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halstrup-walcher PS 3 Series Instruction Manual

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Document 7100.005374
Instruction Manual
PSx3xxIO
halstrup-walcher GmbH
Stegener Straße 10
D-79199 Kirchzarten
Phone: +49 (0) 76 61/39 63–0
E-Mail: info@halstrup-walcher.com
Internet: www.halstrup-walcher.com

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  • Page 1 Instruction Manual PSx3xxIO halstrup-walcher GmbH Stegener Straße 10 D-79199 Kirchzarten Phone: +49 (0) 76 61/39 63–0 E-Mail: info@halstrup-walcher.com Internet: www.halstrup-walcher.com Document 7100.005374...
  • Page 2 Instruction Manual PSx3xxIO Revision overview Version: Date: Author: Amendments: 14.07.14 Initial Revision 02.11.17 Additions process-data 05.05.20 Additions Thermoprotec 06.07.22 Revision overview; UKCA; Pin assignment; Error Acknowledge; Readjustment; Referencing value; Mapping end; Manual turning; Decl. of conformity 17.08.22 Chapter 1.5 and 3 software version number changed 29.09.22 Chapter 3.2 Table of speed and torque parameters 05.12.22...
  • Page 3 This is documented by the CE and the UKCA mark being affixed. Accessoires PSx3xx-CA series We offer you the corresponding supply and data plugs for all unit types. Please contact our sales department, stating the complete type designation, at the following e-mail address Vertrieb@halstrup-walcher.de...

  • Page 4: Table Of Contents

    Instruction Manual PSx3xxIO Contents Safety precautions ..................... 6 Qualified personnel ...................... 6 Explanation of symbols ....................6 Appropriate use ......................7 Inappropriate use ......................8 Limitation of liability ...................... 9 Faults, maintenance, repair, disposal ................9 Product labeling ......................10 Differences between software versions ..............
  • Page 5 Instruction Manual PSx3xxIO 5.5.2 Positioning run without loop................42 5.5.3 Manual run ......................42 5.5.4 Special features for the target speed ...............42 Special features ....................... 43 Speed, acceleration and deceleration ................ 43 Maximum torque and maximum start-up torque ............43 Behaviour of the drive in the case of blocking ............44 Readjustment in case of manual displacement externally ..........

  • Page 6: Safety Precautions

    Instruction Manual PSx3xxIO Safety precautions This section provides an overview of all the important safety aspects for optimum protection of personnel and for safe and trouble-free operation. 1.1 Qualified personnel These operating instructions are intended for qualified electricians and fitters who are authorized to install, electrically connect, commission and label devices and systems in accordance with safety standards, as well as for the operator and manufacturer of the system on which the drives are installed.

  • Page 7: Appropriate Use

    Instruction Manual PSx3xxIO 1.3 Appropriate use Positioning systems are especially suitable for automatically setting tools, stops or spindles for wood-processing equipment, packing lines, printing equipment, filling units and other types of special machines. PSx3xx positioning systems are not stand-alone devices and may only be used if coupled to another machine.

  • Page 8: Inappropriate Use

    Instruction Manual PSx3xxIO 1.4 Inappropriate use The use of the positioning devices outside of the operating conditions and technical data and specifications described in the documentation is considered “improper”. The drives are designed for intended operation under normal ambient conditions (according to EN / IEC / UL 61010-1), with the exception of an extended temperature range.

  • Page 9: Limitation Of Liability

    Instruction Manual PSx3xxIO 1.5 Limitation of liability The device may only be operated in accordance with these operating instructions. All information and instructions in these operating instructions have been compiled taking into account the applicable standards and regulations, the state of the art and our many years of experience and knowledge.

  • Page 10: Product Labeling

    Instruction Manual PSx3xxIO 1.7 Product labeling Warning symbol Meaning Reference to further documentation Read the operating instructions and safety instructions before transportation, installation or commissioning Warning of hot surface The appliance can become very hot during operation. Temperatures of over 70°C can occur. In the event of a fault, internal components may be overloaded.

  • Page 11: Device Description

    Instruction Manual PSx3xxIO Device description 2.1 Functional description The PSx3xx positioning system, an intelligent, compact, complete solution for positioning auxiliary and positioning axes, consists of an EC motor, gear power amplifier, control electronics, absolute measuring system and IO-Link interface. The integrated absolute measuring system eliminates the need for a time-consuming reference run.

  • Page 12: Installation

    Instruction Manual PSx3xxIO Installation 3.1 Electrical connection NOTICE The following notes on the power supply should be observed. Minimum cross-sections are required for connection to the power supply. For power cables mounted on the device, use only the cross-sections listed below. In order to minimize voltage drop on longer cables, we always recommend using the largest available cross-section.

  • Page 13: Assembly Of The Positioning System

    Instruction Manual PSx3xxIO 3.2 Assembly of the positioning system CAUTION The maximum permissible axial and radial forces (see chapter 7.3 Physical data) on the motor shaft must not be exceeded during transportation, installation or operation. CAUTION Take the weight of the device into account when selecting the fastening screws! Tightening torques of the fixing screws according to the screw manufacturer's specifications! WARNING...
  • Page 14 Instruction Manual PSx3xxIO CAUTION The PSx3xx must have a little gap on all sides when mounted, as it can move axially and/or radially during positioning if the hollow shaft and solid shaft are not 100% aligned. This "staggering" is not a defect of the PSx3xx and also has no influence on the function, as long as it can move freely.

  • Page 15: Solid Shaft

    Instruction Manual PSx3xxIO 3.2.2 Solid shaft The PSx3xx is installed on the machine by mounting the drive to the axis to be driven using a coupling and an intermediate flange. CAUTION Under no circumstances may the housing cover be used for the purpose of the transmission of force.

  • Page 16: Powering The Device

    Instruction Manual PSx3xxIO 3.4 Powering the device CAUTION For motor power use a single fuse with max. 3,5 A for each PSx3xx. For motor power use a single fuse with max. 10 A for each PSE34xx. For control power you can use a fuse with max. 2,0 A, so it is possible to power up to 10 units parallel with one fuse.

  • Page 17: Pin Assignment For The Power Supply And Io-Link For Pse34Xx

    Instruction Manual PSx3xxIO 3.5.2 Pin assignment for the power supply and IO-Link for PSE34xx connector pattern assignment type (external top view) HAN4A, Harting 1. +24V motor 2. GND motor 5. Housing 1. +24V control unit M12 (A-cod.); 5-pol 3. GND control unit 4.

  • Page 18: Commissioning

    Instruction Manual PSx3xxIO 3.7 Commissioning After applying the supply voltage, the PSx3xx may perform no initial reference loop before the first positioning. A positioning or manual drive order may be commenced immediately. Process of the positioning operation (with loop) The PSx3xx distinguishes between the following cases in a positioning process (assumption: The direction in which each target position is approached is forwards): 1.

  • Page 19: Io-Link

    Instruction Manual PSx3xxIO IO-Link For the IO-Link interface, IEC 61131-9 Version 1.1.2 is used as the SDCI protocol. The format of the output data can either be structured according to the Time Stamp Specification of the Sick company (consisting of a time stamp and two control bits), or they consist of a control word and a setpoint (process data;...
  • Page 20 Bit 0: parameter (write) access lock 16 bit access locks Bit 1: data storage lock Bit 2: local parameterisation lock Bit 3: local user interface lock Vendor name 16 halstrup-walcher GmbH String Vendor text www.hwg.eu String Product depending on the gearbox type,...
  • Page 21 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range Status requests (continuation) Actual value Current actual position, value in 1/100 ±31 bit mm (for default settings of numerator ISDU 124 and denominator ISDU 125 and spindle pitch 4 mm) Writing onto this register causes the current position to be “referenced”...
  • Page 22 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range Run commands Set control If this par. is set to 0 and the subsequent 0…1 word write command affects the control word 8 bit (110), the writing of the control word is suppressed.
  • Page 23 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range “Bus communication” parameter group Process data 0  with time stamp function 0, 1 format 1  with 6 bytes of output data or 2**) 2  with 8 bytes of output data**) 8 bit After saving and restarting, the device reports with the Device ID which...
  • Page 24 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range “Position values” parameter group Direction of 0: clockwise 0 or 1 rotation (when looking at the output shaft) 8 bit 1: counter clockwise Changes only possible when at standstill Actual value With these values, any user resolution 1...10000...
  • Page 25 Instruction Manual PSx3xxIO Loop length Minimum number of steps in which the 0.025…1 drive approaches a target in a predefined revolutio direction n or 0 Value in steps (0  no loop) 32 bit Drag error Maximum drag error before the "drag 20...1000 error"...
  • Page 26 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range “Position values” parameter group (continuation) Number Number of steps for the brake release 1...50 breaking free drive 16 bit steps Configuration Reaction of the drive to a connection 16 bit failure connection...
  • Page 27 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range "Torque" parameter group Maximum Value in cNm start-up 16 bit torque Maximum Applies after the end of the start-up phase torque (during the start phase, the value from 16 bit ISDU 152 applies);...
  • Page 28 Instruction Manual PSx3xxIO Designation ISDU Function Value Secu Delivery R/W Number range “Other” parameter group General 171-180 10 freely-usable registers 16 bit purpose UMot limit Voltage limit for Bit ‘motor power present’ 180...240 in 0.1 V 16 bit Temperature Temperature limit °C for overtemperature 10...70 limit 16 bit...

  • Page 29: Table Of The Speed And Torque Values For Various Models Of Gears

    Instruction Manual PSx3xxIO 4.2 Table of the speed and torque values for various models of gears Device type 301-x 302-x 305-x 322-14 325-14 PSE and PSS 311-x 312-x 315-8 332-14 335-14 ISDU Value range Name delivery 15...230 10...150 3...70 20...200 10...100 Target speed target speed for...
  • Page 30 Instruction Manual PSx3xxIO Device model PSE 3110-14 3125-14 3325-14 3410-14 3418-14 ISDU Value range Name delivery 1…30 1…12 2...18 10...100 5...90 Target speed target speed for 1…30 1…12 2...18 10...100 5...90 manual run Target speed 1…30 1…12 2...18 10...100 5...90 Target speed 1…30 1…12...
  • Page 31 Instruction Manual PSx3xxIO Device type 3210-14 3218-14 3310-14 ISDU Value range Name delivery 5…38 3...26 Target speed target speed for 5…38 3...26 manual run Target speed 5…38 3...26 Target speed 5…38 3...26 Acceleration 20...117 11...70 Deceleration 20...117 11...70 Maximum torque 100...1000 180...1800 1000...

  • Page 32: Process Data Definition

    Instruction Manual PSx3xxIO 4.3 Process Data Definition 4.3.1 Process output data (from the point of view of the IO-Link master) Assignment for the variant "time stamp function”: Meaning Control bits 0  abort run 1  Manual drive to larger values 2 ...

  • Page 33: Process Input Data (From The Point Of View Of The Io-Link Master)

    Instruction Manual PSx3xxIO 4.3.2 Process input data (from the point of view of the IO-Link master) Assignment: Byte Meaning Corresponding IO-Link ISDU’s 0-15 Status 16-31 Actual rpm (1/min) 32-63 Actual value The assignments are not changeable. NOTICE Some IO-Link bus masters process the data in the opposite byte order, this applies to both the output and the input data.
  • Page 34 Instruction Manual PSx3xxIO Forward jog key active Bit 3: set: - If Pin 2 of the key connector is connected with Pin 1 (+24V), reset: - If Pin 2 of the key connector is disconnected with Pin 1 (+24V), Motor power present Bit 4: set: - If the motor supply voltage is above the Umot limit (ISDU 181) and below...
  • Page 35 Instruction Manual PSx3xxIO Bit 11: Manual displacement set: - If the drive, at a standstill, is rotated from the outside by more than the value set in the positioning window reset: - by ordering a positioning order - after a correctly-completed initial reference loop Bit 12: Incorrect target value set: - If a transferred target value is outside of the limit switch limits, also caused...

  • Page 36: Detailed Description Of The Control Bits

    Instruction Manual PSx3xxIO 4.5 Detailed description of the control bits Bit 0: Manual run to larger values Manual run to smaller values Bit 1: Transfer target values: For transferring a target value with the help of the Bit 2: process data, the positioning is only started if this bit is set. Bit 3: Release for manual run in jog key mode: This bit must be set in order to switch from jog key mode (run activated via the keys, if bit 5 is set;...
  • Page 37 Instruction Manual PSx3xxIO Run with drag error correction: With a set bit, the drive attempts, under Bit 12: consideration of the set maximum current, to amend a tracking error that has occurred by controlling the speed at a value which is slightly above or below the specified target speed (ISDU 142).

  • Page 38: Sequence Of Positioning

    Instruction Manual PSx3xxIO Sequence of positioning 5.1 Positioning run By default, the PSx3xx always approaches each setpoint from the same direction. If a target is located in the opposite direction to the loop direction, the setpoint is first overrun by the value of the loop length (ISDU 132) and only then finally approached. In this way, for example, the backlash of a driven spindle can be eliminated The PSx3xx thus distinguishes the following cases during a positioning process: Assumption: Each target position is approached in forward direction, i.e.

  • Page 39: Positioning Run Without Loop

    Instruction Manual PSx3xxIO 5.2 Positioning run without loop The "Positioning without looping" mode is mainly used to move small distances for fine corrections. Each position is approached directly. Any play in the driven spindle is NOT eliminated. The internal gear backlash of the PSx3xx does not appear in this case either, as the position detection takes place directly at the output shaft.

  • Page 40: Positioning Drive With Inactivated Time Stamp

    Instruction Manual PSx3xxIO 5.3.4 Positioning drive with inactivated time stamp - target position transfer (control word, ISDU 110 = 0x10 and target position, ISDU 112): Drive starts to move - Cancellation of drive by withdrawing the release (send control word = 0x00) - if a new target position is transferred during the positioning drive, the new destination is approached immediately.

  • Page 41: Positioning Run

    Instruction Manual PSx3xxIO 5.4.1 Positioning run - to control the drive, it must first be switched to the IO-Link status "operate". - transfer target position: Control word = 0x14 and the desired target position  Drive starts to move - Cancellation of drive by withdrawing the release: Control word = 0x00 - if a new target position is transferred during the positioning run, the new destination is approached immediately.

  • Page 42: Positioning Run

    Instruction Manual PSx3xxIO 5.5.1 Positioning run - to control the drive, it must first be switched to the IO-Link status "operate". - transfer target position: Control word = 0x14, desired target speed and the desired target position  Drive starts to move - Cancellation of drive by withdrawing the release: Control word = 0x00 - if a new target position is transferred during the positioning run, the new destination is...

  • Page 43: Special Features

    Instruction Manual PSx3xxIO Special features 6.1 Speed, acceleration and deceleration The initial reference loop and the manual run are performed at the maximum speed specified in ISDU 145, positioning runs with the maximum velocity from ISDU 142. For counter clockwise runs the maximum speed from ISDU 143 also applies, for clockwise runs the one from ISDU 144.

  • Page 44: Behaviour Of The Drive In The Case Of Blocking

    Instruction Manual PSx3xxIO 6.3 Behaviour of the drive in the case of blocking If, during a run the achievable speed is lower than the limit value of 30% for longer than 200 ms (ISDU 159) of the selected maximum speed (ISDU 146) (these are the default values), a block is detected, the run is aborted and the bit 'positioning error’...

  • Page 45: Readjustment In Case Of Manual Displacement Externally

    Instruction Manual PSx3xxIO 6.4 Readjustment in case of manual displacement externally If the PSx3xx at standstill is rotated against the loop direction by an external force after a correctly-completed positioning run (or manual run to a range limit) and the release bit (Bit 4) and the readjustment bit (Bit 10) are set in the control word, it tries to approach the previously-sent target position again (readjustment).

  • Page 46: Calculation Of The Physical Absolute Position

    Instruction Manual PSx3xxIO 6.5 Calculation of the physical absolute position NOTICE This calculation only applies for software versions < 267. For the calculation of the physical absolute position for software versions ≥ 267 see chapter “Extended positioning range”. The actuator PSx3xx has an absolute measuring system with a measuring range of 250 revolutions.

  • Page 47: Use Of The "Upper Mapping End" Parameter

    Instruction Manual PSx3xxIO Comments: 1) For the calculation of the upper mapping end (ISDU 128) (as in the above examples) a safety margin of 3 turns (default 1200 steps) must be complied with, because the maximum possible position value is 3 rotations underneath the top end mapping.

  • Page 48: Shifting The Positioning Range Upwards Starting From The Delivery State

    Instruction Manual PSx3xxIO 6.6.2 Shifting the positioning range upwards starting from the delivery state In the following example, starting from the DS, the maximum possible positioning range is shifted slightly upwards using the parameter “upper mapping end”: Here, the upper mapping end was increased from the value 102,400 to 116,200. Consequently, a higher proportion of the possible positioning range is above 51,200 and a smaller proportion below 51,200.

  • Page 49: Shifting The Positioning Range Downwards Starting From The Delivery State

    Instruction Manual PSx3xxIO 6.6.3 Shifting the positioning range downwards starting from the delivery state In the following example, starting from the DS, the maximum possible positioning range is shifted slightly downwards using the parameter “upper mapping end”: Here, the upper mapping end was decreased from the value 102,400 to 88,600. Consequently, a higher proportion of the possible positioning range is below 51,200 and a smaller proportion above 51,200.

  • Page 50: Shifting The Positioning Range Depending On The Actual Position

    Instruction Manual PSx3xxIO 6.6.4 Shifting the positioning range depending on the actual position If (in contrast to the examples above) the actual position is not in the delivery state (i.e. value 51,200), this is included in the calculation of the possible value range for the upper mapping end.
  • Page 51 Instruction Manual PSx3xxIO Example: Spindle with 5 mm pitch, specified unit for target and actual values: 1µm  1 rotation = 5mm = 5,000µm  Number of steps per rotation = 5,000 Using the formula Number of steps per rotation = 400 * denominator / numerator the following result is obtained: numerator = 400;...

  • Page 52: Step-By-Step Instructions For Determining The Positioning Range

    Instruction Manual PSx3xxIO 6.6.5 Step-by-step instructions for determining the positioning range The following section describes the procedure for determining those parameters that have an influence on the target and actual position as well as the positioning range. The individual steps must be carried out in the specified order. 1) Setting the direction of rotation: The direction of rotation determines with which direction of rotation of the output shaft the position values increase and with which direction of rotation of...

  • Page 53: Extended Positioning Range

    Instruction Manual PSx3xxIO 5) Setting upper and lower limits: If necessary, the maximum possible positioning range can be restricted to prevent incorrect target positions that lead to a collision. 6.7 Extended positioning range Devices from software version V267 have the feature “Extended positioning range”. The positioning range can be freely selected (within the numerical limits) using the upper and lower limit (ISDUs 129/130).

  • Page 54: Special Features When Setting Some Parameters

    Instruction Manual PSx3xxIO end is changed. However, the actual value (both during operation and when switching on again) is not affected. The use of all other parameters is not affected by the feature “Extended positioning range”. When writing these values, the special features as described below apply. 6.8 Special features when setting some parameters 1) In the event of a change of the direction of rotation (ISDU 123), the referencing value (ISDU 127), the upper mapping end (ISDU 128) and the upper and lower...

  • Page 55: Using Actual Value Assessment Factors To Set The Spindle Pitch

    Instruction Manual PSx3xxIO NOTICE The removal of the motor power supply has no influence on the internal measuring system. 6.9 Using actual value assessment factors to set the spindle pitch On ISDU 124 (numerator factor) and 125 (denominator factor), any spindle resolutions can be mapped: Number of steps per revolution = 400 * (denominator / numerator) Both factors are set to a value of 400 by default, resulting in a resolution of 0.01 mm...

  • Page 56: Abort Run In The Event Of Failure Of The Master

    Instruction Manual PSx3xxIO 6.11 Abort run in the event of failure of the master If the connection to the master is interrupted during a positioning, a drive that has already started cannot be cancelled by the master. In this case, there are three possible reactions: 1) If a positioning is in progress, the drive should end this positioning as planned and then start no new positioning, as long as there is no connection.
  • Page 57 Instruction Manual PSx3xxIO The waiting time until the drive transfers to manual drive is set with ISDU 163. In manual drive, the drive moves to the respective end switch position (ISDU 129 and 130). If both keys are pressed during a jog drive, the run is immediately cancelled. A new jog drive is only possible again if both keys have been released.

  • Page 58: Manual Turning With The Adjustment Facility

    Instruction Manual PSx3xxIO 6.13 Manual turning with the adjustment facility When mounting or dismounting a PSx3xx, it may be necessary to manually turn the output shaft to a certain position. For this purpose, the actuators are equipped with a manual adjustment facility: First, the corresponding cover in the cover must be removed.

  • Page 59: Devices With Optional Snap Brake

    Instruction Manual PSx3xxIO 6.14 Devices with optional snap brake The device models PSx30x-14, PSx31x-14, PSx32x and PSx33x can be supplied with an optional snap brake. This brake prevents the output shaft from turning when the power supply to the motor is removed, or, if the motor holding torque is too low, to a maximum of the level of the nominal torque.

  • Page 60: Reference Runs

    Instruction Manual PSx3xxIO 6.16 Reference runs The Positioning System PSx3xx is equipped with an absolute measuring system, therefore no reference run is required when the drive is switched on. If, in certain cases, a reference drive to a hard block is still desired (e.g. once in the installation of the drive onto the machine), the procedure should be as follows: 1) Before ordering the reference drive, the following settings must be applied: Set max.

  • Page 61: Technical Data

    Instruction Manual PSx3xxIO Technical data For additional specifications and dimension drawings, please visit our website at https://www.halstrup-walcher.de/en/products/drive-technology/ 7.1 Ambient conditions Ambient temperature 0 °C to +45 °C Storage temperature -10 °C to +70 °C shock resistance according to 50 g 11 ms...

  • Page 62: Electrical Data

    Instruction Manual PSx3xxIO 7.2 Electrical data Nominal power output PSx30x, PSx31x, 25 W with 30% duty cycle PSE31xx PSx32x, PSx33x 35 W with 30% duty cycle PSE34xx 100 W with 20 % duty cycle Supply voltage 24 VDC ± 10% (supply voltage for motor and control unit are galvanically isolated) advice: use regulated power supplys Nominal current, control unit...

  • Page 63: Physical Data

    Instruction Manual PSx3xxIO 7.3 Physical data Positioning range 250 usable revolutions, no mechanical limit The measuring system includes 256 revolutions, minus 3 revolutions security reserve on both range limits Torsional rigidity max. 0.2° (angle of rotation when switching from operation without backlash to maximum torque) Gear backlash max.

  • Page 64: Certificate Of Conformity

    Instruction Manual PSx3xxIO Certificate of Conformity...
  • Page 65 Instruction Manual PSx3xxIO...
  • Page 66 Instruction Manual PSx3xxIO Notes...
  • Page 67 Instruction Manual PSx3xxIO Notes...

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