Aerotech Automation1 XR3 Series User manual

Revision 2.01

Automation1 XR3 Drive Rack

HARDWAREMANUAL

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Table of Contents

Automation1 XR3 Drive Rack 1

Table of Contents 3

List of Figures 5

List of Tables 7

EU Declaration of Conformity 9

Agency Approvals 11

Safety Procedures and Warnings 13

Installation Overview 15

Chapter 1: Introduction 17

1.1. Electrical Specifications 21

1.1.1. System Power Requirements 23

1.2. Mechanical Specifications 24

1.2.1. Mounting and Cooling 24

1.2.2. Dimensions 25

1.3. Environmental Specifications 27

1.4. Drive and Software Compatibility 28

Chapter 2: Installation and Configuration 29

2.1. Electrical Installation 30

2.1.1. AC Power Connections 31

2.1.2. Minimizing Noise for EMC/CECompliance 32

2.1.3. I/O and Signal Requirements 32

2.1.4. Internal Shunt Option [-SI#] 33

2.2. Motor Power Output Connector 34

2.2.1. Brushless Motor Connections 35

2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 36

2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 37

2.2.2. DCBrush Motor Connections 38

2.2.2.1. DC Brush Motor Phasing 38

2.2.3. Stepper Motor Connections 39

2.2.3.1. Stepper Motor Phasing 39

2.3. Feedback Connector 40

2.3.1. Primary Encoder Inputs 41

2.3.1.1. Square WaveEncoder 42

2.3.1.2. Absolute Encoder 43

2.3.1.3. Sine Wave Encoder [-CT1/-CT2/-CT4 Option] 44

2.3.1.4. Encoder Phasing 46

2.3.2. Hall-Effect Inputs 47

2.3.3. Thermistor Input 48

2.3.4. Encoder Fault Input 49

2.3.5. End of Travel and Home Limit Inputs 50

2.3.5.1. End of Travel and Home Limit Phasing 52

2.3.6. Brake Output 53

2.4. Position Synchronized Output Connector (PSO) 54

2.4.1. PSO Isolated Outputs 55

2.4.2. PSO TTLOutputs 56

2.4.3. External PSO Synchronization 57

2.4.4. DataAcquisition Inputs 58

2.5. HSOUTConnector (High-Speed Outputs) 59

2.6. DOUTConnector (Digital Outputs) 61

2.7. DINConnector (Digital Inputs) 65

2.8. Aux Encoder Connectors 68

2.8.1. Square WaveEncoder 69

2.8.2. Absolute Encoder 70

2.8.3. Sine Wave Encoder [-CT4 Option] 71

2.9. AnalogI/OConnectors 73

2.9.1. Analog Outputs 74

2.9.2. Analog Inputs (Differential) 75

XR3 Hardware Manual Table of Contents

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2.9.3. Joystick Interface 76

2.10. Safe Torque Off Input (STO) 78

2.10.1. STOStandards 80

2.10.2. STO Functional Description 81

2.10.3. STO Startup Validation Testing 82

2.10.4. STO Diagnostics 83

2.11. HyperWire Interface 84

2.12. Cooling Options [-C0/-C1/-C2Option] 85

2.13. PC Configuration and Operation Information 88

Chapter 3: Maintenance 89

3.1. Preventative Maintenance 90

3.2. Fuse Specifications 91

Appendix A: Warranty and Field Service 93

Appendix B: Voltage Selection Operation 95

Appendix C: Revision History 97

Index 99

Table of Contents XR3 Hardware Manual

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List of Figures

Figure 1-1: Functional Diagram 20

Figure 1-2: Dimensions with Chassis Slides 25

Figure 1-3: Dimensions without Chassis Slides 26

Figure 2-1: Power and Control Connections 30

Figure 2-2: Brushless Motor Configuration 35

Figure 2-3: Positive Motor Direction 36

Figure 2-4: Encoder and Hall Signal Diagnostics 36

Figure 2-5: Brushless Motor Phasing Oscilloscope Example 37

Figure 2-6: Brushless Motor Phasing Goal 37

Figure 2-7: DC Brush Motor Configuration 38

Figure 2-8: Positive Motor Direction 38

Figure 2-9: Stepper Motor Configuration 39

Figure 2-10: Positive Motor Direction 39

Figure 2-11: Square Wave Encoder Schematic (Feedback Connector) 42

Figure 2-12: Absolute Encoder Schematic (Feedback Connector) 43

Figure 2-13: Sine Wave Encoder Phasing Reference Diagram 44

Figure 2-14: Sine Wave Encoder Schematic (Feedback Connector) 45

Figure 2-15: Encoder Phasing Reference Diagram (Standard) 46

Figure 2-16: Position Feedback in the DiagnosticDisplay 46

Figure 2-17: Hall-Effect Inputs Schematic (Feedback Connector) 47

Figure 2-18: Thermistor Input Schematic (Feedback Connector) 48

Figure 2-19: Encoder Fault Input Schematic (Feedback Connector) 49

Figure 2-20: End of Travel and Home Limit Input Connections 51

Figure 2-21: End of Travel and Home Limit Input Schematic (Feedback Connector) 51

Figure 2-22: End of Travel and Home Limit Input Diagnostic Display 52

Figure 2-23: Brake Output Connections (Feedback Connector) 53

Figure 2-24: PSO Output Sources Current 55

Figure 2-25: PSOOutput Sinks Current 55

Figure 2-26: PSO TTLOutputs Schematic 56

Figure 2-27: PSO Clock Inputs Schematic 57

Figure 2-28: DataAcquisition Input Schematic 58

Figure 2-29: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs 60

Figure 2-30: Digital Output Schematic 63

Figure 2-31: Digital Outputs Connected in Current Sourcing Mode 64

Figure 2-32: Outputs Connected in Current Sinking Mode 64

Figure 2-33: Digital Input Schematic 66

Figure 2-34: Digital Inputs Connected to Current Sinking (NPN) Devices 67

Figure 2-35: Digital Inputs Connected to Current Sourcing (PNP) Devices 67

Figure 2-36: Square Wave Encoder Interface (Aux EncoderConnector) 69

Figure 2-37: Absolute Encoder Schematic (Aux Encoder Connector) 70

Figure 2-38: Sine Wave Encoder Phasing Reference Diagram 71

Figure 2-39: Sine Wave Encoder Schematic (AuxEncoder Connector) 72

Figure 2-40: Analog Outputs Schematic 74

Figure 2-41: Analog Inputs Schematic 75

Figure 2-42: Joystick Interface Inputs Schematic 76

Figure 2-43: Joystick Cable Wiring Schematic 77

Figure 2-44: Typical Configuration 79

Figure 2-45: STO Timing 83

XR3 Hardware Manual List of Figures

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Figure 2-46: Location of the Rear Fan and Air Flow 85

Figure 2-47: -C0 Fan Location and Direction of Air Flow 85

Figure 2-48: -C1 Model Showing Perforated Covers for External Fans 86

Figure 2-49: -C2 1U Fan Location and Air Flow 87

Figure 3-1: Drive Interface Board 91

Figure B-1: Voltage Selection Switch Access 96

List of Figures XR3 Hardware Manual

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List of Tables

Table 1-1: FeatureSummary 17

Table 1-2: Configurations and Options 18

Table 1-3: Chassis Electrical Specifications 21

Table 1-4: PWMAmplifier Electrical Specifications 22

Table 1-5: Linear Amplifier Electrical Specifications 22

Table 1-6: Mounting Specifications 24

Table 1-7: Environmental Specifications 27

Table 1-8: Drive and Software Compatibility 28

Table 2-1: Main AC Power Input Voltages and Current Requirements 31

Table 2-2: I/O and Signal Specifications 32

Table 2-3: Maximum Energy That The XR3 Can Safely Absorb During Regeneration 33

Table 2-4: Motor Power Output Connector Pinout 34

Table 2-5: Mating Connector Part Numbers for the Motor Power Output Connector 34

Table 2-6: Hall Signal Diagnostics 36

Table 2-7: Feedback Connector Pinout 40

Table 2-8: Mating Connector Part Numbers for the Feedback Connector 40

Table 2-9: Multiplier Options 41

Table 2-10: Primary Encoder Input Pins on the Feedback Connector 41

Table 2-11: Square Wave Encoder Specifications 42

Table 2-12: Sine Wave Encoder Specifications 44

Table 2-13: Hall-Effect Feedback Pins on the Feedback Connector 47

Table 2-14: Thermistor Input Pin on the Feedback Connector 48

Table 2-15: Encoder Fault Input Pin on the Feedback Connector 49

Table 2-16: End of Travel and Home Limit Pins on the Feedback Connector 50

Table 2-17: Brake Output Pins on the Feedback Connector 53

Table 2-18: Brake Output Specifications 53

Table 2-19: PSOConnector Pinout 54

Table 2-20: PSOSpecifications 54

Table 2-21: PSOIsolated Output Specification 55

Table 2-22: Isolated Output Pins on the PSOConnector 55

Table 2-23: PSOTTLOutputs Specification 56

Table 2-24: TTLOutput Pins on the PSOConnector 56

Table 2-25: External PSO Sync Input Pins on the PSO Connector 57

Table 2-26: Data Acquisition Input Pins on the PSOConnector 58

Table 2-27: DataAcquisition Opto-Isolator Input Specifications 58

Table 2-28: High-Speed Output Specifications 59

Table 2-29: HSOUTConnector Pinout 59

Table 2-30: Mating Connector Part Numbers for the HSOUTConnector 59

Table 2-31: Digital Output Specifications 61

Table 2-32: DOUTConnector Digital Outputs Pinout 62

Table 2-33: Mating Connector Part Numbers for the DOUTConnector 62

Table 2-34: DINConnector Digital Inputs Pinout 65

Table 2-35: Mating Connector Part Numbers for the DINConnector 65

Table 2-36: Digital Input Specifications 65

Table 2-37: AuxEncoder Connector Pinout 68

Table 2-38: Mating Connector Part Numbers for the Aux Encoder Connectors 68

Table 2-39: Square Wave Encoder Specifications 69

Table 2-40: Sine Wave Encoder Specifications 71

XR3 Hardware Manual List of Tables

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Table 2-41: AnalogI/OConnector Pinout 73

Table 2-42: Mating Connector Part Numbers for the AnalogI/OConnectors 73

Table 2-43: Analog Output Specifications 74

Table 2-44: Analog Output Pins on the Analog I/OConnector 74

Table 2-45: Analog Input Specifications 75

Table 2-46: Analog Input Pins on the Analog I/O Connector 75

Table 2-47: Joystick Interface Pins on the Analog I/OConnectors 76

Table 2-48: STO Connector Pinout 78

Table 2-49: Mating Connector Part Numbers for the STOConnector 78

Table 2-50: STOElectrical Specifications 79

Table 2-51: STOStandards 80

Table 2-52: STOStandards Data 80

Table 2-53: STOSignal Delay 82

Table 2-54: Motor Function Relative to STOInput State 82

Table 2-55: STOTiming 83

Table 2-56: HyperWire Card Part Number 84

Table 2-57: HyperWire Cable Part Numbers 84

Table 3-1: LEDDescription 89

Table 3-2: Troubleshooting 89

Table 3-3: Preventative Maintenance 90

Table 3-4: Drive Interface Board Motor Power Fuse Replacement Part Numbers 91

Table B-1: AC Voltage Selector Switch Settings 96

List of Tables XR3 Hardware Manual

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EU Declaration of Conformity

Manufacturer Aerotech, Inc.

Address 101 Zeta Drive

Pittsburgh, PA 15238-2811

USA

Product XR3

Model/Types All

This is to certify that the aforementioned product is in accordance with the applicable requirements of

the following Directive(s):

2014/30/EU Electromagnetic Compatibility (EMC)

2014/35/EU Low Voltage Directive

EU 2015/863 Directive, Restricted Substances (RoHS 3)

and has been designed to be in conformity with the applicable requirements of the following Standard(s)

when installed and used in accordance with the manufacturer’s supplied installation instructions.

EN 61010-1:2010 Safety Requirements for Electrical Equipment

EN 55011:1998 / EN 55022 Conducted and Radiated Emissions

IEC 61800-5-1 Electrical Safety for Power Drive Systems

IEC 61800-5-2 Functional Safety for Power Drive Systems

EN 61800-3:2004 EMCRequirements for Power Drives

Authorized Representative: Simon Smith, European Director

Address: Aerotech Ltd

The Old Brick Kiln, Ramsdell, Tadley

Hampshire RG26 5PR

Name / Alex Weibel

Position Engineer Verifying Compliance

Location Pittsburgh, PA

Date 3/26/2021

XR3 Hardware Manual EU Declaration of Conformity

www.aerotech.com 9

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EU Declaration of Conformity XR3 Hardware Manual

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