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2.2.1. Brushless Motor Connections

The configuration shown in

Figure 2-3

is an example of 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.

XL5e Hardware Manual

2.2.1. Brushless Motor Connections

www.aerotech.com

29

Содержание Automation1 XL5e

Страница 1: ...Revision 1 01 Automation1 XL5e High Performance Linear Digital Drive 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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 12: ...This page intentionally left blank Safety Procedures and Warnings XL5e Hardware Manual 12 www aerotech com...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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