Ensemble LAB Hardware Manual

Transcription

1 Ensemble LAB Hardware Manual Revision: JOG USB AXIS AUX I/O JOYSTICK ESTOP USB ETHERNET WARNING: HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED J106 J105 TB101 J104 J103

2 Global Technical Support Go to for information and support about your Aerotech products. The website provides downloadable resources (such as up-to-date software, product manuals, and Help files), training schedules, and PC-to-PC remote technical support. You can also complete Product Return (RMA) forms and get information about repairs and spare or replacement parts. For immediate help, contact a service office or your sales representative. Have your customer order number available before you call or include it in your . Phone: Fax: service@aerotech.com United Kingdom Phone: +44 (0) Fax: +44 (0) service@aerotech.co.uk Germany Phone: +49 (0) Fax: +49 (0) service@aerotechgmbh.de France Phone: sales@aerotech.co.uk United States (World Headquarters) 101 Zeta Drive Pittsburgh, PA Japan Phone: +81 (0) Fax: +81 (0) service@aerotechkk.com.jp China Phone: +86 (21) saleschina@aerotech.com Taiwan Phone: +886 (0) service@aerotech.tw This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies. Copyright , Aerotech, Inc., All rights reserved.

3 Ensemble LAB Hardware Manual Table of Contents Table of Contents Ensemble LAB Hardware Manual 1 Table of Contents iii List of Figures v List of Tables vi EU Declaration of Conformity 7 Agency Approvals 8 Safety Procedures and Warnings 9 Quick Installation Guide 11 Chapter 1: Introduction Electrical Specifications System Power Requirements Mechanical Specifications Environmental Specifications Drive and Software Compatibility 20 Chapter 2: Installation and Configuration Unpacking the Chassis Electrical Installation AC Power Connection IO and Signal Wiring Requirements Minimizing Conducted, Radiated, and System Noise Motor and Feedback Connections Encoder Interface RS-422 Line Driver Encoder (Standard) Analog Encoder Interface Encoder Phasing Hall-Effect Interface Thermistor Interface End of Travel Limit Input Interface End of Travel Limit Phasing Motor Output Interface Brushless Motor Connections DC Brush Motor Connections Stepper Motor Connections Emergency Stop Sense Input (TB101) Auxiliary I/O Connector (J106) Auxiliary Encoder Channel Position Synchronized Output (PSO) Opto-Isolated Outputs Opto-Isolated Inputs High-Speed User Inputs Analog Output Analog Input Joystick Interface (J105) Communication (Ethernet and USB) USB Interface Ethernet Interface PC Configuration and Operation Information 60 Chapter 3: Maintenance Preventative Maintenance 61 iii

4 Table of Contents Ensemble LAB Hardware Manual Appendix A: Warranty and Field Service 63 Appendix B: Revision History 65 Index 67 iv

5 Ensemble LAB Hardware Manual Table of Contents List of Figures Figure 1-1: Ensemble LAB Controller 13 Figure 1-2: Functional Diagram 15 Figure 1-3: Dimensions 18 Figure 2-1: Power and Control Connections 22 Figure 2-2: Power Switch 22 Figure 2-3: Line Driver Encoder Interface 28 Figure 2-4: Analog Encoder Phasing Reference Diagram 29 Figure 2-5: Analog Encoder Interface 30 Figure 2-6: Encoder Phasing Reference Diagram (Standard) 31 Figure 2-7: Position Feedback in the Diagnostic Display 32 Figure 2-8: Hall-Effect Inputs 33 Figure 2-9: Thermistor Interface Inputs 34 Figure 2-10: End of Travel Limit Input Connections 35 Figure 2-11: End of Travel Interface Inputs 35 Figure 2-12: Limit Input Diagnostic Display 36 Figure 2-13: Brushless Motor Configuration 38 Figure 2-14: Encoder and Hall Signal Diagnostics 39 Figure 2-15: Motor Phasing Oscilloscope Example 40 Figure 2-16: Brushless Motor Phasing Goal 40 Figure 2-17: DC Brush Motor Configuration 41 Figure 2-18: Clockwise Motor Rotation 41 Figure 2-19: Stepper Motor Configuration 42 Figure 2-20: Clockwise Motor Rotation 42 Figure 2-21: ESTOP Sense Input (TB102) 43 Figure 2-22: Auxiliary Encoder Channel 46 Figure 2-23: PSO Interface 48 Figure 2-24: Outputs Connected in Current Sourcing Mode (J106) 50 Figure 2-25: Outputs Connected in Current Sinking Mode (J106) 50 Figure 2-26: Inputs Connected in Current Sourcing Mode (J106) 52 Figure 2-27: Inputs Connected in Current Sinking Mode (J106) 52 Figure 2-28: High Speed User Inputs (J106) 53 Figure 2-29: Analog Output 0 (J106) 54 Figure 2-30: Analog Input 0 (J106) 55 Figure 2-31: Joystick Interface 56 Figure 2-32: USB Connection Location (for PC Communication) 58 Figure 2-33: Ethernet Connection Location 59 v

6 Table of Contents Ensemble LAB Hardware Manual List of Tables Table 1-1: Ordering Options 14 Table 1-2: Electrical Specifications 16 Table 1-3: Physical Specifications 18 Table 1-4: Drive and Software Compatibility 20 Table 2-1: Main AC Power Input Voltages and Current Requirements 23 Table 2-2: I/O and Signal Wiring Specifications 24 Table 2-3: Ferrite Bead Part Numbers 25 Table 2-4: Motor Power and Feedback Connector 26 Table 2-5: Encoder Interface Pin Assignment 27 Table 2-6: Encoder Specifications 28 Table 2-7: Analog Encoder Specifications 29 Table 2-8: Hall-Effect Feedback Interface Pin Assignment 33 Table 2-9: Thermistor Interface Pin Assignment 34 Table 2-10: End of Travel Interface Pin Assignment 35 Table 2-11: Motor Output Connections 37 Table 2-12: TB101 ESTOP Pin Assignment 43 Table 2-13: Electrical Noise Suppression Devices 43 Table 2-14: Auxiliary I/O Interface Pin Assignment (J106) 44 Table 2-15: Auxiliary Encoder Specifications 45 Table 2-16: Auxiliary Encoder Channel Pin Assignment (J106) 45 Table 2-17: PSO Specifications 47 Table 2-18: PSO Pin Assignment 47 Table 2-19: Port 0 Digital Output Connector Pin Assignment 49 Table 2-20: Digital Output Specifications 49 Table 2-21: Opto-Isolated Input Specifications 51 Table 2-22: Port 0 Digital Input Connector Pin Assignment (J106) 51 Table 2-23: High-Speed Input Specifications 53 Table 2-24: Port 0 High Speed Digital Input Connector Pin Assignment (J106) 53 Table 2-25: Analog Output 0 Specifications 54 Table 2-26: Analog Output Connector Pin Assignment (J106) 54 Table 2-27: Differential Analog Input 0 Specifications 55 Table 2-28: Analog Input Connector Pin Assignment (J106) 55 Table 2-29: Joystick Connector Pin Assignment (J105) 57 Table 3-1: Preventative Maintenance 61 vi

7 Ensemble LAB Hardware Manual Declaration of Conformity EU Declaration of Conformity Manufacturer Address Product Model/Types Aerotech, Inc. 101 Zeta Drive Pittsburgh, PA USA Ensemble LAB All This is to certify that the aforementioned product is in accordance with the applicable requirements of the following Directive(s): 2014/35/EU 2011/65/EU Low Voltage Directive LVD RoHS 2 Directive and has been designed to be in conformity with the applicable requirements of the following documents when installed and used in accordance with the manufacturer s supplied installation instructions. EN :2010 Safety requirements for electrical equipment Name Position Location / Alex Weibel Engineer Verifying Compliance Pittsburgh, PA 7

8 Declaration of Conformity Ensemble LAB Hardware Manual Agency Approvals Aerotech, Inc. Model Ensemble LAB Motion Controllers have been tested and found to be in accordance to the following listed Agency Approvals: Approval / Certification: CUS NRTL Approving Agency: TUV SUD America Inc. Certificate #: U Standards: UL :2012; CAN/CSA-C22.2 No :2012; EN :

9 Ensemble LAB Hardware Manual Safety Procedures and Warnings Safety Procedures and Warnings The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure to observe these precautions could result in serious injury to those individuals performing the procedures and/or damage to the equipment. N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any time. All drawings and illustrations are for reference only and were complete and accurate as of this manual s release. Refer to for the most up-to-date information. W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the following precautions must be followed. 1. Operators must be trained before allowing them to operate the equipment. 2. All service and maintenance must be performed by qualified personnel. 3. Modification or use of this product in an unspecified manner may result in equipment damage or bodily injury (shock or death). 4. The user must read this manual, Ensemble Help file, and related documentation thoroughly before operating the equipment. 5. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid potential hazards. 6. This product must be mounted securely. Improper mounting can result in injury and damage to the equipment. D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of electrical shock, bodily injury or death the following precautions must be followed. 1. Risk of injury during operation due to moving parts connected to the Ensemble LAB. 2. Do not connect or disconnect any electrical components or connecting cables while connected to a power source. 3. Disconnect electrical power before making any mechanical adjustments or performing maintenance. 4. Make sure the system is properly grounded in accordance with local electrical safety requirements. 5. Operator safeguarding requirements must be addressed during final integration of the product. 9

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11 Ensemble LAB Hardware Manual Quick Installation Guide Quick Installation Guide This chapter describes the order in which connections and settings should typically be made to the Ensemble LAB. If a custom interconnection drawing was created for your system (look for a line item on your Sales Order under the heading Integration ), that drawing can be found on your installation device AXIS B WARNING: HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED AUX I/O J106 JOYSTICK J105 ESTOP TB101 USB J104 ETHERNET J103 A Topic Section A Connect the AC Power Section 2.2. B Connect the Motor Power and Feedback Section

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13 Ensemble LAB Hardware Manual Introduction Chapter 1: Introduction Aerotech s Ensemble LAB is a one to four axis desktop standalone motion controller with an integrated power supply. The Ensemble LAB is designed for applications where ease of operation is desired without sacrificing overall system capability. Number of Axes 4 Maximum Encoder Inputs 4 Amplifier Type Linear Digital Inputs Four Optically Isolated; Two High Speed; One ESTOP Digital Outputs Four Optically Isolated Analog Inputs One 16-Bit differential analog input (±10 V) Analog Outputs One 16-Bit differential analog output (±10 V) Dedicated Axis I/O Two Limit Inputs (CW, CCW); Three Hall-Effect Inputs Feedback Type (Standard) 10 MHz Square Wave /40 MHz Count Rate Feedback Type (Optional) Interpolated (65,536 max) Sin/Cos; 200 khz max input frequency Communication Interfaces 10/100 Base T Ethernet; USB 2.0 Expansion Interface USB 1.1 Servo Loop Update 10 khz maximum Current Loop Update 20 khz Programming Environment Multi-Tasking AeroBasic Host Operating System Windows 7 (for Remote Programming and Diagnostic Tools) C JOG 1 2 D A B 3 4 USB E L AXIS F WARNING: HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED AUX I/O J106 G JOYSTICK J105 H ESTOP TB101 I USB J104 J ETHERNET J103 K A Touch Screen D Power Switch G Auxiliary I/O port (J106) B Keypad E USB (device) port H Joystick port (J105) K C Jog Buttons F Motor / Feedback Connector (1-4) I ESTOP port (TB101) J L USB (host) port (J104) Ethernet port (J103) AC Power Figure 1-1: Ensemble LAB Controller Chapter 1 13

14 Introduction Ensemble LAB Hardware Manual Table 1-1: Ordering Options Number of Axes (required) -2DS Configured for 2 axis DC brush/stepper motor operation -3DS Configured for 3 axis DC brush/stepper motor operation -4DS Configured for 4 axis DC brush/stepper motor operation -2DSA Configured for 2 axis AC brushless, DC brush/stepper motor operation -3DSA Configured for 3 axis AC brushless, DC brush/stepper motor operation -4DSA Configured for 4 axis AC brushless, DC brush/stepper motor operation Line Voltage (required) -A 115 VAC input -B 230 VAC input -C 100 VAC input -D 200/208 VAC input Bus Voltage (required) -24B ±24VDC bus for stepper, DC, and brushless motor devices Feedback Type (optional) -MXU1 Interpolation circuit allowing analog sine wave input on encoder channel 1 up to x8192. No real-time output or PSO support. -MXU2 Interpolation circuit allowing analog sine wave input on encoder channel 2 up to x8192. No real-time output or PSO support. -MXU3 Interpolation circuit allowing analog sine wave input on encoder channel 3 up to x8192. No real-time output or PSO support. -MXU4 Interpolation circuit allowing analog sine wave input on encoder channel 4 up to x8192. No real-time output or PSO support. -MXR1 Interpolation circuit allowing analog sine wave input on encoder channel 1 up to x Real-time output and PSO support. -MXR2 Interpolation circuit allowing analog sine wave input on encoder channels 1 and 2 up to x Real-time output and PSO support. -MXR3 Interpolation circuit allowing analog sine wave input on encoder channels 1, 2, and 3 up to x Real-time output and PSO support. -MXR4 Interpolation circuit allowing analog sine wave input on encoder channels 1, 2, 3, and 4 up to x Real-time output and PSO support. PSO Output (optional) -PSO Single axis Position Synchronized Output. Can be configured to track quadrature or MXR input encoder channels. Line Cord (required) -ENGLAND U.K. compatible line cord -GERMANY German compatible line cord -ISRAEL Israel compatible line cord -INDIA India compatible line cord -AUSTRALIA Australia compatible line cord -US-115VAC US 115 VAC compatible line cord -US-230VAC US 230 VAC compatible line cord -NO-LINECORD No line cord Standard Motor Power and Feedback Combination Cables C meters long; for use with single 25 pin D feedback and motor stages (25 Pin D, Brushless motor, not rated for continuous flex) C meters long; for use with BMS/BM motor with 9-pin limits (25 Pin D, 4 Pin HPD, 9 Pin D, Brushless motor, not rated for continuous flex) 14 Chapter 1

15 Ensemble LAB Hardware Manual Introduction The following block diagram shows a connection summary (refer to Chapter 2 for more detailed connection information). Controller Amplifier Keypad LCD Touch Display Ethernet J103 Ethernet Port Encoder +5V / Common PSO Output SIN, COS, MRK (RS422) 4 Opto Outputs 4 Opto Inputs 2 High Speed Opto Inputs Analog Input 0 +/- Analog Output 0 AUX I/O J106 USB (Front) USB Port JOYSTICK J105 USB J104 USB Port -MXU/-MXR Option SIN, COS, MRK (RS422) CW, CCW, Home Limits; Hall A, B, C; Motor Over Temperature Encoder +5V / Common Motor (A, B, C) MOTOR POWER and FEEDBACK J1-J4 ESTOP External Interface (/ESTOP1) TB101 Motor Power AC Power Input Control Power Supply Amplifier Control Power Heatsink Over Temperature Linear Amplifier Figure 1-2: Functional Diagram Chapter 1 15

16 Introduction Ensemble LAB Hardware Manual 1.1. Electrical Specifications The electrical specifications for the Ensemble LAB are listed below. Table 1-2: Electrical Specifications Description Ensemble LAB Power Input Voltage 100 VAC 115 VAC 200 VAC 230 VAC Supply Input Frequency Hz Inrush Current 7 A 8 A 13 A 15 A Maximum Continuous Input Current 2 A 2 A 1 A 1 A Input Current Aerotech doesn't specify the input current or power to the drives because it is dependent on the amount of real power being delivered to the drive (refer to Section ). Output Voltage (1) ± A Peak Output Current (1) 5 A Continuous Output Current (1) 2.5 A Bus Voltage Power Amplifier Bandwidth (1) ±24 VDC 2500 Hz Maximum (software selectable) Minimum Load Resistance 0.5 Ω Output Impedance 0.3 Ω User Power Supply Output 5 VDC (@ 500 ma) Mode of Operation Brush, Stepper, Brushless (2) 1. Load Dependent 2. The Brushless motor mode of operation is only available if the -2DS, -3DS, or -4DS option has been purchased. 16 Chapter 1

17 Ensemble LAB Hardware Manual Introduction System Power Requirements The following equations can be used to determine total system power requirements. The actual power required from the mains supply will be the combination of actual motor power (work), motor resistance losses, and efficiency losses in the power electronics or power transformer. An EfficiencyFactor of approximately 50% should be used in the following equations. Linear Motor Pdiss[W] = MotorCurrentPeak[A] * TotalBusVoltage[V] * 3 / 2 Pin = SUM ( Pdiss ) / EfficiencyFactor Chapter 1 17

18 Introduction Ensemble LAB Hardware Manual 1.2. Mechanical Specifications The following figure shows the Ensemble LAB package dimensions AXIS AUX I/O JOYSTICK ETHERNET ESTOP USB WARNING: HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED J106 J105 TB101 J104 J [0.09] 95.6 [3.76] 13.3 [0.52] 4.9 [0.19] [10.73] 44.8 [1.76] [14.58] JOG USB 98.4 [3.88] [1.29] [11.99] DRAWING NUMBER: 620E1415 REV- DIMENSIONS: MM [IN] Figure 1-3: Dimensions Table 1-3: Physical Specifications Weight 5.7 kg [12.6 lbs] 18 Chapter 1

19 Ensemble LAB Hardware Manual Introduction 1.3. Environmental Specifications Ambient Temperature Operating: 0 to 50 C (32 to 122 F) Storage: -30 to 85 C (-22 to 185 F) Humidity Maximum relative humidity is 80% for temperatures up to 31 C. Decreasing linearly to 50% relative humidity at 40 C. Non condensing. Altitude Up to 2000 meters. Pollution Pollution degree 2 (normally only non-conductive pollution). Use Indoor use only. Chapter 1 19

20 Introduction Ensemble LAB Hardware Manual 1.4. Drive and Software Compatibility The following table lists the available drives and which version of the software first supported the drive. Drives that list a specific version number in the Last Software Version column will not be supported after the listed version. Table 1-4: Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version CL A CP A 1.00 Current B 2.54 Current Epaq Current A 2.55 Current Epaq MR with ML drives Current Epaq MR with MP drives Current A 2.55 Current HLe Current HPe Current LAB Current ML Current MP Current A 2.55 Current QDe/QL/QLe Current QLAB Current 20 Chapter 1

21 Ensemble LAB Hardware Manual Installation and Configuration Chapter 2: Installation and Configuration D A N G E R : To minimize the possibility of bodily injury or death, disconnect all electrical power prior to performing any maintenance or making adjustments to the equipment Unpacking the Chassis D A N G E R : All electronic equipment and instrumentation are wrapped in antistatic material and packaged with desiccant. Ensure that the antistatic material is not damaged during unpacking. D A N G E R : Cables should not be connected to or disconnected from the Ensemble LAB drive chassis while power is applied, nor should any drive modules be removed or inserted into it with power applied. Doing so may cause damage to the system or its components. Visually inspect the container of the Ensemble LAB for any evidence of shipping damage. If any such damage exists, notify the shipping carrier immediately. Remove the packing list from the Ensemble LAB container. Make sure that all the items specified on the packing list are contained within the package. All of the documentation provided with the Ensemble LAB should be saved for future reference. Additional information about the Ensemble LAB system is provided on the Serial and Power labels that are placed on the Ensemble LAB chassis. The system serial number label contains important information such as the: Customer order number (please provide this number when requesting product support) Drawing number System part number The Ensemble LAB power label contains the factory configured AC power requirements. D A N G E R : The AC power label must be changed if the AC Input Voltage is reconfigured. Chapter 2 21

22 Installation and Configuration Ensemble LAB Hardware Manual 2.2. Electrical Installation Motor, power, control, and position feedback cable connections are made to the rear of the Ensemble LAB. For a complete list of electrical specifications, refer to Section 1.1. Electrical Specifications H AXIS B WARNING: HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED AUX I/O J106 C JOYSTICK J105 D ESTOP TB101 E USB J104 F ETHERNET J103 G B Motor Power / Feedback Connector C Aux I/O Connector D Joystick Connector E ESTOP Terminal Block F USB Port G Ethernet Port Figure 2-1: Power and Control Connections JOG 1 2 A 3 USB 4 A Power Switch Figure 2-2: Power Switch All low voltage connections must be made using cables/wires sized for the maximum currents that will be carried. Insulation on these cables/wires must be rated at 300 V if this wiring can come into contact with wiring operating above 100 V (AC & Motor wiring). Low voltage wiring should not be bundled with AC and motor wiring to minimize signal disturbances due to EMI interference and coupling. N O T E : The machine integrator, OEM or end user is responsible for meeting the final protective grounding requirements of the system. N O T E : Confirm that the AC power is the correct voltage before turning on power to the Ensemble LAB. 22 Chapter 2

23 Ensemble LAB Hardware Manual Installation and Configuration AC Power Connection AC input power to the Ensemble LAB is applied to the AC power receptacle that is located on the rear panel. The power cord connected to this receptacle also provides the protective earth ground connection and may serve as a Mains disconnect. The main power switch is located on the front panel of the Ensemble LAB. Refer to Section 1.1. for the electrical specifications. W A R N I N G : The AC power cord is the Mains disconnect. Table 2-1: Main AC Power Input Voltages and Current Requirements AC Input Voltage Input Amps (maximum continuous) Connector Port 100 VAC 50/60 Hz 2 A 115 VAC 50/60 Hz 2 A 200 VAC 50/60 Hz 1 A 230 VAC 50/60 Hz 1 A The AC power cord to the Ensemble LAB must be rated for the line voltage being used and have a minimum current capacity of 5 A. The insulation for the AC power wiring must be appropriately rated for the environment. The temperature rating of the insulation must be at least 80ºC. Environmental conditions may necessitate the need to meet additional AC wiring requirements or specifications. AC wiring should not be bundled with signal wiring to minimize EMI coupling and interference. D A N G E R : See the user documentation provided with your Ensemble LAB system to determine if the Ensemble LAB chassis is limited to only one AC input voltage. Operation at other voltages may result in damage to the Ensemble LAB chassis. Chapter 2 23

24 Installation and Configuration Ensemble LAB Hardware Manual IO and Signal Wiring Requirements The I/O, communication, and encoder feedback connections are typically very low power connections. In some applications, especially when there are significant wire distances, a larger wire size may be required to reduce the voltage drop that occurs along the wire. This increase may be necessary in order to keep the voltage within a specified range at a remote point. Low voltage and high voltage wires should be kept physically separated so that they cannot contact one another. This reduces the risk of electric shock and improves system performance. Table 2-2: I/O and Signal Wiring Specifications Connection Specification Value Cable/Wire Rating (1) 300 V Signal Wiring Minimum Current Capacity.25 A Temperature Rating (Insulation) (2) 80 C Cable/Wire Rating (1) 300 V Low Voltage Power Minimum Current Capacity (3) 1 A Temperature Rating (Insulation) (2) 80 C V if the wiring is not in close proximity to wiring operating at voltages above 60 V. 2. Insulation rating will need to be rated for the higher voltage if the wiring is in proximity to wiring operating at voltages above 60 V. 3. Larger gauge wire may be required to minimize voltage drop due to voltage (IR) loss in the cable. 24 Chapter 2

25 Ensemble LAB Hardware Manual Installation and Configuration Minimizing Conducted, Radiated, and System Noise To reduce electrical noise, observe the following motor and input power wiring techniques. 1. Use shielded cable to carry the motor current and tie the shield to earth ground. 2. Use a cable with sufficient insulation. This reduces the capacitive coupling between the leads that, in turn, reduces the current generated in the shield wire. 3. Provide strong earth ground connections to the amplifier and the motor. Offering electrical noise a low impedance path to earth ground not only reduces radiated emissions, but also improves system performance. 4. User connections to the product must be made using shielded cables with metal D-style connectors and back shells. The shield of the cables must be connected to the metal back shell in order for the product to conform to the radiated emission standards. 5. The Ensemble LAB is a component designed to be integrated with other electronics. EMC testing must be conducted on the final product configuration. 6. Ferrite beads or Aerotech s FBF-1 or FBF-2 filter adapters, may be used on the motor leads to reduce the effects of amplifier EMI/RFI, produced by PWM (pulse width modulation) amplifiers. Table 2-3: Ferrite Bead Part Numbers Wire Size Aerotech P/N Third Party P/N 13.3 mm 2 (#6 AWG) N/A # Elna Fair-Rite Products 8.3 mm 2 (#8 AWG) ECZ00285 # Elna Fair-Rite Products 2.0 mm 2 (#14 AWG) EIZ01027 # Elna Fair-Rite Products 1.3 mm 2 (#16 AWG) EIZ01025 # Elna Fair-Rite Products 0.8 mm 2 (#18 AWG) EIZ01001 # Elna Fair-Rite Products 0.5 mm 2 (#20 AWG) EIZ01001 # Elna Fair-Rite Products Chapter 2 25

26 Installation and Configuration Ensemble LAB Hardware Manual 2.3. Motor and Feedback Connections Each 25-pin, D-style connector has encoder, limits, and Hall inputs, a 5 V power supply, and motor connections. Table 2-4: Motor Power and Feedback Connector Pin# Description In/Out/Bi Connector 1 Key -- 2 Cosine-N Input 3 Sine-N Input 4 Marker-N Input 5 Encoder Common -- 6 Limit Common -- 7 Negative (CCW) hardware limit Input 8 HALL A Input 9 HALL C Input 10 Motor Ground MTR ØA (Motor Phase A) Output 12 MTR ØB (Motor Phase B) Output 13 MTR ØC (Motor Phase C) Output 14 Cosine Input 15 Sine Input 16 Marker Input 17 Encoder/Limits +5 V Output 18 ID Bidirectional 19 Positive (CW) hardware limit Input 20 Motor Thermistor Input 21 HALL B Input 22 Motor Ground MTR ØA (Motor Phase A) Output 24 MTR ØB (Motor Phase B) Output 25 MTR ØC (Motor Phase C) Output Mating Connector Aerotech P/N Third Party P/N 25-Pin D-Connector ECK00101 FCI DB25P064TXLF Backshell ECK00656 Amphenol 17E Chapter 2

27 Ensemble LAB Hardware Manual Installation and Configuration Encoder Interface The Ensemble LAB is equipped with standard and auxiliary encoder feedback channels. The standard encoder interface is accessible through the feedback connector. The standard interface is a line driver encoder that will accept an RS-422 differential line driver signal. If the drive had been purchased with the - MXU or -MXR option, the standard encoder interface has been configured to accept an analog encoder. Refer to Section for encoder feedback phasing. Refer to Section 2.5. for the auxiliary encoder channel. N O T E : Encoder wiring should be physically isolated from motor, AC power, and all other power wiring. N O T E : The PSO feature is not compatible with the -MXU option. The PSO feature operates with the -MXR or -MXH option and with square wave encoders. Table 2-5: Encoder Interface Pin Assignment Pin# Description In/Out/Bi 2 Cosine-N Input 3 Sine-N Input 4 Marker-N Input 5 Encoder Common Cosine Input 15 Sine Input 16 Marker Input 17 Encoder/Limits +5 V Output Chapter 2 27

28 Installation and Configuration Ensemble LAB Hardware Manual RS-422 Line Driver Encoder (Standard) The standard encoder interface accepts an RS-422 differential quadrature line driver signal. Invalid or missing signals will cause a feedback fault when the axis is enabled. An analog encoder is used with the -MXU or -MXR option (refer to Section for more information). Table 2-6: Encoder Specifications Specification Encoder Frequency x4 Quadrature Decoding Value 10 MHz maximum (25 nsec minimum edge separation) 40 million counts/sec +5V 10K 10K 10K 10K +3.3V PIN-14 PIN-2 PIN-15 PIN ENCODER FAULT DETECTION DS26LV V PIN-16 PIN-4 MRK+ COS+ COS- SIN+ SIN- MRK- 180 DS26LV32 Figure 2-3: Line Driver Encoder Interface 28 Chapter 2

29 Ensemble LAB Hardware Manual Installation and Configuration Analog Encoder Interface If the -MXU or -MXR option has been purchased, the primary encoder channel will accept an analog encoder input signal. The multiplication (interpolation) factor is determined by the EncoderMultiplicationFactor axis parameter. Table 2-7: Analog Encoder Specifications Specification MXU MXR Input Frequency (max) 200 khz 200 khz Input Amplitude 0.6 to 2.25 Vpk-Vpk 0.6 to 2.25 Vpk-Vpk Interpolation Factor (software selectable) 8,192 65,536 MXR Interpolation Latency N/A ~ 3.25 µsec (analog input to quadrature output) The encoder interface pin assignment is indicated in Section The gain, offset, and phase balance of the analog Sine and Cosine encoder input signals are controlled by the EncoderCosineGain, EncoderCosineOffset, EncoderPhase, EncoderSineGain, EncoderSineOffset axis parameters. Encoder signals should be adjusted for optimum performance using the Feedback Tuning tab of the Ensemble Digital Scope utility. It will automatically adjust the encoder parameters for optimum performance. See the Ensemble Help File for more information. SIN LINEAR MOTOR Forcer Wires Positive MOVE (Clockwise) SIN-N Magnet Track Forcer COS 1Vpk-pk COS-N ROTARY MOTOR MRK Motor Shaft MRK-N CW Rotation (Positive Direction) Motor Mounting Flange (Front View) Positive MOVE (Clockwise) Figure 2-4: Analog Encoder Phasing Reference Diagram Chapter 2 29

30 Installation and Configuration Ensemble LAB Hardware Manual PIN K 33PF 10PF 1K 220PF 4.7K - SIN PIN K + AD K 33PF +2.4V REF + 10UF 6.3V.1 A A PIN K 33PF 10PF 1K 220PF 4.7K - COS PIN K + AD K 33PF +2.4V REF + 10UF 6.3V.1 A A PIN-16 1K 82PF 8.06K 1K 1K - - MRK PIN-4 1K + AD PF + MAX V REF 1K 82PF 1M 10PF 33 1K.1.1 A A Figure 2-5: Analog Encoder Interface 30 Chapter 2

31 Ensemble LAB Hardware Manual Installation and Configuration Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-6 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors). To verify, move the motor by hand in the CW (positive) direction while observing the position of the encoder in the diagnostics display (see Figure 2-7). The Motor Phasing Calculator in the Configuration Manager can be used to determine proper encoder polarity. For dual loop systems, the velocity feedback encoder is displayed in the diagnostic display (Figure 2-7) SIN LINEAR MOTOR Forcer Wires Positive MOVE (Clockwise) SIN-N Magnet Track Forcer COS 1Vpk-pk COS-N ROTARY MOTOR MRK MRK-N Motor Shaft CW Rotation (Positive Direction) Motor Mounting Flange (Front View) Positive MOVE (Clockwise) Figure 2-6: Encoder Phasing Reference Diagram (Standard) N O T E : Encoder manufacturers may refer to the encoder signals as A, B, and Z. The proper phase relationship between signals is shown in Figure Chapter 2 31

32 Installation and Configuration Ensemble LAB Hardware Manual Figure 2-7: Position Feedback in the Diagnostic Display 32 Chapter 2

33 Ensemble LAB Hardware Manual Installation and Configuration Hall-Effect Interface The Hall-effect switch inputs are recommended for AC brushless motor commutation but not absolutely required. The Hall-effect inputs accept 5-24 VDC level signals. Table 2-8: Hall-Effect Feedback Interface Pin Assignment Pin# Description In/Out/Bi 8 HALL A Input 9 HALL C Input 21 HALL B Input +5V +3.3V 10K 10K 10K PIN-8 PIN-21 PIN-9 HALLA HALLB HALLC 10K 10K 10K LVC245 Figure 2-8: Hall-Effect Inputs Chapter 2 33

34 Installation and Configuration Ensemble LAB Hardware Manual Thermistor Interface The thermistor input is used to detect an over temperature condition in a motor using a positive temperature coefficient sensor. As the temperature of the sensor increases, so does the resistance. Under normal operating conditions, the resistance of the thermistor is low (i.e., 100 ohms) which will result in a low input signal. If the increasing temperature causes the thermistor s resistance to increase, the signal will be seen as a logic high, triggering an over temperature fault. Table 2-9: Thermistor Interface Pin Assignment Pin# Description In/Out/Bi 20 Motor Thermistor Input +5V +3.3V 1K PIN-20 THERM1 10K.01 74LVC245 Figure 2-9: Thermistor Interface Inputs 34 Chapter 2

35 Ensemble LAB Hardware Manual Installation and Configuration End of Travel Limit Input Interface End of Travel (EOT) limits are required to define the end of the physical travel on linear axes. Positive or clockwise motion is stopped by the clockwise (CW) end of travel limit input. Negative or counterclockwise motion is stopped by the counterclockwise (CCW) end of travel limit input. The Home Limit switch can be parameter configured for use during the home cycle, however, the CW or CCW EOT limit is typically used instead. All of the end-of-travel limit inputs accept 5-24 VDC level signals. Limit directions are relative to the encoder polarity in the diagnostics display (refer to Figure 2-12). The active state of the EOT limits is software selectable (by the EndOfTravelLimitSetup axis parameter) V Limit Com 17 6 Normally closed shown (typical). CW 19 CCW Figure 2-10: End of Travel Limit Input Connections Table 2-10: End of Travel Interface Pin Assignment Pin# Description In/Out/Bi 7 Negative (CCW) hardware limit Input 17 Encoder/Limits +5 V Output 19 Positive (CW) hardware limit Input +5V +3.3V 10K 10K PIN-7 PIN-19 CCW CW 10K 10K LVC245 Figure 2-11: End of Travel Interface Inputs Chapter 2 35

36 Installation and Configuration Ensemble LAB Hardware Manual End of Travel Limit Phasing If the EOT limits are reversed, you will be able to move further into a limit but be unable to move out. To correct this, swap the connections to the CW and CCW inputs at the motor feedback connector. The logic level of the EOT limit inputs may be viewed in the diagnostic display. Figure 2-12: Limit Input Diagnostic Display 36 Chapter 2

37 Ensemble LAB Hardware Manual Installation and Configuration Motor Output Interface The Ensemble LAB is capable of driving three motor types: Brushless Motors: refer to Section DC Brush Motors: refer to Section Stepper Motors: refer to Section Table 2-11: Motor Output Connections Pin# Description In/Out/Bi 10 Motor Ground MTR ØA (Motor Phase A) Output 12 MTR ØB (Motor Phase B) Output 13 MTR ØC (Motor Phase C) Output 22 Motor Ground MTR ØA (Motor Phase A) Output 24 MTR ØB (Motor Phase B) Output 25 MTR ØC (Motor Phase C) Output Chapter 2 37

38 Installation and Configuration Ensemble LAB Hardware Manual Brushless Motor Connections The configuration shown in Figure 2-13 is an example of a typical brushless motor connection. To Backshell Motor Frame AC Brushless Motor [Pins 10, 22] ØA [Pins 11, 23] ØB [Pins 12, 24] ØC [Pins 13, 25] Figure 2-13: Brushless Motor Configuration N O T E : Brushless motors are commutated electronically by the controller. The use of Hall effect devices for commutation is recommended. The controller requires that the Back-EMF of each motor phase be aligned with the corresponding Hall-effect signal. To ensure proper alignment, motor, Hall, and encoder connections should be verified using one of the following methods: powered, through the use of a test program; or unpowered using an oscilloscope. Both methods will identify the A, B, and C Hall/motor lead sets and indicate the correct connections to the controller. N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. 38 Chapter 2

39 Ensemble LAB Hardware Manual Installation and Configuration Powered Motor Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor, Hall, and encoder phasing. Feedback Monitoring The state of the encoder and Hall-effect device signals can be observed in the Motion Composer. A 0 for the given Hall input indicates zero voltage or logic low, where a 1 indicates 5V or logic high. Figure 2-14: Encoder and Hall Signal Diagnostics Chapter 2 39

40 Installation and Configuration Ensemble LAB Hardware Manual Unpowered Motor and Feedback Phasing Disconnect the motor from the controller and connect the motor in the test configuration shown in Figure This method will require a two-channel oscilloscope, a 5V power supply, and six resistors (10,000 ohm, 1/4 watt). All measurements should be made with the probe common of each channel of the oscilloscope connected to a neutral reference test point (TP4, shown in Figure 2-15). Wave forms are shown while moving the motor in the positive direction. CHANNEL 1 CHANNEL 2 TP1 TP2 TP3 TP4 Power Supply 10K OHM TYP "Wye" Configuration Motor Lead 1 = ØB Motor Lead 2 = ØC Motor Lead 3 = ØA COM +5V TP5 TP6 TP7 10K OHM TYP COM +5V Hall 1 Hall 2 Hall 3 Figure 2-15: Motor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined, the motor can now be connected to an Aerotech system. Connect motor lead A to motor connector A, motor lead B to motor connector B, and motor lead C to motor connector C. Hall leads should also be connected to their respective feedback connector pins (Hall A lead to the Hall A feedback pin, Hall B to Hall B, and Hall C to Hall C). The motor is correctly phased when the Hall states align with the Back EMF as shown in (Figure 2-16). Use the CommutationOffset parameter to correct for Hall signal misalignment Hall A Hall B +5V 0V Hall C ØC ØB ØA ØC ØB +V Motor Back EMF 0V -V Figure 2-16: Brushless Motor Phasing Goal 40 Chapter 2

41 Ensemble LAB Hardware Manual Installation and Configuration DC Brush Motor Connections The configuration shown in Figure 2-17 is an example of a typical DC brush motor connection. To Backshell Motor Frame RTN [Pins 10, 22] ØA [Pins 11, 23] + DC Brush - Motor Figure 2-17: DC Brush Motor Configuration DC Brush Motor Phasing A properly phased motor means that the positive motor lead should be connected to the ØA motor terminal and the negative motor lead should be connected to the ØC motor terminal. To determine if the motor is properly phased, connect a voltmeter to the motor leads of an un-powered motor: 1. Connect the positive lead of the voltmeter to the one of the motor terminals. 2. Connect the negative lead of the voltmeter to the other motor terminal. 3. Rotate the motor clockwise by hand. ROTARY MOTOR Motor Mounting Flange (Front View) Motor Shaft POSITIVE MOTION Figure 2-18: Clockwise Motor Rotation 4. If the voltmeter indicates a negative value, swap the motor leads and rotate the motor (CW, by hand) again. When the voltmeter indicates a positive value, the motor leads have been identified. 5. Connect the motor lead from the voltmeter to the ØA motor terminal on the Ensemble LAB. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the Ensemble LAB. N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. Chapter 2 41

42 Installation and Configuration Ensemble LAB Hardware Manual Stepper Motor Connections The configuration shown in Figure 2-19 is an example of a typical stepper motor connection. In this case, the effective motor voltage is half of the applied bus voltage. For example, an 80V motor bus supply is needed to get 40V across the motor. To Backshell Motor Frame A A' ØA [Pins 11, 23] ØB [Pins 12, 24] B B' Stepper Motor Note the common connection of A and B phases. Figure 2-19: Stepper Motor Configuration Stepper Motor Phasing A stepper motor can be run with or without an encoder. If an encoder is not being used, phasing is not necessary. With an encoder, test for proper motor phasing by running a positive motion command. If there is a positive scaling factor (determined by the CountsPerUnit parameters) and the motor moves in a clockwise direction, as viewed looking at the motor from the front mounting flange, the motor is phased correctly. If the motor moves in a counterclockwise direction, swap the motor leads and re-run the command. Proper motor phasing is important because the end of travel (EOT) limit inputs are relative to motor rotation. ROTARY MOTOR Motor Mounting Flange (Front View) Motor Shaft POSITIVE MOTION Figure 2-20: Clockwise Motor Rotation N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. N O T E : After the motor has been phased, use the ReverseMotionDirection parameter to change the direction of positive motion. 42 Chapter 2

43 Ensemble LAB Hardware Manual Installation and Configuration 2.4. Emergency Stop Sense Input (TB101) The ESTOP sense input is used to monitor the state of an external safety circuit only. This state is indicated by the software and may be used to facilitate system restart. This ESTOP sense input is not intended to be a complete safety system. W A R N I N G : The user is responsible for assessing operator risk levels and designing the external safety circuits appropriately. The ESTOP input is scaled for an input voltage of 5-24 volts. If the ESTOP bit is enabled in the FaultMask axis parameter, the ESTOP input must be driven to prevent the ESTOP fault condition. +3.3V ESTOP SWITCH + ESTOP+ TB K 2K 24VDC 1UF 1K - ESTOP- TB K PS Figure 2-21: ESTOP Sense Input (TB102) Table 2-12: TB101 ESTOP Pin Assignment Pin Description In/Out/Bi Connector Port 1 Emergency Stop Opto-Isolated Input + Input 2 Emergency Stop Opto-Isolated Input - Input N OT E : Connecting the ESTOP input to a relay or other noise producing device requires the use of noise suppression devices such as those in Table These devices are applied across the switched coil to suppress transient voltages. Table 2-13: Electrical Noise Suppression Devices Device Aerotech P/N Third Party P/N RC (.1uf / 200 ohm) Network EIC240 Electrocube RG Varistor EID160 Littelfuse V250LA40A Chapter 2 43

44 Installation and Configuration Ensemble LAB Hardware Manual 2.5. Auxiliary I/O Connector (J106) The Auxiliary I/O connector provides 1 analog and 6 digital inputs, 1 analog and 4 digital outputs, and a secondary RS-422 line driver encoder input. Table 2-14: Auxiliary I/O Interface Pin Assignment (J106) Pin# Description In/Out/Bi Connector 1 Auxiliary Sine+ Bidirectional 2 Auxiliary Sine- Bidirectional 3 High-Speed Input 4 + user interrupt Input 4 High-Speed Input 4 - user interrupt Input 5 High-Speed Input 5 + user interrupt Input 6 High-Speed Input 5 - user interrupt Input 7 Opto-Isolated Output 0 Output 8 Opto-Isolated Output 1 Output 9 Opto-Isolated Output 2 Output 10 Auxiliary Cosine+ Bidirectional 11 Auxiliary Cosine- Bidirectional Volt (500 ma max) Output 13 Analog Input 0 + (Differential) Input 14 Analog Input 0- (Differential) Input 15 Output Common - 16 Opto-Isolated Output 3 Output 17 Opto-Isolated Input 0 / CCW EOT Input (1) Input 18 Opto-Isolated Input 1 / CW EOT Input (1) Input 19 Auxiliary Marker- / PSO output (2) Bidirectional 20 Auxiliary Marker+ / PSO output (2) Bidirectional 21 Common (+5 Volt User Supply, 500 ma max) - 22 Analog Output 0 Output 23 Analog Common - 24 Input Common - 25 Opto-Isolated Input 2 / Home Input (1) Input 26 Opto-Isolated Input 3 Input (1) Software configured option (2) For PSO, see Section Mating Connector Aerotech P/N Third Party P/N Connector ECK01259 Kycon K86-AA-26P Backshell ECK01022 Amphenol NOTE: These items are provided as a set under the Aerotech P/N: MCK-26HDD Chapter 2

45 Ensemble LAB Hardware Manual Installation and Configuration Auxiliary Encoder Channel The auxiliary encoder interface accepts an RS-422 differential quadrature line driver signal. Invalid or missing signals will cause a feedback fault when the axis is enabled. This encoder channel can be used as an input for master/slave operation (handwheel) or for dual feedback systems. The auxiliary encoder interface does not support analog encoders and cannot be used as an input for the -MXU or -MXR option. The auxiliary encoder channel can also be used to echo the standard encoder signals or as the PSO output. Configuring the PSO hardware will automatically configure this encoder channel as an output (refer to Section ) and will remove the 180 ohm terminator resistors. Table 2-15: Auxiliary Encoder Specifications Specification Encoder Frequency x4 Quadrature Decoding MXR Interpolation Latency Value 10 MHz maximum (25 nsec minimum edge separation) 40 million counts/sec ~ 3.25 µsec (analog input to quadrature output) N O T E : Use the EncoderDivider parameter to configure the bi-directional encoder interface on the auxiliary I/O connector. The EncoderDivider parameter converts the auxiliary encoder interface to an output and defines a divisor for the encoder echo. Refer to the Ensemble Help file for more information. N O T E : You cannot echo the standard encoder signals on the with the -MXU option. Table 2-16: Auxiliary Encoder Channel Pin Assignment (J106) Pin# Description In/Out/Bi 1 Auxiliary Sine+ Bidirectional 2 Auxiliary Sine- Bidirectional 10 Auxiliary Cosine+ Bidirectional 11 Auxiliary Cosine- Bidirectional Volt (500 ma max) Output 19 Auxiliary Marker- / PSO output (2) Bidirectional 20 Auxiliary Marker+ / PSO output (2) Bidirectional 21 Common (+5 Volt User Supply, 500 ma max) - (2) For PSO, see Section Chapter 2 45

46 Installation and Configuration Ensemble LAB Hardware Manual AUX SIN- J V 180 S D IN AUX SIN+ J106-1 AUX COS- J ADG801 ENCODER FAULT DETECTION +5V ADM S D IN AUX COS+ J ADG801 ADM1485 AUX MRK- J V 1K +5V S D 180 IN AUX MRK+ J ADG801 1K ADM1485 Figure 2-22: Auxiliary Encoder Channel 46 Chapter 2

47 Ensemble LAB Hardware Manual Installation and Configuration Position Synchronized Output (PSO) The PSO can be programmed to generate an output synchronized to the feedback position and is typically used to fire a laser or sequence an external device. Trigger signals may be derived from a feedback channel or a software trigger. The position synchronized output pulse is generated using high-speed hardware, allowing minimal latency between the trigger condition and the output. The PSO output is available on the dual-function AUX Marker/PSO signal lines. The auxiliary marker must be configured as an output using the PSOOUTPUT CONTROL command. Refer to the Help File for more information. An RS-422 line receiver or opto-isolator is recommended, especially when using long cable lengths in noisy environments or when high frequency pulse transmission is required. It is best to locate the line receiver or opto-isolator close to the receiving electronics. Table 2-17: PSO Specifications Specification Value Maximum Input Tracking Rate (1) Single-Axis Tracking 33.3 MHz Maximum Quadrature Encoder Output Frequency Maximum PSO Output (Fire) Frequency (2) Standard Feedback -MXR Feedback 40 MHz 16 MHz 12.5 MHz Firing Latency(3) Single-Axis Tracking 80 nsec 1. Signals in excess of this rate will cause a loss of PSO accuracy. 2. The optocoupler that you use on the output might have an effect on this rate. 3. MXR encoder multiplier options have an additional latency of ~3.25 microseconds between the measurement position and the update of the PSO hardware. Table 2-18: PSO Pin Assignment Pin# Description In/Out/Bi 19 Auxiliary Marker- / PSO output Bidirectional 20 Auxiliary Marker+ / PSO output Bidirectional 23 Analog Common - Chapter 2 47