Yaskawa SmartTrac PG Card User Manual

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Technical Manual

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SMART TRAC PG Card

Table of Contents

Important Safety and Warranty Information 1

Warnings, Cautions and Notes.....................................................................................................................1

General Safety Precautions - Warnings ......................................................................................................2

Important Warranty Information................................................................................................................2

Smart Trac PG Card 3

General Capabilities......................................................................................................................................3

Closed-loop Control..........................................................................................................................3

Position Control ................................................................................................................................3

Digital Input......................................................................................................................................3

Analog Input .....................................................................................................................................3

Quick Start.....................................................................................................................................................4

Installing the Smart Trac PG Card 7

Unpacking ......................................................................................................................................................7

ElectroStatic Discharge (ESD) Procedures.......................................................................................7

Unpacking Procedure........................................................................................................................7

Installing the Smart Trac PG Card .............................................................................................................7

Using the Smart Trac PG Card 11

Basic Features..............................................................................................................................................11

Port Address ................................................................................................................................................11

Encoders.......................................................................................................................................................12

Digital Inputs ...............................................................................................................................................12

Analog Inputs...............................................................................................................................................12

Testing Card Installation 15

Test Points....................................................................................................................................................15

Checking Analog Input Signals..................................................................................................................16

Checking the Power Supply........................................................................................................................16

Checking Encoder Pulses............................................................................................................................16

Checking Pulses at Input to Smart Trac PG Card...................................................................................17

Checking Pulses at a MagneTek VCM Motor ..........................................................................................18

Troubleshooting Your Smart Trac PG Card 19

Symptoms and Corrective Action..............................................................................................................19

Appendix A – Specifications 21

Smart Trac PG Card Specifications ..........................................................................................................21

Technical Manual TM 3554-0020 Table of Contents •• i

SMART TRAC PG Card

Appendix B - Card Layout 25

Smart Trac PG Card – Component Side...................................................................................................25

Smart Trac PG Card – Solder Side ...........................................................................................................26

Appendix C - Connections 29

Feedback Encoder Input (J3).....................................................................................................................29

Logic Input (J4)...........................................................................................................................................29

Follower Encoder Input (J5) ......................................................................................................................30

Monitor Output (J6)....................................................................................................................................30

Analog Channel 0 (J9).................................................................................................................................30

Analog Channel 1 (J10)...............................................................................................................................31

Shield Termination (J11)............................................................................................................................31

Shield Termination (J12)............................................................................................................................31

Appendix D – Removing the Smart Trac Card Stack 35

General Procedures.....................................................................................................................................35

Appendix E – Technical Support 39

Getting Help.................................................................................................................................................39

References ....................................................................................................................................................39

Problem Report ...........................................................................................................................................40

Appendix F – Replaceable Parts Listing 41

Replaceable Parts Listing ...........................................................................................................................41

Glossary of Terms 43

Index 45

ii •• Table of Contents Technical Manual TM 3554-0020

SMART TRAC PG Card

Important Safety and Warranty
Information

Warnings, Cautions and Notes

WARNING

A statement of conditions which MUST BE OBSERVED to

prevent personal injury or death.

WARNING - ESD

A statement of conditions which must be observed to prevent
damage to components due to ESD (ElectroStatic Discharge) and
to prevent personal injury or death.

CAUTION

A statement of conditions which must be observed to prevent
undesired equipment faults, Smart Trac AC1 system degradation
and damage to equipment.

IMPORTANT

A statement of conditions which should be observed during Smart Trac AC
DeviceNet setup or operation to ensure dependable service.

NOTE: Notes indicate information that is in addition to a discussion of the topic
in adjoining text. Alternatively, it may limit or restrict the paragraph(s) that
follow(s) to specific models or conditions.

Technical Manual TM 3554-0020 Important Safety and Warranty Information •• 1

SMART TRAC PG Card

TIP - Tips indicate information that should make a procedure easier or more
efficient.

General Safety Precautions ­Warnings

Important safety information follows. Please read and understand all
precautions listed below before proceeding with the specification, installation,
set-up or operation of your Smart Trac AC1. Failure to follow any of the
following precautions may result in personal injury or death, or damage to the
equipment.

WARNING - ESD

The Control Printed Circuit Board (PCB) employs CMOS
Integrated Circuits that are easily damaged by static electricity.
Use proper ElectroStatic Discharge (ESD) procedures when
handling the Control PCB. See Smart Trac AC1 Technical Manual
for details. Failure to comply may result in damage to equipment

and/or personal injury.

Important Warranty Information.

Do not modify your Smart Trac AC1, its components, or any of the procedures
contained in the technical documentation supplied by MagneTek. Any
modification of this product by the user is not the responsibility of MagneTek
and will void the warranty.

2 •• Important Safety and Warranty Information Technical Manual TM 3554-0020

Smart Trac PG Card

General Capabilities

SMART TRAC PG Card

Closed-loop Control

Position Control

Digital Input

Analog Input

A Smart Trac PG Card added to your Smart Trac AC1 provides closed loop flux
vector control and closed loop speed control. With the card, 5 V to 12 V
differential quadrature signals at a rate of up to 300 KHz with a 540 ohm input
load may be input. Quadrature phasing of encoder inputs is 90 degrees +/- 22
degrees maximum at 300 kHz. Follower applications may use a second encoder
input. A 12 VDC power supply rated at 200 mA supplies power to the encoder.

The Smart Trac PG Card also provides position control. Start and stop signals
control two 32-bit counters that can be used to measure the rotation of either
start or stop signals. The Start and Stop signals can come from one of three
sources: the marker pulse of either encoder; one of the two digital inputs (i.e.,
connected to proximity switches); or software command.

The two 12 VDC input signals can be used as general purpose inputs if not
needed for position control.

Two analog input channels can accommodate either load cells or potentiometers.
The input voltage range for each channel is ± 600 mV or ± 10 Volts, selectable.

The Smart Trac PG Card also supplies:

• an A/D converter with 12 bits of resolution.

• a +5VDC, 50 mA power supply.

• reference voltages of +10VDC and -10VDC, both rated at 10 mA.

Quick Start

1. Remove all Smart Trac cards except the Smart Trac Inverter and CPU
cards per instructions in "Installing the Smart Trac PG Card. "

2. Install the Smart Trac PG card as the second card of the card stack.

3. Make connections to the PG card terminal blocks per information
contained in this manual and your situation.

4. Replace all other cards per the instructions in "Installing the Smart Trac
PG Card."

5. Power up and test functionality of your Smart Trac AC1, including that
of the Smart Trac PG card.

Technical Manual TM 3554-0020 Smart Trac PG Card •• 3

SMART TRAC PG Card

THIS PAGE INTENTIONALLY LEFT BLANK

4 •• Smart Trac PG Card Technical Manual TM 3554-0020

SMART TRAC PG Card

Installing the Smart Trac PG
Card

Unpacking

ElectroStatic
Discharge (ESD)
Procedures

Unpacking Procedure

WARNING WARNING -- ESD ESD

Keep electronic circuit boards in ElectroStatic Discharge (ESD)
protective bags when not being handled. Use proper ESD
procedures (including an ESD wrist strap) when handling circuit
boards. Failure to comply may result in damage to equipment.

When working with an ElectroStatic Discharge (ESD) sensitive device, you
should be grounded at all times. The easiest and most common way to provide
this ground is to use an approved ESD wrist strap. The strap is secured to your
wrist with a wire attached to the strap and clipped or taped to the chassis of the
unit being worked on. Any static is dissipated through the wire to ground,
greatly reducing the possibility of damage to the device.

It is a good idea to touch the chassis with your finger before handling any
electrostatic device. Any static electricity will be discharged to chassis ground
and will not be transferred to the device.

Always store devices (cards, other electronic components) in ESD protective
bags when not being handled.

Remove the protective shipping and packing material from the card. Ensure
contact wedges and other shipping devices have been removed.

Installing the Smart Trac PG Card

The Smart Trac PG Card must be positioned above the Smart Trac CPU card on
the Smart Trac AC1 card stack.

NOTE: If replacing or adding a Smart Trac PG card to an existing Smart Trac
card stack, see Appendix D – "Removing the Smart Trac Card Stack" before
continuing.

Technical Manual TM 3554-0020 Installing the Smart Trac PG Card •• 5

Card

SMART TRAC PG Card

Standoffs (4
places on top of
each card)

4CN

Connector

2CN

Connector

Smart Trac
Genius PCIM
Card

Optional
PC/104
Card

Smart Trac
Ethernet

Smart Trac
PS Card

Smart Trac
PG Card

Smart Trac
CPU Card

Inverter Control
Card

Adapter
Ring

Main Chassis

Figure 1. Smart Trac PG Card Stack Position

1. Power off the Smart Trac AC1. Disconnect it and tag it as "Out of
Service". Perform this and all other steps required to remove all cards
located in a stack position above the PG Card. See "Appendix D –
Removing the Smart Trac Card Stack"

2. To replace the PG card, orient the PG card so that the PC/104
connector and the J2 connector align with the PC/104 connector on the
Smart Trac CPU card and the 4CN connector on the Inverter Control
board. Be careful to align the PC/104 connector pins with the
receptacle on the Smart Trac CPU card so the pins don’t bend when the
card is pushed into place.

3. Gently but firmly push the Smart Trac PG card onto the Smart Trac
CPU card. Make sure connecting pins are in alignment and J2 mates
with 4CN before pushing the two boards tightly together. Secure the
card using four (4) metal standoffs and one (1) plastic standoff.

6 •• Installing the Smart Trac PG Card Technical Manual TM 3554-0020

SMART TRAC PG Card

4. Replace the Smart Trac PS or Ethernet card and other cards by
reversing the procedures described in the Appendix "Removal of the
Smart Trac Card Stack."

Technical Manual TM 3554-0020 Installing the Smart Trac PG Card •• 7

SMART TRAC PG Card

Using the Smart Trac PG Card

Basic Features

The Smart Trac PG card has:

• Two encoder inputs for closed loop flux vector control, closed loop
speed control and position control.

• Digital inputs (if not needed for position control).

• Analog inputs to accommodate load cells or potentiometers.

Port Address

The Smart Trac PG card uses a port address of "1". Hardwired on the card, the
address may be overridden if two Smart Trac PG cards must be used. Contact
MagneTek for details.

Encoders

Connect encoders at Terminal Block J3 (feedback encoder input) or at Terminal
Block J5 (follower encoder input). Only the feedback encoder Terminal Block
J3 provides a 12 volt power supply for the encoder.

Channel 0 - feedback encoder

Use Channel 0 for the encoder of the motor connected to the Smart Trac AC1. It
provides feedback to both the Smart Trac AC1 inverter control card and CPU.
Terminal Block J3 provides these connections for differential A, B and Z inputs
and a 12-volt @200ma power supply. A and B are used for speed and position
control. Z is used for position start and stop only.

Channel 1 - follower encoder

Use Channel 1 for another feedback source. It only provides feedback for the
Smart Trac CPU card. Terminal Block J5 provides connections for differential
A, B and Z inputs.

Digital Inputs

Two +12 Volt digital inputs are located on Terminal Block J4 for proximity
switch inputs (LI0 and LI1). Each of the digital inputs sinks 10mA and may be
used for position start and stop, or as a general purpose input.

Technical Manual TM 3554-0020 Using the Smart Trac PG Card •• 9