Aerotech Ndrive HL (EDU176 Rev1.08b) Digital Servo Drive

Aerotech Ndrive HL (EDU176 Rev1.08b) Digital Servo Drive

Product Overview

1.1 Model and Power Specifications

Model Bus Voltage Peak Current Continuous Current Continuous Output Power

HL‑10‑40 ±40VDC 10A 5A 337W

HL‑20‑40 ±40VDC 20A 10A 675W

HL‑10‑80 ±80VDC 10A 5A 675W

Power supply: single-phase AC input 100-230VAC; Linear amplifier architecture, without PWM switching noise; The servo closed-loop has a maximum update rate of 8kHz.

1.2 Core Hardware Features

Supporting motors: brushed DC (torque mode/speedometer speed mode), brushless servo motor, stepper motor.

feedback system

Standard: Differential TTL line driven encoder;

-MXH option: Analog sine cosine encoder, programmable multiplier up to 2048;

-RDP option: Supports feedback from rotary transformers.

Communication: 3-channel FireWire for A3200 bus; RS-232/422 local debugging; The ENET option provides 10/100M Ethernet and is only used for third-party IO expansion. It cannot replace FireWire for motion control.

IO (onboard standard)

6-way optocoupler digital input (including 2-channel 50ns high-speed differential input), 4-channel optocoupler digital output;

1 differential 16 bit analog input, 1 18 bit analog output;

Onboard+5V/500mA encoder power supply (self recovering fuse protection).

PSO position synchronization output (laser triggered)

Standard single axis PSO; DUALPSO dual axis, TRIPLEPSO three-axis vector PSO;

Single axis delay of 200ns, multi axis delay of 275ns; hardware FIFO depth of 255, supporting vector distance triggering, window triggering, data capture/update;

IOPSO option is required to use optically isolated PSO output.

Complete hardware protection: Control power undervoltage, continuous overcurrent, power stage bias undervoltage, output phase/ground short circuit, bus overvoltage, IGBT overheating.

Environmental conditions: working temperature 5-40 ℃; Storage -20~70 ℃; Non condensing humidity ≤ 80% RH; maximum altitude 2000m, for indoor use only.

Mechanical: The total weight of the machine is about 10kg; M4 screws are installed; A 1-inch ventilation gap must be maintained around the driver; Supports two installation positions.

1.3 Main ordering options

Option Function Description

IOPSO/IOPSOH extended IO board; IOPSOH has a higher output current; Add isolated IO, brake relay, additional analog IO, opto isolated PSO, SSI Net

DUALPSO/TRIPLEPSO biaxial/triaxial vector PSO laser triggered, dependent on IOPSO board

MXH analog sine and cosine encoder multiplier board, up to x 2048

ENET Ethernet interface

RDP Rotary Transformer Feedback Interface

AUXPWR independent 85-240VAC auxiliary control power supply; Main power outage maintains logic, feedback, and communication operation (Keep Alive, emergency stop scenario)

PSOOPTO1-4 different specifications of PSO optocoupler isolation modules

1.4 CE Compliance Points

Meet the EN61010-1 safety standard; Belonging to equipment components, the final whole machine needs to undergo EMC testing again;

After a power outage, the internal high voltage can be maintained for more than 5 seconds; Shielded cables must be used, and FireWire cables require the installation of specified ferrite magnetic rings; Grounding and emergency stop protection are the responsibility of the system integrator.

Installation and Configuration

Safety warning: Cut off all power before wiring; Disconnect the mechanical load during debugging to prevent accidental motor rotation and injury.

2.1 Power terminal

TB101 main power (AC1/AC2): single-phase AC input; Motor three-phase output A/B/C; External delay fuse maximum 10A, cable # 14AWG.

AUXPWR (AL1/AL2) auxiliary power supply: independent 85-240VAC; Cut off motor power during emergency stop, maintain control circuit, and cooperate with external safety emergency stop relay.

TB201 ESTOP emergency stop detection input: It is only a signal detection port and does not constitute a safety emergency stop circuit in itself; Input 5-24V; requires the user to connect an external safety relay circuit; Axis parameter FaultMask enables ESTOP fault.

2.2 Wiring and phase setting of various motors

Brushed DC motor - torque mode: motor connected to A and C; B suspended; The forward command axis is clockwise (viewed from the flange) as positive, and if it is reversed, switch the A/C.

Brushed DC motor speedometer mode: The speedometer signal is connected to J205 analog input 0, with a maximum ± 10V; overvoltage requires voltage division.

Brushless servo motor: three-phase A/B/C, Hall HA/HB/HC connected to J207;

Aerotech's original factory motor is directly equipped with matching cables; Third party motors must be phase modulated;

There are two schemes for phase modulation: ① Run the A3200 example MsetDebug. Pm software for phase modulation; ② Power off oscilloscope to measure back electromotive force and Hall timing;

The Hall signal can be monitored in real-time on the Nstat software diagnostic page.

Stepper motor: Two phase windings connected to A/B/C terminals; Switch A/B incorrectly.

2.3 Feedback, limit, and return to zero wiring

J207 (25 pin D-SUB, motor feedback): Main encoder, Hall sensor, motor thermistor PTC, CW/CCW positive and negative limit, Home return to zero, brake output. PTC>1k Ω reports motor overheating fault.

J205 (26 pin D-SUB, auxiliary IO): Second auxiliary encoder channel (master-slave follower, handwheel, PSO); High speed input, universal IO, analog.

Limit switch: supports normally open/normally closed; Nstat can be used to view the status; Reverse the limit logic and switch the CW/CCW pins.

2.4 FireWire Multi Axis Networking

Set the unique device address (1-32) of the driver using dip switch S2, corresponding to the A3200 axis number;

Topology: Recommended star daisy chain hybrid; Up to 16 drives per chain; The maximum number of axes for the entire system is 32;

Debugging process: The driver is first powered on separately for testing, and then connected to the bus to avoid damage to the entire FireWire network caused by a single failure; Use Aerotech NConnect series FireWire cables.

2.5 Mandatory EMC Requirements for Wiring

Although the HL linear amplifier itself has low switching noise, it still requires:

The shielding layer of the motor cable is grounded for protection;

Power cables and encoder/IO signal lines are physically separated and routed separately;

Install magnetic rings on FireWire cables;

All devices are reliably grounded for protection.

Detailed technology of hardware interface

3.1 J205 auxiliary IO connector (26 pin D-SUB)

Auxiliary second encoder channel: Bidirectional RS-422, up to 8MHz; Used for handwheel, master-slave synchronization PSO； MXH doubling is not supported.

Digital IO In8-In11/Out8-Out11: Normal IO; In12 and In13 are 50ns high-speed differential inputs used for external event capture; Out11 can output low-speed PSO (only 1kHz).

Analog channel: 1 differential analog input ± 10V; 1 analog output ± 10V.

3.2 PSO Position Synchronization Output Core Principle

Fully implemented in hardware, without occupying DSP, used for synchronous marking in laser processing:

Signal source: main encoder, auxiliary encoder SSI‑Net；

Single axis maximum tracking 20MHz, multi axis (DUAL/TRIPLE) 5MHz;

Built in 255 depth hardware FIFO; Support vector distance triggering and window triggering; Support Data Capture (capture location/IO) and Data Update (synchronous rewriting of IO/analog output);

Output format: RS-422 differential, open collector; The high-speed optical isolation output must rely on the IOPSO option.

3.3 J207 motor feedback 25 pin D-SUB

Main encoder (TTL/band MXH supports sine cosine analog encoder); Hall; Motor thermal sensitivity; CW/CCW limit, Home return to zero; Brake output.

Onboard+5V maximum 500mA for encoder, self recovering fuse.

3.4 J206 RS‑232/422

Only used for local parameter debugging, this port is not necessary for normal operation, and motion control is controlled through the FireWire bus.

3.5 Voltage Current Mode (V-I Mode)

Supports independent voltage current control mode and can save parameters to Flash; The manual provides parameter configuration, operating mode, and corresponding fault conditions.

Hardware Description of Option Board

4.1- IOPSO/- IOPSOH Expansion Board

TB301: Brake relay, two 18 bit analog outputs;

TB302: Two 16 bit analog inputs;

TB304/TB305: 8-way isolated output, 8-way isolated input, supports current injection/pulling mode, IOPSOH outputs 1A per channel;

J301: PSO laser output interface, absolute RS-485 encoder;

J302/J303: Dual channel SSI Net, high-speed forwarding of encoder signals between drivers to achieve multi axis PSO.

4.2 DUALPSO / TRIPLEPSO

Dual axis/three-axis vector PSO, IOPSO board must be installed to transmit encoder information of each axis through SSI Net.

4.3-ENET Ethernet (J204)

10/100M， Only for third-party network IO expansion, cannot be used for motion control bus.

4.4-RDP Rotary Transformer Options

Rotation as position feedback; The complete process includes hardware jumpers, zero calibration, and calibration.

Accessories

Complete set of supporting cables: motor cables, feedback cables, FireWire bus cables, with part numbers provided;

Connection scheme for joystick and electronic handwheel, wiring schematic, can be connected to J205 or IOPSO board IO port for manual debugging.

Troubleshooting and Maintenance

Fault comparison table: phenomena, causes, and solutions of overcurrent, overvoltage, overheating, communication faults, feedback faults, etc.

Hardware testing points and jumper definitions: testing points and jumper settings for control boards, power supply boards, and motor power boards.

Definition of LED status indicator light, quickly determine the power, enable, and fault status of the driver.

JTAG debugging port, fuse, backup battery replacement part number.

Preventive maintenance: Regularly clean the dust in the cooling air duct and check the tightness of the connectors; The maximum temperature of the HL linear amplifier casing can reach 75 ℃, which is allowed by the design.

Supporting software tools (shared with Ndrive HP)

Nstat: diagnostic tool to view real-time status of Hall, encoder, limit, and IO;

Nparm: Axis parameter configuration;

Nview HMI: Human Machine Interface;

MsetDebug. Pcm example program: third-party motor phase debugging tool.