Aerotech Ensemble LAB User manual

USB
JOG
1
2
3
4
J103J104
J105J106 TB101
ETHERNET
USBESTOPJOYSTICKAUX I/O
AXIS
4 3 2 1
WARNING: HAZARDOUS
VOLTAGE PRESENT UP TO
10 MINUTES AFTER
POWER IS DISCONNETED
Revision: 1.02.00
Ensemble LAB Hardware
Manual

Global Technical Support
Go to www.aerotech.com/global-technical-support for information and support about your Aerotech products. The website
provides downloadable resources (such as up-to-date software, product manuals, and Help files), training schedules, and
PC-to-PC remote technical support. You can also complete Product Return (RMA) forms and get information about repairs
and spare or replacement parts. For immediate help, contact a service office or your sales representative. Have your
customer order number available before you call or include it in your email.
United States (World Headquarters)
Phone: [phone]
Fax: [phone]
Email: [e-mail]
101 Zeta Drive
Pittsburgh, PA 15238-2897
www.aerotech.com
United Kingdom Japan
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Germany China
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
France Taiwan
Phone: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
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.
Copyright © 2012-2016, Aerotech, Inc., All rights reserved.

Ensemble LAB Hardware Manual Table of Contents
Table of Contents
Ensemble LAB Hardware Manual 1
Table of Contents iii
List of Figures v
List of Tables vi
EU Declaration of Conformity 7
Agency Approvals 8
Safety Procedures and Warnings 9
Quick Installation Guide 11
Chapter 1: Introduction 13
1.1. Electrical Specifications 16
1.1.1. System Power Requirements 17
1.2. Mechanical Specifications 18
1.3. Environmental Specifications 19
1.4. Drive and Software Compatibility 20
Chapter 2: Installation and Configuration 21
2.1. Unpacking the Chassis 21
2.2. Electrical Installation 22
2.2.1. AC Power Connection 23
2.2.2. IO and Signal Wiring Requirements 24
2.2.3. Minimizing Conducted, Radiated, and System Noise 25
2.3. Motor and Feedback Connections 26
2.3.1. Encoder Interface 27
2.3.1.1. RS-422 Line Driver Encoder (Standard) 28
2.3.1.2. Analog Encoder Interface 29
2.3.1.3. Encoder Phasing 31
2.3.2. Hall-Effect Interface 33
2.3.3. Thermistor Interface 34
2.3.4. End of Travel Limit Input Interface 35
2.3.4.1. End of Travel Limit Phasing 36
2.3.5. Motor Output Interface 37
2.3.5.1. Brushless Motor Connections 38
2.3.5.2. DC Brush Motor Connections 41
2.3.5.3. Stepper Motor Connections 42
2.4. Emergency Stop Sense Input (TB101) 43
2.5. Auxiliary I/OConnector (J106) 44
2.5.1. Auxiliary Encoder Channel 45
2.5.2. Position Synchronized Output (PSO) 47
2.5.3. Opto-Isolated Outputs 0-3 49
2.5.4. Opto-Isolated Inputs 0-3 51
2.5.5. High-Speed User Inputs 4-5 53
2.5.6. Analog Output 0 54
2.5.7. Analog Input 0 55
2.6. Joystick Interface (J105) 56
2.7. Communication (Ethernet and USB) 58
2.7.1. USB Interface 58
2.7.2. Ethernet Interface 59
2.8. PC Configuration and Operation Information 60
Chapter 3: Maintenance 61
3.1. Preventative Maintenance 61
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Table of Contents Ensemble LAB Hardware Manual
Appendix A: Warranty and Field Service 63
Appendix B: Revision History 65
Index 67
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Ensemble LAB Hardware Manual Table of Contents
List of Figures
Figure 1-1: Ensemble LAB Controller 13
Figure 1-2: Functional Diagram 15
Figure 1-3: Dimensions 18
Figure 2-1: Power and Control Connections 22
Figure 2-2: Power Switch 22
Figure 2-3: Line Driver Encoder Interface 28
Figure 2-4: Analog Encoder Phasing Reference Diagram 29
Figure 2-5: Analog Encoder Interface 30
Figure 2-6: Encoder Phasing Reference Diagram (Standard) 31
Figure 2-7: Position Feedback in the Diagnostic Display 32
Figure 2-8: Hall-Effect Inputs 33
Figure 2-9: Thermistor Interface Inputs 34
Figure 2-10: End of Travel Limit Input Connections 35
Figure 2-11: End of Travel Interface Inputs 35
Figure 2-12: Limit Input Diagnostic Display 36
Figure 2-13: Brushless Motor Configuration 38
Figure 2-14: Encoder and Hall Signal Diagnostics 39
Figure 2-15: Motor Phasing Oscilloscope Example 40
Figure 2-16: Brushless Motor Phasing Goal 40
Figure 2-17: DC Brush Motor Configuration 41
Figure 2-18: Clockwise Motor Rotation 41
Figure 2-19: Stepper Motor Configuration 42
Figure 2-20: Clockwise Motor Rotation 42
Figure 2-21: ESTOP Sense Input (TB102) 43
Figure 2-22: Auxiliary Encoder Channel 46
Figure 2-23: PSOInterface 48
Figure 2-24: Outputs Connected in Current Sourcing Mode (J106) 50
Figure 2-25: Outputs Connected in Current Sinking Mode (J106) 50
Figure 2-26: Inputs Connected in Current Sourcing Mode (J106) 52
Figure 2-27: Inputs Connected in Current Sinking Mode (J106) 52
Figure 2-28: High Speed User Inputs (J106) 53
Figure 2-29: Analog Output 0 (J106) 54
Figure 2-30: Analog Input 0 (J106) 55
Figure 2-31: Joystick Interface 56
Figure 2-32: USB Connection Location (for PCCommunication) 58
Figure 2-33: Ethernet Connection Location 59
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Table of Contents Ensemble LAB Hardware Manual
List of Tables
Table 1-1: Ordering Options 14
Table 1-2: Electrical Specifications 16
Table 1-3: Physical Specifications 18
Table 1-4: Drive and Software Compatibility 20
Table 2-1: Main AC Power Input Voltages and Current Requirements 23
Table 2-2: I/Oand Signal Wiring Specifications 24
Table 2-3: Ferrite Bead Part Numbers 25
Table 2-4: Motor Power and Feedback Connector 26
Table 2-5: Encoder Interface Pin Assignment 27
Table 2-6: Encoder Specifications 28
Table 2-7: Analog Encoder Specifications 29
Table 2-8: Hall-Effect Feedback Interface Pin Assignment 33
Table 2-9: Thermistor Interface Pin Assignment 34
Table 2-10: End of Travel Interface Pin Assignment 35
Table 2-11: Motor Output Connections 37
Table 2-12: TB101ESTOPPin Assignment 43
Table 2-13: Electrical Noise Suppression Devices 43
Table 2-14: Auxiliary I/O Interface Pin Assignment (J106) 44
Table 2-15: Auxiliary Encoder Specifications 45
Table 2-16: Auxiliary Encoder Channel Pin Assignment (J106) 45
Table 2-17: PSO Specifications 47
Table 2-18: PSOPin Assignment 47
Table 2-19: Port 0 Digital Output Connector Pin Assignment 49
Table 2-20: Digital Output Specifications 49
Table 2-21: Opto-Isolated Input Specifications 51
Table 2-22: Port 0 Digital Input Connector Pin Assignment (J106) 51
Table 2-23: High-Speed Input Specifications 53
Table 2-24: Port 0 High Speed Digital Input Connector Pin Assignment (J106) 53
Table 2-25: Analog Output 0 Specifications 54
Table 2-26: Analog Output Connector Pin Assignment (J106) 54
Table 2-27: Differential Analog Input 0 Specifications 55
Table 2-28: Analog Input Connector Pin Assignment (J106) 55
Table 2-29: Joystick Connector Pin Assignment (J105) 57
Table 3-1: Preventative Maintenance 61
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Ensemble LAB Hardware Manual Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Ensemble LAB
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2014/35/EU Low Voltage Directive LVD
2011/65/EU RoHS2 Directive
and has been designed to be in conformity with the applicable requirements of the following documents when
installed and used in accordance with the manufacturer’s supplied installation instructions.
EN 61010-1:2010 Safety requirements for electrical equipment
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
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Declaration of Conformity Ensemble LAB Hardware Manual
Agency Approvals
Aerotech, Inc. Model Ensemble LAB Motion Controllers have been tested and found to be in accordance to
the following listed Agency Approvals:
Approval / Certification: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 14 08 68995
Standards: UL 61010-1:2012; CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-
1:2010
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Ensemble LAB Hardware Manual Safety Procedures and Warnings
Safety Procedures and Warnings
The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure
to observe these precautions could result in serious injury to those individuals performing the procedures
and/or damage to the equipment.
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. Refer to www.aerotech.com for the most up-to-date information.
W A R N I N G :
To minimize the possibility of electrical shock, bodily injury or death the following precautions
must be followed.
1. Operators must be trained before allowing them to operate the equipment.
2. All service and maintenance must be performed by qualified personnel.
3. Modification or use of this product in an unspecified manner may result in equipment
damage or bodily injury (shock or death).
4. The user must read this manual, EnsembleHelp file, and related documentation
thoroughly before operating the equipment.
5. Cables can pose a tripping hazard. Securely mount and position all system cables to
avoid potential hazards.
6. This product must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
D A N G E R :
This product contains potentially lethal voltages. To reduce the possibility of electrical shock,
bodily injury or death the following precautions must be followed.
1. Risk of injury during operation due to moving parts connected to the Ensemble LAB.
2. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
3. Disconnect electrical power before making any mechanical adjustments or performing
maintenance.
4. Make sure the system is properly grounded in accordance with local electrical safety
requirements.
5. Operator safeguarding requirements must be addressed during final integration of the
product.
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Safety Procedures and Warnings Ensemble LAB Hardware Manual
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Ensemble LAB Hardware Manual Quick Installation Guide
Quick Installation Guide
This chapter describes the order in which connections and settings should typically be made to the
Ensemble LAB. 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.
J103J104
J105J106 TB101
ETHERNET
USBESTOPJOYSTICKAUX I/O
AXIS
4 3 2 1
WARNING: HAZARDOUS
VOLTAGE PRESENT UP TO
10 MINUTES AFTER
POWER IS DISCONNETED
B
A
Topic Section
A
Connect the ACPower Section 2.2.
B
Connect the Motor Power and Feedback Section 2.3.
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Quick Installation Guide Ensemble LAB Hardware Manual
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Ensemble LAB Hardware Manual Introduction
Chapter 1: Introduction
Aerotech’s Ensemble LAB is a one to four axis desktop standalone motion controller with an integrated
power supply. The Ensemble LAB is designed for applications where ease of operation is desired without
sacrificing overall system capability.
Number of Axes 4 Maximum
Encoder Inputs 4
Amplifier Type Linear
Digital Inputs Four Optically Isolated; Two High Speed; One ESTOP
Digital Outputs Four Optically Isolated
Analog Inputs One 16-Bit differential analog input (±10V)
Analog Outputs One 16-Bit differential analog output (±10V)
Dedicated Axis I/O Two Limit Inputs (CW, CCW); Three Hall-Effect Inputs
Feedback Type (Standard) 10 MHz Square Wave /40 MHz Count Rate
Feedback Type (Optional) Interpolated (65,536 max) Sin/Cos; 200 kHz max input frequency
Communication Interfaces 10/100 Base T Ethernet; USB 2.0
Expansion Interface USB 1.1
Servo Loop Update 10 kHz maximum
Current Loop Update 20 kHz
Programming Environment Multi-Tasking AeroBasic
Host Operating System Windows 7 (for Remote Programming and Diagnostic Tools)
USB
JOG
1
2
3
4
J103J104
J105J106 TB101
ETHERNET
USBESTOPJOYSTICKAUX I/O
AXIS
4 3 2 1
WARNING: HAZARDOUS
VOLTAGE PRESENT UP TO
10 MINUTES AFTER
POWER IS DISCONNETED JK
I
F
B
C
D
E
A
L
H
G
A
Touch Screen
D
Power Switch
G
Auxiliary I/Oport
(J106)
J
USB (host) port
(J104)
B
Keypad
E
USB(device) port
H
Joystick port (J105)
K
Ethernet port (J103)
C
Jog Buttons
F
Motor / Feedback
Connector (1-4)
I
ESTOP port
(TB101)
L
ACPower
Figure 1-1: Ensemble LAB Controller
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Introduction Ensemble LAB Hardware Manual
Table 1-1: Ordering Options
Number of Axes (required)
-2DS Configured for 2 axis DC brush/Stepper motor operation
-3DS Configured for 3 axis DC brush/Stepper motor operation
-4DS Configured for 4 axis DC brush/Stepper motor operation
-2DSA Configured for 2 axis AC brushless, DC brush/Stepper motor operation
-3DSA Configured for 3 axis AC brushless, DC brush/Stepper motor operation
-4DSA Configured for 4 axis AC brushless, DC brush/Stepper motor operation
Line Voltage (required)
-A 115 VAC input
-B 230 VAC input
-C 100 VAC input
-D 200/208 VAC input
Bus Voltage (required)
-24B ±24VDC bus for stepper, DC, and brushless motor devices
Feedback Type (optional)
-MXU1 Interpolation circuit allowing analog sine wave input on encoder channel 1 up to x8192.
No real-time output or PSO support.
-MXU2 Interpolation circuit allowing analog sine wave input on encoder channel 2 up to x8192.
No real-time output or PSO support.
-MXU3 Interpolation circuit allowing analog sine wave input on encoder channel 3 up to x8192.
No real-time output or PSO support.
-MXU4 Interpolation circuit allowing analog sine wave input on encoder channel 4 up to x8192.
No real-time output or PSO support.
-MXR1 Interpolation circuit allowing analog sine wave input on encoder channel 1 up to x65536.
Real-time output and PSOsupport.
-MXR2 Interpolation circuit allowing analog sine wave input on encoder channels 1 and 2 up to
x65536. Real-time output and PSOsupport.
-MXR3 Interpolation circuit allowing analog sine wave input on encoder channels 1, 2, and 3 up
to x65536. Real-time output and PSOsupport.
-MXR4 Interpolation circuit allowing analog sine wave input on encoder channels 1, 2, 3, and 4
up to x65536. Real-time output and PSOsupport.
PSOOutput (optional)
-PSO Single axis Position Synchronized Output. Can be configured to track quadrature or MXR
input encoder channels.
Line Cord (required)
-ENGLAND U.K. compatible line cord
-GERMANY German compatible line cord
-ISRAEL Israel compatible line cord
-INDIA India compatible line cord
-AUSTRALIA Australia compatible line cord
-US-115VAC US 115 VACcompatible line cord
-US-230VAC US230 VACcompatible line cord
-NO-LINECORD No line cord
Standard Motor Power and Feedback Combination Cables
C24100-50 5.0 meters long; for use with single 25 pin D feedback and motor stages (25 PinD,
Brushless motor, not rated for continuous flex)
C24210-50 5.0 meters long; for use with BMS/BMmotor with 9-pin limits (25 PinD, 4 Pin HPD, 9 Pin
D, Brushless motor, not rated for continuous flex)
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Ensemble LAB Hardware Manual Introduction
The following block diagram shows a connection summary (refer to Chapter 2 for more detailed connection
information).
Controller Amplifier
MOTOR POWER
and FEEDBACK
J1-J4
AUX I/O
J106
LCD Touch
Display
Encoder +5V / Common
Motor (A, B, C)
SIN, COS, MRK (RS422)
-MXU/-MXR
Option
CW, CCW, Home Limits;
Hall A, B, C;
Motor Over Temperature
Amplifier
Control
Power
Control
Power
Supply
AC Power
Input Linear Amplifier
Heatsink Over
Temperature
Analog Output 0
Analog Input 0 +/-
2 High Speed Opto Inputs
4 Opto Inputs
4 Opto Outputs
SIN, COS, MRK (RS422)
Encoder +5V / Common
PSO Output
Motor
Power
USB Port
USB
J104
Ethernet Port
Ethernet
J103
JOYSTICK
J105
ESTOP
External
Interface
(/ESTOP1)
TB101
USB Port
USB
(Front)
Keypad
Figure 1-2: Functional Diagram
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Introduction Ensemble LAB Hardware Manual
1.1. Electrical Specifications
The electrical specifications for the Ensemble LAB are listed below.
Table 1-2: Electrical Specifications
Description Ensemble LAB
Power
Supply
Input Voltage 100 VAC 115 VAC 200 VAC 230 VAC
Input Frequency 50-60 Hz
Inrush Current 7 A 8 A 13 A 15 A
Maximum Continuous
Input Current
2 A 2 A 1 A 1 A
Input Current Aerotech doesn't specify the input current or power to the drives
because it is dependent on the amount of real power being
delivered to the drive(refer to Section 1.1.1.).
Output Voltage (1) ±22.5 V @ 5 A
Peak Output Current (1) 5 A
Continuous Output Current (1) 2.5 A
Bus Voltage ±24 VDC
Power Amplifier Bandwidth (1) 2500 Hz Maximum (software selectable)
Minimum Load Resistance 0.5 Ω
Output Impedance 0.3 Ω
User Power Supply Output 5 VDC (@ 500 mA)
Mode of Operation Brush, Stepper, Brushless(2)
1. Load Dependent
2. The Brushless motor mode of operation is only available if the -2DS, -3DS, or -4DS option has been purchased.
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Ensemble LAB Hardware Manual Introduction
1.1.1. 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.
Linear Motor
Pdiss[W] = MotorCurrentPeak[A] * TotalBusVoltage[V] * 3 / 2
Pin = SUM (Pdiss ) / EfficiencyFactor
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Introduction Ensemble LAB Hardware Manual
1.2. Mechanical Specifications
The following figure shows the Ensemble LAB package dimensions.
USB
JOG
1
2
3
4
J103J104
J105J106 TB101
ETHERNET
USBESTOPJOYSTICKAUX I/O
AXIS
4 3 2 1
WARNING: HAZARDOUS
VOLTAGE PRESENT UP TO
10 MINUTES AFTER
POWER IS DISCONNETED
2.3 [0.09]272.5 [10.73]4.9 [0.19]
98.4 [3.88]
370.2 [14.58]
304.4 [11.99]32.9 [1.29]
44.8 [1.76]
95.6 [3.76]
13.3 [0.52]
DRAWING NUMBER: 620E1415 REV-
DIMENSIONS: MM [IN]
Figure 1-3: Dimensions
Table 1-3: Physical Specifications
Weight
5.7 kg [12.6 lbs]
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Ensemble LAB Hardware Manual Introduction
1.3. Environmental Specifications
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. Non condensing.
Altitude Up to 2000 meters.
Pollution Pollution degree 2 (normally only non-conductive pollution).
Use Indoor use only.
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Introduction Ensemble LAB Hardware Manual
1.4. Drive and Software Compatibility
The following table lists the available drives and which version of the software first supported the drive.
Drives that list a specific version number in the Last Software Version column will not be supported after
the listed version.
Table 1-4: Drive and Software Compatibility
Drive Type Firmware Revision First Software Version Last Software Version
CL - 1.01 5.02
A 2.55 5.02
CP A 1.00 Current
B 2.54 Current
Epaq - 1.00 Current
A 2.55 Current
Epaq MR with ML drives - 3.00 Current
Epaq MR with MP drives - 1.00 Current
A 2.55 Current
HLe - 2.51 Current
HPe - 2.51 Current
LAB - 4.04 Current
ML - 3.00 Current
MP - 1.00 Current
A 2.55 Current
QDe/QL/QLe - 5.01 Current
QLAB - 4.07 Current
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