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Aerotech Automation1 XL2e, Hardware Manual

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Summary of Contents for Automation1 XL2e

Page 1: ...Revision 1 01 Automation1 XL2e High Performance Linear 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: ...onnections 34 2 2 3 1 Stepper Motor Phasing 34 2 3 Feedback Connector 35 2 3 1 Primary Encoder Inputs 36 2 3 1 1 Square Wave Encoder Primary 37 2 3 1 2 Absolute Encoder Primary 38 2 3 1 3 Sine Wave En...

Page 4: ...ccessories 75 4 1 DIN Rail Mounting 76 4 2 Joystick Interface 77 4 3 Handwheel Interface 78 Chapter 5 Maintenance 79 5 1 Preventative Maintenance 80 5 2 Fuse Specifications 81 Appendix A Warranty and...

Page 5: ...tions 45 Figure 2 21 End of Travel and Home Limit Input Schematic Feedback Connector 45 Figure 2 22 End of Travel and Home Limit Input Diagnostic Display 46 Figure 2 23 Brake Connected to the 25 Pin F...

Page 6: ...Figure 4 2 Two Axis Joystick Interface 77 Figure 4 3 Handwheel Interconnection to the Aux Connector 78 List of Figures XL2e Hardware Manual 6 www aerotech com...

Page 7: ...Hall Effect Feedback Pins on the Feedback Connector 41 Table 2 18 Thermistor Input Pin on the Feedback Connector 42 Table 2 19 Encoder Fault Input Pin on the Feedback Connector 43 Table 2 20 End of T...

Page 8: ...70 Table 3 16 Mating Connector Part Numbers for the Digital Output Connector EB1 70 Table 3 17 Digital Input Specifications EB1 73 Table 3 18 Digital Input Connector Pinout EB1 73 Table 3 19 Mating Co...

Page 9: ...wing standard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 61010 1 2010 A1 2016 Safety Requirements for Electrical Equipment EN 61800 3 2017 EM...

Page 10: ...This page intentionally left blank EU Declaration of Conformity XL2e Hardware Manual 10 www aerotech com P E N D I N G...

Page 11: ...2015 up to PL e IEC 61508 1 2010 up to SIL3 IEC 61508 2 2010 up to SIL3 IEC 61800 5 2 2016 IEC 62061 2005 up to SILCL3 IEC 62061 2005 AMD1 2012 up to SILCL3 IEC 62061 2005 AMD2 2015 up to SILCL3 Visit...

Page 12: ...This page intentionally left blank Agency Approvals XL2e Hardware Manual 12 www aerotech com P E N D I N G...

Page 13: ...vided by the equipment could be impaired l The life expectancy of the product could be decreased Safety notes and symbols are placed throughout this manual to warn you of the potential risks at the mo...

Page 14: ...at all components are grounded correctly and that they obey the local electrical safety requirements 7 Install the necessary precautions to supply safety and protection to the operator DANGER System t...

Page 15: ...ed on the packing list are contained within the package The documentation for the drive is on the included installation device The documents include manuals interconnection drawings and other document...

Page 16: ...he amplifier Motor Output connector Section 2 2 Connect the motor to the amplifier Feedback connector Section 2 3 2 Connect a PC or drive based controller HyperWire port to the HyperWire In port Secti...

Page 17: ...motion control applications that require the highest positioning accuracy and lowest generated noise Refer to Table 1 1 for a complete list of features and options Figure 1 1 XL2e High Performance Li...

Page 18: ...axis Part Speed PSO PSO2 Two axis PSO firing includes Two axis Part Speed PSO PSO3 Three axis PSO firing includes Three axis Part Speed PSO PSO5 Two axis Part Speed PSO firing which uses the PSO firin...

Page 19: ...The block diagram that follows shows a summary of the connector signals Figure 1 2 Functional Diagram XL2e Hardware Manual Chapter 1 XL2e Overview www aerotech com 19...

Page 20: ...ature 75 C Time to reach maximum temperature at maximum continuous power 8 minutes Power Amplifier Bandwidth 2500 Hz maximum software selectable Modes of operation Brushless Brush Stepper Protection F...

Page 21: ...Specifications XL2e Customer Supplied Enclosure IP54 Compliant For DIN Rail Mounting refer to Section 4 1 DIN Rail Mounting Weight 1 0 kg Mounting Hardware M3 5 6 screws four locations not included M...

Page 22: ...1 2 2 Dimensions Figure 1 3 Dimensions 1 2 2 Dimensions XL2e Hardware Manual 22 www aerotech com...

Page 23: ...Figure 1 4 Dimensions EB1 XL2e Hardware Manual 1 2 2 Dimensions www aerotech com 23...

Page 24: ...tive humidity is 80 for temperatures 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 opera...

Page 25: ...each drive In the Last 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 First Software Ver...

Page 26: ...This page intentionally left blank 1 4 Drive and Software Compatibility XL2e Hardware Manual 26 www aerotech com...

Page 27: ...4 for the internal fuse value and part number For an isolated DC supply connect 0V to protective ground at the supply Use twisted pair wiring to minimize radiated noise emissions refer to Figure 2 1...

Page 28: ...ssions refer to Figure 2 2 IMPORTANT Refer to local electrical safety requirements to correctly size external system wires Figure 2 2 Motor Supply Connections Table 2 3 Motor Supply Connector Wiring S...

Page 29: ...external system wires The 8 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 Pi...

Page 30: ...tated electronically by the controller The use of Hall effect devices for commutation is recommended The controller requires that the Back EMF of each motor phase be aligned with the corresponding Hal...

Page 31: ...ignals 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 Figure...

Page 32: ...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 33: ...inal To determine if the motor is properly phased connect a voltmeter to the motor leads of an un powered motor 1 Connect the positive lead of the voltmeter to the one of the motor terminals 2 Connect...

Page 34: ...r can be run with or without an encoder Without an Encoder You do not need to phase the motor With an Encoder Because the end of travel EOT limit inputs are relative to motor rotation it is important...

Page 35: ...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 C...

Page 36: ...are Wave or Absolute encoders Square Wave encoders MX3 Sine Wave high performance Square Wave or Absolute encoders Sine Wave standard performance or Square Wave encoders IMPORTANT Physically isolate t...

Page 37: ...gnal 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...

Page 38: ...ring 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 t...

Page 39: ...rate emulated encoder signals These signals can be output on the Auxiliary Encoder AUX connector or used internally by the PSO Refer to the EncoderDivider and PrimaryEmulatedQuadratureDivider paramete...

Page 40: ...while observing the position of the encoder in the diagnostics display see Figure 2 16 For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 16 Figure 2...

Page 41: ...hasing Table 2 17 Hall Effect Feedback Pins on the Feedback Connector Pin Description In Out Bi 3 5V Power 1 Output 5 Hall Effect Sensor B brushless motors only Input 10 Hall Effect Sensor A brushless...

Page 42: ...causes the resistance of the thermistor 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 i...

Page 43: ...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 44: ...agnostics display refer to Figure 2 22 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 Output 20 Sig...

Page 45: ...20 End of Travel and Home Limit Input Connections Figure 2 21 End of Travel and Home Limit Input Schematic Feedback Connector XL2e Hardware Manual 2 3 5 End of Travel and Home Limit Inputs www aerotec...

Page 46: ...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 Di...

Page 47: ...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 Voltage 24 VD...

Page 48: ...the user of the drive 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 STO 2 IN wire strands Table 2 23...

Page 49: ...ws one safety device connected to multiple drives in parallel WARNING The drive does not check for short circuits on the external STO wiring If this is not done by the external safety device short cir...

Page 50: ...1508 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 PL e Ca...

Page 51: ...e 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 functionalit...

Page 52: ...fer 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 separately i...

Page 53: ...ed 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 input...

Page 54: ...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 55: ...tion Description DriveEncoderOutputConfigureDivider DriveEncoderOutputConfigureInput DriveEncoderOutputOn DriveEncoderOutputOff Configure each Sync port as an input or an output PsoDistanceConfigureIn...

Page 56: ...2 7 System Interconnection Figure 2 26 System Wiring Drawing Best Practice 2 7 System Interconnection XL2e Hardware Manual 56 www aerotech com...

Page 57: ...Figure 2 27 System Interconnection Drawing Best Practice XL2e Hardware Manual 2 7 System Interconnection www aerotech com 57...

Page 58: ...n Information For more information about hardware requirements PC configuration programming system operation and utilities refer to the Help file 2 8 PC Configuration and Operation Information XL2e Ha...

Page 59: ...e EB1 I O option board has 8 digital inputs 8 digital outputs 1 analog input 1 analog output and PSO outputs Figure 3 1 XL2e with EB1 I O Option Board Connectors XL2e Hardware Manual Chapter 3 EB1 I O...

Page 60: ...Hz Output Latency Fire event to output change TTL 5 ns Isolated 150 ns Table 3 2 PSO Interface Connector Pinout EB1 Pin Description In Out Bi Connector 1 PSO Output Output 2 PSO Output Output 3 PSO Ou...

Page 61: ...nd 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 62: ...h the with the MX2 or MX3 option incremental sine wave primary encoder inputs Table 3 4 Auxiliary Encoder Connector Pinout Pin Description In Out Bi Connector 1 Auxiliary Marker Input 2 Auxiliary Cosi...

Page 63: ...d 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 minim...

Page 64: ...ce and noise immunity You cannot use an absolute encoder with incremental signals on the Auxiliary Encoder Connector Refer to Figure 3 6 for the serial data stream interface Refer to the Help file for...

Page 65: ...enerate emulated quadrature signals from the auxiliary connector For the highest performance use twisted pair double shielded cable with the inner shield connected to signal common and the outer shiel...

Page 66: ...Figure 3 8 Sine Wave Encoder Schematic Aux Connector 3 2 3 Sine Wave Encoder Auxiliary MX3 Option XL2e Hardware Manual 66 www aerotech com...

Page 67: ...ector 1 5 V 250 mA max Output 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 9 Mating Connector Part Numbers for the Analog I O Connector EB1...

Page 68: ...the system or reset the drive Table 3 10 Analog Output Specifications EB1 Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Table 3 11 Analog Output Pins on t...

Page 69: ...Figure 3 10 Table 3 12 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 the...

Page 70: ...gital 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 Outpu...

Page 71: ...Figure 3 11 Digital Outputs Schematic EB1 XL2e Hardware Manual 3 4 Digital Outputs EB1 www aerotech com 71...

Page 72: ...Figure 3 12 Digital Outputs Connected in Current Sourcing Mode EB1 Figure 3 13 Digital Outputs Connected in Current Sinking Mode EB1 3 4 Digital Outputs EB1 XL2e Hardware Manual 72 www aerotech com...

Page 73: ...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 18 Digital Input Connector Pinout EB1 Pin Description In Out Bi...

Page 74: ...ll sourcing or all sinking configuration Figure 3 15 Digital Inputs Connected to Current Sourcing PNP Devices EB1 Figure 3 16 Digital Inputs Connected to Current Sinking NPN Devices EB1 3 5 Digital In...

Page 75: ...uals index aspx Table 4 1 Standard Interconnection Cables Cable Part Description Joystick Refer to Section 4 2 Joystick Interface Handwheel Refer to Section 4 3 Handwheel Interface C20934 XX or C20935...

Page 76: ...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 77: ...the joystick is in the center location 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...

Page 78: ...rential quadrature signals to the drive IMPORTANT You can find instructions on how to enable the handwheel in the online Help file Connect a handwheel to the Aux connector as shown in Figure 4 3 Figur...

Page 79: ...s the danger of electric shock 3 All tests must be done by an approved service technician Voltages inside the controller and at the input and output power connections can kill you Table 5 1 LED Descri...

Page 80: ...ds and electrically conductive material go into the chassis Examine all cables and connections to make sure they are correct Make sure that all connections are correctly attached and not loose Replace...

Page 81: ...Fuse Description Size Aerotech P N Third Party P N F1 Control Power at 24V Input 2 A S B EIF01066 Littelfuse 0473002 MRT1L F201 Motor Power at B Input 5 A S B EIF01061 Littlefuse 39215000440 F202 Moto...

Page 82: ...This page intentionally left blank 5 2 Fuse Specifications XL2e Hardware Manual 82 www aerotech com...

Page 83: ...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 84: ...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 85: ...Revision Description 1 01 The following sections have been updated l Section 1 1 Electrical Specifications l Chapter 4 Cables and Accessories 1 00 New manual XL2e Hardware Manual Appendix B Revision...

Page 86: ...This page intentionally left blank Appendix B Revision History XL2e Hardware Manual 86 www aerotech com...

Page 87: ...alog Output Typical Connection EB1 68 Analog Outputs EB1 68 Aux Connector Analog Encoder 65 Sine Wave Encoder 65 AUX Connector Mating Connector Part Numbers 62 AUX Connector Pinout 62 Aux Encoder Conn...

Page 88: ...s 22 Dimensions without EB1 22 Dimensions with EB1 23 DIN Rail Mounting 76 DIN Rail Mounting Procedure 76 Drawing number 15 Drive and Software Compatibility 25 E EAM00914 76 Electrical Safety for Powe...

Page 89: ...31 PSO Isolated Output Sinks Current 61 PSO Isolated Output Sources Current 61 PSO TTL Outputs Schematic 61 Sine Wave Encoder Schematic Aux Connector 66 Square Wave Encoder Schematic Feedback Connect...

Page 90: ...nnector 47 Digital Input Connector EB1 73 Digital Output Connector EB1 70 Encoder Fault Input Pin Feedback Connector 43 Encoder Input Feedback Connector 36 End of Travel Limit Input Pins Feedback Conn...

Page 91: ...eatures 18 Stepper Motor Configuration 34 Stepper Motor Connections Motor Power Output Connector 34 Stepper Motor Phasing 34 STO 48 Connector Pinout 48 Diagnostics 53 Electrical Specifications 49 Exte...

Page 92: ...Index XL2e Hardware Manual This page intentionally left blank 92 www aerotech com...

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