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Copley Controls XEL-230-18, User Manual

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Copley Controls XEL-230-18 User Manual Download Page 134

Xenus Plus User Guide 

16-01344 Rev 06

 

 

 

 

Copley Controls 

134 

APPENDIX 

A: R

EGEN 

R

ESISTOR 

S

IZING AND 

C

ONFIGURATION

 

This chapter describes the steps used to determine if a regen resistor is required and what the 
optimal resistor characteristics would be for a given application. For an overview of regeneration 
and regen resistors, see 

Regen Resistor Theory (p. 61). 

To configure a custom regen resistor, see 

the 

CME User Guide

. Additional information about regeneration can be found in this document on 

the web-site: 

http://www.copleycontrols.com/Motion/pdf/Xenus_regen_guide-03-04.pdf

 

 

The contents of this chapter include: 

 

A.1: Sizing a Regen Resistor ......................................................................................................................................................... 135

 

 

Summary of Contents for XEL-230-18

Page 1: ...123123 P N 16 01344 Revision 06 August 30 2019 Xenus Plus User Guide...

Page 2: ...Xenus Plus User Guide 16 01344 Rev 06 This page for notes...

Page 3: ...3 8 Analog Inputs 68 3 9 Digital Inputs 69 3 10 Analog Output 70 3 11 Digital Outputs 70 3 12 Encoder Power Outputs 71 3 13 Primary Encoder Inputs 71 3 14 Analog Encoder Inputs 72 3 15 Hall Switch In...

Page 4: ...2 XTL FA 01 Edge Filter Wiring 154 E Connecting XPL XP2 for Serial Control 157 E 1 Single Axis and Multi Drop 158 F Ordering Guide and Accessories 159 F 1 Drive Model Numbers 160 F 2 Accessory Model N...

Page 5: ...pdate to reflect latest revisions of IEC 61800 5 1 2016 and IEC 61800 5 2 2016 06 August 26 2019 ECO 074059 Update to change XEL XPL XML STO to MTO to differentiate from certified STO on XE2 XP2 XM2 N...

Page 6: ...The complete EC Declarations of Conformity for all products are available on the internet at www copleycontrols com Original Instructions This manual is considered to be original instructions as defin...

Page 7: ...cations along with other documents data sheets and software releases can be found at http www copleycontrols com Comments Copley Controls welcomes your comments on this manual For contact information...

Page 8: ...alls for non latched behavior When using non latched faults be sure to safeguard against unexpected motion Failure to heed this warning can cause equipment damage injury or death DANGER Using CME or s...

Page 9: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 9 This page for notes...

Page 10: ...ntrols 10 CHAPTER 1 INTRODUCTION This chapter provides an overview of the Copley Controls Xenus Plus drives Contents include 1 1 Xenus Plus Family Overview 11 1 2 CME 12 1 3 CML CMO 13 1 4 Copley Virt...

Page 11: ...operates in the same way as STO but does not have the certifications of STO Xenus Plus models support a wide range of feedback devices The standard versions support digital quadrature encoders analog...

Page 12: ...uded within the scope of this manual unless otherwise noted A separate 24 Vdc logic supply is required to power the internal logic and control circuits These are isolated from the high voltage power s...

Page 13: ...at can be used by Visual Basic NET LabVIEW or any other program supporting the Microsoft COM object interface 1 4 Copley Virtual Machine CVM Copley Virtual Machine CVM is an embedded virtual programma...

Page 14: ...1 Drive Power Architecture 15 2 2 Operating Modes 17 2 3 Input Command Types 28 2 4 Communication 33 2 5 Status Indicators 38 2 6 Protection 50 2 7 Position and Velocity Errors 52 2 8 Inputs XEL XPL...

Page 15: ...d IN16 22 analog inputs AIN1 2 Hall inputs and encoder inputs are referenced to signal ground Inputs IN6 9 and IN16 19 are two groups of four opto isolated inputs with a common terminal for each group...

Page 16: ...he single axis model Although not shown connections to a second motor applicable for the dual axis drive models are essentially duplicates of the first The second motor power connections originate fro...

Page 17: ...ted by R in the model number support standard single speed transmit type resolvers Digital quadrature and Sin Cos analog encoders are incremental types that typically use Hall feedback for commutating...

Page 18: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 18...

Page 19: ...ct the motor and or mechanical system Feedback The nature of servo control loops is that they receive feedback from the device they are controlling For example the position loop uses the actual motor...

Page 20: ...cations where there is a constant force applied to or required of the servomotor and the system must control this force Typical applications would be a vertical axis holding against gravity or web ten...

Page 21: ...rrent loop integral The integral of the current error is multiplied by this value Integral gain reduces the current error to zero over time It controls the DC accuracy of the loop or the flatness of t...

Page 22: ...ces an error signal The velocity loop feedback signal is always from the motor feedback device even when an additional encoder is attached to the load The error signal is then processed using the inte...

Page 23: ...Ramp Specifies the deceleration rate used by the velocity loop when the drive is hardware disabled Fast stop ramp is not used when drive is software disabled If the brake delay option is programmed t...

Page 24: ...the Low Gains Shift option is available to increase the gains adjustment resolution Such low values are likely to be called for when tuning a linear motor with an encoder resolution finer than a micr...

Page 25: ...rator updates the calculated profile in real time as position commands are received The output of the generator is an instantaneous position command limited position In addition values for the instant...

Page 26: ...position loop to calculate the velocity command Gain Description Pp Position loop proportional The loop calculates the position error as the difference between the actual and limited position values T...

Page 27: ...nually turn in one direction and only the position within a revolution is of interest to the user With the wrap value set relative moves will move the relative distance called for Example if the wrap...

Page 28: ...he input to command ratio allowing the use of an optimal command range for any given input voltage signal range For example in current mode with default scaling 10 Vdc of input generates a command equ...

Page 29: ...set to 5V After this a 0 Vdc input command would be interpreted as 5 Vdc which would produce 1000 rpm CCW rotation A 10 Vdc command would be interpreted as 5 Vdc and produce 1000 rpm CW rotation Moni...

Page 30: ...verted so that increased duty cycle commands negative output and vice versa 100 Duty Cycle Format Two Wire One input takes a PWM waveform of fixed frequency and variable duty cycle and the other input...

Page 31: ...cceleration and deceleration rates When using digital or analog command inputs the trajectory generator can be disabled by setting the Max Accel limit to zero Note that when using CAN EtherCAT ASCII s...

Page 32: ...own below The drive can be set to increment position on the rising or falling edge of the signal Stepping resolution can be programmed for electronic gearing Quadrature Format In quadrature format A B...

Page 33: ...the drive is controlled over the CAN or EtherCAT interface or by the digital inputs CAN interface XPL XP2 When operating as a CAN node the drive takes command inputs over a CANopen network EtherCAT XE...

Page 34: ...ogrammed position The drive supports both trapezoidal and s curve profiles Profile Velocity Mode 3 The drive is programmed with a velocity a direction and acceleration and deceleration rates When the...

Page 35: ...de ID in the range of 1 127 Address 0 is reserved and should only be used when the drive is serving as a CME serial port multi drop gateway There are several basic methods for setting the CAN address...

Page 36: ...nodes and are independent of the physical position on the network Fixed addresses begin with 1001 0x3E9 and increment thereafter as nodes are found Each dual axis drive is addressed as a single physi...

Page 37: ...ilable for servo drives are 0 1 4 5 8 9 and 12 13 With the 2 axis XM2 the valid node addresses are 0 4 8 and 12 These address Axis A of the servo drives Axis B of the drives can then be addressed by a...

Page 38: ...ne or both MTO inputs are de energized The drive is hardware software enabled but the PWM outputs cannot produce current in the motor when MTO is active Steady red A non latched fault has occurred Bli...

Page 39: ...work Status Indicators XEL J7 LINK and ACT Indicators EtherCAT Network Status LINK shows the state of the physical link network ACT shows activity on the network LINK Green ACT Yellow Description On O...

Page 40: ...commands Green Slow Blinking Drive OK but NOT enabled Will run when enabled Green Fast Blinking Positive or Negative limit switch active Drive will only move in direction not inhibited by limit switch...

Page 41: ...Indicator Indicates the state of the ESM EtherCAT state machine RUN Green Meaning Off Init Blinking Pre operational Single flash Safe operational On Operational XE2 800 1818 800 1819 800 1887 J8 ERR I...

Page 42: ...reen flash twice followed by a pause MTO is active One or both MTO inputs are de energized The drive is hardware software enabled but the PWM outputs cannot produce current in the motor when MTO is ac...

Page 43: ...ctive One or both STO inputs are de energized The drive is hardware software enabled but the PWM outputs cannot produce current in the motor when STO is active Red Solid Transient fault condition Driv...

Page 44: ...Drive is enabled and operational Slow blinking green Drive is disabled No faults or warnings are active Fast blinking green A limit switch is active The drive is enabled Green flash twice followed by...

Page 45: ...Note that green and red codes alternate each indicating a different set of conditions The red green ACT ERR LEDs indicate the status of the physical layer The green ACT LED indicates physical connect...

Page 46: ...n Pre operational Steady green Operational Single flash green Stopped ERR Red LED CANopen Physical Layer Status Single flash red Warning Limit Reached Double flash red Error Control Event Triple flash...

Page 47: ...ndicator State Blinking red Normal transmit receive data on the network For firmware version V2 0 and higher Both LEDs blink in unison to show bus activity and low level bus errors ACT Indicator State...

Page 48: ...s Green Slow Blinking Drive OK but NOT enabled Will run when enabled Green Fast Blinking Positive or Negative limit switch active Drive will only move in direction not inhibited by limit switch Green...

Page 49: ...ctivity On and flickering Port open and activity XP2 J8 RUN Indicator Indicates the state of the CANopen state machine RUN Green Meaning Blinking Pre operational Single flash Stopped On Operational XP...

Page 50: ...fault occurs with the exception of a following error the drive s PWM output stage is disabled the fault type is recorded in the drive s internal error log which can be viewed with CME and the status...

Page 51: ...rnal temperature exceeds specified temperature Power module temperature falls below specified temperature Motor Phasing Error Encoder based phase angle does not agree with Hall switch states This faul...

Page 52: ...error fault 2 7 2 Following Error Faults When the position error reaches the programmed fault threshold the drive immediately faults The following error fault can be disabled For detailed information...

Page 53: ...rations After a Non Latched Following Error Fault The clearing of a non latched following error depends on the drive s mode of operation Issuing a new trajectory command over the CAN bus or the ASCII...

Page 54: ...e difference between commanded and actual velocity When the position or velocity error exceeds the programmed tracking window value a status word bit is set The bit is not reset until the error remain...

Page 55: ...switches and the motor temperature sensor Debounce Time To prevent undesired multiple triggering caused by switch bounce upon switch closures each input can be programmed with a debounce time The prog...

Page 56: ...ral purpose and HS high speed Input reference functions such as Pulse and Direction Pulse Up Pulse Down and Quadrature A B are wired to inputs that have the HS filters and inputs with the GP filters a...

Page 57: ...ndicator turns red Default behavior If after re enabling the amp the limit switch is still active the drive will only allow movement in the opposite direction Hold position behavior If the Hold positi...

Page 58: ...ound to source or sink current The output current rating is 20 mA The brake output OUT6 is described below in Brake Operation There is one programmable analog output AOUT1 It has an output voltage ran...

Page 59: ...rake Stop Activation Velocity OR the Brake Stop Delay Time expires the brake output activates and PWM Delay Brake Stop Response Time count begins When response time has passed the drive s output stage...

Page 60: ...d the brake will be released after the programmable time expires Motor Brake Enable Delay Time The programmable value in the Motor Wiring Detection also sets the time between the activation of the bra...

Page 61: ...regen resistor to dissipate the regen energy so that the internal bus voltage is limited to a value that permits the continued operation of the drive PWM outputs Regen Circuit Components The drive pr...

Page 62: ...240 Vac 75J 43J 32 J Step 3 Divide the regen energy by the continuous power rating of 20 Watts to get the dwell time that can dissipate the regen energy in the resistor Dwell Time 32 Joules 20 Watts 1...

Page 63: ...external regen resistor For electrical safety reasons and for all Xenus Plus Dual models the specified mating plug must always be plugged into and secured to J2 regardless of whether a regen resistor...

Page 64: ...l Regen Resistor 67 3 7 Digital Command Inputs 68 3 8 Analog Inputs 68 3 9 Digital Inputs 69 3 10 Analog Outputs 70 3 11 Digital Outputs 70 3 12 Encoder Power Outputs 71 3 13 Primary Encoder Inputs 71...

Page 65: ...L 230 36 40 R XPL 230 36 40 R XML 230 36 40 R XEL 230 40 R N XPL 230 40 R N XML 230 40 R N 800 1819 800 1887 800 1818 Mains Voltage 100 240 Vac 1 or 3 Mains Frequency 47 to 63 Hz Max Mains Current 1 1...

Page 66: ...1 Second Continuous Current 6 Adc 4 24 Arms 12 Adc 8 5 Arms 20 Adc 14 1 Arms 10 Adc 7 Arms 4 5 Adc 3 18 Arms Efficiency 97 230 Vac and rated continuous current Output Type 3 phase IGBT inverter 16 kH...

Page 67: ...Model XEL 230 18 R XPL 230 18 R XML 230 18 R XEL 230 36 40 R XPL 230 36 40 R XML 230 36 40 R XE2 230 20 R N XP2 230 20 R N XM2 230 20 R N 800 1818 800 1887 800 1818 Continuous Power 2 kW 4 kW 4 kW 4 k...

Page 68: ...Differential non isolated Single ended Measurement Range 10 Vdc 0 5 Vdc Maximum Voltage Differential Input to Ground 10 Vdc 10 Vdc 10 Vdc 10 Vdc Input Impedance 5 k 4 99 k pull up to 5V Resolution 16...

Page 69: ...differential pairs as digital command inputs XE2 XP2 XM2 800 1818 800 1819 800 1887 Channels XE2 XP2 XM2 800 1818 22 IN1 IN22 800 1819 800 1887 20 IN1 IN20 IN1 11 21 22 IN2 5 12 15 IN6 9 16 19 IN10 2...

Page 70: ...de to 24V Maximum Voltage 40 Vdc 5Vdc 30Vdc 32 Vdc Maximum Sink Current 1 Adc 32 mA 20 mA 1 Adc Low Level Output Resistance 0 2 Not applicable Rout only applies to MOSFET outputs Not applicable Rout o...

Page 71: ...nt sec Function Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation X is equivalent to Marker Index or Z channels depending on the...

Page 72: ...r or resolver required for sinusoidal commutation and position or velocity modes of operation XE2 XP2 XM2 800 1818 Channels 4 Type Differential non isolated Signals Sin Sin Cos Cos for each axis Nomin...

Page 73: ...ors in trapezoidal mode Commutation initialization and phase error detection in sinusoidal mode XE2 XP2 XM2 800 1818 Channels 6 U V and W for each axis Type 74HC14 Schmitt trigger w RC Filter 10 k pul...

Page 74: ...encoder or resolver required for sinusoidal commutation and position or velocity modes of operation XE2 XP2 XM2 Channels 6 Type Transmit 1 1 to 2 1 transformation ratio Signals Ref Ref Sin Sin Cos Cos...

Page 75: ...5 MHz 50 Duty Cycle 5 MHz Line 20 Mcount sec XE2 XP2 XM2 800 1818 800 1819 800 1887 Channels 8 Type Bi Directional Differential RS 422 Non isolated Signals A A B B X X S S for each axis Input Voltage...

Page 76: ...p or reset Data Format N 8 1 Flow Control None Protocol Binary or ASCII format Function Set up control and diagnostics status XE2 XP2 XM2 800 1818 800 1819 800 1887 Channels 1 Type RS 232 DTE Signals...

Page 77: ...ported Modes Cyclic Synchronous Position Velocity Profile Current Velocity and Position PVT Position Velocity Time and Homing Torque current Velocity Node Address Selection Slaves are automatically as...

Page 78: ...dicators p 38 Model XE2 800 1818 800 1819 800 1887 XP2 XM2 LED Network Status RUN EtherCAT State Machine ESM status per ETG 1300 S R V1 0 1 ERR Error status warnings L A Link Act shows state of the Et...

Page 79: ...ion Model XEL 230 18 R XPL 230 18 R XML 230 18 R XEL 230 36 R XPL 230 36 R XML 230 36 R XEL 230 40 R XPL 230 40 R XML 230 40 R Output Power Mains Voltage Maximum Continuous 120 Vac 30 W 55 W 92 W 240...

Page 80: ...6 mm X 3 59 in 91 1 mm XE2 XP2 XM2 N models 800 1818 800 1887 9 24 in 234 7 mm X 5 57 in 141 6 mm X 2 31 in 58 7 mm Weight XE2 XP2 XM2 non N models 800 1819 4 19 lb 1 90 kg XE2 XP2 XM2 N models 800 18...

Page 81: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 81 3 25 Dimensions 3 25 1 XEL XPL Dimensions 3 25 2 XML Dimensions...

Page 82: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 82 3 25 3 XE2 XP2 XM2 non N models 800 1819 Dimensions...

Page 83: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 83 3 25 4 XE2 XP2 XM2 N models 800 1818 800 1887 Dimensions 3 25 5 Dimensions with Heatsink Kit Installed...

Page 84: ...tor connections Contents include 4 1 General Wiring Instructions 85 4 2 AC Mains J1 88 4 3 Motor s 91 4 4 Regen Resistor Optional 93 4 5 Logic Supply Brake 96 4 6 Ferrules XE2 XP2 XM2 800 1819 98 4 7...

Page 85: ...ended Failure to heed this warning may cause equipment damage WARNING Do not ground mains connected circuits Do not ground Mains connected circuits J1 J2 J3 and J4 for XE2 XP2 XM2 800 1818 800 1819 80...

Page 86: ...live in the event of an insulation failure Protective earth connections for the motor and regen resistor housings are subject to local electrical codes and must be reviewed for compliance with those...

Page 87: ...06 Copley Controls 87 Connector Locations Connector locations for 1 axis models are shown below XEL XPL XML Connector locations for 2 axis models are shown below Note J12 is on the upper end panel XE2...

Page 88: ...V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 Connector and tool are included in Connector Kits XEL CK XML CK and XPL CK Pin Description Pin Signal Function...

Page 89: ...or L2 3 PE ground Chassis safety ground 4 Frame ground Frame ground 5 L3 AC power input L3 AC Mains Fuse Recommendation All Xenus Plus models Recommended fuse type Class CC 600 Vac rated Ferraz Shawmu...

Page 90: ...te and earth equipment frame as short as possible An unplated tab on the drive heatplate is provided for making this connection This tab also provides a connection point for a second protective earthi...

Page 91: ...36 A and 40 A models 12 AWG 600 V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in Connector Kits XEL CK XML CK and XP...

Page 92: ...12 AWG 600 V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 or 231 291 Standard connector and tool are included in Connector Kits XE2 CK XM2 CK and XP2 CK Pin De...

Page 93: ...r and tool are included in Connector Kits XEL CK XML CK and XPL CK Pin Description Pin Signal Function 1 Regen DC Bus to one side of regen resistor 2 N C No connection 3 Regen Collector of regen trans...

Page 94: ...le terminal block Manufacturer PN Wago 231 303 107 000 Wire Size 22 12 AWG Recommended Wire 12 AWG 600 V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 or 231 29...

Page 95: ...Fusing External Regen Resistor Recommended Fuses Regen Resistor Fuse type XTL RA 03 Cooper Bussman KLM 8 Littelfuse KLKD008 Ferraz Shawmut ATM 10 or equivalent XTL RA 04 Cooper Bussman KLM 12 Littelfu...

Page 96: ...Wago 721 103 026 047 Wire Size 22 14 AWG Recommended Wire 18 AWG Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in Connector Kits XEL CK XML CK and XPL CK Pin De...

Page 97: ...CK XP2 CK and XM2 CK Pin Description Pin Signal Function 1 RTN 24 Vdc Logic power supply return 2 Brake B Return or low side of motor brake B 3 Brake A Return or low side of motor brake A 4 Brake 24 V...

Page 98: ...Mfgr PNUM A B C D E SL 2 x 18 2 x 1 0 Red Altech 2776 0 15 4 61 8 2 32 2 4 09 3 2 13 5 8 23 11 0 43 2 x 18 2 x 1 0 Gray Altech 2775 0 14 6 57 8 2 32 2 0 08 3 0 12 5 5 22 11 0 43 2 x 20 2 x 0 75 White...

Page 99: ...on Pin Signal Function 1 Frame Ground Cable shield connection 2 MTO 1 High Side MTO inputs 3 MTO 1 4 MTO 2 Low Side MTO inputs 5 MTO 2 6 MTO LED PWM outputs state LED outputs 7 MTO LED 8 MTO GND Signa...

Page 100: ...ion transformer 4 7 3 MTO Power Requirements The 24V power supply for the MTO inputs must be SELV or PELV rated The 24V power supply for the drive control power must be SELV or PELV rated 4 7 4 MTO Wi...

Page 101: ...ts of output contacts One set K1 K2 responds immediately to changes on the safety relay inputs and the other K3 K4 after a user switch programmable delay A double pole single throw E stop switch is us...

Page 102: ...llows time for the drive to remain in an enabled state while it performs a controlled deceleration that brings the motor to a standstill before the MTO function is activated preventing any torque prod...

Page 103: ...uld have crimp and poke contacts with gold flash or plating and jack screws This is an example of a cable connector that is suitable for the XEL XPL XML drives Housing AMP Tyco PN 205204 4 D Sub 9M ti...

Page 104: ...8 2 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 STO 1 STO 1 Input 3 STO 1 4 STO 2 STO 2 Input 5 STO 2 6 STO 1 STO 1 Input Pins 2 6 and pins 3 7 are connected together...

Page 105: ...age is enabled producing torque in the motor If the STO feature is not used these connections must be made in order for the Xenus Plus to be enabled It is important to note that the XE2 XP2 XM2 800 18...

Page 106: ...le connector is shown below Pin Description Pin Signal Function 1 N C No connection 2 RxD Receive data input from computer 3 Signal ground Power supply ground 4 Signal ground Power supply ground 5 TxD...

Page 107: ...is the last node on a network only the IN port is used No terminator is required on the OUT port Pin Description Pin Signal Function 1 TX Transmit data 2 TX Transmit data 3 RX Receive data 4 5 6 RX R...

Page 108: ...CAN_Gnd Ground 0 V V 4 No connection 5 Pass through to second connector no internal connection 6 CAN_SHLD Pass through to second connector no internal connection 7 CAN_Gnd Ground 0 V V 8 CAN V Pass th...

Page 109: ...ockets shown below accept standard optical fiber The IN port connects to a master or to the OUT port of a device that is upstream between the XML XM2 and the master The OUT port connects to downstream...

Page 110: ...le shield connection 2 Ref AIN1 Analog command positive input single analog 3 Ref AIN1 Analog command negative input single analog 4 IN1 Enable 5 IN2 Programmable input 6 IN3 Mode dependent See Mode D...

Page 111: ...cated Inputs These inputs are dedicated to specific functions depending on operating mode Mode Selected Command Source Function Digital Input Single Ended Digital Input Differential Multi Mode Port Cu...

Page 112: ...ply Motion Controller 5 Vdc 1 K J8 OUT1 OUT2 OUT3 HS Signal Ground Relay Lamp Typical Output Loads Flyback diode required for inductive loads 5 Vdc J8 18 R 32 mA NC7SZ125 J8 23 Drive Typical Circuit J...

Page 113: ...enus Plus User Guide 16 01344 Rev 06 Copley Controls 113 Analog Input Wiring Diagram Analog Output Wiring Diagram J8 9 J8 15 J8 1 40 2 K A Out Drive J8 Sgnd 6 5V 6 5V 100 1V Measurement Frame gnd Sgnd...

Page 114: ...n 1 Frame Ground Cable shield connection 2 COMM_A Common signal for first group of optically isolated programmable inputs 3 IN7 GPI Optically isolated programmable input 4 IN8 GPI 5 IN9 GPI 6 IN10 GPI...

Page 115: ...am J9 J9 2 J9 3 J9 4 J9 5 J9 6 COMM_A IN7 4 99 K IN8 4 99 K IN9 4 99 K IN10 4 99 K 24V 24V GND 5 1V 5 1V 5 1V 5 1V Opto isolators 4 7 K 4 7 K 4 7 K 4 7 K J9 J9 7 J9 8 J9 9 J9 10 J9 11 COMM_B IN11 4 99...

Page 116: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 116 Optically Isolated Programmable Outputs Wiring Diagram...

Page 117: ...n 1 Frame Ground Cable shield connection 2 AIN1 Analog command negative input single analog 3 AIN1 Analog command positive input single analog 4 AIN2 Analog command negative input single analog 5 AIN2...

Page 118: ...round Signal ground reference for inputs and outputs 38 B 5Vdc Out4 39 B MultiEnc S Programmable differential input output port 40 B MultiEnc X 41 B MultiEnc B 42 B MultiEnc A 43 N C 44 Signal ground...

Page 119: ...ti Mode Port Current Velocity PWM 50 IN 14 IN12 IN13 A A PWM Input Current Velocity PWM 100 IN 14 IN12 IN13 A A PWM Input IN 15 IN14 IN15 B B Direction Input Position Pulse Direction IN 14 IN12 IN13 A...

Page 120: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 120 Analog Input Wiring Diagram Multi Mode Port Interface Diagram...

Page 121: ...Signal Function 1 Frame Ground Cable shield connection 2 IN6 GPI Optically isolated programmable input 3 IN7 GPI 4 IN8 GPI 5 IN9 GPI 6 COM1 Common signal for first group of optically isolated program...

Page 122: ...isolated programmable input 8 IN17 GPI 9 IN18 GPI 10 OUT1 GPI Optically isolated programmable output negative signal 11 OUT2 GPI 12 OUT3 GPI 13 S1_A S1_A S4_A signals are outputs driven by 453 ohm re...

Page 123: ...P2 XM2 800 1818 J9 J9 6 J9 2 J9 3 J9 4 J9 5 COM1 IN6 4 99 K IN7 4 99 K IN8 4 99 K IN9 4 99 K 24V 24V GND 5 1V 5 1V 5 1V 5 1V Opto isolators 4 7 K 4 7 K 4 7 K 4 7 K J9 J9 17 J9 7 J9 8 J9 9 J9 18 COM2 I...

Page 124: ...uide 16 01344 Rev 06 Copley Controls 124 Optically Isolated Programmable Inputs Wiring Diagram 800 1819 800 1887 Note Wiring diagram for IN6 IN9 on the 800 1819 and 800 1887 is the same as for the XE2...

Page 125: ...ically Isolated Programmable Outputs Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 800 1887 J9 Wiring Signal Pins Signal Pins OUT1 19 OUT1 10 OUT2 20 OUT2 11 OUT3 21 OUT3 12 OUT4 22 OUT4 13 OUT5 23 OUT...

Page 126: ...is drive has one feedback connector J10 The Xenus Plus Dual Axis drive has two feedback connectors J10 and J11 All feedback connectors have identical wiring specifications with the exception of the 80...

Page 127: ...XML models Digital input on the XE2 XP2 XM2 800 1818 models 8 Encoder X1 Input Primary incremental encoder inputs 9 Encoder X1 Input 10 Encoder B1 Input 11 Encoder B1 Input 12 Encoder A1 Input 13 Enc...

Page 128: ...in 20 S4 Cos Resolver Cos inputs 21 S2 Cos 22 R2 Ref Resolver Ref inputs 23 R1 Ref 24 IN15 XEL XPL XML IN21 IN22 XE2 XP2 General purpose input IN21 is on J10 IN22 is on J11 25 Signal Ground Signal and...

Page 129: ...23 Resolver Ref Resolver Ref inputs 24 N C No connection 25 Signal ground Signal and 5 Vdc ground 26 Signal ground Signal and 5 Vdc ground Quad A B Incremental Encoder Wiring Diagram In XEL XPL XML th...

Page 130: ...XML there are two encoder 5V outputs at 400 mA each and in the XE2 XP2 XM2 800 1818 there are 4 encoder 5V outputs at 500 mA each J10 2 J10 3 J10 4 J10 1 J10 6 J10 5 Typical Circuit 5 V 400 mA 5 Vdc 1...

Page 131: ...puts at 400 mA each and in the XE2 XP2 XM2 800 1818 there are 4 encoder 5V outputs at 500 mA each J10 19 J10 18 J10 21 J10 20 J10 1 Frame Gnd Analog Encoder Case Ground SIN SIN COS COS SIN SIN COS COS...

Page 132: ...344 Rev 06 Copley Controls 132 Resolver Wiring Diagram Resolver Wiring Diagram 800 1819 800 1887 J10 23 J10 22 J10 21 J10 20 J10 1 Frame Gnd Resolver Case Ground REF REF COS COS R1 R2 S2 S4 Drive J10...

Page 133: ...Over Temperature Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 800 1887 General Purpose Input Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 800 1887 J10 7 Drive J10 J10 5 27 Hz LPF 12 bit A D Thermisto...

Page 134: ...or characteristics would be for a given application For an overview of regeneration and regen resistors see Regen Resistor Theory p 61 To configure a custom regen resistor see the CME User Guide Addit...

Page 135: ...motor 5 Resistance line to line of the motor windings For rotary motor applications gather this additional information 1 Load inertia seen by the motor 2 Inertia of the motor For linear motor applica...

Page 136: ...termine the Amount of Energy Dissipated by the Motor Calculate the amount of energy dissipated by the motor due to current flow though the motor winding resistance using the following formulas Pmotor...

Page 137: ...sipated in the regen resistor in Joules Ereturned Energy delivered back to the drive from the motor in Joules Eamp Energy that the drive will absorb in Joules A 1 8 Calculate Pulse Power of Each Decel...

Page 138: ...uivalent should be selected The peak and continuous currents as well as the peak current time must be taken into consideration for proper fuse selection The duration of the peak current is the deceler...

Page 139: ...The current loop I2T limit specifies the maximum amount of time that the peak current can be applied to the motor before it must be reduced to the continuous limit or generate a fault This chapter de...

Page 140: ...tor Variable at a rate related to the output current Sampling Frequency The value of the I2T Accumulator Variable is incrementally increased for output currents greater than the Continuous Current Lim...

Page 141: ...aveforms The algorithm essentially calculates the RMS value of the output current and thus operates the same way regardless of the output current frequency and wave shape A B At time 0 plot diagram A...

Page 142: ...tinuous current limit is zero At approximately 3 5 seconds the commanded current falls below the continuous current limit and once again the output current follows the commanded current Because the ac...

Page 143: ...X C THERMAL CONSIDERATIONS This chapter describes operating temperature characteristics heatsink options and heatsink mounting instructions Contents include C 1 Operating Temperature and Cooling Confi...

Page 144: ...e operation at 55 C 1 2 3 4 5 6 20 30 40 50 60 Ambient Temperature C No Heatsink 3 Continious Output Current Adc Standard Heatsink w fan Low Profile Heatsink w fan Standard Heatsink Low Profile Heatsi...

Page 145: ...odels Due to the fan and heatsink integrated into their design the XE2 XP2 XM2 800 1819 models can operate at full load conditions both axes simultaneously over the full specified operating range Care...

Page 146: ...Model 800 1818 The following chart shows the maximum allowable ambient temperature as a function of output current for the model 800 1818 drive Data is given for two different mounting configurations...

Page 147: ...n contact with the mounting surface and the large side of the heatplate is exposed The heatsink data is taken with heatsink fins running vertically When fan cooling is used vertical mounting is not ne...

Page 148: ...tective sheet from one side of the pad Place the interface pad on the drive taking care to center the pad holes over the heatsink mounting holes Remove the clear protective sheet from the pad Mount th...

Page 149: ...ace Orient the heatsink so that the edge with part number is away from you The hole for the Xenus Plus Dual grounding lug should be to your left 2 Remove the clear protective film from the thermal mat...

Page 150: ...er Guide 16 01344 Rev 06 Copley Controls 150 APPENDIX D XENUS PLUS FILTER This chapter provides an overview of the Model XTL FA 01 edge filter Contents include D 1 Overview 151 D 2 XTL FA 01 Edge Filt...

Page 151: ...al filter increases the rise time by at least a factor of 3 substantially reducing noise in the system Copley Controls drives typically have a 150 ns rise time high frequency component in the MHz rang...

Page 152: ...800 1819 800 1887 XEL XML XPL 230 18 or XEL XML XPL 230 36 drives the XTL FA 01 operates below maximum temperature values and thus requires no cooling fan When used with XEL XML XPL 40 drives running...

Page 153: ...Xenus Plus User Guide 16 01344 Rev 06 Copley Controls 153 D 1 5 XTL FA 01 Edge Filter Dimensions The following diagram shows the mounting dimensions of the XTL FA 01 Edge Filter...

Page 154: ...y or death DANGER Risk of electric shock High voltage circuits on Xenus Plus J1 J2 and J3 and on Filter J1 and J2 are connected to mains power Failure to heed this warning can cause equipment damage i...

Page 155: ...Description Pin Signal Function 1 Frame Ground Chassis ground and cable shield 2 Phase W Phase W input from drive 3 Phase V Phase V input from drive use for DC motor connection 4 Phase U Phase U inpu...

Page 156: ...er Wiring with Brush Motor This is an example for a Xenus Plus Single Axis drive For Xenus Plus Dual Axis connectors J3 or J4 on the drive are used for outputs to the filter D 2 8 XTL FA 01 Edge Filte...

Page 157: ...Copley Controls 157 APPENDIX E CONNECTING XPL XP2 FOR SERIAL CONTROL This chapter describes how to connect one or more XPL XP2 drives for control via the RS 232 bus on one of the drives Contents Inclu...

Page 158: ...et or power cycled to make the new address setting take effect E 1 3 Multi Drop Network Connections A serially connected XPL XP2 drive can be used as a multi drop gateway for access to other XPL XP2 d...

Page 159: ...ORIES This chapter lists part numbers for drives and accessories Contents include F 1 Drive Model Numbers 160 F 2 Accessory Model Numbers 163 F 3 Heatsink Kits 164 F 4 Regen Resistor Assemblies 165 F...

Page 160: ...Xenus Plus EtherCAT Servo drive 12 36 A with resolver feedback XEL 230 36 R HL Xenus Plus EtherCAT Servo drive 12 36 A with resolver feedback and factory fitted low profile heatsink XEL 230 36 R HS Xe...

Page 161: ...0 18 R HS Xenus Plus Standard Servo drive 6 18 A with resolver feedback and factory fitted standard heatsink XPL 230 36 R Xenus Plus Standard Servo drive 12 36 A with resolver feedback XPL 230 36 R HL...

Page 162: ...0 18 R HS Xenus Plus MACRO Servo drive 6 18 A with resolver feedback and factory fitted standard heatsink XML 230 36 R Xenus Plus MACRO Servo drive 12 36 A with resolver feedback XML 230 36 R HL Xenus...

Page 163: ...Connector High Density D Sub Male 26 position solder cup Norcomp 180 026 103L001 1 Backshell D Sub RoHS metalized for above Norcomp 939 015 020R121 XE2 XP2 XM2 800 1818 800 1819 800 1887 Model Qty Ref...

Page 164: ...XEL 1 ft 0 3 m XP2 NC 10 J8 CANopen network cable for XP2 10 ft 3 m XP2 NC 01 CANopen network cable for XP2 1 ft 0 3 m XP2 NC 10 J8 CANopen network cable for XP2 10 ft 3 m XP2 NC 01 CANopen network ca...

Page 165: ...ge Filter XTL FA 01 Edge Filter Connector Kit for all Xenus Plus models Model Qty Ref Description Mfr Model No XTL FK 1 J1 Plug 5 position 5 0 mm female Wago 721 104 026 047 1 J2 Plug 4 position 5 0 m...

Page 166: ...10 kW 1000 ms XEL XML XPL 230 36 XEL XML XPL 230 36 R XEL XML XPL 230 40t XEL XML XPL 230 40 R XE2 XP2 XM2 230 20 800 1818 800 1819 800 1887 XE2 XP2 XM2 230 20 R WARNING High Temperature Risk Setting...

Page 167: ...Xenus Plus User Guide 16 01344 Revision 06 August 30 2019 2019 Copley Controls Analogic Motion Controls 20 Dan Road Canton MA 02021 USA All rights reserved...

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