Aerotech Automation1 XL5e User manual

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

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Product names mentioned herein are used for identification purposes only and may be
trademarks of their respective companies.
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
XL5e Hardware Manual Table of Contents
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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
Table of Contents XL5e Hardware Manual
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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
XL5e Hardware Manual List of Figures
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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
XL5e Hardware Manual List of Tables
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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
XL5e Hardware Manual EU Declaration of Conformity
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PENDING

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PENDING

Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
XL5e drive.
lRead all parts of this manual before you install or operate the XL5e 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 XL5e 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 XL5e. 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 XL5e is a high-performance linear amplifier designed for motion control applications that require the
highest positioning accuracy and lowest generated noise. The XL5e is factory configured for the specified
AC input voltage, motor output voltage, and current. Refer to Table 1-1 for a complete list of features
and ordering options.
Figure 1-1: XL5e High Performance Linear Amplifier
XL5e Hardware Manual Chapter 1: Introduction
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Table 1-1: FeatureSummary
Standard Features
l100 - 240 VACcontrol supply input Section 2.1.1.
lFactory-configured motor supply ACinput 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
-20 20 A Peak
Bus Voltage
-VB4 ±40 VDC Bus Voltage (available for -10 or -20 option boards)
-VB5 ±60 VDC Bus Voltage (available for -10 option board)
-VB6 ±80 VDC Bus Voltage (available for -10 option board)
Input Line Voltage
-VL1 120 VAC
-VL2 240 VAC
-VL3 100 VAC
-VL4 200 VAC
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), may be connected in current sourcing or sinking
mode
l16 digital logic outputs (5 - 24 VDC), user defined as current sourcing or sinking
lDigital logic laser firing (PSO) output
Chapter 1: Introduction XL5e Hardware Manual
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Options (Continued)
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).
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
XL5e Hardware Manual Chapter 1: Introduction
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The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
Chapter 1: Introduction XL5e Hardware Manual
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1.1. Electrical Specifications
Table 1-2: Linear Amplifier Specifications
XL5e-10-VB4 XL5e-20-VB4 XL5e-10-VB5
XL5e-10-
VB6
Nominal Motor Bus Voltage ±40 V ±40 V ±60 V ±80 V
Peak Output Current 10 Apk 20 Apk 10 Apk 10 Apk
Continuous Output Current
@ 25°C (1)(2)
5 Apk /
5 Apk
5 Apk /
9 Apk
3.2 Apk /
6 Apk
2.5 Apk /
4.5 Apk
Continuous Output Current
@ 35°C (1)(2)
4 Apk /
5 Apk
4 Apk /
8 Apk
2 Apk /
5.5 Apk
2 Apk /
4 Apk
Maximum Continuous Total
Power Dissipation (2)(3)(4)
340 W /
585 W
Peak Amplifier Power
Dissipation per phase (5) 1200 W
Effective Heatsink Thermal
Resistance (2) .15°C/W / .085°C/W
Maximum Transistor Temperature 75°C
Time to reach maximum temperature at
maximum continuous power 10 minutes
Motor
Supply
Input Frequency 50-60 Hz
Inrush current 68 Apk @ 240 V
ACLine Voltage
ACInput (Switch Selectable):
100 VAC (90 - 112 VAC)
120 VAC (103 - 127 VAC)
200 VAC (180 - 224 VAC)
240 VAC (207 - 254 VAC)
Input current
(maximum,
continuous)
7 Arms @ 120 V /
3.5 Arms @ 240 V
Control
Supply
Input Frequency 50-60 Hz
Inrush current 68 Apk @ 240 V
Input current
(maximum,
continuous)
.25 Arms
Current Loop Bandwidth 2500 Hz (software selectable)
Minimum load resistance 0 Ω
Minimum load inductance 0 H
Modes of operation Brushless, Brush, Stepper
Protection Features Peak current limit, Over temperature, RMS current limit,
Dynamic power limit (SOA)
Encoder Supply 5 V @ 500 mA
(1) AC or DC motor type with a 0 Ω winding resistance assumed.
(2) The first value is for a stationary AC or DC motor. The second value is for a moving AC motor.
(3) De-rate at temperatures above 25°C ambient.
(4) Amplifier power dissipation is calculated as (Vbus – Vout) · Iout for each phase. A 40B configuration that drives 1 A into
0 Ω results in 40 W of power dissipation in the amplifier.
(5) The XL5e amplifier has peak power-limiting circuitry to protect itself from damage. The Power Limiting bit in the Drive
Status word indicates if this has occurred.
XL5e Hardware Manual 1.1. Electrical Specifications
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1.2. Mechanical Specifications
1.2.1. Mounting and Cooling
Install the XL5e in an IP54 compliant enclosure to comply with safety standards. Make sure that there is
sufficient clearance surrounding the drive for free airflow and for the cables and connections.
Table 1-3: Mounting Specifications
XL5e
Customer-Supplied Enclosure IP54 Compliant
Weight ~11.31 kg
Mounting Hardware M4 [#8] screws (four locations, not included)
Mounting Orientation Vertical (typical)
Dimensions Refer to Section 1.2.2. Dimensions
Minimum Clearance Airflow ~25 mm
Connectors ~100 mm
Operating Temperature Refer to Section 1.3. Environmental Specifications
1.2. Mechanical Specifications XL5e Hardware Manual
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