Aerotech Automation1 XC2 User manual

Revision 2.01
Automation1 XC2 PWMDigital Drive
HARDWAREMANUAL

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Product names mentioned herein are used for identification purposes only and may be
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Copyright © 2019-2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 XC2 PWMDigital Drive 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Agency Approvals 11
Safety Procedures and Warnings 13
Installation Overview 15
Chapter 1: Introduction 17
1.1. Electrical Specifications 20
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 26
Chapter 2: Installation and Configuration 27
2.1. Input Power Connections 28
2.1.1. Control Supply Connector 28
2.1.2. Motor Supply Connector 29
2.1.3. Minimizing Noise for EMC/CECompliance 30
2.2. Motor Power Output Connector 31
2.2.1. Brushless Motor Connections 32
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 33
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 34
2.2.2. DCBrush Motor Connections 35
2.2.2.1. DC Brush Motor Phasing 36
2.2.3. Stepper Motor Connections 37
2.2.3.1. Stepper Motor Phasing 38
2.3. Feedback Connector 39
2.3.1. Primary Encoder Inputs 40
2.3.1.1. Square WaveEncoder 41
2.3.1.2. Absolute Encoder 42
2.3.1.3. Sine Wave Encoder [-MX1 Option] 43
2.3.1.4. Encoder Phasing 45
2.3.2. Hall-Effect Inputs 46
2.3.3. Thermistor Input 47
2.3.4. Encoder Fault Input 48
2.3.5. End of Travel and Home Limit Inputs 49
2.3.5.1. End of Travel and Home Limit Phasing 51
2.3.6. Brake Outputs 52
2.4. Safe Torque Off Input (STO) 53
2.4.1. STOStandards 55
2.4.2. STO Functional Description 56
2.4.3. STO Startup Validation Testing 57
2.4.4. STO Diagnostics 58
2.5. HyperWire Interface 59
2.6. System Interconnection 60
2.7. PC Configuration and Operation Information 62
Chapter 3: -EB1 I/O Option Board 63
3.1. Position Synchronized Output Interface [-EB1] 64
3.2. Auxiliary Encoder Input [-EB1] 66
3.2.1. Square WaveEncoder 67
3.3. Analog I/O [-EB1] 68
3.3.1. Analog Input (Differential) [-EB1] 69
3.3.2. Analog Output 0 [-EB1] 70
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3.4. Digital Inputs [-EB1] 71
3.5. Digital Outputs [-EB1] 73
Chapter 4: Cables and Accessories 77
4.1. DIN Rail Mounting 78
4.2. Joystick Interface 79
4.3. Handwheel Interface 80
4.4. Dual-PSO Adapter Cable 81
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
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List of Figures
Figure 1-1: XC2 High Performance PWMAmplifier 17
Figure 1-2: Functional Diagram 19
Figure 1-3: Dimensions 23
Figure 1-4: Dimensions [-EB1] 24
Figure 2-1: Control Supply Connections 28
Figure 2-2: Motor Supply Connections 29
Figure 2-3: Brushless Motor Configuration 32
Figure 2-4: Positive Motor Direction 33
Figure 2-5: Encoder and Hall Signal Diagnostics 33
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 34
Figure 2-7: Brushless Motor Phasing Goal 34
Figure 2-8: DC Brush Motor Configuration 35
Figure 2-9: Positive Motor Direction 36
Figure 2-10: Stepper Motor Configuration 37
Figure 2-11: Positive Motor Direction 38
Figure 2-12: Square Wave Encoder Schematic (Feedback Connector) 41
Figure 2-13: Absolute Encoder Schematic (Feedback Connector) 42
Figure 2-14: Sine Wave Encoder Phasing Reference Diagram 43
Figure 2-15: Sine Wave Encoder Schematic (Feedback Connector) 44
Figure 2-16: Encoder Phasing Reference Diagram (Standard) 45
Figure 2-17: Position Feedback in the DiagnosticDisplay 45
Figure 2-18: Hall-Effect Inputs Schematic (Feedback Connector) 46
Figure 2-19: Thermistor Input Schematic (Feedback Connector) 47
Figure 2-20: Encoder Fault Input Schematic (Feedback Connector) 48
Figure 2-21: End of Travel and Home Limit Input Connections 50
Figure 2-22: End of Travel and Home Limit Input Schematic (Feedback Connector) 50
Figure 2-23: End of Travel and Home Limit Input Diagnostic Display 51
Figure 2-24: Brake Connected to the 25-Pin Feedback Connector (Typical) 52
Figure 2-25: Typical Configuration 54
Figure 2-26: STO Timing 58
Figure 2-27: System Wiring Drawing (Best Practice) 60
Figure 2-28: System Interconnection Drawing (Best Practice) 61
Figure 3-1: XC2 with -EB1 I/O Option Board Connectors 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 Input Schematic [-EB1] 69
Figure 3-7: Analog Output Schematic [-EB1] 70
Figure 3-8: Digital Inputs Schematic [-EB1] 71
Figure 3-9: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 72
Figure 3-10: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 72
Figure 3-11: Digital Outputs Schematic [-EB1] 74
Figure 3-12: Digital Outputs Connected in Current Sourcing Mode [-EB1] 75
Figure 3-13: Digital Outputs Connected in Current Sinking Mode [-EB1] 75
Figure 4-1: Din Rail Clip Dimensions 78
Figure 4-2: Two Axis Joystick Interface 79
Figure 4-3: Handwheel Interconnection to the Aux Connector 80
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Figure 4-4: Dual-Axis PSOCable Connection 81
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List of Tables
Table 1-1: FeatureSummary 18
Table 1-2: Electrical Specifications 20
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 Wiring Specifications 28
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 28
Table 2-3: Motor Supply Connector Wiring Specifications 29
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 29
Table 2-5: Motor Power Output Connector Pinout 31
Table 2-6: Mating Connector Part Numbers for the Motor Power Output Connector 31
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 32
Table 2-8: Hall Signal Diagnostics 33
Table 2-9: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 35
Table 2-10: Wire Colors for Aerotech-Supplied Stepper Motor Cables 37
Table 2-11: Feedback Connector Pinout 39
Table 2-12: Mating Connector Part Numbers for the Feedback Connector 39
Table 2-13: Multiplier Options 40
Table 2-14: Primary Encoder Input Pins on the Feedback Connector 40
Table 2-15: Square Wave Encoder Specifications 41
Table 2-16: Sine Wave Encoder Specifications 43
Table 2-17: Hall-Effect Feedback Pins on the Feedback Connector 46
Table 2-18: Thermistor Input Pin on the Feedback Connector 47
Table 2-19: Encoder Fault Input Pin on the Feedback Connector 48
Table 2-20: End of Travel and Home Limit Pins on the Feedback Connector 49
Table 2-21: Brake Output Pins on the Feedback Connector 52
Table 2-22: Brake Control Specifications 52
Table 2-23: STO Connector Pinout 53
Table 2-24: Mating Connector Part Numbers for the STOConnector 53
Table 2-25: STOElectrical Specifications 54
Table 2-26: STOStandards 55
Table 2-27: STOStandards Data 55
Table 2-28: STOSignal Delay 57
Table 2-29: Motor Function Relative to STOInput State 57
Table 2-30: STOTiming 58
Table 2-31: HyperWire Card Part Number 59
Table 2-32: HyperWire Cable Part Numbers 59
Table 3-1: PSO Specifications [-EB1] 64
Table 3-2: PSO Interface Connector Pinout [-EB1] 64
Table 3-3: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 64
Table 3-4: Auxiliary Encoder Connector Pinout 66
Table 3-5: Mating Connector Part Numbers for the AUX Connector 66
Table 3-6: Square Wave Encoder Specifications 67
Table 3-7: Analog I/O Connector Pinout [-EB1] 68
Table 3-8: Mating Connector Part Numbers for the Analog I/O Connector [-EB1] 68
Table 3-9: Differential Analog Input Specifications [-EB1] 69
Table 3-10: Analog Input Pins on the Analog I/OConnector [-EB1] 69
Table 3-11: Analog Output Specifications [-EB1] 70
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Table 3-12: Analog Output Pins on the Analog I/OConnector [-EB1] 70
Table 3-13: Digital Input Specifications [-EB1] 71
Table 3-14: Digital Input Connector Pinout [-EB1] 71
Table 3-15: Mating Connector Part Numbers for the Digital Input Connector [-EB1] 71
Table 3-16: Digital Output Specifications [-EB1] 73
Table 3-17: Digital Output Connector Pinout [-EB1] 73
Table 3-18: Mating Connector Part Numbers for the Digital Output Connector [-EB1] 73
Table 4-1: Standard Interconnection Cables 77
Table 4-2: Mounting Parts 78
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
List of Tables XC2 Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product 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
EU 2015/863 Directive, Restricted Substances (RoHS 3)
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 61326-1:2013 EMCRequirements for Electrical Equipment
EN 61010-1:2010/A1:2019 Safety Requirements for Electrical Equipment
EN ISO 13849-1:2015 SafetyRelated Parts of Control Systems
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 3/25/2021
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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 #: U8V 068995 0028 Rev. 02
Standards: CAN/CSA-C22.2 No. 61010-1:2012/U2:2016-04; EN 61010-
1:2010/A1:2019; UL 61010-1:2012/R:2016-04
Approval: Safety Components (STO)
Approving Agency: TUVSUD
Certificate #: Z10 068995 0030 Rev. 00
Standards: IEC61508-1:2010 (up to SIL3)
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 XC2
drive.
lRead all parts of this manual before you install or operate the XC2 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.
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 XC2 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 main-
tenance 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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Installation Overview
This image shows the order in which to make connections and settings that are typical to the 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.
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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.
Figure 1: Installation ConnectionOverview
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Chapter 1: Introduction
The XC2 is a high performance digital drive based on the HyperWire communication protocol. The drive
provides deterministic behavior, auto-identification, is fully software configurable. A double precision
floating point DSP controls the digital PID and current loops in the XC2.
Figure 1-1: 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.
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
PSO (requires -EB1 option) Section 3.1.
-PSO1 One-axis PSO firing (includes One-axis Part-Speed PSO)
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 1-2: Functional Diagram
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1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description XC2-10
Motor
Supply
Input Voltage 15-100 VDC max
Input Current
(Continuous) 5 Arms
Input Current Refer to Section 1.1.1. System Power Requirements
Control
Supply
Input Voltage 24 VDC
Input Current 2 A max, 0.4 Atypical without brake
Output Voltage (1) 15-100 VDC
Peak Output Current (1 second) 10 A
Continuous Output Current 5 A
Power Amplifier Bandwidth 2500 Hz maximum (software selectable)
Power Amplifier Efficiency 85% - 95% (2)
PWM Switching Frequency 20 kHz
Minimum Load Inductance 0.1 mH @100 VDC
User Power Supply Output 5 VDC (@ 500 mA)
Modes of Operation Brushless; Brush; Stepper
Protective Features
Output short circuit; Peak over current; RMS over current; Over
temperature; Control power supply under voltage; Power stage
bias supply under voltage
(1) DC input voltage and load dependent.
(2) Dependent on total output power: efficiency increases with increasing output power.
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