Aerotech Ensemble CL User manual

P/N:EDU189
Revision: 4.09.00
Ensemble CL
Hardware Manual
RELAY TB206
NC
C
NO
OPTO IN TB205
+5V
C
0
1
2
3
4
5
6
7
OPTO IN TB204
C
0
1
2
3
4
5
6
7
GND
OPTO OUT TB203
OP
OM
0
1
2
3
4
5
6
7
OPTO OUT TB202
OP
OM
0
1
2
3
4
5
6
7
TB201
AGND
AIN+
AIN-
AOUT
J103
ETHERNET
AEROTECH.AEROTECH.
COMCOM
TM
J103
ETHERNET
AEROTECH.AEROTECH.
COMCOM
TM
J104
MOTOR FEEDBACK
ESTOP
TB101
J105
MOTOR
SUPPLY MOTOR
OUTPUT
TB102
28 VAC 10A MAX
0 VAC-CT
EXTERNAL
TRANSFORMER
REQUIRED
50/60Hz
A
B
High Voltage
DANGER!
C
ENB/FLT
MARKER
POWER
INPOS
AUX I/O
J104
MOTOR FEEDBACK
ESTOP
TB101
J105
MOTOR
SUPPLY MOTOR
OUTPUT
TB102
28 VAC 10A MAX
28 VAC 10A MAX 28 VAC 10A MAX
0 VAC-CT
EXTERNAL
TRANSFORMER
REQUIRED
50/60Hz
A
B
High Voltage
DANGER!
C
ENB/FLT
MARKER
POWER
INPOS
AUX I/O

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]
Fax: [phone]
Email: [e-mail]
Phone: [phone]
Email: [e-mail]
France Taiwan
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 © 2007-2015, Aerotech, Inc. All rights reserved.

Table of Contents Ensemble CL
Table of Contents
Table of Contents iii
List of Figures v
List of Tables vii
EC Declaration of Conformity ix
Safety Procedures and Warnings xi
Quick Installation Guide xiii
Chapter 1: Introduction 1
1.1. Drive and Software Compatibility 4
1.2. Electrical Specifications 5
1.2.1. System Power Requirements 6
1.3. Mechanical Design 7
1.4. Environmental Specifications 8
Chapter 2: Installation and Configuration 9
2.1. Power Connections 9
2.1.1. Control Supply Connections (TB103) 10
2.1.2. Motor Supply Connections (TB102) 11
2.1.3. Transformer Options 12
2.2. Motor Output Connections 15
2.2.1. Brushless Motor Connections 16
2.2.1.1. Powered Motor Phasing 17
2.2.1.2. Unpowered Motor and Feedback Phasing 19
2.2.2. DC Brush Motor Connections 22
2.2.2.1. DC Brush Motor Phasing 23
2.2.3. Stepper Motor Connections 24
2.2.3.1. Stepper Motor Phasing 25
2.3. Motor Feedback Connections (J104) 26
2.3.1. Encoder Interface (J104) 27
2.3.1.1. RS-422 Line Driver Encoder (Standard) 28
2.3.1.2. EnDat Encoder Interface (J104) 29
2.3.1.3. Resolute Encoder Interface (J104) 30
2.3.1.4. Analog Encoder Interface 31
2.3.1.5. Encoder Phasing 33
2.3.2. Hall-Effect Interface (J104) 35
2.3.3. Thermistor Interface (J104) 36
2.3.4. Encoder Fault Interface (J104) 37
2.3.5. End Of Travel Limit Input Interface (J104) 38
2.3.5.1. End Of Travel Limit Phasing 40
2.3.6. Brake Output (J104) 41
2.4. Emergency Stop Sense Input (TB101) 42
2.4.1. Typical ESTOP Interface 43
2.5. Auxiliary I/O Connector (J105) 44
2.5.1. Auxiliary Encoder Channel (J105) 45
2.5.2. Position Synchronized Output (PSO)/Laser Firing (J105) 47
2.5.3. Opto-Isolated Outputs (J105) 49
2.5.4. Opto-Isolated Inputs (J105) 51
2.5.5. High Speed User Inputs 4-5 (J105) 53
2.5.6. Analog Output 0 (J105) 54
2.5.7. Analog Input 0 (J105) 55
2.6. Aeronet Interface (J107/J108) 56
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2.7. RS-232 Interface (TB104) 57
2.8. PC Configuration and Operation Information 58
Chapter 3: -I/O Expansion Board 59
3.1. Analog Output (TB201) 60
3.2. Analog Input (TB201) 61
3.3. Opto-Isolated Inputs (TB204, TB205) 62
3.4. Opto-Isolated Outputs (TB202, TB203) 65
3.5. User Power (TB204, TB205) 69
3.6. Brake / Mechanical Relay (TB206) 70
3.6.1. Brake Configuration Jumpers 70
3.6.2. Mechanical Relay Specifications 70
3.6.3. Brake / Mechanical Relay Interface Connector 71
Chapter 4: Standard Interconnection Cables 73
4.1. Joystick Interface 74
4.2. Handwheel Interface 76
Chapter 5: Maintenance 77
5.1. Control Board 78
5.2. Preventative Maintenance 80
Appendix A: Warranty and Field Service 81
Appendix B: Revision History 83
Index 85
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Table of Contents Ensemble CL
List of Figures
Figure 1-1: Ensemble CL Networked Digital Drive 1
Figure 1-2: Functional Diagram 3
Figure 1-3: Dimensions 7
Figure 2-1: Control Supply Connections 10
Figure 2-2: Motor Bus Input Connections 11
Figure 2-3: Transformer Examples 12
Figure 2-4: 40 VDC Motor Power with a TV0.3-28-56-ST Transformer 13
Figure 2-5: Control and Motor Power Wiring using a TM3 or TM5 Transformer 14
Figure 2-6: Brushless Motor Configuration 16
Figure 2-7: Encoder and Hall Signal Diagnostics 18
Figure 2-8: Motor Phasing Oscilloscope Example 19
Figure 2-9: Hall Phasing with Oscilloscope 20
Figure 2-10: Brushless Motor Phasing Goal 21
Figure 2-11: DC Brush Motor Configuration 22
Figure 2-12: Clockwise Motor Rotation 23
Figure 2-13: Stepper Motor Configuration 24
Figure 2-14: Clockwise Motor Rotation 25
Figure 2-15: Line Driver Encoder Interface (J104) 28
Figure 2-16: Serial Data Stream Interface 29
Figure 2-17: Serial Data Stream Interface 30
Figure 2-18: Analog Encoder Phasing Reference Diagram 31
Figure 2-19: Analog Encoder Interface (J104) 32
Figure 2-20: Encoder Phasing Reference Diagram (Standard) 33
Figure 2-21: Position Feedback in the DiagnosticDisplay 34
Figure 2-22: Hall-Effect Inputs (J104) 35
Figure 2-23: Thermistor Interface Input (J104) 36
Figure 2-24: Encoder Fault Interface Input (J104) 37
Figure 2-25: End of Travel Limit Input Connections 38
Figure 2-26: End of Travel Limit Interface Input (J104) 39
Figure 2-27: Limit Input Diagnostic Display 40
Figure 2-28: ESTOPSenseInput (TB101) 42
Figure 2-29: Typical Emergency Stop Circuit 43
Figure 2-30: Auxiliary Encoder Channel (J105) 46
Figure 2-31: PSOInterface 48
Figure 2-32: Outputs Connected in Current Sinking Mode (J105) 50
Figure 2-33: Outputs Connected in Current Sourcing Mode (J105) 50
Figure 2-34: Inputs Connected in Current Sinking Mode (J105) 52
Figure 2-35: Inputs Connected in Current Sourcing Mode (J105) 52
Figure 2-36: High Speed User Inputs (J105) 53
Figure 2-37: Analog Output 0 (J105) 54
Figure 2-38: Analog Input 0 (J105) 55
Figure 2-39: Aeronet Connection with Three Discrete Drives 56
Figure 2-40: RS-232 Interface (TB104) 57
Figure 3-1: Ensemble CL with -IO Option Board 59
Figure 3-2: Analog Output 1 Connector (TB201) 60
Figure 3-3: Analog Input Typical Connection (TB201) 61
Figure 3-4: Opto-Isolated Inputs 63
Figure 3-5: Inputs Connected to a Current Sourcing Device 64
Figure 3-6: Inputs Connected to a Current Sinking Device 64
Figure 3-7: Opto-Isolated Outputs (-IOBoard) 66
Figure 3-8: Outputs Connected in Current Sourcing Mode 67
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Figure 3-9: Outputs Connected in Current Sinking Mode 68
Figure 3-10: Brake Connected to J104 71
Figure 3-11: Brake Connected to TB206 72
Figure 4-1: Single Axis Joystick Interface (to Aux I/O) 74
Figure 4-2: Two Axis Joystick Interface (to the Aux I/O of two drives) 74
Figure 4-3: Two Axis Joystick Interface (to the Aux I/O and I/O Board) 75
Figure 4-4: Handwheel Interconnection (to Aux I/O) 76
Figure 4-5: Handwheel Interconnection (to Aux I/O via a BBA32 Module) 76
Figure 5-1: Control Board Assembly 78
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Table of Contents Ensemble CL
List of Tables
Table 1-1: FeatureSummary 2
Table 1-2: Accessories 2
Table 1-3: Ensemble Drive and Software Compatibility 4
Table 1-4: Electrical Specifications 5
Table 1-5: Physical Specifications 7
Table 2-1: Control Supply ACInput Wiring 10
Table 2-2: Control Supply Mating Connector 10
Table 2-3: Motor Supply Mating Connector 11
Table 2-4: TransformerOptions 12
Table 2-5: Motor Power Output Connections (TB102) 15
Table 2-6: Motor Power Output Mating Connector 15
Table 2-7: Wire Colors for Aerotech Supplied Cables (Brushless) 16
Table 2-8: Wire Colors for Aerotech Supplied Cables (DCBrush) 22
Table 2-9: Wire Colors for Aerotech Supplied Cables (Stepper) 24
Table 2-10: Motor Feedback Connector Pin Assignment (J104) 26
Table 2-11: Encoder Interface Pin Assignment 27
Table 2-12: Analog Encoder Specifications 31
Table 2-13: Hall-Effect Feedback Interface Pin Assignment (J104) 35
Table 2-14: Hall-Effect Feedback Interface Pin Assignment (J104) 36
Table 2-15: Encoder Fault Interface Pin Assignment (J104) 37
Table 2-16: End of Travel Limit Input Interface Pin Assignment (J104) 38
Table 2-17: Brake Output Pin Assignment (J104) 41
Table 2-18: Electrical Noise Suppression Devices 42
Table 2-19: Electrical Noise Suppression Devices 42
Table 2-20: TB101 Mating Connector 42
Table 2-21: Typical ESTOPRelay Ratings 43
Table 2-22: Auxiliary I/O Connector Pin Assignment (J105) 44
Table 2-23: Auxiliary Encoder Channel Pin Assignment (J105) 45
Table 2-24: PSOOutput Pin Assignment (J105) 47
Table 2-25: PSO Output Sources 47
Table 2-26: Port 0 Digital Output Connector Pin Assignment (J105) 49
Table 2-27: Digital Output Specifications 49
Table 2-28: Port 0 Digital Input Connector Pin Assignment (J105) 51
Table 2-29: PS2806-4 Opto-Device Specifications 51
Table 2-30: Port 0 High Speed Digital Input Connector Pin Assignment (J105) 53
Table 2-31: Input Voltage Jumper Configuration 53
Table 2-32: Analog Output Connector Pin Assignment (J105) 54
Table 2-33: Analog Input Connector Pin Assignment (J105) 55
Table 2-34: Aeronet Cable Part Numbers 56
Table 2-35: RS-232 Connector Pin Assignment (TB104) 57
Table 2-36: RS-232 Port Connector Mating Connector (TB104) 57
Table 3-1: -IO Expansion Board Jumper Configuration 59
Table 3-2: -IO Option Board Fuse Information 59
Table 3-3: Analog Output Connector Pin Assignment (TB201) 60
Table 3-4: Analog Output Mating Connector 60
Table 3-5: Analog Inputs Connector Pin Assignment (TB201) 61
Table 3-6: Analog Input Mating Connector 61
Table 3-7: PS2806-4 Opto-Device Specifications 62
Table 3-8: Port 1 Opto-Isolated Input Connector Pin Assignment (TB204) 62
Table 3-9: Port 2 Opto-Isolated Input Connector Pin Assignment (TB205) 62
Table 3-10: Opto-Isolated Input Mating Connector 62
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Table 3-11: Port 1 Opto-Isolated Output Connector Pin Assignment (TB202) 65
Table 3-12: Port 2 Opto-Isolated Output Connector Pin Assignment (TB203) 65
Table 3-13: Opto-Isolated Output Mating Connector 65
Table 3-14: Output Specifications (TB202, TB203) 67
Table 3-15: User Common Connector Pin Assignment (TB204) 69
Table 3-16: +5 Volt Power Connector Pin Assignment (TB205) 69
Table 3-17: -IO Expansion Board Brake Jumper Configuration 70
Table 3-18: Voltage and Current Specifications (TB206) 70
Table 3-19: Brake / Mechanical Relay Connector Pin Assignment (TB206) 71
Table 3-20: Mating Connector 71
Table 3-21: Brake / Mechanical Relay Connector Pin Assignment (J104) 71
Table 4-1: Standard Interconnection Cables 73
Table 4-2: Cable Part Numbers 75
Table 5-1: LEDDescription 77
Table 5-2: Control Board Jumper Configuration 79
Table 5-3: Control Board Fuse Information 79
Table 5-4: LEDDescription 79
Table 5-5: Preventative Maintenance 80
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Declaration of Conformity Ensemble CL
EC Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Product Ensemble CL
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2006/95/EC Low Voltage Directive
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 61000-4-3 Radiated RFI/EMI Immunity
EN 61010-1 Safety requirements for electrical equipment
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date July 9, 2015
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