Aerotech XC2e User manual

Revision 1.00
XC2e
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 © 2019-2020, Aerotech, Inc., All rights reserved.

Table of Contents
XC2e 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
Quick Installation Guide 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 27
2.1.1. Control Supply Connector 27
2.1.2. Motor Supply Connector 28
2.1.3. Minimizing Noise for EMC/CECompliance 29
2.2. Motor Power Output Connector 30
2.2.1. Brushless Motor Connections 31
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 32
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 33
2.2.2. DCBrush Motor Connections 34
2.2.2.1. DC Brush Motor Phasing 35
2.2.3. Stepper Motor Connections 36
2.2.3.1. Stepper Motor Phasing 37
2.3. Feedback Connector 38
2.3.1. Primary Encoder Inputs 39
2.3.1.1. Square WaveEncoder 40
2.3.1.2. Absolute Encoder 41
2.3.1.3. Sine Wave Encoder [-MX2/-MX3 Option] 42
2.3.1.4. Encoder Phasing 44
2.3.2. Hall-Effect Inputs 45
2.3.3. Thermistor Input 46
2.3.4. Encoder Fault Input 47
2.3.5. End of Travel and Home Limit Inputs 48
2.3.5.1. End of Travel and Home Limit Phasing 50
2.3.6. Brake Outputs 51
2.4. Safe Torque Off Input (STO) 52
2.4.1. STOStandards 54
2.4.2. STO Functional Description 55
2.4.3. STO Startup Validation Testing 56
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XC2e Hardware Manual Table of Contents

2.4.4. STO Diagnostics 57
2.5. HyperWire Interface 58
2.6. System Interconnection 59
2.7. PC Configuration and Operation Information 60
Chapter 3: -EB1 I/O Option Board 61
3.1. Position Synchronized Output (PSO) Interface [-EB1] 62
3.2. Auxiliary Encoder Input [-EB1] 64
3.3. Analog I/O [-EB1] 66
3.3.1. Analog Input (Differential) [-EB1] 67
3.3.2. Analog Output 0 [-EB1] 68
3.4. Digital Inputs [-EB1] 69
3.5. Digital Outputs [-EB1] 71
Chapter 4: Cables and Accessories 75
4.1. DIN Rail Mounting 76
4.2. Joystick Interface 77
4.3. Handwheel Interface 78
Chapter 5: Maintenance 79
5.1. Preventative Maintenance 79
5.2. Fuse Specifications 80
Appendix A: Warranty and Field Service 81
Appendix B: Revision History 83
Index 85
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List of Figures
Figure 1-1: XC2e 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 27
Figure 2-2: Motor Supply Connections 28
Figure 2-3: Brushless Motor Configuration 31
Figure 2-4: Positive Motor Direction 32
Figure 2-5: Encoder and Hall Signal Diagnostics 32
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 33
Figure 2-7: Brushless Motor Phasing Goal 33
Figure 2-8: DC Brush Motor Configuration 34
Figure 2-9: Positive Motor Direction 35
Figure 2-10: Stepper Motor Configuration 36
Figure 2-11: Positive Motor Direction 37
Figure 2-12: Square Wave Encoder Schematic (Feedback Connector) 40
Figure 2-13: Absolute Encoder Schematic (Feedback Connector) 41
Figure 2-14: Analog Encoder Phasing Reference Diagram 42
Figure 2-15: Analog Encoder Schematic (Feedback Connector) 43
Figure 2-16: Encoder Phasing Reference Diagram (Standard) 44
Figure 2-17: Position Feedback in the DiagnosticDisplay 44
Figure 2-18: Hall-Effect Inputs Schematic (Feedback Connector) 45
Figure 2-19: Thermistor Input Schematic (Feedback Connector) 46
Figure 2-20: Encoder Fault Input Schematic (Feedback Connector) 47
Figure 2-21: End of Travel and Home Limit Input Connections 49
Figure 2-22: End of Travel and Home Limit Input Schematic (Feedback Connector) 49
Figure 2-23: End of Travel and Home Limit Input Diagnostic Display 50
Figure 2-24: Brake Connected to the 25-Pin Feedback Connector (Typical) 51
Figure 2-25: Typical Configuration 53
Figure 2-26: STO Timing 57
Figure 2-27: System Interconnection Drawing (Best Practice) 59
Figure 3-1: XC2e with -EB1 I/O Option Board Connectors 61
Figure 3-2: PSO Output Sources Current 63
Figure 3-3: PSOOutput Sinks Current 63
Figure 3-4: PSO TTLOutputs Schematic 63
Figure 3-5: Auxiliary Encoder Interface 65
Figure 3-6: Analog Input Schematic [-EB1] 67
Figure 3-7: Analog Output Schematic [-EB1] 68
Figure 3-8: Digital Inputs Schematic [-EB1] 69
Figure 3-9: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 70
Figure 3-10: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 70
Figure 3-11: Digital Outputs Schematic [-EB1] 72
Figure 3-12: Digital Outputs Connected in Current Sourcing Mode [-EB1] 73
Figure 3-13: Digital Outputs Connected in Current Sinking Mode [-EB1] 73
Figure 4-1: Din Rail Clip Dimensions 76
Figure 4-2: Two Axis Joystick Interface 77
Figure 4-3: Handwheel Interconnection to the Aux Connector 78
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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 2-1: Control Supply Connector Wiring Specifications 27
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 27
Table 2-3: Motor Supply Connector Wiring Specifications 28
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 28
Table 2-5: Motor Power Output Connector Pinout 30
Table 2-6: Mating Connector Part Numbers for the Motor Power Output Connector 30
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 31
Table 2-8: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 34
Table 2-9: Wire Colors for Aerotech-Supplied Stepper Motor Cables 36
Table 2-10: Feedback Connector Pinout 38
Table 2-11: Mating Connector Part Numbers for the Feedback Connector 38
Table 2-12: Multiplier Options 39
Table 2-13: Primary Encoder Input Pins on the Feedback Connector 39
Table 2-14: Square Wave Encoder Specifications 40
Table 2-15: Analog Encoder Specifications 42
Table 2-16: Hall-Effect Feedback Pins on the Feedback Connector 45
Table 2-17: Thermistor Input Pin on the Feedback Connector 46
Table 2-18: Encoder Fault Input Pin on the Feedback Connector 47
Table 2-19: End of Travel and Home Limit Pins on the Feedback Connector 48
Table 2-20: Brake Output Pins on the Feedback Connector 51
Table 2-21: Brake Control Specifications 51
Table 2-22: STO Connector Pinout 52
Table 2-23: Mating Connector Part Numbers for the STOConnector 52
Table 2-24: STOElectrical Specifications 53
Table 2-25: STOStandards 54
Table 2-26: STOStandards Data 54
Table 2-27: STOSignal Delay 56
Table 2-28: Motor Function Relative to STOInput State 56
Table 2-29: STOTiming 57
Table 2-30: HyperWire Card Part Number 58
Table 2-31: HyperWire Cable Part Numbers 58
Table 3-1: PSO Specifications [-EB1] 62
Table 3-2: PSO Interface Connector Pinout [-EB1] 62
Table 3-3: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 62
Table 3-4: Auxiliary Encoder RS-422 Specifications 64
Table 3-5: Auxiliary Encoder Connector Pinout 64
Table 3-6: Mating Connector Part Numbers for the AUX Connector 64
Table 3-7: Analog I/O Connector Pinout [-EB1] 66
Table 3-8: Mating Connector Part Numbers for the Analog I/O Connector [-EB1] 66
Table 3-9: Differential Analog Input Specifications [-EB1] 67
Table 3-10: Analog Input Pins on the Analog I/OConnector [-EB1] 67
Table 3-11: Analog Output Specifications [-EB1] 68
Table 3-12: Analog Output Pins on the Analog I/OConnector [-EB1] 68
Table 3-13: Digital Input Specifications [-EB1] 69
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XC2e Hardware Manual List of Tables

Table 3-14: Digital Input Connector Pinout [-EB1] 69
Table 3-15: Mating Connector Part Numbers for the Digital Input Connector [-EB1] 69
Table 3-16: Digital Output Specifications [-EB1] 71
Table 3-17: Digital Output Connector Pinout [-EB1] 71
Table 3-18: Mating Connector Part Numbers for the Digital Output Connector [-EB1] 71
Table 4-1: Standard Interconnection Cables 75
Table 4-2: Mounting Parts 76
Table 5-1: Preventative Maintenance 79
Table 5-2: Control Board Fuse Specifications 80
List of Tables XC2e Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XC2e
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 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 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 5/21/2020
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Agency Approvals
Aerotech tested its XC2e 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
XC2e.
lRead all parts of this manual before you install or operate the XC2e 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 AerotechGlobal Technical
Support
WARNING: This product has been designed for light industrial manufacturing or
laboratory environments. The protection provided by the equipment could be impaired if
the product is used in a manner not specified by the manufacturer.
DANGER: The voltage from this product can kill you. To decrease the risk of electrical
shock, injury, and death, you must obey the precautions that follow.
1. Before you do maintenance to the equipment, disconnect the electrical power.
2. 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.
3. Before you connect wires to this product, disconnect the electrical power.
4. To decrease the risk of electrical shock and injury, you must supply operators with
the necessary precautions and protection from live electrical circuits.
5. While the drive is connected to a power source, do not connect or disconnect elec-
trical components and cables.
6. Make sure that all components are grounded correctly and that they obey the local
electrical safety requirements.
7. Make sure that you install the necessary precautions to supply safety and pro-
tection to the operator.
8. Moving parts can cause crushing or shearing injuries. You must limit 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,
injury, and death, you must obey the precautions that follow.
1. Make sure that all system cables are correctly attached and positioned.
2. Use this product only in environments and operating conditions that are approved
in this manual.
3. Only operators who have received training can operate this equipment. All servicing
and maintenance must be done only by approved personnel.
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Quick Installation Guide
This image shows the order in which to make connections and settings that are typical to the XC2e. 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.
Motor and
Feedback
Connections
Section 2.2. Motor Power Output Connector and Section 2.3.
Feedback Connector
HyperWire Section 2.5. HyperWire Interface
Digital / Analog I/O Chapter 3: -EB1 I/O Option Board (if you purchased the I/O option)
STO Section 2.4. Safe Torque Off Input (STO)
Control Supply Section 2.1.1. Control Supply Connector
Motor Supply Section 2.1.2. Motor Supply Connector
Figure 1: Quick Start Connections
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Chapter 1: Introduction
The XC2e 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 XC2e.
Figure 1-1: XC2e High Performance PWMAmplifier
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XC2e Hardware Manual Chapter 1: Introduction

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 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 sink-
ing devices
l8 digital logic outputs (5 - 24 VDC), can be connected as current sourcing or
sinking
lDigital logic laser firing (PSO)output
PSO Section 3.1.
-PSO1 One axis PSOfiring (requires -EB1 option)
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.
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
Chapter 1: Introduction XC2e 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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XC2e Hardware Manual Chapter 1: Introduction

1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description XC2e-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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