Aerotech Automation1 iXL5e User manual

Revision 1.07
Automation1 iXL5e and XL5e High-Performance
Linear Digital Drives
HARDWAREMANUAL

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

Table of Contents
Automation1 iXL5e and XL5e 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: iXL5e/XL5e Overview 17
1.1. Electrical Specifications 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 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 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) [-MX2/-MX3 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. Auxiliary I/O Connector 57
2.5.1. Auxiliary Encoder Interface 58
2.5.1.1. Square WaveEncoder (Auxiliary) 59
2.5.1.2. Absolute Encoder (Auxiliary) 60
2.5.1.3. Sine Wave Encoder (Auxiliary) [-MX3 Option] 61
2.5.2. Position Synchronized Output (PSO) 63
2.5.3. Digital Outputs 65
2.5.4. Digital Inputs 68
2.5.5. High-Speed Inputs 70
2.5.6. Analog Output 0 71
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2.5.7. Analog Input 0 (Differential) 72
2.6. Brake Power Supply Connector 73
2.7. HyperWire Interface 74
2.8. Sync Port 75
2.9. Industrial Ethernet (iXL5e Only) 75
2.10. System Interconnection 76
2.11. PC Configuration and Operation Information 79
Chapter 3: -EB1 Option Expansion Board 81
3.1. Digital Outputs [-EB1] 82
3.2. Digital Inputs [-EB1] 86
3.3. Analog Outputs [-EB1] 89
3.4. Analog Inputs [-EB1] 90
3.5. PSOInterface [-EB1] 91
Chapter 4: Cables and Accessories 93
4.1. Joystick Interface 94
4.2. Handwheel Interface 96
Chapter 5: Maintenance 97
5.1. Preventative Maintenance 98
5.2. Fuse Specifications 99
Appendix A: Warranty and Field Service 101
Appendix B: Voltage Selection Operation 103
Appendix C: Revision History 105
Index 107
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List of Figures
Figure 1-1: iXL5e High Performance Linear Amplifier 17
Figure 1-2: XL5e High Performance Linear Amplifier 18
Figure 1-3: Functional Diagram 21
Figure 1-4: Dimensions 24
Figure 1-5: Dimensions [-EB1] 25
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: DC Brush Motor Configuration 33
Figure 2-10: Positive Motor Direction 34
Figure 2-11: Stepper Motor Configuration 35
Figure 2-12: Positive Motor Direction 35
Figure 2-13: Three Phase Stepper Motor Configuration 36
Figure 2-14: Positive Motor Direction 36
Figure 2-15: Square Wave Encoder Schematic (Feedback Connector) 39
Figure 2-16: Absolute Encoder Schematic (Feedback Connector) 40
Figure 2-17: Sine Wave Encoder Phasing Reference Diagram 41
Figure 2-18: Sine Wave Encoder Schematic (Feedback Connector) 42
Figure 2-19: Encoder Phasing Reference Diagram (Standard) 43
Figure 2-20: Position Feedback in the DiagnosticDisplay 43
Figure 2-21: Hall-Effect Inputs Schematic (Feedback Connector) 44
Figure 2-22: Thermistor Input Schematic (Feedback Connector) 45
Figure 2-23: Encoder Fault Input Schematic (Feedback Connector) 46
Figure 2-24: End of Travel and Home Limit Input Connections 48
Figure 2-25: End of Travel and Home Limit Input Schematic (Feedback Connector) 48
Figure 2-26: End of Travel and Home Limit Input Diagnostic Display 49
Figure 2-27: Brake Connected to the 25-Pin Feedback Connector (Typical) 50
Figure 2-28: Typical STO Configuration 52
Figure 2-29: STO Timing 56
Figure 2-30: Square Wave Encoder Interface (Aux I/OConnector) 59
Figure 2-31: Absolute Encoder Schematic (Auxiliary I/O Connector) 60
Figure 2-32: Sine Wave Encoder Phasing Reference Diagram 61
Figure 2-33: Sine Wave Encoder Schematic (Auxiliary I/OConnector) 62
Figure 2-34: PSO Interface 64
Figure 2-35: Digital Output Schematic (Aux I/OConnector) 66
Figure 2-36: Digital Outputs Connected in Current Sourcing Mode 67
Figure 2-37: Digital Outputs Connected in Current Sinking Mode 67
Figure 2-38: Digital Inputs Schematic (Aux I/OConnector) 68
Figure 2-39: Digital Inputs Connected to Current Sourcing Devices 69
Figure 2-40: Digital Inputs Connected to Current Sinking Devices 69
Figure 2-41: High-Speed Inputs 70
Figure 2-42: Analog Output 0 Schematic 71
Figure 2-43: Analog Input 0 Schematic 72
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Figure 2-44: Drive-Based System Wiring Drawing (Best Practice) 76
Figure 2-45: PC-Based System Wiring Drawing (Best Practice) 76
Figure 2-46: Drive-Based Controller System Interconnection (Best Practice) 77
Figure 2-47: PC-Based Controller System Interconnection (Best Practice) 78
Figure 3-1: -EB1 I/O Option Board Connectors (iXL5e shown) 81
Figure 3-2: Digital Outputs Schematic [-EB1] 84
Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 85
Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 85
Figure 3-5: Digital Inputs Schematic [-EB1] 87
Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 88
Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 88
Figure 3-8: Analog Output Typical Connection [-EB1] 89
Figure 3-9: Analog Input Typical Connection [-EB1] 90
Figure 3-10: PSO Output Sources Current 92
Figure 3-11: PSOOutput Sinks Current 92
Figure 3-12: PSO TTLOutputs Schematic 92
Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 94
Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 95
Figure 4-3: Handwheel Interconnection to Aux I/O Connector 96
Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 96
Figure B-1: Voltage Selection Switch Access 104
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List of Tables
Table 1-1: FeatureSummary 19
Table 1-2: Linear Amplifier Specifications 22
Table 1-3: Mounting Specifications 23
Table 1-4: Environmental Specifications 26
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: DC Brush Voltage Output Configuration 33
Table 2-10: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 33
Table 2-11: Wire Colors for Aerotech-Supplied Stepper Motor Cables 35
Table 2-12: Feedback Connector Pinout 37
Table 2-13: Feedback Mating Connector Ratings 37
Table 2-14: Multiplier Options 38
Table 2-15: Primary Encoder Pins on the Feedback Connector 38
Table 2-16: Square Wave Encoder Specifications 39
Table 2-17: Sine Wave Encoder Specifications 41
Table 2-18: Hall-Effect Feedback Pins on the Feedback Connector 44
Table 2-19: Thermistor Input Pin on the Feedback Connector 45
Table 2-20: Encoder Fault Input Pin on the Feedback Connector 46
Table 2-21: End of Travel and Home Limit Pins on the Feedback Connector 47
Table 2-22: Brake Output Pins on the Feedback Connector 50
Table 2-23: Brake Control Specifications 50
Table 2-24: STO Connector Pinout 51
Table 2-25: STOMating ConnectorRatings 51
Table 2-26: STOElectrical Specifications 52
Table 2-27: STOStandards 53
Table 2-28: STOStandards Data 53
Table 2-29: STOSignal Delay 55
Table 2-30: Motor Function Relative to STOInput State 55
Table 2-31: STOTiming 56
Table 2-32: Auxiliary I/O Connector Pinout 57
Table 2-33: Auxiliary I/OMating Connector Ratings 57
Table 2-34: Auxiliary Encoder Pins on the Auxiliary I/OConnector 58
Table 2-35: Square Wave Encoder Specifications 59
Table 2-36: Sine Wave Encoder Specifications 61
Table 2-37: PSO Specifications 63
Table 2-38: PSOPins on the Auxiliary I/OConnector 63
Table 2-39: Digital Output Specifications 65
Table 2-40: Digital Output Pins on the Auxiliary I/O Connector 65
Table 2-41: Digital Input Specifications 68
Table 2-42: Digital Input Pins on the Auxiliary I/O Connector 68
Table 2-43: High-Speed Input Specifications 70
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Table 2-44: High-Speed Input Pins on the Auxiliary I/O Connector 70
Table 2-45: Analog Output Specifications 71
Table 2-46: Analog Output Pins on the Auxiliary I/O Connector 71
Table 2-47: Analog Input Specifications 72
Table 2-48: Analog Input Pins on the Auxiliary I/O Connector 72
Table 2-49: Brake Power Supply Connector Pinout 73
Table 2-50: Brake Power Supply Mating Connector Ratings 73
Table 2-51: HyperWire Card Part Number 74
Table 2-52: HyperWire Cable Part Numbers 74
Table 2-53: Sync-Related Functions 75
Table 2-54: SyncPort Cables 75
Table 3-1: Digital Output Specifications [-EB1] 82
Table 3-2: Digital Output 1 Connector Pinout [-EB1] 83
Table 3-3: Digital Output 2 Connector Pinout [-EB1] 83
Table 3-4: Digital Output 1 and 2 Mating Connector Ratings [-EB1] 83
Table 3-5: Digital Input Specifications [-EB1] 86
Table 3-6: Digital Input 1 Connector Pinout [-EB1] 86
Table 3-7: Digital Input 2 Connector Pinout [-EB1] 87
Table 3-8: Digital Input 1 and 2 Mating Connector Ratings [-EB1] 87
Table 3-9: Analog Output Specifications [-EB1] 89
Table 3-10: Analog Output Connector Pinout [-EB1] 89
Table 3-11: Analog Output Mating Connector Ratings [-EB1] 89
Table 3-12: Differential Analog Input Specifications [-EB1] 90
Table 3-13: Analog Input Connector Pinout [-EB1] 90
Table 3-14: Analog Input Mating Connector Ratings [-EB1] 90
Table 3-15: PSO Specifications [-EB1] 91
Table 3-16: PSO Interface Connector Pinout [-EB1] 91
Table 3-17: PSO Interface Mating Connector Ratings [-EB1] 91
Table 4-1: Standard Interconnection Cables 93
Table 5-1: LEDDescription 97
Table 5-2: Troubleshooting 97
Table 5-3: Preventative Maintenance 98
Table 5-4: Fuse Specifications 99
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXL5e/XL5e
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 7/25/2022
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Agency Approvals
Aerotech tested its iXL5e/XL5e 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.
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