Aerotech HPe 150 User manual

P/N:EDU198
Revision: 4.06.00
Ensemble HPe 150/200
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 © 2008-2015, Aerotech, Inc. All rights reserved.

Table of Contents Ensemble HPe 150/200
Table of Contents
Table of Contents iii
List of Figures v
List of Tables vii
EC Declaration of Conformity ix
Agency Approvals x
Safety Procedures and Warnings xi
Quick Installation Guide xiii
Chapter 1: Introduction 1
1.1. Drive and Software Compatibility 5
1.2. Electrical Specifications 6
1.2.1. System Power Requirements 7
1.3. Mechanical Design 8
1.4. Environmental Specifications 10
Chapter 2: Installation and Configuration 11
2.1. Power Connections 12
2.1.1. Control Supply Connections 13
2.1.2. Motor Supply Connections 14
2.1.3. Minimizing Conducted, Radiated, and System Noise 15
2.2. Motor Output Connections 16
2.2.1. Brushless Motor Connections 17
2.2.1.1. Powered Motor Phasing 18
2.2.1.2. Unpowered Motor and Feedback Phasing 20
2.2.2. DC Brush Motor Connections 23
2.2.2.1. DC Brush Motor Phasing 24
2.2.3. Stepper Motor Connections 25
2.2.3.1. Stepper Motor Phasing 26
2.3. Motor Feedback Connections (J207) 27
2.3.1. Encoder Interface (J207) 28
2.3.1.1. RS-422 Line Driver Encoder (Standard) 29
2.3.1.2. EnDat Encoder Interface (J207) 30
2.3.1.3. Resolute Encoder Interface (J207) 31
2.3.1.4. Analog Encoder Interface 32
2.3.1.5. Encoder Phasing 34
2.3.2. Hall-Effect Interface (J207) 36
2.3.3. Thermistor Interface (J207) 37
2.3.4. Encoder Fault Interface (J207) 38
2.3.5. End Of Travel Limit Input Interface (J207) 39
2.3.5.1. End Of Travel Limit Phasing 41
2.3.6. Brake Output (J207) 42
2.4. Emergency Stop Sense Input (TB201) 43
2.4.1. Typical ESTOP Interface 44
2.5. Auxiliary I/O Connector (J205) 45
2.5.1. Auxiliary Encoder Channel (J205) 46
2.5.2. Position Synchronized Output (PSO)/Laser Firing (J205) 48
2.5.3. Opto-Isolated Outputs 0-3 (J205) 50
2.5.4. Opto-Isolated Inputs 0-3 (J205) 52
2.5.5. High Speed User Inputs 4-5 (J205) 54
2.5.6. Analog Output 0 (J205) 55
2.5.7. Analog Input 0 (J205) 56
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2.6. Brake Power Supply (TB202) 57
2.6.1. Solid State Relay Specifications (TB202) 60
2.7. Aeronet Interface (J209/J210) 61
2.8. RS-232 Interface (J206) 62
2.9. -EXTSHUNT Option (TB101) 63
2.10. PC Configuration and Operation Information 66
Chapter 3: -I/O Expansion Board 67
3.1. Brake / Mechanical Relay (TB301) 68
3.1.1. Brake Configuration Jumpers 68
3.1.2. Mechanical Relay Specifications 68
3.1.3. Brake / Mechanical Relay Interface Connector 69
3.2. PSO Output Interface (TB302) 71
3.2.1. PSOOpto Output 72
3.2.2. -DUALPSO and -TRIPLEPSO Laser Firing Options 73
3.2.2.1. Multi-Axis Firing 73
3.2.3. PSO Opto Output (Archive) 75
3.3. Analog Outputs (TB303) 77
3.4. Analog Inputs (TB304) 78
3.5. User Power (TB305, TB306) 79
3.6. Opto-Isolated Inputs (TB305, TB306) 80
3.7. Opto-Isolated Outputs (TB307, TB308) 83
3.8. SSINET (J302/J303) 87
Chapter 4: -RDP Expansion Board 89
Chapter 5: Standard Interconnection Cables 93
5.1. Joystick Interface 94
5.2. Handwheel Interface 96
Chapter 6: Maintenance 97
6.1. Power Board 98
6.2. Control Board 99
6.3. Preventative Maintenance 101
Appendix A: Warranty and Field Service 103
Appendix B: Revision History 105
Index 107
Ensemble HPe 150/200 Table of Contents

Table of Contents Ensemble HPe 150/200
List of Figures
Figure 1-1: Ensemble HPe150/200 Networked Digital Drive 1
Figure 1-2: Functional Diagram 4
Figure 1-3: Dimensions 8
Figure 2-1: Control Supply Connections 13
Figure 2-2: Motor Bus Input Connections 14
Figure 2-3: Brushless Motor Configuration 17
Figure 2-4: Encoder and Hall Signal Diagnostics 19
Figure 2-5: Motor Phasing Oscilloscope Example 20
Figure 2-6: Hall Phasing with Oscilloscope 21
Figure 2-7: Brushless Motor Phasing Goal 22
Figure 2-8: DC Brush Motor Configuration 23
Figure 2-9: Clockwise Motor Rotation 24
Figure 2-10: Stepper Motor Configuration 25
Figure 2-11: Clockwise Motor Rotation 26
Figure 2-12: Line Driver Encoder Interface (J207) 29
Figure 2-13: Serial Data Stream Interface 30
Figure 2-14: Serial Data Stream Interface 31
Figure 2-15: Analog Encoder Phasing Reference Diagram 32
Figure 2-16: Analog Encoder Interface (J207) 33
Figure 2-17: Encoder Phasing Reference Diagram (Standard) 34
Figure 2-18: Position Feedback in the DiagnosticDisplay 35
Figure 2-19: Hall-Effect Inputs (J207) 36
Figure 2-20: Thermistor Interface Input (J207) 37
Figure 2-21: Encoder Fault Interface Input (J207) 38
Figure 2-22: End of Travel Limit Input Connections 39
Figure 2-23: End of Travel Limit Interface Input (J207) 40
Figure 2-24: Limit Input Diagnostic Display 41
Figure 2-25: ESTOPSenseInput (TB201) 43
Figure 2-26: Typical Emergency Stop Circuit 44
Figure 2-27: Auxiliary Encoder Channel (J205) 47
Figure 2-28: PSOInterface 49
Figure 2-29: Outputs Connected in Current Sinking Mode (J205) 51
Figure 2-30: Outputs Connected in Current Sourcing Mode (J205) 51
Figure 2-31: Inputs Connected in Current Sinking Mode (J205) 53
Figure 2-32: Inputs Connected in Current Sourcing Mode (J205) 53
Figure 2-33: High Speed User Inputs (J205) 54
Figure 2-34: Analog Output 0 (J205) 55
Figure 2-35: Analog Input 0 (J205) 56
Figure 2-36: Brake Connected to J207 58
Figure 2-37: Brake Connected to TB202 59
Figure 2-38: Aeronet Connection with Three Discrete Drives 61
Figure 2-39: RS-232 Interface (J206) 62
Figure 3-1: Ensemble HPe150/200 with -IO Option Board 67
Figure 3-2: Brake Connected to J207 69
Figure 3-3: Brake Connected to TB301 70
Figure 3-4: PSO Output Sources Current 72
Figure 3-5: PSOOutput Sinks Current 72
Figure 3-6: Two/Three Axis Laser Firing Interconnection 74
Figure 3-7: PSOInterface (Sinking) 75
Figure 3-8: PSOInterface (Sourcing) 75
Figure 3-9: PSO Opto-Chip Installation 76
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Figure 3-10: Analog Output 1 Connector (TB303) 77
Figure 3-11: Analog Input Typical Connection (TB304) 78
Figure 3-12: Opto-Isolated Inputs 81
Figure 3-13: Inputs Connected to a Current Sourcing Device 82
Figure 3-14: Inputs Connected to a Current Sinking Device 82
Figure 3-15: Opto-Isolated Outputs (-IOBoard) 84
Figure 3-16: Outputs Connected in Current Sourcing Mode 85
Figure 3-17: Outputs Connected in Current Sinking Mode 86
Figure 3-18: J302/J303 88
Figure 4-1: -RDPOption Board 89
Figure 4-2: Resolver/Inductosyn Recommended Wiring 91
Figure 4-3: Resolver Inputs 91
Figure 4-4: Encoder Emulation Outputs 92
Figure 4-1: Single Axis Joystick Interface (to Aux I/O) 94
Figure 4-2: Two Axis Joystick Interface (to the Aux I/O of two drives) 94
Figure 4-3: Two Axis Joystick Interface (to the Aux I/O and I/O Board) 95
Figure 4-4: Two Axis Joystick Interface (to the I/OBoard) 95
Figure 4-5: Handwheel Interconnection (to Aux I/O) 96
Figure 4-6: Handwheel Interconnection (to Aux I/O via a BBA32 Module) 96
Figure 5-1: Power Board Assembly 98
Figure 5-2: Control Board Assembly 99
Ensemble HPe 150/200 Table of Contents

Table of Contents Ensemble HPe 150/200
List of Tables
Table 1-1: FeatureSummary 2
Table 1-2: Accessories 3
Table 1-3: Ensemble Drive and Software Compatibility 5
Table 1-4: Electrical Specifications 6
Table 1-5: Physical Specifications 9
Table 1-6: Heat Sink Specifications 9
Table 2-1: Control Supply ACInput Wiring 13
Table 2-2: Motor Supply Input Wiring 15
Table 2-3: Motor Power Output Connections 16
Table 2-4: Wire Colors for Aerotech Supplied Cables (Brushless) 17
Table 2-5: Wire Colors for Aerotech Supplied Cables (DCBrush) 23
Table 2-6: Wire Colors for Aerotech Supplied Cables (Stepper) 25
Table 2-7: Motor Feedback Connector Pin Assignment (J207) 27
Table 2-8: Encoder Interface Pin Assignment 28
Table 2-9: Analog Encoder Specifications 32
Table 2-10: Hall-Effect Feedback Interface Pin Assignment (J207) 36
Table 2-11: Hall-Effect Feedback Interface Pin Assignment (J207) 37
Table 2-12: Encoder Fault Interface Pin Assignment (J207) 38
Table 2-13: End of Travel Limit Input Interface Pin Assignment (J207) 39
Table 2-14: Brake Output Pin Assignment (J207) 42
Table 2-15: Electrical Noise Suppression Devices 43
Table 2-16: Electrical Noise Suppression Devices 43
Table 2-17: TB201 Mating Connector 43
Table 2-18: Typical ESTOPRelay Ratings 44
Table 2-19: Auxiliary I/O Connector Pin Assignment (J205) 45
Table 2-20: Auxiliary Encoder Channel Pin Assignment (J205) 46
Table 2-21: PSOOutput Pin Assignment (J205) 48
Table 2-22: PSO Output Sources 48
Table 2-23: Port 0 Digital Output Connector Pin Assignment (J205) 50
Table 2-24: Digital Output Specifications 50
Table 2-25: Port 0 Digital Input Connector Pin Assignment (J205) 52
Table 2-26: PS2806-4 Opto-Device Specifications 52
Table 2-27: Port 0 High Speed Digital Input Connector Pin Assignment (J205) 54
Table 2-28: Input Voltage Jumper Configuration 54
Table 2-29: Analog Output Connector Pin Assignment (J205) 55
Table 2-30: Analog Input Connector Pin Assignment (J205) 56
Table 2-31: Brake Output Connector Pin Assignment (TB202) 57
Table 2-32: Mating Connector (TB202) 57
Table 2-33: Brake Output Connector Pin Assignment (J207) 57
Table 2-34: Relay Specifications 60
Table 2-35: Aeronet Cable Part Numbers 61
Table 2-36: RS-232 Connector Pin Assignment (J206) 62
Table 2-37: RS-232 Port Connector Mating Connector (J206) 62
Table 2-38: Recommended Shunt Resistors and Wire Gauge 63
Table 2-39: Maximum Storage Energy 64
Table 3-1: -IO Expansion Board Jumper Configuration 67
Table 3-2: -IO Option Board Fuse Information 67
Table 3-3: -IO Expansion Board Brake Jumper Configuration 68
Table 3-4: Voltage and Current Specifications (TB301) 68
Table 3-5: Brake / Mechanical Relay Connector Pin Assignment (TB301) 69
Table 3-6: Mating Connector 69
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Table 3-7: Brake / Mechanical Relay Connector Pin Assignment (J207) 69
Table 3-8: PSO Output Interface Connector Pin Assignment (TB302) 71
Table 3-9: PSO Output Mating Connector 71
Table 3-10: PSO Output Polarity Settings for JP2 72
Table 3-11: Output Specifications 72
Table 3-12: SSINet Cable Part Numbers 73
Table 3-13: Laser Output Opto-Isolator Specifications 75
Table 3-14: Analog Output Connector Pin Assignment (TB303) 77
Table 3-15: Analog Output Mating Connector 77
Table 3-16: Analog Inputs Connector Pin Assignment (TB304) 78
Table 3-17: Analog Input Mating Connector 78
Table 3-18: User Common Connector Pin Assignment (TB305) 79
Table 3-19: +5 Volt Power Connector Pin Assignment (TB306) 79
Table 3-20: PS2806-4 Opto-Device Specifications 80
Table 3-21: Port 1 Opto-Isolated Input Connector Pin Assignment (TB305) 80
Table 3-22: Port 2 Opto-Isolated Input Connector Pin Assignment (TB306) 80
Table 3-23: Opto-Isolated Input Mating Connector 80
Table 3-24: Port 1 Opto-Isolated Output Connector Pin Assignment (TB307) 83
Table 3-25: Port 2 Opto-Isolated Output Connector Pin Assignment (TB308) 83
Table 3-26: Opto-Isolated Output Mating Connector 83
Table 3-27: Output Specifications (TB307, TB308) 85
Table 3-28: J302, J303 2-Channel SSINet Connector Pin Assignment 87
Table 4-1: -RDP Expansion Board Jumper Configuration 89
Table 4-2: -RDP Connector Pin Assignment (J401/J402) 90
Table 4-3: Resolver Mating Connector 90
Table 4-4: Resolver Test Points 92
Table 4-1: Standard Interconnection Cables 93
Table 4-2: Cable Part Numbers 95
Table 5-1: LEDDescription 97
Table 5-2: Fuse Information 98
Table 5-3: Control Board Jumper Configuration 99
Table 5-4: Control Board Fuse Information 100
Table 5-5: LEDDescription 100
Table 5-6: Preventative Maintenance 101
Ensemble HPe 150/200 Table of Contents

Declaration of Conformity Ensemble HPe 150/200
EC Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Ensemble HPe 150/200
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2006/95/EC Low Voltage 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 61000-4-3 Radiated RFI/EMI Immunity
EN 61010-1 Safety requirements for electrical equipment
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date May 11, 2015
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Agency Approvals
Aerotech, Inc. Model Ensemble HPe 150/200 Series Digital Drives 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 13 11 68995 013
File / Report #: 090-1309372-000
Standards: UL 61010-1; CAN/CSA-C22.2 No. 61010-1
Ensemble HPe 150/200 Declaration of Conformity

Electrical Safety Ensemble HPe 150/200
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 : Read this manual in its entirety before installing, operating, or servicing this product. If you do
not understand the information contained herein, contact an Aerotech representative before proceeding.
Strictly adhere to the statements given in this section and other handling, use, and operational information
given throughout the manual to avoid injury to you and 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.
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 making any mechanical adjustments or performing
maintenance.
2. Disconnect electrical power before performing any wiring.
3. Access to the Ensemble HPe 150/200 and component parts must be restricted while
connected to a power source.
4. 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.
5. Install the Ensemble HPe 150/200 inside a rack or enclosure.
6. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
7. Make sure the Ensemble HPe 150/200 and all components are properly grounded in
accordance with local electrical safety requirements.
8. Operator safeguarding requirements must be addressed during final integration of the
product.
D A N G E R : The Ensemble HPe 150/200 case temperature may exceed 75°C in some
applications.
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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 the Ensemble HPe 150/200to environments or conditions outside of the
listed specifications. Exceeding environmental or operating specifications can cause
damage to the equipment.
5. If the Ensemble HPe 150/200 is used in a manner not specified by the manufacturer, the
protection provided by the Ensemble HPe 150/200 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. The Ensemble HPe 150/200 is intended for light industrial manufacturing or laboratory use.
Use of the Ensemble HPe 150/200 for unintended applications can result in injury and
damage to the equipment.
Ensemble HPe 150/200 Electrical Safety

Quick Installation Guide Ensemble HPe 150/200
Quick Installation Guide
This chapter describes the order in which connections and settings should typically be made to the
Ensemble HPe 150/200. 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 software DVD.
BRAKE PS-
ENB/FLT
MARKER
AUX I/O
J205
RS232
J206
ESTOP
TB201
MOTOR
FEEDBACK
J207
PWR
POS
ENET
J204
NC
B-
B
B+
C
B
A
AC3
AC2
TB102
AC1
C
NO
C
0
1
2
3
4
5
6
7
GND
OP
OM
0
1
2
3
4
5
6
7
TB304TB303TB302
TB301
RELAY
DC BUS
USB
MOTOR
OUTPUT
MOTOR
SUPPLY
J402
TB202
PS +
PS -
J208
CH 2
240V~ MAX
50/60Hz
75A MAX
TB101
CONTROL
SUPPLY
85-240V~
50/60Hz
1 AMP MAX
EXTERNAL
SHUNT
J401
CH 1
RESOLVER
BRAKE
HSO-P
AIN3-
AIN3+
AIN2-
AIN2+
AIN1-
AIN1+
AIN0-
AIN0+
AGND
AGND
AOUT3
AOUT2
AOUT1
AOUT0
HSO-M
PSO-N
OPTO
OUT
TB307
OPTO
OUT
TB308
OPTO
IN
TB305
OPTO
IN
TB306
J302
SSINET
J303
High Voltage
DANGER!
12
43
12
43
AC2
AC1
2
1
AERONET INPUT
J209
AERONET OUTPUT
J210
C
0
1
2
3
4
5
6
7
+5V
OP
OM
0
1
2
3
4
5
6
7
AEROTECH.COM
TM
e
POWER
Connect the Motor Output (TB102) and Motor Feedback (J207).
Connect the PC to either the Ethernet (J204) or the USB (J208).
Connect any additional I/O as required (not shown, user-specific).
Connect to the Control Supply (TB101).
Connect to the Motor Supply (TB102).
Note: Connect to ESTOP (TB201) in this step if applicable.
1
6
6
1
1
3
Connect a multi-axis Ensemble system with Aeronet (J209, J210).
2
4
5
6
5
2
3
Figure 1: Quick Start Connections
Topic Section
Motor Output Section 2.2. Motor Output Connections
Motor Feedback Section 2.3. Motor Feedback Connections (J207)
Aeronet Section 2.7. Aeronet Interface (J209/J210)
Ethernet / USB No Section / Standard Connection
Control Supply Section 2.1.1. Control Supply Connections
Motor Supply Section 2.1.2. Motor Supply Connections
Additional I/O User / Application dependent
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Ensemble HPe 150/200 Quick Installation Guide
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Introduction Ensemble HPe 150/200
Chapter 1: Introduction
Aerotech’s Ensemble HPe 150/200 (High Power PWM) network digital drive is a high performance
amplifier.The drive provides deterministic behavior, auto-identification, and easy software setup. The
Ensemble HPe 150/200’s high performance double precision floating point DSP controls the digital PID and
current loops. All system configuration is done using software-settable parameters, including control loop
gains and system safety functions.
The Ensemble HPe 150/200 is offered with an optional encoder interpolation feature (-MXH), an auxiliary
square wave encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -IO
option), a resolver input (-RDP option), and separate power connections for motor and control supply
voltages.
BRAKE PS-
ENB/FLT
MARKER
AUX I/O
J205
RS232
J206
ESTOP
TB201
MOTOR
FEEDBACK
J207
PWR
POS
ENET
J204
NC
B-
B
B+
C
B
A
AC3
AC2
TB102
AC1
C
NO
C
0
1
2
3
4
5
6
7
GND
OP
OM
0
1
2
3
4
5
6
7
TB304TB303TB302
TB301
RELAY
DC BUS
USB
MOTOR
OUTPUT
MOTOR
SUPPLY
J402
TB202
PS +
PS -
J208
CH 2
240V~ MAX
50/60Hz
75A MAX
TB101
CONTROL
SUPPLY
85-240V~
50/60Hz
1 AMP MAX
EXTERNAL
SHUNT
J401
CH 1
RESOLVER
BRAKE
HSO-P
AIN3-
AIN3+
AIN2-
AIN2+
AIN1-
AIN1+
AIN0-
AIN0+
AGND
AGND
AOUT3
AOUT2
AOUT1
AOUT0
HSO-M
PSO-N
OPTO
OUT
TB307
OPTO
OUT
TB308
OPTO
IN
TB305
OPTO
IN
TB306
J302
SSINET
J303
High Voltage
DANGER!
12
43
12
43
AC2
AC1
2
1
AERONET INPUT
J209
AERONET OUTPUT
J210
C
0
1
2
3
4
5
6
7
+5V
OP
OM
0
1
2
3
4
5
6
7
AEROTECH.COM
TM
e
POWER
Standard
Connector Description
TB101 Control Supply
TB101 External Shunt
TB102 Motor Supply
TB102 Motor Output
TB102 DC Bus Output
J204 Ethernet Port
J205 Auxiliary I/O
J206 RS-232
TB201 Emergency Stop Sense
Input (ESTOP)
J207 Motor Feedback
J208 USB Port
J209 Aeronet Input
J210 Aeronet Output
TB202 Brake Power
-IO/-IOH Board Option
Connector Description
TB301 Relay
J302 SSINET
J303 SSINET
TB302 Dedicated PSO Output
TB303 Analog Outputs
TB304 Analog Inputs
TB305 Opto-Inputs
TB306 Opto-Inputs
TB307 Opto-Outputs
TB308 Opto-Outputs
-RDP Option
Connector Description
J401 R/D Channel 1
J402 R/D Channel 2
Figure 1-1: Ensemble HPe 150/200 Networked Digital Drive
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2 Chapter 1 www.aerotech.com
Table 1-1: FeatureSummary
Standard Features
lLine driver square wave quadrature encoder input for position and velocity feedback
lLine driver square wave auxiliary quadrature encoder input or output for PSO
lFour opto-isolated user outputs
lSix opto-isolated user inputs(two high speed)
lOne 16-bit differential analog input (±10 V)
lOne 16-bit analog output (±10 V)
lDedicated 5-24 V Emergency Stop sense input
l14 - 240 VAC motor supply inputs (producing 20-320 VDC)
l85 - 240 VAC control supply inputs
lSingle axis Position Synchronized Output (PSO)
lAbsolute Encoder support
lCalibration (refer to the EnsembleHelp file for more information)
lCamming (refer to the EnsembleHelp file for more information)
l10/100 BASE-T Ethernet port for use with Ethernet I/O modules
Options
-S Internal shunt resistor network. A shunt circuit prevents the bus voltage from
causing damage to the amplifier (available for high-energy systems).
440 W continuous
-IO lThree 16-bit analog outputs (±10 V)
lThree 16-bit differential analog inputs (±10 V)
lOne fail-safe brake or user relay output
l16 optically isolated logic inputs (5 - 24 VDC), may be connected in current
sourcing or sinking mode
l16 optically isolated logic outputs (5 - 24 VDC), user defined as current
sourcing or sinking
lTwo SSINETinterfaces (each is a two-channel bi-directional RS-422
interface)
lOptically isolated laser firing (PSO) output
-DUALPSO Two axis Position Synchronized Output (PSO)
-TRIPLEPSO Three axis Position Synchronized Output (PSO)
-PSOOPTO1 Opto isolator for PSO (5V, high speed, high current, HCPL2601), standard
-PSOOPTO2 Opto isolator for PSO (15VDC, high speed, low current, 6N136)
-PSOOPTO3 Opto isolator for PSO (30VDC, low speed, high current, 4N33)
-PSOOPTO4 Opto isolator for PSO (5-25VDC, 40kHz, 50mA, TIL117-M)
-PSONC PSOOutput normally closed
-MXH Interpolation circuit allowing for analog sine wave input on the standard encoder
channel. Interpolation factor: 65,536
-EXTSHUNT Connection provided for an external shunt resistor network. A shunt circuit
prevents the bus voltage from causing damage to the amplifier (available for high-
energy systems).
-RDP Resolver to digital converter input
Ensemble HPe 150/200 Introduction

Introduction Ensemble HPe 150/200
Table 1-2: Accessories
Accessories
MCK-NDRIVE Mating connector kit for J206 (J205 mate is always provided)
JI Industrial Joystick (NEMA12 (IP54) rated); refer to Section 5.1.
PS24-1 24 VDC, 1Apower supply for optional brake/relay output
BRAKE24-2 24 VDC, 2 A power supply for optional brake
Cables
Interconnection A complete list of Aerotech cables can be found on the website at
http://www.aerotechmotioncontrol.com/manuals/index.aspx
Joystick/Handwheel Refer to Section 5.1. or Section 5.2.
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4 Chapter 1 www.aerotech.com
The following block diagram shows a connection summary. For detailed connection information, refer to
Chapter 2 and Chapter 3.
16 Opto Outputs
(Sinking or Sourcing)
TB307/TB308
OPTO OUT
16 Opto Inputs TB305/TB306
OPTO IN
4* Analog Inputs +/- TB304
AIN
4* Analog Outputs TB303
AOUT
* There are a total of four analog inputs and four analog outputs available if the -IO Option has been
purchased.The analog I/O normally available on J205 is accessed through TB303 and TB304.
PSO Opto-Output TB302
PSO Output
Relay
(jumper configurable)
TB301
RELAY
Brake Supply Input
TB202
BRAKE PS ±
TB101
-EXTSHUNT
option
+
2
1
TB102
DC BUS
OUTPUT B-
B+
B-
B+
Encoder +5V / Common
Brake +/- (with the -IO Option)
SIN, COS, MRK (RS422)
-MXH
Option
J207
MOTOR
FEEDBACK
CW, CCW, Home Limits;
Encoder Fault; Hall A, B, C;
Motor Over Temperature
Emergency Stop Sense Input
TB201
ESTOP
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
J205
AUX I/O
SIN
COS
REF J401
Channel 1 R/D
J402
Channel 2 R/D
J204
ENET
PWM Power
Amplifier
Heatsink Over
Temperature A
B
C
TB102
MOTOR
SUPPLY
AC1
AC2
AC3
AC2
AC1
AC3 B
A
C
TB102
MOTOR
OUTPUT
Isolated
Power Supply
TB101
CONTROL
SUPPLY
AC1
AC2
AC2
AC1
-IO Option
+12V
-12V
J403
Resolver Power
(opt)
-RDP Option
SIN/COS J302/J303
SSINET
USB 2.0 Port
J208
USB
Ethernet Port
J206
Serial
Communication
RS-232 (RS-422/RS-485)
J209/J210
AERONET
Aeronet Input (J209)
Aeronet Output (J210)
Figure 1-2: Functional Diagram
Ensemble HPe 150/200 Introduction

Introduction Ensemble HPe 150/200
1.1. Drive and Software Compatibility
The following table lists the available Ensemble drives and which version of the Ensemble software first
provided support for a given drive. Drives that list a specific version number in the Last Software Version
column will not be supported after the listed version.
Table 1-3: Ensemble Drive and Software Compatibility
Drive Type Firmware Revision First Software Version Last Software Version
CL - 1.01 Current
A 2.55 Current
CP A 1.00 Current
B 2.54 Current
Epaq(1) - 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
(1) This section does not apply to the EpaqMR. The EpaqMR contains multiple ML or MP drives. Refer to
either the ML or MP drive type to determine the value for your EpaqMR.
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1.2. Electrical Specifications
Table 1-4: Electrical Specifications
Description HPe 150 HPe 200
Motor
Supply
Input Voltage 14-240 VAC
Input Frequency 50-60 Hz
Maximum Continuous Input
Current 43.30 Arms 57.74 Arms
Input Current Refer to Section 1.2.1. System Power Requirements
Control
Supply
Input Voltage 85-240 VAC
Input Frequency 50-60 Hz
Input Current .25 A max
Output Voltage (1)
340 VDC max
Peak Output Current (1 second) 150 A 200 A
Continuous Output Current 75 A 100 A
Power Amplifier Bandwidth 2500 Hz maximum (software selectable)
Power Amplifier Efficiency 85% - 95% (2)
PWM Switching Frequency 20 kHz
Minimum Load Inductance 0.8 mH @160 VDC (1 mH @ 320 VDC)
User Power Supply Output 5 VDC (@ 500 mA)
Modes of Operation Brushless; Brush; Stepper
Protective Features
Output short circuit; Peak over current, DCbus over
voltages; 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.
(1) AC input voltage and load dependent.
(2) Dependent on total output power: efficiency increases with increasing output power.
Ensemble HPe 150/200 Introduction