1. Manuals
  2. Brands
  3. RTA Manuals
  4. Servo Drives
  5. X-PLUS RS4
  6. Instruction manual

RTA X-PLUS RS4 Instruction Manual

Stepping motor drives
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Fig 14 - LED.cdr
Fig 14 - LED.cdr

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the X-PLUS RS4 and is the answer not in the manual?

Questions and answers

Summary of Contents for RTA X-PLUS RS4

  • Page 1 Fig 14 - LED.cdr Fig 14 - LED.cdr...
  • Page 2 INDEX TERMS AND USE WARNINGS HAZARDS AND PRECAUTIONS MAINTENANCE BASIC MAINTENANCE FAILURES DIRECTIVES BEFORE USE IDENTIFICATION LABEL NOMENCLATURE DEVICE ASPECT AND DIMENSIONS EXTERNAL ELECTRICAL CONNECTION INSTALLATION INSTALLATION CONDITIONS THERMAL DISSIPATION CONNECTIONS WIRING WARNINIGS ELECTROMAGNETIC INTERFERENCE AND IMMUNITY GROUNDING CONNECTION CONNECTORS WIRING GENERAL DESCRIPTION GENERAL CHARACTERISTICS LOGIC INPUTS AND OUTPUTS...
  • Page 3 POWER-ON AND SIGNALLING MOTOR POWER-ON SIGNALLING AND ERROR CODES SAFETY FUNCTION INTRODUCTION INTENDED USE DIRECTIVES AND STANDARDS DESIGN: SYSTEM CONSTRAINTS AND DETERMINATION OF SIL AND PL VALUES SIL1 / PL CONFIGURATION, 1001 ARCHITECTURE, WITHOUT MONITOR SIL1 / PL CONFIGURATION, 1002 ARCHITECTURE, WITHOUT MONITOR SIL2 / PL CONFIGURATION, 1002 ARCHITECTURE, WITH MONITOR SIL3 / PL...
  • Page 4 TERMS AND USE For the purposes of this manual the terms used assume the meaning below described: - DRIVE: electronic part of an electromechanical motion system, which receives some digital or analog input signals from an external control system and gives to the stepping motor the suitable phase excitation sequences, in order to obtain the mechanical movements required by the control system.
  • Page 5 This manual covers the following standard items: - Drivers for stepping motors of series X-PLUS RS4 in all standard versions. - Special X-PLUS RS4 series drives limited to those characteristics unchanged from the standard models (see chap. 6). Standard drives are all models (see chap. 6 for complete identification) whose characteristics comply completely with those described in this manual.
  • Page 6 RTA for further information. Take into account that RTA has over forty years of experience in any kind of applications, which cannot be condensed in a manual but can always be at customer disposal.

  • Page 7: Hazards And Precautions

    INFORMATION X-PLUS RS4 series drives are suitable to drive two phases stepping motors with 4, 6 or 8 series drives are suitable to drive two phases stepping motors with 4, 6 or 8 series drives are suitable to drive two phases stepping motors with 4, 6 or 8 terminals.
  • Page 8 WARNING! X-PLUS RS4 series drives are designed for use in general industrial equipments. Do not use in are designed for use in general industrial equipments. Do not use in are designed for use in general industrial equipments. Do not use in...
  • Page 9 Only STO inputs must be used for functional safety funct STO inputs must be used for functional safety functions. RTA cannot be considered liable cannot be considered liable for property losses, equipment damages and personnel injuries arising from use or installation...

  • Page 10: Basic Maintenance

    In case of failure, the drive must be sent for repair to RTA ve must be sent for repair to RTA In any cases, never try to repair a faulty device. In any cases, never try to repair a faulty device. Only RTA is authorized for repairs. zed for repairs. XPLRS4001E...
  • Page 11 Conformity declaration regarding above Conformity declaration regarding above mentioned products is kept by RT mentioned products is kept by RTA (as manufacturer residing in EU country) together with technical construction file and are available residing in EU country) together with technical construction file and are available residing in EU country) together with technical construction file and are available on request.

  • Page 12: Before Use

    BEFORE USE IDENTIFICATION LABEL Figure 2 - Identification label NOMENCLATURE The identification of the specific drive models belonging to this series is accomplished by means of the following coding: X-PLUS RS x.y Where the character: can be: 4 for the step/dir version is not present in standard models.
  • Page 13 DEVICE ASPECT AND DIMENSIONS Figure 3 - External view of the drive (dimension in mm) XPLRS4001E 12/72...
  • Page 14 Figure 4 - Rotary switch, DIP switch and C8 connector (Top view and frontal view) EXTERNAL ELECTRICAL CONNECTION - C1: power line connector (HV, PE and motor power) - C2: analog input connector and incremental encoder repeater output - C3: digital input and output connector - C4: incremental encoder input and power connector...

  • Page 15: Installation Conditions

    INSTALLA INSTALLATION INSTALLATION CONDITIONS INSTALLATION CONDITIONS All products considered in this manual have the following common characteristics: All products considered in this manual have the following common characteristics: All products considered in this manual have the following common characteristics: IP20 protection degree: it is user responsibility to provide an adequate protection enclosure : it is user responsibility to provide an adequate protection enclosure : it is user responsibility to provide an adequate protection enclosure suitable to meet the standards regarding the specific application in which the products are used.
  • Page 16 To get more elements proportional to the uncertainty of the data is recommended. To get more accurate information, please contact RTA e information, please contact RTA describing all the data describing all the data of the particular application.
  • Page 17 The shield of this cable has to be directly connected to X has to be directly connected to X-PLUS RS4 drive terminal 5. The shield of encoder cable nal 5. The shield of encoder cable has to be directly connected to the terminal 6 of the drive.
  • Page 18 2014/30/CE directive. The real specific standard compliance have to be proved in the complete installation. In fact the effectiveness of the suggested application notes depends also on machine topology and on the measurement setup. Test performed by RTA simulating typical installations and following the mentioned above indications show that EN61800-3 standard compliance applications can be achieved.
  • Page 19 Figure 5 – Wiring scheme XPLRS4001E 18/72...

  • Page 20: Grounding Connection

    GROUNDING CONNECTION GROUNDING CONNECTION CAUTION! The 6 terminal of C1 connector 6 terminal of C1 connector must to be connected to the ground. Terminal 6 of connector C1 is the only point of the drive unit that must be grounded (PE of connector C1 is the only point of the drive unit that must be grounded (PE of connector C1 is the only point of the drive unit that must be grounded (PE terminal).

  • Page 21: Connectors Wiring

    CONNECTORS WIRING SCREW CONNECTORS (C1 connector, power line connections) To tighten the connector screws use a torque of about 5.5 Nm. SPRING CONNECTORS (other connectors) For the drive-encoder connection (C4 connector) it is recommended to use a shielded cable with "twisted-pair"...

  • Page 22: General Description

    GENERAL DESCRIPTION X-PLUS RS4 is a drive for bipolar stepping motor. It requires two power lines with different voltage: the first at 24 V nominal value for the control logic circuit and the second in the range 120 ÷ 230 V nominal value for the motor power supply.
  • Page 23 Auto-Sync mode This feature allows the drive to recover independently - within predefined limits - possible deviations between the real position of the motor shaft and the commanded position that could lead to a loss of control of the rotor by the drive (following error). If the rotor is stopped, the maximum permitted deviation is equal to a full step ( 1.8°).

  • Page 24: General Characteristics

    10. GENERAL CHARACTERISTICS LOGIC INPUTS AND OUTPUTS Figure 8 - Logic signal connectors EDM OUTPUT AND STO INPUTS (C6 and C7 Connectors) C6 and C7 connectors are the input and output terminals by which the STO (Safe Torque Off) functionalities can be implemented. To allow the current flow to the motor (if Curr_ON input is ON), it is necessary to provide +24V nominal voltage between terminals STO1+ and STO1- (STO1 input) and +24V nominal voltage XPLRS4001E...
  • Page 25 between terminals STO2+ and STO2- (STO2 input) otherwise the current in the motor is forbidden. The available signals and their correspondence with numbering on the connectors C6 and C7 are shown in the following table: PIN Number Function Note ± Error Detection monitor output Bidirectional Error Detection monitor output...
  • Page 26 GND: terminal – encoder power supply Table 2 Note1: in the table above, the colours of the conductors of a RTA standard encoder cable are reported. Note2: Negative power supply of the encoder (terminal 48) is connected to the terminal 25 of C2, 58 of C5 and 74 of C7.
  • Page 27 The DIR input terminals (pin 54 and pin 55) allow the Master to control the direction of motor running (in STEP & DIRECTION mode) or the movement of the motor with rotation speed dependent on the frequency of the signal applied to this input (in LINE RECEIVER mode). Note: for all the settings of DIP 4, 5 and 6 different than those indicated above, the ANALOG VELOCITY mode is active: the motor run with a speed proportional to the voltage applied to the analog input (pin 26 and pin 27 of C2) and direction of rotation dependent on the polarity of the...
  • Page 28 ANALOG INPUT AND ENCODER REPEATER (C2 Connector) In the table below the available signals and their correspondence with numbering on connector C2 are shown: PIN number Function Note OUT_B- encoder B phase repetition, output - RS-422 type output (differential or line driver) OUT_B+ encoder B phase repetition, output + OUT_A- encoder A phase repetition, output - RS-422 type output...
  • Page 29 DIGITAL INPUTS AND OUTPUTS (C3 Connector) The available signals and their correspondence with numbering shown on connector C3 are listed in the below table: PIN number Function Note OUT_COM: output common Can be used for O1/FE_WARN: output 1 / Following Error Warning mechanical impact homing : output 2 / Fault FAULT...
  • Page 30 Note: The O2/ FAULT output DOES NOT indicate the current inhibition condition due to the low level of STO1 or STO2 input signals (on the terminals of the C6 and C7 connectors): this condition is indicated only by LEDs in front of the drive. To monitor the status of STO signals the EDM output (on the terminals of the connectors C6 and C7) must be used.
  • Page 31 Note: The following interfacing examples MUST NOT be used with STO1, STO2 inputs and MONITOR output. Figure 11 - Interfacing between an output of a X-PLUS RS4 series drive and an input of an external system operating at voltage V+...
  • Page 32 ≤ V ≤ 24 V Figure 13 - Interface between an external control system with an NPN type open collector output and a logic input of a X-PLUS RS4 series drive ≤ V ≤ 24 V Figure 14 - Interfacing between an external control system with a PNP type output and a logic input of a X-PLUS RS4 series drive ≤...
  • Page 33 MOTOR OUTPUTS AND POWER SUPPLY INPUT (C5, C1 connectors) LOGIC POWER SUPPLY (C5 Connector) Following are the logic power inputs and the matching with the numbering reported on the C5 connector: PIN number Function Note +24V LV power input + 24 V GND output - power supply +24V LVDC Table 6 Note: For a proper operation of the drive, the power supply providing the LV...
  • Page 34 POWER SUPPLY (C1 Connector Connector) Figure 16 16 - Outputs and power supply (C1 connector) WARNING! The power outputs are those intended for connecting the stepper motor. The power outputs are those intended for connecting the stepper motor. The power input can be connected ected directly to the mail or to an insulation trasformer n insulation trasformer.
  • Page 35 The electrical ratings and the physical dimensions of the drive are shown in the following table: Function Value Note Nominal Value 110 - 230 Frequency (Hz) 50 - 60 Nominal Value Nominal Value Tolerance Nominal Value Rms Value Max input current Max input power (VA) 440 - 920...

  • Page 36: Motor Limits

    MOTOR LIMITS X-PLUS RS4 drives can be used with many different motor types; never PLUS RS4 drives can be used with many different motor types; nevertheless there are some theless there are some limitations about the characteristics of the motor as specified in the following tables.
  • Page 37 REVERSE ENERGY MANAGEMENT REVERSE ENERGY MANAGEMENT(C8 Connector) The drive is equipped with a reverse energy dissipation circuit. This system, in particular The drive is equipped with a reverse energy dissipation circuit. This system, in particular The drive is equipped with a reverse energy dissipation circuit. This system, in particular applications where strong accelerations applications where strong accelerations or high inertia values are expected, can contribute to values are expected, can contribute to...
  • Page 38 When all the operating conditions of a new application are defined, it is strongly recommended to measure motor body temperature: this measurement should be made in the real and final working conditions of the machine (motor mounted in its mounting flange and working with the effective machine cycle).

  • Page 39: Drive Settings

    11. DRIVE SETTINGS CPR ENCODER AND REVOLUTION DIRECTION By means of the 16-position rotary switch it is possible to set on the drive the resolution of the encoder (CPR) and the direction of revolution (CW or CCW). If an operation mode with encoder is selected (rotary switch positions different from 0 and from 8), the drive works in Auto Sync mode;...
  • Page 40 MOTOR MODEL AND GAINS By means of DIP 1, 2 and 3 of the Dip-switch to 8 switches you can set some configuration parameters. In particular it is possible to define the current values from standstill (standstill) and in motion and the optimal values of some internal parameters to optimize the operation of the drive depending on the nominal value of the power supply voltage: 230 VAC (EU) or 120 VAC (US).

  • Page 41: Control Modes

    CONTROL MODES The DIP 4, 5 and 6 of the 8-position Dip-switch allow to set the desired drive control mode, as shown in Table 15. Note: At the first power-ON of the drive (switching to Current ON state) the drive performs a self-calibration procedure that require a time interval no longer than 1 second.
  • Page 42 possible "dead band" (speed tight tight to zero with an input voltage around 0 mV) can be chosen around 0 mV) can be chosen by DIP 4, 5 and 6 as shown in Table Table 14. The maximum allowed acceleration is 24000 rpm/s. .
  • Page 43 The REPEATER PULSE outputs (OUT_A and OUT_B, PIN 21, 22, 23, 24 and 25) can be used to drive a second motor physically connected to the same axis as the primary motor (GANTRY axis) by a second X-Plus RS4 drive. To implement a GANTRY axis with two drives it is therefore necessary to connect the PULSE REPEATER outputs of the first drive (master) to the PULSE TRAIN inputs of the second drive (slave).
  • Page 44 12. POWER-ON AND SIGNALLING MOTOR POWER-ON When the drive is properly powered (LV and HV ) and the correct voltage level applied to the STO inputs, the motor can be move to current-on state (torque available at the shaft) or current-off state by means of the CURR_ON digital input (Pin 56 and 57).
  • Page 45 OFF = drive not powered or powered with a voltage value outside the correct range Fast flashing (100ms ON 100ms OFF) = RTA reserved mode - the drive has successfully saved data in non-volatile memory; it is necessary to wait 5 seconds before the drive returns to operating mode.
  • Page 46 Slow flashing (1 s ON, 1 s OFF) = the CURR_ON signal is high, but a fault has occurred and the CURR_ON signal must be brought to a low level in order to reset the fault state. Fast flashing (500 ms ON, 500 ms OFF) = RTA reserved mode (internal parameter configuration)
  • Page 47 Error Codes The number of flashes of the yellow LED corresponds to the error code. The possible values are as follows: 1 = High Voltage out of range - HVAC power voltage is outside the allowed operating range (too low, off or too high) 2 = active STO1 protection - STO1 is not powered or there is a fault in the relevant circuits 3 = active STO2 protection - STO2 is not powered or there is a fault in the relevant...

  • Page 48: Safety Function

    RTA srl will not be held responsible. Failure to apply the advice provided in this manual that affect the safety functions may cause damage to things, the environment or people for whom RTA srl will not be held responsible. XPLRS4001E...

  • Page 49: Intended Use

    Unless otherwise provided, all components of the chain involved in the integrated safety system shall be fail-safe. The single module that includes an X-PLUS RS4 is suitable for use in safety-related control circuits with systematic "SC3" capacity and integrity level up to "SIL3" depending on the arrangement of STO inputs.

  • Page 50: Directives And Standards

    DIRECTIVES AND STANDARDS The devices are developed, manufactured and tested according to the relevant safety standards and applicable Directives: STANDARDS: "Low Voltage Directive": EN 61800-5-1:2007+A11:2021 - Variable speed electric drives Safety requirements. Electric, thermal and energy. "Machinery Directive": EN 61800-5-2:2017 - Variable speed electric drive systems Functional safety requirements.
  • Page 51 The device under consideration is intended to be a part of the safety circuit and, depending on the safety chain chosen, may be a complete element or a subsystem, depending on the (sub)system in which it is included. Please contact RTA in case of doubts about the calculation constraints of SFF. XPLRS4001E 50/72...
  • Page 52 SIL1 / PL c CONFIGURATION, 1001 ARCHITECTURE, WITHOUT MONITOR The following assumptions have been made during the FMEDA analysis: The input is generated by one single channel (STO1 input connected to safety PLC digital output, STO2 input connected to 24V). Figure 18 - connection diagram SIL1/PLc, 1001 architecture, without monitor The output safety function includes the safe activation of the internal bridge.
  • Page 53 The expected installation environment must be comparable to IEC 60654-1 Class C (sheltered location) with temperature limits within the manufacturer's rating and an average temperature over a long period of time of 60 °C. Please contact RTA in case of use in heavy environment.
  • Page 54 SIL1 / PL c CONFIGURATION, 1002 ARCHITECTURE, WITHOUT MONITOR The following assumptions have been made during the FMEDA analysis: The input is generated by one single channel (STO1 and STO2 inputs are parallel connected and controlled by the series of two independent digital outputs of the safety PLC FAIL TO OPEN / NORMALLY OPEN contacts).
  • Page 55 The expected installation environment must be comparable to IEC 60654-1 Class C (sheltered location) with temperature limits within the manufacturer's rating and an average temperature over a long period of time of 60 °C. Contact RTA in case of installation in heavy environments.
  • Page 56 SIL2 / PL d CONFIGURATION, 1002 ARCHITECTURE, WITH MONITOR The following assumptions have been made during the FMEDA analysis: The input is generated by on single channel (STO1 and STO2 inputs parallel connected and controlled by the series of two independent digital outputs of the safety PLC, FAIL TO OPEN / NORMALLY OPEN contacts).
  • Page 57 The monitor output alerts the user’s put alerts the user’s logic solver (safety PLC) on inco incoherent status of the drive when compared to the to the expected status of the STO1 and STO2 inputs. The user status of the STO1 and STO2 inputs. The user shall manage the monitor through the manage the monitor through the logic solver in order to activate alternative solver in order to activate alternative safety...
  • Page 58 The required installation environment is assumed to be comparable to IEC 60654-1 Class C (sheltered location) with temperature limits within the manufacturer’s rating and a maximum average temperature value over a long period of time of 60 ºC. Contact RTA in case of installation in heavy environments.
  • Page 59 SIL3 / PL e CONFIGURATION, 1002 ARCHITECTURE, WITH MONITOR The following assumptions have been made during the FMEDA analysis: The input is generated by two isolated and independent channels (STO1 input connected to a safety PLC output and STO2 input connected to a second safety PLC output). Figure 22 - SIL3/PLe connection diagram, 1002 architecture, with monitor The EDM (Error Detection Monitor) output is assumed to be connected and managed by the user logic solver (safety PLC).
  • Page 60 The required installation environment shall be comparable to IEC 60654-1 Class C (fixed position) with temperature limits within the manufacturer’s nominal values and a maximum average temperature value over a long period of time of 60 ºC. Contact RTA in case of installation in heavy environments.
  • Page 61 STO TIMING The correct and stable enabling of STO function is effective after a maximum time of 20 ms after STO1 and STO2 switching off. Monitor Output indicates that STO function is active with a maximum delay of 20 ms from STO1 and STO2 input signals switch off (see Figure 23).
  • Page 62 TIMING OF INPUT-OFF SHOT PULSE FOR SAFETY DEVICE SELF OFF SHOT PULSE FOR SAFETY DEVICE SELF OFF SHOT PULSE FOR SAFETY DEVICE SELF-DIAGNOSIS If a safety PLC, which generates self If a safety PLC, which generates self-diagnostic impulses (i.e. voltage drop drop on STO1 and STO2 signals) is used, these must have a maximum duration of 1 ms ( these must have a maximum duration of 1 ms (see Figure 24...
  • Page 63 PARAMETERS RELATING TO THE INTEGRITY OF THE SAFETY FUNCTION SIL1/PLc configuration, 1OO1 Architecture, without monitor Safety Integrity Related parameter Value / Description Assessment type FMEDA Assessment / Route 1H (EN62061, EN61508-2) Device type Simplex, A (EN62061, EN61508-2) Operation mode Low Demand Mode / High Demand Mode (EN62061, EN61508-1) Hardware fault Tolerance (HFT) (EN62061, EN61508-2)
  • Page 64 SIL1/PLc configuration, 1OO2 Architecture, without monitor Safety Integrity Related parameter Value / Description Assessment type FMEDA Assessment / Route 1H (EN62061, EN61508-2) Device type Simplex, A (EN62061, EN61508-2) Operation mode Low Demand Mode / High Demand Mode (EN62061, EN61508-1) Hardware fault Tolerance (HFT) (EN62061, EN61508-2) Architecture 1oo1...
  • Page 65 SIL2/PLd configuration, 1OO2 Architecture, with monitor Safety Integrity Related parameter Value / Description Assessment type FMEDA Assessment / Route 1H (EN62061, EN61508-2) Device type Simplex, A (EN62061, EN61508-2) Operation mode Low Demand Mode / High Demand Mode (EN62061, EN61508-1) Hardware fault Tolerance (HFT) (EN62061, EN61508-2) Architecture 1oo2 internal...
  • Page 66 SIL3/PLe configuration, 1OO2 Architecture, with monitor Safety Integrity Related parameter Value / Description Assessment type FMEDA Assessment / Route 1H (EN62061, EN61508-2) Device type Simplex, A (EN62061, EN61508-2) Operation mode Low Demand Mode / High Demand Mode (EN62061, EN61508-1) Hardware fault Tolerance (HFT) (EN62061, EN61508-2) Architecture 1oo2 full (internal/external)
  • Page 67 The assumption of a constant failure rate is based on the bathtub curve, which shows the typical behavior of electronic components. Early failures are cleaned up by the burn-in procedure implemented by RTA for each produced part and therefore the assumption of a constant failure rate during the life-time is valid if the predefined life-time is not exceeded.

  • Page 68: Installation, Commissioning And Maintenance

    INSTALLATION, COMMISSIONING AND MAINTENANCE INSTALLATION, COMMISSIONING AND MAINTENANCE INSTALLATION, COMMISSIONING AND MAINTENANCE INFORMATION The installation must be carried out by qualif The installation must be carried out by qualified personnel and must preserve the SIL level of ied personnel and must preserve the SIL level of the loop.
  • Page 69 Before check the correct working of SAFE TORQUE OFF function, please verify that every drive Before check the correct working of SAFE TORQUE OFF function, please verify that every drive Before check the correct working of SAFE TORQUE OFF function, please verify that every drive connections properly operate.
  • Page 70 Please note that even when the safety function is active, the power supply of th Please note that even when the safety function is active, the power supply of th Please note that even when the safety function is active, the power supply of the drive is not interrupted.

  • Page 71: System Configuration

    SYSTEM CONFIGURATION SYSTEM CONFIGURATION STO1 and STO2 inputs and EDM output are opto STO1 and STO2 inputs and EDM output are opto-isolated from each other and isolated from each other and respect to the internal power circuits. The C6 and C7 connectors are the physical terminals through which the The C6 and C7 connectors are the physical terminals through which the safety safety features STO (Safe Torque Off) and EDM (Error Detection Monitor)
  • Page 72 Figure 25 - Connection diagram to a Safety Unit STO INPUTS The available signals and the correspondence with the numbers on the C6 and C7 connectors are listed below: PIN numbers Functions Notes ± : Error Detection Monitor output terminal bidirectional : Error Detection Monitor output terminal ∓...
  • Page 73 ERROR DETECTION MONITOR (EDM) ERROR DETECTION MONITOR (EDM) The output of Error Detection Monitor (EDM) The output of Error Detection Monitor (EDM) allow to verify any connection errors in the STO to verify any connection errors in the STO circuit and between the Safety Unit and the STO1 and STO2 inputs. The following Table shows circuit and between the Safety Unit and the STO1 and STO2 inputs.
  • Page 74 XPLRS4001E 73/72...

Table of Contents