NOTE

Integrated Motion and
Machine Control Solutions
www.aerotech.com 1
Aerotech’s Advanced Automation Technologies:
46 years in the making... and going strong...

• Controls
• Software
• Amplifiers
• Motors
• PLC
• Fieldbus
• I/O
• Vision
• Peripherals
• Robotics
• Data Acquisition
2 Integrated Motion and Machine Control Solutions

Contents
Introduction
WORLD HEADQUARTERS 4 Aerotech Integrated Motion and Machine Control
Aerotech, Inc.
101 Zeta Drive, Pittsburgh, PA 15238 Motion Composer Software
Ph: 412-963-7470
Email: sales@aerotech.com
7 Setup and Configuration
9 Advanced Diagnostic and Tuning Capabilities
Aerotech United Kingdom
The Old Brick Kiln, Ramsdell, Tadley 15 Integrated Development Environment and .NET
Hampshire RG26 5PR, UK 18 Integrated Automation: MotionPAC – PLC and Motion
Ph: +44 (0)1256 855055
Email: sales@aerotech.co.uk 32 Operator Interface
Aerotech Germany 33 Software Architecture
Gustav-Weißkopf-Str. 18, 90768 Fürth, Germany
Ph: +49 (0)911 967 9370 Controller Architecture
Email: sales@aerotechgmbh.de
34 Automation 3200 Digital Automation Platform
Aerotech Japan 36 Ensemble Stand-Alone Multi-Axis Controller
WBG Marive East 22F, 2-6-1 Nakase
Mihama Ward, Chiba, Japan 261-7122 38 Soloist Stand-Alone Single-Axis Controller
Ph: +81 (0)50 5830 6821
Email: sales@aerotechkk.co.jp
40 Controller and Drive Technology
Aerotech China Controller Features

Room 101, No. 28 Building, Tianlin Road 140
Xuhui District, Shanghai, China 200234 48 Standard Control Capabilities
Ph: +86 (21) 6126 1058 52 Advanced Control Capabilities
Email: sales@aerotech.com
65 Fieldbus and Networking
Aerotech Taiwan 66 Hexapod and Piezo Controls
5F, No 32, Aly 18, Lane 478, Ruiguang Rd
Neihu District, Taipei City, 114, Taiwan R.O.C.
Ph: +886 (0)2 8751 6690 Quick Reference
Email: sales@aerotech.tw
68 Controller Comparison Chart
Aerotech France 72 Hardware Comparison Chart
28300 Coltainville, France
Ph: +33 2 37 21 87 65 74 Servomotors
Email: cmonnier@aerotech.com
Corporate Overview
Aerotech Italy
20089 Rozzano (MI), Italy 81 Markets and Industries
Ph: +39 02 94759294 88 Worldwide Training and Support
89 ISO Certification
Copyright © 2017, Aerotech, Inc. 90 Aerotech at a Glance
Information in this brochure is subject to change without notice.
www.aerotech.com 3
Configure Your Automation Solution with Aerotech
Common Software Platform:

Tools, Powerful Programming Environment, Calculators, Diagnostics
Aerotech Diagnostics PID Calculator

Integrated
Motion and
Machine
Control
• High
performance
• Easy to use
• Flexible
• Scalable
• Networked
• Lowest cost of
ownership Autotune PLC Loop Transmission
• Advanced
control
technology
• Controls servo,
piezo, voice
coil, and
stepper motor

Develop your own applications with
.NET, C#, VB.NET, C, LabVIEW,® Tango,
AeroBasic™ or PLC languages
Award-Winning Controllers
Automation 3200 Ensemble™ Soloist™

• PC-based • Stand-alone • Stand-alone
• 1 to 32 axes of coordinated motion • 1 to 10 axis controller • Network up to 1024 single axes
• Up to 32 tasks • Up to 4 tasks • Up to 4 tasks
• RS-274 (G-code) • Versatile, cost-effective, coordinated motion • Elegant, economical, versatile controller
• Advanced features for demanding applications • PWM or linear drives • PWM or linear drives (10-150 A peak)
• PWM or linear drives (up to 150 A) (10-150 A peak) • Drives brushless, linear, rotary, DC brush
• Scanner control for marking • Drives brushless, linear, rotary, or stepper motors
• Tightly integrated laser functionality DC brush or stepper motors
• Retro-fit package for old controls • Desktop, rack mount or panel mount
• Integrated PLC and Motion - MotionPAC
Piezo Controls
• Network up to 32
• Coordinated motion with servo and stepper motor stages
• Available in desktop or rackmount configuration
• Powered by Automation 3200 motion controller
www.aerotech.com 5
Configure Your Automation Solution with Aerotech
Linear and Rotary Servomotors/Accessories
Fieldbus and Network Connectivity Custom Controls, Drives and Motors

• EtherNet /IP™ • EtherCAT™
• PROFINET • Ethernet TCP/IP
• Modbus®/TCP • USB PLC Industrial PC
• RS-232 • GPIB
Software Fieldbus - I/O Custom Motors

Scalable Automation Control Software for Simple Applications and the Power User
Integrated Configuration Manager for Easy Setup
Motion Composer:
Compare Tool Standard motion Configurable
parameter tips toolbars workspace with your
files preferences
Use the same

Standard
Windows® Aerotech software
with the A3200,
menus
See all the

controllers on
Ensemble, or Soloist
the network
• Configuration Manager to
organize your applications
Work with this
controller • Calculators for quick
and easy setup
Network • Extensive diagnostics for

Explorer commissioning
for project
management
• Integrated Development
Environment for fast
File space development
on the
controller • Data Acquisition and
Analysis Tools for
increasing performance
• Fully compliant .NET 2.0
shortens the development cycle
Extensive Hyperlink to Context sensitive
calculators for associated subjects integrated help
system setup
www.aerotech.com 7
Calculators for Quick and Easy Setup
Easily switch axis

to be configured
Current loop Select your motor or add a

calculator custom motor
PID gain System knows all

calculator parameters of Aerotech
components
Configure feedback Select amplifier

for user units type
Directly enter any

parameter values here
Summary of default,
current and new values for
all parameters

Extensive Diagnostics for all System Signals and
Variables Shorten Debug and Startup Time
System toolbar for Axis toolbar for Standard toolbar for Issue immediate
system control control of each axis program control commands without
operator interface open
Control all axes at

once
Dockable windows for
custom work environment
Multiple tabs for organized

programming
Configurable to see only
the information you want
Real-time readout of
system state variables
Real-time access to
system signals
Real-time reporting of
all faults
Real-time system
information
View task status as needed
Watch any variables as the program runs
Pop-up error reporting
Compiler output screen
www.aerotech.com 9
Advanced Diagnostic and Tuning Capabilities Minimize

Startup Time and Allow Easy Optimization of Motion
Input amplitude and

frequency range for test
Select desired system

Save plots for future
bandwidth and phase
reference
margin
Current and recommended Scope, tuning and data

gains pop up after each run collection fully integrated
with controller
Use sinusoidal sweep or

white noise method
Automatic calculation of
PID-FF gains

Use Encoder Tuning Tool to Increase
System Accuracy
One click
tuning
Optimally calculates gain
and phase of amplified
sine encoder channels in
seconds
Fully integrated
with controller
Actual encoder
performance
Graphical display of the

Lissajous plot to optimize
the encoder signal
www.aerotech.com 11
Loop Transmission is a Tuning and Diagnostic Utility

that Greatly Enhances System Performance
Graphical loop shaping — Automatic calculation of

add filters or change gain gain margin
by dragging the gain curve,
and the filter coefficients
and PID gains are calculated
automatically
Identify resonances
and use filters
Calculator and loop

shaping to increase
Open or closed performance
loop response
Automatic calculation of
Analyze position
phase margin
loop, velocity loop
or current loop
System frequency
response or Bode plot

Fully Integrated Digital Filter Calculator
Makes Performance Enhancements Easy
Select your filter type: low pass, high

pass, notch, resonant, lead/lag
Axis selection Add up to eight filters

per axis
Discrete time gains are

automatically calculated
and stored in the
parameter file
Configure filters for
your application by
specifying frequency,
depth and width
Cursor control to read out
gain and phase
Composite frequency
response of all filters
Store all parameters in the

parameter file
www.aerotech.com 13
Integrated I/O Panel for Debug,

Commissioning or Operations
View I/O axis

information and
program at the
same time
Use the I/O panel during
programming to test as
you go
Monitor digital I/O control
Monitor analog I/O

Tool tip provides
physical connector
and pin on the drive to
easily associate electrical
wiring with software
variables
Set analog I/O

during commissioning
for easy testing
Set digital I/O during test
and commissioning

Integrated Development Environment
Shortens Development Time
Hide the axis manager

while programming to see
more code
Visual Studio®- like project Minimize development

management for advanced time with debug features,
programming break point, step in and
step over
Powerful IntelliSense®
capability
Full diagnostic
instrumentation while
debugging
Insert breakpoints to
debug program
Watch window shows

variable values for easy
Low learning curve with debugging
strict implementation of
.NET naming conventions
Detailed error explanation Link to help file for

in error list description of error
www.aerotech.com 15
Create Reusable Modules

with AeroBasic™
Create reusable code Real-time code

with libraries and environment
#include files
Advanced programming
Write easy-to-read and
techniques result in code
maintainable code by
that is easy to read, simple
using #define (rather
to maintain and reusable
than numeric constants)
for other projects
Protect intellectual
property by using a library;
permit or deny end users
access to source code
Built-in software security

key for OEMs

Create Easy to Maintain Code
with AeroBasic™
User defined Memory management is

variable types allow an done by the operating
object-oriented approach system
to system design
Keeping all motion code

in one function creates
Use structures to define modularity, which brings
your own data types products to market faster
and reduces maintenance
cost
Advanced variable types Variable initialization

such as arrays and strings reduces code size and
allow for more advanced increases readability for
program design multiple developers
Standard program flow:

while/wend
for/next
repeat
if/then/else
www.aerotech.com 17
Integrated Automation: MotionPAC
Program in IEC 61131-3: LD, FBD, ST
• 30% to 50% Online mode displays

all Tag values
Axis manager Standard LD
reduction in
development
time
• High-
performance
motion fully
integrated with
standard PLC Define
environment hardware
• Easy-to-use
diagnostics and Create
tools libraries
• Standards &
Flexibility:
LD, FBD or ST
IEC 61131-3, programs
.NET, PLCopen,
PC-based
Combine LD and FBD in Completely integrated Tag database

the same program motion blocks

Integrated Automation: MotionPAC –
PLC and Motion
HMI MotionPAC
• Program selection and run • IEC 61131-3
• Jog panel • PLCopen
• Machine control • Aerotech motion blocks
• Customizable buttons • Axis manager
• Axis manager • Extensive development & debug
environment
• Simulate program
Motion Composer
• Axis manager Scope
• Low-level motion • Signal capture & analysis
diagnostics
• Autotuning
• Motion programming
• Loop transmission
• Advanced control
algorithms • Encoder tuning
• Advanced controls
Beckhoff Wago Central Machine Tag Database

• Data acquisition • Tags available in all applications by
synchronized with motion name
& PLC
• Define both local or global machine Tags
• High-speed registration
• Define Tags in I/O definition, ST, LD,
• Position Synchronized FBD or motion program
Output
• Machine interlocks
• Fieldbus I/O
www.aerotech.com 19
Use Tags in Operator Interface by Name
Use shared Tags defined in

MotionPAC by name in a
button action
View CNC code running at

same time as PLC code
Use shared Tags by name
in program called by a
button click

Standard PLC Functions: IEC 61131-3
Ladder Diagram Motion Blocks (Partial List) Functions (Partial List)

• VALUE • MoveAbsolute • ABS
• TRUE • MoveRelative • ACOS
• FALSE • MoveSuperimposed • B_BCD_TO_DINT
• COMMENT • MoveVelocity • B_BCD_TO_INT
• CONNECTOR • Home • DELETE
• JUMP • Stop • DINT_TO_BOOL
• LABEL • PositionProfile • EXP
• RETURN • MoveContinuous • EXPT
• CONTACT (NO, NC) • Halt • FIND
• COIL • CamIn/CamOut • GE
• LEFT POWERRAIL • CamTableSelect • GE_STRING
• RIGHT POWERRAIL • GearInPos • INT_TO_BOOL
• GearIn/GearOut • INT _TO_BYTE
Function Blocks • Phasing • INT _TO_DINT
• CTD • INT _TO_DWORD

• LE
• CTU Administrative Motion Blocks
• LE_STRING
• CTUD (Partial List)
• F_TRIG • LEFT
• ReadStatus
• R_TRIG • LEN
• ReadAxisError
• RS • MULTIME
• ReadParameter
• SR • NE
• WriteParameter
• TOF • OR
• ReadActualPosition
• TOF_R • REAL_TO_BOOL
• AbortTrigger
• TON • SEL_TO_BOOL
• ReadDigitalInput
• TON_R • SEL _TO_BYTE
• ReadDigitalOutput
• TP • TRUNC _SINT
• WriteDigitalOutput
• TP_R • UDINT_TO_BOOL
• SetPosition
www.aerotech.com 21
One I/O and Data Dictionary for the Machine
Integrated Development Environment

Shortens Development Time
Drive I/O connected to Fieldbus I/O connected

system to the system
I/O defined in
one place
I/O available in Easily map I/O to

all applications: program Tags
scope, configurator,
MotionPAC (PLC) and
Motion Composer
Memory
management
automatically done
by the MotionPAC
One I/O and Data Dictionary for the Machine

Use Scope to Plot Any Motion,
PLC, I/O, Variable or Tag
Motion variables
All information in Global
Tag database available
for real time plotting and
analysis with all motion
variables
PLC Tags
www.aerotech.com 23
SDK: Software Development Kit
Use the Aerotech standard GUI...

...or build a custom interface for your application
• Easy to use • C#
• VB.NET®
• Faster
• Managed C++
development
• LabVIEW® (VIs provided)
• Lower • C Library
maintenance
• EPICS
cost

.NET Library
• High-end motion with a custom GUI
• Use the best language for the application
• Fully functional libraries for each language
All Aerotech applications are written using the .NET library. Aerotech
provides customers with the same tools used at Aerotech. OBJECT MODEL
TAKE ADVANTAGE OF:

.NET Framework 2.0 Libraries Include:
• Generics • Initialization functions
• Enumerations • Global data functions
• Indexers • Motion functions
• Events • Error handling
• Exceptions • Status and position
functions
Object Model • Analog and digital I/O
functions
• Well-organized structure
with two main classes: • Parameter functions
network and controllers • Run CNC program
• Common features are higher functions
in the hierarchy • Utility functions
• Minimal code required to • Get and set variable
accomplish the task at hand functions
www.aerotech.com 25
Motion Designer: Graphical Trajectory Generation and Data Analysis
Applications
• Dynamic environment simulation • Gyros or accelerometers; tracking or
• Sensor or component testing beam-steering gimbals
• Crash sensors and roll-over sensors
• Minimize
programming
time
• Import actual
data Create and modify multi-
axis trajectories using Cursor
• Import from predefined building blocks control
Excel or to provide rapid motion
prototyping
MATLAB® Apply
filters to
Perform data analysis shape
such as FFT, max, the
min, average, rms and trajectory
standard deviation from frequency
an existing trajectory content
for diagnosing system
performance Import
existing
position,
velocity or
Add standard filter acceleration
types: notch, resonant, data
low pass and high pass
View the
composite
Enter standard filter filter before
frequency parameters applying
to the
trajectory
Digital filter coefficients are

automatically calculated
Cursor control

Create periodic motion
Automatic AeroBasic™
program generation for all
controllers
Project tree for simple

organization
Point-to-point moves
Overlay multiple trials for easy

comparison
Trajectory properties
(e.g., user units)
Easily modify an existing

trajectory
Automatically calculates
missing state information
(e.g., acceleration, velocity
or position)
Rapid motion programming
www.aerotech.com 27
Motion Simulator – GUI
Aerotech Motion Simulator – The Integrated, Easy to Use,

Graphical Trajectory Generation, Data Analysis and Enhanced
Machine Performance Toolkit
• Operate 1,2,3 axis motion Aerotech’s Motion Simulator software is an easy-to-use Windows®-based program for creating
simulators simple and advanced motion stimuli for testing and calibrating inertial sensors and systems. The
Aerotech Motion Simulator software includes all controls for manually or automatically running
• Frequency response mode 1-3 axis motion simulations. The GUI provides a user interface and programming environment
that requires no third-party development software.
allows input sine sweep and UUT
performance tests on customer
device Key Features:
• Harmonic Cancellation optimizes • User-friendly Windows®-based graphical user interface
motion position errors generated
• Trajectory tracking from Ethernet, analog or Windows® program inputs
by sinusoidal motion
• Iterative Learning minimizes position error
• Overlap multiple runs of a trajectory to easily see how program changes modify
the motion
• Perform data analysis such as FFT, max, min, average, rms and standard
deviation from an existing trajectory for diagnosing system performance
• Data input file formats include Excel, CSV or MATLAB®; Motion Simulator can
calculate the missing state variables

Main Screen Motion Designer
Program Frequency Response
Track screen allows external signal selection for tracking Data Analysis
www.aerotech.com 29
CADFusion
Generate Motion Programs Directly From Your CAD Drawing
• Easily imports vector-based

drawing files and produces
G-code motion programs
• Interactive canvas allows easy
editing and creation of new
shapes and text
• Automatic and manual shape
re-ordering options allow for
optimal tool and processing
paths
• Export to RS-274D
G-code format
• Allows user-defined initialization,
process shutdown, and
shuttering commands (tool on/
off)
• Offers seamless use of
Aerotech’s powerful controller
features such as PSO (Position
Synchronized Output)

Simulation API
Open Simulation Environment
• Support for Coppelia Robotics

virtual robot experimentation
platform (V-REP)
• Full system modeling capability
• Visualization and selection of
coordinate systems for multi-
DOF systems like hexapods
• Pre-configured models connect
directly to Aerotech’s A3200
motion controller
• Import custom objects as 3D
mesh files
• Supports collision detection
between all elements in the
environment
• Control grippers and vacuum
pickup devices with Aerotech
I/O
www.aerotech.com 31
Operator Interface
Configurable Operator Interface
Issue immediate Configurable axis Configurable

commands manager jog pad User customizable
buttons
• Use the Aerotech Operator
Interface (OI) for fast deployment
• Customize the OI to suit the
application
• User customizable buttons that
can execute standard G-code and
AeroBasic™
Active program Standard machine Designed for touch Set up simple or

controls screen complex action —
user can attach a
standard G-code
program to a button

Advanced Software Architecture
Layered for flexibility • Customizable at many layers • Most cost-effective solution
www.aerotech.com 33
Digital Automation Platform
Distributed Motion Control Use Nservo to

®
• Motion trajectory generation and synchronization are Retrofit Existing
centralized at the PC Motors & Drives or
• Motion execution is decentralized at the drives Drive Large Motors
• A3200 operates on any standard desktop or industrial PC
Digital Automation • Servo loops are closed on the drive
Platform Npaq® 6-Axis High

• Higher throughput due to high Performance Drive Rack
performance control, network
and high-power drives
• Higher accuracy and repeatability Nservo
Nstep
due to all digital drives and
advanced servo algorithms
• Faster startup and changeover
results from fully integrated
motion platform, easy-to-use
Any Servo
setup tools and extensive Amplifier Any Stepper
diagnostics Drive AGV
Galvo
• Lower startup and life-cycle cost Control
due to less components and
reduced engineering Any
Stepper
Motor
• Higher reliability due to fewer
components
• Simplified integration
®

The Intelligent 32-Axis Motion, Vision, Fieldbus
Interface
PLC, Robotics and I/O Platform
• Easily installed digital drives
• FireWire® (IEEE-1394) industry standard, high-performance
motion bus
FireWire®
Smart Camera
Nmark SSaM
or Ethernet
Nmark GCL Ndrive HLe
Ndrive HPe
Ndrive ML
Ndrive CP
Any Brush, Brushless

or Stepper Motor
with any Drive
Digital Drive Features
• PWM or linear (10 A to 150 A peak)
• Integrated 10/100 Base-T Ethernet
• Encoder, resolver or inductosyn feedback
• Onboard x65536 encoder multiplication
• 20 kHz position, velocity and Easily integrates with Ethernet I/O
current-loop sample rate Keyence LK-G Series Laser Expansion
• Integral power supply Displacement Sensors Analog and
• Sinusoidal commutation Discrete I/O
• Local I/O ports

www.aerotech.com 35
Stand-Alone Multi-Axis Automation Controller
Maple or PC Master
®
Ethernet TCP/IP
USB
RS-232
EtherNet/IP™
Modbus® TCP
Stand-Alone EPICS
Multi-Axis
Modbus® TCP
Automation Smart Camera

Controller Joystick
Handwheel Brushless
Linear Motors
• Easy to use
• Powerful architecture
• Distributed control
• Network ready 6-Axis Stand-Alone, Rack
Mount or Desktop Plus
Three Axes
Joystick
IEEE-488
EtherNet/IP™
Modbus® TCP USB
EPICS RS-232
Ethernet TCP/IP

Software, Controls, Drives and I/O... All in One Package
10-Axis, Stand-Alone, All Digital, Panel-Mount Controllers
from 10 to 150 A peak
AeroNet
Ensemble
CP Ensemble
HPe Ensemble
ML Ensemble
MP
Brushless Ensemble
Servomotors Stepper Ensemble
ML
Motors HLe
DC Brush
Motors
Slotless Motors Brushless

Slotless
Motors
Efficient motion Easily integrates with

USB programming Keyence LK-G Series Laser
RS-232 with IDE Displacement Sensors
Ethernet TCP/IP
Applications Capability
• Semiconductor • Point-to-Point
• Medical • Linear and Circular
• Test and Inspection Interpolation
• Packaging • Electronic Gearing
• Velocity Profiling
• Gantry
www.aerotech.com 37
Stand-Alone Single-Axis Automation Controller
Ethernet
Modbus®
Ethernet TCP/IP
RS-232
USB
Operator
Interface RS-232
Stand-Alone
Modbus® TCP
EtherNet/IP™
EtherNet/IP™
Single-Axis
Automation
Controller
• Easy to use
Modbus® TCP
• Scalable
DC Brush Motors
• Ethernet/USB connectivity
Brushless
Servomotor
Modbus® TCP
Analog
Joystick
Quadrature
Encoder
Handwheel

Software, Controls, Drives and I/O in One Compact Package
from 10 to 150 A peak
Soloist HPe 150

Soloist HPe
Soloist CP
Soloist MP Soloist ML
Brushless Linear
Motors Stepper Soloist HLe
Slotless
Motors Motors
Brushless
Servomotors
ASR2000
Spindle
Easily integrates with

Keyence LK-G Series
Laser Displacement
Sensors
LAN/WAN/Internet up to
1024 on one network
Connect, program or monitor

locally or remotely
www.aerotech.com 39
Controller and Drive Technology
MP for OEMs lowers costs • CP solutions for less integration work • HPe for the highest performance solution
Ndrive® MP Ndrive® CP
Ensemble® MP Emergency Stop
Sense Input (TB101,
Ensemble® CP
Soloist® MP Top) Soloist® CP
Width: 41.1 mm Width: 63.5 mm
Height: 141.2 mm Height: 198.2 mm
Two 16-Bit Analog
Inputs, One
LED Status Analog Output
FireWire® Indicators (TB201)
(IEEE-1394)
(J101, J102) Second Encoder Ethernet TCP/IP
Interface (J201) (J101, J102) Eight Opto-Isolated
Outputs, Common
Sink or Common
Source (User
LED Status Defined) (TB202)
Indicators Motor
Brake Relay (TB201)
Feedback
Connector
Eight Opto-Isolated
(J103)
Outputs, Common
One 12-Bit Analog Sink or Common
Input and One16- Source (User
Bit Analog Output Defined) (TB203)
(TB202) Emergency
Stop Sense
Eight Opto- Input
Motor Feedback Isolated Inputs, Eight Opto-Isolated
(TB101) Inputs, Common
Connector (J103) Common Sink or
Common Source Sink or Common
(User Defined) Auxiliary I/O Source (User Defined)
(TB203) (J104) (TB204)
Eight Opto-Isolated
10-80 VDC 7-240 VAC Inputs, Common
Bus Voltage Eight Opto- Single-Phase
Isolated Outputs, Sink or Common
Input Input Source (User
Common Sink or
Common Source Defined) (TB205)
Motor Output (User Defined) Motor Output
10-80 VDC, 10 Apk (TB204) 10-320 VDC, 10-30 Apk Brake Relay
(TB206)
24-80 VDC, 2 A Control
Max Logic Power Supply
Input (TB103, (Bottom)
Bottom)

Ndrive® HPe Ndrive® HPe
Ensemble® HPe Ensemble® HPe
Soloist® HPe Ethernet (J204)
Resolver Interface
(Opt) (J401, J402)
Soloist® HPe Communication
Channel (Device #) Resolver Interface
Settings (Opt) (J401, J402)
FireWire®
(IEEE-1394) Ethernet (J204)
(J201, J202,
J203)
IEEE-1397
Control PSO/Absolute FireWire® (J201,
Supply Encoder LED Status J202, J203)
Interface (J301) Indicators
PSO/Absolute
1-3 Phase Encoder Interface
7-240 VAC Two Channels SSINet 1-3 Phase (J301)
50/60 Hz for Buffered RS-422 7-240 VAC
(Multiplied) Encoder 50/60 Hz Two Channels
IN/OUT (J302, J303) SSINet for Buffered
3 Phase RS-422 (Multiplied)
10-320 VDC LED Status Indicators Encoder IN/OUT
Motor Output 3 Phase (J302, J303)
Two 18-Bit Analog 10-320
10-30 Apk Outputs and Brake Relay Two 18-Bit Analog
VDC Motor
(TB301) Output Outputs and Brake
50-100 Apk Relay (TB301)
Auxiliary I/O Two 16-Bit Analog
(J205) Inputs (TB302) Two 16-Bit Analog
User Power Inputs (TB302)
(TB303)
RS-232 (J206) User Power (TB303)
Emergency Eight Opto-Isolated Eight Opto-Isolated

Stop Sense Outputs, Common Outputs, Common
Input (TB201) Sink or Common Control Sink or Common
Source (User- Supply Source (User-
Power LED Defined) (TB304) Defined) (TB304)
External Eight Opto-Isolated
Model shown is Eight Opto-Isolated Shunt
10 to 30 amps Inputs, Common Sink Inputs, Common Sink
peak with I/O or Common Source Power LED or Common Source
expansion (User-Defined) (TB305) (User-Defined) (TB305)
Model shown is 50 Auxiliary I/O (J205) Motor Feedback

Motor Feedback Connector (J207) Connector (J207)
to 100 amps peak
with I/O expansion RS-232 (J206) Emergency Stop
Sense Input (TB201)
www.aerotech.com 41
Linear Drive Ndrive® HPe150 Ndrive® ML

Ensemble® HPe150 Ensemble® ML
Advantages
• Ultra-smooth Soloist® HPe150 Soloist® ML
motion during Width: 229.7 mm Width: 41.1 mm
reversals
• Superior
in-position Emergency Stop Second Encoder
Sense Input Interface (J201)
stability (TB101, Top)
• Integrated with
controls
Relay
• No switching Line
Supply
noise
Ethernet Brake
• No dead band Resolver (IEEE-1394) Relay
Motor (J101, J102) (TB201)
• Low EMI Power USB
LED Status
External One 12-Bit
Indicators
Shunt
Applications Brake
Power
Analog Input
and One16-
Bit Analog
• Nondestructive Motor
Control Output
Feedback
testing Supply Ethernet Connector
(TB202)
(J103)
• Stencil cutting Eight Opto-
Isolated
• Any small move, Auxiliary Inputs,
I/O Common Sink
or sinusoidal Additional or Common
movements RS-232 Digital ±40 VDC Bus
Voltage Input
Source (User
and Defined)
• Very slow ESTOP Analog (TB203)
I/O
velocity Motor Output Eight Opto-
±40 VDC, 10 Apk
applications Motor Isolated
Feedback Outputs,
• Stent Common Sink
24 VDC, 2 A Max or Common
manufacturing Logic Power Input Source (User
(TB103, Bottom)
• Target tracking Defined)
(TB204)
• Piezo stages

Ndrive® HLe Nstep
Ensemble® HLe Width: 49.2 mm
Height: 161.8 mm
Soloist® HLe PSO/Absolute Encoder
Interface (J301)
Width: 206.9 mm
Height: 234.3 mm FireWire® (IEEE-1394)
Resolver Interface (Opt) One Input and Output per
(J201, J202, J203)
(J401, J402) Axis and Sixteen Additional
I/O Points
Main Supply Reset

Motor Output (TB101) LED
AC1, AC2, Ground Power LED
Enable LEDs Enabled LEDs

Axis 1 and 2 Axis 3 and 4
Two Channels SSINet
for Buffered RS-422
(Multiplied) Encoder IN/ FireWire®
Ethernet
OUT (J302, J303)
(J204)
LED Status
Control Supply
Indicators
Amplifier Amplifier
Two 18-Bit Analog Interface
Outputs/Brake Relay Interface Axis 3
Axis 1
(TB301)
Auxiliary I/O (J205)
Two 16-Bit Analog Encoder
Inputs (TB302) Input Axis 1 Encoder Input
Axis 3
User Power (TB303)
RS-232 (J206)
Emergency Stop Eight Opto-Isolated Amplifier
Sense Input (TB201) Outputs, Common Interface Axis 2 Amplifier
Sink or Common Interface Axis 4
Power/Enabled LED
Source
(User-Defined)
(TB304) Encoder
Encoder Input
Input Axis 2
Axis 4
Eight Opto-Isolated
Motor Feedback Inputs, Common
Connector (J207) Sink or Common
Source (User-
Defined)
(TB305)
www.aerotech.com 43
Nmark GCL Nmark SSaM

® ®

Height: 219 mm Height: 199.0 mm
FireWire®
FireWire®
2-Axis Galvo Opto-Isolated I/O

Motor and
Laser Output Feedback
Laser Interface
I/O
Analog I/O
Encoder Input
Encoder Output
Motor
Supply

Nservo Nservo – OEM
Width: 87.6 mm 4 Axis or Less
Height: 230.4 mm Width: 284.5 mm
ESTOP Height: 276.9 mm
and Extra Eight
Opto- Eight PSO and
Encoder
Outputs Opto-Inputs Brake
Analog I/O Channel
General
Purpose 48 Bit
I/O
FireWire®
(J101, J102) AC Input
Ethernet
(J103) Encoder
Limits and
LED Indicators Motor
(J103) Optional Power
Power
Supply
4-Axis
Option
AC Input
FireWire®
Analog I/O ESTOP Eight Eight PSO and

and Extra Opto- Opto-Inputs Brake
Amplifier General Encoder Outputs
Enable, Purpose 48-Bit Channel
Active State I/O
Selection
www.aerotech.com 45
Npaq® and Epaq Rack Mount or Desktop Solutions in One Box Minimize Wiring
Console Npaq® Npaq® MR/Epaq MR

6 Axis or Less 8 Axis or Less
Power
Switch
Laser Feedback
(Optional) Power Switch/ Circuit Breaker
FireWire®
Resolver Inputs (Optional) Joystick
Analog I/O (Optional) Communication Analog
User I/O Channel Numbers
Emergency Stop ESTOP Connection
(Optional)
I/O Encoder Motor 115 VAC or

FireWire®
220 VAC
AC Power Input Motor Output Encoder Ethernet
Feedback (Optional)

Ensemble® Epaq Ensemble® LAB
5 Axis or Less 4 Axis or Less
Width: 431.8 mm LCD Width: 370.2 mm
Height: 177.8 mm Screen Height: 98.4 mm
Directional
Keypad Directional
Numeric
Power Touch Screen Keypad
ESTOP Button Keypad
Switch Interface Power
(Optional)
Switch
Jog
Buttons
AC Power Options Axes 2 through
Input 6 (Optional) USB
Control Axis 1 Port
Board
AC Power
Axes 1 through 4 Input
I/O Joystick USB
ESTOP Ethernet
www.aerotech.com 47
Standard Control Capabilities
Aerotech controllers offer the broadest array of programming interfaces and core motion capabilities of any automation
system available today. Aerotech controllers have the programming flexibility and capability to meet the requirements of the
most demanding motion applications of OEMs and end-users alike.
Point-to-Point Motion Acceleration Limiting Coordinated Motion
Basic independent Anticipate sharp Linear and circular

axis positioning corners and small motions are
with programmable radius supported in all
accel/decel and arcs and languages.
feedrate. automatically
decelerate as
needed.
Arbitrary Path Generation (PVT) Electronic Gearing On the Fly End-Point Modification
Specify discrete Electronically Modify the

position, velocity control one axis as endpoint during
and time and the a simple ratio or as execution of the
controller will a complex function motion profile.
interpolate to of another axis;
create a smooth, fire I/O in real time
contiguous path. during a move.
Cutter Compensation Parts Rotation Velocity Profiling
Also known Use when a two- Maintains a

as tool radius dimensional part constant vector
compensation, must be repeated velocity along the
this feature in different programmed path.
automatically orientations
adjusts the path to without translating
allow for the radius the part program
of a cutting tool. many times over.

Seven Segment Acceleration Velocity Blending Fast Position Capture
Specify the The velocity Store positions

acceleration profile changes to the next based on the
in seven segments, velocity command, transition of a
providing precise acceleration digital input,
control over limited, without allowing close
system motion. stopping. correlation of
axis positions to
external events.
Retrace Intra-Block Retrace High-Speed Registration
Retrace a path Retrace a path High-speed

block by block. inside a block. registration to
trigger motion
is useful in
packaging and
labeling.
Gantry Mode Kinematics Analog Power Control
Complex gantry Execute complex Adjust the setting

control is reduced inverse kinematic of an analog output
to a few simple equations within in relationship to
commands to the flow of the vector speed of
handle dual the trajectory two axes to permit
motor and/or generation. the automatic
dual feedback regulation of
configurations. laser power or
material dispensing
processes.
www.aerotech.com 49
Standard Control Capabilities
Motor Control Orthogonality Correction Axis Calibration

All controllers Improve X-Y planar Compensate
operate brush, accuracy by simply for repeatable
brushless or stepper entering the known mechanical errors
motors in any orthogonality error in a positioning
combination. and the controller system.
will compensate.
Sinusoidal Commutation 3D Error Correction Dual-Loop Control

Brushless motors Measure XYZ errors Dual-loop control
produce smoothest and the controller is used to eliminate
motion when can correct the the effects of
sinusoidally commanded backlash and other
commutated, position to sources of error.
eliminating the accurately move to
need for multiple all locations in the
transducers and 3D space.
reducing cabling.
Quadrature Encoder Analog Feedback Resolver/Inductosyn

Use a standard For high resolution, Programmable
A,B quadrature short travel carrier frequencies
encoder, applications, linear make resolvers/
incremental or drives accept inductosyns easy
absolute. analog inputs from to integrate.
analog sensors.

Laser Interferometer Encoder Tachometer
Systems Systems requiring For dual feedback

requiring high resolution use systems use tach
ultra-high a 1 Vpp encoder for velocity control
resolution with Aerotech and encoder for
and feedback multiplier, up to position control.
stability use 65,536 and
interferometer 2 MHz input
feedback. frequency.
PIDFF Safe Zones Slice Move

PID digital Safe zones can be Increase scanning
control loop with set up on multi-axis throughput by
feedforward systems to protect blending step
for velocity, against crashes. and scan into a
acceleration and contoured move.
friction.
Limits Spindle Control CAM Profiling

Set up hard limits Spindle commands Electronically
and soft limits for use standard command one
maximum safety m-codes. axis position as a
and flexibility. function of another
axis with a CAM
table and fire I/O
during the move.
www.aerotech.com 51
Advanced Control
Reduce Position Error
Continuously adapts and tracks sinusoids
Harmonic
Cancellation Position error
without harmonic
cancellation
• Reduce position error on
periodic trajectories
• Reject periodic disturbances
Following Error, um
• Built-in setup wizards
• Adapts to magnitude and
frequency of error source
Position error
with harmonic
cancellation
Time, ms
10 Hz Command; ± 1 mm
Applications
• Machining • Cogging Reduction • MEMS Sensor Testing
• Spindle Control • EDM/ECM • Rq Wafer Inspection

1st Iteration
Following Error Under Learning Control Iterative Learning

Control
• Repeating move sequences can
be learned and optimized
Following Error, nm
• Reduce following error

• Increase dynamic accuracy
• Increase production rates
Time, ms
Final Iteration
Applications
• Stencil Cutting • Sensor Testing
• Stent Cutting • Micromachining
www.aerotech.com 53
Advanced Control
Improved Settling Time
ETM Off
Enhanced Throughput
Module (ETM)
• Multi-axis feedforward capability
• Faster settling time
• Increase rate stability
Position
Time
ETM On
Applications
• Pick and Place Machines
• Semiconductor Inspection
• Genome Sequencing

Dynamic Position Error, Circle XY - Gain Scheduled Kpos
Normal
Directional Gain
Scheduling
Gain Scheduled Kpos
Pos Error x (µm)
• Decrease settle time
Time (seconds)
• Increase in-position stability
Normal
Gain Scheduled Kpos
Pos Error y (µm)
Time (seconds)
Normal
Vector Pos Error (µm)
Gain Scheduled Kpos
Time (seconds)
System automatically adjusts gain based

on error motion during settling
www.aerotech.com 55
Advanced Control
EasyTune /EasySetup
®
• Automatically tune servo and

piezo axes
• Hands-off! EasyTune requires no
user input or controls knowledge
• Set a custom performance target
– improves throughput and
system stability
EasyTune®
Catalog Manager Motor Phasing Calculator

Reduce cross-axis position error during acceleration
Without cross-axis
feedforward Cross-Axis
Feedforward
Position Error in Z-Axis Resulting from 1 mm Step in Y-Axis
• Reduce position error on an axis
due to acceleration of another
axis
Z-Axis Error (µm)
Time (s)
15x reduction in peak With cross-axis

error feedforward
www.aerotech.com 57
Advanced Control
Reduce Vibration at the Work Point
Command Shaping
• Increase throughput
• Faster settle time at the work
point
• No additional sensors required
• Reduced vibration in point-to-
point moves
• Easy tuning
Position error at work point to 30 mm step move
Applications
• Pick and Place Machines
• Semiconductor Inspection
• Genome Sequencing

High Accuracy Firing Based on Actual
Calibrated Encoder Counts
Array-Based Firing
User Specified Pulse Train
• PSO fire points are defined in an array based on calibrated
position
• Pulse train specified with absolute or incremental positions
Position Synchronized
• Variable pulse width Output (PSO)
• Specify pulse lead, pulse and pulse tail for precise energy
delivery • Increase throughput
Single Pulse Output • Higher accuracy
User Specified Pulse Train
• 1-, 2- or 3-axis PSO
• Configurable command pulse train
Windowing • Use to trigger

• Output pulses are constrained inside a user-defined window with • Laser firing
the first pulse relative to the edge of the window
• Excellent when the processing of a part requires the axes • Camera capture
to move beyond the part for settling or direction reversal in
Position applications such as flat-panel manufacturing or fuel-injector • Data acquisition
Upper Limit drilling
Lower Limit • Nondestructive test triggering
Window Output
Fixed Distance Firing

• Single- or multiple-pulse output as a function of up to 3 axes’
position feedback
• Minimizes heat-affected zone in welding, cutting and drilling
Consistent • Outstanding for stent manufacturing, hermetic welding and
spacing of pulses
drilling holes in turbine blades
regardless of
velocity through
the contour
www.aerotech.com 59
Advanced Control
Gantry Control
• Both spars are programmed and
commanded as a single axis
• Easy homing
• Marker offset for high accuracy
• Orthogonality correction
Gantry Modes
• Current Synchronization
• Position Synchronization
Gantry Configuration
• 2 Motors, 2 Encoders
• 2 Motors, 1 Encoder
• 1 Motor, 1 Encoder

Open architecture, PC-based robot controller for three-
axis (X/Y/Z) Delta robots. Includes a pre-configured
installation of Aerotech’s A3200 automation platform
with robot specific programming extensions, NEMA
32 frame size motors, drives, and cables. Key system
features include: Delta Robot Control
• Industrial panel-mount PC with
solid-state disk drive
• Teach mode with user defined
number of points
• Synchronization with moving
material
• Target position command queue of
user defined depth
• Real-time simultaneous display of
tool and work-point coordinates
• G code and AeroBasic™ motion
command syntax
• Control up to 20 additional axes
• Optional IEC 61131-3 PLC
interface with support for
PLCopen and .NET
• Servomotor with absolute
feedback device and brake
• Ndrive CP10 drives
• 5 meter long motor power and
feedback cables
www.aerotech.com 61
Advanced Control
Directly Synchronize Scanhead and Servo Motion for

Ultimate Flexibility in Marking Applications
Laser Marking–
Nmark® CLS
(Closed-Loop Scanner)
• Expand scanner field-of-view
without sacrificing effective pixel
resolution
• Mark long vectors with one
continuous pass
• Draw large-scale graphics without Dynamic field-of- Continuous marking
view movement of long objects
stitching multiple exposures allows marking through combined
of non-repetitive servo and scanner
• Mark on a tube or other patterns over large motion eliminates
irregularly shaped object without areas, greatly
expanding the
line breaks that
can occur when
manually repositioning scanner operating stitching together
envelope adjacent marking
• Single programming environment fields
for both scanner and servo axes
minimizes application complexity
• Eliminate angular errors
• Scanner programmed with
standard RS-274 G code
• Laser firing based on real-time
scanner position

High-Performance
Galvanometer
Scanners
Vector Applications
• Cutting
• Welding
Nmark AGV-HP Nmark AGV-HPO Nmark GCL • Sealing
• Highest accuracy scanner • Highest accuracy scanner • Closed-loop, two-axis servo
available attains single-digit, available attains single-digit, drive for Aerotech’s AGV • Ablation
micron-level accuracy over micron-level accuracy over series scanners
the field of view the field of view • Marking
• Infinite Field of View (IFOV)
• Optical feedback technology • Optical feedback technology seamlessly combines AGV
significantly improves thermal significantly improves thermal and servo motion to expand
stability stability the scanner work area Graphic Applications
• Industry-best resolution of • Industry-best resolution of • Full servo state control
>24 bits when used with >24 bits when used with with “zero-tracking error” • Bar Code
Aerotech’s Nmark GCL Aerotech’s Nmark GCL eliminates speed-related part
controller controller distortion such as necking
• Serialization
• Wide range of apertures and • Wide range of apertures on circles and rounding of • Engraving
focal lengths and focal lengths, and many corners
choices of mirror surface • Position-based laser firing • Character Scribing
treatments for a variety of (PSO) with windowing
laser wavelengths maintains consistent spot
spacing over a wide range of
operating speeds
www.aerotech.com 63
Advanced Control
Advanced Friction Model
Measured Data
Estimated Data
Friction Compensation
Current (Amps)
• Reduced settle time
• Reduced error at direction
reversals
Velocity (mm/sec)
Friction Compensation Results

High speed, high Direction Reversal Without Friction Compensation
accelerations and minimal With Friction Feedforward
Compensation
position error achieved
with feedforward
additive force
Time

Fieldbus and Networking
Aerotech controllers support a multitude of industry-standard communication

protocols to facilitate easy component networking, device connectivity and
superior motion system performance.
Networking
Type Plant Fieldbus Motion Drive I/O
Ethernet EtherNet/ Modbus®

Protocol USB RS-232 RS-485 OPC* EtherCAT DeviceNet™* CANopen* PROFIBUS FireWire® Aeronet Analog Digital
TCP/IP IP™ TCP
A3200
Ensemble
Soloist
Aerotech controllers
Aerotech drives
use state-of-the-
include a standard
art communication
complement of
Aerotech controllers connect seamlessly to your existing Aerotech controllers support a variety of fieldbus standards for
Summary on-board analog
corporate network or PC via these standard protocols. communication protocols to fit your application. motion network
and digital I/O, with
communication to
an option for an
ensure a robust, high-
expanded I/O board.
performance system.
*Coming Soon
Fieldbus I/O with Corporate networking protocols allow Fieldbus communication protocols provide extensive options for communicating
Hilscher NetX remote control and monitoring of your with PLCs and other components in your system.
technology motion system.
Aerotech’s motion networking architectures are truly plug-and-play, making
setup quick and easy.
www.aerotech.com 65
Hexapod Control
Aerotech’s HEX RC
Aerotech’s HEX RC is a high-performance, 6-axis motion controller ideal for controlling robotic systems
like hexapods. The HEX RC is 4U high, rack-mountable, and compatible with the Automation 3200
(A3200) motion platform. A high-performance processor provides the intense computing power needed
to run up to 32 axes, perform complex, synchronized motion trajectories, manipulate I/O, and collect
• 4U high, rack-mount, six-axis data at high speeds.
controller for brush, brushless,
and stepper motors
• Ideal for controlling six-axis
robotic systems like hexapods
• Real-time A3200 distributed
control architecture allows
synchronized motion on up to 32
axes
• FireWire® or ASCII command
interface via TCP/IP
• Optional integrated encoder
multipliers for high resolution
positioning and reduced
integration complexity
• Optional six-axis jog pendant
• Program in native RS-274 G-code,
AeroBasic™ command set, C, C++/
CLI, .NET, MATLAB®, LabVIEW®,
or IEC 61131-3 (LD, FBD, ST)
for the ultimate in programming
flexibility

Piezo Controllers
Ensemble QL/QLe™
The Ensemble QL/QLe™ panel-mount nanopositioning piezo drive
family is designed for seamless use with the Ensemble family of drives
and controllers. The QL/QLe connects to any Ensemble controller
network enabling coordinated motion between piezo stages and servo
axes at much higher rates than other controller or drive products. This
power, versatility, and affordability make the Ensemble QL/QLe drives
ideal for applications ranging from the most demanding fundamental
scientific research to advanced OEM machine systems.
Ensemble QDe™
The Ensemble QDe™ is a high-performance desktop nanopositioning
piezo drive designed for seamless use with the Ensemble family of
drives and controllers. The QDe connects to any Ensemble controller
network enabling coordinated motion between piezo stages and servo
axes at much higher rates than other controller or drive products.
This power and versatility make the Ensemble QDe ideal for single or
multi-axis applications ranging from fundamental scientific research to
advanced OEM machine systems.
Ensemble QLAB™
The Ensemble QLAB™ is a high-performance nanopositioning piezo
stage controller for 1 to 4 axes of motion. The flexible controller
platform allows user-configurable open-loop and closed-loop operation
on a per axis basis. Simple software commands allow the user to switch
between open-loop and closed-loop if an axis is configured for closed-
loop mode.
www.aerotech.com 67
Controller Comparison Chart
Basic Functions A3200 Ensemble Soloist
Up to 32 axes Up to 10 axes
Multi-Axis coordinated coordinated
Single axis
PC-based software
Architecture controller
Stand-alone Stand-alone
Number of Tasks 32 4 4
CNC Functionality/RS-274
Coordinated Motion
Unsure about which controller is
right for your application? Point-to-Point Motion
Cutter Compensation
Consult the chart to see which
controller fits your needs. Multi-Block Look-Ahead
Acceleration Limiting/Look-Ahead
Gantry Mode
Velocity Blending
Electronic Gearing
Electronic Cam Profiling
Arbitrary Path Generation
Jog and Offset, Jog and Return
Velocity Profiling
Retrace (Block by Block)
Axis Calibration
3D Error Mapping
Sinusoidal Commutation
Analog Power Control
Servo, Stepper or DC Motor Controller
Expanded IO Available
Encoder Tuning
Dual Loop Control
PLC (IEC 61131-3)

Advanced Functions A3200 Ensemble Soloist
IDE
.NET, AeroBasic™
Fast Position Capture

High-Speed Registration
On the Fly End-Point Modification
Orthogonality Correction
Parts Rotation
Use the Best
Intra-Block Retrace Controller
Iterative Learning Control for Your
PSO
Harmonic Cancellation
Yes, up to 3 axes Yes, up to 3 axes Yes
Application
Direction Gain Scheduling
Inertial Damping
Friction Compensation
Linear Drive Amplifiers
Machine Retrofit Hardware Available
Galvo Integration
Seven Segment Acceleration Profile
Slice Move
Corner Rounding
Coordinate Transformations With Plug-In
Kinematics With Plug-In
Loop Transmission
Advanced Diagnostics and Tuning
Auto Focus
MATLAB®
Force Control
Soft Landing
Piezo Nanopositioners
HexGen Hexapod
RCP-DELTA Delta Robot
www.aerotech.com 69
Aerotech Electrical Value
Power Supply Circuit Breakers Door Interlock
• Wired and tested consoles

• Wired panels and 19-inch racks
• Integrated subsystem with PC,
controls, drives, cables, power
supply or transformer, line
filtering, PLC motion, I/O
and customer I/O
• CE/UL standards
PLC Logic I/O Using WAGO Customer Specific I/O
• Comply with NFPA79 wiring
standard
Nsys Complete
Consoles
Complete consoles are available that
integrate all of the electronics for your
system, including the controller, drives and/
or drive racks, I/O and monitor.

Aerotech Machine Safety Standards
Loss of
Safety Single Double
Fault Function Fault Fault
Safety Level Detection Probability Covered Covered Input ESTOP Signal Supply Power to Drive
Category B None Very High No No No specific design No specific design
Category 1 None Very High No No Simple mushroom switch One relay
One positive guided relay

Category 2 Low High No No Simple mushroom switch with auxiliary contact for
checking
Two positive guided

Dual circuit mushroom relays with cross checking
Category 3 Medium Medium Yes No
with fault detection
Dual circuit mushroom

Two positive guided
Category 4 High Low Yes Yes with independent fault
relays with cross checking
detection
www.aerotech.com 71
Hardware Options
MP CP HPe HLe ML Integrated Drive Racks Nservo Nstep Nmark™ Console QL/QLe
A3200
Drives
Npaq®, Npaq MR, or HEX RC drive chassis
Ensemble
N/A N/A N/A N/A
Controls
Ensemble Epaq, Epaq MR, LAB, QLAB, or QDe drive
chassis and motion controller
Soloist
N/A N/A N/A N/A N/A N/A
Controls
Axes 1 1 1 1 1 1 to 8 1 to 8 2 or 4 2 or 4 3 1 to 12
Three-Phase Clock and Clock and
Output Type PWM PWM PWM Linear Linear PWM and Linear PWM and Linear
±10 V Direction Direction
N/A
Epaq/Epaq MR: 10 A
Npaq: 10-30 A Epaq: 10 A
Peak Output 10 A 10-30 A 10-150 A 10-20 A 10 A Npaq MR: 10 A Ensemble LAB: 5 A N/A N/A N/A N/A
Current Hex RC: 10 A Ensemble QLAB: 300 mA
Ensemble QDe: 250 mA
Epaq: 24-90 VDC; ±10-40 VDC
Npaq: 10-320 VDC Epaq MR: 10-80 VDC
DC Bus 10-80 VDC
10-320 VDC 10-320 VDC ±40-80 VDC ±40 VDC Npaq MR: 10-80 VDC Ensemble LAB: ±24 VDC N/A N/A N/A N/A
Voltage (Output)
Hex RC: 80 VDC Ensemble QLAB: -30 to +150 V
Ensemble QDe: -30 to +150 V
16
Standard 1-AI
6-DI/4-DO 6-DI/4-DO 6-DI/4-DO 6-DI/4-DO Multiple Configurations 11-DI/8-DO
Assignable N/A N/A
1-AI per axis
I/O 1-AI/1-AO 1-AI/1-AO 1-AI/1-AO 1-AI/1-AO Available 4-AI/2-AO
IO
Optional 8-DI/8-DO 16-DI/16-DO 16-DI/16-DO 16-DI/16-DO 16-DI/16-DO Multiple Configurations Via Optional
N/A N/A N/A
Multiple Configurations Available
I/O 1-AI/1-AO 1-AI/1-AO 4-AI/4-AO 4-AI/4-AO 1-AI/1-AO Available Ethernet Port
Npaq or HEX RC:

12-bit Epaq or Epaq MR: Two 16-bit
Four 16-bit differential AI
I/O differential AI 16-bit differential AI Same as ML or MP per axis differential AI
Two 16-bit single-ended AO N/A N/A N/A
Spec 16-bit 16-bit single-ended AO Ensemble QLAB: 4 AI, 4 AO Two 16-bit
Npaq MR:
single-ended AO Ensemble QDe: 1 16-bit, 1 18-bit single-ended AO
Same as ML or MP per axis
Incremental
Encoder
Absolute
Encoder
Resolver/
Inductosyn
Capacitive
Probes
Laser
Interferometer
All units capable of sinusoidal commutation, dual-loop control and drive brushless, brush, or stepper motor

Aerotech Drive Solutions
The BA series amplifiers are Aerotech’s stand-alone PWM drive for three-
phase AC brushless and single-phase DC brush motors.
BL series amplifiers are highly reliable linear brushless servo amplifiers.
BA PWM Amplifiers
• Wide output power range from 10 A peak to 100 A peak at 320 VDC
• No transformer required; direct connection to AC line
• Capable of running brushless or single-phase DC brush motors
• Velocity, torque and dual-phase mode input command
• Accepts both encoder or tachometer feedback for velocity control
• Can be externally commutated
• UL, CE and CSA approval
BL Linear Amplifier
• Non-switching, high-performance linear operation for ultra-smooth
control of brushless motors
• Totally modular design accepts 110 VAC or 220 VAC input power
• Ideal for air-bearing systems and noise-sensitive applications
www.aerotech.com 73
Aerotech Servomotors
Rotary Motors
Torque Torque
Type: Brushless Type: Brushless, Slotless
• Ironless/cogless design for Continuous Torque: 0.16 - 31.6 N·m Continuous Torque: 0.27 - 2.86 N·m
superior motion Peak Torque:
Rated Speed:
0.48 - 94.9 N·m
2400 - 4000 rpm
Peak Torque:
Rated Speed:
1.07 - 11.43 N·m
2000 - 4000 rpm
• Iron-core motors for high

force output Torque Torque
• Frameless torque motors for Type:
Continuous Torque:
DC Brush
0.25 - 1.48 N·m
Type:
Continuous Torque:
Stepper
0.78 - 11.5 N·m
custom machines Peak Torque: 1.84 - 7.1 N·m Peak Torque: ---
Rated Speed: 3000 - 6000 rpm Rated Speed: ---
• Ultra-precision positioning
Full line of DC brush, brushless, servo and stepper motors to fit almost any situation.
• Low heat generation
Brushless motors feature neodymium iron boron magnets for maximum torque and
• Vacuum compatible options acceleration in a small package.
• NEMA 17, 23, 34, 42 and IEC 142

Frameless Rotary Motors Brushless Linear Servomotors —
Flat and U-Channel
Torque Force Force
Type: Frameless Type: Flat Type: U Channel
Continuous Torque: 0.20 - 29.09 N·m Continuous Force: 19 - 697 N Continuous Force: 14 - 1063 N
Peak Torque: 0.82 - 116.37 N·m Peak Force: 75 - 1507 N Peak Force: 56 - 4252 N
Rated Speed: 200 - 8000 rpm
Five frameless designs for easy integration Aerotech’s proprietary coil winding Linear servomotors are ideal for:
into OEM machines. technology produces the highest force • Robotics • Fiber Optics/Photonics
Slotless stator and high-pole-count rotor to volume ratios available. Alignment and Positioning
• Packaging
provide zero cogging for exceptional velocity Direct drive, noncontacting forcer coil • Machine Tools
control. eliminates backlash, windup and wear • Actuators
for a maintenance-free system. • Tables/Stages • Semiconductor Equipment
• Assembly • Electronic Manufacturing
Advanced magnetic field synthesis and analysis yields

highest motor output power per unit volume.
www.aerotech.com 75
Custom Motors
We customize for you
Change Coil Winding Change Thermistor Cable Exit on Side Change Port Interface
Longer Stack
Smaller OD
Longer or Shorter Track Add Hole for Sensor

Different
Winding
Higher
Strength
Magnet Larger ID

Change Longer or Shorter
Coil Track
Winding
Length
New Mounting
Interface
New Winding
Different Flange
Different Change
Encoder Shaft
Shorter
Housing Higher Load
Bearings
www.aerotech.com 77
We customize for you...
Hardware • Software • Firmware • Packaging • Motors • HMI • Electronics • I/O
Connectivity Custom Control Algorithms

• Ethernet • Create algorithms at the application, motion
• Fieldbus engine, firmware, or hardware layer
• Wireless • Flexible control architecture
• USB • Custom kinematics
Custom Automation Custom Drives

• Coordinate motion, PLC, robotics, • Plug-in architecture speeds
vision, and communications with one development of custom
automation control algorithms – for example, 2D bar
code, interfaces to non-standard
• Galvo control
sensors, and signal outputs
• Piezo control synchronized to servo sample
time
• Integration with process control
• Packaging can be customized
• HMI integration
for specific form factor and
space constraints
• Custom algorithms can be
developed at the firmware layer
Custom
Software
• Custom operator
interfaces
• Custom
applications
Custom Motor Design
• Custom motors optimized for your specific
• Custom software
application at a minimal price
libraries
• Customized motor mechanical characteristics
• Program in nearly
including torque/force, length, width, height
any language
Vision Integration • Customized motor electrical characteristics
including bus voltage, resistance, inductance,
• Interface with standard pole pitch, and current
cameras and machine vision systems
• Custom motors for low-volume projects
• Registration marks or fiducials can be located and used as
a home or reference position • Completely new motor design
• Vision can be coordinated with servo motion for vision

guided robotics

We implement with you...
Tuning • Parameters • Optimize Performance • HMI • Write Software
We will work with you onsite

or at our facility to meet your
machine specifications.
Aerotech personnel will: Benefits include:

• Perform parameter setup and system • Write PLC programs using Ladder, • Maximize machine
tuning Function Block, or Structured Text performance
• Setup of the Advanced Controls • Product customization • Minimize machine
Toolbox to achieve the highest development time
performance possible • Product application
• Minimize cost
• Write motion programs in AeroBasic™ • Write/configure HMIs
• Write software (.NET, C) by applying • Integration with process controller

our libraries
www.aerotech.com 79
Accessories
Available Accessories:
Maple Joystick Transformers Cables Server Line Filters

Operator
Interface Handwheel/ Power Supplies Automation MXH Multiplier Panel PC
Pendant Boxes

Markets and Industries
Aerotech controls
and components
have become the
preferred solution
for a variety of
applications in a
host of industries
around the world.
Laser Processing Machine Tools
Semiconductor Processing Automotive
Military and Aerospace Packaging
Electronics Manufacturing University Research
Medical Device Manufacturing Industrial R&D
Test and Inspection Photovoltaic Manufacturing
www.aerotech.com 81
Aerotech Customer Applications
A3200 A3200 or Ensemble Ensemble

• Stencil Cutting • Dispensing (Printed • Packaging Machines (Multi-
• Wire Bonding Electronics, Material Axis Applications)
Dispensing) • Web Applications
• Die Bonding
• PCB Assembly (Pick and • Printing Applications
• Labeling • Optics Polishing
Place of SMT, Through-Hole)
• Stent Manufacturing • Rollover Unit Testing
• Web • VIA Drilling
• e-Beam Welding • IMU Testing
Applications • Wafer Scribing and
• EDM • ECM
• Case Erectors Singulation (Dicing)
• Drilling and Milling • Marking
• Die Bonding
• Grinding and Polishing • Vertical Form, Fill, and Seal
• Resistor Trimming
• Waterjet Cutting • AOI/X-Ray Inspection
• Fuel Injector Drilling • Chip Testing Soloist
• Fuel Cell Manufacturing • Chip Packaging • EDM & ECM
• Crystallography • Crystallography • Packaging Machines (Case
Erectors, Labeling Machines,
• Target Tracking • Flat Panel Augers)
• Beam Steering • Semiconductor Testing • Printing
• Pipe Thread Measurement • Semiconductor • Gyro Testing
Manufacturing
• Accelerometer Testing
• Photovoltaic Cell
Manufacturing • Optical Polishing (Spindle
Axis)
• DNA Analysis
• Beam Steering
• Image Duplication
• Holographic Writing
• Sensor Testing
• Sensor Manufacturing

Stent and Medical Device Aerotech’s highly successful
VascuLathe® and LaserTurn®
Manufacturing platforms deliver maximum
productivity in a compact,
Aerotech’s experience in market-specific solutions easy to maintain package with
provides an edge in processes involving photonics, the lowest cost of ownership
semiconductor processing, medical device in the industry. With the
manufacturing and laser processing. With a number A3200’s PSO functionality, the • Laser Cutting
of specially developed motion platforms for these throughput possible with the
industries, Aerotech provides a one-stop-shop for LaserTurn® and VascuLathe® • Welding
your motion requirements. series is unmatched.
• Wafer Dicing
Controllers • Solar Panel
to Use: Scribing
• A3200 • Fuel Injector
Drilling
• Turbine Blade
Inspection
Solar Panel Scribing

Extensive application experience and a
broad array of motion products make
Aerotech the perfect partner for your
photovoltaic (solar cell) manufacturing
or testing platform. Our worldwide
operation has engineered and
manufactured a multitude of motion Controllers
platforms for solar cell manufacturing and to Use:
inspection. These platforms range from • A3200
small format systems for R&D to full-size
production panel processing systems. • Ensemble
www.aerotech.com 83
Aerotech Customer Applications
Packaging
Line following applications including:
• Labeling, cut-to-length, fly cutting, lane
diversion, rotary knife and many others.
Basic features for line following:

• Fuel Cell • Auxiliary encoder input for measuring line
Manufacturing speed
• High-speed registration for measuring line
• 3D Laser position
Processing • The relationship between line speed/
position can be an arbitrary function or simply
• MRI Machines
1-to-1
• Lab Automation
Controllers to Use:
• Target Tracking • Soloist
• Optical Testing • Ensemble
• A3200
High Accuracy, Multi-Axis

Inspection Systems
Real-time PVT Ethernet
input from host
The A3200 controller is uniquely suited to

complex inspection applications like turbine
blade inspection that requires 5 axes or more of
coordinated motion integrated with a sensor or Measurement System
camera. Vision
Ultrasonic
PSO Trigger
Controllers to Use: High-speed
Data acquisition
position capture Other sensor
• A3200 with linear drives from sensor or
host system

Optical Mounts and Gimbals
• Directing optics, lasers or antennas
• LOS target tracking
• Precision pointing
Controllers to Use: • Gyro Testing

• A3200 • Reticle Inspection
• Ensemble
• Lithography
• Wafer Defect
Detection
• Thin Film
Measurement
• Pick and Place
Fuel Cell Manufacturing

Operations
• Laser machining the membranes
(also referred to as MEAs)
• Welding the plates/membranes together
• Stacking the membranes into a cell
• Inspection of the MEAs, plates and cells
Controllers to Use:
• A3200
www.aerotech.com 85
Controls Timeline
With 46 years in the business of designing and building

motion systems, Aerotech has the experience and knowledge
to understand the challenges and solutions of industrial and UNIDEX® 14
laboratory processes.
UNIDEX® 31
1970 1980 1990
UNIDEX® 3
UNIDEX® 21
UNIDEX®
NC200 UNIDEX® 11
Model 10
SMART I UNIDEX® 1
UNIDEX® 16
NC300
Model 20
UNIDEX® 4
1000 Series
UNIDEX® 12
UNIDEX 2
®
BM Series

PC-Based
UNIDEX® 500
®
Integrated Automation Delta

BLM Series PLC + Motion = MotionPAC Robot
Control
UNIDEX® 600
2000 2010 2016

Hexapod
Control
UNIDEX® 400 UNIDEX® 511

Piezo Controls
UNIDEX® 100
Stand-Alone
BAI
Aerotech has manufactured advanced motion controllers since
1970. From the industry workhorse PCI cards to state-of-the-art
BMS Series
software-based control coupled with intelligent networked drives,
the science of motion control has been our business for decades.
S Series
www.aerotech.com 87
Worldwide Training and Support
Training Program:
• Standard and customized courses
• Hands-on training with Aerotech controllers
• Interactive training with experienced instructors
• Comfortable, spacious facilities
Aerotech offers comprehensive • Online training modules
worldwide training and customer
service at customer facilities or at • Online FAQs
one of our Aerotech training centers. • At customer site or at Aerotech
Installation and Startup (Commissioning)

Aerotech offers startup and commissioning services to minimize startup times, reduce costs
and accelerate time-to-production. By combining our product knowledge with your process
and application expertise, new systems and applications can be completed faster and at a
reduced overall cost.
Engineering Support
Aerotech provides complete engineering support for our products, including onsite support
and maintenance, and remote support via phone, fax, website and/or WebEx® software. As a
manufacturer staffed by engineers, we understand the unacceptability of downtime.
Join.Me.
Aerotech can remotely support your startup, commissioning and debugging of systems over
the internet.

Aerotech is an ISO 9001 Registered Company
Since 1995, Aerotech’s quality

system has been certified to the
ISO 9001 standard. The ISO 9001
standard encompasses the Aerotech
organization through manufacturing.
Aerotech U.S.A. Aerotech Germany As part of our commitment to the
ISO standard, we formally survey
our customers on a monthly basis
which provides valuable feedback to
continually improve our products and
processes.
Aerotech United Kingdom Aerotech Japan
www.aerotech.com 89
Aerotech at a Glance
High-Volume Worldwide Service Technically Superior

Manufacturing and Support Components
Highest
performance
Worldwide startup brushless linear
service and on-site and rotary
training motors
ADRT rotary ALS1000 linear

stages motor stage
Fully equipped
on-site training
facilities
A3200 Soloist® Ensemble®
Award-winning Automation 3200

Over 100,000 axes installed 1-32 axis motion, vision, PLC, robotics
worldwide
and I/O platform

High Performance Best-in-Class Comprehensive Technical
Sub-Assemblies Subsystems Support Services
XYAB subsystem Highly integrated motion

for high dynamic subsystems with machine
accuracy positioning frame, display and
packaged electronics Custom software
in laser drilling and
application support
micromachining
applications
Custom-engineered,
HexGen high-load, vacuum and cleanroom
compatible systems 3D models to
ultra-precision hexapod
facilitate faster
provides unmatched
and more accurate
performance
system layout
RCP-DELTA robot
capable of 15g’s
of acceleration and
up to 200 pick and Advanced analytical
place operations techniques for
per minute optimization of
system geometry
Highest throughput linear motor

Cartesian gantry systems
www.aerotech.com 91
Aerotech Worldwide
Corporate Headquarters • Pittsburgh, PA • USA Aerotech Aerotech Aerotech Aerotech Aerotech Aerotech
UK Germany Japan China Taiwan Thailand
H Aerotech Headquarters l Direct Field Sales Office

s Aerotech Subsidiary n Representative
www.aerotech.com
92 Integrated Motion and Machine Control Solutions CA0117B

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Integrated Motion and

Machine Control Solutions

2 Integrated Motion and Machine Control Solutions

Aerotech China Controller Features

Common Software Platform:

Aerotech Diagnostics PID Calculator

4 Integrated Motion and Machine Control Solutions

Automation 3200 Ensemble™ Soloist™

Linear and Rotary Servomotors/Accessories

Fieldbus and Network Connectivity Custom Controls, Drives and Motors

Software Fieldbus - I/O Custom Motors

6 Integrated Motion and Machine Control Solutions

Integrated Configuration Manager for Easy Setup

Use the same

See all the

Network • Extensive diagnostics for

Calculators for Quick and Easy Setup

Easily switch axis

Current loop Select your motor or add a

PID gain System knows all

Configure feedback Select amplifier

Directly enter any

8 Integrated Motion and Machine Control Solutions

Control all axes at

Multiple tabs for organized

Watch any variables as the program runs

Pop-up error reporting

Compiler output screen

Advanced Diagnostic and Tuning Capabilities Minimize

Input amplitude and

Select desired system

Current and recommended Scope, tuning and data

Use sinusoidal sweep or

10 Integrated Motion and Machine Control Solutions

Graphical display of the

Loop Transmission is a Tuning and Diagnostic Utility

Graphical loop shaping — Automatic calculation of

Calculator and loop

12 Integrated Motion and Machine Control Solutions

Select your filter type: low pass, high

Axis selection Add up to eight filters

Discrete time gains are

Store all parameters in the

Integrated I/O Panel for Debug,

View I/O axis

Monitor analog I/O

Set analog I/O

14 Integrated Motion and Machine Control Solutions

Hide the axis manager

Visual Studio®- like project Minimize development

Watch window shows

Detailed error explanation Link to help file for

Create Reusable Modules

Create reusable code Real-time code

Built-in software security

16 Integrated Motion and Machine Control Solutions

User defined Memory management is

Keeping all motion code

Advanced variable types Variable initialization

Standard program flow:

Program in IEC 61131-3: LD, FBD, ST

• 30% to 50% Online mode displays

Combine LD and FBD in Completely integrated Tag database

18 Integrated Motion and Machine Control Solutions