Aerotech XC4 User manual

Revision: 1.00.00
XC4 Hardware Manual

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Pittsburgh, PA 15238-2811
www.aerotech.com
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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 © 2018-2019, Aerotech, Inc., All rights reserved.

XC4 Hardware Manual Table of Contents
Table of Contents
XC4 Hardware Manual 1
Table of Contents 3
List of Figures 5
List of Tables 7
EU Declaration of Conformity 9
Safety Procedures and Warnings 11
Quick Installation Guide 13
Chapter 1: Introduction 15
1.1. Electrical Specifications 18
1.1.1. System Power Requirements 19
1.2. Mechanical Specifications 20
1.3. Environmental Specifications 22
1.4. Drive and Software Compatibility 23
Chapter 2: Installation and Configuration 25
2.1. Input Power Connections 25
2.1.1. Control Supply Connector 25
2.1.2. Motor Supply Connector 26
2.1.3. Transformer Options 27
2.1.4. Minimizing Conducted,Radiated, and System Noise for EMC/CECompliance 34
2.2. Motor Power Output Connector 35
2.2.1. Brushless Motor Connections 36
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 37
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 38
2.2.2. DCBrush Motor Connections 39
2.2.2.1. DC Brush Motor Phasing 40
2.2.3. Stepper Motor Connections 41
2.2.3.1. Stepper Motor Phasing 42
2.3. Feedback Connector 43
2.3.1. Encoder Interface 44
2.3.1.1. RS-422 Line Driver Encoder 45
2.3.1.2. Absolute Encoder 46
2.3.1.3. Analog Encoder [-MX1 Option] 47
2.3.1.4. Encoder Phasing 49
2.3.2. Hall-Effect Interface 51
2.3.3. Thermistor Input Interface 52
2.3.4. Encoder Fault Input Interface 53
2.3.5. End of Travel Limit Input Interface 54
2.3.5.1. End of Travel Limit Phasing 56
2.3.6. Brake Output Interface 57
2.4. Safe Torque Off Input (STO) 58
2.4.1. STOStandards 60
2.4.2. STO Functional Description 60
2.4.3. STO Startup Validation Testing 61
2.4.4. STO Diagnostics 62
2.5. Auxiliary I/O Connector 63
2.5.1. Auxiliary Encoder Channel 64
2.5.2. Position Synchronized Output (PSO) 66
2.5.3. Digital Outputs 68
2.5.4. Digital Inputs 71
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Table of Contents XC4 Hardware Manual
2.5.5. High-Speed Inputs 4-5 73
2.5.6. Analog Output 0 74
2.5.7. Analog Input 0 (Differential) 75
2.6. Brake Power Supply Connector 76
2.7. HyperWire Interface 77
2.8. External Shunt Option [-SX1] 78
2.9. Sync Port 80
2.10. System Interconnection 81
2.11. PC Configuration and Operation Information 82
Chapter 3: -EB1 I/O Option Board 83
3.1. Digital Outputs [-EB1] 84
3.2. Digital Inputs [-EB1] 88
3.3. Analog Outputs [-EB1] 91
3.4. Analog Inputs [-EB1] 92
3.5. Position Synchronized Output (PSO) Interface [-EB1] 93
Chapter 4: Cables and Accessories 95
4.1. Joystick Interface 96
4.2. Handwheel Interface 98
Chapter 5: Maintenance 99
5.1. Preventative Maintenance 99
5.2. Fuse Specifications 100
Appendix A: Warranty and Field Service 101
Appendix B: Revision History 103
Index 105
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XC4 Hardware Manual List of Figures
List of Figures
Figure 1-1: XC4 Networked Digital Drive 15
Figure 1-2: Functional Diagram 17
Figure 1-3: Dimensions 20
Figure 1-4: Dimensions [-EB1] 21
Figure 2-1: Control Supply Connections 25
Figure 2-2: Motor Supply Connections 26
Figure 2-3: Transformer Examples 27
Figure 2-4: 40 VDC Motor Power with a TV0.3-28-56-ST Transformer 28
Figure 2-5: 80 VDC Motor Power with a TV0.3-28-56-ST Transformer 29
Figure 2-6: 40 Volt DC Bus from 115 and 230 VAC Source 30
Figure 2-7: 80 Volt DC Bus from 115 and 230 VAC Source (TV0.3-56) 31
Figure 2-8: 160 Volt DC Bus from 115 and 230 VAC Source (TV0.3-56) 32
Figure 2-9: Control and Motor Power Wiring using a TM3 or TM5 Transformer 33
Figure 2-10: Brushless Motor Configuration 36
Figure 2-11: Positive Motor Direction 37
Figure 2-12: Encoder and Hall Signal Diagnostics 37
Figure 2-13: Brushless Motor Phasing Oscilloscope Example 38
Figure 2-14: Brushless Motor Phasing Goal 38
Figure 2-15: DC Brush Motor Configuration 39
Figure 2-16: Positive Motor Direction 40
Figure 2-17: Stepper Motor Configuration 41
Figure 2-18: Positive Motor Direction 42
Figure 2-19: Line Driver Encoder Schematic (Feedback Connector) 45
Figure 2-20: Absolute Encoder Schematic (Feedback Connector) 46
Figure 2-21: Analog Encoder Phasing Reference Diagram 47
Figure 2-22: Analog Encoder Schematic (Feedback Connector) 48
Figure 2-23: Encoder Phasing Reference Diagram (Standard) 49
Figure 2-24: Position Feedback in the DiagnosticDisplay 50
Figure 2-25: Hall-Effect Inputs Schematic (Feedback Connector) 51
Figure 2-26: Thermistor Input Schematic (Feedback Connector) 52
Figure 2-27: Encoder Fault Input Schematic (Feedback Connector) 53
Figure 2-28: End of Travel Limit Input Connections 55
Figure 2-29: End of Travel Limit Input Interface Schematic (Feedback Connector) 55
Figure 2-30: Limit Input Diagnostic Display 56
Figure 2-31: Brake Connected to the 25-Pin Feedback Connector (Typical) 57
Figure 2-32: Typical Configuration 59
Figure 2-33: STO Timing 62
Figure 2-34: Auxiliary Encoder ChannelSchematic (Aux I/OConnector) 65
Figure 2-35: PSOInterface 67
Figure 2-36: Digital Output Schematic (Aux I/OConnector) 69
Figure 2-37: Digital Outputs Connected in Current Sourcing Mode 70
Figure 2-38: Digital Outputs Connected in Current Sinking Mode 70
Figure 2-39: Digital Inputs Schematic (Aux I/OConnector) 71
Figure 2-40: Digital Inputs Connected to Current Sinking Devices 72
Figure 2-41: Digital Inputs Connected to Current Sourcing Devices 72
Figure 2-42: High-Speed Inputs 73
Figure 2-43: Analog Output 0 Schematic 74
Figure 2-44: Analog Input 0 Schematic 75
Figure 2-45: System Interconnection Drawing (Best Practice) 81
Figure 3-1: XC4 with -EB1 I/O Option Board Connectors 83
Figure 3-2: Digital Outputs Schematic [-EB1] 86
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List of Figures XC4 Hardware Manual
Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 87
Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 87
Figure 3-5: Digital Inputs Schematic [-EB1] 89
Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 90
Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 90
Figure 3-8: Analog Output Typical Connection [-EB1] 91
Figure 3-9: Analog Input Typical Connection [-EB1] 92
Figure 3-10: PSO Output Sources Current 94
Figure 3-11: PSOOutput Sinks Current 94
Figure 3-12: PSO TTLOutputs Schematic 94
Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 96
Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 97
Figure 4-3: Handwheel Interconnection to Aux I/O Connector 98
Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 98
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XC4 Hardware Manual List of Tables
List of Tables
Table 1-1: Features and Options 16
Table 1-2: Electrical Specifications 18
Table 1-3: Unit Weight 20
Table 1-4: Environmental Specifications 22
Table 1-5: Drive and Software Compatibility 23
Table 2-1: Control Supply Wiring Specifications 25
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 25
Table 2-3: Motor Supply Connector Wiring Specifications 26
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 26
Table 2-5: Nominal Motor Operating Voltages / Required ACVoltages 27
Table 2-6: TransformerOptions 27
Table 2-7: Motor Power Output Connector Pinout 35
Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector 35
Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables 36
Table 2-10: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 39
Table 2-11: Wire Colors for Aerotech-Supplied Stepper Motor Cables 41
Table 2-12: Feedback Connector Pinout 43
Table 2-13: Mating Connector Part Numbers for the Feedback Connector 43
Table 2-14: Encoder Interface Pins on the Feedback Connector 44
Table 2-15: RS-422 Line Driver Encoder Specifications 45
Table 2-16: Analog Encoder Specifications 47
Table 2-17: Hall-Effect Feedback Pins on the Feedback Connector 51
Table 2-18: Thermistor Input Pin on the Feedback Connector 52
Table 2-19: Encoder Fault Input Pin on the Feedback Connector 53
Table 2-20: End of Travel Limit Input Pins on the Feedback Connector 54
Table 2-21: Brake Output Pins on the Feedback Connector 57
Table 2-22: Brake Control Specifications 57
Table 2-23: STO Connector Pinout 58
Table 2-24: Mating Connector Part Numbers for the STOConnector 58
Table 2-25: STOElectrical Specifications 58
Table 2-26: STOStandards 60
Table 2-27: STOStandards Data 60
Table 2-28: STOSignal Delay 61
Table 2-29: Motor Function Relative to STOInput State 61
Table 2-30: STOTiming 62
Table 2-31: Auxiliary I/O Connector Pinout 63
Table 2-32: Mating Connector Part Numbers for the Auxiliary I/OConnector 63
Table 2-33: Auxiliary Encoder RS-422 Specifications 64
Table 2-34: Auxiliary I/O Pins on the Auxiliary I/OConnector 64
Table 2-35: PSO Specifications 66
Table 2-36: PSOPins on the Auxiliary I/OConnector 66
Table 2-37: Digital Output Specifications 68
Table 2-38: Digital Output Pins on the Auxiliary I/O Connector 68
Table 2-39: Digital Input Specifications 71
Table 2-40: Digital Input Pins on the Auxiliary I/O Connector 71
Table 2-41: High-Speed Input Specifications 73
Table 2-42: High-Speed Input Pins on the Auxiliary I/O Connector 73
Table 2-43: Analog Output Specifications 74
Table 2-44: Analog Output Pins on the Auxiliary I/O Connector 74
Table 2-45: Analog Input Specifications 75
Table 2-46: Analog Input Pins on the Auxiliary I/O Connector 75
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List of Tables XC4 Hardware Manual
Table 2-47: Brake Power Supply Connector Pinout 76
Table 2-48: Mating Connector Part Numbers for the Brake Power Supply Connector 76
Table 2-49: HyperWire Card Part Number 77
Table 2-50: HyperWire Cable Part Numbers 77
Table 2-51: -SX1Component Information 78
Table 2-52: Maximum Additional Storage Energy 79
Table 2-53: Sync-Related Commands 80
Table 2-54: SyncPort Cables 80
Table 3-1: Digital Output Specifications [-EB1] 84
Table 3-2: Digital Output 1 Connector Pinout [-EB1] 85
Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] 85
Table 3-4: Digital Output 2 Connector Pinout [-EB1] 85
Table 3-5: Mating Connector Part Numbers for the Digital Output 2 Connector [-EB1] 85
Table 3-6: Digital Input Specifications [-EB1] 88
Table 3-7: Digital Input 1 Connector Pinout [-EB1] 88
Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] 88
Table 3-9: Digital Input 2 Connector Pinout [-EB1] 89
Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] 89
Table 3-11: Analog Output Specifications [-EB1] 91
Table 3-12: Analog Output Connector Pinout [-EB1] 91
Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] 91
Table 3-14: Differential Analog Input Specifications [-EB1] 92
Table 3-15: Analog Input Connector Pinout [-EB1] 92
Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] 92
Table 3-17: PSO Specifications [-EB1] 93
Table 3-18: PSO Interface Connector Pinout [-EB1] 93
Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 93
Table 4-1: Standard Interconnection Cables 95
Table 5-1: Preventative Maintenance 99
Table 5-2: Control Board Fuse Specifications 100
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XC4 Hardware Manual EU Declaration of Conformity
EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XC4
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
2011/65/EU RoHS2 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 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 3/27/2019
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EU Declaration of Conformity XC4 Hardware Manual
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XC4 Hardware Manual Safety Procedures and Warnings
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the XC4. Read all parts of this manual
before you install or operate the XC4 or before you do maintenance to your system. To prevent injury to you
and damage to the equipment, obey the precautions in this manual. The precautions that follow apply when
you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury to you or
damage to the equipment can occur. If you do not understand the information in this manual, contact
Aerotech Global Technical Support.
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.
NOTE: All 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.
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. Obey the information in this manual.
2. Before you do maintenance to the equipment, disconnect the electrical power.
3. Wait at least ten (10) minutes after removing the power supply before doing maintenance or
an inspection. Otherwise, there is the danger of electric shock.
4. Before you connect wires to this product, disconnect the electrical power.
5. To decrease the risk of electrical shock and injury, you must supply operators with the
necessary precautions and protection from live electrical circuits.
6. While the drive is connected to a power source, do not connect or disconnect electrical
components and cables.
7. Make sure that all components are grounded correctly and that they obey the local electrical
safety requirements.
8. Make sure that you install the necessary precautions to supply safety and protection to the
operator.
9. 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. Obey the information in this manual.
2. Make sure that all system cables are correctly attached and positioned.
3. Use this product only in environments and operating conditions that are approved in this
manual.
4. 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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Safety Procedures and Warnings XC4 Hardware Manual
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XC4 Hardware Manual Quick Installation Guide
Quick Installation Guide
This image shows the order in which to make connections and settings that are typical to the XC4. 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 2.7. HyperWire Interface
Digital / Analog I/O Section 2.5. Auxiliary I/O Connector and 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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Quick Installation Guide XC4 Hardware Manual
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XC4 Hardware Manual Chapter 1: Introduction
Chapter 1: Introduction
The XC4 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 XC4.
The XC4 offers standard Safe Torque Off (STO) inputs and optional Position Synchronized Output (PSO)
outputs. The XC4 is offered with an optional encoder interpolation feature (-MX1), 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: XC4 Networked Digital Drive
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Chapter 1: Introduction XC4 Hardware Manual
Table 1-1: Features and Options
Standard Features
l100 - 240 VAC control supply inputs Section 2.1.1.
l240 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 Section 2.3.1.2.
lOne fail-safe brake 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.
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), may be connected 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
-MX1 Interpolation circuit allowing for analog sine wave input on the standard encoder channel
with an interpolation factor of 16,384
PSO Section 2.5.2.
-PSO1 One-axis PSOfiring
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
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XC4 Hardware Manual Chapter 1: Introduction
The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
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Chapter 1: Introduction XC4 Hardware Manual
1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description XC410 XC420 XC430
Motor Supply
Input Voltage 240 VAC
Input Frequency 50-60 Hz
Inrush Current 64 A @ 230 VAC; 32 A @ 115 VAC
Maximum
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 40 A
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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XC4 Hardware Manual Chapter 1: Introduction
1.1.1. System Power Requirements
The following equations can be used to determine total system power requirements. The actual power
required from the mains supply will be the combination of actual motor power (work), motor resistance
losses, and efficiency losses in the power electronics or power transformer.
Use an EfficiencyFactor of approximately 90% in the following equations.
Brushless Motor
Output Power
Rotary Motors Power Output [W] = Torque [N·m] * Angular velocity[rad/sec]
Linear Motors Power Output [W] = Force [N] * Linear velocity[m/sec]
Rotary or Linear Motors Power Output [W] = Bemf [V] * I(rms) * 3
Power Loss = 3 * I(rms)^2 * R(line-line)/2
Power Input = (Power Output + Power Loss) / EfficiencyFactor
DC Brush Motor
Power Output [W] = Torque [N·m] * Angular velocity[rad/sec]
Power Loss = I(rms)^2 * R
Power Input = (Pout + Ploss) / EfficiencyFactor
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Chapter 1: Introduction XC4 Hardware Manual
1.2. Mechanical Specifications
The XC4 must be installed in an IP54 compliant enclosure to comply with safety standards. Mount the XC4
so free airflow is available at the front, top, and along the sides of the chassis for cooling. You must also
allow space for connections and cables along the front, top, and bottom.
The figure that follows shows the dimensions and the typical mounting orientation of the XC4.
Table 1-3: Unit Weight
XC4
Weight ~1.4 kg
Figure 1-3: Dimensions
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