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Dr. Fritz Faulhaber GmbH & Co. KG. This document has been prepared with care. Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any liability for any errors in this document or for the consequences of such errors. Equally, no liability can be accepted for direct or consequential damages resulting from improper use of the equipment.
General product description ................13 Product information ..................... 14 Product variants ....................15 3.3.1 Speed Controllers for motors in the lower power range ....15 3.3.1.1 SC 1801 S ................15 3.3.1.2 SC 1801 F ................16 3.3.1.3 SC 1801 P ................17 3.3.2 Speed Controllers for motors in the medium power range ....
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Content 4.3.3 Shielding ....................37 4.3.3.1 Establishing the shield connection ........38 4.3.3.2 Establishing shield connection with cable lug ..... 39 4.3.4 Sensor and encoder interfaces ............. 40 4.3.4.1 Analog sensors and analog Hall sensors ......40 4.3.4.2 Incremental encoders / Digital Hall sensors / Digital sensors 41 4.3.5 Using filters ...................
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Accessories ........................72 Warranty ......................... 73 10 Additional documents ....................74 10.1 Declaration of Conformity SC 1801 S/F/P ............74 10.2 Declaration of Incorporation SC 1801 S/F/P ............76 10.3 Declaration of Conformity SC 2402 P and SC 2804 S .......... 77 10.4 Declaration of Incorporation SC 2402 P and SC 2804 S ........
All data in this document relate to the standard versions of the series listed above. Associated documents For certain actions during commissioning and operation of FAULHABER products additional information from the following manuals is useful: Manual...
About this document List of abbreviations Abbreviation Meaning Absolute encoder Brushless Direct Current Back-induced electromotive force Electromagnetic compatibility Electrostatic discharge Flat Flexible Cable Flexible Printed Circuit Ground Low Insertion Force Pulse Width Modulation Speed Controller Transistor Transistor Logic 12th edition, 30.08.2021 7000.05024, 12th edition, 30.08.20217000.05024...
About this document Symbols and designations DANGER DANGER Danger with high level of risk: if not avoided, death or serious injury will result. Measures for avoidance WARNING WARNING Danger with medium level of risk: if not avoided, death or serious injury may result. ...
The Speed Controllers described here are designed for the activation and speed control of DC and BL motors in the low (SC 1801), medium (SC 2402 / SC 2804) and higher power range (SC 5004 / SC 5008). The following points must be observed to ensure that the motors are used as intended: ...
Safety Safety instructions In addition to the safety risks described in this technical manual, machine-specific dangers could arise that cannot be foreseen by the manufacturer of the Speed Controller (e.g., risk of injury from driven components). The manufacturer of the machine in which the Speed Controller is installed must perform a risk analysis in accordance with the regulations appli- cable to the machine and inform the end user of the residual risks.
Connect the wires as shown in the connection assignment. 2.2.3 Sensitivity to solvents The housings of the SC 1801 S and SC 1801 F Speed Controllers have only limited resistance to solvents, such as alcohols and acetone. Protect the housings against contact with solvents or substances containing solvents.
Safety EC directives on product safety The following EC directives on product safety must be observed. If the Motion Controller is being used outside the EU, international, national and regional directives must be also observed. Machinery Directive (2006/42/EC) The controllers with attached motor described in this technical manual may be drive sys- tems according to the Machinery Directive.
Product description General product description FAULHABER Speed Controllers are based on an integrated microcontroller and are used for speed control in the motor models listed in chap. 2.1, p. 9. The Speed Controllers are equipped with the following functions for controlling the...
Product description Product information xxxx: Product variant Housing with screw-type terminal strip (motor) Housing with LIF connector (motor) Board version with male connectors Max. continuous output current 1 A Max. continuous output current 2 A Max. continuous output current 4 A Max.
Speed Controller with housing and screw terminals on the supply and motor side. Assembly sleeves Screw terminal block on the motor side Screw terminal block on the supply side Tab. 1: Product variants of the SC 1801 S series Variant Standard configuration Speed range Power supply of elec- Optional configurations –1...
FFC and FPC, 3-pole LIF plug connector on the motor side for FFC and FPC, 8-pole Screw terminal block on the supply side Tab. 2: Product variants of the SC 1801 F series Variant Standard configuration Speed range Power supply of elec- Optional configurations –1...
Speed Controller without housing (board version) with plug connectors on the supply and motor side. Plug connector on the motor side Plug connector on the supply side Tab. 3: Product variants of the SC 1801 P series Variant Standard configuration Speed range Power supply of elec- Optional configurations –1...
Product description 3.3.2 Speed Controllers for motors in the medium power range 3.3.2.1 SC 2804 S Speed Controller with metal housing and screw terminals on the supply and motor side. Mounting holes Screw terminal block on the supply side Screw terminal block on the motor side Tab.
Product description 3.3.2.2 SC 2402 P Speed Controller without housing (board version) with plug connectors on the supply and motor side. Plug connector on the supply side Plug connector on the motor side Tab. 5: Product variants of the SC 2402 P series Variant Standard configuration Speed range...
Product description 3.3.3 Speed Controllers for motors in the higher power range 3.3.3.1 SC 5008 S Speed Controller with metal housing and screw terminals on the supply and motor side. Mounting holes Screw terminal block on the supply side Screw terminal block on the motor side Tab.
Product description 3.3.3.2 SC 5004 P Speed Controller without housing (board version) with plug connectors on the supply and motor side. Plug connector on the supply side Plug connector on the motor side Tab. 7: Product variants of the SC 5004 P series Variant Standard configuration Speed range...
Installation Installation Only trained experts and instructed persons with knowledge of the following fields may install and commission the Motion Controller: Automation technology Standards and regulations (such as the EMC Directive) Low Voltage Directive Machinery Directive ...
2. Protect the fastening screws to prevent displacement due to the effect of heat. Tab. 8: Attachment specifications Speed Controller Min. tightening torque (Ncm) Max. tightening torque (Ncm) SC 1801 S/F SC 2804 S SC 5008 S 12th edition, 30.08.2021 7000.05024, 12th edition, 30.08.20217000.05024...
Dimension power supply units and any other peripheral components accordingly. For applications with high load inertia, the FAULHABER Braking Chopper of the BC 5004 series can be used to limit overvoltages and thereby protect the power supply. For more detailed information see the data sheet for the Braking Chopper.
For DC motors with encoders, the signal cables must be installed directly at the device on both connection sides with one turn through one Star-TEC each (e.g., Würth Elek- tronik No.: 74271132). EMC suppressor circuit 1 (SC 1801) 220 nF 220 nF nsoll Fig.
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EMC suppressor circuit 2 (SC 1801) 0 – 10 V DC nsoll Fig. 5: EMC suppressor circuit for SC 1801 with suppressor diodes Separate suppressor diodes (D1 and D2, e.g., P6KE18 from STMicroelectronics) for U and U with separate power supplies.
Digital output with open collector and integrated pull-up resistor The digital output can be configured for various tasks (see chap. 5.3, p. 60) Encoder or enable (only with corresponding hardware, not SC 1801) Encoder or brake (only with corresponding hardware, not SC 1801) 12th edition, 30.08.2021...
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= 15 mA Digital output Open collector with pull-up resistor: SC 1801, SC 2402, SC 2804: 22 kΩ SC 5004, SC 5008: 47 kΩ Lines per revolution are dependent on configuration and sen- sor system (see Tab. 19)
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Longer connection cables are generally permissible, but must be validated for the target installation. Optimization of the behavior in respect of transient emission and interference resistance may require additional EMC measures (see chap. 4.2.2.2, p. 25). SC 1801 S SC 1801 P SC 1801 F SC 2804 S...
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Clockwise rotation with homopolar connec- tion Anticlockwise rotation with oppositely poled connection Tab. 15: Electrical data – power supply for external consumer loads Designation SC 1801 SC 2402 SC 2804 SC 5004 SC 5008 13 (V Output voltage 5 V DC Max.
Installation 4.2.3 Connection examples 4.2.3.1 Connection examples for the supply side NOTICE NOTICE Damage to the electronics caused by excessive power supply. Observe the minimum and maximum power supply. Normal operation (speed set value specification by U nsoll 0 – 10 V ∗...
Installation The connected motor rotates clockwise at a load-dependent speed. The speed can be adapted by changing U If the digital output is configured as the frequency output (see chap. 5.3, p. 60), the speed signal can be measured at the digital output. 4.2.3.2 Connection examples for the motor side DC motor without encoder (not SC 5004 and SC 5008)
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Installation BL motors with digital/analog Hall sensors Motor Phase C Mot C BL-Motor Motor Phase B Mot B Motor Phase A Mot A SGND +5 V Power Supply Hall Sensor C Sens C Hall Sensor B Sens B Hall Sensor A Sens A Fig.
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Installation BL motor with digital Hall sensors and incremental encoders (only option 4475) Channel A Channel B Motor Phase C Mot C BL-Motor Motor Phase B Mot B Motor Phase A Mot A SGND +5 V Power Supply Hall Sensor C Sens C Hall Sensor B Sens B...
Installation Electromagnetic compatibility (EMC) Follow the instructions in the following chapters to perform an EMC-compliant installa- tion. WARNING WARNING The Motion Controller can cause high-frequency interference which can affect the function of electronic implants and other electronic devices. Take appropriate interference suppression measures, particularly during use in residen- tial environments.
Installation 4.3.2 Cable routing WARNING WARNING Voltages >25 V AC are generated and transmitted in the drive system. Set up the wiring of the drive system in a touch-proof manner. Only operate the drive system on an SELV or PELV power supply network. The cable routing depends on various factors, such as: Is the cable shielded, twisted? ...
Installation 4.3.3 Shielding Shield cables in all cases. Shield cables that are longer than 3 m with tightly meshed copper braiding. Shield all supply lines according to current guidelines/standards (e.g., IPC-A-620B) and connect using (round) shield clamp. In special cases (e.g., with pigtail) or after qualification, the shield can be omitted for the following cables: Cables with length <50 cm ...
Installation 4.3.3.1 Establishing the shield connection The best results when establishing a shield connection on the cable are achieved in the fol- lowing way: Fig. 21: Motor cable shield connection Outer cable shield Heat-shrink tubing Braided shield Crimp-sleeve Shield clamp 1.
Installation 4.3.3.2 Establishing shield connection with cable lug A shield connection with cable lug should be avoided whenever possible. If it is necessary, however, the connection should be established as follows. Fig. 22: Shield connection with cable lug Screw Lock washer Wall Spring washer Wire eyelet...
Installation 4.3.4 Sensor and encoder interfaces The sensor systems used at FAULHABER for angle determination should be divided accord- ing to their useful frequency range. Depending on the frequency range, various filter meas- ures are suitable. Analog Hall sensors (very low frequency) ...
EFM 5001/5003/5008 6501.00352 6501.00357 6501.00358 Fig. 24: Filter categories from FAULHABER 4.3.5.1 Input-side filters These filters are for applications that either cannot use the motor filter (e.g., integrated controllers) or in which the filtering by the motor filters is not sufficient. In this case, two fil- tering measures are used: ...
0 V voltage (GND) of the motor supply (connection X5 of the supply side). 4.3.5.3 Insulation resistance The filters from FAULHABER are not intended for an insulation resistance test. Discharging of the common-mode interference with capacitors prevents a meaningful result from an insulation resistance test. 4.3.5.4 Coiling ferrite ring Ideally, ferrites made of manganese-zinc material are used that are active in the 1…10 MHz...
Installation 4.3.6 Error avoidance and troubleshooting 1. Can the problem clearly be traced back to the FAULHABER drive system? a) Switch the output stage off and on. The voltage controller mode is suitable here. b) Unplug controller supply voltages or operate controller via a separate external power supply used solely for this purpose.
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Installation Conformity measurements The following points must be observed during the conformity measurement: Conducted interference voltage measurement Radiated interference voltage measurement When laying cables, remove all loops. Where possible, lay cables over a grounding plate. Lay the cables with a meandering shape. Connect the shield of the motor cable on the motor The connection of the motor cable shield is to be as ...
Description of functions Description of functions Operating modes 5.1.1 Speed-controlled operation of the DC motors The actual speed value for the speed controller can be determined in different ways. The configurations described below differ in this regard. The digital output is permanently programmed as fault output. 5.1.1.1 DC motors with encoder Digital output...
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Description of functions Actual speed value and direction of rotation are determined using different signals: Designation Explanation Actual speed value Determined via the quadrature signals of the incremental encoder. Two-edge evaluation without detection of the direction of rotation. Direction of rotation Determined via direction of rotation input.
Description of functions 5.1.1.2 DC motors without encoder (not SC 5004 and SC 5008) Digital output Electronics supply Motor supply 22 kΩ Protection function: Overtemperature Motor + MOSFET Power DC-Motor output Setpoint input generator Motor – PI velocity nsoll soll stage controller 0 –...
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Description of functions The following basic parameters are preset in this configuration: Designation Explanation Set-point specification Analog Digital output Fault output (cannot be changed) Operating mode Speed-controlled 2-quadrant operation with brake func- The speed is reduced by short-circuiting the motor tion The following settings can be made by the user: Designation...
Description of functions 5.1.2 Speed-controlled operation of the BL motors The actual value for speed used for speed control can be determined by means of the sig- nals used for commutation. The configurations described below differ with regard to the used sensor systems.
Description of functions The following settings can be made by the user: Designation Explanation Set-point specification The following set value specifications can be set (see chap. 5.2, p. 58): Fixed speed mode Speed set value specification via analog signal ...
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Description of functions The following basic parameters are preset in this configuration: Designation Explanation Set-point specification Analog Digital output Frequency output Operating mode Speed-controlled 4-quadrant operation with brake func- Active acceleration and braking of the motor. tion Brake function can be activated/deactivated. The following settings can be made by the user: Designation Explanation...
Description of functions 5.1.2.3 BL motors without Hall sensors (sensorless operation, not SC 5004 and SC 5008) Digital output Electronics supply Motor supply 22 kΩ Protection function: Overtemperature 3 Phase Phase A MOSFET Power Phase B BL-Motor output Setpoint input block Phase C PI velocity...
Description of functions The following basic parameters are preset in this configuration: Designation Explanation Set-point specification Analog Digital output Frequency output (cannot be changed) Operating mode Speed-controlled 2-quadrant operation No active brake function The following settings can be made by the user: Designation Explanation Set-point specification...
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Description of functions The following basic parameters are preset in this configuration: Designation Explanation Set-point specification Analog Digital output Frequency output Operating mode Speed-controlled Speed filter Active 4-quadrant operation with brake func- Active acceleration and braking of the motor. tion Brake function can be activated/deactivated.
Description of functions 5.1.2.5 BL motors with digital Hall sensors and incremental encoders (option 4475) Fig. 32: Block diagram of a BL motor with digital Hall sensors and incremental encoders The resolution of the incremental encoder means that stable speed control is possible above approx.
Description of functions The following settings can be made by the user: Designation Explanation Set-point specification The following set value specifications can be set (see chap. 5.2, p. 58): Fixed speed mode Speed set value specification via analog signal ...
Description of functions The following basic parameters are preset in this configuration: Designation Explanation Set-point specification Analog Digital output Frequency output Operating mode Speed-controlled 2-quadrant operation with The speed is reduced by short-circuiting the motor. brake function When using the SC 5004 / SC 5008 controller, the fastest possible braking ope- ration is performed taking into account the permissible motor current.
Description of functions Set-point specification The following setting options for set value specification are possible: Fixed speed specification Analog set value specification PWM set value specification 5.2.1 Fixed speed specification In fixed speed mode, the motor is operated at a certain speed. In this case, the set speed to be set is fixed using a parameter (see chap.
Description of functions The analog input can process voltages from 0 V to 10 V. An analog set value specification of 10 V corresponds to the value specified in the parameter n setMax A linear conversion is performed between 0 V and 10 V: ...
Description of functions Configuration of the digital output The digital output can be configured for the following tasks: Fault output (not with BL motors in sensorless operation) When current limitation is activated, the output switches to high level. The delay ...
Tab. 18: Device-specific values for motor continuous current (I ) and peak current (I cont Device type Motor continuous current (I Peak current (I Unit cont SC 1801 SC 2402 SC 2804 SC 5004 SC 5008 delivery state 5.4.3 Fixed speed In fixed speed mode, the speed set value is preset via a configurable parameter (see chap.
Option Controller Value Speed per 1 V type setMax BL motors (2-pole) with digital Hall sensors 3530 SC 1801 30 000 min 3 000 min SC 2402 20 000 min 2 000 min SC 2804 20 000 min 2 000 min...
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Option Controller Value Speed per 1 V type setMax BL motors (14-pole) with digital Hall sensors 6340 SC 1801 10 000 min 1 000 min SC 2402 10 000 min 1 000 min SC 2804 10 000 min 1 000 min...
The use of a programming adapter is necessary for making changes to the factory setting. Preconfigured for 2-pole motors (delivery state). When operated with 4-pole motors, the Speed Controller must be reconfigured with the FAULHABER Motion Manager software. Preset to 256 pulses Preset to 512 pulses.
Description of functions 5.4.8 Start time (only BL motors in sensorless operation) In sensorless operation, the BL motor starts via a synchronous drive. The time between switchover from one commutation state (phase) to the next commutation state can be set to the connected motor.
Description of functions Protective functions 5.5.1 t current limitation t current limitation protects the motor against overheating. A thermal current model which calculates the motor temperature is created for this purpose. The motor current is influenced depending on the calculated temperature. The following values are relevant for t current limitation: ...
Description of functions The current controller comes into effect and limits the motor current to the peak cur- rent (I ). At the same time, the flowing current is used to calculate a model tempera- ture in a thermal current model. ...
Description of functions Voltage output at motor The power stage of the Speed Controller uses pulse width modulation (PWM). In the case of a fixed PWM frequency, the duty cycle between the switch-on time and switch-off time is set according to the controller output value. Since in the case of pulse width modulation the inductance of the motor acts as a current filter, a high PWM frequency is selected (96 kHz and 24 kHz with motors in sensorless operation).
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Description of functions Current g (t) mitt Time (t*10 µs) Fig. 40: PWM frequency = 96 kHz Efficiency during operation with PWM (96 kHz): η = 74.3% At a higher PWM frequency, a better motor efficiency is achievable and the current has a lower ripple.
Commissioning Commissioning CAUTION CAUTION Risk of injury caused by protruding, rotating or moving parts of the driven mechanical units. Attach suitable guards. NOTICE NOTICE Damage to the motor and/or Speed Controller as a result of incorrectly set control para- meters.
Maintenance Maintenance Maintenance tasks The motor is generally maintenance-free. Where the device is mounted in a cabinet, depending on the deposition of dust the air filter should be regularly checked and cleaned if necessary. Troubleshooting If unexpected malfunctions occur during operation according to the intended use, please contact your support partner.
Accessories Accessories The following accessories are available: Article Article no. Programming adapter USB 6501.00096 Programming adapter USB 6501.00097 Use is dependent on the size of the Speed Controller Details on configuration can be found in the Motion Manager manual (see chap. 1.2, p.
Warranty Warranty Products of the company Dr. Fritz Faulhaber GmbH & Co. KG are produced using the most modern production methods and are subject to strict quality inspections. All sales and deliv- eries are performed exclusively on the basis of our General Conditions of Sale and Delivery which can be viewed on the FAULHABER home page www.faulhaber.com/gtc and down-...
Additional documents 10.4 Declaration of Incorporation SC 2402 P and SC 2804 S 12th edition, 30.08.2021 7000.05024, 12th edition, 30.08.20217000.05024...
Additional documents 10.6 Declaration of Incorporation SC 5004 P and SC 5008 S 12th edition, 30.08.2021 7000.05024, 12th edition, 30.08.20217000.05024...