Aerotech Automation1 iXC2 User manual

Revision 2.05
Automation1 iXC2 and XC2 PWM Digital Drives
HARDWAREMANUAL

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Copyright © 2019-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 iXC2 and XC2 PWM Digital Drives 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Agency Approvals 10
Safety Procedures and Warnings 11
Handling and Storage 13
Installation Overview 14
Chapter 1: iXC2/XC2 Overview 17
1.1. Electrical Specifications 21
1.1.1. System Power Requirements 21
1.2. Mechanical Specifications 22
1.2.1. Mounting and Cooling 22
1.2.2. Dimensions 23
1.3. Environmental Specifications 25
1.4. Drive and Software Compatibility 25
Chapter 2: Installation and Configuration 27
2.1. Input Power Connections 27
2.1.1. Control Supply Connector 27
2.1.2. Motor Supply Connector 28
2.1.3. Minimizing Noise for EMC/CECompliance 29
2.2. Motor Power Output Connector 30
2.2.1. Brushless Motor Connections 31
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 32
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 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. Stepper Motor Phasing 36
2.3. Feedback Connector 37
2.3.1. Primary Encoder Inputs 38
2.3.1.1. Square WaveEncoder (Primary) 39
2.3.1.2. Absolute Encoder (Primary) 40
2.3.1.3. Sine Wave Encoder (Primary) [-MX1 Option] 41
2.3.1.4. Encoder Phasing 43
2.3.2. Hall-Effect Inputs 44
2.3.3. Thermistor Input 45
2.3.4. Encoder Fault Input 46
2.3.5. End of Travel and Home Limit Inputs 47
2.3.5.1. End of Travel and Home Limit Phasing 49
2.3.6. Brake Outputs 50
2.4. Safe Torque Off Input (STO) 51
2.4.1. STOStandards 53
2.4.2. STO Functional Description 54
2.4.3. STO Startup Validation Testing 55
2.4.4. STO Diagnostics 56
2.5. HyperWire Interface 57
2.6. System Interconnection 58
2.7. PC Configuration and Operation Information 61
Chapter 3: -EB1/-EB2 Option Expansion Board 63
3.1. PSOInterface [-EB1/-EB2] 64
3.2. Auxiliary Encoder Interface [-EB1/-EB2] 66
3.2.1. Square WaveEncoder (Auxiliary) 67
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3.3. Analog I/O [-EB1] 68
3.3.1. Analog Output 0 [-EB1] 69
3.3.2. Analog Input (Differential) [-EB1] 70
3.4. Digital Outputs [-EB1] 71
3.5. Digital Inputs [-EB1] 74
3.6. Industrial Ethernet (iXC2 -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. Preventative Maintenance 86
5.2. Fuse Specifications 86
Appendix A: Warranty and Field Service 87
Appendix B: Revision History 89
Index 91
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List of Figures
Figure 1-1: iXC2 High Performance PWMAmplifier 17
Figure 1-2: XC2 High Performance PWMAmplifier 18
Figure 1-3: Functional Diagram 20
Figure 1-4: Dimensions [-EB0] 23
Figure 1-5: Dimensions [-EB1/-EB2] 24
Figure 2-1: Control Supply Connections 27
Figure 2-2: Motor Supply Connections 28
Figure 2-3: Brushless Motor Configuration 31
Figure 2-4: Positive Motor Direction 32
Figure 2-5: Encoder and Hall Signal Diagnostics 32
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 33
Figure 2-7: Brushless Motor Phasing Goal 33
Figure 2-8: DC Brush Motor Configuration 34
Figure 2-9: Positive Motor Direction 34
Figure 2-10: Stepper Motor Configuration 35
Figure 2-11: Positive Motor Direction 35
Figure 2-12: Stepper Motor Configuration 36
Figure 2-13: Positive Motor Direction 36
Figure 2-14: Square Wave Encoder Schematic (Feedback Connector) 39
Figure 2-15: Absolute Encoder Schematic (Feedback Connector) 40
Figure 2-16: Sine Wave Encoder Phasing Reference Diagram 41
Figure 2-17: Sine Wave Encoder Schematic (Feedback Connector) 42
Figure 2-18: Encoder Phasing Reference Diagram (Standard) 43
Figure 2-19: Position Feedback in the DiagnosticDisplay 43
Figure 2-20: Hall-Effect Inputs 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 Input Connections 48
Figure 2-24: End of Travel and Home Limit Input Schematic (Feedback Connector) 48
Figure 2-25: End of Travel and Home Limit Input Diagnostic Display 49
Figure 2-26: Brake Connected to the 25-Pin Feedback Connector (Typical) 50
Figure 2-27: Typical STO Configuration 52
Figure 2-28: STO Timing 56
Figure 2-29: Drive-Based System Wiring Drawing (Best Practice) 58
Figure 2-30: PC-Based System Wiring Drawing (Best Practice) 58
Figure 2-31: Drive-Based Controller System Interconnection (Best Practice) 59
Figure 2-32: PC-Based Controller System Interconnection (Best Practice) 60
Figure 3-1: Expansion Option Board Connectors (iXC2 shown) 63
Figure 3-2: PSO Output Sources Current 65
Figure 3-3: PSOOutput Sinks Current 65
Figure 3-4: PSO TTLOutputs Schematic 65
Figure 3-5: Square Wave Encoder Interface (Aux Connector) 67
Figure 3-6: Analog Output Schematic [-EB1] 69
Figure 3-7: Analog Input Schematic [-EB1] 70
Figure 3-8: Digital Outputs Schematic [-EB1] 72
Figure 3-9: Digital Outputs Connected in Current Sourcing Mode [-EB1] 73
Figure 3-10: Digital Outputs Connected in Current Sinking Mode [-EB1] 73
Figure 3-11: Digital Inputs Schematic [-EB1] 75
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Figure 3-12: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 76
Figure 3-13: Digital 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 82
Figure 4-4: Dual-Axis PSOCable Connection 83
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List of Tables
Table 1-1: FeatureSummary 19
Table 1-2: Electrical Specifications 21
Table 1-3: Mounting Specifications 22
Table 1-4: Environmental Specifications 25
Table 1-5: Drive and Software Compatibility 25
Table 2-1: Control Supply Connector Pinout 27
Table 2-2: Control Supply Mating Connector Ratings 27
Table 2-3: Motor Supply Connector Pinout 28
Table 2-4: Motor Supply Mating Connector Ratings 28
Table 2-5: Motor Power Output Connector Pinout 30
Table 2-6: Motor Power Output Mating Connector Ratings 30
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 31
Table 2-8: Hall Signal Diagnostics 32
Table 2-9: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 34
Table 2-10: Wire Colors for Aerotech-Supplied Stepper Motor Cables 35
Table 2-11: Feedback Connector Pinout 37
Table 2-12: Feedback Mating Connector Ratings 37
Table 2-13: Multiplier Options 38
Table 2-14: Primary Encoder Pins on the Feedback Connector 38
Table 2-15: Square Wave Encoder Specifications 39
Table 2-16: Sine Wave Encoder Specifications 41
Table 2-17: Hall-Effect Feedback Pins on the Feedback Connector 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 Connector 47
Table 2-21: Brake Output Pins on the Feedback Connector 50
Table 2-22: Brake Control Specifications 50
Table 2-23: STO Connector Pinout 51
Table 2-24: STOMating ConnectorRatings 51
Table 2-25: STOElectrical Specifications 52
Table 2-26: STOStandards 53
Table 2-27: STOStandards Data 53
Table 2-28: STOSignal Delay 55
Table 2-29: Motor Function Relative to STOInput State 55
Table 2-30: STOTiming 56
Table 2-31: HyperWire Card Part Number 57
Table 2-32: HyperWire Cable Part Numbers 57
Table 3-1: PSO Specifications [-EB1/-EB2] 64
Table 3-2: PSO Interface Connector Pinout [-EB1/-EB2] 64
Table 3-3: PSO Interface Mating Connector Ratings [-EB1/-EB2] 64
Table 3-4: Auxiliary Encoder Connector Pinout 66
Table 3-5: AUX Mating Connector Ratings 66
Table 3-6: Square Wave Encoder Specifications 67
Table 3-7: Analog I/O Connector Pinout [-EB1] 68
Table 3-8: Analog I/O Mating Connector Ratings [-EB1] 68
Table 3-9: Analog Output Specifications [-EB1] 69
Table 3-10: Analog Output Pins on the Analog I/OConnector [-EB1] 69
Table 3-11: Differential Analog Input Specifications [-EB1] 70
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Table 3-12: Analog Input Pins on the Analog I/OConnector [-EB1] 70
Table 3-13: Digital Output Specifications [-EB1] 71
Table 3-14: Digital Output Connector Pinout [-EB1] 71
Table 3-15: Digital Output Mating Connector Ratings [-EB1] 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 79
Table 4-2: Mounting Parts 80
Table 5-1: LEDDescription 85
Table 5-2: Troubleshooting 85
Table 5-3: Preventative Maintenance 86
Table 5-4: Control Board Fuse Specifications 86
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXC2/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
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/AMD1:2016 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 7/19/2022
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Agency Approvals
Aerotech tested its XC2 drives and found that they obey the standards that follow:
Approval: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U10 068995 0033 Rev. 00
Standards: CSA C22.2 No. 61010-1:2012/A1:2018-11,
UL 61010-1:2012/R2019-07
Certificate #: N8AUS 068995 0032 Rev. 01
Standards: CE Attestation of Conformity,
Low Voltage Directive 2014/35/EU,
EN 61010-1:2010/AMD1:2019
IMPORTANT: The safety components (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 (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.
Safety notes and symbols are placed throughout this manual to warn you of the potential risks at the
moment of the safety note or if you fail to obey the safety note.
The voltage can cause shock, burn, or death.
You are at risk of physical injury.
You could damage the drive.
A surface can be hot enough to burn you.
Your actions, the temperature of the system, or the condition of the atmosphere
that surround the system could start a fire.
Components are sensitive to electrostatic discharge.
Unsecured cables could cause you to:
ltrip and fall
ldrag the product off of its mounting location
ldamage the cable connections.
A blue circle symbol is an action or tip that you should obey. Some examples
include:
lGeneral tip
lRead the manual/section
lWear protective safety equipment (eye protection, ear protection, gloves)
lIf applicable, do not lift unassisted
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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 one (1) minute after removing the power supply before doing
maintenance 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
electrical 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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Handling and Storage
Unpacking the drive
IMPORTANT: All electronic equipment and instrumentation is wrapped in antistatic
material and packaged with desiccant. Ensure that the antistatic material is not
damaged during unpacking.
Inspect the shipping container for any evidence of shipping damage. If any damage exists, notify the
shipping carrier immediately.
Remove the packing list from the shipping container. Make sure that all the items specified on the
packing list are contained within the package.
The documentation for the drive is on the included installation device. The documents include
manuals, interconnection drawings, and other documentation pertaining to the system. Save this
information for future reference. Additional information about the system is provided on the Serial
and Power labels that are placed on the chassis.
The system serial number label contains important information such as the:
lCustomer order number (please provide this number when requesting product support)
lDrawing number
lSystem part number
Handling
IMPORTANT: It is the responsibility of the customer to safely and carefully lift and
move the drive.
lBe careful when you move or transport the drive.
lRefer to Section 1.2. Mechanical Specifications for dimensions and weight spe-
cifications.
lRetain the shipping materials for future use.
lTransport or store the drive in its protective packaging.
WARNING: Electrostatic Discharge (ESD) Sensitive Components!
You could damage the power supply or drives if you fail to observe the correct
ESDpractices.
Wear an ESDwrist strap when you handle, install, or do service to the system assembly.
Storage
Store the drive in the original shipping container. If the original packaging included ESDprotective
packaging, make sure to store the drive in it. The storage location must be dry, free of dust, free of
vibrations, and flat.
Refer to Section 1.3. Environmental Specifications.
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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 iXC2/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.
Figure 1: Installation Connection Overview for the iXC2
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 2.5.
4Connect additional I/O as required by your application
(if you purchased the I/O option). 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.
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Figure 2: Installation ConnectionOverviewfor the XC2
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 2.5.
3Connect additional I/O as required by your application
(if you purchased the I/O option). 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.
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Chapter 1: iXC2/XC2 Overview
The iXC2 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 XC2 is a high performance 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-identification and are fully software
configurable. A double precision floating point DSP controls the digital PID and current loops in the
drive.
Figure 1-1: iXC2 High Performance PWMAmplifier
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Figure 1-2: XC2 High Performance PWMAmplifier
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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 output (Section 2.3.6.)
lTwo STOsense inputs (Section 2.4.)
lOne 10/100/1000 BASE-T Ethernet Port (iXC2 Only)
lOne USB2.0 Type CPort (iXC2 Only)
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
lDigital logic laser firing (PSO)output
lAuxiliary encoder input channel
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
-EB2
Industrial Ethernet Expansion board (iXC2 only)
lDigital logic laser firing (PSO)output
lAuxiliary encoder input channel
lTwo 10/100/1000 BASE-T Industrial Ethernet Ports
PSO (Section 3.1.)
-PSO1 One-axis PSO firing (includes One-axis Part-Speed PSO)
NOTE:Requires -EB1 or -EB2 option to generate a PSO output pulse
Multiplier (Section 2.3.1.3.)
-MX0 No encoder multiplier
-MX1 Interpolation circuit allowing for analog sine wave input on the primary 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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The block diagram that follows shows a summary of the connector signals.
Figure 1-3: Functional Diagram
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