AEROTECH EDU209 Epaq MR Stand Alone Controller and Drive Rack User Manual
- June 14, 2024
- aerotech
Table of Contents
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. Q: Where can I find the electrical specifications for the EpaqMR?
A: The electrical specifications can be found in Chapter 1:
Introduction, specifically section 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. 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
2
3
4
5
6
7
8
1
2
3
4
5
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7
8
1
2
3
4
5
6
7
8
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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10
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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
4
5
6
7
8
1
2
3
4
5
6
7
8
31
2
3
4
5
6
7
8
1
2
3
4
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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Epaq MR Hardware Manual
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
5
6
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
13
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
14
Chapter 1
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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
15
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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Chapter 1
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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
17
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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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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Introduction
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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Introduction
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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Epaq MR Hardware Manual
Installation and Configuration
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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Epaq MR Hardware Manual
Installation and Configuration
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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Installation and Configuration
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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Installation and Configuration
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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Installation and Configuration
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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Installation and Configuration
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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Installation and Configuration
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.
0°
90° 180° 270° 360° 450° 540° 630° 720° 810°
LINEAR MOTOR
SIN
Forcer Wires
SIN-N
Magnet Track
0°
90° 180° 270° 360° 450° 540° 630° 720° 810°
COS
1Vpk-pk
Forcer
Positive MOVE (Clockwise)
COS-N
ROTARY MOTOR
0°
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).
0°
90° 180° 270° 360° 450° 540° 630° 720° 810°
SIN
SIN-N
LINEAR MOTOR Forcer Wires
Magnet Track
Forcer
Positive MOVE (Clockwise)
0°
90° 180° 270° 360° 450° 540° 630° 720° 810°
COS
1Vpk-pk
COS-N
0°
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
Epaq MR Hardware Manual
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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Epaq MR Hardware Manual
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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Options
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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Options
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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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Appendix A
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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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Appendix B
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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
9 79
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References
- Precision Motion & Automation Company | Aerotech
- Precision Motion & Automation Company | Aerotech
- Contact Your Global Precision Motion Partner | Aerotech
- Global Tech Support – Aerotech US
- Global Tech Support – Aerotech US
- Global Tech Support – Aerotech US
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