Aerotech XL2e User manual

Revision 1.01
Automation1 XL2e High-Performance
Linear Digital Drive
HARDWAREMANUAL

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Copyright © 2021-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 XL2e High-Performance Linear 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: XL2e Overview 17
1.1. Electrical Specifications 20
1.2. Mechanical Specifications 21
1.2.1. Mounting and Cooling 21
1.2.2. Dimensions 22
1.3. Environmental Specifications 24
1.4. Drive and Software Compatibility 25
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
2.2. Motor Power Output Connector 29
2.2.1. Brushless Motor Connections 30
2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 31
2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 32
2.2.2. DCBrush Motor Connections 33
2.2.2.1. DC Brush Motor Phasing 33
2.2.3. Stepper Motor Connections 34
2.2.3.1. Stepper Motor Phasing 34
2.3. Feedback Connector 35
2.3.1. Primary Encoder Inputs 36
2.3.1.1. Square WaveEncoder (Primary) 37
2.3.1.2. Absolute Encoder (Primary) 38
2.3.1.3. Sine Wave Encoder (Primary) [-MX2/-MX3 Option] 39
2.3.1.4. Encoder Phasing 40
2.3.2. Hall-Effect Inputs 41
2.3.3. Thermistor Input 42
2.3.4. Encoder Fault Input 43
2.3.5. End of Travel and Home Limit Inputs 44
2.3.5.1. End of Travel and Home Limit Phasing 46
2.3.6. Brake Outputs 47
2.4. Safe Torque Off Input (STO) 48
2.4.1. STOStandards 50
2.4.2. STO Functional Description 51
2.4.3. STO Startup Validation Testing 52
2.4.4. STO Diagnostics 53
2.5. HyperWire Interface 54
2.6. Sync Port 55
2.7. System Interconnection 56
2.8. PC Configuration and Operation Information 58
Chapter 3: -EB1 I/O Option Board 59
3.1. Position Synchronized Output Interface [-EB1] 60
3.2. Auxiliary Encoder Input [-EB1] 62
3.2.1. Square WaveEncoder (Auxiliary) 63
3.2.2. Absolute Encoder (Auxiliary) 64
3.2.3. Sine Wave Encoder (Auxiliary) [-MX3 Option] 65
3.3. Analog I/O [-EB1] 67
3.3.1. Analog Output 0 [-EB1] 68
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3.3.2. Analog Input (Differential) [-EB1] 69
3.4. Digital Outputs [-EB1] 70
3.5. Digital Inputs [-EB1] 73
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 80
5.2. Fuse Specifications 81
Appendix A: Warranty and Field Service 83
Appendix B: Revision History 85
Index 87
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List of Figures
Figure 1-1: XL2e High-Performance Linear Digital Drive 17
Figure 1-2: Functional Diagram 19
Figure 1-3: Dimensions 22
Figure 1-4: Dimensions [-EB1] 23
Figure 2-1: Control Supply Connections 27
Figure 2-2: Motor Supply Connections 28
Figure 2-3: Brushless Motor Configuration 30
Figure 2-4: Positive Motor Direction 31
Figure 2-5: Encoder and Hall Signal Diagnostics 31
Figure 2-6: Brushless Motor Phasing Oscilloscope Example 32
Figure 2-7: Brushless Motor Phasing Goal 32
Figure 2-8: DC Brush Motor Configuration 33
Figure 2-9: Positive Motor Direction 33
Figure 2-10: Stepper Motor Configuration 34
Figure 2-11: Positive Motor Direction 34
Figure 2-12: Square Wave Encoder Schematic (Feedback Connector) 37
Figure 2-13: Absolute Encoder Schematic (Feedback Connector) 38
Figure 2-14: Sine Wave Encoder Phasing Reference Diagram 39
Figure 2-15: Encoder Phasing Reference Diagram (Standard) 40
Figure 2-16: Position Feedback in the DiagnosticDisplay 40
Figure 2-17: Hall-Effect Inputs Schematic (Feedback Connector) 41
Figure 2-18: Thermistor Input Schematic (Feedback Connector) 42
Figure 2-19: Encoder Fault Input Schematic (Feedback Connector) 43
Figure 2-20: End of Travel and Home Limit Input Connections 45
Figure 2-21: End of Travel and Home Limit Input Schematic (Feedback Connector) 45
Figure 2-22: End of Travel and Home Limit Input Diagnostic Display 46
Figure 2-23: Brake Connected to the 25-Pin Feedback Connector (Typical) 47
Figure 2-24: Typical STO Configuration 49
Figure 2-25: STO Timing 53
Figure 2-26: System Wiring Drawing (Best Practice) 56
Figure 2-27: System Interconnection Drawing (Best Practice) 57
Figure 3-1: XL2e with -EB1 I/O Option Board Connectors 59
Figure 3-2: PSO Output Sources Current 61
Figure 3-3: PSOOutput Sinks Current 61
Figure 3-4: PSO TTLOutputs Schematic 61
Figure 3-5: Square Wave Encoder Interface (Aux Connector) 63
Figure 3-6: Absolute Encoder Schematic (Auxiliary Encoder Connector) 64
Figure 3-7: Sine Wave Encoder Phasing Reference Diagram 65
Figure 3-8: Sine Wave Encoder Schematic (Aux Connector) 66
Figure 3-9: Analog Output Schematic [-EB1] 68
Figure 3-10: Analog Input Schematic [-EB1] 69
Figure 3-11: Digital Outputs Schematic [-EB1] 71
Figure 3-12: Digital Outputs Connected in Current Sourcing Mode [-EB1] 72
Figure 3-13: Digital Outputs Connected in Current Sinking Mode [-EB1] 72
Figure 3-14: Digital Inputs Schematic [-EB1] 73
Figure 3-15: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 74
Figure 3-16: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 74
Figure 4-1: Din Rail Clip Dimensions 76
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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: Linear Amplifier Specifications 20
Table 1-3: Mounting Specifications 21
Table 1-4: Environmental Specifications 24
Table 1-5: Drive and Software Compatibility 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 29
Table 2-6: Mating Connector Part Numbers for the Motor Power Output Connector 29
Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables 30
Table 2-8: Hall Signal Diagnostics 31
Table 2-9: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 33
Table 2-10: Wire Colors for Aerotech-Supplied Stepper Motor Cables 34
Table 2-11: Feedback Connector Pinout 35
Table 2-12: Mating Connector Part Numbers for the Feedback Connector 35
Table 2-13: Multiplier Options 36
Table 2-14: Primary Encoder Input Pins on the Feedback Connector 36
Table 2-15: Square Wave Encoder Specifications 37
Table 2-16: Sine Wave Encoder Specifications 39
Table 2-17: Hall-Effect Feedback Pins on the Feedback Connector 41
Table 2-18: Thermistor Input Pin on the Feedback Connector 42
Table 2-19: Encoder Fault Input Pin on the Feedback Connector 43
Table 2-20: End of Travel and Home Limit Pins on the Feedback Connector 44
Table 2-21: Brake Output Pins on the Feedback Connector 47
Table 2-22: Brake Control Specifications 47
Table 2-23: STO Connector Pinout 48
Table 2-24: Mating Connector Part Numbers for the STOConnector 48
Table 2-25: STOElectrical Specifications 49
Table 2-26: STOStandards 50
Table 2-27: STOStandards Data 50
Table 2-28: STOSignal Delay 52
Table 2-29: Motor Function Relative to STOInput State 52
Table 2-30: STOTiming 53
Table 2-31: HyperWire Card Part Number 54
Table 2-32: HyperWire Cable Part Numbers 54
Table 2-33: Sync-Related Functions 55
Table 2-34: SyncPort Cables 55
Table 3-1: PSO Specifications [-EB1] 60
Table 3-2: PSO Interface Connector Pinout [-EB1] 60
Table 3-3: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 60
Table 3-4: Auxiliary Encoder Connector Pinout 62
Table 3-5: Mating Connector Part Numbers for the AUX Connector 62
Table 3-6: Square Wave Encoder Specifications 63
Table 3-7: Sine Wave Encoder Specifications 65
Table 3-8: Analog I/O Connector Pinout [-EB1] 67
Table 3-9: Mating Connector Part Numbers for the Analog I/O Connector [-EB1] 67
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Table 3-10: Analog Output Specifications [-EB1] 68
Table 3-11: Analog Output Pins on the Analog I/OConnector [-EB1] 68
Table 3-12: Differential Analog Input Specifications [-EB1] 69
Table 3-13: Analog Input Pins on the Analog I/OConnector [-EB1] 69
Table 3-14: Digital Output Specifications [-EB1] 70
Table 3-15: Digital Output Connector Pinout [-EB1] 70
Table 3-16: Mating Connector Part Numbers for the Digital Output Connector [-EB1] 70
Table 3-17: Digital Input Specifications [-EB1] 73
Table 3-18: Digital Input Connector Pinout [-EB1] 73
Table 3-19: Mating Connector Part Numbers for the Digital Input Connector [-EB1] 73
Table 4-1: Standard Interconnection Cables 75
Table 4-2: Mounting Parts 76
Table 5-1: LEDDescription 79
Table 5-2: Troubleshooting 79
Table 5-3: Preventative Maintenance 80
Table 5-4: Control Board Fuse Specifications 81
List of Tables XL2e Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XL2e
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
EU 2015/863 Amendment 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 61010-1:2010/A1:2016 Safety Requirements for Electrical Equipment
EN 61800-3:2017 EMCRequirements for Power Drives
IEC 61800-5-1:2016 Electrical Safety for Power Drive Systems
IEC 61800-5-2:2016 Functional Safety for Power Drive Systems
EN 55011/55032:2015 Conducted and Radiated Emissions
Authorized
Representative / Simon Smith, European Director
Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Engineer Verifying
Compliance / Alex Weibel
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Date 1/6/2022
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