Aerotech XR3 User manual

Revision: 1.03.00
XR3 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.
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United States (World Headquarters)
Email: [e-mail]
Phone: [phone]
Fax: [phone]
101 Zeta Drive
Pittsburgh, PA 15238-2811
www.aerotech.com
United Kingdom China
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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 © 2016-2020, Aerotech, Inc., All rights reserved.

XR3 Hardware Manual Table of Contents
Table of Contents
XR3 HARDWAREMANUAL 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Agency Approvals 11
Safety Procedures and Warnings 13
Quick Installation Guide 15
Chapter 1: Introduction 17
1.1. Electrical Specifications 21
1.1.1. System Power Requirements 23
1.2. Mechanical Specifications 24
1.2.1. Mounting and Cooling 24
1.2.2. Dimensions 25
1.3. Environmental Specifications 27
1.4. Drive and Software Compatibility 28
Chapter 2: Installation and Configuration 29
2.1. Unpacking the Chassis 29
2.2. Electrical Installation 30
2.2.1. AC Power Connections 31
2.2.2. Minimizing Conducted,Radiated, and System Noise for EMC/CECompliance 32
2.2.3. I/O and Signal Requirements 32
2.2.4. Internal Shunt Option [-SI#] 33
2.3. Motor Power Output Connector 34
2.3.1. Brushless Motor Connections 35
2.3.1.1. Brushless Motor Powered Motor and Feedback Phasing 36
2.3.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 37
2.3.2. DCBrush Motor Connections 38
2.3.2.1. DC Brush Motor Phasing 38
2.3.3. Stepper Motor Connections 39
2.3.3.1. Stepper Motor Phasing 39
2.4. Feedback Connector 40
2.4.1. Primary Encoder Inputs 41
2.4.1.1. Square WaveEncoder 42
2.4.1.2. Absolute Encoder 43
2.4.1.3. Sine Wave Encoder [-CT1/-CT2/-CT4 Option] 44
2.4.1.4. Encoder Phasing 46
2.4.2. Hall-Effect Inputs 48
2.4.3. Thermistor Input 49
2.4.4. Encoder Fault Input 50
2.4.5. End of Travel and Home Limit Inputs 51
2.4.5.1. End of Travel and Home Limit Phasing 53
2.4.6. Brake Output 54
2.5. Position Synchronized Output Connector (PSO) 55
2.5.1. PSO Isolated Outputs 56
2.5.2. PSO TTLOutputs 57
2.5.3. PSO Clock Inputs 58
2.5.4. DataAcquisition Inputs 59
2.6. HSOUTConnector (High-Speed Outputs) 60
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Table of Contents XR3 Hardware Manual
2.7. DOUTConnector (Digital Outputs) 62
2.8. DINConnector (Digital Inputs) 66
2.9. Aux Encoder Connectors 69
2.10. AnalogI/OConnectors 70
2.10.1. Analog Outputs 71
2.10.2. Analog Inputs (Differential) 72
2.10.3. Joystick Interface 73
2.11. Safe Torque Off Input (STO) 75
2.11.1. STOStandards 77
2.11.2. STO Functional Description 77
2.11.3. STO Startup Validation Testing 78
2.11.4. STO Diagnostics 79
2.12. HyperWire Interface 80
2.13. External and Fan Tray Cooling Options [-C0/-C1/-C2Option] 81
2.14. PC Configuration and Operation Information 84
Chapter 3: Maintenance 85
3.1. Preventative Maintenance 85
3.2. Fuse Specifications 86
Appendix A: Warranty and Field Service 87
Appendix B: Voltage Selection Operation 89
Appendix C: Revision History 91
Index 93
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XR3 Hardware Manual List of Figures
List of Figures
Figure 1-1: Functional Diagram 20
Figure 1-2: Dimensions with Chassis Slides 25
Figure 1-3: Dimensions without Chassis Slides 26
Figure 2-1: Power and Control Connections 30
Figure 2-2: Power Switch 30
Figure 2-3: Brushless Motor Configuration 35
Figure 2-4: Positive Motor Direction 36
Figure 2-5: Encoder and Hall Signal Diagnostics 36
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 37
Figure 2-7: Brushless Motor Phasing Goal 37
Figure 2-8: DC Brush Motor Configuration 38
Figure 2-9: Positive Motor Direction 38
Figure 2-10: Stepper Motor Configuration 39
Figure 2-11: Positive Motor Direction 39
Figure 2-12: Square Wave Encoder Schematic (Feedback Connector) 42
Figure 2-13: Absolute Encoder Schematic (Feedback Connector) 43
Figure 2-14: Analog Encoder Phasing Reference Diagram 44
Figure 2-15: Analog Encoder Schematic (Feedback Connector) 45
Figure 2-16: Encoder Phasing Reference Diagram (Standard) 46
Figure 2-17: Position Feedback in the DiagnosticDisplay 47
Figure 2-18: Hall-Effect Inputs Schematic (Feedback Connector) 48
Figure 2-19: Thermistor Input Schematic (Feedback Connector) 49
Figure 2-20: Encoder Fault Input Schematic (Feedback Connector) 50
Figure 2-21: End of Travel and Home Limit Input Connections 52
Figure 2-22: End of Travel and Home Limit Input Schematic (Feedback Connector) 52
Figure 2-23: End of Travel and Home Limit Input Diagnostic Display 53
Figure 2-24: Brake Output Connections (Feedback Connector) 54
Figure 2-25: PSO Output Sources Current 56
Figure 2-26: PSOOutput Sinks Current 56
Figure 2-27: PSO TTLOutputs Schematic 57
Figure 2-28: PSO Clock Inputs Schematic 58
Figure 2-29: DataAcquisition Input Schematic 59
Figure 2-30: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs 61
Figure 2-31: Digital Output Schematic 64
Figure 2-32: Digital Outputs Connected in Current Sourcing Mode 65
Figure 2-33: Outputs Connected in Current Sinking Mode 65
Figure 2-34: Digital Input Schematic 67
Figure 2-35: Digital Inputs Connected to Current Sinking (NPN) Devices 68
Figure 2-36: Digital Inputs Connected to Current Sourcing (PNP) Devices 68
Figure 2-37: Aux Encoder Inputs Schematic 69
Figure 2-38: Analog Outputs Schematic 71
Figure 2-39: Analog Inputs Schematic 72
Figure 2-40: Joystick Interface Inputs Schematic 73
Figure 2-41: Joystick Cable Wiring Schematic 74
Figure 2-42: Typical Configuration 76
Figure 2-43: STO Timing 79
Figure 2-44: Location of the Rear Fan and Air Flow 81
Figure 2-45: -C0 Fan Location and Direction of Air Flow 81
Figure 2-46: -C1 Model Showing Perforated Covers for External Fans 82
Figure 2-47: -C2 1U Fan Location and Air Flow 83
Figure 3-1: Drive Interface Board 86
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List of Figures XR3 Hardware Manual
Figure B-1: Voltage Selection Switch Access 90
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XR3 Hardware Manual List of Tables
List of Tables
Table 1-1: FeatureSummary 17
Table 1-2: Configurations and Options 18
Table 1-3: Chassis Electrical Specifications 21
Table 1-4: PWMAmplifier Electrical Specifications 22
Table 1-5: Linear Amplifier Electrical Specifications 22
Table 1-6: Mounting Specifications 24
Table 1-7: Environmental Specifications 27
Table 1-8: Drive and Software Compatibility 28
Table 2-1: Main AC Power Input Voltages and Current Requirements 31
Table 2-2: I/O and Signal Specifications 32
Table 2-3: Maximum Energy That The XR3 Can Safely Absorb During Regeneration 33
Table 2-4: Motor Power Output Connector Pinout 34
Table 2-5: Mating Connector Part Numbers for the Motor Power Output Connector 34
Table 2-6: Feedback Connector Pinout 40
Table 2-7: Mating Connector Part Numbers for the Feedback Connector 40
Table 2-8: Multiplier Options 41
Table 2-9: Primary Encoder Input Pins on the Feedback Connector 41
Table 2-10: Square Wave Encoder Specifications 42
Table 2-11: Analog Encoder Specifications 44
Table 2-12: Hall-Effect Feedback Pins on the Feedback Connector 48
Table 2-13: Thermistor Input Pin on the Feedback Connector 49
Table 2-14: Encoder Fault Input Pin on the Feedback Connector 50
Table 2-15: End of Travel and Home Limit Pins on the Feedback Connector 51
Table 2-16: Brake Output Pins on the Feedback Connector 54
Table 2-17: Brake Output Specifications 54
Table 2-18: PSOConnector Pinout 55
Table 2-19: PSOSpecifications 55
Table 2-20: PSOIsolated Output Specification 56
Table 2-21: Isolated Output Pins on the PSOConnector 56
Table 2-22: PSOTTLOutputs Specification 57
Table 2-23: TTLOutput Pins on the PSOConnector 57
Table 2-24: Clock Input Pins on the PSOConnector 58
Table 2-25: Data Acquisition Input Pins on the PSOConnector 59
Table 2-26: DataAcquisition Opto-Isolator Input Specifications 59
Table 2-27: High-Speed Output Specifications 60
Table 2-28: HSOUTConnector Pinout 60
Table 2-29: Mating Connector Part Numbers for the HSOUTConnector 60
Table 2-30: Digital Output Specifications 62
Table 2-31: DOUTConnector Digital Outputs Pinout 63
Table 2-32: Mating Connector Part Numbers for the DOUTConnector 63
Table 2-33: DINConnector Digital Inputs Pinout 66
Table 2-34: Mating Connector Part Numbers for the DINConnector 66
Table 2-35: Digital Input Specifications 67
Table 2-36: AuxEncoder Connector Pinout 69
Table 2-37: Mating Connector Part Numbers for the Aux Encoder Connectors 69
Table 2-38: AnalogI/OConnector Pinout 70
Table 2-39: Mating Connector Part Numbers for the AnalogI/OConnectors 70
Table 2-40: Analog Output Specifications 71
Table 2-41: Analog Output Pins on the Analog I/OConnector 71
Table 2-42: Analog Input Specifications 72
Table 2-43: Analog Input Pins on the Analog I/O Connector 72
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List of Tables XR3 Hardware Manual
Table 2-44: Joystick Interface Pins on the Analog I/OConnectors 73
Table 2-45: STO Connector Pinout 75
Table 2-46: Mating Connector Part Numbers for the STOConnector 75
Table 2-47: STOElectrical Specifications 75
Table 2-48: STOStandards 77
Table 2-49: STOStandards Data 77
Table 2-50: STOSignal Delay 78
Table 2-51: Motor Function Relative to STOInput State 78
Table 2-52: STOTiming 79
Table 2-53: HyperWire Card Part Number 80
Table 2-54: HyperWire Cable Part Numbers 80
Table 3-1: Preventative Maintenance 85
Table 3-2: Drive Interface Board Motor Power Fuse Replacement Part Numbers 86
Table B-1: AC Voltage Selector Switch Settings 90
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XR3 Hardware Manual EU Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XR3
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2014/30/EU Electromagnetic Compatibility (EMC)
2014/35/EU Low Voltage Directive
EU 2015/863 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.
EN 61010-1:2010 Safety Requirements for Electrical Equipment
EN 55011:1998 / EN 55022 Conducted and Radiated Emissions
IEC 61800-5-1 Electrical Safety for Power Drive Systems
IEC 61800-5-2 Functional Safety for Power Drive Systems
EN 61800-3:2004 EMCRequirements for Power Drives
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 4/27/2020
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EU Declaration of Conformity XR3 Hardware Manual
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XR3 Hardware Manual Agency Approvals
Agency Approvals
Aerotech tested its XR3 drive racks and found that they obey the standards that follow:
Approval / Certification: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 068995 0027 Rev. 01
Standards: CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-1:2010; UL 61010-1:2012
Approval: Safety Components (STO)
Approving Agency: TUVSUD
Certificate #: Z10 068995 0030 Rev. 00
Standards: IEC61508-1:2010 (up to SIL3)
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 XR3 Hardware Manual
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XR3 Hardware Manual Safety Procedures and Warnings
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the XR3. Read all parts of this manual
before you install or operate the XR3 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. Before you do maintenance to the equipment, disconnect the electrical power.
2. 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.
3. Before you connect wires to this product, disconnect the electrical power.
4. To decrease the risk of electrical shock and injury, you must supply operators with the
necessary precautions and protection from live electrical circuits.
5. While the drive is connected to a power source, do not connect or disconnect electrical
components and cables.
6. Make sure that all components are grounded correctly and that they obey the local electrical
safety requirements.
7. Make sure that you install the necessary precautions to supply safety and protection to the
operator.
8. 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.
DANGER:Heavy Object
1. Use a cart to move the product.
2. To avoid injury, use two or more people to move and install this product.
3. Lift this product only by the base. Do not use the cables or the connectors to lift or move this
product.
4. Do not use the handles on the front of the product to lift or move this product. Use the
handles only to slide the product in and out of its enclosure.
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Safety Procedures and Warnings XR3 Hardware Manual
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. Make sure that all system cables are correctly attached and positioned.
2. This product is heavy. Use two or more people to move and install this product. Failure to do
so can result in back or other injury.
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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XR3 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 XR3. 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.
ACPower Section 2.2.1. AC Power Connections
HyperWire Section 2.12. HyperWire Interface
Motor Power Section 2.3. Motor Power Output Connector
Feedback Section 2.4. Feedback Connector
Figure 1: Quick Start Connections
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Quick Installation Guide XR3 Hardware Manual
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XR3 Hardware Manual Chapter 1: Introduction
Chapter 1: Introduction
The XR3 is a high-performance, 6-axis drive rack with field replaceable front-mounted amplifiers. All
versions are 3U in size and rack-mountable.
Table 1-1: FeatureSummary
Standard Features
lTwo independent bus supplies (factory configured) Section 1.1.
lLinear or PWM amplifiers Section 1.1.
lSoftware configurable for brush, brushless, ceramic, and stepper motor operation
(the XR3 must be factory wired for an XSL3-10-40 amplifier to drive a stepper
motor)
Section 2.3.
l6 channels of line driver square wave or optional analog sine wave quadrature
encoder position and/or velocity feedback
Section 2.4.
lSingle axis PSO (Laser Firing) standard (2- and 3-axis firing optional) Section 2.5.
Auxiliary Power Outputs
l+5 V provided on all axis feedback connectors for encoder, Hall, and limit power Section 2.4.
l+5 Vprovided on I/O connectors Section 2.9.
I/O
lBrake Output Section 2.4.
lThree PSO External Sync inputs Section 2.5.
lThree TTL or isolated PSOoutputs Section 2.5.2.
lOne Data Acquisition Input Section 2.5.4.
lUp to 12 High Speed Differential outputs Section 2.6.
l16 digital outputs Section 2.7.
l16 digital inputs Section 2.8.
lTwo 16-bit analog outputs per axis Section 2.10.1.
lTwo 16-bit differential analog inputs per axis; two inputs used for joystick inputs Section 2.10.2.
lThree dedicated joystick digital inputs Section 2.10.3.
lTwo STOsense Inputs Section 2.11.
Feedback / Limit Inputs
lEncoder / Marker Inputs (primary) Section 2.4.1.
lHall Inputs (3 per axis) Section 2.4.2.
lFour analog sensor inputs per axis with one used as a motor over-temperature input and one used as
an encoder fault input
nThermistor Section 2.4.3.
nEncoder Fault Section 2.4.4.
lCW, CCW, and Home Limit Inputs Section 2.4.5.
lEncoder / Marker Inputs (auxiliary) Section 2.9.
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Chapter 1: Introduction XR3 Hardware Manual
Table 1-2: Configurations and Options
Input Line Voltage
-VL1 115 VAC
-VL2 230 VAC
-VL3 100 VAC
-VL4 200 VAC
Bus Voltage 1 and Bus Voltage 2 Configurations
Bus Voltage 1 (Required) Bus Voltage 2 (Optional)
-- -- -VB0 Not wired (Bus Voltage 2 only)
-VB1 ±10 VDC (200 W Power Supply), bipolar -VB1 ±10 VDC (200 W Power Supply), bipolar
-VB2 ±20 VDC (200 W Power Supply), bipolar -VB2 ±20 VDC (200 W Power Supply), bipolar
-VB3 ±30 VDC (200 W Power Supply), bipolar -VB3 ±30 VDC (200 W Power Supply), bipolar
-VB4 ±40 VDC (300 W Power Supply), bipolar -VB4 ±40 VDC (300 W Power Supply), bipolar
-VB5 ±80 VDC (300 W Power Supply), bipolar -VB5 ±80 VDC (300 W Power Supply), bipolar
-VB7 160 VDC, unipolar -VB7 160 VDC, unipolar
-VB8 320 VDC, unipolar -VB8 320 VDC, unipolar
Split Bus Options
-SB0 No split, Axis 1-6 Bus Voltage 1
-SB1 Axis 1 Bus Voltage 1, Axis 2-6 Bus Voltage 2
-SB2 Axis 1-2 Bus Voltage 1, Axis 3-6 Bus Voltage 2
-SB3 Axis 1-3 Bus Voltage 1, Axis 4-6 Bus Voltage 2
-SB4 Axis 1-4 Bus Voltage 1, Axis 5-6 Bus Voltage 2
-SB5 Axis 1-5 Bus Voltage 1, Axis 6 Bus Voltage 2
Axis Control Board Section 2.4.1.3.
Axis 1 (Required) Axis 2-6 (Optional)
-CT0 No control board 0 No control board
-CTN No multiplier N No multiplier
-CT1 Primary feedback multiplier (standard
performance) 1Primary feedback multiplier (standard performance)
-CT2 Primary feedback multiplier (high
performance) 2Primary feedback multiplier (high performance)
-CT4 Primary and auxiliary multiplier (high
performance) 4Primary and auxiliary multiplier (high performance)
Note:"-CT" is applied to the first axis option only. A three axis order would look like:-CT111.
Axis Amplifier Section 1.1.
Axis 1 (Required) Axis 2-6 (Optional)
-P0 None P0 None
-P1 XSP3-10 PWMamplifier P1 XSP3-10 PWMamplifier
-P2 XSP3-20 PWMamplifier P2 XSP3-20 PWMamplifier
-P3 XSP3-30 PWMamplifier P3 XSP3-30 PWMamplifier
-L1 XSL3-10-40 linearamplifier L1 XSL3-10-40 linearamplifier
Note:"-" is applied to the first axis option only. A three axis order would look like:-P1P1P1.
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XR3 Hardware Manual Chapter 1: Introduction
Cooling Options Section 2.13.
-C0 Built-in fan pulls cooling air from left side through the amplifier compartment
-C1 No cooling fan. External cooling through vented covers is required.
-C2 1U-high fan tray for cooling
Mounting Options Section 1.2.
-MT0 Rack-mounted configuration
-MT1 Rack-mounted configuration with drawer slides
Line Cord Options
-LC0 No line cord
-LC1 U.S. 115 VAC line cord
-LC2 U.S. 230 VAC line cord
-LC3 German compatible line cord
-LC4 U.K. compatible line cord
-LC5 Israel compatible line cord
-LC6 India compatible line cord
-LC7 Australia compatible line cord
PSO Section 2.5.
-PSO1 One-axis PSOfiring
-PSO2 Two-axis PSOfiring
-PSO3 Three-axis PSOfiring
-PSO5 Two-axis part-speed PSO firing
-PSO6 Three-axis part-speed PSO firing
Internal Shunt Section 2.2.4.
-SI0 No internal shunt
-SI1 Internal shunt for first bus
-SI2 Internal shunt for second bus
-SI3 Internal shunt for first and second bus
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
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Chapter 1: Introduction XR3 Hardware Manual
The block diagram that follows shows a summary of the connector signals.
Figure 1-1: Functional Diagram
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