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

Instruction Manual
PSx3xxDP

halstrup-walcher GmbH
Stegener Straße 10

D-79199 Kirchzarten, Germany
Phone: [phone]

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

Internet: www.halstrup-walcher.com

Document 7100.003964 03/2017

PSx3xxDP Instruction Manual

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Table of Contents

1 Purpose of instruction manual .......................................................................................... 5

2 Conformity .......................................................................................................................... 5

3 Safety precautions ................................................................ ............................................. 6

3.1 Appropriate use ................................................................................................................ 6

3.2 Shipping, assembly, electrical connections and start-up ................................................... 6

3.3 Troubleshooting, maintenance, repairs, disposal .............................................................. 6

3.4 Symbols............................................................................................................................ 7

4 Instrument description ...................................................................................................... 8

4.1 Functions .......................................................................................................................... 8

4.2 Assembly .......................................................................................................................... 8

4.3 Pin assignment ................................................................................................................. 9

4.4 Setting the device address and terminating resistors ...................................................... 10

4.5 LED status ...................................................................................................................... 10

4.6 Using the bus to set the address .................................................................................... 11

4.7 Using the parameter module to set the address (firmware version 8) ............................. 11

5 Jog key operation ............................................................................................................ 12

5.1 Connecting the keyboard ................................................................................................ 12

5.2 Using the control unit to activate the jog keys ................................................................. 12

5.3 Direct positioning using the jog keys ............................................................................... 12

5.4 Incremental manual operation ........................................................................................ 12

5.5 Incremental operation ..................................................................................................... 12

6 Start-up ............................................................................................................................. 13

6.1 Setting the reference position ......................................................................................... 13

6.2 Positioning sequence...................................................................................................... 13

6.3 Positioning sequence (without reference loop)................................................................ 13

7 Interface ............................................................................................................................ 14

7.1 Status byte configuration ................................................................................................ 14

7.1.1 Target position reached............................................................................................... 14

7.1.2 Drive running ............................................................................................................... 14

7.1.3 Motor supply voltage OK ............................................................................................. 15

7.1.4 Ready ......................................................................................................................... 15

7.1.5 Hardware error ............................................................................................................ 15

7.1.6 Positioning run aborted ............................................................................................... 15

7.1.7 Jog key, down ................................................................ ............................................. 15

7.1.8 Jog key, up.................................................................................................................. 15

7.1.9 Temperature too high .................................................................................................. 15

7.1.10 Drag error ................................................................................................................ 16

7.1.11 Invalid target/parameter value ................................................................................. 16

7.1.12 Positioning error ...................................................................................................... 16

7.1.13 Manual rotation ........................................................................................................ 16

7.1.14 No supply voltage available to motor ....................................................................... 16

7.1.15 Upper range limit ..................................................................................................... 16

7.1.16 Lower range limit ..................................................................................................... 16

7.2 Actual position .............................................................................................................. 16

7.3 Control byte configuration ............................................................................................... 17

7.3.1 Confirmation ................................................................................................................ 17

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7.3.2 Release bit .................................................................................................................. 17

7.3.3 Manual run release ..................................................................................................... 17

7.3.4 Run with no reference loop ......................................................................................... 17

7.3.5 Set value for reference position ................................................................................... 17

7.3.6 Set and save reference position .................................................................................. 18

7.3.7 Accept and proceed to position ................................................................................... 18

7.3.8 Manual run, down........................................................................................................ 18

7.3.9 Manual run, up ............................................................................................................ 18

7.4 Target position ................................................................................................................ 18

7.5 Parameters ..................................................................................................................... 18

7.5.1 Direction of rotation ..................................................................................................... 19

7.5.2 Direction of travel ........................................................................................................ 20

7.5.3 Position correction ....................................................................................................... 20

7.5.4 Jog key operation ........................................................................................................ 20

7.5.5 Hardware resolution .................................................................................................... 20

7.5.6 Software resolution ..................................................................................................... 20

7.5.7 Positioning window ...................................................................................................... 20

7.5.8 Max. run distance, positive .......................................................................................... 21

7.5.9 Max. run distance, negative ........................................................................................ 21

7.5.10 Target rpm, positioning run ...................................................................................... 21

7.5.11 Target rpm, manual run ........................................................................................... 21

7.5.12 Max. rpm, left ........................................................................................................... 21

7.5.13 Max. rpm, right......................................................................................................... 21

7.5.14 Max. torque ............................................................................................................. 21

7.5.15 Max. torque, left ....................................................................................................... 21

7.5.16 Max. torque, right ..................................................................................................... 21

7.5.17 Max. starting torque ................................................................................................. 21

7.5.18 Duration of starting torque ....................................................................................... 21

7.5.19 Holding torque ......................................................................................................... 22

7.5.20 Drag error ................................................................................................................ 22

7.5.21 Min. rpm for detecting an obstacle ........................................................................... 22

7.5.22 Time required to detect an obstacle ......................................................................... 22

7.5.23 Wait time between runs ........................................................................................... 22

7.5.24 Min. supply voltage .................................................................................................. 22

7.5.25 Filter value for voltage monitoring ............................................................................ 22

7.5.26 Loop length .............................................................................................................. 23

7.5.27 Jog key increment size ............................................................................................ 23

7.5.28 Jog key pause ......................................................................................................... 23

7.5.29 Factor for ramp length ............................................................................................. 23

7.5.30 Limiting temperature ................................................................................................ 23

7.5.31 Reference position MSW ......................................................................................... 23

7.5.32 Reference position LSW .......................................................................................... 23

7.5.33 Production date ....................................................................................................... 23

7.5.34 Serial number .......................................................................................................... 23

7.5.35 Device type .............................................................................................................. 24

7.5.36 Software version ................................................................................................ ...... 24

7.5.37 Hardware version .................................................................................................... 24

7.5.38 Device temperature ................................................................................................. 24

7.5.39 Actual rpm ................................ ................................................................ ............... 24

7.5.40 Max. actual torque (current) ..................................................................................... 24

7.5.41 Run time MSW ........................................................................................................ 24

7.5.42 Run time LSW ......................................................................................................... 24

7.5.43 Drag position ........................................................................................................... 24

7.5.44 Motor supply voltage ............................................................................................... 24

7.5.45 Motor current ........................................................................................................... 24

7.5.46 Supply voltage for control unit .................................................................................. 24

7.5.47 Error code ................................................................................................................ 25

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7.6 Changing parameter values ............................................................................................ 25

8 Backing up parameter data and the error memory ........................................................ 26

9 Technical data .................................................................................................................. 27

9.1 Drive speed and torque .................................................................................................. 27

9.2 Drive speed and torque PSE34xx ................................................................................... 28

9.3 Ambient conditions ......................................................................................................... 29

9.4 Electrical data ................................................................................................................. 29

9.5 Physical data .................................................................................................................. 30

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1 Purpose of instruction manual

This instruction manual describes the features of the PSx 3xxDP positioning systems and
provides guidelines for their use.

Improper use of these instruments or failure to follow these instructions may cause injury
or equipment damage. All individuals responsible for operating these instruments must
therefore be properly trained and aware of the hazards, and must carefully follow these
operating instructions and the safety precautions detailed within. 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 instruments.
 It must be provided to any individuals who assume responsibility for operating the

instrument at a later date.

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

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

2 Conformity

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

© 2006, 2007, 2014, 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 instruments;
copying this manual in part or in full or distributing it to third parties is prohibited.

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3 Safety precautions

3.1 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.

PSx3xxDP positioning systems are not stand-alone instruments 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 instrument may only be handled as indicated in this manual. Modifications to the
instrument 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.

3.2 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 instrument and set up its electrical connections.

The instrument 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.

3.3 Troubleshooting, maintenance, repairs, disposal

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

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

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

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

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3.4 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 instrument properly.

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4 Instrument description

4.1 Functions

The PSx3xxDP 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 Profibus DP 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.

PSx3xxDP positioning systems convert a digital positioning signal into an angle of
rotation.

4.2 Assembly

Hollow shaft:
The PSx3xxDP 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.

Solid shaft:
The PSx3xxDP 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 PSx3xxDP rearward is prohibited (e.g. it’s not allowed to turn the

output shaft by an external force)

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4.3 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 PSx3xxDP.
A series 715 (B-coded) 5-pin round socket and 5-pin plug are provided for connecting the
bus
A Binder series 718 4-pin plug is used to connect the jog keys (optional).

Supply voltage connector: Profibus DP connector (B encoded)
(external top view) (external top view)

Binder 713/763 Harting(PSE34xxDP)

1 +24VDC (final stage) 1 VP +5V
2 ground (final stage) 2 RxD/TxD–N / A cable
3 +24VDC (control unit) 3 DGND (reference potential to VP)
4 ground (control unit) 4 RxD/TxD–P / B line
5 housing/pressure balance 5 shield

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.

Optional connectors

Connector for external keyboard )
4-pin Binder 718 connector
(External top view)

1

bn

+24V(from control unit)

2

ws

forward key

3

bl

reverse key

4

sw

GND(from control unit)

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.

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4.4 Setting the device address and terminating resistors

Removing the protective cap provides access to two rotary switches for setting the device
address and a DIP switch to set the terminating resistors.

The rotary switches indicate the tens and ones places of the address selected. A setting
of 01 is the delivery state; the PSx3xxDP identifies itself using address 1 at the bus.

To activate the terminating resistors both switches must be in position ON (If active,
remove the connection to a following device).

Switch configurations:

PSx30xDP,
PSx31xDP-8,
Psx32xDP,
PSx31xxDP

PSx31xDP-14,
PSx33xDP-14

PSx34xxDP

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

4.5 LED status

The red LED indicates the operating status of the Profibus DP.

LED status

Meaning

LED remains lit

The Profibus DP is not connected or is inactive

LED flashes

The instrument has detected data transfer activity on the bus and
identified the transfer rate.

LED is not lit

Provided the power supply is switched on, an unlit LED indicates
that the instrument is involved in bus communication.

The green LED indicates the status of the power supply.

LED status

Meaning

LED remains lit

Power supply of control unit and motor is activ

LED flashes

Power supply of the motor is inactive.

LED is not lit

Power supply of the control unit is inactive. The status of the
motor supply could not be detected in this case.