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Aerotech Automation1 XR3 Series Hardware Manual

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Automation1 XR3 Drive Rack

HARDWARE MANUAL
Revision 2.01

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Summary of Contents for Aerotech Automation1 XR3 Series

  • Page 1: Automation1 Xr3 Drive Rack

    Automation1 XR3 Drive Rack HARDWARE MANUAL Revision 2.01...
  • 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

    2.4.4. Data Acquisition Inputs 2.5. HSOUT Connector (High-Speed Outputs) 2.6. DOUT Connector (Digital Outputs) 2.7. DIN Connector (Digital Inputs) 2.8. Aux Encoder Connectors 2.8.1. Square Wave Encoder 2.8.2. Absolute Encoder 2.8.3. Sine Wave Encoder [-CT4 Option] 2.9. Analog I/O Connectors 2.9.1. Analog Outputs 2.9.2. Analog Inputs (Differential) www.aerotech.com...
  • Page 4 2.10.4. STO Diagnostics 2.11. HyperWire Interface 2.12. Cooling Options [-C0/-C1/-C2 Option] 2.13. PC Configuration and Operation Information Chapter 3: Maintenance 3.1. Preventative Maintenance 3.2. Fuse Specifications Appendix A: Warranty and Field Service Appendix B: Voltage Selection Operation Appendix C: Revision History Index www.aerotech.com...

  • Page 5: List Of Figures

    Sine Wave Encoder Phasing Reference Diagram Figure 2-39: Sine Wave Encoder Schematic (Aux Encoder Connector) Figure 2-40: Analog Outputs Schematic Figure 2-41: Analog Inputs Schematic Figure 2-42: Joystick Interface Inputs Schematic Figure 2-43: Joystick Cable Wiring Schematic Figure 2-44: Typical Configuration Figure 2-45: STO Timing www.aerotech.com...
  • Page 6 Figure 2-47: -C0 Fan Location and Direction of Air Flow Figure 2-48: -C1 Model Showing Perforated Covers for External Fans Figure 2-49: -C2 1U Fan Location and Air Flow Figure 3-1: Drive Interface Board Figure B-1: Voltage Selection Switch Access www.aerotech.com...

  • Page 7: List Of Tables

    Mating Connector Part Numbers for the DIN Connector Table 2-36: Digital Input Specifications Table 2-37: Aux Encoder Connector Pinout Table 2-38: Mating Connector Part Numbers for the Aux Encoder Connectors Table 2-39: Square Wave Encoder Specifications Table 2-40: Sine Wave Encoder Specifications www.aerotech.com...
  • Page 8 Table 2-56: HyperWire Card Part Number Table 2-57: HyperWire Cable Part Numbers Table 3-1: LED Description Table 3-2: Troubleshooting Table 3-3: Preventative Maintenance Table 3-4: Drive Interface Board Motor Power Fuse Replacement Part Numbers Table B-1: AC Voltage Selector Switch Settings www.aerotech.com...

  • Page 9: Eu Declaration Of Conformity

    XR3 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 following Directive(s):...
  • Page 10 EU Declaration of Conformity XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 11: Agency Approvals

    Certificate #: Z10 068995 0030 Rev. 00 Standards: IEC 61508-1:2010 (up to SIL 3) 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 12 Agency Approvals XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 13: Safety Procedures And Warnings

    To find the newest information about this product, refer to www.aerotech.com. If you do not understand the information in this manual, contact Aerotech Global Technical Support. IMPORTANT: This product has been designed for light industrial manufacturing or laboratory environments.
  • Page 14 2. Do not use the cables or the connectors to lift or move this product. 3. Use this product only in environments and operating conditions that are approved in this manual. 4. Only trained operators should operate this equipment. www.aerotech.com...

  • Page 15: Installation Overview

    Connect the power source to the AC Power Input. Section 2.1.1. Connect a PC HyperWire port to the HyperWire In port. Section 2.11. Connect the motors to the Motor Power inputs. Section 2.2. Connect the motors to the Motor Feedback inputs. Section 2.3. Figure 1: Installation Connection Overview  www.aerotech.com...
  • Page 16 Installation Overview XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 17: Chapter 1: Introduction

    Four analog sensor inputs per axis with one used as a motor over-temperature input and one used as an encoder fault input Thermistor Section 2.3.3. Encoder Fault Section 2.3.4. CW, CCW, and Home Limit Inputs Section 2.3.5. Encoder / Marker Inputs (auxiliary) Section 2.8. www.aerotech.com...

  • Page 18: Table 1-2: Configurations And Options

    Axis 1 (Required) Axis 2-6 (Optional) None None XSP3-10 PWM amplifier XSP3-10 PWM amplifier XSP3-20 PWM amplifier XSP3-20 PWM amplifier XSP3-30 PWM amplifier XSP3-30 PWM amplifier XSL3-10-40 linear amplifier XSL3-10-40 linear amplifier Note: "-" is applied to the first axis option only. A three axis order would look like: -P1P1P1. www.aerotech.com...
  • Page 19 Internal Shunt Section 2.1.4. -SI0 No internal shunt -SI1 Internal shunt for first bus -SI2 Internal shunt for second bus -SI3 Internal shunt for first and second bus Version -DEFAULT Firmware Matches Software Line -LEGACY Legacy Firmware Version X.XX.XXX www.aerotech.com...

  • Page 20: Figure 1-1: Functional Diagram

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

  • Page 21: Electrical Specifications

    Peak and RMS over current limit. Over Temperature shutdown. Bus supply inrush current limit during initial power-on. Opto and transformer isolation between control and power Indicator (Power) stages. Indicator (Enabled) Power switch contains a power-on indicator. Protection Individual Amplifier LED’s indicates drive enabled state. www.aerotech.com...

  • Page 22: Table 1-4: Pwm Amplifier Electrical Specifications

    20 minutes continuous power (1) This specification depends on the motor supply voltage, the motor speed, and motor resistance. Contact an Aerotech sales engineer for more information. (2) This specification assumes that an AC or DC motor type with a 0 Ω winding resistance is used.

  • Page 23: System Power Requirements

    Power Output [W] = Torque [N·m] * Angular velocity[rad/sec] Power Loss = I(rms)^2 * R Power Input = (Pout + Ploss) / EfficiencyFactor Linear Motor Power Dissipation [W] = MotorCurrentPeak[A] * TotalBusVoltage[V] * 3 / 2 Power Input = (Power Dissipation) / EfficiencyFactor www.aerotech.com...

  • Page 24: Mechanical Specifications

    3. Lift this product only by the base. Do not use the cables or the connectors to lift or move this product. 4. Do not use the handles on the front of the product to lift or move this product. Use the handles only to slide the product in and out of its enclosure. www.aerotech.com...

  • Page 25: Dimensions

    XR3 Hardware Manual 1.2.2. Dimensions 1.2.2. Dimensions Figure 1-2: Dimensions with Chassis Slides www.aerotech.com...

  • Page 26: Figure 1-3: Dimensions Without Chassis Slides

    1.2.2. Dimensions XR3 Hardware Manual Figure 1-3: Dimensions without Chassis Slides www.aerotech.com...

  • Page 27: 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 28: Drive And Software Compatibility

    Last Software Version column, drives that show a specific version number are not supported after that version. Table 1-8: Drive and Software Compatibility Drive Type Software First Software Version Last Software Version Automation1 Current Automation1 XR3 A3200 6.04 Current www.aerotech.com...

  • Page 29: Chapter 2: Installation And Configuration

    1. Lift this product only by the base.Do not use the cables or the connectors to lift or move this product. 2. Do not use the handles on the front of the product to lift or move this product. Use the handles only to slide the product in and out of its enclosure. www.aerotech.com...

  • Page 30: Electrical Installation

    WARNING: Before powering on the XR3, verify that all drive modules and cables to the XR3 have been properly installed. Refer to the remaining chapters of this manual for installation and configuration procedures. Confirm that the AC power is the correct voltage before turning on power to the XR3. www.aerotech.com...

  • Page 31: Ac Power Connections

    EMI coupling and interference. DANGER: See the user documentation provided with your XR3 system to determine if the XR3 chassis is limited to only one AC input voltage. Operation at other voltages may result in damage to the XR3 chassis. www.aerotech.com...

  • Page 32: Minimizing Noise For Emc/Ce Compliance

    EMC system evaluation. 1. Add a clamp-on ferrite to the feedback cable close to the drive. [Aerotech PN ECZ02348, Fair-rite PN 0446167281] 2.1.3. I/O and Signal Requirements The I/O, communication, and encoder feedback connections are typically very low power connections. In some applications, especially when there are significant wire distances, a larger wire size may be required to reduce the voltage drop that occurs along the wire.

  • Page 33: Internal Shunt Option [-Si#]

    For multiple axes, add the energy contribution for each axis that shares a power supply and decelerates simultaneously. Compare the sum against the maximum energy limits shown in Table 2-3. For Linear Axes: For Rotary Axes: moving mass [kg] inertia [kg·m 2 ] speed [m/s] speed [rad/s] stored energy [J] stored energy [J] www.aerotech.com...

  • Page 34: Motor Power Output Connector

    Brushless Phase A Motor Power 1.3 mm (#16 AWG) DC Brush + Stepper Table 2-5: Mating Connector Part Numbers for the Motor Power Output Connector Aerotech P/N Third Party Source P/N Description Male 5 Pin D-Style ECK01236 ITT Cannon DBM5W5PK87 Contact (QTY. 5) ECK00660 ITT Cannon DM53745-7...

  • Page 35: Brushless Motor Connections

    Section 2.2.1.2. for unpowered motor and feedback phasing. For Aerotech-supplied systems, the motor, encoder and Hall sensors are correctly configured and connection adjustments are not necessary. A motor filter module can be installed between the drive and the motor to reduce the effects on PWM generated noise currents.

  • Page 36: Brushless Motor Powered Motor And Feedback Phasing

    Observe the state of the encoder and Hall-effect device signals in the Diagnostics section of the Status Utility. Table 2-6: Hall Signal Diagnostics Hall-Signal Status Definition 0 V or logic low 5 V or logic high Figure 2-3: Positive Motor Direction Figure 2-4: Encoder and Hall Signal Diagnostics www.aerotech.com...

  • Page 37: Brushless Motor 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 38: Dc Brush Motor Connections

    5. Connect the motor lead from the positive lead of the voltmeter to the ØA motor terminal on the XR3. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the XR3. For Aerotech-supplied systems, the motor, encoder and Hall sensors are correctly configured and connection adjustments are not necessary. www.aerotech.com...

  • Page 39: Stepper Motor Connections

    After the motor has been phased, if you want to change the direction of positive motion, use the ReverseMotionDirection parameter. Figure 2-10: Positive Motor Direction For Aerotech-supplied systems, the motor, encoder and Hall sensors are correctly configured and connection adjustments are not necessary. www.aerotech.com...

  • Page 40: Feedback Connector

    Pin # Description In/Out/Bi Connector Reserved Motor Over Temperature Thermistor Input +5V Power Plug and Play Serial Data (for Aerotech stages only) Bidirectional Hall-Effect Sensor B (brushless motors only) Input Encoder Marker Reference Pulse - Input Absolute Encoder Clock -...

  • Page 41: Primary Encoder Inputs

    Absolute Encoder Data - Bidirectional Encoder Cosine + Input Encoder Cosine - Input +5V Power Encoder Sine + Input Encoder Sine - Input Absolute Encoder Data+ Bidirectional Signal Common Signal Common (1) The maximum combined current output is 500 mA. www.aerotech.com...

  • Page 42: Square Wave Encoder

    Use twisted-pair wiring for the highest performance and noise immunity. Table 2-11: Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum (25 ns minimum edge separation) x4 Quadrature Decoding 40 million counts/sec Figure 2-11: Square Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 43: Absolute Encoder

    You cannot echo an absolute encoder signal. Refer to Figure 2-12 for the serial data stream interface. Refer to the Help file for information on how to set up your EnDat or BiSS absolute encoder parameters. Figure 2-12: Absolute Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 44: Sine Wave Encoder [-Ct1/-Ct2/-Ct4 Option]

    65,536 -CT2/-CT4 Primary Encoder Channel 800 nsec (analog input to quadrature output) Interpolation Latency Input Common Mode 1.5 to 3.5 VDC (1) Measured as SIN(+) - SIN(-) or COS(+) - COS(-) Figure 2-13: Sine Wave Encoder Phasing Reference Diagram www.aerotech.com...

  • Page 45: Figure 2-14: Sine Wave Encoder Schematic (Feedback Connector)

    XR3 Hardware Manual 2.3.1.3. Sine Wave Encoder [-CT1/-CT2/-CT4 Option] Figure 2-14: Sine Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 46: Encoder Phasing

    Figure 2-15: Encoder Phasing Reference Diagram (Standard) IMPORTANT: Encoder manufacturers may refer to the encoder signals as A, B, and Z. The proper phase relationship between signals is shown in Figure 2-15. Figure 2-16: Position Feedback in the Diagnostic Display www.aerotech.com...

  • Page 47: Hall-Effect Inputs

    Hall-Effect Sensor B (brushless motors only) Input Hall-Effect Sensor A (brushless motors only) Input Hall-Effect Sensor C (brushless motors only) Input +5V Power Signal Common Signal Common (1) The maximum combined current output is 500 mA. Figure 2-17: Hall-Effect Inputs Schematic (Feedback Connector) www.aerotech.com...

  • Page 48: Thermistor Input

    1.385 kΩ. The circuit includes a 12 kΩ internal pull-up resistor which corresponds to a trip voltage of +0.52 V. Table 2-14: Thermistor Input Pin on the Feedback Connector Pin # Description In/Out/Bi Motor Over Temperature Thermistor Input Figure 2-18: Thermistor Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 49: Encoder Fault Input

    The nominal trip voltage of the encoder fault input is +2.5 V. Table 2-15: Encoder Fault Input Pin on the Feedback Connector Pin # Description In/Out/Bi Encoder Fault Input Input Figure 2-19: Encoder Fault Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 50: End Of Travel And Home Limit Inputs

    IMPORTANT: Use NPN-type normally-closed limit switches (Active High) to provide fail- safe behavior in the event of an open circuit. www.aerotech.com...

  • Page 51: Figure 2-20: End Of Travel And Home Limit Input Connections

    XR3 Hardware Manual 2.3.5. End of Travel and Home Limit Inputs Figure 2-20: End of Travel and Home Limit Input Connections Figure 2-21: End of Travel and Home Limit Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 52: End Of Travel And Home Limit Phasing

    CW and CCW inputs at the Feedback connector or swap the CW and CCW limit functionality in the software using the EndOfTravelLimitSetup parameter. View the logic level of the EOT limit inputs in the Diagnostics display (shown in Figure 2-22). Figure 2-22: End of Travel and Home Limit Input Diagnostic Display www.aerotech.com...

  • Page 53: Brake Output

    Specification Value Output Voltage 24 V Output Current .5 A Total Brake Current with all Axes Combined Figure 2-23: Brake Output Connections (Feedback Connector) IMPORTANT: The brake itself will normally cause a small change in axis position when activated. www.aerotech.com...

  • Page 54: Position Synchronized Output Connector (Pso)

    PSO Specifications  Specification Value 12.5 MHz Maximum PSO Output (Fire) Frequency Isolated 5 MHz Output Latency 50 ns [Fire event to output change] Isolated 150 ns 1. Signals in excess of this rate will cause a loss of PSO accuracy www.aerotech.com...

  • Page 55: Pso Isolated Outputs

    Output PSO Output 2 + (Isolated) [A3200: PSO Output 1 +] Output PSO Output 1 - (Isolated) [A3200: PSO Output 0 -] Output PSO Output 1 + (Isolated) [A3200: PSO Output 0 +] Output Figure 2-24: PSO Output Sources Current Figure 2-25: PSO Output Sinks Current www.aerotech.com...

  • Page 56: Pso Ttl Outputs

    Pin # Description In/Out/Bi PSO Output 3 (5 V TTL) [A3200: PSO Output 2] Output Ground PSO Output 2 (5 V TTL) [A3200: PSO Output 1] Output Ground Ground PSO Output 1 (5 V TTL) [A3200: PSO Output 0] Output Figure 2-26: PSO TTL Outputs Schematic www.aerotech.com...

  • Page 57: External Pso Synchronization

    External PSO Sync 2 + [A3200: External PSO Sync 1 +] Input External PSO Sync 2 - [A3200: External PSO Sync 1 -] Input External PSO Sync 3 + [A3200: External PSO Sync 2 +] Input External PSO Sync 3 - [A3200: External PSO Sync 2 -] Input Figure 2-27: PSO Clock Inputs Schematic www.aerotech.com...

  • Page 58: Data Acquisition Inputs

    Data Acquisition Input Pins on the PSO Connector Pin # Description In/Out/Bi Data Acquisition + Input Data Acquisition - Input Table 2-27: Data Acquisition Opto-Isolator Input Specifications Specification (HCPL-0630) Value Input Voltage 5-24 V Input Current 10 mA Figure 2-28: Data Acquisition Input Schematic www.aerotech.com...

  • Page 59: Hsout Connector (High-Speed Outputs)

    Output Axis 6 High-Speed Output 1 + Output Axis 6 High-Speed Output 1 - Output Table 2-30: Mating Connector Part Numbers for the HSOUT Connector Mating Connector Aerotech P/N Third Party P/N 25-Pin D-Connector ECK00101 FCI DB25P064TXLF Backshell ECK00656 Amphenol 17E-1726-2...

  • Page 60: Figure 2-29: Diagram Showing Axis 1 And Axis 2 High-Speed Outputs

    IMPORTANT: The High-Speed Output signal format is not directly compatible with clock and direction inputs found on most stepper motor drives. Use an external RS-422 line receiver to provide the signal level translation. Figure 2-29: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs www.aerotech.com...

  • Page 61: Dout Connector (Digital Outputs)

    24 V (26 V Maximum) Maximum Sink/Source Current 250 mA/output Output Saturation Voltage 0.9 V at maximum current Output Resistance 3.7 Ω Rise / Fall Time 250 µs (2K pull up to 24V) Reset State Output Off (High Impedance State) www.aerotech.com...

  • Page 62: Table 2-32: Dout Connector Digital Outputs Pinout

    Output Port 3 Digital Output 14 Output Port 3 Digital Output 15 Output Ground Table 2-33: Mating Connector Part Numbers for the DOUT Connector 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 63: Figure 2-30: Digital Output Schematic

    XR3 Hardware Manual 2.6. DOUT Connector (Digital Outputs) Figure 2-30: Digital Output Schematic www.aerotech.com...

  • Page 64: Figure 2-31: Digital Outputs Connected In Current Sourcing Mode

    2.6. DOUT Connector (Digital Outputs) XR3 Hardware Manual Figure 2-31: Digital Outputs Connected in Current Sourcing Mode Figure 2-32: Outputs Connected in Current Sinking Mode www.aerotech.com...

  • Page 65: Din Connector (Digital Inputs)

    Port 0 Digital Input 1 Input Port 0 Digital Input 0 Input Port 0 Digital Input Common Table 2-35: Mating Connector Part Numbers for the DIN Connector Mating Connector Aerotech P/N Third Party P/N 25-Socket D-Connector ECK00300 Cinch DB-25S Backshell ECK00656 Amphenol 17E-1726-2...

  • Page 66: Figure 2-33: Digital Input Schematic

    2.7. DIN Connector (Digital Inputs) XR3 Hardware Manual Figure 2-33: Digital Input Schematic www.aerotech.com...

  • Page 67: Figure 2-34: Digital Inputs Connected To Current Sinking (Npn) Devices

    XR3 Hardware Manual 2.7. DIN Connector (Digital Inputs) Figure 2-34: Digital Inputs Connected to Current Sinking (NPN) Devices Figure 2-35: Digital Inputs Connected to Current Sourcing (PNP) Devices www.aerotech.com...

  • Page 68: Aux Encoder Connectors

    Auxiliary Cosine + Bidirectional Absolute Encoder Clock + Output Auxiliary Marker - Input Table 2-38: Mating Connector Part Numbers for the Aux Encoder Connectors Mating Connector Aerotech P/N Third Party P/N 9-Pin D-Connector ECK00137 Cinch DE-9P Backshell ECK01021 Amphenol 17E-1724-2 www.aerotech.com...

  • Page 69: Square Wave Encoder

    Use twisted-pair wiring for the highest performance and noise immunity. Table 2-39: Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum (25 ns minimum edge separation) x4 Quadrature Decoding 40 million counts/sec Figure 2-36: Square Wave Encoder Interface (Aux Encoder Connector) www.aerotech.com...

  • Page 70: Absolute Encoder

    You cannot use an absolute encoder with incremental signals on the Aux Encoder Connector. Refer to Figure 2-37 for the serial data stream interface. Refer to the Help file for information on how to set up your EnDat or BiSS absolute encoder parameters. Figure 2-37: Absolute Encoder Schematic (Aux Encoder Connector) www.aerotech.com...

  • Page 71: Sine Wave Encoder [-Ct4 Option]

    65,536 -CT2/-CT4 Primary Encoder Channel 800 nsec (analog input to quadrature output) Interpolation Latency Input Common Mode 1.5 to 3.5 VDC (1) Measured as SIN(+) - SIN(-) or COS(+) - COS(-) Figure 2-38: Sine Wave Encoder Phasing Reference Diagram www.aerotech.com...

  • Page 72: Figure 2-39: Sine Wave Encoder Schematic (Aux Encoder Connector)

    2.8.3. Sine Wave Encoder [-CT4 Option] XR3 Hardware Manual Figure 2-39: Sine Wave Encoder Schematic (Aux Encoder Connector) www.aerotech.com...

  • Page 73: Analog I/O Connectors

    +5 VA Ground Joystick Button A Input Joystick Button B Input Joystick Interlock Input Table 2-42: Mating Connector Part Numbers for the Analog I/O Connectors Mating Connector Aerotech P/N Third Party P/N Amphenol 17EHD-015P- 15-Pin D-Connector ECK01287 AA000 Backshell ECK01021 Amphenol 17-1724-2 www.aerotech.com...

  • Page 74: Analog Outputs

    Output Current 5 mA Resolution (bits) 16 bits Table 2-44: Analog Output Pins on the Analog I/O Connector Pin # Description In/Out/Bi Ground Analog Output 0 Output Ground Ground Analog Output 1 Output Ground Ground Figure 2-40: Analog Outputs Schematic www.aerotech.com...

  • Page 75: Analog Inputs (Differential)

    Analog Input Pins on the Analog I/O Connector Pin # Description In/Out/Bi Analog Input 0+ Input Analog Input 0- Input Ground Ground Analog Input 1 + Input Analog Input 1 - Input Ground Ground Ground Figure 2-41: Analog Inputs Schematic www.aerotech.com...

  • Page 76: Joystick Interface

    Pin # Description In/Out/Bi Analog Input 0+ Input Analog Input 0- Input Analog Input 1 + Input Analog Input 1 - Input +5 VA Ground Joystick Button A Input Joystick Button B Input Joystick Interlock Input Figure 2-42: Joystick Interface Inputs Schematic www.aerotech.com...

  • Page 77: Figure 2-43: Joystick Cable Wiring Schematic

    XR3 Hardware Manual 2.9.3. Joystick Interface Aerotech Multi-Axis Joystick (NEMA12 (IP54) rated) is powered from 5 V and has a nominal 2.5 V 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 78: Safe Torque Off Input (Sto)

    Reserved Used to defeat STO by connecting to STO 1- Power Supply - and STO 2- Table 2-49: Mating Connector Part Numbers for the STO Connector Mating Connector Aerotech P/N Third Party P/N 9-Pin D-Connector ECK00137 Cinch DE-9P Backshell ECK01021 Amphenol 17E-1724-2...

  • Page 79: Figure 2-44: Typical Configuration

    WARNING: The XR3 does not check for short circuits on the external STO wiring. If this is not done by the external safety device, short circuits on the wiring must be excluded. Refer to EN ISO 13849-2. For Category 4 systems, the exclusion of short circuits is mandatory. Figure 2-44: Typical Configuration www.aerotech.com...

  • Page 80: Sto Standards

    Interval for manual STO test: EN/IEC 61508 Once per year for SIL2/PL d/category 3 Once per three months for SIL3/PL e/category 3 Once per day for SIL3/PL e/category 4 SIL3 EN/IEC 61508 PFH < 3 FIT SFF > 99% www.aerotech.com...

  • Page 81: Sto Functional Description

    Connect the ESTOP signal directly to a digital input, in addition to the external timer, to allow the XR3 to begin a software-controlled stop as soon as the ESTOP signal becomes active. Use the EmergencyStopFaultInput [A3200: ESTOPFaultInput] parameter to configure a digital input as an ESTOP input. www.aerotech.com...

  • Page 82: Sto Startup Validation Testing

    (open circuit or 0 V), and that the STO channel is in the safe state. DANGER: The STO circuit does not remove lethal voltage from the motor terminals. AC mains power must be removed before servicing. www.aerotech.com...

  • Page 83: Sto Diagnostics

    STO inputs before the STO Delay Time, an STO hardware shutdown will not occur but a software stop may, depending on the width of the STO pulse. The controller will ignore STO active pulses shorter in length than the STOPulseFilter parameter setting. www.aerotech.com...

  • Page 84: 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 85: Cooling Options [-C0/-C1/-C2 Option]

    Location of the Rear Fan and Air Flow Built In Cooling [-C0] Built-in fans pull cooling air from the left side through the amplifier compartment. Refer to Figure 2-47. Figure 2-47: -C0 Fan Location and Direction of Air Flow www.aerotech.com...
  • Page 86 If you ordered an XR3 with the External Cooling option, you will be required to provide forced air-cooling to the XR3 drive chassis. Provide cooling to the XR3 by directing the airflow through the perforated covers of the XR3 chassis. Refer to Figure 2-48. Figure 2-48: -C1 Model Showing Perforated Covers for External Fans www.aerotech.com...
  • Page 87 Fan Tray Option [-C2] If you ordered an XR3 with the Fan Tray option, Aerotech will attach a 1U fan tray to the bottom of the chassis at the factory. The tray houses two fans that will direct airflow through the XR3 drive chassis from the bottom to the top.

  • Page 88: Pc Configuration And Operation Information

    2.13. PC Configuration and Operation Information XR3 Hardware Manual 2.13. 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 89: Chapter 3: Maintenance

    The light is configured to blink for setup. Table 3-2: Troubleshooting Symptom Possible Cause and Solution Make sure the power LED is illuminated (this indicates that power is present). No Communication Make sure that all communication cables (HyperWire, for example) are fully inserted in their ports. www.aerotech.com...

  • Page 90: Preventative Maintenance

    Do not use fluids and sprays to clean the XR3 because they can easily go into the chassis or onto the outer connectors and components. If a cleaning solution goes into the XR3, 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 91: Fuse Specifications

    The most likely reason for a fuse to blow is if you have connected the unit to the wrong AC line voltage. Table 3-4: Drive Interface Board Motor Power Fuse Replacement Part Numbers Manufacturer Fuse Description Aerotech P/N F1 (-VB1 to -VB2) 2 A SLO BLO, 3AG EIF00102 Littelfuse 313002 F1 (-VB3 to -VB5)
  • Page 92 3.2. Fuse Specifications XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 93: Appendix A: Warranty And Field Service

    Aerotech’s products are specifically designed and/or manufactured for buyer’s use or purpose. Aerotech’s liability on any claim for loss or damage arising out of the sale, resale, or use of any of its products shall in no event exceed the selling price of the unit.
  • Page 94 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 95: Appendix B: Voltage Selection Operation

    2. Remove the four screws that secure the panel on the front of the XR3 3. Carefully remove the panel without pulling out the wiring connected to the Power Switch. 4. Use Table B-1 to set all of the voltage selector switches to the position indicated for the desired operating voltage. www.aerotech.com...

  • Page 96: Table B-1: Ac Voltage Selector Switch Settings

    Table B-1 applies to the Drive Interface Board with the P/N: EFN01746-01 (manual revision 1.00.00 and up). Customers with the Beta hardware and Beta manual revision should contact Aerotech for more information if you need to change voltage settings. Table B-1: AC Voltage Selector Switch Settings 100 VAC...

  • Page 97: Appendix C: Revision History

    Section 2.8. Aux Encoder Connectors Figure 2-43 Section 2.10. Safe Torque Off Input (STO) Section 2.12. Cooling Options [-C0/-C1/-C2 Option] 1.01 Revision changes have been archived. If you need a copy of this revision, contact 1.00 Aerotech Global Technical Support. Beta www.aerotech.com...
  • Page 98 Appendix C: Revision History XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 99: Index

    Brushless Motor Unpowered Motor and Feedback Ambient Temperature Phasing Analog Encoder (Aux Connector) Built In Cooling Analog Encoder (Feedback Connector) Built In Cooling [-C0] Analog Encoder Phasing Reference Diagram 44,71 Bus Voltage 1 and Bus Voltage 2 Configurations Analog Encoder Schematic (Aux Encoder Connector) www.aerotech.com...
  • Page 100 End of Travel Limit Input Connections (DIN Connector) End of Travel Limit Input Diagnostic Display Digital Inputs Connector (DIN Connector) End of Travel Limit Input Pins on the Feedback Connector 50 Digital Output Pinout (DOUT Connector) End of Travel Limit Input Schematic www.aerotech.com...
  • Page 101 Analog Encoder Schematic (Feedback Connector) Square Wave Encoder Schematic (Feedback Analog Inputs Schematic Connector) Analog Outputs Schematic (Analog I/O Connectors) Stepper Motor Configuration Brake Option Connections (Internal) STO Timing Brushless Motor Configuration (Motor Power Output 35 Thermistor Input Schematic www.aerotech.com...
  • Page 102 Mating Connector Part Numbers Internal Shunt Motor Function Relative to STO Input State Introduction Motor Power Output Connector IP54 Compliant Brushless Motor Connections IP54 Enclosure (STO) DC Brush Motor Connections Isolated Output Current Sinks Schematic (PSO) Mating Connector Part Numbers www.aerotech.com...
  • Page 103 Home Limit Input Pins (Feedback Connector) Safe Torque Off Input (STO) HSOUT Connector Safety Procedures and Warnings Isolated Output Pins (PSO Connector) serial data stream 43,70 Joystick Interface Pins (Analog I/O Connectors) serial number Motor Power Output Connector Servo Amplifier Electrical Specifications www.aerotech.com...
  • Page 104 Square Wave Encoder Schematic (Feedback Connector) Square Wave Encoder Specifications (Feedback Voltage Selection Connector) 42,69 Voltage Selection Switch Access Standard Features Stepper Motor Configuration Stepper Motor Connections (Motor Power Output Warranty and Field Service Connector) Stepper Motor Phasing Connector Pinout Diagnostics Electrical Specifications www.aerotech.com...

This manual is also suitable for:

Xsr3-10Xsr3-20Xsr3-30Xsl3-10-40

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