Aerotech A3200 Series User manual

Revision: 1.00.00
HEXRCHardware Manual
ON
OFF
     
AEROTECH.
COM
0
A
HEX RC
Powered by
3
2
0
USB
MOTOR / FEEDBACK
DIGITAL / ANALOG IO MPGA
DVI
USB2 USB3 ETHERNET FIREWIRE
ESTOP
1 2
1 2
3 4 5 6

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 © 2016, Aerotech, Inc. All rights reserved.

Table of Contents HEXRCHardware Manual
Table of Contents
Table of Contents iii
List of Figures v
List of Tables vi
EC Declaration of Conformity vii
Safety Procedures and Warnings ix
Quick Installation Guide xi
Chapter 1: Introduction 1
1.1. Electrical Specifications 5
1.2. Mechanical Specifications 7
1.3. Environmental Specifications 9
1.4. Drive and Software Compatibility 10
Chapter 2: Installation and Configuration 11
2.1. Unpacking the Chassis 11
2.2. Electrical Installation 12
2.2.1. ACPower Connections 13
2.2.2. Minimizing Conducted, Radiated, and System Noise 14
2.2.3. I/O and Signal Wiring Requirements 14
2.3. Motor Feedback Connections 15
2.3.1. Encoder Inputs 16
2.3.1.1. Square Wave (RS-422) Encoder 17
2.3.1.2. Analog Encoder Interface 18
2.3.1.3. Encoder Phasing 20
2.3.2. Hall-Effect Inputs 21
2.3.3. Thermistor Input 22
2.3.4. End Of Travel Limit Inputs 23
2.3.4.1. End Of Travel Limit Phasing 24
2.3.5. Motor Output Interface 25
2.3.5.1. Brushless Motor Connections 26
2.3.5.2. DC Brush Motor Connections 29
2.3.5.3. Stepper Motor Connections 30
2.4. Digital and Analog I/O Connections 31
2.4.1. Differential Analog Input 1 32
2.4.2. Analog Output 1 33
2.4.3. Opto-Isolated Outputs 34
2.4.4. Opto-Isolated Inputs 36
2.5. DVI Connector 38
2.6. USB Connectors 39
2.7. Ethernet Connector 40
2.8. FireWire® Connector 41
Chapter 3: Options 43
3.1. Emergency Stop (-EST3) 44
3.2. MPGA32 Connector 47
Chapter 4: Maintenance 49
4.1. Power Board Assembly 50
4.2. Preventative Maintenance 51
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HEXRCHardware Manual Table of Contents
Appendix A: Warranty and Field Service 53
Appendix B: Revision History 55
Index 57
iv www.aerotech.com

Table of Contents HEXRCHardware Manual
List of Figures
Figure 1-1: Chassis Layout 1
Figure 1-2: Functional Diagram 4
Figure 1-3: Dimensions 8
Figure 2-1: Power and Control Connections 12
Figure 2-2: Power Switch 12
Figure 2-3: Line Driver Encoder Interface 17
Figure 2-4: Analog Encoder Phasing Reference Diagram 18
Figure 2-5: Analog Encoder Signals 19
Figure 2-6: Encoder Phasing Reference Diagram (Standard) 20
Figure 2-7: Position Feedback in the DiagnosticDisplay 20
Figure 2-8: Hall-Effect Inputs 21
Figure 2-9: Thermistor Input 22
Figure 2-10: End of Travel Limit Input Connections 23
Figure 2-11: End of Travel Limit Inputs 23
Figure 2-12: Limit Input Status Utility 24
Figure 2-13: Brushless Motor Configuration 26
Figure 2-14: Encoder and Hall Signal Diagnostics 27
Figure 2-15: Motor Phasing Oscilloscope Example 28
Figure 2-16: Brushless Motor Phasing Goal 28
Figure 2-17: DC Brush Motor Configuration 29
Figure 2-18: Clockwise Motor Rotation 29
Figure 2-19: Stepper Motor Configuration 30
Figure 2-20: Clockwise Motor Rotation 30
Figure 2-21: Analog Input 1 32
Figure 2-22: Analog Output 1 33
Figure 2-23: Outputs Connected in Current Sourcing Mode 35
Figure 2-24: Outputs Connected in Current Sinking Mode 35
Figure 2-25: Inputs Connected to a CurrentSourcing Device 37
Figure 2-26: Inputs Connected to a Current Sinking Device 37
Figure 2-27: DVIConnector Location 38
Figure 2-28: USB 2.0 Location 39
Figure 2-29: USB 3.0 Location 39
Figure 2-30: Ethernet Connection 40
Figure 2-31: FireWire Location 41
Figure 3-1: ESTOP Option Interface 44
Figure 3-2: ESTOP(-EST3) Option 45
Figure 3-3: ESTOP(-EST3) with MPGA32 Option 46
Figure 3-4: MPGA32 Connector Location 47
Figure 4-1: Power Board 50
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HEXRCHardware Manual Table of Contents
List of Tables
Table 1-1: Feature Summary 2
Table 1-2: Ordering Options 3
Table 1-3: Chassis Electrical Specifications 5
Table 1-4: Servo Amplifier Electrical Specifications (MP) 6
Table 1-5: Unit Weight 8
Table 1-6: A3200 Drive and Software Compatibility 10
Table 2-1: Main ACPower Input Voltages and Current Requirements 13
Table 2-2: ACPower Cord Wiring Specifications 13
Table 2-3: I/Oand Signal Wiring Specifications 14
Table 2-4: Recommended Wire Sizes 14
Table 2-5: Motor Feedback Connector Pin Assignment 15
Table 2-6: Encoder Pin Assignment 16
Table 2-7: Encoder Specifications 17
Table 2-8: Analog Encoder Specifications 18
Table 2-9: Hall-Effect Feedback Pin Assignment 21
Table 2-10: Thermistor Interface Pin Assignment 22
Table 2-11: End of Travel Limit Inputs Pin Assignment 23
Table 2-12: Motor Output Connections 25
Table 2-13: Digital / Analog IOConnector Pin Assignment 31
Table 2-14: Differential Analog Input 1 Specifications 32
Table 2-15: Differential Analog Inputs Connector Pin Assignment 32
Table 2-16: Analog Output 1 Specifications 33
Table 2-17: Analog Output Connector Pin Assignment 33
Table 2-18: Opto-Isolated Output Specifications 34
Table 2-19: Opto-Isolated Output Connector Pin Assignment 34
Table 2-20: Digital Input Specifications 36
Table 2-21: Opto-Isolated Input Connector Pin Assignment 36
Table 2-22: Ethernet Cable Listing 40
Table 2-23: FireWire Repeaters (for cables exceeding 4.5 m (15 ft) specification) 41
Table 2-24: FireWire Cables (copper and glass fiber) 41
Table 3-1: Options and Capabilities 43
Table 3-2: ESTOPOption Mating Connector 44
Table 3-3: ESTOPSafety Ratings 45
Table 3-4: Relay Specifications 45
Table 3-5: MPGA Connector Pin Assignments 48
Table 4-1: Component Select 50
Table 4-2: Preventative Maintenance 51
vi www.aerotech.com

Declaration of Conformity HEXRCHardware Manual
EC Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product HEXRC
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
2006/42/EC Machinery Directive
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 Safety requirements for electrical equipment
ISO 13849-1 & -2 Safety related parts of control systems
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
www.aerotech.com vii

HEXRCHardware Manual Declaration of Conformity
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Electrical Safety HEXRCHardware Manual
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.
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. Disconnect electrical power before servicing equipment.
2. Disconnect electrical power before performing any wiring.
3. To minimize the possibility of electrical shock and bodily injury, extreme care must be
exercised when any electrical circuits are in use. Suitable precautions and protection must
be provided to warn and prevent persons from making contact with live circuits.
4. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
5. All components must be properly grounded in accordance with local electrical safety
requirements.
6. Operator safeguarding requirements must be addressed during final integration of the
product.
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. Use of this equipment in ways other than described by this manual can cause personal
injury or equipment damage.
2. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts
must be restricted while connected to a power source.
3. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid
potential hazards.
4. Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
5. If the product is used in a manner not specified by the manufacturer, the protection
provided by the product can be impaired and result in damage, shock, injury, or death.
6. Operators must be trained before operating this equipment.
7. All service and maintenance must be performed by qualified personnel.
8. This product is intended for light industrial manufacturing or laboratory use. Use of this
product for unintended applications can result in injury and damage to the equipment.
www.aerotech.com ix

HEXRCHardware Manual Electrical Safety
x www.aerotech.com
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Quick Installation Guide HEXRCHardware Manual
Quick Installation Guide
This chapter describes the order in which connections and settings should typically be made to the HEXRC.
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.
The HEXRC is provided to the user fully configured for operation of a Hexapod, including servo tuning for
the user's load requirements (if provided to Aerotech).
For additional information about HEXRC , programming, utilities, and system operation see the A3200Help
file in the Aerotech folder of the Windows Start menu on the HEXRC.
MOTOR / FEEDBACK
DIGITAL / ANALOG IO MPGA
DVI
USB2 USB3 ETHERNET FIREWIRE
ESTOP
1 2
1 2
3 4 5 6
PC Connection
2
3
Motor Power and Feedback
4
ESTOP
Connect the power source to the
AC Power input
1
2Connect a monitor, keyboard, and
mouse (optional)
Connect each Hexapod stage cable to
a Motor/Feedback connector.
NOTE: Each axis of the HEXAPOD will be numbered
and must be connected to the corresponding
Motor/Feedback controller.
3
Connect the external Emergency Stop
(ESTOP) to the HEX RC Controller (if
the -EST3 option is present).
4
AC Power
1
Figure 1: Quick Start Connections
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HEXRCHardware Manual Quick Installation Guide
xii www.aerotech.com
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Introduction HEXRCHardware Manual
Chapter 1: Introduction
Aerotech’s HEXRC is a high-performance, 6-axis motion controller ideal for controlling robotic systems like
hexapods. The HEXRC is 4U high, rack-mountable, and compatible with the Automation 3200 motion
platform.
The HEXRC features 6-axes of drives capable of controlling any combination of brush, brushless, or
stepper motors. The HEXRC performs both current loop and servo loop closures digitally to ensure the
highest level of positioning accuracy and performance. With the A3200 distributed control architecture, the
HEXRC can connect and control up to 26 additional axes of servo, stepper, or piezo-driven stages.
In environments such as beamlines, the HEXRC can interface with a host control platform and receive
control commands via an ASCII command interface over TCP/IP. Alternatively, the HEXRC can act as a
master controller and control other A3200 external drives via the FireWire interface.
The HEXRC can accept amplified-sine or digital encoders. With on-board encoder multiplication up to 4096
high-resolution positioning is realized in a cost-effective, high-performance package.
An optional 6-axis jog pendant can be added for manual control of the positioning system. In safety critical
applications, an emergency stop option with redundant safety relays is available.
ON
OFF
     
AEROTECH.
COM
0
A
HEX RC
Powered by
3
2
0
USB
MOTOR / FEEDBACK
DIGITAL / ANALOG IO MPGA
DVI
USB2 USB3 ETHERNET FIREWIRE
ESTOP
1 2
1 2
3 4 5 6
ESTOP
DVI
Motor / Feedback
Digital / Analog I/O
MPGA
Power Switch / Circuit Breaker
USB
Firewire
AC Power Input
USB Ethernet
Figure 1-1: Chassis Layout
www.aerotech.com Chapter 1 1

HEXRCHardware Manual Introduction
Table 1-1: Feature Summary
Feature Description
Processor Intel i5, 4 Core, 3.1 GHz, 6 MB Cache, 8 GB memory
Number of Axes Six
Encoder Inputs Six (1 Vpp or RS-422)
Motor Style Brush, Brushless, Stepper
Power Supply Single-Phase 100-240 VAC; 50/60 Hz (factory configured)
Power Output 600 w continuous
Bus Voltage 80 VDC
Peak Output Current (1 sec) (1) 10 Apk
ContinuousOutput Current (1) 5 Apk
Digital Inputs 16, opto-isolated
Digital Outputs 16, opto-isolated
Analog Inputs Eight total, ±10 V 12-bit differential
One on each I/O connector, One on each axis connector
Analog Outputs Two, ±5 V 16-bit
High-Speed Data Capture Yes (50 ns latency)
Emergency Stop (ESTOP) Optional
Position Synchronized Output
(PSO)
Single Axis Standard
Primary Encoder Input
Frequency(1Vpp)
200 kHz sine wave
Primary Encoder Input Fre-
quency (RS-422)
10 MHz square wave / 40 MHz count rate
Interfaces ASCII command interface via TCP/IP; FireWire (IEEE-1394)
Fieldbus Modbus TCP on PC
USBPorts Three (USB 3.0 x 2; USB 2.0 x 1), Used for Peripheral Device
Connection
Video Port DVI-I
Jog Pendant Optional, Six Axis (MPGA)
Encoder Multiplication Programmable up to x4096
Current Loop Update Rate 20 kHz
Servo Loop Update Rate 8 kHz
Power Amplifier Bandwidth Selectable through software
Minimum Load Inducatance 0.1 mH
Operating Temperature 0 to 50°C
Storage Temperature -30 to 85°C
Weight 25 kg
1. Peak value of the sine wave; rms current for ACmotors is 0.707* Apk
2 Chapter 1 www.aerotech.com

Introduction HEXRCHardware Manual
Table 1-2: Ordering Options
HEXRCMulti-Axis Robotic Controller
HEX RC Rack-mount, six-axis, robotic controller with FireWire® with TCP/IP ASCII interfaces;
100-240 VAC singlephase power supply.
Line Voltage (Required)
-A 115 VAC line
-B 230 VAC line
-C 100 VAC line
-D 200 VAC line
Line Cord (Optional)
-LC1 US 115 VAC line cord
-LC2 US 230 VAC line cord
-LC3 UK compatible line cord
-LC4 German compatible line cord
-LC5 Israel compatible line cord
-LC6 India compatible line cord
-LC7 Australian compatible line cord
Jog Pendant Connection (Required)
-JP0 Standard – No jog pendant connector interface
-JP1 Connector interface for six-axis jog pendant (MPGA32); jog-pendant must be ordered as
separate line item
Options
-EST3 ESTOP3 – controller stops motion, then disables servo control; internal positive guided
relays with monitor contact disconnect AC power source from motor (uses two relays for
redundancy); contains one-second bus discharge resistors; operator risk assessment is
the responsibility of the end user or integrator
-SL1 Rack-mount slides
Accessories (Ordered as a separate line item)
MPGA32 Six-axis jog pendant
www.aerotech.com Chapter 1 3

HEXRCHardware Manual Introduction
The following block diagram illustrates the features and options of the HEXRC.
Encoder +5V / Common
Analog Input 0 ±
SIN, COS, MRK
-MXU
MOTOR OUTPUT/
FEEDBACK
(up to x6)
CW, CCW, Home Limits;
Encoder Fault; Hall A, B, C;
Motor Over Temperature
Amplifier
Control
Power
Motor
Power
ESTOP
AC Power
Input
Amplifier
Heatsink Over
Temperature
ESTOP
(optional)
Switch
Control
Power
Supply
Analog Input 1 ±
Analog Output 1
8 Opto Outputs
(Sinking or Sourcing)
8 Opto Inputs
(Sinking or Sourcing)
DIGITAL /
ANALOG IO
(up to x2)
SIN, COS
5V, COM
ESTOP
24V, COM
MPGA
(Option)
FireWire PortCommunications
Ethernet PortCommunications
USB (x3)Communications
Video PortDVI
Motor (+, -, )
Figure 1-2: Functional Diagram
4 Chapter 1 www.aerotech.com

Introduction HEXRCHardware Manual
1.1. Electrical Specifications
The electrical specifications for the HEXRC drive chassis are listed in Table 1-3 and the electrical
specifications for the servo amplifiers in Table 1-4 and 1.1.
Table 1-3: Chassis Electrical Specifications
Description Specifications
Total Motor Power Supply 80 V @ 600W
Input
Current
100 VAC 10 A Maximum
115 VAC 10 A Maximum
200 VAC 6 A Maximum
230VAC 5 A Maximum
Inrush Current 100 A @ 254 VAC
Leakage Current <1/5 mA @ 60 Hz / 254 VAC
AC Power Input
AC input (factory configured): AC Hi, AC Lo, Earth Ground ( ),
l100 VAC (90-112 VAC, 49-63 Hz)
l115 VAC (103-127 VAC, 49-63 Hz)
l200 VAC (180-224 VAC, 49-63 Hz)
l230 VAC (207-254 VAC, 49-63 Hz)
Auxiliary Power Outputs +5 V is provided on all axis feedback connectors for encoder, Hall, and limit
power.
Protection
lPower switch / breaker (10 A, Supplemental Protection only).
lFuses on motor bus supply transformer.
lBus supply inrush current limit during power-on.
Indicator (Power) Power switch contains a power-on indicator.
www.aerotech.com Chapter 1 5

HEXRCHardware Manual Introduction
The HEXRCuses an Ndrive MP10 with encoder multiplier (MXU)for each axis. The first two axes contain
the I/O option, which is available to the user through the two Digital/Analog I/O connectors on the rear panel
of the HEXRC.
Table 1-4: Servo Amplifier Electrical Specifications (MP)
MP 10
Output Voltage 80 VDC (referenced to earth ground)
Peak Output Current (1 second) 10 A
Continuous Output Current 5 A
Power Amplifier Bandwidth 2500 Hz maximum (software selectable)
Power Amplifier Efficiency 85% - 95%
PWM Switching Frequency 20 kHz
Minimum Load Inductance 0.1 mH @ 80 VDC
User Power Supply Output 5 VDC (@ 500 milliamps)
Modes of Operation Brushless; Brush; Stepper
Protective Features
Output short circuit; Peak over current; RMSover current;
Over temperature; Control power supply under voltage;
Power stage bias supply under voltage
Isolation Optical and transformer isolation between control and power
stages.
6 Chapter 1 www.aerotech.com

Introduction HEXRCHardware Manual
1.2. Mechanical Specifications
The HEXRC must be installed in a rack mount console to comply with safety standards. Mount the
HEXRC so free airflow is available at the rear of the chassis. Allowance must also be made for the rear
panel connections and cables.
D A N G E R / H E A V Y : Refer to Table 1-5 for chassis mass specifications.
lThe HEXRC exceeds 25 kg (55 lbs).
lUse both handles to carefully lift and carry the HEXRC.
www.aerotech.com Chapter 1 7

HEXRCHardware Manual Introduction
ON
OFF
     
AEROTECH.
COM
0
A
HEX RC
Powered by
3
2
0
USB
MOTOR / FEEDBACK
DIGITAL / ANALOG IO MPGA
DVI
USB2 USB3 ETHERNET FIREWIRE
ESTOP
1 2
1 2
3 4 5 6
447.6 [17.62]
444.5 [17.50]
110.6 [4.35]
82.0 [3.23]
66.2 [2.60]
37.7 [1.48]
94.7 [3.73]
139.3 [5.48]
7.1 [0.28]
(4 PLS.)
177.0 [6.97]
8.3 [0.33] (TYP.)
Drawing Number: 620E1422-
463.5 [18.25]
466.0 [18.35]
476.2 [18.75]
482.6 [19.00]
428.5 [16.87]
535.9 [21.10]
41.7 [1.64]
570.9 [22.47]
Figure 1-3: Dimensions
Table 1-5: Unit Weight
Description Weight
Chassis Weight (typical) 25 kg
8 Chapter 1 www.aerotech.com