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Aerotech Automation1 XL5e, Hardware Manual

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Aerotech Automation1 XL5e Hardware Manual Download Page 15

Chapter 1: Introduction

The XL5e is a high-performance linear amplifier designed for motion control applications that require the
highest positioning accuracy and lowest generated noise. The XL5e is factory configured for the specified
AC input voltage, motor output voltage, and current. Refer to

Table 1-1

for a complete list of features

and ordering options.

Figure 1-1:

XL5e High Performance Linear Amplifier

XL5e Hardware Manual

Chapter 1: Introduction

www.aerotech.com

15

Summary of Contents for Automation1 XL5e

Page 1: ...Revision 1 01 Automation1 XL5e 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: ...nections 34 2 2 3 1 Stepper Motor Phasing 35 2 3 Feedback Connector 36 2 3 1 Primary Encoder Inputs 37 2 3 1 1 Square Wave Encoder 38 2 3 1 2 Absolute Encoder 39 2 3 1 3 Sine Wave Encoder MX2 MX3 Opti...

Page 4: ...B1 88 3 5 Position Synchronized Output Interface EB1 89 Chapter 4 Cables and Accessories 91 4 1 Joystick Interface 92 4 2 Handwheel Interface 94 Chapter 5 Maintenance 95 5 1 Preventative Maintenance 9...

Page 5: ...ult Input Schematic Feedback Connector 45 Figure 2 22 End of Travel and Home Limit Input Connections 47 Figure 2 23 End of Travel and Home Limit Input Schematic Feedback Connector 47 Figure 2 24 End o...

Page 6: ...Analog Output Typical Connection EB1 87 Figure 3 9 Analog Input Typical Connection EB1 88 Figure 3 10 PSO Output Sources Current 90 Figure 3 11 PSO Output Sinks Current 90 Figure 3 12 PSO TTL Outputs...

Page 7: ...ecifications 40 Table 2 18 Hall Effect Feedback Pins on the Feedback Connector 43 Table 2 19 Thermistor Input Pin on the Feedback Connector 44 Table 2 20 Encoder Fault Input Pin on the Feedback Connec...

Page 8: ...1 81 Table 3 6 Digital Input Specifications EB1 84 Table 3 7 Digital Input 1 Connector Pinout EB1 84 Table 3 8 Mating Connector Part Numbers for the Digital Input 1 Connector EB1 84 Table 3 9 Digital...

Page 9: ...s been designed to be in conformity with the applicable requirements of the following Standard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 613...

Page 10: ...This page intentionally left blank EU Declaration of Conformity XL5e Hardware Manual 10 www aerotech com P E N D I N G...

Page 11: ...ct the electrical power 2 Restrict access to the XL5e 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 12: ...This page intentionally left blank Safety Procedures and Warnings XL5e Hardware Manual 12 www aerotech com...

Page 13: ...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 14: ...This page intentionally left blank Installation Overview XL5e Hardware Manual 14 www aerotech com...

Page 15: ...t positioning accuracy and lowest generated noise The XL5e is factory configured for the specified AC input voltage motor output voltage and current Refer to Table 1 1 for a complete list of features...

Page 16: ...Two High Speed Inputs Section 2 5 5 l One 16 bit analog output 10 V Section 2 5 6 l One 16 bit differential analog input 10 V Section 2 5 7 Options Peak Current Section 1 1 10 10 A Peak 20 20 A Peak B...

Page 17: ...One axis PSO firing includes One 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 PS...

Page 18: ...The block diagram that follows shows a summary of the connector signals Figure 1 2 Functional Diagram Chapter 1 Introduction XL5e Hardware Manual 18 www aerotech com...

Page 19: ...C Input current maximum continuous 7 Arms 120 V 3 5 Arms 240 V Control Supply Input Frequency 50 60 Hz Inrush current 68 Apk 240 V Input current maximum continuous 25 Arms Current Loop Bandwidth 2500...

Page 20: ...connections Table 1 3 Mounting Specifications XL5e Customer Supplied Enclosure IP54 Compliant Weight 11 31 kg Mounting Hardware M4 8 screws four locations not included Mounting Orientation Vertical ty...

Page 21: ...1 2 2 Dimensions Figure 1 3 Dimensions XL5e Hardware Manual 1 2 2 Dimensions www aerotech com 21...

Page 22: ...Figure 1 4 Dimensions EB1 1 2 2 Dimensions XL5e Hardware Manual 22 www aerotech com...

Page 23: ...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 24: ...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 Version...

Page 25: ...on the packing list are contained within the package The documentation for the XL5e is on the included installation device The documents include manuals interconnection drawings and other documentatio...

Page 26: ...l filter for CE compliance Install the external filter module as close as possible to the XL5e Use a Schaffner FN2080 filter an Aerotech UFM ST noise filter module or equivalent device IMPORTANT Refer...

Page 27: ...or 80 VDC motor voltage options IMPORTANT Refer to local electrical safety requirements to correctly size external system wires IMPORTANT Make sure that the ground connection is installed correctly be...

Page 28: ...t 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 Pinout Pin Description Recommended Wire Size Connector Earth Ground...

Page 29: ...re commutated 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 correspon...

Page 30: ...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 31: ...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 32: ...figuration possible to minimize heat generation in the amplifier Figure 2 8 DC Brush Motor Configuration Figure 2 9 DC Brush Motor Configuration Table 2 9 DC Brush Voltage Output Configuration Connect...

Page 33: ...positive or clockwise CW direction by hand Figure 2 10 Positive Motor Direction 4 If the voltmeter indicates a negative value swap the motor leads and move the motor by hand in the positive direction...

Page 34: ...us supply is needed to get 40V across the motor Figure 2 11 Stepper Motor Configuration Table 2 11 Wire Colors for Aerotech Supplied Stepper Motor Cables Pin Wire Color Set 1 1 Wire Color Set 2 Green...

Page 35: ...parameters and the motor moves in a clockwise direction when you view the motor from the front mounting flange Figure 2 12 If the motor moves in a counterclockwise direction swap the motor leads and...

Page 36: ...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 37: ...Square Wave or Absolute encoders Square Wave or Absolute encoders MX3 Sine Wave high performance Square Wave or Absolute encoders Sine Wave standard performance Square Wave or Absolute encoders IMPORT...

Page 38: ...nal connection Use twisted pair wiring for the highest performance and noise immunity Table 2 16 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum e...

Page 39: ...g for the highest performance and noise immunity You cannot echo an absolute encoder signal Refer to Figure 2 14 for the serial data stream interface Refer to the Help file for information on how to s...

Page 40: ...e signals can be output on the Auxiliary Encoder AUX connector SYNC port connector or used internally by the PSO Refer to the EncoderDivider and PrimaryEmulatedQuadratureDivider parameters and the enc...

Page 41: ...Figure 2 16 Sine Wave Encoder Schematic Feedback Connector www aerotech com 41 XL5e Hardware Manual 2 3 1 Primary Encoder Inputs...

Page 42: ...hile observing the position of the encoder in the diagnostics display see Figure 2 18 For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 18 Figure 2 17...

Page 43: ...vice phasing Table 2 18 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 brushl...

Page 44: ...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 45: ...ameter 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 20 Encoder Fault Inp...

Page 46: ...e diagnostics display refer to Figure 2 24 Table 2 21 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 47: ...22 End of Travel and Home Limit Input Connections Figure 2 23 End of Travel and Home Limit Input Schematic Feedback Connector www aerotech com 47 XL5e Hardware Manual 2 3 5 End of Travel and Home Limi...

Page 48: ...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 49: ...powering the brake circuit Table 2 22 Brake Output Pins on the Feedback Connector Pin Description In Out Bi 13 Brake Output Output 25 Brake Output Output Table 2 23 Brake Control Specifications Specif...

Page 50: ...the sole responsibility of the user of the XL5e 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 I...

Page 51: ...shows one safety device connected to multiple XL5es in parallel WARNING The XL5e does not check for short circuits on the external STO wiring If this is not done by the external safety device short ci...

Page 52: ...1508 2 2010 SIL 3 EN ISO 13849 1 2015 Category 4 PL e EN IEC 62061 2005 with Amendments SIL 3 Table 2 28 STO Standards Data Standard Value EN ISO 13849 1 2015 MTTFD 1000 years DCAVG 99 Maximum PL e Ca...

Page 53: ...le 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 functionali...

Page 54: ...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 55: ...d SIL level the STO circuit must be activated power removed from both inputs according to the interval specified in Table 2 28 Table 2 31 STO Timing Time Description Value T1 STO Delay Time STO input...

Page 56: ...directional 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 57: ...outputs You can only echo incremental square wave primary encoder inputs or with the MX2 or MX3 option incremental sine wave primary encoder inputs You cannot use the absolute encoder interface when y...

Page 58: ...gnal connection Use twisted pair wiring for the highest performance and noise immunity Table 2 35 Square Wave Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum 25 ns minimum...

Page 59: ...nce and noise immunity You cannot use an absolute encoder with incremental signals on the Auxiliary I O Connector Refer to Figure 2 29 for the serial data stream interface Refer to the Help file for i...

Page 60: ...ot generate 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 s...

Page 61: ...Figure 2 31 Sine Wave Encoder Schematic Auxiliary I O Connector XL5e Hardware Manual 2 5 Auxiliary I O Connector www aerotech com 61...

Page 62: ...sed to drive an opto coupler or general purpose TTL input This signal is active high and is driven to 5 V when a PSO fire event occurs When the drive is reset or after initial power up the PSO pins re...

Page 63: ...Figure 2 32 PSO Interface XL5e Hardware Manual 2 5 Auxiliary I O Connector www aerotech com 63...

Page 64: ...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 removed...

Page 65: ...Figure 2 33 Digital Output Schematic Aux I O Connector XL5e Hardware Manual 2 5 Auxiliary I O Connector www aerotech com 65...

Page 66: ...Figure 2 34 Digital Outputs Connected in Current Sourcing Mode Figure 2 35 Digital Outputs Connected in Current Sinking Mode 2 5 Auxiliary I O Connector XL5e Hardware Manual 66 www aerotech com...

Page 67: ...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 Descri...

Page 68: ...Figure 2 37 Digital Inputs Connected to Current Sinking Devices Figure 2 38 Digital Inputs Connected to Current Sourcing Devices 2 5 Auxiliary I O Connector XL5e Hardware Manual 68 www aerotech com...

Page 69: ...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 Specifications Specification Value In...

Page 70: ...ystem 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 Auxili...

Page 71: ...efer to Figure 2 41 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 Tab...

Page 72: ...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 73: ...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 74: ...ion Description DriveEncoderOutputConfigureDivider DriveEncoderOutputConfigureInput DriveEncoderOutputOn DriveEncoderOutputOff Configure each Sync port as an input or an output PsoDistanceConfigureInp...

Page 75: ...connection Click on the image below to open a separate pdf window with a larger view of the drawing Figure 2 42 System Wiring Drawing Best Practice XL5e Hardware Manual 2 9 System Interconnection www...

Page 76: ...Figure 2 43 System Interconnection Drawing Best Practice 2 9 System Interconnection XL5e Hardware Manual 76 www aerotech com...

Page 77: ...n Information For more information about hardware requirements PC configuration programming system operation and utilities refer to the Help file XL5e Hardware Manual 2 10 PC Configuration and Operati...

Page 78: ...This page intentionally left blank 2 10 PC Configuration and Operation Information XL5e Hardware Manual 78 www aerotech com...

Page 79: ...EB1 I O option board has 16 digital inputs 16 digital outputs 3 analog inputs 3 analog outputs and PSO outputs Figure 3 1 XL5e with EB1 I O Option Board Connectors XL5e Hardware Manual Chapter 3 EB1 I...

Page 80: ...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 81: ...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 Opt...

Page 82: ...Figure 3 2 Digital Outputs Schematic EB1 3 1 Digital Outputs EB1 XL5e Hardware Manual 82 www aerotech com...

Page 83: ...Figure 3 3 Digital Outputs Connected in Current Sourcing Mode EB1 Figure 3 4 Digital Outputs Connected in Current Sinking Mode EB1 XL5e Hardware Manual 3 1 Digital Outputs EB1 www aerotech com 83...

Page 84: ...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 85: ...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 86: ...n 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 Digita...

Page 87: ...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 Output...

Page 88: ...nce 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 89: ...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 Interface Connector Pinout EB1 Pin Description In Out Bi Connector 1 PSO O...

Page 90: ...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 91: ...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 XL5...

Page 92: ...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 93: ...Figure 4 2 Two Axis Joystick Interface to the I O board XL5e Hardware Manual 4 1 Joystick Interface www aerotech com 93...

Page 94: ...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 95: ...is 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 Desc...

Page 96: ...ctions 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 the...

Page 97: ...at AC1 100 VAC 120 VAC 8 A S B EIF01022 Littelfuse 0215008 HXP F6 XL5e 10 Motor Bus Voltage Negative 5 A S B EIR01023 Littelfuse 0215005 HXP XL5e 20 Motor Bus Voltage Negative 10 A S B EIR01020 Littel...

Page 98: ...This page intentionally left blank 5 2 Fuse Specifications XL5e Hardware Manual 98 www aerotech com...

Page 99: ...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 100: ...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 101: ...should not be changed when using off line supplies Damage to the unit may result if this function is used improperly If the user changes the voltage selector settings it is also the user s responsibi...

Page 102: ...Figure B 1 Voltage Selection Switch Access Appendix B Voltage Selection Operation XL5e Hardware Manual 102 www aerotech com...

Page 103: ...en updated l Dimension drawings have been updated l Absolute Encoder support on the Auxiliary I O connector has been added l System Wiring best practices drawing has been added l Appendix B has been u...

Page 104: ...This page intentionally left blank Appendix C Revision History XL5e Hardware Manual 104 www aerotech com...

Page 105: ...Connector 70 Analog Output 0 Specifications Aux I O Connector 70 Analog Output Connector EB1 Mating Connector Part Numbers 87 Analog Output Connector Pinout EB1 87 Analog Output Pins Aux I O Connecto...

Page 106: ...g Devices Aux I O Connector 68 Digital Inputs Connected to Current Sourcing Devices Aux I O Connector 68 Digital Inputs Schematic Aux I O Connector 67 Digital Inputs Schematic EB1 85 Digital Output 1...

Page 107: ...t Typical Connection EB1 87 Brake Connected to the Feedback Connector 49 Brushless Motor Configuration Motor Power Output Connector 29 Control Supply Connections 26 DC Brush Motor Configuration Motor...

Page 108: ...isplay 48 Home Limit Input Pins on the Feedback Connector 46 Home Limit Input Schematic 47 Humidity 23 HyperWire 73 Cable Part Numbers 73 Card Part Number 73 I I O Option Board EB1 79 Input Power Conn...

Page 109: ...or Power Output Connector 28 Primary Encoder Inputs Feedback Connector 37 PSO Interface Connector EB1 89 PSO Pins Aux I O Connector 62 STO Connector 50 Thermistor Input Pin Feedback Connector 44 Pollu...

Page 110: ...edback Connector 38 58 Standard Features 16 Stepper Motor Configuration 34 Stepper Motor Connections Motor Power Output Connector 34 Stepper Motor Phasing 35 STO 50 Connector Pinout 50 Diagnostics 55...

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