Advantech Automation1 iXC4e User manual

Revision 2.02
Automation1 iXC4e and XC4e
PWMHigh-Performance Digital Drives
HARDWAREMANUAL

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This manual contains proprietary information and may not be reproduced, disclosed, or
used in whole or in part without the express written permission of Aerotech, Inc.
Product names mentioned herein are used for identification purposes only and may be
trademarks of their respective companies.
Copyright © 2018-2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 iXC4e and XC4e PWMHigh-Performance Digital Drives 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Agency Approvals 11
Safety Procedures and Warnings 13
Installation Overview 15
Chapter 1: Introduction 17
1.1. Electrical Specifications 21
1.1.1. System Power Requirements 22
1.2. Mechanical Specifications 23
1.2.1. Mounting and Cooling 23
1.2.2. Dimensions 24
1.3. Environmental Specifications 26
1.4. Drive and Software Compatibility 27
Chapter 2: Installation and Configuration 29
2.1. Input Power Connections 30
2.1.1. Control Supply Connector 30
2.1.2. Motor Supply Connector 31
2.1.3. Transformer Options 32
2.1.4. Minimizing Noise for EMC/CECompliance 39
2.2. Motor Power Output Connector 40
2.2.1. Brushless Motor Connections 41
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 42
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 43
2.2.2. DCBrush Motor Connections 44
2.2.2.1. DC Brush Motor Phasing 45
2.2.3. Stepper Motor Connections 46
2.2.3.1. Stepper Motor Phasing 47
2.3. Feedback Connector 48
2.3.1. Primary Encoder Inputs 49
2.3.1.1. Square WaveEncoder 50
2.3.1.2. Absolute Encoder 51
2.3.1.3. Sine Wave Encoder [-MX2/-MX3 Option] 52
2.3.1.4. Encoder Phasing 54
2.3.2. Hall-Effect Inputs 55
2.3.3. Thermistor Input 56
2.3.4. Encoder Fault Input 57
2.3.5. End of Travel and Home Limit Inputs 58
2.3.5.1. End of Travel and Home Limit Phasing 60
2.3.6. Brake Outputs 61
2.4. Safe Torque Off Input (STO) 62
2.4.1. STOStandards 64
2.4.2. STO Functional Description 65
2.4.3. STO Startup Validation Testing 66
2.4.4. STO Diagnostics 67
2.5. Auxiliary I/O Connector 68
2.5.1. Auxiliary Encoder Inputs 69
2.5.1.1. Square WaveEncoder 70
2.5.1.2. Absolute Encoder 71
2.5.1.3. Sine Wave Encoder [-MX3 Option] 72
2.5.2. Position Synchronized Output (PSO) 74
2.5.3. Digital Outputs 76
2.5.4. Digital Inputs 79
2.5.5. High-Speed Inputs 81
2.5.6. Analog Output 0 82
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2.5.7. Analog Input 0 (Differential) 83
2.6. Brake Power Supply Connector 84
2.7. HyperWire Interface 85
2.8. External Shunt Option [-SX1] 86
2.9. Sync Port 88
2.10. System Interconnection 89
2.11. PC Configuration and Operation Information 92
Chapter 3: -EB1 I/O Option Board 93
3.1. Digital Outputs [-EB1] 94
3.2. Digital Inputs [-EB1] 98
3.3. Analog Outputs [-EB1] 101
3.4. Analog Inputs [-EB1] 102
3.5. Position Synchronized Output Interface [-EB1] 103
Chapter 4: Cables and Accessories 105
4.1. Joystick Interface 106
4.2. Handwheel Interface 108
Chapter 5: Maintenance 109
5.1. Preventative Maintenance 110
5.2. Fuse Specifications 111
Appendix A: Warranty and Field Service 113
Appendix B: Revision History 115
Index 117
Table of Contents iXC4e/XC4e Hardware Manual
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List of Figures
Figure 1-1: iXC4e Digital Drive-Based Controller 17
Figure 1-2: XC4e Digital Drive 18
Figure 1-3: Functional Diagram 20
Figure 1-4: Dimensions 24
Figure 1-5: Dimensions [-EB1] 25
Figure 2-1: Control Supply Connections 30
Figure 2-2: Motor Supply Connections 31
Figure 2-3: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) 33
Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) 34
Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) 35
Figure 2-6: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) 36
Figure 2-7: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) 37
Figure 2-8: TM3/TM5 Transformer Control and Motor Power Wiring 38
Figure 2-9: Brushless Motor Configuration 41
Figure 2-10: Positive Motor Direction 42
Figure 2-11: Encoder and Hall Signal Diagnostics 42
Figure 2-12: Brushless Motor Phasing Oscilloscope Example 43
Figure 2-13: Brushless Motor Phasing Goal 43
Figure 2-14: DC Brush Motor Configuration 44
Figure 2-15: Positive Motor Direction 45
Figure 2-16: Stepper Motor Configuration 46
Figure 2-17: Positive Motor Direction 47
Figure 2-18: Square Wave Encoder Schematic (Feedback Connector) 50
Figure 2-19: Absolute Encoder Schematic (Feedback Connector) 51
Figure 2-20: Sine Wave Encoder Phasing Reference Diagram 52
Figure 2-21: Sine Wave Encoder Schematic (Feedback Connector) 53
Figure 2-22: Encoder Phasing Reference Diagram (Standard) 54
Figure 2-23: Position Feedback in the DiagnosticDisplay 54
Figure 2-24: Hall-Effect Inputs Schematic (Feedback Connector) 55
Figure 2-25: Thermistor Input Schematic (Feedback Connector) 56
Figure 2-26: Encoder Fault Input Schematic (Feedback Connector) 57
Figure 2-27: End of Travel and Home Limit Input Connections 59
Figure 2-28: End of Travel and Home Limit Input Schematic (Feedback Connector) 59
Figure 2-29: End of Travel and Home Limit Input Diagnostic Display 60
Figure 2-30: Brake Connected to the 25-Pin Feedback Connector (Typical) 61
Figure 2-31: Typical Configuration 63
Figure 2-32: STO Timing 67
Figure 2-33: Square Wave Encoder Interface (Aux I/OConnector) 70
Figure 2-34: Absolute Encoder Schematic (Auxiliary I/O Connector) 71
Figure 2-35: Sine Wave Encoder Phasing Reference Diagram 72
Figure 2-36: Sine Wave Encoder Schematic (Auxiliary I/OConnector) 73
Figure 2-37: PSOInterface 75
Figure 2-38: Digital Output Schematic (Aux I/OConnector) 77
Figure 2-39: Digital Outputs Connected in Current Sourcing Mode 78
Figure 2-40: Digital Outputs Connected in Current Sinking Mode 78
Figure 2-41: Digital Inputs Schematic (Aux I/OConnector) 79
Figure 2-42: Digital Inputs Connected to Current Sourcing Devices 80
Figure 2-43: Digital Inputs Connected to Current Sinking Devices 80
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Figure 2-44: High-Speed Inputs 81
Figure 2-45: Analog Output 0 Schematic 82
Figure 2-46: Analog Input 0 Schematic 83
Figure 2-47: Drive-Based System Wiring Drawing (Best Practice) 89
Figure 2-48: PC-Based System Wiring Drawing (Best Practice) 89
Figure 2-49: Drive-Based Controller System Interconnection (Best Practice) 90
Figure 2-50: PC-Based Controller System Interconnection (Best Practice) 91
Figure 3-1: -EB1 I/O Option Board Connectors (iXC4e shown) 93
Figure 3-2: Digital Outputs Schematic [-EB1] 96
Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 97
Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 97
Figure 3-5: Digital Inputs Schematic [-EB1] 99
Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 100
Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 100
Figure 3-8: Analog Output Typical Connection [-EB1] 101
Figure 3-9: Analog Input Typical Connection [-EB1] 102
Figure 3-10: PSO Output Sources Current 104
Figure 3-11: PSOOutput Sinks Current 104
Figure 3-12: PSO TTLOutputs Schematic 104
Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 106
Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 107
Figure 4-3: Handwheel Interconnection to Aux I/O Connector 108
Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 108
List of Figures iXC4e/XC4e Hardware Manual
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List of Tables
Table 1-1: Featuresand Options 19
Table 1-2: Electrical Specifications 21
Table 1-3: Mounting Specifications 23
Table 1-4: Environmental Specifications 26
Table 1-5: Drive and Software Compatibility 27
Table 2-1: Control Supply Wiring Specifications 30
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 30
Table 2-3: Motor Supply Connector Wiring Specifications 31
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 31
Table 2-5: Nominal Motor Operating Voltages / Required ACVoltages 32
Table 2-6: TransformerOptions 32
Table 2-7: Motor Power Output Connector Pinout 40
Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector 40
Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables 41
Table 2-10: Hall Signal Diagnostics 42
Table 2-11: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 44
Table 2-12: Wire Colors for Aerotech-Supplied Stepper Motor Cables 46
Table 2-13: Feedback Connector Pinout 48
Table 2-14: Mating Connector Part Numbers for the Feedback Connector 48
Table 2-15: Multiplier Options 49
Table 2-16: Primary Encoder Input Pins on the Feedback Connector 49
Table 2-17: Square Wave Encoder Specifications 50
Table 2-18: Sine Wave Encoder Specifications 52
Table 2-19: Hall-Effect Feedback Pins on the Feedback Connector 55
Table 2-20: Thermistor Input Pin on the Feedback Connector 56
Table 2-21: Encoder Fault Input Pin on the Feedback Connector 57
Table 2-22: End of Travel and Home Limit Pins on the Feedback Connector 58
Table 2-23: Brake Output Pins on the Feedback Connector 61
Table 2-24: Brake Control Specifications 61
Table 2-25: STO Connector Pinout 62
Table 2-26: Mating Connector Part Numbers for the STOConnector 62
Table 2-27: STOElectrical Specifications 63
Table 2-28: STOStandards 64
Table 2-29: STOStandards Data 64
Table 2-30: STOSignal Delay 66
Table 2-31: Motor Function Relative to STOInput State 66
Table 2-32: STOTiming 67
Table 2-33: Auxiliary I/O Connector Pinout 68
Table 2-34: Mating Connector Part Numbers for the Auxiliary I/OConnector 68
Table 2-35: Auxiliary Encoder Pins on the Auxiliary I/OConnector 69
Table 2-36: Square Wave Encoder Specifications 70
Table 2-37: Sine Wave Encoder Specifications 72
Table 2-38: PSO Specifications 74
Table 2-39: PSOPins on the Auxiliary I/OConnector 74
Table 2-40: Digital Output Specifications 76
Table 2-41: Digital Output Pins on the Auxiliary I/O Connector 76
Table 2-42: Digital Input Specifications 79
Table 2-43: Digital Input Pins on the Auxiliary I/O Connector 79
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Table 2-44: High-Speed Input Specifications 81
Table 2-45: High-Speed Input Pins on the Auxiliary I/O Connector 81
Table 2-46: Analog Output Specifications 82
Table 2-47: Analog Output Pins on the Auxiliary I/O Connector 82
Table 2-48: Analog Input Specifications 83
Table 2-49: Analog Input Pins on the Auxiliary I/O Connector 83
Table 2-50: Brake Power Supply Connector Pinout 84
Table 2-51: Mating Connector Part Numbers for the Brake Power Supply Connector 84
Table 2-52: HyperWire Card Part Number 85
Table 2-53: HyperWire Cable Part Numbers 85
Table 2-54: -SX1Component Information 86
Table 2-55: Maximum Additional Storage Energy for a Standard iXC4e/XC4e 87
Table 2-56: Sync-Related Functions 88
Table 2-57: SyncPort Cables 88
Table 3-1: Digital Output Specifications [-EB1] 94
Table 3-2: Digital Output 1 Connector Pinout [-EB1] 95
Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] 95
Table 3-4: Digital Output 2 Connector Pinout [-EB1] 95
Table 3-5: Mating Connector Part Numbers for the Digital Output 2 Connector [-EB1] 95
Table 3-6: Digital Input Specifications [-EB1] 98
Table 3-7: Digital Input 1 Connector Pinout [-EB1] 98
Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] 98
Table 3-9: Digital Input 2 Connector Pinout [-EB1] 99
Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] 99
Table 3-11: Analog Output Specifications [-EB1] 101
Table 3-12: Analog Output Connector Pinout [-EB1] 101
Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] 101
Table 3-14: Differential Analog Input Specifications [-EB1] 102
Table 3-15: Analog Input Connector Pinout [-EB1] 102
Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] 102
Table 3-17: PSO Specifications [-EB1] 103
Table 3-18: PSO Interface Connector Pinout [-EB1] 103
Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 103
Table 4-1: Standard Interconnection Cables 105
Table 5-1: LEDDescription 109
Table 5-2: Troubleshooting 109
Table 5-3: Preventative Maintenance 110
Table 5-4: Control Board Fuse Specifications 111
List of Tables iXC4e/XC4e Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXC4e/XC4e
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of
the following directive(s):
2014/30/EU Electromagnetic Compatibility (EMC)
2014/35/EU Low Voltage Directive
2006/42/EC Machinery Directive
2011/65/EU RoHS 2 Directive
EU 2015/863 Amendment RoHS 3 Directive
and has 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 61010-1:2010/A1:2016 Safety Requirements for Electrical Equipment
EN 61800-3:2004/A1:2011 EMCRequirements for Power Drives
IEC 61800-5-1:2016 Electrical Safety for Power Drive Systems
IEC 61800-5-2:2016 Functional Safety for Power Drive Systems
EN 55011:2000/A2:2003 Conducted and Radiated Emissions
EN 55022:1998 Conducted and Radiated Emissions
Authorized
Representative / Simon Smith, European Director
Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Engineer Verifying
Compliance / Alex Weibel
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Date 7/2/2021
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Agency Approvals
Aerotech tested its XC4e drives and found that they obey the standards that follow:
IMPORTANT: iXC4e certification is pending.
Approval: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8V 068995 0028 Rev. 02
Standards: CAN/CSA-C22.2 No. 61010-1:2012,
EN 61010-1:2010/A1:2016,
UL 61010-1:2012
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 (up to SIL3),
IEC 61508-2:2010 (up to SIL3),
IEC 61800-5-2:2016,
IEC 62061:2005 (up to SILCL3),
IEC 62061:2005/AMD1:2012 (up to SILCL3),
IEC 62061:2005/AMD2:2015 (up to SILCL3)
Visit https://www.tuev-sued.de/product-testing/certificates to view Aerotech's TÜV SÜD certificates.
Type the certificate number listed above in the search bar or type "Aerotech" for a list of all Aerotech
certificates.
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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
drive.
lRead all parts of this manual before you install or operate the drive or before you do
maintenance to your system.
lTo prevent injury to you and damage to the equipment, obey the precautions in this
manual.
lAll specifications and illustrations are for reference only and were complete and accurate
as of the release of this manual. To find the newest information about this product,
refer to www.aerotech.com.
If you do not understand the information in this manual, contact Aerotech Global
Technical Support.
IMPORTANT: This product has been designed for light industrial manufacturing or
laboratory environments. If the product is used in a manner not specified by the
manufacturer:
lThe protection provided by the equipment could be impaired.
lThe life expectancy of the product could be decreased.
DANGER: To decrease the risk of electrical shock, injury, death, and damage to the
equipment, obey the precautions that follow.
1. Before you do maintenance to the equipment, disconnect the electrical power.
2. Restrict access to the drive 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 power source.
4. Wait at least ten (10) minutes after removing the power supply before doing main-
tenance or an inspection. Otherwise, there is the danger of electric shock.
5. Supply each operator with the necessary protection from live electrical circuits.
6. Make sure that all components are grounded correctly and that they obey the local elec-
trical safety requirements.
7. Install the necessary precautions to supply safety and protection to the operator.
DANGER: System travel can cause crush, shear, or pinch injuries. Restrict access to all
motor and stage parts while your system is connected to a power source.
WARNING: To prevent damage to the equipment and decrease the risk of electrical shock
and injury, obey the precautions that follow.
1. Make sure that all system cables are correctly attached and positioned.
2. Do not use the cables or the connectors to lift or move this product.
3. Use this product only in environments and operating conditions that are approved in
this manual.
4. Only trained operators should operate this equipment.
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Installation Overview
The images that follow show the order in which to make connections and settings that are typical to the
iXC4e/XC4e. If a custom interconnect drawing was supplied with your system, that drawing is on your
Storage Device and shows as a line item on your Sales Order in the Integration section.
1Connect the motor to the amplifier Motor Output connector. Section 2.2.
Connect the motor to the amplifier Feedback connector. Section 2.3.
2Connect the PCto the USB or Ethernet port. N/A
3Connect the next drive in the system to the HyperWire Out port. Section 2.7.
4Connect additional I/O as required by your application
(if you purchased the I/O option).
Section 2.5./
Chapter 3
5Connect the Safe Torque Off (STO). Section 2.4.
6Connect the power supply to the Control Supply connector. Section 2.1.1.
7Connect the motor power to the Motor Supply connector. Section 2.1.2.
Figure 1: Installation ConnectionOverviewfor the iXC4e
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1Connect the motor to the amplifier Motor Output connector. Section 2.2.
Connect the motor to the amplifier Feedback connector. Section 2.3.
2Connect a PCor drive-based controller HyperWire port to the HyperWire In
port. Section 2.7.
3Connect additional I/O as required by your application
(if you purchased the I/O option).
Section 2.5./
Chapter 3
4Connect the Safe Torque Off (STO). Section 2.4.
5Connect the power supply to the Control Supply connector. Section 2.1.1.
6Connect the motor power to the Motor Supply connector. Section 2.1.2.
Figure 2: Installation ConnectionOverviewfor the XC4e
Installation Overview iXC4e/XC4e Hardware Manual
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Chapter 1: Introduction
The iXC4e is a high-performance digital drive-based controller. It runs the Automation1-iSMC controller
to generate commands for itself as well as for additional drives on the chain.
The XC4e is a high performance digital drive. The XC4e is based on the HyperWire communication
protocol and receives commands from a PC or drive-based controller.
Both drives provide deterministic behavior, auto-identification, and are fully software configurable. A
double precision floating point DSP controls the digital PID and current loops. Both drives offer
standard Safe Torque Off (STO) inputs and optional Position Synchronized Output (PSO) outputs. And
both drives are offered with optional encoder interpolation features (-MX2/-MX3), an auxiliary encoder
input for dual loop control, dedicated analog and digital I/O (expandable with the -EB1 option), and
separate power connections for motor and control supply voltages.
Figure 1-1: iXC4e Digital Drive-Based Controller
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Figure 1-2: XC4e Digital Drive
Chapter 1: Introduction iXC4e/XC4e Hardware Manual
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Table 1-1: Featuresand Options
Standard Features
l100-240 VAC control supply inputs Section 2.1.1.
l0-240 VAC motor supply inputs (producing 340 VDC) Section 2.1.2.
lLine driver square wave quadrature encoder input for position and velocity feedback Section 2.3.1.
lAbsolute Encoder support on the Feedback Connector Section 2.3.1.2.
lOne fail-safe brake output Section 2.3.6.
lTwo STOsense inputs Section 2.4.
lLine driver square wave auxiliary quadrature encoder input or output for PSO Section 2.5.1.
lAbsolute Encoder support on the Auxiliary I/OConnector Section 2.5.1.2.
lFour digital user outputs Section 2.5.3.
lSix digital user inputs
nFour Digital Inputs Section 2.5.4.
nTwo High-Speed Inputs Section 2.5.5.
lOne 16-bit analog output (±10 V) Section 2.5.6.
lOne 16-bit differential analog input (±10 V) Section 2.5.7.
lOne 10/100/1000 BASE-T Ethernet Port iXC4e Only
lOne USB2.0 Type CPort iXC4e Only
Options
Peak Current Section 1.1.
-10 10 A Peak, 5 A Continuous Current
-20 20 A Peak, 10 A Continuous Current
-30 30 A Peak, 10 A Continuous Current
Expansion Board Chapter 3
-EB0 No expansion board
-EB1
I/Oexpansion board
lThree 16-bit analog outputs (±10 V)
lThree 16-bit differential analog inputs (±10 V)
l16 digital logic inputs (5 - 24 VDC); connect to current sourcing or sinking devices
l16 digital logic outputs (5 - 24 VDC); user defined as current sourcing or sinking
lDigital logic laser firing (PSO) output
Multiplier Section 2.3.1.3.
-MX0 No encoder multiplier
-MX2 Interpolation circuit allowing for analog sine wave input on the primary encoder channel with
an interpolation factor of 65,536.
-MX3
Interpolation circuit allowing for analog sine wave input on the primary encoder channel with
an interpolation factor of 65,536 and an auxiliary encoder channel with an interpolation factor
of 16,384.
PSO Section 2.5.2.
-PSO1 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 PSO firing, which uses the PSO firing circuit based off of the commanded
vector velocity of up to 2 axes (includes One-Axis PSO).
-PSO6 Three-axis Part-Speed PSO firing, which uses the PSO firing circuit based off of the commanded
vector velocity of 3 or more axes (includes One-Axis PSO).
External Shunt Section 2.8.
-SX0 No connector for the External Shunt
-SX1 Connection provided for an external shunt resistor network
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
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The block diagram that follows shows a summary of the connector signals.
Figure 1-3: Functional Diagram
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