ANORAD CORPORATION

PC-2000 MOTION
CONTROL SYSTEM
USER GUIDE

February 2001
Revision 2 Preliminary
Item Code 802140

Excellence in Motion

A Rockwell Automation Business

PC-2000 SYSTEM
USER GUIDE
February 2001
Item Number 802140

Revision 2

 Copyright 1999 Anorad Corporation, All rights Reserved

Anorad Corporation
110 Oser Avenue
Hauppauge, NY 11788

Web site http://www.anorad.com

E-mail anorad@anorad.com

Technical Support:
Tel (613) 231-1990 ext. 285
Fax (613) 231-7260
E-mail techsupport@anorad.com

PROPRIETARY
This document is the property of Anorad Corporation and is protected by copyright. The
information contained herein is proprietary and may not be reproduced, transferred, or
disclosed to others in whole or in part without express written permission from Anorad
Corporation.
NOTICE
This document was written to accompany PC-2000 Motion Control System. The
information contained in this document is subject to change without notice. Anorad shall
not be liable for errors contained herein or direct or indirect, special, incidental or
consequential damages in connection with the furnishing, performance, or use of this
manual.
TRADEMARK ACKNOWLEDGEMENTS
Terms mentioned in this document that are known to be trademarks are listed below
Anorad Corporation cannot attest to the accuracy of this information. Use of a term in this
book should not be regarded as affecting the validity of any trademark.
Microsoft is a trademark of Microsoft Corporation
Windows NT is a trademark of Microsoft Corporation
Bit 3 is a trademark of Bit 3 Corporation
Anorad is a trademark of Anorad Corporation
The Anorad logo is a trademark of Anorad Corporation

ii Rev 2
 Technical Support

Thank for choosing an Anorad motion control system to perform you motion needs. We
at Anorad Corporation strive to please our customers. We want your system to work and
for you to be happy with it. Anorad provides Technical Support free of charge for one
year from the date of system shipment.

Before calling for Technical Support, make sure you know which products and what
version of software you are using. The software version is printed on the distribution
disk and is displayed in the

Customer Service Technicians are available Monday through Friday 9am to 5pm
EDT. Please contact:

Technical Support:
Telephone: (613) 231-1990 ext. 285
Fax: (613) 231-7260
E-mail: techsupport@anorad.com

Rev 2 iii
iv Rev 2
 Table of Contents

TECHNICAL SUPPORT ..........................................................................................................................III

TABLE OF CONTENTS.............................................................................................................................V

CHAPTER 1 INTRODUCTION............................................................................................................. 1-1

1.1 USING THIS MANUAL ................................................................................................................... 1-1
1.2 INTENDED AUDIENCE - PROGRAMMING REQUIREMENT ............................................................... 1-1
1.3 HARDWARE REQUIREMENT .......................................................................................................... 1-2
1.4 SOFTWARE REQUIREMENT ........................................................................................................... 1-2
1.5 WARNINGS, CAUTIONS, AND NOTES ............................................................................................ 1-2
1.5.1 Reading and Training for Users and Operators.................................................................. 1-2
1.5.2 System Safeguards............................................................................................................... 1-2
1.5.3 Safety Features included in the MIC ................................................................................... 1-3
1.5.4 Computer-Controlled Motion Devices ................................................................................ 1-3
1.5.5 Manually-Controlled Motion Devices ................................................................................. 1-3
1.5.6 Other Computer-Controlled Devices .................................................................................. 1-3
1.5.7 Program Security ............................................................................................................... 1-3
1.5.8 Overspeed Protection ....................................................................................................... 1-4
1.5.9 Voltage Interruptions........................................................................................................ 1-4
1.5.10 Inappropriate Uses of the PC-2000 System ................................................................. 1-4
1.6 STANDARDS COMPLIANCE ........................................................................................................... 1-4
CHAPTER 2 OVERVIEW ...................................................................................................................... 2-1
2.1 INTRODUCTION............................................................................................................................. 2-1
2.2 PC-2000 SERVO MOTION CONTROLLER ..................................................................................... 2-1
2.3 4U MOTOR INTERFACE CHASSIS .................................................................................................. 2-1
2.4 ANORAD 2U DUAL HIGH-VOLTAGE POWER SUPPLY ................................................................... 2-1
2.5 ANORAD AMPLIFIER MODULES.................................................................................................... 2-1
CHAPTER 3 PC-2000 MOTION CONTROLLER............................................................................... 3-1
3.1 INTRODUCTION............................................................................................................................. 3-1
3.2 JUMPERS, SWITCHES, AND INDICATORS ....................................................................................... 3-1
3.2.1 ISA Bus Resource Allocation (S1) ....................................................................................... 3-1
3.2.2 Options Switches (S2).......................................................................................................... 3-2
3.2.3 Watchdog Timer (JP1/JP2) ................................................................................................. 3-2
3.2.4 Reset (SW1) ......................................................................................................................... 3-2
3.2.5 LED Indicators (LED1-8) ................................................................................................... 3-2
3.3 CONNECTORS ............................................................................................................................... 3-3
3.3.1 J1 Connector ....................................................................................................................... 3-3
3.3.1.1 Emergency Stop and High-Power Enable Circuits ....................................................................... 3-4
3.3.1.1.1 E-Stop Input ......................................................................................................................... 3-4

Rev 2 v
 3.3.1.1.2 High-Power Enable Output ................................................................................................... 3-4
3.3.1.2 Servo Amplifier Interface ............................................................................................................ 3-5
3.3.1.2.1 Enable/Fault.......................................................................................................................... 3-5
3.3.1.2.2 Control.................................................................................................................................. 3-5
3.3.1.3 Home/Limit Sensor Interface ....................................................................................................... 3-5
3.3.1.4 Encoder Interface......................................................................................................................... 3-6
3.3.1.4.1 Incremental Encoders............................................................................................................ 3-6
3.3.1.4.2 Absolute Encoders ................................................................................................................ 3-6
3.3.1.5 Analog Sensor Interface............................................................................................................... 3-6
3.3.1.6 High-Speed Digital I/O Connections............................................................................................ 3-7
3.3.1.6.1 Latch Input Signals ............................................................................................................... 3-7
3.3.1.6.2 Strobe Output Signals ........................................................................................................... 3-7
3.3.2 General Purpose I/O........................................................................................................... 3-8
3.3.2.1 Inputs .......................................................................................................................................... 3-9
3.3.2.2 Outputs........................................................................................................................................ 3-9
3.3.3 Serial I/O and Stand-Alone Power Connections............................................................... 3-10
3.3.3.1 RS-232 Connector ..................................................................................................................... 3-10
3.3.3.2 RS-422/485 Connector .............................................................................................................. 3-10
3.3.3.3 Typical Cable Connections ........................................................................................................ 3-10
3.3.3.4 Stand-Alone Power.................................................................................................................... 3-10
3.3.4 Expansion Connectors (J6, J10) ....................................................................................... 3-10
3.4 PC-2000 SERVO CONTROLLER SPECIFICATIONS.........................................................................3-11
CHAPTER 4 MOTOR INTERFACE CHASSIS .................................................................................. 4-1
4.1 INTRODUCTION .............................................................................................................................4-1
4.2 MIC OVERVIEW ...........................................................................................................................4-1
CHAPTER 5 INSTALLATION.............................................................................................................. 5-1
5.1 INTRODUCTION .............................................................................................................................5-1
5.2 SITE PREPARATION .......................................................................................................................5-1
5.3 UNPACKING ..................................................................................................................................5-3
5.4 INSTALLATION ..............................................................................................................................5-4
5.4.1 Introduction ........................................................................................................................ 5-4
5.4.2 Circuit Cards ...................................................................................................................... 5-4
5.4.3 Cabling ............................................................................................................................... 5-4
5.4.4 Connecting AC Power......................................................................................................... 5-6
5.4.5 AC Power Requirements ..................................................................................................... 5-6
5.4.5.1 Facility Overvoltage Protection.................................................................................................... 5-6
5.4.6 Function of System Power Switch with 4U Motor Interface Chassis ......................... 5-6
5.4.6.1 Connecting AC Power Cord to the MIC ............................................................................... 5-7
5.4.6.2 System Grounding Information............................................................................................ 5-7
5.4.7 Fuse Information................................................................................................................. 5-7
5.4.7.1 Procedure to Remove Fuse Holder ............................................................................................... 5-7
5.4.7.2 Cooling Fan ............................................................................................................................ 5-8
5.4.8 Removing and Installing Modules....................................................................................... 5-8
5.4.8.1 Removing Modules................................................................................................................ 5-8
5.4.8.2 Installing Modules ................................................................................................................. 5-9
5.4.9 Verification ....................................................................................................................... 5-10
CHAPTER 6 MIC FUNCTIONAL DESCRIPTION............................................................................ 6-1
6.1 INTRODUCTION .............................................................................................................................6-1
6.2 MIC..............................................................................................................................................6-1
6.2.1 Connectors .......................................................................................................................... 6-1
6.2.2 Connector Pinouts .............................................................................................................. 6-1
6.2.2.1 Quadrature Interface .................................................................................................................... 6-4
6.3 BACKPLANES AND BOARDS..........................................................................................................6-6
6.3.1 Introduction ........................................................................................................................ 6-6

vi Rev 2
 6.3.2 PC-2000 Backplane............................................................................................................. 6-6
6.3.2.1 Buss Power Selection .................................................................................................................. 6-7
6.3.2.2 Backplane Jumpers ............................................................................................................... 6-9
6.3.3 Encoder Interface Board ................................................................................................... 6-10
6.4 4096X PLUG-IN MULTIPLIER MODULE ....................................................................................... 6-12
6.4.1 Introduction....................................................................................................................... 6-12
6.4.2 Overview............................................................................................................................ 6-12
6.4.3 4096X Plug-in Multiplier Module Specifications .............................................................. 6-12
6.4.4 4096x Plug-in Multiplier Module...................................................................................... 6-13
6.4.5 Connectors ........................................................................................................................ 6-14
6.4.5.1 J2 - RS-232 Internal Use Programming Port ............................................................................. 6-14
6.4.5.2 J3 - Internal Debug Port............................................................................................................. 6-14
6.4.5.3 J4 Optional Test Point Connector .............................................................................................. 6-14
6.4.6 Test Points ......................................................................................................................... 6-15
6.4.7 Jumper Settings ................................................................................................................. 6-15
6.4.8 LED's................................................................................................................................. 6-16
6.4.9 Maximum Multiplier Input ................................................................................................ 6-16
6.4.10 Speed Limit Calculations................................................................................................... 6-16
6.4.11 Sine/Cosine Biasing........................................................................................................... 6-17
6.4.12 Reference Pulse ................................................................................................................. 6-18
6.4.13 Calibration Requirements ................................................................................................. 6-18
6.4.13.1 Digital I/O............................................................................................................................. 6-19
6.4.13.2 E-Stop Logic ......................................................................................................................... 6-19
6.4.13.3 Dynamic Brake Logic............................................................................................................ 6-20
6.4.13.4 Limit and Home Switch Interface .......................................................................................... 6-21
CHAPTER 7 MAINTENANCE .............................................................................................................. 7-1
7.1 INTRODUCTION............................................................................................................................. 7-1
7.2 TROUBLESHOOTING ..................................................................................................................... 7-1
CHAPTER 8 2U DUAL HIGH-VOLTAGE POWER SUPPLY .......................................................... 8-1
8.1 2U DUAL HIGH-VOLTAGE POWER SUPPLY SPECIFICATIONS ....................................................... 8-1
8.2 LINE VOLTAGE SELECTION .......................................................................................................... 8-2
8.3 CONNECTORS ............................................................................................................................... 8-2
8.4 FUSES ........................................................................................................................................... 8-2
8.4.1 Input fuses ........................................................................................................................... 8-2
8.4.2 Output Fuses ....................................................................................................................... 8-2
CHAPTER 9 AMPLIFIER MODULES ................................................................................................. 9-1
9.1 SOFTWARE COMMUTATION, SINUSOIDAL BRUSHLESS, AMPLIFIER 69350................................... 9-2
9.1.1 Introduction......................................................................................................................... 9-2
9.1.2 Jumper Settings and Descriptions ....................................................................................... 9-2
9.1.3 Potentiometers Description ................................................................................................. 9-3
9.1.4 Test Point Descriptions ....................................................................................................... 9-3
9.1.5 Software Amplifier Block Diagram ..................................................................................... 9-5
9.1.6 Software Commutation ........................................................................................................ 9-6
9.1.7 Motherboard Peak and Continuous Current Settings ......................................................... 9-8
9.1.7.1 Peak Current Adjustment Procedure ............................................................................................ 9-8
9.1.7.2 Continuous Current Adjustment Procedure.................................................................................. 9-8
9.1.8 Extra Help For Software Commutation.............................................................................. 9-9
9.2 TRAPEZOIDAL AMPLIFIER (MOTHERBOARD WITH PLUG-IN) 67192 ........................................... 9-10
9.2.1 Introduction....................................................................................................................... 9-10
9.2.2 Mother Board Jumper Settings and Descriptions ............................................................. 9-10
9.2.3 Mother Board Potentiometers Description ....................................................................... 9-10
9.2.4 Trapezoidal Amplifier Motherboard Board Layout .......................................................... 9-11
9.2.5 Motherboard Amplifier Block Diagram ............................................................................ 9-12

Rev 2 vii
 9.2.6 Daughterboard Plug-in Block Schematic ......................................................................... 9-13
9.2.7 Motherboard Test Point Descriptions............................................................................... 9-14
9.2.8 Trapezoidal Plug-In Daughterboard Jumper Settings and Descriptions.......................... 9-14
9.2.9 Trapezoidal Plug-In Daughterboard Potentiometers Description.................................... 9-14
9.2.10 Trapezoidal Plug-In Daughterboard Test Point Descriptions.......................................... 9-15
9.2.11 Trapezoidal Plug-In Daughterboard LED Description .................................................... 9-15
9.2.12 Daughterboard Layout...................................................................................................... 9-15
9.2.13 Peak And Continuous Current Adjustment ....................................................................... 9-16
9.2.13.1 Motherboard Peak and Continuous Current Settings .............................................................. 9-16
9.2.13.1.1 Peak Current Adjustment Procedure ................................................................................. 9-16
9.2.13.1.2 Continuous Current Adjustment Procedure ....................................................................... 9-16
9.2.13.2 Plug-In Peak Current Adjustment .......................................................................................... 9-17
9.2.14 Trapezoidal Motor And Hall Phasing............................................................................... 9-19
9.2.14.1 Trapezoidal Hall to Hall Phasing Verification Procedure ....................................................... 9-19
9.2.14.2 Trapezoidal Motor and Hall Effect Phasing Procedure........................................................... 9-20
9.2.14.3 Phase Verification ................................................................................................................. 9-22
9.2.15 Limit Input Verification..................................................................................................... 9-23
9.2.16 Servo Amplifier Modes of Operation ................................................................................ 9-23
9.2.17 Torque (Current) Mode.................................................................................................... 9-23
9.2.18 Velocity Loop .................................................................................................................... 9-24
9.2.18.1 Introduction........................................................................................................................... 9-24
9.2.18.2 Types of feedback and signals ............................................................................................... 9-24
9.2.18.3 Setup Procedure .................................................................................................................... 9-25
9.3 SINUSOIDAL BRUSHLESS SERVO AMPLIFIER 69080 ....................................................................9-27
9.3.1 Introduction ...................................................................................................................... 9-27
9.3.2 Jumper Settings and Descriptions..................................................................................... 9-27
9.3.3 Fault LED Description ..................................................................................................... 9-27
9.3.4 Sinusoidal Board Layout................................................................................................... 9-28
9.3.5 Sinusoidal Amplifier Block Diagram ................................................................................ 9-29
9.3.6 Potentiometers Description............................................................................................... 9-30
9.3.7 Test Point Descriptions..................................................................................................... 9-30
9.3.8 Sinusoidal Hall Sensor Calibration Procedure ................................................................ 9-31
9.3.9 Motherboard Peak and Continuous Current Settings....................................................... 9-32
9.3.9.1 Peak Current Adjustment Procedure .......................................................................................... 9-32
9.3.9.2 Continuous Current Adjustment Procedure ................................................................................ 9-32
9.3.10 Motor Phase to Hall Sensor Setup Procedure .................................................................. 9-33
9.3.10.1 Extra help for Motor and Sensor Phasing............................................................................... 9-35
9.3.10.2 Phase Verification ................................................................................................................. 9-35
9.3.11 Limit Input Verification..................................................................................................... 9-35
9.4 BRUSHLESS LINEAR AB SINE SERVO AMPLIFIER 69532.............................................................9-37
9.4.1 Introduction ...................................................................................................................... 9-37
9.4.2 Jumper Setting and Description........................................................................................ 9-37
9.4.3 Potentiometers Description............................................................................................... 9-37
9.4.4 Test Point Description ...................................................................................................... 9-38
9.4.5 Fault LED Description ..................................................................................................... 9-38
9.4.6 Board Layout .................................................................................................................... 9-39
9.4.7 Software Commutation...................................................................................................... 9-40
9.4.8 Extra Help For Software Commutation ........................................................................... 9-42
9.4.9 Peak Current Adjustment Procedure. ............................................................................... 9-42
9.5 SINUSOIDAL BRUSHLESS SERVO AMPLIFIER 69812 ....................................................................9-43
9.5.1 Introduction ...................................................................................................................... 9-43
9.5.2 Jumper Setting and Description........................................................................................ 9-43
9.5.3 Potentiometers Description............................................................................................... 9-43
9.5.4 Test Points Description..................................................................................................... 9-44
9.5.5 Fault LED Description ..................................................................................................... 9-44
9.5.6 Board Layout .................................................................................................................... 9-45

viii Rev 2
 9.6 SINUSOIDAL HALL SENSOR CALIBRATION PROCEDURE ............................................................. 9-46
9.7 SINUSOIDAL MOTOR AND HALL SENSOR PHASING PROCEDURE ................................................ 9-47
9.7.1 Extra help for Motor and Sensor Phasing......................................................................... 9-49
9.7.2 Phase Verification ............................................................................................................. 9-49
9.8 SERVO AMPLIFIER MODE OF OPERATION................................................................................... 9-49
9.9 PEAK CURRENT ADJUSTMENT PROCEDURE................................................................................ 9-49
9.10 MOTION VERIFICATION PROCEDURE.......................................................................................... 9-50

LIST OF FIGURES
Figure 3-1 E-Stop Input Interface ............................................................................................................... 3-4
Figure 3-2 High-Power Enable Output Interface ........................................................................................ 3-4
Figure 3-3 Drive Fault/Enable Interface ..................................................................................................... 3-5
Figure 3-4 Sensor Input Circuit................................................................................................................... 3-5
Figure 3-5 Encoder Interface Circuit........................................................................................................... 3-6
Figure 5-1 PC-2000 System Layout............................................................................................................ 5-5
Figure 6-1 MIC Connectors ....................................................................................................................... 6-2
Figure 6-2 Pinouts for PWR-1 Connector ................................................................................................... 6-5
Figure 6-3 Motor Interface Chassis Front View.......................................................................................... 6-6
Figure 6-4 Motor Driver Power Buss Jumpers........................................................................................... 6-7
Figure 6-5 PC 2000 Backplane Physical Layout* Part Number 800632 ................................................... 6-8
Figure 6-6 Encoder Interface Board.......................................................................................................... 6-10
Figure 6-7 4096x Multiplier Module, Item Number 74281 ...................................................................... 6-13
Figure 6-8 Lissajous Pattern...................................................................................................................... 6-17
Figure 6-9Home pulse............................................................................................................................... 6-18
Figure 6-10 E-Stop Logic.......................................................................................................................... 6-19
Figure 6-11 Dynamic Brake Logic............................................................................................................ 6-20
Figure 6-12 PC-2000 Controller Switch Interface .................................................................................... 6-21
Figure 8-1 2U Dual High-Voltage Power Supply Front View.................................................................... 8-1
Figure 8-2 2U Dual High-Voltage Power Supply Rear View ..................................................................... 8-1
Figure 9-1 Software Commutation Sinusoidal Brushless Amplifier Part Number 69350
(Also used as Brushless Trapezoidal Amplifier Motherboard) ........................................................... 9-4
Figure 9-2 Software Amplifier Block Diagram........................................................................................... 9-5
Figure 9-3 Phase to Phase Method (a)......................................................................................................... 9-6
Figure 9-4 Phase to Common Method (b)................................................................................................... 9-7
Figure 9-5 Brushless Trapezoidal Amplifier Motherboard Part Number. 69350
(Software Commutation Brushless Sinusoidal Amplifier) ................................................................ 9-11
Figure 9-6 Motherboard Amplifier Block Diagram .................................................................................. 9-12
Figure 9-7 Daughterboard Plug-in Schematic........................................................................................... 9-13
Figure 9-8 Trapezoidal Plug-in Daughterboard ........................................................................................ 9-15
Figure 9-9 Peak and Continuous current setting ....................................................................................... 9-17
Figure 9-10 Trapezoidal Plug-in peak current settings ............................................................................. 9-18
Figure 9-11 Hall effect phase relationship ................................................................................................ 9-19
Figure 9-12 Motor and hall monitoring..................................................................................................... 9-20
Figure 9-13 Motor B.E.M.F. and hall effect phasing ................................................................................ 9-20
Figure 9-14 Motor and Hall Phase Relationship ....................................................................................... 9-22
Figure 9-15 Various damping conditions.................................................................................................. 9-26
Figure 9-16 Brushless Sinusoidal Amplifier Part Number 69080 (for sinewave hall sensors inputs) ...... 9-28
Figure 9-17Sinusoidal Amplifier Block Diagram ..................................................................................... 9-29
Figure 9-18 Motor Phase and Hall Sensor Phasing Setup......................................................................... 9-33
Figure 9-19 Motor B.E.M.F. and Hall Sensor Relationship...................................................................... 9-34
Figure 9-20 AB Sine Board Layout ......................................................................................................... 9-39
Figure 9-21 Phase to Phase Method a ....................................................................................................... 9-40
Figure 9-22 Phase to Common Method b ................................................................................................. 9-41
Figure 9-23 Sinusoidal Brushless Board 69812 Layout............................................................................ 9-45
Figure 9-24 Motor B.E.M.F. and Hall sensor relationship........................................................................ 9-48

Rev 2 ix
x Rev 2
 Chapter 1

Introduction

1.1 Using This Manual

This manual contains functional description and maintenance procedures for the
PC-2000 Motion Control System the chapter are outlined as follows:

Chapters 1 through 3 - introduces the motion controller by describing, theory of operation,

features and host PC installation instructions.

Chapters 4 through 6 - Covers the installation and maintenance of the Motor Interface
Chassis (MIC)

Chapter 7 - Is a troubleshooting guide.

Chapter 9 - Installation and adjustment procedures for the various amplifiers used with the
PC-2000 Motion Controller

Appendices A – Schematics

1.2 Intended Audience - Programming Requirement

This manual is for use by hardware installation personnel. This user guide will enable you to
integrate your hardware for motion and I/O control. We assume that you are proficient with
technical skills require. We are happy to assist you with the your installation if the is a
special need that is not covered in this manual.

Rev 2 1-1
1.3 Hardware Requirement
The PC-2000 Motion Controller requires a host PC with an available ISA Slot, 32 MB RAM
running under Window NT version 4.0., and 8k upper conventional memory. The memory
for this device must be mapped into the PC address space between 640KB and 1MB usually
reserved by the PC for adapter cards. In addition, the board requires an IRQ line assigned if
interrupts are to be utilized. The PC-2000 Motion controller requires mapping for I/O
registers into the PC I/O space.

1.4 Software Requirement

The PC must be running under Windows NT Workstation version 4.0.

Either Microsoft Visual C/C++ v5.0 or Visual Basic v5.0 is required to access and utilize the
Anorad DLL supplied. There must be at least 5MB of available hard disk space for
installation of software modules.

1.5 Warnings, Cautions, and Notes

There are three levels of special notation used in this manual. They are:

WARNING: Injury or major equipment damage could result if the actions

indicated in a “WARNING” are not complied with. A warning
statement typically describes the hazard, its possible effect,
and the measures that must be taken to reduce the hazard.

CAUTION: Damage to your equipment could result if the action specified

in the “CAUTION” is not complied with.

NOTE: A “NOTE” provides supplementary information, emphasizes a

point or procedure, or gives a tip for easier operation.

1.5.1 Reading and Training for Users and Operators

1.5.2 System Safeguards

Safeguards should be an integral part of motion workcell design, installation, operation
training, and operating procedures.

Systems have various communications features to aid in constructing system safeguards.

These features are described in section XX of this user’s guide.

1-2 Rev 2
1.5.3 Safety Features included in the MIC
The PC-2000 Motion Controller has two important safety features, the High Power Enable
(HPE) Out put and the E-Stop String Input. These features allow easy integration of safety
functionality in to your motion platform. We recommend these signals be integrated with a
light tower system and door interlocks to best effect a safety system.

WARNING

Entering the workcell when either the HPE is enabled or E-

Stop disable can result in severe injury. This warning applies
to each of the next three sections.

1.5.4 Computer-Controlled Motion Devices

Anorad systems are computer controlled, and the programs that is currently running the motion
platform may cause it to move at times of a long paths you may not anticipate. When the HPE
is enabled do not enter the workcell because the motion platform might move unexpectedly.
Anorad recommends the use of additional safety features such as light curtains and magnetic
interlocks to prevent entry to the workcell while HIGH POWER is enabled.

1.5.5 Manually-Controlled Motion Devices

Anorad motion platforms can also be controlled manually when the HPE is enabled. When the
HPE is enable motion can be initiated for the system keyboard or other input device such as a
joystick. Always include in your design safety measures that will disable the HPE to prevent
any one for initiating unexpected motion.

1.5.6 Other Computer-Controlled Devices

In addition, PC-2000 Motion Controller can be programmed to control equipment or devices
other than the motion platforms. The program controlling these other devices may cause
them to operate unexpectedly. Make sure that safeguards are in place to prevent personnel
from entering the workcell when a program is running. Anorad recommends the use of
additional safety features such as light curtains and magnetic interlocks to prevent entry to
the workcell while HIGH POWER is enabled. These devices can be connected using the
emergency stop circuitry.

1.5.7 Program Security

Programs and data stored in memory can be changed by trained personnel using the C++
commands and instructions documented in the ANO-2000 NT API library functions manual.
To prevent unauthorized alteration of programs, you should restrict access to the Windows
NT Workstation. This can be done by using passwords on the Workstation and limiting
access to development personnel.

Rev 2 1-3
1.5.8 Overspeed Protection

Overspeed protection for a robot or motion system has to be taken into account during
system integration by the integrator or end-user. Overspeed protection is not guaranteed by
the controller hardware parameter alone.

1.5.9 Voltage Interruptions

The AC supply to the controller is monitored via onboard watchdog timers. When power
failure is sensed the High Power Enable and individual Drive Enable signals will be turned
off. The user must ensure that these signals are used to prevent a hazardous condition.

1.5.10 Inappropriate Uses of the PC-2000 System

The PC-2000 Motion Controller System is intended for use as sub system of a complete
industrial automation system. The PC-2000 Motion Controller sub-system must be installed
inside a suitable enclosure. Installation and usage must comply with all safety instructions
and warnings in this manual. Installation and usage must also comply with all applicable
local or national statutory requirements and safety standards. The PC-2000 Motion
Controller Card is not intended for use in any of the following situations:

• In hazardous (explosive) atmospheres

• In mobile, portable, marine, or aircraft systems
• In life-support systems
• In residential installations
• In situations where the PC-2000 Motion Controller System may come into contact
with liquids.
• In situations where the PC-2000 Motion Controller will be subject to extremes of
heat or humidity. See specifications for allowable temperature and humidity ranges.

1.6 Standards Compliance

TBD

1-4 Rev 2
 Chapter 2

Overview

2.1 Introduction
This section is a brief description of the components and options that available with the PC-
2000 Motion Controller System.

2.2 PC-2000 Servo Motion Controller

The PC-2000 Servo Controller is a 16-bit ISA (PC-AT) Bus compatible multi-axis motion
controller that performs high-precision trajectory control of 1 to 6 axes. Distributed control
topologies are also supported with remote communication provided by RS-232 and/or RS-485
serial ports. The controller interfaces to servo amplifiers and feedback devices via the 4U
Motor Interface Chassis (MIC). The controller receives power from the PC, or in stand-alone
applications, from the MIC.

2.3 4U Motor Interface Chassis

The Motor Interface Chassis (MIC) provides an interface between the PC-2000 Motion
Controller and motion platform. It houses up to six servo amplifiers, an encoder multiplier
interface, and low voltage power supply for encoder multipliers and other peripherals. The MIC
backplane distributes power from an external Dual High-Voltage Power Supply over two power
busses, accommodating both high and low voltage amplifiers.

2.4 Anorad 2U Dual High-Voltage Power Supply

This compact dual power supply provides 1.5 kV-A for each of its outputs. Nine models
range from single 50V or 150 to dual 250V. The universal design allows it to operate in all
regents of the world using either single phase 230 Volts or two phase 208 Volts.

2.5 Anorad Amplifier Modules

Anorad integrates a variety of servo amplifiers with the PC-2000 motion controller. Using both
high and low voltages with a choice of trapezoidal, sinusoidal and software commutation. The
versatility of the MIC allows easy integration of most any Eurocard type servo amplifier.

Rev 2 2-1
 Chapter 3

PC-2000 Motion Controller

3.1 Introduction
The PC-2000 Motion Controller (PC-2000) can control a wide range of actuators including
electromagnetic and piezo-electric motors. Linear or rotary motors may be of DC
brush/brushless or AC brushless type. Sinusoidal or 6-step software commutation is
supported, eliminating the requirement for hall effect switches. Flexible n-dimensional
gearing, contouring, and interpolation modes are available for coordinated motion
requirements. Please refer to the Ano-2000 NT API Library Programming Manual (Item
Number 802139) for detailed descriptions of the different motion modes and configuration
requirements.

Interfacing of incremental and absolute optical encoders, laser interferometers, and analog
sensors are supported. Joystick control is supported for development, testing, and debugging.
Dedicated programmable strobe and latch lines enable many advanced applications such as
precision position triggering/gating and data collection. Programmable home and limit
sensing coupled with index sensing provide interface flexibility. Drive and encoder fault
sensing together with dedicated Emergency Stop and High-Power Enable signals help to
assure safety of operation.

3.2 Jumpers, Switches, and Indicators

3.2.1 ISA Bus Resource Allocation (S1)
The PC-2000 communicates with the host PC through a 4K x 16 bit block of RAM. Four 8-
bit I/O registers define the RAM base address and select the active interrupt line used for
host interrupts. The I/O register base address is set by an 8-position DIP switch (S1), located
on the PC-2000. Following power up or a PC reset, the I/O registers will contain the ASCII
characters “PC2K”. The on-board processor may be reset by software by writing an ASCII
“R” to the Reset Register followed by any other 8-bit value. Communication with the PC-
2000 will be disabled until the registers are programmed. Once a register is written, the
registers will read back the written value. Under certain conditions, the PC-2000 will
interrupt the PC via the selected interrupt line. The interrupt service routine will read the
interrupt value at RAM location BASE ADDRESS + 0FFEh. Reading this value will also
clear the interrupt line.

Rev 2 3-1
Table 3-1 I/O Register Map Base Address

S1 Position 8 7 6 5 4 3 2 1
ISA Address A9 A8 A7 A6 A5 A4 A3 A2
Table 3-2 I/O Register Map

I/O Base Default

Register Definition Access
Address Offset Value
0 Memory Addr. low R/W “P”
1 Memory Addr. high R/W “C”
2 Interrupt register R/W “2”
3 Reset R/W “K”
Table 3-3 I/O Register Bit Map

Register Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0

Memory addr. Low A15 A14 A13 X X X X X
Memory addr. High A23 A22 A21 A20 A19 A18 A17 A16
Interrupt register * Int15 Int12 Int11 Int10 Int09 Int07 Int05 X

* Only one interrupt should be selected at any one time

3.2.2 Options Switches (S2)

The 8-Position Option Switches are not implemented at this time.

3.2.3 Watchdog Timer (JP1/JP2)

Watchdog Function JP1 JP2

Disabled ON OFF
150ms timeout OFF ON

3.2.4 Reset (SW1)

Depressing the Reset switch (SW1) will immediately reset the PC-2000 DSP and all on-
board logic functions, but will not affect the PC host processor or the host I/O registers.

3.2.5 LED Indicators (LED1-8)

The 8 LED’s indicate Status during normal operation.

Indicator Indication when Illuminated

LED1 Axis 1 Enabled
LED2 Axis 2 Enabled
LED3 Axis 3 Enabled
LED4 Axis 4 Enabled
LED5 Axis 5 Enabled
LED6 Axis 6 Enabled
LED7 High Power Enabled
LED8 Emergency Stop Inactive

3-2 Rev 2
3.3 Connectors
3.3.1 J1 Connector
Table 3-4 J1 Connector Pin Assignments
Position Signal Position Signal
1 ADC1 51 ADC3
2 ADC2 52 ADC4
3 IN1 53 IN3
4 IN2 54 IN4
5 OUT1 55 OUT3
6 OUT2 56 OUT4
7 +A1 57 +I1
8 -A1 58 -I1
9 +B1 59 SNSR_A1
10 -B1 60 SNSR_B1
11 +A2 61 +I2
12 -A2 62 -I2
13 +B2 63 SNSR_A2
14 -B2 64 SNSR_B2
15 +A3 65 +I3
16 -A3 66 -I3
17 +B3 67 SNSR_A3
18 -B3 68 SNSR_B3
19 +A4 69 +I4
20 -A4 70 -I4
21 +B4 71 SNSR_A4
22 -B4 72 SNSR_B4
23 +A5 73 +I5
24 -A5 74 -I5
25 +B5 75 SNSR_A5
26 -B5 76 SNSR_B5
27 +A6 77 +I6
28 -A6 78 -I6
29 +B6 79 SNSR_A6
30 -B6 80 SNSR_B6
31 ENB1 81 ENB4
32 FLT1 82 FLT4
33 ENB2 83 ENB5
34 FLT2 84 FLT5
35 ENB3 85 ENB6
36 FLT3 86 FLT6
37 DAC_A1 87 DAC_B1
38 AGND 88 AGND
39 DAC_A2 89 DAC_B2
40 AGND 90 AGND
41 DAC_A3 91 DAC_B3
42 AGND 92 AGND
43 DAC_A4 93 DAC_B4
44 AGND 94 AGND
45 DAC_A5 95 DAC_B5
46 AGND 96 AGND
47 DAC_A6 97 DAC_B6
48 AGND 98 AGND
49 ESTOP 99 HPE
50 GND 100 GND

Rev 2 3-3
3.3.1.1 Emergency Stop and High-Power Enable Circuits

3.3.1.1.1 E-Stop Input

The E-STOP input is intended to signal the PC-2000 to shut down all motion and power in
an orderly fashion in the event of a system malfunction or on operator command.

Figure 3-1 E-Stop Input Interface

300
E-STOP

3.3.1.1.2 High-Power Enable Output

The High-Power Enable circuit (HPE) is intended to shut down the motor power supplies in
the event of a system malfunction in response to an ESTOP. Following braking of all axes,
the HPE signal will deactivate, removing power from the motors.

Figure 3-2 High-Power Enable Output Interface

+5V
300

HPE

3-4 Rev 2
3.3.1.2 Servo Amplifier Interface

3.3.1.2.1 Enable/Fault

The digital drive interface signals enable the drives and receive fault status.

Figure 3-3 Drive Fault/Enable Interface

+5V

4.7K Ω

1.0K Ω

0.1 µF

Drive Fault Circuit Drive Enable Circuit

3.3.1.2.2 Control

Two digital to analog converters per axis allows maximum flexibility in controlling different
types of motors with different types of drives. A single analog output ranging from +10V to -
10V is the standard and is sufficient for most applications utilizing brush and brushless DC
motors. For applications where brushless motors are used without hall-effect sensors, two
analog outputs are used to control two phase currents through software commutation. The
axis position as read by the encoder is processed at the servo update rate for commutating
the motor.

3.3.1.3 Home/Limit Sensor Interface

The PC-2000 reads two logic level inputs per axis. These signals may be interpreted as
limits, direction or any user determined function. Open collector devices may be connected
to these inputs. The figure below details the input circuits for limit interface.

Figure 3-4 Sensor Input Circuit

+5V

4.7K Ω

1.0K Ω

0.1 µF

Rev 2 3-5
3.3.1.4 Encoder Interface
Figure 3-5 Encoder Interface Circuit

1 0 0Ω

3.3.1.4.1 Incremental Encoders

Three differential receivers per axis accept quadrature signals A and B and reference Index
from the encoder. 4X multiplication is done internal to the FPGA before counting into a 16-
bit up/down counter. Axis position is latched at the servo update rate and read by the
processor. The figure below details the input circuits for the encoder interface.

3.3.1.4.2 Absolute Encoders

When interfacing to analog multipliers, the quadrature interface imposes a velocity

limitation on the motion. In order to avoid this, the multipliers are equipped with counter
logic. The absolute 16-bit position and various other data is transmitted serially over the A
lines and clocked by the B lines in response to a strobe signal. The strobe signal is
transmitted every servo cycle over the Index lines by the PC-2000 when an axis is
programmed to serial encoder mode.

3.3.1.5 Analog Sensor Interface

Four channels of differential analog inputs are available for a variety of applications. They
may be accessed individually or differentially. These inputs may be used to inject analog
signals into the servo feedback loops, or to inject analog stimulus into the servo amplifier.
Force sensors, current sensors, LVDT’s, resolvers, or any other suitable sensors may be used
as feedback. A standard joystick may be used as a control input. The input voltage range is
±10 volts. The 12-bit conversion is completed in 16 microseconds. The resolution is 5
millivolts. The analog inputs are typically sampled at the servo update rate of 8KHz.

3-6 Rev 2
3.3.1.6 High-Speed Digital I/O Connections

3.3.1.6.1 Latch Input Signals

Any one of these four inputs may be used in either polarity to store the instantaneous
position of any or all of the six axes in response to an index or other input signal edge. The
latency from latch input to capture is less than 50ns.

+5V

4.7K Ω

1.0K Ω

0.1 µF

Latch Input Circuit

3.3.1.6.2 Strobe Output Signals

Any one of these outputs may be used as a strobe at a programmable position for a
programmable duration and polarity for any one of the six axes. The latency from count to
strobe output is less than 50ns. The strobe may be programmed for a specific pulse width
from 1µs to 6.5ms. Alternately, the strobe can be programmed to toggle at precise intervals
of time or position.

Strobe Output Circuit

Rev 2 3-7
3.3.2 General Purpose I/O
The General Purpose I/O lines are intended for any specific digital I/O functions required for
the application. The 50 pin ribbon cable header is pinned out for direct connection to an
Opto 22 G4PB32DEC signal conditioning rack or similar. When connecting to the Opto 22
rack, module positions 0-7 correspond to GPIN0-GPIN7, modules 8-23 correspond to
GPOUT0-GPOUT15, and module positions 24-31 correspond to GPIN8-GPIN15
respectively.

Table 3-5 General Purpose I/O Pin Assignments (J5)

Position Signal Position Signal

1 GPIN9 2 GPIN12
3 GPIN11 4 GPIN8
5 GPIN14 6 GPIN15
7 GPIN10 8 GPIN13
9 GPOUT13 10 GPOUT15
11 GPOUT11 12 GPOUT9
13 GPOUT10 14 GPOUT8
15 GPOUT14 16 GPOUT12
17 GND 18 NC
19 GND 20 NC
21 GND 22 GND
23 GND 24 NC
25 GND 26 GND
27 NC 28 GND
29 NC 30 GND
31 GND 32 GND
33 NC 34 GND
35 GPIN4 36 GPIN6
37 GPIN0 38 GPIN2
39 GPIN1 40 GPIN3
41 GPIN7 42 GPIN5
43 GPOUT5 44 GPOUT2
45 GPOUT7 46 GPOUT6
47 GPOUT0 48 GPOUT3
49 GPOUT4 50 GPOUT1

3-8 Rev 2
3.3.2.1 Inputs
Sixteen general-purpose inputs may be used as needed in the application.

+5V

4.7K Ω

1.0K Ω

0.1 µF

Latch Input Circuit

3.3.2.2 Outputs
Sixteen general-purpose outputs may be used as needed in the application.
+5V

4.7K Ω

General-Purpose Output Circuit

Rev 2 3-9
3.3.3 Serial I/O and Stand-Alone Power Connections

3.3.3.1 RS-232 Connector

Table 3-6 RS-232 Pin Assignments (J2)

Position Signal Position Signal

1 NC 2 NC
3 TXD 4 RTS
5 RXD 6 CTS
7 NC 8 NC
9 GND 10 NC

3.3.3.2 RS-422/485 Connector

Table 3-7 RS-422/485 Pin Assignments (J3)

Position Signal Position Signal

1 +TXD 2 -TXD
3 +RTS 4 -RTS
5 +RXD 6 -RXD
7 +CTS 8 -CTS
9 GND 10 NC

3.3.3.3 Typical Cable Connections

The PC-2000 RS-232 Connector (J2), when cabled to a DB9 connector, is wired as Data
Communications Equipment (DCE), which allows a “straight-through” connection to a PC
which is typically wired as Data Terminal Equipment (DTE). If connecting to a modem or
other DCE, then the appropriate null modem connections must be made.

3.3.3.4 Stand-Alone Power

Power Connector Pin
Assignments (J3)
Position Signal
1 +5
2 +12
3 -12
4 GND

3.3.4 Expansion Connectors (J6, J10)

The expansion connectors are not as yet implemented.

3-10 Rev 2
3.4 PC-2000 Servo Controller Specifications
Table 3-8 Technical Specifications for PC-2000 Servo Controller

Power (nominal voltage @ max. current) 5V @ ?A, +12V @ ?A, -12V @ ?A

Dimensions See Appendix A
Weight TBD g
Ambient Temperature TBD °C to TBD°C
Humidity TBD % to TBD %, non-condensing
Altitude Up to TBD m

Rev 2 3-11
3-12 Rev 2
 Chapter 4

Motor Interface Chassis

4.1 Introduction
Section describes the layout of the Motor Interface Chassis (MIC). The functional
description is supported by board level sketches with connector and jumper function tables.
It continues with a description of sensor interfaces, safety controls, and parameters of
matching power supplies. The manual concludes with a section on troubleshooting.

4.2 MIC Overview

The MIC can operate up to six axes from a single enclosure. Front and rear hardware
configurations of the MIC are shown Section 3 - “Functional Description”

The MIC’s PC-2000 Backplane provides an interface between the Servo Amplifier Boards
and an externally mounted PC-2000 Motion Controller Board. The Encoder Interface Board
with Optional Encoder Multipliers installed, enables the PC-2000 Motion Controller to use
analog sinusoidal type encoders.

The host PC is the system interface for commanding motion control and monitoring the PC –
2000 Motion Controller. Communications with the processor board is accomplished though
a series of text string commands generated in a user defined environment. Control
commands, known as API Libraries are found in the “Ano-2000 API Library Documentation
Manual”, Part Number 802139.

Rev 2 4-1
4-2 Rev 2
 Chapter 5

Installation

5.1 Introduction
The installation of the MIC includes site preparation to system checkout. To best effect the
MIC, these procedures should be followed in the order they are presented.

5.2 Site Preparation

The MIC operates from a 115/220 volt (± 5%), 60/50 Hz, 15/10 ampere power line. For
optimum performance of the chassis and components, the power source must be from a
dedicated, computer-grade line. Before the installation of the chassis can proceed, this line
must be checked using a power line monitor to guarantee that it is of computer grade. Table
2-1 illustrates other site planning considerations necessary for the performance of the
system.

Rev 2 5-1
Table 5-1 Site Planning Requirements

SITE APPLICABILITY
The equipment contains semiconductors and other
Temperature
electronic components that are sensitive to excessive
heat. Adequate ventilation is required to allow air
circulation through the cabinet grill. The chassis does not
require any special cooling considerations except to avoid
mounting it near any heat generating objects such as
heat register. Sustained average temperature should not
be greater than 104 F (40° C), nor less than 32° F (0°
C).

Humidity Avoid excessive humidity which may cause condensation

on metal surfaces and consequently produce corrosion.
The maximum permissible humidity is 80% (relative) non-
condensing .

Accessibility The chassis, whether it is a stand alone or a rack

mounted unit, must be located where sufficient working
space is available for one technician. Locations where
equipment may be inadvertently hidden or blocked by the
placement of bulky items should be avoided.

Dust and airborne Avoid placing equipment in areas where dust or other
contaminants airborne contaminants are present. Chemical fumes or
vapors will cause corrosion or oxidation of electrical
contacts.

Vibration The equipment should be installed in a location free of

vibration to avoid disconnecting or loosening
components.

Ambient light Sufficient light should be readily available to enable

inspection, testing, and other functions to be performed
on the chassis.

5-2 Rev 2
5.3 Unpacking
The chassis is shipped in a heavy cardboard container wrapped anti-rust paper and sitting on
a form-fitting foam bed. If the container is damaged in any way, contact the shipping carrier
immediately before opening the carton.

NOTE:

It would be a good idea to have an agent from the carrier

present before removing the system from a damaged
container.

The box and packing material should be retained for equipment relocation, or if it becomes
necessary to return the chassis for factory service.

WARNING

Do not use a sharp instrument such as a knife to open

shipping carton, or to remove any packing. A sharp
instrument can cause damage to system components and
chassis finish.

Open the shipping carton and carefully remove chassis from the box. Inspect the parts by
performing the following:

Check the circuit card ESD safe packages for tears or damage.
Check the chassis for any physical damage to covers, grills or side
plates.
Check that the supporting documentation is present in the carton.
Unwrap the cables and inspect them for completeness, damaged
connectors or pins.
Open the cover and make sure that unit contains the components listed
on the inventory sheet.

If the chassis, or its components are damaged, or pieces of the inventory are missing, contact
ANORAD immediately at (516) 231-1990 extension 285.

WARNING

Due to the CMOS devices present on the circuit cards,

extreme care must be taken when handling the cards to avoid
electrical static discharge (ESD). The user must wear a
ground strap when handling cards to eliminate any static
electric charge.

Rev 2 5-3
5.4 Installation
5.4.1 Introduction
ANORAD recommends checking out the MIC before permanent installation and operation.
Verify all connections and perform tests before installing in equipment rack or at a stand
alone location.

5.4.2 Circuit Cards

WARNING

Make sure all electrical power is off when removing or

installing the circuit cards.

Using standard shop practices open host computer and install the PC-2000 Processor Board.
Position the card in available slot making sure that its properly seated and secured. Refer to the
ANO-2000 NT API Library Programming Manual for more details on installation. When
utilizing PC-2000 I/O the adjacent slot must be left open. Install I/O ribbon cable so the cables
can exit the chassis at the open slot. Close host computer and proceed with installation and
checkout.

Place MIC on suitable work surface. Remove front cover for access to circuit cards, and
verify they are firmly in place. Refer to Figure 6-2 “MIC Front View”.

If present, the optional encoder interface board is installed horizontally on the left side of the
5U enclosure and is secure by the red locking tabs. Verify it is properly installed. If card is
loose, fully release locking tab, reposition card, and depress locking tab.

The Servo Amplifier cards are installed vertically on the lower right side of the enclosure.
They are secured by a hold down bar and some will have a red locking tab. Verify they are
secure. If not: remove the hold down bar, fully release locking tab, reposition cards, secure
locking tab, and then secure the hold down bar.

5.4.3 Cabling
Using Figure 5-1 “PC-2000 System Layout’ for reference, attach the 100 pin HIPPI cable
between the host computer and the MIC. Connect motor power, commutation, encoder
cables to the axis and the MIC. At this time install optional I/O inputs to the host computer.

5-4 Rev 2
 Typical Motor
MOTOR-1 Layout

MTR-1
ENCODERS

Rev 2
SERVO HALL EFFECT-1
Z

HE-1
AMPLIFIER
ROTORY
MOTORS

MOTOR-2 HALL

MTR-2
SENSORS

A
HOST PC
SERVO
HALL EFFECT-2

HE-2
PC-2000 AMPLIFIER
PROCESSOR

MOTOR-3 Y

MTR-3
100 pin HIPPI SERVO HALL EFFECT-3
HALL
Figure 5-1 PC-2000 System Layout

HE-3
Cable AMPLIFIER SENSORS ENCODERS
LINEAR

100 PIN HIPPI CABLE

MOTORS
MOTOR-4
MTR-4

SERVO HALL EFFECT-4

HE-4

AMPLIFIER

ENC-1
ENC-2
PCLM PCLM SIGNAL
AMPLIFIER PCLM
HE-5/PCLM

MOTORS

ENC-3
PCLM
ENC-4 PCLM SIGNAL
AMPLIFIER
HE-6/PCLM

OPTIONAL OPTIONAL OPTIONAL

ENCODER ENCODER ENCODER
ENC-5

MULITIPLIER MULITIPLIER MULITIPLIER

1 2 3

OPTIONAL OPTIONAL OPTIONAL

ENCODER ENCODER ENCODER
MULITIPLIER MULITIPLIER MULITIPLIER
ENC-6

4 5 6
PC-2000 BACKPLANE

ENCODER MULTIPLIER INTERFACE

5-5
MIC

PC-2000 System Layout

5.4.4 Connecting AC Power
The MIC Interface Chassis has auto-switching power supplies that operates from 90 to 250
VAC single phase.

5.4.5 AC Power Requirements

Table 5-2 MIC Power Requirements

Auto Switching Minimum Maximum Frequency/ Recommended External

Nominal Voltage Operating Operating Phasing Circuit Breaker (user-
Ranges Voltage Voltage supplied)
50-60 Hz,
90V to 250V 90V 250V 10 amps
Single phase

Power to the MIC and all amplifiers and motion devices must come from a single source. If
the Controller is used with a motion platform, see the motion platform user’s guide or
instruction handbook for additional power requirements.

5.4.5.1 Facility Overvoltage Protection

The user must protect the controller from excessive overvoltages and voltage spikes. In
particular, if the country of installation requires a CE-certified installation, or compliance
with IEC 1131-2, the following information may be helpful.

IEC 1131-2 requires that the installation must ensure that category II overvoltages (i.e., line-
spikes not directly due to lightening strikes) are not exceeded. Transient overvoltages at the
point of connection to the power source shall be controlled not to exceed overvoltage
category II, i.e. not higher than the impulse voltage corresponding to the rated voltage for the
basic insulation. The user-supplied equipment or transient suppressor shall be capable of
absorbing the energy in the transient.

In the industrial environment, non-periodic overvoltage peaks may appear on mains power
supply lines as a result of power interruptions to high energy equipment (such as a blown
fuse on one branch in a 3-phase system). This will cause high current pulses at relatively low
voltage levels. The user shall take the necessary steps to prevent damage to the controller
system (such as by interposing a transformer). See IEC 1131-4 for additional information.

5.4.6 Function of System Power Switch with 4U Motor Interface Chassis

The power switch is located on the left side inside the chassis door of the MIC. The power
switch turns on the internal power supply and the fan.

• The On/Off power switch ( I = On, o = Off)

5-6 Rev 2
5.4.6.1 Connecting AC Power Cord to the MIC
The AC power cord can be of 110VAC or 220 VAC type the MIC power supply adjust to the
input voltage.

5.4.6.2 System Grounding Information

The detachable three-wire power cord is used for connection to both the power source and
protective ground. The protective ground conductor in the power cord is internally connected
to the exposed metal parts of the controller. To ensure electrical-shock protection, the
protective ground conductor must be connected to a properly grounded power source.

WARNING

Ensure that a proper protective ground connection exists

before turning on the power.

5.4.7 Fuse Information

The two fuses (F1 and F2) at the power entry module on the rear panel are for the incoming
AC power lines. See the table below for ratings.

WARNING:

Only skilled or instructed personnel should attempt to change

any fuses. Always replace blown fuses with new fuses of the
same type and rating.

5.4.7.1 Procedure to Remove Fuse Holder

1) Turn off AC power to the controller and disconnect the power cord from the AC power
source.

2) Remove the AC power cord from the socket on the MIC.

3) To remove the fuse holder, insert a small flat-blade screwdriver into the slot on either
side of the fuse holder depress tabs then slide out to release the fuse holder.

4) To reinstall the fuse holder, insert it in place, and then press down firmly until the entire
holder snaps into position.

Rev 2 5-7
 NOTE

The “T” suffix indicates the fuse response time - a 3 AT fuse

rating specifies a 3 amp “slow blow” type.
Fuse Rating Type
F1 - AC Line fuse at Power 3 AT/250 V IEC 127-style 5 x 20 mm
F2 - AC Line fuse at Power 3 AT/250 V IEC 127-style 5 x 20 mm

5.4.7.2 Cooling Fan

The exhaust fan is located on the side of the MIC and requires ½ inch clearance. The bottom
and side of the chassis have louvers for air intake. The bottom of the chassis requires ¼ inch
clearance; the side requires ½ inch. The unit is shipped with 4 rubber feet for bottom clearance.
These feet can be removed when the unit is rack mounted.

5.4.8 Removing and Installing Modules

The MIC is shipped from the factory with all the amplifier modules specified on the sales
order installed in the chassis. You may want to add modules in the future or remove and re-
install a module for some reason. Additional modules should generally be added to the
chassis from left to right, starting with the slot to the right of the last existing module.
However, you can add any optional module to any unused slot, in any order you like

CAUTION

Always turn off the controller power switch before installing or

removing modules or jumper plugs. Damage to the controller
can occur if the controller is not turned off.

CAUTION

You must take precautions to prevent modules from being

exposed to electro-static discharge (ESD) while you are
handling or storing them. Anorad recommends using a ground
strap on your wrist when working with modules outside of the
controller. Use anti-static bags to protect modules when
outside the controller.

5.4.8.1 Removing Modules

1) Open front access door and turn off the controller.

2) Remove card retainer bar.

3) Pull out the top card ejector as you start to pull the module out of the chassis. Remove
the module from the chassis and store it in a safe place. (follow anti-static precautions.)

5-8 Rev 2
 WARNING

Do not attempt to install or remove any boards without first

turning off the power to the Controller and all related external
power supplies. Failure to observe this warning could cause
damage to your equipment.

5.4.8.2 Installing Modules

1) Open front access door and turn off the controller.

2) Remove card retainer bar.

3) Verify that the intended slot for the module is ready to accept the module. If the slot has
been unused, make sure the are jumper connectors installed are for the proper buss
voltage and the backplane is populated with brake relays and chokes.

4) Align the module with the card guide slots at the top and bottom of the card cage. Slide
the module in slowly. Apply straight-forward pressure to the front edge of the module
until it is firmly seated in the backplane connector, and the face of the module is flush
with the other modules.

5) Press the ejector flush with the edge of the card, install the card retainer bar in front the
module.

CAUTION

It should not be necessary to use excess pressure or force to

engage the connectors. If the board does not properly
connect with the backplane, remove the module and inspect
all connectors and guide slots for possible damage or
obstructions.

Rev 2 5-9
5.4.9 Verification
CAUTION:

Due to the CMOS devices present on the circuit cards, care

must be taken when handling the cards to avoid electrical
static discharge. The user must wear a ground strap when
handling cards to eliminate any static electric charge.

Perform the actions listed if the unit fails to respond proceed to “Troubleshooting” in
“Section 7.2 - Maintenance.” If the procedures within the maintenance section do not resolve
the problem, contact ANORAD at (516) 231-1990 extension 285.

1) Connect power cable to power source. Apply power and verify LEDs on the
circuit cards are lit.

2) Verify communication link between host computer and MIC.

3) Using commands provided in “Ano-2000 NT API Library Documentation”

Part Number 802139 issue an axis move command.

5-10 Rev 2
 Chapter 6

MIC Functional Description

6.1 Introduction
This section describes the functional operation of the Motor Interface Chassis (MIC). It also
details the backplane interfaces, connectors, jumper settings and power supplies.

6.2 MIC
6.2.1 Connectors
MIC accepts a 100 interface cable from the PC-2000 Motion Controller Card located in the
host processor. Axis connections include the motor power (MTR-1 through MTR-6),
commutation (COM-1 through COM-6), and encoder (ENC-1 through ENC-6). See Figure
6-1 “MIC Connectors” for layout of connectors.

6.2.2 Connector Pinouts

The following tables show connector pinouts and signal names for the MIC.

Table 6-1 Pinouts for MTR-1 through MTR-6

Pin # Signal
A1 Motor Phase A
A2 Motor Phase B
A3 Motor Phase C
A4 Motor Ground
1 Tachometer/ Motor Ptc
2 Brake
3 Tach/Motor PTC Return
4 Brake Return
5 Shield

Rev 2 6-1
Figure 6-1 MIC Connectors

MTR 6 MTR 5 MTR 4 MTR 3 MTR 2 MTR 1

A U X I/O ANALOG PW R 1

ENC 1

SAFETY
ENC 2

ENC 3

ENC 4

A C P W R IN
ENC 5 9 0-25 0 V A C
5 0/60 H z 2 .5A
F U S E X 2 :T3 A

ENC 6
H E /P M 6 H E /P M 5 H E /P M 4 H E /P M 3 H E /P M 2 H E /P M 1

CONTROL
PW R 2

6-2 Rev 2
Table 6-2 Pinouts Control Connector

Position Signal Position Signal

1 1AIN 51 3AI N
2 2AIN 52 4AIN
3 1INP 53 3INP
4 2INP 54 4INP
5 1OUT 55 3OUT
6 2OUT 56 4OUT
7 1CHA+ 57 1IND+
8 1CHA- 58 1IND-
9 1CHB+ 59 1SENP
10 1CHB- 60 1SENQ
11 2CHA= 61 2IND+
12 2CHA- 62 2IND-
13 2CHB+ 63 2SENP
14 2CHB- 64 2SENQ
15 3CHA+ 65 3IND+
16 3CHA- 66 3IND-
17 3CHB+ 67 3SENP
18 3CHB- 68 3SENQ
19 4CHA+ 69 4IND+
20 4CHA- 70 4IND-
21 4CHB+ 71 4SENP
22 4CHB- 72 4SENQ
23 5CHA+ 73 5IND+
24 5CHA- 74 5IND-
25 5CHB+ 75 5SENP
26 5CHB- 76 5SENQ
27 6CHA+ 77 6IND+
28 6CHA- 78 6IND-
29 6CHB+ 79 6SENP
30 6CHB- 80 6SENQ
31 1/ENB 81 /4ENB
32 1FLT 82 4FLT
33 2/ENB 83 /5ENB
34 2FLT 84 5FLT
35 3/ENB 85 /6ENB
36 3FLT 86 6FLT
37 1CMD0 87 1CMD1
38 1RTN0 88 1RTN1
39 2CMD0 89 2CMD1
40 2RTN0 90 2RTN1
41 3CMD0 91 3CMD1
42 3RTN0 92 3RTN1
43 4CMD0 93 4CMD1
44 4RTN0 94 4RTN1
45 5CMD0 95 5CMD1
46 5RTN0 96 5RTN1
47 6CMD0 97 6CMD1
48 6RTN0 98 6RTN1
49 XEMO 99 HPEN
50 IORTN 100 DRVRTN

Rev 2 6-3
Table 6-3 Pinouts for ENC-1 through ENC-6

Pin # Signal
1 SIN/A+
2 COS/B+
3 REF/I+
4 5VDC
5 SENP
6 SENQ
7 NC
8 SHEILD
9 NC
10 +12VDC
11 5VDC
12 VDC
13 SHLD
14 SIN/A-
15 COS/B-
16 REF/I-
17 0VDC
18 0VDC
19 0VDC
20 0VDC
21 1V+
22 NC
23 -12VDC
** CONNECTED TO CHASSIS GROUND 24 NC
25 0VDC

6.2.2.1 Quadrature Interface

NOTE:

It is highly recommended that a differential type encoder be

used whenever possible to provide the maximum possible
noise immunity.

Other types of feedback devices such as linear encoders, resolver/inductosyn, interferometer

or LVDT transducers are interfaced via plug-in modules.
Table 6-4 Pinouts for HE 1 through HE 6

Signal when used for Signal when used for

Pin #
PCLM Hall Effect
1 DRVHTP COMM +5V/+I
2 MTR_C COMM S2/+A
3 MTR_DWN COMM S3/+B
4 MTR_COM MOTOR PTC
5 MTR_UP SHIELD
6 HTPRTN COMM RTN/-I
7 SHLD COMM S1/-A
8 NC COMM –B
9 SHLD MOTOR PTC RTN

6-4 Rev 2
Figure 6-2 Pinouts for PWR-1 Connector

Pin # Signal
1 Buss A VDC
2 Buss A RTN
3 Buss B VDC
4 Buss B RTN

Table 6-5 Pinouts for Safety Connector

Pin # Signal
1 +24V
2 XEMO
3 Pin 7 on K7 relay
4 +24V
5 S24V
6 GND

Table 6-6 Pinouts for Analog Connector

Pin # Signal
1 SOUT0
2 SOUT1
3 1AIN
4 2AIN
5 3AIN
6 4AIN
7 +12V
8 SHLD
9 SRTN0
10 SRTN1
11 GND
12 GND
13 GND
14 GND
15 -12V

Table 6-7 Pinouts for Digital Connector

Pin # Signal
1 HPEN
2 1INP
3 2INP
4 3INP
5 4INP
6 +5V
7 24+V
8 SHLD
9 XEMO
10 1OUT
11 2OUT
12 3OUT
13 4OUT
14 GDN
15 GND

Rev 2 6-5
6.3 Backplanes And Boards
6.3.1 Introduction
The following section describes the functionality and settings of PC-2000 Backplane,
Encoder Multiplier Interface, and the Encoder Multiplier. Figure 6-2 shows the front view of
the Motor Interface Chassis

Figure 6-3 Motor Interface Chassis Front View

Fuse F1A US E Fuse F1A US E Fuse F1A US E US E Fuse F1A US E US E

U F

U F

U F
U F

U F
U F

SE

SE

SE

SE
SE

SE

FU

FU

FU
T7A / T7A / T3A / T7A /

FU

FU

FU
SE SE SE SE SE SE
F F F F F F
250V 250V 250V 250V

Fuse F1B US E Fuse F1B US E Fuse F1B US E US E Fuse F1B US E US E

U F

U F

U F

U F

U F
U F

SE

SE

SE
SE

SE

SE

FU

FU

FU
T7A / T7A / T3A / T7A /

FU

FU
FU
SE SE SE S SE S
F F F EF F EF
250V 250V 250V 250V
X -A X IS Y -A X IS Z -A X IS θ-A X IS

DRV 5
DRV 12
DRV 11

DRV 3
DRV

DRV

6.3.2 PC-2000 Backplane

This discussion of the PC-2000 Backplane is supported by the Figure 6-4 “PC-2000
Backplane Physical Layout”. Here you will find the description of jumper settings,
connector ports, and PC-2000 backplane. The PC -2000 backplane provides power and an
interface for command and communications between the PC-2000 processor, up to six servo
amplifiers.

6-6 Rev 2
6.3.2.1 Buss Power Selection
Each axis has one set of jumpers or a switch on the backplane to determine the power input
to the servo amplifier.

Figure 6-4 Motor Driver Power Buss Jumpers

T o se lect T o se lect
B uss A B uss B
use th is p lug use th is p lug
S lide S W 1 -6 to select buss
com bina tion com bina tion

1 1 1
VDC

to A m p P lu g 1
2 2 2
P lu g 1
U p for B u ss A
3 3 3
or
Buss A D o w n fo r B u s s B
1 1 1
RTN

to A m p
2
P lu g 2 P lu g 2
Buss B 2 2

3 3 3

Jumper Function
JP1 High Side
Power Buss Selection Amplifier 1
JP2 Low Side
JP3 High Side
Power Buss Selection Amplifier 2
JP4 Low Side
JP5 High Side
Power Buss Selection Amplifier 3
JP6 Low Side
JP7 High Side
Power Buss Selection Amplifier 4
JP8 Low Side
JP9 High Side
Power Buss Selection Amplifier 5
JP10 Low Side
JP11 High Side
Power Buss Selection Amplifier 6
JP12 Low Side

Rev 2 6-7
Figure 6-5 PC 2000 Backplane Physical Layout*
Part Number 800632
Schematic Number 800632-S

R e la y 1 R e la y 2 R e la y 3 R e la y 4 R e la y 5 R e la y 6
F AN

F AN

J3 2 J3 4 J3 6 J3 8 J4 0 J4 2
J3 1 J3 3 J3 5 J3 7 J3 9 J4 1

J2 4 JP 2 5 JP 2 6 JP 2 7 JP 2 8 JP 2 9 JP 3 0
BUSS INPUT

L2 L5 L8 L11 L14 L17

L1 L4 L7 L10 L13 L16

JP2 JP4 JP6 JP8 JP10 JP12

L3 L6 L9 L12 L15 L18

JP1 JP3 JP5 JP7 JP9 JP11

EG

L O G IC
J2 3

* See Figure 6-1 for connectors on back of board.

6-8 Rev 2
Table 6-8 Amplifier Board Connectors

Connector Function
J25 Motor Amplifier 1
J26 Motor Amplifier 2
J27 Motor Amplifier 3
J28 Motor Amplifier 4
J29 Motor Amplifier 5
J30 Motor Amplifier 6

Table 6-9 J23 Internal Power Connector

Pin Signal
1 +5 VDC
2 +5 VDC
3 GND
4 GND
5 -12 VDC
6 +12 VDC
7 +24 VDC
8 NC

6.3.2.2 Backplane Jumpers

Figure 6-4, shows the PC-2000 backplane the J1-J6 connector accepts EUROCARD-format
servo amplifier board with DIN-type power connector. The two fuse spade connectors the
on backplane are wired to fuses on the front panel.

Rev 2 6-9
6.3.3 Encoder Interface Board
The Encoder Interface Board, Figure 6-5 provides an interface between an encoder with
sine/cosine output and individual 4096X encoder multiplier boards. The Encoder Interface
Board has six connectors J1 through J6; each connector accepts a plug-in 4096X encoder
multiplier board. Axes requiring encoder signal conversion will have the encoder selection
jumper removed JP1 through JP6 respectively and an encoder multiplier board inserted at the
appropriate connector. A differential driver transmits the quadrature signal to the processor.

Figure 6-6 Encoder Interface Board

J1
JP1

J4 JP2

J2 JP3

JP4
J5

J3 JP5

ANORAD CORPORTION JP6

PC2000 ENCODER INTERFACE J6

C8000635

Table 6-10 Encoder Interface Connectors

Connector Function
J1 multiplier for ENC 1
J2 multiplier for ENC 2
J3 multiplier for ENC 3
J4 multiplier for ENC 4
J5 multiplier for ENC 5
J6 multiplier for ENC 6

6-10 Rev 2
Table 6-11 Encoder Interface Test Points

Test Point Signal

TP 1 1IGATE
TP 2 1INDEX
TP 3 2IGATE
TP 4 2INDEX
TP 5 3IGATE
TP 6 3INDEX
TP 7 4IGATE
TP 8 4INDEX
TP 9 5IGATE
TP 10 5INDEX
TP 11 6IGATE
TP 12 6INDEX
TP 13 1CMD1
TP 14 2CMD1
TP 15 3CMD1
TP 16 4CMD1
TP 17 5CMD0
TP 18 5CMD1
TP 19 6CMD0
TP 20 6CMD1
TP 21 GND
TP 22 GND
Table 6-12 Encoder Interface Jumper Function

Jumper Setting Function

JP1 IN = bypass multiplier, OUT 4096X board Installed
JP2 IN = bypass multiplier, OUT 4096X board Installed
JP3 IN = bypass multiplier, OUT 4096X board Installed
JP4 IN = bypass multiplier, OUT 4096X board Installed
JP5 IN = bypass multiplier, OUT 4096X board Installed
JP6 IN = bypass multiplier, OUT 4096X board Installed

Rev 2 6-11
6.4 4096x Plug-in Multiplier Module
6.4.1 Introduction
The purpose of this manual is to support the installation and maintenance of a 4096x Plug-in
Multiplier Module. Manual sections include installation, operational verification, and
component and connector definitions. Use this document to verify the setup and correct
functioning condition of encoder multiplier. The proprietary design of unit prohibits user
replaceable components. It is recommended the multiplier card be returned to ANORAD for
repairs.

6.4.2 Overview
The 4096x Plug-in Multiplier Module is an IPC-2000 controller compatible device. It
accepts differential sin and cosine input signals and outputs a high-speed serial data stream
containing: twenty bits of position data and twelve bits miscellaneous data ever 125µs. The
miscellaneous data will occasionally contain information on the sine, cosine, and home pulse
voltages as well as encoder error messages signal references.

6.4.3 4096X Plug-in Multiplier Module Specifications

♦ Position processor based on software tracking of position, velocity and
acceleration

♦ DSP based (TI TMS 320 F240) processor.

♦ Output serial data stream 32 bits synchronous

♦ High noise immunity, typically 0.2 volts of noise translates to 16 counts

rms of position error at 1024X

♦ Auto calibration of SIN/COS signals. No potentiometer adjustments.

♦ Compact size, fits on current IPC axis card.

♦ Serial RS232 available for debugging or programming update capability

6-12 Rev 2
6.4.4 4096x Plug-in Multiplier Module
The 4096x Plug-in Multiplier Module outputs serial signals from a sine/cosine input. The
input signals from the encoder can be either single ended or differential. The plug-in
multiplier accepts the low level signals, which are buffered and then amplified to the correct
levels. The signals are divided equally for increased resolution and a quadrature signal is
generated. The Multiplier logic converts Sine and Cosine encoder inputs to a serial format
and has four available multiplication factors. The digitized sin, cosine and reference signals
are transmitted as part of the serial data stream that allows the system controller to perform
axis homing functions. Section 6.5.9 shows the maximum input frequency allowed for this
multiplier. Do not exceed maximum input frequencies stated.

Figure 6-7 4096x Multiplier Module, Item Number 74281

FOR INTERNAL USE ONLY

J2
1
R101
R102
R103
R104
R105
R106
R107
R108
R109
R110
R111
R112
R113
R114
R115

LED2 LED1
U11

TP8

1 TP7
TP6
TP5
TP4
TP3
TP2
TP1
JP4
J4

J1 JP3
1
JP1 JP2 ADDITIONAL
SEE TABLE FOR JUMPER TEST POINTS
FOR STAND ALONE USE CONFIGURATIONS

Rev 2 6-13
6.4.5 Connectors

6.4.5.1 J2 - RS-232 Internal Use Programming Port

This connector is for internal use only there are no user signals available.

Pin Signal
1 +5V
2 TXD
3 RXD
4 GND

6.4.5.2 J3 - Internal Debug Port

This connector is for internal use only there are no user signals available.

Pin Signal
1 TMS
2 /TRST
3 TDI
4 GND
5 +5V
6 GND
7 TDO
8 GND
9 TCK
10 GND
11 TCK
12 GND
13 EMU0
14 EMU1

6.4.5.3 J4 Optional Test Point Connector

The signals available at this header are dependent on the options that are selected with this
encoder multiplier. Some of the signal sources can generate internally or externally
depending on the presence, configuration and programming of the U8 programmable chip.

Pin Signal
1 +5V
2 AQUAD
3 BQUAD
4 INDEX
5 CONVST
6 SERCLK
7 SERDAT
8 GND

6-14 Rev 2
6.4.6 Test Points
Table 6-13 Test Points

Test Point Signal Name

TP 1 SIN
TP 2 COS
TP 3 REF
TP 4 NC
TP 5 PW0
TP 6 PW1
TP 7 SENS3
TP 8 GND

6.4.7 Jumper Settings

Table 6-14 Jumper Settings

JP1 & JP2

Configuration JP1 JP2

Stand Alone Closed Closed
J1

JP1 JP2 Sub System Open Closed

JP3

Encoder Resolution (X)* Connect Link(s)

256x 1-2,3-4
1024X 3-4
2048X 1-2
JP3
1
4096X none

∗ The multiplier modules supplied with the system are configured at the factory with proms
and logic to achieve the proper multiplication. The jumpers configuration will match
programmed configuration.

JP4

This jumper is for internal use only.

Rev 2 6-15
6.4.8 LED's
Table 6-15 LEDs

LED Description

LED1 ON when there is an encoder fault of if it hasn't be calibrated

LED2 For internal use only

6.4.9 Maximum Multiplier Input

The maximum multiplier input frequency is 250 kHz.

6.4.10 Speed Limit Calculations

max number of counts
Maximum Speed = * sample rate
multiplier resolution

For example, the Maximum speed calculation for 4096x resolution multiplier is as follows:

219 counts / sample

Maximum Speed = * 8000 samples / second
4096 counts / cycle

Maximum Speed = 1024 X10 3 cycles / second

6-16 Rev 2
6.4.11 Sine/Cosine Biasing
Accuracy of the tracking logic is sensitive to the offset bias. Sine and cosine inputs are
biased so they are centered at 2.5 volts. If not properly centered the counts for each quarter
cycle will be in error. The amplified sine and cosine signals from the encoder should be a 4
±0.5 volt peak-to-peak sinewave.

Verify signals as follows:

.5 Volt/DivX - Y M o d e

1) Set oscilloscope to X-Y mode with scale at 0.5 volt/div. 4 Vpp

Centered
Around
2.5 Volts±0.5V

2) From the encoder multiplier board connect TP 1 (sine) to

Channel A, TP 2 (cosine) to Channel B and TP 2 and
TP8 to oscilloscope GND. Inner
Limit
3.5Vpp Outter
Limit
4.5Vpp

Figure 6-7 represents the lissajous pattern that should be

present. Ch A = Sin @ TP1 Ch B = Cos @ TP2

Figure 6-8 Lissajous Pattern

NOTE

Shrinkage greater than .5 volt should not occur while running

at maximum velocity.

Rev 2 6-17
6.4.12 Reference Pulse
The encoder home signals available at TP 3 and should be a pulse between 2 and 4 volts.

Figure 6-9Home pulse

TP 3 WAVEFORM

TP3
4.5 max

2.5 volts 3.0 to 4.0

volts

0 min

6.4.13 Calibration Requirements

The 4096x Multiplier Module requires a calibration motion upon powered-up. The unit must
see slow speed motion generating a specific sin/cosine signal to calibrate the unit properly.
The parameters for signal are as follows:

Offsets: 2.5 Volts ± 0.5 volts

Amplitude: Min 3.5 volts pp

Max 4.5 volts pp

Max Velocity: 70 counts/125 µs or 560,000 counts /second,

a minimum 50 cycles are required to calibrate a 4µ pitch encoder.

It is recommended that the initial system homing routine contain a motion with these
parameters to accommodate the multiplier module's initialization requirements.

6-18 Rev 2
6.4.13.1 Digital I/O
PC-2000 Digital I/O is routed directly to the Host Processor. An I/O port is installed next to
the PC-2000 Processor to accept a 40 pin flat ribbon cable. See “ANO-2000 NT API
Library Programming Manual, for details additional details.

6.4.13.2 E-Stop Logic

Many safety specifications call for a means to remove motor power in case of an emergency
or fault. The PC-2000 backplane provides a 3 position screw-type connector for this
purpose. A short or low resistance contact (below 100 ohms) is required across pins 1 and 2
in order to enable the DC power buss. The PC-2000 processor monitors this signal and is
capable of reporting status to the host system. A 3 pin Phoenix screw terminal block on the
rear panel of the chassis brings the normally closed contacts of the front panel "ALL STOP"
switch to the PC-2000 backplane. Remote E-STOP switches may be wired in series if
required.

Figure 6-10 E-Stop Logic

E-STOP
SWITCH

110 VAC 24VAC CR1 CR2

E-STOP
CONNECTOR
25 PIN 'D'
MALE
1 GND
7 GND CR1 CR2
SERVO
BOARD IN J2 22 ABORT
PC 2 E-STOP
1

CONTACT MUST BE REAR OF '5U'; CONTACT MUST BE

CLOSED TO CONTROL CLOSED TO ENABLE
ENABLES MOTION BOX BUSS SUPPLY TO
DRIVES

Rev 2 6-19
6.4.13.3 Dynamic Brake Logic
Figure 6-11 Dynamic Brake Logic

AMP +
L1

+ MOTOR
L2

L3

DRIVE ENABLE

TO
24V OTHER
RELAYS
SAFTEY
INTERLOCK
HDE

6-20 Rev 2
6.4.13.4 Limit and Home Switch Interface
The PC-2000 board provides 12 inputs, two on each encoder connector, for limit functions.
Figure 6-11 “PC-2000 Controller Switch Interface” shows two typical methods for limit
switch interfacing. See Table x-x for Encoder Pinouts.

NOTE:

Whenever possible use limit switch which opens only on limit.

If the limit switches fails, the system will default to a servo off
state.

Figure 6-12 PC-2000 Controller Switch Interface

ENC-1
PIN 21

1 SENSOR1 ENC-1
PIN 05
OPTICAL
SWITCH

1 SENSOR2 ENC-1
PIN 06
OPTICAL
SWITCH

1 SENSOR RTN ENC-1

PIN 20

TYPICAL PHOTO-ELECTRIC SWITCH INTERFACE

1 SENSOR1 ENC-1
PIN 05

SENSOR RTN ENC-1

PIN 18

1 SENSOR2 ENC-1
PIN 06

SENSOR RTN ENC-1

PIN 19

TYPICAL MECHANICAL SWITCH INTERFACE

Rev 2 6-21
 Chapter 7

Maintenance

7.1 Introduction
This section contains troubleshooting and repair information for the MIC for the PC-2000
configuration in the event that a failure requires the replacement of a component. The
procedures in this section are designed to isolate and replace major subassemblies in the
chassis so the unit can be repaired and returned to service as quickly as possible. The
troubleshooting procedures provided address the most probable faults that may occur on a
MIC.

7.2 Troubleshooting
Troubleshooting for the chassis is setup in a tabular format, showing two columns to define
the symptom and probable cause for that symptom. The probable cause column also
contains possible corrective actions to be taken to resolve a failure, or references to other
procedures in this manual where pertinent information can be located.

The troubleshooting procedures provided in Table 4-1 assume that the chassis and related
circuit cards have been properly installed, see section 5.4. If the procedures provided in this
section do not locate the fault, contact ANORAD at (516) 231-1990 extension 285.

Table 4-1 MIC Troubleshooting

Symptom Probable Cause
Main power is on, but no LEDs are Main power buss is not connected.
illuminated on any of the cards.
Circuit breaker switch, on power supply module, is not
on or tripped.
Possible short circuit in the MIC.
Problem with +5 volts, or ± 15 volts. Check voltage
Fan operates, but LEDs are not on.
adjustment. Voltages should be within ± 5% of
nominal voltages shown.
Check that the HIPPI cable is properly connected.
There is no communication with MIC.
Check the HIPPI cable for broken wires or defects.

Rev 2 7-1
 Symptom Probable Cause
Servo amplifier can not be enabled. Fuse on linear power supply is blown. Replace.
Linear power supply for servo amplifier is defective.
EMO is not on.
The communication with the controller is Switch on servo amplifier is turned OFF. On the low
good, but servo amplifier can not be voltage amplifier, OFF is in the down position. On the
enabled. high voltage amplifier, OFF is in the up position.
Servo amplifier is enabled, but when Check for blown fuse at the rear of the chassis.
commanded becomes disabled (LED off).
Motor cable is disconnected.
Hall effect cable is disconnected (where applicable).
The Position Error (PE) number in the parameter
screen is set too low.
Check motor and hall effect phasing.
Encoder cable is disconnected.
System is communicating, but counts on
the screen are incorrect. Check the encoder cable for broken wire or defects.
Encoder multiplier jumpers JP1 through JP6 on
Encoder Interface Card are not set properly.
If using multipliers, check sine/cosine on TP 1 and TP
2 on the multiplier plug-in card.
Either the sine or cosine signal is missing from the
System displays an erratic count.
multiplier plug-in card or the level is not within 2.5-
4.5 volts peak-to-peak.
Encoder scale may be dirty.
There is no home pulse or the adjustment of the
System completes a home sequence, but
direction sensor for home pulse is not present.
the status bit shows that it has not finished
home successfully. Check amplitude of the home pulse. Amplitude should
be a minimum of 3 volts peak-to-peak.
Home search distance is too small. Distance should be
set to ensure that the home pulse is located.
Check that the sine and cosine signals are between 2.5
volts and 4.5 volts peak-to-peak.
Check that the sine/cosine offset is less than 2.5 volts.
Definition of sensor inputs is incorrect.
When system is commanded to home, it
searches for home but runs into limit. Sensors may be defective.
The home search distance is too large.
During machine operation the system lost a sine or
Axis is unstable (oscillates).
cosine signal. The cable carriers may have a broken
cable or a cable is about to break. Connect an
oscilloscope to sine or cosine (TP 1 and TP 2) and with
the servo amplifier switch turned off, move the stage
by hand slowly back and forth. Check lissajous pattern
to see if the signal is not lost from time to time. Repeat
procedure while moving the stage quickly and to the
end of its travel.
Axis not tuned correctly. Refer to ANO-2000 NT API
Library Functions Documentation

7-2 Rev 2
 Symptom Probable Cause
Missing position feedback and/or not plugged in correctly,
Loss of axis control.
or has a broken wire.
Encoder failure, check lissajous pattern.
Servo amplifier has failed. Replace amplifier card and
Axis runs away.
perform calibration procedure, see appropriate servo
amplifier section for procedure.
Make sure axis is not impaired by physical obstruction.
Axis runs, but when commanded to do
the home sequence, moves a short Make sure system counts correctly.
distance and becomes disabled.
Check lissajous pattern.
Position error limit may be too small.

The controller shows a limit indication, Check sensor inputs.

but the stage is not at the end of its Verify sensor input definitions in the parameter section of
travel. the software documentation.
Check Cable (encoder/limit)
One of four conditions may have caused the LED to come
The stage is not in limit, but the
on.
controller shows that the stage is in limit
and the red LED on the servo amplifier 1- + Limit condition
card is on. 2- - Limit condition
3- Over voltage condition.
4- Over current condition.
Check for any of the above possible causes.
A large position error may have disabled the machine from
Machine operates for a while, then stops.
the controller.
An over-current condition exists; motor may have a short
to ground.
An over-temperature condition exists.
- Cooling fan in the rear of the controller is not
operating.
- The controller front has been left open. This
must be kept shut at all times.
Servo amplifier has failed. Replace amplifier card and
perform calibration procedure, see appropriate Servo
Amplifier Manual for procedure.

Rev 2 7-3
7-4 Rev 2
 Chapter 8

2U Dual High-Voltage Power Supply

Figure 8-1 2U Dual High-Voltage Power Supply Front View

P/S ENABLE

P/S A

P/S B

AN O RA D

Figure 8-2 2U Dual High-Voltage Power Supply Rear View

AC PWR IN
208-230VAC
50/60 Hz 3KVA
FUSE X 2: T15A
P/S 2 P/S 1
F4 F3 F2 F1
F F F F
SE SE SE SE
US

US

US
SE
FU

FU

FU

FU
E

E
FUSE FUSE FUSE FUSE

LINE SELECT
208VAC 230VAC
AC PWR IN

8.1 2U Dual High-Voltage Power Supply Specifications

Dimensions: 3.5″ × 19″ × 14.625″
Input voltage: 208 or 230 VAC switchable
Output power: 1.5 kV-A per supply
Output Voltage: (Volts) PS1 PS2
802106-50 50 -
-150 150 -
-250 250 -
-50/50 50 50
-50/150 50 150
-50/250 50 250
-150/150 150 150
-150/250 150 250
-250/250 250 250

Rev 2 8-1
8.2 Line Voltage Selection
The line selection switch allows this power supply to be use in any facility around the world.
For single-phase power source select 230 Volts and for two-phase power source select 208
Volts.

8.3 Connectors
Output Power
V+ RED
1 1
PS2
V- BROWN
2 2
V+ RED
3 3
V- BROWN PS1
4 4

P/S Enable
ENABLE+ RED

ENABLE- BLACK 2U
Dual Power
Supply

8.4 Fuses
8.4.1 Input fuses
F1 and F2 are line voltage input fuses and require T15A slo-blow fuses

8.4.2 Output Fuses

F3 and F4 are the power supply output fuses; their ratings are dependent on the Item Number
found on the ID plate next to the power select switch. Locate the Item Number and compare
it to the chart below to find the proper fuse rating.

Item Number Fuse 3 (F3) Fuse 4 (F4)

802106 -50 20 20
-150 7 7
-250 4 4
-50/50 20 20
-50/150 20 7
-50/250 20 4
-150/150 7 7
-150/250 7 4
-250/250 4 4

8-2 Rev 2
 Chapter 9

Amplifier Modules

Rev 2 9-1
9.1 Software Commutation, Sinusoidal Brushless,
Amplifier 69350
9.1.1 Introduction
This section contains the descriptions of jumpers, potentiometers, test points, current scaling,
fault LED description and calibration procedures for the Software Commutation, Sinusoidal
Brushless, DC Servo Amplifier Part Number 69350.

Before installing or replacing servo amplifier, check that all jumpers are set according to the
original factory settings or according to user options. Before starting the setup and
calibration procedure become familiar with the layout of the board. See Figure 9-1 Board
Layout.

9.1.2 Jumper Settings and Descriptions

The as shipped configuration of your amplifier may not take advantage of all the jumper
options. The following table describes each jumper and its setting.

Table 9-1 Software Amplifier Jumper Settings and Descriptions

Jumper Name Description

JP1 Overvoltage 160VDC=off, 320VDC = On
JP3 Commutation Mode Select Position “B” for Software
JP5 - Not Used
JP6 - Not Used
JP7 Phase A Compensation Factory Set
JP8 Phase B Compensation Factory Set
JP9 Phase C Compensation Factory Set
JP10 CMD Single Ended or Differential OFF = Differential
ON = Single ended
JP11 PTC Motor Temp Sensor Input. Install if sensor not used

9-2 Rev 2
9.1.3 Potentiometers Description
The Sinusoidal Brushless Servo amplifier provides potentiometer for peak and continuous
current adjustment. During the servo amplifier setup and calibration, reference is made to
these potentiometers.

Table 9-2 Potentiometers Description

Potentiometer Name Description

RV5 Peak Current 2A/V-LP 5A/V-SP
RV6 Continuous Current 2A/V-LP 5A/V-SP

WARNING

The heat sink must be in place prior to starting normal system

operation. Non compliance will cause the amplifier to over
heat.

9.1.4 Test Point Descriptions

Table 9-3 Test Point Descriptions

Test Point Name Description

TP1 Common (RTN)
TP2 Command Input
TP5 Peak Current 2A/V-LP
5A/V-SP
TP6 Continuous Current 2A/V-LP
5A/V-SP
TP7 Current Monitor 2A/V-SP
5A/V-SP
TP8 Current Fault 1 = Current fault
TP9 Over Temperature 1 = Over temperature fault
TP10 Over Voltage 1= Over voltage fault

Rev 2 9-3
Figure 9-1 Software Commutation Sinusoidal Brushless Amplifier Part Number 69350
(Also used as Brushless Trapezoidal Amplifier Motherboard)

JP10

JP11
A B
JP9
U23

A B
JP8
A B
JP7

JP4
A B

JP3
JP2

TP10
TP1

TP5
TP6
TP7
TP8
TP9
JP1

RV5

RV6

S1
D1

D2

9-4 Rev 2
9.1.5 Software Amplifier Block Diagram
Figure 9-2 Software Amplifier Block Diagram

Rev 2 9-5
9.1.6 Software Commutation
Before setting up this amplifier with a controller that generates A and B software
commutated signals, determine if the controllers requires the motor phase connections in
specific sequence. The sequence may be needed to generate the correct software
commutation of the A and B command signals. If not, connect the motor to the amplifier as
listed in Table 9-4.

Table 9-4 Motor Phase Connections

Anorad
Motor Amplifier J1
Backplane
Phases Connector
(Motor Connector)
Phase "A" 2D, 2B, 2Z A1
Phase "B" 6D, 6B, 6Z A2
Phase "C" 10D, 10B, 10Z A3
Motor Ground Connect To Controller Chassis A4
Motor Shield Connect To Controller Chassis 5

Some of the ANORAD controllers require a specific motor phase sequence. Verify this by doing
the following:

6) Check motor resistance.

7) Using an oscilloscope to check motor B.E.M.F. There are two methods of checking the
motor B.E.M.F. These two methods are shown in Figure 9-3 Method (a) and 9-4 Method
(b). The method shown in Figure 9-3 is the phase to phase motor method that will show
a 60° phase shift.

8) The method shown in Figure 9-4 is the phase to common method, which will show a
120° phase shift.

Figure 9-3 Phase to Phase Method (a)

RED CH1

WHT CH2

BLK REF

GRN

GRN/YELL

9-6 Rev 2
Figure 9-4 Phase to Common Method (b)

CH1
RED 20K

WHT 20K REF

BLK 20K

CH2
GRN

GRN/YELL

9) Verify that the system is counting correctly. This is very important considering that any
system miscount will result in an erratic system operation as well as the lost of the
software commutation control.

10) Identify the direction of positive counting. Motor phasing needs to be done while
moving in the direction of a positive counting.

11) Find which motor phase lead or lag while moving positive.

a) If using method (a), motor phase "AB" should lead "CB" by 60o.

b) If using method (b), motor phase "A" should lead "B" by 120o.
12) Using a dual Channel storage oscilloscope, connect channel 1 between any two motor
phases.
13) Connect scope channel 2 to the third motor phase.
14) While moving the motor by hand in the positive direction, observe the phase shift
relationship. While moving positive, phase "AB" should lead phase "CB" by 60o or
motor phase "A" should lead phase "B" by 120o.

If the selected motor phases are phase shifted by the correct amount, reverse the
connection of scope channel 1 and channel 2.

15) When using method (a), if one combination is found to be correct, label the motor phase
connected to channel 1 as phase "A” and the motor phase connected to channel 2 as
phase "C". Label the motor phase connected to the scope reference as phase "B".

16) When using method (b), if one combination is found to be correct, label the motor phase
connected to channel 1 as phase "A” and the motor phase connected to channel 2 as
phase "B". Label the motor phase connected to the scope reference as phase "C".

17) Setup the controller software commutation parameters.

a) Magnet pitch (encoder counts per magnet pitch).

b) Magnet pitch offset (in units/counts).

Rev 2 9-7
 c) Any other related parameters.

18) Connect motor to amplifier.

19) Connect A and B controller command signal to the amplifier.

20) Install motor fuses on the backplane. Make sure that the fuses used do not exceed the
motor continuous current rating.

21) Execute commutation start up program.

9.1.7 Motherboard Peak and Continuous Current Settings

Peak and continuous current adjustments are the same for all configurations of the drive and
commutation scheme. Potentiometers RV5 and RV6 are provided to set the peak and
continuous current limits of the drive as described in the procedures below.

9.1.7.1 Peak Current Adjustment Procedure

1) Determine the maximum allowable current the motor can withstand for 2 seconds. If the
value is less than 10 Amps, it is recommend to use the -LP drive (10 Amps Max).

2) With the ENABLE /RESET switch in the Reset position (Down), connect a DVM to
TP5 (Peak Current) and TP1 (Common).

3) Monitor TP5 and adjust RV5 to achieve the desired voltage according to the following
formula:

For -LP version (10 Amps Max)

TP5 Voltage = Desired Peak Current Limit * 0.5 Volts/Amp

Example: If the Peak current of the motor is 7 amps then
TP5 Voltage = 7 * 0.5 = 3.5 V
For -SP version (25 Amps Max)
TP5 Voltage = Desired Peak Current Limit * 0.2 Volts/amp
Example: If the Peak current of the motor is 17 amps then
TP5 Voltage = 17 * 0.2 = 3.4 V

9.1.7.2 Continuous Current Adjustment Procedure

1) Determine the maximum allowable continuous current the motor can withstand. If the
value is less than 10 Amps, it is recommend to use the -LP drive (10 Amps Max).

2) With the ENABLE/RESET switch in the Reset position, connect a DVM to TP6
(Continuous Current) and TP1 (Common).

9-8 Rev 2
 Monitor TP6 and adjust RV6 to achieve the desired voltage according to the following
formula:
For -LP version (5 amps max)
TP6 Voltage = (Desired Continuous Current Limit) * 0.5 Volts/Amp
Example: If the Continuous Current of the motor is 4 amps then,
TP6 Voltage = 4 * 0.5 = 2 V
For -SP version (10 amps max)
TP6 Voltage = (Desired Continuous Current Limit) * 0.2 Volts/amp
Example: If the Continuous current of the motor is 7 amps then,
TP6 Voltage = 7 * 0.2 = 1.4 V
Table 9-5 Peak and Continuous current setting

MOTOR AMPLIFIER MOTOR SET RV5 MOTOR SET RV6

TYPE TYPE Ip (TP5) Ic (TP6)
LA-S-1-P -LP 10A 8A 4.0V 3A 1.5V
LA-S-2-P -SP 25A 16A 3.2V 6A 1.2V
LA-S-3-PP -SP 25A 24A 4.8V 9A 1.8

LCK-S-1 -LP 10A 7A 3.5V 2.8 1.4V

LCK-S-2-P -SP 25A 15A 3.0V 5.6 1.1V
LCK-S-3-P -SP 25A 21A 4.2V 8.4 1.7V

LEA-S-2-S -LP 10A 9A 4.5V 3.2A 1.6V

LEA-S-4-S -LP 10A 9A 4.5V 3.2A 1.6V
LEA-S-6-S -LP 10A 9A 4.5V 3.2A 1.6V
LEA-S-8-SP -SP 25A 18A 3.6V 6.4A 1.3V

9.1.8 Extra Help For Software Commutation

• Verify that all the jumpers on the amplifier are set correctly.
• Verify that none of the motor phase are shorted to chassis or to each other.
• Verify that all commutation parameters are correct.
• Check for blown fuses.
• Check that the motor is connected correctly.
• Make sure that the run LED (D1) is ON.
• Turn the Enable Switch S1 is in the Up position (Enable).

Rev 2 9-9
9.2 Trapezoidal Amplifier (Motherboard with Plug-in)
67192
9.2.1 Introduction
This section contain the description of jumpers, potentiometers, test points and set up
procedures for the Trapezoidal Brushless Servo Amplifier.

The Trapezoidal Amplifier Part Number 67192 consists of two boards: a motherboard which
is the Software Commutation Sinusoidal Brushless Amplifier (Item Number 69350) and a
Trapezoidal plug-in board (Item Number 69675).

9.2.2 Mother Board Jumper Settings and Descriptions

The as shipped configuration of your amplifier may not take advantage of all the jumper
options. The following table describes each jumper and its setting.

Table 9-6 Trapezoidal Amplifier Jumper Settings and Descriptions

Jumper Name Description

JP1 Over voltage 160VDC = OFF
320VDC = ON
JP3 Commutation mode Select “A” = Trapezoidal
JP5 Motor Reverse Always set to “A”
JP6 Current or Velocity C = current, V = velocity
JP7 Phase A Compensation Factory Set
JP8 Phase B Compensation Factory Set
JP9 Phase C Compensation Factory Set
JP10 Single Ended or Differential Differential = OFF, Single = ON
JP11 PTC Motor Temp. Sensor Not PTC = ON

9.2.3 Mother Board Potentiometers Description

The Trapezoidal Servo amplifier provides potentiometer for peak and continuous current
adjustment. During the servo amplifier setup and calibration, reference is made to these
potentiometers.

Table 9-7 Motherboard Potentiometers Description

Potentiometer Name Description

RV5 Peak Current Limit 2A/V -LP or 5A/V -SP
RV6 Continuous Current Limit 2A/V -LP or 5A/V -SP

9-10 Rev 2
9.2.4 Trapezoidal Amplifier Motherboard Board Layout
Figure 9-5 Brushless Trapezoidal Amplifier Motherboard Part Number 69350
(Software Commutation Brushless Sinusoidal Amplifier)

JP10

JP11
A B
JP9
U23

A B
JP8
A B
JP7

JP4
A B

JP3
JP2

TP10
TP1

TP5
TP6
TP7
TP8
TP9
JP1

RV5

RV6

S1
D1

D2

Rev 2 9-11
9.2.5 Motherboard Amplifier Block Diagram
Figure 9-6 Motherboard Amplifier Block Diagram

9-12 Rev 2
9.2.6 Daughterboard Plug-in Block Schematic
Figure 9-7 Daughterboard Plug-in Schematic

Rev 2 9-13
9.2.7 Motherboard Test Point Descriptions
Table 9-8 Motherboard Test Point Descriptions

Test Point Name Description

TP1 Common
TP5 Peak Current Limit 2A/V -LP or 5A/V -SP
TP6 Continuous Current Limit 2A/V -LP or 5A/V -SP
TP7 Current Monitor 2A/V -LP or 5A/V -SP
TP8 Current Fault 1 = Current fault
TP9 Over Temperature 1 = Over temperature fault
TP10 Over Voltage 1 = Over voltage fault

9.2.8 Trapezoidal Plug-In Daughterboard Jumper Settings and Descriptions

Table 9-9 Trapezoidal Plug-In Daughterboard Jumper Settings and Descriptions

Jumper Name Description

J1 Current or Velocity C = Current,
V = Velocity*
J2 Tachometer Reverse Always set to “A”*
J3 Sensor Phase Select 60/300 or 120/240 degrees.
Select 120
J4 Motor Reverse Always set to “A”
J5 Phase A Command ON
J6 Phase B Command ON
J7 Phase C Command ON

* When connecting a tachometer feed back, begin the set up of the trapezoidal plug-
in board as if it were to use a current command. Proceed with all the calibration,
motor phasing and current adjustments. When normal setup is complete then setup
the velocity loop.

For now, set J1 to “C” and J2 to “A”.

9.2.9 Trapezoidal Plug-In Daughterboard Potentiometers Description

Table 9-10 Trapezoidal Plug-In Daughterboard Potentiometers Description

Potentiometer Name
R4 Command Gain
R21 Tachometer Gain
R25 Tachometer Compensation
R27 Peak Current
R31 Input Gain Balance

9-14 Rev 2
9.2.10 Trapezoidal Plug-In Daughterboard Test Point Descriptions
Table 9-11 Trapezoidal Plug-In Daughterboard Test Point Descriptions

Test Point Name

TP1 Common
TP2 Command input
TP3 Tachometer input
TP4 Tachometer Compensation
TP5 Peak Current Limit
TP6 Hall Sensor 1 (S1)
TP7 Hall Sensor 2 (S2)
TP8 Hall Sensor 3 (S3)

9.2.11 Trapezoidal Plug-In Daughterboard LED Description

Table 9-12 Trapezoidal Plug-In Daughterboard LED Description

LED Name
D8 Hall Sensor Phase Error

9.2.12 Daughterboard Layout

Figure 9-8 Trapezoidal Plug-in Daughterboard
TACH

A B
REV

J2

120/240
J7

MOTOR REVERSE

SENSOR SELECT
J5 J6

A B

P2
P1

60/300
J4

J3
C
V
J1

TP6
TP7
TP8
R21

R25

R27

R31
R4

TP1 TP2 TP3 TP4 TP5 S1 S2 S3

SIG TACH COMP LIM BAL HALL
ERROR

Rev 2 9-15
9.2.13 Peak And Continuous Current Adjustment
When setting up peak current, note that this setting is to be done on the motherboard as well
as on the plug-in module. The setting performed on the motherboard sets the threshold for
the fault logic detection, whereas the setting performed on the plug-in module limits the
command input. This prevents the amplifier from receiving a command that is larger than
the current capacity of the motor.

9.2.13.1 Motherboard Peak and Continuous Current Settings

Peak and continuous current adjustments are the same for all configurations of the drive and
commutation scheme. Potentiometers RV5 and RV6 are provided to set the peak and
continuous current limits of the drive as described in the procedures below.

9.2.13.1.1 Peak Current Adjustment Procedure

1) Determine the maximum allowable current the motor can withstand for 2
seconds. If the value is less than 10 Amps, it is recommend to use the -LP
drive (10 Amps Max).
2) With the ENABLE /RESET switch in the Reset position (Down), connect a
DVM to TP5 (Peak Current) and TP1 (Common).
3) Monitor TP5 and adjust RV5 to achieve the desired voltage according to the
following formula:
For -LP version (10 Amps Max)

TP5 Voltage = Desired Peak Current Limit * 0.5 Volts/Amp

Example: If the Peak current of the motor is 7 amps then
TP5 Voltage = 7 * 0.5 = 3.5 V
For -SP version (25 Amps Max)
TP5 Voltage = Desired Peak Current Limit * 0.2 Volts/amp
Example: If the Peak current of the motor is 17 amps then
TP5 Voltage = 17 * 0.2 = 3.4 V

9.2.13.1.2 Continuous Current Adjustment Procedure

1) Determine the maximum allowable continuous current the motor can

withstand. If the value is less than 10 Amps, it is recommend to use the -LP
drive (10 Amps Max).

9-16 Rev 2
 2) With the ENABLE/RESET switch in the Reset position, connect a DVM to
TP6 (Continuous Current) and TP1 (Common).
Monitor TP6 and adjust RV6 to achieve the desired voltage according to the following
formula:
For -LP version (5 amps max)
TP6 Voltage = (Desired Continuous Current Limit) * 0.5 Volts/Amp
Example: If the Continuous Current of the motor is 4 amps then,
TP6 Voltage = 4 * 0.5 = 2 V
For -SP version (10 amps max)
TP6 Voltage = (Desired Continuous Current Limit) * 0.2 Volts/amp
Example: If the Continuous current of the motor is 7 amps then,
TP6 Voltage = 7 * 0.2 = 1.4 V

Figure 9-9 Peak and Continuous current setting

MOTOR AMPLIFIER MOTOR SET RV5 MOTOR SET RV6

TYPE TYPE Ip (TP5) Ic (TP6)
LA-S-1-P -LP 10A 8A 4.0V 3A 1.5V
LA-S-2-P -SP 25A 16A 3.2V 6A 1.2V
LA-S-3-PP -SP 25A 24A 4.8V 9A 1.8

LCK-S-1 -LP 10A 7A 3.5V 2.8 1.4V

LCK-S-2-P -SP 25A 15A 3.0V 5.6 1.1V
LCK-S-3-P -SP 25A 21A 4.2V 8.4 1.7V

LEA-S-2-S -LP 10A 9A 4.5V 3.2A 1.6V

LEA-S-4-S -LP 10A 9A 4.5V 3.2A 1.6V
LEA-S-6-S -LP 10A 9A 4.5V 3.2A 1.6V
LEA-S-8-SP -SP 25A 18A 3.6V 6.4A 1.3V

9.2.13.2 Plug-In Peak Current Adjustment

The following adjustment requires a command input voltage to be injected into the CMD+ of
the amplifier with reference to CMD- (Common). For this, use an external voltage source.
The max voltage applied should be the same as the max command voltage that is expected
from the controller, typical +/-10V.

1) Connect the hall sensor cable to the amplifier.

2) Disconnect the motor cable from the amplifier. This is very important!
3) Turn power on.
4) Turn the Enable Switch On (Up position)
5) Force the Enable input to go Low. Do this by using the controller or shorting
the input 16B to ground.

Rev 2 9-17
 6) If the motor PTC is not connected, install jumper J11.
7) At this time the red LED should be OFF and the Green LED should be ON.
8) Turn R4 (SIG) fully CCW (Counter Clock Wise) and turn R27 (LIM) fully
CW (Clockwise)
9) With an oscilloscope, connect channel 1 to TP2, reference to TP1.
10) Connect scope channel 2 to TP5.
11) At this time TP5 should read 0 volt. If it is not, adjust R31 (BALANCE) to 0
volt.
12) Turn R4 (SIG) CW until the voltage on TP5 is 3.0 V
The max command input to the amplifier should generate peak current equal to the peak
operating current of the motor. If the amplifier’s max current equals the motor’s peak
operation current then leave TP5 set to 3 volts.

If not, adjust R27 (LIM) to achieve the desired voltage according to the following formula:

TP5 Voltage = (3 * Motor Peak Current) / Amplifier Peak Current

for -LP
TP5 Voltage = .3 * Motor Peak Current
for -SP
TP5 Voltage = .12 * Motor Peak Current
Figure 9-10 Trapezoidal Plug-in peak current settings

MOTOR AMPLIFIER MOTOR SET R27

TYPE TYPE Ip (TP5)
LA-S-1-P -LP 10A 8A 2.4V
LA-S-2-P -SP 25A 16A 1.92V
LA-S-3-PP -SP 25A 24A 2.88V

LCK-S-1 -LP 10A 7A 2.1V

LCK-S-2-P -SP 25A 15A 1.8V
LCK-S-3-P -SP 25A 21A 2.52V

LEA-S-2-S -LP 10A 9A 2.7V

LEA-S-4-S -LP 10A 9A 2.7V
LEA-S-6-S -LP 10A 9A 2.7V
LEA-S-8-SP -SP 25A 18A 2.16V

9-18 Rev 2
9.2.14 Trapezoidal Motor And Hall Phasing

This procedure is for hall effect sensors set at 120o spacing. Motor Verification, before
performing this procedure.

9.2.14.1 Trapezoidal Hall to Hall Phasing Verification Procedure

1) Connect the hall effect sensors to the servo amplifier via the hall sensors input
connector on the backplane.
2) Do not connect the motor phases (Motor leads) at this time.
3) Turn power ON. The green (D1) should be ON.
4) Move the axis by hand and record the direction in which the system counts
negative. If a position feedback device is not installed yet, predetermine which
direction the system is going to count negative. The system can be phased in
either direction but, for the purpose of this procedure, motor and hall effect
sensors are going to be in phased while moving in the negative direction.
5) On the Plug-in Connect scope channel 1 to TP6 (S1), scope channel 2 to TP7
(S2) and scope reference to TP1 (RTN).
6) Using a dual Channel storage oscilloscope, verify that all the three sensors are
switching at the proper interval. (See Figure 9-11)
Figure 9-11 Hall effect phase relationship

S1

S2

S3

0o 120 o 240 o 360 o

Rev 2 9-19
9.2.14.2 Trapezoidal Motor and Hall Effect Phasing Procedure
1) Connect scope channel 1 to TP6 (S1) and reference to TP1 (RTN).

2) Connect scope channel 2 to one motor lead and scope channel 2 reference to another
motor lead. (See Figure 9-12)

Figure 9-12 Motor and hall monitoring

RED REF

WHT CH2

BLK

GRN

GRN/YELL
TP1
REF
TP6
TP7 CH1
TP8

3) Move the motor by hand and observe the relationship between the sensor signal and the
motor B.E.M.F. Find a combination of motor phases that will be in phase with the hall
sensor when moving the motor in the negative direction. When the motor is moved in
the positive direction, the relationship should be 180o out of phase. See Figure 9-13 (a)
and (b).

4) Label the phase connected to scope channel 2 as phase "A", and the phase connected to
scope channel 1 reference, as phase "C". Label the last phase "B".

5) Connect scope channel 2 to TP7 (S2) and reference to TP1 (RTN).

Figure 9-13 Motor B.E.M.F. and hall effect phasing

Negitive Direction Positive Direction

(a) (b)
6) Connect scope channel 2 to motor phase "B" and scope channel 2 reference to motor
phase "A".

9-20 Rev 2
 7) Move the motor by hand and observe the relationship between the sensor signal and the
motor B.E.M.F. They should be in phase when moving the motor in the negative
direction. See Figure 9-13(a).

8) Connect scope channel 1 to TP8 (S3) and reference to TP1 (RTN).

9) Connect scope channel 2 to motor phase "C" and scope channel 2 reference to motor
phase "B".

10) Move the motor by hand and observe the relationship between the sensor signal and the
motor B.E.M.F. They should be in phase when moving the motor in the negative
direction. See Figure 9-13(a).

11) Turn power OFF.

Summary: Motor Phase AC is in phase with S1.

Motor Phase BA is in phase with S2.
Motor Phase CB is in phase with S3.

* See Figure 9-14

12) Connect all motor phases as described in Table 9-13. If due to system considerations the
motor direction needs to be reversed, swap sensor 1 and sensor 2 and motor phase "A"
and "C". This will reverse the hall sensors and motor phase by 180o.

Table 9-13 Motor Phase Connections

Anorad
Motor Amplifier J1
Backplane
Phase Connector
(Motor Connector)
Phase "A" 2D, 2B, 2Z A1
Phase "B" 6D, 6B, 6Z A2
Phase "C" 10D, 10B, 10Z A3
Motor Ground Connect to Controller Chassis A4
Motor Shield Connect to Controller Chassis 5

Rev 2 9-21
Figure 9-14 Motor and Hall Phase Relationship

Phase A
in relation to
Phase C

Phase B
in relation to
Phase A

Phase C
in relation to
Phase B

S1
(TP6)

S2
(TP7)

S3
(TP8)
0o 1 2 0o 2 4 0o 3 6 0o

9.2.14.3 Phase Verification

Input a small CMD signal, Enable the amplifier through the S1 switch and observe
the motor moves slowly and smoothly in one direction. If this occurs, the phasing
procedure is complete. If it is not, begin again at Section 9.4.14

If system considerations require the motor direction be reversed, swap hall sensor
excitation signals I+ and I-.

9-22 Rev 2
9.2.15 Limit Input Verification
Any application using rotary or linear motors should have electrical limits setup at both ends
of travel least 2mm away from the hard stops (hard limits). This is necessary so when system
travels to any of its limits both the controller and the amplifier will stop it. When the positive
or negative limit inputs are in a logic "1" state, an internal logic circuit will activate the
Brake command. These inputs are interlocked with the polarity of the analog input signal
command to control the direction of motion.

To verify the limits are connected correctly to the positive and negative limit inputs, do as
follows:

1) Input a small positive command signal (CMD) to 26D input, reference to 26B.
2) Enable the amplifier through the S1 switch.
3) Observe that the motor moves slowly and smoothly in the positive counting
direction. As soon as it gets to the +limit, the system should stop. If the system
continues to drive further into +limit, the connection is not correct. Verify the
connection to the +limit input is to pin 14D.
4) Input a small negative command signal (CMD) to 26D input, reference to 26B.
5) Observe that the motor moves slowly and smoothly in the negative counting
direction. As soon as it gets to the -limit, the system should stop. If the system
continues to drive further into -limit, the connection is not correct. Verify the
connection to the -limit input is to pin 18D.

9.2.16 Servo Amplifier Modes of Operation

There are two basic modes of operations on this amplifier:

a) Torque or current mode.

b) Velocity mode.

9.2.17 Torque (Current) Mode

The factory default setting is for torque mode. When the torque mode is selected, a single
command is applied. The command input could be differential or single ended.
A +/- 10V command can be applied to the CMD(+) input with the analog ground connection to
CMD(-) input.

Rev 2 9-23
9.2.18 Velocity Loop
WARNING:

If the polarity of the tachometer is not correct a run away

condition might occur and if the velocity loop compensation is
not correct, violent oscillation might occur. Therefore perform
the following procedure carefully.

9.2.18.1 Introduction
The purpose of this procedure is to provide the user with some basic information on how to
setup the outer velocity feedback loop around the inner current loop.

9.2.18.2 Types of feedback and signals

The magnitude of the velocity feedback signal depends upon the type of velocity feedback
system used. There are two types:

1) tachometer mounted on the motor shaft

2) electronic tachometer generated from encoder position.
Set the tachometer to provide a positive signal at the TACH(+) input when there is a positive
signal at the CMD(+) input.

The magnitude of this velocity signal at TACH(+) and TACH(-) should be 20% or more
below the maximum velocity command signal at CMD(+) and CMD(-).

Example: If a +10V velocity command signal is applied to generate a maximum

motion of 10 inches per second, the tachometer output should be no more
than +8V for that speed.

9-24 Rev 2
9.2.18.3 Setup Procedure
NOTE:

Perform the adjustments only after you have verified that the
current loop works correctly.

1) On daughterboard set J2 jumper to “A” and J1 jumper to “V”

2) Turn R21 (Tachometer Gain Pot) fully CW (clockwise).
3) Turn R25 (Comp Gain Pot) fully CW (clockwise).
4) Connect the input velocity command to the input differential CMD (+)(26D)
and CMD (-) (26B). If connected verify they are correct.
NOTE:
For the velocity command use a function
generator. Set the amplitude of the signal
to 0 volt bias around 0 volts.
5) Connect the velocity feedback signal to the differential feedback inputs
TACH(+) (18B) and TACH (-) (18Z). If connected verify they are correct.
6) Connect motor.
7) Apply a 0 volt velocity command.
8) Connect the enable input to GND.
9) Enable the amplifier through SW1.
10) The GREEN LED should be ON and the RED LED should be OFF.
11) At this time, the system should not run away, if it does, disable the amplifier
and reverse the tachometer wiring, or for the moment, set jumper J2 to position
“B”. Do not confuse a run away condition with a slide drift that could result
from tachometer offset. If this is the case correct the offset by adjusting the
Balance potentiometer (R31).
12) Apply a small positive or negative velocity command.
13) The system should drift in one or the other direction. At this time, the velocity
14) loop is closed.
15) Disable the amplifier through SW1.
16) Using a function generator apply a signal low in magnitude and frequency.

Rev 2 9-25
 17) Connect an oscilloscope on TP3 reference to TP1.
18) Examine the system response.
19) Adjust the Compensation potentiometer (R25) or as desire, adjust the resistors
and capacitor values of the difference filters.
20) There should be no ringing or oscillations. The ideal step response for most
applications is critically damped. See Figure 9-15.
Figure 9-15 Various damping conditions

Under damped Critically damped Over damped

9-26 Rev 2
9.3 Sinusoidal Brushless Servo Amplifier 69080
9.3.1 Introduction
This section contains the description of jumpers, potentiometers, test points, current scaling,
fault LED description and calibration procedure for the Sinusoidal Brushless DC Servo
Amplifier.

Before installing or replacing any servo amplifier, check that all jumpers are set according to
the original factory setting or according to the options that the user wants. Before starting
the setup and calibration procedures familiarize yourself with the layout of the board. See
Figure 9-16 Sinusoidal Brushless Board Layout.

9.3.2 Jumper Settings and Descriptions

The as shipped configuration of your amplifier may not take advantage of all the jumper
options. The following table describes each jumper and its setting.

Table 9-14 Jumper Settings and Descriptions

Jumper Name Description

JP1 Over Current 160VDC Jumper Off
320VDC Jumper On
JP3 Commutation Mode Select “A” for Sinusoidal
Commutation
JP5 Motor Reverse Select “A”
JP6 Current or Velocity Mode Select “C” *
JP7 Phase A Compensation Factory Set
JP8 Phase B Compensation Factory Set
JP9 Phase C Compensation Factory Set
JP10
JP11 PTC Motor Temperature Install Jumper when not using Motor
Sensor Temperature Sensor
* Note: Velocity mode is not supported.

9.3.3 Fault LED Description

Table 9-15 Fault LED Description

LED Color Description

D1 Green Enable or Fault
D2 Red Disable or any fault

Rev 2 9-27
9.3.4 Sinusoidal Board Layout
Figure 10-16 shows the location of the test points, jumpers and potentiometers. Become
familiar with the location of these components before starting the procedures.

Figure 9-16 Brushless Sinusoidal Amplifier Part Number 69080

(for sinewave hall sensors inputs)

JP10

JP11
A B
JP9
U23

A B
JP8
A B
JP7

JP4
A B

JP6
A B

JP5

A B

JP3
JP2

TP10
TP1

TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
JP1

RV2

RV3

RV3

RV4

RV5

RV6

S1
D1

D2

9-28 Rev 2
9.3.5 Sinusoidal Amplifier Block Diagram
Figure 9-17Sinusoidal Amplifier Block Diagram

Rev 2 9-29
9.3.6 Potentiometers Description
The Sinusoidal Brushless Servo amplifier provides potentiometers for gain, current and
tachometer adjustment. During the servo amplifier setup and calibration, reference is made
to these potentiometers.
Table 10-3 Potentiometer Descriptions
Potentiometer Name Description
RV1 Hall Sensor A Gain Adjust to 11.5 V max Peak to Peak
RV2 Hall Sensor A Balance Hall sensor offset adjustment
RV3 Hall Sensor B Gain Adjust to 11.5 V max Peak to Peak
RV4 Hall Sensor B Balance Hall sensor offset adjustment
RV5 Peak Current Limit 2A/V - LP
5A/V - SP
RV6 Continuous Current Limit 2A/V - LP
5A/V - SP
RV7 Phase A Balance Factory Adj
RV8 Phase B Balance Factory Adj
RV9 Phase C Balance Factory Adj

9.3.7 Test Point Descriptions

Table 10-4 Test Point Description
Test Point Name Description
TP1 Common (RTN) All the adjustments are done in reference to
this point
TP2 Command Input ±10V
TP3 Hall Sensors “A” Adjust RV1 & RV2
TP4 Hall Sensor “B” Adjust RV3 & RV4
TP5 Peak Current 10 Amps Max for -LP (2Amp/Volt)
25 Amps Max for -SP (5 Amp/Volt)
TP6 Continuous Current 5 Amps Max for -LP (2Amp/Volt)
10 Amps Max for -SP (5 Amp/Volt)
TP7 Current Monitor 2 Amp/volt -LP
5 Amp/volt -SP
TP8 Current Fault 1 = Over Current Fault
TP9 Over Temperature 1 = Over Temperature Fault
TP10 Over Voltage 1 = Over Voltage Fault

9-30 Rev 2
 WARNING

Always have the heat sink installed before starting normal

system operation. Failure to do so will cause the amplifier to
over heat.

9.3.8 Sinusoidal Hall Sensor Calibration Procedure

This calibration must be done when a new motor or a new servo amplifier is installed in a
system. The adjustment of the hall sensors is critical. "A" and "B" hall sensor inputs have
their own amplitude (gain) and offset adjustment potentiometers. An amplitude mismatch or
an incorrect offset will cause faulty system performance or no performance at all.

It is recommend the user become familiar with the potentiometers and test points on the
amplifier, before performing this procedure. The following table shows the potentiometers
and related test points.

Table 9-16 Motor Phase Connections

Signal Potentiometer Test Point

A hall gain RV1 TP3
A hall offset RV2
B hall gain RV3 TP4
B hall offset RV4
Common TP1

1) Disconnect motor phases from the servo amplifier.

2) Connect the hall sensor cable to the amplifier.

3) Place the switch (S1), to the OFF (Down) position. (Hall Sensor calibration is done with
the amplifier switch OFF.)

4) Before turning on the system power make sure that the oscilloscope is isolated. Turn on
the power supply. Fault indicator (red LED) should light up.

5) Connect oscilloscope Channel 1 to TP3, and the Channel 2 to TP4. Connect reference of
the oscilloscope to TP1 - signal ground.

6) While moving linear table by hand adjust hall sensor A output amplitude at
potentiometer RV1 to 11.5V (+ 0.5V) peak-to-peak. Repeat this procedure for hall
sensor B adjusting potentiometer RV3. Adjust offset for Hall A with RV2 and Hall B
with RV4 so that both waveforms are symmetrical around 0 volts, within 0.25V.
(Difference between the absolute values of the most positive and most negative voltage
of hall sensor output must be less than 0.25V).

7) Using both scope channels verify that signals at TP3 and TP4 of the hall sensor board
are shifted against each other by 120 degrees. See Figure 9-18.

Rev 2 9-31
9.3.9 Motherboard Peak and Continuous Current Settings
Peak and continuous current adjustments are the same for all configurations of the drive and
commutation scheme. Potentiometers RV5 and RV6 are provided to set the peak and
continuous current limits of the drive as described in the procedures below.

9.3.9.1 Peak Current Adjustment Procedure

1) Determine the maximum allowable current the motor can withstand for 2 seconds. If the
value is less than 10 Amps, it is recommend to use the -LP drive (10 Amps Max).

2) With the ENABLE /RESET switch in the Reset position (Down), connect a DVM to
TP5 (Peak Current) and TP1 (Common).

3) Monitor TP5 and adjust RV5 to achieve the desired voltage according to the following
formula:

For -LP version (10 Amps Max)

TP5 Voltage = Desired Peak Current Limit * 0.5 Volts/Amp

Example: If the Peak current of the motor is 7 amps then
TP5 Voltage = 7 * 0.5 = 3.5 V
For -SP version (25 Amps Max)
TP5 Voltage = Desired Peak Current Limit * 0.2 Volts/amp
Example: If the Peak current of the motor is 17 amps then
TP5 Voltage = 17 * 0.2 = 3.4 V

9.3.9.2 Continuous Current Adjustment Procedure

Determine the maximum allowable continuous current the motor can withstand. If the value
is less than 10 Amps, it is recommend to use the -LP drive (10 Amps Max).

With the ENABLE/RESET switch in the Reset position, connect a DVM to TP6
(Continuous Current) and TP1 (Common). Monitor TP6 and adjust RV6 to achieve the
desired voltage according to the following formula:

For -LP version (5 amps max)

TP6 Voltage = (Desired Continuous Current Limit) * 0.5 Volts/Amp
Example: If the Continuous Current of the motor is 4 amps then,
TP6 Voltage = 4 * 0.5 = 2 V
For -SP version (10 amps max)
TP6 Voltage = (Desired Continuous Current Limit) * 0.2 Volts/amp

9-32 Rev 2
 Example: If the Continuous current of the motor is 7 amps then,
TP6 Voltage = 7 * 0.2 = 1.4 V

Table 9-17 Peak and Continuous Current Setting

Motor Amplifier Motor Set Rv5 Motor Set RV6

Type Type Ip (TP5) Ic (TP6)
LA-S-1-P -LP 10A 8A 4.0V 3A 1.5V
LA-S-2-P -SP 25A 16A 3.2V 6A 1.2V
LA-S-3-PP -SP 25A 24A 4.8V 9A 1.8

LCK-S-1 -LP 10A 7A 3.5V 2.8 1.4V

LCK-S-2-P -SP 25A 15A 3.0V 5.6 1.1V
LCK-S-3-P -SP 25A 21A 4.2V 8.4 1.7V

LEA-S-2-S -LP 10A 9A 4.5V 3.2A 1.6V

LEA-S-4-S -LP 10A 9A 4.5V 3.2A 1.6V
LEA-S-6-S -LP 10A 9A 4.5V 3.2A 1.6V
LEA-S-8-SP -SP 25A 18A 3.6V 6.4A 1.3V

9.3.10 Motor Phase to Hall Sensor Setup Procedure

The objective is to find the correct phase relationship of the hall sensors with the motor
phases. As shown in Figure 9-19, Motor phase AC is in phase with "A" hall sensor; and
Motor phase BA is in phase with "B" hall sensor.

Figure 9-18 Motor Phase and Hall Sensor Phasing Setup

RED CH1

WHT REF

BLK

GRN

GRN/YELL

SINUSOIDAL CH2
A+
AMPLIFIER
HALL
EFFECT B+

Rev 2 9-33
Figure 9-19 Motor B.E.M.F. and Hall Sensor Relationship.

Phase A
Reference
Phase C

Phase B
Reference
Phase A

Phase C
Reference
Phase B

A-Hall
TP3

B-Hall
TP4

0o 120 o 240 o 360 o

1) Using a dual channel storage oscilloscope, connect channel 1 to TP3 and reference to
TP1.

2) Scope channel 2 to one motor lead and its reference, to another motor lead.

3) While moving the motor by hand in any direction, observe the phase relationship.

4) If the selected motor phases are not in phase with hall sensor "A" at TP3, select different
combination until the motor B.E.M.F. is in phase with the hall effect signal.

5) If one combination is found to be in phase, record the direction in which the motor
moved to get both signals (motor and hall), in phase.

6) Label the motor lead connected to channel 2 as phase "A", and the phase connected to
channel 2 reference as phase "C".

7) Label the third phase as phase "B".

8) Summary:
Motor phase AC is in phase with hall sensor "A" at TP3. (See Figure 9-19)

9-34 Rev 2
 9) Connect channel 1 to TP4 and reference to TP1.

10) Connect scope channel 2 to phase "B" and reference to phase "A".

11) Move the motor by hand in the same direction as recorded before and verify that the
motor B.E.M.F. is in phase with the hall sensor "B" at TP4.

Summary:
Motor phase BA is in phase with hall sensor "B" at TP4. (See Figure 9-19)

12) Turn power OFF.

9.3.10.1 Extra help for Motor and Sensor Phasing

If the correct phase relationship between motor and hall effect sensor can not be found verify
the following:

a) Verify that none of the motor phases are shorted to chassis or to each other.
b) Verify that while moving the motor by hand, both hall effect signals at TP2 and TP4,
are 120o out of phase.

If motor phase AC is in phase with hall sensor "A" (TP3) moving in one direction, but can
not find motor phase BA in phase with hall sensor "B" (TP4), re-label motor wire "A" as "C"
and motor wire "C" as "A". Do not re-label wire "B". At this time, motor phase AC will be
in phase with hall sensor "A", but now in the opposite direction.

9.3.10.2 Phase Verification

Input a small CMD signal, enable the amplifier through the S1 switch and observe the motor
moving slowly and smoothly in one direction. If this occurs, the phasing procedure is
complete. If not, begin again at Section 9.5.10.

If system considerations require the motor direction be reversed, swap hall sensor excitation
signals I+ and I-.

9.3.11 Limit Input Verification

Any application using rotary or linear motors should have electrical limits setup at both ends
of travel least 2mm away from the hard stops (hard limits). This is necessary so when system
travels to any of its limits both the controller and the amplifier will stop it. When the positive
or negative limit inputs are in a logic "1" state, an internal logic circuit will activate the
Brake command. These inputs are interlocked with the polarity of the analog input signal
command to control the direction of motion.

To verify the limits are connected correctly to the positive and negative limit inputs, do as
follows:

Rev 2 9-35
 1) Input a small positive command signal (CMD) to 26D input, reference to 26B.

2) Enable the amplifier through the S1 switch.

3) Observe that the motor moves slowly and smoothly in the positive counting direction.
As soon as it gets to the +limit, the system should stop. If the system continues to drive
further into +limit, the connection is not correct. Verify the connection to the +limit
input is to pin 14D.

4) Input a small negative command signal (CMD) to 26D input, reference to 26B.

5) Observe that the motor moves slowly and smoothly in the negative counting direction.
As soon as it gets to the -limit, the system should stop. If the system continues to drive
further into -limit, the connection is not correct. Verify the connection to the -limit input
is to pin 18D.

9-36 Rev 2
9.4 Brushless Linear AB Sine Servo Amplifier 69532
9.4.1 Introduction
This section contains the description of jumpers, potentiometers, test points, current scaling,
fault LED description and calibration procedure for the Software Commutation Sinusoidal
Brushless DC Servo Amplifier. See Drawing C-50475 Rev (a).

Before installing or replacing any servo amplifier, check that all jumpers are set according to
the original factory setting or according to the options that the user wants. Before starting the
setup and calibration procedures become familiar with the layout of the board. See Figure 9-
20 AB Sine Board Layout.

9.4.2 Jumper Setting and Description

Some of the jumper options available are not installed at the factory. The following table
describes all jumper settings. Installing any jumper will override any control signal
connected to the input. The Enable and the Brake jumpers should not be install permanently.
If they are installed, the user will have to reset the amplifier, using the reset switch on
the front edge of the board, each time the unit is powered up.

Jumper Name Description

JP1 (+)LIMIT Installed permanently.
JP2 (-)LIMIT Installed permanently.
JP3 BRAKE Enable or disable dynamic braking.
JP4 DISABLE CCL Disable cont. current limit. (Do not install)
JP5 Cont. Curr Continuous current set to 3 amps with 10k in JP3.
JP6 /ENABLE Enable or disable motion in both directions.

9.4.3 Potentiometers Description

The Sinusoidal Brushless Servo amplifier provides potentiometers for peak current
adjustment. During the servo amplifier setup and calibration, reference is made to this
potentiometer.

Potentiometer Name Description

R78 Peak Current. Peak current adj. 9.3V. (1 amp/volt for 69532)

Note: For access to some of these test points the heat sink plate must be removed and a card extender must be
installed.

Rev 2 9-37
 WARNING

Always reinstall the heat sink before starting the normal

system operation. Failure to do so will cause the amplifier to
over heat.

9.4.4 Test Point Description

TEST POINT NAME DESCRIPTION
TP1A Ground This point is common to +Vs Dc Rtn.
TP1 "B" phase curr. "B" phase current sense.
TP2 "A" phase curr. "A" phase current sense.
TP3 "A" curr comm. "A" current command.
TP4 Phase "A" Power transistors phase "A".
TP5 (+)Limit (+) Limit input test point.
TP6 (-)Limit (-) Limit input test point.
TP7 Brake Brake input test point.
TP8 Abs Curr. Absolute current F/B.
TP9 "B" curr comm. "B" current command.
TP10 Peak Curr. Peak current setting.
TP11 "C" phase curr. "C" phase current sense.
TP12 Phase "B" Power transistors phase "B".
TP13 "B" CMD input "B" command input.
TP14 "-A" CMD input "-A" command input.
TP15 "A" CMD input "A" command input.
TP16 "-B" CMD input "-B" command input.
TP17 Phase "C" Power transistors phase "C".

9.4.5 Fault LED Description

LED DESCRIPTION
LED2 Brake, +Limit, -Limit and over current condition.
LED1 Over current., over temp., & drive disable condition.

9-38 Rev 2
9.4.6 Board Layout
Figure 9-20 shows the location of the test points, jumpers and potentiometers. Become
familiar with the location of these components before starting the procedures.

Figure 9-20 AB Sine Board Layout

TP17
TP12
TP4
TP3
TP2

TP9
TP1A

TP8

TP16
TP1

TP14
TP13
TP11

S1
TP5
TP6
TP7

TP10

JP6
LED1

LED2

TP15
R78
JP1
JP2
JP3
JP4

Rev 2 9-39
9.4.7 Software Commutation
Before setting up this amplifier with a controller that generates A and B software
commutated signals, consider if the controllers requires the motor phase connections in
particular sequence. The sequence may be needed to generate the correct software
commutation of the A and B command signals. If this is the case, connect the motor to the
amplifier as follows:

Anorad
Motor Amplifier J1
Backplane
Phases Connector
(Motor Connector)
Phase "A" 2D, 2B, 2Z A1
Phase "B" 6D, 6B, 6Z A2
Phase "C" 10D, 10B, 10Z A3
Motor Ground 4D, 4B, 4Z A4
Motor Shield 12Z 5

Some of the ANORAD controllers require a specific motor phase sequence. Verify this by
doing followings:

1) Check motor resistance.

2) Using an oscilloscope, check motor B.E.M.F. There are two methods of checking the
motor B.E.M.F. These two methods are shown in Figure 9-21 and 9-22 the method
shown in Figure 9-21 is the phase to phase motor method, which will show a 60° phase
shift.

3) The method shown in Figure 9-20 is the phase to common method, which will show a
120° phase shift.

Figure 9-21 Phase to Phase Method a

RED CH1

WHT CH2

BLK REF

GRN

GRN/YELL

9-40 Rev 2
Figure 9-22 Phase to Common Method b

CH1
RED 20K

WHT 20K REF

BLK 20K

CH2
GRN

GRN/YELL

4) Verify that the system is counting correctly. This is very important considering that any
system miscounts will result in an erratic system operation as well as the lost of the
software commutation control.

5) Identify the direction of positive counting. Motor phasing needs to be done while
moving in the direction of a positive counting.

6) Find which motor phase lead or lag while moving positive.

a) If using method (a), motor phase "AB" should lead "CB" by 60o.

b) If using method (b), motor phase "A" should lead "B" by 120o.

7) Using a dual Channel storage oscilloscope, connect channel 1 between any two motor
phases.

8) Connect scope channel 2 to the third motor phase.

9) While moving the motor by hand in the positive direction, observe the phase shift
relationship. While moving positive, phase "AB" should lead phase "CB" by 60o or
motor phase "A" should lead phase "B" by 120o.

10) If the selected motor phases are phase shifted by the correct amount, reverse the
connection of scope channel 1 and channel 2.

11) When using method (a), if one combination is found to be correct, label the motor phase
connected to channel 1 as phase "A” and the motor phase connected to channel 2 as
phase "C". Label the motor phase connected to the scope reference as phase "B".

12) When using method (b), if one combination is found to be correct, label the motor phase
connected to channel 1 as phase "A” and the motor phase connected to channel 2 as
phase "B". Label the motor phase connected to the scope reference as phase "C".

13) Setup the controller software commutation parameters.

Rev 2 9-41
 a) Magnet pitch (encoder counts per magnet pitch).

b) Magnet pitch offset (in units/counts)

c) Any other related parameters.

14) Connect motor to amplifier.

15) Connect A and B controller command signal to the amplifier.

16) Install motor fuses on the backplane. Make sure that the fuses used do not exceed the
motor continuous current rating.

17) Execute commutation start up program.

9.4.8 Extra Help For Software Commutation

- Verify that all the jumpers on the amplifier are set correctly.
- Verify that none of the motor phases are shorted to chassis or to each other.
- Verify that all commutation parameters are correct.
- Check for blown fuses.
- Check that the motor is connected correctly.
- Make sure that the Enable/disable LED2 is off.
- Turn the Enable Switch S1 is in the Up position (Enable).

9.4.9 Peak Current Adjustment Procedure.

The current scaling factor for amplifier 69532 TP1 - 3, TP8 - 11 and J1-14B is 1 amp/volt

Obtain Peak current rating for the motor from motor specifications, calculate peak current
setting and adjust R78 pot to the calculated value. Check the voltage at TP10 in reference to
TP1A A negative voltage is detected at TP10. The scaling factor determined from the table
above.

Example:

1) If the motor peak current rating = 7 amps.

2) We choose the amplifier scaling factor of 1 amp/volt.
3) Motor peak current/Amplifier scaling factor = Peak current setting
4) 7 amp/1 amp/volt = 7 volts
5) Then adjust R78 to so that TP10 reads -7 volts in reference to TP1A
REF The maximum voltage setting is = -9.3 volts.
The amplifier peak current is = 9 amps (69532).
The amplifier peak current is = 18 amps (72063).

9-42 Rev 2
9.5 Sinusoidal Brushless Servo Amplifier 69812
9.5.1 Introduction
This section contains the description of jumpers, potentiometers, test points, current scaling,
fault LED description and calibration procedure for the Sinusoidal Brushless DC Servo
Amplifier. See drawing C-50474 Rev (-). This amplifier has no velocity feedback option.

The 69812 amplifier is a high voltage high current. (18 amps peak and 3.5 amps continuous).

Before installing or replacing any Servo amplifier, check that all jumpers are set according to
the original factory setting or according to the options that the user wants. Before starting
the setup and calibration procedures become familiar with the layout of the board. See
Figure 9-23 Sinusoidal Brushless Board Layout.

9.5.2 Jumper Setting and Description

Some of the jumper options available are not installed at the factory. The following table
describes all jumper settings. Installing any of these jumpers will override any control signal
connected to the input. The Enable and the Brake jumpers should not be install permanently.
If they are installed, the user will have to reset the amplifier, using the reset switch on
the front edge of the board, each time the unit is powered up.

Jumper Name Description

JP1 BRAKE Enable or disable dynamic braking.
JP2 DISABLE CCL Disable cont. current limit. (Do not install)
JP3 Cont. Curr Continuous current set to 3 amps with 10k in JP3.
JP4 (-)LIMIT Enable or disable motion in the negative direction.
JP5 (+)LIMIT Enable or disable motion in the positive direction.
JP6 /ENABLE Enable or disable motion in both directions.

9.5.3 Potentiometers Description

The Sinusoidal Brushless Servo amplifier provides potentiometers for hall sensors gain and
offset adjustment and peak current adjustment. During the servo amplifier setup and
calibration, reference is made to these potentiometers.

POT NAME DESCRIPTION

R78 "A" gain "A" hall sensor gain. (See note below)
R79 "A" offset "A" hall sensor offset. (See note below)
R64 "B" gain "B" hall sensor gain. (See note below)
R47 "B" offset "B" hall sensor gain. (See note below)
R65 Peak Curr. Peak Current adjustment. -8.8V max.

Rev 2 9-43
9.5.4 Test Points Description
Note: For access to some of these test points the heat sink plate must be removed and a card extender must be
installed.

WARNING

Always reinstall the heat sink before starting the normal

system operation. Failure to do so will cause the
amplifier to over heat.
Test Point Name Description
TP1 Ground This point is common to +Vs Dc Rtn.
TP2 "A" phase comm. "A" phase current command.
TP3 CMD input Hall effect excitation signal (I+ and I-).
TP4 Reference Reference (+12 volts).
TP5 "A" phase curr. "A" phase current sense.
TP6 "C" phase curr. "C" phase current sense.
TP7 VA "A" hall sensor input.
TP8 CMD input CMD(+) and CMD(-) input.
TP9 Abs Curr. Absolute current F/B. (1 amp/v or 2 amps/v)
TP10 "B" hall gain "B" hall sensor gain.
TP11 "A" hall gain "A" hall sensor gain.
TP12 - Reserved.
TP13 "B" phase comm. "B" phase current command.
TP14 Peak Curr Peak current setting.
TP15 Brake Brake input test point.
TP16 (+)Limit (+) Limit input test point.
TP17 (-)Limit (-) Limit input test point.
TP18 VB "B" hall sensor input.
TP19 B phase curr. "B" phase current sense.

9.5.5 Fault LED Description

LED Description
LED1 Brake, +Limit, -Limit and over current condition.
LED2 Over current., over temperature., & drive disable condition.

9-44 Rev 2
9.5.6 Board Layout
Figure 9-23 shows the location of the test points, jumpers and potentiometers. Become
familiar with the location of these components before starting the procedures.

Figure 9-23 Sinusoidal Brushless Board 69812 Layout

R65

R79
R47

R64
R78

JP6
JP5
JP4
JP3
JP2
JP1
TP19
TP1

S1
R22
LED1

LED2

Rev 2 9-45
9.6 Sinusoidal Hall Sensor Calibration Procedure
This calibration must be done when a new motor or a new servo amplifier is installed in a
system. The adjustment of the hall sensors is critical. "A" and "B" hall sensor inputs have
their own amplitude (gain) and offset adjustment potentiometers. An amplitude mismatch or
an incorrect offset will cause faulty system performance or no performance at all.

It is recommended the user become familiar with the most important potentiometers and test
point on the amplifier, before performing this procedure. The following table shows the
potentiometers and related test points.

SIGNAL POTENTIOMETER TEST POINT

A hall gain R78 TP11
A hall offset R79
B hall gain R64 TP10
B hall offset R47
Reference TP4
REFER TO DRAWING # C-50474

Our goal is, to inject a 1 volt signal (read at TP8) and adjust R78 and R64 to an amplitude of
600 mV. peak to peak. (read at TP11 and TP10). Both signals need to be biased around 0
volt in reference to TP4. Remember that TP4 is not ground.

1) Install JP1, JP4, JP5 and JP6 or connect all the TTL inputs control signal of the amplifier
to Vcc Rtn.

2) Connect the sinusoidal hall effect sensors to the servo amplifier via the hall sensors input
connector on the backplane.

3) Do not connect the motor phases (Motor leads) at this time.

4) Turn power ON.

5) Connect an external power supply to the CMD(+) input and ground to CMD(-).

6) With a DVM (Digital Volt Meter), monitor TP8 reference to TP4 and adjust the power
supply to 1 volt.

7) Turn the Reset switch S1 to the Up position (ON).

8) Verify that the voltage at TP3 is the same as it is at TP8 (but opposite polarity). If it is
not, that indicates that the amplifier is not enabled. At this time the LED2 (drive Enable)
should be OFF.

For Amplifier 69812Adjust Hall Amplitude To: +/- 575 mV. (1.15 V. peak to peak)

9-46 Rev 2
 9) Using a dual channel storage oscilloscope, connect channel 1 to TP11 (Hall "A") and
reference to TP4.

10) While moving the motor by hand, adjust R78 until you get a sine wave of 600 mV peak-
to-peak or 1.15 V. peak to peak. At this time, adjust R79 for any offset. This signal
needs to be biased around 0 volt, reference to TP4.

11) Connect channel 1 to TP10 (hall "B") and reference to TP4.

12) While moving the motor by hand, adjust R64 until you get a sine wave of 600 mV peak
to peak or 1.15 V. peak to peak. At this time, adjust R47 for any offset. This signal needs
to be biased around 0 volt reference to TP4.

13) Connect channel 1 to TP11 (hall "A") and reference to TP4 and channel 2 to TP10 (hall
"B").

14) While moving the motor by hand, view both hall effect signals at TP11 and TP10.
Verify that there is a 120o phase difference. If these signals are not 120o out of phase,
then one of the two differential sinusoidal hall sensors inputs is reversed. Correct this
problem and double check again.

9.7 Sinusoidal Motor and Hall Sensor Phasing Procedure

The objective is to find the correct phase relationship of the hall sensors with the motor
phases. As it is shown in Figure 9-24, Motor phase AB is in phase with "A" hall sensor;
Motor phase BC is in phase with "B" hall sensor.

1) Using a dual Channel storage oscilloscope, connect channel 1 to TP11 and reference to
TP4.

2) Connect scope channel 2 to one motor lead and scope channel 2 reference, to another
motor lead.

3) While moving the motor by hand in any direction, observe the phase relationship.

4) If the selected motor phases are not in phase with hall sensor "A" at TP11, select
different combination until the motor B.E.M.F. is in phase with the hall effect signal.

5) If one combination is found to be in phase, record the direction in which the motor
moved to get both signals (motor and hall), in phase.

6) Label the motor lead connected to channel 2 as phase "A", and the phase connected to
channel 2 reference as phase "B".

Rev 2 9-47
Figure 9-24 Motor B.E.M.F. and Hall sensor relationship

PHS A
REF.
PHS B

PHA B
REF.
PHS C

PHS C
REF.
PHS A

A-HALL
TP11

B-HALL
TP10

0o 120 o 240 o 360 o

7) Label the third phase as phase "C".

Summary:

Motor phase AB is in phase with hall sensor "A" at TP11. (See Figure 9-24)

8) Connect channel 1 to TP10 and reference to TP4.

9) Connect scope channel 2 to phase "B" and reference to phase "C".

10) Move the motor by hand in the same direction as recorded before and verify that the
Motor B.E.M.F. is in phase the hall sensor "B" at TP10.

Summary:
Motor phase BC is in phase with hall sensor "B" at TP10. (See Figure 9-24)

11) Turn power OFF.

9-48 Rev 2
9.7.1 Extra help for Motor and Sensor Phasing
If the correct phase relationship between motor and hall effect sensor can not be found,
verify the following:

a) Verify that none of the motor phases is shorted to chassis or to each other.
b) Verify that while moving the motor by hand, both hall effect signals at TP11 and
TP10 are 120o out of phase. If these signals are not 120o out of phase, then one of
the two differential sinusoidal hall sensor inputs (A+ and A- or B+ and B-) is
reversed.

If motor phase AB is in phase with hall sensor "A" (TP11) moving in a one direction and
motor phase BC can not found in phase with hall sensor "B" (TP10), re-label motor wire "A"
as "B" and motor wire "B" as "A". Do not re-label wire "C". At this time, motor phase AB
will be in phase with hall sensor "A", but now in the opposite direction as it was before.

9.7.2 Phase Verification

Reduce the current by 50%, by turning potentiometer R65 fully counter clockwise then 50%
clockwise. Input a small CMD signal, Enable the amplifier through the S1 switch and
observe that the motor moves slowly and smoothly in one direction. If this occurs, the
phasing procedure is complete. If it does not, begin again at Section 9.9.

If due to system considerations the motor direction may need to be reversed, swap hall
sensor excitation signals I+ and I-.

9.8 Servo Amplifier Mode of Operation.

This amplifier can only be set for current mode. A single command can be applied and this
command input could be differential or single ended. Refer to drawing # C-50474.

A +/- 10V command can be applied to the CMD(+) input and the analog ground connection
to CMD(-) input.

9.9 Peak Current Adjustment Procedure

For Amplifier 69812 current scaling factor for TP2, TP13, TP5, TP6, TP19 and TP9 is 2
amps/volt

Obtain Peak current rating for the motor from motor specifications, calculate peak current
setting and adjust R65 pot to the calculated value. Check the voltage at TP14 in reference to
TP4. A negative voltage value will be detected at TP14. Refer to the table for the scaling
factor to the amplifier.

Rev 2 9-49
Example
1) If the motor peak current rating = 7 amps.

2) The amplifier scaling factor is = 1 amp/volt.

3) Motor peak current/Amplifier scaling factor = Peak current setting

4) 7 amps/1 amp/volt = 7 volts

5) Then adjust R65 to so TP14 reads -7 volts in reference to TP4

REF. The maximum voltage setting is = -8.8 volts.

The amplifier peak current is = 7 amps.

9.10 Motion Verification Procedure.

1) Install JP1, JP4, JP5 and JP6 or connect all the TTL inputs control signal of the amplifier
to Vcc Rtn.

2) Turn Switch S1 to the down position (OFF).

3) Connect the sinusoidal hall effect sensors to the servo amplifier via the hall sensors input
connector on the backplane.

4) Connect the motor to the amplifier via a backplane (Dwg. # B-48578).

5) Turn power on.

6) Turn the Reset switch to the UP position (ON).

7) At this time the LED2 (drive Enable) should be OFF.

8) Using an external power supply, apply a positive analog input command and verify that
the motor moves in the positive direction as required by the system. Motion should be
smooth. Start with a voltage no higher than 100mV. and then increase the voltage until
the motor overcome the friction.
It is highly recommended to fuse the motor to the rated continuous current of the
motor. All of ANORAD backplanes make provisions for fuses.

• If the motor does not move in a slow smooth drift, then check the following:

− Motor is connected correctly.

− Enable/disable LED2 is off.
− Enable Switch S1 is in the Up position (Enable).
− Motor fuses have not blown.
9-50 Rev 2
Rev 2 9-51
Anorad Corporation
110 Oser Avenue
Hauppauge, NY 11788

Web site http://www.anorad.com

E-mail anorad@anorad.com

Technical Support:
Tel (631) 231-1990 x 285
Fax (631) 231-7260

Excellence in Motion

Item Number 802140