Aerotech Automation1 iXL2e User manual

Revision 1.04
Automation1 iXL2e and XL2e High-Performance
Linear Digital Drives
HARDWAREMANUAL

GLOBALTECHNICALSUPPORT
Go to the Global Technical Support Portal for information and support about your
Aerotech, Inc. products. The 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 email or have it
available before you call.
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 © 2021-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 iXL2e and XL2e High-Performance Linear 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: iXL2e/XL2e Overview 17
1.1. Electrical Specifications 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 26
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
2.2. Motor Power Output Connector 29
2.2.1. Brushless Motor Connections 30
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 31
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 32
2.2.2. DCBrush Motor Connections 33
2.2.2.1. DC Brush Motor Phasing 33
2.2.3. Stepper Motor Connections 34
2.2.3.1. Stepper Motor Phasing 34
2.2.4. Three Phase Stepper Motor Connections 35
2.2.4.1. Stepper Motor Phasing 35
2.3. Feedback Connector 36
2.3.1. Primary Encoder Inputs 37
2.3.1.1. Square WaveEncoder (Primary) 38
2.3.1.2. Absolute Encoder (Primary) 39
2.3.1.3. Sine Wave Encoder (Primary) [-MX2/-MX3 Option] 40
2.3.1.4. Encoder Phasing 41
2.3.2. Hall-Effect Inputs 42
2.3.3. Thermistor Input 43
2.3.4. Encoder Fault Input 44
2.3.5. End of Travel and Home Limit Inputs 45
2.3.5.1. End of Travel and Home Limit Phasing 47
2.3.6. Brake Outputs 48
2.4. Safe Torque Off Input (STO) 49
2.4.1. STOStandards 51
2.4.2. STO Functional Description 52
2.4.3. STO Startup Validation Testing 53
2.4.4. STO Diagnostics 54
2.5. HyperWire Interface 55
2.6. Sync Port 56
2.7. System Interconnection 57
2.8. PC Configuration and Operation Information 60
Chapter 3: -EB1/-EB2 Option Expansion Board 61
3.1. PSOInterface [-EB1/-EB2] 62
3.2. Auxiliary Encoder Interface [-EB1/-EB2] 64
3.2.1. Square WaveEncoder (Auxiliary) 65
3.2.2. Absolute Encoder (Auxiliary) 66
Hardware Manual iXL2e/XL2e
www.aerotech.com 3

3.2.3. Sine Wave Encoder (Auxiliary) [-MX3 Option] 67
3.3. Analog I/O [-EB1] 69
3.3.1. Analog Output 0 [-EB1] 70
3.3.2. Analog Input (Differential) [-EB1] 71
3.4. Digital Outputs [-EB1] 72
3.5. Digital Inputs [-EB1] 75
3.6. Industrial Ethernet (iXL2e -EB2 Option Only) 78
Chapter 4: Cables and Accessories 79
4.1. DIN Rail Mounting 80
4.2. Joystick Interface 81
4.3. Handwheel Interface 82
Chapter 5: Maintenance 83
5.1. Preventative Maintenance 84
5.2. Fuse Specifications 85
Appendix A: Warranty and Field Service 87
Appendix B: Revision History 89
Index 91
iXL2e/XL2e Hardware Manual
4 www.aerotech.com

List of Figures
Figure 1-1: iXL2e High-Performance Linear Digital Drive 17
Figure 1-2: XL2e High-Performance Linear Digital Drive 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 30
Figure 2-4: Positive Motor Direction 31
Figure 2-5: Encoder and Hall Signal Diagnostics 31
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 32
Figure 2-7: Brushless Motor Phasing Goal 32
Figure 2-8: DC Brush Motor Configuration 33
Figure 2-9: Positive Motor Direction 33
Figure 2-10: Stepper Motor Configuration 34
Figure 2-11: Positive Motor Direction 34
Figure 2-12: Three Phase Stepper Motor Configuration 35
Figure 2-13: Positive Motor Direction 35
Figure 2-14: Square Wave Encoder Schematic (Feedback Connector) 38
Figure 2-15: Absolute Encoder Schematic (Feedback Connector) 39
Figure 2-16: Sine Wave Encoder Phasing Reference Diagram 40
Figure 2-17: Encoder Phasing Reference Diagram (Standard) 41
Figure 2-18: Position Feedback in the DiagnosticDisplay 41
Figure 2-19: Hall-Effect Inputs Schematic (Feedback Connector) 42
Figure 2-20: Thermistor Input Schematic (Feedback Connector) 43
Figure 2-21: Encoder Fault Input Schematic (Feedback Connector) 44
Figure 2-22: End of Travel and Home Limit Input Connections 46
Figure 2-23: End of Travel and Home Limit Input Schematic (Feedback Connector) 46
Figure 2-24: End of Travel and Home Limit Input Diagnostic Display 47
Figure 2-25: Brake Connected to the 25-Pin Feedback Connector (Typical) 48
Figure 2-26: Typical STO Configuration 50
Figure 2-27: STO Timing 54
Figure 2-28: Drive-Based System Wiring Drawing (Best Practice) 57
Figure 2-29: PC-Based System Wiring Drawing (Best Practice) 57
Figure 2-30: Drive-Based System Interconnection Drawing (Best Practice) 58
Figure 2-31: PC-Based System Interconnection Drawing (Best Practice) 59
Figure 3-1: Expansion Option Board Connectors (iXL2e shown) 61
Figure 3-2: PSO Output Sources Current 63
Figure 3-3: PSOOutput Sinks Current 63
Figure 3-4: PSO TTLOutputs Schematic 63
Figure 3-5: Square Wave Encoder Interface (Aux Connector) 65
Figure 3-6: Absolute Encoder Schematic (Auxiliary Encoder Connector) 66
Figure 3-7: Sine Wave Encoder Phasing Reference Diagram 67
Figure 3-8: Sine Wave Encoder Schematic (Aux Connector) 68
Figure 3-9: Analog Output Schematic [-EB1] 70
Figure 3-10: Analog Input Schematic [-EB1] 71
Figure 3-11: Digital Outputs Schematic [-EB1] 73
Figure 3-12: Digital Outputs Connected in Current Sourcing Mode [-EB1] 74
Hardware Manual iXL2e/XL2e
www.aerotech.com 5

Figure 3-13: Digital Outputs Connected in Current Sinking Mode [-EB1] 74
Figure 3-14: Digital Inputs Schematic [-EB1] 76
Figure 3-15: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 77
Figure 3-16: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 77
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
iXL2e/XL2e Hardware Manual
6 www.aerotech.com

List of Tables
Table 1-1: FeatureSummary 19
Table 1-2: Linear Amplifier Specifications 21
Table 1-3: Mounting Specifications 22
Table 1-4: Environmental Specifications 25
Table 1-5: Drive and Software Compatibility 26
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 29
Table 2-6: Motor Power Output Mating Connector Ratings 29
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 30
Table 2-8: Hall Signal Diagnostics 31
Table 2-9: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 33
Table 2-10: Wire Colors for Aerotech-Supplied Stepper Motor Cables 34
Table 2-11: Feedback Connector Pinout 36
Table 2-12: Feedback Mating Connector Ratings 36
Table 2-13: Multiplier Options 37
Table 2-14: Primary Encoder Pins on the Feedback Connector 37
Table 2-15: Square Wave Encoder Specifications 38
Table 2-16: Sine Wave Encoder Specifications 40
Table 2-17: Hall-Effect Feedback Pins on the Feedback Connector 42
Table 2-18: Thermistor Input Pin on the Feedback Connector 43
Table 2-19: Encoder Fault Input Pin on the Feedback Connector 44
Table 2-20: End of Travel and Home Limit Pins on the Feedback Connector 45
Table 2-21: Brake Output Pins on the Feedback Connector 48
Table 2-22: Brake Control Specifications 48
Table 2-23: STO Connector Pinout 49
Table 2-24: STOMating ConnectorRatings 49
Table 2-25: STOElectrical Specifications 50
Table 2-26: STOStandards 51
Table 2-27: STOStandards Data 51
Table 2-28: STOSignal Delay 53
Table 2-29: Motor Function Relative to STOInput State 53
Table 2-30: STOTiming 54
Table 2-31: HyperWire Card Part Number 55
Table 2-32: HyperWire Cable Part Numbers 55
Table 2-33: Sync-Related Functions 56
Table 2-34: SyncPort Cables 56
Table 3-1: PSO Specifications [-EB1/-EB2] 62
Table 3-2: PSO Interface Connector Pinout [-EB1/-EB2] 62
Table 3-3: PSO Interface Mating Connector Ratings [-EB1/-EB2] 62
Table 3-4: Auxiliary Encoder Connector Pinout 64
Table 3-5: AUX Mating Connector Ratings 64
Table 3-6: Square Wave Encoder Specifications 65
Table 3-7: Sine Wave Encoder Specifications 67
Table 3-8: Analog I/O Connector Pinout [-EB1] 69
Table 3-9: Analog I/O Mating Connector Ratings [-EB1] 69
Hardware Manual iXL2e/XL2e
www.aerotech.com 7

Table 3-10: Analog Output Specifications [-EB1] 70
Table 3-11: Analog Output Pins on the Analog I/OConnector [-EB1] 70
Table 3-12: Differential Analog Input Specifications [-EB1] 71
Table 3-13: Analog Input Pins on the Analog I/OConnector [-EB1] 71
Table 3-14: Digital Output Specifications [-EB1] 72
Table 3-15: Digital Output Connector Pinout [-EB1] 72
Table 3-16: Digital Output Mating Connector Ratings [-EB1] 72
Table 3-17: Digital Input Specifications [-EB1] 75
Table 3-18: Digital Input Connector Pinout [-EB1] 75
Table 3-19: Digital Input Mating Connector Ratings [-EB1] 75
Table 4-1: Standard Interconnection Cables 79
Table 4-2: Mounting Parts 80
Table 5-1: LEDDescription 83
Table 5-2: Troubleshooting 83
Table 5-3: Preventative Maintenance 84
Table 5-4: Control Board Fuse Specifications 85
iXL2e/XL2e Hardware Manual
8 www.aerotech.com

EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXL2e/XL2e
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 61800-3:2017 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 55011/55032:2015 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
Hardware Manual iXL2e/XL2e
www.aerotech.com 9

Agency Approvals
Aerotech tested its iXL2e/XL2e 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
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.
iXL2e/XL2e Hardware Manual
10 www.aerotech.com

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
Hardware Manual iXL2e/XL2e
www.aerotech.com 11

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.
iXL2e/XL2e Hardware Manual
12 www.aerotech.com

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.
Hardware Manual iXL2e/XL2e
www.aerotech.com 13

Installation Overview
The images that follow show the order in which to make connections and settings that are typical to
the iXL2e/XL2e. 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 iXL2e
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.
iXL2e/XL2e Hardware Manual
14 www.aerotech.com

Figure 2: Installation ConnectionOverview for the XL2e
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.
Hardware Manual iXL2e/XL2e
www.aerotech.com 15

This page intentionally left blank.
iXL2e/XL2e Hardware Manual
16 www.aerotech.com

Chapter 1: iXL2e/XL2e Overview
The iXL2e is a high-performance linear drive-based controller. It runs the Automation1-iSMC
controller to generate commands for itself as well as for additional drives on the chain.
The XL2e is a high performance linear amplifier. The XL2e 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: iXL2e High-Performance Linear Digital Drive
Hardware Manual iXL2e/XL2e
www.aerotech.com 17

Figure 1-2: XL2e High-Performance Linear Digital Drive
iXL2e/XL2e Hardware Manual
18 www.aerotech.com

Table 1-1: FeatureSummary
Standard Features
l24 VDC control supply input (Section 2.1.1.)
l±5 to ±48 VDC bipolar 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 (iXL2e Only)
lOne USB2.0 Type CPort (iXL2e 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
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
-EB2
Industrial Ethernet Expansion Board (iXL2e 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)
-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).
NOTE:Requires -EB1 option to generate a PSO output pulse
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.
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
Hardware Manual iXL2e/XL2e
www.aerotech.com 19

The block diagram that follows shows a summary of the connector signals.
Figure 1-3: Functional Diagram
iXL2e/XL2e Hardware Manual
20 www.aerotech.com