Denali XCR Cable Kit - Product Manual

Introduction

This document explains the content and wiring details of the Denali XCR Cable Kit (DEN-CAB). The kit is provided as a tool to speed up the connection between Denali XCR and the user's application.

It is composed of the following components:

1 x Power supply cable - 300 mm (C-DEN-PSU)
1 x Input / Output cable - 250 mm (C-DEN-IO)
1 x EtherCAT Communication and Safety cable - 1 m (C-DEN-ECAT)
1 x Feedback cable - 250 mm (C-DEN-FEED)
1 x Motor power cable - 300 mm (C-DEN-CO)
10 x Extra Wires for Feedback & Input / Outputs - 250 mm (C-PC-EXTRA)

Power Supply Cable

The Power supply cable is provided with a length of 300 m. It consists of a set of 2 x 20 AWG cables with a 2pin Molex Pico-lock connector on one side and flying leads on the other. Molex Pico-lock connector should be plugged directly into the XCR P1 connector.

Side 1 - pin	Side 2 - pin	Wire color	Signal	Function
1	Flying lead	Black	+V_BUS	Power supply positive
2	Flying lead	Black	GND_P	Power supply return

Input / Output Cable

The Input / Output cable is provided with a length of 250 m. It consists of a set of 7 x 28 AWG cables with a 20-pin Molex Pico-clasp connector on one side and flying leads on the other. Molex Pico-clasp connector should be plugged directly into the XCR P2 connector.

The cables are tied by means of spiral wraps in 3 different groups to simplify their identification:

Digital Incremental Encoder
Digital Halls
Absolute Encoder

The pinout of the Feedback cable is as follows:

Side 1 - pin	Side 2 - pin	Wire color	Signal / Label	Function
1	Flying lead	Red	+5V_I/O	+5 V 60 mA output, can be used for peripherals such as switches, I/Os, or even supply the safety inputs.
2	Flying lead	Black	GND_D	Digital signal ground.
3	Flying lead	Orange	IN1	Digital input 1. 3.3 V logic levels, tolerant to 6 V continuous, can be used with 5 V logic.
5	Flying lead	Green	IN2	Digital input 2. 3.3 V logic levels, tolerant to 6 V continuous, can be used with 5 V logic.
16	Flying lead	Black	GND_D	Digital signal ground.
18	Flying lead	Blue	CAN_L	CAN bus line dominant low. Pins 17 and 18 are internally connected, can be useful for daisy-chain wiring.
20	Flying lead	Brown	CAN_H	CAN bus line dominant high. Pins 19 and 20 are internally connected, can be useful for daisy-chain wiring.

EtherCAT + Safety Cable

The EtherCAT and Safety cable is provided with a length of 1 m. It consists of a CAT6 (28 AWG - twisted pair & shielded) cable with a 8-pin Molex Pico-clasp connector on one side and a shielded RJ45 connector + flying leads on the other. Molex Pico-clasp connector should be plugged directly into the DEN-XCR P3 connector.

Side 1 - pin	Side 2 - pin	Wire color	Twisted	Signal / Label	Function
1	Flying lead	Red	-	SAFETY_IN_A	Safe Input A for STO and SBC (positive, active from 5 V to 30 V, ISOLATED). Internal bypass from P3 to P4.
2	Flying lead	Black	-	SAFETY_RETURN	Safe Inputs Return common (optocoupler LEDs cathode, ISOLATED). Internal bypass from P3 to P4.
3	Flying lead	Yellow	-	SAFETY_IN_B	Safe Input B for STO and SCB (positive, active from 5 V to 30 V, ISOLATED). Internal bypass from P3 to P4.
4	1	White - Orange	TX_D	TX_D+	Transmit Data+ line.
5	2	Orange	TX_D	TX_D-	Transmit Data- line.
6	3	White - Green	RX_D	RX_D+	Receive Data+ line.
7	6	Green	RX_D	RX_D-	Receive Data- line.
8	Shroud / Shield	Drain wire	-	GND_ETH/PE	Connection for the EtherCAT cable shield. This pin is directly connected to the chassis of the drive - PE. To do so it is recommended to use a cable shield termination like TE S02-16-R.

Feedback Cable

The Feedback cable is provided with a length of 250 mm. It consists of a set of 30 x 28 AWG cables with a 30-pin Molex Pico-clasp connector on one side and flying leads on the other. Molex Pico-clasp connector should be plugged directly into the DEN-XCR P5 connector.

Side 1 - pin	Side 2 - pin	Wire color	Signal / Label	Function
1	Flying lead	Black	GND_D	Digital ground.
2	Flying lead	Blue	MOTOR_TEMP_RET	Motor temperature sensor return (referred to GND_D). Do not use this pin as GND for any other purpose than the negative for motor temperature sensing.
3	Flying lead	Orange	ENC_Z-	Differential digital incremental encoder index- input. Leave unconnected if using single-ended encoders.
4	Flying lead	Blue	MOTOR_TEMP_IN	Motor temperature sensor input. A 1.65 kΩ pull-up resistor to 3.3 V is included on the drive.
5	Flying lead	Green	ENC_Z+	Differential digital incremental encoder index+ input.
6	Flying lead	Black	GND_D	Digital ground.
7	Flying lead	Blue	ENC_B-	Differential digital incremental encoder B- input. Leave unconnected if using single-ended encoders.
8	Flying lead	Yellow	HALL_3	Digital hall sensor 3 input, 1 kΩ pullup to 3.3 V included.
9	Flying lead	Brown	ENC_B+	Differential digital incremental encoder B+ input.
10	Flying lead	Blue	HALL_2	Digital hall sensor 2 input, 1 kΩ pullup to 3.3 V included.
11	Flying lead	Yellow	ENC_A-	Differential digital incremental encoder A- input. Leave unconnected if using single-ended encoders.
12	Flying lead	White	HALL_1	Digital hall sensor 1 input, 1 kΩ pullup to 3.3 V included.
13	Flying lead	White	ENC_A+	Differential digital incremental encoder A+ input.
14	Flying lead	Brown	+3.3V_FEEDBACKS	3.3V 250mA power supply output for feedbacks.
15	Flying lead	Brown	+3.3V_FEEDBACKS	3.3V 250mA power supply output for feedbacks.
16	Flying lead	Brown	+3.3V_FEEDBACKS	3.3V 250mA power supply output for feedbacks.
17	Flying lead	Red	+5V_FEEDBACKS	5V 500 mA power supply output for feedbacks.
18	Flying lead	Red	+5V_FEEDBACKS	5V 500 mA power supply output for feedbacks.
19	Flying lead	Red	+5V_FEEDBACKS	5V 500 mA power supply output for feedbacks.
20	Flying lead	Red	+5V_FEEDBACKS	5V 500 mA power supply output for feedbacks.
21	Flying lead	Brown	ABS1_CLK-	Absolute encoder 1 CLK negative signal output. For single-ended absolute encoders with TTL or CMOS levels leave this pin floating and connect the clock to ABS1_CLK+.
22	Flying lead	Brown	ABS2_CLK-	Absolute encoder 2 CLK negative signal output. For single-ended absolute encoders with TTL or CMOS levels leave this pin floating and connect the clock to ABS2_CLK+.
23	Flying lead	Blue	ABS1_CLK+	Absolute encoder 1 CLK positive signal output.
24	Flying lead	Blue	ABS2_CLK+	Absolute encoder 2 CLK positive signal output.
25	Flying lead	Yellow	ABS1_DATA-	Absolute encoder 1 DATA negative signal input. For single-ended absolute encoders with TTL or CMOS levels leave this pin floating and connect the signal to ABS1_DATA+.
26	Flying lead	Yellow	ABS2_DATA-	Absolute encoder 2 DATA negative signal input. For single-ended absolute encoders with TTL or CMOS levels leave this pin floating and connect the signal to ABS2_DATA+.
27	Flying lead	White	ABS1_DATA+	Absolute encoder 1 DATA positive signal input.
28	Flying lead	White	ABS2_DATA+	Absolute encoder 2 DATA positive signal input.
29	Flying lead	Black	GND_D	Digital ground.
30	Flying lead	Black	GND_D	Digital ground.

Motor Power Cable

The Motor power cable is provided with a length of 300 mm. It consists of a set of 4 x 20 AWG cables with a 4-pin Molex Pico-lock connector on one side and flying leads on the other. Molex Pico-lock connector should be plugged directly into the DEN-XCR P6 connector.

Side 1 - pin	Side 2 - pin	Wire color	Signal / Label	Function
1	Flying lead	Black	PH_C	Motor phase C
2	Flying lead	Black	PH_B	Motor phase B
3	Flying lead	Black	PH_A	Motor phase A
4	Flying lead	Black	PE	Protective earth connection, internally connected to standoffs.

Extra wires for Feedbacks and Input / Outputs (C-PC-EXTRA)

Additionally, a set of 10 x 28 AWG cables with a pre-crimped Molex Pico-clasp socket on one side and flying leads on the other is provided.

These cables could be used to populate any specific functionality not provided in the C-PC-FEED or C-PC-IO connectors.