioning error resulting from a yaw motion A 10 www aerotech com Soloist Hardwar
80. gh the 7 existing encoder feedback cable without the need for additional wiring as indicated RS232 TX Figure 3 15 Failsafe brakes used by Aerotech require a 24 VDC supply capable of RS232 RX supplying 1 ampere of current GND BRAKE PS This brake output may also be used as a general purpose relay For this reason the BRAKE PS normally closed normally open and common contacts are available on the TB206 connector of the IO option See the BrakeOnDriveDisable axis parameter for information on activating the brake output automatically or the BRAKE command for manually toggling the output both in the Soloist help See Section 4 2 6 in Chapter 4 for more information on using the brake output MOTOR FEEDBACK J103 See Section 3 3 for the J103 mating connector part number Solois am Table 3 12 Brake Power Input Pin out on Connector TB103 Pin Label Description In Out Bi 5 Brake Power Optional Brake Power Input Input 6 Brake Power Optional Brake Power Input Input i Table 3 13 Brake Relay Output Pin out on Connector J103 ou Pin Label Description In Out Bi 2 13 Brake Optional Brake Relay Output Output 25 Brake Optional Brake Relay Output Output 2 5V O TO_CONTROLLER 24 Volt User Supplied External Brake Power Supply PS710A 1A SK 03 25 BRAKE 4103 15 Figure 3 15 Brake Connector 103
81. gure 2 9 Brushless Motor Connections www aerotech com 2 13 Installation and Configuration Soloist Hardware Manual Clockwise CW Positive Direction an Motor Shaft Motor Mounting Flange Front View 2 7 2 1 Brushless Motor Phasing When configuring the Soloist to run a non Aerotech brushless motor the motor leads A B and C on TB102 must be correctly connected for proper operation An AC brushless motor is correctly phased if a positive motion command causes CW motor rotation as viewed when looking at the motor from the front mounting flange See illustration The PosScaleFactor parameter must be set to a positive value Motor phasing is unrelated to the direction of motion commanded from within a user task Instead it is determined solely by which motor lead is connected to the LIA OB and OC motor terminals After correctly phasing the motor you can reverse the motor direction when commanding a positive move from a user task by negating the sign of the PosScaleFactor parameter Before running the Soloist Programs Samples MsetDebug Ab configure the axis parameters For configuration information see Getting Started in Soloist Help Motor phasing is determined by two methods In the first method the motor open loop is actively driven under program control The Soloist Programs Samples MsetDebug Ab can be used for this purpose The motor phasing is correct if the program causes the motor to move in
82. he output is measured and compared to the input Output is adjusted to reach the desired condition Computer Numerical Control A computer based motion control device programmable in numerical word address format Defined as the ratio of the force required to move a given load to the magnitude of that load Nonuniform angular linear velocity Cogging appears as a jerkiness especially at low speeds and is due to magnetic poles attracting to steel laminations The action of steering currents to the proper motor phases to produce optimum motor torque force In brush type motors commutation is done electromechanically via the brushes and commutator A brushless motor is electronically commutated using a position feedback device such as an encoder or Hall effect devices Stepping motors are electronically commutated without feedback in an open loop fashion www aerotech com Soloist Hardware Manual Glossary of Terms Commutation 6 Step Commutation Modified 6 Step Commutation Sinusoidal Coordinated Motion Critical Speed Current Command Current Peak Current rms Also referred to as trapezoidal commutation The process of switching motor phase current based on three Hall effect signals spaced 120 electrical degrees beginning 30 degrees into the electrical cycle This method is the easiest for commutation of brushless motors Also referred to as modified sine commutation The process of switching motor pha
83. igurations 2 12 Brushless 2 12 DC Brush 2 12 Stepper 2 12 Motor and Feedback Connections 2 12 2 15 2 19 2 21 Motor Connections 2 3 2 12 2 15 2 19 2 21 Motor Feedback Connector Pinouts 3 16 Motor Feedback 3 15 Connector 4 10 Motor Feedback Connector Location 1 3 Motor Frame Connection 2 3 Motor Output Terminals A B and C 2 3 Motor Phasing 2 18 N NCDrive Hardware 1 3 NDrive Connection Test 2 16 Noise Back propagation 2 9 O Optional AC Power Supply Input 2 3 Optional Analog Input Connector Pinouts 3 12 4 2 Options AUXPWR Auxiliary Power 4 1 Options 1 5 4 1 AUXPWR Auxiliary Power 1 5 Industrial Joystick 4 1 S Shunt 1 5 4 1 Opto Isolated Input Connector Pinouts 4 6 4 7 Opto Isolated Inputs TB305 4 6 Opto Isolated Output Connector Current Sinking Mode 4 5 Current Sourcing Mode 4 5 Pinouts 4 4 Specifications 4 4 Opto Isolated Outputs TB304 4 4 Output Current Peak 1 5 Phase Hall Sequence 2 16 Pinouts Analog Output Connector 3 11 4 3 Brake Relay Connector 4 10 Optional Analog Input Connector 3 12 4 2 Opto Isolated Input Connector 4 6 4 7 Opto Isolated Output Connector 4 4 User Power Connector 4 9 Power 1 5 Power Connections 2 3 Preventative Maintenance 6 7 Product Overview 1 1 R Relay K1 Contact Ratings 4 10 Revision History C 1 RS 232 RS 422 Connector Pinouts 3 19 ii www aerotech com Soloist Hardware Manual
84. igure 4 4 Connecting Outputs in Current Sinking Mode Be sure to set the DrivelOConfig axis parameter to configure the outputs as current sinking or current sourcing All outputs on a single port 0 1 or 2 must be connected as all sourcing or as all sinking outputs Diode required for an inductive load 80 mA Max PS2802 4 Connection required to minimize glitching 18707 2 5 24 VDC Figure 4 5 Connecting Outputs in Current Sourcing Mode www aerotech com 4 5 z ui Soloist Options Soloist Hardware Manual S 0 1 2 3 4 5 6 7 V 0281 4 Suppression diodes must be installed on outputs that are used to drive relays or other inductive devices to protect the output devices from being damaged by the inductive spikes that occur when the device is turned off Suppressor diodes can be installed on all outputs to provide greater protection The 1N914 diode is recommended for this application It is important that the diode be installed correctly normally reversed biased See Figure 4 4 for an example of a current sinking output with diode suppression and Figure 4 5 for an example of a current sourcing output with diode suppression 4 2 4 Port 1 and Port 2 Opto Isolated Inputs TB204 TB205 The digital inputs are configured for 5 24 volt logic Using a higher input voltage requires adding external series res
85. ill 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 the repair Aerotech Inc Phone 412 963 7470 101 Zeta Drive Fax 412 963 7459 Pittsburgh PA 15238 2897 USA B 2 www aerotech com Soloist Hardware Manual Technical Changes APPENDIX C TECHNICAL CHANGES Current Changes e Archive of Changes In This Section C 1 Current Changes Table C 1
86. ing point relative move The physical property of an object to resist changes in velocity when acted upon by an outside force Inertia is dependent upon the mass and shape of an object The deviation of a lead screw or ball screw from its nominal pitch A device for translating rotary motion into linear motion Unit consists of an externally threaded screw and an internally threaded carriage nut See Ball Screw WWW aerotech com A 5 Glossary of Terms Soloist Hardware Manual Life Limit Switch Limits Linear Motor Load Carrying Capability Master Slave MMI Motion Profile Motor Brush Motor Brushless Motor Stepping NC NEMA Non Volatile Memory Open Collector Open Loop The minimum rated lifetime of a stage at maximum payload while maintaining positioning specifications A sensor used to determine the end of travel on a linear motion assembly Sensors called limits that alert the control electronics that the physical end of travel is being approached and motion should stop A motor consisting of 2 parts typically a moving coil and stationary magnet track When driven with a standard servo amplifier it creates a thrust force along the longitudinal axis of the magnet track The maximum recommended payload that does not degrade the listed specifications for a mechanical stage Type of coordinated motion control where the master axis position is used to generate one or
87. istors to limit the current The opto isolator is a PS2806L 4 device The inputs may be connected to current sourcing or current sinking devices as shown in Figure 4 6 and Figure 4 7 Each 8 bit bank of inputs TB204 and TB205 must be connected to either all current sourcing or all current sinking devices Also note in the tables below that inputs TB204 and TB205 have two different common inputs at Pin 1 respectively See Section 3 1 3 for opto isolated EOT limit inputs 50281 NI OldO Table 4 7 Port 1 Opto Isolated Input Connector Pin out TB204 Pin Label Description In Out Bi C Input Common for inputs 0 07 TB204 Input Input 0 Input 0 Optically Isolated pin 1 Input Input 1 Input 1 Optically Isolated pin 1 Input Input 2 Input 2 Optically Isolated pin 1 Input Input 3 Input 3 Optically Isolated See pin 1 Input Input 4 Input 4 Optically Isolated pin 1 Input Input 5 Input 5 Optically Isolated pin 1 Input Input 6 Input 6 Optically Isolated pin 1 Input Input 7 Input 7 Optically Isolated pin 1 Input GND Signal Common N A Inputs 0 7 on each Port 0 1 and 2 must be used in all current sourcing or all current sinking mode No combination of these two modes is allowed 4 6 WW aerotech com Soloist Hardware Manual Soloist Options Table 4 8 Port 2 Opto Isolated Input Connector Pin out TB205 Pin Label Description In O
88. l pull up 10K input Commutation signals used with brushless motors to provide motor rotor position information to the controller This allows Feedback Inputs the three motor phase s currents to be varied commutated to rotate the motor in the desired direction at the desired speed TTL level input Sine Sine N Pin 17 Pin 18 Cosine Cosine N Pin 14 Pin 15 Encoder input 0 to 5VDC internal pull up 10K input 5V Pin 16 On board 5V power supply 250 mA maximum Auxiliary Power output Outputs 5V Pin 3 On board 5V power supply 500 mA maximum output for encoder Output short circuit Peak over current DC bus over voltage RMS over current Features Ole tenerae Control power supply under voltage Power stage bias supply Designed to under voltage EN61010 UL3101 Optical and transformer isolation between control and power Isolation stages LED indicates drive power LED indicates drive enabled Indicator power Indicator enabled www aerotech com 1 7 Introduction Soloist Hardware Manual 1 7 Physical Dimensions The physical dimensions for the Soloist are shown in Figure 1 4 Separate Soloist s from each other and provide 25 mm 1 inch of free air space
89. l versed in vacuum and clean room techniques ATS125 Linear Stage The ATS125 is Aerotech s smallest hard cover side sealed stage design The brushless integral motor option further reduces the overall footprint of the stage enabling its deployment in space constrained applications The ATS125 provides low cost with high performance providing travels up to 600 mm and speeds up to 600 mm s Engineering Reference Aerotech provides answers to common questions encountered when implementing motion control and positioning solutions including resolution accuracy and repeatability linear stage terminology rotary stage terminology E metrology testing and certification cantilevered loading loading versus lifetime computing maximum data rate motor sizing and much more http Awww aerotech com 2 of 2 4 12 2005 6 06 36 PM Catalog Click to view brochure Automation Solutions for Laser Processing Medical Device Manufacturing and Life Sciences Click to view brochure Deutsche Version Automation Solutions for the Fiberoptics Industry Click to view catalog Linear Motors Application Guide Click to view guide VascuLathe High Performance Stent Cutting System Click to view brochure Optical Mounts and Gimbals brochure Click to view brochure
90. led from the mechanical system WARNING Operator must be trained before operating equipment WARNING To minimize the possibility of electrical shock and bodily injury to workers when any electrical circuit is in use you must ensure that no one is exposed to the circuitry DANGER To prevent bodily injury make certain that all electrical power switches all switches external to the amplifier are in the off position prior to making any mechanical adjustments DANGER 2 2 www aerotech com Soloist Hardware Manual Installation and Configuration 2 3 Motor and AC Power Connections The three phase motor terminal connections are made at connections A B and C Motor Connections A B C and its Protective Ground must be made with 14 AWG wire rated 300 Volts Motor frame and shield connects to e ground Input voltage connection to the Soloist is made at the AC1 and AC2 terminals Earth ground is connected to ground Connections AC1 and AC2 and its protective ground must be made with 14 AWG wire rated 300 Volts Table2 1 Main AC Power Input and Motor Output TB102 Pin Description Wire Gauge ACI 240 Volt AC Maximum Input 14 AWG AC2 240 Volt AC Maximum Input 14 AWG GND Protective Ground required for safety 14 AWG GND Protective Ground to Motor required for safety 14 AWG ZA Phase A Motor Output 14 AWG 2B Phase B Motor
91. lity it is the non responsiveness of the system load to reversal of input command www aerotech com Glossary of Terms Ball Screw Ball Screw Lead Bandwidth Baud Rate BCD Bearing Bidirectional Repeatability CAM Profile Cantilevered Load Closed Loop CNC Coefficient of Friction Cogging Commutation Soloist Hardware Manual A precision device for translating rotary motion into linear motion A lead screw is a low cost lower performance device performing the same function Unit consists of an externally threaded screw and an internally threaded ball nut The linear distance a carriage will travel for one revolution of the ball screw lead screw A measurement expressed in frequency hertz of the range which an amplifier or motor can respond to an input command from DC to 3dB on a frequency sweep The number of bits transmitted per second on a serial communication channel such as RS 232 or modem Binary Coded Decimal A number system using four bits to represent 0 F 15 A support mechanism allowing relative motion between two surfaces loaded against each other This can be a rotary ball bearing linear slide bearing or air bearing zero friction See Repeatability A technique used to perform nonlinear motion that is electronically similar to the motion achieved with mechanical cams A load not symmetrically mounted on a stage A broad term relating to any system where t
92. lly to the Soloist refer to Section 6 4 for their locations All test points not shown are for Aerotech internal use only Table 6 2 Soloist Control Board Test Points Test Point Description 5 Volt supply TP2 12 Volt supply TP3 12 Volt supply TP4 Common 5 3 3 Volt supply Table 6 3 IO Option Board Test Points Test Point Description TP4 Common www aerotech com 6 3 Troubleshooting Soloist Hardware Manual DANGER 6 3 Fuse Replacement Table 6 4 lists the manufacturer and Aerotech s part number for typical replacement fuses Additional fuse information can be found on the system drawing supplied with the unit See Section 6 4 for fuse location information Table 6 4 Soloist Fuse Information NUR Aerotech Manufacturer s Fuse Description Size PN PN LittleFuse F1 Optional Shunt Fuse 2A S B 5 mm EIF01019 215002 F2 Control Power F 95A amp B 5sum Erop 1206086 ontro ower Fuse 3 mm 230 2508 Soloist10 Wickman AS B 0017 VAC mta 279 5 mm 00173 1951500 Soloist20 LittleFuse F4 10A S B 5 mm EIF01006 VAC Input at TB102 1 218010 Soloist30 LittleFuse 10A S B 5 mm 01 VAC Input at TB102 1 oh BS ee 218010 Always disconnect the mains power connection before opening the Soloist chassis Table 6 5 IO Board Fuse Information I Aerotech Manufacturer s
93. more slave axis position commands Man Machine Interface used as a means of getting operator data into the system See HMI A method of describing a process in terms of velocity time and position The conductive element in a DC brush type motor used to transfer current to the internal windings Type of direct current motor that utilizes electronic commutation rather than brushes to transfer current Specialized motor that allows discrete positioning without feedback Used for noncritical low power applications since positional information is easily lost if acceleration or velocity limits are exceeded Numerical Control Automated equipment or process used for contouring or positioning See CNC National Electrical Manufacturer s Association Sets standards for motors and other industrial electrical equipment Memory in a system that maintains information when power is removed A signal output that is performed with a transistor Open collector output acts like a switch closure with one end of the switch at circuit common potential and the other end of the switch accessible Control circuit that has an input signal only and thus cannot make any corrections based on external influences www aerotech com Soloist Hardware Manual Glossary of Terms Operator Interface Optical Encoder Opto isolated Orthogonality Overshoot PID Pitch of travel Pitch Error PLC PWM Quadrature Radial
94. n the Soloist HMI esses 2 20 Figure 2 17 Limit Inputs in Soloist HMI Program eee 2 21 Figure 2 18 Limit Inputs in the Soloist HMI Program eese 2 21 Figure 3 1 PSO Interface J104 sess eee nennen 3 3 Figure 3 2 Primary Secondary Encoder Channels J103 J104 3 4 Figure 3 3 User Outputs J 104 eei eset 3 6 Figure 3 4 Outputs Connected as Current Sinking ese 3 7 Figure 3 5 Outputs Connected as Current Sourcing 2 44440211 3 7 Figure 3 6 Connecting Current Sinking Inputs sse 3 9 Figure 3 7 Connecting Current Sourcing 3 9 Figure 3 8 Low Speed and High Speed User Inputs 104 3 10 Figure 3 9 Analog Output 0 J104 essere 3 11 Figure 3 10 Analog Input 0 J104 ettet tee tre 3 12 Figure 3 11 PSO Block 3 14 Figure 3 12 Data Capture Data Update 3 14 Figure 3 13 Limit Thermistor and Hall Effect Inputs J103 3 16 Figure 3 14 Optional MXU Analog Encoder Interface 103 3 17 Figure 3 15 Brake Connector 103
95. ng at DC bus voltages of 100 VDC or 340 VDC e g 115 VAC to 230 VAC input power Figure 2 5 Back Propagation Line Filter Connection 2 5 2 I O and Signal Wiring Requirements The I O communication and encoder feedback connections are low power connections Wire and connectors used for signal wiring must be rated for at least 30 V and have a current capacity of at least 25 Amp Wires and connectors used for low voltage power connections such as 5V must have a current capacity of at least 1 Amp encoder feedback 5V supply requires 6 Amps in some applications In applications where there are significant wire distances a larger wire size is required to reduce the voltage drops that occur along the wires This increase is necessary to keep the voltage within tolerance at a remote point When signal wiring is in close proximity to wiring operating at voltages above 60 Volts the insulation rating of the signal wiring must be rated for the higher voltage Use signal wiring with a voltage rating of at least 300 Volts when it is in proximity to AC power or motor power wiring For additional information on connecting analog and digital I O see Chapter 3 and for additional information about optional I O see Chapter 4 AUX 1 0 J104 WWW aerotech com 2 9 Installation and Configuration Soloist Hardware Manual 26 Emergency Stop Sense Input TB101 If you purchased the AUXPWR option the opto isolated input PS2806 1 device ac
96. nnections at connector J103 For proper operation the CEMF generated motor phase voltages must be aligned to the amplifier s generated output voltage with the given Hall effect sequence shown in Figure 2 12 2 16 www aerotech com Soloist Hardware Manual Installation and Configuration Test Setup Brushless Motor TP1 6 BLK A B COM COM ee pe 10K OHM TYP WHT TP5 ORN HA TP6 BLU HB 7 HC Clockwise Rotation or Plus Motion 0 60 120 180 240 360 1 2 3 4 5 6 Hall A 5V ov Hall B Hall C C B A C B Ms 20V Motor Back EMF ov 20V Notes 1 All voltage measurements are made with reference to TP4 Signal Common Neutral 2 Clockwise rotation is viewed looking into the front of the motor shaft Figure 2 12 Motor Phasing www aerotech com 2 17 Installation and Configuration Soloist Hardware Manual 2 7 5 Stepper Motor Connections When you connect a stepper motor that is an Aerotech motor with Aerotech cabling no motor phasing process is required a S Beck V Note the connection of the two motor phases For full cable drawings refer to your software CD ROM Figure 2 13 Stepper Motor Connections 2 7 3 1 Stepper Motor Phasing Process A stepper motor is phased correctly when a positive motion comman
97. of the standard cables used for interconnecting various items to the Soloist The 4xx in the tables below is used to specify the length in decimeters specifies the length in feet To identify your cable or for a wiring drawing see your Soloist software CD ROM Table 5 1 Standard Interconnection Cables Cable Part Description C13803 xx DC Brush Motor Cable DC MTR amp FB 25DU FL 24MS MAX107DM C15291 xx Encoder Feedback Cable BL FB 25DU 17MS 9DU MAX120DM C15805 xx Motor Cable BL MTR FL 4MS C1650X Encoder Feedback Cable BL FB 25DU 25DU MAX120DM 1839 Encoder Feedback Cable BL FB 25DU 25DU 9DU MAX120DM C18982 Motor and Encoder Feedback Cable BL MTR amp FB FL 25DU 25DU 107DM MAX C19360 xx Motor Cable BL MTR FL 4DU MAX450DM C19791 Joystick Extension Cable with Flying Leads JSXT FLY XX C19792 Joystick Extension Cable with D Style Connectors JSXT 26HD XX C19851 Hi Flex Motor Cable BL MTR FL 4DU HF 46DM C2025 1 xx Stepper Motor Cable ECZ01231 2 Interconnect Cable www aerotech com 5 1 Accessories Soloist Hardware Manual Table 5 2 Combined Motor amp Feedback Cables Soloist Part Number s Description Stage Motor BL MTR amp FB 2
98. onnections Replace worn or frayed cables Replace broken connectors 6 5 1 Cleaning The Soloist chassis can be wiped with a clean dry soft cloth The cloth may be slightly moistened if required with water or isopropyl alcohol to aid in cleaning if necessary In this case be careful not to allow moisture to enter the Soloist or onto exposed connectors components Fluids and sprays are not recommended because of the chance for internal contamination which may result in electrical shorts and or corrosion The electrical power must be disconnected from the Soloist while cleaning Do not allow cleaning substances or other fluids to enter the Soloist or to get on to any of the connectors Cleaning labels should be avoided to prevent erasing label information Disconnect power to the Soloist main supply and optional supply before cleaning DANGER www aerotech com 6 7 Troubleshooting Soloist Hardware Manual LJ LJ 6 8 www aerotech com Soloist Hardware Manual Glossary of Terms APPENDIX A GLOSSARY OF TERMS In This Section e Glossary Abbe Error Abbe Offset Absolute Move Absolute Programming AC Brushless Servo Acceleration Accuracy Accuracy Grade ASCII Axial Runout Axis of Rotation Back emf Kemf Backlash The positioning error resulting from angular motion and an offset between the measuring device and the point of interest The value of the offse
99. or provides six user inputs and four outputs as well as a secondary line driver encoder interface Additional I O is provided by the IO option board as described in Chapter 4 Three user inputs may be used as opto isolated end of travel limit EOT 1104 inputs See the following sub sections each type of I O Table 3 1 Auxiliary I O Connector Mating Connector J104 Aerotech Third Party Source Connector 01259 86 26 Back shell ECK00600 Cinch DA24658 Screw Locks Qty 2 EIZ00294 TRW D 20419 16 www aerotech com 3 1 Technical Details Soloist Hardware Manual A re settable fuse protects the external power provided by the Soloist to the user Should M an over current condition occur the fusing device would open to protect against the AUNO overload To reset the device remove the overload condition J104 Table 3 2 Auxiliary I O Connector Pin out J104 Pin Label Description In Out Bi 1 Auxiliary Sine Secondary Encoder Channel Input 2 Auxiliary Sine _Secondary Encoder Channel Input 3 In 4 Port 0 Input 4 High Speed Opto user interrupt Input 4 In 4 Port 0 Input 4 High Speed Opto user interrupt Input G3 OQ 5 In 5 Port 0 Input 5 High Speed Opto user interrupt Input OQ 6 In 5 Port 0 In
100. ous ways and the cables required to so do If two separate Soloists are being used to read the joystick only one Soloist should be used to provide 5 Volt power to the potentiometers The second Soloist should connect differentially to the second joystick potentiometer by connecting Analog Input to common and Analog Input to the potentiometers wiper as shown in the following figure JOY X 1 Second Soloist Analog Input 0 19 A B J104 Analog Input 0 14 Kh 192 j Analog Input O 13 Jov Y i Om Analog InputO 44 Common EU EJ usi 12 5 Volts 2 First Soloist vols J104 Common 23 Input Common 24 ovals T Button A IN914 Input 8 17 D Button B Input 9 18 Joy Interlock 1 8 Buttons Input 10 25 ji 6 Is all B A Speed select N Exit Slew Mode Axis Pair Select Figure 5 1 Joystick Interface www aerotech com 5 5 Accessories Soloist Hardware Manual A standard Aerotech JI joystick may be connected to J104 of the Soloist as a single axis joystick through the following cable shown below Figure 5 2 and Figure 5 3 Figure 5 2 indicates the required cable and Figure 5 3 indicates the interconnection of the joystick to the Soloist The following drawings Figure 5 2 and Figure 5 3 are shown for reference only and were complete and accurate as of this manual s release The most
101. put 0 Output 0 Optically Isolated Output utput 1 Output 1 Optically Isolated Output utput 2 Output 2 Optically Isolated Output Q tput 3 Output 3 Optically Isolated Output o utput 4 Output 4 Optically Isolated Output Output 5 Output 5 Optically Isolated Output Output 6 Output 6 Optically Isolated Output Output 7 Output 7 Optically Isolated Output Table 4 5 Port 2 Opto Isolated Output Connector Pin out TB203 ar Pin Label Description In Out Bi D E 1 Output Common Plus for TB203 Input 3 o 2 Output Common Minus for TB203 Input 3 3 Output 0 Output 0 Optically Isolated Output H S 4 Output 1 Output 1 Optically Isolated Output 6 T 5 Output 2 Output 2 Optically Isolated Output 7 6 Output 3 Output 3 Optically Isolated Output 7 Output 4 Output 4 Optically Isolated Output 8 Output 5 Output 5 Optically Isolated Output 9 Output 6 Output 6 Optically Isolated Output 10 Output 7 Output 7 Optically Isolated Output Table 4 6 Output Specifications TB202 TB203 Specification Value 90 mWatts Channel 40 Volt Maximum 80 mAmps Channel 0 7 10 9 Volts Rise Fall Time 250 usec typical Maximum Output Frequency kHz 4 4 www aerotech com Soloist Hardware Manual Soloist Options Connection required to minimize glitching oP Diode required for an inductive load PS2802 4 F
102. put 5 High Speed Opto user interrupt Input O60 7 Out 0 Port 0 Output 0 Port 0 Output OX 8 Out Output 1 Port 0 Output 96 9 Out2 Port 0 Output 2 Port 0 o9 10 Auxiliary Cosine Secondary Encoder Channel Input O 11 Auxiliary Cosine Secondary Encoder Channel Input O60 12 5 Volt 5 Volt 500mA max Output 929 13 Analog 0 In Analog Input 0 Differential Input 14 Analog 0 In _Analog Input 0 Differential Input 15 Out Com Output 0 3 opto isolator common connection 16 Out3 Port 0 Output 3 Port 0 Output 17 10 Port 0 Input 0 CCW EOT Input Port 0 Input 18 1 Port 0 Input 1 CW EOT Input Port 0 Input 19 Auxiliary Marker Secondary Encoder Channel PSO Output Bidir 20 Auxiliary Marker Secondary Encoder Channel PSO Output Bidir 21 Common Common 5V Supply Return 22 Analog 0 Out Analog Output 0 Output 23 Common Common 5 Supply Return 24 In Com Input 0 3 opto isolator common connection 25 12 Port 0 Input 2 Home EOT Input Port 0 Input 26 In3 Port0 Input 3 Port 0 Planned Feature Consult Aerotech Inc for availability Total user 5 V power is limited to 500 mA by an internal re settable fuse Sixteen additional digital inputs and outputs are provided by Ports 1 and
103. r direction when commanding a positive move from a user task by negating the sign of the PosScaleFactor parameter To determine which motor lead is connected to the and motor terminals connect a voltmeter to the motor leads of an un powered motor Rotate the motor CW by hand Swap the voltmeter connections to the motor until the voltmeter indicates a positive voltage The motor lead now connected to the positive lead of the voltmeter is the motor lead as indicated in the previous figure and must be connected to the motor terminal The other motor lead is connected to the motor terminal 2 12 WWW aerotech com Soloist Hardware Manual Installation and Configuration 2 7 20 Brushless Motor Connections When you connect a brushless motor that is an Aerotech motor with Aerotech cabling no motor phasing process is required If you are using an Aerotech brushless motor with the Soloist see the system interconnection drawing in Figure 2 9 to determine the motor phase and Hall connections If standard Aerotech brushless motors and cabling are not used the motor must be correctly phased as described in the following section Motor Frame Green White amp Shield ook Brushless Motor Typical motor cables used are the C13802 BADC MSO or BADC MSONT For full cable drawings refer to your software CD ROM Fi
104. re the BFC BFCMX or BFCD cables For full cable drawings refer to your software CD ROM Figure 2 10 Hall Effect Feedback Connections ChkOut_13 Axis 170 i p CW Limit Input Level CCW Limit Input Level H Home Limit Input Level H HallA Input Level L ono E ESTOP Input Level Sine Encoder Error Signal ux RES qn m Figure 2 11 Hall Effect Feedback Inputs in the Soloist HMI Program WWW aerotech com 2 15 Installation and Configuration Soloist Hardware Manual CW Rotation Positive Direction DANGER Motor Shaft 2 7 2 3 Hall Effect Phasing For an AC brushless motor with an unknown Hall sequence one of two methods can be used to determine the proper motor connections to the Soloist Before running the Soloist Programs Samples MsetDebug Ab configure the axis parameters For configuration information see Getting Started in Soloist Help In the first method the motor is actively driven under program control The Soloist Programs Samples MsetDebug Ab can be used for this purpose You must swap the Hall signals until they generate the sequence as defined in Figure 2 12 After the Hall sequence is correct the program correctly determines if a commutation offset is required The value of the CfgMotOffsetAng axis parameter that is required to correctly phase the motor is indicated The second method is a non powered
105. riable ratio Once per revolution signal provided by some incremental encoders to accurately specify a reference point within that revolution Also known as Zero Reference Signal or Index Pulse Measure of the smallest positional change which can be detected by the encoder A 1000 line encoder with a quadrature output will produce 4000 counts per revolution Position encoding device in which the output is a series of pulses relative to the amount of movement Signal that provides process or loop information such as speed torque and position back to the controller to produce a closed loop system Measure of the vertical deviation of a stage as it travels in a horizontal plane The value of force that a particular motor can produce in a continuous stall or running as calculated by the rms values condition The maximum value of force that a particular motor can produce When sizing for a specific application the peak force is usually that required during acceleration and deceleration of the move profile The peak force is used in conjunction with the continuous force and duty cycle to calculate the rms force required by the application The resistance to motion between two surfaces in contact with each other WWW aerotech com Soloist Hardware Manual Glossary of Terms G P I B Gain Grating Period Hall Effect Sensors HED HMI Home Home Switch Hysteresis IEEE 488 Incremental Move
106. rnal Transformer esses esee nennen enne enne 2 6 2 5 1 Minimizing 50 60 HZ Line Interference 2 9 2 5 2 T O and Signal Wiring Requirements sss 2 9 Emergency Stop Sense Input TB101 sss 2 10 2 6 1 Typical ESTOP Interface 2 11 Motor Connections eoero ar eriei i enne 2 12 2 7 1 DC Brush Motor Connections in Torque 2 12 2 7 1 1 DC Brush Motor Phasing 2 22 2 2 12 2 7 2 Brushless Motor 4 2 13 2 7 2 1 Brushless Motor Phasing esee 2 14 2 7 2 2 Brushless Motor Hall Effect Feedback COMME CHONG ss 2 15 2 7 2 3 Hall Effect 2 22222 21 2 16 27 3 Stepper Motor Connections 2 18 2 7 3 1 Stepper Motor Phasing Process 2 18 Encoder Feedback Connections sese 2 19 281 Encoder Phasing n 2 20 End of Travel Limit 2 21 2 9 1 End of Travel Limit 2 2 2 2 2 21 Communication Channel 01010121 2 22 Soloist Help 2 24 TECHNICAL DETAILS eese esee eee eene enses enano 3 1 Port 0 I O and the Secondary Encoder Channel J104
107. se current based on three Hall effect signals spaced 120 electrical degrees beginning at 0 electrical degrees This method is slightly more difficult to implement than standard 6 step but more closely approximates the motor s back emf The result is smoother control and less ripple Aerotech s BA series self commutate using this method The process of switching motor phase current based on motor position information usually from an encoder In this method the three phase currents are switched in very small increments that closely resemble the motor s back emf Sinusoidal commutation requires digital signal processing to convert position information into three phase current values and consequently is most expensive to implement The result however is the best possible control All Aerotech controllers as well as the BAS series amplifiers commutate using this method Multi axis motion where the position of each axis is dependent on the other axis such that the path and velocity of a move can be accurately controlled Drawing a circle requires coordinated motion A term used in the specification of a lead screw or ball screw indicating the maximum rotation speed before resonance occurs This speed limit is a function of the screw diameter distance between support bearings and bearing rigidity Motor driver or amplifier configuration where the input signal is commanding motor current directly which translates to motor torque
108. st HMI Program Axis 1 0 ChkOut_14 gt CW Limit Input Level JH CCW Limit Input Level Home Limit Input Level JH Marker Input Level L Hall Input Level Hall B Input Level Figure 2 18 Limit Inputs in the Soloist HMI Program 2 9 1 End of Travel Limit Phasing If the EOT limits are reversed swap the connections to the CW and CCW inputs at the Soloist J103 connector View the EOT limit inputs in the Soloist HMI in the Diagnostic panel s Axis I O section as shown in Figure 2 17 WW aerotech com 2 21 Installation and Configuration Soloist Hardware Manual 2 10 Communication Channel Settings You must assign a unique device number the drive number to each Soloist in your DEVICE system which is determined by the communication connection to the Soloist HMI or CONFIG NUMBER library interface If a USB communication connection is used the drive number is assigned with the S1 switch located on the side of the Soloist If the Ethernet communication connection is used the drive number is assigned by setting the IP address For additional information see the Soloist Help ELELE o MEL nensi The Soloist network can support up to 1 024 Soloists However only 32 Soloists can be connected to a single PC using the USB interface because of the limitations of the 51 bal at a fal Ca Ua al dl Lal switch Using the
109. t between the measuring device and the point of interest A move referenced to a known point or datum A positioning coordinate reference where all positions are specified relative to a reference or home position A servomotor with stationary windings in the stator assembly and permanent magnet rotor AC brushless generally refers to a sinusoidally wound motor such as BM series to be commutated via sinusoidal current waveform see DC brushless servo The change in velocity as a function of time An absolute measurement defining the difference between actual and commanded position In reference to an encoder grating accuracy grade is the tolerance of the placement of the graduations on the encoder scale American Standard Code for Information Interchange This code assigns a number to each numeral and letter of the alphabet Information can then be transmitted between machines as a series of binary numbers Positioning error of the rotary stage in the vertical direction when the tabletop is oriented in the horizontal plane Axial runout is defined as the total indicator reading on a spherical ball positioned 50 mm above the tabletop and centered on the axis of rotation A center line about which rotation occurs The voltage generated when a permanent magnet motor is rotated This voltage is proportional to motor speed and is present whether or not the motor windings are energized A component of bidirectional repeatabi
110. terial handling that is found on the ASR1100 but the ASR1200 also includes a sealed water jacket for wet cutting processes The ASR1200 series utilizes Aerotech s direct drive brushless motor technology to maximize positioning performance in 24 7 production environments Soloist Single Axis Servo Controller Aerotech s Soloist is a single axis servo controller that combines a power supply amplifier and position controller in a single package The Soloist can control up to four tasks simultaneously as well as handle variables A 7 and manage for demanding production applications It has high speed position latch inputs and advanced data logging capabilities that make it ideal for laboratory test and industrial applications NServo Easy machine retrofits preserve your capital investment NServo provides an economical method to retrofit any existing system that uses analog servo amplifiers to the performance and flexibility of the Automation 3200 platform NServo is a digital 2 or 4 axis 20 kHz sample time servo position and velocity controller NServo complements the Automation 3200 system s network digital drives Ndrive NLdrive NCdrive and Npaq allowing industry standard analog amplifiers to interface to Aerotech s digital drive network ARA1000 Rotary Stage The ARA1000 rotary actuator was designed for applications requiring articulation for large http Awww aerotech com 1 of 2 4
111. tion Soloist Hardware Manual 2 4 Wiring Grounding and Shielding Techniques To reduce electrical noise in the Soloist follow the motor and input power wiring techniques explained in the following section 2 41 Minimizing EMI Interference e Use shielded cable to carry the motor current and tie the shield to earth ground e Use a cable with sufficient insulation This reduces the capacitive coupling between the leads that in turn reduces the current generated in the shield wire Provide strong earth ground connections to the amplifier and the motor Offering electrical noise a low impedance path to earth ground not only reduces radiated emissions but also improves system performance If possible do not route motor cables near cables carrying logic signals Use shielded cable to carry logic signals Ferrite beads can be used to reduce the effects of amplifier switching Table 2 3 Wire Part Numbers Wire Gauge Aerotech PN Third Party PN 14 AWG EIZ01027 2643002402 Elna Fair Rite Products 16 AWG EIZ01025 2643250402 Elna Fair Rite Products 18 AWG EIZ01001 42673000801 Elna Fair Rite Products 2 4 www aerotech com Soloist Hardware Manual Installation and Configuration 2 4 22 AUXPWR Auxiliary Power Option The AUXPWR option provides keep alive power for the Soloist to remain operational when motor power is removed for example when an
112. tions 6 6 Preventative 6 7 Current Chang s to REEL EDU ege dh C 1 e Vill www aerotech com Soloist Hardware Manual Regulatory Information DECLARATION OF CONFORMITY Manufacturer s Name and Address Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 2897 Declares that the product Product Name Soloist Conforms to the following product specifications with the exceptions listed below Safety EN 61010 1 1993 Safety Requirements and complies with EMC directive 89 336 EEC and 73 23 EEC low voltage directive General notes concerning the test setup Safety related requirements to ensure compliance Soloist must be installed within an enclosure with construction compliant unlimited circuits Pittsburgh PA David F Kincel bid E ie September 2004 Quality Assurance Manager Alex Weibel___ Clo Mku ed Engineer Verifying Compliance General notes concerning the test setup Safety related requirements to ensure compliance Exceptions to EN 61010 1 e Soloist must be installed within an enclosure with construction compliant for unlimited circuits user is responsible for meeting final protective ground requirements AC power disconnect is AC power cord located on front panel of Soloist End user is responsible for determining and providing supply disconnect for system
113. tivates by an external fail safe emergency stop circuit It is not intended to be an emergency stop circuit in itself It is scaled for a 24 volt input voltage or a 5 volt input by changing JP6 as shown in the following table Using a higher input voltage requires adding an external series resistor to limit the current If the ESTOP bit is enabled in the FaultMaskGlobal axis parameter see the Soloist Help the ESTOP input must be driven to prevent the ESTOP fault condition For typical ESTOP wiring see the following schematic and interface drawing Table 2 4 ESTOP Input Voltage Jumper Jumper Setting Description 1 2 24 Volt DC Input 23 5 Volt DC Input Factory default setting 3 3V R284 10K 510 1 2W 510 1 2W 939 PS2806 1 Figure 2 6 ESTOP Sense Input TB101 Connecting the E Stop input to a relay or other noise producing device circuit requires one or more noise suppression devices such as those in Table 2 5 or other appropriate devices WARNING Table 2 5 Electrical Noise Suppression Devices Noise Suppression Device Aerotech P N Third party P N RC 1uf 200 ohm Network EIC240 Electrocube RG1782 8 Varistor EID160 Littlefuse V250LA40A 2 10 www aerotech com Soloist Hardware Manual Installation and Configuration 2 6 1 Typical ESTOP Interface By connecting an emergency stop circuit to the Soloist you disable power to the motor by removing power to the pow
114. to control a number of input and output discrete devices Pulse Width Modulation Switch mode technique used in amplifiers and drivers to control motor current The output voltage is constant and switched at the bus value 160 VDC with a 115 VAC input line Refers to the property of position transducers that allows them to detect direction of motion using the phase relationship of two signal channels A 1000 line encoder will yield 4000 counts via quadrature Positioning error of the rotary stage in the horizontal direction when the tabletop is oriented in the horizontal plane Radial runout is defined as the total indicator reading on a spherical ball positioned 50 mm above the tabletop and centered on the axis of rotation Time it takes to accelerate from one velocity to another WWW aerotech com A 7 Glossary of Terms Range RDC Repeatability Resolution Retroreflector Roll of travel Roll Error Rotor RS 232C RS 274 RS 422 Runout Servo System Soloist Hardware Manual The maximum allowable travel of a positioning stage Resolver to Digital Converter Electronic component that converts the analog signals from a resolver transmitter type into a digital word representing angular position The maximum deviation from the mean each side when repeatedly approaching a position Unidirectional repeatability refers to the value established by moving toward a position in the same direction
115. ure 4 9 Brake Connected to J103 The user is responsible for providing fuse protection for the Brake circuit www aerotech com 4 11 Soloist Options Soloist Hardware Manual Step 3 Suppression and Snubber requirements Due to the inductive effects of the load brake suppression and or snubber components are needed to reduce arching and prevent damage to the Brake Relay contacts Suppression can also reduce the electrical noise that is emitted when a circuit is turned off Following are three suppression circuit examples Example 1 Figure 4 8 is an example of a typical 24 VDC brake circuit In that example the suppression component is the Varistor connected across the brake This method of suppression is used for systems operating at voltages up to 25 VDC and AC systems operating at voltages up to 18 VAC If the voltage is greater than 25 VDC or 18 VAC one of the other methods should be used Example 2 Figure 4 10 is a suppression circuit that can be used for both AC and DC systems In this method a resistor capacitor and a varistor are combined and placed across the load see Figure 4 10 In some cases better results are obtained by installing the suppressor circuit across the contacts The ratings and values for these components are described below Resistor R is calculated by the following formula Watt rating O Watt R ohms Voltage Load current If R is less than 24 ohms use 24 ohm resistor If R is greater
116. ut Bi Input Common for inputs 0 7 TB205 Input Input 0 Optically Isolated pin 1 Input Input 1 Optically Isolated pin 1 Input Input 2 Optically Isolated pin 1 Input Input 3 Optically Isolated pin 1 Input Input 4 Optically Isolated See pin 1 Input Input 5 Optically Isolated pin 1 Input Input 6 Optically Isolated pin 1 Input Input 7 Optically Isolated pin 1 Input Internal 5 Volt Power Supply Total user 5V power is limited to 500mA by internal re settable fuse 52806 4 Figure 4 6 Inputs Connected in Current Sourcing Mode www aerotech com 4 7 Soloist Options Soloist Hardware Manual 52806 4 Figure 4 7 Inputs Connected in Current Sinking Mode 4 8 www aerotech com Soloist Hardware Manual Soloist Options 4 2 5 User Power TB204 TB205 Pin 10 of TB204 provides the common return for the user power from the Soloist s internal power supply 0 Table 4 9 User Common Connector Pin out TB204 d Pin Label Description In Out Bi 3 10 GND User Common for user 5 VDC power N Pin 10 of TB205 provides 5 VDC power to the user from the Soloist s internal power 6 7 supply which be used to power external devices 3 Amps maximum i zZ Table 4 10 5 Volt Power Connector Pin out TB205 Pin Label Description In Out Bi 10
117. ut data rate 50 nsec minimum edge separation however the maximum PSO tracking rate is 25 Mhz A software command may also be used to generate an output pulse The synchronized output pulse is solely generated within sophisticated and versatile high speed hardware providing excellent firing accuracy and allowing minimal delays between the trigger condition and the output PSO latency is 210 nanoseconds including the propagation delay of the output device The output pulse is a differential RS 422 signal available on the J104 connector see Section 3 1 1 for more information Additionally the PSO options provide Data Capture capabilities shown in Figure 3 11 and Figure 3 12 For programming information refer to the Soloist HMI Help Refer to Figure 3 11 and Figure 3 12 for a block diagram of the PSO capabilities Table 3 9 PSO Output Source PSO Output Type Maximum Frequency Requires User Isolation RS 422 Marker output on the Secondary Encoder J104 10 MHz Yes The PSO hardware operates in machine counts The PSO hardware typically generates a trigger from a position change The comparison of the desired trigger position to feedback position occurs at a 25 Mhz rate The output pulse is also user programmable and is generated by dedicated hardware logic It may be a single or multiple pulse per trigger event A trigger event may generate a single pulse or a programmable number of pulses www aerotech com 3 13
118. vided by the IO option as described in Chapter 4 Sixteen additional digital inputs and outputs are provided by Ports 1 and 2 on the on the IO Option board as described in Chapter 4 Table 3 6 Port 0 Digital Input Connector Pin out J104 Description In Out Bi Input 4 High Speed Opto user interrupt Input Input 4 High Speed Opto user interrupt Input 5 5 Input 5 High Speed Opto user interrupt Input 6 In 5 Input 5 High Speed Opto user interrupt Input 17 0 Input 0 CCW EOT Input Input 18 1 Input 1 CW EOT Input Input 24 In Com Input 0 3 opto isolator common connection 25 In 2 Input 2 Home EOT Input Input 26 In 3 Input 3 Input Note Port 0 digital Inputs 0 3 must all be used in either current sourcing or current sinking mode No combination of these two modes is allowed 3 8 www aerotech com Soloist Hardware Manual Technical Details 5 24NDC INPUT COMMON CDE cor P T9 INPUT 0 10K OPTO_INPUT_1 10K Q104 25 0FT0 N 10K 104 26 0 10K 52806 4 V Figure 3 6 Connecting Current Sinking Inputs INPUT_COMMON 1 OPTO_INPUT_O OPTO_INPUT_1 52806 4 Figure 3 7 Connecting Current Sourcing Inputs www aerotech com 3 9 Technical Details Soloist Hardware Manual 5V 5V RLS4148 Figure 3 8 Low Speed and High Speed User Inputs J104

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