YET XtraDrive XD Series How to use

XtraDrive (XD-) SERIES
AC SERVO DRIVER
Prior to installing the product, read these instructions thoroughly and
retain for future reference.
Short Form
Installation Guide
Catalog No. 8U0107

Short Form Installation Guide Introduction
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Short Form Installation Guide Introduction
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Copyright 2003 by Yaskawa Eshed Technology Ltd.
XtraDrive Short Form Installation Guide
Cat. No. 8U0107, Rev. B
February 2003
All rights reserved. No part of this publication may be stored in a retrieval system, or
reproduced in any way, including but not limited to photocopy, photography,
magnetic or other recording, without the prior agreement and written permission of
the publisher. Program listings may be entered, stored and executed in a computer
system, but not reproduced for publication.
This guide is designed to provide information about the XtraDrive hardware. Every
effort has been made to make this guide complete and as accurate as possible.
However, no warranty of suitability, purpose or fitness is made or implied. YET Ltd.
is not liable or responsible to any person or entity for loss or damage in connection
with or stemming from the use of XtraDrive and/or the information contained in this
publication
YET Ltd. bears no responsibility for errors, which may appear in this publication and
retains the right to make changes to the products and the guide without prior notice.
MAIN OFFICE
13 Hamelacha St.,
Afeq Industrial Estate
Rosh Ha’ayin 48091
ISRAEL
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Homepage: www.yetmotion.com
USA OFFICE
Mr. Tomas Rincon
1651 Pondside Drive
Statesboro, GA 30458
USA
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Homepage: www.yetmotion.com

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1. Introduction..........................................................................................................6
1.1. Safety Precautions..........................................................................................7
1.2. Warning Label ...............................................................................................9
1.3. Parts..............................................................................................................10
2. Checking On Delivery........................................................................................11
2.1. Checking Items ............................................................................................11
2.2. Appearance and Nameplate .........................................................................12
2.3. Type Designation.........................................................................................12
3. Installation..........................................................................................................13
3.1. Storage Temperature Range.........................................................................13
3.2. Operating Conditions...................................................................................13
3.3. Installation Locations...................................................................................13
3.4. Orientation ...................................................................................................14
3.5. Multiple XtraDrive Installation....................................................................15
•Front Panel...................................................................................................15
•Cooling.........................................................................................................15
•Where Mounted Side by Side ......................................................................16
•Environment Inside Control Box.................................................................16
3.6. Voltage Resistance Test...............................................................................16
4. Wiring .................................................................................................................17
4.1. Cable Specifications.....................................................................................17
4.2. Connecting to Peripheral Devices................................................................20
4.2.1. Single-phase 200V Main Circuit .........................................................20
4.2.2. Example of Connections for Single-phase 200V XtraDrive................21
4.2.3. Single-phase 0.8kW 200V Main Circuit..............................................22
4.2.4. Example of Connections for Single-phase 200V 0.8kW XtraDrive....23
4.2.5. Three-phase 200V Main Circuit ..........................................................24
4.2.6. Example of Connections for Three-phase 200V XtraDrive ................25
4.2.7. Three-phase 400V Main Circuit ..........................................................26
4.2.8. Example of Connections for Three-phase 400V XtraDrive ................27
4.3. AC Power Source Supply ............................................................................29
4.4. DC Power Source Supply ............................................................................29
4.5. Noise Control...............................................................................................29
5. Operation............................................................................................................30
5.1. Precautions at Test Run ...............................................................................30
5.2. Conducting Test Run for Servomotor Without Load ..................................30
5.3. Conducting Test Run with Servomotor Connected to Machine..................30
5.4. Precautions During Operation......................................................................30
6. Inspection and Maintenance.............................................................................31
6.1. XtraDrive .....................................................................................................31
6.2. Replacing Parts ............................................................................................32
6.3. Operating Conditions...................................................................................32
6.4. Replacing Battery for Absolute Encoder.....................................................32
6.4.1. Recommended Battery.........................................................................32
6.4.2. Replacing Battery.................................................................................32
7. Installation Conditions of EMC Directive.......................................................33
7.1. EMC Installation Conditions .......................................................................33
7.2. Installation for Single- and Three-phase 200V XtraDrive(PC)...................33
7.3. Installation for Single- and Three-phase 200V XtraDrive (PLC)................34
7.4. Installation for Three-phase 400V XtraDrive..............................................35
7.5. Cable Core and Cable Clamp.......................................................................36

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7.5.1. Cable Core ...........................................................................................36
7.5.2. Cable Clamp.........................................................................................36
8. Peripheral Devices .............................................................................................37
8.1. Peripheral Device Types and Capacities......................................................37
8.2. Noise Filter for Brake Power Supply...........................................................38
8.3. Cable Specifications.....................................................................................38
8.4. Recommended Ferrite Cores........................................................................38
8.5. Shield Box....................................................................................................38
9. Appendix A.........................................................................................................39
9.1. I/O Signals Connector CN1 .........................................................................39
9.2. Encoder Connector CN2..............................................................................40
9.3. Serial Communication Connector CN3 .......................................................41
9.4. Analog Monitor Connector CN5 .................................................................41
9.5. Connecting Pulse A/B Encoder without C Pulse (Index Pulse) ..................42

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1. Introduction
This guide describes the XtraDrive XD- SERIES AC SERVO DRIVER
controlling Yaskawa ∑-II series or any compatible AC servomotor.
The product conforms to the following standards:
EN61000-6-2: 1999
EN55011: 1998, Group 1 Class A
However, because this product is a built-in type, reconfirmation of the above
standards is required after being installed in the final product.
Upon receipt of the product and prior to installing the product, read these
instructions carefully and retain for future reference. This will enable you to
properly use the XtraDrive Series AC Servo Driver and carry out periodic
inspection, maintenance, etc.
Related documents:
Title Catalog No.
XtraDrive Series Servo System User’s Manual 8U0108
AC Servo Motor Instructions for Yaskawa ∑-II
series motors or documentation for other
compatible motors
TOE-C231-2 (for ∑-II)
Manufacturer’s motor
specification
XtraWare User's Manual 8U0109
Topics described in this manual include:
!
!!
! Safety precautions
!
!!
! Checking XtraDrive upon delivery
!
!!
! Installing XtraDrive
!
!!
! Wiring XtraDrive
!
!!
! Operating XtraDrive
!
!!
! Inspecting and maintaining XtraDrive
Some drawings in this guide are shown as typical examples and may differ from
the shipped product.
You can order a copy of this guide by contacting your YET representative
Contact information is provided on the copyright page. Please state the catalog
number, which appears on the front cover.
Notes:
Some drawings in this guide are shown with the protective cover or shields
removed in order to enhance clarity. Make sure all covers and shields are
replaced before operating this product.
YET is not responsible for accidents or damages resulting from product
modifications made by the user.

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1.1. Safety Precautions
In this guide, safety precautions are classified as WARNING or CAUTION.
It is extremely important that you pay close attention to these precautions.
The following symbols are used:
WARNING
Indicates a potentially hazardous situation,
which, if not avoided, could result in death or serious personal injury.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, could result in minor or moderate personal injury
and/or damage to the equipment. In some instances, items described in
CAUTION could also result in a serious accident.
Read the following safety precautions thoroughly before installation,
operation, maintenance or inspection of the XtraDrive Servo Drives.
WARNING
Installation
# After voltage resistance test, wait at least five minutes before
servicing the product.
Failure to observe this warning could result in electric shock.
Reference
Page No.
13
Wiring
# XtraDrive grounding must be in accordance with the national code
and consistent with sound local practices.
Failure to observe this warning could result in electric shock or fire.
17
Inspection and Maintenance
# Be sure to turn OFF power before inspection or maintenance.
Failure to observe this warning could result in electric shock.
# Never open the terminal cover while power is ON, and never turn
ON power when the terminal cover is open.
Failure to observe this warning could result in electric shock.
# After turning OFF power, wait at least five minutes before servicing
the product.
Failure to observe this warning could result in residual electric
charges causing electric shock.
31
31
31

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CAUTION
Receiving
# Use the specified combination of servomotor and XtraDrive.
Failure to observe this caution could result in fire or equipment
failure.
Reference
Page No.
11
Installation
# Never use the equipment near flammable materials or where it
may be exposed to splashes of water or corrosive or flammable
gases.
Failure to observe this caution could result in electric shock or fire.
13
Wiring
# Do not connect three-phase power supply to XtraDrive output
terminals U, V, and W.
Failure to observe this caution could result in personal injury or
fire.
# Securely tighten screws on the terminal block and ground
terminals of power input and motor connections.
# When using a 400V XtraDrive, the amount of current leaking from
the power line increases. Therefore, use cables and isolation
materials rated for 400V, and keep the wires as short as possible.
17
17
17
Operation
# To avoid accidents, perform a test run of the servomotor with no
load.
Failure to observe this caution could result in personal injury.
# Before starting operation with a load connected, set up user
constants suitable for the machine.
Failure to do so could result in overrun failure. When the load
moves vertically, incorrect setting of the user constants may cause
the load to fall.
# Before starting operation with a load connected, make sure
emergency-stop procedures are in place.
Failure to observe this caution could result in personal injury.
# During operation, do not touch the XtraDrive's heat sink.
Failure to observe this caution could result in burns.
# Motor overload protection is internally provided. For further
information, refer to the XtraDrive User Manual Cat. No. 8U0108.
30
30
30
30
31
Inspection and Maintenance
# Never change wiring while power is ON.
Failure to observe this warning could result in electric shock or
personal injury.
31

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1.2. Warning Label

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1.3. Parts
The part names of the XtraDrive series AC Servo Driver are shown in the
following diagram:

Short Form Installation Guide Checking On Delivery
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2. Checking On Delivery
CAUTION
# Use the specified combination of servomotor and XtraDrive.
Failure to observe this caution could result in fire or equipment failure.
For more information, refer to the XtraDrive Series User Manual (Cat. No. 8U0108).
2.1. Checking Items
When XtraDrive series products are delivered, check the following:
Item Remarks
Are the delivered
products the ones you
ordered?
Check the types marked on the nameplates of the
servomotor and XtraDrive.
Does the motor shaft
rotate smoothly?
The motor shaft should rotate smoothly when rotated
manually. If the motor has brakes, it cannot be turned
manually.
Is there any visible
damage?
Check the overall appearance, and check for damage or
scratches resulting from transportation.
Are any screws loose? Tighten any loose screws with a screwdriver.
If any of the above items are faulty or incorrect, contact your local sales
representative or the dealer from whom you purchased the product(s).

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2.2. Appearance and Nameplate
0.03(0.04)kW(hp)
S/N 002006000000000
200-230V 0-230V
0.33 AMPS
U
RL
TYPE
SERIAL NUMBER
APPLICABLE POWER SUPPLY
SERVOMOTOR OUTPUT
2.3. Type Designation
XD - 01 - M S
XtraDrive Series
Max. Applicable
Servomotor Power
(see table below)
Input Voltage:
M - 200VAC, or
T - 400VAC
Extended Functionality
By Option Boards:
S - no CN10 connector, or
N - with CN10 connector
Design Version #
Blank, or 01-FF
(optional)
Blank, or
R - Rack mounted, or
V - Board coating
(optional)
Blank, or Y followed by 1 to 4 alphanumeric characters
to identify customer applications
(optional)
01 R Y999
Output
Capacity
Code
Max. Applicable
Servomotor Power (kW)
Output
Capacity
Code
Max. Applicable
Servomotor Power (kW)
P3 0.03 08 0.75
P5 0.05 10 1.0
01 0.10 15 1.5
02 0.20 20 2.0
04 0.40 30 3.0
05 0.50

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3. Installation
XtraDrive series servo driver is a base-mount type servo controller. Incorrect
installation will cause problems. Always observe the installation instructions
provided below.
CAUTION
# Never use the equipment near flammable materials or where it may be
exposed to splashes of water or corrosive or flammable gases.
Failure to observe this caution could result in electric shock or fire.
3.1. Storage Temperature Range
If the XtraDrive is to be stored with the power cable disconnected, store it in
a temperature range of between -20 ~ +85°C.
3.2. Operating Conditions
Ensure the following operating conditions for XtraDrive use:
Installation category (Overvoltage category)*: II
Pollution degree *: 2
Protection class *: 1X
Maximum altitude: 1000 m
* Conforming to the following standards:
EN55011: 1198 Group 1 Class A
EN61000-6-2: 1999
3.3. Installation Locations
Different locations for the XtraDrive necessitate certain conditions as
described in the following table:
Installation
Location Notes
Inside a control panel
Design the control panel size, unit layout, and cooling
method so that temperature around the periphery of the
XtraDrive does not exceed 55οC.
Near a heating unit
Suppress radiated heat from the heating unit and a
temperature rise caused by convection so that the
temperature around the periphery of the XtraDrive does not
exceed 55οC.
Near a source of
vibration
Install a vibration isolator underneath the XtraDrive to
prevent it from receiving vibration.
In a location where
corrosive gases are
present
Corrosive gases do not immediately affect the XtraDrive but
will eventually cause contactor-related devices to
malfunction. Take appropriate action to protect against
corrosive gases.
Other Avoid installation in a hot and humid place or where
excessive dust or iron powder is present in the air.

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3.4. Orientation
Install the XtraDrive perpendicular to the wall and orientate it as shown in
the figure below.
Firmly secure the XtraDrive through two or four mounting holes (depending
on the XtraDrive capacity).
Ventilation
Wall

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3.5. Multiple XtraDrive Installation
When installing multiple XtraDrives side by side in a control panel, observe
the following:
30mm(1.2in.)or more
or more
50mm(2in.)
or more
50mm(2in.)
C
3
N
1
N
C
2
N
C
C
3
N
1
N
C
2
N
C
C
3
N
1
N
C
2
N
C
N
C
N
C
3
1
C
2
N
FAN
30mm(1.2in.)or more
10mm(0.4in.)or more
FAN
• Front Panel
Install XtraDrive perpendicular to the wall so that the front panel (digital operator
mounted face) faces outward.
• Cooling
Provide sufficient space around each XtraDrive to allow cooling by fan and
natural convection. When installing XtraDrives side by side, provide at least
10mm (0.4in.) space between them and at least 50mm (2in) space above and
below them as shown in the figure above.
Install cooling fans above the XtraDrives to prevent the temperature around
each XtraDrive from increasing excessively and also to maintain an even
temperature inside the control panel.

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• Where Mounted Side by Side
When installing XtraDrives side by side, provide at least 10 mm (0.4 in) space
between them and at least 50 mm (2 in) space above and below them as shown in
the figure above. Install cooling fans above the XtraDrives to prevent the
temperature around each XtraDrive from increasing excessively and also to
maintain the temperature inside the control panel evenly.
• Environment Inside Control Box
Maintain the following conditions inside the control box:
!
!!
! Ambient temperature for XtraDrive: 0 to 55οC
!
!!
! Humidity: 90% RH or less, no condensing.
!
!!
! Vibration: 4.9 m/s2
!
!!
! No freezing.
!
!!
! Ambient temperature to ensure long-term reliability: 45οC or less
3.6. Voltage Resistance Test
# After voltage resistance test, wait at least five minutes before servicing the
product.
Failure to observe this warning could result in electric shock.
Conduct voltage resistance tests under the following conditions:
Voltage: 1500 Vrms AC, for one minute
Breaking current: 30 mA or more
Frequency: 50 or 60 Hz
Voltage applied points: Between the frame ground and the point where the
terminals L1, L2, L3, L1C, L2C, U, V and W are
connected.
WARNING

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4. Wiring
This section provides a standard example for connecting XD series products to
peripheral devices and briefly explains how to connect each peripheral device.
# XtraDrive grounding must be in accordance with the national code and
consistent with sound local practices.
Failure to observe this warning could result in electric shock or fire.
CAUTION
# Do not connect three-phase power supply to XtraDrive output terminals U, V
and W.
Failure to observe this caution could result in personal injury or fire.
# Securely tighten screws on the terminal block and ground terminals of power
input and motor connections.
Failure to observe this caution can result in a fire.
# When using a 400V XtraDrive, the amount of current leaking from the power
line increases. Therefore, use cables and isolation materials rated for 400V,
and keep the wires as short as possible.
Refer to the XtraDrive's Design and Maintenance Manual for the following
wiring instructions:
!
!!
! Main circuit wiring
!
!!
! I/O signal wiring
!
!!
! Encoder wiring
!
!!
! Example of connections
4.1. Cable Specifications
Ratings and specifications of cables for XtraDrives are summarized in the
following tables.
CAUTION
# Do not bundle or run power and signal lines together in same duct.
Keep power and signal lines at least 30 cm (11.81 in) apart.
# Use twisted-pair wires or shielded multi-core twisted-pair wires for signal and
encoder (PG) feedback lines.
# The maximum length for signal lines are as follows:
$ Maximum of 3 m (9.84 ft) for reference input lines.
$ Maximum of 20 m (65.6 ft) for PG feedback lines.
$ Use a cable with 50 m (164.0 ft) specifications for distances over 20 m (65.6 ft).
WARNING

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The following table provides wire size specifications.
Wire Size [mm2(in2)]
External Terminal Name
P3** P5** 01** 02** 04**
Main circuit
power input
terminals
L1, L2
(Single
phase)
AWG16
[HIV 1.25 (0.002)]
AWG14
[HIV 2.0
(0.003)]
Motor
connection
terminals
U, V, W AWG16 [HIV 1.25 (0.002)]
Online
terminals
Control power
supply input
terminals
L1C, L2C AWG16 [HIV 1.25 (0.002)]
Control I/O
signal connector CN1
PG signal
connector CN2
Twisted-pair or shielded twisted-pair wires.
Core wire at least 0.12 mm2 (0.0002 in2),
tinned, annealed copper twisted wires.
Finished cable dimensions:
Max. Ø16 mm (0.63 in) for CN1 and max.
Ø 6.8 mm (0.27 in) for CN2.
For
200 V
Offline
terminals
Ground terminal AWG14 [HIV 2.0 (0.003)] min.
Wire Size [mm2(in2)]
External Terminal Name
05** 08** 10** 15** 20** 30**
Main circuit
power input
terminals
L1,L2,L3
(Three
phase)
AWG14
[HIV 2.0 (0.003)] AWG12 [HIV 3.5 (0.005)]
Motor
connection
terminals U, V, W AWG14 [HIV
2.0 (0.003)] AWG12 [HIV 3.5 (0.005)]
AWG10
[HIV
5.5
(0.009)]
Online
terminals
Control power
supply input
terminals L1C, L2C AWG16 [HIV 1.25 (0.002)]
Control I/O
signal connector CN1
PG signal
connector CN2
Twisted-pair or shielded twisted-pair wires.
Core wire at least 0.12 mm2 (0.0002 in2),
tinned, annealed copper twisted wires.
Finished cable dimensions:
Max. Ø16 mm (0.63 in) for CN1 and max.
Ø 6.8 mm (0.27 in) for CN2.
For
200 V
Offline
terminals
Ground terminal AWG14 [HIV 2.0 (0.003)] min.

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The following table shows types of cables and must be used with the
previous tables for wire size specifications.
Cable Types
Symbol Name
Allowable Conductor
Temperature ºC
PVC Normal vinyl cable -
IV 600V vinyl cable 60
HIV Temperature-resistant
vinyl cable 75
The following table shows appropriate cables for CN1 and CN2 XtraDrive
connectors.
Wire sizes were selected for three cables per bundle at 40ºC ambient
temperature with the rated current.
Connector Name
and Signal Item Specification
Cable Twisted-pair or shielded twisted-pair wire.
Applicable wire AWG24 [0.2 mm2(0.0003 in2)], AWG26 [0.12 mm2
(0.0002 in2)], AWG28 [0.08 mm2(0.0001 in2)],
AWG30 [0.05 mm2(0.00008 in2)].
Control
I/O Signal
Connector CN1
Finished cable
dimension Ø16.0 mm (Ø 0.63 in) MAX.
Cable Shielded twisted-pair wire.
Applicable wire
AWG24 [0.2 mm2(0.0003 in2)], AWG26 [0.12 mm2
(0.0002 in2)], AWG28 [0.08 mm2(0.0001 in2)],
AWG30 [0.05 mm2(0.00008 in2)].
Use AWG22 [0.33 mm2(0.001 in2)] for encoder
power supply and AWG26 [0.12 mm2(0.0002 in2)]
for other signals. These conditions permit wiring
distances up to 20 m (65.6 ft).
PG Signal
Connector CN2
Finished cable
dimension Ø6.8 mm (Ø 0.27 in) MAX.

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4.2. Connecting to Peripheral Devices
4.2.1. Single-phase 200V Main Circuit