Aerotech Automation1 iXR3 Bedienungsanleitung

Revision 2.08

Automation1 iXR3 and XR3 Drive Racks

HARDWAREMANUAL

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Table of Contents

Automation1 iXR3 and XR3 Drive Racks 1

Table of Contents 3

List of Figures 5

List of Tables 7

EU Declaration of Conformity 9

Agency Approvals 10

Safety Procedures and Warnings 11

Handling and Storage 13

Installation Overview 14

Chapter 1: iXR3/XR3 Overview 15

1.1. Electrical Specifications 21

1.1.1. System Power Requirements 24

1.2. Mechanical Specifications 25

1.2.1. Mounting and Cooling 25

1.2.2. Dimensions 26

1.3. Environmental Specifications 28

1.4. Drive and Software Compatibility 29

Chapter 2: Installation and Configuration 31

2.1. Electrical Installation 31

2.1.1. AC Power Connections 33

2.1.2. Minimizing Noise for EMC/CECompliance 34

2.1.3. I/O and Signal Requirements 34

2.1.4. Internal Shunt Option [-SI#] 35

2.2. Motor Power Output Connector 36

2.2.1. Brushless Motor Connections 37

2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 38

2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 39

2.2.2. DCBrush Motor Connections 40

2.2.2.1. DC Brush Motor Phasing 40

2.2.3. Stepper Motor Connections 41

2.2.3.1. Stepper Motor Phasing 41

2.2.4. Three Phase Stepper Motor Connections 42

2.2.4.1. Stepper Motor Phasing 42

2.3. Feedback Connector 43

2.3.1. Primary Encoder Inputs 44

2.3.1.1. Square WaveEncoder (Primary) 45

2.3.1.2. Absolute Encoder (Primary) 46

2.3.1.3. Sine Wave Encoder (Primary) [-CT1/-CT2/-CT4 Option] 47

2.3.1.4. Encoder Phasing 49

2.3.2. Hall-Effect Inputs 50

2.3.3. Thermistor Input 51

2.3.4. Encoder Fault Input 52

2.3.5. End of Travel and Home Limit Inputs 53

2.3.5.1. End of Travel and Home Limit Phasing 55

2.3.6. Brake Output 56

2.4. Position Synchronized Output Connector (PSO) 57

2.4.1. PSO Isolated Outputs 58

2.4.2. PSO TTLOutputs 59

2.4.3. External PSO Synchronization 60

2.4.4. DataAcquisition Inputs 61

2.5. HSOUTConnector (High-Speed Outputs) 62

2.6. DOUTConnector (Digital Outputs) 64

2.7. DINConnector (Digital Inputs) 68

2.8. Aux Encoder Connectors 71

2.8.1. Square WaveEncoder (Auxiliary) 72

2.8.2. Absolute Encoder (Auxiliary) 73

2.8.3. Sine Wave Encoder (Auxiliary) [-CT4 Option] 74

iXR3/XR3 Hardware Manual Table of Contents

www.aerotech.com 3

2.9. AnalogI/OConnectors 76

2.9.1. Analog Outputs 77

2.9.2. Analog Inputs (Differential) 78

2.9.3. Joystick Interface 79

2.10. Safe Torque Off Input (STO) 81

2.10.1. STOStandards 83

2.10.2. STO Functional Description 84

2.10.3. STO Startup Validation Testing 85

2.10.4. STO Diagnostics 86

2.11. HyperWire Interface 87

2.12. Sync Port 88

2.13. Industrial Ethernet (iXR3 Only) 88

2.14. Cooling Options [-C0/-C1/-C2Option] 89

2.15. PC Configuration and Operation Information 92

Chapter 3: Maintenance 93

3.1. Preventative Maintenance 94

3.2. Fuse Specifications 95

3.3. Amplifier Replacement 96

Appendix A: Warranty and Field Service 99

Appendix B: Voltage Selection Operation 101

Appendix C: Revision History 103

Index 105

Table of Contents iXR3/XR3 Hardware Manual

4 www.aerotech.com

List of Figures

Figure 1-1: iXR3 Connection Overview 15

Figure 1-2: XR3 Connection Overview 16

Figure 1-3: Functional Diagram 20

Figure 1-4: iXR3/XR3 ACPower Label Location 21

Figure 1-5: Dimensions with Chassis Slides 26

Figure 1-6: Dimensions without Chassis Slides 27

Figure 2-1: iXR3 Connection Overview 31

Figure 2-2: XR3 Connection Overview 32

Figure 2-3: Brushless Motor Configuration 37

Figure 2-4: Positive Motor Direction 38

Figure 2-5: Encoder and Hall Signal Diagnostics 38

Figure 2-6: Brushless Motor Phasing Oscilloscope Example 39

Figure 2-7: Brushless Motor Phasing Goal 39

Figure 2-8: DC Brush Motor Configuration 40

Figure 2-9: Positive Motor Direction 40

Figure 2-10: Stepper Motor Configuration 41

Figure 2-11: Positive Motor Direction 41

Figure 2-12: Three Phase Stepper Motor Configuration 42

Figure 2-13: Positive Motor Direction 42

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

Figure 2-15: Absolute Encoder Schematic (Feedback Connector) 46

Figure 2-16: Sine Wave Encoder Phasing Reference Diagram 47

Figure 2-17: Sine Wave Encoder Schematic (Feedback Connector) 48

Figure 2-18: Encoder Phasing Reference Diagram (Standard) 49

Figure 2-19: Position Feedback in the DiagnosticDisplay 49

Figure 2-20: Hall-Effect Inputs Schematic (Feedback Connector) 50

Figure 2-21: Thermistor Input Schematic (Feedback Connector) 51

Figure 2-22: Encoder Fault Input Schematic (Feedback Connector) 52

Figure 2-23: End of Travel and Home Limit Input Connections 54

Figure 2-24: End of Travel and Home Limit Input Schematic (Feedback Connector) 54

Figure 2-25: End of Travel and Home Limit Input Diagnostic Display 55

Figure 2-26: Brake Output Connections (Feedback Connector) 56

Figure 2-27: PSO Output Sources Current 58

Figure 2-28: PSOOutput Sinks Current 58

Figure 2-29: PSO TTLOutputs Schematic 59

Figure 2-30: PSO Clock Inputs Schematic 60

Figure 2-31: DataAcquisition Input Schematic 61

Figure 2-32: Diagram Showing Axis 1 and Axis 2 High-Speed Outputs 63

Figure 2-33: Digital Output Schematic 66

Figure 2-34: Digital Outputs Connected in Current Sourcing Mode 67

Figure 2-35: Outputs Connected in Current Sinking Mode 67

Figure 2-36: Digital Input Schematic 69

Figure 2-37: Digital Inputs Connected to Current Sourcing (PNP) Devices 70

Figure 2-38: Digital Inputs Connected to Current Sinking (NPN) Devices 70

Figure 2-39: Square Wave Encoder Interface (Aux EncoderConnector) 72

Figure 2-40: Absolute Encoder Schematic (Aux Encoder Connector) 73

Figure 2-41: Sine Wave Encoder Phasing Reference Diagram 74

Figure 2-42: Sine Wave Encoder Schematic (AuxEncoder Connector) 75

iXR3/XR3 Hardware Manual List of Figures

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Figure 2-43: Analog Outputs Schematic 77

Figure 2-44: Analog Inputs Schematic 78

Figure 2-45: Joystick Interface Inputs Schematic 79

Figure 2-46: Joystick Cable Wiring Schematic 80

Figure 2-47: Typical STO Configuration 82

Figure 2-48: STO Timing 86

Figure 2-49: Location of the Rear Fan and Air Flow 89

Figure 2-50: -C0 Fan Location and Direction of Air Flow 89

Figure 2-51: -C1 Model Showing Perforated Covers for External Fans 90

Figure 2-52: -C2 1U Fan Location and Air Flow 91

Figure 3-1: Drive Interface Board 95

Figure 3-2: Amplifier Removal 96

Figure 3-3: Slot Details 97

Figure B-1: Voltage Selection Switch Access 102

List of Figures iXR3/XR3 Hardware Manual

6 www.aerotech.com

List of Tables

Table 1-1: FeatureSummary 17

Table 1-2: Configurations and Options 18

Table 1-3: Electrical Specifications 22

Table 1-4: PWMAmplifier Electrical Specifications 23

Table 1-5: Linear Amplifier Electrical Specifications 23

Table 1-6: Mounting Specifications 25

Table 1-7: Environmental Specifications 28

Table 1-8: Drive and Software Compatibility 29

Table 2-1: Main AC Power Input Voltages and Current Requirements 33

Table 2-2: I/O and Signal Specifications 34

Table 2-3: Maximum Energy That The iXR3/XR3 Can Safely Absorb During Regeneration 35

Table 2-4: Motor Power Output Connector Pinout 36

Table 2-5: Mating Connector Part Numbers for the Motor Power Output Connector 36

Table 2-6: Hall Signal Diagnostics 38

Table 2-7: Feedback Connector Pinout 43

Table 2-8: Mating Connector Part Numbers for the Feedback Connector 43

Table 2-9: Multiplier Options 44

Table 2-10: Primary Encoder Input Pins on the Feedback Connector 44

Table 2-11: Square Wave Encoder Specifications 45

Table 2-12: Sine Wave Encoder Specifications 47

Table 2-13: Hall-Effect Feedback Pins on the Feedback Connector 50

Table 2-14: Thermistor Input Pin on the Feedback Connector 51

Table 2-15: Encoder Fault Input Pin on the Feedback Connector 52

Table 2-16: End of Travel and Home Limit Pins on the Feedback Connector 53

Table 2-17: Brake Output Pins on the Feedback Connector 56

Table 2-18: Brake Output Specifications 56

Table 2-19: PSOConnector Pinout 57

Table 2-20: PSOSpecifications 57

Table 2-21: PSOIsolated Output Specification 58

Table 2-22: Isolated Output Pins on the PSOConnector 58

Table 2-23: PSOTTLOutputs Specification 59

Table 2-24: TTLOutput Pins on the PSOConnector 59

Table 2-25: External PSO Sync Input Pins on the PSO Connector 60

Table 2-26: Data Acquisition Input Pins on the PSOConnector 61

Table 2-27: DataAcquisition Opto-Isolator Input Specifications 61

Table 2-28: High-Speed Output Specifications 62

Table 2-29: HSOUTConnector Pinout 62

Table 2-30: Mating Connector Part Numbers for the HSOUTConnector 62

Table 2-31: Digital Output Specifications 64

Table 2-32: DOUTConnector Digital Outputs Pinout 65

Table 2-33: Mating Connector Part Numbers for the DOUTConnector 65

Table 2-34: DINConnector Digital Inputs Pinout 68

Table 2-35: Mating Connector Part Numbers for the DINConnector 68

Table 2-36: Digital Input Specifications 68

Table 2-37: AuxEncoder Connector Pinout 71

Table 2-38: Mating Connector Part Numbers for the Aux Encoder Connectors 71

Table 2-39: Square Wave Encoder Specifications 72

Table 2-40: Sine Wave Encoder Specifications 74

iXR3/XR3 Hardware Manual List of Tables

www.aerotech.com 7

Table 2-41: AnalogI/OConnector Pinout 76

Table 2-42: Mating Connector Part Numbers for the AnalogI/OConnectors 76

Table 2-43: Analog Output Specifications 77

Table 2-44: Analog Output Pins on the Analog I/OConnector 77

Table 2-45: Analog Input Specifications 78

Table 2-46: Analog Input Pins on the Analog I/O Connector 78

Table 2-47: Joystick Interface Pins on the Analog I/OConnectors 79

Table 2-48: STO Connector Pinout 81

Table 2-49: Mating Connector Part Numbers for the STOConnector 81

Table 2-50: STOElectrical Specifications 82

Table 2-51: STOStandards 83

Table 2-52: STOStandards Data 83

Table 2-53: STOSignal Delay 85

Table 2-54: Motor Function Relative to STOInput State 85

Table 2-55: STOTiming 86

Table 2-56: HyperWire Card Part Number 87

Table 2-57: HyperWire Cable Part Numbers 87

Table 2-58: Sync-Related Functions 88

Table 2-59: SyncPort Cables 88

Table 2-60: -C1 Option Airflow Specifications 90

Table 3-1: LEDDescription 93

Table 3-2: Troubleshooting 93

Table 3-3: Preventative Maintenance 94

Table 3-4: Drive Interface Board Motor Power Fuse Replacement Part Numbers 95

Table B-1: AC Voltage Selector Switch Settings 102

List of Tables iXR3/XR3 Hardware Manual

8 www.aerotech.com

EU Declaration of Conformity

Manufacturer Aerotech, Inc.

Address 101 Zeta Drive

Pittsburgh, PA 15238-2811

USA

Product iXR3/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

2006/42/EC Machinery Directive

2011/65/EU RoHS 2 Directive

EU 2015/863 Amendment RoHS 3 Directive

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/A1:2016 Safety Requirements for Electrical Equipment

EN 61800-3:2004/A1:2011 EMCRequirements for Power Drives

IEC 61800-5-1:2016 Electrical Safety for Power Drive Systems

IEC 61800-5-2:2016 Functional Safety for Power Drive Systems

EN 55011:2000/A2:2003 Conducted and Radiated Emissions

EN 55022:1998 Conducted and Radiated Emissions

Authorized

Representative / Simon Smith, European Director

Aerotech Ltd

The Old Brick Kiln, Ramsdell, Tadley

Hampshire RG26 5PR

Engineer Verifying

Compliance / Alex Weibel

Aerotech, Inc.

101 Zeta Drive

Pittsburgh, PA 15238-2811

USA

Date 3/17/2022

iXR3/XR3 Hardware Manual EU Declaration of Conformity

www.aerotech.com 9

Agency Approvals

Aerotech tested its XR3 drive racks and found that they obey the standards that follow:

IMPORTANT: iXR3 certification is pending.

Approval: CUS NRTL

Approving Agency: TUV SUD America Inc.

Certificate #: U8 068995 0027 Rev. 02

Standards: CAN/CSA-C22.2 No. 61010-1:2012,

EN 61010-1:2010/A1:2016,

UL 61010-1:2012

Approval: Safety Components (STO)

Approving Agency: TUVSUD

Certificate #: Z10 068995 0030 Rev. 00

Standards: EN ISO 13849-1:2015 (up to PL e),

IEC 61508-1:2010 (up to SIL3),

IEC 61508-2:2010 (up to SIL3),

IEC 61800-5-2:2016,

IEC 62061:2005 (up to SILCL3),

IEC 62061:2005/AMD1:2012 (up to SILCL3),

IEC 62061:2005/AMD2:2015 (up to SILCL3)

Visit https://www.tuev-sued.de/product-testing/certificates to view Aerotech's TÜV SÜD certificates.

Type the certificate number listed above in the search bar or type "Aerotech" for a list of all Aerotech

certificates.

Agency Approvals iXR3/XR3 Hardware Manual

10 www.aerotech.com

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