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This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies.
XC2 Hardware Manual Table of Contents Table of Contents XC2 Hardware Manual Table of Contents List of Figures List of Tables EU Declaration of Conformity Safety Procedures and Warnings Quick Installation Guide Chapter 1: Introduction 1.1. Electrical Specifications 1.1.1. System Power Requirements 1.2.
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Table of Contents XC2 Hardware Manual 3.3.1. Analog Input (Differential) [-EB1] 3.3.2. Analog Output [-EB1] 3.4. Digital Inputs [-EB1] 3.5. Digital Outputs [-EB1] Chapter 4: Cables and Accessories 4.1. DIN Rail Mounting 4.2. Joystick Interface 4.3. Handwheel Interface Chapter 5: Maintenance 5.1.
Motor Power Output Connector Pinout Table 2-6: Mating Connector Part Numbers for the Motor Power Output Connector Table 2-7: Wire Colors for Aerotech-Supplied Brushless Motor Cables Table 2-8: Wire Colors for Aerotech-Supplied DC Brush Motor Cables Table 2-9: Wire Colors for Aerotech-Supplied Stepper Motor Cables...
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List of Tables XC2 Hardware Manual Table 3-17: Digital Output Connector Pinout [-EB1] Table 3-18: Mating Connector Part Numbers for the Digital Output Connector [-EB1] Table 4-1: Standard Interconnection Cables Table 4-2: Mounting Parts Table 5-1: Preventative Maintenance Table 5-2: Control Board Fuse Specifications www.aerotech.com...
XC2 Hardware Manual EU Declaration of Conformity EU Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product Model/Types This is to certify that the aforementioned product is in accordance with the applicable requirements of the...
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Safety Procedures and Warnings This manual tells you how to carefully and correctly use and operate the XC2. Read all parts of this manual before you install or operate the XC2 or before you do maintenance to your system. To prevent injury to you and damage to the equipment, obey the precautions in this manual.
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Quick Installation Guide Quick Installation Guide This image shows the order in which to make connections and settings that are typical to the XC2. If a custom interconnect drawing was supplied with your system, that drawing is on your Storage Device and shows as a line item on your Sales Order in the Integration section.
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Chapter 1: Introduction Chapter 1: Introduction The XC2 is a high performance digital drive based on the HyperWire communication protocol. The drive provides deterministic behavior, auto-identification, is fully software configurable. A double precision floating point DSP controls the digital PID and current loops in the XC2.
XC2 Hardware Manual Chapter 1: Introduction The block diagram that follows shows a summary of the connector signals. Figure 1-2: Functional Diagram www.aerotech.com...
Chapter 1: Introduction XC2 Hardware Manual 1.1. Electrical Specifications Table 1-2: Electrical Specifications Description XC2-10 Input Voltage 15-100 VDC Motor Input Current Supply (Continuous) Input Current Refer to Section 1.1.1. System Power Requirements Input Voltage 24 VDC Control Supply Input Current...
XC2 Hardware Manual Chapter 1: Introduction 1.1.1. System Power Requirements The following equations can be used to determine total system power requirements. The actual power required from the mains supply will be the combination of actual motor power (work), motor resistance losses, and efficiency losses in the power electronics or power transformer.
1.2. Mechanical Specifications The XC2 must be installed in an IP54 compliant enclosure to comply with safety standards. Mount the XC2 so free airflow is available at the front, top, and along the sides of the chassis for cooling. You must also allow space for connections and cables along the front, top, and bottom.
Chapter 1: Introduction XC2 Hardware Manual 1.3. Environmental Specifications Table 1-4: Environmental Specifications Operating: 0° to 40°C (32° to 104° F) Ambient Temperature Storage: -30° to 85°C (-22° to 185° F) Humidity The maximum relative humidity is 80% for temperatures that are less Non-condensing than 31°C and decreases linearly to 50% relative humidity at 40°C.
XC2 Hardware Manual Chapter 1: Introduction 1.4. Drive and Software Compatibility This table shows the available drives and which version of the software first supported each drive. In the Last Software Version column, drives that show a specific version number are not supported after that version.
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Chapter 2: Installation and Configuration 2.1. Input Power Connections The XC2 has two DC input power connectors. One connector is for control power and the other connector is for motor power. For a full list of electrical specifications, refer to Section 1.1.
2.1.2. Motor Supply Connector Motor power is applied to the DC+ and 0V terminals of the XC2 Motor Supply connector. Wires must be properly matched to the branch protection and must be sized to meet local electrical safety codes. The DC+ input is connected to an internal fuse.
2.1.3. Minimizing Conducted, Radiated, and System Noise for EMC/CE Compliance NOTE: The XC2 is a component designed to be integrated with other electronics. EMC testing must be conducted on the final product configuration. To reduce electrical noise, observe the following motor and input power wiring techniques.
DANGER: Disconnect power before doing maintenance to the equipment. Wait at least one (1) minute after removing the power supply before doing maintenance or an inspection. Otherwise, there is the danger of electric shock. The XC2 can be used to drive the following motor types: Brushless (refer to Section 2.2.1.)
Black #3 Violet & Blue (1) Wire Color Set #1 is the wire set typically used by Aerotech. (2) “&” indicates two wires (Red & Orange); “ / ” indicates a single wire (Green/White). Brushless motors are commutated electronically by the controller. The use of Hall effect devices for commutation is recommended.
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing Refer to the Motor Phasing Calculator in the Configuration Manager for motor, Hall, and encoder phasing. Figure 2-4: Positive Motor Direction Feedback Monitoring The state of the encoder and Hall-effect device signals can be observed in the Status Utility.
With the designations of the motor and Hall leads of a third party motor determined, the motor can now be connected to an Aerotech system. Connect motor lead A to motor connector A, motor lead B to motor connector B, and motor lead C to motor connector C. Hall leads should also be connected to their respective feedback connector pins (Hall A lead to the Hall A feedback pin, Hall B to Hall B, and Hall C to Hall C).
Red & Orange Red & Orange Yellow & Blue Black Yellow & Blue (1) Wire Color Set #1 is the typical wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire. www.aerotech.com...
5. Connect the motor lead from the positive lead of the voltmeter to the ØA motor terminal on the XC2. Connect the motor lead from the negative lead of the voltmeter to the ØC motor terminal on the XC2.
Green/Yellow & Shield Green/Yellow & Shield Black Brown Yellow White White & Red (1) Wire Color Set #1 is the typical wire set used by Aerotech. (2) “&” (Red & Orange) indicates two wires; “ / ” (Green/White) indicates a single wire. www.aerotech.com...
Proper motor phasing is important because the end of travel (EOT) limit inputs are relative to motor rotation. Figure 2-11: Positive Motor Direction For Aerotech-supplied systems, the motor, encoder and Hall sensors are correctly configured and connection adjustments are not necessary. NOTE: After the motor has been phased, use the ReverseMotionDirection parameter to change the direction of “positive”...
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.3. Feedback Connector The Feedback connector (a 25-pin, D-style connector) has inputs for an encoder, limit switches, Hall-effect devices, motor over-temperature device, 5 V encoder and limit power, and optional brake connections. The...
(Section 2.3.1.3.). There are two multiplier options (consult your order information to determine which option your XC2 has been configured with): -MX0: This option allows the XC2 to accept RS-422 or absolute encoder signals. -MX1: This option allows the XC2 to accept analog signals in addition to RS-422 and absolute encoder signals.
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.3.1.1. RS-422 Line Driver Encoder NOTE: Aerotech recommends that you use twisted pair wiring for all differential signals. Table 2-13: RS-422 Line Driver Encoder Specifications Specification Value Encoder Frequency 10 MHz maximum (25 ns minimum edge separation)
Chapter 2: Installation and Configuration 2.3.1.2. Absolute Encoder NOTE: Aerotech recommends that you use twisted pair wiring for all differential signals. The XC2 retrieves absolute position data along with encoder fault information via a serial data stream from the absolute encoder. See Figure 2-13 for the serial data stream interface.
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.3.1.3. Analog Encoder [-MX1 Option] NOTE: Aerotech recommends that you use twisted pair wiring for all differential signals. The interpolation factor is determined by the EncoderMultiplicationFactor parameter and is software selectable. Use the Feedback Tuning tab of Digital Scope to automatically adjust the value of the gain, offset, and phase balance controller parameters to get the best performance.
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.3.1.4. Encoder Phasing Incorrect encoder polarity will cause the system to fault when enabled or when a move command is issued. Figure 2-16 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors).
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.3.2. Hall-Effect Interface The Hall-effect switch inputs are recommended for AC brushless motor commutation but not absolutely required. The Hall-effect inputs accept 5 VDC level signals. Hall states (0,0,0) or (1,1,1) are invalid and will generate a "Hall Fault"...
XC2 Hardware Manual Chapter 2: Installation and Configuration 2.3.3. Thermistor Input Interface The thermistor input is used to detect a motor over temperature condition by using a positive temperature coefficient sensor. As the temperature of the sensor increases, so does the resistance. Under normal operating conditions, the resistance of the thermistor is low which will result in a low input signal.
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.3.4. Encoder Fault Input Interface The encoder fault input is for use with encoders that have a fault output. This is provided by some manufactures and indicates a loss of encoder function. The active state of this input is parameter configurable and the controller should be configured to disable the axis when the fault level is active.
Counterclockwise End of Travel Limit Input Aerotech recommends that you use NPN-type normally-closed limit switches and select Active High for this option. This configuration provides fail-safe limit behavior in the even of an open circuit. PNP type limit switches can also be used and will require an external pull-down resistor as shown in Figure 2-21.
XC2 Hardware Manual Chapter 2: Installation and Configuration 2.3.5.1. End of Travel Limit Phasing If the EOT limits are reversed, you will be able to move further into a limit but be unable to move out. To correct this, swap the connections to the CW and CCW inputs at the Feedback connector or swap the CW and CCW limit functionality in the software using the EndOfTravelLimitSetup parameter.
XC2 Hardware Manual 2.3.6. Brake Output Interface The XC2 has a dedicated brake control circuit. The brake is typically configured for automatic control using the EnableBrakeControl parameter. The brake output can also be manually controlled if you use the BRAKE command.
24 V signals. NOTE: The XC2 might be equipped with an STO bypass plug. The bypass plug defeats the STO safety circuit and allows the system to run at all times. To use the STO safety functionality, remove the plug and make connections as outlined in this section.
Chapter 2: Installation and Configuration XC2 Hardware Manual WARNING: The XC2 does not check for short circuits on the external STO wiring. If this is not done by the external safety device, short circuits on the wiring must be excluded. Refer to EN ISO 13849-2.
The XC2 software monitors each STO channel and will generate an Emergency Stop software fault when either channel signals the stop state. Each STO channel contains a fixed delay which allows the XC2 to perform a controlled stop before the power amplifier transistors are turned off.
321 Safety Relay Unit. Place this device between the system ESTOP wiring and the XC2's STO inputs. Connect the ESTOP signal directly to a digital input, in addition to the external timer, to allow the XC2 to begin a software-controlled stop as soon as the ESTOP signal becomes active. Use the ESTOPFaultInput parameter to configure a digital input as an ESTOP input.
Diagnostic Test Delay Time has elapsed. The diagnostic check verifies that each channel has entered the safe state. The XC2 is held in the safe state if it determines that one of the channels has not properly entered the safe state. An open circuit or short to 24 V in either STO channel will result in this condition (refer to Section 2.4.3.).
Chapter 2: Installation and Configuration XC2 Hardware Manual 2.5. HyperWire Interface The HyperWire bus is the high-speed communications connection to the XC2 operating at 2 gigabits per second. The PC sends all command and configuration information through the HyperWire bus. Table 2-29:...
XC2 Hardware Manual Chapter 2: Installation and Configuration 2.6. PC Configuration and Operation Information For more information about hardware requirements, PC configuration, programming, system operation, and utilities, refer to the Help file. www.aerotech.com...
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Chapter 3: -EB1 I/O Option Board XC2 Hardware Manual 3.1. Position Synchronized Output (PSO) Interface [-EB1] The PSO output signal is available on the -EB1 option board in two signal formats: TTL and Isolated. Table 3-1: PSO Specifications [-EB1] Specification...
XC2 Hardware Manual Chapter 3: -EB1 I/O Option Board Isolated Signals This output signal is a fully-isolated 5-24V compatible output capable of sourcing or sinking current. This output is normally open and only conducts current when a PSO fire event occurs.
When configured as inputs, invalid or missing signals will cause a feedback fault when the axis is enabled. NOTE: Aerotech recommends that you use twisted pair wiring for all differential signals. Table 3-4: Auxiliary Encoder RS-422 Specifications...
Chapter 3: -EB1 I/O Option Board XC2 Hardware Manual 3.3. Analog I/O [-EB1] The Analog I/O connector has one differential analog input and one analog output. Table 3-7: AI/O Connector Pinout [-EB1] Pin# Description In/Out/Bi Connector +5 V Output Analog Input 0+...
XC2 Hardware Manual Chapter 3: -EB1 I/O Option Board 3.3.1. Analog Input (Differential) [-EB1] To interface to a single-ended, non-differential voltage source, connect the signal common of the source to the negative input and connect the analog source signal to the positive input. A floating signal source must be referenced to the analog common.
Chapter 3: -EB1 I/O Option Board XC2 Hardware Manual 3.3.2. Analog Output [-EB1] The analog output can be set from within a program or it can be configured to echo the state of select servo loop nodes. The analog output is set to zero when you power on the system or reset the drive.
XC2 Hardware Manual Chapter 3: -EB1 I/O Option Board 3.4. Digital Inputs [-EB1] Input bits are arranged in groups of 4 and each group shares a common pin. This lets a group be connected to current sourcing or current sinking devices, based on the connection of the common pin in that group.
Chapter 3: -EB1 I/O Option Board XC2 Hardware Manual NOTE: Each bank of four inputs must be connected in an all sourcing or all sinking configuration. Figure 3-9: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] Figure 3-10: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1]...
XC2 Hardware Manual Chapter 3: -EB1 I/O Option Board 3.5. Digital Outputs [-EB1] Optically-isolated solid-state relays drive the digital outputs. You can connect the digital outputs in current sourcing or current sinking mode but you must connect all four outputs in a port in the same configuration.
XC2 Hardware Manual Chapter 3: -EB1 I/O Option Board Figure 3-12: Digital Outputs Connected in Current Sourcing Mode [-EB1] Figure 3-13: Digital Outputs Connected in Current Sinking Mode [-EB1] www.aerotech.com...
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XC2 Hardware Manual Chapter 4: Cables and Accessories Chapter 4: Cables and Accessories NOTE: Find Aerotech cable drawings on the website at http://www.aerotechmotioncontrol.com/manuals/index.aspx.. Table 4-1: Standard Interconnection Cables Cable Part # Description Joystick Section 4.2. ECZ01231 BBA32 Interconnect Cable (1) The “-xx” indicates length in decimeters. “-yy” would indicate length in feet.
4.1. DIN Rail Mounting DIN Rail Mounting Procedure: 1. Mount the DIN rail clip to the XC2. The clip and #6-32 x 1/4 flat head screws are included in the XC2- DIN clip kit. 2. Cut the DIN rail so that one complete mounting hole extends beyond the last component at each end.
Chapter 4: Cables and Accessories 4.2. Joystick Interface Aerotech Multi-Axis Joystick (NEMA12 (IP54) rated) is powered from 5 V and has a nominal 2.5 V output in the center detent position. Three buttons are used to select axis pairs and speed ranges. An optional interlock signal is used to indicate to the controller that the joystick is present.
4.3. Handwheel Interface A handwheel can be used to manually control axis position. The handwheel must provide 5V differential quadrature signals to the XC2 NOTE: You can find instructions on how to enable the handwheel in the Help file. Connect a handwheel to the Aux connector as shown in Figure 4-2.
DANGER: Before you clean the XC2, disconnect the electrical power from the drive. Use a clean, dry, soft cloth to clean the chassis of the XC2. If necessary, you can use a cloth that is moist with water or isopropyl alcohol. If you use a moist cloth, make sure that moisture does not go into the XC2.
Chapter 5: Maintenance XC2 Hardware Manual 5.2. Fuse Specifications WARNING: Replace fuses only with the factory-specified value and type. Table 5-2: Control Board Fuse Specifications Fuse Description Size Aerotech P/N Third Party P/N Control Power at DC+ Input EIF00136 Littelfuse 0251002.MXL Motor Power at DC+ Input 5 A S.B.
Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer, whether or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided, or whether or not Aerotech’s...
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Aerotech's approval. On-site Warranty Repair If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts, and cannot be returned to the Aerotech service center for repair, and if Aerotech determines the problem could be warranty-related, then the following policy applies:...
XC2 Hardware Manual Index Index Analog Output Typical Connection [-EB1] Analog Outputs [-EB1] AUX Connector Mating Connector Part Numbers 62 -EB1 AUX Connector Pinout Analog Input Auxiliary Encoder Channel [-EB1] Analog Outputs Auxiliary Encoder Connector Pinout Auxiliary Encoder Interface Channel...
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Index XC2 Hardware Manual connections, examining Digital Outputs Schematic [-EB1] Continuous Output Current specifications Dimensions Control Board Fuse Specifications Dimensions (without -EB1) Control Supply Connections Dimensions with -EB1 Control Supply Connector DIN Rail Mounting Mating Connector Part Numbers DIN Rail Mounting Procedure...
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XC2 Hardware Manual Index connections Digital Inputs Connected to a Current Sourcing Device [-EB1] examining, dangerous fluids Digital Inputs Schematic [-EB1] examining, dangerous material Digital Outputs Schematic [-EB1] Dimensions (without -EB1) Feature Summary Dimensions with -EB1 Feedback Connector End of Travel Limit Input Connections...
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Index XC2 Hardware Manual Motor Supply at AC1 material, electrically conductive Mating Connector P/N Global Technical Support Analog I/O (AI/O) Connector [-EB1] AUX Connector Hall-Effect Feedback Pins on the Feedback Control Supply Connector Connector Digital Input Connector [-EB1] Hall-Effect Inputs Schematic...
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XC2 Hardware Manual Index Output Voltage specifications Position Synchronized Output (PSO) Interface [- EB1] Overview Positive Motor Direction Power Amplifier Bandwidth specifications PC Configuration and Operation Information Power Requirements Peak Output Current specifications Preventative Maintenance Phasing Protective Features DC Brush Motor...
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Connector) Stepper Motor Phasing Warranty and Field Service Wire Colors for Aerotech-Supplied Brushless Connector Pinout Motor Cables Diagnostics Wire Colors for Aerotech-Supplied DC Brush Motor Cables Electrical Specifications Wire Colors for Aerotech-Supplied Stepper Motor External Delay Timer Cables Functional Description...