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2.2.1. Brushless Motor Connections

The configuration in

Figure 2-3

shows a typical brushless motor connection.

Figure 2-3:

Brushless Motor Configuration

Table 2-7:

Wire Colors for Aerotech-Supplied Brushless Motor Cables 

Pin

Wire Color Set 1

(1)

Wire Color Set 2

Wire Color Set 3

Wire Color Set 4

Green/Yellow &

Shield

(2)

Green/Yellow &

Shield

Green/Yellow &

Shield

Green/Yellow &

Shield

A

Black

Blue & Yellow

Black #1

Black & Brown

B

Red

Red & Orange

Black #2

Red & Orange

C

White

White & Brown

Black #3

Violet & Blue

(1) Wire Color Set #1 is the wire set typically used by Aerotech.
(2) “&” indicates two wires (Red & Orange); “ / ” indicates a single wire (Green/White).

Brushless motors are 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 corresponding
Hall-effect signal. To ensure proper alignment, motor, Hall, and encoder connections should be
verified using one of the following methods:

powered

, through the use of a test program; or

unpowered

using an oscilloscope. Both methods will identify the A, B, and C Hall/motor lead sets and

indicate the correct connections to the controller. Refer to

Section 2.2.1.1.

for powered motor

phasing or

Section 2.2.1.2.

for unpowered motor and feedback phasing.

For Aerotech-supplied systems, the motor, encoder and Hall sensors are correctly configured and
connection adjustments are not necessary.

A motor filter module such as the MFM10 can be installed between the drive and the motor, which
will reduce the level of PWM amplifier related current spikes in the system.

Hardware Manual

iXC2/XC2

www.aerotech.com

31

Содержание Automation1 iXC2

Страница 1: ...Revision 2 05 Automation1 iXC2 and XC2 PWM Digital Drives HARDWARE MANUAL...

Страница 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...

Страница 3: ...ng 33 2 2 2 DC Brush Motor Connections 34 2 2 2 1 DC Brush Motor Phasing 34 2 2 3 Stepper Motor Connections 35 2 2 3 1 Stepper Motor Phasing 35 2 2 4 Three Phase Stepper Motor Connections 36 2 2 4 1 S...

Страница 4: ...EB2 Option Only 77 Chapter 4 Cables and Accessories 79 4 1 DIN Rail Mounting 80 4 2 Joystick Interface 81 4 3 Handwheel Interface 82 4 4 Dual PSO Adapter Cable 83 Chapter 5 Maintenance 85 5 1 Preventa...

Страница 5: ...Schematic Feedback Connector 44 Figure 2 21 Thermistor Input Schematic Feedback Connector 45 Figure 2 22 Encoder Fault Input Schematic Feedback Connector 46 Figure 2 23 End of Travel and Home Limit I...

Страница 6: ...ital Inputs Connected to Current Sinking NPN Devices EB1 76 Figure 4 1 Din Rail Clip Dimensions 80 Figure 4 2 Two Axis Joystick Interface 81 Figure 4 3 Handwheel Interconnection to the Aux Connector 8...

Страница 7: ...tor 44 Table 2 18 Thermistor Input Pin on the Feedback Connector 45 Table 2 19 Encoder Fault Input Pin on the Feedback Connector 46 Table 2 20 End of Travel and Home Limit Pins on the Feedback Connect...

Страница 8: ...71 Table 3 16 Digital Input Specifications EB1 74 Table 3 17 Digital Input Connector Pinout EB1 74 Table 3 18 Digital Input Mating Connector Ratings EB1 74 Table 4 1 Standard Interconnection Cables 7...

Страница 9: ...ndard s when installed and used in accordance with the manufacturer s supplied installation instructions EN 61010 1 2010 AMD1 2016 Safety Requirements for Electrical Equipment EN 61800 3 2004 A1 2011...

Страница 10: ...ponents STO certification is pending for the iXC2 Approval Safety Components STO Approving Agency TUV SUD Certificate Z10 068995 0030 Rev 00 Standards EN ISO 13849 1 2015 up to PL e IEC 61508 1 2010 u...

Страница 11: ...protection provided 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 r...

Страница 12: ...Make sure that 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 DA...

Страница 13: ...important information such as the l Customer order number please provide this number when requesting product support l Drawing number l System part number Handling IMPORTANT It is the responsibility...

Страница 14: ...tor to the amplifier Motor Output connector Section 2 2 Connect the motor to the amplifier Feedback connector Section 2 3 2 Connect the PC to the USB or Ethernet port N A 3 Connect the next drive in t...

Страница 15: ...drive based controller HyperWire port to the HyperWire In port Section 2 5 3 Connect additional I O as required by your application if you purchased the I O option Chapter 3 4 Connect the Safe Torque...

Страница 16: ...This page intentionally left blank iXC2 XC2 Hardware Manual 16 www aerotech com...

Страница 17: ...rformance digital drive The XC2 is based on the HyperWire communication protocol and receives commands from a PC or drive based controller Both drives provide deterministic behavior and auto identific...

Страница 18: ...Figure 1 2 XC2 High Performance PWM Amplifier iXC2 XC2 Hardware Manual 18 www aerotech com...

Страница 19: ...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...

Страница 20: ...The block diagram that follows shows a summary of the connector signals Figure 1 3 Functional Diagram iXC2 XC2 Hardware Manual 20 www aerotech com...

Страница 21: ...Control power supply under voltage Power stage bias supply under voltage 1 DC input voltage and load dependent 2 Dependent on total output power efficiency increases with increasing output power 1 1...

Страница 22: ...ign phase IMPORTANT The amount of airflow required to keep the drive temperature within a sufficient range is dependent on the operating conditions You could be required to supply additional airflow t...

Страница 23: ...1 2 2 Dimensions IMPORTANT iXC2 and XC2 dimensions are the same iXC2 is shown Figure 1 4 Dimensions EB0 Hardware Manual iXC2 XC2 www aerotech com 23...

Страница 24: ...IMPORTANT iXC2 EB1 EB2 and XC2 EB1 dimensions are the same iXC2 EB1 is shown Figure 1 5 Dimensions EB1 EB2 iXC2 XC2 Hardware Manual 24 www aerotech com...

Страница 25: ...s product above 2 000 m or below sea level contact Aerotech Inc Pollution Pollution Degree 2 Typically only nonconductive pollution occurs Operation Use only indoors 1 4 Drive and Software Compatibili...

Страница 26: ...This page intentionally left blank iXC2 XC2 Hardware Manual 26 www aerotech com...

Страница 27: ...e The 24V input is connected to an internal fuse Refer to Table 5 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...

Страница 28: ...igure 2 2 Figure 2 2 Motor Supply Connections Table 2 3 Motor Supply Connector Pinout Pin Description DC Motor Power Input 15 100 VDC 0 V Motor Power Input Common Protective Ground 0 75 mm2 18 AWG min...

Страница 29: ...O wiring 3 Mount drives 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 supply place...

Страница 30: ...ical shock The 7 pin terminal block style motor output connector is located on the front panel Table 2 5 Motor Power Output Connector Pinout Pin Description Connector Earth Ground to Motor A Brushless...

Страница 31: ...or 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 and encoder conne...

Страница 32: ...nals 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 2...

Страница 33: ...r 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 co...

Страница 34: ...e C motor terminal 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 termi...

Страница 35: ...stepper motor 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 i...

Страница 36: ...ith an Encoder Because the end of travel EOT limit inputs are relative to motor rotation it is important to phase the motor Run a positive motion command The motor is phased correctly if there is a po...

Страница 37: ...ess 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 Cosine Input 16 5V Power 1 Ou...

Страница 38: ...r Table 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...

Страница 39: ...signal 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 minimu...

Страница 40: ...ring for the highest performance and noise immunity You cannot echo an absolute encoder signal Refer to Figure 2 15 for the serial data stream interface Refer to the Help file for information on how t...

Страница 41: ...cannot 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 sh...

Страница 42: ...Figure 2 17 Sine Wave Encoder Schematic Feedback Connector 2 3 1 Primary Encoder Inputs iXC2 XC2 Hardware Manual 42 www aerotech com...

Страница 43: ...le observing the position of the encoder in the diagnostics display see Figure 2 19 For dual loop systems the velocity feedback encoder is displayed in the diagnostic display Figure 2 19 Figure 2 18 E...

Страница 44: ...ct device phasing 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...

Страница 45: ...mperature 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 th...

Страница 46: ...input is parameter 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 Encod...

Страница 47: ...polarity in the diagnostics display refer to Figure 2 25 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...

Страница 48: ...Figure 2 23 End of Travel and Home Limit Input Connections Figure 2 24 End of Travel and Home Limit Input Schematic Feedback Connector iXC2 XC2 Hardware Manual 48 www aerotech com...

Страница 49: ...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...

Страница 50: ...rake output 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 M...

Страница 51: ...uits between connector pins The primary concern is a short circuit between STO 1 IN and STO 2 IN wire strands Table 2 23 STO Connector Pinout Pin Signal Description In Out Bi Connector 1 Power Supply...

Страница 52: ...50 m Figure 2 27 shows 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 saf...

Страница 53: ...2010 SIL 3 EN 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 DCAV...

Страница 54: ...ll disable 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 fun...

Страница 55: ...TO 2 do not 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...

Страница 56: ...der to meet the 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...

Страница 57: ...controller 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 Pa...

Страница 58: ...2 6 System Interconnection Figure 2 29 Drive Based System Wiring Drawing Best Practice Figure 2 30 PC Based System Wiring Drawing Best Practice iXC2 XC2 Hardware Manual 58 www aerotech com...

Страница 59: ...Figure 2 31 Drive Based Controller System Interconnection Best Practice Hardware Manual iXC2 XC2 www aerotech com 59...

Страница 60: ...Figure 2 32 PC Based Controller System Interconnection Best Practice iXC2 XC2 Hardware Manual 60 www aerotech com...

Страница 61: ...guration and Operation Information For more information about hardware requirements PC configuration programming system operation and utilities refer to the Help file Hardware Manual iXC2 XC2 www aero...

Страница 62: ...This page intentionally left blank iXC2 XC2 Hardware Manual 62 www aerotech com...

Страница 63: ...s 8 digital outputs 1 analog input 1 analog output and PSO outputs The EB2 option board is only available on the iXC2 It has an auxiliary encoder PSO Outputs and two Industrial Ethernet ports not show...

Страница 64: ...utput Latency Fire event to output change TTL 5 ns Isolated 150 ns Table 3 2 PSO Interface Connector Pinout EB1 EB2 Pin Description In Out Bi Connector 1 PSO Output Output 2 PSO Output Output 3 PSO Ou...

Страница 65: ...e overload protected 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 si...

Страница 66: ...e 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 Bi Connector...

Страница 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...

Страница 68: ...d N A 6 Analog Output 0 Output Table 3 8 Analog I O Mating Connector Ratings EB1 Specification Description Type 6 Pin Terminal Block Part Numbers Aerotech ECK02405 Phoenix 1704755 Conductor Cross Sect...

Страница 69: ...u power on the system or reset the drive Table 3 9 Analog Output Specifications EB1 Specification Value Output Voltage 10 V to 10 V Output Current 5 mA Resolution bits 16 bits Table 3 10 Analog Output...

Страница 70: ...g common Refer to Figure 3 7 Table 3 11 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 rang...

Страница 71: ...26 V Maximum Maximum Sink Source Current 250 mA output Output Saturation Voltage 0 9 V at maximum current Output Resistance 3 7 Rise Fall Time 250 s 2K pull up to 24V Reset State Output Off High Impe...

Страница 72: ...Figure 3 8 Digital Outputs Schematic EB1 iXC2 XC2 Hardware Manual 72 www aerotech com...

Страница 73: ...Figure 3 9 Digital Outputs Connected in Current Sourcing Mode EB1 Figure 3 10 Digital Outputs Connected in Current Sinking Mode EB1 Hardware Manual iXC2 XC2 www aerotech com 73...

Страница 74: ...urrent Turn On Time Turn Off Time 5 V to 24 V 6 mA 10 s 43 s Table 3 17 Digital Input Connector Pinout EB1 Pin Description In Out Bi Connector 1 Input Common for Inputs 0 3 Output 2 Input 0 Optically...

Страница 75: ...Figure 3 11 Digital Inputs Schematic EB1 Hardware Manual iXC2 XC2 www aerotech com 75...

Страница 76: ...ed in an all sourcing or all sinking configuration Figure 3 12 Digital Inputs Connected to Current Sourcing PNP Devices EB1 Figure 3 13 Digital Inputs Connected to Current Sinking NPN Devices EB1 iXC2...

Страница 77: ...Industrial Ethernet ports IMPORTANT Industrial Ethernet is only available on the iXC2 EB2 Option l For the location of the ports refer to Figure 1 1 l For cable part numbers refer to Table 4 1 l For...

Страница 78: ...This page intentionally left blank iXC2 XC2 Hardware Manual 78 www aerotech com...

Страница 79: ...ection 4 2 Joystick Interface Handwheel Refer to Section 4 3 Handwheel Interface ECZ03125 3 and ECZ03125 9 Dual PSO Adapter Cable refer to Section 4 4 Dual PSO Adapter Cable C20934 XX or C20935 XX 1 B...

Страница 80: ...he DIN Rail 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...

Страница 81: ...ate unless 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...

Страница 82: ...e 5V differential 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...

Страница 83: ...4 4 Dual 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 Hardware Manual iXC2 XC2 www aerotech com 83...

Страница 84: ...This page intentionally left blank iXC2 XC2 Hardware Manual 84 www aerotech com...

Страница 85: ...ise there is 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...

Страница 86: ...nections are correctly attached and not loose Replace cables that are worn Replace all broken connectors Cleaning DANGER Before you clean the iXC2 XC2 disconnect the electrical power from the drive Us...

Страница 87: ...Materials Authorization 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...

Страница 88: ...eriods then special 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 sect...

Страница 89: ...y l Agency Approvals 2 01 Updated l Section 2 5 HyperWire Interface l Section 2 6 System Interconnection l Section 3 2 Auxiliary Encoder Interface EB1 EB2 2 00 General Update 1 02 The following sectio...

Страница 90: ...This page intentionally left blank iXC2 XC2 Hardware Manual 90 www aerotech com...

Страница 91: ...ncoder Connector Pinout 66 Auxiliary Encoder Input EB1 66 Auxiliary Encoder Input EB2 66 B BiSS absolute encoder 40 Brake Connected to the Feedback Connector 50 Brake Control Relay Specifications 50 B...

Страница 92: ...r specifications 21 Electrical Safety for Power Drive Systems 9 Electrical Specifications 21 Electromagnetic Compatibility EMC 9 EMC CE Compliance 29 Enclosure IP54 Compliant 22 encoder absolute 40 En...

Страница 93: ...ector 39 Square Wave Encoder Schematic EB1 67 Stepper Motor Configuration 35 STO Timing 56 Thermistor Input Schematic 45 Three Phase Stepper Motor Configuration 36 TTL Outputs Schematic PSO 65 Typical...

Страница 94: ...ector EB1 68 Analog Input Pins Analog I O Connector EB1 70 Analog Output Pins Analog I O Connector EB1 69 Brake Output Pins Feedback Connector 50 Control Supply Connector Wiring 27 Digital Input Conne...

Страница 95: ...ons Motor Power Output Connector 35 Stepper Motor Phasing 35 36 STO 51 Connector Pinout 51 Diagnostics 56 Electrical Specifications 52 External Delay Timer 54 Functional Description 54 Mating Connecto...

Страница 96: ...Index iXC2 XC2 Hardware Manual This page intentionally left blank 96 www aerotech com...

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