Aerotech XC2 User manual

Revision: 1.00.00
XC2 Hardware Manual

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Pittsburgh, PA 15238-2811
www.aerotech.com
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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
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Copyright © 2019, Aerotech, Inc., All rights reserved.

XC2 Hardware Manual Table of Contents
Table of Contents
XC2 Hardware Manual 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Safety Procedures and Warnings 11
Quick Installation Guide 13
Chapter 1: Introduction 15
1.1. Electrical Specifications 18
1.1.1. System Power Requirements 19
1.2. Mechanical Specifications 20
1.3. Environmental Specifications 22
1.4. Drive and Software Compatibility 23
Chapter 2: Installation and Configuration 25
2.1. Input Power Connections 25
2.1.1. Control Supply Connector 25
2.1.2. Motor Supply Connector 26
2.1.3. Minimizing Conducted,Radiated, and System Noise for EMC/CECompliance 27
2.2. Motor Power Output Connector 28
2.2.1. Brushless Motor Connections 29
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 30
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 31
2.2.2. DCBrush Motor Connections 32
2.2.2.1. DC Brush Motor Phasing 33
2.2.3. Stepper Motor Connections 34
2.2.3.1. Stepper Motor Phasing 35
2.3. Feedback Connector 36
2.3.1. Encoder Interface 37
2.3.1.1. RS-422 Line Driver Encoder 38
2.3.1.2. Absolute Encoder 39
2.3.1.3. Analog Encoder [-MX1 Option] 40
2.3.1.4. Encoder Phasing 42
2.3.2. Hall-Effect Interface 44
2.3.3. Thermistor Input Interface 45
2.3.4. Encoder Fault Input Interface 46
2.3.5. End of Travel Limit Input Interface 47
2.3.5.1. End of Travel Limit Phasing 49
2.3.6. Brake Output Interface 50
2.4. Safe Torque Off Input (STO) 51
2.4.1. STOStandards 53
2.4.2. STO Functional Description 53
2.4.3. STO Startup Validation Testing 54
2.4.4. STO Diagnostics 55
2.5. HyperWire Interface 56
2.6. PC Configuration and Operation Information 57
Chapter 3: -EB1 I/O Option Board 59
3.1. Position Synchronized Output (PSO) Interface [-EB1] 60
3.2. Auxiliary Encoder Channel [-EB1] 62
3.3. Analog I/O [-EB1] 64
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Table of Contents XC2 Hardware Manual
3.3.1. Analog Input (Differential) [-EB1] 65
3.3.2. Analog Output [-EB1] 66
3.4. Digital Inputs [-EB1] 67
3.5. Digital Outputs [-EB1] 69
Chapter 4: Cables and Accessories 73
4.1. DIN Rail Mounting 74
4.2. Joystick Interface 75
4.3. Handwheel Interface 76
Chapter 5: Maintenance 77
5.1. Preventative Maintenance 77
5.2. Fuse Specifications 78
Appendix A: Warranty and Field Service 79
Appendix B: Revision History 81
Index 83
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XC2 Hardware Manual List of Figures
List of Figures
Figure 1-1: XC2 High Performance PWMAmplifier 15
Figure 1-2: Functional Diagram 17
Figure 1-3: Dimensions 20
Figure 1-4: Dimensions [-EB1] 21
Figure 2-1: Control Supply Connections 25
Figure 2-2: Motor Supply Connections 26
Figure 2-3: Brushless Motor Configuration 29
Figure 2-4: Positive Motor Direction 30
Figure 2-5: Encoder and Hall Signal Diagnostics 30
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 31
Figure 2-7: Brushless Motor Phasing Goal 31
Figure 2-8: DC Brush Motor Configuration 32
Figure 2-9: Positive Motor Direction 33
Figure 2-10: Stepper Motor Configuration 34
Figure 2-11: Positive Motor Direction 35
Figure 2-12: Line Driver Encoder Schematic (Feedback Connector) 38
Figure 2-13: Absolute Encoder Schematic (Feedback Connector) 39
Figure 2-14: Analog Encoder Phasing Reference Diagram 40
Figure 2-15: Analog Encoder Schematic (Feedback Connector) 41
Figure 2-16: Encoder Phasing Reference Diagram (Standard) 42
Figure 2-17: Position Feedback in the DiagnosticDisplay 43
Figure 2-18: Hall-Effect Inputs Schematic (Feedback Connector) 44
Figure 2-19: Thermistor Input Schematic (Feedback Connector) 45
Figure 2-20: Encoder Fault Input Schematic (Feedback Connector) 46
Figure 2-21: End of Travel Limit Input Connections 48
Figure 2-22: End of Travel Limit Input Interface Schematic (Feedback Connector) 48
Figure 2-23: Limit Input Diagnostic Display 49
Figure 2-24: Brake Connected to the 25-Pin Feedback Connector (Typical) 50
Figure 2-25: Typical Configuration 52
Figure 2-26: STO Timing 55
Figure 3-1: XC2 with -EB1 I/O Option Board Connectors 59
Figure 3-2: PSO Output Sources Current 61
Figure 3-3: PSOOutput Sinks Current 61
Figure 3-4: PSO TTLOutputs Schematic 61
Figure 3-5: Auxiliary Encoder Interface 63
Figure 3-6: Analog Input Schematic [-EB1] 65
Figure 3-7: Analog Output Schematic [-EB1] 66
Figure 3-8: Digital Inputs Schematic [-EB1] 67
Figure 3-9: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 68
Figure 3-10: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 68
Figure 3-11: Digital Outputs Schematic [-EB1] 70
Figure 3-12: Digital Outputs Connected in Current Sourcing Mode [-EB1] 71
Figure 3-13: Digital Outputs Connected in Current Sinking Mode [-EB1] 71
Figure 4-1: Two Axis Joystick Interface 75
Figure 4-2: Handwheel Interconnection to the Aux Connector 76
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List of Figures XC2 Hardware Manual
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XC2 Hardware Manual List of Tables
List of Tables
Table 1-1: FeatureSummary 16
Table 1-2: Electrical Specifications 18
Table 1-3: Unit Weight 20
Table 1-4: Environmental Specifications 22
Table 1-5: Drive and Software Compatibility 23
Table 2-1: Control Supply Connector Wiring Specifications 25
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 25
Table 2-3: Motor Supply Connector Wiring Specifications 26
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 26
Table 2-5: Motor Power Output Connector Pinout 28
Table 2-6: Mating Connector Part Numbers for the Motor Power Output Connector 28
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 29
Table 2-8: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 32
Table 2-9: Wire Colors for Aerotech-Supplied Stepper Motor Cables 34
Table 2-10: Feedback Connector Pinout 36
Table 2-11: Mating Connector Part Numbers for the Feedback Connector 36
Table 2-12: Encoder Interface Pins on the Feedback Connector 37
Table 2-13: RS-422 Line Driver Encoder Specifications 38
Table 2-14: Analog Encoder Specifications 40
Table 2-15: Hall-Effect Feedback Pins on the Feedback Connector 44
Table 2-16: Thermistor Input Pin on the Feedback Connector 45
Table 2-17: Encoder Fault Input Pin on the Feedback Connector 46
Table 2-18: End of Travel Limit Input Pins on the Feedback Connector 47
Table 2-19: Brake Output Pins on the Feedback Connector 50
Table 2-20: Brake Control Specifications 50
Table 2-21: STO Connector Pinout 51
Table 2-22: Mating Connector Part Numbers for the STOConnector 51
Table 2-23: STOElectrical Specifications 51
Table 2-24: STOStandards 53
Table 2-25: STOStandards Data 53
Table 2-26: STOSignal Delay 54
Table 2-27: Motor Function Relative to STOInput State 54
Table 2-28: STOTiming 55
Table 2-29: HyperWire Card Part Number 56
Table 2-30: HyperWire Cable Part Numbers 56
Table 3-1: PSO Specifications [-EB1] 60
Table 3-2: PSO Interface Connector Pinout [-EB1] 60
Table 3-3: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 60
Table 3-4: Auxiliary Encoder RS-422 Specifications 62
Table 3-5: Auxiliary Encoder Connector Pinout 62
Table 3-6: Mating Connector Part Numbers for the AUX Connector 62
Table 3-7: AI/O Connector Pinout [-EB1] 64
Table 3-8: Mating Connector Part Numbers for the Analog I/O Connector [-EB1] 64
Table 3-9: Differential Analog Input Specifications [-EB1] 65
Table 3-10: Analog Input Pins on the Analog I/OConnector [-EB1] 65
Table 3-11: Analog Output Specifications [-EB1] 66
Table 3-12: Analog Output Pins on the Analog I/OConnector [-EB1] 66
Table 3-13: Digital Input Specifications [-EB1] 67
Table 3-14: Digital Input Connector Pinout [-EB1] 67
Table 3-15: Mating Connector Part Numbers for the Digital Input Connector [-EB1] 67
Table 3-16: Digital Output Specifications [-EB1] 69
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List of Tables XC2 Hardware Manual
Table 3-17: Digital Output Connector Pinout [-EB1] 69
Table 3-18: Mating Connector Part Numbers for the Digital Output Connector [-EB1] 69
Table 4-1: Standard Interconnection Cables 73
Table 4-2: Mounting Parts 74
Table 5-1: Preventative Maintenance 77
Table 5-2: Control Board Fuse Specifications 78
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XC2 Hardware Manual EU Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XC2
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
2011/65/EU RoHS2 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 61326-1:2013 EMCRequirements for Electrical Equipment
EN 61010-1:2010 Safety Requirements for Electrical Equipment
EN ISO 13849-1:2015 SafetyRelated Parts of Control Systems
Authorized Representative: Simon Smith, European Director
Address: Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date 5/3/2019
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PENDING

EU Declaration of Conformity XC2 Hardware Manual
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PENDING

XC2 Hardware Manual Safety Procedures and Warnings
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the XC2. Read all parts of this manual
before you install or operate the XC2 or before you do maintenance to your system. To prevent injury to you
and damage to the equipment, obey the precautions in this manual. The precautions that follow apply when
you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury to you or
damage to the equipment can occur. If you do not understand the information in this manual, contact
Aerotech Global Technical Support.
This product has been designed for light industrial manufacturing or laboratory environments. The protection
provided by the equipment could be impaired if the product is used in a manner not specified by the
manufacturer.
NOTE: All 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.
DANGER: The voltage from this product can kill you. To decrease the risk of electrical shock,
injury, and death, you must obey the precautions that follow.
1. Obey the information in this manual.
2. Before you do maintenance to the equipment, disconnect the electrical power.
3. Wait at least one (1) minute after removing the power supply before doing maintenance or an
inspection. Otherwise, there is the danger of electric shock.
4. Before you connect wires to this product, disconnect the electrical power.
5. To decrease the risk of electrical shock and injury, you must supply operators with the
necessary precautions and protection from live electrical circuits.
6. While the drive is connected to a power source, do not connect or disconnect electrical
components and cables.
7. Make sure that all components are grounded correctly and that they obey the local electrical
safety requirements.
8. Make sure that you install the necessary precautions to supply safety and protection to the
operator.
9. Moving parts can cause crushing or shearing injuries. You must limit 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, injury,
and death, you must obey the precautions that follow.
1. Obey the information in this manual.
2. Make sure that all system cables are correctly attached and positioned.
3. Use this product only in environments and operating conditions that are approved in this
manual.
4. Only operators who have received training can operate this equipment. All servicing and
maintenance must be done only by approved personnel.
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Safety Procedures and Warnings XC2 Hardware Manual
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XC2 Hardware Manual Quick Installation Guide
Quick Installation Guide
This image shows the order in which to make connections and settings that are typical to the XC2. 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.
Motor and Feedback
Connections
Section 2.2. Motor Power Output Connector and Section 2.3. Feedback
Connector
HyperWire Section 2.5. HyperWire Interface
Digital / Analog I/O Chapter 3: -EB1 I/O Option Board (if you purchased the I/O option)
STO Section 2.4. Safe Torque Off Input (STO)
Control Supply Section 2.1.1. Control Supply Connector
Motor Supply Section 2.1.2. Motor Supply Connector
Figure 1: Quick Start Connections
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Quick Installation Guide XC2 Hardware Manual
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XC2 Hardware Manual Chapter 1: Introduction
Chapter 1: Introduction
The XC2 is a high performance digital drive based on the HyperWire communication protocol. The drive
provides deterministic behavior, auto-identification, is fully software configurable. A double precision floating
point DSP controls the digital PID and current loops in the XC2.
Figure 1-1: XC2 High Performance PWMAmplifier
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Chapter 1: Introduction XC2 Hardware Manual
Table 1-1: FeatureSummary
Standard Features
l24 VDC control supply input Section 2.1.1.
l15 - 100 VDC motor supply inputs Section 2.1.2.
lLine driver square wave quadrature encoder input for position and velocity
feedback Section 2.3.1.
lAbsolute Encoder support Section 2.3.1.2.
lOne fail-safe brake Section 2.3.6.
lTwo STOsense inputs Section 2.4.
Options
Peak Current Section 1.1.
-10 10 A Peak, 5 A Continuous Current
Expansion Board Chapter 3
-EB0 No expansion board
-EB1
I/Oexpansion board
l16-bit analog output (±10 V)
l16-bit differential analog input (±10 V)
l8 digital logic inputs (5 - 24 VDC), can be connected to current sourcing or
sinking devices
l8 digital logic outputs (5 - 24 VDC), can be connected as current sourcing or
sinking
lDigital logic laser firing (PSO)output
PSO Section 3.1.
-PSO1 One axis PSOfiring (requires -EB1 option)
Multiplier Section 2.3.1.3.
-MX0 No encoder multiplier
-MX1 Interpolation circuit allowing for analog sine wave input on the standard encoder
channel with an interpolation factor of 16,384
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
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XC2 Hardware Manual Chapter 1: Introduction
The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
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Chapter 1: Introduction XC2 Hardware Manual
1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description XC2-10
Motor
Supply
Input Voltage 15-100 VDC
Input Current
(Continuous) 5 Arms
Input Current Refer to Section 1.1.1. System Power Requirements
Control
Supply
Input Voltage 24 VDC
Input Current 2 A max
Output Voltage (1) 15-100 VDC
Peak Output Current (1 second) 10 A
Continuous Output Current 5 A
Power Amplifier Bandwidth 2500 Hz maximum (software selectable)
Power Amplifier Efficiency 85% - 95% (2)
PWM Switching Frequency 20 kHz
Minimum Load Inductance 0.1 mH @100 VDC
User Power Supply Output 5 VDC (@ 500 mA)
Modes of Operation Brushless; Brush; Stepper
Protective Features
Output short circuit; Peak over current; DC bus over voltage; RMS over
current; Over temperature; 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.
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XC2 Hardware Manual Chapter 1: Introduction
1.1.1. System Power Requirements
The following equations can be used to determine total system power requirements. The actual power
required from the mains supply will be the combination of actual motor power (work), motor resistance
losses, and efficiency losses in the power electronics or power transformer.
Use an EfficiencyFactor of approximately 90% in the following equations.
Brushless Motor
Output Power
Rotary Motors Power Output [W] = Torque [N·m] * Angular velocity[rad/sec]
Linear Motors Power Output [W] = Force [N] * Linear velocity[m/sec]
Rotary or Linear Motors Power Output [W] = Bemf [V] * I(rms) * 3
Power Loss = 3 * I(rms)^2 * R(line-line)/2
Power Input = (Power Output + Power Loss) / EfficiencyFactor
DC Brush Motor
Power Output [W] = Torque [N·m] * Angular velocity[rad/sec]
Power Loss = I(rms)^2 * R
Power Input = (Pout + Ploss) / EfficiencyFactor
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Chapter 1: Introduction XC2 Hardware Manual
1.2. Mechanical Specifications
The XC2 must be installed in an IP54 compliant enclosure to comply with safety standards. Mount the XC2
so free airflow is available at the front, top, and along the sides of the chassis for cooling. You must also
allow space for connections and cables along the front, top, and bottom.
The figure that follows shows the dimensions and the typical mounting orientation of the XC2.
Table 1-3: Unit Weight
XC2
Weight ~0.54 kg
Figure 1-3: Dimensions
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