Aerotech AUTOMATION1-GL4 User manual

Patent Number: US 8,426,768 B2
Revision 2.01
Automation1 GL4 Galvo Scan-Head Drive
HARDWAREMANUAL

GLOBALTECHNICALSUPPORT
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Aerotech, Inc. products. The website supplies software, product manuals, Help files,
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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 © 2016-2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 GL4 Galvo Scan-Head Drive 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
Installation Overview 13
Chapter 1: Introduction 15
1.1. Electrical Specifications 17
1.2. Mechanical Specifications 18
1.2.1. Mounting and Cooling 18
1.2.2. Dimensions 19
1.3. Environmental Specifications 20
1.4. Drive and Software Compatibility 21
Chapter 2: Installation and Configuration 23
2.1. Input Power Connections 24
2.1.1. Control Supply Connector 24
2.1.2. Motor Supply Connector 25
2.1.3. External Power Supply Options 26
2.1.4. Minimizing Noise for EMC/CECompliance 28
2.2. HyperWire Interface 29
2.3. Laser Output Connectors 30
2.3.1. Position Synchronized Output (PSO) 35
2.4. Encoder Output Connector 36
2.5. Galvo Motor Connectors 38
2.5.1. Analog Encoder Inputs 39
2.5.2. End of Travel Limit Input Interface 40
2.5.2.1. End of Travel Limit Phasing 42
2.5.3. Thermistor Input 43
2.6. Digital and Analog I/O Connectors 44
2.6.1. Digital Outputs 45
2.6.2. Digital Inputs 47
2.6.3. Analog Outputs 48
2.6.4. Analog Inputs (Differential) 49
2.7. Encoder Input Connectors 50
2.7.1. Emergency Stop Sense Input 52
2.8. Laser Output Polarity Switches 53
2.9. Sync Port 54
2.10. PC Configuration and Operation Information 55
Chapter 3: Maintenance 57
3.1. Preventative Maintenance 58
3.2. Board Assembly 59
Appendix A: Warranty and Field Service 61
Appendix B: Revision History 63
Index 65
GL4 Hardware Manual Table of Contents
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List of Figures
Figure 1-1: GL4 Networked Digital Galvo Controller 15
Figure 1-2: Functional Diagram 16
Figure 1-3: Dimensions 19
Figure 2-1: Control Supply Connections 24
Figure 2-2: Motor Supply Connections 25
Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 27
Figure 2-4: Third-Party Power Supply Connection 27
Figure 2-5: Laser Interface Outputs 31
Figure 2-6: Current Sinking Configuration with Isolation 32
Figure 2-7: Current Sinking Configuration without Isolation 32
Figure 2-8: Current Sourcing Configuration with Isolation 33
Figure 2-9: Current Sourcing Configuration without Isolation 33
Figure 2-10: TTLOutput 34
Figure 2-11: Encoder Outputs 36
Figure 2-12: PSOExternal Sync Input 37
Figure 2-13: End of Travel Limit Input Connections 41
Figure 2-14: End of Travel Limit Interface Input Schematic 41
Figure 2-15: Limit Input Diagnostic Display 42
Figure 2-16: Thermistor Input Input Schematic 43
Figure 2-17: Digital Outputs Connected in Current Sourcing Mode 46
Figure 2-18: Digital Outputs Connected in Current Sinking Mode 46
Figure 2-19: Digital Inputs Connected to Current Sourcing Devices 47
Figure 2-20: Digital Inputs Connected to Current Sinking Devices 47
Figure 2-21: Analog Outputs Schematic 48
Figure 2-22: Analog Inputs Schematic 49
Figure 2-23: Encoder Input Connections Schematic 51
Figure 2-24: ESTOP Sense Input Schematic 52
Figure 2-25: Laser Output Polarity Switches 53
Figure 3-1: Control Board Assembly 59
Figure 3-2: Power Board Assembly 60
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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: Environmental Specifications 20
Table 1-5: Drive and Software Compatibility 21
Table 2-1: Control Supply Connector Wiring Specifications 24
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 24
Table 2-3: Motor Supply Wiring Specifications 25
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 25
Table 2-5: HyperWire Card Part Number 29
Table 2-6: HyperWire Cable Part Numbers 29
Table 2-7: Laser Output Connector A Pinout 30
Table 2-8: Laser Output Connector B Pinout 30
Table 2-9: Mating Connector Part Numbers for the Laser Output Connectors 30
Table 2-10: Laser Output Specifications 31
Table 2-11: PSOPins on the Laser Output A Connector 35
Table 2-12: PSOPins on the Laser Output B Connector 35
Table 2-13: PSO Specifications 35
Table 2-14: Encoder Output Connector Pinout 36
Table 2-15: Mating Connector Part Numbers for the Encoder Output Connector 36
Table 2-16: PSOExternal Sync Specifications 37
Table 2-17: Galvo Motor Connector Pinout 38
Table 2-18: Mating Connector Part Numbers for the Galvo Motor Connectors 38
Table 2-19: Analog Encoder Specifications 39
Table 2-20: End of Travel Limit Input Pins on the Galvo Motor Connectors 40
Table 2-21: Thermistor Input Pins on the Galvo Motor Connectors 43
Table 2-22: Digital and Analog I/O Connector APinout 44
Table 2-23: Digital and Analog I/O Connector B Pinout 44
Table 2-24: Mating Connector Part Numbers for the Digital / Analog I/OConnectors 44
Table 2-25: Digital Output Specifications 45
Table 2-26: Digital Output Pins on the Digital/Analog I/O A Connector 45
Table 2-27: Digital Input Specifications 47
Table 2-28: Digital Input Pins on the Digital/Analog I/O B Connector 47
Table 2-29: Analog Output Specifications 48
Table 2-30: Analog Output Pins on the Digital / Analog I/O B Connector 48
Table 2-31: Analog Input Specifications 49
Table 2-32: Analog Input Pins on the Digital / Analog I/O B Connector 49
Table 2-33: Encoder Input Specifications 50
Table 2-34: Axis 1 Encoder Input Pinout (Encoder Input Connector A) 50
Table 2-35: Axis 2 Encoder Input Pinout (Encoder Input Connector B) 50
Table 2-36: Mating Connector Part Numbers for the Encoder Input Connectors 50
Table 2-37: GL4 to Drive Cable Part Numbers 50
Table 2-38: ESTOP Pins on the Encoder Input Connector 52
Table 2-39: Electrical Noise Suppression Devices 52
Table 2-40: Sync-Related Functions 54
Table 2-41: SyncPort Cables 54
Table 3-1: LEDDescription 57
Table 3-2: Troubleshooting 57
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Table 3-3: Preventative Maintenance 58
Table 3-4: Control Board Fuse Specifications 59
Table 3-5: Power Board Fuse Specifications 60
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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
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.
EN 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 6/30/2021
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Agency Approvals
Aerotech tested its GL4 drives and found that they obey the standards that follow:
Approval: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 068995 0031 Rev. 00
Standards: CAN/CSA-C22.2 No. 61010-1:2012 ,
EN 61010-1:2010,
UL 61010-1:2012
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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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
drive.
lRead all parts of this manual before you install or operate the 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.
DANGER: To decrease the risk of electrical shock, injury, death, and damage to the
equipment, obey the precautions that follow.
1. Before you do maintenance to the equipment, disconnect the electrical power.
2. Restrict access to the drive when it is connected to a power source.
3. Do not connect or disconnect electrical components, wires, and cables while this product
is connected to a power source.
4. Wait at least ten (10) minutes after removing the power supply before doing main-
tenance or an inspection. Otherwise, there is the danger of electric shock.
5. Supply each operator with the necessary protection from live electrical circuits.
6. Make sure that all components are grounded correctly and that they obey the local elec-
trical safety requirements.
7. Install the necessary precautions to supply safety and protection to the operator.
DANGER: System travel can cause crush, shear, or pinch injuries. Restrict 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
and injury, obey the precautions that follow.
1. Make sure that all system cables are correctly attached and positioned.
2. Do not use the cables or the connectors to lift or move this product.
3. Use this product only in environments and operating conditions that are approved in
this manual.
4. Only trained operators should operate this equipment.
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Installation Overview
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.
1Connect a PCHyperWire port to an amplifier HyperWire port. Section 2.2.
2Connect the Digital/Analog I/O. Section 2.6.
3Connect to Axis 1 and Axis 2 motor and feedback connectors. Section 2.5.
4Connect to the Control Supply connector. Section 2.1.1.
5Connect to the Motor Supply connector. Section 2.1.2.
Figure 1: Installation ConnectionOverview
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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 that uses the PSO firing circuit based off of the
commanded vector velocity of up to three axes 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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The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
Chapter 1: Introduction GL4 Hardware Manual
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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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1.2. Mechanical Specifications
1.2.1. Mounting and Cooling
Install the GL4 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
GL4
Customer-Supplied Enclosure IP54 Compliant
Weight ~2.9 kg
Mounting Hardware M4 [#8] screws (four locations, not included)
Mounting Orientation Vertical (typical)
Dimensions Refer to Section 1.2.2. Dimensions
Minimum Clearance Airflow ~25 mm
Connectors ~100 mm
Operating Temperature Refer to Section 1.3. Environmental Specifications
1.2. Mechanical Specifications GL4 Hardware Manual
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1.2.2. Dimensions
Figure 1-3: Dimensions
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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
1.3. Environmental Specifications GL4 Hardware Manual
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