gsk GSK GSSpindle User Manual

Preface

In this user manual we try to describe the matters concerning the operation of this GS Series Spindle Servo Drive Unit to the greatest extent. However, it is impossible to give particular descriptions for all unnecessary or unallowable operations due to length limitation and products application conditions; Therefore, the items not presented herein should be regarded as “impossible” or “unallowable”.

Copyright is reserved to GSK CNC Equipment Co., Ltd. It is illegal for any organization or individual to publish or reprint this manual. GSK CNC Equipment Co., Ltd. reserves the right to ascertain their legal liability.

I

GS Series Spindle Servo Drive Unit User Manual

Preface

Dear customers,

We are honored and thankful for your purchase of this GSK product! This manual describes items concerning GS Series Spindle Servo

Drive Unit in detail, such as performance, installation, connection, commissioning, usage and maintenance etc.

To ensure safe and effective running, please read this manual carefully before installation and operation.

To avoid injury to operators and other personnels, and damage to the mechanical equipments, please pay special attention to the following warning signs when reading this manual.

Danger Mal-operation may lead to serious injury or death.

Caution Mal-operation may lead to minor injury or physical damage.

Notice It indicates a potential situation which, if not avoided, may result in an undesirable result or state.

It reminds users of the important instructions and requirements.

Forbidden (definitely cannot be done)

Compulsive (must be done)

II

Caution

Danger

Tighten all terminals of main circuits properly.

!result in loose connection which can easily lead to spark hazard or even fire disaster.Failure to observe it may

Make sure that the input power is OFF before wiring.

!	Failure to observe it may
	result in electric shock.

Wire layout or overhaul should be done by electrical engineering

technician.

!Failure to observe it may result in electric shock or fire disaster.

Wiring should be performed according to the method described in User

Manual.

!Failure to observe it may result in equipment damage and electric shock.

DO NOT operate the switch with wet hand.

Failure to observe it may result in electric shock.

DO NOT open the terminal strip cover after power-on or in running state.

Failure to observe it may result in electric shock.

Mount the drive unit on noncombustible, and keep it far away from inflammables.

!Failure to observe it may result in fire disaster.

Make sure the grounding terminal PE of servo unit is well grounded.

!Failure to observe it may result in electric shock.

Moving, checking, and maintaining equipments or wiring should be

performed 5 minutes after power-off.

!Failure to observe it may result in electric shock.

DO tighten the power terminals and motor output terminals.

!Failure to observe it may result in fire disaster.

DO NOT put hand into servo unit.

Failure to observe it may result in electric shock.

DO NOT touch the wiring terminals of servo unit main circuits.

Failure to observe it may result in electric shock.

III

GS Series Spindle Servo Drive Unit User Manual

Danger

The servo unit may be activated suddenly after power resumption, so DO NOT operate the servo motor axes connection device immediately.

Failure to observe it may result in personal injury.

DO NOT place cables beside sharp edges, and AVOID heavy load or tension imposing on cables.

Failure to observe it may result in electric shock, equipment fault or damage.

DO NOT prevent radiation or put objects in cooling fan or radiator.

Failure to observe it may result in equipment damage or fire disaster.

DO NOT perform live-wire operation on the servo drive device when the cover of terminal strip is taken apart.

Failure to observe it may result in electric shock.

Caution

IV

Caution

Caution

DO NOT connect power input wires R, S, T to motor output wire terminals U, V, W.

Failure to observe it may result in device damage.

DO NOT touch the radiation device of motor and servo unit when they are running, because high temperature may be caused.

Failure to observe it may result in scald.

DO NOT alter, dismantle or repair the drive unit without authorization.

Failure to observe it may result in device damage.

DO NOT turn ON/OFF the input power frequently.

Failure to observe it may result in device damage.

DO NOT make excessive changes to parameters.

Failure to observe it may result in device damage.

The scrapped components of servo unit should be handled as industrial waste and cannot be reused.

Failure to observe it may result in accident.

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GS Series Spindle Servo Drive Unit User Manual

Safety Responsibility

Manufacturer’s Responsibility

——Be responsible for the danger which should be eliminated and/or controlled on design and configuration of the provided Servo Drive Unit and accessories.

——Be responsible for the safety of the provided Servo Drive Unit and accessories. ——Be responsible for the provided information and advice for the users.

User’s Responsibility

——Be trained with the safety operation of Servo Drive Unit and familiar with the safety operation procedures.

——Be responsible for the dangers caused by adding, changing or altering to the original Servo Drive Unit and the accessories.

——Be responsible for the failure to observe the provisions for operation, adjustment, maintenance, installation and storage in the manual.

This manual is reserved by end user.

We are full of heartfelt gratitude to you for supporting us in the use of GSK’s products.

VI

Contents

	Contents
CHAPTER I INSTRUCTION......................................................................................................................		1
1.1	Basics ..............................................................................................................................................	1
1.2	Product Confirmation .......................................................................................................................	6
1.2.1 Instruction of AC Spindle Servo Motor Model...........................................................................		6
1.2.2 Instruction of Spindle Servo Unit ..............................................................................................		7
1.2.3 Overall Appearance of Spindle Servo Unit ...............................................................................		8
1.3	Technical Specification ..................................................................................................................	11
1.3.1 Technical Specification of Spindle Motor................................................................................		11
1.3.2 Technical Specification of AC Spindle Servo Unit ..................................................................		13
1.4	Ordering Guidelines.......................................................................................................................	15
1.4.1 Model Selection Process ........................................................................................................		15
1.4.2 Examples ................................................................................................................................		15
1.4.3 Standard Ex-factory Accessories............................................................................................		17
CHAPTER II INSTALLATION/MOUNTING .............................................................................................		21
2.1	Spindle Servo Motor ......................................................................................................................	21
2.1.1 Dimensions for Spindle Motor Installation ..............................................................................		21
2.1.2 Installation of Spindle Motor ...................................................................................................		23
2.2	Spindle Servo Unit .........................................................................................................................	25
2.2.1 Installation Dimension.............................................................................................................		26
2.2.2 Installation Intervals ................................................................................................................		28
CHAPTER III CONNECTION ..................................................................................................................		31
3.1	Connection of Peripheral Equipments ...........................................................................................	32
3.2	Connection of Main Circuit ............................................................................................................	37
3.2.1 Connection..............................................................................................................................		37
3.2.2 Wiring of Main Circuit..............................................................................................................		38
3.2.3 Servo Motor Connection Instruction .......................................................................................		38
3.3	Connection of Control Signal.........................................................................................................	40
3.3.1 CN1 Control Signal .................................................................................................................		40
3.3.2 Speed Command Input...........................................................................................................		43
3.3.3 Position Command Input ........................................................................................................		44
3.3.4 Digital Input .............................................................................................................................		47
3.3.5 Digital Output ..........................................................................................................................		49
3.3.6 Position Signal Output ............................................................................................................		52
3.4	Connection of Position Feedback Signal.......................................................................................	53
3.4.1 Motor Encoder Position Feedback Signal Interface CN2 .......................................................		53

VII

	GS Series Spindle Servo Drive Unit	User Manual
3.4.2 2nd Position Feedback Signal Interface CN3 ........................................................................		57
3.4.3 Interface CN3 of GS Series MDR Products ...........................................................................		58
3.5 GSK-CAN Communication............................................................................................................		59
3.6	Connection in Different Working Mode .........................................................................................	60
3.6.1 Connection in Speed Mode....................................................................................................		60
3.6.2 Connection in Position Mode .................................................................................................		63
3.6.3 Connection in Speed/Position Mode......................................................................................		65
CHAPTER IV DISPLAY AND OPERATION ...........................................................................................		69
4.1	Operation Panel ............................................................................................................................	69
4.2	Display Menu ................................................................................................................................	70
4.3	Status Monitoring ..........................................................................................................................	71
4.4	Parameter Setting .........................................................................................................................	74
4.5	Parameter Management ...............................................................................................................	75
CHAPTER V GENERAL COMMISSIONING..........................................................................................		77
5.1	Running in Manual/JOG Mode......................................................................................................	78
5.1.1 Manual Running .....................................................................................................................		79
5.1.2 JOG Running..........................................................................................................................		80
5.2	Running in Speed Mode ...............................................................................................................	81
5.2.1 Analog Speed Command .......................................................................................................		81
5.2.2 Internal Speed Command ......................................................................................................		84
5.3	Running in Position Mode .............................................................................................................	85
5.4	Running in Speed/Position Mode .................................................................................................	87
CHAPTER VI FUNCTIONALITY TESTING............................................................................................		91
6.1	Instruction for Basic Performance Parameters Setting.................................................................	91
6.1.1 Setting Methods .....................................................................................................................		91
6.1.2 Three Gains of Closed-Loop Control .....................................................................................		93
6.2	Switching of Motor Rotation Directions.........................................................................................	94
6.3	Braking Stop..................................................................................................................................	96
6.4	Testing in Position Mode...............................................................................................................	97
6.4.1 Electronic Gear Ratio of Position Command .........................................................................		97
6.4.2 Position Arrival Signal ............................................................................................................		98
6.4.3 Position Deviation Clear.........................................................................................................		99
6.4.4 Pulse Command Inhibition .....................................................................................................		99
6.5	Testing in Speed Mode ...............................................................................................................	100
6.5.1 Orientation Function.............................................................................................................		100
6.5.2 Adjustment of Analog Commands .......................................................................................		105
6.5.3 Speed Arrival Signal.............................................................................................................		106

VIII

Contents

6.5.4 Zero Speed Clamp................................................................................................................		107
6.5.5 Speed Command Electronic Gear Ratio ..............................................................................		108
6.6	Spindle Clamp Interlock Signal (BREF).......................................................................................	109
CHAPTER VII PARAMETERS ..............................................................................................................		111
7.1	Parameter List .............................................................................................................................	111
CHAPTER VIII ABNORMALITIES AND REMEDIES ............................................................................		123
8.1	Remedies for Normal Faults........................................................................................................	123
8.1.1 Speed Mode .............................................................................................................................		123
8.1.2 Position Mode .......................................................................................................................		125
8.1.3 Others ...................................................................................................................................		126
8.2	Alarms and Remedies .................................................................................................................	128
8.3	Inspection and Maintenance........................................................................................................	133
APPENDIX A Model Code Parameters and Feed Servo Motors Table................................................		135
APPENDIX B Peripheral Equipments ...................................................................................................		136
B.1 Circuit Breaker and Contactor (essential) ...................................................................................		136
B.2 Three-phase AC filter (recommended)........................................................................................		136
B.3 AC Reactor (recommended) .......................................................................................................		137
APPENDIX C BRAKING RESISTOR SELECTION...............................................................................		138
APPENDIX D CONNECTION DIAGRAMS BETWEEN SPINDLE SERVO UNIT AND CNC SYSTEM
...............................................................................................................................................................		141

IX

Chapter I Instruction

CHAPTER I INSTRUCTION

1.1Basics

¾Fundamental principles and circuits of spindle servo drive

The spindle servo drive is composed of spindle servo unit and spindle servo motor (three-phase AC asynchronous servo motor, hereinafter called servo motor). The servo unit rectifies AC to DC, and by controlling the ON/OFF of power transistor, it generates current approximated to sinewave whose phase difference is 120° in the three-phase stator winding of servo motor (i.e., DC-AC). Thus, a magnetic field is created in the servo motor, and the rotator generates current as a result of magnetic field induction. The interaction between the inductive current and magnetic field leads to the generation of a torque which causes the rotator to work. Higher frequency of current which goes through the servo motor winding corresponds to quicker servo motor speed; the larger current amplitude corresponds to larger output torque of the servo motor (torque= force × arm length). Figure 1-1 shows the main circuit of servo unit; PG represents the encoder.

Fig. 1-1 Main circuit of spindle servo unit

¾Basic structure of spindle servo drive

The servo unit receives speed (or position) commands from control device (also called upper computer) such as CNC system. It controls the frequency and magnitude of current which goes through the servo motor winding, so that the rotation speed (or angle) of servo motor rotator can be approximated to the speed (or position) command value, and the difference between actual rotation speed (or angle) and commanded value can be detected. By constantly adjusting the frequency and magnitude of current, the servo unit can limit the differences within the required range. Figure 1-2 shows the basic structure of spindle servo drive.

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GS Series Spindle Servo Drive Unit User Manual

	Specify
CNC		Control	Power Drive	Motor	Machine
System		Unit	Unit

Feedback

Detection

Spindle Servo Drive

Fig. 1-2 Basic structure of spindle servo drive

¾General concept of control

zControl: A process of the characteristics (such as speed) of an object (such as servo motor) reaching or approximating to the desired value is called CONTROL. The object herein is called PLANT; and its characteristic is called CONTROLLED VARIABLES; the unit which realizes the control is called CONTROL UNIT; the process of receiving the desired value by the control unit is called SPECIFY; the process of inputting and reacting to controlled variable is called FEEDBACK; the unit that detects the controlled variables is called FEEDBACK UNIT; the feedback can be divided into positive feedback (same direction) and negative feedback( reversed direction) according to the controlled variables and output direction. The drive is composed of plant, feedback unit and control unit. There are two kinds of drives: open-loop control device and closed-loop control device. They are distinguished by the absence/presence of feedback unit and its position in drive. The closed-loop control device described in this manual is negative feedback closed-loop control device.

In this manual, the spindle servo unit is the control unit; the plant is the servo motor; the motor rotation speed (or angle) is the controlled variable; the encoder is the feedback unit; the speed feedback is realized when actual speed is detected by encoder for speed control. Spindle servo unit belongs to closed-loop control device.

zOpen-loop control device: Feedback unit is absent in the control device, so the actual controlled variables do not affect the output of control unit. Take stepper motor drive for example: after the servo unit outputs the phase sequence changes of current, the rotator of stepper motor should follow the change; however, since there is no feedback unit, the rotator may not catch up with the changes due to overload or fast acceleration/deceleration, this is the so-called “out-of-synchronism”. Shown in Figure 1-3.

Machine

Specify

Command Drive

Circuit Motor

Fig. 1-3 Open-loop control device

z Closed-loop control: The controlled variable is detected by feedback unit and sent to

2

Chapter I Instruction

control unit. According to the detection points, the closed-loop control device can be divided into full-closed-loop control and semi-closed-loop control. The former one is to detect the controlled variables directly for feedback (see Fig. 1-4); the mechanical position is controlled variables; the grating ruler mounted on the machine is taken as feedback unit; the encoder on the servo motor serves as speed feedback unit. Thus the full-closed-loop control can be realized. If there is no grating ruler, the encoder serves as both position and speed feedback unit (see Fig. 1-5). Thus, the semi-closed-loop control can be realized.

					Machine
Specify
Command		Position		Speed	Motor
		Comparision		Comparision
					PG
					Speed
					Feedback
			Position
			Feedback

Fig. 1-4 Full-closed-loop control device

Machine

Specify
Command	Position	Speed	Motor
	Comparision	Comparision

PG

Fig. 1-5 Semi-closed-loop control device

z PID control: It is the most commonly used algorithm. “P” is Proportional, representing the linear proportional relationship between input and output of control unit. The larger the value is, the more sensitive the system is, and the smaller the steady-state error will be (impossible to eliminate); however, too large proportional coefficient will lead to system instability. “I” is Integral, representing the accumulation of past errors. Larger integral time constant means the system is more stable till the stead-state error is eliminated; however, it also may lead to lower response of the system. “D” is Differential, representing the prediction of future errors, based on current rate of change. It can decrease the following error and improve the dynamic property. When the integral is too large, the system will be unstable. P, I, D are interacted for the balance among system response, control precision and stability. Since the integral control will easily cause impact and oscillation, PI control (i.e., proportion and integral control) is mainly described in this manual.

¾Concept about servo control

There are three kinds of control mode: position control, speed control and torque control. Shown

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GS Series Spindle Servo Drive Unit User Manual

in Fig. 1-6:

zPosition control: Specify the rotation direction and angle (position) of the motor in forms of digital pulse or data communication.

zSpeed control: Specify the rotation direction and speed of the motor in forms of analog voltage or data communication.

zTorque control: Specify the magnitude and direction of output torque of the motor in forms of analog voltage or data communication.

The servo drive described in this manual repels the torque control signal, therefore the torque control mode is not provided here.

Fig. 1-6 Three-loop control system

¾Performance norm of spindle servo drive

Dynamic performance: means the response speed, dynamic error and steady-state error of spindle servo drive when the load is specified or changed. The following figure shows the dynamic response of step signal specified by spindle servo drive (the full line represents the specified signal and dashed line represents the output signal; similarly hereinafter).

C(t)
Rmax(t)	±5%R(t)
R(t)
0.9R(t)
t r	t
	t s

Fig. 1-7 Dynamic response curve

Rise time tr: The duration that the rotation output value rises from 0 to 90% of the steady-state value for the first time. It represents the speed of dynamic response.

4

Chapter I Instruction

Settling time ts: The range -5 ~+5% of the steady-state value is taken as permitted error zone. The settling time is the minimum duration of the response curve to reach the zone (no excess any more). It is used to measure the speed of the whole control process.

Percent overshoot σ: It is the maximum fraction by which the response overshoots the steady-state value and expressed as a percentage, i.e.

σ(%) = Rmax (t) − R(t) ×100%

R(t)

Steady-state error: The difference between the steady-state output value to the reference input value at steady state is called the steady state error of the system.

Static performance: Stability is the crucial factor of a spindle servo drive. The static performance mainly refers to positioning accuracy which means the difference between the reference state and actual state after the transient process. The static precision can be affected by measurement device error as well as the system error which is related to the system structure and parameters. Fig. 1-8 shows the static curve of position servo drive.

θ	Commanded
	Position
	Following
	Response
Following Error
Lag	t

Fig. 1-8 Static curve

Following error: The difference between the required position and actual position is called following error. It equals to commanded position value minus actual position value.

Servo rigidity: The capacity of resisting deviation which is caused by load.

¾Comparison between spindle servo drive and inverter drive

Although both two kinds of devices can realize the conversion of AC-DC-AC, and drive the three-phase asynchronous motor, the spindle servo drive bears larger current frequency range and wider valid regulating range. Since an encoder is mounted on servo motor, the spindle servo drive belongs to closed-loop control device. Whereas, no encoder is mounted on an inverter-fed motor, the inverter drive belongs to open-loop control device. Motor’s rotation speed will change as the load changes; however, since feedback control function is not available, the inverter cannot recover the speed like the servo unit does. To reduce cost, the overload capacity of inverter is 10%~20%, and that of servo unit is greater than 50%. Higher overload capacity means faster acceleration and response.

Compared with inverter drives, the spindle servo drives have the following advantages:

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GS Series Spindle Servo Drive Unit User Manual

zBoth speed and position control are available; the control precision is high;

zWider regulating range; capable of outputting valid torque in zero-speed state;

zSmall speed fluctuation when load changes; quick to recover;

zStrong overload capacity; fast response; high efficiency; adaptable to sudden start/stop conditions;

1.2Product Confirmation

Check the following items after receiving the products. Please contact us or the supplier if you come across any question.

	Item	Remark
	Check the consistency of servo	Check the nameplate.
	unit and servo motor
	Check the completeness of	Check the contents on packing list and contact
	accessories	the supplier if an inconsistency is found.
	Check whether the product is	Check the overall appearance.
	damaged during delivery
	Check whether the screw is	Check for loose connection with a screwdriver.
	loose

Caution 1. Spindle servo unit with loss or damage of parts should not be installed.

2.Servo unit should be matched with a servo motor with suitable power.

3.There are two types of GS series products: D-SUB and MDR. Make sure that the used product meets the requirements.

1.2.1Instruction of AC Spindle Servo Motor Model

¾Nameplate of spindle servo motor:

Flange mounting plane B5

¾Instruction of spindle servo motor model:

6

Chapter I Instruction

1.2.2 Instruction of Spindle Servo Unit

Example: (nameplate)

Corresponding servo motor model

Product model

AC Asynchronous Spindle Servo Unit

Model:GS3075Y-CP2-7.5

SVD: V3.04

Software version

Servo Motor

ZJY-208-7.5BH

Input Power Three-phase 380V(-15% +10%)50/60Hz

Ex-factory date

No.

100620

EXW. Date

2010/9

R

GSK CNC Equipment Co., Ltd

Tel .[phone] Fax.[phone]

Product number

Input power supply

Model instruction:

GS

3

075

Y

-

C

P

2

GS Series MDR Servo Unit, G: GSK; S: SERVO

Voltage grade code, 2: 220V; 3: 380V; 4: 440V.

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GS Series Spindle Servo Drive Unit User Manual

Nominal current of power component (in three digits): 048, 050, 075, 100, 148, 150 (unit: A)

Motor type: T: synchronous servo motor; Y: asynchronous servo motor.

Communication bus code; N: none; C: GSK-CAN; L: GSK-Link

Feedback (encoder) interface type code; P: incremental encoder; A: Absolute encoder, no backup battery; B: absolute encoder (with backup battery which is used when power-off).

Feedback (encoder) interface configuration code (in 1 digit); 1: The input interface CN2 for motor feedback

(i.e., the 1st position feedback); 2: Input interfaces CN2 and CN3 for motor feedback and the 2nd position feedback.

Position feedback signal interface type and configuration:

			Instruction for feedback (encoder) interface type and configuration
	P	1	CN2; incremental encoder;
		2	CN2 and CN3; incremental encoder;
		1	CN2; incremental encoder or absolute encoder (compatible with Biss and TAMAGAWA
	A		communication protocols; automatic identification);
	B	2	CN2 and CN3; incremental encoder or absolute encoder (compatible with Biss and
			TAMAGAWA communication protocols; automatic identification);

1.2.3 Overall Appearance of Spindle Servo Unit

According to different signal interfaces, the GS Series Spindle Servo Unit can be divided into D-SUB type and MDR type. The products that adopt D-SUB interfaces provided by WIESON Company belong to D-SUB type. They are matched with incremental encoder and not equipped with GSK-CAN. The products that adopt MDR interfaces provided by 3M Company belong to MDR type. They are compatible with absolute encoder and equipped with GSK-CAN bus.

8

Chapter I Instruction

zOverall Appearance of GS Series AC Spindle Servo Unit (D-SUB Type)

The figure below shows the structure of following products: GS3048Y-N Series, GS3050Y-N Series, GS3075Y-N Series GS3100Y-N Series, GS3148Y-N Series, GS4048Y-N Series, GS4050Y-N Series, GS4075Y-N Series, GS4100Y-N Series, GS4148Y-N Series.

Increase parameter number

and value. Decrease parameter

number and value.

Move to the digit to be edited.

Return to the previous menu or cancel the last operation.

Enter to a sub-menu or confirm the operation

	Indicator	‘CHARGE” is the indicator of DC
		bus voltage in the main circuit.
		ON: normal
		OFF: the bus is discharged
		When ‘CHARGE' indicator comes
		ON, connecting or disconnecting the
		servo unit line, power supply line, motor
		line or braking resistor line is forbidden.

Terminal block of main circuit

Connection should be done

!according to contents in Section 3.2.2 with suitable terminals, and tighten the screw afterwards.

input power ground; GND of motor protective ground

R
AC			Serie
	Servo	Mot or	Driv es Unit

CHARGE

POWER

C N 3

C N 2

C N 1

LED monitoring window

Monitor the running status or parameter modification and management.

	Indicator	‘POWER’ is the indicator of
		power supply of control circuit.
		ON: normal
		OFF: power failure

CN1: Control signal interface

(44-pole DB female)

For external speed command signal, position command signal and output signal

CN2: encoder feedback input interface

(25-pole DB female)

For incremental encoder differential signal, motor position feedback input

CN3: 2nd position encoder feedback input interface (9-pole DB female)

For incremental encoder differential signal, spindle encoder position feedback input

Open

	R	380V
	S
	T
	P	BRAKE
	B
	U	MOTOR
	V
	W
	r	380V
	t

Terminal block of main circuit

!Check the nameplate before connection; make sure that the input power voltages R, S, T, r, t are correct. Connect to U, V, W as market at the terminal end; if Err-27 occurs, exchange any of the two phases.

Fig. 1-9 (a) Overall appearance of GS Series AC spindle servo unit (D-SUB type)

9

GS Series Spindle Servo Drive Unit User Manual

The figure below shows the structure of following D-SUB products: GS3150Y-N Series, GS4150Y-N Series.

Fig. 1-9 (b) Overall appearance of GS Series AC spindle servo unit (D-SUB type)

zOverall Appearance of GS Series AC Spindle Servo Unit (MDR Type)

The figure below shows the structure of following products: GS3048Y-C Series, GS3050Y-C Series, GS3075Y-C Series, GS3100Y-C Series, GS3148Y-C Series, GS4048Y-C Series, GS4050Y-C Series, GS4075Y-C Series, GS4100Y-C Series, GS4148Y-C Series.

Backup battery

(See the instruction of servo unit model)

Increase parameter number

and value. Decrease parameter

number and value.

Move to the digit to be edited.

Return to the previous menu or cancel the last operation.

Enter to a sub-menu or confirm the operation

	Indicator	‘CHARGE” is the indicator of DC
		bus voltage in the main circuit.
		ON: normal
		OFF: the bus is discharged
		When ‘CHARGE' indicator comes
		ON, connecting or disconnecting the
		servo unit line, power supply line, motor
		line or braking resistor line is forbidden.
		Terminal block of main circuit
		Connection should be done
	!	according to contents in Section 3.2.2
		with suitable terminals, and tighten
		the screw afterwards.

R
A C	Serv o		r	Series
		Moto		Driv e Unit

CHARGE

POWER

C N 3

C N 2

C N 1

C N 4

C N 5

LED monitoring window

Monitor the running status or parameter modification and management.

	Indicator	‘POWER’ is the indicator of power
		supply of control circuit.
		ON: normal
		OFF: power failure

CN1: control signal interface (50-pin high-density )

For external speed command signal, position command signal, input/output signal.

CN2: encoder feedback input interface (26-pin high-density)

For incremental or absolute encoder feedback input signal

CN3: 2nd position encoder feedback

input interface (20-pin high-density)

For spindle encoder position feedback input, incremental or absolute input signal.

	input power ground; GND	CN4, CN5: GSK-CAN
		communication interface
	of motor protective ground
		Realize servo unit commissioning and
		real-time monitoring.

Fig. 1-10 (a) Overall appearance of GS Series AC spindle servo unit (MDR type)

10

Chapter I Instruction

The figure below shows the structure of following products: GS3150Y-C Series, GS4150Y-C Series.

LED monitoring window

Monitor the running status or parameter modification and management.

	Indicator	‘CHARGE” is the indicator of DC
		bus voltage in the main circuit.
		ON: normal
		OFF: the bus is discharged
		When ‘CHARGE' indicator comes
		ON, connecting or disconnecting the
		servo unit line, power supply line, motor
		line or braking resistor line is forbidden.
		Terminal block of main circuit
		Connection should be done
	!	according to contents in Section 3.2.2
		with suitable terminals, and tighten
		the screw afterwards.
		input power ground; GND
		of motor protective ground

Terminal block of control power line

Check the nameplate before

!connection; make sure the r,t power voltages are correct.

	R
	AC Servo		Series
		Motor Drive	Unit

CHARGE

POWER

R	380V	C
		N
S		3
T
		C
P		N
	BRAKE	2
B
U
	MOTOR	C
V		N
		1
W
		C
		N
		4
		C
		N
		5
r	380V
t

Increase parameter number and value.

Decrease parameter number and value.

Move to the digit to be edited.

Return to the previous menu or

cancel the last operation. Enter to a sub-menu or

confirm the operation

	Indicator	‘POWER’ is the indicator of power
		supply of control circuit.
		ON: normal
		OFF: power failure

CN1: control signal interface (50pin high-density )

For external speed command signal, position command signal, input/output signal.

CN2: encoder feedback input interface (26-pin high-density)

For incremental or absolute encoder feedback input signal

CN3: 2nd position encoder feedback

input interface (20-pin high-density)

For spindle encoder position feedback

input, incremental or absolute input signal.

CN4, CN5: GSK-CAN communication interface

Realize servo unit commissioning and real-time monitoring.

Fig. 1-10 (b) Overall appearance of GS Series AC spindle servo unit (MDR type)

1.3 Technical Specification

1.3.1 Technical Specification of Spindle Motor

	SPEC	ZJY208	ZJY208	ZJY208	ZJY265	ZJY265	ZJY265	ZJY182	ZJY182
	Item	-2.2AM	-3.7AM	-5.5AM	-7.5AM	-11AM	-15AM	-1.5BH	-2.2BH
	Rated power	2.2	3.7	5.5	7.5	11	15	1.5	2.2
	(kW)

Servo Unit			Three-phase AC 380V 50 Hz /60Hz
Power Supply
Rated Current	6.7	10.2	15.5		21	31	48.3	7.3		7.5
(A)
Rated	33.3	33.3	33.3		33.3	33.3	33.3	50		50
Frequency(Hz)
Rated	21	35	53		72	105	143	9.5		14
Torque(N·m)
30min Power	3.7	5.5	7.5		11	15	18.5	2.2		3.7
(kW)
30min Current	9.8	13.8	19.6		28	39	56	9.3		11
(A)
30min Torque	35	53	72		105	143	177	14		24
(N·m)
Rated Speed	1000	1000	1000		1000	1000	1000	1500		1500
(r/min)
Constant Power			1000 4000
Range
Max. Speed				M:7000					H:10000

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GS Series Spindle Servo Drive Unit User Manual

SPEC	ZJY208	ZJY208	ZJY208	ZJY265	ZJY265	ZJY265	ZJY182	ZJY182
Item	-2.2AM	-3.7AM	-5.5AM	-7.5AM	-11AM	-15AM	-1.5BH	-2.2BH

Rotary Inertia	0.0168	0.0238	0.0309	0.0413	0.0826	0.086	0.0056	0.0074
Weight (kg)	51	66	77	51	125	143	27	32
Installation			IM B5 or B3				IM B35
Power Supply of	Three-phase AC 380V 50Hz 40W			Three-phase AC 380V 50Hz 70W			Three-phase AC 380V
Cooling Fan		0.14A			0.21A		50Hz 30W 0.08A

	SPEC	ZJY182-3.7BH	ZJY208-3.7 ZJY208-5.5 ZJY208-7.5			ZJY265-7.5B	ZJY265-11B ZJY265-15B
	Item		B	B	B	M	M	M
	Rated Power	3.7	3.7	5.5	7.5	7.5	11	15
	(kW)

Servo Unit
Power				Three-phase AC 380V		50 Hz /60Hz
Supply
Rated	15.5	8.9		13.7	18.4	18			26		35
Current (A)
Rated
Frequency	50	50		50	50	50			50		50
(Hz)
Rated	24
Torque		24		35	48	49			72		98
(N·m)
30min Power	5.5	5.5		7.5	11	11			15		18.5
(kW)
30min	19.6	13		18	25	26			34		42
Current (A)
30min	35
Torque		35		48	70	74			100		123
(N·m)
Rated Speed	1500	1500		1500	1500	1500			1500		1500
(r/min)
Constant
Power					1500 5000
Range
Max. Speed	H:10000		M:7000, H:10000						M:7000
Rotary	0.0115	0.0168		0.0238	0.0309	0.0413			0.0744		0.0826
Inertia
Weight (kg)	43	51		66	77	89			107		125
Installation	IM B35				IM B5 or B3
Power	Three-phase
	AC 380V							Three-phase AC 380V 50Hz
Supply of		Three-phase AC 380V 50Hz 40W 0.14A
	50Hz 30W								70W 0.21A
Cooling Fan
	0.08A
Protection				IP54 GB/T 4942.1—2006
Level
Insulation				F GB 755—2008
Level
Vibration				R GB 10068—2008
Level
Internal				Incremental encoder1024 p/r
Encoder

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Chapter I Instruction

Mechanical Characteristics of Motor

P/PN: Power/Rated power; T/TN: Torque/Rated torque; n: Rotation speed of spindle servo motor;

ZJY182 rated rotation speed: 1500r/min					ZJY208 rated rotation speed: 1500r/min

ZJY265 rated rotation speed: 1500r/min			ZJY208, ZJY265 rated rotation speed: 1500r/min
		Power in continuous working status;			Power in 30min’s working status;
		Torque in continuous working status;			Torque in 30min’s working status

1.3.2 Technical Specification of AC Spindle Servo Unit

	Model	GS3048Y	GS3050Y	GS3075Y	GS3100Y	GS3148Y	GS3150Y
		GS4048Y	GS4050Y	GS4075Y	GS4100Y	GS4148Y	GS4150Y
	Rated Power (kW)	1.5, 2.2	3.7, 5.5	5.5, 7.5	7.5, 11	11	15, 18.5
	Input Power	Input power of GS3□□□Y Series is: Three-phase AC380V 0.85 1.1 , 50/60Hz±1Hz
		Input power of GS4□□□Y Series is: Three-phase AC440V 0.85% 1.1 , 50/60Hz±1Hz
	Dimension (mm)	112×230×1	120×270×218	130×305×248.5	160×305×273.5		160×370×273.5
	(width×height×depth)	82
	Regulating Range			1 10000
	(r/min)
	Speed Fluctuation			Rated Speed ×0.1%
	Rate
	Working Mode		MANUAL, JOG, SPEED, POSITION, SPEED/POSITION

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		GS Series Spindle Servo Drive Unit	User Manual
	Internal Speed Mode	Motor rotates at the speeds set by internal parameters (speed closed-loop control)\
		Running speed is selected by input signal.
	External Speed Mode	Motor rotates at the speed specified by external analog voltage (speed closed-loop control)
	External Speed	10V +10V or 0V +10V, selected by parameters
	Command Mode
	Speed Command	Speed command frequency multiplication; frequency division coefficient:1~100
	Electronic Gear
	Position Mode	Motor rotates by position pulse command (position closed-loop control); the direction and
		quantity of pulse command determine the rotation direction and angle; the pulse frequency
		determines the rotation speed.
	Position Command	Pulse/direction; CCW pulse/CW pulse; A/B two-phase orthogonal pulse; max. pulse
	Pulse Mode	frequency: 1MHz
	Position Command	Command pulse frequency multiplication coefficient: 1 32767; Command pulse frequency
	Electronic Gear	division coefficient: 1 32767
	Positioning Accuracy	±0.088° (matched with incremental encoder with 1024 lines)
	Orientation	4-point orientation; 4 orientation angle is set by parameters; orientation position is selected
		through input signal; orientation error is ±180°/C (C is the line number of position feedback
		encoder)
	Motor Feedback Input	GS3□□□Y-NP2 and GS4□□□Y-NP2 D-SUB type: adopt incremental encoder;
		GS3□□□Y-C□2 and GS4□□□Y-C□2 MDR type: adopt incremental encoder or absolute
		encoder (compatible with two communication protocols: Biss and TAMAGAWA).
	2nd Position Feedback	GS3□□□Y-NP2 D-SUB type: adopt incremental encoder;
		GS3□□□Y-C□2 MDR type: adopt incremental encoder or absolute encoder (compatible with
	Input	two communication protocols: Biss and TAMAGAWA).
	(optional)
		GS3□□□Y-NP2 D-SUB type: motor feedback input signal or 2nd position feedback input
		signal output in 1:1;
	Position Feedback	GS3□□□Y-C□2 MDR type : motor feedback input signal or 2nd position feedback input
	Output	signal output in frequency division; the range of numerator and dominator in position
		feedback output gear ratio is 1 32767, and the dominator should be larger than or equal to
		numerator;
	Communication Bus	GS3□□□Y-NP2 and GS4□□□Y-NP2 D-SUB type : no communication bus;
		GS3□□□Y-C□2 and GS4□□□Y-C□2 MDR type : GSK-CAN
	Input Signal	Servo enable; CCW start; CW start; orientation/speed selection; orientation start; 2nd speed
		gain selection; spindle clamping interlock signal; zero-speed clamping; alarm clear;
		speed/position switching
	Output Signal	Servo ready; zero speed output; position/speed arrival; orientation completed; alarm output
		speed/position status; encoder zero point;
	Function Protection	Undervoltage protection; overvoltage protection; servo unit overcurrent protection; servo
		motor thermal overload protection; overspeed protection; overshoot protection; brake
		abnormality protection; encoder abnormality protection; motor overheat protection.
	Operation and Display	5 keys for manual, JOG operation and parameter modification, setting, writing and backup;
		6-digit LED displays rotation speed, current position, command pulse accumulation, position
		deviation, motor torque, motor current, absolute position of rotator, I/O signal status etc.
	Braking Resistor	Externally connected (no internal braking resistor)

Note: CCW means the motor rotates in counter clockwise direction (viewing from the shaft extension side). CW means the motor rotates in clockwise direction (viewing from the shaft extension side).

14

Chapter I Instruction

1.4 Ordering Guidelines

1.4.1 Model Selection Process

Rated rotation speed is 1000r/min (recommended in turning machine

Rated rotation speed is 1500r/min (recommended in milling machine)

1. Flange mounting or foot mounting;

2. With or without a keyway;

Pay attention to the difference between economical type and universal type

	Select motor	1.5 2.2 3.7 5.5
		7.5 11 15 18.5 are
	power
		optional Unit: kW
	Select the rated
	rotation speed
	Select the max.	1. Low: 4500r/min
		2: Medium:7000r/min
	rotation speed
		3. High: 10000r/min;

Select the mounting method

Select the

encoder

Select the motor model

Select the servo unit model

After selecting the motor model, you can select the servo unit model according to the relationship described in 1.4.2.

1.4.2 Examples

1. The model of GS Series servo device (including ZJY Series spindle servo motor) is shown as follows:

GS servo unit model — ZJY spindle servo motor model

Example: GS3075Y-NP2—ZJY208-7.5BM -B5LY1

Instruction: the model of spindle servo unit is GS3075Y-NP2, and the corresponding model of spindle servo motor is ZJY208-7.5BM -B5ALY1. The accessories are the standard ones (see Section 1.4.3).

2. The model of GS Series servo device (not including ZJY Series spindle servo motor) is shown as follows:

GS servo unit model — Servo motor model

Example: GS3075Y-NP2— ZJY208-7.5BM -B5LY1

Instruction: the model of spindle servo unit is GS3075Y-NP2, and the ex-factory parameters should be set according to the model in the brackets. The accessories are the standard ones (see Section 1.4.3).

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GS Series Spindle Servo Drive Unit User Manual

Model list of GS Series servo unit and ZJY Series servo motor:

	Servo Unit			Major Parameters of Spindle Motor
		Motor Model
			Rated	Rated		Rated
	Model
					Max. Speed		Standard Encoder
			Power	Speed		Current
							1024-line
		ZJY182-1.5BH	1.5kW	1500 rpm	10000rpm	7.3 A	incremental
							encoder
							1024-line
	GS3048Y-NP2	ZJY182-2.2BH	2.2kW	1500 rpm	10000rpm	7.5 A	incremental
	GS3048Y-CP2						encoder
	GS4048Y-NP2						1024-line
	GS4048Y-CP2	ZJY208-2.2AM	2.2kW	1000rpm	7000rpm	6.7A	incremental
							encoder
							1024-line
		ZJY208-2.2BM	2.2kW	1500rpm	7000rpm	9.3A	incremental
							encoder
					7000rpm		1024-line
		ZJY182-3.7BH	3.7kW	1500 rpm		15.5 A	incremental
					10000rpm
							encoder
							1024-line
	GS3050Y-NP2	ZJY208-3.7AM	3.7kW	1000rpm	7000rpm	10.2A	incremental
	GS3050Y-CP2						encoder
	GS4050Y-NP2	ZJY208-3.7BM			7000rpm		1024-line
	GS4050Y-CP2		3.7kW	1500rpm		8.9A	incremental
		ZJY208-3.7BH			10000rpm
							encoder
		ZJY208-5.5BM			7000rpm		1024-line
			5.5kW	1500rpm		13.7A	incremental
		ZJY208-5.5BH			10000rpm
							encoder
							1024-line
		ZJY208-5.5AM	5.5kW	1000rpm	7000rpm	15.5A	incremental
	GS3075Y-NP2						encoder
							1024-line
	GS3075Y-CP2	ZJY208-7.5BM			7000rpm
			7.5kW	1500rpm		18.4A	incremental
	GS4075Y-NP2	ZJY208-7.5BH			10000rpm
							encoder
	GS4075Y-CP2
							1024-line
		ZJY265-7.5BM	7.5kW	1500rpm	7000rpm	18A	incremental
							encoder

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Chapter I Instruction

	Servo Unit			Major Parameters of Spindle Motor
		Motor Model
			Rated	Rated		Rated
	Model
					Max. Speed		Standard Encoder
			Power	Speed		Current
							1024-line
	GS3100Y-NP2	ZJY265-7.5AM	7.5kW	1000rpm	7000rpm	21A	incremental
	GS3100Y-CP2						encoder
	GS4100Y-NP2						1024-line
	GS4100Y-CP2	ZJY265-11BM	11kW	1500rpm	7000rpm	26A	incremental
							encoder
	GS3148Y-NP2						1024-line
	GS3148Y-CP2
		ZJY265-11AM	11kW	1000rpm	7000rpm	31A	incremental
	GS4148Y-NP2
							encoder
	GS4148Y-CP2
							1024-line
		ZJY265-15AM	15kW	1000rpm	7000rpm	48.3A	incremental
	GS3150Y-NP2						encoder
							1024-line
	GS3150Y-CP2
		ZJY265-15BM	15kW	1500rpm	7000rpm	35A	incremental
	GS4150Y-NP2
							encoder
	GS4150Y-CP2
							1024-line
		ZJY265-18.5BM	18.5kW	1500rpm	7000rpm	48.7A	incremental
							encoder

1.4.3 Standard Ex-factory Accessories

The standard ex-factory accessories are listed in the table below. If additional accessories are needed otherwise, please contact our sales office or technical personnels.

zGS Series MDR product accessories list

Type	Name	Model	Number	Explanation	Remark
	DB-44 male plug and plastic		1	CN1 connecting plug
	case
Servo unit
	DB-25 male plug and plastic		1	CN2 connecting plug
(separate	case
order
	DB-9 male plug and plastic case		1	CN3 connecting plug
-no spindle
	Aluminum-shell braking resistor			Including 1m connecting
servo
				line (refer to Appendix C
motor)
				for the specification and
				quantity)

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		GS Series Spindle Servo Drive Unit				User Manual
	Type	Name	Model	Number	Explanation		Remark
		GS Series Spindle Servo Unit		1	Technical materials
		Manual
		DB-44 male plug and plastic		1	CN1 connecting plug
		case
		DB-9 male plug and plastic case		1	CN3 connecting plug
		Motor encoder line	-00-761A	1	Standard length: 3m		Matched
	Servo unit	Motor encoder line	-00-765*	1	Standard length: 3m		with ZJY
	and spindle	Motor fan line	-00-768A	1	Standard length: 3m		Series
	servo	Aluminum-shell braking resistor			Including 1m connecting		spindle
	motor				line (refer to Appendix C		servo motor
					for the specification and
					quantity)
		GS Series Spindle Servo Unit		1	Technical materials
		Manual
	Servo unit	DB-25 male plug and plastic		1	CN2 connecting plug		CN1-CNC
		case
							signal
	(without
		DB-9 male plug and plastic case		1	CN3 connecting plug
	spindle						connecting
		Aluminum-shell braking resistor			Including 1m connecting
	servo						cable is
					line (refer to Appendix C
	motor) and						provided
					for the specification and
	CNC						together
					quantity)
	system
		GS Series Spindle Servo Unit			Technical materials		with CNC
				1
		Manual					system
		DB-9 male plug and plastic case		1	CN3 connecting plug
		Motor encoder line	-00-761A	1	Standard length: 3m		CN1-CNC
	Servo unit,	Motor power line	-00-765*	1	Standard length: 3m		signal
	spindle	Motor fan line	-00-768A	1	Standard length: 3m		connecting
	servo	Aluminum-shell braking resistor			Including 1m connecting		cable is
	motor and				line (refer to Appendix C		provided
	CNC				for the specification and		together
	system				quantity)		with CNC
		GS Series Spindle Servo Unit		1	Technical materials
							system
		Manual

Note 1: A fan with 440V power should be selected to match with GS4000 Series spindle motor.

zGS Series MDR product accessories list

Type	Name	Model	Number	Explanation	Remark
Servo unit,	MDR20 (20pin) plug and plastic case		1	CN3 connecting plug	Servo signal
servo	Motor encoder line	-00-761A	1	Standard length: 3m	line,

18

Chapter I Instruction

motor and	Motor power line	-00-765*	1	Standard length: 3m; “*”	GSK-CNC
CNC				indicates the suffix letters	communicati
system				(see the Motor Power Line	on line and
				Specification)	terminal plug
	Aluminum-shell braking resistor			Including 1m connecting	are provided
				line; see Appendix C for	together with
				specification and quantity	CNC system
	GS Series Spindle Servo Unit Manual		1	Technical materials

Note 2: So far, GSK-CAN serial bus is supported in GSK988T. GS300Y-CP2 Series MDR spindle servo unit is applicable.

1. Make clear the model, quantity of products to be ordered (servo unit, servo motor, isolation transformer and CNC). When you need an exclusive software/hardware version or optional accessories, write it on the order sheet.

2.Make clear the type, specification, quantity of non-standard accessories (such as special cable or cable length, or special cable processing).

3.Make clear the code of shaft-extension, structure or leading-out pattern of servo motor. Write special items on the order sheet.

4.When only servo unit (without servo motor) is ordered, write the model of servo model behind the servo unit mode (for example: GS3050T-NP2 ZJY182-3.7BH ). So that relevant parameters can be set before delivery.

5.The spindle servo unit and servo motor with 3-phase AC440V input power are out of stock. They are produced according to the order.

19

GS Series Spindle Servo Drive Unit User Manual

20