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-IO Expansion Board

Ensemble HLe

3.1. Relay Connector (TB301)

The relay can be used to automatically control a fail-safe brake on a vertical axis. It can also be used as a
general purpose relay. The normally-open relay contacts are accessible through TB301 and the Motor
Feedback connector. The normally-closed relay contact is only accessible through TB301 (see

).

The Motor Feedback connector allows the brake wires to be included in the motor feedback cable and
eliminate the need for a separate brake cable.

The brake output can be software configured; refer to the Ensemble Help file for more information (see topics
for the EnableBrakeControl parameter and the BRAKE command).

When TB301 is used to power the mechanical brake control relay, the solid state brake control relay (TB202)
should not be used.

The user must verify that the application will be within the specifications of the Brake/Relay contacts.

Table 3-3:

Voltage and Current Specifications (TB301)

Relay K1 Contact Ratings

Maximum Switched Voltage

150 VDC, 125 VAC

Maximum Switched Current

1A

Maximum Carrying Current

1A

Maximum Switched Power

30 W (DC), 60 VA (AC)

N O T E :

Do not exceed Maximum Current or Maximum Power specifications.

Table 3-4:

Brake / Mechanical Relay Connector Pinout (TB301)

Pin#

Description

In/Out/Bi

1

Brake Relay Output Normally Closed Contact

Output

2

Brake Relay Output Common Contact

Output

3

Brake Relay Output Normally Open Contact

(1)

Output

(1) For JP3 jumper configuration, refer to

Table 3-5:

Mating Connector Part Numbers for the Relay Connector (TB301)

Description

Aerotech P/N

Phoenix P/N

Wire Size:

AWG [mm

2

]

3-Pin Terminal Block

ECK01449

1881338

0.5 - 0.080 [20-28]

The configuration of JP3 (

) allows either the Brake + or the Brake - output to be switched by the

relay and connected at the Motor Feedback connector or for the brake to be connected at TB301. Refer to

for more information.

Table 3-6:

-IO Expansion Board Brake Jumper Configuration

Jumper

Setting

Description

JP2

1-2

PSO Output Active High, Low Z during reset

2-3

(1)

PSO Output Active Low, High Z during reset

JP3

1-2, 3-4

Switch Brake +

5-6, 7-8

(1)

Switch Brake -

1-3

Relay Only

(1) default

www.aerotech.com

Chapter 3

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Summary of Contents for Ensemble HLe

Page 1: ...Revision 4 09 00 Ensemble HLe Hardware Manual ...

Page 2: ... 967 6870 101 Zeta Drive Pittsburgh PA 15238 2811 www aerotech com United Kingdom Japan Email Support aerotech com Phone 44 0 1256 855055 Fax 44 0 1256 855649 Email Support aerotech com Phone 81 0 50 5830 6814 Fax 81 0 43 306 3773 Germany China Email Support aerotech com Phone 49 0 911 967 9370 Fax 49 0 911 967 93720 Email Support aerotech com Phone 86 21 5508 6731 France Taiwan Email Support aero...

Page 3: ... Motor Connections 33 2 2 3 1 Stepper Motor Phasing 34 2 3 Motor Feedback Connections J207 35 2 3 1 Encoder Interface J207 36 2 3 1 1 RS 422 Line Driver Encoder Standard 37 2 3 1 2 Absolute Encoder Interface J207 38 2 3 1 3 Analog Encoder Interface 39 2 3 1 4 Encoder Phasing 41 2 3 2 Hall Effect Interface J207 43 2 3 3 Thermistor Interface J207 44 2 3 4 Encoder Fault Interface J207 45 2 3 5 End Of...

Page 4: ... 5 User Power TB305 TB306 78 3 6 Opto In Connector Digital Inputs TB305 TB306 79 3 7 Opto Out Connector Digital Outputs TB307 TB308 82 3 8 SSINET J302 J303 86 Chapter 4 RDP Expansion Board 89 Chapter 5 Standard Interconnection Cables 93 5 1 Joystick Interface 94 5 2 Handwheel Interface 97 Chapter 6 Maintenance 99 6 1 Power Board 100 6 2 Control Board 102 6 3 Preventative Maintenance 104 Appendix A...

Page 5: ...4 Figure 2 20 Encoder Fault Interface Input J207 45 Figure 2 21 End of Travel Limit Input Connections 46 Figure 2 22 End of Travel Limit Interface Input J207 47 Figure 2 23 Limit Input Diagnostic Display 48 Figure 2 24 ESTOP Sense Input TB201 50 Figure 2 25 Typical Emergency Stop Circuit 51 Figure 2 26 Auxiliary Encoder Channel J205 54 Figure 2 27 PSO Interface 56 Figure 2 28 Outputs Connected in ...

Page 6: ... Resolver Inductosyn Recommended Wiring 91 Figure 4 3 Resolver Inputs 91 Figure 4 4 Encoder Emulation Outputs 92 Figure 5 1 Single Axis Joystick Interface to Aux I O 94 Figure 5 2 Two Axis Joystick Interface to the Aux I O of two drives 95 Figure 5 3 Two Axis Joystick Interface to the Aux I O and I O Board 95 Figure 5 4 Two Axis Joystick Interface to the I O Board 96 Figure 5 5 Handwheel Interconn...

Page 7: ...18 Brake Output Pins on the Motor Feedback Connector J207 49 Table 2 19 Electrical Noise Suppression Devices 50 Table 2 20 Mating Connector Part Numbers for the ESTOP Connector 50 Table 2 21 Typical ESTOP Relay Ratings 51 Table 2 22 Auxiliary I O Connector Pinout J205 52 Table 2 23 Mating Connector Part Numbers for the Auxiliary I O Connector 52 Table 2 24 Auxiliary Encoder Specifications 53 Table...

Page 8: ...TB305 78 Table 3 19 5 Volt Power Pin on the Opto In Connector TB306 78 Table 3 20 Digital Input Device Specifications 79 Table 3 21 Port 1 Opto In Connector Pinout TB305 79 Table 3 22 Port 2 Opto In Connector Pinout TB306 79 Table 3 23 Mating Connector Part Numbers for the Opto In Connectors TB305 TB306 79 Table 3 24 Digital Output Specifications TB307 TB308 82 Table 3 25 Port 1 Opto Out Connector...

Page 9: ...ective 2011 65 EU RoHS 2 Directive and has been designed to be in conformity with the applicable requirements of the following Standard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 61800 3 2004 EMC Requirements for Power Drives EN 61010 1 2010 Safety Requirements for Electrical Equipment Authorized Representative Simon Smith European Directo...

Page 10: ...fication CUS NRTL Approving Agency TUV SUD America Inc Certificate U8 17 01 68995 023 Standards CAN CSA C22 2 No 61010 1 2012 UL 61010 1 2012 Visit https www tuev sued de product testing certificates to view Aerotech s TÜV SÜD certificates Type the certificate number listed above in the search bar or type Aerotech for a list of all Aerotech certificates Ensemble HLe Declaration of Conformity ...

Page 11: ...mplete and accurate as of this manual s release Refer to www aerotech com for the most up to date information 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 Disconnect electrical power before servicing equipment 2 Disconnect electrical power before performing any wiring ...

Page 12: ...earing injuries Access to all stage and motor parts must be restricted while connected to a power source 3 Cables can pose a tripping hazard Securely mount and position all system cables to avoid potential hazards 4 Do not expose this product to environments or conditions outside of the listed specifications Exceeding environmental or operating specifications can cause damage to the equipment 5 Op...

Page 13: ...heading Integration that drawing can be found on your installation device Figure 1 Quick Start Connections Topic Section Motor Output Section 2 2 Motor Output Connections Motor Feedback Section 2 3 Motor Feedback Connections J207 Aeronet Section 2 7 Aeronet Interface J209 J210 Ethernet USB No Section Standard Connection Control Supply Section 2 1 1 Control Supply Connections Motor Supply Section 2...

Page 14: ...Ensemble HLe Quick Installation Guide 14 www aerotech com This page intentionally left blank ...

Page 15: ...int DSP controls the digital PID and current loops All system configuration is done using software settable parameters including control loop gains and system safety functions The Ensemble HLe is offered with an optional encoder interpolation feature MXH an auxiliary square wave encoder input for dual loop control dedicated analog and digital I O expandable with the IO option a resolver input RDP ...

Page 16: ...One 24 VDC 1 A brake relay Section 2 6 l Calibration Refer to the Help file l Camming Refer to the Help file l 10 100 BASE T Ethernet port for use with Ethernet I O modules Refer to the Help file Table 1 2 Ordering Options Options Power Stage Options Section 1 2 10 40 10 A peak 5 A continuous 40 VDC bus 20 40 20 A peak 10 A continuous 40 VDC bus 10 60 10 A peak 5 A continuous 60 VDC bus 10 80 10 A...

Page 17: ...e must be returned to Aerotech if firmware calibration updates are required read write access to parameters and programs is supported Resolver Options Chapter 4 RDP1 10K One channel resolver to digital converter input 10 kHz carrier frequency RDP1 7 5K One channel resolver to digital converter input 7 5 kHz carrier frequency RDP1 5K One channel resolver to digital converter input 5 kHz carrier fre...

Page 18: ...hapter 1 www aerotech com The following block diagram shows a connection summary For detailed connection information refer to Chapter 2 and Chapter 3 Figure 1 2 Functional Diagram Ensemble HLe Introduction ...

Page 19: ...f 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 5 Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version HLe 2 51 Current www aerotech com Chapter 1 19 ...

Page 20: ...ut Current 25 A max Output Voltage 1 36 V 20A 38 V 10A 58 V 10A 78 V 10A Peak Output Current 2 20 10 10 10 Continuous Output Current 2 10 5 5 5 Power Amplifier Bandwidth selectable via parameters 2500 Hz maximum software selectable Minimum Load Resistance 0 5 Ω Output Impedance 0 2 Ω each phase User Power Supply Output 5 VDC 500 mA Modes of Operation Brushless Brush Stepper Protective Features Pea...

Page 21: ...rom 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 www aerotech com Chapter 1 21 ...

Page 22: ...ion compliant for unlimited circuits enclosure Each unit should be separated from other drives and surrounded by 25 mm 1 of free air space A space of 100 mm 4 should be allowed along the front of the unit for cable connections Figure 1 3 Dimensions Slim Version Ensemble HLe Introduction ...

Page 23: ...mble HLe Figure 1 4 Dimensions Full Version with IO and RDP options Table 1 7 Physical Specifications Weight Slim 9 98 kg 22 0 lb w IO option 10 07 kg 22 2 lb w RDP option 10 07 kg 22 2 lb www aerotech com Chapter 1 23 ...

Page 24: ...erature 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 Ensemble HLe Introduction ...

Page 25: ... input is internally fused The AC2 input is not internally fused but can be connected to a voltage source other than Neutral if an external 2 A time delay fuse is used Although the control power supply contains an internal filter an additional external filter located as close as possible to the Ensemble HLe may be required for CE compliance Aerotech recommends Schaffner FN2080 Figure 2 1 Control S...

Page 26: ...trical safety requirements to correctly size external system wires and match wires to fuses or circuit breakers l The recommended wire size is 2 0 mm2 14 AWG l External fuses or a circuit breaker 10 A maximum time delay type are required for the AC1 and AC2 inputs W A R N I N G Do not operate the Ensemble HLe without the safety ground connection in place W A R N I N G Do not operate the Ensemble H...

Page 27: ...Connections Pin Description Recommended Wire Size ØA Phase A Motor Lead 1 3 mm2 16 AWG ØB Phase B Motor Lead 1 3 mm2 16 AWG ØC Phase C Motor Lead 1 3 mm2 16 AWG RT Brushless Motors with Wye connection only 1 3 mm2 16 AWG Earth Ground to Motor required for safety 1 3 mm2 16 AWG Table 2 4 Mating Connector Part Numbers for the Motor Power Output Connector Description Aerotech P N Phoenix P N Tighteni...

Page 28: ...indicates a single wire N OTE 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 thro...

Page 29: ...ation Ensemble HLe 2 2 1 1 Powered Motor Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor Hall and encoder phasing Figure 2 4 Encoder and Hall Signal Diagnostics www aerotech com Chapter 2 29 ...

Page 30: ...tion Figure 2 5 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...

Page 31: ...ore using in the current loop calculator or linear amplifier protection parameters Figure 2 7 DC Brush Motor Configuration Figure 2 8 DC Brush Motor Configuration with RT Connection Table 2 6 DC Brush Voltage Output Configuration Connection HLe 20 40 HLe 10 40 HLe 10 60 HLe 10 80 A C 80V 80V 120V 160V A RT 40V 40V 60V 80V Table 2 7 Wire Colors for Aerotech Supplied Cables DC Brush Pin Wire Color S...

Page 32: ...f the voltmeter to the other motor terminal 3 Rotate the motor clockwise by hand Figure 2 9 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 HLe Connec...

Page 33: ...plied bus voltage For example an 80V motor bus supply is needed to get 40V across the motor Figure 2 10 Stepper Motor Configuration Table 2 8 Wire Colors for Aerotech Supplied Cables Stepper Pin Wire Color Set 1 1 Wire Color Set 2 Green Yellow Shield 2 Green Yellow Shield A Black Brown B Red Yellow C White White Red 1 Wire Color Set 1 is the typicalAerotech wire set used by Aerotech 2 Red Orange i...

Page 34: ...king 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 Figure 2 11 Clockwise Motor Rotation N OTE If using standard Aerotech motors and cables motor and encoder connection a...

Page 35: ...ut 7 Encoder Marker Reference Pulse Input Absolute Encoder Interface Clock Output 8 Absolute Encoder Interface Data Bidirectional 9 Reserved N A 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 Encoder Cosine Input 16 5V Power for Limit Switches 500 mA max...

Page 36: ...r to Section 2 3 1 4 for encoder feedback phasing Refer to Section 2 5 for the auxiliary encoder channel N OTE Encoder wiring should be physically isolated from motor AC power and all other power wiring Table 2 11 Encoder Pins on the Motor Feedback Connector Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V Power for Encoder 500 mA max Output 6 Encoder Marker Reference Pulse Input Absolute...

Page 37: ...ing signals will cause a feedback fault when the axis is enabled An analog encoder is used with the MXH option refer to Section 2 3 1 3 for more information Table 2 12 Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec Figure 2 12 Line Driver Encoder Interface J207 www aerotech com Chapter 2 37 ...

Page 38: ...n via a serial data stream from the absolute encoder See Figure 2 13 for the serial data stream interface Refer to the Help file for information on how to set up your EnDat or Resolute absolute encoder parameters The encoder interface pinout is indicated in Section 2 3 1 Figure 2 13 Serial Data Stream Interface Ensemble HLe Installation and Configuration ...

Page 39: ...g input to quadrature output Refer to Figure 2 14 for the typical input circuitry The encoder interface pin assignment is indicated in Section 2 3 1 The gain offset and phase balance of the analog Sine and Cosine encoder input signals can all be adjusted via controller parameters Encoder signals should be adjusted using the Feedback Tuning tab of the Digital Scope which will automatically adjust t...

Page 40: ...40 Chapter 2 www aerotech com Figure 2 15 Analog Encoder Interface J207 Ensemble HLe Installation and Configuration ...

Page 41: ...ositive direction while observing the position of the encoder in the diagnostics display see Figure 2 17 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 17 Figure 2 16 Encoder Phasing Reference Diagram Standard N OTE Encoder manufacturers ma...

Page 42: ...42 Chapter 2 www aerotech com Figure 2 17 Position Feedback in the Diagnostic Display Ensemble HLe Installation and Configuration ...

Page 43: ...Hall Fault axis fault Refer to Section 2 2 1 1 for Hall effect device phasing Table 2 14 Hall Effect Feedback Pins on the Motor Feedback Connector J207 Pin Description In Out Bi 1 Chassis Frame Ground N A 3 5V Power for Encoder 500 mA max Output 5 Hall Effect Sensor B brushless motors only Input 10 Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sensor C brushless motors only Input...

Page 44: ...ce of the thermistor is low i e 100 ohms which will result in a low input signal As the increasing temperature causes the thermistor s resistance to increase the signal will be seen as a logic high triggering an over temperature fault The nominal trip value of the sensor is 1k Ohm Table 2 15 Thermistor Pin on the Motor Feedback Connector J207 Pin Description In Out Bi 2 Motor Over Temperature Ther...

Page 45: ...es and indicates a loss of encoder function The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active Table 2 16 Encoder Fault Pin on the Motor Feedback Connector J207 Pin Description In Out Bi 23 Encoder Fault Input Input Figure 2 20 Encoder Fault Interface Input J207 www aerotech com Chapter 2 45 ...

Page 46: ...tive 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 Opto isolated user inputs 0 3 can also be used as the end of travel limit inputs see Section 2 5 4 Figure 2 21 End of Travel Limit Input Connections Table 2 17 End of Travel Limit Input...

Page 47: ...Installation and Configuration Ensemble HLe Figure 2 22 End of Travel Limit Interface Input J207 www aerotech com Chapter 2 47 ...

Page 48: ...rther 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 shown in Figure 2 23 Figure 2 23 Limit Input Diagnostic Display Ensemble HLe Installation and Configuration ...

Page 49: ... refer to the Ensemble Help file for more information Use either the solid state relay on the Ensemble HLe or the mechanical relay on the IO board when connecting a power supply to the brake outputs on J207 Do not use both relays at the same time Refer to Section 2 6 for more information on using the brake output with the solid state relay Refer to Section 3 1 for more information on using the bra...

Page 50: ...or interconnection details 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 Figure 2 24 ESTOP Sense Input TB201 N OTE Connecting the ESTOP input to a relay or other noise producing device requires the use of noise suppression devices such as those in Table 2 1...

Page 51: ...intaining control power as shown in the Figure 2 25 The external relay must be sized based on the number of the Ensemble HLes connected and the peak current rating of each drive Figure 2 25 Typical Emergency Stop Circuit Table 2 21 Typical ESTOP Relay Ratings Axes AC1 AC3 Aerotech P N Third Party P N 1 32 16 ECW1018 Sprecher Schuh CA7 16C xx xxx 2 to 5 85 43 ECW1019 Sprecher Schuh CA7 43C xx xxx w...

Page 52: ...idirectional 12 5 Volt 500 mA max Output 13 Analog Input 0 Differential Input 14 Analog Input 0 Differential Input 15 Output Common 16 Digital Output 3 Output 17 Digital Input 0 CCW EOT Input 1 Input 18 Digital 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 ...

Page 53: ...r resistors Table 2 24 Auxiliary Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec N OTE Use the EncoderDivider parameter to configure the bi directional encoder interface on the aux iliary I O connector The EncoderDivider parameter converts the auxiliary encoder interface to an output and define...

Page 54: ...54 Chapter 2 www aerotech com Figure 2 26 Auxiliary Encoder Channel J205 Ensemble HLe Installation and Configuration ...

Page 55: ... opto isolator close to the receiving electronics Table 2 26 PSO Specifications Specification Value Maximum Input Tracking Rate 1 Single Axis Tracking 16 6 MHz Dual Axis Tracking 8 33 MHz Triple Axis Tracking 8 33 MHz Maximum Quadrature Encoder Output Frequency Standard Feedback 40 MHz MXH Feedback 25 MHz Maximum PSO Output Fire Frequency 2 12 5 MHz Firing Latency 3 Single Axis Tracking 160 nsec D...

Page 56: ...56 Chapter 2 www aerotech com Figure 2 27 PSO Interface Ensemble HLe Installation and Configuration ...

Page 57: ...he opto isolator s common connections can be directly connected to the drive s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 28 Digital Output Specifications Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50 C Output Saturation Voltage 2 75 V at maximum current Output Resistance 33...

Page 58: ...om N OTE Outputs must be connected as all sourcing or all sinking Figure 2 28 Outputs Connected in Current Sourcing Mode J205 Figure 2 29 Outputs Connected in Current Sinking Mode J205 Ensemble HLe Installation and Configuration ...

Page 59: ...nected to the drive s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 30 Digital Input Specifications Input Voltage Approximate Input Current Turn On Time Turn Off Time 5 V 1 mA 200 usec 2000 usec 24 V 6 mA 4 usec 1500 usec Table 2 31 Port 0 Digital Input Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 17 Digital Input 0...

Page 60: ...ank of 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 2 30 Inputs Connected in Current Sourcing Mode J205 Figure 2 31 Inputs Connected in Current Sinking Mode J205 Ensemble HLe Installation and Configuration ...

Page 61: ...t 0 High Speed Digital Input Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 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 Table 2 34 Input Voltage Jumper Configuration Jumper Setting Description JP3 1 2 1 24 V operation High Speed Input 5 2 3 5 V operation H...

Page 62: ...5 Analog Output 0 Specifications TB102 B Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Resolution volts 305 µV Table 2 36 Analog Output Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 22 Analog Output 0 Output 23 Analog Common Figure 2 33 Analog Output 0 J205 Ensemble HLe Installation and Configuration ...

Page 63: ...referenced to the analog common as shown in Figure 2 34 Table 2 37 Differential Analog Input 0 Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Resolution volts 305 µV 1 Signals outside of this range may damage the input Table 2 38 Analog Input Pins on the Auxiliary I O Connector J205 Pin Description In Out Bi 13 Analog Input 0 Differential Input 14 Analog Input 0 Di...

Page 64: ...cs for the EnableBrakeControl parameter and the BRAKE command When TB202 is used to power the solid state brake control relay the mechanical brake control relay present on the I O board should not be used N OTE The brake power supply must be externally fused The user must verify that the brake power requirements are within the specifications of the brake control relay Table 2 39 Relay Specificatio...

Page 65: ...ake Connected to J207 N OTE The user is responsible for providing fuse protection for the brake circuit Figure 2 36 is an example of a 24 VDC brake connected to TB202 The user must connect J207 pin 13 to J207 pin 25 In this case J207 would function as an interlock to prevent the brake from releasing if the Motor Feedback connector is not connected Figure 2 36 Brake Connected to TB202 www aerotech ...

Page 66: ...ary units will result in a connection failure Any discrete unit is capable of acting as the primary Ensemble HLe The unit acting as the primary is dictated by the connection of the Aeronet A primary drive will only act as an output A secondary drive in a configuration with three or more drives will act as an input and output The last drive connected in any configuration will only act as an input F...

Page 67: ...utput 2 RS 232 Transmit Output 3 RS 232 Receive Input 4 Reserved Output 5 Ground N A 6 Reserved Output 7 Reserved Input 8 Reserved Input 9 Reserved N A 1 Totaluser 5 V power is limited to 500 mA Table 2 44 Mating Connector Part Numbers for the the RS 232 Connector J206 Mating Connector Aerotech P N Third Party P N 9 Pin D Connector ECK00137 Cinch DE 9P Backshell ECK01021 Amphenol 17E 1724 2 Figure...

Page 68: ... PC Configuration and Operation Information For additional information about PC configuration hardware requirements programming utilities and system operation refer to the Ensemble Help file Ensemble HLe Installation and Configuration ...

Page 69: ...gital opto inputs 16 digital opto outputs 2 SSINET connections 3 analog inputs 3 analog outputs and a brake relay output D A N G E R Always disconnect the Mains power connection before opening the Ensemble HLe chassis Figure 3 1 Ensemble HLe with IO Option Board www aerotech com Chapter 3 69 ...

Page 70: ... High Low Z during reset 2 3 1 PSO Output Active Low High Z during reset JP3 1 2 3 4 Switch Brake 5 6 7 8 1 Switch Brake 1 3 Relay Only 1 default Table 3 2 IO Option Board Fuse Information Fuse Description Size Aerotech P N Manufacturer s P N F1 5 VDC User Power 3 A resettable EIF01001 Raychem RGE300 Ensemble HLe IO Expansion Board ...

Page 71: ...gs Maximum Switched Voltage 150 VDC 125 VAC Maximum Switched Current 1A Maximum Carrying Current 1A Maximum Switched Power 30 W DC 60 VA AC N OTE Do not exceed Maximum Current or Maximum Power specifications Table 3 4 Brake Mechanical Relay Connector Pinout TB301 Pin Description In Out Bi 1 Brake Relay Output Normally Closed Contact Output 2 Brake Relay Output Common Contact Output 3 Brake Relay O...

Page 72: ...at JP3 is set 1 2 and 3 4 with all others removed Figure 3 2 Brake Connected to J207 Figure 3 3 is an example of a 24 VDC Brake connected to TB301 In this example JP3 must be set 1 3 and all other jumpers removed Otherwise the user must connect J207 pin 13 to J207 pin 25 In this case J207 would function as an interlock to prevent the Brake from releasing if the Motor Feedback connector is not conn...

Page 73: ...f the open collector output defined in Table 3 7 Multiple opto coupler options are available depending on output speed voltage and current requirements An external power supply is required for the PSOOPTO1 2 options Table 3 7 PSO Output Interface Connector Pin Assignment TB302 Pin Description In Out Bi 1 Reserved 2 PSO Output Output 3 Opto Isolator Common Input Table 3 8 Mating Connector Part Numb...

Page 74: ...er configurations 3 2 1 1 Multi Axis Firing In this example the X axis has the TRIPLEPSO option and the Y and Z axes represent the other two axes that will be tracked The Y and Z axes output their encoder feedback through SSINet ports 1 and 2 respectively to the X axis The Z axis must have its SSINet port 1 configured as an output for its encoder feedback signal and the Y axis must have its SSINet...

Page 75: ... IO Expansion Board Ensemble HLe Figure 3 6 Two Three Axis Laser Firing Interconnection www aerotech com Chapter 3 75 ...

Page 76: ... 0 on J205 see Section 2 5 6 TB303 lets you connect to all of the analog outputs from one connector do not connect to AOUT0 at both TB303 and J205 Table 3 13 Analog Output Connector Pin Assignment TB303 Pin Description In Out Bi 1 Analog Output 0 Output 2 Analog Output 1 Output 3 Analog Output 2 Output 4 Analog Output 3 Output Table 3 14 Mating Connector Part Numbers for the Analog Output Connecto...

Page 77: ...n J205 see Section 2 5 7 TB304 lets you connect to all of the analog inputs in one place do not connect to AIN0 at both TB304 and J205 Table 3 16 Analog Inputs Connector Pin Assignment TB304 Pin Description In Out Bi 1 Analog Common N A 2 Non Inverting Analog Input 0 Input 3 Inverting Analog Input 0 Input 4 Non Inverting Analog Input 1 Input 5 Inverting Analog Input 1 Input 6 Analog Common N A 7 N...

Page 78: ...ween the TB306 5V terminal and TB305 GND terminal Table 3 18 User Common Pin on the Opto In Connector TB305 Pin Description In Out Bi 10 Signal Common N A Table 3 19 5 Volt Power Pin on the Opto In Connector TB306 Pin Description In Out Bi 10 Internal 5 Volt Power Supply 0 5 A max N A Ensemble HLe IO Expansion Board ...

Page 79: ... Digital Input Common for inputs 0 7 Input 2 Digital Input 0 Optically Isolated Input 3 Digital Input 1 Optically Isolated Input 4 Digital Input 2 Optically Isolated Input 5 Digital Input 3 Optically Isolated Input 6 Digital Input 4 Optically Isolated Input 7 Digital Input 5 Optically Isolated Input 8 Digital Input 6 Optically Isolated Input 9 Digital Input 7 Optically Isolated Input 10 Signal Com...

Page 80: ...80 Chapter 3 www aerotech com Figure 3 9 Digital Inputs TB305 shown Ensemble HLe IO Expansion Board ...

Page 81: ... bank of 8 Inputs must be connected in the all sourcing or all sinking configuration Figure 3 10 Digital Inputs Connected to a Current Sourcing Device Figure 3 11 Digital Inputs Connected to a Current Sinking Device www aerotech com Chapter 3 81 ...

Page 82: ...lation and will reduce noise immunity Table 3 24 Digital Output Specifications TB307 TB308 Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink Source Current 60 mA channel 50 C Output Saturation Voltage 2 75 V at maximum current Output Resistance 33 Ω Rise Fall Time 250 usec typical Reset State Output Off High Impedance State Suppression diodes must be installed on outputs d...

Page 83: ...put 5 Optically Isolated Output 9 Digital Output 6 Optically Isolated Output 10 Digital Output 7 Optically Isolated Output Table 3 26 Port 2 Opto Out Connector Pinout TB308 Pin Description In Out Bi 1 Digital Output Common Plus Input 2 Digital Output Common Minus Input 3 Digital Output 0 Optically Isolated Output 4 Digital Output 1 Optically Isolated Output 5 Digital Output 2 Optically Isolated Ou...

Page 84: ...84 Chapter 3 www aerotech com Figure 3 12 Digital Outputs IO Board Ensemble HLe IO Expansion Board ...

Page 85: ... IO Expansion Board Ensemble HLe Figure 3 13 Digital Outputs Connected in Current Sourcing Mode Figure 3 14 Digital Outputs Connected in Current Sinking Mode www aerotech com Chapter 3 85 ...

Page 86: ...oder signal input to the Ensemble HLe unless the MXH option is present N OTE The SSINet 1 and 2 interfaces are both physically hardwired to the J302 and J303 connectors If SSINet 1 is configured as an input a signal driven into the SSINet 1 connections on J302 will also be present on the SSINet 1 connections of J303 effectively making SSINet 1 on J303 an un buffered out put of this same signal Lik...

Page 87: ... IO Expansion Board Ensemble HLe Figure 3 15 J302 J303 www aerotech com Chapter 3 87 ...

Page 88: ...Ensemble HLe IO Expansion Board 88 Chapter 3 www aerotech com This page intentionally left blank ...

Page 89: ...e motor the alignment between the resolver and motor must be known This alignment can be determined by using the controller s software Refer to the Ensemble Help file for information on configuring parameters for an axis with resolver feedback Channel 1 is on J401 and channel 2 is on J402 The RDP option can supply up to 7 VRMS reference voltage and requires 2 VRMS on the sine and cosine inputs D A...

Page 90: ...Reference Output 9 REF Resolver Reference Output 8 Shield Reference Shield 7 ENC SIN Encoder Emulation Sine optional Output 11 ENC SIN Encoder Emulation Sine optional Output 1 ENC COS Encoder Emulation Cosine optional Output 6 ENC COS Encoder Emulation Cosine optional Output 2 ENC MRK Encoder Emulation Marker optional Output 12 ENC MRK Encoder Emulation Marker optional Output Table 4 3 Resolver Ma...

Page 91: ... RDP Expansion Board Ensemble HLe Figure 4 2 Resolver Inductosyn Recommended Wiring Figure 4 3 Resolver Inputs www aerotech com Chapter 4 91 ...

Page 92: ...ignal Common N A Table 4 5 External Power Mating Connector Description Aerotech P N Phoenix P N Wire Size AWG mm2 3 Pin Terminal Block ECK01449 1881338 0 5 0 080 20 28 Table 4 6 Resolver Test Points Test Point Description TP4 Signal Common TP10 Sine Input Channel 1 TP11 Cosine Input Channel 1 TOP Reference Signal Channel 1 TP13 Resolver Channel 1 Error TP20 Sine Input Channel 2 TP21 Cosine Input C...

Page 93: ...an be found on the website at http www aerotechmotioncontrol com manuals index aspx Table 5 1 Standard Interconnection Cables Cable Part Description Joystick See Section 5 1 ECZ01231 BBA32 Interconnect Cable 1 The xx indicates length in decimeters yy would indicate length in feet www aerotech com Chapter 5 93 ...

Page 94: ...ystick control will not activate unless the joystick is in the center location Third party devices can be used provided they produce a symmetric output voltage within the range of 10V to 10V The following drawings illustrate how to connect a single or two axis joystick For cable details refer to Table 5 2 Refer to the Ensemble Help file for programming information about how to change joystick para...

Page 95: ...Accessories Ensemble HLe Figure 5 2 Two Axis Joystick Interface to the Aux I O of two drives Figure 5 3 Two Axis Joystick Interface to the Aux I O and I O Board www aerotech com Chapter 5 95 ...

Page 96: ...iption UPC C227712 XX JSXT FLY 26HD 15DU MAX300DM ENSEMBLEHLE DUAL AXIS 630B2277 12 C227713 XX JSXT 26HD 15DU MAX300DM ENSEMBLEHLE SINGLE AXIS 630B2277 13 C227714 XX JSXT 26HD 26HD 15DU MAX300DM ENSEMBLEHLE DUAL AXIS 630B2277 14 C227716 XX JSXT FLY 15DU MAX 300 DM ENSEMBLEHLE DUAL AXIS 630B2277 16 96 Chapter 5 www aerotech com ...

Page 97: ...ovide 5V differential quadrature signals to the Ensemble HLe A handwheel can be connected to the Aux I O as shown in Figure 5 5 or Figure 5 6 N OTE See the Ensemble Help file for information on enabling the handwheel Figure 5 5 Handwheel Interconnection to Aux I O Figure 5 6 Handwheel Interconnection to Aux I O via a BBA32 Module www aerotech com Chapter 5 97 ...

Page 98: ...98 Chapter 5 www aerotech com Ensemble HLe Accessories This page intentionally left blank ...

Page 99: ...cription LED Description ENB FLT Turns green to indicate that the axis is enabled Turns red to indicate a fault condition The ENB FLT LED will flash between RED and GREEN if the drive is enabled and in a fault condition MARKER Turns green to indicate that the marker input is high PWR Turns green when power is applied POS Turns green to indicate that the axis is in position If the power light flash...

Page 100: ...Ensemble HLe Maintenance 6 1 Power Board D A N G E R Always disconnect the Mains power connection before opening the Ensemble HLe chassis Figure 6 1 Power Board Assembly 100 Chapter 6 www aerotech com ...

Page 101: ...Littelfuse 215010 P 10 60 5A S B EIF01023 Littelfuse 215005 P 10 80 5A S B EIF01023 Littelfuse 215005 P F3 Line voltage dependent see Table 6 3 EIF01023 5 A Fuse Littelfuse 215005 P EIF01020 10 A Fuse Littelfuse 215010 P Table 6 3 Line Voltage Fuse Information Line Voltage Fuse F3 Value 100V C 10A SB 115V A 10A SB 200V D 5A SB 230V B 5A SB www aerotech com Chapter 6 101 ...

Page 102: ... 2 Control Board Assembly Table 6 4 Control Board Jumper Configuration Jumper Setting Description JP2 1 2 1 Watchdog enabled 2 3 Watchdog disabled JP3 1 2 1 24 V operation High Speed Input 5 2 3 5 V operation High Speed Input 5 JP4 1 2 1 24 V operation High Speed Input 4 2 3 5 V operation High Speed Input 4 1 Default 102 Chapter 6 www aerotech com ...

Page 103: ... Fuse 5 A EIF01002 Raychem MINISMDC050 Table 6 6 LED Description LED Description ENB FLT Turns green to indicate that the axis is enabled Turns red to indicate a fault condition The ENB FLT LED will flash between RED and GREEN if the drive is enabled and in a fault condition MARKER Turns green to indicate that the marker input is high PWR Turns green when power is applied POS Turns green to indica...

Page 104: ...ductive material exposure Any fluids or electrically conductive material must not be permitted to enter the Ensemble HLe Visually inspect all cables and connections Tighten or re secure any loose connections Replace worn or frayed cables Replace broken connectors Cleaning The Ensemble HLe chassis can be wiped with a clean dry soft cloth The cloth may be slightly moistened if required with water or...

Page 105: ...approval A Return Materials Authorization 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 aerotech com Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than thirty 30 ...

Page 106: ...ons stated in the following On Site Non Warranty Repair section apply On site Non Warranty Repair If any Aerotech product cannot be made functional by telephone assistance or purchased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site Field Service Representative in a reasonable amount...

Page 107: ...ction 2 5 7 Differential Analog Input 0 J205 l Section 3 2 PSO Output Interface TB302 l Section 3 3 Analog Outputs TB303 l Section 3 4 Analog Inputs TB304 l Section 3 6 Opto In Connector Digital Inputs TB305 TB306 l Section 3 7 Opto Out Connector Digital Outputs TB307 TB308 4 08 00 l Added TUV certification information Agency Approvals l Added RoHS statement to Declaration of Conformity l Updated ...

Page 108: ...Ensemble HLe Revision History 108 Appendix B www aerotech com This page intentionally left blank ...

Page 109: ...g Output 1 Connector 76 Analog Output 1 Connector Pin Assignment 76 Analog Outputs I O Board 76 Auxiliary Encoder Channel 53 54 Auxiliary Encoder Channel Pin Assignment 53 55 Auxiliary I O Connector 52 Auxiliary I O Connector Pin Assignment 52 B Brake Mechanical Relay 71 Brake Mechanical Relay Connector Pin Assignment 71 Brake Connected to J207 65 72 Brake Connected to TB20 65 Brake Connected to T...

Page 110: ...face J207 46 End of Travel Limit Input Interface Pin Assignment 46 End of Travel Limit Interface Input 47 End Of Travel Limit Phasing 48 EnDat absolute encoder 38 EnDat Encoder Interface 38 Environmental Specifications 24 external emergency stop relay circuit 51 external power connector 92 External Power Pin Assignment 92 F Fuse Information 101 G Global Technical Support 2 H Hall Effect Feedback I...

Page 111: ...ut Impedance 20 Output Specifications 82 Output Voltage 20 Outputs Connected in Current Sinking Mode 58 85 Outputs Connected in Current Sourcing Mode58 85 P PC Configuration and Operation Information 68 Peak Output Current specifications 20 Pollution 24 Position Feedback in the Diagnostic Display 42 Position Synchronized Output PSO Laser Firing55 Power Amplifier Bandwidth specifications 20 Power B...

Page 112: ... 64 65 71 TB301 71 72 TB302 73 TB303 76 TB304 77 TB305 78 79 TB306 78 79 TB307 82 TB308 82 Technical Support 2 Thermistor Interface 44 Thermistor Interface Input 44 Two Axis Joystick Interface 95 Two Three Axis Laser Firing Interconnection 75 Typical Emergency Stop Circuit 51 Typical ESTOP Interface 51 U unit separation 22 unit weight 23 Unpowered Motor and Feedback Phasing 30 Use 24 User Common C...

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