Aerotech Automation1 XL5e User manual

Revision 1.01
Automation1 XL5e High-Performance
Linear Digital Drive
HARDWAREMANUAL

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Copyright © 2019-2021, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 XL5e High-Performance Linear Digital Drive 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Safety Procedures and Warnings 11
Installation Overview 13
Chapter 1: Introduction 15
1.1. Electrical Specifications 19
1.2. Mechanical Specifications 20
1.2.1. Mounting and Cooling 20
1.2.2. Dimensions 21
1.3. Environmental Specifications 23
1.4. Drive and Software Compatibility 24
Chapter 2: Installation and Configuration 25
2.1. Input Power Connections 26
2.1.1. Control Supply Connector 26
2.1.2. Motor Supply Connector 27
2.2. Motor Power Output Connector 28
2.2.1. Brushless Motor Connections 29
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 30
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 31
2.2.2. DCBrush Motor Connections 32
2.2.2.1. DC Brush Motor Phasing 33
2.2.3. Stepper Motor Connections 34
2.2.3.1. Stepper Motor Phasing 35
2.3. Feedback Connector 36
2.3.1. Primary Encoder Inputs 37
2.3.1.1. Square WaveEncoder 38
2.3.1.2. Absolute Encoder 39
2.3.1.3. Sine Wave Encoder [-MX2/-MX3 Option] 40
2.3.1.4. Encoder Phasing 42
2.3.2. Hall-Effect Inputs 43
2.3.3. Thermistor Input 44
2.3.4. Encoder Fault Input 45
2.3.5. End of Travel and Home Limit Inputs 46
2.3.5.1. End of Travel and Home Limit Phasing 48
2.3.6. Brake Outputs 49
2.4. Safe Torque Off Input (STO) 50
2.4.1. STOStandards 52
2.4.2. STO Functional Description 53
2.4.3. STO Startup Validation Testing 54
2.4.4. STO Diagnostics 55
2.5. Auxiliary I/O Connector 56
2.5.1. Auxiliary Encoder Inputs 57
2.5.1.1. Square WaveEncoder 58
2.5.1.2. Absolute Encoder 59
2.5.1.3. Sine Wave Encoder [-MX3 Option] 60
2.5.2. Position Synchronized Output (PSO) 62
2.5.3. Digital Outputs 64
2.5.4. Digital Inputs 67
2.5.5. High-Speed Inputs 69
2.5.6. Analog Output 0 70
2.5.7. Analog Input 0 (Differential) 71
2.6. Brake Power Supply Connector 72
2.7. HyperWire Interface 73
2.8. Sync Port 74
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2.9. System Interconnection 75
2.10. PC Configuration and Operation Information 77
Chapter 3: -EB1 I/O Option Board 79
3.1. Digital Outputs [-EB1] 80
3.2. Digital Inputs [-EB1] 84
3.3. Analog Outputs [-EB1] 87
3.4. Analog Inputs [-EB1] 88
3.5. Position Synchronized Output Interface [-EB1] 89
Chapter 4: Cables and Accessories 91
4.1. Joystick Interface 92
4.2. Handwheel Interface 94
Chapter 5: Maintenance 95
5.1. Preventative Maintenance 96
5.2. Fuse Specifications 97
Appendix A: Warranty and Field Service 99
Appendix B: Voltage Selection Operation 101
Appendix C: Revision History 103
Index 105
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List of Figures
Figure 1-1: XL5e High Performance Linear Amplifier 15
Figure 1-2: Functional Diagram 18
Figure 1-3: Dimensions 21
Figure 1-4: Dimensions [-EB1] 22
Figure 2-1: Control Supply Connections 26
Figure 2-2: Motor Supply Connections 27
Figure 2-3: Brushless Motor Configuration 29
Figure 2-4: Positive Motor Direction 30
Figure 2-5: Encoder and Hall Signal Diagnostics 30
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 31
Figure 2-7: Brushless Motor Phasing Goal 31
Figure 2-8: DC Brush Motor Configuration 32
Figure 2-9: DC Brush Motor Configuration 32
Figure 2-10: Positive Motor Direction 33
Figure 2-11: Stepper Motor Configuration 34
Figure 2-12: Positive Motor Direction 35
Figure 2-13: Square Wave Encoder Schematic (Feedback Connector) 38
Figure 2-14: Absolute Encoder Schematic (Feedback Connector) 39
Figure 2-15: Sine Wave Encoder Phasing Reference Diagram 40
Figure 2-16: Sine Wave Encoder Schematic (Feedback Connector) 41
Figure 2-17: Encoder Phasing Reference Diagram (Standard) 42
Figure 2-18: Position Feedback in the DiagnosticDisplay 42
Figure 2-19: Hall-Effect Inputs Schematic (Feedback Connector) 43
Figure 2-20: Thermistor Input Schematic (Feedback Connector) 44
Figure 2-21: Encoder Fault Input Schematic (Feedback Connector) 45
Figure 2-22: End of Travel and Home Limit Input Connections 47
Figure 2-23: End of Travel and Home Limit Input Schematic (Feedback Connector) 47
Figure 2-24: End of Travel and Home Limit Input Diagnostic Display 48
Figure 2-25: Brake Connected to the 25-Pin Feedback Connector (Typical) 49
Figure 2-26: Typical Configuration 51
Figure 2-27: STO Timing 55
Figure 2-28: Square Wave Encoder Interface (Aux I/OConnector) 58
Figure 2-29: Absolute Encoder Schematic (Auxiliary I/O Connector) 59
Figure 2-30: Sine Wave Encoder Phasing Reference Diagram 60
Figure 2-31: Sine Wave Encoder Schematic (Auxiliary I/OConnector) 61
Figure 2-32: PSOInterface 63
Figure 2-33: Digital Output Schematic (Aux I/OConnector) 65
Figure 2-34: Digital Outputs Connected in Current Sourcing Mode 66
Figure 2-35: Digital Outputs Connected in Current Sinking Mode 66
Figure 2-36: Digital Inputs Schematic (Aux I/OConnector) 67
Figure 2-37: Digital Inputs Connected to Current Sinking Devices 68
Figure 2-38: Digital Inputs Connected to Current Sourcing Devices 68
Figure 2-39: High-Speed Inputs 69
Figure 2-40: Analog Output 0 Schematic 70
Figure 2-41: Analog Input 0 Schematic 71
Figure 2-42: System Wiring Drawing (Best Practice) 75
Figure 2-43: System Interconnection Drawing (Best Practice) 76
Figure 3-1: XL5e with -EB1 I/O Option Board Connectors 79
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Figure 3-2: Digital Outputs Schematic [-EB1] 82
Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 83
Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 83
Figure 3-5: Digital Inputs Schematic [-EB1] 85
Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 86
Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 86
Figure 3-8: Analog Output Typical Connection [-EB1] 87
Figure 3-9: Analog Input Typical Connection [-EB1] 88
Figure 3-10: PSO Output Sources Current 90
Figure 3-11: PSOOutput Sinks Current 90
Figure 3-12: PSO TTLOutputs Schematic 90
Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 92
Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 93
Figure 4-3: Handwheel Interconnection to Aux I/O Connector 94
Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 94
Figure B-1: Voltage Selection Switch Access 102
List of Figures XL5e Hardware Manual
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List of Tables
Table 1-1: FeatureSummary 16
Table 1-2: Linear Amplifier Specifications 19
Table 1-3: Mounting Specifications 20
Table 1-4: Environmental Specifications 23
Table 1-5: Drive and Software Compatibility 24
Table 2-1: Control Supply Wiring Specifications 26
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 26
Table 2-3: Motor Supply Connector Wiring Specifications 27
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 27
Table 2-5: Motor Power Output Connector Pinout 28
Table 2-6: Mating Connector Part Numbers for the Motor Power Output Connector 28
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 29
Table 2-8: Hall Signal Diagnostics 30
Table 2-9: DC Brush Voltage Output Configuration 32
Table 2-10: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 32
Table 2-11: Wire Colors for Aerotech-Supplied Stepper Motor Cables 34
Table 2-12: Feedback Connector Pinout 36
Table 2-13: Mating Connector Part Numbers for the Feedback Connector 36
Table 2-14: Multiplier Options 37
Table 2-15: Primary Encoder Input Pins on the Feedback Connector 37
Table 2-16: Square Wave Encoder Specifications 38
Table 2-17: Sine Wave Encoder Specifications 40
Table 2-18: Hall-Effect Feedback Pins on the Feedback Connector 43
Table 2-19: Thermistor Input Pin on the Feedback Connector 44
Table 2-20: Encoder Fault Input Pin on the Feedback Connector 45
Table 2-21: End of Travel and Home Limit Pins on the Feedback Connector 46
Table 2-22: Brake Output Pins on the Feedback Connector 49
Table 2-23: Brake Control Specifications 49
Table 2-24: STO Connector Pinout 50
Table 2-25: Mating Connector Part Numbers for the STOConnector 50
Table 2-26: STOElectrical Specifications 51
Table 2-27: STOStandards 52
Table 2-28: STOStandards Data 52
Table 2-29: STOSignal Delay 54
Table 2-30: Motor Function Relative to STOInput State 54
Table 2-31: STOTiming 55
Table 2-32: Auxiliary I/O Connector Pinout 56
Table 2-33: Mating Connector Part Numbers for the Auxiliary I/OConnector 56
Table 2-34: Auxiliary Encoder Pins on the Auxiliary I/OConnector 57
Table 2-35: Square Wave Encoder Specifications 58
Table 2-36: Sine Wave Encoder Specifications 60
Table 2-37: PSO Specifications 62
Table 2-38: PSOPins on the Auxiliary I/OConnector 62
Table 2-39: Digital Output Specifications 64
Table 2-40: Digital Output Pins on the Auxiliary I/O Connector 64
Table 2-41: Digital Input Specifications 67
Table 2-42: Digital Input Pins on the Auxiliary I/O Connector 67
Table 2-43: High-Speed Input Specifications 69
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Table 2-44: High-Speed Input Pins on the Auxiliary I/O Connector 69
Table 2-45: Analog Output Specifications 70
Table 2-46: Analog Output Pins on the Auxiliary I/O Connector 70
Table 2-47: Analog Input Specifications 71
Table 2-48: Analog Input Pins on the Auxiliary I/O Connector 71
Table 2-49: Brake Power Supply Connector Pinout 72
Table 2-50: Mating Connector Part Numbers for the Brake Power Supply Connector 72
Table 2-51: HyperWire Card Part Number 73
Table 2-52: HyperWire Cable Part Numbers 73
Table 2-53: Sync-Related Functions 74
Table 2-54: SyncPort Cables 74
Table 3-1: Digital Output Specifications [-EB1] 80
Table 3-2: Digital Output 1 Connector Pinout [-EB1] 81
Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] 81
Table 3-4: Digital Output 2 Connector Pinout [-EB1] 81
Table 3-5: Mating Connector Part Numbers for the Digital Output 2 Connector [-EB1] 81
Table 3-6: Digital Input Specifications [-EB1] 84
Table 3-7: Digital Input 1 Connector Pinout [-EB1] 84
Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] 84
Table 3-9: Digital Input 2 Connector Pinout [-EB1] 85
Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] 85
Table 3-11: Analog Output Specifications [-EB1] 87
Table 3-12: Analog Output Connector Pinout [-EB1] 87
Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] 87
Table 3-14: Differential Analog Input Specifications [-EB1] 88
Table 3-15: Analog Input Connector Pinout [-EB1] 88
Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] 88
Table 3-17: PSO Specifications [-EB1] 89
Table 3-18: PSO Interface Connector Pinout [-EB1] 89
Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 89
Table 4-1: Standard Interconnection Cables 91
Table 5-1: LEDDescription 95
Table 5-2: Troubleshooting 95
Table 5-3: Preventative Maintenance 96
Table 5-4: Fuse Specifications 97
List of Tables XL5e Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product 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
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
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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