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Xenus Plus 1&2-Axis User Guide

1. Pin Signal Function 1 Frame Ground Cable shield connection 2 AIN1 Analog command negative input single analog 3 AIN1 Analog command positive input single analog 4 AIN2 Analog command negative input single analog 5 AIN2 Analog command positive input single analog 6 Signal ground Signal ground reference for inputs and outputs 7 IN1 Enable 8 IN2 Diff1 9 IN3 Diff1 Mode dependent dedicated input 10 IN4 Diff2 11 IN5 Diff2 12 IN11 Enable 13 IN12 Diff3 14 IN13 Diff3 Mode dependent dedicated input 15 IN14 DiffA 16 Signal ground Signal ground reference for inputs and outputs 17 A 5Vdc Out3 18 A MultiEnc S Programmable differential input output port 19 A MultiEnc X Programmable differential input output port Continued Copley Controls 114 Xenus Plus User Guide 16 01344 Rev 01 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 Programmable differential input output port 29 N C 30 IN15 Diff4 Mode dependent dedicated input 31 Signal ground Signal ground reference for inputs and outputs 32
2. 147 Copley Controls 3 Xenus Plus User Guide 16 01344 Rev 01 D2 XTE FA 01 Edge Filter Wirilig 2 223 iore ir eerte naso trace cr ea E wend anaes be EE AEAEE ene 150 E Connecting XPL XP2 for Serial Control 154 E 1 Single Axis and Multi Drop 155 F Ordering Guide and Accessories 156 F 1 Drive Model Numbers 157 F 2 Accessory Model Numbers 160 F 3 Heatsink Kits 161 F 4 Regen Resistor Assemblies 162 F 5 Edge Filter 162 FG Order Example zoe deese bote bte themit rsa nen MDC Le s D DEL MEI 162 F 7 Copley Standard Regen Resistor Specifications ccccccccecceeseceeeeeeneeeeeaeeeeeeaeeeseaeeeeeaeeeseaeeseaaeesseaaeeesaeeseeaeeesenaeeeseneesess 163 Copley Controls 4 Xenus Plus User Guide 16 01344 Rev 01 ABOUT THIS MANUAL Title Number Revision Title The Xenus Plus User Guide Document Number 16 01344 Current Revision 1 Revision History Revision Date ECO Comments AA December 30 2014 ECO 056871 Initial Release Originated from 16 01018 Rev 07 00 March 9 2015 ECO 056484 Updated PE symbols and clarified mandatory use of line filters 01 April 2 2015 ECO 057985 OVC II Mains Requirement and full address for Mfr amp EU Rep Add model 800 1818 EC Declaration of Conformity The products covered by this
3. 85 4 2 AC Mains J1 m m 88 4 3 Motor s sesssssss sezi iris 91 4 4 Regen Resistor Optional T 93 4 5 Logic Supply Brake 96 4 6 Ferrules XE2 XP2 XM2 800 1819 Man 98 4 7 Safe Torque Off sess E EA 99 4 8 RS 232 Serial Communications 103 4 9 Network Ports tas ee 104 4 10 Control I O T wet 107 A VAG Motor FOCU DECK HL 123 Copley Controls 84 Xenus Plus User Guide 16 01344 Rev 01 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 A DANGER gt DANGER DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death Risk of electric shock High voltage circuits connected to mains power XEL XPL XML J1 J2 J3 XE2 XP2 XM2 800 1818 800 1819 J1 J2 J3 and J4 Failure to heed this warning can cause equipment damage injury or death d DANGER gt WARNING Refer to the Xenus Plus Dual Axis STO User Manual The information provided in the Xenus Plus Dual Axis STO User Manual must be considered for any application
4. Recommended Wire Description Euro style 3 position 5 08 mm pluggable female terminal block Manufacturer PN Wago 231 303 107 000 Note 1 Wire Size 22 12 AWG 12 AWG 600 V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 or 231 291 Standard connector and tool are included in Connector Kits XE2 CL XP2 CK and XM2 CK Note 1 For RoHS compliance append RNO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 Regen DC Bus to one side of regen resistor 2 Regen Collector of regen transistor to one side of regen resistor 3 Frame ground Enclosure ground and cable shield 1 The mating connector must be installed at location J2 regardless of whether a regen resistor is connected WARNING A mating connector must be installed at location J2 whenever AC mains power is applied and within the capacitor discharge time Otherwise the terminals of J2 are exposed and present a shock hazard under these conditions Wiring Diagram Integrated Regen Resistor Heatsink HV Bus Regen Frame Ground Copley Controls 94 Xenus Plus User Guide 16 01344 Rev 01 Wiring Diagram External Regen Resistor HV Bus Regen Resistor Fusing External Regen Resistor Recommended Fuses Regen Resistor Fuse type XTL RA 03 Cooper Bussman KLM 8 Littelf
5. Active Regen Dwell Time 62 Xenus Plus User Guide 16 01344 Rev 01 Internal Regen Resistor If too much energy is added to the capacitor bank the voltage rises to a point where the drive s over voltage protection shuts down the drive To prevent this a regen circuit shunts some of the energy into the internal regen resistor when the voltage rises too high External Regen Resistor All of the Xenus Plus Dual Axis drives including the 800 1818 provide for connection to an external regen resistor In the case of the XE2 XP2 XM2 800 1819 models for regen energy that exceeds the rating of the internal regen resistor and external regen resistor can be used This is done by unplugging the internal regen resistor from J2 and connecting the external regen resistor in its place Model 800 1818 drives do not have an internal regen resistor but are supplied with a regen mating plug connected to J2 This mating plug is used to connect to an external regen resistor For electrical safety reasons and for all Xenus Plus Dual models the specified mating plug must always be plugged into and secured to J2 regardless of whether a regen resistor internal or external is connected Regen Circuit Components The drive provides an internal transistor that is used in combination with an external resistor Copley Controls supplies compatible resistors as described in Regen Resistor Assemblies p 162 When using a resistor acquired from another
6. 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 Green flash twice STO is active One or both STO inputs are de energized The drive is hardware amp software followed by a pause enabled but the PWM outputs cannot produce current in the motor when STO is active Steady red A non latched fault has occurred Blinking red A latched fault has occurred XEL J6 NET Indicator EtherCAT State Machine Run Green Color Blink Code Meaning Not illuminated Initialization Blinking Pre operational Single flash Safe operational Steady Operational Error Red Not illuminated No error Blinking Invalid configuration A change of state commanded by the master is not possible or is illegal Single flash Local error The slave has initiated a change of state by itself in response to an error Double flash Watchdog timeout The EtherCAT sync manager watchdog timer has timed out Copley Controls 38 Xenus Plus User Guide 16 01344 Rev 01 2 5 2 XEL J7 EtherCAT Network Status Indicators D rumes 144 ud XEL J7 LINK and ACT Indicators EtherCAT Network Status LINK shows the state of the physical link network ACT shows activity on the network E
7. I pue dodo G QU db Qi UD Gb E Op US QD UD C M QD Nb QD V Gb QD ED QU UD b ID M UD Go E D Ip ED Gr E Uo E M ED Qo Up Go ED GU ED Gp ED E Ep GE d IQ i pa eikeen Axis A Axis B Axis A Axis B Node 0 Node 1 Node 4 Node 5 i I 1 Node 13 F 4 baee anes m mam m m mmm mmm man m mmm mnm wmm mc mmm mmmmmd Bamescn an m amm m m m 0 00 0p 0m m M 0 Mo On Om Un 0m MD Up Em Eo E E O5 Uo E Om UD Om Gn 0n 0o Om m m m o om em en m m m m n m m m m d 2 4 4 PWM Switching Frequency Synchronizing In some situations such as when sampling small analog signals it is desirable to synchronize the PWM switching frequency among multiple drives In these cases one drive serves as a master for one or more slave drives The distributed clock feature of EtherCAT or the Time function in CANopen can be used to establish PWM switching frequency synchronization among the network connected drives Note that when the STO function is active there is no PWM switching or current at the drive motor outputs See Safe Torque Off p 50 Copley Controls 37 Xenus Plus User Guide 16 01344 Rev 01 2 5 Status Indicators 2 5 1 XEL J6 STAT amp NET Drive and EtherCAT State Machine Indicators acam Drive Status lt a Bel XEL J6 STAT Indicator Drive Status XEL Drive status indicator color blink codes are described below
8. 19 3 Sin 20 S4 Cos Resolver Cos inputs 21 S2 Cos 22 R2 Ref Resolver Ref inputs 23 R1 Ref 24 IN15 XEL XPL XML General purpose input IN21 IN22 XE2 XP2 IN21 is on J10 IN22 is on J11 25 Signal Ground Signal and 5 Vdc ground 26 Signal Ground Signal and 5 Vdc ground Pin Description 800 1819 Pin Signal Function 1 Frame Ground Cable shield connection 2 N C 3 N C No connection 4 N C 5 Signal Ground Signal and 5 Vdc ground 6 N C No connection 7 isle Motor over temperature switch May be programmed to other functions Digital input 8 N C No connection 9 Resolver Abs A 10 Resolver Abs B Type 2 motor only 11 Resolver Abs C 12 N C 13 N C No connection 14 N C 15 N C 16 Signal Ground Signal and 5 Vdc ground 17 5 Vdc Encoder 5 Vdc power supply output 18 Resolver Inc A Type 2 amp Type 1 motors Copley Controls 125 Xenus Plus User Guide 16 01344 Rev 01 Pin Signal Function 19 Resolver Inc B 20 Resolver Inc C 21 N C i 22 NIC No connection 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 Quad A B Incremental Encoder Wiring Diagram MAX 3097 Incremental Encoder Case Ground MAX 3362 In XEL XPL XML there are two encoder 5V outputs
9. Lo z 200 200 200 ms ms ms red C Steady red Bus Off off Copley Controls 46 Xenus Plus User Guide 16 01344 Rev 01 2 5 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 ACT Indicator State Blinking green Normal transmit receive data on the network Low level CAN bus errors e Bit Error e Stuff Error Blinking red e CRC Error e Form Error e Acknowledgment Error Reference Bosch CAN Specification Version 2 0 for details ACT ERR ACT ERR Copley Controls 47 Xenus Plus User Guide 16 01344 Rev 01 2 5 9 XP2 J7 Axis A B Drive Status Indicators The LEDs located on connector J7 indicate axis A and B drive status Drive Status eta jo wenn ONINMVA vac 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 Green Slow Blinking Drive OK but NOT enabled Will run when enabled Green Fast Blinking Positive or Negative limit switch active Drive will only move in directi
10. pts cn Pi gie wm EA 76 19 18 a1 7 92 7 92 201 17 5 51 135 88 72 145 35 3 25 2 XML Dimensions 7 92 201 17 7 54 191 52 19 483 5 12 130 07 a o0 76 20 Chassis grounding tab Th 0 190 4 83 rF 19 4 83 a S i yee UR 1 1 00 25 40 UU 221 58 67 7 f i SHH REA ARH EH i 76 19 18 LLL aan 7 92 201 17 5 51 139 88 572 145 35 Copley Controls 81 Xenus Plus User Guide 16 01344 Rev 01 3 25 3 XE2 XP2 XM2 800 1819 Dimensions ooo 9 240 234 7 EN 5 417 137 6 5 62 142 7 0 19 4 75 2 310 58 67 F 5 040 128 02 093 2 36 pe Copley Controls 82 Xenus Plus User Guide 16 01344 Rev 01 3 25 4 800 1818 Dimensions 9 24 234 7 8 86 225 0 19 4 8 on i i 1 22 31 4 76 121 2 99 76 138 7 5 46 It 0 19 4 7 0888080000 8000880880 0000008009 8000000808 0 24 6 1 o 9 24 234 7 8 86 225 0 19 4 8 0 19 4 7 1 00 25 4 0 76 19 3 i 2 31 58 7 Copley Controls 83 Xenus Plus User Guide 16 01344 Rev 01 CHAPTER 4 WIRING This chapter describes the wiring of drive and motor connections Contents include 4212 General WiIFING IMSIHUCHONS eT
11. A 5Vdc Out3 33 A MultiEnc S 34 A MultiEnc X 35 A MultiEnc B 36 A MultiEnc A 37 Signal ground 38 B 5Vdc Out4 Programmable differential input output port Signal ground reference for inputs and outputs 39 B MultiEnc S 40 B MultiEnc X 41 B MultiEnc B 42 B MultiEnc A Programmable differential input output port 43 N C 44 Signal ground Signal ground reference for inputs and outputs Mode Dependent Dedicated Inputs Axis A These inputs are for Axis A and are dedicated to specific functions depending on operating mode Selected Command Source Mode Digital Input Digital Input Multi Mode Function Single Ended Differential Port Current amp Velocit PWM 50 IN 4 IN2 amp IN3 A amp A PWM Input Current amp Velocity IN 4 IN2 amp IN3 A amp A PWM Input PWM 100 IN5 IN4 amp IN5 B amp B Direction Input Position IN 4 IN2 amp IN3 A amp A Pulse Input Pulse amp Direction IN 5 IN4 amp IN5 B amp B Direction Input Position IN 4 IN2 amp IN3 A amp lA Count Up Up Down IN 5 IN4 amp IN5 B amp B Count Down Position IN4 IN2 amp IN3 A amp A Channel A Quadrature IN 5 IN4 amp IN5 B amp B Channel B Copley Controls 115 Xenus Plus User Guide 16 01344 Rev 01 Axis B These inputs are for Axis B and are dedicated to specific functions depending
12. R XPL 230 36 40 R 800 1818 XML 230 18 R XML 230 36 40 R XM2 230 20 R 800 1819 Continuous Power 2 kW 4 kW 4 kW 4 kW Peak Power 5 kw 10 kw 10 kw 10 kw Minimum Resistance 30 Q 150 150 150 Minimum Resistor 25W 50W 50W 50W Wattage Turn On Voltage 390 Vdc Turn Off Voltage 380 Vdc DC Bus Capacitance 2350 uF nominal Regen Energy Absorption Capacity Input Voltage 120 Vac 208 Vac 240 Vac 145 Joules 77 Joules 43 Joules 3 6 Regen Circuit Output Internal Regen Resistor XE2 XP2 XM2 800 1819 Copley Controls Internal Regen Resistor Ratings Max Energy 100 W s J Resistance 180 Power continuous 20 W Power peak 70 W Time 2000 mS 67 Xenus Plus User Guide 16 01344 Rev 01 3 7 Digital Command Inputs Pulse and direction Count up count down 2 MHz with active driver Digital Position Command maximum rate Quadrature A B encoder 2 M line sec 8 M count sec after maximum rate quadrature Digital Current amp Velocity PWM frequency range 1 kHz 100 kHz Command PWM minimum pulse width 220 ns 3 8 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 Maximum Voltage Differential 10 Vdc 10 Vdc Input to Ground 10 Vdc 10 Vdc Input Impedance 5 kQ 4 99 kQ pull up to 5V Resolution 16 Bit 12 Bit Anti aliasing
13. e 127 9 e e 1 s INPUT 1 of G FILTER FILTER i I iia I Inertia I L CURRENT g OFFSET LIMITED ACTUAL CURRENT CURRENT L b ewe e e e e e a e e e e e e o o e d poe e e 9 Bu eee eee eee eee ee ee o be eee eee eee eee ee ee ee eee eS ee ee eeeeeeeeeeeee ee Copley Controls 18 Xenus Plus User Guide 16 01344 Rev 01 Basic Attributes of All Control Loops These loops and servo control loops in general share several common attributes Loop Attribute Description Command input receives a velocity command that is the desired motor speed Every loop is given a value to which it will attempt to control For example the velocity loop Limits Limits are set on each loop to protect the motor and or mechanical system Feedback Gains values of these gains can be adjusted during drive setup to improve the loop performance Adjusting these values is often referred to as tuning the loop The nature of servo control loops is that they receive feedback from the device they are controlling For example the position loop uses the actual motor position as feedback These are constant values that are used in the mathematical equation of the servo loop The The loop generates a control signal This signal can be used as the command signal t
14. 1 m cu PrSub Male Norcomp 180 026 103L001 1 Backshell D Sub RoHS metalized for above Norcomp 939 015 020R121 XE2 XP2 XM2 800 1818 800 1819 Model Qty Ref Name Description Mfr Model No 1 J1 AC Pwr Plug 5 position 5 08 mm female Wago 231 305 107 000 Note 1 1 J2 Regen Plug 3 position 5 08 mm female Wago 231 303 107 000 Note 1 2 J3 J4 Motor Plug 4 position 5 08 mm female Wago 231 304 107 000 Note 1 1 J5 Brake Plug 5 position 3 5 mm female Wago 734 105 107 000 Note 1 1 J5 Tool Tool wire insertion amp extraction 734 series Wago 734 191 4 is P Tool Tool wire insertion amp extraction 231 series Wago 231 291 XE2 CK ui Connector 1 Connector DE 9M 9 position standard male AMP Tyco 205204 4 Kit 9 d 2 Safety AMPLIMITE HDP 20 Crimp Snap Contacts 24 20 AWG Sel Au Ni AMP Tyco 66506 9 1 Backshell DE 9 RoHS metallized for J6 Norcomp 979 009 020R121 1 Connector high density DB 44M 44 position male solder cup Norcomp 180 044 103L001 1 in Sonia Backshell DB 44 44 Pin RoHS metallized Norcomp 979 025 020R121 2 J9 VO Connector high density DA 26F 26 position female solder cup Norcomp 180 026 203L001 2 J10 11 Feed Connector high density DA 26M 26 position male solder cup Norcomp 180 026 103L001 3 J9 11 back Backshell DA 26 RoHS metallized Norcomp 979 015 020R121 SER CK 1 J7 RS 232 Serial Cable Kit XE2 NC 10 1 Et
15. 34 Xenus Plus User Guide 16 01344 Rev 01 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 CANopen provides the protocol for mapping device and master internal commands to messages that can be shared across the network Feedback Software Application Master Controller Status Control CAN Network CANopen Device CAN Addressing A CANopen network can support up to 127 nodes Each node must have a unique and valid seven bit address Node ID in the range of 1 127 Address 0 is reserved and should only be used when the drive is serving as a CME 2 serial port multi drop gateway There are several basic methods for setting the CAN address as described below These method can be used in any combination producing a CAN address equal to the sum of the settings Addressing Method Description Use switch If the address number lt 15 CAN address can be set using the CAN ADDR switch only Use inputs Use the drive s programmable digital inputs user selects how many 1 7 and which inputs are used Use programmed value Program address into flash only For more information on CAN addressing see th
16. 5 L3 AC power input L3 AC Mains Fuse Recommendation All Xenus Plus models Recommended fuse type Class CC 600 Vac rated Ferraz Shawmut ATDR Littelfuse CCMR Bussman LP CC or equivalent 1 EMI Line Filter is necessary to meet EMC requirements WARNING EMC requirements Use if an EMI Line Filter with Xenus Plus Dual Axis drives is mandatory for meeting category Il environment 1 A surge protection device SPD is required to establish an over voltage relevant standards assume AC mains with over voltages per OVC III An SPD is required to limit over voltages to OVC II levels Copley Controls WARNING The AC mains supplying the drive must be limited to over voltages of Category II The 89 Xenus Plus User Guide 16 01344 Rev 01 AC Mains Wiring Diagram Single Phase XE2 XP2 XM2 800 1818 800 1819 Heatplate Keep wire length as short as possible Not to exceed 1 m 3 28 ft r 100 240 Vac L2 AC MAINS 19 Line filter Filter Concepts SF20L i 2 or equivalent used for CE compliance Protective oun 2 Earth Ground Fuses not required on neutral N line ta AC Mains Wiring Diagram Three Phase XE2 XP2 XM2 800 1818 800 1819 Heatplate Kem wire length possible Not to exceed 1 m 3 28 ft ce AC MAINS 100 7240 Vac Line filter Filter Concepts 3F15F or equivalent used for CE compliance Protective Grounding
17. 800 1819 18 Adc 36 Adc 40 Adc 20 Adc 3 Ade Peak Current 6 36 12 7 Arms 25 5 Arms 28 3 Arms 14 Arms Arms Peak Current Time 1 Second Continuous Current 6 Adc 12 Adc 20 Adc 10 Adc AAE 4 24 Arms 8 5 Arms 14 1 Arms 7 Arms pe i Efficiency gt 97 230 Vac and rated continuous current 3 phase IGBT inverter Output Type 16 kHz center weighted PWM space vector modulation PWM Ripple Frequency 32 kHz Minimum Load 400 uH line to line Inductance NOTE See Xenus Plus Filter p 146 Error Bookmark not defined Capacitor Discharge Wait 5 minutes after disconnecting mains power before handling Heat sinking and or forced air cooling required for continuous output power rating Consult factory for operation with inductance lower than 400 uH Copley Controls 66 Guide 16 01344 Rev 01 Xenus Plus User 3 4 Control Loops Type Current Velocity Position 100 digital Sampling rate time Current Velocity Position 16 kHz 62 5 us 4 kHz 250 us 4 kHz 250 us Current Loop Small Signal Bandwidth gt 2 kHz Tuning and load impedance dependent Programmable Loop Filters n Velocity loop output filter default 200 Hz low pass Bus Voltage Changes in bus or mains voltage do not affect tuning Compensation 3 5 Regen Circuit Output External Regen Resistor XEL 230 18 R XEL 230 36 40 R XE2 230 20 R XP2 230 20 R Model XPL 230 18
18. F 6 Order Example Order 1 XEL 230 18 drive with standard heatsink fitted at the factory Connector Kit and serial Qty Item Description cable kit 1 XEL 230 18 HS Xenus Plus EtherCAT Servo drive with standard heatsink installed 1 XEL CK Connector Kit with solder cup connectors 1 SER CK Serial Cable Kit for connecting the PC to the drive Copley Controls 162 Xenus Plus User Guide 16 01344 Rev 01 F 7 Copley Standard Regen Resistor Specifications F 7 1 Specifications Specifications for Copley s standard regen resistors are described below Default Max Peak Peak Model Resistance Continuous Continuous P Power For Use With ower Power Power Time XEL XML XPL 230 18 XTL RA 03 30 Ohms 65 W 400 W 5 kW 1000 ms yer ML XPL 230 18 R XEL XML XPL 230 36 XEL XML XPL 230 36 R XEL XML XPL 230 40 XTL RA 04 15 Ohms 65 W 400 W 10 kw 1000 ms XEL XML XPL 230 40 R XE2 XP2 XM2 230 20 800 1819 XE2 XP2 XM2 230 20 R High Temperature Risk Setting Default Continuous Power for a standard Copley regen resistor to a value greater than the default of 65 W may cause the resistor casing to heat to temperatures that could cause injury If higher settings are required contact Copley Controls customer support WARNING Failure to heed this warning can cause equipment damage or injury F 7 2 Dimensions The diagram below shows XTL RA 03 and XTL RA 04 m
19. I T Accumulator Variable n 1 I T Accumulator Variable n Actual Output Current n 1 Continuous Current Limit Update period After each sample the updated value of the I T Accumulator Variable is compared with the I T setpoint If the T Accumulator Variable value is greater than the I T Setpoint value then the drive limits the output current to the Continuous Current Limit When current limiting is active the output current will be equal to the Continuous Current Limit if the commanded current is greater than the Continuous Current Limit If instead the commanded current is less than or equal to the Continuous Current Limit the output current will be equal to the commanded current Copley Controls 138 Xenus Plus User Guide 16 01344 Rev 01 B 1 3 T Current Limit Algorithm Application Example IT Example Parameters Operation of the I T current limit algorithm is best understood through an example For this example a motor with the following characteristics is used e Peak Current Limit 12 A e l T Time Limit 1 S e Continuous Current Limit 6 A From this information the I T setpoint is I T setpoint 12 A 6 A 1 S 108 A S See the example plot diagrams on the next page Copley Controls 139 Xenus Plus User Guide 16 01344 Rev 01 IT Example Plot Diagrams The plots that follow show the response of a drive configured w I T setpoint 108 A S to a given current command For this example D
20. Scaling could also be useful if for example the signal source generates a signal range between 0 and 10 Vdc but the command range only requires 7 5 Vdc of input In this case scaling allows the drive to equate 7 5 Vdc with the drive s peak current in current mode or maximum velocity in velocity mode increasing the resolution of control Dead Band To protect against unintended response to low level line noise or interference the drive can be programmed with a dead band to condition the response to the input signal voltage The drive treats anything within the dead band ranges as zero and subtracts the dead band value from all other values For instance with a dead band of 100 mV the drive ignores signals between 100 mV and 100 mV and treats 101 mV as 1 mV 200 mV as 100 mV and so on 200 100 Dead Band Output e 100 200 200 100 0 100 200 Input Copley Controls 28 Xenus Plus User Guide 16 01344 Rev 01 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 The offset can also set up the drive for bi directional operation from a
21. Solder style connector included in Connector Kits XEL CK XML CK and XPL CK Pin connections for the bulkhead connector on the drive are shown here 18 X 26 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 Ref AIN1 Analog command positive input single analog 3 Ref AIN1 Analog command negative input single analog 4 IN1 Enable 5 IN2 Programmable input 6 IN3 7 INA Mode dependent See Mode Dependent Dedicated Inputs p 108 8 IN5 9 AOUT Programmable 12 bit 5 Vdc 10 ING Mode dependent See Mode Dependent Dedicated Inputs p 108 11 AIN2 Analog input 2 positive input 12 AIN2 Analog input 2 negative input 1s otal aA Mode dependent See Mode Dependent Dedicated Inputs p 108 14 Multi mode port S2 15 Signal Ground Signal ground reference for inputs and outputs 16 OUT1 17 OUT2 Programmable outputs 18 OUT3 HS 19 Signal Ground Signal ground for 5Vdc inputs and outputs Continued Copley Controls 107 Xenus Plus User Guide 16 01344 Rev 01 Pin Description continued a To Moe deo Ens on J8 20 J10 6 and J10 17 not to exceed 400 mA 21 Multi Mode Port X 22 Multi Mode Port X 23 Multi Mode Port B Programmable differential input output port 24 Multi Mode Port B See Mode Dependent Dedicated Inputs below 25 Mul
22. the limit switch is still active the drive will only allow Position movement in the opposite direction Hold position behavior If the Hold position when limit switch is active option is set the drive prevents any motion while a limit switch is active CAUTION If the drive is switched back to current or velocity mode with this option selected the limit switches will no longer function For more information on Hold position when limit switch is active see the CME 2 User Guide Using Custom Output to Signal Limit Switch Activation In addition to the response described above any of the drive s digital outputs can be configured to go active when a positive or negative limit switch is activated For more information see the CME 2 User Guide 2 9 3 Analog Inputs Two programmable differential analog inputs AIN1 and AIN2 are connected on J12 As reference inputs they can take position velocity torque commands from a controller If not used as command inputs they can be used as general purpose analog inputs The input voltage range is X 10V Copley Controls 57 Xenus Plus User Guide 16 01344 Rev 01 2 10 Outputs XEL XPL XML The Xenus Plus XEL XPL and XML drives have 6 programmable digital outputs one opto isolated and five non isolated and one programmable analog output The XEL XPL XML features six programmable digital outputs OUT1 5 are general purpose outputs OUTE is specifically designed as a brake out
23. www copleycontrols com Motion Downloads index html Comments Copley Controls welcomes your comments on this manual For contact information see http www copleycontrols com Motion Contact index html Copyrights No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Copley Controls Xenus XEL XE2 XPL XP2 XML and XM2 are registered trademarks of Copley Controls CME 2 is a registered trademark of Copley Controls Windows XP Windows 7 Visual Basic and NET are trademarks or registered trademarks of the Microsoft Corporation LabVIEW is a registered trademark of National Instruments EtherCAT is a registered trademark and patented technology licensed by Beckhoff Automation GmbH Germany Document Validity We reserve the right to modify our products The information in this document is subject to change without notice and does not represent a commitment by Copley Controls Copley Controls assumes no responsibility for any errors that may appear in this document Copley Controls 7 Xenus Plus User Guide 16 01344 Rev 01 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 voltag
24. 13 Regen Resistor Theory 61 3 Specifications 64 3 1 Agency Approvals 65 EA POWerINDUT tae cco er te wena e eae a A EE a E A E E A 65 3 3 Power OULDUL A ker ous 66 3 4 Control LOOPS 5 2 eerte drehen 67 3 5 Regen Circuit Output External Regen Resistor 2 067 3 6 Regen Circuit Output Internal Regen ReSistor ccccsccecesseeeseseeeeeeaeeeeeaeeeeeaeeeseaaeeeeaneeeeeaaeeesaaeeseeaeeesseaeeeseeesseeeeetenaeeetes 67 3 7 Digital Command NUNS E ERE m 68 3 8 Analog Inputs 68 3 9 Digital Inputs 69 3 10 Analog Outputs 70 3 11 Digital Outputs 70 3 12 Encoder Power Outputs ze 71 3 13 Primary Encoder INpUtS e 71 3 14 Analog Encoder Inputs EM 72 3 15 Hall Switch Inputs na lS 3 16 Resolver Interface 14 3 17 Multi Mode Port 75 3 18 Serial Interface 76 3 19 Network Interfaces wie LE 3 20 SlAtUS INDICATORS 2 3 C EAA AUT LOVONS KH a 3 22 Power Dissipation 3 23 Thermal Impedance nee 3 24 Mechanical and Environmental 1 coceveteagscenecavececusatcageesacnesctdayiasstedsatsegocdetsasoeeuts ce casavedyaterashessacenauidvateubenat
25. 36 XML 230 36 R 12 8 49 36 25 5 XPL 230 36 XPL 230 36 R 100 240 XEL 230 40 XEL 230 40 R 1g 39 XML 230 40 XML 230 40 R 20 14 1 40 28 3 50 60 Hz XPL 230 40 XPL 230 40 R 2505070 XE2 230 20 R XP2 230 20 R 10 7 07 20 14 1 AME 230 29 XM2 230 20 R 800 1819 MEUS 800 1818 4 5 3 18 9 6 36 The XEL XML XPL model numbers may be followed by HL or HS to specify the low profile or standard heatsink option respectively Note that as a convenience to customers Copley offers a certain level of customization to tailor Xenus Plus drives for a given application This level of customization is most often limited to factory configuration of user programmable parameters but can include signal level hardware differences to accommodate less common motor feedback devices Drives with this customization carry the Xenus Plus or Xenus Plus 2 Axis marking but are assigned customer specific model numbers that begin with 800 followed by four or five alphanumeric characters These Xenus Plus and Xenus Plus 2 Axis 800 number models are included within the scope of this manual unless otherwise noted A separate 24 Vdc logic supply is required to power the internal logic and control circuits These are isolated from the high voltage power supply and inverter stage that connect to the mains This simplifies system design by allowing the mains to be completely disconnected from the drive for safety reasons while allowing the log
26. CAN 7 AN P AN P AN P 6 ort ADDR c ort PERS 9A 0 ort A ADDRESSES MUST BE 120 Ohm SET BEFORE POWER UP Terminator OR RESET Copley Controls 155 Xenus Plus User Guide 16 01344 Rev 01 APPENDIX F ORDERING GUIDE AND ACCESSORIES This chapter lists part numbers for drives and accessories Contents include Fe Te Drive MOGel NUIMDGIS ireki ranie a E a E A A E A canes udenae hand siconie uid tue E decent 157 F 2 Accessory Model Numbers 160 F 3 Heatsink Kits 161 F 4 Regen Resistor Assemblies 162 F 5 Edge Filter 162 F 6 Order Example F 7 Copley Standard Regen Resistor Specifications Copley Controls 156 Xenus Plus User Guide 16 01344 Rev 01 F 1 Drive Model Numbers XEL Model Number Description XEL 230 18 Xenus Plus EtherCAT Servo drive 6 18 A XEL 230 18 HL Xenus Plus EtherCAT Servo drive 6 18 A with factory fitted low profile heatsink XEL 230 18 HS XEL 230 36 Xenus Plus EtherCAT Servo drive 6 18 A with factory fitted standard heatsink Xenus Plus EtherCAT Servo drive 12 36 A XEL 230 36 HL Xenus Plus EtherCAT Servo drive 12 36 A with factory fitted low profile heatsink XEL 230 36 HS Xenus Plus EtherCAT Servo drive 12 36 A with factory fitted standard heatsink XEL 230 40 Xenus Plus EtherCAT Servo drive 20 40 A XEL 230 40 HL Xenus Plus
27. Earth Ground tab 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 Il environment Example parts are Cooper Bussman BSPM3240DLG 3 phase or BSPM2240S3G two polel In order to minimize electrical noise it is important to keep the connection between the drive heatplate and earth equipment frame as short as possible An unplated tab on the drive heatplate is provided for making this connection This tab also provides a connection point for a second protective earthing conductor to address the touch current requirements of IEC 61800 5 1 The Xenus Plus Dual Axis models use a diode rectifier and DC bus capacitance to convert the incoming AC mains voltage to DC for powering the output stage inverter Depending on actual drive load conditions the total harmonic distortion THD of the current drawn from the AC mains can exceed 10 Management of current THD must be considered in the overall system and harmonic filtering may be required Users should refer to Clause B 4 of IEC 61800 3 2004 A1 2011 for further details In the presence of commutation notch disturbances on the incoming AC mains the DC bus voltage in the Xenus Plus Dual Axis models can exceed the overvoltage shutdown level 4
28. EtherCAT Servo drive 20 40 A with factory fitted low profile heatsink XEL 230 40 HS Xenus Plus EtherCAT Servo drive 20 40 A with factory fitted standard heatsink XEL 230 18 R Xenus Plus EtherCAT Servo drive 6 18 A with resolver feedback XEL 230 18 R HL Xenus Plus EtherCAT Servo drive 6 18 A with resolver feedback and factory fitted low profile heatsink XEL 230 18 R HS Xenus Plus EtherCAT Servo drive 6 18 A with resolver feedback and factory fitted standard heatsink XEL 230 36 R Xenus Plus EtherCAT Servo drive 12 36 A with resolver feedback XEL 230 36 R HL Xenus Plus EtherCAT Servo drive 12 36 A with resolver feedback and factory fitted low profile heatsink XEL 230 36 R HS Xenus Plus EtherCAT Servo drive 12 36 A with resolver feedback and factory fitted standard heatsink XEL 230 40 R Xenus Plus EtherCAT Servo drive 20 40 A with resolver feedback XEL 230 40 R HL Xenus Plus EtherCAT Servo drive 20 40 A with resolver feedback and factory fitted low profile heatsink XEL 230 40 R HS Xenus Plus EtherCAT Servo drive 20 40 A with resolver feedback and factory fitted standard heatsink NOTE Heatsink kits for field installation may be ordered separately XE2 Model Number Description XE2 230 20 Xenus Plus 2 Axis EtherCAT Servo drive 10 20 A encoder feedback XE2 230 20 R Xenus Plus 2 Axis EtherCAT Servo drive 10 20 A resolver feedback 800 181
29. Met M E 3 59 a 3 98 Hae b im 101 1 3 15 3 59 80 i PY O8 PX OUS XN m7 OUS S 912 QR 2 612 W rn M v wanda 1 P n g HEN Ld MA NA ka A Iw neereeeeerreeer ee 1 a ai ac acabar Jar Jar jar jar jab Jab at at Jar Jar i T Ty cT 1 L J T 60 4 1 38 1 eee 76 2 z EN 188 4 8 If n Cc T a a T i a F j a 5 49 139 4 a a a 4 a JY T 188 t 4 8 Le Copley Controls 149 Xenus Plus User Guide D 2 XTL FA 01 Edge Filter Wiring This section describes the wiring of the XTL FA 01 Edge Filter D 2 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 DANGER Hazardous voltages Exercise caution when installing Failure to heed this warning can cause equipment damage injury or death Risk of electric shock High voltage circuits on Xenus Plus J1 J2 and J3 and on Filter J1 and J2 are connected to mains power Failure to heed this warning can cause equipment damage injury or death DANGER Do not ground mains connected circuits With the exception of the ground pins on Xenus Plus J1 J2 and J3 and on Filter J1 and J2 all of the other circuits on these connectors are mains connected and must never be grounded WARNING Failure to heed this warning can cause equipment damage
30. Optically isolated programmable output negative signal Copley Controls 111 Xenus Plus User Guide Optically Isolated Programmable Inputs Wiring Diagram Opto isolators AS iw 4 99 KQ AAA N8 4 99 KQ A A NI 2f qun Opto isolators COMM B 4 99 KQ IN11 IN12 IN13 4 99 KQ IN14 J9 11 N V Copley Controls GND 24V Ko GND 24V Le 16 01344 Rev 01 Xenus Plus User Guide 16 01344 Rev 01 Optically Isolated Programmable Outputs Wiring Diagram Opto isolators 20 7 3 NU RL 14 30 Vde Max ama RL W 30 Vdc Max Copley Controls 113 Xenus Plus User Guide 16 01344 Rev 01 4 10 3 Non Isolated Control XE2 XP2 XM2 800 1818 800 1819 J12 Mating Connections Description Manufacturer PN Wire Size 44 Position 0 1 x 0 09 High Density D Sub male Solder Style Norcomp 180 044 24 30 AWG Connector 103L001 Norcomp 979 025 Back shell 020R121 Solder style connector included in Connector Kits XE2 CK XP2 CK and XM2 CK Pin connections for the bulkhead connector on the drive are shown here 1 15 o OOoOOOOOOO0OoOOoOooOoO0cO0O OOoOooooooooooo O00000 00000000 Pin Description S T E 16 31 44 30
31. Plus User Guide 16 01344 Rev 01 Motor Wiring Detection When a brake is in use the drive can check for a disconnected motor Upon enable the drive will apply current to the motor output while keeping the brake engaged for the Brake Hold Time on Enable If no current can be detected in the windings the brake will not be released and a Wiring Detection Fault will occur If the motor is connected and current can be detected the brake will be released after the programmable time expires f amp Motor Wiring Detection xj Enable Input Brake Output l Motor Check Current lt p Brake Hold Time on Enable Brake Hold Time On Enable 0 ms Motor Check Current o Set Defaults Close Motor Brake Enable Delay Time The programmable value in the Motor Wiring Detection also sets the time between the activation of the brake and PWM outputs of the drive e When the value is positive the PWM outputs will turn on when the drive is enabled and the brake will be released after the programmable delay expires e When the value is negative the brake is released immediately when the drive is enabled and the PWM outputs are enabled after the programmable delay expires The graphic below is not part of CME2 but shows the timings in the same colors as the Brake setting screen Enable Input 1 i i i Brake Hold Time on Enable gt 0 1 Brake Output i Brake Hold Time on Enable lt 0 PWM Outputs 1 Copl
32. Power Drive Systems Part 3 EMC Requirements and JA1 2011 Specific Test Methods Category 3 PDS PRODUCT SAFETY IEC 61800 5 1 2007 Adjustable Speed Electric Power Drive Systems Part 5 1 Safety Requirements Electrical Thermal and Energy FUNCTIONAL SAFETY IEC 61800 5 2 2007 Adjustable Speed Electric Power Drive Systems Part 5 2 Safety Requirements Functional ISO 13849 1 2006 Safety of Machinery Safety Related Parts of Control Systems Part 1 General Principles for Design These products also comply with the following Underwriters Laboratories standard and SEMI standard UL 61800 5 1 2012 Adjustable Speed Electric Power Drive Systems Part 5 1 Safety Requirements Electrical Thermal and Energy File No E168959 SEMI F47 0706 Specification for Semiconductor Processing Equipment Voltage Sag Immunity Testing Performed By Underwriters Laboratories 1285 Walt Whitman Road Melville NY www ul com TUV SUD America Inc 10040 Mesa Rim Road San Diego CA www TUVamerica com Test Site Services Inc P O Box 766 Marlboro MA www testsiteservices com Year in which the CE Marking was affixed 2014 Signed for and on behalf of the above named manufacturer Place and dote of issue Canton MA USA 03 31 2015 Name function Timothy Walsh Manager Corporate Product Compliance amp Reliability _ Signature amp a dz l j An EC Authorized Representative BK Medical ApS Mileparken 34 DK 2730 Herlev D
33. Protections The drive protects the regen circuit against short circuit and uses T peak current time algorithms to protect both the external resistor and the internal transistor Configurable Custom Resistor The following values can be entered for a custom resistor using CME 2 Option Description Resistance Value Value in Ohms of the resistor Continuous Power Continuous power rating of the resistor Peak Power Peak power rating of the resistor Time at Peak Power Time at peak power of resistor For more information see Regen Resistor Sizing and Specification p 132 Copley Controls 61 Xenus Plus User Guide 16 01344 Rev 01 2 13 2 XE2 XP2 XM2 800 1819 Regeneration The Xenus Plus Dual Axis drives excluding the 800 1818 have an internal regen resistor which can dissipate regenerative energy that exceeds the absorption capacity of the internal bus capacitance The internal regen resistor will be switched on when the energy shown in the table has been absorbed and the bus voltage driven up to 390 Vdc at which point the internal regen resistor will be switched to dissipate the kinetic energy of the load Absorption a Absorption is the energy that can be transferred to the internal capacitors during Vac E deceleration This table shows the energy absorption in W s for a drive operating 400 455 at some typical mains voltages The capacitor bank is 2350 uF and the
34. Provides power for motor encoders and or Hall switches 3 13 Primary Encoder Inputs XEL XPL XML Channels 3 Tupe Differential RS 422 line receiver w RC filter Non isolated Signals A A B B S S X X Input Voltage Range 7 Vdc Differential Input Threshold 0 2 Vdc Termination Resistance 121 0 Maximum Frequency 5 MHz Line 20 Mcount sec Function Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation X is equivalent to Marker Index or Z channels depending on the encoder manufacturer This channel is only required in certain homing modes while under CAN control XE2 XP2 XM2 800 1818 Channels 8 Type Pieter RS 422 line receiver w RC filter Non isolated Signals A A B B S S X X for each axis Input Voltage Range 7 Vdc Differential Input Threshold 0 2 Vdc Termination Resistance A and B Channels 121 Q X Channel 130 Q with 1 kQ pull up to 5V on X and 1 KQ pull down on X S Channel 221 Q with 1 KQ pull up to 5V on S and 1 kQ pull down on S Maximum Frequency Function 5 MHz Line 20 Mcount sec Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation S and X channels are bi directional NOTE There is no Digital Encoder feedback on 800 1819 drives Copley Controls 71 Xenus Plus User Guid
35. Signals Ref Ref Sin Sin Cos Cos for each axis 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 Reference Max Current 100 mA per axis Max RPM 20 000 Function 800 1819 Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation Contact Copley Controls for details Copley Controls 74 Xenus Plus User Guide 16 01344 Rev 01 3 17 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 Vde Differential Input Threshold 0 2 Vdc Termination Resistance None Output Mode Buffered primary incremental encoder Function Emulated incremental or serial encoder from analog encoder or resolver Programmable Input Mode Secondary digital quadrature input Current Velocity mode PWM input Position Mode Digital command input Maximum Frequency Output Mode Buffered Encoder 5 MHz Line 20 Mcount sec Emulated Encoder 4 5 MHz Line 18 Mcount sec Input Mode PWM Input 100Khz Digital Command 5 MHz 50 Duty Cycle Secondary Encoder 5 MHz Line 20 Mcount sec XE2 XP2 XM2 800 1818 800 1819 Channels 8 Type Bi Directional Differential RS 422 Non isolate
36. The primary effect of this gain is to decrease following error during acceleration and deceleration Gain Multiplier The output of the position loop is multiplied by this value before being passed to the velocity loop Position Loop Feedback Xenus Plus supports two position feedback configurations e Single sensor Position loop feedback comes from the encoder or resolver on the motor e Dual sensor Position loop feedback comes from the encoder attached to the load Note that in either case velocity loop feedback comes from the motor encoder or resolver For more information see Position Feedback p 17 Position Loop Output The output of the position loop is a velocity command used as the input to the velocity loop Copley Controls 26 Xenus Plus User Guide 16 01344 Rev 01 Position Wrap The position wrap feature causes the position reported by the drive to wrap back to zero at a user defined value instead of continually increasing Once set the reported position will be between 0 and n 1 where n is the user entered wrap value This feature is most useful for rotary loads that continually turn in one direction and only the position within a revolution is of interest to the user With the wrap value set relative moves will move the relative distance called for Example if the wrap value is set to 1000 and a relative move of 2500 is commanded the axis will turn 2 72 revolutions Absolute moves will move the shortes
37. Xenus Plus Standard Servo drive 6 18 A with resolver feedback and factory fitted standard heatsink Xenus Plus Standard Servo drive 12 36 A with resolver feedback XPL 230 36 R HL Xenus Plus Standard Servo drive 12 36 A with resolver feedback and factory fitted low profile heatsink XPL 230 36 R HS Xenus Plus Standard Servo drive 12 36 A with resolver feedback and factory fitted standard heatsink XPL 230 40 R XPL 230 40 R HL Xenus Plus Standard Servo drive 20 40 A with resolver feedback Xenus Plus Standard Servo drive 20 40 A with resolver feedback and factory fitted low profile heatsink XPL 230 40 R HS Xenus Plus Standard Servo drive 20 40 A with resolver feedback and factory fitted standard heatsink NOTE NOTE Heatsink kits for field installation may be ordered separately Copley Controls 158 Xenus Plus User Guide 16 01344 Rev 01 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 XML 230 36 HL Xenus Plus MACRO Servo drive 12 36 A Xenus Plus MACRO Servo drive 12 36 A with factory fitted low profile heatsink XML 230 36 HS Xenus Plus MACRO Servo drive 12 36 A with factory fitted standard heatsink XML 230 40 Xenus Plus MACR
38. Xenus Plus User Guide 16 01344 Rev 01 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 This ground is connected to the drive chassis Wiring to this ground should be done using the same gauge wire as that used for the mains This wire is a protective bonding conductor that should be connected to an earthed ground point and must not pass through any circuit interrupting devices J2 Regen and J3 Motor Connector Grounds On Xenus Plus Single Axis drives the ground terminals at J2 1 and J3 5 connect to the drive chassis On Xenus Plus Dual Axis drives the ground terminals at J2 3 and J3 J4 1 connect to the drive chassis These ground terminals are provided as cable shield and protective earth connection points for the motor and regen resistor cables Connection of cable shields to these points is made to provide electrical noise reduction Connection of motor or regen cable protective earth conductors to these points is made to prevent the motor or regen resistor housing from becoming hazardous live in the event of an insulation failure Protective ear
39. a velocity a relative or absolute target position acceleration and deceleration rates On command a complete motion profile is executed traveling the programmed distance or ending at the programmed position The drive supports both trapezoidal and s curve profiles Profile Velocity Mode 3 The drive is programmed with a velocity a direction and acceleration and deceleration rates When the drive is enabled the motor accelerates to the set velocity and continues at that speed When the drive is halted the velocity decelerates to zero Profile Torque Mode 4 The drive is programmed with a torque command When the drive is enabled or the torque command is changed the motor torque ramps to the new value at a programmable rate When the drive is halted the torque ramps down at the same rate Homing Mode 6 Used to move the axis from an unknown position to a known reference or zero point with respect to the mechanical system The homing mode is configurable to work with a variety of combinations of encoder index home switch and limit switches Interpolated Position PVT or Position Velocity Time Mode 7 The controller sends the drive a sequence of points each of which is a segment of a larger more complex move rather than a single index or profile The drive then uses cubic polynomial interpolation to connect the dots so that the motor reaches each point at the specified velocity at the programmed time Copley Controls
40. and 240 Vac mains voltages Model XEL XML XPL 230 18 R Mains 120 Vac 60 50 1N 2 Low Profile Heatsink 1 No Heatsink 40 All other heatsink fan 30 combinations enable operation at Ambient Temperature C 55 C 20 1 2 3 4 5 6 Continuous Output Current Adc Model XEL XML XPL 230 36 R Mains 120 Vac 60 B w fan S 50 NAN D 4 Low Profile e ON Heatsink w fan ELELEEELNCD NE sersa E PEERS LAE CES EES 2 Low Profile FLEETING E Ne 20 1 No Heatsink 123 4 5 6 7 8 9 10 11 12 Continious Output Current Adc Model XEL XML XPL 230 40 R 60 50 40 30 Ambient Temperature C 20 Copley Controls 2 4 6 8 10 12 14 16 18 20 Continuous Output Current Adc Standard Heatsink w fan Low Profile Heatsink w fan Low Profile Heatsink or no Heatsink w fan Standard Heatsink 1 No Heatsink C Ambient Temperature Ambient Temperature C Ambient Temperature C 60 50 40 30 20 60 50 40 30 20 60 3 Allother heatsink fan combinations enable GUN operation at 55 C 2 Low Profile Heatsink 1 No Heatsink 1 2 3 4 5 6 Continuous Output Current Adc Mains 240 Vac HHN CHEN REIE H NIA LLEEELLENLERS ATT 5 Standard Heatsink w fan 4 Low Pr
41. be able to control the on off state of the PWM outputs Although all models have the STO feature there are important differences in the STO design between the Single Axis XEL XPL XML and the Dual Axis XE2 XP2 XM2 800 1 818 800 1819 versions The STO circuit in the single axis models was designed using guidance from IEC 61800 5 2 an international standard that specifies requirements for motor drive functional safety features including STO The STO feature in the dual axis models was developed in accordance with several functional safety standards and has both SIL and Category Performance Level ratings The design and development of the STO feature on these models are being submitted to TUV SUD for approval Following approval the Xenus Plus Dual Axis products will bear the TUV SUD Functional Safety mark For more information on STO for the Xenus Plus Dual Axis models see the Xenus Plus Dual Axis STO Manual Xenus Plus models support a wide range of feedback devices The standard versions support digital quadrature encoders analog sin cos encoders and EnDat BiSS SSI and Absolute A encoders The R version supports brushless resolvers The standard and R versions can emulate a digital quadrature encoder output from the analog encoder or resolver respectively Xenus Plus models can operate in several basic ways e As a traditional motor drive accepting current velocity or position commands from an external controller In current and velo
42. filter 14 5 kHz 27 Hz Scan Time 62 5 us 250 us Programmable Current velocity or Function position command Motor temperature sensor XE2 XP2 XM2 800 1818 800 1819 Channels 2 AIN1 AIN2 Type Differential non isolated Measurement Range 10 Vdc Maximum Voltage Differential 10 Vdc Input to Ground 10 Vdc Input Impedance 5 kQ Resolution 14 bit Anti aliasing filter 14 5 kHz Scan Time 62 5 us Function Programmable Copley Controls 68 Xenus Plus User Guide 16 01344 Rev 01 3 9 Digital Inputs XEL XPL XML Channels 15 IN1 IN15 IN1 IN2 IN15 IN3 IN6 IN7 IN14 Non isolated line receiver w Opto isolated bi polar 2 Type Schmitt trigger w RC filter RC filter programmable as 4 groups of 4 with common for yp 24Vdc max single ended or 2 differential each group Single ended Input Voltage Range 0 Vdc 24 Vdc 0 12Vdc 15 30 Vdc i lt 1 13 Vd Logic Low Input 3 Vdc lt 2 3 Vde N A Voltage Logic High Input _ Voltage gt 3 15 Vde gt 2 7 Vdc N A Scan Time 250 us 250 us 250 us Debounce Type Digital Digital Digital Time Programmable 0 10 000 ms Programmable 0 10 000 ms Programmable 0 10 000 ms IN1 enable Function IN2 IN15 programmable Note Inputs 3 amp 4 and 5 amp 6 can be programmed to function as differential pairs as digital command inputs XE2 XP2 XM2 800 1818 800 1819 Channels XE2 XP2
43. html 3 2 Power Input XEL 230 40 R Model XPL 230 18 CR XPL230 3840 R AUZOA 8 sop stg 230 18 R XML 230 36 40 R 800 1819 100 240 Vac Mains Voltage 19o39 Mains Frequency 47 to 63 Hz Max Mains Current 12 10 1 Arms 20 0 Arms 18 0 Arms 16 0 Arms Max Mains Current 3 6 4 Arms 10 4 Arms 14 0 Arms 7 5 Arms Current Inrush 15 A peak at 120 Vac 35 A peak at 240 Vac Mains Supply Short Circuit Current Rating SCCR 5 kArms maximum Logic Supply Voltage 20 to 32 Vdc Logic Supply Current 500 mA maximum 1 1 A maximum 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 Logic supply current draw depends on the number of encoders connected to the drive The maximum current draw given assumes that the four drive encoder supplies 5V are each loaded to 500mA Copley Controls 65 Xenus Plus User Guide 3 3 Power Output 16 01344 Rev 01 XEL 230 18 R XEL 230 36 R XEL 230 40 R Senin m Model XPL 230 18 R XPL 230 36 R XPL 230 40 R XM2 230 20 i 800 1818 XML 230 18 R XML 230 36 R XML 230 40 R 230 20 R
44. on operating mode Selected Command Source Mode Digital Input Digital Input Multi Mode Function Single Ended Differential Port Current amp Velocit PWAL EOS IN 14 IN12 amp IN13 A amp A PWM Input Current amp Velocity IN 14 IN12 amp IN13 A amp A PWM Input PWM 10096 IN 15 IN14 amp IN15 B amp B Direction Input Position IN 14 IN12 amp IN13 A amp A Pulse Input Pulse amp Direction IN 15 IN14 amp INT5 B amp B Direction Input Position IN 14 IN12 amp IN13 A amp A Count Up Up Down IN 15 IN14 amp IN15 B amp B Count Down Position IN 14 IN12 amp IN13 A amp A Channel A Quadrature IN 15 IN14 amp IN15 B amp B Channel B Digital Inputs IN1 IN5 IN11 IN15 Wiring Diagram IN 1 11 R1 15k R2 15k Vmax 24V IN2 5 amp IN12 15 R1 10k R2 1k Vmax 5V Drive J12 74HC14 Control IN1 IN11 IN2 IN3 IN4 IN5 IN12 IN13 IN14 IN15 Copley Controls 116 Xenus Plus User Guide 16 01344 Rev 01 Analog Input Wiring Diagram REF AIN2 REF AIN2 Signal Ground Multi Mode Port Interface Diagram 5V The connector labels on this diagram are for Axis A Axis B 1k Labels for Axis B are here J12 24 S 1 J12 39 S 1k x 412 18 rey rs e J12 25 IX p J12 33 P J12 40 X i 312 34 Controller J
45. 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 When the inputs are energized current is flowing through the input diodes the control core will be able to control the on off state of the PWM outputs Although all models have the STO feature there are important differences in the STO design between the single axis XEL XPL XML and the dual axis XE2 XP2 XM2 800 1818 800 1819 versions The STO circuit in the single axis models was designed using guidance from IEC 61800 5 2 an international standard that specifies requirements for motor drive functional safety features including STO The STO feature in the dual axis models was developed in accordance with several functional safety standards and has both SIL and Category Performance Level ratings The design and development of the STO feature on these models are being submitted to TUV SUD for approval Pending such approval the XE2 XP2 XM2 800 1818 800 1819 products will bear the TUV SUD Functional Safety mark For more information on STO for the Xenus Plus Dual Axis models see the Xenus Plus Dual Axis STO Manual 2 6 2 Faults Overview Xenus Plus detects and responds to a set of conditions regarded as faults such as drive ove
46. second connector No termination required Function Copley Controls Real time motion control Real time motion control Real time motion control TT Xenus Plus User Guide 16 01344 Rev 01 3 20 Status Indicators Model XEL XPL XML STAT Bicolor LED status of EtherCAT bus indicated NET by color and blink codes to CAN Indicator Bicolor LED status of NET LED Network Status Specification 303 3 CAN bus indicated by color and blink codes to Bicolor LED status of Ethernet CAN Indicator the MACRO interface Link green shows port Specification CiA 303 3 open closed ACT yellow shows activity LED Drive Status AMP Bi Color LED For status indicator locations and codes see Status Indicators p 38 Model XE2 800 1818 800 1819 XP2 XM2 RUN RUN EtherCAT State Machine ae ESM status per ETG 1300 CANopen Finite State NET LED Network Status LED Drive Status S R V1 0 1 ERR Error status amp warnings L A Link Act shows state of the EtherCAT network AMP Automaton FSA status ERR Error status amp warnings L A Link Act shows state of the CANopen network Two Bi Color LEDs Each dedicated to one axis Two Bi Color LEDs Each dedicated to the status of the MACRO interface of one axis For status indicator locations and codes see Status Indicators p 38 3 21 Fault Levels Amp Ove
47. the drive 4 Torque constant of the motor 5 Resistance line to line of the motor windings For rotary motor applications gather this additional information 1 Load inertia seen by the motor 2 nertia of the motor For linear motor applications gather this additional information 1 Mass of the moving load 2 Mass of the motor forcer block if the motor rod is stationary OR Mass of the motor rod if the motor forcer block is stationary A 1 2 Observe the Properties of Each Deceleration During a Complete Cycle of Operation For each deceleration during the motion cycle determine 1 Speed at the start of the deceleration 2 Speed at the end of the deceleration 3 Time over which the deceleration takes place Copley Controls 133 Xenus Plus User Guide 16 01344 Rev 01 A 1 3 Calculate Energy Returned for Each Deceleration Use the following formulas to calculate the energy returned during each deceleration Rotary motor Euec Jt w1 w2 Where Eae Energy returned by the deceleration in Joules J Load inertia on the motor shaft plus the motor inertia in kg m w1 Shaft speed at the start of deceleration in radians per second w2 Shaft speed at the end of deceleration in radians per second w 2 rr RPM 60 Linear motor Egec 72 Mi Vi i V Where Ege Energy returned by the deceleration in Joules M Total mass of the load and the moving part of the motor in kg V Velocity at the start of deceleration in me
48. user guide comply with the applicable EC Directives including 2004 108 EC EMC Directive and 2006 95 EC Low Voltage Directive Complete EC Declarations of Conformity are available on the internet at www copleycontrols com Name and Address of the Manufacturer Name and Address of the authorized representative Analogic Corporation d b a Copley Controls BK Medical ApS 20 Dan Road Mileparken 34 DK 2730 Canton MA 02021 Herlev USA Denmark Overview and Scope This manual describes the operation and installation of the XEL XE2 XPL XP2 XML XM2 800 1818 and 800 1819 drives manufactured by Copley Controls All Xenus plus products have serial numbers that incorporate the week and year of production into the first 4 digits WWYY of the serial number Copley Controls 5 Xenus Plus User Guide 16 01344 Rev 01 EC Declaration of Conformity The complete EC Declarations of Conformity for all products are available on the internet at www copleycontrols com copley controls EC DECLARATION OF CONFORMITY Objects of this deciaration We Analogic Corporation d b a Copley Controls hereby declare that the objects of this declaration manufactured by us and described above are in conformity with EC Directives 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive and 2011 65 EU RoHS Directive Conformity is declared under the following standards IEC 61800 3 2004 Adjustable Speed Electric
49. 0 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 Diagram Sample Placement of Limit Switches The following diagram shows these limit switches in use on a sample motion stage Mechanical Limits of Motion Stage 34 Negative Home Positive Limit Switch Limit Switch Switch Copley Controls 56 Xenus Plus User Guide 16 01344 Rev 01 How the Drive Responds to Limit Switch Activation The drive stops any motion in the direction of an active limit switch as described below The response is identical in current and velocity modes and slightly different in position mode Mode Drive Response to Active Positive or Negative Limit Switch Current Drive prohibits travel in positive or negative direction Travel in the opposite direction is still allowed Drive status indicator flashes green at fast rate Warning is displayed on CME 2 Control Panel and CME 2 Control Panel limit indicator turns red Velocity Drive stops responding to position commands until the drive is disabled and re enabled or the fault is cleared over the CANopen interface Drive status indicator flashes green at fast rate Warning is displayed on CME 2 Control Panel and CME 2 Control Panel limit indicator turns red Default behavior If after re enabling the amp
50. 00V In the event that commutation notches result in DC bus voltages above the overvoltage shutdown threshold in the end use system measures to reduce commutation notch disturbances may be required Copley Controls 90 Xenus Plus User Guide 16 01344 Rev 01 4 3 Motor s 4 3 1 J2 XEL XPL XML 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 Recommended Wire 22 12 AWG 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 Pin Description Note 1 For ROHS compliance append RNO1 0000 to the part numbers listed above Pin Signal Function 1 Ground Motor frame ground and cable shield 2 W Phase W output of drive 3 V Phase V output of drive use for DC motor connection 4 U Phase U output of drive use for DC motor connection Brushless Motor Wiring Diagram c Brushless Earth ground Brush Motor Wiring Diagram Copley Controls Earth ground 91 Xenus Plus User Guide 16 01344 Rev 01 4 3 2 J3 J4 XE2 XP2 XM2 800 1818 800 1819 Mating Connector Recommended Wire Description Eur
51. 05 026 047 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 2 Insertion Extraction Tool Wago 231 131 Note 1 For ROHS compliance append RN01 0000 to the Wago part numbers listed above Copley Controls 153 Xenus Plus User Guide 16 01344 Rev 01 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 4 Single Axis and Multi Drop nr rrr net rrr tienen tr he eek e center a E ES YER PERI E eS REX ERE KE ERR SENETA EVE Eaei 155 Copley Controls 154 Xenus Plus User Guide 16 01344 Rev 01 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 For experimentation and simple setup and control a telnet device such as the standard Microsoft Windows HyperTerminal can also be used to send commands in ASCII format For more information see Copley Controls ASCII RS 232 User Guide The serially connected drive can also be used as a multi drop gateway for access to other drives linked in a series of CAN bus connections Instructions for hooking up a single axis connection and a multi drop network appea
52. 1 Wire Size 28 14 AWG Recommended Wire 18 AWG Wire Insertion Extraction Tool Wago 734 191 Standard connector and tool are included in Connector Kits XE2 CK XP2 CK and XM2 CK Note 1 For RoHS compliance append RNO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 RTN 24 Vdc Logic power supply return 2 Brake B Return or low side of motor brake B 3 Brake A Return or low side of motor brake A 4 Brake 24 Vdc 24 Vdc for both brakes 5 24 Vdc input 24 Vdc Logic power supply Logic Supply Brake Wiring Diagram Brake A 24 Vdc Isolated Logic _ Brake B Power Pow er Supply l Supply forBrakeA OS NI E Required Isolated Logic 3 ii Pow er Supply i ALT forBrakeB I AT Note that the 24Vdc supply must be a SELV or PELV type in applications using the XE2 XP2 XM2 STO feature See the Xenus Plus Dual Axis STO Manual for further details Copley Controls 97 Xenus Plus User Guide 4 6 Ferrules XE2 XP2 XM2 800 1818 800 1819 AC POWER REGEN AND MOTOR OUTPUTS J1 J4 Wago MCS MIDI Classic 231 305 107 000 J1 231 303 107 000 J2 231 304 107 000 J3 J4 female connector with screw flange 16 01344 Rev 01 pi
53. 1 Outputs XE2 XP2 XM2 800 1818 800 1819 XE2 XP2 XM2 800 1818 models have 7 programmable digital outputs while the 800 1819 has 5 OUT1 OUT5 are opto isolated two terminal SSR Solid State Relay switches each with a series resistor and Zener clamping diodes across the outputs allow driving of resistive inductive R L loads without the need for external flyback diodes The 800 1819 does not utilize OUT 4 5 For a list of digital output functions see the CME 2 User Guide Brake outputs OUT6 and OUT7 are isolated open drain MOSFETs with internal flyback diodes connected to the 24 Vdc input OUT6 and OUT7 are specifically designed as brake outputs for axis A and B respectively but can be programmed to perform other functions There are no analog outputs in XE2 XP2 XM2 800 1818 800 1819 2 12 Brake Operation 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 By eliminating the need to connect into the drive control connector having the brake output on the 24 Vdc power connector simplifies wiring when the brake wires are in the power cable of the motor Copley Controls 58 Xen
54. 12 26 B IB r3 1 or ie J12 20 re Y f Y Position J12 41 A T J12 35 l Encoder J12 27 A l 1 1 J12 21 Fa J12 37 Sig Gnd aAMti tt J12 36 J12 1 F G p Sgnd i i c mS me L FG Tes Copley Controls 117 Xenus Plus User Guide 16 01344 Rev 01 4 10 4 Isolated Control XE2 XP2 XM2 800 1818 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 Norcomp 180 026 Style Connector 203L001 pie Norcomp 979 015 Back shell 020R121 Solder style connector included in Connector Kits XE2 CK XP2 CK and XM2 CK Pin connections for the bulkhead connector on the drive are shown here 18 26 19 10 XE2 XP2 XM2 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 IN6 GPI 3 IN7 GPI SH Optically isolated programmable input 5 IN9 GPI 6 COM1 Common signal for first group of optically isolated programmable inputs IN6 IN9 7 IN16 GPI 8 IN17 GPI Optically isolated programmable input 9 IN18 GPI 10 OUT1 GPI 11 OUT2 GPI 12 OUT3 GPI Optically isolated programmable output negative signal 13 OUT4 GPI 14 OUT5 GPI 15 N C No connection 16 N C No connection 17 COM2 Common signal for first group of optic
55. 44 Rev 01 2 7 Position and Velocity Errors 2 7 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 position tracking window Likewise in velocity or position mode any difference between the limited velocity command and actual velocity is a velocity error The drive s velocity loop uses a velocity tracking window method to handle velocity errors There is no velocity error fault 2 7 2 Following Error Faults When the position error reaches the programmed fault threshold the drive immediately faults The following error fault can be disabled For detailed information see Following Error Fault Details p 53 2 7 3 Following Error Warnings When the position error reaches the programmed warning threshold the drive immediately sets the following error warning bit in the status word This bit can be read over the CAN network It can also be used to activate a digital output 2 7 4 Position and Velocity Tracking Windows When the position error exceeds the programmed tracking window value a status word bit is set The bit is not reset until the position error remains within the tracking window for the programmed tracking time A similar method is used to handle velocity e
56. 7 5 30 FERRULE PART NUMBERS DOUBLE WIRE INSULATED AWG mm Color Mfgr PNUM A B Cc D E SL 2x18 2x1 0 Red Altech 2776 0 15 4 61 8 2 32 2 4 09 3 2 13 5 8 23 11 0 43 2x18 2x1 0 Gray Altech 2775 0 14 6 57 8 2 32 2 0 08 3 0 12 5 5 22 11 0 43 2x20 2x0 75 White Altech 2794 0 14 6 57 8 2 32 1 7 07 3 0 12 5 0 20 11 0 43 2x20 2x0 75 Gray TE 966144 2 15 0 59 8 0 31 1 70 07 2 8 11 5 0 20 10 39 2x22 2x0 50 White TE 966144 1 15 0 59 8 0 31 1 40 06 2 5 10 4 7 19 10 39 SINGLE WIRE DOUBLE WIRE emm HE ML Copley Controls pus TT mi cE 98 Xenus Plus User Guide 16 01344 Rev 01 4 7 Safe Torque Off 4 7 1 XEL XPL XML J5 The following information is for XEL and XPL drives only Mating Connector Description Manufacturer PN Wire Size Connector D Sub 9 position male solder cup Norcomp 171 009 103L001 Backshell D Sub RoHS metallized for above Norcomp 979 009 020R121 24 20AWG Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 STO 1 hu High Side STO inputs 3 STO 1 4 STO 2 Low Side STO inputs 5 STO 2 LO 6 STO LED PWM outputs state LED outputs 7 STO LED 8 STO GND Signal ground 9 STO 24V Internal current source for STO bypassing Copley Controls 99 Xenus Plus User Guide 16 01344 Rev 01 Saf
57. 8 Xenus Plus 2 Axis EtherCAT Servo drive 4 5 9 A encoder feedback 800 1819 Custom Xenus Plus 2 Axis EtherCAT Servo drive 10 20 A resolver feedback XP2 Model Number Description XP2 230 20 Xenus Plus 2 Axis CANopen Servo drive 10 20 A encoder feedback XP2 230 20 R Xenus Plus 2 Axis CANopen Servo drive 10 20 A resolver feedback Copley Controls 157 Xenus Plus User Guide 16 01344 Rev 01 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 XPL 230 36 HL Xenus Plus Standard Servo drive 12 36 A Xenus Plus Standard Servo drive 12 36 A with factory fitted low profile heatsink XPL 230 36 HS Xenus Plus Standard Servo drive 12 36 A with factory fitted standard heatsink XPL 230 40 Xenus Plus Standard Servo drive 20 40 A XPL 230 40 HL Xenus Plus Standard Servo drive 20 40 A with factory fitted low profile heatsink XPL 230 40 HS Xenus Plus Standard Servo drive 20 40 A with factory fitted standard heatsink XPL 230 18 R Xenus Plus Standard Servo drive 6 18 A with resolver feedback XPL 230 18 R HL Xenus Plus Standard Servo drive 6 18 A with resolver feedback and factory fitted low profile heatsink XPL 230 18 R HS XPL 230 36 R
58. C 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 PT current limit S Wl llessesees commanded actual Current A Time S A PT Accumulator 120 Qoi ee ep ee eg x 80 B 60 MM P2T Setpoint 2 2 40 P2T Accumulator M 20 0 0 1 2 3 4 5 6 Fa Time S B At time 0 plot diagram A shows that the actual output current follows the commanded current Note that the current is higher than the continuous current limit setting of 6 A Under this condition the I T Accumulator Variable begins increasing from its initial value of zero Initially the output current linearly increases from 6 A up to 12 A over the course of 1 2 seconds During this same period the I T Accumulator Variable increases in a non linear fashion because of its dependence on the square of the current At about 1 6 seconds the I T Accumulator Variable reaches a value equal to the I T setpoint At this time the drive limits the output current to the continuous current limit even though the commanded current remains at 12 A The IT Accumulator Variable value remains constant during the next 2 seconds since the difference between the actual output current and the continuous current
59. Copley Controls 16 01344 Rev 01 150 Xenus Plus User Guide 16 01344 Rev 01 D 2 2 Connector Locations Edge Filter J1 connects to Xenus Plus J2 J3 or J4 for XE2 XP2 XM2 800 1818 800 1819 Edge Filter J2 connects to the motor Copley Controls 151 Xenus Plus User Guide 16 01344 Rev 01 D 2 3 Cable Notes 1 Keep the Edge Filter to Xenus Plus cable as short as possible A typical length is 7 inches 2 To reduce noise twisted shielded cable must be used and the signal cables should not be bundled in the same conduit D 2 4 Edge Filter Input J1 From Drive Mating Connector Description Euro style 5 position 5 0 mm pluggable female terminal block Manufacturer PN Wago 721 105 026 047 Note 1 Connector Wire Size 22 12 AWG Recommended Wire 12 AWG 600 V Shielded cable used for CE compliance Wire Insertion Extraction Tool Wago 231 131 Connector and tool are included in Connector Kit XTL FK Note 1 For RoHS compliance append RNO1 0000 to the Wago part numbers listed above Pin Description Pin Signal Function 1 Frame Ground Chassis ground and cable shield 2 Phase W Phase W input from drive 3 Phase V Phase V input from drive use for DC motor connection 4 Phase U Phase U input from drive use for DC motor connection 5 No connection D 2 5 Edge Filter Output J2 To Motor Mating Connector Description Euro style 4 positi
60. IENCOEF RPOWSNOULDULS ML C M 71 Primary Encoder Inputs 71 Analog Encoder Inputs quz Hall Switch Inputs 73 Resolver Interface 74 Multi Mode Port 75 Serial Interface 76 Network Interfaces IT Status Indicators 78 Fault Levels 78 Power Dissipation i 79 Thermal Impedance we 79 Mechanical and Environmental ccccccccccccccssssececececsesssseeeeecccesaeeeeeeecceeeseeeeeeseseaseeeececsesnsseeeeeseeseaseeeeeeseseqaeeeecseteeeeeeess 80 SDIMO MSIONS NN TETTE toD m E PMHet 81 Copley Controls 64 Xenus Plus User Guide 16 01344 Rev 01 3 1 Agency CE Compliant UL Compliant RoHS Compliant Approvals Standard XEL XPL XML XE2 XP2 XM2 800 1818 800 1819 UL UL 61010 1 Compliant UL 61800 5 1 Compliant Functional Safety Electrical safety IEC 61010 1 UL 61010 1 IEC 61508 1 IEC 61508 2 ISO 13849 1 ISO 13849 2 IEC 61800 5 2 IEC 61800 5 1 UL 61800 5 1 EMC IEC 55011 2009 A1 2010 CLA IEC 61000 6 1 2007 SEMI F47 0706 IEC 61800 3 2004 A1 2011 SEMI F47 0706 The Xenus Plus Dual Axis models comply with the requirements for immunity to low frequency disturbances specified in IEC 61800 3 2004 A1 2011 CE Declaration of Conformity available at http www copleycontrols com Motion Downloads xenusData
61. ML provides a suite of C libraries allowing a C application program to communicate with and control a drive over the CANopen network CMO provides a similar suite of COM objects that can be used by Visual Basic NET LabVIEW or any other program supporting the Microsoft COM object interface 1 4 Copley Virtual Machine CVM Copley Virtual Machine CVM is an embedded virtual programmable controller used to download Copley s Indexer 2 or CPL programs to Copley drives It is accessed via CME 2 and can be opened from CME 2 s main window 1 5 Indexer 2 Copley s Indexer 2 is an indexer configured and programmed using the tools built into CME 2 1 6 CPL CPL is Copley s high level programming language for writing custom CVM programs It expands on the features of Indexer 2 with interrupts and features that are faster and more flexible including looping and branching capabilities Copley Controls 13 Xenus Plus User Guide 16 0344 Rev 01 CHAPTER 2 OPERATIONAL THEORY This chapter describes the basics of Xenus Plus operation Contents include 2 1 Drive Power Architecture certet titer cadre eed rh idee Ee wei dba cheeses d RR ees 2 2 Operating Modes 2 3 Input Command Types 2 4 Communication 2 5 Status Indicators 2 6 Protection 2 7 Position and Velocity Errors ses 2 8 Inputs XEL XPL XML 2 9 In
62. NO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 Regen DC Bus to one side of regen resistor 2 N C No connection 3 Regen Collector of regen transistor to one side of regen resistor 4 N C No connection 5 Ground Enclosure ground and cable shield Regen Resistor Wiring Diagram Drive DC Bus 1 Regen Resistor Enclosure Fuses optional 1 FG ud Fuses may be required by local electrical codes Regen Resistor Fusing Recommended Fuses Regen Resistor Fuse type XTL RA 03 Cooper Bussman KLM 8 Littelfuse KLKDOOS8 Ferraz Shawmut ATM 10 or equivalent XTL RA 04 Cooper Bussman KLM 12 Littelfuse KLKD012 Ferraz Shawmut ATM 15 or equivalent User Supplied See Regen Resistor Sizing and Configuration p 132 Copley Controls 93 Xenus Plus User Guide 16 01344 Rev 01 4 4 2 J2 XE2 XP2 XM2 800 1819 With the exception of model 800 1818 the Xenus Plus Dual Axis models are provided with an integrated regen resistor that is pre wired and connected to J2 If a given application requires a higher capacity regen resistor then the user may disconnect the integrated resistor from J2 and connect an external resistor instead An external regen resistor may be used with model 800 1818 Connection details for both the integrated and external regen resistors are provided as follows Mating Connector
63. O Servo drive 20 40 A XML 230 40 HL Xenus Plus MACRO Servo drive 20 40 A with factory fitted low profile heatsink XML 230 40 HS Xenus Plus MACRO Servo drive 20 40 A with factory fitted standard heatsink XML 230 18 R Xenus Plus MACRO Servo drive 6 18 A with resolver feedback XML 230 18 R HL Xenus Plus MACRO Servo drive 6 18 A with resolver feedback and factory fitted low profile heatsink XML 230 18 R HS XML 230 36 R Xenus Plus MACRO Servo drive 6 18 A with resolver feedback and factory fitted standard heatsink Xenus Plus MACRO Servo drive 12 36 A with resolver feedback XML 230 36 R HL Xenus Plus MACRO Servo drive 12 36 A with resolver feedback and factory fitted low profile heatsink XML 230 36 R HS Xenus Plus MACRO Servo drive 12 36 A with resolver feedback and factory fitted standard heatsink XML 230 40 R XML 230 40 R HL Xenus Plus MACRO Servo drive 20 40 A with resolver feedback Xenus Plus MACRO Servo drive 20 40 A with resolver feedback and factory fitted low profile heatsink XML 230 40 R HS Xenus Plus MACRO Servo drive 20 40 A with resolver feedback and factory fitted standard heatsink NOTE Heatsink kits for field installation may be ordered separately XM2 Model Number Description XM2 230 20 Xenus Plus 2 Axis MACRO Servo drive 10 20 A encoder feedback XM2 230 20 R Xenus Plus 2 Axis MACRO Servo drive 10 20 A resolver feedback C
64. TN 23 S2 RTN S1 RTN S4 RTN connect to the input diode cathodes of the optical limit switches on 24 S3 RTN the motor 25 S4 RTN 26 N C No connection Copley Controls 119 Xenus Plus User Guide 16 01344 Rev 01 Optically Isolated Programmable Inputs Wiring Diagram XE2 XP2 XM2 800 1818 Opto isolators GND 24V m Opto isolators GND 24V IN16 uem v IN17 rr IN18 z 4 99 KQ A992 Tinira EN 1 Copley Controls 120 Xenus Plus User Guide 16 01344 Rev 01 Optically Isolated Programmable Inputs Wiring Diagram 800 1819 E eic usimcmum 6VISO Note 6VISO and ISOGND are from an internally generated non regulated and isolated power supply Note Wiring diagram for IN6 IN9 on the 800 1819 is the same as for the XE2 XP2 XM2 800 1818 Copley Controls 121 Xenus Plus User Guide 16 01344 Rev 01 Optically Isolated Programmable Outputs Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 tesedciessisticitestendesitiumssertamiatEE as 300mA SR OUTn min max ESTRE PEE E at 24 Vdc J9 Wiring Signal Pins Signal Pins OUT1 19 OUT1 10 OUT2 20 OUT2 11 OUT3 21 OUT3 12 OUT4 22 OUT4 13 OUT5 23 OUT5 14 Note Model 800 1819 does not have OUT4 and OUT5 Copley Controls 122 Xenus Plus User Guide 16 01344 Rev 01 4 11 Motor Feedba
65. XM2 800 1818 22 IN1 IN22 800 1819 20 IN1 IN20 IN1 11 21 22 IN2 5 12 15 IN6 9 16 19 IN10 20 Non isolated line receiver w RC filter Opto isolated bi Ket roveriem Type Schmitt trigger w RC programmable as 4 polar 2 groups of 4 Sianas on Coik yp filter 24Vdc max single ended or 2 with common for each g connectors differential Single group ended Input Voltage 0 Vdc 24 Vdc 0 12Vdc 15 30 Vdc 0 Vdc 24 Vdc Range Logie Law input Siena lt 2 3 Vdc lt 6 Vdc ave Voltage Logic High Input _ Voltage gt 3 15 Vde gt 2 7 Vdc gt 10 Vdc gt 3 15 Vde Scan Time 250 us Debounce Type Digital Digital Digital Digital Time Programmable 0 Programmable 0 Programmable 0 Programmable 0 10 000 ms 10 000 ms 10 000 ms 10 000 ms Function All programmable Note 800 1819 does not utilize IN21 22 and dedicates IN16 19 to optical limit switches of motors Copley Controls 69 Xenus Plus User Guide 16 01344 Rev 01 3 10 Analog Outputs XEL XPL XML Channels 1 Type Single ended Range 0 5 Vde Resolution 12 Bit NOTE There are no analog outputs available on XE2 XP2 XM2 800 1818 800 1819 drives 3 11 Digital Outputs XEL XPL XML Channels 6 OUT1 OUT6 OUT1 OUT 2 OUT3 OUTA OUT5 OUT6 Type Current sinking open drain MOSFET with High speed Opto isolated Opto isolated motor External flyback diode required if driving SVdc CMOS Darlingtons brake control ind
66. XTL FA 01 operates below maximum temperature values and thus requires no cooling fan When used with XEL XML XPL 40 drives running continuous currents greater than 12 Adc the XTL FA 01 should be cooled with an external fan The fan should have a flow rate of at least 110 CFM The filter has been tested using the Comair Rotron MD24B2 24 Vdc powered fan Fan Mounting Guidelines Most of the filter s heat is transferred to ambient air rather than through the heat plate Thus it is very important to mount the filter and fan in such a way that the fan can blow up through the filter s cover slots Mount the filter on edge and mount the fan below it so that it blows up through the cover slots There is no heatsink option for the XTL FA 01 edge filter Copley Controls 148 Xenus Plus User Guide 16 01344 Rev 01 D 1 5 XTL FA 01 Edge Filter Dimensions The following diagram shows the mounting dimensions of the XTL FA 01 Edge Filter 2 55 64 8 as 1 00 ie 25 4 LT 1 n i E N i s TIJSmpemegmggmemrmmrmrnm memes 1 Wy M6 M4 vy
67. Xenus Plus User Guide 16 01344 Rev 01 XPL J6 NET Indicator CANopen RUN and ERR States Network Status J6 The color blink codes of the NET indicator on J6 comply with CAN Indicator Specification CiA 303 3 as shown on the following pages 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 red green ACT ERR LEDs indicate the status of the physical layer The green ACT LED indicates physical connection and activity No connection or network errors show the red ERR LED In addition these are turned off when the CAN node ID selector CAN ADDR is set to 0 A setting of 0 which is invalid shuts down most operations on the CAN interface and the LEDs are shut off to indicate this status Copley Controls 45 Xenus Plus User Guide 16 01344 Rev 01 XPL J6 NET Indicator CANopen RUN and ERR States RUN Green LED CANopen State Machine Mode of Operation Indicator State Diagram Blinking green Pre operational 200 Steady green Operational green off Single flash green Stopped 1 second green off 200 ms ERR Red LED CANopen Physical Layer Status 1 second i Warning Limit p S a a a Single flash red Reached off 3 200 ms 1 second red Double flash red Error Control Event off d EH U ee 200 200 ms ms 1 second red Triple flash red Sync Error off a
68. ally isolated programmable inputs IN16 IN19 18 IN19 GPI Optically isolated programmable input 19 OUT 1 GPI Optically isolated programmable output positive signal 20 OUT2 GPI Optically isolated programmable output positive signal Copley Controls 118 Xenus Plus User Guide 16 01344 Rev 01 Continued Pin Description continued 21 OUT3 GPI 22 OUT4 GPI Optically isolated programmable output positive signal 23 OUT5 GPI 24 N C 25 N C No connection 26 N C 800 1819 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 IN6 GPI 3 IN7 GPI NE CPI Optically isolated programmable input 5 IN9 GPI 6 COM1 Common signal for first group of optically isolated programmable inputs IN6 IN9 7 IN16 GPI 8 IN17 GPI Optically isolated programmable input 9 IN18 GPI 10 OUT1 GPI 11 OUT2 GPI Optically isolated programmable output negative signal 12 OUT3 GPI 13 STA 14 S2 A S1 A S4 A signals are outputs driven by 453 ohm resistors that connect to an internal voltage source 6VISO These provide limited current to drive the input diode 1 S3_A anodes of optical limit switches on the motor 16 S4 A 17 N C No connection 18 IN19 GPI Optically isolated programmable input 19 OUT1 GPI 20 OUT2 GPI Optically isolated programmable output positive signal 21 OUT3 GPI 22 S1_R
69. 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 Increasing the duty cycle toward 100 commands a positive output and decreasing the duty cycle toward zero commands a negative output a Decreasing Duty Cycle Increasing Duty Cycle PWM Input 50 Duty Cycle Amplifier Output 0 Max The command can be inverted so that increased duty cycle commands negative output and vice versa 100 Duty Cycle Format Two Wire One input takes a PWM waveform of fixed frequency and variable duty cycle and the other input takes a DC level that controls the polarity of the output A 0 duty cycle creates a zero command and a 100 duty cycle creates a maximum command level The command can be inverted so that increasing the duty cycle decreases the output and vice versa 100 100 Duty Cycle Duty Cycle PWM Input Direction Input Max Amplifier Output 0 Min Failsafe Protection from 0 or 100 Duty Cycle Commands In both formats the drive can be programmed to interpret 0 or 100 duty cycle as a zero command This provides a measure of safety in case of a controller failure or a cable break Copley Controls 30 Xenus Plus User Guide 16 01344 Rev 01 2 3 3 Digital Input Three Formats In position m
70. at 400 mA each and in the XE2 XP2 XM2 800 1818 there are 4 encoder 5V outputs at 500 mA each Copley Controls 126 Xenus Plus User Guide 16 01344 Rev 01 Hall Switch Wiring Diagram Secale eases ave eee eee 5V 400 mA In XEL XPL XML there are two encoder 5V outputs at 400 mA each and in the XE2 XP2 XM2 800 1818 there are 4 encoder 5V outputs at 500 mA each Copley Controls 127 Xenus Plus User Guide 16 01344 Rev 01 Analog Sin Cos Encoder Wiring Diagram Drive 10k Q sin 121Q 10k Q AA pna 10k Q cos 10k Q pone 10k Q index 10k Q poe 5V 400 mA V J10 SIN i r i SIN Analog SIN Encoder INX E INX INX c E 3 X INX C 5 VDC Pod Encoder A pe ra v Frame Gnd q Ed Case Ground In XEL XPL XML there are two encoder 5V outputs at 400 mA each and in the XE2 XP2 XM2 800 1818 there are 4 encoder 5V outputs at 500 mA each Copley Controls 128 Xenus Plus User Guide 16 01344 Rev 01 Resolver Wiring Diagram Resolver Case Ground Resolver Wiring Diagram 800 1819 Resolver J10 J11 F G Resolver Interface Circuit Copley Controls 129 Xenus Plus User Guide 16 01344 Rev 01 Motor Over Temperature Wiring Diagram XEL XPL XML 12 bit 27 Hz A D LPF e Thermistor l Posistor or Switch Motor Over Temperature Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 J10 J11 Thermistor Posis
71. between the actual and the limited commanded Cp Current loop proportional 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 The integral of the current error is multiplied by this value Integral gain reduces the current error to zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral is the accumulated sum of the current error value over time Ci Current loop integral Current Loop Output The output of the current loop is a command that sets the duty cycle of the PWM output stage of the drive Auto Tune CME 2 provides a current loop Auto Tune feature which automatically determines optimal Cp and Ci values for the motor For more information see the CME 2 User Guide Copley Controls 21 Xenus Plus User Guide 16 01344 Rev 01 2 2 5 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 The velocity loop feedback signal is always from the motor feedback device even when an additional encoder is at
72. city modes they can 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 and Direction or Count Up Count Down format as well as A B quadrature commands from a master encoder Pulse to position ratio is programmable for electronic gearing e Asa node ona CANopen network CANopen compliance allows the drive to take instruction from a master application to perform torque velocity and position profiling interpolated position and homing operations Multiple drives can be tightly synchronized for high performance coordinated motion e Asa node on an EtherCAT or MACRO network e Asa stand alone controller running CVM control programs such as the Indexer 2 Program It can also be controlled directly over an RS232 serial link with simple ASCII format commands Mains input voltage to the drive can range from 100 to 240 Vac single or three phase and 47 to 63 Hz This allows Xenus Plus the ability to work in the widest possible range of industrial settings Several models are available with peak output current ratings of 18 to 40 Amps Copley Controls 11 Xenus Plus User Guide 16 01344 Rev 01 Model Data Continuous Standard Resolver Current pes dial Vac Adc Arms XEL 230 18 XEL 230 18 R XML 230 18 XML 230 18 R 6 4 24 18 12 7 XPL 230 18 XPL 230 18 R XEL 230 36 XEL 230 36 R XML 230
73. ck 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 over temperature 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 All feedback connectors have identical wiring specifications with the exception of the 800 1819 Mating Cable Connector Description Manufacturer PN Wire Size 26 Position High Density D Sub Male Solder Style Norcomp 180 026 103L001 24 30 AWG Connector Back shell Norcomp 979 015 020R121 Solder style connector included in Connector Kits XEL CK XE2 CK XPL CK XP2 CK XML CK and XM2 CK Pin connections for the bulkhead connector on the drive are shown here 10 Tc Noe 19 oOo oOo o9o oOo o0o 9 9 9 9 tt 26 lt 18 Copley Controls 123 Xenus Plus User Guide 16 01344 Rev 01 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 Vde Encoder and or Halls 5 Vdc power supply output Motor over temperatu
74. copley G3 controls Xenus Plus User Guide if a 2 J3 H d i34vs E ite A E NN ne en t yy i 7 P 2 E v Az P N 16 01344 Revision 01 April 2 2015 Xenus Plus User Guide 16 01344 Rev 01 This page for notes Xenus Plus User Guide 16 01344 Rev 01 TABLE OF CONTENTS p nIDABILCS urim 5 1 Introduction 1 1 Xenus Plus Family Overview wa 11 1 2 CME 2 ineunda neri ce 2 12 TSP CML OMO ccs s 43 1 4 Copley Virtual Machine CVM wae 13 WO AMGOKCR 2idetec ee C wn T 13 joo lc SER 13 2 Operational Theory 14 2 1 Drive Power Architecture w 19 2 2 Operating Modes asasan eds 17 2 3 Input Command Types inasra a aa aii aadis Nakaa ia aada eaa a a aN aE Ea pE Eaa R 28 2 4 Communication 93 2 5 Status Indicators 38 2 6 Protection eee 50 2 7 Position and Velocity Errors 292 2 8 Inputs XEL XPL XML een 255 2 9 Inp ts XE2 XP2 XM2 800 1818 800 1819 iria di e te c pe esa ce tace Ee eat de et Meere REAA EAE EAN EiT 56 271102 Outputs EPiUBPA 58 2 11 Outputs XE2 XP2 XM2 800 1818 800 1819 58 2 12 Brake Operation ssssssssssss 58 2
75. d Signals A A B B X X S S for each axis Input Voltage Range 7 Vdc Differential Input Threshold 0 2 Vdc A and B Channels None Termination Resistance X Channel 130 Q with 1 kQ pull up to 5V on X and 1 kQ pull down on X S Channel 221 Q with 1 KQ pull up to 5V on S and 1 kQ pull down on S Output Mode Buffered primary incremental encoder Function Emulated incremental or serial encoder from analog encoder or resolver Programmable Input Mode Secondary digital quadrature input Current Velocity mode PWM input Position Mode Digital command input Maximum Frequency Output Mode Buffered Encoder 5 MHz Line 20 Mcount sec Emulated Encoder 4 5 MHz Line 18 Mcount sec Input Mode PWM Input 100Khz Digital Command 5 MHz 50 Duty Cycle Secondary Encoder 5 MHz Line 20 Mcount sec Copley Controls 75 16 01344 Rev 01 Xenus Plus User Guide 3 18 Serial Interface XEL XPL XML Channels 1 Type RS 232 DTE Signals Rxd Txd Gnd Baud Rate 9 600 to 115 200 defaults to 9600 on power up or reset Data Format N 8 1 Flow Control None Protocol Binary or ASCII format Function Set up control and diagnostics status XE2 XP2 XM2 800 1818 800 1819 Copley Controls Channels 1 Type RS 232 DTE Signals Rxd Txd Gnd Baud Rate 9 600 to 115 200 defaults to 9600 on power up or reset Data Format N 8 1 Flow Control None Protocol Binary or ASCII forma
76. e 16 01344 Rev 01 3 14 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 0 6 Vdc Input to Ground 0 to 3 5 Vdc Differential Input Impedance 121 0 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 XE2 XP2 XM2 800 1818 Channels 4 Type Differential non isolated Signals Sin Sin Cos Cos for each axis Nominal Voltage 1 Vpk pk Maximum Voltage Differential 0 6 Vdc Input to Ground 0 to 3 5 Vdc Differential Input Impedance 121 0 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 NOTE There is no Analog Encoder feedback on 800 1819 drives Copley Controls 72 Xenus Plus User Guide 16 01344 Rev 01 3 15 Hall Switch Inputs XEL XPL XML Channels 3 U V and W 74HC14 Schmitt trigger w RC Filter Type Input Voltage Range 10 kQ pull up resistor to internal 5 Vdc 0 Vdc 24 Vdc Low Level Input Voltage 1 35 Vdc High Level Input Voltage gt 3 65 Vdc Timing Edge detection RC Filter Time Constant 1 us wh
77. e s enable input or though software commands After re enabling the drive will operate normally Drive Response to a Latched Following Error Fault When a latched following error fault occurs the drive disables the output PWM stage without first attempting to apply a deceleration rate Resuming Operations After a Latched Following Error Fault A latched following error fault can be cleared using the steps used to clear other latched faults e Power cycle the 24 Vdc to the drive e Cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e irj Access the CME 2 Control Panel and press Clear Faults or Reset e Clear the fault over the CANopen network or serial bus Copley Controls 53 Xenus Plus User Guide 16 01344 Rev 01 2 7 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 The bit is not reset until the error remains within the tracking window for the programmed tracking time Velocity Tracking Illustration The following diagram illustrates the use of tracking window and time settings in velocity mode Actual Velocity Limited Velocity S
78. e an encoder attached to the load provides position loop feedback and the motor encoder or resolver provides velocity loop feedback 2 2 3 Control Modes and 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 In velocity mode the velocity loop drives the current loop In current mode the current loop is driven directly by external or internal current commands Copley Controls 17 Xenus Plus User Guide 16 01344 Rev 01 www MM MM MMM MM wm em ww www www eww ew ew 9 POSITION LOOP ACTUAL MOTOR POSITION POSITION LIMITED POSITION ERROR POSITION ERROR PROFILE AND FEEDFORWARD POSITION O DRIVE VELOCITY LOOP TRAJECTORY GENERATOR PROFILE ACCELERATION S PROFILE VELOCITY VELOCITY LOOP Velocity Limits ACTUAL ax Accel vetocity dT Max Velocity LIMITED VELOCITY ecel VELOCITY Abort Decel ER COMMANDED VELOCITY COMMAND Y FILTER VELOCITY LIMITS COMMANDED CURRENT p e e e eee c e c c Gm Gm Gm GOD GOD GOD GO FF A Current Limits Peak CURRENT LOOP Continuous 6
79. e outputs OUT6 7 are opto isolated and referenced to the 24V return Outputs OUT 1 5 are two terminal MOSFET SSRs The CAN interface is optically isolated Deriving internal operating voltages from a separate source enables the drive to stay on line when the mains have been disconnected for emergency stop or operator intervention conditions This allows CAN bus and serial communications to remain active so that the drive can be monitored by the control system while the mains power is removed 2 1 2 High Voltage Mains power drives the high voltage section It is rectified and capacitor filtered to produce the DC bus the DC link power that drives the PWM inverter where it is converted into the voltages that drive a three phase brushless or DC brush motor 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 This prevents charging the internal capacitors to an overvoltage condition Copley Controls 15 Xenus Plus User Guide 16 01344 Rev 01 2 1 3 Power and Isolation 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 dr
80. e CME 2 User Guide For more information on CANopen operations see the following Copley Controls documents e CANopen Programmer s Manual e CML Reference Manual e CMO Copley Motion Objects Programmer s Guide Copley Controls 35 Xenus Plus User Guide 16 01344 Rev 01 2 4 2 EtherCAT Communication Details XEL XE2 800 1818 800 1819 The XEL XE2 800 1818 800 1819 models accept CAN application layer over EtherCAT CoE commands EtherCAT supports two types of addressing nodes on the network auto increment and fixed Nodes on an EtherCAT network are automatically addressed by their physical position on the network The first drive found on the network is address 1 OxFFFF The second is 2 OxFFFE and so on Fixed addresses are assigned by the master when it scans the network to identify all of the nodes and are independent of the physical position on the network Fixed addresses begin with 1001 Ox3E9 and increment thereafter as nodes are found Each dual axis drive is addressed as a single physical node on the EtherCAT network having two axes of motion a Software Application Master Contgroller EtherCAT rh aL 2222 22 EtherCAT n a 2222 22 EtherCAT Device EtherCAT Device ID 0x1003 As an alternate to the default addressing switches S1 and S2 may be used to program a drive s Device ID or Station Alias with a value between 0x01 and OxFF 1 255 decimal In dual axis drives the seco
81. e 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 STO Xenus Plus Bypass Connections HV Motor H Low Side PWM J Ouputs T i STO 1 STO 2 DIAG ON 8 Signal ground LO 424v Output From 24V input on J4 3 e e e Copley Controls 100 Xenus Plus User Guide 16 01344 Rev 01 4 7 2 XE2 XP2 XM2 800 1818 800 1819 J6 The following information is for XE2 XP2 XM2 and 800 1819 drives only Mating Connector AU NI Description Manufacturer PN Wire Size Connector D Sub 9 position standard AMP Tyco 205204 4 AMPLIMITE HDP 20 Crimp Snap contacts 24 20AWG sel AMP Tyco 66506 9 24 20AWG Backshell D Sub RoHS metallized for J6 Norcomp 979 009 020R121 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 STO 1 STO 1 Input 3 STO 1 4 STO 2 STO 2 Input 5 STO 2 6 STO 1 STO 1 Input Pins 2 amp 6 and pins 3 amp 7 are connected together inside the drive This second set of connectio
82. e equipment damage injury or death Copley Controls 50 Xenus Plus User Guide 16 01344 Rev 01 Clearing Latched Faults A latched fault is cleared only after the fault has been corrected and at least one of the following actions has been taken e Power cycle the 24 Vdc to the drive e Cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e irj Access the CME 2 Control Panel and press Clear Faults or Reset e Clear the fault over the CANopen network or serial bus Example Non Latched vs Latched Faults For example the drive temperature reaches the fault temperature level and the drive reports the fault and disables the PWM output Then the drive temperature is brought back into operating range If the Drive Over Temperature fault is not latched the fault is automatically cleared and the drive s PWM outputs are enabled If the fault is latched the fault remains active and the drive s PWM outputs remain disabled until the faults are specifically cleared as described above Fault Descriptions e The set of possible faults is described below For details on limits and ranges see Fault Levels p 78 Fault Description Drive Over Temperature Fault Occurs When Drive s internal temperature exceeds specified temperature Fault is Corrected When Power module temperature falls below specified temperature Motor Phasing Err
83. e only Fast Stop Ramp Specifies the deceleration rate used by the velocity loop when the drive is hardware disabled Fast stop ramp is not used when drive is software disabled If the brake delay option is programmed the fast stop ramp is used to decelerate the motor before applying the brake Note that Fast Stop Ramp is used only in velocity mode In position mode the trajectory generator handles controlled stopping of the motor There is one exception if a non latched following error occurs in position mode then the drive drops into velocity mode and the Fast Stop Ramp is used For more information see Following Error Fault Details p 53 Diagram Effects of Limits on Velocity Command The following diagram illustrates the effects of the velocity loop limits Limited Velocity Commanded Velocity Vel Limite Copley Controls uu aa l Accel Limit H Decel Limit 23 Xenus Plus User Guide 16 01344 Rev 01 Velocity Loop Gains The velocity loop uses these gains Gain Description The velocity error the difference between the actual and the limited commanded Vp Velocity loop proportional velocity is multiplied by this gain The primary effect of this gain is to increase bandwidth or decrease the step response time as the gain is increased The integral of the velocity error is multiplied by this value Integral gain reduces the velocity error t
84. eaving the maximum acceleration set to zero will prevent other position modes from operating correctly The following diagram summarizes the position loop Pe ree a a a a a au ee ee A eee X A A X X Au X A A A A e X A A a ee eee eee ee e I POSITION LOOP ACTUAL MOTOR POSITION LIMITED ERROR POSITION POSITION ERROR PROFILE AND FEEDFORWARD POSITION DRIVE VELOCITY LOOP TRAJECTORY GENERATOR MASON J V PROFILE VELOCITY VELOCITY LOOP Velocity Limits ACTUAL Accel a VELOCITY dT Max Velocity LIMITED VELOCITY Decel VELOCITY ERROR Abort Decel COMMANDED i MEUM commanp T FILTER VELOCITY LIMITS OUTPUT COMMANDED CURRENT eee er eee eee eee eee eee e e P I Current Limits i To CURRENT LOOP reak E T Continuous A 12T Q 9 9 6 r h INPUT INPUT E S 1 FILTER FILTER re c I 1 I Inertia I I il CURRENT 1 OFFSET LIMITED ACTUAL i CURRENT CURRENT b e e a e a e e e e a i e e e a e e e e Idd go e e ew eee uA uA Gu Gu Gu eee ee Fg Copley Controls 25 Xenus Plus User Guide 16 01344 Rev 01 Trajectory Limits In position mode the trajectory generator applies the following user set limits to generate the motion profile Limiter Description Maximum Velocity Limits the maximum speed of the profile Maximum Acceleration Limits the maximum acceleration rate of the pr
85. emp switches and have fixed pull ups to 5 Vdc and 330 us RC filters to Schmitt triggers These are found on the feedback connectors for Axis A IN10 and Axis B IN20 The 800 1819 does not utilize IN21 and IN22 and dedicates IN16 19 to the output of optical limit switches mounted on motors For a list of input functions see the CME 2 User Guide Input Filters Two types of input RC filters are used GP general purpose and HS high speed Input reference functions such as Pulse and Direction Pulse Up Pulse Down and Quadrature A B are wired to inputs that have the HS filters and inputs with the GP filters are used for general purpose logic functions limit switches and the motor temperature sensor Debounce Time To prevent undesired multiple triggering caused by switch bounce upon switch closures each input can be programmed with a debounce time The programmed time specifies how long an input must remain stable at a new state before the drive recognizes the state The debounce time is ignored if the input is used as a digital command input Configure for Pull Up Pull Down Resistors by Groups Pre defined groups of inputs can be programmed to have either an internal pull up or pull down resistor 2 9 2 Limit Switches 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 2
86. en driven by active sources Commutation of brushless motors in trapezoidal mode Funetion Commutation initialization and phase error detection in sinusoidal mode XE2 XP2 XM2 800 1818 Channels 6 U V and W for each axis 74HC14 Schmitt trigger w RC Filter Type 10 kQ pull up resistor to internal 5 Vdc Input Voltage Range 0 Vdc 24 Vdc Low Level Input Voltage lt 1 35 Vdc High Level Input Voltage gt 3 65 Vdc Timing RC Filter Time Constant Edge detection 1 us when driven by active sources Function Commutation of brushless motors in trapezoidal mode Commutation initialization and phase error detection in sinusoidal mode NOTE Digital Halls not supported 800 1819 drives Copley Controls 73 Xenus Plus User Guide 16 01344 Rev 01 3 16 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 Reference Max Current 100 mA Max RPM 20 000 Incremental or analog encoder or resolver required for sinusoidal commutation Function and position or velocity modes of operation XE2 XP2 XM2 Channels 6 Type Transmit 1 1 to 2 1 transformation ratio
87. energy absorption is shared with both axes If the deceleration energy is less than the 120 145 absorption capacity of the drive then a regeneration resistor will not be used because the bus voltage will not rise enough to hit the over voltage level that 200 85 would disable the PWM outputs 240 43 E Energy Joules Watt seconds J Rotary Moment of Inertia kg m P Power Watts locity Step 1 Find the energy of motion for a rotating load for this example let it be 75 Joules E J RPM 182 75J Step 2 Subtract the absorption at your mains voltage to get the energy that must be dissipated in the regen resistor during the Regen Time Use 240 Vac 75J 43J 32 J Step 3 Divide the regen energy by the continuous power rating of 20 Watts to get the dwell time that can dissipate the regen energy in the resistor Dwell Time 32 Joules 20 Watts 1 6 sec Step 4 Find the total regen cycle time by adding the deceleration time to the dwell time Regen Time 1 25 sec Dwell Time 1 60 sec Cycle Time 2 85 sec Internal Regen Resistor Ratings Max Energy 100 W s J Resistance 18W Power continuous 20 W Power peak 70 W Time 2000 ms Copley Controls Decel time Absorption Internal Regen Velocity Bus Voltage Regen Active Regen Dwell Time a Regen E Cycle Time Energy Balance Regen Peak Cycle Time e Power Continuous Power Regen La
88. enmork Tel 45 44528100 Person Authorized to compile technical file Jens Rasmussen Director of Quality BK Medical ApS Analogic Corporation d b a Copley Controls 20 Dan Road Canton MA 02021 781 828 8090 www copleycontrols com 16 01368 revOO 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 Copley Controls 6 Xenus Plus User Guide 16 01344 Rev 01 Related Documentation For important setup and operation information see the CME 2 User Guide Under Using CME2 here http Awww copleycontrols com Motion Downloads software html Users of the CANopen features should also read these Copley Controls documents e CANopen Programmer s Manual e CMO Copley Motion Objects Programmer s Guide e CML Reference Manual And this guide for MACRO network users e MACRO Network User Guide Also of related interest e Indexer 2 Program User s Guide describes use of Indexer Program to create motion control sequences e ASCII Programmer s Guide describes how to send ASCII format commands over a drive s serial bus to set up and control one or more drives Copley Amplifier Parameter Dictionary Copley Camming User Guide Copley Controls Serial Encoder Guide CPL User Guide e Xenus Plus Dual Axis STO Manual Links to these publications along with other documents data sheets and software releases can be found at http
89. erssesieets 80 3 25 DIMOMSIONS m 81 4 Wiring encre eeu ere 84 4 1 General Wiring Instructions 85 4 2 AC Mains J1 88 4 3 Motor s iiciin iina 2 91 4 4 Regen Resistor Optional 23 49 4 5 Logic Supply Brake noie niter eie tete eol eer v espe eae reb Gants ee b Ul ae eel EX MEE E era 96 4 6 Ferrules XE2 XP2 XM2 800 1818 800 1819 ssssssssssssssseseeeneenennee nennen nennen tretne rnit re trennen erret nnne nns 98 4 7 Safe Torque Off ssssssssssssssssss 99 4 8 RS 232 Serial Communications 103 4 9 Network Ports 104 4 10 Control I O 107 4 11 Motor Feedback ssess 123 A Regen Resistor Sizing and Config ration 2 cierre rtc uui ruunt run caer ea scdsteceoeaateadenasrousdesedevecseuestesdezueyscvecckverteniecedceed 132 A T Sizing a nre T as 5319 ERR TETTE DR 133 B T Time Limit Algorithm B 1 T Algorithm a 620 oT OE TETTE o 34 UP LET ERE ELE 141 C 1 Operating Temperature and Cooling Configurations cccccccceeeeeeeeeeceeeseeeeeeeaeeeseaeeeeceaaeeesaeeeeeaeeeseeeeseeaeeesecaeeeseneeeseaees 142 C 2 Heatsink Mounting Instructions XEL XPL XML 145 D XenusPlusFilter eene 146 BE Exo Um
90. es Exercise caution when installing and adjusting Persons responsible for installing and commissioning Xenus Plus servo drives must be experienced in all aspects of electrical DANGER equipment installations Failure to heed this warning can cause equipment damage injury or death Risk of electric shock Wait 5 minutes after disconnecting mains power before handling High voltage circuits connected to mains power After disconnecting mains power wait 5 DANGER minutes before handling drive to allow for discharge of internal DC bus capacitance XEL XPL XML J1 J2 J3 XE2 XP2 XM2 800 1818 800 1819 J1 J2 J3 and J4 Failure to heed this warning can cause equipment damage injury or death 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 DANGER Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against unexpected motion Failure to heed this warning can cause equipment damage injury or death gt Using CME 2 or serial commands may affect or suspend CANopen operations gt When operating the drive as a CANopen node the use of CME 2 or ASCII serial DANGER commands may affect CANopen operations in progress Using such comma
91. ey Controls 60 Xenus Plus User Guide 16 01344 Rev 01 2 13 Regen Resistor Theory 2 13 1 XEL XPL XML 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 The remainder of the energy is added to the electrical energy already stored in the internal capacitor bank of the drive The result of this energy being added is an increase in the voltage on the capacitor bank External Regen Resistor If too much energy is added to the capacitor bank the voltage rises to a point where the drives over voltage protection shuts down the drive To prevent this an internal transistor switch can drive an external regen resistor to dissipate the regen energy so that the internal bus voltage is limited to a value that permits the continued operation of the drive PWM outputs Regen Circuit Components The drive provides an internal transistor that is used in combination with an external resistor Copley Controls supplies compatible resistors as described in Regen Resistor Assemblies p 162 When using a resistor acquired from another source be sure it meets the specifications described in Regen Resistor Sizing and Specification p 132 Regen Circuit
92. filter allows advanced users to define their own filters incorporating two poles and two zeros For more information on the velocity loop filters see the CME 2 User Guide Velocity Loop Outputs The output of the velocity loop is a current command used as the input to the current loop Copley Controls 24 Xenus Plus User Guide 16 01344 Rev 01 2 2 6 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 When using the CAN bus serial bus or CVM Control Program a trapezoidal or S curve profile can be programmed The trajectory generator updates the calculated profile in real time as position commands are received The output of the generator is an instantaneous position command limited position In addition values for the instantaneous profile velocity and acceleration are generated These signals along with the actual position feedback are processed by the position loop to generate a velocity command To bypass the trajectory generator while in digital or analog position modes set the maximum acceleration to zero The only limits in effect will now be the velocity loop velocity limit and the current limits Note that l
93. g or falling edge of the signal Stepping resolution can be programmed for electronic gearing Quadrature Format In quadrature format A B quadrature commands from a master encoder via two inputs provide velocity and direction commands as shown below A Input OSUL TUL B Input TIILO TITUL LO Velocity Command The ratio can be programmed for electronic gearing Copley Controls 32 Xenus Plus User Guide 16 01344 Rev 01 2 4 Communication As described below the drive features multiple communication interfaces each used for different purposes Interface Description 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 RS 232 port over this link for drive commissioning adjustments and diagnostics For RS 232 port specifications see Serial Interface p 76 For RS 232 port wiring instructions see RS 232 Serial Communications p 103 Note that CME 2 can be used to make adjustments even when the drive is being controlled over the CAN interface or by the digital inputs CAN interface XPL XP2 When operating as a CAN node the drive takes command inputs over a CANopen network CAN communications are described in the next section EtherCAT XEL XE2 800 1818 800 1819 XEL XE2 800 1818 800 1819 accepts CANopen commands over Et
94. gle Phase XEL XPL XML Keep wire length Heatplate as short as eS possible Not to exceed 1 m 3 28 ft CE LINE FILTER L2 AC MAINS 100 240 Vac Li 19 Line filter Filter Concepts SF20L or equivalent used for CE compliance Earth Ground a lem Fuse not required on neutral N line Copley Controls 88 Xenus Plus User Guide 16 01344 Rev 01 AC Mains Wiring Diagram Three Phase XEL XPL XML Keep wire length Heatplate as short as oo SSS SSS SS possible Not to exceed 1 m 3 28 ft ce AC MAINS 100 240 Vac 30 Line filter Filter Concepts 3F15F or equivalent used for CE compliance Protective Grounding Earth Ground tab 4 2 2 XE2 XP2 XM2 800 1818 800 1819 Mating Connector Description Euro style 5 08 mm pluggable female terminal block Manufacturer PN Wago 231 305 107 000 Note 1 Wire size 22 12 AWG 12 AWG 600 V Recommended Wile Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 or 231 291 Connector and tool are included in Connector Kits XE2 CK XP2 CK and XM2 CK Note 1 For RoHS compliance append RNO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 L1 AC power input hot or L1 2 L2 AC power input neutral or L2 3 PE ground Chassis safety ground 4 Frame ground Frame ground
95. he edge filter can increase rise time to 500 ns reducing the high frequency noise emissions by the square law The differential filter is designed with 82 uH inductors and a proprietary passive circuit The inductance will provide a total of 164uH in series with the load helping to reduce ripple current This brings low inductance motors into the required range The common mode filter is designed with a 220 uH common mode toroid that works with the cable capacitance to earth ground to remove common mode switching noise Filter 82uH u Ed 82uH t NNi 82uH Common Differential Mode eT Raw PWM Filtered Copley Controls 147 Xenus Plus User Guide 16 01344 Rev 01 D 1 3 XTL FA 01 Edge Filter Specifications Voltage maximum 373 Vdc me Current maximum 20 Adc Voltage maximum 373 Vdc Output Current maximum 20 Adc Peak Current Peak Current Time 40 Adc for 1 second Rise Fall Time 500 ns typical Differential Mode Inductance 82 uH per phase 162 uH phase phase nominal Common Mode Inductance 220 UH nominal Nominal Resistance 27 milliohms per leg 54 milliohms phase phase nominal Agency Approvals UL508C EN60204 RoHS Weight 1 Ib 11 oz D 1 4 Thermal Considerations Cooling Requirements When used with XE2 XP2 XM2 230 20 800 1818 800 1819 XEL XML XPL 230 18 or XEL XML XPL 230 36 drives the
96. he energy being delivered to the motor using the I T Accumulator Variable The value stored in the I T Accumulator Variable is compared with the I T setpoint that is calculated from the user entered Peak Current Limit IT Time Limit and Continuous Current Limit Whenever the energy delivered to the motor exceeds the T setpoint the algorithm protects the motor by limiting the output current or generates a fault B 1 2 IT Formulas and Algorithm Operation Calculating the I T Setpoint Value The IT setpoint value has units of Amperes seconds A S and is calculated from programmed motor data The setpoint is calculated from the Peak Current Limit the I T Time Limit and the Continuous Current Limit as follows T setpoint Peak Current Limit Continuous Current Limit I T Time Limit I T Algorithm Operation During drive operation the I T algorithm periodically updates the IT Accumulator Variable at a rate related to the output current Sampling Frequency The value of the IT Accumulator Variable is incrementally increased for output currents greater than the Continuous Current Limit and is incrementally decreased for output currents less than the Continuous Current Limit The I T Accumulator Variable is not allowed to have a value less than zero and is initialized to zero upon reset or 24 Vdc logic supply power cycle Accumulator Increment Formula At each update a new value for the I T Accumulator Variable is calculated as follows
97. herCAT MACRO XML XM2 The XML XM2 typically runs in torque mode accepting commands over the MACRO network Velocity mode is also supported Using CME 2 can affect or suspend CAN operations DANGER When operating the drive as a CANopen node use of CME 2 to change drive parameters can affect CANopen operations in progress Using CME 2 to initiate motion can cause CANopen operations to suspend The operations may restart unexpectedly when the CME 2 move is stopped Failure to heed this warning can cause equipment damage injury or death Copley Controls 33 Xenus Plus User Guide 16 01344 Rev 01 2 4 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 These profiles specify how various types of devices including motion control devices can use the CAN network in a highly efficient manner Xenus Plus supports the relevant CANopen profiles allowing it to operate in the following modes of operation profile torque profile velocity profile position interpolated position and homing Supported CANopen Modes Profile Position Mode 1 The drive is programmed with
98. hercat network cable 10 ft 3m J8 Network XE2 NC 01 1 Ethercat network cable 1 ft 0 3 m Note 1 For RoHS compliance append RNO1 0000 to the Wago part numbers listed above Note 2 Insertion extraction tool for J6 contacts is AMP Tyco 91067 2 not included in XP2 CK Copley Controls 160 Xenus Plus User Guide 16 01344 Rev 01 CANopen Connector Kit XPL XP2 Model Qty Ref Description 1 J7 Sub D 9 position female to RJ 45 adapter XPL NK 1 7 CAN bus Network Cable 10 ft 3 m 1 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 CAN bus Network Cable for XPL 10 ft 3 m XPL NC 01 J7 CAN bus Network Cable for XPL 1 ft 0 3 m XPL NT CAN bus Network Terminator for XPL XEL NC 10 J EtherCAT Network Cable for XEL 10 ft 3 m XEL NC 01 EtherCAT Network Cable for XEL 1 ft 0 3 m XP2 NC 10 J8 CANopen network cable for XP2 10 ft 3 m XP2 NC 01 CANopen network cable for XP2 1 ft 0 3 m XP2 NC 10 J8 CANopen network cable for XP2 10 ft 3 m XP2 NC 01 CANopen network cable for XP2 1 ft 0 3 m F 3 Heatsink Kits XE2 XP2 XM2 models have integral heatsinks and cooling fans The heatsink k
99. ic side of the drive to stay powered This allows the drive to retain position information and maintain communication through the digital I O or over the serial or CAN EtherCAT or MACRO ports when disconnected from the mains The Xenus Plus models are RoHS compliant 1 2 CME2 Drive commissioning is fast and simple using Copley Controls CME 2 software CME 2 communicates with Xenus Plus via an RS 232 CANopen or EtherCAT link and all of the operations needed to configure the drive are accessible through CME 2 The multi drop feature allows CME 2 to use a single RS 232 serial connection to one drive as a gateway to other drives linked together by CAN bus connections Auto phasing of brushless motor Hall sensors and phase wires eliminates wire and try Connections are made once and CME 2 does the rest Encoder or resolver wire swapping to establish the direction of positive motion is also eliminated Motor data can be saved as CCM files Drive data is saved as CCX files that contain all drive settings plus motor data This makes it possible to quickly set up drives by copying configurations from one drive to another Copley Controls 12 Xenus Plus User Guide 16 01344 Rev 01 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 C
100. ion table use the following formula to determine the energy that can be absorbed by the drive Weapacity V C Viegen S 1 414 M anne Where Weapacity The energy that can be absorbed by the bus capacitors in Joules C Bus capacitance in Farads Viegen Voltage at which the regen circuit turns on in volts Vmains Mains voltage applied to the drive in volts AC A 1 7 Calculate Energy to be Dissipated for Each Deceleration For each deceleration where the energy exceeds the drive s capacity use the following formula to calculate the energy that must be dissipated by the regen resistor E regen E retumed zx Eamp Where Eegen Energy that must be dissipated in the regen resistor in Joules Eretunea Energy delivered back to the drive from the motor in Joules Eamp Energy that the drive will absorb in Joules A 1 8 Calculate Pulse Power of Each Deceleration that Exceeds Drive Capacity For each deceleration where energy must be dissipated by the regen resistor use the following formula to calculate the pulse power that will be dissipated by the regen resistor Pouise E regen Taecel Where Pouse Pulse power in Watts Eegen Energy that must be dissipated in the regen resistor in Joules Tuecel Time of the deceleration in seconds A 1 9 Calculate Resistance Needed to Dissipate the Pulse Power Using the maximum pulse power from the previous calculation calculate the resistance value of the regen resistor required to dis
101. ired for continuous power output Size XE2 XP2 XM2 800 1818 800 1819 XE2 XP2 XM2 800 1819 9 24 in 234 7 mm X 5 42 in 137 6 mm X 3 59 in 91 1 mm 800 1818 9 24 in 234 7 mm X 5 57 in 141 6 mm X 2 31 in 58 7 mm Weight Ambient Temperature XE2 XP2 XM2 800 1819 4 19 Ib 1 90 kg 800 1818 3 13 Ib 1 42 kg Contaminants Storage 40 to 85 C Operating 0 to 40 C Humidity 0 to 95 non condensing Pollution degree 2 Ingress Protection IP20 Vibration 2 g peak 10 500 Hz sine IEC60068 2 6 Shock 10 g 10 ms half sine pulse IEC60068 2 27 Environment IEC68 2 1990 Cooling XE2 XP2 XM2 800 1819 Integrated heatsink and cooling fan provide required cooling 800 1818 Dependent on mounting orientation and ambient airflow Copley Controls 80 Xenus Plus User Guide 16 01344 Rev 01 3 25 Dimensions 3 25 1 XEL XPL Dimensions 7 92 201 17 EE RP d islata i R 094 2 37 TYP 1 29 32 69 T P Cl 5 12 130 07 1 Plus 3 00 76 20 XENUS a el p s HP am ais a NE pr T mT PETS 190 1 H 24 6 12 Chassis 7 54 191 52 S S grounding 19 4 83 z tab H ja is E S 1 00 25 40 Jaaa
102. it MAX 3097 lt Copley Controls 109 Xenus Plus User Guide 16 01344 Rev 01 Analog Input Wiring Diagram VCMD REF AIN 7 Gi T REF AIN2 REF AIN2 Measurement Frame gnd Copley Controls 110 Xenus Plus User Guide 16 01344 Rev 01 4 10 2 Isolated Control XEL XPL XML J9 Mating Connector Description Manufacturer PN Wire Size 15 Position High density D Sub male solder cup Nelle 1807019 24 30 AWG Backshell Norcomp 979 009 020R121 Solder style connector included in Connector Kits XEL CK XML CK and XPL CK Pin connections for the bulkhead connector on the drive are shown here 6 1 11 5 15 10 J9 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 COMM_A Common signal for first group of optically isolated programmable inputs 3 IN7 GPI 4 IN8 GPI 5 INO GPI Optically isolated programmable input 6 IN10 GPI 7 COMM B Common signal for second group of optically isolated programmable inputs 8 IN11 GPI 9 IN12 GPI i 10 IN13 GPI Optically isolated programmable input 11 IN14 GPI 12 OUT5 GPI Optically isolated programmable output positive signal 13 OUT5 GPI Optically isolated programmable output negative signal 14 OUT4 GPI Optically isolated programmable output positive signal 15 OUT4 GPI
103. it Yellow Description On Off Port open no activity On Flicker Port open network activity Off On Port closed Copley Controls 39 Xenus Plus User Guide 16 01344 Rev 01 2 5 3 XE2 800 1818 800 1819 J7 Axis A B Drive Status Indicators Drive Status vom ene SM ca V4 jo S NINMVA XE2 800 1818 800 1819 J7 Axis A B Drive Status Indicators XE2 800 1818 800 1819 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 Green Fast Blinking Positive or Negative limit switch active Drive will only move in direction not inhibited by limit switch Green flash twice STO is active One or both STO inputs are de energized The drive is hardware amp software followed by a pause enabled but the PWM outputs cannot produce current in the motor when STO is active Red Solid Transient fault condition Drive will resume operation when fault is removed Red Blinking Latching fault Operation will not resume until fault is cleared or drive is Reset Copley Controls 40 Xenus Plus User Guide 16 01344 Rev 01 2 5 4 XE2 800 1818 800 1819 J8 Network Status Indicators fe seta 14 jn ONINMVAM m Network Status XE2 800 1818 800 1819 J8 L A Indicators Shows the state of the physical link and activity o
104. its for XEL XPL XML models are optional and provide cooling when required by the installation XEL XPL XML Low Profile Model Qty Description XEL HL 1 Heatsink low profile XPL HL 1 Heatsink thermal material AMEME 1 Heatsink hardware mounting kit XEL XPL XML Standard Model Qty Description XEL HS 1 Heatsink standard XPL HS 1 Heatsink thermal material AME HS 1 Heatsink hardware mounting kit These kits contain the parts needed for field installation of a heatsink Copley Controls 161 Xenus Plus User Guide 16 01344 Rev 01 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 XM2 230 20 800 1819 For more information see Regen Resistor data sheet http www copleycontrols com Motion Downloads xenusPlusData html F 5 Edge Filter Model Description XTL FA 01 Xenus Plus Edge Filter XTL FA 01 Edge Filter Connector Kit for all Xenus Plus models Model Qty Ref Description Mfr Model No 1 J1 Plug 5 position 5 0 mm female Wago 721 104 026 047 XTL FK 1 J2 Plug 4 position 5 0 mm female Wago 721 105 026 047 2 Insertion Extraction Tool Wago 231 131 Note 1 For ROHS compliance append RN01 0000 to the Wago part numbers listed above
105. ive models are essentially duplicates of the first The second motor power connections originate from a second PWM inverter in the Mains circuit block and the second motor feedback connections originate from a second set of Feedback Power and Decoding circuitry in the Signal GND referenced block i SHIELD FRAME GROUND REGEN REGEN r wtf aes 2350 pF DC BUS DC BUS Protective Earth Ground 4 Nerta f CONTROL Gah Me a were SYSTEM DECODING FEEDBACK ease tint conmo T LOGIC SIGNAL GND MEL S xt GROUND Earth Ground The isolation barriers associated with the general purpose inputs and outputs or the STO inputs are not shown Copley Controls 16 Xenus Plus User Guide 16 01344 Rev 01 2 2 Operating Modes 2 2 1 Commutation Modes The drive supports three commutation modes to drive brush and brushless motors brushless sinusoidal brushless trapezoidal and DC brush Brushless motors driven with sinusoidal phase currents are commonly called AC brushless while those which commutate using only Hall feedback are called DC brushless motors In DC brushless motors only two phases are driven at a time and the current between them is controlled to be DC AC brushless motors drive all three phases each with sinusoidal currents and 120 degrees of pha
106. limit is zero At approximately 3 5 seconds the commanded current falls below the continuous current limit and once again the output current follows the commanded current Because the actual current is less than the continuous current the I T Accumulator Variable value begins to fall incrementally The IT Accumulator Variable value continues to fall until at approximately 5 0 seconds when the commanded current goes above the continuous current limit again The actual output current follows the current command until the I T Accumulator Variable value reaches the I T setpoint and current limiting is invoked Copley Controls 140 Xenus Plus User Guide 16 01344 Rev 01 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 142 C 2 Heatsink Mounting Instructions XEL XPL XML esses tneenrenrenne nre nretrrenni triti ten etre nnn erre nrs trennen 145 Copley Controls 141 Xenus Plus User Guide 16 01344 Rev 01 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
107. m Pa Tracking Window Tracking Time Tracking Window Output Copley Controls 54 Xenus Plus User Guide 16 01344 Rev 01 2 8 Inputs XEL XPL XML The Xenus Plus XEL XPL and XML drives have 15 digital inputs and 3 analog inputs 2 8 1 Digital Inputs The Xenus Plus XEL XPL and XML 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 For a list of input functions see the CME 2 User Guide Input Filters Two types of input RC filters are used GP general purpose and HS high speed Input reference functions such as Pulse and Direction Pulse Up Pulse Down and Quadrature A B are wired to inputs that have the HS filters and inputs with the GP filters are used for general purpose logic functions limit switches and the motor temperature sensor Debounce Time To prevent undesired multiple triggering caused by switch bounce upon switch closures each input can be programmed with a debounce time The programmed time specifies how long an input must remain stable at a new state before the drive recognizes the state The debounce time is ignored if the input is used as a digital command input Configure for Pull Up Pull Down Resistors by Groups Pre defined groups of inputs can be prog
108. n 7 STO 1 points is provided to simplify wiring of the STO bypass connections 8 STO GND 24V ground 9 STO 24V Internal power source for STO bypassing Refer to the Xenus Plus Dual Axis STO User Manual DANGER The information provided in the Xenus Plus Dual Axis STO User Manual must be considered for any application using the XE2 XP2 XM2 drive STO feature Failure to heed this warning can cause equipment damage injury or death Copley Controls 101 Xenus Plus User Guide 16 01344 Rev 01 Safe Torque Off Bypass Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 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 It is important to note that the XE2 XP2 XM2 800 1818 800 1819 and XEL XPL XML STO bypass connections are different The diode shown in the muting bypass plug should be used if XE2 XP2 XM2 800 1818 800 1819 and XEL XPL XML drives are used on the same equipment Otherwise the diode may be replaced by a jumper Bypass Plug Connections Jumper pins 2 4 3 5 6 8 7 9 Vin PWM Signals Xenus Plus Dual Axis Bm STO 1 Voltage Regulator VI STO 1 PWM Output
109. n modes the current command is generated by the velocity loop Offset The current loop offset is intended for use in applications where there is a constant force applied to or required of the servomotor and the system must control this force Typical applications would be a vertical axis holding against gravity or web tensioning This offset value is summed with the current command before the limiting stage Limits The current command is limited based on the following parameters Limiter Description Peak Current Limit Maximum current that can be generated by the drive for a short duration of time This value cannot exceed the peak current rating of the drive T cid Curent Maximum current that can be constantly generated by the drive 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 i 2 nh 3 58 s es g T Time Limit For more details see IT Time Limit Algorithm p 137 Note Although the current limits set by the user may exceed the drive s internal limits the drive operates using both sets of limits in parallel and therefore will not exceed its own internal limits regardless of the values programmed Ramp Rate of change in current command Copley Controls 20 Xenus Plus User Guide 16 01344 Rev 01 Current Loop Gains The current loop uses these gains Gain Description The current error the difference
110. n spacing 5 08 mm 0 2 in J3 J4 Tool Conductor capacity Bare stranded AWG 28 14 0 08 2 5 mm2 Insulated ferrule AWG 24 16 0 25 1 5 mm2 Stripping length 8 9 mm Operating Tool Wago MCS MIDI Classic 231 291 AWG mm Color Mfgr PNUM A B C D SL 14 2 5 Blue Wago 216 206 15 0 0 59 8 0 0 31 2 05 08 4 2 0 17 4 8 aa 10 0 39 16 1 5 Black Wago 216 204 14 0 0 59 8 0 0 31 1 7 07 3 5 0 14 4 0 0 16 10 0 39 18 1 0 Red Wago 216 223 12 0 47 6 0 24 1 4 055 3 0 12 3 5 14 8 31 0 75 Gray Wago 216 222 12 0 47 6 0 24 1 2 047 2 8 11 3 3 13 8 31 22 0 5 White Wago 216 221 12 0 47 6 0 24 1 0 039 2 6 10 3 1 12 7 5 30 NOTES y Fi PNUM Part Number C D SL Stripping length 3 Dimensions mm in lt lt _ B 4 A 24V amp BRAKE J5 Wago MCS MINI 734 105 107 000 female connector with screw flange pin spacing 3 5 mm 0 138 in J5 Tool Conductor capacity Bare stranded AWG 28 16 0 08 1 5 mm2 Insulated ferrule AWG 24 16 0 25 1 5 mm2 Stripping length 0 24 0 28 in 6 7 mm i Operating tool Wago MCS MINI 734 191 edes e 3 2 FERRULE PART NUMBERS SINGLE WIRE INSULATED AWG mm Color Mfgr PNUM A B C D E SL 18 1 0 Red Wago 216 223 12 0 47 6 0 24 1 4 06 3 0 12 3 5 14 8 31 20 0 75 Gray Wago 216 222 12 0 47 6 0 24 1 2 05 2 8 11 3 3 13 8 31 22 0 5 White Wago 216 221 12 0 47 6 0 24 1 0 04 2 6 10 3 1 12
111. n the link L A Green Meaning Off No link On Port open no activity On and flickering Port open and activity XE2 800 1818 800 1819 J8 RUN Indicator Indicates the state of the ESM EtherCAT state machine RUN Green Meaning Off Init Blinking Pre operational Single flash Safe operational On Operational XE2 800 1818 800 1819 J8 ERR Indicator Indicates that errors have occurred on the EtherCAT drive or network ERR Red Meaning Off EtherCAT communications are working correctly Blinking Invalid configuration general configuration error Single flash Local error slave has changed EtherCAT state autonomously Double flash PDO or EtherCAT watchdog timeout or an application watchdog timeout has occurred Copley Controls 41 Xenus Plus User Guide 16 01344 Rev 01 2 5 5 XML J6 Drive and MACRO Network Status Indicators 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 Slow blinking green Fast blinking green Drive is enabled and operational Drive is disabled No faults or warnings are active A limit switch is active The drive is enabled Green flash twice followed by a pause STO is active One or both STO inputs are de energized The drive is hardware amp software enabled but the PWM outputs ca
112. nclude 1 1 Xenus Plus Family OVEWMVIOW 11 DOME E A vesyecestustnnss E E EE E EA 12 Ve GMUCMO erene 13 1 4 Copley Virtual Machine CVM ceceeeeseeereeseeneeesecseceeeesesaeeeeeeaeeeaeeaeeseesaeceeeeesaeeceesaeeeaesaesaeeeeesaeseeeeieseseeeeaeeeeseateseseateneeeatee 13 ESAE EDI A E EEA E A A 13 Copley Controls 10 Xenus Plus User Guide 16 01344 Rev 01 1 1 Xenus Plus Family Overview Each Xenus Plus servo drive provides 100 digital control of brushless or brush motors in an off line 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 comes in six basic models to support three network interface protocols single axis XEL and dual axis XE2 which support CANopen over EtherCAT the single axis XML and dual axis XM2 which support MACRO and single axis XPL and dual axis XP2 which support CANopen 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 When the inputs are energized the control core will
113. nd drive follows the first s Device ID value Use of a station alias guarantees that a given drive can be accessed absolutely independent of the cabling configuration S1 S2 X10 X1 DEV ID The fixed address and station alias are always available If the switch based station alias is used it is the responsibility of the user to ensure that each drive has a unique station alias Copley Controls 36 Xenus Plus User Guide 16 01344 Rev 01 2 4 3 MACRO Communication Details XML XM2 The XML XM2 typically runs in torque mode accepting commands over the MACRO network Velocity mode is also supported MACRO Addressing A MACRO network or ring for the XML XM2 can have up to sixteen master controllers with hex addresses from 0x00 to OxOF Each master can control up to eight servo drives This works out to a maximum of 128 servo drives on a MACRO ring A MACRO address is eight bits long Switch S1 controls bits 7 4 to select the MACRO master and switch S2 controls bits 3 0 and selects the node address Node addresses available for servo drives are 0 1 4 5 8 9 and 12 13 With the 2 axis XM2 the valid node addresses are O 4 8 and 12 These address Axis A of the servo drives Axis B of the drives can then be addressed by adding 1 to the address set by node switch S2 Delta Tau PMAC Card 2 axes per XM2 4 XM2 per IC 8 axes per IC PMAC I I J I i i I 32 Axis per I card i I LI
114. nds to initiate motion may cause CANopen operations to suspend CANopen operations may restart unexpectedly when the commanded motion is stopped Failure to heed this warning can cause equipment damage injury or death Latching an output does not eliminate the risk of unexpected motion with non latched faults gt Associating a fault with a latched custom configured output does not latch the fault itself DANGER After the cause of a non latched fault is corrected the drive re enables without operator intervention In this case motion may re start unexpectedly For more information see Clearing Latched Faults p 51 Failure to heed this warning can cause equipment damage injury or death Use equipment as described Operate drives within the specifications provided in this manual Failure to heed this warning can cause equipment damage injury or death can exceed 100C depending on drive use conditions Drive heatsink surfaces can exceed 80C and regen resistor surface Do not touch drive heatsink during operation and allow it to cool before handling after DANGER power is removed Failure to heed this warning can cause injury Copley Controls 8 Xenus Plus User Guide 16 01344 Rev 01 This page for notes Copley Controls 9 Xenus Plus User Guide 16 01344 Rev 01 CHAPTER 1 INTRODUCTION This chapter provides an overview of the Copley Controls Xenus Plus drives Contents i
115. nnot produce current in the motor when STO is active Steady red A non latched fault has occurred Blinking red A latched fault has occurred XML J6 NET Indicator MACRO Network Status NET Description Off MACRO network has not been detected Blinking green MACRO network detected and has disabled drive Copley Controls Green MACRO network detected and is trying to enable drive This condition can occur while the AMP LED shows any of its valid color combinations Steady red MACRO network errors have been detected 42 Xenus Plus User Guide 16 01344 Rev 01 2 5 6 XM2 J7 Drive and MACRO Network Status Indicators ETE EE ONINUUM ac Drive Status Network Status XM2 J7 Axis A B Drive Status AMP Indicators XM2 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 Drive will only move in direction not inhibited by limit switch Green flash twice followed by a pause STO is active One or both STO inputs are de energized The drive is hardware amp software enabled but the PWM outputs cannot produce current in the motor when STO is active Red Solid Transie
116. nt fault condition Drive will resume operation when fault is removed Red Blinking Latching fault Operation will not resume until fault is cleared or drive is Reset XM2 J8 Axis A B NET Indicator MACRO Network NET Status NET Description Off MACRO network has not been detected Blinking green MACRO network detected and has disabled drive Green MACRO network detected and is trying to enable drive This condition can occur while the AMP LED shows any of its valid color combinations This LED must be green for the AMP LED to become green Steady red MACRO network errors have been detected Copley Controls 43 Xenus Plus User Guide 16 01344 Rev 01 2 5 7 XPL J6 STAT Drive Status Indicator Drive Status J6 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 The drive is enabled Green flash twice STO is active One or both STO inputs are de energized The drive is hardware amp software followed by a pause enabled but the PWM outputs cannot produce current in the motor when STO is active Steady red A non latched fault has occurred Blinking red A latched fault has occurred Copley Controls 44
117. o Signal Ground on the drive and be unconnected at the encoder or resolver Copley Controls 86 Xenus Plus User Guide 16 01344 Rev 01 Connector Locations Connector locations for 1 axis models are shown below XEL XPL XML Connector locations for 2 axis models are shown below Note J1 is on the upper end panel XE2 800 1819 XP2 XM2 800 1818 Copley Controls 87 Xenus Plus User Guide 16 01344 Rev 01 4 2 AC Mains J1 4 2 1 XEL XPL XML Mating Connector Description Euro style 7 5 mm pluggable female terminal block with preceding ground receptacle Manufacturer PN Wago 721 204 026 045 Note 1 Wire size 22 12 AWG 18 A models 14 AWG 600 V Recommended Wire 20 A 36 Aand 40 A models 12 AWG 600 V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 Connector and tool are included in Connector Kits XEL CK XML CK and XPL CK Note 1 For RoHS compliance append RNO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 L1 AC power input hot or L1 2 L2 AC power input neutral or L2 3 Protective ground Chassis safety ground 4 L3 AC power input L3 AC Mains Fuse Recommendation All Xenus Plus models Recommended fuse type Class CC 600 Vac rated Ferraz Shawmut ATDR Littelfuse CCMR Bussman LP CC or equivalent AC Mains Wiring Diagram Sin
118. o another Output control loop or the input to a power drive a i Gains ControlLoop I i I Command I Input Limits 1 i Output H i Feedback b em am em e amp i i i i D l B Copley Controls 19 Xenus Plus User Guide 16 01344 Rev 01 2 2 4 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 This error signal is then processed using the integral and proportional gains to produce a command This command is then applied to the drive s power stage Pe o e a 9 H i A A X A A A H A A e e i Current Limits i l Peak CURRENT HV I Continuous ERROR I2T I i cowwawpED UE ee l TORQUE CURRENT FORCE PWM OUTPUTS I j CURRENT OFFSET LIMITED CURRENT ACTUAL CURRENT I CURRENT LOOP he emm e a cu eee u Gu GU eee eee eee eee UD P Gu m m wm Current Loop Inputs e The drive s analog or PWM inputs e Anetwork command CAN or RS 232 Serial e A CVM control program e The drive s internal function generator In velocity or positio
119. o style 4 position 5 08 mm pluggable female terminal block Manufacturer PN Wago 231 304 107 000 Note 1 Wire Size 22 12 AWG 12 AWG 600 V Shielded cable required for CE compliance Wire Insertion Extraction Tool Wago 231 131 or 231 291 Standard connector and tool are included in Connector Kits XE2 CK XM2 CK and XP2 CK Note 1 For ROHS compliance append RNO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 Ground Motor frame ground and cable shield 2 W Phase W output of drive 3 V Phase V output of drive use for DC motor connection 4 U Phase U output of drive use for DC motor connection Brushless Motor Wiring Diagram Brushless Motor Earth ground Brush Motor Wiring Diagram Copley Controls Earth ground 92 Xenus Plus User Guide 16 01344 Rev 01 4 4 Regen Resistor Optional 4 4 1 J3 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 18 A models 14 AWG 600 V Recommended Wire 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 Note 1 For RoHS compliance append R
120. o zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral is the accumulated sum of the velocity error value over time Vi Velocity loop integral Velocity Gains Shift The Velocity Gains Shift feature adjusts the resolution of the units used to express Vp and Vi providing more precise tuning If the non scaled value of Vp or Vi is 64 or less the Low Gains Shift option is available to increase the gains adjustment resolution Such low values are likely to be called for when tuning a linear motor with an encoder resolution finer than a micrometer If the non scaled value of Vp or Vi is 24001 or higher the High Gains Shift option is available to decrease the gains adjustment resolution VELOCITY LOOP i i I I i LIMITED OUTPUT COMMANDED VELOCITY H FILTERS CURRENT ACTUAL i MOTOR vetocity I Gain Shift ON lb e e e CEEE eee eee e Velocity Loop Command and Output Filters The velocity loop contains two programmable digital filters The input filter should be used to reduce the effects of a noisy velocity command signal The output filter can be used to reduce the excitation of any resonance in the motion system Two filter classes can be programmed the Low Pass and the Custom Bi Quadratic The Low Pass filter class includes the Single Pole and the Two Pole Butterworth filter types The Custom Bi Quadratic
121. ode 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 When using digital or analog command inputs the trajectory generator can be disabled by setting the Max Accel limit to zero Note that when using the CAN bus serial bus or CVM Control Program setting Max Accel to zero prevents motion Pulse and Direction Format In pulse and direction format one input takes a series of pulses as motion step commands and another input takes a high or low signal as a direction command as shown below Pulse Input JU ULL Bb Direction Input Ll eS Velocity MER E UM E 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 Copley Controls 31 Xenus Plus User Guide 16 01344 Rev 01 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 JUUUL 4 Down Input o OUUU Velocity Command The drive can be set to increment position on the risin
122. ofile Maximum Deceleration Limits the maximum deceleration rate of the profile Abort Deceleration Specifies the deceleration rate used by the trajectory generator when motion is aborted Position Loop Inputs From the Trajectory Generator The position loop receives the following inputs from the trajectory generator Input Description Profile Velocity The instantaneous velocity value of the profile Used to calculate the velocity feed forward value Profile Acceleration The instantaneous acceleration deceleration value of the profile Used to calculate the acceleration feed forward value Limited Position The instantaneous commanded position of the profile Used with the actual position feedback to generate a position error 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 Vff Velocity feed forward The value of the profile velocity is multiplied by this value The primary effect of this gain is to decrease following error during constant velocity Aff Acceleration feed forward The value of the profile acceleration is multiplied by this value
123. ofile Heatsink w fan 3 Standard Heatsink 2 Low Profile Heatsink or No Heatsink w fan 1 No Heatsink 123 4 5 6 7 8 9 10 11 12 Continious Output Current Adc 50 40 30 20 2 4 6 8 10 12 14 16 18 20 Continuous Output Current Adc Standard Heatsink w fan Low Profile Heatsink w fan Low Profile Heatsink or no Heatsink w fan Standard Heatsink 1 No Heatsink 142 Xenus Plus User Guide 16 01344 Rev 01 C 1 2 XEL XPL and XML Heatsink and Fan Configurations No Heatsink Low Profile Heatsink Standard Heatsink No Fan With Fan Select a 4 25 inch square fan that supplies forced air at a minimum rate of 300 linear feet per minute C 1 3 XE2 XP2 XM2 and 800 1819 Models Due to the fan and heatsink integrated into their design the XE2 XP2 XM2 800 1819 models are able to operate at full load conditions both axes simultaneously over the full specified operating range Care must be taken in mounting the drives to ensure that airflow is not impeded The heatsink fan surface of the drive should be at least 1 5 in 38 1mm from any other surface including other drives for adequate cooling Copley Controls 143 Xenus Plus User Guide 16 01344 Rev 01 C 1 4 Model 800 1818 The following chart shows the maximum allowable ambient temperature as a function of output current for the model 800 1818 drive Data is gi
124. on 5 0 mm pluggable female terminal block Manufacturer PN Wago 721 104 026 047 Note 1 Connector Wire Size 22 12 AWG Recommended Wire 12 AWG 600 V Shielded cable used for CE compliance Wire Insertion Extraction Tool Wago 231 131 Connector and tool are included in Connector Kit XTL FK Note 1 For ROHS compliance append RN01 0000 to the Wago part numbers listed above Pin Description Pin Signal Function 1 Ground Chassis ground and cable shield 2 Phase W Phase W output to motor 3 Phase V Phase V output to motor use for DC motor connection 4 Phase U Phase U output to motor use for DC motor connection Copley Controls 152 Xenus Plus User Guide 16 01344 Rev 01 D 2 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 are used for outputs to the filter J4 on the drive Brushless Motor D 2 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 2 8 XTL FA 01 Edge Filter Ordering Brush Motor Filter Model Description XTL FA 01 Xenus Plus Edge Filter Connector Kit Model XTL FK Qty Ref Description Mfr Model No 1 J1 Plug 5 position 5 0 mm female Wago 721 1
125. on not inhibited by limit switch Green flash twice STO is active One or both STO inputs are de energized The drive is hardware amp software followed by a pause enabled but the PWM outputs cannot produce current in the motor when STO is active Red Solid Transient fault condition Drive will resume operation when fault is removed Red Blinking Latching fault Operation will not resume until fault is cleared or drive is Reset Copley Controls 48 Xenus Plus User Guide 16 01344 Rev 01 2 5 10 XP2 J8 RUN ERR amp L A Indicators wem PM TTE 1 NINN WAA 6 L A RUN L A TIU a iH 1A ifi ERR XP2 J8 L A Indicators Shows the state of the physical link and activity on the link L A Green Meaning Off No link On Port open no activity On and flickering Port open and activity XP2 J8 RUN Indicator Indicates the state of the CANOpen state machine RUN Green Meaning Blinking Pre operational Single flash Stopped On Operational XP2 J8 ERR Indicator Indicates that errors have occurred on the CANOpen drive or network ERR Red Meaning Single flash red Warning Limit Reached Double flash red Error Control Event Triple flash red Sync Error Steady red Bus Off Copley Controls 49 Xenus Plus User Guide 16 01344 Rev 01 2 6 Protection 2 6 1 Safe Torque Off All of the Xenus Plus models
126. opley Controls 159 Xenus Plus User Guide 16 01344 Rev 01 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 html Connector Kit with Solder Cup Feedback and Control Connectors XEL XPL XML Model Qty Ref Description Mfr Model No 1 J1 Plug 4 position 7 5 mm female Wago 721 204 026 045 Note 1 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 Note 1 1 J3 Plug 5 position 5 0 mm male Wago 721 605 000 044 Note 1 1 J4 Plug 3 position 5 0 mm female Wago 721 103 026 047 Note 1 4 Tool wire insertion and extraction Wago 231 131 Eek 1 E Connector D Sub 9 position male solder cup Norcomp 171 009 103L001 XML CK 1 Backshell D Sub RoHS metalized for above Norcomp 979 009 020R121 oe 1 d Connector high density D Sub 26 position female solder cup Norcomp 180 026 203L001 1 Backshell D Sub RoHS metalized for above Norcomp 979 015 020R121 1 d Connector high density D Sub 15 position male solder cup Norcomp 180 015 103L001 1 Backshell D Sub RoHS metalized for above Norcomp 979 009 020R121
127. or Encoder based phase angle does not agree with Hall switch states This fault can occur only with brushless motors set up using sinusoidal commutation It does not occur with resolver feedback or with Halls correction turned off Encoder based phase angle agrees with Hall switch states Feedback error Motor Over Temperature Over current condition detected on the output of the internal 5 Vdc supply used to power the feedback Resolver or analog encoder not connected or levels out of tolerance Motor over temperature switch changes state to indicate an over temperature condition Encoder power returns to specified voltage range Feedback signals stay within specified levels Temperature switch changes back to normal operating state Under Voltage Bus voltage falls below specified voltage limit DC bus voltage returns to specified voltage range Over Voltage Bus voltage exceeds specified voltage limit DC bus voltage returns to specified voltage range Following Error Short Circuit Detected User set following error threshold exceeded Output to output output to ground internal PWM bridge fault See Position and Velocity Errors p 52 Short circuit has been removed oOver Current Latched Output current IT limit has been exceeded Drive is reset and re enabled Latched by default Copley Controls 51 Xenus Plus User Guide 16 013
128. 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 LIT LJ L1 LJ LJ FL Lr LT 1 2 3 4 5 6 7 8 Pin Description Pin Signal Function 1 TX Transmit data 2 TX Transmit data 3 RX Receive data 4 5 6 RX Receive data 7 8 B Table applies to both EtherCAT connectors EtherCAT Bus Wiring Diagram The XEL drive uses connector J7 The XE2 800 1818 800 1819 drives use connector J8 EtherCAT Network In Opto isolation EtherCAT Network Out Opto isolation Copley Controls 104 Xenus Plus User Guide 16 01344 Rev 01 4 9 2 CAN Bus XPL XP2 Mating Connector 8 position modular connector RJ 45 style Copley Controls provides the following assemblies e Prefabricated 10 foot cable PN XPL NC 10 e Prefabricated 1 foot cable PN XPL NC 01 e Terminator Plug PN XPL NT A diagram of the female connector is shown below LT L1 L1 LJ LJ Er LJ LT 2 3 4 5 6 7 8 Pin Description Pin Signal Function 1 CAN H CAN H bus line dominant high 2 CAN L CAN L bus line dominant low 3 CAN Gnd Ground 0 V V 4 No connection 5 Pass through
129. ounting dimensions in mm 4 3 hole 225 2 Copley Controls 163 Xenus Plus User Guide P N 16 01344 Revision 01 April 2 2015 2011 2012 2013 2014 2015 Copley Controls Analogic Motion Controls 20 Dan Road Canton MA 02021 USA All rights reserved
130. put but can be programmed for other functions For a list of digital output functions see Control I O p 107 OUT1 OUT3 are connected on J8 Opto isolated OUT4 and OUT5 are on J9 OUT6 Brake is on J4 OUT1 and OUT2 are current sinking MOSFETs each with a pull up resistor in series with a diode connected to the drive s internal 5 Vdc supply This design allows the outputs to be directly connected to optically isolated PLC inputs that reference a voltage higher than 5 Vdc typically 24 Vdc The diode prevents current flow between the 24 Vdc supply and the internal 5 Vdc supply though the pull up resistor This current if allowed to flow could turn on the PLC input giving a false indication of the drive s true output state OUT1 and OUT2 require an external fly back diode to be installed across any inductive loads such as relays that are connected to them OUT3 is a 5V high speed buffered CMOS output OUTA and OUT5 are opto isolated Darlingtons with a 30 Vdc maximum output Zener clamping diodes across outputs allow driving of resistive inductive R L loads without external flyback diodes The outputs are two terminal and for connection to 24V or ground to source or sink current The output current rating is 20 mA The brake output OUT6 is described below in Brake Operation There is one programmable analog output AOUT1 It has an output voltage range of 5 Vdc An op amp buffers the output of a 12 bit D A converter 2 1
131. puts XE2 XP2 XM2 800 1819 2 10 Outputs XEL XPL XML 2 11 Outputs XE2 XP2 XM2 800 1819 2 12 Brake Operation 2 13 Regen Resistor Theory Copley Controls 14 Xenus Plus User Guide 16 01344 Rev 01 2 1 Drive Power Architecture 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 With the Xenus Plus Single Axis drives digital inputs IN1 6 and IN15 analog inputs AIN1 3 digital outputs OUT1 3 Hall inputs and encoder inputs are all referenced to signal ground Inputs IN7 10 and IN11 14 are groups of four opto isolated inputs with a common terminal for each group Outputs OUT4 5 are two terminal Darlington opto isolators The brake output OUTE6 is opto isolated and referenced to the 24Vdc return The CAN interface is optically isolated With the Xenus Plus Dual Axis drives digital inputs IN1 5 IN10 11 and IN16 22 analog inputs AIN1 2 Hall inputs and encoder inputs are referenced to signal ground Inputs IN6 9 and IN16 19 are two groups of four opto isolated inputs with a common terminal for each group Brak
132. r temperature and excessive following error When any fault occurs with the exception of a following error the drive s PWM output stage is disabled the fault type is recorded in the drive s internal error log which can be viewed with CME 2 and the status LED changes to indicate a fault condition exists A digital output can also be programmed to activate on a fault condition The following error fault behaves with slight differences as described in Following Error Fault Details p 53 The drive s PWM output stage can be re enabled after the fault condition is corrected and the drive faults are cleared The process for clearing faults varies depending on whether the fault is configured as non latched or latched The fault clearing descriptions below apply to all faults except for the following error fault which is described in Following Error Fault Details p 53 Clearing Non Latched Faults The drive clears a non latched fault without operator intervention when the fault condition is corrected 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 non DANGER latched behavior When using non latched faults be sure to safeguard against unexpected motion Failure to heed this warning can caus
133. r Temperature gt 80 C DC Bus Under Voltage 60 Vdc DC Bus Over Voltage gt 400 Vdc Encoder Power lt 4 25 Vdc AC Loss Detection Loss of mains voltage between L1 amp L2 pins of J1 Copley Controls 78 Xenus Plus User Guide 3 22 Power Dissipation 16 01344 Rev 01 Copley Controls 5 10 15 Continuous Output Current A 3 23 Thermal Impedance See Thermal Considerations p 141 Model XEL 230 18 R XEL 230 36 R XEL 230 40 R Output Power Mains XPL 230 18 R XPL 230 36 R XPL 230 40 R p Voltage XML 230 18 R XML 230 36 R XML 230 40 R Maximum 120 Vac 30 Ww 55 Ww 92 Ww Continuous 240 Vac 40W 75W 120W Single Axis Power Dissipation 120 100 st ie E 120VAC a s 40 o a 20 79 16 01344 Rev 01 Xenus Plus User Guide 3 24 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 Standard HS Heat Sink Low profile CHL Heat Sink 3 0 Ib 1 36 kg Add 1 86 Ib 0 84 kg Add 3 1 Ib 1 40 kg Ambient Temperature Storage 40 to 85 C Operating 0 to 45 C Humidity 0 to 95 non condensing Contaminants Pollution degree 2 Environment IEC68 2 1990 Cover Material Meets U L Spec 94 V 0 Flammability Rating Cooling Heat sink and or forced air cooling requ
134. r below E 1 2 Single Axis Connections For RS 232 serial bus control of a single axis set the CAN node address of that axis drive to zero 0 Note that if the CAN node address is switched to zero after power up the drive must be reset or power cycled to make the new address setting take effect Serial Copley Amplifi PC PLC or HMI COM port SER CK Serial Cable Kit op ey Ampiiiier 9pin D sub with ASCII for ASCII Control for RS 232 RS 232 ADDRESS MUST BE SET TO ZERO BEFORE POWER UP OR RESET E 1 3 Multi Drop Network Connections A serially connected XPL XP2 drive can be used as a multi drop gateway for access to other XPL XP2 drives linked in a series of CAN bus connections Set the CAN node address of the serially connected drive gateway to zero 0 Assign each additional drive in the chain a unique CAN node address value between 1 and 127 If the XP2 is used as the master axis B is sequentially addressed automatically Also when using XP2 as a master axis A will not be available for CAN controls Use 120 Ohms termination on the first and last drive TERMINATION MUST BE 120 Ohm USED ON FIRST ANDLAST Terminator NODE PC PLC or HMI SOME 4 opinDsup SERCK Sera Cable kir gt TS CANIPOR for ASCII Conto rohs Pn Desu with ASCII RS 232 xd CAN Network Cable UTP CAT 5E Gigabit Ethernet RJ45 RJ45 UU ME
135. rammed to have either an internal pull up or pull down resistor See J8 Pin Description p 107 for groupings 2 8 2 Analog Inputs Two programmable differential analog inputs AIN1 and AIN2 are connected on J8 with 10 Vdc range As a reference input AIN1 can take position velocity torque commands from a controller The second input AIN2 is programmable for other functions The ratio of drive output current or velocity vs reference input voltage is programmable Analog input AIN3 Motemp is for use with a motor over temperature switch or sensor connected on J10 Copley Controls 55 Xenus Plus User Guide 16 01344 Rev 01 2 9 Inputs XE2 XP2 XM2 800 1818 800 1819 The XE2 XP2 XM2 and 800 1818 drives have 22 digital inputs and 2 analog inputs The 800 1819 a custom version of the XE2 has 20 digital inputs and 2 analog inputs 2 9 1 Digital Inputs IN1 amp IN11 are general purpose Schmitt trigger single ended inputs with programmable pull up down to 5 Vdc ground and 1 5 us RC filters 24 Vdc compatible IN21 amp IN22 have fixed pull ups to 5V and the same electrical specs as IN1 amp IN11 otherwise IN2 IN5 and IN12 IN15 are programmable as single ended or differential inputs IN6 9 and IN16 19 are single ended opto isolated inputs with a common terminal for each group that can connect to ground or 24 Vdc to work with current sourcing or current sinking outputs from a control system IN10 amp IN20 are for motor overt
136. re switch May be programmed to other functions 7 Motemp Analog input on the XEL XPL XML models Digital input on the XE2 XP2 XM2 800 1818 models 8 Encoder X1 Input 9 Encoder X1 Input 10 Encoder B1 Input i Primary incremental encoder inputs 11 Encoder B1 Input 12 Encoder A1 Input 13 Encoder A1 Input 14 Encoder S1 Input 15 Encoder S1 Input 16 Signal Ground Signal and 5 Vdc ground 17 5 Vdc Encoder and or Halls 5 Vdc power supply output 18 Sin1 19 Sin1 20 Cos1 Analog Sin Cos Index encoder signals 21 Cos1 22 Index1 23 Index1 24 IN15 XEL XPL XML General purpose input IN21 IN22 XE2 XP2 IN21 is on J10 IN22 is on J11 25 Signal Ground Signal and 5 Vdc ground 26 Signal Ground Signal and 5 Vdc ground Copley Controls 124 Xenus Plus User Guide 16 01344 Rev 01 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 Motor over temperature switch May be programmed to other functions 7 Motemp Analog input on the XEL XPL XML models Digital input on the XE2 XP2 models 16 Signal Ground Signal and 5 Vdc ground 17 5 Vde Encoder and or Halls 5 Vdc power supply output 18 1 Sin ao Resolver Sin inputs
137. rrors For detailed information see Tracking Window Details p 54 Copley Controls 52 Xenus Plus User Guide 16 01344 Rev 01 2 7 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 Additional responses and considerations depend on whether the fault is non latched or latched as described below Drive Response to Non Latched Following Error Fault When a non latched following error fault occurs the drive drops into velocity mode and applies the Fast Stop Ramp deceleration rate to bring the motor to a halt The drive PWM output stage remains enabled and the drive holds the velocity at zero using the velocity loop Resuming Operations After a Non Latched Following Error Fault The clearing of a non latched following error depends on the drive s mode of operation Issuing a new trajectory command over the CAN bus or the ASCII interface will clear the fault and return the drive to normal operating condition If the drive is receiving position commands from the digital or differential inputs then the drive must be disabled and then re enabled using the driv
138. s I I STO 2 at C H4 af S STO 2 3 STO 1 pr eg STO 1 TO PWR 6 5 mA l STO GND Sgnd O XE2 and XEL XPL STO bypass connections are different 1 The diode shown should be used if XE2 and XEL XPL drives are used on the same J iG Frame Ground equipment Otherwise the diode may be replaced by a jumper XE2 STO bypass connectors are not compatible with XEL XPL drives l Copley Controls 102 Xenus Plus User Guide 16 01344 Rev 01 4 8 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 0 0 0 oO oO Oo 1 2 3 4 5 6 Pin Description Pin Signal Function 1 N C No connection 2 RxD Receive data input from computer 3 Signal ground Power supply ground 4 Signal ground Power supply ground 5 TxD Transmit data output to computer 6 N C No connection RS 232 Serial Communications Wiring Diagram XEL XPL and XML drives use connector J6 XE2 XP2 XM2 800 1818 and 800 1819 drives use connector J7 Copley Controls 103 Xenus Plus User Guide 16 01344 Rev 01 4 9 Network Ports 4 9 1 EtherCAT XEL XE2 800 1818 800 1819 Mating Connector Dual RJ 45 sockets accept standard Ethernet cables The IN port connects to a master
139. s the deceleration time Tdecel associated with the maximum pulse power regen event Use the following formulas to determine the minimum peak and continuous current ratings of the fuse For related drive specifications see Regen Circuit Output p 67 The peak current is determined by the chosen regen resistor value Ipeak Viegen Rregen Where Ibeak The current though the regen resistor during regeneration in Amps Viegen The voltage at which the regen circuit turns on Rregen The resistance value of the chosen regen resistor in Ohms The continuous current is determined by the continuous regen power leont Pont Vegen Where lon The minimum continuous current rating the fuse requires in Amps Peont The continuous power calculated in the previous step in Watts Viegen The voltage at which the regen circuit turns on Copley Controls 136 Xenus Plus User Guide 16 01344 Rev 01 APPENDIX B IT Time Limit ALGORITHM The current loop I T 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 I T limit Contents Include Bitzi Algorithm eere tees cen lspci Aa EG RR pd AL Sea Sit 138 Copley Controls 137 Xenus Plus User Guide 16 01344 Rev 01 B 1 T Algorithm B 1 1 PT Overview The l T current limit algorithm continuously monitors t
140. se shift between them 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 When driving a DC brush motor the drive operates as a traditional H Bridge drive using only the U amp V PWM outputs 2 2 2 Position Feedback Types Encoder and Resolver Support The standard versions of the Xenus Plus drives support digital quadrature encoders analog sin cos encoders and a variety of serial and absolute encoder formats Resolver versions designated by R in the model number support standard single speed transmit type resolvers Digital quadrature and sin cos analog encoders are incremental types that typically use Hall feedback for commutating brushless motors Resolvers and absolute rotary encoders do not require Halls for commutation because they provide the absolute feedback of the position of the motor rotor Multi Mode Port All versions support a multi mode port This interface can be configured to e Provide a buffered digital encoder output based on the digital quadrature encoder input e Provide an emulated digital encoder output based on the analog encoder or resolver input e Provide an emulated serial encoder output e Provide a second digital encoder input to be used in the dual encoder position mode In this mod
141. sipate the maximum pulse power For related drive specifications see Regen Circuit Output p 67 R Viegen Pouise max Where R Resistance in Ohms Poulse max The maximum pulse power Viegen The voltage at which the regen circuit turns on Choose a standard value of resistance less than the calculated value This value must be greater than the minimum regen resistor value specified in Regen Circuit Output p 67 Copley Controls 135 Xenus Plus User Guide 16 01344 Rev 01 A 1 10 Calculate Continuous Power to be Dissipated Use the following formula to calculate the continuous power that must be dissipated by the regen resistor Use each deceleration where energy is dissipated by the regen resistor Pront Eegen 1 E regen 2 E regen D x Toydle Where Poen The continuous power that will be dissipated by the resistor in Watts Eregen n Energy being dissipated during decelerations in Joules Toyae Total cycle time in seconds 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 67 A 1 11 Select Fuses For custom regen resistors Cooper Bussman KLM fuses or equivalent should be selected The peak and continuous currents as well as the peak current time must be taken into consideration for proper fuse selection The duration of the peak current i
142. source be sure it meets the specifications described in Regen Resistor Sizing and Specification p 132 Regen Circuit Protections The drive protects the regen circuit against short circuit and uses I T peak current time algorithms to protect both the external resistor and the internal transistor Configurable Custom Resistor The following values can be entered for a custom resistor using CME 2 Option Description Resistance Value Value in Ohms of the resistor Continuous Power Continuous power rating of the resistor Peak Power Peak power rating of the resistor Time at Peak Power Time at peak power of resistor Copley Controls 63 Xenus Plus User Guide 16 01344 Rev 01 CHAPTER 3 SPECIFICATIONS This chapter describes the drive specifications Contents include 3 TAGONCY AP PIOVAIS An tesa creatine eiecisedcacxetateioateasacrssvutebsbadeguneaie M 65 3 2 Power Input 65 3 3 Power Output 66 3 4 Control LoOps erret nnns 67 3 5 Regen Circuit Output External Regen Resistor 67 3 6 Regen Circuit Output Internal Regen Resistor 67 3 1 rez gare Ue EE P E Mm 68 Esp creme O 68 3 9 Digital Inputs 69 Analog Outputs 70 Digital Outputs T 70 P
143. t Function Set up control and diagnostics status 76 Xenus Plus User Guide 3 19 Network Interfaces 16 01344 Rev 01 XEL XE2 Model 800 1818 800 1819 XPL XP2 XML XM2 Channels 1 1 1 2 eight position RJ 45 2 eight position RJ 45 2 Duplex type SC optical Connectors style style fiber connector CAN_H CAN_L Signals 100BASE TX CAN Gnd CAN 5 Vdc pd acad Pass though only 9 P CAN V2 0b physical layer Format EtherCAT for high speed connections compliant Motion Control Device CANopen over EtherCAT Under DSP 402 of the Protocol CoE based on DSP 402 CANopen DS 301 V4 01 MACRO for motion control devices EN 50325 4 Application Layer Supported Modes Cyclic Synchronous Position amp Velocity Profile Current Velocity and Position PVT Position Velocity Time and Homing Torque current Velocity Node Address Selection Slaves are automatically assigned addresses based on their position in the bus Two 16 position hexadecimal rotary switches can be used to define a cabling independent Station Alias Two 16 position hexadecimal rotary switches on front panel OR programmable digital inputs OR stored in flash memory OR combination of above Two 16 position hexadecimal rotary switches are used to define a MACRO node address Bus Termination No termination required External 121 Q resistor across CAN_H and CAN_L when termination plug is installed in
144. t distance to arrive at the programmed position This could be in the positive or negative direction Moves programmed to a point greater than the wrap value will cause an error To configure the position wrap feature see the CME 2 User Guide Copley Controls 27 Xenus Plus User Guide 16 01344 Rev 01 2 3 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 3 1 Analog Command Input Overview The drive can be driven by an analog voltage signal through the analog command input The drive converts the signal to a current velocity or position command as appropriate for current velocity or position mode operation respectively The analog input signal is conditioned by the scaling dead band and offset settings Scaling The magnitude of the command generated by an input signal is proportional to the input signal voltage Scaling controls the input to command ratio allowing the use of an optimal command range for any given input voltage signal range For example in current mode with default scaling 10 Vdc of input generates a command equal to the drive s peak current output 5 Vdc equals half of that
145. tached to the load The error signal is then processed using the integral and proportional gains to produce a current command Programmable digital filters are provided on both the input and output command signals COMMANDED VELOCITY Inputs Velocity Limits Accel Max Velocity Decel Abort Decel VELOCITY LOOP VELOCITY BD LIMITED VELOCITY eae e e I Current 1 17 o c l o Ue e e e e e e d Commanded Current In velocity mode the velocity command comes from one of the following The drive s analog or PWM inputs A network command CAN or RS 232 Serial A CVM control program The drive s internal function generator In position mode the velocity command is generated by the position loop Copley Controls 22 Xenus Plus User Guide 16 01344 Rev 01 Velocity Loop Limits The velocity command is limited based on the following set of parameters designed to protect the motor and or the mechanical system Limiter Description Velocity Limit Sets the maximum velocity command input to the velocity loop Acceleration Limit Limits the maximum acceleration rate of the commanded velocity input to the velocity loop This limit is used in velocity mode only Deceleration Limit Limits the maximum deceleration rate of the commanded velocity input to the velocity loop This limit is used in velocity mod
146. ters per second V Velocity at the end of deceleration in meters per second A 1 4 Determine the Amount of Energy Dissipated by the Motor Calculate the amount of energy dissipated by the motor due to current flow though the motor winding resistance using the following formulas P motor 3 4 Rwinding F Kt Where Pmotor Power dissipated in the motor in Watts Rwinding Line to line resistance of the motor F Force needed to decelerate the motor Nm for rotary applications N for linear applications Kt Torque constant for the motor Nm Amp for rotary applications N Amp for linear applications E motor P motor Taecel Where Emotor Energy dissipated in the motor in Joules Tuecel Time of deceleration in seconds A 1 5 Determine the Amount of Energy Returned to the Drive Calculate the amount of energy that will be returned to the drive for each deceleration using the following formula E retumed E dec 2 E motor Where Eretunea Energy returned to the drive in Joules Ege Energy returned by the deceleration in Joules Emo Energy dissipated by the motor in Joules Copley Controls 134 Xenus Plus User Guide 16 01344 Rev 01 A 1 6 Determine if Energy Returned Exceeds Drive Capacity Compare the amount of energy returned to the drive in each deceleration with the drive s energy absorption capacity For related drive specifications see Regen Circuit Output p 67 For mains voltages not listed in the specificat
147. th connections for the motor and regen resistor housings are subject to local electrical codes and must be reviewed for compliance with those codes It is the responsibility of the end user to ensure compliance with local electrical codes and any other applicable standards It is strongly recommended that motor and regen resistor housings also be connected to protective earth connection points located as close to the motor and regen resistor as possible In many applications the machine frame is used as a primary or supplemental protective earth connection point for the motor and regen resistor housings Signal Grounding The drive signal ground must be connected to the control system signal ground The drive signal ground is not connected to earth ground internal to the drive Therefore the control system signal ground can be connected to earth ground without introducing a ground loop Cable Shielding Shields on cables reduce emissions from the drive and help protect internal circuits from interference due to external sources of electrical noise The shields shown in the wiring diagrams are also required for CE compliance Cable shields should be tied at both ends to earth or chassis ground The housing and pin 1 of J8 J9 and J10 J9 J12 for XE2 XP2 XM2 800 1819 are connected to the drive s chassis Feedback cables with inner outer shielding should connect the outer shield to the motor and drive frame grounds The inner shield should connect t
148. ti Mode Port A 26 Multi Mode Port A Mode Dependent Dedicated Inputs These inputs are dedicated to specific functions depending on operating mode Selected Command Source Mode Digital Input Digital Input Multi Mode Function Single Ended Differential Port UTOR i IN 5 IN3 amp KINAC A amp A PWM Input PWM 50 Current amp Velocity IN 5 IN3 amp INA A amp A PWM Input PWM 10096 IN 6 IN5 amp ING B amp B Direction Input Position IN 5 IN3 amp INA A amp A Pulse Input Pulse amp Direction IN 6 IN5 amp IN6 B amp B Direction Input Position IN5 IN3 amp IN4 A amp A Count Up Up Down IN 6 IN5 amp ING B amp B Count Down Position IN 5 IN3 amp INA A amp A Channel A Quadrature IN 6 IN5 amp ING B amp B Channel B Digital Inputs IN1 IN6 Wiring Diagram Typical Circuit 5 Vdc Motion Controller 10 KQ pull up pull dow n HS IN1 IN2 GP IN3 ING Copley Controls Signal Ground R 10KQ 24V MAX R 1KQ 12V MAX 108 Xenus Plus User Guide 16 01344 Rev 01 Digital Outputs Wiring Diagram Typical Output Loads Typical Circuits Motion Controller External Power Supply Ground OUT3 HS G 32 mA NC7SZ125 Flyback diode required for inductive loads Multi Mode Port Interface Diagram Typical Circu
149. to second connector no internal connection 6 CAN_SHLD Pass through to second connector no internal connection 7 CAN_Gnd Ground 0 V V 8 CAN V Pass through to second connector no internal connection Table applies to both CAN connectors CAN Bus Wiring Diagram The XPL drive uses connector J7 The XP2 drive uses connector J8 CAN CAN r 39 CAN Gnd CAN Network 7 Drive Jx Opto isolation CAN CAN CAN Gnd CAN Network 7 Note 1 If this is the last amplifier on the network use Copley Terminator Plug PN XPL NT to terminate the bus Copley Controls 105 Xenus Plus User Guide 16 01344 Rev 01 4 9 3 MACRO Port J7 XML J8 XM2 The XML XM 2 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 XM2 and the master The OUT port connects to downstream nodes If XML XM2 is the last node on a network only the IN port is used No terminator is required on the OUT port Copley Controls 106 Xenus Plus User Guide 16 01344 Rev 01 4 10 Control I O 4 10 1 Non Isolated Control 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 180 026 203L001 24 30 AWG Back shell Norcomp 979 015 020R121
150. tor or Switch General Purpose Input Wiring Diagram XEL XPL XML IN15 Copley Controls 130 Xenus Plus User Guide 16 01344 Rev 01 General Purpose Input Wiring Diagram XE2 XP2 XM2 800 1818 800 1819 J10 J11 J10 J11 24 IN15 Copley Controls 131 Xenus Plus User Guide 16 01344 Rev 01 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 61 To configure a custom regen resistor see the CME 2 User Guide Additional information about regeneration can be found in this document on the web site http www copleycontrols com Motion pdf Xenus regen quide 03 04 pdf The contents of this chapter include AA Sizing a Regen Resisto inssi nea ien Re ERE In RI m ERE EE qetaatenuetpesbendheaustpsapenube ETSAK EPE aneia EREE 133 Copley Controls 132 Xenus Plus User Guide 16 01344 Rev 01 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 For all applications gather the following information 1 Details of the complete motion profile including times and velocities 2 Drive model number 3 Applied line voltage to
151. uctive loads buffer with 36V current sinking with Zener diodes flyback diode to 24V across outputs Maximum 40 Vdc 5Vdc 30Vdc 32 Vdc Voltage Maximum 1 Adc 32 mA 20 mA 1 Adc Sink Current Low Level 0 20 Not Not applicable 0 14 Q Output applicable Rout only Resistance Rout only applies to applies to MOSFET MOSFET outputs outputs Function Programmable Brake Programmable XE2 XP2 XM2 800 1818 800 1819 Note 800 1819 does not utilize OUT4 5 Channels XE2 XP2 XM2 800 1818 7 OUT1 OUT7 800 1819 5 OUT1 OUT3 OUT6 OUT7 OUT1 OUT 5 OUT 6 OUT 7 Opto isolated MOSFET SSR with 1 series P beca Type resistor and 36V Zener flyback diodes across Opie isolated currentsinking with dlyBaeis diode to 24 Vdc outputs Maximum Voltage 30Vdc 32 Vdc Maximum Sink Cument 300 mA 1 Adc Low Level Output Not applicable 0 14 QO Resistance Programmable Function Brake Programmable Copley Controls 70 16 01344 Rev 01 Xenus Plus User Guide 3 12 Encoder Power Outputs 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 XM2 800 1818 800 1819 Number 4 Voltage Output 5 Vdc 2 Maximum Current Output 500 mA Short Circuit Protection Fold back current limiting Function
152. uni polar input voltage An example of this would be a 0 to 10 Vdc velocity command that had to control 1000 rom CCW to 1000 rpm CW Scale would be set to 2000 rpm for a 10 Vdc input and Offset set to 5V After this a 0 Vdc input command would be interpreted as 5 Vdc which would produce 1000 rom CCW rotation A 10 Vdc command would be interpreted as 5 Vdc and produce 1000 rpm CW rotation Monitoring the Analog Command Voltage The analog input voltage can be monitored in the CME 2 control panel and oscilloscope The voltage displayed in both cases is after both offset and deadband have been applied Analog Command in Position Mode The Xenus Plus Analog Position command operates as a relative motion command When the drive is enabled the voltage on the analog input is read Then any change in the command voltage will move the axis a relative distance equal to the change in voltage from its position when enabled To use the analog position command as an absolute position command the drive should be homed every time it is enabled The Homing sequence may be initiated by CAN ASCII serial or CVM Indexer program commands Copley Controls 29 Xenus Plus User Guide 16 01344 Rev 01 2 3 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
153. us Plus User Guide 16 01344 Rev 01 There should be only one conductor in each position of the brake connector If brakes are to be wired directly to J 4 or J5 for their 24V power use a double wire ferrule Information for ferrules can be found in 4 12 XEL XPL XML XE2 XP2 XM2 For more information see Logic Supply Brake p 96 Brake Stop Sequences e Disabling the drive by a hardware or software command starts the following sequence of events e The motor begins to decelerate at Abort Deceleration rate in position mode or Fast Stop Ramp rate in velocity mode At the same time the Brake Stop Delay Time count begins This allows the drive to slow the motor before applying the brake e When the motor slows to Brake Stop Activation Velocity OR the Brake Stop Delay Time expires the brake output activates and PWM Delay Brake Stop Response Time count begins e When response time has passed the drive s output stages are disabled This delay ensures the brake has time to lock in before disabling the power section Enable Input Brake Stop delay time Lio n Speed i is i Brake Stop activation velocity Brake Ouptput i Enable tHe Pati delay Power Section Brake Stop response time This sequence is not available in the current mode of operation Instead in current mode the drive output turns off and the brake output activates immediately when the disable command is received Copley Controls 59 Xenus
154. use KLKD008 Ferraz Shawmut ATM 10 or equivalent XTL RA 04 User Supplied Cooper Bussman KLM 12 Littelfuse KLKD012 Ferraz Shawmut ATM 15 or equivalent See Regen Resistor Sizing and Configuration p 132 Copley Controls 95 Xenus Plus User Guide 16 01344 Rev 01 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 Note 1 For RoHS compliance append RNO1 0000 to the part numbers listed above Pin Description Pin Signal Function 1 RTN 24 Vdc return 2 Brake Return or low side of motor brake 3 24 Vdc 24 Vdc Logic power supply Logic Supply Brake Wiring Diagram Drive Isolated Logic Power Supply 24 Vdc Power Supply Required Copley Controls 96 Xenus Plus User Guide 16 01344 Rev 01 4 5 2 XE2 XP2 XM2 800 1818 800 1819 J5 The following information is for XE2 XP2 XM2 800 1819 drives only Mating Connector Description Euro style 3 5 mm 5 position pluggable female terminal block Manufacturer PN Wago 734 105 107 000 Note
155. using the XE2 XP2 XM2 800 1818 800 1819 drive STO feature Failure to heed this warning can cause equipment damage injury or death Do not plug or unplug connectors with power applied The connecting or disconnecting of cables while the drive has 24Vdc and or mains power applied is not recommended Failure to heed this warning may cause equipment damage gt WARNING gt WARNING Do not ground mains connected circuits Do not ground Mains connected circuits J1 J2 J3 and J4 for XE2 XP2 XM2 800 1818 800 1819 J1 J2 and J3 for XEL XPL XML Failure to heed this warning can cause equipment damage Risk of Radio Frequency Interference The Xenus Plus Dual Axis drives are not intended for use on a low voltage public network which supplies domestic premises Radio frequency interference should be expected if used on such a network gt WARNING EMI Line Filter is necessary to meet EMC requirements Use if an EMI Line Filter with Xenus Plus Dual Axis drives is mandatory for meeting EMC requirements gt WARNING A surge protection device SPD is required to establish an over voltage category Il environment The AC mains supplying the XE2 XP2 XM2 800 1818 800 1819 drives must be limited to over voltages of Category Il The relevant standards assume AC mains with over voltages per OVC III An SPD is required to limit over voltages to OVC II levels Copley Controls 85
156. ven for two different mounting configurations with the drive operating from maximum rated mains input voltage mN N Edge Mountin i Kh N EMA Li Lo S TN TN pt TN T NWN pt J LE pt f f pt ft ft ft I 0 5 10 15 20 2 30 35 4 0 4 5 Total continuous output current in Adc peak of sine of axes A amp B operating simultaneously 9 8 Flat Mounting Edge Mounting Maximum ambient operating temperature C Copley Controls 144 Xenus Plus User Guide 16 01344 Rev 01 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 Clear Protective Sheet Discard Dry Film Interface Pad Blue Protective Sheet Discard Place the interface pad on the drive taking care to center the pad holes over the heatsink mounting holes Remove the clear protective sheet from the pad Mount the heatsink onto the drive taking care to see that the holes in the heatsink interface pad and drive all line up Torque the 8 32 mounting screws to 16 20 Ib in 1 8 2 3 Nm 8 32 Mounting Screws Heatsink Dry Film Interface Pad Xenus Amplifier NOTE The dra
157. wing shows the standard heatsink kit but the mounting instructions given are valid for the low profile heatsink kit as well Copley Controls 145 Xenus Plus User Guide 16 01344 Rev 01 APPENDIX D XENUS PLUS FILTER This chapter provides an overview of the Model XTL FA 01 edge filter Contents include DE Me 147 13 2 XTL FA 01 Edge Filter Wiring rrr rore rnit tinet tinae Pha ek n ener erit p na ere ce Da ea ER reini 150 146 Copley Controls Xenus Plus User Guide 16 01344 Rev 01 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 Differential edge filtering reduces the high frequency component of the PWM signal thus producing a signal with less energy that can be coupled during transmission Common mode filtering reduces the unnecessary common mode noise generated by PWM signals D 1 2 Description and Functional Diagram The differential filter increases the rise time by at least a factor of 3 substantially reducing noise in the system Copley Controls drives typically have a 150 ns rise time high frequency component in the MHz range Thus t

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Xenus Plus 1&2-Axis User Guide