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Aerotech Ensemble CL Hardware Manual

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Hardware Manual
TM
AEROTECH.
AEROTECH.
COM
COM
ENB/FLT
POWER
MARKER
INPOS
ETHERNET
J103
MOTOR FEEDBACK
J104
ESTOP
TB101
AUX I/O
J105
EXTERNAL
TRANSFORMER
REQUIRED
28 VAC 10A MAX
0 VAC-CT
28 VAC 10A MAX
50/60Hz
A
B
C
DANGER!
High Voltage
Ensemble CL
Revision: 4.09.00
TM
AEROTECH.
AEROTECH.
COM
COM
AGND
ENB/FLT
POWER
AIN+
MARKER
AIN-
INPOS
AOUT
OP
OM
ETHERNET
0
J103
1
2
3
4
5
6
7
OP
OM
0
1
MOTOR FEEDBACK
2
J104
3
4
5
6
7
ESTOP
TB101
AUX I/O
C
J105
0
1
2
3
4
5
6
7
GND
EXTERNAL
C
TRANSFORMER
0
REQUIRED
1
2
28 VAC 10A MAX
3
0 VAC-CT
4
5
28 VAC 10A MAX
6
50/60Hz
7
+5V
A
NC
B
C
C
NO
DANGER!
High Voltage
P/N: EDU189

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Summary of Contents for Aerotech Ensemble CL

  • Page 1 Ensemble CL Hardware Manual P/N: EDU189 Revision: 4.09.00 AEROTECH. AEROTECH. AEROTECH. AEROTECH. AGND ENB/FLT ENB/FLT POWER POWER AIN+ MARKER MARKER AIN- INPOS INPOS AOUT ETHERNET ETHERNET J103 J103 MOTOR FEEDBACK MOTOR FEEDBACK J104 J104 ESTOP ESTOP TB101 TB101 AUX I/O J105...
  • 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 CL Table of Contents Table of Contents List of Figures List of Tables EC Declaration of Conformity Safety Procedures and Warnings Quick Installation Guide xiii Chapter 1: Introduction 1.1. Drive and Software Compatibility 1.2. Electrical Specifications 1.2.1.

  • Page 4: Table Of Contents

    Ensemble CL Table of Contents 2.7. RS-232 Interface (TB104) 2.8. PC Configuration and Operation Information Chapter 3: -I/O Expansion Board 3.1. Analog Output (TB201) 3.2. Analog Input (TB201) 3.3. Opto-Isolated Inputs (TB204, TB205) 3.4. Opto-Isolated Outputs (TB202, TB203) 3.5. User Power (TB204, TB205) 3.6.

  • Page 5: Table Of Contents Ensemble Cl

    Analog Input 0 (J105) Figure 2-39: Aeronet Connection with Three Discrete Drives Figure 2-40: RS-232 Interface (TB104) Figure 3-1: Ensemble CL with -IO Option Board Figure 3-2: Analog Output 1 Connector (TB201) Figure 3-3: Analog Input Typical Connection (TB201) Figure 3-4:...
  • Page 6 Ensemble CL Table of Contents Figure 3-9: Outputs Connected in Current Sinking Mode Figure 3-10: Brake Connected to J104 Figure 3-11: Brake Connected to TB206 Figure 4-1: Single Axis Joystick Interface (to Aux I/O) Figure 4-2: Two Axis Joystick Interface (to the Aux I/O of two drives)

  • Page 7: List Of Tables

    Table 2-5: Motor Power Output Connections (TB102) Table 2-6: Motor Power Output Mating Connector Table 2-7: Wire Colors for Aerotech Supplied Cables (Brushless) Table 2-8: Wire Colors for Aerotech Supplied Cables (DC Brush) Table 2-9: Wire Colors for Aerotech Supplied Cables (Stepper)
  • Page 8 Ensemble CL Table of Contents Table 3-11: Port 1 Opto-Isolated Output Connector Pin Assignment (TB202) Table 3-12: Port 2 Opto-Isolated Output Connector Pin Assignment (TB203) Table 3-13: Opto-Isolated Output Mating Connector Table 3-14: Output Specifications (TB202, TB203) Table 3-15: User Common Connector Pin Assignment (TB204)

  • Page 9: Ec Declaration Of Conformity

    Declaration of Conformity Ensemble CL EC Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2897 Product Ensemble CL Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the...
  • Page 10 Ensemble CL Declaration of Conformity This page intentionally left blank. www.aerotech.com...

  • Page 11: Safety Procedures And Warnings

    7. Make sure the Ensemble CL and all components are properly grounded in accordance with local electrical safety requirements. 8. Operator safeguarding requirements must be addressed during final integration of the product. D A N G E R : The Ensemble CL case temperature may exceed 70°C in some applications. www.aerotech.com...
  • Page 12 Exceeding environmental or operating specifications can cause damage to the equipment. 5. If the Ensemble CL is used in a manner not specified by the manufacturer, the protection provided by the Ensemble CL 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 CL. 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 CL Quick Installation Guide This page intentionally left blank. www.aerotech.com...

  • Page 15: Chapter 1: Introduction

    The Ensemble CL is offered with an optional encoder interpolation feature (-MXU), an auxiliary square wave encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -IO option), and separate power connections for motor and control supply voltages.

  • Page 16: Table 1-1: Feature Summary

    24 VDC, 2 A power supply for optional brake Transformers Refer to Section 2.1.3. for listings, wiring, and specifications Cables Interconnection A complete list of Aerotech cables can be found on the website at http://www.aerotechmotioncontrol.com/manuals/index.aspx Joystick/Handwheel Refer to Section 4.1. Section 4.2. Chapter 1...
  • Page 17 Introduction Ensemble CL The following block diagram shows a connection summary. For detailed connection information, refer to Chapter 2 and Chapter 3. D A N G E R :  An external center-tapped power transformer is required! Do not connect the motor power supply to a voltage greater than 28 VAC (2Ø).

  • Page 18: Drive And Software Compatibility

    Ensemble CL Introduction 1.1. Drive and Software Compatibility The following table lists the available Ensemble drives and which version of the Ensemble software first provided support for a given drive. Drives that list a specific version number in the Last Software Version column will not be supported after the listed version.

  • Page 19: Electrical Specifications

    Introduction Ensemble CL 1.2. Electrical Specifications The safe operating range is load dependent. Table 1-4: Electrical Specifications Description CL 10 Motor Supply Input Voltage Two Phase 28 VAC (56 VAC with a center tap) Input Frequency 50-60 Hz Inrush Current...

  • Page 20: System Power Requirements

    Ensemble CL Introduction 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 21: Mechanical Design

    Introduction Ensemble CL 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 22: Environmental Specifications

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

  • Page 23: Chapter 2: Installation And Configuration

    Ensemble CL Chapter 2: Installation and Configuration 2.1. Power Connections The Ensemble CL 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 24: Control Supply Connections (Tb103)

    The control power supply input allows the Ensemble CL to maintain communications if the motor power is removed, such as in an Emergency Stop condition. The control power supply requires a minimum of 85 VAC input to operate properly.

  • Page 25: Motor Supply Connections (Tb102)

    TB102 also provides the safety ground connection for the CL. The transformer primary wiring requires external fuses or a circuit breaker. W A R N I N G : Do not operate the Ensemble CL without the safety ground connection in place. EXTERNAL TRANSFORMER...

  • Page 26: Transformer Options

    Installation and Configuration 2.1.3. Transformer Options Aerotech offers three transformer options for the CL: TM3, TM5, and the TV0.3-28-56-ST. Refer to the TM3 or TM5 manuals for interconnection help. Manuals for the TM3 and TM5 are located on the installation device that came with the A3200 software. For the TM3, the manual part number is EDO117.
  • Page 27 Installation and Configuration Ensemble CL Integral Fuse 3.15A Slow-Blow F1-IN AC HI Internal Thermal 115 VAC AC LO Switch F1-OUT 50/60 HZ INPUT 115V SAFETY 100V 115V 100V Frame Ground 115 VAC INPUT Secondary = Dual 28 VAC (±40 VDC Bus) Integral Fuse 3.15A Slow-Blow...
  • Page 28 Ensemble CL Installation and Configuration 1ST CL TM3/TM5 TRANSFORMER MODULE 28 VAC 10A MAX 0 VAC-CT 28 VAC 10A MAX 50/60Hz 115~ 115~ CONTROL SUPPLY TB103 3rd CL 115~ 115~ 2nd CL 4th CL 24VDC 1A MAX – Transformer Use to power User-Supplied...

  • Page 29: Motor Output Connections

    Installation and Configuration Ensemble CL 2.2. Motor Output Connections The Ensemble CL 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 30: Brushless Motor Connections

    Both methods will identify the A, B, and C Hall/motor lead sets and indicate the correct connections to the drive. N O T E :  If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required.

  • Page 31: Powered Motor Phasing

    Installation and Configuration Ensemble CL 2.2.1.1. Powered Motor Phasing To test the initial set of motor connections, run the MotorVerification.ab test program. The program will attempt to move the motor forward in a positive (CW) direction. Depending on the information that the program gathers during the test, you may be prompted to rearrange motor lead connections and run the test again.
  • Page 32 Ensemble CL Installation and Configuration Figure 2-7: Encoder and Hall Signal Diagnostics Chapter 2 www.aerotech.com...

  • Page 33: Unpowered Motor And Feedback Phasing

    1. Aerotech phasing configuration expects ØC to be the lead signal (in time), ØB to follow it, and ØA to follow ØB. This means that whichever signal has its sine wave peak farthest to the left should be designated as the ØC signal.
  • Page 34 After the motor leads have been tested, the next step is to determine the phase of the Hall signals. The required (by an Aerotech system) relationship between motor and Hall leads is that the peak of a motor lead signal should correspond to the low voltage phase of the Hall signal (as shown in Figure 2-9).
  • Page 35 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. Connect Hall lead A to Pin 10 of the feedback connector.

  • Page 36: 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 Chapter 2 www.aerotech.com...

  • Page 37: 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 CL. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the Ensemble CL.

  • Page 38: Stepper Motor Connections

    Green/Yellow & Shield Black Brown Yellow 0VAC-CT 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 Chapter 2 www.aerotech.com...

  • Page 39: Stepper Motor Phasing

    POSITIVE MOTION Figure 2-14: 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 40: Motor Feedback Connections (J104)

    Ensemble CL Installation and Configuration 2.3. Motor Feedback Connections (J104) 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 41: Encoder Interface (J104)

    Motor Feedback (J104) connector. The standard encoder interface will accept an RS-422 differential line driver signal. If the Ensemble CL has been purchased with the -MXU option, the standard encoder interface can optionally be configured for an analog encoder input via parameter settings.

  • Page 42: Line Driver Encoder (Standard)

    Ensemble CL Installation and Configuration 2.3.1.1. RS-422 Line Driver Encoder (Standard) The standard encoder interface accepts an RS-422 differential quadrature line driver signal in the range of 0 to 5 Volts. It accepts a 10 MHz (max) encoder signal frequency (25 nsec minimum edge separation), producing 40 million counts per second after times four (x4) quadrature decoding.

  • Page 43: Endat Encoder Interface (J104)

    Installation and Configuration Ensemble CL 2.3.1.2. EnDat Encoder Interface (J104) The Ensemble CL retrieves absolute position data along with encoder fault information via a serial data stream from the absolute encoder. See Figure 2-16 for the serial data stream interface. Set up of this...

  • Page 44: Resolute Encoder Interface (J104)

    Ensemble CL Installation and Configuration 2.3.1.3. Resolute Encoder Interface (J104) The Ensemble CL retrieves absolute position data along with encoder fault information via a serial data stream from the resolute encoder. See Figure 2-17 for the serial data stream interface. Set up of this interface requires setting parameters ResoluteEncoderResolution, ResoluteEncoderSetup, and ResoluteEncoderUserResolution.

  • Page 45: Analog Encoder Interface

    Installation and Configuration Ensemble CL 2.3.1.4. Analog Encoder Interface If the -MXU option has been purchased, the standard encoder channel will accept an analog encoder input signal. The multiplication (interpolation) factor is determined by the EncoderMultiplicationFactor parameter. Table 2-12: Analog Encoder Specifications...
  • Page 46 Ensemble CL Installation and Configuration J104-17 SIN+ 82PF 82PF J104-18 SIN- AD822 82PF 82PF COS+ J104-14 82PF 82PF COS- J104-15 AD822 82PF 82PF MRK+ J104-7 82PF 82PF MRK- J104-6 AD822 82PF 82PF Figure 2-19: Analog Encoder Interface (J104) Chapter 2...

  • Page 47: Encoder Phasing

    Installation and Configuration Ensemble CL 2.3.1.5. Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-20 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors).
  • Page 48 Ensemble CL Installation and Configuration Figure 2-21: Position Feedback in the Diagnostic Display Chapter 2 www.aerotech.com...

  • Page 49: Hall-Effect Interface (J104)

    Installation and Configuration Ensemble CL 2.3.2. Hall-Effect Interface (J104) 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. Refer to Section 2.2.1.1. for Hall-effect device phasing.

  • Page 50: Thermistor Interface (J104)

    Ensemble CL Installation and Configuration 2.3.3. Thermistor Interface (J104) The thermistor input is used to detect an over temperature condition in a motor 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 51: Encoder Fault Interface (J104)

    Installation and Configuration Ensemble CL 2.3.4. Encoder Fault Interface (J104) The encoder fault input is used with encoders having a fault output. Each manufacturer uses this signal to indicate different faults. Table 2-15: Encoder Fault Interface Pin Assignment (J104) Pin#...

  • Page 52: End Of Travel Limit Input Interface (J104)

    Ensemble CL Installation and Configuration 2.3.5. End Of Travel Limit Input Interface (J104) End of Travel (EOT) limits are required to define the end of the physical travel on linear axes. Positive or clockwise motion is stopped by the clockwise (CW) end of travel limit input. Negative or counterclockwise motion is stopped by the counterclockwise (CCW) end of travel limit input.
  • Page 53 Installation and Configuration Ensemble CL +3.3V CW LIMIT J104-12 CCW LIMIT J104-24 HM LIMIT J104-22 Figure 2-26: End of Travel Limit Interface Input (J104) www.aerotech.com Chapter 2...

  • Page 54: End Of Travel Limit Phasing

    Ensemble CL 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 J104 connector. The logic level of the EOT limit inputs may be viewed in the diagnostic display (shown in...

  • Page 55: Brake Output (J104)

    Installation and Configuration Ensemble CL 2.3.6. Brake Output (J104) The Brake Output pins provide a direct connection to the mechanical relay on the optional -IO board. The brake output pins in J104 permit the brake to be wired with other signals in the feedback cable. The brake is configured for automatic or manual control using controller parameters (refer to the Ensemble Help file for...

  • Page 56: Emergency Stop Sense Input (Tb101)

    Ensemble CL Installation and Configuration 2.4. Emergency Stop Sense Input (TB101) The ESTOP sense input (TB101) 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 57: Typical Estop Interface

    Ensemble CL 2.4.1. Typical ESTOP Interface The user can connect an external emergency stop relay circuit to the Ensemble CL’s motor power supply input. This will remove power to the motor while maintaining control power, as shown in the Figure 2-29.

  • Page 58: Auxiliary I/O Connector (J105)

    Input (1) Software configured option (2) For PSO, see Section 2.5.2. Mating Connector Aerotech P/N Third Party P/N Connector ECK01259 Kycon K86-AA-26P Backshell ECK01022 Amphenol 17-1725-2 NOTE: These items are provided as a set under the Aerotech P/N: MCK-26HDD. Chapter 2 www.aerotech.com...

  • Page 59: Auxiliary Encoder Channel (J105)

    Installation and Configuration Ensemble CL 2.5.1. Auxiliary Encoder Channel (J105) The auxiliary encoder interface accepts a 5 VDC RS-422 differential quadrature line driver signal. It accepts a 10 MHz (max) encoder signal frequency (25 nsec minimum edge separation), producing 40 million counts per second, after times four (x4) quadrature decoding.
  • Page 60 Ensemble CL Installation and Configuration ADG802 90.9 90.9 AUX SIN+ IN J105-1 AUX SIN- IN J105-2 ADG802 90.9 90.9 ADM1485 AUX COS+ IN J105-10 AUX COS- IN J105-11 ADG802 90.9 90.9 ADM1485 AUX MRK- IN J105-19 AUX MRK+ IN J105-20...

  • Page 61: Position Synchronized Output (Pso)/Laser Firing (J105)

    Ensemble CL 2.5.2. Position Synchronized Output (PSO)/Laser Firing (J105) The Ensemble CL includes a Position Synchronized Output (PSO) feature. The PSO output is available on the dual function AUXMRK± differential signal lines (use of an RS-422 line receiver or opto-isolator is recommended).
  • Page 62 Ensemble CL Installation and Configuration Differential +5 VDC J105 120 - 180 (typical) Active Low Aux. Marker Output * Opto-Isolated +5 VDC Isolated Section J105 10 mA 180 Aux. Marker To Laser Active Low 1N4148 Output* HCPL-2601 or 6N136 * Active low output shown. Opposite polarity available by reversing connections to Pins 19 and 20.

  • Page 63: Opto-Isolated Outputs (J105)

    Installation and Configuration Ensemble CL 2.5.3. Opto-Isolated Outputs (J105) All outputs are rated for 24 VDC and 80 mA per output. The outputs are software configurable as current sinking (see Figure 2-32) or current sourcing (see Figure 2-33) . Table 2-26:...
  • Page 64 Ensemble CL Installation and Configuration J105 LOAD 5-24 VDC ELECTRONIC SWITCHES OPTOOUT0 J105-7 LOAD OPTOOUT1 J105-8 LOAD OPTOOUT2 J105-9 LOAD OPTOOUT3 J105-16 OPTOCOM J105-15 EACH OUTPUT 80 mA MAXIMUM DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.

  • Page 65: Opto-Isolated Inputs (J105)

    Installation and Configuration Ensemble CL 2.5.4. Opto-Isolated Inputs (J105) User inputs are scaled for an input voltage of 5-24 VDC. Figure 2-34 Figure 2-35, respectively, illustrate how to connect a device in current sinking and sourcing current modes. Table 2-28:...
  • Page 66 Ensemble CL Installation and Configuration J105 OPTOINCOM J105-24 OPTOIN0 J105-17 5-24VDC OPTOIN1 J105-18 OPTOIN2 J105-25 OPTOIN3 J105-26 INPUT SWITCHES Figure 2-34: Inputs Connected in Current Sinking Mode (J105) J105 INPUT SWITCHES OPTOIN0 J105-17 OPTOIN1 J105-18 OPTOIN2 J105-25 5-24VDC OPTOIN3 J105-26...

  • Page 67: High Speed User Inputs 4-5 (J105)

    Installation and Configuration Ensemble CL 2.5.5. High Speed User Inputs 4-5 (J105) The high-speed inputs are scaled for 5 V or 24 V input voltages based on a jumper setting (Table 2-31). A higher input voltage requires adding external series resistors to limit the current to 10 mA. The high-speed inputs are isolated by an HCPL-0630 and have a typical delay of 50 nanoseconds.

  • Page 68: Analog Output 0 (J105)

    Ensemble CL Installation and Configuration 2.5.6. Analog Output 0 (J105) Analog Output 0 produces a single ended output in the range of ±10 volts with a resolution of 305 µV (16-bit). The maximum recommended output current is 5 mA (2 k Ohm load). The analog output voltage is referenced to J105-23.

  • Page 69: Analog Input 0 (J105)

    Installation and Configuration Ensemble CL 2.5.7. Analog Input 0 (J105) Analog Input 0 is a 16-bit differential input that accepts a voltage in the range of ±10 V with a resolution of 305 µV. Signals outside of this range may damage the input. To interface to a single-ended (non-differential) voltage source, connect the signal common of the source to the negative input (pin 14, ANALOG_IN-) and the analog source signal to the positive input (pin 13, ANALOG_IN+).

  • Page 70: Aeronet Interface (J107/J108)

    Any discrete unit is capable of acting as the primary Ensemble CL. 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 71: Interface (Tb104)

    Installation and Configuration Ensemble CL 2.7. RS-232 Interface (TB104) Connecting the RS-232 port to a user’s PC requires a standard cable (not a null modem). Table 2-35: RS-232 Connector Pin Assignment (TB104) Pin# Description In/Out/Bi +5 Volt Power Output Output...

  • Page 72: Pc Configuration And Operation Information

    Ensemble CL Installation and Configuration 2.8. PC Configuration and Operation Information For additional information about Ensemble CL and PC configuration, hardware requirements, programming, utilities and system operation refer to the Ensemble Help file. Chapter 2 www.aerotech.com...

  • Page 73: Chapter 3: -I/O Expansion Board

    The -IO option board is 16 digital opto-inputs, 16 digital opto-outputs, 1 analog input, 1 analog output, and a brake/relay output. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble CL chassis.

  • Page 74: Analog Output (Tb201)

    Ensemble CL -IO Expansion Board 3.1. Analog Output (TB201) The 16-bit analog output produces a single-ended output voltage in the range of ±10 V with a resolution of 305 µV. The maximum recommended output current is 5 mA. Analog outputs are referenced to TB201-1. The analog output is set to zero when the system is powered-up or during a system reset.

  • Page 75: Analog Input (Tb201)

    -IO Expansion Board Ensemble CL 3.2. Analog Input (TB201) The I/O board analog input is a 12-bit differential input that accepts a voltage in the range of ±10 volts with a resolution of 4.88 millivolts. Signals outside of this range may damage the input. 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.

  • Page 76: Opto-Isolated Inputs (Tb204, Tb205)

    Ensemble CL -IO Expansion Board 3.3. Opto-Isolated Inputs (TB204, TB205) These opto-isolated inputs use a PS2806-4 device and are configured for 5-24 volt input levels. The inputs may be connected to current sourcing or current sinking devices, as shown in...
  • Page 77 -IO Expansion Board Ensemble CL W A R N I N G : Opto-isolated inputs and outputs should not be powered by the user output power. Doing so would compromise the isolation provided by the opto-isolator. N O T E : Each bank of 8 Inputs must be connected in the all sourcing or all sinking configuration.
  • Page 78 Ensemble CL -IO Expansion Board TB204 INPUT SWITCHES OPTOIN0 TB204-2 OPTOIN1 TB204-3 5-24 VDC OPTOIN2 TB204-4 OPTOIN3 TB204-5 OPTOINCOM TB204-1 Figure 3-5: Inputs Connected to a Current Sourcing Device TB204 OPTOINCOM TB204-1 OPTOIN0 TB204-2 5-24 VDC OPTOIN1 TB204-3 OPTOIN2 TB204-4...

  • Page 79: Opto-Isolated Outputs (Tb202, Tb203)

    -IO Expansion Board Ensemble CL 3.4. Opto-Isolated Outputs (TB202, TB203) The outputs are software configurable as sourcing or sinking. The outputs are driven by PS2802-4 opto- isolators rated for 24 volts maximum and up to 80 mA/output @ 20°C. Outputs must be connected in either all sinking or all sourcing mode.
  • Page 80 Ensemble CL -IO Expansion Board OPTOOUT0 TB202-3 OPTOOUT1 TB202-4 OPTOOUT2 TB202-5 OPTOOUT3 TB202-6 PS2802-4 OPTOOUT4 TB202-7 OPTOOUT5 TB202-8 OPTOOUT6 TB202-9 OPTOOUT7 TB202-10 OPTOOUT BANK1 V- TB202-2 PS2802-4 Figure 3-7: Opto-Isolated Outputs (-IO Board) Chapter 3 www.aerotech.com...
  • Page 81 -IO Expansion Board Ensemble CL Table 3-14: Output Specifications (TB202, TB203) PS2802-4 Opto Device Specifications Value Maximum Voltage 24 V maximum Maximum Sink/Source Current 80 mA/channel @ 20°C; 60 mA/channel @ 50°C Output Saturation Voltage 2.75 V at maximum current Output Resistance 33 Ω...
  • Page 82 Ensemble CL -IO Expansion Board TB202 TB202-1 LOAD 5-24 VDC OUTPUT SWITCHES OPTOOUT0 TB202-3 LOAD OPTOOUT1 TB202-4 LOAD OPTOOUT2 TB202-5 LOAD OPTOOUT3 TB202-6 TB202-2 EACH OUTPUT 80 mA MAXIMUM DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.

  • Page 83: User Power (Tb204, Tb205)

    -IO Expansion Board Ensemble CL 3.5. User Power (TB204, TB205) A user accessible power supply (+5V at 0.5 A) is available between the TB205 +5V terminal and TB204 GND terminal. Table 3-15: User Common Connector Pin Assignment (TB204) Pin# Description...

  • Page 84: Brake / Mechanical Relay (Tb206)

    Ensemble CL -IO Expansion Board 3.6. Brake / Mechanical Relay (TB206) The relay output is typically used for automatic control of a fail-safe brake on a vertical axis. It can also be used as a general purpose relay. The brake output can be software configured; refer to the Ensemble Help file for more information (see topics for the EnableBrakeControl parameter and the BRAKE command).

  • Page 85: Brake / Mechanical Relay Interface Connector

    CHANGE JUMPERS TO: OPTIONAL RC SNUBBER: CIRCUIT JP1 1-2 IN, 3-4 IN, ALL OTHER JUMPERS OUT 47 1/2 W RESISTOR .1uF 250 VAC CAPACITOR VARISTOR: AEROTECH P/N ECR181 HARRIS P/N: V33ZA1 Figure 3-10: Brake Connected to J104 www.aerotech.com Chapter 3...
  • Page 86 JP1-A RLYV23026SMT BRAKE- J104-13 JP1-B BRAKE JP1-C JP1-D BRAKE+ J104-25 CHANGE JUMPERS TO: JP1 1-3 IN, 1-2 OUT, 3-4 OUT, 5-6 OUT, 7-8 OUT VARISTOR: AEROTECH P/N ECR181 HARRIS P/N: V33ZA1 Figure 3-11: Brake Connected to TB206 Chapter 3 www.aerotech.com...

  • Page 87: Chapter 4: Standard Interconnection Cables

    Accessories Ensemble CL Chapter 4: 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 4-1: Standard Interconnection Cables Cable Part # Description Joystick Section 4.1. ECZ01231 BBA32 Interconnect Cable (1) The “-xx”...

  • Page 88: Joystick Interface

    Accessories 4.1. 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 89 Accessories Ensemble CL Second Drive to cable shield AGND JOY-Y Analog Input 1+ Common Analog Input 1- Joystick J105 First Drive JOY-X Analog Input 0+ Common Analog Input 0- +5 Volts AGND Common Input Common IN914 Button A Input 1...

  • Page 90: Handwheel Interface

    Accessories 4.2. 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 CL. A handwheel can be connected to the Aux I/O as shown in...

  • Page 91: Chapter 5: Maintenance

    This section covers the internal boards, important board components, and how to clean the drive. Troubleshooting is covered in-depth in the Ensemble Help file. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble CL chassis.

  • Page 92: Control Board

    1 2 3 5 6 CL Board Assembly PAD1 Drawing Number: 690D1627, Rev. A- PAD-C1 PAD-B1 PAD-A1 Figure 5-1: Control Board Assembly D A N G E R : Always disconnect the Mains power connection before opening the Ensemble CL chassis. Chapter 5 www.aerotech.com...
  • Page 93 Maintenance Ensemble CL Table 5-2: Control Board Jumper Configuration  Jumper Setting Description Watchdog enabled Watchdog disabled 24 V operation (High Speed Input 5) 5 V operation (High Speed Input 5) 24 V operation (High Speed Input 4) 5 V operation(High Speed Input 4) (1) Default Table 5-3: Control Board Fuse Information ...

  • Page 94: Preventative Maintenance

    Cleaning  The Ensemble CL 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 CL or onto exposed connectors / components.

  • Page 95: 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 96 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 97: Appendix B: Revision History

    July 01, 2010 4.02.00 April 23, 2010 4.00.00 February 12, 2009 Revision changes have been archived. If you need a copy of this revision, contact Aerotech Global Technical Support. 1.04.00 November 05, 2008 1.03.00 September 10, 2008 1.02.00 August 19, 2008 1.01.00...
  • Page 98 Ensemble CL Revision History This page intentionally left blank. Appendix B www.aerotech.com...

  • Page 99: Index

    Index Ensemble CL Index Auxiliary Encoder Channel Pin Assignment 45,47 Auxiliary I/O Connector -I/O Expansion Board Auxiliary I/O Connector Pin Assignment -IO Board Fuse Information -IO Expansion Board Brake Jumper Brake / Mechanical Relay Configuration Brake / Mechanical Relay Connector Pin...
  • Page 100 Ensemble CL Index DC Brush Motor Phasing Feedback Monitoring Declaration of Conformity Digital Input Connector Pin Assignment Hall-Effect Feedback Interface Pin Digital Input Specifications Assignment 35-36 Digital Output Connector Pin Assignment Hall-Effect Inputs Digital Output Specifications Hall-Effect Interface dimensions Hall Signal Phasing...
  • Page 101 Index Ensemble CL Position Synchronized Output (PSO) feature Limit Input Diagnostic Display Position Synchronized Output (PSO)/Laser Firing 47 Line Driver Encoder Interface Power Amplifier Bandwidth specifications Powered Motor Phasing Mechanical Design Preventative Maintenance Mechanical Relay Specifications Protective Features Minimum Load...
  • Page 102 Ensemble CL Index TB201 60-61 TB202 65,67 TB203 65,67 TB204 62,69 TB205 62,69 TB206 70-72 Thermistor Interface Thermistor Interface Input Transformer Examples Transformer Options Two Axis Joystick Interface Typical Emergency Stop Circuit Typical ESTOP Interface unit separation unit weight Unpowered Motor and Feedback Phasing...

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