Copley Controls Corp. XTL User manual

Xenus XTL™User Guide
P/N 95-00875-000
Revision 3
June 2008

Xenus XTL User Guide
This page for notes.

Copley Controls Corp. 3
TABLE OF CONTENTS
About This Manual ................................................................................................................................................................................ 5
1: Introduction ................................................................................................................................................................................. 9
1.1: Amplifier ............................................................................................................................................................................... 10
1.2: CME 2 .................................................................................................................................................................................. 11
1.3: CMO/CML ............................................................................................................................................................................ 11
2: Operational Theory.................................................................................................................................................................... 13
2.1: Amplifier Internal Power........................................................................................................................................................ 14
2.2: Synchronizing PWM Switching Frequency............................................................................................................................ 16
2.3: Commutation Modes ............................................................................................................................................................ 16
2.4: Feedback.............................................................................................................................................................................. 16
2.5: Operating Modes .................................................................................................................................................................. 17
2.6: CANopen Operation ............................................................................................................................................................. 28
2.7: Limit Switches ...................................................................................................................................................................... 30
2.8: Brake Operation ................................................................................................................................................................... 31
2.9: Status Indicators................................................................................................................................................................... 32
2.10: Protection ........................................................................................................................................................................... 34
2.11: Position and Velocity Errors................................................................................................................................................ 36
2.12: Communication .................................................................................................................................................................. 39
2.13: Inputs ................................................................................................................................................................................. 40
2.14: Outputs............................................................................................................................................................................... 41
2.15: Regen Resistor Theory....................................................................................................................................................... 42
3: Specifications ............................................................................................................................................................................ 43
3.1: Agency Approvals................................................................................................................................................................. 44
3.2: Power Input .......................................................................................................................................................................... 44
3.3: Power Output........................................................................................................................................................................ 44
3.4: Control Loops ....................................................................................................................................................................... 45
3.5: Regen Circuit Output ............................................................................................................................................................ 45
3.6: Digital Command Input ......................................................................................................................................................... 45
3.7: Analog Command Input........................................................................................................................................................ 46
3.8: Digital Inputs......................................................................................................................................................................... 46
3.9: Digital Outputs...................................................................................................................................................................... 46
3.10: Brake Output ...................................................................................................................................................................... 47
3.11: Encoder Power Supply Output............................................................................................................................................ 47
3.12: Primary Encoder Inputs ...................................................................................................................................................... 47
3.13: Analog Encoder Inputs ....................................................................................................................................................... 47
3.14: Hall Switch Inputs ............................................................................................................................................................... 48
3.15: Resolver Interface .............................................................................................................................................................. 48
3.16: Multi-Mode Port .................................................................................................................................................................. 48
3.17: Serial Interface ................................................................................................................................................................... 49
3.18: CAN Interface..................................................................................................................................................................... 49
3.19: Status Indicators................................................................................................................................................................. 49
3.20: Fault Levels ........................................................................................................................................................................ 49
3.21: Power Dissipation............................................................................................................................................................... 50
3.22: Thermal Impedance............................................................................................................................................................ 50
3.23: Mechanical and Environmental........................................................................................................................................... 50
3.24: Dimensions......................................................................................................................................................................... 51
4: Wiring......................................................................................................................................................................................... 53
4.1: General Wiring Instructions .................................................................................................................................................. 54
4.2: AC Mains (J1)....................................................................................................................................................................... 56
4.3: Motor (J2) ............................................................................................................................................................................. 57
4.4: Regen Resistor (J3) (Optional) ............................................................................................................................................. 59
4.5: Logic Supply / Brake (J4)...................................................................................................................................................... 60
4.6: RS-232 Serial Communications (J5)..................................................................................................................................... 61
4.7: CAN Bus (J6) ....................................................................................................................................................................... 62
4.8: Control (J7)........................................................................................................................................................................... 63
4.9: Motor Feedback (J8)............................................................................................................................................................. 67
5: Quick Setup with CME 2 ........................................................................................................................................................... 73
5.1: Warnings .............................................................................................................................................................................. 74
5.2: CME 2 Installation and Serial Port Setup.............................................................................................................................. 75
5.3: Prerequisites ........................................................................................................................................................................ 79
5.4: Basic Setup .......................................................................................................................................................................... 81
5.5: Motor/Feedback Setup ......................................................................................................................................................... 84
5.6: Amplifier Configuration ......................................................................................................................................................... 93
5.7: Command Input.................................................................................................................................................................. 103
5.8: Auto Phase......................................................................................................................................................................... 110
5.9: Current Loop....................................................................................................................................................................... 116
5.10: Velocity Loop.................................................................................................................................................................... 120
5.11: Position Loop.................................................................................................................................................................... 122
5.12: Completion Steps ............................................................................................................................................................. 126
6: Using CME 2 ............................................................................................................................................................................ 127

Table of Contents Xenus XTL User Guide
4Copley Controls Corp.
6.1: CME 2 Overview................................................................................................................................................................. 128
6.2: Manage Amplifier and Motor Data ...................................................................................................................................... 133
6.3: Downloading Firmware ....................................................................................................................................................... 136
6.4: Control Panel...................................................................................................................................................................... 138
6.5: Manual Phasing.................................................................................................................................................................. 142
6.6: Home Function ................................................................................................................................................................... 144
A: Regen Resistor Sizing and Configuration ............................................................................................................................. 145
A.1: Sizing a Regen Resistor..................................................................................................................................................... 146
A.2: Configuring a Custom Regen Resistor ............................................................................................................................... 150
B: I2TTime Limit Algorithm ......................................................................................................................................................... 153
B.1: I2TAlgorithm ...................................................................................................................................................................... 154
C: Thermal Considerations.......................................................................................................................................................... 159
C.1: Operating Temperature and Cooling Configurations .......................................................................................................... 160
C.2: Heatsink Mounting Instructions .......................................................................................................................................... 162
D: Xenus Filter.............................................................................................................................................................................. 163
D.1: Overview............................................................................................................................................................................ 164
D.2: XTL-FA-01 Edge Filter Specifications ................................................................................................................................ 165
D.3: Thermal Considerations ..................................................................................................................................................... 165
D.4: XTL-FA-01 Edge Filter Dimensions.................................................................................................................................... 166
D.5: XTL-FA-01 Edge Filter Wiring ............................................................................................................................................ 167
D.6: XTL-FA-01 Edge Filter Ordering......................................................................................................................................... 171
E: Connecting for Serial Control................................................................................................................................................. 173
E.1: Single-Axis and Multi-Drop ................................................................................................................................................. 174
F: Ordering Guide and Accessories ........................................................................................................................................... 175
F.1: Amplifier Model Numbers ................................................................................................................................................... 176
F.2: Accessory Model Numbers................................................................................................................................................. 177
F.3: Order Example ................................................................................................................................................................... 178
F.5: Copley Standard Regen Resistor Specifications................................................................................................................. 179

Copley Controls Corp. 5
ABOUT THIS MANUAL
Overview and Scope
This manual describes the operation and installation of the Xenus XTL amplifier manufactured by
Copley Controls Corporation.
Related Documentation
For important setup and operation information, see the CME 2 User Guide.
Users of the CANopen features should also read these Copley Controls documents:
•CANopen Programmer’s Manual
•CML Reference Manual
•Copley Motion Objects Programmer’s Guide
Also of related interest:
•Copley Indexer 2 Program User’s Guide (describes use of Indexer Program to create motion
control sequences)
•Copley Controls ASCII Interface Programmer’s Guide (describes how to send ASCII format
commands over an amplifier’s serial bus to set up and control one or more amplifiers)
•Copley Amplifier Parameter Dictionary
•Copley Camming User Guide
•Copley DeviceNet Programmer’s Guide
Information on Copley Controls Software can be found at:
http://www.copleycontrols.com/Motion/Products/Software/index.html
Comments
Copley Controls Corporation welcomes your comments on this manual.
For contact information, see http://www.copleycontrols.com
Copyrights
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of Copley Controls
Corporation.
Xenus and XTL are registered trademarks of Copley Controls Corporation.
CME 2 is a registered trademark of Copley Controls Corporation.
Windows NT, ME, 2000, XP, Vista, Visual Basic, Excel, and .NET are trademarks or registered
trademarks of the Microsoft Corporation.
LabVIEW is a registered trademark of National Instruments.
Document Validity
We reserve the right to modify our products. The information in this document is subject to change
without notice and does not represent a commitment by Copley Controls Corporation. Copley
Controls Corporation assumes no responsibility for any errors that may appear in this document.

About this Manual Xenus XTL User Guide
6Copley Controls Corp.
Product Warnings
Observe all relevant state, regional, and local safety regulations when installing and using this
product. For safety and to assure compliance with documented system data, only Copley Controls
Corporation should perform repairs to amplifiers.
DANGER: Hazardous voltages.
!
DANGER
Exercise caution when installing and adjusting.
Failure to heed this warning can cause equipment damage, injury, or death.
Risk of electric shock.
!
DANGER
High-voltage circuits on J1, J2, and J3 are connected to mains power.
Failure to heed this warning can cause equipment damage, injury, or death.
Risk of unexpected motion with non-latched faults.
!
DANGER
After the cause of a non-latched fault is corrected, the amplifier re-enables the PWM
output stage without operator intervention. In this case, motion may re-start
unexpectedly. Configure faults as latched unless a specific situation calls for non-
latched behavior. When using non-latched faults, be sure to safeguard against
unexpected motion.
Failure to heed this warning can cause equipment damage, injury, or death.
Using CME 2 or serial commands may affect or suspend CAN operations.
!
DANGER
When operating the amplifier as a CAN node, the use of CME 2 or ASCII serial
commands may affect CAN operations in progress. Using such commands to initiate
motion may cause CAN operations to suspend.
CAN operations may restart unexpectedly when the commanded motion is stopped.
Failure to heed this warning can cause equipment damage, injury, or death.
Latching an output does not eliminate the risk of unexpected motion with non-
latched faults.
!
DANGER
Associating a fault with a latched, custom-configured output does not latch the fault
itself. After the cause of a non-latched fault is corrected, the amplifier re-enables
without operator intervention. In this case, motion may re-start unexpectedly.
For more information, see Clearing Non-Latched Faults (p. 34).
Failure to heed this warning can cause equipment damage, injury, or death.
Use equipment as described.
!
DANGER
Operate amplifiers within the specifications provided in this manual.
Failure to heed this warning can cause equipment damage, injury, or death.

Xenus XTL User Guide About this Manual
Copley Controls Corp. 7
Revision History
Revision Date DECO# Comments
1December 2007 16236 Initial release.
2February 2008 16714 Updated Multi-Mode Port Interface Diagram (p. 66).
3June 2008 17111 Updated Web page references and made other minor changes.

About this Manual Xenus XTL User Guide
8Copley Controls Corp.
This page for notes.

Copley Controls Corp. 9
CHAPTER
1: INTRODUCTION
This chapter provides an overview of the Copley Controls Xenus XTL amplifier.
Contents include:
Title Page
1.1: Amplifier ............................................................................................................................................................................... 10
1.2: CME 2 .................................................................................................................................................................................. 11
1.3: CMO/CML ............................................................................................................................................................................ 11

Introduction Xenus XTL User Guide
10 Copley Controls Corp.
1.1: Amplifier
Xenus provides 100% digital control of brushless or brush motors in an off-line powered package.
It can also control a Copley Controls ServoTube motor. Xenus can operate from single or three-
phase mains with a continuous power output of up to 4 kW.
Xenus is offered in three versions to support three types of feedback devices. The standard
version supports digital quadrature encoders. The –S version supports analog sin/cos encoders.
The -R version supports brushless resolvers. The –S and -R versions can emulate a digital
quadrature encoder output from the analog encoder or resolver respectively.
Xenus can operate in several basic ways:
•As a traditional motor amplifier accepting current, velocity or position commands from an
external controller. In current and velocity modes it can accept ±10 Vdc analog, digital 50%
PWM or PWM/polarity inputs. In position mode, inputs can be incremental position commands
from step-motor controllers in Pulse and Direction or Count Up/Count Down format, as well as
A/B quadrature commands from a master-encoder. Pulse-to-position ratio is programmable for
electronic gearing.
•As a node on a CANopen network. CANopen compliance allows the amplifier to take
instruction from a master application over a CAN network to perform torque, velocity, and
position profiling, interpolated motion, and homing operations. Multiple drives can be tightly
synchronized for high performance coordinated motion.
•As a node on a DeviceNet network. Xenus can be operated over a DeviceNet network by
PLCs and other controllers.
•As a stand-alone controller running Copley Virtual Machine (CVM) control programs such as
the Indexer 2 Program. It can also be controlled directly over an RS232 serial link with simple
ASCII format commands.
Mains input voltage to the amplifier can range from 100 to 240 Vac, single or three-phase, and 47
to 63 Hz. This allows Xenus the ability to work in the widest possible range of industrial settings.
Several models are available, with peak current ratings of 18 to 40 amps:
Model
Quad A/B
Encoder
Resolver Sin/Cos Encoder Continuous
Current
Peak Current Vac
XTL-230-18 XTL-230-18-R XTL-230-18-S 6 A 18 A
XTL-230-36 XTL-230-36-R XTL-230-36-S 12 A 36 A
XTL-230-40 XTL-230-40-R XTL-230-40-S 20 A 40 A
100 to
240
Aseparate +24 Vdc logic supply powers the internal logic and control circuits. These are isolated
from the high-voltage power supply and inverter stage that connect to the mains. This simplifies
system design by allowing the mains to be completely disconnected from the amplifier for safety
reasons while allowing the logic side of the amplifier to stay powered. This allows the amplifier to
retain position information and maintain communication through the digital I/O or over the serial or
CAN ports when disconnected from the mains.
The Xenus XTL is RoHS compliant.