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Aerotech Automation1 XR3 Series, Hardware Manual

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Aerotech Automation1 XR3 Series Hardware Manual Download Page 15

Installation Overview

This image shows the order in which to make connections and settings that are typical to the XR3. If a
custom interconnect drawing was supplied with your system, that drawing is on your Storage Device and
shows as a line item on your Sales Order in the Integration section.

1

Connect the power source to the AC Power Input.

Section 2.1.1.

2

Connect a PC HyperWire port to the HyperWire In port.

Section 2.11.

3

Connect the motors to the Motor Power inputs.

Section 2.2.

4

Connect the motors to the Motor Feedback inputs.

Section 2.3.

Figure 1:

Installation Connection Overview 

XR3 Hardware Manual

Installation Overview

www.aerotech.com

15

Summary of Contents for Automation1 XR3 Series

Page 1: ...Revision 2 01 Automation1 XR3 Drive Rack HARDWARE MANUAL...

Page 2: ...spare or replacement parts To get help immediately contact a service office or your sales representative Include your customer order number in your email or have it available before you call This man...

Page 3: ...2 2 2 DC Brush Motor Connections 38 2 2 2 1 DC Brush Motor Phasing 38 2 2 3 Stepper Motor Connections 39 2 2 3 1 Stepper Motor Phasing 39 2 3 Feedback Connector 40 2 3 1 Primary Encoder Inputs 41 2 3...

Page 4: ...83 2 11 HyperWire Interface 84 2 12 Cooling Options C0 C1 C2 Option 85 2 13 PC Configuration and Operation Information 88 Chapter 3 Maintenance 89 3 1 Preventative Maintenance 90 3 2 Fuse Specificati...

Page 5: ...ions 51 Figure 2 21 End of Travel and Home Limit Input Schematic Feedback Connector 51 Figure 2 22 End of Travel and Home Limit Input Diagnostic Display 52 Figure 2 23 Brake Output Connections Feedbac...

Page 6: ...and Direction of Air Flow 85 Figure 2 48 C1 Model Showing Perforated Covers for External Fans 86 Figure 2 49 C2 1U Fan Location and Air Flow 87 Figure 3 1 Drive Interface Board 91 Figure B 1 Voltage S...

Page 7: ...edback Connector 49 Table 2 16 End of Travel and Home Limit Pins on the Feedback Connector 50 Table 2 17 Brake Output Pins on the Feedback Connector 53 Table 2 18 Brake Output Specifications 53 Table...

Page 8: ...Mating Connector Part Numbers for the STO Connector 78 Table 2 50 STO Electrical Specifications 79 Table 2 51 STO Standards 80 Table 2 52 STO Standards Data 80 Table 2 53 STO Signal Delay 82 Table 2...

Page 9: ...g Standard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 61010 1 2010 Safety Requirements for Electrical Equipment EN 55011 1998 EN 55022 Conduc...

Page 10: ...This page intentionally left blank EU Declaration of Conformity XR3 Hardware Manual 10 www aerotech com...

Page 11: ...EN 61010 1 2010 UL 61010 1 2012 Approval Safety Components STO Approving Agency TUV SUD Certificate Z10 068995 0030 Rev 00 Standards IEC 61508 1 2010 up to SIL 3 Visit https www tuev sued de product t...

Page 12: ...This page intentionally left blank Agency Approvals XR3 Hardware Manual 12 www aerotech com...

Page 13: ...the product could be decreased DANGER To decrease the risk of electrical shock injury death and damage to the equipment obey the precautions that follow 1 Before you do maintenance to the equipment d...

Page 14: ...lide the product in and out of its enclosure WARNING To prevent damage to the equipment and decrease the risk of electrical shock and injury obey the precautions that follow 1 Make sure that all syste...

Page 15: ...shows as a line item on your Sales Order in the Integration section 1 Connect the power source to the AC Power Input Section 2 1 1 2 Connect a PC HyperWire port to the HyperWire In port Section 2 11...

Page 16: ...This page intentionally left blank Installation Overview XR3 Hardware Manual 16 www aerotech com...

Page 17: ...l 5 V provided on I O connectors Section 2 8 I O l Brake Output Section 2 3 l Three PSO External Sync inputs Section 2 4 l Three TTL or isolated PSO outputs Section 2 4 2 l One Data Acquisition Input...

Page 18: ...Voltage 2 SB4 Axis 1 4 Bus Voltage 1 Axis 5 6 Bus Voltage 2 SB5 Axis 1 5 Bus Voltage 1 Axis 6 Bus Voltage 2 Axis Control Board Section 2 3 1 3 Axis 1 Required Axis 2 6 Optional CT0 No control board 0...

Page 19: ...One axis PSO firing includes One axis Part Speed PSO PSO2 Two axis PSO firing includes Two axis Part Speed PSO PSO3 Three axis PSO firing includes Three axis Part Speed PSO PSO5 Two axis Part Speed PS...

Page 20: ...The block diagram that follows shows a summary of the connector signals Figure 1 1 Functional Diagram Chapter 1 Introduction XR3 Hardware Manual 20 www aerotech com...

Page 21: ...imum VL2 230 VAC 5 A Maximum VL3 100 VAC 10 A Maximum VL4 200 VAC 5 A Maximum AC Power Input AC input Switch Selectable AC Hi AC Lo Earth Ground l 100 VAC 90 112 VAC 50 60 Hz l 115 VAC 103 127 VAC 50...

Page 22: ...fication depends on the motor supply voltage the motor speed and motor resistance Contact an Aerotech sales engineer for more information 2 This specification assumes that an AC or DC motor type with...

Page 23: ...ut Power Rotary Motors Power Output W Torque N m Angular velocity rad sec Linear Motors Power Output W Force N Linear velocity m sec Rotary or Linear Motors Power Output W Bemf V I rms 3 Power Loss 3...

Page 24: ...Specifications XR3 Customer Supplied Enclosure IP54 Compliant Weight 25 kg Dimensions Refer to Section 1 2 2 Dimensions Minimum Clearance Airflow 25 mm Connectors 100 mm Operating Temperature Refer t...

Page 25: ...1 2 2 Dimensions Figure 1 2 Dimensions with Chassis Slides XR3 Hardware Manual 1 2 2 Dimensions www aerotech com 25...

Page 26: ...Figure 1 3 Dimensions without Chassis Slides 1 2 2 Dimensions XR3 Hardware Manual 26 www aerotech com...

Page 27: ...emperatures that are less than 31 C and decreases linearly to 50 relative humidity at 40 C Operating Altitude 0 m to 2 000 m 0 ft to 6 562 ft above sea level If you must operate this product above 2 0...

Page 28: ...Software Version column drives that show a specific version number are not supported after that version Table 1 8 Drive and Software Compatibility Drive Type Software First Software Version Last Softw...

Page 29: ...to the system Save this information for future reference Additional information about the system is provided on the Serial and Power labels that are placed on the XR3 chassis The system serial number...

Page 30: ...ring operating above 100 V AC and motor wiring Low voltage wiring should not be bundled with AC and motor wiring to minimize signal disturbances due to EMI interference and coupling IMPORTANT The mach...

Page 31: ...urrent requirements for the XR3 drive chassis are listed in Table 2 1 WARNING The AC power cord is the Mains disconnect Table 2 1 Main AC Power Input Voltages and Current Requirements AC Input Voltage...

Page 32: ...cations 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 th...

Page 33: ...acitance Energy J VB7 with split bus 125 VAC 8000 uF 200 VDC 35 VB7 without split bus 125 VAC 16000 uF 200 VDC 70 VB8 with split bus 240 VAC 2300 uF 400 VDC 52 VB8 without split bus 240 VAC 4600 uf 40...

Page 34: ...power D style motor power connectors Axis 1 6 are located on the rear panel The pin assignments for these connectors are shown in Table 2 4 Table 2 4 Motor Power Output Connector Pinout Pin Descriptio...

Page 35: ...erified 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 c...

Page 36: ...signals in the Diagnostics section of the Status Utility Table 2 6 Hall Signal Diagnostics Hall Signal Status Definition 0 V or logic low ON 5 V or logic high Figure 2 3 Positive Motor Direction Figur...

Page 37: ...tor 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...

Page 38: ...minals 2 Connect the negative lead of the voltmeter to the other motor terminal 3 Move or rotate the motor in the positive or clockwise CW direction by hand Figure 2 8 Positive Motor Direction 4 If th...

Page 39: ...ve to motor rotation it is important to phase the motor Run a positive motion command The motor is phased correctly if there is a positive scaling factor determined by the CountsPerUnit parameters and...

Page 40: ...10 Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sensor C brushless motors only Input 12 Clockwise End of Travel Limit Input 13 Brake Output Output 14 Encoder Cosine Input 15 Encode...

Page 41: ...solute encoders Square Wave or Absolute encoders CT2 Sine Wave high performance Square Wave or Absolute encoders Square Wave or Absolute encoders CT4 Sine Wave high performance Square Wave or Absolute...

Page 42: ...nal connection Use twisted pair wiring for the highest performance and noise immunity Table 2 11 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum e...

Page 43: ...ing for the highest performance and noise immunity You cannot echo an absolute encoder signal Refer to Figure 2 12 for the serial data stream interface Refer to the Help file for information on how to...

Page 44: ...UT High Speed Output connector or used internally by the PSO Refer to the EncoderDivider and PrimaryEmulatedQuadratureDivider A3200 EmulatedQuadratureDivider parameters and the encoder output function...

Page 45: ...Figure 2 14 Sine Wave Encoder Schematic Feedback Connector XR3 Hardware Manual 2 3 1 3 Sine Wave Encoder CT1 CT2 CT4 Option www aerotech com 45...

Page 46: ...n while observing the position of the encoder in the diagnostics display see Figure 2 16 For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 16 Figure 2...

Page 47: ...evice phasing Table 2 13 Hall Effect Feedback Pins on the Feedback Connector Pin Description In Out Bi 3 5V Power 1 N A 5 Hall Effect Sensor B brushless motors only Input 10 Hall Effect Sensor A brush...

Page 48: ...re causes the thermistor s resistance to increase the sensor will trigger an over temperature fault The thermistor is connected between Pin 2 and Signal Common The nominal trip value of the sensor is...

Page 49: ...rameter configurable and the controller should be configured to disable the axis when the fault level is active The nominal trip voltage of the encoder fault input is 2 5 V Table 2 15 Encoder Fault In...

Page 50: ...e diagnostics display refer to Figure 2 22 Table 2 16 End of Travel and Home Limit Pins on the Feedback Connector Pin Description In Out Bi 12 Clockwise End of Travel Limit Input 16 5V Power N A 20 Si...

Page 51: ...20 End of Travel and Home Limit Input Connections Figure 2 21 End of Travel and Home Limit Input Schematic Feedback Connector XR3 Hardware Manual 2 3 5 End of Travel and Home Limit Inputs www aerotec...

Page 52: ...e CW and CCW inputs at the Feedback connector or swap the CW and CCW limit functionality in the software using the EndOfTravelLimitSetup parameter View the logic level of the EOT limit inputs in the D...

Page 53: ...the brake output Refer to the Help file for more information Table 2 17 Brake Output Pins on the Feedback Connector Pin Description In Out Bi 13 Brake Output Output 25 Brake Output Output Table 2 18 B...

Page 54: ...V TTL A3200 PSO Output 1 Output 11 Ground N A 12 Ground N A 13 PSO Output 1 5 V TTL A3200 PSO Output 0 Output 14 Data Acquisition Input 15 PSO Output 3 Isolated A3200 PSO Output 2 Output 16 PSO Outpu...

Page 55: ...ut Specification Specification Value Outputs 5 24 V 250 mA Table 2 22 Isolated Output Pins on the PSO Connector Pin Description In Out Bi 15 PSO Output 3 Isolated A3200 PSO Output 2 Output 16 PSO Outp...

Page 56: ...tputs Specification Specification Value Outputs TTL 5 V 50 mA Table 2 24 TTL Output Pins on the PSO Connector Pin Description In Out Bi 8 PSO Output 3 5 V TTL A3200 PSO Output 2 Output 9 Ground N A 10...

Page 57: ...the synchronization signal occurs Table 2 25 External PSO Sync Input Pins on the PSO Connector Pin Description In Out Bi 2 External PSO Sync 1 A3200 External PSO Sync 0 Input 3 External PSO Sync 1 A32...

Page 58: ...can be used with sourcing or sinking drivers Table 2 26 Data Acquisition Input Pins on the PSO Connector Pin Description In Out Bi 1 Data Acquisition Input 14 Data Acquisition Input Table 2 27 Data Ac...

Page 59: ...put 0 Output 4 Axis 2 High Speed Output 1 Output 5 Axis 2 High Speed Output 1 Output 7 Axis 3 High Speed Output 0 Output 6 Axis 3 High Speed Output 0 Output 18 Axis 3 High Speed Output 1 Output 17 Axi...

Page 60: ...n be used to transmit clock and direction signals for driving an external device In this configuration High Speed Output 0 transmits the direction signal and High Speed Output 1 transmits the clock si...

Page 61: ...urrent sinking output that has diode suppression refer to Figure 2 32 The digital outputs are not designed for high voltage isolation applications and they should only be used with ground referenced c...

Page 62: ...d N A 14 Port 2 Digital Output Common N A 15 Port 2 Digital Output 8 Output 16 Port 2 Digital Output 9 Output 17 Port 2 Digital Output 10 Output 18 Port 2 Digital Output 11 Output 19 Port 3 Digital Ou...

Page 63: ...Figure 2 30 Digital Output Schematic XR3 Hardware Manual 2 6 DOUT Connector Digital Outputs www aerotech com 63...

Page 64: ...Figure 2 31 Digital Outputs Connected in Current Sourcing Mode Figure 2 32 Outputs Connected in Current Sinking Mode 2 6 DOUT Connector Digital Outputs XR3 Hardware Manual 64 www aerotech com...

Page 65: ...ital Input 14 Input 6 Port 3 Digital Input 13 Input 7 Port 3 Digital Input 12 Input 8 Port 3 Digital Input Common N A 9 Port 2 Digital Input 11 Input 10 Port 2 Digital Input 10 Input 11 Port 2 Digital...

Page 66: ...Figure 2 33 Digital Input Schematic 2 7 DIN Connector Digital Inputs XR3 Hardware Manual 66 www aerotech com...

Page 67: ...e 2 34 Digital Inputs Connected to Current Sinking NPN Devices Figure 2 35 Digital Inputs Connected to Current Sourcing PNP Devices XR3 Hardware Manual 2 7 DIN Connector Digital Inputs www aerotech co...

Page 68: ...iveEncoderOutputConfigureInput function A3200 EncoderDivider parameter to configure the Sine and Cosine connector pins as RS 422 outputs You can only echo incremental square wave primary encoder input...

Page 69: ...l connection Use twisted pair wiring for the highest performance and noise immunity Table 2 39 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum edg...

Page 70: ...ormance and noise immunity You cannot use an absolute encoder with incremental signals on the Aux Encoder Connector Refer to Figure 2 37 for the serial data stream interface Refer to the Help file for...

Page 71: ...system noise use it only if necessary You can use a sine wave encoder with the CT4 multiplier option as an input to the PSO The CT4 option generates emulated quadrature signals For the highest perfor...

Page 72: ...Figure 2 39 Sine Wave Encoder Schematic Aux Encoder Connector 2 8 3 Sine Wave Encoder CT4 Option XR3 Hardware Manual 72 www aerotech com...

Page 73: ...O Connector Pinout Pin Description In Out Bi Connector 1 Analog Input 0 Input 2 Analog Input 0 Input 3 Ground N A 4 Analog Output 0 Output 5 Ground N A 6 Analog Input 1 Input 7 Analog Input 1 Input 8...

Page 74: ...e 2 43 Analog Output Specifications Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Table 2 44 Analog Output Pins on the Analog I O Connector Pin Descriptio...

Page 75: ...nalog Input Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Input Impedance 1 M 1 Signals outside of this range may damage the input Table 2 46 Analog Input Pins on the...

Page 76: ...e 2 43 shows you how to connect a joystick to the Analog I O connector Table 2 47 Joystick Interface Pins on the Analog I O Connectors Pin Description In Out Bi 1 Analog Input 0 Input 2 Analog Input 0...

Page 77: ...o the controller that the joystick is present Joystick control will not activate unless the joystick is in the center location Third party devices can be used provided they produce a symmetric output...

Page 78: ...ility of the user of the XR3 WARNING STO wires must be insulated to prevent short circuits between connector pins The primary concern is a short circuit between STO 1 and STO 2 wire strands or solder...

Page 79: ...re 2 44 shows one safety device connected to multiple XR3s in parallel WARNING The XR3 does not check for short circuits on the external STO wiring If this is not done by the external safety device sh...

Page 80: ...08 1 2010 SIL 3 EN IEC 61508 2 2010 SIL 3 EN ISO 13849 1 2015 Category 4 PL e EN IEC 62061 2005 with Amendments SIL 3 Table 2 52 STO Standards Data Standard Value EN ISO 13849 1 2015 MTTFD 1000 years...

Page 81: ...the axis as soon as the deceleration ramp is complete This is typically configured to occur before the STO channel turns off the power amplifier transistors The software controlled stop functionality...

Page 82: ...tch Refer to Section 2 10 4 2 10 3 STO Startup Validation Testing Verify the state of the STO 1 and STO 2 channels by manually activating the external STO hardware Each STO channel must be tested sepa...

Page 83: ...listed SIL level the STO circuit must be activated power removed from both inputs according to the interval specified in Table 2 52 Table 2 55 STO Timing Time Description Value T1 STO Delay Time STO...

Page 84: ...r to re establish communication WARNING Do not connect or disconnect HyperWire cables while you are loading firmware or damage to the drives may occur Table 2 56 HyperWire Card Part Number Part Number...

Page 85: ...r fan on all models The fan pulls air into the chassis Refer to Figure 2 46 Figure 2 46 Location of the Rear Fan and Air Flow Built In Cooling C0 Built in fans pull cooling air from the left side thro...

Page 86: ...de forced air cooling to the XR3 drive chassis Provide cooling to the XR3 by directing the airflow through the perforated covers of the XR3 chassis Refer to Figure 2 48 Figure 2 48 C1 Model Showing Pe...

Page 87: ...factory The tray houses two fans that will direct airflow through the XR3 drive chassis from the bottom to the top Refer to Figure 2 49 The dimensions of the XR3 with the optional fan trays are shown...

Page 88: ...n Information For more information about hardware requirements PC configuration programming system operation and utilities refer to the Help file 2 13 PC Configuration and Operation Information XR3 Ha...

Page 89: ...is the danger of electric shock 3 All tests must be done by an approved service technician Voltages inside the con troller and at the input and output power connections can kill you Table 3 1 LED Desc...

Page 90: ...nections to make sure they are correct Make sure that all connections are correctly attached and not loose Replace cables that are worn Replace all broken connectors Cleaning DANGER Before you clean t...

Page 91: ...placement Part Numbers Bus Fuse Description Aerotech P N Manufacturer P N Bus 1 F1 VB1 to VB2 2 A SLO BLO 3AG EIF00102 Littelfuse 313002 F1 VB3 to VB5 3 A SLO BLO 3AG EIF00103 Littelfuse 313003 F1 VB7...

Page 92: ...This page intentionally left blank 3 2 Fuse Specifications XR3 Hardware Manual 92 www aerotech com...

Page 93: ...ization RMA number must accompany any returned product s The RMA number may be obtained by calling an Aerotech service center or by submitting the appropriate request available on our website www aero...

Page 94: ...ial rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply On sit...

Page 95: ...mer derived bus voltages This voltage selector function should not be changed when using off line supplies Damage to the unit may result if this function is used improperly If the user changes the vol...

Page 96: ...Beta manual revision should contact Aerotech for more information if you need to change voltage settings Table B 1 AC Voltage Selector Switch Settings S1 S2 S3 S4 100 VAC A B A B 115 VAC A A A A 200 V...

Page 97: ...laration of Conformity l Table 1 2 l Figure 1 1 l Section 1 2 Mechanical Specifications l Section 2 1 4 Internal Shunt Option SI l Section 2 3 1 Primary Encoder Inputs l Section 2 5 HSOUT Connector Hi...

Page 98: ...This page intentionally left blank Appendix C Revision History XR3 Hardware Manual 98 www aerotech com...

Page 99: ...on the Analog I O Connector 75 Analog Input Specifications Analog I O Connectors 75 Analog Inputs Analog I O Connectors 75 Analog Inputs Schematic 75 Analog Output Pins on the Analog I O Connector 74...

Page 100: ...tic DOUT Connector 63 Digital Output Specifications DOUT Connector 61 Digital Outputs Connected in Current Sinking Mode DOUT Connector 64 Digital Outputs Connected in Current Sourcing Mode DOUT Connec...

Page 101: ...Axis 2 High Speed Outputs HSOUT Connector 60 Digital Input Schematic DIN Connector 66 Digital Inputs Connected to Current Sinking Devices DIN Connector 67 Digital Inputs Connected to Current Sourcing...

Page 102: ...olated Output Current Sinks Schematic PSO 55 Isolated Output Current Sources Schematic PSO 55 Isolated Output Pins on the PSO Connector 55 Isolated Outputs PSO 55 J Joystick Interface Analog I O Conne...

Page 103: ...rface Pins Analog I O Connectors 76 Motor Power Output Connector 34 Primary Encoder Inputs Feedback Connector 41 PSO Connector 54 STO Connector 78 Thermistor Input Pin Feedback Connector 48 TTL Output...

Page 104: ...er Inputs Schematic Aux Encoder Connector 69 Square Wave Encoder Schematic Feedback Connector 42 Square Wave Encoder Specifications Feedback Connector 42 69 Standard Features 17 Stepper Motor Configur...

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