Aerotech Automation1 XC4e User manual

Revision 2.01
Automation1 XC4e High-Performance
PWMDigital Drive
HARDWAREMANUAL

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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 © 2018-2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 XC4e High-Performance 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. Transformer Options 30
2.1.4. Minimizing Noise for EMC/CECompliance 37
2.2. Motor Power Output Connector 38
2.2.1. Brushless Motor Connections 39
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 40
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 41
2.2.2. DCBrush Motor Connections 42
2.2.2.1. DC Brush Motor Phasing 43
2.2.3. Stepper Motor Connections 44
2.2.3.1. Stepper Motor Phasing 45
2.3. Feedback Connector 46
2.3.1. Primary Encoder Inputs 47
2.3.1.1. Square WaveEncoder 48
2.3.1.2. Absolute Encoder 49
2.3.1.3. Sine Wave Encoder [-MX2/-MX3 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 68
2.5.1.2. Absolute Encoder 69
2.5.1.3. Sine Wave Encoder [-MX3 Option] 70
2.5.2. Position Synchronized Output (PSO) 72
2.5.3. Digital Outputs 74
2.5.4. Digital Inputs 77
2.5.5. High-Speed Inputs 79
2.5.6. Analog Output 0 80
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2.5.7. Analog Input 0 (Differential) 81
2.6. Brake Power Supply Connector 82
2.7. HyperWire Interface 83
2.8. External Shunt Option [-SX1] 84
2.9. Sync Port 86
2.10. System Interconnection 87
2.11. PC Configuration and Operation Information 89
Chapter 3: -EB1 I/O Option Board 91
3.1. Digital Outputs [-EB1] 92
3.2. Digital Inputs [-EB1] 96
3.3. Analog Outputs [-EB1] 99
3.4. Analog Inputs [-EB1] 100
3.5. Position Synchronized Output Interface [-EB1] 101
Chapter 4: Cables and Accessories 103
4.1. Joystick Interface 104
4.2. Handwheel Interface 106
Chapter 5: Maintenance 107
5.1. Preventative Maintenance 108
5.2. Fuse Specifications 109
Appendix A: Warranty and Field Service 111
Appendix B: Revision History 113
Index 115
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List of Figures
Figure 1-1: XC4e Digital Drive 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: Transformer Examples 30
Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) 31
Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) 32
Figure 2-6: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) 33
Figure 2-7: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) 34
Figure 2-8: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) 35
Figure 2-9: TM3/TM5 Transformer Control and Motor Power Wiring 36
Figure 2-10: Brushless Motor Configuration 39
Figure 2-11: Positive Motor Direction 40
Figure 2-12: Encoder and Hall Signal Diagnostics 40
Figure 2-13: Brushless Motor Phasing Oscilloscope Example 41
Figure 2-14: Brushless Motor Phasing Goal 41
Figure 2-15: DC Brush Motor Configuration 42
Figure 2-16: Positive Motor Direction 43
Figure 2-17: Stepper Motor Configuration 44
Figure 2-18: Positive Motor Direction 45
Figure 2-19: Square Wave Encoder Schematic (Feedback Connector) 48
Figure 2-20: Absolute Encoder Schematic (Feedback Connector) 49
Figure 2-21: Sine Wave Encoder Phasing Reference Diagram 50
Figure 2-22: Sine Wave Encoder Schematic (Feedback Connector) 51
Figure 2-23: Encoder Phasing Reference Diagram (Standard) 52
Figure 2-24: Position Feedback in the DiagnosticDisplay 52
Figure 2-25: Hall-Effect Inputs Schematic (Feedback Connector) 53
Figure 2-26: Thermistor Input Schematic (Feedback Connector) 54
Figure 2-27: Encoder Fault Input Schematic (Feedback Connector) 55
Figure 2-28: End of Travel and Home Limit Input Connections 57
Figure 2-29: End of Travel and Home Limit Input Schematic (Feedback Connector) 57
Figure 2-30: End of Travel and Home Limit Input Diagnostic Display 58
Figure 2-31: Brake Connected to the 25-Pin Feedback Connector (Typical) 59
Figure 2-32: Typical Configuration 61
Figure 2-33: STO Timing 65
Figure 2-34: Square Wave Encoder Interface (Aux I/OConnector) 68
Figure 2-35: Absolute Encoder Schematic (Auxiliary I/O Connector) 69
Figure 2-36: Sine Wave Encoder Phasing Reference Diagram 70
Figure 2-37: Sine Wave Encoder Schematic (Auxiliary I/OConnector) 71
Figure 2-38: PSOInterface 73
Figure 2-39: Digital Output Schematic (Aux I/OConnector) 75
Figure 2-40: Digital Outputs Connected in Current Sourcing Mode 76
Figure 2-41: Digital Outputs Connected in Current Sinking Mode 76
Figure 2-42: Digital Inputs Schematic (Aux I/OConnector) 77
Figure 2-43: Digital Inputs Connected to Current Sinking Devices 78
Figure 2-44: Digital Inputs Connected to Current Sourcing Devices 78
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Figure 2-45: High-Speed Inputs 79
Figure 2-46: Analog Output 0 Schematic 80
Figure 2-47: Analog Input 0 Schematic 81
Figure 2-48: System Wiring Drawing (Best Practice) 87
Figure 2-49: PC-Based Controller System Interconnection (Best Practice) 88
Figure 3-1: XC4e with -EB1 I/O Option Board Connectors 91
Figure 3-2: Digital Outputs Schematic [-EB1] 94
Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 95
Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 95
Figure 3-5: Digital Inputs Schematic [-EB1] 97
Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 98
Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 98
Figure 3-8: Analog Output Typical Connection [-EB1] 99
Figure 3-9: Analog Input Typical Connection [-EB1] 100
Figure 3-10: PSO Output Sources Current 102
Figure 3-11: PSOOutput Sinks Current 102
Figure 3-12: PSO TTLOutputs Schematic 102
Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 104
Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 105
Figure 4-3: Handwheel Interconnection to Aux I/O Connector 106
Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 106
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List of Tables
Table 1-1: Featuresand Options 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 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: Nominal Motor Operating Voltages / Required ACVoltages 30
Table 2-6: TransformerOptions 30
Table 2-7: Motor Power Output Connector Pinout 38
Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector 38
Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables 39
Table 2-10: Hall Signal Diagnostics 40
Table 2-11: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 42
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: Sine Wave Encoder Specifications 70
Table 2-38: PSO Specifications 72
Table 2-39: PSOPins on the Auxiliary I/OConnector 72
Table 2-40: Digital Output Specifications 74
Table 2-41: Digital Output Pins on the Auxiliary I/O Connector 74
Table 2-42: Digital Input Specifications 77
Table 2-43: Digital Input Pins on the Auxiliary I/O Connector 77
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Table 2-44: High-Speed Input Specifications 79
Table 2-45: High-Speed Input Pins on the Auxiliary I/O Connector 79
Table 2-46: Analog Output Specifications 80
Table 2-47: Analog Output Pins on the Auxiliary I/O Connector 80
Table 2-48: Analog Input Specifications 81
Table 2-49: Analog Input Pins on the Auxiliary I/O Connector 81
Table 2-50: Brake Power Supply Connector Pinout 82
Table 2-51: Mating Connector Part Numbers for the Brake Power Supply Connector 82
Table 2-52: HyperWire Card Part Number 83
Table 2-53: HyperWire Cable Part Numbers 83
Table 2-54: -SX1Component Information 84
Table 2-55: Maximum Additional Storage Energy for a Standard XC4e 85
Table 2-56: Sync-Related Functions 86
Table 2-57: SyncPort Cables 86
Table 3-1: Digital Output Specifications [-EB1] 92
Table 3-2: Digital Output 1 Connector Pinout [-EB1] 93
Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] 93
Table 3-4: Digital Output 2 Connector Pinout [-EB1] 93
Table 3-5: Mating Connector Part Numbers for the Digital Output 2 Connector [-EB1] 93
Table 3-6: Digital Input Specifications [-EB1] 96
Table 3-7: Digital Input 1 Connector Pinout [-EB1] 96
Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] 96
Table 3-9: Digital Input 2 Connector Pinout [-EB1] 97
Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] 97
Table 3-11: Analog Output Specifications [-EB1] 99
Table 3-12: Analog Output Connector Pinout [-EB1] 99
Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] 99
Table 3-14: Differential Analog Input Specifications [-EB1] 100
Table 3-15: Analog Input Connector Pinout [-EB1] 100
Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] 100
Table 3-17: PSO Specifications [-EB1] 101
Table 3-18: PSO Interface Connector Pinout [-EB1] 101
Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 101
Table 4-1: Standard Interconnection Cables 103
Table 5-1: LEDDescription 107
Table 5-2: Troubleshooting 107
Table 5-3: Preventative Maintenance 108
Table 5-4: Control Board Fuse Specifications 109
List of Tables XC4e Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XC4e
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
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 3/24/2021
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Agency Approvals
Aerotech tested its XC4e 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
XC4e drive.
lRead all parts of this manual before you install or operate the XC4e 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 XC4e 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 ten (10) minutes 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 XC4e. 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 2.7.
3Connect additional I/O as required by your application
(if you purchased the I/O option).
Section 2.5./
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 XC4e 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 XC4e.
The XC4e offers standard Safe Torque Off (STO) inputs and optional Position Synchronized Output (PSO)
outputs. The XC4e is offered with optional encoder interpolation features (-MX2/-MX3), an auxiliary
encoder input for dual loop control, dedicated analog and digital I/O (expandable with the -EB1 option),
and separate power connections for motor and control supply voltages.
Figure 1-1: XC4e Digital Drive
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Table 1-1: Featuresand Options
Standard Features
l100-240 VAC control supply inputs Section 2.1.1.
l0-240 VAC motor supply inputs (producing 340 VDC) Section 2.1.2.
lLine driver square wave quadrature encoder input for position and velocity feedback Section 2.3.1.
lAbsolute Encoder support on the Feedback Connector Section 2.3.1.2.
lOne fail-safe brake output Section 2.3.6.
lTwo STOsense inputs Section 2.4.
lLine driver square wave auxiliary quadrature encoder input or output for PSO Section 2.5.1.
lAbsolute Encoder support on the Auxiliary I/OConnector Section 2.5.1.2.
lFour digital user outputs Section 2.5.3.
lSix digital user inputs
nFour Digital Inputs Section 2.5.4.
nTwo High-Speed Inputs Section 2.5.5.
lOne 16-bit analog output (±10 V) Section 2.5.6.
lOne 16-bit differential analog input (±10 V) Section 2.5.7.
Options
Peak Current Section 1.1.
-10 10 A Peak, 5 A Continuous Current
-20 20 A Peak, 10 A Continuous Current
-30 30 A Peak, 10 A Continuous Current
Expansion Board Chapter 3
-EB0 No expansion board
-EB1
I/Oexpansion board
lThree 16-bit analog outputs (±10 V)
lThree 16-bit differential analog inputs (±10 V)
l16 digital logic inputs (5 - 24 VDC); connect to current sourcing or sinking devices
l16 digital logic outputs (5 - 24 VDC); user defined as current sourcing or sinking
lDigital logic laser firing (PSO) output
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.
PSO Section 2.5.2.
-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).
External Shunt Section 2.8.
-SX0 No connector for the External Shunt
-SX1 Connection provided for an external shunt resistor network
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
Chapter 1: Introduction XC4e Hardware Manual
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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 -10 Option -20 Option -30Option
Motor Supply
Input Voltage 0-240 VAC
Input Frequency 50-60 Hz
Inrush Current 34 Apk @ 240 V
Max Continuous
Input Current 5 Arms 10 Arms 10 Arms
Input Current Refer to Section 1.1.1. System Power Requirements
Control Supply
Input Voltage 100-240 VAC
Input Frequency 50-60 Hz
Inrush Current 68 Apk @ 240 V
Input Power 10 W
Output Voltage (1) 340 VDC
Peak Output Current (1 second) (3) 10 A 20 A 30 A
Continuous Output Current (3) 5 A 10 A 10 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 @160 VDC (1 mH @ 320 VDC)
User Power Supply Output 5 VDC (@ 500 mA)
Modes of Operation Brushless; Brush; Stepper
Protective Features
Output short circuit; Peak over current; DC bus over voltage;
RMS over current; Over temperature; Control power supply
under voltage; Power stage bias supply under voltage
Isolation Optical and transformer isolation between control and
power stages.
(1) AC input voltage and load dependent.
(2) Dependent on total output power: efficiency increases with increasing output power.
(3) Current is measured as the peak amplitude in any motor phase
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