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Revision 2.01

Automation1 XC4 PWM Digital Drive

HARDWARE MANUAL

Summary of Contents for Automation1 XC4

Page 1: ...Revision 2 01 Automation1 XC4 PWM Digital Drive HARDWARE MANUAL...

Page 2: ...spare or replacement parts To get help immediately contact a service office or your sales representative Include your customer order number in your email or have it available before you call This man...

Page 3: ...and Feedback Phasing 41 2 2 2 DC Brush Motor Connections 42 2 2 2 1 DC Brush Motor Phasing 43 2 2 3 Stepper Motor Connections 44 2 2 3 1 Stepper Motor Phasing 45 2 3 Feedback Connector 46 2 3 1 Prima...

Page 4: ...1 90 3 2 Digital Inputs EB1 94 3 3 Analog Outputs EB1 97 3 4 Analog Inputs EB1 98 3 5 Position Synchronized Output Interface EB1 99 Chapter 4 Cables and Accessories 101 4 1 Joystick Interface 102 4 2...

Page 5: ...or 49 Figure 2 21 Sine Wave Encoder Phasing Reference Diagram 50 Figure 2 22 Sine Wave Encoder Schematic Feedback Connector 51 Figure 2 23 Encoder Phasing Reference Diagram Standard 52 Figure 2 24 Pos...

Page 6: ...cted to Current Sourcing PNP Devices EB1 96 Figure 3 7 Digital Inputs Connected to Current Sinking NPN Devices EB1 96 Figure 3 8 Analog Output Typical Connection EB1 97 Figure 3 9 Analog Input Typical...

Page 7: ...pecifications 48 Table 2 18 Sine Wave Encoder Specifications 50 Table 2 19 Hall Effect Feedback Pins on the Feedback Connector 53 Table 2 20 Thermistor Input Pin on the Feedback Connector 54 Table 2 2...

Page 8: ...umbers for the Digital Output 2 Connector EB1 91 Table 3 6 Digital Input Specifications EB1 94 Table 3 7 Digital Input 1 Connector Pinout EB1 94 Table 3 8 Mating Connector Part Numbers for the Digital...

Page 9: ...n conformity with the applicable requirements of the following Standard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 61326 1 2013 EMC Requireme...

Page 10: ...This page intentionally left blank EU Declaration of Conformity XC4 Hardware Manual 10 www aerotech com...

Page 11: ...010 1 2010 A1 2019 UL 61010 1 2012 R 2016 04 Approval Safety Components STO Approving Agency TUV SUD Certificate Z10 068995 0030 Rev 00 Standards IEC 61508 1 2010 up to SIL 3 Visit https www tuev sued...

Page 12: ...This page intentionally left blank Agency Approvals XC4 Hardware Manual 12 www aerotech com...

Page 13: ...ct the electrical power 2 Restrict access to the XC4 when it is connected to a power source 3 Do not connect or disconnect electrical components wires and cables while this product is connected to a p...

Page 14: ...This page intentionally left blank Safety Procedures and Warnings XC4 Hardware Manual 14 www aerotech com...

Page 15: ...r Section 2 2 Connect the motor to the amplifier Feedback connector Section 2 3 2 Connect a PC HyperWire port to the HyperWire In port Section 2 7 3 Connect additional I O as required by your applicat...

Page 16: ...This page intentionally left blank Installation Overview XC4 Hardware Manual 16 www aerotech com...

Page 17: ...current loops in the XC4 The XC4 offers standard Safe Torque Off STO inputs and optional Position Synchronized Output PSO outputs The XC4 is offered with an optional encoder interpolation feature MX1...

Page 18: ...Current Section 1 1 10 10 A Peak 5 A Continuous Current 20 20 A Peak 10 A Continuous Current 30 30 A Peak 10 A Continuous Current Expansion Board Chapter 3 EB0 No expansion board EB1 I O expansion boa...

Page 19: ...The block diagram that follows shows a summary of the connector signals Figure 1 2 Functional Diagram XC4 Hardware Manual Chapter 1 Introduction www aerotech com 19...

Page 20: ...dwidth 2500 Hz maximum software selectable Power Amplifier Efficiency 85 95 2 PWM Switching Frequency 20 kHz Minimum Load Inductance 0 1 mH 160 VDC 1 mH 320 VDC User Power Supply Output 5 VDC 500 mA M...

Page 21: ...roximately 90 in the following equations Brushless Motor Output Power Rotary Motors Power Output W Torque N m Angular velocity rad sec Linear Motors Power Output W Force N Linear velocity m sec Rotary...

Page 22: ...d connections Table 1 3 Mounting Specifications XC4 Customer Supplied Enclosure IP54 Compliant Weight 2 36 kg Mounting Hardware M4 8 screws four locations not included Mounting Orientation Vertical ty...

Page 23: ...1 2 2 Dimensions Figure 1 3 Dimensions XC4 Hardware Manual 1 2 2 Dimensions www aerotech com 23...

Page 24: ...Figure 1 4 Dimensions EB1 1 2 2 Dimensions XC4 Hardware Manual 24 www aerotech com...

Page 25: ...emperatures that are less than 31 C and decreases linearly to 50 relative humidity at 40 C Operating Altitude 0 m to 2 000 m 0 ft to 6 562 ft above sea level If you must operate this product above 2 0...

Page 26: ...Software Version column drives that show a specific version number are not supported after that version Table 1 5 Drive and Software Compatibility Drive Type Software First Software Version Last Softw...

Page 27: ...on the packing list are contained within the package The documentation for the XC4 is on the included installation device The documents include manuals interconnection drawings and other documentatio...

Page 28: ...uld be required to add an external filter for CE compliance Install the external filter as close as possible to the XC4 Use a Schaffner FN2080 filter an Aerotech UFM ST noise filter module or equivale...

Page 29: ...onnect the filter as close as possible to the drive For more information about the AC line filter refer to Section 2 1 4 IMPORTANT Refer to local electrical safety requirements to correctly size exter...

Page 30: ...ltage When rectified by the drive it produces a 40 or 80 VDC power bus TM3 Power up to 4 drives providing 300 watts of power TM5 Power up to 4 drives providing 500 watts of power TV0 3 28 Generate 28...

Page 31: ...Figure 2 4 TV0 3 28 56 ST Transformer Control and Motor Power Wiring 40 VDC Bus XC4 Hardware Manual 2 1 3 Transformer Options www aerotech com 31...

Page 32: ...Figure 2 5 TV0 3 28 56 ST Transformer Control and Motor Power Wiring 80 VDC Bus 2 1 3 Transformer Options XC4 Hardware Manual 32 www aerotech com...

Page 33: ...Figure 2 6 TV0 3 28 56 ST Transformer Control and Motor Power Wiring 160 VDC Bus XC4 Hardware Manual 2 1 3 Transformer Options www aerotech com 33...

Page 34: ...Figure 2 7 TV0 3 28 Transformer Control and Motor Power Wiring 40 VDC Bus 2 1 3 Transformer Options XC4 Hardware Manual 34 www aerotech com...

Page 35: ...Figure 2 8 TV0 3 56 Transformer Control and Motor Power Wiring 80 VDC Bus XC4 Hardware Manual 2 1 3 Transformer Options www aerotech com 35...

Page 36: ...Figure 2 9 TM3 TM5 Transformer Control and Motor Power Wiring 2 1 3 Transformer Options XC4 Hardware Manual 36 www aerotech com...

Page 37: ...parate wire for each ground connection to the drive Use the shortest possible wire length The following additional changes could be required for EMC compliance and are recommended during initial EMC s...

Page 38: ...e external system wires The 7 pin terminal block style motor output connector is located on the front panel The pinout for this connector is shown in Table 2 7 Table 2 7 Motor Power Output Connector P...

Page 39: ...l effect devices for commutation is recommended The controller requires that the Back EMF of each motor phase be aligned with the corresponding Hall effect signal To ensure proper alignment motor Hall...

Page 40: ...gnals in the Diagnostics section of the Status Utility Table 2 10 Hall Signal Diagnostics Hall Signal Status Definition 0 V or logic low ON 5 V or logic high Figure 2 11 Positive Motor Direction Figur...

Page 41: ...otor Phasing Oscilloscope Example With the designations of the motor and Hall leads of a third party motor determined the motor can now be connected to an Aerotech system Connect motor lead A to motor...

Page 42: ...Wire Colors for Aerotech Supplied DC Brush Motor Cables Pin Wire Color Set 1 1 Wire Color Set 2 Wire Color Set 3 Green White Shield 2 Green Yellow Shield Green Yellow Shield A Red Orange Red Red Orang...

Page 43: ...e positive or clockwise CW direction by hand Figure 2 16 Positive Motor Direction 4 If the voltmeter indicates a negative value swap the motor leads and move the motor by hand in the positive directio...

Page 44: ...bus supply is needed to get 40V across the motor Figure 2 17 Stepper Motor Configuration Table 2 12 Wire Colors for Aerotech Supplied Stepper Motor Cables Pin Wire Color Set 1 1 Wire Color Set 2 Green...

Page 45: ...t parameters and the motor moves in a clockwise direction when you view the motor from the front mounting flange Figure 2 18 If the motor moves in a counterclockwise direction swap the motor leads and...

Page 46: ...Hall Effect Sensor A brushless motors only Input 11 Hall Effect Sensor C brushless motors only Input 12 Clockwise End of Travel Limit Input 13 Brake Output Output 14 Encoder Cosine Input 15 Encoder Co...

Page 47: ...iplier Options Option Primary Encoder Accepts Auxiliary Encoder Accepts MX0 Square Wave or Absolute encoders Square Wave or Absolute encoders MX1 Sine Wave Square Wave or Absolute encoders Square Wave...

Page 48: ...al connection Use twisted pair wiring for the highest performance and noise immunity Table 2 17 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum ed...

Page 49: ...g for the highest performance and noise immunity You cannot echo an absolute encoder signal Refer to Figure 2 20 for the serial data stream interface Refer to the Help file for information on how to s...

Page 50: ...oderMultiplierSetup parameter to enable the high bandwidth mode Because this mode increases sensitivity to system noise use it only if necessary You cannot use a sine wave encoder with the MX1 multipl...

Page 51: ...Figure 2 22 Sine Wave Encoder Schematic Feedback Connector www aerotech com 51 XC4 Hardware Manual 2 3 1 Primary Encoder Inputs...

Page 52: ...hile observing the position of the encoder in the diagnostics display see Figure 2 24 For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 24 Figure 2 23...

Page 53: ...evice phasing Table 2 19 Hall Effect Feedback Pins on the Feedback Connector Pin Description In Out Bi 3 5V Power 1 N A 5 Hall Effect Sensor B brushless motors only Input 10 Hall Effect Sensor A brush...

Page 54: ...re causes the thermistor s resistance to increase the sensor will trigger an over temperature fault The thermistor is connected between Pin 2 and Signal Common The nominal trip value of the sensor is...

Page 55: ...rameter configurable and the controller should be configured to disable the axis when the fault level is active The nominal trip voltage of the encoder fault input is 2 5 V Table 2 21 Encoder Fault In...

Page 56: ...e diagnostics display refer to Figure 2 30 Table 2 22 End of Travel and Home Limit Pins on the Feedback Connector Pin Description In Out Bi 12 Clockwise End of Travel Limit Input 16 5V Power N A 20 Si...

Page 57: ...28 End of Travel and Home Limit Input Connections Figure 2 29 End of Travel and Home Limit Input Schematic Feedback Connector www aerotech com 57 XC4 Hardware Manual 2 3 5 End of Travel and Home Limi...

Page 58: ...he CW and CCW inputs at the Feedback connector or swap the CW and CCW limit functionality in the software using the EndOfTravelLimitSetup parameter View the logic level of the EOT limit inputs in the...

Page 59: ...formation on powering the brake circuit Table 2 23 Brake Output Pins on the Feedback Connector Pin Description In Out Bi 13 Brake Output Output 25 Brake Output Output Table 2 24 Brake Control Specific...

Page 60: ...vel is the sole responsibility of the user of the XC4 WARNING STO wires must be insulated to prevent short circuits between connector pins The primary concern is a short circuit between STO 1 IN and S...

Page 61: ...re 2 32 shows one safety device connected to multiple XC4s in parallel WARNING The XC4 does not check for short circuits on the external STO wiring If this is not done by the external safety device sh...

Page 62: ...N IEC 61508 2 2010 SIL 3 EN ISO 13849 1 2015 Category 4 PL e EN IEC 62061 2005 with Amendments SIL 3 Table 2 29 STO Standards Data Standard Value EN ISO 13849 1 2015 MTTFD 1000 years DCAVG 99 Maximum...

Page 63: ...the axis as soon as the deceleration ramp is complete This is typically configured to occur before the STO channel turns off the power amplifier transistors The software controlled stop functionality...

Page 64: ...match Refer to Section 2 4 4 2 4 3 STO Startup Validation Testing Verify the state of the STO 1 and STO 2 channels by manually activating the external STO hardware Each STO channel must be tested sepa...

Page 65: ...listed SIL level the STO circuit must be activated power removed from both inputs according to the interval specified in Table 2 29 Table 2 32 STO Timing Time Description Value T1 STO Delay Time STO...

Page 66: ...idirectional Absolute Encoder Clock Output 12 5 Volt 500 mA max N A 13 Analog Input 0 Differential Input 14 Analog Input 0 Differential Input 15 Digital Output Common N A 16 Digital Output 3 Output 17...

Page 67: ...re the Sine and Cosine connector pins as RS 422 outputs You can only echo incremental square wave primary encoder inputs You cannot use the absolute encoder interface when you echo incremental signals...

Page 68: ...nal connection Use twisted pair wiring for the highest performance and noise immunity Table 2 36 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum e...

Page 69: ...nce and noise immunity You cannot use an absolute encoder with incremental signals on the Auxiliary I O Connector Refer to Figure 2 35 for the serial data stream interface Refer to the Help file for i...

Page 70: ...pulse transmission is required It is best to locate the line receiver close to the receiving electronics A 5 V TTL signal is used to drive an opto coupler or general purpose TTL input This signal is...

Page 71: ...Figure 2 36 PSO Interface XC4 Hardware Manual 2 5 Auxiliary I O Connector www aerotech com 71...

Page 72: ...h voltage isolation applications and they should only be used with ground referenced circuits The digital outputs have overload protection They will resume normal operation when the overload is remove...

Page 73: ...Figure 2 37 Digital Output Schematic Aux I O Connector XC4 Hardware Manual 2 5 Auxiliary I O Connector www aerotech com 73...

Page 74: ...Figure 2 38 Digital Outputs Connected in Current Sourcing Mode Figure 2 39 Digital Outputs Connected in Current Sinking Mode 2 5 Auxiliary I O Connector XC4 Hardware Manual 74 www aerotech com...

Page 75: ...e 2 41 Digital Input Specifications Input Voltage Approximate Input Current Turn On Time Turn Off Time 5 V to 24 V 6 mA 10 s 43 s Table 2 42 Digital Input Pins on the Auxiliary I O Connector Pin Descr...

Page 76: ...Figure 2 41 Digital Inputs Connected to Current Sinking Devices Figure 2 42 Digital Inputs Connected to Current Sourcing Devices 2 5 Auxiliary I O Connector XC4 Hardware Manual 76 www aerotech com...

Page 77: ...his feature the PSO Waveform module will not generate the configured waveform when an output event is received until the rising edge of the synchronization signal occurs Table 2 43 High Speed Input Sp...

Page 78: ...system or reset the drive Table 2 45 Analog Output Specifications Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Table 2 46 Analog Output Pins on the Auxil...

Page 79: ...Refer to Figure 2 45 Table 2 47 Analog Input Specifications Specification Value AI AI 10 V to 10 V 1 Resolution bits 16 bits Input Impedance 1 M 1 Signals outside of this range may damage the input Ta...

Page 80: ...wer Supply Connector Pinout Pin Description In Out Bi Connector 1 Brake Power Supply Input 2 Brake Power Supply Input Table 2 50 Mating Connector Part Numbers for the Brake Power Supply Connector Desc...

Page 81: ...r to re establish communication WARNING Do not connect or disconnect HyperWire cables while you are loading firmware or damage to the drives may occur Table 2 51 HyperWire Card Part Number Part Number...

Page 82: ...ted during deceleration Table 2 53 SX1 Component Information Component Description Aerotech P N Recommended Shunt Resistor 50 min 300 W Vishay Dale RBEF030050R00KFBVT ECR01039 1 Pin Mating Connector Q...

Page 83: ...ulate the parameters of the shunt resistor Equation 3 PPEAK peak power that the regeneration circuit must accommodate W tD deceleration time s Equation 4 PAV average power dissipated on shunt resistor...

Page 84: ...eDivider DriveEncoderOutputConfigureInput DriveEncoderOutputOn DriveEncoderOutputOff A3200 ENCODER OUT command Configure each Sync port as an input or an output PsoDistanceConfigureInputs A3200 PSOTRA...

Page 85: ...rconnection Click on the image below to open a separate pdf window with a larger view of the drawing Figure 2 46 System Wiring Drawing Best Practice XC4 Hardware Manual 2 10 System Interconnection www...

Page 86: ...Figure 2 47 PC Based Controller System Interconnection Best Practice 2 10 System Interconnection XC4 Hardware Manual 86 www aerotech com...

Page 87: ...n Information For more information about hardware requirements PC configuration programming system operation and utilities refer to the Help file XC4 Hardware Manual 2 11 PC Configuration and Operatio...

Page 88: ...This page intentionally left blank 2 11 PC Configuration and Operation Information XC4 Hardware Manual 88 www aerotech com...

Page 89: ...EB1 I O option board has 16 digital inputs 16 digital outputs 3 analog inputs 3 analog outputs and PSO outputs Figure 3 1 XC4 with EB1 I O Option Board Connectors XC4 Hardware Manual Chapter 3 EB1 I...

Page 90: ...her inductive devices To see an example of a current sourcing output that has diode suppression refer to Figure 3 3 To see an example of a current sinking output that has diode suppression refer to Fi...

Page 91: ...G 10 Pin Terminal Block ECK02395 Phoenix 1700841 0 5 0 14 20 26 Table 3 4 Digital Output 2 Connector Pinout EB1 Pin Description In Out Bi Connector 1 Output Common for Outputs 12 15 N A 2 Output 12 Op...

Page 92: ...Figure 3 2 Digital Outputs Schematic EB1 3 1 Digital Outputs EB1 XC4 Hardware Manual 92 www aerotech com...

Page 93: ...Figure 3 3 Digital Outputs Connected in Current Sourcing Mode EB1 Figure 3 4 Digital Outputs Connected in Current Sinking Mode EB1 XC4 Hardware Manual 3 1 Digital Outputs EB1 www aerotech com 93...

Page 94: ...d circuits Table 3 6 Digital Input Specifications EB1 Input Voltage Approximate Input Current Turn On Time Turn Off Time 5 V to 24 V 6 mA 10 s 43 s Table 3 7 Digital Input 1 Connector Pinout EB1 Pin D...

Page 95: ...n for Inputs 16 19 N A 7 Input 16 Optically Isolated Input 8 Input 17 Optically Isolated Input 9 Input 18 Optically Isolated Input 10 Input 19 Optically Isolated Input Table 3 10 Mating Connector Part...

Page 96: ...in an all sourcing or all sinking configuration Figure 3 6 Digital Inputs Connected to Current Sourcing PNP Devices EB1 Figure 3 7 Digital Inputs Connected to Current Sinking NPN Devices EB1 3 2 Digit...

Page 97: ...Output Current 5 mA Resolution bits 16 bits Table 3 12 Analog Output Connector Pinout EB1 Pin Description In Out Bi Connector 1 Analog Output 1 Output 2 Analog Output 2 Output 3 Analog Output 3 Outpu...

Page 98: ...ance 1 M 1 Signals outside of this range may damage the input Table 3 15 Analog Input Connector Pinout EB1 Pin Description In Out Bi Connector 1 5V 250 mA max N A 2 Analog Input 1 Input 3 Analog Input...

Page 99: ...n Value Output TTL 5 V 50 mA max Isolated 5 24 V 250 mA Maximum PSO Output Fire Frequency TTL 12 5 MHz Isolated 5 MHz Output Latency Fire event to output change TTL 5 ns Isolated 150 ns Table 3 18 PSO...

Page 100: ...d will turn off if the maximum output current is exceeded Figure 3 10 PSO Output Sources Current Figure 3 11 PSO Output Sinks Current TTL Signals This output signal is a 5V TTL signal which is used to...

Page 101: ...on the website at http www aerotechmotioncontrol com manuals index aspx Table 4 1 Standard Interconnection Cables Cable Part Description Joystick See Section 4 1 ECZ01231 BBA32 Interconnect Cable XC4...

Page 102: ...vices can be used provided they produce a symmetric output voltage within the range of 10 V to 10 V Connecting joystick with an Aerotech cable all Aerotech cables are labeled to identify the connector...

Page 103: ...Figure 4 2 Two Axis Joystick Interface to the I O board XC4 Hardware Manual 4 1 Joystick Interface www aerotech com 103...

Page 104: ...IMPORTANT You can find instructions on how to enable the handwheel in the Help file Connect a handwheel to the Aux I O as shown in Figure 4 3 or Figure 4 4 Figure 4 3 Handwheel Interconnection to Aux...

Page 105: ...s the danger of electric shock 3 All tests must be done by an approved service technician Voltages inside the con troller and at the input and output power connections can kill you Table 5 1 LED Descr...

Page 106: ...nections to make sure they are correct Make sure that all connections are correctly attached and not loose Replace cables that are worn Replace all broken connectors Cleaning DANGER Before you clean t...

Page 107: ...ty P N F100 Control Power at Line Input L 2 A S B EIF01044 Littelfuse 0877002 MXEP F101 SX1 External Shunt Option 8 A S B EIF01022 Littelfuse 0215008 HXP F102 Motor Bus Supply at AC1 XC4 10 5 A S B EI...

Page 108: ...This page intentionally left blank 5 2 Fuse Specifications XC4 Hardware Manual 108 www aerotech com...

Page 109: ...ization RMA number must accompany any returned product s The RMA number may be obtained by calling an Aerotech service center or by submitting the appropriate request available on our website www aero...

Page 110: ...al rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply On site...

Page 111: ...em Wiring best practices drawing has been added 2 00 General Update 1 02 The following sections have been updated l Agency Approvals l Section 2 3 1 Primary Encoder Inputs 1 01 The following sections...

Page 112: ...This page intentionally left blank Appendix B Revision History XC4 Hardware Manual 112 www aerotech com...

Page 113: ...ations Aux I O Connector 78 Analog Output Connector EB1 Mating Connector Part Numbers 97 Analog Output Connector Pinout EB1 97 Analog Output Pins Aux I O Connector 78 Analog Output Specifications EB1...

Page 114: ...I O Connector 75 Digital Inputs EB1 94 Digital Inputs Connected to a Current Sinking Device EB1 96 Digital Inputs Connected to a Current Sourcing Device EB1 96 Digital Inputs Connected to Current Sink...

Page 115: ...Analog Input 0 Schematic Aux I O Connector 79 Analog Input Typical Connection EB1 98 Analog Output 0 Schematic Aux I O Connector 78 Analog Output Typical Connection EB1 97 Brake Connected to the Feedb...

Page 116: ...ck Connector 56 Home Limit Input Connections 57 Home Limit Input Diagnostic Display 58 Home Limit Input Pins on the Feedback Connector 56 Home Limit Input Schematic 57 Humidity 25 HyperWire 81 Cable P...

Page 117: ...EB1 95 Digital Input Pins Aux I O Connector 75 Digital Output 1 Connector EB1 91 Digital Output Pins Aux I O Connector 72 Encoder Fault Input Pin Feedback Connector 55 Encoder Input Feedback Connecto...

Page 118: ...pecifications 61 Unit Weight 22 Square Wave Encoder 48 68 Square Wave Encoder Inputs Schematic Aux I O Connector 68 Square Wave Encoder Schematic Feedback Connector 48 Square Wave Encoder Specificatio...

Page 119: ...ation 61 U Unit Weight 22 Unpacking the Chassis 27 Use 25 User Power Supply specifications 20 W Warranty and Field Service 109 Wire Colors for Aerotech Supplied Brushless Motor Cables 39 Wire Colors f...

Page 120: ...Index XC4 Hardware Manual This page intentionally left blank 120 www aerotech com...

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