Copley Controls Xenus Plus Series User manual

123123
P/N 16-01344
Revision 06
August 30, 2019
Xenus Plus™
User Guide

Xenus Plus User Guide 16-01344 Rev 06
This page for notes

Xenus Plus User Guide 16-01344 Rev 06
Copley Controls 3
TABLE OF CONTENTS
About This Manual..................................................................................................................................................................................... 5
1: Introduction.................................................................................................................................................................................... 10
1.1: Xenus Plus Family Overview.................................................................................................................................................... 11
1.2: CME.......................................................................................................................................................................................... 12
1.3: CML/CMO................................................................................................................................................................................. 13
1.4: Copley Virtual Machine (CVM) ................................................................................................................................................. 13
1.5: Indexer 2................................................................................................................................................................................... 13
1.6: CPL........................................................................................................................................................................................... 13
2: Operational Theory........................................................................................................................................................................ 14
2.1: Drive Power Architecture.......................................................................................................................................................... 15
2.2: Operating Modes ...................................................................................................................................................................... 17
2.3: Input Command Types ............................................................................................................................................................. 28
2.4: Communication......................................................................................................................................................................... 33
2.5: Status Indicators....................................................................................................................................................................... 38
2.6: Protection.................................................................................................................................................................................. 50
2.7: Position and Velocity Errors...................................................................................................................................................... 52
2.8: Inputs XEL/XPL/XML................................................................................................................................................................ 55
2.9: Inputs XE2/XP2/XM2/800-1818/800-1819/800-1887 ............................................................................................................... 56
2.10: Outputs, XEL/XPL/XML .......................................................................................................................................................... 58
2.11: Outputs, XE2/XP2/XM2/800-1818/800-1819/800-1887 ......................................................................................................... 58
2.12: Brake Operation...................................................................................................................................................................... 58
2.13: Regen Resistor Theory........................................................................................................................................................... 61
3: Specifications ................................................................................................................................................................................ 64
3.1: Agency Approvals..................................................................................................................................................................... 65
3.2: Power Input............................................................................................................................................................................... 65
3.3: Power Output............................................................................................................................................................................ 66
3.4: Control Loops ........................................................................................................................................................................... 67
3.5: Regen Circuit Output (External Regen Resistor)...................................................................................................................... 67
3.6: Regen Circuit Output (Internal Regen Resistor)....................................................................................................................... 67
3.7: Digital Command Inputs ........................................................................................................................................................... 68
3.8: Analog Inputs............................................................................................................................................................................ 68
3.9: Digital Inputs............................................................................................................................................................................. 69
3.10: Analog Output......................................................................................................................................................................... 70
3.11: Digital Outputs ........................................................................................................................................................................ 70
3.12: Encoder Power Outputs.......................................................................................................................................................... 71
3.13: Primary Encoder Inputs .......................................................................................................................................................... 71
3.14: Analog Encoder Inputs ........................................................................................................................................................... 72
3.15: Hall Switch Inputs ................................................................................................................................................................... 73
3.16: Resolver Interface................................................................................................................................................................... 74
3.17: Multi-Mode Port ...................................................................................................................................................................... 75
3.18: Serial Interface........................................................................................................................................................................ 76
3.19: Network Interfaces.................................................................................................................................................................. 77
3.20: Status Indicators..................................................................................................................................................................... 78
3.21: Fault Levels ............................................................................................................................................................................ 78
3.22: Power Dissipation................................................................................................................................................................... 79
3.23: Thermal Impedance................................................................................................................................................................ 79
3.24: Mechanical and Environmental............................................................................................................................................... 80
3.25: Dimensions............................................................................................................................................................................. 81
4: Wiring.............................................................................................................................................................................................. 84
4.1: General Wiring Instructions ...................................................................................................................................................... 85
4.2: AC Mains (J1)........................................................................................................................................................................... 88
4.3: Motor(s) .................................................................................................................................................................................... 91
4.4: Regen Resistor (Optional) ........................................................................................................................................................ 93
4.5: Logic Supply / Brake................................................................................................................................................................. 96
4.6: Ferrules –XE2/XP2/XM2/800-1818/800-1819/800-1887......................................................................................................... 98
Motor Torque Off ............................................................................................................................................................................ 99
4.7: (MTO) ....................................................................................................................................................................................... 99
4.8: Safe Torque Off (STO) ........................................................................................................................................................... 104
4.9: RS-232 Serial Communications.............................................................................................................................................. 106
4.10: Network Ports ....................................................................................................................................................................... 107
4.11: Control I/O ............................................................................................................................................................................ 110
4.12: Motor Feedback.................................................................................................................................................................... 126
A: Regen Resistor Sizing and Configuration................................................................................................................................. 134
A.1: Sizing a Regen Resistor......................................................................................................................................................... 135
B: I2T Time Limit Algorithm................................................................................................................................................................... 139
B.1: I2T Algorithm........................................................................................................................................................................... 140
C: Thermal Considerations.............................................................................................................................................................. 143
C.1: Operating Temperature and Cooling Configurations ............................................................................................................. 144
C.2: Heatsink Mounting Instructions (XEL/XPL/XML).................................................................................................................... 148

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C.3: Heatsink Mounting Instructions (XE2/XP2/XM2, “-N” and 800-1887 Models) ...................................................................... 149
D: Xenus Plus Filter.......................................................................................................................................................................... 150
D.1: Overview ................................................................................................................................................................................ 151
D.2: XTL-FA-01 Edge Filter Wiring................................................................................................................................................ 154
E: Connecting XPL/XP2 for Serial Control..................................................................................................................................... 157
E.1: Single-Axis and Multi-Drop..................................................................................................................................................... 158
F: Ordering Guide and Accessories............................................................................................................................................... 159
F.1: Drive Model Numbers............................................................................................................................................................. 160
F.2: Accessory Model Numbers..................................................................................................................................................... 163
F.3: Heatsink Kits........................................................................................................................................................................... 164
F.4: External Regen Resistor Assemblies..................................................................................................................................... 165
F.5: Edge Filter .............................................................................................................................................................................. 165
F.6: Order Example ....................................................................................................................................................................... 165
F.7: Copley Standard Regen Resistor Specifications.................................................................................................................... 166

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ABOUT THIS MANUAL
Title, Number, Revision
Title
The Xenus Plus User Guide
Document Number
16-01344
Current Revision
06
Revision History
Revision
Date
ECO
Comments
AA
December 30, 2014
ECO-056871
Initial Release. Originated from 16-01018 Rev 07
00
March 9, 2015
ECO-056484
Updated PE symbols and clarified mandatory use of
line filters.
01
April 2, 2015
ECO-057985
OVC II Mains Requirement and full address for Mfr
& EU Rep. Add model 800-1818
02
September 18,
2015
ECO-059376
Correct input voltage rating (from 5V to 12V) for
single ended/differential non-isolated digital inputs
03
February 7, 2017
ECO-064419
Allow use of isolation transformer to eliminate need
for SPD and allow drive operation up to 4000m
04
March 17, 2017
ECO-066092
Update to reflect EN 61800-5-2:2007
05
February 1, 2019
ECO- 072319
Update to reflect latest revisions of IEC 61800-5-
1:2016 and IEC 61800-5-2:2016
06
August 26, 2019
ECO-074059
Update to change XEL, XPL, XML STO to MTO to
differentiate from certified STO on XE2, XP2, XM2.
No change to certification of XE2, XP2, XM2.
EC Declaration of Conformity
The products covered by this user guide comply with the applicable EC Directives including
2014/30/EU (EMC Directive) and 2014/35/EU (Low Voltage Directive). Complete EC Declarations
of Conformity are available on the internet at www.copleycontrols.com.
Name and Address of the Manufacturer: Name and Address of the authorized representative:
Analogic Corporation d/b/a Copley Controls BK Medical ApS
20 Dan Road Mileparken 34, DK-2730
Canton, MA 02021 Herlev
USA Denmark
Overview and Scope
This manual describes the operation and installation of the XEL, XE2, XPL, XP2, XML, XM2, 800-
1818, 800-1819 and 800-1887 drives manufactured by Copley Controls. All Xenus Plus products
have serial numbers that incorporate the week and year of production into the first 4 digits (WWYY)
of the serial number.

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EC Declaration of Conformity
The complete EC Declarations of Conformity for all products are available on the internet at
www.copleycontrols.com.
Original Instructions
This manual is considered to be “original instructions” as defined in EC Directive 2006/42/EC and
the contents have been verified by Copley Controls.

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Related Documentation
For important setup and operation information, see the CME User Guide (Under Using CME2 here:
http://www.copleycontrols.com/Motion/Downloads/software.html).
Users of the CANopen features should also read these Copley Controls documents:
•CANopen Programmer’s Manual
•CMO (Copley Motion Objects) Programmer’s Guide
•CML Reference Manual
And, this guide for MACRO network users:
•MACRO Network User Guide
Also of related interest:
•Indexer 2 Program User’s Guide (describes use of Indexer Program to create motion
control sequences)
•ASCII Programmer’s Guide (describes how to send ASCII format commands over a
drive’s serial bus to set up and control one or more drives)
•Copley Amplifier Parameter Dictionary
•Copley Camming User Guide
•Copley Controls Serial Encoder Guide
•CPL User Guide
•Xenus Plus Dual-Axis STO Manual
Links to these publications, along with other documents, data sheets and software releases, can
be found at: http://www.copleycontrols.com.
Comments
Copley Controls 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.
Xenus XEL, XE2, XPL, XP2, XML and XM2 are registered trademarks of Copley Controls.
CME is a registered trademark of Copley Controls.
Windows XP, Windows 7, Visual Basic, and .NET are trademarks or registered trademarks
of the Microsoft Corporation.
LabVIEW is a registered trademark of National Instruments.
EtherCAT is a registered trademark and patented technology,
licensed by Beckhoff Automation GmbH, Germany.
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.
Copley Controls assumes no responsibility for any errors that may appear in this document.

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Product Warnings
Observe all relevant state, regional and local safety regulations when installing and using this
product. There are no user serviceable parts in the Xenus Plus servo drives.
Removal of the cover or tampering with internal components will void the warranty
DANGER
DANGER: Hazardous voltages.
Exercise caution when installing and adjusting. Persons responsible for installing and
commissioning Xenus Plus servo drives must be experienced in all aspects of electrical
equipment installations.
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
Risk of electric shock. Wait 5 minutes after disconnecting mains power
before handling.
High-voltage circuits connected to mains power. After disconnecting mains power, wait 5
minutes before handling drive to allow for discharge of internal DC bus capacitance.
XEL/XPL/XML
J1, J2, J3
XE2/XP2/XM2/800-1818/800-1819/800-1887
J1, J2, J3, and J4
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
Risk of unexpected motion with non-latched faults.
After the cause of a non-latched fault is corrected, the drive 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.
DANGER
Using CME or serial commands may affect or suspend CANopen operations.
When operating the drive as a CANopen node, the use of CME or ASCII serial commands
may affect CANopen operations in progress. Using such commands to initiate motion may
cause CANopen operations to suspend. CANopen operations may restart unexpectedly
when the commanded motion is stopped.
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
Latching an output does not eliminate the risk of unexpected motion with
non-latched faults.
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 drive re-enables without operator
intervention. In this case, motion may re-start unexpectedly. For more information, see
Clearing Latched Faults (p.51).
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
Use equipment as described.
Operate drives within the specifications provided in this manual.
Failure to heed this warning can cause equipment damage, injury, or death.
DANGER
Drive heatsink surfaces can exceed 80C and regen resistor surface
can exceed 100C depending on drive use conditions
Do not touch drive heatsink during operation and allow it to cool before handling after
power is removed.
Failure to heed this warning can cause injury
!
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CHAPTER
1: INTRODUCTION
This chapter provides an overview of the Copley Controls Xenus Plus drives.
Contents include:
1.1: Xenus Plus Family Overview.................................................................................................................................................... 11
1.2: CME.......................................................................................................................................................................................... 12
1.3: CML/CMO................................................................................................................................................................................. 13
1.4: Copley Virtual Machine (CVM) ................................................................................................................................................. 13
1.5: Indexer 2................................................................................................................................................................................... 13
1.6: CPL........................................................................................................................................................................................... 13