Aerotech Automation1 iXR3 User manual

Revision 2.08
Automation1 iXR3 and XR3 Drive Racks
HARDWAREMANUAL

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Copyright © 2016-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 iXR3 and XR3 Drive Racks 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Agency Approvals 10
Safety Procedures and Warnings 11
Handling and Storage 13
Installation Overview 14
Chapter 1: iXR3/XR3 Overview 15
1.1. Electrical Specifications 21
1.1.1. System Power Requirements 24
1.2. Mechanical Specifications 25
1.2.1. Mounting and Cooling 25
1.2.2. Dimensions 26
1.3. Environmental Specifications 28
1.4. Drive and Software Compatibility 29
Chapter 2: Installation and Configuration 31
2.1. Electrical Installation 31
2.1.1. AC Power Connections 33
2.1.2. Minimizing Noise for EMC/CECompliance 34
2.1.3. I/O and Signal Requirements 34
2.1.4. Internal Shunt Option [-SI#] 35
2.2. Motor Power Output Connector 36
2.2.1. Brushless Motor Connections 37
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 38
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 39
2.2.2. DCBrush Motor Connections 40
2.2.2.1. DC Brush Motor Phasing 40
2.2.3. Stepper Motor Connections 41
2.2.3.1. Stepper Motor Phasing 41
2.2.4. Three Phase Stepper Motor Connections 42
2.2.4.1. Stepper Motor Phasing 42
2.3. Feedback Connector 43
2.3.1. Primary Encoder Inputs 44
2.3.1.1. Square WaveEncoder (Primary) 45
2.3.1.2. Absolute Encoder (Primary) 46
2.3.1.3. Sine Wave Encoder (Primary) [-CT1/-CT2/-CT4 Option] 47
2.3.1.4. Encoder Phasing 49
2.3.2. Hall-Effect Inputs 50
2.3.3. Thermistor Input 51
2.3.4. Encoder Fault Input 52
2.3.5. End of Travel and Home Limit Inputs 53
2.3.5.1. End of Travel and Home Limit Phasing 55
2.3.6. Brake Output 56
2.4. Position Synchronized Output Connector (PSO) 57
2.4.1. PSO Isolated Outputs 58
2.4.2. PSO TTLOutputs 59
2.4.3. External PSO Synchronization 60
2.4.4. DataAcquisition Inputs 61
2.5. HSOUTConnector (High-Speed Outputs) 62
2.6. DOUTConnector (Digital Outputs) 64
2.7. DINConnector (Digital Inputs) 68
2.8. Aux Encoder Connectors 71
2.8.1. Square WaveEncoder (Auxiliary) 72
2.8.2. Absolute Encoder (Auxiliary) 73
2.8.3. Sine Wave Encoder (Auxiliary) [-CT4 Option] 74
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2.9. AnalogI/OConnectors 76
2.9.1. Analog Outputs 77
2.9.2. Analog Inputs (Differential) 78
2.9.3. Joystick Interface 79
2.10. Safe Torque Off Input (STO) 81
2.10.1. STOStandards 83
2.10.2. STO Functional Description 84
2.10.3. STO Startup Validation Testing 85
2.10.4. STO Diagnostics 86
2.11. HyperWire Interface 87
2.12. Sync Port 88
2.13. Industrial Ethernet (iXR3 Only) 88
2.14. Cooling Options [-C0/-C1/-C2Option] 89
2.15. PC Configuration and Operation Information 92
Chapter 3: Maintenance 93
3.1. Preventative Maintenance 94
3.2. Fuse Specifications 95
3.3. Amplifier Replacement 96
Appendix A: Warranty and Field Service 99
Appendix B: Voltage Selection Operation 101
Appendix C: Revision History 103
Index 105
Table of Contents iXR3/XR3 Hardware Manual
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List of Figures
Figure 1-1: iXR3 Connection Overview 15
Figure 1-2: XR3 Connection Overview 16
Figure 1-3: Functional Diagram 20
Figure 1-4: iXR3/XR3 ACPower Label Location 21
Figure 1-5: Dimensions with Chassis Slides 26
Figure 1-6: Dimensions without Chassis Slides 27
Figure 2-1: iXR3 Connection Overview 31
Figure 2-2: XR3 Connection Overview 32
Figure 2-3: Brushless Motor Configuration 37
Figure 2-4: Positive Motor Direction 38
Figure 2-5: Encoder and Hall Signal Diagnostics 38
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 39
Figure 2-7: Brushless Motor Phasing Goal 39
Figure 2-8: DC Brush Motor Configuration 40
Figure 2-9: Positive Motor Direction 40
Figure 2-10: Stepper Motor Configuration 41
Figure 2-11: Positive Motor Direction 41
Figure 2-12: Three Phase Stepper Motor Configuration 42
Figure 2-13: Positive Motor Direction 42
Figure 2-14: Square Wave Encoder Schematic (Feedback Connector) 45
Figure 2-15: Absolute Encoder Schematic (Feedback Connector) 46
Figure 2-16: Sine Wave Encoder Phasing Reference Diagram 47
Figure 2-17: Sine Wave Encoder Schematic (Feedback Connector) 48
Figure 2-18: Encoder Phasing Reference Diagram (Standard) 49
Figure 2-19: Position Feedback in the DiagnosticDisplay 49
Figure 2-20: Hall-Effect Inputs Schematic (Feedback Connector) 50
Figure 2-21: Thermistor Input Schematic (Feedback Connector) 51
Figure 2-22: Encoder Fault Input Schematic (Feedback Connector) 52
Figure 2-23: End of Travel and Home Limit Input Connections 54
Figure 2-24: End of Travel and Home Limit Input Schematic (Feedback Connector) 54
Figure 2-25: End of Travel and Home Limit Input Diagnostic Display 55
Figure 2-26: Brake Output Connections (Feedback Connector) 56
Figure 2-27: PSO Output Sources Current 58
Figure 2-28: PSOOutput Sinks Current 58
Figure 2-29: PSO TTLOutputs Schematic 59
Figure 2-30: PSO Clock Inputs Schematic 60
Figure 2-31: DataAcquisition Input Schematic 61
Figure 2-32: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs 63
Figure 2-33: Digital Output Schematic 66
Figure 2-34: Digital Outputs Connected in Current Sourcing Mode 67
Figure 2-35: Outputs Connected in Current Sinking Mode 67
Figure 2-36: Digital Input Schematic 69
Figure 2-37: Digital Inputs Connected to Current Sourcing (PNP) Devices 70
Figure 2-38: Digital Inputs Connected to Current Sinking (NPN) Devices 70
Figure 2-39: Square Wave Encoder Interface (Aux EncoderConnector) 72
Figure 2-40: Absolute Encoder Schematic (Aux Encoder Connector) 73
Figure 2-41: Sine Wave Encoder Phasing Reference Diagram 74
Figure 2-42: Sine Wave Encoder Schematic (AuxEncoder Connector) 75
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Figure 2-43: Analog Outputs Schematic 77
Figure 2-44: Analog Inputs Schematic 78
Figure 2-45: Joystick Interface Inputs Schematic 79
Figure 2-46: Joystick Cable Wiring Schematic 80
Figure 2-47: Typical STO Configuration 82
Figure 2-48: STO Timing 86
Figure 2-49: Location of the Rear Fan and Air Flow 89
Figure 2-50: -C0 Fan Location and Direction of Air Flow 89
Figure 2-51: -C1 Model Showing Perforated Covers for External Fans 90
Figure 2-52: -C2 1U Fan Location and Air Flow 91
Figure 3-1: Drive Interface Board 95
Figure 3-2: Amplifier Removal 96
Figure 3-3: Slot Details 97
Figure B-1: Voltage Selection Switch Access 102
List of Figures iXR3/XR3 Hardware Manual
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List of Tables
Table 1-1: FeatureSummary 17
Table 1-2: Configurations and Options 18
Table 1-3: Electrical Specifications 22
Table 1-4: PWMAmplifier Electrical Specifications 23
Table 1-5: Linear Amplifier Electrical Specifications 23
Table 1-6: Mounting Specifications 25
Table 1-7: Environmental Specifications 28
Table 1-8: Drive and Software Compatibility 29
Table 2-1: Main AC Power Input Voltages and Current Requirements 33
Table 2-2: I/O and Signal Specifications 34
Table 2-3: Maximum Energy That The iXR3/XR3 Can Safely Absorb During Regeneration 35
Table 2-4: Motor Power Output Connector Pinout 36
Table 2-5: Mating Connector Part Numbers for the Motor Power Output Connector 36
Table 2-6: Hall Signal Diagnostics 38
Table 2-7: Feedback Connector Pinout 43
Table 2-8: Mating Connector Part Numbers for the Feedback Connector 43
Table 2-9: Multiplier Options 44
Table 2-10: Primary Encoder Input Pins on the Feedback Connector 44
Table 2-11: Square Wave Encoder Specifications 45
Table 2-12: Sine Wave Encoder Specifications 47
Table 2-13: Hall-Effect Feedback Pins on the Feedback Connector 50
Table 2-14: Thermistor Input Pin on the Feedback Connector 51
Table 2-15: Encoder Fault Input Pin on the Feedback Connector 52
Table 2-16: End of Travel and Home Limit Pins on the Feedback Connector 53
Table 2-17: Brake Output Pins on the Feedback Connector 56
Table 2-18: Brake Output Specifications 56
Table 2-19: PSOConnector Pinout 57
Table 2-20: PSOSpecifications 57
Table 2-21: PSOIsolated Output Specification 58
Table 2-22: Isolated Output Pins on the PSOConnector 58
Table 2-23: PSOTTLOutputs Specification 59
Table 2-24: TTLOutput Pins on the PSOConnector 59
Table 2-25: External PSO Sync Input Pins on the PSO Connector 60
Table 2-26: Data Acquisition Input Pins on the PSOConnector 61
Table 2-27: DataAcquisition Opto-Isolator Input Specifications 61
Table 2-28: High-Speed Output Specifications 62
Table 2-29: HSOUTConnector Pinout 62
Table 2-30: Mating Connector Part Numbers for the HSOUTConnector 62
Table 2-31: Digital Output Specifications 64
Table 2-32: DOUTConnector Digital Outputs Pinout 65
Table 2-33: Mating Connector Part Numbers for the DOUTConnector 65
Table 2-34: DINConnector Digital Inputs Pinout 68
Table 2-35: Mating Connector Part Numbers for the DINConnector 68
Table 2-36: Digital Input Specifications 68
Table 2-37: AuxEncoder Connector Pinout 71
Table 2-38: Mating Connector Part Numbers for the Aux Encoder Connectors 71
Table 2-39: Square Wave Encoder Specifications 72
Table 2-40: Sine Wave Encoder Specifications 74
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Table 2-41: AnalogI/OConnector Pinout 76
Table 2-42: Mating Connector Part Numbers for the AnalogI/OConnectors 76
Table 2-43: Analog Output Specifications 77
Table 2-44: Analog Output Pins on the Analog I/OConnector 77
Table 2-45: Analog Input Specifications 78
Table 2-46: Analog Input Pins on the Analog I/O Connector 78
Table 2-47: Joystick Interface Pins on the Analog I/OConnectors 79
Table 2-48: STO Connector Pinout 81
Table 2-49: Mating Connector Part Numbers for the STOConnector 81
Table 2-50: STOElectrical Specifications 82
Table 2-51: STOStandards 83
Table 2-52: STOStandards Data 83
Table 2-53: STOSignal Delay 85
Table 2-54: Motor Function Relative to STOInput State 85
Table 2-55: STOTiming 86
Table 2-56: HyperWire Card Part Number 87
Table 2-57: HyperWire Cable Part Numbers 87
Table 2-58: Sync-Related Functions 88
Table 2-59: SyncPort Cables 88
Table 2-60: -C1 Option Airflow Specifications 90
Table 3-1: LEDDescription 93
Table 3-2: Troubleshooting 93
Table 3-3: Preventative Maintenance 94
Table 3-4: Drive Interface Board Motor Power Fuse Replacement Part Numbers 95
Table B-1: AC Voltage Selector Switch Settings 102
List of Tables iXR3/XR3 Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXR3/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
2006/42/EC Machinery 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/A1:2016 Safety Requirements for Electrical Equipment
EN 61800-3:2004/A1:2011 EMCRequirements for Power Drives
IEC 61800-5-1:2016 Electrical Safety for Power Drive Systems
IEC 61800-5-2:2016 Functional Safety for Power Drive Systems
EN 55011:2000/A2:2003 Conducted and Radiated Emissions
EN 55022:1998 Conducted and Radiated Emissions
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 3/17/2022
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Agency Approvals
Aerotech tested its XR3 drive racks and found that they obey the standards that follow:
IMPORTANT: iXR3 certification is pending.
Approval: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 068995 0027 Rev. 02
Standards: CAN/CSA-C22.2 No. 61010-1:2012,
EN 61010-1:2010/A1:2016,
UL 61010-1:2012
Approval: Safety Components (STO)
Approving Agency: TUVSUD
Certificate #: Z10 068995 0030 Rev. 00
Standards: EN ISO 13849-1:2015 (up to PL e),
IEC 61508-1:2010 (up to SIL3),
IEC 61508-2:2010 (up to SIL3),
IEC 61800-5-2:2016,
IEC 62061:2005 (up to SILCL3),
IEC 62061:2005/AMD1:2012 (up to SILCL3),
IEC 62061:2005/AMD2:2015 (up to SILCL3)
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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