Motion Control INFO-HCS2r

tor-
-Mo ller l
AC ntro gita
Co % di
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10

Technical Data

Sampling rate
- 12kHz (flow, velocity and position
control)

High-precision and very fast posi- On the HCS Servo- controllers, all off- Types
tioning and control tasks are imple- the-shelf three-phase synchronous - 2.5A / 600VDC
mented using the Stand Alone Servo- and asynchronous motors can be ope- - 5A / 600VDC
controllers INFO-HCS. rated, as well as specially developed - 16A / 600VDC
The 3 phase power supply is is done by asynchronous motors for servo-ope- - 32A / 600VDC
the INFO-HCP Module. The controller ration.
is equipped with a phase monitor. Three different PID parameter sets and Path curves
As on all intelligent periphery boards, 8 motor configurations are available - S-curve
a PowerPC processor ensures adequa- to users. In addition, up to 6 parame- - ISO-code
te power. ters can be recorded. - User-specific algorithmen

Resolver input
- 12 ... 16-Bit
- Resolver signal as incremental
transmitter output

Incremental input
- RS422 signal, electrically isolated

Motors
- Synchronous three-phase motors
- Asynchronous three-phase motors
- Standard motors

5V Supply
- for incremental transmitter

Order Nr INFO-HCS2r 610535101-2.5A

Order Nr INFO-HCS2r 610535102-5A
Order Nr INFO-HCS2r 610535100-16A
Order Nr INFO-HCS2x 609930200-32A

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 INFO-HCS2r Motion Control

Functions Description

Controller types Four variants of the INFO-HCS are available. In addition to the specified nominal
current, the servo-controllers can be operated during 5s with the current IMAX 5S.

INFO-HCSr 2.5A 5A 16A 32A*

INENN 2.5ARMS 5ARMS 16ARMS 32ARMS

IMAX 5s 10ARMS 15ARMS 35ARMS 70ARMS
UCC 565V 565V 565V 565V

Integration in the *) larger dimensions. The AC servo-controllers are systematically integrated in the
INFO-Link INFO-Link. Analog interfaces and asynchronicities between the field bus master and
the controller are eliminated. All parameters are read and written via the INFO-Link
or via a serial connection using tools and are available throughout the network.

PID parameter sets The different PID parameter sets are freely available to the user. The parameter sets
are simultaneously active, allowing load changes to be optimally accommodated.
Example: PID parameter set 1 for upward stroke with load; parameter set 2 for
downward stroke without load; parameter set 3 for stand-by with reduced current
input. In addition to the PID parameters, it is possible to specify pilot controls
(boosters) for velocity and acceleration.

Computing power The PowerPC 403-66MHz performs the following taks at a clock rate of 12kHz:
− PID position controller, velocity control, active current control
− Power factor compensation
− Encoder correction (incremental transmitter)
− Limitation for: IMAX, I2t , controller, motor temperatures
− Logger of 6 freely selectable parameters such as rotary speed, active
current, path error, target/actual velocities, etc.

Position registration Synchronous motors require a resolver for position registration. The resolution of
the resolver is 12 ... 16-Bit. 16-Bit precision can only be achieved at standstill.
Asynchronous motors require either a resolver or an incremental transmitter for
position registration. For uncontrolled rotary speed operation, no actual value
registration is necessary.
The incremental transmitter may also be used as an additional encoder. The
measurement value can if required also be included directly in the control algorithm,
or be used as an independent measured variable.

Operational reliability Various quantities of the AC servo-controller are continuously monitored in order
to ensure maximum operational reliability. Short-circuit stoppages prevent shorts
to motor or ground. In the individual phases, quick-action current cutouts protect
the motor and the output stage. These become active when the drive is jammed
or is stopped abruptly. The motor and the output stage are monitored for
overtemperature. The motor temperature can be measured as required by means
of a bimetal switch (digital) or via an NTC in the motor (voltage value).

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 Motion Control INFO-HCS2r

Interfaces Wiring

RS232 interface RS232 interface

The RS232 interface serves as direct
RS 232 Stecker Kabel 9-Pol-Stecker connection of the controllers to the PC.
INFO-HCSr
INFO-ACSr PC, Laptop
Pin-5 GND Schirm Pin-5
Pin-2 Rx Eingang ← Pin-3 Incremental transmitter,
Pin-3 Tx Ausgang → Pin-2 external zero pulse
Inputs 1..3 are sized for 5V.
Pin-6 Eingang ← Pin-4 Input 0 is sized for 24V. This input is
DSR reserved for external controller enable
Pin-4 DTR Ausgang → Pin-6 and can be included in the EMERGENCY
stop circuit.

If the inputs 1...3 are operated with 24V,

a series resistor of 1.2kΩ is necessary.
Input 1 is reserved for an external zero
pulse. The incremental transmitter is
Inputs connected to the inputs 2,3. Trak A is
connected to input 2; Trak B to input 3.
The supply of the transmitter is provided
by the INFO-HCSr: 5V or 24V. Instead of
the incremental transmitter, it is also
possible to connect limit switches.

Outputs
The two outputs are reserved for "Motor
control active" and "Current reduction
active".

Resolver
The resolver positon of the motor is
Outputs available on the outputs A, B, und NM
(connector 32d ... 32z) as an encoder
signal. A, B, NM are TTL Signals.
(74HC14)

Supply of the incremental

transmitter
The DC/DC converter on the board also
supplies +5V to the incremental enco-
der. A special power supply for the trans-
mitter therefore is unnecessary (not elec-
trically isolated from the 24V supply).

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 INFO-HCS2r Motion Control

Specifications Connector Allocations

Climatic conditions d b z
Ambient temperature: 2 O + Active O - Active I + 24 V
- Storage: -20...+80°C 4 O + 24 V O 0 V I 0 V
- Operation: 0 ... +45°C 6 O + I-Red O - I-Red Shield
- Board temperature: 8 O + 24 V O 0 V Shield
Operation: 0...+70 °C
10 I + Ext. EN I - Ext. EN Shield
- Relative air humidity 12 O + 24 V O 0 V Shield
no condensation: 80% 14 I + In 1 I - In 1 Shield
- Enclosure IP-20 16 O + 24 V O 0 V Shield
- Pollution degree: 2 (EN 50178)
18 I + INC A I - INC A Shield
20 O + 24 V O 0 V Shield
Motor 22 I + INC B I - INC B MTemp+
- All types of three-phase motors 24 O + 5 V O + 5 V MTemp -
asynchronous und synchronous 26 I + Cos I - Cos Shield
- Minimum inductivity: 1mH 28 I + Sin I - Sin Shield
- Minimum resistance: 0.2Ω Connector 1 30 O + Ref O - Ref Shield
- Max. motor voltage: 565V angled 32 O + A O + B O + NM
- Max. line length: 20m DIN 41612, Type F-48
- Motor temperature monitoring: 2,8mm pin
bimetal or KTY-84 (NTC) on
connector 1, 22z,24z
- Observe voltage resistance of
winding
d z
Resolver-Eingänge 4 I + 565 V
- 12 ... 16 Bit Auflösung 6 I + 565 V
- 4Vrms Sinus, Brückenschaltung 8 I + 565 V
- 2Vrms Sin/Cos Input 10 O U
- Inkrementalgeber-Ausgang: 12 O U
Resolver-Signal als Inkremental-
Signal (Ausgang) A,B-Spuren,Null- 14 O V
impuls: TTL-Pegel (St. 1: 26...32) 16 O V

18 O W
Intermediate circuit, brakes 20 O W
- 565V DC
22 I - 565 V
- Brake-IGBT (PH-4) 24 I - 565 V
(refer: INFO-HCPr, HCPx) 26 I - 565 V
28 I T.-Switch
Finale Stage Connector 2 30 0 T.-Switch
- Loss power (INENN) angled 32 O Ground
INFO-HCSr-2.5A: 30W DIN 41612, Type H-15
INFO-HCSr-5A: 60W 6,3mm pin
INFO-HCSr-16A: 120W
INFO-HCSx-32A: 240W
- Short-circuit protection:
Short to ground, short to phase
- Temperature monitor:
Precision: ± 2°

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 Motion Control INFO-HCS2r

Wiring Specifications

Control

Ext. En
Resolv

Output
Power

Active
Motor
Error

PWM

Inc B
Inc A
Com
Imax

Input
Supply 24V DC

Ucc
Rec

OK
- Electrically isolated
- Operating voltage:
24V DC +10%, -5%
Y0

- Current consumption: 380 mA

0X

Sampling rate
- Sampling rate: 8 ...12kHz
(current, velocity and position
control)

Outputs Out 0,1

- Connector 1, Pin 1..8
- Outputs electrically isolated:
VOFF: 24V
Adressing (blue) ION: 500mA
S1,S2 (Y0,0X) Axis Incr. transmitter
(Adr.) (channel) (channel) Inputs INP 0..3
- Electrically isolated:
00 ... 03 0 ... 3 - Input 0: 24V
10 ... 13 4 ... 7 - Input 1..3 without connection: 5V
... - with 1.2kΩ series resistor: 24V
70 ... 73 28 ... 31
Increment inputs
80, 82 0, 2 1, 3 - Incremental transmitter input with
90, 92 4, 6 5, 7 A,B tracks
... - Interface: 5V / RS422
F0, F2 28, 30 29, 31 - max. count frequency: 2.5MHz
The incremental transmitter can be integrated directly into the control algorithm.
If 0x80 is added to the current axis number (increase rotary switch Y0 by 8), the 5 Supply
incremental transmitter will report on the next follownig channel number. - Voltage: 5V; +10%
In this connection, only even addresses are allowed for the controller so that the max. current: 200mA
incremental encoder will always come to lie on an odd address. - Supply for additional incremental
transmitter (no electric isolation
LEDs on receiver module from 24V board supply)
Power = +5V supply
Rec = INFO-Link receiver signal OK Mounting
- Connector DIN 41612,
LEDs Type F-48, Typ H-15
The functions of the other LEDs on the front panel are described starting on page 7. - 19" Rack mounting
- Dimensions: (DxHxW;SE)
Jumpers (light green) 2.5A 100 x 234 x 45.4 mm; 9SE
The jumpers influence the light intensity of the transmitting LED and thereby the 5A 100 x 234 x 71 mm; 14SE
segment length of the fiberoptic cable to the next board. 16A 100 x 234 x 106 mm; 21 SE
32A 160 x 234 x 106 mm; 21 SE
Segment length Jumper position
0 ... 10m no jumper RS232 interface (violet)
8 ... 30m >10 Communication with the controller is
20 ... 50m >30 done either via the INFO-Link or via the
RS232 interface with the aid of the pro-
gram ACS-Show.

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 INFO-HCS2r Motion Control

Connections Connections

Board supply
For the board supply, a 3-phase rectifier
without electrolytic capacitor is sufficient.
To avoid trouble, however, we recom-
mend an electrolytic capacitor of 4'700
... 10'000µF.
The rack must be provided with a power
line filter, immediately after entry of the
power supply.

Screening lines
The signals of the resolver are extremely M
susceptible to interference; therefore the ϑ
resolver must be installed with a twisted-
pair and screened cable.

The incremental transmitter and the se-

rial interface as well as the motor cables
must always be connected with screened
lines!

Bonding
Always connect all screens at both ends.
To avoid undesirable discharge currents
through the screening, it may be neces-
sary to provide a binding conductor, es-
pecially with large distances or different
supplies.

Screen bar Motor temperature switch

The control cabinet must be provided Open = Motor overtemperature connector Ph2, Pin T+, T-
with a screen bar to which all screened Closed = Ok
cables are connected.
Metallic connectors with all-round con- Inputs, Outputs
tacting of the screen are also suitable for
cable entries. Extern Enable, 24V (Inp0) Zero Mark (Inp1)
Incremental encoder trac A (Inp2) Incremental encoder B (Inp3)
Controller Aktiv (Out 0) Current reduction Aktiv (Out 1)
Connectors All inputs and outputs must be wired inside the cabinet.
Interruptions in the resolver and motor
cables at the cabinet entries etc. should
be implemented using metallic connec-
tors and not terminal connections.

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 Motion Control INFO-HCS2r

Grounding Wiring

Motor temperature
The motor temperature can be measu-
red as required by a bimetal switch (T-
switch) or using an NTC (MTemp).

Sensor leads in the motor cables

If the leads of the bimetal switch are
located in the motor cables, these must
be wired to connectors Ph 2.

Sensor leads in the resolver cable

If the leads of the bimetal switch or of the
NTC are located in the resolver cable,
these must be wired to connector Ph 2.
(insulation class!)

Filter
The 24V supply must be provided with a
filter, as well as the 3 x 400V AC of the
power supply. The optimal filter may
have to be determined by a measure-
ment for line-bound emission, as the
radiated interference depend, among
other things, on the motor cable length.

Grounding
The casing of the INFO-HCS board is
Grounding of INFO-ACSr
grounded. Take care to ensure that the
casing is connected to the mounting
Cooling plate so that good conduction exists.
(EMC and heat dissipation). As the resol-
All INFO-HCS controllers must be cooled with an additional fan inside the cabinet ver is mounted directly onto the motor,
to dissipate the exhaust heat. this motor transmitter combination must
must always be grounded, as otherwise
Further documentation the transmitter electronics will be expo-
See also INDEL wiring guidelines and INDEL design guidelines. sed to interference.

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INFO-HCS2r Motion Control

LEDs Function of the LEDs on the Front Panel

Active Motor control active (Out 0)

Requires external enable (Ext En, INP-0). Output stage ON, motor energized and
with current and 4k-Pos control on Active or Simulation.
In the event of an error, the controller will quit the active state.

Output Current reduction mode active (Out 1)

In this operation mode, the controller limits the maximum current to Ired. Out-1 of
4k-Pos-Job = 1

Ext. En External controller enable (INPUT 0)

Interlocks output stage by hardware function, i.e. the controller cannot be switched
to active without external enable.
INP-0 can be included in the emergency off circuit. Without connection: 5V input,
connected with 1.2kΩ series resistor → 24V input.

Input Free input (INPUT 1)

Free 5V input, can be read in 4k-Pos Job. (See software manual)

Inc A Incremental transmitter track A (INPUT 2)

Allocated as standard as incremental transmitter input A (additional encoder).
5V input, or RS 422 interface.

IncB Incremental transmitter track B (INPUT 3)

Allocated as standard as incremental transmitter input B (for the additional
encoder). 5V input, for RS 422 interface.

OK Error Emergency system

In the emergency system, Flash-PROM burning is supported. To enable the
controller to start in the emergency system, you must plug a short-circuit connector
onto the serial interface (front panel).

Connections: Signals Pin

RxD, TxD 2, 3
DSR, DTR 6, 4

Once the controller has been started up, the short-circuit connector can be removed
and the serial cable to the PC can be connected again.

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 Motion Control INFO-HCS2r

Function of the LEDs on the Front Panel LEDs

Blink code Controller status

The LEDs indicate by lighting, fast or slow blinking the status of different
functions of the controller. For the following sketch, the following applies:
E = Error; Delete Error from Software: Deactive, Active
W = Warning
Please use the program "ACS-Show" as additional help in verifying the
error.

same rhythm as OK-LED on controller

approx. 3 times per second

approx. 1.5 times per second

Intermediate circuit voltage (565 VDC) U CC

(see also modulation, PWM-LED)
=E Intermediate circuit voltage lower 20V (UCC MIN)

=E Intermediate circuit voltage higher 800V (UCC MAX)

=E Phase error, see below

= W Intermediate circuit voltage lower 500V (UCC OK)

= Intermediate circuit voltage 501 ... 799V

Ballast resistance Ballast

Dimming = Ballast resistance is switched on-off (PWM output)
Ballast + U CC
=E Discharge does not work: UCC does not become smaller
although ballast resistance is on.
(UCC blinks with same frequency as ballast LED)
Causes:
- No ballast resistance connected
- Extraneous supply through parallel-connected controllers (UCC bridged)

Phase error Ballast + U CC

=E A phase has failed.

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INFO-HCS2r Motion Control

LEDs Function of the LEDs on the Front Panel

IMAX Motor current

=E I2t exceeded (I2t ≥ 120%)

=E Motor overloaded or blocked (excessive load with

excessive starting current).
= W I2t exceeded, motor current is limited to Inom
(I2t = 100 ... 119%)

= W IMAX reached; if the controller is operated in the current

limiting mode, this warning is displayed when Ired is reached.

Control Temperature output stage

=E Output stage overheated (from 80°C)
= W Output stage hot (from 75° C)

Motor Motor: Temperature, short circuit

=E Motor short circuit, or output stage defective

=E Motor temperature switch tripped for over 10s

= W Motor temperature switch tripped

Resolver Resolver
=E Resolver connection defective or incorrect.
This error also occurs when the rotor is turning
while the axis is switched to active.

=E Maximum mechanical rotary speed exceeded

PWM Modulation
=E Current offset too high (Test before Active)

=E Current measurement range exceeded

= W PWM 100% modulation reached (poss. UCC too low?)

If the motor is operated with high rpm, the PWM-LED will start to blink.
UCC is fully modulated, i.e. the full int. circuit voltage is present at the motor.
This is an allowable operating condition. With high power (current) and high rpm,
the intermediate circuit voltage will drop and the UCC LED and the PWM LED will start
to blink. In this state, the controller is allowed to be in continuous operation. Only when
the controller exceeds the maximum allowable path error (increment, entrainment
error) is the loading limit reached and the controller switches to Error.

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 Motion Control INFO-HCS2r

Function of the LEDs on the Front Panel LEDs

Important!
If the maximum rpm cannot be reached because path errors, entrainment errors
occur while the UCC LED is blinking, check the following causes:
− Inadequate power of supply mains (400V). Inadequately sized or
too high-ohmic isolating transformer. Observe line length and
cross-section of the supply line.
− Overloaded motor.

Remedy:
− Increase intermediate circuit voltage with additional transformer windings
Observe max. UCC=720V!
− If several controllers exist distribute them among different phases.
− Possibly apply additional power pack (INFO-ACPr).

CPU-OK, controller active OK

Controller deactive, OFF, CPU ok

Controller active, ON, CPU ok

Errors Error
=E Software error, CPU on Trap

Wrong control parameters Error + Control

=E After the controller is switched on (not Active), the
Control LED together with Error LED indicate unplausible or
missing control parameters. With the factory-set
parameters, this status display appears.

Wrong motor parameters Error + Motor

=E After the controller is switched on (not Active) the
Motor LED together with Error LED indicates unplausible or
missing motor parameters. With the factory-set
parameters, this status display appears.

RAM errorr Error + U CC

=E If this error message appears, the controller must be
subjected to a hardware overhaul. Please contact
Indel AG.

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 INFO-HCS2r Motion Control

Notes on Safety

Terms In the following text, the term "Module" refers to the AC Servo-controller and the
associated power components as well as control components which have an
operating voltage of over 50V AC.

Specialist personnel Only qualified specialst personnel are allowed to carry out work such as handling,
installation, start-up and maintenance.

Documentation Before installation and start-up, please read the present documentation. Incorrect
handling of the Modules may lead to personal injury or property damage. Always
observe the technical data and the information provided on the connection
conditions.

ESD The Modules contain electrostatically endangered components which might be

damanged by improper treatment. Discharge your body before touching the
Modules. Avoid contact with highly insulating materials (synthetic fibers, plastic
film, etc.). Place the Modules on a conductive base.

During operation, keep all covers and cabinet doors closed. If you touch live
Live components components, you may risk death or serious injuries or property damage.
Never disconnect the electrical connections of the Modules while they are energized
and never withdraw rack boards from the rack while they are energized. In the worst
case, this may cause electric arcs, injuring persons and damaging contacts.

Control and power connections may be live even if a motor is not turning. After the
operating voltage has been switched off, residual voltages may remain present
during several minutes. Measure the intermediate circuit voltage and wait until the
Deactivation
voltage has dropped below 50V.

These notes on safety do not claim to be complete. Should you have any inquiries,
please call us. (Phone +41 1 956 20 00)
Inquiries

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