Aerotech Automation1 iXC4 Bedienungsanleitung

Revision 2.04

Automation1 iXC4 and XC4

PWMDigital Drives

HARDWAREMANUAL

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Table of Contents

Automation1 iXC4 and XC4 PWMDigital Drives 1

Table of Contents 3

List of Figures 5

List of Tables 7

EU Declaration of Conformity 9

Agency Approvals 10

Safety Procedures and Warnings 11

Handling and Storage 13

Installation Overview 14

Chapter 1: iXC4/XC4 Overview 17

1.1. Electrical Specifications 21

1.1.1. System Power Requirements 22

1.2. Mechanical Specifications 23

1.2.1. Mounting and Cooling 23

1.2.2. Dimensions 24

1.3. Environmental Specifications 26

1.4. Drive and Software Compatibility 27

Chapter 2: Installation and Configuration 29

2.1. Input Power Connections 29

2.1.1. Control Supply Connector 29

2.1.2. Motor Supply Connector 30

2.1.3. Transformer Options 31

2.1.4. Minimizing Noise for EMC/CECompliance 38

2.2. Motor Power Output Connector 39

2.2.1. Brushless Motor Connections 40

2.2.1.1. Brushless Motor Powered Motor and Feedback Phasing 41

2.2.1.2. Brushless Motor Unpowered Motor and Feedback Phasing 42

2.2.2. DCBrush Motor Connections 43

2.2.2.1. DC Brush Motor Phasing 43

2.2.3. Stepper Motor Connections 44

2.2.3.1. Stepper Motor Phasing 44

2.2.4. Three Phase Stepper Motor Connections 45

2.2.4.1. Stepper Motor Phasing 45

2.3. Feedback Connector 46

2.3.1. Primary Encoder Inputs 47

2.3.1.1. Square WaveEncoder (Primary) 48

2.3.1.2. Absolute Encoder (Primary) 49

2.3.1.3. Sine Wave Encoder (Primary) [-MX1 Option] 50

2.3.1.4. Encoder Phasing 52

2.3.2. Hall-Effect Inputs 53

2.3.3. Thermistor Input 54

2.3.4. Encoder Fault Input 55

2.3.5. End of Travel and Home Limit Inputs 56

2.3.5.1. End of Travel and Home Limit Phasing 58

2.3.6. Brake Outputs 59

2.4. Safe Torque Off Input (STO) 60

2.4.1. STOStandards 62

2.4.2. STO Functional Description 63

2.4.3. STO Startup Validation Testing 64

2.4.4. STO Diagnostics 65

2.5. Auxiliary I/O Connector 66

2.5.1. Auxiliary Encoder Inputs 67

2.5.1.1. Square WaveEncoder (Auxiliary) 68

2.5.1.2. Absolute Encoder (Auxiliary) 69

2.5.2. Position Synchronized Output (PSO) 70

2.5.3. Digital Outputs 72

2.5.4. Digital Inputs 75

iXC4/XC4 Hardware Manual Table of Contents

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2.5.5. High-Speed Inputs 77

2.5.6. Analog Output 0 78

2.5.7. Analog Input 0 (Differential) 79

2.6. Brake Power Supply Connector 80

2.7. HyperWire Interface 81

2.8. External Shunt Option [-SX1] 82

2.9. Sync Port 84

2.10. System Interconnection 85

2.11. PC Configuration and Operation Information 88

Chapter 3: -EB1 I/O Option Board 89

3.1. Digital Outputs [-EB1] 90

3.2. Digital Inputs [-EB1] 94

3.3. Analog Outputs [-EB1] 97

3.4. Analog Inputs [-EB1] 98

3.5. PSOInterface [-EB1] 99

Chapter 4: Cables and Accessories 101

4.1. Joystick Interface 102

4.2. Handwheel Interface 104

Chapter 5: Maintenance 105

5.1. Preventative Maintenance 106

5.2. Fuse Specifications 107

Appendix A: Warranty and Field Service 109

Appendix B: Revision History 111

Index 113

Table of Contents iXC4/XC4 Hardware Manual

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List of Figures

Figure 1-1: iXC4 Digital Drive-Based Controller Labeled 17

Figure 1-2: XC4 Digital Drive Labeled 18

Figure 1-3: Functional Diagram 20

Figure 1-4: Dimensions 24

Figure 1-5: Dimensions [-EB1] 25

Figure 2-1: Control Supply Connections 29

Figure 2-2: Motor Supply Connections 30

Figure 2-3: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (40 VDC Bus) 32

Figure 2-4: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (80 VDC Bus) 33

Figure 2-5: TV0.3-28-56-ST Transformer Control and Motor Power Wiring (160 VDC Bus) 34

Figure 2-6: TV0.3-28 Transformer Control and Motor Power Wiring (40 VDC Bus) 35

Figure 2-7: TV0.3-56 Transformer Control and Motor Power Wiring (80 VDC Bus) 36

Figure 2-8: TM3/TM5 Transformer Control and Motor Power Wiring 37

Figure 2-9: Brushless Motor Configuration 40

Figure 2-10: Positive Motor Direction 41

Figure 2-11: Encoder and Hall Signal Diagnostics 41

Figure 2-12: Brushless Motor Phasing Oscilloscope Example 42

Figure 2-13: Brushless Motor Phasing Goal 42

Figure 2-14: DC Brush Motor Configuration 43

Figure 2-15: Positive Motor Direction 43

Figure 2-16: Stepper Motor Configuration 44

Figure 2-17: Positive Motor Direction 44

Figure 2-18: Three Phase Stepper Motor Configuration 45

Figure 2-19: Positive Motor Direction 45

Figure 2-20: Square Wave Encoder Schematic (Feedback Connector) 48

Figure 2-21: Absolute Encoder Schematic (Feedback Connector) 49

Figure 2-22: Sine Wave Encoder Phasing Reference Diagram 50

Figure 2-23: Sine Wave Encoder Schematic (Feedback Connector) 51

Figure 2-24: Encoder Phasing Reference Diagram (Standard) 52

Figure 2-25: Position Feedback in the DiagnosticDisplay 52

Figure 2-26: Hall-Effect Inputs Schematic (Feedback Connector) 53

Figure 2-27: Thermistor Input Schematic (Feedback Connector) 54

Figure 2-28: Encoder Fault Input Schematic (Feedback Connector) 55

Figure 2-29: End of Travel and Home Limit Input Connections 57

Figure 2-30: End of Travel and Home Limit Input Schematic (Feedback Connector) 57

Figure 2-31: End of Travel and Home Limit Input Diagnostic Display 58

Figure 2-32: Brake Connected to the 25-Pin Feedback Connector (Typical) 59

Figure 2-33: Typical STO Configuration 61

Figure 2-34: STO Timing 65

Figure 2-35: Square Wave Encoder Interface (Aux I/OConnector) 68

Figure 2-36: Absolute Encoder Schematic (Auxiliary I/O Connector) 69

Figure 2-37: PSO Interface 71

Figure 2-38: Digital Output Schematic (Aux I/OConnector) 73

Figure 2-39: Digital Outputs Connected in Current Sourcing Mode 74

Figure 2-40: Digital Outputs Connected in Current Sinking Mode 74

Figure 2-41: Digital Inputs Schematic (Aux I/OConnector) 75

Figure 2-42: Digital Inputs Connected to Current Sourcing Devices 76

Figure 2-43: Digital Inputs Connected to Current Sinking Devices 76

iXC4/XC4 Hardware Manual List of Figures

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Figure 2-44: High-Speed Inputs 77

Figure 2-45: Analog Output 0 Schematic 78

Figure 2-46: Analog Input 0 Schematic 79

Figure 2-47: Drive-Based System Wiring Drawing (Best Practice) 85

Figure 2-48: PC-Based System Wiring Drawing (Best Practice) 85

Figure 2-49: Drive-Based Controller System Interconnection (Best Practice) 86

Figure 2-50: PC-Based Controller System Interconnection (Best Practice) 87

Figure 3-1: -EB1 I/O Option Board Connectors (iXC4 shown) 89

Figure 3-2: Digital Outputs Schematic [-EB1] 92

Figure 3-3: Digital Outputs Connected in Current Sourcing Mode [-EB1] 93

Figure 3-4: Digital Outputs Connected in Current Sinking Mode [-EB1] 93

Figure 3-5: Digital Inputs Schematic [-EB1] 95

Figure 3-6: Digital Inputs Connected to Current Sourcing (PNP) Devices [-EB1] 96

Figure 3-7: Digital Inputs Connected to Current Sinking (NPN) Devices [-EB1] 96

Figure 3-8: Analog Output Typical Connection [-EB1] 97

Figure 3-9: Analog Input Typical Connection [-EB1] 98

Figure 3-10: PSO Output Sources Current 100

Figure 3-11: PSOOutput Sinks Current 100

Figure 3-12: PSO TTLOutputs Schematic 100

Figure 4-1: Two Axis Joystick Interface (to the Aux I/O of two drives) 102

Figure 4-2: Two Axis Joystick Interface (to the I/Oboard) 103

Figure 4-3: Handwheel Interconnection to Aux I/O Connector 104

Figure 4-4: Handwheel Interconnection to the Aux I/O through a BBA32 Module 104

List of Figures iXC4/XC4 Hardware Manual

6 www.aerotech.com

List of Tables

Table 1-1: Features and Options 19

Table 1-2: Electrical Specifications 21

Table 1-3: Mounting Specifications 23

Table 1-4: Environmental Specifications 26

Table 1-5: Drive and Software Compatibility 27

Table 2-1: Control Supply Wiring Specifications 29

Table 2-2: Mating Connector Part Numbers for the Control Supply Connector 29

Table 2-3: Motor Supply Connector Wiring Specifications 30

Table 2-4: Mating Connector Part Numbers for the Motor Supply Connector 30

Table 2-5: Nominal Motor Operating Voltages / Required ACVoltages 31

Table 2-6: TransformerOptions 31

Table 2-7: Motor Power Output Connector Pinout 39

Table 2-8: Mating Connector Part Numbers for the Motor Power Output Connector 39

Table 2-9: Wire Colors for Aerotech-Supplied Brushless Motor Cables 40

Table 2-10: Hall Signal Diagnostics 41

Table 2-11: Wire Colors for Aerotech-Supplied DCBrush Motor Cables 43

Table 2-12: Wire Colors for Aerotech-Supplied Stepper Motor Cables 44

Table 2-13: Feedback Connector Pinout 46

Table 2-14: Mating Connector Part Numbers for the Feedback Connector 46

Table 2-15: Multiplier Options 47

Table 2-16: Primary Encoder Input Pins on the Feedback Connector 47

Table 2-17: Square Wave Encoder Specifications 48

Table 2-18: Sine Wave Encoder Specifications 50

Table 2-19: Hall-Effect Feedback Pins on the Feedback Connector 53

Table 2-20: Thermistor Input Pin on the Feedback Connector 54

Table 2-21: Encoder Fault Input Pin on the Feedback Connector 55

Table 2-22: End of Travel and Home Limit Pins on the Feedback Connector 56

Table 2-23: Brake Output Pins on the Feedback Connector 59

Table 2-24: Brake Control Specifications 59

Table 2-25: STO Connector Pinout 60

Table 2-26: Mating Connector Part Numbers for the STOConnector 60

Table 2-27: STOElectrical Specifications 61

Table 2-28: STOStandards 62

Table 2-29: STOStandards Data 62

Table 2-30: STOSignal Delay 64

Table 2-31: Motor Function Relative to STOInput State 64

Table 2-32: STOTiming 65

Table 2-33: Auxiliary I/O Connector Pinout 66

Table 2-34: Mating Connector Part Numbers for the Auxiliary I/OConnector 66

Table 2-35: Auxiliary Encoder Pins on the Auxiliary I/OConnector 67

Table 2-36: Square Wave Encoder Specifications 68

Table 2-37: PSO Specifications 70

Table 2-38: PSOPins on the Auxiliary I/OConnector 70

Table 2-39: Digital Output Specifications 72

Table 2-40: Digital Output Pins on the Auxiliary I/O Connector 72

Table 2-41: Digital Input Specifications 75

Table 2-42: Digital Input Pins on the Auxiliary I/O Connector 75

Table 2-43: High-Speed Input Specifications 77

iXC4/XC4 Hardware Manual List of Tables

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Table 2-44: High-Speed Input Pins on the Auxiliary I/O Connector 77

Table 2-45: Analog Output Specifications 78

Table 2-46: Analog Output Pins on the Auxiliary I/O Connector 78

Table 2-47: Analog Input Specifications 79

Table 2-48: Analog Input Pins on the Auxiliary I/O Connector 79

Table 2-49: Brake Power Supply Connector Pinout 80

Table 2-50: Mating Connector Part Numbers for the Brake Power Supply Connector 80

Table 2-51: HyperWire Card Part Number 81

Table 2-52: HyperWire Cable Part Numbers 81

Table 2-53: -SX1Component Information 82

Table 2-54: Maximum Additional Storage Energy for a Standard iXC4/XC4 83

Table 2-55: Sync-Related Functions 84

Table 2-56: SyncPort Cables 84

Table 3-1: Digital Output Specifications [-EB1] 90

Table 3-2: Digital Output 1 Connector Pinout [-EB1] 91

Table 3-3: Mating Connector Part Numbers for the Digital Output 1 Connector [-EB1] 91

Table 3-4: Digital Output 2 Connector Pinout [-EB1] 91

Table 3-5: Mating Connector Part Numbers for the Digital Output 2 Connector [-EB1] 91

Table 3-6: Digital Input Specifications [-EB1] 94

Table 3-7: Digital Input 1 Connector Pinout [-EB1] 94

Table 3-8: Mating Connector Part Numbers for the Digital Input 1 Connector [-EB1] 94

Table 3-9: Digital Input 2 Connector Pinout [-EB1] 95

Table 3-10: Mating Connector Part Numbers for the Digital Input 2 Connector [-EB1] 95

Table 3-11: Analog Output Specifications [-EB1] 97

Table 3-12: Analog Output Connector Pinout [-EB1] 97

Table 3-13: Mating Connector Part Numbers for the Analog Output Connector [-EB1] 97

Table 3-14: Differential Analog Input Specifications [-EB1] 98

Table 3-15: Analog Input Connector Pinout [-EB1] 98

Table 3-16: Mating Connector Part Numbers for the Analog Input Connector [-EB1] 98

Table 3-17: PSO Specifications [-EB1] 99

Table 3-18: PSO Interface Connector Pinout [-EB1] 99

Table 3-19: Mating Connector Part Numbers for the PSO Interface Connector [-EB1] 99

Table 4-1: Standard Interconnection Cables 101

Table 5-1: LEDDescription 105

Table 5-2: Troubleshooting 105

Table 5-3: Preventative Maintenance 106

Table 5-4: Control Board Fuse Specifications 107

List of Tables iXC4/XC4 Hardware Manual

8 www.aerotech.com

EU Declaration of Conformity

Manufacturer Aerotech, Inc.

Address 101 Zeta Drive

Pittsburgh, PA 15238-2811

USA

Product iXC4/XC4

Model/Types All

This is to certify that the aforementioned product is in accordance with the applicable requirements

of the following directive(s):

2014/30/EU Electromagnetic Compatibility (EMC)

2014/35/EU Low Voltage Directive

2006/42/EC Machinery Directive

2011/65/EU RoHS 2 Directive

EU 2015/863 Amendment RoHS 3 Directive

and has been designed to be in conformity with the applicable requirements of the following

standard(s) when installed and used in accordance with the manufacturer’s supplied installation

instructions.

EN 61010-1:2010/A1:2016 Safety Requirements for Electrical Equipment

EN 61800-3:2004/A1:2011 EMCRequirements for Power Drives

IEC 61800-5-1:2016 Electrical Safety for Power Drive Systems

IEC 61800-5-2:2016 Functional Safety for Power Drive Systems

EN 55011:2000/A2:2003 Conducted and Radiated Emissions

EN 55022:1998 Conducted and Radiated Emissions

Authorized

Representative / Simon Smith, European Director

Aerotech Ltd

The Old Brick Kiln, Ramsdell, Tadley

Hampshire RG26 5PR

Engineer Verifying

Compliance / Alex Weibel

Aerotech, Inc.

101 Zeta Drive

Pittsburgh, PA 15238-2811

USA

Date 1/28/2022

iXC4/XC4 Hardware Manual EU Declaration of Conformity

www.aerotech.com 9

Agency Approvals

Aerotech tested its XC4 drives and found that they obey the standards that follow:

IMPORTANT: iXC4 certification is pending.

Approval: CUS NRTL

Approving Agency: TUV SUD America Inc.

Certificate #: U8V 068995 0028 Rev. 02

Standards: CAN/CSA-C22.2 No. 61010-1:2012,

EN 61010-1:2010/A1:2016,

UL 61010-1:2012

Approval: Safety Components (STO)

Approving Agency: TUVSUD

Certificate #: Z10 068995 0030 Rev. 00

Standards: EN ISO 13849-1:2015 (up to PL e),

IEC 61508-1:2010 (up to SIL3),

IEC 61508-2:2010 (up to SIL3),

IEC 61800-5-2:2016,

IEC 62061:2005 (up to SILCL3),

IEC 62061:2005/AMD1:2012 (up to SILCL3),

IEC 62061:2005/AMD2:2015 (up to SILCL3)

Visit https://www.tuev-sued.de/product-testing/certificates to view Aerotech's TÜV SÜD certificates.

Type the certificate number listed above in the search bar or type "Aerotech" for a list of all Aerotech

certificates.

Agency Approvals iXC4/XC4 Hardware Manual

10 www.aerotech.com

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