halstrup-walcher PS*3**DN, PSW3**DN, PSS3**DN, PSE3**DN Instruction Manual

Instruction Manual
PSx3xxDN

halstrup-walcher GmbH
Stegener Straße 10

D-79199 Kirchzarten, Germany
Phone: [phone]

Fax: [phone]
E-mail: [e-mail]

Internet: www.halstrup-walcher.com

Document 7100.004144 03/2017

PSx3xxDN Instruction Manual

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Table of Contents

1 Safety precautions ............................................................................................................ 4

1.1 Appropriate use .............................................................................................................. 4

1.2 Shipping, assembly, electrical connections and start-up................................................. 4

1.3 Troubleshooting, maintenance, repairs, disposal............................................................ 4

1.4 Symbols ................................................................................................ ......................... 5

2 Device description ......................................................................................................... 5

2.1 Features ..................................................................................................................... 5

2.2 Installation .................................................................................................................. 5

2.3 Pin assignment........................................................................................................... 6

2.4 Setting the device address and baud rate .................................................................. 7

2.5 Start-up ...................................................................................................................... 9

2.6 CAN Bus .................................................................................................................... 9

3 Sequence of positioning steps ........................................................................................ 26

4 Special features .............................................................................................................. 27

5 Technical data ................................................................................................................. 33

PSx3xxDN Instruction Manual

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Purpose of instruction manual

This instruction manual describes the features of PSx3xxDN positioning systems and
provides guidelines for their use.

Improper use of these devices or failure to follow these instructions may cause injury
or equipment damage. All individuals responsible for operating these devices must
therefore be properly trained and aware of the hazards. The instruction manual, and
in particular the safety precautions contained therein, must be followed carefully.

Contact the manufacturer if you do not understand any part of this instruction
manual.

Handle this manual with care:

 It must be readily available throughout the lifecycle of the devices.
 It must be provided to any individuals who assume responsibility for operating the

device at a later date.

 It must include any supplementary materials provided by the manufacturer.
The manufacturer reserves the right to continue developing this device model without

documenting such development in each individual case. The manufacturer will be
happy to determine whether this manual is up-to-date.

Conformity

This device corresponds to the state of the art and meets all legal requirements set
forth in EC directives as evidenced by the CE label.

© 2010, 2015, 2016, 2017

The manufacturer owns the copyright to this instruction manual. This manual contains
data, instructions and drawings pertaining to the features and usage of these devices;
copying this manual in part or in full or distributing it to third parties is prohibited.

PSx3xxDN Instruction Manual

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1 Safety precautions

1.1 Appropriate use

Positioning systems are especially suitable for automatically setting tools, stops or
spindles for wood-processing equipment, packing lines, printing equipment, filling
units and other types of special machines.

PSx3xxDN positioning systems are not stand-alone devices and may only be
used if coupled to another machine.

Always observe the operating requirements—particularly the permissible supply
voltage—indicated on the rating plate and in the “Technical data” section of this
manual.

The device may only be handled as indicated in this manual. Modifications to the
device are prohibited. The manufacturer is not liable for damages caused by improper
use or failure to follow these instructions. Violations of this type render all warranty
claims null and void.

1.2 Shipping, assembly, electrical connections and start-up

Only technical personnel who are appropriately trained and authorized by the
operator of the facility may assemble the device and set up its electrical connections.

The device may only be operated by appropriately trained individuals who have been
authorized by the operator of the facility.

Specific safety precautions are given in individual sections of this manual.

1.3 Troubleshooting, maintenance, repairs, disposal

The individual responsible for the electrical connections must be notified immediately
if the device is damaged or if errors occur.

This individual must take the device out of service until the error has been corrected
and ensure that it cannot be used unintentionally.

This device requires no maintenance.
Only the manufacturer may perform repairs that require the housing to be opened.
The electronic components of the device contain environmentally hazardous

materials and materials that can be reused. For this reason the device must be
recycled in accordance with the environmental guidelines of the jurisdiction in
question once it has been taken permanently out of service.

PSx3xxDN Instruction Manual

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1.4 Symbols

The symbols given below are used throughout this manual to indicate instances when
improper operation could result in the following hazards:

WARNING! This warns you of a potential hazard that could lead to bodily injury up
to and including death if the corresponding instructions are not followed.

WARNING: This warns you of a potential hazard that could lead to significant

property damage if corresponding instructions are not followed.

INFORMATION: This indicates that the corresponding information is important

for operating the device properly

2 Device description

2.1 Features

The PSx3xxDN positioning system, an intelligent, compact, complete solution for
positioning auxiliary and positioning axes, consists of an EC motor, gear power
amplifier, control electronics, absolute measuring system and DeviceNet interface.
The integrated absolute measuring system eliminates the need for a time-consuming
reference run. Connecting to a bus system simplifies the wiring. A hollow shaft with
adjustable collar makes assembly quite simple. The positioning system is especially
suitable for automatically setting tools, stops or spindles for wood-processing
equipment, packing lines, printing equipment, filling units and other types of special
machines.

PSx3xxDN positioning systems convert a digital positioning signal into an angle of
rotation.

2.2 Installation

Hollow shaft:
The PSx3xxDN is mounted onto the machine by sliding the hollow shaft of the

positioning gear onto the axis to be driven and then securing it with an adjustable
collar (recommended diameter of the axis is either 8h9 or 14h9; wrench torque for
screw: 1.5Nm). The adjustable collar should be tightened only just to the point where
it can no longer rotate freely.
Securing the pin under the hollow shaft into an appropriate bore will prevent further
rotation.\line (see drawing)

PSx3xxDN Instruction Manual

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Solid shaft:
The PSx3xxDN is mounted on the machine by fixing the solid shaft with coupling and

intermediate flange to the axis of the machine.

Never apply force to the housing cover, e.g., for supporting weight.

Driving the PSx3xxDN rearward is prohibited (e.g. it’s not allowed to turn
the output shaft by an external force).

2.3 Pin assignment

For the supply voltage either a Binder series 715 (B-coded) round, 5-pin plug for PSE
and PSS devices or a 5-pin Harting plug with protective sleeve (HAN4A) for the
PSE34xx devices is located in the housing cover of the PSx3xxDN.
A series 713 (A coded) 5-pin round socket and 5-pin plug are provided for connecting
the CAN bus.
A Binder series 718 4-pin plug is used to connect the jog keys (optional).

Connector for supply to motor:

Round plug Harting plug

(external top view)

1 +24V motor
2 GND motor
3 not assigned
4 not assigned
5 housing/air drill

Connector for jog keys:

(external top view)

1 +24V (output)
2 forward key
3 reverse key
4 ground

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Round plug for CAN bus: Round socket for CAN bus:

(external top view) (external top view)

1 shield
2 +24V control module
3 GND
4 CAN_H
5 CAN_L

To prevent the ingression of fluids into the PSW-housing during

cooldown, use a special cable with an airtube for pressure
balancing of your PSW.

Electrical grounding

Next to the connecting plugs there is a M4 stud bolt. It is recommended to connect
the positioning system with a cable as short as possible to the machine base. The
minimum wire cross section therefor is 1.5mm².

2.4 Setting the device address and baud rate

Removing the protective cap provides access to two rotary switches for setting the
device address at the bus and a 2-pin sliding switch for setting the baud rate.

The rotary switches indicate the tens and ones places of the address selected. If the
switches are resting in positions between 64 and 99, the address is set using
DeviceNet (PSE object; class 100, instance 1, attribute 38; starting from software
version 147).
The delivery setting is 99, the PSx3xxDN reports to the bus with the address 63.

If the switches have been used to set the address (i.e. the switch setting is < 64), this
value cannot be changed via DeviceNet.

The yellow LED represents the state of the motor supply voltage, the red and green
LEDs represent the DeviceNet state.

PSx3xxDN Instruction Manual

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Switch configurations:

PSx30xDN, PSx31xDN-8,

PSx32xDN, PSE31xxDN

PSx31xDN-14, PSx33xDN

PSE 34xxDN

Setting the baud rate:
Up to firmware version 210:

1

2

PSx30xDN, PSx31xDN-8,
PSx32xDN, PSx31xxDN,

PSx31xDN-14, PSx33xDN,
PSx34xxDN,

OFF

OFF

125 kBaud

OFF

ON

500 kBaud

250 kBaud

ON

OFF

250 kBaud

500 kBaud

ON

ON

baud rate is set via bus (default = 125 kBaud)

For firmware version 211 and higher

1

2

PSx30xDN, PSx31xDN,
PSx31xxDN, PSx32xDN,
PSx33xDN

PSx34xxDN,

OFF

OFF

125 kBaud

OFF

ON

500 kBaud

250 kBaud

ON

OFF

250 kBaud

500 kBaud

ON

ON

baud rate is set via bus (default = 125 kBaud)

If the device names are given without the diameter of the output shaft (-8, -

14), the relevant information is valid for all offered output shafts (applies
throughout the document).

‘x’ in the device name stands for a number in the range 0..9. ‘xx’ in the

device name stands for a number in the range 10..999.

Important: Always replace the protective cap after setting the address.
This will prevent dust and contaminants from entering the device.

In some stainless steel variants the protective cap is not present. In this
case, device address and baud rate can only be set via bus.

PSx3xxDN Instruction Manual

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2.5 Start-up

Positioning sequence (with reference loop)
The PSx3xxDN distinguishes between the following steps of a positioning sequence

(Presumption: the target position is always approached through forward motion):

1. New position value is larger than the current value: position approached directly.

2. New position value is smaller than the current value: the device reverses an

additional 5/8 of one rotation and approaches the exact position after resuming
forward motion.

3. New position value after reverse run without loop: the device always approaches

the position by moving in forward direction; if necessary, it will first reverse by 5/8
of a rotation.

Once the target position has been reached, the device compares it to the internal
absolute encoder status. If a discrepancy is detected, the device then sets the “error”
bit (bit 9 in the status word).

Positioning sequence (without loop)

The “positioning without loop” mode is used primarily for moving the small distances

involved in fine adjustments. In this case, each position is approached directly. This
does NOT eliminate any play present in the spindle in question. The PSx3xxDN
internal gear backlash does not play a role in this case, as position data are acquired
directly at the output shaft.

Runs which involve specifically a block run (e.g. reference runs on block),
may only be started with reduced torque (max. torque max. 10% of the
nominal torque).

2.6 CAN Bus

A DeviceNet protocol corresponding to ODVA CIP Networks Library Volume One
Edition 3.1 and Volume Three Edition 1.3 is the protocol used for the CAN bus
interface:

 A group 2 server with UCMM support
 2 explicit connections to the master
 4 fixed mapping assemblies
 I/O messages via poll, bit strobe and change-of-state/cyclic
 Multicast poll is not supported
 Heartbeat, default = inactive
 DeviceNet LED that displays status as follows:

 off:

either the device is switched off or no CAN bus is connected

 green, steady:

CAN communication OK, device operational

 green, flashing:

either no UCMM connection to the master or no learning run has been
performed

PSx3xxDN Instruction Manual

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 red, flashing:

relatively minor error, at least one I/O connection has timed out

 red, steady:

major error, e.g., bus conflict with another station

 red-green, flashing:

communication error

a) Table of implemented attribute entries

The following attributes are part of the PSE object (class ID 100), 1st instance:

Description

Attr.
No.

Function

Range of
value

Back
up

Delivery
State

R/W

target value

1

target position to be achieved
value in 1/100 mm (for default settings of
numerator, Attr. 16 and denominator, Attr.

17)

31 bit

no 0 R/W

actual value

3

current actual position
value in 1/100 mm (for default settings of
numerator, Attr. 16 and denominator, Attr.

17)
Writing onto this index number causes the
current position to be "referenced" onto
the transferred value

31 bit

no R/W

reference
value

4

correction factor for the target, actual and
limit switch values

31 bit

yes 0 R/W

drag error

5

maximum drag error before the “drag
error" bit is set.
Value given in increments (at a resolution
of 0.5 mm)

20...1000
16 bit

yes

40

R/W

positioning
window

6

permissible difference between target and
actual values for “position reached” bit
The maximum value that can be set
changes according to the same factor as
the resolution

1...100
16 bit

yes 2 R/W
actual value

assessment,
numerator

16

These values can be used to set a
desired user resolution to the drive.
For a numerator factor of 400, the
denominator factor holds the spindle pitch
per resolution
e.g.: spindle pitch 1.5 mm with resolution
1/100 mm:
numerator = 400, denominator = 150

1...10000
16 bit

yes

400

R/W

actual value
assessment,
denominator

17

1...10000
16 bit

yes

400

R/W
target rpm

posi

18

value in rpm
maximum rpm to be used for positioning
runs

see table
16 bit

yes

see table

R/W
target rpm
hand

19

value in rpm
maximum rpm to be used for manual runs

see table
16 bit

yes

see table

R/W

maximum
torque

20

Applies after completion of start phase
(during start phase the value of Attr. 24
applies); value in cNm

see table
16 bit

yes

see table

R/W

upper limit

22

maximum permitted target position
permissible values: (-252...+509)*spindle
pitch + reference value

31 bit

yes

101200

R/W

PSx3xxDN Instruction Manual

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Name

Attr.
No.

Function

Range of
value

Back
up

Delivery
State

R/W

lower limit

23

minimum permissible target position
permissible values: upper limit -

0...250*spindle pitch + reference value

31 bit

yes

1200

R/W

maximum
start-up
torque

24

value in cNm

see table
16 bit

yes

see
table

R/W

time period
for start-up
torque

25

value in msec

10...1000
16 bit

yes

200

R/W

rpm limit for
aborting run

26

value in % of the target rpm

30...90
16 bit

yes

60

(PSx3110
and
PSx3125)

30

(all others)

R/W

time elapsed
until speed
falls below
rpm limit for
aborting run

27

value in msec

50...500
16 bit

yes

200

R/W
length of loop

31

minimum number of increments which the
drive moves in a pre-defined direction
when approaching a target position
value in increments (value = 0  no loop)

0.025…1

rotations
or 0
32 bit

yes

250

R/W
maximum
rpm, counter­clockwise

32

value in rpm

see table
16 bit

yes

see
table

R/W

maximum
rpm,
clockwise

33

value in rpm

see table
16 bit

yes

see
table

R/W

size of
individual
increment

34

number of increments when external keys
pressed (or when activating a jog run bit)
for a short-time

1...100
16 bit

yes 1 R/W

idle period for
manual run

35

Span of time a manual run key must be
pressed (or a jog run bit must be
activated) in order to begin a manual run
value in steps of 5 msec

20...2000
16 bit

yes

200

R/W