Xenus PlusTM User Guide P/N 16-01018 Revision 07 August 2014
Xenus Plus User Guide This page for notes
TABLE OF CONTENTS About This Manual ................................................................................................................................................................................ 5 1: Introduction ............................................................................................................................................................................... 10 1.1: Xenus Plus Family Overview ......................................................................
Xenus Plus User Guide D: E: F: Table of Contents Xenus Plus Filter ..................................................................................................................................................................... 139 D.1: Overview ............................................................................................................................................................................ 140 D.2: XTL-FA-01 Edge Filter Specifications .......................................
ABOUT THIS MANUAL Title, Number, Revision Title The Xenus Plus User Guide Document Number 16-01018 Current Revision 07 Revision History Revision Date ECO Comments 0.1 July 2010 00 December 2010 ECO-38399 First customer release. 01 April 2011 ECO-40588 Second customer release. Various updates including Mains data. 02 May 2012 ECO-051418 Mains single phase diagram fix. 03 October 2013 ECO-051770 Added XE2, XP2 and functional safety information.
Xenus Plus User Guide About this Manual EC Declaration of Conformity - Contents The complete EC Declarations of Conformity for all products are available on the internet at www.copleycontrols.com. Original Instructions This manual is considered to be “original instructions” as defined in EC Directive 2006/42/EC and the contents have been verified by Copley Controls.
Xenus Plus User Guide About this Manual Related Documentation For important setup and operation information, see the CME 2 User Guide (Under Using CME2 here: http://www.copleycontrols.com/Motion/Downloads/software.html).
Xenus Plus User Guide About this Manual Product Warnings Observe all relevant state, regional and local safety regulations when installing and using this product. There are no user serviceable parts in the Xenus Plus servo drives. Removal of the cover or tampering with internal components will void the warranty ! DANGER: Hazardous voltages. Exercise caution when installing and adjusting. Failure to heed this warning can cause equipment damage, injury, or death. DANGER Risk of electric shock.
Xenus Plus User Guide About this Manual This page for notes.
CHAPTER 1: INTRODUCTION This chapter provides an overview of the Copley Controls Xenus Plus drives. Contents include: 1.1: Xenus Plus Family Overview ................................................................................................................................................ 11 1.2: CME 2 .................................................................................................................................................................................. 12 1.3: CML/CMO ........
Xenus Plus User Guide Introduction 1.1: Xenus Plus Family Overview Each Xenus Plus servo drive provides 100% digital control of brushless or brush motors in an offline powered package. It can also control a Copley Controls ServoTube motor. Xenus Plus can operate from single or three-phase mains with a continuous power output of up to 4 kW.
Xenus Plus User Guide Introduction Model Data Standard Resolver Continuous Current Peak Current XEL-230-18 XML-230-18 XPL-230-18 XEL-230-18 -R XML-230-18 -R XPL-230-18 -R 6A 18 A XEL-230- 36 XML-230- 36 XPL-230- 36 XEL-230- 36 -R XML-230- 36 -R XPL-230- 36 -R 12 A 36 A XEL-230-40 XML-230-40 XPL-230-40 XEL-230-40 -R XML-230-40 -R XPL-230-40 -R 20 A 40 A XE2-230-20 XP2-230-20 800-1782 800-1808 XE2-230-20 -R XP2-230-20 -R 10 A 20 A - Vac 100 to 240 The XEL/XML/XPL model numbers may b
Xenus Plus User Guide Introduction 1.3: CML/CMO Copley Motion Libraries (CML) and Copley Motion Objects (CMO) make CANopen or EtherCAT network commissioning fast and simple. All network housekeeping is taken care of automatically by a few simple commands linked into your application program. CML provides a suite of C++ libraries, allowing a C++ application program to communicate with and control a drive over the CANopen network.
CHAPTER 2: OPERATIONAL THEORY This chapter describes the basics of Xenus Plus operation. Contents include: 2.1: Drive Internal Power ............................................................................................................................................................. 15 2.2: PWM Switching Frequency Synchronizing ............................................................................................................................ 16 2.3: Commutation Modes ........................
Xenus Plus User Guide Operational Theory 2.1: Drive Internal Power Power distribution within Xenus Plus is divided into three sections: +24 Vdc, logic/signal, and high voltage. Each is isolated from the other. 2.1.1: Logic/Signal Power An internal DC/DC converter operates from the +24 Vdc Logic Supply input and creates the required logic/signal operating voltages, the isolated voltages required for the high-voltage control circuits, and a +5 Vdc supply for powering the motor encoder and Hall circuits.
Xenus Plus User Guide Operational Theory 2.1.3: Power and Grounding Diagram The graphic below shows the different power sections within the Xenus Plus drives and the isolation barriers between them. Note that the diagram shows the power and feedback connections to one motor and applies directly to the single axis model. Although not shown, connections to a second motor (applicable for the dual axis drive models) are essentially duplicates of the first.
Xenus Plus User Guide Operational Theory 2.3: Commutation Modes The drive supports three commutation modes to drive brush and brushless motors: AC brushless sinusoidal, AC brushless trapezoidal, and DC brush. In most applications, sinusoidal commutation is preferred over trapezoidal, because it reduces torque ripple and offers the smoothest motion at any velocity or torque. In the sinusoidal commutation mode, an encoder or a resolver are required for all modes of operation.
Xenus Plus User Guide Operational Theory 2.5: Operating Modes 2.5.1: Modes and Control Loops Nesting of Control Loops and Modes Copley Controls drives use up to three nested control loops - current, velocity, and position - to control a motor in three associated operating modes. Control Loops Illustration In position mode, the drive uses all three loops. As shown below, the position loop drives the nested velocity loop, which drives the nested current loop.
Xenus Plus User Guide Operational Theory 2.5.2: Current Mode and Current Loop Current Loop Diagram As shown below, the “front end” of the current loop is a limiting stage. The limiting stage accepts a current command, applies limits, and passes a limited current command to the summing junction. The summing junction takes the limited current command, subtracts the actual current (represented by the feedback signal), and produces an error signal.
Xenus Plus User Guide Operational Theory Current Loop Gains The current loop uses these gains: Gain Description Cp - Current loop proportional The current error (the difference between the actual and the limited commanded current) is multiplied by this value. The primary effect of this gain is to increase bandwidth (or decrease the step-response time) as the gain is increased. Ci - Current loop integral The integral of the current error is multiplied by this value.
Xenus Plus User Guide Operational Theory 2.5.3: Velocity Mode and Velocity Loop Velocity Loop Diagram As shown below, the velocity loop limiting stage accepts a velocity command, applies limits, and passes a limited velocity command to the input filter. The filter then passes a velocity command to the summing junction. The summing junction subtracts the actual velocity, represented by the feedback signal, and produces an error signal.
Xenus Plus User Guide Operational Theory Diagram: Effects of Limits on Velocity Command The following diagram illustrates the effects of the velocity loop limits. Limited Velocity Commanded Velocity Vel Limit Accel Limit Decel Limit Velocity Loop Gains The velocity loop uses these gains: Gain Description Vp - Velocity loop proportional The velocity error (the difference between the actual and the limited commanded velocity) is multiplied by this gain.
Xenus Plus User Guide Operational Theory 2.5.4: Position Mode and Position Loop Position Loop Diagram The drive receives position commands from the digital or analog command inputs, over the CAN interface or serial bus, or from the CVM Control Program. When using digital or analog inputs, the drive's internal trajectory generator calculates a trapezoidal motion profile based on trajectory limit parameters.
Xenus Plus User Guide Operational Theory Position Loop Gains The following gains are used by the position loop to calculate the velocity command: Gain Description Pp - Position loop proportional The loop calculates the position error as the difference between the actual and limited position values. This error in turn is multiplied by the proportional gain value. The primary effect of this gain is to reduce the following error.
Xenus Plus User Guide Operational Theory 2.6: Input Command Types The drive can be controlled by a variety of external sources: analog voltage or digital inputs, CAN network (CANopen), EtherCAT, CoE (CANopen over EtherCAT), MACRO, or over an RS-232 serial connection using ASCII commands. The drive can also function as a stand-alone motion controller running an internal CVM program or using its internal function generator. 2.6.
Xenus Plus User Guide Operational Theory Offset To remove the effects of voltage offsets between the controller and the drive in open loop systems, CME 2 provides an Offset parameter and a Measure function. The Measure function takes 10 readings of the analog input voltage over a period of approximately 200 ms, averages the readings, and then displays the results. The Offset parameter allows the user to enter a corrective offset to be applied to the input voltage.
Xenus Plus User Guide Operational Theory 2.6.2: PWM Input Two Formats The drive can accept a pulse width modulated signal (PWM) signal to provide a current command in current mode and a velocity command in velocity mode. The PWM input can be programmed for two formats: 50% duty cycle (one-wire) and 100% duty cycle (two-wire). 50% Duty Cycle Format (One-Wire) The input takes a PWM waveform of fixed frequency and variable duty cycle. As shown below, a 50% duty cycle produces zero output from the drive.
Xenus Plus User Guide Operational Theory 2.6.3: Digital Input Three Formats In position mode, the drive can accept position commands via two digital inputs, using one of these signal formats: pulse and direction, count up/count down, and quadrature. In all three formats, the drive can be configured to invert the command. Pulse Smoothing In position mode, the drive’s trajectory generator ensures smooth motion even when the command source cannot control acceleration and deceleration rates.
Xenus Plus User Guide Operational Theory Count Up/Count Down Format In the count up/count down format, one input takes each pulse as a positive step command, and another takes each pulse as a negative step command, as shown below. Up Input Down Input Velocity Command The drive can be set to increment position on the rising or falling edge of the signal. Stepping resolution can be programmed for electronic gearing.
Xenus Plus User Guide Operational Theory 2.7: Communication As described below, the drive features multiple communication interfaces, each used for different purposes. Interface Description RS-232 port The drive features a three-wire RS-232 port. Control commands can be sent over the RS-232 port using Copley Controls ASCII interface commands. In addition, CME 2 software communicates with the drive (using a binary protocol) over this link for drive commissioning, adjustments, and diagnostics.
Xenus Plus User Guide Operational Theory 2.7.1: CAN Communication Details (XPL/XP2) CAN Network and CANopen Profiles for Motion In position mode, the XPL/XP2 can take instruction over a two-wire Controller Area Network (CAN). CAN specifies the data link and physical connection layers of a fast, reliable network. CANopen is a set of profiles (specifications) built on a subset of the CAN application layer protocol.
Xenus Plus User Guide Operational Theory CANopen Architecture As shown below, in a CANopen motion control system, control loops are closed on the individual drives, not across the network. A master application coordinates multiple devices, using the network to transmit commands and receive status information. Each device can transmit to the master or any other device on the network.
Xenus Plus User Guide Operational Theory 2.7.2: EtherCAT Communication Details (XEL/XE2/800-1782) The XEL/XE2/800-1782 models accept CAN application layer over EtherCAT (CoE) commands. EtherCAT Addressing Nodes on an EtherCAT network are automatically addressed by their location. The first drive on the network is station address -1. The second is -2, and so on. Each dual axis drive is addressed as a single physical node on the EtherCAT network having two axes of motion.
Xenus Plus User Guide Operational Theory 2.8: Limit Switches 2.8.1: Use Digital Inputs to Connect Limit Switches Limit switches help protect the motion system from unintended travel to the mechanical limits. In the Xenus Plus Single Axis products, any of the digital inputs 1-14 (1-20 for Xenus Plus Dual Axis), can be can be programmed as positive or negative limit switch inputs. With the drive operating as a CAN node, an input can also be programmed as a home limit switch for CANopen homing operations.
Xenus Plus User Guide Operational Theory 2.9: Brake Operation 2.9.1: Digital Output Controls Brake Many control systems employ a brake to hold the axis when the drive is disabled. Xenus Plus drives have digital outputs designed specifically for brake outputs. Other outputs can be used but these are recommended. Unlike the other outputs, these brake specific outputs are optically isolated from the control signals and have internal fly back diodes connected to the +24 Vdc input.
Xenus Plus User Guide Operational Theory 2.10: Status Indicators 2.10.1: XEL J6 STAT & NET: Drive and EtherCAT State Machine Indicators J6 STAT-Drive Status NET-EtherCAT Network Status J7 Activity Status (Yellow) Out (B) Link Status (Green) Activity Status (Yellow) In (A) Link Status (Green) XEL J6 STAT Indicator: Drive Status XEL Drive status indicator color/blink codes are described below. Color/Blink Code Meaning Not illuminated No +24 Vdc power to drive.
Xenus Plus User Guide Operational Theory 2.10.
Xenus Plus User Guide Operational Theory 2.10.3: XE2/800-1782 J7 Axis A/B: Drive Status Indicators J7 A-Axis A B-Axis B J8 L/A-Link activity Out RUN-State of the ESM L/A-Link activity In ERR-Errors XE2/800-1782 J7 Axis A/B Drive Status Indicators XE2/800-1782 indicator color/blink codes are described below. Color/Blink Code Meaning Green/Solid Drive OK and enabled. Will run in response to reference inputs or EtherCAT commands. Green/Slow Blinking Drive OK but NOT-enabled. Will run when enabled.
Xenus Plus User Guide Operational Theory 2.10.4: XE2/800-1782 J8 RUN, ERR, & L/A Indicators J7 A-Axis A B-Axis B J8 L/A-Link activity Out RUN-State of the ESM L/A-Link activity In ERR-Errors XE2/800-1782 J8 L/A Indicators Shows the state of the physical link and activity on the link.
Xenus Plus User Guide Operational Theory 2.10.5: XML J6: Drive and MACRO Network Status Indicators J6 STAT-Drive Status NET-MACRO Network Status XML J6 STAT Indicator: Drive Status Indicator color/blink codes are described below. Color/Blink Code Meaning Not illuminated No +24 Vdc power to drive. Steady green Drive is enabled and operational. Slow-blinking green Drive is disabled. No faults or warnings are active. Fast-blinking green A limit switch is active. The drive is enabled.
Xenus Plus User Guide Operational Theory 2.10.6: 800-1808 J7: Drive and MACRO Network Status Indicators 800-1808 J7 Axis A/B: Drive Status Indicators 800-1808 indicator color/blink codes are described below. Color/Blink Code Meaning Green/Solid Drive OK and enabled. Will run in response to reference inputs or MACRO commands. Green/Slow Blinking Drive OK but NOT-enabled. Will run when enabled. Green/Fast Blinking Positive or Negative limit switch active.
Xenus Plus User Guide Operational Theory 2.10.7: XPL J6 STAT: Drive Status Indicator J6 STAT-Drive Status NET-CAN Network Status J7 Activity / Error Out In Activity / Error XPL J6 STAT Indicator XPL Drive status indicator color/blink codes are described below. Color/Blink Code Meaning Not illuminated No +24 Vdc power to drive. Steady green Drive is enabled and operational. Slow-blinking green Drive is disabled. No faults or warnings are active. Fast-blinking green A limit switch is active.
Xenus Plus User Guide Operational Theory XPL J6 NET Indicator: CANopen RUN and ERR States The XPL NET indicator color/blink codes comply with CAN Indicator Specification CiA 303-3 as shown below. Green is the RUN state and red is the ERR state. Note that green and red codes alternate, each indicating a different set of conditions. The green RUN led indicates the state of the CANopen state machine (pre-operational, operational, or stopped).
Xenus Plus User Guide Operational Theory 2.10.8: XPL J7 Activity/Error: CAN Network Activity and Errors For firmware versions before V2.0: Both LEDs blink in unison: Green = receive data, Red = transmit data ACT Indicator State Blinking red Normal transmit/receive data on the network For firmware version V2.0 and higher: Both LEDs blink in unison to show bus activity and low-level bus errors.
Xenus Plus User Guide Operational Theory 2.10.9: XP2 J7 Axis A/B: Drive Status Indicators The LEDs located on connector J7 indicate axis A and B drive status. J7 A-Axis A B-Axis B J8 L/A-Link activity Out RUN-State of the ESM L/A-Link activity In ERR-Errors XP2 J7 Axis A/B: Drive Status Indicators XP2 indicator color/blink codes are described below. Color/Blink Code Meaning Green/Solid Drive OK and enabled. Will run in response to reference inputs or CANopen commands.
Xenus Plus User Guide Operational Theory 2.10.10: XP2 J8 RUN, ERR, & L/A Indicators J7 A-Axis A B-Axis B J8 L/A-Link activity Out RUN-State of the ESM L/A-Link activity In ERR-Errors XP2 J8 L/A Indicators Shows the state of the physical link and activity on the link.
Xenus Plus User Guide Operational Theory 2.11: Protection 2.11.1: Safe Torque Off All of the Xenus Plus models provide a Safe Torque Off (STO) function. Two inputs are provided which, when de-energized, prevent the upper and lower devices in the PWM outputs from being operated by the digital control core. This provides a positive OFF capability that cannot be overridden by the control firmware, or associated hardware components.
Xenus Plus User Guide Operational Theory Clearing Non-Latched Faults The drive clears a non-latched fault, without operator intervention, when the fault condition is corrected. ! DANGER Risk of unexpected motion with non-latched faults. After the cause of a non-latched fault is corrected, the drive re-enables the PWM output stage without operator intervention. In this case, motion may re-start unexpectedly. Configure faults as latched unless a specific situation calls for nonlatched behavior.
Xenus Plus User Guide Operational Theory *Following Error User set following error threshold exceeded. See Position and Velocity Errors (p. 50). *Short Circuit Detected Output to output, output to ground, internal PWM bridge fault. Short circuit has been removed. ○Over Current (Latched) Output current I T limit has been exceeded. 2 Drive is reset and re-enabled. *Latched by default.
Xenus Plus User Guide Operational Theory 2.12: Position and Velocity Errors 2.12.1: Error-Handling Methods In position mode, any difference between the limited position output of the trajectory generator and the actual motor position is a position error. The drive’s position loop uses complementary methods for handling position errors: following error fault, following error warning, and a positiontracking window.
Xenus Plus User Guide Operational Theory 2.12.5: Following Error Fault Details Position Error Reaches Fault Level As described earlier, position error is the difference between the limited position output of the trajectory generator and the actual position. When position error reaches the programmed Following Error Fault level, the drive faults (unless the following error fault is disabled.) As with a warning, a status bit is set. In addition, the fault is recorded in the error log.
Xenus Plus User Guide Operational Theory 2.12.6: Tracking Window Details Proper Tracking Over Time As described earlier, position error is the difference between the limited position output of the trajectory generator and the actual position. Velocity error is the difference between commanded and actual velocity. When the position or velocity error exceeds the programmed tracking window value, a status word bit is set.
Xenus Plus User Guide Operational Theory 2.13: Inputs XEL/XPL/XML The Xenus Plus XEL and XPL drives have 15 digital inputs and 3 analog inputs. 2.13.1: Digital Inputs The Xenus Plus XEL and XPL drives feature 14 programmable digital inputs. Non-isolated inputs IN1-IN6 are connected on J8. Opto-isolated IN7-IN14 are connected on J9. IN3-IN6 are single ended or differential programmable inputs. The IN15 digital input on J10 is for an encoder fault signal on.
Xenus Plus User Guide Operational Theory 2.14: Inputs XE2/XP2/800-1782/800-1808 The XE2, XP2, and 800-1808 drives have 22 digital inputs and 2 analog inputs. The 800-1782, a custom version of the XE2, has 20 digital inputs and 2 analog inputs 2.14.1: Digital Inputs IN1,10,11,20,21 and 22 are general purpose Schmitt trigger single ended inputs with programmable pull-up/down to +5 Vdc/ground and 1 μs RC filters (24 Vdc compatible).
Xenus Plus User Guide Operational Theory 2.15: Outputs, XEL/XPL/XML The Xenus Plus XEL and XPL drives have 6 programmable digital outputs (one opto-isolated and five non-isolated) and one programmable analog output. 2.15.1: Digital Outputs The XEL/XPL/XML features six programmable digital outputs. OUT1~5 are general-purpose outputs. OUT6 is specifically designed as a brake output but can be programmed to perform any of the functions. For a list of digital output functions, see Control I/O (p.
Xenus Plus User Guide Operational Theory 2.16: Outputs, XE2/XP2/800-1782/800-1808 XE2/XP2/800-1808 has 7 programmable digital outputs, while the 800-1782 has 5. OUT1~5 are general-purpose outputs. The 800-1782 does not utilize OUT 4~5. OUT6 and OUT7 are specifically designed as brake outputs for axis A and B respectively, but can be programmed to perform other functions. For a list of digital output functions, see the CME 2 User Guide. There are no analog outputs in XE2/XP2/800-1782/800-1808.
Xenus Plus User Guide Operational Theory 2.17: Regen Resistor Theory 2.17.1: Regeneration When a load is accelerated, electrical energy is converted into mechanical energy. During deceleration the conversion is reversed. This is called regeneration. Some of this regenerated energy is lost to friction in the mechanical system. More of this energy is converted to heat due to I2R losses in the motor windings, cabling, and drive electronics.
CHAPTER 3: SPECIFICATIONS This chapter describes the drive specifications. Contents include: 3.1: Agency Approvals ................................................................................................................................................................. 59 3.2: Power Input .......................................................................................................................................................................... 59 3.3: Power Output........................
Xenus Plus User Guide Specifications 3.
Xenus Plus User Guide Specifications 3.3: Power Output Model Peak Current XEL-230-18 (-R) XPL-230-18 (-R) XML-230-18 (-R) 18 Adc [12.7 Arms] XEL-230-36 (-R) XPL-230-36 (-R) XML-230-36 (-R) 36 Adc [25.5 Arms] Peak Current Time Continuous Current* Efficiency Output Type PWM Ripple Frequency Minimum Load Inductance XEL-230-40 (-R) XPL-230-40 (-R) XML-230-40 (-R) XE2-230-20 (-R) XP2-230-20 (-R) 800-1808 800-1782 40 Adc [28.3 Arms] 20 Adc [14 Arms] 20 Adc [14.
Xenus Plus User Guide Specifications 3.4: Control Loops Type Current Velocity Position Sampling rate (time) Current Velocity Position 100% digital. 16 kHz (62.5 µs) 4 kHz (250 µs) 4 kHz (250 µs) Current Loop Small Signal Bandwidth > 2 kHz (Tuning and load impedance dependent) Loop Filters Programmable Velocity loop output filter default: 200 Hz low pass. Bus Voltage Compensation Changes in bus or mains voltage do not affect tuning. 3.
Xenus Plus User Guide Specifications 3.7: Analog Inputs XEL/XPL/XML Channels 3 (AIN1~IN3) AIN1~AIN2 AIN3 Type Differential, non-isolated Single-ended Measurement Range ±10 Vdc 0-5 Vdc ±10 Vdc ±10 Vdc ±10 Vdc ±10 Vdc Input Impedance 5k 4.99 k Resolution 16 Bit 12 Bit Anti-aliasing filter 14.5 kHz 27 Hz Scan Time 62.5 s 250 s Function Programmable.
Xenus Plus User Guide Specifications 3.8: Digital Inputs XEL/XPL/XML Channels 15 (IN1~IN15) IN1~IN2, IN15 IN3~IN6 IN7~IN14 Type Schmitt trigger w/ RC filter, 24Vdc max Non-isolated line receiver w/ RC filter, programmable as 4 single-ended or 2 differential Single-ended Opto-isolated, bi-polar, 2 groups of 4 with common for each group Input Voltage Range 0 Vdc-24 Vdc 0-12Vdc ±15 - 30 Vdc Logic Low Input Voltage <= +1.13 Vdc <= +2.3 Vdc N/A Logic High Input Voltage >= +3.15 Vdc >= +2.
Xenus Plus User Guide Specifications 3.9: Analog Outputs XEL/XPL/XML Channels 1 Type Single-ended Range 0-5 Vdc Resolution 12 Bit NOTE: There are no analog outputs available on XE2 or XP2 drives. 3.
Xenus Plus User Guide Specifications 3.11: Encoder Power Supply Output XEL/XPL/XML Number 2 Voltage Output +5 Vdc ±2% Maximum Current Output 400 mA Short Circuit Protection Fold-back current limiting Function Provides power for motor encoder and/or Hall switches. XE2/XP2/800-1782/800-1808 Number 4 Voltage Output +5 Vdc ±2% Maximum Current Output 500 mA Short Circuit Protection Fold-back current limiting Function Provides power for motor encoders and/or Hall switches. 3.
Xenus Plus User Guide Specifications 3.13: Analog Encoder Inputs XEL/XPL/XML Channels 2 Type Differential, non-isolated Signals Sin(+), Sin(-), Cos(+), Cos(-) Nominal Voltage 1 Vpk-pk Maximum Voltage Differential Input to Ground ±0.6 Vdc 0 to +3.5 Vdc Differential Input Impedance 121 Bandwidth 230 kHz Interpolation 1 to 1024, programmable Function Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation.
Xenus Plus User Guide Specifications 3.14: Hall Switch Inputs XEL/XPL/XML Channels 3 (U, V and W) Type 74HC14 Schmitt trigger w/ RC Filter 10 k pull up resistor to internal +5 Vdc Input Voltage Range 0 Vdc - +24 Vdc Low Level Input Voltage < +1.35 Vdc High Level Input Voltage > +3.65 Vdc Timing Edge detection. RC Filter Time Constant 1 s when driven by active sources. Function Commutation of brushless motors in trapezoidal mode.
Xenus Plus User Guide Specifications 3.15: Resolver Interface XEL/XPL/XML Channels 3 Type Transmit, 1:1 to 2:1 transformation ratio Signals Ref(+), Ref(-), Sin(+), Sin(-), Cos(+), Cos(-) Resolution 14 bits (equivalent to a 4096 line quadrature encoder) Reference Frequency 8 kHz Reference Voltage 2.8 Vrms, auto-adjustable by drive for proper feedback levels.
Xenus Plus User Guide Specifications 3.16: Multi-Mode Port XEL/XPL/XML Channels 4 Type Bi-Directional, Differential RS-422. Non-isolated Signals A, /A, B, /B, X, /X, S, /S Input Voltage Range ±7 Vdc Differential Input Threshold ±0.
Xenus Plus User Guide Specifications 800-1782 Channels 6 Type Differential RS-422. Non-isolated Signals A, /A, B, /B, X, /X for each axis Input Voltage Range ±7 Vdc Differential Input Threshold ±0.
Xenus Plus User Guide Specifications 3.
Xenus Plus User Guide Specifications 3.18: Network Interfaces Model XEL/XE2/800-1782 Channels XPL/XP2 XML/800-1808 1 Connectors 2 eight-position (RJ-45 style). 2 Duplex type SC optical fiber connector. Signals 100BASE-TX CAN_H, CAN_L, CAN_Gnd (CAN +5 Vdc Pass though only) Format EtherCAT CAN V2.0b physical layer for high-speed connections compliant Protocol CANopen over EtherCAT (CoE) based on DSP-402 for motion control devices.
Xenus Plus User Guide Specifications 3.19: Status Indicators Model LED: Network Status XEL XPL XML STAT NET NET Bicolor LED, status of EtherCAT bus indicated by color and blink codes to CAN Indicator Specification 303-3 Ethernet: Link (green) shows port open-closed ACT (yellow) shows activity Bicolor LED, status of CAN bus indicated by color and blink codes to CAN Indicator Specification CiA 303-3 Bicolor LED, status of the MACRO interface.
Xenus Plus User Guide Specifications 3.21: Power Dissipation Output Power Mains Voltage XEL-230-18 (-R) XPL-230-18 (-R) XML-230-18 (-R) XEL-230-36 (-R) XPL-230-36 (-R) XML-230-36 (-R) Maximum Continuous 120 Vac 30 W 55 W 92 W 240 Vac 40 W 75 W 120 W Model: XEL-230-40 (-R) XPL-230-40 (-R) XML-230-40 (-R) 3.22: Thermal Impedance See Thermal Considerations (p. 133).
Xenus Plus User Guide Specifications 3.23: Mechanical and Environmental XEL/XPL/XML Size 7.92 in (201,2 mm) X 5.51 in (139,9 mm) X 2.31 in (58,7 mm) Weight Driver without Heat Sink Low profile (–HL) Heat Sink Standard (–HS) Heat Sink 3.0 lb (1.36 kg) 1.86 lb (0.84 kg) 3.1 lb (1.40 kg) Ambient Temperature Storage Operating -40 to +85°C 0 to +45°C Humidity 0% to 95%, non-condensing Contaminants Pollution degree 2 Environment IEC68-2: 1990 Cover Material Meets U.L.
Xenus Plus User Guide Specifications 3.24: Dimensions 3.24.
Xenus Plus User Guide Specifications 3.24.
Xenus Plus User Guide Specifications 3.24.
Xenus Plus User Guide CHAPTER 4: WIRING This chapter describes the wiring of drive and motor connections. Contents include: 4.1: General Wiring Instructions ................................................................................................................................................... 80 4.2: AC Mains (J1) XEL/XPL/XML/XE2/XP2/800-1782/800-1808 ................................................................................................. 83 4.3: Motor(s) ...............................
Xenus Plus User Guide Wiring 4.1: General Wiring Instructions 4.1.1: Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code (NEC) or its national equivalent, and all prevailing local codes. ! DANGER: Hazardous voltages. Exercise caution when installing and adjusting. Failure to heed this warning can cause equipment damage, injury, or death. DANGER Risk of electric shock. ! DANGER High-voltage circuits connected to mains power.
Xenus Plus User Guide Wiring 4.1.2: Grounding Considerations Primary Grounding Functions A grounding system has three primary functions: electrical safety, voltage-reference, and shielding. J1-3 Protective Earth Ground The protective earth (PE) ground at J1-3 (for both single and dual axis drives), is the electrical safety ground and is intended to carry the fault currents from the mains in the case of an internal failure or short-circuit of electronic components.
Xenus Plus User Guide Wiring 4.1.3: Connector Locations Connector locations for XEL, XPL and XML (J1-J10), are shown below. XEL XPL XML Connector locations for XE2 and XP2 (J1-J12), are shown below.
Xenus Plus User Guide Wiring 4.2: AC Mains (J1) XEL/XPL/XML/XE2/XP2/8001782/800-1808 The Mains connector information below is true for all of the Xenus Plus drives. Mating Connector Description Euro-style 7,5 mm pluggable female terminal block with preceding ground receptacle.
Xenus Plus User Guide Wiring AC Mains Wiring Diagram (Single-Phase) XEL/XPL/XML AC Mains Wiring Diagram (Three-Phase) XEL/XPL/XML Copley Controls 84
Xenus Plus User Guide Wiring AC Mains Wiring Diagram (Single-Phase) XE2/XP2/800-1782/800-1808 AC Mains Wiring Diagram (Three-Phase) XE2/XP2/800-1782/800-1808 In the end product installation, a UL RC (Recognized Component) SPD (Surge Protective Device) type 1CA, 2CA, 3CA or a UL Listed (VZCA) SPD type 1, 2, or 3 rated 2500 V, with a minimum SCCR of 5 kA, 240 Vac, and surge voltage monitoring needs to be provided. The purpose of the SPD is to establish an over-voltage CAT II environment.
Xenus Plus User Guide Wiring 4.3: Motor(s) Mating Connector Description Euro-style, 4 position, 5.0 mm pluggable female terminal block Manufacturer PN Wago: 721-104/026-047 (Note 1) Wire Size 22 - 12 AWG Recommended Wire 18 A models: 14 AWG, 600 V 20 A, 36 A and 40 A models: 12 AWG, 600 V Shielded cable required for CE compliance Wire Insertion/Extraction Tool Wago: 231-131 Standard connector and tool are included in Connector Kits XEL-CK, XML-CK, and XPL-CK.
Xenus Plus User Guide Wiring 4.4: Regen Resistor (Optional) 4.4.1: XEL/XPL/XML Mating Connector Description Euro-style, 5 position, 5.0 mm pluggable male terminal block. Manufacturer PN Wago: 721-605/000-044 (Note 1) Wire Size 22 - 12 AWG Recommended Wire 18 A models: 14 AWG, 600 V 36 A and 40 A models: 12 AWG, 600 V Shielded cable required for CE compliance Wire Insertion/Extraction Tool Wago: 231-131 Standard connector and tool are included in Connector Kits XEL-CK, XML-CK, and XPL-CK.
Xenus Plus User Guide Wiring 4.4.2: XE2/XP2/800-1782/800-1808 Mating Connector Description Euro-style, 3 position, 5.0 mm pluggable male terminal block. Manufacturer PN Wago: 721-603/000-044 (Note 1) Wire Size 22 - 12 AWG Recommended Wire 18 A models: 14 AWG, 600 V 36 A and 40 A models: 12 AWG, 600 V Shielded cable required for CE compliance Wire Insertion/Extraction Tool Wago: 231-131 Standard connector and tool are included in Connector Kits XE2-CL and XP2-CK.
Xenus Plus User Guide Wiring 4.5: Logic Supply / Brake 4.5.1: XEL/XPL/XML (J4) The following information is for XEL/XPL/XML drives only. Mating Connector Description Euro-style, 3 position, 5.0 mm pluggable female terminal block. Manufacturer PN Wago: 721-103/026-047 (Note 1) Wire Size 22 - 14 AWG Recommended Wire 18 AWG Wire Insertion/Extraction Tool Wago: 231-131 Standard connector and tool are included in Connector Kits XEL-CK, XML-CK, and XPL-CK.
Xenus Plus User Guide Wiring 4.5.2: XE2/XP2/800-1782/800-1808 (J5) The following information is for XE2/XP2/800-1782/800-1808 drives only. Mating Connector Description Euro-style 5.0 mm pluggable female terminal block. Manufacturer PN Wago: 721-105/026-047 (Note 1) Wire Size 28 - 14 AWG Recommended Wire 18 AWG Wire Insertion/Extraction Tool Wago: 231-131 Standard connector and tool are included in Connector Kits XEL-CK, XML-CK, and XPL-CK.
Xenus Plus User Guide Wiring 4.6: Safe Torque Off 4.6.1: XEL/XPL/XML (J5) The following information is for XEL and XPL drives only. Mating Connector Description Manufacturer PN Connector, D-Sub, 9-position, male, solder cup Norcomp: 171-009-103L001 Backshell, D-Sub, RoHS, metallized, for above Norcomp: 979-009-020R121 Wire Size 24-20AWG Poke & crimp connector required and included in Connector Kits XE2-CK, and XP2-CK. Pin Description Pin Signal Function 1 Frame Ground Cable shield connection.
Xenus Plus User Guide Wiring Safe Torque Off Wiring Diagram (XEL/XPL/XML) NOTE: The diagram below includes the STO bypass connections that will energize both STO-1 and STO-2 inputs. When this is done the STO feature is de-activated and control of the output PWM stage is under control of the digital control core. If not using the STO feature, these connections must be made in order for the Xenus Plus to be enabled.
Xenus Plus User Guide Wiring 4.6.2: XE2/XP2/800-1782/800-1808 (J6) The following information is for XE2, XP2, 800-1782, and 800-1808 drives only. Mating Connector Description Manufacturer PN Connector, D-Sub, 9-position, standard AMP/Tyco: 205204-4 AMPLIMITE HDP-20 Crimp-Snap contacts, 24-20AWG, sel AU/NI AMP/Tyco: 66506-9 Backshell, D-Sub, RoHS, metallized, for J6 Norcomp: 979-009-020R121 Wire Size 24-20AWG Solder style connector included in Connector Kits XE2-CK and XP2-CK.
Xenus Plus User Guide Wiring Safe Torque Off Bypass Wiring Diagram (XE2/XP2/800-1782/800-1808) The diagram below includes the STO bypass connections that will energize the two inputs (three opto-couplers). When this is done the STO feature is de-activated and control of the output PWM stage is delegated to the digital control core. If the STO feature is not being used, these connections must be made in order for the Xenus Plus to be enabled.
Xenus Plus User Guide Wiring 4.7: RS-232 Serial Communications Mating Connector 6-position, modular connector (RJ-11 style). Copley Controls provides a prefabricated cable and modular-to-9-pin sub-D adapter in RS-232 Serial Cable Kit, PN SER-CK. A diagram of the female connector is shown below.
Xenus Plus User Guide Wiring 4.8: Network Ports 4.8.1: EtherCAT (XEL/XE2/800-1782) Mating Connector Dual RJ-45 sockets accept standard Ethernet cables. The IN port connects to a master, or to the OUT port of a device that is ‘upstream’ between the Xenus Plus and the master. The OUT port connects to ‘downstream’ nodes. If Xenus Plus is the last node on a network, only the IN port is used. No terminator is required on the OUT port.
Xenus Plus User Guide Wiring 4.8.2: CAN Bus (XPL/XP2) Mating Connector 8-position, modular connector (RJ-45 style). Copley Controls provides the following assemblies: Prefabricated 10 foot cable, PN XPL-NC-10 Prefabricated 1 foot cable, PN XPL-NC-01 Terminator Plug, PN XPL-NT A diagram of the female connector is shown below.
Xenus Plus User Guide Wiring 4.8.3: MACRO Port (J7-XML/J8-800-1808) The XML/800-1808’s duplex SC sockets, shown below, accept standard optical fiber. The IN port connects to a master or to the OUT port of a device that is “upstream,” between the XML/800-1808 and the master. The OUT port connects to “downstream” nodes. If XML/800-1808 is the last node on a network, only the IN port is used. No terminator is required on the OUT port.
Xenus Plus User Guide Wiring 4.9: Control I/O 4.9.1: XEL/XPL/XML (J8) Mating Connectors Description Manufacturer PN Wire Size 26 Position, 0.1 x 0.09 High Density D-Sub Female, Solder Style Connector Norcomp 180-026203L001 24 - 30 AWG Back shell Norcomp 979-015020R121 Solder style connector included in Connector Kits XEL-CK, XML-CK, and XPL-CK.
Xenus Plus User Guide Wiring …Pin Description, continued: +5 Vdc output. Total load current on J8-20, J10-6, and J10-17 not to exceed 400 mA. 20 +5 Vdc 21 Multi-Mode Port /X 22 Multi-Mode Port X 23 Multi-Mode Port /B 24 Multi-Mode Port B 25 Multi-Mode Port /A 26 Multi-Mode Port A Programmable differential input/output port. See Mode Dependent Dedicated Inputs (below). Mode-Dependent Dedicated Inputs These inputs are dedicated to specific functions, depending on operating mode.
Xenus Plus User Guide Wiring Digital Outputs Wiring Diagram J8 Drive Typical Output Loads + 5 Vdc Typical Circuits Relay 1K J8-16 J8-17 J8-15 * Lamp OUT1 Motion Controller OUT2 External Power Supply Signal Ground + 5 Vdc J8-18 OUT3 (HS) R +/- 32 mA NC7SZ125 * Flyback diode required for inductive loads Multi-Mode Port Interface Diagram Drive J8 + 5 Vdc MAX 3362 1.5 K J8-13 J8-14 1.
Xenus Plus User Guide Wiring Analog Input Wiring Diagram Drive J8 5K 37.4 K J8-2 - + Vref D/A 5.36 K REF+ (AIN+) VCMD + REF- (AIN-) VCMD - ± 10V J8-3 37.4 K J8-1 5K J8-15 Sgnd 1.5 V 5K Frame Gnd 5.36 K 37.4 K Vref + 37.4 K 5K J8-11 REF+ (AIN2+) J8-12 REF - (AIN2-) J8-19 Sgnd 1.5 V Analog Output Wiring Diagram J8 Drive 40.2 K 6.5V - Measurement 100 J8-9 A Out + 1V -6.
Xenus Plus User Guide Wiring 4.10: Secondary I/O 4.10.1: XEL/XPL/XML (J9) Mating Connector Description Manufacturer PN Wire Size 15 Position, High-density, D-Sub, male, solder cup. Norcomp: 180-015103L001 24 - 30 AWG Backshell Norcomp: 979-009020R121 Solder style connector included in Connector Kits XEL-CK, XML-CK, and XPL-CK.
Xenus Plus User Guide Wiring Optically Isolated Programmable Inputs Wiring Diagram J9 Opto-isolators 4.7 K [COMM_A] J9-2 4.99 K [IN7] GND 24V + J9-3 5.1V 4.7 K 4.99 K [IN8] J9-4 4.99 K [IN9] J9-5 4.99 K [IN10] J9-6 5.1V 4.7 K 5.1V 4.7 K + 5.1V 24V J9 Opto-isolators 4.7 K [COMM_B] J9-7 4.99 K [IN11] GND 24V + J9-8 5.1V 4.7 K 4.99 K [IN12] J9-9 4.99 K [IN13] J9-10 4.99 K [IN14] J9-11 5.1V 4.7 K 5.1V 4.7 K + 5.
Xenus Plus User Guide Wiring Optically Isolated Programmable Outputs Wiring Diagram J9 Opto-isolators 20 20 20 mA OUT4 + J9-14 OUT4 J9-15 R-L + 30 Vdc Max 20 mA OUT5 + J9-12 R-L + 30 Vdc Max OUT5 - J9-13 Copley Controls 105
Xenus Plus User Guide Wiring 4.10.2: XE2/XP2/800-1782/800-1808 (J12) Mating Connections Description Manufacturer PN Wire Size 44 Position, 0.1 x 0.09 High Density D-Sub male, Solder Style Connector Norcomp 180-044103L001 24 - 30 AWG Back shell Norcomp 979-025020R121 Solder style connector included in Connector Kits XE2-CK and XP2-CK.
Xenus Plus User Guide Wiring …Pin Description, continued: 20 A-MultiEnc /B Programmable differential input/output port. 21 A-MultiEnc /A Programmable differential input/output port. 22 Signal ground Signal ground reference for inputs and outputs. 23 B +5Vdc Out4 24 B-MultiEnc /S 25 B-MultiEnc /X 26 B-MultiEnc /B 27 B-MultiEnc /A 28 N/C 29 N/C 30 IN15 Diff4(-) Mode dependent dedicated input. 31 Signal ground Signal ground reference for inputs and outputs.
Xenus Plus User Guide Wiring Axis B These inputs are for Axis B and are dedicated to specific functions, depending on operating mode.
Xenus Plus User Guide Wiring Analog Input Wiring Diagram Drive J12 5K D/A 5.36 K 37.4 K J12-3 - + Vref VCMD + REF- (AIN1-) VCMD - J12-2 37.4 K ± 10V J12-1 Frame Gnd 5K J12-16 Signal Ground Sgnd 1.5 V 5K REF+ (AIN1+) 5.36 K 37.4 K Vref + 37.4 K 5K J12-5 REF+ (AIN2+) J12-4 REF - (AIN2-) J8-19 J12-6 Signal Ground Sgnd 1.5 V Multi-Mode Port Interface Diagram Drive J12 The connector labels on this diagram are for Axis A. Labels for Axis B are here + 5 Vdc MAX 3362 1.
Xenus Plus User Guide Wiring 4.10.3: Isolated Control XE2/XP2/800-1808 (J9) J9 is a 26 position male D-sub connector used for isolated controls Mating Connections Description Manufacturer PN Wire Size 26 Position, High-Density D-Sub Female Solder Style Connector Norcomp 180-026203L001 24 - 30 AWG Back shell Norcomp 979-015020R121 Solder style connector included in Connector Kits XE2-CK and XP2-CK.
Xenus Plus User Guide Wiring …Pin Description, continued: 21 OUT3+ GPI 22 OUT4+ GPI 23 OUT5+ GPI 24 N/C 25 N/C 26 N/C Optically isolated programmable output positive signal. No connection. 800-1782 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection.
Xenus Plus User Guide Wiring Optically Isolated Programmable Inputs Wiring Diagram, XE2/XP2/800-1808 J9 Opto-isolators GND [COM1] 4.7 K 4.99 K [IN6] J9-6 24V + J9-2 5.1V 4.7 K 4.99 K [IN7] J9-3 5.1V 4.7 K 4.99 K [IN8] J9-4 5.1V 4.7 K 4.99 K [IN9] J9-5 + 5.1V 24V J9 GND Opto-isolators [COM2] 4.7 K 4.99 K [IN16] J9-17 24V + J9-7 5.1V 4.7 K 4.99 K [IN17] J9-8 5.1V 4.7 K 4.99 K [IN18] J9-9 5.1V 4.7 K 4.99 K [IN19] J9-18 + 5.
Xenus Plus User Guide Wiring Optically Isolated Programmable Inputs Wiring Diagram, 800-1782 Note: Wiring diagram for IN6 – IN9 on the 800-1782 is the same as for the XE2/XP2/800-1808.
Xenus Plus User Guide Wiring Optically Isolated Programmable Outputs Wiring Diagram, XE2/XP2/800-1808 J9 Opto-isolators 20 60 mA OUT1 + OUT1 - 20 J9-19 R-L + 30 Vdc Max J9-10 60 mA OUT2 + J9-20 R-L + 30 Vdc Max OUT2 - J9-11 20 60 mA OUT3 + OUT3 - 20 J9-21 R-L + 30 Vdc Max J9-12 60 mA OUT4 + J9-22 R-L + 30 Vdc Max + 30 Vdc Max OUT4 - J9-13 20 60 mA OUT5 + J9-23 R-L OUT5 - J9-14 Optically Isolated Programmable Outputs Wiring Diagram, 800-1782 Note: Wiring diagram applies
Xenus Plus User Guide Wiring 4.11: Motor Feedback The following motor feedback information is true for single and dual axis drives with the exception of the motor over-temperature input. In the Xenus Plus Single Axis models the motor overtemperature input is an analog input whereas it is a digital input in the Xenus Plus Dual Axis models. The Xenus Plus Single Axis drive has one feedback connector, J10. The Xenus Plus Dual Axis drive has two feedback connectors, J10 and J11.
Xenus Plus User Guide Wiring Pin Description Quad A/B Incremental Encoder Pin Signal Function 1 Frame Ground Cable shield connection. 2 Digital Hall U 3 Digital Hall V 4 Digital Hall W 5 Signal Ground Signal and +5 Vdc ground. 6 +5 Vdc Encoder and/or Halls +5 Vdc power supply output. Total load current on J10-6, J10-17, and J8-20 not to exceed 400 mA. 7 Motemp Motor over temperature switch. May be programmed to other functions. Analog input on the XEL/XPL/XML models.
Xenus Plus User Guide Wiring Pin Description Resolver Xenus Plus (-R) Pin Signal Function 1 Frame Ground Cable shield connection. 2 Digital Hall U 3 Digital Hall V 4 Digital Hall W 5 Signal Ground Signal and +5 Vdc ground. 6 +5 Vdc Encoder and/or Halls +5 Vdc power supply output. Total load current on J10-6, J10-17, and J8-20 not to exceed 400 mA. 7 Motemp Motor over temperature switch. May be programmed to other functions. Analog input on the XEL/XPL/XML models.
Xenus Plus User Guide Wiring …Pin Description, continued: 17 +5 Vdc Encoder +5 Vdc power supply output. Total load current on J10-6, J10-17, and J8-20 not to exceed 400 mA. 18 Resolver Inc A 19 Resolver Inc B 20 Resolver Inc C 21 N/C 22 N/C 23 Resolver Ref(+) Resolver Ref inputs. 24 N/C No connection 25 Signal ground Signal and +5 Vdc ground. 26 Signal ground Signal and +5 Vdc ground.
Xenus Plus User Guide Wiring Hall Switch Wiring Diagram Drive J10 + 5 Vdc Typical Circuit 10 K 10 K J10-2 J10-3 100 pƒ 5V @ 400 mA J10-4 J10-6 U Hall V Hall W Hall 5 Vdc Gnd Halls Halls Power J10-5 J10-1 Frame Gnd Case Ground In XEL/XPL/XML there are two encoder +5V outputs at 400 mA each, and in the XE2/XP2/800-1808 there are 4 encoder +5V outputs at 500 mA each.
Xenus Plus User Guide Wiring Analog Sin/Cos Encoder Wiring Diagram Drive J10 10k + sin - 121 J10-19 J10-18 10k SIN (+) SIN (+) SIN (-) SIN (-) COS (+) COS (+) COS (-) COS (-) INX (+) INX (+) INX (-) INX (-) Analog Encoder 10k cos J10-21 + - 121 J10-20 10k 10k index J10-23 + - 121 J10-22 10k 5V @ 400 mA J10-17 J10-5 J10-1 + 5 VDC Gnd Frame Gnd Encoder Power Case Ground In XEL/XPL/XML there are two encoder +5V outputs at 400 mA each, and in the XE2/XP2/800-1808 there
Xenus Plus User Guide Wiring Resolver Wiring Diagram Drive J10 J10-23 J10-22 J10-19 J10-18 J10-21 J10-20 J10-1 Copley Controls REF(+) R1 REF(-) R2 Resolver SIN (+) S3 SIN (-) S1 COS (+) S2 COS (-) S4 Frame Gnd Case Ground 121
Xenus Plus User Guide Wiring Resolver Wiring Diagram, 800-1782 Motor Over Temperature Wiring Diagram: XEL/XPL/XML Drive J10 +5 V 5K 12-bit A/D 27 Hz LPF 100 K J10-7 J10-5 Copley Controls Thermistor, Posistor, or Switch 122
Xenus Plus User Guide Wiring Motor Over Temperature Wiring Diagram: XE2/XP2/800-1782/800-1808 Drive J10, J11 +5 V Thermistor, Posistor 5k or Switch 10k J10,J11-7 33 nƒ J10,J11-5 General Purpose Input Wiring Diagram: XEL/XPL/XML Drive J10 +5 V 10k 10k J10-24 100 pƒ [IN15] J10-25 General Purpose Input Wiring Diagram: XE2/XP2/800-1782/800-1808 Drive J10, J11 +5 V 10k 10k J10,J11-24 100 pƒ [IN15] J10,J11-25 Copley Controls 123
Xenus Plus User Guide APPENDIX A: REGEN RESISTOR SIZING AND CONFIGURATION This chapter describes the steps used to determine if a regen resistor is required and what the optimal resistor characteristics would be for a given application. For an overview of regeneration and regen resistors, see Regen Resistor Theory (p. 57) To configure a custom regen resistor, see the CME 2 User Guide. The contents of this chapter include: A.1: Sizing a Regen Resistor ........................................................
Xenus Plus User Guide Regen Resistor Sizing and Configuration A.1: Sizing a Regen Resistor A.1.1: Gather Required Information Calculating the power and resistance of the regen resistor requires information about the drive and the rotary or linear motor application.
Xenus Plus User Guide Regen Resistor Sizing and Configuration A.1.3: Calculate Energy Returned for Each Deceleration Use the following formulas to calculate the energy returned during each deceleration: Rotary motor: Edec= ½ Jt (ω12 - ω22) Where: Edec = Energy returned by the deceleration, in Joules. Jt = Load inertia on the motor shaft plus the motor inertia in kg m2. ω1 = Shaft speed at the start of deceleration in radians per second. ω2 = Shaft speed at the end of deceleration in radians per second.
Xenus Plus User Guide Regen Resistor Sizing and Configuration For mains voltages not listed in the specification table, use the following formula to determine the energy that can be absorbed by the drive. Wcapacity = ½ C (Vregen2 - (1.414 Vmains)2) Where: Wcapacity = The energy that can be absorbed by the bus capacitors, in Joules. C = Bus capacitance in Farads. Vregen = Voltage at which the regen circuit turns on, in volts. Vmains = Mains voltage applied to the drive, in volts AC. A.1.
Xenus Plus User Guide Regen Resistor Sizing and Configuration Choose a resistor with a power rating equal to or greater than the calculated continuous power. Verify that the calculated power value is less than the continuous regen power rating specified in Regen Circuit Output (p. 61). A.1.11: Select Fuses For custom regen resistors, Cooper Bussman KLM fuses, or equivalent, should be selected.
Xenus Plus User Guide APPENDIX 2 B: I T TIME LIMIT ALGORITHM The current loop I2T limit specifies the maximum amount of time that the peak current can be applied to the motor before it must be reduced to the continuous limit or generate a fault. This chapter describes the algorithm used to implement the I2T limit. Contents Include: B.1: I2T Algorithm..............................................................................................................................................................
Xenus Plus User Guide 2 I T Time Limit Algorithm B.1: I2T Algorithm B.1.1: I2T Overview The I2T current limit algorithm continuously monitors the energy being delivered to the motor using the I2T Accumulator Variable. The value stored in the I2T Accumulator Variable is compared with the I2T setpoint that is calculated from the user-entered Peak Current Limit, I2T Time Limit, and Continuous Current Limit.
Xenus Plus User Guide 2 I T Time Limit Algorithm B.1.3: I2T Current Limit Algorithm – Application Example I2T Example: Parameters Operation of the I2T current limit algorithm is best understood through an example. For this example, a motor with the following characteristics is used: Peak Current Limit – 12 A I2T Time Limit – 1 S Continuous Current Limit – 6 A From this information, the I2T setpoint is: I2T setpoint = (12 A2–6 A2) * 1 S = 108 A2S See the example plot diagrams on the next page.
2 Xenus Plus User Guide I T Time Limit Algorithm I2T Example: Plot Diagrams The plots that follow show the response of a drive (configured w/ I2T setpoint = 108 A2S) to a given current command. For this example, DC output currents are shown in order to simplify the waveforms. The algorithm essentially calculates the RMS value of the output current, and thus operates the same way regardless of the output current frequency and wave shape.
APPENDIX C: THERMAL CONSIDERATIONS This chapter describes operating temperature characteristics, heatsink options, and heatsink mounting instructions. Contents include: C.1: Operating Temperature and Cooling Configurations ........................................................................................................... 134 C.2: Heatsink Mounting Instructions (XEL/XPL/XML) ................................................................................................................. 137 C.
Xenus Plus User Guide Thermal Considerations C.1: Operating Temperature and Cooling Configurations C.1.1: XEL, XPL, and XML Models The following charts show the maximum allowable ambient temperature of Xenus Plus drives for a variety of operating conditions and cooling configurations. The operating conditions considered cover a range of continuous output currents at both 120 Vac and 240 Vac mains voltages.
Xenus Plus User Guide Thermal Considerations C.1.2: XEL, XPL, and XML Heatsink and Fan Configurations No Heatsink No Fan With Fan* 4.25 in Fan Low-Profile Heatsink No Fan With Fan* 4.25 in Fan Standard Heatsink No Fan With Fan* 4.25 in Fan * Select a 4.25-inch square fan that supplies forced air at a minimum rate of 300 linear feet per minute.
Xenus Plus User Guide Thermal Considerations C.1.
Xenus Plus User Guide Thermal Considerations C.2: Heatsink Mounting Instructions (XEL/XPL/XML) A dry film interface pad is used in place of thermal 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. Remove the blue protective sheet from one side of the pad.
Xenus Plus User Guide Thermal Considerations C.3: Heatsink Mounting Instructions (XE2/XP2/8001782/800-1808) description The XE2-HK is a kit containing a heatsink and mounting hardware for field installation of a standard heatsink onto Xenus Plus XE2 model servo drive. To order an XE2 drive with heatsink fitted at the factory, add “-H” to the model part number. installation 1) Place the heatsink fins-down on a work surface. Orient the heatsink so that the edge with part number is away from you.
APPENDIX D: XENUS PLUS FILTER This chapter provides an overview of the Model XTL-FA-01 edge filter. Contents include: D.1: Overview ............................................................................................................................................................................ 140 D.2: XTL-FA-01 Edge Filter Specifications ................................................................................................................................. 141 D.
Xenus Plus User Guide Xenus Plus Filter D.1: Overview The XTL-FA-01 edge filter can be used to minimize noise on the output of any Xenus Plus drive. D.1.1: Differential and Common Mode Filtering Most noise is capacitively coupled from the motor power cable to neighboring cables. To minimize this noise, the XTL-FA-01 edge filter uses both differential edge filtering and common mode filtering.
Xenus Plus User Guide Xenus Plus Filter D.
Xenus Plus User Guide Xenus Plus Filter D.4: XTL-FA-01 Edge Filter Dimensions The following diagram shows the mounting dimensions of the XTL-FA-01 Edge Filter.
Xenus Plus User Guide Xenus Plus Filter D.5: XTL-FA-01 Edge Filter Wiring This section describes the wiring of the XTL-FA-01 Edge Filter. D.5.1: Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code (NEC) or its national equivalent, and all prevailing local codes. ! DANGER: Hazardous voltages. Exercise caution when installing. Failure to heed this warning can cause equipment damage, injury, or death. DANGER ! Risk of electric shock.
Xenus Plus User Guide Xenus Plus Filter D.5.2: Connector Locations Edge Filter J1 connects to Xenus Plus J2 (J3 or J4 for XE2/XP2/800-1782/800-1808). Edge Filter J2 connects to the motor.
Xenus Plus User Guide Xenus Plus Filter D.5.3: Cable Notes 1 2 Keep the Edge Filter to Xenus Plus cable as short as possible. A typical length is 7 inches. To reduce noise, twisted shielded cable must be used and the signal cables should not be bundled in the same conduit. D.5.4: Edge Filter Input (J1) From Drive Mating Connector Description Euro-style, 5 position, 5.
Xenus Plus User Guide Xenus Plus Filter D.5.6: Diagram: Edge Filter Wiring with Brushless Motor This is an example for a Xenus Plus Single Axis drive. For Xenus Plus Dual Axis, connectors J3 or J4 on the drive are used for outputs to the filter. D.5.7: Diagram: Edge Filter Wiring with Brush Motor This is an example for a Xenus Plus Single Axis drive. For Xenus Plus Dual Axis, connectors J3 or J4 on the drive are used for outputs to the filter. D.5.
APPENDIX E: CONNECTING XPL/XP2 FOR SERIAL CONTROL This chapter describes how to connect one or more XPL/XP2 drives for control via the RS-232 bus on one of the drives. Contents Include: E.1: Single-Axis and Multi-Drop .................................................................................................................................................
Xenus Plus User Guide Connecting XPL/XP2 for Serial Control XPL/XP2 For Serial Control E.1: Single-Axis and Multi-Drop An XPL/XP2 drive’s RS-232 serial bus can be used by CME 2 for drive commissioning. The serial bus can also be used by an external control application (HMI, PLC, PC, etc.) for setup and direct serial control of the drive. The control application can issue commands in ASCII format.
APPENDIX F: ORDERING GUIDE AND ACCESSORIES This chapter lists part numbers for drives and accessories. Contents include: F.1: Drive Model Numbers ......................................................................................................................................................... 150 F.2: Accessory Model Numbers ................................................................................................................................................. 153 F.3: Heatsink Kits ..........
Xenus Plus User Guide Ordering Guide and Accessories F.
Xenus Plus User Guide Ordering Guide and Accessories Drive Model Numbers (cont’d) XPL Model Number Description XPL-230-18 Xenus Plus Standard Servo drive 6/18 A XPL-230-18-HL Xenus Plus Standard Servo drive 6/18 A with factory-fitted, low-profile heatsink XPL-230-18-HS Xenus Plus Standard Servo drive 6/18 A with factory-fitted, standard heatsink XPL-230-36 Xenus Plus Standard Servo drive 12/36 A XPL-230-36-HL Xenus Plus Standard Servo drive 12/36 A with factory-fitted, low-profile heatsink XP
Xenus Plus User Guide Ordering Guide and Accessories Drive Model Numbers (cont’d) XML Model Number Description XML-230-18 Xenus Plus MACRO Servo drive 6/18 A XML-230-18-HL Xenus Plus MACRO Servo drive 6/18 A with factory-fitted, low-profile heatsink XML-230-18-HS Xenus Plus MACRO Servo drive 6/18 A with factory-fitted, standard heatsink XML-230-36 Xenus Plus MACRO Servo drive 12/36 A XML-230-36-HL Xenus Plus MACRO Servo drive 12/36 A with factory-fitted, low-profile heatsink XML-230-36-HS Xe
Xenus Plus User Guide Ordering Guide and Accessories F.2: Accessory Model Numbers Software Model Description CME2 CME 2 Drive Configuration Software (Download) CML Copley Motion Libraries (Download, license required) CMO Copley Motion Objects (Download) CPL Copley Programming Language (Download, license required) Links to these software releases can be found at: http://www.copleycontrols.com/Motion/Downloads/index.
Xenus Plus User Guide Ordering Guide and Accessories CANopen Connector Kit (XPL/XP2) Model Qty Ref Description 1 XPL-NK J7 1 J7 1 Sub-D 9-position female to RJ-45 adapter CAN bus Network Cable, 10 ft (3 m) CAN bus RJ-45 Network Terminator Individual Cable Assemblies (and Related Accessories) Model Ref Description SER-CK J6 RS-232 Serial Cable Kit (for connecting PC to drive) XPL-CV J7 Sub-D 9-position female to RJ-45 adapter for XPL (PC to CANopen cable adapter) XPL-NC-10 XPL-NC-01 CAN bus Ne
Xenus Plus User Guide Ordering Guide and Accessories F.4: Regen Resistor Assemblies Model Description XTL-RA-03 Regen Resistor Assembly (for use with XEL/XML/XPL-230-18) XTL-RA-04 Regen Resistor Assembly (for use with XEL/XML/XPL-230-36, XEL/XML/XPL-230-40 and XE2/XP2-230-20/800-1782/800-1808) For more information, see Regen Resistor data sheet: http://www.copleycontrols.com/Motion/Downloads/xenusPlusData.html F.
Xenus Plus User Guide Ordering Guide and Accessories F.7: Copley Standard Regen Resistor Specifications F.7.1: Specifications Specifications for Copley’s standard regen resistors are described below.
Xenus Plus User Guide P/N 16-01018 Revision 07 August 2014 2011, 2012, 2013, 2014 Copley Controls Analogic Motion Controls 20 Dan Road Canton, MA 02021 USA All rights reserved
