Aerotech Automation1 XL4s User manual

Revision: 1.04.00
XL4s HARDWAREMANUAL

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website supplies software, product manuals, Help files, training schedules, and PC-to-PC remote technical support. If
necessary, you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts.
To get help immediately, contact a service office or your sales representative. Include your customer order number in your
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United States (World Headquarters)
Email: [e-mail]
Phone: [phone]
Fax: [phone]
101 Zeta Drive
Pittsburgh, PA 15238-2811
www.aerotech.com
United Kingdom China
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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 © 2018-2020, Aerotech, Inc., All rights reserved.

XL4s Hardware Manual Table of Contents
Table of Contents
XL4s HARDWAREMANUAL 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Conformity 7
Agency Approvals 9
Safety Procedures and Warnings 11
Quick Installation Guide 13
Chapter 1: Introduction 15
1.1. Electrical Specifications 17
1.2. Mechanical Specifications 18
1.2.1. Mounting and Cooling 18
1.2.2. Dimensions 19
1.3. Environmental Specifications 20
1.4. Drive and Software Compatibility 21
Chapter 2: Installation and Configuration 23
2.1. Input Power Connections 23
2.1.1. Control Supply Connector 23
2.1.2. Motor Supply Connector 24
2.1.3. External Power Supply Options 25
2.1.4. Minimizing Conducted,Radiated, and System Noise for EMC/CECompliance 27
2.2. HyperWire Interface 28
2.3. Position Synchronized Output Connector 29
2.4. Encoder Output Connector 30
2.5. Stage Motor and Feedback Connector 32
2.5.1. Analog Encoder Inputs 33
2.6. Digital and Analog I/O Connectors 34
2.6.1. Digital Outputs 35
2.6.2. Digital Inputs 37
2.6.3. Analog Outputs 38
2.6.4. Analog Inputs (Differential) 39
2.7. Encoder Input Connectors 40
2.7.1. Emergency Stop Sense Input 42
2.8. Laser Output Polarity Switch 43
2.9. Sync Port 44
2.10. PC Configuration and Operation Information 45
Chapter 3: Maintenance 47
3.1. Preventative Maintenance 47
3.2. Board Assembly 48
Appendix A: Warranty and Field Service 51
Appendix B: Revision History 53
Index 55
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List of Figures XL4s Hardware Manual
List of Figures
Figure 1-1: XL4s High Performance Linear Amplifier 15
Figure 1-2: Functional Diagram 16
Figure 1-3: Dimensions 19
Figure 2-1: Control Supply Connections 23
Figure 2-2: Motor Supply Connections 24
Figure 2-3: Control and Motor Power Wiring using a TM3 Transformer 25
Figure 2-4: Third-Party Power Supply Connection 26
Figure 2-5: Encoder Outputs Schematic 30
Figure 2-6: PSOExternal Sync Input Schematic 31
Figure 2-7: Digital Outputs Connected in Current Sourcing Mode 36
Figure 2-8: Digital Outputs Connected in Current Sinking Mode 36
Figure 2-9: Digital Inputs Connected to Current Sinking Devices 37
Figure 2-10: Digital Inputs Connected to Current Sourcing Devices 37
Figure 2-11: Analog Outputs Schematic 38
Figure 2-12: Analog Inputs Schematic 39
Figure 2-13: Encoder Input Connector Encoder Connections 41
Figure 2-14: ESTOP Sense Input Schematic 42
Figure 2-15: Laser Output Polarity Switch Location 43
Figure 3-1: Control Board Assembly 48
Figure 3-2: Power Board Assembly 49
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XL4s Hardware Manual List of Tables
List of Tables
Table 1-1: FeatureSummary 15
Table 1-2: Electrical Specifications 17
Table 1-3: Mounting Specifications 18
Table 1-4: Environmental Specifications 20
Table 1-5: Drive and Software Compatibility 21
Table 2-1: Control Supply Connector Wiring Specifications 23
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 23
Table 2-3: Motor Supply Wiring Specifications 24
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 24
Table 2-5: HyperWire Card Part Number 28
Table 2-6: HyperWire Cable Part Numbers 28
Table 2-7: PSOConnector APinout 29
Table 2-8: PSOConnector BPinout 29
Table 2-9: Mating Connector Part Numbers for the PSOConnectors 29
Table 2-10: PSO Specifications 29
Table 2-11: Encoder Output Connector Pinout 30
Table 2-12: Mating Connector Part Numbers for the Encoder Output Connector 30
Table 2-13: PSOExternal Sync Specifications 31
Table 2-14: Stage Motor and Feedback Connector Pinout 32
Table 2-15: Mating Connector Part Numbers for the Stage Motor and Feedback Connector 32
Table 2-16: Analog Encoder Input Specifications 33
Table 2-17: Digital and Analog I/O Connector APinout 34
Table 2-18: Digital and Analog I/O Connector B Pinout 34
Table 2-19: Mating Connector Part Numbers for the Digital / Analog I/OConnectors 34
Table 2-20: Digital Output Specifications 35
Table 2-21: Digital Output Pins on the Digital/Analog I/O A Connector 35
Table 2-22: Digital Input Specifications 37
Table 2-23: Digital Input Pins on the Digital/Analog I/O B Connector 37
Table 2-24: Analog Output Specifications 38
Table 2-25: Analog Output Pins on the Digital / Analog I/O B Connector 38
Table 2-26: Analog Input Specifications 39
Table 2-27: Analog Input Pins on the Digital / Analog I/O B Connector 39
Table 2-28: Encoder Input Connector Specifications 40
Table 2-29: Encoder Input Connector A Pinout 40
Table 2-30: Encoder Input Connector B Pinout 40
Table 2-31: Mating Connector Part Numbers for the Encoder Input Connector 40
Table 2-32: ESTOP Pins on the Encoder Input Connector 42
Table 2-33: Electrical Noise Suppression Devices 42
Table 2-34: Sync-Related Commands 44
Table 2-35: SyncPort Cables 44
Table 3-1: Preventative Maintenance 47
Table 3-2: Control Board Fuse Specifications 48
Table 3-3: Power Board Fuse Specifications 49
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List of Tables XL4s Hardware Manual
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XL4s Hardware Manual EU Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XL4s
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2014/35/EU Low Voltage Directive
EU 2015/863 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 Safety Requirements for Electrical Equipment
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 4/27/2020
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EU Declaration of Conformity XL4s Hardware Manual
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XL4s Hardware Manual Agency Approvals
Agency Approvals
Aerotech tested its XL4s drives and found that they obey the standards that follow:
Approval / Certification: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 16 04 68995 018
Standards: CAN/CSA-C22.2 No. 61010-1:2012; EN 61010-1:2010; UL 61010-1:2012
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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Agency Approvals XL4s Hardware Manual
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XL4s Hardware Manual Safety Procedures and Warnings
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the XL4s. Read all parts of this manual
before you install or operate the XL4s 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. Before you do maintenance to the equipment, disconnect the electrical power.
2. Wait at least ten (10) minutes after removing the power supply before doing maintenance or
an inspection. Otherwise, there is the danger of electric shock.
3. Before you connect wires to this product, disconnect the electrical power.
4. To decrease the risk of electrical shock and injury, you must supply operators with the
necessary precautions and protection from live electrical circuits.
5. While the drive is connected to a power source, do not connect or disconnect electrical
components and cables.
6. Make sure that all components are grounded correctly and that they obey the local electrical
safety requirements.
7. Make sure that you install the necessary precautions to supply safety and protection to the
operator.
8. 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. Make sure that all system cables are correctly attached and positioned.
2. Use this product only in environments and operating conditions that are approved in this
manual.
3. 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 XL4s Hardware Manual
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XL4s 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 XL4s. 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.
HyperWire Section 2.2. HyperWire Interface
Digital / Analog I/O Section 2.6. Digital and Analog I/O Connectors
Motor and Feedback
Connections Section 2.5. Stage Motor and Feedback Connector
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 XL4s Hardware Manual
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XL4s Hardware Manual Chapter 1: Introduction
Chapter 1: Introduction
The XL4s is a high-performance linear amplifier designed to eliminate the non-linearities common with PWM
amplifiers. The drive provides deterministic behavior, auto-identification, and easy software setup.
Figure 1-1: XL4s High Performance Linear Amplifier
Table 1-1: FeatureSummary
Standard Features
l85-240 VAC; 50-60 Hz control supply Section 2.1.1.
l±40 VDC max motor supply Section 2.1.2.
lTwo HyperWire ports Section 2.2.
lDual-Axis PSOfiring Section 2.3.
lThree-axis Part-Speed PSO firing Refer to the
online Help
lTwo auxiliary channels of 40 MHz line driver quadrature encoder inputs Section 2.7.
lFour optically-isolated digital outputs; 5-24V Section 2.6.1.
lFour optically-isolated digital inputs; 5-24V Section 2.6.2.
lTwo 16-bit single-ended analog outputs; ±10 V Section 2.6.3.
lOne 16-bit differential analog input; ±10 V Section 2.6.4.
lDedicated 5-24V Emergency Stop sense input Section 2.7.1.
lTwo Sync ports Section 2.9.
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Chapter 1: Introduction XL4s Hardware Manual
The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
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XL4s Hardware Manual Chapter 1: Introduction
1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description XL4s
Motor Supply Input Voltage ±40 VDC(max)
Input Current (continuous) 10 A
Control Supply
Input Voltage 85-240 VAC
Input Frequency 50-60 Hz
Inrush Current 16 A
Input Current 0.35A(max)
Output Voltage 76 V
Peak Output Current 20 A
Continuous Output Current 5 A
Minimum Load Resistance 0.5 Ω
User Power Supply Output 5 VDC (@ 500 mA)
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Chapter 1: Introduction XL4s Hardware Manual
1.2. Mechanical Specifications
1.2.1. Mounting and Cooling
Install the XL4s in an IP54 compliant enclosure to comply with safety standards. Make sure that there is
sufficient clearance surrounding the drive for free airflow and for the cables and connections.
Table 1-3: Mounting Specifications
XL4s
Enclosure IP54 Compliant
Weight ~2.9 kg
Mounting Hardware M4 [#8] screws (four locations, not included)
Mounting Orientation Vertical (typical)
Dimensions Refer to Section 1.2.2. Dimensions
Minimum Clearance Airflow ~25 mm
Connectors ~100 mm
Operating Temperature Refer to Section 1.3. Environmental Specifications
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XL4s Hardware Manual Chapter 1: Introduction
1.2.2. Dimensions
Figure 1-3: Dimensions
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Chapter 1: Introduction XL4s Hardware Manual
1.3. Environmental Specifications
Table 1-4: Environmental Specifications
Ambient Temperature Operating: 0° to 40°C (32° to 104° F)
Storage: -30° to 85°C (-22° to 185° F)
Humidity
Non-condensing
The maximum relative humidity is 80% for temperatures 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 2,000 m or below sea level,
contact Aerotech, Inc.
Pollution Pollution Degree 2
Typically only nonconductive pollution occurs.
Operation Use only indoors
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