Copley Controls Xenus R10 User manual

Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
CONTROL MODES
•Indexer, Point-to-Point, PVT
•Camming, Gearing, Position, Velocity, Torque
COMMAND INTERFACE
•CANopen
•ASCII and discrete I/O
•Stepper commands
Single-ended or Differential selectable
•±10V position/velocity/torque command
•PWM velocity/torque command
•Master encoder (Gearing/Camming)
COMMUNICATIONS
•CANopen
•RS-232
•RS-422 (Optional)
FEEDBACK
•Digital quad A/B encoder
•Aux encoder / emulated encoder out
•Analog sin/cos encoder (-S versions)
•Resolver (-R versions)
•Digital Halls
I/O - DIGITAL
•12 inputs, 4 outputs
ACCESSORIES
•External regen resistors
•Externaledgelter
DIMENSIONS: mm [in]
•191 x 140 x 64 [7.5 x 5.5 x 2.5]
Model Vac Ic Ip
R10-230-18 100 - 240 6 18
R10-230-36 100 - 240 12 36
R10-230-40 100 - 240 20 40
Add -S to part numbers above for sin/cos feedback
Add -R for resolver feedback
DESCRIPTION
Xenus R10 is a ruggedized, AC powered servo drive for position, velocity, and torque control of AC brushless and DC brush motors. It
operates on a distributed control network, as a stand-alone indexing drive, or with external motion controllers.
IndexingmodesimpliesoperationwithPLC’sthatuseoutputstoselectandlaunchindexesandinputstoreadbackdrivestatus.A
singleserialportonthePLCcansendASCIIdatatomultipledrivestochangemotionprolesasmachinerequirementschange.
CANbusoperationsupportsProlePosition,ProleVelocity,ProleTorque,InterpolatedPosition,andHoming.Upto127XenusR10
drivescanoperateonasingleCANbusandgroupsofdrivescanbelinkedviatheCANsothattheyexecutemotionprolestogether.
Operation in torque (current), velocity, and position modes with external motion controllers is supported. Input command signals are
±10 Vdc (torque, velocity, position), PWM/Polarity (torque, velocity), or Step/Direction (position).
RUGGEDIZED STANDARDS CONFORMANCE
Ambient Temperature Non-Operating -50ºC to 85ºC
Operating -40ºC to 70ºC
Thermal Shock Operating -40ºC to 70ºC in 1 minute
Relative Humidity Non-Operating 95% non-condensing at 60ºC
Operating 95% non-condensing at 60ºC
Vibration Operating 5 Hz to 500 Hz, up to 3.85 grms
Altitude Non-Operating -400 m to 12,200 m
Operating -400 m to 5,000 m
Shock Crash Safety 75 gpeak acceleration
Operating 40 gpeak acceleration
MIL-STDspecications MIL-STD- 461,704,810,1275,1399
IECspecications IEC- 60068,60079
R

Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
GENERAL SPECIFICATIONS
Test conditions: Wye connected load: 2 mH line-line. Ambient temperature = 25 °C. Power input = 230 Vac, 60 Hz, 1Ø
MODEL R10-230-18 R10-230-36 R10-230-40 Same specs for -S and -R 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 100~240 100~240 100~240 Vac, ±10%, 1Ø or 3Ø, 47~400 Hz
Maximum Mains Current, 1Ø (Note 3) 10.1 20.0 20.0 Arms
Maximum Mains current, 3Ø (Note 3) 6.4 10.4 15.4 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
Dual loop position control using secondary encoder input
Sampling rate (time) Current loop: 15 kHz (66.7 us) Velocity, position loops: 3 kHz (333 us)
 Commutation Sinusoidaleld-orientedcontrolortrapezoidalforbrushlessmotors
Bandwidth Current loop: 2.5 kHz typical, bandwidth will vary with tuning & load inductance
HV Compensation Changes in bus voltage do not affect bandwidth
Minimum load inductance 200 µH line-line
COMMAND INPUTS (NOTE: DIGITAL INPUT FUNCTIONS ARE PROGRAMMABLE)
Distributed Control Modes
 CANopen Position,Velocity,Torque,Homing,Prole,andInterpolatedprolemodes
ASCII Multiple drives accessible from a single RS-422 port
Stand-alone mode
Analog torque, velocity, position reference ±10 Vdc, 12 bit resolution Dedicated differential analog input
Input impedance 74.8 kΩBetween Ref(+), Ref(-)
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
 Inputs[IN1~5,11,12] 74HC14Schmitttrigger,330µsRClter,Vin-LO<1.35Vdc,Vin-HI>3.65Vdc,+24Vdcmax
[IN1] dedicated to drive enable function, other inputs are programmable
 Input[IN6] 74HC14Schmitttrigger,100nsRClter,Vin-LO<1.35Vdc,Vin-HI>3.65Vdc,+12Vdcmax
 Inputs[IN7~10] Single-ended:Comparatorwith2.5Vdcreference,100nsRClter,Vin-LO<2.3Vdc,Vin-HI>2.45Vdc
 Differential:RS-485linereceiveroninputpairs[IN9-7],and[IN10-8],100nsRClters,+12Vdcmax
All inputs 10 kΩpull-up to +5 Vdc or pull-down to ground, selectable in groups, active level programmable
DIGITAL OUTPUTS (NOTE 2)
Number 4
[OUT1], [OUT2], [OUT3] Current-sinking MOSFET with 1 kΩpullup to +5 Vdc through diode
Current rating 1 Adc max, +40 Vdc max. Functions programmable
 Externalybackdioderequiredifdrivinginductiveloads
 Brake[OUT4] Opto-isolated,current-sinkingwithybackdiodeto+24Vdc,1Adcmax
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)
Primary increment encoder for models with -S option that use sin/cos signals as analog Halls
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
RS-422 PORT (Optional)
Signals XMT-A, XMT-B, RCV-A, RCV-B, in a 6-position, 6-contact RJ-11 style modular connector
Mode Full-duplex, RS-422 slave, 9,600 to 115,200 baud
Protocol Binary and ASCII formats
CAN PORTS
Signals CANH, CANL, Gnd in 8-position RJ-45 style modular connector, wired as per CAN Cia DR-303-1, V1.1
Format CAN V2.0b physical layer for high-speed connections compliant
 Data CANopenDeviceProleDSP-402
Address selection 16 position rotary switch on front panel with 3 additional address bits available as
 digitalinputsorprogrammabletoashmemory(7-bitaddressing,127nodesperCANnetwork)
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
3. The actual mains current is dependent on the mains voltage, number of phases, and motor load and operating conditions.
The Maximum Mains Currents shown above occur when the drive is operating from the maximum input voltage and is producing
the rated continuous output current at the maximum output voltage.

Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
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303-3GENERAL)
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
PROTECTIONS
 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
I2T 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
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
1.9 lb (0.86 kg) for XSL-HS heatsink, 1.26 lb (0.57 kg) for XSL-HL heatsink
Contaminants Pollution degree 2
Environment IEC68-2: 1990
Cooling Heat sink and/or forced air cooling required for continuous power output
AGENCY STANDARDS CONFORMANCE
In accordance with EC Directive 2004/108/EC (EMC Directive)
EN 55011: 2007 CISPR 11:2003/A2:2006
Industrial,Scientic,andMedical(ISM)RadioFrequencyEquipment
-Electromagnetic Disturbance Characteristics - Limits and Methods of Measurement Group 1, Class A
EN 61000-6-1: 2007 Electromagnetic Compatibility (EMC) - Part 6-1: Generic Standards - Immunity for residential,
Commercial and Light Industrial Environments
In accordance with EC Directive 2006/95/EC (Low Voltage Directive)
IEC 61010-1:2001 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use
Underwriters Laboratory Standards
UL 508C, 3
rd Ed.: 2008 UL Standard for Power Conversion Equipment
ENCODER
DIGITAL 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, 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(-)
Frequency 230 kHz 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
 Frequency Consultfactoryforspeeds>10,000RPM
ANALOG HALLS
Type HA/HB, 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 HA(+), HA(-), HB(+), HB(-)
Use Multi-mode port as primary incremental encoder input for position feedback
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(-), X, /X, on -S versions (X & /X index signals are digital)
Hall & encoder power +5 Vdc @ 400 mA maximum
Motemp [IN5] Motor overtemperature sensor input, 4.99 kΩto +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
GENERALSPECIFICATIONS(CONT’D)

REGEN+
REGEN-
REGEN+
REGEN-
3.00 (76,2)
1.5 (38,1)
7.15 (181,6) 5.54 (140,7)
2.55 (64,8)
1.99 (50,5)
0.925 (23,5)
STANDARD
HEATSINK OPTION (-HS)
6.75
(171,5)
LOW-PROFILE
HEATSINK OPTION (-HL)
0.88 (22,4)
1.00 (25,4)
8 x 0.160
7.55 (191,7)
(4,1)
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).
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
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
Resolver R1, R2, S1, S2, S3, S4
 Motemp[IN5] Motorovertemperaturesensorinput.Activelevelprogrammable.4.99kΩto+5Vdcorground
Disables drive when motor over-temperature condition occurs
Same input circuit as GP digital inputs
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(CONT’D)
DIMENSIONS
Inches (mm)

6
9
1
5
RxD
TxD
Gnd
D-Sub 9M
(DTE)
RxD
TxD
123456
RJ-11
(DTE)
RxD
32
TxD
25
Gnd
RxD
TxD
Gnd 53
6
9
1
5
D-Sub 9F
RxD TxD
123456
RJ-11
(DTE)
CANopen
RS-232
CANopen
CAN Addr 0
CAN Master CAN Node CAN Node
CAN Addr 1 CAN Addr n
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
CME 2 SOFTWARE
Drive setup is fast and easy using CME 2 software communicating via RS-232 or over the CAN bus.
All of the operations needed to configure the drive are accessible through this powerful and intuitive program. Auto-
phasing of brushless motor Hall sensors and phase wires eliminates “wire and try”. Connections are made once and
CME 2 does the rest thereafter. Encoder wire swapping to establish the direction of positive motion is eliminated.
Motor data can be saved as .ccm files. Drive data is saved as .ccx files that contain all drive settings plus motor
data. This eases system management as files can be cross-referenced to drives. Once a drive configuration
has been completed systems can be replicated easily with the same setup and performance.
When operating as a stand-alone drive that takes command inputs from an external controller, CME 2 isusedforconguration.When
operated as a CAN node, CME 2 can be used for programming before and after installation in a CAN network. Xenus can also be controlled
via CME 2 while it is in place as a CAN node. During this process, drive operation as a CAN node is suspended. When adjustments are
complete, CME 2 relinquishes control of the drive and returns it to the CAN node state.
COMMUNICATIONS
RS-232
Xenus operates as a DTE device from a three-wire, full-duplex RS-232 port at 9,600 to 115,200 Baud, 8 bits, no parity, and one stop
bit. The SER-CK Serial Cable Kit provides an adapter that connects to the COMM port of a PC (a 9 position, male D-Sub connector) and
accepts a modular cable with RJ-11 connectors for connection to the Xenus RS-232 port (J6).
RS-232 MULTI-DROP
TheRS-232specicationmakesnoallowanceformorethantwodevicesonaseriallink.But,multipleXenusdrivescancommunicate
over a single RS-232 port by daisy-chaining a master drive to other drives using CAN cables. In the CAN protocol, address 0 is reserved
for the CAN master and thereafter all other nodes on a CAN network must have unique, non-zero addresses. When the Xenus CAN
address is set to 0, it acts as a CAN master, converting the RS-232 data into CAN messages and passing it along to the other drives
which act as CAN nodes.
ASCII COMMUNICATIONS
The Copley ASCII Interface is a set of ASCII format commands that can be used to operate and monitor Copley Controls Accelnet,
Stepnet,andXenusseriesampliersoveranRS-232serialconnection.Forinstance,afterbasicampliercongurationvalueshave
been programmed using CME 2, a control program can use the ASCII Interface to:
•EnabletheamplierinProgrammedPositionmode.
•Hometheaxis.
•Issueaseriesofmovecommandswhilemonitoringposition,velocity,andotherrun-time
variables.
Additional information can be found in the ASCII Programmers Guide on the Copley website:
http://www.copleycontrols.com/motion/downloads/pdf/ASCII_ProgrammersGuide.pdf
SER-CK SERIAL CABLE KIT ADAPTER CONNECTIONS J5 SIGNALSPC COMM PORT SIGNALS

CAN Status LED
J4 J5
Drive Status LED
6
9
1
5
D-Sub 9F
33
22
1
8
CAN_L
CAN_GND
CAN_H
CAN_L
RJ-45
CAN_GND
CAN_H
71
J4 J5
Pin 8Pin 1
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
CANOPEN COMMUNICATION
Xenus uses the CAN physical layer signals CANH, CANL, and GND for connection, and CANopen protocol for communication.
Before installing the drive in a CAN system, it must be assigned a CAN address. A maximum of 127 CAN nodes are allowed on a single
CAN bus. The rotary switch on the front panel controls the four lower bits of the seven-bit CAN address. When the number of nodes on
a bus is less than sixteen, the CAN address can be set using only the switch.
For installations with sixteen or more CAN nodes on a network CME2 can be used to congure Xenus to use the rotary switch,
or combinations of digital inputs and programmed offset in ash memory to congure the drive with a higher CAN node address.
For more information on CANopen communications, download the CANopen Manual from the Copley web-site:
http://www.copleycontrols.com/motion/downloads/pdf/CANopenProgrammersManual.pdf
CANOPEN
Based on the CAN V2.0b physical layer, a robust, two-wire communication bus originally designed for automotive use where low-cost
and noise-immunity are essential, CANopen adds support for motion-control devices and command synchronization. The result is a
highly effective combination of data-rate and low cost for multi-axis motion control systems. Device synchronization enables multiple
axes to coordinate moves as if they were driven from a single control card.
Note: Red & green led on-times do not overlap.
LEDcolormaybered,green,off,orashingofeithercolor.
CAN S TATUS LED
CANOPEN CONNECTORS
Dual RJ-45 connectors that accept standard
Ethernet cables are provided for CAN bus
connectivity. Pins are wired-through so that
drives can be daisy-chained and controlled
with a singleconnectiontotheuser’s
CAN interface. A CAN terminator should
be placed in the last drive in the chain.
The XTL-NK connector kit provides a D-Sub
adapter that plugs into a CAN controller
and has an RJ-45 socket that accepts the
Ethernet cable.
XTL-NK CAN CONNECTOR KIT
The kit contains the XTL-CV adapter that converts the CAN interface D-Sub
9M connector to an RJ-45 Ethernet cable socket, plus a 10 ft (3 m) cable and
terminator.Bothconnectorpin-outsconformtotheCiADR-303-1specication.
J6 CAN CONNECTIONS
COMMUNICATIONS (CONTINUED)

RJ-12
(DTE)
D-Sub 9M
red Gnd
Gnd 43
green Gnd
Gnd 64
black
82RD A(-)
TD A(-)
blue
RD A(-) 26TD A(-)
RD B(+)
white
31
TD B(+)
yellow
RD B(+) TD B(+)
75
123456
6
9
1
5
A
B
RxD
TxD
RD A(-)
TD A(-)
RD B(+)
TD B(+) B(Z)
A(Y)
1 2 3 4 5 6
A
8
3white
black
yellow
blue
green
red
2
6
433
44
7
8
3
2
7
B
A
B
RxD
RxD
TxD
RxD
TxD
Serial port J5
RJ-11 Jack
D-Sub
9M
D-Sub
9F
Modular
Cable with
RJ-12 Plugs
Twisted-pair
Shielded
Cable
RJ-12
Jack
Generic RS-422
Receive-only
Slave
RS-422 Master
B&B Electronics
Model 422PP9R
Serial to RS-422
Converter
Copley R10
QVS #CC436 Adapter
B(Z)
A(Y)
A(-)
B(+)
B(+)
A(-)
1
2
6
5
1
2
6
5
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
DRIVE STATUS LED
A single bi-color LED gives the state of the drive by changing color, and either blinking or remaining solid.
The possible color and blink combinations are:
•Green/Solid: Drive OK and enabled. Will run in response to reference inputs or CANopen 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.
Drive Fault conditions:
• Overorunder-voltage
• Motorover-temperature
• Encoder+5Vdcfault
• Short-circuitsfromoutputtooutput
• Short-circuitsfromoutputtoground
• Internalshortcircuits
• Driveover-temperature
Faults are programmable to be either
transient or latching
COMMUNICATIONS (CONTINUED)
RS-422 (OPTIONAL)
Thedriveisconguredforfull-duplexoperationasaRS-422slave.BecauseRS-422allowsonlyonedriverpersignal-pair,itispossible
tohaveotherRS-422receive-onlynodesconnectedtothecablefromtheMaster’stransmitport.Thedataprotocolisthesameasthat
of the RS-232 port. The diagram below shows connections using a wiring adapter from QVS, model CC436 to convert the modular cable
for the drive to a Dsub-9M connector. The RS-422 signals are shown sourced from a model 422PP9R RS-232 to RS-422 converter from
B&B Electronics.
J5 SIGNALS
RS-422 CONNECTIONS
RS-422 ADAPTER (USER SUPPLIED)
This shows the connections to make using
a QVS CC436 adapter. This comes with the
connections to the RJ-12 already made and
the pins for the D-sub uncommitted. Insert
these into the D-sub as shown.

Current or
Velocity
Polarity or
Direction
[IN9]
[IN10]
Duty = 0~100%
Current or
Velocity
No function
[IN9]
[IN10]
Duty = 50% ±50%
<no connection>
Current or
Velocity
[IN9+]
[IN7-]
Duty = 50% ±50%
No
Function
<no connection>
[IN10+]
[IN8-]
PWM
[IN9+]
[IN7-]
Duty = 0 - 100%
Direction
[IN10+]
[IN8-]
PULSE
[IN9+]
[IN7-]
DIRECTION
[IN10+]
[IN8-]
PULSE
[IN9+]
[IN7-]
DIRECTION
[IN10+]
[IN8-]
CD (Count-Down)
CU (Count-Up)
Pulse
Direction
[IN9]
[IN10]
CU
CD
[IN9]
[IN10]
CU (Count-Up)
CD (Count-Down)
Enc. B
Enc. A
[IN9]
[IN10]
Encoder ph. A
Encoder ph. B
Enc A
[IN10+]
[IN8-]
Encoder ph. A
Enc. B
[IN9+]
[IN7-]
Encoder ph. B
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
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
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.
SINGLE-ENDED PWM & DIRECTION
SINGLE-ENDED 50% PWM DIFFERENTIAL 50% PWM
DIFFERENTIAL PWM & DIRECTION

100 pF
1k
+5 V
C
10k
10k
10k
74HC14
[IN6]
[IN7-]
+5 V
100 pF
100 pF
100 pF
100 pF
10k
[IN9+]
[IN10+]
[IN8-]
1k
1k
1k
1k
10k
10k
33 nF
10k
74HC14
MAX3283
[IN11]
[IN12]
D
100 pF
1k
2.5V
+5 V
10k 100 pF
1k
+5 V
C
D
10k
[IN6]
74HC14
MAX3281
33 nF
10k
10k
10k
[IN11]
[IN12]
+
[IN7]
[IN8]
100 pF
1k
MAX3281
[IN9]
[IN10]
33nF
10k
10k 74HC14
[IN1]
[IN2]
[IN3]
A
+5.0 V
33nF
*3.3nF
10k
10k
*4.99k 74HC14
[IN4]
*[IN5]
+5.0 V
B
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
COMMAND INPUTS (CONTINUED)
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
[IN6~10] 12 VDC MAX, [IN11~12] 24 VDC MAX
DIGITAL INPUTS
Xenus 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 24VDC MAX
Group Inputs
A 1,2,3
B 4,5
C 6,7,8
D 9,10,11,12
PULL-UP/PULL-DOWN CONTROL
In addition to the active level and function
for each programmable input, the input
resistors are programmable in four groups
to either pull up to +5 Vdc, or down to
ground. Grounded inputs with HI active
levelsinterfacetoPLC’sthathavePNP
outputs that source current from +24 Vdc
sources. Inputs pulled up to +5 Vdc work
with open-collector, or NPN drivers that
sink current to ground. The table below
shows the PU/PD groups and the inputs
they control.`

+5.0 Vdc
[OUT1]
[OUT2]
[OUT3]
1k
HALL U, V, W 10 k
3.3 nF
74HC14
+5V
10 k
UVW
OUTPUTS
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 10 of 30
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. Resolver models can also take Hall signal at inputs [IN6~8]. See
page 15 for connections.
DIGITAL OUTPUTS
The digital outputs are open-drain MOSFETs with 1 kΩpull-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 kΩresistor to
+5 Vdc in the drive. This could turn the PLC input on, giving a false indication of the drive
output state.
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 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.
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.

J8-8
BRUSHLESS
RESOLVER -
+
-
+
J8-13
J8-12
Sin
Cos
J8-7
J8-3
J8-2 Ref
R1
R2
S3
S1
S2
S4
Frame
Ground
J8-1
10 k
3.3 nF
74HC14
+5V
4.99 k
[IN5]
4
+5 Vdc
Signal Ground Signal Ground 5
+5 Vdc Vcc
0V +5 vdc
to Halls
Vcc
0V
+5 vdc
to Encoder
HA-
HA+
HB-
HB+
/A
A
/B
X
/X
B
Frame
Gnd
Frame
Gnd
HA(+)
HA(-)
HB(+)
HB(-)
N.C.
N.C.
21
22
23
26
24
25
1
20
19
7
8
11
12
13
1
14
J8J7
Digital
Incremental
Encoder
Analog
Halls
Hall feedback for
brushless motor commutation
Position feedback for
position/velocity control
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 11 of 30
ANALOG HALLS (-S MODELS) + DIGITAL ENCODER
For position feedback with higher resolution than is possible
by interpolating analog Halls, a digital incremental encoder
is connected to the multi-mode port. The Halls are then used
for commutation and the multi-mode port is programmed as a
differential input for the Secondary Incremental motor encoder.
MOTOR TEMPERATURE SENSOR
Digital input [IN5] is for use with a motor overtemperature switch. The input should
be programmed as a pull-up to +5 Vdc if the motor switch is grounded when cold,
and open or high-impedance when over-heating.
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.
ANALOG ENCODER (-S MODELS)
Xenus supports analog encoder signals for position feedback. The Sin and Cos inputs
are differential with 121 Ωterminating resistors and accept 1.0 Vp-p signals in the
A/B format used by encoders with analog outputs such as Heidenhain, Stegman,
and Renishaw. When Copley’s ServoTube motors are used the analog encoder
supplies both commutation and incremental position feedback.
DIGITAL ENCODERS
ThequadA/Bencoderinterfaceisadifferentialline-receiverwithR-Clteringon
the inputs. Encoders with differential outputs are required because they are less
susceptible to noise that can degrade single-ended outputs. Encoder cables should
use twisted-pairs for each signal pair: A & /A, B & /B, X & /X. An overall shield
should be used, and for longer cables, shields for individual pairs may be necessary
to guarantee signal integrity.
MOTORCONNECTIONS(CONT’D)
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.
= Shielded cables required
for CE compliance

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
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 12 of 30
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.
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.

DANGER: HIGH VOLTAGE
CIRCUITS ON J1, J2, & J3
ARE CONNECTED TO
MAINS POWER
7
8
11
12
13
DIGITAL
ENCODER
DIGITAL
HALLS
TEMP
SENSOR
7
6
5
12
11
4
14
2
3
13
1-HV
J8
21
22
23
26
24
25
1
14
1
20
19
2
+5 Vdc @ 400 mA
Signal Ground
15 Signal Ground
Ref(-)
Multi-Mode
Encoder
Port
A
/A
B
/B
X
/X
Frame Ground
+24V
BRAKE
RTN J4
Earth
Fuse
J1
4
L3
1
AC MAINS:
100 to 240 Vac
1Ø or 3Ø
47 to 63 Hz
H
1
4
5
J3
REGEN+
REGEN-
Frame Ground
2
3
J2
U
V
W
BRUSHLESS
MOTOR
* Fuse
* Fuse
4
3
2
1
Mot U
Mot V
Mot W
Frame Ground
3
L2 N
2
1
L1
L3
L2
L1
[IN7] HS
[IN8] HS
[IN9] HS
[IN10] HS
10
[IN1] Enable
[IN4] GP
[IN2] GP
[IN3] GP
3Ref(+) J7
±10 Vdc
Analog
Reference
[IN6] HS
9[IN12] GP
8[IN11] GP
17 [OUT2]
16 [OUT1]
18 [OUT3]
Frame
Gnd
10
Motemp [IN5]
Signal Ground 15
Signal Ground 5
BRAKE
+24 Vdc
0.5 Adc
+
-
LINE
FILTER
* Fuse
* Fuse
Control Power Supply
Required for
Drive Operation
Drive mounting screw
+5 Vdc 4
+5 Vdc 2
Hall W 9
Hall V 6
Hall U 3
A
/A
B
/B
X
/X
/A
A
/B
B
/X
Vcc
0V
X
Outputs Buffered
Quad A/B from
Encoder
* Optional
(Note 1)
(Note 1)
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 13 of 30
QUAD A/B
CONNECTIONS
= SHIELDED CABLES
REQUIRED
FOR CE COMPLIANCE
CONTROL
CABLE TO J7
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

DANGER: HIGH VOLTAGE
CIRCUITS ON J1, J2, & J3
ARE CONNECTED TO
MAINS POWER
7
8
11
12
13 ANALOG
Sin/Cos
ENCODER
DIGITAL
ENCODER
INDEX
DIGITAL
HALLS
TEMP
SENSOR
7
6
5
12
11
4
14
2
3
13
1-HV
J8
21
22
23
26
24
25
1
14
1
20
19
2
+5 Vdc @ 400 mA
Signal Ground
15 Signal Ground
Ref(-)
Multi-Mode
Encoder
Port
A
/A
B
/B
X
/X
Frame Ground
+24V
BRAKE
RTN J4
Earth
Fuse
J1
4
L3
1
AC MAINS:
100 to 240 Vac
1Ø or 3Ø
47 to 63 Hz
H
1
4
5
J3
REGEN+
REGEN-
Frame Ground
2
3
J2
U
V
W
BRUSHLESS
MOTOR
* Fuse
* Fuse
4
3
2
1
Mot U
Mot V
Mot W
Frame Ground
3
L2 N
2
1
L1
L3
L2
L1
[IN7] HS
[IN8] HS
[IN9] HS
[IN10] HS
10
[IN1] Enable
[IN4] GP
[IN2] GP
[IN3] GP
3Ref(+) J7
±10 Vdc
Analog
Reference
[IN6] HS
9[IN12] GP
8[IN11] GP
17 [OUT2]
16 [OUT1]
18 [OUT3]
Frame
Gnd
10
Motemp [IN5]
Signal Ground 15
Signal Ground 5
BRAKE
+24 Vdc
0.5 Adc
+
-
LINE
FILTER
* Fuse
* Optional
* Fuse
Control Power Supply
Required for
Drive Operation
Drive mounting screw
+5 Vdc 4
+5 Vdc 2
Hall W 9
Hall V 6
Hall U 3
Sin(+)
Sin(-)
Cos(+)
Cos(-)
S-
X
/X
S+
C-
C+
/X
Vcc
0V
X
Outputs Emulated
Quad A/B from
Analog Encoder
Note:
Index signals X & /X are
digital
+5 vdc to
Encoder
& Halls
(Note 1)
(Note 1)
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 14 of 30
SIN/COS (-S OPTION)
CONNECTIONS
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
3) Page 11 shows connections for analog Hall commutation with digital incremental position feedback.
= SHIELDED CABLES RE-
QUIRED
FOR CE COMPLIANCE
CONTROL
CABLE TO J7

-HV
+
-
5
100 to 240 Vac
Fuse L3
L2
L1
1
H
N
FILTER
LINE
Hall W
0V
Digital
Halls
Hall V
Hall U
+5V
Signal Gnd
[IN6]
[IN7]
[IN8]
+5V
Output
15,19
10
20
11
12
Motemp [IN5]
Signal Ground
Signal Ground
Frame
Gnd
BRUSHLESS
RESOLVER
R2
R1
S1
S4
S2
S3
Frame
Gnd
R1
S3
S2
S1
S4
R2
J8
J7
Signal Ground
Ref(-)
Ref(+)
±10 Vdc
Analog
Reference
DANGER: HIGH VOLTAGE
CIRCUITS ON J1, J2, & J3
ARE CONNECTED TO
MAINS POWER
BRAKE
+24 Vdc
0.5 Adc
Control Power Supply
Required for
Drive Operation
2
3
1
+24V
BRAKE
RTN J4 J3
REGEN+
Frame Ground
REGEN-
J2
Mot U
Mot V
Mot W
Frame Ground
BRUSHLESS
MOTOR
* Optional
* Fuse
* Fuse
* Fuse
* Fuse
U
V
W
Signal Ground
[IN9] HS
[IN10] HS
[IN1] Enable
[IN4] GP
[IN2] GP
[IN3] GP
[IN12] GP
[IN11] GP
[OUT2]
[OUT1]
[OUT3]
J1
L3
L2
Drive mounting screw
14
13
15
9
8
17
16
18
4
3
2
1
L1
1
5
2
3
4
3
2
1
Earth
7
6
5
4
10
15
6
1
12
13
7
8
2
11
3
Inputs Secondary
Outputs Emulated
Quad A/B from
Resolver
Position Encoder
Frame Ground
Multi-Mode
Encoder
Port
21
22
23
26
24
25
19
2
3
1
A
/A
B
/B
X
/X
4
AC MAINS:
1Ø or 3Ø
47 to 63 Hz
(Note 1)
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 15 of 30
RESOLVER (-R OPTION)
CONNECTIONS
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
3) Usage of [IN6~8] for Hall sensors is optional. If not used for Halls, these are programmable, high-speed inputs.
Signal Ground for Halls can use J7-15, J7-19, or J8-5.
= SHIELDED CABLES
REQUIRED FOR
CE COMPLIANCE
CONTROL
CABLE TO J7

~
~-
+
~+
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)
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 16 of 30
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 R10 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R10 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.

3 TURNS
AROUND
TOROID
INDUCTOR
MOTOR
MAINS
REGEN
CONTROLLER
XENUS
FEEDBACK
LINE
FILTER
J1
J2
J8J7
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 R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 17 of 30
GROUNDING & SHIELDING FOR CE

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
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
QUAD A/B
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 R10-230-36-R and R10-230-40-R models,
AWG 14, 600V for R10-230-18-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 R10-230-36-R and R10-230-40-R models,
AWG 14, 600V for R10-230-18-R
Shielded cable required for CE compliance
J3 CABLE CONNECTOR:
Wago: 51111279 or 721-605/000-044/RN01-0000
Euro-style 5,0 mm pluggable male terminal block
Cable: AWG 12, 600 V recommended
for R10-230-36-R and R10-230-40-R models,
AWG 14, 600V for R10-230-18-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

Pin Signal Pin Signal Pin Signal
1Frame Gnd 6Hall V 11 Encoder /B
2+5 Vdc (Note 1) 7Encoder /X 12 Encoder B
3Hall U 8Encoder X 13 Encoder /A
4+5 Vdc (Note 1) 9Hall W 14 Encoder A
5Signal Gnd 10 [IN5] Motemp 15 Signal Gnd
Pin Signal Pin Signal Pin Signal
1Frame Gnd 10 [IN6] HS 19 Signal Gnd
2 Ref(-) 11 [IN7] HS 20 +5 Vdc (Note 1)
3 Ref(+) 12 [IN8] HS 21 Multi Encoder /X
4[IN1] Enable 13 [IN9] HS 22 Multi Encoder X
5[IN2] GP 14 [IN10] HS 23 Multi Encoder /B
6[IN3] GP 15 Signal Gnd 24 Multi Encoder B
7[IN4] GP 16 [OUT1] 25 Multi Encoder /A
8[IN11] GP 17 [OUT2] 26 Multi Encoder A
9[IN12] GP 18 [OUT3]
Pin Signal
6No connect
5TxD Output
4Ground
3Ground
2RxD Input
1No connect
Pin Signal
1CAN_H
2CAN_L
3CAN_GND
4No connection
5No connection
6(CAN_SHLD)
7CAN_GND
8(CAN_V+)
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
QUAD A/B
J8 MOTOR FEEDBACK
J7 CONTROL SIGNALS
J6 CAN BUS
J5 RS-232 (DTE)
ISOLATED CIRCUIT
Notes:
1. CAN circuits are opto-isolated from drive circuits.
2. CAN_GND connects to drive Signal Ground.
3. CAN_SHLD and CAN_V+ are wired-thru on both
J6 connectors and have no connection to the drive.
J5 CABLE CONNECTOR:
RJ-11 style, male, 6 position
Cable: 6-conductor modular type
J6 CABLE CONNECTOR:
RJ-45 style, male, 8 position
Cable: 8-conductor modular type
J7 CABLE CONNECTOR:
High-Density D-Sub, 26 Position, Male
J8 CABLE CONNECTOR:
High-Density D-Sub, 15 Position, Male
Notes:
1. The total current drawn from the +5 Vdc outputs cannot exceed 400 mA

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
Xenus R10
RoHS
R10
RUGGEDIZED DIGITAL
SERVO DRIVE FOR
BRUSHLESS/BRUSH MOTORS
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 30
SIN/COS (-S OPTION)
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 R10-230-36-R and R10-230-40-R models,
AWG 14, 600V for R10-230-18-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 R10-230-36-R and R10-230-40-R models,
AWG 14, 600V for R10-230-18-R
Shielded cable required for CE compliance
J3 CABLE CONNECTOR:
Wago: 51111279 or 721-605/000-044/RN01-
0000
Euro-style 5,0 mm pluggable male terminal
block
Cable: AWG 12, 600 V recommended
for R10-230-36-R and R10-230-40-R models,
AWG 14, 600V for R10-230-18-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