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Aerotech Ensemble HLe Hardware Manual

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Ensemble HLe Hardware
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Revision: 4.09.00

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  • Page 1: Ensemble Hle Hardware Manual

    Ensemble HLe Hardware Manual Revision: 4.09.00...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents Ensemble HLe Table of Contents Ensemble HLe Hardware Manual Table of Contents List of Figures List of Tables EU Declaration of Conformity Agency Approvals Safety Procedures and Warnings Quick Installation Guide Chapter 1: Introduction 1.1. Drive and Software Compatibility 1.2.
  • Page 4 Ensemble HLe Table of Contents 2.9. PC Configuration and Operation Information Chapter 3: -I/O Expansion Board 3.1. Relay Connector (TB301) 3.2. PSO Output Interface (TB302) 3.2.1. -DUALPSO and -TRIPLEPSO Laser Firing Options 3.2.1.1. Multi-Axis Firing 3.3. Analog Outputs (TB303) 3.4. Analog Inputs (TB304) 3.5.

  • Page 5: List Of Figures

    Brake Connected to TB202 Figure 2-37: Aeronet Connection with Three Discrete Drives Figure 2-38: RS-232 Interface (J206) Figure 3-1: Ensemble HLe with -IO Option Board Figure 3-2: Brake Connected to J207 Figure 3-3: Brake Connected to TB301 Figure 3-4: PSO Output Sources Current Figure 3-5: PSO Output Sinks Current...
  • Page 6 Ensemble HLe Table of Contents Figure 3-10: Digital Inputs Connected to a Current Sourcing Device Figure 3-11: Digital Inputs Connected to a Current Sinking Device Figure 3-12: Digital Outputs (-IO Board) Figure 3-13: Digital Outputs Connected in Current Sourcing Mode Figure 3-14:...

  • Page 7: List Of Tables

    Motor Power Output Connections Table 2-4: Mating Connector Part Numbers for the Motor Power Output Connector Table 2-5: Wire Colors for Aerotech Supplied Cables (Brushless)  Table 2-6: DC Brush Voltage Output Configuration Table 2-7: Wire Colors for Aerotech Supplied Cables (DC Brush)  ...
  • Page 8 Ensemble HLe Table of Contents Table 3-1: -IO Expansion Board Jumper Configuration Table 3-2: -IO Option Board Fuse Information  Table 3-3: Voltage and Current Specifications (TB301) Table 3-4: Brake / Mechanical Relay Connector Pinout (TB301) Table 3-5: Mating Connector Part Numbers for the Relay Connector (TB301) Table 3-6: -IO Expansion Board Brake Jumper Configuration ...

  • Page 9: Eu Declaration Of Conformity

    Declaration of Conformity Ensemble HLe EU Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product Ensemble HLe Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the...

  • Page 10: Agency Approvals

    Ensemble HLe Declaration of Conformity Agency Approvals Aerotech, Inc. Model Ensemble HLe Series Linear Drives 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.

  • Page 11: Safety Procedures And Warnings

    Safety Procedures and Warnings This manual tells you how to carefully and correctly use and operate the Ensemble HLe. Read all parts of this manual before you install or operate the Ensemble HLe or before you do maintenance to your system. To prevent injury to you and damage to the equipment, obey the precautions in this manual.
  • Page 12 Ensemble HLe Electrical Safety 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. If the product is used in a manner not specified by the manufacturer, the protection provided by the product can be impaired and result in damage, shock, injury, or death.

  • Page 13: Quick Installation Guide

    This chapter describes the order in which connections and settings should typically be made to the Ensemble HLe. 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.
  • Page 14 Ensemble HLe Quick Installation Guide This page intentionally left blank. www.aerotech.com...

  • Page 15: Chapter 1: Introduction

    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 option), and separate power connections for motor and control supply voltages.

  • Page 16: Table 1-1: Feature Summary

    Feature Summary Standard Features Ensemble HLe series linear digital drive with Ethernet TCP/IP and USB interface, 10-20 A peak, 5-10 A continuous, ±40 VDC to ±80 VDC bus, and control supply 115/230 VAC input to power logic circuitry; supports voice coil and brushless, brush, and stepper motors. Includes: 85 - 240 VAC control supply inputs Section 2.1.1.

  • Page 17: Table 1-3: Ordering Options (Continued)

    -LCK Locked drive; firmware and calibration data on the drive cannot be modified by the user after the product leaves Aerotech; the drive must be returned to Aerotech if firmware/calibration updates are required; read/write access to parameters and programs is supported...

  • Page 18: Figure 1-2: Functional Diagram

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

  • Page 19: Drive And Software Compatibility

    Introduction Ensemble HLe 1.1. 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.

  • Page 20: Electrical Specifications

    Ensemble HLe Introduction 1.2. Electrical Specifications The safe operating range is load dependent. Table 1-6: Electrical Specifications HLe 20-40 HLe 10-40 HLe 10-60 HLe 10-80 Input Voltage 100, 115, 200, 230 VAC (model dependent) Input 50-60 Hz Frequency Inrush Current 10, 11.5, 20, 23 A (model dependent)

  • Page 21: System Power Requirements

    Introduction Ensemble HLe 1.2.1. 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.

  • Page 22: Mechanical Design

    Ensemble HLe Introduction 1.3. Mechanical Design Install the unit into a construction 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.

  • Page 23: Figure 1-4: Dimensions (Full Version With -Io And -Rdp Options)

    Introduction Ensemble 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...

  • Page 24: Environmental Specifications

    Ensemble HLe Introduction 1.4. Environmental Specifications The environmental specifications for the Ensemble HLe are listed below. Operating: 0° to 50°C (32° to 122° F) Ambient Temperature Storage: -30° to 85°C (-22° to 185° F) Maximum relative humidity is 80% for temperatures up to 31°C. Decreasing Humidity linearly to 50% relative humidity at 40°C.

  • Page 25: Chapter 2: Installation And Configuration

    Ensemble HLe Chapter 2: Installation and Configuration 2.1. Power Connections The Ensemble HLe has two AC input connectors; one for control power and a second for motor power. For a complete list of electrical specifications, refer to Section 1.2. N O T E : The machine integrator, OEM or end user is responsible for meeting the final protective ground- ing requirements of the system.

  • Page 26: Motor Supply Connections

    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 HLe without proper branch protection.

  • Page 27: Motor Output Connections

    Installation and Configuration Ensemble HLe 2.2. Motor Output Connections The Ensemble HLe is capable of controlling three motor types: Brushless (see Section 2.2.1.) DC Brush (see Section 2.2.2.) Stepper (see Section 2.2.3.) For a complete list of electrical specifications, refer to Section 1.2.

  • Page 28: Brushless Motor Connections

    Refer to Section 2.2.1.1. for powered motor phasing or Section 2.2.1.2. for unpowered motor and feedback phasing. N O T E :  If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required. Chapter 2 www.aerotech.com...

  • Page 29: Powered Motor Phasing

    Installation and Configuration 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...

  • Page 30: Unpowered Motor And Feedback Phasing

    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).

  • Page 31: Dc Brush Motor Connections

    Red & Orange Yellow & Blue Black Yellow & Blue (1) Wire Color Set #1 is the typical Aerotech wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire www.aerotech.com Chapter 2...

  • Page 32: Dc Brush Motor Phasing

    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. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the Ensemble HLe.

  • Page 33: Stepper Motor Connections

    Green/Yellow & Shield Black Brown Yellow White White & Red (1) Wire Color Set #1 is the typical Aerotech wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire www.aerotech.com Chapter 2...

  • Page 34: Stepper Motor Phasing

    Figure 2-11: 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 dir- ection of “positive”...

  • Page 35: Motor Feedback Connections (J207)

    Installation and Configuration Ensemble HLe 2.3. Motor Feedback Connections (J207) The motor feedback connector (a 25-pin, D-style connector) has inputs for an encoder, limit switches, Hall- effect devices, motor over-temperature device, 5 Volt encoder and limit power, and optional brake connection.

  • Page 36: Encoder Interface (J207)

    Motor Feedback (J207) connector. The standard encoder interface will accept an RS-422 differential line driver signal. If the Ensemble HLe has been purchased with the -MXH option, the standard encoder interface can be configured for an analog encoder input via parameter settings.

  • Page 37: Line Driver Encoder (Standard)

    Installation and Configuration Ensemble HLe 2.3.1.1. 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 -MXH option (refer to Section 2.3.1.3.

  • Page 38: Absolute Encoder Interface (J207)

    Ensemble HLe Installation and Configuration 2.3.1.2. Absolute Encoder Interface (J207) The Ensemble HLe retrieves absolute position data along with encoder fault information 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.

  • Page 39: Analog Encoder Interface

    Installation and Configuration Ensemble HLe 2.3.1.3. Analog Encoder Interface If the -MXH option has been purchased, the standard encoder channel will accept a differential analog encoder input signal. The interpolation factor is determined by the EncoderMultiplicationFactor parameter and is software selectable (refer to the Ensemble Help file).

  • Page 40: Figure 2-15: Analog Encoder Interface (J207)

    Ensemble HLe Installation and Configuration Figure 2-15: Analog Encoder Interface (J207) Chapter 2 www.aerotech.com...

  • Page 41: Encoder Phasing

    Installation and Configuration Ensemble HLe 2.3.1.4. Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-16 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors).

  • Page 42: Figure 2-17: Position Feedback In The Diagnostic Display

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

  • Page 43: Hall-Effect Interface (J207)

    Installation and Configuration Ensemble HLe 2.3.2. Hall-Effect Interface (J207) 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. Hall states (0,0,0) or (1,1,1) are invalid and will generate a "Hall Fault"...

  • Page 44: Thermistor Interface (J207)

    Ensemble HLe Installation and Configuration 2.3.3. Thermistor Interface (J207) The thermistor input is used to detect a motor over temperature condition by 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...

  • Page 45: Encoder Fault Interface (J207)

    Installation and Configuration Ensemble HLe 2.3.4. Encoder Fault Interface (J207) The encoder fault input is for use with encoders that have a fault output. This is provided by some manufactures 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.

  • Page 46: End Of Travel Limit Input Interface (J207)

    Ensemble HLe Installation and Configuration 2.3.5. End Of Travel Limit Input Interface (J207) End of Travel (EOT) limits are used to define the end of physical travel. The EOT limit inputs accept 5-24 VDC level signals. The active state of the EOT limits is software selectable by the EndOfTravelLimitSetup axis parameter (refer to the Ensemble Help file).

  • Page 47: Figure 2-22: End Of Travel Limit Interface Input (J207)

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

  • Page 48: End Of Travel Limit Phasing

    Ensemble HLe Installation and Configuration 2.3.5.1. 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...

  • Page 49: Brake Output (J207)

    2.3.6. Brake Output (J207) The Brake Output pins provide a direct connection to either the solid state relay on the Ensemble HLe or the mechanical relay on the optional -IO board. The brake output pins in J207 permit the brake to be wired with other signals in the feedback cable.

  • Page 50: Emergency Stop Sense Input (Tb201)

    Ensemble HLe Installation and Configuration 2.4. Emergency Stop Sense Input (TB201) 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.

  • Page 51: Typical Estop Interface

    Ensemble HLe 2.4.1. Typical ESTOP Interface The user can connect an external emergency stop relay circuit to the Ensemble HLe’s motor power supply input. This will remove power to the motor while maintaining control power, as shown in the Figure 2-25.

  • Page 52: Auxiliary I/O Connector (J205)

    Section 2.5.2. Table 2-23: Mating Connector Part Numbers for the Auxiliary I/O Connector Mating Connector Aerotech P/N Third Party P/N Connector ECK01259 Kycon K86-AA-26P Backshell ECK01022 Amphenol 17E-1725-2 NOTE: These items are provided as a set under the Aerotech P/N: MCK-26HDD. Chapter 2 www.aerotech.com...

  • Page 53: Auxiliary Encoder Channel (J205)

    Installation and Configuration Ensemble HLe 2.5.1. Auxiliary Encoder Channel (J205) 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.

  • Page 54: Figure 2-26: Auxiliary Encoder Channel (J205)

    Ensemble HLe Installation and Configuration Figure 2-26: Auxiliary Encoder Channel (J205) Chapter 2 www.aerotech.com...

  • Page 55: Position Synchronized Output (Pso)/Laser Firing (J205)

    Installation and Configuration Ensemble HLe 2.5.2. Position Synchronized Output (PSO)/Laser Firing (J205) 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.

  • Page 56: Figure 2-27: Pso Interface

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

  • Page 57: Digital Outputs 0-3 (J205)

    Installation and Configuration Ensemble HLe 2.5.3. Digital Outputs 0-3 (J205)  The digital outputs are optically-isolated and may be connected in sourcing or sinking configurations. The digital outputs are designed to connect to other ground referenced circuits and are not intended to provide high-voltage isolation.

  • Page 58: Figure 2-28: Outputs Connected In Current Sourcing Mode (J205)

    Ensemble HLe Installation and Configuration N O T E : 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) Chapter 2...

  • Page 59: Digital Inputs 0-3 (J205)

    Installation and Configuration Ensemble HLe 2.5.4. Digital Inputs 0-3 (J205)  The digital inputs are opto-isolated and may be connected to current sourcing or current sinking devices, as shown in Figure 2-30 Figure 2-31. These inputs are designed to connect to other ground-referenced circuits and are not intended for high-voltage isolation.

  • Page 60: Figure 2-30: Inputs Connected In Current Sourcing Mode (J205)

    Ensemble HLe Installation and Configuration N O T E : Each bank 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) Chapter 2 www.aerotech.com...

  • Page 61: High-Speed User Inputs 4-5 (J205)

    Installation and Configuration Ensemble HLe 2.5.5. High-Speed User Inputs 4-5 (J205) The high-speed inputs 4-5 are typically used as a sample signal for data collection. Table 2-32: High-Speed Input Specifications Specification Value Input Voltage 5V or 24 V input voltages based on a jumper setting...

  • Page 62: Analog Output 0 (J205)

    Ensemble HLe Installation and Configuration 2.5.6. Analog Output 0 (J205) The analog output is set to zero when power is first applied to the system or during a system reset. Table 2-35: Analog Output 0 Specifications (TB102 B) Specification Value Output Voltage -10 V to +10 V...

  • Page 63: Differential Analog Input 0 (J205)

    Installation and Configuration Ensemble HLe 2.5.7. Differential Analog Input 0 (J205) To interface to a single-ended (non-differential) voltage source, connect the signal common of the source to the negative input and the analog source signal to the positive input. A floating signal source should be...

  • Page 64: Brake Power Supply Connector (Tb202)

    Ensemble HLe Installation and Configuration 2.6. Brake Power Supply Connector (TB202) TB202 is the power supply connection to the onboard solid state brake control relay. 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 output.

  • Page 65: Figure 2-35: Brake Connected To J207

    Installation and Configuration Ensemble HLe Figure 2-35 is an example of a +24 VDC brake connected to the Motor Feedback connector. In this example the external +24 VDC power source is connected to TB202. Figure 2-35: Brake Connected to J207 N O T E :  ...

  • Page 66: Aeronet Interface (J209/J210)

    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.

  • Page 67: Interface (J206)

    Installation and Configuration Ensemble HLe 2.8. RS-232 Interface (J206) Connecting the RS-232 port to a user’s PC requires a standard cable (not a null modem). Table 2-43: RS-232 Connector Pinout (J206) Pin# Description In/Out/Bi Connector +5 Volt Power Output Output...

  • Page 68: Pc Configuration And Operation Information

    Ensemble HLe Installation and Configuration 2.9. PC Configuration and Operation Information For additional information about PC configuration, hardware requirements, programming, utilities, and system operation refer to the Ensemble Help file. Chapter 2 www.aerotech.com...

  • Page 69: Chapter 3: -I/O Expansion Board

    The -IO option board is 16 digital 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...

  • Page 70: Table 3-1: -Io Expansion Board Jumper Configuration

    Ensemble HLe -IO Expansion Board Table 3-1: -IO Expansion Board Jumper Configuration Jumper Setting Description PSO Output Active High, Low Z during reset PSO Output Active Low, High Z during reset 1-2, 3-4 Switch Brake + 5-6, 7-8 Switch Brake -...

  • Page 71: Relay Connector (Tb301)

    -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.

  • Page 72: Figure 3-2: Brake Connected To J207

    Ensemble HLe -IO Expansion Board N O T E :   The user is responsible for providing fuse protection for the brake circuit. Figure 3-2 is an example of a +24 VDC Brake connected to the Motor Feedback connector. In this example the external +24 power source is connected to TB301.

  • Page 73: Pso Output Interface (Tb302)

    JP2 is installed in the 1-2 position giving normally-closed operation. This mode should be used with caution since the Ensemble HLe cannot maintain the closed state when its AC mains power is turned off. The PSO- NC (JP2 1-2 setting) should not be used when fail-safe operation is required. JP2 jumper settings are shown Table 3-9.

  • Page 74: Dualpso And -Triplepso Laser Firing Options

    Figure 3-6) from J302 to J302 of each HPe (J302 to J302 or J303 to J303 of the other Ensemble HLe, both connectors have two bi-directional ports). Refer to the Ensemble Help File for programming information. Software controlled PSO pre-scalars may be used to limit the data rate of each encoder being tracked without affecting the servo loop data rate.

  • Page 75: Figure 3-6: Two/Three Axis Laser Firing Interconnection

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

  • Page 76: Analog Outputs (Tb303)

    Ensemble HLe -IO Expansion Board 3.3. Analog Outputs (TB303) The analog output is set to zero when power is first applied to the system or during a system reset. Table 3-12: Analog Output Specifications (TB102 B) Specification Value Output Voltage -10 V to +10 V...

  • Page 77: Analog Inputs (Tb304)

    -IO Expansion Board Ensemble HLe 3.4. Analog Inputs (TB304) To interface to a single-ended (non-differential) voltage source, connect the signal common of the source to the negative input and the analog source signal to the positive input. A floating signal source should be...

  • Page 78: User Power (Tb305, Tb306)

    Ensemble HLe -IO Expansion Board 3.5. User Power (TB305, TB306) A user accessible power supply (+5V at 0.5 A) is available between the TB306 +5V terminal and TB305 GND terminal. Table 3-18: User Common Pin on the Opto In Connector (TB305)

  • Page 79: Opto In Connector (Digital Inputs) (Tb305, Tb306)

    -IO Expansion Board Ensemble HLe 3.6. Opto In Connector (Digital Inputs) (TB305, TB306) The digital inputs are opto-isolated and may be connected to current sourcing or current sinking devices, as shown in Figure 3-10 Figure 3-11. These inputs are designed to connect to other ground-referenced circuits and are not intended for high-voltage isolation.

  • Page 80: Figure 3-9: Digital Inputs (Tb305 Shown)

    Ensemble HLe -IO Expansion Board Figure 3-9: Digital Inputs (TB305 shown) Chapter 3 www.aerotech.com...

  • Page 81: Figure 3-10: Digital Inputs Connected To A Current Sourcing Device

    -IO Expansion Board Ensemble HLe N O T E : Each 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...

  • Page 82: Opto Out Connector (Digital Outputs) (Tb307, Tb308)

    Ensemble HLe -IO Expansion Board 3.7. Opto Out Connector (Digital Outputs) (TB307, TB308) The digital outputs are optically-isolated and may be connected in sourcing or sinking configurations. The digital outputs are designed to connect to other ground referenced circuits and are not intended to provide high-voltage isolation.

  • Page 83: Table 3-25: Port 1 Opto Out Connector Pinout (Tb307)

    -IO Expansion Board Ensemble HLe N O T E : Power supply connections must always be made to both the Output Common Plus (OP) and Output Common Minus (OM) pins as shown in Figure 3-13 Figure 3-14. N O T E : Outputs must be connected as all sourcing or all sinking.

  • Page 84: Figure 3-12: Digital Outputs (-Io Board)

    Ensemble HLe -IO Expansion Board Figure 3-12: Digital Outputs (-IO Board) Chapter 3 www.aerotech.com...

  • Page 85: Figure 3-13: Digital Outputs Connected In Current Sourcing Mode

    -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...

  • Page 86: Ssinet (J302/J303)

    -IO Expansion Board 3.8. SSINET (J302/J303) The SSINet is designed for daisy-chaining encoder signals from one Ensemble HLe to another for two/three- axis PSO (laser firing). This allows one Ensemble HLe containing the -DUALPSO or -TRIPLEPSO options to track the vectorial position change of two/three axes in real-time. These encoder signals may also be used for user-defined purposes.

  • Page 87: Figure 3-15: J302/J303

    -IO Expansion Board Ensemble HLe Figure 3-15: J302/J303 www.aerotech.com Chapter 3...
  • Page 88 Ensemble HLe -IO Expansion Board This page intentionally left blank. Chapter 3 www.aerotech.com...

  • Page 89: Chapter 4: -Rdp Expansion Board

    -RDP Expansion Board Ensemble HLe Chapter 4: -RDP Expansion Board The resolver to digital option (-RDP) provides up to two industry standard resolver or inductosyn channels that can be used as a feedback device. The standard reference frequency output is 5 kHz, with factory options for either 7.5 kHz or 10.0 kHz.

  • Page 90: Table 4-2: -Rdp Connector Pin Assignment (J401/J402)

    Ensemble HLe -RDP Expansion Board Table 4-2: -RDP Connector Pin Assignment (J401/J402) Pin# Label Description In/Out/Bi Shell Shield Connecter shell for cable shield termination Input SIN+ Resolver Sine + Input SIN- Resolver Sine - Input Shield Resolver Sine Shield Shield...

  • Page 91: Figure 4-2: Resolver/Inductosyn Recommended Wiring

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

  • Page 92: Figure 4-4: Encoder Emulation Outputs

    Ensemble HLe -RDP Expansion Board Figure 4-4: Encoder Emulation Outputs The external power connector (J403) is a factory-select configuration and is not available on all drives. Table 4-4: External Power Pin Assignment (J403)  Pin# Label Description In/Out/Bi +12V +12 Volts DC...

  • Page 93: Chapter 5: Standard Interconnection Cables

    Accessories Ensemble HLe Chapter 5: Standard Interconnection Cables N O T E : A complete list of Aerotech cables can be found on the website at http://www.aerotechmotioncontrol.com/manuals/index.aspx. Table 5-1: Standard Interconnection Cables Cable Part # Description Joystick Section 5.1. ECZ01231 BBA32 Interconnect Cable (1) The “-xx”...

  • Page 94: Joystick Interface

    Accessories 5.1. Joystick Interface Aerotech joysticks JI (NEMA12 (IP54) rated) and JBV are powered from 5V and have a nominal 2.5V output in the center detent position. Three buttons are used to select axis pairs and speed ranges. An optional interlock signal is used to indicate to the controller that the joystick is present.

  • Page 95: Figure 5-2: Two Axis Joystick Interface (To The Aux I/O Of Two Drives)

    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...

  • Page 96: Table 5-2: Cable Part Numbers

    Ensemble HLe Accessories Figure 5-4: Two Axis Joystick Interface (to the I/O Board) Table 5-2: Cable Part Numbers Part # Cable Description 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...

  • Page 97: Handwheel Interface

    Ensemble HLe 5.2. Handwheel Interface A handwheel (such as the Aerotech HW-xxx-xx) can be used to manually control axis position. The handwheel must provide 5V differential quadrature signals to the Ensemble HLe. A handwheel can be connected to the Aux I/O as shown in...
  • Page 98 Ensemble HLe Accessories This page intentionally left blank. Chapter 5 www.aerotech.com...

  • Page 99: Chapter 6: Maintenance

    Maintenance Ensemble HLe Chapter 6: Maintenance D A N G E R : Always disconnect the Mains power connection before opening the Ensemble HLe chassis. D A N G E R : Before performing any tests, be aware of lethal voltages inside the controller and at the input and output power connections.

  • Page 100: Power Board

    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 Chapter 6 www.aerotech.com...

  • Page 101: Table 6-2: Fuse Information

    Maintenance Ensemble HLe Table 6-2: Fuse Information Fuse Drive Size Aerotech P/N Manufacturer's P/N 10-40 5A S.B. EIF01023 Littelfuse 215005.P 20-40 10A S.B. EIF01020 Littelfuse 215010.P 10-60 5A S.B. EIF01023 Littelfuse 215005.P 10-80 5A S.B. EIF01023 Littelfuse 215005.P EIF01023 (5 A Fuse) Littelfuse 215005.P...

  • Page 102: Control Board

    Ensemble HLe Maintenance 6.2. Control Board D A N G E R : Always disconnect the Mains power connection before opening the Ensemble HLe chassis. Figure 6-2: Control Board Assembly Table 6-4: Control Board Jumper Configuration  Jumper Setting Description Watchdog enabled Watchdog disabled 24 V operation (High Speed Input 5)

  • Page 103: Table 6-5: Control Board Fuse Information

    Maintenance Ensemble HLe Table 6-5: Control Board Fuse Information  Fuse Description Size Aerotech P/N Manufacturer's P/N Radial Lead Resettable Fuse 3 A EIF01001 Raychem RGE300 Surface Mount Fuse .05 A EIF01028 Raychem MICROSMD005F-2 Surface Mount Fuse .05 A EIF01028 Raychem MICROSMD005F-2 Surface Mount Fuse .05 A...

  • Page 104: Preventative Maintenance

    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 isopropyl alcohol to aid in cleaning if necessary. In this case, be careful not to allow moisture to enter the Ensemble HLe or onto exposed connectors / components.

  • Page 105: Appendix A: Warranty And Field Service

    Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer, whether or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided, or whether or not Aerotech’s...
  • Page 106 Aerotech's approval. On-site Warranty Repair If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts, and cannot be returned to the Aerotech service center for repair, and if Aerotech determines the problem could be warranty-related, then the following policy applies:...

  • Page 107: Appendix B: Revision History

    I/O Expansion Board revision update (refer to manual revision 4.07.00 for jumper locations). Feature summary updated (added -PSONC): Table 1-1 I/O Board revision updated: Figure 3-1 4.07.00 4.06.00 4.05.00 4.04.00 Revision changes have been archived. If you need a copy of this revision, contact Aerotech Global Technical Support. 4.03.00 4.02.00 4.01.00 4.00.00 www.aerotech.com Appendix B...
  • Page 108 Ensemble HLe Revision History This page intentionally left blank. Appendix B www.aerotech.com...

  • Page 109: Index

    Index Ensemble HLe Index Analog Output 1 Connector Analog Output 1 Connector Pin Assignment -DUALPSO and -TRIPLEPSO Laser Firing Analog Outputs (I/O Board) Options Auxiliary Encoder Channel 53-54 -I/O Expansion Board Auxiliary Encoder Channel Pin Assignment 53,55 -IO Board Fuse Information...
  • Page 110 Ensemble HLe Index EnDat absolute encoder DC Brush Motor Connections EnDat Encoder Interface DC Brush Motor Phasing Environmental Specifications Declaration of Conformity external emergency stop relay circuit Digital Input Connector Pin Assignment external power connector Digital Input Specifications External Power Pin Assignment...
  • Page 111 Index Ensemble HLe J206 Output Impedance J207 35-38,40,43-47,49,65,72 Output Specifications J209 Output Voltage J210 Outputs Connected in Current Sinking Mode 58,85 J302 Outputs Connected in Current Sourcing Mode 58,85 J303 J401 PC Configuration and Operation Information J402 Peak Output Current specifications...
  • Page 112 Ensemble HLe Index RS-232 Connector Pin Assignment Typical ESTOP Interface RS-232 Interface RS-232 Port Connector Mating Connector unit separation RS-422 Line Driver Encoder (Standard) unit weight Unpowered Motor and Feedback Phasing serial data stream Single Axis Joystick Interface User Common Connector Pin Assignment...

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