Aerotech Automation1 SI4 Series User manual

Revision 1.01
Automation1 SI4 Stepper Controller
HARDWAREMANUAL

GLOBALTECHNICALSUPPORT
Go to the Global Technical Support Portal 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.
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 © 2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 SI4 Stepper 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 23
1.2.4. OEMMounting 24
1.3. Environmental Specifications 25
1.4. Drive and Software Compatibility 26
Chapter 2: Installation and Configuration 27
2.1. Input Power Connections 28
2.1.1. Control Supply Connector 28
2.1.2. Minimizing Noise for EMC/CECompliance 29
2.2. Axis Connector 30
2.2.1. Stepper Clock and Stepper Direction Signals 31
2.2.2. End of Travel Limits 33
2.2.2.1. End of Travel Limit Phasing 34
2.2.3. Amplifier Fault Inputs 35
2.2.4. Amplifier Enable Output 36
2.2.5. Primary Encoder Inputs 37
2.2.5.1. Square WaveEncoder 38
2.2.5.2. Absolute Encoder 39
2.2.5.3. Encoder Phasing 40
2.2.5.4. Stepper Motor Phasing 41
2.3. Digital I/O Connector 42
2.3.1. Digital Inputs 43
2.3.2. Digital Outputs 45
2.3.3. High-Speed User Input 48
2.3.4. Position Synchronized Output (PSO) Interface 49
2.4. HyperWire Interface 50
2.5. System Interconnection 51
2.6. PC Configuration and Operation Information 52
Chapter 3: Maintenance 53
3.1. Preventative Maintenance 54
Appendix A: Warranty and Field Service 55
Appendix B: Revision History 57
Index 59
SI4 Hardware Manual Table of Contents
www.aerotech.com 3

List of Figures
Figure 1-1: SI4 Stepper Controller 13
Figure 1-2: SI4-OEM Stepper Controller 14
Figure 1-3: Functional Diagram 16
Figure 1-4: Dimensions [-2P1 (Standard 2-Axis)] 19
Figure 1-5: Dimensions [-4P1 (Standard 4-Axis)] 20
Figure 1-6: Dimensions [-2P2 (OEM2-Axis)] 21
Figure 1-7: Dimensions [-4P2 (OEM 4-Axis)] 22
Figure 1-8: Din Rail Clip Dimensions 23
Figure 2-1: Control Supply Connections 28
Figure 2-2: Stepper Clock and Stepper Direction Timing 31
Figure 2-3: Stepper Clock and Stepper Direction Output Schematic 32
Figure 2-4: End of Travel Limit Input Connections 33
Figure 2-5: End of Travel Limit Input Schematic 33
Figure 2-6: End of Travel Limit Input Diagnostic Display 34
Figure 2-7: Fault Input Schematic 35
Figure 2-8: Amplifier Enable Output Schematic 36
Figure 2-9: Square Wave Encoder Schematic (Axis Connector) 38
Figure 2-10: Absolute Encoder Schematic (Axis Connector) 39
Figure 2-11: Encoder Phasing Reference Diagram (Standard) 40
Figure 2-12: Position Feedback in the DiagnosticDisplay 40
Figure 2-13: Positive Motor Direction 41
Figure 2-14: Digital Inputs Schematic 43
Figure 2-15: Digital Inputs Connected to Current Sourcing (PNP) Devices 44
Figure 2-16: Digital Inputs Connected to Current Sinking (NPN) Devices 44
Figure 2-17: Digital Outputs Schematic 46
Figure 2-18: Digital Outputs Connected in Current Sourcing Mode 47
Figure 2-19: Digital Outputs Connected in Current Sinking Mode 47
Figure 2-20: High-Speed Input 48
Figure 2-21: PSO TTLOutputs Schematic 49
Figure 2-22: System Interconnection Drawing (Best Practice) 51
List of Figures SI4 Hardware Manual
4 www.aerotech.com

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 23
Table 1-5: OEMMounting Parts 24
Table 1-6: Environmental Specifications 25
Table 1-7: Drive and Software Compatibility 26
Table 2-1: Control Supply Connector Wiring Specifications 28
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 28
Table 2-3: Axis Connector Pinout 30
Table 2-4: Mating Connector Part Numbers for the Axis Connector 30
Table 2-5: Clock and Direction Pins on the Axis Connector 31
Table 2-6: Stepper Clock and Stepper Direction Signal Output Specifications 31
Table 2-7: Stepper Direction Signal Output Polarity 31
Table 2-8: End of Travel Limit Pins on the Axis Connector 33
Table 2-9: Amplifier Fault Input Specifications 35
Table 2-10: Amplifier Enable Connector Pin on the Axis Connector 36
Table 2-11: Amplifier Enable Output Specifications 36
Table 2-12: Primary Encoder Input Pins on the Axis Connector 37
Table 2-13: Square Wave Encoder Specifications 38
Table 2-14: Digital I/O ConnectorPinout 42
Table 2-15: Mating Connector Part Numbers for the Digital I/OConnector 42
Table 2-16: Digital Input Specifications 43
Table 2-17: Digital Input Pins on the Digital I/O Connector 43
Table 2-18: Digital Output Specifications 45
Table 2-19: Digital Output Pins on Digital I/OConnector 45
Table 2-20: High-Speed Input Specifications 48
Table 2-21: High-Speed Input Pins on the Digital I/O Connector 48
Table 2-22: PSO Specifications 49
Table 2-23: PSOOutput Pins on the Digital I/O Connector 49
Table 2-24: HyperWire Card Part Number 50
Table 2-25: HyperWire Cable Part Numbers 50
Table 2-26: LEDDescription 53
Table 2-27: Troubleshooting 53
Table 2-28: Preventative Maintenance 54
SI4 Hardware Manual List of Tables
www.aerotech.com 5

This page intentionally left blank.
List of Tables SI4 Hardware Manual
6 www.aerotech.com

EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product SI4
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
EU 2015/863 Directive, Restricted Substances (RoHS 3)
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 for
Measurement, Control, and Laboratory Use
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 3/25/2021
SI4 Hardware Manual EU Declaration of Conformity
www.aerotech.com 7

This page intentionally left blank.
EU Declaration of Conformity SI4 Hardware Manual
8 www.aerotech.com

Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the SI4
drive.
lRead all parts of this manual before you install or operate the SI4 drive 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.
SI4 Hardware Manual Safety Procedures and Warnings
www.aerotech.com 9

This page intentionally left blank.
Safety Procedures and Warnings SI4 Hardware Manual
10 www.aerotech.com

Installation Overview
This image shows the order in which to make connections and settings that are typical to the SI4. 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 motor feedback and amplifier to the Axis Connectors. Section 2.2.
2Connect the PCHyperWire to the HyperWire Inport. Section 2.4.
3Connect additional I/O as required by your application. Section 2.3.
4Connect the power supply to the Control Supply. Section 2.1.1.
Figure 1: Installation ConnectionOverview(4 Axis Shown)
SI4 Hardware Manual Installation Overview
www.aerotech.com 11

1Connect the motor feedback and amplifier to the Axis Connectors. Section 2.2.
2Connect the PCHyperWire to the HyperWire Inport. Section 2.4.
3Connect additional I/O as required by your application. Section 2.3.
4Connect the power supply to the Control Supply. Section 2.1.1.
Figure 2: Installation ConnectionOverview(4 Axis OEMShown)
Installation Overview SI4 Hardware Manual
12 www.aerotech.com

Chapter 1: Introduction
The SI4 is a multi-axis digital drive based on the HyperWire communication protocol. The drive provides
deterministic behavior, auto-identification, and is fully software configurable. The drive controls
amplifiers which accept clock-and-direction commands.
Figure 1-1: SI4 Stepper Controller
SI4 Hardware Manual Chapter 1: Introduction
www.aerotech.com 13

Figure 1-2: SI4-OEM Stepper Controller
Chapter 1: Introduction SI4 Hardware Manual
14 www.aerotech.com

Table 1-1: FeatureSummary
Standard Features
l24 VDC control supply input Section 2.1.1.
lSingle-ended and line driver square wave quadrature encoder input for position
feedback Section 2.2.5.
Options
Configuration
-2P1 Two Axes of Control, Standard Packaging
-2P2 Two Axes of Control, OEM Packaging
-4P1 Four Axes of Control, Standard Packaging
-4P2 Four Axes of Control, OEM Packaging
Encoder Section 2.2.5.2.
-A0 No Absolute Encoder support
-A1 Absolute Encoder support
PSO Section 2.3.4.
-PSO1 One-axis PSO firing (includes One-axis Part-Speed PSO)
-PSO2 Two-axis PSO firing (includes Three-axis Part-Speed PSO)
-PSO3 Three-axis PSO firing (includes Three-axis Part-Speed PSO)
-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 (includes One-Axis PSO).
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
SI4 Hardware Manual Chapter 1: Introduction
www.aerotech.com 15

The block diagram that follows shows a summary of the connector signals.
Figure 1-3: Functional Diagram
Chapter 1: Introduction SI4 Hardware Manual
16 www.aerotech.com

1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description SI4
Control Supply
Input Voltage 24 VDC
Input Current 2-Axis:2 A max, 0.45 Atypical
4-Axis:2 A max, 0.6 Atypical
User Power Supply Output 5 VDC (@ 500 mA)
Modes of Operation Stepper
Protective Features Output short circuit;
Control power supply under voltage
SI4 Hardware Manual 1.1. Electrical Specifications
www.aerotech.com 17

1.2. Mechanical Specifications
1.2.1. Mounting and Cooling
Install the SI4 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
SI4
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 SI4 Hardware Manual
18 www.aerotech.com

1.2.2. Dimensions
Figure 1-4: Dimensions [-2P1 (Standard 2-Axis)]
SI4 Hardware Manual 1.2.2. Dimensions
www.aerotech.com 19

Figure 1-5: Dimensions [-4P1 (Standard 4-Axis)]
1.2.2. Dimensions SI4 Hardware Manual
20 www.aerotech.com