Compumotor. S Drive User Guide

Transcription

1 Compumotor S Drive User Guide Compumotor Divion Parker Hannifin Corporation p/n H March 1997

2 User Information To ensure that equipment described in th User Guide, as well as all equipment connected to and used with it, operates satfactorily and safely, all applicable local and national codes that apply to installing and operating equipment must be followed. Since codes can vary geographically and can change with time, it user's responsibility to identify and comply with applicable standards and codes. WARNING: Failure to comply with applicable codes and standards can result in damage to equipment and/or serious injury to personnel. Personnel who are to install and operate equipment should study th user guide and all referenced documentation prior to installation and/or operation of equipment. In no event will provider of equipment be liable for any incidental, consequential, or special damages of any kind or nature whatsoever, including but not limited to lost profits aring from or in any way connected with use of th user guide or equipment. Compumotor Divion of Parker Hannifin Corporation, 1997 All Rights Reserved The information in th User Guide, including any apparatus, methods, techniques, and concepts described herein, are proprietary property of Parker Compumotor or its licensors, and may not be copied, dclosed, or used for any purpose not expressly authorized by owner reof. Since Parker Compumotor constantly strives to improve all of its products, we reserve right to change th User Guide and equipment mentioned rein at any time without notice. Technical Asstance Contact your local automation technology center (ATC) or dtributor, or... North America and Asia: Compumotor Divion of Parker Hannifin 5500 Business Park Drive Rohnert Park, CA Telephone: (800) Fax: (707) FaxBack: (800) BBS: (707) Europe (non-german speaking): Parker Digiplan 21 Balena Close Poole, Dorset England BH17 7DX Telephone: Fax: Germany, Austria, Switzerland: HAUSER Elektronik GmbH Postfach: Robert-Bosch-Str. 22 D Offenburg Telephone: (0781) Fax: (0781) Automation Compumotor

3 USER GUIDE CHANGE SUMMARY The following a summary of primary changes to th User Guide since last version was released. Th User Guide, version H, supersedes version G. An Appendix entitled LVD Installation Instructions has been added to th User Guide. The appendix contains additional procedures you must follow to install S Drive so that it complies with Low Voltage Directive (LVD) of European Economic Community. User Guide Change Summary i

4 Product Type: S3, S6 and S8 Step Motor Drives The above products are in compliance with requirements of directives 72/23/EEC Low Voltage Directive 93/68/EEC CE Marking Directive The S Drive, when installed according to procedures in main body of th User Guide, may not necessarily comply with Low Voltage Directive (LVD) of European Community. To install S Drive so that it complies with LVD, you must follow additional procedures described in Appendix entitled LVD Installation Instructions. If you do not follow se instructions, protection of product may be impaired. S Drives are sold as complex components to professional assemblers. As components, y are not required to be compliant with Electromagnetic Compatibility Directive 89/336/EEC. However, information offered in Compumotor s EMC Installation Guide on how to install se drives in a manner most likely to minimize effects of drive emsions and to maximize immunity of drives from externally generated interference. ii S Drive User Guide

5 TABLE OF CONTENTS How To Use Th User Guide... vii Assumptions... vii Contents of Th Manual... vii Installation Process Overview... viii Developing Your Application... viii Installation Preparation... viii Related Publications... viii Chapter ➀ Introduction... 1 Product Description... 1 Features... 1 Chapter ➁ Getting Started... 3 What You Should Have... 3 High-Power and Low-Power Drives... 3 Quick Test... 3 Attach Motor... 5 Quick Test with Indexer... 6 Chapter ➂ Installation... 9 Installation Precautions... 9 Environmental Considerations... 9 Wiring Considerations... 9 Preventing Electrical Noe Problems DIP Switches Installation Overview Series vs. Parallel Motor Wiring Motor Heating Motor Configuration Compumotor Motors Drive/Motor Connection Pin Motor Connector Compumotor Motors Setting Motor Current Non-Compumotor Motors Drive/Motor Connection Wiring Configurations Lead Motor Lead Motor Lead Motor Parallel Configuration Series Configuration Terminal Connections Non-Compumotor Motors Setting Motor Current Drive Configuration Automatic Standby Function Motor Resolutions Motor Waveforms Automatic Test Function How To Use Th User Guide iii

6 Drive/Indexer Connection Step & Direction Signal Specification Shutdown & Set Zero Phase Signal Specification Fan Connection AC Power Connection Transformers S: Series Configuration P: Parallel Configuration Testing System Drive Mounting Minimum Width Minimum Depth Motor Mounting Attaching Load Couplings Tuning Resonance Mid-Range Instability Tuning Procedures Gauging Motor Resonance Motor Waveforms Rotary vs. Linear Indexers Chapter ➃ Hardware Reference Environmental Specifications Electrical Specifications Input Power Output Power Output Type Fault Output Minimum Motor Winding Inductance Maximum Motor Winding Inductance Minimum Motor Hipot...40 Step & Direction Signal Specification Step Pulse Input Direction Input Shutdown & Set Zero Phase Signal Specification Shutdown Input (Amplifier Dable) Set Zero Phase Input Fault Output Operational Specifications Repeatability Hysteres Rotor Inertia Drive Dimensions Motor Dimensions DIP Switch Summary Motor Performance Specifications iv S Drive User Guide

7 Chapter ➄ Troubleshooting Maintenance Drive Maintenance Motor Maintenance Reducing Electrical Noe Problem Isolation Front Panel LEDs Common Problems and Solutions Testing Motor Returning System Appendix LVD Installation Instructions Complying with Low Voltage Directive (LVD) Additional Installation Procedures for LVD Compliance Environmental Conditions Electrical Mechanical Servicing S Drive Thermal Safety Sonic Pressure Table of Graphic Symbols and Warnings Index How To Use Th User Guide v

8 vi S Drive User Guide

9 How To Use Th User Guide Assumptions Contents of Th Manual Chapter ➀ Introduction Th User Guide designed to help you install, develop, and maintain your system. Each chapter begins with a lt of specific objectives that should be met after you have read chapter. Th section intended to help you find and use information in th User Guide. Th User Guide assumes that you have skills or fundamental understanding of following information. Basic electronics concepts (voltage, switches, current, etc.) Basic motion control concepts (torque, velocity, dtance, force, etc.) With th basic level of understanding, you will be able to effectively use th User Guide to install, develop, and maintain your system. Th User Guide contains following information. Th chapter provides a description of product and a brief account of its specific features. Chapter ➁ Getting Started Chapter ➂ Installation Th chapter contains a detailed lt of items you should have received with your S Drive shipment. It will help you to become familiar with system and ensure that each component functions properly. Th chapter provides instructions for you to properly mount system and make all electrical connections. Upon completion of th chapter, your system should be completely installed and ready to perform basic operations. Tuning considerations and procedures are also provided. Chapter ➃ Hardware Reference Th chapter contains information on system specifications (dimensions and performance). It may be used as a quick-reference tool for proper switch settings and connections. Chapter ➄ Troubleshooting Th chapter will help you identify and resolve system problems. How To Use Th User Guide vii

10 Installation Process Overview To ensure trouble-free operation, pay special attention to environment in which S Drive equipment will operate, layout and mounting, and wiring and grounding practices used. These recommendations are intended to help you easily and safely integrate S Drive equipment into your manufacturing facility. Industrial environments often contain conditions that may adversely affect solid-state equipment. Electrical noe or atmospheric contamination, may also affect S Drive System. Developing Your Application Before you attempt to develop and implement your application, re are several sues that you should consider and address. ➀ ➁ ➂ Installation Preparation Related Publications Recognize and clarify requirements of your application. Clearly define what you expect system to do. Assess your resources and limitations. Th will help you find most efficient and effective means of developing and implementing your application. Follow guidelines and instructions outlined in th user guide. Do not skip any steps or procedures. Proper installation and implementation can only be ensured if all procedures are completed in proper sequence. Before you attempt to install th product, you should complete following steps: ➀ Review th entire user guide. Become familiar with User Guide s contents so that you can quickly find information you need. ➁ Develop a basic understanding of all system components, ir functions, and interrelationships. ➂ Complete basic system configuration and wiring instructions (in a simulated environment, not a permanent installation) provided in Chapter ➁ Getting Started. ➃ Perform as many basic functions as you can with preliminary configuration. You can only perform th task if you have reviewed entire user guide. You should try to simulate task(s) that you expect to perform when you permanently install your application (however, do not attach a load at th time). Th will give you a realtic preview of what to expect from complete configuration. ➄ After you have tested all of system s functions and used or become familiar with all of system s features, carefully read Chapter ➂ Installation. ➅ After you have read Chapter ➂ and clearly understand what must be done to properly install system, you should begin installation process. Do not deviate from sequence or installation methods provided. ➆ Before you begin to customize your system, check all of system functions and features to ensure that you have completed installation process correctly. The successful completion of se steps will prevent subsequent performance problems and allow you to olate and resolve any potential system difficulties before y affect your system s operation. Current Parker Compumotor Motion Control Catalog viii S Drive User Guide

11 C H A P T E R ➀ Introduction Product Description Features The information in th chapter will enable you to: Understand product s basic functions and features The S Drive a bipolar, recirculating, microstepping drive that runs two-phase permanent magnet hybrid step motors. The drive uses MOSFET technology to give high performance in a small package while providing short-circuit protection, brownout protection, overtemperature protection, and a built-in power supply. The S Drive compatible with all Compumotor indexers. The S Drive requires no external power supply. It uses 120VAC directly for its power inputs. Compumotor s motors are two-phase hybrid motors (permanent magnet type). Four, six, or eight lead motors may be used, with internal phases connected for parallel or series operation, provided motor s inductance does not drop below 2 mh. For best performance, maintain motor inductance from 5 mh - 50 mh, but motors with inductance ratings as low as 0.5 mh may be used. You can panel mount S Drive in a minimum depth or width configuration by moving its mounting tabs. The S Drive also provides following features: Microprocessor controlled microstepping provides smooth operation over a wide range of speeds Short circuit protection for phase-to-phase and phase-to-ground short circuits Overtemperature and undervoltage protection Uses low-inductance motors for improved high-speed performance (23, 34, 42 frame size motors available with torques from 65-2,400 oz-in) Three state current control for reduced motor/drive heating LED status indicators: power, step, undervoltage, overtemperature (latched), motor fault (latched) Motor connector interlock to prevent connector damage Optically coupled step, direction, shutdown, and set zero phase inputs are compatible with all Compumotor indexers (25-pin D connector) A fault output to signal or equipment if a fault occurs High motor voltage (170VDC) operation for high-speed torque 90VAC - 132VAC, 50/60Hz power input 16 DIP switch selectable motor resolutions (200-50,800 steps/rev) Operates linear motor forcers 2 MHz step input Chapter 1 Introduction 1

12 2 S Drive User Guide

13 C H A P T E R ➁ Getting Started What You Should Have The information in th chapter will enable you to: Verify that each component of your system has been delivered safely Become familiar with system components and ir interrelationships Ensure that each component functions properly by bench testing Inspect S Drive upon receipt for obvious damage to its shipping container. Report any such damage to shipping company. Parker Compumotor cannot be held responsible for damage incurred in shipment. The following items should be present and in good condition. Part Part Number Power Cable (S8 has 2 cables) S Drive S6 (Low) or S8 (High)* S Drive User Guide A Motor Variety of sizes available** *The S8 Drive includes a fan kit **Refer to subsequent tables in th chapter for specific motor sizes High-Power and Low-Power Drives Quick Test You should verify which type of S Drive you have before proceeding with th chapter. The high-power version of drive (S8) provides bipolar 0-8 amps/phase (up to 2,400 ozin). The low-power version of drive (S6) provides bipolar 0-6 amps/phase (up to 400 oz-in). You can determine which drive you have by checking label on side of drive. The label identifies unit as S8 DRIVE or S6 DRIVE. You must be aware of drive s type to set motor current correctly (using DIP switches). There are different DIP switch settings for two drive types. If you did not receive drive type that you ordered, please call your local Automation Technology Center (ATC) or dtributor. Th section will show you how to set S Drive s DIP switches and wire unit to quickly ensure that your system operating properly. Detailed installation instructions are provided in Chapter ➂ Installation. You will need following tools to complete se steps: A Phillips head screw driver (to move mounting brackets) A flat screw driver (to adjust DIP switches and make connections) Chapter 2 Getting Started 3

14 CAUTION Never adjust DIP switches with a pencil. Lead from pencil may contaminate drive. The figure below shows location of S Drive s DIP switches Expanded View of DIP Switches MICROSTEP DRIVE S SERIES MOTOR FAULT OVERTEMP UNDERVOLTAGE STEP POWER Automation OFF ON Tuning Pots Phase B Offset Phase A Offset Phase Balance DIP Switches Cover removed SW2 SW1 Bottom View DIP Switch & Tuning Pot Locations ❶ Set DIP Switches The S Drive has two sets of DIP switches. Each set of DIP switches has eight individual switches. The first set of switches will be referred to as SW1 and second set as SW2. The individual switch will be preceded by # symbol. Hence, third switch on SW1 will be referred to as SW1-#3, while third switch on SW2 will be referred to as SW2-#3. The first thing that you must do set motor current on S Drive to match motor that you are using. Use directions below to set DIP switches for your motor. (Drive/Motor systems are shipped from factory with motor current set for that system. Drive-only products are shipped from factory with motor current set at minimum current level.) ➀ ➁ ➂ Be sure that power not applied to unit. Remove panel that covers DIP switches. Set motor current for your Compumotor using following tables: SW1-#1 thru SW1-#6 control motor current. Make required adjustments to match drive and motor types that you are using. 4 S Drive User Guide

15 Motor Size Current SW1-#1 SW1-#2 SW1-#3 SW1-#4 SW1-#5 SW1-#6 S57-51S 1.18 off off on on off off S57-51P 2.28 off on on off off off S57-83S 1.52 off on off off off off S57-83P 3.09 on off off off off off S57-102S 1.71 off on off off on off S57-102P 3.47 on off off on off off S83-62S 2.19 off on off on on on S83-62P 4.42 on off on on on off S83-93S 2.85 off on on on on off S83-93P 5.62 on on on off on on S83-135S 3.47 on off off on off off S83-135P 6.00 on on on on on on S: Series Configuration P: Parallel Configuration Setting S6 Motor Current (S Series Compumotor Motors) Motor Size Current SW1-#1 SW1-#2 SW1-#3 SW1-#4 SW1-#5 SW1-#6 S S 6.02 on off on on on on S P 8.0 on on on on on on S S 3.55 off on on on off off S P 6.99 on on off on on on S S 6.02 on off on on on on S P 8.0 on on on on on on S: Series Configuration P: Parallel Configuration Setting S8 Motor Current (S Series Compumotor Motors) The previous tables show motor current settings for series and parallel motor configurations. Refer to Chapter ➂ Installation for specific motor configuration instructions. Compumotor ships all S Drive systems in series configurations. If you use a non-compumotor motor, special precautions and instructions are required. Read instructions in Chapter ➂ Installation for non-compumotor motors thoroughly before attempting to set motor current or wire your motor. ➃ ➄ ❷ Attach Motor To test system, you will use Automatic Test function. DIP switch SW2-#8 controls th function. Turn SW2-#8 on to enable function. The Automatic Test function rotates motor in an Alternating mode approximately 6 revolutions at 1 rps (12 inches at 2 ips if a L20 Linear Motor used). After you have properly set motor current (SW1-#1 thru SW1-#6) and Automatic Test function (SW2-#8), screw plate that covers DIP switches back onto drive. Do not change any or DIP switch settings. WARNING POWER MUST BE OFF before cabling drive. Lethal voltages are present inside drive and on its screw terminals. When connecting motor to drive, be sure connector firmly seated. The S Drive motor pre-wired in series. Plug pre-wired motor cable into Motor connector on drive. If you use a non-compumotor motor, refer to Chapter ➂ Installation for instructions on wiring motor to drive. Do not connect motor to load at th time. Chapter 2 Getting Started 5

16 Compumotor To power source Protective rubber boot protects pre-wired cable connections Motor AC Power VAC 50/60Hz INLK A-CT A + A - EARTH B + B - B-CT INLK MOTOR CAUTION! HIGH VOLTAGE ON EXPOSED TERMINALS Heatsink INDEXER MOTOR FAULT OVERTEMP UNDER VOLTAGE STEP POWER MICROSTEP DRIVE S SERIES Automation Test Configuration (S6 Drive Shown) ❸ Apply Power The power cable a pre-wired, molded AC cord. Complete following steps to apply power. ➀ Plug pre-wired cable into power connector on drive. ➁ Plug or end of cable into a 115VAC power source. If you are using S8 Drive (high power), you must also plug in fan s power cable to 115VAC. The fan must be on when power applied to drive. The motor should rotate in an Alternating mode approximately 6 revolutions at 1 rps. The green Power LED should be on. ➂ To stop motor, you must unplug power cable from power source. The motor may continue to run for a few seconds after you remove power. The successful completion of th test indicates that amplifier, motor, and microprocessor are operating properly. You can now test indexer interface ( Step, Direction, and Shutdown inputs). Be sure that power not applied to system when you begin. To perform th test, complete following steps. Quick Test with Indexer With no power applied to drive, perform following steps to test indexer interface. Th test assumes that your indexer s motor resolution set to 25,000 steps/rev. Th default motor resolution setting for S Drive. ➀ Remove panel that covers DIP switches. Turn DIP switch SW2-#8 off to dable Automatic Test function. Ensure that switches SW2-#1 through SW2-#4 are off. Do not change any or DIP switch settings. Screw panel back onto drive. 6 S Drive User Guide

17 ➁ ➂ Connect your Compumotor indexer to drive s 25-pin D indexer connector. The appropriate cable provided with indexer. Ensure that pre-wired motor cable that you connected in previous test still connected. Apply power to drive and indexer. Compumotor To power source Protective rubber boot protects pre-wired cable connections Motor AC Power VAC 50/60Hz INLK A-CT A + A - EARTH B + B - B-CT INLK MOTOR CAUTION! HIGH VOLTAGE ON EXPOSED TERMINALS Heatsink INDEXER Indexer MOTOR FAULT OVERTEMP UNDER VOLTAGE STEP POWER MICROSTEP DRIVE S SERIES Automation Test Configuration (S6 Drive Shown) ➃ ➄ ➅ Using indexer, send step pulses to drive that will rotate motor one CW revolution (25,000 step pulses) at an acceleration of 1 rps 2 and a velocity of 1 rps (25,000 steps per second). When drive receives step pulses, motor should rotate one CW revolution. The green Power LED and green step LED should be on when drive receiving pulses. Using indexer, send step pulses to drive that will rotate motor one CCW revolution at an acceleration of 1 rps 2 and a velocity of 1 rps (25,000 steps per second). When drive receives step pulses, motor should rotate one CCW revolution. The green Power LED on when power applied to drive and green step LED should be on when drive receiving pulses. (Th LED will flicker during low step rates and shine more brightly at higher step rates.) Now you will test Shutdown input. With no step pulses applied to drive, activate Shutdown input. Refer to your indexer s operations manual for instructions on activating Shutdown input. By activating Shutdown input, all current will be removed from motor. You should be able to turn motor shaft manually. Try to turn shaft slowly now. If you can turn it easily, Shutdown input working properly. If shaft still has torque, check your wiring and try test again. Chapter 2 Getting Started 7

18 8 S Drive User Guide

19 C H A P T E R ➂ Installation Installation Precautions The information in th chapter will enable you to: Ensure that complete system installed correctly Mount all system components properly Before proceeding with th chapter, you should have completed steps and procedures in Chapter ➁ Getting Started. Th section contains precautions that you must follow to configure and operate your S Drive system properly. Environmental Considerations An internal rmostat will shut down drive if it reaches 158 F (70 C) internally. Current settings in excess of 4A in high ambient temperature environments (above 113 F [45 C]) may require fan cooling to keep heatsink temperature within allowable limits and to keep drive from shutting itself down due to overtemperature. The maximum allowable motor case temperature 212 F (100 C). Actual temperature re duty cycle dependent. CAUTION When connected in parallel, S Drive motors can overheat if operated at high speeds for extended periods of time. Wiring Considerations There are hazardous voltages present on S Drive s connectors when power applied. To prevent injuries to personnel and damage to equipment, note following guidelines: Never connect/dconnect motor from drive when power applied. If you do, motor connector may be damaged. Power should never be applied to drive when motor not connected. Never increase current setting (using drive s DIP switches) to more than 10% greater than current specified for motor you are using. Excessive current may cause motor to overheat and result in a motor failure. Verify that re are no wire whkers that can short out motor connections. If motor turns wrong direction after you connect motor wires to connector and connector to drive, you can change direction by reversing leads going to A+ and A- on motor terminal. Chapter 3 Installation 9

20 Never extend INLNK jumper beyond connector. Th jumper protects motor connector and should not be used as a system interlock. Never probe drive. Never connect anything or than motor to motor terminals. Probing or opening drive in any or way will void warranty. Hazardous voltages are present within drive. The rmal interface will be broken if you open drive. The rmal interface critical to reliability of drive. Grounding Proper grounding of electrical equipment essential to ensure safety. You can reduce effects of electrical noe due to electromagnetic interference (EMI) by grounding. All Compumotor equipment should be properly grounded. Refer to National Electrical Code publhed by National Fire Protection Association of Boston, MA for more information on grounding requirements. In general, all components and enclosures must be connected to earth ground through a grounding electrode conductor to provide a low-impedance path for ground fault or noeinduced currents. All earth ground connections must be continuous and permanent. Compumotor recommends a single-point grounding setup. Prepare components and mounting surfaces prior to installation so that good electrical contact made between mounting surfaces of equipment and enclosure. Remove paint from equipment surfaces where ground contact will be bolted to a panel and use star washers to ensure solid, bare metal contact. For temporary installation, or when you cannot implement grounding method described above, connect GND terminal on AC power connector to earth ground. Whenever possible, route high-power signals (i.e., motor and power) away from logic signals (i.e., step and direction, RS-232C, RS-422/485, parallel output) to prevent electrical noe problems. Preventing Electrical Noe Problems The S Drive provides power to motor by switching 170VDC (120VAC input) at 21 KHz (nominal). Th has potential to radiate or conduct electrical noe along motor cable, through motor, and into frame to which motor attached. It can also be conducted out of drive into AC power line. Use following steps to prevent problems caused by electrical noe generated by S Drive: ➀ Ground motor casing (already done for you with Compumotor motors). WARNING You must ground motor casing. Motor winding case capacitance can cause large potentials to develop at motor. Th can create a lethal shock hazard. ➁ ➂ ➃ ➄ ➅ Avoid extended motor cable runs. Mount drive as close as practical to motor. Mount equipment that sensitive to electrical noe as far as possible from S Drive and motor. Filter power to S Drive with a PI type filter and an olation transformer (refer to power ratings later in th chapter). The filter reduces AC line noe that S Drive generates back into AC line. The Corcom EP Series filter works well with S Drive. Corcom 1600 Winchester Road Libertyville, IL Telephone: (847) Provide a separate power line for S Drive. Do not use same power circuit for equipment that sensitive to electrical noe and S Drive. Shield motor cable in conduit and ensure conduit taken to a low impedance earth ground. 10 S Drive User Guide

21 DIP Switches The S Drive has two sets of DIP switches (refer to figure below). Each set of DIP switches has eight individual switches. The first set of switches referred to as SW1 and second set as SW2. The individual switch will be preceded by # symbol. Hence, third switch on SW1 referred to as SW1-#3, while third switch on SW2 referred to as SW2-#3. To modify any of drive s switch settings, remove power from drive and follow steps below. ➀ ➁ ➂ Remove panel that covers DIP switches. Make required adjustments. Screw panel back into place over switches. The S Drive recognizes changes to its switch settings during power up only. WARNING Never adjust switches with power applied to unit. Hazardous voltages are contained within drive when power applied Expanded View of DIP Switches MICROSTEP DRIVE S SERIES MOTOR FAULT OVERTEMP UNDERVOLTAGE STEP POWER Automation OFF ON Tuning Pots Phase B Offset Phase A Offset Phase Balance DIP Switches Cover removed SW2 SW1 Bottom View DIP Switch & Tuning Pot Locations Chapter 3 Installation 11

22 Installation Overview The procedures in th chapter will enable you to configure and wire your system. The following graphic shows front panel of S Drive. The following installation steps will be dcussed: ➀ Series vs. Parallel Motor Wiring ➁ Motor/S Drive Configuration (Wiring & Motor Current) Compumotor Motors Non-Compumotor Motors ➂ Set Or DIP Switches ➃ Wire Indexer to S Drive ➄ Fan connection (for S6 fan standard for S8) ➅ Apply Power to S Drive ➆ Test System ➇ Mount S Drive and motor ➈ Attach Load Compumotor AC Power VAC 50/60Hz INLK A-CT A + A - EARTH B + B - B-CT INLK MOTOR Heatsink 1 Step+ 14 Step- 2 Direction+ 15 Direction- 16 Shutdown+ 17 Shutdown- 25-Pin D Connector INDEXER CAUTION! HIGH VOLTAGE ON EXPOSED TERMINALS MOTOR FAULT OVERTEMP UNDER VOLTAGE STEP POWER MICROSTEP DRIVE S SERIES Automation S Drive Wiring Diagram (S6 Drive Shown) Do not deviate from steps in th chapter. Do not wire or apply power to system until you are instructed to do so. If you do not follow se steps, you may damage your system. 12 S Drive User Guide

23 ➊ Series vs. Parallel Motor Wiring S Series motors are shipped from factory wired in series. You may re-wire motor (shown later in th chapter Wiring Configurations). Parallel configurations provide more torque than series configurations provide at high speeds (refer to speed/torque curves in Chapter ➃ Hardware Reference). You must observe certain precautionary measures to prevent overheating when using motors wired in parallel configurations (refer to Non- Compumotor Drive/Motor Connection later in th chapter). Motor Heating S Series motors that are wired in series can be run continuously at speeds that incur peak motor loss. S Series motors that are wired in parallel, however, cannot be run at peak motor loss levels continuously without overheating (unless extensive cooling measures are employed). Most applications do not require continuous slewing at high speed. Therefore, average motor loss will be within safe limits. ❷ Motor Configuration The S Drive can run Compumotor and Non-Compumotor motors. Th section provides instructions for configuring Compumotor and Non-Compumotor motors. Follow only directions that apply to type of motor that you are using. Compumotor Motors Drive/Motor Connection Compumotor motors are pre-wired in series and require no setup or than being plugged into drive. If you plan to run motor series, no furr motor wiring setup required. Your S Drive s motor connector may be a 7-pin or 9-pin connector. Follow instructions that apply to your connector only. Frame size 23 and 34 motors (S57 or S83) are 8 lead motors. Frame size 42 (S106) are 4 lead motors. The graphic below represents motor winding color code for 8 lead, 23 and 34 frame size motors. Red Phase A Windings Yellow Blue PM Black Phase B Windings White Orange Brown Green 8-Lead Motor Winding Color Code S Series motors in 23 and 34 frame sizes (S57 and S83 series) are constructed with an 8 conductor motor cable to allow you to change motor configuration on connector at drive. The 42 frame size motors (S106 series) are constructed with a 4-lead motor cable, but motors can be configured by removing cover plate on back of motor and rewiring at screw terminals. Chapter 3 Installation 13

24 S Series and Parallel Connections The S pre-wired in series. If you remove motor s back panel, you can wire it in parallel. Series and Parallel Motor Terminal # Wire Color 1 Red 3 Black 5 Green 4 White Drive Terminal Wires Motor Terminal # Wire Color Red Black Green White To Drive Terminal A+ A- B+ B- Inside Motor Wiring Wire Color Pin # Dark Orange #1 Blue #2 Black #3 White #4 Green #5 Yellow #6 Brown #7 Orange #8 S Motor Wiring Diagram SERIES PARALLEL RED 1 RED PHASE A WINDINGS PM 6 2 PHASE A WINDINGS PM BLACK 3 PHASE B WINDINGS BLACK 3 PHASE B WINDINGS WHITE GREEN WHITE GREEN S Series and Parallel Connections 14 S Drive User Guide

25 S Series and Parallel Connections The S pre-wired in series. If you remove motor s back panel, you can wire it in parallel. Series and Parallel Motor Terminal # Wire Color 1 Red 3 Green 5 Black 4 White S Motor Wiring Diagram SERIES PARALLEL RED 1 RED PHASE A WINDINGS PM 6 5 PHASE A WINDINGS PM BLACK 3 PHASE B WINDINGS BLACK 3 PHASE B WINDINGS WHITE GREEN WHITE GREEN S Series and Parallel Connections Chapter 3 Installation 15

26 S Series and Parallel Connections The S pre-wired in series. If you remove motor s back panel, you can wire it in parallel. Series and Parallel Motor Terminal # Wire Color 1 Red 3 Black 4 White 5 Green S Motor Wiring Diagram SERIES PARALLEL RED 1 RED PHASE A WINDINGS PM 6 2 PHASE A WINDINGS PM BLACK 3 PHASE B WINDINGS BLACK 3 PHASE B WINDINGS WHITE GREEN WHITE GREEN S Series and Parallel Connections 16 S Drive User Guide

27 9-Pin Motor Connector The 9-pin version of MOTOR connector shown below. Before connecting motor, determine which motor wires correspond to Phase A and Phase B. The 9-pin motor connector provides for easier installation when motor wired in series. A-CT and B-CT are not connections y are terminal blocks. INLK A-CT A + A - EARTH B + B - B-CT INLK MOTOR S Drive 9-Pin Motor Connector The following tables show color codes for following types of motor connections to S Drive 9-pin MOTOR connector. 8 Lead Motors Series (S57 and S83) 8 Lead Motors Parallel (S57 and S83) 4 Lead Motors Series or Parallel (S106) Pin Color A-CT Yellow & Blue A+ Red A- Black EARTH Shield B+ White B- Green B-CT Orange & Brown Jumper INLK to INLK Color Code 9-Pin Connector/8 Lead Motor (Series) Pin Color A-CT N.C. A+ Red & Blue A- Black & Yellow EARTH Shield B+ White & Brown B- Green & Orange B-CT N.C. Jumper INLK to INLK Color Code 9-Pin Connector/8 Lead Motor (Parallel) Pin Color A-CT N.C. A+ Red A- Black EARTH Shield B+ White B- Green B-CT N.C. Jumper INLK to INLK Color Code 9-Pin Connector/4Lead Motor (S & P) Chapter 3 Installation 17

28 Once you determine wiring configuration, connect motor to drive s screw terminals according to appropriate color code table. The following instructions should also be completed. ➀ ➁ Connect shield to MOTOR connector s shield. Th a very important safety precaution. If your motor does not have a ground (shield) wire, attach a lug to motor case and connect motor to EARTH. Connect a short jumper wire from INLK (first pin of connector) to INLK (last pin of connector). Th a connector interlock. The drive will not operate if th jumper msing or extended. Extended Motor Cables The table below contains recommended motor cables for various motor types and minimum recommended motor/driver wire size (AWG) and restance. Motor Maximum Current Per Less than ft. Series Winding (Amps) 100 ft. (20.5M) (30.5M - 71M) S AWG 20 AWG S AWG 18 AWG S AWG 14 AWG Recommended Motor Cables Cable runs of more than 200 feet (71M) are not recommended. Cable runs greater than 50 feet may degrade system performance. Compumotor Motors Setting Motor Current You should verify which type of S Drive you have before setting motor current. The highpower drive (S8) provides bipolar 0-8 amps/phase (up to 2,400 oz-in). The low-power drive (S6) provides bipolar 0-6 amps/phase (up to 400 oz-in). You can determine which drive you have by checking label on side of drive. The label identifies unit as S8 DRIVE or S6 DRIVE. You must be aware of drive s type to set motor current correctly (using DIP switches). The tables below contain proper motor current settings for Compumotor motors. SW1-#1 through SW1-#6 control motor current. Adjust motor current to match drive and motor that you are using. A complete lt of all current motor current settings provided in Chapter ➃ Hardware Reference. Motor Size Current SW1-#1 SW1-#2 SW1-#3 SW1-#4 SW1-#5 SW1-#6 S57-51S 1.18 off off on on off off S57-51P 2.28 off on on off off off S57-83S 1.52 off on off off off off S57-83P 3.09 on off off off off off S57-102S 1.71 off on off off on off S57-102P 3.47 on off off on off off S83-62S 2.19 off on off on on on S83-62P 4.42 on off on on on off S83-93S 2.85 off on on on on off S83-93P 5.62 on on on off on on S83-135S 3.47 on off off on off off S83-135P 6.00 on on on on on on S: Series Configuration P: Parallel Configuration S6 Drive Motor Current (Compumotor Motors) Motor Size Current SW1-#1 SW1-#2 SW1-#3 SW1-#4 SW1-#5 SW1-#6 S S 6.02 on off on on on on S P 8.0 on on on on on on S S 3.55 off on on on off off S P 6.99 on on on on on on S S 6.23 on on off off off on S P 8.0 on on on on on on S: Series Configuration P: Parallel Configuration S8 Drive Motor Current (Compumotor Motors) 18 S Drive User Guide

29 Non-Compumotor Motors Drive/Motor Connection Compumotor does not recommend that you use non-compumotor motors with S Drive. If you do use a non-compumotor motor, it must meet following requirements: A minimum inductance of 2 mh, series or parallel, may be used (Compumotor recommends a minimum inductance of 5 mh). A minimum of 500VDC high-pot insulation rating from phase-to-phase and phase-to-ground. The motor must not have riveted rotors or stators. Do not use solid rotor motors. Test all motors carefully. Verify that motor temperature in your application within system limitations. The motor manufacturer s maximum allowable motor case temperature must not be exceeded. You should test motor over a 2- to 3-hour period. Motors tend to have a long rmal time constant, but can still overheat, which results in motor damage. CAUTION Consult a Compumotor Applications Engineer if you intend to use a non-compumotor motor. Wiring Configurations 4-Lead Motor 6-Lead Motor You can determine motor s wiring configuration by referencing manufacturer s motor specification document supplied with motor. You can also determine wiring configuration with an ohmmeter using procedures below (4-Lead Motor, 6-Lead Motor, 8 Lead Motor). Once you determine correct motor wiring configuration, use terminal connection diagram that applies to your configuration (refer to Terminal Connections section later in th chapter). ➀ ➁ ➂ ➃ Label one motor lead A+. Connect one lead of an ohmmeter to A+ lead and touch or lead of ohmmeter to three remaining motor leads until you find lead that creates continuity. Label th lead A-. Label two remaining leads B+ and B-. Verify that re continuity between B+ and B- leads. Proceed to Terminal Connections section below. ➀ Determine, with an ohmmeter, which three of six motor leads are common (one phase). ➁ Label each one of se three motor leads A. ➂ Using ohmmeter, verify that remaining three leads are common. ➃ Label or three leads B. ➄ Set ohmmeter range to approximately 100 ohm scale. ➅ Connect negative lead of ohmmeter to one of motor leads labeled A. Alternately measure restance to two remaining motor leads also labeled A. The restance measurements will reflect one of following scenarios: Helpful Hint: Scenario #1 The restance measurements to two remaining motor leads are virtually identical. Label two remaining motor leads A+ and A-. Label motor lead connected to negative lead of ohmmeter A-CT (th center tap lead for Phase A of motor). Chapter 3 Installation 19

30 Helpful Hint: Scenario #2 The restance measurement to second of three motor leads measures 50% of restance measurement to third of three motor leads. Label second motor lead A-CT (th center tap lead for Phase A of motor). Label third motor lead A-. Label motor lead connected to ohmmeter A+. ➆ ➇ ➈ Repeat procedure as outlined in step 6 for three leads labeled B (B-CT center tap lead for Phase B of motor). If your S Drive has a 7-pin motor connector, cover two motor leads labeled A-CT and B-CT with electrical tape or shrink tubing to prevent se leads from shorting out to anything else. Do not connect se leads toger or to anything else. If your S Drive has a 9-pin motor connector, connect A-CT motor lead to A-CT pin on MOTOR connector. Connect B-CT motor lead to B-CT pin on MOTOR connector. Proceed to Terminal Connections section below. 8-Lead Motor Because of complexity involved in phasing an 8-lead motor, you must refer to manufacturer s motor specification document. You can configure 8-lead motor in parallel or series. Using manufacturer s specifications, label motor leads as shown in Terminal Connections section. Parallel Configuration Use following procedures for parallel configurations. ➀ ➁ ➂ ➃ Connect motor leads A1 and A3 and relabel th common point A+. Connect motor leads A2 and A4 and relabel th common point A-. Connect motor leads B1 and B3 and relabel th common point B+. Connect motor leads B2 and B4 and relabel th common point B-. Series Configuration Use following procedures for series configurations. ➀ ➁ ➂ ➃ ➄ ➅ ➆ If your S Drive has a 7-pin motor connector, connect motor leads labeled A2 and A3 toger and cover th connection with electrical tape or shrink tubing. Make sure se leads are not connected to S Drive. If your S Drive has a 9-pin motor connector, you can connect A2 and A3 to A-CT. You may also connect B2 and B3 to B-CT. Relabel A1 lead to A+. Relabel A4 lead to A-. If your S Drive has a 7-pin motor connector, connect motor leads labeled B2 and B3 toger and cover th connection with electrical tape or shrink tubing. Make sure se leads are not connected to S Drive. Relabel B1 lead to B+. Relabel B4 lead to B-. Proceed to Terminal Connections section next page. 20 S Drive User Guide

31 Terminal Connections After determining motor s wiring configuration, connect motor leads to 9-pin or 7-pin MOTOR connector using diagrams below. 4 or 6 Lead Motor 8 Lead Motor Series A1 S Drive S Drive S Drive A2 N.C. A+ A- EARTH B+ B- N.C. A+ A- EARTH B+ B- A3 A4 B1 B2 B3 B4 A+ A- EARTH B+ B- Parallel A1 A2 A3 A4 B1 B2 B3 B4 7-Pin Motor Connector (Non-Compumotor Motors) 4 Lead Motor 6 Lead Motor S Drive S Drive A-CT A+ A- EARTH B+ B- B-CT A-CT A+ A- EARTH B+ B- B-CT 8 Lead Motor Series A1 Parallel A1 S Drive A2 S Drive A2 A-CT A+ A- EARTH B+ B- B-CT A3 A4 B1 B2 B3 B4 A-CT A+ A- EARTH B+ B- B-CT A3 A4 B1 B2 B3 B4 9-Pin Motor Connector (Non-Compumotor Motors) CAUTION Do not connect or dconnect motor with power on. Th will damage contacts of motor connector and may cause personal injury. Chapter 3 Installation 21

32 Extended Motor Cables The table below contains recommended motor cables for various motor types and minimum recommended motor/driver wire size (AWG) and restance. Motor Maximum Current Per Less than ft. Series Winding (Amps) 100 ft. (20.5M) (30.5M - 71M) S AWG 20 AWG S AWG 18 AWG S AWG 14 AWG Recommended Motor Cables Cable runs of more than 200 feet (71M) are not recommended. Cable runs greater than 50 feet may degrade system performance. Non-Compumotor Motors Setting Motor Current Compumotor does not recommend that you use non-compumotor motors with S Drive. If you do, refer to formulas below that correspond to your motor (4-lead, 6-lead, or 8-lead) and use S6/S8 motor current tables to set motor current. Never increase current more than 10% above specified rating. 4-Lead Motors If you use a 4-lead motor, manufacturer s current setting will translate directly to values shown in S6/S8 motor current tables. 6-Lead Motors If you use a 6-lead motor, and manufacturer specifies motor current as a unipolar rating, you must use following formula to convert unipolar current rating to correct bipolar rating. Unipolar Current X.707 = Bipolar Current After you make conversion, use S6/S8 motor current tables to set motor current. If manufacturer specifies motor current as a bipolar rating, you can use motor current tables on next page directly (no conversion) to set motor current. 8-Lead Motors If you are using an 8-lead motor, manufacturers generally rate motor current in one of two ways: If motor current lted as a unipolar rating, use following formula to convert unipolar current rating to correct bipolar current rating. Unipolar Current X.707 = Bipolar Series Current If you are wiring motor in series, use motor current tables on next page and converted value to set motor current. If you wire motor in parallel, you must double converted value and use Table 3-11 or 3-12 to set motor current. If motor current lted as a bipolar series rating, you can wire motor in series and use motor current tables on next page directly (no conversion) to set motor current. If motor current lted as a bipolar series rating and you wire motor in parallel, you must double manufacturer s rating and n use motor current tables on next page to set motor current. If you have any questions with regard to configurations, please call Compumotor s Applications Engineering Department at S Drive User Guide

33 Low-Power S6 Drive Current SW1 SW2 SW3 SW4 SW5 SW6 Current SW1 SW2 SW3 SW4 SW5 SW off off off off off off 3.09 on off off off off off 0.13 off off off off off on 3.19 on off off off off on 0.23 off off off off on off 3.28 on off off off on off 0.32 off off off off on on 3.38 on off off off on on 0.42 off off off on off off 3.47 on off off on off off 0.51 off off off on off on 3.57 on off off on off on 0.61 off off off on on off 3.66 on off off on on off 0.70 off off off on on on 3.76 on off off on on on 0.80 off off on off off off 3.85 on off on off off off 0.89 off off on off off on 3.95 on off on off off on 0.99 off off on off on off 4.04 on off on off on off 1.08 off off on off on on 4.14 on off on off on on 1.18 off off on on off off 4.23 on off on on off off 1.27 off off on on off on 4.33 on off on on off on 1.37 off off on on on off 4.42 on off on on on off 1.46 off off on on on on 4.51 on off on on on on 1.52 off on off off off off 4.58 on on off off off off 1.62 off on off off off on 4.68 on on off off off on 1.71 off on off off on off 4.77 on on off off on off 1.81 off on off off on on 4.86 on on off off on on 1.90 off on off on off off 4.96 on on off on off off 2.00 off on off on off on 5.05 on on off on off on 2.09 off on off on on off 5.15 on on off on on off 2.19 off on off on on on 5.24 on on off on on on 2.28 off on on off off off 5.34 on on on off off off 2.38 off on on off off on 5.43 on on on off off on 2.47 off on on off on off 5.53 on on on off on off 2.57 off on on off on on 5.62 on on on off on on 2.66 off on on on off off 5.72 on on on on off off 2.76 off on on on off on 5.81 on on on on off on 2.85 off on on on on off 5.91 on on on on on off 2.95 off on on on on on 6.00 on on on on on on High-Power S8 Drive Setting S6 Drive Motor Current (Non-Compumotor Motors) Current SW1 SW2 SW3 SW4 SW5 SW6 Current SW1 SW2 SW3 SW4 SW5 SW off off off off off off 4.12 on off off off off off 0.18 off off off off off on 4.25 on off off off off on 0.30 off off off off on off 4.38 on off off off on off 0.43 off off off off on on 4.50 on off off off on on 0.56 off off off on off off 4.63 on off off on off off 0.69 off off off on off on 4.75 on off off on off on 0.81 off off off on on off 4.89 on off off on on off 0.93 off off off on on on 5.01 on off off on on on 1.06 off off on off off off 5.14 on off on off off off 1.19 off off on off off on 5.26 on off on off off on 1.31 off off on off on off 5.39 on off on off on off 1.44 off off on off on on 5.51 on off on off on on 1.59 off off on on off off 5.64 on off on on off off 1.69 off off on on off on 5.77 on off on on off on 1.82 off off on on on off 5.90 on off on on on off 1.94 off off on on on on 6.02 on off on on on on 2.03 off on off off off off 6.11 on on off off off off 2.16 off on off off off on 6.23 on on off off off on 2.28 off on off off on off 6.36 on on off off on off 2.41 off on off off on on 6.48 on on off off on on 2.54 off on off on off off 6.61 on on off on off off 2.66 off on off on off on 6.73 on on off on off on 2.79 off on off on on off 6.87 on on off on on off 2.91 off on off on on on 6.99 on on off on on on 3.04 off on on off off off 7.12 on on on off off off 3.17 off on on off off on 7.24 on on on off off on off on on off on off 7.37 on on on off on off 3.42 off on on off on on 7.49 on on on off on on 3.55 off on on on off off 7.62 on on on on off off 3.67 off on on on off on 7.75 on on on on off on 3.80 off on on on on off 7.87 on on on on on off 3.93 off on on on on on 8.00 on on on on on on Setting S8 Drive Motor Current (Non-Compumotor Motors) Chapter 3 Installation 23

34 ❸ Drive Configuration In th section, you will set following DIP switch selectable functions: Auto Standby function Motor Resolutions Motor Waveforms Auto Run function Automatic Standby Function The Automatic Standby function allows motor to cool when it not moving. Th function reduces current to motor when drive does not receive a step pulse for one second. Switches SW1-#7 through SW1-#8 control Automatic Standby. Full power restored upon first step pulse that drive receives. Do not use th function in systems that use an indexer and an encoder for position maintenance. If used in th environment, system will go in and out of Auto Standby mode. Current SW1-#7 SW1-#8 * Full Current off off 75% on off 50% off on 25% on on * Default Setting Automatic Standby Function Motor Resolutions Switches SW2-#1 - SW2-#4 control motor resolution. Your indexer and drive must be set to same resolution. If drive and indexer s motor resolution settings do not match, commanded accelerations and velocities will not be performed accurately. Resolution SW2-#1 SW2-#2 SW2-#3 SW2-#4 50,800 steps off off off on 50,000 steps off off on off 36,000 steps off off on on 25,600 steps off on off off 25,400 steps off on off on * 25,000 steps off off off off 21,600 steps off on on off 20,000 steps off on on on 18,000 steps on off off off 12,800 steps on off off on 10,000 steps on off on off 5,000 steps on off on on 2,000 steps on on off off 1,000 steps on on off on 400 steps on on on off 200 steps on on on on * Default Setting Motor Resolution Settings 24 S Drive User Guide