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
XL2e Hardware Manual List of Tables
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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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Agency Approvals
Approval: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #:
Standards: CAN/CSA-C22.2 No. 61010-1:2012,
EN 61010-1:2010/A1:2016,
UL 61010-1:2012
Approval: Safety Components (STO)
Approving Agency: TUVSUD
Certificate #: Z10 068995 0030 Rev. 00
Standards: EN ISO 13849-1:2015 (up to PL e),
IEC 61508-1:2010 (up to SIL3),
IEC 61508-2:2010 (up to SIL3),
IEC 61800-5-2:2016,
IEC 62061:2005 (up to SILCL3),
IEC 62061:2005/AMD1:2012 (up to SILCL3),
IEC 62061:2005/AMD2:2015 (up to SILCL3)
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
drive.
lRead all parts of this manual before you install or operate the 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.
Safety notes and symbols are placed throughout this manual to warn you of the potential risks at the
moment of the safety note or if you fail to obey the safety note.
The voltage can cause shock, burn, or death.
You are at risk of physical injury.
You could damage the drive.
A surface can be hot enough to burn you.
Your actions, the temperature of the system, or the condition of the atmosphere
that surround the system could start a fire.
Components are sensitive to electrostatic discharge.
Unsecured cables could cause you to:
ltrip and fall
ldrag the product off of its mounting location
ldamage the cable connections.
A blue circle symbol is an action or tip that you should obey. Some examples
include:
lGeneral tip
lRead the manual/section
lWear protective safety equipment (eye protection, ear protection, gloves)
lIf applicable, do not lift unassisted
XL2e Hardware Manual Safety Procedures and Warnings
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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 drive 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 one (1) minute after removing the power supply before doing
maintenance 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
Unpacking the Chassis
IMPORTANT: All electronic equipment and instrumentation is wrapped in antistatic
material and packaged with desiccant. Ensure that the antistatic material is not
damaged during unpacking.
Inspect the shipping container for any evidence of shipping damage. If any damage exists, notify the
shipping carrier immediately.
Remove the packing list from the shipping container. Make sure that all the items specified on the
packing list are contained within the package.
The documentation for the drive is on the included installation device. The documents include
manuals, interconnection drawings, and other documentation pertaining to the system. Save this
information for future reference. Additional information about the system is provided on the Serial
and Power labels that are placed on the chassis.
The system serial number label contains important information such as the:
lCustomer order number (please provide this number when requesting product support)
lDrawing number
lSystem part number
XL2e Hardware Manual Installation Overview
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Connection Overview
This image shows the order in which to make connections and settings that are typical to the XL2e. 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.
Figure 1: Installation ConnectionOverview
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or drive-based controller HyperWire port to the HyperWire In
port. Section 2.5.
3Connect additional I/O as required by your application
(if you purchased the I/O option). 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.
Installation Overview XL2e Hardware Manual
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Chapter 1: XL2e Overview
The XL2e is a high-performance linear amplifier designed for motion control applications that
require the highest positioning accuracy and lowest generated noise. Refer to Table 1-1 for a
complete list of features and options.
Figure 1-1: XL2e High-Performance Linear Digital Drive
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Table 1-1: FeatureSummary
Standard Features
l24 VDC control supply input (Section 2.1.1.)
l±5 to ±48 VDC bipolar 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 output (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 sinking
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 (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).
NOTE:Requires -EB1 option to generate a PSO output pulse
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: XL2e Overview XL2e 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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1.1. Electrical Specifications
Table 1-2: Linear Amplifier Specifications
XL2e
Motor
Supply
Input Voltage ±5 VDC to ±48 VDC
Input Current
(continuous) 5 A
Input Current 10 A
Control
Supply
Input Voltage 24 VDC
Input Current 2 A max, 0.75 A typical without brake
Output Voltage (maximum) ±48 VDC
Peak Output Current (1 second) (1) 10 Apk
Continuous Output Current (2, 3) ±48 Bus ±40 Bus ±24 Bus ±20 Bus ±12 Bus
Stationary AC or DC motor 1.3 Apk 1.6 Apk 2.7 Apk 3.3 Apk 5.0 Apk
AC motor that is in motion 1.7 Apk 2.2 Apk 3.8 Apk 4.5 Apk 5.0 Apk
Maximum Continuous Total
Power Dissipation (3) 180 W
Peak Amplifier Power
Dissipation per phase (4) 400 W
Effective Heatsink Thermal
Resistance 0.25°C/W
Maximum Transistor Temperature 75°C
Time to reach maximum
temperature at maximum
continuous power
8 minutes
Power Amplifier Bandwidth 2500 Hz maximum (software selectable)
Modes of operation Brushless, Brush, Stepper
Protection Features
Peak current limit; Over temperature; RMS current limit;
Control power supply under voltage; Dynamic power limit
(SOA)
(1) This specification depends on the motor supply voltage, the motor speed, and motor resistance. Contact an Aerotech
sales engineer for more information.
(2) This specification assumes that an AC or DC motor type with a 0 Ω winding resistance is used.
(3) The specification will be lower when the ambient temperature exceeds 25°C.
(4) The amplifier will limit peak power to protect itself from damage. The Amplifier Status internal signal in the Data
Visualizer shows the current state of the power limiting circuitry.
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