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Aerotech Ensemble Epaq Hardware Manual

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Ensemble Epaq Hardware
Manual
Revision: 2.04.00

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Summary of Contents for Aerotech Ensemble Epaq

  • Page 1 Ensemble Epaq Hardware Manual Revision: 2.04.00...
  • Page 2 This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies.

  • Page 3: Table Of Contents

    Table of Contents Ensemble Epaq Hardware Manual 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. Electrical Specifications 1.2. Mechanical Specifications 1.3.

  • Page 4: Table Of Contents

    Ensemble Epaq Hardware Manual Table of Contents 3.2.1. Solid State Relay Specifications 3.3. Analog Input 1 3.4. Analog Output 1 3.5. Opto-Isolated Inputs 3.6. Opto-Isolated Outputs 3.7. Auxiliary Encoder Channel/PSO Output 3.7.1. Position Synchronized Output (PSO)/Laser Firing (Aux Enc Connector) Chapter 4: Standard Interconnection Cables 4.1.

  • Page 5: List Of Figures

    RS-232/RS-485 Interface Figure 2-34: Epaq Connected to Three Ensemble MPs Figure 2-35: GPIB Connector Location Figure 3-1: Ensemble Epaq with -IO Option Board Figure 3-2: User Power Connector Location Figure 3-3: Brake Power Supply Connector Location Figure 3-4: Brake Connected to the Feedback Connector...
  • Page 6 Ensemble Epaq Hardware Manual Table of Contents Figure 3-14: Auxiliary Encoder Channel Figure 3-15: PSO Interface Figure 4-1: Joystick Interface Figure 4-2: Joystick Connector Location Figure 4-3: Handwheel Interconnection Figure 5-1: Control Board Assembly Figure 5-2: Power Board Assembly Figure 5-3:...

  • Page 7: List Of Tables

    Table 2-3: Motor Power Output Connections Table 2-4: Terminal Block Mating Connector Table 2-5: Wire Colors for Aerotech Supplied Cables (Brushless) Table 2-6: Wire Colors for Aerotech Supplied Cables (DC Brush) Table 2-7: Wire Colors for Aerotech Supplied Cables (Stepper) Table 2-8:...
  • Page 8 Ensemble Epaq Hardware Manual Table of Contents This page intentionally left blank. viii www.aerotech.com...

  • Page 9: Ec Declaration Of Conformity

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

  • Page 11: Safety Procedures And Warnings

    Exceeding environmental or operating specifications can cause damage to the equipment. 5. If the Ensemble Epaq is used in a manner not specified by the manufacturer, the protection provided by the Ensemble Epaq can be impaired and result in damage, shock, injury, or death.
  • Page 12 Ensemble Epaq Electrical Safety This page intentionally left blank. www.aerotech.com...

  • Page 13: Quick Installation Guide

    Quick Installation Guide Ensemble Epaq Hardware Manual Quick Installation Guide This chapter describes the order in which connections and settings should typically be made to the Epaq. There are four standard connections that must be made to the Epaq. GPIB...
  • Page 14 Ensemble Epaq Hardware Manual Quick Installation Guide This page intentionally left blank. www.aerotech.com...

  • Page 15: Chapter 1: Introduction

    Ensemble Epaq Hardware Manual Chapter 1: Introduction Aerotech’s Epaq is a 3U height, 19” wide, rack-mountable, intelligent drive chassis, capable of powering up to nine axes of motion. Six axes of motion control are available in one integrated, stand-alone package and can be expanded to nine axes of motion control externally.

  • Page 16: Table 1-1: Feature Summary

    Ensemble Epaq Hardware Manual Introduction N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any time. All drawings and illustrations are for reference only and were complete and accurate as of this manual’s release.
  • Page 17 Introduction Ensemble Epaq Hardware Manual Feature Details Command Execution AUTO Program runs to completion upon startup Modes SINGLE Full debug capability to step, step over, step into individual program lines IMMEDIATE Commands are executed upon entry Axes controlled with jog pad on front panel or optional...

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

    Ensemble Epaq Hardware Manual Introduction Table 1-2: Configurations and Options Rack or Desk-Mount Options Desktop Epaq (contains desktop related components) Rack-mount Epaq (contains rack-mount related components) Standard or Blank Front Panel Options -FPD Standard front panel (with keypad and display )
  • Page 19 Introduction Ensemble Epaq Hardware Manual Axis 1 Amplifier Options /1-MP10I Digital PWM, 10 A peak, 5 A continuous with I/O /1-MP10I Digital PWM, 10 A peak, 5 A continuous with I/O /1-MP10MI Digital PWM, 10 A peak, 5 A continuous with 4096X MXU with I/O /1-MP10-HBI Digital PWM, 10 A peak, 5 A continuous with I/O and half bus option...
  • Page 20 Software Options Five Axis Contouring supplies the ability to coordinate motion on five or more axes. Aerotech's EtherNet/IP™ option interfaces with Aerotech Ensemble drives and the various ODVA Common Industrial Protocol (CIP™) objects that are used. The Dynamic Controls Toolbox contains a collection of controller-level algorithms that are designed to improve machine positioning, increase throughput, and reduce cycle times.
  • Page 21 Introduction Ensemble Epaq Hardware Manual The following block diagram illustrates the features and options of the Epaq. Controller Amplifier -IO Option* Keypad Encoder +5V / Common LCD Display PSO Output, Encoder Echo SIN, COS, MRK (RS422) Ethernet Port ENET Brake Power...

  • Page 22: Electrical Specifications

    Ensemble Epaq Hardware Manual Introduction 1.1. Electrical Specifications The electrical specifications for the Epaq drive chassis are listed in Table 1-3 and the electrical specifications for the servo amplifiers in Table 1-4. N O T E :  Specifications represent the maximum capability of a feature. Other system constraints may res- ult in significantly less performance.

  • Page 23: Table 1-4: Servo Amplifier Electrical Specifications

    Introduction Ensemble Epaq Hardware Manual Table 1-4: Servo Amplifier Electrical Specifications Description Peak Bus Voltage 80 VDC 40 VDC Peak Output Current 10 A 10 A Continuous Output Current PWM Switching Frequency 20 kHz Power Amplifier Bandwidth Software Selectable Software Selectable Minimum Load Inductance 0.1 mH @ 80 VDC...

  • Page 24: Mechanical Specifications

    Figure 1-3. W A R N I N G :  Use both handles to lift and carry the Ensemble Epaq. All Epaq chassis’s are built to the user’s specifications, with the requested options, causing a variation in the actual product weight.
  • Page 25 Introduction Ensemble Epaq Hardware Manual GPIB AXIS 1 AXIS 2 AXIS 3 AXIS 4 AXIS 5 AXIS 6 AUX ENC AUX ENC AUX ENC AUX ENC AUX ENC AUX ENC BRAKE PWR BRAKE PWR BRAKE PWR BRAKE PWR BRAKE PWR BRAKE PWR 13.0 [0.51]...

  • Page 26: Environmental Specifications

    Ensemble Epaq Hardware Manual Introduction 1.3. Environmental Specifications The environmental specifications for the Epaq are listed below. Ambient Temperature Operating: 0° to 50°C Storage: -30° to 80°C Humidity Maximum relative humidity is 80% for temperatures up to 31°C. Decreasing linearly to 50% relative humidity at 40°C. Non condensing.

  • Page 27: Drive And Software Compatibility

    Introduction Ensemble Epaq Hardware Manual 1.4. 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 28 Ensemble Epaq Hardware Manual Introduction This page intentionally left blank. Chapter 1 www.aerotech.com...

  • Page 29: Chapter 2: Installation And Configuration

    Installation and Configuration Ensemble Epaq Hardware Manual Chapter 2: Installation and Configuration This section describes the minimum hardware installation and configuration requirements for the Epaq drive chassis. This installation will provide information on AC power connections and brush, brushless, and stepper motor wiring.

  • Page 30: Electrical Installation

    Ensemble Epaq Hardware Manual Installation and Configuration 2.1. Electrical Installation Motor, power, control and position feedback cable connections are made to the rear of the Epaq. AC Power Control Board Axis 1 Axes 2 through 6 (Optional) Input and Options...
  • Page 31 Installation and Configuration Ensemble Epaq Hardware Manual All low voltage connections must be made using cables/wires sized for the maximum currents that will be carried. Insulation on these cables/wires must be rated at 300 V if this wiring can come into contact with wiring operating above 100 V (AC &...

  • Page 32: Ac Power Connections

    Ensemble Epaq Hardware Manual Installation and Configuration 2.1.1. AC Power Connections AC input power to the Epaq drive chassis is applied to the AC power receptacle that is located on the rear panel. The power cord connected to this receptacle also provides the protective earth ground connection and serves as a mains disconnect.

  • Page 33: Table 2-1: Main Ac Power Input Voltages And Current Requirements

    EMI coupling and interference. D A N G E R :  See the user documentation provided with your Ensemble Epaq system to determine if the Ensemble Epaq chassis is limited to only one AC input voltage. Operation at other voltages may result in damage to the Ensemble Epaq chassis.

  • Page 34: Minimizing Conducted, Radiated, And System Noise

    7. Ferrite beads or Aerotech’s FBF-1 or FBF-2 filter adapters, may be used on the motor leads to reduce the effects of amplifier EMI/RFI, produced by PWM (pulse width modulation) amplifiers. Refer to the FBF-1 and FBF-2 drawings on your installation device for more information on the ferrite beads.

  • Page 35: Motor Output Connections

    Installation and Configuration Ensemble Epaq Hardware Manual 2.2. Motor Output Connections The Epaq can be used to drive 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 1.1.

  • Page 36: 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 37: Powered Motor Phasing

    Installation and Configuration Ensemble Epaq Hardware Manual 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 38 Ensemble Epaq Hardware Manual Installation and Configuration Figure 2-6: Encoder and Hall Signal Diagnostics Chapter 2 www.aerotech.com...

  • Page 39: 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 40 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 (the relationship is shown in Figure 2-8).
  • Page 41 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 42: 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 43: Dc Brush Motor Phasing

    5. Connect the motor lead from the voltmeter to the ØA motor terminal on the Epaq. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the Epaq. N O T E :  If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required.

  • Page 44: Stepper Motor Connections

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

  • Page 45: 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 46: Motor Feedback Connections

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3. Motor Feedback Connections 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 connections.

  • Page 47: Table 2-8: Motor Feedback Connector Pin Assignment

    Installation and Configuration Ensemble Epaq Hardware Manual Table 2-8: Motor Feedback Connector Pin Assignment Pin# Description In/Out/Bi Chassis Frame Ground Motor Over Temperature Thermistor Input +5V Power for Encoder (500 mA max) Output Reserved Hall-Effect Sensor B (brushless motors only) Input...

  • Page 48: Encoder Interface

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.1. Encoder Interface The Epaq is equipped with standard and auxiliary encoder feedback channels. The standard encoder interface is accessible through the feedback connector. The standard interface is a line driver encoder that will accept an RS-422 differential line driver signal.

  • Page 49: Line Driver Encoder (Standard)

    Installation and Configuration Ensemble Epaq Hardware Manual 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 VDC in line driver format. It allows up to an 10 MHz encoder signal (25 nsec minimum edge separation), producing 40 million counts per second, after times four (x4) quadrature decoding.

  • Page 50: Analog Encoder Interface

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.1.2. Analog Encoder Interface If the -MXU or -MXH option has been purchased, the primary encoder channel will accept an analog encoder input signal. The multiplication (interpolation) factor is determined by the EncoderMultiplicationFactor axis parameter.
  • Page 51 Installation and Configuration Ensemble Epaq Hardware Manual MRK+ J103-7 82PF 82PF 82PF 82PF MRK- J103-6 82PF 82PF 10UF 6.3V SIN+ J103-17 82PF 82PF 82PF 82PF SIN- J103-18 82PF 82PF 10UF 6.3V COS+ J103-14 82PF 82PF 82PF 82PF COS- J103-15 82PF 82PF 10UF 6.3V...

  • Page 52: Encoder Phasing

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.1.3. Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-19 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors).
  • Page 53 Installation and Configuration Ensemble Epaq Hardware Manual Figure 2-20: Position Feedback in the Diagnostic Display www.aerotech.com Chapter 2...

  • Page 54: Hall-Effect Interface

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.2. Hall-Effect Interface 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 55: Thermistor Interface

    Installation and Configuration Ensemble Epaq Hardware Manual 2.3.3. Thermistor Interface 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 56: End Of Travel Limit Input Interface

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.4. End Of Travel Limit Input Interface 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 57 Installation and Configuration Ensemble Epaq Hardware Manual ENC+5V CW LIMIT PIN-12 CCW LIMIT PIN-24 HOME LIMIT PIN-22 Figure 2-24: End of Travel Limit Interface Input www.aerotech.com Chapter 2...

  • Page 58: End Of Travel Limit Phasing

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.4.1. End Of Travel Limit Phasing If the EOT limits are reversed, you will be able to move further into a limit but be unable to move out. To correct this, swap the connections to the CW and CCW inputs at the motor feedback connector. The logic level of the EOT limit inputs may be viewed in the diagnostic display (shown in...

  • Page 59: Encoder Fault Interface

    Installation and Configuration Ensemble Epaq Hardware Manual 2.3.5. Encoder Fault Interface 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 Pin#...

  • Page 60: Brake Output

    Ensemble Epaq Hardware Manual Installation and Configuration 2.3.6. Brake Output The Brake Output pins provide a direct connection to the solid state relay on the Epaq. The brake output pins 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 more information).

  • Page 61: Analog Input

    Installation and Configuration Ensemble Epaq Hardware Manual 2.3.7. Analog Input 0 Analog Input 0 is a 16-bit differential input that accepts a voltage in the range of ±10 volts with a resolution of 305 µVolts. 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 8, AIN 0-) and the analog source signal to the positive input (pin 19, AIN 0+).

  • Page 62: Emergency Stop Sense Input (Estop)

    Ensemble Epaq Hardware Manual Installation and Configuration 2.4. Emergency Stop Sense Input (ESTOP) There are two emergency stop options for the Epaq, -ESTOP0 and -ESTOP1. W A R N I N G : The machine integrator, OEM, or end user is responsible for performing the design, integration, and test of the safety system in accordance with the relevant safety standards.

  • Page 63: Table 2-18: Electrical Noise Suppression Devices

    Installation and Configuration Ensemble Epaq Hardware Manual Connecting the ESTOP input to a relay or other noise producing device requires the use of noise suppression devices such as those in Table 2-18. These devices are applied across the switched coil to suppress transient voltages.

  • Page 64: Communicating With The Epaq

    Ensemble Epaq Hardware Manual Installation and Configuration 2.5. Communicating with the Epaq Either USB or Ethernet can be used to connect any of the supplied software applications or a custom application built with the supplied .NET library to the controller. Ethernet sockets are also available for Modbus or general ASCII communication with another hardware device.

  • Page 65: Ethernet Interface

    PC. This type of connection is not feasible unless the PC has two Ethernet cards. If the PC cannot be connected to an external network, Aerotech recommends Method 2. Method 2 is a more typical configuration. The network can be a local network (the PC and Epaq are connected through a hub or switch) or remote (the devices are connected through a router).

  • Page 66: Interface

    Ensemble Epaq Hardware Manual Installation and Configuration 2.5.3. RS-232 Interface Connecting the RS-232 port to a user’s PC requires a standard 9-pin cable (not a null modem). If the /RS232- 1 option has been purchased, an additional RS-232 port will be located at the J100 connector. The additional RS-232 port will be identical in form and function to the standard RS-232 port.
  • Page 67 Installation and Configuration Ensemble Epaq Hardware Manual SERIAL COMMUNICATIONS MODE SELECT JP2 JP3 JP4 JP5 JP6 JP7 JP8 JP9 J104-1 RS232 SMDC050 (DEFAULT) TX/TX1+ RS232 J104-2 (RESERVED) RS422 RS485 RX/RX1+ J104-3 MAX232E TX1- J104-4 10UF 6.3V ADM485 RX1- J104-6 J104-5...

  • Page 68: External Drive Interface

    Ensemble Epaq Hardware Manual Installation and Configuration 2.5.4. External Drive Interface Use this option to connect up to three more Ensemble discrete drives. GPIB AXIS 1 AXIS 2 AXIS 3 AXIS 4 AXIS 5 AXIS 6 AUX ENC AUX ENC...

  • Page 69: General Purpose Interface Bus (Gpib)

    Installation and Configuration Ensemble Epaq Hardware Manual 2.5.5. General Purpose Interface Bus (GPIB) The Epaq contains a standard GPIB interface bus. Refer to the Ensemble Help file for more information. GPIB GPIB AXIS 1 AXIS 1 AXIS 2 AXIS 2 AXIS 3...

  • Page 70: Pc Configuration And Operation Information

    Ensemble Epaq Hardware Manual Installation and Configuration 2.6. PC Configuration and Operation Information For additional information about Epaq and PC configuration, hardware requirements, programming, utilities and system operation refer to the Ensemble Help file. Chapter 2 www.aerotech.com...

  • Page 71: Chapter 3: -Io Expansion Board

    The auxiliary encoder channel can be used for dual- loop configurations, to echo the primary encoder, or for the PSO output. -I/O Option Board Drawing Number: 690D1616 Rev A. Auxiliary Brake Analog Opto-Isolated Opto-Isolated Encoder Power Inputs Outputs Figure 3-1: Ensemble Epaq with -IO Option Board www.aerotech.com Chapter 3...

  • Page 72: User Power

    Ensemble Epaq Hardware Manual -IO Expansion Board 3.1. User Power A user-accessible power supply (+5V at 0.5 A) is available between Pin 3 and Pin 4. Table 3-1: User Power Connector Pin Assignment Pin# Label Description In/Out/Bi User +5V Volt Power (500 m A max)

  • Page 73: Brake Power Supply

    -IO Expansion Board Ensemble Epaq Hardware Manual 3.2. Brake Power Supply This connector is the power supply connection to the onboard solid state brake control relay. The relay is typically used to automatically control a fail-safe brake on a vertical axis. It can also be used as a general purpose output.

  • Page 74: Table 3-5: Motor Feedback Connector Brake Output Connector Pin Assignment

    Ensemble Epaq Hardware Manual -IO Expansion Board Table 3-5: Motor Feedback Connector Brake Output Connector Pin Assignment  Pin# Description In/Out/Bi Optional Brake - Output Output Optional Brake + Output Output Figure 3-4 is an example of a +24 VDC Brake connected to the Motor Feedback connector. In this example the external +24 VDC power source is connected to the Brake Power Supply connector.

  • Page 75: Solid State Relay Specifications

    3.2.1. Solid State Relay Specifications The user must verify that the application will be within the specifications of the Brake output. Table 3-6: Relay Specifications Solid State Relay Rating (M36), Aerotech PN. ECS1074 Operating Voltage 24 VDC (typical) / 48 VDC (max) Maximum Current 0.5 Amps...
  • Page 76 Ensemble Epaq Hardware Manual -IO Expansion Board 3.3. Analog Input 1 On ML amplifiers, Analog Input 1 is a 16-bit differential input that accepts a voltage in the range of ±10 volts with a resolution of 305 µVolts. On MP amplifiers, Analog Input 1 is a 12-bit differential input that accepts a voltage in the range of ±10 volts with a resolution of 305 µVolts.

  • Page 77: Table 3-7: Analog Inputs Connector Pin Assignment

    -IO Expansion Board Ensemble Epaq Hardware Manual N O T E : Analog Input 0 is available on the Motor Feedback connector (refer to Section 2.3.7.). Table 3-7: Analog Inputs Connector Pin Assignment Pin# Label Description In/Out/Bi AGND Analog Common...

  • Page 78: Table 3-9: Analog Output Connector Pin Assignment

    Ensemble Epaq Hardware Manual -IO Expansion Board 3.4. Analog Output 1 The 16-bit analog output produces a single-ended output voltage in the range of ±5 volts with a resolution of 153 µVolts. The maximum output current recommended is 5 mA. Analog outputs are referenced to pin-1. The analog output is set to zero when the system is powered-up or during a system reset.

  • Page 79: Opto-Isolated Inputs

    -IO Expansion Board Ensemble Epaq Hardware Manual 3.5. Opto-Isolated Inputs 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 80 Ensemble Epaq Hardware Manual -IO Expansion Board EPAQ INPUT SWITCH DEVICES OPTOIN0 PIN-2 OPTOIN1 PIN-3 5-24 VDC OPTOIN2 PIN-4 OPTOIN3 PIN-5 COMMON (0-3) PIN-1 Figure 3-9: Inputs Connected to a Current Sourcing Device EPAQ COMMON (0-3) PIN-1 OPTOIN0 5-24 VDC...

  • Page 81: Opto-Isolated Outputs

    -IO Expansion Board Ensemble Epaq Hardware Manual 3.6. Opto-Isolated Outputs 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 82: Table 3-16: Output Specifications

    Ensemble Epaq Hardware Manual -IO Expansion Board Table 3-16: Output Specifications 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 83 -IO Expansion Board Ensemble Epaq Hardware Manual EPAQ OPTOOUTV+ PIN-1 OUTPUT SWITCH DEVICES LOAD 5-24 VDC OPTOOUT3 PIN-6 LOAD OPTOOUT2 PIN-5 LOAD OPTOOUT1 PIN-4 LOAD OPTOOUT0 PIN-3 OPTOOUTV- PIN-2 CONNECTION REQUIRED EACH OUTPUT 80mA MAXIMUM DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.

  • Page 84: Auxiliary Encoder Channel/Pso Output

    Ensemble Epaq Hardware Manual -IO Expansion Board 3.7. Auxiliary Encoder Channel/PSO Output 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 85 -IO Expansion Board Ensemble Epaq Hardware Manual AUXSIN- PIN-9 AUXSIN+ PIN-4 ADM1485 AUXMRK- PIN-1 ENCODER FAULT DETECTION AUXMRK+ PIN-6 ADM1485 AUXCOS- PIN-3 AUXCOS+ PIN-2 ADM1485 Figure 3-14: Auxiliary Encoder Channel www.aerotech.com Chapter 3...

  • Page 86: Position Synchronized Output (Pso)/Laser Firing (Aux Enc Connector)

    3.7.1. Position Synchronized Output (PSO)/Laser Firing (Aux Enc Connector) The Ensemble Epaq 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 87 -IO Expansion Board Ensemble Epaq Hardware Manual Differential +5 VDC 120 - 180 (typical) Active Low Aux. Marker Output * Opto-Isolated +5 VDC Isolated Section 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 1 and 6.
  • Page 88 Ensemble Epaq Hardware Manual -IO Expansion Board This page intentionally left blank. Chapter 3 www.aerotech.com...

  • Page 89: Chapter 4: Standard Interconnection Cables

    Cables Ensemble Epaq Hardware Manual 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. 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.

  • Page 90: Table 4-1: Joystick Connector Pin Assignment

    Ensemble Epaq Hardware Manual Cables JOY- STICK AXIS 1 AXIS 1 AXIS 2 AXIS 2 AXIS 3 AXIS 3 AXIS 4 AXIS 4 AXIS 5 AXIS 5 AXIS 6 AXIS 6 GPIB GPIB AUX ENC AUX ENC AUX ENC AUX ENC...

  • Page 91: Handwheel Interface

    See the Ensemble Help file for information on enabling the handwheel using the HANDWHEEL command. A handwheel with a standard 25-pin D-style connector can be connected to the Aux Enc connector of the Epaq using an Aerotech C20932 cable. GPIB...
  • Page 92 Ensemble Epaq Hardware Manual Cables This page intentionally left blank. Chapter 4 www.aerotech.com...

  • Page 93: Chapter 5: Maintenance

    Maintenance Ensemble Epaq Hardware Manual Chapter 5: Maintenance This section covers the internal boards, important board components, and how to clean the drive. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble Epaq chassis.

  • Page 94: Chassis Control Board

    Ensemble Epaq Hardware Manual Maintenance 5.1. Chassis Control Board Figure 5-1 highlights the important components located on the control board assembly. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble Epaq chassis.

  • Page 95: Table 5-3: Control Board Jumper Configuration

    Maintenance Ensemble Epaq Hardware Manual Table 5-3: Control Board Jumper Configuration  Jumper Setting Description Normal Watchdog defeated (1) Default Table 5-4: Serial Communication Mode Jumper Select Jumper Setting Mode RS-232 RS-232 RS-422 RS-485 (1) Default (2) Reversed www.aerotech.com Chapter 5...

  • Page 96: Power Board

    Ensemble Epaq Hardware Manual Maintenance 5.2. Power Board Figure 5-2 highlights the important components located on the power board assembly. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble Epaq chassis. 3 ASB...

  • Page 97: Integrated Axis Control Boards (Amplifier)

    Maintenance Ensemble Epaq Hardware Manual 5.3. Integrated Axis Control Boards (Amplifier) Figure 5-3 Figure 5-4 highlight the important components located on the MP and ML axis control boards. Refer to Table 5-5 for fuse replacement information. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble Epaq chassis.
  • Page 98 Ensemble Epaq Hardware Manual Maintenance TB102 (MOTOR POWER) J103 (MOTOR FEEDBACK) TP17 TP21 TB104 TB105 5ASB 5ASB Drawing Number: 690D1652 Figure 5-4: ML Board Assembly Chapter 5 www.aerotech.com...

  • Page 99: Integrated Axis I/O Expansion Board (Amplifier)

    Maintenance Ensemble Epaq Hardware Manual 5.4. Integrated Axis I/O Expansion Board (Amplifier) The figure below highlights the important components located on the -IO option board. Refer to Chapter 3: - IO Expansion Board for a description of user accessible features. D A N G E R : Always disconnect the Mains power connection before opening the Ensemble Epaq chassis.

  • Page 100: Fuse Replacement

    1. F1 is soldered to the circuit board, contact Aerotech for repair if fuse is open. D A N G E R :  Residual voltages greater than 60V may be present inside the Ensemble Epaq chassis for longer than 5 seconds after power has been disconnected.

  • Page 101: Preventative Maintenance

    (Mains disconnect). D A N G E R :  Residual voltages greater than 60V may be present inside the Ensemble Epaq chassis for longer than 5 seconds after power has been disconnected.
  • Page 102 Ensemble Epaq Hardware Manual Maintenance This page intentionally left blank. Chapter 5 www.aerotech.com...

  • Page 103: 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 104 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 105: Appendix B: Revision History

    4.1. Section 3.7. Section 3.7.1. updated 2.02.00 January 27, 2011 Revision changes have been archived. If you need a copy of this revision, contact Aerotech Global Technical Support. 2.01.00 September 13, 2010 2.00.00 April 26, 2010 1.02.00 September 17, 2008 1.01.00...
  • Page 106 Ensemble Epaq Hardware Manual Revision History This page intentionally left blank. Appendix B www.aerotech.com...

  • Page 107: Appendix C: Chassis Disassembly

    W A R N I N G : All service and maintenance must be performed by qualified personnel. D A N G E R :  Residual voltages greater than 60V may be present inside the Ensemble Epaq chassis for longer than 5 seconds after power has been disconnected.
  • Page 108 Ensemble Epaq Hardware Manual Chassis Disassembly 1. Remove the [x8] screws fastening the rear section of the Epaq cover and lift off the rear cover. 2. Remove the [x2] screws (shown in Detail A) for each amplifier to be removed.

  • Page 109: Index

    Index Ensemble Epaq Hardware Manual Index Chassis Control Board Chassis Electrical Specifications -I/O Expansion Board Check chassis for loose or damaged parts / -IO Option Board Assembly hardware Check for fluids or electrically conductive 2006/95/EC material exposure Cleaning AC Power Connections...
  • Page 110 Ensemble Epaq Hardware Manual Index Environmental Specifications Line Driver Encoder Interface ESTOP ESTOP0 Maintenance ESTOP1 Minimizing Conducted, Radiated, and System Noise Ethernet Interface Motor Feedback Connections Motor Feedback Connector Mating Connector Feature Summary Motor Feedback Connector Pin Assignment Feedback Monitoring...
  • Page 111 Index Ensemble Epaq Hardware Manual PS2806-4 device PSO Interface PSO Output Sources Quick Start Connections xiii Rack or Desk-Mount Options relative phasing/order RS-422 Line Driver Encoder (Standard) Serial Communication Mode Jumper Select Servo Amplifier Electrical Specifications Software Options solid state brake control relay...
  • Page 112 Ensemble Epaq Hardware Manual Index This page intentionally left blank. www.aerotech.com...

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