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Advantech Automation1 XC4 Hardware Manual

Advantech Automation1 XC4 Hardware Manual

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Automation1 XC4 PWM Digital Drive
HARDWARE MANUAL
Revision 2.01

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Summary of Contents for Advantech Automation1 XC4

  • Page 1: Automation1 Xc4 Pwm Digital Drive

    Automation1 XC4 PWM Digital Drive HARDWARE MANUAL Revision 2.01...
  • Page 2 GLOBAL TECHNICAL SUPPORT Go to the Global Technical Support Portal for information and support about your Aerotech, Inc. products. The website supplies software, product manuals, Help files, training schedules, and PC-to-PC remote technical support. If necessary, you can complete Product Return (RMA) forms and get information about repairs and spare or replacement parts.

  • Page 3: Table Of Contents

    XC4 Hardware Manual Table of Contents Table of Contents Automation1 XC4 PWM Digital Drive Table of Contents List of Figures List of Tables EU Declaration of Conformity Agency Approvals Safety Procedures and Warnings Installation Overview Chapter 1: Introduction 1.1. Electrical Specifications 1.1.1.
  • Page 4 Table of Contents XC4 Hardware Manual 2.6. Brake Power Supply Connector 2.7. HyperWire Interface 2.8. External Shunt Option [-SX1] 2.9. Sync Port 2.10. System Interconnection 2.11. PC Configuration and Operation Information Chapter 3: -EB1 I/O Option Board 3.1. Digital Outputs [-EB1] 3.2.

  • Page 5: List Of Figures

    XC4 Hardware Manual List of Figures List of Figures Figure 1-1: XC4 Digital Drive Figure 1-2: Functional Diagram Figure 1-3: Dimensions Figure 1-4: Dimensions [-EB1] Figure 2-1: Control Supply Connections Figure 2-2: Motor Supply Connections Figure 2-3: Transformer Examples Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus)
  • Page 6 List of Figures XC4 Hardware Manual Figure 2-45: Analog Input 0 Schematic Figure 2-46: System Wiring Drawing (Best Practice) Figure 2-47: PC-Based Controller System Interconnection (Best Practice) Figure 3-1: XC4 with -EB1 I/O Option Board Connectors Figure 3-2: Digital Outputs Schematic [-EB1] Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] Figure 3-4:...

  • Page 7: List Of Tables

    XC4 Hardware Manual List of Tables List of Tables Table 1-1: Features and Options Table 1-2: Electrical Specifications Table 1-3: Mounting Specifications Table 1-4: Environmental Specifications Table 1-5: Drive and Software Compatibility Table 2-1: Control Supply Wiring Specifications Table 2-2: Mating Connector Part Numbers for the Control Supply Connector Table 2-3: Motor Supply Connector Wiring Specifications...
  • Page 8 List of Tables XC4 Hardware Manual Table 2-44: High-Speed Input Pins on the Auxiliary I/O Connector Table 2-45: Analog Output Specifications Table 2-46: Analog Output Pins on the Auxiliary I/O Connector Table 2-47: Analog Input Specifications Table 2-48: Analog Input Pins on the Auxiliary I/O Connector Table 2-49: Brake Power Supply Connector Pinout Table 2-50:...

  • Page 9: Eu Declaration Of Conformity

    XC4 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 following Directive(s): 2014/30/EU Electromagnetic Compatibility (EMC) 2014/35/EU...
  • Page 10 EU Declaration of Conformity XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 11: Agency Approvals

    XC4 Hardware Manual Agency Approvals Agency Approvals Aerotech tested its XC4 drives and found that they obey the standards that follow: Approval: CUS NRTL Approving Agency: TUV SUD America Inc. Certificate #: U8V 068995 0028 Rev. 02 CAN/CSA-C22.2 No. 61010-1:2012/U2:2016-04; EN 61010- Standards: 1:2010/A1:2019;...
  • Page 12 Agency Approvals XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 13: Safety Procedures And Warnings

    XC4 Hardware Manual Safety Procedures and Warnings Safety Procedures and Warnings IMPORTANT: This manual tells you how to carefully and correctly use and operate the XC4 drive. Read all parts of this manual before you install or operate the XC4 drive or before you do maintenance to your system.
  • Page 14 Safety Procedures and Warnings XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 15: Installation Overview

    XC4 Hardware Manual Installation Overview Installation Overview This image shows the order in which to make connections and settings that are typical to the XC4. 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.
  • Page 16 Installation Overview XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 17: Chapter 1: Introduction

    XC4 Hardware Manual Chapter 1: Introduction Chapter 1: Introduction The XC4 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 XC4. The XC4 offers standard Safe Torque Off (STO) inputs and optional Position Synchronized Output (PSO) outputs.

  • Page 18: Table 1-1: Features And Options

    Chapter 1: Introduction XC4 Hardware Manual Table 1-1: Features and Options Standard Features 100-240 VAC control supply inputs Section 2.1.1. 0-240 VAC motor supply inputs (producing 340 VDC) Section 2.1.2. Line driver square wave quadrature encoder input for position and velocity Section 2.3.1.

  • Page 19: Figure 1-2: Functional Diagram

    XC4 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...

  • Page 20: Electrical Specifications

    1.1. Electrical Specifications XC4 Hardware Manual 1.1. Electrical Specifications Table 1-2: Electrical Specifications Description -10 Option -20 Option -30 Option Input Voltage 0-240 VAC Input Frequency 50-60 Hz 34 A @ 240 V Inrush Current Motor Supply Maximum Continuous Input 10 A 10 A Current Input Current...

  • Page 21: System Power Requirements

    XC4 Hardware Manual 1.1.1. System Power Requirements 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.

  • Page 22: Mechanical Specifications

    1.2. Mechanical Specifications XC4 Hardware Manual 1.2. Mechanical Specifications 1.2.1. Mounting and Cooling Install the drive in an IP54 compliant enclosure to comply with safety standards. Make sure that there is sufficient clearance surrounding the drive for free airflow and for the cables and connections. Table 1-3: Mounting Specifications Customer-Supplied Enclosure...

  • Page 23: Dimensions

    XC4 Hardware Manual 1.2.2. Dimensions 1.2.2. Dimensions Figure 1-3: Dimensions www.aerotech.com...

  • Page 24: Figure 1-4: Dimensions [-Eb1]

    1.2.2. Dimensions XC4 Hardware Manual Figure 1-4: Dimensions [-EB1] www.aerotech.com...

  • Page 25: Environmental Specifications

    XC4 Hardware Manual 1.3. Environmental Specifications 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 than 31°C and decreases linearly to 50% relative humidity at 40°C.

  • Page 26: Drive And Software Compatibility

    Last Software Version column, drives that show a specific version number are not supported after that version. Table 1-5: Drive and Software Compatibility Drive Type Software First Software Version Last Software Version Automation1 Current Automation1 XC4 A3200 6.04 Current www.aerotech.com...

  • Page 27: Chapter 2: Installation And Configuration

    XC4 Hardware Manual Chapter 2: Installation and Configuration Chapter 2: Installation and Configuration Unpacking the Chassis IMPORTANT: All electronic equipment and instrumentation is wrapped in antistatic material and packaged with desiccant. Ensure that the antistatic material is not damaged during unpacking. Inspect the container of the XC4 for any evidence of shipping damage.

  • Page 28: Input Power Connections

    2.1. Input Power Connections XC4 Hardware Manual 2.1. Input Power Connections The XC4 has two AC 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. Refer to Section 2.10.

  • Page 29: Motor Supply Connector

    XC4 Hardware Manual 2.1.2. Motor Supply Connector 2.1.2. Motor Supply Connector Motor power is applied to the AC1 and AC2 terminals of the XC4 Motor Supply connector. The XC410 AC1 input is internally connected to a 5 A fuse. The XC420/30 AC1 input is internally connected to a 10 A fuse.

  • Page 30: Transformer Options

    2.1.3. Transformer Options XC4 Hardware Manual 2.1.3. Transformer Options You can connect an external isolation transformer to the Motor Supply AC Input to reduce the operating voltage of the motor. Using a transformer can also reduce electrical noise. Table 2-5: Nominal Motor Operating Voltages / Required AC Voltages  AC Voltage DC Voltage Table 2-6:...

  • Page 31: Figure 2-4: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (40 Vdc Bus)

    XC4 Hardware Manual 2.1.3. Transformer Options Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) www.aerotech.com...

  • Page 32: Figure 2-5: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (80 Vdc Bus)

    2.1.3. Transformer Options XC4 Hardware Manual Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) www.aerotech.com...

  • Page 33: Figure 2-6: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (160 Vdc Bus)

    XC4 Hardware Manual 2.1.3. Transformer Options Figure 2-6: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) www.aerotech.com...

  • Page 34: Figure 2-7: Tv0.3-28 Transformer Control And Motor Power Wiring (40 Vdc Bus)

    2.1.3. Transformer Options XC4 Hardware Manual Figure 2-7: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) www.aerotech.com...

  • Page 35: Figure 2-8: Tv0.3-56 Transformer Control And Motor Power Wiring (80 Vdc Bus)

    XC4 Hardware Manual 2.1.3. Transformer Options Figure 2-8: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) www.aerotech.com...

  • Page 36: Figure 2-9: Tm3/Tm5 Transformer Control And Motor Power Wiring

    2.1.3. Transformer Options XC4 Hardware Manual Figure 2-9: TM3/TM5 Transformer Control and Motor Power Wiring www.aerotech.com...

  • Page 37: Minimizing Noise For Emc/Ce Compliance

    XC4 Hardware Manual 2.1.4. Minimizing Noise for EMC/CE Compliance 2.1.4. Minimizing Noise for EMC/CE Compliance IMPORTANT: The XC4 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 feedback and input power wiring techniques. 1.

  • Page 38: Motor Power Output Connector

    2.2. Motor Power Output Connector XC4 Hardware Manual 2.2. Motor Power Output Connector DANGER: Before you do maintenance to the equipment, disconnect the electrical power. Wait at least ten (10) minutes after removing the power supply before doing maintenance or an inspection. Otherwise, there is the danger of electric shock. The XC4 can be used to drive the following motor types: Brushless (refer to Section...

  • Page 39: Brushless Motor Connections

    XC4 Hardware Manual 2.2.1. Brushless Motor Connections 2.2.1. Brushless Motor Connections The configuration shown in Figure 2-10 is an example of a typical brushless motor connection. Figure 2-10: Brushless Motor Configuration Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables  Wire Color Set 1 Wire Color Set 2 Wire Color Set 3...

  • Page 40: Brushless Motor Powered Motor And Feedback Phasing

    2.2.1. Brushless Motor Connections XC4 Hardware Manual 2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing Observe the state of the encoder and Hall-effect device signals in the Diagnostics section of the Status Utility. Table 2-10: Hall Signal Diagnostics Hall-Signal Status Definition 0 V or logic low 5 V or logic high...

  • Page 41: Brushless Motor Unpowered Motor And Feedback Phasing

    XC4 Hardware Manual 2.2.1. Brushless Motor Connections 2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing Disconnect the motor from the controller and connect the motor in the test configuration shown in Figure 2-13. This method will require a two-channel oscilloscope, a 5V power supply, and six resistors (10,000 ohm, 1/4 watt).

  • Page 42: Dc Brush Motor Connections

    2.2.2. DC Brush Motor Connections XC4 Hardware Manual 2.2.2. DC Brush Motor Connections The configuration shown in Figure 2-15 is an example of a typical DC brush motor connection. Refer to Section 2.2.2.1. for information on motor phasing. Figure 2-15: DC Brush Motor Configuration Table 2-11: Wire Colors for Aerotech-Supplied DC Brush Motor Cables Wire Color Set 1...

  • Page 43: Dc Brush Motor Phasing

    XC4 Hardware Manual 2.2.2. DC Brush Motor Connections 2.2.2.1. DC Brush Motor Phasing A properly phased motor means that the positive motor lead should be connected to the ØA motor terminal and the negative motor lead should be connected to the ØC motor terminal. To determine if the motor is properly phased, connect a voltmeter to the motor leads of an un-powered motor: 1.

  • Page 44: Stepper Motor Connections

    2.2.3. Stepper Motor Connections XC4 Hardware Manual 2.2.3. Stepper Motor Connections The configuration shown in Figure 2-17 is an example of a typical stepper motor connection. Refer to Section 2.2.3.1. for information on motor phasing. In this case, the effective motor voltage is half of the applied bus voltage. For example, an 80V motor bus supply is needed to get 40V across the motor.

  • Page 45: Stepper Motor Phasing

    XC4 Hardware Manual 2.2.3. Stepper Motor Connections 2.2.3.1. Stepper Motor Phasing A stepper motor can be run with or without an encoder. Without an Encoder: You do not need to phase the motor. With an Encoder: Because the end of travel (EOT) limit inputs are relative to motor rotation, it is important to phase the motor.

  • Page 46: Feedback Connector

    2.2.3. Stepper Motor Connections XC4 Hardware Manual 2.3. Feedback Connector The connector pin assignment is shown in Table 2-13 with detailed connection information in the following sections. Table 2-13: Feedback Connector Pinout Pin # Description In/Out/Bi Connector Reserved Motor Over Temperature Thermistor Input +5V Power Plug and Play Serial Data (for Aerotech stages only)

  • Page 47: Primary Encoder Inputs

    XC4 Hardware Manual 2.3.1. Primary Encoder Inputs 2.3.1. Primary Encoder Inputs The primary encoder inputs are accessible through the Feedback connector. Use the PrimaryFeedbackType [A3200: PositionFeedbackType or VelocityFeedbackType] parameter to configure the XC4 to accept an encoder signal type. Square Wave encoder signals: Section 2.3.1.1.

  • Page 48: Square Wave Encoder

    2.3.1. Primary Encoder Inputs XC4 Hardware Manual 2.3.1.1. Square Wave Encoder The XC4 accepts RS-422 square wave encoder signals. The XC4 will generate a feedback fault if it detects an invalid signal state caused by an open or shorted signal connection. Use twisted-pair wiring for the highest performance and noise immunity.

  • Page 49: Absolute Encoder

    XC4 Hardware Manual 2.3.1. Primary Encoder Inputs 2.3.1.2. Absolute Encoder The XC4 retrieves absolute position data along with encoder fault information through a serial data stream from the absolute encoder. Use twisted-pair wiring for the highest performance and noise immunity. You cannot echo an absolute encoder signal. Refer to Figure 2-20 for the serial data stream interface.

  • Page 50: Sine Wave Encoder [-Mx1 Option]

    2.3.1. Primary Encoder Inputs XC4 Hardware Manual 2.3.1.3. Sine Wave Encoder [-MX1 Option] The Sine Wave Encoder option provides higher positioning resolution by subdividing the fundamental output period of the encoder into smaller increments. The amount of subdivision is specified by the PrimaryEncoderMultiplicationFactor [A3200: EncoderMultiplicationFactor] parameter.

  • Page 51: Figure 2-22: Sine Wave Encoder Schematic (Feedback Connector)

    XC4 Hardware Manual 2.3.1. Primary Encoder Inputs Figure 2-22: Sine Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 52: Encoder Phasing

    2.3.1. Primary Encoder Inputs XC4 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 2-23 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors).

  • Page 53: Hall-Effect Inputs

    XC4 Hardware Manual 2.3.2. Hall-Effect Inputs 2.3.2. Hall-Effect Inputs 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"...

  • Page 54: Thermistor Input

    2.3.3. Thermistor Input XC4 Hardware Manual 2.3.3. Thermistor Input 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.

  • Page 55: Encoder Fault Input

    XC4 Hardware Manual 2.3.4. Encoder Fault Input 2.3.4. Encoder Fault Input 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.

  • Page 56: End Of Travel And Home Limit Inputs

    2.3.5. End of Travel and Home Limit Inputs XC4 Hardware Manual 2.3.5. End of Travel and Home Limit Inputs End of Travel (EOT) limits are required to define the end of the physical travel on linear axes. Positive or clockwise motion is stopped by the clockwise (CW) end of travel limit input. Negative or counterclockwise motion is stopped by the counterclockwise (CCW) end of travel limit input.

  • Page 57: Figure 2-28: End Of Travel And Home Limit Input Connections

    XC4 Hardware Manual 2.3.5. End of Travel and Home Limit Inputs Figure 2-28: End of Travel and Home Limit Input Connections Figure 2-29: End of Travel and Home Limit Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 58: End Of Travel And Home Limit Phasing

    2.3.5. End of Travel and Home Limit Inputs XC4 Hardware Manual 2.3.5.1. End of Travel and Home 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.

  • Page 59: Brake Outputs

    XC4 Hardware Manual 2.3.6. Brake Outputs 2.3.6. Brake Outputs The XC4 has a dedicated brake control circuit. Configure the brake with the BrakeSetup [A3200: EnableBrakeControl] parameter for automatic control (typical). You can also use software commands to directly control the brake output. Refer to Section 2.6.

  • Page 60: Safe Torque Off Input (Sto)

    2.4. Safe Torque Off Input (STO) XC4 Hardware Manual 2.4. Safe Torque Off Input (STO) The STO circuit is comprised of two identical channels, each of which must be energized in order for the XC4 to produce motion. Each STO input is opto-isolated and accepts 24V levels directly without the need for external current limiting resistors.

  • Page 61: Figure 2-32: Typical Configuration

    XC4 Hardware Manual 2.4. Safe Torque Off Input (STO) Table 2-27: STO Electrical Specifications Status Value STO off (motion allowed) 18-24 V, 7 ma STO on (safe state entered, no motion) 0-6 V 22-26 AWG (0.5 - 0.14 mm Recommended Wire Gauge STO System Power Supply PELV STO Wire Length (maximum)

  • Page 62: Sto Standards

    2.4. Safe Torque Off Input (STO) XC4 Hardware Manual 2.4.1. STO Standards Table 2-28 describes and specifies the safety requirements at the system level for the Safe Torque Off (STO) feature of the XC4. This assumes that diagnostic testing is performed according to Section 2.4.4.

  • Page 63: Sto Functional Description

    XC4 Hardware Manual 2.4. Safe Torque Off Input (STO) 2.4.2. STO Functional Description The motor can only be activated when voltage is applied to both STO 1 and STO 2 inputs. The STO state will be entered if power is removed from either the STO 1 or the STO 2 inputs. When the STO state is entered, the motor cannot generate torque or force and is therefore considered safe.

  • Page 64: Sto Startup Validation Testing

    2.4. Safe Torque Off Input (STO) XC4 Hardware Manual Non-standard STO delay times are provided by special factory order. In this case, the non-standard STO delay time is indicated by a label placed on the slice amplifier’s main connector (STO DELAY = xx sec). Table 2-30: STO Signal Delay Value...

  • Page 65: Sto Diagnostics

    XC4 Hardware Manual 2.4. Safe Torque Off Input (STO) 2.4.4. STO Diagnostics Activation of STO means removing power from the XC4’s STO inputs. This is typically done by pressing the emergency stop switch. The XC4 initiates a diagnostic check every time the STO is activated after the Diagnostic Test Delay Time has elapsed.

  • Page 66: Auxiliary I/O Connector

    2.5. Auxiliary I/O Connector XC4 Hardware Manual 2.5. Auxiliary I/O Connector The Auxiliary I/O connector has 1 analog input, 6 digital inputs, 1 analog output, 4 digital outputs, a secondary line driver encoder input, and a secondary absolute encoder interface. Table 2-33: Auxiliary I/O Connector Pinout Pin# Description...

  • Page 67: Auxiliary Encoder Inputs

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector 2.5.1. Auxiliary Encoder Inputs The Auxiliary Encoder connector gives you a second encoder input channel. This channel is typically used for dual loop applications. Use the AuxiliaryFeedbackType [A3200: PositionFeedbackType or VelocityFeedbackType] parameter to configure the XC4 to accept an encoder signal type.

  • Page 68: Square Wave Encoder

    2.5. Auxiliary I/O Connector XC4 Hardware Manual 2.5.1.1. Square Wave Encoder The XC4 accepts RS-422 square wave encoder signals. The XC4 will generate a feedback fault if it detects an invalid signal state caused by an open or shorted signal connection. Use twisted-pair wiring for the highest performance and noise immunity.

  • Page 69: Absolute Encoder

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector 2.5.1.2. Absolute Encoder The XC4 retrieves absolute position data along with encoder fault information through a serial data stream from the absolute encoder. Use twisted-pair wiring for the highest performance and noise immunity. You cannot use an absolute encoder with incremental signals on the Auxiliary I/O Connector. Refer to Figure 2-35 for the serial data stream interface.

  • Page 70: Position Synchronized Output (Pso)

    2.5. Auxiliary I/O Connector XC4 Hardware Manual 2.5.2. Position Synchronized Output (PSO) The PSO signal is available on the dual-function AUX Marker/PSO signal lines. Use the PSO pulse external sync functions [A3200: PSOOUTPUT PULSE EXTSYNC command] to configure the auxiliary marker as an output.

  • Page 71: Figure 2-36: Pso Interface

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector Figure 2-36: PSO Interface www.aerotech.com...

  • Page 72: Digital Outputs

    2.5. Auxiliary I/O Connector XC4 Hardware Manual 2.5.3. Digital Outputs 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 the same configuration.

  • Page 73: Figure 2-37: Digital Output Schematic (Aux I/O Connector)

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector Figure 2-37: Digital Output Schematic (Aux I/O Connector) www.aerotech.com...

  • Page 74: Figure 2-38: Digital Outputs Connected In Current Sourcing Mode

    2.5. Auxiliary I/O Connector XC4 Hardware Manual Figure 2-38: Digital Outputs Connected in Current Sourcing Mode Figure 2-39: Digital Outputs Connected in Current Sinking Mode www.aerotech.com...

  • Page 75: Digital Inputs

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector 2.5.4. Digital Inputs You can connect the digital inputs to current sourcing or current sinking devices but you must connect all four inputs in the same configuration. Refer to Figure 2-42 Figure 2-41. The digital inputs are not designed for high-voltage isolation applications.

  • Page 76: Figure 2-41: Digital Inputs Connected To Current Sinking Devices

    2.5. Auxiliary I/O Connector XC4 Hardware Manual Figure 2-41: Digital Inputs Connected to Current Sinking Devices Figure 2-42: Digital Inputs Connected to Current Sourcing Devices www.aerotech.com...

  • Page 77: High-Speed Inputs

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector 2.5.5. High-Speed Inputs High-speed inputs 20 and 21 can be used as general purpose inputs or as the trigger signal for high speed data collection. Refer to the DriveDataCaptureConfigureTrigger() function [A3200: DATAACQ TRIGGER command] topic in the Help file for more information. You can use the external PSO synchronization functions [A3200: PSOOUTPUT PULSE EXTSYNC command] to synchronize waveform generation with an external synchronization signal.

  • Page 78: Analog Output

    2.5. Auxiliary I/O Connector XC4 Hardware Manual 2.5.6. Analog Output 0 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. Table 2-45: Analog Output Specifications Specification...

  • Page 79: Analog Input 0 (Differential)

    XC4 Hardware Manual 2.5. Auxiliary I/O Connector 2.5.7. Analog Input 0 (Differential) 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.

  • Page 80: Brake Power Supply Connector

    2.6. Brake Power Supply Connector XC4 Hardware Manual 2.6. Brake Power Supply Connector This port is the power supply connection to the on-board brake control circuit. Refer to Section 2.3.6. more information about the brake output interface. Table 2-49: Brake Power Supply Connector Pinout Connector Pin# Description In/Out/Bi...

  • Page 81: Hyperwire Interface

    XC4 Hardware Manual 2.7. HyperWire Interface 2.7. HyperWire Interface The HyperWire bus is the high-speed communications connection from the controller. It operates at 2 gigabits per second. The controller sends all command and configuration information through the HyperWire bus. HyperWire cables can be safely connected to or disconnected from a HyperWire port while the PC and/or drive is powered on.

  • Page 82: External Shunt Option [-Sx1]

    2.8. External Shunt Option [-SX1] XC4 Hardware Manual 2.8. External Shunt Option [-SX1] DANGER: The shunt resistor dissipates a high quantity of power. To prevent the danger of electric shock or fire, you must obey the precautions that follow: Correctly size, mount, and protect the external shunt resistor. Do not touch the shunt resistor terminals.

  • Page 83: Table 2-54: Maximum Additional Storage Energy For A Standard Xc4

    XC4 Hardware Manual 2.8. External Shunt Option [-SX1] Table 2-54: Maximum Additional Storage Energy for a Standard XC4 Bus Voltage Maximum Additional Energy 160 V 71.3 J 320 V 25.2 J If a shunt resistor is required, calculate the value of resistance necessary to dissipate the energy.  Equations 3, 4, and 5: Calculate the parameters of the shunt resistor.

  • Page 84: Sync Port

    2.9. Sync Port XC4 Hardware Manual 2.9. Sync Port The Sync port is a bi-directional high speed proprietary interface that lets you transmit encoder signals between drives. This is typically used for multi-axis PSO applications where one or two drives send their encoder signals to a main drive that has the PSO logic and PSO output signal.

  • Page 85: System Interconnection

    XC4 Hardware Manual 2.10. System Interconnection 2.10. System Interconnection Click on the image below to open a separate pdf window with a larger view of the drawing. Figure 2-46: System Wiring Drawing (Best Practice) www.aerotech.com...

  • Page 86: Figure 2-47: Pc-Based Controller System Interconnection (Best Practice)

    2.10. System Interconnection XC4 Hardware Manual Figure 2-47: PC-Based Controller System Interconnection (Best Practice) www.aerotech.com...

  • Page 87: Pc Configuration And Operation Information

    XC4 Hardware Manual 2.11. PC Configuration and Operation Information 2.11. 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...
  • Page 88 2.11. PC Configuration and Operation Information XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 89: Chapter 3: -Eb1 I/O Option Board

    XC4 Hardware Manual Chapter 3: -EB1 I/O Option Board Chapter 3: -EB1 I/O Option Board The -EB1 I/O option board has 16 digital inputs, 16 digital outputs, 3 analog inputs, 3 analog outputs, and PSO outputs. Figure 3-1: XC4 with -EB1 I/O Option Board Connectors www.aerotech.com...

  • Page 90: Digital Outputs [-Eb1]

    3.1. Digital Outputs [-EB1] XC4 Hardware Manual 3.1. 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.

  • Page 91: Table 3-2: Digital Output 1 Connector Pinout [-Eb1]

    XC4 Hardware Manual 3.1. Digital Outputs [-EB1] Table 3-2: Digital Output 1 Connector Pinout [-EB1] Pin# Description In/Out/Bi Connector Output Common for Outputs 4-7 Output 4 (Optically-Isolated) Output Output 5 (Optically-Isolated) Output Output 6 (Optically-Isolated) Output Output 7 (Optically-Isolated) Output Output Common for Outputs 8-11 Output 8 (Optically-Isolated) Output...

  • Page 92: Figure 3-2: Digital Outputs Schematic [-Eb1]

    3.1. Digital Outputs [-EB1] XC4 Hardware Manual Figure 3-2: Digital Outputs Schematic [-EB1] www.aerotech.com...

  • Page 93: Figure 3-3: Digital Outputs Connected In Current Sourcing Mode [-Eb1]

    XC4 Hardware Manual 3.1. Digital Outputs [-EB1] Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] www.aerotech.com...

  • Page 94: Digital Inputs [-Eb1]

    3.2. Digital Inputs [-EB1] XC4 Hardware Manual 3.2. 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.

  • Page 95: Figure 3-5: Digital Inputs Schematic [-Eb1]

    XC4 Hardware Manual 3.2. Digital Inputs [-EB1] Table 3-9: Digital Input 2 Connector Pinout [-EB1] Pin# Description In/Out/Bi Connector Input Common for Inputs 12-15 Input 12 (Optically-Isolated) Input Input 13 (Optically-Isolated) Input Input 14 (Optically-Isolated) Input Input 15 (Optically-Isolated) Input Input Common for Inputs 16-19 Input 16 (Optically-Isolated) Input...

  • Page 96: Figure 3-6: Digital Inputs Connected To Current Sourcing (Pnp) Devices [-Eb1]

    3.2. Digital Inputs [-EB1] XC4 Hardware Manual IMPORTANT: Each bank of four inputs must be connected in an all sourcing or all sinking configuration. Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] www.aerotech.com...

  • Page 97: Analog Outputs [-Eb1]

    XC4 Hardware Manual 3.3. Analog Outputs [-EB1] 3.3. Analog Outputs [-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. Table 3-11: Analog Output Specifications [-EB1] Specification...

  • Page 98: Analog Inputs [-Eb1]

    3.4. Analog Inputs [-EB1] XC4 Hardware Manual 3.4. Analog Inputs [-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.

  • Page 99: Position Synchronized Output Interface [-Eb1]

    XC4 Hardware Manual 3.5. Position Synchronized Output Interface [-EB1] 3.5. Position Synchronized Output Interface [-EB1] The PSO output signal is available on the -EB1 option board in two signal formats: TTL and Isolated. The PSO signal is also available on the AUX I/O connector. Refer to Section 2.5.2.

  • Page 100: Figure 3-10: Pso Output Sources Current

    3.5. Position Synchronized Output Interface [-EB1] XC4 Hardware Manual 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. The PSO Isolated Outputs are overload protected and will turn off if the maximum output current is exceeded.

  • Page 101: Chapter 4: Cables And Accessories

    XC4 Hardware Manual Chapter 4: Cables and Accessories Chapter 4: Cables and Accessories IMPORTANT: 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 4.1. ECZ01231 BBA32 Interconnect Cable www.aerotech.com...

  • Page 102: Joystick Interface

    4.1. Joystick Interface XC4 Hardware Manual 4.1. 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.

  • Page 103: Figure 4-2: Two Axis Joystick Interface (To The I/O Board)

    XC4 Hardware Manual 4.1. Joystick Interface Figure 4-2: Two Axis Joystick Interface (to the I/O board) www.aerotech.com...

  • Page 104: Handwheel Interface

    4.2. Handwheel Interface XC4 Hardware Manual 4.2. Handwheel Interface A handwheel can be used to manually control axis position. The handwheel must provide 5V differential quadrature signals to the XC4 IMPORTANT: You can find instructions on how to enable the handwheel in the Help file. Connect a handwheel to the Aux I/O as shown in Figure 4-3 Figure...

  • Page 105: Chapter 5: Maintenance

    XC4 Hardware Manual Chapter 5: Maintenance Chapter 5: Maintenance IMPORTANT: For your own safety and for the safety of the equipment: Do not remove the cover of the XC4 Do not attempt to access the internal components. A fuse that needs to be replaced indicates that there is a more serious problem with the system or setup.

  • Page 106: Preventative Maintenance

    5.1. Preventative Maintenance XC4 Hardware Manual 5.1. Preventative Maintenance Do an inspection of the XC4 and the external wiring one time each month. It might be necessary to do more frequent inspections based on:  The operating conditions of the system. How you use the system.

  • Page 107: Fuse Specifications

    XC4 Hardware Manual 5.2. Fuse Specifications 5.2. Fuse Specifications WARNING: Replace fuses only with the same type and value. Table 5-4: Control Board Fuse Specifications Aerotech Third Party P/N Fuse Description Size F100 Control Power at Line Input (L) 2 A S.B. EIF01044 Littelfuse 0877002.MXEP F101 -SX1 (External Shunt) Option...
  • Page 108 5.2. Fuse Specifications XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 109: Appendix A: Warranty And Field Service

    XC4 Hardware Manual Appendix A: Warranty and Field Service Appendix A: Warranty and Field Service Aerotech, Inc. warrants its products to be free from harmful defects caused by faulty materials or poor workmanship for a minimum period of one year from date of shipment from Aerotech. Aerotech’s liability is limited to replacing, repairing or issuing credit, at its option, for any products that are returned by the original purchaser during the warranty period.
  • Page 110 Appendix A: Warranty and Field Service XC4 Hardware Manual Rush Service At times, the buyer may desire to expedite a repair. Regardless of warranty or out-of-warranty status, the buyer must issue a valid purchase order to cover the added rush service cost. Rush service is subject to Aerotech's approval.

  • Page 111: Appendix B: Revision History

    XC4 Hardware Manual Appendix B: Revision History Appendix B: Revision History Revision Description Absolute Encoder support on the Auxiliary I/O connector has been added. 2.01 System Wiring (best practices) drawing has been added 2.00 General Update The following sections have been updated: Agency Approvals 1.02 Section 2.3.1.
  • Page 112 Appendix B: Revision History XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 113: Index

    XC4 Hardware Manual Index Index Analog Output 0 Specifications (Aux I/O Connector) Analog Output Connector [-EB1] Mating Connector Part Numbers Analog Output Connector Pinout [-EB1] Analog Output Pins (Aux I/O Connector) -EB1 Analog Output Specifications [-EB1] Analog Inputs Analog Output Typical Connection [-EB1] Analog Outputs Analog Outputs [-EB1] Digital Inputs...
  • Page 114 Index XC4 Hardware Manual Digital Input Specifications (Aux I/O Connector) Digital Input Specifications [-EB1] Cable Wires Digital Inputs (Aux I/O Connector) Brushless Motors Digital Inputs [-EB1] DC Brush Motors Digital Inputs Connected to a Current Sinking Device [- Stepper Motors EB1] Cables Digital Inputs Connected to a Current Sourcing Device [-...
  • Page 115 XC4 Hardware Manual Index encoder Figure absolute 49,69 -EB1 I/O Option Board Connectors Encoder and Hall Signal Diagnostics Absolute Encoder Schematic (Auxiliary I/O Connector) 69 Encoder Fault Input (Feedback Connector) Absolute Encoder Schematic (Feedback Connector) Encoder Fault Input Pin on the Feedback Connector Analog Encoder Schematic (Feedback Connector) Encoder Input (Feedback Connector) Analog Input 0 Schematic (Aux I/O Connector)
  • Page 116 Index XC4 Hardware Manual Positive Motor Direction PSO Interface (Aux I/O Connector) I/O Option Board [-EB1] PSO Isolated Output Sinks Current Input Power Connections PSO Isolated Output Sources Current inspecting cooling vents PSO TTL Outputs Schematic Inspection Sine Wave Encoder Schematic (Feedback Connector) 51 Installation and Configuration Square Wave Encoder Inputs Schematic (Aux I/O Installation Connection Overview...
  • Page 117 XC4 Hardware Manual Index Minimum Load Inductance specifications Auxiliary I/O Connector Modes of Operation Auxiliary I/O Pins (Aux I/O Connector) Motor Connector Brake Output Connector Mating Connector Part Numbers Brake Output Pins (Feedback Connector) Motor Function Relative to STO Input State Digital Input 1 Connector [-EB1] Motor Power Output Connector Digital Input 2 Connector [-EB1]...
  • Page 118 Index XC4 Hardware Manual PSO Specifications [-EB1] Square Wave Encoder Specifications (Feedback Connector) 48,68 PWM Switching Frequency specifications Standard Features Stepper Motor Configuration Stepper Motor Connections (Motor Power Output Resolute absolute encoder 49,69 Connector) Revision History Stepper Motor Phasing RS-422 Encoder Specifications (Feedback Connector) 48,68 RS-422 Line Driver Encoder 48,68 Connector Pinout...
  • Page 119 XC4 Hardware Manual Index TV0.3-56 Transformer (80 VDC Bus) Two Axis Joystick Interface Two Axis Joystick Interface (to the I/O board of two drives) Typical STO Configuration Unit Weight Unpacking the Chassis User Power Supply specifications Warranty and Field Service Wire Colors for Aerotech-Supplied Brushless Motor Cables Wire Colors for Aerotech-Supplied DC Brush Motor...
  • Page 120 Index XC4 Hardware Manual This page intentionally left blank. www.aerotech.com...

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