Aerotech Automation1 iXI4 User manual

Revision 1.02
Automation1 iXI4 and XI4 Transconductance
Amplifier Controllers
HARDWAREMANUAL

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Aerotech, Inc. Product names mentioned herein are used for identification purposes
only and may be trademarks of their respective companies.
Copyright © 2020-2022, Aerotech, Inc., All rights reserved.

Table of Contents
Automation1 iXI4 and XI4 Transconductance Amplifier Controllers 1
Table of Contents 3
List of Figures 5
List of Tables 6
EU Declaration of Conformity 9
Safety Procedures and Warnings 11
Handling and Storage 12
Installation Overview 13
Chapter 1: iXI4/XI4 Overview 15
1.1. Electrical Specifications 21
1.2. Mechanical Specifications 22
1.2.1. Mounting and Cooling 22
1.2.2. Dimensions 23
1.2.3. DIN Rail Mounting 27
1.2.4. OEMMounting 28
1.3. Environmental Specifications 29
1.4. Drive and Software Compatibility 29
Chapter 2: Installation and Configuration 31
2.1. Input Power Connections 31
2.1.1. Control Supply Connector 31
2.1.2. Minimizing Noise for EMC/CECompliance 31
2.2. Axis Connector 32
2.2.1. Current Command Output Signals 33
2.2.2. Stepper Clock and Stepper Direction Signals 34
2.2.3. Hall-Effect Inputs 36
2.2.3.1. Brushless Motor Powered Motor and Feedback Phasing 37
2.2.4. End of Travel Limits 38
2.2.4.1. End of Travel Limit Phasing 39
2.2.5. Amplifier Fault Inputs 40
2.2.6. Amplifier Enable Output 41
2.2.7. Primary Encoder Inputs 42
2.2.7.1. Square WaveEncoder (Primary) 43
2.2.7.2. Absolute Encoder (Primary) 44
2.2.7.3. Sine Wave Encoder (Primary) 45
2.2.7.4. Encoder Phasing 47
2.2.7.5. Stepper Motor Phasing 48
2.2.8. Auxiliary Encoder Input 49
2.2.8.1. Square WaveEncoder (Auxiliary) 49
2.3. Digital I/O Connector 50
2.3.1. Digital Outputs 51
2.3.2. Digital Inputs 54
2.3.3. High-Speed User Input 56
2.4. Analog I/O and Laser Interface Connector 57
2.4.1. Position Synchronized Output (PSO) Interface 58
2.4.2. Analog Outputs 60
2.4.3. Analog Inputs (Differential) 61
2.4.4. Sync Port 62
2.5. HyperWire Interface 63
2.6. System Interconnection 64
2.7. PC Configuration and Operation Information 66
Chapter 3: Cables and Accessories 67
3.1. Joystick Interface 67
3.2. Handwheel Interface 68
Chapter 4: Maintenance 69
4.1. Preventative Maintenance 70
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Appendix A: Warranty and Field Service 71
Appendix B: Revision History 73
Index 75
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List of Figures
Figure 1-1: iXI4 Transconductance Amplifier Controller 15
Figure 1-2: XI4 Transconductance Amplifier Controller 16
Figure 1-3: iXI4-OEM Transconductance Amplifier Controller 17
Figure 1-4: XI4-OEM Transconductance Amplifier Controller 18
Figure 1-5: Functional Diagram 20
Figure 1-6: Dimensions [-2P1 (Standard 2-Axis)] 23
Figure 1-7: Dimensions [-4P1 (Standard 4-Axis)] 24
Figure 1-8: Dimensions [-2P2 (OEM2-Axis)] 25
Figure 1-9: Dimensions [-4P2 (OEM 4-Axis)] 26
Figure 1-10: Din Rail Clip Dimensions 27
Figure 2-1: Control Supply Connections 31
Figure 2-2: Current Command Output Schematic 33
Figure 2-3: Stepper Clock and Stepper Direction Timing 34
Figure 2-4: Stepper Clock and Stepper Direction Output Schematic 35
Figure 2-5: Hall-Effect Inputs Schematic 36
Figure 2-6: Positive Motor Direction 37
Figure 2-7: Encoder and Hall Signal Diagnostics 37
Figure 2-8: End of Travel Limit Input Connections 38
Figure 2-9: End of Travel Limit Input Schematic 38
Figure 2-10: End of Travel Limit Input Diagnostic Display 39
Figure 2-11: Fault Input Schematic 40
Figure 2-12: Amplifier Enable Output Schematic 41
Figure 2-13: Square Wave Encoder Schematic (Axis Connector) 43
Figure 2-14: Absolute Encoder Schematic (Axis Connector) 44
Figure 2-15: Sine Wave Encoder Phasing Reference Diagram 45
Figure 2-16: Sine Wave Encoder Schematic (Axis Connector) 46
Figure 2-17: Encoder Phasing Reference Diagram (Standard) 47
Figure 2-18: Position Feedback in the DiagnosticDisplay 47
Figure 2-19: Positive Motor Direction 48
Figure 2-20: Square Wave Encoder Interface (Auxiliary) 49
Figure 2-21: Digital Outputs Schematic 52
Figure 2-22: Digital Outputs Connected in Current Sourcing Mode 53
Figure 2-23: Digital Outputs Connected in Current Sinking Mode 53
Figure 2-24: Digital Inputs Schematic 54
Figure 2-25: Digital Inputs Connected to Current Sourcing (PNP) Devices 55
Figure 2-26: Digital Inputs Connected to Current Sinking (NPN) Devices 55
Figure 2-27: High-Speed Input 56
Figure 2-28: PSO TTLOutputs Schematic 58
Figure 2-29: PSOExternal Sync Input Schematic 59
Figure 2-30: Analog Outputs Schematic 60
Figure 2-31: Analog Inputs Schematic 61
Figure 2-32: Drive-Based Controller System Interconnection (Best Practice) 64
Figure 2-33: PC-Based Controller System Interconnection (Best Practice) 65
Figure 3-1: Two Axis Joystick Interface 67
Figure 3-2: Handwheel Interconnection to Axis Connector 68
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List of Tables
Table 1-1: FeatureSummary 19
Table 1-2: Electrical Specifications 21
Table 1-3: Mounting Specifications 22
Table 1-4: Mounting Parts 27
Table 1-5: OEMMounting Parts 28
Table 1-6: Environmental Specifications 29
Table 1-7: Drive and Software Compatibility 29
Table 2-1: Control Supply Connector Wiring Specifications 31
Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 31
Table 2-3: Axis Connector Pinout 32
Table 2-4: Mating Connector Part Numbers for the Axis Connector 32
Table 2-5: Current Command Pins on the Axis Connector 33
Table 2-6: Current Command Signal Output Specifications 33
Table 2-7: Clock and Direction Pins on the Axis Connector 34
Table 2-8: Stepper Clock and Stepper Direction Signal Output Specifications 34
Table 2-9: Stepper Direction Signal Output Polarity 34
Table 2-10: Hall-Effect Feedback Pins on the Axis Connector 36
Table 2-11: Hall Signal Diagnostics 37
Table 2-12: End of Travel Limit Pins on the Axis Connector 38
Table 2-13: Amplifier Fault Input Specifications 40
Table 2-14: Amplifier Enable Connector Pin on the Axis Connector 41
Table 2-15: Amplifier Enable Output Specifications 41
Table 2-16: Multiplier Options 42
Table 2-17: Primary Encoder Input Pins on the Axis Connector 42
Table 2-18: Square Wave Encoder Specifications 43
Table 2-19: Sine Wave Encoder Specifications 45
Table 2-20: Auxiliary Encoder Pins on the Axis Connector 49
Table 2-21: Square Wave Encoder Specifications 49
Table 2-22: Digital I/O ConnectorPinout 50
Table 2-23: Mating Connector Part Numbers for the Digital I/OConnector 50
Table 2-24: Digital Output Specifications 51
Table 2-25: Digital Output Pins on Digital I/OConnector 51
Table 2-26: Digital Input Specifications 54
Table 2-27: Digital Input Pins on the Digital I/O Connector 54
Table 2-28: High-Speed Input Specifications 56
Table 2-29: High-Speed Input Pins on the Digital I/O Connector 56
Table 2-30: Analog I/O and Laser Interface ConnectorPinout 57
Table 2-31: Mating Connector Part Numbers for the Laser Interface Connector 57
Table 2-32: PSO Specifications 58
Table 2-33: PSOExternal Sync Specifications 58
Table 2-34: PSOOutput Pins on the Analog I/O and Laser Interface Connector 58
Table 2-35: Analog Output Specifications 60
Table 2-36: Analog Output Pins on the Analog I/O and Laser Interface Connector 60
Table 2-37: Analog Input Specifications 61
Table 2-38: Analog Input Pins on the Analog I/O and Laser Interface Connector 61
Table 2-39: Sync-Related Functions 62
Table 2-40: SyncPort Cables 62
Table 2-41: HyperWire Card Part Number 63
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Table 2-42: HyperWire Cable Part Numbers 63
Table 3-1: Standard Interconnection Cables 67
Table 4-1: LEDDescription 69
Table 4-2: Troubleshooting 69
Table 4-3: Preventative Maintenance 70
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EU Declaration of Conformity
Manufacturer Aerotech, Inc.
Address 101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Product iXI4/XI4
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.
IEC 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 1/13/2022
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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
controller.
lRead all parts of this manual before you install or operate the controller 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 controller.
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
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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 controller 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 controller.
lBe careful when you move or transport the controller.
lRefer to Section 1.2. Mechanical Specifications for dimensions and weight spe-
cifications.
lRetain the shipping materials for future use.
lTransport or store the controller 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 controller in the original shipping container. If the original packaging included
ESDprotective packaging, make sure to store the controller in it. The storage location must be:
ldry
lfree of dust
lfree of vibrations
lflat
Refer to Section 1.3. Environmental Specifications
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Installation Overview
The images that follow show the order in which to make connections and settings that are typical to
the iXI4/XI4. 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.
IMPORTANT: Standard and OEMconnections are the same. Standard view shown.
Figure 1: Installation ConnectionOverview(iXI4 4-Axis Shown)
1Connect the motor feedback and amplifier to the Axis Connectors. Section 2.2.
2Connect the PCto the USB or Ethernet port. N/A
3Connect the next drive in the system to the HyperWire Out port. Section 2.5.
4Connect additional I/O as required by your application. Section 2.3. /
Section 2.4.
5Connect the power supply to the Control Supply. Section 2.1.1.
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IMPORTANT: Standard and OEMconnections are the same. Standard view shown.
Figure 2: Installation ConnectionOverview(XI4 4-Axis Shown)
1Connect the motor feedback and amplifier to the Axis Connectors. Section 2.2.
2Connect the PCHyperWire to the HyperWire Inport. Section 2.5.
3Connect additional I/O as required by your application. Section 2.3. /
Section 2.4.
4Connect the power supply to the Control Supply. Section 2.1.1.
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Chapter 1: iXI4/XI4 Overview
The iXI4 is a multi-axis digital drive-based controller. It runs the Automation1-iSMC controller to
generate commands for itself as well as for additional drives on the chain.
The XI4 is a multi-axis digital drive based on the HyperWire communication protocol. It receives
commands from a PC or a drive-based controller.
Both drives provide deterministic behavior, auto-identification, and are fully software configurable.
They can control industry-standard analog transconductance amplifiers that accept analog current
commands and clock-and-direction commands.
Figure 1-1: iXI4 Transconductance Amplifier Controller
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Figure 1-2: XI4 Transconductance Amplifier Controller
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Figure 1-3: iXI4-OEM Transconductance Amplifier Controller
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Figure 1-4: XI4-OEM Transconductance Amplifier Controller
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Table 1-1: FeatureSummary
Standard Features
l24 VDC control supply input (Section 2.1.1.)
lAnalog current command outputs (± 10V) (Section 2.2.1.)
lStepper clock and direction outputs (Section 2.2.2.)
lLine driver square wave quadrature encoder input for position feedback (Section 2.2.7.)
lLine driver square wave auxiliary () quadrature encoder input or output for PSO (Section
2.2.8.1.)
lEight digital user outputs (Section 2.3.1.)
lNine digital user inputs
nEight digital inputs (Section 2.3.2.)
nOne high-speed input (Section 2.3.3.)
lTwo 16-bit analog outputs (± 10V) (Section 2.4.2.)
lFour 16-bit differential analog inputs (± 10V) (Section 2.4.3.)
lOne 10/100/1000 BASE-T Ethernet Port (iXI4 Only)
lOne USB2.0 Type CPort (iXI4 Only)
Options
Configuration
-2P1 Two Axes of Control, Standard Packaging
-2P2 Two Axes of Control, OEM Packaging
-4P1 Four Axes of Control, Standard Packaging
-4P2 Four Axes of Control, OEM Packaging
Encoder (Section 2.2.7.2.)
-A0 No Absolute Encoder support
-A1 Absolute Encoder support
Multiplier (Section 2.2.7.3.)
-MX0 No encoder multiplier
-MX1 Interpolation circuit allowing for analog sine wave input on the primary encoder
channel with an interpolation factor of 16,384.
PSO (Section 2.4.1.)
-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)
-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).
Version
-DEFAULT Firmware Matches Software Line
-LEGACY Legacy Firmware Version X.XX.XXX
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The block diagram that follows shows a summary of the connector signals.
Figure 1-5: Functional Diagram
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