Parker Automation XL50 Manual

Automation
XL25/XL50/XL80
Stepper Drives
User Guide
Part No: 1600.286.02 March, 2002

IMPORTANT INFORMATION FOR USERS
Installation and Operation of Motion Control Equipment

It is important that motion control equipment is installed and operated in such a way that all applicable safety
requirements are met. It is your responsibility as an installer to ensure that you identify the relevant safety
standards and comply with them; failure to do so may result in damage to equipment and personal injury. In
particular, you should study the contents of this user guide carefully before installing or operating the
equipment.
The installation, set-up, test and maintenance procedures given in this User Guide should only be carried
out by competent personnel trained in the installation of electronic equipment. Such personnel should be
aware of the potential electrical and mechanical hazards associated with mains-powered motion control
equipment - please see the safety warning below. The individual or group having overall responsibility for
this equipment must ensure that operators are adequately trained.
Under no circumstances will the suppliers of the equipment be liable for any incidental, consequential or
special damages of any kind whatsoever, including but not limited to lost profits arising from or in any way
connected with the use of the equipment or this user guide.
SAFETY WARNING
High-performance motion control equipment is capable of producing rapid movement and very high forces.
Unexpected motion may occur especially during the development of controller programs. KEEP WELL
CLEAR of any machinery driven by stepper or servo motors. Never touch any part of the equipment while it
is in operation.
This product is sold as a motion control component to be installed in a complete system using good
engineering practice. Care must be taken to ensure that the product is installed and used in a safe manner
according to local safety laws and regulations. In particular, the product must be enclosed such that no part
is accessible while power may be applied.
This and other information from Parker-Hannifin Corporation, its subsidiaries and authorised distributors
provides product or system options for further investigation by users having technical expertise. Before you
select or use any product or system, it is important that you analyse all aspects of your application and
review the information concerning the product in the current product catalogue. The user, through its own
analysis and testing, is solely responsible for making the final selection of the system and components and
assuring that all performance, safety and warning requirements of the application are met.
If the equipment is used in any manner that does not conform to the instructions given in this user guide,
then the protection provided by the equipment may be impaired.
The information in this user guide, including any apparatus, methods, techniques, and concepts described
herein, are the proprietary property of Parker Electromechanical Division or its licensers, and may not be
copied, disclosed, or used for any purpose not expressly authorised by the owner thereof.
Since Parker Electromechanical constantly strives to improve all of its products, we reserve the right to
modify equipment and user guides without prior notice. No part of this user guide may be reproduced in any
form without the prior consent of Parker Electromechanical Division.
Electromechanical Division of Parker Hannifin plc, 2002

All Rights Reserved
Product Type: XL25, XL50 & XL80
The above product is in compliance with the requirements of directives
73/23/EEC Low Voltage Directive
93/68/EEC CE Marking Directive
89/336/EEC Electromagnetic Compatibility Directive
Provided the installation requirements described in this user guide are met, and there are
no special requirements of the installation and operating environment so that the
application may be considered typical, the XL drive series installation will conform to the
protection requirements of Council Directive 89/336/EEC as amended by Directive
92/31/EEC on the approximation of the laws of the Member States relating to
Electromagnetic Compatibility when operated and maintained as intended.
In assessing the overall compliance of an installation consideration must also be given to

the effects of mains harmonics and flicker when interfacing the total supply system to the
public low voltage supply system.
In accordance with IEC 61800-3:1997 (Adjustable speed electrical power drive systems)
this product is of the restricted sales distribution class which meets the needs of an
industrial environment when installed as directed. However, further measures may need
to be taken for use of the product in a domestic environment.
WARNING Risk of damage and/or personal injury
The XL drives and XL_PSU power supply described in this user guide contain no
user-serviceable parts. Attempting to open the case of any unit, or to replace any
internal component, may result in damage to the unit and/or personal injury.
Contact Addresses
For engineering For engineering

assistance in Europe: assistance in Germany
Parker Hannifin plc Parker Hannifin GmbH
Electromechanical Electromechanical
Division - Digiplan Division - Hauser
21 Balena Close P. O. Box: 77607-1720
Poole, Dorset Robert-Bosch-Str. 22
England, BH17 7DX D-77656 Offenburg, Germany
Tel: +44 (0)1202-699000 Tel: +49 (0)781 509-0
Fax: +44 (0)1202-695750 Fax: +49 (0)781 509-176
e-mail: [email protected] e-mail: [email protected]
e-mail: [email protected]
Website: www.parker-emd.com Website: www.parker-emd.com
For engineering For engineering

assistance in Italy assistance in the U.S.:
Parker Hannifin SpA Parker Hannifin Corporation
Divisione SBC Compumotor Division
20092 Cinisello Balsamo 5500 Business Park Drive, Suite D
Milan, Rohnert Park
Italy Via Gounod, 1 CA 94928
USA
Tel: +39 02 6601 2478 Tel: (800) 358-9070
Fax: +39 02 6601 2808 Fax: (707) 584-3793
FaxBack System: (800) 936-6939
e-mail: [email protected] e-mail: [email protected]
Website: www.parker-emd.com Website: www.compumotor.com
Symbols used, have the following meanings:
Caution -
Refer to the
accompanying documentation
Protective conductor terminal

CONTENTS i
Contents
1. Introduction...........................................................................................................1
2. Mechanical Installation .........................................................................................3
3. Electrical Installation.............................................................................................9
4. Control of XL Step Direction Drives......................................................................33
5. Maintenance and Troubleshooting .......................................................................43
6. Hardware Reference ............................................................................................47
Index..........................................................................................................................53
User Guide Change Summary

This user guide, version 1600.286.02, is the second version of the XL25/XL50/XL80
Stepper Drives User Guide.
When a user guide is updated, the new or changed text is differentiated with a change
bar in the outside margin (this paragraph is an example). If an entire section is changed,
the change bar is located on the outside margin of the section title.
Major changes in revision 02 include:
Addition of XL80 information

SY motor range
XL PSU information
Correction of input supply voltage range
ii XL25, XL50 & XL80 STEPPER DRIVE USER GUIDE
Latest Changes Sheet
Known changes required to be made to this issue of user guide are listed below:
Note: This sheet is intended for documenting any changes or corrections necessary in
this issue of user guide. Any necessary changes we become aware of will be added to
this sheet and will be incorporated into the main part of the user guide when it is next
issued.
1. INTRODUCTION 1
1. Introduction
XL25/XL50/XL80 Product Description

XL25, XL50 and XL80 are low powered stepper drives offering a cost-effective solution for
applications involving single or multiple axis solutions. Designed to be used with existing
general purpose stepper motors, the drives can be powered from a 20-84V (XL25)
40-84V (XL50) or 40-84V (XL80) DC supply and are fully LVD compliant. EMC compliance
is achieved using an external line filter and following the wiring and layout recommendations
described in the section Electrical Installation. Three models provide an output current
range of 1.25 to 8.0A:
XL80 providing a motor voltage of 80V at 8.0A peak

The XL25 and XL50 share a similar case size, while the XL80 is slightly wider. Figure 1-1
illustrates the two case styles. See Mechanical Installation for dimension information.
XL25/50 XL80
Figure 1-1. XL25/XL50 and XL80

2 XL25, XL50 & XL80 STEPPER DRIVE USER GUIDE
Product Features
Protection Circuits Function Indicators

Motor short circuits Drive Status (HV)/zero phase
Overvoltage Fault Status (ST)
Overtemperature
+24V reverse polarity
Adjustments Outputs and Inputs

(Bit switch) Fault
Step/direction or Step+/Step- Zero phase
Standby 50% or 70% Oscillator monitor
Resolution Clock
Current level in 10% increments Direction
(External) Shutdown
SLOW & FAST ADJUST SLOW & FAST
Acceleration rate Analogue input (Fast)
Further Information
This user guide contains all the necessary information for the effective use of this drive.
However, to gain a more in-depth understanding of drive applications and motion control,
consider attending one of our English Customer Specific Technical Workshops, details of
which can be found on our web site (www.parker-emd.com) under Sales & Services,
Training.
Examples of previous courses that have proved to be of benefit include:
Use and programming of DIN rail H & L series drives

PDFX training
Using the 6K controller
EASI Tools programming
Mechanical product training for ET/ER, XR and HPLA
2. MECHANICAL INSTALLATION 3
2. Mechanical Installation
Environment
XL25/XL50/XL80 drives have an operating temperature range of 0 to 50C Max, and can be
used within humidity limits of 5-95% non-condensing. The drives should only be used,
guarded from operator contact in an atmosphere of Pollution Degree 2, which means only
dry, non conductive pollution is acceptable. The storage temperature limits are -20 to 70C.
It is recommended the drives are powered from the XL_PSU, which provides all the
necessary power supplies and eliminates the need for an EMC filter. One XL_PSU can
supply up to six drives, alternatively, drives can be powered from a DC supply, fed from an
isolated transformer. The insulation of the transformer must be suitably rated for the
Installation Category and working voltage on the primary.
Drive Cooling
XL25 and XL50 drives are cooled by natural convection, whilst the XL80 is fitted with an
integral fan. To aid cooling, drives should be installed vertically in an area where there is at
least a 50mm air gap above and below the package and a 10mm gap either side. Avoid
mounting heat producing equipment directly below a drive.
In the final installation, check that the ambient temperature specification of 50C Max
(without forced air cooling) is not exceeded directly below the top-most drives and that any
circulating air flow is not being blocked from reaching the drives. For cabinet cooling
calculations a drive dissipation figure of 15W can be assumed for the XL25/XL50 and 25W
for the XL80.
Drive Dimensions
XL25 and XL50 drives share the same dimensions which are shown in Figure 2-1.
137.4 max with fixings

30
15
4.5
10
5
175
195
185 ctrs
130
Figure 2-1. XL25/XL50 Dimensions

XL80 has the dimensions shown in Figure 2-2. Note the double slot fixing used on the base
of this wider drive. The XL80 has the same fixing positions as the XL_PSU, but the drive is
slightly wider (51mm) than the XL_PSU.
51
4.5
25.5
137.4 max (with fixings)
5
10
X1
+DC
-DC
+24V
GND
MOTOR
MOTOR
185 ctrs
SCN
195
X2
175
CTRL
I/O
XL
X3
OSC
HV ST
4.5
130
13 ref 25 ctrs
Figure 2-2. XL80 Dimensions
Mechanical Installation of Drives

It is recommended the drive is mounted vertically on a metal backplane, using M4 screws.
XL_PSU Dimensions
The XL_PSU dimensions are shown in Figure 2-3.
50
25 Mounting holes
4.5 mm diameter
+DC (80V)
-DC
EXT. BRAKING RES.
+24V
GND
P1
N MAINS
INPUT
L
175 110V-230V~
50/60 Hz
250VA 185 195
P2
XL
Power
Supply
Unit
HV STATUS
BRAKING RES.
24V STATUS
12.5 12.5 130

25
Figure 2-3. XL_PSU Dimensions
XL_PSU Mounting Information

The supply should be mounted vertically, near the drives it will supply. Both the top 4.5mm
diameter fixing hole and the bottom two 4.5mm width fixing slots should be used.
The supply should be mounted with a minimum free space of 50mm both below and above
its case. A side clearance of 10mm free space on both sides should be allowed.
Note, the supply must not be mounted above or close to other products which generate a
significant amount of heat by radiation or convection.
Motor Mounting Mechanical Considerations

Motors should be securely fixed in position at all times. Do not test a motor/drive
combination without first securing the motor see the Safety Warning at the front of this user
guide.
CAUTION risk of equipment damage
Do not back drive the motor, that is use the motor in an application that may cause the
motor shaft to be mechanically rotated in a manner uncontrolled by the drive.
Back driving the motor at high speed may damage the drive.
Back driving the motor at low to medium speeds may establish sufficient voltage on
the drives capacitors to energise the drive.
3. ELECTRICAL INSTALLATION 9
3. Electrical Installation
Installation Safety Requirements

XL stepper drives meet the requirements of both the EU Low Voltage Directive and EMC
directive when installed according to the instructions given within this section. The drive
must be installed in an enclosure to protect it from atmospheric contaminants and no
operator access should be allowed to the drive while it has DC power applied. Metal
equipment cabinets are ideally suited for housing the equipment since they can provide
operator protection, EMC screening, and can be fitted with interlocks arranged to remove all
power when the cabinet door is open.
Precautions
During installation, take the normal precautions against damage caused by electrostatic
discharges. Earthed wrist straps should always be worn.
All user I/O connections should be screened, using 360 braided screen - do not use a foil
screen.
A switch or circuit breaker must be included in the installation, which must be clearly marked
as the disconnecting device and should be within easy reach of the machine operator.
Cabinet Installation
To produce an EMC and LVD compliant installation it is recommended that drives are
mounted within a steel equipment cabinet. This form of enclosure is not essential to
achieving EMC compliance, but does offer the benefits of operator protection and reduces
the contamination of the equipment from industrial processes.
A steel equipment cabinet will screen radiated emissions provided all panels are bonded to a
central earth point. Separate earth circuits are commonly used within equipment cabinets to
minimise the interaction between independent circuits. A circuit switching large currents and
sharing a common earth return with another low level signal circuit could conduct electrical
noise into the low level circuit, thereby possibly interfering with its operation. For this reason
so called dirty earth and clean earth circuits may be formed within the same cabinet, but all
such circuits will eventually need to be returned to the cabinets main star earth point.
Individual drives are designed to be mounted on a metal earth plane to which the EMC
filters earth connection is also attached. The earth plane will have its own individual star
point earth which should be hard wired (using an insulated copper conductor) back to the
cabinets clean earth connection point.
Power Supply Connections

XL drives must be powered from DC supplies only.
X1 IMPORTANT
1 DC+
2 DC- Connect positive voltage
3 EARTH to pin 1 and negative to
4 24V DC
5 0V (GND 24V) pin 2. Reversing polarity
6 A+ will damage the drive.
7 A-
8 MOTOR GND
9 B+
10 B-
Figure 3-1. X1 Connections
Mating connector type is: Wieland 8213B/10 F OB, part number 25.323.4053.0
Supply Requirements
XL drives must be powered from DC supplies as specified below:
Drive Type DC Supply Voltage

between DC+ and DC-
XL25 20 to 84V absolute limits
Table 3-1. Drive Supply Voltages
Note: DC+ identifies the positive side of a DC supply.
The power supply must be isolated from the mains.
Safety Earth Requirements

The drives must be earthed, using the earth pin on X1 (pin 3).
XL Power Supply
The XL_PSU module is a 250W, power factor corrected, switched mode power supply for
use with XL stepper drives. Designed for direct operation from world-wide single phase AC
input voltages, the supply is capable of powering up to six drives without the need for an
EMC mains input filter*. The use of the XL_PSU offers the following benefits:
Auto-adapts to supplies between 95 and 264V AC

No EMC filter*
Less cabinet space
Built-in +24V DC supply
*For drives with up to 30 metre motor leads.
Physical Appearance
Housed in a slim, 50mm-wide metal case, the XL_PSU is shown in Figure 3-2. This form of
case matches the appearance of the XL drives and has the same height and depth.
Figure 3-2. XL_PSU Switched Mode Power Supply

AC Supply Connections
Input AC supplies need to be connected to the 3-way mains input connector P2. Use
approved mains cable, with a minimum wire size of 0.75mm2. The supplied mating
connector is a Phoenix Contact, having the name MSTB 2,5/3-STF-5,08 and order number
1777992.
P2
L N EARTH (GND.)
Figure 3-3. P2 Power In Socket Wiring
Output Connections
1
+DC (80V)
2
3
-DC
4
5 EXT. BRAKING RES.
6
7
+24V P1
8 Phoenix Contact
9 10-way female socket
GND
10
Figure 3-4. P1 Output Power Connector
Power out (+80V) is taken from pins 1 and 2 (use 32/02 1 mm2 cable), the return connection
being pins 3 and 4. +24V is available on pins 7 and 8 with the return connection being made
to the GND pins 9 and 10. The earth pin 6 is internally connected to the -DC pins 3 and 4.
The supplied mating connector is a Phoenix Contact, having the name IC 2,5/10-STF-5,08
and order number 1825394.
No connection exists between the earth pin 6 and the GND pins 9 and 10
Supply/Drive Connections
When used to supply up to six drives the power supply can be wired as shown in Figure 3-5.
Mininum spacing
10 mm between drives & PSU
+DC (80V)
-DC
EXT. BRAKING RES.
+24V
GND
MAINS
N
INPUT
L
110V-230V~
50/60 Hz
250VA
XL
Power
Supply
Unit
HV STATUS
BRAKING RES.
24V STATUS
Red
Black
Green/yellow
Figure 3-5. Power Supply and Drive Connections
Note: A kit of five connecting links is available, called XL-connect. You will need one kit for
every drive.
Power Dump/Braking Resistor Considerations

The XL power supply incorporates a regenerative power dumping circuit which may be used
to divert regenerated power into a dump or brake resistor. The need for such a circuit should
ideally be determined during system design, but the calculations are repeated here for
reference.
Calculating the Need for a Braking Resistor

For one drive axis a dump resistor will be required if the deceleration time in seconds is less
than (J2-0.2), where J is the total inertia in kg.m2 and is the maximum speed in revs/sec.
In a multi-axis system where a number of axes are decelerating at the same time, a given
axis will not pump the HV up, provided that the deceleration time on that individual axis is
greater than J112, where J1 is the inertial of axis 1 and 1 is the angular speed of axis 1.
Generally, other operating axes will absorb power from the supply and will add greater
capacitive loading and will therefore reduce the need for power dumping. If it is known that
certain conditions will cause several axes to decelerate together (say axes 3 & 4), then
check that the J2 value minus the deceleration time for each axis (both 3 & 4), added
together, do not give a result that is greater than 0.2. If they do, a dump resistor is likely to
be required.
External Braking Resistor Installation

If required, an external braking resistor may be fitted between pins 1 and 2 of P1 and pin 5 of
P1, as shown. The need for a braking resistor should be considered if the application
requires large inertial loads to be decelerated quickly. During deceleration if the drive faults-
out with over voltage or the braking resistor LED flashes orange - requesting power
dumping, it is likely a braking resistor needs to be fitted.
Note: If a braking resistor is fitted, a ferrite ring-core needs to be fitted over the braking
resistor leads, as shown in Figure 3-6. A suitable ring-core is the Parker Chomerics part
number H8FE-1115-NC, as used for the drives motor cable. The ferrite may be held in
place using heat shrinkable tubing, or cable ties. An in-line 5 X 20 mm fuse is recommended
to be fitted between pin 2 of P1 and the braking resistor. The fuse should have a maximum
value of 3.15A with a time delay low breaking characteristic.
The braking resistor should be wired using 16/02 0.5 mm2 cable.
1
2
3 Maximum
4 distance
150 mm
5
6
7
P1
8 Ferrite
9 absorber
10
In-line
fuse holder
These components are
to be mounted away from
operator contact. High voltages
and high temperature can
External braking be expected during normal
resistor. operation.
Figure 3-6. Braking Resistor Wiring

An internal dump switch has a peak rating of 800W. The dump resistor used should be
10 Ohms (nominal) with a power rating of 100W.
LED Indicators Function

Three tri-state LEDs are positioned on the front panel of the XL_PSU. Their function is
described in Table 3-2.
Position Colour Function

Left Orange AC Input present and PSU fault. No
HV output
Green AC Input present
No colour AC input off
Middle Orange Dump request

Green 80V DC present
Right Red 24V disabled by overcurrent fault

Orange 24V supplied by external supply
Green 24V supplied by XL_PSU
No colour No 24V present
Table 3-2. LED Indicators Function
The XL drives and XL_PSU power supply described in this user guide contain no user-
serviceable parts. Attempting to open the case of any unit, or to replace any internal
component, may result in damage to the unit and/or personal injury.
Discrete Power Supply Recommendations

If the XL_PSU is not being used individual XL drives can be powered from
transformer/bridge rectifier power supplies of the type shown in Figure 3-7. This design
suggests suitable component values for powering particular drive types, but can be adapted
to power more than one drive provided component power ratings are not exceeded.
Bridge rectifier rated at

2A min. for XL25 drive
Line Fuse 3A min. for XL50 drive
AC Fuse
TD/HBC 4A min. for XL80 drive
TD/HBC
Must have adequate cooling
6K8 2.5W HV bleed resistor
EMC
filter
X1.1
X1.2
Isolating
transformer Capacitor 2200F for XL25
with screen 3300F for XL50
4700F for XL80 X1.3
1metre max. from

capacitor to drive
Figure 3-7. Drive Power Supply
Note: The -DC input must be reliably earthed at X1.3.
Transformer Sizing
A DC input is required by the drive, which can be generated by rectifying and smoothing the
secondary voltage of a transformer. This is an unregulated supply so do not select a
secondary voltage which generates a DC output that exceeds 80V.
The size of transformer required for a stepper drive installation depends very much on the
application and on the maximum shaft power delivered by individual motors. However, the
following figures may be taken as a guide.
Assuming a torque margin of 25-30% has been allowed, the maximum demand from a single
XL25 drive is approximately 80VA, 125VA for an XL50 and 170VA for an XL80. These are
peak figures, which in most practical situations, and particularly in point-to-point positioning
systems, will cause the average power demand to be much lower than this. The peak power
demand may be significantly higher if a high performance enhanced-hybrid motor is used.
In multi-axis applications, the peak demand will depend on the maximum number of axes
running simultaneously; very little power is used by a stationary axis. You should allow
approximately 10VA for a stationary XL25 axis, 15VA for a stationary XL50 axis and 25VA
for a stationary XL80 axis. For example, a typical system with four XL50 drives in which no
more than two axes are in motion at any one time would comfortably operate from a 250-
300VA transformer.
It is worth noting that in a one-off or low volume application it is usually preferable to be

slightly generous in sizing the transformer, rather than spend a great deal of engineering
effort trying to calculate the minimum possible rating. In low-power systems the potential
savings in transformer cost are not large, although size and weight may also be a
consideration. In a higher volume application the same principles apply to the prototype
installation, but measurements of the supply current drawn under working conditions will give
a useful guide to the final specification required.
Low Voltage Operation

The drive specification allows for 24V DC -15%, which works out at a little over 20V. This is
the lowest that the supply should ever fall to if the risk of an under voltage fault is to be
avoided. Supply ripple could use up part or all of this tolerance, so make sure that any ripple
on the DC supply does not cause the input to dip below 20V.
Fuses
Fuses should be time delay, high breaking capacity and should be rated for the number of
drives and expected in-rush current.
AC Fuse
The secondary AC fuse is intended to protect power supply components and should have a
value twice that of the bridge rectifier current rating with a minimum value of 5A to prevent
nuisance blowing.
Line Fuse
Fit line fuses to protect the transformer and associated wiring. If you cannot identify the live
wire, fuse both phase conductors. Calculate the fuse value using:
1.5 VA
in amps, but needs to be a minimum of 2A to cope with in-
supply volts
rush current
Fuse types should be anti-surge HBC (High Breaking Capacity).

+24V Supply Connections

XL drives require a logic supply of +24V DC at 100mA per drive to power the oscillator.
Note: Drive control from an external step/direction source makes this supply unnecessary.
The +24V supply is connected to X1.4 and the return to X1.5, the total wire length, from
supply to drive, must not exceed 10m.
Connect the +24V supply 0V line to system earth (0V) at some convenient point before the
EMC filter input.
X1
4
5
- +
LOAD
3VK3
LINE
To backplane
star earth point +24V
0V
Earth connection at only

one point
Figure 3-8. +24V Supply Connections
The supply should be fused with a quick acting fuse, rated at 3A for up to 10 axes, with a 2A
increase for every extra 5 axes. Note: The +24V supply used must meet the voltage
requirements specification of +24V DC +10% -15%, ripple <1V p-p.
EMC Installation
These EMC installation recommendations are based on the expertise acquired during the
development of compliant applications which Parker believe are typical of the way a drive or
drives may be used. Provided you have no special installation requirements or untypical
operating environment requirements, XL drives will conform with current EMC Directives, as
defined at the front of this user guide.
General Requirements
XL drives will require an external filter to meet EMC installation compliance requirements,
unless they use the XL_PSU. It is recommended that the drive is mounted on a conductive
panel which is shared with the EMC filters. If the panel has a paint finish, it will be necessary
to remove the paint in certain areas to ensure filters and drives make a good large-area
metal to metal contact between case and panel.
Filters should be mounted close to the drive and supply wiring kept as short as practical.
Attempt to layout the wiring in a way that minimises cross-coupling between filtered and non-
filtered conductors. This means avoiding running wires from the output of a filter close to
those connected to its input. Where you wish to minimise the cross-coupling between wires
avoid running them side-by-side one another, if they must cross, cross them at 90 to each
other. Keep wiring supported and close to cabinet metalwork. A typical EMC layout is given
in Figure 3-9.
Recommended EMC filter types are CORCOM 6FC10 for loads up to 6A and 3VK3 for the
+24V supply up to 3A. Larger systems may require higher current rated filters.
Lead length X1
restriction
(less than 1 metre)
X2
DC Supply
CABINET
BACK
X3 PLANE
Star earth point

to the metal
backplane
- +
Output
(load)
CORCOM LOAD
6FC10 3VK3
LINE
(line)
Input
Power wiring conduit
Figure 3-9. XL25/XL50 EMC Installation

Motor Connections (EMC)

The recommended wire size for XL25/XL50/XL80 motor cables, of length less than 20m, is
1mm2. For motor cable lengths greater than 20m (up to a maximum of 50m) use a wire size
of 2.5mm2. Use a cable containing five conductors plus the braided screen (such as Lapp
34805), the green wire being used to provide an earth return to the drive. Termination at the
motor must be made using a 360 bond to the motor body, and this may be achieved by
using a suitable clamp. Many stepper motors are designed to accommodate an appropriate
terminal gland which can be used for this purpose.
All motor connections must be made using a high quality braided-screen cable. Cables
using a metallised plastic bandage for an earth screen are unsuitable and in fact provide
very little screening. Care must be taken when terminating the cable screen, the screen
itself is comparatively fragile; bending it round a tight radius can seriously affect the
screening performance. The selected cable must have a temperature rating which is
adequate for the expected operating temperature of the motor case.
At the drive end of the cable, a 360 connection to the screen should be made using the
brass P-clip provided beneath the motor connector. The diameter of the P-clip is 6mm for
use with the ready made motor cables having 1mm2 conductors. The P-clip needs to be
firmly clamped to the copper braid. If the connection appears loose, fold the braid back on
itself to increase the amount of braid under the clip and re-tighten.
Custom cables will require the cable insulation to be removed to expose the braided screen.
If you are using a motor cable with 2.5mm2 conductors the size of the brass P-clip will need
to be 9mm to accommodate the increased cable diameter. A ferrite absorber, with a
specification matching that of the Chomerics H8FE-1115-NC, is also required to be
positioned on the motor cable using heat shrink sleeving or cable ties. The position of the
absorber should be just below the drive, as shown in Figure 3-10. Always secure the cable
using the P-clip, as shown. Do not rely upon the connector alone holding the motor cable in
place. The X1 connector must not be stressed by hanging cables, as this may lead to
connector over-heating.
X1
Red
Black
Green/yellow
Exposed braid
under P-clip
X2
X3
Ferrite
absorber
Figure 3-10. Position of absorber & motor wiring details
There must be no break in the 360 coverage that the screen provides around the cable
conductors. If a connector must be used it should retain the 360 coverage, possibly by the
use of an additional metallic casing where it passes through the bulkhead of the enclosure.
The cable screen must not be bonded to the cabinet at the point of entry. Its function is to
return high-frequency chopping current back to the drive. This may require mounting the
connector on a sub-panel insulated from the main cabinet, or using a connector having an
internal screen which is insulated from the connector housing. Within the cabinet itself, all
the motor cables should lie in the same trunking as far as possible. They must be kept
separate from any low-level control signal cables. This applies particularly where the control
cables are un-screened and run close to the drive.
Note that the motor cable routing within the equipment cabinet should be kept at least
300mm away from I/O cables carrying control signals.
Ferrite absorber specifications

The absorber used for motor cables is made from a low-grade ferrite material which has high
losses at radio frequencies. The absorber acts like a high impedance in this waveband. The
recommended component is produced by Parker Chomerics and is suitable for use with a
cable having an outside diameter up to 10mm. The specification is as follows:
Chomerics part number H8FE-1115-NC
Outside diameter 17.5mm
Inside diameter 10.7mm
Length 28.5mm
Impedance at 25MHz 80 ohm
Impedance at 100MHz 120 ohm
Curie temperature 130C (the device should not be operated near this temperature)
Motor Selection
Usually optimum performance will be obtained when the current rating of the motor is
between 1 and 1.5 times the drive rating, but remember the current rating of a motor is its
DC rating, whilst drives are rated at peak output. To match a particular motors current
rating, multiply the drives peak output current by 0.7. Drives can be de-rated to
accommodate motors with lower current ratings (using the bit switch), however the high
speed torque will be reduced.
Do not use a drive setting which gives an output current greater than the motor rating.
With 4 lead motors the bipolar rating is quoted and this should match the criteria stated
above.
With 8 lead motors the bipolar rating of the motor, which is normally quoted, refers to a
parallel winding connection. With the windings connected in series the current rating of the
motor connection will be 50% that of the bipolar rating, and the motor will give improved low-
speed torque, but reduced high-speed torque.
The XL25/XL50/XL80 will drive motors having an inductance as low as 0.5mH, but the
recommended motor inductance range is between 0.8mH and 10mH.
Performance of the XL25/XL50/XL80 is optimised for the following motor types, listed in
Table 3-3 and Table 3-4.
Motor Type Motor Rated Motor

Current in Inductance XL80 XL50 XL25
Amps* in mH per
phase
SY561 4.2 1.0
SY562 4.2 2.6
SY563 6.5 1.2
SY871 4.2 1.6
SY872 6.5 1.5
SY873 8.4 1.7
SY1072 8.0 2.4
SY1073 10.0 2.7
*(parallel connection)
Table 3-3. SY Optimum Motor Types
Motor Type Motor Rated Motor

Current in Inductance XL80 XL50 XL25
Amps* in mH
STT57-51P 3.0 2.0
STT57-83P 6.6 0.8
STT57-102P 6.5 1.0
STT83-62P 4.5 1.5
STT83-93P 7.0 2.0
STT83-135P 10.0 1.6
STT57-51M 1.4 9.5
STT57-83M 2.7 5.7
STT57-102M 4.1 2.5
STT83-62M 2.4 5.2
STT83-93M 5.6 3.2
STT83-135M 5.4 5.6
*(parallel connection)
Table 3-4. ST Optimum Motor Types
Motor Voltage Ratings

Motors with a withstand voltage rating from phase to earth of 1000V AC should be used. An
insulation withstand rating of 500V AC is acceptable if an isolating transformer with earth
screen is used to power the system, and the secondary is earthed, as specified.
Large Motors
The largest recommended motor size is a 34-frame 3-stack. Please contact Parker EMD if
you wish to use a larger frame motor.
Motor Connections (at the motor)

Motor connections should be made directly between the drive and motor, the use of any
switching devices, such as contactors is not recommended.
In the majority of applications the drive will be used with an eight lead motor with the
windings connected in parallel or series, as shown in Figure 3-11. Motor connections will
need to be determined from the motors data sheet. These are normally identified by wire
colour or terminal markings, depending upon the make of the motor.
- + - +
MOTOR CONNECTOR
X1 +
6 A+
7 A-
- SAFETY
8 Gnd MOTOR
+ EARTH
9 B+
10 B-
- PARALLEL
Motor case CONNECTIONS
- + - +
MOTOR CONNECTOR
X1 +
6 A+
7 A-
- SAFETY
8 Gnd MOTOR
+ EARTH
9 B+
10 B-
- SERIES
Motor case
CONNECTIONS
Figure 3-11. 8 Lead Motor Connection Options
WARNING - High Temperature
The motor case temperature may exceed 70C and should be guarded from operator
contact.
Motor Safety Earth/Ground Connection

It is recommended that the case of an installed motor is independently bonded to a local
safety earth point. The safety earth lead should be at least 2.5mm2 in area.
Motor Overload/Short Circuit Protection

The motor outputs are protected against overload and short circuits. The motor output will
shut down within one second, when an overload of 250% of peak motor current is applied.
Note: In the case of stepper motors, locked rotor conditions do not cause an overload, so the
only foreseeable failure mode is a short circuit which is immediately detected by the
protection circuit.
Motor Wiring Identification Tables

The following tables supply serial and parallel connection information for a range of different
motor types.
Note: The SY56 can be supplied as a 4-terminal motor, as shown in Figure 3-12.
SY56 Series terminal

layout, viewed from the
A- B+ back of the motor
1 A+ B- 6
2 3 45
Figure 3-12. SY56 Motor Connections

MAKE TYPE A+ A- B- B+ NOTES

Parker EMD 8-lead Red Yel Pink Blk Link Blue & Violet, link White & Grey
STT/STL
T.Box 1 2 3 4 Link 5 & 6, link 7 & 8
Parker 4-lead - - - - Internally wired in parallel
OEM Series
8-lead Red Black Green White Link Blue & Yellow
Link Orange & Brown
Parker 8-lead Red Black White Green Link Yel & Blue
QM & S Motors Link Org & Brown
Parker T.Box 1 3 4 5 Link 2 & 6
QM & S Motors Link 7 & 8
(except 106-205)
Parker T.Box 1 3 7 8 Link 5 & 6
QM & 106-205 Link 2 & 4
RS & TS
Parker EMD 8-lead Blue Green Red Brown Link White to Black
SY 56 Series Link Grey to Yellow
T.Box - - - - Internally wired in parallel
Parker EMD 8-lead blue green red brown Link Yel & Gry, Link Blk & Wh
SY 87/102 Series T.Box 5 8 4 1 Link 7 & 6, Link 3 & 2
Pacific Scientific 6-lead Black Orange Red Yellow White/Blk/Org,
8-lead Black Orange Red Yellow Link Wh/Blk & Wh/Org
Link Wh/Red & Wh/Yel
T.Box 1 3 2 4 Link 5 & 6, Link 7 & 8
Astrosyn, 6-lead Red Red/Wh Grn Grn/Wh White & Black N/C
Rapidsyn,
Slo-syn T.Box 1 3 4 5 2 & 6 N/C
(X6)
Slo-syn 8-lead Red Red/Wh Grn Grn/Wh Link Black & White
Link Org & Blk/Wh
T.Box 1 3 5 4 Link 2 & 6, Link 7 & 8
(X8)
Stebon 8-lead Red Yel Pink Blk Link Blue & Violet, link White & Grey
T.Box 1 2 3 4 Link 5 & 6, link 7 & 8
M.A.E 6-lead Grn/W Grn Red Red/Wh White & Black N/C
h
8-lead Black Orange Red Yellow Link Wh/Blk & Wh/Org
Link Wh/Red & Wh/Yel
T.Box 6 5 8 7 Link 1 & 3, Link 2 & 4
Zebotronics T.Box 5 8 4 1 Link 2 & 3, Link 6 & 7
Oriental 6-lead Black Green Red Blue Yellow & White N/C
Sonceboz 8-lead Green Grn/Wh Red Red/Wh Link Org & Blk/Wh
Link Black & White
Japan Servo 6-lead Red Blue Green Yellow 2 X White N/C
Escap 8-lead Brown Org/Wh Red Yel/Wh Link Brn/Wh & Org
Link Red/Wh & Yellow
Bodine 8-lead Brown Orange Yellow Red Link Wh/Brn & Wh/Org
Link Wh/Yel & Wh/Red
T.Box 1 3 4 2 Link 5 & 7, Link 6 & 8
Table 3-5. Motor Connection Data - Windings in Series

MAKE TYPE A+ A- B- B+ NOTES

Parker EMD 8-lead Red & Blue Yel & Violet Wh & Pink Blk & Grey
STT/STL
T.Box 1&6 2&5 3&8 4&7
Parker 4-lead Red Black Green White
OEM Series
8-lead Red & Blue Black & Green & White &
Yellow Org Brown
Parker 8-lead Red & Blue Black & White & Brn Green &
QM & S Motors Yellow Orange
Parker T.Box 1&2 3&6 4&7 5&8
QM & S Motors
(except 106-205)
Parker T.Box 1&5 3&6 2&7 4&8
QM & 106-205
RS & TS
Parker EMD 8-lead Blu & Gry Grn & Yel Red & Blk Brn & Wh
SY 56 T.Box 2 1 5 6
Parker EMD 8-lead Blu & Gry Grn & Yel Red & Blk Brn & Wh
SY 87/102Series T.Box 5&6 8&7 4&3 1&2
Pacific Scientific 6-lead Black Wh/Blk/ Red Wh/Red/ Org & Yellow N/C
Orange Yellow
8-lead Black & Orange & Red/ Yellow &
Wh/Or Wh/Blk Wh/Yel Wh/Red
T.Box 1&5 3&6 2&7 4&8
Astrosyn, 6-lead Red Black Green White Red/Wh &
Rapidsyn, Grn/Wh N/C
Slo-syn T.Box 1 6 4 2 3 & 5 N/C
(X6)
Slo-syn 8-lead Red & Blk & Grn & Org &
White Red/Wh Blk/Wh Grn/Wh
T.Box 1&2 3&6 4&7 5&8
(X8)
Stebon 8-lead Red & Blue Yel & Violet Wh & Pink Blk & Grey
T.Box 1&6 2&5 3&8 4&7
M.A.E 6-lead Grn/Wh White Red Black Grn & Red N/C
8-lead Black & Or & Wh/Blk Red & Yel &
Wh/Or Wh/Yel Wh/Red
T.Box 3&6 1&5 4&8 2&7
Zebotronics T.Box 5&6 8&7 4&3 1&2
Oriental 6-lead Black Yellow Red White Grn & Blue N/C
Sonceboz 8-lead Grn & Or & Grn/Wh Red & Blk &
Blk/Wh White Red/Wh
Japan Servo 6-lead Red White* Green White*
Escap 8-lead Brn & Brn/Wh & Red & Red/Wh &
Orange Org/Wh Yellow Yel/Wh
Bodine 8-lead Brn & Wh/Brn & Or Yel & Wh/Yel &
Wh/Or Wh/Red Red
T.Box 1&7 3&5 4&6 2&8
*use correct white for each phase

For 6-lead motors, connections shown are for one half-winding.
N/C means No Connection
Table 3-6. Motor Connection Data - Windings in Parallel
Control Wiring
The XL drive connector layout is shown in Figure 3-13.
X1 Power
& Motor
10
mating Motor scn.
connector
for X1 9 5 Ctrl
X2 I/O
6
D-type 9-way
Bit female socket
switch
15 8
X3 OSC
9 D-type 15-way
1
female socket
LEDs
HVST
Figure 3-13. XL Connector Layout

Terminal Description
X3 Connector
User control signals are routed to the drives internal oscillator via connector X3. A multi-way
screened cable should be used for all control signal connections, with the screen terminated
onto the D-type shell.
Connector Type
15-way D-type female connector.
Connector Pin Out
Connector Signal Name

Pin
1 12V osc. reference 5%
9 12V osc. reference 5%
2 & 10 FAST ADJUST
3 & 11 SLOW ADJUST
4 & 12 External acceleration Capacitor FAST
5 Osc. monitor output*
6 Direction
7 FAST
8 SLOW
13 Shutdown
14 Analogue input FAST 0-10V
15 0V ground return for all control inputs
Table 3-7. X3 Signal Connections
*Output pulse width typically 1s (maximum frequency 200 kHz). This is an open collector
output which will require an external pull-up resistor of 4k7 (0.25W) to the +24V supply.
X2 Connector
Connector X2 is used for axis control, where an external controller is used to provide system
intelligence and generates the necessary Step and Direction signals. A multi-way screened
cable should be used for these control signals, where the screen makes a 360 connection
at both ends of the cable.
Connector Type
9-way D-type female.
Connector Pin Out
Connector Signal Name

Pin
1 Step + [stepdown +]
2 Dir. + [stepup +]
3 Zero Phase*
(open collector NPN active low)
4 Fault (open collector NPN active high)
5 Shutdown +
6 Step - [stepdown -]
7 Dir. - [stepup -]
8 Fault, Zero Phase External Reference
(open collector opto-coupler outputs, 5mA
max. current at 30V max.)
9 Shutdown -
Table 3-8. X2 Signal Connections
*Low going signal which occurs 50 times per motor revolution. If the drive is set to 4000
steps/rev, the zero phase signal will be active every 80 motor steps, or every
8 motor steps when the drive is set to 400 steps/rev.
Note: The FAULT and ZERO PHASE outputs are connected internally as shown. The
FAULT output transistor is normally turned ON, turning OFF when a fault occurs. The ZERO
PHASE output transistor is normally OFF and turns ON at positions of zero phase.
Note: The FAULT and ZERO PHASE Drive
outputs are connected internally as shown. 4

The FAULT output transistor is normally FAULT+
turned ON, turning OFF when a fault occurs.
The ZERO PHASE output transistor is
normally OFF and turns ON at positions of 3
ZERO PHASE
zero phase.
8
Motor Connector (Part of X1)

Motor connections need to be made using a side entry plug, as specified below. For full
motor cable wiring details see the EMC installation information.
It is recommended that motor connections are made directly between the motor and drive,
avoiding any switching devices, such as contactors or relays. However, if such switching is
essential, precautions must be taken to ensure motor connections are switched in both
phases when the drive is de-energised and the motor current has collapsed to zero. It is
essential to ensure that the contactor/relay does not open or close when the drive is
energised.
Connector Type
Mating connector type is: Wieland 8213B/10 F OB, part number 25.323.4053.0
Connector Pin Out
Pin Connection Signal Name

6 Motor Phase A+
7 Motor Phase A-
8 Motor GND (drain)
9 Motor Phase B+
10 Motor Phase B-
Table 3-9. Part of X1 Motor Connections

4. CONTROL OF DIN RAIL STEP DIRECTION DRIVES 33
4. Control of XL Step Direction Drives
Overview
This section describes the operation of XL step direction drives using the internal oscillator or
external control. Internal oscillator operation is used for stand-alone applications, where a
single axis is being controlled manually or via a dedicated interface. External control allows
the drive to be used in multi axis applications where an external controller provides all the
necessary intelligence and generates the required Step and Direction signals.
Compared to the DIN Rail H & L drives: XL does not offer boost, has only a DC power input,
and has no power dump option, unless used with the XL_PSU.
Default Settings
When the drive leaves the factory the default settings are as follows:
Control step/direction
Standby current reduction 50%
Resolution 4000 steps per rev.
Current 50% of peak rating
To alter these default values see Bit Switch Settings later in this section.
Control of the XL step-direction drive

XL drives are controlled by step and direction signals. These signals may be derived either
from an external step-direction source or from the internal oscillator built into the drive. The
drive will also accept step-up/step-down signals from an external source.
Using an external step-direction source

The step and direction inputs are designed to accept differential signals with TTL levels.
This arrangement gives improved noise immunity over single-ended systems. The step-
direction and shutdown input circuits are shown in Figure 4-1. Bit switch 2 should be OFF
when using a step-direction source.
Drive
(DIR+)
STEP+ HCPL2631
SDOWN+ 220R
(DIR-)
STEP-
SDOWN-
Figure 4-1. Step, Direction and Shutdown Input Circuit
The motor performs a step when Step+ goes high with respect to Step-. The maximum
frequency on the step input is 200kHz, allowing a theoretical maximum speed of 3000rpm to
be achieved at a resolution of 4000 steps/rev. In practice the maximum attainable speed will
depend on the characteristics of the motor in use. The allowable width of the step pulse
depends on the maximum input frequency to be used; the pulse width should never exceed
the interval between pulses, in other words the signal becomes a square wave at the
maximum frequency. Therefore at 200kHz the maximum pulse width is 2.5S. The
minimum step pulse width is 1S.
With the motor connected according to the information supplied, it should rotate clockwise
when viewed from the shaft end when Direction+ is high with respect to Direction-. The
direction signal should only be changed when the motor is stationary, and to maintain
positional integrity the first step pulse should not occur within 1S of a direction change.
Using a step-up/step-down source

Some types of stepper controller generate an output in the form of two independent step
pulse trains, one for each direction of rotation. The XL drive will accept this type of signal
when bit switch 2 is ON.
Connect the step-down signal to the normal step inputs and the step-up signal to the
direction inputs. The motor should rotate clockwise from a step-up pulse and counter-
clockwise from a step-down pulse. The guidelines regarding step pulse width are the same
for step-up/step-down as for step-direction operation.
Using the internal oscillator

XL step-direction drives incorporate an internal oscillator which will deliver a controlled pulse
stream to the drive. The oscillator may be controlled by operator push-buttons, relay
contacts or external NPN transistors. It has two speed ranges, designated Slow and Fast,
which are both adjustable by means of external programming resistors. Separate control
inputs are provided for each speed range; these inputs are internally pulled up to +12V, and
must be taken to 0V to start the oscillator. The input circuits are shown in Figure 4-2.
Drive Drive
+12V +12V
SLOW FAST
+
-
Figure 4-2. Enable circuits for Slow and Fast Inputs
When the Slow input is taken low, the oscillator will run at a constant frequency determined
by the Slow Range programming resistor. The frequency must therefore correspond to a
speed within the start-stop range of the motor. Taking the Fast input low will cause the
oscillator to accelerate up to the programmed Fast speed at a preset rate. The preset rate
may be reduced by the addition of an external capacitor. Alternatively, an analogue input
allows the Fast speed to be controlled by an external signal in the range 0-10V DC.
A separate Auxiliary Direction input is provided to control motor direction when the internal
oscillator is used. This input is internally pulled up to +12V and if left open-circuit will
produce counter clockwise (CCW) rotation, for a correctly wired motor. Taking this input low
will reverse direction provided that the differential Direction+ and Direction- inputs are open-
circuit.
Setting the oscillator speeds

The programmed speed in each range is determined by an external resistor connected
between the appropriate Adjust input and one of the two 12V reference pins
(see Figure 4-3). Two reference pins are provided to minimise the number of connections
that need to be made to a single pin.
Drive SLOW ADJUST Drive FAST ADJUST
External External
slow speed fast speed
set resistor set resistor
Ref. +12V Ref. +12V
Figure 4-3. Slow and Fast Adjust Inputs
The required resistor value may be estimated from Tables A & B below. These tables show
the approximate shaft speeds obtained at a resolution of 4000 steps/rev; at 2000, 800 or 400
steps/rev, the shaft speed will be respectively 2, 5 and 10 times faster for the same resistor
value. Note that the quoted speeds are nominal and are subject to a 20% tolerance.
If a potentiometer is to be used to vary the speed, it is preferable to use the analogue control
input rather than to adjust the Fast programming resistor. The analogue control input
operates via the acceleration/deceleration circuit, therefore turning the potentiometer rapidly
will not de-synchronise the motor.
Resistor ohms Speed revs/sec

100K 0.3
56K 0.6
33K 1.1
22K 1.7
10K 3.7
5.6K 6.4
3.3K 10.2
2.2K 14.2
1K 25.1
560 35
330 44
220 50
100 59
0 69
Table 4-1. Fast range speed vs. resistor value at 4000 steps/rev.
Resistor ohms Speed revs/sec

100K 0.3
56K 0.6
33K 1.0
22K 1.5
10K 2.7
5.6K 4.0
3.3K 5.2
2.2K 6.1
1K 7.5
560 8.2
0 9.3
Table 4-2. Slow range speed vs. resistor value at 4000 steps/rev.
Using the analogue speed control input

This input allows the oscillator speed to be determined by an analogue voltage in the range
0-10V DC. +10V will produce the full programmed speed and 0V zero speed. The
speed/voltage characteristic is approximately linear. There is a nominal 0.5V deadband at
the 0V end to ensure that the oscillator can be stopped completely.
The analogue control voltage may be derived Drive Internal

Circuit Details
from a potentiometer connected between pin
1 and pin 12 on connector X11/X21. The
suggested resistance of the potentiometer is ANALOGUE_IN +
82K
2K; this is also the minimum allowable value.
A larger value of potentiometer can be used -
(up to 10K), but the speed control achieved
by using the higher value potentiometer will Reference
be less linear. 1K8 voltage
39K
GND
Figure 4-4. Analogue Input
Setting the acceleration/deceleration rate

When using the fast speed range, the oscillator accelerates up to and down from the
programmed speed. The acceleration profile is basically exponential (see Figure 4-5), whilst
the deceleration profile is linear. The default acceleration and deceleration times are 45mS
and 30mS respectively.
These times may be extended by fitting an

external capacitor between pin 4 and pin 1
on X3 (the negative end of the capacitor to Velocity
pin 4). The internal acceleration capacitor is
4.7F; the acceleration & deceleration times
will be in proportion to the total capacitance.
So an external 4.7F capacitor will give an
acceleration time of 90mS, and a 47F
capacitor will give 495mS (these times are
Time
subject to a 20% tolerance).
Figure 4-5. Acceleration Profile

External Oscillator Connections
Fixed resistor Variable resistor

X3 speed control X3 speed control
8 8 2K precision
15 potentiometer
15
direction
slow
fast
Analogue
speed
- - Optional control
Optional acceleration
+ acceleration + capacitor
capacitor
Fast speed 9 Fast speed 9
resistor* 1 resistor* 1
Slow speed
resistor*
* Multi-turn potentiometers could be used to give adjustable pre-set speeds.

Figure 4-6. External Oscillator Control
Additional control signals on the step-direction drive

Shutdown. The differential Shutdown inputs (X2 pins 5 and 9) allow the drive to be remotely
de-energised, in other words the output stage will be turned off completely which leaves the
motor shaft free to rotate. The drive is de-energised when Shutdown+ goes high with
respect to Shutdown-. There is also an auxiliary Shutdown input on pin 13 of connector X3
which is internally pulled up to +12V and will de-energise the drive when taken to 0V.
The motor shaft should not be rotated at high speed with the drive de-energised as this may
damage the power output stage.
Fault. If the drive shuts down as a result of a fault condition, such as an external short circuit
or over-temperature fault, the Fault output will turn OFF. This output is opto-isolated but has
a common return with the Zero Phase signal (see circuit in Figure 4-7). The signal may be
used to indicate to an external controller that the drive has shut down. De-energise and re-
energise the drive, or cycle the power, to reset the fault condition. Please refer to the
troubleshooting section for information on fault diagnosis.
The opto is ON for a drive HEALTHY signal and so turns OFF under fault conditions.
Drive User wiring

+12V
Drive OK Drive User wiring
+24V max
2K2
FAULT+ FAULT+
4 4
OR User
8 8 FAULT-
FAULT- input
4K7 circuit
0V
0V
Figure 4-7. Fault Output Configurations
Zero Phase. The 'Zero Phase' condition corresponds with a specific current combination in
the motor windings which occurs 50 times per revolution. This output turns on when the
drive is at each Zero Phase point, and it indicates that the motor shaft is in one of 50 specific
and repeatable orientations. The function may be used to improve homing repeatability by
offsetting the effect of small variations in the home switch operating point.
The drive is reset to the Zero Phase state at power-up (orange LED).
Oscillator monitor. This is an output signal which may be used to monitor the step pulse
stream from the internal oscillator. For instance it may be taken to a counter to indicate
current position or to provide feedback when the oscillator is used within a positioning
system. The signal comes from an NPN open-collector transistor which turns on during each
step pulse. The pulse width is typically 1s wide and a maximum frequency of 200kHz.
Bit Switch Settings

Configuration of step direction drives is performed by bit switch settings. Located between
connectors X2 and X3 the bit switch is mounted as shown in Figure 4-8. If you alter bit
switch settings, the new setting will only take effect by cycling the power to the drive.
The drive is supplied with all bit switches turned OFF, as shown.
X2
OFF
1 2 3 4 5 6 7 8
ON
X3
Figure 4-8. Bit Switch Layout
Switch Functions
Switch Function Description

Number
1 Reserved -
2 Step/dir. (OFF default) Allows conventional or
Step+/Step- (ON) two step line control
3 Standby 50% (OFF default) Standby select
70% (ON)
4 Resolution bit 1 Set motor resolution
5 Resolution bit 2 Set motor resolution
6 Current select bit 1 Set motor current
Table 4-3. Bit Switch Functions

Bits 4 and 5 set the resolution according to the following table:
Bit switch 4 Bit switch 5 Motor resolution in steps per

rev
OFF OFF 4000*
OFF ON 2000
ON OFF 800
ON ON 400
* default value
Table 4-4. Motor Resolution Settings
Bits 6,7 and 8 set the motor current as a percentage of the drives peak current rating:
Bit switch 6 Bit switch 7 Bit switch 8 Current level as a

percentage (%)
ON ON ON 100
ON ON OFF 90
ON OFF ON 80
ON OFF OFF 70
OFF ON ON 60
OFF ON OFF 50
OFF OFF ON 50
OFF OFF OFF 50*
* default value
Table 4-5. Motor Current Settings
5. MAINTENANCE AND TROUBLESHOOTING 43
5. Maintenance and Troubleshooting
Maintenance
XL systems do not require any routine maintenance, but occasional checking of the following
points is recommended.
Motor inspection
Periodically check the motor to ensure that the mounting bolts and couplings are tight.
Check that the motor cables are not being damaged by moving parts and are not being
pulled or forced into tight bends during machine operation. Check all cable connectors and
particularly the safety earth connection.
Drive inspection
Check that the drives are clear of loose material and that there is adequate clearance to
allow a free flow of air through the ventilation slots. Check that drive fixing screws are tight
and that the motor screen connection is secure.
Troubleshooting
IMPORTANT NOTE - ensure that power is turned off before any connections are
removed or changed. Removing a drive with power applied can turn a recoverable fault
situation into a major problem.
Drive LED indications

In the event of any system malfunction, the first thing to check is the status of the LEDs on
the front of the drive module. If no LEDs are illuminated, verify that power is turned on and
that the correct supply (see Table 3-1) is present at the X1 connector. If it is, but there are
still no LEDs illuminated, the drive is faulty and needs to be returned for repair.
The XL drives and XL_PSU power supply described in this user guide contain no user-
serviceable parts. Attempting to open the case of any unit, or to replace any internal
component, may result in damage to the unit and/or personal injury.
The drive LEDs are 3-colour devices and provide information on the state of the drive as
shown in Figure 5-1.
Step-direction
Drive
15 8 Orange - HV OK & Zero Phase

Green - HV OK
X3 Red - Drive Indexer Fault
9 1 Orange - Drive Standby but Healthy
Green - Drive Ready/Energised
Not used
LEDs
Note: Standby means the drive is shutdown or de-energised.
Figure 5-1. Drive LED Indicators
Power (left) LED

In normal operation this LED is either green or orange. When green it indicates that the
power supply is healthy; orange shows both that power is healthy and that the drive is in its
zero phase state. The LED should show orange when the drive is first powered up and no
step pulses have been applied.
Drive Status (middle) LED

In normal operation this LED should be green, showing that the drive is healthy and is
energised, i.e. not in a standby condition.
When this LED is orange, the drive is in a standby or de-energised state but is otherwise
healthy. In this condition there will be no holding torque from the motor and the drive will not
respond to step pulses. If this is the cause of the problem, check the status of the differential
Shutdown inputs (X2 pins 5 and 9) and also the auxiliary Shutdown input on X3 pin 13.
If the centre LED is red it indicates that the drive has shut down due to a fault condition.
This may be due to any of the following causes:
1. The power input voltage is either too high or too low. Check that the supply is within the
limits specified in the Hardware Reference Section.
2. The X1 connector may not be fully inserted into the drive - check that the wiring is not
preventing the connector from being pushed fully home.
3. There is a short circuit across two of the motor connections or between one of the motor
connections and ground. Disconnect power, remove X1 and check the motor connections
with a meter. This condition may also arise if a very low inductance motor is used - the
preferred range is 0.8mH to 10mH.
5. MAINTENANCE AND TROUBLESHOOTING 45
4. The drive has shut down due to excess temperature rise. Check that the ventilation slots
at the top and bottom of the housing are not obstructed and that there is free flow of air
through the drive. Make sure that the drive is not mounted directly above a source of heat
such as a power supply, and if possible check the ambient temperature in the vicinity of the
drive casing. Allow the drive to cool down and re-check. If the motor has ample torque for
the application, try reducing the current setting on the bit switch which will reduce the drive
dissipation.
5. There is an internal fault in the drive or with the internally-generated logic supply. In
either case the drive will need to be returned for repair.
Right LED
This LED has no function in the XL25/XL50 or XL80 drive.
Further checks
If you can safely do so, check that there is holding torque from the motor. However, take
care not to touch any part of the system if this could result in personal injury should
unexpected motion occur - see the safety warning at the front of this User Guide.
Drive LEDs OK but no holding torque from the motor
Disconnect power, remove X1 and check the motor connections for continuity across each
phase. Check that the drive has not been de-energised by a Shutdown signal as detailed
above.
Motor has holding torque but will not run
This suggests that step pulses are not reaching the drive, or that they are not at the required
level. This could be caused by bit switch 2 being in the ON position whilst the direction input
signal is active. Note: If you are attempting to operate in STEP/DIRECTION mode, but the
motor only steps in one direction, check the setting of bit switch 2 (it should be OFF).
If step pulses are generated by an external source, the required signal on the step and
direction inputs is differential at nominal TTL (5V) levels. The minimum differential voltage is
3.5V and step pulses must be at least 1S wide.
If the internal oscillator on the drive is being used to generate step pulses, but the motor is
not moving, check the following points:
1. An external 24V DC supply is required to run the internal oscillator (it is not needed if the
drive is controlled from an external step/direction source). The oscillator will not run if the
polarity of this supply is incorrect - positive should be on X1 pin 4 and negative (or 0V) on
X1 pin 5.
2. For the oscillator to run, a logic low level (<1V) must be present on either the Slow or Fast
control inputs, or the analogue speed control input must be above the 0.5V deadband.
3. An appropriate speed control resistor or potentiometer must be fitted between the Slow
and/or Fast range set input and a 12V reference terminal (two reference terminals are
provided to make wiring easier).
If an oscilloscope is available, the oscillator output pulses may be checked on the Monitor
terminal (X3 pin 5), provided a pull-up resistor is fitted.
Returning the System

If a drive module is found to be faulty, you should contact your Parker Automation
Technology Centre or the machinery manufacturer who supplied the product. Equipment for
repair should NOT be returned directly to Parker without prior authorisation. Repairs will be
carried out by Parker but will be processed via your supplier.
Parker may at their discretion authorise direct shipment to and from Poole, Offenburg or
Rohnert Park, but only by prior arrangement with your supplier. Existing UK, European and
USA customers who purchase equipment directly from Parker should contact Poole,
Offenburg or Rohnert Park for further information (contact numbers are at the front of this
User Guide).
6. HARDWARE REFERENCE 47
6. Hardware Reference
Drive Specification - XL25 XL50 & XL80

Functional Specification
Parameter Value
Amplifier type MOSFET chopper
Motor resolution 400, 800, 2000, 4000 steps/rev
Maximum stepping rate 200kHz at 4000 steps/rev
Nominal chopping frequency 28kHz (XL25), 20kHz (XL50 & XL80)
Protection circuits Short circuit (phase-to-phase, across phases
and phase to ground), motor overcurrent,
over/under voltage, logic supply fault, over
temperature, ext. 24V reversed
Maximum output current XL25: 2.5A peak +/-10%
XL50: 5A peak +/-10%
XL80: 8A peak +/-10%
Output current adjustment 50% to 100% of maximum current, switch
selectable in 10% increments
Standby current reduction 50% or 70% selected by switch
Standby reduction time 30mS from last step pulse
Nominal motor bus voltage 80V DC
Supply voltage, DC operation XL25: 20 to 84V absolute limits
XL50: 40 to 84V absolute limits
XL80: 40 to 84V absolute limits
Optional logic supply input* 24V DC +10% -15%, ripple <1V p-p
Logic supply current* 100mA
LED status indicators (tri-colour) HV OK/zero phase, drive OK/energised/fault
Motor inductance range (recommended) 0.8 - 10mH
Step, Direction and Shutdown input levels Differential TTL
Fault & Zero phase outputs OPTO outputs 5mA max. at 30V max.
* required for internal oscillator only
Table 6-1. Functional Specification
Oscillator Specification
Parameter Value
Speed ranges at 4000 steps/rev
Fast range 0-50 revs/sec
Slow range 0-8 revs/sec (higher speeds available at
lower drive resolution)
Speed adjustment - slow External resistor - see table 4-2
Speed adjustment - fast External resistor or 0-10V analogue input
Analogue fast speed adjustment <0.5V = zero speed, +10V = max speed
Preset acceleration time (Fast range only) 45mS
Preset deceleration time (Fast range only) 30mS
Accel/decel time adjustment External capacitor (for capacitor C in F, new
accel time = preset time x {C+4.7}/4.7)
Oscillator monitor output NPN open-collector transistor, 30mA max
ON current, 30V max OFF voltage.
1s pulse width, 200kHz max.
+12V reference supply current limit 10mA
Table 6-2. Oscillator Specification
Drive Environment Specification
Parameters All drive types

Environment Pollution degree 2, Installation category II
Operating temperature range 0 to 50C ambient
Storage temperature range -20 to 70C
Humidity 5 to 95% non-condensing
Cooling Natural convection
Housing Aluminium
Protection class IP20
Weight of drive XL25/XL50 0.4kg XL80 0.45kg
Table 6-3. Environment Specification

XL_PSU Electrical Specification
Parameter Value
Input voltage
Nominal 110 to 230 V AC RMS
Min/Max 95 to 264V AC RMS
Mains supply frequency range 50/60Hz +/- 2Hz
Input power factor Better than 0.9 at 250W load
Output voltage 80V DC 5% (no load)
Output current
230V AC input, no 24V load 3.1A continuous, 7.5A peak
230V AC input, max 24V load 2.6A continuous, 7.0A peak
<150V AC input, no 24V load 2.5A continuous, 6.2A peak
<150V AC input, max 24V load 2.0A continuous, 5.7A peak
Protection Short circuit / overload protected
On board capacitance 6600F
24V Auxiliary output
Voltage 24V DC +10% -15%
Current 1.8A Max
Protection Short circuit / overload protected
Output cable length restriction not to exceed 10m in length
Total output power 250W continuous
Peak 600W for 1 second.
Below input voltages of 150V AC,
output power is 200W continuous,
500W peak.
Protection circuits
XL_PSU Module Overtemperature
Output
Current Short circuit / Overload
Power Excessive continuous power
+24V supply
Current Short circuit
Voltage Reverse polarity
Connection / disconnection Hot plugging protection
Table 6-4. XL_PSU Electrical Specification

XL_PSU Mechanical Specification
Parameter Value
Housing Two part brushed aluminium case
Dimensions
Depth 130 mm Max
Width 50 mm Max
Height 175 mm Max (195 mm at flange
mount)
Weight 1 kg
Table 6-5. XL_PSU Mechanical Specification

XL_PSU Environment Specification
Parameter Value
Pollution Degree 2
Installation category II*
Operating temperature range 0 to 50C ambient
Storage temperature range -20 to 70C
Humidity 5 to 95% non condensing
Altitude 2000 metres
Ingress protection IP20
Cooling Natural convection with integral fan.
Unit to be mounted vertically with at
least 50mm free space above and
below the package. Side clearance of
10mm free space both sides.
Table 6-6. XL_PSU Environment Specification
*Note: Installation category (also called Overvoltage Category) specifies the level of mains
voltage surges that the equipment will be subjected to. The category depends upon the
location of the equipment, and on any external surge protection provided. Equipment in an
industrial environment, directly connected to major feeders/short branch circuits, is subjected
to Installation Category III. If this is the case, a reduction to Installation Category II is
required. This can be achieved by use of an isolating transformer with an earthed screen
between primary and secondary, or by fitting varistors from live to neutral and from neutral to
earth. Varistors for a 120V AC input should be rated to absorb at least 40 Joules. For
example, DIN-rail mounted surge suppressor RS 240-062 (110V AC, 70J) or
Farnell 294-275 (110V AC, 80J) would be suitable. Varistors for a 240V AC input should be
rated to absorb at least 80 Joules. For example, DIN-rail mounted surge suppressor RS
240-078 (240V AC, 140J) or Farnell 294-287 (240V AC, 140J) would be suitable.
INDEX 53
Index
+ Drive inspection, 43
+24V fuse rating, 19 Dump resistor connections, 15
+24V supply connections, 19 E
+24V supply lead length restrictions, 19 Earth arrangements, 9
A Earth wiring, 10
Absorber ferrite, 23 Electrostatic precautions, 9
AC fuse value, 18 EMC
Acceleration capacitor, 37 typical installation, 20
Acceleration setting, 37 EMC filter
Adjustments, 2 spacing, 20
Air gap distances, 3 EMC Installation, 19
Analogue control input, 35 general requirements, 19
Auxiliary direction input, 35 EMC requirements, 9
Axis control connector, 31 EMC wiring
Axis control screened cables, 31 recommendations, 20
B Environment specification, 48
Bipolar rating, 23 External control connector, 31
Bit switch External speed control, 34
cycle power, 40 F
default settings, 40 Factory settings, 33
settings, 40 Fast input, 34
Bit switch default settings, 33 Fault output, 38
Braking resistor, 16 Ferrite absorber
Braking resistor calculations, 14 Curie temperature, 23
Braking resistor connections, 15 impedance, 23
Bus voltage, 47 part number, 23
C size, 23
Cabinet installation, 9 Ferrite absorber specification, 23
Capacitor acceleration control, 37 Function indicators, 2
Chop frequency, 47 Fuse for +24V supply, 19
Clean earth, 9 H
Control input connector X3, 30 Humidity, 48
Control of drives, 33 I
Cooling requirements, 3 Inputs & outputs, 2
Current switch settings, 41 Installation, 9
D Installation Category, 3
DC supplies, 10 Installation safety requirements, 9
DC supply volts, 10 Internal oscillator, 34
Default settings, 33 L
Dimensions, 4 Large motors, 25
Disconnecting device, 9 Line fuse type, 18
Drive Line fuse values, 18
cooling, 3 Low voltage operation, 18
dimensions, 4 LVD requirements, 9
mechanical mounting, 5
54 INDEX
M PSU discrete design, 17

Maintenance, 43 R
Motor Resistor selection fast, 36
cable choice, 21 Resistor selection slow, 36
cable lengths, 21 Resolution setting, 41
connections, 21, 25 Returning the system, 46
current setting, 40 S
direction, 34 Safety earth wiring, 10
inductance, 47 Screened connections, 9
inductance values, 23 Secondary fuse value, 18
largest size, 25 Selecting motor resolution, 41
minimum inductance values, 23 Series connections, 25
resolution, 40 Series motor wiring connections, 27
rotation with drive de-energised, 38 Short circuit protection, 26
safety earth connection, 26 Shutdown input, 38
selection, 23 Slow input, 34
wire size, 21 Speed control external, 34
Motor connector, 32 Speed control input, 36
Motor current selection, 41 Speed control linearity, 35
Motor inspection, 43 Speed control potentiometer, 37
Motor mounting precautions, 7 Standby switch, 40
Motor wiring identification tables, 26 Star point, 9
Motors Step direction input, 33
4 lead, 23 Step direction source, 33
6 lead, 23 Step frequency input, 34
8 lead, 23 Step pulse width, 34
optimum types, 24 Step up step down, 34
voltage rating, 25 Step/set_dir switch, 40
Mounting, 5 Supply +24V, 19
O Supply connections, 12
Oscillator monitor output, 39 Supply fuses, 18
Oscillator specification, 48 Supply volts, 10
Oscillator speed, 35 T
Output connections, 12 Temperature
Overload of outputs, 26 ambient, 48
P Transformer
P1 connector part number, 12 multi axis systems, 18
P2 connector part number, 12 sizing for applications, 18
Parallel connections, 25 VA rating, 17
Parallel motor wiring connections, 28 Transformer selection guide, 17
Product W
description, 1 Weight XL25/50, 48
features, 2 Weight XL80, 48
types, 1 Wire size of motor earth, 26
Product features, 2 X
Programming resistors, 35 X3
Protection circuits, 2 terminal description, 30
Protection class, 48 XL
PSU connecting links, 13 connector layout, 29
INDEX 55
XL_PSU XL_PSU drive wiring diagram, 13

dimensions, 6, 50 XL_PSU mounting information, 6
electrical specification, 49 XL_PSU product appearance, 11
environment specification, 51 XL25 supply volts, 10
input voltage, 49 XL50
LED indicators, 16 supply volts, 10
mechanical specification, 50 XL80 supply volts, 10
output voltage, 49 XL-connect kit, 13
power output, 49 Z
product description, 11 Zero phase output, 39
weight, 50
CUSTOMER FEEDBACK
Customer Feedback
If you have spotted any errors, omissions or inconsistent information within this user guide
please let us know. Either use this page (or a photocopy) to describe the error and Fax. it to
the number given below. Alternatively, you may phone or email the correction.
Name of user guide:
Part number: 1600. _ _ _ . _ _ Found on the title page in the bottom left corner.
Your name:
Contact number or email address:
Description of the error: (Please include page number)
Errors can be reported By phone, via a technical Or by email:

by Fax: support engineer:
+44 (0)1202 695750 +44 (0)1202 699000 [email protected]

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Automation

Part No: 1600.286.02 March, 2002

Installation and Operation of Motion Control Equipment

Electromechanical Division of Parker Hannifin plc, 2002

The above product is in compliance with the requirements of directives

73/23/EEC Low Voltage Directive

93/68/EEC CE Marking Directive

89/336/EEC Electromagnetic Compatibility Directive

In assessing the overall compliance of an installation consideration must also be given to

WARNING Risk of damage and/or personal injury

For engineering For engineering

For engineering For engineering

Symbols used, have the following meanings:

Protective conductor terminal

User Guide Change Summary

Major changes in revision 02 include:

Addition of XL80 information

Latest Changes Sheet

XL25/XL50/XL80 Product Description

XL80 providing a motor voltage of 80V at 8.0A peak

Figure 1-1. XL25/XL50 and XL80

Protection Circuits Function Indicators

Adjustments Outputs and Inputs

Examples of previous courses that have proved to be of benefit include:

Use and programming of DIN rail H & L series drives

137.4 max with fixings

Figure 2-1. XL25/XL50 Dimensions

Figure 2-2. XL80 Dimensions

Mechanical Installation of Drives

EXT. BRAKING RES.

12.5 12.5 130

Figure 2-3. XL_PSU Dimensions

XL_PSU Mounting Information

Motor Mounting Mechanical Considerations

CAUTION risk of equipment damage

Installation Safety Requirements

Power Supply Connections

Figure 3-1. X1 Connections

Drive Type DC Supply Voltage

Table 3-1. Drive Supply Voltages

Note: DC+ identifies the positive side of a DC supply.

The power supply must be isolated from the mains.

Safety Earth Requirements

Auto-adapts to supplies between 95 and 264V AC

Figure 3-2. XL_PSU Switched Mode Power Supply

Figure 3-3. P2 Power In Socket Wiring

Figure 3-4. P1 Output Power Connector

EXT. BRAKING RES.

Figure 3-5. Power Supply and Drive Connections

Power Dump/Braking Resistor Considerations

Calculating the Need for a Braking Resistor

External Braking Resistor Installation

Figure 3-6. Braking Resistor Wiring

LED Indicators Function

Position Colour Function

Middle Orange Dump request

Right Red 24V disabled by overcurrent fault

Table 3-2. LED Indicators Function

WARNING Risk of damage and/or personal injury

Discrete Power Supply Recommendations