Aerotech AUTOMATION1-GL4 User manual

Patent Number: US 8,426,768 B2
Revision: 1.04.00
AUTOMATION1-GL4
HARDWAREMANUAL

Global Technical Support
Go to www.aerotech.com/global-technical-support for information and support about your Aerotech, Inc. products. The
website supplies software, product manuals, Help files, training schedules, and PC-to-PC remote technical support. If
necessary, you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts.
To get help immediately, contact a service office or your sales representative. Include your customer order number in your
email or have it available before you call.
United States (World Headquarters)
Email: [e-mail]
Phone: [phone]
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101 Zeta Drive
Pittsburgh, PA 15238-2811
www.aerotech.com
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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 © 2016-2019, Aerotech, Inc., All rights reserved.

GL4 Hardware Manual Table of Contents
Table of Contents
AUTOMATION1-GL4 HARDWAREMANUAL 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Conformity 7
Agency Approvals 9
Safety Procedures and Warnings 11
Quick Installation Guide 13
Chapter 1: Introduction 15
1.1. Electrical Specifications 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. Input Power Connections 21
2.1.1. Control Supply Connector 21
2.1.2. Motor Supply Connector 22
2.1.3. External Power Supply Options 23
2.1.4. Minimizing Conducted,Radiated, and System Noise for EMC/CECompliance 25
2.2. HyperWire Interface 26
2.3. Laser Output Connectors 27
2.3.1. Position Synchronized Output (PSO) 32
2.4. Encoder Output Connector 33
2.5. Galvo Motor Connectors 35
2.5.1. Analog Encoder Inputs 36
2.5.2. Galvo Motor Connection 36
2.5.3. End of Travel Limit Input Interface 37
2.5.3.1. End of Travel Limit Phasing 39
2.5.4. Thermistor Interface 40
2.6. Digital and Analog I/O Connectors 41
2.6.1. Digital Outputs 42
2.6.2. Digital Inputs 44
2.6.3. Analog Outputs 45
2.6.4. Analog Inputs (Differential) 46
2.7. Encoder Input Connectors 47
2.7.1. Emergency Stop Sense Input 49
2.8. Laser Output Polarity Switches 50
2.9. Sync Port 51
2.10. PC Configuration and Operation Information 52
Chapter 3: Maintenance 53
3.1. Preventative Maintenance 53
3.2. Board Assembly 54
Appendix A: Warranty and Field Service 57
Appendix B: Revision History 59
Index 61
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List of Figures GL4 Hardware Manual
List of Figures
Figure 1-1: GL4 Networked Digital Galvo Controller 15
Figure 1-2: Functional Diagram 16
Figure 1-3: Dimensions 18
Figure 2-1: Control Supply Connections 21
Figure 2-2: Motor Supply Connections 22
Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 23
Figure 2-4: Third-Party Power Supply Connection 24
Figure 2-5: Laser Interface Outputs 28
Figure 2-6: Current Sinking Configuration with Isolation 29
Figure 2-7: Current Sinking Configuration without Isolation 29
Figure 2-8: Current Sourcing Configuration with Isolation 30
Figure 2-9: Current Sourcing Configuration without Isolation 30
Figure 2-10: TTLOutput 31
Figure 2-11: Encoder Outputs 33
Figure 2-12: PSOExternal Sync Input 34
Figure 2-13: End of Travel Limit Input Connections 38
Figure 2-14: End of Travel Limit Interface Input Schematic 38
Figure 2-15: Limit Input Diagnostic Display 39
Figure 2-16: Thermistor Interface Input Schematic 40
Figure 2-17: Digital Outputs Connected in Current Sourcing Mode 43
Figure 2-18: Digital Outputs Connected in Current Sinking Mode 43
Figure 2-19: Digital Inputs Connected to Current Sinking Devices 44
Figure 2-20: Digital Inputs Connected to Current Sourcing Devices 44
Figure 2-21: Analog Outputs Schematic 45
Figure 2-22: Analog Inputs Schematic 46
Figure 2-23: Encoder Input Connections Schematic 48
Figure 2-24: ESTOP Sense Input Schematic 49
Figure 2-25: Laser Output Polarity Switches 50
Figure 3-1: Control Board Assembly 54
Figure 3-2: Power Board Assembly 55
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GL4 Hardware Manual List of Tables
List of Tables
Table 1-1: FeatureSummary 15
Table 1-2: Electrical Specifications 17
Table 1-3: Unit Weight 18
Table 1-4: Environmental Specifications 19
Table 1-5: Drive and Software Compatibility 20
Table 2-1: Control Supply Connector Wiring Specifications 21
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 21
Table 2-3: Motor Supply Wiring Specifications 22
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 22
Table 2-5: HyperWire Card Part Number 26
Table 2-6: HyperWire Cable Part Numbers 26
Table 2-7: Laser Output Connector A Pinout 27
Table 2-8: Laser Output Connector B Pinout 27
Table 2-9: Mating Connector Part Numbers for the Laser Output Connectors 27
Table 2-10: Laser Output Specifications 28
Table 2-11: PSOPins on the Laser Output A Connector 32
Table 2-12: PSOPins on the Laser Output B Connector 32
Table 2-13: PSO Specifications 32
Table 2-14: Encoder Output Connector Pinout 33
Table 2-15: Mating Connector Part Numbers for the Encoder Output Connector 33
Table 2-16: PSOExternal Sync Specifications 34
Table 2-17: Galvo Motor Connectors Pinout 35
Table 2-18: Mating Connector Part Numbers for the Galvo Motor Connectors 35
Table 2-19: Analog Encoder Specifications 36
Table 2-20: End of Travel Limit Input Pins on the Galvo Motor Connectors 37
Table 2-21: Thermistor Interface Pins on the Galvo Motor Connectors 40
Table 2-22: Digital and Analog I/O Connector APinout 41
Table 2-23: Digital and Analog I/O Connector B Pinout 41
Table 2-24: Mating Connector Part Numbers for the Digital / Analog I/OConnectors 41
Table 2-25: Digital Output Specifications 42
Table 2-26: Digital Output Pins on the Digital/Analog I/O A Connector 42
Table 2-27: Digital Input Specifications 44
Table 2-28: Digital Input Pins on the Digital/Analog I/O B Connector 44
Table 2-29: Analog Output Specifications 45
Table 2-30: Analog Output Pins on the Digital / Analog I/O B Connector 45
Table 2-31: Analog Input Specifications 46
Table 2-32: Analog Input Pins on the Digital / Analog I/O B Connector 46
Table 2-33: Encoder Input Specifications 47
Table 2-34: Axis 1 Encoder Input Pinout (Encoder Input Connector A) 47
Table 2-35: Axis 2 Encoder Input Pinout (Encoder Input Connector B) 47
Table 2-36: Mating Connector Part Numbers for the Encoder Input Connectors 47
Table 2-37: GL4 to Drive Cable Part Numbers 47
Table 2-38: ESTOP Pins on the Encoder Input Connector 49
Table 2-39: Electrical Noise Suppression Devices 49
Table 2-40: Sync-Related Commands 51
Table 2-41: SyncPort Cables 51
Table 3-1: Preventative Maintenance 53
Table 3-2: Control Board Fuse Specifications 54
Table 3-3: Power Board Fuse Specifications 55
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List of Tables GL4 Hardware Manual
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GL4 Hardware Manual EU Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product GL4
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
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.
EN 61010-1:2010 Safety Requirements for Electrical Equipment
Authorized Representative: Simon Smith, European Director
Address: Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date 11/27/2019
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EU Declaration of Conformity GL4 Hardware Manual
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GL4 Hardware Manual Agency Approvals
Agency Approvals
Aerotech tested its GL4 drives and found that they obey the standards that follow:
Approval / Certification: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 16 06 68995 021
Standards: UL 61010-1:2012; CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-1:2010
Visit https://www.tuev-sued.de/product-testing/certificates to view Aerotech's TÜV SÜD certificates. Type
the certificate number listed above in the search bar or type "Aerotech" for a list of all Aerotech certificates.
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Agency Approvals GL4 Hardware Manual
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GL4 Hardware Manual Safety Procedures and Warnings
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the GL4. Read all parts of this manual
before you install or operate the GL4 or before you do maintenance to your system. To prevent injury to you
and damage to the equipment, obey the precautions in this manual. The precautions that follow apply when
you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury to you or
damage to the equipment can occur. If you do not understand the information in this manual, contact
Aerotech Global Technical Support.
This product has been designed for light industrial manufacturing or laboratory environments. The protection
provided by the equipment could be impaired if the product is used in a manner not specified by the
manufacturer.
NOTE: All 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.
DANGER: The voltage from this product can kill you. To decrease the risk of electrical shock,
injury, and death, you must obey the precautions that follow.
1. Obey the information in this manual.
2. Before you do maintenance to the equipment, disconnect the electrical power.
3. Wait at least ten (10) minutes after removing the power supply before doing maintenance or
an inspection. Otherwise, there is the danger of electric shock.
4. Before you connect wires to this product, disconnect the electrical power.
5. To decrease the risk of electrical shock and injury, you must supply operators with the
necessary precautions and protection from live electrical circuits.
6. While the drive is connected to a power source, do not connect or disconnect electrical
components and cables.
7. Make sure that all components are grounded correctly and that they obey the local electrical
safety requirements.
8. Make sure that you install the necessary precautions to supply safety and protection to the
operator.
9. Moving parts can cause crushing or shearing injuries. You must limit access to all motor and
stage parts while your system is connected to a power source.
WARNING: To prevent damage to the equipment and decrease the risk of electrical shock, injury,
and death, you must obey the precautions that follow.
1. Obey the information in this manual.
2. Make sure that all system cables are correctly attached and positioned.
3. Use this product only in environments and operating conditions that are approved in this
manual.
4. Only operators who have received training can operate this equipment. All servicing and
maintenance must be done only by approved personnel.
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Safety Procedures and Warnings GL4 Hardware Manual
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GL4 Hardware Manual Quick Installation Guide
Quick Installation Guide
This image shows the order in which to make connections and settings that are typical to the GL4. 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.
HyperWire Section 2.2. HyperWire Interface
Digital / Analog I/O Section 2.6. Digital and Analog I/O Connectors
Galvo Connections Section 2.5. Galvo Motor Connectors
Control Supply Section 2.1.1. Control Supply Connector
Motor Supply Section 2.1.2. Motor Supply Connector
Figure 1: Quick Start Connections
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Quick Installation Guide GL4 Hardware Manual
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GL4 Hardware Manual Chapter 1: Introduction
Chapter 1: Introduction
The GL4 is a closed-loop scanner module that lets you control servo motion from the galvo scanner to mark
parts with no limit to size and complexity. The GL4 supports CO2 and YAG lasers and includes Position
Synchronized Output (PSO) laser firing that uses real-time scanner positional feedback.
Figure 1-1: GL4 Networked Digital Galvo Controller
Table 1-1: FeatureSummary
Standard Features
l85-240 VAC; 50-60 Hz control supply Section 2.1.1.
l±40 VDC max motor supply Section 2.1.2.
lTwo HyperWire ports Section 2.2.
lThree TTL laser outputs Section 2.3.
lThree optically-isolated laser outputs Section 2.3.
lDual-Axis PSOfiring Section 2.3.1.
lThree-axis Part-Speed PSO firing Refer to the
online Help
lTwo auxiliary channels of 40 MHz line driver quadrature encoder inputs Section 2.7.
lFour optically-isolated digital outputs; 5-24V Section 2.6.1.
lFour optically-isolated digital inputs; 5-24V Section 2.6.2.
lTwo 16-bit single-ended analog outputs; ±10 V Section 2.6.3.
lOne 16-bit differential analog input; ±10 V Section 2.6.4.
lDedicated 5-24V Emergency Stop sense input Section 2.7.1.
lTwo Sync ports Section 2.9.
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Chapter 1: Introduction GL4 Hardware Manual
The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
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GL4 Hardware Manual Chapter 1: Introduction
1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description GL4
Motor Supply Input Voltage ±40 VDC(max)
Input Current (continuous) 10 A
Control Supply
Input Voltage 85-240 VAC
Input Frequency 50-60 Hz
Inrush Current 16 A
Input Current 0.35A(max)
Output Voltage 38 V
Peak Output Current 20 A
Continuous Output Current 5 A
Minimum Load Resistance 0.5 Ω
User Power Supply Output 5 VDC (@ 500 mA)
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Chapter 1: Introduction GL4 Hardware Manual
1.2. Mechanical Specifications
Mount the GL4 so free airflow is available at the front, top, and along the sides of the chassis for cooling. You
must also allow space for connections and cables along the front, top, and bottom.
The figure that follows shows the dimensions and the typical mounting orientation of the GL4.
Table 1-3: Unit Weight
GL4
Weight 2.9 kg [6.4 lb]
Figure 1-3: Dimensions
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GL4 Hardware Manual Chapter 1: Introduction
1.3. Environmental Specifications
Table 1-4: Environmental Specifications
Ambient Temperature Operating: 0° to 40°C (32° to 104° F)
Storage: -30° to 85°C (-22° to 185° F)
Humidity
Non-condensing
The maximum relative humidity is 80% for temperatures that are less
than 31°C and decreases linearly to 50% relative humidity at 40°C.
Operating Altitude
0 m to 2,000 m (0 ft to 6,562 ft) above sea level.
If you must operate this product above 2,000 m or below sea level,
contact Aerotech, Inc.
Pollution Pollution Degree 2
Typically only nonconductive pollution occurs.
Operation Use only indoors
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Chapter 1: Introduction GL4 Hardware Manual
1.4. Drive and Software Compatibility
This table shows the available drives and which version of the software first supported each drive. In the
Last Software Version column, drives that show a specific version number are not supported after that
version.
Table 1-5: Drive and Software Compatibility
Drive Type Firmware Revision First Software Version Last Software Version
GL4 - 6.04.000 Current
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