HPD N
(HPD2N, HPD5N, HPD8N, HPD16N,
HPD20N,HPD24N)
User’s manual
rev. 8.5
November 2004
software rel. 41
M
+
-
X1
X2 X3
1
11
2020
10
X5
X6
X7
1
12
X4
HPD
HIGH PERFORMANCE DRIVE
DIGITAL-LOCK
VARIABLE RATIO
POSITIONER
STEP MOTOR
SIMULATION
EASY
MAINTENANCE
TORQUE CONTROL
ACCELERATION
CONTROL
SPINDLE ORIENTATION
FOR TOOL CHANGING
SOFTWARE & HARDWARE
EXPANSION
RS-485 or RS-422 SERIAL LINK
BUILT-IN P.L.C.
EXTENDED
VOLTAGE RANGE
HPD :
everywhere
for any
a
pp
licatio
n
Parker H an nifin S.p. A.
Divisione S .B. C.
Via Gounod, 1 – 20092 Cinisello B.
(Milano) – Italy
Phone: +39-02-66012478
Fax: +39-02- 66012808
E-ma il: drive s bc @park er.com
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
2
WARNING
HIGH VOLTAGE !
Certain circuits in the
HPD drive carry dangerously high voltages that could cause serious
personal injury or death.
Do not attempt to service any parts of the drive when it is connected to the power
supply.
If you need to access internal parts, before working on the drive allow at least 15 minutes
after power-down to allow the DC bus capacitors to discharge. It is the User’s responsibility
to make sure that the installation is executed in accordance with established industrial health
and safety standards.
In relation to the interpretation of standards, note that the drive is considered as a component
and not as a machine.
Any tampering or unauthorised modification of the drive will invalidate the guarantee
immediately. Guarantee cover is otherwise provided for 1 (one) year.
This instruction manual is applicable to the standard version of the drive.
Parker Hannifin S.p.A. - S.B.C. Division declines all liability for any whatsoever form of
damage caused by inappropriate use of the drive.
Training courses can be supplied by Parker Hannifin S.p.A. - S.B.C. Division on request.
Cod 0907131040
Installation and maintenance of the drive and connected
equipment must be performed exclusively by qualified and
trained personnel with basic skills in electronics.
Commissioning of the drive must performed exclusively by
qualified and trained personnel with advanced skills in
electronics and drive technology.
The quoted performance of the HPD drive is guaranteed only
when used with series MB synchronous motors
manufactured by Parker Hannifin S.p.A. - S.B.C. Division
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
3
CONTENTS:
1. INTRODUCTION...................................................................................................................... 5
1.1. General information .......................................................................................................5
1.2. Product description......................................................................................................... 5
1.3. Direct mains connection................................................................................................. 6
1.4. Identification .................................................................................................................. 6
2. Technical data ............................................................................................................................ 7
2.1. Main hardware specifications.........................................................................................7
2.2. Software features............................................................................................................8
2.3. Compliance with EMC standards................................................................................... 8
2.4. Safety.............................................................................................................................. 8
3. INSTALLATION.......................................................................................................................9
3.1. Safety instructions.......................................................................................................... 9
3.2. Interference suppression hints...................................................................................... 10
3.3. Mains filter installation instructions............................................................................. 10
3.4. Control cubicle layout example....................................................................................12
3.5. HPD drive mains filters................................................................................................ 13
3.6. Terminal assignments................................................................................................... 16
3.7. Power connections........................................................................................................18
3.8. Power connection layout..............................................................................................19
3.9. Signal cable connections..............................................................................................20
3.10. Signal cable connection layout..................................................................................... 20
3.11. Frequency input connection......................................................................................... 20
3.11.1. Encoder emulation................................................................................................23
3.12. Serial line connection................................................................................................... 23
3.13. Braking resistor............................................................................................................ 24
3.14. Backup.......................................................................................................................... 24
4. PARAMETERS AND PROGRAMMING .............................................................................. 25
4.1. Using the keypad..........................................................................................................26
4.2. Commissioning the HPD drive ....................................................................................27
4.3. Basic parameters ..........................................................................................................30
4.4. Basic commands........................................................................................................... 36
4.5. Calibrating speed loop.................................................................................................. 37
4.6. Operating modes .......................................................................................................... 43
4.6.1. Torque control...................................................................................................... 43
4.6.2. Acceleration control.............................................................................................43
4.6.3. Low voltage procedure (rel. Sw.41 or more)....................................................... 44
4.6.4. Maintenance and commissioning......................................................................... 45
4.6.5. Positioner.............................................................................................................. 46
4.6.6. Digital locking......................................................................................................48
4.6.7. Stepper motor emulation...................................................................................... 49
4.6.8. Spindle orientation ............................................................................................... 51
4.7. Block diagrams............................................................................................................. 51
4.8. Digital input and output programming......................................................................... 58
4.8.1. Pico-PLC..............................................................................................................58
4.8.2. Examples and applications................................................................................... 63
4.9. Programming with Pcbrush..........................................................................................80
5. SERIAL INTERFACE............................................................................................................. 81
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
4
5.1. Communication protocol..............................................................................................81
5.2. Serial addresses and parameter lengths........................................................................87
6. Appendix A: HPD drive mechanical dimensions .................................................................... 89
7. Appendix B: hardware characteristics...................................................................................... 90
8. Appendix C: DC bus voltage thresholds..................................................................................91
9. Appendix D: Standard settings.................................................................................................91
10.Appendix E: Software timers...................................................................................................92
11.Appendix F: pico-PLC default program.................................................................................. 93
12.Appendix G: flash information................................................................................................94
13.Appendix H: Alarms................................................................................................................95
14.Appendix I:options................................................................................................................... 97
15.Appendix L: EC4.....................................................................................................................98
15.1. Product description....................................................................................................... 98
15.2. Main characteristics......................................................................................................98
15.3. EC-4 block diagram .....................................................................................................99
15.4. Product and connectors identification........................................................................ 100
15.5. EC-4 installation......................................................................................................... 101
16.Profibus-DP connector...........................................................................................................102
17.Can Bus Connector ................................................................................................................ 103
18.Digital I/O.............................................................................................................................. 104
19.Encoder and serial link........................................................................................................... 106
20.Motion functions concepts..................................................................................................... 108
21.Examples of applications.......................................................................................................109
21.1. Power supply for presses............................................................................................109
21.2. Electronic cam............................................................................................................110
21.3. Positioner with 250 preset levels................................................................................ 111
21.4. Two-axis extractor......................................................................................................112
21.5. Vertical robot..............................................................................................................113
21.6. Continuous press........................................................................................................ 114
21.7. On the fly cutting........................................................................................................115
21.8. Heat sealer.................................................................................................................. 116
22.Appendix M: external bracking modul.................................................................................. 117
23.Appendix N application description form.............................................................................. 119
24.Revision history of the User’s Manual ..................................................................................121
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
5
1. INTRODUCTION
1.1. General information
This manual describes operations required for the installation and commissioning of the
HPD (High Performance drive) drive for brushless motors. Read all chapters of the manual
carefully before using the drive.
Peerlessness with previous versions: if you wire together the DC BUSes, the drive must be
of the same family (HPD with HPD, HPD N with HPD N - not HPD with HPD N !
Pay attention when ordering a spare part !).
Except the above situation, the
HPD N can replace a HPD drive.
When using the backup feature, DO NOT change the HPD N with the HPD: the
circuitry is different and the HPD requires the external relay.
1.2. Product description
The HPD drive is a digital frequency converter for driving AC brushless motors. The
adoption of a Parametric Operator Interface makes drive configuration procedures faster and
easier to repeat. The large number of configuration possibilities makes the drive suitable for
numerous applications.
A high power 16 bit micro-controller allows speed control with the characteristics required
of a servo controller, plus a range of auxiliary functions that can help reduce the presence of
control electronics in the application and thus permit considerable economic savings.
In addition to the positioner functions with trapezoidal profile, digital lock, spindle
orientation, stepper motor emulation, torque control and acceleration control, the HPD drive
also has an internal pico-PLC. The pico-PLC adopts the most diffused industrial
programming standards and offers considerable freedom for use of inputs and outputs. It also
enables users to develop a range of additional functions that are not among the basic features
of the drive.
The HPD drive is complete with an RS-422/RS-485 serial interface which can be used for
configuration, monitoring, or simultaneous transmission of commands to a multiple system
comprising up to 32 HPD drives.
In addition to the above functionality, the HPD drive is designed as an open system with
the facility to accommodate hardware and software expansion cards. For further information
on currently available expansion cards contact Parker Hannifin S.p.A. - S.B.C. Division
directly or your local Dealer.
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
6
1.3. Direct mains connection
The HPD series of drives is specifically designed for direct connection to a three-phase
mains power supply from 90 to 460V~ 50/60 Hz, without interposing transformers. It is the
responsibility of the User to connect the system via protection fuses. The use of single phase
power supplies is permitted although motor power output must be derated in this case.
Maximum motor power is calculated by the following formula:
Pmax = 14⋅10-3 Vrete2 [watt] only HPD2
Pmax = 27⋅10
-3
Vrete2 [watt] only HPD5 and HPD8
Not applicable HPD16 HPD20 HPD24
All protections required for safety, such as overvoltage detection, short circuit fault
protection and inverter and motor overtemperature detection are integral with the drive.
Mains filters and motor filters must be calculated during the design of the electrical cubicle
so that EMC standards are met in order to qualify for CE marking.
Chapter 2 provides a detailed view of problems related to EMC.
N.B. leave at least 60 sec. after switching the drive off before switching it on again.
The HPD “N” has 2.5 seconds circa of power-on time.
Previously, it was nearly 10 seconds.
1.4. Identification
HPD drives are available in 6 models: HPD2N, HPD5N, HPD8N, HPD16N, HPD20N and
HPD25N. The number that follows HPD is the value of drive rated current in amperes.
Another yellow warning label is placed on the right side of the HPD “N” drive:
SUITABLE FOR USE ON A CIRCUIT CAPABLE OF
DELIVERING NOT MORE THAN 5000 rms
SYMMETRICAL AMPERES, 480 V MAXIMUM
WARNING
DEVICE IS LIVE UP TO 60s AFTER REMOVING
FROM MAIN VOLTAGE
GROUND PE MUST ALWAYS BE CONNECTED
ATTENTION
L' APPAREIL EST SOUS TENSION PENDANT
60s APRES LA COUPURE DE LA TENSION RESEAU.
TERRE PE DOIT ETRE TOUJOURS CONNECTE
Parker Hannifin S.p.A. Divisione S.B.C.
Via Gounod 1 – 20092 Cinisello B.
(Milano) – Italy
POWER INPUT
3XAC90...480V XXA
50...60 Hz
READINSTALLATION
INSTRUCTION MANUAL BEFORE
INSTALLING
POWER OUTPUT
3XAC90...480 XXA
0...500 Hz
USE COPPER WIRE RATED
60/75°C
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
7
2. Technical data
2.1. Main hardware specifications
The maximum voltage value is 480Vac (instead of former 460Vac). Ensure that the maximum
voltage across terminals L1, L2, L3 does not exceed more than 10% the 480Vac, even in the
worst case (see EN60204-1 standard, section 4.3.1). An excessive voltage may damage the
drive. The following table describes the new ratings:
Description Unit Value
Mains voltage V~ 90…480
Models
HPD2N HPD5N HPD8N HPD16N HPD20N HPD24N
Rated current A 2 5 8 16 20 25
Peak current (4 seconds) A 4 10 16 32 65 50
Input current FLA 1.6 4.2 6.2 12 15 19
Rated motor torque (@400 V~) KW 1 2.5 4.1 8.3 10 12.5
Control-stage power dissipation W 18
Power-stage dissipation W 25 60 89 158 200 246
Enviromental temperature o
C
45
Braking resistor internal / external
Internal braking resistor power dissipation W 120 240
Feedback resolver (speed 1)
Power-stage switching frequency KHz 8
Max. output frequency Hz 450
Protection Grade IP 20
Digital Inputs 24V =
No
8
Digital Outputs 24V = / 100mA / PNP
No
6
Digital Output “Voltage-Free”
No
1
Encoder Simulation RS-422 steps/rev 128..16384
Frequency/sign Input or ext. Encoder KHz 800 / 200
Analogue reference V ±10 diff 15 bits
Aux. Analogue Input V ±10 diff 10 bits
Aux. Analogue Output V ±10 - 8 bits
Tacho Output V ±10 V
Serial link RS-422 / RS-485
Encoder Simulation Backup V 24 =
Encoder Simulation Backup A max. 2
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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2.2. Software features
The following capabilities are implemented in the basic software supplied with the HPD
drive:
• Speed control
• Advanced torque limit manager
• Speed windows management
• Positioning with trapezoidal speed profile
• Digital locking functions with variable transmission ratio and phase shifting
• Spindle orientation
• Stepper motor emulation
• Torque control with overlaid speed control
• Acceleration ramp control with overlaid speed control
• Simplified maintenance and start-up mode
• Internal PLC for advanced input/output programming functions
2.3. Compliance with EMC standards
Immunity:
EN50082-1* / EN61000-6-2 Basic immunity specifications
IEC1000-4-2 (ex IEC 801-2) level 3 Electrostatic discharge immunity
IEC1000-4-3 (ex IEC 801-3) level 3 Electromagnetic field immunity
IEC1000-4-4 (ex IEC 801-4) level 4 Fast transient burst conducted immunity
Compatibility:
EN50081-1* / EN61000-6-4 Basic radio interference specifications
EN55011 group 1, class A Measurement limits for radio interference
EN55011 group 1, class B* Measurement limits for radio interference
2.4. Safety
Safety standard EN60065
Low voltage Directive 73/23/CEE amended by 93/68/CEE
Applied standard EN60204-1
Available with markcULus UL508C
* Conformity for use in domestic or industrial surroundings depends on the nature of the installation.
This is a product of the restricted sales distribution class according to EN61800-3.
In a domestic environment this product may cause radio interference, in that case the user
must use the properly measures.
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
9
3. INSTALLATION
• The HPD drive must be installed in a vertical position (power terminal block X4 at the
top).
• Leave at least 190 mm clearance above and below the drive.
3.1. Safety instructions
• Make sure the drive is correctly sized for the motor you intend to connect. Compare rated
voltage and current.
• Wire up electrical panel/drive/motor in accordance with the instructions in this section of
the manual, taking into consideration EMC requirements and established safety legislation.
• The User is responsible for installing fuses on the drive A.C. power supply.
• A differential interrupter could not be used on the entry of feeding of the converter. The
protection against indirect contacts must be realized through other streets, for instance
through a overcurrent disconnecting switch in accord to the EN 50178/ 1994 Sez. 5.3.2.3
and to the EN 60204-1 Sez. 6.3 6.3.1 6.3.2 6.3.3 and however in accord to the laws of the
country of installation.
• Before feed the converter, all the components and the motor must be to earth or connected
to the points of earth through isolated cables.
The current of loss toward earth is superior at 3,5mA o'clock. E' therefore application
an excellent connection of earth (EN 50178/ 1994 [sez]. 5.12.11.1).
• Power conductors and control circuits must be kept apart (at least 20 cm) and, when they
must cross, intersections must be at a right angle. Motor lines and mains power lines must
never be parallel.
• All power conductors must be sufficiently sized (refer to table in heading 2.7; in all cases
compliance with IEC227-2 must be guaranteed).
• Conductors connected to the system by means of the terminal strip must not be soldered
(EN60065, art.15.3.5).
• Make sure drive and motor and properly earthed.
• Make sure that the maximum voltage on terminals L1, L2, L3 does not exceed rated
voltage by more than 10% in the worst possible case (see EN60204-1, section 4.3.1).
Excessively high mains feeding voltage can damage the drive.
• Do not detach electrical connections when the drive is connected to the power supply.
• Follow all installation instructions in this manual step by step. If you are in doubt, contact
S.B.C. customer service.
• Dangerous voltages may remain for 60 seconds after mains disconnection and system
power-down; do not touch power cables during this interval.
• Do not open the drive casing. This action is potentially dangerous and will automatically
invalidate the guarantee.
Installation and wiring must be carried out with the entire electrical panel disconnected from
the power supply. Make sure that the drive enable command is disconnected from the
emergency circuit. Qualified technical personnel must preside when the power panel is
powered up for the first time.
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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3.2. Interference suppression hints
Because of the high speed voltage wavefronts in PWM, high levels of stray current may
sometimes flow through capacitive couplings and earth systems. Stray currents of this type
can affect other functional units. It is therefore prudent to calculate the presence of an amount
of spurious energy that depends on the size of the system (drives, motor lines, motor).
Spurious energy generates EM radiation that can interfere with the operation of nearby
systems. Existing standards do not set down limits for this type of radiation.
Preventive measures
Basic methods for preventing interference are: decoupling of drive from its surroundings,
high quality and properly sized conductors to neutralise voltages (earthing), and adequate
shielding. Shields, filters and drives must have a large contact area to achieve the maximum
possible decoupling and hence optimal noise suppression. Attention must be paid, however, to
the entire installation, as this is one of the most important precautions in assuring efficient
noise suppression.
High frequency interference takes the form of radiation, especially from the motor lines.
This effect can be reduced with the use of shielding.
Another essential counter-measure for noise suppression is the use of filters.
The use of filters is aimed at reducing conducted interference on wiring and the return of
conducted interference to source (drive) through routes offering the lowest impedance. This
method provides effective protection for other systems connected to the same electrical line,
also protecting the drive from interference originating from other systems. When installing
filters consider the mains input and motor feeding output; the motor feeding output can be
protected with output filters that minimise interference levels (generally torroidal ferrite core
coils bearing several windings of all three motor wires).
3.3. Mains filter installation instructions
To guarantee electromagnetic compatibility in compliance with the relevant standards the
maximum priority must be awarded to EMC requirements when designing the control cubicle.
To obtain the best results from filters follow the instructions in this section carefully, because
even a complex and expensive filter is ineffective unless it is installed
taking EMC aspects into consideration.
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
11
Avoid:
- routing noise emitting cables parallel to “clean” cables
- parallel cables, especially in the vicinity of the filter (ensure physical separation)
- cable loops (keep cables as short as possible and close to the common potential).
Additional measures
- With the exception of mains cables to the filter, all power and control wiring must be
shielded and, wherever possible, kept segregated (minimum distance 20 cm). If control and
power cables must cross, the intersection must be at a right angle.
- Shielded cables must be installed on a copper bar by means of a high conductivity wire
clamp. The area of contact must be as large as possible and the shield must be unbroken. In
general the shield should be connected at each extremity. In certain circumstances, however,
control cable shields may be connected only at one end to eliminate mains hum that could
interfere with the control signal. Decide case by case as numerous factors must be considered.
Adopt the following general approach: if the shield is solely for shielding, connect at both
ends. If current flowing in the shield interferes with the shielded signals, connect at one end
only.
- The incoming cable must be connected to an earth terminal by means of a screw to ensure
proper contact between shield and earth.
- RF interference suppression filters must be installed as close as possible to the drive and
must have a large area of contact with the power panel or the baseplate. Remove all paint. The
filter earth terminal must be connected to the earth bar along the shortest possible route.
- As far as possible keep the power side (drive) and control side (PLC or NC) physically
separated by separating the metal mounting plates. Do not route any cables through the
mounting plates.
Protective measures for drives with > 3.5mA dispersion current per phase
Interference currents dispersed through the earth system may be considerable in certain
conditions. Therefore, make sure all suppression filters are properly earthed before they are
connected. Cable sizes must be in line with the requirements of safety standards.
If a suppression filter is permanently connected and current dispersion during normal
operation is greater than 3.5mA (which would be expected with most drives) adopt one of the
following measures additionally:
a) Increase shield size to at least 10 mm².
b) Install a detection system to monitor the shield and automatically disconnect the drive in
the presence of faults.
c) Install a second conductor in parallel (electrically) with the shield using separate
terminals.
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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3.4. Control cubicle layout example
All conductors down-line of the mains filter must be
shielded and mounted to a copper bar with large contact area. Also
the copper bar must present an ample area of contact with the
cubicle mounting plate.
Large surface area partition shield with generous contact
area around perimeter. Remove paint from contact points in the
cubicle.
POWER CONTROL
filter
drive
Cubicle interior or mounting plate
control
cable
mains
cable
max.
30 cm
cable
motor
keep separate as far as possible
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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3.5. HPD drive mains filters
S.B.C. has developed a special series of filters for HPD drives. When the filters are
installed in accordance with our instructions, compliance with EN55011-class A is
guaranteed; for class B rating add a transformer to the power supply (shielded primary and
secondary). Users must allow space in the control cubicle to accommodate filters
implemented at the time of the project. Parker Hannifin S.B.C. division filters provide both
mains and motor output filter functions.
Filters of different manufacture can also be utilised. In this case
Parker Hannifin S.B.C.
division offers its technical support by testing the filter you intend to use and generating
a test data report.
CERTIFIED FILTER CONFIGURATIONS IN COMPLIANCE WITH EN55011 (group
1 classes A and B)
High attenuation S.B.C. three-phase filters are specifically designed for S.B.C. brushless
motor drives in compliance with the standard IEC950 for stray current up to 3.5 mA (380 - 50
Hz) for semi-static equipment.
TECHNICAL FEATURES
Enclosure metal
Protection degree IP20
Temperature -25 … +50 oC
Rated voltage 480 V~ @ 50°C, 50-60 Hz
S.B.C. FILTERS
code typo current
A @ 40°C
enclosure
SBC3RD7M mains 8
SBC3RD16M mains 18
SBC3RD30M mains 34
SBC3M10M motor 10 F6
SBC3M20M motor 20 F6
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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Configuration 1 Class A
filtro rete
SBC3RDXX
convertitori
RETE
M
M
M
M
H P D
H P D
H P D
H P D
Where HPD rating is between 2 and 16 A
The sum of the rated current values must not exceedthe XX mains filter rted current
.01 .1 1 10 30
120
90
60
30
0
dBuVMHz
Limit: C22_A_QP Title: DEFINIT4 Date: 06-25-1995
PMM 8010
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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Configuration 2 Class B
mains filter
SBC3RDXX
drivesi
SBC3MYY
MAINS
M
motor filter
SBC3MYY
M
SBC3MYY
M
SBC3MYY
M
H P D
H P D
H P D
H P D
Where HPD rating is between 2 and 16 A
The sum of drive rated current values must not exceed the XX mains filter rated current
YY can be 10 or 20 and represents the motor filter rated current;
drive rated current must not exceed that of the filter
.01 .1 1 10 30
120
90
60
30
0
dBuVMHz
Limit: C22_B_QP Title: DEFINI12 Date: 06-25-1995
PMM 8010
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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3.6. Terminal assignments
High Performance Drive
X3
X2
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
X7
X6
X5
E
N
C
O
D
E
R
O
U
T
E
N
C
O
D
E
R
I
N
S
E
R
I
A
L
L
I
N
K
X1
1
2
3
4
5
6
7
8
9
10
16
19
17
18
20
12
13
14
11
15
6
7
9
8
10
2
4
3
5
1
Serial interface
Encoder IN
Encoder OUT
Control voltages and
digital inputs
Power
Resolver
Analog signals and
digitaloutputs
Parker Hannifin S.p.A. - S.B.C. Division HPD N User’s Manual
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Terminal board X1 Terminal board X4
1 motor PTC + ( 24 V ) 1 L 1
2 motor PTC - 2 L 2
3 resolver, EXCT + 3 L 3
4 resolver, EXCT - 4 U PHASE
5 resolver, SIN + 5 V PHASE
6 resolver, SIN - 6 W PHASE
7 resolver, COS + 7 AB
8 resolver, COS - 8 BB
9 0 V 9 EB
10 0 V 10 IB
11 + DC BUS
12 - DC BUS
Terminal board X2 Terminal board X3
1 reference high + 1 + 10 V - 10 mA max
2 reference low - 2 0 V
3 0 V 3 - 10 V - 10 mA max
4 Aux reference high + 4 0 V
5 Aux reference low - 5 + 24 V - IN
6 0 V 6 0 V
7 Aux. analogue output 7 0 V
8 0 V 8 + V backup
9 tacho output 9 - V backup
10 0 V 10 0 V
11 digital out 0 11 drive enable
12 digital out 1 12 digital input 1
13 digital out 2 13 digital input 2
14 digital out 3 14 digital input 3
15 digital out 4 15 digital input 4
16 digital out 5 16 digital input 5
17 digital out 6 A 17 digital input 6
18 digital out 6 B 18 digital input 7
19 + 24 Vdc - OUT 200 mA 19 + 24 V - OUT 200 mA
20 0 V 20 0 V
DB9 female type
X5
D DB9 female type
X6
DB9 male type
X7
1 TX 1 A 1 PHA
2 RX 2 /A 2 /PHA
3 /TX 3 B 3 PHB
4 /RX 4 /B 4 /PHB
5 5 -BRA 5 PHC
6 +BR 6 +BRB 6 /PHC
7 -BR 7 0 V 7 0 V
8 0 V 8 -BRB 8
9 0 V 9 +BRA 9
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3.7. Power connections
For the motor cable consider
Choice between cable for fixed or floating installation.
Cable must be shielded and suitably sized in terms of insulation and wire sections.
Reticulated polypropylene is the preferred insulation material.
Length (max 100 m); note that conductor-conductor capacitance must not exceed 8 nF.
If cable length exceeds 35 m install a triple inductance between drive and motor with rated
current identical to HPD rated current.
Minimum conductor size is 1.5mm2 for HPD2N and HPD5N , 2.5mm2 for HPD8N and
4mm2 for HPD16N, HPD20N and HPD24N.
For the mains power cable
Power cables must not be shielded.
Minimum conductor size is 1.5mm2 for HPD2 and HPD5, 2.5mm2 for HPD8 and 4mm2
for HPD16 HPD20N and HPD24N.
Input fuses must be rated as follows:
MODEL Slow blow fuses
(A)
HPD2N 6
HPD5N 10
HPD8N 16
HPD16N 20
HPD20N 25
HPD24N 25
Resolver cable
The cable must comprise 4 twisted pairs with individual shields and one common shield.
Capacitance for the length of cable must not exceed 10 nF; wire size must be no less than
0.35mm2.
Maximum length is 100 m.
See the section “resolver connections”.
EMI filter connection
The connection between filter and drive must never exceed 30 cm. If the distance is less
than 15 cm unshielded cables are possible, otherwise a shielded cable must be used.
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Earth connections
To reduce the length of individual conductors that must be connected to earth we
recommend using an earth busbar located as near as possible to the drive.
The busbar must be made of copper to ensure low inductance. It must also be mounted on
insulated fixings. The adjacent table shows minimum dimensions according to length.
3.8. Power connection layout
A
B
C
D
1
EMC filter
X4
FERRITE CORE
TOROIDAL
COIL
MAIN
S
MOTOR
EART H ST UD
SCREW
A
B
C
D
E
F
RESOLVER
X1
E
J
K
G
H
*
*
FERRITE COI L, MOT OR FILTER O R NOT PROTECTION
ACCOR DING TO CHOSEN CO NFI GURATI ON
SERVOMOTOR "MB"
DRIVE "HPD"
M
2
3
4
5
6
7
8
9
10
11
12
L1
L2
L3
PE
10
9
1
2
3
4
5
6
7
8
A
B
C
A
B
C
D
E
F
J
K
Connection 360°
Connection 360°
ATTENTION: respect suitable connections meticulously (with particular attention to the
shield) for a correct operation system.
N.B. the protection of the resolver cable in general must be all connected to the clamp 9 of
X1. Side motor,the protection of the connected duplex cable to [j-k] must be connected to
H, the general protection to G. the other protections must not be connected.
Length (m) width (mm) thickness
(mm)
0.5 20 6
1 40 6
1.5 50 6
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3.9. Signal cable connections
A twisted and shielded pair must be employed for the analogue reference.
The cable for emulated encoder signals must comprise three twisted pairs with a common
shield.
Normal cables can be used for digital inputs/outputs.
Minimum size of all signal wires is 0.35mm
2
3.10. Signal cable connection layout
CONTROLLER
HPD
REF+
REF-
A
/A
B
/B
C
/C
23X2 - Reference in
1
1
2
3
4
5
6
7
X7 - Encoder out
24Vdc
19
11
13
X3 - Inputs
11
X2 - Outputs
TO EARTH BAR
20
MOTION
Encoder in
Output
Enable
Input
Reference out
3.11. Frequency input connection
The frequency input, RS-422 type in X6, can be software-configured in two different ways:
the first (default) to accept two quadrature signals (for example, from encoders), the second is
frequency/direction type (see chapter
Basic parameters bit b42.5).
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In the first case the scheme to use is the follow:
7
1
0V
2
3
4
X6
8
6
5
9
HPD
A
A
B
B
In case of parallel connections to more than one HPD,
connections to pins 9, 5, 6, and 8, must
be made only on the last drive in the group.
In the second case, there are two possible solution for to control the drive with input signal
from X6 frequency/direction type:
-
by “PLC-Line driver interface” board (available to our products);
-
by showed below.
When CLOCK and DIR signals are to 24Vdc, execute the connections: channel A is dedicated
to frequency while channel B to direction.
O
O
O
- Cable shielded with 3twisted pairs.
- Connect the resistances near to the terminal of the drive
(max. 5cm).
- For the fixing of the cable-shields use the connections
shown on the picture beneath.
360° connection
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When CLOCK and DIR signals are to 5Vdc, execute the connections:
HPD connection with digital locking
1
2
3
4
7
X6 (HPD)
X6 (HPD)maste
r
A
A
B
B
GND
1
2
3
4
7
X7 (HPD)
see text for burden resistors
The example in the figure shows the connection between two HPD drives in digital lock
with a master, but this configuration can be extended to several drives connected in series. On
the final drive in the series connect the burden resistors by jumpering pin 1 with pin 9, pin 2
with pin 5, pin 3 with pin 6 and pin 4 with pin 8 on connector X6. The master can be an
externally fed encoder, or the simulated encoder output on another drive.
The signal from the master encoder must be differential type 5V RS-422; it is therefore
possible to connect a maximum of 10 slave HPDs.
If the master is an HPD drive, then up to 32 units can be connected in digital lock mode
using the same simulated encoder signal (RS-422 standard).
For the relative programming of the HPD, consult the
Digital locking chapter in this
manual.
360° connection
- Cable shielded with 3twisted pairs.
- Connect the resistances near to the terminal of the drive
(max. 5cm).
- For the fixing of the cable-shields use the connections
shown on the picture beneath.
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3.11.1. Encoder emulation
On connector X7 there are signals of encoder emulation phase A, phase B and phase C
(reference zero). The signals are RS-422 type. For the relative programming of pulses per
revolution consult the
Basic parameters chapter in this manual, bit b42.0, b42.1 and b42.2
(default = 1024 pulses/revolution).
3.12. Serial line connection
The HPD drive serial line can be configured as RS-422 or RS-485 depending on the
connection. In both cases termination resistors must be used (150
Ω). Where more than one
HPD drive is connected to the bus the final node must be terminated as shown below. The
two cases are illustrated in the following diagrams.
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3.13. Braking resistor
HPD drives are equipped with an integrated braking resistor. If you intend to dissipate more
power, use an external braking resistor. To connect up the system (which must be carried out
in conditions of complete safety) disconnect the jumper between terminals 9 and 10 of
terminal board X4; connect one end of the resistor to terminal 9 and the other to terminal 11on
X4. The external resistor value must be 40 ohm for HPD2N, HPD5N, HPD8N and HPD16N,
27 ohm for HPD20N and HPD24N, and a thermal magnetic circuit breaker must be installed
between resistor and drive. The minimum wire size for the connection is 4 mm
2
; the
connection cables should be as short as possible and, in any event, no longer than 3 metres.
R
External Resistance
Terminal Board X4 for HPD
Internal Resistance
3.14. Backup
Precaution for simulation encoder:
- Use an external 24Vdc 2A regulated power supply with protected output.
- Set the parameter b99.8 = 1 (the automatic reset of the undervoltage alarm when the mains
voltage is restored). Now the backup function does not need the external relay.
Furthermore is not required to write in the pico-PLC the programme described in the
example 11 - “Examples and applications” chapter.
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4. PARAMETERS AND PROGRAMMING
The features: torque, speed, acceleration and position control are the task of a dedicated
electronic circuits. In this chapter you can see how to set up and the meaning of any
parameter, functional block diagrams and advanced functions description too.
In the figure below it is described the general block diagram of the drive’s functions that you
can configure by parameters.
See chapter
Block diagrams for a better description of how to use the drive, especially for
operating modes. See chapter
Pico-PLC to understand how to connect peripheral systems
(inputs/outputs) to the parametric system of the HPD drive.
Parameters are divided as follows:
REFERENCE
MANAGER
LIMIT SWITCH
&
STOP
SPEED
REGULATOR
OPERATING
MODE
TORQUE
LIMIT
MANAGER
TORQUE DEMAND
analogue
digital
internal
MISCELLANEOUS
SPEED
WINDOWS
TORQUE
MODE
ACCEL.
MODE
MAINT.
MODE
POSITIO.
MODE
DIGITAL
LOCK
MODE
STEPPER
MODE
SPINDLE
ORIENT.
MODE
EXTERN.
MODE
TRIPS
MANAGER
b40.2
Pr31
from Pr0 to Pb42 basic parameters
from Pr50 to Pb70 operating mode parameters
from Pr71 to Pb99 pico-PLC parameters
from In0 to In63 pico-PLC instructions
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The principal parameter units and resolutions are:
4.1. Using the keypad
The keypad-display module is designed to provide an intuitive operator interface. It can be
used to program operating data, monitor system status and enter commands.
The module has only three keys, located at the top of the front panel just below the
display. The keys are marked: [M], [+] and [-].
[M] is used to change the display mode and consequently also the function of [+] and [-].
There are two display modes: parameter mode and parameter value mode.
When the unit is powered up, provided there are no active alarms, the message “IdLE”
(drive disabled) or “run” (drive enabled) is displayed; this is also the position of parameter
Pr0.
Press [+] or [-] to scroll through the parameters.
If you want to check a parameter value, press [M]; when the value is shown it can be
updated using [+] and [-].
To return to parameter mode press [M] again.
The display can be shown in various forms, depending on the parameter in question.
If you need to increase (or decrease) a parameter value quickly, press [M] while the up key
[+] (or down key [-] ) is pressed.
M
Pr. 01
Pb. 40
+
-
+
-
Pr. 02
+
-
In. 00
In. XX
+
-
M
XXXXX
M
M
XXXXX
+
-
+ 1
+ 9
M
- 1
- 9
M
M
M
XXXXX
+
-
+ 1
+ 9
M
- 1
- 9
M
M
M
b40.XX
+
-
1
0
M
M
XX
+
done
M
PLC inst.
M
+
-
1st oper.
M
+
-
2nd oper.
M
+
-
3rd oper.
M
+
-
HPD keypad
Pb. 99
M
XX
+
-
b99.XX
M
+
-
IDLE
parameter unit resolution
speed revolutions per minute 1
acceleration seconds / 1000 rpm. 0.001
position 4096 steps / revolution 1/4096 revolution
current % of the drive peak current 0.1
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In addition to the parameter values and the pico-PLC instructions, the display may show the
following messages:
r. xx At the time of power-up this message indicates the software version installed (2
seconds approx.).
IdLE At power-up and in correspondence with Pr0 this message shows that no alarms are
present and the system is disabled.
run At the time of power-up and in correspondence with Pr0 this message indicates that
no alarms are present and the drive is enabled; the motor shaft may be spinning.
Er. xx In correspondence with Pr0 this message indicates that the drive has detected an
alarm (xx indicates the alarm code) and has therefore been disabled. When an alarm
is detected the display automatically switches to parameter Pr0 and shows the alarm
code.
dcbuS In correspondence with Pr0 this message indicates that the drive is not operating at
low voltage (b40.10=0) and that DC bus voltage is still below the 120 V threshold;
the inrush current circuit is still connected so the drive is not yet ready (b41.4=0).
Prxx Indication of parameter xx (value displayed by pressing “M”).
Pb. xx Indication of bit parameter xx.
bxx.yy Indication of bit yy of parameter xx; press “M” to display bit status.
In. xx Indication of instruction xx of PLC program.
donE Displayed for approximately 1 second each time a command is entered.
rESet Displayed for approximately 1 second each time an alarm reset command is entered
(b99.10).
tESt Displayed during wiring test (b70.3).
rEtrY It’s displayed when a writing error is detected storing the pico-PLC instructions
(b99.14) or while saving parameters (b99.15).
4.2. Commissioning the HPD drive
The steps described in this section must be followed carefully when the drive is started up
for the first time.
1) Connect the motor to the drive in compliance with the wiring diagrams in the manual.
2) Make sure the drive is disabled (terminal 11 of board X3 must be open)
3) Power up the drive.
4) After some seconds the display shows “IdLE”.
5) Setting essential parameters:
Pr33 calculation (rated current)
Pr33=
InM
InD 2
100⋅⋅
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