Page 1 CK3A-series Direct PWM Amplifier User’s Manual CK3A-G305L CK3A-G310L CK3A-G320L O050-E1-05...
Page 2 Moreover, because OMRON is constantly striving to improve its high-quality products, the infor- mation contained in this manual is subject to change without notice. 3. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON as- sumes no responsibility for errors or omissions.
Page 3: Intended Audience
Introduction Introduction Thank you for purchasing the CK3A Direct PWM Amplifier. This manual contains the necessary information for proper mounting, installation, wiring, configuration, and troubleshooting of the CK3A Direct PWM Amplifier. Intended Audience This manual is intended for the following personnel, who must also have knowledge of electrical systems, such as an electrical engineer or equivalent: •...
Page 4: Manual Structure
Manual Structure Manual Structure Page Structure The following page structure is used in this manual. Level 1 heading Level 2 heading Level 2 heading Level 3 Page tab heading (section No.) Procedure Level 3 steps heading Special information Icons indicating precautions, reference, or additional information.
Page 5: Special Information
Manual Structure Special Information Special information in this manual is classified as follow: Precautions for Safe Use Precautions on what to do and what not to do to ensure safe usage of the product. Precautions for Correct Use Precautions on what to do and what not to do to ensure proper operation and performance. Additional Information Additional information to read as required.
Page 6 Manual Structure CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 7: Sections In This Manual
Sections in this Manual Sections in this Manual Introduction to the Amplifier Specifications Mounting and Installation Wiring Software Configuration Troubleshooting Appendices CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 8: Table Of Contents
CONTENTS CONTENTS Introduction ......................1 Intended Audience ........................1 Notice ............................1 Applicable Products ......................... 1 Manual Structure ..................... 2 Page Structure ......................... 2 PMAC Script ..........................2 Special Information ........................3 Sections in this Manual ..................5 CONTENTS ......................6 Terms and Conditions Agreement ...............
Page 9: Contents
CONTENTS 1-2-1 Preparation ......................1-10 1-2-2 Safety ........................1-10 1-2-3 Mounting and Wiring ....................1-10 1-2-4 Safety Test and Power Up ..................1-10 1-2-5 Controller Settings for Amplifier ................1-11 1-2-6 Test Run ........................1-11 Section 2 Specifications ..............2-1 Amplifier Specifications ................
Page 10 CONTENTS Overall Wiring Diagram Examples ............4-19 4-6-1 CK3A-G305L ......................4-19 4-6-2 CK3A-G310L and CK3A-G320L ................4-20 4-6-3 Amplifier Fault Relay ....................4-21 Wiring Conforming to EMC Directives ............ 4-22 4-7-1 Peripheral Equipment Connection Example ............4-23 Selecting Peripheral Components............4-25 4-8-1 Main Circuit AC Power Supply .................
Page 11 A-3-1 Rotary Servo Motor w/ Quadrature Encoder ............A-47 A-3-2 OMRON G5 Servo Motor ..................A-49 A-3-3 OMRON 1S Servo Motor (ACC-84E) ..............A-52 A-3-4 Linear Servo Motor w/ Sinusoidal Encoder .............. A-54 A-3-5 Linear Servo Motor w/ BiSS Encoder (ACC-84E) ........... A-56 A-4 Gate1 “Script”...
Page 12: Terms And Conditions Agreement
Omron’s exclusive warranty is that the Products will be free from defects in materials and workmanship for a period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron). Omron disclaims all other warranties, express or implied.
Page 13: Application Considerations
Disclaimers Performance Data Data presented in Omron Company websites, catalogs and other materials is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of Omron’s test conditions, and the user must correlate it to actual application requirements. Actual performance is subject to the Omron’s Warranty and Limitations of Liability.
Page 14 (i) antivirus protection, (ii) data input and output, (iii) maintaining a means for reconstruction of lost data, (iv) preventing Omron Products and/or software installed thereon from being infected with computer viruses and (v) protecting Omron Products from unauthorized access.
Page 15: Safety Precautions
Safety Precautions Safety Precautions To ensure safe and correct use of the CK3A Direct PWM Amplifier, the Safety Precautions section must be read carefully and fully before installation and wiring. This User’s Manual must be provided to the end-user, and kept in a readily accessible location for reference. Definition of Precautionary Information The safety precautions described in this manual are extremely important for safety.
Page 16: Precautionary Information
Safety Precautions Precautionary Information Illustrations contained in this manual sometimes depict conditions without covers and safety shields for the purpose of showing the details. When you use this product, be sure to install the covers and shields as specified and use the product according to this manual. Transporting and Unpacking WARNING When transporting the Amplifier, do not carry it by the cables.
Page 17 Circuit Breaker to protect against short circuiting of external wiring and failure of the product. Not doing so may cause a fire. The CK3A series provides solid state short circuit protection, so the end product assembly shall be marked: Integral solid state short circuit protection does not provide branch circuit protection.
Page 18: Software Configuration
Safety Precautions Software Configuration WARNING Make sure that the Motor-specific protection parameters in the Controller, especially I2T thermal protection including Motor[x].I2tSet, Motor[x].I2tTrip, and Motor[x].MaxDac are set correctly. Not doing so may result in Motor burning, fire, or serious injury. While Main Power Is applied WARNING Before carrying out wiring or inspection, turn OFF the main circuit power and wait for at least 5 minutes.
Page 19: Fail-Safe Measures
Safety Precautions Fail-safe Measures WARNING Provide safety measures, such as cutting OFF main circuit power, in external circuits to ensure safety in the system if an Amplifier error or abnormality occurs due to malfunction of the products or due to other external factors affecting operation. Not doing so may result in serious accidents.
Page 20: During Operation
Safety Precautions During Operation WARNING Do not enter the machine operating area during operation. Doing so may cause injury. Do not touch the Amplifier heatsink, Shunt Resistor, or Motor while the power is supplied or for at least 5 minutes after the power had been turned OFF because they get hot. Doing so may cause fire or a burn injury.
Page 21: Precautions For Safe Use
Precautions for Safe Use Precautions for Safe Use Transporting • Do not drop any unit or subject it to abnormal vibration or shock. Doing so may result in unit malfunction, burning, or electric shock. Mounting • Be sure to observe the mounting direction and clearance with the surroundings. •...
Page 22: Power Supply Design
Precautions for Safe Use Power Supply Design • Power supply must be within the rated capacity range specified in this manual. • Install external breakers and take other safety measures against short-circuit and over-current. • Do not apply voltages in excess of the range specified in this manual. Motor Selection •...
Page 23: Turning Power Off
Precautions for Safe Use Turning Power OFF • Following, is the correct procedure for turning the Amplifier OFF: Turn OFF main circuit power (e.g. 200VAC) – always before 24VDC logic power If the Amplifier is programmed (set up by the strobe word in the Controller) to discharge capacitor energy, wait a minimum of 3 seconds.
Page 24: Precautions For Correct Use
Precautions for Correct Use Precautions for Correct Use General Precaution • Take appropriate and sufficient countermeasures when installing the Amplifier in the following locations. a) Locations subject to strong, high-frequency electromagnetic noise b) Locations subject to static electricity or other forms of noise c) Locations subject to strong electromagnetic fields d) Locations subject to possible exposure to radioactivity e) Locations close to power lines...
Page 25: Power On/Off
Precautions for Correct Use Wiring • Wire the cables correctly and securely. • Carefully perform the wiring and assembling. • Use crimp terminals to wire screw type terminal blocks. Do not connect bare stranded wires directly to terminals blocks. • Always use the power supply voltage specified in the manual. •...
Page 26: Operation
Precautions for Correct Use Operation • Make sure the connectors are firmly plugged in, and the terminal block are tightly screwed in. • Install a proper stopping device on the machine to ensure safety. The dynamic brake mechanism is not a stopping device. •...
Page 27: Location Of Warning Label
Precautions for Correct Use Location of Warning Label The Amplifier bears a warning label at the following location. Be sure to observe the instructions provided on this label. Warning label location ⚫ Instructions on Warning Display Note the above is an example of warning display. CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 28 Precautions for Correct Use Location of Display Code The Amplifier bears a display code label at the following location. This is intended for quick reference. Refer to the troubleshooting section of this manual for display code details. Display code label location ⚫...
Page 29: Items To Check After Unpacking
Items to Check after Unpacking Items to Check after Unpacking After you unpack the product, check the following items: • Is this the model you ordered? • Was there any damage sustained during shipment? Location of Nameplate The Amplifier bears a nameplate label at the following location. Nameplate location Information on Nameplate Amplifier model...
Page 30: Accessories
Included Included Included NOT Included CK3A-G320L If any item is missing or a problem is found such as Amplifier damage, contact your local OMRON dealer or sales office where the product was purchased. CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 31: Regulations And Standards
Regulations and Standards Regulations and Standards This section describes the standards applicable to the CK3A Direct PWM Amplifier. Conformance to EU Directives Item Standard EMC Directive EN61800-3 second environment Low Voltage Directive EN61800-5-1 C2 category Functional Safety EN61800-5-2 SIL3 (STO) RoHS EN IEC 63000 Conformance to UL Directives...
Page 32 Regulations and Standards When you use the Amplifier in South Korea, observe the following precautions. 사 용 자 안 내 문 이 기기는 업무용 환경에서 사용할 목적으로 적합성평가를 받은 기기로서 가 정용 환경에서 사용하는 경우 전파간섭의 우려가 있습니다. This product meets the electromagnetic compatibility requirements for business use. There is a risk of radio interference when this product is used in home.
Page 33: Versions
Versions Versions The CK3A Direct PWM Amplifier uses unit version. Unit versions are useful to manage differences in product modifications, upgrades etc... Hardware Version The hardware unit version of the CK3A Direct PWM Amplifier is displayed on the nameplate. Nameplate location Amplifier version Firmware Version The amplifier firmware version can be retrieved per the instructions in the Software Configuration...
Page 34: Related Manuals
Related Manuals Related Manuals The following, are related manuals for reference. Contact your local OMRON representative for procuring them. Manual Name Cat. No. Application Description O050 • Introduction to the Amplifier CK3A-series Direct Learning about the PWM Amplifier User’s specifications, •...
Page 35: Terminology
Terminology Terminology TERM DESCRIPTION Power PMAC • PMAC is the acronym for Programmable Multi-Axis Controller • Power refers to the generation of the CPU at the time of creation of this manual CK3M CK3M-series Programmable Multi-Axis Controller (Power PMAC CPU inside) UMAC •...
Page 36: Manual Revision History
Manual Revision History Manual Revision History A manual revision code appears as a suffix to the catalog number on the front and back covers of the manual. evision code Revision code Date Revised Content April 2022 Original production April 2022 UKCA Update March 2023 Corrected UL Marking...
Page 37: Introduction To The Amplifier
Introduction to the Amplifier Section 1 Introduction to the Amplifier This section describes the features, overall configuration, name of each part, and operating procedure of the CK3A Direct PWM Amplifier. Outline ......................1-2 1-1-1 Amplifier Features ...................... 1-2 1-1-2 Typical Configuration ....................1-3 1-1-3 Part Names and Locations ..................
Page 38: Outline
The CK3A Direct PWM (hereinafter referred to occasionally as Amplifier) is a line of Amplifier products designed to interface with Digital Direct PWM servo cards, typically integrated with OMRON and Delta Tau Data systems, Inc. (hereinafter referred to as Delta Tau) series of Turbo (legacy) and Power PMAC controllers.
Page 39: Typical Configuration
1 Introduction to the Amplifier 1-1-2 Typical Configuration The CK3A Direct PWM Amplifier connects to the CK3M or UMAC Controller via PWM cable. • The Motor connects directly to the CK3A Direct PWM Amplifier. • The encoder connects directly to the Controller. Power PMAC Controller (PWM) Amplifier Direct PWM...
Page 40: Part Names And Locations
1 Introduction to the Amplifier 1-1-3 Part Names and Locations CK3A-G305L Main power supply & shunt resistor connector (CN1) Logic power connector (CN2) Terminal 7-segment LED display PWM connector (CN5) STO connector (CN4) Display code (label) Terminal 1 - 4 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 41 1 Introduction to the Amplifier Motor connector (CN3) Terminal Control power LED indicator STO LED indicator Amplifier enabled LED indicator Shunt LED indicator Bus (charge) LED indicator Front View 1 - 5 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 42 1 Introduction to the Amplifier CK3A-G310L and CK3A-G320L Main power supply & shunt resistor connector (CN1) Logic power connector (CN2) Terminal 7-segment LED display PWM connector (CN5) STO connector (CN4) Display code (label) Terminal 1 - 6 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 43 1 Introduction to the Amplifier Terminal Motor connector (CN3) Logic power LED indicator STO LED indicator Amplifier enabled LED indicator Shunt LED indicator Bus (charge) LED indicator Front View 1 - 7 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 44: Part Functions
1 Introduction to the Amplifier 1-1-4 Part Functions Status LED Indicators The following LED indicators are located on the front of the Amplifier: Name Color Description Green Indicates the logic power supply status Green Indicates the amplifier enabled status Yellow Indicates if shunt operation is active Red/Green Indicates STO input status...
Page 45: Ground Terminals
1 Introduction to the Amplifier Logic Power Supply Connector (CN2) The CN2 connector (3-pin) is used to supply 24VDC logic power to the Amplifier. Motor Connector (CN3) The CN3 connector is used to connect the Motor to the Amplifier. It is a 3-pin connector for the CK3A- G305L model and 4-pin connector for the CK3A-G310L and CK3A-G320L models.
Page 46: Operating Procedure
1 Introduction to the Amplifier 1-2 Operating Procedure This section describes the necessary steps to integrate the CK3A Direct PWM Amplifier into a system. 1-2-1 Preparation Item Reference Power PMAC Controller Must have PWM Option shown in system configuration Logic power supply Must be within the specifications stated in this manual Main circuit power supply Must be within the specifications stated in this manual...
Page 47: Controller Settings For Amplifier
1 Introduction to the Amplifier 1-2-5 Controller Settings for Amplifier Precautions for Safe Use This step should be performed with the main circuit power OFF. Item Reference • Install the Power PMAC IDE Software on the computer in use Preparation •...
Page 48 1 Introduction to the Amplifier 1 - 12 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 49: Specifications
Specifications Section 2 Specifications This section describes the general specifications of the CK3A Direct PWM Amplifier. Amplifier Specifications ................2-2 2-1-1 General/Mechanical ....................2-2 2-1-2 Environmental ......................2-2 2-1-3 Electrical ........................2-3 2-1-4 Performance ......................2-5 2-1-5 Regenerative Energy Absorption ................2-6 Functions and Data Reporting ..............
Page 50: Amplifier Specifications
2 Specifications 2-1 Amplifier Specifications This section describes the general, mechanical, environmental, functions, and electrical specifications of the Amplifier. 2-1-1 General/Mechanical Item Specification Number of axes Enclosure Panel mount Protective case IP20 (built into IP54 panel) Grounding 200V class D grounding, 100 Ω or less Vibration resistance 10 to 60 Hz at an acceleration of 5.88 m/s or less...
Page 51: Electrical
2 Specifications 2-1-3 Electrical The following section details the key electrical specifications for each of the CK3A-G3⬜⬜L Amplifiers. Item Unit CK3A-G305L CK3A-G310L CK3A-G320L Voltage Current consumption Inrush current Inrush time msec Voltage 240 ± 5% 3-Phase AC F.L.A. Frequency 50 / 60 240 ±...
Page 52 In addition to configuring the ADC Strobe Word, the CK3A-G310L requires a special part number and factory modification to operate with low voltage (48VDC) main power input. Contact your local Omron representative for this option. Power Output De-Rating by 1-Phase Input Voltage (CK3A-G320L Only) 1ϕ...
Page 53: Performance
2 Specifications 2-1-4 Performance Precautions for Safe Use Install a proper stopping device on the machine to ensure safety. The dynamic brake mechanism is not a stopping device. Precautions for Safe Use Install a proper stopping device on the machine to ensure safety. The dynamic brake mechanism is not a stopping device.
Page 54: Regenerative Energy Absorption
2 Specifications 2-1-5 Regenerative Energy Absorption The Amplifier has built-in capacitors, which absorb the regenerative energy produced during motor deceleration and dynamic braking due to counter EMF. When the built-in capacitors cannot absorb all regenerative energy, the Internal (or external) shunt resistor absorbs the rest of the energy. If the amount of regenerative energy from the Motor is too large, the regeneration operation is stopped, and the Motor is disabled with an overvoltage error (A5) in order to prevent the internal shunt resistor from burning.
Page 55: Horizontal Axis
2 Specifications Regenerative Energy Calculation ⚫ Horizontal Axis Positive speed Motor operation (speed) Negative speed Motor torque output Symbol Description S1, S2 Motor speed at the start of deceleration [r/min] for rotary Motor, [m/s] for linear Motor , TD Deceleration torque [N.m] Deceleration time [s] The regenerative energy absorption Eg , and Eg...
Page 56: Vertical Axis
2 Specifications ⚫ Vertical Axis Upward Motor operation (speed) Downward Motor torque output Symbol Description S1, S2 Motor speed at the start of deceleration [r/min] for rotary Motor, [m/s] for linear Motor , TD Deceleration torque [N.m] Downward constant-speed torque [N.m] Deceleration time [s] Downward constant-speed time [s] The regenerative energy absorption for each area Eg...
Page 57 2 Specifications Necessary Regeneration Energy vs. Amplifier Absorption Capacity If both of the previously calculated regenerative energy E , and E [J] values are smaller than or equal to the Amplifier’s capacitors regenerative absorption capacity E [J], then there is nothing to do. However, if either E or E [J] is larger than the Amplifier’s capacitors regenerative absorption...
Page 58: Functions And Data Reporting
2 Specifications 2-2 Functions and Data Reporting The CK3A Direct PWM Amplifier interfaces with the Controller via PWM cable. The Amplifier has functions that can be configured by the Controller. Also, data and status bits that can be read in the Controller. Precautions for Correct Use If the PWM cable is unplugged or logic power is OFF, the functions, data and status information is not accessible.
Page 59: Data Reporting
2 Specifications 2-2-2 Data Reporting The Amplifier can report (to the Controller) the following data. Item Specification DC bus voltage Reports the DC link bus voltage in VDC Power module temperature Reports the power module temperature in ℃ Firmware version Reports the Amplifier firmware version Current rating Reports the current rating of the Amplifier in Amperes...
Page 60: Part Number Designation
2 Specifications 2-3 Part Number Designation This section shows the part number designation. Amplifier Part Number - G 3 05: 5A Continuous/10A Peak 10: 10A Continuous/20A Peak 20: 20A Continuous/60A Peak 2 - 12 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 61: Mounting And Installation
Mounting and Installation Section 3 Mounting and Installation This section describes the mounting and installation methods of the CK3A Direct PWM Amplifier. All dimensions given in millimeters. External and Mounting Dimensions ............3-2 3-1-1 CK3A-G305L Dimensions and Mounting ..............3-2 3-1-2 CK3A-G310L and CK3A-G320L Dimensions and Mounting ........
Page 62: External And Mounting Dimensions
3 Mounting and Installation 3-1 External and Mounting Dimensions 3-1-1 CK3A-G305L Dimensions and Mounting External Dimensions 212.5 Air Out 2-M4 Air In Mounting Dimensions 2-M4 50±0.5 3 - 2 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 63: Ck3A-G310L And Ck3A-G320L Dimensions And Mounting
3 Mounting and Installation 3-1-2 CK3A-G310L and CK3A-G320L Dimensions and Mounting External Dimensions Air Out 2-M4 Air In Mounting dimensions 3-M4 39±0.5 78±0.5 3 - 3 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 64: Installation
3 Mounting and Installation 3-2 Installation 3-2-1 Ventilation Install the Amplifier according to the dimension specifications shown below. Ensure proper dissipation of heat from the Amplifier and convection inside the panel. If the Amplifiers are installed side by side, install a ventilation system or fan for air circulation to prevent uneven temperatures inside the panel. 3-2-2 Panel Clearance Single-Unit Installation...
Page 65 3 Mounting and Installation Multi-Unit Side-by-side Front View Side View ⚫ CK3A-G305L Dimension Minimum Distance [mm] T (top) B (bottom) S (side) ⚫ CK3A-G310L and CK3A-G320L Dimension Minimum Distance [mm] T (top) B (bottom) S (side) 3 - 5 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 66: Mounting Direction
3 Mounting and Installation 3-2-3 Mounting Direction The Amplifier should be mounted vertically in the gravity direction where the bottom is parallel to the floor. Air OUT Gravity Direction Air IN Bottom of Amplifier Front View Side View 3 - 6 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 67: Installation Conditions
3 Mounting and Installation 3-2-4 Installation Conditions • The panel environmental (such as operating temperature and humidity) conditions must abide by the environmental specifications stated in this manual. Operating the Amplifier outside of these conditions may result in malfunction. Dimension Distance Operating ambient temperature 0 to 55℃...
Page 68 3 Mounting and Installation 3 - 8 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 69: Wiring
Wiring Section 4 Wiring This section describes the wiring methods of the CK3A Direct PWM Amplifier. Main Circuit Power and Shunt (CN1) ............4-3 4-1-1 Connector Pinout ....................... 4-3 4-1-2 Wire size ........................4-4 4-1-3 Wiring Examples ......................4-5 Logic Power Supply (CN2) ............... 4-10 4-2-1 Connector Pinout .....................
Page 70 4 Wiring 4-8-3 Logic Power Supply ....................4-25 4-8-4 Noise Filter ....................... 4-26 4-8-5 Voltage Surge Absorber................... 4-26 4-8-6 Molded Case Circuit Breaker (MCCB) ..............4-27 4-8-7 External Shunt Resistor ................... 4-27 4-8-8 Direct PWM Cable ....................4-28 4-8-9 Compatible Motors ....................4-29 4 - 2 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 71: Main Circuit Power And Shunt (Cn1)
4 Wiring 4-1 Main Circuit Power and Shunt (CN1) 4-1-1 Connector Pinout CK3A-G305L Mating Connector Spring Opener TE Connectivity PN 1981045-1 10-pin receptacle TE Connectivity PN 1-2134249-0 Symbol Description and Specifications Main circuit power supply input. • 3-phase 240VAC 50/60Hz across L1-L2-L3 •...
Page 72: Wire Size
4 Wiring CK3A-G310L and CK3A-G320L Mating Connector Spring Opener TE Connectivity PN 2260828-1 6-pin receptacle TE Connectivity PN 6-2260663-1 Symbol Description and Specifications Main circuit power supply input. • 3-phase 240VAC 50/60Hz across L1-L2-L3 • 1-phase 110VAC or 240VAC 50/60Hz across L1-L2, leave L3 floating (open) Shunt resistor terminals.
Page 73: Wiring Examples
4 Wiring 4-1-3 Wiring Examples Three-Phase AC The Amplifier is designed to operate with three-phase AC main circuit power input. The following diagram depicts this wiring scheme. CK3A-G3 L Three-phase Main Circuit Input MCCB (Fuse) Noise Filter Main circuit contactor Ground to 100 Ω...
Page 74 4 Wiring Single-Phase AC The Amplifier can operate with single-phase AC main circuit power input. The following diagram depicts this wiring scheme. CK3A-G3 L Single-phase Main Circuit Input MCCB (Fuse) Main circuit contactor Noise Filter Ground to 100 Ω or less 1MC: Magnetic contactor Surge suppressor...
Page 75 4 Wiring Precautions for Correct Use The ADC Strobe Word setting in the controller must be set accordingly for successful low voltage operation. CK3A-G305L DC Main Circuit Input Source Ground to Power Supply 100 Ω or less MCCB (Fuse) Ground to Low voltage mode 100 Ω...
Page 76 4 Wiring DC Input (Low Voltage Mode) for CK3A-G320L The CK3A-G320L can operate with low voltage (100VDC) main circuit power input. The following diagram depicts this wiring scheme. Precautions for Correct Use The ADC Strobe Word setting in the controller must be set accordingly for successful low voltage operation.
Page 77 4 Wiring Shunt Resistor Wiring The following diagrams show the internal and external shunt resistor wiring configurations. ⚫ CK3A-G305L Internal Shunt Resistor External Shunt Resistor External shunt resistor Internal shunt resistor Ground to Ground to 100 Ω or less 100 Ω or less CK3A-G305L CK3A-G305L Precautions for Correct Use...
Page 78: Logic Power Supply (Cn2)
4 Wiring 4-2 Logic Power Supply (CN2) 4-2-1 Connector Pinout Mating Connector 3-pin terminal block Phoenix Contact PN 1754571 ODT PN 016-175457-1P3 Symbol Description and Specifications 24VDC Logic power supply input. Not connected (leave floating) 4-2-2 Wire size The recommended wire gauge for the logic power supply input is AWG 20 – 16, 0.5 – 1.5 mm 4-2-3 Wiring Example 24VDC...
Page 79: Motor Connection (Cn3)
4 Wiring 4-3 Motor Connection (CN3) 4-3-1 Connector Pinout CK3A-G305L Mating Connector Spring Opener TE Connectivity PN 1981045-1 ODT PN 100-000032 3-pin receptacle TE Connectivity PN 3-2229794-1 ODT PN 017-000002 Symbol Description and Specifications Motor phases output terminals. • For brushless Motor, connect U, V, and W •...
Page 80: Wire Size
4 Wiring CK3A-G310L and CK3A-G320L Mating Connector Spring Opener TE Connectivity PN 2260828-1 ODT PN 100-000033 4-pin receptacle TE Connectivity PN 4-2260663-1 ODT PN 017-000001 Symbol Description and Specifications Motor phases output terminals. • FG is frame ground, tie Motor frame ground wire to this terminal •...
Page 81: Wiring Examples
4 Wiring 4-3-3 Wiring Examples CK3A-G305L ⚫ Brushless Motor Ground to 100 Ω or less Motor cable CK3A-G305L ⚫ Brushed Motor Ground to 100 Ω or less Motor cable CK3A-G305L CK3A-G310L and CK3A-G320L ⚫ Brushless Motor Motor cable Ground to 100 Ω...
Page 82: Safe Torque Off Sto (Cn4)
4 Wiring 4-4 Safe Torque OFF STO (CN4) 4-4-1 Connector Pinout Mating Connector 5-pin terminal block Phoenix Contact PN 1745920 ODT PN 040-000005 Symbol Description and Specifications Safe Torque Off STO control terminals. STO OUT • To disable the STO function; Short-circuit STO OUT and STO DIS, leave all other STO DIS terminals floating (open).
Page 83: Wire Size
4 Wiring 4-4-2 Wire Size The recommended wire gauge for the STO functions is AWG 20 – 16, 0.5 – 1.5 mm 4-4-3 Wiring Examples Disabling the STO STO OUT STO DIS STO 1 STO 2 Ground to 100 Ω or less STO FB CK3A-G3 Using STO 1 Only...
Page 84 4 Wiring Using STO 2 Only STO OUT STO DIS STO 1 STO 2 Ground to 100 Ω or less STO FB CK3A-G3 Using Both STO 1 and STO 2 STO OUT STO DIS STO 1 STO 2 Ground to 100 Ω...
Page 85 4 Wiring STO Feedback 24VDC 24 VDC Output-1 Output-2 Input Safety Device STO OUT (i.e. OMRON NX-Safety units) STO DIS STO 1 Ground to STO 2 100 Ω or less STO FB 24VDC PNP output (25 mA max.) CK3A-G3 4 - 17...
Page 86: Direct Pwm Connection (Cn5)
4 Wiring 4-5 Direct PWM Connection (CN5) Connector Pinout Symbol Description Function PHACLK1+ Phase clock Input N.C. No connect ADCCLK1+ A/D converter clock Input ADCSTB1+ A/D converter strobe Input ADCDAT1A+ Phase A current data Output ADCDAT1B+ Phase B current data Output AENA1+ Amplifier enable...
Page 87: Overall Wiring Diagram Examples
4 Wiring 4-6 Overall Wiring Diagram Examples 4-6-1 CK3A-G305L MCCB (Fuse) Noise Filter Main circuit contactor Ground to or less 1MC: Magnetic contactor Surge suppressor Amplifier fault relay CK3A-G305L Amplifier 24VDC 24 VDC STO OUT External shunt resistor STO DIS Internal shunt resistor STO 1 STO 2...
Page 88: Ck3A-G310L And Ck3A-G320L
4 Wiring 4-6-2 CK3A-G310L and CK3A-G320L MCCB (Fuse) Main circuit contactor Noise Filter Ground to 100 Ω or less 1MC: Magnetic contactor Surge suppressor Amplifier fault relay CK3A-G3 L Amplifier 24VDC 24 VDC Internal shunt resistor External shunt resistor STO OUT STO DIS STO 1 STO 2...
Page 89: Amplifier Fault Relay
4 Wiring 4-6-3 Amplifier Fault Relay If it is desired to disconnect the main power supply in case of an Amplifier fault, then the output signal that controls the relay coil must come from the Controller. This can be done in a PLC that mirrors the corresponding motor amplifier fault bit.
Page 90: Wiring Conforming To Emc Directives
The CK3A Direct PWM Amplifiers conform to the EMC Directives (EN 61800-3) under the wiring conditions described in this section. The following conditions are determined so that the CK3A series can conform to EMC Directives. When the products are installed in the equipment, the customer must perform the check to confirm that the overall machine conforms to EMC Directives.
Page 91: Peripheral Equipment Connection Example
4 Wiring 4-7-1 Peripheral Equipment Connection Example Ground plate STO OUT STO DIS STO 1 STO 2 STO FB 24VDC Controller DC 24V Supply 1-ph: 100/200 VAC 3-ph: 200 VAC Note For single-phase inputs, connect between L1 and L2. Note For CK3A-G305L, FG does not exist on Motor connector, use FG screw terminal instead. •...
Page 92: Component Details
Controller OMRON CK3M-series CK3A-G3 W/ Direct PWM UMAC-series W/ Direct PWM Note Consult with third party manufacturer(s) or OMRON sales representative for detailed specifications. Cable Information Ferrite core Max. Length Shielded Interface Logic power supply cable 2 turns Main circuit power supply cable...
Page 93: Selecting Peripheral Components
The main circuit DC power supply must be chosen in compliance with the specifications listed in the Specifications section of this manual. The following are suggested 48VDC power supplies. Power Supply Manufacturer S8VK-G series OMRON S8FS-G series OMRON S8FS-C series OMRON Precautions for Correct Use The choice of the DC power supply rating depends on the application requirements.
Page 94: Noise Filter
OMRON R88A-FI1S330-SE 3-ph 400VAC OMRON Note Contact your local OMRON sales representative for detailed specifications. 4-8-5 Voltage Surge Absorber Surge absorbers protect from lightning surge voltage and abnormal voltage in the power input line. The following are suggested surge absorbers.
Page 95: Molded Case Circuit Breaker (Mccb)
Specifications section of this manual. The following are recommended external shunt resistors. Amplifier Model External Shunt Resistor Manufacturer Specifications CK3A-G305L R88A-RR30020 OMRON 60W, 20Ω CK3A-G310L R88A-RR30017 OMRON 60W, 17Ω CK3A-G320L Note Contact your local OMRON sales representative for detailed specifications. 4 - 27 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 96: Direct Pwm Cable
4 Wiring 4-8-8 Direct PWM Cable Part Number Name Length 200-602739-036x CABPWM-2 0.9 m (36in) 200-602739-072x CABPWM-4 1.8 m (72in) 200-602739-144x CABPWM-6 3.6 m (144in) 4 - 28 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 97: Compatible Motors
4 Wiring 4-8-9 Compatible Motors The CK3A-series product line is capable of interfacing to a wide variety of motors. The Amplifier can control almost any type of three-phase Motor, including AC/DC brushless (synchronous) servo rotary or linear, and AC Induction (asynchronous) motors. Additionally, the amplifier can control permanent magnet DC brush motors such as a voice-coil actuator (using two of the amplifier’s three phases).
Page 98 4 Wiring Rated and Peak Current Current is directly proportional to torque. • Rated current typically correlates to steady state position holding or constant speed motion. • Peak current typically correlates to transient (acceleration) motion. ⚫ Motor rated current less than or equal to the Amplifier rated current If the Motor rated current is less than or equal to the Amplifier rated current, then the Motor can be compatible (no issue here) and could achieve optimal steady state motion performance.
Page 99: Motor Inductance
4 Wiring Motor Inductance PWM outputs require significant Motor inductance to turn the on-off voltage signals into relatively smooth current flow with small ripple. Typically, Motor inductance of servomotors is 1 to 15 mH. The CK3A-series can drive this range easily. For lower-inductance motors (below 1mH), problems could occur due to PWM switching where large ripple currents flow through the Motor, causing excessive energy waste and heating.
Page 100 4 Wiring 4 - 32 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 101: Software Configuration
Software Configuration Section 5 Software Configuration This section describes the software configuration of the CK3A Direct PWM Amplifier. Outline of Software Configuration ............. 5-3 5-1-1 Controller Amplifier Interface ..................5-3 5-1-2 Summary ........................5-3 5-1-3 Intended Users ......................5-4 5-1-4 Intended Hardware ....................5-4 5-1-5 Gate3 Alias Names ....................
Page 102 5 Software Configuration 5-6-1 Status Bits Set 1 ...................... 5-16 5-6-2 Status Bits Set 2 ...................... 5-17 5-6-3 Status Bits Set 3 ...................... 5-18 Details of the Amplifier Data ..............5-19 CK3A Sample PLCs .................. 5-21 5-8-1 Implementing the Sample PLC ................5-21 5-8-2 Delay Timer Subroutine ...................
Page 103: Outline Of Software Configuration
5 Software Configuration 5-1 Outline of Software Configuration This section provides an overview of the Software Configuration for better understanding. 5-1-1 Controller Amplifier Interface The CK3A Direct PWM Amplifier interfaces with the controller via PWM cable. It does not communicate with the PC directly, and it does not contain any configuration settings. Using a structure element in the Controller called ADC Strobe Word (explained in a later section), it is possible to control the Amplifier functions, and specify which status bits and data information are reported to the Controller.
Page 104: Software Configuration
5 Software Configuration 5-1-3 Intended Users The Software Configuration section requires general understanding of the Power PMAC Gate3 and channels architecture. 5-1-4 Intended Hardware The Software Configuration section pertains to the CK3M and UMAC series of the Power PMAC Controllers using the following axis cards. •...
Page 105: Basic Configuration
5 Software Configuration 5-2 Basic Configuration This section describes the minimum necessary settings that allow the basic configuration of the CK3A Direct PWM Amplifier. Additional Information • Motor and encoder setup are not discussed in this section. Refer to the Appendices section for that purpose.
Page 106: Motor Settings
5 Software Configuration 5-2-4 Motor Settings Motor[x].AdcMask = $FFFF0000 Motor[x].CurrentNullPeriod = 0 For PMAC I2T settings, the maximum ADC value for each model is shown below. Model Max ADC CK3A-G305L 15.735 CK3A-G310L 31.470 CK3A-G320L 93.844 Precautions for Safe Use PMAC I2T settings, including Motor[x].I2tSet, Motor[x].I2tTrip and Motor[x].MaxDac must be set up correctly.
Page 107: Details Of The Adc Strobe Word
5 Software Configuration 5-3 Details of the ADC Strobe Word This section describes the details of the ADC Strobe Word which software settings allow the user to: • Control the Amplifier functions • Access the Amplifier status bits • Access the Amplifier data information The structure element of the ADC Strobe Word is Gate3[i].AdcAmpStrobe.
Page 108: Explicit Addresses
5 Software Configuration 5-3-2 Explicit Addresses The Gate3[i].AdcAmpStrobe structure element cannot be used for bitwise (individual bit) mapping. If necessary, explicit addressing must be used instead. Following, is a list of those addresses for the first eight Gate3[i] indexes, typically corresponding to the first 32 Amplifier channels.
Page 109: Details Of The Amplifier Functions
5 Software Configuration 5-4 Details of the Amplifier Functions This section describes the Amplifier functions which can be set from the Controller. 5-4-1 Features The Amplifier functions, controlled by the ADC Strobe Word, allow the user to: • Set the bus discharge mode •...
Page 110 5 Software Configuration = 1 Discharge ON If bit #5 of the ADC Strobe Word is set to 1, and when the main circuit power is removed, the Amplifier discharges the residual energy quickly into the internal or external shunt resistor. Precautions for Safe Use If a Shunt resistor is not connected, the Amplifier will remain charged.
Page 111: Clear Fault
5 Software Configuration 5-4-3 Clear Fault Bit #16 of the ADC Strobe Word clears the Amplifier display errors after fault condition has been removed. Additional Information • Clearing Soft start (A2), ADC offset (A9), and Short Circuit (AC) faults requires a logic power cycle of the Amplifier.
Page 112: Dynamic Brake Control
5 Software Configuration 5-4-5 Dynamic Brake Control Bit #20 of the ADC Strobe Word controls the dynamic brake function. Precautions for Safe Use • The dynamic brake function is intended for the stop at the time of an error and therefore it has a short-time rating.
Page 113: Low Voltage (Lv) Mode
5 Software Configuration 5-4-6 Low Voltage (LV) Mode Bit #21 of the ADC Strobe Word specifies whether the Amplifier will be used with low voltage main circuit power supply or not. • For the CK3A-G305L model, this refers to a main circuit power supply voltage of 48VDC. •...
Page 114: Details Of The Adc Registers
5 Software Configuration 5-5 Details of the ADC Registers This section describes the details of the ADC registers. For each channel of the Power PMAC Controller (typically connected to one Amplifier), there are two ADC registers defined as follows. Name Structure Element ADC A Gate3[i].Chan[j].AdcAmp[0]...
Page 115: Adc Registers Explicit Addresses
5 Software Configuration 5-5-3 ADC Registers Explicit Addresses The Gate3[i].Chan[j].AdcAmp[k] structure elements cannot be used for bitwise (individual bit) mapping. Explicit addressing must be used instead. Following, is a list of those addresses for the first eight Gate3[i] indexes, typically corresponding to the first 32 Amplifier channels: ADC A Structure element Address ADC B Structure element...
Page 116: Details Of The Status Bits
5 Software Configuration 5-6 Details of the Status Bits This section describes the details of the three sets of status bits which can be reported by the CK3A Amplifier to the Controller. 5-6-1 Status Bits Set 1 For any “correct” setting of the ADC Strobe Word, the following status bits can be found in ADC A, Gate3[i].Chan[j].AdcAmp[0]: Bit # Item...
Page 117: Status Bits Set 2
5 Software Configuration 5-6-2 Status Bits Set 2 If bits [11:08] of the ADC Strobe Word are set to 0, the Amplifier reports status bits set 2 in ADC B, Gate3[i].Chan[j].AdcAmp[1]: Bit # Item Specification Fault/Display Code Power input status =1 AC power applied, =0 Removed Over temperature =0 no fault, =1 fault...
Page 118: Status Bits Set 3
5 Software Configuration 5-6-3 Status Bits Set 3 If bits [11:08] of the ADC Strobe Word are equal to 1, the Amplifier reports status bits set 3 in ADC B, Gate3[i].Chan[j].AdcAmp[1]: Bit # Item Specification Fault/Display Code I2T integrator status =0 OFF, =1 ON ADC offset =0 no fault, =1 fault...
Page 119: Details Of The Amplifier Data
5 Software Configuration 5-7 Details of the Amplifier Data This section describes the details of the data which can be reported by the CK3A Amplifier to the Controller. Overview and Examples Bits [11:08] of the ADC Strobe Word also specify which Amplifier data is reported to the Controller. The reported data is found in ADC B bits [15:08].
Page 120: Power Module Temperature
5 Software Configuration The following, are examples for quick access from the IDE terminal window. Using Gate3 index 0 channel 0 typically tied to Amplifier/Motor #1. Global definitions GLOBAL Ck3a1DcBus, Ck3a1Temp, Ck3a1FwVer, Ck3a1CurRating DC Bus Voltage Gate3[0].AdcAmpStrobe = (Gate3[0].AdcAmpStrobe & $FFF0FF) | $200 Ck3a1DcBus = ((Gate3[0].Chan[0].AdcAmp[1] &...
Page 121: Ck3A Sample Plcs
5 Software Configuration 5-8 CK3A Sample PLCs This section provides a Power PMAC script list of suggested variables, pointer definitions, and sample PLC programs for 4- and 8- motors allowing the user to easily: • Control the Amplifier functions • Read the Amplifier data •...
Page 122: Delay Timer Subroutine
5 Software Configuration 5-8-2 Delay Timer Subroutine The delay timer subroutine is used to introduce time delay in Power PMAC script PLC programs. This delay timer subroutine exists in most IDE project templates. It is shown here for reference. OPEN SUBPROG DelayTimer SUB: sec (DelayTimeSec)
Page 123: Explanation Of The User-Shared Memory
5 Software Configuration 5-8-3 Explanation of the User-Shared Memory Status bits set 1 is reported in the ADC A register of a given channel. These bits can be accessed at all time without any special setting of the ADC Strobe Word. However, status bits sets 2, and 3 share the same location of the ADC B register.
Page 124: Ck3A Sample Definitions 4-Motors
5 Software Configuration 5-8-4 CK3A Sample Definitions 4-Motors // GATE3[0], CH. 1 – 4 AMPLIFIER FUNCTIONS ====================== // #define Gate30WpDis Gate3[0].WpKey = $AAAAAAAA GLOBAL Ck3a0Clrf, Ck3a0FanCtrl, Ck3a0BusDisCtrl, Ck3a0DbCtrl Gate30DataCtrl ->U.IO:$90020C.16.4 Ck3a0BusDisState ->U.IO:$90020C.13.1 Ck3a0ClrfBit ->U.IO:$90020C.24.1 Ck3a0FanState ->U.IO:$90020C.25.1 Ck3a0DbState ->U.IO:$90020C.28.1 // CH. 1 – 4 ADC B REGISTERS [15:08] ============================ // Ck3a1AdcBData ->U.IO:$900024.8.8 // Gate3[0].Chan[0].AdcAmp[1]...
Page 125 5 Software Configuration // CH. 4, Gate3[0].Chan[3].AdcAmp[0], STATUS SET 1 ============== // Ck3a4PwrFlt ->U.IO:$9001A0.8.1 Ck3a4SoftStartFlt ->U.IO:$9001A0.9.1 Ck3a4StoStatus ->U.IO:$9001A0.10.1 Ck3a4ShuntShortFlt ->U.IO:$9001A0.11.1 Ck3a4OverVoltFlt ->U.IO:$9001A0.12.1 Ck3a4I2tFlt ->U.IO:$9001A0.13.1 Ck3a4ShortFlt ->U.IO:$9001A0.14.1 Ck3a4OverLoadFlt ->U.IO:$9001A0.15.1 // CH. 1, SYS.UDATA[256000] STATUS SET 2 ======================== // Ck3a1PwrStatus ->U.USER:$FA000.0.1 Ck3a1OverTempFlt ->U.USER:$FA000.2.1 Ck3a1ShuntOverLFlt ->U.USER:$FA000.3.1...
Page 126: Ck3A Sample Plc 4-Motors
5 Software Configuration 5-8-5 CK3A Sample PLC 4-Motors OPEN PLC Ck3aPLC // CH. 1 - 4 STATUS BITS SET 2 Gate30WpDis Gate30DataCtrl = 0 CALL DelayTimer.msec(1) Sys.Udata[256000] = Ck3a1AdcBData Sys.Udata[256001] = Ck3a2AdcBData Sys.Udata[256002] = Ck3a3AdcBData Sys.Udata[256003] = Ck3a4AdcBData CALL DelayTimer.msec(1) // CH.
Page 127 5 Software Configuration // GATE3[0] CH. 1-4 FAN CTRL IF(Ck3a0FanCtrl == 1 && Ck3a0FanState == 0) Gate30WpDis Ck3a0FanState = 1 IF(Ck3a0FanCtrl == 0 && Ck3a0FanState == 1) Gate30WpDis Ck3a0FanState = 0 // GATE3[0] CH1-4 DYNAMIC BRAKE CONTROL IF(Ck3a0DbCtrl == 1 && Ck3a0DbState == 1) Gate30WpDis Ck3a0DbState = 0 IF(Ck3a0DbCtrl == 0 &&...
Page 128: Ck3A Sample Definitions 8-Motors
5 Software Configuration 5-8-6 CK3A Sample Definitions 8-Motors // GATE3[0], CH. 1 – 8 AMPLIFIER FUNCTIONS ====================== // #define Gate30WpDis Gate3[0].WpKey = $AAAAAAAA #define Gate31WpDis Gate3[1].WpKey = $AAAAAAAA GLOBAL Ck3a0Clrf, Ck3a0FanCtrl, Ck3a0BusDisCtrl, Ck3a0DbCtrl GLOBAL Ck3a1Clrf, Ck3a1FanCtrl, Ck3a1BusDisCtrl, Ck3a1DbCtrl Gate30DataCtrl ->U.IO:$90020C.16.4 Ck3a0BusDisState ->U.IO:$90020C.13.1 Ck3a0ClrfBit ->U.IO:$90020C.24.1...
Page 129 5 Software Configuration // CH. 3, Gate3[0].Chan[2].AdcAmp[0], STATUS SET 1 ============== // Ck3a3PwrFlt ->U.IO:$900120.8.1 Ck3a3SoftStartFlt ->U.IO:$900120.9.1 Ck3a3StoStatus ->U.IO:$900120.10.1 Ck3a3ShuntShortFlt ->U.IO:$900120.11.1 Ck3a3OverVoltFlt ->U.IO:$900120.12.1 Ck3a3I2tFlt ->U.IO:$900120.13.1 Ck3a3ShortFlt ->U.IO:$900120.14.1 Ck3a3OverLoadFlt ->U.IO:$900120.15.1 // CH. 4, Gate3[0].Chan[3].AdcAmp[0], STATUS SET 1 ============== // Ck3a4PwrFlt ->U.IO:$9001A0.8.1 Ck3a4SoftStartFlt ->U.IO:$9001A0.9.1 Ck3a4StoStatus ->U.IO:$9001A0.10.1...
Page 130 5 Software Configuration // CH. 1, SYS.UDATA[256000] STATUS SET 2 ======================== // Ck3a1PwrStatus ->U.USER:$FA000.0.1 Ck3a1OverTempFlt ->U.USER:$FA000.2.1 Ck3a1ShuntOverLFlt ->U.USER:$FA000.3.1 Ck3a1PwmFreqFlt ->U.USER:$FA000.4.1 Ck3a1PwmCmdFlt ->U.USER:$FA000.5.1 Ck3a1AmpEna ->U.USER:$FA000.6.1 // CH. 2, SYS.UDATA[256001] STATUS SET 2 ======================== // Ck3a2PwrStatus ->U.USER:$FA004.0.1 Ck3a2OverTempFlt ->U.USER:$FA004.2.1 Ck3a2ShuntOverLFlt ->U.USER:$FA004.3.1 Ck3a2PwmFreqFlt ->U.USER:$FA004.4.1 Ck3a2PwmCmdFlt ->U.USER:$FA004.5.1...
Page 131 5 Software Configuration // CH. 1, SYS.UDATA[256040] STATUS SET 3 ======================== // Ck3a1I2tint ->U.USER:$FA0A0.2.1 Ck3a1AdcOffsetFlt ->U.USER:$FA0A0.4.1 Ck3a1Ready ->U.USER:$FA0A0.6.1 // CH. 2, SYS.UDATA[256041] STATUS SET 3 ======================== // Ck3a2I2tint ->U.USER:$FA0A4.2.1 Ck3a2AdcOffsetFlt ->U.USER:$FA0A4.4.1 Ck3a2Ready ->U.USER:$FA0A4.6.1 // CH. 3, SYS.UDATA[256042] STATUS SET 3 ======================== // Ck3a3I2tint ->U.USER:$FA0A8.2.1 Ck3a3AdcOffsetFlt...
Page 132: Ck3A Sample Plc 8-Motors
5 Software Configuration 5-8-7 CK3A Sample PLC 8-Motors OPEN PLC Ck3aPLC // CH. 1 - 8 STATUS BITS SET 2 Gate30WpDis Gate30DataCtrl = 0 Gate31WpDis Gate31DataCtrl = 0 CALL DelayTimer.msec(1) Sys.Udata[256000] = Ck3a1AdcBData Sys.Udata[256001] = Ck3a2AdcBData Sys.Udata[256002] = Ck3a3AdcBData Sys.Udata[256003] = Ck3a4AdcBData Sys.Udata[256004] = Ck3a5AdcBData Sys.Udata[256005] = Ck3a6AdcBData Sys.Udata[256006] = Ck3a7AdcBData...
Page 133 5 Software Configuration // CH. 1 - 8 FIRMWARE VERSION Gate30WpDis Gate30DataCtrl = 6 Gate31WpDis Gate31DataCtrl = 6 CALL DelayTimer.msec(1) IF(Ck3a1Ready == 0) Ck3a1FwVer = Ck3a1AdcBData IF(Ck3a2Ready == 0) Ck3a2FwVer = Ck3a2AdcBData IF(Ck3a3Ready == 0) Ck3a3FwVer = Ck3a3AdcBData IF(Ck3a4Ready == 0) Ck3a4FwVer = Ck3a4AdcBData IF(Ck3a5Ready == 0) Ck3a5FwVer = Ck3a5AdcBData IF(Ck3a6Ready == 0) Ck3a6FwVer = Ck3a6AdcBData IF(Ck3a7Ready == 0) Ck3a7FwVer = Ck3a7AdcBData...
Page 134: Enabling The Ck3A Plc On Power-Up
5 Software Configuration // GATE3[1] CH. 5-8 CLEAR FAULT(S) IF(Ck3a1Clrf == 1) Gate31WpDis Ck3a1ClrfBit = 1 CALL DelayTimer.msec(10) Gate31WpDis Ck3a1ClrfBit = 0 Ck3a1Clrf = 0 // CH. 1 - 8 LOGIC POWER OFF? IF(Ck3a1Ready == 1) Ck3a1DcBus,4 = 0 IF(Ck3a2Ready == 1) Ck3a2DcBus,4 = 0 IF(Ck3a3Ready == 1) Ck3a3DcBus,4 = 0 IF(Ck3a4Ready == 1) Ck3a4DcBus,4 = 0 IF(Ck3a5Ready == 1) Ck3a5DcBus,4 = 0...
Page 135: Using The Ck3A Plc
5 Software Configuration 5-8-9 Using the CK3A PLC Functions control The suggested Amplifier functions structure looks like Ck3a{i}{function name} where: • {i} is the Gate3 index • {function name} is the desired function Following, is a summary of the possible commands: Precautions for Correct Use The desired ADC Strobe Word resulting from function changes must be updated and saved in the main project file or configuration to apply in subsequent power cycles.
Page 136: Reading Data
5 Software Configuration Reading Data The suggested Amplifier data structure looks like Ck3a{x}{data name} where: • {x} is the Motor/Amplifier number • {data name} is the desired data to be read These variables can be placed in the IDE watch window for monitoring, used in PLC programs, or operator interface display.
Page 137 5 Software Configuration Reading Status bits The suggested Amplifier status structure looks like Ck3a {x} {status name} where: • {x} is the Motor/Amplifier number • {Status name} is the desired status to be read These variables can be placed in the IDE watch window for monitoring, used in PLC programs, or operator interface display.
Page 138 5 Software Configuration 5 - 38 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 139: Troubleshooting
Troubleshooting Section 6 Troubleshooting This section describes the LED indications, error display codes, and troubleshooting methods of the CK3A Direct PWM Amplifier. LED Indicators .................... 6-2 Display Codes ..................... 6-3 6-2-1 Normal Mode Operation ..................... 6-3 6-2-2 Error Codes ........................ 6-3 6-2-3 Troubleshooting Error Codes ..................
Page 140: Led Indicators
6 Troubleshooting 6-1 LED Indicators The following LED indicators are located on the front Amplifier. Below, is a description of their color designation and description. Name Indicator Status Color Description Logic 24V logic power applied and within range Green Power 24V logic power not applied, or not within range Not lit (Amplifier OFF)
Page 141: Display Codes
6 Troubleshooting 6-2 Display Codes This section describes the error codes on the dual 7-segment display. 6-2-1 Normal Mode Operation In normal mode operation, the Amplifier displays the following code. Display Fault Description No fault Amplifier OFF Amplifier not enabled No fault (Motor KILLED, servo OFF) Amplifier enabled...
Page 142 6 Troubleshooting Display Fault Description Reset Auto Main Power Circuit The main circuit power input (AC or DC) is not present or removed resets Logic Soft Start Overload Too many main circuit power cycles without enough time in between power cycle Logic Shunt Short Circuit...
Page 143: Troubleshooting Error Codes
6 Troubleshooting 6-2-3 Troubleshooting Error Codes Display Error and Troubleshooting Amplifier OFF • Check logic power supply and wiring, measure 24VDC input, make sure it is between 22.0 - 26.4VDC Under Voltage Warning (if AC main power supply input) • If in low voltage mode, this is normal indication •...
Page 144 6 Troubleshooting Display Error and Troubleshooting STO Input • The STO error display A6 is latched until cleared by ADC Strobe Word or Amplifier enabled (servo ON) • If not using the STO input, make sure STO disable short-circuit between CN4.1 and CN4.2 is installed •...
Page 145 6 Troubleshooting Display Error and Troubleshooting PWM frequency out of range • Make sure the PWM frequency setting in the Controller is within range • Read PWM frequency reported by Amplifier in IDE software • Check PWM connection, makes sure connector is plugged in tightly •...
Page 146: Fault Thresholds
6 Troubleshooting 6-2-4 Fault Thresholds Item Error Threshold Over voltage (A5) 403 VDC Shunt turn ON 390 VDC Shunt turn OFF 370 VDC Under Voltage Warning If AC main power supply and voltage is between 80-100VDC Under voltage (A1) – Normal AC mode 80 VDC Under voltage (A1) –...
Page 147: Amplifier Operation Troubleshooting
• Make sure external shunt resistor is installed installed • External shunt resistor used is and wired correctly • Use recommended Omron external shunt or not within specifications • ADC Strobe Word setting for shunt with correct specifications • Set ADC Strobe Word correctly for discharge discharge ON mode not set •...
Page 148 6 Troubleshooting 6 - 10 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 149: Appendices
A-3-1 Rotary Servo Motor w/ Quadrature Encoder ............A-47 A-3-2 OMRON G5 Servo Motor ..................A-49 A-3-3 OMRON 1S Servo Motor (ACC-84E) ..............A-52 A-3-4 Linear Servo Motor w/ Sinusoidal Encoder .............. A-54 A-3-5 Linear Servo Motor w/ BiSS Encoder (ACC-84E) ........... A-56 A-4 Gate1 “Script”...
Page 150: Automatic Motor Setup Using Ide
A Appendices A-1 Automatic Motor Setup Using IDE This section describes the steps for setting up a brushless servo Motor with the CK3A Direct PWM Amplifier using the IDE System Setup tool. Configuration Item Notes Controller This example is applicable to CK3M AX, or UMAC ACC-24E3 Amplifier CK3A-G305L (110VAC supply voltage) Motor...
Page 151 A Appendices Steps Illustration CPU (system and global) settings • Click on “Clock Settings” Clock Settings • Set phase frequency • Set servo frequency • Set real-time frequency • Set PWM frequency. Must be [8–20KHz] for CK3A channel • “Accept” when finished •...
Page 152 • Click on Amplifier details (database icon), or select default, or previously saved Amplifier from database (pulldown menu) • Choose Manufacturer (OMRON and Delta Tau are defaults) • Under OMRON, choose CK3A model • Click on Select Amplifier. No need to make any changes here •...
Page 153 A Appendices Steps Illustration Specify Motor • Click on Motor details (database icon), or select previously saved Motor from database (pulldown menu) • Click on “New” for new Motor • Enter “New” Motor information • “Save” to database • “Select Motor” •...
Page 154 A Appendices Steps Illustration Specify Encoder • Click on encoder details (database icon), or select previously saved encoder from database (pulldown menu) • Click on “New” for new Encoder • Enter new Encoder information. Note effective resolution result (for user units calculation in the next step) •...
Page 155 A Appendices Steps Illustration Hardware Interface • Click on “Hardware Interface” • Typically, the one item to consider in this page is the over-travel limits. They should be disabled if not wired. • “Accept” • “Interactive Feedback” for next step Interactive Feedback •...
Page 156 A Appendices Steps Illustration Test and Set • These tests will move the Motor, often at high rate of acceleration. Caution must be taken. Motor must be mounted and fixed firmly. • User can choose “Auto” or “Manual” • “Auto” will perform listed tests sequentially •...
Page 157 A Appendices Steps Illustration • The result shows criteria chosen by the Auto- tuning algorithm. It is possible to modify these parameters (e.g. 0 integral ratio) and “ e-Tune” • The result shows a tuning analysis. This explains the choice of bandwidth and some of the system limitations •...
Page 158 A Appendices Steps Illustration Acceleration/Deceleration Limits • Generally, the main consideration here is Jog and Abort linear acceleration/deceleration time or rate Max programmed accel/decel are usually configured for motion programs in conjunction with coordinate system settings • “Accept” and “Motor Jerk Control” for next item Motor Jerk Control •...
Page 159: Power Pmac3 Manual Motor Setup
A Appendices A-2 Power PMAC3 Manual Motor Setup This section describes the step-by-step procedure for manually setting up a brushless Motor with a Power PMAC Controller with Gate3, ACC-84E, and CK3A Direct PWM Amplifier. The procedure steps are shown below. Creating an IDE project Basic optimization, system and gates settings Encoder on-going position, verification...
Page 160 A Appendices New IDE Project Creating a new project is done from the file menu. • File > New > Project • Choose template • Choose project location • Enter project name A - 12 CK3A-series Direct PWM Amplifier Safety Manual (O050)
Page 161 A Appendices Systemsetup.cfg If the IDE System setup tool is not used, systemsetup.cfg file should be disabled. • Right-click on project name • Properties • Download Systemsetup.cfg File > NO > OK A - 13 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 162 A Appendices Project Organization The majority of the parameters described in the following sections are typically placed under Global Includes. Files in this folder can be managed per the user preference. They can be added, deleted, inserted from an existing project, re-named, sorted out (moved up and down) etc… efer to the IDE Manual to learn about these manipulations.
Page 163 A Appendices A-2-2 Basic Optimization, System and Gates Settings This section describes basic optimization, clock frequencies, and CK3A-specific structure elements. Structure Element Description and Examples Sys.WpKey Write protect key for Gate3 Disable write protection, typical, = $AAAAAAAA Sys.MaxCoords Highest number of coordinate systems to be used + 1 Example, = 2 (using coordinate systems 0..1, 0 is usually unused) Sys.MaxMotors Highest number of motors to be used + 1...
Page 164: Additional Information
A Appendices Gate3[i].AdcAmpHeaderBits Amplifier ADC number of header bits (CK3A specific) Always = 4 for CK3A Gate3[i].Chan[j].PackInData ADC input pack data enable Always = 0 for CK3A Gate3[i].Chan[j].PackOutData ADC output pack data enable Always = 0 for CK3A Additional Information Detailed descriptions can be found in the Power PMAC Software Reference Manual.
Page 165 A Appendices ECT Entry for Digital Quadrature Structure Element Typical Setting EncTable[n].Type EncTable[n].pEnc = Gate3[i].Chan[j].ServoCapt.a EncTable[n].pEnc1 = Sys.pushm EncTable[n].ScaleFactor = 1 / 256 ECT Entry for Standard Analog Sinusoidal x16384 (UMAC and CK3M) Structure Element Typical Setting EncTable[n].Type EncTable[n].pEnc = Gate3[i].Chan[j].ServoCapt.a EncTable[n].pEnc1 = Sys.pushm EncTable[n].ScaleFactor...
Page 166 A Appendices ECT Entry for Serial w/ Gate3 (CK3W-AX and ACC-24E3) Structure Element Typical Setting EncTable[n].Type EncTable[n].pEnc = Gate3[i].Chan[j].SerialEncDataA.a EncTable[n].pEnc1 = Sys.pushm = No. of data bits to shift left to bit #31 + index2. This is the 2 shift operation. EncTable[n].Index1 In example diagram below, = 8 = No.
Page 167 A Appendices ⚫ Other necessary settings for this type of processing Structure Element Setting ACC84E[i].SerialEncCtrl Refer to the Power PMAC Software Reference Manual ACC84E[i].Chan[0].SerialEncCmd Refer to the Power PMAC Software Reference Manual Additional Information After setting up ACC84E[i].SerialEncCtrl and ACC84E[i].Chan[j].SerialEncCmd successfully, raw serial encoder data can be seen in ACC84E[i].Chan[j].SerialEncDataA, and ACC84E[i].Chan[j].SerialEncDataB.
Page 168 A Appendices Structure Element Description and Examples Motor[x].ServoCtrl Activate Motor channel Typical, = 1 Motor[x].pEnc Position feedback pointer Typical, = EncTable[n].a (corresponding ECT) Motor[x].pEnc2 Velocity feedback pointer, always =Motor[x].pEnc for single feedback Typical, = EncTable[n].a (corresponding ECT) Motor[x].PosSf Position scale factor (allows conversion to user units) 20-bit rotary Motor in degrees, = 360 / 1048576 Linear Motor with 1 nm scale, = 1 / 1000000 Motor[x].Pos2Sf...
Page 169: A-2-4 Motor Setup And Commissioning
A Appendices A-2-4 Motor Setup and Commissioning This section discusses the general guidelines for the remaining Motor structure elements, and certain commissioning procedures. Generic Motion Elements Structure Element Description Motor[x].AbortTa Abort deceleration Time [msec] if >= 0 Inverse rate [msec / user unit] if <...
Page 170 A Appendices Additional Information Motor[x].pLimits is automatically set up by the firmware by hardware recognition. Motor[x].pLimits specifies the (flag pointer) source of the hardware over-travel limits. If they are not wired, or desired to be disabled then Motor[x].pLimits can be set =0. Common Amplifier and Direct PWM Control Elements Structure Element Description...
Page 171 A Appendices Structure Element Description and Examples Motor[x].PhaseEncLeftShift Number of bits to shift phase-position source data left (to bit #31) Digital quadrature Analog sinusoidal Analog sinusoidal ACI Serial w/ Gate3 = 8 in this example Gate3[i].Chan[j].SerialEncDataA Example of position data Serial w/ ACC-84E = 15 in this example ACC84E[i].Chan[j].SerialEncDataA...
Page 172 A Appendices PMAC I2T setup requires the knowledge of the maximum current, rated current, time allowed at maximum current, and current scaling in the Amplifier. The following table is a reminder of the CK3A Amplifier specifications. Specification CK3A-G305L CK3A-G310L CK3A-G320L Rated RMS current 10 A 20 A...
Page 173: Current Loop Tuning
A Appendices Current Loop Tuning This section shows an overview of the manual current loop tuning tool in the IDE. [50 – 100] % [25 – 50] % [10 – 100] msec Conservative start 0.1 Conservative start = IiGain * 10 Field Description and Range Magnitude...
Page 174 A Appendices Step Response Observation Counter-measure “Sluggish” response. Increase Motor[x].IiGain and Motor[x].IpfGain Very low natural (proportionally). frequency and long settling time. “Under-damped” Increase Motor[x].IpfGain. response. Too much overshoot. “Over-damped” Increase Motor[x].IiGain or response (curve decrease Motor[x].IpfGain. shape). Causing lower natural frequency and longer settling time.
Page 175 A Appendices Establishing Phase Reference (Motor Phasing) Precautions for Safe Use Motor phasing in this section will cause Motor movement. Care must be taken. This section discusses the two most common “initial” phasing methods. There are no fundamental differences between them. Either method can be used with any type of brushless Motor and encoder. The table below provides a suggestion and further information.
Page 176 A Appendices ⚫ Manual Phasing Method The manual phasing method consists of locking the Motor tightly onto the zero position of the commutation electrical cycle (conventionally phase B in PMAC) by forcing current into the Motor[x].IbBias offset. The tighter the Motor is locked, the better is the phase reference. This procedure is usually performed from the terminal window in the IDE using the steps described below.
Page 177 A Appendices ⚫ Automatic Stepper-Motor Phasing Method The automatic stepper phasing method is one of two phase referencing routines built into the Power PMAC firmware. It requires the setting of the following structure elements. Structure Element Description and Example Motor[x].PhaseFindingDac Phasing search output (current/torque) magnitude Typical range, [Motor[x].I2tSet/4 –...
Page 178 A Appendices Open Loop Test Precautions for Safe Use • Do not attempt to close the position loop on a Motor which open loop test has not passed. This may lead to dangerous runaway conditions. • The open loop test will move the Motor. Care must be taken. The open loop test is a critical step in the setup of a commutated “brushless”...
Page 179 A Appendices ⚫ Limited Amount of Travel Some Motors may have a limited amount of travel which makes it difficult to perform an open loop test. In this case, a manual open loop test could be performed from the terminal window in the IDE. •...
Page 180 A Appendices Position Loop (Basic) Tuning Precautions for Safe Use Do not attempt to perform position loop tuning prior to passing the open loop test. This may lead to dangerous runaway conditions. The basic auto tune tool can be used to obtain initial gains. Raw encoder counts per revolution for rotary, inch or millimeter for linear motors Conservative start [10 –...
Page 181 A Appendices ⚫ Step Move (Basic) Tuning Position The goal of the step move tuning is to “superimpose” the actual position on top of the commanded “step” position. Commanded That is, by optimizing the following structure element gains. Actual • Motor[x].Servo.Kp •...
Page 182 A Appendices Step Response Observation Counter-measure • “Sluggish” response. Motor Increase Motor[x].Servo.Kp and Motor[x].Servo.Kvfb may feel loose. • Too little servo “effort” (proportionally) command. About 1% of Motor[x].MaxDac in this example. • Relatively long settling time • “Over-damped” response Increase Motor[x].Servo.Kp and or decrease Motor[x].Servo.Kvfb •...
Page 183 A Appendices ⚫ Parabolic Move (Basic) Tuning Velocity F.E. The goal of the parabolic move tuning is to “superimpose” the actual velocity on top of the commanded “parabolic” position with minimum and Following Error centered (around zero) following error. Time That is, by optimizing the following structure element Commanded Actual...
Page 184 A Appendices Step Response Observation Counter-measure • High acceleration correlation Increase Motor[x].Servo.Kaff (following error looks like V shape) • High velocity correlation Increase Motor[x].Servo.Kvff (following error looks like step) • Note, that for move and settle (point to point) applications, it is not necessary to adjust Motor[x].Servo.Kvff independently.
Page 185 A Appendices Absolute Position Setup (Absolute Homing) This section describes the basic operation for setting up “absolute” position read for absolute serial encoders. The necessary elements to set up for this feature are shown below. Structure Element Description and Example Motor[x].pAbsPos Power-on absolute position pointer Typically, for Gate3, = Gate3[i].Chan[j].SerialEncDataA.a...
Page 186 A Appendices Example Motor[x].AbsPosFormat Setting An absolute serial encoder with 17 bits of binary single- • Gate3 turn (or linear scale), and no multi-turn, position data 00: unsigned binary 17 bits located in the lower fields of serial data A register. Motor[x].AbsPosFormat = $ •...
Page 187 A Appendices Example Motor[x].AbsPosFormat Setting A 36-bit binary absolute serial encoder with 24 bits of • Gate3 single-turn position data, and 12 bits of multi-turn position Shift data A left 8 bits data. 36 bits 01: signed binary • Gate3 Motor[x].AbsPosFormat = $ Gate3[i].Chan[j].SerialEncDataA Serial data B start at bit 0...
Page 188: Precautions For Correct Use
A Appendices Absolute Phase Reference Setup Precautions for Correct Use • Motor must have been successfully phased prior to setting up absolute phase reference. • Motor[x].PhaseFindingDac, and Motor[x].PhaseFindingTime must be equal to zero. This section describes the setup of absolute phase (commutation) reference for Motors with Hall effect sensors and absolute serial encoder.
Page 189 A Appendices ⚫ Absolute Phase Reference Using Hall Effect Sensors Absolute phase reference setup using the conventional 120° hall effect sensor spacing is described in this section. Precautions for Correct Use • Motor must have been successfully phased prior to setting up absolute phase reference. •...
Page 190 A Appendices ⚫ Absolute Phase Reference Using an Absolute Encoder Precautions for Correct Use • Motor must have been successfully phased prior to setting up absolute phase reference. • Motor[x].PhaseFindingDac, and Motor[x].PhaseFindingTime must be equal to zero. The maximum number of bits that can be used for absolute phase reference is 32. It is not necessary to use the full position data stream.
Page 191 A Appendices Absolute Phase Reference Settings An absolute serial encoder with 17 bits of binary single-turn (or linear scale), and no multi-turn, position data located in the lower fields of serial data A register. • Gate3 Gate3[i].Chan[j].SerialEncDataA Rotary: Motor[x].AbsPhasePosSf = 2048 * NoOfPolePairs / 2 Linear: Motor[x].AbsPhasePosSf = 2048 * RESmm / ECLmm Motor[x].pAbsPhasePos = Gate3[i].Chan[j].SerialEncDataA.a Motor[x].AbsPhasePosFormat = $00001100...
Page 192 A Appendices Example Absolute Phase Reference Settings An absolute serial encoder with 36 bits of single-turn (or linear scale) position data located in serial data A and B registers consecutively. • Gate3 Gate3[i].Chan[j].SerialEncDataA Gate3[i].Chan[j].SerialEncDataB Rotary: Motor[x].AbsPhasePosSf = 2048 * NoOfPolePairs / 2 Linear: Motor[x].AbsPhasePosSf = 2048 * RESmm * 2 / ECLmm Motor[x].pAbsPhasePos = Gate3[i].Chan[j].SerialEncDataA.a...
Page 193: A-2-5 Reversing Motor Operation Direction
A Appendices A-2-5 Reversing Motor Operation Direction Precautions for Safe Use • The following setting modifications should not be applied while the Motor is energized. • Motor must be re-phased after implementing operation direction change. • Over-travel and soft limits must be modified accordingly when a Motor operation direction is changed.
Page 194: Gate3 "Script" Motor Setup Samples
A Appendices A-3 Gate3 “Script” Motor Setup Samples Brushless Motor setup samples w/ Power PMAC ACC-24E3, ACC-84E, and CK3M AX units are provided in this section for reference. Precautions for Safe Use The samples provided in this section are for reference only, they may not operate your Motor immediately.
Page 195: A-3-1 Rotary Servo Motor W/ Quadrature Encoder
A Appendices A-3-1 Rotary Servo Motor w/ Quadrature Encoder Hardware Configuration Item Notes Controller This sample is applicable to UMAC ACC-24E3, and CK3M AX Amplifier CK3A-G310L (three-phase 208VAC main supply voltage) Motor Rotary servo Motor, 200VAC, 11/23A, 4 pole pairs Encoder Digital quadrature, 2,000-line (8,000 counts per revolution with x4 decode) System Gates...
Page 196 A Appendices Motor Setup and Commissioning GLOBAL Ck3a1MaxAdc = 31.470 CK3A MAX ADC GLOBAL Mtr1CtsPerRev = 8000 COUNTS PER REVOLUTION GLOBAL Mtr1PolePairs = 4 NO. OF POLE PAIRS GLOBAL Mtr1MaxRmsCur = 20 MAX RMS CUR.(MTR>CK3A) GLOBAL Mtr1RatedRmsCur = 10 RATED RMS CUR.(MTR>CK3A) GLOBAL Mtr1TimeAtMaxCur = 2 TIME ALLOWED AT MAX CUR.
Page 197: A-3-2 Omron G5 Servo Motor
A Appendices A-3-2 OMRON G5 Servo Motor Hardware Configuration Item Notes Controller This setup sample is applicable to CK3M AX, or UMAC ACC-24E3 Amplifier CK3A-G305L (110VAC main supply voltage) Motor G5 Servo Motor R88M-K40030H-S2, 200VAC, 2.4/10.2A, 5 pole pairs Encoder...
Page 198 A Appendices Motor Setup and Commissioning GLOBAL Ck3a1MaxAdc = 15.735 CK3A MAX ADC GLOBAL Mtr1SingleTurn = 20 SINGLE TURN ST BITS GLOBAL Mtr1CtsPerRev = EXP2(Mtr1SingleTurn) COUNTS PER REV. =2 GLOBAL Mtr1PolePairs = 5 NUMBER OF POLE PAIRS GLOBAL Mtr1MaxRmsCur = 10 MAX RMS CUR.(CK3A<MTR) GLOBAL Mtr1RatedRmsCur = 2.5...
Page 199 A Appendices Special PLC for this Motor/Encoder Assembly The first time this G5 encoder is supplied with power, it requires a special procedure to move to an index mark before the absolute position (and phase reference) can be read. The following is a sample PLC that performs this procedure.
Page 200: A-3-3 Omron 1S Servo Motor (Acc-84E
A Appendices A-3-3 OMRON 1S Servo Motor (ACC-84E) Hardware Configuration Item Notes Controller This setup sample is applicable to UMAC ACC-24E3 w/ ACC-84E (1S protocol) Amplifier CK3A-G305L (110VAC main supply voltage) Motor 1S Servo Motor R88M-1M10030S, 100VAC, 1.5/4.7A Encoder 1S serial absolute 23-bit single-turn, 16-bit multi-turn System Gates Sys.WpKey = $AAAAAAAA...
Page 201 A Appendices Motor Setup and Commissioning GLOBAL Ck3a1MaxAdc = 15.735 CK3A MAX ADC GLOBAL Mtr1SingleTurn = 23 SINGLE TURN ST BITS GLOBAL Mtr1MultiTurn = 16 MULTI TURN MT BITS GLOBAL Mtr1CtsPerRev = EXP2(Mtr1SingleTurn) COUNTS PER REV. =2 GLOBAL Mtr1PolePairs = 5 NUMBER OF POLE PAIRS GLOBAL Mtr1MaxRmsCur = 4.7...
Page 202: A-3-4 Linear Servo Motor W/ Sinusoidal Encoder
A Appendices A-3-4 Linear Servo Motor w/ Sinusoidal Encoder Hardware Configuration Item Notes Controller This sample is applicable to UMAC ACC-24E3 (standard sinusoidal), and CK3M AX (sinusoidal) Amplifier CK3A-G310L (three-phase 208VAC main supply voltage) Motor Linear servo Motor, 200VAC, 2.6/8.3A, 60.96mm electrical cycle length Encoder Sinusoidal, 20µm (resolution) sine cycle length System Gates...
Page 203 A Appendices Motor Setup and Commissioning GLOBAL Ck3a1MaxAdc = 31.470 CK3A MAX ADC GLOBAL Mtr1Res = 0.020 RESOLUTION, ENC. PITCH [mm] GLOBAL Mtr1CtsPerMm = 16384 / Mtr1Res COUNTS PER MM GLOBAL Mtr1Ecl = 60.96 ELECTRICAL CYCLE LENGTH [mm] GLOBAL Mtr1MaxRmsCur = 8.3 MAX RMS CUR.(MTR<CK3A) GLOBAL Mtr1RatedRmsCur = 2.6...
Page 204: A-3-5 Linear Servo Motor W/ Biss Encoder (Acc-84E
A Appendices A-3-5 Linear Servo Motor w/ BiSS Encoder (ACC-84E) Hardware Configuration Item Notes Controller This sample is applicable to UMAC ACC-24E3 w/ ACC-84E(BiSS) Amplifier CK3A-G310L (three-phase 208VAC main supply voltage) Motor Linear servo Motor, 200VAC, 2.6/8.3A, 60.96mm electrical cycle length Encoder BiSS, 32-bit, 1nm resolution System Gates...
Page 205 A Appendices Motor Setup and Commissioning GLOBAL Ck3a1MaxAdc = 31.470 CK3A MAX ADC GLOBAL Mtr1Res = 0.000001 1nm RESOLUTION [mm] GLOBAL Mtr1CtsPerMm = 1 / Mtr1Res COUNTS PER MM GLOBAL Mtr1Ecl = 60.96 ELECTRICAL CYCLE LENGTH [mm] GLOBAL Mtr1MaxRmsCur = 8.3 MAX RMS CUR.(MTR<CK3A) GLOBAL Mtr1RatedRmsCur = 2.6...
Page 206: Gate1 "Script" Motor Setup Samples
A Appendices A-4 Gate1 “Script” Motor Setup Samples Brushless Motor setup samples w/ Gate1 (UMAC ACC-24E2) are provided in this section for reference. Precautions for Safe Use The samples provided in this section are for reference only, they may not operate your Motor immediately.
Page 207: A-4-1 Power Pmac With Gate1 (Acc-24E2
A Appendices A-4-1 Power PMAC with Gate1 (ACC-24E2) Hardware Configuration Item Notes Controller This sample is applicable to Power PMAC UMAC with ACC-24E2 Amplifier CK3A-G305L (single-phase 110VAC main supply voltage) Motor Rotary servo Motor, 48VDC, 3/9A, 2 pole pairs Encoder Digital quadrature, 500-line (2,000 counts per revolution with x4 decode) System Gates Sys.WpKey = $AAAAAAAA...
Page 208 A Appendices Motor Setup and Commissioning GLOBAL Ck3a1MaxAdc = 15.735 CK3A MAX ADC GLOBAL Mtr1CtsPerRev = 2000 COUNTS PER REVOLUTION GLOBAL Mtr1PolePairs = 4 NO. OF POLE PAIRS GLOBAL Mtr1MaxRmsCur = 9 MAX RMS CUR.(MTR>CK3A) GLOBAL Mtr1RatedRmsCur = 3 RATED RMS CUR.(MTR>CK3A) GLOBAL Mtr1TimeAtMaxCur = 2 TIME ALLOWED AT MAX CUR.
Page 209: A-4-2 Turbo Pmac With Gate1 (Acc-24E2
A Appendices A-4-2 Turbo PMAC with Gate1 (ACC-24E2) Hardware Configuration Item Notes Controller This sample is applicable to Turbo PMAC UMAC with ACC-24E2 Amplifier CK3A-G305L (single-phase 110VAC main supply voltage) Motor Rotary servo Motor, 48VDC, 3/9A, 2 pole pairs Encoder Digital quadrature, 500-line (2,000 counts per revolution with x4 decode) System Gates END GAT...
Page 210 A Appendices Motor Setup and Commissioning I7210 = 3 ENC. COUNTING DIRECTION I100 = 1 SERVOCTRL ENABLE I101 = 1 PHASECTRL ENABLE I124 = $800001 FLAG CONTROL I184 = $FFFF00 ADC MASK (FOR CK3A) I172 = 683 PHASE OFFSET, TYPICAL FOR BRUSHLESS I166 = I7200 * 48 / 155 PWM SCALE FACTOR, MOTOR<SUPPLY VOLTAGE I170 = 2...
Page 211: Ck3A Sample Plcs For Gate1
A Appendices A-5 CK3A Sample PLCs for Gate1 A-5-1 Power PMAC with Gate1 CK3A Definitions 4-Motors // GATE3[0], CH. 1 – 4 AMPLIFIER FUNCTIONS ====================== // GLOBAL Ck3a0Clrf, Ck3a0FanCtrl, Ck3a0BusDisCtrl, Ck3a0DbCtrl $6000B0 is Gate1[i].AdcStrobe, Gate30DataCtrl ->U.IO:$6000B0.16.4 the address is found as Ck3a0BusDisState ->U.IO:$6000B0.13.1 follows:...
Page 212 A Appendices // CH. 2, SYS.UDATA[256001] STATUS SET 2 ======================== // Ck3a2PwrStatus ->U.USER:$FA004.0.1 $FA004 is Sys.Udata[256001], Ck3a2OverTempFlt ->U.USER:$FA004.2.1 the address can be found as follows: Ck3a2ShuntOverLFlt ->U.USER:$FA004.3.1 Sys.Udata[i].a – Sys.pushm Ck3a2PwmFreqFlt ->U.USER:$FA004.4.1 Ck3a2PwmCmdFlt ->U.USER:$FA004.5.1 Ck3a2AmpEna ->U.USER:$FA004.6.1 // CH. 3, SYS.UDATA[256002] STATUS SET 2 ======================== // Ck3a3PwrStatus ->U.USER:$FA008.0.1 $FA008 is Sys.Udata[256002],...
Page 213 A Appendices CK3A Sample PLC 4-Motors OPEN Ck3aPLC // CH. 1-4 STATUS BITS SET 2 Gate30DataCtrl = 0 CALL DelayTimer.msec(1) Sys.Udata[256000] = Ck3a1AdcBData Sys.Udata[256001] = Ck3a2AdcBData Sys.Udata[256002] = Ck3a3AdcBData Sys.Udata[256003] = Ck3a4AdcBData CALL DelayTimer.msec(1) // CH. 1-4 STATUS BITS SET 3 Gate30DataCtrl = 1 CALL DelayTimer.msec(1)
Page 214: A-5-2 Turbo Pmac With Gate1
A Appendices A-5-2 Turbo PMAC with Gate1 CK3A Definitions 4-Motors // CH. 1-4 AMPLIFIER FUNCTIONS #define Ck3a0Clrf P1000 #define Ck3a0BusDisCtrl P1001 #define Ck3a0FanCtrl P1002 #define Ck3a0DbCtrl P1003 #define Ck3a0BusDisState P1004 #define Ck3a0FanState P1005 #define Ck3a0DbState P1006 // CH. 1-4 ADC B DATA REGISTERS #define Ck3a1AdcBData M1000 #define Ck3a2AdcBData...
Page 215 A Appendices #define Ck3a3PwrFlt M1020 #define Ck3a3SoftStartFlt M1021 #define Ck3a3StoStatus M1022 #define Ck3a3ShuntShortFlt M1023 #define Ck3a3OverVoltFlt M1024 #define Ck3a3I2tFlt M1025 #define Ck3a3ShortFlt M1026 #define Ck3a3OverLoadFlt M1027 Ck3a3PwrFlt->Y:$78215,0,1 Ck3a3SoftStartFlt->Y:$78215,1,1 Ck3a3StoStatus->Y:$78215,2,1 Ck3a3ShuntShortFlt->Y:$78215,3,1 Ck3a3OverVoltFlt->Y:$78215,4,1 Ck3a3I2tFlt->Y:$78215,5,1 Ck3a3ShortFlt->Y:$78215,6,1 Ck3a3OverLoadFlt->Y:$78215,7,1 #define Ck3a4PwrFlt M1028 #define Ck3a4SoftStartFlt M1029 #define Ck3a4StoStatus M1030 #define Ck3a4ShuntShortFlt...
Page 216 A Appendices #define Ck3a4PwrStatus M1054 #define Ck3a4OverTempFlt M1055 #define Ck3a4ShuntOverLFlt M1056 #define Ck3a4PwmFreqFlt M1057 #define Ck3a4PwmCmdFlt M1058 #define Ck3a4AmpEna M1059 Ck3a4PwrStatus->X:$10F3,0,1 Ck3a4OverTempFlt->X:$10F3,2,1 Ck3a4ShuntOverLFlt->X:$10F3,3,1 Ck3a4PwmFreqFlt->X:$10F3,4,1 Ck3a4PwmCmdFlt->X:$10F3,5,1 Ck3a4AmpEna->X:$10F3,6,1 // Ch. 1-4 STATUS BITS SET 3, ADC B (STROBE [11:8] = 1) #define Ck3a1I2tint M1060 #define Ck3a1AdcOffsetFlt M1061...
Page 217 A Appendices CK3A Sample PLC 4-Motors // MOTORS 1-4 CK3A PLC OPEN PLC 1 CLEAR I5111 = 1 * 8388608 / I10 WHILE (I5111 > 0) ENDW // STATUS BITS SET 2 I7206 = (I7206 & $FFF0FF) | $0 I5111 = 1 * 8388608 / I10 WHILE (I5111 > 0) ENDW Ch1Mirror2 = Ck3a1AdcBData Ch2Mirror2 = Ck3a2AdcBData Ch3Mirror2 = Ck3a3AdcBData...
Page 218 A Appendices // DYNAMIC BRAKE CONTROL Ck3a0DbState = (I7206 & $100000) / 1048576 I5111 = 1 * 8388608 / I10 WHILE (I5111 > 0) ENDW IF(Ck3a0DbCtrl = 1 AND Ck3a0DbState = 1) I7206 = (I7206 & $EFFFFF) | $0 ENDIF IF(Ck3a0DbCtrl = 0 AND Ck3a0DbState = 0) I7206 = (I7206 &...
Page 219: Sto Safety Precautions
A Appendices A-6 STO Safety Precautions A-6-1 Risk Analysis Introduction During normal operation, the amplifier will not generate any output unless it is connected and commanded by a controller. Therefore, in the event that the motor must be stopped, the amplifier must cease outputting any current to the motor.
Page 220 A Appendices Potential Risks in CK3A ⚫ General Any deviation from methods described in this user manual or disregarding any warnings included herein may cause damage, serious injuries, or death. ⚫ Electric Shock The amplifier’s main input can be up to 240VAC, in either 1-phase or 3-phase. This voltage level is dangerous and can cause serious injury or death.
Page 221: Incorrect Wiring
A Appendices Hazards and Mitigation The STO function is one of the tools at a system designer’s disposal to make sure the output of the amplifier turns off and remains off. It accomplishes this by removing the gate voltage of the IGBT inside of the amplifier, which in turn prevents it from generating any output.
Page 222: A-6-2 Sto Specifications
A Appendices A-6-2 STO Specifications This section describes the general specifications of the STO function. General STO reaction time: See Section エラー! 参照元が見つかりません。 “エラー! 参照元が見つかりません。エラー! 参照元が見つかりません。” for information. STO reaction time: The time until the amplifier output is de-energized upon activating STO. STO function PFH(1/h) STO function via safety input signals...
Page 223: A-6-3 Theory Of Operation Of Sto
Appendices A-6-3 Theory of Operation of STO The Safe Torque Off (STO) function prevents the motor from generating force or torque. In other words, if the motor is stopped, this safety function prevents it from moving, or if the motor is in motion when the STO function is enabled, it will continue to an uncontrolled stop in accordance with the stop category of IEC 60204-1.
Page 224 Appendices CK3A A - 76 CK3A-series Direct PWM Amplifier User’s Manual (O050)
Page 225 Contact...
Page 226 Hoffman Estates, IL 60169 U.S.A. Tel: (31) 2356-81-300 Fax: (31) 2356-81-388 Tel: (1) 847-843-7900 Fax: (1) 847-843-7787 ©OMRON Corporation 2022-2025 All Rights Reserved. OMRON ASIA PACIFIC PTE. LTD. OMRON (CHINA) CO., LTD. In the interest of product improvement, 438B Alexandra Road, #08-01/02 Alexandra Room 2211, Bank of China Tower, specifications are subject to change without notice.

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