Advantech Automation1 XC4e Hardware Manual
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Advantech Automation1 XC4e Hardware Manual

Pwm high-performance digital drives
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Automation1 iXC4e and XC4e
PWM High-Performance Digital Drives
HARDWARE MANUAL
Revision 2.14

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  • Page 1: Automation1 Ixc4E And Xc4E Pwm High-Performance Digital Drives

    Automation1 iXC4e and XC4e PWM High-Performance Digital Drives HARDWARE MANUAL Revision 2.14...
  • 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

    Hardware Manual iXC4e/XC4e Table of Contents Automation1 iXC4e and XC4e PWM High-Performance Digital Drives Table of Contents List of Figures List of Tables EU Declaration of Conformity UKCA Declaration of Conformity Korean Certification Agency Approvals Safety Procedures and Warnings Handling and Storage Installation Overview Chapter 1: iXC4e/XC4e Overview 1.1.
  • Page 4 iXC4e/XC4e Hardware Manual 2.5.1. Auxiliary Encoder Interface 2.5.1.1. Square Wave Encoder (Auxiliary) 2.5.1.2. Absolute Encoder (Auxiliary) 2.5.1.3. Sine Wave Encoder (Auxiliary) [-MX3 Option] 2.5.2. Position Synchronized Output (PSO) 2.5.3. Digital Outputs 2.5.4. Digital Inputs 2.5.5. High-Speed Inputs 2.5.6. Analog Output 0 2.5.7.

  • Page 5: List Of Figures

    Hardware Manual iXC4e/XC4e List of Figures Figure 1-1: iXC4e Digital Drive-Based Controller Figure 1-2: XC4e Digital Drive Figure 1-3: Functional Diagram Figure 1-4: Dimensions Figure 1-5: Dimensions [-EB1] Figure 2-1: Control Supply Connections Figure 2-2: Motor Supply Connections Figure 2-3: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus)
  • Page 6 iXC4e/XC4e Hardware Manual Figure 2-44: Digital Inputs Connected to Current Sourcing Devices Figure 2-45: Digital Inputs Connected to Current Sinking Devices Figure 2-46: High-Speed Inputs Figure 2-47: Analog Output 0 Schematic Figure 2-48: Analog Input 0 Schematic Figure 2-49: Drive-Based System Wiring Drawing (Best Practice) Figure 2-50: PC-Based System Wiring Drawing (Best Practice) Figure 2-51:...

  • Page 7: List Of Tables

    Hardware Manual iXC4e/XC4e List of Tables Table 1-1: Example Order and Ordering Options Table 1-2: Electrical Specifications (Common) Table 1-3: Electrical Specifications (by Ordering Option) Table 1-4: Mounting Specifications Table 1-5: Environmental Specifications Table 1-6: Drive and Software Compatibility Table 2-1: Control Supply Connector Pinout Table 2-2: Control Supply Mating Connector Ratings...
  • Page 8 iXC4e/XC4e Hardware Manual Table 2-43: Digital Output Pins on the Auxiliary I/O Connector Table 2-44: Digital Input Specifications Table 2-45: Digital Input Pins on the Auxiliary I/O Connector Table 2-46: High-Speed Input Specifications Table 2-47: High-Speed Input Pins on the Auxiliary I/O Connector Table 2-48: Analog Output Specifications Table 2-49:...

  • Page 9: Eu Declaration Of Conformity

    Hardware Manual iXC4e/XC4e EU Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product iXC4e/XC4e 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 Low Voltage Directive...

  • Page 10: Ukca Declaration Of Conformity

    iXC4e/XC4e Hardware Manual UKCA Declaration of Conformity Manufacturer Aerotech, Inc. Address 101 Zeta Drive Pittsburgh, PA 15238-2811 Product iXC4e/XC4e Model/Types To which this declaration relates, meets the essential health and safety requirements and is in conformity with the relevant UK Legislation listed below: Electrical Equipment (Safety) Regulations 2016 Electromagnetic Compatibility Regulations 2016 Supply of Machinery (Safety) Regulations 2008...

  • Page 11: Korean Certification

    Hardware Manual iXC4e/XC4e Korean Certification Registration of Broadcasting and Communication Equipments It is verified that the foregoing equipment has been registered under the Clause 3, Article 58-2 of the radio Waves Act. www.aerotech.com...

  • Page 12: Agency Approvals

    iXC4e/XC4e Hardware Manual Agency Approvals The iXC4e/XC4e drives have been tested by the following NRTL(s) and have been certified to the standards that follow: Approval: CUS NRTL Approving Agency: TÜV SÜD America Inc. U10 068995 0033 Certificate #: CSA C22.2 No. 61010-1:2012/A1:2018-11, Standards: UL 61010-1:2012/R2019-07 N8AUS 068995 0032...

  • Page 13: Safety Procedures And Warnings

    Hardware Manual iXC4e/XC4e Safety Procedures and Warnings IMPORTANT: This manual tells you how to carefully and correctly use and operate the drive. Read all parts of this manual before you install or operate the drive or before you do main- tenance to your system.
  • Page 14 iXC4e/XC4e Hardware Manual DANGER: To decrease the risk of electrical shock, injury, death, and damage to the equipment, obey the precautions that follow. 1. Before you do maintenance to the equipment, disconnect the electrical power. 2. Restrict access to the drive when it is connected to a power source. 3.

  • Page 15: Handling And Storage

    Hardware Manual iXC4e/XC4e Handling and Storage Unpacking the drive 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 shipping container for any evidence of shipping damage. If any damage exists, notify the shipping carrier immediately.

  • Page 16: Installation Overview

    iXC4e/XC4e Hardware Manual Installation Overview The images that follow show the order in which to make connections and settings that are typical to the iXC4e/XC4e. 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 17 Hardware Manual iXC4e/XC4e Figure 2: Installation Connection Overview for the XC4e Connect the motor to the amplifier Motor Output connector. Section 2.2. Connect the motor to the amplifier Feedback connector. Section 2.3. Connect a PC or drive-based controller HyperWire port to the HyperWire In port. Section 2.7.
  • Page 18 iXC4e/XC4e Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 19: Chapter 1: Ixc4E/Xc4E Overview

    Hardware Manual iXC4e/XC4e Chapter 1: iXC4e/XC4e Overview The iXC4e is a high-performance digital drive-based controller. It runs the Automation1-iSMC controller to generate commands for itself as well as for additional drives on the chain. The XC4e is a high performance digital drive. The XC4e is based on the HyperWire communication protocol and receives commands from a PC or drive-based controller.

  • Page 20: Figure 1-2: Xc4E Digital Drive

    iXC4e/XC4e Hardware Manual Figure 1-2: XC4e Digital Drive www.aerotech.com...

  • Page 21: Feature Summary

    Hardware Manual iXC4e/XC4e 1.1. Feature Summary 100-240 VAC control supply inputs (Section 2.1.1.) 0-240 VAC motor supply inputs (producing 340 VDC) (Section 2.1.2.) 20 kHz Servo Loop Update Rate Line driver square wave quadrature encoder input for position and velocity feedback (Section 2.3.1.) Absolute Encoder support on the Feedback Connector...

  • Page 22: Ordering Options

    iXC4e/XC4e Hardware Manual 1.2. Ordering Options Table 1-1: Example Order and Ordering Options Example Automation1-iXC4e-20-EB1-MX2-PSO6-SX1 Options Automation1 Drive -XC4e Enhanced PWM Servo Drive -iXC4e Enhanced PWM Servo Drive with Motion Controller Peak Current (Section 1.4.) 10 A Peak, 5 A Continuous Current 20 A Peak, 10 A Continuous Current 30 A Peak, 10 A Continuous Current Expansion Board...

  • Page 23: Functional Block Diagram

    Hardware Manual iXC4e/XC4e 1.3. Functional Block Diagram The block diagram that follows shows a summary of the connector signals. Figure 1-3: Functional Diagram www.aerotech.com...

  • Page 24: Electrical Specifications

    iXC4e/XC4e Hardware Manual 1.4. Electrical Specifications Table 1-2: Electrical Specifications (Common) Description Specification Input Voltage 100-240 VAC (±10%) Input Frequency 50-60 Hz Inrush Current 68 A @ 240 V Control Supply Input Current 0.5 A Internal Fuse 2 A/250 V, 35 A interrupt rating, L terminal only External Breaker 20 A maximum (Type-C) Suitable for use on a circuit capable of delivering not more than...

  • Page 25: System Power Requirements

    Hardware Manual iXC4e/XC4e WARNING: Electric Shock or Fire Hazard! A fault current interruption could be the result of an open branch-circuit protective device. To reduce the risk of fire or electric shock, examine the current-carrying parts and other controller components. Replace all damaged parts. If a burnout of the current element of an overload relay occurs, you must replace the complete overload relay.

  • Page 26: Mechanical Specifications

    iXC4e/XC4e Hardware Manual 1.5. Mechanical Specifications 1.5.1. Mounting and Cooling The drive must be installed in an enclosed control cabinet suitable for installation of power equipment. A minimum enclosure rating of IP54 is required to comply with safety standards. Make sure that there is sufficient clearance surrounding the drive for free airflow and for the routing of cables and connections.

  • Page 27: Dimensions

    Hardware Manual iXC4e/XC4e 1.5.2. Dimensions IMPORTANT: iXC4e and XC4e dimensions are the same. iXC4e is shown. Figure 1-4: Dimensions www.aerotech.com...

  • Page 28: Figure 1-5: Dimensions [-Eb1]

    iXC4e/XC4e Hardware Manual IMPORTANT: iXC4e-EB1 and XC4e-EB1 dimensions are the same. iXC4e-EB1 is shown. Figure 1-5: Dimensions [-EB1] www.aerotech.com...

  • Page 29: Environmental Specifications

    Hardware Manual iXC4e/XC4e 1.6. Environmental Specifications The environmental specifications are listed below. Table 1-5: Environmental Specifications Operating: 0 °C to 40 °C (32 °F to 104 °F) Temperature Maximum Surrounding Air: 40 °C (104 °F) Storage: -30 °C to 85 °C (-22 °C 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 30 iXC4e/XC4e Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 31: Chapter 2: Installation And Configuration

    Hardware Manual iXC4e/XC4e Chapter 2: Installation and Configuration The sections in this chapter include details on how to set up the electrical and safety components of your system. Obey all safety warnings, including those in Safety Procedures and Warnings. 2.1. Input Power Connections The drive has two AC input power connectors.

  • Page 32: Motor Supply Connector

    iXC4e/XC4e Hardware Manual 2.1.2. Motor Supply Connector DANGER: Shock and Fire Hazard! Electrical wiring must be designed and installed in accordance with local electrical safety regulations to prevent the risk of fire and electrical shock. Motor power is applied to the AC1 and AC2 terminals of the Motor Supply connector. Peak Current Option -10: The AC1 input is internally connected to a 5 A fuse.

  • Page 33: Transformer Options

    Hardware Manual iXC4e/XC4e 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 34: Figure 2-3: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (40 Vdc Bus)

    iXC4e/XC4e Hardware Manual Figure 2-3: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) www.aerotech.com...

  • Page 35: Figure 2-4: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (80 Vdc Bus)

    Hardware Manual iXC4e/XC4e Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) www.aerotech.com...

  • Page 36: Figure 2-5: Tv0.3-28-56-St Transformer Control And Motor Power Wiring (160 Vdc Bus)

    iXC4e/XC4e Hardware Manual Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) www.aerotech.com...

  • Page 37: Figure 2-6: Tv0.3-28 Transformer Control And Motor Power Wiring (40 Vdc Bus)

    Hardware Manual iXC4e/XC4e Figure 2-6: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) www.aerotech.com...

  • Page 38: Figure 2-7: Tv0.3-56 Transformer Control And Motor Power Wiring (80 Vdc Bus)

    iXC4e/XC4e Hardware Manual Figure 2-7: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) www.aerotech.com...

  • Page 39: Figure 2-8: Tm3/Tm5 Transformer Control And Motor Power Wiring

    Hardware Manual iXC4e/XC4e Figure 2-8: TM3/TM5 Transformer Control and Motor Power Wiring www.aerotech.com...

  • Page 40: Minimizing Noise For Emc/Ce Compliance

    iXC4e/XC4e Hardware Manual 2.1.4. Minimizing Noise for EMC/CE Compliance IMPORTANT: The iXC4e/XC4e 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 41: Motor Power Output Connector

    Hardware Manual iXC4e/XC4e 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 drive can be used to drive the following motor types: Brushless (refer to Section...

  • Page 42: Brushless Motor Connections

    iXC4e/XC4e Hardware Manual 2.2.1. Brushless Motor Connections The configuration in Figure 2-9 shows a typical brushless motor connection. Figure 2-9: 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 Wire Color Set 4 Green/Yellow &...

  • Page 43: Brushless Motor Powered Motor And Feedback Phasing

    Hardware Manual iXC4e/XC4e 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 Figure 2-10: Positive Motor Direction...

  • Page 44: Brushless Motor Unpowered Motor And Feedback Phasing

    iXC4e/XC4e Hardware Manual 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- 12. This method will require a two-channel oscilloscope, a 5V power supply, and six resistors (10,000 ohm, 1/4 watt).

  • Page 45: Dc Brush Motor Connections

    Hardware Manual iXC4e/XC4e 2.2.2. DC Brush Motor Connections The configuration shown in Figure 2-14 is an example of a typical DC brush motor connection. Refer to Section 2.2.2.1. for information on motor phasing. Figure 2-14: DC Brush Motor Configuration Table 2-11: Wire Colors for Aerotech-Supplied DC Brush Motor Cables Wire Color Set 1 Wire Color Set 2...

  • Page 46: Stepper Motor Connections

    iXC4e/XC4e Hardware Manual 2.2.3. Stepper Motor Connections The configuration shown in Figure 2-16 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 80 V motor bus supply is needed to get 40 V across the motor.

  • Page 47: Three Phase Stepper Motor Connections

    Hardware Manual iXC4e/XC4e 2.2.4. Three Phase Stepper Motor Connections IMPORTANT: This feature is only supported in Automation1 software version 2.2.0. or later. The configuration shown in Figure 2-18 is an example of a typical three phase stepper motor connection. Refer to Section 2.2.4.1.

  • Page 48: Feedback Connector

    iXC4e/XC4e 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 Output Plug and Play Serial Data (for Aerotech stages only) Bidirectional...

  • Page 49: Primary Encoder Inputs

    Hardware Manual iXC4e/XC4e 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 drive to accept an encoder signal type. Square Wave encoder signals: Section 2.3.1.1. Absolute encoder signals: Section 2.3.1.2.

  • Page 50: Square Wave Encoder (Primary)

    iXC4e/XC4e Hardware Manual 2.3.1.1. Square Wave Encoder (Primary) The drive accepts RS-422 square wave encoder signals. The drive 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 51: Absolute Encoder (Primary)

    Hardware Manual iXC4e/XC4e 2.3.1.2. Absolute Encoder (Primary) The drive 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 2-21 for the serial data stream interface.

  • Page 52: Sine Wave Encoder (Primary) [-Mx2/-Mx3 Option]

    iXC4e/XC4e Hardware Manual 2.3.1.3. Sine Wave Encoder (Primary) [-MX2/-MX3 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. Use Encoder Tuning [A3200: Feedback Tuning] to adjust the value of the gain, offset, and phase balance controller parameters to get the best performance.

  • Page 53: Figure 2-23: Sine Wave Encoder Schematic (Feedback Connector)

    Hardware Manual iXC4e/XC4e Figure 2-23: Sine Wave Encoder Schematic (Feedback Connector) www.aerotech.com...

  • Page 54: Encoder Phasing

    iXC4e/XC4e 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 2-24 illustrates the proper encoder phasing for clockwise motor rotation (or positive forcer movement for linear motors). To verify, move the motor by hand in the CW (positive) direction while observing the position of the encoder in the diagnostics display (see Figure 2-25).

  • Page 55: Hall-Effect Inputs

    Hardware Manual iXC4e/XC4e 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" axis fault. Refer to Section 2.2.1.1.

  • Page 56: Thermistor Input

    iXC4e/XC4e 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. As the increasing temperature causes the resistance of the thermistor to increase, the sensor will trigger an over temperature fault.

  • Page 57: Encoder Fault Input

    Hardware Manual iXC4e/XC4e 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 manufacturers 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 58: End Of Travel And Home Limit Inputs

    iXC4e/XC4e 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 59: Figure 2-29: End Of Travel And Home Limit Input Connections

    Hardware Manual iXC4e/XC4e Figure 2-29: End of Travel and Home Limit Input Connections Figure 2-30: End of Travel and Home Limit Input Schematic (Feedback Connector) www.aerotech.com...

  • Page 60: End Of Travel And Home Limit Phasing

    iXC4e/XC4e 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 61: Brake Outputs

    Hardware Manual iXC4e/XC4e 2.3.6. Brake Outputs The drive 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 62: Safe Torque Off Input (Sto)

    iXC4e/XC4e 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 drive to produce motion. Each STO input is opto-isolated and accepts 24 V levels directly without the need for external current limiting resistors.

  • Page 63: Figure 2-33: Typical Sto Configuration

    Hardware Manual iXC4e/XC4e Table 2-28: 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) 50 m Figure 2-33...

  • Page 64: Sto Standards

    iXC4e/XC4e Hardware Manual 2.4.1. STO Standards Table 2-29 describes and specifies the safety requirements at the system level for the Safe Torque Off (STO) feature of the drive. This assumes that diagnostic testing is performed according to Section 2.4.4. Table 2-30. Table 2-29: STO Standards Standard...

  • Page 65: Sto Functional Description

    Hardware Manual iXC4e/XC4e 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 66: Sto Startup Validation Testing

    iXC4e/XC4e 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 2-31: STO Signal Delay Value STO Time Delay...

  • Page 67: Sto Diagnostics

    Hardware Manual iXC4e/XC4e 2.4.4. STO Diagnostics Activation of STO means removing power from the drive STO inputs. This is typically done by pressing the emergency stop switch. The drive initiates a diagnostic check every time the STO is activated after the Diagnostic Test Delay Time has elapsed.

  • Page 68: Auxiliary I/O Connector

    iXC4e/XC4e 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 2-34: Auxiliary I/O Connector Pinout Pin# Description In/Out/Bi...

  • Page 69: Auxiliary Encoder Interface

    Hardware Manual iXC4e/XC4e 2.5.1. Auxiliary Encoder Interface The Auxiliary Encoder connector gives you a second encoder channel. This channel is typically used for dual loop applications. Use the AuxiliaryFeedbackType [A3200: PositionFeedbackType or VelocityFeedbackType] parameter to configure the drive to accept an encoder signal type. Square Wave encoder signals: Section 2.5.1.1.

  • Page 70: Square Wave Encoder (Auxiliary)

    iXC4e/XC4e Hardware Manual 2.5.1.1. Square Wave Encoder (Auxiliary) The drive accepts RS-422 square wave encoder signals. The drive 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 71: Absolute Encoder (Auxiliary)

    Hardware Manual iXC4e/XC4e 2.5.1.2. Absolute Encoder (Auxiliary) The drive 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 2-36 for the serial data stream interface.

  • Page 72: Sine Wave Encoder (Auxiliary) [-Mx3 Option]

    iXC4e/XC4e Hardware Manual 2.5.1.3. Sine Wave Encoder (Auxiliary) [-MX3 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 AuxiliaryEncoderMultiplicationFactor parameter. Use Encoder Tuning [A3200: Feedback Tuning] to adjust the value of the gain, offset, and phase balance controller parameters to get the best performance.

  • Page 73: Figure 2-38: Sine Wave Encoder Schematic (Auxiliary I/O Connector)

    Hardware Manual iXC4e/XC4e Figure 2-38: Sine Wave Encoder Schematic (Auxiliary I/O Connector) www.aerotech.com...

  • Page 74: Position Synchronized Output (Pso)

    iXC4e/XC4e 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. Refer to the Help file for more information. Use the PsoOutputConfigureOutput() function [A3200: PSOOUTPUT CONTROL command] to transmit the PSO output signal on the Marker ±...

  • Page 75: Figure 2-39: Pso Interface

    Hardware Manual iXC4e/XC4e Figure 2-39: PSO Interface www.aerotech.com...

  • Page 76: Digital Outputs

    iXC4e/XC4e 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. Refer to Figure 2-41 Figure 2-42.

  • Page 77: Figure 2-40: Digital Output Schematic (Aux I/O Connector)

    Hardware Manual iXC4e/XC4e Figure 2-40: Digital Output Schematic (Aux I/O Connector) www.aerotech.com...

  • Page 78: Figure 2-41: Digital Outputs Connected In Current Sourcing Mode

    iXC4e/XC4e Hardware Manual Figure 2-41: Digital Outputs Connected in Current Sourcing Mode Figure 2-42: Digital Outputs Connected in Current Sinking Mode www.aerotech.com...

  • Page 79: Digital Inputs

    Hardware Manual iXC4e/XC4e 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 2-44 Figure 2-45. The digital inputs are not designed for high-voltage isolation applications.

  • Page 80: Figure 2-44: Digital Inputs Connected To Current Sourcing Devices

    iXC4e/XC4e Hardware Manual Figure 2-44: Digital Inputs Connected to Current Sourcing Devices Figure 2-45: Digital Inputs Connected to Current Sinking Devices www.aerotech.com...

  • Page 81: High-Speed Inputs

    Hardware Manual iXC4e/XC4e 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 82: Analog Output

    iXC4e/XC4e 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 2-48: Analog Output Specifications Specification...

  • Page 83: Analog Input 0 (Differential)

    Hardware Manual iXC4e/XC4e 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 84: Brake Power Supply Connector

    iXC4e/XC4e 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 2-52: Brake Power Supply Connector Pinout Connector Pin# Description In/Out/Bi...

  • Page 85: Hyperwire Interface

    Hardware Manual iXC4e/XC4e 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. This device consumes one of the available axes of control on the HyperWire communication network.

  • Page 86: External Shunt Option [-Sx1]

    iXC4e/XC4e Hardware Manual 2.8. External Shunt Option [-SX1] The -SX1 option provides a connection for a user-provided shunt resistor to dissipate excess energy and keep the internal drive voltage within safe levels. The drive switches this resistor "ON" when the internal bus voltage reaches approximately 380 VDC.

  • Page 87: Table 2-57: Maximum Additional Storage Energy For A Standard Ixc4E/Xc4E

    Hardware Manual iXC4e/XC4e Equation 2:   You will need a shunt resistor if the regenerated energy is greater than the Maximum Additional Storage Energy that the internal bus capacitor can store (Table 2-57). = (1/2)· C · (V Where: = bus capacitor (F) [1,200 µF] = turn on voltage for shunt circuit (V) [380 V] = nominal bus voltage (V) [160 V or 320 V, Typical] Table 2-57:...

  • Page 88: Sync Port

    iXC4e/XC4e 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. The drive contains two Sync ports, labeled A and B. To avoid signal contention, all Sync ports default to the input state during reset and immediately after power is applied to the drive.

  • Page 89: System Interconnection

    Hardware Manual iXC4e/XC4e 2.11. System Interconnection Figure 2-49: Drive-Based System Wiring Drawing (Best Practice) Figure 2-50: PC-Based System Wiring Drawing (Best Practice) www.aerotech.com...

  • Page 90: Figure 2-51: Recommended System Connections For A Drive-Based Controller

    iXC4e/XC4e Hardware Manual Figure 2-51: Recommended System Connections for a Drive-Based Controller www.aerotech.com...

  • Page 91: Figure 2-52: Recommended System Connections For A Pc-Based Controller

    Hardware Manual iXC4e/XC4e Figure 2-52: Recommended System Connections for a PC-Based Controller www.aerotech.com...

  • Page 92: Pc Configuration And Operation Information

    iXC4e/XC4e Hardware Manual 2.12. 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 93: Chapter 3: -Eb1 Option Expansion Board

    Hardware Manual iXC4e/XC4e Chapter 3: -EB1 Option Expansion 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: -EB1 I/O Option Board Connectors (iXC4e shown) www.aerotech.com...

  • Page 94: Digital Outputs [-Eb1]

    iXC4e/XC4e 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. Refer to Figure 3-3 Figure...

  • Page 95: Table 3-2: Digital Output 1 Connector Pinout [-Eb1]

    Hardware Manual iXC4e/XC4e Table 3-2: Digital Output 1 Connector Pinout [-EB1] Pin# Description In/Out/Bi Connector Output Common for Outputs 4-7 Output 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 Output 8 (Optically-Isolated) Output...

  • Page 96: Figure 3-2: Digital Outputs Schematic [-Eb1]

    iXC4e/XC4e Hardware Manual Figure 3-2: Digital Outputs Schematic [-EB1] www.aerotech.com...

  • Page 97: Figure 3-3: Digital Outputs Connected In Current Sourcing Mode [-Eb1]

    Hardware Manual iXC4e/XC4e 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 98: Digital Inputs [-Eb1]

    iXC4e/XC4e 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. To be able to connect an input group to current sourcing devices, connect the input group's common pin to the power supply return (-).

  • Page 99: Figure 3-5: Digital Inputs Schematic [-Eb1]

    Hardware Manual iXC4e/XC4e Table 3-7: Digital Input 2 Connector Pinout [-EB1] Pin# Description In/Out/Bi Connector Input Common for Inputs 12-15 Output 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 Output Input 16 (Optically-Isolated) Input...

  • Page 100: Figure 3-6: Digital Inputs Connected To Current Sourcing (Pnp) Devices [-Eb1]

    iXC4e/XC4e 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 101: Analog Outputs [-Eb1]

    Hardware Manual iXC4e/XC4e 3.3. Analog Outputs [-EB1] The analog outputs can be set from within a program or they can be configured to echo the state of select servo loop nodes. The analog outputs are set to zero when you power on the system or reset the drive. Table 3-9: Analog Output Specifications [-EB1] Specification...

  • Page 102: Analog Inputs [-Eb1]

    iXC4e/XC4e 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 103: Pso Interface [-Eb1]

    Hardware Manual iXC4e/XC4e 3.5. PSO Interface [-EB1] The Position Synchronized Output (PSO) 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. Table 3-15: PSO Specifications [-EB1] Specification...

  • Page 104: Figure 3-10: Pso Output Sources Current

    iXC4e/XC4e 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 105: Chapter 4: Cables And Accessories

    Hardware Manual iXC4e/XC4e Chapter 4: Cables and Accessories Table 4-1: Standard Interconnection Cables Cable Part # Description Joystick Refer to Section 4.1. HyperWire Refer to Section 2.7. ECZ01231 BBA32 Interconnect Cable (1, 2) ENET-CAT5e-xx Ethernet CAT5e Cable (1, 2, 3) USB-AMCM-xx USB Cable A-Male to C-Male (1) The "-xx"...

  • Page 106: Joystick Interface

    iXC4e/XC4e 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 107: Figure 4-2: Two Axis Joystick Interface (To The I/O Board)

    Hardware Manual iXC4e/XC4e Figure 4-2: Two Axis Joystick Interface (to the I/O board) www.aerotech.com...

  • Page 108: Handwheel Interface

    iXC4e/XC4e 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 drive. IMPORTANT: You can find instructions on how to enable the handwheel in the online Help file.

  • Page 109: Chapter 5: Maintenance

    Hardware Manual iXC4e/XC4e Chapter 5: Maintenance IMPORTANT: For your own safety and for the safety of the equipment: Do not remove the cover of the iXC4e/XC4e. 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 110: Preventative Maintenance

    iXC4e/XC4e Hardware Manual 5.1. Preventative Maintenance Do an inspection of the iXC4e/XC4e 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. Table 5-3: Preventative Maintenance Check...

  • Page 111: Fuse Specifications

    Hardware Manual iXC4e/XC4e 5.2. Fuse Specifications WARNING: Replace fuses only with the same type and value. Table 5-4: Control Board Fuse Specifications Aerotech Third Party SCCR Fuse Description Size Littelfuse F100 Control Power at Line Input (L) 2 A S.B. 35 A EIF01044 0877002.MXEP...
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  • Page 113: Appendix A: Warranty And Field Service

    Hardware Manual iXC4e/XC4e 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 114 iXC4e/XC4e 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 115: Appendix B: Revision History

    Hardware Manual iXC4e/XC4e Appendix B: Revision History Revision Description Updated: Agency Approvals (Agency Approvals) 2.14 Feature Summary (Section 1.1.) Table 5-1 (red power description) 2.13 Update to Section 1.4. Electrical Specifications New: Korean Certification Updated: 2.12 Agency Approvals Section 1.4. Electrical Specifications Section 2.4.
  • Page 116 iXC4e/XC4e Hardware Manual This page intentionally left blank. www.aerotech.com...

  • Page 117: Index

    iXC4e/XC4e Hardware Manual Index Index Analog Input Connector [-EB1] Mating Connector Part Numbers Analog Input Connector Pinout [-EB1] Analog Input Pins (Aux I/O Connector) Analog Input Typical Connection [-EB1] -EB1 Analog Inputs [-EB1] Analog Inputs Analog Output 0 on the Aux I/O Connector Analog Outputs Analog Output 0 Schematic (Aux I/O Connector) Digital Inputs...
  • Page 118 Index iXC4e/XC4e Hardware Manual Brake Outputs (Feedback Connector) Digital Input 1 Connector Pinout [-EB1] Brake Power Supply Connector Digital Input 2 Connector [-EB1] Mating Connector Part Numbers Brake Power Supply Connector Mating Connector Part Numbers Digital Input 2 Connector Pinout [-EB1] Brushless Motor Configuration (Motor Power Output Digital Input Pins on the Aux I/O Connector Connector)
  • Page 119 iXC4e/XC4e Hardware Manual Index Electrical Specifications Pinout Minimum Load Inductance Primary Encoder Motor Type RS-422 Line Driver Encoder Power Amplifier Bandwidth Square Wave Encoder PWM Switching Frequency Thermistor Input SCCR Travel Limit Input User Power Supply Output Feedback Monitoring Electromagnetic Compatibility (EMC) Figure EMC/CE Compliance -EB1 I/O Option Board Connectors...
  • Page 120 Index iXC4e/XC4e Hardware Manual Motor Supply Connections Outputs Connected in Current Sinking Mode [-IO] I/O Option Board [-EB1] Outputs Connected in Current Sourcing Mode [-EB1] Input Power Connections Positive Motor Direction inspecting cooling vents PSO Isolated Output Sinks Current Inspection PSO Isolated Output Sources Current Installation and Configuration PSO TTL Outputs Schematic...
  • Page 121 iXC4e/XC4e Hardware Manual Index Minimum Load Inductance specifications 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 Control Supply Connector Wiring Motor Power Output Connector Digital Input 1 Connector [-EB1] Brushless Motor Connections Digital Input 2 Connector [-EB1]...

  • Page 122: Table 2-37: Square Wave Encoder Specifications

    Index iXC4e/XC4e Hardware Manual PSO Tracking Sine Wave Encoder (Feedback Connector) Sync Port Square Wave Encoder (Feedback Connector) 50,70 PWM Switching Frequency specifications STO Electrical Specifications Unit Weight Square Wave Encoder Square Wave Encoder (Auxiliary I/O Connector) Real-Time Clock Requirements Square Wave Encoder Inputs Schematic (Aux I/O Connector)70 Revision History Square Wave Encoder Schematic (Feedback Connector)
  • Page 123 iXC4e/XC4e Hardware Manual Index Three Phase Stepper Motor Connections (Motor Power Output Connector) Transformer Options Travel Limit Input (Feedback Connector) TTL Outputs Schematic (PSO) TV0.3-28 TV0.3-28-56-ST Transformer TV0.3-28-56-ST Transformer (160 VDC Bus) TV0.3-28-56-ST Transformer (40 VDC Bus) TV0.3-28-56-ST Transformer (80 VDC Bus) TV0.3-28 Transformer (40 VDC Bus) TV0.3-56 TV0.3-56 Transformer (80 VDC Bus)
  • Page 124 Index iXC4e/XC4e Hardware Manual This page intentionally left blank. www.aerotech.com...

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