AEROTECH EDU209 Epaq MR Stand Alone Controller and Drive Rack User Manual

June 14, 2024
aerotech

EDU209 Epaq MR Stand Alone Controller and Drive Rack

Product Information

Specifications

  • P/N: EDU209
  • Revision: 1.07.00a
  • Manufacturer: Aerotech, Inc.
  • Website: www.aerotech.com

Product Usage Instructions

Chapter 1: Introduction

The Epaq MR is a hardware device manufactured by Aerotech, Inc.
It is designed for various applications and offers a range of
features and functionalities. This chapter provides an overview of
the product and its electrical, mechanical, environmental
specifications, as well as drive and software compatibility.

Chapter 2: Installation and Configuration

This chapter explains the steps required to install and
configure the Epaq MR. It covers topics such as unpacking the
chassis, electrical installation, motor output connections, motor
feedback connections, digital/analog IO connections, and
communications connector.

2.1. Unpacking the Chassis

Before starting the installation process, carefully unpack the
Epaq MR chassis and ensure all components are present and
undamaged.

2.2. Electrical Installation

To ensure proper functioning of the Epaq MR, follow the
instructions provided for AC power connections, minimizing
conducted, radiated, and system noise, I/O and signal wiring
requirements, and voltage selection.

2.3. Motor Output Connections

This section explains how to connect different types of motors
to the Epaq MR, including brushless motors, DC brush motors, and
stepper motors. It also provides instructions for motor
phasing.

2.4. Motor Feedback Connections

The Epaq MR supports various types of motor feedback, including
encoder inputs, hall-effect inputs, thermistor input, encoder fault
input, end of travel limit inputs, brake output, and differential
analog input 0. This section provides detailed instructions on how
to connect and configure these feedback connections.

2.5. Digital/Analog IO Connections

Learn how to connect and configure analog input 1, analog output
1, opto-isolated outputs, and opto-isolated inputs in this
section.

2.6. Aux Encoder

If you require an auxiliary encoder for your application, this
section provides instructions on how to connect and configure it.
It also explains the position synchronized output (PSO)/laser
firing feature.

2.7. Communications Connector

This section covers the communications connector of the Epaq MR,
providing information on its usage and configuration.

Chapter 3: Options

This chapter discusses additional options available for the Epaq
MR, including the emergency stop (ESTOP) feature and joystick
interface. It provides instructions on how to connect and configure
these options.

Chapter 4: Maintenance

Learn about the power board assembly and preventative
maintenance tasks to ensure the optimal performance and longevity
of your Epaq MR.

FAQ

  1. 1. Q: Where can I find the electrical specifications for the Epaq  

    MR?

A: The electrical specifications can be found in Chapter 1:
Introduction, specifically section 1.1.

  1. 1. Q: How do I connect a brushless motor to the Epaq MR?

A: Instructions for connecting a brushless motor can be found in
Chapter 2: Installation and Configuration, section 2.3.1.

  1. 1. Q: What is the purpose of the communications connector?

A: The communications connector is used for communication and
configuration of the Epaq MR. More information can be found in
Chapter 2: Installation and Configuration, section 2.7.

Epaq MR Hardware Manual
P/N: EDU209 Revision: 1.07.00a

AEROTECH.COM
ON OFF TM
Epaq MR

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

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4

5

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7

8

1

2

3

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1

2

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MOTOR

DIGITAL / ANALOG IO

ESTOP

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: +1-412-967-6440

101 Zeta Drive

Fax: +1-412-967-6870

Pittsburgh, PA 15238-2811

Email: service@aerotech.com

www.aerotech.com

United Kingdom

Japan

Phone: +44 (0)1256 855055

Phone: +81 (0)50 5830 6814

Fax: +44 (0)1256 855649

Fax: +81 (0)43 306 3773

Email: service@aerotech.co.uk

Email: service@aerotechkk.co.jp

Germany

China

Phone: +49 (0)911 967 9370 Fax: +49 (0)911 967 93720 Email: service@aerotechgmbh.de

Phone: +86 (21) 3319 7715 Email: service@aerotech.com

France

Taiwan

Phone: +33 2 37 21 87 65

Phone: +886 (0)2 8751 6690

Email: service@aerotech.co.uk

Email: service@aerotech.tw

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 © 2009-2023, Aerotech, Inc., All rights reserved.

Table of Contents

Epaq MR Hardware Manual

Table of Contents

Epaq MR Hardware Manual

1

Table of Contents

3

List of Figures

5

List of Tables

6

EU Declaration of Conformity

7

Agency Approvals

8

Safety Procedures and Warnings

9

Quick Installation Guide

11

Chapter 1: Introduction

13

1.1. Electrical Specifications

16

1.1.1. System Power Requirements

19

1.2. Mechanical Specifications

20

1.3. Environmental Specifications

22

1.4. Drive and Software Compatibility

23

Chapter 2: Installation and Configuration

25

2.1. Unpacking the Chassis

25

2.2. Electrical Installation

26

2.2.1. AC Power Connections

27

2.2.2. Minimizing Conducted, Radiated, and System Noise

28

2.2.3. I/O and Signal Wiring Requirements

29

2.2.4. Voltage Selection

30

2.3. Motor Output Connections

31

2.3.1. Brushless Motor Connections

32

2.3.1.1. Powered Motor Phasing

33

2.3.1.2. Unpowered Motor and Feedback Phasing

34

2.3.2. DC Brush Motor Connections

35

2.3.2.1. DC Brush Motor Phasing

35

2.3.3. Stepper Motor Connections

36

2.3.3.1. Stepper Motor Phasing

36

2.4. Motor Feedback Connections

37

2.4.1. Encoder Inputs

38

2.4.1.1. RS-422 Line Driver Encoder (Standard)

39

2.4.1.2. Analog Encoder Interface

40

2.4.1.3. Encoder Phasing

42

2.4.2. Hall-Effect Inputs

44

2.4.3. Thermistor Input

45

2.4.4. Encoder Fault Input

46

2.4.5. End Of Travel Limit Inputs

47

2.4.5.1. End Of Travel Limit Phasing

48

2.4.6. Brake Output

49

2.4.7. Differential Analog Input 0

50

2.5. Digital / Analog IO Connections

51

2.5.1. Analog Input 1

52

2.5.2. Analog Output 1

53

2.5.3. Opto-Isolated Outputs

54

2.5.4. Opto-Isolated Inputs

56

2.6. Aux Encoder

58

2.6.1. Position Synchronized Output (PSO)/Laser Firing

60

2.7. Communications Connector

62

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Epaq MR Hardware Manual
2.8. Ext Drive Connector 2.9. RS-232 Interface 2.10. PC Configuration and Operation Information
Chapter 3: Options
3.1. Emergency Stop (ESTOP1,2,3) 3.2. Joystick Interface
Chapter 4: Maintenance
4.1. Power Board Assembly 4.2. Preventative Maintenance
Appendix A: Warranty and Field Service Appendix B: Revision History Index

Table of Contents
63 64 65
67
68 72
75
76 77
79 81 83

4

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Table of Contents

Epaq MR Hardware Manual

List of Figures

Figure 1-1: Chassis Layout

13

Figure 1-2: Functional Diagram

15

Figure 1-3: Dimensions (4 Axis Version)

20

Figure 1-4: Dimensions (8 Axis Version)

21

Figure 2-1: Power and Control Connections

26

Figure 2-2: Power Switch

26

Figure 2-3: AC Line Filter (UFM-ST)

28

Figure 2-4: Voltage Selection Switch Access

30

Figure 2-5: Motor Output Connections

31

Figure 2-6: Brushless Motor Configuration

32

Figure 2-7: Encoder and Hall Signal Diagnostics

33

Figure 2-8: Motor Phasing Oscilloscope Example

34

Figure 2-9: Brushless Motor Phasing Goal

34

Figure 2-10: DC Brush Motor Configuration

35

Figure 2-11: Clockwise Motor Rotation

35

Figure 2-12: Stepper Motor Configuration

36

Figure 2-13: Clockwise Motor Rotation

36

Figure 2-14: Line Driver Encoder Interface

39

Figure 2-15: Analog Encoder Phasing Reference Diagram

40

Figure 2-16: Analog Encoder Signals

41

Figure 2-17: Encoder Phasing Reference Diagram (Standard)

42

Figure 2-18: Position Feedback in the Diagnostic Display

43

Figure 2-19: Hall-Effect Inputs

44

Figure 2-20: Thermistor Input

45

Figure 2-21: Encoder Fault Interface Input

46

Figure 2-22: End of Travel Limit Inputs

47

Figure 2-23: Limit Input Diagnostic Display

48

Figure 2-24: Analog Input 0

50

Figure 2-25: Analog Input 1

52

Figure 2-26: Analog Output 1

53

Figure 2-27: Outputs Connected in Current Sourcing Mode

55

Figure 2-28: Outputs Connected in Current Sinking Mode

55

Figure 2-29: Inputs Connected to a Current Sourcing Device

57

Figure 2-30: Inputs Connected to a Current Sinking Device

57

Figure 2-31: Auxiliary Encoder Channel

59

Figure 2-32: PSO Interface

61

Figure 2-33: Ethernet Interface

62

Figure 2-34: Ethernet Connection

62

Figure 2-35: Aeronet Interface

63

Figure 2-36: RS-232 Interface

64

Figure 3-1: ESTOP Option Interface

68

Figure 3-2: ESTOP1

69

Figure 3-3: ESTOP2

70

Figure 3-4: ESTOP3

71

Figure 3-5: Joystick Interface

72

Figure 3-6: Joystick Interface

73

Figure 4-1: Power Board

76

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Epaq MR Hardware Manual

Table of Contents

List of Tables

Table 1-1: Feature Summary

14

Table 1-2: Chassis Electrical Specifications

16

Table 1-3: Servo Amplifier Electrical Specifications (MP)

17

Table 1-4: Linear Amplifier Electrical Specifications (ML)

18

Table 1-5: Unit Weight

21

Table 1-6: Drive and Software Compatibility

23

Table 2-1: Main AC Power Input Voltages and Current Requirements

27

Table 2-2: AC Power Wiring Specifications

27

Table 2-3: UFM-ST Electrical Specifications

28

Table 2-4: I/O and Signal Power Wiring Specifications

29

Table 2-5: AC Voltage Selector Switch Settings for 115 VAC or 230 VAC Option

30

Table 2-6: AC Voltage Selector Switch Settings for 100 VAC or 200 VAC Option

30

Table 2-7: Motor Power Output Connector Pin Assignment

31

Table 2-8: Motor Power Output Mating Connector

31

Table 2-9: Motor Feedback Connector Pin Assignment

37

Table 2-10: Encoder Pin Assignment

38

Table 2-11: Encoder Specifications

39

Table 2-12: Analog Encoder Specifications

40

Table 2-13: Hall-Effect Feedback Pin Assignment

44

Table 2-14: Thermistor Interface Pin Assignment

45

Table 2-15: Encoder Fault Pin Assignment

46

Table 2-16: End of Travel Limit Inputs Pin Assignment

47

Table 2-17: Brake Output Pin Assignment

49

Table 2-18: Relay Specifications

49

Table 2-19: Differential Analog Input 0 Specifications

50

Table 2-20: Differential Analog Input 0 Pin Assignment

50

Table 2-21: Digital / Analog IO Connector Pin Assignment

51

Table 2-22: Analog Input 1 Specifications

52

Table 2-23: Analog Inputs Connector Pin Assignment

52

Table 2-24: Analog Output Specifications (TB102 B)

53

Table 2-25: Analog Output Connector Pin Assignment

53

Table 2-26: Opto-Isolated Output Connector Pin Assignment

54

Table 2-27: Output Specifications

54

Table 2-28: Digital Input Specifications

56

Table 2-29: Opto-Isolated Input Connector Pin Assignment

56

Table 2-30: Aux Encoder Specifications

58

Table 2-31: Auxiliary Encoder Channel Pin Assignment

58

Table 2-32: PSO Specifications

60

Table 2-33: Ethernet Cable Listing

62

Table 2-34: Aeronet Cable

63

Table 2-35: RS-232 Connector Pin Assignment

64

Table 3-1: Options and Capabilities

67

Table 3-2: ESTOP Option Mating Connector

68

Table 3-3: ESTOP Safety Ratings

68

Table 3-4: Relay Specifications

69

Table 3-5: Joystick Interface Connector Pin Assignment

72

Table 4-1: Component Select

76

Table 4-2: Preventative Maintenance

77

6

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Declaration of Conformity

Epaq MR Hardware Manual

EU Declaration of Conformity

Manufacturer

Aerotech, Inc.

Address

101 Zeta Drive

Pittsburgh, PA 15238-2811

USA

Product

Epaq MR

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 2006/42/EC 2011/65/EU

Low Voltage Directive LVD Safety of Machinery 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 61010-1:2010 ISO 13849-1 & -2

Safety requirements for electrical equipment Safety of Machinery – General Principals of Design

Name Position Location

/ Alex Weibel Engineer Verifying Compliance Pittsburgh, PA

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Epaq MR Hardware Manual

Declaration of Conformity

Agency Approvals

Aerotech, Inc. Model Epaq MR Drive Racks have been tested and found to be in accordance to the following listed Agency Approvals:

Approval / Certification: Approving Agency: Certificate #: Standards:

CUS NRTL TUV SUD America Inc. U8 13 10 68995 012 UL 61010-1:2004; CAN/CSA-C22.2 No. 61010-1:2004; EN 610101:2010

8

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Electrical Safety

Epaq MR Hardware Manual

Safety Procedures and Warnings
The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure to observe these precautions could result in serious injury to those individuals performing the procedures and/or damage to the equipment.
D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of electrical shock, bodily injury, or death the following precautions must be followed. 1. Ensure that all electrical power switches are in the off position when servicing the
equipment. 2. Disconnect electrical power before servicing equipment. 3. Disconnect electrical power before performing any wiring. 4. Access to the Epaq MR and component parts must be restricted while connected to a
power source. 5. Residual voltages greater than 60V may be present inside Epaq MR chassis for longer than
10 seconds after power has been disconnected. 6. To minimize the possibility of electrical shock and bodily injury, extreme care must be
exercised when any electrical circuits are in use. Suitable precautions and protection must be provided to warn and prevent persons from making contact with live circuits. 7. Install the Epaq MR inside a rack or enclosure. 8. Do not connect or disconnect any electrical components or connecting cables while connected to a power source. 9. All components must be properly grounded in accordance with local electrical safety requirements. 10. Operator safeguarding requirements must be addressed during final integration of the product.
W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the following precautions must be followed. 1. Use of this equipment in ways other than described by this manual can cause personal
injury or equipment damage. 2. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts
must be restricted while connected to a power source. 3. Cables can pose a tripping hazard. Securely mount and position all system cables to
avoid potential hazards. 4. Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to the equipment. 5. If the product is used in a manner not specified by the manufacturer, the protection provided by the product can be impaired and result in damage, shock, injury, or death. 6. Operators must be trained before operating this equipment. 7. All service and maintenance must be performed by qualified personnel. 8. This product is intended for light industrial manufacturing or laboratory use. Use of this product for unintended applications can result in injury and damage to the equipment.

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Epaq MR Hardware Manual

Electrical Safety

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Quick Installation Guide

Epaq MR Hardware Manual

Quick Installation Guide
This chapter describes the order in which connections and settings should typically be made to the Epaq MR. If a custom interconnection drawing was created for your system (look for a line item on your Sales Order under the heading “Integration”), that drawing can be found on your installation device.
There are four standard connections that must be made to the Epaq MR.

8 Axis Model
4

MotFoEr EFDeBeAdCbKack

2 COMMUNICATIONS EXT DRIVE

RS232

PC Connection

AUX ENCODER

JOYSTICK

AC Power
1

1

2

3

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8

1

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7

8

31

2

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8

1

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5

6

7

8

MotMorOPTOoRwer

DIGITAL / ANALOG IO

1 Connect the power source to the AC Power input 2 Connect the PC 3 Connect the Motors to the Motor Power inputs 4 Connect the Motors to the Motor Feedback inputs

4 Axis Model
2
PC Connection

RS232

MoFtEoErDFBeAeCdKback
4

1

2

3

4

31

2

3

4

AUX ENCODER

1

2

3

4

1

2

3

4

AC Power
1

ESTOP JOYSTICK

EXT DRIVE COMMUNICATIONS

MoMtoOrTOPRower

DIGITAL / ANALOG IO

ESTOP

Quick Start Summary
Topic AC Power PC Communication Motor Power Motor Feedback

Figure 1: Quick Start Connections
Section Section 2.2.1. AC Power Connections Section 2.7. Communications Connector Section 2.3. Motor Output Connections Section 2.4. Motor Feedback Connections

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Quick Installation Guide

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Introduction

Epaq MR Hardware Manual

Chapter 1: Introduction
Aerotech’s Epaq MR is a 3U height, 19″ wide, rack-mountable, intelligent drive chassis, that consists of up to eight ultra-compact PWM and Linear network digital drives providing up to eight axes of motion. Each drive provides deterministic behavior, auto-identification, and easy software setup. High performance double precision floating point DSP controls the digital PID and current loops. All system configuration is done using software-settable parameters, including control loop gains and system safety functions.
Communicate with the PC with a standard commercial Ethernet network connection. I/O options are configurable per axis and include a 16 channel digital I/O interface (8 inputs and 8 outputs), one analog input, one analog output, and a single axis Position Synchronized Output (PSO) signal. Other features and options available with the MR drive chassis include: an external joystick connection port, integral encoder resolution multiplication, and integral emergency stop components.
N O T E : The Epaq MR can contain a mix of multiple discrete ML and MP drives. When using the Ensemble software, the drives inside the Epaq MR will appear as if they were individual drives on the network. Motion and I/O commands on axes within the Epaq MR are programmed in the same manner as would be done for discrete units.

AEROTECH.COM
ON OFF TM
Epaq MR

Motor Feedback
FEEDBACK

Power Switch / Circuit Breaker

Ethernet Auxiliary Encoder

Aeronet

RS232

COMMUNICATIONS EXT DRIVE

RS232

Joystick

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

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7

8

1

2

3

4

5

6

7

8

AC Power Input

MOTOR

DIGITAL / ANALOG IO

Motor Output
Figure 1-1:

Digital / Analog IO
Chassis Layout

ESTOP
ESTOP

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Chapter 1

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Epaq MR Hardware Manual

Introduction

Table 1-1: Feature Summary

Standard Features

l Line driver square wave quadrature encoder input for standard position and velocity feedback

l One 16-bit differential analog input (±10 V)

l Dedicated 5-24 V Emergency Stop sense input

l Dedicated Hall inputs (3 per axis)

l Dedicated over travel and home input limits

l Calibration (refer to the Ensemble Help file for more information)

l Camming (refer to the Ensemble Help file for more information)

l 10/100 BASE-T Ethernet port for use with Ethernet I/O modules

Options

-IO

l One 16-bit analog output (±10 V)

l One 12- or 16-bit differential analog input (±10 V)

l One fail-safe brake or user relay output

l 8 optically isolated logic inputs (5 – 24 VDC), may be connected in current sourcing or sinking mode

l 8 optically isolated logic outputs (5 – 24 VDC), user defined as current sourcing or sinking

l Auxiliary encoder input channel

l RS-422 differential PSO signal

-MXU (option on the MP) x4,096 encoder interpolation for sine/cosine encoders

-MXU (option on the ML) x4,096 encoder interpolation for sine/cosine encoders

-MXH (option on the ML) x65,536 encoder interpolation for sine/cosine encoders

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Introduction

Epaq MR Hardware Manual

The following block diagram illustrates the features and options of the Epaq MR.

COMMUNICATIONS EXT DRIVE
RS232
JOYSTICK (optional)
ESTOP (optional)
AC Power Input

Ethernet Port Aeronet Output

Encoder +5V / Common PSO Output, Encoder Echo
SIN, COS, MRK

AUX ENCODER (up to x8, optional)

+5V / Common RS232
Digital Input (x3) Analog Input +/- (x2)
Switch

Analog Input 1 +/Analog Output 1
8 Opto Outputs (Sinking or Sourcing)
8 Opto Inputs (Sinking or Sourcing)
-MXU or -MXH Option(1)
SIN, COS, MRK
CW, CCW, Home Limits; Encoder Fault; Hall A, B, C; Motor Over Temperature
Brake +/Encoder +5V / Common
Analog Input 0 +/-

DIGITAL / ANALOG IO (up to x8, optional)
MOTOR FEEDBACK (up to x8)

ESTOP Motor Power
Control Amplifier Power Control Supply Power

Heatsink Over Temperature
Amplifier

A

MOTOR

B

OUTPUT

(up to x8)

C

(1) -MXH or -MXU on ML drives; -MXU on MP drives
Figure 1-2: Functional Diagram

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Chapter 1

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Epaq MR Hardware Manual

Introduction

1.1. Electrical Specifications
The electrical specifications for the Epaq MR drive chassis are listed in Table 1-2 and the electrical specifications for the servo amplifiers in Table 1-3 and Table 1-4.

N O T E : Specifications represent the maximum capability of a feature. Other system constraints may result in significantly less performance. This is particularly applicable to the motor output specifications. The motor output specifications are affected by the Bus supply, the number of axes that are operating at the same time, the type of motion, the AC Line voltage, and motor requirements.

Table 1-2: Chassis Electrical Specifications

Description Bus Voltage Options

Specifications

4-Axis

8-Axis

Unipolar

Bipolar

Unipolar

Bipolar

40 LP@ 300W

10B @ 400W

40LP @ 500W

10B @ 400W

80 LP @ 300W

20B @ 500W

40LP @ 500W

20B @ 500W

40 @ 600W

30B @ 500W 40LP @1000W 30B @ 500W

80 @ 600W

40B @ 600W 40LP @1000W 40B @ 1000W

100 VAC

10 A Maximum

Input Current

115 VAC 200 VAC

10 A Maximum 6 A Maximum

230 VAC

5 A Maximum

Inrush Current

100 A @ 254 VAC

Leakage Current

<1/5 mA @ 60 Hz / 254 VAC

AC Power Input

AC input (factory configured): AC Hi, AC Lo, Earth Ground ( ), l 100 VAC (90-112 VAC, 49-63 Hz) l 115 VAC (103-127 VAC, 49-63 Hz) l 200 VAC (180-224 VAC, 49-63 Hz) l 230 VAC (207-254 VAC, 49-63 Hz)

Auxiliary Power Outputs

+5 V is provided on all axis feedback connectors for encoder, Hall, and limit power.

Protection

l Power switch breaker (10 Amps, Supplemental Protection only). l Fuses on motor bus supply transformer. l Bus supply inrush current limit during power- on.

Indicator (Power)

Power switch contains a power-on indicator.

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Introduction

Epaq MR Hardware Manual

Aerotech doesn’t specify the input current or power to the drives because it is dependent on the amount of real power being delivered to the drive (refer to Section 1.1.1.).

Table 1-3: Servo Amplifier Electrical Specifications (MP)

MP 10

Input Voltage

10-80 VDC

Motor Supply

Input Current (Continuous)

5 Arms

Control Supply Output Voltage (1)

Input Voltage Input Current

24-80 VDC (±10%) 1 A max
10-80 VDC

Peak Output Current (1 second)

10 A

Continuous Output Current

5A

Power Amplifier Bandwidth Power Amplifier Efficiency

2500 Hz maximum (software selectable) 85% – 95%(2)

PWM Switching Frequency

20 kHz

Minimum Load Inductance

0.1 mH @ 80 VDC

User Power Supply Output

5 VDC (@ 500 milliamps)

Modes of Operation

Brushless; Brush; Stepper

Protective Features

Output short circuit; Peak over current, DC bus over voltages; RMS over current; Over temperature; Control power supply under voltage; Power stage bias supply under voltage

Isolation

Optical and transformer isolation between control and power stages.

1. AC input voltage and load dependent. 2. Dependent on total output power: efficiency increases with increasing output power.

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Chapter 1

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Epaq MR Hardware Manual

Introduction

Table 1-4: Linear Amplifier Electrical Specifications (ML)

Description

ML 10

Input Voltage

±40 VDC (max)

Motor Supply

Input Current (continuous)

5A

Input Current (peak)

10 A

Control Supply Output Voltage (1)

Input Voltage Input Current

Peak Output Current (2)

Continuous Output Current (2)

24 VDC typical (18-36 VDC) 700 mA (max) ±38V @ 10 A 10 5

Power Amplifier Bandwidth

2500 Hz maximum (software selectable)

Minimum Load Resistance

0.5

Output Impedance

0.2 (each phase)

User Power Supply Output

5 VDC (@ 500 mA)

Modes of Operation

Brushless; Brush; Stepper

Protective Features

Peak current limit; Over temperature; RMS current limit; Dynamic power dissipation limit

Isolation

Isolation between control and power stages.

1. Load Dependent 2. Peak and continuous output current is load dependent (the amplifier will limit its output current based on motor speed and motor resistance).

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Chapter 1

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Introduction

Epaq MR Hardware Manual

1.1.1. System Power Requirements
The following equations can be used to determine total system power requirements. The actual power required from the mains supply will be the combination of actual motor power (work), motor resistance losses, and efficiency losses in the power electronics or power transformer.
For switching amplifier types: An EfficiencyFactor of approximately 90% should be used in the following equations.

Brushless Motor Output Power Rotary Motors Linear Motors Rotary or Linear Motors

Pout [W] = Torque [N·m] Angular velocity[rad/sec] Pout [W] = Force [N] Linear velocity[m/sec] Pout [W] = Bemf [V] I(rms) 3

Ploss = 3 I(rms)^2 R(line-line)/2 Pin = SUM ( Pout + Ploss ) / EfficiencyFactor DC Brush Motor Pout [W] = Torque [N·m] Angular velocity[rad/sec] Ploss = I(rms)^2 R Pin = SUM ( Pout + Ploss ) / EfficiencyFactor
For linear amplifier types: An EfficiencyFactor of approximately 50% should be used in the following equations.
Linear Motor Pdiss[W] = MotorCurrentPeak[A] TotalBusVoltage[V] 3 / 2 Pin = SUM ( Pdiss ) / EfficiencyFactor

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1.2. Mechanical Specifications
The Epaq MR must be installed in a rack mount console to comply with safety standards. Mount the Epaq MR so free airflow is available at the rear of the chassis. Allowance must also be made for the rear panel connections and cables.

W A R N I N G : Use both handles to lift and carry the Epaq MR.

RS232

EXT DRIVE COMMUNICATIONS

424.9 [16.93] FEEDBACK AUX ENCODER

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

MOTOR

DIGITAL / ANALOG IO

JOYSTICK ESTOP

566.1 [22.29]

333.7 [13.14]

37.7 [1.48]

41.7 [1.64]

Dimensions: MM [IN]

444.5 [17.50]

8.3 [0.33] (TYP.)

482.6 [19.00] 465.9 [18.34]

132.5 [5.22] 7.1 [0.28] (4 pls)

AEROTECH.COM
ON OFF TM
Epaq MR

Drawing Number: 620E1408-

Figure 1-3: Dimensions (4 Axis Version)

57.2 [2.25]

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424.9 [16.93]

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

MOTOR

DIGITAL / ANALOG IO

ESTOP

566.1 [22.29]

492.5 [19.39]

37.7 [1.48]

41.7 [1.64]

Dimensions: MM [IN]

444.5 [17.50]

8.3 [0.33] (TYP.)

482.6 [19.00] 465.9 [18.34]

132.5 [5.22] 7.1 [0.28] (4 pls)

AEROTECH.COM
ON OFF TM
Epaq MR

57.2 [2.25]

Drawing Number: 620E1408-

Figure 1-4: Dimensions (8 Axis Version)

All Epaq MR chassis’s are built to the user’s specifications causing a variation in actual product weight.

Table 1-5: Unit Weight
Description Chassis Weight (typical)

Weight 23 kg

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1.3. Environmental Specifications

The environmental specifications for the Epaq MR are listed below.

Ambient Temperature
Humidity
Altitude Pollution Use Audible Noise

Operating: 5° to 40°C (41° to 104° F) Storage: -20° to 70°C (-4° to 158° F) Maximum relative humidity is 80% for temperatures up to 31°C. Decreasing linearly to 50% relative humidity at 40°C. Non condensing. Up to 2000 meters. Pollution degree 2 (normally only non-conductive pollution). Indoor use only. 71 db at 1 meter (rear fan and side fan) 77 db at 1 meter (rear fan and side fan)

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1.4. Drive and Software Compatibility

The following table lists the available drives and which version of the software first supported the drive. Drives that list a specific version number in the Last Software Version column will not be supported after the listed version.

Table 1-6: Drive and Software Compatibility

Drive Type

Firmware Revision

CL

A

CP

A B

Epaq

A

Epaq MR with ML drives

Epaq MR with MP drives

A

HLe

HPe

LAB

ML

MP

A

QDe/QL/QLe

QLAB

First Software Version 1.01 2.55 1.00 2.54 1.00 2.55 3.00 1.00 2.55 2.51 2.51 4.04 3.00 1.00 2.55 5.01 4.07

Last Software Version 5.02 5.02
Current Current Current Current Current Current Current Current Current Current Current Current Current Current Current

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Chapter 2: Installation and Configuration
2.1. Unpacking the Chassis
Visually inspect the container of the Epaq MR for any evidence of shipping damage. If any such damage exists, notify the shipping carrier immediately.
Remove the packing list from the Epaq MR container. Make sure that all the items specified on the packing list are contained within the package.
D A N G E R : Cables should not be connected to or disconnected from the Epaq MR drive chassis while power is applied, nor should any drive modules be removed or inserted into it with power applied. Doing so may cause damage to the system or its components.
A documentation package is provided with the Epaq MR either in a large manilla envelope or on the installation device containing manuals, interconnection drawings, and other documentation pertaining to the Epaq MR system. This information should be saved for future reference. Additional information about the Epaq MR system is provided on the Serial and Power labels that are placed on the Epaq MR chassis.
The system serial number label, located on the side panel closest to the AC power inlet, contains important information such as the:
l Customer order number (please provide this number when requesting product support) l Drawing number l System part number
The AC power input label is located beside the AC power inlet and contains the factory configured AC power requirements.
For label locations, refer to Figure 2-1

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2.2. Electrical Installation
Motor, power, control and position feedback cable connections are made to the rear of the Epaq MR.

System Serial Label (side)

Motor Feedback Communications

Auxiliary Encoder

Ext Drive

RS232

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

AC Power Input

MOTOR

DIGITAL / ANALOG IO

ESTOP

AC Power Label

Motor Output

Digital / Analog IO

Figure 2-1: Power and Control Connections

ESTOP Joystick

AEROTECH.COM
ON OFF TM
Epaq MR

Figure 2-2:

Power Switch / Circuit Breaker
Power Switch

All low voltage connections must be made using cables/wires sized for the maximum currents that will be carried. Insulation on these cables/wires must be rated at 300 V if this wiring can come into contact with wiring operating above 100 V (AC Power Input and Motor wiring). Low voltage wiring should not be bundled with AC and motor wiring to minimize signal disturbances due to EMI interference and coupling.

N O T E : The machine integrator, OEM, or end user is responsible for meeting the final protective grounding requirements of the system.

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2.2.1. AC Power Connections

AC input power to the Epaq MR drive chassis is applied to the AC power receptacle that is located on the rear panel. The power cord connected to this receptacle also provides the protective earth ground connection and may serve as a Mains disconnect. The main power switch located on the front panel of the Epaq MR drive chassis also functions as a 10 A breaker (supplementary protection only) for the incoming AC power.

The Epaq MR drive chassis is factory configured for one of four specified input voltages. The factory configured AC input voltages, along with the current requirements for the Epaq MR drive chassis, are listed in Table 2-1.

Table 2-1:

Main AC Power Input Voltages and Current Requirements

AC Input Voltage

Input Amps (maximum continuous)

100 VAC 50/60 Hz

10 A

115 VAC 50/60 Hz

10 A

200 VAC 50/60 Hz

6A

230 VAC 50/60 Hz

5A

The AC power cord/wiring specifications are listed in Table 2-2. Environmental conditions may necessitate the need to meet additional AC wiring requirements or specifications. AC wiring should not be bundled with signal wiring to minimize EMI coupling and interference.

Table 2-2: AC Power Wiring Specifications

Specification

Value

Cord/Wire Rating

300 V

Minimum Current Capacity Temperature Rating (Insulation)(1)

10 A 80°C

1. The insulation rating for the AC power wiring must be appropriately rated for the operating environment.

Refer to Figure 2-1 for label locations.

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2.2.2. Minimizing Conducted, Radiated, and System Noise

To reduce electrical noise, observe the following wiring techniques.
1. Use shielded cable to carry the motor current and tie the shield to earth ground.
2. Use a cable with sufficient insulation. This will reduce the capacitive coupling between the leads that, in turn, reduces the current generated in the shield wire.
3. Motor cables must be physically separated from low level cables carrying FireWire, encoder, and I/O signals.
4. User connections to the product must be made using shielded cables with metal D-style connectors and back shells. The shield of the cables must be connected to the metal back shell in order for the product to conform to the radiated emission standards.
5. The Epaq MR is a component designed to be integrated with other electronics. EMC testing must be conducted on the final product configuration.

The Epaq MR can generate conducted (AC line) and radiated noise when configured with MP drives. Minimize conducted emissions by using line filters. A line filter should be located as close to the drive as possible for maximum effectiveness. Aerotech recommends Schaffner FN2080-10-06 (Aerotech P/N: ECZ01449) or Aerotech’s UFM-ST product (refer to Figure 2-3).

Table 2-3: UFM-ST Electrical Specifications Specification Input Voltage Range Output Voltage Range Maximum Continuous Current
Frequency Phases Leakage Current Fuse Protection

Value 0-240 VAC 0-240 VAC 8 Arms with convection cooling 10 Arms with forced air cooling 50/60 Hz Single Phase 1.1 mA (max) Internal 10 A fuses on AC1 and AC2 inputs

AC1 TB1-1 AC2 TB1-2

F2 10 ASB 3AG
F1 10 ASB 3AG

TO MAINS

LINE

LOAD

INTERNAL FILTER COMPONENTS

TB2-1 AC1 TB2-2 AC2

TO DRIVE

QVR2 JP4 V20E385P
QVR1 JP3 V20E385P

GND TB1-3

Figure 2-3: AC Line Filter (UFM-ST)

TB2-3 GND

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2.2.3. I/O and Signal Wiring Requirements

The I/O, communication, and encoder feedback connections are typically very low power connections. In some applications, especially when there are significant wire distances, a larger wire size may be required to reduce the voltage drop that occurs along the wire. This increase may be necessary in order to keep the voltage within a specified range at a remote point.

Low voltage and high voltage wires should be kept physically separated so that they cannot contact one another. This reduces the risk of electric shock and improves system performance.

Table 2-4: I/O and Signal Power Wiring Specifications

Connection

Specification Cable/Wire Rating (1)

Value 300 V

Signal Wiring Low Voltage Power

Minimum Current Capacity Temperature Rating (Insulation) (2) Cable/Wire Rating (1) Minimum Current Capacity (3) Temperature Rating (Insulation) (2)

.25 A 80°C 300 V 1A 80°C

1. 30 V if the wiring is not in close proximity to wiring operating at voltages above 60 V. 2. Insulation rating will need to be rated for the higher voltage if the wiring is in proximity to wiring operating at voltages above 60 V. 3. Larger gauge wire may be required to minimize voltage drop due to voltage (IR) loss in the cable.

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2.2.4. Voltage Selection
You can reconfigure the transformers primary windings to support different AC line voltages by changing the Voltage Selection switches that are located on the left side of the chassis. The Voltage Selector can only be used with transformer-derived bus voltages. This Voltage Selector function should not be changed when using off-line supplies.
If you change the Voltage Selector settings, you must also update the AC power label located next to the AC inlet to reflect the new settings.
D A N G E R : Disconnect Mains power before changing the voltage selector settings.

W A R N I N G : The Voltage Selector must be configured to match the AC line voltage. You could damage the unit if the Voltage Selector is set for the incorrect AC line voltage.

For systems ordered with 115VAC (-A) or 230VAC (-B) input voltage:

Table 2-5: AC Voltage Selector Switch Settings for 115 VAC or 230 VAC Option

Input Voltage

Switch 1 Position

Switch 2 Position

115 VAC

DOWN

DOWN

230 VAC

UP

UP

For systems ordered with 100VAC (-C) or 200VAC (-D) input voltage:

Table 2-6: AC Voltage Selector Switch Settings for 100 VAC or 200 VAC Option

Input Voltage

Switch 1 Position

Switch 2 Position

100 VAC

DOWN

DOWN

200 VAC

UP

UP

N O T E : The Voltage Selection switches will be partially hidden if you purchased the MR with the SLIDE option.

Figure 2-4: Voltage Selection Switch Access

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2.3. Motor Output Connections
The Epaq MR can be used to drive three motor types: Brushless, DC Brush, and Stepper motors.
The DC brush, brushless, and stepper motor connections are made to the 5-pin high power “D” style motor power connectors (Axis 1-8) that are located on the rear panel. The pin assignments for these connectors are shown in Table 2-7.
Motor Output

5

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

4

AUX ENCODER

JOYSTICK

3

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

2

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

Figure 2-5:

MOTOR

DIGITAL / ANALOG IO

Motor Output Connections

Table 2-7: Motor Power Output Connector Pin Assignment Pin Description 1 Brushless Phase A Motor Power / DC Brush + / Stepper 2 Brushless Phase B Motor Power / DC Brush – / Stepper 3 Brushless Phase C Motor Power / Stepper Returns 4 Reserved 5 Ground

ESTOP
Wire Size 1.3 mm2 (#16 AWG) 1.3 mm2 (#16 AWG) 1.3 mm2 (#16 AWG) 1.3 mm2 (#16 AWG) 1.3 mm2 (#16 AWG)

Table 2-8: Motor Power Output Mating Connector

Description

Aerotech P/N

Male 5 Pin D-Style

ECK01236

Contact (QTY. 5)

ECK00660

Backshell

ECK00656

Third Party Source P/N ITT Cannon DBM5W5PK87
ITT Cannon DM53745-7 Amphenol 17-1726-2

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2.3.1. Brushless Motor Connections
The configuration shown in Figure 2-6 is an example of a typical brushless motor connection.

5

Motor Frame

AC

Brushless

4

Motor

3

Phase C

2

Phase B

1

Phase A

Figure 2-6: Brushless Motor Configuration
Brushless motors are commutated electronically by the controller, typically using Hall-effect devices. If you are using standard Aerotech motors and cables, motor phasing adjustments are not required and this section may be skipped.
The controller requires that the Back-EMF of each motor phase be aligned with the corresponding Hall-effect signal. To ensure proper alignment, motor, Hall, and encoder connections should be verified using one of the following methods: powered, through the use of a test program; or unpowered using an oscilloscope. Both methods will identify the A, B, and C Hall/motor lead sets and indicate the correct connections to the controller. Refer to Section 2.3.1.1. for powered motor phasing or Section 2.3.1.2. for unpowered motor and feedback phasing.

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2.3.1.1. Powered Motor Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor, Hall, and encoder phasing. Feedback Monitoring The state of the encoder and Hall-effect device signals can be observed in the Motion Composer. A “0” for the given Hall input indicates zero voltage or logic low, where a “1” indicates 5V or logic high.

Figure 2-7: Encoder and Hall Signal Diagnostics

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2.3.1.2. Unpowered Motor and Feedback Phasing
Disconnect the motor from the controller and connect the motor in the test configuration shown in Figure 2-8. This method will require a two-channel oscilloscope, a 5V power supply, and six resistors (10,000 ohm, 1/4 watt). All measurements should be made with the probe common of each channel of the oscilloscope connected to a neutral reference test point (TP4, shown in Figure 2-8). Wave forms are shown while moving the motor in the positive direction.

CHANNEL 1 CHANNEL 2

TP1 TP2 TP3 TP4

Power Supply
COM +5V
TP5 TP6 TP7

10K OHM TYP
“Wye” Configuration
10K OHM TYP

Motor Lead 1 = ØB
Motor Lead 2 = ØC
Motor Lead 3 = ØA COM +5V
Hall 1 Hall 2 Hall 3

Figure 2-8: Motor Phasing Oscilloscope Example

With the designations of the motor and Hall leads of a third party motor determined, the motor can now be connected to an Aerotech system. Connect motor lead A to motor connector A, motor lead B to motor connector B, and motor lead C to motor connector C. Hall leads should also be connected to their respective feedback connector pins (Hall A lead to the Hall A feedback pin, Hall B to Hall B, and Hall C to Hall C). The motor is correctly phased when the Hall states align with the Back EMF as shown in (Figure 2-9). Use the CommutationOffset parameter to correct for Hall signal misalignment.

0° 60° 120° 180° 240° 300° 360°

1

23

4

5

6

Hall A
+5V 0V
Hall B

Hall C

ØC

ØB

Motor Back EMF

ØA

ØC

ØB

+V

0V -V

Figure 2-9: Brushless Motor Phasing Goal

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2.3.2. DC Brush Motor Connections
The configuration shown in Figure 2-10 is an example of a typical DC brush motor connection. Refer to Section 2.3.2.1. for information on motor phasing.

5

Motor Frame

4

3

– DC Brush +

Motor

2

1

Figure 2-10: DC Brush Motor Configuration
2.3.2.1. DC Brush Motor Phasing A properly phased motor means that the positive motor lead should be connected to the ØA motor terminal and the negative motor lead should be connected to the ØC motor terminal. To determine if the motor is properly phased, connect a voltmeter to the motor leads of an un-powered motor:
1. Connect the positive lead of the voltmeter to the one of the motor terminals. 2. Connect the negative lead of the voltmeter to the other motor terminal. 3. Rotate the motor clockwise by hand.
ROTARY MOTOR

Motor Mounting Flange (Front View)

Motor Shaft

POSITIVE MOTION

Figure 2-11: Clockwise Motor Rotation

4. If the voltmeter indicates a negative value, swap the motor leads and rotate the motor (CW, by hand) again. When the voltmeter indicates a positive value, the motor leads have been identified.

5. Connect the motor lead from the voltmeter to the ØA motor terminal on the Epaq MR. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the Epaq MR.

N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required.

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2.3.3. Stepper Motor Connections
The configuration shown in Figure 2-12 is an example of a typical stepper motor connection. Refer to Section 2.3.3.1. for information on motor phasing.
In this case, the effective motor voltage is half of the applied bus voltage. For example, an 80V motor bus supply is needed to get 40V across the motor.
Motor Frame

5

B’

B

4 A’
3

2

Stepper

Motor

1

A

Note the common connection of A and B phases.

Figure 2-12: Stepper Motor Configuration
2.3.3.1. Stepper Motor Phasing
N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are not required.
A stepper motor can be run with or without an encoder. If an encoder is not being used, phasing is not necessary. With an encoder, test for proper motor phasing by running a positive motion command.
If there is a positive scaling factor (determined by the CountsPerUnit parameters) and the motor moves in a clockwise direction, as viewed looking at the motor from the front mounting flange, the motor is phased correctly. If the motor moves in a counterclockwise direction, swap the motor leads and re- run the command.
Proper motor phasing is important because the end of travel (EOT) limit inputs are relative to motor rotation.

ROTARY MOTOR

Motor Mounting Flange (Front View)

Motor Shaft

POSITIVE MOTION

Figure 2-13: Clockwise Motor Rotation

N O T E : After the motor has been phased, use the ReverseMotionDirection parameter to change the direction of “positive” motion.

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2.4. Motor Feedback Connections

The motor feedback connector (a 25-pin, D-style connector) has connections for an encoder, limit switches, Hall-effect devices, motor over-temperature device, 5 V encoder and limit power, and optional brake connections. The connector pin assignment is shown in Table 2-9 with detailed connection information in the following sections.

Table 2-9: Motor Feedback Connector Pin Assignment Pin# Description 1 Chassis Frame Ground 2 Motor Over Temperature Thermistor 3 +5V Power for Encoder (500 mA max) 4 Reserved 5 Hall-Effect Sensor B (brushless motors only) 6 Encoder Marker Reference Pulse 7 Encoder Marker Reference Pulse + 8 Analog Input 0 9 Reserved 10 Hall-Effect Sensor A (brushless motors only) 11 Hall-Effect Sensor C (brushless motors only) 12 Clockwise End of Travel Limit 13 Optional Brake – Output 14 Encoder Cosine + 15 Encoder Cosine 16 +5V Power for Limit Switches (500 mA max) 17 Encoder Sine + 18 Encoder Sine 19 Analog Input 0 + 20 Signal Common for Limit Switches 21 Signal Common for Encoder 22 Home Switch Input 23 Encoder Fault Input 24 Counterclockwise End of Travel Limit 25 Optional Brake

  • Output

In/Out/Bi N/A Input
Output N/A Input Input Input Input N/A Input Input Input
Output Input Input Output Input Input Input N/A N/A Input Input Input Output

Connector 25 13
14 1

Mating Connector 25-Pin D-Connector Backshell

Aerotech P/N ECK00101 ECK00656

Third Party P/N FCI DB25P064TXLF Amphenol 17E-1726-2

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2.4.1. Encoder Inputs
The Epaq MR is equipped with standard and auxiliary encoder feedback channels. The standard encoder interface is accessible through the Motor Feedback connector. By default, it accepts an RS-422 differential line driver signal. If the -MXU or -MXH option has been purchased, the standard encoder interface has been configured for an analog encoder input via parameter settings.
Refer to Section 2.4.1.3. for encoder feedback phasing. Refer to Section 2.6. for the auxiliary encoder channel.
N O T E : Encoder wiring should be physically isolated from motor, AC power and all other power wiring.

N O T E : The PSO feature is not compatible with the -MXU option. The PSO feature operates with the MXH option and with square wave encoders.

Table 2-10: Encoder Pin Assignment Pin# Description 1 Chassis Frame Ground 3 +5V Power for Encoder (500 mA max) 6 Encoder Marker Reference Pulse 7 Encoder Marker Reference Pulse + 14 Encoder Cosine + 15 Encoder Cosine 17 Encoder Sine

  • 18 Encoder Sine 21 Signal Common for Encoder

In/Out/Bi N/A
Output Input Input Input Input Input Input N/A

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2.4.1.1. RS-422 Line Driver Encoder (Standard)

The standard encoder interface accepts an RS-422 differential quadrature line driver signal. Invalid or missing signals will cause a feedback fault when the axis is enabled.

An analog encoder is used with the -MXH/-MXU option (refer to Section 2.4.1.2. for more information).

Table 2-11: Encoder Specifications Specification Encoder Frequency x4 Quadrature Decoding

Value 10 MHz maximum (25 nsec minimum edge separation)
40 million counts/sec

Figure 2-14: Line Driver Encoder Interface

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2.4.1.2. Analog Encoder Interface
If the -MXH/-MXU option has been purchased, the standard encoder channel will accept a differential analog encoder input signal. The interpolation factor is determined by the EncoderMultiplicationFactor parameter and is software selectable (refer to the Ensemble Help file).

Table 2-12: Analog Encoder Specifications

Specification

MP (MXU)

Input Frequency (max)

200 kHz

Input Amplitude

0.6 to 2.25 Vpk-Vpk

Interpolation Factor (software selectable)

4,096

MXH Interpolation Latency

N/A

ML (MXU) 500 kHz 0.6 to 2.25 Vpk-Vpk
4,096
N/A

ML (MXH) 500 kHz 0.6 to 2.25 Vpk-Vpk
65,536 ~ 3.25 µsec (analog input to
quadrature output)

Refer to Figure 2-15 for the MXU/MXH typical input circuitry.

The encoder interface pin assignment is indicated in Section 2.4.1.

The gain, offset, and phase balance of the analog Sine and Cosine encoder input signals can all be adjusted via controller parameters. Encoder signals should be adjusted using the Feedback Tuning tab of the Digital Scope, which will automatically adjust the encoder parameters for optimum performance. See the Ensemble Help file for more information.

90° 180° 270° 360° 450° 540° 630° 720° 810°

LINEAR MOTOR

SIN

Forcer Wires

SIN-N

Magnet Track

90° 180° 270° 360° 450° 540° 630° 720° 810°

COS

1Vpk-pk

Forcer

Positive MOVE (Clockwise)

COS-N

ROTARY MOTOR

90° 180° 270° 360° 450° 540° 630° 720° 810°

MRK

Motor Shaft

MRK-N

Positive MOVE (Clockwise)

CW Rotation (Positive Direction)

Motor Mounting Flange (Front View)

Figure 2-15: Analog Encoder Phasing Reference Diagram

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Figure 2-16: Analog Encoder Signals

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2.4.1.3. Encoder Phasing
Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-17 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors). To verify, move the motor by hand in the CW (positive) direction while observing the position of the encoder in the diagnostics display (see Figure 2-18). The Motor Phasing Calculator in the Configuration Manager can be used to determine proper encoder polarity.
For dual loop systems, the velocity feedback encoder is displayed in the diagnostic display (Figure 2-18).

90° 180° 270° 360° 450° 540° 630° 720° 810°

SIN

SIN-N

LINEAR MOTOR Forcer Wires
Magnet Track

Forcer

Positive MOVE (Clockwise)

90° 180° 270° 360° 450° 540° 630° 720° 810°

COS

1Vpk-pk

COS-N

90° 180° 270° 360° 450° 540° 630° 720° 810°

ROTARY MOTOR

MRK MRK-N

Motor Shaft
CW Rotation (Positive Direction)

Motor Mounting Flange (Front View)

Positive MOVE (Clockwise)
Figure 2-17: Encoder Phasing Reference Diagram (Standard)

N O T E : Encoder manufacturers may refer to the encoder signals as A, B, and Z. The proper phase relationship between signals is shown in Figure 2-17.

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Figure 2-18: Position Feedback in the Diagnostic Display

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2.4.2. Hall-Effect Inputs

The Hall-effect switch inputs are recommended for AC brushless motor commutation but not absolutely required. The Hall-effect inputs accept 5-24 VDC level signals. Hall states (0,0,0) or (1,1,1) are invalid and will generate a “Hall Fault” axis fault.

Refer to Section 2.3.1.1. for Hall-effect device phasing.

Table 2-13: Hall-Effect Feedback Pin Assignment Pin# Description 1 Chassis Frame Ground 3 +5V Power for Encoder (500 mA max) 5 Hall-Effect Sensor B (brushless motors only) 10 Hall-Effect Sensor A (brushless motors only) 11 Hall-Effect Sensor C (brushless motors only) 21 Signal Common for Encoder

In/Out/Bi N/A
Output Input Input Input N/A

Figure 2-19: Hall-Effect Inputs

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2.4.3. Thermistor Input

The thermistor input is used to detect a motor over temperature condition by using a positive temperature coefficient sensor. As the temperature of the sensor increases, so does the resistance. Under normal operating conditions, the resistance of the thermistor is low (i.e., 100 ohms) which will result in a low input signal. As the increasing temperature causes the thermistor’s resistance to increase, the signal will be seen as a logic high triggering an over temperature fault. The nominal trip value of the sensor is 1k Ohm.

Table 2-14: Thermistor Interface Pin Assignment Pin# Description 2 Motor Over Temperature Thermistor

In/Out/Bi Input

Figure 2-20: Thermistor Input

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2.4.4. Encoder Fault Input

The encoder fault input is for use with encoders that have a fault output. This is provided by some manufactures and indicates a loss of encoder function. The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active.

Table 2-15: Encoder Fault Pin Assignment Pin# Description 23 Encoder Fault Input

In/Out/Bi Input

Figure 2-21: Encoder Fault Interface Input

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2.4.5. End Of Travel Limit Inputs

End of Travel (EOT) limits are used to define the end of physical travel. The EOT limit inputs accept 5-24 VDC level signals. The active state of the EOT limits is software selectable by the EndOfTravelLimitSetup axis parameter (refer to the Ensemble Help file). Limit directions are relative to the encoder polarity in the diagnostics display (refer to Figure 2-23).

Positive motion is stopped by the clockwise (CW) end of travel limit input. Negative motion is stopped by the counterclockwise (CCW) end of travel limit input. The Home Limit switch can be parameter configured for use during the home cycle, however, the CW or CCW EOT limit is typically used instead.

Table 2-16: End of Travel Limit Inputs Pin Assignment Pin# Description 12 Clockwise End of Travel Limit 16 +5V Power for Limit Switches (500 mA max) 20 Signal Common for Limit Switches 22 Home Switch Input 24 Counterclockwise End of Travel Limit

In/Out/Bi Input Output N/A Input Input

USER WIRING
TO LIMIT SWITCH POWER
PIN-16

CONTROLLER

+5V

ENC +5V

10K PIN-12 CW-LIMIT

PIN-24 CCW-LIMIT

10K

PIN-22 HOME-LIMIT

10K

.001 .001
10K .001
10K 10K .01UF .01UF .01UF

PIN-20
OPTIONAL HOME LIMIT NORMALLY CLOSED LIMITS SHOWN
Figure 2-22: End of Travel Limit Inputs

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2.4.5.1. End Of Travel Limit Phasing
If the EOT limits are reversed, you will be able to move further into a limit but be unable to move out. To correct this, swap the connections to the CW and CCW inputs at the motor feedback connector. The logic level of the EOT limit inputs may be viewed in the Diagnostic Display (shown in Figure 2-23).

Figure 2-23: Limit Input Diagnostic Display

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2.4.6. Brake Output

The Brake Output is a factory wired option allowed for one or more axes. The brake pins are used to automatically control a fail-safe brake (typically used on a vertical axis). The I/O option is required for each axis with a brake. The brake is configured for automatic or manual control using controller parameters (refer to the Ensemble Help file for more information).

Table 2-17: Brake Output Pin Assignment Pin# Description 13 Optional Brake – Output 25 Optional Brake + Output

In/Out/Bi Output Output

Table 2-18: Relay Specifications

Solid State Relay Rating

Maximum Voltage

24 VDC

Maximum Current

0.5 Amps

Maximum Power

560 mW

Output Resistance

0.1 ohm (typical)

Turn-on/Turn-off Time < 3 ms (with 500 ohm load at 5 VDC)

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2.4.7. Differential Analog Input 0

To interface to a single-ended (non-differential) voltage source, connect the signal common of the source to the negative input and the analog source signal to the positive input. A floating signal source should be referenced to the analog common as shown in Figure 2-24.

Table 2-19: Differential Analog Input 0 Specifications

Specification (AI+) – (AI-)

MP Drive Value +10 V to -10 V (1)

Resolution (bits)

16 bits

Resolution (volts)

305 µV

1. Signals outside of this range may damage the input

ML Drive Value +10 V to -10 V (1)
16 bits 305 µV

Table 2-20: Differential Analog Input 0 Pin Assignment Pin# Description 8 Analog Input 0 19 Analog Input 0 + 21 Signal Common for Encoder

In/Out/Bi Input Input N/A

ANALOG IN+

PIN-19

Shielded

100

Cable

Signal Source

ANALOG INPIN-8 100
GND PIN-21

64.9K .1

.001 16.2K

64.9K 16.2K

OP279 .001

Figure 2-24: Analog Input 0

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2.5. Digital / Analog IO Connections

The IO connections includes 8 digital opto-inputs, 8 digital opto-outputs, 1 analog input, 1 analog output, a second encoder channel, and a brake/relay output. This connector is installed only if the -IO option has been ordered for the axis.

Table 2-21: Digital / Analog IO Connector Pin Assignment Pin# Description 1 Non-Inverting Analog Input 1+ 2 InvertingAnalog Input 13 Internal +5 Volt Power Supply (500 mA max) 4 Input Common for Opto-Inputs 0 – 3 5 Optically- Isolated Input 0 6 Optically-Isolated Input 1 7 Optically-Isolated Input 2 8 Optically-Isolated Input 3 9 Output Common + 10 Optically-Isolated Output 0 11 Optically-Isolated Output 1 12 Optically-Isolated Output 2 13 Optically- Isolated Output 3 14 Analog Output 1 15 Ground 16 Input Common for Opto-Inputs 4 – 7 17 Optically-Isolated Input 4 18 Optically-Isolated Input 5 19 Optically-Isolated Input 6 20 Optically-Isolated Input 7 21 Output Common 22 Optically-Isolated Output 4 23 Optically-Isolated Output 5 24 Optically- Isolated Output 6 25 Optically-Isolated Output 7

In/Out/Bi Input Input Output Input Input Input Input Input Input Output Output Output Output Output N/A Input Input Input Input Input Input Output Output Output Output

Connector
13 25 14 1

Mating Connector 25-Pin D-Connector Backshell

Aerotech P/N ECK00101 ECK00656

Third Party P/N FCI DB25P064TXLF Amphenol 17E-1726-2

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2.5.1. Analog Input 1

To interface to a single-ended (non-differential) voltage source, connect the signal common of the source to the negative input and the analog source signal to the positive input. A floating signal source should be referenced to the analog common as shown in Figure 2-25.

Table 2-22: Analog Input 1 Specifications

Specification (AI+) – (AI-)

MP Drive Value +10 V to -10 V (1)

Resolution (bits)

12 bits

Resolution (volts)

4.88 mV

1. Signals outside of this range may damage the input

ML Drive Value +10 V to -10 V (1)
16 bits 305 µV

Table 2-23: Analog Inputs Connector Pin Assignment Pin# Description 1 Non- Inverting Analog Input 1+ 2 InvertingAnalog Input 115 Ground

In/Out/Bi Input Input N/A

ANALOG IN1+

Shielded

PIN-1

100

Cable

Signal

Source

64.9K .1

.001 16.2K

ANALOG IN1PIN-2 100
GND PIN-15

64.9K

10 OP279

Figure 2-25: Analog Input 1

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2.5.2. Analog Output 1
The analog output is set to zero when power is first applied to the system or during a system reset.

N O T E : The Epaq MR does not have an “Analog Output 0”.

Table 2-24: Analog Output Specifications (TB102 B) Specification Output Voltage Output Current Resolution (bits) Resolution (volts)

Value -5 V to +5 V
5 mA 16 bits 153 µV

Table 2-25: Analog Output Connector Pin Assignment Pin# Description 14 Analog Output 1 15 Ground

In/Out/Bi Output
N/A

-5VA +5VA

S2

D

S1

IN

20K

ADG419

+5VA

20K

PIN-14 AOUT

10K

PIN-15 GND

LMH6643

Figure 2-26: Analog Output 1

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2.5.3. Opto-Isolated Outputs
The digital outputs are optically-isolated and may be connected in sourcing or sinking configurations. The digital outputs are designed to connect to other ground referenced circuits and are not intended to provide high-voltage isolation.
The outputs are software-configurable and must be connected in either all sinking or all sourcing mode. Figure 2-27 and Figure 2-28 illustrate how to connect to an output in current sourcing and current sinking modes.
The opto-isolator’s common connections can be directly connected to the drive’s power supply; however, doing so will effectively defeat the isolation and will reduce noise immunity.
N O T E : Power supply connections must always be made to both the Output Common Plus (OP) and Output Common Minus (OM) pins as shown in Figure 2-27 and Figure 2-28.

N O T E : All outputs on this connector map to output port 1 within the Ensemble software.

Table 2-26: Opto-Isolated Output Connector Pin Assignment Pin# Description 9 Output Common + 10 Optically-Isolated Output 0 11 Optically-Isolated Output 1 12 Optically-Isolated Output 2 13 Optically-Isolated Output 3 21 Output Common 22 Optically-Isolated Output 4 23 Optically-Isolated Output 5 24 Optically- Isolated Output 6 25 Optically-Isolated Output 7

In/Out/Bi Input Output Output Output Output Input Output Output Output Output

Table 2-27: Output Specifications Opto Device Specifications Maximum Voltage Maximum Sink/Source Current Output Saturation Voltage Output Resistance Rise / Fall Time Reset State

Value 24 V maximum 60 mA/channel @ 50°C 2.75 V at maximum current
33 250 usec (typical) Output Off (High Impedance State)

Suppression diodes must be installed on outputs driving relays or other inductive devices. This protects the outputs from damage caused by inductive spikes. Suppressor diodes, such as the 1N914, can be installed on all outputs to provide protection. It is important that the diode be installed correctly (normally reversed biased). Refer to Figure 2-28 for an example of a current sinking output with diode suppression and Figure 227 for an example of a current sourcing output with diode suppression.

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OPTOOUTV + PIN-9
OPTOOUT 7 1 PIN-25

OPTOOUT6 PIN-24

OPTOOUT 5 PIN-23
OPTOOUT 4 PIN-22

OPTOOUT 3 PIN-13

OPTOOUT 2 PIN-12

OPTOOUT 1 PIN-11
OPTOOUT 0 PIN-10
OUTPUT SWITCHES

+ LO-AD

+ LOAD

+ LO-AD

+ LOAD

+ LOAD

+ LO-AD

+ LOAD

3 + LO-AD
5-24 VDC + –

OPTOOUTV- 2 PIN-21
1 EACH OUTPUT 60 mA MAXIMUM 2 CONNECTION REQUIRED 3 DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.
Figure 2-27: Outputs Connected in Current Sourcing Mode

OPTOOUTV + 1 PIN-9

OUTPUT SWITCHES OPTOOUT 7 2
PIN-25
OPTOOUT 6 PIN-24
OPTOOUT 5 PIN-23
OPTOOUT 4 PIN-22
OPTOOUT 3 PIN-13
OPTOOUT 2 PIN-12
OPTOOUT 1 PIN-11
OPTOOUT 0 PIN-10
OPTOOUTVPIN-21

+ LOAD

+ LOAD

+ LOAD

+ LOAD

+ LOAD

+ LOAD

+ LOAD

5-24 VDC + –
+ LOAD
3

1 CONNECTION REQUIRED

2 EACH OUTPUT 60 mA MAXIMUM

3 DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.

Figure 2-28: Outputs Connected in Current Sinking Mode

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2.5.4. Opto-Isolated Inputs
The digital inputs are opto-isolated and may be connected to current sourcing or current sinking devices, as shown in Figure 2-29 and Figure 2-30. These inputs are designed to connect to other ground-referenced circuits and are not intended for high-voltage isolation.
The opto-isolator’s common connections can be directly connected to the drive’s power supply; however, doing so will effectively defeat the isolation and will reduce noise immunity.

N O T E : All inputs on this connector map to input port 1 within the Ensemble software.

Table 2-28: Digital Input Specifications

Input Voltage

Approximate Input Current

+5 V

1 mA

+24 V

6 mA

Turn On Time 200 usec 4 usec

Turn Off Time 2000 usec 1500 usec

Table 2-29: Opto-Isolated Input Connector Pin Assignment Pin# Description 4 Input Common for Opto-Inputs 0 – 3 5 Optically-Isolated Input 0 6 Optically- Isolated Input 1 7 Optically-Isolated Input 2 8 Optically-Isolated Input 3 16 Input Common for Opto-Inputs 4 – 7 17 Optically-Isolated Input 4 18 Optically- Isolated Input 5 19 Optically-Isolated Input 6 20 Optically-Isolated Input 7

In/Out/Bi Input Input Input Input Input Input Input Input Input Input

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+ 5-24 VDC –

INPUT SWITCHES

OPTOIN 0 OPTOIN 1 OPTOIN 2 OPTOIN 3

PIN-5 PIN-6 PIN-7 PIN-8

COMMON (0-3) PIN-4

+ 5-24 VDC –

OPTOIN 4 PIN-17 OPTOIN 5 PIN-18 OPTOIN 6 PIN-19 OPTOIN 7 PIN-20

COMMON (4-7) PIN-16

Figure 2-29: Inputs Connected to a Current Sourcing Device

+ 5-24 VDC –
+ 5-24 VDC –

COMMON (0-3)

INPUT SWITCHES

OPTOIN 0

OPTOIN 1

PIN-4 PIN-5 PIN-6

OPTOIN 2 OPTOIN 3 COMMON (4-7) OPTOIN 4

PIN-7 PIN-8 PIN-16 PIN-17

OPTOIN 5 PIN-18

OPTOIN 6 OPTOIN 7

PIN-19 PIN-20

Figure 2-30: Inputs Connected to a Current Sinking Device

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2.6. Aux Encoder

The auxiliary encoder interface accepts a RS-422 differential quadrature line driver signal. This encoder channel can be used as an input for master/slave operation (handwheel), for dual feedback systems, or as an output to echo the standard encoder signals.

The auxiliary encoder channel can also be used as the PSO output. Configuring the PSO hardware will automatically configure this encoder channel as an output (refer to Section 2.6.1.) and will remove the 180 ohm terminator resistors.

The auxiliary encoder interface does not support analog encoders and thus cannot be used as an input for the -MXU or -MXH option in MP and ML drives.

This connector is installed only if the -IO option has been ordered for the axis.

Table 2-30: Aux Encoder Specifications

Specification

Value

Encoder Frequency

10 MHz maximum (25 nsec minimum edge separation)

x4 Quadrature Decoding

40 million counts/sec

MXH Interpolation Latency

~ 3.25 µsec (analog input to quadrature output)

Table 2-31: Auxiliary Encoder Channel Pin Assignment
Pin# Description 1 Auxiliary RS-422 Encoder Sine + 2 Auxiliary RS-422 Encoder Cosine + 3 Auxiliary RS-422 Marker Pulse +/ PSO Output (1)
4 Encoder +5 Volt Power 5 Encoder Power Common 6 Auxiliary RS-422 Encoder Sine 7 Auxiliary RS-422 Encoder Cosine 8 Auxiliary RS-422 Marker Pulse – / PSO Output (1)
9 Encoder Power Common
(1) For PSO, see Section 2.6.1. Position Synchronized Output (PSO)/Laser Firing

In/Out/Bi Bidirectional Bidirectional Bidirectional
Output N/A
Bidirectional Bidirectional Bidirectional
N/A

Connector
5 9 6
1

Mating Connector 9-Pin D-Connector Backshell

Aerotech P/N ECK00137 ECK01021

Third Party P/N Cinch DE-9P Amphenol 17-1724-2

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+5V AUXSINPIN – 6
180

AUXSIN+ PIN – 1
AUXMRKPIN – 8 180
AUXMRK+ PIN – 3
AUXCOSPIN – 7 180

ADM1485 +5V

+5V

ADM1485

ENCODER FAULT
DETECTION

Terminating resistors are not present when configured as an output.

AUXCOS+ PIN – 2
Figure 2-31:

ADM1485
Auxiliary Encoder Channel

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2.6.1. Position Synchronized Output (PSO)/Laser Firing
The PSO can be programmed to generate an output synchronized to the feedback position and is typically used to fire a laser or sequence an external device. Trigger signals may be derived from a feedback channel or a software trigger. The position synchronized output pulse is generated using high-speed hardware, allowing minimal latency between the trigger condition and the output.
The PSO output is available on the dual-function AUX Marker/PSO signal lines. The auxiliary marker must be configured as an output using the PSOOUTPUT CONTROL command. Refer to the Help File for more information.
An RS-422 line receiver or opto-isolator is recommended, especially when using long cable lengths in noisy environments or when high frequency pulse transmission is required. It is best to locate the line receiver or opto- isolator close to the receiving electronics.

N O T E : The PSO feature is not compatible with the -MXU option. The PSO feature operates with the MXH option and with square wave encoders.

Table 2-32: PSO Specifications

Specification Maximum Input Tracking Rate (1)

Single-Axis Tracking Dual-Axis Tracking (3)

Maximum Quadrature Encoder Output Frequency Maximum PSO Output (Fire) Frequency (2)

Standard Feedback -MXH Feedback (3)

Firing Latency

Single-Axis Tracking Dual-Axis Tracking (3)

1. Signals in excess of this rate will cause a loss of PSO accuracy.

2. The optocoupler that you use on the output might have an effect on this rate.

3. Epaq MR with ML drives

Value 16.6 MHz 8.33 MHz 40 MHz 25 MHz 12.5 MHz 160 nsec 220 nsec

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Differential
+5 VDC 1K
Aux. Marker
1K

120 – 180 (typical) 3 8

Active Low Output *

Opto-Isolated
+5 VDC
1K 3
Aux. Marker 8
1K

10 mA 180 1N4148

Isolated Section vcc
To Laser Active Low
Output*

9
HCPL-2601 or 6N136

  • Active low output shown. Opposite polarity available by reversing connections to Pins 3 and 8.
    Figure 2-32: PSO Interface

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2.7. Communications Connector
The Ethernet connector (Communications) provides a 10/100 Ethernet connection to the Epaq MR controller. This can be connected directly to a hub or switch, or to a PC using a crossover cable. This port is viewed by the supplied software applications to communicate with the controller. It can also be configured for Modbus TCP/IP or simple ASCII communications.
Communications

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

MOTOR

DIGITAL / ANALOG IO

ESTOP

Figure 2-33: Ethernet Interface

Table 2-33: Ethernet Cable Listing Cable Name ENET-XOVER-X

Length x = 9, 15, 30, 45, 60, 75, 100 or 150 decimeters

AEROTECH.COM
TM Epaq MR

Crossover CAT5 cable
ON OFF

Ethernet I/O Module or PC

AEROTECH.COM
TM Epaq MR

Ethernet HUB or Switch

Ethernet I/O Module or PC

ON
OFF
standard CAT5 cable

standard CAT5 cable

Figure 2-34: Ethernet Connection

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2.8. Ext Drive Connector
The EXT DRIVE connector allows additional external drives to be connected to the Epaq MR chassis. This must be done using a CAT-6 shielded cable configured for the Epaq MR to the drive’s Aeronet input.
EXT DRIVE

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

MOTOR

DIGITAL / ANALOG IO

ESTOP

Figure 2-35: Aeronet Interface

Table 2-34: Aeronet Cable

Cable Name

Description

ENET-CAT6-X

A CAT6 cable

Length x = 3, 10, 20, 30, 45, 75, or 90 decimeters

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2.9. RS-232 Interface
The RS-232 port can be used for simple ASCII communications with another device. A one-to-one cable (not a null modem) is required for connection to a PC.

FEEDBACK

RS232

COMMU5NICATIONS E1XT DRIVE

9

6

RS232

AUX ENCODER

JOYSTICK

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

MOTOR

DIGITAL / ANALOG IO

ESTOP

Figure 2-36: RS-232 Interface

Table 2-35: RS-232 Connector Pin Assignment

Pin

Label

RS-232 Description

1

+5V

+5V Power

2

TX

Transmit

3

RX

Receive

4

N/A

5

Common Signal Common

6

N/A

7-9 Reserved/Do Not Connect

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2.10. PC Configuration and Operation Information
For additional information about PC configuration, hardware requirements, programming, utilities, and system operation refer to the Ensemble Help file.

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Options

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Chapter 3: Options

Table 3-1 provides a description of the various Epaq MR options.

Table 3-1: Options and Capabilities

Option

Section

Chassis Slides Section 1.2.

Mechanical

Specifications

Emergency Stop Section 3.1.

Emergency Stop

(ESTOP1,2,3)

MXU

Section 2.4.1.2.

Analog Encoder

Interface

Failsafe Brake Section 2.4.6. Brake

Output

Output

Joystick Interface

Section 3.2. Joystick Interface

Description / Capabilities Mounting option
ESTOP Sense Input EN ISO 13849-1, Category 2, Category 3
Encoder Resolution Multiplier, up to 1,024 times 200 kHz / 2 MHz max input freq. respectively
Brake is configured to an axis Standard brake voltage is 24 VDC Opto 22 module controlled brake output Joystick option

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Options

3.1. Emergency Stop (ESTOP1,2,3)
ESTOP1, 2, and 3 are integrated emergency stop hardware options available on the Epaq MR. User connections are made via the optional 15D ESTOP connector.
l ESTOP1 uses a single relay to disconnect the motor power supply from the internal drive modules. l ESTOP2 uses two relays in series to disconnect the motor power supply from the drive modules. l ESTOP3 uses two relays in series to disconnect the motor power supply from the drive modules and
dissipates the stored energy in the motor power supply.
All relays are force guided and have a monitor contact.

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

ESTOP

JOYSTICK

8 15

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

9 1

MOTOR

DIGITAL / ANALOG IO

Figure 3-1: ESTOP Option Interface

Table 3-2: ESTOP Option Mating Connector

Mating Connector

Aerotech P/N

15-Pin D-Connector

ECK00100

Backshell

ECK01022

ESTOP
Third Party P/N FCI DA15P064TXLF Amphenol 17E-1725-2

The ESTOP1,2,3 options can be used to provide performance in accordance with EN ISO 13849-1 as shown in Table 3-3.

Table 3-3: ESTOP Safety Ratings

Option

Relays

ESTOP1

1 force guided relay with monitor contact

ESTOP2

2 force guided relays with monitor contacts

ESTOP3

2 force guided relays with monitor contracts

EN ISO 13849-1 Category 2, PL d Category 3, PL d Category 3, PL d

W A R N I N G : The machine integrator, OEM, or end user is responsible for performing the design, integration, and test of the safety system in accordance with the relevant safety standards. This responsibility includes the use of safety monitoring devices, interlocks, switches, light curtains and all other means of providing operator protection.

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Table 3-4: Relay Specifications

ESTOP1 CR1 and ESTOP2 CR1 and CR2

Relay Part Number Aerotech: ECW01106

Sprecher & Schuh: CA7-16E-01-24E

AC-1 (resistive load) Rating of 32 A

Turn On

The coil requires 17.0 W to turn on (which is equal to 700 mA @ 24 V)

On / Holding

The coil requires 1.7 W on (holding) current (which is equal to 70 mA @ 24 V)

ESTOP3 CR1 and CR2

Relay Part Number Aerotech: ECW01107

Sprecher & Schuh: CA7-16E-M31-24E

AC-1 (resistive load) Rating of 32 A

Turn On

The coil requires 17.0 W to turn on (which is equal to 700 mA @ 24 V)

On / Holding

The coil requires 1.7 W on (holding) current (which is equal to 70 mA @ 24 V)

AC INLET

SWITCH/BREAKER

CR1

ESTOP N.C.

9

9

10 10

7

7

8

8

2

2

5

5

6

6

3

3

4

4

1

1

+24 DC POWER SUPPLY

+24V

COM

CR1

CR1 CR1

ESTOP OPTO

15-PIN MALE “D” (ECK00100) BACKSHELL (ECK01022)

15-PIN FEMALE “D” (ECK00326) JACKSOCKET (ECK00328)

User-Supplied Circuitry Shown for Reference.

Figure 3-2: ESTOP1

SOFT-START BOARD

DRIVE ASSEMBLY

MOTORS

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Options

AC INLET

SWITCH/BREAKER

CR1

CR2

ESTOP N.C.
ESTOP N.C.

9

9

10 10

7

7

8

8

SAFETY MONITOR
RESET

2

2

5

5

6

6

3

3

4

4

1

1

+24 DC POWER SUPPLY

+24V

COM

CR1 CR2

CR1 CR2 CR1 CR2

ESTOP OPTO

15-PIN MALE “D” (ECK00100) BACKSHELL (ECK01022)

15-PIN FEMALE “D” (ECK00326) JACKSOCKET (ECK00328)

User-Supplied Circuitry Shown for Reference.

Figure 3-3: ESTOP2

SOFT-START BOARD

DRIVE ASSEMBLY

MOTORS

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Epaq MR Hardware Manual

AC INLET

SWITCH/BREAKER

CR1

CR2

ESTOP N.C.
ESTOP N.C.

9

9

10 10

7

7

8

8

+24 DC POWER SUPPLY

+24V

COM

CR1 CR2

SAFETY MONITOR
RESET

2

2

5

5

6

6

3

3

4

4

1

1

CR1 CR1 CR2

15-PIN MALE “D” (ECK00100) BACKSHELL (ECK01022)

15-PIN FEMALE “D” (ECK00326) JACKSOCKET (ECK00328)

User-Supplied Circuitry Shown for Reference.

CR2
CR1 CR2

ESTOP OPTO
Motor Power Supply

Figure 3-4: ESTOP3

SOFT-START BOARD

DRIVE ASSEMBLY

MOTORS

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3.2. Joystick Interface
The Joystick Interface is an optional 15-pin `D’ style connector accessible at the rear of the Epaq MR chassis. The joystick option is factory wired to a specified axis’ I/O option board. The Joystick Interface uses two analog inputs and three dedicated inputs (joystick buttons). IO signals not used by the joystick are not available to the user. Joystick electrical connections are shown in Figure 3-6.

FEEDBACK

COMMUNICATIONS EXT DRIVE

RS232

AUX ENCODER

Joystick

JOYSTICK

8 15

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

9 1

MOTOR
Figure 3-5:

DIGITAL / ANALOG IO
Joystick Interface

Table 3-5: Joystick Interface Connector Pin Assignment

Pin # Label

Description

1 +5V

+5V power

2 JSA

Joystick button A (Input 5) Axis Select

3 JOY X

Analog Input 0

4 Common

Joystick power common

5 Not Used

Not Used

6 JOY Y

Analog Input 1

7 JS B

Joystick button B (Input 6) Speed Select

8 Not Used

Not Used

9 Not Used

Not Used

10 Not Used

Not Used

11 Not Used

Not Used

12 Shield

Shield

13 Interlock

Joystick Interlock (Input 7)

14 Not Used

Not Used

15 Not Used

Not Used

Mating Connector 15-Pin D-Connector Backshell

Aerotech P/N ECK00100 ECK01022

ESTOP
In/Out/Bi Output Input Input N/A N/A Input Input N/A N/A N/A N/A N/A Input N/A N/A
Third Party P/N FCI DA15P064TXLF Amphenol 17E-1725-2

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Epaq MR Hardware Manual

Aerotech joysticks JI (NEMA12 (IP54) rated) and JBV are powered from 5V and have a nominal 2.5V output in the center detent position. Three buttons are used to select axis pairs and speed ranges. An optional interlock signal is used to indicate to the controller that the joystick is present. Joystick control will not activate unless the joystick is in the center location. Third party devices can be used provided they produce a symmetric output voltage within the range of -10V to +10V.
All joystick operating parameters are software configurable. Refer to the Ensemble Help file for additional information.

Controller Analog Input 0 PIN-3

JOY-X

Analog Input 1 PIN-6

JOY-Y

AEROTECH, INC. 101 ZETA DRIVE PITTSBURGH, PA 15238
A CB

+5 Volts PIN-1

+5 Volts

Common PIN-4

Common

Input 5 PIN-2 Input 6 PIN-7 Input 7 PIN-13

Button A Button B Joy Interlock

Button A: Axis Pair Select Button B: Speed Select Button C: Exit Slew Mode
IN914

Shield

Button B Button A Button C Buttons are all Normally Open
Figure 3-6: Joystick Interface

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Maintenance

Epaq MR Hardware Manual

Chapter 4: Maintenance
This section covers the internal boards, important board components, and how to clean the drive.
D A N G E R : Always disconnect the Mains power connection before opening the Epaq MR chassis.
D A N G E R : Before performing any tests, be aware of lethal voltages inside the controller and at the input and output power connections. A qualified service technician or electrician should perform these tests.

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Maintenance

4.1. Power Board Assembly
D A N G E R : Always disconnect the Mains power connection before opening the Epaq MR chassis. Fuses must not be changed with Mains power applied to unit.
The Epaq MR is factory wired for either 100/200 VAC or 115/230 VAC input voltage. The input voltage select switches (S1 and S2) are located on the left side of the Epaq MR power board. Both switches must be set the same, all UP or all DOWN. The UP setting on S1 and S2 configures the Epaq MR for high voltage (200 or 230 V). The DOWN setting is for low voltage (100 or 115 V).

W A R N I N G : Do not change power switches while power is connected.

W A R N I N G : Improper configuration will cause fuses F1-F4 to open.

W A R N I N G : An input power label is affixed to the back of the Epaq MR at the factory. If you change the input voltage, you are responsible for changing the label on the back of the unit.

1

MATE: ECK01577

BW6 +

TB8

BW5

1

MATE: ECK01577

TB7

BW4 +

*Fuse values are option-based. Contact Aerotech GTS for more information.

MATE: ECK00213

MATE: ECK00213

TB3 1

TB4 1

B

S2

F3 3ASB 3AG (Default*)

A

TB2

1

MATE: ECK01577

B

S1

A

TB1

1

MATE: ECK01577

F1 3ASB 3AG (Default*)

F2 4ASB 3AG (Default*)

F4 4ASB 3AG (Default*)

TR1 5 OHM TR2 5 OHM

DS1

C2 BR2
C1 BR1
J1 1 K1
Board Assembly
Drawing Number: 690D1645, Rev. -1

1

MATE: ECK01577

TB6

1 TB5 MATE: ECK00213

Table 4-1: Component Select

Component

100/115 VAC

SW1, SW2

B

BW4, BW6

BW5

Figure 4-1: Power Board

200/230 VAC A –

Bipolar –
Factory Select Installed

Unipolar –
Installed Factory Select

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Maintenance

Epaq MR Hardware Manual

4.2. Preventative Maintenance
The Epaq MR and external wiring should be inspected monthly. Inspections may be required at more frequent intervals, depending on the environment and use of the system. The table below lists the recommended checks that should be made during these inspections.

D A N G E R : Disconnect power to Epaq MR main supply before servicing.

D A N G E R : Disconnect power to avoid shock hazard.

Table 4-2: Preventative Maintenance Check Visually Check chassis for loose or damaged parts / hardware. Note: Internal inspection is not required. Inspect cooling vents. Check for fluids or electrically conductive material exposure. Visually inspect all cables and connections.

Action to be Taken Parts should be repaired as required. If internal damage is suspected, these parts should be checked and repairs made if necessary.
Remove any accumulated material from vents.
Any fluids or electrically conductive material must not be permitted to enter the Epaq MR.
Tighten or re-secure any loose connections. Replace worn or frayed cables. Replace broken connectors.

Cleaning
The Epaq MR chassis can be wiped with a clean, dry, soft cloth. The cloth may be slightly moistened if required with water or isopropyl alcohol to aid in cleaning if necessary. In this case, be careful not to allow moisture to enter the Epaq MR or onto exposed connectors / components. Fluids and sprays are not recommended because of the chance for internal contamination, which may result in electrical shorts and/or corrosion. The electrical power must be disconnected from the Epaq MR while cleaning. Do not allow cleaning substances or other fluids to enter the Epaq MR or to get on to any of the connectors. Avoid cleaning labels to prevent removing the label information.

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Warranty and Field Service

Epaq MR Hardware Manual

Appendix A: Warranty and Field Service
Aerotech, Inc. warrants its products to be free from harmful defects caused by faulty materials or poor workmanship for a minimum period of one year from date of shipment from Aerotech. Aerotech’s liability is limited to replacing, repairing or issuing credit, at its option, for any products that are returned by the original purchaser during the warranty period. Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer, whether or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided, or whether or not Aerotech’s products are specifically designed and/or manufactured for buyer’s use or purpose. Aerotech’s liability on any claim for loss or damage arising out of the sale, resale, or use of any of its products shall in no event exceed the selling price of the unit.
THE EXPRESS WARRANTY SET FORTH HEREIN IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, BY OPERATION OF LAW OR OTHERWISE. IN NO EVENT SHALL AEROTECH BE LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGES.
Return Products Procedure
Claims for shipment damage (evident or concealed) must be filed with the carrier by the buyer. Aerotech must be notified within thirty (30) days of shipment of incorrect material. No product may be returned, whether in warranty or out of warranty, without first obtaining approval from Aerotech. No credit will be given nor repairs made for products returned without such approval. A “Return Materials Authorization (RMA)” number must accompany any returned product(s). The RMA number may be obtained by calling an Aerotech service center or by submitting the appropriate request available on our website (www.aerotech.com). Products must be returned, prepaid, to an Aerotech service center (no C.O.D. or Collect Freight accepted). The status of any product returned later than thirty (30) days after the issuance of a return authorization number will be subject to review.
Visit https://www.aerotech.com/global-technical-support.aspx for the location of your nearest Aerotech Service center.
Returned Product Warranty Determination
After Aerotech’s examination, warranty or out-of-warranty status will be determined. If upon Aerotech’s examination a warranted defect exists, then the product(s) will be repaired at no charge and shipped, prepaid, back to the buyer. If the buyer desires an expedited method of return, the product(s) will be shipped collect. Warranty repairs do not extend the original warranty period.
Fixed Fee Repairs – Products having fixed-fee pricing will require a valid purchase order or credit card particulars before any service work can begin.
All Other Repairs – After Aerotech’s evaluation, the buyer shall be notified of the repair cost. At such time the buyer must issue a valid purchase order to cover the cost of the repair and freight, or authorize the product(s) to be shipped back as is, at the buyer’s expense. Failure to obtain a purchase order number or approval within thirty (30) days of notification will result in the product(s) being returned as is, at the buyer’s expense.
Repair work is warranted for ninety (90) days from date of shipment. Replacement components are warranted for one year from date of shipment.

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Warranty and Field Service

Rush Service

At times, the buyer may desire to expedite a repair. Regardless of warranty or out-of-warranty status, the buyer must issue a valid purchase order to cover the added rush service cost. Rush service is subject to Aerotech’s approval.

On-site Warranty Repair

If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts, and cannot be returned to the Aerotech service center for repair, and if Aerotech determines the problem could be warranty-related, then the following policy applies:

Aerotech will provide an on-site Field Service Representative in a reasonable amount of time, provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs. For warranty field repairs, the customer will not be charged for the cost of labor and material. If service is rendered at times other than normal work periods, then special rates apply.

If during the on-site repair it is determined the problem is not warranty related, then the terms and conditions stated in the following “On-Site Non- Warranty Repair” section apply.

On-site Non-Warranty Repair

If any Aerotech product cannot be made functional by telephone assistance or purchased replacement parts, and cannot be returned to the Aerotech service center for repair, then the following field service policy applies:

Aerotech will provide an on-site Field Service Representative in a reasonable amount of time, provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs and the prevailing labor cost, including travel time, necessary to complete the repair.

Service Locations

http://www.aerotech.com/contact-sales.aspx?mapState=showMap

USA, CANADA, MEXICO Aerotech, Inc.
Global Headquarters Phone: +1-412-967-6440
Fax: +1-412-967-6870

CHINA Aerotech China Full-Service Subsidiary Phone: +86 (21) 3319 7715

GERMANY Aerotech Germany Full-Service Subsidiary Phone: +49 (0)911 967 9370 Fax: +49 (0)911 967 93720

JAPAN Aerotech Japan Full-Service Subsidiary Phone: +81 (0)50 5830 6814 Fax: +81 (0)43 306 3773

TAIWAN Aerotech Taiwan Full-Service Subsidiary Phone: +886 (0)2 8751 6690

Have your customer order number ready before calling.

UNITED KINGDOM Aerotech United Kingdom
Full-Service Subsidiary Phone: +44 (0)1256 855055
Fax: +44 (0)1256 855649

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Revision History

Epaq MR Hardware Manual

Appendix B: Revision History

1.07.00a Changes: Updated fuse information on Figure 4-1.

Revision
1.07.00
1.06.00
1.05.00 1.04.00 1.03.00 1.02.00 1.01.00 1.00.00

Description The following sections have been updated:
l EU Declaration of Conformity l Agency Approvals l Section 2.2.3. I/O and Signal Wiring Requirements l Section 2.3.1.2. Unpowered Motor and Feedback Phasing l Section 2.4.1.3. Encoder Phasing l Section 2.4.7. Differential Analog Input 0 l Analog Input 1 l Section 2.5.2. Analog Output 1 l Section 2.5.4. Opto-Isolated Inputs l Section 2.6. Aux Encoder l Declaration of Conformity updated: EU Declaration of Conformity l AC Power Connections section updated: Section 2.2.1. l I/O and Signal Wiring Requirements section updated: Section 2.2.3. l Brushless Motor Connections updated: Section 2.3.1. l Powered Motor Phasing section updated:Section 2.3.1.1. l Unpowered Motor and Feedback Phasing updated: Section 2.3.1.2. l Analog Input 0 section updated: Section 2.4.7. l Analog Input 1 section updated: Section 2.5.1. l Opto- Isolated Inputs section updated: Section 2.5.4. l Opto-Isolated Outputs section updated: Section 2.5.3. l Aux Encoder section updated: Section 2.6.
Revision changes have been archived. If you need a copy of this revision, contact Aerotech Global Technical Support.

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Index

Epaq MR Hardware Manual

Index

-I/O Expansion Board

67

2

2014/35/EU

7

A

AC Power Connections

27

AC Power Input

16

AC Power Wiring Specifications

27

Aeronet Interface

63

Altitude

22

Ambient Temperature

22

Analog Encoder Specifications

40

Analog Input 0

50

Analog Input 1

52

Analog Output 1

53

Audible Noise

22

Aux Encoder

58

Auxiliary Power Outputs

16

B

Brake Output

49

Brushless Motor Connections

32

Brushless Motor Phasing

32

Brushless Motor Phasing Goal

34

Bus Voltage Options

16

C

Chassis Electrical Specifications

16

Check chassis for loose or damaged parts /

hardware

77

Check for fluids or electrically conductive

material exposure

77

Communications Connector

62

Continuous Output Current specifications 17-18

Control Supply specifications

17-18

D

DC Brush Motor Connections

35

DC Brush Motor Phasing

35

Declaration of Conformity

7

Digital / Analog IO Connections

51

dimensions

20

Drive and Software Compatibility

23

E

Efficiency of Power Amplifier specifications

17

Electrical Installation

26

Electrical Specifications

16-18

Encoder and Hall Signal Diagnostics

33

Encoder Fault Input

46

Encoder Fault Interface Input

46

Encoder Fault Pin Assignment

46

Encoder Inputs

38

Encoder Phasing

42

Encoder Phasing Reference Diagram

42

Encoder Pin Assignment

38

End Of Travel Limit Input Interface (J207)

47

End Of Travel Limit Phasing

48

Environmental Specifications

22

ESTOP

68

Ethernet Interface

62

Ext Drive Connector

63

F

Feature Summary

14

Feedback Monitoring

33

Functional Diagram

15

G

Global Technical Support

2

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Index

H

Hall-Effect Feedback Interface Pin Assignment 44

Hall-Effect Inputs

44

Humidity

22

I

I/O and Signal Wiring Requirements

29

Inrush Current

16

inspect all cables and connections

77

Inspect cooling vents

77

Inspection

77

Installation and Configuration

25

Introduction

13

ISO 13849-1 & -2

7

Isolation

17-18

J

Joystick Interface

72

L

Leakage Current

16

Limit Input Diagnostic Display

48

Line Driver Encoder Interface

39

line filter

28

Linear Amplifier Electrical Specifications

18

low voltage connections

26

M

Maintenance

75

Mating Connector

31

Mechanical Dimensions

20

Minimum Load

18

Minimum Load Inductance specifications

17

Modes of Operation

17-18

Motor Feedback Connections

37

Motor Feedback Connector Pin Assignment

37

Motor Output Connections

31

Motor Phasing Oscilloscope Example

34

Motor Power Output Connections

31

Motor Power Output Mating Connector

31

Motor Supply specifications

17-18

N

Noise

22

O

optional joysticks

73

Opto-Isolated Inputs

56

Opto-Isolated Outputs

54

Output Impedance

18

Output Voltage

18

Output Voltage specifications

17

Overview

13

P

PC Configuration and Operation Information 65

Peak Output Current specifications

17-18

Pollution

22

Position Feedback in the Diagnostic Display 43

Position Synchronized Output (PSO)

60

Position Synchronized Output (PSO)/Laser Firing 60

Power Amplifier Bandwidth specifications 17-18

Powered Motor Phasing

33

Preventative Maintenance

77

Protection

16

Protective Features

17-18

PSO

60

PSO Output Sources

60

PWM Switching Frequency specifications

17

Q

Quick Installation Guide

11

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Index

Quick Start Connections R
RS-422 Line Driver Encoder (Standard) S
Safety Procedures and Warnings Servo Amplifier Electrical Specifications Solid State Relay Rating Stepper Motor Connections Stepper Motor Phasing Support
T Technical Support Thermistor Input
U UFM-ST unit weight Unpacking the Chassis Unpowered Motor and Feedback Phasing Use User Power Supply specifications
V Voltage Selection
W Warnings Warranty and Field Service

11
39
9 17 49 36 36
2
2 45
28 21 25 34 22 17-18
30
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