Ensemble Epaq Hardware Manual

Transcription

Ensemble Epaq Hardware
Manual
P/N: EDU184
Revision: 2.04.00
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 PCto-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 15238-2897
Email: [email protected]
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
Germany
China
Phone: +49 (0)911 967 9370
Phone: +86 (21) 3319 7715
Fax: +49 (0)911 967 93720
France
Taiwan
Phone: +33 1 64 93 58 67
Phone: +886 (0)2 8751 6690
This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the
express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and
may be trademarks of their respective companies.
Copyright © 2006-2015, Aerotech, Inc. All rights reserved.
Table of Contents
Table of Contents
Table of Contents
List of Figures
List of Tables
iii
v
vii
EC Declaration of Conformity
ix
Safety Procedures and Warnings
xi
Quick Installation Guide
xiii
Chapter 1: Introduction
1
1.1. Electrical Specifications
1.2. Mechanical Specifications
1.3. Environmental Specifications
1.4. Drive and Software Compatibility
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Chapter 2: Installation and Configuration
15
2.1. Electrical Installation
2.1.1. AC Power Connections
2.1.2. Minimizing Conducted, Radiated, and System Noise
2.1.3. I/O and Signal Wiring Requirements
2.2. Motor Output Connections
2.2.1. Brushless Motor Connections
2.2.1.1. Powered Motor Phasing
2.2.1.2. Unpowered Motor and Feedback Phasing
2.2.2. DC Brush Motor Connections
2.2.2.1. DC Brush Motor Phasing
2.2.3. Stepper Motor Connections
2.2.3.1. Stepper Motor Phasing
2.3. Motor Feedback Connections
2.3.1. Encoder Interface
2.3.1.1. RS-422 Line Driver Encoder (Standard)
2.3.1.2. Analog Encoder Interface
2.3.1.3. Encoder Phasing
2.3.2. Hall-Effect Interface
2.3.3. Thermistor Interface
2.3.4. End Of Travel Limit Input Interface
2.3.4.1. End Of Travel Limit Phasing
2.3.5. Encoder Fault Interface
2.3.6. Brake Output
2.3.7. Analog Input 0
2.4. Emergency Stop Sense Input (ESTOP)
2.5. Communicating with the Epaq
2.5.1. USB Interface
2.5.2. Ethernet Interface
2.5.3. RS-232 Interface
2.5.4. External Drive Interface
2.5.5. General Purpose Interface Bus (GPIB)
2.6. PC Configuration and Operation Information
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Chapter 3: -IO Expansion Board
57
3.1. User Power
3.2. Brake Power Supply
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iii
Table of Contents
3.2.1. Solid State Relay Specifications
3.3. Analog Input 1
3.4. Analog Output 1
3.5. Opto-Isolated Inputs
3.6. Opto-Isolated Outputs
3.7. Auxiliary Encoder Channel/PSO Output
3.7.1. Position Synchronized Output (PSO)/Laser Firing (Aux Enc Connector)
Chapter 4: Standard Interconnection Cables
4.1. Joystick Interface
4.2. Handwheel Interface
Chapter 5: Maintenance
5.1. Chassis Control Board
5.2. Power Board
5.3. Integrated Axis Control Boards (Amplifier)
5.4. Integrated Axis I/O Expansion Board (Amplifier)
5.5. Fuse Replacement
5.6. Preventative Maintenance
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Appendix A: Warranty and Field Service
89
Appendix B: Revision History
91
Appendix C: Chassis Disassembly
93
Index
95
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Table of Contents
List of Figures
Figure 1-1:
Figure 1-2:
Figure 1-3:
Figure 2-1:
Figure 2-2:
Figure 2-3:
Figure 2-4:
Figure 2-5:
Figure 2-6:
Figure 2-7:
Figure 2-8:
Figure 2-9:
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Figure 2-11:
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Figure 2-24:
Figure 2-25:
Figure 2-26:
Figure 2-27:
Figure 2-28:
Figure 2-29:
Figure 2-30:
Figure 2-31:
Figure 2-32:
Figure 2-33:
Figure 2-34:
Figure 2-35:
Figure 3-1:
Figure 3-2:
Figure 3-3:
Figure 3-4:
Figure 3-5:
Figure 3-6:
Figure 3-7:
Figure 3-8:
Figure 3-9:
Figure 3-10:
Figure 3-11:
Figure 3-12:
Figure 3-13:
Epaq Networked Digital Drive
Functional Diagram
Dimensions
Power and Control Connections
Power Switch
Power Supply Connection
Motor Power Connections
Brushless Motor Configuration
Encoder and Hall Signal Diagnostics
Motor Phasing Oscilloscope Example
Hall Phasing with Oscilloscope
Brushless Motor Phasing Goal
DC Brush Motor Configuration
Clockwise Motor Rotation
MP Stepper Motor Configuration
ML Stepper Motor Configuration
Motor Feedback Connections
Line Driver Encoder Interface
Analog Encoder Phasing Reference Diagram
Analog Encoder Interface
Encoder Phasing Reference Diagram (Standard)
Position Feedback in the Diagnostic Display
Hall-Effect Inputs
Thermistor Interface Input
End of Travel Limit Input Connections
End of Travel Limit Interface Input
Limit Input Diagnostic Display
Encoder Fault Interface Input
Analog Input 0
User Interrupt Inputs
ESTOP Connector and Pin Location
USB Connector Location
Ethernet Connector Location
RS-232 Connector Location
RS-232/RS-485 Interface
Epaq Connected to Three Ensemble MPs
GPIB Connector Location
Ensemble Epaq with -IO Option Board
User Power Connector Location
Brake Power Supply Connector Location
Brake Connected to the Feedback Connector
Brake Connected to Brake Power Supply connector
Analog Input 1 Connector Location
Analog Input Typical Connection
Analog Output 1 Connector
Inputs Connected to a Current Sourcing Device
Inputs Connected to a Current Sinking Device
Outputs Connected in Current Sourcing Mode
Outputs Connected in Current Sinking Mode
Connector and Pin Locations
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Figure 3-14:
Figure 3-15:
Figure 4-1:
Figure 4-2:
Figure 4-3:
Figure 5-1:
Figure 5-2:
Figure 5-3:
Figure 5-4:
Figure 5-5:
Figure C-1:
vi
Auxiliary Encoder Channel
PSO Interface
Joystick Interface
Joystick Connector Location
Handwheel Interconnection
Control Board Assembly
Power Board Assembly
MP Board Assembly
ML Board Assembly
-IO Option Board Assembly
Chassis Disassembly
Table of Contents
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Table of Contents
List of Tables
Table 1-1:
Table 1-2:
Table 1-3:
Table 1-4:
Table 1-5:
Table 1-6:
Table 2-1:
Table 2-2:
Table 2-3:
Table 2-4:
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Table 3-1:
Table 3-2:
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Table 4-1:
Table 5-1:
Table 5-2:
Table 5-3:
Table 5-4:
Table 5-5:
Table 5-6:
Feature Summary
Configurations and Options
Chassis Electrical Specifications
Servo Amplifier Electrical Specifications
Physical Specifications
Ensemble Drive and Software Compatibility
Main AC Power Input Voltages and Current Requirements
Ferrite Bead Part Numbers
Motor Power Output Connections
Terminal Block Mating Connector
Wire Colors for Aerotech Supplied Cables (Brushless)
Wire Colors for Aerotech Supplied Cables (DC Brush)
Wire Colors for Aerotech Supplied Cables (Stepper)
Motor Feedback Connector Pin Assignment
Motor Feedback Mating Connector
Encoder Interface Pin Assignment
Analog Encoder Specifications
Hall-Effect Feedback Interface Pin Assignment
Thermistor Interface Pin Assignment
End of Travel Limit Input Interface Pin Assignment
Encoder Fault Interface Pin Assignment
Brake Output Pin Assignment
Analog Input 0 Pin Assignment
Electrical Noise Suppression Devices
RS-232 Connector Pin Assignment
Aeronet Cable Part Numbers
User Power Connector Pin Assignment
Brake Power Mating Connector
Brake Power Connector Pin Assignment
Motor Feedback Connector Brake Output Connector Pin Assignment Relay Specifications
Analog Inputs Connector Pin Assignment
Analog Output Connector Pin Assignment
Digital Input Specifications Port 1 Opto-Isolated Input Connector Pin Assignment
Opto-Isolated Input Mating Connector
Port 1 Opto-Isolated Output Connector Pin Assignment Opto-Isolated Output Mating Connector
Output Specifications
PSO Output Pin Assignment (Aux Enc)
PSO Output Sources
Joystick Connector Pin Assignment
Troubleshooting
LED Description
Control Board Jumper Configuration Serial Communication Mode Jumper Select
Fuse Information
Preventative Maintenance
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Table of Contents
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www.aerotech.com
Declaration of Conformity
EC Declaration of Conformity
Manufacturer
Address
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2897
USA
Epaq
All
Product
Model/Types
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2006/95/EC
2006/42/EC
2011/65/EU
Low Voltage Directive
Machinery Directive
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
EN ISO 13849-1 & -2
Name
Position
Location
Date
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Safety requirements for electrical equipment
Safety related parts of control systems
/ Alex Weibel
Engineer Verifying Compliance
Pittsburgh, PA
June 3, 2015
ix
Declaration of Conformity
x
www.aerotech.com
Electrical Safety
Ensemble Epaq
Safety Procedures and Warnings
Read this manual in its entirety before installing, operating, or servicing this product. If you do not understand
the information contained herein, contact an Aerotech representative before proceeding. Strictly adhere to
the statements given in this section and other handling, use, and operational information given throughout
the manual to avoid injury to you and damage to the equipment.
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. Disconnect electrical power before making any mechanical adjustments or performing
maintenance.
2. Disconnect electrical power before performing any wiring.
3. Residual voltages greater than 60V may be present inside Ensemble Epaq chassis for
longer than 10 seconds after power has been disconnected.
4. 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.
5. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
6. Make sure the Ensemble Epaq and all components are properly grounded in accordance
with local electrical safety requirements.
7. 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 the Ensemble Epaq to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
5. If the Ensemble Epaq is used in a manner not specified by the manufacturer, the protection
provided by the Ensemble Epaq 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. The Ensemble Epaq is intended for light industrial manufacturing or laboratory use. Use of
the Ensemble Epaq for unintended applications can result in injury and damage to the
equipment.
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xi
Ensemble Epaq
Electrical Safety
xii
www.aerotech.com
This chapter describes the order in which connections and settings should typically be made to the Epaq.
There are four standard connections that must be made to the Epaq.
AXIS 1
GPIB
2
USB
ESTOP
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
USB
MRK IN POS
MRK IN POS
1
Ethernet
AXIS 3
ENET
4
4
MRK IN POS
EXT DRIVE
4
MRK IN POS
1
1
4
4
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
4
4
4
4
4
1
1
1
1
1
Motor Feedback
1
MRK IN POS
1
AIN/AOUT
1
MRK IN POS
1
JOYSTICK
1
AC Power
10
10
OPTO-IN
J100
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
OPTO-IN
FEEDBACK 1
RS232
A
B
10
C
DANGER!
MOTOR
High Voltage
3
A
B
10
C
A
B
10
C
Motor Power
OPTOOUT
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
1 From the power source to the AC Power input
2 From the PC to the USB or Ethernet input
3 From the Motor to the Motor Power input
4 From the Motor to the Motor Feedback input (depending on the type of motor).
Topic
Section
AC Power
PC Communication
Motor Power
Motor Feedback
Section 2.1.1. AC Power Connections
Section 2.5. Communicating with the Epaq
Section 2.2. Motor Output Connections
Section 2.3. Motor Feedback Connections
Figure 1:
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Quick Start Connections
xiii
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www.aerotech.com
Introduction
Chapter 1: Introduction
Aerotech’s Epaq is a 3U height, 19” wide, rack-mountable, intelligent drive chassis, capable of powering up
to nine axes of motion. Six axes of motion control are available in one integrated, stand-alone package and
can be expanded to nine axes of motion control externally. This flexible configuration style allows users to
mix and match drive types (linear versus PWM, brush or brushless, stepper, etc.) within the same
positioning system using a common programming and control platform. Multiple Epaqs can be controlled
from one Windows PC through Ethernet or USB. Optional on-board encoder interpolation offers the user
programmable axis resolution (assuming a sine-wave encoder input signal), including the ability to change
interpolation (multiplication) values through software.
Directional Keypad
LCD Screen
Power LED
POWER
Power
Switch
ESTOP
Button
AC Power
Input
Control Board
and Options
Axis 1
Axes 2 through 6 (Optional)
AXIS 1
GPIB
17
18
19
20
AXIS 2
AXIS 3
AXIS 4
AXIS 5
21
AXIS 6
5
1
6
AUX ENC
12
BRAKE PWR
+5V/GND
ESTOP
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
USB
9
MRK IN POS
MRK IN POS
1
ENET
13
4
2
MRK IN POS
1
4
7
1
JOYSTICK
MRK IN POS
1
1
4
4
4
4
AIN/AOUT
14
EXT DRIVE
MRK IN POS
1
AIN/AOUT
10
MRK IN POS
1
AIN/AOUT
AIN/AOUT
1
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
4
4
4
4
4
1
1
1
1
1
15
3
10
J100
10
OPTO-IN
8
10
OPTO-IN
16
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
FEEDBACK 1
10
OPTO-IN
10
OPTO-IN
FEEDBACK 1
FEEDBACK 1
OPTO-IN
FEEDBACK 1
11
RS232
A
B
10
C
4
DANGER!
MOTOR
High Voltage
Control Board
1.
2.
3.
4.
A
B
10
C
OPTOOUT
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
Axis 1
USB connector
Ethernet connector
Joystick 15-pin D-style connector
RS-232 9-pin D-style connector
Axis 1 I/O (standard on Axis 1)
5.
6.
7.
8.
GPIB IEEE-488 Connector (talker/listener)
ESTOP (Emergency Stop) 9-pin D-style connector
External Drive Connector
J100 / additional optional RS-232 connector
12.
13.
14.
15.
16.
Figure 1-1:
www.aerotech.com
MOTOR
A
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
Additional Axes
9.
LED Status Display
10. Feedback 25-pin D-style connector
11. Motor Connector (terminal block)
Options
A
B
10
C
OPTOOUT
Auxiliary Encoder 9-pin D-style connector
Brake Power (terminal block)
Analog Input/Output (terminal block)
Opto-Isolator Input (terminal block)
Opto-Isolator Output (terminal block)
17.
18.
19.
20.
21.
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Axes 2 through 6 are optional.
The I/O board is optional on axes
2 through 6.
In this example:
This Epaq is configured for 5 axes
Axis 5 does not support the -IO option
Epaq Networked Digital Drive
Chapter 1
1
Introduction
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
Table 1-1:
Feature Summary
Feature
Details
Axes
Axis Loop Type /
Update Rate
On-Board Memory
One to six axes (integral), expandable to nine externally
PID loop with up to 20 kHz servo update rate with feedforward; four userconfigurable digital filters (e.g., notch, low pass)
Program Storage
2 MB flash memory for user programs, parameters,
miscellaneous storage
Program Execution 8 MB RAM
Brushless (linear or rotary) servo with on-board commutation
DC brush servo
Stepper / microstepper (on-board commutation)
6-channel encoder interface, differential RS-422 signal, sine, cosine, and marker;
40 MHz input data rate; optional onboard analog encoder interpolation (of up to
1024-times encoder multiplication)
Absolute, incremental, dynamic trajectory correction
Independent
Point-to-point incremental; target position or velocity;
velocity profiles; time based; free run
Coordinated
Advanced queuing and deferred execution features for
simultaneous command execution
Interpolated
Up to 6-axis linear and circular interpolation
Digitally Geared
Gearing with optional auxiliary encoder input
Advanced Features Automatic PID loop gain computation (autotuning)
Contouring
Cubic spline curve-fitting; velocity profiling
Error Mapping
2D error mapping, backlash compensation
Linear and jerk limiting parabolic; independent acceleration and deceleration
profiles possible
Rate, time, or distance based; independent acceleration and deceleration
capability
Up to 5 independent tasks
Driver Type
Compatibility
Position Feedback
Position Modes
Motion Types
Acceleration Profiles
Acceleration Ramp
Programmable
Multitasking
Programming
Process Time
2
Command Set
AeroBASIC, LabVIEW, VB.Net, C#, Native C++
programming
Interface
On-board menu-driven program selection from front panel;
program editing and download with Windows® PC through
Ethernet or USB to Host PC, or ASCII commands via RS232, IEEE-488, or Ethernet
Command execution up to 1000 lines of code per 1 ms (from command sent to
motion start); read request @ 1 ms; average is 7 µs per program line (e.g., c = a +
b)
Chapter 1
www.aerotech.com
Introduction
Feature
Details
Command Execution
Modes
AUTO
SINGLE
Input/Output
Encoder Inputs
Additional Interfaces
Other IO
Power Output
Capability
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Program runs to completion upon startup
Full debug capability to step, step over, step into individual
program lines
IMMEDIATE
Commands are executed upon entry
JOG
Axes controlled with jog pad on front panel or optional
joystick
REMOTE
Command execution controlled by remote host through
Ethernet, RS-232, or IEEE-488 communications port via
ASCII strings
Standard
The chassis includes: ESTOP, RS-232, GPIB Each
amplifier axis includes: CW, CCW, and Home limits; DIR,
CLK, Hall effects, amplifier thermistor; 1 channel of 16-bit
A/D per axis (±10 VDC)
Optional IO Board
Eight opto-inputs with the IO board option; eight opto
(can be added to
outputs with the IO board option; sinking and sourcing
each amplifier axis) selection is available through the parameters; 5-24 VDC
can be used with any IO pins; single axis PSO (each axis
with optional IO; one additional 12-bit (±10 VDC) input and
one additional 16-bit (±5 VDC) output; brake relay: 0.5
amp solid-state relay available with option board;
secondary TTL RS-422 auxiliary encoder input; position
latch with 50 ns position capture latency
TTL RS-422 standard, and on optional IO auxiliary encoder input; optional
amplified sine encoder input on primary encoder channel; programmable
resolution up to 1024 times the analog encoder resolution; 10 MHz TTL RS-422
square wave primary or auxiliary encoder; 250 kHz amplified sine primary (with
optional onboard encoder multiplier board)
Serial
10/100 Base T Ethernet communication interface for
system setup, application networking, Epaq-to-Epaq
communications, embedded programming, immediate
commands, and Modbus over TCP; USB communication
interface for system setup, application networking,
Windows® PC control interface; RS-232 port with
programmable baud rate, length, parity, stop bits (second
RS-232 port optional)
Machine Control
ESTOP discrete input to stop all axes
Display
Backlit 8 x 40 character LCD
Keypad
5-key input pad
Parallel
One optional GPIB (IEEE-488)
600 watt, 54 VDC power supply for bus power to axis drives; optional 24 VDC
Chapter 1
3
Table 1-2:
Introduction
Rack or Desk-Mount Options
-S
Desktop Epaq (contains desktop related components)
-R
Rack-mount Epaq (contains rack-mount related components)
Standard or Blank Front Panel Options
-FPD
Standard front panel (with keypad and display )
-FPDE
Standard front panel (with keypad, display, and ESTOP switch)
-FPB
Blank front panel (without display or keypad)
-FPBE
Blank front panel with ESTOP switch (without display or keypad)
Bus Power Supply [Option uses transformer]
/XYY
X is the line voltage (X = A, B, C, or D)
A
115 VAC Input
B
230 VAC Input
C
100 VAC Input
D
200 VAC Input
YY is the bus voltage
10B
±10 VDC supply
20B
±20 VDC supply
30B
±30 VDC supply
40
40 V supply for up to 6 axes; required with /ESTOP0, /ESTOP1, /BRAKE-x
40B
±40 VDC supply
40LP
40 V low power supply for up to 3 axes; without /ESTOPx or /BRAKE-x
80
80LP
Obsolete Bus Power Supply (as of September 2008)
/24LP*
/24*
/48*
/54*
/90*
90 V supply for up to 6 axes; not compatible with /ESTOP and /BRAKE-x (if brake
control is needed, an external BRAKE24-2 must be used)
4
Chapter 1
www.aerotech.com
Introduction
Axis 1 Amplifier Options
/1-MP10I
Digital PWM, 10 A peak, 5 A continuous with I/O
/1-MP10I
/1-MP10MI
Digital PWM, 10 A peak, 5 A continuous with 4096X MXU with I/O
/1-MP10-HBI
Digital PWM, 10 A peak, 5 A continuous with I/O and half bus option
/1-MP10MI-HB
Digital PWM, 10 A peak, 5 A continuous with 4096X MXU, I/O, and half bus option
/1-ML10I
Digital Linear, 10 A peak, 5 A continuous with I/O
/1-ML10MI
Digital Linear, 10 A peak, 5 A continuous with 4096X MXU with I/O
/1-ML10HI
Digital Linear, 10 A peak, 5 A continuous with 65536X MXH with I/O
NOTE: The -HB option is a half bus option. It is only available in an Epaq that has PWM (MP) and linear
(ML) drives. For example, if the -HB option is ordered with the -40B bus, the MP drive(s) will be powered
from half the bus (common to +40, a 40 VDC bus).
Axis 2-6 Amplifier Options
/x-MP10
Digital PWM, 10 A peak, 5 A continuous
/x-MP10I
/x-MP10M
Digital PWM, 10 A peak, 5 A continuous with 4096X MXU
/x-MP10MI
Digital PWM, 10 A peak, 5 A continuous with 4096X MXU with I/O
/x-MP10-HB
Digital PWM, 10 A peak, 5 A continuous with half bus option
/x-MP10-HBI
Digital PWM, 10 A peak, 5 A continuous with I/O and half bus option
/x-MP10M-HB
Digital PWM, 10 A peak, 5 A continuous with 4096X MXU and half bus option
/x-MP10MI-HB
Digital PWM, 10 A peak, 5 A continuous with 4096X MXU, I/O, and half bus option
/x-ML10
Digital Linear, 10 A peak, 5 A continuous
/x-ML10I
Digital Linear, 10 A peak, 5 A continuous with I/O
/x-ML10M
Digital Linear, 10 A peak, 5 A continuous with 4096X MXU
/x-ML10MI
Digital Linear, 10 A peak, 5 A continuous with 4096X MXU with I/O
/x-ML10H
Digital Linear, 10 A peak, 5 A continuous with 65536X MXH
/x-ML10HI
Digital Linear, 10 A peak, 5 A continuous with 65536X MXH with I/O
/x-BLANK
No amplifier
/x-BLANKW
No amplifier, pre-wired only
*where x represents the axis number
www.aerotech.com
Chapter 1
5
Line Cord Options
/ENGLAND
/GERMANY
/ISRAEL
/AUSTRALIA
/INDIA
/US-115VAC
/US-230VAC
/NO-LINECORD
Brake Options
/BRAKE-1
/BRAKE-2
/BRAKE-3
/BRAKE-4
/BRAKE-5
/BRAKE-6
Software Options
5AX
EIP
Introduction
U.K. line cord
German line cord
Israel line cord
Australia line cord
India line cord
U.S. 115 VAC line cord
U.S. 230 VAC line cord
No line cord
Axis 1 wired for 24 V/1 A brake (/24LP not allowed )
Axis 2 wired for 24 V/1 A brake (amp must have “I” or “MI” option, /24LP not allowed)
Five Axis Contouring supplies the ability to coordinate motion on five or more axes.
Aerotech's EtherNet/IP™ option interfaces with Aerotech Ensemble drives and the
various ODVA Common Industrial Protocol (CIP™) objects that are used.
DCT
The Dynamic Controls Toolbox contains a collection of controller-level algorithms
that are designed to improve machine positioning, increase throughput, and reduce
cycle times.
ETM
The Enhanced Throughput Module improves machine throughput by measuring base
or frame vibration directly and using this information in a servo control algorithm.
Options (multiple selections allowable)
/ESTOP0
Disconnect AC to motor power supply; requires -FPDE or -FPBE options, and /24 or
/48 or /54 options
/ESTOP1
Disconnect AC to motor power supply using power relay; user connection via rear
panel 15D 24V connector; requires /24, /48, or /54 option
/GPIB
IEEE-488 GPIB interface (talker/listener)
/EXTAMP
External amplifier interface
/RS232-1
RS-232 port (additional RS-232 port at the J100 location)
6
Chapter 1
www.aerotech.com
Introduction
The following block diagram illustrates the features and options of the Epaq.
Controller
Amplifier
-IO Option*
Keypad
LCD Display
Encoder +5V / Common
PSO Output, Encoder Echo
SIN, COS, MRK (RS422)
AUX
ENC
Brake Power
Input or Relay
BRK
PWR
Ethernet Port
ENET
USB
USB Port
Analog Input 1 +/-
AIN /
AOUT
Analog Output 1
JOYSTICK
OPTO
OUT
8 Opto Outputs
(Sinking or Sourcing)
RS-232
RS-422
or
RS-485
RS-232
+5V / Common
OPTO
IN
8 Opto Inputs
(Sinking or Sourcing)
GPIB
Interface
(/GPIB)
-MXU/-MHX
Option
SIN, COS, MRK (RS422)
CW, CCW, Home Limits;
Encoder Fault; Hall A, B, C;
Motor Over Temperature
ESTOP
External
Interface
(/ESTOP1)
(/ESTOP0)
ESTOP
External Drive
(/EXTAMP)
Control
Power
Supply
AC Power
Input
Motor
Power
FEEDBACK
(Motor
Feedback)
Brake +/- (with the -IO Option)
Encoder +5V / Common
Analog Input 0 +/-
Amplifier
Control
Power
Heatsink Over
Temperature
A
PWM Amplifier
B
A
B
C
MOTOR
(Motor
Output)
C
* The -IO option is required on Amp 1, optional on Amps 2 through 6.
Figure 1-2:
www.aerotech.com
Functional Diagram
Chapter 1
7
Introduction
1.1. Electrical Specifications
The electrical specifications for the Epaq drive chassis are listed in Table 1-3 and the electrical
specifications for the servo amplifiers in 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 1-3:
Description
Specification
Bus Voltage Options *
40 VDC or 80 VDC at 600 W; 40 VDC or 80 VDC at 300 W [Factory
Configured]
90 - 112 VAC, 50/60 Hz, 10 A maximum
103 - 127 VAC, 50/60 Hz, 10 A maximum
180 - 224 VAC, 50/60 Hz, 6 A maximum
207 - 254 VAC, 50/60 Hz, 5 A maximum
+5 V provided on all axis feedback connectors for encoder, Hall, and limit
power
Fuse in AC power inlet (10 A, supplemental protection only)
Amplifier Output short circuit protection
Peak and RMS over current limit
Over Temperature shutdown
Opto and transformer isolation between control and power stages
Power switch contains a power-on indicator
Individual Amplifier LED’s indicates drive enabled state
Designed to EN61010 / UL3101
AC Power
100 VAC
115 VAC
200 VAC
230 VAC
Auxiliary Power Outputs
Protection
Isolation
Indicator (Power)
Indicator (Enabled)
Standards Conformity
* Bus power supplies of 24, 48, 54, and 90 VDC are obsolete as of September 2008.
8
Chapter 1
www.aerotech.com
Introduction
Table 1-4:
Description
Peak Bus Voltage
Peak Output Current
Continuous Output Current
PWM Switching Frequency
Power Amplifier Bandwidth
Minimum Load Inductance
Power Input
MP
ML
80 VDC
40 VDC
10 Apk
10 Apk
5A
5A
20 kHz
N/A
Software Selectable
Software Selectable
0.1 mH @ 80 VDC
N/A
100 to 230 VAC nominal input voltage (50/60 Hz)
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
Pout [W] = Torque [N·m] * Angular velocity[rad/sec]
Linear Motors
Pout [W] = Force [N] * Linear velocity[m/sec]
Rotary or Linear Motors
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
www.aerotech.com
Chapter 1
9
Introduction
1.2. Mechanical Specifications
Mount the Epaq so free airflow is available at the rear and along the sides of the chassis for standard cooling.
Allowance must also be made for the rear panel connections and cables.The outline dimensions for the Epaq
are shown in Figure 1-3.
W A R N I N G : Use both handles to lift and carry the Ensemble Epaq.
All Epaq chassis’s are built to the user’s specifications, with the requested options, causing a variation in the
actual product weight.
Table 1-5:
Physical Specifications
Description
Chassis Weight
Footprint
10
Weight
10 kg (600 W power supply and 6 amplifiers installed)
17.2" (W) x 12.3" (D) x 7.0" (H)
Chapter 1
www.aerotech.com
AXIS 2
AXIS 1
GPIB
13.0 [0.51]
(TYP)
ESTOP
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
81.8 [3.22]
Introduction
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
USB
MRK IN POS
MRK IN POS
1
ENET
MRK IN POS
1
4
4
AIN/AOUT
MRK IN POS
1
4
AIN/AOUT
1
MRK IN POS
1
4
AIN/AOUT
1
MRK IN POS
1
4
AIN/AOUT
1
1
4
AIN/AOUT
1
AIN/AOUT
1
1
EXT DRIVE
4
4
4
4
4
4
1
1
1
1
1
1
JOYSTICK
7.9 [0.31]
(TYP)
10
OPTO-IN
10
OPTO-IN
10
OPTO-IN
10
OPTO-IN
10
OPTO-IN
OPTO-IN
FEEDBACK 1
FEEDBACK 1
FEEDBACK 1
FEEDBACK 1
FEEDBACK 1
FEEDBACK 1
A
B
10
C
A
B
10
C
A
B
10
C
A
B
10
C
A
B
10
C
A
B
10
C
OPTOOUT
DANGER!
High Voltage
MOTOR
OPTOOUT
MOTOR
OPTOOUT
MOTOR
OPTOOUT
OPTOOUT
MOTOR
MOTOR
OPTOOUT
MOTOR
14.2 [0.56]
10
J100
RS232
20.0 [0.79]
(TYP)
431.8 [17.00]
471.7 [18.57]
312.4 [12.30]
41.0 [1.61]
(TYP)
503.5 [19.82]
13.4 [0.53]
REAR VIEW ROTATED 180°
19.7 [0.78]
41.3 [1.63]
16.6 [0.65]
(TYP)
431.8 [17.00]
177.8 [7.00]
60.2 [2.37]
482.6 [19.00]
8.7 [0.34]
(TYP)
465.1 [18.31]
EPAQ SIDE VIEW
WITH FEET SHOWN
6.6 [0.26]
(TYP)
101.6 [4.00]
38.1 [1.50]
453.7 [17.86]
POWER
620E1392G
EPAQ FRONT VIEW
Figure 1-3:
www.aerotech.com
Dimensions
Chapter 1
11
Introduction
1.3. Environmental Specifications
The environmental specifications for the Epaq are listed below.
Ambient Temperature
Humidity
Altitude
Pollution
Use
Audible Noise
12
Operating: 0° to 50°C
Storage: -30° to 80°C
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
Chapter 1
www.aerotech.com
Introduction
1.4. Drive and Software Compatibility
The following table lists the available Ensemble drives and which version of the Ensemble software first
provided support for a given 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:
Ensemble Drive and Software Compatibility
Drive Type
Firmware Revision
First Software Version
Last Software Version
1.01
Current
CL
A
2.55
Current
A
1.00
Current
CP
B
2.54
Current
1.00
Current
Epaq(1)
A
2.55
Current
HLe
2.51
Current
HPe
2.51
Current
LAB
4.04
Current
ML
3.00
Current
1.00
Current
MP
A
2.55
Current
QDe/QL/QLe
5.01
Current
QLAB
4.07
Current
(1) This section does not apply to the Epaq MR. The Epaq MR contains multiple ML or MP drives. Refer to
either the ML or MP drive type to determine the value for your Epaq MR.
www.aerotech.com
Chapter 1
13
Introduction
14
Chapter 1
www.aerotech.com
Installation and Configuration
Chapter 2: Installation and Configuration
This section describes the minimum hardware installation and configuration requirements for the Epaq drive
chassis. This installation will provide information on AC power connections and brush, brushless, and
stepper motor wiring. This section also describes the motor phasing requirements for encoders and Hall
devices.
www.aerotech.com
Chapter 2
15
2.1. Electrical Installation
Motor, power, control and position feedback cable connections are made to the rear of the Epaq.
AC Power
Input
Control Board
and Options
Axis 1
Axes 2 through 6 (Optional)
AXIS 1
GPIB
17
18
19
20
AXIS 2
AXIS 3
AXIS 4
AXIS 5
21
AXIS 6
5
1
6
AUX ENC
12
BRAKE PWR
+5V/GND
ESTOP
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
USB
9
MRK IN POS
MRK IN POS
1
ENET
MRK IN POS
1
13
4
4
2
1
14
EXT DRIVE
4
7
1
JOYSTICK
MRK IN POS
1
4
AIN/AOUT
AIN/AOUT
10
MRK IN POS
1
4
AIN/AOUT
MRK IN POS
1
1
4
AIN/AOUT
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
4
4
4
4
4
1
1
1
1
1
15
3
10
10
J100
16
FEEDBACK 1
10
OPTO-IN
OPTO-IN
8
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
FEEDBACK 1
OPTO-IN
FEEDBACK 1
11
RS232
DANGER!
Control Board
A
B
10
C
OPTOOUT
OPTOOUT
MOTOR
MOTOR
High Voltage
1.
2.
3.
4.
A
B
10
C
A
B
10
C
4
A
B
10
C
OPTOOUT
MOTOR
17.
18.
19.
20.
21.
Axis 1 I/O (standard on Axis 1)
5.
6.
7.
8.
GPIB IEEE-488 Connector (talker/listener)
ESTOP (Emergency Stop) 9-pin D-style connector
External Drive Connector
J100 / additional optional RS-232 connector
12.
13.
14.
15.
16.
Figure 2-1:
MOTOR
OPTOOUT
MOTOR
Additional Axes
9.
LED Status Display
10. Feedback 25-pin D-style connector
11. Motor Connector (terminal block)
Options
A
B
10
C
OPTOOUT
MOTOR
Axis 1
USB connector
Ethernet connector
Joystick 15-pin D-style connector
RS-232 9-pin D-style connector
A
B
10
C
OPTOOUT
Auxiliary Encoder 9-pin D-style connector
Brake Power (terminal block)
Analog Input/Output (terminal block)
Opto-Isolator Input (terminal block)
Opto-Isolator Output (terminal block)
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Axes 2 through 6 are optional.
The I/O board is optional on axes
2 through 6.
In this example:
This Epaq is configured for 5 axes
Axis 5 does not support the -IO option
Power and Control Connections
The power switch is located on the front of the Epaq. The AC inlet located on the rear panel contains two
10 A fuses that provide protection to the Epaq system in case of severe overloads. These fuses meet the
maximum current requirements of the Epaq system.
Directional Keypad
LCD Screen
Power LED
POWER
Power
Switch
ESTOP
Button
Figure 2-2:
16
Power Switch
Chapter 2
www.aerotech.com
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 & 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 : Protective grounding is through the main power connection. The supply connection is the main
power cord (the main power disconnect).
N O T E : Confirm that the AC power is the correct voltage before connecting and turning on power to the
Epaq.
The external +5 Volt power is fused by re-settable (semiconductor) fuses located on the Rear Panel
Interface board. These fuses protect the system should a fault or overload condition occur with the optical
encoders, joystick, I/O bus, or Miscellaneous I/O connectors. This fuse will reset itself when the overload
condition is removed (power may also need to be turned off to reset the fuse). In addition to this fuse, each
drive module has a safety fuse.
Some Epaq systems may use +12 Volts for the limit switch supply (special request / requirements). The
Epaq can also provide an external +24 Volt output for Brake applications. The +24 V Brake output is only
provided when the Brake option is used.
www.aerotech.com
Chapter 2
17
2.1.1. AC Power Connections
AC input power to the Epaq 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
serves as a mains disconnect. The main power fuses are located on the rear panel of the Epaq drive chassis
in the AC inlet (supplementary protection only). Standard AC input voltages along with the current
requirements for the Epaq drive chassis are listed in Table 2-1.
W A R N I N G : The AC power cord is the Mains disconnect.
AXIS 1
GPIB
ESTOP
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
ENA CTL
AXIS 3
AUX ENC
ENA CTL
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
USB
MRK IN POS
ENET
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
1
1
1
4
4
4
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
1
4
4
4
4
4
4
1
1
1
1
1
1
EXT DRIVE
JOYSTICK
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK 1
RS232
A
B
10
C
DANGER!
MOTOR
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
OPTO-IN
FEEDBACK 1
The power cord provides the protective earth ground connection and
serves as a mains disconnect. The AC inlet located on the rear panel
of the Epaq drive chassis contains two 10 A fuses (supplementary
protection only) for incoming AC power.
A
B
10
C
OPTOOUT
High Voltage
10
OPTO-IN
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
Main Power Switch
POWER
100/115/200/230 VAC
Do Not Apply Power Until All
Connections Have Been Made.
Front View
Figure 2-3:
18
Power Supply Connection
Chapter 2
www.aerotech.com
Table 2-1:
Main AC Power Input Voltages and Current Requirements
AC Input Voltage
Input Amps (maximum continuous)
100 VAC 50/60 Hz
120 VAC 50/60 Hz
200 VAC 50/60 Hz
230 VAC 50/60 Hz
10 Amps
10 Amps
6 Amps
5 Amps
The AC power cord/wiring to the Epaq must be rated for at least 300 V and have a minimum current capacity
of 10 amps. The insulation rating for the AC power wiring must be appropriately rated for the environment.
The temperature rating of the insulation must be at least 80ºC. 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.
D A N G E R : See the user documentation provided with your Ensemble Epaq system to
determine if the Ensemble Epaq chassis is limited to only one AC input voltage. Operation at
other voltages may result in damage to the Ensemble Epaq chassis.
www.aerotech.com
Chapter 2
19
2.1.2. Minimizing Conducted, Radiated, and System Noise
To reduce electrical noise, observe the following motor and input power 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 reduces the capacitive coupling between the leads that, in
turn, reduces the current generated in the shield wire.
3. Provide strong earth ground connections to the amplifier and the motor. Offering electrical noise a low
impedance path to earth ground not only reduces radiated emissions, but also improves system
performance.
4. Motor cables must be physically separated from low level cables carrying encoder and IO signals.
5. 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.
6. The Epaq is a component designed to be integrated with other electronics. EMC testing must be
conducted on the final product configuration.
7. Ferrite beads or Aerotech’s FBF-1 or FBF-2 filter adapters, may be used on the motor leads to reduce
the effects of amplifier EMI/RFI, produced by PWM (pulse width modulation) amplifiers. Refer to the
FBF-1 and FBF-2 drawings on your installation device for more information on the ferrite beads.
Table 2-2:
Ferrite Bead Part Numbers
Wire Size
Aerotech P/N
Third Party P/N
2.0 mm2 (#14 AWG)
1.3 mm2 (#16 AWG)
0.8 mm2 (#18 AWG)
0.5 mm2 (#20 AWG)
EIZ01027
EIZ01025
EIZ01001
EIZ01001
#2643002402 Elna-Fair-Rite Products
2.1.3. I/O and Signal Wiring Requirements
The I/O, communication, and encoder feedback connections are typically low amplitude signals. Wire and
connectors used for signal wiring must be rated for at least 30 V and have a current capacity of at least .25
Amp. Wires and connectors used for low voltage power connections such as +5V must have a current
capacity of at least 1 Amp (encoder feedback +5V supply requires .6 Amps in some applications). In
applications where there are significant wire distances, a larger wire size is required to reduce the voltage
drops that occur along the wires. This increase is necessary to keep the voltage within tolerance at a remote
point.
When signal wiring is in close proximity to wiring operating at voltages above 60 Volts, the insulation rating
of the signal wiring must be rated for the higher voltage. Use signal wiring with a voltage rating of at least 300
Volts when it is in proximity to AC power or motor power wiring.
20
Chapter 2
www.aerotech.com
2.2. Motor Output Connections
The Epaq can be used to drive three motor types:
l
Brushless (see Section 2.2.1.)
l
DC Brush (see Section 2.2.2.)
l
Stepper (see Section 2.2.3.)
For a complete list of electrical specifications, refer to Section 1.1.
AXIS 1
GPIB
ESTOP
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
ENA CTL
AXIS 6
AUX ENC
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
USB
MRK IN POS
MRK IN POS
1
ENET
MRK IN POS
1
4
4
AIN/AOUT
MRK IN POS
1
4
AIN/AOUT
1
MRK IN POS
1
4
AIN/AOUT
1
MRK IN POS
1
1
1
4
AIN/AOUT
4
AIN/AOUT
1
AIN/AOUT
1
1
EXT DRIVE
4
4
4
4
4
4
1
1
1
1
1
1
JOYSTICK
10
Motor Power
10
OPTO-IN
J100
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
10
OPTO-IN
FEEDBACK 1
FEEDBACK 1
OPTO-IN
FEEDBACK 1
RS232
A
B
10
C
A
B
10
C
OPTOOUT
DANGER!
MOTOR
High Voltage
MOTOR
Figure 2-4:
Table 2-3:
MOTOR
A
B
10
C
OPTOOUT
A
B
10
C
OPTOOUT
MOTOR
MOTOR
OPTOOUT
MOTOR
Motor Power Connections
Description
Phase A Motor Lead
Phase B Motor Lead
Phase C Motor Lead
Earth Ground to Motor (required for safety)
Table 2-4:
A
B
10
C
OPTOOUT
Motor Power Output Connections
Pin
ØA
ØB
ØC
A
B
10
C
OPTOOUT
Recommended Wire Size
0.5 mm2 (#20 AWG)
0.5 mm2 (#20 AWG)
0.5 mm2 (#20 AWG)
0.5 mm2 (#20 AWG)
Type
4-Pin Terminal Block
www.aerotech.com
Aerotech P/N
Phoenix P/N
ECK01523
1827729
Chapter 2
Tightening Torque
(Nm)
0.22 - 0.25
Wire Size: AWG
[mm2 ]
14-30 [2.0 - 0.0516]
21
2.2.1. Brushless Motor Connections
The configuration shown in Figure 2-5 is an example of a typical brushless motor connection.
Install Aerotech FBF-1 or FBF-2, or 10 Beads per wire at drive
(Elna Fair-Rite #2643002402, or #2643250402)
Motor Frame
MOTOR
Green/Yellow & Shield
AC
Brushless
Motor
Black
A
B
C
Red
White
NOTE:
Listed wire colors are for Aerotech supplied cables.
Figure 2-5:
Table 2-5:
Brushless Motor Configuration
Wire Colors for Aerotech Supplied Cables (Brushless)
Pin
Wire Color Set 1 (1)
Green/Yellow &
Shield (2)
Wire Color Set 2
Green/Yellow &
Shield
Wire Color Set 3
Green/Yellow &
Shield
Wire Color Set 4
Green/Yellow &
Shield
A
B
C
Black
Red
White
Blue & Yellow
Red & Orange
White & Brown
Black #1
Black #2
Black #3
Black & Brown
Red & Orange
Violet & Blue
(1) Wire Color Set #1 is the typical Aerotech wire set used by Aerotech.
(2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire
N O T E : Brushless motors are commutated electronically by the controller. The use of Hall effect devices
for commutation is recommended.
The drive 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.
There are two methods for verifying motor connections: powered, through the use of a test program; and an
unpowered method using an oscilloscope. Both methods will identify the A, B, and C Hall/motor lead sets
and indicate the correct connections to the drive.
N O T E : If using standard Aerotech motors and cables, motor and encoder connection adjustments are
not required.
22
Chapter 2
www.aerotech.com
2.2.1.1. Powered Motor Phasing
To test the initial set of motor connections, run the MotorVerification.ab test program.
The program will attempt to move the motor forward in a positive (CW) direction. Depending on the
information that the program gathers during the test, you may be prompted to rearrange motor lead
connections and run the test again. Refer to Section 2.2.1. for connector pin output information.
W A R N I N G : The MotorVerification.ab program moves the motor in “Open-Loop” mode,
bypassing many of the standard safety faults.
W A R N I N G : It is recommended that rotary motors be disconnected from the stage/load
before running this test. Linear motor systems must be free from obstruction to prevent damage
to other components. Operators must remain clear of all moving parts during the test.
Hall Signal Phasing
With the information gathered while the program is running, the Hall signal wires may have to be swapped.
After the Hall sequence is correct, the program will determine if a commutation offset is required (and
calculate a value for the CommutationOffset1 axis parameter that will have to be entered into the parameter
editor). Refer to Section 2.3.2. for more information and connector pin output assignments.
Encoder Phasing
The MotorVerification.ab program also determines if the feedback wiring is correct. Follow the program
prompts to establish the correct feedback wiring. Refer to Section 2.3. for connector pin output assignments
and Section 2.3.1.3. for phasing information.
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.
1CommutationOffset has replaced CfgMotOffsetAng in software version 3.00.000.
www.aerotech.com
Chapter 2
23
Figure 2-6:
24
Chapter 2
www.aerotech.com
2.2.1.2. Unpowered Motor and Feedback Phasing
Disconnect the motor from the controller and connect the motor in the test configuration shown in Figure 2-7.
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 2-7).
To determine the relative phasing/order of the three motor lead signals in relation to each other, connect
channel 1 of the oscilloscope to TP1. Connect channel 2 to TP2 and move the motor in the positive direction
(CW) by hand. Note the peak of the sine wave signal of channel 1 in comparison to the peak of the sine wave
signal of channel 2. Next, disconnect channel 2 from TP2 and reconnect it to TP3 and again move the motor
in the positive direction. Note the peak of the sine wave signal of channel 3 in comparison to the peak of the
sine wave signal of channel 1.
Aerotech phasing configuration expects ØC to be the lead signal (in time), ØB to follow it, and ØA to follow
ØB. This means that whichever signal has its sine wave peak farthest to the left should be designated as the
ØC signal.
Channel 1 at TP1 and Channel 2 at TP3
Channel 1 at TP1 and Channel 2 at TP2
CH2
(TP2)
CH2
(TP3)
CH1
(TP1)
CH1
(TP1)
In this example:
The peak of the sine wave signal at TP2 precedes the
peaks of the sine wave signals at TP1 and TP3. The peak
of the sine wave signal at TP1 precedes the peak of the
sine wave signals at TP3.
Signals Combined for Comparison
ØC
ØB
ØA
ØC
ØB
MOTOR
TP2 = Motor Lead 2 = ØC signal
TP1 = Motor Lead 1 = ØB signal
TP3 = Motor Lead 3 = ØA signal
After the phasing process is complete,
the ØA, ØB, and ØC signal motor leads
should be connected to their respective
Motor Outputs (A to A, B to B and C to C).
TP1
CHANNEL 1
Motor Lead 1 = ØB
TP2
CHANNEL 2
A
B
C
TP3
10K OHM
TYP
TP4
Power Supply
"Wye"
Configuration
Motor Lead 2
= ØC
Motor Lead 3
= ØA
COM
COM
+5V
+5V
10K OHM
TYP
Figure 2-7:
www.aerotech.com
TP5
Hall 1
TP6
Hall 2
TP7
Hall 3
Chapter 2
25
After the motor leads have been tested, the next step is to determine the phase of the Hall signals. The
required (by an Aerotech system) relationship between motor and Hall leads is that the peak of a motor lead
signal should correspond to the low voltage phase of the Hall signal (the relationship is shown in Figure 2-8).
With channel 1 still connected to one of the motor leads, connect channel 2 of the oscilloscope to TP5, TP6,
and then TP7, while advancing the motor in the positive direction after each connection. Note which of the
three Hall signals has the complimentary phase relationship to the motor lead that channel 1 is connected to
(as shown in Figure 2-8).
Move channel 1 of the oscilloscope to the second motor lead and repeat the steps from above. Note which
Hall signal corresponds to the currently selected motor lead and repeat the process for the 3rd motor lead.
TP1
Channel 1 at TP1 and Channel 2 at TP5, TP6, and TP7
TP5
(CH2)
CHANNEL 1
TP6
(CH2)
TP3
Hall
B
TP4
TP7
(CH2)
Power Supply
ØB
TP1
(CH1)
TP2
COM
+5V
TP5
CHANNEL 2
TP6
TP7
TP5
(CH2)
In this example:
The low voltage phase of the TP6 Hall signal corresponds
Hall with the peak phase of the motor sine wave of TP1 (in the
C previous example designated as ØB). The signal at TP6
should be designated as Hall B.
Motor Feedback
TP6
(CH2)
TP7
(CH2)
Hall Pin Assignemt
TP2
(CH1)
ØC The low voltage phase of the TP7 Hall
signal corresponds with the peak phase
of the motor sine wave of TP2 (in the
previous example designated as ØC).
The signal at TP7 should be designated
as Hall C.
The low voltage phase of the TP5 Hall
signal corresponds with the peak phase
Hall of the motor sine wave of TP3 (in the
A previous example designated as ØA).
The signal at TP5 should be designated
as Hall A.
11
10
Hall C
Hall A
5
Hall B
TP5
(CH2)
TP6
(CH2)
TP7
(CH2)
After the phasing process is complete,
the Hall A, Hall B, and Hall C signal
ØA leads should be connected to their
respective Motor Feedback
connector inputs (Hall A to Pin 10,
Hall B to Pin 5, and Hall C to Pin 11).
TP3
(CH1)
Figure 2-8:
26
Pin Hall Positions
10
Hall A
5
Hall B
11
Hall C
Hall Phasing with Oscilloscope
Chapter 2
www.aerotech.com
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. Connect Hall lead A to Pin 10 of the feedback
connector. Hall lead B should connected to Pin 5 and Hall lead C should connect to Pin 11 of the feedback
connector.
The motor is correctly phased when the Hall states correspond to the
states at each of the electrical angles. The Hall signal leads must be
associated with its corresponding motor leads.
0°
1
60°
2
120°
3
180°
4
240°
5
300° 360°
6
Hall A
+5V
0V
Hall B
Hall C
ØC
ØB
ØA
ØC
ØB
+V
Motor Back
EMF
0V
-V
Feedback Pins Hall Positions
10
5
11
Figure 2-9:
www.aerotech.com
Corresponding Motor Lead
Hall A
Hall B
Hall C
Motor Connector
ØA
ØB
ØC
Chapter 2
27
2.2.2. DC Brush Motor Connections
The configuration shown in Figure 2-10 is an example of a typical DC brush motor connection. Refer to
Section 2.2.2.1. for information on motor phasing.
Install Aerotech FBF-1 or FBF-2,
or 10 Beads per wire at drive
(Elna Fair-Rite #2643002402,
or #2643250402)
MOTOR
Motor Frame
Green & White & Shield
A
B
C
Red & Orange
+ DC Brush Motor
no connection
Yellow & Blue
NOTE:
Listed wire colors are for Aerotech supplied cables.
Figure 2-10:
Table 2-6:
DC Brush Motor Configuration
Wire Colors for Aerotech Supplied Cables (DC Brush)
Pin
Green & White & Shield (2)
Wire Color Set 2
Wire Color Set 3
A
C
Red & Orange
Yellow & Blue
Red
Black
Red & Orange
Yellow & Blue
28
Chapter 2
www.aerotech.com
2.2.2.1. 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 (CW) by hand.
ROTARY MOTOR
Motor Mounting
Flange (Front View)
Motor Shaft
POSITIVE MOTION
Figure 2-11:
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. Connect the motor
lead from the negative lead of the voltmeter to the ØC motor terminal on the Epaq.
not required.
www.aerotech.com
Chapter 2
29
2.2.3. Stepper Motor Connections
The configuration shown in Figure 2-12 is an example of a typical stepper motor connection. Refer to Section
2.2.3.1. 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.
Install Aerotech FBF-1 or FBF-2, or 10 Beads per
wire at drive (Elna Fair-Rite #2643002402,
or #2643250402)
MOTOR
Motor Frame
A
B
Black
A
B
C
A'
Stepper
Motor
Red
White
B'
NOTE:
Listed wire colors are for
Aerotech supplied cables.
Note the common connection
of A and B phases.
Figure 2-12:
MP Stepper Motor Configuration
Install Aerotech FBF-1 or FBF-2, or 10 Beads per
wire at drive (Elna Fair-Rite #2643002402,
or #2643250402)
MOTOR
Motor Frame
Black
A
B
C
A
B
Stepper
Motor
Red
White
NOTE:
Listed wire colors are for
Aerotech supplied cables.
A'
B'
Note the common connection
of A and B phases.
Figure 2-13:
Table 2-7:
ML Stepper Motor Configuration
Wire Colors for Aerotech Supplied Cables (Stepper)
Pin
Green/Yellow & Shield (2)
Wire Color Set 2
A
B
C
Black
Red
White
Brown
Yellow
White & Red
30
Chapter 2
www.aerotech.com
2.2.3.1. Stepper Motor Phasing
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 CountsPerUnit1 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 2-14:
not required.
N O T E : After the motor has been phased, use the ReverseMotionDirection2 parameter to change the direction of “positive” motion.
1CountsPerUnit has replaced CntsPerMetricUnit, CntsPerEnglishUnit, and CntsPerRotaryUnit in software
version 3.00.000.
2ReverseMotionDirection has replaced the functionality of reversing the sign on the PosScaleFactor to
change the direction of positive motion in software version 3.00.000.
www.aerotech.com
Chapter 2
31
2.3. Motor Feedback Connections
The motor feedback connector (a 25-pin, D-style connector) has inputs for an encoder, limit switches, Halleffect devices, motor over-temperature device, 5 volt encoder and limit power, and optional brake
connections. The connector pin assignment is shown in Table 2-8 with detailed connection information in the
following sections.
25 13
14 1
AXIS 2
AXIS 1
GPIB
ESTOP
USB
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
FEEDBACK
ENA CTL
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
MRK IN POS
ENET
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
1
1
1
1
4
4
4
4
4
AIN/AOUT
AIN/AOUT
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
1
AIN/AOUT
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
AIN/AOUT
1
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
1
4
4
4
4
4
4
1
1
1
1
1
1
EXT DRIVE
JOYSTICK
10
10
FEEDBACK 1
FEEDBACK 1
RS232
A
B
10
C
MOTOR
Figure 2-15:
32
10
OPTO-IN
FEEDBACK 1
A
B
10
C
OPTOOUT
OPTOOUT
DANGER!
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
OPTO-IN
FEEDBACK 1
Motor Feedback
A
B
10
C
High Voltage
10
OPTO-IN
OPTO-IN
J100
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
Chapter 2
www.aerotech.com
Table 2-8:
Pin#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Description
In/Out/Bi
Chassis Frame Ground
Motor Over Temperature Thermistor
+5V Power for Encoder (500 mA max)
Reserved
Hall-Effect Sensor B (brushless motors only)
Encoder Marker Reference Pulse Encoder Marker Reference Pulse +
Analog Input 0 Reserved
Hall-Effect Sensor A (brushless motors only)
Hall-Effect Sensor C (brushless motors only)
Clockwise End of Travel Limit
Optional Brake - Output
Encoder Cosine +
Encoder Cosine +5V Power for Limit Switches (500 mA max)
Encoder Sine +
Encoder Sine Analog Input 0 +
Signal Common for Limit Switches
Signal Common for Encoder
Home Switch Input
Encoder Fault Input
Counterclockwise End of Travel Limit
Optional Brake + Output
Table 2-9:
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
Motor Feedback Mating Connector
Aerotech P/N
Third Party P/N
Connector
ECK00101
Cinch P/N DB25P
Backshell
ECK00656
Amphenol P/N 17-1726-2
www.aerotech.com
Chapter 2
33
2.3.1. Encoder Interface
The Epaq is equipped with standard and auxiliary encoder feedback channels. The standard encoder
interface is accessible through the feedback connector. The standard interface is a line driver encoder that
will accept an RS-422 differential line driver signal. If the drive had been purchased with the -MXU option, the
standard encoder interface has been configured to accept an analog encoder.
Refer to Section 2.3.1.3. for encoder feedback phasing. Refer to Section 3.7. 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.
N O T E : If the Feedback Connector is factory configured for the -MXU option, it cannot be used with a
square wave encoder.
Table 2-10:
Pin#
1
3
6
7
14
15
17
18
21
34
Description
In/Out/Bi
Encoder Marker Reference Pulse Encoder Marker Reference Pulse +
Encoder Cosine +
Encoder Cosine Encoder Sine +
Encoder Sine Signal Common for Encoder
Chapter 2
N/A
Output
Input
Input
Input
Input
Input
Input
N/A
www.aerotech.com
2.3.1.1. RS-422 Line Driver Encoder (Standard)
The standard encoder interface accepts an RS-422 differential quadrature line driver signal in the range of 0
to 5 VDC in line driver format. It allows up to an 10 MHz encoder signal (25 nsec minimum edge separation),
producing 40 million counts per second, after times four (x4) quadrature decoding.
An analog encoder is used with the -MXU or -MXH option (refer to Section 2.3.1.2. for more information).
+3.3V
PIN-17
PIN-18
PIN-7
PIN-6
PIN-14
PIN-15
10K
10K
10K
10K
+3.3V
SIN+
180
SIN-
MRK+
180
MRKCOS+
180
COS-
DS26LV32AT
10K
10K
10K
ENCODER
FAULT DETECTION
10K
Figure 2-16:
www.aerotech.com
Chapter 2
35
2.3.1.2. Analog Encoder Interface
If the -MXU or -MXH option has been purchased, the primary encoder channel will accept an analog encoder
input signal. The multiplication (interpolation) factor is determined by the EncoderMultiplicationFactor1 axis
parameter.
Table 2-11:
Specification
MP
Input Frequency (max)
Input Amplitude
ML
200 kHz
500 kHz
0.6 to 2.25 Vpk-Vpk
Interpolation Factor (software selectable)
4,096
4,096 (-MXU)
65,536 (-MXH)
Refer to Figure 2-17 for the typical input circuitry.
The encoder interface pin assignment is indicated in Section 2.3.1.
The gain, offset, and phase balance of the analog Sine and Cosine encoder input signals are controlled by
the EncoderCosineGain2, EncoderCosineOffset3, EncoderPhase4, EncoderSineGain5, EncoderSineOffset6
axis parameters. Encoder signals should be adjusted for optimum performance using the Feedback Tuning
tab of the Ensemble Digital Scope utility. It 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
Positive MOVE
(Clockwise)
Forcer Wires
Magnet
Track
SIN-N
0°
90°
180°
270°
360°
450°
540°
630°
720°
Forcer
810°
1Vpk-pk
COS
COS-N
ROTARY MOTOR
0°
90°
180°
270°
360°
450°
540°
630°
720°
810°
Motor Shaft
MRK
Motor Mounting
Flange (Front View)
MRK-N
CW Rotation
(Positive Direction)
Positive MOVE (Clockwise)
Figure 2-17:
Analog Encoder Phasing Reference Diagram
1EncoderMultiplicationFactor has replaced CfgFbkEncMultFactorMxu in software version 3.00.000.
2EncoderCosineGain has replaced CfgFbkEncCosGain in software version 3.00.000.
3EncoderCosineOffset has replaced CfgFbkEncCosOffset in software version 3.00.000.
4EncoderPhase has replaced CfgFbkEncPhase in software version 3.00.000.
5EncoderSineGain has replaced CfgFbkEncSineGain in software version 3.00.000.
6EncoderSineOffset has replaced CfgFbkEncSineOffset in software version 3.00.000.
36
Chapter 2
www.aerotech.com
J103-7
MRK+
1K
82PF
82PF
1K
82PF
1K
A
J103-6
82PF
MRK-
+
1K
1K
82PF
33
.47
.1
82PF
1K
+
10UF 6.3V
A
J103-17
SIN+
1K
82PF
82PF
82PF
1K
1K
A
J103-18
82PF
-
SIN+
1K
82PF
33
.47
.1
82PF
2K
1K
+
10UF 6.3V
A
J103-14
COS+
82PF
1K
82PF
1K
1K
82PF
A
J103-15
82PF
COS-
+
2K
1K
82PF
33
.47
.1
82PF
1K
+
10UF 6.3V
A
Figure 2-18:
www.aerotech.com
Chapter 2
37
2.3.1.3. Encoder Phasing
Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued.
Figure 2-19 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 2-20). The MotorVerification.ab program can be
used if the motor can not be moved by hand. If the program causes the Position Feedback to count more
negative, swap the connections to the controllers SIN and the SIN-N encoder inputs.
However, if this axis is configured for dual loop with two feedback devices (one for position and one for
velocity feedback), invert the sign of only the parameter associated with the incorrectly phased feedback
device. For dual loop systems, the velocity feedback encoder is displayed in “Auxiliary Encoder Input” in the
Diagnostic display.
0°
90°
180°
270°
360°
450°
540°
630°
720°
810°
LINEAR MOTOR
COS
Positive MOVE
(Clockwise)
Forcer Wires
Magnet Track
COS-N
0°
90°
180°
270°
360°
450°
540°
630°
720°
Forcer
810°
1Vpk-pk
SIN
ROTARY MOTOR
SIN-N
0°
90°
180°
270°
360°
450°
540°
MRK
630°
720°
810°
Motor Shaft
Motor Mounting
Flange (Front View)
CW Rotation
(Positive Direction)
MRK-N
Positive MOVE (Clockwise)
Figure 2-19:
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 2-19.
38
Chapter 2
www.aerotech.com
Figure 2-20:
www.aerotech.com
Chapter 2
39
2.3.2. Hall-Effect Interface
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.
Refer to Section 2.2.1.1. for Hall-effect device phasing.
Table 2-12:
Pin#
1
3
5
10
11
21
Description
In/Out/Bi
Hall-Effect Sensor B (brushless motors only)
Hall-Effect Sensor A (brushless motors only)
Hall-Effect Sensor C (brushless motors only)
Signal Common for Encoder
N/A
Output
Input
Input
Input
N/A
Figure 2-21:
40
10K
.01UF
.01UF
.01UF
10K
HALL C
.001
PIN-11
10K
HALL B
.001
PIN-5
10K
HALL A
.001
PIN-10
10K
10K
ENC+5V
Hall-Effect Inputs
Chapter 2
www.aerotech.com
2.3.3. Thermistor Interface
The thermistor input is used to detect an over temperature condition in a motor 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. If the increasing temperature causes the thermistor’s resistance to increase, the signal will be seen
as a logic high, triggering an over temperature fault.
Table 2-13:
Pin#
2
Thermistor Interface Pin Assignment
Description
In/Out/Bi
Motor Over Temperature Thermistor
Input
1K
ENC+5V
10K
.01UF
THERMISTOR
.001
PIN-2
Figure 2-22:
www.aerotech.com
Thermistor Interface Input
Chapter 2
41
2.3.4. End Of Travel Limit Input Interface
End of Travel (EOT) limits are required to define the end of the physical travel on linear axes. Positive or
clockwise motion is stopped by the clockwise (CW) end of travel limit input. Negative or counterclockwise
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. All of the end-of-travel limit inputs accept 5-24 VDC level signals. Limit directions are relative to the
encoder polarity in the diagnostics display (refer to Figure 2-23).
The active state of the EOT limits is software selectable (by the EndOfTravelLimitSetup1 axis parameter).
25
13
+5V
16
Limit Com
20
CW
12
CCW
24
Home
22
Normally closed shown (typical).
May be a
separate switch.
14
1
FEEDBACK
Figure 2-23:
Table 2-14:
Pin#
12
16
20
22
24
End of Travel Limit Input Connections
End of Travel Limit Input Interface Pin Assignment
Description
In/Out/Bi
Clockwise End of Travel Limit
+5V Power for Limit Switches (500 mA max)
Home Switch Input
Counterclockwise End of Travel Limit
Input
Output
N/A
Input
Input
1EndofTravelLimitSetup has replaced LimitLevelMask in software version 3.00.000.
42
Chapter 2
www.aerotech.com
10K
Figure 2-24:
www.aerotech.com
.01UF
HOME LIMIT
.01UF
10K
.01UF
10K
CCW LIMIT
.001
PIN-22
10K
.001
PIN-24
CW LIMIT
.001
PIN-12
10K
10K
ENC+5V
End of Travel Limit Interface Input
Chapter 2
43
2.3.4.1. 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 2-25).
Figure 2-25:
44
Chapter 2
www.aerotech.com
2.3.5. Encoder Fault Interface
The encoder fault input is used with encoders having a fault output. Each manufacturer uses this signal to
indicate different faults.
Table 2-15:
Pin#
23
Description
In/Out/Bi
Encoder Fault Input
Input
1K
ENC+5V
10K
ENCFLT
.001
.01UF
PIN-23
Figure 2-26:
www.aerotech.com
Chapter 2
45
2.3.6. Brake Output
The Brake Output pins provide a direct connection to the solid state relay on the Epaq. The brake output pins
permit the brake to be wired with other signals in the feedback cable. The brake is configured for automatic or
manual control using controller parameters (refer to the Ensemble Help file for more information).
Refer to Section 3.2. for more information on using the brake output with the solid state relay.
Table 2-16:
Pin#
13
25
46
Brake Output Pin Assignment
Description
In/Out/Bi
Output
Output
Chapter 2
www.aerotech.com
2.3.7. Analog Input 0
Analog Input 0 is a 16-bit differential input that accepts a voltage in the range of ±10 volts with a resolution of
305 µVolts. Signals outside of this range may damage the input. To interface to a single-ended (nondifferential) voltage source, connect the signal common of the source to the negative input (pin 8, AIN 0-) and
the analog source signal to the positive input (pin 19, AIN 0+). A floating signal source should be referenced
to the signal common (pin 20, AGND) as shown in Figure 2-27.
Table 2-17:
Pin#
8
19
20
Analog Input 0 Pin Assignment
Description
In/Out/Bi
Analog Input 0 Analog Input 0 +
Input
Input
N/A
ANALOG IN+
PIN-19
100
64.9K
.001
+
SIGNAL
SOURCE
SHIELDED
CABLE
16.2K
.1
ANALOG INPIN-8
+
100
64.9K
AGND
PIN-20
Figure 2-27:
www.aerotech.com
OP279
16.2K
.001
Analog Input 0
Chapter 2
47
2.4. Emergency Stop Sense Input (ESTOP)
There are two emergency stop options for the Epaq, -ESTOP0 and -ESTOP1.
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.
The -ESTOP0 option provides the user with a mushroom switch on the front panel of the unit, whose action
is defined by the controllers software parameters. As such, it does not meet most user's requirements for an
emergency stop circuit. ESTOP0 is not compliant with EN ISO 13849-1.
The -ESTOP1 option provides the user with an internal positive guided relay, which when triggered by the
operator, will open, removing the AC power from the motors DC power supply, and will additionally open the
normally closed relay at J70 pins 3 and 4, which is used by the external portion of the ESTOP circuit for
cross-checking. No ESTOP switch is provided. The user may connect their own ESTOP switch (or series
chain of switches) to J70 pins 9 and 10, as illustrated in the figure below (refer to Figure 2-29 for connector
pin location). ESTOP1 is rated Category 2 and PL d in accordance with EN ISO 13849-1.
D1
IN4004
CR1
J70
COMMON
ESTOP INPUT
2
10
+24 VDC
CR1
NC
NC
USER’S
NORMALLY CLOSED
ESTOP CHAIN
NC1
NC2
CHASSIS
9
3
4
1
15 PIN FEMALE "D"
(ECK00326)
Figure 2-28:
User Interrupt Inputs
W A R N I N G : Opening the motor leads at the Motor Output while the axis is enabled will
damage the drive. To protect the drive, the ESTOP circuit should open the AC motor power
input (Motor Supply).
48
Chapter 2
www.aerotech.com
Connecting the ESTOP input to a relay or other noise producing device requires the use of noise suppression
devices such as those in Table 2-18. These devices are applied across the switched coil to suppress
transient voltages.
Table 2-18:
Electrical Noise Suppression Devices
Device
RC (.1uf / 200 ohm) Network
Varistor
Aerotech P/N
EIC240
EID160
Third Party P/N
Electrocube RG1782-8
Littelfuse V250LA40A
ESTOP
15 8
AXIS 1
GPIB
9
ESTOP
AXIS 2
AXIS 3
AXIS 4
AXIS 5
AXIS 6
1
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 2-29:
www.aerotech.com
A
B
10
C
B
10
C
OPTOOUT
MOTOR
MOTOR
A
B
10
C
B
10
C
B
10
C
OPTOOUT
OPTOOUT
OPTOOUT
OPTOOUT
MOTOR
MOTOR
OPTOOUT
MOTOR
ESTOP Connector and Pin Location
Chapter 2
49
2.5. Communicating with the Epaq
Either USB or Ethernet can be used to connect any of the supplied software applications or a custom
application built with the supplied .NET library to the controller. Ethernet sockets are also available for
Modbus or general ASCII communication with another hardware device. RS-232 can be used for general
ASCII communication with another hardware device, but can not be used with the supplied software
applications.
2.5.1. USB Interface
The USB connection is established through a Type B female connector labeled USB on the back panel of the
Epaq. This can be accomplished by one of these two methods:
Method 1: Directly connect to the PC with a standard USB cable. The cable connector type must be
Type A or Type B male depending on the PC, and Type B male on the Epaq.
Method 2: Connect through a USB hub. The cable connector type must be Type A or Type B male
depending on the hub, and Type B male on the Epaq.
Method 1 is the most commonly used. Method 2 is necessary only when the number of Epaqs to be
connected is larger than the number of available USB ports on the PC.
USB
AXIS 1
GPIB
ESTOP
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
BRAKE PWR
+5V/GND
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
USB
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 2-30:
50
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
MOTOR
OPTOOUT
OPTOOUT
MOTOR
A
B
10
C
B
10
C
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
USB Connector Location
Chapter 2
www.aerotech.com
2.5.2. Ethernet Interface
The Ethernet interface is the high-speed communications media to the Epaq. Command and configuration
information is sent through this interface.
The Ethernet connection is established through the RJ-45 connector labeled ENET on the back panel of the
Epaq. Connection is accomplished by one of these two methods:
Method 1: Directly connect to the PC with an RJ-45 crossover cable.
Method 2: Connect through a network with a standard RJ-45 cable.
Method 1 is the most secure because is guarantees that the only members of the network are the Epaq and
the PC. This type of connection is not feasible unless the PC has two Ethernet cards. If the PC cannot be
connected to an external network, Aerotech recommends Method 2.
Method 2 is a more typical configuration. The network can be a local network (the PC and Epaq are
connected through a hub or switch) or remote (the devices are connected through a router). When connecting
to a remote network, a crossover cable cannot be used; instead, there must be a hub, switch, or router
interface between the PC and the Epaq.
ENET
AXIS 1
GPIB
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
ENET
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 2-31:
www.aerotech.com
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
A
B
10
C
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
OPTOOUT
MOTOR
Ethernet Connector Location
Chapter 2
51
2.5.3. RS-232 Interface
Connecting the RS-232 port to a user’s PC requires a standard 9-pin cable (not a null modem). If the /RS2321 option has been purchased, an additional RS-232 port will be located at the J100 connector. The additional
RS-232 port will be identical in form and function to the standard RS-232 port.
This interface is also jumper configurable for RS-422 or RS-485 communication; refer to the Figure 2-33 for
jumper configuration.
9
5
GPIB
RS232
AXIS 1
6
1
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
OPTO-IN
FEEDBACK
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
MOTOR
High Voltage
Figure 2-32:
Table 2-19:
Pin #
1
2
3
4
5
6
7-9
52
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
MOTOR
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
OPTOOUT
OPTOOUT
MOTOR
MOTOR
MOTOR
RS-232 Connector Location
RS-232 Connector Pin Assignment
Label
RS-232 Description
+5V
+5V Power
TX/TX1+
Transmit
RX/RX1+
Receive
TX1N/A
Common
Signal Common
RX1N/A
Reserved/Do Not Connect
RS-485 Description
+5V Power
Transmit +
Receive +
Transmit Signal Common
Receive -
Chapter 2
In/Out/Bi
Output
Output
Bidirectional
Output
N/A
Bidirectional
www.aerotech.com
+5V
SERIAL COMMUNICATIONS MODE SELECT
F2
JP7 JP8 JP9
RS232
(DEFAULT)
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
RS232
(RESERVED)
1-2
1-2
1-2
1-2
2-3
2-3
1-2
1-2
RS422
2-3
2-3
2-3
2-3
1-2
1-2
1-2
2-3
RS485
2-3
1-2
2-3
2-3
1-2
1-2
2-3
2-3
J104-1
SMDC050
TX/TX1+
1
JP2 JP3 JP4 JP5 JP6
J104-2
3
JP5
3
+5V
1
2
JP7
2
+5V
RX/RX1+
1
.47
MAX232E
J104-3
2
2
1
3
JP4
3
JP6
.47
1
JP9
+5V
3
2
2
+
1
3
TX1-
J104-4
3
RX1-
J104-6
180
10UF 6.3V
JP2
2
1
3
JP8
ADM485
2
1
JP3
180
J104-5
ADM485
Figure 2-33:
www.aerotech.com
RS-232/RS-485 Interface
Chapter 2
53
2.5.4. External Drive Interface
Use this option to connect up to three more Ensemble discrete drives.
AXIS 1
GPIB
ESTOP
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 5
ENA CTL
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
USB
MRK IN POS
ENET
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
1
1
1
4
4
4
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
1
4
4
4
4
4
4
1
1
1
1
1
1
EXT DRIVE
JOYSTICK
10
10
OPTO-IN
J100
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
FEEDBACK 1
10
OPTO-IN
OPTO-IN
FEEDBACK 1
FEEDBACK 1
RS232
A
B
10
C
A
B
10
C
OPTOOUT
DANGER!
MOTOR
High Voltage
A
B
10
C
OPTOOUT
MOTOR
Aeronet Output
J106
MOTOR
OPTOOUT
MOTOR
Aeronet Output
J106
S/N -
MOTOR
S/N -
AERONET
OUTPUT
J106
AERONET
OUTPUT
J106
AERONET
OUTPUT
J107
AERONET
INPUT
J107
AERONET
INPUT
J107
AERONET
INPUT
P/N -Aeronet
Input
J107
RS232 TX
RS232 RX
GND
WARNING:
P/N -
Aeronet Input
J107
TB104
RS232 TX
RS232 RX
GND
TB105
WARNING:
DISCONNECT POWER
BEFORE SERVICING
Table 2-20:
A
B
10
C
OPTOOUT
J106
TB105
Figure 2-34:
A
B
10
C
OPTOOUT
MOTOR
S/N -
Ensemble Epaq connected to
three Ensemble MPs through the
External Drive (Aeronet) connector.
A
B
10
C
OPTOOUT
ESTOP
P/N -
RS232 TX
RS232 RX
GND
TB105
WARNING:
DISCONNECT POWER
BEFORE SERVICING
TB104
Aeronet Input
J107
ESTOP
DISCONNECT POWER
BEFORE SERVICING
TB104
DANGER!
DANGER!
DANGER!
High Voltage
High Voltage
High Voltage
ESTOP
Epaq Connected to Three Ensemble MPs
Aeronet Cable Part Numbers
Cable Part Number
Length
ENET-CAT6-3
ENET-CAT6-10
ENET-CAT6-20
ENET-CAT6-30
ENET-CAT6-45
ENET-CAT6-76
ENET-CAT6-90
A CAT6 cable; length is 3 decimeters
Cable lengths are in decimeters, 10dm = 1 meter = 3.28 feet
54
Chapter 2
www.aerotech.com
2.5.5. General Purpose Interface Bus (GPIB)
The Epaq contains a standard GPIB interface bus.
Refer to the Ensemble Help file for more information.
GPIB
AXIS 1
GPIB
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
BRAKE PWR
+5V/GND
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
USB
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 2-35:
www.aerotech.com
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
MOTOR
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
OPTOOUT
MOTOR
GPIB Connector Location
Chapter 2
55
2.6. PC Configuration and Operation Information
For additional information about Epaq and PC configuration, hardware requirements, programming, utilities
and system operation refer to the Ensemble Help file.
56
Chapter 2
www.aerotech.com
-IO Expansion Board
Chapter 3: -IO Expansion Board
The -IO option contains 8 digital opto-inputs, 8 digital opto-outputs, 1 analog input, 1 analog output, a
brake/relay output, and an auxiliary encoder channel. The auxiliary encoder channel can be used for dualloop configurations, to echo the primary encoder, or for the PSO output.
-I/O Option Board
Drawing Number: 690D1616 Rev A.
F1
F2
A
B
10
C
OPTOOUT
OPTO-IN
Opto-Isolated
Outputs
FEEDBACK 1
MOTOR
1
4
AIN/AOUT
1
4
1
Opto-Isolated
Inputs
MRK IN POS
ENA CTL
Figure 3-1:
www.aerotech.com
Analog
I/O
10
Brake
Power
AUX ENC
BRAKE PWR
+5V/GND
AXIS 1
Auxiliary
Encoder
Ensemble Epaq with -IO Option Board
Chapter 3
57
-IO Expansion Board
3.1. User Power
A user-accessible power supply (+5V at 0.5 A) is available between Pin 3 and Pin 4.
Table 3-1:
Pin#
3
4
User Power Connector Pin Assignment
Label
+5V
Common
Table 3-2:
Description
User +5V Volt Power (500 m A max)
User Power Common
In/Out/Bi
Output
N/A
Type
Aerotech P/N
ECK01293
Tightening
Torque (Nm)
N/A
Phoenix P/N
1881341
Wire Size: mm2 [AWG]
0.5 - 0.080 [20-28]
1
AXIS 1
GPIB
AXIS 2
AXIS 3
AXIS 4
AXIS 5
AXIS 6
4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 3-2:
58
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
A
B
10
C
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
OPTOOUT
MOTOR
User Power Connector Location
Chapter 3
www.aerotech.com
-IO Expansion Board
3.2. Brake Power Supply
This connector is the power supply connection to the onboard solid state brake control relay.
The relay is typically used to automatically control a fail-safe brake on a vertical axis. It can also be used as
a general purpose output.
1
AXIS 1
GPIB
AXIS 2
AXIS 3
AXIS 4
AXIS 5
AXIS 6
4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
OPTO-IN
FEEDBACK
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
MOTOR
High Voltage
Figure 3-3:
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
MOTOR
OPTOOUT
MOTOR
Brake Power Supply Connector Location
Typically the brake is wired directly to the Motor Feedback connector and the brake power supply is
connected to the Brake Power Supply connector (see Figure 3-4). The brake can also be connected in series
with the Brake Power Supply and interlocked using Motor Feedback brake pins (see Figure 3-5).
A varistor must be connected across the brake to minimize high voltage transients.
The brake output can be software configured; refer to the Ensemble Help file for more information (see topics
for the EnableBrakeControl1 axis parameter and the BRAKE command).
When the Brake Power Supply connector is used to power the solid state brake control relay, the mechanical
brake control relay present on the I/O board should not be used.
N O T E : The brake power supply must be externally fused.
Table 3-3:
Pin#
1
2
Brake Power Connector Pin Assignment
Label
BRAKE V+
BRAKE V-
Table 3-4:
Description
Brake Power Supply (+)
Brake Power Supply (-)
In/Out/Bi
Input
Input
Type
Aerotech P/N
ECK01293
Phoenix P/N
1881341
Tightening
Torque (Nm)
N/A
0.5 - 0.080 [20-28]
1EnableBrakeControl has replaced BrakeOnDriveDisable in software version 3.00.000.
www.aerotech.com
Chapter 3
59
Table 3-5:
Pin#
13
25
-IO Expansion Board
Motor Feedback Connector Brake Output Connector Pin Assignment Description
In/Out/Bi
Output
Output
Figure 3-4 is an example of a +24 VDC Brake connected to the Motor Feedback connector. In this example
the external +24 VDC power source is connected to the Brake Power Supply connector.
EPAQ
BRAKE
CONNECTOR PS+
PIN-1
1A
+
24 VDC
1N5369
-
PS710A-1ASK
FEEDBACK
CONNECTOR
PIN-25
1
2
BRAKE
FEEDBACK
CONNECTOR
PIN-13
BRAKE
CONNECTOR PSPIN-2
1
NOISE SUPPRESSION CIRCUIT
2
VARISTOR: AEROTECH P/N ECR180
HARRIS P/N V33ZA1
Figure 3-4:
N O T E : The user is responsible for providing fuse protection for the brake circuit.
60
Chapter 3
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-IO Expansion Board
Figure 3-5 is an example of a 24 VDC Brake connected to the Brake Power Supply connector. The user must
connect [Motor Feedback connector pin 13] to [Motor Feedback connector pin 25]. In this case, the Motor
Feedback connector would function as an interlock to prevent the brake from releasing if the Motor Feedback
connector is not connected.
EPAQ
BRAKE
CONNECTOR PS+
PIN-1
1A
+
24 VDC
1N5369
-
PS710A-1ASK
FEEDBACK
CONNECTOR
PIN-25
BRAKE
1
FEEDBACK
CONNECTOR
PIN-13
BRAKE
CONNECTOR PSPIN-2
1
VARISTOR: AEROTECH P/N ECR180
HARRIS P/N V33ZA1
Figure 3-5:
Brake Connected to Brake Power Supply connector
3.2.1. Solid State Relay Specifications
The user must verify that the application will be within the specifications of the Brake output.
Table 3-6:
Relay Specifications
Solid State Relay Rating (M36), Aerotech PN. ECS1074
Operating Voltage
24 VDC (typical) / 48 VDC (max)
Maximum Current
0.5 Amps
Maximum Power
560 mW
Output Resistance
0.1 ohm (Typical)
Turn-On/Turn-Off Time
< 3 mSec. (with 500 ohm load at 5 VDC)
W A R N I N G : Do not exceed the maximum specifications.
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Chapter 3
61
-IO Expansion Board
3.3. Analog Input 1
On ML amplifiers, Analog Input 1 is a 16-bit differential input that accepts a voltage in the range of ±10 volts
with a resolution of 305 µVolts.
On MP amplifiers, Analog Input 1 is a 12-bit differential input that accepts a voltage in the range of ±10 volts
with a resolution of 305 µVolts.
Signals outside of this range may damage the input. 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 signal common (pin 1, AGND) as shown
in Figure 3-7. AXIS 1
GPIB
AXIS 2
AIN/AOUT
BRAKE PWR 1
AUX ENC
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
AUX ENC
+5V/GND
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
4
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 3-6:
62
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
A
B
10
C
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
OPTOOUT
MOTOR
Analog Input 1 Connector Location
Chapter 3
www.aerotech.com
-IO Expansion Board
N O T E : Analog Input 0 is available on the Motor Feedback connector (refer to Section 2.3.7.).
Table 3-7:
Pin#
1
2
3
Label
AGND
AIN1+
AIN1-
Table 3-8:
Description
Analog Common
Non-inverting Analog Input 1
Inverting Analog Input 1
In/Out/Bi
N/A
Input
Input
Type
Aerotech P/N
ECK01293
Phoenix P/N
1881341
Tightening
Torque (Nm)
N/A
0.5 - 0.080 [20-28]
ANALOG IN1+
PIN-2
1K
64.9K
.001
+
SIGNAL
SOURCE
SHIELDED
CABLE
.1
-
16.2K
ANALOG IN1PIN-3
10
+
1K
64.9K
OP279
AGND
PIN-1
Figure 3-7:
www.aerotech.com
Analog Input Typical Connection
Chapter 3
63
-IO Expansion Board
3.4. Analog Output 1
The 16-bit analog output produces a single-ended output voltage in the range of ±5 volts with a resolution of
153 µVolts. The maximum output current recommended is 5 mA. Analog outputs are referenced to pin-1. The
analog output is set to zero when the system is powered-up or during a system reset.
N O T E : Analog Output 0 is not present on the Epaq.
Table 3-9:
Pin#
1
4
Analog Output Connector Pin Assignment
Label
AGND
AOUT1
Table 3-10:
Description
Analog Common
Analog Output 1
In/Out/Bi
N/A
Output
Type
Aerotech P/N
ECK01293
Tightening
Torque (Nm)
N/A
Phoenix P/N
1881341
-5VA
0.5 - 0.080 [20-28]
+5VA
D
S2
S1
20K
IN
ADG419
A
+5VA
20K
PIN-4
-
AOUT1
10K
+
PIN-1
AGND
LMH6643
A
A
Figure 3-8:
64
Chapter 3
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-IO Expansion Board
3.5. Opto-Isolated Inputs
These opto-isolated inputs use a PS2806-4 device and are configured for 5-24 volt input levels. The inputs
may be connected to current sourcing or current sinking devices, as shown in Figure 3-9 and Figure 3-10.
See Section 2.3.4. for opto-isolated EOT limits.
Inputs 0-3 and inputs 4-7 have separate common inputs, pin 1 and pin 10, respectively. Each 4-bit bank of
inputs must be connected in the same configuration (sinking or sourcing).
Table 3-11:
Digital Input Specifications Input Voltage
Approximate Input Current
Turn On Time
Turn Off Time
+5 V
+24 V
1 mA
6 mA
200 usec
4 usec
2000 usec
1500 usec
Table 3-12:
Pin#
1
2
3
4
5
6
7
8
9
10
Port 1 Opto-Isolated Input Connector Pin Assignment
Label
C (0-3)
0
1
2
3
4
5
6
7
C (4-7)
Table 3-13:
Description
Input Common for inputs 0 - 3
Input 0 (Optically-Isolated)
Input Common for inputs 4 - 7
In/Out/Bi
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Opto-Isolated Input Mating Connector
Type
Aerotech P/N
ECK01294
Phoenix P/N
1881406
Tightening
Torque (Nm)
N/A
0.5 - 0.080 [20-28]
W A R N I N G : Opto-isolated inputs and outputs should not be powered by the user output
power. Doing so would compromise the isolation provided by the opto-isolator.
N O T E : Inputs must be connected in the all sourcing or all sinking configuration.
www.aerotech.com
Chapter 3
65
-IO Expansion Board
EPAQ
INPUT SWITCH DEVICES
OPTOIN0
OPTOIN1
+
5-24 VDC
OPTOIN2
OPTOIN3
-
COMMON (0-3)
Figure 3-9:
PIN-2
PIN-3
PIN-4
PIN-5
PIN-1
Inputs Connected to a Current Sourcing Device
EPAQ
COMMON (0-3)
+
5-24 VDC
OPTOIN0
OPTOIN1
OPTOIN2
OPTOIN3
PIN-1
PIN-2
PIN-3
PIN-4
PIN-5
INPUT SWITCH DEVICES
Figure 3-10:
66
Chapter 3
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-IO Expansion Board
3.6. Opto-Isolated Outputs
The outputs are software configurable as sourcing or sinking. The outputs are driven by PS2802-4 optoisolators rated for 24 volts maximum and up to 80 mA/output @ 20°C.
Outputs must be connected in either all sinking or all sourcing mode. Figure 3-11 and Figure 3-12 illustrate
how to connect to an output in current sinking and current sourcing modes, respectively.
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 3-11 and Figure 3-12.
Table 3-14:
Pin#
1
2
3
4
5
6
7
8
9
10
Port 1 Opto-Isolated Output Connector Pin Assignment Label
OP
OM
0
1
2
3
4
5
6
7
Table 3-15:
Description
Output Common Plus
Output Common Minus
Output 0 (Optically-Isolated)
In/Out/Bi
Input
Input
Output
Output
Output
Output
Output
Output
Output
Output
Opto-Isolated Output Mating Connector
Type
Aerotech P/N
ECK01294
Phoenix P/N
1881406
Tightening
Torque (Nm)
N/A
0.5 - 0.080 [20-28]
W A R N I N G : Opto-isolated inputs and outputs should not be powered by the user output
power. Doing so would compromise the isolation provided by the opto-isolator.
N O T E : Outputs must be connected as all sourcing or all sinking.
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Chapter 3
67
Table 3-16:
-IO Expansion Board
PS2802-4 Opto Device Specifications
Value
Maximum Voltage
Maximum Sink/Source Current
Output Saturation Voltage
Output Resistance
Rise / Fall Time
Maximum Output Frequency
24 V maximum
80 mA/channel @ 20°C; 60 mA/channel @ 50°C
2.75 V at maximum current
33 Ω
250 usec (typical)
1 kHz
EPAQ
OPTOOUTV+
PIN-1
OPTOOUT3
PIN-6
2
1
+
LOAD
-
OPTOOUT2
PIN-5
+
LOAD
-
OPTOOUT1
PIN-4
5-24 VDC
OUTPUT SWITCH DEVICES
OPTOOUTVPIN-2
-
+
LOAD
-
3
1
EACH OUTPUT 80mA MAXIMUM
2
DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.
3
CONNECTION REQUIRED
Figure 3-11:
68
+
+
LOAD
-
OPTOOUT0
PIN-3
Chapter 3
www.aerotech.com
-IO Expansion Board
EPAQ
OPTOOUTV+
PIN-1
1
OUTPUT SWITCH DEVICES
+
LOAD
-
OPTOOUT3
PIN-6
5-24 VDC
+
LOAD
-
OPTOOUT2
PIN-5
+
LOAD
-
OPTOOUT1
PIN-4
OPTOOUT0
PIN-3
+
+
LOAD
2
3
OPTOOUTVPIN-2
1
CONNECTION REQUIRED
2
EACH OUTPUT 80mA MAXIMUM
3
DIODE REQUIRED ON EACH OUTPUT THAT DRIVES AN INDUCTIVE DEVICE (COIL), SUCH AS A RELAY.
Figure 3-12:
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). See Figure 3-12 for an example of a current sinking output with diode suppression and Figure 3-11
for an example of a current sourcing output with diode suppression.
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Chapter 3
69
-IO Expansion Board
3.7. Auxiliary Encoder Channel/PSO Output
The auxiliary encoder interface accepts a 5 VDC RS-422 differential quadrature line driver signal. It accepts
a 10 MHz (max) encoder signal frequency (25 nsec minimum edge separation), producing 40 million counts
per second, after times four (x4) quadrature decoding.
This encoder channel can be used as an input for master/slave operation (handwheel) or for dual feedback
systems. The auxiliary encoder interface does not support analog encoders and cannot be used as an input
for the -MXH or -MXU option.
The auxiliary encoder channel can also be used to echo the standard encoder signals or as the PSO output.
Configuring the PSO hardware will automatically configure this encoder channel as an output (refer to
Section 3.7.1.) and will remove the 180 ohm terminator resistors.
N O T E : Use the EncoderDivider parameter to configure the bi-directional encoder interface on the auxiliary I/O connector. The EncoderDivider parameter converts the auxiliary encoder interface to an output
and defines a divisor for the encoder echo. Refer to the Ensemble Help file for more information.
N O T E : You cannot echo the standard encoder signals on the Epaq with the -MXU option.
AUX ENC
6
9
1
5
AXIS 1
GPIB
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
10
10
OPTO-IN
J100
FEEDBACK 1
FEEDBACK
OPTO-IN
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 3-13:
70
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
A
B
10
C
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
OPTOOUT
MOTOR
Connector and Pin Locations
Chapter 3
www.aerotech.com
-IO Expansion Board
+5V
AUXSINPIN-9
180
AUXSIN+
PIN-4
ADM1485
+5V
AUXMRKPIN-1
180
ENCODER
FAULT
DETECTION
AUXMRK+
PIN-6
ADM1485
+5V
AUXCOSPIN-3
180
AUXCOS+
PIN-2
ADM1485
Figure 3-14:
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Chapter 3
71
-IO Expansion Board
3.7.1. Position Synchronized Output (PSO)/Laser Firing (Aux Enc Connector)
The Ensemble Epaq includes a Position Synchronized Output (PSO) feature. The PSO output is available on
the dual function AUXMRK± differential signal lines (use of an RS-422 line receiver or opto-isolator is
recommended). The auxiliary marker must be configured as an output using the PSOOUTPUT CONTROL
command, see the Ensemble Help file for specific details.
The PSO can be programmed to generate an output synchronized to the encoder position, typically used to
fire a laser or sequence an external device. Trigger signals may be derived from the standard encoder
channel, auxiliary encoder channel, or a software trigger. The synchronized output pulse is generated using
high-speed hardware, allowing minimal latency (200 nanoseconds) between the trigger condition and the
output.
N O T E : When using the MRK± signals with single-ended systems, do not connect MRK+ or MRK- to
GROUND (GND).
The PSO can track an encoder with a maximum data (count) rate of 16.7 MHz (single axis tracking). Signals
in excess of this rate will cause a loss of PSO accuracy.
Multi-axis PSO can track encoder signals with a maximum data rate of 8.33 MHz. Signals in excess of this
rate will cause a loss of PSO accuracy. Software controlled PSO pre-scalars may be used to limit the data
rate of each encoder being tracked without affecting the servo loop data rate.
Table 3-17:
Pin#
PSO Output Pin Assignment (Aux Enc)
Description
In/Out/Bi
Auxiliary RS-422 Marker Pulse - / PSO Output
(1)
Bidirectional
6
Auxiliary RS-422 Marker Pulse +/ PSO Output
(1)
Bidirectional
8
Encoder Power Common
1
N/A
(1) For PSO, see Section 3.7.1.
Table 3-18:
PSO Output Sources
PSO Output Type
RS-422 Marker (1)
Max Frequency
12.5 MHz
See Also
Section 3.7.
(1) software configurable as the PSO output or Marker input Refer to the Ensemble Help File for programming information.
72
Chapter 3
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-IO Expansion Board
Differential
+5 VDC
1K
Aux
Enc
120 - 180 Ω (typical)
6
Active Low
Output *
Aux. Marker
1
1K
Opto-Isolated
+5 VDC
1K
Isolated Section
Aux
Enc
vcc
10 mA 180 Ω
6
Aux. Marker
1
To Laser
Active Low
Output*
1N4148
1K
8
HCPL-2601 or
6N136
* Active low output shown. Opposite polarity available by reversing connections to Pins 1 and 6.
Figure 3-15:
www.aerotech.com
PSO Interface
Chapter 3
73
-IO Expansion Board
74
Chapter 3
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Cables
Chapter 4: Standard Interconnection Cables
N O T E : A complete list of Aerotech cables can be found on the website at
http://www.aerotechmotioncontrol.com/manuals/index.aspx.
4.1. Joystick Interface
Aerotech joysticks JI (NEMA12 (IP54) rated) and JBV are powered from 5V and have a nominal 2.5V output
in the center detent position. Two switches 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.
Refer to the Ensemble Help file for programming information about how to change joystick parameters.
Analog Input 0
3
JOY-X
AEROTECH, INC.
101 ZETA DRIVE
PITTSBURGH, PA
15238
A
Analog Input 1
6
+5 Volts
1
Common
4
Input 8
2
Input 9
7
Input 10
13
C
B
JOY-Y
+5 Volts
Common
Button A: Axis Pair Select
Button B: Speed Select
Button C: Exit Slew Mode
IN914
Button A
Button B
Joy Interlock
Button B
Button A
Button C
Buttons are all Normally Open
Figure 4-1:
www.aerotech.com
Joystick Interface
Chapter 4
75
15
Cables
8
JOYSTICK
AXIS 1
GPIB
9 1
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
BRAKE PWR
+5V/GND
AXIS 3
AUX ENC
BRAKE PWR
+5V/GND
AXIS 4
AUX ENC
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
ENA CTL
ENA CTL
ENA CTL
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
JOYSTICK
10
10
OPTO-IN
J100
FEEDBACK 1
OPTO-IN
FEEDBACK
FEEDBACK 1
FEEDBACK
RS232
A
B
10
C
DANGER!
High Voltage
MOTOR
Figure 4-2:
Table 4-1:
Pin #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
76
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
B
10
C
OPTOOUT
MOTOR
MOTOR
A
B
10
C
B
10
C
OPTOOUT
OPTOOUT
MOTOR
OPTOOUT
MOTOR
Joystick Connector Location
Joystick Connector Pin Assignment
Label
+5V
Button
AIN0
Common
N.C.
AIN1
Button
N.C.
N.C.
N.C.
N.C.
N.C.
Interlock
N.C.
N.C.
Description
+5 Volt Power to joystick
Button A (Axis Select)
X Potentiometer
Common
Reserved / No Connection
Y Potentiometer
Button B (Speed Select)
Joystick Interlock Input
Chapter 4
In/Out/Bi
Output
Input
Input
Input
Input
Input
-
www.aerotech.com
Cables
4.2. Handwheel Interface
The user may connect a handwheel or any device producing differential quadrature signals, for manual
positioning of the axes. See the Ensemble Help file for information on enabling the handwheel using the
HANDWHEEL command. A handwheel with a standard 25-pin D-style connector can be connected to the
Aux Enc connector of the Epaq using an Aerotech C20932 cable.
AXIS 1
GPIB
ESTOP
AXIS 2
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
MRK IN POS
AXIS 4
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
To AUX
ENC
USB
ENET
AXIS 3
AXIS 5
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AXIS 6
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
AUX ENC
BRAKE PWR
+5V/GND
ENA CTL
C20932 Cable
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
MRK IN POS
1
1
1
1
1
4
4
4
4
4
AIN/AOUT
AIN/AOUT
AIN/AOUT
AIN/AOUT
1
4
AIN/AOUT
AIN/AOUT
1
1
1
1
1
1
4
4
4
4
4
4
1
1
1
1
1
1
EXT DRIVE
JOYSTICK
10
10
OPTO-IN
J100
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
10
OPTO-IN
FEEDBACK 1
OPTO-IN
FEEDBACK 1
RS232
A
B
10
C
A
B
10
C
OPTOOUT
DANGER!
High Voltage
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
A
B
10
C
OPTOOUT
MOTOR
OPTOOUT
MOTOR
HW500-XX
Figure 4-3:
www.aerotech.com
Handwheel Interconnection
Chapter 4
77
Cables
78
Chapter 4
www.aerotech.com
Maintenance
Chapter 5: 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 Ensemble
Epaq 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.
Table 5-1:
Troubleshooting
Symptom
Possible Cause and Solution
Epaq does not respond (no
indicators on)
Motor spins uncontrollably
Brushless motor will not spin
Amplifier faults (“ENA” LED
de-energizes) when motor
decelerates.
Amplifier Faults (Amplifier
“ENA” LED de-energizes).
Encoder Feedback Fault
Table 5-2:
LED
ENB/FLT
MARKER
CTL*
POS
1. Power is not connected to the Epaq.
2. Power switch is not on.
3. AC power fuse has blown (check the fuse at the AC inlet on the rear
of the Epaq).
Encoder (sine and cosine) signals are improperly connected. See Section
2.2. for motor connection and phasing information.
Motor phases A, B, and C connected incorrectly relative to Hall A, Hall B,
and Hall C inputs. See Section 2.2. for motor connection and phasing
information.
Bus over voltage detected or incorrect parameter setting.
1. RMS current exceeded - run at lower current.
2. Axis parameters not set correctly or attempting to exceed system
capability or setting.
3. Over temperature condition - Turn off and let amplifier cool down.
Provide better ventilation.
4. Motor Feedback problem (Encoder or Hall inputs).
1. Bad encoder feedback device.
2. Power supply voltage low at encoder.
LED Description
Description
Turns green to indicate that the axis is enabled. Turns red to indicate a fault condition. The ENB/FLT LED will flash between RED and GREEN if the drive is
enabled and in a fault condition.
Turns green to indicate that the marker input is high.
Turns green when power is applied.
Turns green to indicate that the axis is in position.
* If the power light flashes continuously and the unit does not operate, there is too much current draw from the 5V power supply or
the control supply voltage level is low.
www.aerotech.com
Chapter 5
79
Maintenance
5.1. Chassis Control Board
Figure 5-1 highlights the important components located on the control board assembly.
Epaq chassis.
1
JP3
J104
(RS-232)
JP5
J103
(JOYSTICK)
1
JP7
1
J102
(ENET)
JP8
1
J101
(USB)
1
J7
1
JP4
1
1
JP6
J8
1
JP9
J6
TP32
1
1
TP35
1 JP2
1
TP27
J5
TP24
TP31
TP23
TP28
TP20
JP1
1
1
TP19
TP16
TP15
TP11
J3
1
1
J1
J2
TP12
TP7
TP6
TP1
J4
Drawing Number: 690D1624
J12
1
Figure 5-1:
80
1
J11
1
J10
1
J9
Chapter 5
www.aerotech.com
Maintenance
Table 5-3:
Jumper
JP1
Control Board Jumper Configuration Setting
1-2 (1)
2-3
Description
Normal
Watchdog defeated
(1) Default
Table 5-4:
Serial Communication Mode Jumper Select
Mode
JP2
JP3
JP4
Jumper Setting
JP5
JP6
JP7
JP8
JP9
RS-232 (1)
RS-232 (2)
RS-422
RS-485
1-2
1-2
2-3
2-3
1-2
1-2
2-3
1-2
1-2
1-2
2-3
2-3
1-2
1-2
2-3
2-3
1-2
2-3
1-2
1-2
1-2
1-2
1-2
2-3
1-2
1-2
2-3
2-3
1-2
2-3
1-2
1-2
(1) Default
(2) Reversed
www.aerotech.com
Chapter 5
81
Maintenance
5.2. Power Board
Figure 5-2 highlights the important components located on the power board assembly.
Epaq chassis.
TB4
TB8
TB3
F3
3 ASB
3 AG
F4
4 ASB
3 AG
F1
3 ASB
3 AG
F2
4 ASB
3 AG
TB5
TB1
TB6
TB7
TB2
Drawing Number:
690C1645
Figure 5-2:
82
Power Board Assembly
Chapter 5
www.aerotech.com
Maintenance
5.3. Integrated Axis Control Boards (Amplifier)
Figure 5-3 and Figure 5-4 highlight the important components located on the MP and ML axis control boards.
Refer to Table 5-5 for fuse replacement information.
J103
(MOTOR FEEDBACK)
DS1
TB102
(MOTOR POWER)
DS2
Epaq chassis.
TB104
F2
5ASB
TB105
Test Points
4
5
Test Points 1 2 3
6
7
8
2 A PICO
F1
9
10
11
12
13
TB103
14
15
Figure 5-3:
www.aerotech.com
Test Points 16
17
18
19
MP Board Assembly
Chapter 5
83
J103
(MOTOR FEEDBACK)
TP17
DS1
TB102
(MOTOR POWER)
Maintenance
DS2
TP21
TB104
TP16
TP15
TP7
TP6
TP5
TP14
TB105
TP4
F2
5ASB
F1
5ASB
Figure 5-4:
84
ML Board Assembly
Chapter 5
www.aerotech.com
Maintenance
5.4. Integrated Axis I/O Expansion Board (Amplifier)
The figure below highlights the important components located on the -IO option board. Refer to Chapter 3: IO Expansion Board for a description of user accessible features.
Epaq chassis.
F1
MICROSMD005F-2
F3
F4
F5
www.aerotech.com
F6
Figure 5-5:
OPTO-IN
F7
AIN/AOUT
F8
BRAKE
POWER
F9
F10
F2
AUX ENC
OPTO-OUT
Chapter 5
85
Maintenance
5.5. Fuse Replacement
Table 5-5 lists the manufacturer and Aerotech’s part number for typical replacement fuses. Additional fuse
information may be provided on a system drawing supplied with the unit.
Table 5-5:
Fuse Information
Description
AC Inlet (rear panel) AC power
fuses
Bus Power Supply Fuses
(Figure 5-2)
Refer to your system drawing.
MP Amplifier fuses (Figure 5-3)
F1 is the Control Power fuse
and F2 is the Bus Power fuse
ML Amplifier Bus fuses (Figure
5-4)
Fuse
Rating
Aerotech P/N
Manufacturer P/N
AC1 F1/F2
10 A S.B.
EIF00120
LittelFuse 215010.P
2 A S.B.
3 A S.B.
4 A S.B.
2 A S.B.
5 A S.B.
(5 mm)
EIF00102
EIF00103
EIF00104
EIF00136
LittelFuse 313002P
LittelFuse 313003P
LittelFuse 313004P
LittelFuse 255002
EIF00179
Wickman 1951500
5 A S.B.
EIF01025
LittelFuse 3721500411
F1, F3
F2, F4
F1 (1)
F2
F1, F2
1. F1 is soldered to the circuit board, contact Aerotech for repair if fuse is open.
D A N G E R : Residual voltages greater than 60V may be present inside the Ensemble Epaq
chassis for longer than 5 seconds after power has been disconnected.
Epaq chassis.
86
Chapter 5
www.aerotech.com
Maintenance
5.6. Preventative Maintenance
The Epaq 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 : To minimize the possibility of electrical shock and bodily injury when servicing the
equipment, ensure that all electrical power switches are in the off position and disconnect main
power (Mains disconnect).
Table 5-6:
Check
Action to be Taken
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.
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.
Tighten or re-secure any loose connections.
Replace worn or frayed cables. Replace broken
connectors.
Cleaning
The Epaq 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 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 while cleaning. Do not allow cleaning substances or other fluids
to enter the Epaq or to get on to any of the connectors. Avoid cleaning labels to prevent removing the label
information.
www.aerotech.com
Chapter 5
87
Maintenance
88
Chapter 5
www.aerotech.com
Warranty and Field Service
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 http://www.aerotech.com/service-and-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.
www.aerotech.com
Appendix A
89
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
90
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
Phone: +49 (0)911 967 9370
Fax: +49 (0)911 967 93720
JAPAN
Aerotech Japan
Phone: +81 (0)50 5830 6814
Fax: +81 (0)43 306 3773
TAIWAN
Aerotech Taiwan
Phone: +886 (0)2 8751 6690
UNITED KINGDOM
Aerotech United Kingdom
Phone: +44 (0)1256 855055
Fax: +44 (0)1256 855649
Appendix A
www.aerotech.com
Revision History
Appendix B: Revision History
Revision
Date
2.04.00
June 3, 2015
General revision / metalwork updated
Added RoHS statement to EC Declaration of Conformity
l
Added Input Power equation: Section 1.1.
l
Updated PSO output specification: Section 3.7.1.
l
Fuse information updated: Section 5.5.
l
Declaration of Conformity updated
l
Motor ground wire removed from ferrite (Figure 2-5, Figure 210, Figure 2-12).
l
Software options added to Table 1-2
l
Added Tightening Torque specification: Section 2.2.
l
Section 2.2.3. updated
l
Added Section 1.4.
l
Added JI NEMA information: Section 4.1.
l
Section 3.7. and Section 3.7.1. updated
Revision changes have been archived. If you need a copy of this
revision, contact Aerotech Global Technical Support.
l
l
2.03.00
June 13, 2013
2.02.00
2.01.00
2.00.00
1.02.00
1.01.00
1.00.00
Prelim
January 27, 2011
September 13, 2010
April 26, 2010
September 17, 2008
July 17, 2008
January 8, 2008
August 29, 2006
www.aerotech.com
New manual
Appendix B
91
Revision History
92
Appendix B
www.aerotech.com
Chassis Disassembly
Appendix C: Chassis Disassembly
Aerotech, Inc. does not recommend opening the chassis to replace or change parts. Aerotech, Inc. does not
consider there to be any user-serviceable parts inside of the Epaq chassis.
The Epaq should returned to the factory for a faulty amplifier.
Under normal operation, a fuse should never blow. A blown fuse indicates a more serious problem and
service should be contacted ([email protected]). Refer to Figure 5-3 for amplifier fuse location. The IO
option board (Figure 5-5) does not have any user-serviceable fuses.
D A N G E R : To minimize the possibility of electrical shock and bodily injury when servicing the
equipment, ensure that all electrical power switches are in the off position and disconnect main
power (Mains disconnect).
W A R N I N G : All service and maintenance must be performed by qualified personnel.
www.aerotech.com
Appendix C
93
Chassis Disassembly
1. Remove the [x8] screws fastening
the rear section of the Epaq cover and
lift off the rear cover.
2. Remove the [x2] screws (shown in
Detail A) for each amplifier to be removed.
3. Remove the green terminal block
mating connectors (shown in Detail A).
4. Disconnect the cabling for each amplifier
to be removed.
Note the orientation of the cabling to
ensure proper pin alignment when
reinstalling an amplifier.
5. Remove the [x1] mounting screw from
the Epaq’s inner chassis.
6. Lift the amplifier out of the chassis.
AXIS 2
AXIS 1
AUX ENC
AUX ENC
ESTOP
BRAKE PWR
+5V/GND
BRAKE PWR
+5V/GND
ENA CTL
ENA CTL
MRK
MRK IN POS
MRK IN POS
1
1
4
4
AIN/AOUT
AIN/AOUT
1
1
4
4
1
1
EXTERNAL
DRIVE
10
10
J100
OPTO-IN
OPTO-IN
FEEDBACK 1
MOTOR
FEEDBACK 1
MOTOR
A
B
10
C
A
B
10
C
OPTOOUT
FEEDBACK
MOTOR
OPTOOUT
DETAIL A
Figure C-1:
94
Chassis Disassembly
Appendix C
www.aerotech.com
Index
Index
C
Chassis Control Board
-
80
-I/O Expansion Board
57
8
85
Check chassis for loose or damaged parts /
hardware
87
Check for fluids or electrically conductive
material exposure
87
Cleaning
87
2
2006/95/EC
ix
A
AC Power Connections
18
Altitude
12
Control Board
80
Ambient Temperature
12
80
Control Board Jumper Configuration
81
Amplifier Options
5
4
36
36
DC Brush Motor Connections
28
Analog Input 0
47
DC Brush Motor Phasing
29
Analog Input 1
62
Digital Input Specifications
65
Analog Input 1 Connector
63
dimensions
10
63
Drive and Software Compatibility
13
64
Analog Output 1 Connector Pin Assignment
64
Electrical Installation
Audible Noise
12
Electrical Specifications
71
Emergency Stop Sense Input (ESTOP)
Auxiliary Encoder Channel Pin Assignment
72
EN 61010-1
B
Brake Connected to Brake Power Supply
connector
61
60
Brake Options
6
Brake Output
46
Brake Output Connector Pin Assignment
59
Brake Power Supply
59
Brushless Motor Connections
22
27
D
E
www.aerotech.com
8
48
ix
24
Encoder Fault Interface (J207)
45
45
45
Encoder Interface
34
34
Encoder Phasing
Bus Power Supply
16
23,38
Encoder Phasing Reference Diagram
38
End Of Travel Limit Input Interface (J207)
42
End Of Travel Limit Phasing
44
4
95
Index
Environmental Specifications
12
ESTOP
48
ESTOP0
48
Maintenance
79
ESTOP1
48
Ethernet Interface
51
Minimizing Conducted, Radiated, and System
Noise
20
32
Motor Feedback Connector Mating Connector
33
33
Motor Output Connections
21
25
Multi-axis PSO
72
F
Feature Summary
2
Feedback Monitoring
23
Functional Diagram
7
Fuse Replacement
86
H
40
Hall-Effect Inputs
40
Hall-Effect Interface
40
Hall Signal Phasing
23
Humidity
12
I/O and Signal Wiring Requirements
20
I/O board analog inputs
62
Inputs
47
66
Inputs Connected to a Current Sourcing Device 66
inspect all cables and connections
87
Inspect cooling vents
87
Inspection
87
15
1
J
Joystick Interface
75
Line Cord Options
96
N
Noise
12
O
Obsolete Bus Power Supply
optional joysticks
4
75
4
Opto-Isolated Input Connector Pin Assignment
65
Opto-Isolated Output Connector Pin Assignment 67
68
69
68
Overview
1
P
PC Configuration and Operation Information
56
Pin Locations (J201)
70
Pollution
12
39
Position Synchronized Output (PSO) feature
72
Position Synchronized Output (PSO)/Laser Firing 72
L
35
M
Options
I
Introduction
44
6
Powered Motor Phasing
23
87
PS2802-4 opto-isolators
67
www.aerotech.com
Index
PS2806-4 device
65
PSO
72
PSO Interface
73
PSO Output Sources
72
Q
Quick Start Connections
xiii
R
Rack or Desk-Mount Options
4
relative phasing/order
25
RS-422 Line Driver Encoder (Standard)
35
S
Serial Communication Mode Jumper Select
81
9
Software Options
6
solid state brake control relay
59
Solid State Relay Rating
61
Solid State Relay Specifications
61
Standard Interconnection Cables
75
Standard or Blank Front Panel Options
4
Stepper Motor Connections
30
Stepper Motor Phasing
31
T
Thermistor Interface
41
U
unit weight
10
Unpowered Motor and Feedback Phasing
25
Use
12
User Power
58
V
verifying motor connections
22
W
Wire Colors for Supplied Cables
www.aerotech.com
22
97
Index
98
www.aerotech.com

Ensemble Epaq Hardware Manual

Transcription

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