Aerotech XL4s User manual

Revision 2.02
Automation1 XL4s High-Performance
Voice-Coil Drive
HARDWAREMANUAL

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Copyright © 2018-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 XL4s High-Performance Voice-Coil Drive 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Conformity 7
Agency Approvals 8
Safety Procedures and Warnings 9
Handling and Storage 11
Installation Overview 12
Chapter 1: XL4s Overview 13
1.1. Electrical Specifications 15
1.2. Mechanical Specifications 16
1.2.1. Mounting and Cooling 16
1.2.2. Dimensions 17
1.3. Environmental Specifications 18
1.4. Drive and Software Compatibility 18
Chapter 2: Installation and Configuration 19
2.1. Input Power Connections 19
2.1.1. Control Supply Connector 19
2.1.2. Motor Supply Connector 20
2.1.3. External Power Supply Options 21
2.1.4. Minimizing Noise for EMC/CECompliance 22
2.2. HyperWire Interface 23
2.3. Position Synchronized Output Connector 24
2.4. Encoder Output Connector 25
2.5. Stage Motor and Feedback Connector 27
2.5.1. Analog Encoder Inputs 28
2.6. Digital and Analog I/O Connectors 29
2.6.1. Digital Outputs 30
2.6.2. Digital Inputs 32
2.6.3. Analog Outputs 33
2.6.4. Analog Inputs (Differential) 34
2.7. Encoder Input Connectors 35
2.7.1. Emergency Stop Sense Input 37
2.8. Laser Output Polarity Switch 38
2.9. Sync Port 39
2.10. PC Configuration and Operation Information 39
Chapter 3: Maintenance 41
3.1. Preventative Maintenance 42
3.2. Board Assembly 43
Appendix A: Warranty and Field Service 45
Appendix B: Revision History 47
Index 49
XL4s Hardware Manual Table of Contents
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List of Figures
Figure 1-1: XL4s High Performance Linear Amplifier 13
Figure 1-2: Functional Diagram 14
Figure 1-3: Dimensions 17
Figure 2-1: Control Supply Connections 19
Figure 2-2: Motor Supply Connections 20
Figure 2-3: Third-Party Power Supply Connection 21
Figure 2-4: Control and Motor Power Wiring using a TM3 Transformer 22
Figure 2-5: Encoder Outputs Schematic 25
Figure 2-6: PSOExternal Sync Input Schematic 26
Figure 2-7: Digital Outputs Connected in Current Sourcing Mode 31
Figure 2-8: Digital Outputs Connected in Current Sinking Mode 31
Figure 2-9: Digital Inputs Connected to Current Sourcing Devices 32
Figure 2-10: Digital Inputs Connected to Current Sinking Devices 32
Figure 2-11: Analog Outputs Schematic 33
Figure 2-12: Analog Inputs Schematic 34
Figure 2-13: Encoder Input Connector Encoder Connections 36
Figure 2-14: ESTOP Sense Input Schematic 37
Figure 2-15: Laser Output Polarity Switch Location 38
Figure 3-1: Control Board Assembly 43
Figure 3-2: Power Board Assembly 44
List of Figures XL4s Hardware Manual
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List of Tables
Table 1-1: FeatureSummary 13
Table 1-2: Electrical Specifications 15
Table 1-3: Mounting Specifications 16
Table 1-4: Environmental Specifications 18
Table 1-5: Drive and Software Compatibility 18
Table 2-1: Control Supply Connector Wiring Specifications 19
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 19
Table 2-3: Motor Supply Wiring Specifications 20
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 20
Table 2-5: HyperWire Card Part Number 23
Table 2-6: HyperWire Cable Part Numbers 23
Table 2-7: PSOConnector APinout 24
Table 2-8: PSOConnector BPinout 24
Table 2-9: Mating Connector Part Numbers for the PSOConnectors 24
Table 2-10: PSO Specifications 24
Table 2-11: Encoder Output Connector Pinout 25
Table 2-12: Mating Connector Part Numbers for the Encoder Output Connector 25
Table 2-13: PSOExternal Sync Specifications 26
Table 2-14: Stage Motor and Feedback Connector Pinout 27
Table 2-15: Mating Connector Part Numbers for the Stage Motor and Feedback Connector 27
Table 2-16: Analog Encoder Input Specifications 28
Table 2-17: Digital and Analog I/O Connector APinout 29
Table 2-18: Digital and Analog I/O Connector B Pinout 29
Table 2-19: Mating Connector Part Numbers for the Digital / Analog I/OConnectors 29
Table 2-20: Digital Output Specifications 30
Table 2-21: Digital Output Pins on the Digital/Analog I/O A Connector 30
Table 2-22: Digital Input Specifications 32
Table 2-23: Digital Input Pins on the Digital/Analog I/O B Connector 32
Table 2-24: Analog Output Specifications 33
Table 2-25: Analog Output Pins on the Digital / Analog I/O B Connector 33
Table 2-26: Analog Input Specifications 34
Table 2-27: Analog Input Pins on the Digital / Analog I/O B Connector 34
Table 2-28: Encoder Input Connector Specifications 35
Table 2-29: Encoder Input Connector A Pinout 35
Table 2-30: Encoder Input Connector B Pinout 35
Table 2-31: Mating Connector Part Numbers for the Encoder Input Connector 35
Table 2-32: ESTOP Pins on the Encoder Input Connector 37
Table 2-33: Electrical Noise Suppression Devices 37
Table 2-34: Sync-Related Functions 39
Table 2-35: SyncPort Cables 39
Table 3-1: LEDDescription 41
Table 3-2: Troubleshooting 41
Table 3-3: Preventative Maintenance 42
Table 3-4: Control Board Fuse Specifications 43
Table 3-5: Power Board Fuse Specifications 44
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List of Tables XL4s Hardware Manual
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product XL4s
Model/Types All
This is to certify that the aforementioned product is in accordance with the applicable requirements
of the following directive(s):
2014/35/EU Low Voltage 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 Safety Requirements for Electrical Equipment
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 1/11/2022
XL4s Hardware Manual EU Declaration of Conformity
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Agency Approvals
Aerotech tested its XL4s drives and found that they obey the standards that follow:
Approval: CUS NRTL
Approving Agency: TUV SUD America Inc.
Certificate #: U8 068995 0031 Rev. 00
Standards: CAN/CSA-C22.2 No. 61010-1:2012 ,
EN 61010-1:2010,
UL 61010-1:2012
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.
XL4s Hardware Manual Agency Approvals
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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
XL4s 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 ten (10) minutes 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.
Safety Procedures and Warnings XL4s Hardware Manual
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Handling and Storage
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
Handling
IMPORTANT: It is the responsibility of the customer to safely and carefully lift and
move the drive.
lBe careful when you move or transport the drive.
lRefer to Section 1.2. Mechanical Specifications for dimensions and weight spe-
cifications.
lRetain the shipping materials for future use.
lTransport or store the drive in its protective packaging.
WARNING: Electrostatic Discharge (ESD) Sensitive Components!
You could damage the power supply or drives if you fail to observe the correct
ESDpractices.
Wear an ESDwrist strap when you handle, install, or do service to the system assembly.
Storage
Store the drive in the original shipping container. If the original packaging included ESDprotective
packaging, make sure to store the drive in it. The storage location must be:
ldry
lfree of dust
lfree of vibrations
lflat
Refer to Section 1.3. Environmental Specifications
XL4s Hardware Manual Handling and Storage
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Installation Overview
This image shows the order in which to make connections and settings that are typical to the XL4s. 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 a PCHyperWire port to the HyperWire Inport. Section 2.2.
2Connect the Digital/Analog I/O. Section 2.6.
3Connect the Stage motor and feedback connector. Section 2.5.
4Connect to the Control Supply connector. Section 2.1.1.
5Connect to the Motor Supply connector. Section 2.1.2.
XL4s Hardware Manual Installation Overview
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Chapter 1: XL4s Overview
The XL4s is a high-performance linear amplifier designed to eliminate the non-linearities common
with PWM amplifiers. The drive provides deterministic behavior, auto-identification, and easy
software setup.
Figure 1-1: XL4s High Performance Linear Amplifier
Table 1-1: FeatureSummary
Standard Features
l85-240 VAC; 50-60 Hz control supply (Section 2.1.1.)
l±40 VDC max motor supply (Section 2.1.2.)
lTwo HyperWire ports (Section 2.2.)
lDual-Axis PSOfiring (Section 2.3.)
lThree-axis Part-Speed PSO firing that uses the PSO firing circuit based off of the commanded
vector velocity of up to three axes (refer to the online Help)
lTwo auxiliary channels of 40 MHz line driver quadrature encoder inputs (Section 2.7.)
lFour optically-isolated digital outputs; 5-24V (Section 2.6.1.)
lFour optically-isolated digital inputs; 5-24V (Section 2.6.2.)
lTwo 16-bit single-ended analog outputs; ±10 V (Section 2.6.3.)
lOne 16-bit differential analog input; ±10 V (Section 2.6.4.)
lDedicated 5-24V Emergency Stop sense input (Section 2.7.1.)
lTwo Sync ports (Section 2.9.)
XL4s Hardware Manual Chapter 1: XL4s Overview
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The block diagram that follows shows a summary of the connector signals.
Figure 1-2: Functional Diagram
Chapter 1: XL4s Overview XL4s Hardware Manual
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1.1. Electrical Specifications
Table 1-2: Electrical Specifications
Description XL4s
Motor Supply
Input Voltage ±40 VDC(max)
Input Current
(continuous) 10 A
Control Supply
Input Voltage 85-240 VAC
Input Frequency 50-60 Hz
Inrush Current 16 A
Input Current 0.35A(max)
Output Voltage 76 V
Peak Output Current 20 A
Continuous Output Current 5 A
Minimum Load Resistance 0.5 Ω
User Power Supply Output 5 VDC (@ 500 mA)
XL4s Hardware Manual 1.1. Electrical Specifications
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1.2. Mechanical Specifications
1.2.1. Mounting and Cooling
Install the drive 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
XL4s
Customer-Supplied Enclosure IP54 Compliant
Weight ~2.9 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 XL4s Hardware Manual
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1.2.2. Dimensions
Figure 1-3: Dimensions
XL4s Hardware Manual 1.2.2. Dimensions
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1.3. Environmental Specifications
The environmental specifications are listed below.
Table 1-4: Environmental Specifications
Ambient
Temperature
Operating: 0° to 40°C (32° to 104° F)
Storage: -30° to 85°C (-22° to 185° F)
Humidity
Non-condensing
The maximum relative humidity is 80% for temperatures that are
less than 31°C and decreases linearly to 50% relative humidity at
40°C.
Operating Altitude
0 m to 2,000 m (0 ft to 6,562 ft) above sea level.
If you must operate this product above 2,000 m or below sea level,
contact Aerotech, Inc.
Pollution Pollution Degree 2
Typically only nonconductive pollution occurs.
Operation Use only indoors
1.4. Drive and Software Compatibility
This table shows the available drives and which version of the software first supported each drive. In
the Last Software Version column, drives that show a specific version number are not supported
after that version.
Table 1-5: Drive and Software Compatibility
Drive Type Software First Software Version Last Software Version
XL4s Automation1 1.2.0 Current
A3200 6.04 Current
1.3. Environmental Specifications XL4s Hardware Manual
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Chapter 2: Installation and Configuration
The sections in this chapter include details on how to set up the electrical and safety components of
your system. Obey all safety warnings, including those in Safety Procedures and Warnings.
2.1. Input Power Connections
The drive has two input power connectors. One connector is for AC control power and the other
connector is for DCmotor power. For a full list of electrical specifications, refer to Section 1.1.
2.1.1. Control Supply Connector
IMPORTANT: To operate correctly, this product must have a power supply connected
to the Motor Supply and a power supply connected to the Control Supply.
The Control Supply input supplies power to the communications and logic circuitry of the drive. The
AC1 input and the AC2 input are connected to fuses inside the drive. Refer to Table 3-5 for fuse
values and part numbers.
The Control Supply contains an internal filter. It is not necessary to use an external filter for CE
compliance.
IMPORTANT: Refer to local electrical safety requirements to correctly size external
system wires.
DANGER: Before you operate the XL4s, install a ground connection for your safety and
to prevent damage to the equipment.
Figure 2-1: Control Supply Connections
Table 2-1: Control Supply Connector Wiring Specifications
Pin Description RecommendedWireSize (1)
AC1 Line Input:85 - 240 Volt AC Input Range 1.3 mm2[#16 AWG]
AC2 Neutral (0V) or 85 - 240 Volt AC Input Range 1.3 mm2[#16 AWG]
Protective Ground 1.3 mm2[#16 AWG]
(1) The wire insulation is rated for 300 V.
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector
Type
Aerotech
P/N
Third Party
P/N
Screw
Torque: N·m
Wire Size:
mm2[AWG]
3-Pin Terminal Block ECK02388 Phoenix 1756272 0.22 - 0.25 2.5 - 0.05 [14-30]
XL4s Hardware Manual Chapter 2: Installation and Configuration
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2.1.2. Motor Supply Connector
IMPORTANT: To operate correctly, this product must have a power supply connected
to the Motor Supply and a power supply connected to the Control Supply.
Motor power is applied to the XL4s at the four terminals of the Motor Supply connector. The DC+
input and the DC- input are connected to fuses inside the drive. Refer to Table 3-5 for fuse values
and part numbers.
IMPORTANT: Refer to local electrical safety requirements to correctly size external
system wires.
DANGER: To prevent the risk of electric shock, do not operate the XL4s without a
ground connection.
Figure 2-2: Motor Supply Connections
Table 2-3: Motor Supply Wiring Specifications
Pin Description Recommended
WireSize (1)
DC+ +40 VDCInput Range 2.1 mm2(#14 AWG)
RET Return for DCInput 2.1 mm2(#14 AWG)
DC- -40 VDCInput Range 2.1 mm2(#14 AWG)
Protective Ground 2.1 mm2(#14 AWG)
(1)The wire insulation is rated for 300 V.
Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector
Type
Aerotech
P/N
Third Part
P/N
Screw
Torque: N·m
Wire Size:
mm2[AWG]
4-Pin Terminal Block ECK002407 Phoenix 1758843 0.5 - 0.6 3.3 - 0.0516 [12-30]
2.1.2. Motor Supply Connector XL4s Hardware Manual
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