Aerotech AUTOMATION1-GL4 Hardware Manual
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Aerotech AUTOMATION1-GL4 Hardware Manual

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AUTOMATION1-GL4
HARDWARE MANUAL
Revision: 1.04.00
Patent Number: US 8,426,768 B2

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Summary of Contents for Aerotech AUTOMATION1-GL4

  • Page 1: Automation1-Gl4 Hardware Manual

    AUTOMATION1-GL4 HARDWARE MANUAL Revision: 1.04.00 Patent Number: US 8,426,768 B2...
  • 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

    GL4 Hardware Manual Table of Contents Table of Contents AUTOMATION1-GL4 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. Electrical Specifications 1.2. Mechanical Specifications 1.3.

  • Page 4: List Of Figures

    Digital Inputs Connected to Current Sourcing Devices Figure 2-21: Analog Outputs Schematic Figure 2-22: Analog Inputs Schematic Figure 2-23: Encoder Input Connections Schematic Figure 2-24: ESTOP Sense Input Schematic Figure 2-25: Laser Output Polarity Switches Figure 3-1: Control Board Assembly Figure 3-2: Power Board Assembly www.aerotech.com...

  • Page 5: List Of Tables

    Table 2-38: ESTOP Pins on the Encoder Input Connector Table 2-39: Electrical Noise Suppression Devices Table 2-40: Sync-Related Commands Table 2-41: Sync Port Cables Table 3-1: Preventative Maintenance Table 3-2: Control Board Fuse Specifications Table 3-3: Power Board Fuse Specifications www.aerotech.com...
  • Page 6 List of Tables GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 7: Eu Declaration Of Conformity

    GL4 Hardware Manual EU Declaration of Conformity EU Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the...
  • Page 8 EU Declaration of Conformity GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 9: Agency Approvals

    U8 16 06 68995 021 Standards: UL 61010-1:2012; CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-1:2010 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. www.aerotech.com...
  • Page 10 Agency Approvals GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 11: Safety Procedures And Warnings

    NOTE: All specifications and illustrations are for reference only and were complete and accurate as of the release of this manual. To find the newest information about this product, refer to www.aerotech.com. DANGER: The voltage from this product can kill you. To decrease the risk of electrical shock, injury, and death, you must obey the precautions that follow.
  • Page 12 Safety Procedures and Warnings GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 13: Quick Installation Guide

    Section 2.2. HyperWire Interface Digital / Analog I/O Section 2.6. Digital and Analog I/O Connectors Galvo Connections Section 2.5. Galvo Motor Connectors Control Supply Section 2.1.1. Control Supply Connector Motor Supply Section 2.1.2. Motor Supply Connector Figure 1: Quick Start Connections  www.aerotech.com...
  • Page 14 Quick Installation Guide GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 15: Chapter 1: Introduction

    Section 2.6.1. Four optically-isolated digital inputs; 5-24V Section 2.6.2. Two 16-bit single-ended analog outputs; ±10 V Section 2.6.3. One 16-bit differential analog input; ±10 V Section 2.6.4. Dedicated 5-24V Emergency Stop sense input Section 2.7.1. Two Sync ports Section 2.9. www.aerotech.com...

  • Page 16: Figure 1-2: Functional Diagram

    Chapter 1: Introduction GL4 Hardware Manual The block diagram that follows shows a summary of the connector signals. Figure 1-2: Functional Diagram www.aerotech.com...

  • Page 17: Electrical Specifications

    Input Frequency 50-60 Hz Control Supply Inrush Current 16 A Input Current 0.35 A (max) Output Voltage 38 V Peak Output Current 20 A Continuous Output Current Minimum Load Resistance 0.5 Ω User Power Supply Output 5 VDC (@ 500 mA) www.aerotech.com...

  • Page 18: Mechanical Specifications

    The figure that follows shows the dimensions and the typical mounting orientation of the GL4. Table 1-3: Unit Weight Weight 2.9 kg [6.4 lb] Figure 1-3: Dimensions www.aerotech.com...

  • Page 19: Environmental Specifications

    0 m to 2,000 m (0 ft to 6,562 ft) above sea level. Operating Altitude If you must operate this product above 2,000 m or below sea level, contact Aerotech, Inc. Pollution Degree 2 Pollution Typically only nonconductive pollution occurs.

  • Page 20: Drive And Software Compatibility

    This table shows the available drives and which version of the software first supported each drive. In the Last Software Version column, drives that show a specific version number are not supported after that version. Table 1-5: Drive and Software Compatibility Drive Type Firmware Revision First Software Version Last Software Version 6.04.000 Current www.aerotech.com...

  • Page 21: Chapter 2: Installation And Configuration

    [#16 AWG] (1)The wire insulation is rated for 300 V. Table 2-2: Mating Connector Part Numbers for the Control Supply Connector Screw Torque Wire Size: Type Aerotech P/N Third Party P/N Value: N·m [AWG] 3-Pin Terminal Block ECK00213 Phoenix 1754465 0.5 - 0.6...

  • Page 22: Motor Supply Connector

    (#14 AWG) (1)The wire insulation is rated for 300 V. Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector Screw Torque Wire Size: Type Aerotech P/N Third Party P/N Value: N·m [AWG] 4-Pin Terminal Block ECK01581 Phoenix 1757035 0.5 - 0.6...

  • Page 23: External Power Supply Options

    Chapter 2: Installation and Configuration 2.1.3. External Power Supply Options You must connect the Motor Supply to a bipolar power supply. Aerotech recommends that you use an Aerotech TM3 transformer which can supply power to a maximum of four controllers. Refer to Figure 2-3.

  • Page 24: Figure 2-4: Third-Party Power Supply Connection

    Chapter 2: Installation and Configuration GL4 Hardware Manual Figure 2-4: Third-Party Power Supply Connection www.aerotech.com...

  • Page 25: Minimizing Conducted, Radiated, And System Noise For Emc/Ce Compliance

    Use a line filter, such as Aerotech’s UFM-ST, on the Control Supply AC inputs. The following additional changes could be required for EMC compliance and are recommended during initial EMC system evaluation.

  • Page 26: Hyperwire Interface

    HyperWire Cable Part Numbers Part Number Description HYPERWIRE-AO10-5 HyperWire cable, active optical, 0.5 m HYPERWIRE-AO10-10 HyperWire cable, active optical, 1.0 m HYPERWIRE-AO10-30 HyperWire cable, active optical, 3.0 m HYPERWIRE-AO10-50 HyperWire cable, active optical, 5.0 m HYPERWIRE-AO10-200 HyperWire cable, active optical, 20.0 m www.aerotech.com...

  • Page 27: Laser Output Connectors

    (1) Refer to Section 2.3.1. for more information Table 2-9: Mating Connector Part Numbers for the Laser Output Connectors Wire Size: mm [AWG] Type Aerotech P/N Third Party P/N 7-Pin Terminal Block ECK01631 Phoenix 1881370 0.5 - 0.080 [20-28] www.aerotech.com...

  • Page 28: Figure 2-5: Laser Interface Outputs

    Table 2-10: Laser Output Specifications Specification Value Maximum Frequency 5 MHz Isolated Voltage 5 - 24 V Output Output Current ≤ 50 mA Maximum Frequency 10 MHz 5V TTL Voltage Output Current 50 mA Figure 2-5: Laser Interface Outputs www.aerotech.com...

  • Page 29: Figure 2-6: Current Sinking Configuration With Isolation

    GL4 Hardware Manual Chapter 2: Installation and Configuration Figure 2-6: Current Sinking Configuration with Isolation Figure 2-7: Current Sinking Configuration without Isolation www.aerotech.com...

  • Page 30: Figure 2-8: Current Sourcing Configuration With Isolation

    Chapter 2: Installation and Configuration GL4 Hardware Manual Figure 2-8: Current Sourcing Configuration with Isolation Figure 2-9: Current Sourcing Configuration without Isolation www.aerotech.com...

  • Page 31: Figure 2-10: Ttl Output

    GL4 Hardware Manual Chapter 2: Installation and Configuration Figure 2-10: TTL Output www.aerotech.com...

  • Page 32: Position Synchronized Output (Pso)

    When the PSO generates pulses, minimum latency occurs between the trigger condition and the output. Aerotech recommends that you use an RS-422 line receiver or an opto-isolator if your system: Uses cables with long lengths in work areas where a lot of electrical noise occurs.

  • Page 33: Encoder Output Connector

    Axis 2 SIN+ Output Axis 2 COS+ Output Reserved Ground Table 2-15: Mating Connector Part Numbers for the Encoder Output Connector Mating Connector Aerotech P/N Third Party P/N 15-Pin D-Connector ECK00100 Amphenol DA15P064TXLF Backshell ECK01022 Amphenol 17E-1725-2 Figure 2-11: Encoder Outputs...

  • Page 34: Figure 2-12: Pso External Sync Input

    Chapter 2: Installation and Configuration GL4 Hardware Manual Table 2-16: PSO External Sync Specifications Specification Value Voltage 3.3 VDC Frequency 25 MHz Maximum On Time 20 ns Minimum Figure 2-12: PSO External Sync Input www.aerotech.com...

  • Page 35: Galvo Motor Connectors

    Encoder Ground Encoder Ground Frame Ground Motor - Output Motor - Output Table 2-18: Mating Connector Part Numbers for the Galvo Motor Connectors Mating Connector Aerotech P/N Third Party P/N 25-Pin D-Connector ECK00101 FCI DB25P064TXLF Backshell ECK00656 Amphenol 17E-1726-2 www.aerotech.com...

  • Page 36: Analog Encoder Inputs

    (1) Any single-ended encoder signal measured with respect to ground. 2.5.2. Galvo Motor Connection The GL4 is configured for AGV galvo motors at the factory. You cannot use the GL4 with other types of motors. AGV galvo motors operate as DC Brush motors over a limited travel. www.aerotech.com...

  • Page 37: End Of Travel Limit Input Interface

    Chapter 2: Installation and Configuration 2.5.3. End of Travel Limit Input Interface Aerotech strongly recommends that you use End of Travel (EOT) limits to define the end of the physical travel. Current-based limits that are software-selectable through the EndOfTravelLimitSetup axis parameter can be used, but only if EOT limits are not available on your galvo motor.

  • Page 38: Figure 2-13: End Of Travel Limit Input Connections

    Chapter 2: Installation and Configuration GL4 Hardware Manual Figure 2-13: End of Travel Limit Input Connections Figure 2-14: End of Travel Limit Interface Input Schematic www.aerotech.com...

  • Page 39: End Of Travel Limit Phasing

    CW and CCW inputs at the motor feedback connector or swap the CW and CCW limit functionality in the software using the EndOfTravelLimitSetup parameter. The logic level of the EOT limit inputs may be viewed in the diagnostic display (shown in Figure 2-15). Figure 2-15: Limit Input Diagnostic Display www.aerotech.com...

  • Page 40: Thermistor Interface

    The nominal trip value of the sensor is 2.4 kΩ. Table 2-21: Thermistor Interface Pins on the Galvo Motor Connectors Description In/Out/Bi Motor Over Temperature Thermistor Input Figure 2-16: Thermistor Interface Input Schematic www.aerotech.com...

  • Page 41: Digital And Analog I/O Connectors

    Output Analog Output 1 Output Input Table 2-24: Mating Connector Part Numbers for the Digital / Analog I/O Connectors Wire Size: mm [AWG] Mating Connector Aerotech P/N Third Party P/N 8-Pin Terminal Block ECK01386 Phoenix 1881383 0.5 - 0.080 [20-28] www.aerotech.com...

  • Page 42: Digital Outputs

    Table 2-26: Digital Output Pins on the Digital/Analog I/O A Connector Pin # Label Description In/Out/Bi Digital Output 0 (Optically-Isolated) Output Digital Output 1 (Optically-Isolated) Output Digital Output 2 (Optically-Isolated) Output Digital Output 3 (Optically-Isolated) Output Digital Output Common Input www.aerotech.com...

  • Page 43: Figure 2-17: Digital Outputs Connected In Current Sourcing Mode

    GL4 Hardware Manual Chapter 2: Installation and Configuration Figure 2-17: Digital Outputs Connected in Current Sourcing Mode Figure 2-18: Digital Outputs Connected in Current Sinking Mode www.aerotech.com...

  • Page 44: Digital Inputs

    Digital Input 0 (Optically-Isolated) Input Digital Input 1 (Optically-Isolated) Input Digital Input 2 (Optically-Isolated) Input Digital Input 3 (Optically-Isolated) Input Digital Input Common Input Figure 2-19: Digital Inputs Connected to Current Sinking Devices Figure 2-20: Digital Inputs Connected to Current Sourcing Devices www.aerotech.com...

  • Page 45: Analog Outputs

    Output Current 5 mA Resolution (bits) 16 bits Table 2-30: Analog Output Pins on the Digital / Analog I/O B Connector Pin # Label Description In/Out/Bi Analog Output 0 Output Analog Output 1 Output Figure 2-21: Analog Outputs Schematic www.aerotech.com...

  • Page 46: Analog Inputs (Differential)

    1. Signals outside of this range may damage the input Table 2-32: Analog Input Pins on the Digital / Analog I/O B Connector Pin # Label Description In/Out/Bi Analog Input + Input Analog Input - Input Ground Figure 2-22: Analog Inputs Schematic www.aerotech.com...

  • Page 47: Encoder Input Connectors

    Output Ground Table 2-36: Mating Connector Part Numbers for the Encoder Input Connectors Wire Size: mm [AWG] Type Aerotech P/N Third Party P/N 6-Pin Terminal Block ECK02220 Phoenix 1881367 0.5 - 0.080 [20-28] Table 2-37: GL4 to Drive Cable Part Numbers...

  • Page 48: Figure 2-23: Encoder Input Connections Schematic

    Chapter 2: Installation and Configuration GL4 Hardware Manual Figure 2-23: Encoder Input Connections Schematic www.aerotech.com...

  • Page 49: Emergency Stop Sense Input

    Refer to Table 2-39 to see the types of devices you can use. Table 2-39: Electrical Noise Suppression Devices Device Aerotech P/N Third Party P/N RC (.1uf / 200 ohm) Network EIC00240 Electrocube RG1782-8 Varistor EID00160 Littelfuse V250LA40A www.aerotech.com...

  • Page 50: Laser Output Polarity Switches

    Chapter 2: Installation and Configuration GL4 Hardware Manual 2.8. Laser Output Polarity Switches Use the Laser Output Polarity switches to specify the active laser output polarity. Refer to Section 2.3. Figure 2-25: Laser Output Polarity Switches www.aerotech.com...

  • Page 51: Sync Port

    Length 3 dm; Connectors: USB Type A to USB Type A CBL-SYNC-5 Length 5 dm; Connectors: USB Type A to USB Type A CBL-SYNC-7 Length 7 dm; Connectors: USB Type A to USB Type A CBL-SYNC-10 Length 10 dm; Connectors: USB Type A to USB Type A www.aerotech.com...

  • Page 52: Pc Configuration And Operation Information

    Chapter 2: Installation and Configuration GL4 Hardware Manual 2.10. PC Configuration and Operation Information For more information about hardware requirements, PC configuration, programming, system operation, and utilities, refer to the Help file. www.aerotech.com...

  • Page 53: Chapter 3: Maintenance

    Do not use fluids and sprays to clean the GL4 because they can easily go into the chassis or onto the outer connectors and components. If a cleaning solution goes into the GL4, internal contamination can cause corrosion and electrical short circuits. Do not clean the labels with a cleaning solution because it might remove the label information. www.aerotech.com...

  • Page 54: Board Assembly

    DANGER: Before you open the GL4 chassis, you must disconnect the Mains power connection. Figure 3-1: Control Board Assembly Table 3-2: Control Board Fuse Specifications Fuse Description Size Aerotech P/N Third Party P/N Control Supply Power at Pin-1 2 A S.B. EIF01048 Littelfuse 0875002.MXEP Control Supply Power at Pin-1 2 A S.B.

  • Page 55: Figure 3-2: Power Board Assembly

    DANGER: Before you open the GL4 chassis, you must disconnect the Mains power connection. Figure 3-2: Power Board Assembly Table 3-3: Power Board Fuse Specifications Fuse Description Size Aerotech P/N Third Party P/N Motor Bus Supply 10 A S.B. EF01020 Littelfuse 215010.P Motor Bus Supply 10 A S.B.
  • Page 56 Chapter 3: Maintenance GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 57: 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 58 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 59: Appendix B: Revision History

    Revision Description 1.04.00 Added cable part numbers: Table 2-37 1.03.00 Updated to AUTOMATION1 hardware 1.02.00 Added Table 2-16 The following sections have been updated: General product update 1.01.00 Section 2.1.4. Minimizing Conducted, Radiated, and System Noise for EMC/CE Compliance 1.00.00 New Manual www.aerotech.com...
  • Page 60 Appendix B: Revision History GL4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 61: Index

    Analog Inputs (Differential) Mating Connector Part Numbers Board Assembly Digital and Analog I/O Connector Analog Outputs C25483 Digital Inputs C26263 Digital Outputs Cables Digital and Analog I/O Connector A Pinout HyperWire Digital and Analog I/O Connector B Pinout Sync Port www.aerotech.com Index...
  • Page 62 Digital Outputs Connected in Current Sinking Pinout Mode End of Travel Limit Input Connections Digital Outputs Connected in Current End of Travel Limit Input Interface Sourcing Mode End of Travel Limit Input Pins on the Galvo Motor Dimensions Connectors Index www.aerotech.com...
  • Page 63 Encoder Output Connector Humidity Galvo Motor Connectors HyperWire Laser Output Connectors Cable Part Numbers Motor Supply Connector Card Part Number Mechanical Specifications Minimizing Conducted, Radiated, and System IFOV Cable Noise for EMC/CE Compliance Input Power Connections Minimum Load Resistance www.aerotech.com Index...
  • Page 64 Analog Output (Digital and Analog I/O End of Travel Limit Input Pins (Galvo Motor Connector) Connectors) Control Board Fuses ESTOP Pins on the Encoder Input Connector 49 Control Supply Connector Wiring Galvo Motor Connectors Digital Inputs Laser Output Connector A Digital Outputs Index www.aerotech.com...
  • Page 65 Thermistor Interface (Galvo Motor Connectors) Thermistor Interface Input Schematic Thermistor Interface Pins on the Galvo Motor Connectors Third-Party Power Supply Connection TM3 Transformer Control and Power Wiring TTL Output Unit Weight User Power Supply Output Warranty and Field Service www.aerotech.com Index...
  • Page 66 Index GL4 Hardware Manual This page intentionally left blank. Index www.aerotech.com...

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