Aerotech Automation1 iXR3 Hardware Manual
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Aerotech Automation1 iXR3 Hardware Manual

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Automation1 iXR3 and XR3 Drive Racks

HARDWARE MANUAL
Revision 2.08

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Summary of Contents for Aerotech Automation1 iXR3

  • Page 1: Automation1 Ixr3 And Xr3 Drive Racks

    Automation1 iXR3 and XR3 Drive Racks HARDWARE MANUAL Revision 2.08...
  • Page 2 Global Technical Support Portal for information and support about your Aerotech, Inc. products. The website supplies software, product manuals, Help files, training schedules, and PC-to-PC remote technical support. If necessary, you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts.

  • Page 3: Table Of Contents

    Hardware Manual Table of Contents Table of Contents Automation1 iXR3 and XR3 Drive Racks Table of Contents List of Figures List of Tables EU Declaration of Conformity Agency Approvals Safety Procedures and Warnings Handling and Storage Installation Overview Chapter 1: iXR3/XR3 Overview 1.1.
  • Page 4 2.13. Industrial Ethernet (iXR3 Only) 2.14. Cooling Options [-C0/-C1/-C2 Option] 2.15. PC Configuration and Operation Information Chapter 3: Maintenance 3.1. Preventative Maintenance 3.2. Fuse Specifications 3.3. Amplifier Replacement Appendix A: Warranty and Field Service Appendix B: Voltage Selection Operation Appendix C: Revision History Index www.aerotech.com...

  • Page 5: List Of Figures

    Digital Inputs Connected to Current Sinking (NPN) Devices Figure 2-39: Square Wave Encoder Interface (Aux Encoder Connector) Figure 2-40: Absolute Encoder Schematic (Aux Encoder Connector) Figure 2-41: Sine Wave Encoder Phasing Reference Diagram Figure 2-42: Sine Wave Encoder Schematic (Aux Encoder Connector) www.aerotech.com...
  • Page 6 -C0 Fan Location and Direction of Air Flow Figure 2-51: -C1 Model Showing Perforated Covers for External Fans Figure 2-52: -C2 1U Fan Location and Air Flow Figure 3-1: Drive Interface Board Figure 3-2: Amplifier Removal Figure 3-3: Slot Details 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 Sync-Related Functions Table 2-59: Sync Port Cables Table 2-60: -C1 Option Airflow Specifications 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

    Hardware Manual EU Declaration of Conformity EU Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product iXR3/XR3 Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the following directive(s):...

  • Page 10: Agency Approvals

    IEC 62061:2005 (up to SILCL3), IEC 62061:2005/AMD1:2012 (up to SILCL3), IEC 62061:2005/AMD2:2015 (up to SILCL3) 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 11: 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 12 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 13: Handling And Storage

    Store the drive rack in the original shipping container. If the original packaging included ESD protective packaging, make sure to store the drive rack in it. The storage location must be dry, free of dust, free of vibrations, and flat. Section 1.3. Environmental Specifications Refer to www.aerotech.com...

  • Page 14: 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. www.aerotech.com...

  • Page 15: Chapter 1: Ixr3/Xr3 Overview

    The iXR3 runs the Automation1-iSMC controller to generate commands for itself as well as for additional drives on the chain. The XR3 is based on the HyperWire communication protocol and receives commands from a PC or drive-based controller. Figure 1-1: iXR3 Connection Overview www.aerotech.com...

  • Page 16: Figure 1-2: Xr3 Connection Overview

    Chapter 1: iXR3/XR3 Overview iXR3/XR3 Hardware Manual Figure 1-2: XR3 Connection Overview www.aerotech.com...

  • Page 17: Table 1-1: Feature Summary

    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 1-3: Functional Diagram

    Chapter 1: iXR3/XR3 Overview iXR3/XR3 Hardware Manual The block diagram that follows shows a summary of the connector signals. Figure 1-3: Functional Diagram www.aerotech.com...

  • Page 21: Electrical Specifications

    AC Line voltage, and motor requirements. The power label shows the factory-configured AC power requirements (Figure 1-4). DANGER: Update the AC power label if you reconfigure the AC Input Voltage. Figure 1-4: iXR3/XR3 AC Power Label Location www.aerotech.com...

  • Page 22: Table 1-3: 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 23: 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 a motor winding resistance of 0 Ω.

  • Page 24: 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 25: 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 26: Dimensions

    1.2.2. Dimensions iXR3/XR3 Hardware Manual 1.2.2. Dimensions IMPORTANT: iXR3 and XR3 dimensions are the same. iXR3 is shown. Figure 1-5: Dimensions with Chassis Slides www.aerotech.com...

  • Page 27: Figure 1-6: Dimensions Without Chassis Slides

    Hardware Manual 1.2.2. Dimensions IMPORTANT: iXR3 and XR3 dimensions are the same. iXR3 is shown. Figure 1-6: Dimensions without Chassis Slides www.aerotech.com...

  • Page 28: 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 29: 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 iXR3 Automation1 2.1.0 Current Automation1 1.2.0 Current A3200 6.04 Current www.aerotech.com...
  • Page 30 1.4. Drive and Software Compatibility iXR3/XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 31: Chapter 2: Installation And Configuration

    AC power and provides protection to the iXR3/XR3 system in case of severe overloads. This breaker is selected to meet the maximum current requirements of the iXR3/XR3 system and is normally a 10 A breaker. Figure 2-1: iXR3 Connection Overview www.aerotech.com...

  • Page 32: Figure 2-2: Xr3 Connection Overview

    WARNING: Before powering on the iXR3/XR3, verify that all drive modules and cables to the iXR3/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 iXR3/XR3. www.aerotech.com...

  • Page 33: Ac Power Connections

    DANGER: Refer to the user documentation provided with your system to determine if the drive rack is limited to only one AC input voltage. You could damage the iXR3/XR3 if you operate the at other voltages may result in damage to the drive rack. www.aerotech.com...

  • Page 34: 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.

  • Page 35: Internal Shunt Option [-Si#]

    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 36: 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 37: 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 38: 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 2-4: Positive Motor Direction Figure 2-5: Encoder and Hall Signal Diagnostics www.aerotech.com...

  • Page 39: 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 40: Dc Brush Motor Connections

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

  • Page 41: Stepper Motor Connections

    After the motor has been phased, if you want to change the direction of positive motion, use the ReverseMotionDirection parameter. Figure 2-11: 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 42: Three Phase Stepper Motor Connections

    2-13). If the motor moves in a counterclockwise direction, reverse the motor leads and re-run the command. After the motor has been phased, if you want to change the direction of positive motion, use the ReverseMotionDirection parameter. Figure 2-13: Positive Motor Direction www.aerotech.com...

  • Page 43: Feedback Connector

    Pin # Description In/Out/Bi Connector Reserved Motor Over Temperature Thermistor Input +5V Power Output 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 - Output...

  • Page 44: Primary Encoder Inputs

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

  • Page 45: Square Wave Encoder (Primary)

    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 2-14: Square Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 46: Absolute Encoder (Primary)

    You cannot echo an absolute encoder signal. Refer to Figure 2-15 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 2-15: Absolute Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 47: Sine Wave Encoder (Primary) [-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 2-16: Sine Wave Encoder Phasing Reference Diagram www.aerotech.com...

  • Page 48: Figure 2-17: Sine Wave Encoder Schematic (Feedback Connector)

    2.3.1.3. Sine Wave Encoder (Primary) [-CT1/-CT2/-CT4 iXR3/XR3 Hardware Option] Manual Figure 2-17: Sine Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 49: Encoder Phasing

    Figure 2-18: 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 2-18. Figure 2-19: Position Feedback in the Diagnostic Display www.aerotech.com...

  • Page 50: Hall-Effect Inputs

    Hall-Effect Sensor A (brushless motors only) Input Hall-Effect Sensor C (brushless motors only) Input +5V Power Output Signal Common Output Signal Common Output (1) The maximum combined current output is 500 mA. Figure 2-20: Hall-Effect Inputs Schematic (Feedback Connector) www.aerotech.com...

  • Page 51: 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 2-21: Thermistor Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 52: 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 2-22: Encoder Fault Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 53: 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 54: Figure 2-23: End Of Travel And Home Limit Input Connections

    2.3.5. End of Travel and Home Limit Inputs iXR3/XR3 Hardware Manual Figure 2-23: End of Travel and Home Limit Input Connections Figure 2-24: End of Travel and Home Limit Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 55: End Of Travel And Home Limit Phasing

    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 2-25). Figure 2-25: End of Travel and Home Limit Input Diagnostic Display www.aerotech.com...

  • Page 56: Brake Output

    Specification Value Output Voltage 24 V Output Current .5 A Total Brake Current with all Axes Combined Figure 2-26: Brake Output Connections (Feedback Connector) IMPORTANT: The brake itself will normally cause a small change in axis position when activated. www.aerotech.com...

  • Page 57: 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 58: 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 2-27: PSO Output Sources Current Figure 2-28: PSO Output Sinks Current www.aerotech.com...

  • Page 59: 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 2-29: PSO TTL Outputs Schematic www.aerotech.com...

  • Page 60: 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 2-30: PSO Clock Inputs Schematic www.aerotech.com...

  • Page 61: 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 2-31: Data Acquisition Input Schematic www.aerotech.com...

  • Page 62: 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 63: Figure 2-32: 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 2-32: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs www.aerotech.com...

  • Page 64: 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 65: 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 66: Figure 2-33: Digital Output Schematic

    2.6. DOUT Connector (Digital Outputs) iXR3/XR3 Hardware Manual Figure 2-33: Digital Output Schematic www.aerotech.com...

  • Page 67: Figure 2-34: Digital Outputs Connected In Current Sourcing Mode

    Hardware Manual 2.6. DOUT Connector (Digital Outputs) Figure 2-34: Digital Outputs Connected in Current Sourcing Mode Figure 2-35: Outputs Connected in Current Sinking Mode www.aerotech.com...

  • Page 68: Din Connector (Digital Inputs)

    Input Port 0 Digital Input 0 Input Port 0 Digital Input Common Output 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 Table 2-36:...

  • Page 69: Figure 2-36: Digital Input Schematic

    Hardware Manual 2.7. DIN Connector (Digital Inputs) Figure 2-36: Digital Input Schematic www.aerotech.com...

  • Page 70: Figure 2-37: Digital Inputs Connected To Current Sourcing (Pnp) Devices

    2.7. DIN Connector (Digital Inputs) iXR3/XR3 Hardware Manual Figure 2-37: Digital Inputs Connected to Current Sourcing (PNP) Devices Figure 2-38: Digital Inputs Connected to Current Sinking (NPN) Devices www.aerotech.com...

  • Page 71: 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 72: Square Wave Encoder (Auxiliary)

    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 2-39: Square Wave Encoder Interface (Aux Encoder Connector) www.aerotech.com...

  • Page 73: Absolute Encoder (Auxiliary)

    You cannot use an absolute encoder with incremental signals on the Aux Encoder Connector. Refer to Figure 2-40 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 2-40: Absolute Encoder Schematic (Aux Encoder Connector) www.aerotech.com...

  • Page 74: Sine Wave Encoder (Auxiliary) [-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 2-41: Sine Wave Encoder Phasing Reference Diagram www.aerotech.com...

  • Page 75: Figure 2-42: Sine Wave Encoder Schematic (Aux Encoder Connector)

    Hardware Manual 2.8.3. Sine Wave Encoder (Auxiliary) [-CT4 Option] Figure 2-42: Sine Wave Encoder Schematic (Aux Encoder Connector) www.aerotech.com...

  • Page 76: Analog I/O Connectors

    Output 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 77: 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 2-43: Analog Outputs Schematic www.aerotech.com...

  • Page 78: 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 2-44: Analog Inputs Schematic www.aerotech.com...

  • Page 79: Joystick Interface

    In/Out/Bi Analog Input 0+ Input Analog Input 0- Input Analog Input 1 + Input Analog Input 1 - Input +5 VA Output Ground Joystick Button A Input Joystick Button B Input Joystick Interlock Input Figure 2-45: Joystick Interface Inputs Schematic www.aerotech.com...

  • Page 80: Figure 2-46: Joystick Cable Wiring Schematic

    2.9.3. Joystick Interface iXR3/XR3 Hardware Manual 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.

  • Page 81: Safe Torque Off Input (Sto)

    Use only to defeat STO by connecting to Power Supply - Output STO 1- and STO 2-. Not for customer use. 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 www.aerotech.com...

  • Page 82: Figure 2-47: Typical Sto Configuration

    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 2-47: Typical STO Configuration www.aerotech.com...

  • Page 83: 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 84: Sto Functional Description

    STO inputs. Connect the ESTOP signal directly to a digital input, in addition to the external timer, to allow the controller 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 85: 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 86: Sto Diagnostics

    If power is reapplied to the 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 87: 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 88: Sync Port

    The controller is equipped with 100BASE-TX Industrial Ethernet ports. IMPORTANT: Industrial Ethernet is only available on the iXR3. For the location of the ports, refer to Figure 1-1. For cable part numbers, refer to Table 1-1. For more information, refer to the Help system. www.aerotech.com...

  • Page 89: 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- Figure 2-50: -C0 Fan Location and Direction of Air Flow www.aerotech.com...

  • Page 90: Figure 2-51: -C1 Model Showing Perforated Covers For External Fans

    You will need to direct airflow through the perforated covers. Refer to Figure 2-51. Table 2-60: -C1 Option Airflow Specifications Amplifier Type Airflow Specification XSP Amplifiers (PWM) 50 CFM XSL Amplifiers (linear) 300 CFM Figure 2-51: -C1 Model Showing Perforated Covers for External Fans www.aerotech.com...

  • Page 91: Figure 2-52: -C2 1U Fan Location And Air Flow

    Fan Tray Option [-C2] If you ordered 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 drive rack from the bottom to the top.

  • Page 92: Pc Configuration And Operation Information

    2.15. PC Configuration and Operation Information iXR3/XR3 Hardware Manual 2.15. 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 93: 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 94: Preventative Maintenance

    Also make sure that it does not go onto the outer connectors and components. Internal contamination from the cleaning solution 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 95: 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) 3 A SLO BLO, 3AG...

  • Page 96: Amplifier Replacement

    Be aware that the amplifier must fit into the top and bottom guides b. Make sure that the amplifier is fully seated against the Drive Interface Board connector at the rear of the amplifier slot. 5. Tighten the two screws to secure the amplifier card in place. www.aerotech.com...
  • Page 97 Hardware Manual 3.3. Amplifier Replacement Figure 3-3: Slot Details www.aerotech.com...
  • Page 98 3.3. Amplifier Replacement iXR3/XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 99: Appendix A: Warranty And Field Service

    All Other Repairs - After Aerotech's evaluation, the buyer shall be notified of the repair cost. At such time the buyer must issue a valid purchase order to cover the cost of the repair and freight, or authorize the product(s) to be shipped back as is, at the buyer's expense.
  • Page 100 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...

  • Page 101: Appendix B: Voltage Selection Operation

    2. Remove the four screws that secure the panel on the front of the iXR3/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 102: 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 103: Appendix C: Revision History

    Table 2-40 2.01 Section 2.8.2. Added Absolute Encoder support on the Auxiliary I/O connector:  Absolute Encoder (Auxiliary) 2.00 1.03 1.02 Revision changes have been archived. If you need a copy of this revision, contact Aerotech Global Technical Support. 1.01 1.00 Beta www.aerotech.com...
  • Page 104 Appendix C: Revision History iXR3/XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 105: Index

    AC Voltage Selector Switch Settings Brushless Motor Configuration (Motor Power Output Agency Approvals Connector) Altitude Brushless Motor Connections (Motor Power Output Connector) Ambient Temperature Brushless Motor Phasing Goal Analog Encoder (Aux Connector) Brushless Motor Phasing Oscilloscope Example Analog Encoder (Aux Encoder) www.aerotech.com...
  • Page 106 Declaration of Conformity Encoder Input (Feedback Connector) Diagram Showing Axis 1 and Axis 2 High-Speed Outputs Encoder Input Pins on the Feedback Connector (HSOUT Connector) Encoder Phasing Digital Input Pinout (DIN Connector) Encoder Phasing Reference Diagram Digital Input Schematic (DIN Connector) www.aerotech.com...
  • Page 107 Absolute Encoder Schematic (Aux Encoder Connector) 73 Stepper Motor Configuration Absolute Encoder Schematic (Feedback Connector) STO Timing Analog Encoder Schematic (Aux Encoder Connector) Thermistor Input Schematic Analog Inputs Schematic Three Phase Stepper Motor Configuration Analog Outputs Schematic (Analog I/O Connectors) TTL Outputs Schematic (PSO) www.aerotech.com...
  • Page 108 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 Isolated Output Current Sources Schematic (PSO) Pinout www.aerotech.com...
  • Page 109 Hall-Effect Feedback Pins (Feedback Connector) Home Limit Input Pins (Feedback Connector) HSOUT Connector Safe Torque Off Input (STO) Isolated Output Pins (PSO Connector) Safety Procedures and Warnings Joystick Interface Pins (Analog I/O Connectors) serial data stream 46,73 Motor Power Output Connector serial number www.aerotech.com...
  • Page 110 45,72 Unit Weight Standard Features Stepper Motor Configuration Stepper Motor Connections (Motor Power Output Connector) Stepper Motor Phasing 41-42 Voltage Selection Voltage Selection Switch Access Connector Pinout Voltage Selection Switches Diagnostics Drive Interface Board Electrical Specifications External Delay Timer www.aerotech.com...
  • Page 111 Hardware Manual Index Warranty and Field Service www.aerotech.com...
  • Page 112 Index iXR3/XR3 Hardware Manual This page intentionally left blank. www.aerotech.com...

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