Aerotech Automation1 iXC4 User manual

Revision 2.04
Automation1 iXC4 and XC4
PWMDigital Drives
HARDWAREMANUAL

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Copyright © 2018-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 iXC4 and XC4 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: iXC4/XC4 Overview 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 29
2.1.1. Control Supply Connector 29
2.1.2. Motor Supply Connector 30
2.1.3. Transformer Options 31
2.1.4. Minimizing Noise for EMC/CECompliance 38
2.2. Motor Power Output Connector 39
2.2.1. Brushless Motor Connections 40
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 41
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 42
2.2.2. DCBrush Motor Connections 43
2.2.2.1. DC Brush Motor Phasing 43
2.2.3. Stepper Motor Connections 44
2.2.3.1. Stepper Motor Phasing 44
2.2.4. Three Phase Stepper Motor Connections 45
2.2.4.1. Stepper Motor Phasing 45
2.3. Feedback Connector 46
2.3.1. Primary Encoder Inputs 47
2.3.1.1. Square WaveEncoder (Primary) 48
2.3.1.2. Absolute Encoder (Primary) 49
2.3.1.3. Sine Wave Encoder (Primary) [-MX1 Option] 50
2.3.1.4. Encoder Phasing 52
2.3.2. Hall-Effect Inputs 53
2.3.3. Thermistor Input 54
2.3.4. Encoder Fault Input 55
2.3.5. End of Travel and Home Limit Inputs 56
2.3.5.1. End of Travel and Home Limit Phasing 58
2.3.6. Brake Outputs 59
2.4. Safe Torque Off Input (STO) 60
2.4.1. STOStandards 62
2.4.2. STO Functional Description 63
2.4.3. STO Startup Validation Testing 64
2.4.4. STO Diagnostics 65
2.5. Auxiliary I/O Connector 66
2.5.1. Auxiliary Encoder Inputs 67
2.5.1.1. Square WaveEncoder (Auxiliary) 68
2.5.1.2. Absolute Encoder (Auxiliary) 69
2.5.2. Position Synchronized Output (PSO) 70
2.5.3. Digital Outputs 72
2.5.4. Digital Inputs 75
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2.5.5. High-Speed Inputs 77
2.5.6. Analog Output 0 78
2.5.7. Analog Input 0 (Differential) 79
2.6. Brake Power Supply Connector 80
2.7. HyperWire Interface 81
2.8. External Shunt Option [-SX1] 82
2.9. Sync Port 84
2.10. System Interconnection 85
2.11. PC Configuration and Operation Information 88
Chapter 3: -EB1 I/O Option Board 89
3.1. Digital Outputs [-EB1] 90
3.2. Digital Inputs [-EB1] 94
3.3. Analog Outputs [-EB1] 97
3.4. Analog Inputs [-EB1] 98
3.5. PSOInterface [-EB1] 99
Chapter 4: Cables and Accessories 101
4.1. Joystick Interface 102
4.2. Handwheel Interface 104
Chapter 5: Maintenance 105
5.1. Preventative Maintenance 106
5.2. Fuse Specifications 107
Appendix A: Warranty and Field Service 109
Appendix B: Revision History 111
Index 113
Table of Contents iXC4/XC4 Hardware Manual
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List of Figures
Figure 1-1: iXC4 Digital Drive-Based Controller Labeled 17
Figure 1-2: XC4 Digital Drive Labeled 18
Figure 1-3: Functional Diagram 20
Figure 1-4: Dimensions 24
Figure 1-5: Dimensions [-EB1] 25
Figure 2-1: Control Supply Connections 29
Figure 2-2: Motor Supply Connections 30
Figure 2-3: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) 32
Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) 33
Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) 34
Figure 2-6: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) 35
Figure 2-7: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) 36
Figure 2-8: TM3/TM5 Transformer Control and Motor Power Wiring 37
Figure 2-9: Brushless Motor Configuration 40
Figure 2-10: Positive Motor Direction 41
Figure 2-11: Encoder and Hall Signal Diagnostics 41
Figure 2-12: Brushless Motor Phasing Oscilloscope Example 42
Figure 2-13: Brushless Motor Phasing Goal 42
Figure 2-14: DC Brush Motor Configuration 43
Figure 2-15: Positive Motor Direction 43
Figure 2-16: Stepper Motor Configuration 44
Figure 2-17: Positive Motor Direction 44
Figure 2-18: Three Phase Stepper Motor Configuration 45
Figure 2-19: Positive Motor Direction 45
Figure 2-20: Square Wave Encoder Schematic (Feedback Connector) 48
Figure 2-21: Absolute Encoder Schematic (Feedback Connector) 49
Figure 2-22: Sine Wave Encoder Phasing Reference Diagram 50
Figure 2-23: Sine Wave Encoder Schematic (Feedback Connector) 51
Figure 2-24: Encoder Phasing Reference Diagram (Standard) 52
Figure 2-25: Position Feedback in the DiagnosticDisplay 52
Figure 2-26: Hall-Effect Inputs Schematic (Feedback Connector) 53
Figure 2-27: Thermistor Input Schematic (Feedback Connector) 54
Figure 2-28: Encoder Fault Input Schematic (Feedback Connector) 55
Figure 2-29: End of Travel and Home Limit Input Connections 57
Figure 2-30: End of Travel and Home Limit Input Schematic (Feedback Connector) 57
Figure 2-31: End of Travel and Home Limit Input Diagnostic Display 58
Figure 2-32: Brake Connected to the 25-Pin Feedback Connector (Typical) 59
Figure 2-33: Typical STO Configuration 61
Figure 2-34: STO Timing 65
Figure 2-35: Square Wave Encoder Interface (Aux I/OConnector) 68
Figure 2-36: Absolute Encoder Schematic (Auxiliary I/O Connector) 69
Figure 2-37: PSO Interface 71
Figure 2-38: Digital Output Schematic (Aux I/OConnector) 73
Figure 2-39: Digital Outputs Connected in Current Sourcing Mode 74
Figure 2-40: Digital Outputs Connected in Current Sinking Mode 74
Figure 2-41: Digital Inputs Schematic (Aux I/OConnector) 75
Figure 2-42: Digital Inputs Connected to Current Sourcing Devices 76
Figure 2-43: Digital Inputs Connected to Current Sinking Devices 76
iXC4/XC4 Hardware Manual List of Figures
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Figure 2-44: High-Speed Inputs 77
Figure 2-45: Analog Output 0 Schematic 78
Figure 2-46: Analog Input 0 Schematic 79
Figure 2-47: Drive-Based System Wiring Drawing (Best Practice) 85
Figure 2-48: PC-Based System Wiring Drawing (Best Practice) 85
Figure 2-49: Drive-Based Controller System Interconnection (Best Practice) 86
Figure 2-50: PC-Based Controller System Interconnection (Best Practice) 87
Figure 3-1: -EB1 I/O Option Board Connectors (iXC4 shown) 89
Figure 3-2: Digital Outputs Schematic [-EB1] 92
Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 93
Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 93
Figure 3-5: Digital Inputs Schematic [-EB1] 95
Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 96
Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 96
Figure 3-8: Analog Output Typical Connection [-EB1] 97
Figure 3-9: Analog Input Typical Connection [-EB1] 98
Figure 3-10: PSO Output Sources Current 100
Figure 3-11: PSOOutput Sinks Current 100
Figure 3-12: PSO TTLOutputs Schematic 100
Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 102
Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 103
Figure 4-3: Handwheel Interconnection to Aux I/O Connector 104
Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 104
List of Figures iXC4/XC4 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 29
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 29
Table 2-3: Motor Supply Connector Wiring Specifications 30
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 30
Table 2-5: Nominal Motor Operating Voltages / Required ACVoltages 31
Table 2-6: TransformerOptions 31
Table 2-7: Motor Power Output Connector Pinout 39
Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector 39
Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables 40
Table 2-10: Hall Signal Diagnostics 41
Table 2-11: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 43
Table 2-12: Wire Colors for Aerotech-Supplied Stepper Motor Cables 44
Table 2-13: Feedback Connector Pinout 46
Table 2-14: Mating Connector Part Numbers for the Feedback Connector 46
Table 2-15: Multiplier Options 47
Table 2-16: Primary Encoder Input Pins on the Feedback Connector 47
Table 2-17: Square Wave Encoder Specifications 48
Table 2-18: Sine Wave Encoder Specifications 50
Table 2-19: Hall-Effect Feedback Pins on the Feedback Connector 53
Table 2-20: Thermistor Input Pin on the Feedback Connector 54
Table 2-21: Encoder Fault Input Pin on the Feedback Connector 55
Table 2-22: End of Travel and Home Limit Pins on the Feedback Connector 56
Table 2-23: Brake Output Pins on the Feedback Connector 59
Table 2-24: Brake Control Specifications 59
Table 2-25: STO Connector Pinout 60
Table 2-26: Mating Connector Part Numbers for the STOConnector 60
Table 2-27: STOElectrical Specifications 61
Table 2-28: STOStandards 62
Table 2-29: STOStandards Data 62
Table 2-30: STOSignal Delay 64
Table 2-31: Motor Function Relative to STOInput State 64
Table 2-32: STOTiming 65
Table 2-33: Auxiliary I/O Connector Pinout 66
Table 2-34: Mating Connector Part Numbers for the Auxiliary I/OConnector 66
Table 2-35: Auxiliary Encoder Pins on the Auxiliary I/OConnector 67
Table 2-36: Square Wave Encoder Specifications 68
Table 2-37: PSO Specifications 70
Table 2-38: PSOPins on the Auxiliary I/OConnector 70
Table 2-39: Digital Output Specifications 72
Table 2-40: Digital Output Pins on the Auxiliary I/O Connector 72
Table 2-41: Digital Input Specifications 75
Table 2-42: Digital Input Pins on the Auxiliary I/O Connector 75
Table 2-43: High-Speed Input Specifications 77
iXC4/XC4 Hardware Manual List of Tables
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Table 2-44: High-Speed Input Pins on the Auxiliary I/O Connector 77
Table 2-45: Analog Output Specifications 78
Table 2-46: Analog Output Pins on the Auxiliary I/O Connector 78
Table 2-47: Analog Input Specifications 79
Table 2-48: Analog Input Pins on the Auxiliary I/O Connector 79
Table 2-49: Brake Power Supply Connector Pinout 80
Table 2-50: Mating Connector Part Numbers for the Brake Power Supply Connector 80
Table 2-51: HyperWire Card Part Number 81
Table 2-52: HyperWire Cable Part Numbers 81
Table 2-53: -SX1Component Information 82
Table 2-54: Maximum Additional Storage Energy for a Standard iXC4/XC4 83
Table 2-55: Sync-Related Functions 84
Table 2-56: SyncPort Cables 84
Table 3-1: Digital Output Specifications [-EB1] 90
Table 3-2: Digital Output 1 Connector Pinout [-EB1] 91
Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] 91
Table 3-4: Digital Output 2 Connector Pinout [-EB1] 91
Table 3-5: Mating Connector Part Numbers for the Digital Output 2 Connector [-EB1] 91
Table 3-6: Digital Input Specifications [-EB1] 94
Table 3-7: Digital Input 1 Connector Pinout [-EB1] 94
Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] 94
Table 3-9: Digital Input 2 Connector Pinout [-EB1] 95
Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] 95
Table 3-11: Analog Output Specifications [-EB1] 97
Table 3-12: Analog Output Connector Pinout [-EB1] 97
Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] 97
Table 3-14: Differential Analog Input Specifications [-EB1] 98
Table 3-15: Analog Input Connector Pinout [-EB1] 98
Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] 98
Table 3-17: PSO Specifications [-EB1] 99
Table 3-18: PSO Interface Connector Pinout [-EB1] 99
Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 99
Table 4-1: Standard Interconnection Cables 101
Table 5-1: LEDDescription 105
Table 5-2: Troubleshooting 105
Table 5-3: Preventative Maintenance 106
Table 5-4: Control Board Fuse Specifications 107
List of Tables iXC4/XC4 Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXC4/XC4
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 1/28/2022
iXC4/XC4 Hardware Manual EU Declaration of Conformity
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Agency Approvals
Aerotech tested its XC4 drives and found that they obey the standards that follow:
IMPORTANT: iXC4 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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