Aerotech Automation1 XR3 Series User manual

Revision 2.01
Automation1 XR3 Drive Rack
HARDWAREMANUAL

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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 XR3 Drive Rack 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
Installation Overview 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. Electrical Installation 30
2.1.1. AC Power Connections 31
2.1.2. Minimizing Noise for EMC/CECompliance 32
2.1.3. I/O and Signal Requirements 32
2.1.4. Internal Shunt Option [-SI#] 33
2.2. Motor Power Output Connector 34
2.2.1. Brushless Motor Connections 35
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 36
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 37
2.2.2. DCBrush Motor Connections 38
2.2.2.1. DC Brush Motor Phasing 38
2.2.3. Stepper Motor Connections 39
2.2.3.1. Stepper Motor Phasing 39
2.3. Feedback Connector 40
2.3.1. Primary Encoder Inputs 41
2.3.1.1. Square WaveEncoder 42
2.3.1.2. Absolute Encoder 43
2.3.1.3. Sine Wave Encoder [-CT1/-CT2/-CT4 Option] 44
2.3.1.4. Encoder Phasing 46
2.3.2. Hall-Effect Inputs 47
2.3.3. Thermistor Input 48
2.3.4. Encoder Fault Input 49
2.3.5. End of Travel and Home Limit Inputs 50
2.3.5.1. End of Travel and Home Limit Phasing 52
2.3.6. Brake Output 53
2.4. Position Synchronized Output Connector (PSO) 54
2.4.1. PSO Isolated Outputs 55
2.4.2. PSO TTLOutputs 56
2.4.3. External PSO Synchronization 57
2.4.4. DataAcquisition Inputs 58
2.5. HSOUTConnector (High-Speed Outputs) 59
2.6. DOUTConnector (Digital Outputs) 61
2.7. DINConnector (Digital Inputs) 65
2.8. Aux Encoder Connectors 68
2.8.1. Square WaveEncoder 69
2.8.2. Absolute Encoder 70
2.8.3. Sine Wave Encoder [-CT4 Option] 71
2.9. AnalogI/OConnectors 73
2.9.1. Analog Outputs 74
2.9.2. Analog Inputs (Differential) 75
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2.9.3. Joystick Interface 76
2.10. Safe Torque Off Input (STO) 78
2.10.1. STOStandards 80
2.10.2. STO Functional Description 81
2.10.3. STO Startup Validation Testing 82
2.10.4. STO Diagnostics 83
2.11. HyperWire Interface 84
2.12. Cooling Options [-C0/-C1/-C2Option] 85
2.13. PC Configuration and Operation Information 88
Chapter 3: Maintenance 89
3.1. Preventative Maintenance 90
3.2. Fuse Specifications 91
Appendix A: Warranty and Field Service 93
Appendix B: Voltage Selection Operation 95
Appendix C: Revision History 97
Index 99
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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: Brushless Motor Configuration 35
Figure 2-3: Positive Motor Direction 36
Figure 2-4: Encoder and Hall Signal Diagnostics 36
Figure 2-5: Brushless Motor Phasing Oscilloscope Example 37
Figure 2-6: Brushless Motor Phasing Goal 37
Figure 2-7: DC Brush Motor Configuration 38
Figure 2-8: Positive Motor Direction 38
Figure 2-9: Stepper Motor Configuration 39
Figure 2-10: Positive Motor Direction 39
Figure 2-11: Square Wave Encoder Schematic (Feedback Connector) 42
Figure 2-12: Absolute Encoder Schematic (Feedback Connector) 43
Figure 2-13: Sine Wave Encoder Phasing Reference Diagram 44
Figure 2-14: Sine Wave Encoder Schematic (Feedback Connector) 45
Figure 2-15: Encoder Phasing Reference Diagram (Standard) 46
Figure 2-16: Position Feedback in the DiagnosticDisplay 46
Figure 2-17: Hall-Effect Inputs Schematic (Feedback Connector) 47
Figure 2-18: Thermistor Input Schematic (Feedback Connector) 48
Figure 2-19: Encoder Fault Input Schematic (Feedback Connector) 49
Figure 2-20: End of Travel and Home Limit Input Connections 51
Figure 2-21: End of Travel and Home Limit Input Schematic (Feedback Connector) 51
Figure 2-22: End of Travel and Home Limit Input Diagnostic Display 52
Figure 2-23: Brake Output Connections (Feedback Connector) 53
Figure 2-24: PSO Output Sources Current 55
Figure 2-25: PSOOutput Sinks Current 55
Figure 2-26: PSO TTLOutputs Schematic 56
Figure 2-27: PSO Clock Inputs Schematic 57
Figure 2-28: DataAcquisition Input Schematic 58
Figure 2-29: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs 60
Figure 2-30: Digital Output Schematic 63
Figure 2-31: Digital Outputs Connected in Current Sourcing Mode 64
Figure 2-32: Outputs Connected in Current Sinking Mode 64
Figure 2-33: Digital Input Schematic 66
Figure 2-34: Digital Inputs Connected to Current Sinking (NPN) Devices 67
Figure 2-35: Digital Inputs Connected to Current Sourcing (PNP) Devices 67
Figure 2-36: Square Wave Encoder Interface (Aux EncoderConnector) 69
Figure 2-37: Absolute Encoder Schematic (Aux Encoder Connector) 70
Figure 2-38: Sine Wave Encoder Phasing Reference Diagram 71
Figure 2-39: Sine Wave Encoder Schematic (AuxEncoder Connector) 72
Figure 2-40: Analog Outputs Schematic 74
Figure 2-41: Analog Inputs Schematic 75
Figure 2-42: Joystick Interface Inputs Schematic 76
Figure 2-43: Joystick Cable Wiring Schematic 77
Figure 2-44: Typical Configuration 79
Figure 2-45: STO Timing 83
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Figure 2-46: Location of the Rear Fan and Air Flow 85
Figure 2-47: -C0 Fan Location and Direction of Air Flow 85
Figure 2-48: -C1 Model Showing Perforated Covers for External Fans 86
Figure 2-49: -C2 1U Fan Location and Air Flow 87
Figure 3-1: Drive Interface Board 91
Figure B-1: Voltage Selection Switch Access 96
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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: Hall Signal Diagnostics 36
Table 2-7: Feedback Connector Pinout 40
Table 2-8: Mating Connector Part Numbers for the Feedback Connector 40
Table 2-9: Multiplier Options 41
Table 2-10: Primary Encoder Input Pins on the Feedback Connector 41
Table 2-11: Square Wave Encoder Specifications 42
Table 2-12: Sine Wave Encoder Specifications 44
Table 2-13: Hall-Effect Feedback Pins on the Feedback Connector 47
Table 2-14: Thermistor Input Pin on the Feedback Connector 48
Table 2-15: Encoder Fault Input Pin on the Feedback Connector 49
Table 2-16: End of Travel and Home Limit Pins on the Feedback Connector 50
Table 2-17: Brake Output Pins on the Feedback Connector 53
Table 2-18: Brake Output Specifications 53
Table 2-19: PSOConnector Pinout 54
Table 2-20: PSOSpecifications 54
Table 2-21: PSOIsolated Output Specification 55
Table 2-22: Isolated Output Pins on the PSOConnector 55
Table 2-23: PSOTTLOutputs Specification 56
Table 2-24: TTLOutput Pins on the PSOConnector 56
Table 2-25: External PSO Sync Input Pins on the PSO Connector 57
Table 2-26: Data Acquisition Input Pins on the PSOConnector 58
Table 2-27: DataAcquisition Opto-Isolator Input Specifications 58
Table 2-28: High-Speed Output Specifications 59
Table 2-29: HSOUTConnector Pinout 59
Table 2-30: Mating Connector Part Numbers for the HSOUTConnector 59
Table 2-31: Digital Output Specifications 61
Table 2-32: DOUTConnector Digital Outputs Pinout 62
Table 2-33: Mating Connector Part Numbers for the DOUTConnector 62
Table 2-34: DINConnector Digital Inputs Pinout 65
Table 2-35: Mating Connector Part Numbers for the DINConnector 65
Table 2-36: Digital Input Specifications 65
Table 2-37: AuxEncoder Connector Pinout 68
Table 2-38: Mating Connector Part Numbers for the Aux Encoder Connectors 68
Table 2-39: Square Wave Encoder Specifications 69
Table 2-40: Sine Wave Encoder Specifications 71
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Table 2-41: AnalogI/OConnector Pinout 73
Table 2-42: Mating Connector Part Numbers for the AnalogI/OConnectors 73
Table 2-43: Analog Output Specifications 74
Table 2-44: Analog Output Pins on the Analog I/OConnector 74
Table 2-45: Analog Input Specifications 75
Table 2-46: Analog Input Pins on the Analog I/O Connector 75
Table 2-47: Joystick Interface Pins on the Analog I/OConnectors 76
Table 2-48: STO Connector Pinout 78
Table 2-49: Mating Connector Part Numbers for the STOConnector 78
Table 2-50: STOElectrical Specifications 79
Table 2-51: STOStandards 80
Table 2-52: STOStandards Data 80
Table 2-53: STOSignal Delay 82
Table 2-54: Motor Function Relative to STOInput State 82
Table 2-55: STOTiming 83
Table 2-56: HyperWire Card Part Number 84
Table 2-57: HyperWire Cable Part Numbers 84
Table 3-1: LEDDescription 89
Table 3-2: Troubleshooting 89
Table 3-3: Preventative Maintenance 90
Table 3-4: Drive Interface Board Motor Power Fuse Replacement Part Numbers 91
Table B-1: AC Voltage Selector Switch Settings 96
List of Tables XR3 Hardware Manual
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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 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.
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 3/26/2021
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Agency Approvals
Aerotech tested its XR3 drive racks and found that they obey the standards that follow:
Approval: 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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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
XR3.
lRead all parts of this manual before you install or operate the XR3 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 XR3 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
electrical 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.
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WARNING: 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.
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 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.
1Connect the power source to the AC Power Input. Section 2.1.1.
2Connect a PCHyperWire port to the HyperWire Inport. Section 2.11.
3Connect the motors to the Motor Power inputs. Section 2.2.
4Connect the motors to the Motor Feedback inputs. Section 2.3.
Figure 1: Installation ConnectionOverview
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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 2.2.
l6 channels of line driver square wave or optional analog sine wave quadrature
encoder position and/or velocity feedback
Section 2.3.
lSingle axis PSO (Laser Firing) standard (2- and 3-axis firing optional) Section 2.4.
Auxiliary Power Outputs
l+5 V provided on all axis feedback connectors for encoder, Hall, and limit power Section 2.3.
l+5 Vprovided on I/O connectors Section 2.8.
I/O
lBrake Output Section 2.3.
lThree PSO External Sync inputs Section 2.4.
lThree TTL or isolated PSOoutputs Section 2.4.2.
lOne Data Acquisition Input Section 2.4.4.
lUp to 12 High Speed Differential outputs Section 2.5.
l16 digital outputs Section 2.6.
l16 digital inputs Section 2.7.
lTwo 16-bit analog outputs per axis Section 2.9.1.
lTwo 16-bit differential analog inputs per axis; two inputs used for joystick inputs Section 2.9.2.
lThree dedicated joystick digital inputs Section 2.9.3.
lTwo STOsense Inputs Section 2.10.
Feedback / Limit Inputs
lEncoder / Marker Inputs (primary) Section 2.3.1.
lHall Inputs (3 per axis) Section 2.3.2.
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 2.3.3.
nEncoder Fault Section 2.3.4.
lCW, CCW, and Home Limit Inputs Section 2.3.5.
lEncoder / Marker Inputs (auxiliary) Section 2.8.
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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 2.3.1.3.
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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Cooling Options Section 2.12.
-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 2.4.
-PSO1 One-axis PSO firing (includes One-axis Part-Speed PSO)
-PSO2 Two-axis PSO firing (includes Two-axis Part-Speed PSO)
-PSO3 Three-axis PSO firing (includes Three-axis Part-Speed PSO)
-PSO5 Two-axis Part-Speed PSO firing, which uses the PSO firing circuit based off of the
commanded vector velocity of up to 2 axes (includes One-Axis 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).
Internal Shunt Section 2.1.4.
-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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The block diagram that follows shows a summary of the connector signals.
Figure 1-1: Functional Diagram
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