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Copley Controls Xenus XSL - User Manual

Copley Controls Xenus XSL
202 pages
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Table of Contents

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Do you have a question about the Copley Controls Xenus XSL and is the answer not in the manual?

Copley Controls Xenus XSL Specifications

General IconGeneral
ModelXenus XSL
Digital Outputs4
Analog Inputs2
Communication ProtocolsCANopen
Continuous Current10 A
Peak Current20 A
FeedbackIncremental Encoder, Hall Sensors
Operating Temperature0°C to +55°C
ProtectionOvervoltage, Undervoltage, Overcurrent, Overtemperature, Short Circuit

Summary

About This Manual

Overview and Scope

Describes the operation and installation of the Xenus amplifier.

Related Documentation

Lists other Copley Controls documents relevant to CANopen features.

Comments

Invites user comments on the manual and provides contact info.

Copyrights

States document reproduction permissions and lists registered trademarks.

Document Validity

Reserves the right to modify products and information without notice.

Product Warnings

DANGER: Hazardous voltages

Warns about hazardous voltages and advises caution during installation.

Risk of electric shock

Warns about high-voltage circuits connected to mains power.

Risk of unexpected motion with non-latched faults

Warns about unexpected motion after correcting non-latched faults.

Using CME 2 or serial commands may affect or suspend CAN operations

Warns that CME 2 or serial commands can affect ongoing CAN operations.

Latching an output does not eliminate the risk of unexpected motion with non-latched faults

Explains that custom outputs don't latch faults, risking unexpected motion.

Use equipment as described

Advises operating amplifiers strictly within the manual's specifications.

Revision History

CHAPTER 1: INTRODUCTION

1.1: Amplifier

Overview of Xenus amplifier capabilities, versions, and models.

1.2: CME 2

Describes CME 2 software for commissioning, multi-drop features.

1.3: CMO;CML

Introduces Copley Motion Libraries (CML) and Objects (CMO) for CANopen.

CHAPTER 2: OPERATIONAL THEORY

2.1: Amplifier Internal Power

Explains the power distribution within the Xenus amplifier.

2.2: Synchronizing PWM Switching Frequency

Discusses synchronizing PWM switching frequency among multiple amplifiers.

2.3: Commutation Modes

Details the three commutation modes for driving motors (sinusoidal, trapezoidal, DC).

2.4: Feedback

Covers encoder and resolver support and secondary encoder interface options.

2.5: Operating Modes

Explains different operating modes (current, velocity, position) and control loops.

2.6: CANopen Operation

Describes CANopen network, profiles for motion, and supported modes.

2.7: Limit Switches

Explains how to use digital inputs for limit switches and amplifier response.

2.8: Brake Operation

Details how digital outputs control the brake and brake/stop sequences.

2.9: Status Indicators

Explains the amplifier and CAN interface status indicator LEDs.

2.10: Protection

Covers amplifier protection mechanisms, including faults and clearing procedures.

2.11: Position and Velocity Errors

Discusses error handling methods like following error and tracking windows.

2.12: Communication

Describes communication interfaces (RS-232, CAN) and CME 2 interaction.

2.13: Inputs

Details digital inputs, input filters, debounce time, and programmable functions.

2.14: Outputs

Explains digital outputs, standard and custom output functions.

2.15: Regen Resistor Theory

Explains regeneration, regen resistors, and circuit components.

CHAPTER 3: SPECIFICATIONS

3.1: Agency Approvals

Lists CE and UL compliance standards for the amplifier.

3.2: Power Input

Specifies mains voltage, frequency, current, and logic supply requirements.

3.3: Power Output

Details peak current, continuous current, efficiency, and output type.

3.4: Control Loops

Lists control loop types, sampling rates, bandwidth, and filters.

3.5: Regen Circuit Output

Provides specifications for continuous power, peak power, and energy absorption.

3.6: Digital Command Input

Details digital position, and digital current & velocity command inputs.

3.7: Analog Command Input

Specifies channels, measurement range, impedance, and bandwidth.

3.8: Digital Inputs

Lists channels, types, input voltage ranges, and debounce settings.

3.9: Digital Outputs

Details channels, type, maximum voltage, sink current, and function.

3.10: Brake Output

Specifies type, maximum sink current, and function for brake control.

3.11: Encoder Power Supply Output

Specifies voltage output, maximum current, and protection for encoders.

3.12: Primary and Secondary Encoder Inputs

Details channels, type, signals, and maximum frequency for encoder inputs.

3.13: Analog Encoder Inputs

Specifies channels, type, signals, nominal voltage, and bandwidth.

3.14: Hall Switch Inputs

Lists channels, type, input voltage ranges, and RC filter time constant.

3.15: Resolver Interface

Details resolution, reference frequency, voltage, and current for resolver interface.

3.16: Encoder Outputs

Specifies channels, type, signals, and maximum frequency for encoder outputs.

3.17: Serial Interface

Details channels, type, signals, baud rate, data format, and protocol.

3.18: CAN Interface

Specifies channels, connectors, signals, format, protocol, and supported modes.

3.19: Status Indicators

Describes the amplifier and CAN interface status indicator LEDs.

3.20: Fault Levels

Lists fault conditions and their threshold levels.

3.21: Power Dissipation

Shows power dissipation charts for different models and mains voltages.

3.22: Thermal Impedance

Refers to thermal considerations for heatsink and cooling configurations.

3.23: Mechanical and Environmental

Details size, weight, ambient temperature, humidity, and environment ratings.

3.24: Dimensions

Provides mechanical drawings with dimensions for the amplifier.

CHAPTER 4: WIRING

4.1: General Wiring Instructions

Covers electrical codes, warnings, and grounding considerations.

4.2: AC Mains (J1)

Details the mating connector, pin assignments, and wiring diagrams for AC mains.

4.3: Motor (J2)

Describes the motor connector and provides wiring diagrams for brushless and brush motors.

4.4: Regen Resistor (J3) (Optional)

Explains the regen resistor connector, pin assignments, and wiring diagram.

4.5: Logic Supply; Brake (J4)

Details the logic supply/brake connector and its wiring diagram.

4.6: RS-232 Serial Communications (J5)

Describes the RS-232 connector, pin assignments, and wiring diagram for PC communication.

4.7: CAN Bus (J6)

Details the CAN bus connector, pin assignments, and wiring diagrams.

4.8: Motor Feedback (J8)

Describes the motor feedback connector and provides wiring diagrams for various feedback types.

CHAPTER 5: QUICK SETUP WITH CME 2

5.1: Warnings

Presents critical safety warnings for CME 2 setup and amplifier operation.

5.2: CME 2 Installation and Serial Port Setup

Guides through CME 2 software installation and serial port configuration.

5.3: Prerequisites

Lists hardware, equipment, and wiring prerequisites before starting setup.

5.4: Basic Setup

Covers initial amplifier setup including motor family, type, and commutation.

5.5: Motor Setup

Details methods for performing motor setup using data files or manual entry.

5.6: Feedback Setup

Guides on configuring rotary and linear motor feedback options.

5.7: Brake;Stop (Optional)

Explains how to configure brake/stop parameters for safety and holding.

5.8: Amplifier Configuration

Covers configuration of digital inputs, outputs, custom outputs, and fault latching.

5.9: Command Input

Details how to configure analog, PWM, digital position, and CAN command inputs.

5.10: Auto Phase

Guides through the auto phase procedure for motor wiring and Hall setup.

5.11: Current Loop

Covers current loop settings and manual tuning procedures.

5.12: Velocity Loop

Explains velocity loop settings and manual tuning procedures.

5.13: Position Loop

Details position loop settings, manual tuning, and S-curve profile testing.

5.14: Completion Steps

Outlines final steps to save configuration and perform testing.

CHAPTER 6: USING CME 2

6.1: CME 2 Overview

Provides an overview of CME 2 software features and the main screen layout.

6.2: Manage Amplifier and Motor Data

Explains how to manage amplifier and motor data using memory and disk storage.

6.3: Downloading Firmware

Guides on acquiring and downloading firmware updates to the amplifier.

6.4: Control Panel

Details the Control Panel's functions for monitoring and controlling the amplifier.

6.5: Scope Tool

Explains how to use the Scope Tool for tuning, monitoring, and diagnostics.

6.6: Error Log and Communications Log

Describes how to view and manage error and communications logs.

6.7: CME 2 Virtual Amplifier

Covers using virtual amplifiers for training and offline file creation.

6.8: Manual Phasing

Provides instructions for manual motor phasing and troubleshooting.

6.9: Auto Tune Current Loop

Guides through the auto-tuning process for the current loop.

6.10: Home Function

Explains how to set and test homing parameters using the Home function.

APPENDIX A: REGEN RESISTOR SIZING AND CONFIGURATION

A.1: Sizing a Regen Resistor

Describes formulas to determine regen resistor requirements based on application.

A.2: Configuring a Custom Regen Resistor

Guides on configuring amplifier settings for a custom regen resistor.

APPENDIX B: I2 T TIME LIMIT ALGORITHM

B.1: I2 T Algorithm

Explains the I2T current limit algorithm, formulas, and operation.

APPENDIX C: VELOCITY LOOP FILTERS

C.1: Advanced Velocity Loop Filter

Details filter overview, types (Low-Pass, Bi-Quad), and instructions.

APPENDIX D: THERMAL CONSIDERATIONS

D.1: Operating Temperature and Cooling Configurations

Shows allowable ambient temperatures for Xenus amplifiers based on cooling options.

D.2: Heatsink Mounting Instructions

Provides instructions for mounting heatsinks using phase change material.

APPENDIX E: XENUS FILTER

E.1: Overview

Introduces the XSL-FA-01 edge filter for minimizing output noise.

E.2: XSL-FA-01 Edge Filter Specifications

Lists electrical specifications for the XSL-FA-01 edge filter.

E.3: Thermal Considerations

Discusses cooling requirements and fan mounting guidelines for the filter.

E.4: XSL-FA-01 Edge Filter Dimensions

Shows mounting dimensions for the XSL-FA-01 edge filter.

E.5: XSL-FA-01 Edge Filter Wiring

Describes wiring of the XSL-FA-01 edge filter, including codes and connector locations.

E.6: XSL-FA-01 Edge Filter Ordering

Lists model numbers and connector kit part numbers for ordering the edge filter.

APPENDIX F: CONNECTING FOR SERIAL CONTROL

F.1: Single-Axis and Multi-Drop

Explains using RS-232 for single-axis control and multi-drop gateway setups.

APPENDIX G: SERVOTUBE MOTOR SETUP

G.1: ServoTube Setup and Configuration

Details ServoTube basic setup, motor/feedback configuration, and initial values.

G.2: ServoTube Auto Phase and Manual Phase

Guides through ServoTube auto and manual phase procedures for motor setup.

G.3: Special ServoTube Setup Completion

Instructs on completing the ServoTube setup by returning to general procedures.

APPENDIX H: ORDERING GUIDE AND ACCESSORIES

H.1: Amplifier Model Numbers

Lists part numbers for various Xenus amplifier models and configurations.

H.2: Accessory Model Numbers

Lists part numbers for software, connector kits, and other accessories.

H.3: Order Example

Provides an example of how to order amplifier and related accessories.

H.4: Control and Feedback Cable Color Codes

Details wire color codes for control and feedback cables.

H.5: Regen Resistor Specifications

Lists specifications and dimensions for Regen Resistor models.

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