3P6-DSD-ESO-60400-00..
Contents
1. M2 MECHANICS THERMOSTAT T Dimensions 578X555X800mm Power dissipation 500 v ER Bend w Catastrophic Limit Circuit e e e o Limit Switches 4 Limit SW Limit SW Y ENCODER ANALOGUE DRIVE and LIMIT SIGNALS 4 SURGE E 9 4 amc ENCODER ANALOGUE DRIVE and LIMIT SIGNALS FOCUS Inrush Supressor ZA 4 4 P ENCODER 2 M 3 ENCODER ANALOGUE DRIVE and LIMIT SIGNALS Velocity POWER DRIVE 8 Controller RFI POWER 3 E 58 LINE FILTER INCREMENTAL ENCODER SIGNALS HARMONIC Regeneration Resistor DRIVE y SCHUKO RECEPTACLES 47Ohms 50W M2 LCU SS gt Limit Switches Limit SW Limit SW Ethernet lt 4 Conditionin VxWorks Console A bai X X uo m 0 SERVO POWER DRIVE ENCODER RS 232 gt Velocity 1 C O 7 x Song A RS 232 e Controller ervo Amps RS29 4 INCREMENTAL ENCODER SIGNALS HARMONIC ti 4 e DRIVE 4 Catastrophic Limit Circuit e o e Limit Switches 4 Limit SW Limit SW Conditioning 4 Ce ESO Standard Cooling Unit y N A POWER DRIVE ENCODER Velocity Controller m T INCREMENTAL ENCODER SIGNA2. 7 2 1 MOTION CONTROL CONCERT 7 2 2 MOTION CONTROL COMPONENTS 2555250 eto 7 2 3 8 20 2 8 2 4 FOCUS X AND Y POSITION AND VELOCITY CONTROL 00 00000 00 9 3 M2DRIVES ELECTROMECHANICAL COMPONENTS ee eere eese eee eee to 00 10 3 1 FOCUS X AND Y DRIVE COMPONENTS enne tenente eneetr nnns aee eterne nane 10 3 2 FOCUS LINEAR ENCODER seen eite s es ettet nnns 11 4 ELECTRONICS CABINET eeieieccecesvoseos es sosta cao vus rose eV eral usw oat ee eeir o 11 Et E 11 42 SERVO AMPLIPIERS tec ete irre e REN restet EEN 11 4 3 VME4SA COMPONENT ADAPTER CONFIOGURATION 11 AA CABINET COOLING UNIT 5 ere IA dte eet obo UTERE 12 4 5 MAINS POWER DISTRIBUTION evecta ee 12 5 672 14 D IT EE 13 5 15 FOCUS X AN Y DRIVE UNITS EE 13 52 CABINE TNL IB nH e 13 5 2 1 Cable Feed trough i a PA Fes rea be 13 CINSIDEPHE 13 E TNR
3. gaere M2 UNIT MINI RACK M2 MECHANICS EXTERNAL Dimensions 578X555X800mm Power dissipation 500W Catastrochic Limit Circuit BREAKER V oF os E it Swit Limit SW Limit SW e ENCODER ANALOGUE DRIVE and LIMIT SIGNALS pore H m SURGE 4 4 ENCODER ANALOGUE DRIVE and LIMIT SIGNALS H FOCUS rosso SERVO AMP ENCODER H ENCODER ANALOGUE DRIVE and LIMIT SIGNALS Velocity DRIVE i Controller Rs INCREMENTAL ENCODER SIGNALS LINE FILTER Regeneration Resistor 5 RECEPTACLES ATOhms 50W M2 LCU Limit Switches Limit Sw Limit SW Ethernet 5 lt Conditioning 4 RS 232 VxWorks Console E d H X lei o SERVO POWER DRIVE ENCODER gt Velocity See AI RS 232 0 Controller one Ne c INCREMENTAL ENCODER SIGNALS 2 2 Regeneration Resistor HARMONIC os SOW DRIVE 4 Catastrophic Limit Circuit s os Limit Switches Limit SW Limit SW fe Conditioning 4 9004 ESO Standard Cooling Unit ENS Y e POWER DRIVE ENCODER Velocity Controller 1 f INCREMENTAL ENCODER SIGNALS DNNE Resistor DR VE INTERNAL TEMP SENSOR Ze Date Init European Southern Observatoi EXTERNAL TEMP SENSOR Drawn 010608 P Gen y p er Control Electronics Title Page Block Diagram 11 1 FDR 60503 JA
4. 1O MAINS distribution FUSE 230VAC C gf J2 GROUND PE rOCHASSIS VME PS wae E 12V VME 12V VME d 712 lt NET Connection a 4 J2 lt D MES FLAT CABLE N E d Ji Empty Slot 22 15V 5 2 FOCUS 8 2 E lt L A a lt M2 X gt 9 A lt 2 VME4SA type SPARE J2 72 LI Empty Slot Je CONT L BH European Southern Observatory 3 6 V2 Cheka pem Control Electronics Title M2 LCU Page Internal Wiring Diagram Part 1 1 1 1 FDR mmm JA Document Number File Name Issue Revisions Date Init 3P6 DSD ESO 60400 0001 M2 LCU 01 skd M2 LCU CON T oO QJ Empty Slot 2 2 a nx SIS Q J1 Empty Slot J2 d 5 QJ Empty Slot O9 LI Empty Slot j n Ee Empty Slot 230VAC 15V 500mA KNIEL PS 15V 15V 500mA KNIEL PS 15V Date Init ann European Observatory Choka Control Electronics Title M2 LCU Page Internal Wiring Diagram Part 2 1A 1 FDR Document Number File Name Issue Rev
5. A GR CHB B CHB B CHC 2 CHC Zz _ SYNC_U im SYNC U 5m SYNC V SYNC V 15 SYNC W om SYNC W 1m 5V DGND 13 Lenght TBD Quantity 3 units D Sub Housing connected to shield Complete double electrical test pin to end and check for shorts between lines Fix the cable firmly to the cover to have EFECTIVE strain relief pink grey yellow green white brown Left without connector and insulation removed at the end of violet each wire for testing black PAIR yellow brown white yellow white green NOT USED brown green red blue grey pink red blue E European Southern Observato Drawn 17 06 03 JA 5 y 3 6 2 Cheka Control Electronics Title Page Cable 4 Encoder Input Signals to AC Servo Amplifier ut 114A 17 06 03 JA Document Number File Name Issue Revisions Date Init 3P6 DSD ESO 60400 0001 Cable4 SKF DIN rail mounted circuit One per axis Focus 2N2907 R3 1 2 3 4 upper 5 6 7 8 lower 1 J 1 2 3 4 5 6 7 8 9 2 2907 10 25V R6 K6 European Southern Observatory La Silla itle Limit Switches Signal Conditioning Circuit ize Document Number A 001 J Alonso File L MSW1 OPJ Date Sunday June 15 2003 heet 2 Limit Switches Signal Conditioning LED 2003
6. 5 6 M2 Limit Switches Signal Conditioner Cannon 9 pins female Cover with nut fixations Cable 2 FOCUS DSUB 9 Connected to this connector RED Connected to the LCU 5V across a 1A fuse BLACK 5 1 4 NOTES Lenght 2 5 m Quantity 1 unit Complete double electrical test pin to end and chek for shorts between lines Fix the cable firmly to the cover to have EFECTIVE strain relief Each cable is fitted with female pins and shrinking tube for insulation The connection to the Mitutoyo cable connector is done inserting pin by pin We are buying the special connector for the final version yellow Phase B HN Phase B green Phase A To MITUTOYO brown Phase A linear encoder connector pink 5V white GND 2 Linear Encoder Cable Connector Ig Type RM12BPG 6P Mafg Hirose 2 6 Pin Assignment e3 15V 4 2 Phase A Phase B 4 Phase A 5 GND 6 Phase B PE European Southern Observato Drawn 24 01 05 JA y 3 6 M2 Cheka hi Control Electronics Title Focus Mitutoyo Linear Encoder Connection 1 1 1 24 01 05 JA Document Number File Name Issue Revisions Init 3P6 DSD ESO 60400 0001 Cable5 SKF
7. ACSA Y LSWC Y VMEASA VMEASA Colour Y Ke M Red 1 5 Black 2 Shield 71 ke Shield 2 1 8 Pink 2 Phase A A6 Grey 3 Phase 7 Yellow 4 Phase B B5 Green 5 Phase Z A4 White 6 Phase Z A2 Brown 7 Lim Violet 3 Low Lim D3 Black 7 GND C6 Blue 7 10 15 2 Red 9 9 Table 6 Cable 1 Y Channel 3 VMEASA to Y ACSA Y LSWC Y See Cable 1 VMEASA to Servo Amplifier and Conditioning Schematic Label Cable 1 Y Shield 1 connected to terminal 3 in series with a 51ohm resistor and 10 capacitor see Cabling Layout Schematic 15 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 Signal Term Pairs ACSA F Name TSCI Colour X7 Shield 1 9 Phase 2 Pink 1 3 Grey 6 Phase 4 Yellow 2 Phase B 5 Green 7 Phase Z 6 White 3 Phase Z 7 Brown 8 Table 7 Cable 2 F TSCI to ACSA See Cable 2 Terminal Strip to Servo Amplifier Schematic Label Cable 2 Signal Term Pairs ACSA X Name TSCI X Colour X7 Shield 1 9 Phase A 2 Pink 1 3 Grey 6 Phase 4 Yellow 2 Phase B 5 Green 7 Phase Z 6 White 3 Phase Z 7 Brown 8 Table 8 Cable 2 X TSCI ACSA X See Cable 2 Terminal Strip to Servo
8. 9 X TSU2 HD X Label Cable 9 X Signal TERM Cables Name TSU Y Colour Brkl 1 Blue Brk2 2 Yellow U 3 Red V 4 Black W 5 White PE 6 N A Shield 7 Shield Table 28 Cable 9 Y TSU2 Y to HD Y Label Cable 9 Y Signal TERM Pair Name TSU3 F Colour SWC3A 1 Black SWC3B 2 Blue Table 29 Cable 10 F TSU3 F to UL E Label Cable 10 3p6 M2 CONTROL ELECTRONICS Page 24 Design Document Signal TERM Pair Name TSU3 X Colour SWC3A 1 Black SWC3B 2 Blue Table 30 Cable 10 X TSU3 X to UL X Label Cable 10 X Signal TERM Pair Name TSU3 Y Colour SWC3A 1 1 SWC3B 2 Table 31 Cable 10 Y TSU3 Y to UL Y Label Cable 10 Y Signal TERM Pair Name TSU3 F Colour SWD3A 3 Black SWD3B 4 Blue Table 32 Cable 11_F TSU3_F to LL F Label Cable 11 Signal TERM Pair Name TSU3_X Colour SWD3A 3 Black SWD3B 4 Blue Table 33 Cable 11 X TSU3 X Label Cable 11 X Signal TERM Pair Name TSU3 Y Colour SWD3A 3 Black SWD3B 4 Blue Table 34 Cable 11 Y TSU3 Y to LL Y Label Cable 211 Y 24 06 2005 Doc 3P6 DSD ESO 60400 0001 Page 25 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60
9. Amplifier Schematic Label Cable 2 X Signal Term Pairs ACSA Y Name Y Colour XI Shield 1 9 Phase 2 Pink 1 3 6 Phase 4 Yellow 2 Phase B 5 Green 7 Phase Z 6 White 3 Phase Z 7 Brown 8 Table 9 Cable 2 X TSCI Y to ACSA Y Label Cable 2 Y See Cable 2 Terminal Strip to Servo Amplifier Schematic 16 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 Signal ACSA F Pair LSWC F Name X3 Colour 11 Violet 4 CWL 10 Black 8 Table 10 Cable 3 F ACSA F to LSWC Label Cable 3 Signal X3 ACSA X Pair LSWC X Colour CCWL 11 Violet 4 10 Black 8 Label Cable 23 X CWL Table 11 Cable Z3 X ACSA XtoLSWC X Signal ACSA Y X3 Pair LSWC Y Colour CCWL 11 Violet 4 10 Black 8 Label Cable 3 Y CWL Table 12 3 Y ACSA Y to LSWC Y Page 17 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 Signal ACSA F Pairs Term Name X9 Colour TSUI F CHA 1 Pink 1 6 Grey 2 2 Yellow 3 CHB 7 Green 4 CHC 3 White 5 CHC 8 Brown 6 SYNC U 4 V
10. Cable 4 Y ACSA Y to TSUI Y See Cable 4 Encoder Input Signals to AC Servo Amplifier Schematic Label Cable 4 Y Signal TERM Cables Term Name X1 TSC2 F Colour TSU2 F Brk1 1 Brown 1 Brk2 2 White 2 U U Yellow 3 V V Grey 4 W W Pink 5 PE PE Green 6 PE PE Shield 7 Table 16 Cable 5 amp TSC2 F to TSU2 F Label Cable 5 Page 19 3 6 2 CONTROL ELECTRONICS 24 06 2005 Doc 3P6 DSD ESO 60400 0001 Design Document Signal ACSA X TERMZ Cables Term Name X1 TSC2 X Colour TSU2 X Brk1 1 Brown 1 Brk2 2 White 2 U U Yellow 3 V V Grey 4 W W Pink 5 PE PE Green 6 PE PE Shield 7 Table 17 Cable 5_ X amp TSC2 X to TSU2 X Label Cable 5 X Signal ACSA Y TERM Cables Term Name Xl TSC2 Y Colour TSU2 Y 1 1 Brown 1 Brk2 2 White 2 U U Yellow 3 V V Grey 4 W W Pink 5 PE PE Green 6 PE PE Shield 7 Table 18 Cable 5 Y ACSA Y amp TSC2 Y to TSU2 Y Label Cable 5 Y Signal LSWC F Pairs TERM Name Colour TSU3 F Shield Earth Earth SWC3A 1 White SWC3B 2 Yellow SWD3A 5 Brown SWD3B 6 Green Table 19 Cable 6 F LSWC to TSU3 E Label Cable 6 Design Documen
11. Document Number File Name issue Revisions int 3P6 DSD ESO 60400 0001 Meblock1 skf Figure 1 M2 Control Electronics Block Diagram 9 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 2 4 Focus X and Y Position and velocity control loops The rotation and angular positioning of the M2 drive screws is performed by means of nested position and velocity control loops The main loop is the position control loop starting with an incremental encoder to sense the relative angular position of the motor A dedicated VME motion controller AP4 compares the sensed position with the position command value calculated by the main instrument control software and generates a corrective action 10 range to the AC servo amplifier AP5 The configuration software sets the position controller parameters like integration gain maximum speed software limits initialization point etc The second loop 18 the velocity control loop The corrective output signal 10V generated by the position control loop is sent to the AC servo amplifier trough the VME driver amplifier VME4SA AP1 this is to have all the limit and init switches signals compatible with the VLT software The AC motor velocity is measured by means of the same incremental encoder coupled to the motor axis used to measure the screw angular position The velocity value is compar
12. feedback and add a linear 45mm stroke resolution 2um precision Mitutoyo encoder measuring directly over the focus carriage for the focus position feedback Refer to 7 12 for the connection details 4 Electronics Cabinet The control electronics is mounted on top of the M2 unit inside a hermetically sealed Kn rr cabinet equipped with an active heat exchanger unit The cabinet houses VME LCU three AC servo amplifiers and support circuitry 4 1 VMELCU The VME LCU is integrated by the following components ESO standard VME RACK with minimized depth 10 Slots VMEBUS with Active Termination and Auto Daisy Chain MVME 712M Transition Module for the CPU I O MVME 2604 Power PC 604 32 bit microprocessor 33MB RAM memory MAC4 INC MACCON Motion Controller Module AP4 VMEASA I ESO DC Servo Amplifier type 1 2 Amps capacity AP1 2X KNIEL 15V 1 6A DC Power Supply VME Power Supply KNIEL FPM 300W Refer to 7 2 7 3 7 4 drawings for a schematic view of the VME LCU VVVVVVV WV 42 Servo Amplifiers Three AC Servo Amplifiers type SC 510 are mounted inside the cabinet as shown on 7 5 Refer to AP5 for a detail description of the SC 510 4 3 45 Component Adapter Configuration For each channel the VME4SA has an eight pin dual in line socket for plug in a small component carrier whose components are dependent on the application refer to AP1 page 8 for a detailed explanation In this application the configuration fo
13. ge Cabling Layout X 1 1 Electronic 5 Cabinet 1 17 06 03 Document Number File Name Issue Revisions Date Init 3P6 DSD ESO 60400 0001 Layout SKF 1 RESISTORS 1 2W M 10 Ohms M 52 10 Ohms P Phase A 2 x Phase A A6 Jr Phase B B B7 27 Phase D B B5 2 A2 Z 4 Jr Phase Z Z 2 2 UPPER LIMIT POS P 2 C5 2 LOWER LIMIT POS N D3 gt D5 gt e GND C6 gt e Vx 15V D2 24 HARTING HART PACK CONNECTOR NOTES Lenght 1 5m Quantity 3 units Complete double electrical test pin to end and chek for shorts between lines At the Harting connector side the cables must point downward when plugged in the VME4SA backplane The 10 Ohm resistors shall be inside the Harting connector cover properly insulated Use heat shrinkable tube at the Harting side to fix the cables firmly to the cover and have EFECTIVE strain relief Shield 1 red black Shield 2 pink grey ll Seen Left without connector and green insulation removed at the end of each wire for testing white PAIRS b white green brown green rown red blue grey pink yellow brown white yellow violet NOT USED black blue red Da
14. 400 0001 Signal Name TSUI Colour Neutral 1 Black F20 2 Black Table 35 Cable 12 TSU1 to Catastrophic Limit Switches Chain Label Cable 12 6 SPARE PARTS LIST Item Description Qty 1 Harmonic Drive Servo Amplifier SC 510 2 MVME712 VME CPU transition module 3 KNIEL gt CP 15 1 6 power supply 4 AC Servo Armonic Drive Actuator FHA 25B with brake 5 6 Line Filter Schaffner FN350 8 29 3 6 M2 Limit Switches Signal Conditioner Module Page 26 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 7 DRAWING and SCHEMATIC DIAGRAM APPENDIX The drawings and circuit schematic diagrams are listed below and annexed to this document as eleven A4 format sheets 7 1 Block Diagram 7 2 2 0 Chassis Layout 7 3 M92 LCU Internal Wiring Diagram Part 1 7 4 M2 LCU Internal Wiring Diagram Part 2 7 5 2 Rack Layout Rear View 7 6 Cabling Layout 7 7 Cable 1 VME4SA to Servo Amplifier and Conditioning PCB 7 8 Cable Z2 Terminal Strip to Servo Amplifier 7 9 Cable 4 Encoder Input Signals to AC Servo Amplifier 7 10 Limit Switches Signal Conditioning Circuit 7 11 Limit Switches Signal Conditioning PCB 7 12 Focus Mitutoyo Linear Encoder Connection M2 TOP UNIT MINI RACK
15. A 25B 3015E E150 are used for rotating the focus X and Y driving screws These actuators integrate a brushless AC motor together with a harmonic reduction gear and an incremental 1500 PPR optical shaft encoder coupled to the motor axis Each linear drive is complemented by end of stroke high precision limit init switches together with coarse catastrophic limit switches Every actuator is accompanied by three screw terminals group the connections from the actuator and limit init switches are routed trough these terminals to the control LCU power amplifiers cabinet The signal groups correspond to AC motor drive incremental encoder and limit init switches The control electronics is mounted on top of the M2 unit inside a hermetically sealed Kn rr cabinet equipped with an active heat exchanger unit The cabinet houses a VME LCU three AC servo amplifiers and support circuitry Externally the control cabinet receives the mains 220VAC supply the Ethernet connection one inlet and one outlet coolant hoses By opening the rear door an external PC could be connected via RS232 to each AC servo amplifier and the LCU console port This is for setup and engineering monitoring of the servo amplifiers and VME CPU configuration 8 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 From the control cabinet three identical groups of signals are routed to its close neighbour the M2 drive 2 3 Mo
16. AFFNER FN350 8 29 THERMOSTAT Kg Schroff 60715 001 Weidmuller SAKS 1 35 fuse 250mA S20 SC L CABINET PE AC Servo Amp L Nand PE connected 1 See ACSA n to the power distribution Wiring over 5 Unit Output Cable 48 n e MN i x 9 E Cabes4n HARMONIC Encoder DRIVE Input Brake Power 3 RI Supply R2 329 d R TSC2 nj IS ran HD n SI X1 U 6 5 W S Cable 10 PAMER mm Upper Limit Limit Switches Signal Conditioner 4 Cable 6 n LSWC n 5 ge i Cable 11 69 earth BAUMER ken Lower Limit LL n rv T EE EE 1 E CRDI Mee S 7 S15 Cable 12 gt 2 ran Catastrophic 3 Schuko outlets LCU Cooling Unit 1 spare Catastrophic Catastrophic mem t Catastrophic b H Catastrophic sw Catastrophic Limit Chain Catastrophic mem Direoty Wied Wiring over M3 Unit to each TP MINISTER ME n ron LN Cable Strain Relief Mains Relay Holding Coil Circuit Date Init Eur n hern rv uropean Southern Observatory 3 6 M2 Cheka n Control Electronics pr Title Pi
17. Aires BIBUNT TP Pr 13 6 8 18 20 22 2220 25 7 DRAWING AND SCHEMATIC DIAGRAM 2 2 4 4 1090 26 7 1 BLOCK DIAGRAM EEE Ie A 26 EE ER CU CHASSIS LAY OUT EE 26 7 3 M2 LCU INTERNAL WIRING DIAGRAM PART 1 26 7 4 M2 LCU INTERNAL WIRING DIAGRAM PART 2 nemen enne 26 7 5 M2 RACK LAYOUT REAR VIEW 5 aiiis eve 26 7 65 GCABEINGISAXOU Ts eet a 26 77 CABLE 1 VME4SA TO SERVO AMPLIFIER AND CONDITIONING eee 26 7 8 CABLE 2 TERMINAL STRIP TO SERVO AMPLIFIER eene 26 7 9 CABLE 4 ENCODER INPUT SIGNALS TO AC SERVO AMPLIFIER eee eene 26 7 10 LIMIT SWITCHES SIGNAL CONDITIONING CIRCUIT enne enhn nnne 26 7 11 LIMIT SWITCHES SIGNAL CONDITIONING PCH nnne 26 729 FOCUS MITUTOYO LINEAR ENCODER CONNECTION ssssssssececsesssseceeececsesssaeceeececsensntsseeceeees 26 INDEX OF FIGURES AND TABLES FIGURE 1 M2 CONTROL ELECTRONICS BLOCK 2 4 412 10 00000000000000000000 8 4 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 TABLE 1 FHA 25B 3015E E150 HARMONIC 10 TABLE 2 ABSOLUTE MAXIMUM MECHANICAL TRAVEL cerent nee enne 10 TABLE 3 COM
18. EUROPEAN SOUTHERN OBSERVATORY Organisation Europ enne pour des Recherches Astronomiques dans l H misph re Austral Europ ische Organisation f r astronomische Forschung in der s dlichen Hemisph re LA SILLA OBSERVATORY 3p6 M2 CONTROL ELECTRONICS Doc No 3P6 DSD ESO 60400 0001 Issue 2 0 Date 24 January 2005 Prepared J Alonso Name Date Signature Approved G Andreoni Name Date Signature Released G Andreoni Name Date Signature 2 3p6 M2 CONTROL ELECTRONICS Design Document 24 06 2005 Doc 3P6 DSD ESO 60400 0001 CHANGE RECORD Section Paragraph 28 05 2004 25 06 2004 24 01 2005 Several corrections additions Mains power distribution modification Several corrections As built Section 3 Focus X and Y limit range Focus Mitutoyo Available spare parts list added Page 3 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 INDEX OF CONTENTS 1 INTRODUCTION e 5 1 1 incite IRR EE EES EE SE 5 12 REFERENCE DOCUM N S e nenne en eren ee 5 133 APPELICABEE DOCUMENTS E etre EE EE 5 1 4 ACRONYMS amp ABBREVIATIONS 6 2 M2 MOTION CONTROL ere
19. LS H ARM INTERNAL TEMP SENSOR 4105 50W M Mt European Southern Observatory EXTERNAL TEMP SENSOR me 3 6 M2 Chckd 6 jos re Control Electronics Title a Block Diagram 1 1 1 FDR 06 05 03 Document Number File Name Issue Revisions Date Init 3P6 DSD ESO 60400 0001 M2block1 skf M2 LCU FRONT SIDE VIEW P KNIEL 15V 500mA 6HE 1 BLIND PLATE BLIND PLATE BLIND PLATE 1 BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE KNIEL 15V 500mA LEGENDE RACK ESO Standard minimize deepth VMEBUS 10 SLOTS ACTIVE TERMINATION AUTO DAISY CHAIN CPUIO TRANSITION MODULE MVME 712M CPU MOTOROLA MVME167 MAC4 INC MACCON MOTION CONTROLLER VME4SA ESO DC SERVO AMPLIFIER TYPE 1 2Amps 2X KNIEL 15V 1 6A Power Supply VME PS KNIEL FPM 300W FOR VME BUS SUPPLY BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE BLIND PLATE REAR SIDE VIEW MVME 712M CPUIO pas s European Observatory A Control Electronics Title M2 LCU Chassis Layout un 1 FOR 06 05 03 Document Number Issue Revisions Date Init 3P6 DSD ESO 60400 0001 M2 LCU skd
20. Measured VLT Very Large Telescope LCU Local Control Unit NTT New Technology Telescope PCB Printed Circuit Board RAM Random Access Memory TTL Transistor Transistor Logic PPR Pulse Per Revolution ZD Zenith Distance 7 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 2 M2 MOTION CONTROL 2 1 Motion Control Concept The concept developed for the motion control of the App M2 unit is based on the standard motion control components used by ESO to build instruments This approach brings various advantages like reduced development and manufacturing costs past proven experience standardised components and shared spare parts The standard VMEASA 15 used as usually done with the MACC INC companion difference with the more typical implementations is that here the VMEASA does not act as the drive motor power amplifier but as a signal driver for a specialized high power AC servo amplifier However the limit and init switches interface capabilities of the VMEASA are still fully used The advantage of this approach is that the specialized AC servo amplifier is absolutely transparent to the VLT software 2 2 Control Components The motion control electronic components used for the M2 are gt and VME 4SA VLT standard modules gt Harmonic Drive AC Servo Amplifier SC500 510 5 Three Harmonic Drive Systems servo actuators type FH
21. PONENT ADAPTER CONFIGURATION netten 12 TABLE4 CABLE 1 F CHANNEL 1 VME4SA TO TSCI F LSWTO 13 TABLE 5 CABLE 1 X CHANNEL 2 VME4SA TO X ACSA X LSWC 14 TABLE 6 CABLE 1 Y CHANNEL 3 VME4SA Y ACSA Y LSWO 14 TABLE 7 CABLE 2_F TSC1_F TO ACSA Ei 15 TABLE 8 2 X TSCI XI 15 TABEEOSCABEBZ2 X ELSCl Y TOAGSA Y EE 15 TABLE 10 CABLE 3 F ACSA F TOLSWO 020 040 00000 nenne nen nennen trente nen renes 16 TABLE 11 3 X ACSA XTOLSWO X eene nennen rre 16 TABLE 12 CABLEZ3 Y ACSA Y TOLSWO Y eene nennen nnne 16 TABLE 13 4 F ACSA F TO TSUI E 17 TABLE 14 4 X ACSA X TO TSUI X nennen eene nennen trennen nennen nnns 17 TABLE US CABLE 4 Y ACSA Y TO TSUT NA EE 18 TABLE 16 5 F ACSA F amp TSC2 TSUA EL 18 TABLE 17 5 X ACSA X amp 2 02 19 TABLE 18 5 Y ACSA Y amp TSC2 Y TOTSU2 0000 0 0081 19 TABLE 19 CABLE 6 FF LSWC TSU3_F eterne nennen nen ree rennen nennen 19 TABLE20 6 X LSWC X TOTSUS3 X en e e eene nnne nennen trennen ener nnns 20 TABLE 21 CABLEZ6 Y LSWC Y TO TSU3 Y detener erred 20 TABLE22 ISCT TOTS EE DEE 20 TABLE 23 CABLE 8 F
22. TSUI E 21 TABLE 24 CABLEZ8 X TSUI XTOHD Ni 21 52 8 Y TSUT Y EE 22 TABLE 26 CABLE 9 F TSU2 F TO HD eere e ee Ended 22 TABLE 27 gt CABLE 9 X TSU2 X TOHD eese eie eii e aai 23 TABLE28 CABLEZ9 Y TSU2 Y TOHD Y 23 TABLE29 CABLE 10 F TSU3 F TO ULF EE 23 TABLE 30 CABLE IO X TSU3 X TO UL E cett ree et eaa ens 24 TABLESIZCABLE IO Y ISUS Y TO UE ha eee t aye Re e 24 TABEE32 CABLE 11 F TSU3 F TOLL P esce ete tertie ie died 24 TABLE 33 11 X TSU3 X TOLL Ni 24 TABLE34 CABLE 1 Y TSU3 Y TOLL e nte eae edic ees 24 TABLE 35 CABLE 12 TSU1 TO CATASTROPHIC LIMIT SWITCHES CHAIN 25 Page 5 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 1 INTRODUCTION Since ever the 3 6 telescope f 8 secondary unit has suffered from severe mechanical instabilities This together with the inability to introduce online corrections to the decentring comma has severely limited the optical performance of the telescope Considering that the new generation of instruments e g HARPS need to exploit the maximum possible optical image quality attainable with the telescope a new mechanical design based on the NTT secondary unit concept was designed and built The new unit is equipped with VLT complaint comp
23. aximum Motor Speed Rpm 4000 Resistance Q 3 7 Inductance mH 5 Weight Kg 4 7 Encoder Resolution Ppr 1500 Encoder Output Signals A A B B C C U U V V W W 5V Line Driver Table 1 FHA 25B 3015E E150 Harmonic Drive The init limit switches BAUMER type g e The catastrophic limit switches are Omron type D4D 1532N e The driving screws are of the zero backlash type equipped with roller screw nuts The pitch is 1 millimetre Focus mm 20 X mm 6 2 Y mm 6 5 Table 2 Absolute Maximum Mechanical Travel e The focus limit switches adjustment is set to 16mm for the normal limit and 16 5mm for the focus catastrophic limit 11 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 The X and Y limit switches adjustment is set to Smm for the normal limit and 5 5mm for the X and Y catastrophic limit 3 2 Focus Linear Encoder Originally the three axes focus X and Y were equipped with rotary encoders inside the AC servo drive actuators These actuators drive the mechanism screw directly and assume that the screw nut combination is backlash free From these encoders the velocity and position feedback for the control system is derived During the preliminary tests we found that the focus screw nut combination has a backlash greater than 100um It was decided to keep the rotary encoder for the velocity
24. d 2 1 Phase A 8 Pink 2 Phase A A6 Grey 3 Phase B7 Yellow 4 Phase B B5 Green 5 Phase Z A4 White 6 Phase Z A2 Brown 7 Upp Lim Violet 3 Low Lim D3 Black 7 GND C6 Blue 7 10 Vx 15V D2 Red 9 9 Table 4 Cable 1 Channel 1 VME4SA to TSC1_F ACSA_F LSWC F See Cable 1 VMEASA to Servo Amplifier and Conditioning PCB Schematic Label Cable 1 Shield 1 connected to terminal 3 in series with a 5lohm resistor and 10nF capacitor see Cabling Layout Schematic 3p6 M2 CONTROL ELECTRONICS Design Document Table 5 Page 14 24 06 2005 Doc 3P6 DSD ESO 60400 0001 Signal Pin Pairs Term ACSA X LSWC X VMEASA VME4SA Colour X Ke M 1 5 Black 2 Shield 71 27 Shield 2 1 8 Pink 2 Phase A A6 Grey 3 Phase B7 Yellow 4 Phase B B5 Green 5 Phase Z A4 White 6 Phase Z A2 Brown 7 Lim Violet 3 Low Lim D3 Black 7 GND C6 Blue 7 10 Vx 15V D2 Red 9 9 Cable 1 Channel 2 VME4SA to TSC1 X ACSA X LSWC X See Cable 1 VMEASA to Servo Amplifier and Conditioning PCB Schematic Label Cable 1 X Shield 1 connected to terminal 3 in series with a 5lohm resistor and 10nF capacitor see Cabling Layout Schematic Signal Pin Pairs Term
25. ed with the commanded velocity value coming from the MAC4 INC output and the error signal is filtered by a digital PID inside the servo amplifier The PID filter parameters are defined by the aid of a MS Windows program talking via RS232 to the amplifier during configuration The parameters are kept in a flash memory inside the amplifier Each function focus X and Y is equipped with limit init and catastrophic limit switches mounted at the end of stroke of each function The mechanical configuration is such that during normal operation the limit init switches are only actuated but in case of malfunction the carriage will continue moving actuating the catastrophic limit switch as well 3p6 M2 CONTROL ELECTRONICS Design Document Page 10 24 06 2005 Doc 3P6 DSD ESO 60400 0001 3 M2 DRIVES ELECTROMECHANICAL COMPONENTS 3 1 Focus X and Y Drive Components three axis use identical electromechanical components Rated Output Power W 160 Rated Output Torque Nm 51 Maximum Output Torque Nm 157 Max Continuous Stall Torque Nm 71 Rated Output Speed Rpm 30 Maximum Output Speed Rpm 40 Rated Current Arms 1 4 Maximum Current Arms 3 2 Ratio 100 Torque Constant Nm A 60 Voltage Constant V Rpm 6 4 Mechanical Time Constant ms 6 8 Electrical Time Constant ms 1 4 Moment of Inertia output 2 3 Power Supply for control Unit VAC 230 Rated Motor Speed Rpm 3000 M
26. iolet 7 SYNC U 5 Black 8 SYNC V 10 White green 9 SYNC 15 Brown green 10 SYNC W 9 Red blue 11 SYNC W 14 Grey pink 12 5V Enc 11 Red 13 DGND 13 Blue 14 Shield D Sub 15 Housing Table 13 Cable 4 to TSUI See Cable 4 Encoder Input Signals to AC Servo Amplifier Schematic Label Cable 4 Signal ACSA X Pairs Term Name X9 Colour TSUI X CHA 1 Pink 1 6 2 2 Yellow 3 CHB 7 Green 4 CHC 3 White 5 CHC 8 Brown 6 SYNC U 4 Violet 7 SYNC U 5 Black 8 SYNC V 10 White green 9 SYNC V 15 Brown green 10 SYNC W 9 Red blue 11 SYNC W 14 Grey pink 12 5V Enc 11 Red 13 DGND 13 Blue 14 Shield D Sub 15 Housing Table 14 Cable 4_X ACSA_X to TSUI X 18 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 See Cable 4 Encoder Input Signals to AC Servo Amplifier Schematic Label Cable 4 X Signal ACSA Y Pairs Term Name X9 Colour TSUI Y CHA 1 Pink 1 6 2 2 Yellow 3 CHB 7 4 3 White 2 8 Brown 6 SYNC U 4 Violet 7 SYNC U 5 Black 8 SYNC V 10 White green 9 SYNC V 15 Brown green 10 SYNC W 9 Red blue 11 SYNC Wi 14 Grey pink 12 5V Enc 11 Red 13 DGND 13 Blue 14 Shield D Sub 15 Housing Table 15
27. isions Date Init 3P6 DSD ESO 60400 0001 M2 LCU 02 skd LIMIT SWITCHES CONDITIONER LIMIT SWITCHES CONDITIONER LIMIT SWITCHES CONDITIONER This surfaces shall be in the same plane HARMONIC DRIVE HARMONIC DRIVE HARMONIC DRIVE AMPLIFIER AMPLIFIER AMPLIFIER 490 mm 20 mm COOLING UNIT REAR SIDE 60mm Lg 60mm COOLING UNIT SUPPORTED OVER SLIDING RAILS TO ALLOW A 25mm CLEARENCE BELOW Date Init Drawn 200408 JA European er Observatory Chekd Set Control Electronics Tite M2 Rack Layout Page Rear View 1 1 1 FDR 060503 Document Number Issue Revisions Date hit 3P6 DSD ESO 60400 0001 rack skf CH1 CH2 CH3 CH4 VME4SA Weidmuller SAKS 1 35 fuse 10A Inrush Supressor 6A 7 Schrack Relay MT306230 230V coil 250V 10A CABINET EXTERNAL BREAKER Switch LE2 16 1752 2 Knob LFS2 N6 175 L N PE 230VAC UPS SUPPLY FROM SCP 1 n SS CN SN n x3 FOCUS X Y Cable 43 n Cable 2 n a X7 R1 and R2 connected to the power resistor x3 FOCUS X Y LIN LOUT UN NN MN PEIN PEIN OVERVOLTAGE PROTECTION HT 2PE 230VAC RFI POWER LINE FILTERS SCH
28. me TSUI X Colour CHA 1 2 Green white CHB 3 Grey CHB 4 Grey white CHC 5 Yellow CHC 6 Yellow white SYNC U 7 Brown SYNC U 8 Brown white SYNC V 9 Blue SYNC V 10 Blue white SYNC W 11 SYNC WI 12 Orange white 5V Enc 13 Red DGND 14 Black Shield 15 Table 24 Cable 8 X TSUI Xto HD X Label Cable 8 X Page 22 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 Signal TERM Pairs Name TSUI Y Colour CHA 1 Green CHA 2 Green white CHB 3 Grey CHB 4 Grey white CHC 5 Yellow CHC 6 Yellow white SYNC U J Brown SYNC U 8 Brown white SYNC V 9 Blue SYNC V 10 Blue white SYNC W 11 SYNC W 12 Orange white 5V Enc 13 14 Black Shield 15 Table 25 Cable 8 Y TSUI Y to HD Y Label Cable 8 Y Signal TERM Cables Name TSU2 F Colour Brkl 1 Blue Brk2 2 Yellow U 3 Red V 4 Black W 5 White PE 6 Green Shield 7 Shield Table 26 Cable 79 F TSU2 F to HD F Label Cable 29 3p6 M2 CONTROL ELECTRONICS Design Document Page 23 24 06 2005 Doc 3P6 DSD ESO 60400 0001 Signal TERM Cables Name TSU2 X Colour Brk1 1 Blue Brk2 2 Yellow U 3 Red V 4 Black W 5 White PE 6 Green Shield 7 Shield Table 27 Cable
29. r channels 1 2 and 3 is identical and as shown in the table below Pin row 1 Pin row 2 Component 1 8 2 1 360K 12 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 3 6 Wire jumper 4 5 Open Table 3 Component Adapter Configuration 4 4 Cabinet Cooling Unit The cabinet cooling unit used is the ESO standard VLT Electronic Cabinet Cooling System AP3 The unit is mounted on the bottom of the cabinet with adequate clearance around it for the proper air circulation Two PT100 elements one mounted over a heat sink in the outer wall of the cabinet and the other in contact with the inner wall of the cabinet are used by the cooling system for keeping the internal temperature the same as the exterior and thus avoiding thermal gradients The heat is removed from the unit by means of circulating water Note that the cooling unit fans are used for blowing air directly over the VME chassis due to space limitations no supplemental fan tray is used in the application 4 5 Mains Power Distribution AC power enters the cabinet via a double pole circuit breaker The control knob of this breaker is located externally over the side wall of the cabinet Internally the AC supply goes to a double contact power relay The coil of the relay is energized with the mains supply and serially connected with the catastrophic limit switches chain a thermosta
30. t 3p6 M2 CONTROL ELECTRONICS Page 20 24 06 2005 Doc 3P6 DSD ESO 60400 0001 Signal LS WC X Pairs TERM Name Colour TSU3 X Shield Earth Earth SWC3A 1 White 1 SWC3B 2 Yellow 2 SWD3A 5 Brown 3 SWD3B 6 Green 4 Table 20 Cable 6 X LSWC X to TSU3 X Label Cable 6 X Signal LS WC Y Pairs TERM Name Jl Colour TSU3 Y Shield Earth Earth SWC3A 1 White 1 SWC3B 2 Yellow 2 SWD3A 5 Brown 3 SWD3B 6 Green 4 Table 21 Cable 6 Y LSWC Y to TSU3 Y Label Cable 6 Y Signal TERM Cables TERM Name TSCI Colour TSUI Neutral 1 White 1 20 2 Black 2 Table 22 Cable 7 TSC1 to TSUI abel Cable 7 3p6 M2 CONTROL ELECTRONICS Design Document Page 21 24 06 2005 Doc 3P6 DSD ESO 60400 0001 Signal TERM Pairs Name TSUI F Colour CHA 1 2 Green white CHB 3 Grey CHB 4 Grey white CHC 5 Yellow CHC 6 Yellow white SYNC U 7 Brown SYNC U 8 Brown white SYNC V 9 Blue SYNC V 10 Blue white SYNC W 11 Orange SYNC W 12 Orange white 5V Enc 13 Red DGND 14 Black Shield 15 Table 23 Cable 8 F TSU1_F to HD F Label Cable 8 Signal TERM Pairs Na
31. t and a protection fuse Finally the mains supply goes through an inrush suppressor an over voltage protector and a power line filter The power distribution after the conditioning is as follows gt Direct connection to the three AC servo amplifiers gt Three Schucko outlets for powering the VME cooling unit and spare Refer to 7 6 for the schematic diagram 13 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 5 CABLING 5 1 Focus X an Y drive units Near each harmonic drive unit a group of three numbered screw terminal strips named TSUI n TSU2 TSUS3 n where n is F X Y to identify the particular group serve both as test points and junction for the connections coming from the LCU cabinet to each harmonic drive unit and limit init switches 5 2 Cabinet The cabinet wiring is as shown on 7 6 For sake of simplicity only one channel is shown 5 2 1 Cable Feed trough The cables feed trough is a custom built piece which allows passing every cable and hose to the cabinet interior keeping adequate seal to prevent the internally circulating air of leaking to the outside environment 5 3 Inside the LCU The LCU wiring is done as shown on 7 3 and 7 4 5 4 Wiring Tables Signal Pin Pairs Term ACSA F LSWC VMEASA VMEASA Colour F X3 M E8 Red 1 5 Black 2 Shield 1 i be Shiel
32. te Init European Southern Observato Drawn 17 06 03 JA 3 6 2 y Chckd hk Control Electronics m P bs Cable 1 VME4SA to Servo Amplifier and Conditioning 1A 1 17 06 03 Document Number File Name Issue Revisions Date Init 3P6 DSD ESO 60400 0001 Cable1 SKF Phase A A 1 Phase A A 6 Phase B B 2 Phase B p 7 Phase Z Z Phase Z Z 8 9 Cannon Dsub 9 pins male Cover with fixation screws NOTES Lenght 1 m Quantity 3 units Complete double electrical test pin to end and chek for shorts between lines Fix the cable firmly to the cover to have EFECTIVE strain relief pink Left without connector and grey insulation removed at the end of each wire for testing yellow PAIRS green violet black blue red hi white green brown green red blue grey pink yellow brown white yellow brown NOT USED PEE European Southern Observato Drawn 17 06 03 5 3 6 2 Cheka mes Control Electronics Title 8 VE P Cable 2 Terminal Strip to Servo Amplifier 1 1 1 17 06 03 Document Number File Name Issue Revisions Date li 3P6 DSD ESO 60400 0001 Cable2 SKF Cannon Dsub 15 pins e high density Screws Cover with fixation CHA A 1
33. tion Control Functions The motion control function of the M2 comprises three identical AC servo drives amplifier combinations with built in digital velocity loop These units provide incremental encoder pulses to the outside world as balanced differential signals and receives an analogue voltage in the range of 10V as the external velocity command On top of the velocity loop a position loop inside the control LCU utilizes the encoder signals as feedback and delivers the required 10V velocity control signal Normal operation init limit functions are implemented by six BAUMER type Com g precision switches These switches report both to the AC servo amplifier and the VMEASA via dedicated signal conditioning circuits mounted over small PCBs A hardware interlocking function called the catastrophic limit is implemented by six rugged limit switches mounted at the end of stroke for the focus X and Y mechanisms The six switches are serially connected and act over the mains power relay coil see Figure 1 below
34. uter controlled servo drives for the focus X and Y motions of the secondary mirror unit 1 1 PURPOSE AND SCOPE This document is intended to serve as a design document construction guide and service manual for the 3p6 M2 control electronics Starting from a general description and block diagram it goes all the way down to the schematic diagrams function tables connection tables and references to the part list 1 2 DOCUMENTS RE1 3 6m Telescope 8 Top end Overhaul User Requirements 3p6 SPE ESO 36022 0001 Issue 1 3 M Sterzik December 12 2001 RE2 Configuration of VLT Standard VME Boards VLT MAN ESO 17210 1358 Issue 1 4 B Gustafsson 5 October 2001 1 3 APPLICABLE DOCUMENTS ESO VME4SA X1 4 Channel DC Servo Amplifier Technical Manual VLT MAN ESO 17130 0273 Issue 3 0 AP2 ESO VME4SA BACKPLANE Technical Manual VLT MAN ESO 17130 0274 Issue 3 0 AP3 Electronic Cabinet Cooling System User Manual VLT MAN ESO 17130 1603 Issue 1 0 F Biancat Marchet April 27 1998 APA USER Manual MACCONTROLLER MAC4 INC Version 4 2 AP5 Harmonic Drive Operations Manual AC Servo Amplifier SC 500 510 AP6 X VLT SPE ESO 10000 0015 VLT Electronic Design Specification Issue 4 0 09 12 96 6 3p6 M2 CONTROL ELECTRONICS 24 06 2005 Design Document Doc 3P6 DSD ESO 60400 0001 1 4 ACRONYMS 8 ABBREVIATIONS DC Direct Current VME Versa Module Europe TBD To Be Defined TBM To Be
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