Aerotech Automation1 GI4 Galvo User manual

Revision 1.00
Automation1 GI4 Galvo Scanner
Controller
HARDWAREMANUAL

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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 © 2020-2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 GI4 Galvo Scanner Controller 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Conformity 7
Safety Procedures and Warnings 9
Installation Overview 11
Chapter 1: Introduction 13
1.1. Electrical Specifications 17
1.2. Mechanical Specifications 18
1.2.1. Mounting and Cooling 18
1.2.2. Dimensions 19
1.2.3. DIN Rail Mounting 21
1.2.4. OEMMounting 22
1.3. Environmental Specifications 23
1.4. Drive and Software Compatibility 24
Chapter 2: Installation and Configuration 25
2.1. Input Power Connections 26
2.1.1. Control Supply Connector 26
2.1.2. Minimizing Noise for EMC/CECompliance 27
2.2. Galvo Interface Connector 28
2.3. Aux Encoders Connector 29
2.3.1. Square WaveEncoder 30
2.4. Digital I/O Connector 31
2.4.1. Digital Outputs 32
2.4.2. Digital Inputs 35
2.4.3. High-Speed User Input 37
2.5. Analog I/O and Laser Interface Connector 38
2.5.1. Laser Interface Outputs 39
2.5.2. Position Synchronized Output (PSO) Interface 40
2.5.3. Analog Outputs 42
2.5.4. Analog Inputs (Differential) 43
2.5.5. Sync Port 44
2.6. HyperWire Interface 45
2.7. System Interconnection 46
2.8. PC Configuration and Operation Information 47
Chapter 3: Maintenance 49
3.1. Preventative Maintenance 50
Appendix A: Warranty and Field Service 51
Appendix B: Revision History 53
Index 55
GI4 Hardware Manual Table of Contents
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List of Figures
Figure 1-1: GI4 Galvo Scanner Controller 13
Figure 1-2: GI4-OEM Galvo Scanner Controller 14
Figure 1-3: Functional Diagram 16
Figure 1-4: Dimensions [-P1 Package] 19
Figure 1-5: Dimensions [-P2 Package] 20
Figure 1-6: Din Rail Clip Dimensions 21
Figure 2-1: Control Supply Connections 26
Figure 2-2: Square Wave Encoder Interface 30
Figure 2-3: Digital Outputs Schematic 33
Figure 2-4: Digital Outputs Connected in Current Sourcing Mode 34
Figure 2-5: Digital Outputs Connected in Current Sinking Mode 34
Figure 2-6: Digital Inputs Schematic 35
Figure 2-7: Digital Inputs Connected to Current Sourcing (PNP) Devices 36
Figure 2-8: Digital Inputs Connected to Current Sinking (NPN) Devices 36
Figure 2-9: High-Speed Input 37
Figure 2-10: TTLOutput 39
Figure 2-11: PSO TTLOutputs Schematic 40
Figure 2-12: PSOExternal Sync Input Schematic 41
Figure 2-13: Analog Outputs Schematic 42
Figure 2-14: Analog Inputs Schematic 43
Figure 2-15: System Interconnection Drawing (Best Practice) 46
List of Figures GI4 Hardware Manual
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List of Tables
Table 1-1: FeatureSummary 15
Table 1-2: Electrical Specifications 17
Table 1-3: Mounting Specifications 18
Table 1-4: Mounting Parts 21
Table 1-5: OEMMounting Parts 22
Table 1-6: Environmental Specifications 23
Table 1-7: Drive and Software Compatibility 24
Table 2-1: Control Supply Connector Wiring Specifications 26
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 26
Table 2-3: Galvo Interface Pinout 28
Table 2-4: Mating Connector Part Numbers for the Galvo Interface Connector 28
Table 2-5: Aux Encoders Connector Pinout 29
Table 2-6: Mating Connector Part Numbers for the Aux Encoders Connector 29
Table 2-7: Square Wave Encoder Specifications 30
Table 2-8: Aux Encoders Connector Pinout 30
Table 2-9: Digital I/O ConnectorPinout 31
Table 2-10: Mating Connector Part Numbers for the Digital I/OConnector 31
Table 2-11: Digital Output Specifications 32
Table 2-12: Digital Output Pins on Digital I/OConnector 32
Table 2-13: Digital Input Specifications 35
Table 2-14: Digital Input Pins on the Digital I/O Connector 35
Table 2-15: High-Speed Input Specifications 37
Table 2-16: High-Speed Input Pins on the Digital I/O Connector 37
Table 2-17: Analog I/O and Laser Interface ConnectorPinout 38
Table 2-18: Mating Connector Part Numbers for the Laser Interface Connector 38
Table 2-19: Laser Output Pins on the Analog I/O and Laser Interface Connector 39
Table 2-20: Laser Output Specifications 39
Table 2-21: PSO Specifications 40
Table 2-22: PSOExternal Sync Specifications 40
Table 2-23: PSOOutput Pins on the Analog I/O and Laser Interface Connector 40
Table 2-24: Analog Output Specifications 42
Table 2-25: Analog Output Pins on the Analog I/O and Laser Interface Connector 42
Table 2-26: Analog Input Specifications 43
Table 2-27: Analog Input Pins on the Analog I/O and Laser Interface Connector 43
Table 2-28: SyncPort Cables 44
Table 2-29: HyperWire Card Part Number 45
Table 2-30: HyperWire Cable Part Numbers 45
Table 3-1: LEDDescription 49
Table 3-2: Troubleshooting 49
Table 3-3: Preventative Maintenance 50
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product GI4
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
2011/65/EU RoHS 2 Directive
EU 2015/863 Amendment RoHS 3 Directive
and has been designed to be in conformity with the applicable requirements of the following
standard(s) when installed and used in accordance with the manufacturer’s supplied installation
instructions.
IEC 61010-1:2010 Safety Requirements for Electrical Equipment
Authorized
Representative / Simon Smith, European Director
Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Engineer Verifying
Compliance / Alex Weibel
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Date 10/21/2021
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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
controller.
lRead all parts of this manual before you install or operate the controller or before
you do maintenance to your system.
lTo prevent injury to you and damage to the equipment, obey the precautions in this
manual.
lAll specifications and illustrations are for reference only and were complete and
accurate as of the release of this manual. To find the newest information about this
product, refer to www.aerotech.com.
If you do not understand the information in this manual, contact Aerotech Global
Technical Support.
IMPORTANT: This product has been designed for light industrial manufacturing or
laboratory environments. If the product is used in a manner not specified by the
manufacturer:
lThe protection provided by the equipment could be impaired.
lThe life expectancy of the product could be decreased.
WARNING: To prevent damage to the equipment and decrease the risk of electrical
shock and injury, obey the precautions that follow.
1. Supply each operator with the necessary protection from live electrical circuits.
2. Install the necessary precautions to supply safety and protection to the operator.
3. Do not connect or disconnect electrical components, wires, and cables while this
product is connected to a power source.
4. Before you connect wires to this product, disconnect the electrical power.
5. Make sure that all components are grounded correctly and that they obey the local
electrical safety requirements.
6. Before you do maintenance to the equipment, disconnect the electrical power.
7. Make sure that all system cables are correctly attached and positioned.
8. Do not use the cables or the connectors to lift or move this product.
9. Use this product only in environments and operating conditions that are approved
in this manual.
10. Only trained operators should operate this equipment.
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Installation Overview
The images that follow show the order in which to make connections and settings that are typical to
the GI4. If a custom interconnect drawing was supplied with your system, that drawing is on your
Storage Device and shows as a line item on your Sales Order in the Integration section.
1Connect the galvo scanner to the Galvo Interface connector. Section 2.2.
2Connect the PCHyperWire to the HyperWire Inport. Section 2.6.
3Connect the laser interface input and additional I/O as required by your
application. Section 2.4.
4Connect the power supply to the Control Supply. Section 2.1.1.
Figure 1: Installation ConnectionOverview(Standard)
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1Connect the galvo scanner to the Galvo Interface connector. Section 2.2.
2Connect the PCHyperWire to the HyperWire Inport. Section 2.6.
3Connect the laser interface input and additional I/O as required by your
application. Section 2.4.
4Connect the power supply to the Control Supply. Section 2.1.1.
Figure 2: Installation ConnectionOverview(OEM)
Installation Overview GI4 Hardware Manual
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Chapter 1: Introduction
The GI4 is a digital drive based on the HyperWire communication protocol. The drive provides
deterministic behavior, auto-identification, and is fully software configurable. The drive provides
open-loop control of galvo scanners. It lets you synchronize galvo and servo motion to mark parts
with no limit to size and complexity.
Figure 1-1: GI4 Galvo Scanner Controller
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Figure 1-2: GI4-OEM Galvo Scanner Controller
Chapter 1: Introduction GI4 Hardware Manual
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Table 1-1: FeatureSummary
Standard Features
l24 VDC control supply input Section 2.1.1.
lThree axis galvo controller interfaces Section 2.2.
lThree TTL laser outputs Section 2.5.
lTwo line driver square wave auxiliary quadrature encoder inputs or outputs Section 2.3.1.
lEight digital user outputs Section 2.4.1.
lNine digital user inputs
nEight digital inputs Section 2.4.2.
nOne high-speed input Section 2.4.3.
lTwo 16-bit analog outputs (± 10V) Section 2.5.3.
lFour 16-bit differential analog inputs (± 10V) Section 2.5.4.
lSync Ports Section 2.5.5.
lIFOVCapability
Options
Packaging
-P1 Standard Packaging
-P2 OEM Packaging
PSO Section 2.5.2.
-PSO0 No PSOfiring.
-PSO5 Two-axis Part-Speed PSO firing, which uses the PSO firing circuit based off of
the commanded vector velocity of 2 or more axes.
-PSO6 Three-axis Part-Speed PSO firing, which uses the PSO firing circuit based off of
the commanded vector velocity of 3 or more axes.
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
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The block diagram that follows shows a summary of the connector signals.
Figure 1-3: Functional Diagram
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1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description GI4
Control Supply Input Voltage 24 VDC
Input Current 2 A max, 0.45 Atypical
User Power Supply Output 5 VDC (@ 500 mA)
Modes of Operation Open loop galvo
Protective Features Control power supply under voltage
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1.2. Mechanical Specifications
1.2.1. Mounting and Cooling
Install the controller in an IP54 compliant enclosure to comply with safety standards. Make sure that
there is sufficient clearance surrounding the drive for free airflow and for the cables and
connections.
Table 1-3: Mounting Specifications
GI4
Customer-Supplied Enclosure
IP54 Compliant
For DIN Rail Mounting,
refer to Section 1.2.3. DIN Rail Mounting
Weight Standard ~0.59 kg
OEM ~0.23 kg
Mounting Hardware Standard M4 [#8] screws (four locations, not included)
OEM M3 screws and M3 standoffs (seven locations)
Mounting Orientation Vertical (typical)
Dimensions Refer to Section 1.2.2. Dimensions
Minimum Clearance Airflow ~25 mm
Connectors ~100 mm
Minimum Airflow
(over the drive)
Standard Provided by internal fan
OEM 4.2 CMF (NOTE:Customer Supplied)
Operating Temperature Refer to Section 1.3. Environmental Specifications
1.2. Mechanical Specifications GI4 Hardware Manual
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1.2.2. Dimensions
Figure 1-4: Dimensions [-P1 Package]
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Figure 1-5: Dimensions [-P2 Package]
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