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

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Instruction Manual PSx3xxPL
1
Instruction Manual PSx3xxPL
D-79199 Kirchzarten
Tel.: +49 (0) 76 61/39 63-0 Fax: +49 (0) 76 61/39 63-99
E-Mail: info@halstrup-walcher.com Internet: www.halstrup-walcher.com
Document 7100.005424 07/2017
Instruction Manual PSx3xxPL
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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 ................................................................................................. 7
2.5 LEDs .................................................................................................................................. 7
2.6 Start-up .............................................................................................................................. 8
2.7 Powerlink interface ............................................................................................................. 9
3 Specials ................................................................................................................................. 22
4 Technical Data ....................................................................................................................... 31
Instruction Manual PSx3xxPL
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Purpose of instruction manual
This instruction manual describes the features of the PSx3xxPL positioning system and provides guidelines for its use.
Improper use of these devices or failure to follow these instructions may cause injury or equipment damage. Every person who uses the devices must therefore read the manual and understand the possible risks. 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 is state of the art. It complies with the legal requirements of EC directives. This is shown by the CE mark.
© 2015, 2016, 2017
The manufacturer owns the copyright to this instruction manual. It contains technical data, instructions and drawings detailing the devices’ features and how to use them. It must not be copied either wholly or in part or made available to third parties.
Instruction Manual PSx3xxPL
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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.
PSx3xxPL 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
Assembly and the electrical connections should only be handled by professionals. They should be given proper training and be authorised by the operator of the facility.
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. The device must therefore be sent to a recycling plant when you no longer wish to use it. The environment codes of your particular country must be complied with.
Instruction Manual PSx3xxPL
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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.
CAUTION! 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 PSx3xxPL 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 EtherCAT 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.
PSx3xxPL positioning systems convert a digital positioning signal into an angle of rotation.
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.
2.2 Installation
Hollow shaft: The PSx3xxPL 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 axis diameter 8h9 resp. 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 (if required, consider drawing on the website).
Instruction Manual PSx3xxPL
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Solid shaft: The PSx3xxPL 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 PSx3xxPL 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 713/763 (A-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 PSx3xxPL. Two round 4-pin sockets, Binder series 825 (D-coded) are provided for connection to the bus.
Supply voltage connector::
Round socket for bus:
Round plugr
Harting plug
(extrenal top view)
(extrenal top view)
(extrenal top view)
1 +24V motor 2 GND motor 3 +24V control unit 4 GND control unit 5 housing/pressure balance
1 TD+ (WH/GN, white/green) 2 RD+ (WH/OG, white/orange) 3 TD- (GN, green) 4 RD (OG, orange)
Due to the use of 4-pin sockets, only four-wire cables should be used.
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.
Instruction Manual PSx3xxPL
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2.4 Setting the device address
Removing the protective cap provides access to two rotary switches for setting the device address at the bus.
The rotary switches indicate the tens and ones places of the address selected. The delivery setting is 00, e.g. before the first start-up a valid address has to be
set.
2.5 LEDs
The following LEDs are located under the transparent sealing plug:
P1/P2: green Link/Act LEDs for ports 1 and 2 BS/BE: Powerlink STATUS and ERROR LEDs (green/red; see Powerlink spec.) V_Motor: The LED is illuminated yellow when power is available to the motor.
Switch configurations: PSx30xPL, PSx31xPL-8, PSx31xPL-14, PSx33xPL
PSx32xPL, PSE31xxPL, PSE34xxPL
Meaning of the LEDs:
1) Each of the ports (P1/P2) has an associated green LED for the “Link” and the “Activity” state.
For each port the following states are possible:
- Off no connection
- On connection; data transmission inactive
- Flickering with 10 Hz connection; data transmission active
2) The green Powerlink LED “Bus Status” (BS) signalizes the CN cycle state.
- Off NOT_ACTIVE
- Flickering with 10 Hz BASIC_ETHERNET
Instruction Manual PSx3xxPL
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- Single flashing with 0.8 Hz PRE-OPERATIONAL_1
- Double flashing with 0.6 Hz PRE-OPERATIONAL_2
- Triple flashing with 0.5 Hz READY_TO_OPERATE
- Flashing with 2.5Hz STOPPED
- On OPERATIONAL
3) The red Powerlink LED “Bus Error” (BE) signalizes an error:
- Off no error
- On error
4) The yellow LED “Motor” indicates the supply voltage for the motor:
- Off supply voltage for motor too low or too high
- On supply voltage for motor ok
2.6 Start-up
After the supply voltage has been hooked up, a positioning or manual run can begin immediately:
a) Positioning run
- To be able to control the drive with the help of PDOs, it has to be switched to the CN cycle state “operational”.
- Transfer target value:
- PDO with control word = 0x14 and desired target value OR
- PDO with control word = 0x10 and target value in SDO #2001 Drive begins run
- Abort run by resetting the release bit:
- PDO with control word = 0x00 OR
- SDO #2024 with value 0x00 (if pre-operational)
- If a new target value is transferred during a positioning run, the device will immediately proceed to the new target. There will be no interruption if the direction of rotation does not need to be altered.
- If a manual run is transmitted during a positioning run, the positioning run will be aborted (speed will be reduced to that of a manual run) and the device proceeds with the manual run.
The following sequence of steps is also possible: Starting situation: release has not been set
- Transfer target value:
- PDO with control word = 0x04 and desired target value OR
- PDO with control word = 0x00 and target value in SDO #2001
- Set release:
- PDO with control word = 0x10 OR
- SDO #2024 with value 0x10 (if pre-operational) Drive begins run
Instruction Manual PSx3xxPL
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Where applicable, positioning runs involve a “loop run” which causes the target position to be reached from a predefined direction. The direction and the length of the loop run can be set to the desired value with SDO #201F (“length of loop”) before the run. With SDO #201F the loop run might also be disabled.
Setting of control word and target value with the help of SDOs is only possible in the CN cycle state “pre-operational”.
b) Manual run
- Start manual run (transmit PDO with control word = 0x11 resp. 0x12 or, if pre­operational, transmit SDO #2024 with value 0x11 resp. 0x12): device begins to run
- End manual run by clearing the manual run command (transmit PDO with control word = 0x10 or, if pre-operational, transmit SDO #2024 with value 0x10) or by deasserting release (transmit PDO with control word = 0x00 or, if pre-operational, transmit SDO #2024 with value 0x00).
- Transferring a target value during a manual run will end the manual run and the device will immediately move on to the transmitted position (PDO with control word = 0x14 and desired target value). If pre-operational, target value in SDO #2001. The drive then automatically deasserts the manual run bits in the control word (bits 0 and
1).
Underwater usage of the PSW is not allowed.
2.7 Powerlink interface
The Powerlink interface is realized according the EPSG standard 301, version 1.2.0:
One send and receive SDO per device One asynchron send and receive PDO, active by default
Instruction Manual PSx3xxPL
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a) Table of entries implemented from object dictionary
Name
Index number
Function
Range of value
Back up
Delivery State
R/W Device Type
1000
returns a “0” when read
32 bit
0 R
Error Register
1001
Error register according CiA DS 301
8 bit
R
Error History
1003
Sub-Index 0: quantitiy of current entrys sub 1 … 254: error entrys (latest entry in sub 1)
8 bit 160 bit
no 0 R/W R
Manufacturer Software Version
100A
denotes the software of the Powerlink drives; when being read the string “PSx3xxIE/PL” is given back
R
Identity
1018
sub index 0: quantity of indexes (= 4) sub 1: Vendor-ID (= 0x000002D8) sub 2: Product code sub 3: Revision number (= 0x00010000) sub 4: Serial number
8 bit 32 bit 32 bit 32 bit 32 bit
4 R R R R R
Receive PDO 1 communi­cation parameter
1400
sub index 0: quantity of indexes (= 2) sub 1: Node ID (= 0)
sub 2: Mapping Version (= 0)
8 bit
0...0 8 bit 8 bit
no
R R/W
R
Receive PDO 1 mapping
1600
sub index 0: quantity of indexes (= 2) sub 1: 0x0010000000002024
sub 2: 0x0020001000002001
2...2 8 bit 64 bit 64 bit
no
2 R/W R
R
Transmit PDO 1 communi­cation parameter
1800
sub index 0: quantity of indexes (= 2) sub 1: Node ID (= 0)
sub 2: Mapping Version (= 0)
8 bit
0...0 8 bit 8 bit
no
R R/W
R
Transmit PDO 1 mapping
1A00
sub index 0: quantity of indexes (= 3) sub 1: 0x0010000000002025
sub 2: 0x0010001000002030 sub 3: 0x0020002000002003
3...3 8 bit 64 bit 64 bit 64 bit
no 3 R/W R
R R
Instruction Manual PSx3xxPL
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Name
Index number
Function
Range of value
Back up
Delivery State
R/W
general purpose register
2000
0...10
10 general purpose registers sub index 0: quantity of indexes (= 10) sub 1..10: general purpose registers
8 bit 32 bit
yes
10 0
R R/W
target value
2001
target position to be achieved value in 1/100 mm (for a 4mm spindle and default settings of numerator, #2010 and denominator, #2011)
31 bit
no 0 R/W
actual value
2003
current actual position value in 1/100 mm (for a 4mm spindle and default settings of numerator #2010 and denominator #2011) Writing onto this index number causes the current position to be “referenced” onto the transferred value. Changes only possible when at standstill
31 bit
no R/W
referencing value
2004
correction factor for the target, actual and limit switch values Changes only possible when at standstill
31 bit
yes 0 R/W
drag error
2005
maximum drag error before the ‘drag error’ bit is set. value in 1/100 mm (for a 4mm spindle and default settings of numerator and denominator)
0...1000 16 bit
yes 0 R/W
positioning window
2006
permissible difference between target and actual values for “position reached” bit value in 1/100 mm (for a 4mm spindle and default settings of numerator and denominator) The maximum value that can be set changes according to the same factor as the resolution. Changes only possible when at standstill
1...100 16 bit
yes 2 R/W
position scaling, numerator
2010
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 Changes only possible when at standstill
1...10000 16 bit
yes
400
R/W
position scaling, denominator
2011
1...10000 16 bit
yes
400
R/W
target rpm posi
2012
value in rpm maximum rpm to be used for positioning runs
see table 16 bit
yes
see table
R/W target rpm hand
2013
value in rpm maximum rpm to be used for manual runs
see table 16 bit
yes
see table
R/W
maximum torque
2014
Applies after completion of start phase (during start phase the value #2018 applies); value in cNm
see table 16 bit
yes
see table
R/W
Instruction Manual PSx3xxPL
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Name
Index number
Function
Range of value
Back up
Delivery State
R/W
upper limit
2016
maximum permitted target position minimum value: upper mapping end - 253 revolutions maximum value: upper mapping end - 3 revolutions Changes only possible when at standstill
31 bit
yes
101200
R/W
lower limit
2017
minimum permitted target position minimum value: upper mapping end - 253 revolutions maximum value: upper mapping end - 3 revolutions Changes only possible when at standstill
31 bit
yes
1200
R/W
maximum start-up torque
2018
value in cNm
see table 16 bit
yes
see table
R/W
time period for start-up torque
2019
Time period at the beginning of a move in which the maximum start-up torque applies value in msec
10...1000 16 bit
yes
200
R/W rpm limit for
aborting run
201A
value in % of the target rpm
30...90 16 bit
yes
30
R/W
time elapsed until speed falls below rpm limit for aborting run
201B
value in msec
50...500 16 bit
yes
200
R/W
acceleration
201C
value in rpm per sec.
see table 16 bit
yes
see table
R/W
deceleration
201D
value in rpm per sec.
see table 16 bit
yes
see table
R/W
length of loop
201F
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) Changes only possible when at standstill
-1…1 rotation 31 bit
yes
-250
R/W
control word
2024
Bit 0: manual run to larger values Bit 1: manual run to smaller values Bit 2: transfer target value (When sending the target values with the help of PDOs, positioning will only take place if this bit is set.) Bit 4: release: The axle will only run if this bit is set. All other bits must be set to 0!
16 bit
no 0 R/W
Instruction Manual PSx3xxPL
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Name
Index number
Function
Range of value
Back up
Delivery State
R/W
status word
2025
Bit 0: target position reached Bit 1: drag error Bit 2: reserved Bit 3: reserved Bit 4: motor power present Bit 5: positioning run aborted Bit 6: drive is running Bit 7: temperature exceeded Bit 8: movement opposite loop direction Bit 9: error Bit 10: positioning error (block) Bit 11: manual displacement Bit 12: incorrect target value Bit 13: motor power was missing Bit 14: positive range limit Bit 15: negative range limit
0..FFFFh 16 bit
R
upper mapping end
2028
definition of the positioning range relative to the absolute measuring system permissible values: (actual position value + 3 revolutions … (actual position value + 253 revolutions) Changes only possible when at standstill
31 bit
yes
102400
R/W
maximum holding torque
202B
maximum holding torque at standstill in cNm
see table 16 bit
yes
see table
R/W
direction of rotation
202C
0: clockwise with larger values (if looking at the output shaft) 1: counter clockwise with larger values Changes only possible when at standstill
0 oder 1 16 bit
yes 0 R/W idle period
202E
idle period in msec when reversing the direction of rotation
10... 10000 16 bit
yes
10
R/W actual rpm
2030
value in rpm
15 bit
R
maximum torque
2031
maximum torque occurring during the most recent run (start phase, during which the maximum start-up torque applies, see SDOs #2018/2019, and the phase when the drive is braking down, are not considered) value in cNm
16 bit
R
actual torque
2033
value in cNm
16 bit
R
U control
203A
current supply voltage for control unit given in increments of 0.1 V
16 bit
R
U motor
203B
current supply voltage for motor given in increments of 0.1 V
16 bit
R
Instruction Manual PSx3xxPL
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Name
Index number
Function
Range of value
Back up
Delivery State
R/W
Umot limit
203C
voltage limit for bit 4 (‘motor power present’); given in increments of 0.1 V
Beginning a positioning run or a manual run is only possible if the supply voltage for the motor is higher than the value of this SDO. During the run the voltage might fall down to 17.5V.
180… 240 16 bit
yes
185
R/W
Umot filter
203D
average time for measuring motor supply voltage; value in msec
100… 1000 16 bit
yes
100
R/W temperature limit
203E
upper temperature limit in °C
10...70 16 bit
yes
70
R/W
device temperature
203F
internal device temperature in °C
16 bit
R
production date
2040
year and week of manufacturing (given as an integer)
YYWW 16 bit
R
serial number
2041
serial device number
0… 65535 16 bit
R
maximum holding torque at end of run
2042
value in cNm
see table 16 bit
yes
see table
R/W
duration of maximum holding torque at end of run
2043
time period at end of run, in which the
‘maximum holding torque at end of run’
applies (value in msec)
0… 1000 16 bit
yes
200
R/W waiting time
for brake (end of run)
2045
time period after the end of run, in which the brake stays released (value in msec)
0...3000 16 bit
yes
1000
R/W
drag error correction
2046
maximum modification of the target speed for drag error correction Changes only possible when at standstill
0…10 16 bit
yes 4 R/W readjustment
2047
readjustment at standstill 0  Off; 1  On
0…1 8 bit
yes 0 R/W
Instruction Manual PSx3xxPL
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Name
Index number
Function
Range of value
Back up
Delivery State
R/W
configuration for connection timeout
2049
Bits 1-0: configuration for connection timeout (if a connection has been established and lost) 0x00: continue moving (drive will continue moving to the actual target position) 0x01: drive will abort any positioning 0x02: drive will move to a save position which is defined by SDO #204A 0x03: reserved Bits 3-2: configuration of save position run when no connection is being established after a certain time at power-up 0x00: no save position run at power-up 0x01: save position run after 15 sec 0x02: save position run after 30 sec 0x03: save position run after 60 sec
16 bit
yes 1 R/W
save position for connection timeout
204A
drive will move to this position if
- a connection loss to the master has been detected and bits 1-0 of SDO #2049 are set to 0x02
- no connection is being established after a certain time at power-up and bits 3-2 of SDO #2049 are being set appropriate
31 bit
yes 0 R/W repetition time for save position run
204B
drive will start another save position run if the last save position run was not successful (e.g. because of undervoltage, positioning error (block) or overtemperature) value in sec; 0 no repetition
16 bit
yes 0 R/W
device model
204D
device model within the PSx drive series as string (e.g. “PSE312-8-PL-0-0”)
R version
204E
software version number
16 bit
R
Instruction Manual PSx3xxPL
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Name
Index number
Function
Range of value
Back up
Delivery State
R/W
delivery state
204F
writing “-2”: sets the values of all parameters to the values which are saved last by the user, without saving the parameters in the EEPROM writing “-1”: sets the values of all parameters to the delivery state, without saving the parameters in the EEPROM writing “1”: saves all parameters in the EEPROM reading directly after boot: 0  content of memory correct ≠ 0  content of memory incorrect reading after saving: 0  saving finished successfully 0 saving is still in progress or is finished incorrectly (the time for saving is up to 200 msec) Changes only possible when at standstill
-2, -1 oder 1
(writing)
0..2
(reading)
15 bit
no R/W
Instruction Manual PSx3xxPL
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Table of rated speed and torque values for various models of gears
device model PSE and PSS
301-x 311-x
302-x 312-x
305-x 315-8
322 332
325 335
328-14
Name
Index number
Range of value
Delivery State
target rpm posi
2012
15...230 230
10...150 150
3...70 70
20...200 170
10...100
85
5…45
45
target rpm hand
2013
15...230
80
10...150
50
3...70 20
20...200 80
10...100 40
5…45
22
acceleration
201C
97...600
600
50...400
400
23...130
130
97...525
525
50...260
260
22…100
100
deceleration
201D
97...600
600
50...400
400
23...130
130
97...525
525
50...260
260
22…100
100
maximum torque
2014
2...125 100
10...250 200
50...600 500
10...250 200
20...500 400
80...960 800
maximum start­up torque
2018
2...125 125
10...250 250
50...600 600
10...250 250
20...500 500
80...960 960
maximum holding torque
202B
0...90 30
0...150 50
0...300
100
0...100 35
0...200 70
0...450
150
maximum holding torque at end of run
2042
0...180 60
0...300
100
0...600
200
0...200 70
0...400
140
0...700
300
device model PSW
301-x 311-x
302-x 312-x
305-x 315-8
322-14 332-14
325-14 335-14
328-14
Name
Index number
Range of value
Delivery State
target rpm posi
2012
15...180 180
10...125 125
3...60 60
20...150 125
10...80 60
5…35
35
target rpm hand
2013
15...180 80
10...125 50
3...60 20
20...150 80
10...80 40
5…35
22
acceleration
201C
97...600 600
50...400 400
23...130 130
97...525 525
50...260 260
22…100
100
deceleration
201D
97...600 600
50...400 400
23...130 130
97...525 525
50...260 260
22…100
100
maximum torque
2014
2...125 100
10...250 200
50...600 500
10...250 200
20...500 400
80...960 800
maximum start­up torque
2018
2...125 125
10...250 250
50...600 600
10...250 250
20...500 500
80...960 960
maximum holding torque
202B
0...90 30
0...150 50
0...300
100
0...100 35
0...200 70
0...450
150
maximum holding torque at end of run
2042
0...180 60
0...300
100
0...600
200
0...200 70
0...400
140
0...700
300
Instruction Manual PSx3xxPL
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device model PSE
3110
3125
3210-x 3310-x
3218
Name
Index number
Range of value
Delivery State
target rpm posi
2012
1…30
30
1…12
12
5...45 38
3...30 28
target rpm hand
2013
1…30
12
1…12
5
5...45 15
3...30 10
acceleration
201C
9…50
50
4…20
20
20...117 117
11...70 70
deceleration
201D
9…50
50
4…20
20
20...117 117
11...70 70
maximum torque
2014
100...1200 1000
250...3000
2500
100...1200
1200
180...2200
2200
maximum start-up torque
2018
100...1200 1200
250...3000
3000
100...1200
1000
180...2200
1800
maximum holding torque
202B
0...600 200
0...1250 450
0...1000 350
0...1800 600
maximum holding torque at end of run
2042
0...1200 400
0...2500 900
0...500 175
0...900 300
device model PSE
3325
3410
3418
Name
Index number
Range of value
Delivery State
target rpm posi
2012
2...18 15
10...100 100
10...90 90
target rpm hand
2013
2...18 6
10...100 40
10...90 30
acceleration
201C
8...45 45
20...350 350
10...315 315
deceleration
201D
8...45 45
20...350 350
10...315 315
maximum torque
2014
250...3000 3000
100...1200
1000
500...2000 1800
maximum start-up torque
2018
250...3000 2500
100...1200
1200
500...2000 2000
maximum holding torque
202B
0...2500 900
0...300 200
0...450 300
maximum holding torque at end of run
2042
0...1250 450
0...600 400
0...900 600
Instruction Manual PSx3xxPL
19
b) PDO definition
1) Receive PDO (from the perspective of the PSx3xxPL) Assignment (cannot be modified):
Bit
Byte
Description
corresponding SDO index number
0-15
0,1
control word
2024h
16-47
2-5
target value
2001h
2) Transmit PDO (from the perspective of the PSx3xxPL) Assignment (cannot be modified):
Bit
Byte
Description
corresponding SDO index number
0-15
0,1
status
2025h
16-31
2,3
current rpm
2030h
32-63
4-7
actual value
2003h
c) Detailed description of the status bits
Bit 0: target position reached This bit is set:
- when a transferred target position has been reached successfully (not at the end of a manual run, elsewise the target position is the same as the applicable limit switch)
- after manual displacement while at standstill, when the actual position is within the positioning window again
This bit is reset:
- after transferring a target position if the difference from the actual value is larger than the positioning window (SDO #2006)
- by a manual run
- if an invalid target value has been transferred
- if rotated manually when on standstill
Bit 1: drag error This bit is set:
- if during a run (except in the braking phase) the difference between actual target position and actual position exceeds the value which has been set with SDO #2005
This bit is reset:
- with each new run command
Bit 2: reserved Bit 3: reserved Bit 4: motor power present
This bit is set:
- if the supply voltage to the motor is above the Umot limit (SDO #203C) and below 30V
This bit is reset:
- if the supply voltage to the motor is below the Umot limit or above 30V
Instruction Manual PSx3xxPL
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Bit 5: positioning run aborted This bit is set:
- if a positioning run is aborted because release in the control word has been withdrawn or because of an invalid bit combination in the control word
This bit is reset:
- with each new run command
Bit 6: drive is running This bit is set:
- when the drive is rotating
This bit is reset:
- when the drive is on standstill
Bit 7: temperature exceeded This bit is set:
- if the internal device temperature device exceeds the limit value (SDO #203E)
This bit is reset:
- if the internal device temperature falls below the limit value by 5°C
Bit 8: movement opposite loop direction This bit is set:
- after power-up or a reset (a lash in a driven spindle which might be present is not yet eliminated)
- when commanding a positioning run or a manual run in opposite of the loop direction
- when commanding a positioning run or a manual run, when no loop is configured (SDO #201F is zero)
This bit is reset:
- when a transferred target position has been reached successfully in the loop direction (not after a manual run)
Bit 9: error This bit is set:
- if an internal problem is detected when calculating a position No run commands can be executed when the error bit is set!
This bit is reset:
- only possible by resetting or power-cycle the drive
Bit 10: positioning error (block) This bit is set:
- if a positioning run or a manual run is aborted because the device is overloaded (block, extreme difficulty while running)
This bit is reset:
- with each new run command
Bit 11: manual displacement This bit is set:
- if, while on standstill, the drive is turned externally by more than the value in the positioning window after a positioning run has been finished correctly
This bit is reset:
- with each new run command
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Bit 12: incorrect target value This bit is set:
- when a transferred target value lies outside of the limit switches; also caused, for instance, because of the actual value of the reference value (SDO #2004)
- when a transferred target value lies inside of the limit switches; but because of a necessary loop run the specified interval would be left
This bit is reset:
- with each new run command
Bit 13: motor power was missing This bit is set:
- if the power to the motor is less than the Umot limit (SDO #203C) or above 30V when initiating a positioning run or amanual run
- if during the run the voltage leaves the given corridor
This bit is reset:
- if the power to the motor is above the Umot limit and below 30V when initiating a positioning run or a manual run
Bit 14 / 15: positive / negative range limit This bit is set:
- if the limit value is reached during a manual run (but not if reached during a positioning run)
- if a limit value is modified such that the current position lies beyond the limit
- if, while on standstill, by means of an external force the drive is moved to a position which is outside the area which is defined by the range limits
This bit is reset:
- as soon as the actual position is again inside the range limits (Exception: After the end of a manual run the drive is located still at the range limit within the positioning window and no new run command was issued yet.)
d) Detailed description of control bits
Bit 0: manual run to larger values Bit 1: manual run to smaller values Bit 2: transfer target value
When transferring target values with the help of PDOs, the target value in the PDO will be taken over if this bit is set. A positioning run which starts simultanously or later uses this target value as new target position. If together with taking over the target value the positioning run shall start immediately, bit 4 (‘release’) has to be set additionally.
If bit 2 is not set, the target value of the PDO will not be taken over, instead there might be commanded positioning runs with the help of SDOs (also in the
state “operational”). In the state “pre-operational” the bit is without meaning.
Bit 3: reserved, must be programmed to 0
Instruction Manual PSx3xxPL
22
Bit 4: Release:
Run commands will only be executed if this bit is set. This bit must be set for positioning runs and manual runs. If this bit is cleared during a run, the run will be aborted and status bit 5 will be set (‘positioning run aborted’).
Bits 5-15: reserved, must be programmed to 0
3 Specials
a) Speed, acceleration and deceleration
Manual runs are performed at the maximum speed specified in SDO #2013; positioning runs are performed at the maximum speed specified in SDO #2012. For all runs the maximum acceleration in SDO #201C and the maximum deceleration in SDO #201D apply. At the end of each run the maximum deceleration decreases during the approach to the destination successively in order to realize a harmonic transient behaviour.
A stop command causes the drive to brake with the maximum deceleration, independently of the setting in SDO #201D.
b) Response of drive in case of block
If during a run due to load the speed falls below the threshold parameter of 30% of the selected maximum speed (SDO #201A) for longer than 200 msec (SDO #201B),
the device detects blocking, aborts the run and sets the ‘positioning error’ bit (here the
default values are given). The drive from now on stands with the selected holding torque (SDO #202B).
New run commands can then be transmitted with no further steps to take, i.e. transmitting a target value (SDO #2001) starts a new run.
An exception is in the case of PDO transfers, if the run should go to the same target than before. In this case, deassert the release (bit 4 of the control word) and assert it
again. Bit 2 (‘transfer target value’) has to be set at the same time. The drive then
moves on when the release bit is being asserted again. In the state “pre-operational” deasserting and asserting the release bit does not cause
a new run. The (old or new) target value has to be sent explicitely by setting SDO #2001.
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, resp. the lowest possible value).
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c) Response of drive in case of manual displacement (readjustment)
If after a correctly finished positioning run (or a manual run to the range limit) during standstill the PSx3xxPN is displaced by external force opposite to the loop direction and the release bit (bit 4 in the control word) is set and the readjustment function (SDO #2047) is enabled, the device will attempt to reach the previously transmitted target value once again (readjustment). The device does not attempt to readjust if
rotated in the loop direction; it merely sets bit 11 in the status word (“manual displacement”) and resets bit 0 (“target position reached”). If the loop run is disabled
(SDO #201F is 0), the drive readjusts the position in both directions.
If at standstill the drive continuously looses its position, the attempt to readjust starts exactly when the actual position is leaving the positioning window (assumed that all the conditions above are being fulfilled). The motor power has to be in a valid range at the time when this transition happens (e.g. bit 4 in the status word is being set). If the motor power is improper at that time, the readjustment fails and bits 10 (“positioning error”)
and 13 (“motor power was missing”) will become active. If later the motor
power comes back again (after leaving the positioning window), there will be no further attempt to readjust. This is to prevent a situation that suddenly a drive begins to run if motor power is being switched on.
If an ongoing positioning run or manual run is aborted (release bit in the control word to 0), the drive readjusts the position not before a new run is being sent and finished successfully.
Deasserting the release bit and/or disabling the readjustment function can completely disable the readjustment process.
Drives with a brake generally don’t have a readjustment function.
d) Positioning sequence with loop
The length of loop (SDO #201F) has the effect of ensuring that a target value is always approached from the same direction. This allows, for example, to eliminate the lash in a driven spindle. The diagram below illustrates the function of the length of loop:
If the target value is above the current position (actual value 1) and the length of loop is > 0, the drive runs past the target value by the specified length of loop (run 1a) and then runs to the target value (run 1b). If the target value is below the current position and the actual value (actual value 2) is outside the length of loop, the drive approaches the target value directly (run 2). If the position always should be approached from the left, the length of loop must be <
0.
Instruction Manual PSx3xxPL
24
Hence the PSx3xxPL differs between the following steps of a positioning sequence (Presumption: the target position is always approached through backward motion, i.e. the length of loop is > 0, which corresponds to the drawing above):
1. New position value is larger than the current value: The device overruns the target position by 5/8 of one rotation, then approaches the exact position in backward motion.
2. New position value is smaller than the current value: The position will be approached directly.
3. New position value is smaller than the current value, but before there was a forward run without loop (e.g. a manual run): Because the loop length is > 0, the device by all means approaches the position by moving in backward direction. The distance in backward direction is at least the length of loop. To achieve this, the device first will run in forward direction, if necessary (i.e. in opposite to the actually desired direction). The maximum length of this run is the length of loop.
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).
In delivery state the length of loop is < 0, i.e. each target position is approached in forward direction.
It is not possible to perform a positioning run to the upper limit (SDO #2016) with a length of loop > 0 because the drive would have to run past the upper limit in order to do so. The same applies to the lower limit (SDO #2017) with a length of loop < 0.
e) 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 PSx3xxPL internal gear backlash does not play a role in this case, as position data are acquired directly at the output shaft.
f) Calculating the absolute physical position
The PSx3xxPL actuator includes an absolute measuring system with measurement range of 256 rotations. In order to avoid an overflow when the drive is switched off and moved by an external force, the user can only command positionings in the range of 250 rotations. Thus the upper as well as the lower 3 rotations of the measurement range are inaccessible. The mapping of the desired positioning range to the physical positioning range is done with the help of the parameter ‘upper mapping end’ (SDO #2028). In the delivery state, the drive is at position 51200, the upper limit switch is set to 101200 and the lower limit switch is set to 1200, yielding a positioning range of ±125
rotations (±50000 increments). So if the desired positioning range doesn’t exceed
±125 rotations, in delivery state none of the following actions to adjust the positioning range have to be taken.
Instruction Manual PSx3xxPL
25
For the realization of any desired positioning range independent of the possible positioning range which is defined by the mounting situation (physical positioning range) there are the following two possibilities:
1) Move the axle (for example a spindle) to the desired position, then move the drive
(with opened collar) to the position value which belongs to the physical position of the axle, only then close the collar. Examples: a) Move the axle in middle position, then move the drive at no-load (with opened
collar) also to middle position (position 51200), then close the collar. The drive is now capable of moving 125 rotations (±50000 increments by default) in each direction.
b) Move the axle completely to the left (resp. bottom), then move the drive at no-
load (with opened collar) without loop to the lowest position (position 1200), then close the collar. The drive is now capable of moving 250 rotations (±100000 increments by default) to the right (resp. top).
c) Move the axle completely to the right (resp. top), then move the drive at no-load
(with opened collar) to the highest position (position 101200), then close the collar. The drive is now capable of moving 250 rotations (±100000 increments by default) to the left (resp. bottom).
2) Mount the drive in any position on the axle, close the collar, then adjust the
positioning range with the help of SDO #2028. SDO #2028 defines the upper end of the positioning range. By default, the upper end is at +256 rotations (position
102400). If the positioning range doesn’t suit to the actual displayed position after mounting the drive, the upper end of the positioning range can be adjusted freely between +3 rotations and +253 rotations (measured from the actual position). Examples: a) After mounting the drive, the displayed position is 51200 (which corresponds
the delivery state). But the positioning range shall solely spread to the right (resp. top).
upper mapping end = actual position + 253 rotations Set SDO #2028 to 152400
b) After mounting the drive, the displayed position is 100000. But the positioning
range shall solely spread to the right (resp. top).
upper mapping end = actual position + 253 rotations Set SDO #2028 to 201200
c) After mounting the drive, the displayed position is 2000. But the positioning
range shall solely spread to the left (resp. bottom).
upper mapping end = actual position + 3 rotations Set SDO #2028 to 3200
Remarks:
1) When calculating the upper mapping end (SDO #2028), a security reserve of 3
rotations has to be kept in mind (1200 increments by default, see the examples above), because the highest possible position value is 3 rotations below the upper mapping end. The lowest possible position value is 253 rotations below the upper mapping end.
2) The above given increment and position values relate to the following settings,
which correspond to the delivery state: a) referencing value (SDO #2004) = 0 b) position scaling, numerator (SDO #2010) = 400 c) position scaling, denominator (SDO #2011) = 400 These 3 SDOs have an influence on the above given increment and position values: With the help of the referencing value a shift can be reached, with the help of the position scaling numerator and denominator a stretching or distension can be reached (see below).
Instruction Manual PSx3xxPL
26
3) When changing the direction of rotation (SDO #202C), the referencing value (SDO
#2004), the upper mapping end (SDO #2028) and the upper and lower limit (SDO #2016 and #2017) are set to delivery state.
4) When changing the upper mapping end (SDO #2028), the upper limit (SDO #2016)
will be set to the value [upper mapping end - 3 rotations x scaling] and the lower limit (SDO #2017) to the value [upper mapping end - 253 rotations x scaling]. This results in a positioning range of 250 rotations.
5) When changing the position scaling numerator or denominator (SDO #2010 or
#2011), the target value, the actual value, the referencing value, the upper mapping end, the upper and lower limit, the drag error, the positioning window and the length of loop are re-calculated.
6) When changing the referencing value (SDO #2004), the target value, the actual
value, the upper mapping end and the upper and lower limit are re-calculated.
7) If the user wants to go over any automatic re-calculation of values when setting up
the device, the optimum order of transfering the parameter is the following: a) direction of rotation (SDO #202C),
position scaling, numerator (SDO #2010),
position scaling, denominator (SDO #2011) b) referencing value (SDO #2004) c) upper mapping end (SDO #2028) d) upper limit (SDO #2016),
lower limit (SDO #2017),
drag error (SDO #2005),
positioning window (SDO #2006),
length of loop (SDO #201F)
8) In order to save the settings permanently in the EEPROM, write 1 to SDO #204F. As soon as reading of SDO #204F shows 0, the saving is finished.
Referencing value (SDO #2004): With the help of the referencing value (SDO #2004) a shift of the whole range of values can be reached. The referencing process affects all transferred values, i.e., the target value, actual value, upper mapping end and upper and lower limit. There are two ways of setting the referencing value:
1) Directly, by writing the referencing value to SDO #2004.
2) Indirectly, by writing an actual value to SDO #2003. This makes it possible to assign any “true” actual value to the current, physical actual value. The resulting difference is then the referencing value. This value will immediately be included in calculations for each transferred value and can also be read via SDO #2004.
When changing the referencing value, automatically the target value, the actual value, the upper mapping end and the upper and lower limit are re-calculated.
The removal of the motor power supply has no affect on the internal measuring system.
g) Using position scaling factors to set the spindle pitch
SDO #2010 (numerator factor) and #2011 (denominator factor) can be used to represent any desired spindle pitch:
factornumerator
factordenom
revolutionperstepsofnumber
.
*400
Both factors are set to a value of 400 by default, resulting in a resolution of 0.01 mm at a spindle pitch of 4 mm.
Instruction Manual PSx3xxPL
27
The denominator factor serves as a simple means of setting the spindle pitch and resolution. The numerator factor is primarily used for setting “unlevel” resolutions.
Examples:
Spindle pitch
Resolution
Numerator
factor
Denominator
factor
4 mm
1/100 mm
400
400
1 mm
1/100 mm
400
100
2 mm
1/10 mm
400
20
Numerator and denominator factors may take on values between 1 and 10,000.
h) Drag error monitoring
During a positioning run, the device compares the computed target position with the current actual value. If the difference is larger than the ‘drag error’ value (SDO #2005), the device sets the corresponding bit in the status word. This situation is especially likely to occur if external factors (required torque, voltage to motor too low) prevent the device from achieving the target rpm
By setting SDO #2005 to 0 the drag error monitoring can be disabled.
i) Drag error correction
With SDO #2046 the drag error correction can be enabled. With this feature enabled, the drive will raise or lower the target speed proportional to the drag error by the configured value. The drive attempts under consideration of the configured maximum current to compensate the drag error which has developped by controlling the target speed to a value which lays slightly above or below the specified value of the target speed (SDO #2012).
By setting SDO #2046 to 0 the drag error correction can be disabled. Drag error monitoring and correction take effect always except during a braking
operation when approaching a target position or when aborting a positioning. The actual target speed when accelerating is determined by the actual speed at the beginning of the positioning and the acceleration setting (SDO #201C).
j) Abort run when the master fails
If the connection to the master is interrupted during a positioning run, the master cannot abort an actual run. In order to generate an automatic run abort in this case,
there’s a mechanism implemented in the drive that monitors the communication to the
Powerlink Managing Node (e.g. the bus master). In case of a timeout, the drive will abort any positioning (if bits 1-0 of SDO #2049 are set to 01, which is the default value). If the connection contains valid data after its re-establishment, the drive might continue to move immediately (where applicable).
Instead of aborting any positioning if the connection to the master is interrupted, alternatively a continuation of the run or a run to a configurable save position might be configured with the help of SDOs #2049, #204A and #204B.
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Instruction Manual PSx3xxPL
29
k) Devices with optional holding brake
The device models PSx30xPL-14, PSx31xPL-14, PSx32xPL and PSx33xPL can be supplied with an optional holding brake. This brake prevents the output shaft from turning when the power supply to the motor is removed, or, if the motor holding torque is too low, to a maximum of the level of the nominal torque. A small degree of rotation always occurs at the output, i.e. the brake cannot be used to hold the drive at a defined position (for this purpose where appropriate the holding torque might be increased with the help of SDO #202B and SDO #2042).
To release the brake when a run command is transmitted, these devices first wait for a short time and then run a few increments against the actual direction of movement. The brake is closing at the end of every run (by default 1 sec after the end of the run, SDO #2045). The advantage of this feature is, that in case of many subsequent runs the brake has not to be released anew each time.
To adjust the position of the drive manually, it is first necessary to remove the rubber­plug in the top cover (if required, consider drawings on the website). Then release the brake by pressing down and simultaneously turning using a hex wrench NW3 (PSx31xPL and PSx33xPL) or NW4 (PSx30xPL and PSx32xPL).
l) Devices with optional friction brake
The device model PSE34xxPL can be supplied with an optional friction brake. This brake prevents the output shaft from turning when the power supply to the motor is removed, or, if the motor holding torque is too low.
A run command is not approached immediately but only after a short idle period to tighten the brake. The brake releases at the end of every run.
To adjust the drive manually, it is first necessary to remove the corresponding rubber­plug in the top cover (if required, consider drawings on the website). The drive can then be rotated using a hex wrench NW4. This is quite difficult as the operator has to overcome both any torque present at the output and the force of the friction brake.
Instruction Manual PSx3xxPL
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m) Reference runs
The PSx3xxPL positioning system is equipped with an absolute measuring system,
therefore there’s no need for a reference run when powering on the drive. However, if
in certain cases a reference run onto a hard block should be desired (e.g. uniquely when installing the drive at a machine), the course of action should be the following:
1) Before commanding the reference run the following settings have to be carried
out:
- set the maximum torque (SDO #2014) and the maximum start-up torque (SDO #2018) to max. 10% of the nominal torque, resp. the lowest possible value
- set the maximum holding torque (SDO #202B) and the maximum holding torque at end of run (SDO #2042) to 0
- set the rpm limit for aborting run (SDO #201A) to 60
- set the time elapsed until speed falls below rpm limit for aborting run (SDO #201B) to 100 (The span of time in which the drive trys to get over the block, decreases: With the reduced values the positioning will be aborted if the speed stays below 60% of the target speed for longer than 100ms. By default, these values are 30% and 200ms.)
- set the corresponding upper and lower limit (SDO #2016 or #2017) in a way that the block location lays considerable within the area between the upper and lower limit
(Otherwise there’s the danger that the block is located within the positioning window and consequently won’t be recognized.)
- Where appropriate, reduce the target speed for manual run (SDO #2013).
2) Now start the reference run as manual run (set bit 0 or 1 and the release bit in the control word).
3) Wait for the drive moving (bit 6 in the status word is set).
4) Wait for the drive has stopped and a positioning error has appeared (bit 6 in the status word is cleared, bit 10 is set).
5) Start a manual run in the opposite direction with the same settings (move a certain distance away from the hard stop in order the drive can move freely).
6) Only now adjust the desired settings of the adove mentioned SDOs for normal operation.
Instruction Manual PSx3xxPL
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4 Technical Data
Ambient conditions
ambient temperature
0 °C to +45 °C
storage temperature
-10 °C to +70 °C
shock resistance according to DIN IEC 68-2-27
50 g 11 ms
resistance to vibration according to nach DIN IEC 68-2-6
10 Hz to 55 Hz 1.5 mm 55 Hz to 1000 Hz 10 g 10 Hz to 2000 Hz 5 g
EMC standards
CE
conformity
CE declaration of conformity available upon request
protection class
PSE
IP 54
PSS
IP 65
PSW
IP 66 (in operation)
IP 68 (at standstill)
duty cycle
Device model
Duty cycle in
%
Base time in
sec.
PSE34xx
PSE30xx to 33xx
PSS
PSW
20 30 20 20
300 300 600 600
Electrical Data
nominal power output PSx30xPL, PSx31xPL,
PSE31xxPL
25 W with 30 % ED
PSx32xPL, PSx33xPL
35 W with 30 % ED
PSE34xxPL
100 W with 20 % ED
supply voltage
24 VDC ±10 % (supply voltages for motor and control unit are galvanically isolated) advice: use regulated power supplys
nominal current, control unit
0.15 A
nominal current, motor PSx30xPL, PSx31xPL,
PSE31xxPL
2.2 A
PSx32xPL, PSx33xPL
3.0 A
PSE34xxPL
7.8 A
positioning resolution
0.9°
positioning accuracy
0.9°
protocol
Ethernet Powerlink (IEC 61158-6-13)
absolute value acquisition
optical - magnetic
Instruction Manual PSx3xxPL
32
Physical data
positioning range
250 usable rotations, no mechanical limits measuring system has a span of 256 turns, minus 3 turns security stock at upper and lower range limit
torsional rigidity (angle of rotation when switching from operation without backlash to maximum torque)
max. 0.2° gear backlash
(without spindle compensation run)
max. 0.5°
spindle lash compensation
automatic loop after every positioning run (may be deactivated)
output shaft
PSE30xPL-8, PSE31xPL-8
8H9 hollow shaft with
adjustable collar
PSE30xPL-14, PSE31xPL-14, PSE32xPL, PSE33xPL
14H7 hollow shaft with
adjustable collar
PSE31xxPL, PSE34xxPL
14H7 hollow shaft with
clamp and feather key
PSS3xxPL-8, PSW3xxPL-8
8H9 hollow shaft with
adjustable collar or
8h8 solid shaft
PSS3xxPL-14, PSW3xxPL-14
14H7 hollow shaft with
adjustable collar or
14h8 solid shaft
recommended diameter of the spindle head
according to the hollow shaft diameter with an interference fit of h9
maximum radial force
40 N
maximum axial force
20 N
dimensions (l x w x h)
see catalog data on our website
weight (approx.)
PSx30xPL-8
650 g
PSx30xPL-14, PSx32xPL
1200 g
PSx31xPL-8
700 g
PSx31xPL-14, PSx33xPL
700 g
PSE31xxPL
1200 g
PSE34xxPL
1900 g
For additional specifications and dimension drawings, please visit our website at
www.halstrup-walcher.de/en/produkte/positioniertechnik/positioniersysteme/index.php
7100.005424E_PSx3xxPL.doc 07/2017 Re / Ka
Instruction Manual PSx3xxPL
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