Aerotech Ensemble CP Series User manual

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Instra

MOTOR FEEDBACK
J103
ESTOP
TB101
ENB/FLT
MARKER
AUX I/O
J104
MOTOR FEEDBACK J103
ESTOP TB101
ENB/FLT
MARKER
RELAY TB206
NC
C
NO
OPTO IN TB205
OPTO IN TB204
C
0
1
2
3
4
5
6
7
GND
OPTO OUT TB203
OPTO OUT TB202
OP
OM
0
1
2
3
4
5
6
7
TB201
AGND
AIN+
AIN-
AOUT
AUX I/O J104
ETHERNET
J102
AEROTECH.AEROTECH.
COMCOM
TMTM
C
0
1
2
3
4
5
6
7
+5V
OP
OM
0
1
2
3
4
5
6
7
AEROTECH.AEROTECH.
COMCOM
TMTM
ETHERNET J102
High Voltage
DANGER!
MOTOR SUPPLY MOTOR OUTPUT
AC1
AC2
A
B
C
240V~
MAX
50/60Hz
15A MAX
PWR
INPOS
TB102
High Voltage
DANGER!
MOTOR SUPPLY MOTOR OUTPUT
AC1
AC2
A
B
C
240V~
MAX
50/60Hz
15A MAX
PWR
INPOS
TB102
Revision: 4.07.00
Ensemble CPHardware Manual
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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]
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Email: [e-mail]
Phone: [phone]
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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 © 2006-2017, Aerotech, Inc., All rights reserved.
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Table of Contents Ensemble CP
Table of Contents
Ensemble CPHardware Manual 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
Quick Installation Guide 13
Chapter 1: Introduction 15
1.1. Drive and Software Compatibility 18
1.2. Electrical Specifications 19
1.2.1. System Power Requirements 20
1.2.2. Power Dissipation 21
1.3. Mechanical Design 22
1.4. Environmental Specifications 23
Chapter 2: Installation and Configuration 25
2.1. Power Connections 25
2.1.1. Control Supply Connections (TB106) 26
2.1.2. Motor Supply Connections (TB102) 27
2.1.3. Transformer Options 28
2.1.4. Minimizing Conducted, Radiated, and System Noise 35
2.2. Motor Output Connections 36
2.2.1. Brushless Motor Connections 37
2.2.1.1. Powered Motor Phasing 38
2.2.1.2. Unpowered Motor and Feedback Phasing 39
2.2.2. DC Brush Motor Connections 40
2.2.2.1. DC Brush Motor Phasing 41
2.2.3. Stepper Motor Connections 42
2.2.3.1. Stepper Motor Phasing 43
2.3. Motor Feedback Connections (J103) 44
2.3.1. Encoder Interface (J103) 45
2.3.1.1. RS-422 Line Driver Encoder (Standard) 46
2.3.1.2. EnDat Encoder Interface (J103) 47
2.3.1.3. Resolute Encoder Interface (J103) 48
2.3.1.4. Analog Encoder Interface 49
2.3.1.5. Encoder Phasing 51
2.3.2. Hall-Effect Interface (J103) 53
2.3.3. Thermistor Interface (J103) 54
2.3.4. Encoder Fault Interface (J103) 55
2.3.5. End Of Travel Limit Input Interface (J103) 56
2.3.5.1. End Of Travel Limit Phasing 58
2.3.6. Brake Output (J103) 59
2.4. Emergency Stop Sense Input (TB101) 60
2.4.1. Typical ESTOP Interface 61
2.5. Auxiliary I/O Connector (J104) 62
2.5.1. Auxiliary Encoder Channel (J104) 63
2.5.2. Position Synchronized Output (PSO)/Laser Firing (J104) 65
2.5.3. Opto-Isolated Outputs (J104) 67
2.5.4. Opto-Isolated Inputs (J104) 69
2.5.5. High-Speed User Inputs 4-5 (J104) 71
2.5.6. Analog Output 0 (J104) 72
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2.5.7. Differential Analog Input 0 (J104) 73
2.6. Brake Power Supply (TB103) 74
2.6.1. Solid State Relay Specifications (TB103) 77
2.7. Aeronet Interface (J107/J108) 78
2.8. RS-232 Interface (TB103) 79
2.9. -EXTSHUNT Option (TB104) 80
2.10. PC Configuration and Operation Information 83
Chapter 3: -I/O Expansion Board 85
3.1. Analog Output (TB201) 86
3.2. Analog Input (TB201) 87
3.3. Opto-Isolated Inputs (TB204, TB205) 88
3.4. Opto-Isolated Outputs (TB202, TB203) 91
3.5. User Power (TB204, TB205) 95
3.6. Brake / Mechanical Relay (TB206) 96
3.6.1. Brake Configuration Jumpers 96
3.6.2. Mechanical Relay Specifications 96
3.6.3. Brake / Mechanical Relay Interface Connector 97
Chapter 4: Standard Interconnection Cables 99
4.1. Joystick Interface 100
4.2. Handwheel Interface 103
Chapter 5: Maintenance 105
5.1. Control Board 106
5.2. Preventative Maintenance 108
Appendix A: Warranty and Field Service 109
Appendix B: Revision History 111
Index 113
Ensemble CP Table of Contents
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Table of Contents Ensemble CP
List of Figures
Figure 1-1: Ensemble CP Networked Digital Drive 15
Figure 1-2: Functional Diagram 17
Figure 1-3: Power Dissipation vs. Output Current 21
Figure 1-4: Ambient Temperature vs. Power Dissipation 21
Figure 1-5: Dimensions 22
Figure 2-1: Control Supply Connections 26
Figure 2-2: Motor Bus Input Connections 27
Figure 2-3: Transformer Examples 28
Figure 2-4: 40 VDC Motor Power with a TV0.3-28-56-ST Transformer 29
Figure 2-5: 80 VDC Motor Power with a TV0.3-28-56-ST Transformer 30
Figure 2-6: 40 Volt DC Bus from 115 and 230 VAC Source 31
Figure 2-7: 80 Volt DC Bus from 115 and 230 VAC Source (TV0.3-56) 32
Figure 2-8: 160 Volt DC Bus from 115 and 230 VAC Source (TV0.3-56) 33
Figure 2-9: Control and Motor Power Wiring using a TM3 or TM5 Transformer 34
Figure 2-10: ACLine Filter (UFM-ST) 35
Figure 2-11: Brushless Motor Configuration 37
Figure 2-12: Encoder and Hall Signal Diagnostics 38
Figure 2-13: Motor Phasing Oscilloscope Example 39
Figure 2-14: Brushless Motor Phasing Goal 39
Figure 2-15: DC Brush Motor Configuration 40
Figure 2-16: Clockwise Motor Rotation 41
Figure 2-17: Stepper Motor Configuration 42
Figure 2-18: Clockwise Motor Rotation 43
Figure 2-19: Line Driver Encoder Interface (J103) 46
Figure 2-20: Serial Data Stream Interface 47
Figure 2-21: Serial Data Stream Interface 48
Figure 2-22: Analog Encoder Phasing Reference Diagram 49
Figure 2-23: Analog Encoder Interface (J103) 50
Figure 2-24: Encoder Phasing Reference Diagram (Standard) 51
Figure 2-25: Position Feedback in the DiagnosticDisplay 52
Figure 2-26: Hall-Effect Inputs (J103) 53
Figure 2-27: Thermistor Interface Input (J103) 54
Figure 2-28: Encoder Fault Interface Input (J103) 55
Figure 2-29: End of Travel Limit Input Connections 56
Figure 2-30: End of Travel Limit Interface Input (J103) 57
Figure 2-31: Limit Input Diagnostic Display 58
Figure 2-32: ESTOPSenseInput (TB101) 60
Figure 2-33: Typical Emergency Stop Circuit 61
Figure 2-34: Auxiliary Encoder Channel (J104) 64
Figure 2-35: PSOInterface 66
Figure 2-36: Outputs Connected in Current Sourcing Mode (J104) 68
Figure 2-37: Outputs Connected in Current Sinking Mode (J104) 68
Figure 2-38: Inputs Connected in Current Sourcing Mode (J104) 70
Figure 2-39: Inputs Connected in Current Sinking Mode (J104) 70
Figure 2-40: High-Speed User Inputs (J104) 71
Figure 2-41: Analog Output 0 (J104) 72
Figure 2-42: Analog Input 0 (J104) 73
Figure 2-43: Brake Connected to J103 75
Figure 2-44: Brake Connected to TB103 76
Figure 2-45: Aeronet Connection with Three Discrete Drives 78
Figure 2-46: RS-232 Interface (TB103) 79
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Figure 3-1: Ensemble CP with -IO Option Board 85
Figure 3-2: Analog Output Connector (TB201) 86
Figure 3-3: Analog Input Typical Connection (TB201) 87
Figure 3-4: Opto-Isolated Inputs 89
Figure 3-5: Inputs Connected to a Current Sourcing Device 90
Figure 3-6: Inputs Connected to a Current Sinking Device 90
Figure 3-7: Opto-Isolated Outputs (-IOBoard) 93
Figure 3-8: Outputs Connected in Current Sourcing Mode 94
Figure 3-9: Outputs Connected in Current Sinking Mode 94
Figure 3-10: Brake Connected to J103 98
Figure 3-11: Brake Connected to TB206 98
Figure 4-1: Single Axis Joystick Interface (to Aux I/O) 100
Figure 4-2: Two Axis Joystick Interface (to the Aux I/O of two drives) 101
Figure 4-3: Two Axis Joystick Interface (to the Aux I/O and I/O Board) 101
Figure 4-4: Two Axis Joystick Interface (to the I/Oboard of two drives) 102
Figure 4-5: Handwheel Interconnection (to Aux I/O) 103
Figure 4-6: Handwheel Interconnection (to Aux I/O via a BBA32 Module) 104
Figure 5-1: Control Board Assembly 106
Ensemble CP Table of Contents
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Table of Contents Ensemble CP
List of Tables
Table 1-1: FeatureSummary 16
Table 1-2: Drive and Software Compatibility 18
Table 1-3: Electrical Specifications 19
Table 1-4: Physical Specifications 22
Table 2-1: Control Supply ACInput Wiring 26
Table 2-2: Control Supply Mating Connector 26
Table 2-3: Motor Supply Mating Connector 27
Table 2-4: Nominal Motor Operating Voltages / Required ACVoltages 28
Table 2-5: TransformerOptions 28
Table 2-6: FerriteNoise Suppression Numbers 35
Table 2-7: UFM-STElectrical Specifications 35
Table 2-8: Motor Power Output Connections (TB102) 36
Table 2-9: Motor Power Output Mating Connector 36
Table 2-10: Wire Colors for Aerotech Supplied Cables (Brushless) 37
Table 2-11: Wire Colors for Aerotech Supplied Cables (DCBrush) 40
Table 2-12: Wire Colors for Aerotech Supplied Cables (Stepper) 42
Table 2-13: Motor Feedback Connector Pin Assignment (J103) 44
Table 2-14: Encoder Interface Pin Assignment 45
Table 2-15: Encoder Specifications 46
Table 2-16: Analog Encoder Specifications 49
Table 2-17: Hall-Effect Feedback Interface Pin Assignment (J103) 53
Table 2-18: Thermistor Interface Pin Assignment (J103) 54
Table 2-19: Encoder Fault Interface Pin Assignment (J103) 55
Table 2-20: End of Travel Limit Input Interface Pin Assignment (J103) 56
Table 2-21: Brake Output Pin Assignment (J103) 59
Table 2-22: Electrical Noise Suppression Devices 60
Table 2-23: TB101 Mating Connector 60
Table 2-24: Typical ESTOPRelay Ratings 61
Table 2-25: Auxiliary I/O Connector Pin Assignment (J104) 62
Table 2-26: Auxiliary Encoder Specifications 63
Table 2-27: Auxiliary Encoder Channel Pin Assignment (J104) 63
Table 2-28: PSO Specifications 65
Table 2-29: PSOOutput Pin Assignment (J104) 65
Table 2-30: Digital Output Specifications 67
Table 2-31: Port 0 Digital Output Connector Pin Assignment (J104) 67
Table 2-32: Opto-Isolated Input Specifications 69
Table 2-33: Port 0 Digital Input Connector Pin Assignment (J104) 69
Table 2-34: High-Speed Input Specifications 71
Table 2-35: Port 0 High Speed Digital Input Connector Pin Assignment (J104) 71
Table 2-36: Input Voltage Jumper Configuration 71
Table 2-37: Analog Output 0 Specifications (TB102B) 72
Table 2-38: Analog Output Connector Pin Assignment (J104) 72
Table 2-39: Differential Analog Input 0 Specifications 73
Table 2-40: Analog Input Connector Pin Assignment (J104) 73
Table 2-41: Brake Output Connector Pin Assignment (TB103) 74
Table 2-42: Mating Connector (TB103) 74
Table 2-43: Brake Output Connector Pin Assignment (J103) 74
Table 2-44: Relay Specifications 77
Table 2-45: Aeronet Cable Part Numbers 78
Table 2-46: RS-232 Connector Pin Assignment (TB103) 79
Table 2-47: RS-232 Port Connector Mating Connector (TB103) 79
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Table 2-48: -EXTSHUNTComponent Information 80
Table 2-49: Maximum Storage Energy 81
Table 3-1: -IO Expansion Board Jumper Configuration 85
Table 3-2: -IO Option Board Fuse Information 85
Table 3-3: Analog Output Specifications (TB102B) 86
Table 3-4: Analog Output Connector Pin Assignment (TB201) 86
Table 3-5: Analog Output Mating Connector 86
Table 3-6: Differential Analog Input 1 Specifications 87
Table 3-7: Analog Inputs Connector Pin Assignment (TB201) 87
Table 3-8: Analog Input Mating Connector 87
Table 3-9: Opto-Isolated Input Device Specifications 88
Table 3-10: Port 1 Opto-Isolated Input Connector Pin Assignment (TB204) 88
Table 3-11: Port 2 Opto-Isolated Input Connector Pin Assignment (TB205) 88
Table 3-12: Opto-Isolated Input Mating Connector 88
Table 3-13: Output Specifications (TB202, TB203) 91
Table 3-14: Port 1 Opto-Isolated Output Connector Pin Assignment (TB202) 92
Table 3-15: Port 2 Opto-Isolated Output Connector Pin Assignment (TB203) 92
Table 3-16: Opto-Isolated Output Mating Connector 92
Table 3-17: User Common Connector Pin Assignment (TB204) 95
Table 3-18: +5 Volt Power Connector Pin Assignment (TB205) 95
Table 3-19: -IO Expansion Board Brake Jumper Configuration 96
Table 3-20: Voltage and Current Specifications (TB206) 96
Table 3-21: Brake / Mechanical Relay Connector Pin Assignment (TB206) 97
Table 3-22: Mating Connector for TB206 97
Table 3-23: Brake / Mechanical Relay Connector Pin Assignment (J103) 97
Table 4-1: Standard Interconnection Cables 99
Table 4-2: Cable Part Numbers 102
Table 5-1: LEDDescription 105
Table 5-2: Control Board Jumper Configuration 107
Table 5-3: Control Board Fuse Information 107
Table 5-4: LEDDescription 107
Table 5-5: Preventative Maintenance 108
Ensemble CP Table of Contents
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Declaration of Conformity Ensemble CP
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Ensemble CP
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 Directive
2014/35/EU Low Voltage Directive LVD
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 55011:1998 RFI Limits and Measurement
EN 61800-3:2004 EMC requirements for power drives
EN 61000-3-2:2000 Harmonic Current Emissions
EN 61000-3-3:1995 Voltage Fluctuation and Flicker
EN 61000-4-2:1995 ESD Immunity
EN 61000-4-3:2002 Radiated RFI/EMI Immunity
EN 61000-4-4:1995 EFT/Burst Immunity
EN 61000-4-5:1995 Surge Immunity
EN 61000-4-6:1996 Conducted Immunity
EN 61000-4-11:1994 Voltage Dips and Interruptions
EN 61010-1:2010 Safety requirements for electrical equipment
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
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