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Aerotech Automation1 XC2 Hardware Manual Download Page 15

Installation Overview

This image shows the order in which to make connections and settings that are typical to the XC2. If a
custom interconnect drawing was supplied with your system, that drawing is on your Storage Device and
shows as a line item on your Sales Order in the Integration section.

1

Connect the motor to the amplifier Motor Output connector.

Connect the motor to the amplifier Feedback connector.

2

Connect a PC HyperWire port to the HyperWire In port.

3

Connect additional I/O as required by your application
(if you purchased the I/O option).

4

Connect the Safe Torque Off (STO).

5

Connect the power supply to the Control Supply connector.

6

Connect the motor power to the Motor Supply connector.

Figure 1:

Installation Connection Overview

XC2 Hardware Manual

Installation Overview

www.aerotech.com

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Summary of Contents for Automation1 XC2

Page 1: ...Revision 2 01 Automation1 XC2 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: ...rush Motor Connections 35 2 2 2 1 DC Brush Motor Phasing 36 2 2 3 Stepper Motor Connections 37 2 2 3 1 Stepper Motor Phasing 38 2 3 Feedback Connector 39 2 3 1 Primary Encoder Inputs 40 2 3 1 1 Square...

Page 4: ...g 78 4 2 Joystick Interface 79 4 3 Handwheel Interface 80 4 4 Dual PSO Adapter Cable 81 Chapter 5 Maintenance 83 5 1 Preventative Maintenance 84 5 2 Fuse Specifications 85 Appendix A Warranty and Fiel...

Page 5: ...dback Connector 48 Figure 2 21 End of Travel and Home Limit Input Connections 50 Figure 2 22 End of Travel and Home Limit Input Schematic Feedback Connector 50 Figure 2 23 End of Travel and Home Limit...

Page 6: ...Figure 4 4 Dual Axis PSO Cable Connection 81 List of Figures XC2 Hardware Manual 6 www aerotech com...

Page 7: ...the Feedback Connector 46 Table 2 18 Thermistor Input Pin on the Feedback Connector 47 Table 2 19 Encoder Fault Input Pin on the Feedback Connector 48 Table 2 20 End of Travel and Home Limit Pins on t...

Page 8: ...e 3 16 Digital Output Specifications EB1 73 Table 3 17 Digital Output Connector Pinout EB1 73 Table 3 18 Mating Connector Part Numbers for the Digital Output Connector EB1 73 Table 4 1 Standard Interc...

Page 9: ...th 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 Requirements for Electri...

Page 10: ...This page intentionally left blank EU Declaration of Conformity XC2 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 XC2 Hardware Manual 12 www aerotech com...

Page 13: ...ect the electrical power 2 Restrict access to the XC2 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...

Page 14: ...This page intentionally left blank Safety Procedures and Warnings XC2 Hardware Manual 14 www aerotech com...

Page 15: ...nnector 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 5 3 Connect additional I O as required by your ap...

Page 16: ...This page intentionally left blank Installation Overview XC2 Hardware Manual 16 www aerotech com...

Page 17: ...protocol The drive provides deterministic behavior auto identification is fully software configurable A double precision floating point DSP controls the digital PID and current loops in the XC2 Figur...

Page 18: ...it analog output 10 V l 16 bit differential analog input 10 V l 8 digital logic inputs 5 24 VDC can be connected to current sourcing or sinking devices l 8 digital logic outputs 5 24 VDC can be connec...

Page 19: ...The block diagram that follows shows a summary of the connector signals Figure 1 2 Functional Diagram XC2 Hardware Manual Chapter 1 Introduction www aerotech com 19...

Page 20: ...er Amplifier Bandwidth 2500 Hz maximum software selectable Power Amplifier Efficiency 85 95 2 PWM Switching Frequency 20 kHz Minimum Load Inductance 0 1 mH 100 VDC User Power Supply Output 5 VDC 500 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: ...Specifications XC2 Customer Supplied Enclosure IP54 Compliant For DIN Rail Mounting refer to Section 4 1 DIN Rail Mounting Weight 0 54 kg Mounting Hardware M3 5 6 screws four locations not included M...

Page 23: ...1 2 2 Dimensions Figure 1 3 Dimensions XC2 Hardware Manual 1 2 2 Dimensions www aerotech com 23...

Page 24: ...Figure 1 4 Dimensions EB1 1 2 2 Dimensions XC2 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 XC2 is on the included installation device The documents include manuals interconnection drawings and other documentatio...

Page 28: ...he supply Use twisted pair wiring to minimize radiated noise emissions refer to Figure 2 1 IMPORTANT Refer to local electrical safety requirements to correctly size external system wires Figure 2 1 Co...

Page 29: ...lectrical safety requirements to correctly size external system wires Figure 2 2 Motor Supply Connections Table 2 3 Motor Supply Connector Wiring Specifications Pin Description Recommended Wire Size D...

Page 30: ...ives power supplies and filter components on a conductive panel Keep wire run lengths to a minimum For the AC power lines feeding the VDC Motor supply and VDC Control sup ply place a line filter such...

Page 31: ...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 5 Table 2 5 Motor Power Output Connector Pin...

Page 32: ...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 33: ...signals in the Diagnostics section of the Status Utility Table 2 8 Hall Signal Diagnostics Hall Signal Status Definition 0 V or logic low ON 5 V or logic high Figure 2 4 Positive Motor Direction Figur...

Page 34: ...tor 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 35: ...re 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 Orange...

Page 36: ...he positive or clockwise CW direction by hand Figure 2 9 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 37: ...bus supply is needed to get 40V across the motor Figure 2 10 Stepper Motor Configuration Table 2 10 Wire Colors for Aerotech Supplied Stepper Motor Cables Pin Wire Color Set 1 1 Wire Color Set 2 Green...

Page 38: ...t parameters and the motor moves in a clockwise direction when you view the motor from the front mounting flange Figure 2 11 If the motor moves in a counterclockwise direction swap the motor leads and...

Page 39: ...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 40: ...2 13 Multiplier Options Option Primary Encoder Accepts Auxiliary Encoder Accepts MX0 Square Wave or Absolute encoders Square Wave encoders MX1 Sine Wave Square Wave or Absolute encoders Square Wave e...

Page 41: ...al connection Use twisted pair wiring for the highest performance and noise immunity Table 2 15 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum ed...

Page 42: ...g for the highest performance and noise immunity You cannot echo an absolute encoder signal Refer to Figure 2 13 for the serial data stream interface Refer to the Help file for information on how to s...

Page 43: ...nnot use a sine wave encoder with the MX1 multiplier option as an input to the PSO The MX1 option does not generate emulated quadrature signals For the highest performance use twisted pair double shie...

Page 44: ...Figure 2 15 Sine Wave Encoder Schematic Feedback Connector 2 3 1 Primary Encoder Inputs XC2 Hardware Manual 44 www aerotech com...

Page 45: ...hile observing the position of the encoder in the diagnostics display see Figure 2 17 For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 17 Figure 2 16...

Page 46: ...evice phasing Table 2 17 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 47: ...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 48: ...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 19 Encoder Fault In...

Page 49: ...e diagnostics display refer to Figure 2 23 Table 2 20 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 50: ...21 End of Travel and Home Limit Input Connections Figure 2 22 End of Travel and Home Limit Input Schematic Feedback Connector 2 3 5 End of Travel and Home Limit Inputs XC2 Hardware Manual 50 www aero...

Page 51: ...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 52: ...put Table 2 21 Brake Output Pins on the Feedback Connector Pin Description In Out Bi 13 Brake Output Output 25 Brake Output Output Table 2 22 Brake Control Specifications Specification Value Maximum V...

Page 53: ...vel is the sole responsibility of the user of the XC2 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 54: ...re 2 25 shows one safety device connected to multiple XC2s in parallel WARNING The XC2 does not check for short circuits on the external STO wiring If this is not done by the external safety device sh...

Page 55: ...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 27 STO Standards Data Standard Value EN ISO 13849 1 2015 MTTFD 1000 years DCAVG 99 Maximum...

Page 56: ...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 57: ...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 58: ...listed SIL level the STO circuit must be activated power removed from both inputs according to the interval specified in Table 2 27 Table 2 30 STO Timing Time Description Value T1 STO Delay Time STO...

Page 59: ...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 31 HyperWire Card Part Number Part Number...

Page 60: ...rconnection Click on the image below to open a separate pdf window with a larger view of the drawing Figure 2 27 System Wiring Drawing Best Practice 2 6 System Interconnection XC2 Hardware Manual 60 w...

Page 61: ...Figure 2 28 System Interconnection Drawing Best Practice XC2 Hardware Manual 2 6 System Interconnection www aerotech com 61...

Page 62: ...n Information For more information about hardware requirements PC configuration programming system operation and utilities refer to the Help file 2 7 PC Configuration and Operation Information XC2 Har...

Page 63: ...he EB1 I O option board has 8 digital inputs 8 digital outputs 1 analog input 1 analog output and PSO outputs Figure 3 1 XC2 with EB1 I O Option Board Connectors XC2 Hardware Manual Chapter 3 EB1 I O...

Page 64: ...d 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 2 PSO Interface Connector Pinout EB1 Pin Descr...

Page 65: ...and will turn off if the maximum output current is exceeded Figure 3 2 PSO Output Sources Current Figure 3 3 PSO Output Sinks Current TTL Signals This output signal is a 5V TTL signal which is used to...

Page 66: ...to configure the Sine and Cosine connector pins as RS 422 outputs You can only echo incremental square wave primary encoder inputs Table 3 4 Auxiliary Encoder Connector Pinout Pin Description In Out B...

Page 67: ...signal connection Use twisted pair wiring for the highest performance and noise immunity Table 3 6 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum...

Page 68: ...nnector 1 5 V 250 mA max N A 2 Analog Input 0 Input 3 Analog Input 0 Input 4 Ground N A 5 Ground N A 6 Analog Output 0 Output Table 3 8 Mating Connector Part Numbers for the Analog I O Connector EB1 T...

Page 69: ...r to Figure 3 6 Table 3 9 Differential Analog Input Specifications EB1 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 t...

Page 70: ...the system or reset the drive Table 3 11 Analog Output Specifications EB1 Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Table 3 12 Analog Output Pins on t...

Page 71: ...3 13 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 14 Digital Input Connector Pinout EB1 Pin Description In Out...

Page 72: ...all sourcing or all sinking configuration Figure 3 9 Digital Inputs Connected to Current Sourcing PNP Devices EB1 Figure 3 10 Digital Inputs Connected to Current Sinking NPN Devices EB1 3 4 Digital In...

Page 73: ...6 Digital Output Specifications EB1 Digital Output Specifications Value Maximum Voltage 24 V 26 V Maximum Maximum Sink Source Current 250 mA output Output Saturation Voltage 0 9 V at maximum current O...

Page 74: ...Figure 3 11 Digital Outputs Schematic EB1 3 5 Digital Outputs EB1 XC2 Hardware Manual 74 www aerotech com...

Page 75: ...Figure 3 12 Digital Outputs Connected in Current Sourcing Mode EB1 Figure 3 13 Digital Outputs Connected in Current Sinking Mode EB1 XC2 Hardware Manual 3 5 Digital Outputs EB1 www aerotech com 75...

Page 76: ...This page intentionally left blank 3 5 Digital Outputs EB1 XC2 Hardware Manual 76 www aerotech com...

Page 77: ...tion Cables Cable Part Description Joystick Refer to Section 4 2 Joystick Interface Handwheel Refer to Section 4 3 Handwheel Interface ECZ03125 3 and ECZ03125 9 Dual PSO Adapter Cable refer to Section...

Page 78: ...il to the mounting surface with 10 32 screws spaced every six inches NOTE Do not install the DIN rail to the mounting surface with the components already attached 4 Install all components on to the DI...

Page 79: ...Third party devices 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 identif...

Page 80: ...differential quadrature signals to the XC2 IMPORTANT You can find instructions on how to enable the handwheel in the Help file Connect a handwheel to the Aux connector as shown in Figure 4 3 Figure 4...

Page 81: ...PSO Adapter Cable The dual PSO adapter cable is available in two lengths 3 dm 9 84 in 9 dm 29 52 in Figure 4 4 Dual Axis PSO Cable Connection XC2 Hardware Manual 4 4 Dual PSO Adapter Cable www aerotec...

Page 82: ...This page intentionally left blank 4 4 Dual PSO Adapter Cable XC2 Hardware Manual 82 www aerotech com...

Page 83: ...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 84: ...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 85: ...Control Board Fuse Specifications Fuse Description Size Aerotech P N Third Party P N F1 Control Power at 24V Input 2 A S B EIF01066 Littelfuse 0473002 MRT1L F2 Motor Power at DC Input 5 A S B EIF0106...

Page 86: ...This page intentionally left blank 5 2 Fuse Specifications XC2 Hardware Manual 86 www aerotech com...

Page 87: ...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 88: ...ial 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 sit...

Page 89: ...der Input EB1 2 00 General Update 1 02 The following sections have been updated l Agency Approvals l Section 1 1 Electrical Specifications l Section 2 3 1 Primary Encoder Inputs 1 01 Added System Inte...

Page 90: ...This page intentionally left blank Appendix B Revision History XC2 Hardware Manual 90 www aerotech com...

Page 91: ...Pinout 66 Auxiliary Encoder Input EB1 66 B BiSS absolute encoder 42 Brake Connected to the Feedback Connector 52 Brake Control Relay Specifications 52 Brake Output Pins on the Feedback Connector 52 Br...

Page 92: ...Encoder Fault Input Feedback Connector 48 Encoder Fault Input Pin on the Feedback Connector 48 Encoder Input Feedback Connector 40 Encoder Input Pins on the Feedback Connector 40 Encoder Phasing 45 E...

Page 93: ...er Motor Configuration 37 STO Timing 58 Thermistor Input Schematic 47 TTL Outputs Schematic PSO 65 Typical STO Configuration 54 fluids dangerous 84 Functional Diagram 19 Fuse Specifications 85 Control...

Page 94: ...Pins Feedback Connector 52 Digital Input Connector EB1 71 Digital Output Connector EB1 73 Encoder Fault Input Pin Feedback Connector 48 Encoder Input Feedback Connector 40 End of Travel Limit Input Pi...

Page 95: ...guration 37 Stepper Motor Connections Motor Power Output Connector 37 Stepper Motor Phasing 38 STO 53 Connector Pinout 53 Diagnostics 58 Electrical Specifications 54 External Delay Timer 56 Functional...

Page 96: ...Index XC2 Hardware Manual This page intentionally left blank 96 www aerotech com...

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