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Aerotech Soloist CP Hardware Manual

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Hardware Manual
ENB/FLT
PWR
MARKER
INPOS
ETHERNET
J102
MOTOR FEEDBACK
J103
TM
TM
AEROTECH.
COM
ESTOP
TB101
AUX I/O
J104
240V~
MAX
50/60Hz
15A MAX
AC1
AC2
DANGER!
A
High Voltage
B
C
Soloist CP
ENB/FLT
AGND
PWR
AIN+
MARKER
INPOS
AIN-
AOUT
OP
OM
0
1
2
3
4
5
6
7
OP
OM
0
1
2
3
4
5
6
7
TM
TM
AEROTECH.
COM
C
0
1
2
3
4
5
6
7
240V~
GND
MAX
50/60Hz
15A MAX
C
0
1
AC1
2
AC2
4
5
6
7
+5V
A
NC
B
C
NO
C
DANGER!
High Voltage
P/N: EDU180
Revision: 4.05.00

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Summary of Contents for Aerotech Soloist CP

  • Page 1 Soloist CP Hardware Manual P/N: EDU180 Revision: 4.05.00 ENB/FLT ENB/FLT AGND AIN+ MARKER INPOS MARKER INPOS AIN- AOUT ETHERNET J102 MOTOR FEEDBACK J103 AEROTECH. ESTOP AEROTECH. TB101 AUX I/O J104 240V~ 240V~ 50/60Hz 50/60Hz 15A MAX 15A MAX DANGER! High Voltage...
  • Page 2 This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies.

  • Page 3: Table Of Contents

    Table of Contents Soloist CP Table of Contents Table of Contents List of Figures List of Tables EC Declaration of Conformity Agency Approvals Safety Procedures and Warnings Quick Installation Guide xiii Chapter 1: Introduction 1.1. Drive and Software Compatibility 1.2. Electrical Specifications 1.2.1.

  • Page 4: Table Of Contents

    Soloist CP Table of Contents 2.5.6. Analog Output 0 (J104) 2.5.7. Analog Input 0 (J104) 2.6. Brake Power Supply (TB103) 2.6.1. Solid State Relay Specifications (TB103) 2.7. RS-232 Interface (TB103) 2.8. -EXTSHUNT Option (TB104) 2.9. PC Configuration and Operation Information Chapter 3: -I/O Expansion Board 3.1.

  • Page 5: Table Of Contents Soloist Cp

    Table of Contents Soloist CP List of Figures Figure 1-1: Soloist CP Networked Digital Drive Figure 1-2: Functional Diagram Figure 1-3: Power Dissipation vs. Output Current  Figure 1-4: Ambient Temperature vs. Power Dissipation Figure 1-5: Dimensions Figure 2-1: Control Supply Connections...
  • Page 6 Soloist CP Table of Contents Figure 3-1: Soloist CP with -IO Option Board Figure 3-2: Analog Output 1 Connector (TB201) Figure 3-3: Analog Input Typical Connection (TB201) Figure 3-4: Opto-Isolated Inputs Figure 3-5: Inputs Connected to a Current Sourcing Device...

  • Page 7: List Of Tables

    Table 2-8: Motor Power Output Connections (TB102) Table 2-9: Motor Power Output Mating Connector Table 2-10: Wire Colors for Aerotech Supplied Cables (Brushless) Table 2-11: Wire Colors for Aerotech Supplied Cables (DC Brush) Table 2-12: Wire Colors for Aerotech Supplied Cables (Stepper)
  • Page 8 Soloist CP Table of Contents Table 3-1: -IO Expansion Board Jumper Configuration Table 3-2: -IO Option Board Fuse Information  Table 3-3: Analog Output Connector Pin Assignment (TB201) Table 3-4: Analog Output Mating Connector Table 3-5: Analog Inputs Connector Pin Assignment (TB201)

  • Page 9: Ec Declaration Of Conformity

    Declaration of Conformity Soloist CP EC Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2897 Product Soloist CP Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the...

  • Page 10: Agency Approvals

    Soloist CP Declaration of Conformity Agency Approvals Aerotech, Inc. Model Soloist CP Series Digital Drives have been tested and found to be in accordance to the following listed Agency Approvals: Approval / Certification: CUS NRTL Approving Agency: TUV SUD America Inc.

  • Page 11: Safety Procedures And Warnings

    7. Make sure the Soloist CP and all components are properly grounded in accordance with local electrical safety requirements. 8. Operator safeguarding requirements must be addressed during final integration of the product. D A N G E R : The Soloist CP case temperature may exceed 70°C in some applications. www.aerotech.com...
  • Page 12 Exceeding environmental or operating specifications can cause damage to the equipment. 5. If the Soloist CP is used in a manner not specified by the manufacturer, the protection provided by the Soloist CP can be impaired and result in damage, shock, injury, or death.

  • Page 13: Quick Installation Guide

    Quick Installation Guide Soloist CP Quick Installation Guide This chapter describes the order in which connections and settings should typically be made to the Soloist CP. If a custom interconnection drawing was created for your system (look for a line item on your Sales Order under the heading “Integration”), that drawing can be found on your installation device.
  • Page 14 Soloist CP Quick Installation Guide This page intentionally left blank. www.aerotech.com...

  • Page 15: Chapter 1: Introduction

    The Soloist CP is offered with an optional encoder interpolation feature (-MXU), an auxiliary square wave encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -IO option), and separate power connections for motor and control supply voltages.

  • Page 16: Table 1-1: Feature Summary

    Soloist CP Introduction Table 1-1: Feature Summary Standard Features Line driver square wave quadrature encoder input for position and velocity feedback Line driver square wave auxiliary quadrature encoder input or output for PSO Four opto-isolated user outputs Six opto-isolated user inputs (two high speed) One 16-bit differential analog input (± 10 V)

  • Page 17: Table 1-2: Accessories

    24 VDC, 2 A power supply for optional brake Transformers Refer to Section 2.1.3. for listings, wiring, and specifications Cables Interconnection A complete list of Aerotech cables can be found on the website at http://www.aerotechmotioncontrol.com/manuals/index.aspx Joystick/Handwheel Refer to Section 4.1. Section 4.2. www.aerotech.com...

  • Page 18: Functional Diagram

    Soloist CP Introduction The following block diagram shows a connection summary. For detailed connection information, refer to Chapter 2 and Chapter 3. -IO Option USB 1.1 Port J101 Analog Input 1 +/- TB201 Analog Output 1 Ethernet Port J102 Encoder +5V / Common...

  • Page 19: Drive And Software Compatibility

    Introduction Soloist CP 1.1. Drive and Software Compatibility The following table lists the available Soloist drives and which version of the Soloist software first provided support for a given drive. Drives that list a specific version number in the Last Software Version column will not be supported after the listed version.

  • Page 20: Electrical Specifications

    Soloist CP Introduction 1.2. Electrical Specifications Table 1-4: Electrical Specifications Description CP 10 CP 20 CP 30 Motor Input Voltage 14-240 VAC Supply Input Frequency 50-60 Hz Inrush Current 32 A @ 230 VAC; 16 A @ 115 VAC Maximum...

  • Page 21: System Power Requirements

    Introduction Soloist CP 1.2.1. System Power Requirements The following equations can be used to determine total system power requirements. The actual power required from the mains supply will be the combination of actual motor power (work), motor resistance losses, and efficiency losses in the power electronics or power transformer. An EfficiencyFactor of approximately 90% should be used in the following equations.

  • Page 22: Power Dissipation

    If the result is lower than the known operating ambient temperature, additional measures are required to cool the Soloist CP. Mounting it to a large metal plate for extra heat-sinking and providing additional fan flow are suggested.

  • Page 23: Mechanical Design

    Ø10.3 [Ø0.41] (TYP.) ENB/FLT AGND AIN+ MARKER INPOS AIN- AOUT AEROTECH. 240V~ 50/60Hz 15A MAX Soloist CP with I/O DANGER! 630D2059, REV H High Voltage 4.7 [0.19] 6.4 [0.25] (TYP.) 167.4 [6.59] REC. MTG. HDWR: M4 [#8] 178.2 [7.02] Figure 1-5: Dimensions...

  • Page 24: Environmental Specifications

    Soloist CP Introduction 1.4. Environmental Specifications The environmental specifications for the Soloist CP are listed below. Ambient Temperature Operating: 0° to 50°C (32° to 122° F) Storage: -30° to 85°C (-22° to 185° F) Humidity Maximum relative humidity is 80% for temperatures up to 31°C. Decreasing linearly to 50% relative humidity at 40°C.

  • Page 25: Chapter 2: Installation And Configuration

    Soloist CP Chapter 2: Installation and Configuration 2.1. Power Connections The Soloist CP has two AC input connectors; one for control power and a second for motor power. For a complete list of electrical specifications, refer to Section 1.2. N O T E : The machine integrator, OEM or end user is responsible for meeting the final protective ground- ing requirements of the system.

  • Page 26: Control Supply Connections (Tb106)

    The control power supply input allows the Soloist CP to maintain communications if the motor power is removed, such as in an Emergency Stop condition. The control power supply requires a minimum of 85 VAC input to operate properly.

  • Page 27: Motor Supply Connections (Tb102)

    W A R N I N G : Do not operate the Soloist CP without the safety ground connection in place. W A R N I N G : Do not operate the Soloist CP without proper branch protection.

  • Page 28: Transformer Options

    Soloist CP Installation and Configuration 2.1.3. Transformer Options An external isolation transformer can be connected to the motor supply AC input. This is done to reduce the operating voltage of the motor and may also reduce electrical noise. Table 2-4: Nominal Motor Operating Voltages / Required AC Voltages ...

  • Page 29: Vdc Motor Power With A Tv0.3-28-56-St Transformer

    Installation and Configuration Soloist CP Integral Fuse 3.15A Slow-Blow Drive F1-IN AC HI Internal Thermal 115 VAC AC LO F1-OUT Switch 50/60 HZ INPUT 115V SAFETY 100V 115V 100V Frame Ground TV0.3-28-56-ST Wiring 115 VAC INPUT Secondary = 28 VAC (40 VDC Bus) Integral Fuse 3.15A Slow-Blow...

  • Page 30: Vdc Motor Power With A Tv0.3-28-56-St Transformer

    Soloist CP Installation and Configuration Integral Fuse 3.15A Slow-Blow Drive F1-IN AC HI Internal Thermal 115 VAC AC LO F1-OUT Switch 50/60 HZ INPUT 115V SAFETY 100V 115V 100V Frame Ground TV0.3-28-56-ST Wiring Secondary = 28+28 = 115 VAC INPUT...

  • Page 31: Volt Dc Bus From 115 And 230 Vac Source

    Installation and Configuration Soloist CP Primary Fuse 4A Slow-Blow Drive #18 WHT AC HI Internal Thermal 115 VAC #18 WHT AC LO 50/60 HZ Switch splice INPUT 28V RED 115V BLK SAFETY 100V ORN 0V GRN 0V GRY 115V BRN...
  • Page 32 Soloist CP Installation and Configuration Primary Fuse 4A Slow-Blow Drive #18 WHT AC HI Internal Thermal 115 VAC #18 WHT AC LO 50/60 HZ Switch splice INPUT 56V RED 115V BLK SAFETY 100V ORN 0V GRN 0V GRY 115V BRN...
  • Page 33 Installation and Configuration Soloist CP Primary Fuse 4A Slow-Blow Drive #18 WHT AC HI Internal Thermal 115 VAC #18 WHT AC LO Switch 50/60 HZ splice INPUT 56V RED 115V BLK SAFETY 100V ORN 0V GRN 0V GRY splice 115V BRN...

  • Page 34: Control And Motor Power Wiring Using A Tm3 Or Tm5 Transformer

    Soloist CP Installation and Configuration 1ST CP TM3/TM5 TRANSFORMER MODULE 115~ 115~ CONTROL SUPPLY 3rd CP 50/60Hz 85-240V~ 0.25A MAX TB106 115~ 115~ 2nd CP 4th CP 24VDC 1A MAX – Transformer Use to power User-Supplied Module ESTOP circuitry AEROTECH.

  • Page 35: Minimizing Conducted, Radiated, And System Noise

    The shield of the cables must be connected to the metal back shell in order for the product to conform to the radiated emission standards. The Soloist CP is a component designed to be integrated with other electronics. EMC testing must be conducted on the final product configuration.

  • Page 36: Motor Output Connections

    Soloist CP Installation and Configuration 2.2. Motor Output Connections The Soloist CP is capable of controlling three motor types: Brushless (see Section 2.2.1.) DC Brush (see Section 2.2.2.) Stepper (see Section 2.2.3.) For a complete list of electrical specifications, refer to Section 1.2.

  • Page 37: Brushless Motor Connections

    Both methods will identify the A, B, and C Hall/motor lead sets and indicate the correct connections to the drive. N O T E :  If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required.

  • Page 38: Powered Motor Phasing

    Soloist CP Installation and Configuration 2.2.1.1. Powered Motor Phasing To test the initial set of motor connections, run the MotorVerification.ab test program. The program will attempt to move the motor forward in a positive (CW) direction. Depending on the information that the program gathers during the test, you may be prompted to rearrange motor lead connections and run the test again.

  • Page 39: Encoder And Hall Signal Diagnostics

    Installation and Configuration Soloist CP Figure 2-12: Encoder and Hall Signal Diagnostics www.aerotech.com Chapter 2...

  • Page 40: Unpowered Motor And Feedback Phasing

    1. Aerotech phasing configuration expects ØC to be the lead signal (in time), ØB to follow it, and ØA to follow ØB. This means that whichever signal has its sine wave peak farthest to the left should be designated as the ØC signal.

  • Page 41: Hall Phasing With Oscilloscope

    After the motor leads have been tested, the next step is to determine the phase of the Hall signals. The required (by an Aerotech system) relationship between motor and Hall leads is that the peak of a motor lead signal should correspond to the low voltage phase of the Hall signal (as shown in Figure 2-14).

  • Page 42: Brushless Motor Phasing Goal

    With the designations of the motor and Hall leads of a third party motor determined, the motor can now be connected to an Aerotech system. Connect motor lead A to motor connector A, motor lead B to motor connector B, and motor lead C to motor connector C. Connect Hall lead A to Pin 10 of the feedback connector.

  • Page 43: Dc Brush Motor Connections

    Red & Orange Yellow & Blue Black Yellow & Blue (1) Wire Color Set #1 is the typical Aerotech wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire www.aerotech.com Chapter 2...

  • Page 44: Dc Brush Motor Phasing

    When the voltmeter indicates a positive value, the motor leads have been identified. 5. Connect the motor lead from the voltmeter to the ØA motor terminal on the Soloist CP. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the Soloist CP.

  • Page 45: Stepper Motor Connections

    Green/Yellow & Shield Black Brown Yellow White White & Red (1) Wire Color Set #1 is the typical Aerotech wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire www.aerotech.com Chapter 2...

  • Page 46: Stepper Motor Phasing

    POSITIVE MOTION Figure 2-19: Clockwise Motor Rotation N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. N O T E :  After the motor has been phased, use the ReverseMotionDirection parameter to change the dir- ection of “positive”...

  • Page 47: Motor Feedback Connections (J103)

    Installation and Configuration Soloist CP 2.3. Motor Feedback Connections (J103) The motor feedback connector (a 25-pin, D-style connector) has inputs for an encoder, limit switches, Hall- effect devices, motor over-temperature device, 5 Volt encoder and limit power, and optional brake connection.

  • Page 48: Encoder Interface (J103)

    Motor Feedback (J103) connector. The standard encoder interface will accept an RS-422 differential line driver signal. If the Soloist CP has been purchased with the -MXU option, the standard encoder interface can optionally be configured for an analog encoder input via parameter settings.

  • Page 49: Line Driver Encoder (Standard)

    Installation and Configuration Soloist CP 2.3.1.1. RS-422 Line Driver Encoder (Standard) The standard encoder interface accepts an RS-422 differential quadrature line driver signal in the range of 0 to 5 Volts. It accepts a 10 MHz (max) encoder signal frequency (25 nsec minimum edge separation), producing 40 million counts per second after times four (x4) quadrature decoding.

  • Page 50: Endat Encoder Interface (J103)

    Soloist CP Installation and Configuration 2.3.1.2. EnDat Encoder Interface (J103) The Soloist CP retrieves absolute position data along with encoder fault information via a serial data stream from the absolute encoder. See Figure 2-21 for the serial data stream interface. Set up of this interface...

  • Page 51: Resolute Encoder Interface (J103)

    Installation and Configuration Soloist CP 2.3.1.3. Resolute Encoder Interface (J103) The Soloist CP retrieves absolute position data along with encoder fault information via a serial data stream from the resolute encoder. See Figure 2-22 for the serial data stream interface. Set up of this interface requires setting parameters ResoluteEncoderResolution, ResoluteEncoderSetup, and ResoluteEncoderUserResolution.

  • Page 52: Analog Encoder Interface

    Soloist CP Installation and Configuration 2.3.1.4. Analog Encoder Interface If the -MXU option has been purchased, the standard encoder channel will accept an analog encoder input signal. The multiplication (interpolation) factor is determined by the EncoderMultiplicationFactor parameter. Table 2-15: Analog Encoder Specifications...

  • Page 53: Analog Encoder Interface (J103)

    Installation and Configuration Soloist CP SIN+ J103-17 82PF 82PF J103-18 SIN- AD822 82PF 82PF COS+ J103-14 82PF 82PF J103-15 COS- AD822 82PF 82PF MRK+ J103-7 82PF 82PF MRK- J103-6 AD822 82PF 82PF Figure 2-24: Analog Encoder Interface (J103) www.aerotech.com Chapter 2...

  • Page 54: Encoder Phasing

    Soloist CP Installation and Configuration 2.3.1.5. Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-25 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors).

  • Page 55: Position Feedback In The Diagnostic Display

    Installation and Configuration Soloist CP Figure 2-26: Position Feedback in the Diagnostic Display www.aerotech.com Chapter 2...

  • Page 56: Hall-Effect Interface (J103)

    Soloist CP Installation and Configuration 2.3.2. Hall-Effect Interface (J103) The Hall-effect switch inputs are recommended for AC brushless motor commutation but not absolutely required. The Hall-effect inputs accept 5-24 VDC level signals. Refer to Section 2.2.1.1. for Hall-effect device phasing.

  • Page 57: Thermistor Interface (J103)

    Installation and Configuration Soloist CP 2.3.3. Thermistor Interface (J103) The thermistor input is used to detect an over temperature condition in a motor using a positive temperature coefficient sensor. As the temperature of the sensor increases, so does the resistance. Under normal operating conditions, the resistance of the thermistor is low (i.e., 100 ohms) which will result in a low input...

  • Page 58: Encoder Fault Interface (J103)

    Soloist CP Installation and Configuration 2.3.4. Encoder Fault Interface (J103) The encoder fault input is used with encoders having a fault output. Each manufacturer uses this signal to indicate different faults. Table 2-18: Encoder Fault Interface Pin Assignment (J103) Pin#...

  • Page 59: End Of Travel Limit Input Interface (J103)

    Installation and Configuration Soloist CP 2.3.5. End Of Travel Limit Input Interface (J103) End of Travel (EOT) limits are required to define the end of the physical travel on linear axes. Positive or clockwise motion is stopped by the clockwise (CW) end of travel limit input. Negative or counterclockwise motion is stopped by the counterclockwise (CCW) end of travel limit input.

  • Page 60: End Of Travel Limit Interface Input (J103)

    Soloist CP Installation and Configuration CW LMT J103-12 CCW LMT J103-24 HM LMT J103-22 Figure 2-31: End of Travel Limit Interface Input (J103) Chapter 2 www.aerotech.com...

  • Page 61: End Of Travel Limit Phasing

    Installation and Configuration Soloist CP 2.3.5.1. End Of Travel Limit Phasing If the EOT limits are reversed, you will be able to move further into a limit but be unable to move out. To correct this, swap the connections to the CW and CCW inputs at the J103 connector. The logic level of the EOT limit inputs may be viewed in the diagnostic display (shown in...

  • Page 62: Brake Output (J103)

    (refer to the Soloist Help file for more information). Use either the solid state relay on the Soloist CP or the mechanical relay on the -IO board when connecting a power supply to the brake outputs on J103. Do not use both relays at the same time.

  • Page 63: Emergency Stop Sense Input (Tb101)

    Installation and Configuration Soloist CP 2.4. Emergency Stop Sense Input (TB101) The ESTOP sense input (TB101) is used to monitor the state of an external safety circuit only. This state is indicated by the software and may be used to facilitate system restart. This ESTOP sense input is not intended to be a complete safety system.

  • Page 64: Typical Estop Interface

    Installation and Configuration 2.4.1. Typical ESTOP Interface The user can connect an external emergency stop relay circuit to the Soloist CP’s motor power supply input. This will remove power to the motor while maintaining control power, as shown in the Figure 2-34.

  • Page 65: Auxiliary I/O Connector (J104)

    Input (1) Software configured option (2) For PSO, see Section 2.5.2. Mating Connector Aerotech P/N Third Party P/N Connector ECK01259 Kycon K86-AA-26P Backshell ECK01022 Amphenol 17-1725-2 NOTE: These items are provided as a set under the Aerotech P/N: MCK-26HDD. www.aerotech.com Chapter 2...

  • Page 66: Auxiliary Encoder Channel (J104)

    Soloist CP Installation and Configuration 2.5.1. Auxiliary Encoder Channel (J104) The auxiliary encoder interface accepts a 5 VDC RS-422 differential quadrature line driver signal. It accepts a 10 MHz (max) encoder signal frequency (25 nsec minimum edge separation), producing 40 million counts per second, after times four (x4) quadrature decoding.

  • Page 67: Auxiliary Encoder Channel (J104)

    Installation and Configuration Soloist CP +3.3V +3.3V 10UF 6.3V SIN+ J103-17 SIN- J103-18 COS+ J103-14 COS- J103-15 AUXSIN+ J104-1 AUXSIN- J104-2 AUXCOS+ J104-10 AUXCOS- J104-11 DS26LV32AT ENCODER FAULT DETECTION 10UF 6.3V MRK- J103-6 MRK+ J103-7 ADM485 AUXMRK+ J104-20 AUXMRK- J104-19...

  • Page 68: Position Synchronized Output (Pso)/Laser Firing (J104)

    Installation and Configuration 2.5.2. Position Synchronized Output (PSO)/Laser Firing (J104) The Soloist CP includes a Position Synchronized Output (PSO) feature. The PSO output is available on the dual function AUXMRK± differential signal lines (use of an RS-422 line receiver or opto-isolator is recommended).

  • Page 69: Pso Interface

    Installation and Configuration Soloist CP Differential +5 VDC 120 - 180 (typical) J104 Active Low Aux. Marker Output * Opto-Isolated +5 VDC Isolated Section J104 10 mA 180 Aux. Marker To Laser Active Low 1N4148 Output* HCPL-2601 or 6N136 * Active low output shown. Opposite polarity available by reversing connections to Pins 19 and 20.

  • Page 70: Opto-Isolated Outputs (J104)

    Soloist CP Installation and Configuration 2.5.3. Opto-Isolated Outputs (J104) All outputs are rated for 24 VDC and 80 mA per output. The outputs are software configurable as current sinking (see Figure 2-37) or current sourcing (see Figure 2-38) . Table 2-29:...

  • Page 71: Outputs Connected In Current Sinking Mode (J104)

    Installation and Configuration Soloist CP J104 LOAD 5-24 VDC OUTPUT SWITCHES OPTOOUT0 J104-7 LOAD OPTOOUT1 J104-8 LOAD OPTOOUT2 J104-9 LOAD OPTOOUT3 J104-16 OPTOCOM J104-15 EACH OUTPUT 80 mA MAXIMUM DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.

  • Page 72: Opto-Isolated Inputs (J104)

    Soloist CP Installation and Configuration 2.5.4. Opto-Isolated Inputs (J104) User inputs are scaled for an input voltage of 5-24 VDC. Figure 2-39 Figure 2-40, respectively, illustrate how to connect a device in current sinking and sourcing current modes. Table 2-31:...

  • Page 73: Inputs Connected In Current Sinking Mode (J104)

    Installation and Configuration Soloist CP J104 OPTOINCOM J104-24 OPTOIN0 5-24 VDC J104-17 OPTOIN1 J104-18 OPTOIN2 J104-25 OPTOIN3 J104-26 INPUT SWITCHES Figure 2-39: Inputs Connected in Current Sinking Mode (J104) J104 INPUT SWITCHES OPTOIN0 J104-17 OPTOIN1 J104-18 5-24 VDC OPTOIN2 J104-25...

  • Page 74: High Speed User Inputs 4-5 (J104)

    Soloist CP Installation and Configuration 2.5.5. High Speed User Inputs 4-5 (J104) The high-speed inputs are scaled for 5 V or 24 V input voltages based on a jumper setting (Table 2-34). A higher input voltage requires adding external series resistors to limit the current to 10 mA. The high-speed inputs are isolated by an HCPL-0630 and have a typical delay of 50 nanoseconds.

  • Page 75: Analog Output 0 (J104)

    Installation and Configuration Soloist CP 2.5.6. Analog Output 0 (J104) Analog Output 0 produces a single ended output in the range of ±10 volts with a resolution of 305 µV (16-bit). The maximum recommended output current is 5 mA (2 k Ohm load). The analog output voltage is referenced to J104-23.

  • Page 76: Analog Input 0 (J104)

    Soloist CP Installation and Configuration 2.5.7. Analog Input 0 (J104) Analog Input 0 is a 16-bit differential input that accepts a voltage in the range of ±10 V with a resolution of 305 µV. Signals outside of this range may damage the input. To interface to a single-ended (non-differential) voltage source, connect the signal common of the source to the negative input (pin 14, ANALOG_IN-) and the analog source signal to the positive input (pin 13, ANALOG_IN+).

  • Page 77: Brake Power Supply (Tb103)

    Installation and Configuration Soloist CP 2.6. Brake Power Supply (TB103) TB103 is the power supply connection to the onboard solid state brake control relay. The relay is typically used to automatically control a fail-safe brake on a vertical axis. It can also be used as a general purpose output.

  • Page 78: Brake Connected To J103

    BRAKE - J103-13 BRAKE PS- TB103-5 NOISE SUPPRESSION CIRCUIT VARISTOR: AEROTECH P/N: ECR181 HARRIS P/N: V33ZA1 Figure 2-44: Brake Connected to J103 N O T E :   The user is responsible for providing fuse protection for the brake circuit.

  • Page 79: Brake Connected To Tb103

    J103 pin 25. In this case, J103 would function as an interlock to prevent the brake from releasing if the Motor Feedback connector is not connected. BRAKE PS+ TB103-6 24VDC 1N5369 PS710A-1ASK BRAKE + J103-25 BRAKE BRAKE - J103-13 BRAKE PS- TB103-5 VARISTOR: AEROTECH P/N: ECR181 HARRIS P/N: V33ZA1 Figure 2-45: Brake Connected to TB103 www.aerotech.com Chapter 2...

  • Page 80: Solid State Relay Specifications (Tb103)

    The user must verify that the brake power requirements are within the specifications of the Brake control relay listed below. Table 2-40: Relay Specifications Solid State Relay Rating (M36), Aerotech PN: ECS1074 Maximum Voltage 24 VDC Maximum Current 0.5 Amps...

  • Page 81: Interface (Tb103)

    Installation and Configuration Soloist CP 2.7. RS-232 Interface (TB103) Connecting the RS-232 port to a user’s PC requires a standard cable (not a null modem). Table 2-41: RS-232 Connector Pin Assignment (TB103) Pin# Description In/Out/Bi +5 Volt Power Output Output...

  • Page 82: Extshunt Option (Tb104)

    The Soloist CP provides an external shunt option for high-energy systems. Internally, the shunt is fused with an 8A slow-blow type fuse. The purpose of the fuse is to protect the electronic switching device and the traces on the circuit board.

  • Page 83: Table 2-45: Maximum Storage Energy

    = turn on voltage for shunt circuit (V) (=380 V) = nominal Bus voltage (V) (160 V or 320 V Typical) For a standard Soloist CP, the maximum energy the internal bus capacitor can store without requiring a shunt resistor is indicated in Table 2-45.
  • Page 84 Soloist CP Installation and Configuration Equation 5:     − − (Watts) CYCLE = time between decelerations + time to deceleration (seconds) CYCLE = hysteresis point of regeneration circuit (=10 V) Additional useful equations: 1 lb-ft = 1.356 Nm ω (Useful as an estimate if the deceleration time is unknown) ω...

  • Page 85: Pc Configuration And Operation Information

    Installation and Configuration Soloist CP 2.9. PC Configuration and Operation Information For additional information about Soloist CP and PC configuration, hardware requirements, programming, utilities and system operation refer to the Soloist Help file. www.aerotech.com Chapter 2...
  • Page 86 Soloist CP Installation and Configuration This page intentionally left blank. Chapter 2 www.aerotech.com...

  • Page 87: Chapter 3: -I/O Expansion Board

    The -IO option board is 16 digital opto-inputs, 16 digital opto-outputs, 1 analog input, 1 analog output, and a brake/relay output. D A N G E R : Always disconnect the Mains power connection before opening the Soloist CP chassis.

  • Page 88: Analog Output (Tb201)

    Soloist CP -IO Expansion Board 3.1. Analog Output (TB201) The 16-bit analog output produces a single-ended output voltage in the range of ±10 V with a resolution of 305 µV. The maximum recommended output current is 5 mA. Analog outputs are referenced to TB201-1. The analog output is set to zero when the system is powered-up or during a system reset.

  • Page 89: Analog Input (Tb201)

    -IO Expansion Board Soloist CP 3.2. Analog Input (TB201) The I/O board analog input is a 12-bit differential input that accepts a voltage in the range of ±10 volts with a resolution of 4.88 millivolts. Signals outside of this range may damage the input. To interface to a single- ended (non-differential) voltage source, connect the signal common of the source to the negative input, and the analog source signal to the positive input.

  • Page 90: Opto-Isolated Inputs (Tb204, Tb205)

    Soloist CP -IO Expansion Board 3.3. Opto-Isolated Inputs (TB204, TB205) These opto-isolated inputs use a PS2806-4 device and are configured for 5-24 volt input levels. The inputs may be connected to current sourcing or current sinking devices, as shown in...
  • Page 91 -IO Expansion Board Soloist CP W A R N I N G : Opto-isolated inputs and outputs should not be powered by the user output power. Doing so would compromise the isolation provided by the opto-isolator. N O T E : Each bank of 8 Inputs must be connected in the all sourcing or all sinking configuration.
  • Page 92 Soloist CP -IO Expansion Board TB204 INPUT SWITCHES OPTOIN0 TB204-2 OPTOIN1 TB204-3 5-24 VDC OPTOIN2 TB204-4 OPTOIN3 TB204-5 OPTOINCOM TB204-1 Figure 3-5: Inputs Connected to a Current Sourcing Device TB204 OPTOINCOM TB204-1 OPTOIN0 TB204-2 5-24 VDC OPTOIN1 TB204-3 OPTOIN2 TB204-4...

  • Page 93: Opto-Isolated Outputs (Tb202, Tb203)

    -IO Expansion Board Soloist CP 3.4. Opto-Isolated Outputs (TB202, TB203) The outputs are software configurable as sourcing or sinking. The outputs are driven by PS2802-4 opto- isolators rated for 24 volts maximum and up to 80 mA/output @ 20°C. Outputs must be connected in either all sinking or all sourcing mode.

  • Page 94: Figure 3-7: Opto-Isolated Outputs (-Io Board)

    Soloist CP -IO Expansion Board OPTOOUT0 TB202-3 OPTOOUT1 TB202-4 OPTOOUT2 TB202-5 OPTOOUT3 TB202-6 PS2802-4 OPTOOUT4 TB202-7 OPTOOUT5 TB202-8 OPTOOUT6 TB202-9 OPTOOUT7 TB202-10 OPTOOUT BANK1 V- TB202-2 PS2802-4 Figure 3-7: Opto-Isolated Outputs (-IO Board) Chapter 3 www.aerotech.com...

  • Page 95: Table 3-14: Output Specifications (Tb202, Tb203)

    -IO Expansion Board Soloist CP Table 3-14: Output Specifications (TB202, TB203) PS2802-4 Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink/Source Current 80 mA/channel @ 20°C; 60 mA/channel @ 50°C Output Saturation Voltage 2.75 V at maximum current Output Resistance 33 Ω...
  • Page 96 Soloist CP -IO Expansion Board TB202 TB202-1 LOAD 5-24 VDC OUTPUT SWITCHES OPTOOUT0 TB202-3 LOAD OPTOOUT1 TB202-4 LOAD OPTOOUT2 TB202-5 LOAD OPTOOUT3 TB202-6 TB202-2 EACH OUTPUT 80 mA MAXIMUM DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.

  • Page 97: User Power (Tb204, Tb205)

    -IO Expansion Board Soloist CP 3.5. User Power (TB204, TB205) A user accessible power supply (+5V at 0.5 A) is available between the TB205 +5V terminal and TB204 GND terminal. Table 3-15: User Common Connector Pin Assignment (TB204) Pin# Description...

  • Page 98: Brake / Mechanical Relay (Tb206)

    Soloist CP -IO Expansion Board 3.6. Brake / Mechanical Relay (TB206) The relay output is typically used for automatic control of a fail-safe brake on a vertical axis. It can also be used as a general purpose relay. The brake output can be software configured; refer to the Soloist Help file for more information (see topics for the EnableBrakeControl parameter and the BRAKE command).

  • Page 99: Brake / Mechanical Relay Interface Connector

    CHANGE JUMPERS TO: OPTIONAL RC SNUBBER: CIRCUIT 47 1/2 W RESISTOR JP1 1-2 IN, 3-4 IN, ALL OTHER JUMPERS OUT .1uF 250 VAC CAPACITOR VARISTOR: AEROTECH P/N ECR181 HARRIS P/N: V33ZA1 Figure 3-10: Brake Connected to J103 www.aerotech.com Chapter 3...

  • Page 100: Figure 3-11: Brake Connected To Tb206

    JP1-A RLYV23026SMT BRAKE- J103-13 JP1-B BRAKE JP1-C JP1-D BRAKE+ J103-25 CHANGE JUMPERS TO: JP1 1-3 IN, 1-2 OUT, 3-4 OUT, 5-6 OUT, 7-8 OUT VARISTOR: AEROTECH P/N ECR181 HARRIS P/N: V33ZA1 Figure 3-11: Brake Connected to TB206 Chapter 3 www.aerotech.com...

  • Page 101: Chapter 4: Standard Interconnection Cables

    Accessories Soloist CP Chapter 4: Standard Interconnection Cables N O T E : A complete list of Aerotech cables can be found on the website at http://www.aerotechmotioncontrol.com/manuals/index.aspx. Table 4-1: Standard Interconnection Cables Cable Part # Description Joystick Section 4.1. ECZ01231 BBA32 Interconnect Cable (1) The “-xx”...

  • Page 102: Joystick Interface

    Accessories 4.1. Joystick Interface Aerotech joysticks JI (NEMA12 (IP54) rated) and JBV are powered from 5V and have a nominal 2.5V output in the center detent position. Three buttons are used to select axis pairs and speed ranges. An optional interlock signal is used to indicate to the controller that the joystick is present.
  • Page 103 Accessories Soloist CP J104 Second Drive AGND Common Input Common Button A Input 1 Button B Input 0 Interlock Input 2 JOY-Y Analog Input 0+ Common Analog Input 0- Joystick J104 First Drive JOY-X Analog Input 0+ Common Analog Input 0-...

  • Page 104: Table 4-2: Cable Part Numbers

    Soloist CP Accessories Joy Interlock Second Drive INPUT 2 Button B INPUT 0 Button A INPUT 1 C (0-7) Common Second Drive Common AGND AGND JOY-Y Analog Input 1+ Analog Input 1+ Common Analog Input 1- Analog Input 1- Joystick...

  • Page 105: Handwheel Interface

    Soloist CP 4.2. Handwheel Interface A handwheel (such as the Aerotech HW-xxx-xx) can be used to manually control axis position. The handwheel must provide 5V differential quadrature signals to the Soloist CP. A handwheel can be connected to the Aux I/O as shown in...
  • Page 106 Soloist CP Accessories This page intentionally left blank. Chapter 4 www.aerotech.com...

  • Page 107: Chapter 5: Maintenance

    This section covers the internal boards, important board components, and how to clean the drive. Troubleshooting is covered in-depth in the Soloist Help file. D A N G E R : Always disconnect the Mains power connection before opening the Soloist CP chassis.

  • Page 108: Control Board

    TB102 J103 J104 J102 J101 TB104 Board Assembly Drawing Number: 690D1610, Rev. B1 Figure 5-1: Control Board Assembly D A N G E R : Always disconnect the Mains power connection before opening the Soloist CP chassis. Chapter 5 www.aerotech.com...

  • Page 109: Table 5-2: Control Board Jumper Configuration

    Optional Shunt Fuse 2 A S.B. EIF01019 LittelFuse 215002 (5 mm) Control Power Fuse 2 A S.B. EIF01029 LittelFuse 3721200041 Soloist CP 10; VAC Input at 5 A S.B. EIF00179 Wickman 1951500 TB102-1 (5 mm) SoloistCP 20; VAC Input at 10 A S.B. EIF01006...

  • Page 110: Preventative Maintenance

    Cleaning  The Soloist CP chassis can be wiped with a clean, dry, soft cloth. The cloth may be slightly moistened if required with water or isopropyl alcohol to aid in cleaning if necessary. In this case, be careful not to allow moisture to enter the Soloist CP or onto exposed connectors / components.

  • Page 111: Appendix A: Warranty And Field Service

    Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer, whether or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided, or whether or not Aerotech’s...
  • Page 112 Aerotech's approval. On-site Warranty Repair 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:...

  • Page 113: Appendix B: Revision History

    August 24, 2007 1.11a May 23, 2007 1.11 July 20, 2006 Revision changes have been archived. If you need a copy of this revision, contact Aerotech Global Technical Support. 1.10a May 08, 2006 1.09 January 13, 2006 1.08 January 03, 2006 1.07...
  • Page 114 Soloist CP Revision History This page intentionally left blank. Appendix B www.aerotech.com...

  • Page 115: Index

    Index Soloist CP Index Analog Input Analog Input (I/O Board) -EXTSHUNT Option Analog Input 1 Connector -I/O Expansion Board Analog Input Connector Pin Assignment -IO Board Fuse Information Analog Inputs Connector Pin Assignment -IO Expansion Board Brake Jumper Analog Output...
  • Page 116 Soloist CP Index Cleaning Encoder Fault Interface Pin Assignment Continuous Output Current specifications Encoder Interface (J207) Control and Motor Power Wiring using a TM3 or Encoder Interface Pin Assignment TM5 Transformer Encoder Phasing 24,40 Control Board Encoder Phasing Reference Diagram...
  • Page 117 Index Soloist CP Inputs Connected to a Current Sinking Device optional joysticks Inputs Connected to a Current Sourcing Device 78 Options inspect all cables and connections Opto-Isolated Input Connector Pin Assignment Inspect cooling vents Opto-Isolated Inputs 58,76-77 Inspection Opto-Isolated Output Connector Pin Assignment 79...
  • Page 118 Soloist CP Index Thermistor Interface Quick Installation Guide xiii Thermistor Interface Input Transformer Examples Recommended Shunt Resistors & Wire Gauge Transformer Options relative phasing/order TV0.3-28-56-ST Transformer Relay Specifications TV0.3-56 Resolute Encoder Interface two-axis joystick RS-232 Connector Pin Assignment Two Axis Joystick Interface...

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