Copley Controls XenusPlus EtherCAT User manual

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 1 of 26
RoHS
DESCRIPTION
Xenus Plus set new levels of performance, connectivity, and exibility. Ethernet based EtherCAT
operates in CANopen over EtherCAT mode (CoE). A wide range of absolute interfaces are built-in
including EnDat, Hiperface, and BiSS.
High resolution A/D converters ensure optimal current loop performance. Both isolated and high-
speed non-isolated I/O are provided. For safety critical applications, redundant power stage enable
inputs can be employed.
Control Modes
• Indexer, Point-to-Point, PVT
• Camming, Gearing
• Position, Velocity, Torque
Command Interface
• CANopen over EtherCAT (CoE)
• ASCII and discrete I/O
• Stepper commands
• ±10V position/velocity/torque (2 inputs)
• PWM velocity/torque command
• Master encoder (Gearing/Camming)
Communications
• EtherCAT
• RS-232
• RS-485 (Optional)
Accessories
• External regen resistors
• External edge lter
Feedback
• Digital quad A/B encoder
• EnDat, Hiperface, BiSS, SSI, Yaskawa &
Panasonic encoders
• Aux. encoder / encoder out
• Analog sin/cos encoder
• Resolver option
• Digital Halls
Safety Disable
• Two active inputs enable power stage
• One output conrms power stage status
I/O Digital
• 15 inputs, 6 outputs
I/O Analog
• 2, 16 bit inputs
• 1, 12 bit output
Dimensions: mm [in]
• 202 x 139 x 52 [7.9 x 5.5 x 2.3]
Model Vac Ic Ip
XEL-230-18 100 - 240 6 18
XEL-230-36 100 - 240 12 36
XEL-230-40 100 - 240 20 40
Add -R for resolver feedback option.

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 2 of 26
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GENERAL SPECIFICATIONS
Test conditions: Wye connected load: 2 mH line-line. Ambient temperature = 25 °C. Power input = 230 Vac, 60 Hz, 1 Ø
MODEL XEL-230-18 XEL-230-36 XEL-230-40 Same specs for XEL and XML models
OUTPUT CURRENT
Peak Current 18 (12.7) 36 (25.5) 40 (28.3) Adc (Arms, sinusoidal)
Peak time 1 1 1 s
Continuous current (Note 1) 6 (4.24) 12 (8.5) 20 (14.1) Adc (Arms, sinusoidal)
INPUT POWER
Mains voltage, phase, frequency 100~240 Vac, ±10%, 1 Ø or 3 Ø, 47~63 Hz
Mains current 20 Arms
+24 Vdc Control power +20 to +32 Vdc, 500 mA max Required for operation
DIGITAL CONTROL
Digital Control Loops Current, velocity, position. 100% digital loop control
Sampling rate (time) Current loop: 15 kHz (67 µs), Velocity & position loops: 3 kHz (333 µs)
Bus voltage compensation Changes in bus or mains voltage do not affect bandwidth
Minimum load inductance 200 µH line-line
COMMAND INPUTS
Distributed Control Mode
CANopen over EtherCAT (CoE) Position, Velocity, Torque, Homing, Prole, Interpolated Prole, and Cyclic Synchronous modes
Stand-alone mode
Analog torque, velocity, position reference ±10 Vdc, 16 bit resolution Dedicated differential analog input
Digital position reference Pulse/Direction, CW/CCW Stepper commands (2 MHz maximum rate)
Quad A/B Encoder 2 M line/sec, 8 Mcount/sec (after quadrature)
Digital torque & velocity reference PWM , Polarity PWM = 0% - 100%, Polarity = 1/0
PWM 50% PWM = 50% ±50%, no polarity signal required
PWM frequency range 1 kHz minimum, 100 kHz maximum
PWM minimum pulse width 220 ns
Indexing Up to 32 programs can be launched from inputs or ASCII commands. Each program can
consist of moves, I/O commands, time delays, and other programmable operations.
Camming Master quadrature encoder provides position as index to cam table.
Digital inputs initiate cam functions.
DIGITAL INPUTS
Number 15
[IN1,2,15] Non-isolated Schmitt trigger, 1 µs RC lter, 24 Vdc max, Vin-LO <= 1.25 Vdc, Vin-HI >= 3.5 Vdc,
Hysteresis = 0.66 Vdc minimum, 10 kΩ programmable per input to pull-up to +5 Vdc or pull-down to ground
[IN3~6] Non-isolated line receiver, 100 ns RC lter, +12 Vdc max, programmable as 4 single-ended, or 2 differential
Single-ended: [IN3,4] or [IN5,6]: Vin-LO <= 2.3 Vdc, Vin-HI >= 2.7 Vdc, Vhysteresis = 400 mVdc
Differential: [IN3/4] or [IN5/6]: Vin-LO <= -200 mVdc, Vin-HI >= 200 mVdc, Vhysteresis = ±200 mVdc
[IN7~14] Isolated: Opto-isolated, ±5 to ±30 Vdc compatible, bi-polar, 2 groups of 4 with common for each group
ANALOG INPUTS
Number 3
[AIN1~2] Differential, ±10 Vdc, 5 kΩ input impedance, 16-bit resolution
[AIN3] Single-ended, motor temperature sensor, 4.99 kΩ pulled-up to +5 Vdc
DIGITAL OUTPUTS
Number 6
[OUT1~2] Current-sinking MOSFET with 1 kΩ pullup to +5 Vdc through diode
1 Adc max, +40 Vdc max; external yback diode required if driving inductive loads
[OUT3] High-speed CMOS buffer, ±20 mA
[OUT4~5] Opto-isolated Darlingtons with 36V Zener yback diodes, 50 mA max
[OUT6] Motor brake control: opto-isolated, current-sinking with yback diode to +24 Vdc, 1 Adc max
ANALOG OUTPUT
Number 1
Range ±5 Vdc single-ended
Resolution 12-bit
MULTI-MODE ENCODER PORT
As Input Secondary digital quadrature encoder (A, /A, B, /B, X, /X), 121 Ωterminating resistors
18 M-counts/sec, post-quadrature (4.5 M-lines/sec)
As Output Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev
from analog sin/cos encoders or resolvers. Buffered signals from digital quad A/B/X primary encoder
A, /A, B, /B, X, /X, from 26LS31 differential line driver
RS-232 PORT
Signals RxD, TxD, Gnd in 6-position, 4-contact RJ-11 style modular connector
Mode Full-duplex, DTE serial communication port for drive setup and control, 9,600 to 115,200 Baud
Protocol Binary and ASCII formats
ETHERCAT PORTS
Format Dual RJ-45 receptacles, 100BASE-TX
Protocol EtherCAT
Data CANopen over EtherCAT (CoE)
STATUS INDICATORS
Drive Status Bicolor LED, drive status indicated by color, and blinking or non-blinking condition
CAN Status Bicolor LED, status of CAN bus indicated by color and blink codes to CAN Indicator Specication 303-3

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 3 of 26
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REGENERATION
Operation Internal solid-state switch drives external regen resistor (see Ordering Guide for types)
Cut-In Voltage +HV > 390 Vdc Regen output is on, (optional external) regen resistor is dissipating energy
Drop-Out Voltage +HV < 380 Vdc Regen output is off, (optional external) regen resistor not dissipating energy
Tolerance ±2 Vdc For either Cut-In or Drop-Out voltage
NOTES:
1. Heatsinking and/or forced-air cooling is required for continuous output power rating
2. Brake[OUT4] is programmable as motor brake, or as general purpose digital output
PROTECTIONS
Mains power loss Interruption or loss of AC power is detected
HV Overvoltage +HV > 400 Vdc Drive PWM outputs turn off until +HV is less than overvoltage
HV Undervoltage +HV < 60 Vdc Drive PWM outputs turn off until +HV is greater than undervoltage
Drive over temperature IGBT > 80 °C ±3 °C Drive PWM outputs turn off until IGBT temperature is below threshold
Short circuits Output to output, output to ground, internal PWM bridge faults, regen resistor fail-shorts
I
2T Current limiting Programmable: continuous current, peak current, peak time
Motor over temperature Drive shuts down when motor over-temperature switch changes to high-resistance state, or opens
Feedback power loss Fault occurs if feedback is removed or +5 V is <85% of normal
MECHANICAL & ENVIRONMENTAL
Size 7.55 in (191,8 mm) X 5.57 in (141,5 mm) X 2.57 in (65,3 mm)
Weight 3.0 lb (1.36 kg) for drive without heatsink
3.1 lb (1.40 kg) for XEL-HS heatsink, 1.86 lb (0.84 kg) for XEL-HL heatsink
Ambient temperature 0 to +45 °C operating, -40 to +85 °C storage
Humidity 0% to 95%, non-condensing
Contaminants Pollution degree 2
Vibration 2 g peak, 10~500 Hz (sine), IEC60068-2-6
Shock 10 g, 10 ms, half-sine pulse, IEC60068-2-27
Environment IEC68-2: 1990
Cooling Heat sink and/or forced air cooling required for continuous power output
AGENCY STANDARDS CONFORMANCE
EN 55011 : 1998 CISPR 11 (1997) Edition 2/Amendment 2:
Limits and Methods of Measurement of Radio Disturbance Characteristics of Industrial, Scientic, and
Medical (ISM) Radio Frequency Equipment
EN 61000-6-1 : 2001 Electromagnetic Compatibility Generic Immunity Requirements
Following the provisions of EC Directive 89/336/EEC:
EN 61010-1 2nd Ed.: 2004 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory use
Following the provisions of EC Directive 2006/95/EC:
UL 508C 3rd Ed.: 2002 UL Standard for Safety for Power Conversion Equipment
Chassis Grounding:
For CE compliance and machine
safety use external tooth lockwashers
between mounting screw head and
drive heatplate. Recommended screws
are #6-32 (M3.5) torqued to 8~10
lb·in (0.79~1.02 N·m).
DIMENSIONS
Inches (mm)
1
43
SCALE
SIZE DWG NO.
C
4321
SHEET 2 OF 2
REV
Copley Controls Corporation.
##-#####-### 1
1:1
A
B
C
D
A
B
C
D
These drawings and specifications are the property of
Copley Controls Corporation and shall not be reproduced,
copied or used as the basis for manufacture or sale of any
apparatus without the express written authorization of
2
139.885.51
2.31 58.67
5.72 145.35
1.00 25.40
4.83.19
7.92 201.17
191.527.54
19.18.76
.31 7.92
32.691.29
5.12
6.12
130.07
191.527.54
201.177.92
4.83.19
TYP.094 2.37
76.203.00
R
.24
.190 4.83

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 4 of 26
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RESOLVER
RESOLVER
Type Brushless, single-speed, 1:1 to 2:1 programmable transformation ratio
Resolution 14 bits (equivalent to a 4096 line quadrature encoder)
Reference frequency 7.5 kHz
Reference voltage 2.8 Vrms, auto-adjustable by the drive to maximize feedback
Reference maximum current 100 mA
Maximum RPM 10,000+
ENCODER EMULATION
Resolution Programmable to 16,384 counts/rev (4096 line encoder equivalent)
Buffered encoder outputs 26C31 differential line driver
MOTOR CONNECTIONS
Phase U, V, W PWM outputs to 3-phase ungrounded Wye or delta connected brushless motors, or DC brush motors (U-V)
Resolver R1, R2, S1, S2, S3, S4
Motemp [IN6] Motor overtemperature sensor input. Active level programmable 0~5 Vdc, 4.99 kΩ pullup to +5 Vdc
Disables drive when motor over-temperature condition occurs
Signal ground Return for temperature sensor
Brake [OUT4] Current-sinking motor brake driver
+24 Vdc From drive +24 Vdc power supply to power motor brake
Frame ground For motor cable shield
FEEDBACK SPECIFICATIONS
INCREMENTAL ENCODERS & HALLS
DIGITAL QUAD A/B ENCODER
Type Quadrature, differential line driver outputs
Signals A, /A, B, /B, (X, /X, index signals optional)
Frequency 5 MHz line frequency, 20 MHz quadrature count frequency
ANALOG ENCODER
Type Sin/cos/index, differential line driver outputs, 0.5 Vpeak-peak (1.0 Vpeak-peak differential)
centered about 2.5 Vdc typical. Common-mode voltage 0.25 to 3.75 Vdc
Signals Sin(+), sin(-), cos(+), cos(-), index(+), index(-)
Frequency 230kHz maximum line (cycle) frequency
Interpolation 10 bits/cycle (1024 counts/cycle)
DIGITAL HALLS
Type Digital, single-ended, 120° electrical phase difference
Signals U, V, W
Inputs 10 kΩ pullups to +5 Vdc, 1 µs RC lter to Schmitt trigger inverters
Frequency Consult factory for speeds >10,000 RPM
ENCODER POWER SUPPLY
Power Supply +5 Vdc @ 400 mA to power encoders & Halls
Protection Current-limited to 750 mA @ 1 Vdc if overloaded
Encoder power developed from +24 Vdc so position information is not lost when AC mains power is removed
MOTOR CONNECTIONS
Phase U, V, W PWM outputs to 3-phase ungrounded Wye or delta connected brushless motors
Hall U, V, W Hall signals
Digital Encoder A, /A, B, /B, X, /X, on standard models
Analog Encoder Sin(+), sin(-), cos(+), cos(-), index(+), index(-)
Hall & encoder power +5 Vdc @ 400 mA maximum
Motemp [IN5] Motor overtemperature sensor input, 4.99 kΩ to +5 Vdc or ground
Signal ground Return for encoder, Halls, and temperature sensor
Brake [OUT4] Current-sinking motor brake driver
+24 Vdc From drive +24 Vdc power supply to power motor brake
Frame ground For motor cable shield
FEEDBACK SPECIFICATIONS

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 5 of 26
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PIN SIGNAL
1 TX+
2TX-
3RX+
6RX-
J7: EtherCAT PORTS
RJ-45 receptacles,
8 position, 4 contact
ETHERCAT COMMUNICATIONS
EtherCAT is the open, real-time Ethernet network developed by Beckhoff based on the widely used 100BASE-TX cabling system. EtherCAT enables high-
speed control of multiple axes while maintaining tight synchronization of clocks in the nodes. Data protocol is CANopen over EtherCAT (CoE) based on
DSP-402 for motion control devices.
ETHERCAT CONNECTIONS
Dual RJ-45 sockets accept standard Ethernet cables. The IN port connects to a master, or to the OUT port of a device that is ‘upstream’, between the
Xenus and the master. The OUT port connects to ‘downstream’ nodes. If Xenus is the last node on a network, only the IN port is used. No terminator is
required on the OUT port.
NET STATUS LED (ON J6)
A bi-color LED indicates the state of the EtherCAT bus.
Green and red colors alternate, and each color has a separate meaning:
Green is the “RUN” or EtherCAT State Machine: Red is the “ERR” indicator:
Off = INIT state Blinking = Invalid conguration
Blinking = PRE-OPERATIONAL Single Flash = Unsolicited state change
Single Flash = SAFE-OPERATIONAL Double Flash = Application watchdog timeout
On = OPERATIONAL
ETHERCAT LEDS (ON J7)
Green and yellow LEDs indicate the state of the EtherCAT interface:
Green is the “Link” indicator: Yellow is the “Activity” indicator:
On = Good Link On = Activity
Off = No Link Blinking Off = No Activity
1 8 1 8
IN (A)
OUT (B)
LINK
(green)
ACTIVITY
(yellow)
AMP STATUS LED
A bi-color LED gives the state of the Accelnet drive.
Colors do not alternate, and can be solid ON or blinking:
Green/Solid = Drive OK and enabled. Will run in response to reference inputs
or EtherCAT commands.
Green/Slow-Blinking = Drive OK but NOT-enabled. Will run when enabled.
Green/Fast-Blinking = Positive or Negative limit switch active.
Drive will only move in direction not inhibited by limit switch.
Red/Solid = Transient fault condition. Drive will resume operation when fault is removed.
Red/Blinking = Latching fault. Operation will not resume until drive is Reset.
EtherCAT
Address Switch
Decimal values
S1 S2
HEX DEC
000
116 1
232 2
348 3
4 64 4
5 80 5
6 96 6
7 112 7
8 128 8
9 144 9
A 160 10
B 176 11
C 192 12
D 208 13
E 224 14
F 240 15
S1 S2
EtherCAT ADDRESS (STATION ALIAS)
In an EtherCAT network, slaves are automatically assigned addresses based on their
position in the bus. But when the device must have a positive identication that is
independent of cabling, a Station Alias is needed. In the XEL, this is provided by two
16-position rotary switches with hexadecimal encoding. These can set the address of the
drive from 0x01~0xFF (1~255 decimal). The chart shows the decimal values of the hex
settings of each switch.
Example 1: Find the switch settings for decimal address 107:
1) Find the highest number under S1 that is less than 107 and set S1 to the hex value in
the same row:
96 < 107 and 112 > 107, so S1 = 96 = Hex 6
2) Subtract 96 from the desired address to get the decimal value of switch S2 and set S2
to the Hex value in the same row:
S2 = (107 - 96) = 11 = Hex B
PIN SIGNAL
2 RxD
3,4 Gnd
5Txd
J5: RS-232 PORT
RJ-11 receptacle,
6 position, 4 contact
RS-232 COMMUNICATIONS
Accelnet EtherCAT is congured via a three-wire, full-duplex DTE RS-232 port that
operates from 9600 to 115,200 Baud. CME 2™ provides a graphic user interface (GUI)
to set up all of Accelnet EtherCAT features via a computer serial port. Connections to the
Accelnet EtherCAT RS-232 port are through J6, an RJ-11 style connector. Signal format
is full-duplex, 3-wire, DTE using RxD, TxD, and Gnd. The Accelnet EtherCAT Serial Cable
Kit (SER-CK) contains a modular cable, and an adapter that connects to a 9-pin, Sub-D
serial port connector (COM1, COM2, etc.) on PC’s and compatibles.

PRELIMINARY
Frame Ground
Signal ground
+24V Output
From 24V input on J4-3
J5
4.99k
5.1V
+HV
High Side PWM
Low Side PWM Motor
Ouputs
4.99k
4.99k
5.1V
ENH
ENH
ENL
ENL
DIAG-ON
36V
10 +V
4.99k
LED(+)
ENL(-)
ENH(+)
Xenus Plus
Safety Override
Connections
ENH(-)
ENL(+)
LED(-)
2
3
1
4
5
6
7
9
8
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 6 of 26
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DESCRIPTION
The XEL has a safety feature that is designed to function under the protocol of EN 954-1. Two opto-couplers are provided which, when de-energized,
prevent the upper and lower devices in the PWM outputs from being operated by the DSP. This provides a positive OFF capability that cannot be
overridden by the DSP, its’ rmware, or associated hardware components. When the opto-couplers are activated (current is owing in the input diodes),
the DSP can control the operation and on/off state of the PWM outputs.
SAFE-OFF
FUNCTIONAL DIAGRAM
In order for the PWM outputs of the Xenus Plus to be activated, current must be owing through both opto-couplers that are connected to the ENH and
ENL terminals of J5, and the drive must be in an ENABLED state. The LED outputs on J5 connect an opto-coupler to an external LED and will conduct
current through the LED to light it whenever the PWM outputs can be activated, or the drive is in a diagnostic state. When the LED opto-coupler is OFF,
the drive is in a Safe state and the PWM outputs cannot be activated to drive a motor.
SAFE-OFF OVERRIDE
The diagram below shows connections that will energize both ENH and ENL opto-couplers. When this is done the SAFE-OFF feature is defeated and
control of the output PWM stage is under control of the DSP. This is the operating mode of CC drives that don’t have the SAFE-OFF feature.
SAFETY CONNECTOR
FUNCTIONAL DIAGRAM
PIN SIGNAL PIN SIGNAL
1Frame Gnd 6Enable LED(+)
2Safe Enable HI(+) 7Enable LED(-)
3 Safe Enable HI(-) 824 Vdc Common
4Safe Enable LO(+) 9+24 Vdc Input
5Safe Enable LO(-)
J5 SIGNALS
J5
1695
SAFETY

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 7 of 26
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PULSE
[IN3+]
[IN4-]
DIRECTION
[IN5+]
[IN6-]
PULSE
[IN3+]
[IN4-]
DIRECTION
[IN5+]
[IN6-]
CD (Count-Down)
CU (Count-Up)
Pulse
Direction
[IN3]
[IN5]
CU
CD
[IN3]
[IN5]
CU (Count-Up)
CD (Count-Down)
Enc. B
Enc. A
[IN3]
[IN5]
Encoder ph. A
Encoder ph. B
Enc A
[IN5+]
[IN6-]
Encoder ph. A
Enc. B
[IN3+]
[IN4-]
Encoder ph. B
DIGITAL POSITION
Digital position commands can be in either single-ended or differential format. Single-ended signals should be sourced from devices with active pull-up
and pull-down to take advantage of the high-speed inputs. Differential inputs have 121 Ωline-terminators.
SINGLE-ENDED PULSE & DIRECTION
DIFFERENTIAL CU/CD
DIFFERENTIAL PULSE & DIRECTION
SINGLE-ENDED CU/CD
QUAD A/B ENCODER SINGLE-ENDED QUAD A/B ENCODER DIFFERENTIAL
DIGITAL TORQUE, VELOCITY
Digital torque or velocity commands can be in either single-ended or differential format. Single-ended signals must be sourced from devices with active
pull-up and pull-down to take advantage of the high-speed inputs.
Current or
Velocity
Polarity or
Direction
[IN3]
[IN5]
Duty = 0~100%
SINGLE-ENDED PWM & DIRECTION
Current or
Velocity
No function
[IN3]
[IN5]
Duty = 50% ±50%
<no connection>
SINGLE-ENDED 50% PWM
Current or
Velocity
[IN3+]
[IN4-]
Duty = 50% ±50%
No
Function
<no connection>
[IN5+]
[IN6-]
DIFFERENTIAL 50% PWM
PWM
[IN3+]
[IN4-]
Duty = 0 - 100%
Direction
[IN5+]
[IN6-]
DIFFERENTIAL PWM & DIRECTION
ANALOG REFERENCE INPUT
A single ±10 Vdc differential input takes inputs from controllers that use PID or similar
compensators, and outputs a current command to the drive. Drive output current or
velocity vs. reference input voltage is programmable.
COMMAND INPUTS

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 8 of 26
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COMMAND INPUTS (CONTINUED)
100pF
10k
10k 74HC2G14
[IN1]
[IN2]
[IN15]
A
+5.0 V
DIGITAL INPUTS
Xenus Plus has twelve digital inputs, eleven of which have programmable functions. Input [IN1] is dedicated to the drive Enable function.
This is done to prevent accidental programming of the input in such a way that the controller could not shut it down.
Two types of RC lters are used: GP (general purpose) and HS (high speed). Input functions such as Pulse/Dir, CW/CCW, Quad A/B are
wired to inputs having the HS lters, and inputs with the GP lters are used for general purpose logic functions, limit switches, and the
motor temperature sensor. Programmable functions of the digital inputs include:
• Positive Limit switch • Step & Direction, or CU/CD
• Negative Limit switch step motor position commands
• Home switch • Quad A/B master encoder
• Drive Reset position commands
• PWM current or velocity commands • Motor over-temperature
• CAN address bits • Motion Prole Abort
DIGITAL INPUT CIRCUITS
24VDC MAX
HS (HIGH SPEED) DIGITAL INPUTS
These inputs have all the programmable functions of the GP inputs plus these additional functions on [IN8] & [IN9]
which can be congured as single-ended or differential:
• PWM 50%, PWM & Direction for Velocity or Current modes
• Pulse/Direction, CU/CD, or A/B Quad encoder inputs for Position or Camming modes
DIFFERENTIALSINGLE-ENDED
12 Vdc max 12 Vdc max
100 pF
1k
+5V
MAX3096
MAX3096
10k
[IN3]
100 pF
1k
[IN4]
+5V
10k
100 pF
1k
+5V
10k
[IN5]
100 pF
1k
[IN6]
+5V
10k
100 pF
1k
2.5V
+5V
MAX3096
MAX3096
MAX3096
MAX3096
10k
+
[IN3]
100 pF
1k
[IN4]
+5V
10k
100 pF
1k
2.5V
+5V
10k
+
[IN5]
100 pF
1k
[IN6]
+5V
10k

PRELIMINARY
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 9 of 26
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OUTPUTS
+
J4
Xenus
3+24V
Brk
0V
2
1
24V
BRK
BRAKE OUTPUT [OUT4]
This output is an open-drain MOSFET with an internal yback diode connected to the +24
Vdc input. It can sink up to 1A from a motor brake connected to the +24 Vdc supply.
The operation of the brake is programmable with CME 2. It can also be programmed as
a general-purpose digital output.
100mA
100mA
+30V max
+
R-L
R-L
16
17
15
+5V
+5V
Xenus
[OUT1]
Sgnd
[OUT2]
J8
DIGITAL OUTPUTS [OUT1], [OUT2]
These are open-drain MOSFETs with 1 kΩ pull-up resistors in series with a diode to +5 Vdc.
They can sink up to 1 Adc from external loads operating from power supplies to +30 Vdc.
The output functions are programmable. The active state of the outputs is programmable
to be on or off. When driving inductive loads such as a relay, an external y-back diode
is required.
The internal diode in the output is for driving PLC inputs that are opto-isolated and
connected to +24 Vdc. The diode prevents conduction from +24 Vdc through the 1 kΩ
resistor to +5 Vdc in the drive. This could turn the PLC input on, giving a false indication
of the drive output state.
OUTPUTS
HIGH SPEED OUTPUT [OUT3]
Output from a CMOS buffer.
Xenus
J8
NC7SZ125
+5 Vdc
18
15
[OUT3]
Sgnd
±20mA
R

PRELIMINARY
QUAD A/B ENCODER WITH FAULT PROTECTION
Encoders with differential line-driver outputs provide incremental
position feedback via the A/B signals and the optional index
signal (X) gives a once per revolution position mark. The
MAX3097 receiver has differential inputs with fault protections
for the following conditions:
Short-circuits line-line: This produces a near-zero voltage
between A & /A which is below the differential fault threshold.
Open-circuit condition: The 121Ωterminator resistor will pull
the inputs together if either side (or both) is open. This will
produce the same fault condition as a short-circuit across the
inputs.
Low differential voltage detection: This is possible with very long
cable runs and a fault will occur if the differential input voltage
is < 200mV.
±15kV ESD protection: The 3097E has protection against high-
voltage discharges using the Human Body Model.
Extended common-mode range: A fault occurs if the input
common-mode voltage is outside of the range of -10V to
+13.2V
Xenus Plus
+5V output @ 400 mA
Signal Ground
21
20
6
5
19 Sin(+)
Sin(-)
Cos(+)
Cos(-)
Inx(+)
Inx(-)
18
1
-
+
-
+
10k
121
J10
10k
121
Encoder
FG
sin
cos
+5V
0V
23
22
-
+
10k
121
indx
Frame Ground
10k
Sin
Cos
Indx
10k
10k
ANALOG SIN/COS INCREMENTAL ENCODER
The sin/cos/index inputs are differential with 121 Ω terminating resistors
and accept 1 Vp-p signals in the format used by incremental encoders
with analog outputs, or with ServoTube motors.
Encoder Xenus Plus
FG Frame Ground
J10
MAX3097
Enc. A
121
A13
12
1
MAX3097
Enc. B
121
B11
10
MAX3097
Enc. Index
121
Z9
8/X
X
/B
B
/A
A
+5V
0V
+5V output @ 400 mA
Signal Ground
6
5
RESOLVER (-R MODELS)
Connections to the resolver should be made with shielded cable
that uses three twisted-pairs. Once connected, resolver set up,
motor phasing, and other commissioning adjustments are made
with CME 2 software. There are no hardware adjustments.
Xenus PlusResolver
FG Frame Ground
J10
Sin(+)
Sin(-)
Cos(-)
Cos(+)
Ref(+)
Ref(-)
21
20
19
18
1
23
22
R/D
Conversion
Sin
S3 S1
S2
S4
R1R2
Cos
Ref
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RoHS
MOTOR CONNECTIONS
Motor connections are of three types: phase, feedback, and thermal sensor. The phase connections carry the drive output currents that
drive the motor to produce motion. A thermal sensor that indicates motor overtemperature is used to shut down the drive to protect
the motor. Feedback can be digital quad A/B encoder, analog sin/cos encoder, resolver or digital Halls, depending on the version of the
drive.

PRELIMINARY
SSI ABSOLUTE ENCODER
The SSI (Synchronous Serial Interface) is an interface used
to connect an absolute position encoder to a motion controller
or control system. The Accelnet drive provides a train of clock
signals in differential format to the encoder which initiates
the transmission of the position data on the subequent
clock pulses. The polling of the encoder data occurs at the
current loop frequency (16 kHz). The number of encoder
data bits and counts per motor revolution are programmable.
The hardware bus consists of four signals: SCLK, SDATA,
SDEN0, and SDEN1. SDATA is a bidirectional [three-state]
data line which requires a pull-up or pull-down resistor. Data
is sent in 8 bit bytes, LSB rst. The SCLK signal is only active
during transfers. Data is clocked out on the falling edge and
clock in on the rising edge of the Master. The other two pins
SDEN0 and SDEN1 are enable pins, active high.
-
+
-
+
Encoder Xenus Plus
121
Sin(+)
Sin(-)
Cos(+)
Cos(-)
Dat
/Dat
Clk
/Clk 121
FG Frame Ground
J10
Clk
Data
MAX3062B
MAX3062B
Data
Clk 9
8
1
15
14
+5V
0V
+5V output @ 400 mA
Signal Ground
6
21
22
10k
10k
121 Sin
Cos
10k
10k
121
sin
cos
19
18
5
ENDAT ABSOLUTE ENCODER
The EnDat interface is a Heidenhain interface that is similar to SSI in
its’ use of clock and data signals, but which also supports analog sin/
cos channels from the same encoder. The number of position data bits is
programmable as is the use of sin/cos channels. Use of sin/cos incremental
signals is optional in the EnDat specication.
Encoder Xenus Plus
121
121
Clk
/Clk
Dat
/Dat
FG Frame Ground
J10
Clk
Data
MAX3062B
MAX3062B
Data
Clk
+5V
0V
+5V output @ 400 mA
Signal Ground
9
8
1
15
14
6
5
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RoHS
MOTOR CONNECTIONS (CONT’D)
BiSS ABSOLUTE ENCODER
BiSS is an - Open Source - digital interface for sensors and actuators.
BiSS refers to principles of well known industrial standards for Serial
Synchronous Interfaces like SSI, AS-Interface® and Interbus® with
additional options.
Serial Synchronous Data Communication
Cyclic at high speed
2 unidirectional lines Clock and Data
Line delay compensation for high speed data transfer
Request for data generation at slaves
Safety capable: CRC, Errors, Warnings
Bus capability incl. actuators
Bidirectional
BiSS B-protocol: Mode choice at each cycle start
BiSS C-protocol: Continuous mode
NIKON-A ABSOLUTE ENCODER
The Nikon A interface is a serial, half-duplex type that is
electrically the same as RS-485
BiSS
Encoder Xenus
121
121
MA+
MA-
SL+
SL-
FG Frame Ground
J3
Clk
Data
MAX3062B
MAX3062B
Master
Slave
V+
V-
+5V output @ 400 mA
Signal Ground
9
8
1
15
14
6
5
Nikon-A
Encoder Xenus
1.2k
1.2k
220
5V
1.2k
1.2k
220
5V
SD+
SD-
0V
+5V
J10
1
9
8
V+
V-
5V output
Signal Ground
6
5
Cmd
D-R
SD
MAX3062B
Cmd
D-R
SD
MAX3062B

PRELIMINARY
MOTOR PHASE CONNECTIONS
The drive output is a three-phase PWM inverter that converts the DC buss voltage
(+HV) into three sinusoidal voltage waveforms that drive the motor phase-coils.
Cable should be sized for the continuous current rating of the motor. Motor cabling
should use twisted, shielded conductors for CE compliance, and to minimize PWM
noise coupling into other circuits. The motor cable shield should connect to motor
frame and the drive frame ground terminal (J2-1) for best results.
Xenus
Halls
+5V output @ 400 mA
* Signal Ground
+5V
0V
6
5
10K
22p
10K
Hall U +5V
J10
2
22p
10K
10K
Hall V +5V
3
22p
10K
10K
Hall W
+5V
4
Hall A
Hall B
Hall C
* Alternate Sgnd connections on J10 are pins 16, 25, 26
DIGITAL HALL SIGNALS
Hall signals are single-ended signals that provide absolute feedback within one
electrical cycle of the motor. There are three of them (U, V, & W) and they may be
sourced by magnetic sensors in the motor, or by encoders that have Hall tracks as
part of the encoder disc. They typically operate at much lower frequencies than the
motor encoder signals, and are used for commutation-initialization after startup,
and for checking the motor phasing after the amplifer has switched to sinusoidal
commutation.
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MOTOR TEMPERATURE SENSOR
Digital input [IN15] Motemp, is for use with a motor overtemperature switch or
sensor. The active level of the input, Vset, is programmable generate an over-
temperature fault if the input voltage is <Vset, or >Vset.
= Shielded cables required
for CE compliance
BRAKE OUTPUT [OUT4]
This output is an open-drain MOSFET with an internal yback diode connected to
the +24 Vdc input. It can sink up to 1A from a motor brake connected to the +24
Vdc supply. The operation of the brake is programmable with CME 2. It can also
be programmed as a general-purpose digital output.
MOTOR CONNECTIONS (CONT’D)
+
J4
Xenus
3+24V
Brk
0V
2
1
24V
BRK
7
5
+5V
Motemp
Thermistor,
Posistor,
or switch * Sgnd
* Alternate Sgnd connections on J10 are pins 16, 25, 26
4.99k
J10

PRELIMINARY
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MULTI-MODE ENCODER PORT
This port consists of three differential input/output channels that take their functions from the Basic Setup of the drive.
On drives with quad A/B encoder feedback, the port works as an output buffering the signals from the encoder. With resolver or sin/cos
encoder versions, the feedback is converted to quad A/B signals with programmable resolution. These signals can then be fed back
to an external motion controller that closes the position or velocity loops. As an input, the port can take quad A/B signals to produce
a dual-loop position control system or use the signals as master-encoder feedback in camming mode. In addition, the port can take
stepper command signals (CU/CD or Pulse/Direction) in differential format.
1k
22 pF
22 pF
2.2k Secondary
Encoder Input
Input/Output
Select
Quad A/B Feedback
Encoder
26CS31
26CS32
+5V
1k
1k
22 pF
22 pF
2.2k Secondary
Encoder Input
Input/Output
Select
Emulated Quad A/B
signals from
analog Sin/Cos encoder
or resolver
26CS31
26CS32
+5V
1k
1k
22 pF
22 pF
2.2k Secondary
Encoder Input
Input/Output
Select
26CS31
26CS32
+5V
1k
AS BUFFERED OUTPUTS FROM A DIGITAL QUADRATURE
FEEDBACK ENCODER
When using a digital quadrature feedback encoder, the A/B/X signals drive
the multi-mode port output buffers directly. This is useful in systems that use
external controllers that also need the motor feedback encoder signals because
these now come from J7, the Control connector. In addition to eliminating “Y”
cabling where the motor feedback cable has to split to connect to both controller
and motor, the buffered outputs reduce loading on the feedback cable that
could occur if the motor encoder had to drive two differential inputs in parallel,
each with it’s own 121 ohm terminating resistor.
AS EMULATED QUAD A/B/X ENCODER OUTPUTS FROM AN
ANALOG SIN/COS FEEDBACK ENCODER
Analog sin/cos signals are interpolated in the drive with programmable
resolution. The incremental position data is then converted back into digital
quadrature format which drives the multi-mode port output buffers. Some
analog encoders also produce a digital index pulse which is connected directly
to the port’s output buffer. The result is digital quadrature A/B/X signals that
can be used as feedback to an external control system.
AS A MASTER OR CAMMING ENCODER INPUT FROM A
DIGITAL QUADRATURE ENCODER
When operating in position mode the multi-mode port can accept digital
command signals from external encoders. These can be used to drive cam
tables, or as master-encoder signals when operating in a master/slave
conguration.
AS DIGITAL COMMAND INPUTS IN PULSE/DIRECTION,
PULSE-UP/PULSE-DOWN, OR
DIGITAL QUADRATURE ENCODER FORMAT
The multi-mode port can also be used when digital command signals are in a
differential format. These are the signals that typically go to [IN9] and [IN10]
when they are single-ended. But, at higher frequencies these are likely to be
differential signals in which case the multi-mode port can be used.
MOTOR CONNECTIONS (CONT’D)

PRELIMINARY
Quad A/B Encoder
15 [OUT4-] GPI
J9
4
3
2
8
7
1
6
5
F. G .
[IN8] GPI
[COMM_A]
[IN7] GPI
[COMM_B]
[IN10] GPI
[IN9] GPI
12
11
10
9
14
13
[IN12] GPI
[OUT5+] GPI
[IN13] GPI
[IN14] GPI
[OUT4+] GPI
[OUT5-] GPI
[IN11] GPI
Multi-Mode
Encoder
Port
Frame Ground
A
/A
B
/B
X
/X
Frame
Gnd
Outputs Buffered
Quad A/B from
Encoder
Sgnd 5
+5 Vdc 6
A
B
/B
X
/X
/A
21
22
23
26
24
25
1
8
9
10
11
12
1
13
Hall W 4
Hall V 3
Hall U 2
7
Motemp
[IN15]
Signal Ground 16
+5 Vdc 17
DIGITAL
ENCODER
DIGITAL
HALLS
/A
A
/B
B
/X
Vcc
0V
X
+5 Vdc @ 400 mA
Signal Ground
Ain1(-)
Ain1(+)
±10 Vdc
Analog
Reference
TEMP
SENSOR
AC MAINS:
100 to 240 Vac
1Ø or 3Ø
47 to 63 Hz
L3
L2
L1
Fuse
1
H
N
LINE
FILTER
BRUSHLESS
MOTOR
DANGER: HIGH VOLTAGE
CIRCUITS ON J1, J2, & J3
ARE CONNECTED TO
MAINS POWER
* Fuse
* Fuse
Earth
* Fuse
* Fuse
* Optional
J3
REGEN+
REGEN-
Frame Ground
U
V
W
1
4
5
2
3
4
3
2
1
Mot U
Mot V
Mot W
Frame Ground
J4
J1
J2
J8
+24V
BRAKE
RTN
Signal Ground
Aout
[OUT2]
[OUT1]
[OUT3]
L3
L2
L1
BRAKE
Required for
Drive Operation
Control Power Supply
+24 Vdc
0.5 Adc
7
12
11
2
3
1
15
10
8
9
17
16
18
Drive mounting screw
[IN1] Enable
[IN4] GP
[IN2] GP
[IN3] GP
Ain2(-)
Ain2(+)
[IN6] HS
[IN5] HS
6
5
4
J10
20
19
2
3
4
3
2
1
+
-
(NOTE 1)
(NOTE 1)
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RoHS
NOTES:
1) The total output current from the +5 Vdc supply to J7-20 cannot exceed 400 mAdc
2) Line lter is required for CE
MOTOR CONNECTIONS (CONT’D)

PRELIMINARY PRELIMINARY
Sin/Cos Encoder
15 [OUT4-] GPI
J9
4
3
2
8
7
1
6
5
F. G .
[IN8] GPI
[COMM_A]
[IN7] GPI
[COMM_B]
[IN10] GPI
[IN9] GPI
12
11
10
9
14
13
[IN12] GPI
[OUT5+] GPI
[IN13] GPI
[IN14] GPI
[OUT4+] GPI
[OUT5-] GPI
[IN11] GPI
Multi-Mode
Encoder
Port
Frame Ground
A
/A
B
/B
X
/X
Frame
Gnd
Outputs Buffered
Quad A/B from
Encoder
Sgnd 5
+5 Vdc 6
Asin(+)
Acos(+)
Acos(-)
Ainx(+)
Ainx(-)
Asin(-)
21
22
23
26
24
25
1
22
23
20
21
18
1
19
Hall W 4
Hall V 3
Hall U 2
7
Motemp
[IN15]
Signal Ground 16
+5 Vdc 17
Sin / Cos
ENCODER
DIGITAL
HALLS
Sin(-)
Sin(+)
Cos(-)
Cos(+)
Index(-)
Vcc
0V
Index(+)
+5 Vdc @ 400 mA
Signal Ground
Ain1(-)
Ain1(+)
±10 Vdc
Analog
Reference
TEMP
SENSOR
AC MAINS:
100 to 240 Vac
1Ø or 3Ø
47 to 63 Hz
L3
L2
L1
Fuse
1
H
N
LINE
FILTER
BRUSHLESS
MOTOR
DANGER: HIGH VOLTAGE
CIRCUITS ON J1, J2, & J3
ARE CONNECTED TO
MAINS POWER
* Fuse
* Fuse
Earth
* Fuse
* Fuse
* Optional
J3 REGEN+
REGEN-
Frame Ground
U
V
W
1
4
5
2
3
4
3
2
1
Mot U
Mot V
Mot W
Frame Ground
J4
J1
J2
J8
+24V
BRAKE
RTN
Signal Ground
Aout
[OUT2]
[OUT1]
[OUT3]
L3
L2
L1
BRAKE
Required for
Drive Operation
Control Power Supply
+24 Vdc
0.5 Adc
7
12
11
2
3
1
15
10
8
9
17
16
18
Drive mounting screw
[IN1] Enable
[IN4] GP
[IN2] GP
[IN3] GP
Ain2(-)
Ain2(+)
[IN6] HS
[IN5] HS
6
5
4
J10
20
19
2
3
4
3
2
1
+
-
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RoHS
NOTES:
1) The total output current from the +5 Vdc supply to J7-20 cannot exceed 400 mAdc
2) Line lter is required for CE
MOTOR CONNECTIONS (CONT’D)

PRELIMINARY
Resolver
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RoHS
NOTES:
1) The total output current from the +5 Vdc supply to J7-20 cannot exceed 400 mAdc
2) Line lter is required for CE
MOTOR CONNECTIONS (CONT’D)
15 [OUT4-] GPI
J9
4
3
2
8
7
1
6
5
F. G .
[IN8] GPI
[COMM_A]
[IN7] GPI
[COMM_B]
[IN10] GPI
[IN9] GPI
12
11
10
9
14
13
[IN12] GPI
[OUT5+] GPI
[IN13] GPI
[IN14] GPI
[OUT4+] GPI
[OUT5-] GPI
[IN11] GPI
Multi-Mode
Encoder
Port
Frame Ground
A
/A
B
/B
X
/X
Frame
Gnd
Outputs Buffered
Quad A/B from
Encoder
Sgnd 5
+5 Vdc 6
Asin(+)
Acos(+)
Acos(-)
Ainx(+)
Ainx(-)
Asin(-)
21
22
23
26
24
25
1
22
23
20
21
18
1
19
Hall W 4
Hall V 3
Hall U 2
7
Motemp
[IN15]
Signal Ground 16
+5 Vdc 17
Resolver
S1 Sin(-)
S3 Sin(+)
S4 Cos(-)
S2 Cos(+)
R2 Ref(-)
R1 Ref(+)
+5 Vdc @ 400 mA
Signal Ground
Ain1(-)
Ain1(+)
±10 Vdc
Analog
Reference
TEMP
SENSOR
AC MAINS:
100 to 240 Vac
1Ø or 3Ø
47 to 63 Hz
L3
L2
L1
Fuse
1
H
N
LINE
FILTER
BRUSHLESS
MOTOR
DANGER: HIGH VOLTAGE
CIRCUITS ON J1, J2, & J3
ARE CONNECTED TO
MAINS POWER
* Fuse
* Fuse
Earth
* Fuse
* Fuse
* Optional
J3 REGEN+
REGEN-
Frame Ground
U
V
W
1
4
5
2
3
4
3
2
1
Mot U
Mot V
Mot W
Frame Ground
J4
J1
J2
J8
+24V
BRAKE
RTN
Signal Ground
Aout
[OUT2]
[OUT1]
[OUT3]
L3
L2
L1
BRAKE
Required for
Drive Operation
Control Power Supply
+24 Vdc
0.5 Adc
7
12
11
2
3
1
15
10
8
9
17
16
18
Drive mounting screw
[IN1] Enable
[IN4] GP
[IN2] GP
[IN3] GP
Ain2(-)
Ain2(+)
[IN6] HS
[IN5] HS
6
5
4
J10
20
19
2
3
4
3
2
1
+
-

PRELIMINARY
~
~-
+
~+
REGEN(-) REGEN(+)
SHIELD
U
V
W
J2
DC BUSS(+)
DC BUSS(-)
J3
1760 µF
L1
MAINS L3
L2
J1
PWM
STAGE
POWER
CONTROL
ISOLATION BARRIER
SHIELD
+5 Vdc
SIGNAL GND
RESOLVER
DRIVE &
DECODING
J8
CONTROL
LOGIC
+5 Vdc
ENABLE [IN1]
SIGNAL GND
CONTROL
SIGNAL
GROUND
CONTROL
SYSTEM
J7
GROUND
+24 Vdc
+24
VDC BRAKE
+24 Vdc
J4
RTN Cntrl
BRAKE
DC/DC
Converter
&
POWER
LOGIC
SIGNAL
DC/DC
(SAFETY GROUND)
PWM
INVERTER MOTOR
RESOLVER
CASE
FRAME GROUND
FRAME GROUND
20
40
60
80
100
120
240220200180160140120100
Energy Absorption vs.
Mains Voltage
Mains Voltage (Vac)
Energy Absorption (W·s)
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RoHS
GROUNDING
A grounding system has three primary
functions: safety, voltage-reference, and
shielding. As a safety measure, the primary
ground at J1-3 will carry fault-currents from
the mains in the case of an internal failure
or short-circuit of electronic components.
Wiring to this is typically done with the
green conductor with yellow stripe using the
same gauge wire as that used for the mains.
The pin on the drive at J1-3 is longer than
the other pins on J1 giving it a rst-make,
last-break action so that the drive chassis is
never ungrounded when the mains power is
connected. This wire is a ‘bonding’ conductor
that should connect to an earthed ground
point and must not pass through any circuit
interrupting devices.
All of the circuits on J1, J2, and J3 are mains-
connected and must never be grounded. The
ground terminals at J1-3, J2-1, and J3-5 all
connect to the drive chassis and are isolated
from all drive internal circuits.
Signal grounding references the drive
control circuits to those of the control
system. These controls circuits typically
have their own earth connection at some
point. To eliminate ground-loops it is
recommended that the drive signal ground
be connected to the control system circuit
ground. When this is done the drive signal
voltages will be referenced to the same 0 V
level as the circuits in the control system.
Small currents ow between controller and
drive when inputs and outputs interact. The
signal ground is the path for these currents
to return to their power sources in both
controller and drive.
Shields on cables reduce emissions from the
drive for CE compliance and protect internal
circuits from interference due to external
sources of electrical noise. Because of their
smaller wire gauge, these should not be
used as part of a safety-ground system.
Motor cases can be safety-grounded either
at the motor, by earthing the frame, or by
a grounding conductor in the motor cable
that connects to J2-1. This cable should
be of the same gauge as the other motor
phase cables.
For CE compliance and operator safety,
the drive should be earthed by using
external tooth lockwashers under the
mounting screws. These will make contact
with the aluminum chassis through the
anodized nish to connect the chassis to
the equipment frame ground.
DRIVE POWER SOURCES
An external +24 Vdc power supply is
required, and powers an internal DC/DC
converter that supplies all the control
voltages for drive operation. Use of an
external supply enables CAN communication
with the drive when the mains power has
been removed.
Power distribution in Xenus Plus is divided
into four sections: +24 Vdc, CAN, signal,
and high-voltage. Each is isolated from
the other and all are isolated from the
chassis.
EXTERNAL +24 VDC
The primary side of the DC/DC converter
operates directly from the external +24
Vdc supply and is isolated from other drive
power sections. The Brake output [OUT4]
operates in this section and is referenced
to the +24 Vdc return (0V). It sinks current
from an external load connected to the
external +24 Vdc power source.
INTERNAL SIGNAL POWER
The signal power section supplies power for
the DSP controller as well as logic inputs
and outputs. Motor feedback signals such
as Halls, encoder, and temperature sensor
operate from this power source. All signal
circuits are referenced to signal ground. This
ground should connect to the control system
circuit ground or common so that drive and
controller inputs and output voltage levels
work properly with each other.
MAINS POWER
Mains power drives the high-voltage
section. It is rectied and capacitor-ltered
to produce +HV which the PWM stage
converts into voltages that drive either
three phase brushless or DC brush motors.
An internal solid-state switch together
with an external power resistor provides
dissipation during regeneration when the
mechanical energy of the motor is converted
back into electrical energy that must be
dissipated before it charges the internal
capacitors to an overvoltage condition. All
the circuits in this section are “hot”, that
is, they connect directly to the mains and
must be considered high-voltages and a
shock hazard requiring proper insulation
techniques during installation.
REGENERATION
The chart below shows the energy absorption
in W·s for a Xenus Plus drive operating at
some typical mains voltages. When the load
mechanical energy is greater than these
values an external regen resistor is available
as an accessory.

PRELIMINARY
3 TURNS
AROUND
TOROID
INDUCTOR
MOTOR
MAINS
REGEN
CONTROLLER
XENUS
Plus
FEEDBACK
LINE
FILTER
J1
J2
J10J8
J3J4
24 V
POWER
SUPPLY
Grounding and shielding are the means of
controlling the emission of radio frequency
energy from the drive so that it does not
interfere with other electronic equipment.
The use of shielded cables to connect the
drive to motors and feedback devices is a
way of extending the chassis of the drive
out to these devices so that the conductors
carrying noise generated by the drive
are completely enclosed by a conductive
shield.
The process begins at the mains connector
of the drive, J1. The ground terminal here
has a circle around it indicating that this is
the safety or “bonding” ground connection.
This should be connected with wire that is
the same gauge as that used for the mains.
In the case of a short-circuit in the drive
the function of this ground connection is to
carry the fault current to earth ground until
the safety device (fuse or circuit breakers)
disconnects the drive from the mains. This
connection ensures that the heatplate of
the drive remains at earth potential and
eliminating a shock hazard that could occur
of the chassis were allowed to oat to the
potential of the mains.
While this connection keeps the heatplate
at earth potential the high frequency noise
generated by switching circuits in the drive
can radiate from the wire used for the
safety ground connection. In order to keep
the path between the heatplate and earth
as short as possible it’s also recommended
to mount the drive to the equipment panel
using external-toothed lock washers. These
will penetrate the anodized nish of the
heatplate (which is an electrical insulator)
and make good electrical contact with the
aluminum plate. Grounding the heatplate
in this way shortens the path from drive
to earth ground and further reduces
emissions.
The heatplate also connects directly to
the frame ground terminals on the motor,
feedback, and regen connectors. Note that
the ground symbols for these do not have
a circle around them which indicates that
these are for shielding and not not for
safety grounding. Motors and their feedback
devices (which are typically in the motor
case) should be grounded by mounting to
equipment that is grounded as a safety
ground. By connecting the shields for these
devices at the drive and at the device, the
connection is continuous and provides a
return path for radio-frequency energy to
the drive.
Notes:
1) Shielded cables required for CE are shown in the
diagram above.
2) Line lter required for CE
3) Ferrite core required for shielded cable to regen
resistor which must be in shielded enclosure.
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 18 of 26
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GROUNDING & SHIELDING FOR CE

PRELIMINARY
Edge Filter
(Optional)
RS-232
(DTE)
CME 2 ASCII
Control
EtherCAT
Master
EtherCAT
Slaves
+24 Vdc
Power
Supply
Motor
Quad A/B
Encoder
Absolute
Encoder
-R
Models
Sin/Cos
Encoder Resolver
Line Filter
Regen
Resistor
(Optional)
Controller
or
PLC
AC Mains
90~264 Vac
47~63 Hz
1 or 3 ph.
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 19 of 26
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INSTALLATION

PRELIMINARY
Quad A/B Encoder
Signal Pin
Motor Phase U 4
Motor Phase V 3
Motor Phase W 2
Cable Shield 1
Signal Pin
Mains Input L3 4
Protective Ground 3
Mains Input L2 2
Mains Input L1 1
Signal Pin
Regen Resistor 1
No Connection 2
Regen Resistor 3
No Connection 4
Cable Shield 5
Signal Pin
+24 Vdc Control Power 3
Brake Output [OUT4] 2
0V (+24 Vdc Return) 1
J1 MAINS CONNECTIONS
J2 MOTOR OUTPUTS
J3 REGEN RESISTOR
J4 +24 VDC & BRAKE
J1 CABLE CONNECTOR:
Wago: 51118287 or 721-204/026-045/RN01-0000
Euro-style 7,5 mm pluggable female terminal block
with preceding ground receptacle
Cable: AWG 12, 600 V recommended
for XEL-230-36-R and XEL-230-40-R models,
AWG 14, 600V for XEL-230-18-R
Shielded cable required for CE compliance
J2 CABLE CONNECTOR:
Wago: 51118008 or 721-104/026-047/RN01-0000
Euro-style 5,0 mm pluggable female terminal block
Cable: AWG 12, 600 V recommended
for XEL-230-36-R and XEL-230-40-R models,
AWG 14, 600V for XEL-230-18-R
Shielded cable required for CE compliance
J3 CABLE CONNECTOR:
Wago: 51111277 or 721-605/000-044/RN01-0000
Euro-style 5,0 mm pluggable male terminal block
Cable: AWG 12, 600 V recommended
for XEL-230-36-R and XEL-230-40-R models,
AWG 14, 600V for XEL-230-18-R
Shielded cable required for CE compliance
WARNING: Hazardous voltages exist on connections
to J1, J2, & J3 when power is applied, and for up to 30
seconds after power is removed.
WIRE INSERTION/EXTRACTION TOOL:
Used on J1, J2, J3, & J4
Wago 231-131 ISOLATED CIRCUIT
ISOLATED CIRCUIT
J4 CABLE CONNECTOR:
Wago: 51117974 or 721-103/026-047/RN01-0000
Euro-style 5,0 mm pluggable terminal block
NOTE: AN EXTERNAL
+24 VDC POWER SUPPLY
IS REQUIRED FOR OPERATION
J1
J2
J3
J4
J5
Xenus
PLUS EtherCAT
Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: [phone] Fax: [phone]
Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com Page 20 of 26
RoHS