DIGITAL SERVO DRIVES FOR BRUSHLESS AC MOTORS

XtrapulsEasy™ 230VAC /17A

XtrapulsEasy™ 60VDC /
10A / 20A / 60A / 120A

XtrapulsEasy™

Installation Guide

1
 XtrapulsEasy™ Installation Guide

WARNING

!
This is a general manual describing a series of servo drives having output capability suitable for driving AC
brushless sinusoidal servo motors.

Please see also:

o XtrapulsEasy™ User Guide for the operation of the drive (commissioning, configuration, ...)
o XtrapulsEasy™ STO for the Safe Torque Off function
o Gem Drive Studio software Quick Start manual for the drive parameterization.

Instructions for storage, use after storage, commissioning as well as all technical details require the
MANDATORY reading of the manual before getting the drives operational.

Maintenance procedures should be attempted only by highly skilled technicians having good knowledge
of electronics and servo systems with variable speed (EN 60204-1 standard) and using proper test
equipment.

The conformity with the standards and the "CE" approval is only valid if the items are installed according to the
recommendations of the drive manuals. Connections are the user's responsibility if recommendations and
drawings requirements are not met.

Any contact with electrical parts, even after power down, may involve physical damage.
Wait at least 10 minutes after power down before handling the drives (a residual voltage of several hundreds
of volts may remain during a few minutes).

Caution: Hot surface, risk of burns (wait for cooling after power down).

ESD INFORMATION (ElectroStatic Discharge)

INFRANOR® drives are designed for being best protected against electrostatic discharges. However,
some components are particularly sensitive and may be damaged if the drives are not properly stored
and handled.
STORAGE
- The drives must be stored in their original packaging.
- When taken out of their packaging, they must be stored positioned on one of their flat metal
surfaces and on a dissipating or electrostatically neutral support.
- Avoid any contact between the drive connectors and material with electrostatic potential
(plastic film, polyester, carpet…).
HANDLING
- If no protection equipment is available (dissipating shoes or bracelets), the drives must be
handled via their metal housing.
- Never get in contact with the connectors.

WASTE DISPOSAL
In order to comply with the 2002/96/EC directive of the European Parliament and of the Council of
27 January 2003 on waste electrical and electronic equipment (WEEE), all INFRANOR® devices
are labelled with a sticker symbolizing a crossed-out dustbin as shown in Appendix IV of the
2002/96/EC Directive.
This symbol indicates that INFRANOR® devices shall be eliminated by selective disposal and not
with household waste.

2
GD1 - Installation guide -Preliminary edition

All electrical industrial automatisms which lifetime is coming to its end are Waste Electronic and Electrical
Equipment (WEEE) according to article R543-172 of the French Environmental Code.

WEEE classification of the INFRANOR products Categorie 9: Monitoring and control instruments

In accordance with the Decree nr. 2012-617 of May 2nd, 2012 which specifies the provisions related to
the professional EEE manufacturers' obligations, INFRANOR France is a member of RECYLUM : eco-
organization ecosystem certified for the collection, treatment and recycling of WEEE.
In France, RECYLUM allows all professionals benefiting from a free collection and recycling solution, in
observance of the regulation, the environment and health.

 Information and sorting instructions regarding INFRANOR  products

Type of waste Waste category Waste management

Waste disposal centre / collection
Packaging Cardboard Recyclable waste
point of recyclable waste
Waste disposal centre / collection
Documents Paper Recyclable waste
point of recyclable waste
Waste disposal centre / metal
Mechanics Metal Recyclable waste
collection point
Waste disposal centre / metal
Heatsinks Metal Recyclable waste
collection point
France:
http://www.ecosystem.eco/fr/sous-
Electronical
WEEE (Waste Electronic and Dangerous industrial rubrique/solutions
boards and
Electrical Equipment) waste
components
Abroad:
Country-specific regulation
 Sorting instructions may vary according to regions / countries.
INFRANOR does not assume any responsibility for any physical or material damage due to improper handling or
wrong descriptions of the ordered items.
Any intervention on the items, which is not specified in the manual, will immediately cancel the warranty.

INFRANOR reserves the right to change any information contained in this manual without notice.

3
XtrapulsEasy™ Installation Guide

Content

PAGE

CONTENT ............................................................................................................................................... 4
CHAPTER 1 – GENERAL ....................................................................................................................... 6
1.1 - INTRODUCTION .......................................................................................................................... 6
1.2 - DESCRIPTION / COMPLIANCE WITH THE STANDARDS ......................................................... 6
1.2.1 - General description ................................................................................................................ 6
1.2.2 - Reference to the standards: ........................................................................................... 7
1.3 - OTHER DOCUMENTS ................................................................................................................. 7
1.4 - ORDERING CODE ....................................................................................................................... 8
1.5 - ACCESSORIES ............................................................................................................................ 8
1.5.1 - Ordering code for separate connector set ............................................................................. 8
1.5.2 - Ordering code for the serial link / CANopen communication adapter ................................... 9
1.5.3 - Ordering code of the braking resistor for XtrapulsEasy™-ak-230/17 .................................... 9
1.5.4 - Ordering code for braking resistor XtrapulsEasy™-ak-60/XX ............................................... 9
CHAPTER 2 – SPECIFICATIONS ........................................................................................................ 10
2.1 - MAIN TECHNICAL DATA ........................................................................................................... 10
2.1.1 - XtrapulsEasy™-ak-230/17 ................................................................................................... 10
2.1.2 - XtrapulsEasy™-ak-60/XX .................................................................................................... 11
2.1.3 - Technical specifications of the whole XtrapulsEasy™ range .............................................. 11
2.2 - DIMENSIONS AND CONNECTOR LOCATION ......................................................................... 14
2.2.1 - XtrapulsEasy™-ak-230/17 dimensions (mm) ...................................................................... 14
2.2.2 - XtrapulsEasy™-ak-60/ 60A & 120A dimensions (mm) ........................................................ 15
2.2.3 - XtrapulsEasy™-ak-60/ 10A & 20A dimensions (mm) .......................................................... 16
2.2.4 - XtrapulsEasy™-ak-230/17: Panel layout dimensions (mm) ................................................ 17
2.2.5 - XtrapulsEasy™-ak-60/XX: Panel layout dimensions (mm) ................................................. 18
CHAPTER 3 – INPUTS - OUTPUTS OF THE XTRAPULSEASY™ RANGE ...................................... 19
3.1 - DISPLAY..................................................................................................................................... 19
3.1.1 - Leds ..................................................................................................................................... 19
3.1.2 - CANopen® communication bus ........................................................................................... 20
3.2 - FEEDBACK CONNECTOR: X1 .................................................................................................. 20
3.2.1 - X1 connector for transmitter resolver input .......................................................................... 20
3.2.2 - X1 connector for Sin Cos tracks input ................................................................................. 21
3.2.3 - X1 connector for incremental TTL & HES encoder input ..................................................... 21
3.3 - INPUTS-OUTPUTS CONNECTOR: X2 ...................................................................................... 22
3.3.1 - Specification of the logic inputs ........................................................................................... 22
3.3.2 - Specification of the logic outputs OUT1 and OUT2 ............................................................. 23
3.3.3 - Specification of the analog inputs ANA1+/- ......................................................................... 23
3.4 - COMMUNICATION CONNECTOR: X5 ...................................................................................... 24
3.5 - 24VDC AUXILIARY POWER SUPPLY CONNECTOR: X3 .......................................................... 24
3.6 - POWER CONNECTORS: X4 ..................................................................................................... 24
3.6.1 - XtrapulsEasy™-ak-230/17: X4 ............................................................................................ 24
3.6.2 - XtrapulsEasy™-ak-60/XX: X4 .............................................................................................. 25
CHAPTER 4 – CONNECTIONS ............................................................................................................ 26
4.1 - EXAMPLES OF CONNECTION DIAGRAMS ............................................................................. 26
4.1.1 - XtrapulsEasy™-ak-230/17 default configuration ................................................................. 26
4.1.2 - XtrapulsEasy™-ak-60/XX default configuration .................................................................. 27
4.1.3 - AOK chaining with XtrapulsEasy™ drives only ................................................................... 28
4.1.4 - AOK chaining with XtrapulsEasy™ and XtrapulsPac™ drives together ............................. 28

4 Content
XtrapulsEasy™ Installation Guide

4.1.5 - Protections ........................................................................................................................... 29

4.1.5.1 - Auxiliary power supply .................................................................................................................. 29
4.1.5.2 - Power supply................................................................................................................................. 29
4.2 - ANALOG INPUTS CONNECTION ............................................................................................. 29
4.2.1 - ANA1 input connection with a differential analog signal source .......................................... 29
4.2.2 - ANA1 input connection with a non-differential analog signal source .................................. 29
4.3 - CONNECTION TO VARIOUS SENSOR TYPES ....................................................................... 30
4.3.1 - Connection to a resolver: X1 - Sub D 15 pin female connector .......................................... 30
4.3.2 - Connection to an incremental TTL encoder: X1 - Sub-D 15 pin female connector ............. 30
4.3.3 - Connection to an incremental TTL encoder with Hall sensor: X1 Sub-D 15 pin female
connector ........................................................................................................................................ 30
4.4 - ACCESSORIES AND CONNECTIONS ..................................................................................... 31
4.4.1 - Connection of the external braking resistor ......................................................................... 31
4.4.2 - Connection of a backup battery ........................................................................................... 31
4.4.3 - Connection of the accessory "COM-Easy communication adapter" ................................... 32
4.5 - CONNECTION TO THE "GEM DRIVE STUDIO" SOFTWARE TOOL ....................................... 33
4.5.1 - Connection of the serial link to the X5 connector ................................................................ 33
4.5.2 - Multi-axis connection of the serial link ................................................................................. 34
4.6 - WIRING INSTRUCTIONS .......................................................................................................... 34
4.6.1 - Ground connection .............................................................................................................. 34
4.6.2 - Shield connection ................................................................................................................ 35
4.6.3 - Example of ground and shield connections ......................................................................... 35
4.6.4 - Motor, resolver and encoder cables .................................................................................... 36
4.6.5 - Serial link and CAN communication cables ......................................................................... 37
4.7 - FIRST POWERING OF THE DRIVE .................................................................................................... 37
4.7.1 - Very important ..................................................................................................................... 37
4.7.2 - Connection of the 24 VDC supply.......................................................................................... 37
4.7.3 - Connection of the mains power supply ............................................................................... 37
4.7.4 - Starting procedure ............................................................................................................... 37
CHAPTER 5 – APPENDIX .................................................................................................................... 38
5.1 - SOFT START SYSTEM OF XTRAPULSEASY™-AK-230/17 .................................................... 38
5.1.1 - Introduction .......................................................................................................................... 38
5.1.2 - Integration recommendations .............................................................................................. 38
5.2 - LOW OPERATING VOLTAGE ................................................................................................... 39
5.3 - SIZING OF THE BRAKING SYSTEM ......................................................................................... 39
5.3.1 - Introduction .......................................................................................................................... 39
5.3.2 - Method for the design of the braking system ...................................................................... 39
5.4 - MAINTENANCE ......................................................................................................................... 41
5.4.1 - Periodical checking .............................................................................................................. 41
5.4.2 - Procedure after a long-time storage .................................................................................... 42
5.4.3 - Warranty .............................................................................................................................. 42
5.5 - OPERATING ENVIRONMENT CONDITIONS ........................................................................... 42

Content 5
XtrapulsEasy™ Installation Guide

Chapter 1 – General

1.1 - INTRODUCTION

XtrapulsEasy™ all-digital drives with sinusoidal PWM control are servo drives that provide the control of
brushless AC motors.

The standard control interface can be:

- CANopen®1,
- Analog.

Series XtrapulsEasy™ drives are dedicated to basic applications that do not have a high level of requirements in
terms of functionalities and where cost effectiveness is very important.

The XtrapulsEasy™ can be used in following typical applications:

• Axes controlled by CANopen® fieldbus according to the DS402 protocol,

• Stand-alone operation as a sequencer with control by means of logic I/Os,
• Traditional analog speed drive with +/- 10 V command and A, B, Z encoder output for the position feedback.

The configuration and parameterization software tool Gem Drive Studio allows a quick configuration of the
XtrapulsEasy™ drives according to the target application.

1.2 - DESCRIPTION / COMPLIANCE WITH THE STANDARDS

1.2.1 - General description

The XtrapulsEasy™ drive can be configured in 4 feedback modes:

- Resolver or Analog hall (Sin Cos Track)

- TTL encoder with or without Hall effect sensors
- Hall effect sensors only
- Sensorless

The appropriate position sensor configuration is software selectable and saved in the drive.

When using a position sensor, this sensor ensures a high dynamic motor torque/force control and full torque/force
is available at low speed and standstill.

▪ With a resolver sensor feedback, the motor absolute position value over one revolution is available and the
servo motor can immediately be enabled after the drive power up.

▪ With an incremental encoder only, a motor phasing procedure (Phasing) must be executed at each drive
power up before the motor enabling.

▪ With an incremental encoder + Hall Effect Sensors (HES) feedback, the motor phasing procedure is no more
necessary and the servo motor can immediately be enabled after the drive power up.

▪ With only a Hall effect Sensor (HES) feedback, the position resolution is low, involving reduced dynamic
performances.

▪ In sensorless mode, a motor phasing procedure is automatically executed at the drive enabling.

1 CANopen® is a registered Community Trademark of CAN in Automation e.V, Germany.

6 Chapter 1 - General
XtrapulsEasy™ Installation Guide

Series XtrapulsEasy™ drives have their own DC/DC converter to provide the voltages required for the drive
operation with a 24 VDC +/- 15 % supply source which is generally available on machines. The auxiliary supply
allows keeping the drive logic supplies after the power supply has been switched off. Thus, the position output
can be kept without new initializations of the machine. A 24 VDC battery supply with specific wiring allows keeping
the position even after switching off the auxiliary 24 V DC supply. This wiring can be used for getting an "absolute"
servo drive operation.
A soft start system limits the inrush current at the mains power on.

All control parameters are programmable via a serial link (e.g. RS-232) and saved in a memory. The auto-tuning
and auto-phasing functions allow a quick and easy commissioning of the drive.

Thanks to the Gem Drive studio software tool, which is PC compatible with the WINDOWS® operating system,
all drive parameters can be displayed and easily modified.

Gem Drive Studio also allows the quick configuration of the XtrapulsEasy™ drive according to the application
type.

The Digital Oscilloscope of this software tool ensures an easy and quick commissioning of the drive.

The Gem Drive Studio software also allows parameterization and diagnostic in a multi-axis configuration.

1.2.2 - Reference to the standards:

Electromagnetic compatibility

According to the Directive 2004/108/EC, the actuators are complying with the Electromagnetic Compatibility
standards regarding the power servos, referenced in the EN 61800-3 – Part 3 about "Electrical power servo
systems with variable speed":

EMISSION
EN 61800-3 C1 category equipment – table 14

IMMUNITY
EN 61000.4-2-3-4.5-6 Expected use: Second environment including other areas than those
directly supplied with electricity by a public low-voltage mains network.

NOTE: Industrial areas and technical rooms are examples of second environment.

Security:

73/23/EEC modified by the directive 93/68/EEC: Low voltage directive

EN 61800-5-1: (Overvoltage category III, System Voltage = 300 V) Electrical, Thermal and Energetic security requirements
EN 60204-1: Safety of machinery: electrical equipment of machines
UL508C: Power Conversion Equipment
UL840: Insulation coordination for electrical equipment
EN 61800-5-2: Adjustable speed electrical power drive systems:
Safety requirements - Functional

EC conformity of the XtrapulsEasy™ drive

1.3 - OTHER DOCUMENTS

• XtrapulsEasy™ User guide.
• XtrapulsEasy™ STO manual.
• Gem Drive Studio software Quick Start manual.

Chapter 1 - General 7
XtrapulsEasy™ Installation Guide

1.4 - ORDERING CODE

XtrapulsEasy-ak-U/I

Logic version
ak: Analog and CANopen® interfaces

Voltage range
230: Voltage range 230VAC
60: Voltage range 60VDC

Current ratings for 230VAC drives

17: 17 Arms

Current rating for 60VDC drives

10: 10Arms
20: 20Arms
60: 60Arms
120: 120Arms

1.5 - ACCESSORIES

1.5.1 - Ordering code for separate connector set

FXX - Easy - U

Connector set type

FL: With command connector set
FC: With power + motor connector set
FCL: With power + motor + command connector set

Rating suffix (not required for FL set)

230: Connector kit for 230VAC drives
060: Connector kit for 60VDC 60A and 120A drives
062: Connector kit for 60VDC 10A and 20A drives

CONNECTOR SET DESCRIPTION

FC-Easy
X3: 2 pin plug connector for the auxiliary 24VDC supply.
X4: 7 or 8 pin power plug connector for mains and motor.

FL-Easy
X1: male 15 pin Sub D connector for the feedback, with the appropriate conducting cover.
X2: female 15 pin Sub D connector for the logic I/Os, with the appropriate conducting cover.
X5: female 9 pin Sub D connector for the RS232 / CAN link, with the appropriate conducting cover.

FCL-Easy
X1: male 15 pin Sub D connector for the feedback, with the appropriate conducting cover.
X2: female 15 pin Sub D connector for the logic I/Os, with the appropriate conducting cover.
X3: 2 pin plug connector for the auxiliary 24VDC supply.
X4: 7 or 8 pin power plug connector for mains and motor.
X5: female 9 pin Sub D connector for the RS232 / CAN link, with the appropriate conducting cover.

8 Chapter 1 - General
XtrapulsEasy™ Installation Guide

1.5.2 - Ordering code for the serial link / CANopen communication adapter

Ordering code: COM-Easy

1.5.3 - Ordering code of the braking resistor for XtrapulsEasy™-ak-230/17

The recommended braking resistor types are:

dp 100 / 35
dp 50 / 200

Ohmic value (Ohm)

Rated power (W)

1.5.4 - Ordering code for braking resistor XtrapulsEasy™-ak-60/XX

The recommended braking resistor type is:

dp 1 / 35

Ohmic value (Ohm)

Rated power (W)

Chapter 1 - General 9
 XtrapulsEasy™ Installation Guide

Chapter 2 – Specifications

2.1 - MAIN TECHNICAL DATA

2.1.1 - XtrapulsEasy™-ak-230/17
Design Stand-alone

Available cooling version Natural convection

Operating power supply voltage (1) 110 to 230VAC +/- 10% single-phase
50 - 60Hz
Grounded neutral system with balanced phase to
ground voltage

Undervoltage threshold(1) 100VDC

Braking threshold(1) 390VDC

Overvoltage threshold(1) 430VDC

EMC filter on the mains power supply Fully integrated in the drive

Motor phase-to-phase output voltage 95% of mains voltage

External braking resistor(1) Minimum external resistor: 50 Ω

Minimum phase-to-phase inductance(1) 1mH

Galvanic isolated auxiliary supply voltage 24VDC +/-15% - 150mA (without output loads)

EMC filter on auxiliary supply Integrated in the drive

(1)
These values correspond to the default configuration of the drive. For lower operating voltage, see section 5.2
"Low operating voltage".

OUTPUT CURRENT RATINGS

Power
Rated Rated input Mains
Max. output losses Maximum
output Thermal current short-
Type current for at rated protection line
current resistance (Arms) circuit
3 s (Arms) (1) current circuit fuses
(Arms) power
(W)
Easy-ak-230/17 17 5 (2) 34 (2) 1.6°C/W 9 (2) 20 A 5 kA

(1) Internal protection automatically divides the time by 3 at standstill.

(2)
As from serial number 11344000.

Maximum surrounding air temperature: 40°C.

10 Chapter 2 – Specifications
 XtrapulsEasy™ Installation Guide

2.1.2 - XtrapulsEasy™-ak-60/XX
Design Stand-alone

Available cooling version Natural convection with heatsink

Operating power supply voltage (1) 24 to 60VDC +/- 10%

Grounded reference voltage

Undervoltage threshold (1) 25VDC

Braking threshold (1) 75VDC

Overvoltage threshold(1) 85VDC

Motor phase-to-phase output voltage 95% of power supply voltage

External braking resistor(1) Minimum external resistor: 1Ω

Minimum phase-to-phase inductance(1) 0.2mH

Galvanic isolated auxiliary supply voltage 24VDC +/-15% - 150mA (without output loads)
Grounded reference voltage

(1)
These values correspond to the default configuration of the drive. For lower operating voltage, see section 5.2
"Low operating voltage".

OUTPUT CURRENT RATINGS

Power losses Rated input Maximum Mains
Max. output Rated output
at rated Thermal current protection short-
TYPE current for current
current Resistance (Arms) line circuit circuit
3 s (Arms) (1) (Arms)
(W) fuses power
Easy-ak-60/10 10 5 3 4.5°C/W 6 10 5 kA
Easy-ak-60/20 20 10 5 4.5°C/W 12 15 5 kA
Easy-ak-60/60 60 25 (2) 18.5 4.5°C/W 29 63 5 kA
Easy-ak-60/120 120 35 (2) 30 3.3°C/W 41 125 5 kA

(1) Internal protection automatically divides the time by 3 at standstill.

(2) Due to the drive's small dimensions, the rated values are guaranteed only up to 20°C room temperature.
External dissipation like an aluminium plate or an external heatsink may be necessary to guarantee the rated
current up to 40°C.
The XtrapulsEasy™-ak-60/XX drive is internally protected against overtemperature.

Maximum surrounding air temperature: 40°C.

2.1.3 - Technical specifications of the whole XtrapulsEasy™ range

Servo loops: current, speed, position Digital

Position sensor Sin Cos tracks (analog Hall)

Transmitter resolver
TTL Incremental encoder
TTL Incremental encoder + Hall Effect sensors
Hall Effect Sensors only

Power protections See section 3.1.1 - LEDs

Switching frequency 8 kHz

Analog input 1 +10 V (resolution: 12 bit)

Speed and position regulators Sampling period = 0.5ms

Anti-wind-up system of the integrator
Anti-resonance filter
Adjustable digital gains

Chapter 2 – Specifications 11
XtrapulsEasy™ Installation Guide

Speed loop bandwidth Selectable cut-off frequency for 45° phase shift:
50Hz (low), 75Hz (medium) or 100Hz (high)

Current loop bandwidth Cut-off frequency for 45° phase shift:

500Hz (low) or 1000Hz (high)

Max. motor speed Adjustable from 100 to 25'000rpm

Drive reaction time 6.25ms

(initialization delay before PWM on)

Encoder position output Encoder output is only available if TTL encoder is connected.

Resolver input Software selectable:

Transmitter resolver:
Excitation frequency: 8 kHz
Max. output current = 30 mA
Transformation ratio: 0.3 to 0.5 (other values are factory set)

Sin Cos tracks :

1Vpp to 4Vpp Sin and Cos signals

Encoder input Software selectable:

Quadrature signals A& B + one Z marker pulse per revolution.

Line receiver: RS-422
Max. frequency of encoder pulses: 400kHz
Resolution: 500 to 106ppr

Hall sensors input 5V to 24V positive logic voltage accepted

External HES supply voltage required if different from 5V
HES sequence error detection

Logic inputs 4 GND referenced logic inputs:

- 3 software configurable logic inputs - Response time: 500μs
- 1 input dedicated to the STO/INHIBIT function
Response time: < 50ms

Capture input 1 programmable input (IN1, IN2 or IN3)

Response time: 62.5μs

Logic outputs 2 software configurable logic outputs type PNP "high side"
24VDC, max. 500mA
Response time: 500μs

Error display Front panel LEDs + diagnostic via serial link or CAN bus

Motor and application parameterization Serial link RS-232 or bus interface with CANopen®
communication protocol

CAN interface CANopen® Protocol (DS301, DSP402)

Automatic functions Drive adjustment to the motor (AUTO-PHASING)

Adjustment of the servo loops (AUTO-TUNING)

MTBF (Mean Time Between Failures) > 100'000 hours

Maximum surrounding air temperature - Operation: -40°C to +50°C: from 40°C, the rated current
must be reduced by 3% per additional Celsius degree
- Storage: -40°C to +50°C

Altitude 1000 m

12 Chapter 2 – Specifications
XtrapulsEasy™ Installation Guide

Moisture < 50% at 40°C and < 90% at 20°C: EN 60204-1 standard
Condensation prohibited (storage and operation)

Cooling Natural air convection

Check for free air convection and for no obstruction of the
upper or lower air admissions.

Environment Open chassis to be mounted inside a cabinet protecting the

drive from conducting dust and condensation (pollution
degree 2 environment) and according to the room
temperature requirements.

Pollution degree of the drive IP20

Mounting position Vertical

Weight XtrapulsEasy™-ak-230/17: approximately 900g

XtrapulsEasy™-ak-60/XX: approximately 400g

Chapter 2 – Specifications 13
XtrapulsEasy™ Installation Guide

2.2 - DIMENSIONS AND CONNECTOR LOCATION

2.2.1 - XtrapulsEasy™-ak-230/17 dimensions (mm)

BOTTOM VIEW

SIDE VIEW FRONT VIEW

UPPER VIEW

14 Chapter 2 – Specifications
XtrapulsEasy™ Installation Guide

2.2.2 - XtrapulsEasy™-ak-60/ 60A & 120A dimensions (mm)

BOTTOM VIEW

SIDE VIEW FRONT VIEW

UPPER VIEW

Chapter 2 – Specifications 15
XtrapulsEasy™ Installation Guide

2.2.3 - XtrapulsEasy™-ak-60/ 10A & 20A dimensions (mm)

BOTTOM VIEW

SIDE VIEW FRONT VIEW

UPPER VIEW

16 Chapter 2 – Specifications
XtrapulsEasy™ Installation Guide

2.2.4 - XtrapulsEasy™-ak-230/17: Panel layout dimensions (mm)

VERTICAL MOUNTING IS MANDATORY

A
C

B B

Description Symbol Easy-ak-230/17

Minimum top and bottom clearance A 50
Minimum side clearance B 30
Recommended pitch C 80

Chapter 2 – Specifications 17
XtrapulsEasy™ Installation Guide

2.2.5 - XtrapulsEasy™-ak-60/XX: Panel layout dimensions (mm)

A
C

B B

Description Symbol Easy-ak-60/ 60A and 120A Easy-ak-60/10A and 20A

Minimum top and bottom clearance A 30 20
Minimum side clearance B 20 15
Recommended pitch C 50 25

18 Chapter 2 – Specifications
XtrapulsEasy™ Installation Guide

Chapter 3 – Inputs - Outputs of the XtrapulsEasy™

range

3.1 - DISPLAY

3.1.1 - Leds

RUN (green)

ERROR (red)

RUN: status of the CANopen® communication bus connection.

ERROR: faults grouped on the ‘ERROR’ LED: these errors are coded and can be displayed by means of the
parameter setting software.

ERROR LED unlit if no fault.

ERROR LED flashing: ‘UNDERVOLTAGE’ error: no power supply voltage.
ERROR LED continuously lit: fault.

The ERROR LED groups the following faults:

• Power supply overvoltage.

• 24VDC logic supply < 17.5VDC.
• Motor phase / GND short-circuit.
• Braking system short-circuited or overheated, or braking resistor in open circuit.
• Motor phase / motor phase short-circuit, power stage overtemperature, defective IGBT module.
• Triggering of the I2t protection.
• Counting error.
• Position following error
• EEPROM error.
• Procedure execution error (busy).
• Current offset error.
• Drive rating overcurrent.
• Motor temperature error.
• Resolver or encoder cable interruption.
• Hall sensors or absolute encoder error.

Notes

Any of these errors (except for the "Undervolt." error) involves:

• The continuous lighting of the red ERROR LED,

• The drive disabling,
• The motor brake control,
• The disabling of the AOK output. This output must be wired as described in the connection diagram of
section 4.1, in order to switch-off the power supply.

The ‘UNDERVOLTAGE’ error (flashing ERROR LED) involves:

• The drive disabling,

• The motor brake control.

Chapter 3 – Inputs-Outputs 19
XtrapulsEasy™ Installation Guide

3.1.2 - CANopen® communication bus

RUN: The CANopen® RUN LED indicates the status of the NMT state machine (see DS-301 – 9.52 NMT state
machine):

CAN RUN LED STATUS

ON 1 000 ms
FLASHING STOP OFF
200 ms

200 ms
ON
BLINKING PRE-OPERATIONAL
OFF
200 ms

ON OPERATIONAL

See "DR-303-3 Indicator specification" for more information.

Note:
Each drive of the network must be configured with one single address.
The factory set addressing is address 1 and the default communication speed is 1 Mbits.

3.2 - FEEDBACK CONNECTOR: X1

The feedback connector is a Sub D 15 pin female.

3.2.1 - X1 connector for transmitter resolver input

The wiring of the XtrapulsEasy™ drive resolver is compatible with the XtrapulsPac™ and XtrapulsCD1™ series.
The “Transmitter resolver” configuration is software selectable and saved in the drive EEPROM.

PIN FUNCTION I/O DESCRIPTION

12 TC- I Motor thermal sensor inputs. The valid
13 TC+ I measurement range is between 100Ω and
44kΩ.
2 S3 (cosine +) I Resolver signal
10 S1 (cosine -) I Resolver signal
11 S2 (sine +) I Resolver signal
3 S4 (sine -) I Resolver signal
5 R1 (reference +) O Resolver signal
4 R2 (reference -) O Resolver signal
Others Reserved

+5V
SPECIFICATION OF THE RESOLVER
INPUT LINES
LM824

S3 (Cos+)
S2 (Sin+)
Ri*
S4 (Sin-)
S1 (Cos-)

(*) For Easy 230V, Ri > 4.9K

For Easy 60 SN < 18110000, Ri > 4.9K
For Easy 60 SN > 18110000, Ri > 8.8K

20 Chapter 3 – Inputs-Outputs
XtrapulsEasy™ Installation Guide

3.2.2 - X1 connector for Sin Cos tracks input

PIN FUNCTION I/O DESCRIPTION
12 TC- I Motor thermal sensor inputs. The valid
13 TC+ I measurement range is between 100Ω and
44kΩ.
2 cosine + I SinCos track signal
10 cosine - I SinCos track signal
11 sine + I SinCos track signal
3 sine - I SinCos track signal
7 +5V O Sensor supply voltage
8 GND O Sensor supply GND
Others Reserved

SPECIFICATION OF THE SIN COS TRACKS INPUT LINES

+5V

LM824

Sin+
Cos+
Ri*
Sin-
Cos-
(*) For Easy 230V: Ri > 4.9K
For Easy 60: SN < 18110000, Ri > 4.9K
For Easy 60: SN > 18110000, Ri > 8.8K

3.2.3 - X1 connector for incremental TTL & HES encoder input

The “Incremental TTL & HES encoder” configuration is software selectable and saved in the drive EEPROM.

PIN FUNCTION I/O DESCRIPTION

9 Z/ marker pulse I Differential input of the encoder marker pulse Z/
1 Z marker pulse I Differential input of the encoder marker pulse Z
2 A/ channel I Differential input of the encoder channel A/
10 A channel I Differential input of the encoder channel A
11 B/ channel I Differential input of the encoder channel B/
3 B channel I Differential input of the encoder channel B
7 +5V O Encoder supply voltage (max. current = 300mA)
8 GND O Encoder supply GND
6 HALL U I Hall sensor input signal phase U
14 HALL V I Hall sensor input signal phase V
15 HALL W I Hall sensor input signal phase W
12 TC- I Motor thermal sensor input. The valid measurement range is between
13 TC+ I 100Ω and 44kΩ.
Others Reserved

Chapter 3 – Inputs-Outputs 21
XtrapulsEasy™ Installation Guide

SPECIFICATION OF THE INCREMENTAL SPECIFICATION OF THE HALL

TTL ENCODER INPUT LINES SENSOR INPUT LINES

+5V
+5V

10K
Receiver Hall U, V, W 10K
26LS32
A, B, Z
10K
GND
*
Ri
A/, B/, Z/

Min. Max.
High input voltage 3.3V 24V + 15%
Low input voltage 0V 0.6V
(*) For Easy 230V, Ri > 4.9K Hall inputs are compatible with open collector
For Easy 60 SN < 18110000, Ri > 4.9K outputs, without any external component.
For Easy 60 SN > 18110000, Ri > 8.8K

3.3 - INPUTS-OUTPUTS CONNECTOR: X2

SUB D 15 PIN MALE CONNECTOR

PIN FUNCTION I/O DESCRIPTION

1 IN1 (configurable) I All logic inputs are referenced to GND
2 IN2 (configurable) I Vin voltage = 18V < Vin < 27V
3 IN3 (configurable) I Input impedance Zin = 10kOhms
4 IN4 (STO/INHIBIT) I IN4 input is dedicated to STO
15 Differential encoder output channel A O Differential encoder outputs
8 Differential encoder output channel A/ O Signals directly provided by the TTL encoder.
14 Differential encoder output channel B O
7 Differential encoder output channel B/ O
13 Differential encoder Marker pulse Z O
6 Differential encoder Marker pulse Z/ O
9 OUT1 O "High side" logic outputs 24V / 500mA
10 OUT2 O
11 GND O
12 ANA1+ I Analog input nr. 1
5 ANA1- I Differential input +/-10V *
(*) For a non-differential input signal, ANA1- must be connected to GND on the drive side.

3.3.1 - Specification of the logic inputs

22 Chapter 3 – Inputs-Outputs
XtrapulsEasy™ Installation Guide

*) From serial number 11420004, the capacitor value is 10µF for the IN4 input only, in order to support safety
relays with test pulse output (for short-circuit detection).

Minimum Recommended Maximum

High input voltage 18V 24V 27V
Low input voltage 0V 0V 5V

3.3.2 - Specification of the logic outputs OUT1 and OUT2

Digital outputs can be paralleled in order to increase the maximum output current.
Be careful to connect all paralleled outputs to the same drive signal.

Paralleled outputs Output voltage Maximum output current

1 24V 500mA
2 24V 900mA

3.3.3 - Specification of the analog inputs ANA1+/-

Chapter 3 – Inputs-Outputs 23
XtrapulsEasy™ Installation Guide

3.4 - COMMUNICATION CONNECTOR: X5

SUB D 9 pin male connector

PIN FUNCTION REMARKS

1 Termination resistor Connect X5.1 to X5.7 to enable the termination resistor
2 CAN-L Line CAN-L (dominant low)
3 GND GND signal for CAN communication
4 TXD Transmit data RS-232
5 GND GND (shield connection if no 360° connection on the connector).
360° shield connection is highly recommended.
6 Reserved
7 CAN-H Line CAN-H (dominant high)
8 RXD Receive data RS-232
9 Reserved

Default parameters for the CANopen® bus are:

- Transmission speed of 1 Mb/s,
- Address set at 1,

Please see Gem Drive Studio Software Quick Start manual for detailed information on changing this
configuration.

The accessory "COM-Easy communication adapter" is to be plugged on the drive X5 connector (see section
4.4.3). It allows the wiring of the standard serial link RS-232 cable as well as of the standard RJ45 cables for the
CANopen interface.

3.5 - 24VDC AUXILIARY POWER SUPPLY CONNECTOR: X3

Manufacturer: Wago
Type: Midi connector
Reference: 721-102/026-000

PIN SIGNAL I/O FUNCTION DESCRIPTION

1 24V I Mains isolated 24VDC auxiliary 24VDC supply: +/- 15%
2 0V = GND I power supply Consumption: 300mA without digital output loads
0V input referenced to the GND
potential on the drive housing

3.6 - POWER CONNECTORS: X4

3.6.1 - XtrapulsEasy™-ak-230/17: X4
Manufacturer: Weidmüller
Type: BLZ 5.08 / 8
Reference: 152706
Tightening torque: 0.4 to 0.5Nm

PIN SIGNAL I/O FUNCTION DESCRIPTION

1 U O Motor phase U Shielded motor cable:
2 V O Motor phase V - PE connection on the bottom plate,
3 W O Motor phase W - 360° shield connection.
4 DC- I/O DC bus negative voltage output For the DC bus paralleling in multi-axis applications
5 DC+ I/O DC bus positive voltage output
6 DR O Braking transistor output Minimum braking resistor value = 50
Connect the braking resistor between pins 5 and 6.
7 L1 I 230VAC single-phase mains input 230VAC single-phase +10% / -15%
8 L2 I supply Fully integrated EMC mains filter.

IMPORTANT
Motor and brake cables must be shielded.
The 360° shield connection must be ensured by metallic collars and connected to the ground reference potential.

24 Chapter 3 – Inputs-Outputs
XtrapulsEasy™ Installation Guide

The GND wire of the motor cable MUST be connected to the housing of the drive by means of a Faston terminal
or ring terminal available at the bottom of the front panel.
See section 4.6 for grounding and shielding precautions.

3.6.2 - XtrapulsEasy™-ak-60/XX: X4
60A and 120A versions:
Manufacturer: Phoenix Contact
Type: PC 5/ 7-STCL1-7.62
Reference: 1778117
Tightening torque: 0.7 to 0.8Nm

10A and 20A versions:

Manufacturer: Phoenix Contact
Type: GMSTBA 2,5/7-G-7,62
Reference: 1766288
Tightening torque: 0.5 to 0.6Nm

PIN SIGNAL I/O FUNCTION DESCRIPTION

1 U O Motor phase U Shielded motor cable with 360° shield connection.
2 V O Motor phase V
3 W O Motor phase W
4 GND I/O GND reference and PE Connect GND signal from the chassis and PE cable
connection from the motor to this pin.
5 DC- I/O DC bus negative voltage
6 DC+ I/O DC bus positive voltage
7 DR O Braking transistor output Minimum braking resistor value = 1
Connect the braking resistor between pins 6 and 7.

IMPORTANT
Motor and brake cables must be shielded.
The 360° shield connection must be ensured by metallic collars and connected to the ground reference potential.
The GND wire of the motor cable MUST be connected to pin 4 of the X4 connector.
See section 4.6 for grounding and shielding precautions.

Chapter 3 – Inputs-Outputs 25
XtrapulsEasy™ Installation Guide

Chapter 4 – Connections

4.1 - EXAMPLES OF CONNECTION DIAGRAMS

4.1.1 - XtrapulsEasy™-ak-230/17 default configuration

Note: The 24V and power supply protection on source side must be ensured by the user.

26 Chapter 4 - Connections
XtrapulsEasy™ Installation Guide

4.1.2 - XtrapulsEasy™-ak-60/XX default configuration

Note: The 24V and power supply protection on source side must be ensured by the user.

Chapter 4 - Connections 27
XtrapulsEasy™ Installation Guide

4.1.3 - AOK chaining with XtrapulsEasy™ drives only

Note: Maximum delay for the power relay deactivation: number of XtrapulsEasy drives x 1ms.

4.1.4 - AOK chaining with XtrapulsEasy™ and XtrapulsPac™ drives together

Example 1

Example 2

(*) INx = IN1 or IN2 or IN3 and OUTy = OUT1 or OUT2.

XtrapulsEasy™ drive inputs and outputs must be configured according to the wiring diagram.

Note: Maximum delay for the power relay deactivation: number of XtrapulsEasy™ drives x 1ms.

28 Chapter 4 - Connections
XtrapulsEasy™ Installation Guide

4.1.5 - Protections
4.1.5.1 - Auxiliary power supply

The final user has to provide an isolated auxiliary 24VDC+/-15% supply (e.g. with isolation transformer) for the
auxiliary supply input, protected by a 3A fuse or circuit breaker.
4.1.5.2 - Power supply

The recommended protection is a D-type: current for 1s = 10 x rated current.

The maximum mains short-circuit power must not exceed 5000Arms.

On XtrapulsEasy™ drives, the recommended fuse or circuit breaker ratings are the following:

Recommended D-type
protection rating
Easy-ak-230/17 10A
Easy-ak-60/10 16A
Easy-ak-60/20 16A
Easy-ak-60/60 32A
Easy-ak-60/120 50A

4.2 - ANALOG INPUTS CONNECTION

4.2.1 - ANA1 input connection with a differential analog signal source

Easy X2 connector
AN+
Pin 12

AN-
Pin 5

GND
Pin 11

4.2.2 - ANA1 input connection with a non-differential analog signal source

Easy X2 connector
AN+
Pin 12

Pin 5

GND
Pin 11

Chapter 4 - Connections 29
XtrapulsEasy™ Installation Guide

4.3 - CONNECTION TO VARIOUS SENSOR TYPES

4.3.1 - Connection to a resolver: X1 - Sub D 15 pin female connector

4.3.2 - Connection to an incremental TTL encoder: X1 - Sub-D 15 pin female

connector

4.3.3 - Connection to an incremental TTL encoder with Hall sensor: X1 Sub-D

15 pin female connector

30 Chapter 4 - Connections
XtrapulsEasy™ Installation Guide

4.4 - ACCESSORIES AND CONNECTIONS

4.4.1 - Connection of the external braking resistor

All XtrapulsEasy™ stand-alone drives are fitted with the power feedback system. When the motor is decelerating
with high inertia and high speed, the mechanical braking energy is reflected to the drive. This energy is dissipated
inside a resistor called "braking resistor".

An electronic control of the dissipated power avoids the overload of the braking resistor. So, if the energy
reflected to the drives is too high, the DC bus voltage will rise up to the release of the "Overvoltage" fault.

The braking resistor MUST be mounted out of range of heat sensitive and inflammable parts (plastic, cable
sleeves, etc.).

In order to avoid any EMC or electrical problem, some rules must be observed:

• heat must be evacuated,

• shielded cables or at least twisted wires must be used,
• wires must bear high voltage and high temperature (recommended type: UL1015, AWG 14)
• wires must be as short as possible (max. 1m).

Example of correctly twisted wires

XtrapulsEasy-ak-230/17 XtrapulsEasy-ak-60/XX

Chapter 4 - Connections 31
XtrapulsEasy™ Installation Guide

4.4.2 - Connection of a backup battery

The XtrapulsEasy™ drive consumption is less than 300 mA with 24VDC. So, a 24V / 30A/h battery can keep the
drive powered during e.g. a long 3-day week-end. This backup method is interesting for saving the machine
initialization as well as the axis position even when moving with the mains switched off.

4.4.3 - Connection of the accessory "COM-Easy communication adapter"

The COM-Easy adapter allows connecting a standard RS-232 serial link cable to the drive. Further, two RJ45
standard connectors are available for the drive connection to the CANopen Communication Network. An internal
120Ohm terminal resistor can be activated by means of a mini-switch mounted on the adapter.

32 Chapter 4 - Connections
XtrapulsEasy™ Installation Guide

Connection tables:

EASY INTERFACE
X1 PINS SIGNAL DESCRIPTION
CONNECTOR
5 GND GND (shield connection if no 360°
Bottom connector X1 connection on the connector).
SUB-D 9 to be connected to 360° shield is strongly recommended.
the drive X5 connector 4 TXD Transmit data RS-232
8 RXD Receive data RS-232

SERIAL LINK
X2 PINS SIGNAL DESCRIPTION
CONNECTOR
5 GND GND (shield connection if no 360°
connection on the connector).
Top connector X2 SUB-D 9 360° shield is strongly recommended.
2 RXD Receive data RS-232
3 TXD Transmit data RS-232

X3 / X4
CANopen CONNECTOR SIGNAL DESCRIPTION
PINS
1 CAN-H CAN-H line (dominant high)
2 CAN-L CAN-L line (dominant low)
3 CAN-GND CAN ground
4 Reserved
RJ45 X3 & X4
5 Reserved
6 Internally connected X3-pin 6 connected to X4-pin 6
7 GND
8 Internally connected X3-pin 8 connected to X4-pin 8

4.5 - CONNECTION TO THE "GEM DRIVE STUDIO" SOFTWARE TOOL

4.5.1 - Connection of the serial link to the X5 connector

360° shield connection

4 TxD
RxD 2 Easy
PC X5
8 RxD
Serial port TxD 3
5 GND
GND 5

Sub D 9 pins female Sub D 9 pins female

Chapter 4 - Connections 33
XtrapulsEasy™ Installation Guide

4.5.2 - Multi-axis connection of the serial link

Setup
monitoring
RT

X5 CAN bus X5 CAN bus X5 RS 232

Host controller
CANopen® DS402
R
T

RT = 120Ohm terminal resistor connected between CAN-L and CAN-H lines

The parameterization of all axes is made by one single connection to the first axis via the serial link RS232. The
other axis are parameterized via the CAN bus.
Internal terminal resistor can be enabled by connecting X5.1 to X5.7.

4.6 - WIRING INSTRUCTIONS

According to the EN61000.4-2-3-4-5 and EN55011 standards.

4.6.1 - Ground connection

LEAKAGE CURRENT TO THE GROUND

The "Electronic Power Unit" equipment which includes the control, the drive, the motor and the sensors,
generates a leakage current to the ground higher than 10 mA continuous: the protection conductor section
must be at least 10mm² (Cu) or 16mm² (Al).

This product may generate a leakage current with a DC component. If a Residual Current Device is used, it
should be:
- of type A in single-phase applications,
- of type B in three-phase applications.

The use of a 300mA trip current is recommended.

The PE wire of the mains cable MUST be connected to the housing by means of a Faston terminal or ring
terminal.

The reference potential must be the ground: 10mm² section or ground braid to the reference potential.

If there is a potential reference, e.g. a chassis or cabinet with low impedance between its various parts, it should
be used for connections to this potential which shall be itself grounded.

Reference potential loops (especially with the ground) are allowed only if these loops have a very low impedance
(< 0.1). Any shield that is not used as a conductor can be connected at both ends under the condition to be
connected over 360° at both ends by means of metal links in order to ensure the shield continuity.

34 Chapter 4 - Connections
XtrapulsEasy™ Installation Guide

4.6.2 - Shield connection

CAUTION!
Each potential conducting element must be shielded. Several potential conductors in one single sleeve
must be twisted and shielded.

A shield has no effect if it is not connected:

- to a reference potential,
- via a 360° shield connection at both ends. This means that the whole shield sleeve circumference must
be directly in contact with the reference signal without any conductor insertion.

Cables with low potential should never run in the proximity of high power lines.

The connectors used for the compliance with the EN61000.4 standard must be made of metal or metalized and
must allow the 360° shield connections.

The shield of the motor and brake cable must be connected over 360°.
The 360° shield connection must be ensured by metallic collars and connected to the ground reference potential.

The shield should never be interrupted or corrupted over the whole cable length.

4.6.3 - Example of ground and shield connections

Chapter 4 - Connections 35
XtrapulsEasy™ Installation Guide

4.6.4 - Motor, resolver and encoder cables

Motors, resolvers and encoders are grounded via their housing.
Cable inputs must be made by means of metal connectors with collars allowing the 360° shield connection.

The resolver cable must be pair twisted and shielded (sin, cos, ref.). Motor cables MUST also be shielded and
connected over 360° at both ends, as shown on the shield connection picture of section 4.6.3.

Encoder inputs A, B, C, D, Z and R require pair twisted and shielded cables. The shield must have a 360°
connection via metallic collars at both ends.

Check that the voltage drop in the power supply lines of the encoder cable is complying with the technical
specifications of the encoder. The voltage drop value for a given cable is calculated as follows:

LC[m].I[mA]
U[V]=40.10−6.
S[mm²]

with U: voltage drop in volts

Lc: cable length in meters
I: encoder current in milliamps (see technical specifications)
S: section in square millimetres

Due to this voltage drop:

▪ an encoder with a wide power supply voltage range should be selected,

▪ if the encoder has power supply SENSE feedback lines, they can be connected to the power supply lines in
order to reduce the voltage drop by the half (the SENSE feedback signal is not used in this drive).

Brake equipped motors must also have their brake cables shielded in order to be EMC compliant.

Maximum cable length: 100m.

For cable length > 25m, we advise:

- the use of the maximum cable section allowed by the connectors,

- the mounting of a reactance with an inductive value between 1% and 3% of the motor inductive value for the
motor cable. The reactance inductive value must be taken into account in the calculation of the current loops.
The current rating of the reactance must be higher than or equal to the drive rating.

The reactance must be mounted at the drive output.

Due to the use of a reactance, a shielded cable is not mandatory anymore.
A more complex sinus filter type B84143V x R127 by company Epcos may also be mounted instead of the
reactance.

UNDESIRABLE EFFECTS OF MOTOR CABLES LONGER THAN 25M:

- Heating of the power module, the motor and the cable.

- High overvoltage on the motor windings, involving a shortening of their lifetime.

The reactance reduces the undesirable effects on motor and drive but it may be quite heated. This requires an
appropriate fan.

36 Chapter 4 - Connections
XtrapulsEasy™ Installation Guide

4.6.5 - Serial link and CAN communication cables

Serial link and CAN communication cables must also be shielded according to the shield connection
recommendations above.

CAUTION!
Control cables (resolver, serial link, CAN) and power cables must be connected and disconnected with the
drive turned OFF.
Reminder:
The power voltage may remain several minutes at the power capacitor terminals.
A contact with high voltage may involve severe physical damage.

4.7 - FIRST POWERING OF THE DRIVE

4.7.1 - Very important

Check the connections, especially of the 24VDC and power supplies. Check that the housing serigraphy actually
corresponds to the power connections.
The 400VAC connection of a 230 VAC drive will destroy it!

Check that the STO/INHIBIT input is powered.

Check for the braking resistor specifications.
Check for the correct groundings as well as the 360° shield connections.

WARNING !
During the machine adjustments, drive connection or parameterization errors may involve dangerous axis
movements. It is the user's responsibility to take all necessary steps in order to reduce the risk of uncontrolled
axis movements during the operator's presence in the pertaining area.

4.7.2 - Connection of the 24 VDC supply

The red Err LED on the front panel must be flashing ("Undervolt." error).
The AOK signal is high. The power voltage relay (Rpu) can then be controlled according to the recommendations
of Chapter 4, section 1 (connection diagram). The connection must be made in compliance with the X3 connector
serigraphy.

4.7.3 - Connection of the mains power supply

The red Err front panel LED must be unlit.

Note: If a fault occurs, the red Err LED remains continuously lit.

4.7.4 - Starting procedure

See XtrapulsEasy™ – User Guide.

Chapter 4 - Connections 37
XtrapulsEasy™ Installation Guide

Chapter 5 – Appendix

5.1 - SOFT START SYSTEM OF XTRAPULSEASY™-AK-230/17

5.1.1 - Introduction
Due to the structure of diode rectifier followed by capacitors of the XtrapulsEasy™-ak-230/17 drive, it is necessary
to limit the inrush current at power up.
The XtrapulsEasy™ drive integrates a soft start system as described below:

XtrapulsEasy

X4.5 DC+

X4.8 L1

L2
X4.7

Soft DC-
start
X4.4

Note: The soft start system remains operational when the drive is powered by the DC- and DC+ inputs.

5.1.2 - Integration recommendations

In order to maximize the lifetime of internal components of the XtrapulsEasy™ drive and external
electromechanical components, it is necessary to switch on only when the soft start system is enabled
("Undervoltage" fault displayed).

UDC

UAC2

Undervolt.
threshold

Undervolt. 2s
fault

t0 t1 t2 t3

Details:

- At t0, the power supply of the drive is switched on. DC bus capacitors are charged via the soft start system.
- After a delay of 2 s at t1, the soft start system is disabled, and the "Undervoltage" fault goes off. The drive is
ready to switch on.
- Between t1 and t2, normal operations are performed by the drive.
- At t2, the drive power supply is switched off. The drive remains operational while the DC bus voltage is higher
than the undervoltage threshold.
- The delay between t2 and t3 is much depending on the application (drive on/off, positive/negative motor
power).
- At t3, the DC bus voltage becomes lower than the undervoltage threshold. The "Undervoltage" fault is
displayed, the drive is disabled and the soft start system is enabled.

38 Chapter 5 - Appendix
XtrapulsEasy™ Installation Guide

5.2 - LOW OPERATING VOLTAGE

XtrapulsEasy™ drives offer the possibility to change the operating voltage.
Thanks to this feature, XtrapulsEasy™ drives are able to work within a wide voltage range, from 24VDC / 17VAC up
to 325VDC / 230VAC.

Please note that the drive specifications are depending on the operating voltage, as shown in the table below:

Operating voltage
17VAC 34VAC 42VAC 48VAC 230VAC
24VDC 48VDC 60VDC 68VDC 325VDC
Minimum 8kHz 0.08mH* 0.15mH 0.2mH 0.24mH 1mH
inductance 16kHz 0.04mH* 0.08mH* 0.1mH 0.12mH 0.5mH
actual operating voltage
Minimum braking resistor Standard minimum braking resistor x standard operating voltage
Undervoltage threshold 17VDC 20VDC 25VDC 30VDC 100VDC
Braking threshold 30VDC 60VDC 75VDC 85VDC 390VDC
Overvoltage threshold 35VDC 70VDC 85VDC 100VDC 430VDC
Drive availability Easy-ak-60/XX N/A
Easy-ak-230/17

(*) For motor inductance lower than 0.1mH, the current loop gains must be manually calculated using the
following procedure :
a) Perform the automatic gain calculation for an inductance of 0.1mH
b) Apply to all the gains found (Id gains and Iq gains) the ratio between your actual inductance and 0.1mH.

Example: Gains found with 0.1mH are Id_proportional=27 Id_integral=51 Iq_proportional=27 Iq_integral=51
Your inductance is 0.05mH, so the correction factor is 0.05mH/0.1mH=0.5
Set the gains to Id_proportional=27*0.5=13 and Iq_proportional=27*0.5=13
Id_integral=51*0.5=25 and Iq_integral=51*0.5=25

IMPORTANT

The use of XtrapulsEasy™ drives at very low operating voltage suffers from several limitations:

- Voltage below +15VDC cannot be accurately measured on the DC link.

- The capacitors bank is optimized for operation at rated voltage. The energy stored in the capacitors is
proportional to the square of the voltage. At very low voltage, the storage ability of regenerative energy is
limited. Extra storage (capacitors, battery, …) can be required to assume proper operations during high
dynamic deceleration phases.

- The detection of a braking transistor error is not active:

o below 40VDC for XtrapulsEasy™ 230VAC drives.

5.3 - SIZING OF THE BRAKING SYSTEM

5.3.1 - Introduction
The braking I²t function defines the maximum allowable duty cycle of the braking transistor.
It protects the braking resistor against overload and overheating.

5.3.2 - Method for the design of the braking system

Two different quantities are necessary to completely define an application:

- The peak power:

o It defines the deceleration energy,
o It is limited by the braking transistor current.
- The average power:
o It defines the heat dissipation

Chapter 5 - Appendix 39
XtrapulsEasy™ Installation Guide

1. Estimation of the regenerative power

The regenerative power must be calculated for each deceleration phase of each motor.
J TOTAL .( n1 − n2 ) TLOAD .( n1 + n2 )
2 2

PLOAD = −
180.t DEC 19
PMOTOR = PLOAD . COUPLING
3
PJOULE =
2
RMOTOR .I MOTOR
2
PELEC = PMOTOR − PJOULE

with: PLOAD: Power regenerated by the load during the deceleration phase in W
JTOTAL: Motor + load inertia of the axis reflected to the motor shaft in kg.m²
n 1: Rotation speed at the beginning of the deceleration phase in RPM
n 2: Rotation speed at the end of the deceleration phase in RPM
tDEC: Deceleration time in s
TLOAD: Torque applied by the load on the motor shaft at the beginning of the deceleration phase in Nm
PMOTOR: Power regenerated on the motor shaft in W
COUPLING: Efficiency of the mechanical coupling (gearbox). If no gearbox is used,COUPLING 1
PJOULE: Losses in the motor windings in W
RMOTOR: Winding resistance measured between two phases of the motor in 
IMOTOR: Average current in one phase of the motor during the deceleration phase in A
PELEC: Average power managed by the drive during the deceleration phase in W.

2. Choice of the ohmic value

2
U BRAKING
RMIN  RBRAKING 
2.PˆELEC

with: RMIN: Minimum braking resistor value in Ohm according to section "Main technical data".
UBRAKING: Triggering threshold of the braking system in V.
RBRAKING: Braking resistor in .
P̂ELEC : Maximum of all PELEC calculated for all motors and for all deceleration phases in W.

3. Average power

The required average power must be calculated to correctly choose the size of the braking resistor and to take
into account the heat dissipation effect in the near environment.


N ,P
PELEC (n, p)  TDEC (n, p)
PAVERAGE = 1,1

TCYCLE

with: PELEC: Power managed by the drive axis n during the deceleration phase p in W

4. Braking I²t setup

2
tON U BRAKING
PI ² t = .
1000 RBRAKING

with: PI²t: Maximum average power allowed by the braking I²t function in W
tON: Conduction time allowed by the braking I²t function in ms
UBRAKING: Triggering threshold of the braking system in V
RBRAKING: Braking resistor in 

40 Chapter 5 - Appendix
XtrapulsEasy™ Installation Guide

5. Connection of the braking resistor

The braking resistor MUST be mounted out of range of heat sensitive and inflammable parts (plastic, cable
sleeves, etc.).

In order to avoid any EMC or electrical problem, some rules must be observed:

• heat must be evacuated,

• shielded cable or at least twisted wires must be used,
• wires must bear high voltage and high temperature (recommended type: UL1015, AWG 14),
• wires must be as short as possible (max. 1m).

5.4 - MAINTENANCE

5.4.1 - Periodical checking

Maintenance procedures should be attempted only by highly skilled technicians having good knowledge
of electronics and servo systems with variable speed (EN 60204-1 standard) and using proper test
equipment.

Risk of electric shock

Any contact with electrical parts, even after power down, may involve physical damage. Wait for at least
10 minutes after power down before handling the drives (a residual voltage of several hundreds of volts may
remain during a few minutes).

Hot surfaces
- Ensure that any contact with hot surfaces is avoided.
- Do not allow flammable or heat-sensitive parts in the immediate vicinity of hot surfaces
- Verify that the product has sufficiently cooled down before handling it.

Damage Action Periodicity

Shock on the housing - Check the drive housing Every year
Cooling - Check the fan operation Every year
- Check the room temperature of the drive
Dust - Check connectors, fan, and cabinet cooling system Every year
Corrosion - Check housing and electrical connection Every year
Mechanical mounting - Check the correct drive fastening Every year
- Check the tightening of the electrical connection

Chapter 5 - Appendix 41
XtrapulsEasy™ Installation Guide

5.4.2 - Procedure after a long-time storage

After a long-time storage, the leakage current of electrolytic capacitors increases dramatically.
In order to avoid any risk of damage or explosion, DC bus capacitors must be reformatted.
When the drive has been stored for 2 years or more, proceed as described below:
1. With a variable AC power supply, apply 25 % of the rated voltage on the mains input during
30 min,
2. With a variable AC power supply, apply 50 % of the rated voltage on the mains input during
30 min,
3. With a variable AC power supply, apply 75 % of the rated voltage on the mains input during
30 min,
4. With a variable AC power supply, apply 100 % of the rated voltage on the mains input during
30 min,

In order to avoid this procedure, the drive can also be powered at rated voltage every year during 1 hour.

5.4.3 - Warranty
Opening the housing will cancel the warranty.

5.5 - OPERATING ENVIRONMENT CONDITIONS

A - CLIMATIC CONDITIONS

1 - Cooling fluid temperature Air : -40°C to +40°C

2 - Air temperature -40°C to +40°C

3 - Relative moisture 5% to 85% without condensation

4 - Dust and particles Clean air (pollution degree 2)

Drive must be protected against conducting dust

5 - Storage periods < 1 year: no restrictions

> 1 year: re-format the power capacitors
according to section 5.4.1.

B - MECHANICAL INSTALLATION CONDITIONS

The drive must be mounted on a stiff surface, in rooms or additional housings without hindering the heatsink.
The reliability may be increased by installing a cooling system (take care of condensation).
Other installation conditions must be specially analysed and subjected to a technical specification in
agreement with INFRANOR.

Vibration level for XtrapulsEasy™-ak-230/17

Vibrations must remain within the limit values of the IEC 60721-3-3, class 3M1 standard for fixed equipment.

Frequency (Hz) Amplitude (mm) Acceleration (m/s2)

2f<9 0,3 not applicable
9  f < 200 not applicable 1

Vibrations which exceed these limits or the use on mobile equipment are considered as unusual operating
conditions.

42 Chapter 5 - Appendix
XtrapulsEasy™ Installation Guide

Vibration level for XtrapulsEasy™-ak-60/XX

The XtrapulsEasy™-ak-60/XX drive can be integrated in mobile equipment which vibration level is up to 4g.

Frequency (Hz) Amplitude (mm) Acceleration (g) Norm

5  f < 25 4,95 not applicable
IEC60068-2-6
25  f < 1000 not applicable 4

The validation profile is shown below:

Definition of the stress axes: Endurance template:

16 sweeps during 2 hours in each axis

4
Z
Y
0
X 5 25 1000
Hz

Shock level for XtrapulsEasy™-ak-60/XX

Level Conditions Standard

15g / 11ms half sinus 6 shocks per axis
3 shocks per direction IEC60068-2-27
Device operating

C - UNUSUAL OPERATING ENVIRONMENT CONDITIONS

The use of the power converter, of its pertaining control system and of the servo in conditions which are
diverging from the usual ones defined by the IEC 60146-1-1 standard must be considered as abnormal.
These abnormal operating conditions must be specified by the purchaser.

Abnormal operating conditions as those listed below may require a special construction or special
protections. The conditions below must be notified if they are known or specified:

1. Exposure to corrosive gas.

2. Exposure to excessive moisture (relative moisture exceeding 85 %).
3. Exposure to excessive dust.
4. Exposure to abrasive dust.
5. Exposure to water steam or condensation.
6. Exposure to oil steam.
7. Exposure to explosive dust or gas mixtures.
8. Exposure to salt air.
9. Exposure to abnormal vibrations, shocks, jerking.
10. Exposure to inclemency or water dripping.
11. Exposure to unusual storing or freight conditions.
12. Exposure to sudden or rough temperature variations.
13. Abnormal exiguity of the available room.
14. Abnormal high nuclear radiations.
15. Altitude higher than 1000 m.
16. Long storage periods.
17. Outdoor equipment.

D - INSTALLATION, COMMISSIONING AND OPERATION

Normal and abnormal operating conditions apply the same way to installation, commissioning and use.

Chapter 5 - Appendix 43
XtrapulsEasy™ Installation Guide

E - EQUIPMENT STORAGE

At receipt, the equipment must be immediately stored under adequate shelter. The transport
packaging is not suited to outdoor or non-protected storing.

Climatic conditions

Equipments must be stored in the environment conditions specified by the IEC 60721-3-1
standard. This includes:
1- Room temperature: class 1K4 with extended low temperature range -40°C to +55°C
2- Relative moisture: class 1K3 5% to 95%

Modules and panels must be protected against condensation. Rough temperature and moisture variations should
be avoided, as far as possible. If the temperature of the storing room is varying such as to subject the equipment
to condensation or to frost, the equipment must then be protected by a reliable heating system which will keep it at
a temperature slightly higher than the surrounding air temperature.
If the equipment has been subjected to a low temperature during a long time, it should not be unpacked before
having reached the surrounding air temperature, in order to avoid condensation. Such moisture in some parts of
the equipment may involve a faulty electric insulation.

F - PARTICULAR STORING RISKS

The following risks must be carefully considered:

1. Water: The equipment must be protected against rain, snow, rime, etc…

2. Altitude: The equipment should not be stored at an altitude higher than 3000m.

3. Corrosive agents: The equipment must be protected against salty sea spray, emanations of dangerous
gasses or corrosive liquids, etc…

4. Duration: the specifications of the above mentioned items are only valid for a total transport and
storage period of up to six months. Longer periods may require a special treatment (smaller
surrounding air temperature range such as in class 1K3).

G - TRANSPORT

1 - Climatic conditions

The equipment can be transported in its standard packaging in the environment conditions specified by
class 2K3 of the IEC 60721-3-2 with extended low temperature range. This includes:

a - Surrounding air temperature: -40°C to +70°C

NOTE: The surrounding air temperature is the temperature which is the nearest to the equipment, i.e.
the inside of the container.
b - Relative moisture: 95% at +40°C
NOTE: Some temperature and moisture combinations may cause condensation.

2 - Mechanical conditions

The equipment may be transported in its standard packaging in the conditions specified by class 2M1 of
the IEC 60721-3-2 standard.
This includes vibrations and shocks (see tables below).

TABLE 4 – Vibration limits during the transport

Frequencies (Hz) Amplitude (mm) Acceleration (m/s2)

2f<9 3.5 -
9  f < 200 - 10
200  f < 500 - 15

44 Chapter 5 - Appendix
XtrapulsEasy™ Installation Guide

TABLE 5 – Shock limits during the transport

Mass (kg) Free fall height (m)

M < 20 0.25
20  M < 100 0.25
100  M 0.10

NOTE: If the equipment may be subjected to shocks or vibrations beyond these limits, it will require special
packaging or transport conditions.

Chapter 5 - Appendix 45
 XtrapulsEasy™ Installation Guide

Infranor Group Infranor worldwide

Infranor creates added value for its customers by providing tailor-made Benelux
motion solutions. China
France
Based on strong working relationships, Infranor offers extensive market
know- how, comprehensive engineering skills and a wide range of high- Germany
quality products leading to productivity gains and therefore to Italy
comparative advantages for its customers in their respective markets. Spain
Switzerland
United Kingdom
USA

Contact Other representations:

Austria, Denmark, India, Israel,
Poland, Slovenia, Turkey

Manufacturer: INFRANOR SAS  29, avenue Jean Moulin  F-65100 LOURDES

©46INFRANOR, September 2020 - All rights reserved

Issue: 2.5 www.infranor.com