XC4E

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Revision:1.02.00 XC4eHARDWARE MANUAL

Gotowww.aerotech.com/global-technical-supportforinformationandsupportaboutyourAerotech,Inc.products.The websitesuppliessoftware,productmanuals,Helpfiles,trainingschedules,andPC-to-PCremotetechnicalsupport.If necessary,youcancompleteProductReturn(RMA)formsandgetinformationaboutrepairsandspareorreplacementparts. Togethelpimmediately,contactaserviceofficeoryoursalesrepresentative.Includeyourcustomerordernumberinyour emailorhaveitavailablebeforeyoucall. UnitedStates(WorldHeadquarters) Email:Support@aerotech.com Phone:+1-412-967-6440 101ZetaDrive Pittsburgh,PA15238-2811 www.aerotech.com UnitedKingdom China Email:Support@aerotech.com Phone:+44(0)1256855055 Fax:+44(0)1256855649 Email:Support@aerotech.com Phone:+86(21)55086731 Germany Taiwan Email:Support@aerotech.com Phone:+49(0)9119679370 Fax:+49(0)91196793720 Email:Support@aerotech.com Phone:+886(0)287516690 France Email:Support@aerotech.com Phone:+33237218765 Thismanualcontainsproprietaryinformationandmaynotbereproduced,disclosed,orusedinwholeorinpartwithoutthe expresswrittenpermissionofAerotech,Inc.Productnamesmentionedhereinareusedforidentificationpurposesonlyand maybetrademarksoftheirrespectivecompanies. Copyright©2018-2020,Aerotech,Inc.,Allrightsreserved.

XC4eHardwareManual TableofContents TableofContents XC4eHARDWARE MANUAL 1 TableofContents 3 ListofFigures 5 ListofTables 7 EUDeclarationofConformity 9 AgencyApprovals 11 SafetyProceduresandWarnings 13 QuickInstallationGuide 15 Chapter1:Introduction 17 1.1.ElectricalSpecifications 20 1.1.1.SystemPowerRequirements 21 1.2.MechanicalSpecifications 22 1.2.1.MountingandCooling 22 1.2.2.Dimensions 23 1.3.EnvironmentalSpecifications 25 1.4.DriveandSoftwareCompatibility 26 Chapter2:InstallationandConfiguration 27 2.1.InputPowerConnections 27 2.1.1.ControlSupplyConnector 27 2.1.2.MotorSupplyConnector 28 2.1.3.TransformerOptions 29 2.1.4.MinimizingConducted, Radiated,andSystemNoiseforEMC/CE Compliance36 2.2.MotorPowerOutputConnector 37 2.2.1.BrushlessMotorConnections 38 2.2.1.1.BrushlessMotorPoweredMotorandFeedbackPhasing 39 2.2.1.2.BrushlessMotorUnpoweredMotorandFeedbackPhasing 40 2.2.2.DC BrushMotorConnections 41 2.2.2.1.DCBrushMotorPhasing 42 2.2.3.StepperMotorConnections 43 2.2.3.1.StepperMotorPhasing 44 2.3.FeedbackConnector 45 2.3.1.PrimaryEncoderInputs 46 2.3.1.1.SquareWave Encoder 47 2.3.1.2.AbsoluteEncoder 48 2.3.1.3.SineWaveEncoder[-MX2/-MX3Option] 49 2.3.1.4.EncoderPhasing 51 2.3.2.Hall-EffectInputs 53 2.3.3.ThermistorInput 54 2.3.4.EncoderFaultInput 55 2.3.5.EndofTravelandHomeLimitInputs 56 2.3.5.1.EndofTravelandHomeLimitPhasing 58 2.3.6.BrakeOutputs 59 2.4.SafeTorqueOffInput(STO) 60 2.4.1.STO Standards 62 2.4.2.STOFunctionalDescription 62 2.4.3.STOStartupValidationTesting 63 2.4.4.STODiagnostics 64 2.5.AuxiliaryI/OConnector 65 2.5.1.AuxiliaryEncoderInputs 66 www.aerotech.com 3

TableofContents XC4eHardwareManual 2.5.2.PositionSynchronizedOutput(PSO) 68 2.5.3.DigitalOutputs 70 2.5.4.DigitalInputs 73 2.5.5.High-SpeedInputs20-21 75 2.5.6.AnalogOutput0 76 2.5.7.AnalogInput0(Differential) 77 2.6.BrakePowerSupplyConnector 78 2.7.HyperWireInterface 79 2.8.ExternalShuntOption[-SX1] 80 2.9.SyncPort 82 2.10.SystemInterconnection 83 2.11.PCConfigurationandOperationInformation 84 Chapter3:-EB1I/OOptionBoard 85 3.1.DigitalOutputs[-EB1] 86 3.2.DigitalInputs[-EB1] 90 3.3.AnalogOutputs[-EB1] 93 3.4.AnalogInputs[-EB1] 94 3.5.PositionSynchronizedOutput(PSO)Interface[-EB1] 95 Chapter4:CablesandAccessories 97 4.1.JoystickInterface 98 4.2.HandwheelInterface 100 Chapter5:Maintenance 101 5.1.PreventativeMaintenance 101 5.2.FuseSpecifications 102 AppendixA:WarrantyandFieldService 103 AppendixB:RevisionHistory 105 Index 107 4 www.aerotech.com

XC4eHardwareManual ListofFigures ListofFigures Figure1-1: XC4eNetworkedDigitalDrive 17 Figure1-2: FunctionalDiagram 19 Figure1-3: Dimensions 23 Figure1-4: Dimensions[-EB1] 24 Figure2-1: ControlSupplyConnections 27 Figure2-2: MotorSupplyConnections 28 Figure2-3: TransformerExamples 29 Figure2-4: TV0.3-28-56-STTransformerControlandMotorPowerWiring(40VDCBus) 30 Figure2-5: TV0.3-28-56-STTransformerControlandMotorPowerWiring(80VDCBus) 31 Figure2-6: TV0.3-28-56-STTransformerControlandMotorPowerWiring(160VDCBus) 32 Figure2-7: TV0.3-28TransformerControlandMotorPowerWiring(40VDCBus) 33 Figure2-8: TV0.3-56TransformerControlandMotorPowerWiring(80VDCBus) 34 Figure2-9: TM3/TM5TransformerControlandMotorPowerWiring 35 Figure2-10: BrushlessMotorConfiguration 38 Figure2-11: PositiveMotorDirection 39 Figure2-12: EncoderandHallSignalDiagnostics 39 Figure2-13: BrushlessMotorPhasingOscilloscopeExample 40 Figure2-14: BrushlessMotorPhasingGoal 40 Figure2-15: DCBrushMotorConfiguration 41 Figure2-16: PositiveMotorDirection 42 Figure2-17: StepperMotorConfiguration 43 Figure2-18: PositiveMotorDirection 44 Figure2-19: SquareWaveEncoderSchematic(FeedbackConnector) 47 Figure2-20: AbsoluteEncoderSchematic(FeedbackConnector) 48 Figure2-21: AnalogEncoderPhasingReferenceDiagram 49 Figure2-22: AnalogEncoderSchematic(FeedbackConnector) 50 Figure2-23: EncoderPhasingReferenceDiagram(Standard) 51 Figure2-24: PositionFeedbackintheDiagnostic Display 52 Figure2-25: Hall-EffectInputsSchematic(FeedbackConnector) 53 Figure2-26: ThermistorInputSchematic(FeedbackConnector) 54 Figure2-27: EncoderFaultInputSchematic(FeedbackConnector) 55 Figure2-28: EndofTravelandHomeLimitInputConnections 57 Figure2-29: EndofTravelandHomeLimitInputSchematic(FeedbackConnector) 57 Figure2-30: EndofTravelandHomeLimitInputDiagnosticDisplay 58 Figure2-31: BrakeConnectedtothe25-PinFeedbackConnector(Typical) 59 Figure2-32: TypicalConfiguration 61 Figure2-33: STOTiming 64 Figure2-34: AuxiliaryEncoderInputSchematic(AuxI/O Connector) 67 Figure2-35: PSO Interface 69 Figure2-36: DigitalOutputSchematic(AuxI/O Connector) 71 Figure2-37: DigitalOutputsConnectedinCurrentSourcingMode 72 Figure2-38: DigitalOutputsConnectedinCurrentSinkingMode 72 Figure2-39: DigitalInputsSchematic(AuxI/O Connector) 73 Figure2-40: DigitalInputsConnectedtoCurrentSinkingDevices 74 Figure2-41: DigitalInputsConnectedtoCurrentSourcingDevices 74 Figure2-42: High-SpeedInputs 75 Figure2-43: AnalogOutput0Schematic 76 Figure2-44: AnalogInput0Schematic 77 Figure2-45: SystemInterconnectionDrawing(BestPractice) 83 Figure3-1: XC4ewith-EB1I/OOptionBoardConnectors 85 Figure3-2: DigitalOutputsSchematic[-EB1] 88 www.aerotech.com 5

ListofFigures XC4eHardwareManual Figure3-3: DigitalOutputsConnectedinCurrentSourcingMode[-EB1] 89 Figure3-4: DigitalOutputsConnectedinCurrentSinkingMode[-EB1] 89 Figure3-5: DigitalInputsSchematic[-EB1] 91 Figure3-6: DigitalInputsConnectedtoCurrentSourcing(PNP)Devices[-EB1] 92 Figure3-7: DigitalInputsConnectedtoCurrentSinking(NPN)Devices[-EB1] 92 Figure3-8: AnalogOutputTypicalConnection[-EB1] 93 Figure3-9: AnalogInputTypicalConnection[-EB1] 94 Figure3-10: PSOOutputSourcesCurrent 96 Figure3-11: PSO OutputSinksCurrent 96 Figure3-12: PSOTTL OutputsSchematic 96 Figure4-1: TwoAxisJoystickInterface(totheAuxI/Ooftwodrives) 98 Figure4-2: TwoAxisJoystickInterface(totheI/O board) 99 Figure4-3: HandwheelInterconnectiontoAuxI/OConnector 100 Figure4-4: HandwheelInterconnectiontotheAuxI/OthroughaBBA32Module 100 6 www.aerotech.com

XC4eHardwareManual ListofTables ListofTables Table1-1: Features andOptions 18 Table1-2: ElectricalSpecifications 20 Table1-3: MountingSpecifications 22 Table1-4: EnvironmentalSpecifications 25 Table1-5: DriveandSoftwareCompatibility 26 Table2-1: ControlSupplyWiringSpecifications 27 Table2-2: MatingConnectorPartNumbersfortheControlSupplyConnector 27 Table2-3: MotorSupplyConnectorWiringSpecifications 28 Table2-4: MatingConnectorPartNumbersfortheMotorSupplyConnector 28 Table2-5: NominalMotorOperatingVoltages/RequiredAC Voltages 29 Table2-6: Transformer Options 29 Table2-7: MotorPowerOutputConnectorPinout 37 Table2-8: MatingConnectorPartNumbersfortheMotorPowerOutputConnector 37 Table2-9: WireColorsforAerotech-SuppliedBrushlessMotorCables 38 Table2-10: WireColorsforAerotech-SuppliedDC BrushMotorCables 41 Table2-11: WireColorsforAerotech-SuppliedStepperMotorCables 43 Table2-12: FeedbackConnectorPinout 45 Table2-13: MatingConnectorPartNumbersfortheFeedbackConnector 45 Table2-14: MultiplierOptions 46 Table2-15: PrimaryEncoderInputPinsontheFeedbackConnector 46 Table2-16: SquareWaveEncoderSpecifications 47 Table2-17: AnalogEncoderSpecifications 49 Table2-18: Hall-EffectFeedbackPinsontheFeedbackConnector 53 Table2-19: ThermistorInputPinontheFeedbackConnector 54 Table2-20: EncoderFaultInputPinontheFeedbackConnector 55 Table2-21: EndofTravelandHomeLimitPinsontheFeedbackConnector 56 Table2-22: BrakeOutputPinsontheFeedbackConnector 59 Table2-23: BrakeControlSpecifications 59 Table2-24: STOConnectorPinout 60 Table2-25: MatingConnectorPartNumbersfortheSTO Connector 60 Table2-26: STO ElectricalSpecifications 60 Table2-27: STO Standards 62 Table2-28: STO StandardsData 62 Table2-29: STO SignalDelay 63 Table2-30: MotorFunctionRelativetoSTO InputState 63 Table2-31: STO Timing 64 Table2-32: AuxiliaryI/OConnectorPinout 65 Table2-33: MatingConnectorPartNumbersfortheAuxiliaryI/O Connector 65 Table2-34: SquareWaveEncoderSpecifications(AuxiliaryEncoder) 66 Table2-35: SineWaveEncoderSpecifications(AuxiliaryEncoder) 66 Table2-36: AuxiliaryEncoderPinsontheAuxiliaryI/O Connector 66 Table2-37: PSOSpecifications 68 Table2-38: PSO PinsontheAuxiliaryI/O Connector 68 Table2-39: DigitalOutputSpecifications 70 Table2-40: DigitalOutputPinsontheAuxiliaryI/OConnector 70 Table2-41: DigitalInputSpecifications 73 Table2-42: DigitalInputPinsontheAuxiliaryI/OConnector 73 Table2-43: High-SpeedInputSpecifications 75 Table2-44: High-SpeedInputPinsontheAuxiliaryI/OConnector 75 Table2-45: AnalogOutputSpecifications 76 Table2-46: AnalogOutputPinsontheAuxiliaryI/OConnector 76 www.aerotech.com 7

ListofTables XC4eHardwareManual Table2-47: AnalogInputSpecifications 77 Table2-48: AnalogInputPinsontheAuxiliaryI/OConnector 77 Table2-49: BrakePowerSupplyConnectorPinout 78 Table2-50: MatingConnectorPartNumbersfortheBrakePowerSupplyConnector 78 Table2-51: HyperWireCardPartNumber 79 Table2-52: HyperWireCablePartNumbers 79 Table2-53: -SX1 ComponentInformation 80 Table2-54: MaximumAdditionalStorageEnergy 81 Table2-55: Sync-RelatedCommands 82 Table2-56: Sync PortCables 82 Table3-1: DigitalOutputSpecifications[-EB1] 86 Table3-2: DigitalOutput1ConnectorPinout[-EB1] 87 Table3-3: MatingConnectorPartNumbersfortheDigitalOutput1Connector[-EB1] 87 Table3-4: DigitalOutput2ConnectorPinout[-EB1] 87 Table3-5: MatingConnectorPartNumbersfortheDigitalOutput2Connector[-EB1] 87 Table3-6: DigitalInputSpecifications[-EB1] 90 Table3-7: DigitalInput1ConnectorPinout[-EB1] 90 Table3-8: MatingConnectorPartNumbersfortheDigitalInput1Connector[-EB1] 90 Table3-9: DigitalInput2ConnectorPinout[-EB1] 91 Table3-10: MatingConnectorPartNumbersfortheDigitalInput2Connector[-EB1] 91 Table3-11: AnalogOutputSpecifications[-EB1] 93 Table3-12: AnalogOutputConnectorPinout[-EB1] 93 Table3-13: MatingConnectorPartNumbersfortheAnalogOutputConnector[-EB1] 93 Table3-14: DifferentialAnalogInputSpecifications[-EB1] 94 Table3-15: AnalogInputConnectorPinout[-EB1] 94 Table3-16: MatingConnectorPartNumbersfortheAnalogInputConnector[-EB1] 94 Table3-17: PSOSpecifications[-EB1] 95 Table3-18: PSOInterfaceConnectorPinout[-EB1] 95 Table3-19: MatingConnectorPartNumbersforthePSOInterfaceConnector[-EB1] 95 Table4-1: StandardInterconnectionCables 97 Table5-1: PreventativeMaintenance 101 Table5-2: ControlBoardFuseSpecifications 102 8 www.aerotech.com

XC4eHardwareManual EUDeclarationofConformity EUDeclarationofConformity Manufacturer Aerotech,Inc. Address 101ZetaDrive Pittsburgh,PA15238-2811 USA Product XC4e Model/Types All Thisistocertifythattheaforementionedproductisinaccordancewiththeapplicablerequirementsofthe followingDirective(s): 2014/30/EU ElectromagneticCompatibility(EMC) 2014/35/EU LowVoltageDirective 2006/42/EC MachineryDirective EU2015/863 RoHS 3Directive andhasbeendesignedtobeinconformitywiththeapplicablerequirementsofthefollowingStandard(s) wheninstalledandusedinaccordancewiththemanufacturer’ssuppliedinstallationinstructions. EN61326-1:2013 EMC RequirementsforElectricalEquipment EN61010-1:2010/A1:2019 SafetyRequirementsforElectricalEquipment ENISO13849-1:2015 Safety RelatedPartsofControlSystems AuthorizedRepresentative:SimonSmith,EuropeanDirector Address: AerotechLtd TheOldBrickKiln,Ramsdell,Tadley HampshireRG265PR UK Name /AlexWeibel Position EngineerVerifyingCompliance Location Pittsburgh,PA Date 4/27/2020 www.aerotech.com 9

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XC4eHardwareManual AgencyApprovals AgencyApprovals AerotechtesteditsXC4edrivesandfoundthattheyobeythestandardsthatfollow: Approval/Certification:CUSNRTL ApprovingAgency: TUVSUDAmericaInc. Certificate#: U8V0689950028Rev.02 Standards: CAN/CSA-C22.2No.61010-1:2012/U2:2016-04;EN61010- 1:2010/A1:2019;UL61010-1:2012/R:2016-04 Approval: SafetyComponents(STO) ApprovingAgency: TUV SUD Certificate#: Z100689950030Rev.00 Standards: IEC 61508-1:2010(uptoSIL 3) Visithttps://www.tuev-sued.de/product-testing/certificatestoviewAerotech'sTÜVSÜDcertificates.Type thecertificatenumberlistedaboveinthesearchbarortype"Aerotech"foralistofallAerotechcertificates. www.aerotech.com 11

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XC4eHardwareManual SafetyProceduresandWarnings SafetyProceduresandWarnings ThismanualtellsyouhowtocarefullyandcorrectlyuseandoperatetheXC4e.Readallpartsofthismanual beforeyouinstalloroperatetheXC4eorbeforeyoudomaintenancetoyoursystem.Topreventinjurytoyou anddamagetotheequipment,obeytheprecautionsinthismanual.Theprecautionsthatfollowapplywhen youseeaDangerorWarningsymbolinthismanual.Ifyoudonotobeytheseprecautions,injurytoyouor damagetotheequipmentcanoccur.Ifyoudonotunderstandtheinformationinthismanual,contact AerotechGlobalTechnicalSupport. Thisproducthasbeendesignedforlightindustrialmanufacturingorlaboratoryenvironments.Theprotection providedbytheequipmentcouldbeimpairediftheproductisusedinamannernotspecifiedbythe manufacturer. NOTE:Allspecificationsandillustrationsareforreferenceonlyandwerecompleteandaccurateasofthe releaseofthismanual.Tofindthenewestinformationaboutthisproduct,refertowww.aerotech.com. DANGER:Thevoltagefromthisproductcankillyou.Todecreasetheriskofelectricalshock,injury,anddeath,youmustobeytheprecautionsthatfollow. 1. Beforeyoudomaintenancetotheequipment,disconnecttheelectricalpower. 2. Waitatleastten(10)minutesafterremovingthepowersupplybeforedoingmaintenanceor aninspection.Otherwise,thereisthedangerofelectricshock. 3. Beforeyouconnectwirestothisproduct,disconnecttheelectricalpower. 4. Todecreasetheriskofelectricalshockandinjury,youmustsupplyoperatorswiththe necessaryprecautionsandprotectionfromliveelectricalcircuits. 5. Whilethedriveisconnectedtoapowersource,donotconnectordisconnectelectrical componentsandcables. 6. Makesurethatallcomponentsaregroundedcorrectlyandthattheyobeythelocalelectrical safetyrequirements. 7. Makesurethatyouinstallthenecessaryprecautionstosupplysafetyandprotectiontothe operator. 8. Movingpartscancausecrushingorshearinginjuries.Youmustlimitaccesstoallmotorand stagepartswhileyoursystemisconnectedtoapowersource. WARNING:Topreventdamagetotheequipmentanddecreasetheriskofelectricalshock,injury,anddeath,youmustobeytheprecautionsthatfollow. 1. Makesurethatallsystemcablesarecorrectlyattachedandpositioned. 2. Usethisproductonlyinenvironmentsandoperatingconditionsthatareapprovedinthis manual. 3. Onlyoperatorswhohavereceivedtrainingcanoperatethisequipment.Allservicingand maintenancemustbedoneonlybyapprovedpersonnel. www.aerotech.com 13

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XC4eHardwareManual QuickInstallationGuide QuickInstallationGuide ThisimageshowstheorderinwhichtomakeconnectionsandsettingsthataretypicaltotheXC4e.Ifa custominterconnectdrawingwassuppliedwithyoursystem,thatdrawingisonyourStorageDeviceand showsasalineitemonyourSalesOrderintheIntegrationsection. MotorandFeedback Connections Section2.2.MotorPowerOutputConnectorandSection2.3.Feedback Connector HyperWire Section2.7.HyperWireInterface Digital/AnalogI/O Section2.5.AuxiliaryI/OConnectorandChapter3:-EB1I/OOptionBoard(ifyou purchasedtheI/Ooption) STO Section2.4.SafeTorqueOffInput(STO) ControlSupply Section2.1.1.ControlSupplyConnector MotorSupply Section2.1.2.MotorSupplyConnector Figure1: QuickStartConnections www.aerotech.com 15

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XC4eHardwareManual Chapter1:Introduction Chapter1:Introduction TheXC4eisahighperformancedigitaldrivebasedontheHyperWirecommunicationprotocol.Thedrive providesdeterministicbehavior,auto-identification,isfullysoftwareconfigurable.Adoubleprecisionfloating pointDSPcontrolsthedigitalPIDandcurrentloopsintheXC4e. TheXC4eoffersstandardSafeTorqueOff(STO)inputsandoptionalPositionSynchronizedOutput(PSO) outputs.TheXC4eisofferedwithoptionalencoderinterpolationfeatures(-MX2/-MX3),anauxiliaryencoder inputfordualloopcontrol,dedicatedanaloganddigitalI/O(expandablewiththe-EB1option),andseparate powerconnectionsformotorandcontrolsupplyvoltages. Figure1-1: XC4eNetworkedDigitalDrive www.aerotech.com 17

Chapter1:Introduction XC4eHardwareManual Table1-1: Features andOptions StandardFeatures l 100-240VACcontrolsupplyinputs Section2.1.1. l 0-240VACmotorsupplyinputs(producing340VDC) Section2.1.2. l Linedriversquarewavequadratureencoderinputforpositionandvelocityfeedback Section2.3.1. l AbsoluteEncodersupport Section2.3.1.2. l Onefail-safebrake Section2.3.6. l TwoSTO senseinputs Section2.4. l LinedriversquarewaveauxiliaryquadratureencoderinputoroutputforPSO Section2.5.1. l Fourdigitaluseroutputs Section2.5.3. l Sixdigitaluserinputs n FourDigitalInputs Section2.5.4. n TwoHigh-SpeedInputs Section2.5.5. l One16-bitanalogoutput(±10V) Section2.5.6. l One16-bitdifferentialanaloginput(± 10V) Section2.5.7. Options PeakCurrent Section1.1. -10 10APeak,5AContinuousCurrent -20 20APeak,10AContinuousCurrent -30 30APeak,10AContinuousCurrent ExpansionBoard Chapter3 -EB0 Noexpansionboard -EB1 I/O expansionboard l Three16-bitanalogoutputs(±10V) l Three16-bitdifferentialanaloginputs(±10V) l 16digitallogicinputs(5-24VDC),canbeconnectedtocurrentsourcingorsinking devices l 16digitallogicoutputs(5-24VDC),userdefinedascurrentsourcingorsinking l Digitallogiclaserfiring(PSO)output Multiplier Section2.3.1.3. -MX0 Noencodermultiplier -MX2 Interpolationcircuitallowingforanalogsinewaveinputontheprimaryencoderchannelwith aninterpolationfactorof65,536 -MX3 Interpolationcircuitallowingforanalogsinewaveinputontheprimaryencoderchannelwith aninterpolationfactorof65,536andanauxiliaryencoderchannelwithaninterpolationfactor of16,384. PSO Section2.5.2. -PSO1 One-axisPSOfiring -PSO2 Two-axisPSOfiring -PSO3 Three-axisPSOfiring -PSO5 Two-axispart-speedPSOfiring -PSO6 Three-axispart-speedPSOfiring ExternalShunt Section2.8. -SX0 NoconnectorfortheExternalShunt -SX1 Connectionprovidedforanexternalshuntresistornetwork Version -DEFAULT FirmwareMatchesSoftwareLine -LEGACY LegacyFirmwareVersionX.XX.XXX 18 www.aerotech.com

XC4eHardwareManual Chapter1:Introduction Theblockdiagramthatfollowsshowsasummaryoftheconnectorsignals. Figure1-2: FunctionalDiagram www.aerotech.com 19

Chapter1:Introduction XC4eHardwareManual 1.1.ElectricalSpecifications Table1-2: ElectricalSpecifications Description XC4e10 XC4e20 XC4e30 MotorSupply InputVoltage 0-240VAC InputFrequency 50-60Hz InrushCurrent 65A MaxContinuous InputCurrent 5Arms 10Arms 10Arms InputCurrent RefertoSection1.1.1.SystemPowerRequirements ControlSupply InputVoltage 100-240VAC InputFrequency 50-60Hz InrushCurrent TBD InputPower 10W OutputVoltage(1) 340VDC PeakOutputCurrent(1second)(3) 10A 20A 30A ContinuousOutputCurrent(3) 5A 10A 10A PowerAmplifierBandwidth 2500Hzmaximum(softwareselectable) PowerAmplifierEfficiency 85%-95%(2) PWMSwitchingFrequency 20kHz MinimumLoadInductance 0.1mH@ 160VDC(1mH@320VDC) UserPowerSupplyOutput 5VDC(@500mA) ModesofOperation Brushless;Brush;Stepper ProtectiveFeatures Outputshortcircuit;Peakovercurrent;DCbusovervoltage; RMSovercurrent;Overtemperature;Controlpowersupply undervoltage;Powerstagebiassupplyundervoltage Isolation Opticalandtransformerisolationbetweencontrolandpower stages. (1)ACinputvoltageandloaddependent. (2)Dependentontotaloutputpower:efficiencyincreaseswithincreasingoutputpower. (3)Currentismeasuredasthepeakamplitudeinanymotorphase 20 www.aerotech.com

XC4eHardwareManual Chapter1:Introduction 1.1.1.SystemPowerRequirements Thefollowingequationscanbeusedtodeterminetotalsystempowerrequirements.Theactualpower requiredfromthemainssupplywillbethecombinationofactualmotorpower(work),motorresistance losses,andefficiencylossesinthepowerelectronicsorpowertransformer. UseanEfficiencyFactorofapproximately90%inthefollowingequations. BrushlessMotor OutputPower RotaryMotors PowerOutput[W]=Torque[N·m]*Angularvelocity[rad/sec] LinearMotors PowerOutput[W]=Force[N]*Linearvelocity[m/sec] RotaryorLinearMotors PowerOutput[W]=Bemf[V]*I(rms)*3 PowerLoss=3*I(rms)^2*R(line-line)/2 PowerInput=(PowerOutput+PowerLoss)/EfficiencyFactor DCBrushMotor PowerOutput[W]=Torque[N·m]*Angularvelocity[rad/sec] PowerLoss=I(rms)^2*R PowerInput=(Pout+Ploss)/EfficiencyFactor www.aerotech.com 21

Chapter1:Introduction XC4eHardwareManual 1.2.MechanicalSpecifications 1.2.1.MountingandCooling InstalltheXC4einanIP54compliantenclosuretocomplywithsafetystandards.Makesurethatthereis sufficientclearancesurroundingthedriveforfreeairflowandforthecablesandconnections. Table1-3: MountingSpecifications XC4e Enclosure IP54Compliant Weight ~2.36kg MountingHardware M4[#8]screws(fourlocations,notincluded) MountingOrientation Vertical(typical) Dimensions RefertoSection1.2.2.Dimensions MinimumClearance Airflow ~25mm Connectors ~100mm OperatingTemperature RefertoSection1.3.EnvironmentalSpecifications 22 www.aerotech.com

XC4eHardwareManual Chapter1:Introduction 1.2.2.Dimensions Figure1-3: Dimensions www.aerotech.com 23

Chapter1:Introduction XC4eHardwareManual Figure1-4: Dimensions[-EB1] 24 www.aerotech.com

XC4eHardwareManual Chapter1:Introduction 1.3.EnvironmentalSpecifications Table1-4: EnvironmentalSpecifications AmbientTemperatureOperating:0°to40°C(32°to104°F) Storage:-30°to85°C(-22°to185°F) Humidity Non-condensing Themaximumrelativehumidityis80%fortemperaturesthatareless than31°Canddecreaseslinearlyto50%relativehumidityat40°C. OperatingAltitude 0mto2,000m(0ftto6,562ft)abovesealevel. Ifyoumustoperatethisproductabove2,000morbelowsealevel, contactAerotech,Inc. Pollution PollutionDegree2 Typicallyonlynonconductivepollutionoccurs. Operation Useonlyindoors www.aerotech.com 25

Chapter1:Introduction XC4eHardwareManual 1.4.DriveandSoftwareCompatibility Thistableshowstheavailabledrivesandwhichversionofthesoftwarefirstsupportedeachdrive.Inthe LastSoftwareVersioncolumn,drivesthatshowaspecificversionnumberarenotsupportedafterthat version. Table1-5: DriveandSoftwareCompatibility DriveType FirmwareRevision FirstSoftwareVersion LastSoftwareVersion XC4e - 6.04.000 Current 26 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Chapter2:InstallationandConfiguration 2.1.InputPowerConnections TheXC4ehastwoAC inputpowerconnectors.Oneconnectorisforcontrolpowerandtheotherconnectoris SystemInterconnectionDrawing. 2.1.1.ControlSupplyConnector TheControlSupplyinputsuppliespowertothecommunicationsandlogiccircuitryoftheXC4e.TheLinput isconnectedtoaninternalfuse.RefertoTable5-2fortheinternalfusevalueandpartnumber.TheNinputis notconnectedtoaninternalfuse.AnexternalfusewillberequiredifNisnotconnectedtoNeutral. TheControlSupplycontainsaninternalfilterbutyoucouldberequiredtoaddanexternalfilterforCE compliance.InstalltheexternalfilterascloseaspossibletotheXC4e.UseaSchaffnerFN2080filter,an AerotechUFM-STnoisefiltermodule,orequivalentdevice. NOTE:Refertolocalelectricalsafetyrequirementstocorrectlysizeexternalsystemwires. Figure2-1: ControlSupplyConnections Table2-1: ControlSupplyWiringSpecifications Pin Description RecommendedWireSize L Line(L): 100-240VACControlPowerInput 0.8mm2(#18AWG) N Neutral(N) or100-240VACControlPowerInputwithexternal fuse 0.8mm2(#18AWG) ProtectiveGround 0.8mm2(#18AWG) Table2-2: MatingConnectorPartNumbersfortheControlSupplyConnector Type AerotechP/N ThirdPartyP/N ScrewTorque Value:N·m WireSize: mm2[AWG] 3-PinTerminalBlock ECK00213Phoenix1754465 0.5-0.6 3.3-0.516[12-30] www.aerotech.com 27

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.1.2.MotorSupplyConnector MotorpowerisappliedtotheAC1andAC2terminalsoftheXC4eMotorSupplyconnector.TheXC4e10 AC1inputisinternallyconnectedtoa5Afuse.TheXC4e20/30AC1inputisinternallyconnectedtoa10A fuse.RefertoTable5-2fortheinternalfusepartnumbers.TheAC2inputisnotinternallyfused.Anexternal fuseisrequiredifAC2isnotconnectedtoNeutral. DANGER:BeforeyouoperatetheXC4e,installagroundconnectionforyoursafetyandtopreventdamagetotheequipment. ForCE compliance,AerotechrecommendsthatyouuseanAClinefilter.Connectthefilterascloseas possibletothedrive.FormoreinformationabouttheAClinefilter,refertoSection2.1.4. NOTE:Refertolocalelectricalsafetyrequirementstocorrectlysizeexternalsystemwires. Figure2-2: MotorSupplyConnections Table2-3: MotorSupplyConnectorWiringSpecifications Pin Description RecommendedWireSize AC1 0-240VAC MotorPowerInput 0.5mm2(#20AWG) AC2 Neutral(N)or240VACMotorPowerInputwithexternalfuse 0.5mm2(#20AWG) ProtectiveGround 0.5mm2(#20AWG) Table2-4: MatingConnectorPartNumbersfortheMotorSupplyConnector Type AerotechP/N ThirdPartyP/N ScrewTorque Value:Nm WireSize: mm2[AWG] 7-PinTerminalBlock ECK02387Phoenix1756353 0.5-0.6 3.3-0.0516[12-30] 28 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.1.3.TransformerOptions YoucanconnectanexternalisolationtransformertotheMotorSupplyAC Inputtoreducetheoperating voltageofthemotor.Usingatransformercanalsoreduceelectricalnoise. Table2-5: NominalMotorOperatingVoltages/RequiredAC Voltages AC Voltage DC Voltage 28 40 56 80 115 160 230 320 Table2-6: Transformer Options Transformer Description TV0.3-28-56-ST Generate28or56VACfrom115VACor230VACinputsourcevoltage.When rectifiedbythedrive,itproducesa40or80VDCpowerbus. TM3 Powerupto4drives,providing300wattsofpower TM5 Powerupto4drivesproviding500wattsofpower TV0.3-28 Generate28VACfrom115VACor230VACinputsourcevoltage.Whenrectified bythedrive,itproducesa40VDCpowerbus. TV0.3-56 Generate56VACfrom115VACor230VACinputsourcevoltage.Whenrectified bythedrive,itproducesan80VDCpowerbus. TV1.5,TV2.5,orTV5 1.5kVA,2.5kVA,or5kVAisolationtransformer;115/230VACinput;28,43,56, 70,115VACoutput Figure2-3: TransformerExamples www.aerotech.com 29

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-4: TV0.3-28-56-STTransformerControlandMotorPowerWiring(40VDCBus) 30 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-5: TV0.3-28-56-STTransformerControlandMotorPowerWiring(80VDCBus) www.aerotech.com 31

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-6: TV0.3-28-56-STTransformerControlandMotorPowerWiring(160VDCBus) 32 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-7: TV0.3-28TransformerControlandMotorPowerWiring(40VDCBus) www.aerotech.com 33

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-8: TV0.3-56TransformerControlandMotorPowerWiring(80VDCBus) 34 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-9: TM3/TM5TransformerControlandMotorPowerWiring www.aerotech.com 35

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.1.4.MinimizingConducted, Radiated,andSystemNoisefor EMC/CE Compliance NOTE:TheXC4eisacomponentdesignedtobeintegratedwithotherelectronics.EMCtestingmustbe conductedonthefinalproductconfiguration. Toreduceelectricalnoise,observethefollowingmotorandinputpowerwiringtechniques. 1. Useshieldedcableformotorandfeedbackconnectors.Connecttheshieldtothebackshellateachend ofthecable. 2. SeparatemotorandpowerwiringfromencoderandI/O wiring. 3. Mountdrives,powersupplies,andfiltercomponentsonaconductivepanel.Mountlinefilterscloseto thedrivetokeepthewirelengthbetweenthedriveandfiltertoaminimum.Usealinefilter,suchas Aerotech’sUFM-ST,ontheMotorSupplyandControlSupplyACinputs. 4. Usethelowestmotorvoltagerequiredbytheapplicationtoreduceradiatedemission. 5. UseanisolationtransformerwithgroundedsecondarytokeeptheeffectsofhighfrequencyPWM amplifiercurrentstoaminimum. 6. Useaseparatewireforeachgroundconnectiontothedrive.Usetheshortestpossiblewirelength. ThefollowingadditionalchangescouldberequiredforEMCcomplianceandarerecommendedduringinitial EMCsystemevaluation. 1. Addaclamp-onferritetothefeedbackcableclosetothedrive. [AerotechPNECZ02348,Fair-ritePN0446167281] 2. Addaclamp-onferritetotheMotorSupplyandControlSupplywires,includingthegroundwire,closeto thedrive. [AerotechPNECZ02347,Fair-ritePN0446164281] 3. AddaferritecoretotheUFM-STACinputwires.WraptheACwiresandgroundwirearoundthecore onetime. [Ferritecore:AerotechPNECZ02350,Fair-ritePN2646102002] 4. Addaferritecoretothemotorphaseandgroundwiresclosetothedrive.Wrapallfourwiresaroundthe ferritecoreonce.RemoveferritebeadsfromAerotechsuppliedcablesifinstalled. [Ferritecore:AerotechPNECZ02349,Fair-ritePN2646626402] 5. InstallamotorfiltermoduleMFM10-1closetothedrive.Theferritecorethatyouaddedtothemotor phaseandgroundwiresshouldbelocatedbetweenthedriveandtheMFM10-1. 36 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.2.MotorPowerOutputConnector DANGER:Beforeyoudomaintenancetotheequipment,disconnecttheelectricalpower.Waitatleastten(10)minutesafterremovingthepowersupplybeforedoingmaintenanceoraninspection.Otherwise,thereisthedangerofelectricshock. TheXC4ecanbeusedtodrivethefollowingmotortypes: l Brushless(refertoSection2.2.1.) l DCBrush(refertoSection2.2.2.) l Stepper(refertoSection2.2.3.) Foracompletelistofelectricalspecifications,refertoSection1.1. The7-pinterminalblockstylemotoroutputconnectorislocatedonthefrontpanel.Thepinoutforthis connectorisshowninTable2-7. Table2-7: MotorPowerOutputConnectorPinout Pin Description RecommendedWireSize Connector EarthGroundtoMotor 1.3mm2(#16AWG) A BrushlessPhaseAMotorLead DC Brush+ Stepper 1.3mm2(#16AWG) B BrushlessPhaseBMotorLead Stepper 1.3mm2(#16AWG) C BrushlessPhaseCMotorLead DC Brush- StepperReturn 1.3mm2(#16AWG) Table2-8: MatingConnectorPartNumbersfortheMotorPowerOutputConnector Type AerotechP/N ThirdPartyP/N ScrewTorque Value:Nm WireSize: mm2[AWG] 7-PinTerminalBlock ECK02387Phoenix1756353 0.5-0.6 3.3-0.0516[12-30] www.aerotech.com 37

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.2.1.BrushlessMotorConnections TheconfigurationshowninFigure2-10isanexampleofatypicalbrushlessmotorconnection. Figure2-10: BrushlessMotorConfiguration Table2-9: WireColorsforAerotech-SuppliedBrushlessMotorCables Pin WireColorSet1(1) WireColorSet2 WireColorSet3 WireColorSet4 Green/Yellow& Shield(2) Green/Yellow& Shield Green/Yellow& Shield Green/Yellow& Shield A Black Blue&Yellow Black#1 Black&Brown B Red Red&Orange Black#2 Red&Orange C White White&Brown Black#3 Violet&Blue (1)WireColorSet#1isthewiresettypicallyusedbyAerotech. (2)“&”indicatestwowires(Red&Orange);“ /”indicatesasinglewire(Green/White). Brushlessmotorsarecommutatedelectronicallybythecontroller.TheuseofHalleffectdevicesfor commutationisrecommended. ThecontrollerrequiresthattheBack-EMFofeachmotorphasebealignedwiththecorrespondingHall-effect signal.Toensureproperalignment,motor,Hall,andencoderconnectionsshouldbeverifiedusingoneofthe followingmethods:powered,throughtheuseofatestprogram;orunpoweredusinganoscilloscope.Both methodswillidentifytheA,B,andCHall/motorleadsetsandindicatethecorrectconnectionstothe feedbackphasing. ForAerotech-suppliedsystems,themotor,encoderandHallsensorsarecorrectlyconfiguredand connectionadjustmentsarenotnecessary. Amotorfiltermodulecanbeinstalledbetweenthedriveandthemotortoreducetheeffectson PWM generatednoisecurrents. 38 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.2.1.1.BrushlessMotorPoweredMotorandFeedbackPhasing RefertotheMotorPhasingCalculatorintheConfigurationManagerformotor,Hall,andencoderphasing. Figure2-11: PositiveMotorDirection FeedbackMonitoring ThestateoftheencoderandHall-effectdevicesignalscanbeobservedintheStatusUtility. A“--”forthegivenHallinputindicateszerovoltageorlogiclow,where“ON”indicates5Vorlogichigh. Figure2-12: EncoderandHallSignalDiagnostics www.aerotech.com 39

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.2.1.2.BrushlessMotorUnpoweredMotorandFeedbackPhasing DisconnectthemotorfromthecontrollerandconnectthemotorinthetestconfigurationshowninFigure2- 13.Thismethodwillrequireatwo-channeloscilloscope,a5Vpowersupply,andsixresistors(10,000ohm, 1/4watt).Allmeasurementsshouldbemadewiththeprobecommonofeachchanneloftheoscilloscope connectedtoaneutralreferencetestpoint(TP4,showninFigure2-13).Waveformsareshownwhilemoving themotorinthepositivedirection. Figure2-13: BrushlessMotorPhasingOscilloscopeExample WiththedesignationsofthemotorandHallleadsofathirdpartymotordetermined,themotorcannowbe connectedtoanAerotechsystem.ConnectmotorleadAtomotorconnectorA,motorleadBtomotor connectorB,andmotorleadCtomotorconnectorC.Hallleadsshouldalsobeconnectedtotheirrespective feedbackconnectorpins(HallAleadtotheHallAfeedbackpin,HallBtoHallB,andHallCtoHallC).The motoriscorrectlyphasedwhentheHallstatesalignwiththeBackEMFasshownin(Figure2-14).Usethe CommutationOffsetparametertocorrectforHallsignalmisalignment. Figure2-14: BrushlessMotorPhasingGoal 40 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.2.2.DC BrushMotorConnections TheconfigurationshowninFigure2-15isanexampleofatypicalDCbrushmotorconnection.Referto Figure2-15: DCBrushMotorConfiguration Table2-10: WireColorsforAerotech-SuppliedDC BrushMotorCables Pin WireColorSet1(1) WireColorSet2 WireColorSet3 Green&White&Shield(2) Green/Yellow&Shield Green/Yellow&Shield A Red&Orange Red Red&Orange C Yellow&Blue Black Yellow&Blue (1)WireColorSet#1isthetypicalwiresetusedbyAerotech. (2)“&”(Red&Orange)indicatestwowires;“ /”(Green/White)indicatesasinglewire. www.aerotech.com 41

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.2.2.1.DCBrushMotorPhasing AproperlyphasedmotormeansthatthepositivemotorleadshouldbeconnectedtotheØAmotorterminal andthenegativemotorleadshouldbeconnectedtotheØCmotorterminal.Todetermineifthemotoris properlyphased,connectavoltmetertothemotorleadsofanun-poweredmotor: 1. Connectthepositiveleadofthevoltmetertotheoneofthemotorterminals. 2. Connectthenegativeleadofthevoltmetertotheothermotorterminal. 3. Moveorrotatethemotorinthepositiveorclockwise(CW)directionbyhand. Figure2-16: PositiveMotorDirection 4. Ifthevoltmeterindicatesanegativevalue,swapthemotorleadsandmovethemotorbyhandinthe positivedirection,again.Whenthevoltmeterindicatesapositivevalue,themotorleadshavebeen identified. 5. ConnectthemotorleadfromthepositiveleadofthevoltmetertotheØAmotorterminalontheXC4e. ConnectthemotorleadfromthenegativeleadofthevoltmetertotheØCmotorterminalontheXC4e. ForAerotech-suppliedsystems,themotor,encoderandHallsensorsarecorrectlyconfiguredand connectionadjustmentsarenotnecessary. 42 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.2.3.StepperMotorConnections TheconfigurationshowninFigure2-17isanexampleofatypicalsteppermotorconnection.RefertoSection Inthiscase,theeffectivemotorvoltageishalfoftheappliedbusvoltage.Forexample,an80Vmotorbus supplyisneededtoget40Vacrossthemotor. Figure2-17: StepperMotorConfiguration Table2-11: WireColorsforAerotech-SuppliedStepperMotorCables Pin WireColorSet1(1) WireColorSet2 Green/Yellow&Shield(2) Green/Yellow&Shield A Black Brown B Red Yellow C White White& Red (1)WireColorSet#1isthetypicalwiresetusedbyAerotech. (2)“&”(Red&Orange)indicatestwowires;“ /”(Green/White)indicatesasinglewire. www.aerotech.com 43

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.2.3.1.StepperMotorPhasing Asteppermotorcanberunwithorwithoutanencoder.Ifanencoderisnotbeingused,phasingisnot necessary.Withanencoder,testforpropermotorphasingbyrunningapositivemotioncommand. Ifthereisapositivescalingfactor(determinedbytheCountsPerUnitparameters)andthemotormovesina clockwisedirection,asviewedlookingatthemotorfromthefrontmountingflange,themotorisphased correctly.Ifthemotormovesinacounterclockwisedirection,swapthemotorleadsandre-runthe command. Propermotorphasingisimportantbecausetheendoftravel(EOT)limitinputsarerelativetomotorrotation. Figure2-18: PositiveMotorDirection ForAerotech-suppliedsystems,themotor,encoderandHallsensorsarecorrectlyconfiguredand connectionadjustmentsarenotnecessary. NOTE:Afterthemotorhasbeenphased,usetheReverseMotionDirectionparametertochangethe directionof“positive”motion. 44 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.FeedbackConnector TheFeedbackconnector(a25-pin,D-styleconnector)hasinputsforanencoder,limitswitches,Hall-effect devices,motorover-temperaturedevice,5Vencoderandlimitpower,andoptionalbrakeconnections.The connectorpinassignmentisshowninTable2-12withdetailedconnectioninformationinthefollowing sections. Table2-12: FeedbackConnectorPinout Pin# Description In/Out/Bi Connector

1 Reserved Input

2 MotorOverTemperatureThermistor Input

3 +5VPower(1) Output

4 PlugandPlaySerialData(forAerotechstagesonly) N/A

5 Hall-EffectSensorB(brushlessmotorsonly) Input

6 EncoderMarkerReferencePulse- Input

AbsoluteEncoderClock- Output

7 EncoderMarkerReferencePulse+ Input

AbsoluteEncoderClock+ Output

8 AbsoluteEncoderData- Bidirectional

9 Reserved N/A

10 Hall-EffectSensorA(brushlessmotorsonly) Input

11 Hall-EffectSensorC(brushlessmotorsonly) Input

12 ClockwiseEndofTravelLimit Input

13 BrakeOutput- Output

14 EncoderCosine+ Input

15 EncoderCosine- Input

16 +5VPower(1) Output

17 EncoderSine+ Input

18 EncoderSine- Input

19 AbsoluteEncoderData+ Bidirectional

20 SignalCommon N/A

21 SignalCommon N/A

22 HomeSwitchInput Input

23 EncoderFaultInput Input

24 CounterclockwiseEndofTravelLimit Input

25 BrakeOutput+ Output

(1)Themaximumcombinedcurrentoutputis500mA. Table2-13: MatingConnectorPartNumbersfortheFeedbackConnector MatingConnector AerotechP/N ThirdPartyP/N 25-PinD-Connector ECK00101 FCIDB25P064TXLF Backshell ECK00656 Amphenol17E-1726-2 www.aerotech.com 45

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.3.1.PrimaryEncoderInputs TheprimaryencoderinputsareaccessiblethroughtheFeedbackconnector.ThePrimaryFeedbackType [A3200:PositionFeedbackTypeorVelocityFeedbackType]parameterconfigurestheXC4etoacceptSquare RefertoSection2.5.fortheauxiliaryencoderinputontheAuxI/Oconnector. Table2-14: MultiplierOptions -MX0SquareWaveorAbsoluteencoders SquareWaveencoders -MX2SineWave(highperformance),SquareWave,or Absoluteencoders SquareWaveencoders -MX3SineWave(highperformance),SquareWave,or Absoluteencoders SineWave(standardperformance)orSquare Waveencoders NOTE:Physicallyisolatetheencoderwiringfrommotor,ACpower,andallotherpowerwiring Table2-15: PrimaryEncoderInputPinsontheFeedbackConnector Pin# Description In/Out/Bi 3 +5VPower(1) Output AbsoluteEncoderClock- Output AbsoluteEncoderClock+ Output 16 +5VPower(1) Output (1)Themaximumcombinedcurrentoutputis500mA. 46 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.1.1.SquareWave Encoder TheXC4eacceptsRS-422squarewaveencodersignals.TheXC4ewillgenerateafeedbackfaultifit detectsaninvalidsignalstatecausedbyanopenorshortedsignalconnection.Usetwisted-pairwiringfor thehighestperformanceandnoiseimmunity. Table2-16: SquareWaveEncoderSpecifications Specification Value EncoderFrequency 10MHzmaximum(25nsminimumedgeseparation) x4QuadratureDecoding 40millioncounts/sec Figure2-19: SquareWaveEncoderSchematic(FeedbackConnector) www.aerotech.com 47

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.3.1.2.AbsoluteEncoder TheXC4eretrievesabsolutepositiondataalongwithencoderfaultinformationthroughaserialdatastream fromtheabsoluteencoder.Usetwisted-pairwiringforthehighestperformanceandnoiseimmunity.Referto Figure2-20fortheserialdatastreaminterface.RefertotheHelpfileforinformationonhowtosetupyour EnDatorBiSSabsoluteencoderparameters. Figure2-20: AbsoluteEncoderSchematic(FeedbackConnector) 48 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.1.3.SineWaveEncoder[-MX2/-MX3Option] TheSineWaveEncoderoptionsupplieshigherpositioningresolutionbysubdividingthefundamentaloutput periodoftheencoderintosmallerincrements.Theamountofsubdivisionisspecifiedbythe PrimaryEncoderMultiplicationFactor[A3200:EncoderMultiplicationFactor]parameter.UsetheFeedback TuningtabofDigitalScopetoautomaticallyadjustthevalueofthegain,offset,andphasebalancecontroller parameterstogetthebestperformance.Formoreinformation,refertotheHelpfile. Highresolutionorhigh-speedencoderscanrequireincreasedbandwidthforcorrectoperation.UsetheHigh SpeedModeofthePrimaryEncoderMultiplierSetup[A3200: EncoderMultiplierSetup]parametertoenablethe highbandwidthmode.Becausethismodeincreasessensitivitytosystemnoise,useitonlyifnecessary. TheXC4ecangenerateemulatedencodersignals.ThesesignalscanbeoutputontheAuxiliaryEncoder (AUX)connector,SYNC portconnector,orusedinternallybythePSO.RefertotheEncoderDividerand PrimaryEmulatedQuadratureDivider[A3200: EmulatedQuadratureDivider]parametersandthe ENCODER OUTcommandintheHelpfileformoreinformation. Forthehighestperformance,usetwistedpairdouble-shieldedcablewiththeinnershieldconnectedtosignal commonandtheoutershieldconnectedtoframeground.Donotjointheinnerandoutershieldsinthecable. Table2-17: AnalogEncoderSpecifications Specification Value InputFrequency(max) 450kHz,2MHz InputAmplitude(1) 0.6to1.75Vpk-pk InterpolationFactor(max) -MX2 65,536 -MX3 Primary: 65,536 Auxiliary: 16,384 -MX2/-MX3PrimaryEncoderChannel InterpolationLatency 800nsec(analoginputtoquadratureoutput) InputCommonMode 1.5to3.5VDC (1)MeasuredasSIN(+)-SIN(-)orCOS(+)-COS(-) Figure2-21: AnalogEncoderPhasingReferenceDiagram www.aerotech.com 49

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-22: AnalogEncoderSchematic(FeedbackConnector) 50 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.1.4.EncoderPhasing Incorrectencoderpolaritywillcausethesystemtofaultwhenenabledorwhenamovecommandisissued. Figure2-23illustratestheproperencoderphasingforclockwisemotorrotation(orpositiveforcermovement forlinearmotors).Toverify,movethemotorbyhandintheCW(positive)directionwhileobservingthe positionoftheencoderinthediagnosticsdisplay(seeFigure2-24).TheMotorPhasingCalculatorinthe ConfigurationManagercanbeusedtodetermineproperencoderpolarity. Fordualloopsystems,thevelocityfeedbackencoderisdisplayedinthediagnosticdisplay(Figure2-24). Figure2-23: EncoderPhasingReferenceDiagram(Standard) NOTE:EncodermanufacturersmayrefertotheencodersignalsasA,B,andZ.Theproperphase relationshipbetweensignalsisshowninFigure2-23. www.aerotech.com 51

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-24: PositionFeedbackintheDiagnostic Display 52 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.2.Hall-EffectInputs TheHall-effectswitchinputsarerecommendedforACbrushlessmotorcommutationbutnotabsolutely required.TheHall-effectinputsaccept5VDClevelsignals.Hallstates(0,0,0)or(1,1,1)areinvalidandwill generatea"HallFault"axisfault. Table2-18: Hall-EffectFeedbackPinsontheFeedbackConnector Pin# Description In/Out/Bi 3 +5VPower(1) Output 16 +5VPower(1) Output (1)Themaximumcombinedcurrentoutputis500mA. Figure2-25: Hall-EffectInputsSchematic(FeedbackConnector) www.aerotech.com 53

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.3.3.ThermistorInput Thethermistorinputisusedtodetectamotorovertemperatureconditionbyusingapositivetemperature coefficientsensor.Asthetemperatureofthesensorincreases,sodoestheresistance.Undernormal operatingconditions,theresistanceofthethermistorislowwhichwillresultinalowinputsignal.Asthe increasingtemperaturecausesthethermistor’sresistancetoincrease,thesensorwilltriggeranover temperaturefault. ThethermistorisconnectedbetweenPin2andSignalCommon.Thenominaltripvalueofthesensoris 1.385kΩ.Thecircuitincludesa12kΩinternalpull-upresistorwhichcorrespondstoatripvoltageof+0.52V. Table2-19: ThermistorInputPinontheFeedbackConnector Pin# Description In/Out/Bi Figure2-26: ThermistorInputSchematic(FeedbackConnector) 54 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.4.EncoderFaultInput Theencoderfaultinputisforusewithencodersthathaveafaultoutput.Thisisprovidedbysome manufacturesandindicatesalossofencoderfunction.Theactivestateofthisinputisparameter configurableandthecontrollershouldbeconfiguredtodisabletheaxiswhenthefaultlevelisactive.The nominaltripvoltageoftheencoderfaultinputis+2.5V. Table2-20: EncoderFaultInputPinontheFeedbackConnector Pin# Description In/Out/Bi Figure2-27: EncoderFaultInputSchematic(FeedbackConnector) www.aerotech.com 55

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.3.5.EndofTravelandHomeLimitInputs EndofTravel(EOT)limitsarerequiredtodefinetheendofthephysicaltravelonlinearaxes.Positiveor clockwisemotionisstoppedbytheclockwise(CW)endoftravellimitinput.Negativeorcounterclockwise motionisstoppedbythecounterclockwise(CCW)endoftravellimitinput.TheHomeLimitswitchcanbe parameterconfiguredforuseduringthehomecycle,however,theCWorCCWEOTlimitistypicallyused instead.Alloftheend-of-travellimitinputsaccept0-5VDClevelsignals.Limitdirectionsarerelativetothe encoderpolarityinthediagnosticsdisplay(refertoFigure2-30). Table2-21: EndofTravelandHomeLimitPinsontheFeedbackConnector Pin# Description In/Out/Bi Theactivestate(High/Low)oftheEOTlimitsissoftwareselectable(bytheEndOfTravelLimitSetupaxis parameter).Figure2-28showsthepossiblewiringconfigurationsfornormally-openandnormally-closed switchesandtheparametersettingtouseforeachconfiguration.UseNPN-typenormally-closedlimit switches(ActiveHigh)toprovidefail-safebehaviorintheeventofanopencircuit. 56 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-28: EndofTravelandHomeLimitInputConnections Figure2-29: EndofTravelandHomeLimitInputSchematic(FeedbackConnector) www.aerotech.com 57

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.3.5.1.EndofTravelandHomeLimitPhasing IftheEOTlimitsarereversed,youwillbeabletomovefurtherintoalimitbutbeunabletomoveout.To correctthis,swaptheconnectionstotheCWandCCWinputsattheFeedbackconnectororswapthe CW andCCWlimitfunctionalityinthesoftwareusingtheEndOfTravelLimitSetupparameter.Viewthelogic leveloftheEOTlimitinputsintheDiagnosticsdisplay (showninFigure2-30). Figure2-30: EndofTravelandHomeLimitInputDiagnosticDisplay 58 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.3.6.BrakeOutputs TheXC4ehasadedicatedbrakecontrolcircuit.Thebrakeistypicallyconfiguredforautomaticcontrolusing theBrakeSetup[A3200: EnableBrakeControl]parameter. ThebrakeoutputcanalsobemanuallycontrolledifyouusetheBRAKEcommand. RefertoSection2.6.formoreinformationonpoweringthebrakecircuit. Table2-22: BrakeOutputPinsontheFeedbackConnector Pin# Description In/Out/Bi Table2-23: BrakeControlSpecifications Specification Value MaximumVoltage 24VDC MaximumCurrent .5A Avaristormustbeconnectedacrossthebraketominimizevoltagetransients. Figure2-31: BrakeConnectedtothe25-PinFeedbackConnector(Typical) www.aerotech.com 59

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.4.SafeTorqueOffInput(STO) TheSTOcircuitiscomprisedoftwoidenticalchannels,eachofwhichmustbeenergizedinorderforthe XC4etoproducemotion.EachSTOinputisopto-isolatedandaccepts24Vlevelsdirectlywithouttheneed forexternalcurrentlimitingresistors. NOTE:TheXC4emightbeequippedwithanSTObypasscircuitboard.Thebypasscircuitboarddefeats theSTOsafetycircuitandallowsthesystemtorunatalltimes.TousetheSTOsafetyfunctionality, removethecircuitboardandmakeconnectionsasoutlinedinthissection. NOTE:Theapplicationcircuitanditssuitabilityforthedesiredsafetylevelisthesoleresponsibilityofthe userofXC4e. WARNING:STO wiresmustbeinsulatedtopreventshortcircuitsbetweenconnectorpins.TheprimaryconcernisashortcircuitbetweenSTO1IN andSTO2IN wirestrands. Table2-24: STOConnectorPinout Pin# Signal Description In/Out/Bi Connector

1 PowerSupply+ UsedtodefeatSTO byconnectingto

2 STO1IN STO Channel1PositiveInput Input

3 RETURN STO NegativeInput Input

4 STO2IN STO Channel2PositiveInput Input

5 PowerSupply- UsedtodefeatSTO byconnectingto

Table2-25: MatingConnectorPartNumbersfortheSTO Connector Description AerotechP/N PhoenixP/N Tightening Torque(Nm) WireSize: AWG[mm2] 5-PinTerminalBlock ECK02393 1827622 0.22-0.25 2.5-0.05[14-30] Table2-26: STO ElectricalSpecifications Status Value STOoff(motionallowed) 18-24V,7ma STOon(safestateentered,nomotion) 0-6V RecommendedWireGauge 22-26AWG(0.5-0.14mm2) STO SystemPowerSupply PELV STOWireLength(maximum) 50m Figure2-32showsonesafetydeviceconnectedtomultipleXC4esinaparallel. 60 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration WARNING:TheXC4edoesnotcheckforshortcircuitsontheexternalSTO wiring.Ifthisisnotdonebytheexternalsafetydevice,shortcircuitsonthewiringmustbeexcluded.RefertoENISO13849-2.ForCategory4systems,theexclusionofshortcircuitsismandatory. Figure2-32: TypicalConfiguration www.aerotech.com 61

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.4.1.STO Standards Table2-27describesandspecifiesthesafetyrequirementsatthesystemlevelfortheSafeTorqueOff (STO)featureoftheXC4e.ThisassumesthatdiagnostictestingisperformedaccordingtoSection2.4.4. andTable2-28. Table2-27: STO Standards Standard MaximumAchievableSafety EN/IEC61800-5-2:2016 SIL3 EN/IEC61508-1:2010 SIL3 EN/IEC61508-2:2010 SIL3 ENISO13849-1:2015 Category4,PLe EN/IEC62061:2005withAmendments SIL3 Table2-28: STO StandardsData Standard Value ENISO13849-1:2015 MTTFD>1000years, DCAVG 99% MaximumPLe,Category4 ENISO13849-1:2015 EN/IEC61508 Lifetime=20years Noprooftestrequired IntervalformanualSTOtest: l OnceperyearforSIL2/PLd/category3 l OnceperthreemonthsforSIL3/PLe/category3 l OnceperdayforSIL3/PLe/category4 EN/IEC61508 SIL3 PFH<3FIT SFF>99% 2.4.2.STOFunctionalDescription ThemotorcanonlybeactivatedwhenvoltageisappliedtobothSTO1andSTO2inputs.TheSTOstatewill beenteredifpowerisremovedfromeithertheSTO1ortheSTO2inputs.WhentheSTO stateisentered, themotorcannotgeneratetorqueorforceandisthereforeconsideredsafe. TheSTOfunctionisimplementedwithtworedundantchannelsinordertomeetstatedperformanceandSIL levels.STO1disconnectsthehighsidepoweramplifiertransistorsandSTO2disconnectsthelowside poweramplifiertransistors.DisconnectingeithersetoftransistorseffectivelypreventstheXC4efrombeing abletoproducemotion. TheXC4esoftwaremonitorseachSTOchannelandwillgenerateanEmergencyStopsoftwarefaultwhen eitherchannelsignalsthestopstate.EachSTOchannelcontainsafixeddelaywhichallowstheXC4eto performacontrolledstopbeforethepoweramplifiertransistorsareturnedoff. AtypicalconfigurationrequiringacontrolledstophastheEmergencyStopFaultmaskbitsetinthe FaultMask,FaultMaskDecel,andFaultMaskDisableparameters.Thisstopstheaxisusingtherate specifiedbytheAbortDecelRateparameter.Thesoftwarewilldisabletheaxisassoonasthedeceleration rampiscomplete.ThisistypicallyconfiguredtooccurbeforetheSTO channelturnsoffthepoweramplifier transistors. 62 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Thesoftwarecontrolledstopfunctionalitymustbeexcludedwhenconsideringoverallsystemsafety.Thisis becausethesoftwareisnotsafetyratedandcannotbeincludedaspartofthesafetyfunction. TheXC4ewilltolerateshortdiagnosticpulsesontheSTO1+andSTO2+inputs.Theparameter "STOPulseFilter" specifiesthemaximumpulsewidththattheXC4ewillignore. Toresumenormaloperation,applypowertobothSTO1andSTO2inputsandclearthe EmergencyStop softwarefaultusingtheFaultAcknowledgebuttonorcommand.TherecommendeduseoftheEmergency StopFaultfaultmaskbitspreventthesystemfromautomaticallyrestarting. Youcanachievelongerdelaytimesthroughtheuseofanexternaldelaytimer,suchastheOmronG9SA- 321SafetyRelayUnit.PlacethisdevicebetweenthesystemESTOPwiringandtheXC4e'sSTOinputs. ConnecttheESTOPsignaldirectlytoadigitalinput,inadditiontotheexternaltimer,toallowtheXC4eto beginasoftware-controlledstopassoonastheESTOPsignalbecomesactive.Usethe EmergencyStopFaultInput[A3200: ESTOPFaultInput]parametertoconfigureadigitalinputasanESTOP input. Non-standardSTOdelaytimesareprovidedbyspecialfactoryorder.Inthiscase,thenon-standardSTO delaytimeisindicatedbyalabelplacedonthesliceamplifier’smainconnector(STODELAY=xxsec). Table2-29: STO SignalDelay Value STO TimeDelay 450-550msec Table2-30: MotorFunctionRelativetoSTO InputState STO1 STO2 MotorFunction Unpowered Unpowered Noforce/torque Unpowered(1) Powered(1) Noforce/torque Powered(1) Unpowered(1) Noforce/torque Powered Powered NormalOperation 2.4.3.STOStartupValidationTesting VerifythestateoftheSTO1andSTO2channelsbymanuallyactivatingtheexternalSTOhardware.Each STO channelmustbetestedseparatelyinordertodetectpotentialshortcircuitsbetweenthechannels.The currentstateoftheSTO1andSTO2inputsisshownintheStatusUtility.A“–”indicatesthattheSTOinput ispoweredbyahighvoltagelevel(24V).An“ON”indicatesthatthevoltagesourcehasbeenremovedfrom theinput(opencircuitor0V),andthattheSTO channelisinthesafestate. DANGER:TheSTOcircuitdoesnotremovelethalvoltagefromthemotorterminals.ACmainspowermustberemovedbeforeservicing. www.aerotech.com 63

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.4.4.STODiagnostics ActivationofSTOmeansremovingpowerfromtheXC4e’sSTOinputs.Thisistypicallydonebypressing theemergencystopswitch.TheXC4einitiatesadiagnosticcheckeverytimetheSTOisactivatedafterthe Diagnostic TestDelayTimehaselapsed.Thediagnosticcheckverifiesthateachchannelhasenteredthe safestate.TheXC4eisheldinthesafestateifitdeterminesthatoneofthechannelshasnotproperly enteredthesafestate.Anopencircuitorshortto24VineitherSTO channelwillresultinthiscondition(refer toSection2.4.3.).TheStatusUtilityscreencanbeusedtoverifythelevelsoftheSTOinputsignalswhile troubleshooting. InordertomeetthelistedSILlevel,theSTOcircuitmustbeactivated(powerremovedfrombothinputs) accordingtotheintervalspecifiedinTable2-28. Table2-31: STO Timing TimeDescription Value T1 STODelayTime(STOinputactivetomotorpoweroff) 450-550msec T2 STOdeactivatedtomotorpoweron(thesoftwareistypicallycon- figuredsothatthemotordoesnotautomaticallyre-energize). <1msec T3 DiagnosticTestDelayTime 550-610msec Figure2-33: STOTiming ThesoftwareistypicallyconfiguredtoexecuteacontrolledstopwhentheSTOstateisfirstdetected.If powerisreappliedtotheSTOinputsbeforetheSTODelayTime,anSTOhardwareshutdownwillnotoccur butasoftwarestopmay,dependingonthewidthoftheSTOpulse.ThecontrollerwillignoreSTOactive pulsesshorterinlengththantheSTOPulseFilterparametersetting. 64 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.5.AuxiliaryI/OConnector TheAuxiliaryI/Oconnectorhas1analoginput,6digitalinputs,1analogoutput,4digitaloutputs,anda secondarylinedriverencoderinput. Table2-32: AuxiliaryI/OConnectorPinout Pin# Description In/Out/Bi Connector

1 AuxiliarySine+ Bidirectional

2 AuxiliarySine- Bidirectional

3 High-SpeedInput20+ Input

4 High-SpeedInput20- Input

5 High-SpeedInput21+ Input

6 High-SpeedInput21- Input

7 DigitalOutput0 Output

8 DigitalOutput1 Output

9 DigitalOutput2 Output

10 AuxiliaryCosine+ Bidirectional

11 AuxiliaryCosine- Bidirectional

12 +5Volt(500mAmax) Output

13 AnalogInput0+(Differential) Input

14 AnalogInput0-(Differential) Input

15 DigitalOutputCommon -

16 DigitalOutput3 Output

17 DigitalInput0/CCWEOTInput(1) Input

18 DigitalInput1/CWEOTInput(1) Input

19 AuxiliaryMarker-/PSOoutput(2)/TTL Output Bidirectional

20 AuxiliaryMarker+/PSOoutput(2) Bidirectional

21 Common -

22 AnalogOutput0 Output

23 AnalogCommon -

24 DigitalInputCommon -

25 DigitalInput2/HomeInput(1) Input

26 DigitalInput3 Input

(1)Softwareconfiguredoption (2)ForPSO,refertoSection2.5.2. Table2-33: MatingConnectorPartNumbersfortheAuxiliaryI/O Connector MatingConnector AerotechP/N ThirdPartyP/N Connector ECK01259 KyconK86-AA-26P Backshell ECK01022 Amphenol17-1725-2 NOTE: TheseitemsareprovidedasasetundertheAerotechP/N: MCK-26HDD. www.aerotech.com 65

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.5.1.AuxiliaryEncoderInputs TheAuxiliaryEncoderconnectorgivesyouasecondencoderinputchannel.Thischannelistypicallyused fordualloopapplications. TheAuxiliaryEncoderinputsupportssquarewaveencodertypesbydefaultandsinewaveencodertypes withthe-MX3option.UsetheAuxiliaryFeedbackType[A3200:PositionFeedbackTypeor VelocityFeedbackType]parametertoconfiguretheencodersignaltype. YoucanconfiguretheAuxiliaryEncoderinputasanoutputthatwilltransmitencodersignalsforexternal use.UsetheEncoderDividerparametertoconfiguretheSine±andCosine±connectorpinsasRS-422 outputs. UsethePSOOUTPUTCONTROLcommandtotransmitthePSOoutputsignalontheMarker±pins differentially.Or,usethePSOOUTPUTCONTROLcommandtoconfiguretheMarker-pinasa 5V TTL PSO output. RefertotheHelpfileformoreinformation. InvalidormissingsignalswillcausetheXC4etogenerateafeedbackfaultwhentheaxisisenabled.Use twisted-pairwiringforthehighestperformanceandnoiseimmunity. Table2-34: SquareWaveEncoderSpecifications(AuxiliaryEncoder) Specification Value EncoderFrequency 10MHzmaximum(25nsminimumedgeseparation) x4QuadratureDecoding 40millioncounts/sec Table2-35: SineWaveEncoderSpecifications(AuxiliaryEncoder) Specification Value InputFrequency(max) 450kHz,2MHz InputAmplitude(1) 0.6to1.75Vpk-pk InterpolationFactor(max) -MX2 65,536 -MX3 Primary: 65,536 Auxiliary: 16,384 -MX2/-MX3PrimaryEncoderChannel InterpolationLatency 800nsec(analoginputtoquadratureoutput) InputCommonMode 1.5to3.5VDC (1)MeasuredasSIN(+)-SIN(-)orCOS(+)-COS(-) Table2-36: AuxiliaryEncoderPinsontheAuxiliaryI/O Connector Pin# Description In/Out/Bi 12 +5Volt(500mAmax) Output (2)ForPSO,refertoSection2.5.2. 66 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-34: AuxiliaryEncoderInputSchematic(AuxI/O Connector) www.aerotech.com 67

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.5.2.PositionSynchronizedOutput(PSO) ThePSOsignalisavailableonthedual-functionAUXMarker/PSOsignallines.Theauxiliarymarkermust beconfiguredasanoutputusingthePSOOUTPUTCONTROLcommand.RefertotheHelpfileformore information. Thedifferentialsignalformatisrecommendedwhenusinglongcablelengthsinnoisyenvironmentsorwhen highfrequencypulsetransmissionisrequired.Itisbesttolocatethelinereceiverclosetothereceiving electronics.A5VTTLsignalisusedtodriveanoptocouplerorgeneralpurposeTTL input.Thissignalis activehighandisdrivento5 VwhenaPSO fireeventoccurs.Whenthedriveisresetorafterinitialpower up,thePSO pins(refertoTable2-38),arenotactivelydrivenandthefailsafestateisdefinedbypull-upand pull-downresistorsasshowninFigure2-35. The-EB1I/OoptionboardhasadditionalPSO signalformats.RefertoSection3.5.formoreinformation. Table2-37: PSOSpecifications Specification Value Output TTL 5V,16mA(max) MaximumPSOOutput(Fire)Frequency TTL 12.5MHz RS-422 12.5MHz OutputLatency [Fireeventtooutputchange] TTL 15ns RS-422 15ns Table2-38: PSO PinsontheAuxiliaryI/O Connector Pin# Description In/Out/Bi

19 AuxiliaryMarker-/PSOoutput/TTL Output Bidirectional

20 AuxiliaryMarker+/PSOoutput Bidirectional

68 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-35: PSO Interface www.aerotech.com 69

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.5.3.DigitalOutputs Optically-isolatedsolid-staterelaysdrivethedigitaloutputs.Youcanconnectthedigitaloutputsincurrent sourcingorcurrentsinkingmodebutyoumustconnectallfouroutputsinthesameconfiguration.Referto Figure2-37andFigure2-38. Youmustinstallsuppressiondiodesondigitaloutputsthatdriverelaysorotherinductivedevices.Toseean exampleofacurrentsourcingoutputthathasdiodesuppression,refertoFigure2-37.Toseeanexampleofa currentsinkingoutputthathasdiodesuppression,refertoFigure2-38 Thedigitaloutputsarenotdesignedforhigh-voltageisolationapplicationsandtheyshouldonlybeusedwith ground-referencedcircuits. NOTE:Thedigitaloutputshaveoverloadprotection.Theywillresumenormaloperationwhentheoverload isremoved. Table2-39: DigitalOutputSpecifications DigitalOutputSpecifications Value MaximumVoltage 24V(26VMaximum) MaximumSink/SourceCurrent 250mA/output OutputSaturationVoltage 0.9Vatmaximumcurrent OutputResistance 3.7Ω Rise/FallTime 250µs(2Kpullupto24V) ResetState OutputOff(HighImpedanceState) Table2-40: DigitalOutputPinsontheAuxiliaryI/OConnector Pin# Description In/Out/Bi 70 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Figure2-36: DigitalOutputSchematic(AuxI/O Connector) www.aerotech.com 71

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-37: DigitalOutputsConnectedinCurrentSourcingMode Figure2-38: DigitalOutputsConnectedinCurrentSinkingMode 72 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.5.4.DigitalInputs Youcanconnectthedigitalinputstocurrentsourcingorcurrentsinkingdevicesbutyoumustconnectall fourinputsinthesameconfiguration.RefertoFigure2-41andFigure2-40.Thedigitalinputsarenot designedforhigh-voltageisolationapplications.Theyshouldonlybeusedwithground-referencedcircuits. Table2-41: DigitalInputSpecifications InputVoltage ApproximateInputCurrent TurnOnTime TurnOffTime +5Vto+24V 6mA 10µs 43µs Table2-42: DigitalInputPinsontheAuxiliaryI/OConnector Pin# Description In/Out/Bi (1)Softwareconfiguredoption Figure2-39: DigitalInputsSchematic(AuxI/O Connector) www.aerotech.com 73

Chapter2:InstallationandConfiguration XC4eHardwareManual Figure2-40: DigitalInputsConnectedtoCurrentSinkingDevices Figure2-41: DigitalInputsConnectedtoCurrentSourcingDevices 74 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.5.5.High-SpeedInputs20-21 High-speedinputs20and21canbeusedasgeneralpurposeinputsorasthetriggersignalforhighspeed datacollection.RefertotheDATAACQ TRIGGER commandtopicintheHelpfileformoreinformation. Table2-43: High-SpeedInputSpecifications Specification Value InputVoltage 5V-24 V inputvoltages InputCurrent 10mA InputDevice HCPL-0630 Delay 50nsec Table2-44: High-SpeedInputPinsontheAuxiliaryI/OConnector Pin# Description In/Out/Bi Figure2-42: High-SpeedInputs www.aerotech.com 75

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.5.6.AnalogOutput0 Theanalogoutputcanbesetfromwithinaprogramoritcanbeconfiguredtoechothestateofselectservo loopnodes. Theanalogoutputissettozerowhenyoupoweronthesystemorresetthedrive. Table2-45: AnalogOutputSpecifications Specification Value OutputVoltage -10Vto+10 V OutputCurrent 5mA Resolution(bits) 16bits Table2-46: AnalogOutputPinsontheAuxiliaryI/OConnector Pin# Description In/Out/Bi Figure2-43: AnalogOutput0Schematic 76 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.5.7.AnalogInput0(Differential) Tointerfacetoasingle-ended,non-differentialvoltagesource,connectthesignalcommonofthesourceto thenegativeinputandconnecttheanalogsourcesignaltothepositiveinput.Afloatingsignalsourcemust bereferencedtotheanalogcommon.RefertoFigure2-44. Table2-47: AnalogInputSpecifications Specification Value (AI+)-(AI-) +10Vto-10V(1) Resolution(bits) 16bits InputImpedance 1MΩ 1.Signalsoutsideofthisrangemaydamagetheinput Table2-48: AnalogInputPinsontheAuxiliaryI/OConnector Pin# Description In/Out/Bi Figure2-44: AnalogInput0Schematic www.aerotech.com 77

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.6.BrakePowerSupplyConnector Thisportisthepowersupplyconnectiontotheon-boardbrakecontrolcircuit.RefertoSection2.3.6.for moreinformationaboutthebrakeoutputinterface. Table2-49: BrakePowerSupplyConnectorPinout Pin# Description In/Out/Bi Connector

1 BrakePowerSupply(+) Input

2 BrakePowerSupply(-) Input

Table2-50: MatingConnectorPartNumbersfortheBrakePowerSupplyConnector Description AerotechP/N PhoenixP/N Tightening Torque(Nm) WireSize: AWG[mm2] 2-PinTerminalBlock ECK02390 1827616 0.22-0.25 0.14-1.5[26-16] 78 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.7.HyperWireInterface TheHyperWirebusisthehigh-speedcommunicationsconnectiontotheXC4eoperatingat2gigabitsper second.ThePC sendsallcommandandconfigurationinformationthroughtheHyperWirebus. Table2-51: HyperWireCardPartNumber PartNumber Description HYPERWIRE-PCIE HyperWireadapter,PCIex4 interface Table2-52: HyperWireCablePartNumbers PartNumber Description HYPERWIRE-AO10-5 HyperWirecable,activeoptical,0.5m HYPERWIRE-AO10-10 HyperWirecable,activeoptical,1.0m HYPERWIRE-AO10-30 HyperWirecable,activeoptical,3.0m HYPERWIRE-AO10-50 HyperWirecable,activeoptical,5.0m HYPERWIRE-AO10-200 HyperWirecable,activeoptical,20.0m www.aerotech.com 79

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.8.ExternalShuntOption[-SX1] The-SX1optionprovidesaconnectionforauser-providedshuntresistortodissipateexcessenergyand keeptheinternaldrivevoltagewithinsafelevels.Thedriveswitchesthisresistor"ON" whentheinternalbus voltagereachesapproximately380VDC.Thisoptionisgenerallyrequiredforsystemsthathavealarge amountofstoredmechanicalenergythatmustbedissipatedduringdeceleration. Propersizing,mounting,andprotectionoftheshuntresistoriscriticalduetothepotentiallylargeamountsof powerdissipated. DANGER:Theshuntresistortemperaturecanexceed70°Cduringnormaloperationandcontainslethalvoltageonitsterminalsandsurface.Itmustbeproperlyenclosedandshieldedtoavoidriskoffireandoperatorshock. Table2-53: -SX1 ComponentInformation Component Description AerotechP/N RecommendedShuntResistor 50Ω(min),300W Vishay/Dale:RBEF030050R00KFBVT ECR01039 1-PinMatingConnector[QTY.2] ScrewTorqueValue:0.6-0.8N·m WireSize:0.2-6mm2[24-10AWG] Phoenix:0708250 ECK02452 F101FuseontheControlBoard 8AS.B. EIF01022 RecommendedWireSize 16AWG(1.3mm2)HighTemperature -- Thefirststepinsizingtheexternalshuntresistoristocalculatethekineticenergyofthesystem(Equation 1).Neglectingthesystem'slosses,thisistheenergythatcanpotentiallyberegeneratedtotheDC bus. Equation1: or (forrotarymotors) (forlinearmotors) JM rotorinertia(kg·m2) JL loadinertia(kg·m2) ωm motorspeedbeforedeceleration(rad/s) MM forcermass(kg) ML loadmass(kg) vm velocity(m/s) Ashuntresistorisrequirediftheregeneratedenergyisgreaterthantheadditionalenergythattheinternalbus capacitorcanstore(Equation2). 80 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration Equation2: C buscapacitor(F)[1,200uF] VM turnonvoltageforshuntcircuit(V)[380V] VNOM nominalbusvoltage(V)[160Vor320V,Typical] ForastandardXC4e,themaximumadditionalenergytheinternalbuscapacitorcanstorewithoutrequiringa shuntresistorisindicatedinTable2-54. Table2-54: MaximumAdditionalStorageEnergy BusVoltage MaximumAdditionalEnergy 160V 71.3J 320V 25.2J Ifashuntresistorisrequired,thenextstepistocalculatethevalueofresistancenecessarytodissipatethe energy.UseEquations3,4,and5tocalculatetheparametersoftheshuntresistor. Equation3: PPEAK peakpowerthattheregenerationcircuitmustaccommodate(W) tD decelerationtime(s) Equation4: PAV averagepowerdissipatedonshuntresistor(W) tCYCLEtimebetweendecelerationevents(s) Equation5: VHYS hysteresisvoltageofregenerationcircuit(V)[10V,Typical] Additionalusefulequations: 1lb·ft=1.356N·m 1rad/s=9.55rpm www.aerotech.com 81

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.9.SyncPort TheSyncportisabi-directionalhighspeedproprietaryinterfacethatletsyoutransmitencodersignals betweendrives.Thisistypicallyusedformulti-axisPSOapplicationswhereoneortwodrivessendtheir encodersignalstoamaindrivethathasthePSOlogicandPSOoutputsignal.TheXC4econtainstwoSync ports,labeledAandB. Toavoidsignalcontention,allSyncportsdefaulttotheinputstateduringresetandimmediatelyafterpower isappliedtothedrive. Table2-55: Sync-RelatedCommands Command Desciption ENCODER OUT ConfigureeachSyncportasaninputoranoutput PSOTRACK INPUTLetthePSOtotracktheSYNCAorSYNCBport.PSOWINDOW INPUT TheSyncportuseslow-voltagedifferentialsignaling(LVDS)andstandardUSB3.0typeA(crossover) cables. Table2-56: Sync PortCables PartNumber Desciption CBL-SYNC-3 Length3dm;Connectors: USBTypeAtoUSBTypeA CBL-SYNC-5 Length5dm;Connectors: USBTypeAtoUSBTypeA CBL-SYNC-7 Length7dm;Connectors: USBTypeAtoUSBTypeA CBL-SYNC-10 Length10dm;Connectors: USBTypeAtoUSBTypeA 82 www.aerotech.com

XC4eHardwareManual Chapter2:InstallationandConfiguration 2.10.SystemInterconnection Clickontheimagebelowtoopenaseparatepdfwindowwithalargerviewofthedrawing. Figure2-45: SystemInterconnectionDrawing(BestPractice) www.aerotech.com 83

Chapter2:InstallationandConfiguration XC4eHardwareManual 2.11.PCConfigurationandOperationInformation Formoreinformationabouthardwarerequirements,PCconfiguration,programming,systemoperation,and utilities,refertotheHelpfile. 84 www.aerotech.com

XC4eHardwareManual Chapter3:-EB1I/OOptionBoard Chapter3:-EB1I/OOptionBoard The-EB1I/Ooptionboardhas16digitalinputs,16digitaloutputs,3analoginputs,3analogoutputs,and PSOoutputs. Figure3-1: XC4ewith-EB1I/OOptionBoardConnectors www.aerotech.com 85

Chapter3:-EB1I/OOptionBoard XC4eHardwareManual 3.1.DigitalOutputs[-EB1] Optically-isolatedsolid-staterelaysdrivethedigitaloutputs.Youcanconnectthedigitaloutputsincurrent sourcingorcurrentsinkingmodebutyoumustconnectallfouroutputsinaportinthesameconfiguration. RefertoFigure3-3andFigure3-4. Thedigitaloutputsarenotdesignedforhigh-voltageisolationapplicationsandtheyshouldonlybeusedwith ground-referencedcircuits. Youmustinstallsuppressiondiodesondigitaloutputsthatdriverelaysorotherinductivedevices.Toseean exampleofacurrentsourcingoutputthathasdiodesuppression,refertoFigure3-3.Toseeanexampleofa currentsinkingoutputthathasdiodesuppression,refertoFigure3-4 NOTE:Thedigitaloutputshaveoverloadprotection.Theywillresumenormaloperationwhentheoverload isremoved. Table3-1: DigitalOutputSpecifications[-EB1] DigitalOutputSpecifications Value MaximumVoltage 24V(26VMaximum) MaximumSink/SourceCurrent 250mA/output OutputSaturationVoltage 0.9Vatmaximumcurrent OutputResistance 3.7Ω Rise/FallTime 250µs(2Kpullupto24V) ResetState OutputOff(HighImpedanceState) 86 www.aerotech.com

XC4eHardwareManual Chapter3:-EB1I/OOptionBoard Table3-2: DigitalOutput1ConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector

1 OutputCommonforOutputs4-7 N/A

2 Output4(Optically-Isolated) Output

3 Output5(Optically-Isolated) Output

4 Output6(Optically-Isolated) Output

5 Output7(Optically-Isolated) Output

6 OutputCommonforOutputs8-11 N/A

7 Output8(Optically-Isolated) Output

8 Output9(Optically-Isolated) Output

9 Output10(Optically-Isolated) Output

10 Output11(Optically-Isolated) Output

Table3-3: MatingConnectorPartNumbersfortheDigitalOutput1Connector[-EB1] MatingConnector AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 10-PinTerminalBlock ECK02395 Phoenix1700841 0.5-0.14[20-26] Table3-4: DigitalOutput2ConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector

1 OutputCommonforOutputs12-15 N/A

2 Output12(Optically-Isolated) Output

3 Output13(Optically-Isolated) Output

4 Output14(Optically-Isolated) Output

5 Output15(Optically-Isolated) Output

6 OutputCommonforOutputs16-19 N/A

7 Output16(Optically-Isolated) Output

8 Output17(Optically-Isolated) Output

9 Output18(Optically-Isolated) Output

10 Output19(Optically-Isolated) Output

Table3-5: MatingConnectorPartNumbersfortheDigitalOutput2Connector[-EB1] MatingConnector AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 10-PinTerminalBlock ECK02395 Phoenix1700841 0.5-0.14[20-26] www.aerotech.com 87

Chapter3:-EB1I/OOptionBoard XC4eHardwareManual Figure3-2: DigitalOutputsSchematic[-EB1] 88 www.aerotech.com

XC4eHardwareManual Chapter3:-EB1I/OOptionBoard Figure3-3: DigitalOutputsConnectedinCurrentSourcingMode[-EB1] Figure3-4: DigitalOutputsConnectedinCurrentSinkingMode[-EB1] www.aerotech.com 89

Chapter3:-EB1I/OOptionBoard XC4eHardwareManual 3.2.DigitalInputs[-EB1] Inputbitsarearrangedingroupsof4andeachgroupsharesacommonpin.Thisletsagroupbeconnectedto currentsourcingorcurrentsinkingdevices,basedontheconnectionofthecommonpininthatgroup. Tobeabletoconnectaninputgrouptocurrentsourcingdevices,connecttheinputgroup'scommonpin tothepowersupplyreturn(-).RefertoFigureFigure3-6. Tobeabletoconnectaninputgrouptocurrentsinkingdevices,connecttheinputgroup'scommonpinto thepowersupplysource(+).RefertoFigureFigure3-7. Thedigitalinputsarenotdesignedforhigh-voltageisolationapplications.Theyshouldonlybeusedwith ground-referencedcircuits. Table3-6: DigitalInputSpecifications[-EB1] InputVoltage ApproximateInputCurrent TurnOnTime TurnOffTime +5Vto+24V 6mA 10µs 43µs Table3-7: DigitalInput1ConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector

1 InputCommonforInputs4-7 N/A

2 Input4(Optically-Isolated) Input

3 Input5(Optically-Isolated) Input

4 Input6(Optically-Isolated) Input

5 Input7(Optically-Isolated) Input

6 InputCommonforInputs8-11 N/A

7 Input8(Optically-Isolated) Input

8 Input9(Optically-Isolated) Input

9 Input10(Optically-Isolated) Input

10 Input11(Optically-Isolated) Input

Table3-8: MatingConnectorPartNumbersfortheDigitalInput1Connector[-EB1] MatingConnector AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 10-PinTerminalBlock ECK02395 Phoenix1700841 0.5-0.14[20-26] 90 www.aerotech.com

XC4eHardwareManual Chapter3:-EB1I/OOptionBoard Table3-9: DigitalInput2ConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector

1 InputCommonforInputs12-15 N/A

2 Input12(Optically-Isolated) Input

3 Input13(Optically-Isolated) Input

4 Input14(Optically-Isolated) Input

5 Input15(Optically-Isolated) Input

6 InputCommonforInputs16-19 N/A

7 Input16(Optically-Isolated) Input

8 Input17(Optically-Isolated) Input

9 Input18(Optically-Isolated) Input

10 Input19(Optically-Isolated) Input

Table3-10: MatingConnectorPartNumbersfortheDigitalInput2Connector[-EB1] MatingConnector AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 10-PinTerminalBlock ECK02395 Phoenix1700841 0.5-0.14[20-26] Figure3-5: DigitalInputsSchematic[-EB1] www.aerotech.com 91

Chapter3:-EB1I/OOptionBoard XC4eHardwareManual NOTE:Eachbankoffourinputsmustbeconnectedinanallsourcingorallsinkingconfiguration. Figure3-6: DigitalInputsConnectedtoCurrentSourcing(PNP)Devices[-EB1] Figure3-7: DigitalInputsConnectedtoCurrentSinking(NPN)Devices[-EB1] 92 www.aerotech.com

XC4eHardwareManual Chapter3:-EB1I/OOptionBoard 3.3.AnalogOutputs[-EB1] Theanalogoutputcanbesetfromwithinaprogramoritcanbeconfiguredtoechothestateofselectservo loopnodes. Theanalogoutputissettozerowhenyoupoweronthesystemorresetthedrive. Table3-11: AnalogOutputSpecifications[-EB1] Specification Value OutputVoltage -10Vto+10 V OutputCurrent 5mA Resolution(bits) 16bits Table3-12: AnalogOutputConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector

1 AnalogOutput1 Output

2 AnalogOutput2 Output

3 AnalogOutput3 Output

4 Ground N/A

Table3-13: MatingConnectorPartNumbersfortheAnalogOutputConnector[-EB1] Type AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 4-PinTerminalBlock ECK02399 Phoenix1768004 0.5-0.14[20-26] Figure3-8: AnalogOutputTypicalConnection[-EB1] www.aerotech.com 93

Chapter3:-EB1I/OOptionBoard XC4eHardwareManual 3.4.AnalogInputs[-EB1] Tointerfacetoasingle-ended,non-differentialvoltagesource,connectthesignalcommonofthesourceto thenegativeinputandconnecttheanalogsourcesignaltothepositiveinput.Afloatingsignalsourcemust bereferencedtotheanalogcommon.RefertoFigure3-9. Table3-14: DifferentialAnalogInputSpecifications[-EB1] Specification Value (AI+)-(AI-) +10Vto-10V(1) Resolution(bits) 16bits InputImpedance 1MΩ 1.Signalsoutsideofthisrangemaydamagetheinput Table3-15: AnalogInputConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector 1 +5V Input

2 AnalogInput1+ Input

3 AnalogInput1- Input

4 AnalogInput2+ Input

5 AnalogInput2- Input

6 AnalogInput3+ Input

7 AnalogInput3- Input

8 Ground N/A

Table3-16: MatingConnectorPartNumbersfortheAnalogInputConnector[-EB1] MatingConnector AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 8-PinTerminalBlock ECK02397 Phoenix1908101 0.5-0.14[20-26] Figure3-9: AnalogInputTypicalConnection[-EB1] 94 www.aerotech.com

XC4eHardwareManual Chapter3:-EB1I/OOptionBoard 3.5.PositionSynchronizedOutput(PSO)Interface[-EB1] ThePSOoutputsignalisavailableonthe-EB1optionboardintwosignalformats:TTLandIsolated. ThePSOsignalisalsoavailableontheAUXI/Oconnector.RefertoSection2.5.2. Table3-17: PSOSpecifications[-EB1] Specification Value Output TTL 5V,16mA(max) Isolated 5-24V,250mA MaximumPSOOutput(Fire)Frequency TTL 12.5MHz Isolated 5MHz OutputLatency [Fireeventtooutputchange] TTL 5ns Isolated 150ns Table3-18: PSOInterfaceConnectorPinout[-EB1] Pin# Description In/Out/Bi Connector

1 PSOOutput+ Output

2 PSOOutput- Output

3 PSO Output(TTL) Output

Table3-19: MatingConnectorPartNumbersforthePSOInterfaceConnector[-EB1] Type AerotechP/N ThirdPartyP/N WireSize:mm2[AWG] 4-PinTerminalBlock ECK02399 Phoenix1768004 0.5-0.14[20-26] www.aerotech.com 95

Chapter3:-EB1I/OOptionBoard XC4eHardwareManual IsolatedSignals Thisoutputsignalisafully-isolated5-24Vcompatibleoutputcapableofsourcingorsinkingcurrent.This outputisnormallyopenandonlyconductscurrentwhenaPSOfireeventoccurs. ThePSO IsolatedOutputsareoverloadprotectedandwillturnoffifthemaximumoutputcurrentis exceeded. Figure3-10: PSOOutputSourcesCurrent Figure3-11: PSO OutputSinksCurrent TTL Signals Thisoutputsignalisa5VTTLsignalwhichisusedtodriveanoptocouplerorgeneralpurposeTTLinput. Thissignalisactivehighandisdrivento5VwhenaPSOfireeventoccurs. Figure3-12: PSOTTL OutputsSchematic 96 www.aerotech.com

XC4eHardwareManual Chapter4:CablesandAccessories Chapter4:CablesandAccessories NOTE:FindAerotechcabledrawingsonthewebsiteat http://www.aerotechmotioncontrol.com/manuals/index.aspx. Table4-1: StandardInterconnectionCables CablePart# Description Joystick SeeSection4.1. ECZ01231 BBA32InterconnectCable (1)The“-xx”indicateslengthindecimeters.“-yy”wouldindicatelengthinfeet. www.aerotech.com 97

Chapter4:CablesandAccessories XC4eHardwareManual 4.1.JoystickInterface AerotechMulti-AxisJoystick(NEMA12(IP54)rated)ispoweredfrom5Vandhasanominal2.5Voutputin thecenterdetentposition.Threebuttonsareusedtoselectaxispairsandspeedranges.Anoptional interlocksignalisusedtoindicatetothecontrollerthatthejoystickispresent.Joystickcontrolwillnot activateunlessthejoystickisinthecenterlocation.Thirdpartydevicescanbeusedprovidedtheyproduce asymmetricoutputvoltagewithintherangeof-10Vto+10V. ConnectingjoystickwithanAerotechcable,allAerotechcablesarelabeledtoidentifytheconnectorand connections.ThejoystickparametersmustbesettomatchtheanaloganddigitalI/O connections. Thefollowingdrawingsillustratehowtoconnectasingle-ortwo-axisjoystick.RefertotheHelpfilefor programminginformationabouthowtochangejoystickparameters. Figure4-1: TwoAxisJoystickInterface(totheAuxI/Ooftwodrives) 98 www.aerotech.com

XC4eHardwareManual Chapter4:CablesandAccessories Figure4-2: TwoAxisJoystickInterface(totheI/O board) www.aerotech.com 99

Chapter4:CablesandAccessories XC4eHardwareManual 4.2.HandwheelInterface Ahandwheelcanbeusedtomanuallycontrolaxisposition.Thehandwheelmustprovide5Vdifferential quadraturesignalstotheXC4e NOTE:YoucanfindinstructionsonhowtoenablethehandwheelintheHelpfile. ConnectahandwheeltotheAuxI/OasshowninFigure4-3orFigure4-4. Figure4-3: HandwheelInterconnectiontoAuxI/OConnector Figure4-4: HandwheelInterconnectiontotheAuxI/OthroughaBBA32Module 100 www.aerotech.com

XC4eHardwareManual Chapter5:Maintenance Chapter5:Maintenance DANGER:BeforeyouopentheXC4echassis,youmustdisconnecttheMainspowerconnection. DANGER:Alltestsmustbedonebyanapprovedservicetechnician.Voltagesinsidethecontrollerandattheinputandoutputpowerconnectionscankillyou. 5.1.PreventativeMaintenance DoaninspectionoftheXC4eandtheexternalwiringonetimeeachmonth.Itmightbenecessarytodomore frequentinspectionsbasedon: l Theoperatingconditionsofthesystem. l Howyouusethesystem. Table5-1: PreventativeMaintenance Check ActiontobeTaken Examinethechassisforhardwareandpartsthatare damagedorloose. Itisnotnecessarytodoaninternalinspection unlessyouthinkinternaldamageoccurred. Repairalldamagedparts. Doaninspectionofthecoolingvents. Removeallmaterialthatcollectedinthevents. Examinetheworkareatomakesurethereareno fluidsandnoelectricallyconductivematerials. Donotletfluidsandelectricallyconductivematerial gointotheXC4e. Examineallcablesandconnectionstomakesure theyarecorrect. Makesurethatallconnectionsarecorrectly attachedandnotloose. Replacecablesthatareworn. Replaceallbrokenconnectors. Cleaning DANGER:BeforeyoucleantheXC4e,disconnecttheelectricalpowerfromthedrive. Useaclean,dry,softclothtocleanthechassisoftheXC4e.Ifnecessary,youcanuseacloththatismoist withwaterorisopropylalcohol.Ifyouuseamoistcloth,makesurethatmoisturedoesnotgointotheXC4e. Alsomakesurethatitdoesnotgoontotheouterconnectorsandcomponents. DonotusefluidsandspraystocleantheXC4ebecausetheycaneasilygointothechassisorontotheouter connectorsandcomponents.IfacleaningsolutiongoesintotheXC4e,internalcontaminationcancause corrosionandelectricalshortcircuits. Donotcleanthelabelswithacleaningsolutionbecauseitmightremovethelabelinformation. www.aerotech.com 101

Chapter5:Maintenance XC4eHardwareManual 5.2.FuseSpecifications WARNING:Replacefusesonlywiththefactory-specifiedvalueandtype. Table5-2: ControlBoardFuseSpecifications FuseDescription Size AerotechP/N ThirdPartyP/N F100ControlPoweratLineInput(L) 2AS.B. EIF01044Littelfuse0877002.MXEP F101-SX1(ExternalShunt)Option 8AS.B. EIF01022 Littelfuse0215008.HXP F102MotorBusSupplyatAC1XC4e-10) 5AS.B. EIF01023 Littelfuse215005.HXP MotorBusSupplyatAC1XC4e-20/-30) 10AS.B. EIF01020 Littelfuse0215010.HXP 102 www.aerotech.com

XC4eHardwareManual AppendixA:WarrantyandFieldService AppendixA:WarrantyandFieldService Aerotech,Inc.warrantsitsproductstobefreefromharmfuldefectscausedbyfaultymaterialsorpoor workmanshipforaminimumperiodofoneyearfromdateofshipmentfromAerotech.Aerotech’sliabilityis limitedtoreplacing,repairingorissuingcredit,atitsoption,foranyproductsthatarereturnedbytheoriginal purchaserduringthewarrantyperiod.Aerotechmakesnowarrantythatitsproductsarefitfortheuseor purposetowhichtheymaybeputbythebuyer,whetherornotsuchuseorpurposehasbeendisclosedto Aerotechinspecificationsordrawingspreviouslyorsubsequentlyprovided,orwhetherornotAerotech’s productsarespecificallydesignedand/ormanufacturedforbuyer’suseorpurpose.Aerotech’sliabilityon anyclaimforlossordamagearisingoutofthesale,resale,oruseofanyofitsproductsshallinnoevent exceedthesellingpriceoftheunit. THEEXPRESSWARRANTYSETFORTHHEREINISINLIEUOFANDEXCLUDESALLOTHER WARRANTIES,EXPRESSEDORIMPLIED,BYOPERATIONOFLAWOROTHERWISE.INNO EVENTSHALLAEROTECHBELIABLEFORCONSEQUENTIALORSPECIALDAMAGES. ReturnProductsProcedure Claimsforshipmentdamage(evidentorconcealed)mustbefiledwiththecarrierbythebuyer.Aerotech mustbenotifiedwithinthirty(30)daysofshipmentofincorrectmaterial.Noproductmaybereturned, whetherinwarrantyoroutofwarranty,withoutfirstobtainingapprovalfromAerotech.Nocreditwillbegiven norrepairsmadeforproductsreturnedwithoutsuchapproval.A"ReturnMaterialsAuthorization(RMA)" numbermustaccompanyanyreturnedproduct(s).TheRMAnumbermaybeobtainedbycallinganAerotech servicecenterorbysubmittingtheappropriaterequestavailableonourwebsite(www.aerotech.com). Productsmustbereturned,prepaid,toanAerotechservicecenter(noC.O.D.orCollectFreightaccepted). Thestatusofanyproductreturnedlaterthanthirty(30)daysaftertheissuanceofareturnauthorization numberwillbesubjecttoreview. Visithttps://www.aerotech.com/global-technical-support.aspxforthelocationofyournearestAerotech Servicecenter. ReturnedProductWarrantyDetermination AfterAerotech'sexamination,warrantyorout-of-warrantystatuswillbedetermined.IfuponAerotech's examinationawarranteddefectexists,thentheproduct(s)willberepairedatnochargeandshipped, prepaid,backtothebuyer.Ifthebuyerdesiresanexpeditedmethodofreturn,theproduct(s)willbeshipped collect.Warrantyrepairsdonotextendtheoriginalwarrantyperiod. FixedFeeRepairs-Productshavingfixed-feepricingwillrequireavalidpurchaseorderorcreditcard particularsbeforeanyserviceworkcanbegin. AllOtherRepairs-AfterAerotech'sevaluation,thebuyershallbenotifiedoftherepaircost.Atsuch timethebuyermustissueavalidpurchaseordertocoverthecostoftherepairandfreight,orauthorize theproduct(s)tobeshippedbackasis,atthebuyer'sexpense.Failuretoobtainapurchaseorder numberorapprovalwithinthirty(30)daysofnotificationwillresultintheproduct(s)beingreturnedasis, atthebuyer'sexpense. Repairworkiswarrantedforninety(90)daysfromdateofshipment.Replacementcomponentsare warrantedforoneyearfromdateofshipment. www.aerotech.com 103

AppendixA:WarrantyandFieldService XC4eHardwareManual RushService Attimes,thebuyermaydesiretoexpeditearepair.Regardlessofwarrantyorout-of-warrantystatus,the buyermustissueavalidpurchaseordertocovertheaddedrushservicecost.Rushserviceissubjectto Aerotech'sapproval. On-siteWarrantyRepair IfanAerotechproductcannotbemadefunctionalbytelephoneassistanceorbysendingandhavingthe customerinstallreplacementparts,andcannotbereturnedtotheAerotechservicecenterforrepair,andif Aerotechdeterminestheproblemcouldbewarranty-related,thenthefollowingpolicyapplies: Aerotechwillprovideanon-siteFieldServiceRepresentativeinareasonableamountoftime,provided thatthecustomerissuesavalidpurchaseordertoAerotechcoveringalltransportationandsubsistence costs.Forwarrantyfieldrepairs,thecustomerwillnotbechargedforthecostoflaborandmaterial.If serviceisrenderedattimesotherthannormalworkperiods,thenspecialratesapply. Ifduringtheon-siterepairitisdeterminedtheproblemisnotwarrantyrelated,thenthetermsand conditionsstatedinthefollowing“On-SiteNon-WarrantyRepair”sectionapply. On-siteNon-WarrantyRepair IfanyAerotechproductcannotbemadefunctionalbytelephoneassistanceorpurchasedreplacementparts, andcannotbereturnedtotheAerotechservicecenterforrepair,thenthefollowingfieldservicepolicy applies: Aerotechwillprovideanon-siteFieldServiceRepresentativeinareasonableamountoftime,provided thatthecustomerissuesavalidpurchaseordertoAerotechcoveringalltransportationandsubsistence costsandtheprevailinglaborcost,includingtraveltime,necessarytocompletetherepair. ServiceLocations http://www.aerotech.com/contact-sales.aspx?mapState=showMap USA,CANADA,MEXICO CHINA GERMANY Aerotech,Inc. AerotechChina AerotechGermany GlobalHeadquarters Full-ServiceSubsidiary Full-ServiceSubsidiary Phone:+1-412-967-6440 Phone:+86(21)55086731 Phone:+49(0)9119679370 Fax:+1-412-967-6870 Fax:+49(0)91196793720 TAIWAN UNITEDKINGDOM AerotechTaiwan AerotechUnitedKingdom Full-ServiceSubsidiary Full-ServiceSubsidiary Phone:+886(0)287516690 Phone:+44(0)1256855055 Fax:+44(0)1256855649 Haveyourcustomerordernumberreadybeforecalling. 104 www.aerotech.com

XC4eHardwareManual AppendixB:RevisionHistory AppendixB:RevisionHistory RevisionDescription 1.02.00 Thefollowingsectionhasbeenupdated: l AgencyApprovals l Section2.3.1.PrimaryEncoderInputs l Section2.5.1.AuxiliaryEncoderInputs 1.01.00 Thefollowingsectionshavebeenupdated: l Section2.1.2. l Section2.10. 1.00.00NewManual www.aerotech.com 105

AppendixB:RevisionHistory XC4eHardwareManual 106 www.aerotech.com Thispageintentionallyleftblank.

www.aerotech.com Index 107 Index -EB1 AnalogInputs 94 AnalogOutputs 93 DigitalInputs 90 DigitalOutputs 86 I/OOptionBoard 85 PositionSynchronizedOutput(PSO)Interface95 -MX2 49 -MX3 49 -SX1 ExternalShuntOption 80 2006/42/EC 9 2014/30/EU 9 2014/35/EU 9 A AbsoluteEncoder(FeedbackConnector) 48 AbsoluteEncoderSchematic(Feedback Connector) 48 AClinefilter 28 AgencyApprovals 11 Altitude 25 AmbientTemperature 25 AnalogEncoder(FeedbackConnector) 49 AnalogEncoderPhasingReferenceDiagram 49 AnalogEncoderSchematic(Feedback Connector) 50 AnalogEncoderSpecifications(Feedback Connector) 49 AnalogInput0ontheAuxI/OConnector 77 AnalogInput0Schematic(AuxI/OConnector)77 AnalogInput0Specifications(AuxI/O Connector) 77 AnalogInputConnector[-EB1]MatingConnector PartNumbers 94 AnalogInputConnectorPinout[-EB1] 94 AnalogInputPins(AuxI/OConnector) 77 AnalogInputTypicalConnection[-EB1] 94 AnalogInputs[-EB1] 94 AnalogOutput0ontheAuxI/OConnector 76 AnalogOutput0Schematic(AuxI/OConnector)76 AnalogOutput0Specifications(AuxI/O Connector) 76 AnalogOutputConnector[-EB1]Mating ConnectorPartNumbers 93 AnalogOutputConnectorPinout[-EB1] 93 AnalogOutputPins(AuxI/OConnector) 76 AnalogOutputSpecifications[-EB1] 93 AnalogOutputTypicalConnection[-EB1] 93 AnalogOutputs[-EB1] 93 AuxI/OConnector AnalogInput0 77 AnalogOutput0 76 AuxiliaryEncoderInputs 66 DigitalInputs 73 DigitalOutputs 70 High-SpeedUserInputs 75 PositionSynchronizedOutput 68 PSO 68 AuxI/OConnectorMatingConnectorPart Numbers 65 AuxiliaryEncoderAnalogSignalSpecifications (AuxI/OConnector) 66 AuxiliaryEncoderInputs(AuxI/OConnector) 66 AuxiliaryEncoderInputsSchematic(AuxI/O Connector) 67 XC4eHardwareManual Index

AuxiliaryEncoderRS-422SignalSpecifications (AuxI/OConnector) 66 AuxiliaryI/OConnector 65 AuxiliaryI/OConnectorPinAssignment 65 AuxiliaryI/OPins(AuxI/OConnector) 66 B BiSSabsoluteencoder 48 BrakeConnectedtotheFeedbackConnector59 BrakeControlRelaySpecifications 59 BrakeOutputConnectorPinout 78 BrakeOutputPinsontheFeedbackConnector59 BrakeOutputs(FeedbackConnector) 59 BrakePowerSupplyConnector 78 BrakePowerSupplyConnectorMating ConnectorPartNumbers 78 BrushlessMotorConfiguration(MotorPower OutputConnector) 38 BrushlessMotorConnections(MotorPower OutputConnector) 38 BrushlessMotorPhasingGoal 40 BrushlessMotorPhasingOscilloscopeExample40 BrushlessMotorPoweredMotorPhasing 39 BrushlessMotorUnpoweredMotorand FeedbackPhasing 40 C CableWires BrushlessMotors 38 DCBrushMotors 41 StepperMotors 43 Cables HyperWire 79 SyncPort 82 CablesandAccessories 97 cables,examining 101 CAN/CSA-C22.2No.61010-1 11 Checkforfluidsorelectricallyconductive materialexposure 101 Cleaning 101 Commands Sync 82 connections,examining 101 ContinuousOutputCurrentspecifications 20 ControlandMotorPowerWiringusingaTM3or TM5Transformer 35 ControlBoardFuseSpecifications 102 ControlSupplyConnections 27 ControlSupplyConnector 27 MatingConnectorPartNumbers 27 WiringSpecifications 27 ControlSupplyspecifications 20 coolingvents,inspecting 101 D DCBrushMotorConfiguration(MotorPower OutputConnector) 41 DCBrushMotorConnections(MotorPower OutputConnector) 41 DCBrushMotorPhasing 42 DeclarationofConformity 9 DifferentialAnalogInputSpecifications[-EB1] 94 DigitalInput1Connector[-EB1]Mating ConnectorPartNumbers 90 DigitalInput1ConnectorPinout[-EB1] 90 DigitalInput2Connector[-EB1]Mating ConnectorPartNumbers 91 DigitalInput2ConnectorPinout[-EB1] 91 DigitalInputPinsontheAuxI/OConnector 73 DigitalInputSpecifications(AuxI/OConnector)73 DigitalInputSpecifications[-EB1] 90 DigitalInputs(AuxI/OConnector) 73 DigitalInputs[-EB1] 90 108 Index www.aerotech.com

www.aerotech.com Index 109 DigitalInputsConnectedtoaCurrentSinking Device[-EB1] 92 DigitalInputsConnectedtoaCurrentSourcing Device[-EB1] 92 DigitalInputsConnectedtoCurrentSinking Devices(AuxI/OConnector) 74 DigitalInputsConnectedtoCurrentSourcing Devices(AuxI/OConnector) 74 DigitalInputsSchematic(AuxI/OConnector) 73 DigitalInputsSchematic[-EB1] 91 DigitalOutput1Connector[-EB1]Mating ConnectorPartNumbers 87 DigitalOutput1ConnectorPinout[-EB1] 87 DigitalOutput2Connector[-EB1]Mating ConnectorPartNumbers 87 DigitalOutput2ConnectorPinout[-EB1] 87 DigitalOutputPins(AuxI/OConnector) 70 DigitalOutputSchematic(AuxI/OConnector)71 DigitalOutputSpecifications(AuxI/OConnector)70 DigitalOutputSpecifications[-EB1] 86 DigitalOutputs(AuxI/OConnector) 70 DigitalOutputs[-EB1] 86 DigitalOutputsConnectedinCurrentSinking Mode(AuxI/OConnector) 72 DigitalOutputsConnectedinCurrentSinking Mode[-EB1] 89 DigitalOutputsConnectedinCurrentSourcing Mode(AuxI/OConnector) 72 DigitalOutputsConnectedinCurrentSourcing Mode[-EB1] 89 DigitalOutputsSchematic[-EB1] 88 Dimensions 23 Dimensions(without-EB1) 23 Dimensionswith-EB1 24 DriveandSoftwareCompatibility 26 E EfficiencyofPowerAmplifierspecifications 20 ElectricalSpecifications 20 ElectromagneticCompatibility(EMC) 9 EMC/CECompliance 36 Enclosure 22 encoder absolute 48 EncoderandHallSignalDiagnostics 39 EncoderFaultInput(FeedbackConnector) 55 EncoderFaultInputPinontheFeedback Connector 55 EncoderInput(FeedbackConnector) 46 EncoderInputPinsontheFeedbackConnector46 EncoderPhasing 51 EncoderPhasingReferenceDiagram 51 EndofTravelLimitInput(FeedbackConnector)56 EndofTravelLimitInputConnections 57 EndofTravelLimitInputDiagnosticDisplay 58 EndofTravelLimitInputPinsontheFeedback Connector 56 EndofTravelLimitInputSchematic 57 EndofTravelLimitPhasing 58 EnDatabsoluteencoder 48 EnvironmentalSpecifications 25 EU2015/863 9 examiningparts cables 101 connections 101 examining,dangerousfluids 101 examining,dangerousmaterial 101 ExternalShuntOption[-SX1] 80 F FeedbackConnector 45 AbsoluteEncoder 48 XC4eHardwareManual Index

RS-422LineDriverEncoder 47 SineWaveEncoder 49 SquareWaveEncoder 47 ThermistorInput 54 TravelLimitInput 56 FeedbackMonitoring 39 Figure -EB1I/OOptionBoardConnectors 85 AbsoluteEncoderSchematic(Feedback Connector) 48 AnalogEncoderSchematic(Feedback Connector) 50 AnalogInput0Schematic(AuxI/O Connector) 77 AnalogInputTypicalConnection[-EB1] 94 AnalogOutput0Schematic(AuxI/O Connector) 76 AnalogOutputTypicalConnection[-EB1] 93 AuxiliaryEncoderInputsSchematic(AuxI/O Connector) 67 BrakeConnectedtotheFeedbackConnector59 BrushlessMotorConfiguration(MotorPower OutputConnector) 38 ControlSupplyConnections 27 DCBrushMotorConfiguration(MotorPower OutputConnector) 41 DigitalInputsConnectedtoaCurrentSinking Device[-EB1] 92 DigitalInputsConnectedtoaCurrent SourcingDevice[-EB1] 92 DigitalInputsConnectedtoCurrentSinking Devices(AuxI/OConnector) 74 DigitalInputsConnectedtoCurrentSourcing Devices(AuxI/OConnector) 74 DigitalInputsSchematic(AuxI/OConnector)73 DigitalInputsSchematic[-EB1] 91 DigitalOutputSchematic(AuxI/OConnector)71 DigitalOutputsConnectedinCurrentSinking Mode(AuxI/OConnector) 72 DigitalOutputsConnectedinCurrent SourcingMode(AuxI/OConnector)72 DigitalOutputsSchematic[-EB1] 88 Dimensions(without-EB1) 23 Dimensionswith-EB1 24 EndofTravelLimitInputConnections 57 EndofTravelLimitInputDiagnosticDisplay58 EndofTravelLimitInputSchematic 57 Hall-EffectInputsSchematic 53 High-SpeedInputs 75 HomeLimitInputConnections 57 HomeLimitInputDiagnosticDisplay 58 HomeLimitInputSchematic 57 IsolatedOutputCurrentSinksSchematic (PSO) 96 IsolatedOutputCurrentSourcesSchematic (PSO) 96 MotorSupplyConnections 28 OutputsConnectedinCurrentSinkingMode [-IO] 89 OutputsConnectedinCurrentSourcing Mode[-EB1] 89 PositiveMotorDirection 39 PSOInterface(AuxI/OConnector) 69 110 Index www.aerotech.com

www.aerotech.com Index 111 PSOIsolatedOutputSinksCurrent 96 PSOIsolatedOutputSourcesCurrent 96 PSOTTLOutputsSchematic 96 SquareWaveEncoderSchematic(Feedback Connector) 47 StepperMotorConfiguration 43 STOTiming 64 ThermistorInputSchematic 54 TTLOutputsSchematic(PSO) 96 TypicalSTOConfiguration 61 fluids,dangerous 101 FunctionalDiagram 19 FuseSpecifications 102 ControlSupplyatL 102 ExternalShunt(-SX1) 102 MotorSupplyatAC1 102 G GlobalTechnicalSupport 2 H Hall-EffectFeedbackPinsontheFeedback Connector 53 Hall-EffectInputs(FeedbackConnector) 53 Hall-EffectInputsSchematic 53 HandwheelInterconnection(toAuxI/Othrough aBBA32Module) 100 HandwheelInterconnectiontotheAuxI/O Connector 100 HandwheelInterface 100 High-SpeedInputPinsontheAuxI/OConnector75 High-SpeedInputSpecifications 75 High-SpeedInputs 75 High-SpeedUserInputs(AuxI/OConnector) 75 HomeLimitInput(FeedbackConnector) 56 HomeLimitInputConnections 57 HomeLimitInputDiagnosticDisplay 58 HomeLimitInputPinsontheFeedback Connector 56 HomeLimitInputSchematic 57 Humidity 25 HyperWire 79 CablePartNumbers 79 CardPartNumber 79 I I/OOptionBoard[-EB1] 85 InputPowerConnections 27 inspectingcoolingvents 101 Inspection 101 InstallationandConfiguration 27 Introduction 17 IP54Compliant 22 IsolatedOutputCurrentSinksSchematic(PSO)96 IsolatedOutputCurrentSourcesSchematic (PSO) 96 Isolation 20 J JoystickInterface 98 L LaserFiring 68 M Maintenance 101 material,electricallyconductive 101 MatingConnector AnalogOutputConnector[-EB1] 93 MatingConnectorP/N AnalogInputConnector[-EB1] 94 AuxI/OConnector 65 BrakePowerSupplyConnector 78 XC4eHardwareManual Index

DigitalInput1Connector[-EB1] 90 DigitalInput2Connector[-EB1] 91 DigitalOutput1Connector[-EB1] 87 DigitalOutput2Connector[-EB1] 87 FeedbackConnector 45 MotorPowerOutputConnector 37 MotorSupplyConnector 28 PSOConnector[-EB1] 95 STOConnector 60 MechanicalSpecifications 22 MinimizingConducted,Radiated,andSystem NoiseforEMC/CECompliance 36 MinimumLoadInductancespecifications 20 ModesofOperation 20 MotorConnector MatingConnectorPartNumbers 45 MotorFunctionRelativetoSTOInputState 63 MotorPowerOutputConnector 37 BrushlessMotorConnections 38 DCBrushMotorConnections 41 MatingConnectorPartNumbers 37 Pinout 37 StepperMotorConnections 43 MotorSupplyConnections 28 MotorSupplyConnector 28 MatingConnectorPartNumbers 28 WiringSpecifications 28 MotorSupplyspecifications 20 MountingandCooling 22 MountingHardware 22 MountingOrientation 22 N NominalMotorOperatingVoltages/Required ACVoltages 29 O Operation 25 OutputVoltagespecifications 20 Overview 17 P PCConfigurationandOperationInformation 84 PeakOutputCurrentspecifications 20 Phasing DCBrushMotor 42 EndofTravelLimits 58 PoweredBrushlessMotor 39 StepperMotor 44 UnpoweredBrushlessMotor/Feedback 40 Pinout AnalogInputConnector[-EB1] 94 AnalogInputPins(AuxI/OConnector) 77 AnalogOutputConnector[-EB1] 93 AnalogOutputPins(AuxI/OConnector) 76 AuxiliaryI/OPins(AuxI/OConnector) 66 BrakeOutputConnector 78 BrakeOutputPins(FeedbackConnector) 59 DigitalInput1Connector[-EB1] 90 DigitalInput2Connector[-EB1] 91 DigitalInputPins(AuxI/OConnector) 73 DigitalOutput1Connector[-EB1] 87 DigitalOutputPins(AuxI/OConnector) 70 EncoderFaultInputPin(Feedback Connector) 55 EncoderInput(FeedbackConnector) 46 EndofTravelLimitInputPins(Feedback Connector) 56 112 Index www.aerotech.com

www.aerotech.com Index 113 FeedbackConnector 45 Hall-EffectFeedbackPins(Feedback Connector) 53 High-SpeedInputPins(AuxI/OConnector)75 HomeLimitInputPins(FeedbackConnector)56 MotorPowerOutputConnector 37 PrimaryEncoderInputs(Feedback Connector) 46 PSOInterfaceConnector[-EB1] 95 PSOPins(AuxI/OConnector) 68 STOConnector 60 ThermistorInputPin(FeedbackConnector)54 Pollution 25 PositionFeedbackintheDiagnosticDisplay 52 PositionSynchronizedOutput(AuxI/O Connector) 68 PositionSynchronizedOutput(PSO)Interface[- EB1] 95 PositiveMotorDirection 39 PowerAmplifierBandwidthspecifications 20 PowerRequirements 21 PreventativeMaintenance 101 PrimaryEncoderInput(FeedbackConnector)46 PrimaryEncoderInputPinsontheFeedback Connector 46 ProtectiveFeatures 20 PSO IsolatedOutputSinksCurrentSchematic 96 IsolatedOutputSourcesCurrentSchematic96 TTLOutputsSchematic 96 PSO(AuxI/OConnector) 68 PSOConnector[-EB1]MatingConnectorPart Numbers 95 PSOInterface(AuxI/OConnector) 69 PSOInterfaceConnectorPinout[-EB1] 95 PSOOutputSources 68 PSOPins(AuxI/OConnector) 68 PSOSpecifications(AuxI/OConnector) 68 PSOSpecifications[-EB1] 95 PWMSwitchingFrequencyspecifications 20 Q QuickInstallationGuide 15 QuickStartConnections 15 R Resoluteabsoluteencoder 48 RevisionHistory 105 RS-422EncoderSpecifications(Feedback Connector) 47 RS-422LineDriverEncoder 47 S SafeTorqueOffInput(STO) 60 SafetyProceduresandWarnings 13 serialdatastream 48 SineWaveEncoder(FeedbackConnector) 49 Specifications AnalogEncoder(FeedbackConnector) 49 AnalogInput0(AuxI/OConnector) 77 AnalogOutput0(AuxI/OConnector) 76 AnalogOutputs[-EB1] 93 AuxiliaryEncoderAnalogSignals(AuxI/O Connector) 66 AuxiliaryEncoderRS-422Signals(AuxI/O Connector) 66 BrakeControlRelay 59 ControlBoardFuses 102 ControlSupplyConnectorWiring 27 DifferentialAnalogInputs[-EB1] 94 DigitalInputs(AuxI/OConnector) 73 DigitalInputs[-EB1] 90 XC4eHardwareManual Index

DigitalOutputs(AuxI/OConnector) 70 DigitalOutputs[-EB1] 86 High-SpeedInputs 75 MotorSupplyConnectorWiring 28 PSO(AuxI/OConnector) 68 PSO[-EB1] 95 RS-422Encoder(FeedbackConnector) 47 SquareWaveEncoder(Feedback Connector) 47 STOElectricalSpecifications 60 UnitWeight 22 SquareWaveEncoder 47 SquareWaveEncoderSchematic(Feedback Connector) 47 SquareWaveEncoderSpecifications(Feedback Connector) 47 StandardFeatures 18 StepperMotorConfiguration 43 StepperMotorConnections(MotorPowerOutput Connector) 43 StepperMotorPhasing 44 STO 60 ConnectorPinout 60 Diagnostics 64 ElectricalSpecifications 60 ExternalDelayTimer 63 FunctionalDescription 62 MatingConnectorPartNumbers 60 MotorFunctionRelativetotheSTOInput State 63 SignalDelay 63 Standards 62 StandardsData 62 StartupValidationTesting 63 Timing 64 TypicalConfiguration 61 Support 2 Sync-RelatedCommands 82 SyncPortCables 82 SyncPorts 82 SystemPowerRequirements 21 T TableofContents 3 TechnicalSupport 2 ThermistorInput(FeedbackConnector) 54 ThermistorInputPinontheFeedbackConnector54 ThermistorInputSchematic 54 TM3 29 TM5 29 TransformerExamples 29 TransformerOptions 29 TravelLimitInput(FeedbackConnector) 56 TTLOutputsSchematic(PSO) 96 TV0.3-28 29 TV0.3-28-56-STTransformer 29 TV0.3-28-56-STTransformer(160VDCBus) 32 TV0.3-28-56-STTransformer(40VDCBus) 30 TV0.3-28-56-STTransformer(80VDCBus) 31 TV0.3-28Transformer(40VDCBus) 33 TV0.3-56 29 TV0.3-56Transformer(80VDCBus) 34 TwoAxisJoystickInterface 98 TwoAxisJoystickInterface(totheI/Oboardof twodrives) 99 TypicalSTOConfiguration 61 U UnitWeight 22 Use 25 114 Index www.aerotech.com

www.aerotech.com Index 115 UserPowerSupplyspecifications 20 W WarrantyandFieldService 103 WireColorsforAerotech-SuppliedBrushless MotorCables 38 WireColorsforAerotech-SuppliedDCBrush MotorCables 41 WireColorsforAerotech-SuppliedStepperMotor Cables 43 XC4eHardwareManual Index

116 Index www.aerotech.com Thispageintentionallyleftblank.

Product Information

XC4E specifications and overview.

Summary

HARDWARE MANUAL

Description

HARDWARE MANUAL

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