AC-Servo Controller SC-610

AC-Servo Controller SC-610
Operations Manual
AC-Servo Controller
SC-610
No. 900105 11/2005
24.11.2005-FA
HARMONIC DRIVE AG has tried to ensure that the information given in this manual is
correct at time of going to print.
However Harmonic Drive AG may not be held responsible for any typographical
mistakes or errors in contents of this manual. The information is subject to change
without prior notice. Harmonic Drive AG would appreciate notice of any mistakes in
the text.
HARMONIC DRIVE AG owns the copyright to this document, which is supplied to
customers on the understanding that it will not be reproduced or disclosed in whole or
in part, without the express permission of Harmonic Drive AG.
Harmonic Drive AG
Hoenbergstraße 14
D-65555 Limburg/ Lahn
Germany
Tel.: +49-6431/ 5008-0
Fax.: +49-6431/ 5008-18
Internet www.harmonicdrive.de
©2005
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page 1
Contents
General Information and
Safety Guide Lines
2
1.0
Specification ...................................
1.1
Usage Definitions .........................
1.2
Identification .................................
1.3
Features .......................................
1.4
Declaration of Conformity .............
1.5
EMC Conformity and CE Marking .
1.6
Technical Data .............................
1.6.1
Power Section ..............................
1.6.2
24VDC Input .................................
1.6.3
Velocity Controller ........................
1.6.4. Encoder Inputs .............................
1.6.4.1 Master-Encoder Input (X9).............
1.6.4.2 Hiperface (X8) ...............................
1.6.4.3 EnDat (X8) ....................................
1.6.4.4 TTL-Encoder (X8) ........................
1.6.5
Encoder Output (X7) .....................
1.6.6
Pulse/Direction Input ....................
1.6.7
Serial Interface .............................
1.6.8
Mechanical Section ......................
1.6.9
Environmental Section .................
1.6.10 Power Supply Section ..................
1.6.10.1 Regeneration ................................
1.6.10.2 Rectifier Section ...........................
5
5
5
6
6
7
7
7
8
8
8
8
8
8
8
9
9
10
10
10
11
11
11
2.0
2.1
2.2
2.3
Installation Recommendations ....
Safety Notice ................................
Electrical Installation ....................
Mechanical Installation .................
12
12
12
13
3.0
3.1
Interconnection Diagrams ............
Interconnection Diagram
Hiperface/EnDat ..............................
Interconnection Diagram Resolver
Interconnect. Diagram TTL-Encoder
Connector Configuration
I/O-Expansion ...............................
14
3.2
3.3
3.4
4.0
Wiring ..............................................
4.1
Power Wiring ................................
4.1.1
Power Supply ...............................
4.1.2
Mains Filter ...................................
4.1.3
Motor Wiring .................................
4.1.4
24VDC Connection ......................
4.1.5
Regeneration Resistor Wiring ......
4.2
Control- and Signal Wiring ...........
4.2.1
Control Inputs ...............................
4.2.2
Control Outputs ............................
4.2.3
Resolver .......................................
4.2.4
Encoder Output ............................
4.2.5
Master Encoder Input ...................
4.2.6
Command Input ............................
4.2.7
Interface Cables ...........................
4.3
Minimum Wiring Diagram .............
Harmonic Drive AG
14
15
16
17
18
18
18
19
20
20
21
22
22
25
25
26
26
27
28
29
5.0
5.1
5.2
System Set Up Procedure ............
Presets .........................................
System Set Up Step by Step .......
35
35
36
6.0
6.1
6.2
Status Indicators ...........................
Status Monitor ..............................
LED Regeneration Load ..............
39
39
41
7.0
I/O Hardware Description .............
7.1
Input Signals ................................
7.2
Output Signals .............................
7.3
Resolver (X8) ...............................
7.4
Encoder Output (X7) ....................
7.5
Encoder (X8) Hiperface/ EnDat ....
7.6
Encoder (X8) TTL-Encoder...........
7.7
I/O-Expansion for 256 Pos. (X12)
7.7.1
Input Signals (X12) ......................
7.7.2
Output Signals (X12) ...................
41
41
43
44
45
45
46
47
47
48
APPENDIX
Appendix A
EMC Installation Instruction ......... A2
EMC Wiring Principle ................... A3
Appendix B
Dimensions .................................. A5
Appendix C
Troubleshooting ........................... A7
Appendix D
Multi-Drop-Applications ................ A10
Appendix E
Software Installation .................... A11
Appendix F
Definition of Motor Parameters .... A12
Appendix G
Wiring description for cables for FHA-C-series actuators with Hiperface ... A13
Appendix H
Wiring description for cables for
FFA-series actuators with resolver A14
Appendix I
Wiring description for cables for
FFA-series actuators with EnDatencoder ......................................... A15
Appendix J
Wiring description for cables for
FHA-Cmini-series actuators with TTLencoder ......................................... A16
Appendix K
Wiring description for cables for
CHA-series actuators with Hiperface A17
900105
11/2005
Page 2
Operations Manual SC-610
General Information and Safety Guidelines
Microsoft and MS-DOS are registered trademarks, and Windows is a trademark of Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.
CE Compliance
A custom unit may be required, contact Harmonic Drive. Compliance to Directive 89/336/EEC is the
responsibility of the system integrator. Servo controller, motor and all system components must have proper
shielding, grounding and filtering.
Product Notice Intended use:
These drives are intended for use in stationary ground based applications in industrial power installations
according to the standards EN60204 and VDE0160. They are designed for machine applications that require
variable speed controlled three phase brushless AC motors.
These drives are not intended for use in applications such as:
Home appliances
Medical instrumentation
Mobile vehicles
Ships
Airplanes
Unless otherwise specified, this drive is intended for installation in a suitable enclosure. The enclosure must
protect the control from exposure to excessive or corrosive moisture, dust and dirt or abnormal ambient
temperatures. The exact operating specifications are found in Section 1 of this manual.
The installation, connection and control of drives is a skilled operation, disassembly or repair must not be
attempted.
In the event that a control fails to operate correctly, contact the place of purchase for return instructions.
Safety Notice:
This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only qualified
personnel should attempt the start-up procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are driven by this
equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the startup procedure or troubleshoot this equipment.
System documentation must be available at all times.
Keep non–qualified personnel at a safe distance from this equipment.
Only qualified personnel familiar with the safe installation, operation and maintenance of this device
should attempt start–up or operating procedures.
Always remove power before making or removing any connections to this control.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
PRECAUTIONS:
Page 3
Classifications of cautionary statements.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury
or death.
Caution:
Indicates a potentially hazardous situation which, if not avoided, could result in
damage to property.
WARNING: Do not touch any circuit board, power device or electrical connection before you first
ensure that power has been disconnected and there is no high voltage present from this equipment
or other equipment to which it is connected. Electrical shock can cause serious or fatal injury.
WARNING: Be sure that you are completely familiar with the safe operation of this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are
controlled by this equipment. Improper use can cause serious or fatal injury.
WARNING: Be sure all wiring complies with the National Electrical Code and all regional and local
codes or CE Compliance. Improper wiring may cause a hazardous condition.
WARNING: Be sure the system is properly grounded before applying power. Do not apply AC
power before you ensure that grounds are connected. Electrical shock can cause serious or fatal
injury.
WARNING: Do not remove cover for at least five (5) minutes after AC power is disconnected to
allow capacitors to discharge. Electrical shock can cause serious or fatal injury.
WARNING: Improper operation of control may cause violent motion of the motor shaft and driven
equipment. Be certain that unexpected motor shaft movement will not cause injury to personnel or
damage to equipment. Peak torque of several times the rated motor torque can occur during control
failure.
WARNING: Motor circuit may have high voltage present whenever AC power is applied, even
when motor is not rotating. Electrical shock can cause serious or fatal injury.
WARNING: If a motor is driven mechanically, it may generate hazardous voltages that are
conducted to its power input terminals. The enclosure must be grounded to prevent a possible
shock hazard.
WARNING: When operating a motor with no load coupled to its shaft, remove the shaft key to
prevent injury if it were to fly out when the shaft rotates.
WARNING: The motor shaft will rotate during the autotune procedure. Be certain that unexpected
motor shaft movement will not cause injury to personnel or damage to equipment.
WARNING: A DB Resistor may generate enough heat to ignite combustible materials. To avoid
fire hazard, keep all combustible materials and flammable vapors away from brake resistors.
WARNING: The user must provide an external hard–wired emergency stop circuit to disable the
control in the event of an emergency.
Caution:
Suitable for use on a circuit capable of delivering not more than the RMS symmetrical
short circuit amperes listed here at rated voltage.
Horsepower RMS Symmetrical Amperes
1-50
5,000
Caution:
To prevent equipment damage, be certain that the input power has correctly sized
protective devices installed as well as a power disconnect.
Harmonic Drive AG
900105
11/2005
Page 4
Operations Manual SC-610
Caution:
Avoid locating control immediately above or beside heat generating equipment, or
directly below water or steam pipes.
Caution:
Avoid locating control in the vicinity of corrosive substances or vapors, metal
particles and dust.
Caution:
For UL installations, do not connect any resolver cable shields to the motor frame. At
a minimum, resolver signal integrity will be compromised and damage to the control may result.
For CE installations, refer to CE guidelines stated in Sections 3 and A1 of this manual.
Caution:
Do not connect AC power to the control terminals U, V and W. Connecting AC power
to these terminals may result in damage to the control.
Caution:
Harmonic Drive recommends not using „Grounded Leg Delta“ transformer power
leads that may create ground loops and degrade system performance. Instead, we recommend using
a four wire Wye.
Caution:
Logic signals are interruptible signals; these signals are removed when power is
removed from the drive.
Caution:
Controls are intended to be connected to a permanent main power source, not a
portable power source. Suitable fusing and circuit protection devices are required.
Caution:
The safe integration of the drive into a machine system is the responsibility of the
machine designer. Be sure to comply with the local safety requirements at the place where the
machine is to be used. In Europe this is the Machinery Directive, the ElectroMagnetic Compatibility
Directive and the Low Voltage Directive. In the United States this is the National Electrical code and
local codes.
Caution:
Controls must be installed inside an electrical cabinet that provides environmental
control and protection. Installation information for the drive is provided in this manual. Motors and
controlling devices that connect to the drive should have specifications compatible to the drive.
Caution:
Violent jamming (stopping) of the motor shaft during operation may damage the
motor and control.
Caution:
connections.
Do not tin (solder) exposed wires. Solder contracts over time and may cause loose
Caution:
Electrical components can be damaged by static electricity. Use ESD (electro–static
discharge) procedures when handling this control.
Caution:
Ensure that resolver or encoder wires are properly connected. Incorrect installation
may result in improper rotation or incorrect commutation.
Caution:
The holes in the top and bottom of the enclosure are for cable clamps. Be sure to use
an M4 bolt 12mm in length. Longer bolts may short circuit the electrical components inside the
control.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page 5
1.0
Specification
1.1
Usage Definitions
The drives of the SC-610 series are electrical equipment for industrial power installations. They are designed
for machine applications, which need variable speed controlled three-phase A.C. motors.
This product is only for use in industrial applications as described in norms EN60204 and VDE0160. This
means use drive in stationary ground based applications only. It is not meant for use in home appliances,
medical equipment, cars, ships or airplanes.
Before the drive is put into operation, please contact your Electric-Supply-Company for special operating
conditions.
1.2
Identification
SC
610
5
A
A
A
H
Product
Series
Nominal
Current
Power
Supply
Not used
this time
Demand/
Input
Motor Feedback
(Op. Modes)
Servo
Controller
Current
Control,
Velocity
Control,
Pulse
Follower,
Handwheel,
Position
Control
Harmonic Drive AG
A: 230VAC
B: 115VAC
2: 2.5 Amp.
C: 230VAC
5: 5 Amp.
plus 24VDC
7: 7.5 Amp.
D: 115VAC
plus 24VDC
900105
A: ±10V,
4 bin.
Inputs
B: ±10V,
8 bin.
Inputs
R: Resolver
H: Hiperface
D: EnDat
E: TTL-Encoder
A/B: Pulse
Follower,
Handwheel
11/2005
Page 6
1.3
Operations Manual SC-610
Features
The SC610 series are 1 axis drives with integrated power supply.
They provide the following features:
POWER SECTION:
• Input-voltage: 1- (direct) or 1-phase with transformer (250VAC max)
• 3 output current versions (2.5A/5A/7.5A) available.
• Ratio peak : nominal current = 2:1.
Both values independently adjustable.
• All drives are short circuit proof (phase/
phase and phase/PE) and require no minimum
load.
CONTROL I/O Section:
• 9 opto-isolated control inputs for dedicated drive
functions
• Optional point-to-point positioning for up
to 16/256 predefined positions
• Resolver / Hiperface input
• Master Encoder input
• Serial interface (RS232C / RS485) for
communication
and programming
• Diagnostic display on front panel
• Amplifier configuration adjustable via software
• Software amplifier tuning capability with graphic
program.
• Wiring of control inputs and outputs via plug type
screw connection (max. wiring diameter 1,5mm²)
or SUB-D connector
GENERAL:
• Protection class IP20 (acc. To DIN40 050 / IEC144)
• Cooling: self-ventilation (internal ventilator)
• UL approved (UL-File-No.: E128059)
1.4
• Output power up to 3kVA
• Internal power supply consisting of rectification,
smoothing, regeneration circuit and surge current
protection
• Brushless-servomotors (2 to 12 poles) can be
connected. (Feedback: 1-pole pair resolver or
Hiperface)
• Power wiring via terminal screws (max. wiring diameter 2.5mm²)
• Resolver feedback
• Hiperface feedback
• Isolation classification according to DIN 0110 with
overvoltage category III
Declaration of Conformity
Herewith we declare, that our products are components only and not ready for immediate or instant use
within the meaning of "Safety law of appliance", "EMC Law" or "Machine directive".
The final mode of operation is defined only by the insertion into the user’s construction.
It is the responsibility of the user to verify that his construction is in accordance with existing regulations.
It is prohibited by law to put the machine into operation before verifying that the machine is in accordance
with EC directive 89/392 and 921/368.
The supplier declares product conformity with the following standards:
DIN VDE 0160 / 05.88
Electronic equipment for use in electrical power installations
DIN VDE 0100
Erection of power installations with nominal voltages up to 1000V
DIN IEC 326 Part 1 / 10.90
Design and use of printed boards
DIN VDE 0110 Part 1-2 / 01.89 Dimensioning of clearance and creepage distances
DIN VDE 0110 Part 20 / 08.90
EN 60529 / 10.91
Harmonic Drive AG
Degrees of protection provided by enclosures
900105
11/2005
Operations Manual SC-610
1.5
Page 7
EMC - Conformity and CE - Marking
The application of EMC conformal component and part systems relieves the observance of EMC Guidelines
and the guarantee of conformity for the manufacturer of machines. Therefore all standard components and
part systems will be tested according to the requirements of EMC regulation.
Those tests will be executed by a competent and independent institution. The conformity of the products will
be confirmed by a declaration of conformity from the European Community.
The installation instructions refer to elimination of radio interference as well as to immunity from noise for
Harmonic Drive Systems.
Thereby the user is informed about the EMC critical parts. The examples don’t show the complete
possibilities of cabinet components or constructions.
Guidelines for CE Conformity
•
Machine Guideline (89/392/EWG)
- Machine Safety Law
•
EMV Guideline (89/336/EWG)
- EMC Law
•
Low Voltage Guideline (73/23/EWG)
- Machine Safety Law
1.6
Technical Data
All values at Tamb = 40 °C, if not otherwise specified. NOTE: Operation at maximum ratings
1.6.1 Power Section
General
Unit
SC-610-2
SC-610-5
SC-610-7
Nominal DC-Bus-Voltage
VDC
160 / 320
160 / 320
160 / 320
Output Voltage Line/Line
fundamental wave;
VRMS
0 ... 230
@VDC-Bus= 320V
Nominal Phase Current (±10%)
ARMS
Peak Phase Current (±10%)
ARMS
Nominal Output Power
kVA
1)
2,5
5,0
7,5
5
10
15
2,4s (+0,5/-0)s
1)
1,01
2,4s (+0,5/-0)s
2,17
Efficiency
%
> 95
Output Frequency
Hz
0 ... 1000
Nominal Switching Frequency
kHz
valid for zero current initial condition
1)
1,25s (+0,5/-0)s
2,99
8,0
1)
1.6.2 24VDC Input (optional)
24V-Input (optional)
Unit
SC-610-X
VDC
20.4 ... 28.8
ARMS
1.75
Input Voltage Range
absolute min./max.1)
max. Vripple = ±10%
Input Current; @ 24VDC
Surge Current at Power On
ARMS
@ 24VDC; @ 100ms
1)
NOTE: Operation at maximum ratings may impair the useful life time
Harmonic Drive AG
900105
4,0
11/2005
Page 8
Operations Manual SC-610
1.6.3 Velocity Controller
Velocity Controller
Unit
SC-610-X
Command Input
VDC
0 ... ±10
Command Signal Resolution
bit
14 bit
Cycle time
µs
250
Unit
SC-610-X
-
Resolver
-
Resolution: 14bit ±4,9mV
Pole Pairs
-
1
Resolver – Winding-Ratio
-
0.5
Unit
SC-610-X
Signal
-
RS422
Operating Mode
-
A, A/ ; B, B/ and C, C/ (quadrature)
MHz
2.5 (quadrature) / 1.25 Pulse and Direction
Unit
SC-610-X
Signal
-
Sinosoidal / Parameter channel RS485
Operating Mode
-
1024 Sin/Cos periods per motor revolution and absolute
Velocity Feedback
Feedback System
Feedback-Resolution
set automatically by software
1.6.4 Encoder-Inputs
1.6.4.1 Master Encoder-Input (X9)
Encoder Input
Max. Input Frequency
1.6.4.2 Hiperface (X8)
Hiperface Input
multiturn position / quadrature counting
Power Supply
8V / 800mA max.
1.6.4.3 EnDat (X8)
Unit
SC-610-X
Signal
-
Sinosoidal / Parameter channel RS485/ Clock
Operating Mode
-
2048 Sin/Cos periods per motor revolution and absolute
Hiperface Input
multiturn position / quadrature counting
Power Supply
5V / 800mA max.
1.6.4.4 TTL-Encoder (X8)
Unit
SC-610-X
Signal
-
Rectangular (A, A/, B, B/, C, C/, U, U/, V, V/, W, W/
Operating Mode
-
2000 pules per motor revolution / quadrature counting
TTL-Encoder Input
Power Supply
Harmonic Drive AG
5V / 250mA max.
900105
11/2005
Operations Manual SC-610
Page 9
1.6.5 Encoder-Output (X7)
Encoder-Output
Signal
Max. frequency
Supply voltage
Output voltage
Output current
Signal form
Pulse lengths
Encoder-Resolution at Hiperface and
EnDat-feedback
Encoder-Resolution at resolver feedback
1)
factory default
Unit
KHz
VDC
VDC
mA
SC-610-X
RS422
100
5 ±5 %
VOH = 2.5 min. / VOL = 0.5 max.
max. 20
Rectangular, pos. logic
P1 = 0.5 P0; PC = 0.25 P0
same as the number of sine/cosine cycles per
revolution
512 / 1024 / 2048 / 40961)
ppr
ppr
The above given signal sequence depends on the connected servo actuator and its feedback system and is
specified as follows:
Actuator type
Direction of rotation at motor shaft
Direction of rotation at gear outputt
FHA-C-HIPERFACE
Counter clockwise
Clockwise
FFA-Resolver/ EnDat
Clockwise
Counter clockwise
FPA-Resolver/ EnDat
Clockwise
Clockwise
FHA-Cmini/ TTL-Encoder
Clockwise
Counter clockwise
1.6.6 Pulse / Direction-Input (X3)
Pulse / Direction Input
Unit
SC-610-X
Signal
VDC
12-29 / opto-isolated
-
Pulse and Direction
MHz
1
ms
1
Operating Mode
Max. Input Frequency
Cycle time
Harmonic Drive AG
900105
11/2005
Page 10
Operations Manual SC-610
1.6.7 Serial Interface
STANDARD
RS232 - Interface
Communication (4 wire)
Transmission Rate
Unit
SC-610-X
-
RS232C (not galvanically isolated, with RTS / CTS)
Baud
up to 57600 max (Software selectable)
Unit
SC-610-X
-
RS485 (not galvanically isolated)
Baud
9600, 19200
Adjustable by DIP-switch AS1.10
RS485 – Interface
Communication
Transmission Rate
1.6.8 Mechanical Section
Mechanical
Mounting
Dimensions of Basic Units
Dimensions for Units with
I/O- Expansion for 256 Positions
Weights for Basic Units
Weights for Units with I/OExpansion for 256 Positions
Unit
SC-610-2
SC-610-5
-
SC-610-7
Panel
mm
67,5 x 173 x 152,5
92,5 x 173 x 152,5
109 x 173 x 152, 5
mm
84 x 173 x 152,5
109 x 173 x 152,5
109 x 173 x 152,5
kg
1,24
2,13
2,19
kg
1,55
2,45
2,45
1.6.9 Environmental Section
Unit
SC-610-X
Operating Temperature Range
°C
+5 ... +40 (Derating 2,5% / K bei 40°C < T ≤ 50°C )
Storage Temperature Range
°C
-25 ... +70
Humidity
%
10 ... 90 non-condensing; IEC 68-2-38
Class of Protection (Enclosure)
-
IP20
Max. Installation Altitude / M.S.L.
m
1000
Derating: 1,1% / 100m
Shock
-
10G; according to DIN IEC 68-2-6/29
Vibration
-
1G; 10 ... 150 Hz; according to DIN IEC 68-2-6/29
Environmental
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page 11
1.6.10 Power Supply Section
1.6.10.1 Regeneration
Regeneration Control Internal
Unit
SC-610-X
VDC
383 ... 373 (at 230 VAC)
Regeneration Resistor External
Switching Threshold; On / Off
195... 188 (at 115 VAC)
Nominal / Peak Power
Max. Regeneration Switching Current
Max. Load Inductance
kW
0,25 / 2,7
A
7/10
µH
100
1.6.10.2 Rectifier Section
Power Supply Internal
Input Voltage (+15% / -20%)
Unit
VAC
f = 50 bis 60Hz
DC-Bus-Voltage
1)
SC-610-X
230 / 115
230 / 115
265 / 130
90 / 90
Vin:
Nominal:
Maximal:
Minimal:
125 ... 360 (at 230 VAC)
VDC
absolute min./max.
125 ... 175 (at 115 VAC)
DC-Bus-Voltage
VDC
absolute min./max. for 24V-Option
1)
NOTE: Operation at maximum ratings may impair the useful life time.
0 ... 350 VDC
Legend:
This is an INFORMATION sign.
By observing this information whilst installing
the drive future operating problems may be
avoided.
This sign means ATTENTION.
Information in an ATTENTION box must
always be observed otherwise dangerous
situations for equipment and personnel may
result.
Harmonic Drive AG
900105
11/2005
Page 12
Operations Manual SC-610
2.0 Installation and Safety Recommendations
The following chapter contains important information
regarding the mechanical and electrical installation
as well Safety Notes.
It is strongly recommended to read and observe this
chapter carefully.
2.1 Safety Notice
Qualified or trained personnel only should install the machine.
Electrical rotating equipment can result in property damage, serious
injury, or death, when improperly installed. Equipment should be
installed in accordance with the local and safety standards for
construction and guide for selection, installation and use of electrical
motors and generators.
Suitable for use on a circuit capable of delivering not more than
5000Arms symmetrical amperes, 250VAC maximum per drive rating.
Electrical and/or mechanical alterations are permitted only when
power is removed.
Drives with the 24V option (C, D) can have power to connector X1
without any indication. The monitor illuminates only if 24V is switched
on.
2.2 Electrical Installation
The wiring, fusing and grounding must be in accordance to the
national electrical code and any local codes.
Use of motor thermo switch:
It is recommended to survey the status of this protective device in the
position control.
Since the leads can carry high voltage-spikes, isolation by means of a
relay should be installed.
The thermal sensor mounted inside the motor of the FFA- and FHA-Cseries actuators is not used in conjunction with the controllers
described herein. The motor is protected by an additional motor-I²tfunction running at the controller, by means of monitoring the motor
effective current. As a result the thermal sensor is not used in this
case!
Connect the PE of all systems to a central point. The diameter of the
cable-lead must be (10mm²) min.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page 13
2.3 Mechanical Installation
For installation of your system use a cabinet with a protection class
that suits your environmental conditions.
As cooling air freely enters the unit, the environment must be free
from corrosive chemical substances, oil, vapor, steam, metal particles
and dust.
Make sure that cooling is provided.
Make sure that the top of the unit is covered during installation to
prevent particles from falling into the unit.
Mount all drives vertical (Connector X1 to the top).
Use the controller in stationary ground based applications only.
For the terminal block connections the following tightening torque
has to be observed:
0.5 to 0.6Nm
Furthermore only copper conductors should be used.
Sudden blocking of the rotating motor shaft can cause serious
damage to motor and drive. It is strongly recommended to install
elastic stoppers in the driven machine.
For safe drive operation a clearance distances around and between
the drives must be observed.
Harmonic Drive AG
900105
11/2005
Page 14
3.0
3.1
Operations Manual SC-610
Interconnection Diagrams
Interconnection Diagram Hiperface/ EnDat
X9
X1
2
Main
Power
Motor
Rx
2
2
24V
OL. Adjustment.
See Manual
Use Copper
Conductors only.
3
Dangerous to accidental
contact up to 5 minutes
after switching off the
main supply.
5 min
1
2
3
4
5
6
7
8
9
10
L
N
U
1
2
3
4
5
6
7
8
9
V
W
R1
R2
X
9
X6
1
2
3
4
5
6
7
8
9
X
6
Control Signals
&
Digital I/O´s
X
7
1
2
3
4
5
CHA
CHB
CHC
N.A.
DGND
6
7
8
9
CHA /
CHB /
CHC /
N.A.
X8
X
3
Hiperface/EnDat
X
8
20
N.A.
RXTXN.A.
DGND
N.A.
TX+
RX+
8V Keyp.
N.A.
RX
TX
N.A.
DGND
N.A.
RTS
CTS
8V Keyp.
X7
Encoder-Output
1
CMD +
CMD AGND
FAULT RELAY
FAULT RELAY
CIV
CREF
CGND
ENABLE
DIN 0, CW-Limit
DIN 1, CCW-Limit
DIN 2, HOLD
DIN 3, FRESET
DIN 4, PULSE
DIN 5, DIRECTION
DIN 6
DIN 7
DOUT 0
DOUT 1
DOUT 2, DrOK
CHA
CHB
CHC
N.A.
DGND
CHA /
CHB /
CHC /
+5V
RS232 / RS485
+24 V
0V
X3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Master Encoder
AS1
PE
NC
1 Data+ / Data+
2 Data- / Data3 +8V / n. a.
4 n. a. / +5V
5 DGN D / DG ND
6 Inside shield
7 CosRef / CosRef
8 n. a. / n. a.
9 n. a. / Clock10 n. a. / Clock+
11 DG ND / DG ND
12 SinRef / SinRef
13 Sin / S in
14 Cos / Cos
15 n. a. / n. a.
Content of delivery: mating connectors to X1, X3 and X8.
Overview of mating connectors:
X1: (10 pole, female)
X6: (9 pole, female, UNC)
X3: (20 pole, female)
X7: (9 pole, male, UNC)
X8: (15 pole, male, UNC)
X9: (9 pole, male, UNC)
Harmonic Drive AG
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11/2005
Operations Manual SC-610
3.2
Page 15
Interconnection Diagram Resolver
X9
X1
PE
NC
2
Main
Power
Motor
Rx
2
2
24V
OL. Adjustment.
See Manual
Use Copper
Conductors only.
3
Dangerous to accidental
contact up to 5 minutes
after switching off the
main supply.
5 min
Master Encoder
AS1
L
N
U
9
10
V
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CMD +
CMD AGND
FAULT RELAY
FAULT RELAY
CIV
CREF
CGND
ENABLE
DIN 0, CW-Limit
DIN 1, CCW-Limit
DIN 2, HOLD
DIN 3, FRESET
DIN 4, PULSE
DIN 5, DIRECTION
DIN 6
DIN 7
DOUT 0
DOUT 1
DOUT 2, DrOK
CHA
CHB
CHC
N.A.
DGND
CHA /
CHB /
CHC /
+5V
W
X
9
R1
R2
X6
RS232 / RS485
1
2
3
4
5
6
7
8
9
+24 V
0V
X
6
X3
Control Signals
&
Digital I/O´s
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
N.A.
RX
TX
N.A.
DGND
N.A.
RTS
CTS
8VKeyp.
N.A.
RXTXN.A.
DGND
N.A.
TX+
RX+
8V Keyp.
X7
Encoder-Output
1
X
7
1
2
3
4
5
CHA
CHB
CHC
N.A.
DGND
6
7
8
9
CHA /
CHB /
CHC /
N.A.
X
3
X8
Resolver
X
8
20
1
2
3
4
5
6
7
8
9
Ref +
Cos +
Sin +
N.A.
AG ND
Ref Cos Sin Screen
The Resolver wiring diagram is only valid for BSM motors, with FFA-motors you must change Sin+
and Sin-.
Content of delivery: mating connectors to X1, X3 and X8.
Overview of mating connectors:
X1: (10 pole, female)
X6: (9 pole, female, UNC)
X3: (20 pole, female)
X7: (9 pole, male, UNC)
X8: (9 pole, female, UNC)
X9: (9 pole, male, UNC)
Harmonic Drive AG
900105
11/2005
Page 16
3.3
Operations Manual SC-610
Interconnection Diagram TTL-Encoder
Control Signals
&
Digital I/O´s
Content of delivery: mating connectors to X1, X3 and X8.
Overview of mating connectors:
X1: (10 pole, female)
X6: (9 pole, female, UNC)
X3: (20 pole, female)
X7: (9 pole, male, UNC)
X8: (15 pole, male, UNC)
X9: (9 pole, male, UNC)
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
3.4
Page 17
Connector Configuration I/O-Expansion for 256 Positions
Caution
1
20
Harmonic Drive AG
900105
11/2005
Page 18
4.0
Operations Manual SC-610
Wiring
In chapter 4.3 you will find the typical (minimum) wiring of the system . The following pages show some
special applications and the typical wiring in more detail.
This chapter is valid for all units.
For the system set-up it is necessary to wire the
system step by step.
It is recommended to follow the system set-up
procedure, especially for users who are not very
familiar with these drivers.
4.1
Power Wiring
4.1.1 Power Supply
The controller can be supplied, like shown below, with 1- phase input voltage. The power supply module
consists of rectification, smoothing, regeneration circuit and surge current protection.
PE
PE
X1.1
L
X1.2
N
X1.3
1)
L1
4)
5)
L1
2)
2
2
N
N
2
3)
1) Autotransfomer
2) Isolating transformer
3) Single phase connection (see also chapter 1 for input voltage)
4) The size of the fuse must fit in order to project the power of the transformer.
Fault current breaker are not permitted for fusing the drive (same for point 5).
5) Each controller is internally fused and therefore self protected. The shown input fuse is only for cable or
lead protection. It is recommended to use a back-up fuse of 16A or 20A (max.); e.g. Neozed type gL slow
blow type). For a fuse size of 16A a lead diameter of up to 1.5mm² can be used and for a 20A fuse the
max. lead diameter has to be 2.5mm².
Harmonic Drive AG
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11/2005
Operations Manual SC-610
Page 19
To avoid an actuation of the controller back-up fuse, it is
recommended to wait about 1 min. between a main power
OFF/ON cycle.
For single phase connection the voltage ripple on the DC-bus is
25Vpp for 5A (peak current SC-610-2), 50Vpp for 10A (peak
current SC-610-5) and for 15 (peak current SC-610-7). This
can limit the max. Speed of the motor.
When the controller will be supplied directly from the main or
via autotransformer, it is NOT PERMITTED to connect the Vccto PE. This connection will damage the controller!
4.1.2 Mains Filter (strongly required)
Following results are desired through the application of mains filters:
The electronic system should be protected from high frequency interferences which could enter via the
mains cable (noise immunity) and vice versa the mains cable may not transmit interferences from the
electronic systems to the adjoining components (elimination of interference).
To choose the fitting mains filter types following points have to be considered:
1. The need of power of the connected controller. Thereby the capacity and the ability of peak phase current
has to be considered. The listed filter can be overloaded by 1.5 of the nominal current during 1 min./h.
2. The required or present mains impedance.
The table below shows the corresponding mains filter types:
Mains Filter for 1 Phase Input
Leakage
Current
Weight
[V]
Rated
Current
(at 40°C)
[A]
[mA]
[kg]
FN - 2070 - 06 - 06
250
6
0.4
0.45
270460
FN - 2070 - 10 - 06
250
10
0.4
0.73
270461
FN - 2070 - 12 - 06
250
12
0.4
0.73
270462
Type
Rated
Voltage
Harmonic
DriveID-No.
Main filter dimensions are shown in appendix B.
Harmonic Drive AG
900105
11/2005
Page 20
Operations Manual SC-610
4.1.3 Motor Wiring
The motor must be connected to the drive terminal block X1:
X1 - 4
X1 - 5
X1 - 6
U
V
W
Phase U
Phase V
Phase W
Depending on the motor there are different connections: RS/FHA-Serie is equipped with a cable exit (flying
leads; not suitable for trailing applications), BSM50, 63 and 80 and FFA-series have a power connector.
A wiring example is shown in chapter 4.3.
The sequence of the motor leads is not arbitrary.
Therefore the motor leads must be wired in the
right sequence to avoid uncontrolled motor
function.
Motor Cables
All cables have to be screened. The maximum cable length is 25m.
4.1.4 24VDC - Connection (optional)
A 24V stand-by option is available for all drives. With this option the control circuits are supplied by an
external voltage. The advantage of the option is that, if the main power is switched off control circuits are still
supplied and position information does not get lost.
Wiring 24VDC-option:
X1-9
X1-10
With the 24V option the DC-Bus voltage can be
variable from 0V to maximum Vcc.
NOTE: The velocity controller can be optimized only for
a certain DC-Bus voltage. Therefore the controller
behaviour will change or different DC-Bus voltages.
The current control will be not affected.
Attention:
Harmonic Drive AG
Please take care of correct connection of
24 VDC and GND!
Miswiring will lead to malfunction.
900105
11/2005
Operations Manual SC-610
Page 21
4.1.5 Regeneration Resistor Wiring
The regeneration resistor can be installed by the user (see chapter 4.3). If during normal operation fault "1"
occurs (overvoltage; see chapter 6), a regeneration resistor must be connected to the controller to overcome this problem. For regeneration resistor installation the recommendations below should be observed.
Selection table:
Regeneration Power
continuous
[W]
44
100
1): Duty cycle = 2% at T = 120s
Regenerationresistor value
[Ω]
Power
supply
[VAC]
56
39
230
230
RegenerationSwitching
current
[A]
7
10
Harmonic
DriveOrder-No.
700889
701121
The generation resistor is not automatically included in the
delivery.
The generation resistor must be mounted horizontal on a
vertical surface for full power rating.
For vertical mounting on a horizontal surface the nominal load
capacity is reduced to 65%.
Take care of good cooling of the regeneration resistor.
The ambient temperature of the resistor can be up to 200°C, in
a distance of 30mm.
Keep a safe distance between regeneration resistor and
flammable materials. The mounting surface can reach a
temperature of 80°C.
Wiring:
The resistor must be wired with a 2 lead (2,5 mm2) screened cable. The resistor housing must be grounded.
Harmonic Drive AG
900105
11/2005
Page 22
4.2
Operations Manual SC-610
Control- and Signal Wiring
This chapter is valid for all versions.
The wiring of the control in- and outputs can be achieved with one cable only unlike shown in the pictures
below. The outputs can be wired. But there is no need for drive operation.
4.2.1 Control Inputs
The control inputs below are opto-isolated. The ground return for all inputs is "CREF", connector X3.7.
Please note there are two different pin assignments for connector X3 available.
The drive can configured either in current, pulse follower, handwheel or velocity mode.
The drive is also equipped with a third control loop. Here it is a point-to-point positioning feature
implemented. Up to 16 different positions (optional 256) can be stored inside the drive. These positions
(including the homing routine) can be selected with the digital inputs and executed with the trigger input.
Positioning is possible with actuators providing Hiperface and resolver feedback. Actuators equipped with a
multiturn absolute Hiperface encoder (SCM-101) do not need a homing cycle since the absolute position is
determined after power on of the drive.
Control Input Function:
Example Configuration for Speed Control and Pulse Follower
Signal
Switch Position / Function
Connector
Pin
closed
open
ENABLE
X3.9
Drive enabled
Drive disabled
DIN 0,
Clockwise direction of rotation
X3.10
Clockwise direction of rotation enabled
disabled
CWLimit1)
DIN 1,
Counter clockwise direction of rotation Counterclockwise dir. of rotation
X3.11
enabled (or position selection)
disabled
CCWLimit1)
DIN 2,
X3.12
STOP Function is active
STOP function is not active
STOP
DIN 3
RESET function is active
X3.13
RESET function is not active
FRESET
Rising edge
DIN 4,
X3.14
Input pulse train (see below)
Pulse
DIN 5,
X3.15
Direction signal (see below)
Direction
DIN 6
X3.16
Digital input 1 = logical 1
Digital input 1 = logical 0
DIN 7
X3.17
Digital input 2 = logical 1
Digital input 2 = logical 0
1)
Please note that servo axes incorporating Harmonic Drive gears (i. e. FHA-, FFA- and RS-series) will be
effected by a change of the turning direction. The MOTORDIRECTION keyword can be used to change motor
direction.
Example Configuration for Position Control
Signal
Connector
Switch Position / Function
Pin
closed
open
ENABLE
X3.9
Drive enabled
Drive disabled
DIN 0
X3.10
Input no. 2 for position selection
DIN 1
X3.11
Input no. 3 for position selection
DIN 2,QUIT
X3.12
Quit running positioning process
Positioning process will be done
DIN 3,
X3.13
RESET function active
RESET function not active
FRESET
DIN 4,
X3.14
Home flag =
Home flag =
closing (or rising) edge
opening (or falling) edge
HOME FLAG
DIN 5,
X3.15
Trigger =
Trigger =
closing (or rising) edge
opening (or falling) edge
TRIGGER
DIN 6
X3.16
Input no. 0 for position selection
DIN 7
X3.17
Input no. 1 for position selection
Wiring proposal for control inputs see chapter 4.3. Hardware description of the inputs refer to chapter 7.
Harmonic Drive AG
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11/2005
Operations Manual SC-610
Page 23
More about control inputs:
"PULSE & DIR":
A drive has a pulse and a direction input. These inputs are like a stepper motor
interface. The incoming pulses (frequency) determine the velocity of the motor and
the direction input the sense (CW, if high level and CCW if low level) of motor shaft
rotation.
"STOP":
If the input is activated the motor will decelerate from the actual velocity to rest at the
rate defined by SPEEDREFDECELTIME (unless SPEEDREFSOURCE is set to 1 - see
the help file) and keep the reached position in controlled manner. The function is
independent of the actual operating mode (current- or velocity mode). This function
can both be activated by hardware input DIN 2 (X3.12), the DIP-switch AS1.5 or by
software.
"QUIT":
If the input is activated the current positioning process will be aborted. A restart
(trigger) is required in order to continue the positioning after the quit input has been
reset to zero
"DIN x":
There are up to 4 machine inputs available.
Inputs X3.16 (DIN 6) and X3.17 (DIN 7) can either be used together with the PLC
program (default) or for selection of the programmed point-to-point move. If more
than three programmed point-to-point moves are needed, the alternative functions of
the inputs X3.10 (DIN 0) and/or X3.11 (DIN 1) must be used.
Please note, that the limit switch function is not available in this case. To substitute
(or add-on) the function of the hardware limit switches, software limit switches can
be defined.
"FRESET":
If the input is activated, the drive will attempt to cancel all types of error and then reenable.
"HOMEINPUT":
(Position Control)
This input is for determination of the home position. It is an edge-controlled input
and the input function can be activated by a rising or falling signal edge.
"PRESETTRIGGERINPUT":
With this input a programmed point-to-point move will be started. If the input
(Position Control)
will be activated, the position move addressed with the MaI´s will be executed. It is
an (rising) edge controlled input.
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11/2005
Page 24
Operations Manual SC-610
Preset timing diagram:
Setup inputs
DIN0 ..
DIN3
Time
Trigger
Input
Trigger Pulse
(at least 2ms)
Time
Re-trigger Time (2ms minimum)
Profiler
Time
Profiler
Latency
Functional example of control inputs:
The wiring of the control inputs is also shown in chapter 4.3 .
The picture on the right hand side shows the function
and the two wiring principles of the control inputs:
The two wiring versions are:
1) Switching to the external control input power supply. The switch will be linked between the control
input (X3.x) and the external power supply (Vext).
The ground return (GNDext) is permanently wired
with CREF (X3.7).
2) Switch to the ground return of the external power
supply. The switch will be linked between the control input and the external ground return (GNDext).
The external power supply (Vext) is permanently
wired with CREF (X3.7).
SWITCH TO
GND ext
Vext
V
ext
Vext
Drive
GNDext
Drive
X3.x
X3.7
X3.7
X3.x
GND
ext
X3.x: "x" for connector pin,
e.g. x=9 → X3.9 = Enable-Input
Voltage range of Vext : +12 ... 29VDC
The control inputs only operate, if they are supplied with an
external voltage.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page 25
Control Input Wiring:
4.2.2 Control Outputs
The control outputs must be supplied with an external voltage. The wiring of the control outputs is optional
and not necessary for proper drive operation.
Control Output Function:
Signal name
Connector
Pin
X3.4
X3.5
X3.18
X3.19
X3.20
FAULT+
FAULT DOUT 0
DOUT 1
DOUT 2,
DrOK
Switch Position / Function
active / closed
not active / open
Controller happy - no fault
Controller not happy - drive
fault
Digital output 0 = logical 1
Digital output 0 = logical 0
Digital output 1 = logical 1
Digital output 1 = logical 0
Digital output 2 = active - no
Digital output 2 not active =
fault
drive fault
More about control outputs:
"FAULT":
This output is a relay contact and consists of two connector pins. It indicates the general
drive status.
The FAULT relay contact is not suitable for switching inductive
loads (relays). Inductive loads can cause some nuisance drive
faults.
"DrOK":
This output has the same functionality than the fault relay output. The output (+24V) is
activated in case the drive is ready for work.
"DOUT x":
These outputs can be used together with the drive internal PLC program. There are 2 digital
outputs available.
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900105
11/2005
Page 26
Operations Manual SC-610
Control Output Wiring:
The control outputs can be wired like shown below. Chapter 7 shows the hardware circuits of the outputs.
All outputs are active "HIGH" (source) and referred to CGND (X3.8).
4.2.3 Resolver (optional)
The resolver must be wired to drive connector X8 and on the motor side with signal connector.
Wiring of the resolver in- and outputs:
The wiring is shown in chapter 4.3.
Maximum cable length is 25m
SIGNAL
Connector - Pin
REF + / X8 - 1
REF - / X8 - 6
COS + / X8 - 2
COS - / X8 - 7
SIN + / X8 - 3
SIN - / X8 - 8
COLOUR CODE
StandardCable Exit
Resolver cable
BSM1R
red
red / white
blue
yellow / white
green
red
yellow
black
pink
yellow
grey
grey
All cables have to be screened.[3x(2x0,14mm2)]
4.2.4 Encoder Output
The controller has an encoder output (X7), which can be used for position- and/or velocity feedback for a
superset controller. The encoder output resolution (pulse per revolution; ppr) can be configured via software.
The following resolutions are available; using resolver feedback
512ppr
2048ppr2)
1024ppr
4096ppr2)
2)
only available if feedback is set to 4096 using the ENCODERLINESOUT keyword.
In case Hiperface-encoder feedback is used the output (X7) corresponds to the physical encoder resolution
multiplied by 4 (ex. 1024ppr x 4)
Wiring of the encoder output:
A wiring proposal is shown in chapter 4.3.
It is strongly recommended to make the wire connection with a twisted and screened cable.
Harmonic Drive AG
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11/2005
Operations Manual SC-610
Page 27
4.2.5 Master Encoder Input (X9)
Handwheel Mode
The controller can be configured as slave device from a handwheel encoder. The ratio between incoming
encoder signals and the motor speed is configurable via software.
Wiring of the encoder input:
The connector X9 must be wired according to the interconnection diagram (see chapter 3.1).
4.2.6 Command Input
The drive has an analog command input (±10V). The input can be wired in "single-ended" or in
"differential mode".
Wiring of the command input:
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900105
11/2005
Page 28
Operations Manual SC-610
4.2.7 Interface Cables
The bit-rate for communication is 57600 baud (factory preset). Other bit-rates are possible. To prevent
interference it is advised to keep cable length at 3m or less. Shielding interface cables is highly
recommended. It is also advised not to run the interface cable next to high power or AC signals such as
servo amplifiers, line voltages etc.
The wiring from PC to drive connector X6 for serial interface must be as shown below:
A) RS232
RS232 is the standard interface.
CAUTION:
The serial connector on the SC610 (X6) can be configured as either
RS232 or RS422 / RS485. Pin 9 is used to carry +8V for powering
certain keypad peripherals. Ensure that pin 9 is not connected to
ground or to equipment that could be damaged by the +8V supply
B) RS485
The RS485 is an optional interface only and must be adjusted via DIP switch AS1.10. For further information
concerning multi-drop applications please refer to appendix D.
3
7
8
2
5
6
7
8
9
TXTX+
RX+
RXDGND
TX+
TXRXRX+
DGND
1)
Drive
9 pol. SUB-D
FEMALE
Master
1) Wiring principle at the master may be different than shown above. Please refer to the interface
description of your master system.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
4.3
Page 29
Minimum Wiring Diagram
Incoming safety ground
Star Point
1)
2)
2)
4)
3)
MOTOR - HOUSING
5)
8)
Brake
n.a.
A
B
C
D
6)
7)
Thermoswitch
red
black
white
Drive
9)
R
POWER
WIRING
1)
2)
3)
4)
5)
6)
7)
8)
9)
Main Power (Autotransformer, Isolating transformer, 1 phase connection; see also chapter 4.1.1)
Fuses (see also chapter 4.1.1)
Main Filter (see also chapter 4.1.2 and appendix A)
Power cable not available from Harmonic Drive. Lead diameter must fit to the transformer and drive.
Flying leads FHA- RS-series
Connector BSM50/63/80
Not valid
Motor cable (see also chapter 4.1.3)
Sizing and further wiring recommendations see chapter 4.1.5.
Harmonic Drive AG
900105
11/2005
Page 30
Operations Manual SC-610
1)
1)
Please refer to appendix A in order to achieve the wiring according
to the EMC regulations
CW Limit and CCW Limit: Please note that servo axes incorporating Harmonic Drive gears (i. e. FHA-,
CHA-, FFA- and RS-C-series) will be effected by a change of the turning direction. In this case CW- and
CCW-limit have to be cross wired.
Harmonic Drive AG
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11/2005
Operations Manual SC-610
Page 31
1)
1)
Please refer to appendix A in order to achieve the
wiring according to the EMC regulations
CW Limit and CCW Limit: Please note that servo axes incorporating Harmonic Drive gears (i. e. FHA-,
CHA-, FFA-and RS-series) will be effected by a change of the turning direction. In this case CW- and CCWlimit have to be cross wired.
Harmonic Drive AG
900105
11/2005
Page 32
Operations Manual SC-610
1)
1)
Please refer to appendix A in order to achieve the
wiring according to the EMC regulations
CW Limit and CCW Limit: Please note that servo axes incorporating Harmonic Drive gears (i. e. FHA-,
CHA-, FFA-and RS-C-series) will be effected by a change of the turning direction. In this case CW- and
CCW-limit have to be cross wired.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page 33
1)
1)
Please refer to appendix A in order to achieve the wiring according
to the EMC regulations
CW Limit and CCW Limit: Please note that servo axes incorporating Harmonic Drive gears (i. e. FHA-,
CHA-, FFA- and RS-C-series) will be effected by a change of the turning direction. In this case CW- and
CCW-limit have to be cross wired.
Harmonic Drive AG
900105
11/2005
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Operations Manual SC-610
Resolver Feedback
(REF+; R1)
(REF-; R3)
(COS+; S1)
(COS-; S3)
(SIN+; S2)
(SIN-; S4)
(AGND)
red
blue
green
yellow
pink
grey
11)
10)
(CREF)
(Enable)
1)
(CW Limit)
(CCW Limit)1)
(CMD+)
(CMD-)
(AGND)
12 ... 29V
Any polarity
12)
13)
Housing
0 ... +/-10V / AGND
14)
(CHA)
(CHA/)
(CHB)
(CHB/)
(CHC)
(CHC/)
(DGND)
1)
1)
16)
CONTROL
WIRING
PC
RS232/422
Screen connection with screen-rails or with screen clamps
(see also appendix A)
10) If a very strong affect of EMI will be expected, it is recommended to connect the inside screens
to AGND.
11) Resolver cable; BSM1R has flying leads
12) Functional description of the control inputs see chapter 4.2.1. The control inputs must be supplied with
an external voltage source.
13) The Control cable is not available from Harmonic Drive. Drawing shows the wiring principle only. Can
be one or more cables.
NOTE: DGND and AGND are internally linked together. If the used controller does not have two
independent grounds, only one GND should be wired to the controller to avoid ground-loops.
14) If the wiring is done like shown in the drawing, the motor rotates clock wise (view at motor shaft) with
a positive voltage on X3.1 referenced to X3.2.
15) Encoder cable, twisted and screened
16) Interface cable refer to 4.2.7
ATTENTION: Please note also chapters 4.0. to 4.2. and Appendix A
1) Please note that servo axes incorporating Harmonic Drive gears (i. e. FHA-, CHA-, FFA- and RS-Cseries) will be effected by a change of the turning direction. In this case CW- and CCW-limit have to be
cross wired.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
5.0
5.1
Page 35
System Set Up Procedure
Presets
Before applying power to the system, the following settings must be checked.
DIP - Switches: Settings and Functions
The pictures show
A) Setting ex
factory
A) settings ex factory
(all DIP-switches
"OFF")
and
B) operating status
(DIP-switch AS1.8
"ON")
OFF
B) Operating
status
ON
OFF
1
2
3
4
5
6
7
8
9
10
of the DIP-switches.
ON
1
2
3
4
5
6
7
8
9
10
Note: For first time installation always make sure that all DIP-switches are in "OFF" position
(see picture A) until motor and drive parameters are downloaded.
Card Address Setting / DIP-Switch AS1.1-4 (Multi-Drop Application)
Each card’s address can be set-up by setting the DIP switch on the card as follows:
AS1.1
AS1.2
AS1.3
AS1.4
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
ON
ON
Card-Address
(Node number)
Will be determined by Mint Keyword “Node”
1
2
3
4
5
6
7
8
9
10 (hex a)
11 (hex b)
12 (hex c)
13 (hex d)
14 (hex e)
Attention:
Reset to “Factory Defaults”
Setting / Function DIP - Switch AS1.5 - 10
DIP-Switch
AS1.
5
6
7
Function
Hold - Position
Terminal resistor
for RS485
automatic
offset tuning
8
ENABLE
9
reserved
Communication
port selection
10
Switch Setting
ON
Hold - Position is
active
OFF *)
Hold – Position is
not active
Activate resistor
Deactivate resistor
automatic offset-tuning is
active
amplifier enabled
(active)
automatic offset-tuning is
not active
amplifier disabled
(not active)
RS485
RS232
*) ex factory
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Operations Manual SC-610
Further explanations to AS1.5, 7, 8:
AS1.5:
If switch is "ON" the motor will decelerate from the actual velocity to rest at the rate defined by
SPEEDREFDECELTIME and keep the reached position in controlled manner. The function is
independent of the actual operating mode (current, velocity or position mode). Hold-Position
function can also be activated by hardware input STOP (X3.12) or by the setup-software.
AS1.7:
If switch is "ON" an automatic offset tuning will be executed if DIP-switch AS8 is changed from
ON to OFF. The purpose of the offset compensation is to cancel offsets on the line. Therefore it
is important to set the analog command to zero.
It is recommended to leave this switch at "OFF" during normal operation.
AS1.8:
In switch position "OFF" the amplifier will be disabled. The function is the same as
hardware enable-input (X3.9) and software command “DRIVEENABLE”.
5.2
System Set Up Step by Step
With all initial settings completed (chapter 5.1), the set-up procedure can begin.
Please perform the initial set-up of the system with no load
applied to avoid damaging your equipment due to unexpected
movement.
1.
Connect your system only to the main power as shown in drawings chapter 4.
When using a transformer, check the secondary voltage of the transformer. Please refer to the
transformer specification.
Harmonic Drive AG
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Operations Manual SC-610
Page 37
After the measurements disconnect the transformer from the
power.
2.
Now you can wire the drive under observance of chapter 4. System must be idle.
It is not advised to connect the motor cable yet. On the other hand the measuring system
(Encoder/Resolver) must be connected to the drive.
Don’t close the ENABLE switch (X3.9).
An external 24VDC power supply must be connected to the
drive, if you have the 24V-option.
3.
Install the connection between PC and the controller with the interface cable. Make sure that the enable
input (X3.9) is not activated (switch opened or no wiring).
Now turn ON the main power. After power on, the LED will show the following state:
LED "DB ON" =
OFF
After power on procedure the monitor will show the final state:
Status
=
Status will show " - " only; decimal point lower right corner must be OFF.
(If status display is showing 8, the amplifier is
enabled. To disable the amplifier check enableinput (X3.9)).
Configure the controller with the help of the WorkBench v5 software and then turn OFF main power.
Please note at this time, that every drive is pre-configured ex factory and basically ready to operate. Please
refer also to motor-drive-assignment according to appendix F.
After turning off the power supply, wait about 5 min. to allow
discharging of the capacitors inside the main power supply.
4.
Now connect the motor cable. Turn ON main power again and activate the enable input (X3.9); close
the switch (see chapter 4). After that the monitor will show the following operating state:
Status
= "-"
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Operations Manual SC-610
Random power on sequence for 24V resp. bus supply.
If the motor develops no torque and
...monitor shows a
or
check the wiring of CW and
CCW-limits (X3-10; X3-11)
or
... monitor shows a “ - “ check ENABLE input (X3-9) and
DIP switch AS 1.8.
If the motor shaft accelerates, turn off the power immediately
and check the motor and measuring system.
If the decimal point on the monitor does not appear, check the
wiring of X3-9 (ENABLE) and DIP-Switch AS1.8.
5. Now you are ready to perform the system tuning. Please tune the drive only in case the performance
concerning accuracy and response is not satisfactory!
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
6.0
Status Indicators
6.1
Status Monitor
Page 39
The controller provides a status monitor. The indicated signs have the following meaning:
For further monitor indications, please refer to appendix C.
Drive
/
comms
watchdog.
Interprocessor
communications
failure.
This is potentially a severe problem if it occurs repeatedly. Communications failure could indicate
a process locking out the interprocessor communications. Clear the error; if the problem persists
then contact technical support.
Over volts.
The DC Bus voltage has exceeded the powerbase overvolts level (see
DRIVEBUSOVERVOLTS). Check the DC Bus level being fed into the system (see Mint keyword
DRIVEBUSVOLTS). This should be close to the nominal voltage (see Mint keyword
DRIVEBUSNOMINALVOLTS). Ensure that your input voltage is relevant to the voltage rating of
your drive. If the input voltage is correct, then this error may be the result of high deceleration
rates. If it is not possible to reduce the harshness of the deceleration rate, then a regeneration
resistor should be used. To help you, use WorkBench v5 capture facility to monitor the DC Bus
level during moves.
Integrated Power Module (IPM) trip.
The unit’s powerbase has been overloaded. This should not happen in normal use if limits have
been configured correctly. See the Mint keyword CURRENTLIMIT and related commands.
Current trip. Instantaneous over-current trip.
One or more of the 3 motor phases has exceeded 300% of Drive Rated Current.
Under volts. The DC Bus voltage has dropped below the powerbase undervolts level (see
DRIVEBUSUNDERVOLTS). This error will only be generated if the drive is in the enabled state. As
with the overvolts error, check the input voltage being fed into the system. The error could also
occur during high acceleration profiles.
Feedback trip. Can be enabled/disabled using FEEDBACKFAULTENABLE. Five consecutive
errors (or five errors in any 500 servo tick period) will cause the drive to trip.
This error indicates loss of encoder/resolver feedback and may indicate that the feedback cable
has become detached or one of the signals has broken. Check the wiring in the Feedback cable;
check for noise immunity; check the feedback device fitted to the motor (if possible).
Motor or Drive trip. The motor I2T or the drive I.T current protection algorithms have exceeded
their limit and tripped the drive (disabled it). Check DRIVEERROR or the Error Log to determine
which error has occurred. The motor and drive current limits are fixed according to the database
parameters. The drive can demand peak current for a short duration (see
DRIVEPEAKDURATION), thereafter it will trip or Foldback according to the setting of
DRIVEOVERLOADMODE. The same is true for the motor (see MOTORPEAKDURATION and
MOTOROVERLOADAREA). Use the Foldback option to automatically foldback the current to a level
where the drive/motor can recover.
(Symbol not flashing)
Motor I2T / It foldback. Motor I2T or Drive I.T algorithm has resulted in the demand current being
folded back to a level where the drive/motor can recover. The motor / drive can run with demand
currents greater than their rated value for a period of time; after that time the drive will either trip
or automatically foldback the demand current.
Overtemperature. The temperature of the drive or motor has exceeded a trip level (see Mint
keyword TEMPERATURELIMITFATAL ) or the Motor overtemperature trip input has been
activated (see Mint keyword MOTORTEMPERATUREINPUT).
Drive enabled. The drive is enabled (except where CONFIG = _cfVirtual, where it is not
physically enabled).
Torque mode. The drive is in Torque mode. See the Mint keywords TORQUE,
TORQUEREFSOURCE and related commands.
Auto tune test driving motor. Autotune is active and driving the motor. The motor may move.
General error. See AXISERROR and DRIVEERROR. The motion toolbar displays the status of
AXISERROR, which is a bit pattern of all latched errors. See also the Error Log topics in the help
file.
Error input. The ERRORINPUT has been activated and generated an error.
Harmonic Drive AG
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Operations Manual SC-610
Position or velocity following error. A following error has occurred. See the Mint keyword
AXISERROR and associated keywords. Following errors could be caused by a badly tuned
drive/motor. At higher acceleration and deceleration rates, the following error will typically be
greater. Ensure that the drive/motor is adequately tuned to cope with these acceleration rates.
The following error limit can be adjusted to suite your application (see Mint keywords
FOLERRORFATAL and VELFATAL). Following error could also be the cause of encoder/resolver
loss (see also Mint keyword FEEDBACKFAULTENABLE).
Follow mode. The drive is in Follow mode. See the Mint keyword FOLLOW.
Hold. The Hold DIP switch is active or the PLC Task has requested a Hold state. Motion will be
ramped to zero demand and will then hold on position while the switch is active.
Homing. The drive is currently homing. See the Mint keyword HOME.
Preset Homing. The drive is currently homing. This motion has been triggered from a Preset
move table.
Incremental move. An incremental move is being profiled. See the Mint keywords INCA and
INCR.
Jog. The drive is jogging. In the Mint help file, see the topics JOG, JOGCOMMAND and Jog screen.
Preset jog. The drive is jogging. The jog was triggered from a Preset jog table.
Overspeed. The measured speed of the motor has exceeded the trip level defined by
DRIVESPEEDFATAL. Check that the trip level is set to a suitable value for your application.
When accelerating to a demand speed close to the trip level, there will typically be a certain
amount of overshoot. Using the Fine-tuning tool, check the amount of overshoot you get with the
acceleration and demand speeds being used in your application.
Positional Move. The drive is performing a linear move. See the Mint keywords MOVEA and
MOVER.
Preset positions. The drive is performing a linear move. This motion has been triggered from a
Preset move table.
Stop. A STOP command has been issued or the stop input is active.
Drive disabled. The drive must be enabled before operation can continue.
Click the Drive enable button in WorkBench v5.
Crash (various). The drive enable input or the Enable DIP switch have become inactive whilst the
drive was in the enable state (or the drive was enabled whilst they were inactive) - bit 13 in
AXISEERROR will be set. The drive can be programmed to ignore this state using the Mint
keyword DRIVEENABLEINPUTMODE (see the Parameters tool).
Suspend. The SUSPEND command has been issued and is active. Motion will be ramped to zero
demand whilst active.
Speed demand. The drive is under speed control. See the Mint keywords SPEEDREF,
SPEEDREFSOURCE and related commands.
(Reserved)
Reverse software or hardware limit. A reverse software limit has been activated.
See AXISERROR and/or AXISSTATUS to determine which applies.
Forward software or hardware limit. A forward software limit has been activated.
See AXISERROR and/or AXISSTATUS to determine which applies.
Firmware being updated (horizontal bars appear sequentially).
downloaded to the drive.
New firmware is being
Initialization error. An initialization error has occurred at power on. See the Error Log or
INITERROR and INITWARNING topics in the help file. Initialization errors should not normally
occur. (possible reasons: Encoder feedback corrupt or 8V fuse of drive damaged X8.3/ X8.5)
Bar is illuminated permanently, dot right corner is flashing: Crash, i.e. interrupt during FirmwareDownload, no communication with the controller possible.
Counter measure: Open software WORK BENCH, start SCAN-procedure and stop it directly
afterwards. The screen shows „No Controller found“. The SELECT Button turn into UPDATE
FIRMWARE. Download the firmware again via this button.
For drives with 24V-option the status monitor works only if the
24V is switched on.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
6.2
Page 41
LED Regeneration Load
This LED located on the front panel indicates the activity of the regeneration. During regenerative actions
this LED will illuminate "YELLOW". This means, power will be dissipated into the regeneration resistor.
7.0
I/O Hardware Description
- Legend:
7.1
Input Signals
Digital Inputs Connector X3 (not valid for DIN4 and DIN5)
Function
Signal
PIN
Enable
DIN 0
ENABLE
9
CWLimit
10
Hardware
- Low Active:
(position select)
DIN 1
CCWLimit
11
(position select)
DIN 2
HOLD
(QUIT)
12
DIN 3
FRESET
13
DIN 6
Position Select
16
DIN 7
Position Select
17
Ground Return
CREF
7
- High Active:
min. Input Impedance RIN = 4.7kΩ;
opto coupled; UIN = 12 .. 29VDC; Delay time Td = 60µs
max. current at 24V: I = 5.2mA
Functions in ( ) are only valid for Position Control mode.
ATTENTION:
Drives with I/O-Expansion (Connector X12 assembled) require the position selection and
trigger input to be used on X12! Please refer to chapter 7.6
Harmonic Drive AG
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Operations Manual SC-610
Fast Inputs Connector X3 only valid for DIN4 and DIN5
Function
Signal
PIN
DIN 4
PULSE
Hardware
14
(HOME FLAG)
DIN 5
Ground Return
DIRECTION
(TRIGGER)
15
CREF
7
min. Input Impedance RIN = 4.7kΩ;
opto coupled; UIN = 12 .. 29VDC; Delay time Td = 60µs
max. current at 24V: I = 5.2mA
Advices for wiring DIN4 and DIN5:
- Shielded and twisted pair cables have to be used in order to avoid disturbance caused by electic
interference.
- Mechanical switches, relay contacts or other sources liable to signal ‘bounce’ should not connected
directly to these fast inputs. This could cause unwanted multiple triggering.
Analog Input Connector X3
Function
Signal
PIN
Hardware
Ucmd = ±10VDC
Velocity- or
CMD+
1
Current-
CMD-
2
Command
AGND
3
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
7.2
Page 43
Output Signals
Digital Outputs Connector X3
Function
Signal
PIN
FAULT REL.
4
FAULT REL.
5
Hardware
Fault
Relay
____________
__________
Contact is closed, if system works correct
UAC = 125V Imax = 0.5A
UDC = 30V Imax = 2A
_____ ______________________________________________
CIV
(+12..+30V)
CIV
DOUT 0
DOUT 1
DOUT 2,
Drive OK
General
Purpose
18
General
Purpose
19
DrOK
20
X3.6
V
=1.2V
max
REST
39V
I
X3.x
(x = 18,19,20)
Signal
CGND
X3.8
Customer
Interface
Voltage
CIV
Ground Return
CGND
Harmonic Drive AG
6
Active High
CGND
I = 50 mA max.
8
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Page 44
7.3
Operations Manual SC-610
Resolver X8
Resolver Signals Connector X8
Function
Signal
PIN
REF +
1
REF -
6
Hardware
Reference
Signal
Signal waveform sinusoidal; f = 7.2 .. 8.0kHz;
17.0Vpp ±5% + 0 .. 0.4 VDC; Ipeak = 0.2A; short circuit proof
Resolver Signals Connector X8
Function
Signal
PIN
COSINE
Input
Cos+
Cos-
2
7
SINE
Input
Sin+
Sin-
3
8
Hardware
Signal waveform sinusoidal;
UIN = 0 .. 10Vpp + 0 .. 0,4VDC; 7.2 .. 8.0kHz
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
7.4
Page 45
Encoder Output X7
Encoder Signals Connector X7
Function
Signal
PIN
Encoder
Channel_A
CHA
CHA /
1
6
Encoder
Channel_B
CHB
CHB /
2
7
Encoder
Channel_C
CHC
CHC /
3
8
7.5
Hardware
I/O-standard RS422
TTL-Signal;
Encoder X8 (HIPERFACE/ EnDat)
Encoder Signals Connector X8
Function
Signal
PIN
Parameter +
Parameter -
Data +
Data -
Hardware
1
2
+ 5V
1kR
Cosine
CosReference
Cos
CosRef -
14
7
Sinus
SinReference
Sin
SinRef
13
12
_____________
________
______
Power supply
Power supply
+8V
+5V
3
4
X8-1 Data+
X8-10 Clock+
X8-2 DataX8-9 Clock-
1kR
X8-7 CosRef-
Clock Clock +
Clock Clock +
9
10
IC 201/
IC 202
130R
100 pF
10kR
33k
X8-12 SinRefX8-8 Ref-
130R
+
Reference
Reference
RR+
8
15
_____________
_
Ground return
Ground return
Shield
________
_
DGND
DGND
Shield
______
5
11
6
Harmonic Drive AG
X8-14 Cos
10kR
1kR
X8-13 Sin
X8-15 Ref+
900105
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Page 46
Operations Manual SC-610
7.6 Encoder X8 (TTL-Encoder)
Encoder Signals Connector X8
Function
Signal
PIN
Encoder
Channel A
CHA
CHA/
1
6
Encoder
Channel B
CHB
CHB/
2
7
Encoder
Channel C
CHC
CHC/
3
8
______________ ________
_
Hall Input
U and U/
Hall Input
V and V/
Hall Input
W and W/
______________
Power Supply
Reference
Harmonic Drive AG
SYNC_U
SYNC_U /
SYNC_V
SYNC_V /
SYNC_W
SYNC_W /
________
_
+ 5V
DGND
Hardware
______ ____________________________________________________
4
5
10
15
9
14
______ _______________________________________________
I/O-Standard RS422
11
TTL-Signal; (f < 125kHz)
@ 350 mA
13
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11/2005
Operations Manual SC-610
7.7
Page 47
SC-610-I/O-Expansion for 256 pre-set positions X12
Signal name
ENABLE
MaI 3 (DIN 0)
MaI 4 (DIN 1)
QUIT (DIN 2)
FRESET
(DIN 3)
HOME FLAG
(DIN 4)
DIN 5
MaI 1 (DIN 6)
MaI 2 (DIN 7)
DIN 8
DIN 9
DIN 10
DIN 11
DIN 12
DIN 13
DIN 14
DIN 15
Trigger
(DIN 16)
DIN 17
Connector
Pin
X3.9
X3.10
X3.11
X3.12
X3.13
Switch position / Function
closed
open
Controller enabled
Controller disabled
Machine Input 3 = logical 1
Machine Input 3 = logical 0
Machine Input 4 = logical 1
Machine Input 4 = logical 0
Abort positioning cycle
No abort condition
RESET Function active
RESET Function not active
X3.14
Home flag = closing (or rising) edge
Home flag = open (or falling) edge
X3.15
X3.16
X3.17
X12.1
X12.14
X12.2
X12.15
X12.3
X12.16
X12.4
X12.17
X12.5
Digital Input 6 = logical 1
Machine Input 1 = logical 1
Machine Input 2 = logical 1
Digital Input 8 = logical 1
Digital Input 9 = logical 1
Digital Input 10 = logical 1
Digital Input 11 = logical 1
Digital Input 12 = logical 1
Digital Input 13 = logical 1
Digital Input 14 = logical 1
Digital Input 15 = logical 1
Trigger = closing (or rising) edge
Digital Input 6 = logical 0
Machine Input 1 = logical 0
Machine Input 2 = logical 0
Digital Input 8 = logical 0
Digital Input 9 = logical 0
Digital Input 10 = logical 0
Digital Input 11 = logical 0
Digital Input 12 = logical 0
Digital Input 13 = logical 0
Digital Input 14 = logical 0
Digital Input 15 = logical 0
Trigger = open (or falling) edge
X12.18
Digital Input 17 = logical 1
Digital Input 17 = logical 0
7.7.1 Input Signals X12
I/O - Expansion
Function
Signal
Signal
Connector X12
PIN
Hardware
- Low Active:
Input
DIN 8
1
Input
DIN 9
14
Input
DIN 10
2
Input
DIN 11
15
Input
DIN 12
3
Input
DIN 13
16
Input
DIN 14
4
Input
DIN 15
17
Common
COM
6
Trigger
DIN 16
5
Input
DIN 17
18
___________________________________________________
Harmonic Drive AG
- High Active:
min. input impedance RIN = 3.3 kΩ;
opto coupled; UIN = 12..29 VDC;
Delay time Td = 7.7 µ s (on); Td = 45
max. current at 24V: I = 7.5 mA
900105
µ s (off)
11/2005
Page 48
Operations Manual SC-610
7.7.2 Output Signals X12
Signal name
DOUT 3
DOUT 4
DOUT 5
DOUT 6
DOUT 7
USR +
USR GND
Connector
Pin
X12.12
X12.24
X12.11
X12.23
X12.10
X12.25
X12.13
Switch Position / Function
active / closed
not active / open
Digital Output 3 = logical 1
Digital Output 3 = logical 0
Digital Output 4 = logical 1
Digital Output 4 = logical 0
Digital Output 5 = logical 1
Digital Output 5 = logical 0
Digital Output 6 = logical 1
Digital Output 6 = logical 0
Digital Output 7 = logical 1
Digital Output 7 = logical 0
-
Digital Outputs Connector X12
Function
Signal
PIN
Output
DOUT 3
12
Output
DOUT 4
24
Hardware
USR +
(+12..+24V)
X12.25
Output
DOUT 5
11
D
I
S
Output
DOUT 6
23
Output
DOUT 7
10
VN330SP
output
driver
X12.X
(X = 10,11,12,23,24)
X12.13
Signal
USR GND
Active High
Customer
Interface
Voltage
Ground Return
Harmonic Drive AG
USR +
25
USR
GND
13
USR GND
900105
I = 250 mA max.
11/2005
Operations Manual SC-610
Page A1
APPENDIX
Harmonic Drive AG
900105
11/2005
Page A2
Operations Manual SC-610
APPENDIX A
EMC Installation Instructions
To ensure electromagnetic compatibility (EMC) at hostile environment inside the cabinet following
instructions are to be observed for construction. The implementation of following provisions enables the
reduction of interference down to required levels.
For the Drives technology following key points are to be considered:
- Grounding
- Screening
- Filtering
Furthermore the relevant chapters of the Installation manual for the controllers have to be observed.
For installation of the drives system the starting point is the installation into a cabinet.
For construction of a cabinet the following installation instructions have to be considered:
A) All metal conducting parts of a cabinet should be arealy conducted to the back plane.
Eventually the connections should be placed with an earthing strap at a central grounding
point .1)
B) There should be a spatial separation between power wiring (motor and power cable) and
control wiring. (Avoid interaction space)
C) The screen connection of the signal and power cables should be arealy conducted to the
screen rails or clamps. The screen rails or clamps should be well conducted to the cabinet.
D) The cable to the regeneration resistor has to be screened. The screen connection should be
on both sides.
E) The location of the mains filter has to be situated close to the drive.
F) Cables running inside the cabinet should be placed as close as possible to conducting metal,
cabinet walls and plates. It is advised to terminate unused wires to chassis ground. 1)
G) In case of bad potential balance between the screen connections a compensating lead with at
least 10mm² has to be provided additionly to reduce the screen current.
1) Grounding in general describes all metal parts which can be connected to a protective
conductor, e.g. housing of cabinet, motor housing, fundament grounder.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A3
EMC Wiring Principle (Example)
Y
Kondensator
FILTER
p
s
q
X10
Caution
U1
Caution
X10
U1
V1
V1
5min
V
W
U
V
W
V2
W2
VCC +
VCC +
VCC -
VCC -
VCC +
VCC -
X10
+24V
0V
+Ready
-Ready
+24V
0V
+BPS Ready
-BPS Ready
X10
X10
V2
L+(L+)
L - ( L -)
L - ( L -)
R x( L + )
R x( L + )
Rx( L- )
Rx( L- )
+24V
0V
+24V
0V
+BPS Ready
-BPS Ready
U2
W2
L+(L+)
+24V
Dan ger ous to ac cident al
con tact up to 5 minu tes
aft er switching o ff th e
ma in su pply.
U2
U
5 min
W1
Dan ger ous to ac cident al
con tact up to 5 minu tes
aft er switching o ff th e
ma in su pply.
W1
L1 L2 L3 B+/R1 R2
0V
Reg. load
Reg. load
Monitor
Monitor
Monitor
X4
X4
X4
Monitor
X4
R eady
Ready
Ready
X3
X3
X5 X2
X5
X2
R eady
X3
X3
X5
X5
X2
r
X2
X6
X6
X7
X7
X6
X6
X7
X7
Monitor
Ready
DB ON
X8
X4
X8
X8
X8
X1
X1
X1
X1
X9
X9
X9
X9
X3
o
CONTROLLER
PE L1 L2 L3 N
16 15 14 13 12 11 10
9
8
7
6
5
4
3
2
1
n
ATTENTION
The drawing shows only the principle
of an EMC wiring.
The shown installation can be different
to any national standard (e.g. VDE).
Harmonic Drive AG
900105
11/2005
Page A4
n
Operations Manual SC-610
CABINET
The drawing shows a cabinet with an electroplated zinc coated back plane, which is arealy
conducted to earth. This design will bring the following advantages:
- All parts mounted on the back plane are arealy conducted to earth.
- All screen connections will have a very low impedance to the earth.
General component placement within the cabinet:
There should be a spatial separation between power wiring (motor and power cable)
and control wiring.
o
SCREEN CONNECTIONS
All connections between the components should be wired with screened cables.
The cable screens should be connected to screen clamps on both sides.
With this wiring a very good screening effect can be achieved, because the clamps are arealy
conducted to the cabinet back plane.
p
EMC - FILTER
The EMI or main filter should be mounted next to the power supply.
For the connection to and from the main filter screened cables should be used. The cable
screens should be connected to screen clamps on both sides.
q
WIRING OF SCREENED CABLES
r
EARTHING
For safety reasons (VDE0160), all components must be connected to earth with a separate
cablelead.
The diameter of the cablelead must be at minimum 10mm².
An earth connetion from the power side must be linked to the housing of the main filter.
Between the main filter and the power supply, no earth connection has to be wired.
s
Y-CAPACITOR
The connection of the regeneration resistor can cause radio emission to be very high. For
minimisation of these emissions it is recommended that a Y-capacitor is connected as shown.
The capacitor should only be connected between the resistor housing and terminal pin R1.
Recommendation:
Harmonic Drive AG
0,1µF / 250VAC
900105
Type: PME265
Supplier: RIFA
11/2005
Operations Manual SC-610
Page A5
APPENDIX B
DIMENSIONS
Harmonic Drive AG
900105
(Values in ( ) refer to the controllers with additional binary inputs.
2,5A-Unit
5A-Unit
7,5A-Unit
A) Drive, Standard-Series without I/O Expansion
11/2005
Page A6
Operations Manual SC-610
B) Main - Filter
Single - phase filter
Dimensions for the following main filters:
FN – 2070 – 06 - 06
FN – 2070 – 10 - 06
FN – 2070 - 12 – 06
not scaled (dimensions in mm)
Dimensions in mm
FN – 2070 - 6 - 06
FN – 2070 - 10 – 06
FN – 2070 - 12 – 06
A
113.5
156
B
57.5
C
46.6
D
94
130.5
E
103
143
F
25
G
12.4
H
32.4
J
4.4
5.3
K
6
L
15.5
C) Regeneration Resistor
not scaled (dimensions in mm)
L = 123 for HA-R56
L = 228 for HA-R39
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A7
APPENDIX C
TROUBLESHOOTING
Monitor
8
1.
2.
3.
Cause
no fault
no fault
Missing, damaged or wrong designed
regeneration resistor.
The unit’s power base has been
overloaded
Power stage fault or motor leads short
circiut
DC bus voltage has dropped below the
powerbase undervolts level
Parting of the cable or resolver leads
short circuit or missing plug-in
connection
Amplifier or motor active current
overload.
Fault detection via software.
1) Cycle time between motor
acceleration and deceleration is too
short. (Duty cycle too high)
2) Missing or faulty motor thermoswitch
wiring.
Amplifier undersized; active motor
torque to high.
3) Amplifier ambient temperatur to high.
Drive / comms watchdog.
Interprocessor failure. Clear the error.
4.
Overcurrent
2x Peak Current Crest Value
Undervoltage;
5.
Feedback fault
6.
Electronic Fusing (see Fault 7 also)
7
1) I²t-Limit Controller/Motor
If I²t-limit is reached, amplifier will
reduce output current to it´s nominal
value. After 2.4s ± 0.5s drive switches
off (amplifier disable) with fault
indication "6; electronic fusing"
2) Motor overtemperature
3)Amplifier overtemperature
Watchdog
When the display shows a "0." a
watchdog timeout occurred in the
processor.
Limit switch (clock wise) active
When the status monitor displays a "-|.", the CW-limit switch has been activated.
0.
-|.
|-.
-
F.
S
J
Harmonic Drive AG
Status
Amplifier disabled
Amplifier enabled
Overvoltage
amplifier DC bus voltage
Integrated Power Module (IPM) Trip
Probable Cause: Check wiring of X3.10 or limit switch
Limit switch (counter clock wise) active
When the status monitor displays a "|-.", the CCW-limit switch has been
activated.
Probable Cause: Check wiring of X3.11 or limit switch
Amplifier disabled
When the status monitor display is blank, the amplifier is disabled and there is no
fault. When the status monitor displays a "d", the amplifier has been disabled.
Probable Cause: The amplifier can be disabled by an input, a DIP switch, or by
the setup software.
Fatal Following Error
When the status monitor displays a "F." the Following Fatal Error is activated
after following error exceeds the user defined Following Fatal Error band.
Stop - Mode
When the status monitor displays a "S" the control has been placed in the STOP
(previous HOLD) position mode.
Probable Cause: The hold position mode can be activated by an input X3.12, the
DIP-switch AS1.5, or by the setup software .
Jog - Mode
When the status monitor displays a "J." the control is in "Jog" system mode. The
"Jog-Mode" can be stopped or started by the setup software.
900105
11/2005
Page A8
Operations Manual SC-610
Problem diagnosis
If you have followed all the instructions in this manual in sequence, you should have few problems installing
the SC-Drive. If you do have a problem, read this section first. In WorkBench v5, use the Error Log tool to
view recent errors and then check the help file. If you cannot solve the problem or the problem persists, the
SupportMe™ feature can be used.
SupportMe™ feature
The SupportMe™ feature (on the Help menu) can be used to e-mail information to technical support
departments (or anyone else you choose). If required, you can choose to add your program files as
attachments. WorkBench v5 will automatically start up your e-mail program and begin a new message, with
comprehensive system information and selected attachments already in place. You can add any additional
message of your own and then send the e-mail. The PC must have email facilities to use the SupportMe™
feature. If you prefer to contact technical support by telephone or fax, contact details are provided at the front
of this manual. Please have the following information ready:
•
•
•
•
•
•
•
•
The serial number of your SC-Drive.
The catalog number indicating the type of SC-Drive you have.
Use the Help, about menu item in WorkBench v5 to view details about your system.
The catalog and specification numbers of the motor that you are using.
Give a clear description of what you are trying to do, for example trying to establish communications
with WorkBench v5 or trying to perform fine-tuning.
Give a clear description of the symptoms that you can observe, for example the Status display, error
messages displayed in WorkBench v5, or the current value of any of the MintMT error keywords
AXISERROR, AXISSTATUS, INITERROR, MISCERROR and DRIVEERROR.
The type of motion generated in the motor shaft.
Give a list of any parameters that you have setup, for example the motor data you entered/selected
in the Commissioning Wizard, the gain settings generated during the tuning process and any gain
settings you have entered yourself.
Power-cycling the SC-Drive
The term „Power-cycle the SC-Drive is used in the Troubleshooting sections. On models with a customer
supplied 24V supply, remove the 24V supply, wait for the SC-Drive to power down completely (all Status
LED segments will turn off), then re-apply the 24V supply. On models with an internally generated 24V
supply, remove the AC power supply, wait for the SC-Drive to power down completely (all Status LED
segments will turn off), then re-apply AC power.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A9
Power on
Problem
The Status display is
showing a flashing symbol
with a static decimal point.
Check
The SC-Drive has detected an error. Use the Error Log tool
to view a list of recent errors, or click the Error button on the
motion toolbar to view a description of the error.
Alternatively, type any or all of these commands in the
Command window:
PRINT AXISERROR, PRINT DRIVEERROR,
PRINT MISCERROR
PRINT INITERROR.
Click the Clear Errors button on the motion toolbar.
Problem
Cannot enable the SC-Drive
because AXISERROR has
bit 13 set
When the SC-Drive is
enabled the motor is
unstable
Check
Check the drive enable input on connector X3 pins 7 and 9
is connected and powered correctly. Check that DIP switch
8 (enable) is set to the On position.
Check that the current loop has been tuned.
Check that the current loop was tuned with the correct motor
data.
If the motor is still unstable try reducing the Speed
Proportional gain (KVPROP) and Speed Integral gain
(KVINT) on the Speed tab of the Fine-tuning window.
Set FOLERRORMODE to zero to ignore the following error
while tuning the gains.
Tuning
I get a Following Error
(AXISERROR bit 5 is set)
and the drive disables when
tuning the gains
I get a Software limit error
(AXISERROR bits 3 or 4 set)
and the drive disables when
tuning the gains
I get a Hardware limit error
(AXISERROR bits 1 or 2 set)
and the drive disables when
tuning the gains
Set SOFTLIMITMODE to zero to ignore the software limit
error while tuning the gains.
Set LIMITMODE to zero to ignore the hardware limit errors
while tuning the gains. Alternatively, disable the hardware
limit inputs.
Status LED shows a digit or ‘E.’
If the Status display shows a flashing digit, ‘E’, or the forward or reverse hardware limit symbol, use the Error
Log tool to view a list of recent errors. Alternatively, type PRINT DRIVEERROR, PRINT AXISERROR and
PRINT MISCERROR as separate commands in the WorkBench v5 Command window. Each of these
commands will return an error code, a description of which can be found in the help file.
Press F1 and locate the DRIVEERROR, AXISERROR and MISCERROR keywords. The Error Handling book
contains topics listing the Status display indicators and basic error codes. Remember that many error codes
are the sum of a bit pattern so may not be listed individually. For help on understanding bit pattern values,
see the Bit pattern values topic in the Keywords book
Harmonic Drive AG
900105
11/2005
Page A10
Operations Manual SC-610
APPENDIX D
Multi - Drop - Applications
This mode is available setting DIP-switch no. 10 at the front panel of the drive to ON. The wiring
principle for multi-drop applications is shown below. Each connected drive will also get it´s own
hardware address. The setting can be done by DIP-switches AS1-4 on the front panel or by using
the setup software Work Bench v5.
The picture below shows termination resistors on the last connected drive. The resistor can be
activated by using DIP-switch AS1.6 and set it to ON-position.
Multi-drop wiring principle for RS485:
SC / A0
SC / An
SC / A1
X6
RS485
X6
RS485
Termination Res.
c/f
X6
RS485
TX-
3
TX-
3
TX-
3
TX+
7
TX+
7
TX+
7
RX+
8
RX+
8
RX+
8
RX-
2
RX-
2
RX-
2
DGND
5
DGND
5
DGND
5
6
6
6
7
7
7
8
8
8
9
9
9
RS485
Interface cable refer
to chapter 4.2.7.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A11
APPENDIX E
Software Installation
General:
The WorkBench set-up software is Windows-based and guides you through all steps
necessary,to set-up your Servo Drive via a serial port of your PC. Online-Help to each topic
makes a manual obsolete.
A) Minimum system requirements
Hardware requirements (minimum):
Processor:
Intel Pentium / 133 MHz
RAM:
32MByte
Hard Disk Space:
40Mbyte
Screen:
800 x 600 (min.)
Recommended:
Intel Pentium, 64 MB RAM, 200 MHz, 60MB hard disk space free
Software requirements:
Operating System:
Recommended:
Windows 2000
Windows 98, Windows ME,
Windows 2000 (SP4+), Windows XP (SP1+)
B) Installation
To install the WorkBench software on your computer's hard disk, please follow the sequence described
below:
1.) Start Windows. Make sure, that no other programs are running, while Installation of WorkBench is done.
2.) Place Installation CD ROM in your computer's CD ROM drive.
3.) Look for E: (if E is your CD ROM drive) and double click on Setup_xxxx.exe.
4.) According to demands from the installation process, insert Installation Disk with required number.
After installation process is finished, a Program Manager Group for WorkBench with WorkBench ProgMan
Icon is created. Double clicking this icon will start the WorkBench set-up program.
Harmonic Drive AG
900105
11/2005
Page A12
Operations Manual SC-610
Appendix F
Definition of Parameters for Controller-Setup
1
2
Motor-Parameters referred to the Motor Shaft
KE
=
Voltage constant in V/Krpm effective value (rms)
Pole Pairs
=
Number of poles divided by 2
IMAX
=
Maximum peak current
IRATED
=
Continuous current
RA (L-L)
=
Armature resistance measured between U and V
or double of phase resistance given in the catalogue
LA (L-L)
=
Armature inductance measured between U and V
or field inductance given in the catalogue
KT
=
Torque constant
JROTOR
=
Moment of Inertia of the Motor (without gear)
System-Parameters
NMAX
=
Maximum motor speed at 10V demand input
Enc. Res.
=
Number of encoder counts per one motor revolution
Power Supply =
3
Amplifier power supply voltage depending on the actuator
System Configuration
HD-No.
=
Part number given on the type lable at the front panel
showing the parameter settings ex stock. First 6 numbers
specify the basic unit. Last 2 numbers define the parameter
settings.
Mod.-No.
=
Part number given on the additional lable at the front panel
showing customers specific parameter settings, if specified.
This Mod.-No. „overwrites“ the HD-No.
The individual motor parameters are given within the motor database of the setup software
Work Bench v5 and will be updated on regular basis.
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A13
APPENDIX G
Harmonic Drive AG
900105
11/2005
Page A14
Operations Manual SC-610
APPENDIX H
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A15
APPENDIX I
Harmonic Drive AG
900105
11/2005
Page A16
Operations Manual SC-610
APPENDIX J
Harmonic Drive AG
900105
11/2005
Operations Manual SC-610
Page A17
APPENDIX K
Harmonic Drive AG
900105
11/2005
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