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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 #

U8 14 08 68995

Standards

UL 61010-1:2012; CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-
1:2010

www.aerotech.com

Summary of Contents for Ensemble LAB

Page 1: ...1 2 3 4 J103 J104 J105 J106 TB101 ETHERNET USB ESTOP JOYSTICK AUX I O AXIS 4 3 2 1 WARNING HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED Revision 1 02 00 Ensemble LAB Hardware...

Page 2: ...ice aerotech com 101 Zeta Drive Pittsburgh PA 15238 2897 www aerotech com United Kingdom Japan Phone 44 0 1256 855055 Fax 44 0 1256 855649 Email service aerotech co uk Phone 81 0 50 5830 6814 Fax 81 0...

Page 3: ...e 27 2 3 1 1 RS 422 Line Driver Encoder Standard 28 2 3 1 2 Analog Encoder Interface 29 2 3 1 3 Encoder Phasing 31 2 3 2 Hall Effect Interface 33 2 3 3 Thermistor Interface 34 2 3 4 End of Travel Limi...

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

Page 5: ...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...

Page 6: ...in 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 Encode...

Page 7: ...applicable requirements of the following Directive s 2014 35 EU Low Voltage Directive LVD 2011 65 EU RoHS 2 Directive and has been designed to be in conformity with the applicable requirements of the...

Page 8: ...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 U8 14 0...

Page 9: ...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 operati...

Page 10: ...Safety Procedures and Warnings Ensemble LAB Hardware Manual 10 www aerotech com This page intentionally left blank...

Page 11: ...as 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 J103 J104 J105 J106 TB101 ETHERNET USB ESTOP JOY...

Page 12: ...Quick Installation Guide Ensemble LAB Hardware Manual 12 www aerotech com This page intentionally left blank...

Page 13: ...andard 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 Interfa...

Page 14: ...time output or PSO support MXR1 Interpolation circuit allowing analog sine wave input on encoder channel 1 up to x65536 Real time output and PSO support MXR2 Interpolation circuit allowing analog sin...

Page 15: ...XR Option CW CCW Home Limits Hall A B C Motor Over Temperature Amplifier Control Power Control Power Supply AC Power Input Linear Amplifier Heatsink Over Temperature Analog Output 0 Analog Input 0 2 H...

Page 16: ...fy 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 1 1 1 Output Voltage 1 22 5 V 5 A Peak Output Current 1 5...

Page 17: ...uired 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 approx...

Page 18: ...RNET USB ESTOP JOYSTICK AUX I O AXIS 4 3 2 1 WARNING HAZARDOUS VOLTAGE PRESENT UP TO 10 MINUTES AFTER POWER IS DISCONNETED 2 3 0 09 272 5 10 73 4 9 0 19 98 4 3 88 370 2 14 58 304 4 11 99 32 9 1 29 44...

Page 19: ...o 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 meter...

Page 20: ...fter the listed version Table 1 4 Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version CL 1 01 5 02 A 2 55 5 02 CP A 1 00 Current B 2 54 Current E...

Page 21: ...mponents 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 Ensem...

Page 22: ...Ethernet Port Figure 2 1 Power and Control Connections USB JOG 1 2 3 4 A A Power Switch Figure 2 2 Power Switch All low voltage connections must be made using cables wires sized for the maximum curren...

Page 23: ...rt 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 ca...

Page 24: ...nnot 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 Signal Wiring Cable Wire...

Page 25: ...ctors 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 design...

Page 26: ...hardware limit Input 8 HALL A Input 9 HALL C Input 10 Motor Ground 11 MTR A Motor Phase A Output 12 MTR B Motor Phase B Output 13 MTR C Motor Phase C Output 14 Cosine Input 15 Sine Input 16 Marker Inp...

Page 27: ...e has been configured to accept an analog encoder Refer to Section 2 3 1 3 for encoder feedback phasing Refer to Section 2 5 for the auxiliary encoder channel N OTE Encoder wiring should be physically...

Page 28: ...n analog encoder is used with the MXU or MXR option refer to Section 2 3 1 2 for more information Table 2 6 Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum...

Page 29: ...n offset and phase balance of the analog Sine and Cosine encoder input signals are controlled by the EncoderCosineGain EncoderCosineOffset EncoderPhase EncoderSineGain EncoderSineOffset axis parameter...

Page 30: ...1K 1K 1K 1K 82PF 82PF 8 06K 10PF 10PF 220PF 10PF AD8656 1M 10UF 6 3V 0018 100 0018 4 7K 4 7K 33PF 33PF 2 43K 100 2 43K MAX991 MRK COS SIN AD8656 A A 1 1K 10PF 220PF 10UF 6 3V 0018 100 0018 4 7K 4 7K...

Page 31: ...ger 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 MRK MRK N Positive MOVE Clockwise Forcer Wire...

Page 32: ...Installation and Configuration Ensemble LAB Hardware Manual Figure 2 7 Position Feedback in the Diagnostic Display 32 Chapter 2 www aerotech com...

Page 33: ...tation 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...

Page 34: ...r 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...

Page 35: ...d 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...

Page 36: ...sed 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 lim...

Page 37: ...l DC Brush Motors refer to Section 2 3 5 2 l Stepper Motors refer to Section 2 3 5 3 Table 2 11 Motor Output Connections Pin Description In Out Bi 10 Motor Ground 11 MTR A Motor Phase A Output 12 MTR...

Page 38: ...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...

Page 39: ...n 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 z...

Page 40: ...ply TP3 TP2 TP1 TP6 TP7 Hall 1 Hall 2 Hall 3 CHANNEL 1 CHANNEL 2 Figure 2 15 Motor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined the...

Page 41: ...r 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 Motor Mou...

Page 42: ...er 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 v...

Page 43: ...the ESTOP input must be driven to prevent the ESTOP fault condition ESTOP SWITCH ESTOP ESTOP 221 1K 1UF 1K 221 1K PS2815 1 2K 3 3V TB101 1 TB101 2 24VDC Figure 2 21 ESTOP Sense Input TB102 Table 2 12...

Page 44: ...Output 10 Auxiliary Cosine Bidirectional 11 Auxiliary Cosine Bidirectional 12 5 Volt 500 mA max Output 13 Analog Input 0 Differential Input 14 Analog Input 0 Differential Input 15 Output Common 16 Opt...

Page 45: ...Specification Value Encoder Frequency 10 MHz maximum 25 nsec minimum edge separation x4 Quadrature Decoding 40 million counts sec MXR Interpolation Latency 3 25 sec analog input to quadrature output...

Page 46: ...2 J106 10 J106 11 AUX SIN AUX SIN AUX COS S 180 D IN 5V 5V 5V 5V ADM1485 ADM1485 ADM1485 ADG801 S 180 D ENCODER FAULT DETECTION IN ADG801 S 180 D IN ADG801 1K 1K AUX COS J106 19 J106 20 AUX MRK AUX M...

Page 47: ...g 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 P...

Page 48: ...ersing connections to Pins 19 and 20 Aux Marker 120 180 typical 10 mA 180 Differential J106 5 VDC 1K 1K 33 33 20 19 Active Low Output Active High Output Aux Marker 74AHCT1G125 Single Ended 5 VDC Isola...

Page 49: ...modes The 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 19 Por...

Page 50: ...VE DEVICE COIL SUCH AS A RELAY LOAD LOAD LOAD LOAD OPTOOUT0 OPTOOUT1 OPTOOUT2 OPTOOUT3 Figure 2 24 Outputs Connected in Current Sourcing Mode J106 OPTOCOM 5 24 VDC 2 1 1 2 EACH OUTPUT 50 mA MAXIMUM OU...

Page 51: ...cted to the drive s power supply however doing so will effectively defeat the isolation and will reduce noise immunity Table 2 21 Opto Isolated Input Specifications Input Voltage Approximate Input Cur...

Page 52: ...S 5 24VDC OPTOINCOM J106 24 J106 26 J106 25 J106 18 J106 17 J106 OPTOIN3 OPTOIN2 OPTOIN1 OPTOIN0 Figure 2 26 Inputs Connected in Current Sourcing Mode J106 INPUT SWITCHES 5 24VDC OPTOINCOM J106 24 J10...

Page 53: ...A Input Device HCPL 0630 Delay 50 nsec Table 2 24 Port 0 High Speed Digital Input Connector Pin Assignment J106 Pin Description In Out Bi 3 High Speed Input 4 user interrupt Input 4 High Speed Input 4...

Page 54: ...ons Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Resolution volts 305 V Table 2 26 Analog Output Connector Pin Assignment J106 Pin Description In Out Bi...

Page 55: ...30 Table 2 27 Differential Analog Input 0 Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Resolution volts 305 V 1 Signals outside of this range may damage the input Ta...

Page 56: ...he center location Third party devices can be used provided they produce a symmetric output voltage within the range of 0V to 5V Refer to the Ensemble Help File for programming information about how t...

Page 57: ...Potentiometer Analog Input 1 Input 4 No Connection 5 Reserved No Connection 6 Y Potentiometer Analog Input 2 Input 7 Button B Speed Select Input 8 Common 9 Reserved No Connection 10 Common 11 Common 1...

Page 58: ...accomplished by one of these two methods Method 1 Directly connect to the PC with a standard USB cable The cable connector type must be Type A or Type B male depending on the PC and Type B male on th...

Page 59: ...ly members of the network are the Ensemble LAB and the PC This type of connection is not feasible unless the PC has two Ethernet cards If the PC cannot be connected to an external network Aerotech rec...

Page 60: ...B Hardware Manual 2 8 PC Configuration and Operation Information For additional information about PC configuration hardware requirements programming utilities and system operation refer to the Ensembl...

Page 61: ...epaired as required If internal damage is suspected these parts should be checked and repairs made if necessary Inspect cooling vents Remove any accumulated material from vents Check for fluids or ele...

Page 62: ...Maintenance Ensemble LAB Hardware Manual 62 Chapter 3 www aerotech com This page intentionally left blank...

Page 63: ...hout such 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 appropria...

Page 64: ...rms and conditions 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...

Page 65: ...top Sense Input TB101 l Section 2 5 1 Auxiliary Encoder Channel l Section 2 5 2 Position Synchronized Output PSO l Section 2 5 3 Opto Isolated Outputs 0 3 l Section 2 5 4 Opto Isolated Inputs 0 3 l Se...

Page 66: ...Revision History Ensemble LAB Hardware Manual 66 Appendix B www aerotech com This page intentionally left blank...

Page 67: ...Brush Motor Phasing 41 Digital Output Specifications 49 dimensions 18 Drive and Software Compatibility 20 E Electrical Specifications 16 Emergency Stop Sense Input TB101 43 Encoder Interface 27 Encod...

Page 68: ...ew 13 P Peak Output Current 16 Pollution 19 Position Synchronized Output 47 Power Amplifier Bandwidth 16 Power Supply 16 Powered Motor Phasing 39 Preventative Maintenance 61 PS2806 4 Opto Device Speci...

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