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BA50/75/100 User`s Manual

1. 1 4 14 2 DIP Switch Z u a ua n rrr ren 1 5 1 4 3 Potentiometers POTS sss 1 6 1 4 4 Connector P1 and Enable Indicator 1 6 14 5 VO CiIrCultty Y asan nan ecce E nei 1 9 1 5 Safety Procedures and Warnings essere 1 11 CHAPTER2 INSTALLATION AND OPERATION 2 1 2 1 Jumper Selections edere Sa us Ud ie eds 2 1 2 2 Wiring Grounding and Shielding Techniques 2 4 2 2 1 Minimizing EMI Interference 2 4 2 2 2 Minimizing 50 60 HZ Line Interference 2 5 2 3 Integrated Configurations esses 2 7 2 3 1 Velocity Command Configuration 2 7 2 3 2 Current Command Configuration 2 8 2 3 3 Dual Phase Command Configuration 2 9 2 4 Control asas 2 10 2 4 1 Setup Torque Command Mode Current 2 10 2 4 2 Setup Velocity Command 2 10 2 4 3 Setup Dual Phase Command Mode 2 12 2 5 Motor Phasing Process n a aina au ene 2 13 2 5 1 Determining Phase Hall Sequence
2. 2 13 2 6 Current Regulator Adjustment sse 2 15 CHAPTER3 TECHNICAL DETAILS 3 1 3 1 Part Number and Ordering Information 3 1 3 2 Electrical Environmental Specifications 3 2 3 3 BA Amplifier Dimensions essen 3 6 CHAPTER 4 TROUBLESHOOTING 4 1 4 1 Amplifier Related Problems sse 4 1 4 2 Fuse Replacement eter e een EE 4 3 4 3 CUS ADIT 8 IB RE 4 4 APPENDIX A GLOSSARY OF TERNMS A 1 APPENDIX B WARRANTY AND FIELD SERVICE B 1 APPENDIX C CABLE DRAWINGS C 1 Descriptiefu s a reet teen toe ot eritis eec 1 INDEX www aerotech com iii Table of Contents BA50 75 100 User s Manual www aerotech com 50 75 100 User s Manual List of Figures LIST OF FIGURES Figure 1 1 50 75 100 Series Amplifiers 1 1 Figure 1 2 Functional Diagram n ee Dundee eon Se erts 1 3 Figure 1 3 Amplifier Hardware 5 ewe eet eo 1 4 Figure 1 4 Fault Output secedere et e heim e eene 1 9 Figure 1 5 Enable Shutdown Inputs eese 1 9 Figure 1 6 PPOIPTIADSUSS S a am
3. V Limit Inputs 5V 5V 5V A A R224 R225 R226 10K 1 10K 1 Se 10K 1 MER R229 214 1 lI 2 10 1 74HC14 R228 HEB 216 4 10K 195 74HC14 R227 HEC 5 6 C PHT 4777 ff 10K 1 C186 C187 C188 74HC14 100 100PF 100 SN 6 R219 Ct79 ANN 5 180 O1UF SN75157 SIN N C Pis cos Cr R220 C181 2 180 01UF 8419155 COS N CPt Figure 1 7 Hall and Encoder Inputs 1 10 www aerotech com BA50 75 100 User s Manual Introduction 1 5 Safety Procedures and Warnings The following statements apply wherever the Warning or Danger symbol appears within this manual Failure to observe these precautions could result in serious injury to those performing the procedures and or damage to the equipment If the equipment is used in a manner not specified by the manufacturer the protection by the equipment may be impaired The user should practice caution when following the given procedures Deviation from this may result in damage to the equipment or machinery 4 WARNING Hazardous voltages are present up to eight minutes after power is disconnected gt WARNING Motor Temperature may exceed 50 C Motors must be mechanically secure before applying power WARNING Amplifier case heatsink temperatures may exceed 50 C m DANGER To minimize the possibility of electrical shock and bodily injury
4. Figure 2 1 BAS50 75 100 Board Assembly Jumpers Shown in Default www aerotech com 2 3 Installation and Operation BA50 75 100 User s Manual 2 2 Wiring Grounding and Shielding Techniques AC power wires 2 and the protective ground wire should be 12 AWG size wire An external 30 amp maximum fuse or breaker is required on the AC power inputs for the BA75 and BA100 A 25 amp max fuse or breaker should be used for the 50 The motor outputs should be connected with the 10 AWG wire The motor protective ground should not be less than 14 AWG wire To reduce electrical noise in the BA Series amplifiers the user should observe the motor and input power wiring techniques explained in the following sections 2 2 1 Minimizing EMI Interference The BA Series are high efficiency PWM amplifiers operating at a 20K Hz switching rate The switching time between positive and negative rails on each of the motor leads is less than 50 nano seconds for a 320 VDC bus This switching rate can generate Electromagnetic Interference EMI into the MHz band To minimize this EMI it 1s recommended that the motor leads be twisted together with the motor cable grounding wire and surrounded with a foil shield Refer to Figure 2 2 In addition to the EMI effects electro static capacitive coupling to the motor frame 15 very high requiring the frame to be grounded in order to eliminate a shock hazard Additional electro static coup
5. 24 WIBLKIRED GRN T I 22 GIYEL SPLICE 24 WIBLU sss 24 WIVIO I 24 RIBLK 5 322BRN 22 PINK 7 44 FT USE GROMMET EIZ131 TO BUILD UP THICKNESS SO THAT CLAMP GRIPS CABLE E5 er gt c HEATSHRINK LIMIT CONNECTOR WIRES PINK WHT VIO WHT BLU RED BLK THIS HEATSHRINK SHOULD TUCK UNDER THE SHRINK THAT IS USED TO STRIP BACK INSULATION SIGUAND TIN WIRES THICKEN OVERALL CABLE LIMIT CONNECTOR 630C1582 1 LEAVE LIMIT CONNECTOR WIRES PROTRUDE OUT OF REVB JACKET 7 1 2 FOR MAKING CONNECTION TO LIMIT 3C1582B1 DWG CONNECTOR ORIGINAL LENGTH OF CABLE MUST BE 15 6 1 2 Figure C 1 BA Feedback Cable PFC STRAIGHT PLUG MS3106A 20 MCM454 INSERT MS20 295 MCM464 CLAMP AM3057 12 MCM457 BUSHING AN3055 22 12 MCM493 CONNECTOR TYPE 9 PIN FEMALE D DE9S ECK340 BACKSHELL 3M 3357 9209 ECK158 OR CINCH DE24657 ECK612 EIZ294 l lt 1 4 k L STRIP BACK INSULATION 3 16 FROM THIS END COVER ALL SOLDER CONNECTIONS WITH HEATSHRINK LOOP LIMIT CONNECTOR WIRES PINK BRN WHT VIO WHT BLU RED BLK BACK OUT OF MS CONNECTOR THROUGH HEATSHIRNK www aerotech com Cable Drawings BA50 75 100 User s Manual STRAIGHT PLUG M33106A 18 MCM475 INSERT MS18 10S MCM495 CLAMP AN3057 1010 MCM477 BUSHING AN 3055 18 10 MCM481 BA AMPLIFIER 15 CONNE
6. 50 75 100 SERIES USER S MANUAL P N EDA140 V1 4 m 4 m 0 I 2 AEROTECH Inc 101 Zeta Drive e Pittsburgh PA 15238 2897 e USA Phone 412 963 7470 e Fax 412 963 7459 Product Service 412 967 6440 412 967 6870 Fax www aerotech com AEROTECH If you should have any questions about the 50 75 or 100 and or comments regarding the documentation please refer to Aerotech online at http www aerotech com For your convenience a product registration form is available at our website Our website is continually updated with new product information updated manuals free downloadable software and special pricing on selected products Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies The BA50 75 100 Series User s Manual Revision History Rev 1 0 June 16 1998 Rev 1 0a July 29 1998 Rev 1 1 May 5 2000 Rev 1 2 February 19 2001 Rev 1 3 August 15 2001 Rev 1 4 June 16 2004 Aerotech Inc 2004 BA50 75 100 User s Manual Table of Contents TABLE OF CONTENTS CHAPTER 1 INTRODUCTION eere eser ete uoto eoa eae nea eS ve erus n aS 1 1 1 1 Prod ct Overview dte i ee ee upas 1 1 1 2 Models Options and Packages sss 1 2 1 3 DrivePackapessu as nuy nene 1 3 1 4 Hardware Overview and Function 1 4 1 4 1 Motor and AC Power Connections
7. 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 starting 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 BA50 75 100 User s 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 serv
8. Pins 1 18 and 2 17 Personality Module RCNI provide gain compensation for phase regulator circuit Similar compensation is provided for phase and circuits as shown in Figure 2 10 The default values for these selectable components RCNI are shown in Figure 2 10 Connection IFDBK pin 12 of P1 is provided for monitoring phase current For AC brushless motor operation the signal at this pin would represent motor phase current For DC brush motor operation this signal would represent the current flowing in the motor armature The scale factor for current feedback on P1 12 is 16 6 Amp Volt for 100 12 5Amp Volt for the BA75 and 8 3Amp Volt for BASO 2 16 www aerotech com BA50 75 100 User s Manual Technical Details CHAPTER 3 TECHNICAL DETAILS In This Section Part Number and Ordering Information Electrical Environmental Specifications BA Amplifier Dimensions 31 Part Number and Ordering Information Ordering information regarding part numbers models and packages is shown below in Table 3 1 Table 3 1 Ordering Information Amplifier Output Current Operating Bus Internal Shunt Series Peak Voltage Power Resistor BA 50 75 100 320 230 VAC input S Shunt regulator Bus Voltage 320 320 VDC bus 230 VAC input direct line operation w shunt regulator Options 8 Shunt r
9. ensure that the motor is decoupled from the mechanical system and or disconnected from the amplifier when servicing the system m WARNING To minimize the possibility of electrical shock and bodily injury when any electrical circuit is in use ensure that no person is exposed to the circuitry gt DANGER To minimize the possibility of 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 gt DANGER www aerotech com 1 11 Introduction BA50 75 100 User s Manual 1 12 www aerotech com BA50 75 100 User s Manual Installation and Operation CHAPTER 2 INSTALLATION AND OPERATION In This Section Jumper Selections Wiring Grounding and Shielding Techniques Integrated Configurations Control Connections Motor Phasing Process Current Regulator Adjustment 2 4 Jumper Selections The BA series amplifiers are jumper selectable providing the user with quick reconfiguration capability of operating modes Table 2 1 lists the jumpers and the default configurations for the amplifiers Figure 2 1 highlights where the jumpers are located on the board with the default configurations www aerotech com 2 1 Installation and Operation BA50 75 100 User s Manual Table 2 1 Jumper Selections Jumper Positions Function Selects brushless mode of operation default Selects brush mode operati
10. 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 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 A 9 Glossary of Terms BA50 75 100 User s Manual Wobble Yaw of travel Yaw Error 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 actua
11. make any corrections based on external influences A 6 www aerotech com BA50 75 100 User s Manual Glossary of Terms Operator Interface Optical Encoder Opto isolated Orthogonality Overshoot PID Pitch of travel Pitch Error PLC PWM Quadrature Radial 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
12. 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 repeatability 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 BA50 75 100 User s 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 15 A support mechanism allowing relative motion between two surfaces loaded against each other This can be a rotary ball bearing l
13. repaired at no charge and shipped prepaid back to the buyer If the buyer desires an air freight return the product s will be shipped collect Warranty repairs do not extend the original warranty period Laser Products Return Procedure Returned Product Warranty Determination www aerotech com B 1 50 75 100 User s Manual Warranty and Field Service 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 15 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 15 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 1s 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 t
14. 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 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 BA50 75 100 User s Manual The maximum allowable travel of a positioning stage Resolver to Digital Converter Electronic component that converts the ana
15. 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 variable 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 1s 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 r
16. 0 User s Manual 1 4 Hardware Overview and Function The BA series consist of two power connections motor power and input power four potentiometers a 10 position DIP switch an enable LED indicator lamp a fault overload indicator lamp and a 25 pin D style connector Refer to Figure 1 3 for locations AUX PWR INPUT Auxiliary Control Power External Shunt Resistor Connections options Motor and AC Power Connections Fault Overload LED Power Enable LED DIP Switch Input Pot Tach Pot Gain Pot Balance Pot Connector 1 E D m n m 0 I va Figure 1 3 Amplifier Hardware 1 4 1 Motor and AC Power Connections The three phase motor terminal connections are made at connections A B and C This area is designated as such on the amplifier Input power to the BA series amplifier is made at the AC1 AC2 and AC3 terminals with earth ground connected to ground Single or three phase power can be made at these connections The BA 50 can be operated on three or single phase AC power For single phase operation connect the AC power to AC1 and AC2 For the BA75 and BA100 only three phase input power should be used 1 4 www aerotech com BA50 75 100 User s Manual Introduction 1 4 2 DIP Switch There is a 10 position DIP switch on the BA drive that provides four discrete functions The switch permits the user to control maximum allowable curr
17. 3 2 3 6 www aerotech com BA50 75 100 User s Manual Technical Details AUX PWR INPUT MOTOR B FAULT OVERLOAD POWER ENABLE CURRENT LIMIT 4 5 RMS LIMIT 241 3 9 50 TEST 9 MODE 10 INPUT TACH GAIN lt EIE YSN vd H YNASLLId ONI Ho310u3V i vi GZ L Ld 3OVJYILNI TOYLNOO Jn O CECU ondas vg 24 1 95 L 31 50 8 2 00 gt 92 7 3 65 gt id 2 5 10 Dimensions Millimeters Inches Figure 3 1 BA50 Dimensions Front View www aerotech com 3 7 Technical Details BA50 75 100 User s Manual i Fo 26 8 1 05 206 8 8 14 4 8 19 ix 22 D 13 0 51 7 2 64 8 2 55 2ft 217 9 8 58 1 _ _ 152 4 6 00 28 6 1 12 Dimensions Millimeters Inches Typ e Figure 3 2 BA50 Preferred Mounting Side View 3 8 Www aerotech com BA50 75 100 User s Manual 92 7 3 65 2 5 10 11 7 46 Technical Details Y 241 3 9 50 217 9 8 58 231 4 9 11 a lj 24 1 95 50 8 2 00 Dimensions Millimeters Inches Typ Typ BA100 85 9 3 38 Figure 3 3 BA75 100 Dimensions Front View www aerotech com 3 9 Technical Details 3 10 BA50 75 100 User s Manual www aerotech com 50 75 100 User s Manual Troubleshooting CHAPTER 4 TROUBLESHOOTING In This Section e Amplifier Related
18. ASE GND EARTH GROUND Figure 2 2 Wiring to Minimize EMI and Capacitive Coupling 2 2 2 Minimizing 50 60 HZ Line Interference Operating the BA series amplifiers from an off line source of 115 VAC or 230 VAC creates some additional problems First there is a potential problem of EMI generated from the switching power stage of the BA amplifier propagating through the bridge rectifier and out through the ACT AC2 and AC3 input AC line connections Back propagation of noise into the AC lines can be minimized using a line filter An example of such a filter and proper connection to the BA amplifier is shown in Figure 2 3 25A slow blow BA50 30A slow blow BA75 Z 30A slow blow BA100 AC1 oo oss BA 2 RFI FILTER AMPLIFIER A O C S EARTH GROUND Figure 2 3 Back Propagation Line Filter Connection www aerotech com 2 5 Installation and Operation BA50 75 100 User s Manual Another problem that potentially exists with off line connections is 50 60 Hz electrostatic coupling between the frame of the AC motor and the ACI AC2 and AC3 AC input power If a single phase supply is used where one side of the phase is referenced to ground the DC bus of the amplifier swings at 50 60 Hz with respect to the motor frame The path of current caused by this coupling between the motor frame and th
19. BA50 75 100 User s Manual 3 3 Amplifier Dimensions The outline dimensions for the BA amplifiers are shown in Figure 3 1 and Figure 3 2 To ensure proper heat dissipation Aerotech recommends the following procedures Use the mounting procedure shown in Figure 3 1 Figure 3 2 and Figure 3 3 For the 50 the wider part of the amp should be mounted to the heat sink if the application requires maximum continuous output current to the motor For a typical servo system e g intermittent duty cycle the 50 can be mounted standing up as shown in Figure 3 1 The BA75 and BA100 are always mounted standing up see Figure 3 3 2 The mounting base should be at least 2 feet x0 25 thick minimum and must be metal aluminum or steel 3 The heat sink should be free of paint or any other thermal Barrier 4 The heat sink must be flat to allow good thermal conductivity between the heat sink and the amplifier 5 If possible add a thermal conductivity enhancer 1 thermal grease between the heat sink and the amplifier 6 Adding an external fan will remove a considerable amount of heat from the heat sink and allow the amplifier to operate at a much cooler temperature The BA100 has an integral fan Heatsink and fan add 83 1millimeters 3 27 inches for BA75 and BA100 only It is advisable that the amplifier be mounted lying flat on a metal panel not less than two square feet for better heat dissipation Refer to Figure
20. CTIONS TB1 1 MOTOR PHASE A a 16 BLK TB1 2 MOTOR PHASE B 16 RED 1 3 MOTOR PHASE C E 16 GRN OR ORN 2 HEATSINK GROUND 9 SCREW FRAME GROUND MOTOR SHIELD TERMINATE END WITH 6 RING TONGUE EIK399 KEEP WIRE SHORT AS POSSIBLE 5 14 5 3 4 11 4 HEATSHRINK SECURED WITH CABLE TIE EIZ100 IL CABLE ECX566 START WITH 17 LENGTH STRIP INSULATION BACK 3 8 AND TIN TOROID ECZ280 WITH 10 TURNS EACH BLACK STRIP BACK INSULATION WIRES TYP 3 PLS RED WHITE OR BROWN COVERED WITH 5 PIECE FO FOI SHIEED BRING OUT 3 16 FROM THIS END OF HEATSHRINK EIW114 DRAIN WIRE COVER WITH COVER ALL SOLDER TEFLON TUBING CONNECTIONS WITH 10 TURNS IS APPROXIMATELY 2 FT LENGTH OF WIRE HEATSHRINK FOR BRAIDED SHIELD SPLICE 22 GRN YEL WIRE TO BRAIDED SHIELD COVER ALL SOLDER CONNECTIONS WITH HEATSHRINK EACH PASS OF WIRE THROUGH TOROID IS 1 TURN FRAME GROUND AND MOTOR SHIELD DO NOT GET WRAPPED AROUND TOROID Figure C 2 BA Series Light Duty Brushless Motor Cable PMC BA 50 only C 2 www aerotech com 50 75 100 User s Manual Index FAULT LED 1 6 Fault Output Circuitry 1 9 Feedback Cable C 1 Limit Inputs Circuitry 1 10 Feedback signals 1 2 Field Service Policy B 1 A Functional diagram 1 3 Accessories 3 1 G Amplifier Faults 4 1 4 3 Amplifier Hardware 1 4 GAIN Pot 1 6 Amplifier Related Problems 4 1 Grounding T
21. Current Command Configuration 2 8 www aerotech com BA50 75 100 User s Manual Installation and Operation 2 3 3 Dual Phase Command Configuration This mode is used with a brushless motor only In this configuration the differential input pre amplifier and self commutation circuits are bypassed The dual phase inputs are sinusoidal and are 120 out of phase from each other The third phase is generated by the amplifier The dual phase command configuration is shown in Figure 2 7 The advantage to this configuration is that it provides the smoothest possible motion MKR MKR N 3 HALL A B C COS COS N ae 17 SIN SIN N 2 5V SIG COM 1 1 2 1 1 1 1 Signals to Position i Velocity Commutation 1 1 T Loop Controller e E in O Brushless Motor Square Wave Quadrature lt Encoder with Commutation E Tracks or Hall Sensors P1 x SIG COM Motor Phase A Motor Phase B Motor Phase C Dual Phase Current m SHIELD Motor Commands Provided Frame By Commutating Controller SIG COM SIG COM ICMDA H3 22 ICMDB Shutdown 10 SHUTDOWN 2 FAULT Fault Y SHIELD Shielded Cabling dj Figure 2 7 Dual Phase Command Configuration www aerotech com 2 9 Installation and Operation BA50 75 100 User s Manual 2 4 Control Connections The BA drives can be wired into a system in one of two ways depending upon t
22. IST OF TABLES Table 1 1 BA Models and Voltage Configurations 1 2 Table 1 2 DIP Switch Functions unn n unas ene 1 5 Table 1 3 Potentiometer Functions sirsie reseso sE N E eia ER ENS es 1 6 Table 1 4 Connector Pl Pinout ea ee HET dE 1 7 Table 2 1 Jumper Selections encuentre ceehes 2 2 Table 3 1 Ordering Information n n nennen 3 1 Table 3 2 Electrical Specifications esee 3 2 Table 4 1 Amplifier Faults Causes and Solutions 4 1 Table 4 2 Fuse Replacement Part Numbers sss 4 3 V V V www aerotech com List of Tables BA50 75 100 User s Manual www aerotech com 50 75 100 Series User s 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 Brushless Servo Amplifier BA 50 75 100 Conforms to the following product specifications LVD UL 61010 1 CAN CSA C22 2 No 1010 1 1010 1 and complies with EMC directive 89 336 EEC Pittsburgh PA David F Kincel E rome January 2004 Quality Assurance Manager Atex weiet Engineer Verifying Compliance General notes concerning the test setup The Brushless Servo Amplifier required external fuse or circuit breaker pro
23. OWER LED 1 6 Pre Amplifier Circuit 2 9 Precautions 1 11 Preferred 3 8 Product Overview 1 1 Safety Procedures 1 11 Self Commutation 2 9 Shielding Techniques 2 4 Switching Rate 2 4 T TACH Pot 1 6 Tachometer 2 7 Test 1 5 Torque Command Bode 2 10 Troubleshooting 4 1 V Velocity 1 5 2 7 Velocity Command 2 7 Velocity Command Mode 2 10 Voltage Configurations 1 2 R w RCNI 2 16 Warnings 1 11 Warranty Policy B 1 Wiring Techniques 2 4 H www aerotech com READER S COMMENTS AEROTECH BAS50 75 100 Series User s Manual P N EDA 140 June 2004 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 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
24. P1 pin 25 ICMD of 5 5 volts Switches SW1 1 through 4 are used to scale this 5 5 volt signal from zero to maximum current Refer to Figure 2 6 for torque command configuration 2 4 2 Setup Velocity Command Mode For this mode a velocity feedback signal is required This feedback signal can be derived from two sources From an analog DC tachometer that is connected to the TACH pin or from an incremental encoder that is connected to the sine and cosine pins Refer to Figure 2 5 To setup the pre amplifier circuit for use in the velocity command mode configure the BA amplifier as follows e Place SW1 position 10 mode to open e Place SW position 9 test to open default e SWI positions 1 through 4 selects current limit positions 5 through 8 selects RMS limit e Potentiometers INPUT GAIN BALance and TACH adjust pre amplifier gain and offset 2 10 www aerotech com BA50 75 100 User s Manual Installation and Operation For most applications under the velocity command mode the preferred starting point for setting the three gain pots is as follows INPUT pot 1 3 CW from full CCW TACH pot full CW GAIN pot full CW These initial settings will usually generate a stable system if it is assumed that the tach feedback gain is around 3 volts Krpm or if an encoder is used and the line resolution is between 1 000 and 1 500 per revolution e JP14 set to 1 2 for encoder 2 3 default for tachometer
25. Problems 4 1 Amplifier Related Problems This section covers symptoms probable causes and solutions related to the BA amplifier operation Table 4 1 lists the most common symptoms of irregular operation and the possible causes and solutions for these faults Always disconnect the main power before servicing WARNING Before performing the tests described in Table 4 1 be aware that lethal voltages exist on the amplifier s PC board and at the input and output power connections A qualified service technician or electrician should perform these tests DANGER Hazardous voltages may be present up to eight minutes after power is disconnected WARNING Table 4 1 Amplifier Faults Causes and Solutions Possible Cause and Solution Insufficient input voltage Use voltmeter to check voltages at ACI AC2 and AC input terminals Short circuit condition at motor connections A B and C Disconnect motor connections from BA50 amplifier and POWER and check resistance at each terminal relative to the other ENABLE LED terminal Resistance should read the same for all terminals fails to energize between 5 and 2 0 Q depending on motor when AC input 3 Short condition between motor connections and case of power is applied motor Use ohmmeter to check resistance between all motor leads and motor frame Ensure the motor is disconnected from amplifier Resistance should read infinity Shutdow
26. age or logic low where a 1 indicates five volts or logic high If an Aerotech brushless motor is used with the BA amplifier motor phase and HALL connections can be easily determined by referring to the system interconnection drawings in Figure 2 5 Figure 2 6 and Figure 2 7 Also refer to the figures in Appendix C 2 5 1 Determining Phase Hall Sequence For a motor with an unknown phase hall sequence a simple test can be performed on the motor to determine the proper connections to the BA amplifier Before performing the following steps ensure that the motor leads are completely disconnected from the amplifier e The tests outlined below do not require that the amplifier be turned on since Figure 2 9 illustrates the generated output voltage of the motor relative to the input Hall sequences The equipment needed for this test is a two channel oscilloscope and three resistors typically 10K ohm 1 2 watt wired in a Wye configuration Connect the ends of the three resistors to motor terminals A B C Use one channel of the oscilloscope to monitor motor terminal A with respect to the Wye neutral e g the point where all three resistors are connected together Turn the shaft of the motor CCW and note the generated voltage This voltage represents the phase A to neutral CEMF With the second oscilloscope probe determine the Hall switch that is in phase with this voltage Similarly phase B and C shoul
27. as wakasha casas 1 10 Figure 1 7 Hall and Encoder InputfS u aasan 1 10 Figure 2 1 BA50 75 100 Board Assembly Jumpers Shown in Default 2 3 Figure 2 2 Wiring to Minimize EMI and Capacitive Coupling 2 5 Figure 2 3 Back Propagation Line Filter Connection eee 2 5 Figure 2 4 Isolation Transformer Connection eliminates torque disturbance eter ater Ue DEDERE 2 6 Figure 2 5 Velocity Command Configuration sse 2 7 Figure 2 6 Current Command Configuration esee 2 8 Figure 2 7 Dual Phase Command Configuration eere 2 9 Figure 2 8 Command Signal Adjustment Portion of the Pre Amplifier Circuit ue tee RUE D OP PRIOR 2 11 Figure 2 9 Motor Phasing an T E enne 2 14 Figure 2 10 Three Phase Current Regulator Circult 2 15 Figure 3 1 50 Dimensions Front View sss 3 7 Figure 3 2 BASO Preferred Mounting Side View 3 8 Figure 3 3 BA75 100 Dimensions Front View 3 9 Figure C 1 BA Feedback Cable PFC essere 1 Figure C 2 BA Series Light Duty Brushless Motor Cable PMC BA 50 T C 2 www aerotech com List of Figures vi BA50 75 100 User s Manual www aerotech com BA50 75 100 User s Manual List of Tables L
28. d be aligned with the other two Hall switches Refer to Figure 2 9 and note the generated output voltages of the amplifier relative to the Hall sequences applied to HALL A HALL B and HALL C connections at connector P1 For proper operation the generated motor phase voltages should be aligned to the amplifier s output generated voltage with the given Hall effect sequence shown in Figure 2 9 www aerotech com 2 13 Installation and Operation BA50 75 100 User s Manual If the sequence of Hall signals relative to the generated motor voltage e g motor CEMF is adhered to as illustrated in Figure 2 9 a positive voltage signal applied to pin 8 INPUT of connector relative to pin 21 INPUT of or pin 19 signal common of will produce a CCW e g a negative rotation rotation of the motor shaft as viewed from the front of the motor 0 Commutation Waveforms Aerotech Motors DEGREES COMMUTATION SEQUENCE HALL 30 001 101 100 110 010 011 001 0 101 100 110 010 011 001 Motor Amplifier PHASE A PHASE B PHASE C Motor Rotation CCW Figure 2 9 Motor Phasing 30 Commutation Waveforms 2 14 www aerotech com BA50 75 100 User s Manual Installation and Operation 2 6 The three phase current regulator circuit is illustrated in Figure 2 10 Details to this circuit like the Pre a
29. e operating modes are current command and velocity command Differential inputs are used for better noise immunity Velocity feedback is from either an encoder or tachometer and logic inputs include directional current limits and shutdown Fault current and velocity outputs simplify monitoring drive status 1 2 www aerotech com BA50 75 100 User s Manual Introduction 1 3 BA Drive Package The standard package includes the heat sink cover shunt regulator control power supply and the bus power supply that operates from 56 230 VAC The power supply is included with the standard package for off line operation without the need for an isolation transformer Figure 1 2 is a functional diagram showing the standard package configuration 215 230 VAC AGTE Control AC2 Voltage Power Supply ICMDB ICMD Mon Integrated ony Protection Input Input Ba gi 3Phase I Current I Regulato Voltage 1 Ba Over Temp TACHL Hall AL Hall BL Hall C Sin Q Sin CosL CosL I ILMT 7 ILMT 7 Under Voltage Detect Rn Directional Circuit Current Limit IFDBK Mon SUPPLY svocL Faut siecom gt Latch Shutdown INL Fault OUT Figure 1 2 Functional Diagram A secondary 115 230 VAC connection is necessary if DC bus power is required to operate below 80 VDC www aerotech com 1 3 Introduction BA50 75 10
30. e amplifier stage passes through the current feedback sensing devices of the amplifier Depending on the magnitude of this current a 50 60 Hz torque disturbance may be present in the position loop To eliminate this problem an isolation transformer can be used to block the 50 60 Hz from being seen by the motor frame Refer to Figure 2 4 for connection of this transformer 25A slow blow BA50 30A slow blow BA75 30A slow blow BA100 1 S d Ac2 115 230 VAC BA 50 60 Hz AMPLIFIER NV J alt It is not recommended that a single supply connection be used for the BA75 and BA100 amplifiers EARTH GROUND Figure 2 4 Isolation Transformer Connection eliminates torque disturbance 2 6 www aerotech com BA50 75 100 User s Manual Installation and Operation 2 3 Integrated Configurations The BA amplifiers can be integrated into a system using three basic configurations velocity command current command and dual phase command Each of these has their advantages and disadvantages depending upon the user s specific needs 2 3 1 Velocity Command Configuration In the velocity command configuration the speed of the motor is controlled by the amplifier A feedback signal from either DC tachometer or an incremental encoder 15 monitored by the amplifier From this signal the amplifier adjusts the velocity o
31. e on this Pin 8 input 2 input input causes CCW motor rotation torque or velocity mode For single ended operation connect command to the input and ground Pin 21 of P1 3 Current command A Jumper selectable current command input Pin 9 input icmda f E pen differential input pre amplifier and self commutation circuit le active high tive low input to shut off Pin 10 sup Jumper selectable active high or active low input Used to shut off power stage and therefore remove all power to the motor 1 current limit input When pulled to its active state motion in the Pin 11 input EU s hen E sss positive direction CW motor shaft rotation is inhibited jumper selectable Current feedback monitor When running a brushless motor this signal represents the current in motor phase A When running a brush motor this signal represents the entire motor current Scaling is as follows Pin 12 output fdbk 50 8 3 Amp V 75 12 5 Amp V BA100 16 6 Amp V Electrical reference for all control circuitry on amplifier This pin is intended signal to be used as the connection point for the signal common of an encoder Pin 14 ground i common Used in conjunction with Pin 2 as the power supply connections to an encoder Recommended reference input for tachometer This point is identical to Pin 15 input tach signal common 1 Hall effect B One of three com
32. echniques 2 4 Applications 1 1 H B ug Hall and Encoder Inputs Circuitry 1 10 BALance Pot 1 6 Hall Connections 2 13 Board assembly 2 3 Hall Effect Device 1 2 Brushless Motor Cable C 2 Hardware Function 1 4 Overview 1 4 Cable C 1 C 2 I Capacitive Coupling 2 4 2 5 Cleaning 4 4 I O Circuitry 1 9 Connector 1 4 3 2 IFDBK 2 16 Connector P1 1 6 2 13 INPUT Pot 1 6 Connector P1 Pinouts 1 7 Integrated 2 7 Control Connections 2 10 Integrated Configurations 2 7 Current 1 5 Isolation Transformer 2 6 Current Command 2 7 2 8 Current Regulator Adjustment 2 15 J D Jumper 2 2 Jumper Selections 2 1 Differential Input 2 9 DIP Switch 1 4 1 5 L Functions 1 5 Drive Package 1 3 LED indicator 1 4 Dual Phase Command 2 7 2 9 Line Filter Connection 2 5 Dual Phase Command Mode 2 12 Line Interference 2 5 E M Electrical Specifications 3 2 Mechanical Drawings 3 6 EMI 2 5 Mode 1 6 EMI Interference 2 4 Models 1 2 ENABLE LED 1 6 Motor 2 14 Enable Shutdown Input Circuitry 1 9 Motor Phasing 2 13 Encoder 2 7 Encoders 1 2 N External Controller 2 7 Noise F Back Propagation 2 5 Fault conditions 1 2 www aerotech com i Index BA50 75 100 User s Manual O Operating modes 1 2 Options 1 2 Order Information 3 1 OVERLOAD LED 1 6 P Part Number Information 3 1 Phase Hall Sequence 2 13 Position 2 8 Potentiometer Functions 1 6 Potentiometers 1 4 1 6 Power 1 2 Power Connections 1 4 2 10 P
33. egulator Examples 25 A cont 50 A peak servo amplifier power supply w shunt regulator Breton 230V AC 1 phase input 37 A cont 75 A peak servo amplifier power supply w shunt regulator la 0 230VAC 3 phase input 50 A cont 100 A peak servo amplifier power supply w shunt regulator F 230VAC 3 phase input Accessories TV0 3 28 0 3 kVA autotransformer 28 or 56 VAC out for 40 or 80 VDC bus 115 230 VAC 50 60 Hz input TV0 3 56 0 3 kVA autotransformer 56 or 115 VAC out for 80 or 160 VDC bus 115 230 VAC 50 60 Hz input 1 5 isolation transformer 115 230 VAC input 28 43 56 70 115 TV1 5 VAC output 2 5 kVA isolation transformer 115 230 VAC input 28 43 56 70 115 TV2 5 VAC output 5 kVA isolation transformer 115 230 VAC input 28 43 56 70 115 TV5 VAC output TB Screw terminal block for BA DB25 control connector LF AC Line Filter general noise suppression not for CE Compliance UFM AC Line Filter Module required for BA amps to meet CE Compliance www aerotech com 3 1 Technical Details BA50 75 100 User s Manual 32 Electrical Environmental Specifications The electrical and environmental specifications and connector pinouts for all BA drive models are listed in Table 3 2 Table 3 2 Electrical Un 50 BA75 BA100 Output Voltage VDC 4032094 Peak Output Current 2 sec current rating based on amplifier A pk mounted to NEMA panel see Figure 3 2 Continuous Output C
34. ent to the motor lt lt Closed Open continuous output current velocity or current operational mode and test mode Figure 1 3 shows the location of this switch on the BA drive Refer to Table 1 2 for the exact RMS switch functions LIMIT TEST 9 Table 1 2 DIP Switch Functions Re qi Current limit These switches affect the GAIN adjustment of the velocity loop Maximum gain adjustment when 1 to 4 are closed s dosed The maximum allowable continuous current is 54 of peak current Closing this position allows the Balance potentiometer to manually control motor Test closed velocity or torque without the need of an input signal depending upon the setting of switch 10 m Velocity Current mode closing this position enables the current mode Switches 1 4 affect the full scale current output range of the amplifier when in current and in velocity mode When all four switches are closed the peak current range is not limited Closing each switch effectively limits the output range of the amplifier by a factor associated with that switch For example closing only SW1 4 54 on a BASO limits the output current to 27 Amp Therefore a 10 Volt input signal would produce a 27 Amp output similarly a 5 Volt input would produce a 13 5 Amp output 5V 10V 27 It should be noted that switches 1 4 have no effect in dual phase mode Switches 5 through 8 de
35. esistance to motion between two surfaces in contact with each other www aerotech com BA50 75 100 User s Manual Glossary of Terms G P I B Gain Grating Period Hall Effect Sensors HED HMI Home Home Switch Hysteresis LIO IEEE 488 Incremental Move 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 1s 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
36. ess 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 phase 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 t
37. f the motor accordingly depending upon the velocity command from the external controller In this configuration the amplifier closes and controls the velocity loop The velocity command configuration is shown in Figure 2 5 This configuration can drive both brush and brushless DC motors E Tachometer 2 Tachometer OPTIONAL OPTIONAL 2 MKR MKR N MKR MKR N m cR on nara c 2 COS COS N 2 2 1 OR REM LI TAN SNSNN E i T ji 4 SV 9 1 1 1 Signals to Optional Square Wave Quadrature 3 Position Loop Controller Encoder with Commutation 2 Tracks or Hall Sensors d d Square Wave Brushless Motor 7 Brush Motor 7 Quadrature Encoder 29 v TIVH N SO0 SOO N NIS NIS WOO 56 AS P1 5V SIG COM SIN For Single Ended Command 4 Motor Phase A Motor 1 Input Connect Signal To P1 8 HALLA Wasi kn Input And To P1 21 Input HALE Motor Phase olor Signal Commons quom TACH io iip iri cip EON 1 TACH T Motor Ei Single Ended or INPUT Frame Differential Velocity INPUT Command SIG COM Shutdown Fault SIG COM SHUTDOWN FAULT SHIELD Shielded Cabling Figure 2 5 Velocity Command Configuration www aerotech com 2 7 Installation and Operation BA50 75 100 User s Manual 2 3 2 Cu
38. fashion A positive voltage on this input causes CW motor rotation icmda Pin 9 icmdb Pin 22 dual phase 10V input ICMDA current command A and ICMDB current command B are jumper selectable current command inputs They bypass the differential input pre amplifier and self commutation circuit They are to be used with controllers that provide external velocity loop and commutation control Hall A Pin 4 Hall B Pin 16 Hall C Pin 17 Hall effect device inputs for commutation 0 to 5 VDC internal pull up and 10K input Commutation signals used with brushless motors to provide motor rotation position information to the amplifier This allows the amplifier to steer the three phases of the motor currents in such a fashion so as to provide rotation of the motor in the desired direction at the desired speed TTL level input Note analog Hall signals are connected at pin 4 and pin 16 Analog Hall commutation is a factory option sine sine N Pin 18 Pin 19 cosine cosine N Pin 5 Pin 6 Encoder inputs for velocity feedback differential 0 to SVDC TTL internal pull up 10K input Sine and cosine are optionally used in conjunction with one another for deriving an electronic tachometer signal tachometer Pin 3 Tachometer input for velocity feedback encoder vs tach velocity feedback is jumper selectable A tachometer may be used in the velocity loop configuration to provide negative feedback to the amplifier This allows the amplifier to cl
39. he desired mode of operation Command signals can be referenced to velocity or torque current control signals The user has access to four potentiometers three that adjust gain while the fourth BALance compensates for input signal offsets Figure 2 8 illustrates a portion of the pre amplifier circuit that is accessible to the user for adjusting command signal gains provided for the selection of the appropriate resistor capacitor pair factory default For adjustments in gain roll off Personality Module RCNI pins 7 10 and 8 9 values are shown in Figure 2 8 2 4 1 Setup Torque Command Mode Current To setup the pre amplifier circuit for use in the torque current command mode configure the BA amplifier as follows e Place SWI position 10 mode to closed default e Place SW position 9 test to open default e SWI positions 1 through 4 selects current limit positions 5 through 8 selects RMS limit e Potentiometers INPUT set full CW and GAIN set full CCW to provide a transconductance gain of 10 volts for full current output TACH have no effect e JP14set to 2 3 default e JP11 and JP13 set to 1 2 default e JP5 JP15 and JP6 set to 1 2 default for brushless motor operation or 2 3 for brush motor operation With this configuration an input signal of 10 volts to pins with respect to INPUT will produce the maximum current output signal viewed at
40. he Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs For warranty field repairs the customer will not be charged for the cost of labor and material If service 15 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 V V V B 2 www aerotech com BA50 75 100 User s Manual Cable Drawings APPENDIX C In Th
41. he components connected to personality module RCNI pins 8 9 and 7 10 may be need to be changed The BALance pot is used to cancel any bias in the internal or external control circuit that would cause the motor to rotate when the input command signal is zero If the TEST switch is closed the effects of the BALance pot are greatly magnified This is useful when a test bias signal is desired for velocity or torque modes to be applied to the amplifier without introducing an external command signal 2 4 3 Setup Dual Phase Command Mode To setup the pre amplifier circuit for use in the dual phase mode configure the BA amplifier as follows e JP11 and JP13 are set to 3 4 e JP5 JP15 and JP6 are set to 1 2 default This mode is used with brushless motors only Refer to Figure 2 7 for dual phase command configuration 2 12 www aerotech com BA50 75 100 User s Manual Installation and Operation 2 5 Motor Phasing Process When configuring the BA amplifier to run a brushless motor the commutation signal input connections labeled HALL A B C on connector P1 pins 4 16 and 17 are necessary These sequences and the generated output motor phase voltages motor output connections B and C are shown in Figure 2 9 The voltages generated are made under the conditions of a positive signal placed at INPUT with respect to INPUT at control signal input output connector P1 A 0 for the given HALL input indicates zero volt
42. he 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 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 Glossary of Terms 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 BA50 75 100 User s 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 time to total cycle time used to determine a motor s rms current and
43. henever the RMS current limit threshold 15 exceeded If the RMS threshold is exceeded for more than two seconds the drive becomes faulted and shuts down 1 6 www aerotech com BA50 75 100 User s Manual Introduction Table 1 4 Connector P1 Pinouts w Input or 6 Connection point to earth ground Used for reducing electrical noise in Pin 1 shield ground control and feedback signals Typically connected to the foil shield of a shielded cable On board 5V power supply Pin 2 is intended for powering an encoder and can supply up to 250mA of current Tachometer input for velocity feedback encoder vs tach velocity feedback is jumper selectable A tachometer may be used in the velocity loop JE Bus input tach configuration to provide negative feedback to the amplifier This allows the amplifier to close the servo loop and control the stability of the loop Hall effect A One of three commutation signals used with brushless motors Pin4 input Hall A Used in conjunction with Hall effect B and Hall effect C to provide motor rotor position information to the amplifier cosine signal from encoder Optionally used in conjunction with sine for deriving an electronic tachometer signal Line receiver input Compliment of cosine P1 5 Line receiver input Signal common Electrical reference for all control circuitry on amplifier Non inverting input of differential input circuit A positive voltag
44. inear 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 the 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 BA50 75 100 User s Manual Commutation 6 Step Commutation Modified 6 Step Commutation Sinusoidal Coordinated Motion Critical Speed Current Command Current Peak Current rms www aerotech com Also referred to as trapezoidal commutation The proc
45. is Section CABLE DRAWINGS EIDSSCEIDLIODe e mas Description The following section provides the user with 2 reference drawings for connecting Aerotech cables to the BA amplifiers SIGNALS CONNECT TO CONTROLLER OR TO BA10 20 SERVO AMPLIFIER AS SYSTEM CONFIGURATION DICTATES BA Series Servo Amp TYPICAL INTERCONNECT 1 1 l l l NOTE SYSTEM CONFIGURATION DETERMINES WHETHER APPLICABLE SIGNAL CONNECTS BA10 20 OR CONNECTIONS TO P1 8 COS N AND P1 19 SIN N ARE NOT APPLICABLE ON l 1 l 1 L REV OR REV A AMPLIFIER PC BUS 690D1499 CONSOLIDATED 5720 20 COND 24 ECX OR 5738 20 COND 22 ECX579 ORAR BASE CABLE IS SIGNAL BUNDLE OF COLOR STRIFE 6821023 ECX413 5 24 GRY WHT BLK A Pu 1 pon 24 VIO GRN WHT E MARKER 24 WIGRY BLU BLK 1 SARKER 24 WIBRN ORN BLK pz 24 WIORN ORN7 RED 24 WIRED WHT RED x 24 WIGRN RED 24 WIYEL BLU RED 2 22 WIBLK GRN BLK 22 YEL RED 7 BLK VETE Ld 24 RIGRN RED WHT HALE EEFECT B 24 RIYEL BLK WHT M 24 WIBLKIBRN BLU WHT J 24 WIBLU WHT 4 ed 24 WIVIO BLK 24 RIBLK ORN L 22 BRN GRN US TE C KMT COM 22 PINK RED A 5 324 TAN BLU
46. l axis of rotation and the theoretical axis of rotation Rotation about the vertical axis perpendicular to the axis of travel Angular movement error that affects straightness and positioning accuracy Positioning error resulting from a yaw motion 10 www aerotech com Warranty and Field Service BA50 75 100 User s Manual APPENDIX B WARRANTY AND FIELD SERVICE In This Section Laser Products Return Procedure Returned Product Warranty Determination Returned Product Non warranty Determination Rush Service On site Warranty Repair On site Non warranty Repair Aerotech Inc warrants its products to be free from defects caused by faulty materials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability 1s 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 whether 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
47. l for AC input and motor output 3 4 www aerotech com BA50 75 100 User s Manual Technical Details Table 3 2 Electrical Specifications Cont d Gain adjusts preamp AC gain BALance nulls command input DC offsets Potentiometers Tach adjusts gain of tach or encoder derived velocity feedback input Input adjusts gain of command input Peak current limit 4 switches allow the user to set the peak current from 6 100 of max value RMS current limit 4 switches allow the user to set the RMS DIP Switches current from 3 54 of max value Mode switch This switch selects current or velocity mode Test This switch selects test mode to allow the BALance pot to be used as velocity or current command Output short circuit Peak over current RMS over current DC bus over voltage detected 1f shunt fuse 1s open Over temperature Control power supply under voltage Power stage bias supply under voltage Opto and transformer isolation between control and power stages Indicator power LED indicates drive power green Indicator LED indicates drive enabled green enabled Indicator fault Protective Features LED indicator drive fault red Refer to Protective Features above LED indicator RMS overload red Energized when RMS limit 15 exceeded Will generate a fault if limit is exceeded for more than two seconds Indicator overload www aerotech com 3 5 Technical Details
48. ling exists between the three twisted motor leads and the foil shield of the motor cable This coupling forces high frequency currents to flow through the returning earth ground of the motor cable To minimize this problem and maintain low levels of EMI radiation perform the following 1 Use shielded cable to carry the motor current and tie the shield to earth ground Refer to Figure 2 2 2 Place one toriod ferrite around the three motor leads two leads for brush motors The toriod should have seven turns for 10 AWG wire This helps reduce the harmonics generated by the 20 KHz switching waveform 3 Use a cable with sufficient insulation This will reduce the capacitive coupling between the leads that in turn reduces the current generated in the shield wire 4 Provide strong earth ground connections to the amplifier additional heat sink and the motor Offering electrical noise a low impedance path to earth ground not only reduces radiated emissions but also improves system performance 5 If possible do not route motor cables near cables carrying logic signals and use shielded cable to carry logic signals 2 4 www aerotech com BA50 75 100 User s Manual Installation and Operation One toroid ferrite around three motor leads two leads for brush motors AC1 SHIELD AC2 TWISTED TOGETHER BA AMPLIFIER dA 7 MOTOR c QS C
49. log 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 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 Sta
50. mplifier circuit described in the previous section are provided so that the user may optimize gains Current Regulator Adjustment The BA amplifier provides three independent current regulator circuits one for each phase of the AC brushless motor for DC brush motors only Phase A regulator is used Regulators A and B are each provided with a current command from either the internal six step commutation circuit or an external current command input ICMDA and ICMDB depending on the settings of JP11 and JP13 Two internally isolated circuits one for phase and the other for phase provide the motor current feedback signals The two current command signals as well as the two current feedback signals are each summed with the result providing the current command and current feedback signals for phase RCN1 2 15 e e IN 1 2 20 0K JP11 9 20 0K Phase A 23K Voltage Command ICMDA E IFDBK 1K P1 12 1 2 10 volts provides maximum current for JP13 a given phase Q5 Phase B 23K Voltage Command ICMDB P1 22 20 0K 20 0K p V Phase C Voltage Command IMPORTANT The sum of the current signals to phase A and B together should never exceed the maximum current rating of a single phase Figure 2 10 Three Phase Current Regulator Circuit www aerotech com 2 15 Installation and Operation BA50 75 100 User s Manual
51. mutation signals used with brushless motors 1 2 5 Hall Used in conjunction with Hall effect A and Hall effect C Pin Eg www aerotech com 1 7 Introduction BA50 75 100 User s Manual Table 1 4 Connector P1 Pinouts Cont d ES Pin 17 input Hall effect C One of three commutation signals used with brushless P motors Used in conjunction with Hall effect A and Hall effect B Sine signal from encoder Optionally used in conjunction with Pin 18 input sine cosine for deriving an electronic tachometer signal Line receiver input Compliment of sine P1 18 Line receiver input Inverting input of differential input circuit A positive voltage on Pin 21 input Sauk this input causes CW motor rotation torque or velocity mode For single ended command operation ground this connection and connect signal to Pin 8 of P1 Pin 22 Input jena Current command B Jumper selectable current command input Bypasses differential input pre amplifier and self commutation Jumper selectable active high or active low open collector output Pin 23 output fault Used to indicate the status of the power stage amplifier enabled or faulted Directional current limit input When pulled to its active state Pin 24 input ilmt motion in the negative direction CCW motor shaft rotation is inhibited jumper selectable Preamplifier current command monitor Used to monitor the output of the preamplifier circuit when in c
52. n P1 10 is not at active state for running amplifier If amplifier faults remove AC for 30 seconds Brushless motor will Motor phases A B and C connected incorrectly relative to not spin in open HA HB and HC hall inputs See section 2 5 for motor phasing loop current mode information www aerotech com 4 1 Troubleshooting BA50 75 100 User s Manual Table 4 1 Amplifier Faults Causes and Solutions Continued Possible Cause and Solution Motor spins uncontrollably in velocity mode configuration Amplifier faults FAULT LED energizes when motor decelerates Motor runs erratic in velocity mode using encoder for velocity feedback Amplifier Faults FAULT LED energizes Encoder sine and cosine signals or tach signals are improperly connected Swap connections to change polarity of feedback Shunt fuse is open This condition indicates an excessive regeneration condition The phase of the sine and cosine signal of the encoder is not separated by 90 The encoder must be adjusted on the motor Noise on the sine and cosine signals of the encoder Use a shield or twisted pair signal common wrapped around sine and cosine wires cable between the motor and the BA amplifier RMS current exceeded turn off and then back on run at lower current Over temperature condition Turn off and let amplifier cool down Provide better ventilation 3 Defective on board power suppl
53. ndard 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 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 BA50 75 100 User s 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
54. o 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 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
55. on Active high shutdown input Logic high on P1 10 shuts off power stage default Active low shutdown input Logic low 0V on P1 10 shuts off power stage Selects brushless mode operation default Selects brush mode operation Selects brushless mode of operation default Selects brush mode operation 0 commutation offset default 30 offset Active low ILMT Logic low on P1 11 stops CW motor movement default Active high ILMT Logic 5 on P1 11 stops CW motor movement Active low ILMT Logic low on P1 24 stops CCW motor movement default Active high ILMT Logic high 5V on P1 24 stops CCW motor movement Power stage drive signal phase A 15 derived from differential pre amp input BA drive performs self commutation default 3 Power stage drive signals are derived from input signal at P1 9 Controller must perform commutation 12 E et 12 29 12 23 NET 23 12 12 ERU d 12 Power stage drive signals are derived from A phase analog Hall factory option Ex 56 ase ERI EUREN Power stage drive signals are derived from A phase differential input factory option Active low fault output Open collector output P1 23 pulls to a logic low to indicate a drive fault Active high fault output Open collector output P1 23 sets to a high impedance state must be pulled to a logic high by an external resistor to indicate a dri
56. ose the servo loop and control the stability of the loop tachometer Pin 15 Reference input for tachometer This point is identical to signal common Modes of Operation jumper selectable Command Inputs Feedback Inputs www aerotech com 3 3 Technical Details BA50 75 100 User s Manual Table 3 2 Electrical Specifications Cont d ilmt Pin 24 ilmt Pin 11 Directional current limit inputs jumper selectable polarity When ILMT is pulled to its active state motion in the positive direction CW motor shaft rotation is inhibited When ILMT is pulled to its active state motion in the negative direction CCW motor shaft rotation is inhibited TTL level input 0 to 5 VDC internal pull up and 10K input Logic Inputs shutdown Pin 10 Jumper selectable active high or active low input Used to shut off power stage and therefore remove all power to the motor TTL level input 0 to 5 VDC internal pull up and 10K input signal ground Pins 7 and 14 Electrical reference for all control circuitry on amplifier signal shield Pin 1 Connected internally to earth ground Used for reducing electrical noise in control and feedback signals fault Pin 23 Jumper selectable active high or active low output Used to indicate the status of the power stage amplifier enabled or disabled The fault output will go to its active state upon a posit Guipits power stage fault thermal overload RMS current limit p
57. ower ranging from 6 000 to 10 000 watts A list of these models and the available voltage configurations is shown in Table 1 1 Table 1 1 BA Models and Voltage Configurations Standard Peak Continuous DC Bus Voltage Model Voltage Output Output Current Range Nominal Configuration Current BAS50 320V 80 320VDC BA75 320V 80 320VDC BA100 320V 80 320VDC The BA drives feature self commutation with digital Hall effect feedback signals The BA drives include a 5 VDC 250 mA supply to power encoders and Hall effect devices HEDs Each model is jumper selectable providing the capability to drive both brush and brushless motors Complete electrical isolation is provided between the control stage and the power stage for all models of the BA series This is accomplished with a transformer isolated control voltage power supply and opto isolation of the drive signals current feedback signals and fault signal between the control and power stages Each drive is fully protected against the following fault conditions Control power supply under voltage RMS current limit exceeded Power stage bias supplies under voltage Over temperature Over current Output short circuits phase to phase and phase to ground and DC bus overvoltage detected if shunt fuse is open vy v Vv Vv V v v Operating modes include current command velocity command or dual phase command for brushless modes of operation only For brush modes of operation the availabl
58. ower supply under voltage condition and DC bus over voltage condition detected if shunt fuse is open Open collector output Requires pull up resistor to external power supply ranging from 5V to 30V fdbk Pin 12 Current feedback monitor When running a brushless motor this signal represents the current in the motor phase A When running a brush motor this signal represents the entire motor current Monitor Outputs phase A output is 8 3 A V for 50 12 5 A V for 75 and 16 6 A V for BA100 icmd Pin 25 Current command monitor Representative of the current command 5 5V output Equals peak current of amplifier 50 amps for BA50 75 for BA75 and 100 for BA100 AC input 2 and earth ground 56 230 VAC 50 60 Hz three phase Note A single phase supply can be connected to any two of the three AC input terminals A single Power Inputs phase supply can only be used with BA50 amplifier 23 amps RMS for BA50 32 amps RMS for BA75 45 amps RMS for BA100 Motor phase A phase B phase C 320 VDC maximum output Motor Outputs 18 amps RMS for the 50 25 amps RMS for the BA75 and 36 amps for the BA100 5V Pin 20 On board 5V power supply 250 mA maximum Auxiliary Power output Outputs 5V Pin 2 On board 5V power supply Pin 2 is intended for powering an encoder Can supply up to 250mA of current control 25 pin D style female Connectors power 8 terminal screw termina
59. 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 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
60. rrent Command Configuration In this configuration the output current to the motor is proportional to the current command input The current command configuration is shown in Figure 2 6 The advantage to this configuration is the sine and cosine signals to the amplifier and a tachometer are not required This configuration will also drive both brush and brushless DC motors WA 1 H P e MKREMKR N i 3 i 2 COS COS N COS COS N 2 SSS ek T SIN 2 RL ene 42 SV SIG COM H 44 1 Signals to Optional Square Wave Quadrature Position Loop Controller Encoder with Commutation 1 1 1 l Tracks or Hall Sensors 1 1 MEORUM le nah sa han 1 og a u PA Square Wave gt o Brushless Motor P Quadrature w 8 x f Encoder O VA 1 P1 r 1 lt 2 20 sv lt 7 SIG COM For Single Ended Command Motor Phase Input Connect Signal To P1 8 25 4 Moir Phase B Input And To 1 21 Input 16 HALEE B To Signal Common gt HALLC C Motor Phase C 2 SHIELD AC 1 Single Ended or INPUT AC2 Differential Velocity INPUT AC3 Command SIG COM ys 14 SIG COM zu Shutd 10 SHUTDOWN Fault lt 123 FAULT 1 SHIELD AN Shielded Cabling Figure 2 6
61. rushless 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 offset 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
62. tection on all AC Mains inputs The BA 50 amplifier required a 25 Amp fuse breaker on AC Main inputs The BA 75 amp 100 required a 30 Amp fuse breaker on AC Main inputs www aerotech com ix Regulatory Information BA50 75 100 Series User s Manual X www aerotech com BA50 75 100 User s Manual Introduction CHAPTER 1 INTRODUCTION In This Section e Product Overview Models Options and Packages BA Drive Package Hardware Overview and Function Safety Procedures and Warnings 1 1 Product Overview The BA High Current Series amplifiers are highly reliable brushless servo amplifiers refer to Figure 1 1 that are easily adaptable to drive brush or brushless servomotors The amplifiers are available in three peak output current ratings of 50 75 and 100 amps The BA amplifier package is a complete modular unit that includes heat sink metal cover and bus power supply that operates from 56 230 VAC The BA drives provide the designer with servo drive flexibility for use in applications such as Machine tools Packaging Labeling X Y stages Inspection Medical Winding Semiconductor fabrication and food processing Y Vv V V V V V VV 18 IDANGER High Voltage p m D 0 m Q I Figure 1 1 BA50 75 100 Series Amplifiers www aerotech com 1 1 Introduction BA50 75 100 User s Manual 1 2 Models Options and Packages The BA high current drives are available in three models with continuous p
63. termine the level where the continuous output current the BA amp protection circuit will produce a fault This type of protection is known as an electronic fuse For low duty cycle and low acceleration system requirements set the DIP switches equally or to the next lower switch setting For high duty cycle and high acceleration system requirements set the DIP switches equally or to the next higher switch setting Closing DIP switches 1 through 4 will allow peak current Closing switches 5 through 8 will allow 5496 peak continuous current for two seconds www aerotech com 1 5 Introduction BA50 75 100 User s Manual The following examples should be used as a guideline for setting the DIP switches Example for a 50 Setting RMS Current Limits To set the continuous current limit to 10A 10A Continuous RMS x 1 414 14 14A continuous peak 14 14A continuous peak 50A max peak x 100 28 Open switches 5 6 and 7 close switch 8 Example for 50 Setting Current Limits To set the peak current to 37A Peak Current 35A peak 50A max peak x 100 75 Close switches 3 and 4 open switches 1 and 2 1 4 3 Potentiometers POTs Potentiometers INPUT TACH GAIN and BALance are associated with the pre amplifier circuit contained in the amplifier Refer to Figure 1 3 for location of the pots on the BA drive These potentiometers are used to adjust the pre amplifier gain when the MODE switch is set for velocity control using an e
64. urrent current rating based on amplifier A pk 5 37 50 mounted to NEMA panel see Figure 3 2 Peak Power Output includes AC Watts 12 000 16 000 20 000 line droop Continuous Power Output includes AC line droop E000 2000 10000 Efficiency Preamp Gain max mode Power Amplifier current command mode Power Amplifier Bandwidth PWM Switching Frequency 9 Minimum Load Inductance 0 8 mH 160 VDC bus 1 6 mH 320 VDC Dissipation 65 Installation Overvoltage category Pollution Degree So L 2 3 2 www aerotech com BA50 75 100 User s Manual Technical Details Table 3 2 Electrical Specifications Cont d Brushless single current command with on board 6 step commutation from HED inputs dual phase commands with sinusoidal commutation provided by an external motion controller third phase command is derived from the amplifier velocity command with 6 step commutation from HED inputs and velocity feedback from the tach or encoder analog Hall effect device HED supplied as a factory option Brush single current command velocity command with velocity feedback from the tach or encoder input Pin 8 input Pin 21 Differential inputs for current or velocity commands 0 to 10 VDC input input non Inverting input can be used in single ended fashion A positive voltage this input causes CCW motor rotation input inverting input can be used in single ended
65. urrent command or velocity command mode This signal can be used in conjunction with the peak current limiting switch SW1 1 through SW1 4 to determine the actual output current When switches SW1 1 SWI 4 are closed this signal has the following gain Pin 25 output icmd 50 9 0 Amp Volt 75 13 6 Amp Volt BA100 18 0 Amp Volt Please see the DIP switch function description in Section 1 4 2 for more information 1 Denotes input pull up to internal 5 V through a 10K resistor 2 Denotes a factory option for analog Hall commutation is available When using analog Hall feedback only Hall A and Hall B connections are used 3 Denotes that pins 21 9 22 and 8 also function as differential inputs for phase A and phase B current commands respectively this is a factory option 1 8 www aerotech com BA50 75 100 User s Manual Introduction 1 4 5 Circuitry The following shows the internal circuitry for the BA amplifier Note that all of the logic inputs can tolerate 24VDC P123 C FAULT OUTPUT B Q3 51K MMBT2222 Capable of 160 mA max Figure 1 4 Fault Output 5V 210 SHUTDOWN ENABLE CTO AW I 10 T 1UF 74HC14 Figure 1 5 Enable Shutdown Inputs www aerotech com 1 9 Introduction BA50 75 100 User s Manual 5V 10K 1 ILMT Crt gt ANN J 10 1 5 1UF 74HC14 10K 1 ILMT CPT24 ANN J o 10K 1 1UF 74HC14 Figure 1 6
66. ve fault default Power stage drive signal phase B is derived from differential pre amp input Drive performs self commutation default Power stage drive signals are derived from input signal at P1 22 Controller must perform commutation Power stage drive signals are derived from B phase analog Hall factory option Power stage drive signals are derived from B phase differential input factory option Current command configuration tachometer feedback through pin 3 of in the velocity loop configuration default Electronic tachometer signal derived from encoder signals in velocity loop configuration Selects brushless mode operation default Selects brush mode operation Signal common of control section connected to earth ground default Signal common not referenced to earth ground P25 0 commutation offset default 30 commutation offset P26 E E 0 commutation offset default 4 2 3 4 3 JP14 JP15 JP22 30 commutation offset E 2 2 www aerotech com INPUT BA50 75 100 User s Manual Installation and Operation LT sar 1o 5 JP8 JP9 JP26 RCN1 H 2 sTeTeTe sTeTeTe Ex eee f TPT Tres T p12 JP15 JP10 JP25 JP14 JPII JP13 752 19 JP20 ELE er 18 JP24
67. velocity feedback e 1 and JP13 set to 1 2 default JP3 JP5 JP15 and JP6 set to 1 2 default for brushless motor operation or 2 3 for brush motor operation NOTE For single ended command input connect signal to P1 8 input and the P1 21 Input to signal common 20 0 62 INPUT ACN Current Command to Commutation Logic 20 0 K 2 67 Volts equals max 1 current d If SW1 Positions 1 through 4 are Encoder Derived closed Velocity ICMD 1K A Figure 2 8 Command Signal Adjustment Portion of the Pre Amplifier Circuit www aerotech com 2 11 Installation and Operation BA50 75 100 User s Manual To minimize the possibility of electrical shock and bodily injury ensure that the motor is decoupled from the mechanical system to avoid personal injury if the motor begins to spin WARNING Starting with a zero input command signal apply power to the amplifier If the motor spins uncontrollably remove power and switch the polarity of the tach input signal If an encoder is being used switch the sine and cosine input signals Verify compliment signals sin amp sin N cos amp cos N are of correct phasing Again apply power to the amplifier If the motor begins to oscillate turn the TACH pot CCW until the oscillation stops The GAIN and TACH potentiometers can be adjusted to provide maximum stiffness on the motor shaft If the desired stiffness is unattainable t
68. xternal DC tachometer or incremental encoder for velocity feedback Refer to Table 1 3 for pot functions Table 1 3 Potentiometer Functions GAIN decrease increase This pot adjusts the velocity loop AC gain of the pre amplifier This pot adjusts the DC gain of the input command present at P1 Pins 8 amp 21 This pot adjusts the DC gain of the tach TACH increase decrease or encoder derived velocity feedback input present at P1 Pin 3 Provides the means of canceling small BALance DC offsets that may be present in the pre amplifier circuit Velocity loop GAIN adjustment is affected by current limit peak switches 1 to 4 Maximum gain when 1 to 4 is closed 1 4 4 Connector P1 and Enable Indicator E p ET ay o z E 2 iP ZA E a m gt e m 59 Connector P1 25 D type female provides the interface for input and output control connections Refer to Table 1 4 for connector pinouts The LED ENABLE indicator will illuminate at all times until there is a fault or external shutdown then the indicator will be off and motor power will be removed Refer to Figure 1 3 for location of these items The POWER LED will be green whenever 5 is present The FAULT LED energizes whenever there is a short circuit current overload thermal overload etc present on the drive The unit must be powered down to clear the fault In addition the OVERLOAD LED energizes w
69. y Return for repair Over loaded logic power supply Remove external device s being powered from the BA 5 V supply 4 2 www aerotech com 50 75 100 User s Manual Troubleshooting 4 3 Fuse Replacement Table 4 2 lists the replacement fuse part numbers both Aerotech and manufacturer Additional fuse information may be described in other documentation Table 4 2 Fuse Replacement Part Numbers Manufacture P N Aerotech P N MDA shunt Buss MDA 3 EIF01017 5A 3AG FI shunt Little Fuse 313005 EIF00105 8A MDA FI shunt Buss MDA 8 EIF00122 Always disconnect the main power before opening the BA amplifier WARNING www aerotech com 4 3 Troubleshooting BA50 75 100 User s Manual 4 3 Cleaning The outside surface of the BA amplifier should be wiped with a clean dry or slightly moistened with water soft cloth Fluids and sprays are not recommended because internal contamination may result in electrical shorts and or corrosion The electrical power must be disconnected from the BA amplifier while cleaning Do not allow cleaning substance to enter BA amplifier or onto any of the connectors Cleaning Labels should be avoided to prevent removing printed user information www aerotech com BA50 75 100 User s Manual Glossary of Terms APPENDIX A In This Section e Glossary GLOSSARY OF TERMS Abbe Error Abbe Offset Absolute Move Absolute Programming AC B

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