Parker Compax3, Compax3 I11 T11, Compax3 S025 V2, Compax3 S038 V4, Compax3 S063 V2 Operating Instructions Manual

Electromechanical Automation

Operating instructions Compax3 I11 T11

Positioning via digital I/Os

I11 T11 192-120101 N6 - March 2004

Release 1/2004 (as from firmware V2.03)

We reserve the right to make technical changes. 10.03.04 09:06 I11 T11 192-120101 N6 - March 2004
The data correspond to the technical state at the time of printing.

Introduction

____________________________

Copyright © 2003 Parker Hannifin GmbH EME
All rights reserved.

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Windows NT®, Window 2000™, Window XP™ and MS-DOS™ are trademarks of
Microsoft Corporation.

EME - Electromechanical Automation Europe

Germany:

England:

Italy:

Parker Hannifin GmbH
Electromechanical Automation
Postfach: 77607-1720
Robert-Bosch-Str. 22
D-77656 Offenburg
Tel.: [phone]
Fax: [phone]

E-mail: [e-mail] mailto:[e-mail]
Internet: www.parker-eme.com http://www.parker-eme.com

Parker Hannifin plc
Electromechanical Automation
21 Balena Close
Poole, Dorset England, BH17 /DX UK
Tel.: [phone]
Fax: [phone]

E-mail: [e-mail] mailto:[e-mail]
Internet: www.parker-eme.com http://www.parker-eme.com

Parker Hannifin S. p. A
Electromechanical Automation
Via Gounod 1
I-20092 Cinisello Balsamo (MI), Italy
Tel.: [phone]
Fax: [phone]

E-mail: [e-mail] mailto:[e-mail]
Internet: www.parker-eme.com http://www.parker-eme.com

EMN - Electromechanical Automation North America

USA:

2 I11 T11 192-120101 N6 - March 2004

Parker Hannifin Corporation
Electromechanical Automation
5500 Business Park Drive
Rohnert Park, CA 94928
Phone #: [phone]
FAX #: [phone]

E-mail: [e-mail] mailto:[e-mail]
Internet: www.compumotor.com http://www.compumotor.com

Parker EME

Device assignment

New Compax3 functions

Contents

1. Introduction .............................................................................................7

1.1 Device assignment .................................................................................. 7

1.2 Type specification plate .......................................................................... 8

1.3 Release 1/2004 ......................................................................................... 9

1.3.1. New Compax3 functions ................................................................................... 9

1.3.1.1 Direct drives ............................................................................................ 9

1.3.1.2 Switching frequency of the power output stage can be set .................... 9

1.3.1.3 Predefined external setpoint value optimized via analogue input........... 9

1.3.1.4 UL certification ........................................................................................ 9

1.3.1.5 New machine zero modes .................................................................... 10

1.3.1.6 RS485 / RS232 interface ...................................................................... 10

1.3.2. New functions of the Compax3 software tools............................................. 10

1.3.2.1 C3 ServoManager: configuration, setup and optimization of

Compax3............................................................................................... 10

1.3.2.2 C3 MotorManager: configuration of almost any motors........................ 11

1.3.2.3 C3 IEC61131-3 - Debugger .................................................................. 11

1.3.2.4 CoDeSys - IEC61131-3 - development tool.......................................... 11

1.3.2.5 CamEditor: cam creation for C3 T40 .................................................... 11

1.3.3. Complements / corrections in manual and online help ............................... 11

1.4 Safety Instructions................................................................................. 12

1.4.1. General hazards ............................................................................................... 12

1.4.2. Safety-conscious working .............................................................................. 12

1.4.3. Special safety instructions ............................................................................. 13

1.5 Warranty conditions .............................................................................. 13

1.6 Conditions of utilization ........................................................................ 14

1.6.1. Conditions of utilization for CE-conform operation..................................... 14

1.6.2. Conditions of utilization for UL permission.................................................. 16

2. Compax3 I11 T11: Positioning via digital I/Os.....................................17

3. Compax3 device description................................................................19

3.1 Plug and connector assignment Compax3.......................................... 20

3.1.1. Function of the LEDs on the front panel ....................................................... 21

3.1.2. Power supply plug X1 for 230VAC devices................................................... 21

3.1.3. Power supply plug X1 for 400 VAC devices.................................................. 22

3.1.4. Ballast resistor / high voltage supply plug X2 for 230VAC devices........... 22

3.1.5. Ballast resistor / high voltage supply plug X2 for 400VAC devices........... 23

3.1.6. Motor / Motor brake (plug X3)......................................................................... 24

3.1.7. Control voltage 24VDC / enable (plug X4) ..................................................... 25

3.1.8. RS232 / RS485 interface (plug X10) ............................................................... 26

I11 T11 192-120101 N6 - March 2004 3

Introduction

New Compax3 functions

3.1.9. Analog / Encoder (plug X11)........................................................................... 27

3.1.9.1 Wiring of the analog input ..................................................................... 27

3.1.9.2 Wiring of analog outputs ....................................................................... 27

3.1.10. Digital inputs/outputs (plug X12) ................................................................... 28

3.1.10.1 Input wiring of digital inputs................................................................... 28

3.1.10.2 Output wiring of digital outputs.............................................................. 29

3.1.11. Resolver / Feedback (connector X13)............................................................ 29

3.2 Installation and dimensions Compax3................................................. 31

3.2.1. Installation and dimensions of Compax3 S0xx V2....................................... 31

3.2.2. Installation and dimensions of Compax3 S038 and S075 V4...................... 32

3.2.3. Installation and dimensions of Compax3 S150 V4....................................... 33

3.2.4. Installation and dimensions of Compax3 S300 V4....................................... 34

4. Setting up Compax3..............................................................................35

4.1 Configuration ......................................................................................... 35

4.1.1. Motor selection ................................................................................................ 37

4.1.2. Optimize motor reference point and switching frequency of the

power output stage.......................................................................................... 38

4.1.3. Ballast resistor ................................................................................................. 39

4.1.4. General drive .................................................................................................... 40

4.1.5. Defining the reference system ....................................................................... 40

4.1.5.1 Measure reference................................................................................ 41

4.1.5.2 Machine reference modes (MN-Ms) ..................................................... 44

4.1.5.3 Adjusting the machine zero proximity switch ........................................ 48

4.1.5.4 Software end limits................................................................................ 49

4.1.6. Defining jerk / ramps ....................................................................................... 50

4.1.6.1 Ramp upon error / deenergize ............................................................. 51

4.1.7. Limit and monitoring settings ........................................................................ 52

4.1.7.1 Current Limit ......................................................................................... 52

4.1.7.2 Positioning window - Position reached ............................................... 52

4.1.7.3 Tracking error limit ................................................................................ 53

4.1.8. Encoder simulation ......................................................................................... 54

4.1.9. Positioning ....................................................................................................... 55

4.1.9.1 Operating modes .................................................................................. 56

4.1.9.2 Define positioning data records ............................................................ 59

4.1.9.3 Dynamic positioning.............................................................................. 62

4.1.10. RS485 setting values....................................................................................... 62

4.1.11. Configuration name / comments.................................................................... 63

4.2 Test commissioning Compax3 ............................................................. 64

4.3 Device status.......................................................................................... 66

4.4 Optimization ........................................................................................... 68

4.4.1. Control dynamics ............................................................................................ 68

4.4.1.1 Stiffness of the speed controller ........................................................... 69

4.4.1.2 Damping of the speed controller ........................................................... 70

4.4.1.3 Filter for speed value ............................................................................ 70

4.4.1.4 Advanced control parameters............................................................... 71

4.4.2. Commissioning mode ..................................................................................... 75

4.4.3. Turning the motor holding brake on and off................................................. 76

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Device assignment

New Compax3 functions

5. RS232 & RS485 – interface record .......................................................77

5.1 ASCII - record......................................................................................... 77

5.2 Binary record.......................................................................................... 79

6. Status values.........................................................................................82

6.1 Device ..................................................................................................... 83

6.2 Motor....................................................................................................... 83

6.3 Positions................................................................................................. 84

6.4 Speeds .................................................................................................... 85

6.5 Currents.................................................................................................. 87

6.6 Inputs ...................................................................................................... 88

6.7 CAM......................................................................................................... 89

6.8 IEC61131-3.............................................................................................. 90

6.9 Transmitter ............................................................................................. 91

7. Error .......................................................................................................92

7.1 Error list.................................................................................................. 92

8. Compax3 Accessories ........................................................................105

8.1 Order code for Compax3..................................................................... 105

8.2 Accessories order code ...................................................................... 106

8.3 Parker servo motors ............................................................................ 108

8.3.1. Direct drives ................................................................................................... 108

8.3.1.1 Transmitter systems for direct drives .................................................. 108

8.3.1.2 Linear motors ...................................................................................... 109

8.3.1.3 Torque motors..................................................................................... 109

8.3.2. Rotary servo motors...................................................................................... 110

8.3.2.1 Motor data table for standard motors.................................................. 113

8.3.2.2 Holding brake ...................................................................................... 114

8.3.2.3 Pulse encoder systems ....................................................................... 114

8.3.2.4 Dimensions of the SMH(A)-motors ..................................................... 115

8.3.2.5 Dimensions of the MH(A)105-motors ................................................. 116

8.3.2.6 Dimensions of the MH(A)145 and MH(A)205 motors ......................... 117

8.3.2.7 Order code for SMH/MH motors ......................................................... 118

8.4 Connections to the motor ................................................................... 119

8.4.1. Resolver cable................................................................................................ 119

8.4.2. SinCos cable .................................................................................................. 120

8.4.3. Overview of motor cables ............................................................................. 120

8.4.4. Motor cable with plug.................................................................................... 121

8.4.5. Motor cable for terminal box ........................................................................ 122

I11 T11 192-120101 N6 - March 2004 5

Introduction

New Compax3 functions

8.5 EMC measures ..................................................................................... 123

8.5.1. Mains filter ...................................................................................................... 123

8.5.1.1 Mains filter NFI01/01 ........................................................................... 123

8.5.1.2 Mains filter NFI01/02 ........................................................................... 124

8.5.1.3 Mains filter for NFI01/03...................................................................... 124

8.5.2. Motor output filter.......................................................................................... 125

8.5.2.1 Motor output filter MDR01/04.............................................................. 125

8.5.2.2 Motor output choke MDR01/01........................................................... 125

8.5.2.3 Motor output choke MDR01/02........................................................... 126

8.5.2.4 Wiring of the motor output filter........................................................... 126

8.6 External ballast resistors .................................................................... 127

8.6.1. BRM8/01 ballast resistors ............................................................................. 128

8.6.2. BRM5/01 ballast resistor ............................................................................... 128

8.6.3. Ballast resistor BRM6/02............................................................................... 128

8.6.4. Ballast resistor BRM4/0x............................................................................... 129

8.7 Operator control module BDM............................................................ 130

8.8 EAM06 terminal block for inputs and outputs................................... 131

8.9 ZBH plug set......................................................................................... 134

8.10 Interface cable...................................................................................... 135

8.10.1. RS232 cable.................................................................................................... 135

8.10.2. RS485 cable to Pop ....................................................................................... 136

8.10.3. I/O interface X12............................................................................................. 137

8.10.4. Ref X11............................................................................................................ 138

8.10.5. Encoder cable ................................................................................................ 139

9. Technical Data.....................................................................................140

10.Index.....................................................................................................147

6 I11 T11 192-120101 N6 - March 2004

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1. Introduction

In this chapter you can read about:

Device assignment ...........................................................................................................................7

Type plate ........................................................................................................................................8

Release 1/2004 ................................................................................................................................9

Safety instructions ..........................................................................................................................12

Warranty conditions........................................................................................................................13

Conditions of utilization...................................................................................................................14

1.1 Device assignment

This manual applies to the following devices:

Introduction

! Compax3 S025 V2 + supplement
! Compax3 S063 V2 + supplement
! Compax3 S038 V4 + supplement
! Compax3 S075 V4 + supplement
! Compax3 S150 V4 + supplement

! Compax3 S300 V4 + supplement

With the supplement:

! F10 (Resolver)

! F11 (SinCos)
! F12 (linear and rotary direct drives)

! I11 T11

I11 T11 192-120101 N6 - March 2004 7

Introduction

1.2 Type specification plate

You will find the exact description of the device on the type specification
plate, which is located on the right side of the device:

Compax3 - Type

specification plate:

1

10

2

3

4

56

Explanation:

1 Type designation

The complete order designation of the device (2, 5, 6, 10, 9)

C3S025V2

2

C3: Abbreviation for Compax3

S: Single axis device with direct AC mains power supply

025: Device current drain in 100mA (025=2.5A)

V2: 230VAC (single phase); V4: 400VAC (three phase)

3 Unique number of the particular device

4 Nominal power supply voltage of the device

5 Designation of the feedback system

F10: Resolver

F11: SinCos© / Single- or Multiturn

F12: Feedback module for direct drives

6 Device interface

I10: Analog, Step/Direction and Encoder Input

I11: Digital inputs/outputs

I20: Profibus DP

I21: CANopen

7 Corresponding fuse protection

8 Date of factory test

9 Options

10 Technology function

T10: Servo Controller

T11: Positioning

T30: Motion control programmable according to IEC61131-3

T40: Electronic cam control

9

8

7

8 I11 T11 192-120101 N6 - March 2004

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1.3 Release 1/2004

In this chapter you can read about:

New Compax3 functions...................................................................................................................9

New functions of the Compax3 software tools ................................................................................10

Complements / corrections in manual and online help ....................................................................11

1.3.1. New Compax3 functions

In this chapter you can read about:

Direct drives .....................................................................................................................................9

Switching frequency of the power output stage can be set................................................................9

Optimization of the predefined external setpoint via the analog input................................................9

UL certification..................................................................................................................................9

New machine zero modes ..............................................................................................................10

RS485 / RS232 interface ................................................................................................................10

Introduction

1.3.1.1 Direct drives

The feedback module F12 supports the following feedback systems:

! Distance coding with 1VSS - Interface
! Distance coding with RS422 - Interface (Encoder)

1.3.1.2 Switching frequency of the power output stage can be set

The switching frequency of the power output stage (see on page 38) can be
increased if necessary. This helps mainly to reduce motor sounds.

Please note that power output stage losses increase with rising switching
frequency. Therefore the nominal device currents must be reduced.

1.3.1.3 Predefined external setpoint value optimized via analogue input

Given an external discrete signal read in via the analog input (possible with I10 T10
and T40), signal steps can only be avoided by averaging.

1.3.1.4 UL certification

Compax3 now with UL certification. (see on page 16)

I11 T11 192-120101 N6 - March 2004 9

Introduction

1.3.1.5 New machine zero modes

! Several new machine zero modes with limit switch: MN-Mode 1,2 7-10, 11-14,

17,18, 23-26, 27-30

! New machine zero modes in connection with the feedback module F12 F12

(direct drives) and distance coded feedback system: MN-Mode 130 - 133

! Limit switch can be configured

1.3.1.6 RS485 / RS232 interface

Compax3 objects can be read in and written via RS232 and RS485 (see on page

77).

1.3.2. New functions of the Compax3 software tools

In this chapter you can read about:

C3 ServoManager: configuring Compax3, setup and optimization..................................................10

C3 MotorManager: configuration of almost any motors...................................................................11

C3 IEC61131-3 - Debugger............................................................................................................11

CoDeSys - IEC61131-3 – development tool .................................................................................11

CamEditor: Cam creation for C3 T40..............................................................................................11

1.3.2.1 C3 ServoManager: configuration, setup and optimization of Compax3

A modified recipe array can be loaded separately (without complete download) into
the device.

Firmware - Download

The Compax3 firmware can only be modified resp. updated with the aid of the C3
ServoManager.

For this you will need a so-called “firmware-package“ (File: .*.fwp).

Setup support

You can set up all Compax3 technology functions easily in the optimization
window.

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Parker EME

1.3.2.2 C3 MotorManager: configuration of almost any motors

New:

! Integration of distance coded feedback systems
! Export / Import of user defined (customer’s) motor
! Calibration of commutation also for linear motors with small travel path

Changes

! Linear motors with brakes can be configured
! Calculation of the recommended number of poles was corrected
! Calibration of SinCos motors was corrected
! The minimum moment of inertia was reduced from 10kgmm
! Configuration of rotatory motors with analog hall sensors was completed

1.3.2.3 C3 IEC61131-3 - Debugger

2

to 1kgmm

Introduction

2

Forcing of the inputs for T30 and T40 is possible.

1.3.2.4 CoDeSys - IEC61131-3 - development tool

New CoDeSys version 2.3.2.6

1.3.2.5 CamEditor: cam creation for C3 T40

-

1.3.3. Complements / corrections in manual and online help

New structure of the manual:

! All technology functions are described in a help.
! Manuals (PDF files) have a new structure:

! I10 T10 manual
! I11 T11 manual
! I20 T11 manual
! I21 T11 manual
! A single manual for all devices programmable according to IEC

(I11 T30, I20 T30, T21 T30, I11 T40, I20 T40, I21 T40)
The assignment of the respective chapters is indicated.

I11 T11 192-120101 N6 - March 2004 11

Introduction

1.4 Safety Instructions

In this chapter you can read about:

General hazards.............................................................................................................................12

Working safely................................................................................................................................12

Special safety instructions ..............................................................................................................13

1.4.1. General hazards

General Hazards on Non-Compliance with the Safety Instructions

The device described in this manual is designed in accordance with the latest
technology and is safe in operation. Nevertheless, the device can entail certain
hazards if used improperly or for purposes other than those explicitly intended.

Electronic, moving and rotating components can

! constitute a hazard for body and life of the user, and
! cause material damage

Usage in accordance with intended purpose

The device is designed for operation in electric power drive systems (VDE0160).
Motion sequences can be automated with this device. Several motion sequences
can be can combined by interconnecting several of these devices. Mutual
interlocking functions must be incorporated for this purpose.

1.4.2. Safety-conscious working

This device may be operated only by qualified personnel.
Qualified personnel in the sense of these operating instructions consists of:

! Persons who, by virtue to their training, experience and instruction, and their

knowledge of pertinent norms, specifications, accident prevention regulations and
operational relationships, have been authorized by the officer responsible for the
safety of the system to perform the required task and in the process are capable
of recognizing potential hazards and avoiding them (definition of technical
personnel according to VDE105 or IEC364),

! Persons who have a knowledge of first-aid techniques and the local emergency

rescue services.

! Persons who have read and will observe the safety instructions.
! Those who have read and observe the manual or help (or the sections pertinent

to the work to be carried out).

This applies to all work relating to setting up, commissioning, configuring,
programming, modifying the conditions of utilization and operating modes, and to
maintenance work.

This manual and the help information must be available close to the device during
the performance of all tasks.

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Parker EME

1.4.3. Special safety instructions

! Check the correct association of the device and its documentation.
! Never detach electrical connections while voltage is applied to them.

! Safety devices must be provided to prevent human contact with moving or

rotating parts.

! Make sure that the device is operated only when it is in perfect condition.
! Implement and activate the stipulated safety functions and devices.

! Operate the device only with the housing closed.
! Ensure that motors and any linear drives present are mounted securely.
! Check that all live terminals are secured against contact. Fatal voltage levels of to

750V occur.

1.5 Warranty conditions

! The device must not be opened.
! Do not make any modifications to the device, except for those described in the

manual.

! Make connections to the inputs, outputs and interfaces only in the manner

described in the manual.

! When installing the device, make sure the heat dissipater receives sufficient air.
! Attach the devices according to the mounting instructions, using the provided

fixing holes. We cannot provide any guarantee for any other mounting methods.

Introduction

Note on exchange of options

Compax3 options must be exchanged in the factory to ensure hardware and
software compatibility.

I11 T11 192-120101 N6 - March 2004 13

Introduction

r

1.6 Conditions of utilization

1.6.1. Conditions of utilization for CE-conform operation

- Industry and trade -

The EC guidelines for electromagnetic compatibility 89/336/EEC and for electrical
operating devices for utilization within certain voltage limits 73/23/EEC are fulfilled
when the following boundary conditions are observed:

Operation of the devices only in the condition in which they were delivered,

i.e. with all housing panels.

Mains filter:

Motor and resolve

cable:

A mains filter is required in the mains input line if the motor cable exceeds a certain
length. Filtering can be provided centrally at the plant mains input or separately at
the mains input to each device.

Commercial and residential area (limit values of Class A in accordance with
EN 61800-3)

The following mains filters are available for independent utilization:

Device: Compax3 Order No.: Condition:

S0xx V2: NFI01/01 Only for motor lines longer than 10m

S038, S075, S150 V4: NFI01/02 Only for motor lines longer than 10m

S300 NFI01/03 Only for motor lines longer than 10m

Industrial area (limit values in accordance with EN 61800-3)

Longer motor cable lengths are possible in industrial areas without a mains power
filter.

Connection length: connection between mains filter and device:

unscreened: < 0.5m
shielded: < 5m (fully shielded on ground – e.g. ground of control cabinet)

Operation of the devices only with Parker motor and resolver cables (their

plugs contain a special full surface area screening).

The following cable lengths are permitted:

Motor cable

< 100 m (the cable should not be rolled up!)
A motor output filter is required for motor cables >20 m.

! MDR01/04 (max. 6.3A rated motor current)
! MDR01/01 (max. 16A rated motor current)
! MDR01/02 (max. 30A rated motor current)

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Parker EME

Introduction

Screening connection of the motor cable

The motor cable should be fully screened and connected to the Compax3 housing.
We offer a special shield connecting terminal as accessory item (see on page

134).

Resolver cable

Motors:

Control:

Grounding:

Cable installation:

Accessories:

Warning:

< 100 m

Operation with standard motors.

Use only with aligned controller (to avoid control loop oscillation).

Connect the filter housing and the Compax3 (grounding screw on the underside) to
the cabinet frame, making sure that the contact area is adequate and that the
connection has low resistance and low inductance.

Never mount the filter housing and the device on paint-coated surfaces!

Signal lines and power lines should be installed as far apart as possible.
Signal leads should never pass close to excessive sources of interference (motors,

transformers etc.).

Make sure to use only the accessories recommended by Parker

Connect all cable shields at both ends, ensuring large contact areas!

This is a product in the restricted sales distribution class according to EN

61800-3. In a domestic area this product can cause radio frequency

disturbance, in which case the user may be required to implement

appropriate remedial measures.

I11 T11 192-120101 N6 - March 2004 15

Introduction

1.6.2. Conditions of utilization for UL permission

UL certification

conform to UL:

Certified

! according to UL508C
! E-File_No.: E235 342

The UL certification is documented by a “UL” logo on the
device (type specification plate)

“UL“ logo

Conditions of utilization

! The devices are only to be installed in a degree of contamination 2 environment

(maximum).

! The devices must be appropriately protected (e.g. by a switching cabinet).
! The terminals are suitable for field wiring.
! Tightening torque of the field wiring terminals (green Phoenix plugs)

! C3SxxxV2 0.57-0.79Nm 5 - 7Lb.in
! C3SxxxV4 exept C3S300V4 0.57-0.79Nm 5 - 7Lb.in

! C3S300V4 1.25-1.7Nm 11 - 15Lb.in

! Temperature rating of field installed conductors shall be at least 60°C Use

copper conductors only
Please use the cables described in the accessories chapter ( see on page 105)
they do have a temperature rating of at least 60°C.

! Maximum ambient temperature: 45°C.
! Suitable for use on a circuit capable of delivering not more than 500 rms

symmetrical amperes, 400 volts maximum.

ATTENTION
Danger of electric shock.
Discharge time of the bus capacitator is 5 minutes.

! The drive provides internal motor overload protection.

This must be set so that 200% of the nominal motor current are not exceeded.

! Cable cross-sections

! Mains input: corresponding to the recommended fuses (see on page 140)
! Motor cable: ( see on page 121) corresponding to the nominal output

currents (see on page 140)

! Maximum cross-section limited by the terminals mm

! C3SxxxV2 2.5mm

! C3SxxxV4 exept C3S300V4 4.0mm
! C3S300V4 6.0mm

! Circuit protection

2

2

2

2

/ AWG

AWG 12

AWG 10
AWG 7

In addition to the branch circuit protection, the devices have to be protected with
the supplementary protector S 261 L, manufactured by ABB.

! C3S025V2: ABB, nom 400V 10A, 6kA
! C3S063V2: ABB, nom 400V, 16A, 6kA
! C3S038V4: ABB, nominal 400V, 10A, 6kA
! C3S075V4: ABB, nominal 400V, 16A, 6kA
! C3S150V4: ABB, nominal 400V, 20A, 6kA
! C3S300V4: ABB, nominal 400V, 25A, 6kA
! C3S300V4: ABB, nominal 400V, 25A, 6kA

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/

Compax3 I11 T11: Positioning via digital I/Os

2. Compax3 I11 T11: Positioning via
digital I/Os

Due to its high functionality, the Positioning version of Compax3 forms an ideal
basis for many applications in high-performance motion automation.

Up to 31 motion profiles (target position, speed, acceleration, retardation, jerk) can
be programmed with the PC software. Positioning is triggered either via the parallel
interface (digital inputs) as single positioning or as positioning sequence. For the
positioning sequence the following motion profile is triggered by each START. The
number of repetitions can be specified for each motion profile.

High-performance control technology and openness for various sender systems
are fundamental requirements for a fast and high-quality automation of movement.

Model / standards

auxiliary material

The structure and size of the device are of considerable importance. Powerful
electronics is an important feature which made it possible to manufacture the
Compax3 so small and compact. All connectors are located on the front of the
Compax3.

Internal mains filters permit connection of motor cables up to a certain length
without requiring additional measures. EMC compatibility is within the limits set by
EN 61800-3, Class A. The Compax3 is CE-conform.

The intuitive user interface familiar from many applications, together with the
oscilloscope function, wizards and online help, simplifies making and modifying
settings via the PC.

The optional Operator control module (BDM01/01 (see on page 130 )) for
Compax3 makes it possible to exchange devices quickly without the need for a PC.

I11 T11 192-120101 N6 - March 2004 17

Compax3 I11 T11: Positioning via digital I/Os

Operating modes

You can select between two operating modes:

! Absolute mode or
! Endless mode

Furthermore, you can activate the functions Manual+ and Manual- via a set-up
mode.

Configuration

Configuration is made on a PC using the Compax3 ServoManager.
Install the program on your PC and connect the PC to the Compax3 X 10 via the
RS232 port.

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Compax3 device description

3. Compax3 device description

In this chapter you can read about:

Plug and connector assignment Compax3......................................................................................20

Installation and dimensions Compax3.............................................................................................31

I11 T11 192-120101 N6 - March 2004 19

Compax3 device description

Conditions of utilization for UL permission

3.1 Plug and connector assignment Compax3

In this chapter you can read about:

Function of the LEDs on the front panel..........................................................................................21

Power supply plug X1 for 230VAC devices.....................................................................................21

Power supply plug X1 for 400VAC devices.....................................................................................22

Ballast resistor / High voltage supply plug X2 for 230VAC devices .................................................22

Ballast resistor / High voltage supply plug X2 for 400VAC devices .................................................23

Motor / Motor brake (plug X3).........................................................................................................24

Control voltage 24 VDC / enable (plug X4) .....................................................................................25

RS 232 / RS485 interface (plug X10)..............................................................................................26

Analog / Encoder (Plug X11) ..........................................................................................................27

Digital inputs/outputs (plug X12).....................................................................................................28

Resolver / Feedback (plug X13)......................................................................................................29

Connection assignment based on the example of Compax3 S025 V2:

X1 AC Versorgung
AC supply

X2
Ballast / DC LS
Ballast / DC HV

X3
Motor / Bremse
Motor / Brake

X4
24VDC / Freigabe
24 VDC / Enable

X10
RS232 / RS485

X11
Analog/Encoder
Analog/Encoder

X12
Ein-/Ausgänge
Inputs/Outputs

X13
Geber
Feedback

Always switch devices off before wiring them!

Dangerous voltages are still present until 5 minutes after
switching off the power supply!

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Plug and connector assignment Compax3

Caution!

When the control voltage is missing there is no indication whether or
not high voltage supply is available.

3.1.1. Function of the LEDs on the front panel

State LED red LED green

Voltages missing off off

While booting alternately flashing

! No configuration present.
! SinCos feedback not detected.
! IEC program not compatible with the

firmware.

! For F12: Hall signals invalid.

Axis without current excitation off Flashes slowly

Function of the LEDs on the front panel

flashing off

Power supplied to axis; commutation calibration

off Flashes quickly

running

Axis with current excitation off on

Axis in fault status / fault present on off

3.1.2. Power supply plug X1 for 230VAC devices

PIN Description

1L

2N

3PE

Mains connection: Compax3 S0xx V2

Controller type S025 V2 S063 V2

Mains voltage

Rated input current

Maximum fuse rating per device

Single phase 230VAC + 10%

80-230VAC+10% / 50-60Hz

6Aeff 16Aeff

10A (automatic circuit
breaker K)

16 A (automatic circuit
breaker K)

Always switch devices off before wiring them!

Dangerous voltages are still present until 5 minutes after
switching off the power supply!

I11 T11 192-120101 N6 - March 2004 21

Compax3 device description

Power supply plug X1 for 400 VAC devices

3.1.3. Power supply plug X1 for 400 VAC devices

PIN Description

1L1

2L2

3L3

4PE

Mains connection Compax3 Sxxx V4

Controller type S038 V4 S075 V4 S150 V4 S300 V4

Mains voltage

Rated input current

Maximum fuse rating per
device

Three-phase 3*400VAC

80-480 VAC+10% / 50-60 Hz

6Aeff 10 Aeff 16Aeff 22Aeff

10A (automatic
circuit breaker
K)

16 A (automatic circuit
breaker K)

25A (automatic
circuit breaker
K)

Always switch devices off before wiring them!

Dangerous voltages are still present until 5 minutes after
switching off the power supply!

3.1.4. Ballast resistor / high voltage supply plug X2 for 230VAC

devices

PIN Description

1 + Ballast resistor

2 - Ballast resistor

3PE

4 + DC high voltage supply

5 - DC high voltage supply

Caution! The connector assignment of X2 is changed!

Please note the screen printing on the front plate of the
device: this is valid

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Ballast resistor / high voltage supply plug X2 for 400VAC devices

Plug and connector assignment Compax3

Brake operation Compax3 Sxxx V2

Controller type S025 V2 S063 V2

Capacitance / storable energy

Minimum ballast - resistance

Recommended nominal power rating

Pulse power rating for 1s

560µF / 15Ws 1120µF /30Ws
100Ω 56Ω

20 ... 60W 60 ... 180W

1kW 2.5kW

Caution!

The power voltage DC of two Compax3 V2 devices (230V devices) must not
be connected.

3.1.5. Ballast resistor / high voltage supply plug X2 for 400VAC

devices

PIN Description

1 + Ballast resistor

2 - Ballast resistor

3PE

4 + DC high voltage supply

5 - DC high voltage supply

Caution! The connector assignment of X2 is changed!

Please note the screen printing on the front plate of the
device: this is valid

Compax3 Sxxx V4 brake operation

Controller type S038 V4 S075 V4 S150 V4 S300 V4

Capacitance / storable
energy

Minimum ballast ­resistance

Recommended nominal
power rating

Pulse power rating for 1s

235µF / 37Ws 470µF / 75Ws 690µF /

110Ws

100Ω 56Ω 22Ω 15Ω

60 ... 250W 60 ... 500 W 60 ... 1000 W 60 ... 1000 W

2.5kW 5kW 10 kW 42kW

1100µF /

176Ws

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Compax3 device description

Motor / Motor brake (plug X3)

Connection of the power voltage of 2 Compax3 V4 devices (400V
devices)

In order to improve the conditions during brake operation, the DC power voltage of
2 devices may be connected.

The capacity as well as the storable energy are increased; furthermore the braking
energy of one device may be utilized by a second device, depending on the
application.

Please connect as follows:

Device 1 X2/4 to device 2 X2/4
Device 1 X2/5 to device 2 X2/5

Please note the following:

Caution! In case of non-compliance with the following instructions, the
device may be destroyed!

! You can only connect two similar devices (same power supply; same rated

currents)

! Connected devices must always be fed separately via the AC power supply.

3.1.6. Motor / Motor brake (plug X3)

PIN Description

1 U (motor)

2 V (motor)

3 W (motor)

4 PE (motor)

5 BR+ Motor holding brake

6 BR- Motor holding brake

Screening connection of the motor cable

The motor cable should be fully screened and connected to the Compax3 housing.
We offer a special shield connecting terminal as accessory item (see on page

134).

Connect the brake only on motors which have a holding
brake! Otherwise make no brake connections at all.

Motor holding brake output

Controller type Compax3

Voltage range

Maximum output current (short circuit
proof)

Motor cable (see on page 121)

24 I11 T11 192-120101 N6 - March 2004

21 – 27VDC

1.6 A

Parker EME

3.1.7. Control voltage 24VDC / enable (plug X4)

PIN Description

1 +24 V

2 Gnd24 V

3 Enable_in

4 Enable_out_a

5 Enable_out_b

Control voltage 24 VDC

Controller type Compax3

Voltage range

Current drain of the device

Total current drain

Ripple

Requirement according to safe extra
low voltage (SELV)

21 - 27VDC

0.8 A

0.8 A + Total load of the digital outputs +
current for the motor holding brake

0.5Vpp

yes

Compax3 device description

Power stage enable: X4/3=24 VDC

Tolerance range: 18.0 V – 33.6 V / 720 Ω

The +24V supply can be taken, for example, from Pin 1.

Safe standstill (X4/3=0V)

For implementation of the "Safe standstill" safety feature in accordance with the
“protection against unexpected start-up“ described in EN1037. Please refer to the
respective chapter (in the paper version “Installation Manual Compax3) with the
respective circuitry examples!

The energy supply to the drive is reliably shut off, the motor has no torque.
A relay contact is located between X4/4 and X4/5 (normally closed contact)

Enable_out_a - Enable_out_b Power output

stage is

Contact opened activated

Contact closed deactivated

Series connection of these contacts permits certain determination of whether all
drives are de-energized.

Relay contact data:

Switching voltage (AC/DC): 100 mV – 60 V
Switching current: 10 mA – 0.3 A

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Compax3 device description

3.1.8. RS232 / RS485 interface (plug X10)

Interface selectable by contact functions assignment of X10/1:
X10/1=0V RS232
X10/1=5V RS485

RS232

PIN
X10

1 (Enable RS232) 0V
2RxD
3TxD
4DTR
5GND
6DSR
7RTS
8CTS
9+5V

RS232 (Sub D)

RS485 2-wire

PIN
X10

1 Enable RS485 (+5V)
2res.
3TxD_RxD/
4res.
5GND
6res.
7TxD_RxD
8res.
9+5V

RS485 two wire (Sub D)
Pin 1 and 9 jumpered externally

RS485 4-wire

PIN
X10

1 Enable RS485 (+5V)
2RxD
3TxD/
4res.
5GND
6res.
7TxD
8RxD/
9+5V

RS485 four wire (Sub D)
Pin 1 and 9 jumpered externally

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3.1.9. Analog / Encoder (plug X11)

PIN X11 Reference

High Density Sub D

1 +24V (output for encoder) max. 70mA

2 Reserved

3 D/A monitor channel 1 (±10V, 8-bit resolution)

4 D/A monitor channel 0 (±10V, 8-bit resolution)

5 +5V (output for encoder) max. 150mA

Compax3 device description

6

7

8

A/ (Encoder simulation)

A (Encoder simulation)

B (Encoder simulation)

9 Reserved

10 Reserved

11 Reserved

12

13

14

15 GND

B/ (Encoder simulation)

N/ (Encoder simulation)

N (Encoder simulation)

3.1.9.1 Wiring of the analog input

2.2K

Ω

10nF

10K

Ain+

Ain-

X11/9

X11/11

10K

2.2K

Ω
Ω

10nF

Ω

3.1.9.2 Wiring of analog outputs

332Ω

I11 T11 192-120101 N6 - March 2004 27

X11/4
X11/3

+/-10V/1mA
(max: 3mA)

X11/15

Compax3 device description

3.1.10. Digital inputs/outputs (plug X12)

The assignment of X12 depends on the operating mode "Normal or Commissioning
Mode".

Only 4 motion profiles can be selected in commissioning mode. The inputs
"Manual+" and "Manual-" are available for this.

PIN

X12/

1 O +24VDC output (max. 400mA)

2 O0 No fault

3 O1 Position reached (max. 100 mA)

4 O2 No power output stage current (max. 100mA)

5 O3 Motor stationary with current, with setpoint 0 (max. 100mA)

6I0 No stop

7 I1 Start (edge)

Input/output I/O /X12

High density/Sub D

Normal mode Commissioning mode

8

I2="1": Quit (positive edge) / Energize the motor

The address of the current positioning data record is newly read
in.

I2="0": Motor deenergized with delay

9 I3 Address 0

10 I4 Address 1

11 I 24V input for the digital outputs Pins 2 to 5

12 I5 Address 2 Manual+

13 I6 Address 3 Manual-

14 I7 MN-Ini* / Address 4 MN-Ini*

15 O Gnd 24 V

*Machine home proximity switch only when the corresponding mode has been
selected. 15 motion profiles (address 0-3) and machine zero run are then possible.

All inputs and outputs have 24V level.
Maximum capacitive load on the outputs: 50 nF (max. 4 Compax3 inputs)

3.1.10.1 Input wiring of digital inputs

SPS/PLC

X12/1

X12/6

X12/15

28 I11 T11 192-120101 N6 - March 2004

22K

F2

Ω

22K

Ω

22K

Ω

10K

100K

Ω

F1

X4/1

Ω

X4/2

24V

0V

Parker EME

The circuit example is valid for all digital inputs!
F1: Delayed action fuse

F2: Quick action electronic fuse; can be reset by switching the 24VDC supply off
and on again.

3.1.10.2 Output wiring of digital outputs

Compax3 device description

24V

0V

F1

X4/1

18.2K

X4/2

F2

X12/1

X12/11

X12/2

Ω

X12/15

The circuit example is valid for all digital outputs!
The outputs are short circuit proof; a short circuit generates an error.

F1: Delayed action fuse
F2: Quick action electronic fuse; can be reset by switching the 24VDC supply off

and on again.

3.1.11. Resolver / Feedback (connector X13)

PIN
X13

Feedback /X13

High Density /Sub D (dependent on the Feedback Module)

Resolver (F10) SinCos (F11) Direct drives (F12)

SPS/

PLC

1 res. res. Sense -

2 res. res. Sense +

3 GND GND Hall1

4 REFres+ Vcc (+8V) Vcc (+5V) (controlled on the encoder

side) max. 200mA load

5 +5V (for temperature sensor) +5V (for temperature and hall

sensors)

6 CLKfbk CLKfbk Hall2

7 SIN- SIN- SIN- / A- (Encoder)

8 SIN+ SIN+ SIN+ / A+ (Encoder)

9 CLKfbk/ CLKfbk/ Hall3

10 Tmot Tmot Tmot

11 COS- COS- COS- / B- (Encoder)

12 COS+ COS+ COS+ / B+ (Encoder)

13 res. DATAfbk N+

14 res. DATAfbk/ N-

15 REFres- GND (Vcc) GND (Vcc)

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Compax3 device description

Note on F12:

+5V (Pin 4) is measured and controlled directly at the end of the line via Sense –
and Sense +.

Maximum length of cable: 100m

Caution! Pin 4 and Pin 5 must under no circumstances be connected!
Resolver cable (see on page 119)
SinCos cable (see on page 120)

30 I11 T11 192-120101 N6 - March 2004