User guide

Copley Controls 3
TABLE OF CONTENTS
About This Manual ................................................................................................................................................................................ 5
1: Introduction ............................................................................................................................................................................... 10
1.1: Xenus Plus Family Overview ................................................................................................................................................ 11
1.2: CME 2 .................................................................................................................................................................................. 12
1.3: CML/CMO ............................................................................................................................................................................ 13
1.4: Copley Virtual Machine (CVM) .............................................................................................................................................. 13
1.5: Indexer 2 .............................................................................................................................................................................. 13
1.6: CPL ...................................................................................................................................................................................... 13
2: Operational Theory .................................................................................................................................................................... 14
2.1: Drive Internal Power ............................................................................................................................................................. 15
2.2: PWM Switching Frequency Synchronizing ............................................................................................................................ 16
2.3: Commutation Modes ............................................................................................................................................................. 17
2.4: Feedback .............................................................................................................................................................................. 17
2.5: Operating Modes .................................................................................................................................................................. 18
2.6: Input Command Types .......................................................................................................................................................... 25
2.7: Communication ..................................................................................................................................................................... 30
2.8: Limit Switches ....................................................................................................................................................................... 34
2.9: Brake Operation.................................................................................................................................................................... 35
2.10: Status Indicators ................................................................................................................................................................. 36
2.11: Protection ........................................................................................................................................................................... 47
2.12: Position and Velocity Errors ................................................................................................................................................ 50
2.13: Inputs XEL/XPL/XML .......................................................................................................................................................... 53
2.14: Inputs XE2/XP2/800-1782/800-1808 ................................................................................................................................... 54
2.15: Outputs, XEL/XPL/XML ...................................................................................................................................................... 55
2.16: Outputs, XE2/XP2/800-1782/800-1808 ............................................................................................................................... 56
2.17: Regen Resistor Theory ....................................................................................................................................................... 57
3: Specifications ............................................................................................................................................................................ 58
3.1: Agency Approvals ................................................................................................................................................................. 59
3.2: Power Input .......................................................................................................................................................................... 59
3.3: Power Output ........................................................................................................................................................................ 60
3.4: Control Loops ....................................................................................................................................................................... 61
3.5: Regen Circuit Output ............................................................................................................................................................ 61
3.6: Digital Command Input ......................................................................................................................................................... 61
3.7: Analog Inputs ........................................................................................................................................................................ 62
3.8: Digital Inputs ......................................................................................................................................................................... 63
3.9: Analog Outputs ..................................................................................................................................................................... 64
3.10: Digital Outputs .................................................................................................................................................................... 64
3.11: Encoder Power Supply Output ............................................................................................................................................ 65
3.12: Primary Encoder Inputs ...................................................................................................................................................... 65
3.13: Analog Encoder Inputs ........................................................................................................................................................ 66
3.14: Hall Switch Inputs ............................................................................................................................................................... 67
3.15: Resolver Interface ............................................................................................................................................................... 68
3.16: Multi-Mode Port .................................................................................................................................................................. 69
3.17: Serial Interface.................................................................................................................................................................... 71
3.18: Network Interfaces .............................................................................................................................................................. 72
3.19: Status Indicators ................................................................................................................................................................. 73
3.20: Fault Levels ........................................................................................................................................................................ 73
3.21: Power Dissipation ............................................................................................................................................................... 74
3.22: Thermal Impedance ............................................................................................................................................................ 74
3.23: Mechanical and Environmental ........................................................................................................................................... 75
3.24: Dimensions ......................................................................................................................................................................... 76
4: Wiring ......................................................................................................................................................................................... 79
4.1: General Wiring Instructions ................................................................................................................................................... 80
4.2: AC Mains (J1) XEL/XPL/XML/XE2/XP2/800-1782/800-1808 ................................................................................................. 83
4.3: Motor(s) ................................................................................................................................................................................ 86
4.4: Regen Resistor (Optional)..................................................................................................................................................... 87
4.5: Logic Supply / Brake ............................................................................................................................................................. 89
4.6: Safe Torque Off .................................................................................................................................................................... 91
4.7: RS-232 Serial Communications ............................................................................................................................................ 95
4.8: Network Ports ....................................................................................................................................................................... 96
4.9: Control I/O ............................................................................................................................................................................ 99
4.10: Secondary I/O ................................................................................................................................................................... 103
4.11: Motor Feedback ................................................................................................................................................................ 115
A: Regen Resistor Sizing and Configuration .............................................................................................................................. 124
A.1: Sizing a Regen Resistor ..................................................................................................................................................... 125
B: I
2
T Time Limit Algorithm ............................................................................................................................................................... 129
B.1: I
2
T Algorithm....................................................................................................................................................................... 130
C: Thermal Considerations .......................................................................................................................................................... 133
C.1: Operating Temperature and Cooling Configurations ........................................................................................................... 134
C.2: Heatsink Mounting Instructions (XEL/XPL/XML) ................................................................................................................. 137
C.3: Heatsink Mounting Instructions (XE2/XP2/800-1782/800-1808) ......................................................................................... 138