Copley Controls Xenus XTL-230-40 manual

Combining Today’s Best Technologies

For Tomorrow’s Break Through Discoveries

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Control Modes

Command Interface

Stepper commands

Single-ended or Differential selectable

™

DIGITAL SERVO DRIVE for BRUSHLESS/BRUSH MOTORS

Communications

Feedback

I/O - Digital

Accessories

Dimensions: mm [in]

Model

XTL-230-18

XTL-230-36

XTL-230-40

Vac

100 - 240

100 - 240

100 - 240

Ic

6

12

20

Ip

18

36

40

Add -S to part numbers above for sin/cos feedback, or add -R for resolver feedback models.

DESCRIPTION

Xenus combines CANopen networking with 100% digital control of brushless or brush motors in an off-line powered package that can operate from single or three-phase mains with continuous power output to 4 kW.

Standard models use quad A/B digital encoders for feedback. Two other versions are available for use with resolvers or sin/cos analog encoders.

Xenus operates as a Motion Control Device under the DSP-402 protocol of the CANopen DS-301 V4.01 (EN 50325-4) application

Drive commissioning is fast and simple using CME 2 software operating under Windows

®

communicating with Xenus via CAN or an

RS-232 link. CAN address selection is by a 16-position rotary switch bus, the additional address bits needed can come from programmable a complete motion index on command with S-curve acceleration & deceleration, top speed, and distance programmable. In PVT mode, the controller sends out a sequence of points each of which is an increment of a larger, more complex move than a single index or the dots” such that the motor reaches each point (Position) at the index, and home switches such that the drive moves the motor into a position that has an absolute reference to some part of the machine. Eleven logic inputs are programmable as limit or home switches, stepper/encoder pulse inputs, reset, digital torque or velocity reference, or motor over-temperature. A twelfth input is dedicated to the drive Enable function. Three programmable logic outputs are for reporting a drive fault or other status indications.

A fourth optically-isolated output can drive a motor brake from the external +24 Vdc power supply or can be programmed as a logic output.

In addition to CANopen motion commands, Xenus can operate as a stand-alone drive. Current and velocity modes accept ±10 Vdc analog, digital 50% PWM or PWM/polarity inputs. In position mode inputs can be incremental position commands from step-motor controllers in Pulse/Direction or CW/CCW format, ±10 Vdc analog, or A/B quadrature commands from a master-encoder. Pulse to position ratio is programmable for electronic gearing.

Power output of the drive varies with the input power which can range from 100 to 240 Vac, and from 47 to 63 Hz. Either single or three phase mains can be used giving Xenus the ability to work in the widest possible range of industrial settings. Signal and control circuits are isolated from the high-voltage power supply and inverter stage that connect to the mains. A +24 Vdc input powers control circuits for keep-alive operation permitting the drive power stage to be completely powered down without losing position information or communications with the control system.

Copley Controls, 20 Dan Road, Canton, MA 02021, USA Tel: 781-828-8090

Tech Support: E-mail: [email protected], Internet: http://www.copleycontrols.com

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GENERAL SPECIFICATIONS

Test conditions: Wye connected load: 2 mH line-line. Ambient temperature = 25 °C. Power input = 230 Vac, 60 Hz, 1 Ø

MODEL

XTL-230-18 XTL-230-36 XTL-230-40

Same specs for -S and -R models

OUTPUT CURRENT

Peak Current

Peak time

Continuous current (Note 1)

18 (12.7)

1

6 (4.24)

INPUT POWER

Mains voltage, phase, frequency

Maximum Mains Current, 1Ø (

Note 3

) 10.1

Maximum Mains current, 3Ø (

Note 3

) 6.4

+24 Vdc Control power

36 (25.5)

1

12 (8.5)

100~240

20.0

10.4

+20 to +32 Vdc, 500 mA max

40 (28.3)

1

20.0

15.4

Adc (Arms, sinusoidal) s

Vac, ±10%, 1 Ø or 3 Ø, 47~63 Hz

Arms

Arms

Required for operation

DIGITAL CONTROL

Digital Control Loops

Sampling rate (time)

Current, velocity, position. 100% digital loop control

Current loop: 15 kHz (67 µs), Velocity & position loops: 3 kHz (333 µs)

Bandwidth

Bus voltage compensation

Minimum load inductance

Current loop: 2.5 kHz typical, bandwidth will vary with tuning & load inductance

Changes in bus or mains voltage do not affect bandwidth

200 µH line-line

COMMAND INPUTS (NOTE: DIGITAL INPUT FUNCTIONS ARE PROGRAMMABLE)

Distributed Control Modes

ASCII

Stand-alone mode

Analog torque, velocity, position reference

Input impedance

Digital position reference

Digital torque & velocity reference

Indexing

Camming

Multiple drives accessible from a single RS-232 port

±10 Vdc, 12 bit resolution

74.8 k

Pulse/Direction, CW/CCW

Quad A/B Encoder

PWM , Polarity

PWM 50%

PWM frequency range

PWM minimum pulse width

Dedicated differential analog input

Between Ref(+), Ref(-)

Stepper commands (2 MHz maximum rate)

2 M line/sec, 8 Mcount/sec (after quadrature)

PWM = 0% - 100%, Polarity = 1/0

PWM = 50% ±50%, no polarity signal required

1 kHz minimum, 100 kHz maximum

220 ns

Up to 32 programs can be launched from inputs or ASCII commands. Each program can consist of moves, I/O commands, time delays, and other programmable operations.

Master quadrature encoder provides position as index to cam table.

Digital inputs initiate cam functions.

DIGITAL INPUTS

Number 12

[IN1] dedicated to drive enable function, other inputs are programmable

All inputs

DIGITAL OUTPUTS (NOTE 2)

Number

[OUT1], [OUT2], [OUT3]

Current rating

10 k pull-up to +5 Vdc or pull-down to ground, selectable in groups, active level programmable

4

Current-sinking MOSFET with 1 k pullup to +5 Vdc through diode

1 Adc max, +40 Vdc max. Functions programmable

MULTI-MODE ENCODER PORT

Secondary digital quadrature encoder (A, /A, B, /B, X, /X), 121 terminating resistors

18 M-counts/sec, post-quadrature (4.5 M-lines/sec)

Primary increment encoder for models with -S option that use sin/cos signals as analog Halls

As Output Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev

As Input from analog sin/cos encoders or resolvers. Buffered signals from digital quad A/B/X primary encoder

A, /A, B, /B, X, /X, from 26LS31 differential line driver

RS-232 PORT

Signals

Mode

Protocol

CAN PORTS

Signals

Format

RxD, TxD, Gnd in 6-position, 4-contact RJ-11 style modular connector

Full-duplex, DTE serial communication port for drive setup and control, 9,600 to 115,200 baud

Binary and ASCII formats

CANH, CANL, Gnd in 8-position RJ-45 style modular connector, wired as per CAN Cia DR-303-1, V1.1

CAN V2.0b physical layer for high-speed connections compliant

Address selection 16 position rotary switch on front panel with 3 additional address bits available as

STATUS INDICATORS

Drive Status

REGENERATION

Operation

Bicolor LED, drive status indicated by color, and blinking or non-blinking condition

Internal solid-state switch drives external regen resistor (see Ordering Guide for types)

Tolerance ±2 Vdc For either Cut-In or Drop-Out voltage

NOTES:

1. Heatsinking and/or forced-air cooling is required for continuous output power rating

2. Brake[OUT4] is programmable as motor brake, or as general purpose digital output

3. The actual mains current is dependent on the mains voltage, number of phases, and motor load and operating conditions.

The Maximum Mains Currents shown above occur when the drive is operating from the maximum input voltage and is producing the rated continuous output current at the maximum output voltage.



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GENERAL SPECIFICATIONS (CONTINUED)

PROTECTIONS

Short circuits

I

2

T Current limiting

Motor over temperature

MECHANICAL & ENVIRONMENTAL

Size

Weight

Ambient temperature

Humidity

Vibration

Shock

Contaminants

Environment

Cooling

™


Output to output, output to ground, internal PWM bridge faults

Programmable: continuous current, peak current, peak time

Drive shuts down when motor over-temperature switch changes to high-resistance state, or opens

7.55 in (191,8 mm) X 5.57 in (141,5 mm) X 2.57 in (65,3 mm)

3.0 lb (1.36 kg) for drive without heatsink

1.9 lb (0.86 kg) for XTL-HS heatsink, 1.26 lb (0.57 kg) for XTL-HL heatsink

0 to +45 °C operating, -40 to +85 °C storage

0% to 95%, non-condensing

2 g peak, 10~500 Hz (sine), IEC60068-2-6

10 g, 10 ms, half-sine pulse, IEC60068-2-27

Pollution degree 2

IEC68-2: 1990

Heat sink and/or forced air cooling required for continuous power output

AGENCY STANDARDS CONFORMANCE

EN 55011 : 1998 CISPR 11 (1997) Edition 2/Amendment 2:

EN 61000-6-1 : 2001

Medical (ISM) Radio Frequency Equipment

Electromagnetic Compatibility Generic Immunity Requirements

Following the provisions of EC Directive 89/336/EEC:

EN 61010-1 2nd Ed.: 2004 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory use

Following the provisions of EC Directive 2006/95/EC:

UL 508C 3rd Ed.: 2002 UL Standard for Safety for Power Conversion Equipment

FEEDBACK SPECIFICATIONS

ENCODER

DIGITAL QUAD A/B ENCODER

Type

Signals

Frequency

ANALOG ENCODER

Type

Signals

Frequency

Interpolation

DIGITAL HALLS

Type

Signals

ANALOG HALLS

Type

Signals

ENCODER POWER SUPPLY

Power Supply

Protection

MOTOR CONNECTIONS

Phase U, V, W

Hall U, V, W

Digital Encoder

Analog Encoder

Hall & encoder power

Motemp [IN5]

Signal ground

Brake [OUT4]

+24 Vdc

Frame ground

Quadrature, differential line driver outputs

A, /A, B, /B, (X, /X, index signals optional)

5 MHz line frequency, 20 MHz quadrature count frequency

Sin/cos, differential line driver outputs, 0.5 Vpeak-peak (1.0 Vpeak-peak differential) centered about 2.5 Vdc typical. Common-mode voltage 0.25 to 3.75 Vdc

Sin(+), sin(-), cos(+), cos(-)

230 kHz maximum line (cycle) frequency

10 bits/cycle (1024 counts/cycle)

Digital, single-ended, 120° electrical phase difference

U, V, W

HA/HB, differential line driver outputs, 0.5 Vpeak-peak (1.0 Vpeak-peak differential) centered about 2.5 Vdc typical. Common-mode voltage 0.25 to 3.75 Vdc

HA(+), HA(-), HB(+), HB(-)

Use Multi-mode port as primary incremental encoder input for position feedback

+5 Vdc @ 400 mA to power encoders & Halls

Current-limited to 750 mA @ 1 Vdc if overloaded

Encoder power developed from +24 Vdc so position information is not lost when AC mains power is removed

PWM outputs to 3-phase ungrounded Wye or delta connected brushless motors

Hall signals

A, /A, B, /B, X, /X, on standard models

Sin(+), sin(-), cos(+), cos(-), X, /X, on -S versions (X & /X index signals are digital)

+5 Vdc @ 400 mA maximum

Motor overtemperature sensor input, 4.99 k to +5 Vdc or ground

Return for encoder, Halls, and temperature sensor

Current-sinking motor brake driver

From drive +24 Vdc power supply to power motor brake

For motor cable shield



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FEEDBACK SPECIFICATIONS (CONTINUED)

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RESOLVER

RESOLVER

Type

Resolution

Reference frequency

Reference voltage

Reference maximum current 100 mA

Maximum RPM

Brushless, single-speed, 1:1 to 2:1 programmable transformation ratio

14 bits (equivalent to a 4096 line quadrature encoder)

7.5 kHz

2.8 Vrms, auto-adjustable by the drive to maximize feedback

10,000+

ENCODER EMULATION

Resolution

Buffered encoder outputs

MOTOR CONNECTIONS

Phase U, V, W

Resolver

Programmable to 16,384 counts/rev (4096 line encoder equivalent)

26C31 differential line driver

PWM outputs to 3-phase ungrounded Wye or delta connected brushless motors

R1, R2, S1, S2, S3, S4

Signal ground

Brake [OUT4]

+24 Vdc

Frame ground

Disables drive when motor over-temperature condition occurs

Same input circuit as GP digital inputs

Return for temperature sensor

Current-sinking motor brake driver

From drive +24 Vdc power supply to power motor brake

For motor cable shield

DIMENSIONS

Inches (mm)

7.55 (191,7)

1.5 (38,1)

8 x 0.160

(4,1)

3.00 (76,2)

Chassis Grounding:

For CE compliance and machine safety use external tooth lockwashers between mounting screw head and drive heatplate. Recommended screws are #6-32 (M3.5) torqued to 8~10 lb·in (0.79~1.02 N·m).

7.15 (181,6)

5.54 (140,7)

1.00 (25,4)

2.55 (64,8)

0.925 (23,5)

0.88 (22,4)

LOW-PROFILE

HEATSINK OPTION (-HL)

6.75

(171,5)

STANDARD

HEATSINK OPTION (-HS)

1.99 (50,5)



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COMMUNICATIONS

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CME 2 SOFTWARE

D r i v e s e t u p i s f a s t a n d e a s y u s i ng C M E 2 s o f tw a r e c o m m u n i c a t i ng v i a R S - 2 3 2 o r o v e r t h e C A N b u s .

All of the operations needed to configure the drive are accessible through this powerful and intuitive program. Auto-

CME 2 does the rest thereafter. Encoder wire swapping to establish the direction of positive motion is eliminated.

Motor data can be saved as .ccm files. Drive data is saved as .ccx files that contain all drive settings plus motor data. T h is eases system m anagemen t as files ca n be cross- reference d to dr ives. Once a drive con figuration h a s b e e n c o m p l e t e d s y s t e m s c a n b e r e p l i c a t e d e a s i l y w i t h t h e s a m e s e t u p a n d p e r f o r m a n c e .

When operating as a stand-alone drive that takes command inputs from an external controller, CME 2 operated as a CAN node, CME 2 can be used for programming before and after installation in a CAN network. Xenus can also be controlled via CME 2 while it is in place as a CAN node. During this process, drive operation as a CAN node is suspended. When adjustments are complete, CME 2 relinquishes control of the drive and returns it to the CAN node state.

RS-232

Xenus operates as a DTE device from a three-wire, full-duplex RS-232 port at 9,600 to 115,200 Baud, 8 bits, no parity, and one stop bit. The SER-CK Serial Cable Kit provides an adapter that connects to the COMM port of a PC (a 9 position, male D-Sub connector) and accepts a modular cable with RJ-11 connectors for connection to the Xenus RS-232 port (J6).

PC COMM PORT SIGNALS SER-CK SERIAL CABLE KIT ADAPTER CONNECTIONS J5 SIGNALS

RS-232 MULTI-DROP over a single RS-232 port by daisy-chaining a master drive to other drives using CAN cables. In the CAN protocol, address 0 is reserved for the CAN master and thereafter all other nodes on a CAN network must have unique, non-zero addresses. When the Xenus CAN address is set to 0, it acts as a CAN master, converting the RS-232 data into CAN messages and passing it along to the other drives which act as CAN nodes.

ASCII COMMUNICATIONS

The Copley ASCII Interface is a set of ASCII format commands that can be used to operate and monitor Copley Controls Accelnet, been programmed using CME 2, a control program can use the ASCII Interface to: variables.

Additional information can be found in the ASCII Programmers Guide on the Copley website: http://www.copleycontrols.com/motion/downloads/pdf/ASCII_ProgrammersGuide.pdf



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COMMUNICATIONS (CONTINUED)

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CANOPEN

Based on the CAN V2.0b physical layer, a robust, two-wire communication bus originally designed for automotive use where low-cost and noise-immunity are essential, CANopen adds support for motion-control devices and command synchronization. The result is a highly effective combination of data-rate and low cost for multi-axis motion control systems. Device synchronization enables multiple axes to coordinate moves as if they were driven from a single control card.

CANOPEN COMMUNICATION

Xenus uses the CAN physical layer signals CANH, CANL, and GND for connection, and CANopen protocol for communication.

Before installing the drive in a CAN system, it must be assigned a CAN address. A maximum of 127 CAN nodes are allowed on a single

CAN bus. The rotary switch on the front panel controls the four lower bits of the seven-bit CAN address. When the number of nodes on a bus is less than sixteen, the CAN address can be set using only the switch.

For more in formati on o n C ANopen commu nicati ons, dow nlo ad th e CANo pen Ma nual from th e Co pley website: http://www.copleycontrols.com/motion/downloads/pdf/CANopenProgrammersManual.pdf

CANOPEN CONNECTORS

Dual RJ-45 connectors that accept standard

Ethernet cables are provided for CAN bus connectivity. Pins are wired-through so that drives can be daisy-chained and controlled with a single connection to the user’s

CAN interface. A CAN terminator should be placed in the last drive in the chain.

The XTL-NK connector kit provides a D-Sub adapter that plugs into a CAN controller and has an RJ-45 socket that accepts the

Ethernet cable.

XTL-NK CAN CONNECTOR KIT

The kit contains the XTL-CV adapter that converts the CAN interface D-Sub

9M connector to an RJ-45 Ethernet cable socket, plus a 10 ft (3 m) cable and

J6 CAN CONNECTIONS

CAN S TATUS LED

Note: Red & green led on-times do not overlap.



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COMMUNICATIONS (CONTINUED)

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DRIVE STATUS LED

A single bi-color LED gives the state of the drive by changing color, and either blinking or remaining solid.

The possible color and blink combinations are:

Drive OK and enabled. Will run in response to reference inputs or CANopen commands.

Drive OK but NOT-enabled. Will run when enabled.

Positive or Negative limit switch active. Drive will only move in direction not inhibited by limit switch.

Transient fault condition. Drive will resume operation when fault is removed.

Latching fault. Operation will not resume until drive is Reset.

Drive Fault conditions:

Faults are programmable to be either

transient or latching



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COMMAND INPUTS

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ANALOG REFERENCE INPUT

A single ±10 Vdc differential input takes inputs from controllers that use PID or similar compensators, and outputs a current command to the drive. Drive output current or velocity vs. reference input voltage is programmable.

DIGITAL POSITION

Digital position commands can be in either single-ended or differential format. Single-ended signals should be sourced from devices with active pull-up and pull-down to take advantage of the high-speed inputs. Differential inputs have 121 line-terminators.

SINGLE-ENDED PULSE & DIRECTION DIFFERENTIAL PULSE & DIRECTION

SINGLE-ENDED CU/CD DIFFERENTIAL CU/CD

QUAD A/B ENCODER SINGLE-ENDED QUAD A/B ENCODER DIFFERENTIAL

DIGITAL TORQUE, VELOCITY

Digital torque or velocity commands can be in either single-ended or differential format. Single-ended signals must be sourced from devices with active pull-up and pull-down to take advantage of the high-speed inputs.

SINGLE-ENDED PWM & DIRECTION DIFFERENTIAL PWM & DIRECTION

SINGLE-ENDED 50% PWM DIFFERENTIAL 50% PWM



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COMMAND INPUTS (CONTINUED)

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DIGITAL INPUTS

Xenus has twelve digital inputs, eleven of which have programmable functions. Input [IN1] is dedicated to the drive Enable function.

This is done to prevent accidental programming of the input in such a way that the controller could not shut it down.

motor temperature sensor. Programmable functions of the digital inputs include:

DIGITAL INPUT CIRCUITS

24VDC MAX 24VDC MAX

PULL-UP/PULL-DOWN CONTROL

In addition to the active level and function for each programmable input, the input resistors are programmable in four groups to either pull up to +5 Vdc, or down to ground. Grounded inputs with HI active levels interface to PLC’s that have PNP outputs that source current from +24 Vdc sources. Inputs pulled up to +5 Vdc work with open-collector, or NPN drivers that sink current to ground. The table below shows the PU/PD groups and the inputs they control.`

Group

A

B

C

D

Inputs

1,2,3

4,5

6,7,8

9,10,11,12

HS (HIGH SPEED) DIGITAL INPUTS

These inputs have all the programmable functions of the GP inputs plus these additional functions on [IN8] & [IN9]

SINGLE-ENDED

12 Vdc max

DIFFERENTIAL

12 Vdc max



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OUTPUTS

DIGITAL OUTPUTS

The digital outputs are open-drain MOSFETs with 1 k pull-up resistors in series with a diode to +5 Vdc. They can sink up to 1 Adc from external loads operating from power supplies to +30 Vdc.

The output functions are programmable. The active state of the outputs is programmable to be on or off.

internal diode in the output is for driving PLC inputs that are opto-isolated and connected to +24 Vdc. The diode prevents conduction from +24 Vdc through the 1 k resistor to

+5 Vdc in the drive. This could turn the PLC input on, giving a false indication of the drive output state.


BRAKE OUTPUT [OUT4]

Vdc input. It can sink up to 1A from a motor brake connected to the +24 Vdc supply.

The operation of the brake is programmable with CME 2. It can also be programmed as a general-purpose digital output.

MOTOR CONNECTIONS

Motor connections are of three types: phase, feedback, and thermal sensor. The phase connections carry the drive output currents that drive the motor to produce motion. A thermal sensor that indicates motor overtemperature is used to shut down the drive to protect the motor. Feedback can be digital quad A/B encoder, analog sin/cos encoder, resolver or digital Halls, depending on the version of the drive.

MOTOR PHASE CONNECTIONS

The drive output is a three-phase PWM inverter that converts the DC buss voltage

(+HV) into three sinusoidal voltage waveforms that drive the motor phase-coils.

Cable should be sized for the continuous current rating of the motor. Motor cabling should use twisted, shielded conductors for CE compliance, and to minimize PWM noise coupling into other circuits. The motor cable shield should connect to motor frame and the drive frame ground terminal (J2-1) for best results.

DIGITAL HALL SIGNALS

Hall signals are single-ended signals that provide absolute feedback within one electrical cycle of the motor. There are three of them (U, V, & W) and they may be sourced by magnetic sensors in the motor, or by encoders that have Hall tracks as part of the encoder disc. They typically operate at much lower frequencies than the motor encoder signals, and are used for commutation-initialization after startup, and for checking the motor phasing after the amplifIer has switched to sinusoidal commutation. Resolver models can also take Hall signal at inputs [IN6~8]. See page 15 for connections.

U

V

W

HALL

U, V, W

+5V

10 k

10 k

3.3 nF

74HC14



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MOTOR CONNECTIONS (CONT’D)

DIGITAL ENCODERS

™ the inputs. Encoders with differential outputs are required because they are less susceptible to noise that can degrade single-ended outputs. Encoder cables should use twisted-pairs for each signal pair: A & /A, B & /B, X & /X. An overall shield should be used, and for longer cables, shields for individual pairs may be necessary to guarantee signal integrity.

ANALOG ENCODER (-S MODELS)

Xenus supports analog encoder signals for position feedback. The Sin and Cos inputs are differential with 121 terminating resistors and accept 1.0 Vp-p signals in the

A/B format used by encoders with analog outputs such as Heidenhain, Stegman, and Renishaw. When Copley’s ServoTube motors are used the analog encoder supplies both commutation and incremental position feedback.


ANALOG HALLS (-S MODELS) + DIGITAL ENCODER

For position feedback with higher resolution than is possible by interpolating analog Halls, a digital incremental encoder is connected to the multi-mode port. The Halls are then used for commutation and the multi-mode port is programmed as a differential input for the Secondary Incremental motor encoder.

RESOLVER (-R MODELS)

Connections to the resolver should be made with shielded cable that uses three twisted-pairs. Once connected, resolver set up, motor phasing, and other commissioning adjustments are made with CME 2 software. There are no hardware adjustments.

MOTOR TEMPERATURE SENSOR

Digital input [IN5] is for use with a motor overtemperature switch. The input should be programmed as a pull-up to +5 Vdc if the motor switch is grounded when cold, and open or high-impedance when over-heating.

+5V

[IN5]

4.99 k

10 k

3.3 nF

74HC14

BRAKE OUTPUT [OUT4] the +24 Vdc input. It can sink up to 1A from a motor brake connected to the +24

Vdc supply.

The operation of the brake is programmable with CME 2. It can also be programmed as a general-purpose digital output.

= Shielded cables required

for CE compliance



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This port consists of three differential input/output channels that take their functions from the Basic Setup of the drive.

On drives with quad A/B encoder feedback, the port works as an output buffering the signals from the encoder. With resolver or sin/cos encoder versions, the feedback is converted to quad A/B signals with programmable resolution. These signals can then be fed back to an external motion controller that closes the position or velocity loops. As an input, the port can take quad A/B signals to produce a dual-loop position control system or use the signals as master-encoder feedback in camming mode. In addition, the port can take stepper command signals (CU/CD or Pulse/Direction) in differential format.

AS BUFFERED OUTPUTS FROM A DIGITAL QUADRATURE

FEEDBACK ENCODER

When using a digital quadrature feedback encoder, the A/B/X signals drive the multi-mode port output buffers directly. This is useful in systems that use external controllers that also need the motor feedback encoder signals because cabling where the motor feedback cable has to split to connect to both controller and motor, the buffered outputs reduce loading on the feedback cable that could occur if the motor encoder had to drive two differential inputs in parallel, each with it’s own 121 ohm terminating resistor.

AS EMULATED QUAD A/B/X ENCODER OUTPUTS FROM AN

ANALOG SIN/COS FEEDBACK ENCODER

Analog sin/cos signals are interpolated in the drive with programmable resolution. The incremental position data is then converted back into digital quadrature format which drives the multi-mode port output buffers. Some analog encoders also produce a digital index pulse which is connected directly to the port’s output buffer. The result is digital quadrature A/B/X signals that can be used as feedback to an external control system.

AS A MASTER OR CAMMING ENCODER INPUT FROM A

DIGITAL QUADRATURE ENCODER

When operating in position mode the multi-mode port can accept digital command signals from external encoders. These can be used to drive cam tables, or as master-encoder signals when operating in a master/slave

AS DIGITAL COMMAND INPUTS IN PULSE/DIRECTION,

PULSE-UP/PULSE-DOWN, OR

DIGITAL QUADRATURE ENCODER FORMAT

The multi-mode port can also be used when digital command signals are in a differential format. These are the signals that typically go to [IN9] and [IN10] when they are single-ended. But, at higher frequencies these are likely to be differential signals in which case the multi-mode port can be used.



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Control cable to J7

(NOTE 1)

(NOTE 1)


for CE compliance

Required for

Drive Operation

DANGER: HIGH VOLTAGE

NOTES:

1) The total output current from the +5 Vdc supply to J7-20 cannot exceed 400 mAdc



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™


Sin/Cos Encoder

Control cable to J7

(NOTE 1)

(NOTE 1)


for CE compliance

NOTES:


3) Page 11 shows connections for analog Hall commutation with digital incremental position feedback.



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™


Control cable to J7

(NOTE 1)


for CE compliance

NOTES:


3) Usage of [IN6~8] for Hall sensors is optional. If not used for Halls, these are programmable, high-speed inputs.



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DRIVE POWER SOURCES

An external +24 Vdc power supply is required, and powers an internal DC/DC converter that supplies all the control voltages for drive operation. Use of an external supply enables CAN communication with the drive when the mains power has been removed.

Power distribution in Xenus is divided into four sections: +24 Vdc, CAN, signal, and high-voltage. Each is isolated from the other and all are isolated from the chassis.

EXTERNAL +24 VDC

The primary side of the DC/DC converter operates directly from the external +24

Vdc supply and is isolated from other drive power sections. The Brake output [OUT4] operates in this section and is referenced to the +24 Vdc return (0V). It sinks current from an external load connected to the external +24 Vdc power source.

INTERNAL SIGNAL POWER

The signal power section supplies power for the DSP controller as well as logic inputs and outputs. Motor feedback signals such as Halls, encoder, and temperature sensor operate from this power source. All signal circuits are referenced to signal ground. This ground should connect to the control system circuit ground or common so that drive and controller inputs and output voltage levels work properly with each other.

™


MAINS POWER

Mains power drives the high-voltage to produce +HV which the PWM stage converts into voltages that drive either three phase brushless or DC brush motors.

An internal solid-state switch together with an external power resistor provides dissipation during regeneration when the mechanical energy of the motor is converted back into electrical energy that must be dissipated before it charges the internal capacitors to an overvoltage condition. All is, they connect directly to the mains and must be considered high-voltages and a shock hazard requiring proper insulation techniques during installation.

All of the circuits on J1, J2, and J3 are mains-

connected and must never be grounded. The ground terminals at J1-3, J2-1, and J3-5 all connect to the drive chassis and are isolated from all drive internal circuits.

Signal grounding references the drive control circuits to those of the control system. These controls circuits typically have their own earth connection at some point. To eliminate ground-loops it is recommended that the drive signal ground be connected to the control system circuit ground. When this is done the drive signal voltages will be referenced to the same 0 V level as the circuits in the control system.

GROUNDING

A grounding system has three primary functions: safety, voltage-reference, and shielding. As a safety measure, the primary ground at J1-3 will carry fault-currents from the mains in the case of an internal failure or short-circuit of electronic components.

Wiring to this is typically done with the green conductor with yellow stripe using the same gauge wire as that used for the mains.

The pin on the drive at J1-3 is longer than last-break action so that the drive chassis is never ungrounded when the mains power is connected. This wire is a ‘bonding’ conductor that should connect to an earthed ground point and must not pass through any circuit interrupting devices. drive when inputs and outputs interact. The signal ground is the path for these currents to return to their power sources in both controller and drive.

Shields on cables reduce emissions from the drive for CE compliance and protect internal circuits from interference due to external sources of electrical noise. Because of their smaller wire gauge, these should not be used as part of a safety-ground system.

Motor cases can be safety-grounded either at the motor, by earthing the frame, or by a grounding conductor in the motor cable that connects to J2-1. This cable should be of the same gauge as the other motor phase cables.

For CE compliance and operator safety, the drive should be earthed by using external tooth lockwashers under the mounting screws. These will make contact with the aluminum chassis through the the equipment frame ground.

REGENERATION

The chart below shows the energy absorption in W·s for a Xenus drive operating at some typical mains voltages. When the load mechanical energy is greater than these values an external regen resistor is available as an accessory.



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GROUNDING & SHIELDING FOR CE

Grounding and shielding are the means of controlling the emission of radio frequency energy from the drive so that it does not interfere with other electronic equipment.

The use of shielded cables to connect the drive to motors and feedback devices is a way of extending the chassis of the drive out to these devices so that the conductors carrying noise generated by the drive are completely enclosed by a conductive shield.

The process begins at the mains connector of the drive, J1. The ground terminal here has a circle around it indicating that this is

This should be connected with wire that is the same gauge as that used for the mains.

In the case of a short-circuit in the drive the function of this ground connection is to carry the fault current to earth ground until the safety device (fuse or circuit breakers) disconnects the drive from the mains. This connection ensures that the heatplate of the drive remains at earth potential and eliminating a shock hazard that could occur potential of the mains.

While this connection keeps the heatplate at earth potential the high frequency noise generated by switching circuits in the drive can radiate from the wire used for the safety ground connection. In order to keep the path between the heatplate and earth as short as possible it’s also recommended to mount the drive to the equipment panel using external-toothed lock washers. These heatplate (which is an electrical insulator) and make good electrical contact with the aluminum plate. Grounding the heatplate in this way shortens the path from drive to earth ground and further reduces emissions.

The heatplate also connects directly to the frame ground terminals on the motor, feedback, and regen connectors. Note that the ground symbols for these do not have a circle around them which indicates that these are for shielding and not not for safety grounding. Motors and their feedback devices (which are typically in the motor case) should be grounded by mounting to equipment that is grounded as a safety ground. By connecting the shields for these devices at the drive and at the device, the connection is continuous and provides a return path for radio-frequency energy to the drive.

™

Notes: diagram above.




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™


WARNING: Hazardous voltages exist on connections

to J1, J2, & J3 when power is applied, and for up to 30

seconds after power is removed.

J1 MAINS CONNECTIONS

J1 CABLE CONNECTOR:

Wago: 51118287 or 721-204/026-045/RN01-0000

Euro-style 7,5 mm pluggable female terminal block with preceding ground receptacle

Cable: AWG 12, 600 V recommended for XTL-230-36-R and XTL-230-40-R models,

AWG 14, 600V for XTL-230-18-R

Shielded cable required for CE compliance

Signal Pin

Mains Input L3 4

Protective Ground

Mains Input L2

Mains Input L1

3

2

1

J2 CABLE CONNECTOR:

Wago: 51118008 or 721-104/026-047/RN01-0000

Euro-style 5,0 mm pluggable female terminal block


AWG 14, 600V for XTL-230-18-R


J2 MOTOR OUTPUTS

Signal Pin

Motor Phase U

Motor Phase V

4

3

Motor Phase W

Cable Shield

2

1

J3 CABLE CONNECTOR:

Wago: 51111277 or 721-605/000-044/RN01-0000

Euro-style 5,0 mm pluggable male terminal block


AWG 14, 600V for XTL-230-18-R


J3 REGEN RESISTOR

Signal Pin

Regen Resistor 1

No Connection

Regen Resistor

2

3

No Connection

Cable Shield

4

5

WIRE INSERTION/EXTRACTION TOOL:

Used on J1, J2, J3, & J4

Wago 231-131

ISOLATED CIRCUIT

NOTE: AN EXTERNAL

+24 VDC POWER SUPPLY

IS REQUIRED FOR OPERATION

J4 CABLE CONNECTOR:

Wago: 51117974 or 721-103/026-047/RN01-0000

Euro-style 5,0 mm pluggable terminal block

J4 +24 VDC & BRAKE

Signal Pin

+24 Vdc Control Power 3

Brake Output [OUT4]

0V (+24 Vdc Return)

ISOLATED CIRCUIT

2

1



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™


J5 RS-232 (DTE)

Pin Signal

6

5

No connect

TxD Output

4

3

2

Ground

Ground

RxD Input

1 No connect

J5 CABLE CONNECTOR:

RJ-11 style, male, 6 position

Cable: 6-conductor modular type

Notes:

1. CAN circuits are opto-isolated from drive circuits.

2. CAN_GND connects to drive Signal Ground.

3. CAN_SHLD and CAN_V+ are wired-thru on both

J6 connectors and have no connection to the drive.

J7 CONTROL SIGNALS

J6 CAN BUS

6

7

8

3

4

5

Pin Signal

1 CAN_H

2 CAN_L

CAN_GND

No connection

No connection

(CAN_SHLD)

CAN_GND

(CAN_V+)

ISOLATED CIRCUIT

J6 CABLE CONNECTOR

:



PIN

6

7

4

5

8

9

1

2

3

SIGNAL

Frame Gnd

Ref(-)

Ref(+)

[IN1] Enable

[IN2] GP

[IN3] GP

[IN4] GP

[IN11] GP

[IN12] GP

PIN SIGNAL

10 [IN6] HS

11 [IN7] HS

12 [IN8] HS

13 [IN9] HS

14 [IN10] HS

15 Signal Gnd

16 [OUT1]

17 [OUT2]

18 [OUT3]

J7 CABLE CONNECTOR:

High-Density D-Sub, 26 Position, Male

PIN

22

23

24

25

26

19

20

21

SIGNAL

Signal Gnd

+5 Vdc (Note 1)

Multi Encoder /X

Multi Encoder X

Multi Encoder /B

Multi Encoder B

Multi Encoder /A

Multi Encoder A

J8 MOTOR FEEDBACK

PIN

1

2

3

4

5

SIGNAL

Frame Gnd

+5 Vdc (Note 1)

Hall U

+5 Vdc (Note 1)

Signal Gnd

PIN SIGNAL

6

7

8

Hall V

Encoder /X

Encoder X

9 Hall W

10 [IN5] Motemp

J8 CABLE CONNECTOR:


PIN

11

12

13

14

15

SIGNAL

Encoder /B

Encoder B

Encoder /A

Encoder A

Signal Gnd

NOTES:

1. The total current drawn from the +5 Vdc outputs cannot exceed 400 mA



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™


Sin/Cos Encoder





J1 CABLE CONNECTOR:

Wago: 51118287 or 721-204/026-045/RN01-0000



AWG 14, 600V for XTL-230-18-R


Signal Pin

Mains Input L3 4

Protective Ground

Mains Input L2

Mains Input L1

3

2

1

J2 CABLE CONNECTOR:

Wago: 51118008 or 721-104/026-047/RN01-0000



AWG 14, 600V for XTL-230-18-R


J2 MOTOR OUTPUTS

Signal Pin

Motor Phase U

Motor Phase V

4

3

Motor Phase W

Cable Shield

2

1

J3 CABLE CONNECTOR:

Wago: 51111277 or 721-605/000-043/RN01-0000



AWG 14, 600V for XTL-230-18-R


J3 REGEN RESISTOR

Signal Pin

Regen Resistor 1

No Connection

Regen Resistor

2

3

No Connection

Cable Shield

4

5



Wago 231-131

ISOLATED CIRCUIT

NOTE: AN EXTERNAL



J4 CABLE CONNECTOR:

Wago: 51117974 or 721-103/026-047/RN01-0000


J4 +24 VDC & BRAKE

Signal Pin


Brake Output [OUT4]

0V (+24 Vdc Return)

ISOLATED CIRCUIT

2

1



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J5 RS-232 (DTE)

Pin Signal

6

5

No connect

TxD Output

4

3

2

Ground

Ground

RxD Input

1 No connect

™


Sin/Cos Encoder

J5 CABLE CONNECTOR:



Notes:





J7 CONTROL SIGNALS

J6 CAN BUS

6

7

8

3

4

5

Pin Signal

1 CAN_H

2 CAN_L

CAN_GND

No connection

No connection

(CAN_SHLD)

CAN_GND

(CAN_V+)

ISOLATED CIRCUIT

J6 CABLE CONNECTOR

:



PIN

6

7

4

5

8

9

1

2

3

SIGNAL

Frame Gnd

Ref(-)

Ref(+)

[IN1] Enable

[IN2] GP

[IN3] GP

[IN4] GP

[IN11] GP

[IN12] GP

PIN SIGNAL

10 [IN6] HS

11 [IN7] HS

12 [IN8] HS

13 [IN9] HS

14 [IN10] HS

15 Signal Gnd

16 [OUT1]

17 [OUT2]

18 [OUT3]

J7 CABLE CONNECTOR:


PIN

22

23

24

25

26

19

20

21

SIGNAL

Signal Gnd

+5 Vdc (Note 1)

Multi Encoder /X

Multi Encoder X

Multi Encoder /B

Multi Encoder B

Multi Encoder /A

Multi Encoder A

J8 MOTOR FEEDBACK

PIN

1

2

3

4

5

SIGNAL

Frame Gnd

+5 Vdc (Note 1)

Hall U

+5 Vdc (Note 1)

Signal Gnd

PIN SIGNAL

6

7

8

Hall V

Encoder /X

Encoder X

9 Hall W

10 [IN5] Motemp

J8 CABLE CONNECTOR:


PIN

11

12

13

14

15

SIGNAL

Encoder Cos(-)

Encoder Cos(+)

Encoder Sin(-)

Encoder Sin(+)

Signal Gnd

NOTES:

1. The total current drawn from the +5 Vdc outputs cannot exceed 400 mA



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™






J1 CABLE CONNECTOR:

Wago: 51118287 or 721-204/026-045/RN01-0000



AWG 14, 600V for XTL-230-18-R


Signal Pin

Mains Input L3 4

Protective Ground

Mains Input L2

Mains Input L1

3

2

1

J2 CABLE CONNECTOR:

Wago: 51118008 or 721-104/026-047/RN01-0000



AWG 14, 600V for XTL-230-18-R


J2 MOTOR OUTPUTS

Signal Pin

Motor Phase U

Motor Phase V

4

3

Motor Phase W

Cable Shield

2

1

J3 CABLE CONNECTOR:

Wago: 51111277 or 721-605/000-043/RN01-0000



AWG 14, 600V for XTL-230-18-R


J3 REGEN RESISTOR

Signal Pin

Regen Resistor 1

No Connection

Regen Resistor

2

3

No Connection

Cable Shield

4

5



Wago 231-131

ISOLATED CIRCUIT

NOTE: AN EXTERNAL



J4 CABLE CONNECTOR:

Wago: 51117974 or 721-103/026-047/RN01-0000


J4 +24 VDC & BRAKE

Signal Pin


Brake Output [OUT4]

0V (+24 Vdc Return)

ISOLATED CIRCUIT

2

1



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™


J5 RS-232 (DTE)

Pin Signal

6

5

No connect

TxD Output

4

3

2

Ground

Ground

RxD Input

1 No connect

J5 CABLE CONNECTOR:



Notes:





J7 CONTROL SIGNALS

J6 CAN BUS

6

7

8

3

4

5

Pin Signal

1 CAN_H

2 CAN_L

CAN_GND

No connection

No connection

(CAN_SHLD)

CAN_GND

(CAN_V+)

ISOLATED CIRCUIT

J6 CABLE CONNECTOR

:



PIN

6

7

4

5

8

9

1

2

3

SIGNAL

Frame Gnd

Ref(-)

Ref(+)

[IN1] Enable

[IN2] GP

[IN3] GP

[IN4] GP

[IN11] GP

[IN12] GP

PIN SIGNAL

10 [IN6] HS

11 [IN7] HS

12 [IN8] HS

13 [IN9] HS

14 [IN10] HS

15 Signal Gnd

16 [OUT1]

17 [OUT2]

18 [OUT3]

J7 CABLE CONNECTOR:


PIN

22

23

24

25

26

19

20

21

SIGNAL

Signal Gnd

+5 Vdc (Note 1)

Multi Encoder /X

Multi Encoder X

Multi Encoder /B

Multi Encoder B

Multi Encoder /A

Multi Encoder A

J8 MOTOR FEEDBACK

PIN

1

2

3

4

5

SIGNAL

Frame Gnd

Ref(-) Output R2

Ref(+) Output R1

N.C.

Signal Gnd

PIN SIGNAL

6

7

8

Frame Gnd

Sin(-) Input S1

Sin(+) Input S3

9 N.C.

10 [IN5] Motemp

J8 CABLE CONNECTOR:


PIN

11

12

13

14

15

SIGNAL

Frame Gnd

Cos(-) Input S4

Cos(+) input S2

N.C.

Signal Gnd

NOTES:

1. The total current drawn from the +5 Vdc output cannot exceed 400 mA



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SINGLE-DRIVE SETUP FOR CANOPEN POSITION CONTROL

™


Xenus

operates as a CAN node. All commands are passed on the CAN bus.

CME 2

SER-CK

(2)

J5

(1)

XTL-NK

COM1

COM2

COMx

(2)

J7

J8

(1)

(3)

XTL-CK

Outputs

(1)

Logic Inputs and

(2) J1~J4 not shown

Motor Feedback:

Resolver and

Temperature Sensor

Serial Cable Kit SER-CK

Connects a PC serial port to Xenus RX-232 connector J5

(1) RS-232 9-pin D-Sub to RJ-11 adapter

(2) 6 ft (2 m) RJ-11 cable

CAN

CARD

CML C++ Libraries

Windows™ 98, 2000,

ME, NT, and Linux

CMO Copley Motion

Objects

Windows™ 98, 2000,

ME, NT, and Linux

CME 2

Windows® 98, 2000,

ME, and NT

Computer:

PC or compatible with

166MHz with 64MB RAM minimum

266 MHz with 128MB RAM recommended

Serial port (RS-232)

CAN bus interface

Using the minimum requirements will allow CME 2 to run

CANopen Network Kit XTL-NK

Connects a CAN card to Xenus connector J6 and includes terminator for ‘last’ drive on CAN bus

(1) CAN card 9-pin D-Sub to RJ-45 adapter

(2) 6 ft (2 m) RJ-45 cable

(3) CAN terminator

Ordering Guide

See page 19 for other parts required (motor, +24 Vdc power supply, etc.) .

Connector/Cable Kit XTL-CK

Includes connectors for J1~J4, J7, J8:

(1) Soldercup connectors for J7 & J8

(2) Wago connectors for J1~J4

See diagram on page 10 for connections to:

J1 AC mains power

J2 Motor phases

J3 Regen resistor

J4 +24 Vdc Aux Power

PART NUMBER DESCRIPTION

XTL-230-18 Xenus XTL Servodrive 6/18 A

XTL-230-36

XTL-230-40

XTL-NK

XTL-CK

CME2

SER-CK

Xenus XTL Servodrive 12/36 A


CANopen Network Kit

Xenus Solder-Cup Connector Kit

CME 2

CME 2 RS-232 Cable Kit




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MULTIPLE-DRIVE SETUP FOR CANOPEN POSITION CONTROL

™

XTL-NK

J6

J6

J6


For multiple-drive installations, use the ordering guide on this page. Computer equipment is the same as for single-drive installations. And Serial Cable

Kit SER-CK is used when CME 2 is in use for drive set up and

XTL-NC-10 or

XTL-NC-01

SER-CK

Fo r side -by-side drive mounting, use XTL-NC-01 cables that are 1 ft long.

Use XTL-NC-10 cables

(length is 10 ft) where distances between drives is greater.

XTL-NC-10

or

XTL-NC-01

Ordering Guide

See page 24~25 for other parts required

(motor, +24V power supply, etc.)

CAN Terminator




XTL-230-40

XTL-NK

XTL-NC-10

XTL-NC-01

XTL-CK

CME2

SER-CK


CANopen Network Kit

CAN Network Cable,10 ft (3 m)

CAN Network Cable,1 ft (0.3 m)


CME 2





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STAND-ALONE OPERATION

™

Xenus takes digital position commands in Pulse/Direction, or CW/CCW format from an external controller or quadrature encoder signals from a master-encoder for electronic gearing. Velocity or torque control can be from ±10V, digital PWM signals.

CME 2

SER

-

CK

COM1

COM2

COMx


J5

J7

J8

XTL-CK

Digital reference signals,

Logic Inputs and Outputs

Motor Feedback

Resolver and

Temperature Sensor

Motion

Controller

CME 2

Windows® 95, 98, 2000,

ME, and NT

Computer:

PC or compatible with

166MHz with 64MB RAM minimum

266 MHz with 128MB RAM recommended

Serial port (RS-232)

Motion controller card

Using the minimum requirements will allow CME 2 to

ORDERING GUIDE

This table shows parts to order for the

See page 24~25 for other parts required

(motor, +24 Vdc power supply, etc.)



XTL-230-36

XTL-230-40

XTL-CK

CME2

SER-CK




CME 2





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INSTALLATION



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Required for CE

™


Required

Required



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HEATSINK & FAN CONFIGURATIONS

NO HEATSINK

NO FAN

™


NO HEATSINK

WITH FAN

LOW-PROFILE

HEATSINK

NO FAN

NOTE: FANS ARE NOT INCLUDED

WITH HEATSINKS OR HEATSINK

KITS

LOW PROFILE HEATSINK

WITH FAN

STANDARD HEAT-

SINK

NO FAN

STANDARD HEATSINK

WITH FAN

HEATSINK MOUNTING grease. The pad is die-cut to shape and has holes for the heat sink mounting screws. There are two protective sheets, blue on one side and clear on the other. Both must be removed when the interface pad is installed.

STEPS TO INSTALL

1. Remove the blue protective sheet from one side of the pad and place the pad on the drive. Make sure that the holes in the pad align with the holes on the drive.

2. Remove the clear protective sheet from the pad.

3. Mount the heatsink onto the drive taking care to see that the holes in the heatsink, pad, and drive all line up.

4. Torque the #6-32 mounting screws to 8~10 lb-in

(0.9~1.13 N·m).

#6-32 Mounting Screws

Heatsink

Dry Film Interface Pad

Clear Protective Sheet

(Discard)

Blue Protective Sheet

(Discard)

Xenus Drive



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™

MAXIMUM OPERATING TEMPERATURE VS HEATSINK TYPE & AIR CIRCULATION


The charts below show that maximum ambient temperature vs. continuous output current for the each of these the drive can be operated with convection or forced-air cooling.



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ORDERING GUIDE

™


Add -S to part numbers above for sin/cos feedback or add -R for resolver feedback models.

XTL-230-18

XTL-230-36

XTL-230-40

ACCESSORIES

Servo Drive 6/18 Adc



XTL-CK

Connector Kit with

Solder Cup Connectors for

J7 & J8

QTY

1

1

1

1

4

1

1

1

1

REF DESCRIPTION

J1 Plug, 4 position, 7.5 mm, female

J2

J3

Plug, 4 position, 5.0 mm, female

Plug, 5 position, 5.0 mm, male

J4 Plug, 3 position, 5.0 mm, female

J1~4 Tool, wire insertion & extraction (for J1~4)

Connector, 26 position, solder-cup

J7

Back shell, for 26 position connector

Connector, 15 position, solder cup

J8

Back shell, for 15 position connector

MANUFACTURERS PART NUMBER

Wago: 51118287 or 721-204/026-045/RN01-0000

Wago: 51118008 or 721-104/026-047/RN01-0000

Wago: 51111279 or 721-605/000-044/RN01-0000

Wago: 51117974 or 721-103/026-047/RN01-0000

Wago: 231-131

High Density D-Sub Male, 26 position connector

Backshell for above

High Density D-Sub Male, 15 position connector

Backshell for above

CME 2

SER-CK

J5

RS-232 Cable Kit

Connectors & Software for CANopen Operation

XTL-NK

1

1

D-Sub 9F to RJ-45 Adapter

CAN bus RJ-45 terminator

XTL-CV

XTL-NC-10

XTL-NC-01

XTL-NT

CMO

CML

1

1

1

1

1

J6

CAN bus network cable, 10 ft (3 m)

D-Sub 9F to RJ-45 Adapter

CAN bus Network Cable, 10 ft (3 m)

CAN bus Network Cable, 1 ft (0.3 m)

CAN bus Network Terminator

CD with CMO Software

CD with CML Software (Note: license fee required)

Heatsink Kits for Field Installation (Optional)

XTL-HL

Heatsink Kit

XTL-HS

Heatsink Kit

Standard

1

1

4

1

1

4

Heatsink thermal material

Heatsink hardware

Heatsink, standard

Heatsink thermal material

Heatsink hardware

Regeneration Resistors (Optional)

XTL-RA-03

XTL-RA-04

Edge Filter (Optional)

XTL-FA-01

Edge Filter

Connector Kit

XTL-FK

1

1

2

Regeneration resistor assembly (for XTL-230-18), 30

Regeneration resistor assembly (for XTL-230-36 & XTL-230-40 models), 15


Plug, 5 position, 5.0 mm, male

Tool, wire insertion & extraction (for J1~4)

Wago: 51118008 or 721-104/026-047/RN01-0000

Wago: 51111277 or 721-605/000-044/RN01-0000

Wago: 231-131

Example: Order one Xenus drive, resolver version, 6/18 A with solder-cup connector Kit, CME 2

Qty Item

1

1

1

1

XTL-230-18-R-HS

XTL-CK

SER-CK

Remarks

Xenus servo drive

Connector Kit

CME 2 CD

Serial Cable Kit



Rev 6.02_tu 02/22/2011

Fax: 781-828-6547

Page 30 of 30



Phone: 877-478-3241

Phone: 877-IP-Tech1


FEEDBACK VERSIONS

Analog Sin/Cos

Quad A/B digital

Resolver

CONTROL MODES

Indexer, Point-to-Point, PVT

Camming, Gearing, Position, Velocity, Torque

COMMAND INTERFACE

CANopen

ASCII and discrete I/O

Stepper commands

±10 Vdc position/velocity/torque command

PWM velocity/torque command

Master encoder (Gearing/Camming)

Digital inputs for indexer control

COMMUNICATIONS

CANopen

RS232

FEEDBACK

Digital Quad A/B encoder

Analog sin/cos encoder (-S versions)

Resolver (-R versions)

Secondary encoder / emulated encoder out

Digital Halls

I/O - DIGITAL

14 inputs, 4 outputs

REGEN

Internal

DIMENSIONS: MM [IN]

126 x 89 x 53 [5.0 x 3.5 x 2.1]

™


Model

XSJ-230-02

XSJ-230-06

XSJ-230-10

Vac

100-240

100-240

100-240

Ic

1

3

5

* Add “-S” to part number for Sin/Cos version

Add “-R” to part number for Resolver version

Ip

2

6

10

DESCRIPTION

Xenus Micro is a compact, AC powered servo drive for position, velocity, and torque control of AC brushless and DC brush motors.

It operates on a distributed control network, as a stand-alone indexing drive, or with external motion controllers.

Feedback options now include brushless resolvers in addition to digital quad A/B and analog sin/cos incremental encoders. The multi-mode encoder port operates as an input or output for the feedback signals. As an input, a secondary digital quad A/B encoder is used for dual-loop position control. Resolver and sin/cos signals are interpolated internally with programmable resolution and appear as digital quad A/B signals when the port functions as an output. Or, the digital quad A/B signals are simply buffered and made available to the system controller, eliminating cumbersome Y-cabling to share a single encoder with drive and control system.

select and launch indexes and inputs to read back drive status. A single serial port on the PLC can send ASCII data to multiple drives

Torque, Interpolated Position, and Homing. Up to 127 Xenus Micro drives can operate on a single CAN bus and groups of drives can be

Operation in torque (current), velocity, and position modes with external motion controllers is supported. Input command signals are ±10 Vdc (torque, velocity, position), PWM/Polarity (torque, velocity), or Step/Direction (position).

Copley Controls, 20 Dan Road, Canton, MA 02021, USA

Web: www.copleycontrols.com Page 1 of 24

RS-232 PORT

Mode

Signals

Protocol

Multi-Drop



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GENERAL SPECIFICATIONS

™

DIGITAL SERVO DRIVE for BRUSHLESS/BRUSH MOTORS max

MODEL

OUTPUT POWER

Peak Current

Peak time

XSJ-230-02 XSJ-230-06 XSJ-230-10

2 (1.4)

1

6 (4.2)

1

3 (2.1)

10 (7.1)

1

5 (3.5)

Adc (Arms, sinusoidal), ±5%

Sec

Adc (Arms, sinusoidal), ±5%

INPUT POWER

HV min

~HV

+24 Vdc max

PWM OUTPUTS

Type

PWM ripple frequency

REGENERATION

Type

Power dissipation

Cut-In Voltage

Drop-Out Voltage

Tolerance

Hysteresis

DIGITAL CONTROL

Digital Control Loops

Sampling rate (time)

Bandwidth

HV Compensation

Minimum load inductance

COMMAND INPUTS

ASCII

Digital position reference

Digital torque & velocity

Indexing

Camming

DIGITAL INPUTS

Number

Type

Pull-up, pull-down control

DIGITAL OUTPUTS

Number

[OUT1], [OUT2], [OUT3]

Ratings

85 to 264 Vac

+20 to +32 Vdc @ 500 mAdc maximum

1 Ø, 50~60 Hz

Logic & control power, required for operation

3-phase MOSFET inverter, 15 kHz center-weighted PWM, space-vector modulation

30 kHz

Internal MOSFET dissipator

80 W peak, 40 W continuous

+HV > 390 Vdc

+HV < 380 Vdc

±2 Vdc

10 ±0.5 Vdc

Regen output is on, regen dissipator is dissipating energy

Regen output is off, regen dissipator not dissipating energy

For either Cut-In or Drop-Out voltage

Differential between Cut-In & Drop-Out voltage

Current, velocity, position. 100% digital loop control

Dual loop position control using secondary encoder input

Current loop: 15 kHz (66.7 us) Velocity, position loops: 3 kHz (333 us)

Current loop: 2.5 kHz typical, bandwidth will vary with tuning & load inductance

Changes in bus voltage do not affect bandwidth

200 µH line-line

Single RS-232 connection passes messages to multiple drives via CAN link drive-drive

Step/Direction or CW/CCW

Quad A/B Encoder

PWM/Polarity

PWM/50%

PWM frequency range

PWM minimum pulse width

Stepper commands (1.5 MHz maximum rate)

20 Mcount/sec after quadrature (5 Mline/sec)

PWM = 0~100%, Polarity = 1/0

PWM = 50% ±50%, no polarity signal required

1 kHz minimum, 100 kHz maximum

220 ns

Index address, index-start, priority-index start

Inputs for master encoder, cam start, cam table address

14: 12 programmable, 1 input dedicated to drive Enable function, 1 for motor temperature switch

8 General-purpose (GP), 3 high-speed single-ended (HS), 2 high-speed differential (HSD), 1 motemp (GP)

10 k to +5 Vdc or ground (programmable), Vin-LO < 1.35 Vdc, Vin-HI >3.65 Vdc

+10 Vdc max for HS inputs, +24 Vdc max for GP inputs

1.5 MHz maximum pulse frequency for HS inputs when driven by active (not open-collector) sources

5 MHz maximum pulse frequency when driven by differential line-drivers

GP & HS inputs are divided into three groups with selectable connection of input pull-up/down resistor to +5 Vdc or ground for each group: [IN1,2,3,4], [IN5,6,7,8], [IN9,10,11]

4

Current-sinking MOSFET with 1 k pull-up to +5 Vdc through diode

250 mAdc max, +30 Vdc max

Full-duplex, DTE serial communication port for drive setup and control; 9,600 to 115,200 baud,

8 data bits, no parity, 1 stop-bit

RxD, TxD, Gnd

Binary or ASCII formats

ASCII communications to multiple Copley drives via a single RS-232 port:



CAN PORT

Format

Signals

Isolation

MOTOR CONNECTIONS

Power

Commutation

Feedback



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Phone: 877-IP-Tech1


™


CAN V2.0b physical layer for high-speed connections compliant

CANH, CANL, Gnd

CAN interface circuit and +5 Vdc supply are optically isolated from drive circuits

U-V-W phases for brushless, U-V for brush motors

Digital Halls, or sin/cos feedback from ServoTube motors

Digital quadrature A/B/(X) encoders; differential inputs (Standard)

Analog sin/cos encoders, 1 Vpeak-peak, differential inputs with 121 terminating resistor (-S option)

Resolver, brushless, single-speed, 1:1 to 2:1 programmable transformation ratio (-R option)

See page 4 for details on encoders and resolvers


As Secondary Encoder Input

As Emulated Encoder Output

As Buffered Encoder Output

LED INDICATORS

Drive Status

CAN Status

Digital quadrature encoder (A, /A, B, /B, X, /X),

20 M counts/sec, post-quadrature (5 M lines/sec)

Quadrature encoder emulation with programmable resolution to 4096 lines (65,536 counts) per rev from analog sin/cos encoders. 18 M counts/sec, post-quadrature (4.5 M lines/sec)

Buffered signals from digital quad A/B/X primary encoder. 20 M counts/sec, post-quadrature (5 M lines/sec)

A, /A, B, /B, X, /X, signals from 26LS31 differential line driver

Bicolor LED, drive status indicated by color, and blinking or non-blinking condition

Bicolor LED, status of CAN bus indicated by color and blink codes to

PROTECTIONS

HV Overvoltage

HV Undervoltage

+HV > 400 Vdc

+HV < 60 Vdc

Drive PWM outputs disabled

Drive PWM outputs disabled

Short circuits

I2T Current limiting

Motor over temperature

Feedback power loss

MECHANICAL & ENVIRONMENTAL

Size

Weight

Output to output, output to ground, internal PWM bridge faults

Programmable: Current foldback to continuous limit when I2T threshold is exceeded

Drive PWM outputs disabled when [IN14] changes state (programmable)

Fault occurs if feedback +5 Vdc output is < 85% of nominal value

126 x 89 x 53 [5.0 x 3.5 x 2.1] mm [in]

0.67 lb (0.30 kg)

Humidity

Vibration

Shock

Contaminants

Environment

Cooling

0% to 95%, non-condensing

2 g peak, 10~500 Hz (sine), IEC60068-2-6

10 g, 10 ms, half-sine pulse, IEC60068-2-27

Pollution degree 2

IEC68-2: 1990

Heat sink and/or forced air cooling required for continuous power output

AGENCY STANDARDS CONFORMANCE

EN 55011 : 1998 CISPR 11 (1997) Edition 2/Amendment 2:

EN 61000-6-1 : 2001 and Medical (ISM) Radio Frequency Equipment

Electromagnetic Compatibility Generic Immunity Requirements

Following the provisions of EC Directive 89/336/EEC:

EN 61010-1 2 nd

Ed.: 2004 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory use

Following the provisions of EC Directive 2006/95/EC

UL 508C 3 rd

Ed.: 2002 UL Standard for Safety for Power Conversion Equipment





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FEEDBACK SPECIFICATIONS

ENCODERS

DIGITAL ENCODER

Type

Signals

Frequency

ANALOG ENCODER (-S VERSIONS)

Type

Signals

Frequency

Interpolation

DIGITAL HALLS

™

Quadrature, differential line driver outputs

A, /A, B, /B, (X, /X, index signals optional)

5 MHz line frequency, 20 MHz quadrature count frequency


Sin/cos, differential line driver outputs, 1.0 Vpeak-peak differential centered about 2.5 Vdc typical. Common-mode voltage 0.25 to 3.75 Vdc

Sin(+), sin(-), cos(+), cos(-)

230 kHz maximum line (cycle) frequency

10 bits/cycle (1024 counts/cycle)

Signals

Frequency

ENCODER POWER SUPPLY

Power Supply

Protection

U, V, W

Consult factory for speeds >10,000 RPM

+5 Vdc @ 400 mA to power encoders & Halls

Current-limited to 750 mA @ 1 Vdc if overloaded

Encoder power developed from +24 Vdc so position information is not lost when AC mains power is removed

RESOLVER (-R VERSIONS)

RESOLVER

Type

Resolution frequency

Reference voltage

Brushless, single-speed, 1:1 to 2:1 programmable transformation ratio

14 bits (equivalent to a 4096 line quadrature encoder)

Reference maximum current 100 mA

Maximum RPM

2.8 Vrms, auto-adjustable by the drive to maximize feedback

10,000+

ENCODER EMULATION

Resolution

Buffered encoder outputs

Programmable to 16,384 counts/rev (4096 line encoder equivalent)

26C31 differential line driver



DIMENSIONS



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4.90

[124.5]

4.37

[111.0]

™


.251

[6.375]

.660

[16.8]

1.750

[44.5]

.156

[3.96]

.27

[6.86]

.156

[3.96]

1.25

[31.8]

Notes

1. Dimensions shown in inches [mm].

2. Use external tooth lockwashers between mounting screw head and drive chassis for safety and CE compliance. Recommended screws are #6-32

(M3.5) torqued to 8~10 lb·in (0.79~1.02 N·m).

Weights:

Drive: 0.67 lb (0.30 kg)

Heatsink: 0.56 lb (0.25 kg)

3.489

[88.62]

.338

[8.59]

4.457

[113.2]

.187

[4.75]

1.045

[26.54]

2.086

[52.98]

2.125

[53.98]

4.506

[114.5]

4.736

[120.3]





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COMMUNICATIONS

™


CME 2 SOFTWARE

Drive setup is fast and easy using CME 2 intuitive program. Auto-phasing of brushless motor Hall sensors and phase wires eliminates “wire and try”. Connections are made once and

CME 2 does the rest thereafter. Encoder wire swapping to establish the direction of positive motion is eliminated.

with the same setup and performance.

When operating as a stand-alone drive that takes command inputs from an external controller, CME 2

When operated as a CAN node, CME 2 is used for programming before and after installation in a CAN network. Xenus Micro can also be controlled via CME 2 while it is in place as a CAN node. During this process, drive operation as a CAN node is suspended. When adjustments are complete, CME 2 relinquishes control of the drive and returns it to the CAN node state.

RS-232

Xenus Micro

than two devices on a serial link. But, multiple Xenus Micro drives can communicate over a single RS-232 port by daisy-chaining a master drive to other drives using CAN cables. In the CAN protocol, address 0 is reserved for the CAN master and thereafter all other nodes on a CAN network must have unique, non-zero addresses. When the Xenus Micro CAN address is set to 0, it acts as a CAN master, converting the RS-232 data into CAN messages and passing it along to the other drives which act as CAN nodes, each having a unique non-zero CAN address.

CAN

Xenus Micro uses the CAN physical layer signals CANH, CANL, and GND for connection, and CANopen protocol for communication. The drive in a CAN system, it must be assigned a non-zero CAN address. A maximum of 127 CAN nodes are allowed on a single CAN bus.

Xenus Micro to use a combination of

ASCII COMMUNICATIONS

The Copley ASCII Interface is a set of ASCII format commands that can be used to operate and monitor Copley Controls Accelnet, been programmed using CME 2, a control program can use the ASCII Interface to:

Additional information can be found in the ASCII Programmers Guide on the Copley website: f

CAN STATUS LED

Drive Fault conditions:

Faults are programmable to be either

transient or latching

Note: Red & green led on-times do not overlap.

DRIVE STATUS LED

A single bi-color LED gives the state of the drive by changing color, and either blinking or remaining solid.

The possible color and blink combinations are:





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COMMAND INPUTS

™

ANALOG TORQUE, VELOCITY, POSITION

A single ±10 Vdc differential input connects to controllers that use PID or similar compensators, and output a current or velocity command to the drive. Drive output current or velocity v s. referen ce inp ut voltage is prog rammab le.

In position-mode, the analog command is converted to a digital position reference based on a programmable ratio of encoder counts vs. input volts. When this is greater than the deadband, which is programmable down to 0 V, it is passed through velocity, acceleration, and deceleration limiters after which it becomes the input to the position loop.

Ref(+)

Ref(-)


37.4k

5.36k

37.4k

+

-

5k

5k

+

-

1.5V

DIGITAL TORQUE, VELOCITY

Digital torque or velocity commands can be in either single-ended or differential format. Single-ended signals should be sourced from devices with active pull-up and pull-down to take advantage of the high-speed inputs. Differential inputs have 121 line-terminators.

SINGLE-ENDED PWM & DIRECTION SINGLE-ENDED 50% PWM

DIFFERENTIAL PWM & DIRECTION DIFFERENTIAL 50% PWM





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DIGITAL POSITION

™

Digital position commands can be in either single-ended or differential format. Single-ended signals should be sourced from devices with active pull-up and pull-down to take advantage of the high-speed inputs. Differential inputs have 121 line-terminators.


SINGLE-ENDED PULSE & DIRECTION DIFFERENTIAL PULSE & DIRECTION

SINGLE-ENDED CU/CD DIFFERENTIAL CU/CD

QUAD A/B ENCODER SINGLE-ENDED QUAD A/B ENCODER DIFFERENTIAL





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This port consists of three differential input/output channels that take their functions from the Basic Setup of the drive.

On drives with quad A/B encoder feedback, the port works as an output buffering the signals from the encoder. With resolver or sin/ cos encoder versions, the feedback is converted to quad A/B signals with programmable resolution. These signals can then be fed back to an external motion controller that closes the position or velocity loops. As an input, the port can take quad A/B signals to produce a dual-loop position control system or use the signals as master-encoder feedback in camming mode. In addition, the port can take stepper command signals (CU/CD or Pulse/Direction) in differential format.

AS BUFFERED OUTPUTS FROM A DIGITAL QUADRATURE

FEEDBACK ENCODER

When using a digital quadrature feedback encoder, the A/B/X signals drive the multi-mode port output buffers directly. This is useful in systems that use external controllers that also need the motor feedback encoder signals because these now come from J7, the Control connector. In addition to eliminating “Y” cabling where the motor feedback cable has to split to connect to both controller and motor, the buffered outputs reduce loading on the feedback cable that could occur if the motor encoder had to drive two differential inputs in parallel,

AS EMULATED QUAD A/B/X ENCODER OUTPUTS FROM AN

ANALOG SIN/COS FEEDBACK ENCODER OR RESOLVER

Analog sin/cos or resolver signals are interpolated in the drive with programmable resolution. The incremental position data is then converted back into digital quadrature format which drives the multi-mode port output buffers. Some analog encoders also produce a digital index pulse which is

A/B/X signals that can be used as feedback to an external control system.

Resolver signals are interpolated with programmable resolution up to 14-bits per revolution (single-speed resolver).

AS A MASTER OR CAMMING ENCODER INPUT FROM A

DIGITAL QUADRATURE ENCODER

When operating in position mode the multi-mode port can accept digital command signals from external encoders. These can be used to drive cam tables, or as master-encoder signals when operating in a master/slave

AS DIGITAL COMMAND INPUTS IN PULSE/DIRECTION,

PULSE-UP/PULSE-DOWN, OR

DIGITAL QUADRATURE ENCODER FORMAT

The multi-mode port can also be used when digital command signals are in a differential format. These are the signals that typically go to [IN9] and [IN10] when they are single-ended. But, at higher frequencies these are likely to be differential signals in which case the multi-mode port can be used.





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™


GP (GENERAL PURPOSE) DIGITAL INPUTS

There are fourteen digital inputs, thirteen of which have programmable functions.

Input [IN1] is not programmable and is dedicated to the drive Enable function. This is done to prevent accidental programming of the input in such a way that the controller could not shut it down. Programmable functions of the digital inputs include:

24 Vdc max 24 Vdc max

24 Vdc max

HS (HIGH SPEED) DIGITAL INPUTS

These are single-ended inputs with all the programmable functions of the

GP inputs plus these additional functions on [IN9] & [IN10]: or A/B Quad encoder inputs

10 Vdc max

HSD (HIGH SPEED DIFFERENTIAL) DIGITAL INPUTS

These are differential inputs with programmable functions.

10 Vdc max

Cam-table start input

DIGITAL OUTPUTS

The digital outputs are open-drain MOSFETs with 1 k pull-up resistors in series with a diode to +5 Vdc. They can sink up to 250 mAdc from external loads operating from power supplies to +30 Vdc. The output functions are programmable. The active state of the outputs is programmable to be on or off.

internal diode in the output is for driving PLC inputs that are opto-isolated and connected to +24 Vdc. The diode prevents conduction from +24 Vdc through the 1 k resistor to

+5 Vdc in the drive. This could turn the PLC input on, giving a false indication of the drive output state.

MOTOR BRAKE OUTPUT

This is an optically isolated output with a higher current rating for that is connected to the AuxHV input (+24 Vdc). Brake timing and function is programmable.





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OUTPUT VOLTAGE LIMITS

™

DIGITAL SERVO DRIVE for BRUSHLESS/BRUSH MOTORS capacitor. As the load power increases, energy is drawn from the capacitor, discharging it until re-charged by the next cycle of the mains. Because the capacitor is only charged for a brief time at

2X the line frequency, the voltage will decrease between these charges producing “ripple” on the DC supply. As the motor voltage increases (a combination of BEMF (Back ElectroMotive Force) and

This is called “clipping” as the output voltage can no longer increase to control motor current. The graph below shows the clipping voltages for the XSJ when operated at some common mains voltages over the range of output currents.

In order to avoid clipping, select a motor winding to provide some headroom between the clipping voltage and the expected terminal voltage to allow for low-line conditions on the mains, resistance changes in the motor due to heating, etc.

bottom of the ripple voltage waveform on the DC supply.

DC SUPPLY VOLTAGE AT LOW OUTPUT CURRENT AND POWER DC SUPPLY VOLTAGE AT HIGH OUTPUT CURRENT AND POWER

Clipping Voltage

Clipping Voltage

EXAMPLE

Assume 8 Adc is required to accelerate a linear motor to 2.5 m/s.

Motor resistance is 12 and BEMF constant is 36 V/m/s. The motor is brushless driven with sinusoidal commutation:

1) Find I*R voltage drop:

8 Adc * 12 * 0.75 = 72 Vdc.

The 0.75 factor converts the line-line resistance of the motor to the effective resistance when commutating sinusoidally.

2) Find BEMF at 2.5 m/s: 36 V/m/s * 2.5 m/s = 90 Vdc

3) Find motor terminal voltage:

I*R + BEMF = 72 + 90 = 162 Vdc

4) The dotted lines on the graph to the right show the clipping voltages at 8 Adc. Operation at 240 Vac would give about 28 V of headroom. But, at 200 Vac, either the motor velocity or accelerating current would have to be reduced to avoid clipping.

Finally, note that the motor resistance will increase 29% if it heats from 25C to 100C. That would change the required terminal voltage to 183 Vdc. In general, allow 20~30% headroom between motor terminal voltage demand and the clipping voltage. Using the oscilloscope in CME 2 software, the bus voltage and motor terminal

CLIPPING VOLTAGE VS. OUTPUT CURRENT in the working machine.





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Corp.

DRIVE CONNECTIONS

™


J5

J6

J3

J2

J4

J1

NOTES

1. The functions of input signals on J5-3,4,5,6,7,8-9,18,19,20,21,22,23-24, and are programmable.

2. The function of [IN1] on J5-17 is always Drive Enable and is not programmable.

The active level of [IN1] is programmable, and resetting the drive or clearing faults with changes on

3. Pins J5-30, J6-13, and J6-17 connect to the same +5 Vdc @ 250 mAdc power source.

Total current drawn from all pins cannot exceed 250 mAdc.





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Corp.

CONNECTORS & SIGNALS

J1 Power

Signal Pin

L1 1

Frame Ground

L2

2

3

J1 Cable Connector:

Euro-style 5,0 mm pluggable male terminal block:

Wago: 721-103/026-047/RN01-0000

Insert/extract lever: Wago: 231-131

J1

1

J2 Motor

Signal Pin

Frame Ground 1

Motor W 2

Motor V 3

Motor U 4

J2 Motor Cable Connector:


Wago: 721-104/026-047/RN01-0000


J3 Brake, 24V Power

Signal Pin Signal

Brake

+24Vdc

Frame Gnd

3

2

1

6

5

4

24V Return

+24Vdc

Frame Gnd

J3 AuxHV/Brake Cable Connector:

6-position poke/crimp

Housing: Molex 43025-0600

Contact: Molex 43030-0008

Crimping tool: Molex 63811-2800

Contact extractor: Molex 11-03-0043

J2

1

J3

J4

1

1

™

1

1

1

J5

J6

J7

Signal

Frame Ground

Signal Ground

CANL

CANH

CAN Power

2

1

4

3

J4 CAN

5

Pin Signal

10 Frame Ground

9

8

Signal Ground

CANL

7

6

CANH

CAN Power

CAN circuits are optically-isolated from drive circuits

J4 CAN Cable Connector:


Housing: Samtec IPD1-5-D

Contacts(20): Samtec CC79L-2024-01-F

Crimping tool: Samtec CAT-HT-179-2024-11

Contact Extractor: Samtec CAT-EX-179-01

3

2

5

4

1

J7 RS-232

Pin Signal

6 No Connect

TxD Output

Signal Ground

Signal Ground

RxD Input

No Connect


Web: www.copleycontrols.com


J5 Signal

Signal

Analog Ref (-) 16

Pin

1

Enable Input [IN1] 17

GP Input [IN3] 18

2

3

GP Input [IN5] 19

GP Input [IN7] 20

HS Input [IN9] 21

HS Input [IN11] 22

HS Input [IN13+] 23

6

7

8

4

5

HS Input [IN13-] 24

GP Output [OUT1] 25

GP Output [OUT3] 26

Multi-Mode Encoder A 27

Multi-Mode Encoder B 28

Multi-Mode Encoder X 29

+5 Vdc Output 30

Signal

Analog Ref (+)

Signal Ground

GP Input [IN2]

GP Input [IN4]

GP Input [IN6]

GP Input [IN8]

HS Input [IN10]

HS Input [IN12-]

9 HS Input [IN12+]

10 GP Output [OUT2]

11 Signal Ground

12 Multi-Mode Encoder /A

13 Multi-Mode Encoder /B

14 Multi-Mode Encoder /X

15 Frame Ground

J5 Control Cable Connector:






J6 Feedback

Signal

No Connection 11

Pin

1

Signal

No Connection

No Connection 12

+5 Vdc Output 13

2

3

No Connection

Signal Ground

Encoder /A 14

Encoder /B 15

Encoder /X 16

+5 Vdc Output 17

Hall U 18

4

5

6

7

8

Encoder A

Encoder B

Encoder X

Signal Ground

Hall V

Signal Ground 19

Motemp [IN14] 20

9

10

Hall W

Frame Ground

J6 Feedback Cable Connector:






J7 RS-232 Cable Connector:

RJ-11 Modular type

6-position, 4 used

Page 13 of 24



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DRIVE CONNECTIONS

™


NOTES



The active level of [IN1] is programmable, and resetting the drive or clearing faults with changes on

3. Pins J5-30, J6-13, and J6-17 connect to the same +5 Vdc @ 250 mAdc power source.

Total current drawn from all pins cannot exceed 250 mAdc.





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J1 Power

Signal Pin

L1 1

Frame Ground

L2

2

3



Wago: 721-103/026-047/RN01-0000


J1

1

J2 Motor

Signal Pin

Frame Ground 1

Motor W 2

Motor V 3

Motor U 4



Wago: 721-104/026-047/RN01-0000



Signal Pin Signal

Brake

+24Vdc

3

2

6 24V Return

5 +24Vdc

Frame Gnd 1 4 Frame Gnd







J2

1

J3

J4

1

1

™

1

1

1

J5

J6

Signal

Frame Ground

Signal Ground

CANL

CANH

CAN Power

2

1

4

3

J4 CAN

5

Pin Signal

10 Frame Ground

9

8

7

6

Signal Ground

CANL

CANH

CAN Power








3

2

5

4

1

J7 RS-232

Pin Signal

6 No Connect

TxD Output

Signal Ground

Signal Ground

RxD Input

No Connect



J7


J5 Signal

Signal

Analog Ref (-) 16

Pin

1


GP Input [IN3] 18

2

3

GP Input [IN5] 19

GP Input [IN7] 20

HS Input [IN9] 21

HS Input [IN11] 22

HS Input [IN13+] 23

6

7

8

4

5

HS Input [IN13-] 24

GP Output [OUT1] 25

GP Output [OUT3] 26




+5 Vdc Output 30

Signal

Analog Ref (+)

Signal Ground

GP Input [IN2]

GP Input [IN4]

GP Input [IN6]

GP Input [IN8]

HS Input [IN10]

HS Input [IN12-]

9 HS Input [IN12+]

10 GP Output [OUT2]

11 Signal Ground




15 Frame Ground







J6 Feedback

Signal

Sin(-) 11

Pin

1

Signal

Sin(+)

Cos(-) 12

+5 Vdc Output 13

2

3

Cos(+ )

Signal Ground

Encoder /A 14

Encoder /B 15

Encoder /X 16

+5 Vdc Output 17

Hall U 18

4

5

6

7

8

Encoder A

Encoder B

Encoder X

Signal Ground

Hall V

Signal Ground 19

Motemp [IN14] 20

9

10

Hall W

Frame Ground








RJ-11 Modular type

6-position, 4 used

Page 15 of 24



Phone: 877-478-3241

Phone: 877-IP-Tech1


Corp.

DRIVE CONNECTIONS

™


NOTES



The active level of [IN1] is programmable, and resetting the drive or clearing faults with changes on enable input is programmable.





Phone: 877-478-3241

Phone: 877-IP-Tech1


Corp.


J1 Power

Signal Pin

L1 1

Frame Ground

L2

2

3



Wago: 721-103/026-047/RN01-0000


J1

1

J2 Motor

Signal Pin

Frame Ground 1

Motor W 2

Motor V 3

Motor U 4



Wago: 721-104/026-047/RN01-0000



Signal Pin Signal

Brake

+24Vdc

3

2

6 24V Return

5 +24Vdc

Frame Gnd 1 4 Frame Gnd







J2

1

J3

J4

1

1

™

1

1

1

J5

J6

Signal

Frame Ground

Signal Ground

CANL

CANH

CAN Power

2

1

4

3

J4 CAN

5

Pin Signal

10 Frame Ground

9

8

7

6

Signal Ground

CANL

CANH

CAN Power








3

2

5

4

1

J7 RS-232

Pin Signal

6 No Connect

TxD Output

Signal Ground

Signal Ground

RxD Input

No Connect



J7


J5 Signal

Signal

Analog Ref (-) 16

Pin

1


GP Input [IN3] 18

2

3

GP Input [IN5] 19

GP Input [IN7] 20

HS Input [IN9] 21

HS Input [IN11] 22

HS Input [IN13+] 23

6

7

8

4

5

HS Input [IN13-] 24

GP Output [OUT1] 25

GP Output [OUT3] 26




+5 Vdc Output 30

Signal

Analog Ref (+)

Signal Ground

GP Input [IN2]

GP Input [IN4]

GP Input [IN6]

GP Input [IN8]

HS Input [IN10]

HS Input [IN12-]

9 HS Input [IN12+]

10 GP Output [OUT2]

11 Signal Ground




15 Frame Ground







Signal

J6 Feedback

Pin Signal

Frame Ground 11

Output R2 Ref(-)

12

1

2

Frame Ground

Ref(+) Output R1

Signal Ground 13

Frame Ground 14

Input S1 Sin(-)

15

Signal Ground 16

Frame Ground

Signal Ground

Motemp [IN14]

17

Input S4 Cos(-) 18

19

20

5

6

7

8

3

4

9

10

Signal Ground

Frame Ground

Sin(+) Input S3

Signal Ground

Frame Ground

Cos(+) Input S2

Signal Ground

Frame Ground








RJ-11 Modular type

6-position, 4 used

Page 17 of 24



Phone: 877-478-3241

Phone: 877-IP-Tech1


™


CABLING FOR COMMUNICATIONS

RS-232

The Serial Cable Kit (SER-CK) is a complete cable assembly that connects a computer serial port (COM1, COM2) to

J7

CANOPEN

into J4 connector pins



The connector kit for CAN networking (XSJ-NK) provides leads must be poked into the XSJ-NT (see table for pins).

The XSJ-NT comprises the a plug for drive J4 and also a 121 leads are left unattached so that the kit can also be used with multiple drives. When this is done, the CAN cables are daisy-chained from drive to drive and the XSJ-NT is only used on the last drive in the chain. The cables used for the daisy-chain are the XSJ-NC-10 or XSJ-NC-

01 which have a J4 connector attached to a cable with

XSJ-NK Connections

D-Sub 9F Pin Wire Color

7

3

2

White/Green

Orange

White/Orange

Note: D-Sub 9F connections comply with CAN CiA DR-303-1

XSJ-NC-01(-10) Connections

Wire Color Drive J4 Cable Connector

Frame Gnd Frame Gnd

White Green

Orange

White/Orange

5

4

3

2

1

10

9

8

7

6

XSJ-NT Connections

Drive J4 Cable Connector

Frame Gnd 5

4

10

9

Frame Gnd

121

Terminator

Connects

3

2

1

8

7

6

Page 18 of 24



Phone: 877-478-3241

Phone: 877-IP-Tech1


™


CABLING FOR COMMUNICATIONS

MULTI-DROP RS-232 address multiple CAN-enabled Copley drives from a single RS-232 port. First, an RS-232 connection is made between the computer and drive #1 which must be given a CAN address of 0. Under normal CAN operation, this address is not allowed for CAN nodes. But, in this case, drive #1 will act as a CAN master and so address 0 is allowed. Next, CAN connections are made between drive #1, drive

resistor between the unique numbers, none of which can be 0.

When ASCII data is exchanged over the serial port, the commands are now preceded with the node address of the drive. Drive #1 converts the data into CAN data which is then sent to all of the drives in the chain. It now appears as though all drives in the chain are connected to the single RS-232 port in the computer and for that reason we refer it as RS-232.

CANopen Data

Serial Data

ASCII or Binary format

Rules for Multi-drop RS-232

Drive #1 must have CAN address 0 and a

121 terminating resistor by drive digital inputs

Drives #2~#N must have different non-zero

CAN addresses

Drive #N (last drive in chain) must have a 121 terminating resistor

All drives in the chain are visible from CME 2 when SER-CK is connected to Drive #1





Phone: 877-478-3241

Phone: 877-IP-Tech1


STAND-ALONE OPERATION

™

Drive takes digital position commands in Pulse/Direction, or CW/CCW format from an external controller or quadrature encoder signals from a master-encoder for electronic gearing. Velocity or torque control can be from ±10 Vdc or digital PWM signals.

CME 2


SINGLE-DRIVE SETUP FOR CANOPEN CONTROL

Drive

operates as a CAN node. All commands are passed on the CAN bus.

CME 2

Rules for Single-Drive CANopen Operation

Drive CAN address must be > 0

Drive must have a 121 terminating resistor





Phone: 877-478-3241

Phone: 877-IP-Tech1


™

MULTIPLE-DRIVE SETUP FOR CANOPEN CONTROL

Rules for Multiple-Drive CANopen Operation

All drives must have CAN addresses > 0 and no drives can have the same CAN address


Drive #N (last drive in chain) must have a 121 terminating resistor

CME 2 can only see the drive to which the SER-CK serial cable is connected

The CAN Master must have a 121 terminating resistor





Phone: 877-478-3241

Phone: 877-IP-Tech1


MOUNTING AND COOLING

™


The ability of the drive to output current at a particular ambient temperature is greatly affected by the way it is mounted and the way

Thermal resistance is a measure of the temperature difference between the transistors and the environment per Watt of power dissipation.

INFINITE HEATSINK

The mounting surface is large enough so that its temperature does not change when absorbing the heat from the drive. Thermal grease is applied to the drive heatplate.

Thermal Resistance

0.23 ºC-W

PANEL MOUNTED, ENCLOSED

Enameled steel panel in an industrial enclosure.

No fan to circulate air in box or to force ambient air through box. A common mounting means for industrial machinery.

FAN COOLED HEATSINK

A fan is mounted close to the heatsink and air velocity is ~400 LFM (~2 m/s).

Thermal Resistance

1.91 ºC/W

Test box dimensions:

Panel: 17x14.5 in (432x368 mm)

Box: 20x16 x 8.62 in

Thermal Resistance

2.00 ºC/W

FAN COOLED, NO HEATSINK

Forced-air at 400 LFM (Linear Feet/Minute) directed at the heatplate.

HEATSINK, CONVECTION COOLED

A heatsink is mounted to the heatplate and is exposed for convection cooling but is not fan cooled or in contact with a heat sinking surface.

NO HEATSINK OR FAN, CONVECTION COOLED

The heatplate is exposed for convection cooling but is not fan cooled or in contact with a heat sinking surface.



Flat mounting

Thermal Resistance

2.9 ºC/W

Thermal Resistance

4.27 ºC/W

Thermal Resistance:

Flat: 6.5 ºC/W

On edge: 6.0 ºC/S

Page 22 of 24



Phone: 877-478-3241

Phone: 877-IP-Tech1


™


MAXIMUM AMBIENT TEMPERATURE VS. OUTPUT CURRENT, MOUNTING, AND COOLING

The graphs below show the maximum ambient operating temperature for the drive vs. output current for the Xenus Micro models at

240 Vac mains voltages and under different mounting and cooling conditions.

XSJ-230-10

Curves:

2) On steel panel in box

3) Heatsink, fan-cooled

4) No heatsink, fan-cooled

5) Heatsink, convection

6) No heatsink, convection

XSJ-230-06

Curves:





6) No heatsink, convection

XSJ-230-02

Curves:





6) No heatsink, convection`





Phone: 877-478-3241

Phone: 877-IP-Tech1


MASTER ORDERING GUIDE

XSJ-230-02

XSJ-230-06

XSJ-230-10

™

Add -S to model number for sin/cos feedback

Add -R to model number for resolver feedback

Servo drive 1/2 Adc

Servo drive 3/6 Adc

Servo drive 5/10 Adc


ACCESSORIES

Drive

Connector

Kit

XSJ-CK

CANopen

Connector

Kit

XSJ-NK

XSJ-NA-10

XSJ-NC-10

XSJ-NC-01

XSJ-NT

SER-CK

XSJ-CV

CME 2

Heatsink Kit

XSJ-HK

QTY

1

1

1

1

1

1

REF

J1

J2

J3

J4

J5

J6

DESCRIPTION

Plug, 3 position, 5.0mm, female


Connector housing, 6 position




MANUFACTURER PART NO.

Wago: 51117974 or 721-103/026-047/RN01-0000

Wago: 51118008 or 721-104/026-047/RN01-0000

Molex: Micro-Fit 43025-0600

Samtec: Mini-Mate IPD1-05-D



2

1

1

66 J4,J5,J6 Contact, female, for AWG 24~20 wire Samtec: Mini-Mate CC79L-2024-01-F

8 J3 Contact, female, for AWG 24~20 wire Molex: Micro-Fit 43030-0008

J1,J2 Wire insertion/extraction tool Wago: 231-131

D-Sub 9 position female to RJ-45 female (XSJ-CV)

J1

1 CANopen terminator (XSJ-NT) (J1 plug with resistor)

J4

J4

J4

J4

J7

J4

1

1

A/R

CANopen network teminator (J4 plug with resistor)

Serial Cable Kit: D-Sub 9F to RJ-11 adapter + 6 ft (1.8 m) modular cable for drive J7

Cable adapter: D-Sub 9F to RJ-45 female, for CAN cables

CME 2™ CD (CME 2)

Heatsink

Thermal Material

Hardware

ORDERING EXAMPLE

1

1

1

1

1

Example: Order 1 XSJ-230-10 drive with resolver feedback, heatsink, and associated components:

Qty Item Remarks

ADD A CAN BUS INTERFACE TO YOUR COMPUTER:

XSJ-230-10-R

XSJ-HK

XSJ-CK

SER-CK

CME2 servo drive

Heatsink kit

Connector Kit

Serial Cable Kit

CME 2™ CD

lated CAN channels in a PCI-card form-factor and works with the XSJ-NK connector kit.



Copley Controls Xenus XTL-230-40 manual

Assistant Bot

Control Modes

Command Interface

Communications

DESCRIPTION

AGENCY STANDARDS CONFORMANCE

Required for

Drive Operation

DANGER: HIGH VOLTAGE

NOTE: AN EXTERNAL

+24 VDC POWER SUPPLY

IS REQUIRED FOR OPERATION

NOTE: AN EXTERNAL

+24 VDC POWER SUPPLY

IS REQUIRED FOR OPERATION

NOTE: AN EXTERNAL

+24 VDC POWER SUPPLY

IS REQUIRED FOR OPERATION

Xenus

Outputs

Resolver and

Temperature Sensor

or

Required for CE

Required

Required

DESCRIPTION

LED INDICATORS

PROTECTIONS

MECHANICAL & ENVIRONMENTAL

AGENCY STANDARDS CONFORMANCE

+

-

Corp.

Corp.

Corp.

Corp.

Corp.

Corp.

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