XG2 EtherCAT Motion Controller
The XG2 EtherCAT Motion Controller is a high-performance industrial control solution engineered for next-level automation efficiency. Boasting faster response speed with ultra-low EtherCAT communication latency, larger load capacity that supports multi-axis and multi-device connectivity, and all-round upgraded functions covering precision interpolation, electronic cam, and multi-axis synchronization, it delivers stable, accurate control for complex production scenarios. Ideal for smart factories, CNC machinery, and automated production lines, this controller simplifies integration, cuts downtime, and boosts overall throughput to meet the demands of modern industrial automation.
Core Product Features
- Elevated Speed Performance: Equipped with an optimized EtherCAT master station, boasting a communication cycle as low as 100 μs and jitter less than 1 μs, delivering a significant boost in multi-axis response speed compared to conventional solutions.
- Expanded Capacity Scaling: Supports up to 64 axes of complex motion control, connects over 100 slave devices, and offers IO expansion capability of thousands of points, meeting the demands of large-scale production lines.
- Comprehensive Function Upgrades: Covers linear/circular/helical interpolation, electronic cam, multi-axis synchronization, and other functions. Supports free switching between CSP/CSV/CST modes, adapting to diverse application scenarios.
- Flexible Compatibility & Expansion: Compatible with linear, tree, ring, and other topological structures. Works seamlessly with servo drives from different brands and integrates effortlessly with vision systems.
- User-Friendly Programming & Operation: Supports multi-language programming and HMI configuration, enabling online parameter modification and remote diagnosis to simplify commissioning and maintenance processes.
Core Competitive Advantages
- High-Precision Synchronized Control: Leverages distributed clock technology to achieve nanosecond-level axis synchronization accuracy, ensuring micron-level positioning error for coordinated multi-axis motion.
- Productivity Efficiency Boost: Fast response and stable operation reduce equipment downtime. Optimized motion trajectories significantly improve production line throughput and shorten cycle times.
- Lower Total Cost of Ownership: Simplifies electrical cabinet wiring and features strong anti-interference capabilities, cutting down long-term maintenance costs. Compatible with existing equipment, minimizing hardware investment for upgrades and replacements.
- Reliable & Stable Operation: Comes with power-failure data storage and multiple program encryption functions. Supports hot-swapping and rapid fault detection, adapting to harsh industrial environments.
- Versatile Application Adaptability: Provides customized motion control solutions for industrial robots, CNC machine tools, printing and packaging equipment, electronic and semiconductor devices, and more.
Core Technical Specifications
| Parameter Category |
Parameter Item |
Specification |
| Core Performance |
Basic Instruction Processing Speed |
0.005-0.01 μs |
| User Program Capacity |
16 MB FlashROM |
| Maximum I/O Points |
1050 Points |
| EtherCAT Motion Control |
Maximum Controlled Axes |
32 Axes (Synchronized Motion) |
| Communication Cycle |
As low as 100 μs, Jitter < 1 μs |
| Maximum Supported Slave Nodes |
Up to 100+ Standard EtherCAT Slaves |
| Synchronization Accuracy |
Nanosecond-level Distributed Clock Synchronization |
| Motion Control Modes |
Free Switching Between CSP/CSV/CST Modes |
| Motion Functions |
Interpolation Functions |
Linear, Circular, Helical Interpolation |
| Electronic Cam |
16 Channels of Electronic Cam & Following Functions |
| High-Speed Pulse Output |
4 Channels of 100 kHz Differential Pulse Output |
| Probe Function |
2 Channels of Touch Probe High-Speed Position Capture |
| Communication Interfaces |
EtherCAT Interface |
2×RJ45, 100 Mbps, Max Station Distance ≤ 100 m |
| Auxiliary Communication |
RS232, RS485, Ethernet (Modbus Supported) |
| Power & Environment |
Operating Power Supply |
24 VDC (18-30 VDC Range) |
| Operating Temperature |
0-55℃ |
| Storage Temperature |
-20-70℃ |
| Protection Class |
IP20 (Panel Mounting) |
XG2 Series EtherCAT Motion Controller Product Model List
| Model |
I/O Configuration (DC24V) |
Output Type |
Pulse Output Channels |
Max Synchronized Axes (EtherCAT) |
Key Features for Overseas |
| XG2-26T4 |
18 DI / 8 DO (Transistor) |
Transistor (NPN) |
4 |
32 |
Entry-level, cost-effective for small automation lines |
| XG2-40T8 |
24 DI / 16 DO (Transistor) |
Transistor (NPN) |
8 |
32 |
Mid-range, ideal for multi-station assembly equipment |
| XG2-60T16 |
36 DI / 24 DO (Transistor) |
Transistor (NPN) |
16 |
32 |
High-I/O, fits printing and packaging machinery |
| XG2-80T20 |
48 DI / 32 DO (Transistor) |
Transistor (NPN) |
20 |
32 |
Large-scale, perfect for CNC machine tools and robot cells |
| XG2-26T4-P |
18 DI / 8 DO (Transistor) |
Transistor (PNP, overseas-friendly) |
4 |
32 |
PNP output, compatible with Western-standard servo systems |
| XG2-40T8-P |
24 DI / 16 DO (Transistor) |
Transistor (PNP, overseas-friendly) |
8 |
32 |
PNP output, for European and American automation setups |
Target Industries & Use Cases
- Automotive Manufacturing
Use Cases: Multi-robot collaboration (welding, gluing, seat assembly) on European/North American automotive assembly lines; cell stacking and module welding on new energy battery pack lines; multi-axis synchronized winding on tire building machines.
Fit Points: 32-axis synchronization + nanosecond-level clock ensures zero-delay coordination between robots, conveyor lines and pressing equipment. PNP models match mainstream servo wiring standards in Europe and America, cutting on-site rewiring costs.
- Semiconductor & Electronics Manufacturing
Use Cases: High-speed pick-and-place positioning for SMT machines in Southeast Asian factories; motion control of wafer dicing platforms; multi-axis linkage drilling for PCB drilling machines.
Fit Points: 100μs communication cycle + helical interpolation delivers micron-level positioning accuracy. Seamless integration with mainstream vision systems enables high-speed, precise placement and drilling.
- CNC Machine Tools
Use Cases: Gantry machining centers and turn-mill composite machines from small-to-medium precision machine tool factories in Germany/Italy; multi-process linkage control on metal cutting production lines.
Fit Points: Linear/circular interpolation + electronic cam guarantees machining precision for complex contours. EtherCAT ring topology enhances anti-interference performance, ideal for high-electromagnetic interference workshop environments.
- Printing & Packaging
Use Cases: Registration control for high-speed flexographic printing presses in North America; coordinated operation of filling, labeling and sealing machines on European food packaging lines; high-speed sorting on e-commerce logistics sorting lines.
Fit Points: Support for 100+ slave nodes synchronizes paper feeding, printing and die-cutting processes. Electronic cam following function maintains stable packaging film tension, reducing product waste rates.
- Industrial Robotics
Use Cases: Joint control of collaborative robots in Europe; six-axis robot welding/handling in U.S. auto parts factories; multi-axis coordination of palletizing robots in logistics warehouses.
Fit Points: Free switching between CSP/CSV/CST modes meets diverse motion requirements of robots. Compatibility with servo drives from multiple brands lowers hardware selection barriers for robot manufacturers.
- Food & Beverage
Use Cases: Bottle positioning and filling volume control on Nordic dairy filling lines; synchronized labeling, capping and coding on South American beer production lines; precise tray conveying for baking equipment.
Fit Points: Remote diagnosis + online parameter modification minimizes production line downtime for debugging. IP20 protection + wide voltage power supply (18-30 VDC) adapts to humid and dusty food workshop environments.
- Logistics & Material Handling
Use Cases: Cross-belt sorters in U.S. e-commerce sorting centers; 3-axis synchronization of stackers in German automated warehouses; motion control for AGV fleet scheduling.
Fit Points: Dual EtherCAT ports + flexible topology enable centralized control of multi-zone sorting lines. Hot-swapping support reduces equipment maintenance downtime.
Overseas Market Adaptation Tips
- Prioritize PNP output models (XG2-26T4-P/40T8-P) in European and American markets to match local equipment wiring habits directly.
- Promote 32-axis + multi-slave node models for semiconductor and electronics manufacturing scenarios to meet high-density I/O and multi-axis linkage requirements.
- Highlight wide voltage tolerance (18-30 VDC) and remote diagnosis capabilities for food and logistics applications in harsh environments, reducing maintenance costs.
Common Installation & Operation Issues
Q1: When connecting to servo drives in Europe/North America, the system prompts communication failure. What's the problem?
A: The most common issue is mismatched output signal types. Most local servo systems in Europe and America use PNP wiring standards, while domestic default models are NPN output. Solution: Replace with PNP-optimized models (XG2-26T4-P/40T8-P) that fit overseas standards; no need to rewire on-site, which saves modification costs.
Q2: After installing in North America, the controller frequently restarts or reports power errors. How to fix it?
A: This is mostly due to inconsistent power grid standards. Solution: Use a high-quality step-down transformer (440V to 220V) with a 24VDC switching power supply that supports 50/60Hz frequency auto-switching.
Q3: When configuring the EtherCAT network in the EU, why does it show "for demo use only" and fail to enter formal operation?
A: This is not a hardware issue but a software configuration problem. Solution: Confirm the network card is EtherCAT-compatible and enable virtualization technology (VT-d) in the BIOS. In TwinCAT, right-click the incompatible network card and select "Install Device as EtherCAT Master" to complete the configuration.
Q4: In Southeast Asian SMT factories, the positioning accuracy of the pick-and-place machine decreases when using XG2. What's the reason?
A: High ambient humidity and voltage fluctuations in Southeast Asian workshops are the main culprits. Solution: Install a waterproof shield for the controller in humid environments and equip it with a voltage stabilizer to ensure the input voltage stays within 18-30VDC.
Q5: When expanding I/O points in German CNC machine tool factories, the new slave modules cannot be recognized. How to troubleshoot?
A: It may be related to the EtherCAT topology and cable length. Solution: Ensure the total length of the EtherCAT line does not exceed 100m per segment; use standard shielded twisted-pair cables. For third-party modules, import their XML description files into the configuration software first.
Q6: In North American food packaging lines, the electronic cam function is unstable, leading to uneven film tension. What should I do?
A: This is usually caused by mismatched motion control modes and on-site speed requirements. Solution: Use the XG2's free mode switching function; configure CSV mode for constant speed conveying and CSP mode for precise positioning during labeling.
Q7: When conducting CE certification in the EU, the controller fails the EMC test due to electromagnetic interference. How to address this?
A: Solution: Use shielded cables for all EtherCAT and power lines, and ensure the shielding layer is grounded at both ends. Keep the controller away from high-power equipment by at least 30cm. Configure the XG2's built-in anti-interference parameters to enhance signal filtering.
Q8: In remote maintenance for Southeast Asian customers, I cannot access the XG2 controller via the network. What's the issue?
A: Most Southeast Asian factories use private IP segments and restrict external network access. Solution: Use the controller's built-in Modbus TCP function to connect to the local router, and configure port mapping on the router to open the maintenance port.
Product Certifications & Quality Assurance
Global Market Certifications
- CE Certification: Complies with the EU Low Voltage Directive and Electromagnetic Compatibility Directive, enabling direct sales in the EU and European Free Trade Area.
- FCC Certification: Meets the US Federal Communications Commission Part 15 Class A standards, complying with electromagnetic compatibility requirements in North America.
- RoHS Certification: Strictly adheres to the EU RoHS 2.0 Directive, meeting global green procurement standards and catering to eco-friendly production needs.
- UL Certification: Core electrical components are UL-certified by Underwriters Laboratories, satisfying electrical safety specifications in the North American market.
- KC Certification (Optional): Customized models for the South Korean market are available, meeting the access requirements for industrial automation equipment in South Korea.
Full-Process Quality Assurance System
- Stringent Production Testing Standards: Each controller undergoes 72-hour high-temperature aging tests, 1,000-hour continuous fault-free multi-axis linkage testing, and 5,000-cycle terminal block insertion tests.
- International Standard Supply Chain Control: Core components sourced from international brands with incoming material inspection following ISO 9001:2015 standard.
- Localized Quality Commitments: Global unified warranty policy: 2-year free warranty + lifetime technical support.
