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Ndrive HP 10/20/30 USER`S MANUAL

1. 1 8 Ndrive HP Dimensions without the IO Option 1 9 Back Propagation Line Filter Connection 2 3 Isolation Transformer Connection Eliminates 50 60 Hz AC 2 3 AUXPWIECO DIUOLL 2 4 Bus 2 5 and TM5 Transformer Options 2 6 40 Volt DC Bus from 115 and 230 VAC Source 2 7 80 Volt DC Bus from 115 and 230 VAC Source 2 8 160 Volt DC Bus from 115 230 VAC Source 2 9 DC Brush Motor Torque Mode Configuration 2 10 DC Brush Motor Wiring with Tachometer 2 12 Brushless Motor Configuration 2 2 13 Hall Effect Feedback Connections 2 15 Hall Effect Feedback Inputs in the Nstat Utility 2 15 Motor 2 17 Stepper Motor 2 18 Encoder Feedback 2 19 Encoder Phasing Reference Diagram 2 20 Encoder and Hall Signals the Nstat Utility Program 2 20 End of Travel Limit input Connections
2. C 1 155 2327 R8 422 a 3 19 Connector Pinouts 3 19 5 1 5 52 Switch 2 22 Safety Procedures 2 1 Shield 0422 2 5 Shielding Techniques 2 2 Soft Start Circuit 1 4 SSI Net J302 J303 Pin Assignments 4 16 Sol Net Cables 4 18 Standard Encoder Input 3 15 Standard Interconnection Cables 5 Standard 1 4 Stepper Motor Configuration 2 10 2 18 Swie hi T 2 22 Switching 2 1 2 2 Tachometer connection 2 12 2 4 2 4 ipo n 2 4 ROUEN PER 2 4 Optional AC Power Supply Input 2 4 2 5 TB301 Brake Relay Current Specifications 4 4 TB301 Brake Relay Voltage Specifications 4 4 Index INDEX 3 Index INDEX 4 Ndrive HP 10 20 30 Manual s 4 11 U DMS 4 8 Three Phase Motor Terminal Connections 2 Unknown Phase Hall Sequence 2 16 3 User Pow
3. 4 15 JEANNE S E 4 17 Two Three Axis Laser Firing Interconnection 4 18 PSO Tracking Rate Block Diagram 4 19 Ethernet Interface 4204 4 21 Resolver Option Assembly 69001599 Rev 0 4 23 Analog Output Connector TB301 4 25 Resolver Located at Maximum of SIN Signal 4 27 Rotating the Resolver to see a circle 4 27 Optimized Resolver Feedback Configuration 4 28 Joystick Interface 5 5 Single Axis Joystick Interface to J205 of the Ndrive 5 6 Single Axis Joystick Interconnect to J205 of the Ndrive 5 7 Two Axis Joystick Interface to the I O on the IOPSO M 5 8 Two Axis Joystick Connection to the I O on the IOPSO loi MP 5 9 Handwheel Interconnection to J205 of the Ndrive 5 10 Handwheel with flying leads no connector 5 11 BBA32 interface used to connect a Handwheel with flying leads no 5 12 Ndrive HP Control Board Assembly 69001577 Rev A 6 3 Ndrive HP Power Board Assembly 69001576 Rev A 6 5 Connector LED 8 D 1 Ty
4. 3 1 3 1 1 Secondary Encoder Channel 205 3 2 3 1 2 User Outputs 9 11 3205 tet 3 4 39 1 3 User Inputs 8 11 4205 vnu metuat ais 3 5 www aerotech com 11 Table of Contents 3 2 3 3 3 4 3 6 CHAPTER 4 4 1 4 2 4 3 4 4 CHAPTER 5 5 1 5 2 5 3 CHAPTER 6 6 1 6 2 Ndrive HP 10 20 30 User s Manual 3 1 4 High Speed User Inputs 12 13 205 3 6 3 1 5 Analog Input 0 7205 3 6 3 1 6 Analog Output 205 3 6 Position Synchronized Output PSO Laser Firing 3 7 3 2 1 Single Axis Laser 3 10 Motor Feedback 207 4 3 11 3 3 1 End of Travel Limit Inputs 3 12 3 3 2 Effect and Thermistor Inputs 3 13 3 3 3 Brake OUIDUL 3 14 ON MEC 2907 aa 3 14 3 3 4 Encoder Interface 3 14 3 3 4 1 Line Driver Encoder Standard 3 15 3 3 4 2 3 16 RS 232 5 422 Port 206 3 19 FireWire Bus J201 J202 203 3 21 Voltage to Current Mode Oper
5. C 1 APPENDIX D REV 0 to REV A COMPARISON D 1 D 1 Connector 2 D 2 2 2 Option CHANGCS rptu ae dn vun a vun D 3 D 3 E Stop Interface for Rev D 5 INDEXA ES Index 1 READER S Comment 1 www aerotech com V Table of Contents Ndrive HP 10 20 30 User s Manual Vi www aerotech com Ndrive HP 10 20 30 User s Manual LIST OF FIGURES Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 2 20 Figure 2 21 Figure 2 22 Figure 2 23 Figure 2 24 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 4 1 Figure 4 2 Ndrive HP 10 20 30 Networked Digital Drives 1 1 Ndrive HP 1 3 Functional 1 4 Ndrive HP Dimensions with Option
6. 1 l 1 1 1 j 1 _ 33 3 1 31 5 2 2 4 0 09 T cL o 5 5 163 9 6 45 5 REC MTG HDWR M4 8 2 175 4 6 90 Figure 1 4 Ndrive HP Dimensions with IO Option The Ndrive HP case temperature may exceed 75 C in some applications HOT 1 8 www aerotech com Ndrive HP 10 20 30 User s Manual Introduction 79 4 3 13 14 3 0 56 50 8 2 00 12 7 0 50 04 7 20 19 _ 29 1 20 36 18 7 0 74 o ip co 1 9 p S x WO amp x 1 yo 8 333 T 0 19 5 2 4 TOM e Ta 163 9 6 45 REC MTG HDWR 4 8 oe hy 175 4 6 90 _ Figure 1 5 Ndrive HP Dimensions without the Option The Ndrive HP case temperature may exceed 75 C in some applications HOT www aerotech com 1 9 Introduction Ndrive HP 10 20 30 User s Manual 1 5 3 Environmental Specifications The environmental specifications for the Ndrive HP are listed below e Temperature Ambient Operating 5 40 C 41 104 F Storage 20 70 C 4 158 F Maximum relative humidity 15 8096 for temperatures up Humidity to 31 C Decreasing linearly to 50 relative humidity at 40 Non condensing Altitude Up to 2000 m Pollution degree 2 normally only non co
7. 100v ORN A 6 ADDITIONAL OR ALTERNATIVE FUSING MAY BE REQUIRED FOR OPTIMUM PERFORMANCE splice splice YEL 56v 115v BRN MAIN SUPPLY gt N 100v GRN splice FRAME GROUND Ndrive HP AUXPWR INTERCONNECT 160VDC BUS TVO 3 56 TV0 3 56 WIRING PRIMARY 230VAC 620B1346 3 SECONDARY 115VAC 160VDC BUS 620B1346 301 DWG TRANSFORMER P N EAX01006 OPTIONAL SUPPLY Figure 2 8 160 Volt DC Bus from 115 and 230 VAC Source www aerotech com 2 9 Installation and Configuration Ndrive HP 10 20 30 Manual 2 5 Motor and Feedback Connections The Ndrive HP can be integrated into a system using three basic configurations DC Brush Velocity or Torque mode brushless and stepper motors Brush and brushless motors may have two feedback devices 2 5 1 DC Brush Motor in Torque Mode Configuration The DC brush motor configuration is shown in Figure 2 9 See Section 2 6 1 for the correct encoder phasing information if Aerotech s standard cabling is not used 240V MAX 50 60Hz Consult the drawing located on your software CD ROM for specific cable information 15 T d Motor Frame Green amp White amp Shield 1 ou 77 Brush connection connection Motor amp Blue DANGER High Voitage Wire Color Set 1 Wire Color Set 2 Wire Color Set 3 D Green amp White amp Shield Green Yellow am
8. Enable 2 Data Collect Stop Collect Start Motion Stop Motion Flt amp ck Collecting Status Fault 52836 Peak To Peak 25343 Offset Cosine 54736 27368 Offset Radius Error 0 RAMs Task 4 Cosine 7 Task 2 43152 65536 Task 4 Figure 4 24 Optimized Resolver Feedback Configuration www aerotech com Ndrive HP 10 20 30 User s Manual Options 4 4 1 3 Configuring the Commutation Initialization The commutation of brushless motors with resolver feedback may be initialized two ways The first method uses the number of motor pole pairs combined with the maximum resolution of the R D board to determine an initial commutation position The second method initializes the motor normally using the Hall effect feedback signals Setting the CfgMotType axis parameter to auto MSET can be used if the R D auto configuration or Hall effect signals cannot be used auto configuration typically CAN T be used with inductosyns as they have multiple electrical cycles per revolution of the motor R D auto configuration will ONLY work if you have EXACTLY 1 cycle of the Sine and Cosine signals per revolution of the motor The Commutation Initialization method of the R D 1 specified through bit 8 of the CfgFbkRDConfig axis parameter Setting this bit to 1 utilizes Hall effect commutation initialization 1 0 commutation 15 initialized similar to encoder feedback N
9. Motor Frame AC Brushless Green Yellow amp Shield Motor qnem Color Set 1_ WireColorSets2 Wire Color Set 3 Wire Color Set 4_ Green Yellow amp Shield Green Yellow amp Shield Green Yellow amp Shield Green Yellow amp Shield Blue amp Yellow Black 1 Black amp Brown Red o Red amp Orange Black 2 Red amp Orange White amp Brown Black Violet amp Blue NOTES amp Red amp Orange implies two wires f Green White implies a single wire Figure 2 11 Brushless Motor Configuration www aerotech com 2 13 Installation and Configuration Ndrive HP 10 20 30 Manual Positive Move clockwise 2 14 2 9 3 1 Brushless Motor Phasing When configuring the Ndrive HP to run a non Aerotech brushless motor the motor leads A B and C on TB102 must be correctly connected for proper operation If an Aerotech motor is used with Aerotech provided cabling no motor phasing process is required If an Aerotech brushless motor is used with the Ndrive HP motor phase and Hall connections can be easily determined by referring to the system interconnection drawing in Figure 2 11 An brushless motor is correctly phased when a positive motion command causes clockwise CW motor rotation as viewed looking at the motor from the front mounting flange This assumes positive CntsPerMetricUnit CntsPerEnglishUnit CntsPerRotaryUnit axis parameter This require
10. 2 27 3 21 POE 2 27 3 21 Minimizing Cable Lengths 2 24 Part Numbers 2 2 2 23 Preferred Configuration 2 24 FireWire 2 27 3 21 Fire WiO 2 24 Fuse Replacement 6 9 Grounding Techniques 2 2 H Handwheel Interface 5 10 Hardware 1 3 Hardware Overview 1 3 HCPESZ60 4 14 High Inrush Currents 1 4 1 5 Input POW 1 3 AGUA 2 3 2 5 Main 2 5 Motor Frame Connections 2 5 Shield Connection 2 5 UA 2 5 Input Power Wiring Techniques 2 2 2 10 Integrated Configurations 2 10 2 15 2 21 1 5 4 10 JOPSO Option 4 IOPSO Option Board Analog Inputs TB302 4 8 Opto Isolated Inputs TB305 4 11 PSO Absolute Encoder Interface 7301 n n 4 13 Isolation transformer 2 3 J201 2 27 3 21 1202 Nd
11. Pin amp Label Description 7 Auxiliary Sine Secondary RS 422 Channel Sine Bi directional Auxiliary Sine Secondary RS 422 Channel Sine Bi directional EIN Input 12 High Speed Opto Input user interrupt Input 12 High Speed Opto Input user interrupt Input 13 High Speed Opto user interrupt Input 13 High Speed Opto Input user interrupt Output Output Output Bi directional 11 Bi directional 1 5 Volt 500mA max Output 1 Analog Input 0 Differential Input 1 Analog Input O Differential Input Output 11 optional PSO Laser Firing Output Out 11 Output Input 8 Input Input 9 Input Secondary RS 422 Channel Mrk PSO Bi directional Auxiliary Marker cui Auxiliary Marker ne RS 422 Channel Mrk PSO Bi directional Common 5 Volt Output 28 AGnd j AndogCommo b Input Total user 5 V power is limited to 500 mA by an internal re settable fuse Common 5 Volt User Supply www aerotech com 3 1 Technical Details Ndrive HP 10 20 30 User s Manual Table 3 2 Auxiliary Connector Mating Connector J205 pf Aerotech Third Party Source 01259 86 26 Back shell 00600 Cinch DA24658 Screw Locks Qty 2 1400294 TRW 0 20419 16 of the external power provided by Ndrive HP to the user is limited to 500 mAmps and protected by a re settable fuse Should an over current conditio
12. C19791 Joystick Extension Cable with Flying Leads C19792 Joystick Extension Cable with D Style Connectors C19793 Two Axis Joystick Adapter Cable J205 on two Ndrive HPs Two Axis Joystick Adapter Cable with Flying Leads J205 and IO option C19851 Hi Flex Motor Cable BL MTR FL 4DU HF 46DM C20251 xx Stepper Motor Cable ECZ01231 BBA32 Interconnect Cable The xx indicates length in decimeters yy would indicate length in feet www aerotech com 5 1 Accessories Ndrive HP 10 20 30 User s Manual Table 5 2 Combined Motor amp Feedback Cables art Number s escription Stage Motor 18982 amp FB 25DU FL 25DU MAX107DM BFMCDNT yy Obsolete 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 ADR175 ASR1000 1100 amp 2000 series with 25D option Motor Output Motor Encoder Limits Halls DC MTR FB 25DU FL 24MS C13803 xx MAX107DM Motor Output WR Any stage having a DC brush motor with a single 24 pin MS style connector for motor power encoder limits and brake Motor Encoder Limits Brake Motor Feedback C20251 xx SM MTR amp FB 25DU FL 23B MAX107DM Any stage having a stepper motor with a single 23 pin Burndy style connector for motor power encod
13. Ndrive HP 10 20 30 Manual Binary Coded Decimal A number system using four bits to represent O 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 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 Non uniform 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 Also referred to as trapezoidal commutation The process of switching mo
14. SERIES THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED OPTIONAL SUPPLY 0 3 28 WIRING PRIMARY 115VAC TRANSFORMER nen TRANSFORMER P N 01007 ELECTRICAL AND AUDIABLE NOISE EMMISSIONS AND PROVIDES INCREASED SERVO PERFORMANCE 5 IT I5 RECOMMENDED THAT THE OPTIONAL AND MAIN SUPPLIES A AUXPWR OPTION 3A SLO BLO CONNECTED TO THE SAME SOURCE TRANSFORMER 18 WHT AC HI AS SHOWN THIS WILL ENSURE NTERNA PROPER SOFT START OPERATION 18 WHT splice AC LO 50 60 HZ INPUT SWITCH RED 28v e 115v BLK IE AC1 IV ORNA splice JA 6 ADDITIONAL OR ALTERNATIVE FUSING MAY BE REQUIRED FOR OPTIMUM PROTECTION GRAY 115v BRN 100v GRN splice FRAME GROUND Ndrive HP AUXPWR INTERCONNECT 40VDC BUS TV0 3 28 OPTIONAL SUPPLY 0 3 28 WIRING PRIMARY 230VAC 620B1346 1 SECONDARY 28VAC 40VDC BUS TRANSFORMER P N EAX01007 620B1346 101 DWG Figure 2 6 40 Volt DC Bus from 115 and 230 VAC Source www aerotech com 2 7 Installation and Configuration Ndrive HP 10 20 30 Manual Ndrive HP PRIMARY FUSE AUXPWR OPTION 4A SLO BLO TRANSFORMER 18 INTERNAL THERMAL SWITCH AC HI 115VAC AC LO 50 60 HZ INPUT SAFTEY splice 18 WHT RED 56v 115 AC1 WORN GRAY NOTES MAIN SUPPLY gt 115v 1 TH
15. mm 2nm Encoder data rate at 200mm sec 500 000 200 100Mhz This exceeds the DUALPSO or TRIPLEPSO maximum encoder tracking rate of 5 MHz and must be reduced by 100 5 20 Set the CfgFbkEneMxhQuadDiv axis parameter to 20 to achieve this The user must now program the PSODISTANCE command in units of 40nm instead of 2 nm www aerotech com Ndrive HP 10 20 30 User s Manual Options 4 3 Ethernet Option J204 The optional Ethernet port provides connectivity to a 10 100Base T ModBus TCP network This 1s typically used for adding analog and digital I O to the controller See the Ethernet I O help on the Window s Start bar on the Automation 3200 menu Table 4 17 Ethernet Connector Pin Assignment J204 Pins Label Description mowe 2 nc 4 onses RC Terminated _ e RCTemimaed m Additionally the IOPSO options provide analog and digital inputs and outputs see Section 4 1 for more information 3 3V ae 16 05042 51 PI H 888888 SH Pit MBO LANS1CITI 0020 250V CONBRJ45GRN YEL Figure 4 19 Ethernet Interface J204 Table 4 18 NConnect I O Cable part Numbers Part Number Description NConnect lO 900 Ethernet crossover cable 900mm 3 ft NConnect IO 1500 Ethernet crossover cable 1500mm 5 ft NConnect IO 3000 Ethernet crossover cable 3000mm 10 ft NConnect IO 4500 Ethernet crossover c
16. 4 4 Table 4 5 Brake Relay Connector Pin Assignment TB301 4 4 Table 4 6 Brake Relay Connector Pin Assignment J207 4 4 Table 4 7 Optional Analog Input Connector Pin Assignment TBO 4 8 Table 4 8 User Power Connector Pin Assignment TB303 4 9 Table 4 9 Opto Isolated Output Connector Pin Assignment TB SOT 4 9 Table 4 10 JOPSO Output Device Specifications TB304 4 9 www aerotech com List of Tables List of Tables Table 4 12 Table 4 13 Table 4 14 Table 4 15 Table 4 16 Table 4 17 Table 4 18 Table 4 19 Table 4 20 Table 4 21 Table 4 22 Table 4 23 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 6 7 Table 6 8 Table 6 9 Table 6 10 Table 6 11 Table C 1 Table C 2 Table D 1 Ndrive HP 10 20 30 User s Manual PSO Absolute Encoder Interface Connector Pin Assignment enata rne 4 13 PSO Absolute Encoder Mating Connector J301 4 13 Laser Output Opto Isolator Specifications 4 14 J302 J303 2 Channel SSI Net Connector Pin TR 4 16 SSI Net Cable Part 4 18
17. the encoder signals from a second third Ndrive must be jumpered or daisy chained from that Ndrive to the Ndrive with the DUALPSO or TRIPLEPSO options This requires an encoder signal from another axis via the J205 connector Section 3 1 1 or via one of the two SSI Net connectors If the J205 connector is used it must be configured as an output via the EncoderDivider axis parameter If the SSI Net 15 used it requires a cable see Table 4 16 and Figure 4 17 from J302 to J302 of each Ndrive J302 to J302 or J303 to J303 of the other Ndrive both connectors have two bi directional ports The ports on each drive must then be configured via their PsoSsil Config PsoSsi2Config and PsoMrk1Config PsoMrk2Config axis parameters out and in respectively so the encoder signals are supplied to the Ndrive with the DUALPSO TRIPLEPSO options Additionally the CfgEncMxhSetup axis parameter must be configured for a 20 MHz clock or less so as not to exceed the 31 nsec minimum edge separation specification Also the PSO pre scalars may be required to limit each encoder being tracked to a 5 MHz data rate which does not affect the servo feedback loop data rate The figure below also shows two three axis firing which are very similar See the Nview HMI help for more information on parameter configurations Note that the J205 encoder channel may be configured as an output via the EncoderDivider axis parameter allowing other multi axis PSO firing config
18. 3 3 All User Inputs 8 13 J205 www aerotech com 3 5 AUX I O 1205 3 6 Technical Details Ndrive HP 10 20 30 User s Manual 3 1 4 High Speed User Inputs 12 13 J205 The high speed inputs shown in Figure 3 3 are scaled for a 5 volt input voltage A higher input voltage requires adding an external series resistor to limit the current to 7 milliamps For example 24 volt operation requires an external 2 700 ohm 1 2 watt resistor in series with one of the input pins The high speed inputs inputs 12 and 13 have a delay of 50 nanoseconds typical See Table 3 2 for the mating connector part number Table 3 6 High Speed User Inputs Pin Assignment on Connector J205 Pin Label Description In OutBi 6 In13 Input 13 High Speed Opto user interrupt 21 5 Volt 5 Volt User Supply 24 InCom Total user 5 V power is limited to 500 mA by an internal re settable fuse 3 1 5 Analog Input 0 J205 The analog inputs accept a signal within the range of 10 through 10 volts DC Signals outside this range may damage the input For analog input technical information see Section 4 1 4 See Table 3 2 for the mating connector part number Table 3 7 Auxiliary Connector Pin Assignment J205 Pin Label _ Descripon 77 W OutBi Analog 0 In Analog Input 0 Differential Analog 0 In Analog Input 0
19. 4 24 4 4 1 1 Configuring the Hardware 4 24 4 4 1 2 Configuring the Analog Feedback 4 25 4 4 1 3 Configuring the Commutation 4 29 ACCESSORIES 5 1 Standard Interconnection Cables 5 1 Joystick 5 5 Handwheel 5 10 TROUBLESHOOTING 6 1 Problems Causes and Solutions 6 1 Ndrive HP Control Board Test 6 2 Ndrive HP Control Board 6 3 WWW aerotech com Ndrive HP 10 20 30 User s Manual Table of Contents 6 4 Ndrive HP Power Board 6 5 6 5 LEI o 6 7 6 6 JTAG Programming Connector 6 8 6 7 Fuse Battery 6 9 6 8 Preventative Maintenance 6 10 OR EE CBIN HE TE 6 10 APPENDIX A GLOSSARY OF TERMS A 1 APPENDIX B WARRANTY and FIELD SERVICE B 1 APPENDIX C TECHNICAL CHANGES
20. A AC Power 2 4 Input Terminal 2 3 2 5 AC2 Input Terminal 2 3 2 5 Input Terminal 2 5 r E EPEAN EE EEA AA E 2 4 E E 2 4 Amplifier Related Problems 6 1 Analog Inputs TB302 4 8 Analog Output Connector Pinouts 4 3 Auxiliary I O Connector Pinouts 3 1 3 2 3 5 3 6 D 4 T 1 5 B Back Propagation Line Filter Connection2 3 gt ET RE 6 9 Battery Replacement 6 9 Brake Relay TB301 Current 8 222 22212 4 4 Brake Relay TB301 Voltage Specifications 4 4 Brake Relay Connector Pinouts 4 4 Brake Configuration Jumpers 4 2 www aerotech com Brushless Motor Configuration 2 10 2 13 2 14 Bus Power 1 4 Cable Interconnections 5 1 Capacitive 2 2 ne 6 10 CODE CL OF 1 3 Connector Pinouts Auxiliary I O 3 1 3 2 3 5 3 6 D 4 EREA O MNT 3 21 1205 EEEE 3 1 3 2 3 5 3 6 D 4 JU e R 3 19 3 11 3 13 3 14 Motor Feedback 3 11 3 13 3 14 5 232 5 422 3 19
21. Feedback Connector Pinouts 3 11 3 13 3 14 Motor 3 11 254 3 11 Motor Feedback CONECO 4 2 Motor Frame 2 5 Motor Output Terminals A B and OM 2 5 www aerotech com Ndrive HP 10 20 30 Manual Motor 2 18 2 19 MAT e M 1 5 MXH Option Specifications 3 17 Clock Frequency 3 17 Interpolation 3 17 Max Input Frequency 3 17 Minimum Edge Separation 3 17 Minimum Pulse Width 3 17 hip me 3 11 3 16 Ndrive Hardware 1 3 Noise Back propagation 2 3 Opiom 2 6 Option E 2 6 Option Transformer 2 6 Optional AC Power Supply Input 2 4 Optional Analog Input Connector Pinouts 4 8 OOS RR 1 5 Opto Isolated Input Connector Pin 4 11 Opto Isolated Inputs TB305 4 11 Opto Isolated Output Connector Current Sinking Mode 4 10 Pin Assignment 222 4 9 Output Current Peak 1 5 P P10 JTAG Programmin
22. INSTALL LABEL TO BACK OF HANDWHEEL HWA32 FLY CABLE LENGTH IN DECIMETERS 32 FLY XX 630B1983 1 REV S N XXXXXX TYPE 4 MIA00424 WORK ORDER NUMBER 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 Ndrive HP HANDWHEEL HWA32 FLY XX 630 1983 1 630B1983 101 DWG HWA32 FLY XX Handwheel with flying leads no connector 5 11 Accessories Ndrive HP BBA32 AUX I O INTERFACE 26 PIN HD M F CABLE 201231 PHOENIX 26 PIN HD BREAKOUT MODULE ECZ01230 Ndrive HP 10 20 30 User s Manual SHOWN FOR REFERENCE AUX SIN AUX SIN 1 OPTO4 BBA32 2 2 AUX I O EXT_OUT 1 INTERFACE EXT OUT2 EXT OUT3 10 AUX COS 11 COS 12 45V 13 ANALOG_IN 14 ANALOG IN 15 EXT_OUTCOM 16 EXT_OUT4 17 EXT IN1 18 EXT IN2 NOTES THE BBA32 CONSISTS OF THE FOLLOWING PARTS 1 ECZ01230 PHOENIX BREAK OUT MODULE 1 ECZ01231 26 PIN HD M F CABLE 2 5FT AUX MRK COM ANALOG1 OUT AGND EXT INCOM EXT IN3 EXT IN4 Ndrive HP BBA32 AUX INTERCONNECT BBA32 620B1343 1 620B1343 101 DWG Figure 5 8 BBA32 interface used to connect Handwheel with flying leads no connector
23. Pin Assignment on Connector J207 Pin Label Description In OutBi 5 Volt 5 Volt Power for Encoder 500mA max Output Hall Effect Sensor B Brushless Motors only Hall Effect Sensor A Brushless Motors only Hall Effect Sensor C Brushless Motors only Signal Common for Encoder Total user 5 V power is limited to 500 mA by an internal re settable fuse 5V 2207 52 74ACT14 5V 74 14 7207 1 7AcTM Figure 3 8 Hall Effect and Thermistor Inputs J207 www aerotech com 3 13 Technical Details Ndrive HP 10 20 30 User s Manual MOTOR FEEDBACK 1207 3 14 3 3 3 Brake Output The brake output provides a direct connection to the brake the relay on the optional IOPSO board The brake output will be present on this connector only when the IOPSO option board is present allowing the brake signal to utilize the existing feedback cable without the need for additional wiring See Section 4 1 3 for more information on the brake output See Table 3 12 for the mating connector part number Table 3 15 Brake Output Pin Assignment on Connector J207 Pinf Label Description 77 In OutlBi Optional Brake Relay Output Output Optional Brake Relay Output Output 3 3 4 Encoder Interface The three encoder signals consists of the following sine Sin cosine Cos and marker Mkr as well as their complimentary signals sine n Sin N c
24. 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 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 betwee
25. also features an optional on board brake relay programmable resolution multiplication up to x 65 536 with a 200 kHz maximum amplified sine wave input frequency and up to three axis Position Synchronized Outputs laser firing In addition the use of the commercially standard FireWire communication link makes integration to the Automation 3200 network plug n play easy Figure 1 1 Ndrive HP 10 20 30 Networked Digital Drives www aerotech com Introduction 1 1 Introduction 1 2 1 1 Ndrive HP 10 20 30 User s Manual Feature Summary Software configurable for brush brushless and stepper motor operation Standard 100 VDC 320 VDC Bus optional 20 VDC 80 VDC Bus requires the AUXPWR option Fully isolated power stage 5 VDC 500 mA fused user output power for encoder and Hall effect signals etc Two mounting orientations optimized for heat transfer or minimal panel space utilization Full protection against the following failure modes 1 Control supply under voltage 2 Continuous current overload 3 Power stage bias supply under voltage 4 Power stage output short circuit phase to phase and phase to ground 5 DC bus over voltage 6 IGBT device over temperature sense Line driver square wave or analog sine wave quadrature encoder primary position and velocity feedback Line driver square wave auxiliary quadrature encoder input or output for PSO laser firing etc 4 opto isolated user outputs standard 6 o
26. an op amp output Table 4 7 Optional Analog Input Connector Pin Assignment TB302 Pinf Label Description In Out Bi Analog Common N A AnalogO Non Inverting Analog Input O Input Analog1 In Non Inverting Analog Input 1 Input Analog In Inverting Analog Input 1 Input ANALOGO IN 1205 12 ANALOGO IN C J205 14 AnalogO In Inverting Analog Input O 12 Use Shielded Cable iPresent with the lopso 12 option only ANALOGI IN 302 4 Figure 4 8 Optional Analog Input Connector TB302 4 8 www aerotech com Ndrive HP 10 20 30 User s Manual 4 1 5 User Power Connector TB303 This connector provides access to the Ndrive HPs internal power supply which may be used to power external devices 500 mAmps maximum It also provides a connection to power the opto isolated PSO Laser Firing output see Figure 4 14 Table 4 8 User Power Connector Pin Assignment TB303 Pin Label Description 5 User Return User 5 Volt Signal Common Output 5 User Return User 5 Volt Signal Common Output User 5 Volt Power Output Power for PSO opto isolated output Common for PSO opto isolated output Total user 5V power from all outputs is limited to 500 mA by an internal re settable fuse 4 1 6 Opto lsolated Outputs TB304 The outputs are software configurable via the DriveIOConf
27. before the standalone mode 15 activated To enter the normal A3200 operating mode power down the drive and set DIP switches 6 and 77 to the ON position Once the parameters are correctly configured to run the motor with the A3200 and verified they can then be saved to the flash memory This initial setup should only need to be performed once for a given system type If the parameter settings for a given axis in the system have already been verified then on all future systems the A3200 software can be used to load the parameters for that axis into the Ndrive so that they can be saved to the flash memory on that drive Re configuration should only need to be done for a different system or if it is expected that some other system parameter may have changed 3 6 2 Saving Parameters to the flash memory on the drive Open the Ndebug exe utility and select the axis by typing AX n where n 15 the 1 based axis number of the axis you wish to select Save the parameters to flash memory by typing FLASHWRITE 1 0 0 This will save the current system configuration into the flash memory on the Ndrive To enter the voltage to current mode power down the Ndrive and set DIP switches 6 and 7 to the OFF position When the unit is powered on again it will auto boot into the voltage to current mode www aerotech com 3 23 Technical Details Ndrive HP 10 20 30 User s Manual 3 24 3 6 3 Operation In the Voltage to Current mode the Nd
28. 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 Encoder Limits 25000 series Halls Brake ARA125 series ASR1000 1100 amp 2000 series with HPD option ATS1100 H series LMA amp LMAC series Motor Feedback C18391 xx BL FB 25DU 25DU 9DU MAX120DM C18393 xx BL FB 25DU 25DU 9DU MAX240DM BFCD yy Obsolete Encoder Halls Brake Any Brushless motor stage having a 25 pin D style connector for encoder halls amp brake and a 9 pin D connector for limits Motor Feedback BM BMS motors with D25 option C15291 xx BL FB 25DU 17MS 9DU MAX120DM C15297 xx BL FB 25DU 17MS 9DU MAX240DM BFC yy Obsolete Encoder Halls Brake Q Any stage having a BM BMS motor with a 17 pin MS style connector for encoder halls amp brake and a 9 pin D connector for limits Motor Feedback Limits The xx indicates length measured in decimeters yy indicates length measured in feet 5 4 www aerotech com Ndrive HP 10 20 30 User s Manual 5 2 Joystick Interface The user may connect an Aerotech JI not JBV or 1 4 joystick or their own joystick and switches to the Ndrive Refer to Figure 5 1 The joystick interlock input must be set to the logic low state to indicate the joystick 1s connected The zero velocity null point for each joystick
29. by no current flow from pin 7 to pin 15 through the fault output failsafe by default no current flow indicates a drive fault When the drive is powered up and no fault condition exists the opto isolator will conduct current 3 6 4 Faults A Drive Fault in the standalone mode can be caused by any of the following issues Drive Over Current Peak current commanded for 1 second e Motor Over Current RMS threshold Thermistor Over Temperature Fault Motor e Amplifier Temperature Fault e Loss of Bus Power www aerotech com Ndrive HP 10 20 30 User s Manual Options CHAPTER4 OPTIONS 4 1 IOPSO and IOPSOH Option Boards see the following sections for details on the connector Pin Assignment and technical information for the IOPSO and IOPSOH options The IOPSO expansion board has 8 opto isolated inputs sinking or sourcing and 8 outputs sinking or sourcing two 18 bit analog outputs two 16 bit differential analog inputs SSI Net absolute encoder interface and brake relay and includes a HCPL2601 opto isolator OUTPUTS ALLEM E NUM a KEKE 4 1 IOPSO Option Board 69001579 Rev Table 4 1 OPSO Option Board Jumpers Jumper Setting Description 00 JP4 1 2 3 4 Brake Option at J207 Auxiliary relay Output Option at TB301 Remove 1 2 3 4 and 2 4 Input 0 at
30. correctly phased when rotated clockwise by hand and the tachometer generates a positive voltage as displayed on analog input 0 and the motors back EMF generates a negative voltage at motor terminal A with the voltmeter common probe at motor terminal C 240 ia Mam Consult the drawing located on your software CD ROM for specific 15 cable information J ACI Motor Frame Green amp White amp Shield E i Red amp Orange DC Brushy 7 np Motor na connection Yellow amp Blue Wire Color Set 1 Wire ColorSet 2 Wire Color Set 3 Green Yellow amp Shield Green Yellow amp Shield FA Rei amp Orme Rei Reda Orange Yellow amp Blue Yellow amp Blue NOTES S Red amp Orange implies two wires I Green White implies a single wire Motor Frame Tachometer Or cable shield and motor frame to mating connector housing Figure 2 10 Brush Motor Wiring with Tachometer 2 12 www aerotech com 10 20 30 Installation and Configuration 2 5 3 Brushless Motor Configuration This mode is used with a brushless motor only See Section 2 6 if Aerotech s standard cabling is not used for information on correctly phasing the motor encoder and Hall feedback devices mme Consult the drawing located on your software CD ROM for specific 50 60 cable information 15
31. 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 www aerotech com Ndrive HP 10 20 30 Manual Retro reflector Roll of travel Roll Error Rotor RS 232C RS 274 RS 422 Run Out Servo System Settling Time Shaft Radial Load Shaft Run Out Slot less Stator Stiction Straightness of Travel Torque www aerotech com 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
32. positive lead of the voltmeter is the motor lead as indicated in the Figure above and should be connected to the A motor terminal The other motor lead connects to the motor terminal www aerotech com Motor Mounting er shaft Flange front Installation and Configuration Ndrive HP 10 20 30 Manual 2 5 2 DC Brush Motor with Tachometer Feedback Configuration The DC brush motor configuration is shown in Figure 2 10 See section 2 6 1 for the correct encoder phasing information if Aerotech s standard cabling is not used The tachometer may be connected to TB302 or J205 as shown in the picture below Note that tachometer feedback uses analog input 0 so it may not be used when tachometer feedback is used To configure the axis parameters in this mode see the Brush Motors in Velocity Mode topic in the Nview HMI help The analog input that the tachometer is connected to is scaled for 10V input maximum The tachometer voltage must not exceed 10 volts or the velocity loop will become unstable possible causing a runaway condition Based upon the tachometer voltage rating a resistor scaling network may be required to limit the tachometer voltage to 10V at maximum speed If noise is present on the tachometer signal a high quality 1 uF capacitor may be required across the tachometer leads before any voltage divider required to limit the maximum input voltage to the analog input The motor and tachometer are
33. pulse output every 1 000 encoder counts in DUALPSO or TRIPLEPSO mode The individual axis speeds approach 20 MHz during the motion and therefore exceed the 5 MHz DUALPSO or TRIPLEPSO tracking limitation The PSOTRACK axis SCALE 4 4 command must be used and the PSODISTANCE values reduced by a factor of 4 as follows PSODISTANCE X FIXED 250 STEPS distance specified with actual resolution B In order to run the servo loop at full encoder resolution and data rates above 20 MHz Ndrive software versions 2 02 and above contain the CfgFbkEncMxhQuadDiv axis parameter which acts as an MXH output divider This parameter allows you to specify a lower resolution for the MXH quadrature output signal only used by DUALPSO or TRIPLEPSO options on other drives The effective resolution 15 the full resolution as derived using CfgFbkEncMultFactorMXH axis parameter divided the CfgFbkEncMxhQuadDiv axis parameter The servo loop always runs at the full resolution as determined by the CfgFbkEncMultFactorMXH axis parameter The CfgFbkEncMxhQuadDiv axis parameter does not affect servo loop resolution Example An application uses a 4um linear encoder with an MXH option on an Ndrive It 15 desired to move the motor at a maximum speed of 200mm second and track using the DUALPSO or TRIPLEPSO option CfgFbkEncMultFactorMXH 500 value for 2nm servo loop 2 resolution Encoder resolution 250 lines mm 500 4 500 000 counts
34. the metal backshell The following modifications ensure compliance e Install a snap on Ferrishield ferrite attenuator P N 5528 2034 on the FireWire cable at the unit e nstall a Curtis P N F1600CA 10 EMI line filter on the AC input e Install two snap on Ferrishield ferrite attenuators P N 5528 2032 and 528 1984 on the AC cable between the EMI line filter and the Ndrive e Connect earth ground to the mounting screw at the AC input e Install SCI 25 pin D style Spectrum EMI filter adapter P N SCI 56 725 001 series with the motor feedback cable at the unit Current generation units Revision A have integral filtering built in which should preclude the use of this EMI filter based upon similar product testing Safety related requirements to ensure compliance exceptions to EN 61010 1 e Ndrive must be installed within an enclosure with construction compliant unlimited circuits e The end user is responsible for meeting the final protective ground requirements e The AC power inlet located on the front of the Ndrive is the power disconnect The end user is responsible for determining and providing a supply disconnect for the system e The end user is responsible for preventing unexpected startup e Connection requirements are described the technical documentation provided with the product The end user is responsible for making the proper connections and meeting any required interlock requirements fo
35. to the I O on the IOPSO Option www aerotech com Ndrive HP 10 20 30 User s Manual Ndrive HP JOYSTICK INTERFACE l IOPSOINTERFACE Accessories NOTES 1 USING C19791 XX CABLE WILL PROVIDE 2 AXES OF SLEWING REQUIRES Ndrive HP TO HAVE THE IOPSO OPTION INSTALLED 2 THE JI JOYSTICK MUST BE USED WITH THE Ndrive HP JBV OR JP4 JOYSTICK VERSIONS ARE NOT COMPATIBLE AGND 1 2 A24 4 C19791 XX WIBRN OO JOYSTICK EXT A2 5 CABLE GND 1 ml Fema 5V IP 7 305 IN2 IN3 J REV A UNITS INDUSTRIAL REV UNITS Ndrive HP JOYSTICK JOYSTICK INTERCONNECT C19791 XX CABLE 629e0B1345 101 DW Figure 5 5 Two Axis Joystick Connection to the I O on the IOPSO Option www aerotech com 5 9 Accessories 5 3 Handwheel Interface Ndrive HP 10 20 30 User s Manual The user may connect a handwheel or any device producing differential quadrature signals for manual positioning of the axes See the Nview HMI help for information on enabling the handwheel via software commands The handwheel may be connected to 1205 of the Ndrive as shown in Figure 5 6 below or the I O available on the IOPSO option shown in subsequent Figures lt 10 FT OR AR LENGTH TO Ndrive HP HANDWHEEL 5V EOM SUMTAK SIN LGF 043 100 SIN N AN ECZ00201 100 LINES REV COS N COS ECX00570 CABLE 8 CON
36. 0 30 Manual APPENDIX GLOSSARY OF TERMS Abbe Error Abbe Offset Absolute Move Absolute Programming AC Brushless Servo Acceleration Accuracy Accuracy Grade ASCII Axial Run Out Axis of Rotation Back EMF Kemf Backlash Ball Screw Ball Screw Lead Bandwidth Baud Rate www aerotech com 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 vert
37. 15 approximately 2 5 volts Be sure to set the JoyStickMinVoltage and JoyStickMax Voltage task parameters Also the two potentiometers may be connected to analog inputs on two different Ndrives since each Ndrive standardly has one analog input Subsequent drawings illustrate how to connect a single axis and a two axis joystick both single and two axis to the Ndrive in various ways and the cables required to so do A two axis Joystick requires 2 analog inputs provided by the IOPSO option When using an external potentiometer such as a joystick to drive the Ndrive analog inputs it must be manually calibrated 1 Set the joystick potentiometer at mid point detent position and record the voltage from the Nstat window 2 Record the voltage at the maximum and minimum deflections of the potentiometer Subtract the two voltages 3 Set the JoyStickMaxVoltage task parameter to the mid point voltage from step 1 plus 1 2 the voltage difference from step 2 4 Set the JoyStickMinVoltage task parameter to the mid point voltage from step 1 minus 1 2 the voltage difference from step 2 If two different Ndrives are being used to read the joystick only one Ndrive should be used to provide 5V power to the potentiometers The second Ndrive should connect differentially to the second joystick potentiometer by connecting the Analog Input to common and the Analog Input to the potentiometers wiper Ndrive HP TB302 Analog Input 1 Analog Inpu
38. 2 11 2 5 2 DC Brush Motor with Tachometer Feedback Configuration 2 12 2 0 3 Brushless Motor Configuration 2 13 2 5 3 1 Brushless Motor Phasing 2 14 2 5 3 2 Brushless Motor Hall Effect Feedback Connections 2 15 2 5 3 3 X Hall Effect Phasing 2 16 2 5 4 Stepper Motor Configuration 2 18 2 5 4 1 Stepper Motor Phasing Process 2 18 2 6 Encoder Feedback 2 19 2 0 1 Encoder ar a UR a fave 2 20 2 7 End of Travel EOT Limit Input Connections 2 21 2 7 1 End of Travel EOT Limit Phasing 2 21 2 8 Communication Channel Settings 2 22 2 9 Connecting Multiple Drives 24222 2 23 2 9 1 and Signal Wiring Requirements 2 24 2 10 Emergency Stop Sense Input 201 2 25 2 10 1 Typical ESTOP Interface 2 26 2 11 Configuration and Operation Information 2 27 CHAPTER 3 TECHNICAL DETAILS 3 1 3 1 Auxiliary Connector 205
39. 2 21 Limit Inputs in the Nstat 2 21 Recommended Star Daisy Chain Configuration 2 23 FireWire Daisy 2 24 ESTOP Sense Input 201 2 25 Typical Emergency Stop 2 26 Secondary Encoder Channel 205 3 3 User Outputs J209 E 3 4 User Inputs 8 13 205 3 5 PSO Diagram Basic Single Axis Firing 3 7 Advanced 1 3 AXIS Firing aui aia a natara rd aba 3 9 Data Capture Data Update Modes 3 10 End of Travel Limit Inputs 3 12 Hall Effect and Thermistor Inputs 207 3 13 Line Driver Encoder Interface Standard 207 3 15 Optional MXH Analog Encoder Interface J207 3 18 RS 232 RS 422 Connector 206 3 20 Normal 3 22 Stand Alone Configuration 3 22 5 Option Board 69001579 Rev 4 1 IOPSOH Option Board 69001623 Rev 0 4 2 www aerotech com List of Figures VII
40. 2 BRAKE 2 c 4207 25 JP1 B 5 a aa BRAKE _ 420 15 Figure 4 6 Suppression for DC Brake Systems The user may reconfigure the connections for the brake such that the positive supply lead is switched by the relay instead of the supply common www aerotech com Ndrive HP 10 20 30 User s Manual Options Example 3 Figure 4 7 is a suppression circuit that can be used for both AC and DC circuits In this method a resistor capacitor and a varistor are used across the load see Figure 4 7 In some cases better results are obtained by installing the suppression devices across the relay contacts The ratings and values for these components are described below Resistor is calculated by the following formula Power rating Watt Resistor ohms Voltage Load current If the resistance of the Resistor is too low the relay contacts may fuse together so if the Resistor 1s less than 24 ohms use a 24 ohm resistor If the resistance of the Resistor 15 too high the contacts may be damaged due to excessive arcing so if the Resistor 15 greater than 240 ohms use a 240 ohm resistor Capacitor C 1 uF rated for AC circuits and a voltage rating of not less than 250 Volts If the voltage rating of the capacitor 15 too low the Varistor may not be able to protect it and it may fail Varistor V Rated for the maximum voltage of the users power supply Typically a varistor rated for a standard 120 VAC line sh
41. 2 Mhz PSOTRACK cmd SSI Net Ports 1 and 2 20 Mhz cmd C9 bkEncMxnSetup axis parameter Pulse Firing Mi Distance y Array SS Net 1 FIFO Load Next Configuration a con Software Primary Encoder Trigger 24 Secondary Encoder Pulse Skip Tracking i i 9 Distance Trigger Pulse PS0 Output es Generator Pulse Output Switching Multiplex Figure 3 4 PSO Diagram Basic Single Axis Firing www aerotech com 3 Technical Details Ndrive HP 10 20 30 User s Manual 3 8 Table 3 10 PSO Output Sources Maximum Standard Requires User High Speed Opto Isolator J301 Table 4 14 5 option Opto Isolated Output 11 J205 Standard RS 422 Marker output on 10 MHz Standard Yes Secondary Encoder J205 The pre scaler in the block diagram is used to normalize the resolution of axes with different machine step sizes or to scale down divide the maximum input frequency to the PSO tracking hardware The PSO hardware operates in machine counts so all axes must be scaled or normalized to like units This allows a trigger to be generated from a true vectorial position change Each of the three possible tracking channels has a pre scaler which may be used to divide the number of encoder counts on that channel Each pre scaler defaults to 1 and may divide the input feedback pulses by up to 1 023 The trigger condition may be a software trigger unde
42. 500mA max Output Output Common 16 Out 11 Output 11 optional PSO Laser Firing Output Output Common 5 Common 5 Volt User Supply Total user 5 V power is limited to 500 mA by an internal re settable fuse 5V 390 oe IN 390 n 30 e 390 PS2802 4 Figure 3 2 User Outputs J205 3 4 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 1 3 User Inputs 8 11 J205 Inputs 8 11 as shown in Figure 3 3 are scaled for an input voltage of 5 24 volts A higher input voltage requires adding external series resistors to limit the current to 20 milliamps Inputs 8 10 may also be used as CW CCW and Home EOT limit inputs respectively by setting bit 22 of the DrivelOConfig axis parameter See Table 3 2 for the mating connector part number AUX 1 0 1205 Table 3 5 User Inputs Pin Assignment on Connector J205 Pins Label mOwBi 21 Common 5 Vo Common 5 Volt User Supply input Common input 10 Home Input input 11 Total user 5 V power is limited to 500 mA by an internal re settable fuse 5 EXT JNCOM 705 274 PGA PUT 11 0205 20 10k INPUT 10 05 25 10k INPUT_9 205 10 10k 8 J205 1 i 10k INPUT 12 OPTO J205 3 W 270 12 0PTO 270 INPUT 13 070 205 5 gt n 270 INPUT 13 OPTO 205 6 V Figure
43. 802 4 Figure 4 9 Connecting Outputs in Current Sinking Mode T T OPTO OU T 1 OUTPUT 0 TE301 3 Diode required for an inductive load 80mA PS2802 4 OUT V T8303 2 Power Supply 24 Volts DC Figure 4 10 Connecting Outputs in Current Sourcing Mode 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 9 for an example of a current sinking output with diode suppression and Figure 4 10 for an example of a current sourcing output with diode suppression 4 10 www aerotech com Ndrive HP 10 20 30 User s Manual Options 4 1 7 Opto Isolated Inputs TB305 The inputs are configured for 5 24 volt logic using a higher input voltage requires adding external series resistors to limit the current The opto isolator is a PS2506L 4 device The inputs may be connected to current sourcing or current sinking devices as shown in Figure 4 11 and Figure 4 12 Each 4 bit bank of inputs 0 3 or 4 7 must be connected to either all current sourcing or all current sinking devices Also note in the table below that inputs 0 3 an
44. A 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 WARNING Step 2 Select Brake Interface Connector The Normally Open N O contacts of the Brake Relay are accessible through TB301 and the Motor Feedback connector J207 The Normally Closed N C contact of the Brake Relay is only accessible through TB301 Figure 4 4 The Motor Feedback connector J207 allows the brake wires to be included in the motor feedback cable and eliminate the need for a separate brake cable Table 4 5 Brake Relay Connector Pin Assignment TB301 Pin Label Description Inv Relay N C Brake Relay Output Normally Closed Contact Output Relay Com Brake Relay Output Common Contact Output Brake Relay Output Normally Open Contact Relay N O See JP1 A JP1 B Output Table 4 6 Brake Relay Connector Pin Assignment J207 Pin Labe Description In Out _ Brake Relay Output Normally Open Contact Brake Power connection See JP1 A JP1 B Output 4 4 www aerotech com Ndrive HP 10 20 30 User s Manual Options Figure 4 4 is an example of a 24 VDC Brake connected to TB301 In this example JP1 A and JP1 B must be configured If JP1 A and JP1 B are configured to 1 3 then J207 pins 13 and 25 will be unused If JP1 A is set 1 2 and JP1 B is set 3 4 a connection be
45. BASE T Ethernet port MCK NDRIVE Mating connector kit for J206 and J207 J205 is always provided Shunt resistor network Standard on the Ndrive HP 30 Auxiliary 85 240 VAC input to power logic circuitry Required for keep alive AUXPWR or 40 80 VDC bus operation 40 120 VDC operation requires external transformer to generate 28 85 VAC bus power input Heat sink with fins Consult factory for availability www aerotech com 1 5 Introduction 1 6 Ndrive HP 10 20 30 User s Manual Table 1 2 Accessories 115 230 VAC 50 60 Hz input 115 230 VAC 50 60 Hz input VAC output VAC output VAC output AC Line Filter Module required to meet CE Compliance Industrial Joystick AC Line Filter general noise suppression not for CE Compliance www aerotech com Ndrive HP 10 20 30 User s Manual Introduction 1 5 Specifications 1 5 1 Electrical Specifications Table 1 3 Electrical Specifications Description Units NdriveHP 10 Ndrive HP 20 Ndrive HP 30 Output Voltage depends on AC input voltage VDC 40 350 See 2 4 2 Minimum Load Inductance 1 mH 3320 VDC 0 8 160 VDC bus Standard 5 0 2 27 Weight with IOPSO or Ib OPSOH option dici Modes of Operation Brushless Brush and Stepper Hall A Pin 10 Hall B Pin 5 Hall C Pin 11 Hall effect device inputs for commutation 0 to 5 VDC internal pull up 10K input Commutation signals used with brushless motors to provide mo
46. Continuous Output Current 1 5 Control BOSE 6 3 Assemb 6 3 JUI De ES os 6 3 6 4 TOS POI 6 2 Control Board Options 1 5 1 5 1 5 1 5 1 5 Determining Proper Connections to the NDrive 2 16 Device 2 22 1 9 DIPSA I sess 1 3 Drive 1 4 DUALPS O 1 5 Electrical Noise Reduction 2 2 Electrical Specifications 1 7 Electrostatic Coupling 2 3 EMI 2222212 2 2 ENET ocn rei meiden 1 5 4 21 Environmental Specifications RT 1 10 1 10 OPETAN E 1 10 Storage 1 10 Ethernet 204 4 21 Index INDEX 1 Index INDEX 2 Pe D UE 1 1 Feedback Connections 2 10 2 15 2 21 Field Service Information C 1 FireWire 400 0 0 1 2 27 3 21 Card and Cable Part Numbers 2 23 Connector 1 3 2 2 27 3 21 OF
47. D 24 SHIELDED 26 PIN HD MALE 86 26 01259 BACKSHELL 17 1725 2 ECK01022 SEE NOTE 3 FOR CONNECTOR VIEW TERMINAL 52949 00234 TYP 6 PLS ADD BRADY WIRE MARKERS TO TERMINALS HWA32 26HD XX AR Figure 5 6 1 INSTALL LABEL TO BACK OF HANDWHEEL HWA32 26HD XX CABLE LENGTH IN DECIM 6308 1983 2 REV S N XXXXXX 7 XXXXXX WORK ORDER NUM TYPE 4 MIA424 2 CABLE LENGTH CAUTION CABLE LENGTHS XX ARE IN DECIMETERS EXAMPLE HWA32 26HD 30 30 30 DECIMETERS 3 METERS 10FT 3 CONNECTOR VIEW FROM SOLDER SIDE Ndrive HP HANDWHEEL HWA32 26HD XX 630B1983 2 630B1983 201 DWG HWA32 26HD XX Handwheel Interconnection to J205 of the Ndrive A handwheel with flying leads no connector may also be connected to the Ndrive via the Aerotech BBA32 to J205 per the next two drawings 5 10 www aerotech com Ndrive HP 10 20 30 User s Manual F 10 FT OR AR LENGTH 4205 VIA BBA32 HANDWHEEL 5V 12 COM 21 SIN 1 3 SIN N 2 5 11 COS 10 GND SUMTAK LGF 043 100 ECZ00201 100 LINES REV ECX00570 CABLE 8 COND 24 SHIELDED FERRULE 3200014 01001 TYP 7 PLS ADD BRADY WIRE MARKERS TO WIRES TERMINAL 52949 AMP EIK00234 TYP 6 PLS ADD BRADY WIRE MARKERS TO TERMINALS HWA32 FLY XX 6in Figure 5 7 www aerotech com Accessories 1
48. D Comparison UPDATED The four LEDS and the seven segment LED have been replaced by 10 individual LEDs Green LED s indicate active conditions and red LED s indicate faults and errors The auxiliary connector 76 in Rev 0 and called J206 Rev A is now a 26 high density D style connector See Table D 1 for the complete pin out of J205 the Auxiliary connector MOVED The RS 232 and Auxiliary connectors had their physical locations swapped NEW A Power LED and a dedicated optically isolated emergency stop sense input have been added www aerotech com D 1 Rev 0 to Rev A Comparison Ndrive HP 10 20 30 Manual D 2 D 1 Connector Renumbering All connectors and terminal blocks have been renumbered Each 15 a 100 200 or 300 series number within a column The first column is 100 series comprising the AC and motor terminal blocks TB101 and TB102 The second column comprises the FireWire connectors down through the motor feedback connector sequentially numbered from J201 through J207 respectively with the ESTOP connector being TB201 The third column being the connectors on the IOPSO option numbered J301 J303 and TB301 through TB305 top to bottom www aerotech com Ndrive HP 10 20 30 Manual D 2 Option Changes The IOPSO3 and IOPSOA options are obsolete now that the IOPSO outputs may software configured as either sourcing or sinking New Features The pin out of J205 has changed due to a larger co
49. Differential Analog Common 4 Total user 5 V power is limited to 500 mA by an internal re settable fuse 3 1 6 Analog Output 0 J205 The analog output may be programmed to output a signal within the range of 10 through 10 volts DC For analog output technical information see Section 4 1 2 Shown in the Table below are the pins relating to the signals described in this section See Table 3 2 for the mating connector part number Table 3 8 Auxiliary Connector Pin Assignment J205 Pin Label Description Analog 0 Out Analog Output 0 Output Analog Common LEN Total user 5 V power is limited to 500 mA by an internal re settable fuse www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 2 Position Synchronized Output PSO Laser Firing The Ndrive includes a Position Synchronized Output PSO or Laser Firing option This feature may be programmed to generate an output synchronized to axes positions based upon a user defined trigger condition most typically but not limited to firing a laser The Ndrive offers three levels of laser firing single axis std and two and three axis Trigger signals may be derived from the primary encoder channel secondary encoder channel either of the two optional SSI Net ports or a software trigger Both SSI Net ports may provide axes encoder signals or marker signals to from another Ndrive at a maximum of a 20 MHz data rate 50 nsec minimum
50. E AUXPWR OPTION IS USED N 56 gt m WHEN THE MAIN SUPPLY POWER x A IS BELOW 100VAC TYPICALLY 28 56VAC INPUT THIS COREESPONDS TO A BUS VOLTAGE OF 40 80VDC Ov BLU 2 FOR 100VAC PRIMARY INPUT PARALLEL THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED FRAME GROUND SUPPLY 3 FOR 200VAC PRIMARY INPUT SERIES THE 100VAC TAPS AND LEAVE THE 115VAC TAPS OPTIONAL TV0 3 56 WIRING SEMIN TED PRIMARY 115VAC SECONDARY 56VAC 80VDC BUS 4 WHEN USING AN ISOLATION TRANSFORMER P N 01006 TRANSFORMER EARTH GROUNDING OF AC LO INPUT TAP REDUCES ELECTRICAL AND AUDIABLE NOISE EMMISSIONS AND PROVIDES INCREASED SERVO PERFORMANCE Ndrive HP PRIMARY FUSE 3A SLO BLO AUXPWR OPTION T m 5 IT IS RECOMMENDED THAT THE INTERNAL Bandi OPTIONAL AND MAIN SUPPLIES SWITCH 18 WHT Splice AC LO 50 60 HZ ARE TURNED ON AT THE SAME RED56v 145vBLK INPUT TIME TO ENSURE PROPER SOFT SAFTEY START OPERATION 100v ORN B JA YEL 56v rh 6 ADDITIONAL OR ALTERNATIVE FUSING MAY BE REQUIRED FOR OPTIMUM PROTECTION 0v GRAY splice 115v BRN MAIN SUPPLY gt 100v GRN splice FRAME GROUND Ndrive HP AUXPWR INTERCONNECT 80VDC BUS 0 3 56 TV0 3 56 WIRING PRIMARY 230VAC 620B1346 2 SECONDARY 56VAC 80VDC BUS TRANSFORMER P N 01006 620B1346 201 DWG OPTIONAL SUPPLY Figu
51. Encoder _ 255 Load Next Secondary Encoder Configuration FIFO 255 Software Trigger 24 Pulse Skip i Prescaler iu Tracking Distance Trigger Integer Counter Generator Pulse Prescaler Switching Multiplex E 1 3 axes Output Integer Prescaler Tracking PSO Output Enable Invalid Load Next Configuration lt High Speed Connection Input 12 2 High Speed Input 13 Enter Exit Detection Switching Multiplex 2 Trigger Reset Inside Window Switching Count Window Multiplex MM and Enter Exit Dat Detection ium Capture Update 2D Window Array Mode See other Block Diagram Figure 3 5 Advanced 1 3 Axis Firing The Data Capture and Data Update modes allow data to be captured or written to the I O on the occurrence of the internal or external trigger Data Capture mode allows position digital inputs etc to be captured 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 6 For a full description of these modes refer to the Nview HMI help These Capture Update modes share four FIFO s queue s with Window 1 and Window 2 preventing the window firing modes from being used with the Capture Update mode Using a queue from a window precludes using that window 1 or 2 for firing however queues from window 1 may be used for data capture update mode while que
52. Ethernet Connector Pin Assignment J204 4 21 NConnect I O Cable part Numbers 4 21 Resolver Connector Pin Assignment J401 J402 4 22 Resolver Mating Connector 4 22 Resolver Jumper Configuration 4 22 Resolver 02011 4 23 External Power Pin Assignment 403 4 23 Standard Interconnection Cables 5 1 Combined Motor amp Feedback 5 2 Individual Motor Cables 5 3 Individual Feedback 5 4 Amplifier Faults Causes and Solutions 6 2 Ndrive HP Control Board Test Points 6 2 Ndrive HP Control Board Jumper Selections 6 4 Ndrive HP Power Board Jumper Selections 6 6 Ndrive HP Power Board Fuse Information 6 6 LED Indicator Description 6 7 JTAG Programming Connector Internal P10 6 8 Fuse Replacement Part Numbers Ndrive Control Board 6 9 Fuse Replacement Part Numbers Ndrive Power Board 6 9 Battery Replacement Part
53. I Net interfaces 15 a two channel bidirectional RS 422 interface most typically for quadrature encoders This allows one channel for the sine signal and one channel for the cosine signal Alternatively one of the SSI Net interfaces may be used to provide an encoder marker signal to another SSI Net interface 1f used Each of these two SSI Net interfaces are both available on the J302 and J303 connectors as illustrated in the following table Note that the J205 encoder channel may also be used as an input output for multi axis PSO firing The SSI Net is designed for daisy chaining encoder signals from one Ndrive to another for two three axis PSO laser firing This allows one Ndrive containing the DUALPSO or TRIPLEPSO options to track the vectorial position change of two three axes in real time These encoder signals may also be used for user defined purposes Refer to Figure 4 16 and Figure 4 17 These four channels are bi directional and configured via the PsoSsilConfig and PsoSsi2Config axis parameters see the Nview help for more information Note that SSI Net 1 is also available on the J301 connector see Section 4 1 8 The signals from these ports will be the same as the differential line driver encoder signal input to the Ndrive unless the MXH option is present The signal output when the MXH option is present will be of a pulse width determined by the MXH clock frequency as indicated in Table Table 3 17 The SSI Net 1 and 2 inter
54. INTERLOCK b SHIELD P E FOLD BACK FOIL SHIELD lt SUCH THAT THE SILVER PART IS OUTSIDE 26 HD MALE K86 AA 26P ECK01259 15 LINE FEMALE D FOLD BACK amp TWIST BACKSHELL 17 1725 2 ECK01022 745493 2 ECK00783 SIRE TO BIN v SEE NOTE 3 FOR CONN CTOR VIEW BACKSHELL 17 1725 2 01022 E REQUIRED COVER JACKSOCKETS 207719 3 ECK00129 2 CABLE LENGTH Ndrive HP JOYSTICK CAUTION CABLE LENGTHS XX ARE IN DECIMETERS EXAMPLE C19792 30 30 30 DECIMETERS 3 METERS 10FT EXIEN 5 JSXT 26HD XX 3 CONNECTOR VIEW FROM SOLDER SIDE UD m qose 6 3 0 1 7 _ 2 630B1979 201 DWG Figure 5 2 Single Axis Joystick Interface to J205 of the Ndrive 5 6 www aerotech com Ndrive HP 10 20 30 User s Manual Accessories Ndrive HP NOTES JOYSTICK INTERFACE 1 USING C19792 XX CABLE WILL ONLY PROVIDE 1 AXIS OF SLEWING REQUIRES Ndrive HP TO HAVE REV A CONTROL BOARD 2 THE JI JOYSTICK MUST BE USED WITH THE Ndrive HP JBV OR JP4 JOYSTICK VERSIONS ARE NOT COMPATIBLE C19792 XX n JOYSTICK EXT J205 24 o o U X 2 Ndrive HP JOYSTICK 19792 CABLE JOYSTICK 620B1345 2 620B1345 201 DWG Figure 5 3 Single Axis Joystick Interconnect to J205 of the Ndrive www aerotech com 5 Accessori
55. List of Figures Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 4 19 Figure 4 20 Figure 4 21 Figure 4 22 Figure 4 23 Figure 4 24 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Figure 6 1 Figure 6 2 Figure D 1 Figure D 2 Ndrive HP 10 20 30 User s Manual Analog Output Connector 4 3 Brake Connected to 4 5 Brake Connected to J207 4 5 Suppression for DC Brake 4 6 Suppression for AC and DC Brake Systems 4 7 Optional Analog Input Connector TB302 4 8 Connecting Outputs in Current Sinking Mode 4 10 Connecting Outputs in Current Sourcing Mode 4 10 Inputs Connected in Current Sinking Mode 4 11 Inputs Connected in Current Sourcing Mode 4 12 Absolute Encoder Interface 01 4 14 PSO Interface 4 15 RS 485 Absolute Encoder Interface J301
56. Ndrive HP 10 20 30 USER S MANUAL P N EDU170 Revision 1 14 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 ph 412 963 7470 fax 412 963 7459 AEROTECH www aerotech com Product Registration Technical Support Revision History Register online at http www aerotech com prodreg cfm United States Phone 412 967 6440 Fax 412 967 6870 Email service aerotech com United Kingdom Phone 44 118 9409400 Fax 44 118 9409401 Email service aerotech co uk Germany Phone 49 911 9679370 Fax 49 911 96793720 Email service aerotechgmbh de Revision 1 00 April 23 2002 Revision 1 01 May 13 2002 Revision 1 02 September 3 2002 Revision 1 03 November 26 2002 Revision 1 04 February 25 2003 Revision 1 05 July 22 2003 Revision 1 06 December 5 2003 Revision 1 07 January 26 2004 Revision 1 08 May 25 2004 Revision 1 09 July 22 2004 Revision 1 10 September 22 2004 Revision 1 11 August 24 2005 Revision 1 12 November 11 2005 Revision 1 13 January 5 2006 Revisoin 1 14 October 2 2006 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2005 2006 Ndrive HP 10 20 30 User s Manual Table of Contents TABLE OF CONTENTS DECLARATION OF CONFORMITY xi CHAPTER 1 INTRODUCTION 1 1 do
57. Number Ndrive HP Control BOANA 6 9 Preventative Maintenance 6 10 Current Technical 04 21 C 1 Technical Change 24 00212 C 2 J205 Auxiliary Connector Pin Assignments D 4 VV www aerotech com Ndrive HP 10 20 30 Manual Regulatory Information DECLARATION OF CONFORMITY Manufacturer s Name Aerotech Inc and Address 101 Zeta Drive Pittsburgh PA 15238 2897 Declares that the product Ndrive HP 10 20 30 Conforms to the following product specifications with the exceptions listed below EMC EN 61800 3 1997 EMC requirements for power drives EN 61326 1 1997 EMC requirements for laboratory equipment EN 55011 1998 RFI Limits and Measurement EN 61000 3 2 1995 Harmonic Current Emissions EN 61000 3 3 1995 Voltage Fluctuation and Flicker EN 61000 4 2 1995 ESD Immunity EN 61000 4 3 1995 Radiated RFI EMI Immunity EN 61000 4 4 1995 EFT Burst Immunity EN 61000 4 5 1995 Surge Immunity EN 61000 4 6 1995 Conducted Immunity 61000 4 11 1995 Voltage Dips and Interruptions Safety EN 61010 1 2001 Safety Requirements Use This product is intended for light industrial manufacturing or laboratory use and complies with EMC directive 89 336 EEC and 73 23 EEC low voltage directive Exceptions to the test standards include ESD Immunity testing pe
58. P Control board the IOPSO option board and jumper configurations are listed 1n Chapter 3 S2 defines the Ndrive HP communication channel number and is the only user configurable switch jumper on the control board see Section 2 8 78201 O J203 J202 J201 Figure 6 1 Ndrive HP Control Board Assembly 690D1577 Rev A www aerotech com 6 3 Troubleshooting Ndrive HP 10 20 30 Manual Table 6 3 Ndrive HP Control Board Jumper Selections Jumpers Position Function P JP2 JP3 pii All out JP5 n Out JP6A Signal Common isolated from Frame Ground Chassis Signal Common connected to Frame Ground Chassis Auxiliary Encoder Channel 2 is an input Auxiliary Encoder Channel 2 is an output 100 Ohm Terminator present for RS 485 port on J301 100 Ohm Terminator not present for RS 485 port on J301 In for 100 Terminator on RS 422 Port 2 J301 J302 J303 In for 100 Terminator on RS 422 Port 1 J301 J302 J303 In for 100 Terminator on RS 422 Port 3 J302 J303 In for 100 Terminator on RS 422 Port 4 J302 J303 Watch Dog Timer Enabled Watch Dog Timer Disabled indicates factory default setting 6 4 owitch 51 is for factory use only and should not be changed by the user www aerotech com Ndrive HP 10 20 30 Manual Troubleshooting 6 4 Ndrive HP Power Board Assembly Figure 6 2 highlights the important components located on the power board assembly Table 6 4 lists the jumpers and th
59. TB305 3 is input 0 Input 0 at TB305 3 drives the external Reset Input PSO Laser Firing Output is Active High PSO Laser Firing Output is Active Low factory default setting www aerotech com 4 1 Ndrive HP Options Ndrive HP 10 20 30 User s Manual The IOPSOH expansion board has 8 opto isolated inputs sinking or sourcing and 8 outputs sinking or sourcing rated at 1 A per channel two 18 bit analog outputs two 16 bit differential analog inputs SSI Net absolute encoder interface and brake relay and includes a HCPL2601 opto isolator TOP VIEW Figure 4 2 IOPSOH Option Board 69001623 Rev 0 Table 4 2 OPSOH Output Device Numbers Output Desinator Description Aerotech PIN 3dPartyPIN 4 1 1 Brake Configuration Jumpers Setting to 1 2 3 4 allows connection of the brake relay to pins 13 and 25 of the motor feedback connector J207 See Figure 4 4 in section 4 1 2 for more information 4 2 www aerotech com Ndrive HP 10 20 30 User s Manual Options 4 1 2 Analog Outputs TB301 Both analog outputs are driven by an 18 bit AD1868 digital to analog converter and buffered by TL084 op amps producing a single ended output voltage in the range of 10 volts This produces a resolution of 76 3 uVolts per bit of the D A The output current is limited to less than 50 mA Note that the analog outputs are referenced to TB302 1 as shown in Fi
60. UT NOTES AUXPWR option can be used when the main supply Bus Power must be removed during emergency stop condition while Logic Encoder power must be maintained When the Main Power is reapplied the Soft Start function of the Ndrive is last Therefore current inrush limiting is recommended Negative temperature coefficient thermistors are used for this purpose Thermistors are to be placed in the AC HI and AC LO lines as shown Recommended Model is P N SL321 R030 AEROTECH 01004 A It is also recommended that the Emergency Stop circuit be tied to one of the Mdrive inputs Through parameters this input can be configured to perform an intelligent shutdown to prevent the axis from jerking when the main supply is re applied NDRIVE AUXPWR OPTION NDRIVE Rev 0 AUXPWR INTERCONNECT E STOP Drawing 620B1346 4 REV S ce oe Figure D 2 Typical Emergency Stop Circuit Rev 0 www aerotech com D 5 Rev 0 to Rev A Comparison Ndrive HP 10 20 30 Manual D 6 www aerotech com Ndrive HP 10 20 30 Manual INDEX 1 10 100BASE T 1 5 4 21 2 20 kHz Switching Rate 2 2 3 3P 000 1 5 4 40 80 VDC Power Transformer 2 6 LUE 4 14 5 50 60 Hz Torque 2 3 6 Eso 4 14
61. able 4500mm 15 ft www aerotech com 4 21 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 4 RDP Resolver Input The optional resolver input provides two industry standard resolver or Inductosyn channels which may each be used as a feedback device Each may be separately configured for resolver or inductosyn input as shown in Table 4 21 The standard reference output frequency is 10 kHz optionally it may be configured as 5 or 7 5 kHz at the factory The Sine and Cosine feedback signals should be adjusted for 2 volts RMS 2 8 volts Peak via the CfgFbkRDGain axis parameter The resolver can be physically aligned to the motor by using the MSET CNC programming command This physical relationship may also be defined via the CfgMotOffsetAng axis parameter of which is described in Section 4 4 1 See the Nview help for information on configuring the axis parameters for an axis with resolver feedback Table 4 19 Resolver Connector Pin Assignment J401 J402 Pins Label Description NA 1 2 3 Note that the following mating connector is always provided with the resolver option which may be ordered separately as part number MCK 15HDD Table 4 20 Resolver Mating Connector 15 Pin male D style con Third Party Source ECK01287 Amphenol 17HD 015P AA000 Back shell ECK01021 Amphenol 17 1724 2 Table 4 21 Resolver Jumper Configuration Inductosyn JP1 1 2 Chann
62. ame and shield connect to B ground Input power to the Ndrive is made at the ACI and AC2 terminals with earth ground connected to ground A three phase power input is also available requires 3 Phase Option Connections at ACI AC2 and AC3 and its Protective Ground should be made with 1 62814 mm 14 AWG wire rated at 300V Twist HI BUS 240 VAC LO Optional 3d phase input Ground AC1 require external fuses or circuit breaker 15 amps max time delay Figure 2 4 Bus Power Table 2 3 TB102 Main AC Power Input and Motor Power Output Label Descipion AC 2 External fuses or circuit breaker 15 Amps time delay type are required for the AC 1 AC2 and AC3 AC inputs for optimum protection The protective devices should be located near the Ndrive HP For optimum protection use 12 Amp protective devices if possible 15 Amp devices may be required in applications requiring maximum power www aerotech com 2 5 Installation and Configuration Ndrive HP 10 20 30 Manual 2 3 3 40 80 VDC Power Transformers The 0 3 56 power transformer is an optional accessory for the Ndrive HP The transformer allows the generation of 56 VAC from a 115 VAC and 230 VAC source respectively When rectified by the Ndrive HP 56 VAC yields an 80 VDC power bus The 0 3 28 power transformer is an optional accessory available for the Ndrive HP This tr
63. ansformer allows for the generation of 28 VAC from a 115 VAC or 230 VAC source respectively When rectified by the Ndrive 28 VAC yields a 40 VDC power bus The following three figures illustrate the six combinations available for both AC input voltages and all three DC bus voltages as well as the use of the AUXPWR option and TMS transformer package is also available to power up to four Ndrives providing 300 or 500 watts of power Figure 2 5 and 5 Transformer Options 2 6 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 4 Typical AC Wiring with AUXPWR Option The user may connect an Ndrive to a 115 230 VAC source and generate a 40 80 160 VDC Bus for the motor power The following three figures illustrate the six combinations available for both AC input voltages and all three DC bus voltages as well as the use of the AUXPWR option Ndrive HP PRIMARY FUSE AUXPWR OPTION 4A SLO BLO U OPTIO TRANSFORMER 18 WHT AC HI THERMAL 115VAC SWITCH 18 WHT AC LO 50 60 HZ RED 28v 115v BLK SAFTEY 100v ORN A GRAY 115v BRN 100v GRN A Ov BLU 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 p A YEL 28v 2 FOR 100VAC PRIMARY INPUT FRAME GROUND PARALLEL THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED 3 FOR 200VAC PRIMARY INPUT
64. ask Status2 Task Status3 Task Model Strip Chart NLagic Fault Drive Status Axis Status SMC Firewire Drive Info uantit Pos Fdbk 0000000000000 0000000000000 0000000000000 PAL 0 0 IN NNN I 018 D 0000000000000 e Position Feedback to monitor 0000000000000 Ex vas 0000000000000 Dig encoder position D 0000 0000 0000 0000 Diq On D MOOT Doo guuu DU guuu OO Doo 0000 0000 0000 0000 DigIn 31 16 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Dig Out 31 16 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Analog In 0 0 00000000 0 00000000 0 00000000 Analog In 1 0 00000000 0 00000000 0 00000000 Firewire Err 0 0 0 HARDWARE Enable L L L cw L L L CQ L Hall A Hall B and Hall C signals L Hall L L Hall B L L Hall C L L L s 1 Figure 2 18 Encoder and Hall Signals in the Nstat Utility Program www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 7 End of Travel EOT Limit Input Connections End of Travel EOT Limits are required to define the end of the physical travel They are also used for homing which defines an absolute reference for the user coordinate system EOT Limits are relative to positive motion which 15 defined as clockwise rotary motion or positive linear motor motion Positive or clockwise motion is stopped by the CW or clockwise EOT limit input etc Normally Closed typical or 1207 Enco
65. at no person is exposed to the circuitry 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 DANGER mechanical adjustments www aerotech com 2 1 Installation and Configuration Ndrive HP 10 20 30 Manual 2 2 2 2 Wiring Grounding and Shielding Techniques To reduce electrical noise in the Ndrive the user should observe the motor and input power wiring techniques explained in the following sections suitable for use on a circuit capable of delivering not more than 5 000A 240 Signal shielding is very important and the wiring should be physically isolated from motor AC power and all other power wiring WARNING 2 2 1 Minimizing EMI Interference The Ndrive HPs are high efficiency PWM amplifiers operating at a 20 kHz switching rate This switching rate can generate Electromagnetic Interference EMI into the MHz band To minimize this EMI it 15 recommended that the motor leads be twisted together with the motor cable grounding wire and surrounded with a foil or braided shield 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 coupling exists between the three twisted motor leads and the foil shield of the motor cable This coupli
66. ation 3 22 3 6 1 Parameter Setup and Hardware Configuration 3 23 3 6 2 Saving Parameters to the flash memory on the LEER 3 23 3 6 3 CCF AO Mia Sonat at embodiment 3 24 ORO ee ene epee ree ere 3 24 OPTIONS 4 1 IOPSO and IOPSOH Option Boards 4 1 4 1 1 Brake Configuration Jumpers 4 2 4 1 2 Analog Outputs 1 4 3 4 1 3 Brake Relay 01 2 2 4 4 4 1 4 Analog Inputs 2 4 8 4 1 5 User Power Connector 4 9 4 1 6 Opto lsolated Outputs TB304 4 9 4 1 7 Opto lsolated Inputs 5 4 11 4 1 8 PSO Absolute Encoder Interface J301 4 13 4 1 9 551 Net 2 channels J302 4 16 DUALPSO and TRIPLEPSO Laser Firing Options 4 18 4 2 1 PSO Tracking Rate Configuration 4 19 ENET Ethernet Option 204 4 21 RDP Resolver 4 22 4 4 1 Resolver Inductosyn Setup
67. board will output its analog inputs for SIN COS into the analog input channels of the Encoder Configuration Feedback utility a utility also used to configure the MXH option The values sampled by the analog inputs reflect the peak value of the carrier frequency sine waves used by the Resolver to Digital converter The Position feedback type at present dictates which analog channels are sampled There are two axis parameters which are used to configure the analog feedback from a resolver or inductosyn for optimum performance e CfgFbkRDGain defines the peak amplitude of the reference sine wave to the resolver e CfgFbkRDCosPhase defines the phase delay on the Cosine phase of the dual phase oscillator www aerotech com Options 4 25 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 26 When to use the CfgFbkRDCosPhase axis Parameter The Cosine reference signal can be adjusted from approximately 0 degrees 1 in phase with the SINE reference signal to 180 degrees with a nominal value of 90 degrees This axis parameter is primarily for use with inductosyns which have a nominal phase shift from the reference signal of 90 degrees This value may vary from system to system and therefore can be adjusted to ensure that the alignment of the feedback signals to the reference signal is at its optimum for better performance This signal can also be used to adjust for resolvers that have a large amount of phase lag T
68. cal Details Table 3 17 MXH Option Specifications CfgFbkEncMult Total Applicable only when signals are output via the SSI Net FactorMXH Axis Multiplication Clock Freq Max Input Min Edge Min Pulse Parameter 2 3 T separaron us width us 4 1 Interpolation includes x4 from quadrature i e MXH50 has net interpolation of x200 x50 from MXH and x4 from quadrature 2 Configurable via the CfgFbkEncMultFactorMXH axis parameter from 1 to 512 in increments of 1 0 yielding a multiplication from x4 to x2048 3 Defined by the CfgFbkEncMxhSetup axis parameter for SSI Net use must be limited to 20 MHz for PSO tracking applications 4 Absolute maximum input frequency limited to 200 kHz due to 1 25 MHz sample rate lesser limit applies only when signals are output via the SSI Net www aerotech com 3 17 Technical Details Ndrive HP 10 20 30 User s Manual 1OUF 6 3V gt 10UF 6 3V Marker 47 4 10UF 6 3V Figure 3 10 Optional MXH Analog Encoder Interface J207 3 18 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 4 RS 232 RS 422 Port J206 The RS 232C and RS 422 factory option ports may not be used simultaneously They are one physical port converted to each interface by the appropriate line driver receiver as shown in Figure 3 11 Connecting the RS 232 port to a user s PC requires only a standard 9 pin cable not a null modem Current
69. cal 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 www aerotech com Ndrive HP 10 20 30 Manual Warranty and Field Service APPENDIX B WARRANTY and FIELD SERVICE 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 Laser Products period of one year from date of shipment This warranty covers defects in workmanship and material and is voided for all laser power supplies p
70. claration Conformity 1 14 Chapter 4 Added high current I O Board option Figure 2 9 Figure 2 10 Updated cable wire color combinations Figure 2 11 Figure 2 15 Figure 4 14 aa schematic to show a transistor output device in Table 5 1 Cable interconnection information updated www aerotech com 1 Technical Changes Ndrive HP 10 20 30 Manual Table C 2 Technical Change Archive Section s Affected 143 Fig 4 3 Corrected typo in Brake circuit Section 4 1 3 Added notes to Brake section C 2 www aerotech com Ndrive HP 10 20 30 Manual Rev 0 to Rev A Comparison APPENDIX D REV 0 to REV A COMPARISON The figure below shows the connector and LED changes between Rev 0 and the Rev A REV 0 REV A FA m mn TU LE n 9 zu Re F ME Fi irl 18 4 F AG me xm Aj E DANGER High 1 N JE 1 9 i 11 ES zig esos 3 HJEMR 3 X i i wW tuz TWAS W3154A5 E j e 05901 1353 BOZA2AISON m LLL Rev A was also produced with a black silkscreen Figure D 1 Connector LE
71. 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 Run out is measured as total indicated reading TIR For a rotary stage axis run out 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 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 ina horizontal plane R
72. cosine signals are improperly Motor spins uncontrollably connected See Section 2 5 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 5 for motor phasing information Bus over voltage detected Ndrive HP 10 20 This condition indicates an excessive regeneration condition The Ndrive HP 10 20 requires that a shunt regulator be added to the unit RMS current exceeded run at lower current Amplifier Faults ENABLE Over temperature condition Turn off and let amplifier LED de energizes cool down Provide better ventilation Defective on board power supply Return for repair Brushless motor will not spin Amplifier faults ENABLE LED de energizes when motor decelerates 6 2 Ndrive HP Control Board Test Points The following test point is available on the control board internal to the Ndrive HP The internal power board has no test points Table 6 2 Ndrive HP Control Board Test Points Test Point Function o Signal Common Analog and Digital 6 2 www aerotech com Ndrive HP 10 20 30 Manual Troubleshooting 6 3 Ndrive HP Control Board Assembly Figure 6 1 highlights the important components located on the control board assembly The Ndrive HP is jumper selectable providing the user with quick reconfiguration capability of operating modes Table 6 3 list the jumpers and the default configurations for the Ndrive H
73. d Feature Summary 1 2 1 2 Connection OvervieW 1 3 1 3 Functional 1 4 1 4 Ordering Information 1 5 15 sessi 1 7 1 5 1 Electrical 1 7 1 5 2 Mechanical Specifications 1 8 1 5 3 Environmental Specifications 1 10 CHAPTER 2 INSTALLATION and CONFIGURATION 2 1 2 1 Safety Procedures and Warnings 2 1 2 2 Wiring Grounding and Shielding Techniques 2 2 2 2 1 Minimizing EMI Interference 2 2 2 2 2 Minimizing 50 60 HZ Line Interference 2 3 2 3 Power 2 4 2 3 1 Control Power Connections TB101 2 4 2 3 2 Motor Power Connections TB102 2 5 2 3 3 40 80 VDC Power Transformers 2 6 2 4 Typical AC Wiring with AUXPWR Option 2 7 2 5 Motor and Feedback 2 10 2 5 1 DC Brush Motor Torque Mode Configuration 2 10 2 5 1 1 Brush Motor Phasing
74. d inputs 4 7 have two different common inputs pin and pin 2 respectively See Section 3 3 1 for opto isolated EOT limit inputs Table 4 11 Opto Isolated Input Connector Pin Assignment TB305 Pin Label Description Input 0 Optically Isolated See pin 1 6 input3 Input3 Opticaly solated Seepin1 Input 8 Input 5 Optically Isolated See pin 2 9 Input 6 Optically Isolated See pin 2 Input 7 Optically Isolated See pin 2 5V 5 24 Volts INPUT COMMON INPUT 0 6 2K INPUT 1 52806 4 Figure 4 11 Inputs Connected in Current Sinking Mode www aerotech com 4 11 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 12 5 24 Volts PS2806 4 Figure 4 12 Inputs Connected in Current Sourcing Mode www aerotech com Ndrive HP 10 20 30 User s Manual 4 1 8 PSO Absolute Encoder Interface J301 This connector utilizes the RS 485 port and the analog sine wave encoder channel as an absolute encoder interface The absolute encoder channel accepts a differential analog encoder up to 200 kHz Typically this is a 1 Volt P P signal varying about a 2 5 Volt reference The two RS 422 channels provide buffered and or multiplied MXH encoder signals to the user for laser firing or other purposes Additionally the IOPSO option provides a RS 422 output and an open collector laser firing signal to the user Only one of these
75. d phasing is determined by which motor lead 1s connected to the OA OB and OC motor terminals Motor phasing is unrelated to the direction of motion commanded from within a motion program After correctly phasing the motor you may reverse the motor direction when commanding a positive move from a motion program by negating the sign of the CntsPerMetricUnit CntsPerEnglishUnit CntsPerRotaryUnit axis parameter Be sure to first configure the axis parameters before running the A3200 Programs Samples MsetDebug Pgm See the Getting Started section in the Nview help for configuration information Motor phasing may be determined by two methods The first of which is by actively driving the motor open loop under program control The A3200 Programs Samples MsetDebug Pgm may be used for this purpose The motor phasing is correct when the program causes the motor to move 1 a positive direction as defined in Figure 2 17 Swapping any two motor lead connections will correct a reversed motor rotation The second method is a non powered method whereby the motor is disconnected from the controller and connected in the test configuration as defined in Figure 2 14 This will identify motor and Hall signal leads A B and C These sequences and the generated output motor phase voltages motor output connections OA OB and are shown in Figure 2 14 The voltages generated are made by moving the motor forcer by hand in a positive CW motion di
76. der Channel Normally Open not shown separate switch For full cable drawings refer to your software CD ROM Figure 2 19 End of Travel Limit input Connections FireWire Drivelnfo TaskStatus TaskStatus2 Task Status3 TaskModel StipChat Ethemet Diagnostics Faut DriveStatus AxisStatus SMC ITA HARDWARE En 8 le Figure 2 20 Limit Inputs in the Nstat Utility 2 7 1 End of Travel EOT Limit Phasing If the EOT limits are reversed swap the connections to the CW and CCW inputs at the Ndrive HP J207 connector The level of the EOT limit inputs may be viewed on the Diagnostic tab of the Nstat utility as shown in Figure 2 19 www aerotech com 2 21 Installation and Configuration Ndrive HP 10 20 30 Manual CONFIG DEVICE NUMBER ON 76543210 51 2 22 2 8 Communication Channel Settings Each Ndrive HP must have a unique communication channel number defined by switch S2 It is recommended that they be sequential beginning with the first device number The 1 device as indicated by the switch settings in row 1 of the following table will be configured by the Axis 1 parameters in the Nparam utility Assuming all axes are selected on the Axis menu in Nparam they will be the parameters in the first column The Ndrive configured as Row 2 indicates below will be configured by the axis parameters in column 2 of the Nparam utility etc Information on connecting opti
77. dered to the circuit board Table 6 9 Fuse Replacement Part Numbers Ndrive Power Board TEMERE Third Party Aerotech Littlefuse Ndrive HP 10 EIF00105 5 S B Supply Main 313005 Fusing for Littlefuse ACT VAC Ndrive HP 20 326010 00117 10 A S B Bus Input Littlefuse Ndrive HP 30 326010 00117 10 S B F2 Shunt Option S Littlefuse 00195 2A S B 5 mm p 235002 Littlefuse Control Power Fuse 230 5008 EIF01010 5AS B Raychem Encoder 5 Volt Power RUSBO90 EIF01003 Optional Aux 85 240 VAC Littlefuse F5 Control Power Supply Input 230003S EIF01013 3AS B AC1 F1 and F2 are normal socketed fuses F3 F5 are soldered to the circuit board Disconnect power to Ndrive HP main supply and optional supply before servicing WARNING Table 6 10 Battery Replacement Part Number Ndrive HP Control Board Battery Third Party P N Aerotech P N 3 V Coin Cell Ray O Vac BR1225 ECZ01079 www aerotech com 6 9 Troubleshooting Ndrive HP 10 20 30 Manual 6 8 Preventative Maintenance The Ndrive HP 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 11 lists the recommended checks that should be made during these inspections The Ndrive HP all Aerotech equipment is not to be used in a manner not specified by Aerotech Inc Table 6 11 Preventa
78. e connection is made to the AC input board with a three terminal connector Aerotech Part ZECK00213 provided See Section 2 4 for various typical AC wiring options 101 1s also typically utilized when an emergency stop circuit is present See Section 2 10 for a typical ESTOP sense input wiring configuration The AUXPWR input is an option that 1f present must be powered It is typically used when the AC bus input power is less than 85 VAC at 102 ACI AC2 AC3 101 15 also typically utilized when an emergency stop circuit is present Optional Supply Connections to ALI AL2 and the Protective Ground should be at least 1 02362 mm 18 AWG wire rated 300 V 3 Amp external fusing may be required for AL2 ALI is fused internally at 3 Amps Optional 85 VAC HI Control to LO A C 240 Ground Figure 2 3 AUXPWAR Option Table 2 2 TB101 Auxiliary AC Supply Input when TB102 AC input 85 VAC AL Optional 85 240 VAC Control Power Input 1 02362 mm 18 AWG AL2 Optional 85 240 VAC Control Power Input 1 02362 mm 18 AWG Protective Ground Required for Safety 1 02362 mm 18 AWG 2 4 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 3 2 Motor Power Connections TB102 The three phase motor terminal connections are made at connections A B and C Motor Connections A B C and its Protective Ground should be made with 1 62814 mm 14 AWG wire rated at 300 V Motor fr
79. e original warranty period After Aerotech s examination the buyer shall be notified of the repair cost At such Returned Product time the buyer must issue a valid purchase order to cover the cost of the repair and Non warranty freight or authorize the product s to be shipped back as is at the buyer s expense Determination 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 15 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 Rush Service 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 www aerotech com B 1 Warranty and Field Service Ndrive HP 10 20 30 Manual On site Warranty Repair On site Non warranty Repair Company Address B 2 If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issu
80. eWire D A 2 TB301 DSP RS 232 RS 422 NOTES A secondary 85 250 VAC connection is necessary if the DC bus power is required to operate below 120 VDC AC input below 85 VAC The Shunt Regulator is optional on the Ndrive HP 10 20 Figure 1 3 Functional Diagram www aerotech com Ndrive HP 10 20 30 User s Manual Introduction 1 4 Ordering Information The Ndrive HP is available in three models with continuous power ranging from 1 360 to 4 080 watts A list of these models and the available voltage configurations are shown in Table 1 1 See Table 1 2 for a list of available accessories Table 1 1 Models Options and Voltage Configurations Model Ndrive HP 10B 5 Ndrive HP 20B Ndrive HP 30B S One additional 18 bit analog outputs 10 Volts One additional 16 bit differential analog inputs 10 Volts One fail safe brake or user relay output 8 optically isolated logic inputs 5 24 VDC user defined as current 5 and sourcing or sinking OPSOH Two bi directional RS 422 encoder inputs outputs SSI Net One absolute RS 485 encoder interface for secondary encoder channel Optically isolated laser firing PSO output Eight in out optically isolated current sourcing sinking logic outputs 5 24 VDO rated for 1 ampere on the IOPSOH option Programmable encoder multiplier up to x 2 048 supports PSO laser firing encoder quadrature output 10 100
81. ection is required for proper operation in this mode since the fire wire connection provides positioning and synchronization information to the drive FireWire Position and Synchronization Signals Ndrive Feedback Figure 3 12 Normal Operation The Voltage to Current mode of the Ndrive allows for a connection to a host controller that outputs 10V DC as a torque current command In this mode a connection to the fire wire 1s not required synchronization is performed internally except for parameter configuration Current Command Enable Fault i J205 Analog Digital 1 0 Position Velocity Ndrive Controller Feedback to Controller Figure 3 13 Stand Alone Configuration This mode allows the drive to be used in a general purpose current control mode with older existing control hardware www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 6 1 Parameter Setup and Hardware Configuration Setup for the Voltage to Current mode should be performed using the Automation 3200 SMC This software interface should be used to configure the parameters on the drive The parameters of principal concern are e Current Loop Parameters gains offsets etc e Feedback configurations feedback types channels etc e Commutation Information pole pairs counts per cycle etc e Current Clamp RMS Current Trap These are the parameters that will need to be saved to the flash memory within the Ndrive
82. edback connections are typically very low power connections Wire and connectors used for signal wiring should be rated for at least 30 V and have a current capacity of at least 0 25 Amp Wires and connectors used for low voltage power connections such as 5V should have a current capacity of at least 1 Amp encoder feedback 5V supply may require 0 6 Amps in some applications In some applications especially when there are significant wire distances a larger wire size may be required to reduce the voltage drop that occurs along the wire This increase may be necessary in order to keep the voltage within a specified range at a remote point When signal wiring 1s in close proximity to wiring operating at voltages above 60 Volts the insulation rating of the signal wiring will also need to be rated for the higher voltage Signal wiring should have a voltage rating of at least 300 Volts when in proximity to AC power or motor power wiring Signal shielding is very important and the wiring should be physically isolated from motor AC power and all other power wiring WARNING www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 10 Emergency Stop Sense Input TB201 This input is to be activated by an external fail safe emergency stop circuit It is not intended to be an emergency stop circuit in itself It 1s scaled for an input voltage of 5 24 volts Using a higher input voltage requires adding an external series resi
83. edge separation Single axis tracking is limited to a 20 MHz data rate and multi axis to a 5 MHz tracking rate The PSOTRACK command may be used to scale the encoder input signal to limit the maximum tracking rate The synchronized output pulse 15 solely generated within sophisticated and versatile high speed hardware allowing minimal delays between the trigger condition and the output Single axis PSO laser firing latency is 200 nanoseconds DUALPSO and TRIPLEPSO laser firing latency 1s 275 nanoseconds not including the propagation delay of the output device Refer to Figure 3 4 for a basic single axis block diagram of the PSO capabilities or Figure 3 5 and Figure 3 6 for a more detailed block diagram of the multi axis capabilities that also apply to single axis firing The output may be either an open collector output dedicated PSO output or user output 11 or a differential RS 422 output The opto isolated output is available in three different configurations as shown in Table 3 9 Additionally the PSO options provide Data Capture and Data Update capabilities also shown in Figure 3 5 and Figure 3 6 For programming information refer to the Nview HMI Help Table 3 9 PSO Encoder Signal Sources and Pre Scaling Methods Encoder Signal Max Data Rate Encoder Input Encoder Output Source w o pre scalar pre scalar pre scalar Primary Encoder 32 Mhz PSOTRACK cmd CigFbkEncQuadDivider axis parameter MXH only Secondary Encoder 3
84. eir default configurations for Ndrive HP Power board Figure 6 2 Ndrive HP Power Board Assembly 69001576 Rev A www aerotech com 6 5 Troubleshooting Ndrive HP 10 20 30 Manual Table 6 4 Ndrive HP Power Board Jumper Selections Jumpers Positions m 85 240 VAC Input Power Applied at 102 Out Less than 850 VAC Applied at TB102 85 240 VAC Input Power Applied at TB102 Less than 85 VAC Applied at TB102 1 2 Shunt Option not Present std On Ndrive HP 10 20 Shunt Option Present std On Ndrive HP 30 115 VAC Shunt Option 165VDC Bus 230 VAC Shunt Option 330VDC Bus JP5 Bus under voltage detection enabled Bus under voltage detection disabled JP6 FireWire Bus power source Disable FireWire Bus power source Factory Default JP3 All jumpers are factory configured and should not be changed by the user Table 6 5 Ndrive HP Power Board Fuse Information Description 00004 Supply Main Fusing for L1 VAC Bus Input Shunt Option S 2 A S B mm Control Power Fuse 5 A S B Encoder 5 Volt Power 9A Auto Reset able Optional 115 230 VAC Control Power Supply 3A S B Input F1 and F2 are standard socketed fuses F3 and F5 are soldered to the circuit board See Chapter 5 Troubleshooting for fuse replacement information 6 6 www aerotech com Ndrive HP 10 20 30 Manual Troubleshooting 6 5 LED Indicators The following LEDs are available on each Ndrive HP Full Ndrive HP sta
85. el 1 Default 2 3 Channel 1 JP2 1 2 Channel 2 Default 2 3 Channel 2 4 22 www aerotech com Ndrive HP 10 20 30 User s Manual Table 4 22 Resolver Test Points E Figure 4 20 Resolver Option Assembly 690D1599 Rev 0 Table 4 23 External Power Pin Assignment J403 Pins labe Description M2VDC 12 Volts DC 32 06 2 Volts DC Signal Gommon www aerotech com Options 4 23 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 24 4 4 1 Resolver Inductosyn Setup There are three fundamental steps of configuring the RDP option board e Configuring the Resolver Hardware e Configuring the Resolver s Analog Feedback Signals e Configuring the Commutation Parameters 4 4 1 1 Configuring the Hardware There is a limited amount of hardware configuration capability on the RDP option board Most of which is configured at the factory 1 e must be ordered as a factory option These features include carrier frequency and the number of R D converter channels one or two There are two jumpers located on the RDP board These are used to select the reference signal for the converter chip i e SIN vs COS Jumper JP1 selects the reference for channel 1 and jumper JP2 selects the reference for channel 2 NOTE Typically these jumpers only require being changed when inductosyns are used The SIN reference is a fixed phase signal which is in phase with the reference signal used by the reso
86. ental Feedback Flatness of travel www aerotech com 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 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 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 cu
87. ential 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 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 Glossary of Terms Glossary of Terms Optical Encoder Opto Isolated Orthogonality Overshoot PID Pitch of travel Pitch Error PLC PWM Quadrature Radial Run Out Ramp Time Range RDC Repeatability Resolution A 6 Ndrive HP 10 20 30 Manual 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 perpendicular offset 90 to a second surface or axis Orthogonality specification refers to the error from 90 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 i
88. er limits and brake Motor Encoder Limits Brake Motor Feedback indicates length measured decimeters indicates length measured in feet 5 2 www aerotech com Ndrive HP 10 20 30 User s Manual Accessories Table 5 3 Individual Motor Cables Part N art Number s escription Stage Motor 15805 BL MTR FL 4MS MAX450DM PMCNT yy Obsolete Any brushless motor stage having a 4 pin MS style connector for motor power BM BMS motors with MS option BMxxxE motors C19360 xx BL MTR FL 4DU MAX450DM PMCHPDNT yy Obsolete 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 5130 135 2200 3600 5000 5000WB 20000 Motor Output amp 25000 series ARA125 series ASR1000 1100 amp 2000 series with HPD option ATS1100 H series LMA amp LMAC series Motor Output indicates length measured in decimeters yy indicates length measured in feet www aerotech com 5 3 Accessories Ndrive HP 10 20 30 User s Manual Table 5 4 Individual Feedback Cables art Number s escription Stage Motor C16501 xx BL FB 25DU 25DU MAX120DM C16505 xx BL FB 25DU 25DU MAX240DM BFCMX yy Obsolete Any brushless motor stage having a 25 pin D style connector for encoder limits halls and
89. er Connector Pin Assignments 4 9 TILIL Pr CN 4 14 2 6 TMS 40000020 2 6 Transformer 2 6 Voltage configurations 1 5 TRIPLEPSO erectione 1 5 Troubleshooting sss 6 1 TV0 3 28 power transformer optional 2 6 W TV0 3 56 power transformer optional 2 6 2 1 Two Axis Laser Firing 4 18 Warranty C 1 Typical AC 2 7 Wiring Techniques 2 2 Typical ESTOP Interface 2 26 www aerotech com READER S COMMENTS Ndrive HP User s Manual AEHOTECH P N EDU170 October 2 2006 Please answer the questions below and add any suggestions for improving this document Is the manual Adequate to the subject Well organized Clearly presented Well illustrated 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 Name Title Company Name Address Mail your comments to or Faxto AEROTECH INC Technical Writing Department 101 Zeta Drive 412 967 6870 Pittsburgh PA 15238 U S A
90. er a vectorial change in position of 5 machine steps Internally this 15 squared and the axes positions are internally squared and compared to 25 If they are equal to or greater than 25 a trigger event occurs The comparison occurs at an 8 Mhz rate 125 nano seconds so should the sum of the square of the axes change in position be equal to 9 during a sample period no trigger occurs However on the next sample the sum of the squares of the axes positions could now be equal to 36 A trigger event would now occur 36 is greater than 25 and the remainder 11 16 then stored to be summed with the squared feedback positions during the next sample period The output pulse is also user programmable It may be a single or multiple pulses per trigger event It too is generated in hardware and fed from a 255 level queue allowing trigger events to advance thru the queue varying the output pulse per trigger event The window modes allow firing to occur or be enabled based upon axes being within a user defined window This window may be one or two dimensional 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 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details SSI Net 1 Marker Firing Configuration 551 Net 2 or Distance Encoder FIFO Primary
91. es Ndrive HP 10 20 30 User s Manual A standard Aerotech JI joystick may be connected to the I O on the IOPSO option via the following cable for a two axis joystick Figure 5 4 indicates the required cable and the Figure 5 5 indicates the interconnection of the joystick to the Ndrive TO Ndrive HP TO MN ECX01009 JOYSTICK 16 COND 24 REV A LENGTH SEE NOTE 2 Du E VIO m m N CONNECTOR SHIELDING RD J 7 20 4 B305 4 IN2 S2 WRAP 6 COPPER FOIL EIA281 s LI EE O OVER GROMMET SHIELD amp DRAIN WIRE o f ee in E WIGRN 5 GROMMET SUPPLIED B302 1 AGND W BACKSHELL 4 415 4 COM B302 3 1 E W BRN ii B302 4 A24 6 Y POT St B305 5 IN3 GRY 13 INTERLOCK FOLD BACK FOIL SHIELD SUCH THAT THE SILVER B303 2 GND A PART IS OUTSIDE FERRULE 3200014 01001 TYP 12 PLS 15 LINE FEMALE D FOLD BACK amp TWIST ADD BRADY WIRE MARKERS SEE NOTE 3 745493 2 ECK00783 SHIELD DRAIN WIRE BACKSHELL 17 1725 2 01022 12 COVER JACKSOCKETS 207719 3 ECK00129 SEE NOTE 2 CABLE LENGTH Ndrive HP EXTENSION CABLE CAUTION CABLE LENGTHS XX ARE IN DECIMETERS EXAMPLE C19791 30 30 30 DECIMETERS 3 METERS 10FT J SXT F LY XX 3 WIRE MARKERS FLAG WIRES WITH BRADY LABELS C19791 XX 630 1 979 1 COMPUTER FILE NO 630B1979 1A1 630B1979 1A1 DWG Figure 5 4 Two Axis Joystick Interface
92. es 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 1s 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 V V www aerotech com 10 20 30 Technical Changes APPENDIX TECHNICAL CHANGES Table C 1 Current Technical Changes Version Section s Description Affected Removed MXU option Figure 1 5 Corrected dimensions without I O Board Section 4 1 8 Corrected pin numbers in PSO interface schematic Page xil Declaration of Updated CE de
93. f tracking the axis position at up to a 20 MHz tracking rate 50 nsec minimum edge separation It may be programmed to fire from any available encoder source see Table 3 9 Single axis firing provides one feature not present with the multi axes firing option it allows for directional based firing This means that you may program a firing distances for the positive and negative motion separately Single axis window firing and Capture Update modes may be used with single axis firing limited only by the use of the Windows internal shared queues See Figure 3 4 for a basic single axis block diagram of the PSO capabilities or Figure 3 5 and Figure 3 6 for a more detailed block diagram of the multi axis capabilities that also apply to single axis firing 3 10 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 3 Motor Feedback J207 The 25 pin D style connector contains all of the required feedback inputs for a servo loop This connector has inputs for a 3 channel encoder three limit switches and three Hall effect devices Each of these inputs provides feedback for the DSP microprocessor controlled position velocity and current loops See Section 2 6 1 Encoder Phasing for information on interfacing non Aerotech motors MOTOR FEEDBACK Table 3 11 Motor Feedback Connector Pin Assignment J207 207 Pin Label Description amp In OutBi N A Input Output N A Hall Effect Sensor B Brushless M
94. faces are both physically hardwired to the J302 and J303 connectors If SSI Net 1 is configured as an input a signal driven into the SSI Net 1 connections on J302 will also be present on the SSI Net 1 connections of J303 effectively making SSI Net 1 on J303 an un buffered output of this same signal Likewise this would also be true for the SSI Net 2 interface Table 4 15 J302 J303 2 Channel SSI Net Connector Pin Assignment Pins Label Description inoue _ 3 SSINet 2 Cosine N MarkerN Bi directional 8 Cosine SSI Net 1 Cosine Marker Bi directional www aerotech com Ndrive HP 10 20 30 User s Manual Options 5 5 45V R25 a R26 0 OHM 100 1 S END M58 1 8 o 4 P 2 7 B t LTC1685 V Ree c uo 5422 2 X 100 1 LTC1685 C96 41 55 2 N v 4 5422 3 a C98 R3422 4M 3 Z M n r R 422 4P Figure 4 16 J301 J302 J303 www aerotech com 4 17 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 2 DUALPSO and TRIPLEPSO Laser Firing Options The Ndrive HP allows two and three axis laser firing via its DUALPSO and TRIPLEPSO options To accomplish this
95. g Connector 6 8 Part Numbers FireWire Card and Cables 2 23 Phase Hall Sequence 2 16 Pin Assignments Opto Isolated Input Connector 4 11 PSO Absolute Encoder Interface J301 RH 4 13 SSI Net J302 303 4 16 User Power Connector 4 9 PinAssignments Opto Isolated Output Connector 4 9 Pinouts Analog Output Connector 4 3 Brake Relay Connector 4 4 Optional Analog Input Connector 4 8 qo I ter 1 5 Power Ferd Ende 6 5 conl NEP 6 5 www aerotech com RR ER 6 6 oLa to 6 6 Power Board Options 3P 3 Phase AC Input 1 5 AUXPWR Auxiliary Power 1 5 HS Heat 5 02 22 2 1 5 S 50 1 5 Power Connections 1 3 2 4 Preventative Maintenance 6 10 PSO Absolute Encoder Interface J301 4 13 PSO Absolute Encoder Interface J301 Pin Assignments 4 13 5 1 2202202 nentes 1 5 4 14 PSOOPTOJ2 einen 1 5 4 14 PSOOPTO3 1 5 4 14 20 4 14 R Relay Contact Ratings 4 4 Revision History
96. gure 4 3 Analog output 0 is also available at J205 see Section 3 1 6 The analog outputs will be zero volts during reset Table 4 3 Analog Output Connector Pin Assignment TB301 In Out Bi Analog 0 Out Analog Output O Output Analog 1 Out Analog Output 1 Output The analog output common may be found at J205 pin 23 or TB302 pin 1 1205 22 AMALOGO OUT ANALOGO OUT ANALOGI OUT Figure 4 3 Analog Output Connector TB301 www aerotech com 4 3 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 1 3 Brake Relay TB301 The relay output 1s typically used to automatically drive a fail safe brake on a vertical axis however it may also be used as a 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 Nview HMI help 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 Step 1 Brake Relay Specifications 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 4 Table 4 4 Voltage and Current Specifications TB301 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 V
97. his current a 50 60 Hz disturbance may be visible in the position error 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 2 Use 1 62814 mm 14 AWG 300 V Torque to copper wire rated for at least 80 C 5 7 in Ib 115 230 VAC 50 60 HZ Earth BANGER Ground This configuration is especially important if the Ndrive HP is operating at DC bus voltages of 150 VDC to 340 VDC e g 115 VAC to 230 VAC input power Figure 2 2 Isolation Transformer Connection Eliminates 50 60 Hz AC Coupling www aerotech com Installation and Configuration Ndrive HP 10 20 30 Manual 2 3 Power Connections The Ndrive HP may powered by one or two separate AC voltages One for motor bus power and optionally a second for control power as described in the following two sub sections If the optional control power input is present it must be powered 2 3 1 Control Power Connections TB101 The AUXPWR option allows the Ndrive HP to remain operational when the motor power is removed such as when an external emergency stop circuit is required If the Ndrive HP was purchased with the AUXPWAR option a separate AC input TB101 has been included on the amplifier The internal power supply of the Ndrive HP requires a minimum of 85 VAC input to operate properly The figure below shows the connection to the separate AC power board Th
98. ical direction when the tabletop is oriented in the horizontal plane Axial run out 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 centerline 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 responsiveness of the system command repeatability it is the non load to reversal of input 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 a modem Glossary of Terms Glossary of Terms BCD Bearing Bidirectional Repeatability CAM Profile Cantilevered Load Closed Loop CNC Coefficient of Friction Cogging Commutation Commutation 6 Step Commutation Modified 6 Step Commutation Sinusoidal A 2 A technique used
99. ications Power Supply Output Voltage Current Viaser Sink 5 VDC 10 mA M12 Device Option Nominal Propagation See Figure 4 14 Frequency Delay Typ TIL117 M 5 25 VDC 50 mA PSOOPTO4 option ABS SIN 10 10 5 0822 100PF mr ABS SIN 10K 33PF T 10K mg y ABS COS 10K 100PF 5 AD822 100PF 7 5 ABS COS 10K Figure 4 13 Absolute Encoder Interface J301 4 14 www aerotech com Ndrive HP 10 20 30 User s Manual Options Opto Isoloted Output 11 HS OUT P gt High 74 14 76 PSO IOC RS422 M TO LASER s _ O a Active Low HS OUT M TE303 5 PSO RS422 P 7101 17 gt I I I I i i v 1 Factory Selact See the Aux Marker on 4205 Pins 19 amp 20 261532 p 205 20 261531 220 Figure 4 14 PSO Interface Output 11 and the Auxiliary Marker on J205 pins 19 and 20 may also be defined as the PSO Laser Firing output via the PSOCONTROL command See Section 3 2 for connection and other information 45V 27 5 4 e 2 3 6864MHZ 1 x1 20 5 19 33PF 33PF 16 d 5485 1 58 F a RS485 P M Figure 4 15 RS 485 Absolute Encoder Interface J301 www aerotech com 4 15 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 16 4 1 9 SSI Net 2 channels J302 J303 Each of the two SS
100. ig axis parameter as sourcing or sinking and are driven by a PS2802 4 opto isolator that 15 rated for 40 volts maximum and up to 80 mA channel not to exceed 90 mW per channel Figure 4 9 and Figure 4 10 illustrate how to connect to an output in current sinking and current sourcing modes The connection must always be made to both the Output Common Plus and Output Common Minus to prevent glitches on the outputs see Figure 4 9 and Figure 4 10 Table 4 9 Opto Isolated Output Connector Pin Assignment TB304 Pinf Label Description In Out OP Output Common Plus Input 3 Output 0 Optically Isolated Output 4 1 Output 1 Optically Isolated 5 Outpu2 Output2 Op caly lsolated Output 6 Output3 Output3 Op caly lsoated Output 8 Output5 Output 5 Optically Isolated Output 9 Output Output Opticaly lsolated Output Table 4 10 JOPSO Output Device Specifications TB304 Specification JOPSO Value IOPSOH Value Maximum Power Dissipation 90 mW atts Channel 600 mWatts Channel Maximum Voltage 40 Volt Maximum 24 Volt Maximum SN N gt 250 usec typical 1 msec typical www aerotech com Options 4 9 5114110 Ndrive HP Options Ndrive HP 10 20 30 User s Manual OUT V 80mA _ Diode required for an inductive load OPTO OUTPUT O 304 5 OUTV Power Supply 24 Volts DC PS2
101. ill eventually be added to the ROM s in dwg format also single and dual axis PSO Laser Firing users may now use optically isolated Output 11 as the firing output so the IOPSO option 15 not required Manual for Rev 0 Ndrives have been renamed with Rev 0 in filename and 15 still distributed with all other Aerotech product manuals www aerotech com Rev 0 to Rev A Comparison 1 3 4 6 7 D 3 Rev 0 to Rev A Comparison Ndrive HP 10 20 30 Manual D 4 Table D 1 J205 Auxiliary Connector Pin Assignments Pins Label Description mouwe miz Input 12High Speed Opto 4 mi2 input 12High Speed Opto input miss 13High Speed Opto Inputi3HighSpeedOpto Input ous outputs outo Output outro output 55 OuCom outputCommon P 16 out Output 11 Opt PSO Output Output ar ms 8 ms mpu9 acea Analog Common P 24 incom 2 mi mt mtt Total user 5 V power is limited to 500 mA by an internal resettable fuse 4 6 8 9 _ www aerotech com Ndrive HP 10 20 30 Manual Rev 0 to Rev A Comparison D 3 E Stop Interface for Rev 0 Refer to Chapter 2 Section 2 10 1 for Rev A Ndrive HP NDRIVE AUXPWR OPTION 5 115 230 VAC 50 60 HZ SAFETY INP
102. ion and Configuration Ndrive HP 10 20 30 Manual 2 20 2 6 1 Encoder Phasing Figure 2 17 illustrates the required encoder phasing for clockwise motor rotation or positive forcer movement through the stationary magnet track If the motor is not visible or may not be manually moved by hand it may be actively driven open loop under program control by running the A3200 Programs Samples MsetDebug Pgm program This program will move the motor in a positive direction allowing the position of the encoder to be monitored in the Pos Fdbk field of the Diagnostics tab of the Nstat utility as shown in Figure 2 18 The program should cause the encoder to produce a more positive position as the program executes If it counts more negative swap the connections to the controllers SIN and the SIN N encoder inputs or you may invert the sign of the CfgFbkVelMultiplier and CfgFbkPosMultiplier parameters However if this axis 1 configured for dual loop two feedback devices one for position and one for velocity feedback invert the sign of only the one parameter associated with the incorrectly phased feedback device Lf oL LINEAR MOTOR cos tiari Positive MOVE COS N d E Clockwise a Ld SIN N F4 ROTARY MOTOR MKR d MIN dl p Motor Shaft Positive MOVE Clockwise 0 Motor Mounting Flange Front View CW Rotation Positive Direction Figure 2 17 Encoder Phasing Reference Diagram Nee IL T
103. ion and or snubber components are needed to reduce arcing and prevent damage to the Brake Relay contacts Suppression can also reduce the electrical noise that is emitted when the circuit is switched off Following are three suppression circuit examples Example 71 Example 2 Figure 4 4 15 an example of a typical 24 VDC brake circuit In this example the Varistor is the suppression device connected across the brake This method of suppression is used in circuits operating at voltages up to 25 VDC and AC circuits operating at voltages up to 18 VAC If the voltage is greater than 25 VDC or 18 VAC one of the other suppression methods should be used Figure 4 6 is an example of a suppression circuit that can be used for systems using a DC supply In this example the diode 1s the suppression component which is connected across the brake It is important that the diode be installed so that it 15 normally reversed biased This diode must have a reverse voltage rating greater than the users DC power supply and a maximum current rating of at least 1 Ampere Due to the time needed for this suppression device to dissipate the energy released by the load inductance there may be a slight delay less than 1 second before the brake responds to its power being switched off If this delay is unacceptable Example 3 should be used RELAY NC IB301 3 RELA Y COMMON TB301 4 t TB301 5 JP1 A 230265 1
104. l user 5 V power is limited to 500 mA by an internal re settable fuse 3 2 www aerotech com Ndrive HP 10 20 30 User s Manual Hem 05 15 AUX cos AUXZCOS ji qp05 1 AUX SIN di SIN AUK uns emen qui EE RC Encoder Fault Detection Figure 3 1 Secondary Encoder Channel J205 www aerotech com Technical Details 33 Es e ma en an 3 3 Technical Details Ndrive HP 10 20 30 User s Manual 3 1 2 User Outputs 8 11 J205 All outputs Figure 3 2 are rated for 40 volts and 80 mAmps per channel Power dissipation may not exceed 90 mWatts per channel Output 11 shown in the following Figure may be defined as a low speed PSO Laser Firing output however it is only rated for a maximum output frequency of 1 kHz with a typical propagation delay of 250 us The auxiliary marker output on pins 19 and 20 of AUX I O J205 may be opto isolated by the user and software configured as the PSO output via the 1205 EncoderDivider axis parameter and the PSOCONTROL command see the Nview help for more information See Section 3 2 for more information on the PSO option See Table 3 2 for the mating connector part number Table 3 4 User Outputs Pin Assignment on Connector J205 Pinf Label Description 8 Ouwo Output Output 9 40 jOupuiO Output 5 Volt 5 Volt
105. lBi CW Lmt Clockwise End of travel limit 5 Volt 5 Volt Power for Limit Switches 500mA max Output Signal Common for Limit Switches Home Switch Input CCW Lmt Counterclockwise End of travel limit Total user 5 V power is limited to 500 mA by an internal re settable fuse 5V 10K TAACTM gt HMLMT BUF m T4ACTI4 Figure 3 7 End of Travel Limit Inputs 3 12 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 3 2 Hall Effect and Thermistor Inputs The Hall effect switch inputs are highly recommended for AC brushless motor commutation but not absolutely required see the Nview help for more information on axis configuration The Hall effect inputs accept 5 24 volt DC logic signals The Pin Assignment for the connector is shown in the table below The thermistor input 15 used to detect an over temperature condition in a motor via 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 FEEDBACK i i 1207 resistance of the thermistor is low 1 100 ohms This will be seen as low input signal After the temperature causes the thermistor s resistance to increase above IK ohms the signal will be seen as a logic high triggering an over temperature fault See Table 3 12 for the mating connector part number Table 3 14 Hall Effect Inputs
106. lasma 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 15 also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or concealed must be filed with the carrier by the Return Procedure buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty without first obtaining approval from Aerotech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product 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 Returned Product upon Aerotech s examination a warranted defect exists then the product s will be Warranty repaired at no charge and shipped prepaid back to the buyer If the buyer desires an Determination airfreight return the product s will be shipped collect Warranty repairs do not extend th
107. lver The COS reference is a variable phase signal which may be phased shifted with respect to the reference of the resolver inductosyn to optimize the alignment of the feedback required for inductosyns which nominally provide a 90 degree phase shift on feedback optional for resolvers with significant phase loss The default phase offset 15 90 degrees For most inductosyns this value will need to be varied from system to system to optimize performance See Figure 4 22 below for example phasing Note that some Aerotech systems may have an optional pre amplifier board This may be installed within the mechanics itself as is the case with an Aerotech AOM360D optical mount If so the first step is to adjust the P1 potentiometer on the pre amplifier board to equalize the Sine and Cosine feedback signals to the same amplitude www aerotech com Ndrive HP 10 20 30 User s Manual Resolver Reference SIN Reference COS Reference Figure 4 21 Analog Output Connector TB301 4 4 1 2 Configuring the Analog Feedback Signals Using the Encoder Feedback Configuration Utility to set up a resolver inductosyn The RDP option of the Ndrive can be optimally aligned quickly using the Encoder Feedback Configuration utility within the Nscope exe utility When the Ndrive is configured for Resolver Feedback via the CfgFbkPosType axis parameter then the currently selected channel 1 or 2 defined via the CfgFbkPosChan axis parameter of the RDP
108. ly the RS 232C port serves only a secondary means to upgrade the firmware in the Ndrive which is done primarily through the FireWire port Table 3 18 J206 RS 232 RS 422 Connector Pin Assignment Pin Label Description 7 2 RS232TXD RS232TransmiOutpt Output 3 RS232RXD RS232Recevelnpt Input 4 RS422TXD RS 422 Transmit Output Output 6 RS422TXD RS 422 Transmit Output Output 8 RS422RXD RS 422 Receive Input Input 9 5Vot 5 Volt Power Output Output Total user 5 V power is limited to 500 mA by an internal re settable fuse Table 3 19 RS 232 RS 422 Port Connector Mating Connector J206 9 Pin D style Connector Third Party Source ECK00137 Cinch DE 9P Back shell ECK01021 Amphenol 17 1724 2 www aerotech com 3 19 Technical Details Ndrive HP 10 20 30 User s Manual 45V 16 3 2 5 1 gt 14 gt RS232TXD J z Mii 5 3 5V V RS422RXD rap RS422RXD RS422TXD RS422TXD ra F S Figure 3 11 RS 232 RS 422 Connector J206 3 20 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 5 FireWire Bus J201 J202 J203 The FireWire bus is the high speed communications media to the Ndrive operating at 400 megabits per second All command and configuration information is sent via the FireWire three ports are effectively in parallel allowing any port to be used when daisy chaining the Ndri
109. mplifier board 1f present may need adjusted www aerotech com Ndrive HP 10 20 30 User s Manual Options Figure 4 22 Resolver Located at Maximum of SIN Signal Figure 4 23 Rotating the Resolver to see a circle www aerotech com 4 27 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 28 Task 3 For this to function you MUST have the proper jumper set to 2 3 for this channel and the bit in the CfgFbkRDConfig axis parameter set to 1 Otherwise erratic results may occur Adjusting the gain of the R D converter Once the phase is adjusted for optimum conversion for inductosyns adjust the CfgFbkRDGain axis parameter until you see the analog signals peaking between approximately 5 000 on the low end and 60 500 on the high end counts This axis parameter can be adjusted via the Ndebug exe utility These numbers equate to approximately 0 38 to 4 62 volts on zero to 5 volt scale or 8 48 volts on a 10V scale 1 via the Nstat exe utility depending upon where you measure the signals This nominally provides 2V RMS 2 83 volts peak to the converter chip on the RDP option board which is required for optimum operation See Figure 4 24 below for an example of an optimum circle Encoder Feedback Configuration Plot Trigger Graph Options Tools Move Tuning Help Sine Gain 50 e Offset 128 eoe Gain 50 ese Offset 128 mes 128
110. n 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 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 Ndrive HP 10 20 30 Manual Life Limit Switch Limits Linear Motor Load Carrying Capability Master Slave Motion Profile Motor Brush Motor Brushless Motor Stepping NC NO NEMA Non Volatile Memory Open Collector Open Loop Operator Interface www aerotech com 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 s
111. n occur the device will open to protect against the overload To reset the device remove the overload condition Please note that the inputs and outputs on the Auxiliary connector J205 begin with number 8 as shown in Table 3 1 Inputs and outputs 0 7 are present on the optional IOPSO card AUX I O 1205 3 1 1 Secondary Encoder Channel J205 The encoder channel can be used as an input for master slave operation handwheel or for dual feedback systems or for an encoder input output for multi axis laser firing see Chap 4 for more information The EncoderDivider axis parameter configures the input output state of this encoder channel This interface may not be multiplied by the MXH option and must be a 5 volt RS 422 line driver encoder It allows up to an 8 MHz encoder signal 31 nsec minimum edge separation producing 32 million counts per second after times four x4 quadrature decoding See Table 3 2 for the mating connector part number The Auxiliary Marker output has a 0 02 us propagation delay typical when used as the PSO firing output Table 3 3 Auxiliary Encoder Pin Assignment on Connector J205 Pin Label Description 5 Volt 5 Volt 500mA max Output 19 Auxiliary Marker Secondary RS 422 Channel Mrk Bidirectional PSO out 20 Auxiliary Marker Secondary RS 422 Channel Mrk Bidirectional PSO out Common 5 Volt Common 5 Volt User Supply Tota
112. nductive pollution Use Indoor use only 1 10 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration CHAPTER 2 INSTALLATION and CONFIGURATION This section covers the hardware configurations using the switches jumpers connectors and power connections when used with a brush brushless or stepper motor Wiring grounding shielding techniques and the motor phasing process are also covered Aside from the obvious requirements of AC input and motor wiring the only other typical requirement is to set the Ndrive HPs communication channel number via switch S2 2 1 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 WARNING damage to the equipment or machinery To minimize the possibility of electrical shock and bodily injury ensure that the motor is decoupled from the mechanical system and no harm to personnel will result if WARNING the motor begins to spin To minimize the possibility of electrical shock and bodily injury when any electrical circuit is in use ensure th
113. ng 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 connect the shield to earth ground 2 Usea cable with sufficient insulation This will reduce the capacitive coupling between the leads that in turn reduces the current generated in the shield wire 3 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 4 If possible do not route motor cables near cables carrying logic signals and use shielded cable to carry logic signals 5 Ferrite beads or Aerotech s FBF 1 or FBF 2 filter adapters may be used on the motor leads to reduce the effects of amplifier EMI RFI produced by PWM pulse width modulation amplifiers Refer to the FBF 1 and FBF 2 drawings on your software or documentation CD ROM for more information on the ferrite beads Table 2 1 Ferrite Bead Part Numbers Aerotech PN Third Party PN 1 62814mm 14 AWG 201027 82643002402 Elna Fair Rite Products 1 29032mm 16 AWG EIZ01025 2643250402 Elna Fair Rite Products 1 02362mm 18 AWG EIZO1001 2673000801 Elna Fair Rite Products 0 81280mm 20 AWG 1401025 2643250402 Fair Rite Products www aero
114. nnector being added summaries of the changes follow see Table D 1 for the complete pin out There are now 4 optically isolated user current sinking outputs standard on J205 They are set as OUTS8 through OUT11 This implies that they are outputs 8 through 11 Outputs 0 7 are on the IOPSO option There are now 6 optically isolated user inputs standard 2 of which are high speed user configurable as sourcing or sinking on J205 They are read as IN8 13 This implies that they are inputs 8 through 13 Inputs 0 7 are on the IOPSO option A motor over temperature thermistor input was added at J207 pin 2 One of the two analog outputs 15 now available standard on J205 as well as TB301 of the IOPSO option One of the two analog inputs is now available standard on J205 as well as TB302 of the IOPSO option User digital inputs on the IOPSO options now have two input commons one for each set of four inputs at TB305 They are pins 1 and 2 as shown the margin The auxiliary encoder secondary feedback may now be configured as an output to prevent the user from having to purchase an IOPSO option for two axis laser firing jumper selectable via JP2 4 This allows it to drive another axis auxiliary encoder channel for dual axis firing on J206 A dedicated optically isolated emergency stop sense input on 201 Joystick handwheel and typical ESTOP usage now supported and documented in the manual for Rev A Ndrives These w
115. nput 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 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 run out 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 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
116. oder signal 31 nsec minimum edge separation producing 32 million counts per second after times four x4 quadrature decoding An analog encoder is used with the MXH option see Figure 3 10 for more information MOTOR FEEDBACK J207 Encoder Fault Detection 7 DS26LV32AT 4 7K Figure 3 9 Line Driver Encoder Interface Standard J207 The Ndrive HP is factory configured for either a square wave differential encoder default OR an analog encoder MXH option www aerotech com 3 15 Technical Details MXH Erase Cycle LIMIT LMT FAULT RMS POS ERR CLMT ENABLE INPOS KERNEL ACTV J MXH Programming Cycle LMT FAULT RMS POSERR CLMT ENABLE INPOS KERNEL ACTV J alternate flashing pattern FAULT POS ERR ENABLE KERNEL 3 16 Ndrive HP 10 20 30 User s Manual 3 3 4 2 MXH Option The MXH encoder input options are defined for a differential analog encoder in the range of 0 to 5 volts The maximum encoder input frequency 15 limited to 200 kHz or less if the encoder signals are to be output via the SSI Net see Table 3 17 The MXH multiplies the resolution up to 512 times in addition to the controller s x4 multiplication providing a maximum of x 2048 multiplication 8 388607 GHz effective data rate as shown in the first two columns of Table 3 17 The MXH multiplication factor is determined by the CfgFbkEncMultFactorMXH axis parameter
117. of 0 1 as shown below This must be done when using DUALPSO or TRIPLEPSO options in order to ensure that encoder count information 15 not lost The 20 MHz data rate limitation effectively limits the maximum speed of the axis see B below In addition the DUALPSO or TRIPLEPSO options have a maximum tracking rate of 5 MHz due to hardware limitations The PSO data rate can be reduced to 5 MHz while allowing the servo loop to operate at 20 MHz by using the following PSOTRACK lt axis gt SCALE 4 4 4 command This command divides the encoder signals before the PSO counters by a factor of 4 and therefore limits the frequency seen by the PSO tracking counters to 5 MHz However the servo loop is still able to run at the full 20 MHz rate The effective PSO programming resolution is now 1 4 that of the servo loop full resolution PSODISTANCE commands should be entered 4 times lower than the full resolution in this case Ndrive HP Ndrive HP with DUALPSO or TRIPLEPSO MXH Auxiliary Auxiliary Encoder 20 MHz Encoder Maximum Encoder Divide by Counter CfgFbkEncMxhQuadDiv lo axis parameter 32 MHz Maximum Encoder PSO Counter Pre Scalar 1 DUALPSO TRIPLEPSO Pre Scalar 2 5 MHx max or Pre Scalar 3 SINGLEPSO J max Figure 4 18 PSO Tracking Rate Block Diagram www aerotech com 4 19 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 20 Example It is desired to generate a
118. ogram by negating the sign of the CntsPerMetricUnit CntsPerEnglishUnit CntsPerRotaryUnit axis parameter 2 18 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 6 Encoder Feedback Connections One encoder feedback device must always be used for all motor types except for stepper motors Each of the two encoder channels in the Ndrive HP accept a differential line driver encoder DC Brush and brushless motors may have a separate position and a velocity feedback device An analog sine wave encoder may be used with Aerotech s MXH multiplier box to multiply the encoder resolution and simultaneously convert it to a differential line driver encoder signal acceptable by the Ndrive HP Signal shielding is very important and the wiring should be physically isolated from motor AC power and all other power wiring J207 Primary Encoder Channel Encoder with MXH Multiplier Encoder 5 Encoder Com Chassis Frame Primary Feedback Sin Sin N L Line Driver Cos EN Encoder with Cos N Hall Feedback 7 H 3 i Analog Sine Wave Optional J205 Secondary Encoder Channel Optional Secondary Feedback n p gt Line Driver mode Encouer Mkr Analog Sine Wave Mkr N with MXH 5 Multiplier Com Chassis Frame For full cable drawings refer to your software CD ROM Figure 2 16 Encoder Feedback Connections www aerotech com 2 19 Installat
119. ons Ndrive HP Figure 2 14 Motor Phasing www aerotech com 2 1 Installation and Configuration Ndrive HP 10 20 30 Manual 2 5 4 Stepper Motor Configuration This mode is used with a stepper motor only See Section 2 6 1 if Aerotech s standard cabling is not used for information on correctly phasing the motor feedback devices 240 Consult the drawing located on your software CD for 50 60Hz specific cable information 15 pce 1 2 Frame A 2 C RI m Wire Color Set 1 Wire Color Set 2 Green Yellow amp Shield Green Yellow amp Shield Note the connection of the two motor phases B Red White Red NOTES amp Red amp Orange implies two wires f Green White implies a single wire Figure 2 15 Stepper Motor Configuration 2 5 4 1 Stepper Motor Phasing Process A stepper motor 15 phased correctly when a positive motion command causes the motor to rotate in a clockwise direction assuming a positive scaling factor as determined by the CntsPerMetricUnit CntsPerEnglishUnit CntsPerRotaryUnit axis parameter To correct the phasing reverse the connections to the and 0B terminals on the Ndrive HP This is important because the end of travel EOT limit inputs are relative to motor rotation After correctly phasing the motor you may reverse the motor direction when commanding a positive move from a motion pr
120. ons such as analog and digital I O and laser firing PSO is provided in Chapter 4 Options Table 2 4 Ndrive HP Switch Settings S2 Switch Settings Off is indicated by www aerotech com 10 20 30 Installation and Configuration 2 9 Connecting Multiple Drives Following are two interconnection diagrams and a chart showing the part numbers of the FireWire Bus PCI card and the various interconnect cables and their part numbers Table 2 5 FireWire Card and Cable Part Numbers FireWire cable 4 5 M 15 feet long 6 pin to 6 pin 32 Axes Maximum 16 drives max in a chain 1394 OHCI FireWire Card Figure 2 21 Recommended Star Daisy Chain Configuration www aerotech com 2 23 Installation and Configuration Ndrive HP 10 20 30 Manual 2 24 Ji02 Ta 2162 servo anh automation 320 tmetion SMC Cantialler 15 02 Meare 101 servo Figure 2 22 FireWire Daisy Chain Before connecting any device to the FireWire bus the device should be powered up and tested independently to prevent damaging linked equipment Ndrive HPs HLs CPs MPs Nservos Nsteps and Npaqs should always have their FireWire cables connected in a star configuration to minimize the FireWire cable lengths WARNING see Figure 2 21 2 9 1 and Signal Wiring Requirements The I O communication and encoder fe
121. osine n Cos N and marker n Mkr N The encoder interface accepts an RS 422 differential quadrature signal in the range of 0 to 5 Volts DC It allows up to an 8 MHz encoder signal 31 nsec minimum edge separation producing 32 million counts per second after times four x4 quadrature decoding Typically the encoder interface accepts this RS 422 signal in line driver format however it may be factory configured as an option to accept this signal as an analog signal for the MXH option see Section 3 3 4 2 for more information See Section 2 6 1 Encoder Phasing for information on interfacing non Aerotech motors See Table 3 12 for the mating connector part number Table 3 16 Motor Feedback Connector Pin Assignment J207 Pinf Label Description amp 6 Encoder Marker Reference Pulse Input _ Total user 5 V power is limited to 500 mA by an internal re settable fuse external power provided by the Ndrive to the user is protected by a re settable fuse Should an over current condition occur the device will open to provide protection against the overload To reset the device remove the over current condition www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details 3 3 4 1 Line Driver Encoder Standard The primary encoder input is standardly configured for a differential line driver encoder in the range of 0 to 5 volts It allows up to an 8 MHz enc
122. otary 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 Glossary of Terms Glossary of Terms Torque Continuous Torque Peak Torque RMS Torque Stall Total Indicated Reading TIR Tuning Unidirectional Repeatability Velocity Command Wobble Yaw of travel Yaw Error A 8 Ndrive HP 10 20 30 Manual 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 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 theoreti
123. ote that this requires proper Hall effect to back EMF configuration and or proper commutation phase shift axis parameter setting see brushless motor setup information for more details Setting this bit to 0 uses the auto Configuration when the axis is enabled The position feedback type dictates which channel is used for commutation initialization Typical configuration of the R D has the CfgFbkPosType axis parameter set to 6 and CfgFbkVelType axis parameter set to O use position If two resolvers or inductosyns are used in a dual loop mode the position source will generate the commutation initialization but the velocity source will maintain commutation position after enable Dual Loop with resolvers and other feedback sources is not advisable www aerotech com 4 29 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 30 Finding the Proper Commutation Offset in R D Auto Configuration Mode The R D Auto Configuration mode assumes that the zero crossing of the R D Converter is aligned with the 0 angle of commutation on the Ndrive Therefore to determine the commutation offset angle perform the following steps The resolver absolute counter may be read in the Ndebug utility via the command sequence DSPMEMREAD 2 OxEBOOO6 for channel 1 OXEBOOO 7 for channel 2 1 Open the Nstat exe utility 2 Select the tab which displays the absolute resolver feedback register 3 Rotate the resolver until you have an app
124. otors only Input input input N A N A 1 Input 11 Hall Effect Sensor C Brushless Motors only Input 1 Input 1 Output 1 Input Input 5V Power for Limit Switches 500mA max Output input input N A N A N A 2 Input 2 N A 2a input Total user 5 V power is limited to 500 mA by an internal re settable fuse Table 3 12 Motor Feedback Connector Mating Connector J207 Aertech Third Party Source 00101 Cinch P N DB25P Back shell ECK00656 Amphenol P N 17 1726 2 All of the external power provided by the Ndrive to the user 15 limited to 500 mAmps and protected by a re settable fuse Should an over current condition occur the device will open to protect against the overload To reset the device remove the overload condition www aerotech com 3 11 Technical Details Ndrive HP 10 20 30 User s Manual 3 3 1 End of Travel Limit Inputs Two of the three limit inputs are end of travel sensing CW Limit and CCW Limit while the third 1s a reference limit Home Limit of the end of travel limit inputs accept 5 24 VDC logic signals The Pin Assignment for the connector is shown in the table below See Table 3 12 for the mating connector part number Alternatively opto isolated user inputs 8 10 may be used as the end of travel limit inputs see Section 3 1 3 MOTOR FEEDBACK 1207 Table 3 13 End of Travel Limit Inputs Pin Assignment Connector J207 Pin Label Description IWn Out
125. ould work well Verify that the capacitor voltage rating 1s greater than the clamp 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 K1 RELAY NC 5 L 18301 57 RELAY COMMON E 18301 2 i 6 10 8501 5 1 RLYV23026SMT 2 BRAKE 4 c J207 25 JP1 B B IB o co BRAKE 420 1 5 Figure 4 7 Suppression for DC Brake Systems The user may reconfigure the connections for the brake such that the positive supply lead is switched by the relay instead of the supply common www aerotech com 4 Ndrive HP Options Ndrive HP 10 20 30 User s Manual 4 1 4 Analog Inputs TB302 Both analog inputs are differential buffered by a precision unity gain differential INA105 amplifier and converted to digital by a 16 bit ADS8320 analog to digital converter allowing an input voltage in the range of 10 volts This produces a resolution of 305 uVolts per bit of the A D Refer to Figure 4 8 To interface to a single ended non differential voltage ground the negative input and connect your signal to the positive input Analog input 0 15 also available at J205 see Section 3 1 5 The analog inputs have a 25k Ohm input impedance and should be driven by a low impedance source such as
126. ower LED 88800556 8 Opto Isolated Inputs Common Sink or Common Source User Defined MXH MXU or Line Driver Encoder Halls Limits Ndrive HP WITH 5 Communication Chan nel OPTION INSTALLED Device Settings Figure 1 2 Ndrive HP Hardware www aerotech com 1 3 Introduction Ndrive HP 10 20 30 User s Manual AC1 AC _ 2 LO AC3 SSI NET Inteqrated Suppl Suppl IOPSO IOPSOH tion pply PP IY Protection 1 3 Functional Diagram The standard package includes the bus power supply that operates from 85 250 VAC 120 350 VDC The power supply is included with the standard package for off line operation without the need for an isolation transformer A soft start circuit 15 included to prevent high inrush currents 85 250 VAC AL E TJAL2 Bus Over Soft vel Voltage Start Detect Module IGBT Power 3 Opt E Opto Isolation Short Circuit P Under 1 Voltage Over E Temperature ra Bi directional Jao3 09 Absolute 4 Encoder _ 4 Outputs x4 4205 rio s EI Encoder 6 Inputs _ __ IOPSO IOPSOH Option ___ amp IN OPTO TB305 _ FT S 78304 i CT ge z PREA J207 Primary Encoder Eee E J202 Fir
127. p Shield Green Yellow amp Shield A Red amp Orange Red Orange Yellow amp Blue Yellow amp Blue NOTES amp Red amp Orange implies two wires I Green White implies a single wire Figure 2 9 DC Brush Motor Torque Mode Configuration 2 10 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 5 1 1 DC Brush Motor Phasing If an Aerotech motor is used with Aerotech provided cabling no motor phasing process is required A DC brush motor is phased correctly when a positive motion command causes clockwise CW motor rotation as viewed looking at the motor from the front mounting flange This assumes the CntsPerMetricUnit CntsPerEnglishUnit CntsPerRotaryUnit axis parameters are set to a positive value This required phasing is determined solely by which motor lead is connected to the A and motor terminals Motor phasing is unrelated to the resultant direction of motion commanded from within a motion program After correctly phasing the motor you may reverse the motor direction when commanding a positive move from a motion program by negating the sign of the CntsPerMetricUnit CntsPerEnglishUnit CntsPerRotaryUnit axis parameters To determine this connect a voltmeter to the motor leads of an un powered motor Rotate the motor by hand clock wise CW Swap the voltmeter connections to the motor until the voltmeter indicates a positive voltage The motor lead now connected to the
128. pical Emergency Stop Circuit Rev O D 5 V VV www aerotech com Ndrive HP 10 20 30 User s Manual LIST OF TABLES Table 1 1 Models Options and Voltage Configurations 1 5 Table 1 2 PRC COS SOIC Said ses aes 1 6 Table 1 3 Electrical Specifications 1 7 Table 2 1 Ferrite Bead Part Numbers 2 2 Table 2 2 TB101 Auxiliary AC Supply Input when TB102 AC input CNRC 2 4 Table 2 3 TB102 AC Power Input and Motor Power Output 2 5 Table 2 4 Ndrive HP Switch Settings 52 2 22 Table 2 5 FireWire Card and Cable Part 2 23 Table 2 6 Electrical Noise Suppression Devices 2 25 Table 3 1 Auxiliary I O Connector Pin Assignment J205 3 1 Table 3 2 Auxiliary I O Connector Mating Connector J205 3 2 Table 3 3 Auxiliary Encoder Pin Assignment on Connector J205 3 2 Table 3 4 User Outputs Pin Assignment on Connector 205 3 4 Table 3 5 User Inputs Pin Assignment on Connector J2095 3 5 Table 3 6 High Speed User Inputs Pin Assignment on Connector 320 M 3 6 Table 3 7 Auxiliary I O Connecto
129. pto isolated user inputs standard 2 of which are high speed 2 differential analog inputs one standard and one available with the IOPSO option 2 analog outputs one standard and one available with the IOPSO option www aerotech com Ndrive HP 10 20 30 User s Manual Introduction 1 2 Connection Overview The Ndrive HP consists of two power connections motor power and input power three FireWire ports an optional Ethernet connection an RS 232 RS 422 connector LED indicator lamps and two D Style connectors for Auxiliary I O 15 and 26 pin and Motor Feedback 25 pin An IOPSO or IOPSOH option is also available which has connectors for PSO absolute encoder SSI Net analog I O digital I O and user power Refer to Figure 1 2 for connector locations Ethernet 1394 Optional FireWire JOPSO or IOPSOH Option Optional Auxiliary Power PSO Absolute Keep Alive Encoder Interface CONFIG DEVICE NUMBER 1 3 Phase TITHTITA 240 VAC Max 50 60 Hz 2 Channels SSINet for 76543210 3 Phase 40 340 VDC buffered RS 422 multiplied 00000008 Motor Output 10 30A pk encoder IN OUT 51 LED Indicators 2 18 Bit Analog Outputs and Brake Relay 6 Inputs 4 Outputs and Line Driver Encoder p 2 16 Bit Analog Inputs Input Output for Master 320 Slaving Camming etc AEROTECH C OM User Power or RS422 8 Opto Isolated Outputs Emergency Stop Common Sink or Common Sense Input Source User Defined P
130. r EN 61000 4 2 resulted in the unit reseting to a safe state when the FireWire connector was directly subjected to the ESD test requirements This condition has been further minimzed on revision A of the product to prevent the possibility of this occurrence Voltage Dips and Interruptions per EN61000 4 11 was successfully tested internally at Aerotech on April 26 2002 EFT Burst Immunity per EN 61000 4 4 resulted in the unit reseting to a safe state when the cables were subjected to the EFT test requirements Not applicable for cables less than 3 meters in length ANO Pittsburgh David F Kincel April 2002 Quality Assurance Manager Alex Weibel LOr Meku aro Engineer Verifying Compliance www aerotech com Regulatory Information Ndrive HP 10 20 30 Manual General notes concerning the test setup This product was tested at F Squared Laboratories in Burton OH on April 16 18 2002 The report numbers are NY011602 01 01E and NY011602 01 02E The Ndrive HP was tested while powered from a 230VAC source with a brushless servomotor connected via PMC 15 and BFC 15 15 foot cables In order for the product to conform to the radiated emission standards the motor cable must be shielded and the shield must be connected to the earth ground A metal D style connector with a metal backshell must be used when connecting to the D style connectors on the Ndrive HP The shield of the feedback cable must be connected to
131. r Pin Assignment J205 3 6 Table 3 8 Auxiliary I O Connector Pin Assignment J205 3 6 Table 3 9 PSO Encoder Signal Sources and Pre Scaling Methods 3 7 3 10 PSO OUTPUT 3 8 Table 3 11 Motor Feedback Connector Pin Assignment J207 3 11 Table 3 12 Motor Feedback Connector Mating Connector J207 3 11 Table 3 13 End of Travel Limit Inputs Pin Assignment on Connector 3 12 Table 3 14 Hall Effect Inputs Pin Assignment on Connector J207 3 13 Table 3 15 Brake Output Pin Assignment on Connector J207 3 14 Table 3 16 Motor Feedback Connector Pin Assignment J207 3 14 Table 3 17 MXH Option Specifications 3 17 Table 3 18 J206 RS 232 RS 422 Connector Pin Assignment 3 19 Table 3 19 RS 232 5 422 Port Connector Mating Connector J200 M 3 19 Table 3 20 J201 J202 J203 FireWire Connector Pin Assignment 3 21 Table 4 1 IOPSO Option Board Jumpers 4 1 Table 4 2 IOPSOH Output Device Numbers 4 2 Table 4 3 Analog Output Connector Pin Assignment TB301 4 3 Table 4 4 Voltage and Current Specifications TB301
132. r program control various other hardware triggers or most typically a user defined change in vectorial position on one to three axes This vectorial position change is monitored via hardware allowing an output pulse to be generated in less than 275 nanoseconds 200 nsec for single axis after the trigger is detected not including the propagation delay of the output device This 15 accomplished via hardware that monitors the designated axes positions calculates the sum of the squares of the axes positions and compares it to the desired squared position trigger value All of the mathematical squaring of the positions occurs in hardware for speed The comparison of the squared command to feedback position occurs at an 8 Mhz rate for multi axis firing and at a 20 MHz rate for single axis firing Furthermore this vectorial position trigger value is queued via a 255 level queue in hardware to the triggering hardware with each trigger advancing thru the queue to the next trigger value This allows the trigger value to be specified as a series of incremental trigger points if desired The absolute accuracy is excellent although point to point accuracy may vary due to the calculated feedback squared firing distance jumping past the internally squared user programmed firing distance This small error is accumulated and subtracted from the next firing distance maintaining absolute accuracy For example if the user programs a trigger to occur aft
133. r the product application e Voltages greater than 60V may be present inside the Ndrive after a discharge time of 5 seconds e The end user must provide protection for power interruption restoration if required e The end user must provide earth fault current protection if required e end user must provide protection against lightning and power switching surges if required e Control and Emergency Stop requirements are to be determined and provided by the end user e Wire and cabling provided with the Ndrive meet Aerotech s electrical and listed environmental requirements The end user must meet the final requirements Failure to follow these procedures may result in serious injury damage and or excessive emissions or reduced immunity of the equipment WARNING www aerotech com Ndrive HP 10 20 30 User s Manual 1 INTRODUCTION Aerotech s Network Digital Drives Ndrive HP complement Automation 3200 System see Figure 1 1 Connected via the IEEE 1394 FireWire communication bus these drives provide deterministic behavior auto identification and easy software setup from the Nmotion SMC software controller Featuring a high speed Harvard architecture DSP the drives have fully digital current and servo loops providing selectable 1 20 kHz servo loop closure 40 MHz line driver encoder data rate and an optional Ethernet port for access to third party networked I O solutions The Ndrive HP
134. rameters before running the A3200 Programs Samples MsetDebug Pgm See the Getting Started section in the Nview help for configuration information The first of which is by actively driving the motor under program control The A3200 Programs Samples MsetDebug Pgm may be used for this purpose The hall signals must be swapped until they generate the sequence as defined in Figure 2 14 After the Hall sequence is correct the program can then correctly determine if a commutation offset is required The test program will indicate the required value of the CfgMotOffsetAng axis parameter to correctly phase the motor The second method is a non powered method whereby the motor is disconnected from the controller and connected in the test configuration as defined in Figure 2 14 This will identify the hall signal and motor leads A B and C The equipment needed for the non powered test is a two channel oscilloscope and three resistors typically 10 K ohm 1 2 watt wired in a Wye configuration The tests outlined below do not require that the amplifier be turned on since Figure 2 14 illustrates the generated output voltage of the amplifier relative to the input Hall sequences Before performing the test in Figure 2 14 ensure that the motor leads are completely disconnected from the amplifier WARNING Connect the ends of the three resistors to three motor leads Use one channel of the oscilloscope to monitor motor terminal A with respect
135. re 2 7 80 Volt DC Bus from 115 and 230 VAC Source 2 8 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration Ndrive HP PRIMARY FUSE AUXPWR OPTION 4A SLO BLO TRANSFORMER HSWHT INTERNAL THERMAL SWITCH AC HI 115VAC AC LO 50 60 HZ NOTES INPUT SAFTEY 18 WHT Slice RED 56v 115v BLK 100v ORN A 1 THE AUXPWR OPTION IS USED WHEN THE MAIN SUPPLY POWER IS n BELOW 100VAC TYPICALLY 28 56VAC lt 2 INPUT THIS COREESPONDS TO A 22 C TOV BRN BUS VOLTAGE OF 40 80VDC THE YEL 56v Iv RN AN CONFIGURATION SHOWN IS FOR ISOLATED 115VAC 160VDC BUS Ov BLU OPERATION 2 FOR 100VAC PRIMARY INPUT PARALLEL THE 100VAC TAPS AND FRAME GROUND LEAVE THE 115VAC TAPS UNTERMINATED 3 FOR 200VAC PRIMARY INPUT SERIES THE 100VAC TAPS AND LEAVE THE 115VAC TAPS UNTERMINATED OPTIONAL SUPPLY TV0 3 56 WIRING PRIMARY 115VAC 4 WHEN USING AN ISOLATION SECONDARY 115VAC 160VDC BUS TRANSFORMER EARTH GROUNDING OF AC LO INPUT TAP REDUCES TRANSFORMER P N EAX01006 ELECTRICAL AND AUDIABLE NOISE EMMISSIONS AND PROVIDES INCREASED SERVO PERFORMANCE ee HP Bey lies 5 IT IS RECOMMENDED THAT THE AUXPWR OPTION 3A SLO BLO TRANSFORMER 18 WHT AC HI OPTIONAL AND MAIN SUPPLIES ARE THERMAL 230VAC CONNECTED TO THE SAME SOURCE SWITCH AS SHOWN THIS WILL ENSURE RED 56v 115v BLK SAFTEY PROPER SOFT START OPERATION
136. rection www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 5 3 2 Brushless Motor Hall Effect Feedback Connections The Hall Effect feedback signals on an AC brushless motor are correctly phased when the hall states correspond to the states at each of the electrical angles shown in Figure 2 14 The Hall states which correspond to the electrical angles are indicated in Figure 2 14 0 for the given Hall input indicates zero voltage or logic low where 1 indicates five volts or logic high These logic levels may be viewed within the Nstat utility on the Diagnostic tab as shown in Figure 2 13 J20 Encoder Channel Hall C 11 Hall Effect gt Encoder 45V Feedback Encoder Com 21 E Chassis Frame For full cable drawings refer to your software CD ROM Figure 2 12 Hall Effect Feedback Connections _ FireWire Drivelnfo TaskStatus TaskStatus2 Task Status StipChat Ethemet Diagnostics Fault smc Quantib HARDWARE Enable L Figure 2 13 Hall Effect Feedback Inputs in the Nstat Utility www aerotech com 2 15 Installation and Configuration Ndrive HP 10 20 30 Manual 2 16 2 5 3 3 Hall Effect Phasing For an AC brushless motor with an unknown hall sequence one of two simple tests can be performed on the motor to determine the proper connections to the Ndrive HP Be sure to first configure the axis pa
137. rive HP 10 20 30 Manual FireWire 22 2 27 3 21 J203 FireWire 2 2 2 27 3 21 T O 4 21 J205 Connector Pinouts 3 3 2 3 5 3 6 J205 Connector D 4 J206 Connector 8 3 19 lp 3 19 3 11 4 2 Connector Pinouts 3 11 3 13 3 14 P 4 13 Joystick 5 5 6 8 JTAG Programming Connector 6 8 Jumpers Control 6 4 4 1 Power 6 6 L Laser Output Opto Isolator Specifications 3 8 4 14 LED THOICALUOT oe 1 3 LED 6 7 6 7 Limit and Hall Effect Inputs 3 13 Line Driver Encoder Standard 3 15 Line Filter Connection 2 3 Lane Interfetelie uei ierit tp boron 2 3 2 14 Logic LOW 2 14 1 5 O 1 3 Motor and Feedback Connection Basic 5 2 10 2 10 ENT 2 10 2 10 Motor and Feedback Connections2 10 2 15 2 21 Motor Connections 2 4 2 10 2 15 2 21 Motor
138. rive acts as a simple voltage to current controller Analog Input 0 provides the current torque command Analog input 0 is accessible through either the IOPSO option board or the J205 connector To emulate a standalone drive the Ndrive also uses Input 8 least significant input bit on the J205 connector as a drive enable input and Output 8 least significant output bit on the J205 connector as a fault output indicator These I O points utilize a default polarity that makes them fail safe Both are optically isolated See Figure 3 2 and Figure 3 3 for I O connection information Also note that the fault output requires a pull up resistor to an external power supply The analog input is configured to accept input voltages from 10V to 10V In this mode 10V is equivalent to peak amplifier current command in the negative CCW direction while 10V is equivalent to peak amplifier current command in the positive CW direction The drives peak current is defined by the drive part number i e Ndrive HL 20 indicates that the peak output current will be 20 amps The analog input is differential utilizing pins J205 13 Analog input 0 and J205 14 Analog input 0 See Figure 4 8 for more information The diagrams above indicate that current flow through pins 17 and 24 will enable the axis to drive current through the motor failsafe by default no motor current will be present Also they indicate that a fault condition will be indicated
139. roximate zero value on the feedback register note that this value will roll over at 65 535 4 Begin with an MSET value of 0 degrees execute MSET commands with an increasing angle until you see a value of 0 indicated for the absolute resolver angle This MSET angle is the desired commutation offset 5 Enter the value from step 4 into the CfeMotOffsetAng axis parameter Note that for negative values you must add 360 degrees valid parameter range 1s 0 360 degrees www aerotech com Ndrive HP 10 20 30 User s Manual Accessories CHAPTER 5 ACCESSORIES 5 1 Standard Interconnection Cables The following three tables show a summary of the standard cables used for interconnecting various items to the Ndrive The in the tables below is used to specify the length in decimeters and the yy specifies the length in feet To identify your cable or for a drawing see your documentation CD or software CD ROM Table 5 1 Standard Interconnection Cables 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 C1839X Encoder Feedback Cable BL FB 25DU 25DU 9DU MAX120DM C18982 Motor and Encoder Feedback Cable 219 BL MTR amp FB FL 25DU 25DU 107DM MAX C19360 xx Motor Cable BL MTR FL 4DU MAX450DM
140. rrent 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 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 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 Glossary of Terms Glossary of Terms Force Continuous Force Peak Friction G P I B Gain Grating Period Hall Effect Sensors HED HMI Home Home Switch Hysteresis 488 Incremental Move Inertia Lead Error Lead Screw A 4 Ndrive HP 10 20 30 Manual 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
141. signals may be used as illustrated in Figure 4 14 Jumper JP3 defines the active state of the open collector output which has three options as defined Table 4 12 See Section 3 2 for more information on the laser firing PSO option Note that the two RS 422 channels are two of the same channels available on the J302 and J303 connectors For information on the RS 422 ports see Figure 4 16 in Section 4 1 9 See Figure 4 14 for the firing output Table 4 12 PSO Absolute Encoder Interface Connector Pin Assignment J301 Pinf Label Description 7 6 Common 5 Volt External 8 Absolute Sine Input Absolute Encoder Interface Input 9 Absolute Cosine Input Absolute Encoder Interface Input Table 4 13 PSO Absolute Encoder Mating Connector J301 15 pin D Style Third Party Source 00100 Keltron DN 15PYSH G Back shell ECK01022 Amphenol P N 17 1725 2 We recommend using the opto isolated output where possible to maintain the isolation between the Ndrive HP and the laser This prevents noise and current spikes from laser firing pulses from being conducted through the Ndrive This requires the user to power the opto isolator at TB303 see Section 4 1 5 for more information www aerotech com Options gt E wv ui gt 4 13 Ndrive HP Options Ndrive HP 10 20 30 User s Manual Table 4 14 Laser Output Opto Isolator Specif
142. stor to limit the current If the ESTOP bit is enabled in the FaultMask axis parameter the ESTOP input must be driven to prevent the ESTOP fault condition For typical ESTOP wiring see the following drawing ESTOP Switch TB201 1 T 5 11 2 PS2806 1 24VDC WwW Figure 2 23 ESTOP Sense Input TB201 Connecting the E Stop input to a relay or other EMI RFI noise producing device circuit requires one or more noise suppression devices such as those in Table 2 6 or other WARNING appropriate devices Table 2 6 Electrical Noise Suppression Devices Device Aerotech P N Third Party P N RC 1uf 200 ohm Network EIC240 Electrocube RG1782 8 Varistor EID160 Littlefuse V250LA40A www aerotech com 2 25 Installation and Configuration Ndrive HP 10 20 30 Manual 2 10 1 Typical ESTOP Interface The user may connect an emergency stop circuit to the Ndrive It will disable power to the motor by removing power to the power stage of the drive while maintaining power to the control section as shown in the following Figure 2 24 For Rev 0 see Appendix D Ndrive HP AUXPWR Option 15A SLO BLO AC HI 85 240 VAC AC LO 50 60 HZ INPUT Ground 24 Teni ESTOP 4 1 AUXPWR option can be used when 24 VDC the main supply Bus Power must be removed during an emergency stop condition while logic encoder power must be maintainted 2 For the E Stop inpu
143. t 1 Analog Common Analog Input 0 Analog Input 0 volts 5 Volts Common Common Common Volts TB305 Input Common Input 0 Input 1 Button B Joy Interlock Buttons ww b e Button A Button B Button C Axis Pair Select Speed Select Exit Slew Mode Figure 5 1 Joystick Interface www aerotech com Accessories 5 5 Accessories Ndrive HP 10 20 30 User s Manual A standard Aerotech JI joystick may be connected to J205 of the Ndrive as a single axis joystick via 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 Ndrive Be sure to set only one of the JoyStickAnalogHorizInput or the JoyStickAnalogVertInput task parameters Also define only one axis each of the SlewPairl through SlewPair8 task parameters TO ECX00570 Ndrive HP 8 COND 24 J205 LENGTH AR SEE NOTE 2 BLU CONNECTOR SHIELDING 5V 2 Nm 5V EXT INCOM 4 Bis EXT IN2 18 2 2 WRAP 6 COPPER FOIL EIA281 ANALOG IN 15 EMEN 22 XPOT OVER GROMMET SHIELD amp DRAIN WIRE UNIES GRN 5 GROMMET SUPPLIED ANALOG IN 14 4 COM W BACKSHELL AGND 23 EXT INT 17 RED 7 S1 EXT IN3 25 x E 113
144. t to be active set up the appropriate FAULTMASK in the axis parameters for the desired action when an E STOP condition is invoked Optional Supply 3 Additional or alternative fusing may be required for optimum protection Ndrive HP AUXPWR Option 15A SLO BLO TB201 E STOP PORT Ndrive HP Rev A and above AUXPWR Interconnect E STOP Figure 2 24 Typical Emergency Stop Circuit 2 26 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 11 PC Configuration and Operation Information The Getting Started Guide PN EDU175 included with the Nmotion SMC s software package provides a quick start guide with basic information The Nview help included with the software provides additional information for configuring the Ndrive HP to the PC as well as information on hardware requirements getting started utilities and system operation and on using the Nview HMI user application www aerotech com 2 2 Installation and Configuration Ndrive HP 10 20 30 Manual 2 28 www aerotech com Ndrive HP 10 20 30 User s Manual Technical Details CHAPTER 3 TECHNICAL DETAILS 3 1 Auxiliary Connector J205 The J205 Auxiliary I O connector provides 6 inputs 4 outputs and a secondary bi directional RS 422 line driver encoder interface See the following sub sections for details on each type of signal within the J205 connector Table 3 1 Auxiliary Connector Pin Assignment J205
145. tationary 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 more slave axis position commands Man Machine Interface used as a means of getting operator data into the system See 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 non critical 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 Also a Normally Closed switch A Normally Open switch National Electrical Manufacturers 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 pot
146. tech com Ndrive HP 10 20 30 Manual Installation and Configuration 2 2 2 Minimizing 50 60 HZ Line Interference Operating the Ndrive HP from an off line source of 115 VAC or 230 VAC may create some additional issues There is a potential problem of EMI generated from the switching power stage of the Ndrive propagating through the bridge rectifier and out through the and AC2 input AC line connections Back propagation of noise into the AC lines can be minimized using a line filter refer to Figure 2 1 Torque to Use 1 62814 mm 14 AWG 300 V copper wire rated for at least 80 C 115 230 VAC Schaffner FN2070 10 06 50 60 HZ includes common mode choke and ferrite Protective Ground DANGER Voltage This configuration is especially important if the Ndrive HP is operating at DC bus voltages of 160 VDC to 340 VDC e g 115 VAC to 230 VAC input power Figure 2 1 Back Propagation Line Filter Connection Second a potential problem that exists with off line connections 1s 50 60 Hz electrostatic coupling between the frame of the AC motor and the AC1 AC2 AC input power Since AC1 is referenced to earth ground at the source 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 the amplifier stage passes through the current feedback sensing devices of the amplifier Depending on the magnitude of t
147. tive Maintenance Action to be Taken Visually Check chassis for loose or Parts should be repaired as required If internal damaged parts hardware damage is suspected these parts should be Note Internal inspection is not required checked and repairs made if necessary Inspect cooling vents Remove any accumulated material from vents Check for fluids or conductive material exposure Any fluids or electrically conductive material electrically must not be permitted to enter the Ndrive Note Disconnect power to avoid shock hazard Tighten or re secure any loose connections Replace worn or frayed cables Replace broken connectors Visually inspect all cables connections 6 8 1 Cleaning The Ndrive HP 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 Ndrive HP 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 Ndrive HP while cleaning Do not allow cleaning substances or other fluids to enter the Ndrive HP or to get on to any of the connectors Cleaning labels should be avoided to prevent erasing label information 6 10 www aerotech com Ndrive HP 10 2
148. to the Wye neutral eg the point where all three resistors are connected together Turn the shaft of the motor CW and note the generated voltage This voltage represents the phase A to neutral Counter EMF CEMF With the second oscilloscope probe determine the Hall switch that is in phase with this voltage Similarly phase B and C should be aligned with the other two Hall switches This will identify each motor and hall lead which are in phase with each other Any motor and hall lead set may be phase A The relative phasing between this set and the other two sets will then determine which is phase B and phase C Refer to Figure 2 14 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 J207 For proper operation the CEMF generated motor phase voltages should be aligned to the amplifier s output generated voltage with the given Hall effect sequence shown in Figure 2 14 www aerotech com Ndrive HP 10 20 30 Manual Installation and Configuration Test Setup Brushless Clockwise Rotation 0 60 120 1809 240 300 360 1 2 3 4 5 6 5V OV HA Bm a OC B OC B 20V Motor Back EMF 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 4207 Hall Positi
149. tor 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 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 motors 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 www aerotech com Ndrive HP 10 20 30 Manual Coordinated Motion Critical Speed Current Command Current Peak Current RMS Cycle DC Brushless Servo Deceleration Duty Cycle Dwell Time Efficiency Electronic Gearing Encoder Marker Encoder Resolution Encoder Increm
150. tor rotation position information to the amplifier This allows the Feedback Inputs three motor phases currents to be varies or commutated to rotate the motor in the desired direction and speed TTL level input sine sine N Pin 17 Pin 18 cosine cosine N Pin 14 Pin 15 Encoder input 0 to SVDC internal pull up 10K input 5V Pin 16 On board 5V power supply 500 mA maximum output 5V Pin 3 On board 5V power supply 500 mA maximum output for encoder Peak over current Protective Features isolation Optical and transformer isolation between control and power stages www aerotech com 1 7 Introduction Ndrive HP 10 20 30 User s Manual 1 5 2 Mechanical Specifications The outline dimensions for the Ndrive HP are shown in Figure 1 4 and Figure 1 5 Units should be separated from each other and surrounded by one inch of free air space This will also allow the standard 228 mm 9 inch FireWire cable to interconnect them 99 0 3 90 24 5 0 97 50 8 2 00 22 1 0 87 24 7 00 19 e 9 1 00 36 i i ME NDS NNI E Nl Lo Ed S S 855 a 9 o 5 3 3
151. tus is available 47 Silas via the Nmotion SMC and its utilities FAULT RMS POS ERR CLMT ENABLE INPOS These LED s may also flash to indicate that the internal MXH option is being re KERNEL _ ACW programmed internally see Section 3 3 4 2 for more information on the LED flashing pattern which indicates the re programming cycle is occurring Table 6 6 LED Indicator Description ACTV Reset indicator CLMT Current is clamped at the value determined by the ThresholdClamplAmp axis parameter ENB Axis is enabled FLT An axis fault has occurred see Fault axis parameter RMS www aerotech com 6 Troubleshooting Ndrive HP 10 20 30 Manual 6 6 JTAG Programming Connector The JT AG connector is for Aerotech use only Table 6 7 JTAG Programming Connector Internal P10 Pinf Label Description ie 4 Key Position No Connection 11 3 3 Volt Standard 5 Volt Optional 6 8 www aerotech com Ndrive HP 10 20 30 Manual Troubleshooting 6 7 Fuse Battery Replacement Table 6 9 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 Table 6 8 Fuse Replacement Part Numbers Ndrive Control Board pe pemen a Control Power Fuse RAYCHEM SMD250 EIF00002 5A F2 4 FireWire 5 Volt Power Fuse RAYCHEM SMD250 EIF00002 A F1 F4 are reset able semiconductor fuses sol
152. tween pins 13 and 25 of J207 1s required In this case J207 functions as an interlock to prevent the Brake from releasing if the Motor Feedback connector is not connected K1 RELAY NC 5 301 3 RELAY COMMON E 5 8301 2 6 10 RELAY NO 537 VSXRSE JP1 A RLYV23026SMT 1 2 BRAKE 5 E 1207 25 JP1 B AEROTECH ECR180 BRAKE ___ G 1907 13 Harris V33ZA1 Add Jumper or change jumpers to BRAKE 1 2 Out 5 4 Out 1 5 In Figure 4 4 Brake Connected to TB301 The user is responsible for providing fuse protection for the Brake circuit WARNING Figure 4 5 is an example of a 24 VDC Brake connected to the Motor Feedback connector J207 In this example the external 24 VDC power source is connected to TB301 Also note that JP1 A is set 1 2 and JP1 B is set 3 4 K1 RELAY NC S 8301 3 E 5 301 4 RELAY NO 6 10 B301 5 RLYV23026SMT 2 BRAKE 1207 25 lt N x VARISTOR 4 5 AEROTECH PN ECRIBQ JP1 B Harris PN V33ZA1 BRAKE 1207 13 Figure 4 5 Brake Connected to J207 The user may reconfigure the connections for the brake such that the positive supply lead is switched by the relay instead of the supply common www aerotech com 4 5 Ndrive HP Options 4 6 Ndrive HP 10 20 30 User s Manual Step Z3 Suppression and Snubber requirements Due to the inductive effects of the brake suppress
153. ues from window 2 may be used for window firing purposes The Capture Update modes vary for Window 1 and Window 2 see Figure 3 6 The data capture mode rate for analog inputs is limited to approximately 100 000 samples per second due to A D conversion rate The data update mode for analog outputs is limited to 500 000 Hertz due to internal serial bus design constraints www aerotech com 3 9 Technical Details From Pulse or Window 40 Mhz 32 Bit Counter Secondary Encoder 4 Aux Inputs 2 High Speed Inputs Primary Encoder 4 Aux Inputs 2 High Speed Inputs 32 Bit Counter from any Window Source Switching Multiplexors Capture Window 1 Analog Output 1 4 Aux Outputs Analog Output 1 Aux 1 and 2 Outputs Analog Output 1 4 Auxiliary Outputs Auxiliary 1 and 2 Outputs Figure 3 6 Ndrive HP 10 20 30 User s Manual gt PSO Output lt gt High Speed Input 12 CC High Speed Input 13 40 Mhz 32 Bit Counter 8 General Purpose Inputs Analog Input 1 General Purpose Inputs 32 Bit Counter from any Window Source Switching Multiplexors Capture Update Window 2 Analog Output 2 8 General Purpose Outputs Analog Output 2 8 General Purpose Ouputs 1 4 Analog Input 2 8 General Purpose Outputs General Purpose Outputs 1 4 Data Capture Data Update Modes 3 2 1 Single Axis Laser Firing Single axis firing requires no additional encoder signals and is capable o
154. urations J302 and J303 each contain Use NConnect SSIMet XX cable between J302 J303 and J302 J303 both SSI Net ports 1 and 2 C19891 X or C19892 X cable between J302 J303 and J205 Hdrive with DUALPSO or TRIPLEPSO Option rE En T ER px T I Sol Met 1 is MESE SSINet2 nra SS Net 1 is an Output j is an Output s mm m i a P 551 Net 2 B isan Input WT raan e et 4 ES act E Figure 4 17 Two Three Axis Laser Firing Interconnection Table 4 16 SSI Net Cable Part Numbers NConnect SSINet 4500 4 5 M 15 FT SSI Net Cable NConnect SSINet 3000 3 0M 10 FT SSI Net Cable NConnect SSINet 1500 1 5 M 5 FT SSI Net Cable NConnect SSINet 900 0 9 M 3 FT SSI Net Cable 4 18 www aerotech com Ndrive HP 10 20 30 User s Manual Options 4 2 1 PSO Tracking Rate Configuration PSO Track Rate Configuration applies to an Ndrive with either the DUALPSO or TRIPLEPSO options and the MXH option with high encoder data rates A The maximum clock frequency of the MXH multiplier should be limited to 20 MHz when using the DUALPSO or TRIPLEPSO options This is due to a maximum encoder date rate of approximately 32 MHz on the Ndrive s encoder input ports The 20 MHz clock rate is achieved by setting the Clock Select 1 field of the CfgFbkEncMxhSetup axis parameter value
155. ve HPs together or with other devices such as the Npaq as shown in Figure 2 22 The FireWire bus power is independent of the Ndrive power should the drive fail communication will be maintained with the other devices Table 3 20 J201 J202 J203 FireWire Connector Pin Assignment Pin Label Description In OutBi FireWire Adapter Power In Out FireWire Common 2 Physical N A isolated from Signal Common 3 Port Communication Signal Bidirectional 4 TPB Port Communication Signal Bidirectional 6 9 Frame ChassisFrame Port 0 1 and 2 respectively as represented in the table by a 3 x The FireWire connector s 7201 7203 have pin 1 the power pin protected by a re settable fuse Should an over current condition occur the device will open to protect against the overload To reset the device remove the overload condition www aerotech com Ts d FIREWIRE 3 21 Technical Details Ndrive HP 10 20 30 User s Manual 3 22 3 6 Voltage to Current Mode Operation The firmware version 2 06 and later on the Ndrive supports a voltage to current mode This mode allows the unit to run in a standalone mode attached to a master position velocity loop controller The standard operating mode of the Ndrive uses an OHCI IEEE 1394 connection from a host PC running the Nmotion SMC software motion controller to control servos This conn
156. which is then multiplied x4 additionally by the controller Each time this axis parameter is changed the controller will internally re program its logic This re programming cycle will take about 3 5 minutes The LED s will indicate that the internal MXH option is being internally erased and then re programmed and that the axis may not be enabled during this time While the MXH option 15 being erased the LED s will indicate the pattern shown to the upper right When the MXH option 15 being re programmed the LEDs will alternate between the two patterns shown to the lower right The Ndrive contains digital potentiometers to adjust the gain offset and phase balance of the analog Sine and Cosine inputs The digital potentiometer settings are controlled by the CfgFbkEncCosGain CfgFbkEncCosOffset CfgFbkEncPhase CfgFbkEncSineGain CfgFbkEncSineOffset axis parameters The MXH option is compatible with the DUALPSO and TRIPLEPSO options A differential line driver encoder may be used also see Figure 3 9 for more information The specifications for the MXH multiplier option are shown in Table 3 17 following table indicates the maximum specifications for the MXH option when the signals are output via the SSI Net Otherwise the only limit is the maximum input frequency of 200 kHz See Figure 3 9 for MXH typical input circuitry The Pin Assignment is indicated in Table 3 11 www aerotech com Ndrive HP 10 20 30 User s Manual Techni
157. www aerotech com Ndrive HP 10 20 30 Manual Troubleshooting CHAPTER6 TROUBLESHOOTING 6 1 Problems Causes and Solutions This section covers symptoms probable causes and solutions related to Ndrive HP 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 Nview HMI help file 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 DANGER technician or electrician should perform these tests A No user serviceable parts inside gt WARNING Motor Ndrive HP chassis may exceed 50 C gt HOT Disconnect power to Ndrive HP main supply and optional supply before servicing gt Hazardous voltages may be present at Mains inlet and motor connectors gt DANGER Voltages must be mechanically secured before applying power gt WARNING Motors must be mechanically secured before applying power gt DANGER www aerotech com 6 1 Troubleshooting Ndrive HP 10 20 30 Manual Risk of electric shock DANGER Residual voltages inside the Ndrive HP controller may exceed 60 Volts after AC power has been disconnected for 10 seconds DANGER Table 6 1 Amplifier Faults Causes and Solutions Symptom Possible Cause and Solution Encoder sine and
158. ypically less than 5 degrees of phase lag is acceptable and does not require use of the COS reference Use of this axis parameter requires that the jumper on the RDP board for this channel JP1 for channel 1 or JP2 for channel 2 be set from 2 3 instead of from 1 2 Also in order for the A D s to sample properly the appropriate bit in the CfgFbkRDConfig axis parameter should be set to 1 bit O for channel 1 or bit 1 for channel 2 For most resolvers use of the CfgFbkRDCosPhase axis parameter is not required If this axis parameter is not being used the jumpers should be set to 1 2 and the bits in the CfgFbkRDConfig axis parameter should be set to 0 Skip to the section on adjusting the R D Gain Adjusting the CfgFbkRDCosPhase axis Parameter After starting the Encoder Feedback Configuration utility make sure the proper axis 1s selected and then start collecting data continuously Set the CfgFbkRDGain axis parameter to 0 to minimize the gain This can be done through the Ndebug exe utility Rotate the resolver or inductosyn until the analog signals are at one of the vertical or horizontal lines this will ease location of a maximum See Figure 4 22 below for an example Adjust the CfgFbkRDCosPhase axis parameter until you locate a local maximum This can be done through the Ndebug exe utility When the maximum has been found rotate the motor in a complete circle to ensure you see a circle If not the P1 amplitude potentiometer on the pre a

Ndrive HP 10/20/30 USER`S MANUAL

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